1196 Tug M1 M1a

TECHNICAL INSTRUCTION REVISION
HIGHLIGHTS
MANUAL CODE: 1196
ANALYST DATE PHONE SIGNATURE
STEVEN SCHWERTFEGER 4/22/15 3-1549 Steven Schwertfeger

DAL MANUAL
P/N:
0559 17616 - 17638, 17691 - 17788, MFR. P/N: MODEL M1/M1A
17795 -
17999, 170000 - 170004, 170007 -
170250,
170254, 170256 - 170430, 170432 -
170514,
170519 - 170526. 170531 - 170534,
170538 - 170633
UNIT: TUG – LOW PROFILE TOW TRACTOR MFR: TUG, INC.
PUBLICATION: OPERATIONS MAINTENANCE AND MFG. / PUB. NO:

PARTS MANUAL
REV. NO: 20 EQUIPMENT:
REMOVE & DESTROY INSERT REMOVE & DESTROY INSERT
NOTE: Check revision log in front of manual

for previous revision and log entry,
then initial and enter on log sheet.
EA 15-504981-03
Remarks: Manual revised to incorporate EA 15-504981-03 TUG M1A Park Brake Relocation
EA 15-581593-03 REV A M1A Electronic Transmission Upgrade
FOR INFORMATION ONLY

HIGHLIGHTS
MANUAL CODE: 1196
LYNN BURNS 10-14-11 4-1150 Lynn Burns

DAL MANUAL MFR. P/N:
0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1/M1A
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633
UNIT: TUG – LOW PROFILE TOW TRACTOR MFR: TUG, INC.
PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

NO:
REV. NO: 19 EQUIPMENT
:
REMOVE & DESTROY INSERT
NOTE: Check revision record in front of manual

ENTIRE CONTENTS *ENTIRE CONTENTS
*NOTE - ALL DAL PAPERWORK IS TO REMAIN IN MANUAL
REMARKS: Manual revised to incorporate vendor revision 10.

HIGHLIGHTS
MANUAL CODE: 1196

0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633
UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

NO:
:

DAL LEP DAL LEP
CHAPTER 4 CHAPTER 4
4-2 4-2
NO REMOVAL TECH TIP – TU 41
ALTERNATOR
REMARKS: Manual revised to incorporate Tech Tip TU 41 Alterntor.

HIGHLIGHTS
MANUAL CODE: 1196

0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633

NO:
:

REMARKS: Manual revised to add vendor revision 9.

HIGHLIGHTS
MANUAL CODE: 1196
LYNN BURNS 5-17--06 4-1150 Lynn Burns

0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633

NO:
:

DAL LEP DAL LEP
CHAPTER 4 CHAPTER 4
4-2 4-2
PAGE 116 PAGE 116
PAGE 117 PAGE 117
REMARKS: Manual revised to add wheel stud part number per Engineer Dan Oliver.
Tug will add this part number in their next revision per Tommy Rampley.

HIGHLIGHTS
MANUAL CODE: 1196

0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633

NO:
:

*NOTE: PLEASE DO NOT REMOVE DAL PAPERWORK.
REMARKS: Manual revised to incorporate latest revision per manufacturer.

HIGHLIGHTS
MANUAL CODE: 1196

0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633

NO:
:
REMOVE & DESTROY INSERT INSERT

DATA PAGE DATA PAGE
DAL LEP DAL LEP
CHAPTER 4 CHAPTER 4
4-2 4-2
PAGE 25 PAGE 25
REMARKS: Manual revised to incorporate EA 15-085652-03, Rev. A -- Deutz

B4FM1011
3KW Starter Upgrade.

HIGHLIGHTS
MANUAL CODE: 1196

0559 17616 - 17638, 17691 - 17788, 17795 - MODEL M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633

NO:
:
REMOVE & DESTROY INSERT INSERT

DATA PAGE DATA PAGE
DAL LEP DAL LEP
CHAPTER 4 CHAPTER 4
4-2 4-2
PAGE 52 PAGE 52
PAGE 53 PAGE 53
PAGE 74 NO REPLACEMENT
REMARKS: Manual revised to incorporate EA 15-74755-3 -- Remove Front Brakes

From S/S Tug M1 Bag Tractor.

HIGHLIGHTS
MANUAL CODE: 1196
LYNN BURNS 4-20-04 4-1150

Lynn Burns
DAL MANUAL 0559 17616 - 17638, 17691 - 17788, 17795 - MFR. P/N: M1
P/N:
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526, 170531 - 170534,
170538 - 170633
UNIT: TUG - TOW TRACTOR MFR: TUG, INC.

NO:

DAL LEP DAL LEP
CHAPTER 2 CHAPTER 2
2-1 2-1
PAGE 2 PAGE 2
CHAPTER 4 CHAPTER 4
4-2 4-2
PAGE 47 PAGE 47
REMARKS:
Manual revised to incorporate changes directed by Engineer,
Dan Oliver concerning tire pressure.

HIGHLIGHTS
MANUAL CODE: 1196
ANALYST DATE PHONE

JERRY MOON / LYNN BURNS 4-9-02 4-1148
DAL MANUAL PIN: 0559 17616 - 17638, 17691 - 17788, 17795 - MFR.P/N: M1
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - 170514,
170519 - 170526. 170531 - 170534,
170538 - 170633
UNIT: TUG - TOW TRACTOR MFR.: TUG, INC.
PUBLICATION: OPERATION, MAINTENANCE & MFG./ PUB.

NO:
PARTS

*ENTIRE CONTENTS ENTIRE CONTENTS
*NOTE: RETAIN ALL DAL PAGES IN FRONT OF MANUAL. Ifyou have any questions regarding
this procedure, please do not hesitate to contact this office @ 714-1148.
REMARKS: Manual revised to incorporate vendor transmittal issued.
• FOR INFORMATION ONLY

REVISION RECORD LOG
This manual is the property of Delta Air lines Inc. It is not to be

transferred from one location or individual to another. (In the
event that this manual is no longer required see SP 1101 for Manual # 1196
disposition.)
Immediately upon receipt of revision, remove and insert manual

pages as specified. Record revision date and date revision is
inserted. Write initials of person inserting revision in “Rev. No.”
column.
Rev. Rev. Date Rev. Rev. Date Rev. Rev. Date

No. No. No.
1. 4-9-02 21. 06/15/2018 41.
2. 4-9-02 22. 04/08/2020 42.
3. 4-9-02 23. 43.
4. 4-9-02 24. 44.
5. 4-9-02 25. 45.
6. 4-9-02 26. 46.
7. 4-9-02 27. 47.
8. 4-9-02 28. 48.
9. 4-9-02 29. 49.
10. 4-9-02 30. 50.
11. 4-9-02 31. 51.
12. 4-9-02 32. 52.
13. 4-20-04 33. 53.
14. 8-20-04 34. 54.
15. 1-26-06 35. 55.
16. 5-17-06 36. 56.
17. 7-24-06 37. 57.
18. 11-21-06 38. 58.
19. 10-14-11 39. 59.
20. 4-22-15 40. 60.
THIS SHEET WILL NOT BE REMOVED AT ANY TIME.

UNIT E.A. EFFECTIVITY
DAL P/N: 0559 17616 - 17638, 17691 -

17788, 17795 -
17999, 170000 - 170004, 170007 - 170250,
170254, 170256 - 170430, 170432 - MFR. P/N: MODEL M1
170514,
170519 - 170526. 170531 - 170534,
170538 - 170633
UNIT: TUG -TOW TRACTOR MFR.: TUG, INC.
PUBLICATION : OPERATION,
MAINTENANCE AND MFR. PUB. NO.:
PARTS
MANUAL CODE: 1196 EQUIPMENT:
MODIFICATION:
GEA 15-73012-3 -- Accelerator Pedal Assembly Replacement.
GEA 15-72850-3 -- Governor Guard Installation.
GEA 20-72804-3 -- Front Wheel Replacement.
GEA 15-73262-3 -- M1 Exhaust Pipe Replacement.
GEA 15-74683-3 -- TU41 Heater Replacement.
GEA 15-74854-3 -- M1 Front Spring Replacement.
EA15-085556-3 -- M1A Crossmember Repair Drawing.
EA 15-74755-3 -- Remove Front Brakes From S/S Tug M1 Bag Tractor.
EA 15-085652-03, Rev. A. -- Deutz B4FM1011 3KW Starter Upgrade.
EA 15-504981-03 -- TUG M1A Park Brake Relocation

EA 15- 567680-03 Tug M1A Horn Button Hazard Elimination
EA 15-581593-03 REV A M1A Electronic Transmission Upgrade
8-1-12
DAL REVISED DATA PAGE
DELTA AIR LINES, INC.
GSE Warranty Procedures

IF YOU ARE IN A BIND AND NEED TO GET THE EQUIPMENT BACK IN
SERVICE IMMEDIATELY, DO WHAT YOU HAVE TO DO, BUT, FOLLOW UP
WITH AN EMAIL (PREFERABLE) OR PHONE CALL (404-714-5166) TO MIKE
MAIER (GSE ASSETS & MTC - DEPT 115).
Otherwise, all manufacturers prefer they be advised of any warranty failures, in advance
of any work being performed. When you have that luxury, do the following:
• Determine if the unit is under warranty. Two years from in service date is the rule of
thumb. If in doubt, contact Mike Maier via email (preferable) or at 404-714-
5166. Provide the following:
Delta Vehicle Number

Serial Number
In Service Date
Hour meter or mileage reading
Component Model Number (if applicable; example: engine model number)
Component Serial Number (if applicable; example: engine serial number)
Detailed explanation of problem
Name, phone number and station code of person requesting warranty
Hours spent (If work has already been performed, provide the labor hours spent
and the part number and cost, of any replacement parts not provided
at no charge by the manufacturer)
• When requested by the manufacturer, return all failed parts via some traceable
method. Retain proof of shipment in local file. Failure to do this may result in a
charge back by the manufacturer. They need these parts for failure analysis and to
recover warranty from their Supplier.
• EBIS - If EBIS is being used to record work performed, ensure thorough entries are
made in each field, especially in the “reason for failure” and “work performed” areas.
4/24/14
WARRANTY
PAGE 1
GSE PARTS SUPPORT

Delta’s Warranty Claim and Ordering Procedure During and After the Warranty Period
During the warranty period the initial contact (whenever possible), for coverage of any part or
system failure, should be with the Warranty Department in Atlanta. After normal working
hours, weekends or holidays when unable to contact Warranty, do whatever is necessary and
be sure a follow-up contact is made with the Warranty Department the following working day
for proper documentation and processing should this occur.
Any items for which replacements are ordered, either stock or non-stock during the warranty
period should be carefully tagged WARRANTY and returned to Department 586 in Atlanta
for processing to the vendor for warranty replacement.
After the specified warranty expires, all non-stock orders should be made with Material Services
Planning - Atlanta.
Please call the Following Extensions in Atlanta:
Warranty Assistance: 4-1332
Engineering Assistance: 4-1148, 4-1316, 3-1556, 3-2225, 4-9848
Material Services Planning Assistance: 4-3631 (Stock Items)

4-3637 (Non-Stock Items)
Technical Procedures Assistance: 4-4636
Purchasing Department Assistance: 4-1171, 4-5050
8-21-01 PARTS SUPPORT

PAGE 1
MODEL M1
TUG - TOW TRACTOR
TUG, INC.
LIST OF EFFECTIVE PAGES

MANUAL CODE: 1196
CHAPTER PAGE DATE CHAPTER PAGE DATE CHAPTER PAGE DATE
60A 5-21-98
66A 4-9-02
DATA 4-27-15 66B 4-9-02
WAR- 1 4-24-14
RANTY
73 4-9-02
PARTS
SUPPORT 1 8-21-01 116 5-17-06
117 5-17-06
4-2 EA 15- 4-27-15

504981-03
CHAPTER
4
TECH TIP 11-27-06
4-2
9 4-9-02
14B 05-21-98
CHAPTER
2 15 05-21-98
25 11-4-04
30 4-9-02
32A 05-21-98
2-1
2 4-20-04 49 4-9-02
52 8-20-04
53 8-20-04
4-27-15 DAL-LEP-1
DAL REVISED
MODEL M1/M1A
LOW PROFILE TOW TRACTOR
OPERATION, MAINTENANCE
& PARTS MANUAL
Delta Air Lines
Rev 10: MAY 2010
ORIGINALLY ISSUED APRIL 1997

Introduction M1A Low Profile Tow Tractor - Delta Air Lines
NOTE: The information contained in this publication is intended

Note exclusively for the use of TUG and its customers. Disclosure to non-TUG
customers may result in legal action by TUG.
NOTE: The information contained in this document is intended to be

accurate and up to date at the time of original issue. TUG reserves the
Note
right to update the information in this document, without warning, as
deemed prudent or necessary by TUG.
INTRO-ii CD368
Rev 7
M1A Low Profile Tow Tractor - Delta Air Lines Introduction
RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: Zip Code:
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual. TUG assumes
no liability for personal injury or equipment failure due to any operation performed without heed to manual
revisions.
Date of original publication: April 1997
Revision Number Date Brief Description
1A July 1997 M1A Modifications
2 June 1999 Updates and Corrections
3 October 2001 Sec 4-2 Restructured; Misc Updates
4 March 2003 Sec 4-2 Rest.; Indexes/LEP Updates
5 January 2004 Parts & Index Updates
6 March 2004 Tire Pressure & Parts Corrections
7 November 2005 Manual Rest. & IPL Updates
8 January 2006 Hydraulic Pressure Update
9 July 2006 Add wheel Stud to 4-2
10 May 2010 Deutz Tier IVi; IPL Updates
CD368 INTRO-iii
Rev 10
LIST OF EFFECTIVE PAGES
Chapter-Section Page Revision Chapter-Section Page Revision

INTRO- 1 Rev 10 INTRO- 37 Rev 10
INTRO- 5 Rev 10
INTRO- 6 Rev 10 SAFETY- 1 Rev 7
INTRO- 14 Rev 7
INTRO- 15 Rev 7 1-TOC- 1 Rev 7
INTRO- 19 Rev 7
INTRO- 20 Rev 7 1-1- 1 Rev 7
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INTRO-iv CD368
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INTRO-vi CD368
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INTRO-viii CD368
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4-3- 27 Rev 10 4-4- 14 Rev 10
4-3- 28 Rev 10 4-4- 15 Rev 10
4-3- 29 Rev 10 4-4- 16 Rev 10
4-3- 30 Rev 10 4-4- 17 Rev 10
4-3- 31 Rev 10 4-4- 18 Rev 10
4-3- 32 Rev 10 4-4- 19 Rev 10
4-3- 33 Rev 10 4-4- 20 Rev 10
4-3- 34 Rev 10 4-4- 21 Rev 10
4-3- 35 Rev 10 4-4- 22 Rev 10
4-3- 36 Rev 10 4-4- 23 Rev 10
4-3- 37 Rev 10 4-4- 24 Rev 10
4-3- 38 Rev 10 4-4- 25 Rev 10
4-3- 39 Rev 10 4-4- 26 Rev 10
4-3- 40 Rev 10 4-4- 27 Rev 10
4-3- 41 Rev 10 4-4- 28 Rev 10
4-3- 42 Rev 10 4-4- 29 Rev 10
4-3- 43 Rev 10 4-4- 30 Rev 10
4-3- 44 Rev 10 4-4- 31 Rev 10
4-3- 45 Rev 10 4-4- 32 Rev 10
4-3- 46 Rev 10 4-4- 33 Rev 10
4-3- 47 Rev 10 4-4- 34 Rev 10
4-3- 48 Rev 10 4-4- 35 Rev 10
4-3- 49 Rev 10 4-4- 36 Rev 10
INTRO-x CD368
Rev 10

4-4- 37 Rev 10
4-4- 38 Rev 10
4-4- 39 Rev 10
4-4- 40 Rev 10
4-4- 41 Rev 10
4-4- 42 Rev 10
4-4- 43 Rev 10
4-4- 44 Rev 10
4-4- 45 Rev 10
4-4- 46 Rev 10
4-4- 47 Rev 10
4-4- 48 Rev 10
4-4- 49 Rev 10
4-4- 50 Rev 10
5-TOC 1 Rev 7
5-TOC 2 Rev 7
5-1- 1 Rev 7
5-1- 2 Rev 8
5-2- 1 Rev 7
5-2- 2 Rev 7
CD368 INTRO-xi
Rev 10
MANUAL TABLE OF CONTENTS
Record of Revisions...........................................................................................................INTRO-iii
List of Effective Pages ...................................................................................................... INTRO-iv
Manual Table of Contents .................................................................................................INTRO-xii
Copyright Notice ............................................................................................................. INTRO-xxv
Introduction .................................................................................................................... INTRO-xxvi
Unit Identification .......................................................................................................... INTRO-xxvi
Model Number Coding ................................................................................................. INTRO-xxvii
Technical Assistance ................................................................................................... INTRO-xxviii
Warranty Policy Statement ............................................................................................. INTRO-xxix
How to Use This Manual .............................................................................................. INTRO-xxxix
SAFETY ............................................................................................................................... SAFETY-I

A. Standard Safety Features .............................................................................. SAFETY-i
B. Available Safety Items as Extra Cost Options .............................................. SAFETY-ii
C. Operator Responsibilities ............................................................................. SAFETY-ii
D. Mechanic Responsibilities ........................................................................... SAFETY-iv
CHAPTER 1: GENERAL INFORMATION AND

OPERATING INSTRUCTIONS
SECTION 1: DESCRIPTION ..................................................................................................... 1-1-1

A. Tractor .................................................................................................................. 1-1-1
B. Component/System .............................................................................................. 1-1-1
1. Engine and Transmission ......................................................................... 1-1-1
2. Drive Shaft ................................................................................................ 1-1-2
3. Drive Axle .................................................................................................. 1-1-2
4. Front Suspension ..................................................................................... 1-1-2
5. Braking System ........................................................................................ 1-1-3
6. Wheels ..................................................................................................... 1-1-3
7. Tires .......................................................................................................... 1-1-3
8. Front and Rear Suspension ...................................................................... 1-1-3
9. Fuel Cell .................................................................................................... 1-1-4
10. Electrical System ...................................................................................... 1-1-4
INTRO-xii CD368
Rev 10
11. Frame and Bumpers ................................................................................. 1-1-4

12. Seat .......................................................................................................... 1-1-4
13. Fasteners .................................................................................................. 1-1-4
14. Towing Bracket ......................................................................................... 1-1-4
15. Cab ........................................................................................................... 1-1-4
16. Overhead Guard ....................................................................................... 1-1-5
17. Optional Equipment .................................................................................. 1-1-5
SECTION 2: OPERATION .......................................................................................................... 1-2-1

A. Controls, Instruments, and Switches.................................................................... 1-2-1
1. Morse Gear Shift Unit ................................................................................ 1-2-2
2. Park Brake Lever ...................................................................................... 1-2-2
3. Ignition Switch ........................................................................................... 1-2-2
4. Accelerator Pedal ..................................................................................... 1-2-2
5. Foot Brake Pedal ...................................................................................... 1-2-2
6. Headlight Switch ....................................................................................... 1-2-2
7. Wiper Control Switch ................................................................................ 1-2-2
8. Heater Switch ........................................................................................... 1-2-2
9. Safe-Start .................................................................................................. 1-2-2
10. Cab Dome Light Switch ............................................................................ 1-2-3
11. Instruments ............................................................................................... 1-2-3
B. Trailers .................................................................................................................. 1-2-3
C. Trailer Braking Systems ....................................................................................... 1-2-4
1. Overrun Brakes ........................................................................................ 1-2-4
2. Parking Brakes ......................................................................................... 1-2-4
D. Safety ................................................................................................................... 1-2-4
1. Tips ........................................................................................................... 1-2-4
2. Precautions ............................................................................................... 1-2-5
E. Procedures ........................................................................................................... 1-2-5
1. Driving Instructions ................................................................................... 1-2-5
2. Towing Instructions ................................................................................... 1-2-6
3. Periodic Maintenance ................................................................................ 1-2-7
SECTION 3: SPECIFICATIONS AND CAPABILITIES .............................................................. 1-3-1

A. Dimensions .......................................................................................................... 1-3-1
B. Engine .................................................................................................................. 1-3-1
1. Deutz F4L 1011F ..................................................................................... 1-3-1
2. Deutz F4M 2011 (Tier II) ............................................................................ 1-3-2
3. Deutz D2011 (Tier IVi) .............................................................................. 1-3-2.
CD368 INTRO-xiii
Rev 10
C. Transmission ........................................................................................................ 1-3-2

D. Electrical System .................................................................................................. 1-3-2
E. Chassis ................................................................................................................ 1-3-2
F. Suspension ........................................................................................................... 1-3-3
G. Braking System .................................................................................................... 1-3-3
1. Service Brake ........................................................................................... 1-3-3
2. Parking Brake ........................................................................................... 1-3-3
H. Axle ....................................................................................................................... 1-3-3
I. Steering System ................................................................................................... 1-3-3
J. Tires ...................................................................................................................... 1-3-4
K. Drive Shaft ............................................................................................................ 1-3-4
L. Fuel System ......................................................................................................... 1-3-4
M. Cooling System .................................................................................................... 1-3-4
N. Instruments ........................................................................................................... 1-3-4
SECTION 4: SHIPPING ............................................................................................................. 1-4-1

A. Preparation ........................................................................................................... 1-4-1
1. Battery ...................................................................................................... 1-4-1
2. Radiator .................................................................................................... 1-4-1
3. Fuel Cell .................................................................................................... 1-4-1
4. Checks ..................................................................................................... 1-4-1
B. Preparing for Operation ........................................................................................ 1-4-2
1. Radiator .................................................................................................... 1-4-2
2. Fuel Cell .................................................................................................... 1-4-2
3. Battery ...................................................................................................... 1-4-2
SECTION 5: STORAGE ............................................................................................................ 1-5-1

A. For One Month ...................................................................................................... 1-5-1
1. Engine ....................................................................................................... 1-5-1
2. Transmission ............................................................................................ 1-5-1
3. Drive Axle and Reduction Gear Box .......................................................... 1-5-1
4. Tires .......................................................................................................... 1-5-1
5. Lubrication ................................................................................................ 1-5-1
6. Fluid Levels ............................................................................................... 1-5-2
7. Wheel Bearings ........................................................................................ 1-5-2
8. Battery ...................................................................................................... 1-5-2
INTRO-xiv CD368
Rev 7
B. For Indefinite Period .............................................................................................. 1-5-2

1. Engine ....................................................................................................... 1-5-2
2. Transmission ............................................................................................ 1-5-3
4. Tires .......................................................................................................... 1-5-3
5. Lubrication ................................................................................................ 1-5-3
6. Fluid Levels ............................................................................................... 1-5-3
7. Wheel Bearings ........................................................................................ 1-5-3
8. Battery ...................................................................................................... 1-5-3
CHAPTER 2: MAINTENANCE
SECTION 1: SERVICING ........................................................................................................... 2-1-1

A. Preparation for Use ............................................................................................... 2-1-1
1. Fuel System .............................................................................................. 2-1-1
2. Battery ...................................................................................................... 2-1-1
3. Brake System ........................................................................................... 2-1-1
5. Rear Axle and Reduction Gear Box .......................................................... 2-1-2
6. Tire Inflation ............................................................................................... 2-1-2
7. Power Steering Fluid ................................................................................. 2-1-2
B. Periodic Maintenance Schedule ........................................................................... 2-1-2
1. Daily ......................................................................................................... 2-1-2
2. Weekly or 50 Hours .................................................................................. 2-1-3
3. Monthly or 200 Hours ................................................................................ 2-1-4
4. Two (2) Months or 400 Hours.................................................................... 2-1-5
5. Ten (10) Weeks or 500 Hours ................................................................... 2-1-5
6. Six (6) Months or 1200 Hours ................................................................... 2-1-6
7. Yearly or 2400 Hours ................................................................................. 2-1-6
8. Lubricant Charts ....................................................................................... 2-1-8
9. Adjustment Instruction ............................................................................ 2-1-11
SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1

A. Loss of Power ...................................................................................................... 2-2-1
B. Rear Axle .............................................................................................................. 2-2-2
CD368 INTRO-xv
Rev 7
C. Twelve (12) Volt System ....................................................................................... 2-2-3

1. Headlights ................................................................................................. 2-2-3
2. Stop Lights ................................................................................................ 2-2-4
3. Back-Up Light ........................................................................................... 2-2-5
4. Turn Signal Lights ..................................................................................... 2-2-6
5. Cab Marker Light ....................................................................................... 2-2-7
6. Wiper Motor .............................................................................................. 2-2-8
7. Horn .......................................................................................................... 2-2-9
8. Electric Fan ............................................................................................. 2-2-11
D. Steering ............................................................................................................... 2-2-12
E. Brake System ..................................................................................................... 2-2-15
F. Alternator ............................................................................................................ 2-2-19
G. Battery ................................................................................................................ 2-2-20
H. Electrical Wiring Diagrams ................................................................................. 2-2-21
Figure 2-1. Wrg Schematic, Deutz 1011F Diesel Eng with Del. Start Option .... 2-2-21
Figure 2-2. Wrg Diagm, Deutz 1011F Diesel Eng with Eng Shut & Trans Inter .. 2-2-22
Figure 2-3. M. Wrg Sch., Deutz F4M2011 (Tier II) Diesel Eng (Delta) (1 of 2) ... 2-2-23
Figure 2-4. Gen Wrg Sch., Deutz D2011 (Tier IVi) Diesel Engine (1 of 2) ......... 2-2-25
SECTION 3: REMOVAL/INSTALLATION ................................................................................... 2-3-1

A. Hood Panel ........................................................................................................... 2-3-1
1. Removal ................................................................................................... 2-3-1
2. Installation ................................................................................................. 2-3-1
B. Radiator/Fan Assembly ........................................................................................ 2-3-1
1. Removal ................................................................................................... 2-3-1
2. Installation ................................................................................................. 2-3-2
C. Oil Cooler .............................................................................................................. 2-3-3
1. Removal ................................................................................................... 2-3-3
2. Installation ................................................................................................. 2-3-3
D. Battery .................................................................................................................. 2-3-4
1. Removal ................................................................................................... 2-3-4
2. Installation ................................................................................................. 2-3-5
E. Operator’s Seat .................................................................................................... 2-3-5
1. Removal ................................................................................................... 2-3-5
INTRO-xvi CD368
Rev 10
2. Installation ................................................................................................. 2-3-5

F. Tires and Wheels .................................................................................................. 2-3-6
1. Rear Tire and Wheel Removal/Installation ................................................ 2-3-6
2. Front Tire and Wheel Removal/Installation ............................................... 2-3-7
G. Drive Shaft ............................................................................................................ 2-3-7
1. Removal ................................................................................................... 2-3-7
2. Installation ................................................................................................. 2-3-8
H. Drive Axle and Mounting Springs ........................................................................... 2-3-8
1. Removal ................................................................................................... 2-3-8
2. Installation ................................................................................................. 2-3-9
I. Engine/Transmission ............................................................................................ 2-3-9
1. Removal ................................................................................................... 2-3-9
2. Installation ............................................................................................... 2-3-12
J. Shifter ................................................................................................................. 2-3-13
1. Removal ................................................................................................. 2-3-13
2. Installation ............................................................................................... 2-3-14
K. Accelerator Pedal, Throttle Control Cable and Modulator Cable ......................... 2-3-14
1. Accelerator Pedal Removal/Installation................................................... 2-3-14
2. Throttle and Modulator Cable Removal ................................................... 2-3-15
3. Throttle and Shift Cables Installation ....................................................... 2-3-15
L. Tail Pipe/Muffler/Exhaust Pipe ............................................................................. 2-3-16
1. Removal ................................................................................................. 2-3-16
2. Installation ............................................................................................... 2-3-17
M. Swing Arm Assembly .......................................................................................... 2-3-19
1. Removal ................................................................................................. 2-3-19
2. Installation ............................................................................................... 2-3-20
N. Steer Valve .......................................................................................................... 2-3-21
1. Removal ................................................................................................. 2-3-21
2. Installation ............................................................................................... 2-3-21
O. Steering Column and Steering Wheel ................................................................. 2-3-22
1. Removal ................................................................................................. 2-3-22
2. Installation: .............................................................................................. 2-3-22
P. Steer Cylinder ..................................................................................................... 2-3-23
1. Removal ................................................................................................. 2-3-23
2. Installation ............................................................................................... 2-3-24
Q. Master Cylinder ................................................................................................... 2-3-24
1. Removal ................................................................................................. 2-3-24
CD368 INTRO-xvii
Rev 7
2. Installation ............................................................................................... 2-3-24

R. Brake Pedal ........................................................................................................ 2-3-25
1. Removal ................................................................................................. 2-3-25
2. Installation ............................................................................................... 2-3-25
S. Parking Brake: Linkage and Lever ...................................................................... 2-3-25
1. Removal ................................................................................................. 2-3-25
2. Installation ............................................................................................... 2-3-26
T. Alternator ............................................................................................................ 2-3-26
1. Removal ................................................................................................. 2-3-26
2. Installation ............................................................................................... 2-3-27
U. Starter/Solenoid .................................................................................................. 2-3-27
1. Removal ................................................................................................. 2-3-27
2. Installation ............................................................................................... 2-3-27
V. Oil Temperature Sending Unit and Gauge .......................................................... 2-3-27
1. Temperature Sending Unit Removal/Installation ..................................... 2-3-27
2. Oil Temperature Gauge Removal/Installation .......................................... 2-3-28
W. Oil Pressure Sending Unit and Gauge ................................................................ 2-3-28
1. Oil Pressure Sending Unit Removal/Installation ..................................... 2-3-28
2. Oil Pressure Gauge Removal/Installation ............................................... 2-3-28
X. Voltmeter............................................................................................................. 2-3-29
1. Removal ................................................................................................. 2-3-29
2. Installation ............................................................................................... 2-3-29
Y. Elapsed Time Indicator ....................................................................................... 2-3-29
1. Removal ................................................................................................. 2-3-29
2. Installation ............................................................................................... 2-3-29
Z. Switches ............................................................................................................. 2-3-30
1. Ignition Switch Removal/Installation ........................................................ 2-3-30
2. Headlight Switch Removal Installation .................................................... 2-3-30
3. Auxiliary Switch Removal/Installation ...................................................... 2-3-30
4. Brake Warning Light Removal/Installation ............................................... 2-3-31
AA. Headlights, Stop Lights, and Turn Signal Lights .................................................. 2-3-31
1. Headlight Removal/Installation ................................................................ 2-3-31
2. Stop Light and Back-Up Light Removal/Installation ................................. 2-3-32
3. Turn Signal Light Removal/Installation .................................................... 2-3-32
BB. Bulb Replacement .............................................................................................. 2-3-32
1. Brake Warning ........................................................................................ 2-3-32
INTRO-xviii CD368
Rev 7
2. Headlight ................................................................................................. 2-3-33

3. Stop Light ................................................................................................ 2-3-33
4. Turn Signal .............................................................................................. 2-3-33
5. Back-Up Light: ........................................................................................ 2-3-33
6. Temperature Gauge ................................................................................ 2-3-33
7. Pressure Gauge ..................................................................................... 2-3-33
8. Voltmeter ................................................................................................. 2-3-33
CC. Cab Door Removal/Installation (Optional) .......................................................... 2-3-34
DD. Cab Assembly Removal/Installation (Optional) ................................................... 2-3-34
EE. Steer Axle Removal / Replacement .................................................................... 2-3-34
1. Removal ................................................................................................. 2-3-34
2. Installation ............................................................................................... 2-3-35
CHAPTER 3: OVERHAUL
SECTION 1: GENERAL ............................................................................................................. 3-1-1
SECTION 2: STEERING ........................................................................................................... 3-2-1
SECTION 3: DRIVE SHAFT UNIVERSAL JOINTS .................................................................. 3-3-1

A. Disassembly ......................................................................................................... 3-3-1
B. Installation ............................................................................................................. 3-3-1
SECTION 4: DRIVE AXLE ......................................................................................................... 3-4-1

A. Reduction Gear Box ............................................................................................. 3-4-1
1. Removal ................................................................................................... 3-4-1
2. Cleaning .................................................................................................... 3-4-2
3. Inspection .................................................................................................. 3-4-2
4. Assembly of the Overhauled Reduction Gear ........................................... 3-4-3
B. Drive Axle .............................................................................................................. 3-4-4
1. Preparation ............................................................................................... 3-4-4
2. Remove Axle Shaft.................................................................................... 3-4-4
3. Disassemble Axle Housing ....................................................................... 3-4-5
4. Remove Pinion and Cage Assembly ........................................................ 3-4-5
5. Disassemble Differential and Gear Assembly .......................................... 3-4-6
6. Pinion and Cage Assembly ....................................................................... 3-4-6
7. Clean ........................................................................................................ 3-4-7
CD368 INTRO-xix
Rev 7
8. Inspect ...................................................................................................... 3-4-7

9. Repair ....................................................................................................... 3-4-8
10. Assembling Pinion and Cage .................................................................... 3-4-8
11. Assembling Differential and Bevel Gear .................................................... 3-4-9
12. Pinion and Cage Assembly ..................................................................... 3-4-10
13. Install Differential Assembly .................................................................... 3-4-10
14. Install Axle Shaft ...................................................................................... 3-4-10
15. Torque Specifications Table .................................................................... 3-4-11
SECTION 5: FRONT AND REAR WHEEL DISC BRAKES ....................................................... 3-5-1

A. Brake Pad Replacement ...................................................................................... 3-5-1
1. Preparation ............................................................................................... 3-5-1
2. Caliper Removal ....................................................................................... 3-5-1
3. Brake Pad Removal .................................................................................. 3-5-2
4. Cleaning and Inspection ............................................................................ 3-5-3
5. Brake Pad Installation ............................................................................... 3-5-3
6. Caliper Installation ..................................................................................... 3-5-4
7. Check-Out ................................................................................................ 3-5-5
B. Caliper Overhaul ................................................................................................... 3-5-5
1. General Layout .......................................................................................... 3-5-5
2. Removal ................................................................................................... 3-5-6
3. Disassembly ............................................................................................. 3-5-6
5. Reassembly .............................................................................................. 3-5-7
6. Installation ................................................................................................. 3-5-8
7. Check-Out ................................................................................................ 3-5-8
C. Rotor ..................................................................................................................... 3-5-9
1. Rotor Removal .......................................................................................... 3-5-9
2. Cleaning .................................................................................................. 3-5-10
3. Inspection ................................................................................................ 3-5-10
4. Rear Reassembly ................................................................................... 3-5-10
5. Front Reassembly .................................................................................. 3-5-10
6. Installation ............................................................................................... 3-5-10
7. Check Out ............................................................................................... 3-5-11
D. Bleeding the Disc Brake System ........................................................................ 3-5-11
1. General ................................................................................................... 3-5-11
INTRO-xx CD368
Rev 7
2. Manual Bleeding ...................................................................................... 3-5-12

3. Pressure Bleeding .................................................................................. 3-5-13
4. Check-Out .............................................................................................. 3-5-13
CHAPTER 4: ILLUSTRATED PARTS LIST

Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number .......................................................................... 4-1-2
2. Part Numbers ........................................................................................... 4-1-2
3. Description and Quantity .......................................................................... 4-1-2
4. Effectivity................................................................................................... 4-1-2
C. Ordering Spare Parts ............................................................................................ 4-1-2
SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

Figure 2-1. Frame Weldment Assembly .............................................................. 4-2-2
Figure 2-2. Frame Assembly - Front .................................................................... 4-2-4
Figure 2-3. Frame Assembly - Rear .................................................................... 4-2-6
Figure 2-4. Frame Crossmembers Installation .................................................... 4-2-8
Figure 2-5. Firewall Assembly ............................................................................ 4-2-10
Figure 2-6. Seat Plate Installation ...................................................................... 4-2-12
Figure 2-7. Body Assembly ................................................................................ 4-2-14
Figure 2-8. Hood and Side Panels Installation (Rev 10)..................................... 4-2-16
Figure 2-9. Cab Weldment ................................................................................ 4-2-18
Figure 2-10. Cab Assembly ............................................................................... 4-2-20
Figure 2-11. Windshield Wiper Assembly .......................................................... 4-2-22
Figure 2-12. Doors Assembly ............................................................................ 4-2-24
Figure 2-13. Door Latch Assembly .................................................................... 4-2-26
Figure 2-14. Seat Installation (Rev 1A) .............................................................. 4-2-28
Figure 2-15. Seat Installation (Rev 10) ............................................................... 4-2-30
Figure 2-16. Light Assemblies ........................................................................... 4-2-32
Figure 2-17. Wheel and Tire Assemby - Front ................................................... 4-2-34
Figure 2-18. Wheel and Tire Assemby - Rear.................................................... 4-2-36
Figure 2-19. Wheels and Tires .......................................................................... 4-2-38
Figure 2-20. Hitch .............................................................................................. 4-2-40
Figure 2-21. Dash Console Assembly (Orig) ..................................................... 4-2-42
Figure 2-22. Dash Console Assembly (Rev 10) ................................................ 4-2-44
CD368 INTRO-xxi
Rev 10
Figure 2-23. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 3) ... 4-2-46
Figure 2-24. Dash Console Assy (Accelerator & Brake Pedals) (Rev 10) ......... 4-2-48
Figure 2-25. Instrument Panel with Override Switch - Deutz ............................. 4-2-50
Figure 2-26. Instrument Panel - Deutz (Rev 3) .................................................. 4-2-52
Figure 2-27. Instrument Panel - Deutz (Rev 10) ................................................ 4-2-54
Figure 2-28. Transmission Cover Decals .......................................................... 4-2-56
Figure 2-29. Circuit Breakers Installation ........................................................... 4-2-58
Figure 2-29a. Circuit Breakers Installation with Cab Option .............................. 4-2-60
Figure 2-30. Relays Installation - Deutz ............................................................. 4-2-62
Figure 2-31. Accelerator and Modulator Cables Installation - Deutz .................. 4-2-64
Figure 2-32. Accelerator and Modulator Cables Installation - Deutz (Rev 10) .... 4-2-66
Figure 2-33. Accelerator Cable Mounting ........................................................... 4-2-68
Figure 2-34. Shifter Assembly ............................................................................ 4-2-70
Figure 2-35. Shifter and Shifter Cable Installation (Rev 3) ................................. 4-2-72
Figure 2-36. Shifter and Shifter Cable Installation (Rev 10) ............................... 4-2-74
Figure 2-37. Shifter Linkage (Rev 3) .................................................................. 4-2-76
Figure 2-38. Shifter Linkage (Rev 10) ................................................................ 4-2-78
Figure 2-39. Hydro-Boost Installation (Rev 7) .................................................... 4-2-80
Figure 2-40. Hydro-Boost Installation (Rev 10) .................................................. 4-2-82
Figure 2-41. Brake Line Assy (Option without Front Brakes) (Up to S/N 2685) . 4-2-84
Figure 2-41a. Brake Line Assy (Option without Front Brakes) (S/N 2685 & Up) 4-2-86
Figure 2-41b. Brake Line Assembly (Option without Front Brakes) (Rev 10) .... 4-2-88
Figure 2-42. Brake Line Assembly - Rear (Rev 3) (Up to S/N 2667) .................. 4-2-90
Figure 2-42a. Brake Line Assembly - Rear (Rev 7) (S/N 2667 & Up) ................ 4-2-92
Figure 2-43. Park Brake Handle Assembly ........................................................ 4-2-94
Figure 2-44. Park Brake Linkage ....................................................................... 4-2-96
Figure 2-45. Park Brake Installation (Rev 2) ...................................................... 4-2-98
Figure 2-46. Park Brake Installation (Rev 3) .................................................... 4-2-100
Figure 2-47. Park Brake Installation (Rev 10) .................................................. 4-2-102
Figure 2-48. Steering Column Assembly ......................................................... 4-2-104
Figure 2-49. Steer Valve Assembly (CharLynn) ................................................ 4-2-106
Figure 2-50. Hydraulic System (CharLynn) - Deutz (Orig) ............................... 4-2-108
Figure 2-51. Hydraulic System (CharLynn) - Deutz (Rev 2) ............................ 4-2-110
Figure 2-52. Hydraulic System - Deutz (Rev 8) ............................................... 4-2-112
Figure 2-53. Hydraulic Power Take-Off - Deutz ............................................... 4-2-114
Figure 2-54. Front (Steer) Axle Assembly (Rev 2) ............................................ 4-2-116
Figure 2-56. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 9) ............. 4-2-120
Figure 2-57. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 10) ........... 4-2-122
INTRO-xxii CD368
Rev 10
Figure 2-58. Tie Rod Assembly - Front (Steer) Axle ......................................... 4-2-124
Figure 2-59. Rear Suspension (Rev 2) ............................................................ 4-2-126
Figure 2-60. Rear Suspension (Rev 3) (Up to S/N 2094) ................................ 4-2-128
Figure 2-61. Rear Suspension (Rev 4) (S/N 2094 thru 2666) .......................... 4-2-130
Figure 2-61a. Rear Suspension (Rev 7) (S/N 2667 & Up) ............................... 4-2-132
Figure 2-62. Rear (Drive) Axle Installation ........................................................ 4-2-134
Figure 2-63. Rear (Drive) Axle Assembly (Orig)............................................... 4-2-136
Figure 2-64. Rear (Drive) Axle Assembly (Rev 3) ............................................ 4-2-140
Figure 2-65. Rear (Drive) Axle Assembly (Rev 10) .......................................... 4-2-142
Figure 2-65. Rear (Drive) Axle Assembly (Rev 10) - Con't. .............................. 4-2-144
Figure 2-66. Reduction Gear Box Assembly .................................................... 4-2-146
Figure 2-67. Drive Shaft ................................................................................... 4-2-148
Figure 2-68. Panhard Arm Assembly ............................................................... 4-2-150
Figure 2-69. Panhard Rod Installation (Up to S/N 2094) .................................. 4-2-152
Figure 2-70. Panhard Rod Installation (S/N 2094 & Up)................................... 4-2-154
Figure 2-71. Rear Brake Caliper Assembly (Up to S/N 2667) .......................... 4-2-156
Figure 2-71a. Rear Brake Caliper Assembly (S/N 2667 thru 3140) ................. 4-2-158
Figure 2-71b. Rear Brake Caliper Assembly (S/N 3140 & Up) ........................ 4-2-160
Figure 2-72. Engine - Deutz Diesel ................................................................. 4-2-162
Figure 2-73. Engine and Engine Mounts - Deutz Diesel (Orig) ........................ 4-2-164
Figure 2-74. Engine Motor Mounts Installation - Deutz Diesel (Rev 3) ............. 4-2-166
Figure 2-75. Engine Motor Mounts Install. - Deutz F4M2011 (Tier II) Diesel ..... 4-2-168
Figure 2-76. Engine Assy - Deutz F4M2011 (Tier II) & D2011 (Tier IVi) Diesel . 4-2-170
Figure 2-77. Engine/Transm Install. - Deutz w/ Ford C6 Trans (Orig) ............ 4-2-172
Figure 2-77. Engine/Transm Install - Deutz w/ Ford C6 Trans (Orig) - Con't .. 4-2-174
Figure 2-78. Engine/Transm Install - Deutz w/ Ford C6 Trans (Rev 10) ......... 4-2-176
Figure 2-79. Alternator Installation - Deutz Tier I (Orig) .................................... 4-2-178
Figure 2-80. Alternator Installation - Deutz Tier I (Rev 3) .................................. 4-2-180
Figure 2-81. Alternator Installation - Deutz F4M2011 (Tier II) (Rev 7) ............... 4-2-182
Figure 2-82. Alternator Installation - Deutz (Tier II & Tier IVi) (Rev 10) ............. 4-2-184
Figure 2-83. Air Intake System - Deutz (Rev 3) ............................................... 4-2-186
Figure 2-84. Fuel Tank Installation (Rev 2) ....................................................... 4-2-188
Figure 2-85. Fuel Tank Installation (Rev 10) ..................................................... 4-2-190
Figure 2-86. Fuel System - Deutz (Orig) ......................................................... 4-2-192
Figure 2-87. Fuel System w/ Racor Filter Option - Deutz ................................ 4-2-194
Figure 2-88. Fuel System w/ Racor Filter Option - Deutz F4M2011 (Tier II) .... 4-2-196
Figure 2-89. Fuel System w/ Racor Filter Opt - Deutz (Tier II & IVi) (Rev 10) .. 4-2-198
Figure 2-90. Exhaust System - Deutz (Rev 2)................................................. 4-2-200
CD368 INTRO-xxiii
Rev 10
Figure 2-92. Exhaust System - Deutz (Tier II & IVi) (Rev 10) ........................... 4-2-204
Figure 2-93. Engine Cooling System - Deutz (Rev 2) ..................................... 4-2-206
Figure 2-95. Engine Cooling System - Deutz (Rev 10) ................................... 4-2-210
Figure 2-96. Battery Installation (Rev 1A) ........................................................ 4-2-212
Figure 2-97. Battery Installation (Rev 3) ........................................................... 4-2-214
Figure 2-98. Horn Installation ........................................................................... 4-2-216
SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-1
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
CHAPTER 5: APPENDICES
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1

A. Daily and Weekly Checks ..................................................................................... 5-1-1
B. Monthly, Two-Month, 10-Week, Six-Month, and Yearly Checks ............................ 5-1-2
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS .............................................. 5-2-1

A. Description ........................................................................................................... 5-2-1
INTRO-xxiv CD368
Rev 10
COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of TUG.
Neither this document, nor any information contained herein, may be reproduced or redistributed in any form
whatsoever without the express, written consent of an authorized agent of TUG.
Any attempt by any person other than an authorized agent of TUG to alter the contents of this manual in any
way shall be construed as copyright infringement, punishable by all applicable laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors, protected
by the same laws governing this operation and maintenance manual.
© Copyright 2010 by TUG. All rights reserved.
CD368 INTRO-xxv
Rev 10
INTRODUCTION
The information and instructions in this handbook are intended to acquaint the operator with the important
operating features of the TUG model M1A Low Profile Tow Tractor. The various controls, gauges, switches,
and operating features are explained and illustrated throughout this handbook. Personnel responsible for
operation of the vehicle should read this manual carefully to become familiar with vehicle operation.
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a TUG identification plate is located on the
operator's compartment of the unit.
TUG TECHNOLOGIES CORPORATION

1995 DUNCAN DRIVE
KENNESAW, GEORGIA 30144
PH: 770 422−7230
MODEL:
SERIAL NO:
DRAWBAR CAP.: LBS.
MANUFACTURE DATE
The serial number identification of each unit will appear on the nameplate along with the date of manufacture.
The mailing address of TUG is also located on the data plate with the TUG logo. This necessary information
will ensure the customer a fast and accurate response to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit serial number
here:
If applicable, enter your company identification number
here:
INTRO-xxvi CD368
Rev 10
MODEL NUMBER CODING
M1A 30 - 1 - 137
Drawbar: Engine: Serial

30 = 3,000 lb DBP 1 = Ford 300 CID (4.9 liter) 6-Cyl Gasoline Number
40 = 4,000 lb DBP 42 = Ford ESG-642 (4.2L) 6-Cyl Gasoline
50 = 5,000 lb DBP 13 = Perkins 1000-4 243 CID (4.0L) 4-Cyl Diesel
60 = 6,000 lb DBP 23 = Perkins 1104C-44 Tier II Diesel
14 = Deutz 1011F Diesel
24 = Deutz F4M2011 Tier II Diesel
34 = Deutz D2011 Tier IVi Diesel
CD368 INTRO-xxvii
Rev 10
TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the M1A Low Profile Tow Tractor to:
TUG Technologies Corporation

P.O. Box 3028
Kennesaw, GA 30156
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
All information in this manual is based on the latest production information available at the time of publication.
Direct any questions concerning the contents or format of this manual to:
TUG Shop
P.O. Box 3028
Kennesaw, GA 30156
Domestic: 1-800-989-8499
International: (770) 422-8021
Fax: (770) 422-8730
Email: TugShop@tugtech.com
INTRO-xxviii CD368
Rev 10
INTRODUCTION
The primary goal of warranty adjustment is to satisfy our customers.

Every satisfied customer strengthens the components of our whole
organization - all aspects of the products themselves and the service that
backs them up. This Manual is directed to TUG Technologies
Distributors, and Customers of TUG Equipment. It should be used to
implement the Warranty Program at every level.
This Warranty Policy and Procedures Manual includes the warranties

of Tug Technologies Products It explains warranty policy and
coverage, and describes the warranty claim process.
Tug Technologies is responsible for handling warranty and policy

adjustments promptly and in accordance with the provisions of the
Sales and Service Agreement, TUG Technologies Warranty Statements
and this Manual. Customers who recognize the Manual as the "heart" of
the warranty system and train their personnel in its use may expect:
Service personnel qualified to submit claims that are properly
completed and fully substantiated, resulting in prompt claims payment.
NOTE: The guidelines and requirements in this Manual apply
to warranty claims submitted to TUG Technologies for reimbursement
to the Customer.
CD368 INTRO-xxix
Rev 10
PRE-DELIVERY PROCEDURES
Establish pre-delivery procedures that ensure the appropriate in-
spections and adjustments are made prior to equipment being
placed in service.
AUTHORIZATION REQUIREMENTS - REPAIRS REQUIRING
PRIOR APPROVAL
Certain repairs and claims require prior approval. Any repair
which will take more then 2 hours labor to complete must have
prior approval.
WARRANTY
A warranty is a specific document that guarantees the quality of goods
to a purchaser within a specified length of time and according to usage
limitations. The TUG Technologies warranty statement defines the con-
ditions of the warranty. A warranty:
Remains in force for the specified period, provided that an occurrence
has not taken place to render the warranty inapplicable.
Assures the owner that if, under the conditions specified, a defect in
factory workmanship or material is encountered, it will be corrected at
no charge or on a pro rata basis.
Extension of coverage by any manufacturer does not change what is
covered in the basic, expressed limited warranty.
WARRANTY STATEMENTS
TUG Technologies Warranty Statements provide detailed information
regarding coverage & usage limitations for TUG products.
INTRO-xxx CD368
Rev 10
WARRANTY POLICY & COVERAGE
SERVICE RECALLS OR OWNER NOTIFICATION PROGRAMS

TUG TECHNOLOGIES may establish a program to resolve extensive customer concern
about a component beyond warranty coverage. Owners are notified to contact TUG
Technologies for replacement/repair. Customers will be notified by TUG TECHNOLOGIES
with information that :
Identifies the component and condition.
Outlines the inspection and repair procedure required to correct the condition.
Defines reimbursement.
WARRANTY CANCELLATION
Certain situations cause a warranty to be canceled. Examples of such situations include, but
are not limited to:
Damaged due to accidents.
Damage due to abuse, improper operation or poor maintenance practices.
Total or partial warranty cancellation is registered in TUG TECHNOLOGIES records.
WARRANTY POLICY & COVERAGE
Shipment:
Shipment is considered acceptable
Freight Charges
To return recalled components is covered when shipped prepaid via least
expensive
Labor for Service :
Reimbursed at the approved hourly warranty labor rate.
Non-TUG Parts
Only covered with prior approval from TUG.
CD368 INTRO-xxxi
Rev 10
WARRANTY EXCLUSIONS
x The following items are examples of some of the non-reimbursable items under the
Warranty and Policy Program.
x Non-reimbursable repairs include:
x Any repair to a unit on which the mileage/hours or date of first use reported has been
misrepresented.
x Any repair to a unit on which the odometer/hour meter has been altered so that the true
mileage/hours cannot be determined. (Applies only to cases in which mileage/hours are
a condition of the warranty.)
x Any repair for which the date on the order has been misrepresented or altered to place
an out-of-warranty component within the warranty provisions.
x Any repair made to a product that has been misused or mistreated, or upon which a
conversion, modification or installation of a non-TUG part has been made so as to affect
the performance, reliability or stability of a part. Any failure to a TUG-supplied part
resulting from such action is not covered by the warranty.
x Parts handling charges.
x Parts damaged due to accident. The warranty on parts damaged because of accident or
an act of nature will be canceled.
x NOTE: Repairs on accident claims or conditions that could have contributed to personal
injury or property damage must not begin until approval is obtained.
x Do not scrap allegedly defective parts that may have contributed to injury or damage
until written approval is received.
x Repairs required because of inadequate or incorrect protection in storage and/or
preparation for storage.
x Repairs of damage or failure caused by poor outside workmanship.
x Any repair operation that changes the existing specifications of the equipment or
component.
x Repair techniques beyond the appropriate shop manual limits.
x Labor performed by other than an authorized TUG technician without prior approval,
unless the situation is an emergency.
x Use of other than genuine TUG parts, unless used in an emergency.
x A second or subsequent repair or adjustment necessitated by an incomplete or improper
original repair or adjustment.
x Adjustments made to improve appearance or performance beyond normal standards.
x Maintenance and normal replacement of service items, e.g., replacement of filters and
fluids, tightening of bolts, nuts or fittings. However, minor labor-only repairs are
reimbursable.
x Any repair to a part that is found not to be defective.
x Replacement of assembly rather than repair if replacement costs exceed repair costs, and
parts are available. Replacement requires prior approval.
x Labor operations such as additional diagnostic time, abnormal accessibility or diagnosis
time, hot testing and testing of new parts after repair. Standard labor allowances are
included in warranty labor time standards.
x Replacement parts damaged in shipment (carrier responsibility).
x Towing expense or transportation for moving equipment between the customer's
location and the repair location.
INTRO-xxxii CD368
Rev 10
Warranty Claim Process

NOTE: No warranty invoice will be accepted unless TUG Technologies has been contacted prior to the
start of work being done to the unit.
Contact TUG Technologies by:

Phone: 1-800-989-8499 Ext. 2 or 770-422-8021
Email (preferred) warranty@tugtech.com
To expedite the claim process please provide the following information:

Unit SN:
Hours of operation:
Description of problem or symptoms.
List of parts required for repairs.
Shipping Address
Contact name
Contact phone numbers
Parts:
TUG Technologies will ship warranty parts out at no charge once the claim has been re-
ceived and accepted.
Return Parts:
Not all failed parts need to be returned to TUG Technologies. If parts are to be returned an
RGA tag will be sent with the replacement warranty parts. The tag must be filled out com-
pletely and attached to the return part(s)
NOTE: Parts not returned within 30 days of claim will be charged to your account.
TUG Technologies reserves the right to invoice for parts being returned for the reasons but
not limited to the reasons listed below.
If deemed if caused by an unwarrantable failure.
If part is damaged due to inadequate packaging.
Part was not supplied by TUG Technologies.
Proper documentation was not provided or sent back with faulty part.
Labor:
TUG Technologies will reimburse labor based on the Standard Labor Rate Chart. Any work
which will exceed the times outlined in this chart requires prior approval. All warranty labor
is subject to TUG Technologies Warranty Approval Process.
CD368 INTRO-xxxiii
Rev 10
AIRCRAFT GROUND SUPPORT EQUIPMENT

WARRANTY POLICY STATEMENT
This Policy Statement sets forth the terms of the warranty provided by TUG Technologies Corp. with respect to
ground power units, air start units, tow tractors, cargo tractors and other equipment sold for use in the commercial
aviation industry (“Aircraft Ground Support Equipment” “Industrial”).
The foregoing warranty gives Buyer specific legal rights that may vary from state to state. Some states do not
permit the limitation of incidental or consequential damages or limitation of remedies under warranties. The above
limitations apply only to the extent permitted by applicable law.
General Warranty Terms & Conditions

Tug Technologies warrants that each new item of equipment is of good workmanship and is free of mechanical
defects, provided that:
1. The equipment is installed and operated in accordance with the Tug Technologies Operation and Maintenance
Manual.
2. The equipment is used under normal operating conditions, for which it was designed.
3. The equipment is not subject to misuse, negligence or accident.
4. The equipment is properly maintained by qualified technicians in accordance with the Tug Technologies
Operation and Maintenance Manual
This warranty expires, unless otherwise agreed by Tug Technologies in a special provision, 24 months after being
shipped , or after 2000 operating hours.
Tug Technologies warranty does not apply to fluids, oils, fuses, bulbs, accumulators, paint, seals, tires, bumpers,
brake or wearable parts, bulbs, batteries. Etc.
All warranty claims must be sent to the warranty department for processing. All information pertaining to specific
claim must be provided for claim to be processed in a timely manner.
All the expenses related to a warranty claim will be invoiced to the buyer until Tug Technologies have evaluated
the claim. Whatever the circumstances, the buyer should not refuse or delay the payment. If the evaluation
concludes to TUG’s full responsibility, a credit will be issued in the favor of the buyer.
This warranty is extended by Tug Technologies only to the buyer of new products from Tug Technologies or its
authorized distributors. The products purchased under this warranty are intended for use exclusively by the buyer.
There shall be no third party beneficiary of this warranty.
Under no circumstances whatever shall Tug Technologies be liable for any special or consequential damages,
whether based on lost goodwill, lost resale profits, work stoppage, impairment of other goods or otherwise, and
whether arising out of breach of any express or implied warranty, breach of contract, negligence or otherwise,
except only in the case of personal injury as may be required by applicable law.
The warranty is automatically void by Tug Technologies in the following cases:

1. The product has received some modification , not authorized or done according to Tug Technologies
requirements.
2. Some original parts have been replaced by parts not provided by Tug Technologies.
INTRO-xxxiv CD368
Rev 10
Tractor Warranty Labor Flat Rate Guide

MA M1A MH MT8 MT12/MR MG MX4/MZ
Body
R&R Hood 0.3 0.5 0.5 0.5 0.5
R&R Radiator Shroud 0.4 0.5 1.0 0.5 0.5 0.5
Repaint 6.0 7.5 10.0 8.0 8.0 6.0 6.0
Repaint Cab 2.0 2.0 4.0 4.0 4.0 2.0 2.0
Brakes
R&R Master Cyl and Bleed 1.5 1.5 1.5 1.0 1.5 1.0 1.0
R&R Brake Booster 1.0 1.0 1.0 1.0 1.0 1.0
Adjust Brake Booster 0.5 0.3
R&R Hard brake lines and Bleed 1.0 1.5 1.5 1.5 1.5 1.5 1.5
R&R Master Cylinder cover gasket 0.2 0.2 0.2 0.2 0.2 0.2 0.2
R&R Brake Pedal 0.2 0.5 0.2 0.5 0.5 0.5 1.5
R&R Brake Return Spring 0.2 0.2 0.2 0.2 0.2 0.2 1.0
R&R Hub Front 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R One Stud 1.0 1.0 2.0 1.0 2.0 1.0 1.0
R&R Park Brake Cable to Rear Wheels / Linkage 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Axle Shaft Leak 1.0 1.5 1.5 1.5 1.5 1.5 1.5
R&R Brake Wheel Cylinder 2.0
Brakes
R&R Calipers and bleed 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Rotor 0.5 0.5 0.5 0.5 0.5
R&R Wheel Bearings 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Wheel Stud 1.0 1.0 2.0 1.0 2.0 1.0 1.0
CAB
R&R Heater 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Heater Core 1.0 1.0 1.0 1.0 1.0 1.0
R&R Heater Fan Motor 1.0 0.4 1.0 1.0 1.0 1.0
R&R Heater Switch 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Wiper Motor 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Wiper Arm 0.2 0.2 0.2 0.2 0.2 0.2 0.2
R&R Wiper Switch 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Outside Door Handle 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Door Operator 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Door Latch Assembly. 0.8 0.8 0.8 0.8 0.8 0.8 0.8
R&R Latch Spring 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Door Closure 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Door Retainer Strap 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Dome Light 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Room Mounted Light 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Vinyl Door 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Adjust Door 0.5 0.5 0.5 0.5 0.5 0.5 0.5
CD368 INTRO-xxxv
Rev 10
Cooling System
R&R Fan 0.5 0.2 0.2 0.2 0.5 0.2
R&R Radiator, & transfer shroud 1.5 1.0 1.5 1.0 1.0 0.5
R&R Top or Bottom hose 0.5 0.5 0.5 0.5 0.5 0.5
R&R Heater Hose 0.5 0.5 0.5 0.5 0.5 0.5
R&R Water Pump 1.5 1.5 1.5 1.5 1.5 1.5
R&R Thermostat 0.5 0.5 0.5 0.5 0.5 0.5
Drive Axle & Mounting

R&R Axle Assembly 4.0 4.5 4.0 4.0 5.0 4.0 4.0
R&R Input Seal 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Input Flange 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Axle Shaft Seal 1.0 1.0 1.0 1.0 1.0 1.0
R&R Shaft "O" Ring Seal 1.0 1.0 1.0
R&R Axle Shaft and Axle Bearing 1.0 1.0 1.0 1.0 1.0 1.0
Drive Shaft
R&R Drive Shaft 1.0 1.0 1.0 1.0 1.0 1.0
R&R One "U" Joint 0.5 0.5 0.5 0.5 0.5 0.5
Electrical
Troubleshoot Short or No Power 2.0 2.0 2.0 2.0 2.0 2.0 2.0
R&R Coolant Temp Sensor 0.5 0.5 0.5 0.5 0.5 0.5
R&R Coolant Gauge 0.5 0.5 0.5 0.5 0.5 0.5
R&R Hour Meter 0.5 0.5 0.5 0.5 0.5 0.5
R&R Ammeter 0.5 0.5 0.5 0.5 0.5 0.5
R&R Electric Fuel Gauge 0.5 0.5 0.5 0.5 0.5 0.5
R&R Electric Fuel Sender 1.0 1.0 1.0 1.0 1.0 1.0
R&R Kysor Coolant Temperature Sensor 0.5 0.5 0.5 0.5 0.5 0.5
R&R Kysor Oil Pressure Sensor 0.5 0.5 0.5 0.5 0.5 0.5
R&R Kysor Override Switch 0.5 0.5 0.5 0.5 0.5 0.5
R&R Light Switch 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Battery Cable 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Wire Harness 4.0 4.0 4.0 4.0 4.0 4.0 5.0
R&R Kysor Warning Light 0.5 0.5 0.5 0.5 0.5 0.5
R&R Protecto Start Relay 0.5 0.5 0.5 0.5 0.5 0.5
R&R Horn 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Horn Relay 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Battery 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Turn Signal Light 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Turn Signal Flasher 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Tighten Battery Cable 0.3 0.3 0.3 0.3 0.3 0.3 0.3
R&R Glow Plug Switch 0.3 0.3 0.3 0.3 0.3 0.3
R&R Brake Switch 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Adjust Brake Switch
INTRO-xxxvi CD368
Rev 10

MA M1A MH MT8 MT12?MR MG MX4/MZ
Controls
R&R Shifter 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Shifter Cable and adjust 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Neutral Safety Switch 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Adjust Neutral Safety Switch 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Park Brake Link 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Accelerator Cable and Adjust 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Accelerator Pedal, hookup and adjust 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Engine
R&R Starter Relay 0.3 0.3 0.3 0.3 0.3 0.3
R&R Starter 1.0 1.0 1.0 1.0 1.0 1.0
R&R Alternator 1.0 1.0 1.0 1.0 1.0 1.0
R&R Fuel Pump or Lift Pump 1.0 1.0 1.0 1.0 1.0
R&R Battery 0.5 0.5 0.5 0.5 0.5 0.5
R&R Valve Cover Gasket 1.0 1.0 1.0 1.0 1.0 1.0
R&R Spark Plug Wires 0.5 0.5 0.5 0.5 0.5
R&R Engine Assembly 8.0 8.0 8.0 8.0 8.0 8.0
R&R Oil Pan 2.0 2.0 2.0 2.0 2.0 2.0
R&R Front Crankshaft Seal 2.0 2.0 2.0 2.0 2.0 2.0
Exhaust
R&R Exhaust Pipe 0.5 0.5 0.5 0.5 0.5 0.5
R&R Muffler 0.5 0.5 0.5 0.5 0.5 0.5
R&R Tail Pipe 0.5 0.5 0.5 0.5 0.5 0.5
Front Suspension and Steering

R&R Front Spring 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Front Axle and Transfer Springs 1.5 1.5 1.5 1.5 1.5 1.5 1.5
R&R Tie Rod End and Adjust Toe In 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R King Pin 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Drag Link 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Pitman Arm - Gas 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Pitman Arm - Diesel 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Steer Cylinder 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Steer Hose - Valve to Cylinder 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Steer Pump 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Steer Hose Pump to Valve 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Steer Sector 2.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Steering Wheel 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Horn Button Kit 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Steer Valve 1.5 1.5 1.5 1.5 1.5 1.5 1.5
R&R Upper Steering Bearing 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Steering Wheel 0.3 0.3 0.3 0.3 0.3 0.3 0.3
CD368 INTRO-xxxvii
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Fuel System
R&R Fuel Cell 1.0 2.5 2.5 2.5 2.5 2.5
R&R Fuel Line Steel 0.5 0.5 0.5 0.5 0.5 0.5
R&R L.P. Lock Off Valve 1.0 1.0 1.0 1.0 1.0 1.0
R&R L.P. Regulator 1.0 1.0 1.0 1.0 1.0 1.0
Miscellaneous
R&R Snow Plow Pump 1.0 1.0
R&R Snow Plow Cylinder 1.0 1.0
Weld Hitch 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Install Rubber Bumper 1.0 1.0 1.0 1.0 1.0 1.0 1.0
R&R Hood Latch 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Install decal 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Seating
R&R Seat Frame 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R&R Seat Mount Bushing 0.1
R&R Four Seat Mount Bushings 0.2
R&R Seate Cushions - Seams Only 0.2
R&R Seat Back - Seams Only 0.2
R&R Bucket Seat 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Transmission
R&R Transmission 4.0 4.0 4.0 4.0 4.0 4.0
R&R Transmission Front Oil Seal Gas 3.0 3.0 3.0 3.0 4.0 3.0
R&R Transmission Rear Oil Seal 1.0 1.0 1.0 1.0 1.0 1.0
R&R Modulator Valve 0.3 0.3 0.3 0.3 0.3 0.3
R&R Modulator Cable 0.8 0.8 0.8 0.8 0.8 0.8
R&R Pan Gasket and Refill 1.0 1.0 1.0 1.0 1.0 1.0
R&R Shifter Interlock Solenoid 0.5 0.5 0.5 0.5 0.5 0.5
R&R Shifter Interlock Brake Switch 0.5 0.5 0.5 0.5 0.5 0.5
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HOW TO USE THIS MANUAL

Important Notice: TUG recommends that the vehicle operator thoroughly study the contents of this handbook
before attempting to operate the vehicle.
This handbook is divided into five chapters. Refer to the Table of Contents at the front of this manual and each
chapter for details of chapter content.
Page numbering system uses a three-part page number. The first number represents the chapter in which the
page appears, the second number indicates the section within that chapter, while the third number is the page
number within that section.
Warnings, Cautions, and Notes are used throughout this handbook. Look for the following symbols, which
point out items of importance to the safety of the individual and protection of equipment.
SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERIOUS

INJURY TO PERSONNEL OR EVEN DEATH.
SAFETY NOTES THAT NEED TO BE FOLLOWED TO PREVENT

DAMAGE TO EQUIPMENT.
Note Relevant information for the reader, that is not hazard-related.
CD368 INTRO-xxxix
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INTRO-xl CD368
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M1A Low Profile Tow Tractor - Delta Air Lines Safety
SAFETY
Operator and mechanic safety is so important at TUG that every component is specifically designed and
carefully built to produce the safest equipment available today. However, safety is more than quality design
and construction. It also requires proper operation and maintenance practices. That is why we have devoted
this chapter of the Operation, Maintenance, and Parts Manual entirely to Safety. THIS CHAPTER MUST BE
READ AND UNDERSTOOD BY EVERY OPERATOR AND MECHANIC THAT MAY BE INVOLVED
WITH THIS EQUIPMENT. When the design features and precautions with which this vehicle is equipped are
combined with proper safety practices and good common sense, the M1A Low Profile Tow Tractor is one of
the safest tractors available today.
The following is a list of the topics covered in this chapter.
A. Standard safety features

B. Available safety items as extra cost options
C. Operator responsibilities
D. Mechanic responsibilities
TUG strongly recommends that this chapter be reproduced and bound in the Operator’s Safety Instruction
Book along with safety rules for the stations where this equipment will be operated and/or maintained.
A. STANDARD SAFETY FEATURES
The following features are standard equipment on every M1A Low Profile Tow Tractor.
1. Recessed headlights.
2. Combination tail and stop lights.
3. Dual hood latches.
4. Power boosted disc brakes systems.
5. Independent mechanically operated park brake.
6. Adjustable over center park brake hand lever.
7. Lighted transmission shift control with Morse shifter lock.
8. Engine speed governor set at 15 mph.
9. Automatic transmission.
10. Rear hitch visibility from the seat.
11. Low center of gravity.
12. Ease of maneuverability.
13. Center of steering wheel horn button.
14. Labeled controls.
15. Reflectors.
16. Low operator seating for easy mounting/dismounting with adjustable seat for proper leg
room.
17. Seat belts.
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Safety M1A Low Profile Tow Tractor - Delta Air Lines
18. Non-slip covering on floor boards.

19. Non slip “Morton cast” surface on brake pedal.
20. Power steering.
21. Four-wheel disc brakes.
22. Split braking systems.
23. Back-up lights.
B. AVAILABLE SAFETY ITEMS AS EXTRA COST OPTIONS
The following features are available as extra cost items on the M1A Low Profile Tow Tractor.
1. Retracting seat belts.

2. Overhead guard.
3. Cab with tempered glass, defroster and wiper.
4. Back-up alarm.
5. Turn signals with hazard warning.
6. Amber flashing light.
7. Amber strobe light.
8. Specialized tires.
9. Reflective striping.
10. Work lights.
11. Ryder safe seat and control module.
12. Engine and fuel system alarms and shut downs.
C. OPERATOR RESPONSIBILITIES
This chapter must be read and thoroughly understood prior to operating or performing any
maintenance on this equipment.
WARNING: FAILURE TO COMPLY WITH THE FOLLOWING SAFETY

PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH AS
WELL AS EQUIPMENT DAMAGE.
1. Always follow the station safety rules. If a written list of the safety rules is not posted at the
station, obtain one prior to operating this tractor.
2. Before using this tractor, always check for proper operation and condition of the lights,
brakes, transmission shifter (locks in “Park”) park brake, steering, horn and tires.
3. Do not operate a tractor with defective brakes, transmission shifter, steering, tires, horn,
parking brake or lights. Refer to the maintenance section in Chapter 2.
4. Always keep hands and feet away from rotating parts and tires. Wear secured clothing.
SAFETY-ii CD368
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5. Always wear suitable footwear when operating this equipment and avoid loose fitting
clothing that might get caught in moving parts.
6. Always bring the unit to a complete stop, place the transmission in neutral, and set the park
brake before dismounting.
7. Always bring the unit to a complete stop before shifting from forward to reverse or from
reverse to forward.
8. Do not shift the transmission into gear with the engine above idle speed. Keep foot off the
accelerator when shifting.
9. Always check the path clear prior to backing.
10. Check local station rules and, if permitted, sound the horn prior to backing.
11. If sounding the horn is not permitted, follow the applicable station rules for alerting other
personnel prior to backing.
12. Always be sure the load is secure prior to moving.
13. Always use safety chains between wagons to protect the wagons from accidental hitch
releases.
14. Always use particular caution when in congested areas and near blind corners and rows of
carts. Be alert for other equipment and personnel.
15. Never operate at speeds which are not consistent with operating conditions. Always limit
speed to ensure adequate time for braking in an emergency.
16. Do not use the tractor to push other equipment. Use the proper towing equipment.
17. Do not allow the tractor to be pushed by other equipment. Use the proper towing equipment.
18. Do not tamper with the engine speed governor.
19. Do not tow objects from any point on the tractor other than the hitch provided. Towing from a
point above the rear axle center line could cause the tractor to roll over backwards.
20. Do not disconnect or otherwise disable the Ryder safety seat system if so equipped.
21. Do not remove radiator cap when the engine is hot as serious burns may result. Allow the
radiator to cool before removing the cap.
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22. Do not use wagons without bulkheads and be sure the load is contained within the bulkheads
of the wagons. Without bulkheads, a sudden stop could cause the load to shift onto the tractor.
23. Never refuel the unit while the engine is running.
24. Do not fill the fuel cell above the bottom of the filler screen. Do not overfill. Clean off any
spilled oil or fuel.
25. Do not smoke while refueling.
26. Do not store, spill or use fuel near an open flame.
27. Do not check the engine oil while the engine is running.
28. Do not use the battery in this unit to start other vehicles.
29. Do not drive across any slope.
30. Always leave room when stopping and starting on hills to allow for slight roll back down hill.
31. Never engage in “horseplay” with the tractor.
32. Always exercise good common sense, stay alert and be aware of what is happening around
the tractor at all times.
33. Always make sure hood latches are in good working condition and are properly secured
before operation of the unit.
D. MECHANIC RESPONSIBILITIES
This chapter must be read and thoroughly understood prior to performing any maintenance on this
equipment.
WARNING: FAILURE TO COMPLY WITH THE FOLLOWING SAFETY

PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH AS
WELL AS EQUIPMENT DAMAGE.
1. Always follow the station safety rules. If a written list of safety rules is not posted at the
station, obtain one prior to operating this tractor.
2. Always review the operator responsibilities section of this chapter prior to operating this
equipment.
SAFETY-iv CD368
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3. Always keep hands and feet away from rotating parts and tires. Wear secured clothing.
4. Always wear suitable footwear when operating or servicing this equipment. Avoid wearing
loose-fitting clothing that might get caught in moving parts.
5. Do not use the tractor to push other equipment. Use the proper towing equipment.
6. Do not allow the tractor to be pushed by other equipment. Use the proper towing equipment.
7. Always stop the engine when adjusting fan and alternator belts.
8. Always keep hands clear of the cooling fan.
9. Do not remove radiator cap when the engine is hot, as serious burns may result. Allow the
radiator to cool before removing the cap.
10. Do not check the engine oil while the engine is running.
11. Always disconnect the battery positive cable when working on the engine or under the hood.
12. If electrolyte is spilled, always wash hands or clothing immediately.
13. Do not touch the engine, exhaust or hydraulic components when they are hot as serious burns
may result.
14. Do not smoke near the battery. Fumes from charging electrolyte are explosive. Always keep
the battery away from sparks, flame and smoking materials.
15. Always remove metal bracelets, watch bands, etc. prior to installing, removing or servicing
the battery.
16. Do not short circuit the battery terminals.
17. When connecting the battery, the positive terminal must always be connected first to prevent
sparks from accidental grounding.
18. Check the governor operation and set at 2400 rpm (maximum).
19. Do not substitute the throttle return springs with lighter or other springs.
20. Check the brakes and fill the master cylinder with DOT 3 brake fluid, (DOT 5 is used on
exported trailers).
21. Check the steering for excessive backlash and adjust as required.
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22. Check all lights.
23. Check the horn operation.
24. Check the neutral start only switch for proper adjustment and operation.
25. Do not disconnect or otherwise disable the Ryder safety seat system if so equipped.
26. Check tire and wheel condition along with proper inflation pressures. Unless beads are seated
when mounting tires, over-inflation can result in explosion.
27. Torque all lug nuts to 125 ft-lb. Recheck the torque at 125 ft-lb after 5 hours of operation.
28. Always use proper lifting equipment safely when removing or replacing heavy components.
29. When working underneath the tractor, be sure it is supported properly on secure jack stands.
Do not rely on hydraulic jacks to support the tractor.
30. If the tractor is on a hydraulic or air operated lift, always be sure the safety support or lock is
in position prior to working under the tractor.
31. Always use a proper transmission jack, and secure the transmission when removing or
replacing it.
32. Always jack the drive wheels off the floor when troubleshooting the drive system.
33. Never refuel the unit when the engine is running.
34. Do not fill the fuel cell above the bottom of the filter screen. Do not overfill. Clean off any
spilled oil or fuel.
35. Do not smoke while refueling.
36. Do not store, spill or use fuel near an open flame.
37. Do not use the battery in this unit to start other vehicles.
38. Do not attempt to install or adjust control cables with the engine running.
39. Always replace a control cable which exhibits any gradual or sudden increase in no-load
friction or resistance or decrease in usable stroke, or which have moisture inside or have been
frozen.
40. Do not use heat to attempt to dry or thaw a control cable.
SAFETY-vi CD368
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41. Do not remove the seals from a control cable or attempt to lubricate it. Any control cable
which exhibits possible lubrication problems should be replaced.
42. Do not attempt to repair or modify a control cable. Any damaged control cable should be
replaced immediately.
43. Always avoid exposing control cables to fuels, oils, chemicals, paint, water or dirt as damage
may result.
44. Always adjust each control cable so that the utilized stroke of the cable is centered within the
cable’s available stroke.
45. Always deflate a tire and wheel assembly prior to removing it for servicing or dismounting.
46. Do not use wheels or wheel components that are cracked, bent, pitted or corroded. Ensure
that all wheel components are of the same type and size, and that wheel size and tire size
match. Inspect all components carefully prior to use.
47. Do not attempt to seat a tire bead or side or lock ring by using inflation pressure or any
flammable or explosive substance such as starting fluid or ether. Never inflate a tire beyond
40 psi to seat tire beads.
48. Do not hammer, pry or weld on or near an inflated or partially inflated wheel and tire
assembly.
49. Do not rework, weld, heat or braze any wheel parts for any reason.
50. Always use a safety cage or other restraining device and a clip-on air chuck with a remote
valve and pressure gauge when inflating a tire. Ensure the tire and wheel assembly is
properly assembled prior to inflating it. Visually inspect it for proper seating of beads or sides
or lock rings prior to removing it from the cage.
51. Do not add air to a tire that has been in service with less than 80% pressure without first fully
deflating, removing, disassembling and inspecting the tire
assembly for damage.
Recommended Tire Pressure 80% Recommended Tire

Pressure
40 psi 32 psi
45 psi 36 psi
60 psi 48 psi
52. Immediately replace any parts that show wear or deterioration.

Grade 8 Bolt
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53. Check the condition and tightness of all fasteners. Always use grade 8 heat treated bolts
throughout the unit. Grade 8 heat treated bolts can be identified by six lines on the bolt head.
54. Always keep good maintenance records.
55. Never engage in “horseplay” with the tractor.
56. Always exercise good common sense, stay alert and be aware of what is happening around
tractor at all times.
57. Always make sure hood latches are in good working condition and are properly secured
before operation of the unit.
WARNNG: IF YOUR TUG TRACTOR IS EQUIPPED WITH A

GASEOUS FUEL INJECTION COMPRESSED NATURAL GAS FUEL
SYSTEM (GFI/CNG), THERE ARE SERIOUS ADDITIONAL SAFETY
CONSIDERATIONS ASSOCIATED WITH TANK MANITENANCE,
REFUELING AND TANK VENTING. PLEASE READ THIS MANUAL
CAREFULLY, PAYING PARTICULAR ATTENTION TO THE
FOLLOWING SECTIONS: MAINTENANCE/TROUBLESHOOTING
SECTION (CHAPTER 2); GFI/CNG GENERAL INFORMATION, TANK
MAINTENANCE WARNINGS, VENTING INSTRUCTION/ TUG
SERVICE BULLETIN, TUG M1 MINI-MANUAL (CHAPTER 5).
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Chapter 1
M1A Low Profile Tow Tractor - Delta Air Lines Table of Contents
CHAPTER 1: GENERAL INFORMATION AND

OPERATING INSTRUCTIONS
TABLE OF CONTENTS

A. Tractor .................................................................................................................. 1-1-1
B. Component/System .............................................................................................. 1-1-1
2. Drive Shaft ................................................................................................ 1-1-2
3. Drive Axle .................................................................................................. 1-1-2
4. Front Suspension ..................................................................................... 1-1-2
5. Braking System ........................................................................................ 1-1-3
6. Wheels ..................................................................................................... 1-1-3
7. Tires .......................................................................................................... 1-1-3
8. Front and Rear Suspension ...................................................................... 1-1-3
9. Fuel Cell .................................................................................................... 1-1-4
10. Electrical System ...................................................................................... 1-1-4
11. Frame and Bumpers ................................................................................. 1-1-4
12. Seat .......................................................................................................... 1-1-4
13. Fasteners .................................................................................................. 1-1-4
14. Towing Bracket ......................................................................................... 1-1-4
15. Cab ........................................................................................................... 1-1-4
16. Overhead Guard ....................................................................................... 1-1-5
17. Optional Equipment .................................................................................. 1-1-5
SECTION 2: OPERATION .......................................................................................................... 1-2-1

A. Controls, Instruments, and Switches.................................................................... 1-2-1
1. Morse Gear Shift Unit ................................................................................ 1-2-2
2. Park Brake Lever ...................................................................................... 1-2-2
3. Ignition Switch ........................................................................................... 1-2-2
4. Accelerator Pedal ..................................................................................... 1-2-2
5. Foot Brake Pedal ...................................................................................... 1-2-2
6. Headlight Switch ....................................................................................... 1-2-2
7. Wiper Control Switch ................................................................................ 1-2-2
8. Heater Switch ........................................................................................... 1-2-2
9. Safe-Start .................................................................................................. 1-2-2
10. Cab Dome Light Switch ............................................................................ 1-2-3
11. Instruments ............................................................................................... 1-2-3
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Table of Contents M1A Low Profile Tow Tractor - Delta Air Lines
B. Trailers .................................................................................................................. 1-2-3

C. Trailer Braking Systems ....................................................................................... 1-2-4
1. Overrun Brakes ........................................................................................ 1-2-4
2. Parking Brakes ......................................................................................... 1-2-4
D. Safety ................................................................................................................... 1-2-4
1. Tips ........................................................................................................... 1-2-4
2. Precautions ............................................................................................... 1-2-5
E. Procedures ........................................................................................................... 1-2-5
1. Driving Instructions ................................................................................... 1-2-5
2. Towing Instructions ................................................................................... 1-2-6
3. Periodic Maintenance ................................................................................ 1-2-7
SECTION 3: SPECIFICATIONS AND CAPABILITIES .............................................................. 1-3-1

A. Dimensions .......................................................................................................... 1-3-1
B. Engine .................................................................................................................. 1-3-1
1. Deutz F4L 1011F ..................................................................................... 1-3-1
2. Deutz F4M 2011 (Tier II) ............................................................................ 1-3-2
3. Deutz D2011 (Tier IVi) ............................................................................... 1-3-2
C. Transmission ........................................................................................................ 1-3-2
D. Electrical System .................................................................................................. 1-3-2
E. Chassis ................................................................................................................ 1-3-3
F. Suspension ........................................................................................................... 1-3-3
G. Braking System .................................................................................................... 1-3-3
1. Service Brake ........................................................................................... 1-3-3
2. Parking Brake ........................................................................................... 1-3-3
H. Axle ....................................................................................................................... 1-3-3
I. Steering System ................................................................................................... 1-3-4
J. Tires ...................................................................................................................... 1-3-4
K. Drive Shaft ............................................................................................................ 1-3-4
L. Fuel System ......................................................................................................... 1-3-4
M. Cooling System .................................................................................................... 1-3-4
N. Instruments ........................................................................................................... 1-3-4
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SECTION 4: SHIPPING ............................................................................................................. 1-4-1

A. Preparation ........................................................................................................... 1-4-1
1. Battery ...................................................................................................... 1-4-1
2. Radiator .................................................................................................... 1-4-1
3. Fuel Cell .................................................................................................... 1-4-1
4. Checks ..................................................................................................... 1-4-1
B. Preparing for Operation ........................................................................................ 1-4-2
1. Radiator .................................................................................................... 1-4-2
2. Fuel Cell .................................................................................................... 1-4-2
3. Battery ...................................................................................................... 1-4-2
SECTION 5: STORAGE ............................................................................................................ 1-5-1

A. For One Month ...................................................................................................... 1-5-1
1. Engine ....................................................................................................... 1-5-1
2. Transmission ............................................................................................ 1-5-1
4. Tires .......................................................................................................... 1-5-1
5. Lubrication ................................................................................................ 1-5-1
6. Fluid Levels ............................................................................................... 1-5-2
7. Wheel Bearings ........................................................................................ 1-5-2
8. Battery ...................................................................................................... 1-5-2
B. For Indefinite Period .............................................................................................. 1-5-2
1. Engine ....................................................................................................... 1-5-2
2. Transmission ............................................................................................ 1-5-3
4. Tires .......................................................................................................... 1-5-3
5. Lubrication ................................................................................................ 1-5-3
6. Fluid Levels ............................................................................................... 1-5-3
7. Wheel Bearings ........................................................................................ 1-5-3
8. Battery ...................................................................................................... 1-5-3
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1-TOC-iv CD368
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Chapter 1
M1A Low Profile Tow Tractor - Delta Air Lines Section 1
SECTION 1: DESCRIPTION
A. TRACTOR
As shown in Figure 1-1, the Tug M1 tractor is a four-wheeled, two wheel drive, with or without cab,
heavy duty towing vehicle. It incorporates:
1. Heavy duty front and rear hydraulically-assisted power disc brake system.
2. 4-cylinder diesel.
3. Automatic transmission.
4. 12-volt electrical system.
Figure 1-1. M1A Low Profile Tow Tractor
B. COMPONENT/SYSTEM
1. Engine and Transmission

The tractor is equipped with an industrial type engine (4-cylinder diesel) with an automatic
transmission. The engine will be certified by the manufacturer to meet the emissions
standards required by Federal Law which are applicable at the date of manufacture. The
diesel engine operates satisfactorily using diesel fuel number 2 and other fuels (see engine
manual for list of acceptable fuels).
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Section 1 M1A Low Profile Tow Tractor - Delta Air Lines
SEE EA APPENDIX FOR EA 15-581593-03 REV A M1A Electronic Transmission Upgrade

(a) Engine
The diesel engine is a heavy duty, industrial type with four (4) stroke cycle and direct
injection.
(b) Transmission
The Ford C6 3-speed automatic transmission is equipped with a torque converter and
park brake assembly.
2. Drive Shaft
The tractor’s drive shaft is an automotive type with double universal joints and a spline
coupling.
3. Drive Axle
The drive axle assembly consists of the differential assembly, the reduction gears and the axle
shafts. It is mounted to the chassis by a pivoting cradle assembly supported by two coil
springs and gas shock absorbers.
4. Front Suspension
(a) Model M1A
The steering axle is of welded steel tube construction mounted to the chassis by two
semi-elliptic, multi-leaf spring assemblies. This is to ensure constant ground contact
of both wheels over uneven ground.
CAUTION: DESPITE THIS SUSPENSION SYSTEM, IT IS

RECOMMENDED THAT THE TRACTOR, WHEN POSSIBLE, IS
DRIVEN OVER SMOOTH, EVEN GROUND.
Turning movement from the steering wheel is transmitted to the axle via a power
steering box and sealed ball jointed linkage. This arrangement provides a high angle
of lock with minimum amount of steering effort. Hydraulic pressure is supplied by a
belt or gear-driven pump.
(b) Model M1
The front suspension consists of two independent swing-arms mounted to the frame
by roller bearing pivots. This design also insures constant ground contact of both
wheels over uneven ground.
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CAUTION: DESPITE THIS SUSPENSION SYSTEM, IT IS

RECOMMENDED THAT THE TRACTOR, WHEN POSSIBLE, IS
DRIVEN OVER SMOOTH, EVEN GROUND.
Turning movement from the steering wheel is transmitted to the axle via a power
steering cylinder and sealed ball jointed linkage. This arrangement provides a high
angle of lock with minimum amount of steering effort. Hydraulic pressure is supplied
by a belt or gear-driven pump.
5. Braking System
There are two braking systems, mechanical and hydraulic, incorporated on the rear axle, and
hydraulic on the front wheels. The mechanical brakes operate by a rod attached to the park
brake lever and a drum on the rear of the transmission. The hydraulic braking system uses a
dual line master cylinder to supply hydraulic pressure for both the front and rear brakes.
6. Wheels
(a) Front: The front axle utilize 2 piece wheels that have 5 bolts on a 5 1/2" bolt circle.
(b) Rear: The drive axle employs one piece heavy duty wheels that have 8 bolts on a
6 1/2" bolt circle.
7. Tires
The tractor’s tires are of pneumatic type which gives a smooth ride combined with maximum
tractive effort. Remember to check the pressure of your pneumatic tires regularly. Uneven
tire pressure will not only increase tire wear, but will also decrease tractive performance.
8. Front and Rear Suspension

The rear (drive) axle incorporates two coil springs and gas shocks attached to a pivoting
lower cradle platform that serves as a mounting point for the differential assembly. The front
suspension consists of two leaf springs mounted directly to the front (steer) axle.
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9. Fuel Cell
The fuel cell is constructed of heavy gauge stainless steel and is mounted below the floor plate
to the right of the operator. The fuel cell is equipped with a protecto-seal filler cap and a fuel
gauge.
10. Electrical System

The tractor utilizes a 12-Volt, automotive type, negative ground, electrical system. The system
includes a minimum 60 ampere alternator, a 70 ampere-hour battery, voltage regulator, ignition
switch, two headlights, rotating strobe light (optional), turn signals (optional), taillight, horn
button and horn, ignition equipment, various gauges and all other circuits. If tractor is equipped
with a cab, the following is added to the above list: wiper motor, clearance lights, heater
blower motor and interior cab light.
11. Frame and Bumpers

The chassis frame is a welded assembly fabricated from 1 inch heavy steel plate (1" on front
bumper, 2" on rear bumper). The frame consists essentially of inner and outer frame rails,
front and rear bumpers, and removable crossmembers. The outside frame rails are formed
and welded to the inside frame rails. The front and rear bumpers are welded to the frame
rails. For corrosion resistance the entire frame is finished in primer and then in paint.
12. Seat
The tractor utilizes one or two bucket style seats with adjustable slides. As an option the
tractor can be fitted with a passenger seat and various seat types.
13. Fasteners
All major structural fasteners are Grade 8, and use high strength locknuts.
14. Towing Bracket

Alternative towing brackets can be fitted to both the front and rear of the tow tractor.
15. Cab
(a) Full: The TUG cab, which fully encloses the driving compartment, was designed for
and fitted to this tractor. The cabs have a front and back windshield, and two (2)
doors. All windows consist of safety glass (Lexan optional) on all four sides for
maximum visibility. A wiper, powered by a small electric motor, is fitted to the front
windshield. The all welded construction to the main cab assembly and the door are
manufactured with the finest of steel. The door has an inside and outside handle.
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(b) Economy: The Economy TUG cab is made the same as the full cab except there are
no doors, rear window, heater and defroster.
16. Overhead Guard

The TUG overhead guard is of welded construction and utilizes 2" by 4" and 2" by 2" heavy
gauge tubing. The overhead guard protects the operator and still gives maximum visibility.
17. Optional Equipment

The following is only a partial list of optional equipment. Your TUG representative can
address your specific needs regarding optional equipment for your TUG ground support
equipment.
(a) Rotating Lights (Red or Amber)

(b) High Water Temperature Shut-Off
(c) Low Oil Pressure Shut-Off
(d) Rubber Bumper, Front
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Chapter 1
SECTION 2: OPERATION
A. CONTROLS, INSTRUMENTS, AND SWITCHES
The tractor controls and instruments include a headlight switch, ignition switch, hour meter, ammeter,
water temperature gauge, oil pressure gauge, heater switch (if equipped), wiper control switch (if
equipped), dome light (if equipped), automotive type 16" steering wheel, Morse gear shift unit, park
brake lever, full-size accelerator pedal, horn button, and a turn signal lever mounted on the steering
column (if equipped).
NOTE: Not all guages are used with all engines. See the Illustrated Parts
Note List in Chapter 4 for the gauges specific to each unit equipped with
specific engines.
The control layout is designed to combine maximum driving comfort with maximum efficiency. The
accompanying illustration (See Figure 2-1) shows the location of the controls, while the following
gives a brief summary of their operation. It is essential that the operator becomes accustomed to both
the location and operation of the controls, before attempting to drive the tow tractor for productive
operation.
Figure 2-1. Operator's Compartment - M1A
CD368 1-2-1
Rev 7
Chapter 1
1. Morse Gear Shift Unit

The Morse gear shift unit is located on the seat plate between the seats, immediately to the
right of the driver’s position. The unit has three positions: Forward, Neutral, and Reverse.
CAUTION: ALWAYS COME TO A COMPLETE STOP BEFORE

SHIFTING FROM FORWARD TO REVERSE OR REVERSE TO
FORWARD.
2. Park Brake Lever

The parking brake lever is connected by a rod to the park brake caliper mounted on the drive
axle. The park brake is used for parking or holding the tractor on grades and should always be
set for parking and released before driving. The brakes are engaged as the lever is pulled
toward the operator. Push the lever away from the operator (down) to release the brake.
3. Ignition Switch
An automotive type switch that incorporates an anti-restart function.
4. Accelerator Pedal
The pedal is connected to the engine via a cable or wire harness.
5. Foot Brake Pedal

Operates the hydraulic brakes on the front and rear wheels.
6. Headlight Switch
The headlight switch turns the headlights ‘“ON” or “OFF”. The toggle in the up position
turns the headlights “ON”.
7. Wiper Control Switch

Controls the windshield wiper motor (optional).
8. Heater Switch
The heater switch controls the heater blower motor (optional).
9. Safe-Start
The safe start relay is in place to prevent accidental engagement of starter while engine is
already running (optional).
1-2-2 CD368
Rev 7
Chapter 1
10. Cab Dome Light Switch

Operates the interior cab light (if equipped with cab).
11. Instruments
(a) Hourmeter: Reads elapsed time the unit has been in operation.
(b) Brake warning light: The light operates when the brakes have a hydraulic fluid
leaking problem.
(c) Voltmeter: The voltmeter indicates the state of charge of the battery.
(d) Oil pressure gauge: This gauge reads the engine oil pressure.
(e) Oil temperature gauge: Measures the temperature of the engine cooling oil system.
B. TRAILERS
The most common types of trailers used in the industry today are the conventional "flat-deck" trailers
and trailers fitted with superstructures. The form of superstructure varies with the trailer’s
application. These variations include bedstead ends, detachable canvas sides detachable chains or
four permanent sides (one or more of which are usually hinged for loading purposes). Both common
types and all variations can be manufactured with either two or four wheel steering.
A two-wheel steer trailer is constructed with its two rear wheels fitting to an axle rigidly mounted to
the trailer chassis, and its two front wheels mounted on a turntable or pivoting axle. The turntable or
pivoting axle is directly connected to a drawbar for towing purposes. When towing a two-wheel steer
trailer, extra care must be taken to allow for rear end swing when cornering. A coupling device, which
is attached to the rear of the trailer, enables additional trailers to be connected, hence creating a trailer
train.
A four-wheel steer trailer has both the front and rear axles mounted on turntables. These turn tables
are interconnected by a tie-bar. The tie-bar runs diagonally from one side of the front turntable to the
opposite side of the rear turntable. If the drawbar, which is attached to the front turntable, moves, then
the tie-bar arrangement causes the front and rear wheels to turn in opposite directions. Steering stops
are placed to prevent the wheels from turning through a full 90° lock that can cause a load
displacement.
CD368 1-2-3
Rev 7
Chapter 1
C. TRAILER BRAKING SYSTEMS
1. Overrun Brakes
Trailers that are consistently used to carry heavy loads are usually fitted with overrun brakes.
These brakes can be either cable or hydraulically operated. The overrun brakes automatically
slow the trailer down when it tends to overrun. In particular, these brakes are recommended
when the tow tractor-trailer combination is being operated on gradients.
2. Parking Brakes
A variety of parking brakes are fitted to trailers. A majority of these brakes are operated when
the drawbar is disconnected from the tow tractor and raised to an upright position. Some
other types of brakes include manually operated park brake levers. If your trailer is not fitted
with a parking brake, remember to securely chock the wheels of the trailer before
disconnecting the trailer’s drawbar from the hitch or the trailer coupling.
D. SAFETY
1. Tips
(a) Observe floor loading limits with the unladen weight of the tractor.
(b) Ensure the trailer’s load is not wider than the aisles en route.
(c) Travel at a speed consistent with the road and load conditions.
(d) Sound the horn and slow down for corners.
(e) Avoid traveling on soft or bumpy ground when possible.
(f) Watch out for pedestrians and do not travel too close behind other vehicles.
(g) Avoid sudden stops.
(h) Do not block fire fighting equipment from use by parking or depositing a trailer in
front of the equipment.
(i) Report any mechanical or electrical irregularities immediately.
(j) Ensure road bridge plates are secure and strong enough to withstand the weight of the
tractor or the combined weight of the trailer and its load.
(k) Keep clear of the edge of loading docks.
1-2-4 CD368
Rev 7
Chapter 1
(l) When cornering, watch for the trailer’s rear end swing.
REMEMBER: A safety minded driver protects both himself, and others,

eliminating unnecessary damage to the tractor and its load.
WARNING: ONLY AUTHORIZED DRIVERS SHOULD BE PERMITTED

TO DRIVE.
2. Precautions
(a) Upon stopping the vehicle, place transmission shift lever in neutral, put parking
brake ON, and turn ignition switch to OFF position.
(b) The maximum tow speed of this tractor is 15 mph.
(c) Only qualified personnel should service this tractor.
E. PROCEDURES
1. Driving Instructions
Before putting the tractor into service, the following items must be checked and executed.
(a) Check fuel level.
(b) Check the pressure of the pneumatic tires and for cuts, breaks and excessive wear.
(c) Check engine oil level.
(d) Check water level in radiator.
(e) Check that the driving seat is adjusted to your requirements.
NOTE: You must be correctly seated in the tractor. This is important

Note because your tractor may be fitted with a Rider-Safe seat. Until this Ryder-
Safe seat is operated (by sitting on the seat), the tractor is inoperative.
(f) Check that all controls are in working order.
(g) Ensure that the shift lever is in Neutral/Park.
(h) Buckle seat belt.
(i) Make sure park brake is set.
CD368 1-2-5
Rev 7
Chapter 1
(j) Turn ignition switch to engage starter.
(k) Apply foot brake.
(l) Release the parking brake.
(m) Move the transmission shift lever into the required position, i.e., Forward or Reverse.
(n) Gently press the accelerator pedal, further press the accelerator until the required
speed is obtained.
Note NOTE: Governor limits speed to a maximum of 15 mph.
WARNING: MATCH DRIVING SPEEDS TO LOADS BEING TOWED

AND WEATHER CONDITIONS. SLOW DOWN WHEN TOWING
HEAVY LOADS AND WHEN ROAD SURFACE IS WET OR ICY,
ESPECIALLY ON GRADES.
(o) To slow the tractor, slowly release the accelerator pedal and apply the service foot
brake. For an emergency stop, release the accelerator pedal and press hard on the
service brake pedal.
(p) Each time you park, apply the park brake, return the transmission shift lever to
Neutral/Park and turn the starter switch to the “OFF” position.
2. Towing Instructions
(a) Ensure the trailer load is secure and is within the rated drawbar pull of the tow
tractor.
(b) Ensure the towing coupling is secure.
(c) Start as slowly as possible to allow any ‘slack’ in towing arrangements to be taken
up.
(d) Travel at a speed consistent with road and load conditions.
(e) Slow down and sound the horn when approaching corners and junctions.
(g) Always be alert. Watch out for pedestrians and never drive too close behind other
vehicles.
(h) Do not carry unauthorized passengers.
1-2-6 CD368
Rev 7
Chapter 1
(i) If your trip involves crossing road bridge plates, ensure they are secure and are strong
enough to withstand the combined weight of the tractor and driver, or trailer and
load.
(j) When approaching the destination, reduce speed sufficiently far away to ensure a
slow, rolling halt. A sudden halt could cause load displacement.
(k) Ensure the trailer’s parking brake is applied before disconnecting the trailer coupling.
If no parking brake is fitted, securely chock the road wheels before disconnecting
coupling.
3. Periodic Maintenance
CAUTION: ONLY QUALIFIED MAINTENANCE MECHANICS

SHOULD PERFORM MAINTENANCE AND SERVICE ITEMS ON
THIS UNIT. REPORT A FAULTY TRACTOR AND DO NOT USE
UNTIL REPAIRED.
Routine maintenance is essential for the tractor to be an efficient materials-handling unit.

Lack of maintenance will result in costly repairs, loss through downtime, and interruptions in
operation.
CD368 1-2-7
Rev 7
Chapter 1
1-2-8 CD368
Rev 7
Chapter 1
SECTION 3: SPECIFICATIONS AND CAPABILITIES
A. DIMENSIONS
Length, excluding coupler ................................................................................................. 107" (272 cm)

Width, overall ...................................................................................................................... 57" (145 cm)
Height, overall, w/o cab ...................................................................................................... 55" (140 cm)
Height, overall, with cab ..................................................................................................... 71" (180 cm)
Wheelbase ........................................................................................................................... 59" (150 cm)
Turning Radius .................................................................................................................. 130" (330 cm)
Ground Clearance (drop box) .................................................................................................. 6" (15 cm)
B. ENGINE
1. Deutz F4L 1011F
Number of Cylinders ................................................................................................................. 4

Cylinder Arrangement ......................................................................................... Vertical In-line
Bore .................................................................................................................................. 91 mm
Stroke .............................................................................................................................. 112 mm
Total Displacement .................................................................................. 2732 cm³ (181 CID)
Compression Ratio ............................................................................................................. 18.5:1
Working Cycle ......................................................................................... 4-stroke Diesel Engine
Combustion System ........................................ Naturally Aspirated Engine with Direct Injection
Direction of Rotation .................................................................................... Counter Clockwise
Weight w/o Cooling system ........................................................................................... 249.5 kg
Lubrication .................................................................................................. Pressure Lubrication
SAE Oil .......................................................................................................................... 20 W 20
Oil Temp in Sump Oil ............................................................................................................. 130
Oil Change with filter .........................................................................................................10.5 L
Valve Clearance at cold engine inlet ....................................................... 0.3mm exhaust:0.5mm
Firing Order ..................................................................................................................... 1-3-4-2
Fuel .......................................................................................................................... No. 2 Diesel
NOTE: See Deutz Operation Manual for more detailed engine data.
CD368 1-3-1
Rev 7
Chapter 1
2. Deutz F4M 2011 (Tier II)

Bore .................................................................................................................................. 94 mm
Stroke .............................................................................................................................. 112 mm
Total Displacement ....................................................................................................... 3108 cm³
Compression Ratio ................................................................................................................ 19:1
Direction of Rotation ........................................................... On Left when Looking at Flywheel
Firing Order ....................................................................................................................... 1,3,4,2
3. Deutz D2011 (Tier IVi)

Bore .................................................................................................................................. 94 mm
Stroke .............................................................................................................................. 112 mm
Total Displacement ....................................................................................................... 3108 cm³
Compression Ratio ................................................................................................................ 19:1
Direction of Rotation ........................................................... On Left when Looking at Flywheel
Firing Order ....................................................................................................................... 1,3,4,2
C. TRANSMISSION
Ford: The C6 3-speed (diesel) or 2-speed (gasoline) automatic transmission is equipped with a torque
converter and park brake assembly.
D. ELECTRICAL SYSTEM
1. Type: 12 Volt, Negative ground
2. Alternator
1-3-2 CD368
Rev 10
Chapter 1
(a) Deutz 1011: 100 Amp (Older Deutz 1011 units use a 60 Amp, Delco style.)
(b) Deutz 2011: 95 Amp, Bosch
3. Battery: 650 Amp - Cold-Cranking
E. CHASSIS
Main Frame ............................................................ Welded construction, 1/4" to 2" (0.64 cm to 1.3 cm)
F. SUSPENSION
Front Axle .............................................................. Two Leaf Springs mounted directly to the steer axle
(Older units may have independent swing arm.)
Rear Axle ......................................................................................................... Axle Cradle; Coil Springs
G. BRAKING SYSTEM
1. Service Brake
Type .............................. Hydraulic Caliper on Disc, Six (6) Calipers Total; Hydraulic-Boosted
2. Parking Brake
Type .................... Mechanical, Orscheln (adjustable) Lever-Activating on Drive Shaft Caliper
H. AXLE
Type of Drive .................................................................................................................................... Rear

Type of Axle Assembly ........................................................................................................... Rigid Drive
Drop Box Ratio .................................................................................................................................... 3:1
Total Ratio ....................................................................................................................................14.142:1
CD368 1-3-3
Rev 7
Chapter 1
I. STEERING SYSTEM
Type of Gearbox ............................................................................................... Ball and Screw, Assisted

Type of Steer ................................................................................................................................... Front
Front Axle Construction .................. Axle Tube with Inclined King Pins, Bushings and Sealed Bearings
(Older units may use independent swing arms with spindle.)
J. TIRES
Front ............................................................................................................................................ 6.90 x 9

Rear ............................................................................................................................................ 8.0. x 16
K. DRIVE SHAFT
Type ..................................................................... Automotive with double universal & spline coupling
L. FUEL SYSTEM
Type ............................................................................................................... Diesel, Gasoline, CNG, LP
M. COOLING SYSTEM
Capacity ..................................................................................................................................... 15 quarts

Engine .......................................................................................................... Heavy duty radiator and fan
Transmission..............................................................................Fluid cooling located in engine radiator
N. INSTRUMENTS
Type ........................................................................................................................................... Electrical

Group .............................................................Voltmeter, Water Temperature, Oil Pressure, Hour Meter
1-3-4 CD368
Rev 7
Chapter 1
SECTION 4: SHIPPING
A. PREPARATION
WARNING: EXTREME HAZARD EXISTS WHEN REFUELING AND

DE-FUELING THE TRACTOR - NO SMOKING, NO OPEN FLAMES, NO
ELECTRICAL DEVICE OPERATIONS.
1. Battery
(a) Disconnect battery terminals from battery posts.
(b) Leave battery in battery box.
2. Radiator
Drain engine coolant from radiator and engine block into an appropriate container.
3. Fuel Cell
(a) Drain fuel from fuel tank into appropriate container.
(b) Disconnect fuel line at lowest readily accessible connection and drain fuel from fuel
line.
(c) Reconnect fuel lines.
(d) Leave fuel cap on tank, but loosened.
4. Checks
(a) Make certain fuel line is connected.
(b) Make certain shut-off valve on radiator is closed.
(c) Make certain fuel cell drain valve is closed.
(d) Before shipping the unit, review the transportation data plate (if equipped) for
additional shipping information.
CD368 1-4-1
Rev 7
Chapter 1
B. PREPARING FOR OPERATION
WARNING: MAKE CERTAIN ALL FUEL LINES ARE PROPERLY

CONNECTED FROM TANK TO FUEL PUMP TO CARBURETOR.
1. Radiator
(a) Make certain that radiator shut-off valve is closed.
(b) Add required amount coolant/water mixture to radiator.
2. Fuel Cell
(a) Add fuel to fuel tank.
(b) Check all fuel lines for leaks.
3. Battery
Connect battery terminals to battery posts.
1-4-2 CD368
Rev 7
Chapter 1
SECTION 5: STORAGE
A. FOR ONE MONTH
1. Engine
(a) Run the engine at 1500 rpm and treat the upper cylinder by spraying an engine
preservative oil into the carburetor or air intake for about two minutes. This oil
should be SAE #10, formulated for antitrust and anticorrosion protection, along with
being a high detergent type that meets requirements for most severe (M.S.) service
and also Ford Specification M-2C35. Open throttle for a short burst of speed, then
shut off the ignition and allow the engine to come to a stop while continuing to spray
the oil into carburetor air intake.
(b) Leave the spark plugs installed and cover all engine openings with dust-proof caps or
shields.
(c) Drain oil from crank case into an appropriate container.
(d) Drain water from radiator and engine block into an appropriate container.
(e) Drain fuel from tank, carburetor and fuel lines into an appropriate container (gasoline
only).
(f) Attach a tag on steering wheel stating, "CAUTION: Oil and water have been
removed from engine."
2. Transmission
No special attention needed.
3. Drive Axle and Reduction Gear Box

No special attention needed.
4. Tires
The tractor should be raised and axles chocked to prevent tire contact with ground. Tire
pressure should be reduced to 15 psi.
5. Lubrication
Ensure that all points are lubricated with specified grease oil, etc.
CD368 1-5-1
Rev 7
Chapter 1
6. Fluid Levels
All fluid levels should be checked and topped up as necessary.
7. Wheel Bearings
Wheel bearings should be repacked.
8. Battery
Disconnect battery terminals.
B. FOR INDEFINITE PERIOD
1. Engine
(a) Run the engine at 1500 rpm and treat the upper cylinders by spraying an engine
preservative oil into the carburetor air intake for about two minutes. This oil should
be SAE #10, formulated for anticorrosive protection, along with being a high
detergent type that meets requirements for most severe (M.S.) service and also For
Specification M-2C35. Open the throttle for a short burst of speed, then shut off the
ignition and allow the engine to come to a stop while continuing to spray the oil into
the carburetor air intake.
(b) Leave the spark plugs installed and cover all engine openings with dust-proof caps or
shields.
(c) Drain oil from crank case into an appropriate container.
(d) Drain fuel from radiator and engine block into an appropriate container.
(e) Drain fuel from tank, carburetor, and fuel lines into an appropriate container.
(f) Attach a tag on steering wheel stating, "CAUTION: Oil and water have been
removed from engine."
1-5-2 CD368
Rev 7
Chapter 1
2. Transmission
CAUTION: PROLONGED STORAGE MAY BE DETRIMENTAL TO THE

SEALS IN THE TRANSMISSION.
(a) Drain transmission fluid into an appropriate container.
(b) Refill transmission.
3. Drive Axle and Reduction Gear Box
(a) Drain drive axle and reduction gear box into an appropriate container by removing
drain plug located on the underside of the differential carrier housing. Reinstall plug
after draining. The drive axle and reduction gear box are connected internally and
share the same oil.
(b) Attach a tag on steering wheel stating, "CAUTION: Oil has been removed from
axle and reduction gear box."
4. Tires
The tractor should be raised and axles chocked to prevent tire contact with the ground. Tire
pressure should be reduced to 15 psi, and sprayed with a rubber preservative.
5. Lubrication
Ensure that all points are lubricated with specified grease, oil, etc.
6. Fluid Levels
All fluid levels should be checked and topped up as necessary.
7. Wheel Bearings
Wheel bearings should be repacked.
8. Battery
The battery should be removed and stored separately. The battery must be stored in a cool
dry place and must not be exposed to direct sunlight. A recommended storeroom temperature
of 32 degrees F (Zero degrees C) should be maintained. If the battery is stored in the open, it
must be covered for protection against dirt and moisture. A slow charge should be given to
the battery every one and two months.
CD368 1-5-3
Rev 7
Chapter 1
1-5-4 CD368
Rev 7
Chapter 2
CHAPTER 2: MAINTENANCE
TABLE OF CONTENTS
SECTION 1: SERVICING ........................................................................................................... 2-1-1

A. Preparation for Use ............................................................................................... 2-1-1
1. Fuel System .............................................................................................. 2-1-1
2. Battery ...................................................................................................... 2-1-1
3. Brake System ........................................................................................... 2-1-1
5. Rear Axle and Reduction Gear Box .......................................................... 2-1-2
6. Tire Inflation ............................................................................................... 2-1-2
7. Power Steering Fluid ................................................................................. 2-1-2
B. Periodic Maintenance Schedule ........................................................................... 2-1-2
1. Daily ......................................................................................................... 2-1-2
2. Weekly or 50 Hours .................................................................................. 2-1-3
3. Monthly or 200 Hours ................................................................................ 2-1-4
4. Two (2) Months or 400 Hours.................................................................... 2-1-5
5. Ten (10) Weeks or 500 Hours ................................................................... 2-1-5
6. Six (6) Months or 1200 Hours ................................................................... 2-1-6
7. Yearly or 2400 Hours ................................................................................. 2-1-6
8. Lubricant Charts ....................................................................................... 2-1-8
9. Adjustment Instruction ............................................................................ 2-1-11
SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1

A. Loss of Power ...................................................................................................... 2-2-1
B. Rear Axle .............................................................................................................. 2-2-2
C. Twelve (12) Volt System ....................................................................................... 2-2-3
1. Headlights ................................................................................................. 2-2-3
2. Stop Lights ................................................................................................ 2-2-4
3. Back-Up Light ........................................................................................... 2-2-5
4. Turn Signal Lights ..................................................................................... 2-2-6
5. Cab Marker Light ....................................................................................... 2-2-7
6. Wiper Motor .............................................................................................. 2-2-8
7. Horn .......................................................................................................... 2-2-9
8. Electric Fan ............................................................................................. 2-2-11
D. Steering............................................................................................................... 2-2-12
E. Brake System ..................................................................................................... 2-2-15
CD368 2-TOC-i
Rev 7
Chapter 2
F. Alternator ............................................................................................................ 2-2-19

G. Battery ................................................................................................................ 2-2-20
H. Electrical Wiring Diagrams ................................................................................. 2-2-21
Figure 2-1. Wrg Schematic, Deutz 1011F Diesel Eng with Del. Start Option .... 2-2-21
Figure 2-2. Wrg Diagm, Deutz 1011F Diesel Eng with Eng Shut & Trans Inter .. 2-2-22
SECTION 3: REMOVAL/INSTALLATION ................................................................................... 2-3-1

A. Hood Panel ........................................................................................................... 2-3-1
1. Removal ................................................................................................... 2-3-1
2. Installation ................................................................................................. 2-3-1
B. Radiator/Fan Assembly ........................................................................................ 2-3-1
1. Removal ................................................................................................... 2-3-1
2. Installation ................................................................................................. 2-3-2
C. Oil Cooler .............................................................................................................. 2-3-3
1. Removal ................................................................................................... 2-3-3
2. Installation ................................................................................................. 2-3-3
D. Battery .................................................................................................................. 2-3-4
1. Removal ................................................................................................... 2-3-4
2. Installation ................................................................................................. 2-3-5
E. Operator’s Seat .................................................................................................... 2-3-5
1. Removal ................................................................................................... 2-3-5
2. Installation ................................................................................................. 2-3-5
F. Tires and Wheels.................................................................................................. 2-3-6
1. Rear Tire and Wheel Removal/Installation ................................................ 2-3-6
2. Front Tire and Wheel Removal/Installation ............................................... 2-3-7
G. Drive Shaft ............................................................................................................ 2-3-7
1. Removal ................................................................................................... 2-3-7
2. Installation ................................................................................................. 2-3-8
H. Drive Axle and Mounting Springs ........................................................................... 2-3-8
1. Removal ................................................................................................... 2-3-8
2. Installation ................................................................................................. 2-3-9
I. Engine/Transmission ............................................................................................ 2-3-9
1. Removal ................................................................................................... 2-3-9
2. Installation ............................................................................................... 2-3-12
2-TOC-ii CD368
Rev 10
Chapter 2
J. Shifter ................................................................................................................. 2-3-13

1. Removal ................................................................................................. 2-3-13
2. Installation ............................................................................................... 2-3-14
K. Accelerator Pedal, Throttle Control Cable and Modulator Cable ......................... 2-3-14
1. Accelerator Pedal Removal/Installation................................................... 2-3-14
2. Throttle and Modulator Cable Removal ................................................... 2-3-15
3. Throttle and Shift Cables Installation ....................................................... 2-3-15
L. Tail Pipe/Muffler/Exhaust Pipe ............................................................................. 2-3-16
1. Removal ................................................................................................. 2-3-16
2. Installation ............................................................................................... 2-3-17
M. Swing Arm Assembly .......................................................................................... 2-3-19
1. Removal ................................................................................................. 2-3-19
2. Installation ............................................................................................... 2-3-20
N. Steer Valve .......................................................................................................... 2-3-21
1. Removal ................................................................................................. 2-3-21
2. Installation ............................................................................................... 2-3-21
O. Steering Column and Steering Wheel ................................................................. 2-3-22
1. Removal ................................................................................................. 2-3-22
2. Installation: .............................................................................................. 2-3-22
P. Steer Cylinder ..................................................................................................... 2-3-23
1. Removal ................................................................................................. 2-3-23
2. Installation ............................................................................................... 2-3-24
Q. Master Cylinder ................................................................................................... 2-3-24
1. Removal ................................................................................................. 2-3-24
2. Installation ............................................................................................... 2-3-24
R. Brake Pedal ........................................................................................................ 2-3-25
1. Removal ................................................................................................. 2-3-25
2. Installation ............................................................................................... 2-3-25
S. Parking Brake: Linkage and Lever ...................................................................... 2-3-25
1. Removal ................................................................................................. 2-3-25
2. Installation ............................................................................................... 2-3-26
T. Alternator ............................................................................................................ 2-3-26
1. Removal ................................................................................................. 2-3-26
2. Installation ............................................................................................... 2-3-27
U. Starter/Solenoid .................................................................................................. 2-3-27
1. Removal ................................................................................................. 2-3-27
2. Installation ............................................................................................... 2-3-27
CD368 2-TOC-iii
Rev 7
Chapter 2
V. Oil Temperature Sending Unit and Gauge .......................................................... 2-3-27

1. Temperature Sending Unit Removal/Installation ..................................... 2-3-27
2. Oil Temperature Gauge Removal/Installation .......................................... 2-3-28
W. Oil Pressure Sending Unit and Gauge ................................................................ 2-3-28
1. Oil Pressure Sending Unit Removal/Installation ..................................... 2-3-28
2. Oil Pressure Gauge Removal/Installation ............................................... 2-3-28
X. Voltmeter............................................................................................................. 2-3-29
1. Removal ................................................................................................. 2-3-29
2. Installation ............................................................................................... 2-3-29
Y. Elapsed Time Indicator ....................................................................................... 2-3-29
1. Removal ................................................................................................. 2-3-29
2. Installation ............................................................................................... 2-3-29
Z. Switches ............................................................................................................. 2-3-30
1. Ignition Switch Removal/Installation ........................................................ 2-3-30
2. Headlight Switch Removal Installation .................................................... 2-3-30
3. Auxiliary Switch Removal/Installation ...................................................... 2-3-30
4. Brake Warning Light Removal/Installation ............................................... 2-3-31
AA. Headlights, Stop Lights, and Turn Signal Lights .................................................. 2-3-31
1. Headlight Removal/Installation ................................................................ 2-3-31
2. Stop Light and Back-Up Light Removal/Installation ................................. 2-3-32
3. Turn Signal Light Removal/Installation .................................................... 2-3-32
BB. Bulb Replacement .............................................................................................. 2-3-32
1. Brake Warning ........................................................................................ 2-3-32
2. Headlight ................................................................................................. 2-3-33
3. Stop Light ................................................................................................ 2-3-33
4. Turn Signal .............................................................................................. 2-3-33
5. Back-Up Light: ........................................................................................ 2-3-33
6. Temperature Gauge ................................................................................ 2-3-33
7. Pressure Gauge ..................................................................................... 2-3-33
8. Voltmeter ................................................................................................. 2-3-33
CC. Cab Door Removal/Installation (Optional) .......................................................... 2-3-34
DD. Cab Assembly Removal/Installation (Optional) ................................................... 2-3-34
EE. Steer Axle Removal / Replacement .................................................................... 2-3-34
1. Removal ................................................................................................. 2-3-34
2. Installation ............................................................................................... 2-3-35
2-TOC-iv CD368
Rev 7
Chapter 2

SECTION 1: SERVICING
A. PREPARATION FOR USE
1. Fuel System
(a) Check all fuel line connections to make sure they are properly connected, from fuel
tank to fuel pump to injector pump.
(b) Make certain fuel cell drain valve is closed.
(c) Fill fuel cell with correct fuel.
2. Battery
(a) Check the battery fluid level. Top off with distilled or approved drinking water, as
necessary.
(b) Connect the battery cables, if disconnected, positive first.
3. Brake System
(a) Check master cylinder fluid level.
(b) If low, check for leaks in brake lines.
4. Engine and Transmission
(a) Check engine oil level, add oil if needed.
(b) Check radiator coolant/water mixture level at the coolant recovery tank. If coolant is
needed, make sure radiator drain valve is closed, then add a 50/50 mix of required
coolant/water mixture at the coolant recovery tank.
(c) Check transmission fluid level.
NOTE: This check is just to determine if there is fluid in the

Note
transmission. If any fluid shows on the dipstick, do not add transmission
fluid until it is checked with the engine running, after the engine has
reached normal operating temperature.
CD368 2-1-1
Rev 7
Chapter 2
(d) Check transmission cooling lines for proper connections.
5. Rear Axle and Reduction Gear Box

Check oil level in the rear axle and gear reduction box and add oil, if needed. The rear axle
and reduction gear box are internally connected.
6. Tire Inflation
Check air pressure in tires and add air if needed.
7. Power Steering Fluid

Check level at reservoir.
B. PERIODIC MAINTENANCE SCHEDULE
The tractor should be maintained in accordance with the following schedules:
1. Daily
(a) Check that all controls are in good working order. Report a faulty TUG control and
do not use until repaired.
(b) Check fuel level.
(c) Check engine oil level.
(d) Check radiator coolant/water level at coolant surge tank.
(e) Check voltmeter for charging.
(f) Check the pressure of the pneumatic tires:
Drive Wheels 45 psi

Steer Wheels 60 psi
WARNING: DO NOT CHANGE PNEUMATIC TIRE FOR CUSHION

TIRE OR VICE VERSA WITHOUT FIRST CONSULTING TUG.. TIRES
OF A DIFFERENT TYPE OR MAKE, TREAD OR MATERIAL CAN
REDUCE THE LOAD CAPACITY OR AFFECT SAFETY.
(g) Check the tire treads for damage. Remove any stone, etc.
2-1-2 CD368
Rev 7
Chapter 2
(h) Check the operation of the headlights and if aimed correctly.
(i) Check the operation of backup, tail, stop and turn signal lights (if equipped).
(j) Check the operation of the cab marker lights, the heater, the wiper and cab light, if
equipped.
(k) Sound the horn.
2. Weekly or 50 Hours
WARNING: LUG NUTS MUST BE RETIGHTENED TO 125 FT-LB

AFTER ANY CHANGE OF A WHEEL AND ANYTIME THE LUG NUTS
HAVE BEEN LOOSENED FOR ANY REASON, AND AT THE
INTERVALS SPECIFIED IN THIS PERIODIC MAINTENANCE
SECTION.
(a) Check that the wheel lug nuts are tightened to 125 ft-lb.
(b) Change engine oil.
Note NOTE: Only the intial change is required at the 50-hour maintenance level,
change monthly or every 200 hours thereafter.
(c) Check the level of the brake fluid in the master cylinder. If low, top off as necessary.
(d) Check the battery charge and fluid level.
(e) Check the drive axle U-bolts and tighten if required.
WARNING: TRANSMISSION FLUID MAY REACH HIGH

TEMPERATURES AND THE CASE MAY BE UNDER PRESSURE. CARE
MUST BE TAKEN WHEN REMOVING THE DIPSTICK TO AVOID
BURNS.
(f) Check the transmission fluid level (with engine running at normal operating
temperature).
(g) Check cylinder head bolt torque and all nuts and bolts for tightness. If required, torque
to specified torque with oiled threads.
(h) Check drive axle and reduction gear box oil level.
CD368 2-1-3
Rev 7
Chapter 2
(i) Check king pins and steer pin for looseness.
(j) Check underneath for oil leaks and damage.
(k) Check exhaust system for leaks and holes.
(l) Check power steering fluid level.
3. Monthly or 200 Hours
(a) Check park brake operation. With the park brake handle in ‘lock’ position, the tractor
should not move on an 8% or less grade. If the tractor does not move, no adjustment
is necessary, but if the tractor rolls, then adjustment is advised. Follow the
recommended adjustment instructions in this section.
(b) Check service brake operation.
(c) Check the fan and alternator belts; tighten, if necessary.
(d) Inspect radiator hoses and clean radiator exterior.
(e) Inspect brake pads; replace if pads are less than one-eighth (1/8) of an inch.
(f) Change engine oil.
NOTE: The intial change is required at the 50-hour maintenance level,

Note change monthly or every 200 hours thereafter.
(g) Change fuel filter.
NOTE: Only the initial change is required at the 200-hour maintenance

Note
level, change every ten (10) weeks or 500 hours thereafter.
(h) Change drive axle and reduction gear box oil.
NOTE: Only the initial change is required at the 200-hour maintenance

Note
level, change every six (6) months or 1200 hours thereafter.
(i) Check intake air filter. Clean or replace as needed.
(j) Lube the adjusting slides beneath the operator’s seat.
(k) Lube the service brake pedal pivot.
2-1-4 CD368
Rev 8
Chapter 2
(l) Lube the drive shaft joints.
(m) Lube the parking brake lever pivots.
(n) Lube the throttle linkage.
(o) Lube the steering axle, king pins, and pivot points.
(p) Lube the sliding bushings on the rear brake calipers.
(q) Lube all grease fittings.
(r) Lube the hood latches and hinges.
(s) Lube the cab door handles (if equipped).
4. Two (2) Months or 400 Hours
(a) Check the cooling system for dirt or rust in coolant.
(b) Check injector pump timing, adjust if necessary.
(c) Check the thermostat in cooling system.
(d) Inspect front wheel bearings; clean and repack.
(e) Check ball joints and tie rod ends looseness.
(f) Check hydraulic pressure relief valve; adjust to 850 psi if needed.
5. Ten (10) Weeks or 500 Hours

Change fuel filter.
NOTE: The initial change is required at the 200-hour maintenance level,

Note change every ten (10) weeks or 500 hours thereafter.
CD368 2-1-5
Rev 8
Chapter 2
6. Six (6) Months or 1200 Hours
(a) Check the differential and reduction gear box bolts are tightened to 492 in-lb.
(b) Change drive axle and reduction gear box oil.
Note NOTE: The initial change is required at the 200-hour maintenance level,
change every six (6) months or 1200 hours thereafter.
(c) Check the steering sector and adjust if necessary.
(d) Check cylinder compression.
(e) Check the intake manifold bolts and tighten, if necessary.
(f) Check the spark-arrest muffler. The spark arrest muffler comes equipped with a pipe
plug located on the bottom of muffler. This plug is designed to allow for removal of
carbon buildup. The following procedure should be performed at least every six
months or 1200 hours of operation.
(1) Remove pipe plug.
(2) Using a rubber mallet, tap the sides of muffler.
(3) Continue tapping until little or no carbon particles fall from plug opening.
(4) Replace pipe plug.
7. Yearly or 2400 Hours
(a) Adjust automatic transmission band.
(b) Change transmission fluid and filter.
(c) Drain, flush, refill and bleed the hydraulic brake system.
2-1-6 CD368
Rev 7
Chapter 2
CD368 2-1-7
Rev 7
Chapter 2
8. Lubricant Charts
13
7
7
4
4
6
6
11
12
6 6
10 9 10
Figure 1-1. Lubrication Schematic
2-1-8 CD368
Rev 7
Chapter 2
Table 1-1. Lubrication Schematic
Item # Component/System Item # Component/System

1 Engine Oil 8 Drive Shaft Joints
2 Transmission 9 Drive Axle and Gear Box
4 King Pins 10 Seat Adjusting Slide
5 Drag Link 11 Hydraulic Brake System
6 Axle Hubs 12 Brake Pedal Pivot
7 Tie Rod Ends 13 Power Steering Fluid
Table 1-2. Component/System to Lubricant (Alphabetical by Component/System)
Component/System Lubricant Type or Specification

Adjusting Slides, Operator’s Seat Multi-Purpose Lithium-Based Grease
Axle Hubs Multi-Purpose Lithium-Based Grease
Brake Calipers, Rear Silicon Base Grease
Brake Pedal Pivot Multi-Purpose Lithium-Based Grease
Cab Door Handles Multi-Purpose Lithium-Based Grease
Drag Link Multi-Purpose Lithium-Based Grease
Drive Axle & Gear Reduction Box Hypoid Gear Oil, SAE 90 EP
Drive Shaft Joints Multi-Purpose Lithium-Based Grease
Engine Oil API Service SF-CC, MS Type
Gear Reduction Box & Drive Axle Hypoid Gear Oil, SAE 90 EP
Hood Latch Multi-Purpose Lithium-Based Grease
Hydraulic Brake System Hydraulic Fluid, DOT 3, Extra Heavy Duty
Parking Brake Linkage Multi-Purpose Lithium-Based Grease
Power Steering Fluid Transmission Fluid; Dexron Type II
Steering King Pins Multi-Purpose Lithium-Based Grease
Throttle Linkage Hypoid Gear Oil, SAE 90 EP
Tie Rod Ends Multi-Purpose Lithium-Based Grease
Transmission, Automatic Transmission Fluid, Dexron Type III
CD368 2-1-9
Rev 7
Chapter 2
Table 1-3. Lubricant to Component/System
Lubricant Component/System
API Service SF-CC, MS Type Engine Oil
Automatic Transmission Fluid, Dexron Type III Transmission, Power Steering
Hydraulic Fluid, DOT 3, Extra Heavy Duty Hydraulic Brake System
Hypoid Gear Oil, SAE 90 EP Drive Axle and Reduction Gear Box
Throttle Linkage
Multi-Purpose Lithium-Based Grease Adjusting Slides, Seat, Operator’s
Axle Hubs
Brake Pedal Pivot
Cab Door Handles
Drag Link
Drive Shaft Joints
Hood Latch and Hinges
Parking Brake Linkage
Rear Brake Calipers
Steer King Pins
Tie Rod Ends
Table 1-4. Lubricant to Commercially Available Product
Lubricant Comercially Available Product

API Service SF-CC, MS Type Texaco Ursa Super Plus Ford Specification No. M-20
Viscosity Atmospheric Temperature

SAE 40 only Above +100 °F (+38 °C)
SAE 30 or 20W-40 +32 °F to +100 °F (0 °C to +38 °C)
SAE 20 or 10W-30 -10 °F to +32 °F (-23 °C to 0 °C)
SAE 10W or 5W-20 Below -10 °F (-23 °C)
Automatic Transmission Fluid Texamatic Dexron III ATF Qualification No. D-20112
Hydraulic Fluid, DOT 3, Extra Heavy Duty Lockheed Super 105 Hydraulic Fluid
Hypoid Gear Oil, SAE 90 EP Texaco MGL 80W-90
Multi-Purpose Lithium-Based Grease Texaco Marfak Multipurpose 2
Silicon Base Grease Ford Part No. D7AZ-19A-331-A
2-1-10 CD368
Rev 7
Chapter 2
9. Adjustment Instruction
(a) Service Brake Adjustment
(1) Loosen stop nut on brake rod.
(2) The Service brake pedal height can be adjusted by threading the clevis on the
master cylinder.
(b) Parking Brake Adjustment
The parking brake is connected via a rigid linkage assembly to the parking brake
assembly just in front of the drive shaft. Starting from the brake handle, the linkage
connects to a lever arm on the park brake drum. When the handle is pulled rearward,
the linkage is engaged, causing the lever arm on the brake drum to force the brake
shoes to contact the drum. To adjust the parking brake, turn the knob on the lever
clockwise to increase the hold on the brakes or counterclockwise to decrease the hold
of the brakes.
(c) Vertical Headlight Adjustment
(1) Loosen the nut on the horizontal bolt.
(2) Aim headlight in desired direction.
(3) Tighten the nut.
(d) Cab Door Adjustment
The adjustment of a cab door is accomplished by loosening the bolts on the hinges
(two (2) per hinge). Hold the door in desired position and secure by tightening the
bolts.
(e) Toe-In Adjustment
Start off on a level piece of pavement that is flat and smooth for at least twenty feet.
Head slowly, and with the cross spoke of the steering wheel at center, run the tractor
absolutely straight without touching the steering wheel. Use the parking brake to stop
the tractor at the end of the run. Taking two flat sticks and a pencil, lie under the
tractor’s front wheels. Lay with the two sticks held together and measure the distance
between the two front wheels, first at 3 o’clock, then at 9 o’clock. Measure the toe-in
on the rim. The back measurement should be 1/8" more than the front mark. In other
words, the wheels should be 1/8" pigeon-toed. Measure again to check yourself for
accuracy.
CD368 2-1-11
Rev 7
Chapter 2
Toe-in is adjusted by changing the length of the tie rod. Remove the cotter pin and
castellated nut from the tie rod end at the steering knuckle. Remove the rod end from
the steering knuckle with a “pickle fork” or by tapping with a rubber head hammer.
Turn the tie rod end clockwise to decrease toe-in or counterclockwise to increase toe-
in, reconnect the rod and check toe-in. Readjust as necessary. Reinstall rod end, nut
and new cotter pin after adjustments are complete.
(f) Front Camber Adjustment (Front Swing-Arm Suspension Only)
The front wheels camber is adjusted at the factory and should not require adjusting
unless the swing arm pivot spindle, swing arm or knuckle assembly is replaced.
To Adjust:
(1) Be sure tractor is on a level surface.
(2) Check front and rear tire pressure. Inflate front to 60 psi, rear to 45 psi.
(3) Remove front wheel hub dust cap.
(4) Clean the end of the hub of paint and dirt.
(5) Mount an alignment gauge on the end of the hub (see Figure 1-2).
Figure 1-2. Alignment Gauge Placement
2-1-12 CD368
Rev 7
Chapter 2
(6) Be sure the wheel and tire is pointing straight ahead.
(7) On the gauge, read the camber scale in positive or negative degrees and write
it down and note the side, left or right.
(8) Repeat items 3 thru 7 on the other side and note the degrees.
(9) Refer to Table 1-5 and locate the degree reading found. Follow across and
the chart will tell you how many of each shims will be required and the
placement, either top or bottom.
(10) Refer to Figure 1-3 as to placement top or bottom.
Figure 1-3. Shim Placement
(11) Raise the front of the tractor and place secure jack stands at the front.
(12) Locate the swing arm pivot and the four securing bolts with the frame.
Loosen all four about 1/4" and tap the bolt head out the 1/4".
(13) Obtain the required shim pack, refer to the chart for placement to correct the
degree reading, refer to step 10 for the specified location. Insert the shim
pack.
NOTE: To open at bottom, place a jack near the tie bar anchor of the swing
Note arm and lift slightly. To open at top, place a jack under the tire and lift
slightly.
(14) Tighten the four bolts securely starting with the two without shims, then
tighten the two with shims.
CD368 2-1-13
Rev 7
Chapter 2
Table 1-5. M1 Shim Pack Determination and Location Chart

Dimensional Shim
Shim Shim Thickness Shim Pack
Thickness Placement
+ 3° 0.1604 0.1471 TOP (4) Med .0336 & (1) .010 0.1444
+ 2 1/2° 0.1337 0.1204 TOP (2) Thick .0516 & (2) .010 0.1232
+ 2° 0.0169 0.0936 TOP (2) Med .0336 & (1) Thin .0276 0.0948
+ 1 7/8° 0.0997 0.0864 TOP (2) Med .0336 & (2) .010 0.0872
+ 1 3/4° 0.0935 0.0802 TOP (3) Thin (.0276) 0.0828
+ 1 5/8° 0.0864 0.0731 TOP (1) Thin .0276 & (1) Med .0336 & (1) .010 0.0712
+ 1 1/2° 0.0802 0.0669 TOP (2) Med .0336 0.0672
+ 1 3/8° 0.073 0.0597 TOP (1) Thick .0516 &(1) .010 0.0616
+ 1 1/4° 0.0668 0.0535 TOP (1) Thick .0516 0.0516
+ 1 1/8° 0.0596 0.0463 TOP (1) Med .0336 &(1) .010 0.0436
+ 1° 0.0535 0.0402 TOP (4) .010 0.04
+ 7/8° 0.0463 0.033 TOP (1) Med .0336 0.0336
+ 3/4° 0.04 0.0267 TOP (1) Thin .0276 0.0276
+ 5/8° 0.0329 0.0196 TOP (2) .010 0.02
+ 1/2° 0.0267 0.0134 TOP (1) .010 0.01
+ 3/8° 0.0196 0.0063
Preferred
+ 1/4° 0.0133 0
Range
+ 1/8° 0.0062
0 0 0.0133 BOTTOM (1) .010 0.01
- 1/8° 0.0062 0.0195 BOTTOM (2) .010 0.02
- 1/4° 0.0133 0.0266 BOTTOM (1) Thin .0276 0.0276
- 3/8° 0.0196 0.0329 BOTTOM (1) Med .0336 0.0336
- 1/2° 0.0267 0.04 BOTTOM (1) Thin .0276 & (1) .010 0.0376
- 5/8° 0.0329 0.0462 BOTTOM (1) Thin .0276 & (2) .010 0.0476
- 3/4° 0.04 0.0533 BOTTOM (1) Thick .0516 0.0516
- 7/8° 0.0463 0.0596 BOTTOM (1) Thick .0516 & (1) .010 0.0616
- 1° 0.0535 0.0668 BOTTOM (2) Med .0336 0.0672
- 1 1/8° 0.0596 0.0729 BOTTOM (2) .010 & (1) Thick .0516 0.0716
- 1 1/4° 0.0668 0.0801 BOTTOM (3) Thin .0276 0.0828
- 1 3/8° 0.073 0.0863 BOTTOM (2) Med .0336 & (2) .010 0.0872
- 1 1/2° 0.0802 0.0935 BOTTOM (2) Med .0336 & (1) Thin .0276 0.0948
- 1 5/8° 0.0864 0.0997 BOTTOM (3) Med .0336 0.1008
- 1 3/4° 0.0935 0.1068 BOTTOM (4) Thin .0276 0.1104
- 1 7/8° 0.0997 . 113 BOTTOM (2) Thick .0516 & (1) .010 0.1132
- 2° 0.1069 0.1202 BOTTOM (2) Thin .0276 & (2) Med .0336 0.1224
- 2 1/2° 0.1337 0.147 BOTTOM (3) Med .0336 & (1) Thick .0516 0.1524
- 3° 0.1604 0.1737 BOTTOM (3) Thick .0516 & (2) .010 0.1748
2-1-14 CD368
Rev 7
Chapter 2
(15) Repeat on the other side.
(16) Lower the tractor to the floor.
(17) Install the camber gauge and check the readings again.
(18) The preferred reading is a + 1/4° with a 1/8° allowed. If reading is within this
range, check the other side. If not, refer to the chart to add or subtract shims
as required to obtain the desired + 1/4° ± 1/8°.
(20) Check and adjust toe-in to 0 - 1/8" by loosening the tie rod jam nuts and
turning the tie rod. When adjusted, tighten the two jam nuts.
(21) Replace both hub dust caps.
(g) Steering Gear Box Adjustment
(1) The adjusting screw is located opposite of the pitman arm spline on the top of
the steering gear box.
(2) Remove the drag link from the pitman arm.
(3) Loosen the lock nut on the adjusting screw.
(4) Turn the adjusting screw clockwise or counterclockwise until the Pitman arm
does not have any free play in it.
(5) Turn the adjusting screw an eighth to a quarter of a turn more in the same
direction used to adjust it.
(6) Tighten lock nut on adjusting screw.
(7) Replace drag link.
CD368 2-1-15
Rev 7
Chapter 2
2-1-16 CD368
Rev 7
Chapter 2
SECTION 2: TROUBLESHOOTING
A. LOSS OF POWER
REDUCTION IN PULLING POWER
CHECK ENGINE PER APPENDIX
OK NOT OK
CHECK TRANSMISSION REPAIR OR ADJUST ENGINE
OK NOT OK
CHECK REAR AXLE ADJUST OR REPAIR
CD368 2-2-1
Rev 7
Chapter 2
B. REAR AXLE
REAR AXLE NOISE
CHECK LUBRICATION
OK NOT OK
CHECK DROP BOX MAGNETIC CHECK LUBRICATION

PLUGS FOR METAL CHIPS
OK NOT OK
CHECK AXLE MAGNETIC PLUGS OVERHAUL BOX DROP FOR METAL CHIPS
OK NOT OK
CHECK BEARINGS OVERHAUL AXLE
OK NOT OK
TEAR DOWN AND INSPECT REPLACE BEARINGS

AXLE AND DROP BOX
2-2-2 CD368
Rev 7
Chapter 2
C. TWELVE (12) VOLT SYSTEM
1. Headlights
POOR, INTERMITTENT OR NO LIGHTS
CHECK CIRCUIT BREAKERS
OK NOT OK
CHECK SEALED BEAM REPLACE CIRCUIT BREAKERS
OK NOT OK
CHECK HEADLIGHT SWITCH REPLACE SEALED BEAMS
OK NOT OK
CHECK WIRING AND

REPLACE HEADLIGHT SWITCH
GROUND CONNECTIONS
CD368 2-2-3
Rev 7
Chapter 2
2. Stop Lights
OK NOT OK
CHECK BULBS OR LAMPS REPLACE CIRCUIT BREAKERS
OK NOT OK
CHECK BRAKE LIGHT SWITCH REPLACE BULBS OR LAMPS
OK NOT OK
CHECK WIRING AND

REPLACE BRAKE LIGHT SWITCH
GROUND CONNECTIONS
2-2-4 CD368
Rev 7
Chapter 2
3. Back-Up Light
OK NOT OK
OK NOT OK
CHECK BACK-UP LIGHT SWITCH REPLACE BULBS OR LAMPS
OK NOT OK
CHECK WIRING AND

REPLACE BACK-UP LIGHT SWITCH
GROUND CONNECTIONS
CD368 2-2-5
Rev 7
Chapter 2
4. Turn Signal Lights
OK NOT OK
OK NOT OK
CHECK WIRING AND

REPLACE BULBS OR LAMPS
GROUND CONNECTIONS
2-2-6 CD368
Rev 7
Chapter 2
5. Cab Marker Light
OK NOT OK
CHECK WIRING AND REPLACE CIRCUIT BREAKERS

GROUND CONNECTIONS
OK NOT OK
CHECK BULB/LAMP CONNECTIONS REPAIR WIRING AND GROUND
CD368 2-2-7
Rev 7
Chapter 2
6. Wiper Motor
WORKS INTERMITTENTLY,
OR WON’T WORK
REPLACE CIRCUIT BREAKERS CHECK WIRING AND

GROUND CONNECTIONS
REPAIR WIRING &

CHECK WIPER CONTROL SWITCH GROUND CONNECTIONS
REPAIR OR REPLACE WIPER MOTOR REPLACE WIPER CONTROLSWITCH
2-2-8 CD368
Rev 7
Chapter 2
7. Horn
OR NO SOUND
CHECK CIRCUIT BREAKER
OK NOT OK
CHECK RELAY REPLACE CIRCUIT BREAKER
OK NOT OK
CHECK HORN REPLACE RELAY
OK NOT OK
CHECK WIRING AND

REPLACE HORN
GROUND CONNECTIONS
CD368 2-2-9
Rev 7
Chapter 2
HORN SOUNDS CONTINUOUSLY
CHECK FOR SHORTED WIRE

BETWEEN HORN BUTTON & RELAY
OK NOT OK
CHECK FOR STUCK HORN BUTTON REPAIR WIRE
OK NOT OK
CHECK RELAY REPAIR BUTTON
2-2-10 CD368
Rev 7
Chapter 2
8. Electric Fan
OR WON’T WORK
CHECK CIRCUIT BREAKER
OK NOT OK
CHECK WIRING AND

REPLACE CIRCUIT BREAKER
GROUND CONNECTIONS
OK NOT OK
CHECK TEMPERATURE SENSOR REPAIR WIRING AND

GROUND CONNECTIONS
OK NOT OK
CHECK FAN CONTROL CIRCUIT BOARD REPLACE TEMPERATURE SENSOR
OK NOT OK
CHECK FAN MOTOR CIRCUIT BOARD REPLACE FAN CONTROL
CD368 2-2-11
Rev 7
Chapter 2
D. STEERING
VEHICLE PULLS TO ONE SIDE
CHECK BRAKES
OK NOT OK
CHECK WHEEL BEARINGS REPAIR BRAKES
OK NOT OK
CHECK TIRE “MATCH” AND INFLATION ADJUST OR REPLACE BEARINGS
OK NOT OK
CHECK STEERING ARM LINKAGE

CHANGE TIRES OR ADJUST INFLATION
REPAIR AS REQUIRED
2-2-12 CD368
Rev 7
Chapter 2
STEERING WANDERS OR WEAVES
CHECK LUBRICATION OF
STEERING SYSTEM
OK NOT OK
CHECK WHEEL BEARINGS LUBRICATE
OK NOT OK
CHECK TOE-IN ADJUST OR REPLACE WHEEL BEARINGS
OK NOT OK
CHECK STEERING GEAR MOUNTINGS ADJUST TOE-IN
OK NOT OK
CHECK STEERING GEAR BOX FOR

ADJUST MOUNTINGS OR TIGHTEN BOLTS
BACKLASH ADJUSTMENT
ADJUST STEERING GEAR BOX
CD368 2-2-13
Rev 7
Chapter 2
STEERING DIFFICULT
CHECK LUBRICATION
OK NOT OK
CHECK STEER CYLINDER LUBRICATE
OK NOT OK
CHECK CHARLYNN VALVE,

ADJUST TO GET EQUAL STEERING
REPLACE IF DAMAGED OR FAULTY
2-2-14 CD368
Rev 7
Chapter 2
E. BRAKE SYSTEM
EXCESSIVE STOPPING DISTANCE
CHECK BRAKE PADS FOR GLAZING

OR EXCESSIVE WEAR
OK NOT OK
CHECK FLUID LEVEL REPLACE BRAKE PADS
OK NOT OK
BLEED BRAKES TOP OFF AS NECESSARY
CD368 2-2-15
Rev 7
Chapter 2
BRAKES DRAG OR UNEVEN PULL
CHECK BRAKE PADS AND ROTOR
OK NOT OK
CHECK FOR SEIZED PISTONS REPLACE PADS OR ROTOR AS NEEDED
NOT OK
INSTALL NEW CALIPER ASSEMBLY
2-2-16 CD368
Rev 7
Chapter 2
BRAKE SPONGY OR EXCESSIVE TRAVEL
CHECK FLUID LINES, FITTINGS

AND MASTER CYLINDER FOR LEAKS
OK NOT OK
TIGHTEN FITTINGS, REPAIR LINES

CHECK FOR LEAKS & REFILL SYSTEM OR OVERHAUL MASTER CYLINDER;
BLEED SYSTEM
OK NOT OK
BLEED BRAKES AND REFILL SYSTEM REPAIR OR REPLACE CALIPERS
CD368 2-2-17
Rev 7
Chapter 2
HARD PEDAL
CHECK HYDRAULIC PRESSURE RELIEF

VALVE IS ADJUSTED TO 850 PSI
OK NOT OK
CHECK BOOSTER FOR ADJUST TO 850 PSI

PRESSURE OR LEAKING
OK NOT OK
INSPECT BRAKE PADS & ROTOR REPLACE BOOSTER
OK NOT OK
CHECK LINES REPLACE PADS OR ROTOR
2-2-18 CD368
Rev 8
Chapter 2
F. ALTERNATOR
ALTERNATOR NOISY
CHECK MOUNTING AND PULLEYS
OK NOT OK
REPLACE ALTERNATOR ADJUST
ALTERNATOR OUTPUT
CONSISTENTLY HIGH
CHECK BATTERY FOR SHORTS OR

INADEQUATE FLUID LEVEL
OK NOT OK
CHECK WIRING BETWEEN BATTERY REPLACE OR REFILL BATTERY

ALTERNATOR AND VOLTAGE
OK NOT OK
CHECK VOLTAGE REGULATOR REPAIR WIRING
OK NOT OK
REPLACE VOLTMETER REPLACE REGULATOR
CD368 2-2-19
Rev 7
Chapter 2
G. BATTERY
BATTERY WILL NOT STAY CHARGED
CHECK SPECIFIC GRAVITY;

CHECK FOR SHORTED CELL
OK NOT OK
CHECK ALTERNATOR OUTPUT AND BELTS CHECK BATTERY
OK NOT OK
CHECK VOLTAGE REGULATOR REPLACE ALTERNATOR OR ADJUST BELTS
OK NOT OK
CHECK FOR BREAKS IN WIRING REPLACE REGULATOR
2-2-20 CD368
Rev 7
Chapter 2
71
66 66
M
WIPER SWITCH WIPER MOTOR
- +
71
BATTERY 71
65 65
RIGHT FRONT
HEADLIGHT 20 AMP
117 89 89 CIRCUIT BREAKER DOME LIGHT
119 SWITCH DOME LIGHT
106 B LIGHT SWITCH 90
B1
B S
M
4 B 89 101
STARTER 63 63
20 5 119
50 AMP
20 6
WHITE
3
BLUE 95 CIRCUIT BREAKER
107
27 66 HEATER SWITCH HEATER BLOWER
2 7 11
RED 65 MOTOR
+ -
1 8 CH-24059 63
SHIFTER 82 82 B1
RELAY
30 WITH NEUTRAL
11 CAB ACCESSORIES
118 SAFETY SWITCH
27
20 AMP
28 BLACK
STARTER-GLOWPLUG RESISTER 12 CIRCUIT BREAKERS A 90
ON INTERLOCK 22 GREEN 90 90 90
RELAY 10 93
1 1 90
2 2
11
101 RIGHT REAR
OIL TEMP.
ALTERNATOR STOP & TAIL
SENDER
OIL 1 80 LIGHT
AC 98 93
TEMP. 78
82
OIL PRESS 98 A 13
B S I B S 102 109
97
99 90 95
I
GS I
28
IGNITION 26 54
SWITCH 2 F
100 BACKUP LIGHT
94 20 58
84 96
27
96 2 77
F
19
OIL PRESSURE
FUEL GAUGE 100
SENDER BRAKE 12
20 S F WARNING
28 LIGHT
99
HOURMETER
12 12
94 BRAKE
VOLTMETER WARNING
94 96 28
F
80 10
F1
F1
RIGHT FRONT 96
TURN SIGNAL 27
26 12
LIGHT
109 109
MANIFOLD HEATER 54
56 94 CONTROL RELAY 20 102
20 BACKUP LIGHT
26 WAIT
28 LIGHT
102 58
MANIFOLD
HEATER 28 27 19
87
77 LEFT REAR
30 FUEL
19 STOP &
104 SENDER
108 HORN TAIL LIGHT
20 F1
HORN
LEFT FRONT 2 1
19 BUTTON 102 86
TURN SIGNAL 85
53
LIGHT
103
FUEL SHUT-OFF HORN RELAY
55
SOLENOID STOP LIGHT
55 GREEN SWITCH
D
27 RE
GREY/BLACK 57 84
20 BL
AC
K
GR
EY 54
BL
YE
52 UE
LL
53
O
107 BROWN
W
LEFT FRONT 51
58 58
HEADLIGHT
58
Figure 2-1. Wiring Schematic, Deutz 1011F Diesel Engine with Delayed Start Option
CD368 2-2-21
Rev 7
Chapter 2
Figure 2-2. Wiring Diagram, Deutz 1011F Diesel Engine

with Engine Shutdown and Transmission Interlock
2-2-22 CD368
Rev 7
Chapter 2
Figure 2-3. Master Wiring Schematic, Deutz F4M2011 (Tier II) Diesel Engine (Delta) (Page 1 of 2)
CD368 2-2-23
Rev 7
Chapter 2
Figure 2-3. Master Wiring Schematic, Deutz F4M2011 (Tier II) Diesel Engine (Delta) (Page 2 of 2)
2-2-24 CD368
Rev 7
Chapter 2
Figure 2-4. General Wiring Schematic, Deutz D2011 (Tier IVi) Diesel Engine (Page 1 of 2)
CD368 2-2-25
Rev 10
Chapter 2
Figure 2-4. General Wiring Schematic, Deutz D2011 (Tier IVi) Diesel Engine (Page 2 of 2)
2-2-26 CD368
Rev 10
Chapter 2
SECTION 3: REMOVAL/INSTALLATION
A. HOOD PANEL
1. Removal
(a) Disconnect hood latches.
(b) Open hood up to vertical position.
(c) Slide hood to driver’s right so that hinges separate. Carefully remove hood.
2. Installation
(a) Position hood panel on top of fire wall in vertical position.
(b) Nudge as needed to align hinge pins with hinge bases.
(c) Force hinges together using pressure combined with slight up and down movement of
the hood.
B. RADIATOR/FAN ASSEMBLY
1. Removal
WARNING: USE EXTREME CARE IN REMOVING THE RADIATOR

CAP. THIS TRACTOR USES A PRESSURIZED COOLING SYSTEM
AND A SUDDEN RELEASE OF PRESSURE CAN CAUSE SERIOUS
PERSONAL INJURY. LOOSEN CAP VERY SLOWLY USING A CLOTH
SHOP TOWEL AND ALLOW STEAM TO ESCAPE.
(a) Remove radiator cap (see warning above) and drain coolant from radiator by turning
radiator drain winged nut counterclockwise. Disconnect coolant recovery hose at
radiator.
(b) Disconnect the two (2) transmission cooling lines from the left portion of the radiator
by disconnecting the line connecting nuts (turn counterclockwise) from the fittings
attached to the radiator.
(c) Remove driver’s side engine side panel by removing (4) hex bolts.
CD368 2-3-1
Rev 7
Chapter 2
(d) Remove first cooling line mount from fender top by removing (1) hex bolt.
(e) Disconnect the two (2) large upper and lower radiator hoses from the radiator by
loosening the hose clamps.
(f) Remove the four (4) bolts attaching the radiator to the front bumper brackets.
(g) Disconnect (3) wires from the electric fan terminals (note location of wires).
(h) Carefully remove the radiator/fan assembly by lifting vertically, maneuvering as

needed to clear mounting tabs from mounting angles.
2. Installation
(a) Lower the radiator into the gap between the engine and front bumper. Align tabs with
rubber based mounts.
(b) Attach the radiator to the (4) front bumper brackets using hardware removed in
previous steps.
(c) Connect the two (2) transmission cooling lines from the left portion of the radiator.
(d) Reattach the first cooling line mount to fender top by replacing (1) hex bolt.
(e) Connect the two (2) large upper and lower radiator hoses to the radiator, and tighten
the hose clamps.
(f) Reconnect coolant overflow hose.
(g) Reconnect (3) wires to the electric fan terminals (refer to wiring diagram).
(h) Attach driver’s side engine side panel using (4) hex bolts.
(i) Check radiator drain nut and make sure it is CLOSED. (Turn clockwise to close;
counterclockwise to open.)
(j) Refill radiator with a 50-50 coolant mix and replace radiator cap.
(k) Run engine and check for leaks. Top off cooling system at coolant recovery tank.
(l) Close hood and secure with the hood latches.
2-3-2 CD368
Rev 7
Chapter 2
C. OIL COOLER
1. Removal
WARNING: OIL AND COOLER ARE VERY HOT AT OPERATING

TEMPERATURES. ALLOW ENGINE TO COOL BEFORE
BEGINNING THIS OPERATION.
(a) Disconnect battery.
(b) Drain engine oil.
(c) Remove air filter cannister.
(1) Detach air intake hose at flexible connection.
(2) Remove two (2) mounting screws from cannister mount plate.
(3) Lift and remove air filter assembly.
(d) Remove top cooler shroud plate.
(1) Remove four (4) bolts attaching top shroud plate to plate mounts and side
shroud.
(2) Remove two (2) upper radiator mount nuts.
(3) Lift out top shroud plate, allowing top rubber mounts to stay attached to top
plate.
(e) Remove two (2) lower oil cooler mount bolts.
(f) Slide oil cooler assembly forward until it clears the fan.
(g) Lift oil cooler up, rotating 90° so that hose ports are at the bottom. Allow engine oil
inside cooler to drain back into engine.
(h) Remove and tie off (2) oil lines.
2. Installation
(a) Attach (2) rubber mounts to the bottom two holes in the oil cooler. Tighten securely.
CD368 2-3-3
Rev 7
Chapter 2
(b) Lower cooler into position in front of fan. Fit rubber mount bolts into lower mount
slots, allowing fan to enter cooler opening. Thread on nuts, but do not tighten.
(c) Fit top shroud plate into place. Attach four mounting bolts, but do not tighten.
(d) Fit top cooler mounts into mounting holes. Attach nuts loosely, but do not tighten.
NOTE: Proper positioning of fan is two-thirds into the oil cooler opening;
Note one third out.
(e) Adjust position of oil cooler until fan is properly located in oil cooler opening. Be sure
to also check fan clearances at edges of cooler opening. Center fan in opening.
Tighten nuts at bottom slot mounts.
(f) Tighten top shroud mount bolts in symetric pairs, checking fan clearance and position
with each pair of bolts tightened. Loosen hardware and adjust cooler position as
needed. Double-check all mounting hardware for tightness once cooler is properly in
place.
(g) Attach oil cooler lines.
Note NOTE: Long line goes to bottom oil port. Tighten fittings securely.
(h) Remount and attach air filter assembly.
(i) Refill engine oil.
(k) Connect battery.
(l) Run engine briefly to circulate new oil. Check oil level and top off as needed.
D. BATTERY
1. Removal
(a) Remove driver’s side floor panel by removing (4) hex bolts.
(b) Disconnect battery cables.
(c) Remove battery hold down.
(d) Remove battery from tractor.
2-3-4 CD368
Rev 7
Chapter 2
2. Installation
(a) Carefully place battery into tractor. Do not drop battery.
(b) Secure the battery with the battery hold down.
CAUTION: MAKE SURE CABLE INSTALLATIONS TO THE

BATTERY ARE CORRECT TO PREVENT DAMAGE TO THE
ALTERNATOR.
(c) Connect positive battery cable.
(d) Connect negative battery cable.
(e) Replace floor panel.
E. OPERATOR’S SEAT
1. Removal
(a) Lift seat plate to vertical position. Secure with seat prop.
(b) Remove the four (4) bolts holding the seat adjustment slides to the seat plate,
disconnect Ryder safety seat quick disconnect (if equipped) and remove the seat.
2. Installation
(a) Lift seat plate to vertical position. Secure with seat prop.
(b) Locate the studs of the adjusting slides to the holes in the seat plate, and tighten with
four (4) nuts, and connect quick disconnect for Ryder safety seat (if equipped).
CD368 2-3-5
Rev 7
Chapter 2
F. TIRES AND WHEELS
1. Rear Tire and Wheel Removal/Installation
CAUTION: DO NOT REMOVE THE HUB NUT FOR WHEEL

REMOVAL. THE HUB NUT IS REMOVED FOR AXLE OR BRAKE
REPAIR ONLY.
(a) Jack rear wheels off the ground using normal jacking procedures.
(1) Use only duty-rated jacks and jack stands. Floor jacks should be rated for a
minimum of two tons. Jack stands should be rated for at least one ton each.
(2) Tractor should be parked on flat, high quality concrete surface before jacking.
WARNING: DO NOT ATTEMPT TO PERFORM MAINTENANCE ON

JACKED TRACTOR IF PARKED ON SOFT OR WET SURFACE.
PERSONAL INJURY, POSSIBLE DEATH AND/OR DAMAGE TO
TRACTOR CAN RESULT.
WARNING: IMPROPER JACKING CAN RESULT IN PERSONAL

INJURY, POSSIBLE DEATH AND/OR DAMAGE TO THE TRACTOR.
(3) Engage the parking brake and chock the wheels.
(4) Position floor jack under front or rear bumper and raise the tractor.
(5) Position jack stands under the bumper and lower the unit onto the jack stands.
WARNING: IF WHEEL IS EQUIPPED WITH RETAINING RING, TIRE

MUST BE COMPLETELY DEFLATED. CAUTION MUST BE TAKEN
WHEN REMOVING RING, IT HAS A TENDENCY TO “FLY” OFF
WHEN REMOVING.
(b) Remove the eight (8) lug nuts which secure the wheel to the drive axle hub and
remove the wheel.
(c) Remove the tire for repair or replacement as required, using proper tire tools.
(d) Install the new or repaired tire onto the wheel.
(e) Install the wheel to the hub with eight (8) lug nuts and torque to 125 ft-lb.
2-3-6 CD368
Rev 7
Chapter 2
2. Front Tire and Wheel Removal/Installation
(a) Jack the front wheels off the ground using normal jacking procedures.
WARNING: IF WHEEL IS EQUIPPED WITH RETAINING RING, TIRE

MUST BE COMPLETELY DEFLATED. CAUTION MUST BE TAKEN
WHEN REMOVING RING, IT HAS A TENDENCY TO “FLY” OFF
WHEN REMOVING.
(b) Remove the five (5) lug nuts which secure the wheel to the steer axle hub and
remove the wheel.
(c) Remove the tire for repair or replacement, as required.
(d) Install the new or repaired tire on the wheel.
(e) Install retaining ring, if required.
(f) Install the wheel to the hub with five (5) lug nuts and torque to 125 ft-lb.
G. DRIVE SHAFT
1. Removal
(a) Chock the wheels securely.
Note NOTE: Do not engage parking brake.
(b) Lift seat plate to vertical position. Secure with seat prop.
(c) Remove the four (4) yoke bolts securing the front of the drive shaft to the
transmission yoke.
(d) Disconnect the rear section of the drive shaft by removing four (4) bolts attaching the
drive shaft coupling plate to the park brake disk at the reduction gear box.
CD368 2-3-7
Rev 7
Chapter 2
2. Installation
(a) Connect the rear section of the drive shaft by installing four (4) bolts to attach the
drive shaft coupling plate to the park brake disk at the reduction gear box.
(b) Install the four (4) yoke bolts securing the front of the drive shaft to the transmission
yoke.
H. DRIVE AXLE AND MOUNTING SPRINGS
1. Removal
(a) Position a heavy duty chain hoist at the rear end of the tractor so that when the drive
axle (with wheels installed) is disconnected from the tractor, the axle may be rolled
out from under the tractor to the rear.
(b) Attach the hoist to the left and right sides of the rear portion of the frame. Tighten and
lock and hoist, but DO NOT lift the rear wheels off the ground.
(c) Chock both front wheels.
(d) Disconnect the two brake lines from the “T” joints at the center of the axle cradle and
drain brake lines.
(e) Place a block under the drive reduction gear housing to prevent the axle from rotating
when the axle is disconnected from the tractor.
(f) Disconnect and remove the drive shaft from the reduction gear box as indicated in
procedure G-1.
(g) Remove the two shock absorber top nuts.
(h) Remove the (2) bolts that hold the spring chain mount angles in place.
(i) Hoist the rear of the tractor approximately seventeen (17) inches and lock hoist in
position, thereby providing clearance from drive axle roll-out.
(j) Remove the main cradle pivot bolt and nut.
(k) Remove the block under the axle reduction gear housing and roll the axle out from
under the tractor.
2-3-8 CD368
Rev 7
Chapter 2

(l) Lower the tractor frame rear end onto blocks approximately fourteen (14) inches in
height until drive axle installation.
2. Installation
(a) With front wheel chocks still in place, hoist the tractor approximately seventeen (17)
inches and lock the hoist in position. Remove the support blocks. Roll the axle into
position.
(b) Align the cradle pivot tube with mounting. Install main pivot bolt and nut.
(c) Using the chain hoist, slowly lower the tractor frame onto the axle and adjust the axle
until the springs and shock absorber shafts line up with in the mounts.
(d) Install (2) nuts to secure shocks.
(e) Reattach the spring chains.
(f) Replace the drive shaft.
(g) Remove the chain hoist.
(h) Connect the brake lines to the “T” joints and the axle.
(i) Add brake fluid to master cylinder, purging brake system of air, following the
procedure in Chapter 3, Section 5.
(j) Remove chocks from front wheels.
I. ENGINE/TRANSMISSION
NOTE: Due to the various equipment available for your M1 Tow Tractor,
Note removal and installation instructions listed here for engine and
transmission are generic. Individual attachments of fuel lines, wiring
harnesses, exhaust and air supply systems will vary according to
equipment type. The serviceman is therefore encouraged to keep careful
notes associated with disassembly.
1. Removal
(a) Park tractor on level spot; chock rear tires; put shifter in neutral and disengage park
brake. Jack up front of tractor, place on jack stands.
CD368 2-3-9
Rev 7
Chapter 2
(b) Disconnect the battery cables from the battery.
(c) Remove the hood (see procedure A-1).
(d) Drain the radiator and remove the radiator and coolant recovery tank. (For radiator
removal, see procedure B-1.)
(e) Drain the oil from the engine.
(f) Remove the exhaust pipe from the engine and muffler.
(g) Disconnect the engine to frame ground cable from the engine, located directly below
the master cylinder reservoir.
(h) Disconnect wires connected to the oil pressure and temperature sending units,
(located just above the oil filter on some units).
(i) Disconnect the cable connected to the starter.
(j) Disconnect the throttle cable from the injector pump or carburetor, and all clips or ties
holding the throttle cable in place.
(k) Disconnect the wires attached to the alternator, temperature sensor and temperature
sending unit. Move that portion of the harness up and out of the way.
(l) If horn is mounted on frame, disconnect wire from horn and remove horn.
(m) Close the fuel line shut-off valve located under the floor plate near the forward
portion of the fuel cell, on tractors so equipped.
(n) Disconnect the main hydraulic hose from the pump (located just in front of the left or
right front shock absorber in some units).
(o) Disconnect the metal fuel line from the rubber line connector line near the fuel pump
and plug the line.
(p) Disconnect (2) hoses from the hydraulic fluid reservoir (on diesel tractors) located on
the fire wire. Pull hoses up and out of the way.
(q) Disconnect the (2) metal fuel lines at the point they become rubber, located below the
master cylinder (diesel only).
(r) Disconnect the air intake line between the intake manifold and the air filter assembly
(diesel only).
2-3-10 CD368
Rev 7
Chapter 2
(s) Disconnect the wire from the glow plug (diesel only).
(t) Disconnect and remove the drive shaft. (See procedure G-1.)
(u) Make sure the shifter is in neutral and remove the gear shift connecting cable from
the transmission.
(v) Remove the brake handle and transmission cover from the floorboard. Also remove
fire wall plate (not applicable on some early units).
NOTE: If transmission is to be detached from engine prior to engine

Note removal, disregard step (w). Go to Step (x).
(w) To remove engine and transmission together:
(1) Remove the bottom bolts from both left and right motor mounts (gasoline and
diesel engines). Also remove the centermount bolts on diesel engines.
(2) Lift and remove the seat plate.
(3) Remove (4) bolts from rear transmission mount.
(4) Attach a chain hoist to the engine/transmission. If necessary, refer to engine

documentation for chain attachment points.
NOTE: At this point, all engine/transmission interfaces to the frame

should have been disconnected or removed. Carefully move all wires
Note
back over the fire wall and check all areas for engine/transmission
removal clearance.
(5) Lift engine/transmission up, then forward, and then up and out.
Note NOTE: The following step (x) is only for engine and transmission
removed separately.
(x) To remove engine and transmission separately:
(1) Remove bell housing bolts; transmission mount bolts.
(2) Slide transmission backward enough to reveal flywheel bolts at torque

converter. Remove torque converter-to-transmission bolts.
(3) Attach a chain hoist to the transmission.
(4) Remove transmission.
CD368 2-3-11
Rev 7
Chapter 2
(5) Attach a chain hoist to the engine. If necessary, refer to engine

documentation for chain attachment points.
(6) Check to make sure that all engine attachments have been removed.
(7) Remove engine.
2. Installation
(a) Lower the engine/transmission into the tractor with a chain hoist so that the engine is
resting on the engine mounts.
(b) Install the (4) engine mounting bolts and the bolts connecting the transmission mounts
to the frame.
(c) Remove the chain hoist from the engine.
(d) Install the transmission cover, shifter and brake handle.
(e) Make sure the shifter is in neutral and connect the gearshift cable to the transmission.
(f) Connect the vacuum hose the vacuum modulator valve line on the transmission near
the exhaust manifold (gasoline only).
(g) Install the drive shaft. (See procedure G-2.)
(h) Connect the metal fuel line to the rubber connector line below the master cylinder.
(i) Connect wire to the oil pressure sending unit and temperature unit.
(j) Install the oil filter.
(k) Reattach wiring to alternator, temperature sensor and sending units.
(l) Connect the engine ground cable to its attachment to the engine near the steering
sector.
(m) Reattach all hydraulic hoses.
(n) Reinstall the radiator. (See procedure B-2.)
(o) Install coolant recovery tank.
(p) Reattach the wire to the glow plug (diesel only).
2-3-12 CD368
Rev 7
Chapter 2
(q) Install the throttle linkage cable to the injector pump (diesel only).
(r) Install the horn (if removed) and connect wire to the horn.
(s) Install the electrical cables to the starter.
(t) Install the engine-to-frame ground cable to the left side of the engine.
(u) Install the exhaust pipe to the engine and muffler.
(v) Attach air filter hose to intake manifold (diesel only).
(w) Install the hood.
(x) Connect battery cables to the battery.
(y) Add engine oil and/or transmission fluid and engine coolant as required.
J. SHIFTER
1. Removal
(a) Make sure the ignition switch is in the “OFF” position, and that tractor is on flat, level
surface. Engage the parking brake.
(b) Elevate and prop seat plate.
(c) Disconnect the shift cable anchor holding the cable in place below the shifter.
(d) Disconnect modular wiring connection.
(e) Remove the four bolts holding the main shifter base to the mounting.
(f) Move the shifter handle forward or backward until the cable attachment pivot is in the
lowest accessible position. Mark the hole location of the pivot.
(g) Remove the nut attached to the cable pivot. Pull the slack of the loose cable out the
open access panel.
(h) Pull shifter assembly up vertically to remove.
(i) Adjust shifter trunnion on transmission to center or neutral position.
CD368 2-3-13
Rev 7
Chapter 2
2. Installation
(a) Make sure that emergency brake is engaged.
(b) Position the shifter just above the mounting point on seat plate so that “Reverse”
indicator is in forward-most position. Slide shifter into position.
NOTE: If shifter installation is a new shifter, locate comparable cable

Note
mounting hole from “Removal” procedure J-1-f.
(c) Move shifter handle forward and/or backward until marked hole location for cable
pivot is visible and accessible.
(d) Access transmission. Move shifter trunnion to the down or “drive” position.
(e) Mount cable end (pivot) into marked hole, entering from the right side. Thread nut
onto pivot and tighten.
(f) Connect the wiring module.
(g) Connect the cable anchor below the shifter.
(h) Position main shifter base over the mounting holes and thread (4) bolts into place.
Make sure shift position is neutral, and tighten bolts.
(i) Start the engine. Test all three shifter positions to ensure that shifting motion is
smooth, and that forward and reverse engage appropriately. If they do not, the cable
must be adjusted looser or tighter at the anchor point below the shifter.
(j) Check that the shifter handle lands at the forward and reverse markers on the shifter
base when gears are engaged, and that when in the neutral position, the handle is
vertical. If not, move the cable attachment pivot over in one direction or the other.
K. ACCELERATOR PEDAL, THROTTLE CONTROL CABLE AND MODULATOR CABLE
1. Accelerator Pedal Removal/Installation
(a) Remove control console enclosure by:
(1) Removing (1) hex bolt on left side, and
(2) Removing ignition switch on right side.
2-3-14 CD368
Rev 7
Chapter 2
(b) Remove ball and socket clips from cable ends or pry balls loose from sockets using a
flat bit screwdriver.
(c) Unhook throttle spring.
(d) Straighten and remove cotter pins from pedal bracket.
(e) Remove accelerator pedal.
(f) Reassemble new pedal assembly in reverse order.
(g) Install controls console enclosure; attach bolt and install ignition switch.
2. Throttle and Modulator Cable Removal
(a) Follow steps K-1-a through K-1-e to remove accelerator pedal.
(b) Disconnect the engine end of the throttle linkage cable by removing the bolt and
retainer clip securing the cable to the cable mount on the engine.
(c) Disengage the snap-out ball connection of the cable from the throttle linkage assembly
on the injection pump or carburetor.
(d) On the engine side of fire wall, remove both cable nuts to release cables from the
cable mount.
NOTE: Transmission end of modulator cable is accessible from beneath

Note the tractor or from above by removing the transmission cover.
(e) Disconnect the transmission end of the modulator cable by removing the bolt and
retainer clip securing the cable to the cable mount on the transmission.
(f) Pull the modulator assembly away from plug-in (rearward).
(g) Disentangle cables and remove.
3. Throttle and Shift Cables Installation
(a) Thread throttle cable (red) and shift cable (black) into place. The throttle cable
begins at the top of the accelerator pedal assembly and terminates at the injector
pump. The modulator cable starts at the same place, crosses over the bell housing
behind the engine, and drops down to the back side of the transmission.
CD368 2-3-15
Rev 7
Chapter 2
(b) From the engine side of fire wall next to the master cylinder, thread cables through the
holes in the mounting brackets. Thread on mounting nuts and tighten.
(c) Snap the cable ball connectors onto the fitting of the linkage connector arm of the
accelerator pedal.
NOTE: Access to top of throttle linkage may be gained by removing the

Note controls console enclosure. See procedure K-1-a.
(d) Connect the engine end of the throttle linkage cable by attaching the bolt and retainer
clip securing the cable to the cable mount on the engine.
(e) Engage the snap-on ball connection of the cable to the throttle linkage assembly on
the injection pump.
(f) Jack up the tractor so that right side of transmission can be accessed from
underneath, or remove transmission cover at floorboard.
(g) Plug the cable end into the modulator receptacle at rear of transmission.
(h) Mount cable clip and tighten securely.
L. TAIL PIPE/MUFFLER/EXHAUST PIPE
The exhaust pipe system is installed new as three pieces: The tail pipe can be accessed from beneath
the seat plate. The muffler can be partially accessed from beneath the seat plate, but must be
additionally accessed from beneath the tractor. The exhaust pipe can be accessed from under the
hood, but must be additionally accessed from beneath the tractor.
1. Removal
It is recommended that the exhaust system be removed in sections. The entire system cannot
be removed intact without radical disassembly of the tractor.
(a) Tail Pipe
(1) Lift the seat plate.
(2) Remove the pipe hanger.
(3) Remove pipe clamp at slip fitting.
2-3-16 CD368
Rev 7
Chapter 2
(4) Detach tail pipe from muffler.
(b) Muffler
(1) Remove tail pipe.
(2) Remove front pipe clamp from muffler.
(3) Disengage muffler and remove.
(c) Exhaust Pipe
(1) Follow steps listed under (a) and (b) to remove other components of exhaust
system.
(2) Chock rear tires. Raise front of tractor using standard jacking techniques.
Place tractor on jack stands.
(3) From beneath tractor, detach pipe strap by removing a single mounting nut
and bolt.
(4) From beneath hood, remove the entire air cleaner assembly, including the
pipes connecting the air filter to the intake plenum.
(5) Remove engine side panel.
(6) Remove cast iron exhaust elbow that connects exhaust pipe to exhaust
manifold by removing (3) bolts at one joint, and three nuts at the other joint.
(7) Lift exhaust pipe, and work up and out of engine cavity.
2. Installation
(a) Exhaust Pipe
(1) Lower exhaust pipe into opening between right side of engine working it
down and in until both ends align to approximately correct locations.
(2) Attach cast iron elbow to exhaust manifold.
(3) Attach exhaust pipe to iron elbow.
(4) Chock the rear tires.
CD368 2-3-17
Rev 7
Chapter 2
(5) Raise tractor front end using the front bumper as a jacking point. Rest weight
of front of tractor on two (2) jack stands.
(6) From beneath tractor, attach pipe clamp/strap assembly to exhaust pipe.
(7) Mount exhaust strap using a single bolt.
(b) Muffler
NOTE: This procedure assumes that exhaust pipe has just been
Note replaced, and that tractor is elevated as indicated in step (a)(4).
(1) Install pipe clamp loosely around muffler opening.
(2) Slip fit muffler onto exhaust pipe.
(3) Position pipe clamp and tighten securely.
(c) Tail Pipe
NOTE: This procedure is written with the assumption that the muffler is
Note installed, and that slip-fit opening on muffler is usable.
(1) Loosely install pipe clamp and strap onto tail pipe.
(2) Lift seat plate and prop in up position.
(3) Install second pipe clamp loosely onto muffler.
(4) Slide tail pipe into muffler opening.
(5) Mount pipe strap by attaching (1) bolt to hole in frame.
(6) Tighten pipe straps.
2-3-18 CD368
Rev 7
Chapter 2
M. SWING ARM ASSEMBLY
1. Removal
NOTE: This procedure removes the entire swing arm suspension

assembly from either the left or right side of the tractor, including the
Note front knuckle and spindle assembly, and the rotor and calipers. For
removal of these attached assemblies, see appropriate removal
instructions.
(a) Chock rear tires; engage hand brake.
(b) Using floor jack under the center of front bumper, lift front of tractor approximately
17" off the pavement. Use (2) jack stands to support elevated tractor. Remove jack.
(c) Remove the tire and wheel assembly.
(d) Accessing from the side, place the jack beneath the swing arm at approximate center
point. Elevate swing arm until it is just parallel to the pavement.
CAUTION: THE MAJORITY OF WEIGHT OF TRACTOR SHOULD

STILL BE RESTING ON JACK STANDS.
(e) Remove the lower bolt of the spring limiter chain.
(f) Remove the lower shock mount bolt.
(g) Gently lower the swing arm until it releases the suspension spring. Remove spring.
(h) Elevate swing arm again until parallel. Make sure that shock absorber is not in the
way, or remove completely if more convenient.
(i) There is a short connecting link between the left and right swing arm assemblies, just
in front of the tie rod. Disconnect the link by removing the closer of the two mounting
bolts.
(j) Remove the brake line bolt located on back side of caliper. Remove cap from brake
reservoir and allow fluid to drain into collection vessel. Move brake line up and out of
the way.
(k) If removing left side swing arm, follow procedure (j) to also disconnect drag link. If
right side, disregard this step.
CD368 2-3-19
Rev 7
Chapter 2
(l) Remove (4) main mounting bolts from behind the pivot point of the swing arm
assembly. Use caution to ensure that assembly is properly balanced on jack stand as it
releases.
(m) Gently lower swing arm assembly until it clears the fender, then roll out from beneath
tractor.
2. Installation
(a) Make sure that front of tractor is elevated high enough to roll swing arm assembly
into place beneath fender.
(b) Balance swing arm on center pad of floor jack, and roll assembly into place below
tractor.
(c) Slowly elevate assembly, adjusting position to align one or more of main mounting
holes.
(d) When in approximate position, thread one bolt into mounting holes, thread on nut
loosely.
(e) Raise or lower, or otherwise adjust position of swing arm assembly until all four
mounting bolts and nuts are in place. Tighten hardware gradually and diagonally until a
minimum of 40 ft-lb tightness is attained at each bolt.
(f) Move connecting link into place between mounting brackets. Again, adjust position of
swing arm as needed to align holes. Install mounting bolt and tighten.
(g) Move tie rod end into place, rotating wheel assembly left or right to attain alignment.
Thread on slotted nut and tighten until tie rod end is fully engaged into tapered
mounting hole. Tighten another 1/4 to 1/2 turn and insert cotter pin.
(h) If applicable, attach drag link and tighten as indicated for tie rod end.
(i) Lower swing arm gently until suspension spring will fit between upper and lower
cups. Install spring and elevate swing arm.
(j) Attach spring limiter chain.
(k) Install shock absorber.
(l) Slowly lower swing arm. Remove floor jack.
(m) Attach brake line hose to back of caliper assembly.
2-3-20 CD368
Rev 7
Chapter 2
(n) Add brake fluid to reservoir and bleed brake lines.
(o) Mount wheel and tire assembly.
N. STEER VALVE
1. Removal
(c) Remove the left tire and wheel assembly. Turn steering hard to the right to expose
steering hydraulics.
(d) Use a sturdy wire or 1/8" inch woven nylon rope to tie off steer valve to the throttle
cable mount bracket above.
(e) Remove (4) bolts connecting th steer column base plate to the steer valve.
(f) Untie the rope or wire. Ease the steer valve off the steer column spline and lower
down to frame crossmember.
(g) Use a paint pen to clearly mark the hydraulic hoses to correct fitting locations.
(h) Detach hydraulic hoses.
(i) Remove steer valve.
2. Installation
(a) Refer to steps (a) through (c) under “removal” to prepare tractor for installation.
(b) Maneuver steer valve into proper orientation at frame crossmember. Attach hydraulic
hoses.
(c) Lift steer valve into position and slide onto steer column spline.
(d) Install four mount bolts through valve mount bracket, steer column base plate and into
steer valve threaded holes. Tighten securely.
CD368 2-3-21
Rev 7
Chapter 2
(e) Fill power steering reservoir with power steering fluid. Start engine to circulate
through system. Top off.
(f) Install tire and wheel assembly. Lower tractor.
O. STEERING COLUMN AND STEERING WHEEL
1. Removal
(a) Remove the instrument console cover (see procedure).
(b) Remove the rubber disc from the dust cover on the steering wheel by inserting a
screw driver under the cover edge and prying it out.
(c) Remove the dust cover.
(d) Remove the horn components.
(e) Remove the steering wheel retaining nut and remove the steering wheel.
(f) Remove the remaining horn components; remove screw securing the wire where
required. Also remove ground wire at fire wall.
(g) Follow procedures N-1-a through N-1-f to detach and move steer valve.
(h) Detach front of steer cylinder by removing cotter pin and castellated nut. Pivot steer
cylinder out of the way.
(i) Remove the steering column retaining strap by removing the two (2) bolts securing
the strap to the support.
(j) Drop steering column down into engine cavity, following a straight line between tie rod
and left pivot arm.
(k) Maneuver column out of fire wall opening and remove.
2. Installation:
(a) Maneuver steering column up through suspension, through fire wall, and into position.
2-3-22 CD368
Rev 7
Chapter 2
(b) Wrap rubber column cushion strap around column at strap location. Attach the
steering column retaining strap by attaching the two (2) bolts through strap and into
two holes in the instrument console. Do not tighten strap bolts.
(c) Position steer valve and column base plate at valve mount bracket holes. Thread four
mounting bolts through cover, column base, and into valve. Tighten bolts securely.
(d) Tighten the retaining strap bolts.
(e) Reattach the front of the steering cylinder.
(f) Turn the front wheels until they are pointed in a straight forward position.
(e) Install and connect the wire to the horn components in the steering column.
(f) Install the steering wheel to the shaft of the column and secure the wheel with the
retaining nut.
(g) Install the remaining horn components.
(h) Install the console cover.
(h) Lower tractor to the floor.
P. STEER CYLINDER
1. Removal
(c) Remove the left tire and wheel assembly. Turn steering hard to the right to expose
steering hydraulics.
(d) Detach hydraulic hoses from cylinder. Plug or tie off to minimize fluid leakage.
(e) Remove cotter pins and castellated nuts from rod ends.
(f) Remove cylinder.
CD368 2-3-23
Rev 7
Chapter 2
2. Installation
(a) Orient cylinder with base rearward. Drop threaded portion of rod ends down through
mounting holes. Extending portion of cylinder points toward the front of vehicle.
Front rod end mounts into steer arm of front axle.
(b) Attach castellated nuts and tighten securely. Install cotter pins.
(c) Attach hydraulic hoses. Long hose mounts to forward fitting. Short hose to base
fitting.
(d) Top off power steering fluid.
(e) Start engine and turn steering through several complete cycles.
(f) Turn off engine and top off fluid again.
(g) Replace left front tire. Remove tractor from jack stands.
Q. MASTER CYLINDER
1. Removal
(a) Disconnect brake lines and from the master cylinder outlet ports.
(b) Remove the master cylinder from the booster by removing the two (2) attachment
nuts.
(c) Remove the cylinder reservoir cover and gasket, and pour out the brake fluid into an
appropriate container.
2. Installation
(a) Prior to installing the master cylinder in the tractor, bleed the master cylinder:
(1) Support the master cylinder in a vise and loosely install a plug in the outlet
port.
(2) Fill the reservoir with brake fluid and depress the cylinder piston several times
until all bubbles cease to appear in the fluid.
2-3-24 CD368
Rev 7
Chapter 2
(3) Tighten the plug and attempt to depress the piston. The piston travel should be
greatly restricted after all air is expelled
(b) Replace the reservoir cover and gasket assembly.
(c) Prior to installing the master cylinder, measure the distance between the inner face of
the piston to the tip of the push rod on the booster. The length should be 0.015 in ±
.005. Adjust the length as required to be within tolerance by turning the adjustment
nut.
(d) Install the master cylinder.
(e) Remove the output port plug and install the brake line.
(f) Bleed the braking system.
R. BRAKE PEDAL
1. Removal
(a) Remove cotter pin from brake pedal rod (secures brake booster push rod to brake
pedal).
(b) Pull booster push rod off of rod on pedal arm.
(c) Remove brake pedal pivot bolt and pedal.
2. Installation
(a) Place brake pedal in installed position and insert brake pedal pivot bolt from left.
Secure with locknut.
(b) Slide booster push rod onto rod on left-side of pedal arm and secure with new cotter
pin.
S. PARKING BRAKE: LINKAGE AND LEVER
1. Removal
(a) Chock the wheels and disengage parking brake.
CD368 2-3-25
Rev 7
Chapter 2
(b) Remove the transmission cover by removing (4) bolts. Slide cover up and over park
brake assembly.
(c) Elevate and prop seat plate.
(d) The parking brake rod is attached to the brake caliper lever arm on the drive shaft.
Remove the rod by removing the cotter pin and pivot pin.
(e) Remove the (4) screws at the base of the parking brake handle assembly.
(f) Lift out brake handle assembly and brake rod.
2. Installation
(a) Install the parking brake assembly to the transmission mount weldment and secure
with mounting bolts.
(b) Elevate the seat plate.
(c) Attach the brake rod to the lever arm on the park brake caliper.
(d) Install the transmission cover and secure with mounting bolts.
(e) Test park brake for appropriate tightness when handle is elevated. Adjust by twisting
brake handle.
(f) Lower the seat plate and un-chock tires.
T. ALTERNATOR
1. Removal
(a) Disconnect the battery ground cable from the battery.
(b) Disconnect all electrical wires from the alternator.
(c) Loosen the alternator mounting bolt on the adjustment arm and the mounting bolt on
the front end of the alternator, and disengage the alternator belt.
(d) Remove the alternator by removing the mounting bolt on the adjustment arm and the
front mounting bolt attaching the alternator to the alternator engine mount.
2-3-26 CD368
Rev 7
Chapter 2
2. Installation
(a) Install the alternator to the alternator engine mount and to the adjustment arm,
tightening the two (2) mounting bolts only finger tight.
(b) Engage the alternator belt, adjust the belt tension to 70-110 lb. by applying pressure
(leverage) to the alternator front housing, and tighten the two (2) mounting bolts.
(c) Attach the modular plug to the connector recess on the alternator.
(d) Connect the black wire to the single post on the back of the alternator. Tighten nut.
(e) Connect battery ground cable.
U. STARTER/SOLENOID
1. Removal
(a) Disconnect the battery ground cable from the battery.
(b) Disconnect all electrical wires from the solenoid.
(c) Remove the solenoid from the firewall by removing the two (2) attachment nuts.
2. Installation
(a) Install the solenoid to the firewall with two (2) attachment nuts.
(b) Connect the starter cable to the main terminal, and solenoid wires to solenoid
terminals.
(c) Connect the battery ground cable to the battery.
V. OIL TEMPERATURE SENDING UNIT AND GAUGE
1. Temperature Sending Unit Removal/Installation
(a) To remove the sending unit, disconnect wire from the unit terminal and unscrew the
unit from its mounting.
CD368 2-3-27
Rev 7
Chapter 2
(b) Install the new sending unit (use thread sealer) by screwing into its mounting hole on
the engine housing and connect wire to unit terminal.
2. Oil Temperature Gauge Removal/Installation
(a) Disconnect the gauge light and housing from the back of the gauge.
(b) Disconnect right and left side terminal post wires and ground wire.
(c) Remove the two (2) nuts securing the gauge to the gauge retainer mount and slide the
gauge out from the operator’s side of the instrument panel.
(d) Place the new gauge into the installed position and secure the gauge retainer mount
with two (2) retaining nuts.
(e) Install wire to the right and left sides and ground wire.
(f) Connect the gauge light and housing to the back of the gauge.
W. OIL PRESSURE SENDING UNIT AND GAUGE
1. Oil Pressure Sending Unit Removal/Installation
(a) To remove the sending unit, disconnect wire from the unit terminal and unscrew the
unit from its mounting.
(b) Install the new sending unit (use thread sealer) by screwing into its mounting hole on
the engine housing and connect wire to the unit terminal.
2. Oil Pressure Gauge Removal/Installation
(a) Disconnect the gauge light and housing from the back side of the gauge.
(b) Disconnect wires from the right and left side terminal posts and ground wire of the
gauge.
(c) Remove the two (2) nuts securing the gauge to the gauge retainer mount and slide the
gauge out from the operator’s side of the instrument panel.
(d) Place the new gauge into the installed position and secure the gauge to the gauge
retainer mount with two (2) retaining nuts.
2-3-28 CD368
Rev 7
Chapter 2
(e) Install wire to the right side and wire to the left side bolt terminals of the gauge using
two (2) retaining nuts. Install ground wire.
(f) Connect the gauge light and housing to the back side of the gauge.
X. VOLTMETER
1. Removal
(a) Disconnect battery ground cable.
(b) Disconnect wires from the voltmeter.
(c) Remove the two (2) nuts securing the voltmeter to the retainer mount and slide the
gauge out the operator’s side of the instrument panel.
2. Installation
(a) Place the new ammeter into the installed position and secure the unit to the retainer
mount.
(b) See wiring diagram for wire installation.
(c) Connect the battery cables to the battery.
Y. ELAPSED TIME INDICATOR
1. Removal
(a) Disconnect the wires from the terminal posts.
(b) Remove the two (2) nuts securing the indicator out the operator’s side of the
instrument panel.
2. Installation
(a) Place the new indicator into the installed position and secure it to the retainer mount
with two (2) bolts.
(b) See wiring diagram for wiring installation.
CD368 2-3-29
Rev 7
Chapter 2
Z. SWITCHES
1. Ignition Switch Removal/Installation
(a) Disconnect the battery cables.
(b) Disconnect the wires from the terminal posts.
(c) Remove the console cover.
(d) Remove the switch by removing the mounting nut on the console frame.
(e) Place the new master switch into position with the “OFF” position of the switch.
(f) Secure the switch with the mounting nut.
(g) See wiring diagram for wire installation.
(h) Connect the battery.
2. Headlight Switch Removal Installation
(a) Disconnect the battery.
(b) Disconnect the wires from the headlight switch.
(c) Remove the switch by removing the retainer nut.
(d) Install the new light switch with the “ON” position of the switch pointing up and
secure the switch with the retainer nut.
(e) See wiring diagram for wire installation.
(f) Connect the battery.
3. Auxiliary Switch Removal/Installation
(b) Disconnect the wires from the auxiliary switch.
(c) Remove the switch by removing the retainer nut.
2-3-30 CD368
Rev 7
Chapter 2
(d) Install the new switch with the “ON” position of the switch pointing up and secure the
switch with the retainer nut.
4. Brake Warning Light Removal/Installation
(b) Disconnect the wires from the brake warning light.
(c) Remove the lens.
(d) Remove the socket by removing the retainer nut.
(e) Install the new socket and secure the socket with the retainer nut.
(f) Install the lens.
(g) See wiring diagram for wire installation.
(h) Connect the battery.
AA. HEADLIGHTS, STOP LIGHTS, AND TURN SIGNAL LIGHTS
1. Headlight Removal/Installation
(b) Disconnect the wire at the disconnect plug.
(c) Remove the nut and lock washer securing the light to the frame rail.
(d) Install the new headlight to the frame rail with a nut and lock washer.
(e) Connect the wire at the disconnect plug.
CD368 2-3-31
Rev 7
Chapter 2
2. Stop Light and Back-Up Light Removal/Installation
NOTE: The procedure for back-up light removal/installation is the same

Note as stop light removal/installation.
(b) Disconnect wires from stop light assembly.
(c) Remove stop light by pressing light rearward and out of rubber grommet, leaving
grommet in rear bumper.
(d) Install new light by pressing light forward into grommet making sure “TOP” on light is
upward.
3. Turn Signal Light Removal/Installation
(b) Disconnect the wires from the turn signal light assembly.
(c) Remove turn signal light assembly by removing the securing bolts and nuts.
(d) Install the new turn signal light assembly by using the securing bolts and nuts.
BB. BULB REPLACEMENT
1. Brake Warning
Remove lens. The bulb is inside the lens. A metal flange protrudes from the bulb. It is located
at the bottom of the bulb. Pull flange with your index finger and thumb to remove bulb. To
replace, press bulb into lens until bulb “locks” into place. Replace lens.
2-3-32 CD368
Rev 7
Chapter 2
2. Headlight
(a) To remove sealed beam, peel grommet from flange and pry sealed beam up with your
index finger. Disconnect wires.
(b) To install sealed beam, connect wires to correct posts. Place index notch in correct
place while peeling grommet from flange and carefully pushing sealed beam into the
headlight assembly.
3. Stop Light
The stoplight bulb is not replaceable separately. The entire stoplight assembly must be
replaced. See Stoplight Removal/Installation section.
4. Turn Signal
To remove bulb, remove retainer ring. Remove lens cover. Remove bulb and replace it. Install
lens cover and replace retainer ring.
5. Back-Up Light:
The back-up light is not replaceable separately. The entire back-up light assembly must be
replaced. The procedure is the same as for the stop light.
6. Temperature Gauge
To remove bulb, pull socket out of the back of the gauge firmly, but do not pull or jerk on the
wire. Remove bulb and replace it. Press socket into the back of the gauge.
7. Pressure Gauge
8. Voltmeter
CD368 2-3-33
Rev 7
Chapter 2
CC. CAB DOOR REMOVAL/INSTALLATION (OPTIONAL)
1. Remove door stop by removing securing bolts.
2. Install door by lifting door straight up and out of hinges.
3. Install the door by lowering the door so that the pegs of the hinge go into the hinge.
4. Replace door stop and secure with bolts and nuts.
DD. CAB ASSEMBLY REMOVAL/INSTALLATION (OPTIONAL)
1. Disconnect the battery.
2. Disconnect the wires going into the cab.
3. Remove cab by removing (4) bolts. The (4) bolts are located as follows: (1) bolt each on the
right and left from sides, and (1) bolts each on the right and left back corners.
4. Install cab and secure by using eight (8) bolts.
5. Connect the wires.
6. Connect the battery.
EE. STEER AXLE REMOVAL / REPLACEMENT
1. Removal
(a) Chock rear tires. Raise front of tractor. Place front bumper on jack stands.
(b) Remove front tires and wheels.
(c) Disconnect front disk brake calipers from caliper mounts. Tie calipers out of the way.
(d) Using a floor jack, secure the front axle from falling. Place floor jack at center of axle
and jack until floor jack is supporting the weight of the axle. Jack stands should still
support the weight of the tractor.
(e) Disconnect drag link or steer cylinder from steer arm.
2-3-34 CD368
Rev 7
Chapter 2
(f) Remove four axle u-bolts.
(g) Slowly lower the steer axle to the floor and roll jack forward until axle clears front of
tractor.
2. Installation
(a) Center and balance front axle on floor jack in front of elevated tractor.
NOTE: Steer stops and tie rod should be on the rearward side of axle
Note assembly.
Roll steer axle assembly into place under front of tractor .
(b) Slowly elevate axle into place.
Note NOTE: Spring tabs on top of axle should align to center of spring.
(c) Place four new axle u-bolts in place over springs directly in front of and behind axle.
(See illustration in section 4-2.)
(d) Place u-bolt brackets (flat plates with four holes) in place beneath axle. Thread four
lock nuts in place per bracket. Tighten nuts gradually in a diagonal pattern until snug.
Torque nuts to 50 ft-lb.
(e) Attach front brake calipers to caliper mounts and tighten bolts securely.
(f) Attach drag link or steer cylinder to steer arm.
NOTE: Center steering wheel and Pitman arm, if applicable, prior to

Note attaching to steer arm. See Pitman arm section.
(g) Attach front tires and wheels. Torque lug nuts to a minimum of 125 ft-lb. Test vehicle
before returning to service.
CD368 2-3-35
Rev 7
Chapter 2
2-3-36 CD368
Rev 7
Chapter 3
CHAPTER 3: OVERHAUL
TABLE OF CONTENTS
SECTION 1: GENERAL ............................................................................................................. 3-1-1
SECTION 2: STEERING ........................................................................................................... 3-2-1
SECTION 3: DRIVE SHAFT UNIVERSAL JOINTS .................................................................. 3-3-1

A. Disassembly ......................................................................................................... 3-3-1
B. Installation ............................................................................................................. 3-3-1
SECTION 4: DRIVE AXLE ......................................................................................................... 3-4-1

A. Reduction Gear Box ............................................................................................. 3-4-1
1. Removal ................................................................................................... 3-4-1
2. Cleaning .................................................................................................... 3-4-2
3. Inspection .................................................................................................. 3-4-2
4. Assembly of the Overhauled Reduction Gear ........................................... 3-4-3
B. Drive Axle .............................................................................................................. 3-4-4
1. Preparation ............................................................................................... 3-4-4
2. Remove Axle Shaft.................................................................................... 3-4-4
3. Disassemble Axle Housing ....................................................................... 3-4-5
4. Remove Pinion and Cage Assembly ........................................................ 3-4-5
5. Disassemble Differential and Gear Assembly .......................................... 3-4-6
6. Pinion and Cage Assembly ....................................................................... 3-4-6
7. Clean ........................................................................................................ 3-4-7
8. Inspect ...................................................................................................... 3-4-7
9. Repair ....................................................................................................... 3-4-8
10. Assembling Pinion and Cage .................................................................... 3-4-8
11. Assembling Differential and Bevel Gear .................................................... 3-4-9
12. Pinion and Cage Assembly ..................................................................... 3-4-10
13. Install Differential Assembly .................................................................... 3-4-10
14. Install Axle Shaft ...................................................................................... 3-4-10
15. Torque Specifications Table .................................................................... 3-4-11
CD368 3-TOC-i
Rev 7
Chapter 3
SECTION 5: FRONT AND REAR WHEEL DISC BRAKES ....................................................... 3-5-1

A. Brake Pad Replacement ...................................................................................... 3-5-1
1. Preparation ............................................................................................... 3-5-1
2. Caliper Removal ....................................................................................... 3-5-1
3. Brake Pad Removal .................................................................................. 3-5-2
5. Brake Pad Installation ............................................................................... 3-5-3
6. Caliper Installation ..................................................................................... 3-5-4
7. Check-Out ................................................................................................ 3-5-5
B. Caliper Overhaul ................................................................................................... 3-5-5
1. General Layout .......................................................................................... 3-5-5
2. Removal ................................................................................................... 3-5-6
3. Disassembly ............................................................................................. 3-5-6
5. Reassembly .............................................................................................. 3-5-7
6. Installation ................................................................................................. 3-5-8
7. Check-Out ................................................................................................ 3-5-8
C. Rotor ..................................................................................................................... 3-5-9
1. Rotor Removal .......................................................................................... 3-5-9
2. Cleaning .................................................................................................. 3-5-10
3. Inspection ................................................................................................ 3-5-10
4. Rear Reassembly ................................................................................... 3-5-10
5. Front Reassembly .................................................................................. 3-5-10
6. Installation ............................................................................................... 3-5-10
7. Check Out ............................................................................................... 3-5-11
D. Bleeding the Disc Brake System ........................................................................ 3-5-11
1. General ................................................................................................... 3-5-11
2. Manual Bleeding ...................................................................................... 3-5-12
3. Pressure Bleeding .................................................................................. 3-5-13
4. Check-Out .............................................................................................. 3-5-13
3-TOC-ii CD368
Rev 7
Chapter 3
SECTION 1: GENERAL
If it is suspected that an overhaul of a system is required, the section or sections that cover the component(s)
should be read thoroughly and understood prior to beginning work. Additionally, many of the subjects
covered in this chapter are initially covered in Chapter 2 (Removal/Installation). Refer to the appropriate
section of chapter 2 for detailed removal and installation instructions associated with the part or system being
overhauled.
If the information you seek is not found in the overhaul section, you may opt to contact sales at (770) 422-
7230 or parts (Tug Shop) at 1-800-989-8499. If necessary, our Technical Publications Department will
assemble the needed information, and get it to you as soon as possible.
Before proceeding with any overhaul, make sure to read the safety section at the beginning of this manual.
Even a seasoned mechanic can benefit, and even avoid injury, by reviewing these time-proven safety
practices.
If the information in this chapter pertaining to your required overhaul does not include illustrations, you may
find some helpful illustrations in chapter 4-2.
CD368 3-1-1
Rev 7
Chapter 3
3-1-2 CD368
Rev 7
Chapter 3
SECTION 2: STEERING
If the tractor has been properly lubricated and maintained and has not experienced damage to the steering
system, the steering components should provide lengthy service without an overhaul. Should an overhaul be
required, follow the procedure below:
A. Raise the front end of the tractor using standard jacking procedures (i.e. chock rear tires, apply park
brake, and place jack stands under front bumper).
B. Inspect the steer cylinder for damage. Also check for wear of the rod ends by grasping the cylinder
and shaking it. If the rod ends are loose, replace the rod ends.
C. Grasp the top and bottom of each tire and shake it to determine any wobble or looseness while
observing the hub and spindle area. If there is any wobble in the hub, but the spindle is rigid, then
the wheel bearings and seals should be adjusted by tightening the hub retainer nut. If excessive noise
is experienced after adjustment, the bearings and seals should be replaced following the procedures
listed below:
1. Remove the front wheels by removing the lug nuts on each wheel.
2. Remove the hub dust cap, cotter pin and spindle nut.
3. Rock the hub assembly to dislocate outer bearing assembly and washer.
4. Grasp the hub and slide it off the spindle.
5. Remove the inner bearing and seal.
6. Remove the inner and outer bearing races and replace with new races.
7. Install new inner bearing and seal into hub, repacking the bearing with lithium-based grease,
and replace hub onto spindle.
8. Repack outer bearing and install onto spindle. Replace washer and thread on spindle nut.
9. While turning the hub assembly, tighten down the spindle nut to 50 ft-lb. to seat the bearings.
Loosen the spindle nut 1/4 turn only. Check hub movement, adjust nut slightly if necessary.
Tighten slightly if necessary to insert new cotter pin.
10. Replace dust cap and wheel torquing lug nuts to 125 ft-lb.
CD368 3-2-1
Rev 7
Chapter 3
11. Repeat procedure as needed to replace pivot hub bearings. (See section 2-3, procedure M for
swing arm removal.)
Note NOTE: Swing arm pivot hubs also contain wheel bearings.
D. Grasp the top and bottom of the wheel and check for king pin bushings wear by shaking the wheel
upward and downward while observing the spindle area. If the spindle area is rigid, but the steering
knuckle has play in it at the king pin, the king pin and bushings should be replaced as follows on each
wheel:
1. Remove the front wheels.
2. Disconnect the tie rod from the steering knuckle.
3. Remove king pin retainer plates and lock bolts top and bottom and pull the king pin up and
out the top or push the king pin down and out the bottom of the steering knuckle.
4. Refer to section 2-3, procedure M: Swing Arm Assembly Removal/Installation. Follow

directions to remove swing arm(s).
NOTE: With appropriate tooling, swing arm bushings can be removed and
Note replaced without swing arm removal process. See step (7).
5. Position swing arm on a machine press. (Or use special tooling with swing arm attached to
tractor.) Note exact positioning of bushings to be removed. Press out old king pin bushings.
6. Press new bushings in place. Do not tap or marr new bushings in any way.
7. Note that axial alignment between bushings must be established. To do so, both bushings
must be reamed along a single axis. A zero tolerance fit is most desirable as a result of this
process and special tooling may be required. If appropriate setups are not available to you,
contact your Tug representative.
8. Using procedures in section 2-3 -M, install reworked swing arm(s).
9. Replace bottom king pin retainer plate.
10. Replace the king pin thrust bearing if worn, and repack the bearing with lithium based grease.
11. Position the steering knuckle onto the swing arm.
12. Install the new king pin and secure it in place using kingpin lock bolts and upper retainer
plate.
3-2-2 CD368
Rev 7
Chapter 3
13. Install the tie rod to the steering knuckle using the castellated nut and the cotter pin.
14. Grease the king pin(s) as during regular service.
15. Install the wheel and check wheel alignment.
E. Grasp the sides of the wheel and shake it from side to side while observing the tie rod ends. If
excessive movement is observed in the rod ends, replace the tie rod ends as follows:
1. Remove the tie rod by removing the cotter pins and castellated nuts at the ends of tie rod.
2. Install a new tie rod assembly to the steering knuckle and secure with castellated nuts and
cotter pins.
3. With the wheels pointing forward adjust the “toe in” by loosening the tie rod and turning the
threaded rod end in or out until the tire centerline-to-centerline distance across the rear of the
tire is 1/8" to inch longer than the centerline-to-centerline distance across the front of the tires.
4. After the toe-in adjustment is complete grease the tie rod ends as in regular maintenance.
CD368 3-2-3
Rev 7
Chapter 3
3-2-4 CD368
Rev 7
Chapter 3
SECTION 3: DRIVE SHAFT UNIVERSAL JOINTS
A. DISASSEMBLY
1. Remove the drive shaft from the tractor.
2. Place one section of the shaft in a vise being careful not to damage it.
3. Remove the snap rings that retain the bearings.
4. Press the bearing out of the flange by using a universal joint removal tool. If the bearing
cannot be pressed all the way out of the flange, remove it with vise grip or channel lock
pliers.
5. Reposition the tool to press on the spider to remove the bearing from the opposite side of the
flange.
6. Remove the flange from the spider.
7. Remove the bearings and spider from the other end of the drive shaft, following the above
procedure.
8. Clean all foreign matter from the flange and yoke of both drive shaft ends. Wash with
cleaning fluid. Use of vapor degreaser is permissible in lieu of kerosene or other solvents.
B. INSTALLATION
1. Start a new bearing into the yoke at the rear of the drive shaft.
2. Position the spider in the rear yoke and press the bearing below the surface.
3. Remove the tool and install a new snap ring.
4. Start a new bearing into the opposite side of the yoke.
5. Install the tool and press on the bearing until the opposite bearing contacts the snap ring.
6. Remove the tool and install a new snap ring.
7. Reposition the drive shaft and install a new spider and two new bearings in the front yoke in
the same manner as the rear yoke.
CD368 3-3-1
Rev 7
Chapter 3
8. Position the flange on the spider and install two new bearings and snap rings.
9. Check the joint for freedom of movement. If a bind has resulted from misalignment during
the foregoing procedure, tap the ears of the drive shaft sharply to relieve the bind. Do not
install the drive shaft unless the universal joints are free of bind.
10. Lubricate the universal joints with long life lithium-based grease.
3-3-2 CD368
Rev 7
Chapter 3
SECTION 4: DRIVE AXLE
If the tractor has been properly lubricated, maintained, and operated and has not experienced damage to the
drive axle, the drive axle will provide many hours of service without an overhaul. If, however, an overhaul is
required, follow the procedure below:
A. REDUCTION GEAR BOX
1. Removal
It is necessary to remove the drive axle from the tractor to conduct disassembly and overhaul
the reduction gear case. Disassembly of the reduction gear case is therefore accomplished as
follows:
(a) Remove drive axle from tractor. (See section 2-3.)
(b) Disconnect the parking brake linkage and remove the brake caliper.
(c) Remove the parking brake rotor from the drive axle input shaft flange.
(d) Drain the gear case by removing the gear case oil drain plug located at the bottom
portion of the reduction gear case.
(e) Remove the input shaft flange from the front side of the reduction gear case by
removing the input shaft retainer nut and washer.
(f) Remove the input shaft rear cap and gasket by removing the attachment bolts.
(g) Remove the large snap ring retaining the input shaft rear bearing in place to the
reduction gear case cover.
(h) Remove the reduction gear case cover by removing the retaining bolts and loosening
the cover from the case by tapping the two case positioning pins from the case side.
(i) Grasp the input shaft from inside the reduction gear case and extract the shaft,
together with its bearings (front and rear), from the case housing.
(j) Remove the reduction gear from the case housing by removing the bevel pinion
bearing nut.
CD368 3-4-1
Rev 7
Chapter 3
(k) Remove the reduction gear case from the drive axle by cutting the lock wire and
removing the gear case retaining nuts and washers.
(l) Remove the input shaft front cap and gasket from the reduction gear case by
removing the attachment bolts.
2. Cleaning
Clean the front and rear bearings on the input shaft with a suitable solvent such as kerosene.
Use of vapor degreaser is permissible in lieu of kerosene or other solvents.
NOTE: Do not clean the bearings with gasoline nor place them in a hot
Note solution tank for cleaning.
3. Inspection
At this point in the disassembly operation, all parts have been disassembled in the reduction
gear case, except for bearings, seals, and the oil filler cap and the oil breather. Inspect all
parts as follows:
(a) Inspect the reduction gear and drive gear for wear or damage. Replace the gears if
they are pitted, galled, worn, or broken.
(b) After cleaning, inspect the bearings and replace the bearings if they are pitted, worn,
or damaged in any way. Remove the bearings as required with a puller.
NOTE: Do not use drifts or hammers in removing bearings, as they may

Note easily mutilate or distort component parts.
(c) Clean and inspect the remaining parts of the reduction gear assembly.
(d) Replace hexagon nuts with rounded corners with new nuts. Replace all lock washers,
oil seals and gaskets with new parts.
NOTE: Use genuine TUG replacement parts for satisfactory service. For
example, making gaskets of foreign material generally leads to
Note mechanical trouble due to variations in the thickness and compressibility
of certain materials.
3-4-2 CD368
Rev 7
Chapter 3
4. Assembly of the Overhauled Reduction Gear
(a) Install new bearings and seals with a suitable press. Lubricate the bearings with
suitable lubricant and coat the seal contacting surfaces with grease.
(b) Apply a non-hardening sealing compound to the input shaft flange cap contact surface
and install the cap to the reduction gear case using the four (4) attachment bolts and
new lock washers.
(c) Install the reduction gear case to the drive axle using the gear case retaining nuts and
washers. Lock-wire the nuts using soft iron wire.
(d) Install the reduction gear and secure the gear with the bevel pinion bearing nut, nut
lock, and bevel pinion bearing locking nut.
(e) Place the input shaft into the gear case housing.
(f) Apply a non-hardening sealing compound to the gear case cover contact surface and
install the cover, aligning the positioning pins of the cover into their retaining holes on
the case. Tap the case cover into the installed position.
(g) Install the gear case cover attachment bolts and torque to specification.
(h) Secure the input shaft in the correct position by installing the rear bearing snap ring.
(i) Install the input shaft rear cap and new gasket using the attachment bolts and new
lock washers.
(j) Install the input shaft flange onto the shaft using the input shaft washer, nut and cotter
pin, torquing the nut to specification.
(k) Assure the gear case oil drain plug is clean and free of any foreign matter and install
the plug into the gear case.
(l) Unless other maintenance is to be performed on the drive axle, fill the reduction gear
case with proper lubricant (SAE 80 W 90).
CD368 3-4-3
Rev 7
Chapter 3
B. DRIVE AXLE
1. Preparation
NOTE: For overhaul of drive axle it should be removed from tractor.

Note (See Chapter 2-3 for drive axle removal instructions.)
(a) Prepare drive axle for disassembly by removing tires, wheels, reduction gear case and
removing the oil plug from the bottom of the axle housing to drain out the oil.
(b) Support axle, on suitable supports on both sides of axle assembly inboard of the
wheels and hubs.
2. Remove Axle Shaft
(a) Disconnect brake lines from caliper and drain fluid into suitable container. Discard
fluid.
(b) Remove brake calipers.
(c) Remove the axle shaft cotter pin, nut and washer from the axle.
(d) Remove the cross-over line, wheel hub and rotor, thereby gaining access to the axle
shaft oil seal retainer.
(e) Remove the oil seal retainer by removing the bolts lock washers holding it in place.
Because of the tight fit of the seal, it may be necessary to use a screwdriver or chisel
with small hammer and lightly tap the back edge of the seal at several points around
its periphery.
(f) Remove the bearing retainer, gasket and shims.
NOTE: At this point the axle shaft may be removed from the housing.
Note The amount of force necessary to remove the axle shaft is dependent
upon condition of the axle; therefore, three alternative methods are
offered.
(g) Wipe the exposed axle shaft free of oil; using both hands, pull the axle shaft, bearings
and cups from the housing. If the shaft cannot be removed in this manner, proceed to
next step.
3-4-4 CD368
Rev 7
Chapter 3
(h) Reinstall axle shaft nut on axle. Using wooden dowel and small hammer, firmly tap
against the back side of the axle nut, driving axle shaft from housing.
CAUTION: DO NOT USE SCREWDRIVER OR OTHER METAL

OBJECTS IN LIEU OF WOODEN DOWEL. METAL OBJECTS WILL
DAMAGE THE AXLE AND NUT. DO NOT USE EXTREME FORCE.
(i) If axle cannot be removed as discussed above, attach axle puller and remove axle in
conventional manner.
(j) Inspect axle bearing cage to assure that all components are removed from cage. The
axle will come out with the axle as will the outer bearing cup and the bearing spacer
collar. The inner bearing cup may be retained in the cage. This should also be
removed using a puller or similar device.
3. Disassemble Axle Housing
(a) Place axle assembly in heavy vise or other heavy holding fixture.
(b) Before disassembling, place length of pipe or suitable support, slightly smaller than
axle shaft splines, approximately two-thirds (2/3) through axle from the case side to
prevent dropping the differential assembly.
(c) Remove bolts, nuts and washers from case and cover and remove cover half.
(d) Remove differential and gear assembly.
(e) Remove pipe.
4. Remove Pinion and Cage Assembly
(a) Remove reduction gear assembly as described above.
(b) Remove the bevel pinion bearing washer; the cork oil retainer; the pinion bearing and
cup; and the bearing shim.
(c) Remove the lock ring from inner end of pinion shaft.
(d) Using puller or similar device, pull pinion and cage from differential case.
CD368 3-4-5
Rev 7
Chapter 3
5. Disassemble Differential and Gear Assembly
(a) Inspect the differential and gear assembly very carefully prior to disassembly as
follows:
(1) Mount the carrier in a holding fixture. Wipe the lubricant from the internal
working parts and visually inspect them for damage.
(2) Rotate the gears to see if there is any roughness which could indicate worn or
damaged bearings or chipped gear. Look carefully at the surface of the gear
teeth for any scoring, flaking, or signs of abnormal wear.
(3) If no obvious maladjustment or damage is noted, inspect the gear contact.
(b) If original identification marks are not clear, mark differential case halves with a
punch or chisel before disassembling, for correct alignment when reassembling.
(c) Cut lock wire, remove cap screws and separate case halves.
(d) Remove spider, pinions, side gears and thrust washers.
NOTE: Gear should not be separated from flange unless it is to be

Note replaced.
(e) Remove bolts and separate gear and case if required.
(f) Remove differential bearings with bearing puller, if necessary to replace.
6. Pinion and Cage Assembly
(a) Tap pinion out of cage with soft mallet or press shaft from cage.
(b) Remove bearings from shaft with suitable puller, if necessary.
3-4-6 CD368
Rev 7
Chapter 3
7. Clean
(a) Cleaning Solutions
CAUTION: DO NOT CLEAN THESE PARTS IN A HOT SOLUTION

TANK OR WITH WATER AND ALKALINE SOLUTIONS, SUCH AS
SODIUM HYDROXIDE, ORTHOSILICATES OR PHOSPHATES. DO
NOT STEAM CLEAN ASSEMBLED DRIVE UNITS AFTER THEY
HAVE BEEN REMOVED FROM THE HOUSING.
Parts having ground and polished surfaces such as gears, bearings, shafts and collars,
should be cleaned in a suitable solvent such as kerosene or diesel fuel oil. Use of
vapor degreaser is permissible in lieu of kerosene or other solvent.
(b) Drying: Dry parts thoroughly immediately after cleaning. Use soft, clean, lintless
absorbent paper towels or wiping rags. Bearings should never be dried by spinning
with compressed air.
8. Inspect
It is impossible to overstress the importance of careful and thorough inspection of drive unit
parts prior to reassembly. Through visual inspection for indications of wear or stress, and the
replacement of such parts as are necessary will eliminate costly and avoidable drive unit
failure. As a general rule, if there is any doubt about the condition of a part, it should be
replaced.
(a) Inspect all bearings, cups and cones, including those not removed from parts of the
drive unit and replace if rollers or cups are pitted or damaged in any way. Remove
parts needing replacement with a suitable puller or in a press with sleeves.
CAUTION: AVOID THE USE OF DRIFTS AND HAMMERS. THEY

MAY EASILY MUTILATE OR DISTORT COMPONENT PARTS.
(b) Inspect first reduction bevel or hypoid and second reduction spur gears for wear or
damage. Gears that are pitted, galled or worn or broken through case hardening
should be replaced.
CD368 3-4-7
Rev 7
Chapter 3
(c) Inspect the differential assembly for the following:
(1) Pitted, scored or worn thrust surfaces of differential case halves, thrust
washers, spider trunnions and differential gears. Thrust washers must be
replaced in sets. The use of a combination of old and new washers will result
in premature failure.
(2) Wear or damage to the differential pinion and side gear teeth. Replace the
differential pinions and side gears in sets.
(d) Inspect spur pinions for wear or damage to teeth.
(e) Check end of pinion for indications of brinelling caused by worn splines. Replace the
parts if the splines of the pinion and/or thru-shaft are worn, permitting movement of
the pinion on the thru-shaft.
(f) Inspect axle shafts for indications of torsional fractures and runout. Axle shafts
should be inspected between centers to ascertain the amount of runout of the ground
surfaces. Runout at the shaft flange and splines should not exceed .005 inch total
indicator reading.
9. Repair
(a) Replace all worn or damaged parts. Hex nuts with rounded corners, all lock washers,
oil seals and gaskets should be replaced at the time of overhaul.
(b) Remove nicks, mars and burrs from machined or ground surfaces. Surfaces must be
clean and free to obtain accurate adjustment and correct torque. A fine mill file or
India stone is suitable for this purpose. Studs must be tight prior to reassembling the
parts.
10. Assembling Pinion and Cage
(a) Press rear thrust bearing onto pinion.
(b) Install lock ring in slot on pinion behind bearing.
(c) Install inner conical bearing and cup on pinion.
(d) Slide spacer on pinion then slide on outer bearing.
3-4-8 CD368
Rev 7
Chapter 3
(e) Assemble the pinion shaft and cage.
CAUTION: FOLLOW TABLE 4-1 FOR TORQUING ALL AXLE

ASSEMBLY FASTENERS.
11. Assembling Differential and Bevel Gear
(a) Rivet bevel gear to case half with new rivets.
(1) If a new gear of differential case is to be used in the assembly, the rivet holes
in the gear and case should be checked for alignment and line reamed, if
necessary. The gear must be tight on the case pilot and riveted flush with the
differential case flange. Check with a .002" feeler gauge.
(2) Rivets should not be heated, but should be upset cold. When the correct rivet
and rivet set is used, the head being formed will be at least 1/8 inch larger in
diameter than the rivet hole.
(3) The head will then be approximately the same height as the pre-formed head.
The formed head should not exceed 1/16 inch less than the pre-formed head
as excessive pressure will cause distortion of the case holes and result in gear
eccentricity.
(b) Lubricate differential case inner walls and all component parts with axle lubricant.
(c) Position thrust washer and side gear in bevel gear and case half assembly.
(d) Place spider with pinions and thrust washers in position.
(e) Install component side gear and thrust washer.
(f) Align mating marks, position component case half and draw assembly together with
four (4) bolts or cap screws equally spaced.
(g) Check assembly for free rotation of differential gears and correct, if necessary.
(h) Install remaining bolts or cap screws, tighten to specified torque and thread with lock
wire.
(i) If bearings are to be replaced, press squarely and firmly on differential ease halves.
CD368 3-4-9
Rev 7
Chapter 3
12. Pinion and Cage Assembly
(a) Coat cage flange contact surface with non-hardening sealing compound.
(b) Position age assembly over studs and tap into position with soft mallet.
13. Install Differential Assembly
(a) Position differential and gear assembly in carrier half.
(b) Coat carrier flange halves with non-hardening compound.
(c) Place new differential carrier gasket over flange half and assemble halves using
differential carrier bolts, lock washers and nuts. Torque per Table I.
(d) Install reduction gear case as described in paragraph (a) above.
14. Install Axle Shaft
(a) Assemble bearings, cups, and bearing spacer collar using press.
(b) Clean and lubricate hub cavity and carefully fit axle shaft into housing.
(c) Install shims (total thickness .043-.045), gaskets, bearing retainer and oil seal retainer.
(d) Install the wheel hub rotor, brake caliper half and cross-over line.
(e) Connect brake lines to calipers.
(f) Install the axle shaft washer and nut, torquing nut to 400-500 ft-lb.
(g) Clean magnetic drain plug then install plug in axle housing.
(h) Fill carrier with 5 pints of oil (SAE #90 for winter; SAE #140 for summer).
(i) Install tires and wheels.
(j) Install axle in vehicle.
(k) Raise rear of vehicle and operate vehicle at moderate speed for 5 minutes to disperse
lubrication.
(l) Check lubrication.
3-4-10 CD368
Rev 7
Chapter 3
15. Torque Specifications Table
Torques given apply to parts coated with machine oil. If dry (or “as received”), increase
torques 10%; for parts coated with multi-purpose gear oil, decrease torques 10%. Nuts on
studs use same torque as for driving stud.
Table 4-1. Torque Specifications
No. Torque (ft-lb.)

Location Diameter
Threads
Min. Max.
Cover to Case 3/8" 16 27 35

Bolt Nuts
3/8" 24 31 39
7/16" 20 42 54
1/2" 20 75 96
Pinion Cage 3/8" 16 27 35

Cap Screws
and Stud Nuts 3/8" 24 31 39
7/16" 20 42 54
9/16" 12 94 120
Differential 3/8" 16 33 43
Case Bolt Nuts
and Cap 1/2" 13 81 104
Screws
1/2" 20 92 118
Pinion Shaft 7/8" 20 175 200

Nuts
1" 20 300 400
Gear to Case
3/8" 24 38 49
Cap Screws
CD368 3-4-11
Rev 7
Chapter 3
3-4-12 CD368
Rev 7
Chapter 3
SECTION 5: FRONT AND REAR WHEEL DISC BRAKES
A. BRAKE PAD REPLACEMENT
Inspect the brake linings any time that the wheels are removed. Check both ends of the outboard pad
by looking in at each end of the caliper. These are the points at which the highest rate of wear
normally occurs. However, at the same time, check the lining thickness of the inboard pad to make
sure that it has not worn prematurely. Look down through the inspection hole in the caliper to view
the inboard pad. Whenever the thickness of any lining is worn to the approximate thickness of the
metal backing, all pads on the axle should be replaced.
1. Preparation
For front service, chock rear wheels and raise front of tractor. For rear service, chock front
tires and raise rear. Use standard jacking procedures and support the unit with jack stands.
2. Caliper Removal
(a) Remove 2/3 of brake fluid from master cylinder reservoir.
(b) Push the piston back into its bore. This can be accomplished by using a C-clamp.
(d) Using 3/8" allen wrench, loosen

and remove (2) mounting
(retainer) bolts (see Figure 5-1).
Lift the caliper off the rotor and
position on drive axle so that the
brake hose will not support the
weight of the caliper.
NOTE: If only brake pads MOUNTING

Note and linings are being BOLTS
replaced, omit step (e).
(e) Disconnect brake line from

caliper and plug openings in
caliper and line to prevent fluid
loss and to keep out
contamination. (See Figure 5-2.)
Figure 5-1. Brake Pad Mounting Bolts
CD368 3-5-1
Rev 7
Chapter 3
(f) Inspect mounting bolts for corrosion. If corrosion is found, use new bolts when
installing caliper.
3. Brake Pad Removal
(a) Remove the inboard pad and spring

from piston. Dislodge the outboard
pad and remove from caliper.
(b) Remove sleeves from mounting bolt

holes and discard. Remove the four
rubber bushings from the grooves in
each of the caliper ears and discard.
(See Figure 5-3)
Figure 5-2. Brake Line Disconnection
BRAKE HOSE
BRAKE HOSE
BOLT
BLEED VALVE
CALIPER
HOUSING
PAD RETAINER
HOUSING
RETAINER BOLT
SLEEVE
O-RING
WASHER BRAKE
HOSE
OUTBOARD PAD
AND LINING
INBOARD PAD
AND LINING
Figure 5-3. Brake Pad Assembly
3-5-2 CD368
Rev 7
Chapter 3
4. Cleaning and Inspection
(a) Examine the piston area for fluid leaks by looking for excessive moisture around boot
area. Check dust boot for cracks, cuts or other damage that would affect its ability to
seal piston bore. If leaks are present or boot shows damage, the caliper should be
overhauled. See specific section.
(b) If no defects are found, wipe clean the inside of the caliper including the four ears
where bushings are to be installed. Wipe the outside surface of the dust boot so that
when piston is pressed to bottom of bore, boot will fold back without coming out of
groove.
5. Brake Pad Installation
(a) Using Delco Silicone Lube No. 179-651, lubricate new sleeves, new rubber bushings,
and bushing grooves. Install rubber bushings in all four caliper ears.
NOTE: It is essential that the new sleeves and rubber bushings which are
Note included in each Delco pad kit be used, and that lubrication instructions be
followed to ensure proper functioning of the sliding caliper design.
(b) Use Delco Tool, J-22835, to install the sleeve. Position the sleeves to that the end
toward the pad is flush with the machined surface of the ear.
(c) Attach pad retainer clip to inboard pad lining so that spring vee is on inner arc of pad.
(d) Install inboard pad and lining as shown. (See Figure 5-4.) Position outer arc of pad
against inner arc of caliper. Depress spring vee to collapse it and enable it to slip
inside of piston cup. Snap pad into place.
RETAINER
CLIP
Figure 5-4. Brake Pad Installation
CD368 3-5-3
Rev 7
Chapter 3
(e) Clip outer pad into place opposite inner pad. Make sure that the tab at the bottom of
the pad is engaged in the caliper cut-out.
6. Caliper Installation
(a) Position caliper over rotor and line up holes in caliper ears with holes in the mounting
bracket. Make sure the brake hose is not twisted or kinked.
(b) Lubricate both ends of the mounting bolts with Delco Silicone Lube No. 179-651.
Start the bolts through the sleeves in the inboard caliper ears and mounting bracket,
making sure that the ends of the bolts pass under the retaining ears of the inboard pad.
Push the bolts through to engage the bushings in the outboard caliper ears, while
threading the bolts into the mounting bracket. Tighten bolts. (See Figure 5-5.)
MOUNTING
BOLTS
ROTOR
Figure 5-5. Brake Caliper Installation
(c) Torque bolts to 40.7-61.0 N-m (30-45 ft-lb)
(d) Remove temporary plugs from brake pipe and fittings, connect brake pipe to caliper.
Torque to 20 N-m (15 ft-lb).
(e) If brass bolt and block were removed with brake pipe, unplug fittings and install bolt
and block using (2) new copper washers. Torque to 40 N-m (30 ft-lb).
(f) Fill master cylinder and bleed hydraulic system.
(g) After installing caliper, set caliper by applying heavy force to brake pedal.
3-5-4 CD368
Rev 7
Chapter 3
7. Check-Out
(a) Check brake pedal for sponginess or hard pedal.
(b) Drive tractor slowly and make several slow speed stops.
(c) Check all brake fluid line fittings and caliper areas for fluid leakage.
(d) Correct any discrepancies before returning tractor to service.
B. CALIPER OVERHAUL
1. General Layout
BRAKE HOSE
BRAKE HOSE
BOLT
BLEED VALVE
CALIPER
HOUSING
HOUSING
PISTON
RETAINER BOLT
SLEEVE
PAD RETAINER
O-RING
PISTON SEAL WASHER BRAKE

HOSE
CALIPER BOOT
OUTBOARD PAD
AND LINING
INBOARD PAD
AND LINING
Figure 5-6. Brake Caliper Assembly
CD368 3-5-5
Rev 7
Chapter 3
2. Removal
See pad replacement section. Removal of the caliper for overhaul is the same as for pad
replacement except that it will be necessary to disconnect the brake hose.
3. Disassembly
(a) Move the caliper to a work bench for overhaul.
(b) Drain fluid from caliper.
(c) Remove pad and spring clip from end of piston.
(d) Before beginning caliper disassembly, thoroughly clean exterior using denatured
alcohol.
(e) Support caliper in a vise and pad caliper interior with shop cloths. Use a piece of 1x 6
soft pine to prevent piston from coming out completely (see Figure 5-7).
(f) Use just enough compressed air in caliper brake line port to force piston out.
Excessive air may cause piston to be blown out of bore and become damaged.
WARNING: USE OF COMPRESSED AIR WITHOUT WOOD BLOCK

MAY RESULT IN DAMAGE TO THE PISTON AND/OR PERSONAL
INJURY.
COMPRESSED
AIR
Figure 5-7. Brake Piston Removal
3-5-6 CD368
Rev 7
Chapter 3
(g) Remove wood block. Gently work piston the rest of the way out of bore.
(h) Use a screwdriver to pry boot out of caliper as shown. Use care to avoid scratching
the caliper bore (see Figure 5-8).
(i) Remove piston seal from caliper bore. Use a piece of wood or plastic (a wooden
toothpick is ideal) so as not to damage caliper bore.
(j) Remove bleed valve.
SCREWDRIVER
Figure 5-8. Brake Piston Boot Removal
4. Cleaning and Inspection
(a) Thoroughly clean all parts not in repair kit with denatured alcohol. Inspect caliper
bore for scoring, nicks, corrosion or wear. Use crocus cloth to polish out any light
corrosion. Replace caliper housing if bore will not clean up using crocus cloth.
(b) Carefully examine the piston exterior for scoring, nicks, corrosion and worn or
damaged surfaces. If any surface defects are detected, replace the piston.
CAUTION: THE PISTON OUTER SURFACE IS THE PRIMARY

SEALING SURFACE IN THE CALIPER ASSEMBLY. IT IS
MANUFACTURED AND PLATED TO CLOSE TOLERANCE.
REFINISHING BY ANY MEANS, OR THE USE OF ANY ABRASIVE IN
THE FIELD IS NOT ACCEPTABLE.
5. Reassembly
(a) Lubricate piston assembly with clean brake fluid.
(b) Position the seal in the caliper bore groove.
CD368 3-5-7
Rev 7
Chapter 3
(c) Assemble a new boot into the piston groove so that the fold faces the open end of the
piston.
(d) Press piston assembly into caliper bore using C-clamp (See Figure 5-9). Be careful
not to unseat the seal.
(e) Position outside diameter of boot in caliper counterbore and seat with Delco tool no.
J-22904.
Figure 5-9. Brake Piston Reassembly
6. Installation
Install caliper following instructions given in pad and lining replacement section. Bleed
system.
7. Check-Out
(d) Correct any discrepancies before returning tractor to service.
3-5-8 CD368
Rev 7
Chapter 3
C. ROTOR
1. Rotor Removal
(a) Rear Rotor Only Removal
(1) Chock the front tires. Raise the rear wheels off the ground using standard
jacking procedures. Support the unit with jack stands.
(2) Inspect the lug nuts which secure the wheel to the drive axle hub and remove
the wheel.
(3) Remove the lugnuts which secure the wheel to the drive axle hub and remove
the wheel.
(4) Reinstall the lugnuts so as to hold the hub against the rotor.
(5) Remove the cotter pin from the hub nut and remove the nut and washer.
(6) Remove caliper assemblies. See specific section.
(7) Slide the wheel hub and rotor off the axle.
(8) Remove the lugnuts thereby separating rotor from hub.
(9) Skip over to procedure 2, Cleaning.
(b) Front Rotor Only Removal
(1) Chock the rear tires. Raise the front wheels off the ground using standard
jacking procedures. Support the unit with jack stands.
(2) Inspect the lug nuts which secure the wheel to the drive axle hub and remove.
(3) Remove the cotter pin from the hub nut and remove the nut and washer.
(4) Remove caliper assemblies. See specific section.
(5) Slide the wheel hub and rotor off the axle.
(6) Press rotor from hub.
CD368 3-5-9
Rev 7
Chapter 3
2. Cleaning
WARNING: NO SMOKING, FIRE OR OPEN FLAME IS PERMITTED IN

AREAS WHERE ALCOHOL IS BEING USED. AVOID INHALATION OF
FUMES.
(a) Clean rotor with alcohol.
(b) Use lint-free cloth to dry.
3. Inspection
(a) Inspect weldments for evidence of corrosion or cracking. Replace if cracked or

severely corroded.
(b) Inspect rubbing surfaces for evidence of corrosion, pitted or scratches. Replace if
scratched, corroded or pitted.
(c) Check the thickness and out of plane limits of the rotor. The minimum limit should be
.885 inches.
4. Rear Reassembly
Using lug nuts, fasten hub and rotor together.
5. Front Reassembly
Press hub onto lugs.
6. Installation
(a) Slide the wheel hub and rotor onto the axle.
(b) Replace caliper assemblies. See specific section.
(c) Replace axle nut and washer and replace cotter pin. Seal with silicone sealer.
(d) Replace wheel and secure with lug nuts. Torque lug nuts to 125 ft-lb.
(e) Lower rear wheels to the ground and un-chock front wheels.
3-5-10 CD368
Rev 7
Chapter 3
7. Check Out
(d) Correct any discrepancies before returning tractor to normal service.
D. BLEEDING THE DISC BRAKE SYSTEM
1. General
(a) If the caliper was removed for overhaul, or if the brake hose or steel line was
disconnected for any other reason, it will be necessary to bleed all air from the
calipers and connecting lines.
(b) Prior to bleeding the system, it is important to check the master cylinder reservoir.
Use hydraulic fluid, DOT 3, Extra Heavy Duty Brake Fluid to bring the level up to
within one-eighth (1/8) inch of the top.
(c) Brakes can be bled either manually or with pressure bleeding equipment.
CAUTION: FLUID WHICH IS DRAINED, FLUSHED OR BLED OUT OF

A TRACTOR’S BRAKE SYSTEM SHOULD BE DISCARDED. IT IS NOT
SAFE FOR REUSE FOR ANY PURPOSE.
CD368 3-5-11
Rev 7
Chapter 3
2. Manual Bleeding
(a) Manual bleeding requires two people; one to pump the brake pedal and another to
operate the bleeder valves. Make sure that the master cylinder is full. After the
bleeder valve is opened, depress the brake pedal one full stroke, close bleeder valve,
then allow the pedal to return slowly to the released position. Allowing the pedal to
return too quickly may draw air into the system. Continue operating the pedal in this
manner until caliper is bled. Refill the master cylinder and go on to next caliper.
CAUTION: IN ORDER TO ENSURE THAT NO AIR CAN BE SUCKED

BACK INTO THE SYSTEM, THE BLEEDER VALVE MUST BE CLOSED
A THE END OF EACH STROKE, BEFORE THE BRAKE PEDAL IS
RELEASED.
(b) Since it is desirable to bleed the longest line first, the normal sequence for manual
bleeding at the wheels is: Rear wheels first, then front. (See Figure 5-10.)
(c) Check the fluid level in the reservoir frequently during the bleeding procedure.
6 5
4 3
2 1
Figure 5-10. Brake Line Bleeding Order
3-5-12 CD368
Rev 7
Chapter 3
3. Pressure Bleeding
(a) If the equipment is available, the pressure bleeding is faster, since the master cylinder
does not have to be refilled several times. Pressure bleeding equipment must be of the
diaphragm type. That is, it must have a rubber diaphragm between the air supply and
the brake fluid to prevent air, moisture, oil and other contaminants from entering the
hydraulic system. Install the special bleeding adapter to the master cylinder. Make
sure that the pressure tank is at least 1/3 full of fluid. Position the tank so that its hose
will easily reach the adapter on master cylinder of the vehicle being serviced, then
make the air pressure connection to the tank (20 to 25 psi). Open the tank valve to
bleed all air out of the hose before connecting it to the adapter. After making this
connection, open the valve when ready to begin bleeding.
CAUTION: DO NOT LIFT, MOVE OR SHAKE THE TANK AFTER AIR

PRESSURE IS APPLIED. THIS MAY CAUSE AIR TO BECOME
TRAPPED IN THE FLUID.
(b) Bleed all rear calipers, then front calipers.
NOTE: Pressure bleeding process may be completed more quickly by lightly

Note tapping the brake pedal when the bleeder valve is opened. This creates
pulsations that tend to purge air from the system.
4. Check-Out
(d) Correct any discrepancies before returning tractor to normal service.
CD368 3-5-13
Rev 7
Chapter 3
3-5-14 CD368
Rev 7
Chapter 4
CHAPTER 4: ILLUSTRATED PARTS LIST

TABLE OF CONTENTS

Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. Figure and Index Number .......................................................................... 4-1-2
2. Part Numbers ........................................................................................... 4-1-2
3. Description and Quantity .......................................................................... 4-1-2
4. Effectivity................................................................................................... 4-1-2
C. Ordering Spare Parts ............................................................................................ 4-1-2
SECTION 2: ILLUSTRATED PARTS LIST ............................................................................... 4-2-1

Figure 2-1. Frame Weldment Assembly .............................................................. 4-2-2
Figure 2-2. Frame Assembly - Front .................................................................... 4-2-4
Figure 2-3. Frame Assembly - Rear .................................................................... 4-2-6
Figure 2-4. Frame Crossmembers Installation .................................................... 4-2-8
Figure 2-5. Firewall Assembly ............................................................................ 4-2-10
Figure 2-6. Seat Plate Installation ...................................................................... 4-2-12
Figure 2-7. Body Assembly ................................................................................ 4-2-14
Figure 2-8. Hood and Side Panels Installation (Rev 10)..................................... 4-2-16
Figure 2-9. Cab Weldment ................................................................................ 4-2-18
Figure 2-10. Cab Assembly ............................................................................... 4-2-20
Figure 2-11. Windshield Wiper Assembly .......................................................... 4-2-22
Figure 2-12. Doors Assembly ............................................................................ 4-2-24
Figure 2-13. Door Latch Assembly .................................................................... 4-2-26
Figure 2-14. Seat Installation (Rev 1A) .............................................................. 4-2-28
Figure 2-15. Seat Installation (Rev 10) ............................................................... 4-2-30
Figure 2-16. Light Assemblies ........................................................................... 4-2-32
Figure 2-17. Wheel and Tire Assemby - Front ................................................... 4-2-34
Figure 2-18. Wheel and Tire Assemby - Rear.................................................... 4-2-36
Figure 2-19. Wheels and Tires .......................................................................... 4-2-38
Figure 2-20. Hitch .............................................................................................. 4-2-40
Figure 2-21. Dash Console Assembly (Orig) ..................................................... 4-2-42
Figure 2-22. Dash Console Assembly (Rev 10) ................................................ 4-2-44
Figure 2-23. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 3) ... 4-2-46
Figure 2-24. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 10) . 4-2-48
CD368 4-TOC-i
Rev 10
Chapter 4
Figure 2-25. Instrument Panel with Override Switch - Deutz ............................. 4-2-50
Figure 2-26. Instrument Panel - Deutz (Rev 3) .................................................. 4-2-52
Figure 2-27. Instrument Panel - Deutz (Rev 10) ................................................ 4-2-54
Figure 2-28. Transmission Cover Decals .......................................................... 4-2-56
Figure 2-29. Circuit Breakers Installation ........................................................... 4-2-58
Figure 2-29a. Circuit Breakers Installation with Cab Option .............................. 4-2-60
Figure 2-30. Relays Installation - Deutz ............................................................. 4-2-62
Figure 2-31. Accelerator and Modulator Cables Installation - Deutz .................. 4-2-64
Figure 2-32. Accelerator and Modulator Cables Installation - Deutz (Rev 10) .... 4-2-66
Figure 2-33. Accelerator Cable Mounting ........................................................... 4-2-68
Figure 2-34. Shifter Assembly ............................................................................ 4-2-70
Figure 2-35. Shifter and Shifter Cable Installation (Rev 3) ................................. 4-2-72
Figure 2-36. Shifter and Shifter Cable Installation (Rev 10) ............................... 4-2-74
Figure 2-37. Shifter Linkage (Rev 3) .................................................................. 4-2-76
Figure 2-38. Shifter Linkage (Rev 10) ................................................................ 4-2-78
Figure 2-39. Hydro-Boost Installation (Rev 7) .................................................... 4-2-80
Figure 2-40. Hydro-Boost Installation (Rev 10) .................................................. 4-2-82
Figure 2-41. Brake Line Assy (Option without Front Brakes) (Up to S/N 2685) . 4-2-84
Figure 2-41a. Brake Line Assy (Option without Front Brakes) (S/N 2685 & Up) 4-2-86
Figure 2-41b. Brake Line Assembly (Option without Front Brakes) (Rev 10) .... 4-2-88
Figure 2-42. Brake Line Assembly - Rear (Rev 3) (Up to S/N 2667) .................. 4-2-90
Figure 2-42a. Brake Line Assembly - Rear (Rev 7) (S/N 2667 & Up) ................ 4-2-92
Figure 2-43. Park Brake Handle Assembly ........................................................ 4-2-94
Figure 2-44. Park Brake Linkage ....................................................................... 4-2-96
Figure 2-45. Park Brake Installation (Rev 2) ...................................................... 4-2-98
Figure 2-46. Park Brake Installation (Rev 3) .................................................... 4-2-100
Figure 2-47. Park Brake Installation (Rev 10) .................................................. 4-2-102
Figure 2-48. Steering Column Assembly ......................................................... 4-2-104
Figure 2-49. Steer Valve Assembly (CharLynn) ................................................ 4-2-106
Figure 2-50. Hydraulic System (CharLynn) - Deutz (Orig) ............................... 4-2-108
Figure 2-51. Hydraulic System (CharLynn) - Deutz (Rev 2) ............................ 4-2-110
Figure 2-52. Hydraulic System - Deutz (Rev 8) ............................................... 4-2-112
Figure 2-53. Hydraulic Power Take-Off - Deutz ............................................... 4-2-114
Figure 2-56. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 9) ............. 4-2-120
Figure 2-57. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 10) ........... 4-2-122
Figure 2-58. Tie Rod Assembly - Front (Steer) Axle ......................................... 4-2-124
Figure 2-59. Rear Suspension (Rev 2) ............................................................ 4-2-126
4-TOC-ii CD368
Rev 10
Chapter 4
Figure 2-60. Rear Suspension (Rev 3) (Up to S/N 2094) ................................ 4-2-128
Figure 2-61. Rear Suspension (Rev 4) (S/N 2094 thru 2666) .......................... 4-2-130
Figure 2-61a. Rear Suspension (Rev 7) (S/N 2667 & Up) ............................... 4-2-132
Figure 2-62. Rear (Drive) Axle Installation ........................................................ 4-2-134
Figure 2-63. Rear (Drive) Axle Assembly (Orig)............................................... 4-2-136
Figure 2-64. Rear (Drive) Axle Assembly (Rev 3) ............................................ 4-2-140
Figure 2-65. Rear (Drive) Axle Assembly (Rev 10) .......................................... 4-2-142
Figure 2-65. Rear (Drive) Axle Assembly (Rev 10) - Con't. .............................. 4-2-144
Figure 2-66. Reduction Gear Box Assembly .................................................... 4-2-146
Figure 2-67. Drive Shaft ................................................................................... 4-2-148
Figure 2-68. Panhard Arm Assembly ............................................................... 4-2-150
Figure 2-69. Panhard Rod Installation (Up to S/N 2094) .................................. 4-2-152
Figure 2-70. Panhard Rod Installation (S/N 2094 & Up)................................... 4-2-154
Figure 2-71. Rear Brake Caliper Assembly (Up to S/N 2667) .......................... 4-2-156
Figure 2-71a. Rear Brake Caliper Assembly (S/N 2667 thru 3140) ................. 4-2-158
Figure 2-71b. Rear Brake Caliper Assembly (S/N 3140 & Up) ........................ 4-2-160
Figure 2-72. Engine - Deutz Diesel ................................................................. 4-2-162
Figure 2-73. Engine and Engine Mounts - Deutz Diesel (Orig) ........................ 4-2-164
Figure 2-74. Engine Motor Mounts Installation - Deutz Diesel (Rev 3) ............. 4-2-166
Figure 2-75. Engine Motor Mounts Install. - Deutz F4M2011 (Tier II) Diesel ..... 4-2-168
Figure 2-76. Engine Assy - Deutz F4M2011 (Tier II) & D2011 (Tier IVi) Diesel . 4-2-170
Figure 2-77. Engine/Transm Install. - Deutz w/ Ford C6 Trans (Orig) ............ 4-2-172
Figure 2-77. Engine/Transm Install - Deutz w/ Ford C6 Trans (Orig) - Con't .. 4-2-174
Figure 2-78. Engine/Transm Install - Deutz w/ Ford C6 Trans (Rev 10) ......... 4-2-176
Figure 2-79. Alternator Installation - Deutz Tier I (Orig) .................................... 4-2-178
Figure 2-80. Alternator Installation - Deutz Tier I (Rev 3) .................................. 4-2-180
Figure 2-81. Alternator Installation - Deutz F4M2011 (Tier II) (Rev 7) ............... 4-2-182
Figure 2-82. Alternator Installation - Deutz (Tier II & Tier IVi) (Rev 10) ............. 4-2-184
Figure 2-83. Air Intake System - Deutz (Rev 3) ............................................... 4-2-186
Figure 2-84. Fuel Tank Installation (Rev 2) ....................................................... 4-2-188
Figure 2-85. Fuel Tank Installation (Rev 10) ..................................................... 4-2-190
Figure 2-86. Fuel System - Deutz (Orig) ......................................................... 4-2-192
Figure 2-87. Fuel System w/ Racor Filter Option - Deutz ................................ 4-2-194
Figure 2-88. Fuel System w/ Racor Filter Option - Deutz F4M2011 (Tier II) .... 4-2-196
Figure 2-89. Fuel System w/ Racor Filter Opt - Deutz (Tier II & IVi) (Rev 10) .. 4-2-198
Figure 2-92. Exhaust System - Deutz (Tier II & IVi) (Rev 10) ........................... 4-2-204
CD368 4-TOC-iii
Rev 10
Chapter 4

Figure 2-95. Engine Cooling System - Deutz (Rev 10) ................................... 4-2-210
Figure 2-96. Battery Installation (Rev 1A) ........................................................ 4-2-212
Figure 2-97. Battery Installation (Rev 3) ........................................................... 4-2-214
Figure 2-98. Horn Installation ........................................................................... 4-2-216
SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-1
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
4-TOC-iv CD368
Rev 10
Chapter 4
SECTION 1: DESCRIPTION
A. INTRODUCTION
The Illustrated Parts List (IPL) contained in this manual furnishes spare parts and replacement parts
information as well as general part and assembly information necessary for maintenance of the TUG
Model M1A Low Profile Tow Tractor.
CD368 4-1-1
Rev 10
Chapter 4
B. USING THE ILLUSTRATED PARTS LIST
The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems which
comprise the M1A Low Profile Tow Tractor. Each IPL consists of a figure illustrating a group of
related parts and a corresponding list identifying the parts by part number(s) and description. The
quantity given in the list is for the particular assembly shown in the illustration and is not necessarily
the quantity for the entire unit.
1. Figure and Index Number

The figure and index number refers to the figure on which the part is depicted. The index
number refers to the individual part shown on the illustration. See the following example for
further explanation of the Figure and Index Number.
2. Part Numbers
Parts are identified by part numbers assigned by TUG or, in the case of fasteners and related
materials, by industry standard specification.
3. Description and Quantity

A description and quantity is provided for each part listed in the IPL. The quantity given for
subassemblies and subparts is the number of subassemblies/parts contained in the component
or system depicted by the associated illustration, not necessarily the entire vehicle.
4. Effectivity
The effectivity of each item in the parts list is given in part or in whole in the “Effective”
column of the IPL. Information concerning the effectivity of a particular part may also be
found in the description column, the figure title or in notes located at the bottom of the IPL
page. Effectivity is usually (but not always) associated with the serial number.
C. ORDERING SPARE PARTS
To ensure that proper spares and replacement parts are obtained, it is recommended that all major
components be procured directly from TUG. Use of parts not manufactured or supplied by TUG may
void the warranty on the vehicle. When replacing structural fasteners, use Grade 8 or higher material.
Spare parts can be ordered directly from TUG by telephoning TUG SHOP at
1-800-989-8499 (toll free in U.S. and Canada) or 770-422-8021 (outside U.S. or Canada). Ask for
TUG SHOP when calling. FAX messages can be sent to 770-422-8730 (U.S.).
4-1-2 CD368
Rev 10
Chapter 4
When ordering parts, please be prepared with TUG part numbers (vendor part number and code if no
TUG part number is available), part description, figure and index number and the revision of the IPL
page (located in the footer of each page, directly under each page number).
TUG SHOP business hours are from 8:00 a.m. until 5:00 p.m. Eastern time, Monday through Friday.
Answering machines are ready to receive calls after regular business hours. All calls received after
hours will be returned during the next regular business day.
CD368 4-1-3
Rev 10
Chapter 4
4-1-4 CD368
Rev 10
Chapter 4
SECTION 2: ILLUSTRATED PARTS LIST
CD368 4-2-1
Rev 7
Chapter 4
3
4
2
1
Figure 2-1. Frame Weldment Assembly
4-2-2 CD368
Rev 10
Chapter 4
Table 2-1. Frame Weldment Assembly
Fig & Tug Part

Description Qty Effective
Ind Number
1-1 M1A-FRAME Frame Kit, Weldment 1 101 & Up
1-2 TM1-1-5004 Bracket, Side Panel Mounting 4 "
1-3 ¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x 1½" Long 8 "
1-4 ¼-20 Nut, Top Lock, ¼-20 8 "
1-5 TM1-2-9826 Pipe, Fuel Filler 7.75 LG 1 "
1-6 T6-4014-103 Hitch Assembly, E-, Standard 1 "
T6-4044-200 Hitch Assembly - Opt. 1 As Req'd
1-7 TM1-4-9510 Crossmember, Deutz - Weldment 1 101 & Up
1-8 TM1-4-8083 Crossmember, Front - Weldment 1 "
1-9 MJ-ND-4006 Ring, Lashing 5/8" x 4¼" x 4¼" - Forged with Bracket 4 "
CD368 4-2-3
Rev 10
Chapter 4
5 7
1
4
6
Figure 2-2. Frame Assembly - Front
4-2-4 CD368
Rev 10
Chapter 4
Table 2-2. Frame Assembly - Front
Fig & Tug Part

Ind Number
2-1 TM1-4-3011 Bumper, Front ½" Thick 1 101 & Up
2-2 TM1-2-3066 Closeout, Bumper 2 "
2-3 TM1-2-8062 Bracket, Head Light 2 101 & Up
2-4 TM1-2-3030 Mount, Radiator Angle (Deutz) 1 4600 & Up
2-5 TM1-1-3004 Support, Front Hood (Deutz) 2 "
2-6 TM1-2-8009 Mount, Radiator Bracket (Deutz) 1 "
2-7 TM1-2-8019 Mount, Fluid Cooler M1 (Deutz) 2 101 & Up
2-8 MJ-ND-4006 Ring, Lashing 5/8" x 4¼" x 4¼" - Forged with Bracket 3 1472 & Up
CD368 4-2-5
Rev 10
Chapter 4
3 2
5
1
Figure 2-3. Frame Assembly - Rear
4-2-6 CD368
Rev 10
Chapter 4
Table 2-3. Frame Assembly - Rear
Fig & Tug Part

Ind Number
3-1 TM1-2-3012 Bumper, Rear 1 Up to 2455

TM1-4-9713 Bumper, Rear - Full Length 1 2455 & Up
3-2 TM1-1-3084 Bracket, Seat Isolator 2 101 & Up
3-3 TM1-2-3080 Angle, 48¾" Firewall Support 1 "
3-4 X1036-101 Doubler, Tail Light 2 101 & Up
3-5 MJ-ND-4006 Ring, Lashing 5/8" x 4¼" x 4¼" - Forged with Bracket 1 1472 & Up
CD368 4-2-7
Rev 10
Chapter 4
Figure 2-4. Frame Crossmembers Installation
4-2-8 CD368
Rev 10
Chapter 4
Table 2-4. Frame Crossmembers Installation
Fig & Tug Part

Ind Number
4-1 TM1-4-3000 Frame Weldment - Diesel 1 Up to 1855

TM1-4-3003 Frame Weldment - Deutz 1 1855 to 2870
TM1-4-9629 Frame Weldment, CharLynn - M1A30-14 (Deutz 1011) - Opt 1 101 & Up
TM1-4-9632 Frame Weldment, CharLynn - M1A60-14 (Deutz 1011) - Opt 1 "
M1A-24-30 Frame Weldment, Modified Side 1 Note 1
M1A-FRAME Frame, Kit, Weldment 1 2871 & Up
4-2 TM1-1-5004 Bracket, Side Panel Mounting 4 101 & Up
4-3 T6-4012-107 Mount, Rubber Seat 2 "
4-4 ½ Washer, Lock ½"ID 7 2509 & Up
4-5 ½-13 x ¾ Bolt, Hex Head Ø ½-13 x ¾" Long 2 Note 1
4-6 TM1-4-3504 Cradle, Rear Assembly 1 "
4-7 TM1-1-8158 Bracket, Brake Line 1 "
4-8 TM1-1-3506 Bushing, Rear Cradle 2 As Req'd
4-9 TM1-2-8080 Mount, Rear Transmission 1 "
4-10 1 Nut, Nylock, Coarse Thread 1" ID 1 101 & Up
4-11 1 1/16 x 2½ Washer, Flat 1 1/16" ID, Ø 2½" 3-4 "
4-12 TM1-4-3503 Crossmember, Cradle, M1 Universal - Weldment 1 1007 & Up
4-13 ½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 7 101 & Up
4-14 ½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾" Long 4 "
4-15 7/16 Washer, Flat 7/16" ID 13 "
4-16 TM1-1-5061 Bolt, Universal Cradle, Crossmember 1 1032 & Up
4-17 ½-13 Nut, Top Lock Hex ½-13 7 "
4-18 TM1-4-9510 Crossmember, with Drag Link Steering (Deutz) - Weldment 1 As Req'd
4-19 TM1-4-8083 Crossmember, Front - Weldment 1 101 & Up
4-20 ¼-20 Nut, Top Lock Hex ¼-20 8 "
4-21 ¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x ½" Long 8 "
Note 1: Effective on units equipped with the Deutz engine option S/N 2387-2394 and S/N 2408-2870.
CD368 4-2-9
Rev 10
Chapter 4
14
15 29
26 13
14
16 28
19 27
17 9 25
20 24
21
14 15
14 10
12
36 15
22 23 11
8 13
13 9
10 20 31
9
32
10
4 30
34 11
33
1 6
11 18
3
7
3 5 35
Figure 2-5. Firewall Assembly
4-2-10 CD368
Rev 10
Chapter 4
Table 2-5. Firewall Assembly
Fig & Tug Part

Ind Number
5-1 TM1-4-5047 Cover, Transmission Universal 1 151 & Up

5-2 ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long 4 "
5-3 ¼ Washer, Lock ¼" ID 11 "
5-4 TM1-2-9671-2 Plate, Transportation Data - Opt. without Cab 1 As Req'd
5-5 TM1-4-8024 Closeout, Firewall 1 917 & Up
5-6 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 7 101 & Up
5-7 TM1-4-8088 Bracket, Brake Booster Mounting - Tier 1 1 Up to 2407
5-8 TM1-4-8013A Firewall/Floorboard - Weldment 1 151 & Up
TM1-4-8013 Firewall/Floorboard 1 As Req'd
5-9 ½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾" Long 11 101 & Up
5-10 ½ Washer, Flat ½" ID 11 "
5-11 ½-13 Nut, Top Lock Hex ½-13 11 "
5-12 TM1-2-8025 Hinge, Firewall Hood M1 (Female) 2 "
5-13 3/8-16 Nut, Lock 3/8" ID 9 "
5-14 3/8 Washer, Flat 3/8" ID 15 "
5-15 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 9 "
5-16 TM1-2-9672-1 Plate, Lubrication Data (Deutz) 1 As Req'd
5-17* TM1-2-3040 Gusset, Firewall R/H 1 "
5-18* TM1-2-3032 Gusset, Firewall L/H 1 "
5-19* TM1-4-9607 Joint, Floorboard Center 1 "
5-20 TM1-1-8089 Rubber, Seat Plate Hinge 2 562 & Up
5-21 TM1-2-8026 Hinge, Bottom Seat Plate M1 2 101 & Up
5-22* ½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 4 As Req'd
5-23* ½-13 Nut, Top Lock Hex ½-13 4 "
5-24* TM1-2-3044 Reinforcement, Center Joint 1 "
5-25 TM1-4-8036 Guard, Seat Plate 1 101 & Up
5-26 3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 5 "
5-27 3/8 Washer, Lock 3/8" ID 5 "
5-28 TM1-4-1022 Guard, Hip Right Side - M1 1 "
5-29 TM1-2-8011 Reinforcement, Firewall - Tier 1 1 Up to 2407
5-30 660-6-0582-26 Bumper, Rubber - Lift Arm 2 978 to 2780
5-31 5/16-18 x 1½ Bolt, Hex Head Ø 5/16-18 x 1½" Long 4 "
5-32 5/16 Washer, Flat 5/16" 8 "
5-33 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
5-34 TM1-2-9671-1 Plate, Transportation Data - Opt. with Cab 1 As Req'd
5-35 T6-4121-109 Spacer, Accelerator Pedal 4 Up to 2780
5-36 TM1-3-9674 Plate, Hydraulic Data - Opt. 1 As Req'd
* Part of TM1-4-8013A
CD368 4-2-11
Rev 10
Chapter 4
18
7 8
6 12
5 19
4
9 15
3 3
10 16
11
7
1 2
17
7
13 14
7
3
7
Figure 2-6. Seat Plate Installation
4-2-12 CD368
Rev 10
Chapter 4
Table 2-6. Seat Plate Installation
Fig & Tug Part

Ind Number
6-1 TM1-4-8013A Firewall/Floorboard - Weldment 1 151 & Up
TM1-4-8013 Firewall/Floorboard 1 As Req'd
6-2 TM1-4-8012 Plate, Seat 1 101 & Up
6-3 3/8-16 Nut, Top Lock Hex 3/8-16 7 "
6-4 TM1-2-8023 Hinge, Top Seat Plate M1 2 "
6-5 TM1-1-9581 Rubber, Seat Plate Lower Hinge 2 151 & Up
6-6 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 4 101 & Up
6-7 3/8 Washer, Flat 3/8" ID 14 "
6-8 TM1-1-3002 Mount, Shifter 1 Up to 1900
TM1-2-9555 Mount, Transmission Cover Shifter 1 1900 & Up
6-9 3/8-16 x ¾ Bolt, Hex Head Ø 3/8-16 x ¾" Long 2 101 & Up
6-11 ¼-20 Nut, Top Lock Hex ¼-20 2 "
6-13 TM1-1-8068 Angle, Upper Seat Plate Prop 1 1270 & Up
6-14 3/8-16 Nut, Top Lock Hex 3/8-16 1 101 & Up
6-15 TM1-1-8066 Rod, Seat Plate Prop 1 1270 & Up
6-16 TM1-1-8069 Bracket, Lower Seat Plate Prop 1 101 & Up
6-18 CMA-504 Strip, Seal - Door, 12' Long 1 "
6-19 1/8 x ½ Screw, Phillips Round Head 20 "
CD368 4-2-13
Rev 10
Chapter 4
Figure 2-7. Body Assembly
4-2-14 CD368
Rev 10
Chapter 4
Table 2-7. Body Assembly
Fig & Tug Part

Ind Number
7-1 T6-4005-109 Handle, Hood 1 101 & Up
7-2 TM1-4-8013 Firewall/Floorboard 1 "
TM1-4-8013A Firewall/Floorboard - Weldment 1 As Req'd
7-3 TM1-4-8012 Plate, Seat 1 "
7-4 TM1-4-8014 Hood 1 "
7-5 TM1-4-8019 Panel, Passenger Side (Deutz) 1 As Req'd
7-6 TM1-4-8018 Panel, Driver Side 1 101 & Up
7-7 TM1-4-8036 Guard, Seat Plate 1 Non-Cab
7-8 MH-1-327 Bracket, Park Brake Cable 4 101 & Up
7-9 TM1-4-9607 Joint, Floorboard Center 1 "
7-10 TM1-4-5047 Cover, Transmission - Universal 1 "
7-11 TM1-4-8024 Closeout, Firewall 1 "
7-12 TM1-1-8048 Rod, Hood Prop 1 "
7-13 TM1-2-8043 Bracket, Lower Hood Prop 1 Up to 633
TM1-2-8284 Bracket, Lower Hood Prop - Weldment 1 633 & Up
7-14 T6-4005-121 Clip, Hood Rod 1 "
7-15 TM1-2-8027 Hinge, Hood Top (Male) 2 101 & Up
7-16 T6-4006-111R Latch, Hood - Rubber with Hooking Bracket 2 "
7-17 TM1-4-1022 Guard, Hip Right Side - M1 1 "
7-18 TM1-2-8025 Hinge, Firewall Hood (Female) 2 101 & Up
CD368 4-2-15
Rev 10
Chapter 4
Figure 2-8. Hood and Side Panels Installation (Rev 10)
4-2-16 CD368
Rev 10
Chapter 4
Table 2-8. Hood and Side Panels Installation (Rev 10)
Fig & Tug Part

Ind Number
8-1 TM1-4-8019 Panel, Passenger Side 1 101 & Up
8-2 TM1-1-5004 Bracket, Side Panel Mounting 4 151 & Up
8-3 T6-4006-111R Latch, Hood - Rubber with Hooking Bracket 2 101 & Up
8-4 ¼-20 Nut, Top Lock Hex ¼-20 10 101 & Up
8-5 TM1-4-8014 Hood 1 "
TM1-4-5008 Hood, Integrated (Deutz) - Opt. 1 As Req'd
8-6 TM1-2-8027 Hinge, Hood Top - M1 (Male) 2 "
8-7 3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 6 101 & Up
8-8 3/8 Washer, Flat 3/8" ID 14 "
8-9 1/8 x 1¼ Pin, Cotter 2 "
8-10 3/8-16 Nut, Top Lock Hex 3/8-16 7 "
8-11 TM1-4-8018 Panel, Driver Side 1 "
8-13 ¼ Washer, Flat ¼" ID 10 "
8-14 TM1-1-8048 Rod, Hood Prop 1 "
8-15 TM1-4-8039 Bracket, Hydraulic Reservoir Mounting - Weldment 1 "
8-16 660-4-0600-5 Bumper 2 As Req'd
8-17 ¼-20 Nut, Top Lock Hex ¼-20 2 101 & Up
8-18 T6-4005-109 Handle, Hood 1 "
8-19 TM1-1-3004 Support, Front Hood 2 562 & Up
8-20 T6-4005-121 Clip, Hood Rod 1 101 & Up
8- CMA-504 Strip, Seal - Door 1 "
CD368 4-2-17
Rev 10
Chapter 4
1
23
24 3
4
5
22
6
12
21
20 19
7
13
18 11
17
16 10
25 14 8
9
26 15 27
Figure 2-9. Cab Weldment
4-2-18 CD368
Rev 10
Chapter 4
Table 2-9. Cab Weldment
Fig & Tug Part

Ind Number
M1A CABK Cab, Kit Weldment 1 101 & Up
9-1* TM1-4-9000 Top, Cab Roof 1 "
9-2* TM1-ND-5050 Headliner 1 "
9-3 TM1-2-9006 Support, Roof 1 "
9-4 TM1-2-5040 Crossmember, Upper Raised Cab 1 "
9-5 TM1-2-5042 Tube, Top Horizontal Side - M1A Raised Cab 2 "
9-6 TM1-2-9014 Post, Rear Corner L/H 1 "
9-7 TM1-4-5032 Panel, L/H Rear Side - 3" Raised Cab 1 "
9-8 TM1-1-9004 Anchor, Rear Cab 2 "
9-9 TM1-2-9008 Tube, Lower Horizontal 2 "
9-10 TM1-2-9012 Post, Left Side Door Vertical 1 "
9-11 TM1-2-9032 Crossmember, Lower Rear 1 "
9-12 TM1-2-9044 Post, Rear Corner R/H 1 "
9-13 TM1-2-9020 Post, Upper Front Corner, L/H 1 "
9-14 TM1-2-9018 Post, Lower Front Corner, L/H 1 "
9-15 TM1-2-9024 Panel, Lower Front, L/H 1 "
9-16 TM1-2-9040 Crossmember, Lower Front 1 "
9-17 TM1-2-9016 Post, Lower Front Corner, R/H 1 "
9-18 TM1-2-9026 Panel, Lower Front, R/H 1 "
9-19 TM1-2-9038 Crossmember, Upper Front 1 "
9-20 T6-9003-317 Anchor, Door Closure 2 "
9-21 TM1-2-9042 Post, Upper Front Corner, R/H 1 "
9-22 TM1-4-5031 Panel, R/H Rear Side - 3" Raised Cab 1 "
9-23 TM1-2-9673 Spacer, Roof Header - M1A 2 "
9-24 TM1-2-9010 Post, Right Side Door Vertical 1 "
9-25 TM1-2-9034 Bracket, Breakeover Support 1 "
9-26 TM1-1-9046 Stop, Windshield Support 1 "
9-27 CMA-127 Hinge, Receiver 4 "
* Not part of M1A CABK
CD368 4-2-19
Rev 10
Chapter 4
31
29
30
31
28
27
25
26 13
12
11
14
17 10
16
15 18
8 7
32
5
6
9
3
4 1
33
24 2
19b
23
20
19
19a 22
21
Figure 2-10. Cab Assembly
4-2-20 CD368
Rev 10
Chapter 4
Table 2-10. Cab Assembly
Tug Part
Fig & Ind Description Qty Effective
Number
10-1 TM1-4-8067 Windshield, Raised Cab 1 As Req'd

10-3 T6-9003-171 Grommet, Windshield 4 "
10-5 CMA-316 Handle, Breakover - Long Rod 1 "
10-6 TM1-1-6525 Handle, Breakover - M1 & M3 Cab 1 "
10-7 CMA-314 Handle, Breakover - Center Tube 1 "
10-8 TM1-3-5005 Rod, Breakover - M1 & M3 Cab 1 "
10-9 ¼ Nut, Flange ¼" ID 4 "
10-10 T6-9003-209A Switch, Wiper/Dome Light 1 "
10-11 T6-9003-197 Light, Dome 1 "
10-12 TM1-2-9025 Bracket, Dome Light 1 "
10-13 ¼x½ Self Tapping Screw Ø ¼" x ½" Long (CE Opt.) 2 "
10-14 CMA-610 Mirror, West Coast, R/H 2 "
10-15 T6-9003-303 Bolt, Striker (Skin Door Opt.) 2 "
10-16 ½ Washer, Flat ½" ID - Opt. 2 "
10-17 CMH-316 Plate, Striker Bolt Mounting 2 "
10-18 TM1-2-9508 Window, Rear Side 2 "
10-19 TM1-2-9830 Hose,Kit, Black, 5/8", Heater 1 "
10-19a TM1-2-9830-2 Hose,Heater, Black, 30" 1 "
10-19b TM1-2-9830-3 Hose,Heater, Black, 15" 1 "
10-20 ------ Clamp, Hose IDEAL 2 "
10-21 TM1-1-9512 Heater Assembly 1 "
10-24 T6-9003-211 Spacer, Groomet 4 "
10-25 TM1-4-9504 Window, Rear Sliding 1 "
10-26 CMA-504 Strip, Seal - Door 1 "
10-27 CMA-308 Hinge, Window, Male Half 2 "
10-28 M1A CABK Cab, Kit Weldment 1 "
10-29 T6-500-103 Reflector, Red Rectangular 4 "
10-30 TM1-4-9000 Top, Cab Roof 1 "
10-31 T6-500-102 Reflector, Amber Rectangular 4 "
10-32 T6-9003-165 Gasket, Class Window (by the foot) 18.33 "
10-33 CMA-605 Mirror, West Coast, L/H 1 "
CD368 4-2-21
Rev 10
Chapter 4
5
6
7 4
8
9
10 3
12
11
1
2
13
6
7
8
9
Figure 2-11. Windshield Wiper Assembly
4-2-22 CD368
Rev 10
Chapter 4
Table 2-11. Windshield Wiper Assembly
Fig & Tug Part

Ind Number
11-1 T6-9003-125 Blade, Wiper 2 As Req'd

11-2 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
11-3 TM1-1-9514 Motor, Wiper 2 "
11-4 ¼ Nut, Flange ¼" ID 6 "
11-6 T6-9003-171 Grommet, Windshield 12 "
11-7 T6-9003-211 Spacer, Grommet 4 "
11-8 CMA-308 Hinge, Window (Male) Half 2 "
11-9 T6-500-107 Grommet 2 "
11-10 T6-9003-123 Arm, Wiper 2 "
11-11 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 6 "
11-13 TM1-4-8067 Windshield, Raised, M1A CAB 1 "
CD368 4-2-23
Rev 10
Chapter 4
Figure 2-12. Doors Assembly
4-2-24 CD368
Rev 10
Chapter 4
Table 2-12. Doors Assembly
Fig & Tug Part

Ind Number
M1A DOORSK Door, Metal, Cab, M1A Kit 1 As Req'd
12-1 AB6-4A Rivet, Blind 26 "
12-2 TM1-2-9048 Tube, Lower Front Horizontal Door 2 "
12-3 3/16 Washer, Flat 3/16" ID 26 "
12-4 T6-9003-322 Closure, Door 2 "
12-5 ¼x½ Screw, Philips Head Ø ¼" x ½" Long 20 "
12-6 TM1-2-9056 Frame, Lower Door 2 "
12-7 TM1-1-9047 Flap, Door Rubber - M1A 2 "
12-8 TM1-2-5043 Cover, Inside Door Handle R/H - M1 1 "
12-9 TM1-2-5036 Cover, Inside Door Handle L/H - M1 1 "
12-10 TM1-2-9510 Window, Lower Side 2 "
12-11 T6-9003-165 Gasket, Glass Window 1 "
12-12 CMA-124 Hinge, L/H Door 2 "
12-13 5/16-18 Nut, Top Lock Hex 5/16-18 8 "
12-14 CMA-504 Strip, Seal - Door 2 "
12-15 TM1-2-9052 Tube, Top Front Vertical Door 2 "
12-16 TM1-ND-6513 Handle Assembly, L/H Door 1 "
12-17 TM1-2-9054 Tube, Top Horizontal Door 2 "
12-18 TM1-4-9500 Window, L/H Door 1 "
12-19 T6-4006-113 Edging, Rubber 1 "
12-20 TM1-4-5028 Skin, Door (Non Rotating Handles) 2 "
12-21 TM1-2-9060 Tube, Rear Vertical Door L/H 1 "
12-22 T6-9003-301 Latch, Rotary L/H 1 "
12-23 TM1-1-8051 Operator, Door Latch - M1 2 "
12-24 T6-9003-302 Latch, Rotary R/H 1 "
12-25 TM1-2-9058 Tube, Rear Vertical Door, R/H 1 "
12-26 TM1-4-9502 Window, R/H Door 1 "
12-27 TM1-ND-6514 Handle Assembly, R/H Door 1 "
12-28 10-32 x ¾ Screw, Philips Head Ø 10/32 x ¾" Long 8 "
12-29 10-32 Nut, Top Lock Hex 10-32 8 "
12-30 CMA-123 Hinge, R/H Door 2 "
12-31 5/16 Washer, Flat 5/16" ID 24 "
12-33 TM1-2-9050 Tube, Bottom, Front, Vertical 2 "
12-34 TM1-4-9686-2 Center, Inside Door 2 "
CD368 4-2-25
Rev 10
Chapter 4
Figure 2-13. Door Latch Assembly
4-2-26 CD368
Rev 10
Chapter 4
Table 2-13. Door Latch Assembly
Fig & Tug Part

Ind Number
13-1 TM1-0-9516 Handle, Door (Recessed) 2 As Req'd
13-2 T6-9003-301 Latch, Rotary L/H 1 "
13-3 T6-9003-303 Bolt, Striker 2 "
13-4 CMH-316 Plate, Striker Bolt Mounting 2 "
13-5 T6-9003-309 Retainer, Door Handle Rod 1 "
13-6 T6-9003-133 Operator, Latch - L & R 2 "
13-7 T6-9003-302 Latch, Rotary R/H 1 "
13-8 CMA-321 Rod, Door Handle Linkage 2 "
13-9 CMA-320 Handle, Center Opening 2 "
13-10 CMA-609 Grip, Handle - Black 2 "
CD368 4-2-27
Rev 10
Chapter 4
Figure 2-14. Seat Installation (Rev 1A)
4-2-28 CD368
Rev 10
Chapter 4
Table 2-14. Seat Installation (Rev 1A)
Fig & Tug Part

Ind Number
14-1 TM1-4-8012 Plate, Seat 1 101 & Up
14-2 TM1-2-8023 Hinge, Top Seat Plate 2 "
14-3 4-100-101A Seat, Vinyl Bucket 2 "
14-4 T6-9011-103 Belt, Seat (Retractable) 2 "
14-5 TM1-1-8066 Rod, Seat Plate Prop 1 "
14-6 TM1-1-8068 Angle, Upper Seat Plate Prop 1 "
14-7 ------ Clip, Hood Prop - Vinyl Coated 1 "
14-8 TM1-2-8026 Hinge, Bottom Seat Plate 2 "
14-9 TM1-2-9555 Mount, Trans. Cover Shifter 1 "
14-10 TM1-1-8089 Rubber, Seat Plate Hinge 4 "
TM1-1-9581 Rubber, Seat Plate Lower Hinge 2 "
CD368 4-2-29
Rev 10
Chapter 4
Figure 2-15. Seat Installation (Rev 10)
4-2-30 CD368
Rev 10
Chapter 4
Table 2-15. Seat Installation (Rev 10)
Fig & Tug Part

Ind Number
15-1 TM1-4-8012 Plate, Seat 2 101 & Up
15-2 TM1-1-9590 Bracket, Seat Belt - M1A 4 "
3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 4 "
3/8 Washer, Flat 3/8" ID 8 "
3/8-16 Nut, Top Lock Hex 3/8-16 4 "
15-3 660-2-3290 Seat, Sears, Vinyl, Coldform with Logo 2 "
15-4 T6-9011-103 Belt, Seat (Retractable) 2 "
½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 4 "
7/16 Washer, Flat 7/16" ID 8 "
½-13 Nut, Top Lock Hex ½-13 16 "
15-5 T6-4006-113 Edging, Rubber 1 "
CD368 4-2-31
Rev 10
Chapter 4
6
3
Figure 2-16. Light Assemblies
4-2-32 CD368
Rev 10
Chapter 4
Table 2-16. Light Assemblies
Fig & Tug Part

Ind Number
16-1 T6-1300-247 Headlight 2 101 & Up

16-2 HRN-M1A-24-111 Harness, Main, M1A Deutz 1 "
16-3 TM1-2-8060 Bracket, Closeout Headlight 2 "
16-4 T6-7006-107A Light, Back-Up (Kit) 2 "
16-5 T6-7006-101A Light, Tail (Kit) 2 "
16-6 X1036-101 Doubler, Tail Light 2 "
CD368 4-2-33
Rev 10
Chapter 4
Figure 2-17. Wheel and Tire Assemby - Front
4-2-34 CD368
Rev 10
Chapter 4
Table 2-17. Wheel and Tire Assemby - Front
Fig & Tug Part

Ind Number
17-1 TM1-ND-9030 Wheel, Two Piece, 9 x 4 2 As Req'd

T6-2400-168 Wheel, Tug Tuff 4.0 x 9.0 (Two - Piece) 2 "
17-2 TM1-ND-1007 Tire, Rib Radial - 6.00 x 9 (Michelin) 2 "
T6-2400-164 Tire, Tug Tuff 690 x 9 (with Liner) 2 "
CD368 4-2-35
Rev 10
Chapter 4
Figure 2-18. Wheel and Tire Assemby - Rear
4-2-36 CD368
Rev 10
Chapter 4
Table 2-18. Wheel and Tire Assemby - Rear
Fig & Tug Part

Ind Number
18-1 T6-9003-549 Wheel, 16" x 6", White 2 As Req'd

T6-2400-169 Wheel, Tug Tuff, 6.75 x 16.5 2 "
18-2 MH-ND-650 Tire, LT215/85R16 2 "
T6-2400-170 Tire, Tug Tuff, 8.75 x 16.5 2 "
CD368 4-2-37
Rev 10
Chapter 4
Figure 2-19. Wheels and Tires
4-2-38 CD368
Rev 10
Chapter 4
Table 2-19. Wheels and Tires
Fig & Tug Part

Ind Number
19-1 T6-2400-186 Tire/Wheel Assembly, Front, MA Standard 2 As Req'd
19-2 T6-2400-164 Tire, Tug Tuff 690 x 9 (with Liner) 2 "
19-3 T6-2400-168 Wheel, Tug Tuff 4.0 x 9.0 (2 Piece) 2 "
19-4 T6-3003-107 Nut, Lug ½-20 26 "
19-5 TM1-1-9814 Tire/Wheel Assembly, 8.75 x 16.52 2 "
19-6 T6-2400-170 Tire, Tug Tuff 8.75 x 16.5, 10PR 2 "
19-7 T6-2400-169 Wheel, Tug Tuff 6.75 x 16.5 2 "
CD368 4-2-39
Rev 10
Chapter 4
2
1
Figure 2-20. Hitch
4-2-40 CD368
Rev 10
Chapter 4
Table 2-20. Hitch
Fig & Tug Part

Ind Number
20-1 T6-4044-200 Hitch Assembly 1 As Req'd

20-2 T6-4014-122 Bracket, Hitch Extension 1 "
CD368 4-2-41
Rev 10
Chapter 4
Figure 2-21. Dash Console Assembly (Orig)
4-2-42 CD368
Rev 10
Chapter 4
Table 2-21. Dash Console Assembly (Orig)
Fig & Tug Part

Ind Number
21-1 TM1-4-8070-6 Console Frame Assembly 1 101 & Up
21-2 TM1-4-8074 Cover, Console 1 "
21-3 TM1-1-5030 Yoke, Transmission Modulator Slide 1 "
21-4 T6-1001-123 Spring, Throttle 2 "
21-5 TM1-1-8092 Closeout, Steering Column 1 "
21-6 TM1-1-8090 Closeout, Steering Column 1 "
21-7 MJ-ND-8002 Yoke 1 "
21-8 TM1-4-8076 Pedal, Brake 1 "
21-9 TM1-4-8090 Pedal, Accelerator M1 Revised 1 "
21-10 T6-1009-109 Stud, Throttle Cable 2 "
21-11 T6-5005-105 Clamp, Upper Steer 1 "
21-12 TM1-1-5031 Bracket, Accelerator Cable Mounting 1 "
21-13 MG-1-585 Spacer, Steer Column 1 "
21-14 TM1-ND-5011 Controller, Glow Plug (Deutz) 1 "
21-15 TM1-ND-5010 Breaker, Circuit - 60A (Deutz) 1 "
21-16 T6-7010-140 Switch, Ignition - CH Lever 1 "
21-17 T6-7006-105 Switch, Stop Light 1 "
CD368 4-2-43
Rev 10
Chapter 4
Figure 2-22. Dash Console Assembly (Rev 10)
4-2-44 CD368
Rev 10
Chapter 4
Table 2-22. Dash Console Assembly (Rev 10)
Fig & Tug Part

Ind Number
22-1 TM1-4-8074 Cover, Console 1 Up to 2319
TM1-4-8072 Cover, Console 1 2319 to 3507
TM1-4-9851 Cover, Console 1 3507 & Up
22-2 TM1-ND-5011 Controller, Glow Plug - Deutz 1 As Req'd
22-3 10-32 Washer, Flat 10-32 8 "
22-4 10-32 x 1 Screw, Philips Head Ø 10-32 x 1" Long 6 "
22-5 10/32 Nut, Top Lock Hex 10-32 6 "
22-6 660-4-0741-5 Breaker, Circuit (20 Amp) 3 101 & Up
22-7 T6-7010-211 Mount, Circuit Breaker 1 "
22-8 10-32 x ¾ Screw, Philips Head Ø 10-32 x ¾" Long 2 As Req'd
22-9 TM1-1-5011 Bracket, Glow Plug Relay Mounting - Deutz 1 "
22-10 660-4-0753-2 Relay - Opt. 1 "
22-11 TM1-ND-5042 Mount, Relay 1 "
22-12 TM1-ND-5010 Breaker, Circuit (60 Amp) - Deutz 1 "
22-13 T6-7013-209 Relay, Horn - Ford, Deutz 1 "
22-14 T6-7010-140 Switch, Ignition C.H. Lever 1 562 & Up
22-15 TM1-4-8070-6 Console Frame Assembly 1 562 to 3507
TM1-4-9852 Console Frame Assembly 1 3508 & Up
22-16 ½-13 Nut, Top Lock Hex ½-13 4 101 & Up
22-17 7/16 Washer, Flat 7/16" ID 8 "
22-18 ½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 4 "
CD368 4-2-45
Rev 10
Chapter 4
4
3
5
1
2
7 6
20
19
18 8
17
9
16
11
14
15 13
10
12
Figure 2-23. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 3)
4-2-46 CD368
Rev 10
Chapter 4
Table 2-23. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 3)
Fig & Tug Part

Ind Number
23-1 TM1-4-8070-6 Console Frame Assembly 1 562 to 3507

23-2 TM1-1-8050 Bracket, Accelerator Stop 1 8510 & Up
TM1-1-8316 Bracket, Accelerator Stop 1 As Req'd
23-3 ¼ Washer, Flat ¼" ID 1 8510 & Up
23-4 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 1 "
23-6 T6-7006-105 Switch, Stop Light 1 101 to 2930
23-7 ½-13 Nut, Top Lock Hex ½-13 1 101 & Up
23-8 660-4-0745-12 Joint, Ball 2 "
23-9 3/32 x 7/8 Pin, Cotter 3/32" x 7/8" Long 2 "
23-10 TM1-4-8090 Pedal, Accelerator M1 Revised 1 562 & Up
23-11 10-32 Nut, Top Lock Hex 10-32 2 101 & Up
23-12 TM1-4-8076 Pedal, Brake 1 "
23-14 ¼-28 Fitting, Grease 1 "
23-15 TM1-ND-5044 Pin, Clevis - Brake Pedal 1 "
23-16 MJ-ND-8002 Yoke 1 "
23-17 ½-20 Nut, Top Lock Hex ½-20 1 "
23-19 1/8 x 1½ Pin, Cotter 1/8" x ½" Long 1 "
23-20 11/16 Washer, Flat 11/16" ID 2 "
CD368 4-2-47
Rev 10
Chapter 4
4
3
5
1
2
7
6
19
18 8
17
9
16
11
14
15 13
10
12
Figure 2-24. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 10)
4-2-48 CD368
Rev 10
Chapter 4
Table 2-24. Dash Console Assembly (Accelerator & Brake Pedals) (Rev 10)
Fig & Tug Part

Ind Number
24-1 TM1-4-9852 Console Frame Assembly 1 3508 & Up

24-2 TM1-1-8050 Bracket, Accelerator Stop 1 8510 & Up
TM1-1-8316 Bracket, Accelerator Stop 1 As Req'd
24-3 ¼ Washer, Flat ¼" ID 1 8510 & Up
24-6 11/16 Washer, Flat, 11/16"ID 2 101 & Up
24-7 ½-13 Nut, Top Lock Hex ½-13 1 "
24-8 660-4-0745-12 Joint, Ball 2 "
24-9 3/32 x 7/8 Pin, Cotter 3/32" x 7/8" Long 2 "
24-11 10-32 Nut, Top Lock Hex 10-32 2 101 & Up
24-12 TM1-4-8076 Pedal, Brake 1 "
24-14 ¼-28 Fitting, Grease 1 "
24-15 TM1-ND-5044 Pin, Clevis - Brake Pedal 1 "
24-16 MJ-ND-8002 Yoke 1 "
24-17 ½-20 Nut, Top Lock Hex ½-20 1 "
24-19 1/8 x 1½ Pin, Cotter 1/8" x ½" Long 1 "
CD368 4-2-49
Rev 10
Chapter 4
Figure 2-25. Instrument Panel with Override Switch - Deutz
4-2-50 CD368
Rev 10
Chapter 4
Table 2-25. Instrument Panel with Override Switch - Deutz
Fig & Tug Part

Ind Number
25-1 TM1-4-2502 Panel, Dash 1 As Req'd
25-2 T6-1300-257 Meter, Hour 1 "
25-3 TM1-ND-5018 Gauge, Oil Temp - Deutz 1 "
25-4 T6-7010-103 Gauge, Oil Pressure & Wedge Base Light 1 "
25-5 TM1-ND-8013 Gauge, Fuel, Datcon 1 "
25-6 T6-7010-133 Voltmeter 1 "
25-7 131282 Bulb 3 "
25-8 TM1-ND-5269 Light, Cold Start Wait - Deutz 1 "
TM1-ND-5269B Bulb, Cold Start Wait 1 "
25-9 T6-7010-129 Socket, Light, with Bulb 1 "
25-10 T6-7010-120 Light, Red Warning - Flat Head (Brake Warning) 1 "
25-11 T6-7010-113 Switch, Toggle (Heater) 1 "
25-12 T6-9003-209A Switch, Wiper/Dome Light 1 "
25-13 T6-7010-120 Light, Red Warning - Flat Head (Low Oil) 1 "
25-14 T6-7010-113 Switch, Toggle (Head Light) 1 "
CD368 4-2-51
Rev 10
Chapter 4
Figure 2-26. Instrument Panel - Deutz (Rev 3)
4-2-52 CD368
Rev 10
Chapter 4
Table 2-26. Instrument Panel - Deutz (Rev 3)
Fig & Tug Part

Ind Number
26-1 TM1-4-2502 Panel, Dash 1 101 & Up
26-2 T6-9003-571 Button, Plug, Black ½" 1 "
MH-ND-955 Switch, Heater/Defroster, 4 Position Fan - 12V 1 As Req'd
26-3 T6-9003-571 Button, Plug, Black ½" 1 101 & Up
T6-9003-209A Switch, Wiper/Dome Light 1 As Req'd
TM1-1-6535 Switch, Dual Wiper 1 "
26-4 T6-1300-257 Meter, Hour 1 101 & Up
26-5 T6-7010-133 Voltmeter 1 "
T6-7010-131 Gauge, Ammeter 1 As Req'd
26-6 TM1-ND-5018 Gauge, Oil Temperature - Deutz 1 101 & Up
TM1-ND-6505 Gauge, Fuel - Datcon #103110 with Light 1 As Req'd
26-8 T6-7010-103 Gauge, Oil Pressure & Wedge Base Light 1 101 & Up
26-9 T6-9003-572 Button, Plug, Black ¾" 1 "
26-13 TM1-ND-5269B Bulb, Cold Start Wait 1 As Req'd
26-13a TM1-ND-5269 Light, Cold Start Wait - Deutz 1 101 & Up
26-14 T6-7010-120 Light, Red Warning, Flat Head 2 "
T6-7010-120 Light, Red Warning, Flat Head - Opt. 1 As Req'd
T6-9003-571 Button, Plug, Black ½" 1 "
26-17 ¼-20 Nut, Top Lock Hex ¼-20 4 "
CD368 4-2-53
Rev 10
Chapter 4
Figure 2-27. Instrument Panel - Deutz (Rev 10)
4-2-54 CD368
Rev 10
Chapter 4
Table 2-27. Instrument Panel - Deutz (Rev 10)
Fig & Tug Part

Ind Number
27-1 TM1-4-2502 Panel, Dash 1 101 & Up
MH-ND-955 Switch, Heater/Defroster, 4 Position Fan - 12V 1 As Req'd
T6-9003-209A Switch, Wiper/Dome Light 1 As Req'd
TM1-1-6535 Switch, Dual Wiper 1 "
27-4 T6-1300-257 Meter, Hour 1 101 & Up
27-5 T6-7010-133 Voltmeter 1 "
T6-7010-131 Gauge, Ammeter 1 As Req'd
27-6 TM1-ND-5018 Gauge, Oil Temperature - Deutz 1 101 & Up
TM1-ND-6505 Gauge, Fuel, Datcon #103110 with Light 1 As Req'd
27-8 T6-7010-103 Gauge, Oil Pressure & Wedge Base Light 1 101 & Up
27-9 T6-9003-572 Button, Plug, Black ¾" 1 "
27-13 TM1-ND-5269B Bulb, Cold Start Wait 1 As Req'd
27-13a TM1-ND-5269 Light, Cold Start Wait - Deutz 1 101 & Up
27-14 T6-7010-120 Light, Red Warning, Flat Head 2 "
T6-7010-120 Light, Red Warning, Flat Head - Opt. 1 As Req'd
T6-9003-571 Button, Plug, Black ½" 1 "
27-17 ¼-20 Nut, Top Lock Hex ¼-20 4 "
CD368 4-2-55
Rev 10
Chapter 4
6
5
4
3
2
1
7
Figure 2-28. Transmission Cover Decals
4-2-56 CD368
Rev 10
Chapter 4
Table 2-28. Transmission Cover Decals
Fig & Tug Part

Ind Number
28-1 TM1-4-5047 Cover, Transmission Universal 1 151 & Up
28-2 T-B2 Decal, "For Industry & Aviation" 1 As Req'd
28-3 T-430 Decal, "Caution: All Operators…" 1 151 & Up
28-4 T6-9011-149 Plate, Data - Draw Bar 1 "
TM1-3-5007 Plate, Data - Draw Bar (EU Opt.) 1 As Req'd
28-5 ------ Decal, "Made in USA" 1 151 & Up
28-6 ML-26 Decal, "Caution" 1 "
28-7 ------ Decal, "Thank You" 1 "
28-8 T-A16 Decal, "Fasten Safety Belt" 1 "
12960001 Decal, "Seat Belt" 1 "
28-9 TY-38 Decal, Hood Latches 1 "
CD368 4-2-57
Rev 10
Chapter 4
Figure 2-29. Circuit Breakers Installation
4-2-58 CD368
Rev 10
Chapter 4
Table 2-29. Circuit Breakers Installation
Fig & Tug Part

Ind Number
29-1 T6-7010-211 Mount, Circuit Breaker 1 101 & Up
29-2 10-32 x ¾ Screw, Phillips Head Ø 10-32 x ¾" Long 2 "
29-3 10-32 Nut, Non-Locking 10-32 2 "
29-4 660-4-0741-5 Breaker, Circuit (20 Amp) 3 "
29-5 ------ Screw, Self Tapping #10 6 "
29-6 10-32 Nut, Top Lock Hex 10-32 3 "
29-7 ------ Wire, Jumper 3½" Long, 10 Gauge 2 "
CD368 4-2-59
Rev 10
Chapter 4
Figure 2-29a. Circuit Breakers Installation with Cab Option
4-2-60 CD368
Rev 10
Chapter 4
Table 2-29a. Circuit Breakers Installation with Cab Option
Fig & Tug Part

Ind Number
29a-1 T6-7010-211 Mount, Circuit Breaker 1 As Req'd
29a-2 10-32 Nut, Non-Locking 10-32 4 "
29a-3 10-32 x ¾ Screw, Phillips Head Ø 10-32 x ¾" Long 2 "
29a-4 10-32 Nut, Top Lock Hex 10-32 2 "
29a-5 660-4-0741-5 Breaker, Circuit (20 Amp) 4 "
29a-6 ------ Screw, Self Tapping #10 8 "
29a-7 ------ Wire, Jumper 3½" Long, 10 Gauge 3 "
CD368 4-2-61
Rev 10
Chapter 4
Figure 2-30. Relays Installation - Deutz
4-2-62 CD368
Rev 10
Chapter 4
Table 2-30. Relays Installation - Deutz
Fig & Tug Part

Ind Number
30-1 660-1-2301 Relay, Dial Timer (Orange) 1 As Req'd
30-2 10-32 x 1 Screw, Phillips Head Ø 10-32 x 1" Long 2 "
30-3 660-4-0753-3 Base, Socket - Electric/Octagon 1 "
30-4 10-32 Nut, Top Lock Hex 10-32 2 "
30-5 ¼-20 Nut, Top Lock Hex ¼-20 4 "
30-7 T6-9011-506 Relay, Electric, Solenoid 2 1360 & Up
CD368 4-2-63
Rev 10
Chapter 4
5 6
7
10
5
8
5
9
2
1
3
Figure 2-31. Accelerator and Modulator Cables Installation - Deutz
4-2-64 CD368
Rev 10
Chapter 4
Table 2-31. Accelerator and Modulator Cables Installation - Deutz
Fig & Tug Part

Ind Number
31-2 ------ Clip, Modulator Retainer 1 "
31-3 660-1-1264 Modulator, with 90" Cable 1 "
31-4 TM1-ND-5045 Cable, Throttle with 3" Stroke (Delta) 1 "
31-5 660-4-0745-12 Joint, Ball 3 "
31-6* TM1-4-8088 Bracket, Brake Booster Mounting 1 "
31-7 TM1-4-8070-6 Console Frame Assembly 1 562-3507
TM1-4-9852 Console Frame Assembly 1 3508 & Up
31-8 TM1-4-8090 Pedal, Accelerator M1 Revised 1 "
31-9 3/32 x 7/8 Pin, Cotter 3/32 x 7/8" Long 2 101 & Up
31-10 10-32 Nut, Top Lock Hex 10-32 3 "
*Part of TM1-4-8013A
CD368 4-2-65
Rev 10
Chapter 4
5 13
4
14
6
7
12 10
5
8
11
9
2
1
3
Figure 2-32. Accelerator and Modulator Cables Installation - Deutz (Rev 10)
4-2-66 CD368
Rev 10
Chapter 4
Table 2-32. Accelerator and Modulator Cables Installation - Deutz (Rev 10)
Fig & Tug Part

Ind Number
32-2 ------ Clip, Modulator Retainer 1 "
32-3 660-1-1264 Modulator, with 90" Cable 1 "
32-4 MI-1-322 Cable, Park Brake/Accelerator 1 "
TM1-ND-5045 Cable, Throttle with 3" Stroke (Delta) 1 "
32-5 660-4-0745-12 Joint, Ball 2 "
32-6 TM1-4-8088 Bracket, Brake Booster Mounting 1 "
32-7 TM1-4-9852 Console Frame Assembly 1 2509 & Up
32-9 3/32 x 7/8 Pin, Cotter 3/32 x 7/8" Long 2 "
32-10 10-32 Nut, Top Lock Hex 10-32 3 "
32-11 TM1-1-5030 Yoke, Transmission Modulator Slide 1 "
32-12 T6-9011-928 Stud, Accelerator 1 "
32-13 TM1-1-9757 Bracket, Accelerator 1 "
32-14 TM1-ND-5256 Spring, Accelerator 1 "
CD368 4-2-67
Rev 10
Chapter 4
Figure 2-33. Accelerator Cable Mounting
4-2-68 CD368
Rev 10
Chapter 4
Table 2-33. Accelerator Cable Mounting
Fig & Tug Part

Ind Number
33-1 TM1-4-8009 Bracket, Alternator Assembly - Deutz 1 101 & Up
33-2 TM1-ND-5045 Cable, Throttle with 3" Stroke (Delta) 1 "
33-3 TM1-1-5033 Arm, 3" Accelerator - Deutz 1 "
33-4 TM1-ND-5256 Spring, Accelerator 1 "
33-5 660-4-0745-12 Joint, Ball 1 "
33-6 TM1-2-8028 Bracket,Throttle Return Spring 1 "
33-7 10MM Washer, Flat M10 2 "
33-8 M10 - 1.5 X 25 Bolt, Hex Head Ø M10-1.5 x 25mm Long 2 "
33-9 ½-13 X 1½ Bolt, Hex Head Ø ½-13 x 1½" Long 2 "
33-11 M8-1.5 X 10 Bolt, Hex Head Ø M8-1.5 x 10mm Long 2 "
CD368 4-2-69
Rev 10
Chapter 4
Figure 2-34. Shifter Assembly
4-2-70 CD368
Rev 10
Chapter 4
Table 2-34. Shifter Assembly
Fig & Tug Part

Ind Number
34-1 TM1-1-8152 Shifter Assembly (Note 1) 1 101 & Up
34-2 TM1-1-8182 Cable, Shifter 58" 1 "
34-3 T6-1021-107 Anchor, Shifter Cable 1 "
Note 1: Shifter assembly shown exploded for reference only. If replacement should
become necessary, replace entire shifter assembly.
CD368 4-2-71
Rev 10
Chapter 4
Figure 2-35. Shifter and Shifter Cable Installation (Rev 3)
4-2-72 CD368
Rev 10
Chapter 4
Table 2-35. Shifter and Shifter Cable Installation (Rev 3)
Fig & Tug Part

Ind Number
35-1 TM1-1-8152 Shifter Assembly 1 As Req'd
35-3 TM1-1-8182 Cable, Shifter 58" 1 101 & Up
35-5 ¼ Washer, Flat ¼" ID 4 1484 & Up
35-6 TM1-2-9555 Mount, Transmission Cover Shifter 1 1876 & Up
35-7 TM1-1-8154 Connection Kit, Transmission 1 101-2965
CD368 4-2-73
Rev 10
Chapter 4
1
6
2
8 3 4
7 5
Figure 2-36. Shifter and Shifter Cable Installation (Rev 10)
4-2-74 CD368
Rev 10
Chapter 4
Table 2-36. Shifter and Shifter Cable Installation (Rev 10)
Fig & Tug Part

Ind Number
36-1 TM1-1-8152 Shifter Assembly 1 As Req'd
36-3 TM1-1-8182 Cable, Shifter 58" 1 101 & Up
36-5 ¼ Washer, Flat ¼" ID 4 1484 & Up
36-6 TM1-2-9555 Mount, Transmission Cover Shifter 1 1876 & Up
36-7 TM1-1-8154 Connection Kit, Transmission 1 101 & Up
36-8 T6-9011-605 Plate, Full Range Shifter 1 2966 & Up
CD368 4-2-75
Rev 10
Chapter 4
Figure 2-37. Shifter Linkage (Rev 3)
4-2-76 CD368
Rev 10
Chapter 4
Table 2-37. Shifter Linkage (Rev 3)
Fig & Tug Part

Ind Number
37-1a ------ Bracket, Mounting 1 "
37-1b ------ Washer, Flat #10 2 "
37-1c 10-32 Nut, Elastic Stop 2 "
37-1d 3/8-24 x 5/8 Screw, Hex Head Ø 3/8-24 x 5/8" Long 1 "
37-1e 3/32 x ½ Pin, Cotter Ø 3/32" x ½" Long 1 "
37-1f T6-1021-103 Linkage, Shift 1 "
37-1g 3/8-24 Nut, Hex 3/8-24 1 "
37-1h ------ Pivot 1 "
37-1i 10-32 U-Bolt 1 "
37-1j ------ Shim, Cable Clamp 1 "
37-2 ------ Bolts, Transmission Oil Pan 2 "
37-3 ------ Lever, Transmission Shift 1 "
37-4 TM1-1-8182 Cable, Shifter 58" 1 "
CD368 4-2-77
Rev 10
Chapter 4
Figure 2-38. Shifter Linkage (Rev 10)
4-2-78 CD368
Rev 10
Chapter 4
Table 2-38. Shifter Linkage (Rev 10)
Fig & Tug Part

Ind Number

38-1a ------ Bracket, Mounting 1 "
38-1a ------ Washer, Flat #10 2 "
38-1a 10-32 Nut, Elastic Stop 2 "
38-1a 3/8-24 x 5/8 Screw, Hex Head Ø 3/8-24 x 5/8" Long 1 "
38-1a 3/32 x ½ Pin, Cotter Ø 3/32" x ½" Long 1 "
38-1a ------ Shim, Cable Clamp 1 "
38-1a 3/8-24 Nut, Hex 3/8-24 1 "
38-1a ------ Pivot 1 "
38-1a 10-32 U-Bolt 1 "
38-2 ------ Bolts, Transmission Oil Pan 2 "
38-3 ------ Lever, Transmission Shift 1 "
38-4 TM1-1-8182 Cable, Shifter, 58" 1 "
38-5 T6-9011-605 Plate, Full Range Shifter 1 2966 & Up
38-6 5/16-18 x 2½" Bolt, Hex Head Ø 5/16-18 x 2½" Long 1 "
38-7 5/16" Washer, Flat, 5/16" ID 1 "
38-8 660-1-2689 Spacer, Upper, C6 Shift Lever 1 "
38-9 5/16-18 Nut, Lock 5/16"ID-18 1 "
CD368 4-2-79
Rev 10
Chapter 4
Figure 2-39. Hydro-Boost Installation (Rev 7)
4-2-80 CD368
Rev 10
Chapter 4
Table 2-39. Hydro-Boost Installation (Rev 7)
Fig & Tug Part

Ind Number
39-1 TM1-4-8088 Bracket, Brake Booster Mounting 1 10 & Up
39-2 TM1-1-8227 Hose, Steering Sector Return 1 "
TM1-ND-8008 Hose, Relief to Hydro-Boost - Opt. 1 As Req'd
39-3 660-1-1342 Hydro-Boost Assembly 1 101 & Up
39-4 T6-600-112 Adaptor 1 "
39-5 MH-ND-565 Line, Brake 10" 2 "
39-6 660-ND-1397 Adaptor, Brake 1 "
39-8 3/8 Washer, Flat 3/8" ID 8 "
39-9 ------ Clamp, Hose 1 "
39-10 MJ-1-5102 Hose, Pump to Booster 1 As Req'd
------ Hose, Hydraulic 5/16" ID (Fuel Line) - Opt. 1 "
39-11 TM1-1-8223 Hose, Hydraulic 3/8" x 29" Long (Pump to Booster) 1 101 & Up
TM1-1-8326 Hose, Steer Valve P to Booster - Opt. 1 As Req'd
39-13 MJ-ND-8002 Yoke 1 "
CD368 4-2-81
Rev 10
Chapter 4
1
13
2 9
8
3 12
10 11
8
7
6
4
5
Figure 2-40. Hydro-Boost Installation (Rev 10)
4-2-82 CD368
Rev 10
Chapter 4
Table 2-40. Hydro-Boost Installation (Rev 10)
Fig & Tug Part

Ind Number
40-1* TM1-4-8088 Bracket, Brake Booster Mounting 1 101 & Up
40-2 TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ 6-7MI 1 3353 & Up
40-3 T6-4900-202 Hydro-Boost Assembly 1 "
40-4 T6-600-112 Adaptor 1 101 & Up
40-5 TM1-1-9797 Hose, Brake at Master Cylinder 2 3353 & Up
40-6 660-ND-1397 Adaptor, Brake 1 101 & Up
40-8 3/8 Washer, Flat 3/8" ID 8 "
40-9 ------ Clamp, Hose #6 1 "
40-10 C406 Hose, 3/8" Low Press (Tank to Booster) 1 3353 & Up
40-11 TM1-1-8228 Hose, Power Steering 1 "
40-13 MJ-ND-8002 Yoke 1 "
*Part of TM1-4-8013A
CD368 4-2-83
Rev 10
Chapter 4
Figure 2-41. Brake Line Assembly (Option without Front Brakes) (Up to S/N 2685)
4-2-84 CD368
Rev 10
Chapter 4
Table 2-41. Brake Line Assembly (Option without Front Brakes) (Up to S/N 2685)
Fig & Tug Part

Ind Number
41-1 MH-ND-565 Line, Brake, 10" 2 Up to 2685
41-2 T6-8011-117 Pigtail, Brake Warning 1 "
41-3 T6-8011-107 Adaptor, Brake Warning 2 "
41-6 T6-8011-113 Valve, Hydraulic Brake Warning 1 "
41-7 T6-600-114 Adaptor, Brake Line to Master Cylinder 2 "
41-8 T6-6011-151 Line, Brake 6" 2 "
41-9 T6-8011-121 Connector 2 "
41-10 5-100-101 Line, Brake, 51" 2 "
41-11 ¼ Clamp, P- (¼") 8 "
41-13 5/16-18 Nut, Flange 5/16-18 (as Spacer) 2 "
41-15 MD-CB21-121 Clip 2 "
41-16 TM1-1-8158 Bracket, Brake Line 1 "
41-17 MH-ND-543 Hose, Brake, 15" 2 "
41-18 T6-6011-111 Tee 2 "
CD368 4-2-85
Rev 10
Chapter 4
20
1
18 19
7
17
8 14
9 13
2
10 12 15
3
4
15 16
5
11
3
6
Figure 2-41a. Brake Line Assembly (Option without Front Brakes) (S/N 2685 & Up)
4-2-86 CD368
Rev 10
Chapter 4
Table 2-41a. Brake Line Assembly (Option without Front Brakes) (S/N 2685 & Up)
Fig & Tug Part

Ind Number
41a-1 TM1-1-9797 Hose, Brake at Master Cylinder 2 2685 & Up
41a-2 TM1-1-9793 Housing, Rubber 1 "
41a-3 TM1-1-9792 Adapter, Brake Proportioning Valve 2 "
41a-4 TM1-1-9787 Valve, Brake Warning 1 "
41a-5 TM1-1-9791 Plug, Brake Proportioning Valve 1 "
41a-6 T6-6011-151 Line, Brake, 6" 2 "
41a-7 TM1-1-9795 Sleeve 1 "
41a-8 TM1-1-9794 Terminal 1 "
41a-9 T6-600-114 Adapter, Brake Line to Master Cylinder 1 "
41a-10 660-ND-1397 Adapter, Brake 1 "
41a-11 T6-8011-121 Connector 2 "
41a-12 5-100-101 Line, Brake, 51" 2 "
41a-13 ¼ Clamp, P- (¼") 8 "
41a-14 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 4 "
41a-15 ¼-20 Nut, Flange ¼-20 (as Spacer) 4 "
41a-16 ¼ Washer, Lock ¼" ID 4 "
41a-17 MD-CB21-121 Clip 2 "
41a-18 TM1-1-8158 Bracket, Brake Line 1 "
41a-19 MH-ND-543 Hose, Brake, 15" 2 "
41a-20 T6-6011-111 Tee 2 "
CD368 4-2-87
Rev 10
Chapter 4
20
27
28
24 20
23
1 19
2 21 22 25
8 29 20 26
9 17
11 18
10 15
3
16
4 15
5 14
13
3
12 7
6
Figure 2-41b. Brake Line Assembly (Option without Front Brakes) (Rev 10)
4-2-88 CD368
Rev 10
Chapter 4
Table 2-41b. Brake Line Assembly (Option without Front Brakes) (Rev 10)
Fig & Tug Part

Ind Number
41b-1 TM1-1-9797 Hose, Brake at Master Cylinder 2 2685 & Up
41b-2 TM1-1-9793 Housing, Rubber 1 "
41b-3 T6-8011-107 Adapter, Brake Warning 2 "
41b-4 TM1-1-9787 Valve, Brake Warning 1 "
41b-5 TM1-1-9791 Plug, Brake Proportioning Valve 1 "
41b-6 MH-ND-565 Line, Brake, 10" 1 "
41b-7 T6-6011-151 Line, Brake, 6" 1 "
41b-8 TM1-1-9795 Sleeve 1 "
41b-9 TM1-1-9794 Terminal 1 "
41b-10 T6-600-114 Adapter, Brake Line to Master Cylinder 1 "
41b-11 T6-6011-111 Tee 1 "
41b-12 660-ND-1397 Adapter, Brake 1 "
41b-13 T6-8011-121 Connector, 1 "
41b-14 5-100-101 Line, Brake, 51" 2 "
41b-15 ¼-20 Nut, Flange ¼-20 (as Spacer) 4 "
41b-16 ¼ Washer, Lock ¼" ID 4 "
41b-17 660-1-3086 Switch, Brake Pressure 1 "
41b-18 ¼ Clamp, P- (¼") 8 "
41b-19 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 4 "
41b-20 MD-CB21-121 Clip 4 "
41b-21 TM1-1-8158 Bracket, Brake Line 1 "
41b-22 MH-ND-543 Hose, Brake, 19" 2 "
41b-23 T6-6011-161 Line, Brake, 30" 1 "
41b-24 T6-6011-141 Line, Brake, 20" 1 "
41b-25 T6-6011-151 Line, Brake, 6" 1 "
41b-26 TM1-1-8258 Anchor, Brake 2 "
41b-27 T6-6011-111 Tee 2 "
41b-28 T6-6011-141 Line, Brake, 20" 1 "
41b-29 660-1-3046 Pigtail, Brake Warning 1 "
CD368 4-2-89
Rev 10
Chapter 4
Figure 2-42. Brake Line Assembly - Rear (Rev 3) (Up to S/N 2667)
4-2-90 CD368
Rev 10
Chapter 4
Table 2-42. Brake Line Assembly - Rear (Rev 3) (Up to S/N 2667)
Fig & Tug Part

Ind Number
42-1 TM1-4-3504 Cradle, Rear Assembly 1 Up to 2094
TM1-4-3504 Cradle, Rear Assembly (Modified) 1 2094-2666
42-2 T6-6011-111 Tee 2 Up to 2667
42-3 T6-6011-161 Line, Brake, 30" 1 "
42-4 T6-6011-151 Line, Brake, 6" 2 "
42-5 5/16-18 Nut, Flange 5/16-18 (as Spacer) 1 "
42-6 T6-8011-121 Connector 1 "
42-7 ¼ Clamp, P- (¼") 2 "
42-9 MH-ND-565 Line, Brake, 10" 1 "
42-10 T6-8013-143 Hose, Brake 4 "
42-11 TM1-1-8258 Anchor, Brake 4 "
42-13 MD-CB21-121 Clip 4 "
42-14 T6-6011-141 Line, Brake, 20" 1 "
CD368 4-2-91
Rev 10
Chapter 4
10
1
9
10
8
7
9
4 3
11 6 8
3
5 11
12 2
10
13 8
9
Figure 2-42a. Brake Line Assembly - Rear (Rev 7) (S/N 2667 & Up)
4-2-92 CD368
Rev 10
Chapter 4
Table 2-42a. Brake Line Assembly - Rear (Rev 7) (S/N 2667 & Up)
Fig & Tug Part

Ind Number
42a-1 TM1-4-3504 Cradle, Rear Assembly (Modified) 1 2667 & Up

42a-2 T6-6011-111 Tee 2 "
42a-3 ¼ Washer, Lock ¼" ID 7 "
42a-4 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 6 "
42a-5 T6-6011-161 Line, Brake, 30" 1 "
42a-6 ¼ Clamp, P- (¼") 2 "
42a-7 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 1 "
42a-8 MD-CB21-121 Clip 4 "
42a-9 TM1-1-8258 Anchor, Brake 4 "
42a-10 T6-8013-143 Hose, Brake 4 "
42a-11 T6-6011-141 Line, Brake, 20" 2 "
42a-12 ¼-20 Nut, Flange ¼-20 (as Spacer) 1 "
42a-13 T6-6011-151 Line, Brake 6" 1 "
CD368 4-2-93
Rev 10
EA: 15-504981-03
Engineering Authorization Delta File Code: 0960-03-15 Issue Date: 12/01/2014
Section 1
General Information
Title TUG M1A Park Brake Relocation
Classification Not Flight Equipment Warranty N Manuals Affected N Project ID/IO/

WBS Element
Customer Delta Air Lines Warranty Critical N ETOPS Affected N
Original Issue Date Passenger Cabin N ELA Affected N

Configuration Change
Contacts
Submitter Murray, Miles E. Approver Heinzel, James
References
EA Rev Approval Manufacturer Doc Document Number Document date
Type Type
Ref Delta Air Lines EAR 15-504981-03 8/8/2014
End of Section 1
File Code: 960-3-15 EA: 15-504981-03
Engineering Authorization Section 2, Page: 1
INTRODUCTION AND PURPOSE

The intent of this Engineering Authorization (EA) is to provide instructions and authorization necessary to
relocate the Park Brake System on TUG M1A Baggage Tractors. Extreme high failure rate of Park Brake
System (both Lever and Mounting Bracket) has warranted the need to develop a new system to eliminate known
failure causes.
The primary cause of failure that has been identified is vibration due to the location of the existing P-Brake
Lever & Linkage assembly. The current version is bracket mounted directly to the side of the transmission.
Because the engine and transmission are both mounted in the unit via rubber Mounts, the lever and actuation
linkage are both subject to continuous vibration and lateral movement. This has called the need for redesigning
and relocating the existing park brake system to prevent premature failure
ESTIMATED TIME OF COMPLETION

2.5 hours
TIME OF ACCOMPLISHMENT
Upon Failure
DELTA DRAWINGS REQUIRED

15-0975: M1A Doghouse Hole Cover
15-0998: M1A Park Brake Relocation Decal
NOTES
1. EA Planner
 Create EBIS work order for all units in the effectivity list included in this EA to be completed upon
failure of the park brake system in each unit. Send to all GSE managers affected by this EA.
2. Technical Publications
 Online manual #1196 – insert EA after e-pg. 335. Cross out pages 336, 337. On pg. 339, cross out lines
44-2 – 44-6, 44-12 – 44-14. On pg. 343, cross out lines 46-1 – 46-15. On pg. 345, cross out lines 47-1 –
47-15.
 Online manual #2062 – insert EA after e-pg. 405. Cross out pages 406, 407. On pg. 415, cross out lines
70-1 – 70-15 and 70-23.
 Online manual #2128 – insert EA after e-pg. 335. On pg.341, cross out lines 54-1 – 54-15.
3. Material Planner
 Kits are to be built upon receipt of order using the provided kit number from the bill of material
 Initial stocking order should be 50 kits.
 Set reorder level at 10 kits.
 Upon receipt of parts, notify the EA planner for release of EA.
File Code: 960-3-15 EA: 15-504981-03
BILL of MATERIALS
M1A Park Brake Relocation Kit #15-504981-03
SUPERSEEDED MFG /
QTY PART NUMBER DESCRIPTION STATUS
PART # SUPPLIER
1 B40023 T6-8005-101 LEVER, PARKING BRAKE TUG
1 499-22-221 66011193 SUPPORT, BRAKE CABLE A & B METALS
CABLE, PARK BRAKE CALIF. PUSH-
1 CA510CABLE N/A
TE523-060-60-060-TE523-69.5 PULL
2 21054CLEVIS NMC # 1-5437 CLEVIS, ¼ INCH 28 TPI X 5/16 INCH SAGE
1 499-22-219 15-0975-002 ALUMINUM DOGHOUSE COVER PLATE A & B METALS
1 15-0998-002 N/A DECAL NAPA
4 501-583R 16125 Bolt, 5/16” -18 x 1 USS Grade 8 NAPA
4 8077-030R 76171 Washer, split lock 5/16” Grade 8 NAPA
2 4852-029R 41151 Nut, 1/4"-28 SAE Grade 8, clevis jam nut NAPA
8 770-4557 N/A RIVET, 3/16", Multi-Grip NAPA
INSTRUCTIONS
1. Secure the vehicle out of service; disable engine operation, lock-out and tag-out powered components as
necessary. Use appropriate PPE, safety glasses, gloves, etc. while performing this operation.
2. Clean the area surrounding the existing brake lever and doghouse and remove the doghouse as shown in
Figures 1 and 2. Then remove the brake lever, linkage rod and the existing mounting bracket using the
necessary tools as shown in Figure 3. Note: Retain bracket mounting hardware.
Figure 1. Figure 2.
File Code: 960-3-15 EA: 15-504981-03
Remove this bracket

retaining the existing
hardware
Figure 3.
3. Install the new bracket using the existing hardware as shown in Figure 4.
Figure 4.
File Code: 960-3-15 EA: 15-504981-03
4. Install a jam nut and clevis to one end of the cable. Temporarily attach the clevis to the swing arm
(activation lever/plate) and route cable as shown in the picture below. Strap it with cable ties to keep it
clear of any moving parts as shown in Figures 5 & 6.
Note: Final adjustments will be needed prior to installing the cotter pin.
Figure 5.
Secure cable with zip ties

away from moving parts.
Figure 6.
File Code: 960-3-15 EA: 15-504981-03
5. New Brake handle will be mounted as shown in Figure 7.
Figure 7.
6. Install the provided decal making sure the lower arrow points to the middle of the lower bolt as shown
in Figure 8. This will allow adequate clearance to open the seat cover.
Place decal along the edge/seam. Lower arrow

must be aligned with the center of the lower bolt.
Figure 8.
File Code: 960-3-15 EA: 15-504981-03
7. Center punch decal circle crosshairs.
8. Removing the seat is recommended to allow clearance for turning the tap handle.
9. Drill and tap the four small holes using a 17/64” drill bit and a 5/16 -18 tap as shown in Figures 9 & 10.
10. Drill the center hole with 9/16 drill bit.
Remove seats for

clearance for tap handle
Figure 9. Figure 10.

9
11. Run the lower jam nut all the way down on brake cable and insert the cable through the /16 hole.
Install second jam nut and tighten as shown in Figure 11.
12. Start the four 5/16 – 18 bolts and lock washers loosely mounting the new brake handle as shown in
Figure 11.
Jam nuts
Figure 11.
File Code: 960-3-15 EA: 15-504981-03
13. Install the jam nut and the clevis onto the cable. Attach clevis to brake lever assembly.
14. Cable, clevis, jam nut and pin assembly should look like Figures 12 & 13. Note: Not all hardware that
comes in kit will be used.
15. Tighten the four bracket mounting bolts.
16. Make adjustments to both clevises as needed.
17. When desired tension is obtained, tighten jam nuts to clevises and then install the cotter pins.
18. The following steps can be completed with the doghouse installed or prior to installing it onto the
tractor. Place a bead of silicone sealer around the hole on the doghouse cover and place the plate on it.

File Code: 960-3-15 EA: 15-504981-03
19. Drill through the holes on the cover and rivet.
Figure 16.
20. Bend the cover along the bend on the doghouse and make sure it is snug and does not have gaps.
Figure 19.
File Code: 960-3-15 EA: 15-504981-03
21. Drill and rivet lower half of plate.
Figure 22.
22. With operator on unit, engage hand brake with vehicle in neutral. Place transmission in drive. If
vehicle moves, adjust the brakes and repeat the process until desired results are achieved.
23. Once complied with, close only the EBIS Work Order card that was generated for this EA. DGS and
Contract Stations submit closeout notifications to the Control Work Center (CWC) via fax at
(404)773-2790.
File Code: 960-3-15 EA: 15-504981-03
EFFECTIVITY
Total Units – 1575
city_abbr cityno city_abbr cityno city_abbr cityno city_abbr cityno city_abbr cityno
ABE 17935 ATL 170321 ATL 170441 ATL 170546 ATL 17849
ABQ 170195 ATL 170322 ATL 170294 ATL 170547 ATL 17850
ANC 170656 ATL 170328 ATL 170548 ATL 17622 ATL 17862
ATL 170180 ATL 170336 ATL 170475 ATL 17630 ATL 17870
File Code: 960-3-15 EA: 15-504981-03
File Code: 960-3-15 EA: 15-504981-03
ATL 171259 BOS 170472 CVG 170303 CVG 170136 DTW 171283
ATL 171262 BWI 170645 CVG 170306 CVG 170151 DTW 171281
AUS 17925 BWI 17739 CVG 170309 CVG 170803 EGE 17931
AUS 170043 BWI 17932 CVG 170310 CVG 170806 EGE 170851
AUS 170784 BWI 170785 CVG 170311 CVG 170807 EWR 170511
BDL 170313 BWI 171063 CVG 170312 CVG 170808 EWR 170512
BDL 170678 BZN 170464 CVG 17710 CVG 170809 EWR 170627
BDL 170673 BZN 17899 CVG 17711 CVG 170810 EWR 170642
BDL 170674 CAE 170401 CVG 17712 CVG 170811 EWR 170643
BHM 170196 CAE 172090 CVG 17717 CVG 170816 EWR 170821
BHM 170197 CHS 170380 CVG 17718 CVG 170817 EWR 171080
BHM 17928 CHS 170402 CVG 17719 CVG 170818 FAY 170634
BMI 170638 CHS 170749 CVG 17722 CVG 171067 FLL 170317
BNA 170265 CHS 17937 CVG 17723 CVG 171068 FLL 170414
BNA 170655 CLE 17907 CVG 170009 CVG 171071 FLL 170506
BNA 170782 CLE 170145 CVG 170012 DAB 17938 FLL 170509
BNA 17735 CLT 17740 CVG 170013 DAB 170107 FLL 17743
BNA 17736 CLT 17741 CVG 170014 DAB 170108 FLL 17744
BNA 17737 CLT 17742 CVG 170015 DAY 17910 FLL 17936
BNA 17922 CLT 17765 CVG 170016 DAY 170147 FLL 170000
BNA 170146 CLT 172068 CVG 170017 DCA 170443 FLL 170024
BNA 172091 CLT 172069 CVG 170018 DCA 170080 FLL 170025
BNA 172041 CMH 170244 CVG 170019 DCA 170073 FLL 170026
BOI 17897 CMH 170245 CVG 170020 DCA 171074 FLL 170243
BOI 17898 CMH 17913 CVG 170021 DCA 171075 FLL 171082
BOI 170854 CMH 17914 CVG 17917 DEN 17732 FLL 171083
BOI 171062 CMH 171064 CVG 17994 DFW 170629 FLL 171084
BOS 170236 CMH 171065 CVG 170036 DFW 17697 FLL 171085
BOS 170237 CMH 171066 CVG 170128 DFW 170044 FLL 171086
BOS 170240 CMH 172052 CVG 170129 DTW 170637 FLL 171087
BOS 170262 COS 17731 CVG 170130 DTW 17939 FLL 171081
BOS 170263 CVG 170249 CVG 170131 DTW 171277 GSO 17940
BOS 170468 CVG 170299 CVG 170132 DTW 171279 GSP 170381
File Code: 960-3-15 EA: 15-504981-03
GSP 170796 IAH 17952 JFK 170114 JFK 150007 KOA 172094
GUM 150219 IAH 17953 JFK 170115 JFK 150008 KOA 172092
GUM 170965 IAH 170082 JFK 170116 JFK 150009 KOA 172093
GUM 172028 IAH 170083 JFK 170117 JFK 150010 LAS 173772
GUM 172182 ICT 172121 JFK 172067 JFK 150014 LAS 170235
HNL 170453 IND 170178 JFK 170831 JFK 150015 LAS 170264
HNL 17945 JAN 170201 JFK 170836 JFK 150020 LAS 17896
HNL 17950 JAX 170194 JFK 170841 JFK 150025 LAS 172045
HNL 172110 JFK 170390 JFK 170843 JFK 172048 LAS 172083
HNL 172112 JFK 170391 JFK 170844 JFK 171366 LAX 170203
HNL 172109 JFK 170297 JFK 170845 JFK 171367 LAX 170204
HOU 17951 JFK 170353 JFK 170846 JFK 171368 LAX 170205
HSV 170630 JFK 170387 JFK 170849 JFK 171373 LAX 170208
IAD 170436 JFK 170660 JFK 170920 JFK 171372 LAX 170366
File Code: 960-3-15 EA: 15-504981-03
LAX 170561 LGA 172056 LGA 171419 MCO 171101 MSP 171347
LAX 170599 LGA 171100 LGA 171422 MGM 172120 MSP 171344
LAX 170600 LGA 171394 LGA 171423 MIA 170267 MSP 171324
LAX 170001 LGA 171395 LGA 171426 MIA 17823 MSP 171325
LAX 170002 LGA 171396 LIH 172095 MIA 17824 MSP 171326
LAX 170102 LGA 171399 LIT 170173 MSN 170720 MSY 170383
LAX 170103 LGA 171400 LIT 170352 MSN 172118 MSY 170384
LAX 170104 LGA 171401 LIT 170155 MSP 17892 MSY 170385
LEX 17766 LGA 171405 LIT 172116 MSP 171319 MSY 17781
LEX 17767 LGA 171406 LIT 172114 MSP 171320 MSY 17965
LEX 17918 LGA 171407 MCI 17768 MSP 171322 MSY 17966
LGA 170174 LGA 171408 MCI 17769 MSP 171323 MSY 17967
LGA 170246 LGA 171410 MCI 17961 MSP 171329 MYR 170636
LGA 170247 LGA 171411 MCI 170798 MSP 171330 MYR 170664
LGA 170248 LGA 171412 MCI 170852 MSP 171331 NAS 171104
LGA 170298 LGA 171413 MCO 170314 MSP 171332 OAK 170355
LGA 170426 LGA 171435 MCO 170608 MSP 171351 OGG 171105
LGA 17616 LGA 171444 MCO 170617 MSP 171360 OKC 17970
LGA 17773 LGA 171416 MCO 17962 MSP 171350 ONT 17746
LGA 170072 LGA 171417 MCO 171102 MSP 171349 ONT 171109
LGA 170076 LGA 171418 MCO 171103 MSP 171348 ORD 170041
File Code: 960-3-15 EA: 15-504981-03
ORD 170142 PHX 170672 SAN 170200 SFO 170523 SLC 170211
ORF 170635 PHX 17838 SAN 170683 SFO 170524 SLC 170212
PDX 170227 PHX 171122 SAN 172027 SFO 17837 SLC 170218
PDX 170003 PIT 170238 SAN 171303 SFO 171286 SLC 170268
PDX 171118 PNS 172002 SAT 170434 SFO 171305 SLC 170273
PDX 171117 PVD 170428 SAV 170229 SFO 171390 SLC 170276
PHL 170549 PVD 17699 SAV 170439 SFO 171391 SLC 170277
PHL 170632 PVD 171128 SAV 17829 SJC 170230 SLC 170280
PHL 170633 RDU 170392 SAV 17830 SJC 17788 SLC 170281
PHL 17695 RDU 170639 SDF 17700 SJC 171285 SLC 170284
PHL 170802 RDU 170652 SDF 172166 SJU 17693 SLC 170289
PHL 170804 RDU 17822 SEA 17982 SJU 17694 SLC 170290
PHL 171312 RHI 170675 SEA 170933 SJU 17797 SLC 170293
PHL 171313 RIC 170405 SEA 170934 SJU 171133 SLC 170354
PHL 171314 RIC 17900 SEA 170935 SJU 171134 SLC 170393
PHX 170357 RIC 170038 SEA 170936 SJU 171135 SLC 170394
PHX 170360 RIC 171129 SEA 170937 SLC 170226 SLC 170395
PHX 170669 RSW 17981 SFO 170177 SLC 170242 SLC 170398
PHX 170670 SAN 170154 SFO 170521 SLC 170209 SLC 170531
PHX 170671 SAN 170179 SFO 170522 SLC 170210 SLC 170532
File Code: 960-3-15 EA: 15-504981-03
SLC 170533 SLC 17845 SLC 171079 TPA 170192 TPA 172055
SLC 170534 SLC 17846 SLC 171140 TPA 170318 TPA 171316
SLC 170538 SLC 17984 SMF 171288 TPA 170455 TUS 170362
SLC 170539 SLC 17985 SMF 171289 TPA 170456 TUS 170363
SLC 170540 SLC 17774 SNA 170544 TPA 170457 TUS 17986
SLC 17703 SLC 17963 SRQ 171136 TPA 170459 TUS 171138
SLC 17704 SLC 170121 STL 17921 TPA 170460 TUS 172050
SLC 17707 SLC 170124 STL 170140 TPA 17785 TYS 170382
SLC 17708 SLC 170792 SYR 170351 TPA 17786 TYS 17987
SLC 17843 SLC 171077 SYR 17906 TPA 170067 YUL 17763
SLC 17844 SLC 171078 TPA 170191 TPA 172054 YUL 17764
Chapter 4
Figure 2-43. Park Brake Handle Assembly
4-2-94 CD368
Rev 10
Chapter 4
Table 2-43. Park Brake Handle Assembly
Fig & Tug Part

Ind Number
43-1 T6-8005-101 Lever, Hand Brake 1 101 & Up
43-2 T6-8005-103 Bushing, Hand Brake 2 "
43-3 MD-CB1-129 Yoke 2 "
43-4 TM1-2-8100 Rod, Parking Brake 1 "
43-5 TM1-4-8044 Mount, Park Brake Handle 1 "
43-7 3/8 Washer, Lock 3/8" ID 2 "
43-8 MD-CB21-115 Pin, Clevis 1 "
43-9 1/8 x 1½ Pin, Cotter Ø 1/8 x 1½" Long 1 "
CD368 4-2-95
Rev 10
Chapter 4
Figure 2-44. Park Brake Linkage
4-2-96 CD368
Rev 10
Chapter 4
Table 2-44. Park Brake Linkage
Fig & Tug Part

Ind Number
44-1 TPG-B9TZ-2A710D Cam & Lever Assembly 1 As Req'd
___________________________________________________________________
44-2 TM1-4-5037 Bracket, Park Brake Anchor - Weldment 1 "
___________________________________________________________________
44-3 T6-8005-101 Lever, Hand Brake 1 "
___________________________________________________________________
___________________________________________________________________
44-5 MD-CB21-115 Pin, Clevis 4 "
___________________________________________________________________
44-6 TPG-C1TT-2857L Clevis 2 "
44-7 TPG-D3TZ-2A663D Bellcrank 1 "
44-8 TPG-386034-S100 Nut, Slotted 9/16-18 1 "
44-9 1/8 x 1 Pin, Cotter Ø 1/8 x 1" Long 1 "
44-10 1/8 x 1¼ Pin, Cotter Ø 1/8 x 1¼" Long 4 "
44-11 TPG-D3TZ-2857A Clevis, Parking Brake 1 "
___________________________________________________________________
44-12 3/8-16 Nut, Hex 3/8-16 (Plated) 1 "
___________________________________________________________________
44-13 ------ Rod, All Thread Ø 3/8-16 x 2½" Long 1 "
___________________________________________________________________
44-14 MD-CB1-129 Yoke 1 "
44-15 TPG-44880-S2 Washer, Flat 9/16" ID 1 "
CD368 4-2-97
Rev 10
Chapter 4
Figure 2-45. Park Brake Installation (Rev 2)
4-2-98 CD368
Rev 10
Chapter 4
Table 2-45. Park Brake Installation (Rev 2)
Fig & Tug Part

Ind Number
45-1 TPG-D3TZ-2614A Drum, Parking Brake 1 As Req'd
45-2 TPG-C6TZ-4A254B Saddle, U-Joint 2 "
45-3 TPG-382884-S2 Bolt Ø 5/16-24 x 1" Long 4 "
45-4 TM1-1-0804 Shaft, Drive (Perkins, Deutz) 1 "
T6-7200-090 Shaft, Drive 1 "
45-5 ½-13 Nut, Top Lock Hex ½-13 4 "
45-6 TPG-385524-S2 Bolt Ø ½-13 x 1½" Long 4 "
45-7 TPG-371887-S2 Nut, Lock 1-20 1 "
45-8 TPG-D3TZ-7089B Flange, Output 1 "
45-9 T6-8005-135 Plate, Park Brake 1 "
45-10 T6-8005-149 Spring, Park Brake Assembly (C-6) 1 "
45-11 T6-8005-147 Spring, Park Brake Assembly (C-6) 2 "
45-12 TPG-58675-S2 Bolt Ø ½-13 x 1½" Long 4 "
45-13 T6-8005-137 Washer, Lock 4 "
45-14 T6-8005-133 Nut, Hex 4 "
45-15 TPG-D6TZ-2A7038 Shield, Park Brake 1 "
45-16 T6-8005-143 Shoe, Park Brake (C-6) 2 "
45-17 D0TZ-7A011A Seal, Transmission 1 "
45-18 D5TZ-7070A Ring, Snap 1 "
45-19 E1ZZ-7065A Bearing Assembly, with Retaining Ring 1 "
45-20 TPG-D1TZ-17285A Spacer, Speedometer Gear 1 "
45-21 TPG-D3TA-2A701AA Pipe, Park Brake Drain 1 "
45-22 3/8-24 Nut, Hex 3/8-24 4 "
45-23 3/8 Washer, Lock 4 "
45-24 ------ Housing, Flange 1 "
45-25 TPG-C8HZ-7A002A Plug, Speedometer Gear Inlet 1 "
45-26 TM1-3-8282 Cam & Lever Assembly 1 "
45-27 D2AZ-7086A Gasket, C6 Tail Shaft and Extension Housing 1 "
45-28 ------ Housing, Extension 1 "
45-29 3/8-16 x 1½ Screw, Hex Washer Head 6 "
45-30 TPG-385554-S2 Stud, 9/16-12-18 x 2.28 1 "
CD368 4-2-99
Rev 10
Chapter 4
4-2-100 CD368
Rev 10
Chapter 4
Fig & Tug Part

Ind Number
___________________________________________________________________
46-1 T6-8005-101 Lever, Hand Brake 1 As Req'd
___________________________________________________________________
46-2 3/8 Washer, Lock 3/8" ID 4 "
___________________________________________________________________
___________________________________________________________________
46-4 3/8 Washer, Flat 3/8" ID 4 "
___________________________________________________________________
___________________________________________________________________
46-6 3/8 x 3/16 Spacer, 3/8" ID x 3/16" Long 2 "
___________________________________________________________________
46-7 TM1-4-5037 Bracket, Park Brake - Weldment 1 "
___________________________________________________________________
46-8 ½ Nut, Nylon Lock - Low Profile, ½" ID 1 "
___________________________________________________________________
46-9 3/8 x 1¼ Pin, Clevis Ø 3/8 x 1¼" Long 1 "
___________________________________________________________________
46-10 1/8 x ¾ Pin, Cotter Ø 1/8 x ¾" Long 4 "
___________________________________________________________________
46-11 MD-CB1-129 Yoke 1 "
___________________________________________________________________
46-12 3/8-24 x 2½ Rod, All Threaded Ø 3/8-24 x 2½" Long 1 "
___________________________________________________________________
46-13 3/8-24 Nut, Jam 3/8-24 1 "
___________________________________________________________________
___________________________________________________________________
46-15 5/16 x 1 Pin, Clevis Ø 5/16 x 1" Long 3 "
46-16 ------ Spacer (Transmission Kit) 1 "
46-17 9/16 Washer, Flat 9/16" ID 1 "
46-19 ½ Nut, Castle ½" ID 1 "
46-22 TPG-B9TZ-2A710D Cam & Lever Assembly 1 675 & Up
CD368 4-2-101
Rev 10
Chapter 4
23
6 2
2 5 3
4
7
4
10
11 12 18
13
17 19
9
14 20 15
2 15
2 21
3
16 14
22
4-2-102 CD368
Rev 10
Chapter 4
Fig & Tug Part

Ind Number
____________________________________________________________________
47-1 T6-8005-101 Lever, Hand Brake 1 101 & Up
____________________________________________________________________
47-2 3/8 Washer, Lock 3/8" ID 6 "
____________________________________________________________________
____________________________________________________________________
47-4 3/8 Washer, Flat 3/8" ID 5 "
____________________________________________________________________
____________________________________________________________________
47-6 3/8 x 3/16 Spacer, 3/8" ID x 3/16" Long 2 "
____________________________________________________________________
47-7 TM1-4-9850 Bracket, Park Brake Handle 1 3436 & Up
____________________________________________________________________
47-8 ½ Nut, Nylon Lock - Low Profile, ½" ID 1 101 & Up
____________________________________________________________________
47-9 3/8 x 1¼ Pin, Clevis Ø 3/8 x 1¼" Long 1 "
____________________________________________________________________
47-10 1/8 x ¾ Pin, Cotter Ø 1/8 x ¾" Long 4 "
____________________________________________________________________
47-11 MD-CB1-129 Yoke 1 "
____________________________________________________________________
47-12 3/8-24 x 2½ Rod, All Threaded Ø 3/8-24 x 2½" Long 1 "
____________________________________________________________________
47-13 3/8-24 Nut, Jam 3/8-24 1 "
____________________________________________________________________
____________________________________________________________________
47-15 5/16 x 1 Pin, Clevis Ø 5/16 x 1" Long 3 "
47-16 ------ Spacer (Transmission Kit) 1 "
47-17 9/16 Washer, Flat 9/16" ID 1 "
47-19 ½ Nut, Castle ½" ID 1 "
47-22 TPG-B9TZ-2A710D Cam & Lever Assembly 1 675 & Up
47-23 3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 1 3436 & Up
CD368 4-2-103
Rev 10
Chapter 4
Figure 2-48. Steering Column Assembly
4-2-104 CD368
Rev 10
Chapter 4
Table 2-48. Steering Column Assembly
Fig & Tug Part

Ind Number
48-1 M3-1-1059 Button, Horn - Two Wire, Isolated Ground 1 As Req'd
48-2 X4015-101 Nut, Column 1 "
48-3 14 GAUGE Spade, 14-Gauge, Female 2 "
48-4 660-1-1977 Wheel, 16" Steering 1 "
48-5 TM1-1-8334 Column, Steer 1 "
48-6 MG-1-585 Spacer, Steer Column 1 "
48-8 TM1-4-8070-6 Console Frame Assembly 1 "
48-9 ------ Rubber, 1½" x 8" 1 "
48-10 T6-5005-105 Clamp, Upper, Steer 1 "
48-11 3/8-16 Nut, Top Lock Hex 3/8-16 2 "
48-12 TM1-1-8092 Closeout, Steer Column 1 "
48-13 TM1-1-8090 Closeout, Steer Column 1 "
CD368 4-2-105
Rev 10
Chapter 4
20 1
19 2
3
18 4
17 5 6
16
15
14 9
11
13
8
12 7
10
Figure 2-49. Steer Valve Assembly (CharLynn)
4-2-106 CD368
Rev 10
Chapter 4
Table 2-49. Steer Valve Assembly (CharLynn)
Fig & Tug Part

Ind Number
49-1 TM1-1-8334 Column, Steer 1 As Req'd
49-3 TM1-4-8336 Bracket, Steer Valve Mounting 1 "
49-4 ½-20 Nut, Top Lock Hex ½-20 3 "
49-5 660-1-3028 Valve, Steer 1 "
49-6 TM1-ND-5266 Boss, Male 6JIC 45° 4 "
49-7 TM1-1-8328 Hose (Steering Valve T to Return) 1 "
49-8 TM1-1-8330 Hose (Steering Valve L to Cylinder) 1 "
49-9 TM1-1-8326 Hose (Steering Valve P to Booster) 1 "
49-10 660-1-2228 End, Tie Rod 1 "
49-11 TM1-1-8332 Hose (Steering Valve R to Cylinder) 1 "
49-12 TM1-2-8032 Cylinder, Power Steering - M1A 1 "
49-13 MD-SO1-140 End, Tie Rod - R/H 1 "
49-14 660-2501-06-06 Elbow, 90° Male, 2501-06-06 2 "
49-15 TM1-1-8256 Spacer, Steer Sector 1" 3 "
49-16 TM1-2-3026 Bracket, Steer Sector Mount 1 "
49-19 3/8 Washer, Flat 3/8" ID 4 "
49-20 3/8 Washer, Lock 3/8" ID 4 "
CD368 4-2-107
Rev 10
Chapter 4
Figure 2-50. Hydraulic System (CharLynn) - Deutz (Orig)
4-2-108 CD368
Rev 10
Chapter 4
Table 2-50. Hydraulic System (CharLynn) - Deutz (Orig)
Fig & Tug Part

Ind Number
50-1 T6-5011-101 Pump Assembly - Power Steering 1 Up to 633
50-2 T6-5011-108 Pulley, Power Steering - GM 1 "
50-3 660-1-1342 Hydro-Boost Assembly 1 "
50-4 TM1-1-8227 Hose, Steer Sector Return 1 "
50-5 TM1-1-8209 Tee, 3/8" Female Pipe 1 "
50-6 TM1-1-8210 Barb, 3/8" Hose 3 "
50-7 TM1-1-8332 Hose (Steering Valve R to Cylinder) 1 "
50-9 660-1-3028 Valve, Steer 1 "
50-10 M3-2-8027 Cylinder, Steer 1 "
50-11 TM1-1-8328 Hose (Steer Valve T to Return) 1 "
50-12 TM1-1-8326 Hose (Steer Valve P to Booster) 1 "
50-13 660-1-2228 End, Tie Rod 1 "
50-14 6F5OX Fitting, Straight-Thread Connector, Triple Lok 4 "
50-15 ------ Tubing, Rubber 3/8" ID Ref. "
50-16 TM1-1-8330 Hose (Steer Valve L to Cylinder) 1 "
50-17 ------ Clamp, Hose 5 "
CD368 4-2-109
Rev 10
Chapter 4
Figure 2-51. Hydraulic System (CharLynn) - Deutz (Rev 2)
4-2-110 CD368
Rev 10
Chapter 4
Table 2-51. Hydraulic System (CharLynn) - Deutz (Rev 2)
Fig & Tug Part

Ind Number
51-1 TM1-ND-8084 Pump, Hydraulic, Engine-Mounted 1 633 & Up
51-2 TM1-3-8002 Tank, Hydraulic Reservoir - M1A 1 "
51-3 660-1-1342 Hydro-Boost Assembly 1 "
51-4 TM1-ND-1018 Barb, Hose, Male Adapter, 3/8" 2 "
51-5 TM1-ND-6509 Elbow, Pump Inlet 1 "
51-6 TM1-ND-8003 Elbow, Pump Outlet 1 "
51-7 TM1-1-8332 Hose (Steer Valve R to Cylinder) 1 "
51-9 660-1-3028 Valve, Steer 1 "
51-10 TM1-2-8032 Cylinder, Power Steering - M1A 1 "
51-11 TM1-1-8328 Hose (Steering Valve T to Return) 1 "
51-12 TM1-1-8326 Hose (Steering Valve P to Booster) 1 "
51-13 660-1-2228 End, Tie Rod 1 "
51-14 TM1-ND-5266 Boss, Male 6JIC 45° 4 "
51-15 TM1-1-8330 Hose (Steering Valve L to Cylinder) 1 "
51-16 ------ Clamp, Hose 5 "
51-18 TM1-ND-6510 Hose, 12FJ-12FJ (Reservoir to Pump Inlet) 1 "
51-19 TM1-ND-8006 Hose, 18" OAL 1 "
51-20 TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ6-7MI 1 "
51-21 TM1-1-8226 Hose, Hydraulic Ø 3/8" x 22" Long 1 "
51-22 660-4-0010-20 Valve, Relief 1 "
51-23 TM1-ND-8011 Adapter, 6FX-6MP 1 "
51-24 TM1-ND-8009 Hose, Hydraulic, 10" OAL 1 "
51-25 ------ Fitting, Straight Connector 1 "
51-26 660-2501-06-06 Elbow, 90° Male, 2501-06-06 2 "
51-27 TM1-ND-6508 Elbow, Reservoir Outlet, 12MJ-12MP90 1 "
51-28 TM1-ND-8011 Adapter, 6FX-6MP 1 "
51-29 TM1-ND-8014 Tee, Relief Valve, M1A 1 "
51-31 TM1-ND-8010 Plug, ¼MP, Brass 1 "
CD368 4-2-111
Rev 10
Chapter 4
SET TO 850 PSI
Figure 2-52. Hydraulic System - Deutz (Rev 8)
4-2-112 CD368
Rev 10
Chapter 4
Table 2-52. Hydraulic System - Deutz (Rev 8)
Fig & Tug Part

Ind Number
52-1 660-4-0013-11 Cap, Filler 1 562 & Up
52-2 TM1-2-8008 Dipstick, Hydraulic Reservoir Cap - M1A 1 750 & Up
52-3 TM1-3-8002 Tank, Hydraulic Reservoir - M1A 1 562 & Up
52-4 3/8-16 Nut, Top Lock Hex 3/8-16 4 "
52-5 5/16 Washer, Flat 5/16" ID 8 "
52-6 TM1-ND-6508 Elbow, Reservoir Outlet, 12MJ-12MP90 1 930 & Up
TM1-ND-8001 Elbow, Reservoir Outlet, 8MT-8NP90 (to Pump) 1 562-929
52-7 TM1-ND-8016 Plug, Magnetic Drain - Hydraulic Reservoir 1 704 & Up
52-8 TM1-4-8039 Bracket, Hydraulic Reservoir Mounting - Weldment 1 562 & Up
52-10 TM1-ND-8009 Hose, Hydraulic, 10" OAL (Relief to Tank) 1 "
52-11 TM1-ND-1018 Nipple, Adapter 2 "
52-12 ------ Clamp, Hose 2 "
52-13 ------ Hose, Hydraulic Ø 5/16" ID (Fuel Line) 1 "
52-14 660-1-1342 Hydro-Boost Assembly 1 101 & Up
52-15 TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ6-7MI (Relief to Hydro-Boost) 1 562 & Up
52-16 ------ Clamp, Hose 1 "
52-17 TM1-ND-8010 Plug, ¼MP, Brass 1 "
52-18 TM1-ND-8014 Tee, Relief Valve, M1A 1 "
52-19 TM1-1-8228 Hose, Power Steering 1 101 & Up
TM1-1-8328 Hose (Steer Valve T to Return) 1 As Req'd
52-20 TM1-ND-8011 Adapter, 6FX-6MP 1 562 & Up
52-21 ¼-20 Nut, Top Lock Hex ¼-20 2 "
52-22 660-4-0010-20 Valve, Relief 1 "
52-23 ¼-20 x 1¾ Bolt, Hex Head Ø ¼-20 x 1¾" Long 2 "
52-24 TM1-2-8030 Bracket, Mounting - Hydraulic Bypass 1 "
52-27 TM1-ND-8006 Hose, 18" OAL (Pump to Relief) 1 "
52-28 TM1-ND-8003 Elbow, Pump Outlet 1 "
52-29 M10-1.5 x 30 Bolt, Metric Ø M10-1.5 x 30mm Long 2 "
52-30 M10 Washer, Lock Metric 10mm 2 "
52-31 M10 Washer, Flat Metric 10mm 2 "
52-32 TM1-ND-8084 Pump, Hydraulic, Engine-Mounted 1 "
52-33 TM1-ND-6509 Elbow, Pump Inlet 1 930 & Up
TM1-ND-8002 Elbow, Pump Inlet 1 562-929
52-34 TM1-ND-6510 Hose, 12FJ-12FJ (Reservoir to Pump Inlet) 1 930 & Up
52-35 TM1-1-8223 Hose, Hydraulic, 3/8" x 29" Long 1 101 & Up
TM1-1-8326 Hose (Steer Valve P to Booster) 1 As Req'd
CD368 4-2-113
Rev 10
Chapter 4
Figure 2-53. Hydraulic Power Take-Off - Deutz
4-2-114 CD368
Rev 10
Chapter 4
Table 2-53. Hydraulic Power Take-Off - Deutz
Fig & Tug Part

Ind Number
53-1 660-1-2345 Sleeve, Spline Shaft Extender 1 633 & Up
53-2 660-1-2344 Extender, Spline Shaft - Deutz Hydraulic Pump 1 "
53-3 TM1-ND-5270 Housing, Rear - PTO 1 "
53-4 TM1-ND-5272 Bearing, Hydraulic Pump - PTO 1 "
53-5 TM1-ND-5273 Belt, Toothed - Hydraulic PTO 1 "
53-6 TM1-ND-5274 Gear, Drive Belt - Hydraulic Drive PTO 1 "
53-7 TM1-ND-5271 Housing, Front - PTO 1 "
53-8 TM1-ND-5275 Cap, Drive Gear - PTO 1 "
CD368 4-2-115
Rev 10
Chapter 4
Figure 2-54. Front (Steer) Axle Assembly (Rev 2)
4-2-116 CD368
Rev 10
Chapter 4
Table 2-54. Front (Steer) Axle Assembly (Rev 2)
Fig & Tug Part

Ind Number
54-1 TM1-ND-8079-1 Axle, Front - Brierton without Brakes 1 615 & Up
54-2 TM1-2-8087 Spring, Leaf - Heavy Duty 2 "
54-3 TM1-1-6541 U-Bolt, Front Axle - M1A 4 "
54-4 TM1-2-8086 Plate, U-Bolt - Front Suspension 2 "
54-5 9/16-18 Nut, Top Lock Hex 9/16-18 8 "
54-6 TM1-2-8085 Shackle, Front Suspension 2 "
54-8 5/8-11 Nut, Top Lock Hex 5/8-11 6 "
54-9 TM1-2-8010 Plate, U-Bolt, Upper 2 702 & Up
CD368 4-2-117
Rev 10
Chapter 4
Figure 2-55. Front (Steer) Axle Assembly (Rev 3)
4-2-118 CD368
Rev 10
Chapter 4
Table 2-55. Front (Steer) Axle Assembly (Rev 3)
Fig & Tug Part

Ind Number
55-1 TM1-4-9510 Crossmember, CharLynn Weld-In 1 As Req'd
55-2 5/8-11 x 6 Bolt, Hex Head Ø 5/8-11 x 6" Long 2 101 & Up
55-3 5/8-11 Nut, Top Lock Hex 5/8-11 6 "
55-5 TM1-2-8085 Shackle, Front Suspension 2 615 & Up
55-6 TM1-2-8087 Spring, Leaf - Heavy Duty 2 1250 & Up
MH-1-806 Bushing, Suspension 1-19/32 x 5/ 8 x 2 4 615 & Up
55-7 TM1-1-6541 U-Bolt, Front Axle - M1A 4 1277 & Up
55-8 TM1-2-8010 Plate, U-Bolt, Upper 2 1050 & Up
55-9 TM1-ND-8079-1 Axle, Front - Brierton without Brakes 1 615 & Up
55-10 TM1-2-8086 Plate, U-Bolt - Front Suspension 2 "
55-11 9/16-18 Nut, Pipe Thread Lock 9/16-18 8 101 & Up
55-12 TM1-4-8083 Crossmember, Front - Weldment 1 "
CD368 4-2-119
Rev 10
Chapter 4
11
10 12
6a
13
6b
5
2 14
15 16
20 17
19
3
18
1 4
Figure 2-56. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 9)
4-2-120 CD368
Rev 10
Chapter 4
Table 2-56. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 9)
Fig & Tug Part

Ind Number
56-1 TM1-ND-8079-1 Axle, Front - Brierton without Brakes 1 As Req'd
56-2 TM1-ND-8090 Nut, Jam ¼-13 HX 2 "
56-3 TM1-ND-8089 Screw, ½-13 x 2" Long 2 "
56-4 TM1-ND-8093 Shim, King Pin 2 "
56-5 440E-46006 Bearing, Thrust - Timken T113 2 "
56-6a TM1-ND-9700 Knuckle Weldment, R/H 1 "
56-6b TM1 ND-9701 Knuckle Weldment, L/H 1 "
56-7 440E-46007 Pin, King KB423 2 "
56-8 TM1-ND-8097 Bushing, 1.235 OD x 1.1 ID - M1A 4 "
56-9 TM1-ND-8099 Gasket, King Pin Cover 4 "
56-10 T6-3001-60005 Cap, King Pin 4 "
56-11 T6-3001-60006 Screw, Button Head 8 "
56-12 ------ Washer, Lock #10 8 "
56-13 TM1-ND-9008 Hub, M1A 2 "
56-14 TM1-ND-9011 Bearing and Race - Outer 2 "
56-15 T6-3001-6002 Washer, Tongued Spindle 2 "
56-16 TM1-ND-9698 Pin, Cotter 3/16 x 2" Long 2 "
56-17 TM1-ND-9697 Nut, Hex Spindle 1-14, 12 Slotted 2 "
56-18 T6-3001-60031 Cap, Grease 2 "
56-19 440E-46009 Nut, Tapered Wheel ½-20 UNF 10 "
56-20 T6-3001-60020 Stud, Wheel 10 "
CD368 4-2-121
Rev 10
Chapter 4
11
4 12
10
8 25
13
7 14
15
6 16
17
2
21 22
3
5
4
18
19
20
1 23
24
2
3
Figure 2-57. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 10)
4-2-122 CD368
Rev 10
Chapter 4
Table 2-57. Knuckle and Hub Assembly - Front (Steer) Axle (Rev 10)
Fig & Tug Part

Ind Number
57-1 TM1-ND-8079-1 Axle, Front - Brierton Without Brakes 1 As Req'd

57-2 T6-3001-60012 Nut, ½-13 UNC, Hex 2 "
57-3 TM1-ND-8089 Bolt, Hex Head Ø ½-13 x 1½" Long 2 "
57-4 T6-3001-60005 Cap, King Pin 4 "
57-5 TM1-ND-8093 Shim, King Pin 2 As Req'd
57-6 T6-3001-601-5 Bearing, Spindle 2 2119 & Up
57-7 T6-3001-60002 Knuckle, Assembly, L/H 1 "
T6-3001-601-3 Knuckle, Assembly, R/H 1 "
57-8 TM1-ND-8098 Pin, King 2 "
57-9 TM1-ND-8097 Bushing, Bronze 2 As Req'd
57-10 TM1-ND-8099 Gasket, King Pin Cover 4 "
57-11 T6-3001-60006 Screw, Button Head, 10-24 UNC x 5/8 Long 8 "
57-12 ------ Washer, Lock, #10 8 "
57-13* TM1-ND-9002 Seal, Grease, Q-623 2 "
57-13* ** Bearing, Inner Wheel 2 "
57-13* ** Race, Inner Wheel Bearing 2 "
57-16 MX4-10067-7 Hub, Cupped and Studded 2 "
57-17* T6-3001-601-2 Stud, Wheel, ½-20 UNF x 1 7/8 10 2119 & Up
57-18 440E-46009 Nut, Lug, ½-20 UNF Tapered Hex 10 As Req'd
57-19* *** Race, Outer Wheel Bearing 2 "
57-20* *** Bearing, Outer Wheel 2 "
57-21 T6-3001-60028 Washer, Spindle, 1" 2 "
57-22 T6-3001-60030 Pin, Cotter 2 "
57-23 TM1-ND-9013 Nut, Spindle, 1-14 UNF Slotted Hex 2 "
57-24* T6-3001-60031 Cap, Grease 2 "
57-25 T6-3001-601-4 Zerk, Grease 4 "
* Part of T6-3001-60025.
**Part of TM1-ND-9003 Inner Bearing and Race Assembly.
***Part of TM1-ND-9011 Outer Bearing and Race Assembly.
CD368 4-2-123
Rev 10
Chapter 4
1a 1
6 1b
2
5
4
3
Figure 2-58. Tie Rod Assembly - Front (Steer) Axle
4-2-124 CD368
Rev 10
Chapter 4
Table 2-58. Tie Rod Assembly - Front (Steer) Axle
Fig & Tug Part

Ind Number
58-1 TM1-ND-8079-11 Tube Assembly, Tie Rod 1 As Req'd
58-1a TM1-ND-8088 End, Tie Rod - L/H 1 "
58-1b TM1-ND-8087 End, Tie Rod - R/H 1 "
58-2 TM1-ND-8079-1 Axle, Front - Brierton without Brakes 1 "
58-3 ------ Nut, Castellated 2 "
58-4 ------ Screw, Socket Head Ø 3/8-24 x ¾" Long 2 "
58-5 ------ Nut, Jam ½-13 HX 2 "
58-6 TM1-ND-9702 Zerk, Grease 4 "
CD368 4-2-125
Rev 10
Chapter 4
Figure 2-59. Rear Suspension (Rev 2)
4-2-126 CD368
Rev 10
Chapter 4
Table 2-59. Rear Suspension (Rev 2)
Fig & Tug Part

Ind Number
59-1 TM1-4-3503 Crossmember, Cradle, M1 Universal - Weldment 1 101 & Up
59-2 TM1-1-3506 Bushing, Rear Cradle 2 "
59-3 TM1-1-3508 Washer, Thrust 2 "
59-4 TM1-4-3504 Cradle Assembly, Rear 1 Up to 2094
TM1-4-3504 Cradle Assembly, Rear (Modified) 1 2094 - 2666
TM1-4-3504 Cradle Assembly, Rear (Modified) 1 2667 & Up
59-5 T6-2002-301 U-Bolt, Rear Axle 2 101 & Up
59-6 TM1-1-3512 Spring, Rear, 13" x 400 lb., Red Coil 2 "
59-7 TM1-0-8130 Shock, with Stud 2 "
59-8 TM1-4-3516 Mount, Spring - Driver Side Rear 1 "
59-9 TM1-1-5061 Bolt, Universal Cradle Crossmember, M1A 1 "
59-10 TM1-1-8160 Bracket, Upper Chain 1 "
59-11 ------ Chain, ¼" Ref. "
59-12 TM1-4-3518 Mount, Spring - Passenger Side Rear 1 "
59-13 TM1-2-5035 Plate, Backing - Drive Axle Pad 2 "
59-14 TM1-2-9063 Pad, Drive Axle Mount - L/H 2 "
CD368 4-2-127
Rev 10
Chapter 4
Figure 2-60. Rear Suspension (Rev 3) (Up to S/N 2094)
4-2-128 CD368
Rev 10
Chapter 4
Table 2-60. Rear Suspension (Rev 3) (Up to S/N 2094)
Fig & Tug Part

Ind Number
60-2 TM1-1-3512 Spring, Rear, 13" x 400 lb., Red Coil 2 101 & Up
60-3 TM1-0-8130 Shock, with Stud 2 Up to 2667
60-6 ½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 8 "
60-7 3/8-16 Nut, Top Lock Hex 3/8-16 6 "
60-10 3/8 Washer, Flat 3/8" ID 12 "
60-11 ------ Chain, Steel, Ø 3/8" x 11" Long, with 9" Heat Shrink 2 "
60-12 ½-13 Nut, Top Lock Hex ½-13 10 "
CD368 4-2-129
Rev 10
Chapter 4
Figure 2-61. Rear Suspension (Rev 4) (S/N 2094 thru 2666)
4-2-130 CD368
Rev 10
Chapter 4
Table 2-61. Rear Suspension (Rev 4) (S/N 2094 thru 2666)
Fig & Tug Part

Ind Number
61-1 TM1-4-3504 Cradle Assembly, Rear (Revised) 1 2094-2666
61-2 TM1-1-3512 Spring, Rear 13" x 400 lb. - Red Coil 2 101 & Up
61-3 TM1-0-8130 Shock, with Stud 2 Up to 2667
61-6 ½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 8 "
61-7 3/8-16 Nut, Top Lock Hex 3/8-16 6 "
61-10 3/8 Washer, Flat 3/8" ID 12 "
61-11 ------ Chain, Steel Ø 3/8" x 11" Long, with 9" Heat Shrink 2 "
61-12 ½-13 Nut, Top Lock Hex ½-13 10 "
CD368 4-2-131
Rev 10
Chapter 4
12
13 10 9
3
8 7
9
6
5 11
6 7 5
4
10
3
3 9
17
2
2 1
10
16
15
14
7
12
5
Figure 2-61a. Rear Suspension (Rev 7) (S/N 2667 & Up)
4-2-132 CD368
Rev 10
Chapter 4
Table 2-61a. Rear Suspension (Rev 7) (S/N 2667 & Up)
Fig & Tug Part

Ind Number
61a-1 TM1-4-3504 Cradle Assembly, Rear (Revised) 1 2667 & Up
61a-2 TM1-1-3512 Spring, Rear 13" x 400 lb. - Red Coil 2 101 & Up
61a-3 TM1-0-8130 Shock, with Stud 2 2667 & Up
61a-4 TM1-4-3518 Mount, Spring - Passenger Side Rear 1 "
61a-5 ½ Washer, Flat ½" ID 20 "
61a-6 ½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼" Long 8 "
61a-7 3/8-16 Nut, Top Lock Hex 3/8-16 6 "
61a-8 TM1-1-8160 Bracket, Upper Chain 2 "
61a-9 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 6 "
61a-10 3/8 Washer, Flat 3/8" ID 12 "
61a-11 ------ Chain, Steel Ø 3/8" x 11" Long, with 9" Heat Shrink 2 "
61a-12 ½-13 Nut, Top Lock Hex ½-13 10 "
61a-13 TM1-4-3516 Mount, Spring - Driver Side Rear 1 "
61a-14 ½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½" Long 2 "
61a-15 TM1-1-5061 Bolt, Universal Cradle Crossmember 1 "
61a-16 1 Washer, Flat 1" ID 4 "
61a-17 1-8 Nut, Top Lock Hex 1-8 1 "
CD368 4-2-133
Rev 10
Chapter 4
9 8 3
7 5
2
4 2
4
10 1
18
3
3
17
6
11
12
13
14 16
15
Figure 2-62. Rear (Drive) Axle Installation
4-2-134 CD368
Rev 10
Chapter 4
Table 2-62. Rear (Drive) Axle Installation
Fig & Tug Part

Ind Number
62-1 T6-9011-621-1 Axle, Rear Drive 14:1 without Mount 1 3041 & Up
T6-9011-622-1 Axle, Rear Drive 20:1 without Mount - Opt 1 As Req'd
62-3 T6-8013-143 Hose, Brake 4 101 & Up
62-4 T6-8013-145 Bolt, Brake Hose 4 "
62-5 T6-8013-147 Washer, Brake Hose 8 "
62-6 TM1-3-3500 Mount, Drive Axle, R/H 1 "
62-7 3/8 Washer, Lock 3/8" ID - High Alloy 4 "
62-8 3/8-24 Nut, Top Lock Hex 3/8-24 4 "
62-9 TM1-1-0804 Shaft, Drive 1 "
62-10 T6-2001-135 Breather 1 "
62-11 TM1-3-3502 Mount, Drive Axle, L/H 1 "
62-12 TM1-4-3504 Cradle Assembly, Rear (Revised) 1 2667 & Up
62-13 TM1-2-5035 Plate, Drive Axle Pad 2 952 & Up
62-14 7/16 Washer, Flat 7/16" ID 4 101 & Up
62-15 3/8-24 Nut, Top Lock Hex 3/8-24 4 "
62-16 TM1-2-9063 Pad, Drive Axle Mount - L/H 2 810 & Up
TM1-2-9062 Pad, Drive Axle Mount - R/H (Opt.) 1 As Req'd
TM1-2-9063 Pad, Drive Axle Mount - L/H (Opt.) 1 "
62-17 M10 Washer, Flat 10mm 4 101 & Up
62-18 T6-2006-103P Bolt, Spicer 4 "
CD368 4-2-135
Rev 10
Chapter 4
Figure 2-63. Rear (Drive) Axle Assembly (Orig)
4-2-136 CD368
Rev 10
Chapter 4
Table 2-63. Rear (Drive) Axle Assembly (Orig)
Fig & Tug Part

Ind Number
63- TM1-0-8105 Axle, Rockwell Rear - M1 -- 101 & Up
TM1-1-9778 Axle, Drive 14:1 -- 2667 & Up
TM1-1-9775 Axle, Drive 20:1 - Opt. -- As Req'd
63-1 T6-2001-602 Differential and Axle Housing Assembly, R/H 1 101 & Up
63-2 T6-2001-601 Differential and Axle Housing Assembly, L/H 1 "
63-3 T6-2001-603 Shaft, Short Axle 1 "
63-4 T6-2001-604 Shaft, Long Axle 1 "
63-5 T6-2001-151 Race, Differential Bearing 2 "
63-6 T6-2001-107 Bearing 2 "
63-7 T6-2001-109 Case, Differential Flange & Tongue 1 "
63-8 T6-2001-291 Bolt Kit 1 "
63-9 T6-2001-111 Ring & Pinion Set - 14:1 Ratio 1 "
63-10 T6-2001-119 Washer, Thrust 2 "
63-11 T6-2001-121 Gear, Side (Gear Kit: Side Gears and Pinions) 2 "
63-12 T6-2001-121 Pinion (Gear Kit: Side Gears and Pinions) 4 "
63-13 T6-2001-127 Washer, Pinion Thrust 4 "
63-14 T6-2001-131 Screw, Cap - Differential and Gear Assembly 8 "
63-15 T6-2001-155 Block, Thrust - Bevel Gear 1 "
63-16 T6-2001-153 Pin, Bevel Gear Thrust Block 1 "
63-17 T6-2001-207 Gasket, Oil Seal (RTV Sealant) 1 "
63-18 T6-2001-145 Bolt, Hex Head 11 "
63-19 T6-2001-149 Nut, Lock 11 "
63-20 T6-2001-147 Washer, Flat 11 "
63-21 T6-2001-143 Plug, Lubricant Fill 1 "
63-22 T6-2001-137 Plug, Lubricant Drain 1 "
63-23 T6-2001-193 Gasket, Bevel Pinion Cage 1 "
63-24 T6-2001-195 Ring, Lock 1 "
63-25 T6-2001-197 Bearing, Bevel Pinion Pilot 1 "
63-26 T6-2001-201 Cup, Pinion Bearing 2 "
63-27 T6-2001-199 Bearing, Pinion 2 "
63-28 T6-2001-135 Breather 1 "
63-29 T6-2001-209 Spacer, Axle 1 "
CD368 4-2-137
Rev 10
Chapter 4
Figure 2-63. Rear (Drive) Axle Assembly (Orig) (Cont'd)
4-2-138 CD368
Rev 10
Chapter 4
Table 2-63. Rear (Drive) Axle Assembly (Orig) (Cont'd)
Fig & Tug Part

Ind Number
63-30 T6-2001-203 Cage, Pinion Bearing 1 101 & Up
63-31 T6-2001-205 Dowel 1 "
63-32 T6-2001-605 Rotor 2 "
63-33 T6-8003-601 Hub, Rear 2 "
63-34 T6-2001-165 Collar, Bearing Spacer 2 "
63-35 T6-2001-167 Race 4 "
63-36 T6-2001-169 Bearing, Drive Axle (Inner & Outer) 4 "
63-37 T6-2001-171 Shim, Drive Axle 2 "
63-38 T6-2001-173 Retainer 2 "
63-39 T6-2001-175 Gasket, Oil Seal Retainer 2 "
63-40 T6-2001-177 Retainer, Oil Seal 2 "
63-41 T6-2001-181 Bolt, Retainer 12 "
63-42 T6-2001-179 Washer, Lock 12 "
63-43 T6-2001-189 Nut, Axle 2 "
63-44 T6-2001-187 Washer, Axle Nut 2 "
63-45 K2418 Pin, Cotter 2 "
63-46 T6-2001-607 Stud, Rear Axle 16 "
63-47 T6-3003-105 Nut, Lug ½-20 THD, Ford 16 "
CD368 4-2-139
Rev 10
Chapter 4
Figure 2-64. Rear (Drive) Axle Assembly (Rev 3)
4-2-140 CD368
Rev 10
Chapter 4
Table 2-64. Rear (Drive) Axle Assembly (Rev 3)
Fig & Tug Part

Ind Number
64-1 TM1-0-8105 Axle, Rockwell Rear - M1 1 101 & Up
TM1-1-9778 Axle, Drive 14:1 1 2667 - 3040
T6-9011-621-1 Axle, Rear, Drive 1 3041 & Up
TM1-1-9775 Axle, Drive 20:1 - Opt. 1 As Req'd
64-3 T6-8013-143 Hose, Brake 4 101 & Up
64-4 T6-8013-145 Bolt, Brake Hose 4 "
64-5 7/16 Washer, Lock 7/16" ID 2 "
64-6 7/16-14 Nut, Top Lock Hex 7/16-14 2 "
64-7 3/8 Washer, Lock 3/8" ID - High Alloy 4 "
64-8 3/8-24 Nut, Top Lock Hex 3/8-24 4 "
64-9 TM1-1-0804 Shaft, Drive (Deutz, Perkins) 1 "
T6-7200-090 Shaft, Drive (Ford) 1 "
64-10 TM1-3-9558 Mount, Panhard Rod 1 "
TM1-4-3504 Cradle Assembly, Rear (Revised) 1 2094-2666
TM1-4-3504 Cradle Assembly, Rear (Revised) 1 2667 & Up
64-12a TM1-1-3502 Tube, Pivot - Rear Cradle 1 101 & Up
64-12b TM1-1-9582 Brace, Cradle Plate, L/H 1 "
64-12c TM1-1-3503 Mount, Rear Cradle Shock 4 "
64-12d TM1-1-3526 Mount, Lower Rear Cradle Chain 2 "
64-12e TM1-1-9579 Brace, Cradle Plate, R/H 1 "
64-12f TM1-1-3501 Spring, Seat - Rear Cradle 2 "
64-12g TM1-4-3505 Plate, Rear Cradle 1 "
64-13 TM1-2-5035 Plate, Drive Axle Pad 2 952 & Up
64-14 7/16 Washer, Flat 7/16" ID 4 101 & Up
64-15 3/8-24 Nut, Top Lock Hex 3/8-24 4 "
64-16 TM1-2-9063 Pad, Drive Axle Mount - L/H 2 810 & Up
64-17 M10 Washer, Flat 10mm 4 101 & Up
64-18 T6-2006-103P Bolt, Spicer 4 "
64-19 T6-2001-135 Breather 1 "
64-20 TM1-3-3502 Mount, Drive Axle, L/H 1 3041 & Up
64-21 TM1-3-3500 Mount, Drive Axle, R/H 1 "
CD368 4-2-141
Rev 10
Chapter 4
14 15 49
3 2 50
16 51 52
8
58
7 57
59
13 60
6 53
12 7
54 61
11 55
10 6 62
8 5 56
17
9 64 63
15
6
18
7 19
20
28
22 21
1 4
48 23
24
47
27 25
46 26
45 29
44 31 30
43 32 24
34
33
35
35 36
41 38
37
42 40
39
30 28
Figure 2-65. Rear (Drive) Axle Assembly (Rev 10)
4-2-142 CD368
Rev 10
Chapter 4
Table 2-65. Rear (Drive) Axle Assembly (Rev 10)
Fig & Tug Part

Ind Number
65- T6-9011-621-1 Axle, Rear Drive, 14:1, without Mount -- 3041 & Up
65-1 T6-9011-621-6 Case, Differential Flange, Half 1 "
65-2 T6-9011-621-7 Case, Differential Plain, Half 1 "
65-3 T6-2001-603 Shaft, Short Axle 1 "
65-4 T6-2001-604 Shaft, Long Axle - Opt. 1 "
65-5 T6-9011-621-11 Cup, Bearing 1 "
65-6* T6-9011-621-12 Flange & Tongue Differential Assembly 1 "
65-7* T6-2001-109 Case, Differential Flange & Tongue 1 "
65-8 T6-2001-107 Bearing 2 "
65-9 T6-9011-621-8 Gear, Set, 14:1 1 "
65-10 T6-2001-291 Bolt Kit 1 "
65-11 T6-2001-135 Breather - Oil 1 "
65-12 T6-2001-153 Pin, Bevel Gear Thrust Block 1 "
65-13 T6-2001-155 Block, Thrust - Bevel Gear 1 "
65-14 T6-2001-149 Locknut 11 "
65-15 T6-2001-147 Washer, Flat 22 "
65-16 T6-9011-621-11 Cup, Bearing 1 "
65-17 T6-9011-621-13 Gasket, Oil Seal 1 "
65-18 T6-2001-145 Bolt, Hex Head 11 "
65-19 T6-9011-621-14 Plug 1 "
65-20 T6-2001-193 Gasket, Bevel Pinion Cage 1 "
65-21 T6-2001-195 Ring, Snap, E25.4 X 1.57 CS 1 "
65-22 T6-9011-621-22 Bearing 1 "
65-23 T6-2001-199 Bearing, Pinion. Inner 1 "
65-24 T6-2001-201 Cup, Pinion Bearing 2 "
65-25 T6-9011-621-15 Shim, Pack 1 "
65-26 T6-2001-203 Cage, Pinion Bearing 1 "
65-27 ------ Stud, .56-18FX.81/.56-12NCX.63/2.31 6 "
65-28 T6-9011-621-16 Gear Case Assembly 1 "
65-29 T6-9011-621-17 Gear Case 1 "
65-30 T6-9011-621-18 Plug 2 "
65-31 T6-2001-199 Bearing, Pinion. Outer 1 "
CD368 4-2-143
Rev 10
Chapter 4
14 15 49
3 2 50
16 51 52
8
58
7 57
59
13 60
6 53
12 7
54 61
11 55
10 6 62
8 5 56
17
9 64 63
15
6
18
7 19
20
28
22 21
1 4
48 23
24
47
27 25
46 26
45 29
44 31 30
43 32 24
34
33
35
35 36
41 38
37
42 40
39
30 28
Figure 2-65. Rear (Drive) Axle Assembly (Rev 10) - Con't.
4-2-144 CD368
Rev 10
Chapter 4
Table 2-65. Rear (Drive) Axle Assembly (Rev 10) - Con't.
Fig & Tug Part

Ind Number
65-32 T6-2001-211 Washer, Keyway 1 3041 & Up
65-33 T6-2001-323 Gear, Driven 1 "
65-34 T6-2001-223 Key, Gear 1 "
65-35 T6-2001-225 Nut, Bevel Pinion Bearing 1 "
65-36 T6-2001-227 Lock, Bevel Pinion Bearing Nut 1 "
65-37 T6-2001-257 Gasket, Reduction Gear 1 "
65-38 T6-2001-263 Dowel, Gear Box Cover 2 "
65-39 T6-9011-621-19 Cover, Gear Case 1 "
65-40 ------ Bolt, .38-24UNFX1.50/1.00 HHCS 15 "
65-41 MJ-ND-2001-49 Washer 4 "
65-42 ------ Bolt, .38-16UNCX1.00/1.00 HHCS 4 "
65-43 T6-2001-329 Cap, Rear Input Shaft Bearing 1 "
65-44 ------ Silastic 1 "
65-45 T6-2001-255 Ring, Snap, Input Shaft Bearing 1 "
65-46 T6-2001-325 Bearing, Rear Input Shaft 1 "
65-47 T6-2001-321 Gear, Input 1 "
65-48 T6-9011-621-20 Bearing 1 "
65-49 T6-2001-609 Rotor, 12.625"OD, .898"Wide 2 "
65-50 T6-2001-607 Stud, Rear Axle, MA 16 "
65-51 T6-2001-165 Colar, Bearing Spacer 2 "
65-52 T6-2001-167 Race 4 "
65-53 T6-2001-165 Bearing, Drive Axle (Inner & Outer) 4 "
65-54 T6-2001-175 Gasket, Oil Seal Retainer 2 "
65-55 T6-2001-173 Retainer 2 "
65-56 T6-2001-177 Retainer, Oil Seal 2 "
65-57 T6-2001-175 Shim, Drive Axle 6 "
65-58 T6-2001-179 Washer, Lock 6 "
65-59 T6-2001-181 Bolt .38-16UNCX1.25/1.00 HHCS 6 "
65-60 T6-2001-606 Hub 2 "
65-61 T6-9011-621-21 O-Ring 2 "
65-62 K2418 Pin, Cotter 2 "
65-63 T6-2001-189 Nut, Axle 2 "
65-64 T6-2001-187 Washer, Axle Nut 2 "
CD368 4-2-145
Rev 10
Chapter 4
Figure 2-66. Reduction Gear Box Assembly
4-2-146 CD368
Rev 10
Chapter 4
Table 2-66. Reduction Gear Box Assembly
Fig & Tug Part

Ind Number
66-1 T6-2001-327 Case and Cover, Reduction Gear 1 101 & Up
66-2 T6-2001-217 Washer, Gear Case to Axle 6 "
66-3 T6-2001-219 Nut, Gear Case to Axle 6 "
66-4 T6-2001-257 Gasket, Reduction Gear Case 1 "
66-5 7/16-14 x 1¾ Bolt, Gear Box Cover 15 "
66-6 7/16 Washer, Lock 7/16" ID Ref. "
66-7 7/16-14 Nut, Lock - Gear Box Cover 15 "
66-8 T6-2001-263 Dowel, Gear Box Cover 2 "
66-9 T6-2001-265 Plug, Fill - Gear Box Oil 1 "
66-10 T6-2001-245 Plug 1 "
66-11 T6-2001-323 Gear, Driven 1 "
66-12 T6-2001-223 Key, Gear 1 "
66-13 T6-2001-227 Nut, Lock - Bevel Pinion Bearing 1 "
66-14 T6-2001-225 Nut, Bevel Pinion Bearing 2 "
66-15 T6-2001-267 Gasket, Rear Input Shaft Cap 1 "
66-16 T6-2001-329 Cap, Rear Input Shaft 1 "
66-17 7/16 Washer, Lock 7/16" ID Ref. "
66-18 T6-2001-273 Screw, Cap - Rear Input Shaft Cover 4 "
66-19 T6-2001-255 Ring, Snap - Input Shaft Bearing 1 "
66-20 T6-2001-325 Bearing, Rear Input Shaft 1 "
66-21 T6-2001-247 Bearing, Input Shaft, Front 1 "
66-22 T6-2001-321 Gear, Input 1 "
66-23 T6-2001-235 Seal, Oil - Input Shaft 1 "
66-24 T6-2001-233 Flange, Input Shaft 1 "
66-25 T6-2001-231 Washer, Input Shaft 1 "
66-26 T6-2001-281 Nut, Input Shaft 1 "
CD368 4-2-147
Rev 10
Chapter 4
Figure 2-67. Drive Shaft
4-2-148 CD368
Rev 10
Chapter 4
Table 2-67. Drive Shaft
Fig & Tug Part

Ind Number
67-1 TM1-1-0804 Shaft, Drive (Deutz, Perkins) 1 As Req'd

67-2 T6-2006-107 U-Joint, Front 1 "
67-3 T6-2002-107 U-Joint, Rear 1 "
67-4 T6-2006-111 End, Flange Yoke 1 "
CD368 4-2-149
Rev 10
Chapter 4
Figure 2-68. Panhard Arm Assembly
4-2-150 CD368
Rev 10
Chapter 4
Table 2-68. Panhard Arm Assembly
Fig & Tug Part

Ind Number
68-1 TM1-2-8120 Tube, Panhard Rod 1 101 & Up
68-2 TM1-1-8082 End, Panhard Rod 1 "
68-3 TM1-2-3024 Bracket, Panhard Arm 1 "
68-4 660-6-0582-26 Bumper, Rubber Lift Arm 2 "
68- T6-500-108 Grommet 1 "
68-6 9/16-12 Nut, Top Lock Hex 9/16-12 2 "
68-7 5/16-18 x 1¾ Bolt, Hex Head Ø 5/16-18 x 1¾" Long 4 "
68-8 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
68-9 ------ Nut, Jam 1 "
CD368 4-2-151
Rev 10
Chapter 4
Figure 2-69. Panhard Rod Installation (Up to S/N 2094)
4-2-152 CD368
Rev 10
Chapter 4
Table 2-69. Panhard Rod Installation (Up to S/N 2094)
Fig & Tug Part

Ind Number
69-1 ½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½" Long 2 As Req'd
69-2 ½ x 1¼ Washer, Flat ½" ID x 1¼" OD 2 "
69-3 TM1-2-3524 Tab, Panhard Arm 2 "
69-4 ½-13 Nut, Hex Crimp ½-13 2 "
69-6 TM1-2-8120W Tube, Panhard Assembly 1 "
69-6a TM1-2-8120 Tube, Panhard Rod 1 "
69-6b TM1-1-9554 End, Panhard Rod 1 "
69-7 TM1-3-9558 Mount, Panhard Rod 1 1630-2093
CD368 4-2-153
Rev 10
Chapter 4
Figure 2-70. Panhard Rod Installation (S/N 2094 & Up)
4-2-154 CD368
Rev 10
Chapter 4
Table 2-70. Panhard Rod Installation (S/N 2094 & Up)
Fig & Tug Part

Ind Number
70-1 ½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½" Long 2 As Req'd
70-2 ½ x 1¼ Washer, Flat ½" ID x 1¼" OD 2 "
70-3 TM1-1-9633 Bracket, Panhard Rod - Weldment 1 "
70-4 ½-13 Nut, Hex Crimp ½-13 2 "
70-6 TM1-2-8120W Tube, Panhard Assembly 1 "
70-6a TM1-2-8120 Tube, Panhard Rod 1 "
70-6b TM1-1-9554 End, Panhard Rod 1 "
70-7 TM1-1-9632 Tower, Panhard Rod - Weldment 1 2094 & Up
CD368 4-2-155
Rev 10
Chapter 4
Figure 2-71. Rear Brake Caliper Assembly (Up to S/N 2667)
4-2-156 CD368
Rev 10
Chapter 4
Table 2-71. Rear Brake Caliper Assembly (Up to S/N 2667)
Fig & Tug Part

Ind Number
71-1 T6-8013-181 Caliper, L/H Rear 1 Up to 2667

T6-8013-183 Caliper, R/H Rear 1 "
71-2 T6-8013-157 Piston 2 "
71-3 T6-8013-153 Boot Kit, Dust 2 "
71-4 T6-8013-149 Pads, Brake - Non-Organic 2 "
T6-8013-201 Pads, Brake - Organic 2 "
71-5 T6-8013-169 Clip, Retainer 2 "
71-6 T6-8013-159 Bolt, Caliper 4 "
71-7 T6-8013-167 Sleeve 4 "
71-8 T6-8013-165 Screw, Bleeder - Delco 2 "
71-9 T6-8013-143 Hose, Brake 2 "
71-10 T6-8013-147 Washer, Brake Hose 4 "
71-11 T6-8013-145 Bolt, Brake Hose 2 "
CD368 4-2-157
Rev 10
Chapter 4
1
2
3
11
4
5
6
7
8
10
11
Figure 2-71a. Rear Brake Caliper Assembly (S/N 2667 thru 3140)
4-2-158 CD368
Rev 10
Chapter 4
Table 2-71a. Rear Brake Caliper Assembly (S/N 2667 thru 3140)
Fig & Tug Part

Ind Number
71a- T6-2201-103-1 Caliper, Brake Assembly 1 2667-3140
71a-1 ------ Pin, Clevis 2 "
71a-2 ------ Stator (Lining) Assembly 2 "
71a-3 ------ Boot, Piston 1 "
71a-4 ------ Ring, Square 1 "
71a-5 ------ Piston 1 "
71a-6 ------ Housing 1 "
71a-7 ------ Clip, Pin 2 "
71a-8 ------ Screw, Bleeder 2 "
71a-9 ------ Plug, Protective 1 "
71a-10 ------ Bushing (Bronze) 2 "
71a-11 ------ Stud, Mounting 2 "
71a- T6-2201-103-2 Service Kit, Caliper Seal and Piston (Includes items 3, 4, and 5) Ref. As Req'd
71a- T6-2201-103-3 Service Kit, Caliper Seal (Includes items 3 and 4) Ref. "
71a- T6-2201-103-4 Service Kit, Caliper Lining and Clip (Includes items 1, 2, and 7) Ref. "
71a- T6-2201-103-5 Service Kit, Caliper Bushing and Stud (Includes items 10 and 11) Ref. "
CD368 4-2-159
Rev 10
Chapter 4
13
12
11
10
9
8
7
6
5
3
2
1
Figure 2-71b. Rear Brake Caliper Assembly (S/N 3140 & Up)
4-2-160 CD368
Rev 10
Chapter 4
Table 2-71b. Rear Brake Caliper Assembly (S/N 3140 & Up)
Fig & Tug Part

Ind Number
71b-1 T6-8013-159 Bolt, Caliper 2 3041 & Up
71b-2 T6-8013-167 Sleeve 2 "
71b-3 ------ Ring, Rubber, Large 2 "
71b-4 ------ Plug, Protective 1 "
71b-5 ------ Screw, Bleeder 1 "
71b-6 T6-9011-621-3 Caliper Assembly, R/F or L/R 1 "
T6-9011-621-4 Caliper Assembly, L/F or R/R 1 "
71b-7 ------ Ring, Rubber, Small 2 "
71b-8 T6-8013-157 Piston 1 "
71b-9 ------ Ring, Square (part of T6-8013-153) 1 "
71b-10 T6-8013-153 Boot, Piston, Kit 1 "
71b-11 T6-8013-149 Pads, Brake, Non-Organic 2 "
T6-8013-201 Pads, Brake, Organic - Opt. 2 "
71b-12 T6-8013-169 Clip, Retainer 1 "
71b-13 ------ Clip, Caliper 1 "
71b-14 T6-9011-621-5 Service Kit, Brake Pads (Includes Items 11, 12 & 13) - Not Shown 1 As Req'd
71b-15 T6-9011-621-9 Service Kit, Bushing & Mounting Stud (Includes Items 1, 2, 3, & 7) - 1 "
Not Shown
71b-16 T6-9011-621-10 Replacement Kit, Piston & Seal (Includes Items 8, 9 & 10) - Not 1 "
Shown
71b-17 T6-9011-621-2 Service Kit, Brake Seal (Includes Items 9 & 10) - Not Shown 1 "
CD368 4-2-161
Rev 10
Chapter 4
Figure 2-72. Engine - Deutz Diesel
4-2-162 CD368
Rev 10
Chapter 4
Table 2-72. Engine - Deutz Diesel
Tug Part
Fig & Ind Description Qty Effective
Number
72-1 TM1-ND-8082 Engine, Deutz with PTO 1 562-2386
TM1-1-9693 Engine, Deutz F4M2011 - Tier II 1 Note 1
ENG-660-34 Engine, Deutz, D2011 L04 1 3506 & Up
Note 1: Effective on units equipped with the Deutz engine option S/N 2387-2394; and
2408 and up.
CD368 4-2-163
Rev 10
Chapter 4
Figure 2-73. Engine and Engine Mounts - Deutz Diesel (Orig)
4-2-164 CD368
Rev 10
Chapter 4
Table 2-73. Engine and Engine Mounts - Deutz Diesel (Orig)
Fig & Tug Part

Ind Number

73-2 TM1-4-5004 Mount, Engine Motor R/H - Weldment (Deutz) 1 As Req'd
73-3 TM1-4-5003 Mount, Engine Motor R/H - Weldment (Deutz) 1 "
73-4 T6-4800-112 Mount, Engine Half, L/H - Weldment (Deutz) 1 "
73-5 TM1-4-9544 Mount, Engine Motor L/H - Weldment (Deutz) 1 "
73-6 ------ Hose, Rubber, 5/16" ID 1 "
73-7 TM1-ND-5027 Fan, Deutz 1 "
73-8 TM1-ND-5004 Mount, Rubber - Engine 1 "
73-9 TM1-ND-5040 Filter, Oil - Deutz 1 "
Note 1: Effective on units equipped with the Deutz engine option S/N 2387-2394;
and S/N 2408 and up.
CD368 4-2-165
Rev 10
Chapter 4
Figure 2-74. Engine Motor Mounts Installation - Deutz Diesel (Rev 3)
4-2-166 CD368
Rev 10
Chapter 4
Table 2-74. Engine Motor Mounts Installation - Deutz Diesel (Rev 3)
Fig & Tug Part

Ind Number
TM1-ND-5258 Engine, Deutz with Integrated Cooling - Opt. 1 As Req'd
660-1-2405 Engine, Deutz with Integrated Cooling - Opt. 1 As Req'd
TM1-F4M-1011 Engine, Deutz Diesel FM4011 1 Up to 2387
74-2 ½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½" Long 2 101 & Up
74-3 7/16 Washer, Flat 7/16" ID 20 "
74-4 M14 Washer, Flat 14mm 4 "
74-5 M14 Washer, Lock 14mm 9 "
74-6 M14-2.0 x 45 Bolt, Hex Head Ø M14-2.0 x 45mm Long 2 "
74-7 TM1-4-9545 Mount, Engine Motor L/H 1 1660 & Up
74-9 3/8 Washer, Lock 3/8" ID 4 "
74-11 TM1-4-9544 Mount, Engine Motor L/H - Weldment (Deutz) 1 1660 & Up
74-12 ½-13 Nut, Top Lock Hex ½-13 10 "
74-14 TM1-1-5025 Washer, Motor Mount Safety - Deutz 2 "
74-17 TM1-4-5003 Mount, Engine Motor R/H - Weldment (Deutz) 1 101 & Up
74-18 TM1-2-8028 Bracket, Throttle Return Spring - Deutz 1 "
74-19 ½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long 2 "
74-20 TM1-1-6526 Heater, Engine - Deutz (Opt.) 1 As Req'd
S/N 2408 and up.
CD368 4-2-167
Rev 10
Chapter 4
21
22 20
13
23
6
14 12
11
13 10
15 9
6
16
8
5
7 6
2 6
17 3
4 5
18
1
19
Figure 2-75. Engine Motor Mounts Installation - Deutz F4M2011 (Tier II) Diesel
4-2-168 CD368
Rev 10
Chapter 4
Table 2-75. Engine Motor Mounts Installation - Deutz F4M2011 (Tier II) Diesel
Fig & Tug Part

Ind Number
75-1 TM1-1-9693 Engine, Deutz F4M2011 - Tier II 1 Note 1
75-3 ½ Washer, Lock ½" ID 10 "
75-4 TM1-1-5025 Washer, Motor Mount Safety - Deutz 2 "
75-5 ½-13 Nut, Top Lock Hex ½-13 10 "
75-9 3/8 Washer, Lock 3/8" ID 4 "
75-10 3/8-16 x ¾ Bolt, Hex Head Ø 3/8-16 x ¾" Long 4 "
75-12 M14 Washer, Lock Metric 14mm 4 "
75-15 TM1-4-9545 Mount, Engine Motor L/H 1 "
75-17 M14 Washer, Flat Metric 14mm 4 "
75-19 TM1-4-9544 Mount, Engine Motor L/H - Weldment (Deutz) 1 "
75-20 02-02-140239 Elbow, 90°, 2MP x 2FP 1 "
75-21 T6-1001-133 Sender, Oil Pressure (Bore & Tap Plug) 1 "
75-22 TM1-ND-5047 Reducer, Oil Sender - Deutz 1 "
75-23 TM1-ND-5046 Adaptor, Oil Sensor - Metric to English 1 "
S/N 2408 and up.
CD368 4-2-169
Rev 10
Chapter 4
22
21
19 20
18
17 3
4
16
15
14 5
13
12
11 7 6
10 8
9
Figure 2-76. Engine Assembly - Deutz F4M2011 (Tier II) & D2011 (Tier IVi) Diesel
4-2-170 CD368
Rev 10
Chapter 4
Table 2-76. Engine Assembly - Deutz F4M2011 (Tier II) & D2011 (Tier IVi) Diesel
Fig & Tug Part

Ind Number
76-1 TM1-1-9693 Engine, Deutz F4M2011, Tier II 1 Note 1
ENG-M1A-24 Engine, Deutz F4M2011, without Cooler 1 3394 - 3505
ENG-660-34 Engine, Deutz D2011 L04, Tier IVi 3506 & Up
76-2 TM1-1-9693-1 Alternator, Tier II (Deutz) 1 2378 & Up
76-3 DEU1179565 Belt - V 1 "
76-4 TM1-ND-5027 Fan - Deutz 1 "
76-5 TM1-2-9738 Bracket, Accelerator Stand Off 1 "
76-6 T6-4800-122 Pulley, PTO (Deutz) 1 "
76-7 TM1-1-9757 Bracket, Accelerator 1 "
76-8 TM1-ND-5053 Sensor, Low Oil Pressure - Opt. 1 As Req'd
76-9 TM1-1-9578 Heater, Block (Deutz) - Opt . 1 "
76-10 TM1-ND-5046 Adapter (Oil Sensor Metric to Engine) 1 2378 & Up
76-11 TM1-ND-5047 Reducer, Oil Sensor (Deutz) 1 "
76-12 02-02-140239 Fitting, 2MP x 2FP-90° 1 "
76-13 T6-1001-133 Sender, Oil Pressure (Bore & Tap Plug) 1 "
76-14 T6-4800-155 Plug, Deutz Fuel Pump 1 "
76-15 TM1-2-9830-3 Hose, Heater, Black, 15" - Opt. 1 As Req'd
76-16 TM1-ND-5040 Filter, Oil (Deutz) - OEM 1 2378 & Up
76-17 TM1-2-9830-1 Hose, Heater, Black, 9.5" - Opt. 1 As Req'd
76-18 TM1-2-9739 Bracket, Exhaust at Engine 1 2378 & Up
76-19 TM1-1-5008 Hose, Oil Cooler (Bottom) 41" (Deutz) 1 "
76-20 TM1-ND-5051 Sender, High Oil Temperature (Deutz) 1 "
76-21 TM1-1-5009 Hose, Oil Cooler (Top) 21" (Deutz) 1 "
76-22 1182388 Starter, Large 3KW (Deutz) 1 "
Note 1: Effective on units equipped with the Deutz engine option S/N 2387-2394, and
2408-3394.
CD368 4-2-171
Rev 10
Chapter 4
4
2
3 8
12
11 13
5
14
10
15
6
17
9
7
16
20 18
21 19
19
22 23
24 20
27
25 26
Figure 2-77. Engine and Transmission Installation - Deutz Diesel w/ Ford C6

Transmission (Orig)
4-2-172 CD368
Rev 10
Chapter 4
Table 2-77. Engine and Transmission Installation - Deutz Diesel w/ Ford C6

Transmission (Orig)
Fig & Tug Part

Ind Number
TM1-ND-5258 Engine, Deutz with Integrated Cooling - Opt. 1 As Req'd
660-1-2405 Engine, Deutz with Integrated Cooling - Opt. 1 As Req'd
TM1-F4M-1011 Engine, Deutz Diesel FM4011 1 Up to 2387
77-2 ------ Adaptor, Drive 1 101 & Up
77-4 ------ Housing, Adaptor 1 "
77-5 10mm x 17mm Washer, 10mm ID x 17mm OD 9 "
77-6 12mm x 25mm Pin, Dowel Ø 12mm x 25mm Long 2 "
77-7 ------ Bolt, Socket Head Ø M10-1.5 x 25mm Long 9 "
77-8 TPG-D5TZ-6375A Flywheel Assembly, C-6 1 "
77-9 TPG-C20Z-6A366A Reinforcement, Plate - Flywheel 1 "
77-10 TPG-378171-S100 Bolt, Hex 6 "
77-11 T6-1008-111 Transmission, C-6 - 3 Speed 1 "
S/N 2408 and up.
CD368 4-2-173
Rev 10
Chapter 4
4
2
3 8
12
11 13
5
14
10
15
6
17
9
7
16
20 18
21 19
19
22 23
24 20
27
25 26

Transmission (Orig) - Con't.
4-2-174 CD368
Rev 10
Chapter 4

Transmission (Orig) - Con't.
Fig & Tug Part

Ind Number
77-12 TM1-1-6548 Bracket, Transmission Line 2 1380 & Up
77-13 7/16 Washer, Flat 7/16" ID 2 101 & Up
77-14 7/16 Washer, Lock 7/16" ID 6 "
77-16 ------ Arm, Shift (Transmission Part) 1 "
77-18 MD-P21-105 Isolator, Transmission Mount C6 1 "
77-22 660-2-2320 Closeout, Flywheel - Deutz Diesel 1 "
77-23 TM1-1-9764 Adapter, 90° 1 "
77-24 T6-9011-404 Adapter, Speedometer, .4105 Ratio 1 "
77-25 MH-ND-553-1 Tip, Adapter - Speedometer Drive 1 "
77-26 MH-ND-553 Sleeve, Pinion - Speedometer 1 "
77-27 MH-ND-553-3 Pinion, Transmission - Speedometer 1 "
CD368 4-2-175
Rev 10
Chapter 4
3 4
8
5
11
6
10 12
13
14
7 15
9
22 17
16
18
21 20
19
19
20

Transmission (Rev 10)
4-2-176 CD368
Rev 10
Chapter 4

Transmission (Rev 10).
Fig & Tug Part

Ind Number

ENG-660-34 Engine, Deutz D2011, Tier IVi 1 3506 & Up
78-2 ------ Adaptor, Drive 1 101 & Up
78-4 ------ Housing, Adaptor 1 "
78-5 10mm x 17mm Washer, 10mm ID x 17mm OD 9 "
78-6 12mm x 25mm Pin, Dowel Ø 12mm x 25mm Long 2 "
78-7 ------ Bolt, Socket Head Ø M10-1.5 x 25mm Long 9 "
78-8 TPG-D5TZ-6375A Flywheel Assembly, C-6 1 "
78-9 TPG-C20Z-6A366A Reinforcement, Plate - Flywheel 1 "
78-10 TPG-378171-S100 Bolt, Hex 6 "
78-11 T6-1008-111 Transmission, C-6 - 3 Speed 1 "
78-12 TM1-1-6548 Bracket, Transmission Line 2 1380 & Up
78-13 7/16 Washer, Flat 7/16" ID 2 101 & Up
78-14 7/16 Washer, Lock 7/16" ID 6 "
78-16 ------ Arm, Shift (Transmission Part) 1 "
78-18 MD-P21-105 Isolator, Transmission Mount, C6 1 "
78-22 660-2-2320 Closeout, Flywheel - Deutz Diesel 1 "
S/N 2408 and up.
CD368 4-2-177
Rev 10
Chapter 4
Figure 2-79. Alternator Installation - Deutz Tier I (Orig)
4-2-178 CD368
Rev 10
Chapter 4
Table 2-79. Alternator Installation - Deutz Tier I (Orig)
Fig & Tug Part

Ind Number
79-1 TM1-2-5003 Bracket, Alternator Adjustment - Deutz 1 101-561

79-2 TM1-4-5000 Bracket, Alternator Mount - Wldmt 1 "
79-3 DEU2108653 Pulley, V-Belt 1 "
79-4 TM1-ND-5008 Belt, (V-) Alternator and Power Steering - Deutz 1 "
79-5 TM1-ND-5005 Alternator, 60 Amp, Delco 3/8 Grv Pulley - Deutz 1 "
79-6 T6-5011-107 Pulley, Power Steering 1 "
CD368 4-2-179
Rev 10
Chapter 4
Figure 2-80. Alternator Installation - Deutz Tier I (Rev 3)
4-2-180 CD368
Rev 10
Chapter 4
Table 2-80. Alternator Installation - Deutz Tier I (Rev 3)
Fig & Tug Part

Ind Number
80-1 660-1-2292 Bracket, Cast Alternator, Deutz 1 562 & Up
80-2 M8 Washer, Flat 8mm ID 4 "
80-3 M8 Washer, Lock 8mm ID 4 "
80-6 3/8 Washer, Lock 3/8" ID 1 "
80-7 3/8 Washer, Flat 3/8" ID 1 "
80-8 3/8 x 3/16 Spacer Ø 3/8" ID x 3/16" Long 1 "
80-9 3/8-16 Nut, Top Lock Hex 3/8-16 1 "
80-10 T6-1211-103 Plug, Alternator Socket 1 "
80-11 T6-1211-101-5 Alternator, 100 Amp, without Pulley (Perkins, Deutz) 1 "
80-12 T6-1211-101-3 Fan, Alternator 1 "
80-13 TM1-ND-5013 Pulley, Alternator, Deutz 1 "
80-14 T6-1211-101-6 Nut, Pulley - Alternator 1 "
80-15 T6-6015-101 Belt, Alternator 1 "
80-16 TM1-4-8009 Bracket, Alternator Assembly 1 "
CD368 4-2-181
Rev 10
Chapter 4
14
13
11
10 12 1
2
9
7 2
5
6
3
Figure 2-81. Alternator Installation - Deutz F4M2011 (Tier II) (Rev 7)
4-2-182 CD368
Rev 10
Chapter 4
Table 2-81. Alternator Installation - Deutz F4M2011 (Tier II) (Rev 7)
Fig & Tug Part

Ind Number
81-1 660-1-2292 Bracket, Cast Alternator, Deutz 1 Note 1
81-3 3/8-20 x 3½ Bolt, Flange Head Ø 3/8-20 x 3½" Long 1 "
81-4 ------ Belt, Alternator 1 "
81-5 TM1-ND-5013 Pulley, Alternator 1 "
81-6 ------ Washer, Spring 1 "
81-7 ------ Nut, Pulley - Bosch Alternator 1 "
81-12 ------ Bracket 1 "
81-13 ------ Fan, Alternator 1 "
81-14 DEU1178607 Alternator, Bosch 1 "
S/N 2408 and up.
CD368 4-2-183
Rev 10
Chapter 4
14
13
11
10 12 1
2
9
7 2
5
6
3
Figure 2-82. Alternator Installation - Deutz (Tier II & Tier IVi) (Rev 10)
4-2-184 CD368
Rev 10
Chapter 4
Table 2-82. Alternator Installation - Deutz (Tier II & Tier IVi) (Rev 10)
Fig & Tug Part

Ind Number
82-1 660-1-2292 Bracket, Cast Alternator, Deutz 1 Note 1
82-3 3/8-20 x 3½ Bolt, Flange Head Ø 3/8-20 x 3½" Long 1 "
82-4 DEU1179565 Belt, Alternator 1 "
82-5 118-2187 Pulley, Alternator, Deutz 1 "
82-6 ------ Washer, Spring 1 "
82-7 ------ Nut, Pulley - Bosch Alternator 1 "
82-12 ------ Bracket 1 "
82-13 118-1859 Fan, Alternator, Deutz 1 "
82-14 TM1-1-9693-1 Alternator, Bosch 1 "
2408 and Up.
CD368 4-2-185
Rev 10
Chapter 4
Figure 2-83. Air Intake System - Deutz (Rev 3)
4-2-186 CD368
Rev 10
Chapter 4
Table 2-83. Air Intake System - Deutz (Rev 3)
Fig & Tug Part

Ind Number
83-1 TM1-0-8140 Filter, Air - Donaldson 1 101 & Up

83-2 TM1-0-8145 Element, Air Filter (Deutz, Perkins) 1 "
83-3 TM1-0-8142 Band, Air Filter - Donaldson 2 "
83-4 ¼-20 x ½ Bolt, Hex Head Bolt Ø ¼-20 x ½" Long 6 "
83-6 ---------- Clamp, Hose 5044 2 "
83-7 TM1-ND-5001 Elbow, Air Cleaner Hose - Deutz 1 As Req'd
83-8 TM1-1-5007 Tube, Air Cleaner Adaptor - Deutz 1 As Req'd
83-9 ---------- Clamp, Hose 5056 2 101 & Up
83-10 TM1-ND-5006 Hose, Air Cleaner Hump - Deutz 1 As Req'd
83-11 TM1-2-8141 Mount, Air Cleaner - Donaldson 1 1400 & Up
83-12 ¼ Nut, Top Lock Hex ¼-20 4 101 & Up
83-13 ¼ Washer, Lock ¼" 2 101 & Up
CD368 4-2-187
Rev 10
Chapter 4
Figure 2-84. Fuel Tank Installation (Rev 2)
4-2-188 CD368
Rev 10
Chapter 4
Table 2-84. Fuel Tank Installation (Rev 2)
Fig & Tug Part

Ind Number
84-1 TM1-4-0806 Tank, Fuel - M1A 1 101 & Up
84-2 TM1-4-8064 Cradle, Fuel Tank 1 "
84-3 ------ Hose, Fuel Filter Ø 2¼" ID x 6" Long 1 "
84-4 TM1-2-8174 Strap, Fuel Tank 1 "
84-5 T6-6003-107 Filter Material, 1" Horse Hair Ref. "
84-6 X6005-101 Sender, Fuel - Kysor 1 "
84-7 T6-6004-101GREEN Cap, Fuel, Diesel (Green) Assembly 1 "
84-8 T6-6004-101S O-Ring 1 "
84-9 ------ Clamp, Hose #40 2 "
CD368 4-2-189
Rev 10
Chapter 4
Figure 2-85. Fuel Tank Installation (Rev 10)
4-2-190 CD368
Rev 10
Chapter 4
Table 2-85. Fuel Tank Installation (Rev 10)
Fig & Tug Part

Ind Number
85-1 ------ Hose, Belt Ø 2" ID x 10" Long 1 101 & Up
85-2 ------ Clamp, Hose Ideal 5040 2 "
85-3 CMA-600 Pipe, Fuel Filter, 12" 1 101-3476
TM1-2-9826 Pipe, Fuel Filler, 7.75 LG 1 3477 & Up
85-4 T6-6004-101S O-Ring 1 101 & Up
85-5 T6-6004-101GREEN Cap Assembly, Fuel, Diesel (Green) 1 "
85-6 TM1-2-8174 Strap, Fuel Tank 1 "
85-7 ------ Filter Material, Horse Hair, 24" x 15" 1 "
85-10 ½x½ Weather Strip, Self-Adhesive 1 "
85-11 ------ Wire, Jumper - 14 Gauge, 4½" Long 1 "
85-12 TM1-ND-8012 Sender, Fuel Datcon 1 830 & Up
85-13 TM1-ND-1006 Gasket, Fuel Sending Unit 1 As Req'd
85-14 TM1-4-0806 Tank, Fuel - M1A 1 101 & Up
85-15 T6-6010-111 Valve, Fuel Drain 1 "
85-16 T6-3200-131 Elbow, Racor 2 690 & Up
85-17 TM1-4-8064 Cradle, Fuel Tank 1 101 & Up
85-18 7/16 Washer, Flat 7/16" ID 10 "
85-19 ½-13 Nut, Top Lock Hex ½-13 5 "
85-20 ½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾" Long (Deutz) 2 "
85-20a ½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long (Deutz) 1 "
85-21 3/8-16 x ½ Bolt, Hex Head Ø 3/8-16 x ½" Long 2 "
85-22 3/8 Washer, Lock 3/8" ID 2 "
85-23 ½-13X1 Bolt, Hex Head Ø ½-13 x 1" Long 2 "
85-24 TM1-3-8190 Guard, Fuel Line 1 "
CD368 4-2-191
Rev 10
Chapter 4
Figure 2-86. Fuel System - Deutz (Orig)
4-2-192 CD368
Rev 10
Chapter 4
Table 2-86. Fuel System - Deutz (Orig)
Fig & Tug Part

Ind Number
86-1 T6-3200-127 Filter, Racor without Heater 1 As Req'd
86-2 TM1-ND-5026 Filter, Fuel, Deutz 1 "
86-3 T6-6006-107A Elbow, 90°, Compression to Pipe 2 "
86-4 T6-6010-111 Valve, Fuel Drain 1 "
86-5 TM1-3-8190 Guard, Fuel Line 1 "
86-6 TM1-4-0806 Tank, Fuel - M1A 1 "
86-7 ------ Clamp, Hose #6 4 "
CD368 4-2-193
Rev 10
Chapter 4
Figure 2-87. Fuel System w/ Racor Filter Option - Deutz
4-2-194 CD368
Rev 10
Chapter 4
Table 2-87. Fuel System w/ Racor Filter Option - Deutz
Fig & Tug Part

Ind Number
87-1 TM1-ND-5033 Filter, Racor 1 As Req'd
87-2 TM1-ND-8010 Plug, ¼ MP, Brass 1 "
87-3 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
87-5 5/16 Washer, Flat 5/16" ID 2 "
87-6 T6-3200-131 Elbow, Racor 4 "
87-7 ------ Tubing, Brake Line Ø 5/16" x 6 3/8" Long 2 "
87-8 ------ Hose, Fuel Ø 3/8" ID x 3" Long 1 "
87-9 ------ Hose, Fuel Ø 3/8" ID x 3½" Long 1 "
87-10 TM1-ND-5057 Line, Main to Pump - SS 1 "
87-11 TM1-ND-5058 Line, Main to Water Separator - SS 1 "
87-14 417-8691 Bracket, Fuel Filter Head - Deutz 1 "
87-15 5/16 Washer, Flat 5/16" ID 2 "
87-17 TM1-ND-5026 Filter, Fuel - Deutz 1 "
87-18 TM1-ND-5055 Line, Fuel Pump to Filter - SS 1 "
87-21 ¼ Clamp, P- (¼") 16 "
87-22 5/16 Nut, Flange 5/16" 8 "
87-23 TM1-ND-5054 Line, Return to Tank - SS 1 "
87-24 TM1-ND-5056 Line, Fuel Filter to Injection Pump 1 "
87-28 ------ Clamp, Hose #4 14 "
87-29 417-9734 Pump, Fuel - Deutz 1 "
CD368 4-2-195
Rev 10
Chapter 4
1
2 5 24
3 3
4 6 25 2
23
7 22
21
8 10 11
9
15
13
12
14
16
17
18
19 20
Figure 2-88. Fuel System w/ Racor Filter Option - Deutz F4M2011 (Tier II)
4-2-196 CD368
Rev 10
Chapter 4
Table 2-88. Fuel System w/ Racor Filter Option - Deutz F4M2011 (Tier II)
Fig & Tug Part

Ind Number
88-1 ------ Mount, Fuel Filter (Included with Engine) 1 Note 1
88-2 5/16 Washer, Flat 5/16" ID 4 "
88-3 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
88-4 ------ Hose, Ø 5/16" ID (Engine to Fuel Filter) 1 "
88-5 5/16-18 x 2 Bolt, Hex Head Ø 5/16-18 x 2½" Long 2 "
88-6 ------ Hose, Ø 5/16" ID (Filter to Fuel Pump) 1 "
88-9 ¼ Clamp, P- (¼") 16 "
88-10 ------ Hose, Ø 5/16" ID (Racor Filter to Pump) 1 "
88-11 ------ Clamp, Hose #4 10 "
88-12 TM1-ND-5058 Line, Main from Tank to Pre-filter - SS 1 "
88-14 ¼-20 Nut, Flange ¼-20 (As Spacer) 8 "
88-16 ------ Hose, Return Ø 5/16" ID (Engine to Tank Fuel Line) 1 "
88-17 ------ Pre-filter 1 "
88-18 ------ Hose, Ø 5/16" ID (Pre-filter to Fuel Pump) 1 "
88-19 ------ Fitting, Straight (Included with Engine) 2 "
88-20 ------ Pump, Fuel (Included with Engine) 1 "
88-21 ------ Hose, Ø 5/16" ID (Tank Fuel Line to Racor Filter) 1 "
88-22 TM1-ND-5033 Filter, Racor 1 "
88-24 Bolt, Hex Head Ø 5/16-18 x 2" Long 2 "
88-25 T6-3200-131 Elbow, Racor Filter 2 "
S/N 2408 and up.
CD368 4-2-197
Rev 10
Chapter 4
1
2 5 21
3 3
4 6 22 2
20
7 19
18
8 10 11
9
15
13
12
14
16
17
Figure 2-89. Fuel System w/ Racor Filter Option - Deutz (Tier II & IVi) (Rev 10)
4-2-198 CD368
Rev 10
Chapter 4
Table 2-89. Fuel System w/ Racor Filter Option - Deutz (Tier II & IVi) (Rev 10)
Fig & Tug Part

Ind Number
89-1 ------ Mount, Fuel Filter (Included with Engine) 1 2187 & Up
89-2 5/16 Washer, Flat 5/16" ID 4 "
89-3 5/16-18 Nut, Top Lock Hex 5/16-18 4 "
89-4 ------ Hose, Ø 5/16" ID (Engine to Fuel Filter) 1 "
89-5 5/16-18 x 2 Bolt, Hex Head Ø 5/16-18 x 2½" Long 2 "
89-6 ------ Hose, Ø 5/16" ID (Filter to Fuel Pump) 1 "
89-9 ¼ Clamp, P- (¼") 16 "
89-10 ------ Hose, Ø 5/16" ID (Racor Filter to Pump) 1 "
89-11 ------ Clamp, Hose #4 10 "
89-12 TM1-ND-5058 Line, Main from Tank to Water Separator 1 "
89-14 ¼-20 Nut, Flange ¼-20 (As Spacer) 8 "
89-16 ------ Hose, Return Ø 5/16" ID (Engine to Tank Fuel Line) 1 "
89-17 ------ Pump, Fuel (Included with Engine) 1 "
89-18 ------ Hose, Ø 5/16" ID (Tank Fuel Line to Racor Filter) 1 "
89-19 TM1-ND-5033 Filter, Racor 1 "
89-21 ------ Bolt, Hex Head Ø 5/16-18 x 2" Long 2 "
89-22 T6-3200-131 Elbow, Racor Filter 2 "
CD368 4-2-199
Rev 10
Chapter 4
Figure 2-90. Exhaust System - Deutz (Rev 2)
4-2-200 CD368
Rev 10
Chapter 4
Table 2-90. Exhaust System - Deutz (Rev 2)
Fig & Tug Part

Ind Number
90-1 TM1-ND-5009 Pipe, Exhaust - Deutz 1 Up to 905
90-2 TM1-4-5009 Pipe, Exhaust with Flex - Deutz 1 905 & Up
90-3 TM1-1-0812 Pipe, Tail (Ford 300, Deutz) 1 101 & Up
90-4 TM1-1-5006 Bracket, Exhaust Pipe Support - Deutz 1 "
90-5 T6-1005-115 Strap, Exhaust Hanger 1 "
90-6 T6-1005-119 Clamp, 2" Exhaust 5 "
90-7 T6-1005-105 Muffler, Gas 1 "
90-8 TM1-2-5034 Mount, Manifold Pipe - M1 1 "
CD368 4-2-201
Rev 10
Chapter 4
Figure 2-91. Exhaust System - Deutz (Rev 3)
4-2-202 CD368
Rev 10
Chapter 4
Table 2-91. Exhaust System - Deutz (Rev 3)
Fig & Tug Part

Ind Number
91-1 TM1-ND-5021 Gasket, Exhaust - Deutz 1 101 & Up
91-2 TM1-ND-5019 Nut, Hex 10mm x 1.25 3 "
91-3 TM1-2-5034 Mount, Manifold Pipe - M1 1 "
91-4 M10 Washer, Flat M10 ID 3 "
91-5 M10 Washer, Lock M10 ID 2 "
91-8 TM1-4-5009 Pipe, Exhaust with Flex - Deutz 1 987 & Up
91-9 T6-1005-119 Clamp, 2" Exhaust 6 101 & Up
91-10 TM1-2-5046 Hanger, J-Hook Exhaust - Opt. 1 As Req'd
91-11 T6-1005-105 Muffler, Gas 1 101 & Up
TM1-ND-9028 Muffler, Spark Arrestor 2" (Curved) - Opt. 1 As Req'd
91-13 7/16 Washer, Flat 7/16" ID 6 "
91-17 TM1-1-0812 Pipe, Tail (Ford 300, Deutz) 1 "
91-18 3/8 Washer, Flat 3/8" ID 4 "
91-19 TM1-2-8148 Bracket, Exhaust 1 As Req'd
CD368 4-2-203
Rev 10
Chapter 4
5
1
2 6
14
3
13
7
11 12
4
8
10
9
Figure 2-92. Exhaust System - Deutz (Tier II & IVi) (Rev 10)
4-2-204 CD368
Rev 10
Chapter 4
Table 2-92. Exhaust System - Deutz (Tier II & IVi) (Rev 10)
Fig & Tug Part

Ind Number
92-1 ------ Turbo, Exhaust (Part of Engine) 1 Note 1
92-2 ------ Gasket, Exhaust (Included with Engine) 1 "
92-3 TM1-2-9739 Bracket, Exhaust at Engine 1 "
92-4 T6-1005-119 Clamp, 2" Exhaust 6 "
92-5 TM1-4-5009 Pipe, Exhaust with Flex - Deutz 1 "
92-6 TM1-2-5046 Hanger, J-Hook Exhaust - Opt. 1 As Req'd
92-7 T6-1005-105 Muffler, Gas 1 Note 1
92-8 3/8-16 Nut, Top Lock Hex 3/8-16 5 "
92-9 7/16 Washer, Flat 7/16" ID 6 "
92-13 TM1-1-0812 Pipe, Tail (Ford 300, Deutz) 1 "
92-14 TM1-2-8148 Bracket, Exhaust 1 "
S/N 2408 and up.
CD368 4-2-205
Rev 10
Chapter 4
Figure 2-93. Engine Cooling System - Deutz (Rev 2)
4-2-206 CD368
Rev 10
Chapter 4
Table 2-93. Engine Cooling System - Deutz (Rev 2)
Fig & Tug Part

Ind Number
93-1 TM1-4-5021 Shroud, Left Side - Deutz 1 As Req'd
93-2 TM1-4-5022 Shroud, Right Side - Deutz 1 "
93-3 TM1-4-5020 Shroud, Top - Deutz 1 "
93-4 TM1-1-5010 Bracket, Lower Oil Cooler Mount 1 "
93-5 TM1-1-5008 Hose, Oil Cooler - 41" Deutz 1 "
93-7 660-1-2412 Damper, Vibration - Oil Cooler Mtg. 2 "
93-8 TM1-ND-5036 Fitting, Oil Cooler 2 "
93-9 MJ-ND-1221 Cooler, Transmission Fluid 1 "
93-10 TM1-ND-5028 Cooler, Oil - Deutz 1 "
93-11 660-1-2412 Damper, Vibration - Oil Cooler Mtg. 2 "
93-12 TM1-1-8352 Cooler, Power Steering & Transmission 1 "
93-13 ------ Hose, Oil Cooler 1 "
93-14 TM1-1-8328 Hose, Steer Valve to Return 1 "
93-15 TM1-ND-5049 Fitting, Oil Cooler, 90° JIC 1 "
CD368 4-2-207
Rev 10
Chapter 4
2 2
3
29 1
2 3
2
3 16
4
6 4 5 13 15 17 23
12
6
3
6
18
10 11 14
4 19
2 20
3
6 6
9 22
7
3 4
8 19
21
6
6
3 24
26
30 27
25 28
3
6
4-2-208 CD368
Rev 10
Chapter 4
Fig & Tug Part

Ind Number
94-1 TM1-4-5020 Shroud, Top - M1A Deutz 1 101 & Up
94-2 5/16-18x1 Bolt, Hex Head Ø 5/16-18 x 1" Long 6 "
94-3 5/16 Washer, Flat 5/16" ID 18 "
94-5 TM1-4-5021 Shroud, Left Side - Deutz 1 "
94-6 5/16-18 Nut, Flange 5/16-18 14 "
94-7 ------ Clamp, P- (1¼") 1 "
94-9 5/8 Hose, Fuel - 2.5 ft Long 2 "
94-11 ------ Clamp, Hose #4 2 "
94-12 660-1-2412 Damper, Vibration, Oil Cooler Mounting 2 562 & Up
94-13 TM1-2-8019 Mount, Fluid Cooler - M1 1 As Req'd
94-14 MJ-ND-1221 Cooler, Transmission Fluid 1 "
94-16 TM1-4-5022 Shroud, Right Side 1 "
94-17 TM1-2-3030 Mount, Radiator Angle 4 620 & Up
94-18 TM1-ND-5028 Cooler, Oil - Deutz 1 101 & Up
94-19 660-1-2308 Fitting, Oil Cooler - Straight Hose Adaptor 2 As Req'd
94-20 TM1-ND-5049 Fitting, Oil Cooler - 90° JIC 1 "
94-21 TM1-ND-5260 Fitting, Oil Cooler - 45° 1 "
94-22 TM1-1-5008 Hose, Oil Cooler - 41" Deutz 1 101 & Up
94-24 M3-1-8170 Isolator, Power Steering Pump 2 As Req'd
94-25 TM1-1-5010 Bracket, Lower Oil Cooler Mount 1 101 & Up
94-26 3/8 Washer, Lock 3/8" ID 2 "
94-27 3/8 Washer, Flat 3/8" ID 2 "
94-28 3/8 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 2 "
94-29 TM1-1-8352 Cooler, Power Steering & Transmission 1 As Req'd
94-30 TM1-1-9758 Filter, Transmission, In-Line 1 "
CD368 4-2-209
Rev 10
Chapter 4
2 2
3
1
2 3
4
2
3 16
6
3
5 13 17 23
4
12
6 4 6 18
15
10
19
11 14 3
2 20
6
6 9 22
7
3
8 19
21
4 6
6
29
3
24
30 26
32
27 31
28
25 11
3
6
4-2-210 CD368
Rev 10
Chapter 4
Fig & Tug Part

Ind Number
95-1 TM1-4-5020 Shroud, Top - M1A Deutz 1 101 & Up
95-2 5/16-18x1 Bolt, Hex Head Ø 5/16-18 x 1" Long 6 "
95-3 5/16 Washer, Flat 5/16" ID 18 "
95-5 TM1-4-5021 Shroud, Left Side - Deutz 1 "
95-6 5/16-18 Nut, Flange 5/16-18 14 "
95-7 ------ Clamp, P- (1¼") 1 "
95-9 5/8 Hose, Fuel - 7.5 ft Long 2 "
95-11 ------ Clamp, Hose #4 2 "
95-12 660-1-2412 Damper, Vibration - Oil Cooler Mtg. 2 562 & Up
95-13 TM1-2-8019 Mount, Fluid Cooler - M1 1 101 -3129
T6-9011-633 Bracket, Top, Fluid Cooler 1 3130 & Up
95-14 660-2-3461 Cooler, Transmission Fluid 1 2004 & Up
95-15 ¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½" Long 2 101 & Up
95-16 TM1-4-5022 Shroud, Right Side 1 "
95-17 TM1-2-3030 Mount, Radiator Angle 4 620 & Up
95-18 TM1-ND-5028 Cooler, Oil - Deutz 1 101-3393
TM1-1-9693-2 Cooler, Oil, Deutz 1 3394 & Up
95-19 660-1-2308 Fitting, Oil Cooler - Straight Hose Adaptor 2 As Req'd
95-20 TM1-ND-5049 Fitting, Oil Cooler - 90° JIC 1 "
95-21 TM1-ND-5260 Fitting, Oil Cooler - 45° 1 "
95-22 TM1-1-5008 Hose, Oil Cooler - 41" Deutz 1 101 & Up
95-24 M3-1-8170 Isolator, Power Steering Pump 2 As Req'd
95-25 TM1-1-5010 Bracket, Lower Oil Cooler Mount 1 101 & Up
95-26 3/8 Washer, Lock 3/8" ID 2 "
95-27 3/8 Washer, Flat 3/8" ID 2 "
95-28 3/8 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long 2 "
95-29 TM1-4-9834 Mount, Fluid Cooler 1 3191 & Up
95-30 TM1-2-8009 Mount, Radiator Bracket - M1A 1 2004 & Up
95-31 TM1-ND-5060 Line, Transmission, Return 1 101 & Up
95-32 TM1-ND-5059 Line, Transmission, Supply 1 "
CD368 4-2-211
Rev 10
Chapter 4
Figure 2-96. Battery Installation (Rev 1A)
4-2-212 CD368
Rev 10
Chapter 4
Table 2-96. Battery Installation (Rev 1A)
Fig & Tug Part

Ind Number
96-1 T6-7001-205 Battery, Group 27 1 Up to 814
96-2 660-4-0509-18 Mini-Strut 1 "
96-3 TM1-2-8312 Panel, Battery Closeout 2 "
96-4 MG-1-320 Trim-Lock 2 "
96-5 TM1-1-8270 Cable, Battery, Red 33EE 1 "
96-6 TM1-1-8272 Cable, Battery, Black 27EE 1 "
96-7 TM1-4-1050 Plate, Floor - Hinged Driver Side 1 "
96- TM1-4-1052 Plate, Floor - Passenger Side 1 "
CD368 4-2-213
Rev 10
Chapter 4
Figure 2-97. Battery Installation (Rev 3)
4-2-214 CD368
Rev 10
Chapter 4
Table 2-97. Battery Installation (Rev 3)
Fig & Tug Part

Ind Number
97-1 TM1-2-8178 Plate, Battery Support 1 101 & Up
97-2 T6-6011-113 Angle, Tee Support 2 "
97-5 T6-9011-101A Hook, Battery Hold Down 1 As Req'd
97-6 TM1-2-8312 Panel, Battery Closeout 2 101 & Up
97-8 MG-1-320 Trim-Lock (3 ft.) 2 814 & Up
97-9 T6-7001-205 Battery, Group 27 1 As Req'd
97-10 T6-9011-101B Tee, Battery Hold Down 1 "
97-11 T6-7016-119 Cable, Battery, Red 48EC 1 "
97-12 660-1-1309 Cable, Battery, Black 40EC 1 "
97-13 T6-7016-121 Cable, Battery, Black 40EE 1 "
97-14 3/8 Washer, Lock 3/8" ID (Deutz) 2 "
97-15 3/8 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½" Long 1 "
97-16 3/8 Nut, Top Lock Hex 3/8-16 1 "
97-17 TM1-4-1050 Plate, Floor - Hinged Driver Side 1 "
CD368 4-2-215
Rev 10
Chapter 4
Figure 2-98. Horn Installation
4-2-216 CD368
Rev 10
Chapter 4
Table 2-98. Horn Installation
Fig & Tug Part

Ind Number
98-1 T6-7013-207 Horn 1 101 & Up

89-1a ------ Horn, with Terminal Application 1 "
98-1b ------ Bolt, Hex Head Ø 8mm 1 "
98-1c ------ Bracket 1 "
98-1d ------ Nut, Lock Ø 8mm 2 "
98-1e ------ Wire, Jumper, with Connectors 1 "
98-1f ------ Washer, Ground Terminal - Bended 1 "
98-1g ------ Washer, Star 1 "
98-1h ------ Bracket, L- 1 "
98-5 ------ Relay, Harness to Horn 1 "
CD368 4-2-217
Rev 10
Chapter 4
4-2-218 CD368
Rev 10
Chapter 4
SECTION 3: NUMERICAL INDEX
Tug Part Number Description Fig & Ind#
——— Adaptor, Drive 77-2

——— Arm, Shift (Transmission Part) 77-16
——— Bearing, Inner Wheel 57-13
——— Bearing, Outer Wheel 57-20
——— Belt, Alternator 81-4
——— Bolt, .38-16UNCX1.00/1.00 HHCS 65-42
——— Bolt, .38-24UNFX1.50/1.00 HHCS 65-40
——— Bolt, Hex Head Ø 5/16-18 x 2" Long 89-21
——— Bolt, Hex Head Ø 8mm 98-1b
——— Bolt, Socket Head Ø M10-1.5 x 25mm Long 77-7
——— Bolts, Transmission Oil Pan 37-2
——— Boot, Piston 71a-3
——— Bracket 81-12
——— Bracket 98-1c
——— Bracket, L- 98-1h
——— Bracket, Mounting 37-1a
——— Bushing (Bronze) 71a-10
——— Chain, ¼” 59-11
——— Chain, Steel Ø 3/8" x 11" Long, with 9" Heat Shrink 61-11
——— Chain, Steel Ø 3/8" x 11" Long, with 9" Heat Shrink 61a-11
——— Chain, Steel, Ø 3/8" x 11" Long, with 9" Heat Shrink 60-11
——— Clamp, Hose 39-9
——— Clamp, Hose #4 87-28
——— Clamp, Hose #4 88-11
CD368 4-3-1
Rev 10
Chapter 4
——— Clamp, Hose #4 89-11

——— Clamp, Hose #4 94-11
——— Clamp, Hose #4 95-11
——— Clamp, Hose #40 84-9
——— Clamp, Hose #6 40-9
——— Clamp, Hose #6 86-7
——— Clamp, Hose 5044 83-6
——— Clamp, Hose 5056 83-9
——— Clamp, Hose IDEAL 10-20
——— Clamp, Hose Ideal 5040 85-2
——— Clamp, P- (1¼”) 94-7
——— Clamp, P- (1¼”) 95-7
——— Clip, Caliper 71b-13
——— Clip, Hood Prop - Vinyl Coated 14-7
——— Clip, Modulator Retainer 31-2
——— Clip, Pin 71a-7
——— Decal, “Made in USA” 28-5
——— Decal, “Thank You” 28-7
——— Fan, Alternator 81-13
——— Filter Material, Horse Hair, 24" x 15" 85-7
——— Fitting, Straight (Included with Engine) 88-19
——— Fitting, Straight Connector 51-25
——— Gasket, Exhaust (Included with Engine) 92-2
——— Horn, with Terminal Application 89-1a
——— Hose, Belt Ø 2" ID x 10" Long 85-1
——— Hose, Fuel Filter Ø 2¼” ID x 6" Long 84-3
——— Hose, Fuel Ø 3/8" ID x 12" Long 87-26
——— Hose, Fuel Ø 3/8" ID x 3½” Long 87-9
——— Hose, Hydraulic 5/16" ID (Fuel Line) - Opt. 39-10
——— Hose, Hydraulic Ø 5/16" ID (Fuel Line) 52-13
——— Hose, Ø 5/16" ID (Engine to Fuel Filter) 88-4
4-3-2 CD368
Rev 10
Chapter 4

——— Hose, Ø 5/16" ID (Filter to Fuel Pump) 88-6
——— Hose, Ø 5/16" ID (Pre-filter to Fuel Pump) 88-18
——— Hose, Ø 5/16" ID (Racor Filter to Pump) 88-10
——— Hose, Ø 5/16" ID (Tank Fuel Line to Racor Filter) 88-21
——— Hose, Oil Cooler 93-13
——— Hose, Return Ø 5/16" ID (Engine to Tank Fuel Line) 88-16
——— Hose, Rubber, 5/16" ID 73-6
——— Housing 71a-6
——— Housing, Adaptor 77-4
——— Housing, Extension 45-28
——— Housing, Flange 45-24
——— Lever, Transmission Shift 37-3
——— Mount, Fuel Filter (Included with Engine) 88-1
——— Nut, Castellated 58-3
——— Nut, Jam 68-9
——— Nut, Jam ½-13 HX 58-5
——— Nut, Lock Ø 8mm 98-1d
——— Nut, Pulley - Bosch Alternator 81-7
——— Pin, Clevis 71a-1
——— Piston 71a-5
——— Pivot 37-1h
——— Pivot 38-1a
——— Plug, Protective 71a-9
——— Plug, Protective 71b-4
——— Pre-filter 88-17
——— Pump, Fuel (Included with Engine) 88-20
——— Race, Inner Wheel Bearing 57-13
CD368 4-3-3
Rev 10
Chapter 4
——— Race, Outer Wheel Bearing 57-19

——— Relay, Harness to Horn 98-5
——— Ring, Rubber, Large 71b-3
——— Ring, Rubber, Small 71b-7
——— Ring, Square 71a-4
——— Ring, Square (part of T6-8013-153) 71b-9
——— Rod, All Thread Ø 3/8-16 x 2½” Long 44-13
——— Rubber, 1½” x 8" 48-9
——— Screw, Bleeder 71a-8
——— Screw, Bleeder 71b-5
——— Screw, Self Tapping #10 29-5
——— Screw, Self Tapping #10 29a-6
——— Screw, Socket Head Ø 3/8-24 x ¾” Long 58-4
——— Shim, Cable Clamp 37-1j
——— Shim, Cable Clamp 38-1a
——— Silastic 65-44
——— Spacer (Transmission Kit) 46-16
——— Stator (Lining) Assembly 71a-2
——— Stud, .56-18FX.81/.56-12NCX.63/2.31 65-27
——— Stud, Mounting 71a-11
——— Tubing, Brake Line Ø 5/16" x 6 3/8" Long 87-7
——— Tubing, Rubber 3/8" ID 50-15
——— Turbo, Exhaust (Part of Engine) 92-1
——— Washer, Flat #10 37-1b
——— Washer, Flat #10 38-1a
——— Washer, Ground Terminal - Bended 98-1f
——— Washer, Lock #10 56-12
——— Washer, Lock, #10 57-12
——— Washer, Spring 81-6
——— Washer, Star 98-1g
——— Wire, Jumper - 14 Gauge, 4½” Long 85-11
——— Wire, Jumper 3½” Long, 10 Gauge 29-7
——— Wire, Jumper 3½” Long, 10 Gauge 29a-7
——— Wire, Jumper, with Connectors 98-1e
02-02-140239 Elbow, 90°, 2MP x 2FP 75-20
4-3-4 CD368
Rev 10
Chapter 4
02-02-140239 Fitting, 2MP x 2FP-90° 76-12

¼ Clamp, P- (¼”) 41-11
¼ Clamp, P- (¼”) 41a-13
¼ Clamp, P- (¼”) 41b-18
¼ Clamp, P- (¼”) 42-7
¼ Clamp, P- (¼”) 42a-6
¼ Clamp, P- (¼”) 87-21
¼ Clamp, P- (¼”) 88-9
¼ Clamp, P- (¼”) 89-9
¼ Nut, Flange ¼” ID 10-9
¼ Nut, Top Lock Hex ¼-20 83-12
¼ Washer, Flat ¼” ID 10-2
¼ Washer, Lock ¼” ID 94-8
¼ Washer, Lock ¼” 83-13
¼ Washer, Lock ¼” ID 41a-16
CD368 4-3-5
Rev 10
Chapter 4
¼ Washer, Lock ¼” ID 41b-16

¼x½ Screw, Philips Head Ø ¼” x ½” Long 12-5
¼x½ Self Tapping Screw Ø ¼” x ½” Long (CE Opt.) 10-13
¼-20 Nut, Flange ¼-20 (as Spacer) 41a-15
¼-20 Nut, Flange ¼-20 (as Spacer) 41b-15
¼-20 Nut, Flange ¼-20 (As Spacer) 88-14
¼-20 Nut, Top Lock Hex ¼-20 26-17
¼-20 Nut, Top Lock Hex ¼-20 27-17
¼-20 Nut, Top Lock Hex ¼-20 30-5
¼-20 Nut, Top Lock Hex ¼-20 52-21
¼-20 Nut, Top Lock, ¼-20 1-4
¼-20 x ½ Bolt, Hex Head Bolt Ø ¼-20 x ½” Long 83-4
¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½” Long 23-4
¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½” Long 42a-4
4-3-6 CD368
Rev 10
Chapter 4

¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾” Long 98-4
¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 11-11
¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 41a-14
¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 41b-19
¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x ½” Long 4-21
¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x 1½” Long 10-23
¼-20 x 1¾ Bolt, Hex Head Ø ¼-20 x 1¾” Long 52-23
¼-28 Fitting, Grease 23-14
½ Nut, Castle ½” ID 46-19
½ Nut, Nylon Lock - Low Profile, ½” ID 46-8
CD368 4-3-7
Rev 10
Chapter 4
½ Washer, Flat ½” ID 33-10

½ Washer, Flat ½” ID 61a-5
½ Washer, Flat ½” ID - Opt. 10-16
½ Washer, Lock ½” ID 75-3
½ Washer, Lock ½”ID 4-4
½ x 1¼ Washer, Flat ½” ID x 1¼” OD 69-2
½-13 Nut, Hex Crimp ½-13 69-4
½-13 Nut, Hex Crimp ½-13 70-4
½-13 Nut, Top Lock Hex ½-13 15-4
½-13 Nut, Top Lock Hex ½-13 22-16
½-13 Nut, Top Lock Hex ½-13 60-12
½-13 Nut, Top Lock Hex ½-13 61-12
½-13 Nut, Top Lock Hex ½-13 61a-12
½-13 Nut, Top Lock Hex ½-13 74-12
½-13 Nut, Top Lock Hex ½-13 85-19
½-13 x ¾ Bolt, Hex Head Ø ½-13 x ¾” Long 4-5
½-13 x 1 Bolt, Hex Head Ø ½-13 x 1" Long 77-20
4-3-8 CD368
Rev 10
Chapter 4
½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼” Long 15-4

½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼” Long 61a-6
½-13 x 1½ Bolt, Hex Head Ø ½-13 x 1½” Long 22-18
½-13 X 1½ Bolt, Hex Head Ø ½-13 x 1½” Long 33-9
½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾” Long 4-14
½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾” Long (Deutz) 85-20
½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long (Deutz) 85-20a
½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½” Long 61a-14
½-13X1 Bolt, Hex Head Ø ½-13 x 1" Long 85-23
½-20 Nut, Top Lock Hex ½-20 23-17
½-20 Nut, Top Lock Hex ½-20 24-17
½x½ Weather Strip, Self-Adhesive 85-10
1 Nut, Nylock, Coarse Thread 1" ID 4-10
1 Washer, Flat 1" ID 61a-16
1 1/16 x 2½ Washer, Flat 1 1/16" ID, Ø 2½” 4-11
1/8 x ½ Screw, Phillips Round Head 6-19
1/8 x ¾ Pin, Cotter Ø 1/8 x ¾” Long 46-10
CD368 4-3-9
Rev 10
Chapter 4

1/8 x 1 Pin, Cotter Ø 1/8 x 1" Long 44-9
1/8 x 1¼ Pin, Cotter 8-9
1/8 x 1¼ Pin, Cotter Ø 1/8 x 1¼” Long 44-10
1/8 x 1½ Pin, Cotter 1/8" x ½” Long 23-19
1/8 x 1½ Pin, Cotter Ø 1/8 x 1½” Long 43-9
10/32 Nut, Top Lock Hex 10-32 22-5
10-32 Nut, Elastic Stop 37-1c
10-32 Nut, Elastic Stop 38-1a
10-32 Nut, Non-Locking 10-32 29-3
10-32 Nut, Non-Locking 10-32 29a-2
10-32 Nut, Top Lock Hex 10-32 12-29
10-32 Nut, Top Lock Hex 10-32 23-11
10-32 Nut, Top Lock Hex 10-32 24-11
10-32 Nut, Top Lock Hex 10-32 29-6
10-32 Nut, Top Lock Hex 10-32 29a-4
10-32 Nut, Top Lock Hex 10-32 30-4
10-32 Nut, Top Lock Hex 10-32 31-10
10-32 Nut, Top Lock Hex 10-32 32-10
10-32 U-Bolt 37-1i
10-32 U-Bolt 38-1a
10-32 Washer, Flat 10-32 22-3
10-32 x ¾ Screw, Philips Head Ø 10/32 x ¾” Long 12-28
10-32 x ¾ Screw, Philips Head Ø 10-32 x ¾” Long 22-8
10-32 x ¾ Screw, Phillips Head Ø 10-32 x ¾” Long 29-2
10-32 x ¾ Screw, Phillips Head Ø 10-32 x ¾” Long 29a-3
10-32 x 1 Screw, Philips Head Ø 10-32 x 1" Long 22-4
10-32 x 1 Screw, Phillips Head Ø 10-32 x 1" Long 30-2
10mm x 17mm Washer, 10mm ID x 17mm OD 77-5
11/16 Washer, Flat 11/16" ID 23-20
11/16 Washer, Flat, 11/16"ID 24-6
118-1859 Fan, Alternator, Deutz 82-13
118-2187 Pulley, Alternator, Deutz 82-5
4-3-10 CD368
Rev 10
Chapter 4
1182388 Starter, Large 3KW (Deutz) 76-22

12960001 Decal, “Seat Belt” 28-8
12mm x 25mm Pin, Dowel Ø 12mm x 25mm Long 77-6
131282 Bulb 25-7
14 GAUGE Spade, 14-Gauge, Female 48-3
3/16 Washer, Flat 3/16" ID 12-3
3/32 x ½ Pin, Cotter Ø 3/32" x ½” Long 37-1e
3/32 x ½ Pin, Cotter Ø 3/32" x ½” Long 38-1a
3/32 x 7/8 Pin, Cotter 3/32 x 7/8" Long 31-9
3/32 x 7/8 Pin, Cotter 3/32" x 7/8" Long 23-9
3/8 Nut, Top Lock Hex 3/8-16 97-16
3/8 Washer, Flat 3/8" ID 15-2
3/8 Washer, Flat 3/8" ID 61a-10
3/8 Washer, Lock 45-23
3/8 Washer, Lock 3/8" ID 43-7
CD368 4-3-11
Rev 10
Chapter 4

3/8 Washer, Lock 3/8" ID - High Alloy 62-7
3/8 Washer, Lock 3/8" ID (Deutz) 97-14
3/8 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼” Long 94-28
3/8 x 1¼ Pin, Clevis Ø 3/8 x 1¼” Long 46-9
3/8 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½” Long 97-15
3/8 x 3/16 Spacer Ø 3/8" ID x 3/16" Long 80-8
3/8 x 3/16 Spacer, 3/8" ID x 3/16" Long 46-6
3/8 x 3/16 Spacer, 3/8" ID x 3/16" Long 47-6
3/8-16 Nut, Hex 3/8-16 (Plated) 44-12
3/8-16 Nut, Lock 3/8" ID 5-13
3/8-16 Nut, Top Lock Hex 3/8-16 11-2
3/8-16 Nut, Top Lock Hex 3/8-16 15-2
3/8-16 Nut, Top Lock Hex 3/8-16 39-12
3/8-16 Nut, Top Lock Hex 3/8-16 40-12
3/8-16 Nut, Top Lock Hex 3/8-16 48-11
3/8-16 Nut, Top Lock Hex 3/8-16 52-4
3/8-16 Nut, Top Lock Hex 3/8-16 60-7
3/8-16 Nut, Top Lock Hex 3/8-16 6-14
3/8-16 Nut, Top Lock Hex 3/8-16 61-7
3/8-16 Nut, Top Lock Hex 3/8-16 61a-7
3/8-16 Nut, Top Lock Hex 3/8-16 6-3
3/8-16 Nut, Top Lock Hex 3/8-16 80-9
3/8-16 Nut, Top Lock Hex 3/8-16 8-10
3/8-16 Nut, Top Lock Hex 3/8-16 91-12
3/8-16 Nut, Top Lock Hex 3/8-16 92-8
3/8-16 x ½ Bolt, Hex Head Ø 3/8-16 x ½” Long 85-21
3/8-16 x ¾ Bolt, Hex Head Ø 3/8-16 x ¾” Long 6-9
4-3-12 CD368
Rev 10
Chapter 4

3/8-16 x 1 Bolt, Hex Head Ø 3/8-16 x 1" Long 15-2
3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼” Long 39-7
3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼” Long 61a-9
3/8-16 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½” Long 47-23
3/8-16 x 1½ Screw, Hex Washer Head 45-29
3/8-20 x 3½ Bolt, Flange Head Ø 3/8-20 x 3½” Long 81-3
3/8-24 Nut, Hex 3/8-24 37-1g
3/8-24 Nut, Hex 3/8-24 38-1a
3/8-24 Nut, Hex 3/8-24 45-22
3/8-24 Nut, Jam 3/8-24 46-13
3/8-24 Nut, Jam 3/8-24 47-13
3/8-24 Nut, Top Lock Hex 3/8-24 62-15
3/8-24 Nut, Top Lock Hex 3/8-24 62-8
3/8-24 Nut, Top Lock Hex 3/8-24 64-15
3/8-24 Nut, Top Lock Hex 3/8-24 64-8
3/8-24 x 2½ Rod, All Threaded Ø 3/8-24 x 2½” Long 46-12
CD368 4-3-13
Rev 10
Chapter 4

3/8-24 x 5/8 Screw, Hex Head Ø 3/8-24 x 5/8" Long 37-1d
3/8-24 x 5/8 Screw, Hex Head Ø 3/8-24 x 5/8" Long 38-1a
4-100-101A Seat, Vinyl Bucket 14-3
417-8691 Bracket, Fuel Filter Head - Deutz 87-14
417-9734 Pump, Fuel - Deutz 87-29
440E-46006 Bearing, Thrust - Timken T113 56-5
440E-46007 Pin, King KB423 56-7
440E-46009 Nut, Tapered Wheel ½-20 UNF 56-19
440E-46009 Nut, Lug, ½-20 UNF Tapered Hex 57-18
5/16 Nut, Flange 5/16" 87-22
5/16 Washer, Flat 5/16" ID 87-15
5/16 Washer, Flat 5/16" 5-32
5/16 Washer, Flat 5/16" ID 12-31
5/16 Washer, Flat 5/16" ID 52-5
5/16 Washer, Flat 5/16" ID 94-3
5/16 Washer, Flat 5/16" ID 95-3
5/16 Washer, Flat, 5/16" ID 38-7
5/16 Washer, Flat 5/16" ID 87-5
5/16 Washer, Flat 5/16" ID 88-2
5/16 Washer, Flat 5/16" ID 89-2
5/16 x 1 Pin, Clevis Ø 5/16 x 1" Long 46-15
5/16-18 Nut, Flange 5/16-18 94-6
5/16-18 Nut, Flange 5/16-18 95-6
5/16-18 Nut, Flange 5/16-18 (as Spacer) 41-13
5/16-18 Nut, Lock 5/16"ID-18 38-9
5/16-18 Nut, Top Lock Hex 5/16-18 12-13
5/16-18 Nut, Top Lock Hex 5/16-18 5-33
5/16-18 Nut, Top Lock Hex 5/16-18 68-8
5/16-18 Nut, Top Lock Hex 5/16-18 87-3
5/16-18 Nut, Top Lock Hex 5/16-18 88-3
5/16-18 Nut, Top Lock Hex 5/16-18 89-3
4-3-14 CD368
Rev 10
Chapter 4

5/16-18 x 1¾ Bolt, Hex Head Ø 5/16-18 x 1¾” Long 68-7
5/16-18 x 2 Bolt, Hex Head Ø 5/16-18 x 2½” Long 88-5
5/16-18 x 2½” Bolt, Hex Head Ø 5/16-18 x 2½” Long 38-6
5/16-18x1 Bolt, Hex Head Ø 5/16-18 x 1" Long 94-2
5/8 Hose, Fuel - 2.5 ft Long 94-9
5/8-11 Nut, Top Lock Hex 5/8-11 54-8
5/8-11 Nut, Top Lock Hex 5/8-11 55-3
5-100-101 Line, Brake, 51" 41-10
5-100-101 Line, Brake, 51" 41a-12
5-100-101 Line, Brake, 51" 41b-14
660-1-1264 Modulator, with 90" Cable 31-3
660-1-1309 Cable, Battery, Black 40EC 97-12
660-1-1342 Hydro-Boost Assembly 39-3
660-1-1977 Wheel, 16" Steering 48-4
660-1-2228 End, Tie Rod 49-10
660-1-2228 End, Tie Rod 50-13
660-1-2228 End, Tie Rod 51-13
660-1-2292 Bracket, Cast Alternator, Deutz 80-1
660-1-2301 Relay, Dial Timer (Orange) 30-1
660-1-2308 Fitting, Oil Cooler - Straight Hose Adaptor 94-19
CD368 4-3-15
Rev 10
Chapter 4
660-1-2344 Extender, Spline Shaft - Deutz Hydraulic Pump 53-2

660-1-2345 Sleeve, Spline Shaft Extender 53-1
660-1-2405 Engine, Deutz with Integrated Cooling - Opt. 74-1
660-1-2412 Damper, Vibration - Oil Cooler Mtg. 93-11
660-1-2412 Damper, Vibration, Oil Cooler Mounting 94-12
660-1-2689 Spacer, Upper, C6 Shift Lever 38-8
660-1-3028 Valve, Steer 49-5
660-1-3028 Valve, Steer 50-9
660-1-3028 Valve, Steer 51-9
660-1-3046 Pigtail, Brake Warning 41b-29
660-1-3086 Switch, Brake Pressure 41b-17
660-2-2320 Closeout, Flywheel - Deutz Diesel 77-22
660-2-3290 Seat, Sears, Vinyl, Coldform with Logo 15-3
660-2-3461 Cooler, Transmission Fluid 95-14
660-2501-06-06 Elbow, 90° Male, 2501-06-06 49-14
660-2501-06-06 Elbow, 90° Male, 2501-06-06 51-26
660-4-0010-20 Valve, Relief 51-22
660-4-0010-20 Valve, Relief 52-22
660-4-0013-11 Cap, Filler 52-1
660-4-0509-18 Mini-Strut 96-2
660-4-0600-5 Bumper 8-16
660-4-0741-5 Breaker, Circuit (20 Amp) 22-6
660-4-0741-5 Breaker, Circuit (20 Amp) 29a-5
660-4-0745-12 Joint, Ball 23-8
660-4-0745-12 Joint, Ball 24-8
660-4-0745-12 Joint, Ball 31-5
660-4-0745-12 Joint, Ball 32-5
660-4-0745-12 Joint, Ball 33-5
660-4-0753-2 Relay - Opt. 22-10
660-4-0753-3 Base, Socket - Electric/Octagon 30-3
660-6-0582-26 Bumper, Rubber - Lift Arm 5-30
660-6-0582-26 Bumper, Rubber Lift Arm 68-4
4-3-16 CD368
Rev 10
Chapter 4
660-ND-1397 Adapter, Brake 41a-10

660-ND-1397 Adapter, Brake 41b-12
660-ND-1397 Adaptor, Brake 39-6
6F5OX Fitting, Straight-Thread Connector, Triple Lok 50-14
7/16 Washer, Flat 7/16" ID 85-18
7/16 Washer, Flat 7/16" ID 15-4
7/16 Washer, Flat 7/16" ID 22-17
7/16 Washer, Flat 7/16" ID 4-15
7/16 Washer, Flat 7/16" ID 62-14
7/16 Washer, Flat 7/16" ID 64-14
7/16 Washer, Flat 7/16" ID 74-3
7/16 Washer, Flat 7/16" ID 77-13
7/16 Washer, Flat 7/16" ID 78-13
7/16 Washer, Flat 7/16" ID 91-13
7/16 Washer, Flat 7/16" ID 92-9
7/16 Washer, Lock 7/16" ID 64-5
7/16 Washer, Lock 7/16" ID 66-17
7/16 Washer, Lock 7/16" ID 66-6
7/16 Washer, Lock 7/16" ID 77-14
7/16 Washer, Lock 7/16" ID 78-14
7/16-14 Nut, Lock - Gear Box Cover 66-7
7/16-14 Nut, Top Lock Hex 7/16-14 64-6
7/16-14 x 1¾ Bolt, Gear Box Cover 66-5
9/16 Washer, Flat 9/16" ID 46-17
9/16 Washer, Flat 9/16" ID 47-17
9/16-12 Nut, Top Lock Hex 9/16-12 68-6
9/16-18 Nut, Pipe Thread Lock 9/16-18 55-11
9/16-18 Nut, Top Lock Hex 9/16-18 54-5
AB6-4A Rivet, Blind 12-1
C406 Hose, 3/8" Low Press (Tank to Booster) 40-10
CMA-123 Hinge, R/H Door 12-30
CMA-124 Hinge, L/H Door 12-12
CD368 4-3-17
Rev 10
Chapter 4
CMA-127 Hinge, Receiver 9-27

CMA-308 Hinge, Window (Male) Half 11-8
CMA-308 Hinge, Window, Male Half 10-27
CMA-314 Handle, Breakover - Center Tube 10-7
CMA-316 Handle, Breakover - Long Rod 10-5
CMA-320 Handle, Center Opening 13-9
CMA-321 Rod, Door Handle Linkage 13-8
CMA-504 Strip, Seal - Door 10-26
CMA-504 Strip, Seal - Door, 12' Long 6-18
CMA-600 Pipe, Fuel Filter, 12" 85-3
CMA-605 Mirror, West Coast, L/H 10-33
CMA-609 Grip, Handle - Black 13-10
CMA-610 Mirror, West Coast, R/H 10-14
CMH-316 Plate, Striker Bolt Mounting 10-17
D0TZ-7A011A Seal, Transmission 45-17
D2AZ-7086A Gasket, C6 Tail Shaft and Extension Housing 45-27
D5TZ-7070A Ring, Snap 45-18
DEU1178607 Alternator, Bosch 81-14
DEU1179565 Belt - V 76-3
DEU1179565 Belt, Alternator 82-4
DEU2108653 Pulley, V-Belt 79-3
E1ZZ-7065A Bearing Assembly, with Retaining Ring 45-19
ENG-660-34 Engine, Deutz D2011 L04, Tier IVi 76-1
ENG-660-34 Engine, Deutz D2011, Tier IVi 78-1
ENG-660-34 Engine, Deutz, D2011 L04 72-1
ENG-M1A-24 Engine, Deutz F4M2011, without Cooler 76-1
HRN-M1A-24-111 Harness, Main, M1A Deutz 16-2
K2418 Pin, Cotter 63-45
M10 Washer, Flat 10mm 62-17
M10 Washer, Flat 10mm ID 80-19
M10 Washer, Flat M10 33-7
M10 Washer, Flat M10 ID 91-4
4-3-18 CD368
Rev 10
Chapter 4
M10 Washer, Flat Metric 10mm 52-31

M10 Washer, Lock 10mm ID 80-20
M10 Washer, Lock M10 ID 91-5
M10 Washer, Lock Metric 10mm 52-30
M10 - 1.5 X 25 Bolt, Hex Head Ø M10-1.5 x 25mm Long 33-8
M10-1.5 x 25 Bolt, Hex Head Ø M10-1.5 x 25mm Long 80-22
M10-1.5 x 30 Bolt, Metric Ø M10-1.5 x 30mm Long 52-29
M14 Washer, Lock 14mm 74-5
M1A CABK Cab, Kit Weldment 10-28
M1A DOORSK Door, Metal, Cab, M1A Kit 11-13
M1A-24-30 Frame Weldment, Modified Side Rails - M1A30-24 (Deutz 2011) 4-1
M1A-FRAME Frame Kit, Weldment 1-1
M1A-FRAME Frame, Kit, Weldment 4-1
M3-1-1059 Button, Horn - Two Wire, Isolated Ground 48-1
M3-1-8170 Isolator, Power Steering Pump 94-24
M3-2-8027 Cylinder, Steer 50-10
CD368 4-3-19
Rev 10
Chapter 4

M8-1.5 X 10 Bolt, Hex Head Ø M8-1.5 x 10mm Long 33-11
MD-CB1-129 Yoke 43-3
MD-CB1-129 Yoke 44-14
MD-CB1-129 Yoke 46-11
MD-CB1-129 Yoke 47-11
MD-CB21-115 Pin, Clevis 43-8
MD-CB21-121 Clip 41-15
MD-CB21-121 Clip 41a-17
MD-CB21-121 Clip 41b-20
MD-CB21-121 Clip 42-13
MD-CB21-121 Clip 42a-8
MD-P21-105 Isolator, Transmission Mount C6 77-18
MD-P21-105 Isolator, Transmission Mount, C6 78-18
MD-SO1-140 End, Tie Rod - R/H 49-13
MG-1-320 Trim-Lock 96-4
MG-1-320 Trim-Lock (3 ft.) 97-8
MG-1-585 Spacer, Steer Column 21-13
MH-1-327 Bracket, Park Brake Cable 7-8
MH-1-806 Bushing, Suspension 1-19/32 x 5/ 8 x 2 55-6
MH-ND-543 Hose, Brake, 15" 41-17
MH-ND-543 Hose, Brake, 15" 41a-19
MH-ND-543 Hose, Brake, 19" 41b-22
MH-ND-553 Sleeve, Pinion - Speedometer 77-26
MH-ND-553-1 Tip, Adapter - Speedometer Drive 77-25
MH-ND-553-3 Pinion, Transmission - Speedometer 77-27
MH-ND-565 Line, Brake 10" 39-5
MH-ND-565 Line, Brake, 10" 41-1
4-3-20 CD368
Rev 10
Chapter 4
MH-ND-565 Line, Brake, 10" 41b-6

MH-ND-650 Tire, LT215/85R16 18-2
MH-ND-955 Switch, Heater/Defroster, 4 Position Fan - 12V 26-2
MI-1-322 Cable, Park Brake/Accelerator 32-4
MJ-1-5102 Hose, Pump to Booster 39-10
MJ-ND-1221 Cooler, Transmission Fluid 93-9
MJ-ND-2001-49 Washer 65-41
MJ-ND-4006 Ring, Lashing 5/8" x 4¼” x 4¼” - Forged with Bracket 1-9
MJ-ND-8002 Yoke 21-7
MJ-ND-8002 Yoke 23-16
MJ-ND-8002 Yoke 24-16
MJ-ND-8002 Yoke 39-13
MJ-ND-8002 Yoke 40-13
ML-26 Decal, “Caution” 28-6
MX4-10067-7 Hub, Cupped and Studded 57-16
T-430 Decal, “Caution: All Operators…” 28-3
T6-1001-123 Spring, Throttle 21-4
T6-1001-133 Sender, Oil Pressure (Bore & Tap Plug) 75-21
T6-1005-105 Muffler, Gas 90-7
T6-1005-105 Muffler, Gas 91-11
T6-1005-105 Muffler, Gas 92-7
T6-1005-115 Strap, Exhaust Hanger 90-5
T6-1005-119 Clamp, 2" Exhaust 90-6
T6-1005-119 Clamp, 2" Exhaust 91-9
T6-1005-119 Clamp, 2" Exhaust 92-4
T6-1008-111 Transmission, C-6 - 3 Speed 77-11
CD368 4-3-21
Rev 10
Chapter 4
T6-1009-109 Stud, Throttle Cable 21-10

T6-1021-103 Linkage, Shift 37-1f
T6-1021-107 Anchor, Shifter Cable 34-3
T6-1211-101-3 Fan, Alternator 80-12
T6-1211-101-5 Alternator, 100 Amp, without Pulley (Perkins, Deutz) 80-11
T6-1211-101-6 Nut, Pulley - Alternator 80-14
T6-1211-103 Plug, Alternator Socket 80-10
T6-1300-247 Headlight 16-1
T6-1300-257 Meter, Hour 25-2
T6-1300-257 Meter, Hour 26-4
T6-1300-257 Meter, Hour 27-4
T6-2001-107 Bearing 63-6
T6-2001-107 Bearing 65-8
T6-2001-109 Case, Differential Flange & Tongue 63-7
T6-2001-111 Ring & Pinion Set - 14:1 Ratio 63-9
T6-2001-119 Washer, Thrust 63-10
T6-2001-121 Gear, Side (Gear Kit: Side Gears and Pinions) 63-11
T6-2001-121 Pinion (Gear Kit: Side Gears and Pinions) 63-12
T6-2001-127 Washer, Pinion Thrust 63-13
T6-2001-131 Screw, Cap - Differential and Gear Assembly 63-14
T6-2001-135 Breather 62-10
T6-2001-135 Breather 63-28
T6-2001-135 Breather 64-19
T6-2001-135 Breather - Oil 65-11
T6-2001-137 Plug, Lubricant Drain 63-22
T6-2001-143 Plug, Lubricant Fill 63-21
T6-2001-145 Bolt, Hex Head 63-18
T6-2001-145 Bolt, Hex Head 65-18
T6-2001-147 Washer, Flat 63-20
T6-2001-147 Washer, Flat 65-15
T6-2001-149 Locknut 65-14
T6-2001-149 Nut, Lock 63-19
T6-2001-151 Race, Differential Bearing 63-5
T6-2001-153 Pin, Bevel Gear Thrust Block 63-16
T6-2001-155 Block, Thrust - Bevel Gear 63-15
4-3-22 CD368
Rev 10
Chapter 4

T6-2001-165 Bearing, Drive Axle (Inner & Outer) 65-53
T6-2001-165 Colar, Bearing Spacer 65-51
T6-2001-165 Collar, Bearing Spacer 63-34
T6-2001-167 Race 65-52
T6-2001-167 Race 63-35
T6-2001-171 Shim, Drive Axle 63-37
T6-2001-173 Retainer 63-38
T6-2001-173 Retainer 65-55
T6-2001-175 Gasket, Oil Seal Retainer 63-39
T6-2001-177 Retainer, Oil Seal 63-40
T6-2001-179 Washer, Lock 63-42
T6-2001-179 Washer, Lock 65-58
T6-2001-181 Bolt .38-16UNCX1.25/1.00 HHCS 65-59
T6-2001-181 Bolt, Retainer 63-41
T6-2001-187 Washer, Axle Nut 63-44
T6-2001-189 Nut, Axle 63-43
T6-2001-189 Nut, Axle 65-63
T6-2001-193 Gasket, Bevel Pinion Cage 63-23
T6-2001-195 Ring, Lock 63-24
T6-2001-195 Ring, Snap, E25.4 X 1.57 CS 65-21
T6-2001-197 Bearing, Bevel Pinion Pilot 63-25
T6-2001-199 Bearing, Pinion 63-27
T6-2001-199 Bearing, Pinion. Inner 65-23
T6-2001-199 Bearing, Pinion. Outer 65-31
T6-2001-201 Cup, Pinion Bearing 63-26
T6-2001-203 Cage, Pinion Bearing 63-30
T6-2001-205 Dowel 63-31
T6-2001-207 Gasket, Oil Seal (RTV Sealant) 63-17
CD368 4-3-23
Rev 10
Chapter 4
T6-2001-209 Spacer, Axle 63-29

T6-2001-211 Washer, Keyway 65-32
T6-2001-217 Washer, Gear Case to Axle 66-2
T6-2001-219 Nut, Gear Case to Axle 66-3
T6-2001-223 Key, Gear 65-34
T6-2001-223 Key, Gear 66-12
T6-2001-225 Nut, Bevel Pinion Bearing 66-14
T6-2001-227 Lock, Bevel Pinion Bearing Nut 65-36
T6-2001-227 Nut, Lock - Bevel Pinion Bearing 66-13
T6-2001-231 Washer, Input Shaft 66-25
T6-2001-233 Flange, Input Shaft 66-24
T6-2001-235 Seal, Oil - Input Shaft 66-23
T6-2001-245 Plug 66-10
T6-2001-247 Bearing, Input Shaft, Front 66-21
T6-2001-255 Ring, Snap - Input Shaft Bearing 66-19
T6-2001-255 Ring, Snap, Input Shaft Bearing 65-45
T6-2001-257 Gasket, Reduction Gear 65-37
T6-2001-257 Gasket, Reduction Gear Case 66-4
T6-2001-263 Dowel, Gear Box Cover 65-38
T6-2001-265 Plug, Fill - Gear Box Oil 66-9
T6-2001-267 Gasket, Rear Input Shaft Cap 66-15
T6-2001-273 Screw, Cap - Rear Input Shaft Cover 66-18
T6-2001-281 Nut, Input Shaft 66-26
T6-2001-291 Bolt Kit 63-8
T6-2001-291 Bolt Kit 65-10
T6-2001-321 Gear, Input 65-47
T6-2001-321 Gear, Input 66-22
T6-2001-323 Gear, Driven 65-33
T6-2001-323 Gear, Driven 66-11
T6-2001-325 Bearing, Rear Input Shaft 65-46
T6-2001-327 Case and Cover, Reduction Gear 66-1
T6-2001-329 Cap, Rear Input Shaft 66-16
T6-2001-329 Cap, Rear Input Shaft Bearing 65-43
T6-2001-601 Differential and Axle Housing Assembly, L/H 63-2
4-3-24 CD368
Rev 10
Chapter 4
T6-2001-602 Differential and Axle Housing Assembly, R/H 63-1

T6-2001-603 Shaft, Short Axle 63-3
T6-2001-604 Shaft, Long Axle 63-4
T6-2001-604 Shaft, Long Axle - Opt. 65-4
T6-2001-605 Rotor 63-32
T6-2001-606 Hub 65-60
T6-2001-607 Stud, Rear Axle 63-46
T6-2001-607 Stud, Rear Axle, MA 65-50
T6-2001-609 Rotor, 12.625"OD, .898"Wide 65-49
T6-2002-107 U-Joint, Rear 67-3
T6-2002-301 U-Bolt, Rear Axle 59-5
T6-2006-103P Bolt, Spicer 62-18
T6-2006-103P Bolt, Spicer 64-18
T6-2006-107 U-Joint, Front 67-2
T6-2006-111 End, Flange Yoke 67-4
T6-2201-103-1 Caliper, Brake Assembly 71a-
T6-2201-103-2 Service Kit, Caliper Seal and Piston (Includes items 3, 4, and 5) 71a-
T6-2201-103-3 Service Kit, Caliper Seal (Includes items 3 and 4) 71a-
T6-2201-103-4 Service Kit, Caliper Lining and Clip (Includes items 1, 2, and 7) 71a-
T6-2201-103-5 Service Kit, Caliper Bushing and Stud (Includes items 10 and 11) 71a-
T6-2400-164 Tire, Tug Tuff 690 x 9 (with Liner) 17-2
T6-2400-168 Wheel, Tug Tuff 4.0 x 9.0 (2 Piece) 19-3
T6-2400-168 Wheel, Tug Tuff 4.0 x 9.0 (Two - Piece) 17-1
T6-2400-169 Wheel, Tug Tuff 6.75 x 16.5 19-7
T6-2400-169 Wheel, Tug Tuff, 6.75 x 16.5 18-1
T6-2400-170 Tire, Tug Tuff 8.75 x 16.5, 10PR 19-6
T6-2400-170 Tire, Tug Tuff, 8.75 x 16.5 18-2
T6-2400-186 Tire/Wheel Assembly, Front, MA Standard 19-1
T6-3001-60002 Knuckle, Assembly, L/H 57-7
T6-3001-60005 Cap, King Pin 56-10
T6-3001-60005 Cap, King Pin 57-4
T6-3001-60006 Screw, Button Head 56-11
T6-3001-60006 Screw, Button Head, 10-24 UNC x 5/8 Long 57-11
CD368 4-3-25
Rev 10
Chapter 4
T6-3001-60012 Nut, ½-13 UNC, Hex 57-2

T6-3001-6002 Washer, Tongued Spindle 56-15
T6-3001-60020 Stud, Wheel 56-20
T6-3001-60028 Washer, Spindle, 1" 57-21
T6-3001-60030 Pin, Cotter 57-22
T6-3001-60031 Cap, Grease 56-18
T6-3001-60031 Cap, Grease 57-24
T6-3001-601-2 Stud, Wheel, ½-20 UNF x 1 7/8 57-17
T6-3001-601-3 Knuckle, Assembly, R/H 57-7
T6-3001-601-4 Zerk, Grease 57-25
T6-3001-601-5 Bearing, Spindle 57-6
T6-3003-105 Nut, Lug ½-20 THD, Ford 63-47
T6-3003-107 Nut, Lug ½-20 19-4
T6-3200-127 Filter, Racor without Heater 86-1
T6-3200-131 Elbow, Racor 85-16
T6-3200-131 Elbow, Racor 87-6
T6-3200-131 Elbow, Racor Filter 88-25
T6-4005-109 Handle, Hood 7-1
T6-4005-109 Handle, Hood 8-18
T6-4005-121 Clip, Hood Rod 7-14
T6-4005-121 Clip, Hood Rod 8-20
T6-4006-111R Latch, Hood - Rubber with Hooking Bracket 7-16
T6-4006-113 Edging, Rubber 12-19
T6-4012-107 Mount, Rubber Seat 4-3
T6-4014-103 Hitch Assembly, E-, Standard 1-6
T6-4014-122 Bracket, Hitch Extension 20-2
T6-4044-200 Hitch Assembly 20-1
T6-4044-200 Hitch Assembly - Opt. 1-6
T6-4121-109 Spacer, Accelerator Pedal 5-35
T6-4800-112 Mount, Engine Half, L/H - Weldment (Deutz) 73-4
T6-4800-122 Pulley, PTO (Deutz) 76-6
T6-4800-155 Plug, Deutz Fuel Pump 76-14
T6-4900-202 Hydro-Boost Assembly 40-3
T6-500-102 Reflector, Amber Rectangular 10-31
4-3-26 CD368
Rev 10
Chapter 4
T6-500-103 Reflector, Red Rectangular 10-29

T6-500-107 Grommet 11-9
T6-500-108 Grommet 68-4
T6-5005-105 Clamp, Upper Steer 21-11
T6-5005-105 Clamp, Upper, Steer 48-10
T6-5011-101 Pump Assembly - Power Steering 50-1
T6-5011-107 Pulley, Power Steering 79-6
T6-5011-108 Pulley, Power Steering - GM 50-2
T6-600-112 Adaptor 39-4
T6-600-112 Adaptor 40-4
T6-600-114 Adapter, Brake Line to Master Cylinder 41a-9
T6-600-114 Adapter, Brake Line to Master Cylinder 41b-10
T6-600-114 Adaptor, Brake Line to Master Cylinder 41-7
T6-6003-107 Filter Material, 1" Horse Hair 84-5
T6-6004-101GREEN Cap Assembly, Fuel, Diesel (Green) 85-5
T6-6004-101GREEN Cap, Fuel, Diesel (Green) Assembly 84-7
T6-6004-101S O-Ring 84-8
T6-6004-101S O-Ring 85-4
T6-6006-107A Elbow, 90°, Compression to Pipe 86-3
T6-6010-111 Valve, Fuel Drain 86-4
T6-6011-111 Tee 41-18
T6-6011-111 Tee 41a-20
T6-6011-111 Tee 41b-11
T6-6011-111 Tee 41b-27
T6-6011-111 Tee 42-2
T6-6011-111 Tee 42a-2
T6-6011-113 Angle, Tee Support 97-2
T6-6011-141 Line, Brake, 20" 41b-24
T6-6011-141 Line, Brake, 20" 41b-28
T6-6011-141 Line, Brake, 20" 42-14
T6-6011-141 Line, Brake, 20" 42a-11
T6-6011-151 Line, Brake 6" 41-8
T6-6011-151 Line, Brake 6" 42a-13
T6-6011-151 Line, Brake, 6" 41a-6
T6-6011-151 Line, Brake, 6" 41b-25
T6-6011-151 Line, Brake, 6" 41b-7
CD368 4-3-27
Rev 10
Chapter 4
T6-6011-151 Line, Brake, 6" 42-4

T6-6011-161 Line, Brake, 30" 41b-23
T6-6011-161 Line, Brake, 30" 42-3
T6-6011-161 Line, Brake, 30" 42a-5
T6-6015-101 Belt, Alternator 80-15
T6-7001-205 Battery, Group 27 96-1
T6-7001-205 Battery, Group 27 97-9
T6-7006-101A Light, Tail (Kit) 16-5
T6-7006-105 Switch, Stop Light 21-17
T6-7006-107A Light, Back-Up (Kit) 16-4
T6-7010-103 Gauge, Oil Pressure & Wedge Base Light 25-4
T6-7010-113 Switch, Toggle (Head Light) 25-14
T6-7010-113 Switch, Toggle (Heater) 25-11
T6-7010-120 Light, Red Warning - Flat Head (Brake Warning) 25-10
T6-7010-120 Light, Red Warning - Flat Head (Low Oil) 25-13
T6-7010-120 Light, Red Warning, Flat Head 26-14
T6-7010-120 Light, Red Warning, Flat Head - Opt. 26-14
T6-7010-129 Socket, Light, with Bulb 25-9
T6-7010-131 Gauge, Ammeter 26-5
T6-7010-133 Voltmeter 25-6
T6-7010-133 Voltmeter 26-5
T6-7010-133 Voltmeter 27-5
T6-7010-140 Switch, Ignition - CH Lever 21-16
T6-7010-140 Switch, Ignition C.H. Lever 22-14
T6-7010-211 Mount, Circuit Breaker 22-7
T6-7010-211 Mount, Circuit Breaker 29a-1
T6-7013-207 Horn 98-1
T6-7013-209 Relay, Horn - Ford, Deutz 22-13
4-3-28 CD368
Rev 10
Chapter 4
T6-7016-119 Cable, Battery, Red 48EC 97-11

T6-7016-121 Cable, Battery, Black 40EE 97-13
T6-7200-090 Shaft, Drive 45-4
T6-7200-090 Shaft, Drive (Ford) 64-9
T6-8003-601 Hub, Rear 63-33
T6-8005-101 Lever, Hand Brake 43-1
T6-8005-103 Bushing, Hand Brake 43-2
T6-8005-133 Nut, Hex 45-14
T6-8005-135 Plate, Park Brake 45-9
T6-8005-137 Washer, Lock 45-13
T6-8005-143 Shoe, Park Brake (C-6) 45-16
T6-8005-147 Spring, Park Brake Assembly (C-6) 45-11
T6-8011-107 Adapter, Brake Warning 41b-3
T6-8011-107 Adaptor, Brake Warning 41-3
T6-8011-113 Valve, Hydraulic Brake Warning 41-6
T6-8011-117 Pigtail, Brake Warning 41-2
T6-8011-121 Connector 41-9
T6-8011-121 Connector 41a-11
T6-8011-121 Connector 42-6
T6-8011-121 Connector, 41b-13
T6-8013-143 Hose, Brake 42-10
T6-8013-143 Hose, Brake 42a-10
T6-8013-143 Hose, Brake 62-3
T6-8013-143 Hose, Brake 64-3
T6-8013-143 Hose, Brake 71-9
T6-8013-145 Bolt, Brake Hose 62-4
T6-8013-147 Washer, Brake Hose 62-5
CD368 4-3-29
Rev 10
Chapter 4
T6-8013-149 Pads, Brake - Non-Organic 71-4

T6-8013-149 Pads, Brake, Non-Organic 71b-11
T6-8013-153 Boot Kit, Dust 71-3
T6-8013-153 Boot, Piston, Kit 71b-10
T6-8013-157 Piston 71-2
T6-8013-157 Piston 71b-8
T6-8013-159 Bolt, Caliper 71-6
T6-8013-159 Bolt, Caliper 71b-1
T6-8013-165 Screw, Bleeder - Delco 71-8
T6-8013-167 Sleeve 71-7
T6-8013-167 Sleeve 71b-2
T6-8013-169 Clip, Retainer 71-5
T6-8013-169 Clip, Retainer 71b-12
T6-8013-181 Caliper, L/H Rear 71-1
T6-8013-183 Caliper, R/H Rear 71-1
T6-8013-201 Pads, Brake - Organic 71-4
T6-8013-201 Pads, Brake, Organic - Opt. 71b-11
T6-9003-123 Arm, Wiper 11-10
T6-9003-125 Blade, Wiper 11-1
T6-9003-133 Operator, Latch - L & R 13-6
T6-9003-165 Gasket, Class Window (by the foot) 10-32
T6-9003-165 Gasket, Glass Window 12-11
T6-9003-171 Grommet, Windshield 10-3
T6-9003-197 Light, Dome 10-11
T6-9003-209A Switch, Wiper/Dome Light 10-10
T6-9003-211 Spacer, Grommet 11-7
T6-9003-211 Spacer, Groomet 10-24
T6-9003-301 Latch, Rotary L/H 12-22
T6-9003-302 Latch, Rotary R/H 12-24
T6-9003-303 Bolt, Striker 13-3
T6-9003-303 Bolt, Striker (Skin Door Opt.) 10-15
4-3-30 CD368
Rev 10
Chapter 4
T6-9003-309 Retainer, Door Handle Rod 13-5

T6-9003-317 Anchor, Door Closure 9-20
T6-9003-322 Closure, Door 12-4
T6-9003-549 Wheel, 16" x 6", White 18-1
T6-9003-571 Button, Plug, Black ½” 26-10
T6-9003-572 Button, Plug, Black ¾” 26-9
T6-9011-101A Hook, Battery Hold Down 97-5
T6-9011-101B Tee, Battery Hold Down 97-10
T6-9011-103 Belt, Seat (Retractable) 14-4
T6-9011-149 Plate, Data - Draw Bar 28-4
T6-9011-404 Adapter, Speedometer, .4105 Ratio 77-24
T6-9011-506 Relay, Electric, Solenoid 30-7
T6-9011-605 Plate, Full Range Shifter 36-8
T6-9011-621-1 Axle, Rear Drive 14:1 without Mount 62-1
T6-9011-621-1 Axle, Rear Drive, 14:1, without Mount 65-
T6-9011-621-1 Axle, Rear, Drive 64-1
T6-9011-621-10 Replacement Kit, Piston & Seal (Includes Items 8, 9 & 10) - Not Shown
71b-16
T6-9011-621-11 Cup, Bearing 65-16
T6-9011-621-11 Cup, Bearing 65-5
T6-9011-621-12 Flange & Tongue Differential Assembly 65-6
T6-9011-621-13 Gasket, Oil Seal 65-17
T6-9011-621-14 Plug 65-19
T6-9011-621-15 Shim, Pack 65-25
T6-9011-621-16 Gear Case Assembly 65-28
CD368 4-3-31
Rev 10
Chapter 4
T6-9011-621-17 Gear Case 65-29

T6-9011-621-18 Plug 65-30
T6-9011-621-19 Cover, Gear Case 65-39
T6-9011-621-2 Service Kit, Brake Seal (Includes Items 9 & 10) - Not Shown 71b-17
T6-9011-621-20 Bearing 65-48
T6-9011-621-21 O-Ring 65-61
T6-9011-621-22 Bearing 65-22
T6-9011-621-3 Caliper Assembly, R/F or L/R 71b-6
T6-9011-621-4 Caliper Assembly, L/F or R/R 71b-6
T6-9011-621-5 Service Kit, Brake Pads (Includes Items 11, 12 & 13) - Not Shown 71b-14
T6-9011-621-6 Case, Differential Flange, Half 65-1
T6-9011-621-7 Case, Differential Plain, Half 65-2
T6-9011-621-8 Gear, Set, 14:1 65-9
T6-9011-621-9 Service Kit, Bushing & Mounting Stud (Includes Items 1, 2, 3, & 7) - Not Shown
71b-15
T6-9011-622-1 Axle, Rear Drive 20:1 without Mount - Opt 62-1
T6-9011-633 Bracket, Top, Fluid Cooler 95-13
T6-9011-928 Stud, Accelerator 32-12
T-A16 Decal, “Fasten Safety Belt” 28-8
T-B2 Decal, “For Industry & Aviation” 28-2
TM1 ND-9701 Knuckle Weldment, L/H 56-6b
TM1-0-8105 Axle, Rockwell Rear - M1 62-18
TM1-0-8130 Shock, with Stud 59-7
TM1-0-8130 Shock, with Stud 61a-3
TM1-0-8140 Filter, Air - Donaldson 83-1
TM1-0-8142 Band, Air Filter - Donaldson 83-3
TM1-0-8145 Element, Air Filter (Deutz, Perkins) 83-2
TM1-0-9516 Handle, Door (Recessed) 13-1
TM1-1-0804 Shaft, Drive 62-9
TM1-1-0804 Shaft, Drive (Deutz, Perkins) 64-9
TM1-1-0804 Shaft, Drive (Perkins, Deutz) 45-4
TM1-1-0812 Pipe, Tail (Ford 300, Deutz) 90-3
4-3-32 CD368
Rev 10
Chapter 4

TM1-1-3002 Mount, Shifter 6-8
TM1-1-3004 Support, Front Hood 8-19
TM1-1-3004 Support, Front Hood (Deutz) 2-5
TM1-1-3084 Bracket, Seat Isolator 3-2
TM1-1-3501 Spring, Seat - Rear Cradle 64-12f
TM1-1-3502 Tube, Pivot - Rear Cradle 64-12a
TM1-1-3503 Mount, Rear Cradle Shock 64-12c
TM1-1-3506 Bushing, Rear Cradle 4-8
TM1-1-3508 Washer, Thrust 59-3
TM1-1-3512 Spring, Rear 13" x 400 lb. - Red Coil 61-2
TM1-1-3512 Spring, Rear 13" x 400 lb. - Red Coil 61a-2
TM1-1-3512 Spring, Rear, 13" x 400 lb., Red Coil 59-6
TM1-1-3526 Mount, Lower Rear Cradle Chain 64-12d
TM1-1-5004 Bracket, Side Panel Mounting 1-2
TM1-1-5006 Bracket, Exhaust Pipe Support - Deutz 90-4
TM1-1-5007 Tube, Air Cleaner Adaptor - Deutz 83-8
TM1-1-5008 Hose, Oil Cooler - 41" Deutz 93-5
TM1-1-5008 Hose, Oil Cooler (Bottom) 41" (Deutz) 76-19
TM1-1-5009 Hose, Oil Cooler (Top) 21" (Deutz) 76-21
TM1-1-5010 Bracket, Lower Oil Cooler Mount 93-4
TM1-1-5011 Bracket, Glow Plug Relay Mounting - Deutz 22-9
TM1-1-5025 Washer, Motor Mount Safety - Deutz 74-14
TM1-1-5030 Yoke, Transmission Modulator Slide 21-3
CD368 4-3-33
Rev 10
Chapter 4
TM1-1-5031 Bracket, Accelerator Cable Mounting 21-12

TM1-1-5033 Arm, 3" Accelerator - Deutz 33-3
TM1-1-5061 Bolt, Universal Cradle Crossmember 61a-15
TM1-1-5061 Bolt, Universal Cradle Crossmember, M1A 59-9
TM1-1-5061 Bolt, Universal Cradle, Crossmember 4-16
TM1-1-6525 Handle, Breakover - M1 & M3 Cab 10-6
TM1-1-6526 Heater, Engine - Deutz (Opt.) 74-20
TM1-1-6535 Switch, Dual Wiper 26-3
TM1-1-6541 U-Bolt, Front Axle - M1A 54-3
TM1-1-6548 Bracket, Transmission Line 77-12
TM1-1-8048 Rod, Hood Prop 7-12
TM1-1-8050 Bracket, Accelerator Stop 23-2
TM1-1-8051 Operator, Door Latch - M1 12-23
TM1-1-8066 Rod, Seat Plate Prop 14-5
TM1-1-8068 Angle, Upper Seat Plate Prop 14-6
TM1-1-8069 Bracket, Lower Seat Plate Prop 6-16
TM1-1-8082 End, Panhard Rod 68-2
TM1-1-8089 Rubber, Seat Plate Hinge 14-10
TM1-1-8090 Closeout, Steer Column 48-13
TM1-1-8090 Closeout, Steering Column 21-6
TM1-1-8152 Shifter Assembly 35-1
TM1-1-8152 Shifter Assembly (Note 1) 34-1
TM1-1-8154 Connection Kit, Transmission 35-7
4-3-34 CD368
Rev 10
Chapter 4
TM1-1-8158 Bracket, Brake Line 41-16

TM1-1-8158 Bracket, Brake Line 41a-18
TM1-1-8158 Bracket, Brake Line 41b-21
TM1-1-8160 Bracket, Upper Chain 59-10
TM1-1-8160 Bracket, Upper Chain 61a-8
TM1-1-8182 Cable, Shifter 58" 34-2
TM1-1-8182 Cable, Shifter, 58" 38-4
TM1-1-8209 Tee, 3/8" Female Pipe 50-5
TM1-1-8210 Barb, 3/8" Hose 50-6
TM1-1-8223 Hose, Hydraulic 3/8" x 29" Long (Pump to Booster) 39-11
TM1-1-8223 Hose, Hydraulic, 3/8" x 29" Long 52-35
TM1-1-8226 Hose, Hydraulic Ø 3/8" x 22" Long 51-21
TM1-1-8227 Hose, Steer Sector Return 50-4
TM1-1-8227 Hose, Steering Sector Return 39-2
TM1-1-8228 Hose, Power Steering 40-11
TM1-1-8256 Spacer, Steer Sector 1" 49-15
TM1-1-8258 Anchor, Brake 41b-26
TM1-1-8258 Anchor, Brake 42-11
TM1-1-8258 Anchor, Brake 42a-9
TM1-1-8270 Cable, Battery, Red 33EE 96-5
TM1-1-8272 Cable, Battery, Black 27EE 96-6
TM1-1-8326 Hose (Steer Valve P to Booster) 50-12
TM1-1-8326 Hose (Steering Valve P to Booster) 49-9
TM1-1-8326 Hose, Steer Valve P to Booster - Opt. 39-11
TM1-1-8328 Hose (Steer Valve T to Return) 50-11
CD368 4-3-35
Rev 10
Chapter 4
TM1-1-8328 Hose (Steering Valve T to Return) 49-7

TM1-1-8328 Hose, Steer Valve to Return 93-14
TM1-1-8330 Hose (Steer Valve L to Cylinder) 50-16
TM1-1-8330 Hose (Steering Valve L to Cylinder) 49-8
TM1-1-8332 Hose (Steer Valve R to Cylinder) 51-7
TM1-1-8332 Hose (Steering Valve R to Cylinder) 49-11
TM1-1-8334 Column, Steer 48-5
TM1-1-8352 Cooler, Power Steering & Transmission 93-12
TM1-1-9004 Anchor, Rear Cab 9-8
TM1-1-9046 Stop, Windshield Support 9-26
TM1-1-9047 Flap, Door Rubber - M1A 12-7
TM1-1-9512 Heater Assembly 10-21
TM1-1-9514 Motor, Wiper 11-3
TM1-1-9554 End, Panhard Rod 69-6b
TM1-1-9578 Heater, Block (Deutz) - Opt . 76-9
TM1-1-9579 Brace, Cradle Plate, R/H 64-12e
TM1-1-9581 Rubber, Seat Plate Lower Hinge 14-10
TM1-1-9582 Brace, Cradle Plate, L/H 64-12b
TM1-1-9590 Bracket, Seat Belt - M1A 15-2
TM1-1-9632 Tower, Panhard Rod - Weldment 70-7
TM1-1-9633 Bracket, Panhard Rod - Weldment 70-3
TM1-1-9693 Engine, Deutz F4M2011 - Tier II 72-1
TM1-1-9693 Engine, Deutz F4M2011, Tier II 76-1
4-3-36 CD368
Rev 10
Chapter 4
TM1-1-9693-1 Alternator, Bosch 82-14

TM1-1-9693-1 Alternator, Tier II (Deutz) 76-2
TM1-1-9693-2 Cooler, Oil, Deutz 95-18
TM1-1-9757 Bracket, Accelerator 32-13
TM1-1-9758 Filter, Transmission, In-Line 94-30
TM1-1-9764 Adapter, 90° 77-23
TM1-1-9775 Axle, Drive 20:1 - Opt. 62-18
TM1-1-9775 Axle, Drive 20:1 - Opt. 64-1
TM1-1-9778 Axle, Drive 14:1 62-18
TM1-1-9778 Axle, Drive 14:1 64-1
TM1-1-9787 Valve, Brake Warning 41a-4
TM1-1-9787 Valve, Brake Warning 41b-4
TM1-1-9791 Plug, Brake Proportioning Valve 41a-5
TM1-1-9791 Plug, Brake Proportioning Valve 41b-5
TM1-1-9792 Adapter, Brake Proportioning Valve 41a-3
TM1-1-9793 Housing, Rubber 41a-2
TM1-1-9793 Housing, Rubber 41b-2
TM1-1-9794 Terminal 41a-8
TM1-1-9794 Terminal 41b-9
TM1-1-9795 Sleeve 41a-7
TM1-1-9795 Sleeve 41b-8
TM1-1-9797 Hose, Brake at Master Cylinder 40-5
TM1-1-9797 Hose, Brake at Master Cylinder 41a-1
TM1-1-9797 Hose, Brake at Master Cylinder 41b-1
TM1-1-9814 Tire/Wheel Assembly, 8.75 x 16.52 19-5
TM1-2-3012 Bumper, Rear 3-1
TM1-2-3024 Bracket, Panhard Arm 68-3
TM1-2-3026 Bracket, Steer Sector Mount 49-16
TM1-2-3030 Mount, Radiator Angle 94-17
TM1-2-3030 Mount, Radiator Angle (Deutz) 2-4
TM1-2-3032 Gusset, Firewall L/H 5-18
TM1-2-3040 Gusset, Firewall R/H 5-17
TM1-2-3044 Reinforcement, Center Joint 5-24
TM1-2-3066 Closeout, Bumper 2-2
TM1-2-3080 Angle, 48¾” Firewall Support 3-3
CD368 4-3-37
Rev 10
Chapter 4
TM1-2-3524 Tab, Panhard Arm 69-3

TM1-2-5003 Bracket, Alternator Adjustment - Deutz 79-1
TM1-2-5034 Mount, Manifold Pipe - M1 90-8
TM1-2-5035 Plate, Backing - Drive Axle Pad 59-13
TM1-2-5035 Plate, Drive Axle Pad 62-13
TM1-2-5036 Cover, Inside Door Handle L/H - M1 12-9
TM1-2-5040 Crossmember, Upper Raised Cab 9-4
TM1-2-5042 Tube, Top Horizontal Side - M1A Raised Cab 9-5
TM1-2-5043 Cover, Inside Door Handle R/H - M1 12-8
TM1-2-5046 Hanger, J-Hook Exhaust - Opt. 91-10
TM1-2-8008 Dipstick, Hydraulic Reservoir Cap - M1A 52-2
TM1-2-8009 Mount, Radiator Bracket - M1A 95-30
TM1-2-8009 Mount, Radiator Bracket (Deutz) 2-6
TM1-2-8010 Plate, U-Bolt, Upper 54-9
TM1-2-8011 Reinforcement, Firewall - Tier 1 5-29
TM1-2-8019 Mount, Fluid Cooler - M1 94-13
TM1-2-8019 Mount, Fluid Cooler M1 (Deutz) 2-7
TM1-2-8023 Hinge, Top Seat Plate 14-2
TM1-2-8023 Hinge, Top Seat Plate M1 6-4
TM1-2-8025 Hinge, Firewall Hood (Female) 7-18
TM1-2-8025 Hinge, Firewall Hood M1 (Female) 5-12
TM1-2-8026 Hinge, Bottom Seat Plate 14-8
TM1-2-8026 Hinge, Bottom Seat Plate M1 5-21
TM1-2-8027 Hinge, Hood Top - M1 (Male) 8-6
TM1-2-8027 Hinge, Hood Top (Male) 7-15
TM1-2-8028 Bracket, Throttle Return Spring - Deutz 74-18
TM1-2-8028 Bracket,Throttle Return Spring 33-6
TM1-2-8030 Bracket, Mounting - Hydraulic Bypass 52-24
TM1-2-8032 Cylinder, Power Steering - M1A 49-12
TM1-2-8043 Bracket, Lower Hood Prop 7-13
TM1-2-8060 Bracket, Closeout Headlight 16-3
4-3-38 CD368
Rev 10
Chapter 4
TM1-2-8062 Bracket, Head Light 2-3

TM1-2-8080 Mount, Rear Transmission 4-9
TM1-2-8085 Shackle, Front Suspension 54-6
TM1-2-8086 Plate, U-Bolt - Front Suspension 54-4
TM1-2-8087 Spring, Leaf - Heavy Duty 54-2
TM1-2-8100 Rod, Parking Brake 43-4
TM1-2-8120 Tube, Panhard Rod 68-1
TM1-2-8120 Tube, Panhard Rod 69-6a
TM1-2-8120W Tube, Panhard Assembly 69-6
TM1-2-8141 Mount, Air Cleaner - Donaldson 83-11
TM1-2-8148 Bracket, Exhaust 91-19
TM1-2-8174 Strap, Fuel Tank 84-4
TM1-2-8178 Plate, Battery Support 97-1
TM1-2-8284 Bracket, Lower Hood Prop - Weldment 7-13
TM1-2-8312 Panel, Battery Closeout 96-3
TM1-2-9006 Support, Roof 9-3
TM1-2-9008 Tube, Lower Horizontal 9-9
TM1-2-9010 Post, Right Side Door Vertical 9-24
TM1-2-9012 Post, Left Side Door Vertical 9-10
TM1-2-9014 Post, Rear Corner L/H 9-6
TM1-2-9016 Post, Lower Front Corner, R/H 9-17
TM1-2-9018 Post, Lower Front Corner, L/H 9-14
TM1-2-9020 Post, Upper Front Corner, L/H 9-13
TM1-2-9024 Panel, Lower Front, L/H 9-15
TM1-2-9025 Bracket, Dome Light 10-12
TM1-2-9026 Panel, Lower Front, R/H 9-18
TM1-2-9032 Crossmember, Lower Rear 9-11
TM1-2-9034 Bracket, Breakeover Support 9-25
TM1-2-9038 Crossmember, Upper Front 9-19
CD368 4-3-39
Rev 10
Chapter 4
TM1-2-9040 Crossmember, Lower Front 9-16

TM1-2-9042 Post, Upper Front Corner, R/H 9-21
TM1-2-9044 Post, Rear Corner R/H 9-12
TM1-2-9048 Tube, Lower Front Horizontal Door 12-2
TM1-2-9050 Tube, Bottom, Front, Vertical 12-33
TM1-2-9052 Tube, Top Front Vertical Door 12-15
TM1-2-9054 Tube, Top Horizontal Door 12-17
TM1-2-9056 Frame, Lower Door 12-6
TM1-2-9058 Tube, Rear Vertical Door, R/H 12-25
TM1-2-9060 Tube, Rear Vertical Door L/H 12-21
TM1-2-9062 Pad, Drive Axle Mount - R/H (Opt.) 62-16
TM1-2-9063 Pad, Drive Axle Mount - L/H 59-14
TM1-2-9063 Pad, Drive Axle Mount - L/H (Opt.) 62-16
TM1-2-9508 Window, Rear Side 10-18
TM1-2-9510 Window, Lower Side 12-10
TM1-2-9555 Mount, Trans. Cover Shifter 14-9
TM1-2-9555 Mount, Transmission Cover Shifter 35-6
TM1-2-9671-1 Plate, Transportation Data - Opt. with Cab 5-34
TM1-2-9671-2 Plate, Transportation Data - Opt. without Cab 5-4
TM1-2-9672-1 Plate, Lubrication Data (Deutz) 5-16
TM1-2-9673 Spacer, Roof Header - M1A 9-23
TM1-2-9738 Bracket, Accelerator Stand Off 76-5
TM1-2-9739 Bracket, Exhaust at Engine 76-18
TM1-2-9826 Pipe, Fuel Filler 7.75 LG 1-5
TM1-2-9826 Pipe, Fuel Filler, 7.75 LG 85-3
TM1-2-9830 Hose,Kit, Black, 5/8", Heater 10-19
TM1-2-9830-1 Hose, Heater, Black, 9.5" - Opt. 76-17
TM1-2-9830-2 Hose,Heater, Black, 30" 10-19a
TM1-2-9830-3 Hose, Heater, Black, 15" - Opt. 76-15
TM1-2-9830-3 Hose,Heater, Black, 15" 10-19b
4-3-40 CD368
Rev 10
Chapter 4
TM1-3-3500 Mount, Drive Axle, R/H 62-6

TM1-3-3502 Mount, Drive Axle, L/H 62-11
TM1-3-5005 Rod, Breakover - M1 & M3 Cab 10-8
TM1-3-5007 Plate, Data - Draw Bar (EU Opt.) 28-4
TM1-3-8002 Tank, Hydraulic Reservoir - M1A 51-2
TM1-3-8190 Guard, Fuel Line 86-5
TM1-3-8282 Cam & Lever Assembly 45-26
TM1-3-9558 Mount, Panhard Rod 64-10
TM1-3-9674 Plate, Hydraulic Data - Opt. 5-36
TM1-4-0806 Tank, Fuel - M1A 84-1
TM1-4-0806 Tank, Fuel - M1A 85-14
TM1-4-0806 Tank, Fuel - M1A 86-6
TM1-4-1022 Guard, Hip Right Side - M1 5-28
TM1-4-1050 Plate, Floor - Hinged Driver Side 96-7
TM1-4-1052 Plate, Floor - Passenger Side 96-7
TM1-4-2502 Panel, Dash 25-1
TM1-4-3000 Frame Weldment - Diesel 4-1
TM1-4-3003 Frame Weldment - Deutz 4-1
TM1-4-3011 Bumper, Front ½” Thick 2-1
TM1-4-3503 Crossmember, Cradle, M1 Universal - Weldment 4-12
TM1-4-3504 Cradle Assembly, Rear 59-4
TM1-4-3504 Cradle Assembly, Rear (Modified) 59-4
TM1-4-3504 Cradle Assembly, Rear (Revised) 61-1
TM1-4-3504 Cradle Assembly, Rear (Revised) 61a-1
CD368 4-3-41
Rev 10
Chapter 4

TM1-4-3504 Cradle, Rear Assembly 42-1
TM1-4-3504 Cradle, Rear Assembly (Modified) 42-1
TM1-4-3504 Cradle, Rear Assembly (Modified) 42a-1
TM1-4-3505 Plate, Rear Cradle 64-12g
TM1-4-3516 Mount, Spring - Driver Side Rear 59-8
TM1-4-3516 Mount, Spring - Driver Side Rear 61a-13
TM1-4-3518 Mount, Spring - Passenger Side Rear 59-12
TM1-4-3518 Mount, Spring - Passenger Side Rear 61a-4
TM1-4-5000 Bracket, Alternator Mount - Wldmt 79-2
TM1-4-5003 Mount, Engine Motor R/H - Weldment (Deutz) 73-3
TM1-4-5008 Hood, Integrated (Deutz) - Opt. 8-5
TM1-4-5009 Pipe, Exhaust with Flex - Deutz 90-2
TM1-4-5020 Shroud, Top - Deutz 93-3
TM1-4-5020 Shroud, Top - M1A Deutz 94-1
TM1-4-5021 Shroud, Left Side - Deutz 93-1
TM1-4-5022 Shroud, Right Side 94-16
TM1-4-5022 Shroud, Right Side - Deutz 93-2
TM1-4-5028 Skin, Door (Non Rotating Handles) 12-20
4-3-42 CD368
Rev 10
Chapter 4
TM1-4-5031 Panel, R/H Rear Side - 3" Raised Cab 9-22

TM1-4-5032 Panel, L/H Rear Side - 3" Raised Cab 9-7
TM1-4-5037 Bracket, Park Brake - Weldment 46-7
TM1-4-5037 Bracket, Park Brake Anchor - Weldment 44-2
TM1-4-5047 Cover, Transmission - Universal 7-10
TM1-4-5047 Cover, Transmission Universal 28-1
TM1-4-8009 Bracket, Alternator Assembly 80-16
TM1-4-8009 Bracket, Alternator Assembly - Deutz 33-1
TM1-4-8012 Plate, Seat 14-1
TM1-4-8013 Firewall/Floorboard 5-8
TM1-4-8013A Firewall/Floorboard - Weldment 5-8
TM1-4-8014 Hood 7-4
TM1-4-8014 Hood 8-5
TM1-4-8018 Panel, Driver Side 7-6
TM1-4-8019 Panel, Passenger Side 8-1
TM1-4-8019 Panel, Passenger Side (Deutz) 7-5
TM1-4-8024 Closeout, Firewall 5-5
TM1-4-8036 Guard, Seat Plate 5-25
TM1-4-8039 Bracket, Hydraulic Reservoir Mounting - Weldment 52-8
TM1-4-8044 Mount, Park Brake Handle 43-5
TM1-4-8064 Cradle, Fuel Tank 84-2
TM1-4-8067 Windshield, Raised Cab 10-1
TM1-4-8067 Windshield, Raised, M1A CAB 11-13
TM1-4-8070-6 Console Frame Assembly 21-1
CD368 4-3-43
Rev 10
Chapter 4

TM1-4-8072 Cover, Console 22-1
TM1-4-8076 Pedal, Brake 21-8
TM1-4-8083 Crossmember, Front - Weldment 1-8
TM1-4-8088 Bracket, Brake Booster Mounting 31-6*
TM1-4-8088 Bracket, Brake Booster Mounting 32-6
TM1-4-8088 Bracket, Brake Booster Mounting - Tier 1 5-7
TM1-4-8090 Pedal, Accelerator M1 Revised 21-9
TM1-4-8336 Bracket, Steer Valve Mounting 49-3
TM1-4-9000 Top, Cab Roof 10-30
TM1-4-9500 Window, L/H Door 12-18
TM1-4-9502 Window, R/H Door 12-26
TM1-4-9504 Window, Rear Sliding 10-25
TM1-4-9510 Crossmember, CharLynn Weld-In 55-1
TM1-4-9510 Crossmember, Deutz - Weldment 1-7
TM1-4-9510 Crossmember, with Drag Link Steering (Deutz) - Weldment 4-18
TM1-4-9544 Mount, Engine Motor L/H - Weldment (Deutz) 73-5
4-3-44 CD368
Rev 10
Chapter 4
TM1-4-9545 Mount, Engine Motor L/H 74-7

TM1-4-9607 Joint, Floorboard Center 5-19
TM1-4-9629 Frame Weldment, CharLynn - M1A30-14 (Deutz 1011) - Opt 4-1
TM1-4-9686-2 Center, Inside Door 12-34
TM1-4-9713 Bumper, Rear - Full Length 3-1
TM1-4-9834 Mount, Fluid Cooler 95-29
TM1-4-9850 Bracket, Park Brake Handle 47-7
TM1-4-9852 Console Frame Assembly 22-15
TM1-F4M-1011 Engine, Deutz Diesel FM4011 74-1
TM1-ND-1006 Gasket, Fuel Sending Unit 85-13
TM1-ND-1007 Tire, Rib Radial - 6.00 x 9 (Michelin) 17-2
TM1-ND-1018 Barb, Hose, Male Adapter, 3/8" 51-4
TM1-ND-1018 Nipple, Adapter 52-11
TM1-ND-5001 Elbow, Air Cleaner Hose - Deutz 83-7
TM1-ND-5004 Mount, Rubber - Engine 73-8
TM1-ND-5005 Alternator, 60 Amp, Delco 3/8 Grv Pulley - Deutz 79-5
TM1-ND-5006 Hose, Air Cleaner Hump - Deutz 83-10
TM1-ND-5008 Belt, (V-) Alternator and Power Steering - Deutz 79-4
TM1-ND-5009 Pipe, Exhaust - Deutz 90-1
TM1-ND-5010 Breaker, Circuit - 60A (Deutz) 21-15
TM1-ND-5010 Breaker, Circuit (60 Amp) - Deutz 22-12
TM1-ND-5011 Controller, Glow Plug - Deutz 22-2
TM1-ND-5011 Controller, Glow Plug (Deutz) 21-14
TM1-ND-5013 Pulley, Alternator 81-5
TM1-ND-5013 Pulley, Alternator, Deutz 80-13
TM1-ND-5018 Gauge, Oil Temp - Deutz 25-3
TM1-ND-5018 Gauge, Oil Temperature - Deutz 26-6
CD368 4-3-45
Rev 10
Chapter 4

TM1-ND-5019 Nut, Hex 10mm x 1.25 91-2
TM1-ND-5021 Gasket, Exhaust - Deutz 91-1
TM1-ND-5026 Filter, Fuel - Deutz 87-17
TM1-ND-5026 Filter, Fuel, Deutz 86-2
TM1-ND-5027 Fan - Deutz 76-4
TM1-ND-5027 Fan, Deutz 73-7
TM1-ND-5028 Cooler, Oil - Deutz 93-10
TM1-ND-5033 Filter, Racor 87-1
TM1-ND-5036 Fitting, Oil Cooler 93-8
TM1-ND-5040 Filter, Oil - Deutz 73-9
TM1-ND-5040 Filter, Oil (Deutz) - OEM 76-16
TM1-ND-5042 Mount, Relay 22-11
TM1-ND-5044 Pin, Clevis - Brake Pedal 23-15
TM1-ND-5045 Cable, Throttle with 3" Stroke (Delta) 31-4
TM1-ND-5046 Adapter (Oil Sensor Metric to Engine) 76-10
TM1-ND-5046 Adaptor, Oil Sensor - Metric to English 75-23
TM1-ND-5047 Reducer, Oil Sender - Deutz 75-22
TM1-ND-5047 Reducer, Oil Sensor (Deutz) 76-11
TM1-ND-5049 Fitting, Oil Cooler - 90° JIC 94-20
TM1-ND-5049 Fitting, Oil Cooler, 90° JIC 93-15
TM1-ND-5050 Headliner 9-2
TM1-ND-5051 Sender, High Oil Temperature (Deutz) 76-20
TM1-ND-5053 Sensor, Low Oil Pressure - Opt. 76-8
TM1-ND-5054 Line, Return to Tank - SS 87-23
4-3-46 CD368
Rev 10
Chapter 4
TM1-ND-5055 Line, Fuel Pump to Filter - SS 87-18

TM1-ND-5056 Line, Fuel Filter to Injection Pump 87-24
TM1-ND-5057 Line, Main to Pump - SS 87-10
TM1-ND-5058 Line, Main from Tank to Pre-filter - SS 88-12
TM1-ND-5058 Line, Main from Tank to Water Separator 89-12
TM1-ND-5058 Line, Main to Water Separator - SS 87-11
TM1-ND-5059 Line, Transmission, Supply 95-32
TM1-ND-5060 Line, Transmission, Return 95-31
TM1-ND-5256 Spring, Accelerator 32-14
TM1-ND-5258 Engine, Deutz with Integrated Cooling - Opt. 74-1
TM1-ND-5260 Fitting, Oil Cooler - 45° 94-21
TM1-ND-5266 Boss, Male 6JIC 45° 49-6
TM1-ND-5269 Light, Cold Start Wait - Deutz 25-8
TM1-ND-5269 Light, Cold Start Wait - Deutz 26-13a
TM1-ND-5269B Bulb, Cold Start Wait 25-8
TM1-ND-5270 Housing, Rear - PTO 53-3
TM1-ND-5271 Housing, Front - PTO 53-7
TM1-ND-5272 Bearing, Hydraulic Pump - PTO 53-4
TM1-ND-5273 Belt, Toothed - Hydraulic PTO 53-5
TM1-ND-5274 Gear, Drive Belt - Hydraulic Drive PTO 53-6
TM1-ND-5275 Cap, Drive Gear - PTO 53-8
TM1-ND-6505 Gauge, Fuel - Datcon #103110 with Light 26-7
TM1-ND-6505 Gauge, Fuel, Datcon #103110 with Light 27-7
TM1-ND-6508 Elbow, Reservoir Outlet, 12MJ-12MP90 51-27
TM1-ND-6509 Elbow, Pump Inlet 51-5
TM1-ND-6510 Hose, 12FJ-12FJ (Reservoir to Pump Inlet) 51-18
TM1-ND-6513 Handle Assembly, L/H Door 12-16
CD368 4-3-47
Rev 10
Chapter 4
TM1-ND-6514 Handle Assembly, R/H Door 12-27

TM1-ND-8001 Elbow, Reservoir Outlet, 8MT-8NP90 (to Pump) 52-6
TM1-ND-8003 Elbow, Pump Outlet 51-6
TM1-ND-8006 Hose, 18" OAL 51-19
TM1-ND-8006 Hose, 18" OAL (Pump to Relief) 52-27
TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ 6-7MI 40-2
TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ6-7MI 51-20
TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ6-7MI (Relief to Hydro-Boost) 52-15
TM1-ND-8008 Hose, Relief to Hydro-Boost - Opt. 39-2
TM1-ND-8009 Hose, Hydraulic, 10" OAL 51-24
TM1-ND-8009 Hose, Hydraulic, 10" OAL (Relief to Tank) 52-10
TM1-ND-8010 Plug, ¼ MP, Brass 87-2
TM1-ND-8010 Plug, ¼MP, Brass 51-31
TM1-ND-8011 Adapter, 6FX-6MP 51-23
TM1-ND-8012 Sender, Fuel Datcon 85-12
TM1-ND-8013 Gauge, Fuel, Datcon 25-5
TM1-ND-8014 Tee, Relief Valve, M1A 51-29
TM1-ND-8016 Plug, Magnetic Drain - Hydraulic Reservoir 52-7
TM1-ND-8079-1 Axle, Front - Brierton without Brakes 54-1
TM1-ND-8079-1 Axle, Front - Brierton Without Brakes 57-1
TM1-ND-8079-11 Tube Assembly, Tie Rod 58-1
TM1-ND-8082 Engine, Deutz with PTO 72-1
4-3-48 CD368
Rev 10
Chapter 4

TM1-ND-8084 Pump, Hydraulic, Engine-Mounted 51-1
TM1-ND-8087 End, Tie Rod - R/H 58-1b
TM1-ND-8088 End, Tie Rod - L/H 58-1a
TM1-ND-8089 Bolt, Hex Head Ø ½-13 x 1½” Long 57-3
TM1-ND-8089 Screw, ½-13 x 2" Long 56-3
TM1-ND-8090 Nut, Jam ¼-13 HX 56-2
TM1-ND-8093 Shim, King Pin 56-4
TM1-ND-8097 Bushing, 1.235 OD x 1.1 ID - M1A 56-8
TM1-ND-8097 Bushing, Bronze 57-9
TM1-ND-8098 Pin, King 57-8
TM1-ND-8099 Gasket, King Pin Cover 56-9
TM1-ND-9002 Seal, Grease, Q-623 57-13
TM1-ND-9008 Hub, M1A 56-13
TM1-ND-9011 Bearing and Race - Outer 56-14
TM1-ND-9013 Nut, Spindle, 1-14 UNF Slotted Hex 57-23
TM1-ND-9028 Muffler, Spark Arrestor 2" (Curved) - Opt. 91-11
TM1-ND-9030 Wheel, Two Piece, 9 x 4 17-1
TM1-ND-9697 Nut, Hex Spindle 1-14, 12 Slotted 56-17
TM1-ND-9698 Pin, Cotter 3/16 x 2" Long 56-16
TM1-ND-9700 Knuckle Weldment, R/H 56-6a
TM1-ND-9702 Zerk, Grease 58-6
TPG-371887-S2 Nut, Lock 1-20 45-7
TPG-378171-S100 Bolt, Hex 77-10
TPG-378171-S100 Bolt, Hex 78-10
TPG-382884-S2 Bolt Ø 5/16-24 x 1" Long 45-3
TPG-385524-S2 Bolt Ø ½-13 x 1½” Long 45-6
TPG-385554-S2 Stud, 9/16-12-18 x 2.28 45-30
TPG-386034-S100 Nut, Slotted 9/16-18 44-8
TPG-44880-S2 Washer, Flat 9/16" ID 44-15
TPG-58675-S2 Bolt Ø ½-13 x 1½” Long 45-12
TPG-B9TZ-2A710D Cam & Lever Assembly 44-1
CD368 4-3-49
Rev 10
Chapter 4

TPG-C1TT-2857L Clevis 44-6
TPG-C20Z-6A366A Reinforcement, Plate - Flywheel 77-9
TPG-C6TZ-4A254B Saddle, U-Joint 45-2
TPG-C8HZ-7A002A Plug, Speedometer Gear Inlet 45-25
TPG-D1TZ-17285A Spacer, Speedometer Gear 45-20
TPG-D3TA-2A701AA Pipe, Park Brake Drain 45-21
TPG-D3TZ-2614A Drum, Parking Brake 45-1
TPG-D3TZ-2857A Clevis, Parking Brake 44-11
TPG-D3TZ-2A663D Bellcrank 44-7
TPG-D3TZ-7089B Flange, Output 45-8
TPG-D5TZ-6375A Flywheel Assembly, C-6 77-8
TPG-D6TZ-2A7038 Shield, Park Brake 45-15
TY-38 Decal, Hood Latches 28-9
X1036-101 Doubler, Tail Light 16-6
X4015-101 Nut, Column 48-2
X6005-101 Sender, Fuel - Kysor 84-6
4-3-50 CD368
Rev 10
Chapter 4
SECTION 4: ALPHABETICAL INDEX
TM1-ND-5046 Adapter (Oil Sensor Metric to Engine) 76-10

TM1-1-9764 Adapter, 90° 77-23
660-ND-1397 Adapter, Brake 41a-10
660-ND-1397 Adapter, Brake 41b-12
T6-600-114 Adapter, Brake Line to Master Cylinder 41a-9
T6-600-114 Adapter, Brake Line to Master Cylinder 41b-10
TM1-1-9792 Adapter, Brake Proportioning Valve 41a-3
T6-8011-107 Adapter, Brake Warning 41b-3
T6-9011-404 Adapter, Speedometer, .4105 Ratio 77-24
T6-600-112 Adaptor 39-4
T6-600-112 Adaptor 40-4
T6-600-114 Adaptor, Brake Line to Master Cylinder 41-7
T6-8011-107 Adaptor, Brake Warning 41-3
TM1-ND-5046 Adaptor, Oil Sensor - Metric to English 75-23
T6-1211-101-5 Alternator, 100 Amp, without Pulley (Perkins, Deutz) 80-11
TM1-ND-5005 Alternator, 60 Amp, Delco 3/8 Grv Pulley - Deutz 79-5
DEU1178607 Alternator, Bosch 81-14
TM1-1-9693-1 Alternator, Bosch 82-14
TM1-1-9693-1 Alternator, Tier II (Deutz) 76-2
TM1-1-8258 Anchor, Brake 41b-26
TM1-1-8258 Anchor, Brake 42-11
TM1-1-8258 Anchor, Brake 42a-9
T6-9003-317 Anchor, Door Closure 9-20
TM1-1-9004 Anchor, Rear Cab 9-8
T6-1021-107 Anchor, Shifter Cable 34-3
TM1-2-3080 Angle, 48¾” Firewall Support 3-3
T6-6011-113 Angle, Tee Support 97-2
CD368 4-4-1
Rev 10
Chapter 4

TM1-1-5033 Arm, 3" Accelerator - Deutz 33-3
T6-9003-123 Arm, Wiper 11-10
TM1-1-9778 Axle, Drive 14:1 62-18
TM1-1-9778 Axle, Drive 14:1 64-1
TM1-1-9775 Axle, Drive 20:1 - Opt. 62-18
TM1-1-9775 Axle, Drive 20:1 - Opt. 64-1
TM1-ND-8079-1 Axle, Front - Brierton Without Brakes 57-1
T6-9011-621-1 Axle, Rear Drive 14:1 without Mount 62-1
T6-9011-622-1 Axle, Rear Drive 20:1 without Mount - Opt 62-1
T6-9011-621-1 Axle, Rear Drive, 14:1, without Mount 65-
T6-9011-621-1 Axle, Rear, Drive 64-1
TM1-0-8142 Band, Air Filter - Donaldson 83-3
TM1-1-8210 Barb, 3/8" Hose 50-6
TM1-ND-1018 Barb, Hose, Male Adapter, 3/8" 51-4
660-4-0753-3 Base, Socket - Electric/Octagon 30-3
T6-7001-205 Battery, Group 27 96-1
T6-7001-205 Battery, Group 27 97-9
T6-2001-107 Bearing 63-6
T6-2001-107 Bearing 65-8
T6-9011-621-20 Bearing 65-48
T6-9011-621-22 Bearing 65-22
TM1-ND-9011 Bearing and Race - Outer 56-14
E1ZZ-7065A Bearing Assembly, with Retaining Ring 45-19
T6-2001-197 Bearing, Bevel Pinion Pilot 63-25
TM1-ND-5272 Bearing, Hydraulic Pump - PTO 53-4
4-4-2 CD368
Rev 10
Chapter 4
——— Bearing, Inner Wheel 57-13

T6-2001-247 Bearing, Input Shaft, Front 66-21
——— Bearing, Outer Wheel 57-20
T6-2001-199 Bearing, Pinion 63-27
T6-2001-199 Bearing, Pinion. Inner 65-23
T6-2001-199 Bearing, Pinion. Outer 65-31
T6-3001-601-5 Bearing, Spindle 57-6
440E-46006 Bearing, Thrust - Timken T113 56-5
DEU1179565 Belt - V 76-3
TM1-ND-5008 Belt, (V-) Alternator and Power Steering - Deutz 79-4
——— Belt, Alternator 81-4
DEU1179565 Belt, Alternator 82-4
T6-6015-101 Belt, Alternator 80-15
TM1-ND-5273 Belt, Toothed - Hydraulic PTO 53-5
T6-9003-125 Blade, Wiper 11-1
T6-2001-181 Bolt .38-16UNCX1.25/1.00 HHCS 65-59
T6-2001-291 Bolt Kit 63-8
T6-2001-291 Bolt Kit 65-10
TPG-385524-S2 Bolt Ø ½-13 x 1½” Long 45-6
TPG-58675-S2 Bolt Ø ½-13 x 1½” Long 45-12
TPG-382884-S2 Bolt Ø 5/16-24 x 1" Long 45-3
——— Bolt, .38-16UNCX1.00/1.00 HHCS 65-42
——— Bolt, .38-24UNFX1.50/1.00 HHCS 65-40
T6-8013-159 Bolt, Caliper 71-6
T6-8013-159 Bolt, Caliper 71b-1
CD368 4-4-3
Rev 10
Chapter 4

7/16-14 x 1¾ Bolt, Gear Box Cover 66-5
TPG-378171-S100 Bolt, Hex 77-10
TPG-378171-S100 Bolt, Hex 78-10
T6-2001-145 Bolt, Hex Head 63-18
T6-2001-145 Bolt, Hex Head 65-18
¼-20 x ½ Bolt, Hex Head Bolt Ø ¼-20 x ½” Long 83-4
¼-20 x ½ Bolt, Hex Head Ø ¼-20 x ½” Long 42a-4
¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x ½” Long 4-21
4-4-4 CD368
Rev 10
Chapter 4

¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 41b-19
¼-20 x 1¾ Bolt, Hex Head Ø ¼-20 x 1¾” Long 52-23
½-13 x 2 Bolt, Hex Head Ø ½-13 x 2" Long (Deutz) 85-20a
½-13 x ¾ Bolt, Hex Head Ø ½-13 x ¾” Long 4-5
½-13X1 Bolt, Hex Head Ø ½-13 x 1" Long 85-23
½-13 x 1¼ Bolt, Hex Head Ø ½-13 x 1¼” Long 61a-6
½-13 X 1½ Bolt, Hex Head Ø ½-13 x 1½” Long 33-9
TM1-ND-8089 Bolt, Hex Head Ø ½-13 x 1½” Long 57-3
½-13 x 1¾ Bolt, Hex Head Ø ½-13 x 1¾” Long (Deutz) 85-20
½-13 x 3½ Bolt, Hex Head Ø ½-13 x 3½” Long 61a-14
CD368 4-4-5
Rev 10
Chapter 4

3/8-16 x ½ Bolt, Hex Head Ø 3/8-16 x ½” Long 85-21
3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼” Long 61a-9
3/8 x 1½ Bolt, Hex Head Ø 3/8-16 x 1½” Long 97-15
4-4-6 CD368
Rev 10
Chapter 4

5/16-18 x 1¾ Bolt, Hex Head Ø 5/16-18 x 1¾” Long 68-7
——— Bolt, Hex Head Ø 5/16-18 x 2" Long 89-21
5/16-18 x 2½” Bolt, Hex Head Ø 5/16-18 x 2½” Long 38-6
——— Bolt, Hex Head Ø 8mm 98-1b
M10 - 1.5 X 25 Bolt, Hex Head Ø M10-1.5 x 25mm Long 33-8
CD368 4-4-7
Rev 10
Chapter 4

M8-1.5 X 10 Bolt, Hex Head Ø M8-1.5 x 10mm Long 33-11
M10-1.5 x 30 Bolt, Metric Ø M10-1.5 x 30mm Long 52-29
T6-2001-181 Bolt, Retainer 63-41
T6-2006-103P Bolt, Spicer 62-18
T6-2006-103P Bolt, Spicer 64-18
T6-9003-303 Bolt, Striker 13-3
T6-9003-303 Bolt, Striker (Skin Door Opt.) 10-15
TM1-1-5061 Bolt, Universal Cradle Crossmember 61a-15
TM1-1-5061 Bolt, Universal Cradle Crossmember, M1A 59-9
TM1-1-5061 Bolt, Universal Cradle, Crossmember 4-16
T6-8013-153 Boot Kit, Dust 71-3
——— Boot, Piston 71a-3
T6-8013-153 Boot, Piston, Kit 71b-10
TM1-1-9582 Brace, Cradle Plate, L/H 64-12b
TM1-1-9579 Brace, Cradle Plate, R/H 64-12e
——— Bracket 98-1c
TM1-1-5031 Bracket, Accelerator Cable Mounting 21-12
TM1-2-5003 Bracket, Alternator Adjustment - Deutz 79-1
4-4-8 CD368
Rev 10
Chapter 4
TM1-4-8009 Bracket, Alternator Assembly 80-16

TM1-4-8009 Bracket, Alternator Assembly - Deutz 33-1
TM1-4-5000 Bracket, Alternator Mount - Wldmt 79-2
TM1-4-8088 Bracket, Brake Booster Mounting - Tier 1 5-7
TM1-1-8158 Bracket, Brake Line 41a-18
TM1-1-8158 Bracket, Brake Line 41b-21
TM1-2-9034 Bracket, Breakeover Support 9-25
TM1-2-8060 Bracket, Closeout Headlight 16-3
TM1-2-9025 Bracket, Dome Light 10-12
TM1-1-5006 Bracket, Exhaust Pipe Support - Deutz 90-4
417-8691 Bracket, Fuel Filter Head - Deutz 87-14
TM1-1-5011 Bracket, Glow Plug Relay Mounting - Deutz 22-9
TM1-2-8062 Bracket, Head Light 2-3
T6-4014-122 Bracket, Hitch Extension 20-2
——— Bracket, L- 98-1h
TM1-2-8043 Bracket, Lower Hood Prop 7-13
TM1-2-8284 Bracket, Lower Hood Prop - Weldment 7-13
TM1-1-8069 Bracket, Lower Seat Plate Prop 6-16
CD368 4-4-9
Rev 10
Chapter 4

TM1-2-8030 Bracket, Mounting - Hydraulic Bypass 52-24
TM1-2-3024 Bracket, Panhard Arm 68-3
TM1-1-9633 Bracket, Panhard Rod - Weldment 70-3
TM1-4-5037 Bracket, Park Brake - Weldment 46-7
TM1-4-5037 Bracket, Park Brake Anchor - Weldment 44-2
MH-1-327 Bracket, Park Brake Cable 7-8
TM1-4-9850 Bracket, Park Brake Handle 47-7
TM1-1-9590 Bracket, Seat Belt - M1A 15-2
TM1-1-3084 Bracket, Seat Isolator 3-2
TM1-2-3026 Bracket, Steer Sector Mount 49-16
TM1-2-8028 Bracket, Throttle Return Spring - Deutz 74-18
T6-9011-633 Bracket, Top, Fluid Cooler 95-13
TM1-1-8160 Bracket, Upper Chain 61a-8
TM1-2-8028 Bracket,Throttle Return Spring 33-6
TM1-ND-5010 Breaker, Circuit - 60A (Deutz) 21-15
660-4-0741-5 Breaker, Circuit (20 Amp) 29a-5
TM1-ND-5010 Breaker, Circuit (60 Amp) - Deutz 22-12
T6-2001-135 Breather 62-10
T6-2001-135 Breather 63-28
T6-2001-135 Breather 64-19
T6-2001-135 Breather - Oil 65-11
131282 Bulb 25-7
4-4-10 CD368
Rev 10
Chapter 4

660-4-0600-5 Bumper 8-16
TM1-4-3011 Bumper, Front ½” Thick 2-1
TM1-2-3012 Bumper, Rear 3-1
TM1-4-9713 Bumper, Rear - Full Length 3-1
660-6-0582-26 Bumper, Rubber - Lift Arm 5-30
660-6-0582-26 Bumper, Rubber Lift Arm 68-4
——— Bushing (Bronze) 71a-10
TM1-ND-8097 Bushing, 1.235 OD x 1.1 ID - M1A 56-8
TM1-ND-8097 Bushing, Bronze 57-9
MH-1-806 Bushing, Suspension 1-19/32 x 5/ 8 x 2 55-6
M3-1-1059 Button, Horn - Two Wire, Isolated Ground 48-1
TM1-1-8272 Cable, Battery, Black 27EE 96-6
660-1-1309 Cable, Battery, Black 40EC 97-12
T6-7016-121 Cable, Battery, Black 40EE 97-13
TM1-1-8270 Cable, Battery, Red 33EE 96-5
CD368 4-4-11
Rev 10
Chapter 4
T6-7016-119 Cable, Battery, Red 48EC 97-11

MI-1-322 Cable, Park Brake/Accelerator 32-4
TM1-1-8182 Cable, Shifter, 58" 38-4
T6-9011-621-4 Caliper Assembly, L/F or R/R 71b-6
T6-9011-621-3 Caliper Assembly, R/F or L/R 71b-6
T6-2201-103-1 Caliper, Brake Assembly 71a-
T6-8013-181 Caliper, L/H Rear 71-1
T6-8013-183 Caliper, R/H Rear 71-1
TM1-3-8282 Cam & Lever Assembly 45-26
T6-6004-101GREEN Cap Assembly, Fuel, Diesel (Green) 85-5
TM1-ND-5275 Cap, Drive Gear - PTO 53-8
660-4-0013-11 Cap, Filler 52-1
T6-6004-101GREEN Cap, Fuel, Diesel (Green) Assembly 84-7
T6-3001-60031 Cap, Grease 56-18
T6-3001-60031 Cap, Grease 57-24
T6-3001-60005 Cap, King Pin 56-10
T6-3001-60005 Cap, King Pin 57-4
T6-2001-329 Cap, Rear Input Shaft 66-16
T6-2001-329 Cap, Rear Input Shaft Bearing 65-43
T6-2001-327 Case and Cover, Reduction Gear 66-1
T6-9011-621-6 Case, Differential Flange, Half 65-1
T6-9011-621-7 Case, Differential Plain, Half 65-2
TM1-4-9686-2 Center, Inside Door 12-34
4-4-12 CD368
Rev 10
Chapter 4
——— Chain, ¼” 59-11

——— Chain, Steel Ø 3/8" x 11" Long, with 9" Heat Shrink 61-11
——— Chain, Steel Ø 3/8" x 11" Long, with 9" Heat Shrink 61a-11
——— Chain, Steel, Ø 3/8" x 11" Long, with 9" Heat Shrink 60-11
T6-1005-119 Clamp, 2" Exhaust 90-6
T6-1005-119 Clamp, 2" Exhaust 91-9
T6-1005-119 Clamp, 2" Exhaust 92-4
——— Clamp, Hose #4 87-28
——— Clamp, Hose #4 88-11
——— Clamp, Hose #4 89-11
——— Clamp, Hose #4 94-11
——— Clamp, Hose #4 95-11
——— Clamp, Hose #40 84-9
——— Clamp, Hose #6 40-9
——— Clamp, Hose #6 86-7
——— Clamp, Hose 5044 83-6
——— Clamp, Hose 5056 83-9
——— Clamp, Hose IDEAL 10-20
——— Clamp, Hose Ideal 5040 85-2
¼ Clamp, P- (¼”) 41-11
¼ Clamp, P- (¼”) 41a-13
¼ Clamp, P- (¼”) 41b-18
¼ Clamp, P- (¼”) 42-7
¼ Clamp, P- (¼”) 42a-6
¼ Clamp, P- (¼”) 87-21
¼ Clamp, P- (¼”) 88-9
¼ Clamp, P- (¼”) 89-9
——— Clamp, P- (1¼”) 94-7
——— Clamp, P- (1¼”) 95-7
T6-5005-105 Clamp, Upper Steer 21-11
T6-5005-105 Clamp, Upper, Steer 48-10
CD368 4-4-13
Rev 10
Chapter 4

MD-CB21-121 Clip 41-15
MD-CB21-121 Clip 41a-17
MD-CB21-121 Clip 41b-20
MD-CB21-121 Clip 42-13
MD-CB21-121 Clip 42a-8
——— Clip, Caliper 71b-13
——— Clip, Hood Prop - Vinyl Coated 14-7
T6-4005-121 Clip, Hood Rod 7-14
T6-4005-121 Clip, Hood Rod 8-20
——— Clip, Pin 71a-7
T6-8013-169 Clip, Retainer 71-5
T6-8013-169 Clip, Retainer 71b-12
TM1-2-3066 Closeout, Bumper 2-2
T6-9003-322 Closure, Door 12-4
T6-2001-165 Colar, Bearing Spacer 65-51
T6-2001-165 Collar, Bearing Spacer 63-34
4-4-14 CD368
Rev 10
Chapter 4
T6-8011-121 Connector 41-9

T6-8011-121 Connector 41a-11
T6-8011-121 Connector 42-6
T6-8011-121 Connector, 41b-13
TM1-ND-5011 Controller, Glow Plug - Deutz 22-2
TM1-ND-5011 Controller, Glow Plug (Deutz) 21-14
TM1-1-9693-2 Cooler, Oil, Deutz 95-18
660-2-3461 Cooler, Transmission Fluid 95-14
T6-9011-621-19 Cover, Gear Case 65-39
TM1-2-5036 Cover, Inside Door Handle L/H - M1 12-9
TM1-2-5043 Cover, Inside Door Handle R/H - M1 12-8
TM1-4-5047 Cover, Transmission - Universal 7-10
CD368 4-4-15
Rev 10
Chapter 4

TM1-4-3504 Cradle Assembly, Rear (Revised) 61a-1
TM1-4-3504 Cradle, Rear Assembly (Modified) 42-1
TM1-4-3504 Cradle, Rear Assembly (Modified) 42a-1
TM1-4-9510 Crossmember, CharLynn Weld-In 55-1
TM1-4-9510 Crossmember, Deutz - Weldment 1-7
TM1-2-9040 Crossmember, Lower Front 9-16
TM1-2-9032 Crossmember, Lower Rear 9-11
TM1-2-9038 Crossmember, Upper Front 9-19
TM1-2-5040 Crossmember, Upper Raised Cab 9-4
TM1-4-9510 Crossmember, with Drag Link Steering (Deutz) - Weldment 4-18
T6-9011-621-11 Cup, Bearing 65-16
T6-9011-621-11 Cup, Bearing 65-5
M3-2-8027 Cylinder, Steer 50-10
660-1-2412 Damper, Vibration, Oil Cooler Mounting 94-12
ML-26 Decal, “Caution” 28-6
4-4-16 CD368
Rev 10
Chapter 4
T-430 Decal, “Caution: All Operators…” 28-3

T-A16 Decal, “Fasten Safety Belt” 28-8
T-B2 Decal, “For Industry & Aviation” 28-2
——— Decal, “Made in USA” 28-5
12960001 Decal, “Seat Belt” 28-8
——— Decal, “Thank You” 28-7
TY-38 Decal, Hood Latches 28-9
T6-2001-601 Differential and Axle Housing Assembly, L/H 63-2
T6-2001-602 Differential and Axle Housing Assembly, R/H 63-1
TM1-2-8008 Dipstick, Hydraulic Reservoir Cap - M1A 52-2
M1A DOORSK Door, Metal, Cab, M1A Kit 11-13
T6-2001-205 Dowel 63-31
TPG-D3TZ-2614A Drum, Parking Brake 45-1
660-2501-06-06 Elbow, 90° Male, 2501-06-06 49-14
660-2501-06-06 Elbow, 90° Male, 2501-06-06 51-26
02-02-140239 Elbow, 90°, 2MP x 2FP 75-20
T6-6006-107A Elbow, 90°, Compression to Pipe 86-3
TM1-ND-5001 Elbow, Air Cleaner Hose - Deutz 83-7
T6-3200-131 Elbow, Racor 85-16
T6-3200-131 Elbow, Racor 87-6
TM1-ND-8001 Elbow, Reservoir Outlet, 8MT-8NP90 (to Pump) 52-6
TM1-0-8145 Element, Air Filter (Deutz, Perkins) 83-2
CD368 4-4-17
Rev 10
Chapter 4
T6-2006-111 End, Flange Yoke 67-4

660-1-2228 End, Tie Rod 49-10
660-1-2228 End, Tie Rod 50-13
660-1-2228 End, Tie Rod 51-13
TM1-ND-8088 End, Tie Rod - L/H 58-1a
TM1-ND-8087 End, Tie Rod - R/H 58-1b
ENG-660-34 Engine, Deutz D2011 L04, Tier IVi 76-1
ENG-660-34 Engine, Deutz D2011, Tier IVi 78-1
TM1-1-9693 Engine, Deutz F4M2011, Tier II 76-1
ENG-M1A-24 Engine, Deutz F4M2011, without Cooler 76-1
ENG-660-34 Engine, Deutz, D2011 L04 72-1
660-1-2344 Extender, Spline Shaft - Deutz Hydraulic Pump 53-2
4-4-18 CD368
Rev 10
Chapter 4
TM1-ND-5027 Fan - Deutz 76-4

——— Fan, Alternator 81-13
T6-1211-101-3 Fan, Alternator 80-12
118-1859 Fan, Alternator, Deutz 82-13
TM1-ND-5027 Fan, Deutz 73-7
T6-6003-107 Filter Material, 1" Horse Hair 84-5
——— Filter Material, Horse Hair, 24" x 15" 85-7
TM1-0-8140 Filter, Air - Donaldson 83-1
TM1-ND-5026 Filter, Fuel, Deutz 86-2
TM1-ND-5040 Filter, Oil - Deutz 73-9
T6-3200-127 Filter, Racor without Heater 86-1
TM1-1-9758 Filter, Transmission, In-Line 94-30
TM1-ND-5040 Filter, Oil (Deutz) - OEM 76-16
02-02-140239 Fitting, 2MP x 2FP-90° 76-12
TM1-ND-5036 Fitting, Oil Cooler 93-8
TM1-ND-5049 Fitting, Oil Cooler, 90° JIC 93-15
——— Fitting, Straight (Included with Engine) 88-19
CD368 4-4-19
Rev 10
Chapter 4
——— Fitting, Straight Connector 51-25

6F5OX Fitting, Straight-Thread Connector, Triple Lok 50-14
T6-9011-621-12 Flange & Tongue Differential Assembly 65-6
T6-2001-233 Flange, Input Shaft 66-24
TPG-D3TZ-7089B Flange, Output 45-8
TM1-1-9047 Flap, Door Rubber - M1A 12-7
M1A-FRAME Frame Kit, Weldment 1-1
TM1-4-3003 Frame Weldment - Deutz 4-1
TM1-4-3000 Frame Weldment - Diesel 4-1
M1A-24-30 Frame Weldment, Modified Side Rails - M1A30-24 (Deutz 2011) 4-1
M1A-FRAME Frame, Kit, Weldment 4-1
TM1-2-9056 Frame, Lower Door 12-6
D2AZ-7086A Gasket, C6 Tail Shaft and Extension Housing 45-27
T6-9003-165 Gasket, Class Window (by the foot) 10-32
TM1-ND-5021 Gasket, Exhaust - Deutz 91-1
——— Gasket, Exhaust (Included with Engine) 92-2
TM1-ND-1006 Gasket, Fuel Sending Unit 85-13
T6-9003-165 Gasket, Glass Window 12-11
T6-9011-621-13 Gasket, Oil Seal 65-17
T6-2001-207 Gasket, Oil Seal (RTV Sealant) 63-17
T6-2001-267 Gasket, Rear Input Shaft Cap 66-15
T6-2001-257 Gasket, Reduction Gear 65-37
T6-2001-257 Gasket, Reduction Gear Case 66-4
TM1-ND-6505 Gauge, Fuel - Datcon #103110 with Light 26-7
4-4-20 CD368
Rev 10
Chapter 4

TM1-ND-6505 Gauge, Fuel, Datcon #103110 with Light 27-7
TM1-ND-5018 Gauge, Oil Temp - Deutz 25-3
T6-9011-621-17 Gear Case 65-29
T6-9011-621-16 Gear Case Assembly 65-28
TM1-ND-5274 Gear, Drive Belt - Hydraulic Drive PTO 53-6
T6-2001-323 Gear, Driven 65-33
T6-2001-323 Gear, Driven 66-11
T6-2001-321 Gear, Input 65-47
T6-2001-321 Gear, Input 66-22
T6-9011-621-8 Gear, Set, 14:1 65-9
T6-2001-121 Gear, Side (Gear Kit: Side Gears and Pinions) 63-11
CMA-609 Grip, Handle - Black 13-10
T6-500-107 Grommet 11-9
T6-500-108 Grommet 68-4
TM1-2-3032 Gusset, Firewall L/H 5-18
TM1-2-3040 Gusset, Firewall R/H 5-17
TM1-ND-6513 Handle Assembly, L/H Door 12-16
TM1-ND-6514 Handle Assembly, R/H Door 12-27
CMA-314 Handle, Breakover - Center Tube 10-7
CMA-316 Handle, Breakover - Long Rod 10-5
TM1-1-6525 Handle, Breakover - M1 & M3 Cab 10-6
CMA-320 Handle, Center Opening 13-9
CD368 4-4-21
Rev 10
Chapter 4
TM1-0-9516 Handle, Door (Recessed) 13-1

T6-4005-109 Handle, Hood 7-1
T6-4005-109 Handle, Hood 8-18
HRN-M1A-24-111 Harness, Main, M1A Deutz 16-2
T6-1300-247 Headlight 16-1
TM1-ND-5050 Headliner 9-2
TM1-1-9512 Heater Assembly 10-21
TM1-1-6526 Heater, Engine - Deutz (Opt.) 74-20
TM1-1-9578 Heater, Block (Deutz) - Opt . 76-9
TM1-2-8026 Hinge, Bottom Seat Plate 14-8
TM1-2-8026 Hinge, Bottom Seat Plate M1 5-21
TM1-2-8025 Hinge, Firewall Hood (Female) 7-18
TM1-2-8025 Hinge, Firewall Hood M1 (Female) 5-12
TM1-2-8027 Hinge, Hood Top - M1 (Male) 8-6
TM1-2-8027 Hinge, Hood Top (Male) 7-15
CMA-124 Hinge, L/H Door 12-12
CMA-123 Hinge, R/H Door 12-30
CMA-127 Hinge, Receiver 9-27
TM1-2-8023 Hinge, Top Seat Plate 14-2
TM1-2-8023 Hinge, Top Seat Plate M1 6-4
CMA-308 Hinge, Window (Male) Half 11-8
CMA-308 Hinge, Window, Male Half 10-27
T6-4044-200 Hitch Assembly 20-1
T6-4044-200 Hitch Assembly - Opt. 1-6
T6-4014-103 Hitch Assembly, E-, Standard 1-6
TM1-4-8014 Hood 7-4
TM1-4-8014 Hood 8-5
TM1-4-5008 Hood, Integrated (Deutz) - Opt. 8-5
T6-9011-101A Hook, Battery Hold Down 97-5
T6-7013-207 Horn 98-1
——— Horn, with Terminal Application 89-1a
TM1-1-8330 Hose (Steer Valve L to Cylinder) 50-16
TM1-1-8332 Hose (Steer Valve R to Cylinder) 51-7
4-4-22 CD368
Rev 10
Chapter 4

TM1-ND-8006 Hose, 18" OAL 51-19
TM1-ND-8006 Hose, 18" OAL (Pump to Relief) 52-27
C406 Hose, 3/8" Low Press (Tank to Booster) 40-10
TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ 6-7MI 40-2
TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ6-7MI 51-20
TM1-ND-8008 Hose, 90°, 14 OAL, 6FJ6-7MI (Relief to Hydro-Boost) 52-15
TM1-ND-5006 Hose, Air Cleaner Hump - Deutz 83-10
——— Hose, Belt Ø 2" ID x 10" Long 85-1
T6-8013-143 Hose, Brake 42-10
T6-8013-143 Hose, Brake 42a-10
T6-8013-143 Hose, Brake 62-3
T6-8013-143 Hose, Brake 64-3
T6-8013-143 Hose, Brake 71-9
TM1-1-9797 Hose, Brake at Master Cylinder 40-5
TM1-1-9797 Hose, Brake at Master Cylinder 41a-1
TM1-1-9797 Hose, Brake at Master Cylinder 41b-1
MH-ND-543 Hose, Brake, 15" 41-17
MH-ND-543 Hose, Brake, 15" 41a-19
MH-ND-543 Hose, Brake, 19" 41b-22
——— Hose, Fuel Filter Ø 2¼” ID x 6" Long 84-3
——— Hose, Fuel Ø 3/8" ID x 3½” Long 87-9
CD368 4-4-23
Rev 10
Chapter 4

TM1-2-9830-3 Hose, Heater, Black, 15" - Opt. 76-15
TM1-2-9830-1 Hose, Heater, Black, 9.5" - Opt. 76-17
TM1-1-8223 Hose, Hydraulic 3/8" x 29" Long (Pump to Booster) 39-11
——— Hose, Hydraulic 5/16" ID (Fuel Line) - Opt. 39-10
TM1-1-8226 Hose, Hydraulic Ø 3/8" x 22" Long 51-21
——— Hose, Hydraulic Ø 5/16" ID (Fuel Line) 52-13
TM1-ND-8009 Hose, Hydraulic, 10" OAL 51-24
TM1-ND-8009 Hose, Hydraulic, 10" OAL (Relief to Tank) 52-10
TM1-1-8223 Hose, Hydraulic, 3/8" x 29" Long 52-35
——— Hose, Ø 5/16" ID (Pre-filter to Fuel Pump) 88-18
——— Hose, Oil Cooler 93-13
TM1-1-5008 Hose, Oil Cooler (Bottom) 41" (Deutz) 76-19
TM1-1-5009 Hose, Oil Cooler (Top) 21" (Deutz) 76-21
MJ-1-5102 Hose, Pump to Booster 39-10
TM1-ND-8008 Hose, Relief to Hydro-Boost - Opt. 39-2
4-4-24 CD368
Rev 10
Chapter 4
——— Hose, Rubber, 5/16" ID 73-6

TM1-1-8227 Hose, Steer Sector Return 50-4
TM1-1-8326 Hose, Steer Valve P to Booster - Opt. 39-11
TM1-1-8328 Hose, Steer Valve to Return 93-14
TM1-1-8227 Hose, Steering Sector Return 39-2
TM1-2-9830-3 Hose,Heater, Black, 15" 10-19b
TM1-2-9830-2 Hose,Heater, Black, 30" 10-19a
TM1-2-9830 Hose,Kit, Black, 5/8", Heater 10-19
——— Housing 71a-6
——— Housing, Extension 45-28
——— Housing, Flange 45-24
TM1-ND-5271 Housing, Front - PTO 53-7
TM1-ND-5270 Housing, Rear - PTO 53-3
TM1-1-9793 Housing, Rubber 41a-2
TM1-1-9793 Housing, Rubber 41b-2
T6-2001-606 Hub 65-60
MX4-10067-7 Hub, Cupped and Studded 57-16
TM1-ND-9008 Hub, M1A 56-13
T6-8003-601 Hub, Rear 63-33
T6-4900-202 Hydro-Boost Assembly 40-3
MD-P21-105 Isolator, Transmission Mount C6 77-18
MD-P21-105 Isolator, Transmission Mount, C6 78-18
660-4-0745-12 Joint, Ball 23-8
660-4-0745-12 Joint, Ball 24-8
660-4-0745-12 Joint, Ball 31-5
660-4-0745-12 Joint, Ball 32-5
660-4-0745-12 Joint, Ball 33-5
CD368 4-4-25
Rev 10
Chapter 4
T6-2001-223 Key, Gear 65-34

T6-2001-223 Key, Gear 66-12
TM1 ND-9701 Knuckle Weldment, L/H 56-6b
TM1-ND-9700 Knuckle Weldment, R/H 56-6a
T6-3001-60002 Knuckle, Assembly, L/H 57-7
T6-3001-601-3 Knuckle, Assembly, R/H 57-7
T6-7006-107A Light, Back-Up (Kit) 16-4
TM1-ND-5269 Light, Cold Start Wait - Deutz 25-8
T6-9003-197 Light, Dome 10-11
T6-7010-120 Light, Red Warning - Flat Head (Brake Warning) 25-10
T6-7010-120 Light, Red Warning - Flat Head (Low Oil) 25-13
T6-7006-101A Light, Tail (Kit) 16-5
MH-ND-565 Line, Brake 10" 39-5
T6-6011-151 Line, Brake 6" 41-8
T6-6011-151 Line, Brake 6" 42a-13
MH-ND-565 Line, Brake, 10" 41b-6
T6-6011-141 Line, Brake, 20" 41b-24
4-4-26 CD368
Rev 10
Chapter 4
T6-6011-141 Line, Brake, 20" 41b-28

T6-6011-141 Line, Brake, 20" 42-14
T6-6011-141 Line, Brake, 20" 42a-11
T6-6011-161 Line, Brake, 30" 41b-23
T6-6011-161 Line, Brake, 30" 42-3
T6-6011-161 Line, Brake, 30" 42a-5
5-100-101 Line, Brake, 51" 41-10
5-100-101 Line, Brake, 51" 41a-12
5-100-101 Line, Brake, 51" 41b-14
T6-6011-151 Line, Brake, 6" 41a-6
T6-6011-151 Line, Brake, 6" 41b-25
T6-6011-151 Line, Brake, 6" 41b-7
T6-6011-151 Line, Brake, 6" 42-4
TM1-ND-5056 Line, Fuel Filter to Injection Pump 87-24
TM1-ND-5055 Line, Fuel Pump to Filter - SS 87-18
TM1-ND-5058 Line, Main from Tank to Pre-filter - SS 88-12
TM1-ND-5058 Line, Main from Tank to Water Separator 89-12
TM1-ND-5057 Line, Main to Pump - SS 87-10
TM1-ND-5058 Line, Main to Water Separator - SS 87-11
TM1-ND-5060 Line, Transmission, Return 95-31
TM1-ND-5059 Line, Transmission, Supply 95-32
T6-1021-103 Linkage, Shift 37-1f
T6-2001-227 Lock, Bevel Pinion Bearing Nut 65-36
T6-2001-149 Locknut 65-14
T6-1300-257 Meter, Hour 25-2
T6-1300-257 Meter, Hour 26-4
T6-1300-257 Meter, Hour 27-4
660-4-0509-18 Mini-Strut 96-2
CMA-605 Mirror, West Coast, L/H 10-33
CMA-610 Mirror, West Coast, R/H 10-14
TM1-1-9514 Motor, Wiper 11-3
TM1-2-8141 Mount, Air Cleaner - Donaldson 83-11
CD368 4-4-27
Rev 10
Chapter 4

T6-7010-211 Mount, Circuit Breaker 29a-1
T6-4800-112 Mount, Engine Half, L/H - Weldment (Deutz) 73-4
TM1-4-9834 Mount, Fluid Cooler 95-29
TM1-2-8019 Mount, Fluid Cooler M1 (Deutz) 2-7
TM1-1-3526 Mount, Lower Rear Cradle Chain 64-12d
TM1-4-8044 Mount, Park Brake Handle 43-5
TM1-2-3030 Mount, Radiator Angle (Deutz) 2-4
TM1-2-8009 Mount, Radiator Bracket - M1A 95-30
TM1-2-8009 Mount, Radiator Bracket (Deutz) 2-6
TM1-1-3503 Mount, Rear Cradle Shock 64-12c
4-4-28 CD368
Rev 10
Chapter 4
TM1-2-8080 Mount, Rear Transmission 4-9

TM1-ND-5042 Mount, Relay 22-11
T6-4012-107 Mount, Rubber Seat 4-3
TM1-1-3002 Mount, Shifter 6-8
TM1-4-3516 Mount, Spring - Driver Side Rear 61a-13
TM1-4-3518 Mount, Spring - Passenger Side Rear 61a-4
TM1-2-9555 Mount, Trans. Cover Shifter 14-9
T6-1005-105 Muffler, Gas 90-7
T6-1005-105 Muffler, Gas 91-11
T6-1005-105 Muffler, Gas 92-7
TM1-ND-9028 Muffler, Spark Arrestor 2" (Curved) - Opt. 91-11
TM1-ND-1018 Nipple, Adapter 52-11
T6-3001-60012 Nut, ½-13 UNC, Hex 57-2
T6-2001-189 Nut, Axle 63-43
T6-2001-189 Nut, Axle 65-63
——— Nut, Castellated 58-3
X4015-101 Nut, Column 48-2
10-32 Nut, Elastic Stop 37-1c
10-32 Nut, Elastic Stop 38-1a
5/16-18 Nut, Flange 5/16-18 94-6
5/16-18 Nut, Flange 5/16-18 95-6
CD368 4-4-29
Rev 10
Chapter 4

¼-20 Nut, Flange ¼-20 (as Spacer) 41b-15
5/16 Nut, Flange 5/16" 87-22
T6-2001-219 Nut, Gear Case to Axle 66-3
T6-8005-133 Nut, Hex 45-14
TM1-ND-5019 Nut, Hex 10mm x 1.25 91-2
3/8-16 Nut, Hex 3/8-16 (Plated) 44-12
3/8-24 Nut, Hex 3/8-24 37-1g
3/8-24 Nut, Hex 3/8-24 38-1a
3/8-24 Nut, Hex 3/8-24 45-22
½-13 Nut, Hex Crimp ½-13 69-4
½-13 Nut, Hex Crimp ½-13 70-4
TM1-ND-9697 Nut, Hex Spindle 1-14, 12 Slotted 56-17
T6-2001-281 Nut, Input Shaft 66-26
——— Nut, Jam 68-9
TM1-ND-8090 Nut, Jam ¼-13 HX 56-2
——— Nut, Jam ½-13 HX 58-5
3/8-24 Nut, Jam 3/8-24 46-13
3/8-24 Nut, Jam 3/8-24 47-13
T6-2001-149 Nut, Lock 63-19
T6-2001-227 Nut, Lock - Bevel Pinion Bearing 66-13
7/16-14 Nut, Lock - Gear Box Cover 66-7
TPG-371887-S2 Nut, Lock 1-20 45-7
3/8-16 Nut, Lock 3/8" ID 5-13
5/16-18 Nut, Lock 5/16"ID-18 38-9
——— Nut, Lock Ø 8mm 98-1d
T6-3003-107 Nut, Lug ½-20 19-4
T6-3003-105 Nut, Lug ½-20 THD, Ford 63-47
10-32 Nut, Non-Locking 10-32 29-3
10-32 Nut, Non-Locking 10-32 29a-2
1 Nut, Nylock, Coarse Thread 1" ID 4-10
4-4-30 CD368
Rev 10
Chapter 4

9/16-18 Nut, Pipe Thread Lock 9/16-18 55-11
T6-1211-101-6 Nut, Pulley - Alternator 80-14
TPG-386034-S100 Nut, Slotted 9/16-18 44-8
TM1-ND-9013 Nut, Spindle, 1-14 UNF Slotted Hex 57-23
440E-46009 Nut, Tapered Wheel ½-20 UNF 56-19
¼ Nut, Top Lock Hex ¼-20 83-12
¼-20 Nut, Top Lock Hex ¼-20 26-17
¼-20 Nut, Top Lock Hex ¼-20 27-17
¼-20 Nut, Top Lock Hex ¼-20 52-21
½-13 Nut, Top Lock Hex ½-13 22-16
½-13 Nut, Top Lock Hex ½-13 60-12
½-13 Nut, Top Lock Hex ½-13 61-12
½-13 Nut, Top Lock Hex ½-13 61a-12
½-13 Nut, Top Lock Hex ½-13 74-12
½-13 Nut, Top Lock Hex ½-13 85-19
½-20 Nut, Top Lock Hex ½-20 23-17
½-20 Nut, Top Lock Hex ½-20 24-17
10/32 Nut, Top Lock Hex 10-32 22-5
10-32 Nut, Top Lock Hex 10-32 12-29
CD368 4-4-31
Rev 10
Chapter 4
10-32 Nut, Top Lock Hex 10-32 23-11

10-32 Nut, Top Lock Hex 10-32 24-11
10-32 Nut, Top Lock Hex 10-32 29-6
10-32 Nut, Top Lock Hex 10-32 30-4
10-32 Nut, Top Lock Hex 10-32 31-10
10-32 Nut, Top Lock Hex 10-32 32-10
3/8 Nut, Top Lock Hex 3/8-16 97-16
3/8-16 Nut, Top Lock Hex 3/8-16 11-2
3/8-16 Nut, Top Lock Hex 3/8-16 15-2
3/8-16 Nut, Top Lock Hex 3/8-16 39-12
3/8-16 Nut, Top Lock Hex 3/8-16 40-12
3/8-16 Nut, Top Lock Hex 3/8-16 48-11
3/8-16 Nut, Top Lock Hex 3/8-16 52-4
3/8-16 Nut, Top Lock Hex 3/8-16 60-7
3/8-16 Nut, Top Lock Hex 3/8-16 6-14
3/8-16 Nut, Top Lock Hex 3/8-16 61-7
3/8-16 Nut, Top Lock Hex 3/8-16 61a-7
3/8-16 Nut, Top Lock Hex 3/8-16 6-3
3/8-16 Nut, Top Lock Hex 3/8-16 80-9
3/8-16 Nut, Top Lock Hex 3/8-16 8-10
3/8-16 Nut, Top Lock Hex 3/8-16 91-12
3/8-16 Nut, Top Lock Hex 3/8-16 92-8
3/8-24 Nut, Top Lock Hex 3/8-24 62-15
3/8-24 Nut, Top Lock Hex 3/8-24 62-8
3/8-24 Nut, Top Lock Hex 3/8-24 64-15
3/8-24 Nut, Top Lock Hex 3/8-24 64-8
5/16-18 Nut, Top Lock Hex 5/16-18 12-13
5/16-18 Nut, Top Lock Hex 5/16-18 5-33
5/16-18 Nut, Top Lock Hex 5/16-18 68-8
5/16-18 Nut, Top Lock Hex 5/16-18 87-3
5/16-18 Nut, Top Lock Hex 5/16-18 88-3
5/16-18 Nut, Top Lock Hex 5/16-18 89-3
5/8-11 Nut, Top Lock Hex 5/8-11 54-8
5/8-11 Nut, Top Lock Hex 5/8-11 55-3
7/16-14 Nut, Top Lock Hex 7/16-14 64-6
4-4-32 CD368
Rev 10
Chapter 4
9/16-12 Nut, Top Lock Hex 9/16-12 68-6

9/16-18 Nut, Top Lock Hex 9/16-18 54-5
¼-20 Nut, Top Lock, ¼-20 1-4
440E-46009 Nut, Lug, ½-20 UNF Tapered Hex 57-18
TM1-1-8051 Operator, Door Latch - M1 12-23
T6-9003-133 Operator, Latch - L & R 13-6
T6-6004-101S O-Ring 84-8
T6-6004-101S O-Ring 85-4
T6-9011-621-21 O-Ring 65-61
TM1-2-9063 Pad, Drive Axle Mount - L/H (Opt.) 62-16
TM1-2-9062 Pad, Drive Axle Mount - R/H (Opt.) 62-16
T6-8013-149 Pads, Brake - Non-Organic 71-4
T6-8013-201 Pads, Brake - Organic 71-4
T6-8013-201 Pads, Brake, Organic - Opt. 71b-11
T6-8013-149 Pads, Brake, Non-Organic 71b-11
TM1-4-5032 Panel, L/H Rear Side - 3" Raised Cab 9-7
TM1-2-9024 Panel, Lower Front, L/H 9-15
TM1-2-9026 Panel, Lower Front, R/H 9-18
TM1-4-8019 Panel, Passenger Side 8-1
TM1-4-8019 Panel, Passenger Side (Deutz) 7-5
TM1-4-5031 Panel, R/H Rear Side - 3" Raised Cab 9-22
CD368 4-4-33
Rev 10
Chapter 4

660-1-3046 Pigtail, Brake Warning 41b-29
T6-8011-117 Pigtail, Brake Warning 41-2
——— Pin, Clevis 71a-1
1/8 x 1¼ Pin, Cotter 8-9
T6-3001-60030 Pin, Cotter 57-22
TM1-ND-9698 Pin, Cotter 3/16 x 2" Long 56-16
1/8 x 1 Pin, Cotter Ø 1/8 x 1" Long 44-9
1/8 x 1¼ Pin, Cotter Ø 1/8 x 1¼” Long 44-10
3/32 x ½ Pin, Cotter Ø 3/32" x ½” Long 37-1e
3/32 x ½ Pin, Cotter Ø 3/32" x ½” Long 38-1a
4-4-34 CD368
Rev 10
Chapter 4

TM1-ND-8098 Pin, King 57-8
440E-46007 Pin, King KB423 56-7
T6-2001-121 Pinion (Gear Kit: Side Gears and Pinions) 63-12
MH-ND-553-3 Pinion, Transmission - Speedometer 77-27
TM1-ND-5009 Pipe, Exhaust - Deutz 90-1
TM1-2-9826 Pipe, Fuel Filler 7.75 LG 1-5
TM1-2-9826 Pipe, Fuel Filler, 7.75 LG 85-3
CMA-600 Pipe, Fuel Filter, 12" 85-3
——— Piston 71a-5
T6-8013-157 Piston 71-2
T6-8013-157 Piston 71b-8
——— Pivot 37-1h
——— Pivot 38-1a
TM1-2-5035 Plate, Backing - Drive Axle Pad 59-13
TM1-2-8178 Plate, Battery Support 97-1
T6-9011-149 Plate, Data - Draw Bar 28-4
TM1-3-5007 Plate, Data - Draw Bar (EU Opt.) 28-4
TM1-4-1052 Plate, Floor - Passenger Side 96-7
TM1-3-9674 Plate, Hydraulic Data - Opt. 5-36
TM1-2-9672-1 Plate, Lubrication Data (Deutz) 5-16
T6-8005-135 Plate, Park Brake 45-9
CD368 4-4-35
Rev 10
Chapter 4
TM1-4-3505 Plate, Rear Cradle 64-12g

TM1-2-9671-1 Plate, Transportation Data - Opt. with Cab 5-34
TM1-2-9671-2 Plate, Transportation Data - Opt. without Cab 5-4
T6-2001-245 Plug 66-10
T6-9011-621-14 Plug 65-19
T6-9011-621-18 Plug 65-30
T6-1211-103 Plug, Alternator Socket 80-10
TM1-1-9791 Plug, Brake Proportioning Valve 41a-5
TM1-1-9791 Plug, Brake Proportioning Valve 41b-5
T6-4800-155 Plug, Deutz Fuel Pump 76-14
T6-2001-265 Plug, Fill - Gear Box Oil 66-9
T6-2001-137 Plug, Lubricant Drain 63-22
T6-2001-143 Plug, Lubricant Fill 63-21
TM1-ND-8016 Plug, Magnetic Drain - Hydraulic Reservoir 52-7
——— Plug, Protective 71a-9
——— Plug, Protective 71b-4
TPG-C8HZ-7A002A Plug, Speedometer Gear Inlet 45-25
TM1-2-9012 Post, Left Side Door Vertical 9-10
TM1-2-9018 Post, Lower Front Corner, L/H 9-14
TM1-2-9016 Post, Lower Front Corner, R/H 9-17
TM1-2-9014 Post, Rear Corner L/H 9-6
TM1-2-9044 Post, Rear Corner R/H 9-12
4-4-36 CD368
Rev 10
Chapter 4
TM1-2-9010 Post, Right Side Door Vertical 9-24

TM1-2-9020 Post, Upper Front Corner, L/H 9-13
TM1-2-9042 Post, Upper Front Corner, R/H 9-21
——— Pre-filter 88-17
TM1-ND-5013 Pulley, Alternator 81-5
118-2187 Pulley, Alternator, Deutz 82-5
TM1-ND-5013 Pulley, Alternator, Deutz 80-13
T6-5011-107 Pulley, Power Steering 79-6
T6-5011-108 Pulley, Power Steering - GM 50-2
T6-4800-122 Pulley, PTO (Deutz) 76-6
DEU2108653 Pulley, V-Belt 79-3
T6-5011-101 Pump Assembly - Power Steering 50-1
417-9734 Pump, Fuel - Deutz 87-29
T6-2001-167 Race 65-52
T6-2001-167 Race 63-35
T6-2001-151 Race, Differential Bearing 63-5
——— Race, Inner Wheel Bearing 57-13
——— Race, Outer Wheel Bearing 57-19
TM1-ND-5047 Reducer, Oil Sender - Deutz 75-22
TM1-ND-5047 Reducer, Oil Sensor (Deutz) 76-11
T6-500-102 Reflector, Amber Rectangular 10-31
T6-500-103 Reflector, Red Rectangular 10-29
TM1-2-3044 Reinforcement, Center Joint 5-24
TM1-2-8011 Reinforcement, Firewall - Tier 1 5-29
660-4-0753-2 Relay - Opt. 22-10
660-1-2301 Relay, Dial Timer (Orange) 30-1
T6-9011-506 Relay, Electric, Solenoid 30-7
——— Relay, Harness to Horn 98-5
T6-7013-209 Relay, Horn - Ford, Deutz 22-13
T6-9011-621-10 Replacement Kit, Piston & Seal (Includes Items 8, 9 & 10) - Not Shown
71b-16
CD368 4-4-37
Rev 10
Chapter 4
T6-2001-173 Retainer 63-38

T6-2001-173 Retainer 65-55
T6-9003-309 Retainer, Door Handle Rod 13-5
T6-2001-111 Ring & Pinion Set - 14:1 Ratio 63-9
T6-2001-195 Ring, Lock 63-24
——— Ring, Rubber, Large 71b-3
——— Ring, Rubber, Small 71b-7
D5TZ-7070A Ring, Snap 45-18
T6-2001-255 Ring, Snap - Input Shaft Bearing 66-19
T6-2001-195 Ring, Snap, E25.4 X 1.57 CS 65-21
T6-2001-255 Ring, Snap, Input Shaft Bearing 65-45
——— Ring, Square 71a-4
——— Ring, Square (part of T6-8013-153) 71b-9
AB6-4A Rivet, Blind 12-1
——— Rod, All Thread Ø 3/8-16 x 2½” Long 44-13
TM1-3-5005 Rod, Breakover - M1 & M3 Cab 10-8
CMA-321 Rod, Door Handle Linkage 13-8
TM1-2-8100 Rod, Parking Brake 43-4
T6-2001-605 Rotor 63-32
T6-2001-609 Rotor, 12.625"OD, .898"Wide 65-49
——— Rubber, 1½” x 8" 48-9
TPG-C6TZ-4A254B Saddle, U-Joint 45-2
4-4-38 CD368
Rev 10
Chapter 4
TM1-ND-8089 Screw, ½-13 x 2" Long 56-3

——— Screw, Bleeder 71a-8
——— Screw, Bleeder 71b-5
T6-8013-165 Screw, Bleeder - Delco 71-8
T6-3001-60006 Screw, Button Head 56-11
T6-3001-60006 Screw, Button Head, 10-24 UNC x 5/8 Long 57-11
T6-2001-131 Screw, Cap - Differential and Gear Assembly 63-14
T6-2001-273 Screw, Cap - Rear Input Shaft Cover 66-18
3/8-24 x 5/8 Screw, Hex Head Ø 3/8-24 x 5/8" Long 37-1d
3/8-24 x 5/8 Screw, Hex Head Ø 3/8-24 x 5/8" Long 38-1a
3/8-16 x 1½ Screw, Hex Washer Head 45-29
¼x½ Screw, Philips Head Ø ¼” x ½” Long 12-5
10-32 x ¾ Screw, Philips Head Ø 10/32 x ¾” Long 12-28
10-32 x ¾ Screw, Philips Head Ø 10-32 x ¾” Long 22-8
10-32 x 1 Screw, Philips Head Ø 10-32 x 1" Long 22-4
10-32 x ¾ Screw, Phillips Head Ø 10-32 x ¾” Long 29-2
10-32 x ¾ Screw, Phillips Head Ø 10-32 x ¾” Long 29a-3
10-32 x 1 Screw, Phillips Head Ø 10-32 x 1" Long 30-2
1/8 x ½ Screw, Phillips Round Head 6-19
——— Screw, Self Tapping #10 29-5
——— Screw, Self Tapping #10 29a-6
——— Screw, Socket Head Ø 3/8-24 x ¾” Long 58-4
TM1-ND-9002 Seal, Grease, Q-623 57-13
T6-2001-235 Seal, Oil - Input Shaft 66-23
D0TZ-7A011A Seal, Transmission 45-17
660-2-3290 Seat, Sears, Vinyl, Coldform with Logo 15-3
4-100-101A Seat, Vinyl Bucket 14-3
¼x½ Self Tapping Screw Ø ¼” x ½” Long (CE Opt.) 10-13
X6005-101 Sender, Fuel - Kysor 84-6
TM1-ND-8012 Sender, Fuel Datcon 85-12
TM1-ND-5051 Sender, High Oil Temperature (Deutz) 76-20
TM1-ND-5053 Sensor, Low Oil Pressure - Opt. 76-8
T6-9011-621-5 Service Kit, Brake Pads (Includes Items 11, 12 & 13) - Not Shown 71b-14
T6-9011-621-2 Service Kit, Brake Seal (Includes Items 9 & 10) - Not Shown 71b-17
T6-9011-621-9 Service Kit, Bushing & Mounting Stud (Includes Items 1, 2, 3, & 7) - Not Shown
CD368 4-4-39
Rev 10
Chapter 4
71b-15
T6-2201-103-5 Service Kit, Caliper Bushing and Stud (Includes items 10 and 11) 71a-
T6-2201-103-4 Service Kit, Caliper Lining and Clip (Includes items 1, 2, and 7) 71a-
T6-2201-103-3 Service Kit, Caliper Seal (Includes items 3 and 4) 71a-
T6-2201-103-2 Service Kit, Caliper Seal and Piston (Includes items 3, 4, and 5) 71a-
T6-7200-090 Shaft, Drive 45-4
TM1-1-0804 Shaft, Drive 62-9
T6-7200-090 Shaft, Drive (Ford) 64-9
TM1-1-0804 Shaft, Drive (Perkins, Deutz) 45-4
T6-2001-604 Shaft, Long Axle 63-4
T6-2001-604 Shaft, Long Axle - Opt. 65-4
TPG-D6TZ-2A7038 Shield, Park Brake 45-15
TM1-1-8152 Shifter Assembly (Note 1) 34-1
——— Shim, Cable Clamp 37-1j
——— Shim, Cable Clamp 38-1a
T6-9011-621-15 Shim, Pack 65-25
TM1-0-8130 Shock, with Stud 61a-3
T6-8005-143 Shoe, Park Brake (C-6) 45-16
4-4-40 CD368
Rev 10
Chapter 4

TM1-4-5022 Shroud, Right Side - Deutz 93-2
TM1-4-5020 Shroud, Top - Deutz 93-3
——— Silastic 65-44
TM1-4-5028 Skin, Door (Non Rotating Handles) 12-20
T6-8013-167 Sleeve 71-7
T6-8013-167 Sleeve 71b-2
TM1-1-9795 Sleeve 41a-7
TM1-1-9795 Sleeve 41b-8
MH-ND-553 Sleeve, Pinion - Speedometer 77-26
660-1-2345 Sleeve, Spline Shaft Extender 53-1
T6-7010-129 Socket, Light, with Bulb 25-9
3/8 x 3/16 Spacer Ø 3/8" ID x 3/16" Long 80-8
3/8 x 3/16 Spacer, 3/8" ID x 3/16" Long 46-6
3/8 x 3/16 Spacer, 3/8" ID x 3/16" Long 47-6
T6-4121-109 Spacer, Accelerator Pedal 5-35
T6-2001-209 Spacer, Axle 63-29
T6-9003-211 Spacer, Grommet 11-7
T6-9003-211 Spacer, Groomet 10-24
TM1-2-9673 Spacer, Roof Header - M1A 9-23
TPG-D1TZ-17285A Spacer, Speedometer Gear 45-20
TM1-1-8256 Spacer, Steer Sector 1" 49-15
660-1-2689 Spacer, Upper, C6 Shift Lever 38-8
14 GAUGE Spade, 14-Gauge, Female 48-3
TM1-1-3512 Spring, Rear 13" x 400 lb. - Red Coil 61-2
CD368 4-4-41
Rev 10
Chapter 4
TM1-1-3512 Spring, Rear 13" x 400 lb. - Red Coil 61a-2

TM1-1-3501 Spring, Seat - Rear Cradle 64-12f
1182388 Starter, Large 3KW (Deutz) 76-22
——— Stator (Lining) Assembly 71a-2
TM1-1-9046 Stop, Windshield Support 9-26
CMA-504 Strip, Seal - Door, 12' Long 6-18
——— Stud, .56-18FX.81/.56-12NCX.63/2.31 65-27
TPG-385554-S2 Stud, 9/16-12-18 x 2.28 45-30
T6-9011-928 Stud, Accelerator 32-12
——— Stud, Mounting 71a-11
T6-2001-607 Stud, Rear Axle 63-46
T6-2001-607 Stud, Rear Axle, MA 65-50
T6-1009-109 Stud, Throttle Cable 21-10
T6-3001-60020 Stud, Wheel 56-20
T6-3001-601-2 Stud, Wheel, ½-20 UNF x 1 7/8 57-17
TM1-1-3004 Support, Front Hood 8-19
TM1-1-3004 Support, Front Hood (Deutz) 2-5
TM1-2-9006 Support, Roof 9-3
660-1-3086 Switch, Brake Pressure 41b-17
T6-7010-140 Switch, Ignition - CH Lever 21-16
4-4-42 CD368
Rev 10
Chapter 4
T6-7010-140 Switch, Ignition C.H. Lever 22-14

T6-7010-113 Switch, Toggle (Heater) 25-11
TM1-2-3524 Tab, Panhard Arm 69-3
TM1-4-0806 Tank, Fuel - M1A 84-1
TM1-4-0806 Tank, Fuel - M1A 85-14
TM1-4-0806 Tank, Fuel - M1A 86-6
T6-6011-111 Tee 41-18
T6-6011-111 Tee 41a-20
T6-6011-111 Tee 41b-11
T6-6011-111 Tee 41b-27
T6-6011-111 Tee 42-2
T6-6011-111 Tee 42a-2
TM1-1-8209 Tee, 3/8" Female Pipe 50-5
T6-9011-101B Tee, Battery Hold Down 97-10
TM1-1-9794 Terminal 41a-8
TM1-1-9794 Terminal 41b-9
MH-ND-553-1 Tip, Adapter - Speedometer Drive 77-25
MH-ND-650 Tire, LT215/85R16 18-2
TM1-ND-1007 Tire, Rib Radial - 6.00 x 9 (Michelin) 17-2
T6-2400-170 Tire, Tug Tuff 8.75 x 16.5, 10PR 19-6
T6-2400-170 Tire, Tug Tuff, 8.75 x 16.5 18-2
TM1-1-9814 Tire/Wheel Assembly, 8.75 x 16.52 19-5
CD368 4-4-43
Rev 10
Chapter 4
T6-2400-186 Tire/Wheel Assembly, Front, MA Standard 19-1

TM1-1-9632 Tower, Panhard Rod - Weldment 70-7
MG-1-320 Trim-Lock 96-4
MG-1-320 Trim-Lock (3 ft.) 97-8
TM1-ND-8079-11 Tube Assembly, Tie Rod 58-1
TM1-1-5007 Tube, Air Cleaner Adaptor - Deutz 83-8
TM1-2-9050 Tube, Bottom, Front, Vertical 12-33
TM1-2-9048 Tube, Lower Front Horizontal Door 12-2
TM1-2-9008 Tube, Lower Horizontal 9-9
TM1-2-8120 Tube, Panhard Rod 68-1
TM1-1-3502 Tube, Pivot - Rear Cradle 64-12a
TM1-2-9060 Tube, Rear Vertical Door L/H 12-21
TM1-2-9058 Tube, Rear Vertical Door, R/H 12-25
TM1-2-9052 Tube, Top Front Vertical Door 12-15
TM1-2-9054 Tube, Top Horizontal Door 12-17
TM1-2-5042 Tube, Top Horizontal Side - M1A Raised Cab 9-5
——— Tubing, Brake Line Ø 5/16" x 6 3/8" Long 87-7
——— Tubing, Rubber 3/8" ID 50-15
——— Turbo, Exhaust (Part of Engine) 92-1
10-32 U-Bolt 37-1i
10-32 U-Bolt 38-1a
T6-2006-107 U-Joint, Front 67-2
T6-2002-107 U-Joint, Rear 67-3
TM1-1-9787 Valve, Brake Warning 41a-4
4-4-44 CD368
Rev 10
Chapter 4
TM1-1-9787 Valve, Brake Warning 41b-4

T6-8011-113 Valve, Hydraulic Brake Warning 41-6
660-4-0010-20 Valve, Relief 51-22
660-4-0010-20 Valve, Relief 52-22
660-1-3028 Valve, Steer 49-5
660-1-3028 Valve, Steer 50-9
660-1-3028 Valve, Steer 51-9
T6-7010-133 Voltmeter 25-6
T6-7010-133 Voltmeter 26-5
T6-7010-133 Voltmeter 27-5
MJ-ND-2001-49 Washer 65-41
T6-2001-147 Washer, Flat 63-20
T6-2001-147 Washer, Flat 65-15
5/16 Washer, Flat 5/16" ID 87-15
5/16 Washer, Flat 5/16" ID 87-5
5/16 Washer, Flat 5/16" ID 88-2
5/16 Washer, Flat 5/16" ID 89-2
7/16 Washer, Flat 7/16" ID 85-18
——— Washer, Flat #10 37-1b
——— Washer, Flat #10 38-1a
CD368 4-4-45
Rev 10
Chapter 4

½ Washer, Flat ½” ID 61a-5
½ Washer, Flat ½” ID - Opt. 10-16
1 1/16 x 2½ Washer, Flat 1 1/16" ID, Ø 2½” 4-11
1 Washer, Flat 1" ID 61a-16
10-32 Washer, Flat 10-32 22-3
11/16 Washer, Flat 11/16" ID 23-20
3/16 Washer, Flat 3/16" ID 12-3
3/8 Washer, Flat 3/8" ID 61a-10
4-4-46 CD368
Rev 10
Chapter 4

5/16 Washer, Flat 5/16" 5-32
5/16 Washer, Flat 5/16" ID 12-31
5/16 Washer, Flat 5/16" ID 52-5
5/16 Washer, Flat 5/16" ID 94-3
5/16 Washer, Flat 5/16" ID 95-3
7/16 Washer, Flat 7/16" ID 15-4
7/16 Washer, Flat 7/16" ID 22-17
7/16 Washer, Flat 7/16" ID 4-15
7/16 Washer, Flat 7/16" ID 62-14
7/16 Washer, Flat 7/16" ID 64-14
7/16 Washer, Flat 7/16" ID 74-3
7/16 Washer, Flat 7/16" ID 77-13
7/16 Washer, Flat 7/16" ID 78-13
7/16 Washer, Flat 7/16" ID 91-13
7/16 Washer, Flat 7/16" ID 92-9
9/16 Washer, Flat 9/16" ID 46-17
9/16 Washer, Flat 9/16" ID 47-17
TPG-44880-S2 Washer, Flat 9/16" ID 44-15
M10 Washer, Flat M10 33-7
M10 Washer, Flat M10 ID 91-4
11/16 Washer, Flat, 11/16"ID 24-6
5/16 Washer, Flat, 5/16" ID 38-7
T6-2001-217 Washer, Gear Case to Axle 66-2
——— Washer, Ground Terminal - Bended 98-1f
T6-2001-231 Washer, Input Shaft 66-25
T6-2001-211 Washer, Keyway 65-32
3/8 Washer, Lock 45-23
T6-2001-179 Washer, Lock 63-42
CD368 4-4-47
Rev 10
Chapter 4
T6-2001-179 Washer, Lock 65-58

T6-8005-137 Washer, Lock 45-13
——— Washer, Lock #10 56-12
¼ Washer, Lock ¼” 83-13
¼ Washer, Lock ¼” ID 41b-16
½ Washer, Lock ½”ID 4-4
M14 Washer, Lock 14mm 74-5
4-4-48 CD368
Rev 10
Chapter 4

3/8 Washer, Lock 3/8" ID (Deutz) 97-14
7/16 Washer, Lock 7/16" ID 64-5
7/16 Washer, Lock 7/16" ID 66-17
7/16 Washer, Lock 7/16" ID 66-6
7/16 Washer, Lock 7/16" ID 77-14
7/16 Washer, Lock 7/16" ID 78-14
M10 Washer, Lock M10 ID 91-5
——— Washer, Lock, #10 57-12
T6-2001-127 Washer, Pinion Thrust 63-13
T6-3001-60028 Washer, Spindle, 1" 57-21
——— Washer, Star 98-1g
T6-2001-119 Washer, Thrust 63-10
TM1-1-3508 Washer, Thrust 59-3
T6-3001-6002 Washer, Tongued Spindle 56-15
½x½ Weather Strip, Self-Adhesive 85-10
660-1-1977 Wheel, 16" Steering 48-4
T6-9003-549 Wheel, 16" x 6", White 18-1
T6-2400-168 Wheel, Tug Tuff 4.0 x 9.0 (2 Piece) 19-3
CD368 4-4-49
Rev 10
Chapter 4
T6-2400-168 Wheel, Tug Tuff 4.0 x 9.0 (Two - Piece) 17-1

T6-2400-169 Wheel, Tug Tuff 6.75 x 16.5 19-7
T6-2400-169 Wheel, Tug Tuff, 6.75 x 16.5 18-1
TM1-ND-9030 Wheel, Two Piece, 9 x 4 17-1
TM1-4-9500 Window, L/H Door 12-18
TM1-2-9510 Window, Lower Side 12-10
TM1-4-9502 Window, R/H Door 12-26
TM1-2-9508 Window, Rear Side 10-18
TM1-4-9504 Window, Rear Sliding 10-25
TM1-4-8067 Windshield, Raised Cab 10-1
TM1-4-8067 Windshield, Raised, M1A CAB 11-13
——— Wire, Jumper - 14 Gauge, 4½” Long 85-11
——— Wire, Jumper 3½” Long, 10 Gauge 29-7
——— Wire, Jumper 3½” Long, 10 Gauge 29a-7
——— Wire, Jumper, with Connectors 98-1e
MD-CB1-129 Yoke 43-3
MD-CB1-129 Yoke 44-14
MD-CB1-129 Yoke 46-11
MD-CB1-129 Yoke 47-11
MJ-ND-8002 Yoke 21-7
MJ-ND-8002 Yoke 23-16
MJ-ND-8002 Yoke 24-16
MJ-ND-8002 Yoke 39-13
MJ-ND-8002 Yoke 40-13
T6-3001-601-4 Zerk, Grease 57-25
TM1-ND-9702 Zerk, Grease 58-6
4-4-50 CD368
Rev 10
Chapter 5
CHAPTER 5: APPENDICES
TABLE OF CONTENTS
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1

A. Daily and Weekly Checks ..................................................................................... 5-1-1
B. Monthly, Two-Month, 10-Week, Six-Month, and Yearly Checks ............................ 5-1-2
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS .............................................. 5-2-1

A. Description ........................................................................................................... 5-2-1
CD368 5-TOC-i
Rev 7
Chapter 5
5-TOC-ii CD368
Rev 7
Chapter 5
SECTION 1: PERIODIC MAINTENANCE CHECKLIST
A. DAILY AND WEEKLY CHECKS
TUG Model M1A Tow Tractor - Delta Air Lines

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 50 100 200 400 500 600 800 1000 1200 2400
Check for Working Controls
Check Fuel Level
Check Engine Oil Level
Check Radiator Coolant/Water Level
Check Tire Pressure and Condition
Check Voltmeter for Charging
Check ALL Lights
Check Horn Operation
Check Lug Nut Tightness
Check Brake Fluid Level in Master Cylinder
Check Battery Charge and Fluid Level
Check/Tighten Drive Axle Mounting Bolts
Check Transmission Fluid Level
Check Cylinder Head Bolt Torque
Check Drive Axle and Reduction Gear Box Oil Level
Check King Pins and Steer Pin for Looseness
Check Underneath for Oil Leaks and Damage
Check Exhaust System
Check Neutral Safety Switch Adjustment
Check Power Steering Fluid Level
CD368 5-1-1
Rev 7
Chapter 5
B. MONTHLY, TWO-MONTH, 10-WEEK, SIX-MONTH, AND YEARLY CHECKS
TUG Model M1A Tow Tractor - Delta Air Lines

Serial Number: Date Manufactured:
Date: ID Number:
Service Requirement in Hours Daily 50 100 200 400 500 600 800 1000 1200 2400
Check Service Brake Operation
Check Park Brake Operation
Check Fan/Alternator Belts
Check Hoses / Clean Radiator Exterior
Check Brake Pads
Change Engine Oil and Filter
Check Air Filter
Lube Operator Seat Slides
Lube Service Brake Pedal Linkage Pivots
Lube Park Brake Lever Pivots
Lube Throttle Linkage
Lube Drive Shaft Joints
Lube Steer Axle, King Pins and Pivot Points
Lube Sliding Bushings on Rear Brake Calipers
Lube ALL Grease Fittings
Lube Hood Latches
Lube Cab Door Handles
Check Cooling System and Thermostat
Check/Adjust Injector Pump Timing
Inspect/Clean/Repack Front Wheel Bearings
Check Ball Joints and Tie Rod Ends for Looseness
Check/Adjust Hydraulic Pressure Relief Valve
Change Fuel Filter
Check Differential and Reduction Gear Box Bolts
Change Drive Axle and Reduction Gear Box Oil
Check/Adjust Steering Sector
Check Cylinder Compression
Check/Tighten Intake Manifold Bolts
Check Spark-Arrest Muffler
Adjust Automatic Transmission Bands
Change Transmission Fluid and Filter C6 Units
Drain/Flush/Refill/Bleed Hydraulic Brake System
5-1-2 CD368
Rev 8
Chapter 5
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS
A. DESCRIPTION
The following pages/booklets contain additional information relevant to the operation and service of
the M1A Low Profile Tow Tractor.
CD368 5-2-1
Rev 7
Chapter 5
5-2-2 CD368
Rev 7
Operation Manual
B/F L 1011F
B/FM 1011F
26
45
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1 Gerade
9683en_k00_vo 1 16.11.2000, 8:45 Uhr
Safety guidelines / Accident prevention
● Please read and observe the information

given in this Operation Manual. This will ● Unauthorized engine modifications will in-
enable you to avoid accidents, preserve the validate any liability claims against the manu-
manufacturer’s warranty and maintain the facturer for resultant damage.
engine in peak operating condition. Manipulations of the injection and regulating
system may also influence the performance
● This engine has been built exclusively for of the engine, and its emissions. Adherence
the application specified in the scope of to legislation on pollution cannot be guaran-
supply, as described by the equipment manu- teed under such conditions.
facturer and is to be used only for the
intended purpose. Any use exceeding that ● Do not change, convert or adjust the cooling
scope is considered to be contrary to the air intake area to the blower.
intended purpose. The manufacturer will The manufacturer shall not be held respon-
not assume responsibility for any damage sible for any damage which results from
resulting therefrom. The risks involved are such work.
to be borne solely by the user.
● When carrying out maintenance/repair op-
● Use in accordance with the intended pur- erations on the engine, the use of DEUTZ
pose also implies compliance with the con- original parts is prescribed. These are spe-
ditions laid down by the manufacturer for cially designed for your engine and guaran-
operation, maintenance and servicing. The tee perfect operation.
engine should only be operated by person- Non-compliance results in the expiry of the
nel trained in its use and the hazards in- warranty!
volved.
● Maintenance and cleaning of the engine
● The relevant accident prevention guidelines should only be carried out when the engine
and other generally accepted safety and is switched off and has cooled down.
industrial hygiene regulations must be ob- You must ensure that the electrical systems
served. have been switched off and the ignition key
has been removed.
● When the engine is running, there is a risk of Accident prevention guidelines concerning
injury through: electrical systems (e.g. VDE-0100/-0101/-
- turning/hot components 0104/-0105 Electrical protective measures
- engines with positive ignition against dangerous touch voltage) are to be
- ignition systems (high electrical voltage) observed.
You must avoid contact at all times! When cleaning with fluids, all electrical com-
ponents are to be covered impermeably.
00_GB.p65 2 04.02.2002, 14:23

Operation Manual
B/F L 1011F
B/FM 1011F
0297␣ 9683 en
Engine Serial Number
Please enter the engine serial number here. This number

should be quoted when inquiring about Customer
Service, Repairs or Spare Parts (see Section 2.1).
All rights reserved. Technical modifications required to
improve our engines are reserved with regard to speci-
fication data and other technical information contained

in this Operation Manual. No parts of this Manual may
be reproduced in any form or by any means without our
written approval.
3 Gerade
1
9683en_k00_vo 3 16.11.2000, 8:45 Uhr
Foreword
Dear Customer,
1 Air / liquid-cooled DEUTZ engines are designed for a
large number of applications. Consequently, a wide
range of variants are offered to meet the require-
ments of specific cases.
Your engine is appropriately equipped for the instal-
lation concerned, which means that not all of the
components described in this Operation Manual are
necessarily mounted to your engine.
We have endeavored to highlight any differences so
that you will be able to locate the operating and
maintenance instructions relevant to your engine
quickly and easily.
Please read this Manual before starting your engine,
and always observe the operating and maintenance
instructions.
We are available to help with any additional inquiries
Sincerely,
DEUTZ AG
9683en_k00_vo 4 16.11.2000, 8:45 Uhr

Index
1 General 3.5 Operating Conditions 6.5.3 Changing V-Belts
2 Engine Description
3.5.1
3.5.2
Winter Operation
High Ambient Temperature,
6.6
6.6.1
Adjustments
Checking / Adjusting Valve Clearances
1
2.1 Model High Altitude 6.7 Accessories
2.1.1. Rating Plate 6.7.1 Battery
2.1.2 Rating Plate Location 4 Operating Media 6.7.2 Three-Phase Alternator
2.1.3 Engine Serial Number 4.1 Lube Oil 6.7.3 Lifting Tackle
2.1.4 Cylinder Numbering 4.1.1 Quality Grade 6.7.4 Ether Starting System
2.1.5 Fuel Delivery Lock 4.1.2 Viscosity 6.8.1 Engine Cleaning
2.2 Engine Illustrations 4.2 Fuel Operating Media
2.2.1 Service Side FL 1011F 4.2.1 Quality Grade 7 Troubleshooting
2.2.2 Exhaust Side FL 1011F 4.2.2 Winter-Grade Fuel 7.1 Diagnostic chart
2.2.3 Service Side BFL 1011F
2.2.4 Exhaust Side BFL 1011F
2.2.5 Service Side FM 1011/ F 5 Routine Maintenance 8 Engine Preservation
2.2.6 Exhaust Side FM 1011/ F 5.1 Maintenance Schedule 8.1 Preservation
2.2.7 Service Side BFM 1011F 5.2 Maintenance Chart 8.1.1 Preserving Engine
2.2.8 Exhaust Side BFM 1011F 5.3 Maintenance Work Completed 8.1.2 Removing Engine Preservations
2.3 Oil Circuit
2.3.1 Lube Oil Circuit 6 Service and Maintenance 9 Technical Specification
2.4 Fuel System Schematic 6.1 Lubrication System 9.1 Engine Specifications and Settings
2.4.1 Fuel System 6.1.1 Oil Change Intervals 9.2 Torque Wrench Settings
6.1.2 Changing Engine Oil, Check Oil Level 9.3 Tools
3 Engine Operation 6.1.3 Changing Oil Filter
3.1 Commissioning 6.2 Fuel System 10 Service
3.1.1 Adding Engine Oil 6.2.1 Changing Fuel Filter
3.1.2 Filling oil bath air filter with engine oil 6.2.2 Clean Strainer of Fuel Filter
3.1.3 Adding Fuel 6.2.3 Change Fuel Leakage Line
3.1.4 Other Preparations 6.3 Cooling System
3.1.5 Additional Maintenance Work 6.3.1 Cleaning Intervals
3.2 Starting 6.4 Combustion Air Cleaner
3.2.1 Starting 6.4.1 Cleaning Intervals
3.3 Monitoring Systems 6.4.2 Emptying Cyclone Type Precleaner
3.3.1 Engine Oil Pressure 6.4.3 Cleaning Oil Bath Air Cleaner
3.3.2 Coolant Temperature 6.4.4. Dry Type Air Cleaner
3.4 Stopping 6.5 Belt Drives
3.4.1 Mechanical Shutdown 6.5.1 Checking V-Belts
3.4.2 Electrical Shutdown 6.5.2 Tensioning V-Belts
5
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1
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9683en_k00_vo 6 16.11.2000, 8:45 Uhr

General
DEUTZ Diesel Engines Care and Maintenance Service

1
are the product of many years of research and Sound care and maintenance practices will ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or for
with stringent quality standards, guarantee their placed on it. Recommended service intervals must spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance work carry out repairs quickly and professionally, using
consumption. carried out conscientiously. only genuine spare parts.
It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced
meet the highest standards for environmental demanding operating conditions. in accordance with state-of-the-art technology.
protection. Please turn to the end of this manual for further
service information.
Beware of Running Engine Safety

California
Proposition 65 Warning
Shut the engine down before carrying out mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
DEUTZ original parts are asbestos-

free.
7 Gerade
9689en_K01_neu 7 30.09.1999, 15:45 Uhr
1
8
9689en_K01_neu 8 30.09.1999, 15:45 Uhr
Engine Description
2
2.1 Model
2.2 Engine Illustration
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
9 9 Gerade
7343en_k02_pdf 9 05.10.1999, 9:20 Uhr

Engine Description 2.1 Model
2.1.1 Rating Plate 2.1.2 Rating Plate Location

2 2.1.3 Engine Serial Number
23045678
A B
22135 *
*000
D
26 332 2 26 421 1 26 422 0
The model A, the engine serial number B and the The rating plate C is attached to the valve cover. The engine serial number B is stamped on the
performance data are stamped on the rating plate. crankcase D as well as the rating plate.
The model and engine serial number must be given
when ordering parts.
10
7343en_k02_pdf 10 05.10.1999, 9:21 Uhr

2.1 Model Engine Description
2.1.4 Cylinder Numbering 2.1.5 Fuel Delivery Lock

2
1 2 3 4
26 431 0 26 387 0
Cylinders are numbered consecutively, beginning The manufacturer shall not be held liable for dam-
at the flywheel end. ages resulting from adjustments made to the regu-
lator by the operator.
The lock screws are protected in order to prevent
this:
1. with locking paint on model:
torque balancer
2. with plastic protective cap on model:
without torque balancer.
Adjustments to the regulator are to

be carried out only by authorized
! DEUTZ SERVICE - specialists.
11 11 Gerade
7343en_k02_pdf 11 05.10.1999, 9:21 Uhr

Engine Description 2.2 Engine Illustrations
2.2.1 Service Side

2 FL 1011F
1 Oil filler neck (valve-gear cover)

2 Charge-air line / air-intake line
3 Fan with integrated generator
21 1 4 Narrow V-belt
5 Solenoid
6 Toothed belt cover
7 V-belt pulley on crankshaft
20 2 8 Oil sump
9 Cut-out handle
10 Speed control lever
19 3 11 Oil dipstick
12 Crankshaft housing
13 Oil fill point (on side of crankcase)
14 Fuel pump
18 4 15 Easy-change fuel filter
16 Connecting facility for oil heater
17 Lube oil easy-change filter
17 5 18 Removable coolant intake hood
19 Injection pumps
20 Date plate
21 Oil cooler
16 6
7
15
14
13 12 11 10 9 8 26 452 0
12
7343en_k02_pdf 12 05.10.1999, 9:21 Uhr

2.2 Engine Illustrations Engine Description
2.2.2 Exhaust side

FL 1011F
2
22 Date plate
23 Connection housing (SAE)
24 Flywheel with ring gear
25 Starter
30 22 26 Front cover
27 Crankcase
28 Cylinder head
29 Exhaust manifold pipe
29 30 Air-intake pipe
28 23
27
26 24
25
26444 0
13 13 Gerade
7343en_k02_pdf 13 05.10.1999, 9:21 Uhr

2.2.3 Service Side

2 BFL 1011F
1 Oil filler neck (valve-gear housing cover)

3 Fan with integrated generator
5 Solenoid
6 Wheel-house cover
20 2 7 V-belt pulley on crankshaft
8 Oil sump
9 Cut-out handle
18 4 14 Fuel pump
15 Easy-change fuel filter
16 Connection facility for oil heater
17 Charge-air pressure full-load stop (LDA)
17 5 18 Lube oil easy-change filter
19 Removable coolant intake hood
20 Injection pumps
6 21 Oil cooler
16
7
15
14
13 12 11 10 9 8 26 443 0
14
7343en_k02_pdf 14 05.10.1999, 9:21 Uhr

2.2.4 Exhaust side

BFL 1011F
2
22 Cylinder head
32 25 Starter
27 Inlet line to TC (Lube oil)
28 Return line from TC (Lube oil)
31 22 29 Induction pipe
30 Turbocharger (TC)
31 Intake manifold
23 32 Air-intake line
30
29
28
24
27
26
25
26448 0
15 15 Gerade
7343en_k02_pdf 15 05.10.1999, 9:21 Uhr

2.2.5 Service Side

2 FM 1011F
1 Oil filler neck (valve-gear housing)

3 Generator
5 Solenoid
6 Wheel-house cover
20 2 7 V-belt pulley on crankshaft
8 Oil sump
9 Cut-out handle
18 4 14 Fuel pump
17 Lube oil easy-change filter
17 5 18 Injection pumps
19 Connection for oil cooler
20 Leakage-fuel line
21 Injection valves
16 6
15 7
14
13 12 11 10 9 8 26 453 0
16
7343en_k02_pdf 16 05.10.1999, 9:21 Uhr

2.2.6 Exhaust side
FM 1011F 2
22 Cylinder head
23 Exhaust manifold line
25 Starter
26 Front cover
28 27 Crankcase
28 Intake pipe
22
27
23
26
24
25
26 447 0
17 17 Gerade
7343en_k02_pdf 17 05.10.1999, 9:21 Uhr

2.2.7 Service Side

2 BFM 1011F

3 Generator
5 Solenoid
6 Wheel-house cover
2 7 V-belt on crankshaft
20 8 Oil sump
9 Cut-out handle
14 Fuel pump
18 4 15 Easy-change fuel filter
17 Charge-air pressure full-load stop (TC)
17 5 18 Lube oil easy-change
19 Injection pumps
20 Oil cooler connection
21 Injection valves
16 6
15 7
14
13 12 11 10 9 8 26 446 0
18
7343en_k02_pdf 18 05.10.1999, 9:21 Uhr

2.2.8 Exhaust side

BFM 1011F
2
22 Cylinder head
25 Starter
32 26 Crankshaft housing
27 Inlet line to TC (Lube oil)
28 Return line from TC (Lube oil)
31 22 29 Induction pipe
30 Turbocharger (TC)
31 Intake manifold
23 32 Air-intake line
30
29
28
24
27
26
25
26 448 0
19 19 Gerade
7343en_k02_pdf 19 05.10.1999, 9:21 Uhr

Engine Description 2.3 Oil Circuit
2.3.1 Lube Oil Circuit Schematic

2
1 Oil sump
2 Intake manifold
9 15 8 11 19 3 Oil pump
4 Main oil duct
5 Oil-cooled cylinder
10 18 6 Cylinder head cooling neck
7 Oil duct for rocker arm lubrication
8 Rocker arm
12 7 9
10
Oil manifold for the thermostat
Intake to external engine oil cooler
11 Return from external engine oil cooler
6 12
13
Thermostat housing with slide thermostat
Oil duct to oil filter
14 Oil filter
13 5 15 Oil duct to the cam, con-rod and
crankshaft bearing
16 Injection jet for cooling the pistons
20 17 Oil return via crankcase to the oil sump
18 Lube oil intake to turbocharger
19 Turbocharger
20 Return from turbocharger to oil sump
14 17 18 16 2 3 4 26 430 0
20
7343en_k02_pdf 20 05.10.1999, 9:21 Uhr

2.4 Fuel System Engine Description
2.4.1 Fuel system schematic

2
1 Fuel line from tank to fuel pump
2 Fuel pump
10 9 3 Fuel line from fuel pump to easy-change
fuel filter
12 8 5 Fuel line from filter to injection pump
6 Injection pumps
7 Fuel distributor line
8 Injection lines
11 9 Injection valves
7 10 Fuel leakage line
11 Fuel overflow pipe
12 Fuel return line to tank
6
4 3 2 5 26 437 0
21 21 Gerade
7343en_k02_pdf 21 05.10.1999, 9:21 Uhr

Engine Operation
3
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 Operating Conditions
23 Gerade
Engine Operation 3.1 Commissioning
3.1.1 Adding Engine Oil

3 3.1.1.1 Initial Engine Oil Fill-Up 3.1.1.2 Initial Engine Oil Fill-up
for B/FM1011F Series for B/FM 1011F Series
● Fill oil into the oil sump up to the “max.” mark on ● Fill oil into the oil sump up to the “min.” mark on
OIL the engine dip stick (for oil top-up quantity see
9.1).
the engine dip stick.
● In addition, top up the oil quantity of the supply
● Start the engine and allow to run at a low idling hoses and of the external oil cooler (according to
speed for approx. 2 mins. manufacturer’s details).
● Switch off the engine. ● Allow the engine to run warm until the thermostat
● Check the oil level, if necessary, top up oil to the opens (at approx. 95oC).
„max.“ mark. ● Allow the engine to run for approx. 2 mins.
● Switch off the engine.
● Check the oil level, and if necessary, top up oil to
the „max.“ mark.
26 432 0
As a rule, engines are delivered empty of oil.

Pour lube oil into the oil filler neck (arrow).
For oil grade and viscosity, see 4.1.
If the person operating the engine does not run up

the engine until the thermostat opens, the oil level
may lie above the „max“. mark on the engine dip
stick when delivered. The level can then only be
assessed after the engine has been run up.
24
3.1 Commissioning Engine Operation
3.1.2 Filling Oil Bath Air Filter with 3.1.3 Adding Fuel
3.1.1.3 Initial Engine Oil Fill-Up for Engine Oil
3
B/FM 1011F Genset Engine
● Fill oil into the oil sump up to the “max.” mark on
the engine dip stick (for oil quantity see 9.1).
● Start up the engine and allow to run at a lower
idling speed for approx. 2 mins.
FUEL
● Check the oil level and fill up with oil up to the
upper „max.“ mark.
24 980 2 26 398 0
Fill oil cup 1 of the oil bath air cleaner with oil up to Use only commercial-grade diesel fuel. For fuel
the arrow. grade, see 4.2. Use summer or winter-grade fuel,
For oil grade and viscosity, see 4.1. depending on the ambient temperature.
Do not fill the precleaner dust col- Never fill the tank while the engine
lector (if fitted) with oil. is running. Keep the filler cap area
! ! clean and do not spill fuel.
25 Gerade
3.1.4 Other Preparations 3.1.5 Additional Maintenance Work

3
● Check battery and cable connections, see 6.7.1 When commissioning new and reconditioned en-
gines, the following additional maintenance work
● Transport hooks must be carried out:
Remove if fitted (see 6.7.3)
After 50-150 OH
● Trial run ● Change lube oil,
After the engine has been prepared, let it run see 6.1.2
for about 10 minutes without load.
● Change oil filter cartridge,
During and after trial run see 6.1.3
– Check the engine for leaks
After the engine has been turned off ● Change fuel filter cartridge,
– Check the oil level, see 6.2.1
see 6.1.2
If necessary, top up oil, ● Check V-belts and retension as necessary,
see 3.1.1 see 6.5.
– Retension V-belts, see 6.5
● Check the engine for leaks
● Breaking in
During the break-in phase – about 200 operat- ● Check the engine mount and adjust as neces-
ing hours – check the oil level twice a day. After sary, see 9.2
the engine is broken in, checking once a day
will be sufficient. After 500 OH
● Check the valve clearance and adjust as neces-
sary, see 6.6.1.
26
3
27 Gerade
Engine Operation 3.2 Starting
3.2.1 Electric Starting

3 Starting without Cold-Start Aid
Before starting, make sure that no-

body is standing in the immediate
vicinity of the engine or driven ma- 2
! chine.
After repair work:
Check that all guards have been
replaced and that all tools have been removed from
the engine.
When starting with glow plugs, do not use any other
starter substance (e.g. injection with start pilot).
Caution: If the speed regulator has been re-
moved, the engine must not be tested under any
circumstances: 1
Disconnect the battery.
26 423 0 25 746 2
● Where possible, disengage the clutch to sepa- ● Insert key.

rate the engine from any driven parts. – Position 0 = no operating voltage
● Move speed control lever 1 into idle position. ● Turn key clockwise
● Move cut-out handle 2 into operating position. – Position 1 = operating voltage
– Pilot lights come on
● Push the key in and turn it further clockwise
against spring pressure
– Position 2 = no function
– Position 3 = start
● Release key as soon as engine fires
– Pilot lights go out
Do not actuate the starter for more than 20 sec-
onds. If the engine does not catch, wait a minute
then try again.
If the engine does not catch after two attempts,
refer to the Diagnosis Chart (see 7.1).
28
3.2 Starting Engine Operation
with Cold-Start Aid with Cold-Start Aid 3

– Glow Plug – Ether Starting System
25 746 2 25 746 2 25 963 0
● Insert key. ● Insert key ● Starting fluid is injected automatically in switch

– Position 0 = no operating voltage – Position 0 = no operating voltage position A, as long as the starter is operated.
● Turn key clockwise ● Turn key clockwise
– Position 1 = operating voltage – Position 1 = operating voltage ● To assist acceleration at lower temperatures
– Pilot lights come on – Pilot lights come on and to avoid white fumes, briefly hold the
● Push key in and turn further clockwise against ● Push key in and turn further clockwise against arctic switch in switch position H.
spring pressure spring pressure
– Position 2 = Preheat, hold for approx. – Position 2 = no function
1 minute. – Position 3 = start
– Preheat lamp comes on ● Release key as soon as engine fires
– Position 3 = Start – Pilot lights go out
– Pilot lights go out The switch must not be moved to
position H when the engine is
! switched off and the ignition is
switched on.
29 Gerade
Engine Operation 3.3 Monitoring Systems
3.3.1 Engine Oil Pressure

3 Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge
25 752 1 25 753 0 25 754 0
● The oil pressure pilot light comes on with oper- ● The pointer must remain in the green sector over ● The pointer must indicate the minimum oil
ating voltage on and engine off. the entire range. pressure (see 9.1).
● The oil pressure pilot light should go out when
the engine is running.
30
3.3 Monitoring Systems Engine Operation
3.3.2 Coolant Temperature

Engine Temperature Gauge
3
24 985 0
● The engine temperature gauge pointer should

remain in the green sector most of the time. It
should rarely enter the yellow-green sector. If the
pointer enters the orange sector, the engine is
overheating. Turn off and establish the cause
from the Diagnosis Chart (see 7.1).
31 Gerade
Engine Operation 3.4 Stopping
3.4.1 Mechanical Shutdown 3.4.2 Electrical Shutdown

3 (Ignition Key)
26 424 0 25 746 2
● Move speed control lever 1 to low idle. ● Turn key counterclockwise (to position 0) and
● Operate shutdown lever 2 until the engine comes remove. The pilot lights will go out.
to a stop. The charge pilot light and the oil
pressure pilot light will come on when the engine
stops.
● Turn key counterclockwise (to position 0) and
remove. The pilot lights will go out.
If possible, do not suddenly switch off the engine

when under full load.
32
3.5 Operating Conditions Engine Operation
3.5.1 Winter Operation

3
● Lube Oil Viscosity ● Battery
– Select the oil viscosity (SAE grade) accord- – Efficient cold starting requires a healthy
ing to the ambient temperature when the battery, see 6.7.1.
engine is started, see 4.1.2. – The starting limit temperatures can be low-
– Increase oil change frequency when oper- ered by 4-5 °C by heating the battery up to
ating below -10 °C, see 6.1.1. about +20 °C . (To do so, remove the battery
and store in a warm place).
● Diesel Fuel
– Use winter-grade diesel fuel for operation
below 0 °C, see 4.2.2.
● Additional Maintenance Work

– Drain the sludge from the fuel tank once a
week. (Unscrew the sludge drain plug)
– If necessary, allow the oil in the oil bath air
cleaner and the engine oil to settle at the
ambient temperature. 26 248 0
– Below -20 °C, after removing the starter if
necessary, smear the ring gear on the fly
wheel via the pinion bore from time to time
with cold-resistant grease.
(e.g. Bosch grease FT 1 V 31).
● Cold-Start Aid
– At temperatures near or below freezing
point, use glow plugs if necessary, see
3.2.1.
This not only lowers the starting limit tem-
perature, but provides easier starting at
temperatures normally not requiring a start-
ing aid.
33 Gerade
Engine Operation 3.5 Operating Conditions
3 3.5.2 High Ambient Temperatures,

High Altitude
● As the altitude and ambient temperature rise, the

density of air tends to decrease, which affects
the maximum power output of the engine, the C F
exhaust gas quality and, in extreme cases, the
starting behavior. Under transient conditions,
the engine can be used at altitudes up to 1000 m
and temperatures up to 30 °C. If the engine is to
operate under more severe conditions (at higher
altitudes or temperatures), it will be necessary to
reduce the injected fuel quantity and thus, en-
0 32
gine power.
● If you have any doubts about engine operation

under these or similar conditions, ask your en-
gine or equipment supplier whether the engine
has been derated in the interests of reliability,
service life and exhaust gas quality (smoke). 25 901 1
Otherwise contact DEUTZ SERVICE.
34
Operating Media
4.1 Lube Oil

4.2 Fuel
4.3 Coolant
© 2002
ENGLISCH • Kapitel 4 • Seite 1
Operating Media 4.1 Lube Oil
4 4.1.1 Quality Grade 4.1.2 Viscosity
Lube oils are differentiated by Deutz Generally, multi-grade oils shall be used. In
according to their performance and quality closed heated rooms at temperatures >5°C,
class. Oils of other, comparable specifications also single-grade oils can be used.
can be used.
As the viscosity of lube oil is dependent on
temperature, the choice of SAE grade
should be governed by the ambient
Approved oils: temperature prevailing at the engine
operating site.
Optimum operating behaviour will be
Deutz DQC I DQC II DQC III attained if you take the accompanying oil
viscosity diagram as a guide.
ACEA E2-96 E3/96/E5-02 E4-99
Should the temperature fall temporarily
API CF/CF-4 CH-4/CG-4 - below the limits of the SAE grade selected,
cold starting may be affected but the engine
DHD - DHD-1 - will not be damaged.
In order to keep wear to a minimum, do not
exceed application limits for extended
The precise assignment of the admissible periods of time.
oil qualities to the engines is indicated in
chapter 6.1.1. Synthetic lube oils feature an improved
If in doubt, contact your service represen- temperature and oxidation stability.
tative.
© 2002
Only with preheating 30 298 1

----
Operating Media 4.2 Fuel
4 4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel
Use commercially available diesel fuel with Waxing may occur at low temperatures,
less than 0.5% sulphur content. If the sulfur clogging the fuel system and reducing engine
content is higher than 0.5%, oil change efficiency. If the ambient temperature is less
intervals should be reduced (see 6.1.1). than 0 °C, winter-grade fuel (suitable down
to -20 °C) should be used. This fuel is usually
The following fuel specifications/standards available from filling stations well in advance
are approved: of the cold months.
(refer to TR 0199-3002)
● At temperatures below -20°C/, kerosene
● Diesel fuel should be added to the diesel fuel. The
- DIN EN 590 relevant percentages are given in the dia-
- BS 2869: A1 and A2 gram at the right
(with A2, take note of the sulfur content!) ● Special diesel fuels can be used for climatic
- ASTM D 975-88; 1-D and 2-D zones down to - 44 °C.
- NATO Code F-54and F-75
- ISO 8217 DMX If summer-grade diesel fuel must be used at
- ISO 8217 DMA temperatures below 0°C, up to 60% kerosene
● Light heating oil can be added (see diagram).
according to DIN 51603 Legend:
ASTM D 396; 1 and 2 In most cases, adequate resistance to cold
BS 2869 Class D can be obtained by adding a flow improver I Summer diesel fuel
(additive). Please contact your Deutz partner.
● Jet fuel
- F34/F35/F44 (kerosene) II Winter diesel fuel
- F54 (equivalent to diesel fuel according to A Outside temperature
DIN EN 590)
- XF 63 (equivalent to F34+F35 with addi- B Percentage of kerosene to be added
tives)
● Bio diesel fuel
- according to DIN 51606- FAME
Exhaust emission values which may be Diesel fuels must never be Mix in tank only. Fill with the
© 2002
determined in the cause of type approval tests mixed with petrol (normal and appropriate amount of kerosene
always refer to the reference fuel prescribed super grade petrol)! first, then add the diesel fuel.
by the authorities for the type approval test.

Routine Maintenance
5
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Work Completed
39 39 Gerade
Routine Maintenance 5.1 Maintenance Schedule
check
5 once
Operating Hours (OP) every 1)
clean see
after every Section
2) 10 OH change
750
1000
250
500
3000
2000
or daily 125
50-150
Operation
● ● Oil level in engine / separate container 9) 6.1.2/3.1.4
● ● Engine leaks
● ● Oil bath- and dry type air cleaners 3) 4) 5) 6.4
● ● Battery and cable connectors 6.7.1
● ● ● ● ● ● Cooling system (depending on engine use 3) 6.3.1
● ●7) ●6) ● Engine oil (depending on engine use) 4) 6) 6.1.1
● ●7) ●6) ● Oil filter cartridge (depending on oil change interval) 4) 6) 6.1.3
● ● ● Fuel filter cartridge 6.2.1
●2) ● ● Valve clearance (adjust if necessary) 6.6.1
● ● Engine mounts (retighten if necessary) 9.2
● ● ● V-belts (retension if necessary) 6.5
● Toothed belts 8) 10)
● ● Injection valves
● ● Fuel pump / strainer 5) 6.2.2
● ● Fuel leakage line (change defective lines) 11) 6.2.3
The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please
observe the operating instructions of the equipment manufacturer.
1) recommended maximum 7) for oil change intervals, turbocharged engines, see Section 6.1.1
2) once when commissioning new and reconditioned engines 8) without toothed belt ventilation renew after 3000 running hours, after 5 years at the
3) clean if needed latest if running hours are not reached: in both cases together with idler pulley
4) Oil quality API-CF-4, CG-4, CH-4 or ACEA-E1-3/96 and E4-98 with toothed belt ventilation renew after 4500 running hours, after 5 years at the latest
5) change if required if running hours are not reached: in both cases together with idler pulley
6) for oil change intervals, naturally aspirated engines, see 9) during run-in period, check 2 x daily
Section 6.1.1 10) retensioning of toothed belts is not permitted
11) Change at the latest after 2 years .
40
5.2 Maintenance Chart Routine Maintenance
5
The maintenance chart shown here is supplied as a self- in. 0,3 mm h
0.012 in.
adhesive label with each engine. It should be affixed a
0,5 mm Std.
where it can be seen clearly on the engine or driven ex.
ex. 0.020 in.
125-
2000
equipment. in. 1000
Check that this is the case. BFL
AIR OIL
500
If necessary, ask your engine or equipment supplier for 10
a fresh supply of labels. FL
1000
Routine work should be carried out according to the
schedule in 5.1. BFL API CD
500 ACEA E1-96
1000
OIL
FL
1000
FU 10 OIL
EL 1000 max.
BFL
OIL
500
FL
B/FL 1011F 1000
0297 7279 1
Stop the engine before carrying out

any maintenance work.
!
41 41 Gerade
Routine Maintenance 5.2 Maintenance Chart
5
The maintenance chart shown here is supplied as a self-
adhesive label with each engine. It should be affixed 0,3 mm
where it can be seen clearly on the engine or driven in. 0.012 in. h
equipment. a
0,5 mm Std.
ex.
ex. 0.020 in.
125-
2000
Check that this is the case. in. 1000
If necessary, ask your engine or equipment supplier for
BFM
a fresh supply of labels. AIR OIL
500
10
Routine work should be carried out according to the FM
schedule in 5.1.
1000
BFM API CD
500 ACEA E1-96
1000
OIL
FM
1000
FU 10 OIL
EL 1000 max.
BFM
OIL
500
FM
B/FM 1011/F 1000
0297 7281 2

!
42
5.3 Completed Maintenance Jobs Routine Maintenance
Hours Date Signaure / Stamp Hours Date Signaure / Stamp

5 1
50-150* -
125 250 2
375 500
3
625 750
875 1000 4
1125 1250
5
1375 1500
1625 1750 6
1875 2000
7
2115 2250
2375 2500 8
2625 2750
9
* Commissioning new and overhauled engines
The maintenance jobs duly completed can be recorded in the above table.
10
49_en
Routine Maintenance 5.3 Completed Maintenance Jobs
Hours. Date Signaure / Stamp Hours Date Signaure / Stamp

1 5
2875 3000
2 3125 3250
3375 3500
3
3625 3750
4 3875 4000
4125 4250
5
4375 4500
6 4625 4750
4875 5000
7
5125 5250
8 5375 5500
5625 5750
9
10
50_en
5.3 Completed Maintenance Jobs Routine Maintenance
Hours Date Signaure / Stamp Hours Date Signaure / Stamp

5 1
5875 6000
6125 6250 2
6375 6500
3
6625 6750
6875 7000 4
7125 7250
5
7375 7500
7625 7750 6
7825 8000
7
8125 8250
8375 8500 8
8625 8750
9
10
51_en
5
Seite 46Gasmotor 1015

Service and Maintenance
6
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air System
6.5 Belt Drives
6.6 Adjustments
6.7 AccessoriesService and Maintenance
47
Service and Maintenance 6.1 Lubrication System
6.1.1 Oil Change Intervals

6 Installed engines
Lube oil intervals in OH
Naturally aspirated engines
Lube oil intervals in OH
Turbocharged engines
API classification CC 1) CD/CE 1) CD/CE/CF-4 —
● The oil change intervals are dependent on the Lube oil quality
CCMC classification D4 D5 2) (SHPD) 3) D4 D5 2) (SHPD) 3)
engine application and the quality of the lube
oil. Normal oil usage, e.g.:
250 500 250 500
● If the engine runs fewer hours during the year Road vehicles, cranes, construction machinery, ships,
than stated in the table, the oil should be changed electrical units, pumps, rail-run vehicles
at least once a year.
Heavy-duty oil usage, e.g.:
● The table refers to the following conditions: Combine harvesters, emergency pumps, underground 125 250 125 250
– For diesel fuel: sulfur content max. 0.5% by equipment, sweeping machines, winter operation
weight. equipment, emergency power generating units
– Continuous ambient temperatures down to
-10 °C (+14 °F). Lube oil intervals in km Lube oil intervals in km
Vehicle engines
Naturally aspirated engines Turbocharged engines
● If the sulfur content is > 0.5 to 1% or the
continuous ambient temperature below -10 °C API classification CC 1) CD/CE 1) CD/CE/CF-4 —
(+14 °F), the intervals between oil changes should Lube oil quality
CCMC classification D4 D5 2) (SHPD) 3) D4 D5 2) (SHPD) 3)
be halved.
Annual average
Service kilometrage speed approx.
group km km/h
I to 30 000 20 5 000 10 000 5 000 10 000
II more than 30 000 40 10 000 20 000 10 000 20 000

to 100 000
III more than 100 000 60 15 000 30 000 15 000 30 000
Change the oil with the engine off but still warm (lube oil temperature approx. 80 °C).
1)
Lube oils having both a C- and an S classification (e.g. CD / SE) can be used. Oils with only a C classification
(e.g. CE) generally perform very well in diesel engines and are to be preferred.
2)
D5 grade oil with sulfate ash content > 1.8% by mass.
● In the case of fuels containing more than 1% sul- 3)
SHPD lube oils can be used.
fur, contact your service representative. These are the equivalent of D5 grade.
6.1 Lubrication System Service and Maintenance
6.1.2 Checking Oil Level / Changing

Engine Oil 6
6.1.2.1 Checking Oil Level 6.1.2.2 Changing the Engine Oil
25729 0 26022 0 26023 0
● Check the oil level with the engine switched off. ● Allow the engine to warm up. ● Place oil tray under the engine.
● Ensure that the engine or vehicle is in a level ● Ensure that the engine or vehicle is on a level ● Unscrew drain plug.
position. position. ● Drain oil.
● Remove the oil dipstick. - Lube oil temperature approx. 80 °C. ● Fit oil drain plug with the new gasket and tighten
● Wipe the dipstick with a non-fibrous,clean cloth ● Turn the engine off. firmly (for torque see 9.2).
● Insert it to the stop and remove again. ● Pour in lube oil
● Check the oil level, and if necessary, top up to - For grade / viscosity, see 4.1.
the "MAX" mark. If the oil level is only just above - For quantity see 9.1.
the "MIN" mark, more oil must be added. ● Check the oil level, see 6.1.2.1
! Be careful when draining hot oil -

danger of scalds!
The oil level must not drop below the "MIN" mark
! Do not let used oil run into the soil
but catch it in a container ready for
proper disposal!
49
6.1.3 Changing Oil Filter

6
25880 0 25881 0 25882 0
● Undo the filter cartridge using a commercial tool ● Clean any dirt from the filter carrier rim. ● Tighten the oil filter cartridge with another half-
and spin off. turn.
● Lightly oil the rubber gasket of the new oil filter
● Catch any dripping oil. cartridge. ● Check oil level, see 6.1.2.
● Screw in the new cartridge finger tight against ● Check oil pressure, see 3.3.1.
the gasket.
● Check cartridge seal for leaks.
Beware of burns from hot oil.
!
6.2 Fuel System Service and Maintenance
6.2.1 Changing Fuel Filter

6
25880 0 25881 0 25882 0
● Close fuel stopcock. smoke. the gasket.

● Clean any dirt from the filter cartridge with a final ● Tighten the fuel filter cartridge with a final half-
● Undo fuel filter cartridge with commercial tool half-turn. turn.
and spin off.
● Apply light film of oil or diesel fuel to the rubber ● Open fuel stopcock.
● Catch any fuel. gasket of the new fuel filter cartridge.
● Check for leaks.
● Screw in the new cartridge finger tight against
Keep naked flames away when work-

ing on the fuel system. Do not The fuel system does not need to be bled.
!
51
Service and Maintenance 6.2 Fuel System
6.2.2 Fuel Pump 6.2.3 Change Fuel Leakage Line

6 Cleaning the Strainer
1 2 4 3
2 3
26 436 0 30 015 0
● Close the fuel shut-off valve. ● Mount the fuel strainer cover 2. ● Close the fuel shutoff valve.
● Loosen and unscrew the hexagonal nut 1. ● Tighten the hexagonal screw 1. ● Disconnect rubber hoses 3 from the injection
● Remove the fuel strainer cover 2 (cover and ● Check for leaks. valves.
strainer, one unit) ● Disconnect rubber hose 1 from fuel tank.
● Clean the fuel strainer with diesel fuel. Replace if ● Disconnect rubber hoses 4, 3 and 1 from unions
necessary. 2 and dispose of in an environmentally friendly
● Place seals 3 in position. manner.
● Connect new rubber hoses 4, 3 and 1 to unions
2.
● Connect rubber hoses 3 to injection valves.
● Connect rubber hose 1 to fuel tank.
● Open fuel shutoff valve.
Keep naked flames away when work- ● Check for leaks after start-up.
ing on the fuel system.
! Do not smoke!
6.3 Cooling System Service and Maintenance
6.3.1 Cleaning Intervals

6
● The amount of contamination in the cooling
system depends on the engine application.
Inspection and cleaning
intervals
● Spilled oil or fuel on the engine increases the risk Engine application
of contamination. Be especially careful if the Recommended
engine is used in dusty environments. OH
● Serious contamination can occur, for example: 2000 Ships, Electrical units in enclosed areas, pumps
– on construction sites where there is a high
level of air-borne dust. 1000 Vehicles on reinforced highways
– in harvesting application where there are 500 Tractors, fork-lift trucks, mobile electrical units
high concentrations of chaff and chopped
straw in the vicinity of the machine. Vehicles on construction sites and on roads with loose surfaces,
250
construction machinery, compressors, mining equipment
● Because applications vary, cleaning intervals
have to be determined from case to case. The 125 Agricultural machinery, tractors used for harvesting purposes
cleaning intervals given in the table on the right
can be used as a guide.
● Clean the engine as described in 6.8.1.
53
53 Gerade
Service and Maintenance 6.4 Combustion Air Filter

6
● The amount of dirt in the air cleaner depends on
the amount of dust in the air and the size of the
air cleaner used. If a high level of dust is antici-
pated, a cyclone-type precleaner can be fitted to
the air cleaner.
● Cleaning intervals will have to be determined

from case to case.
● Air cleaner servicing is needed when:

– Service indicator
the red signal 1 is fully visible when the
engine is off.
– Service switch
the yellow pilot light comes on when the
engine is running.
25 885 1
● After carrying out service work, reset the signal
by pressing the button on the service indicator.
54
6.4 Combustion Air Filter Service and Maintenance
6.4.2 Emptying Cyclone Type 6.4.3 Cleaning Oil Bath Air Cleaner
Precleaner
6
25 886 0 25 887 1
● Undo wing nut 1 and remove cover 2. ● Turn engine off and wait about 10 minutes for the ● Clean filter housing 1 if very dirty.
● Remove collector bowl 3 from lower section 4 oil to drain from filter housing 1. ● Inspect and replace rubber gasket 5 and 6 if
and empty. Clean leaves, straw and other foreign ● Release snap clips 2 and remove oil cup 3 necessary.
matter from lower section of precleaner. together with filter element 4. If necessary prise ● Fill oil cup with engine oil up to the mark (arrow)
● Reposition collector bowl 3 onto lower section 4, element out with a screwdriver, taking care not to (for viscosity, see 4.1.2).
fasten cover 2 in place by tightening wing nut 1. damage the rubber gasket 5. ● Refit oil cup and element to filter housing and
● Remove dirty oil and sludge. Clean oil cup. secure with snap clips.
● Clean filter element 4 in diesel fuel and allow to
drip-dry.
Never clean air cleaner with gaso-

line. Dispose of cold oil in accord-
Never fill collector bowl with oil. Replace collector
bowl if damaged.
! ance with environmental regula-
tions!
55
55 Gerade
Service and Maintenance 6.4 Combustion Air Cleaner
6.4.4 Dry Type Air Cleaner

6 Dust Discharge Valve Filter Cartridge
25 888 1 25 889 0
● Empty dust discharge valve 1 by pressing apart ● Undo clip fasteners 1. ● After five cleaner services or after two years at
lips of discharge slot as indicated by arrows. ● Take off hood 2 and remove cartridge 3. the latest, replace safety cartridge 4 (never clean).
● Clean discharge slot from time to time. ● Clean cartridge (replace at least once a year) To do so:
● Remove any caked dirt by pressing together the ● Clean cartridge 3. – Undo hex. nut 5 and remove cartridge 4.
upper section of the valve. Blow out from inside out with dry compressed – Install new cartridge, insert and tighten hex
air (max. 5 bar), (or in difficult cases, tap out, nut.
taking care not to damage the cartridge, or wash ● Install cartridge 3, replace hood 2 and do up clip
according to manufacturer’s instructions). fasteners 1.
● Through regular removal and replacement, the
gaskets on the filter cartridge can become dam-
aged. Check paper filter (light showing through)
and gaskets for damage. Replace if necessary.
Never clean filter cartridge with
gasoline or hot fluids.
!
56
6.5 Belt Drives Service and Maintenance
6.5.1 Checking V-Belts

6
26 427 0 26 261 0
● Inspect entire V-belt for damage. – Carefully remove the gauge without alter-
● Replace damaged V-belts. ing the position of the indicator arm 1.
● After installing new belts, run engine for 15 – Read off the value where the black indicator
minutes, then check belt tension. arm 1 intersects scale 5 (arrow). For set-
● To check the tension of the V-belt, use a tension tings, see 9.1.
gauge (see 9.3). – If necessary, retension belt and measure
– Place indicator arm 1 into gauge. again.
– Position gauge on V-belt 2, midway be-
tween the pulleys, with flange 3 on bottom
of gauge against the edge of belt.
– Push slowly on the black pad 4 at right
angles to belt 2 until the spring is heard or
felt to trigger. Check tension and change belts only
with the engine off. Refit belt guard,
! if provided. When new V-belts are fitted, check the belt tension
after ca. 15 minutes running time.
57
57 Gerade
Service and Maintenance 6.5 Belt Drives
6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts

6
4 4
1
2
2
1 3
3
26 425 0 26 426 0
● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1, 2 and 3.

● Adjust alternator 4 in direction of arrow by
● Adjust alternator 4 in direction of arrow by turning bolt 3.
turning bolt 3 until correct belt tension is achieved. ● Remove and replace belt.
● Adjust alternator 4 against the direction of the
● Retighten bolts 1, 2 and 3. arrow by turning bolt 3, until correct belt tension
is achieved.
● Retighten bolts 1, 2 and 3.
Check, tension and change belts

only with the engine off. Refit belt
! guard, if provided.
58
59
59 Gerade
Service and Maintenance 6.6 Adjustments
6.6.1 Checking / Adjusting Valve

6 Clearances
19 691 2 25 893 0
● Remove the cylinder head cover. ● Adjust valve clearance if necessary:

● Position crankshaft as per schematic 6.6.1.1. – Release locknut 4.
● Before adjusting valve clearance, allow engine to – Use allen key 7 to turn setscrew 5 so that
cool down for at least 30 minutes. The oil tem- the correct clearance is attained after locknut
perature should be below 80 °C. 4 has been tightened.
● Check valve clearance 1 between rocker arm / ● Check and adjust valve clearance on all remain-
tappet contact face 2 and valve stem 3 with feeler ing cylinders.
gauge 6 (there should be only slight resistance ● Replace cylinder head cover (use new gasket if
when feeler blade is inserted). needed).
For permissible valve clearance, see 9.1.
60
6.6 Adjustments Service and Maintenance
6.6.1.1 Valve Clearance Adjustments

Schematic
6
● Crankshaft Position 1:
1 Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance of valves marked
in black on schematic. Mark respective rocker
1 2 1 2 3 1 2 3 4 arm with chalk to show that adjustment has been
done.
2 ● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in black on
schematic.
1 2 1 2 3 1 2 3 4
25 894 4
61
61 Gerade
Service and Maintenance 6.7 Accessories
6.7.1 Battery
6 6.7.1.1 Checking Battery and Cable 6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Electrolyte
Connectors Density
25 895 0 24 232 3 25 896 0
● Keep battery clean and dry. ● Remove caps 1. ● Measure the electrolyte density of individual
● Undo dirty clamps. ● If testers 2 are used, the electrolyte should come cells with a commercial hydrometer.
● Clean terminal posts (+ and -) and clamps of the up to their base.
battery, and grease with acid-free and acid- ● If testers are not used, the electrolyte level should The hydrometer reading (see table on following
resistant grease. be 10-15 mm above the top of the plates. page) indicates the state of charge.
● When reassembling, ensure that clamps make ● If necessary, top up with distilled water. During measurement, the temperature of the
good contact. Do up clamp bolts finger tight. ● Replace caps. electrolyte should preferably be 20 °C.
62
6.7 Accessories Service and Maintenance
6
Electrolyte density
in kg/l in ° Bé (Baumégrad)*
State of Charge
Normal Tropics Normal Tropics
1.28 1.23 32 27 Fully charged
1.20 1.12 24 16 Half charged, recharge
1.12 1.08 16 11 Discharged, recharge immediately
* Measurement of electrolyte density in ° Bé

(Baumé-grad) is out of date and rarely used
today.
The gases emitted by the battery

are explosive! Keep sparks and na-
! ked flames away from the battery.
Do not allow battery acid to come
into contact with skin or clothing.
Wear protective goggles. Do not rest tools on the
battery.
63
63 Gerade
6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

6
Notes on the three-phase system:
● Never disconnect the cables between battery,
alternator and regulator while the engine is run-
ning.
● If, however, it is necessary to start and operate
the engine without the battery, disconnect the
regulator from the alternator before starting.
● Be sure not to confuse the battery terminals. 2 1
● Replace defective bulb of the charge pilot lamp
immediately.
● When washing the engine, cover up the alterna-
tor and regulator.
● The habit of touching a lead against the frame to
check whether it is live must under no circum-
stances be used with three-phase electrical sys-
tems.
● In case of electric welding, connect the ground 26 434 0 26 435 0
terminal on the welder directly to the piece being
welded. ● Always use proper lifting tackle 1 when trans-
porting the engine.
● After transportation and before commissioning
of the engine:
Remove attachment eyes 2.
Use only the correct lifting tackle.
64
6.7.4 Ether Starting System

6.7.4.1 Changing the Fluid Container 6
25 965 0 25 956 0
● Before removing the container, clean the con- ● Place the container 1 on the solenoid valve 2 and
tainer support and the top of the solenoid valve. tighten by hand.
● Loosen the bracket 1. ● When mounting, ensure that gasket 3 is seated
● Unscrew the fluid container 2. correctly.
● Empty or replace the depressurized fluid con- ● Pull in the brackets.
tainer. ● Check for leaks.
Before commissioning, leave the

fluid container of the ether starting
! system in position for 15 minutes.
Check for leaks. The starting fluid is
inflammable. Ensure that the con-
tainer is not damaged. Prevent foreign substances
from entering the container. The fluid container
must not be stored at temperatures above 50 °C.
65
65 Gerade
Service and Maintenance 6.8 Engine Cleaning
6.8.1 Engine Cleaning

6
Preparation
● Remove engine covers and cooling air hood.
Replace them after cleaning and before the test
run.
● Cover electrical / electronic components / con-
nections (eg. generator, starter, governor, sole-
noid).
Using compressed air
● Blow air through the engine, taking particular
care not to damage the cooler and cooling fins
(begin to blow through air from the exhaust
side).
Remove the dirt which has blown into the inte-
rior space.
Using cold-cleaning compound
● Spray the engine with the commercial cold-
cleaning compound and allow to react for approx.
10 mins.
● Spray clean the engine with a strong water jet,
repeat if necessary.
● Allow the engine to run up so that the remaining
water evaporates.
Using high pressure device

● Clean the engine with a steam jet (max. spray
pressure
of 60 bar, max. steam temperature of 90ºC).
● Allow the engine to run up so that the remaining
water evaporates.
Clean the engine only when the
! engine is switched off.
66
Faults, Causes and Remedies
7
7.1 Diagnosis Chart
67
Faults, Causes and Remedies 7.1 Diagnosis Chart
7
● Faults are often caused by maloperation of the engine
or failure to service the engine.
● In the event of a fault, always check whether the

operating and servicing regulations have been ad-
hered to.
● A corresponding fault table can be found on the

adjacent page.
● If you cannot ascertain the cause of a fault or cannot

rectify the fault, please contact DEUTZ SERVICE.
7.1 Diagnosis Chart Faults, Causes and Remedies
Fault Remedy
Engine fails or is difficult to start Check P 7
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes – blue
– white
– black
Cause Section
● Not declutched (where possible) Operation P
● ● Below starting limit temperature P
● ● Oil level too low A
● ● ● ● Oil level too high P
● ● ● Excessive inclination of engine S
● ● Incorrect lube oil SAE class or quality Operating W
● ● ● ● Fuel quality not as per operating manual media W
● ● ● Air cleaner clogged / turbocharger defective Combustion air P/W
● ● ● Air cleaner service switch / indicator defective P/W
● LDA* defective P
● ● Charge air line leaking P
● Oil cooler panels clogged Cooling system P/R
● Cooling fan defective, split or loose V-belt P/W
● Cooling air temperature rise / heating short circuit P
● Resistance in cooling system too great / through-flow quantity too small P
● Battery defective or discharged Electrics P/A
* LDA = Aneroid device
69
Faults, Causes and Remedies 7.1 Diagnosis Chart
Fault Remedy
7 Engine fails or is difficult to start Check P
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine smokes – blue
– white
– black
Cause Section
● Electric cable connections to starter electrical system loose or oxidized Electrics P
● Starter defect or pinion does not engage P
● Solenoid defective (release switch) P
● ● ● ● ● Incorrect valve clearance Engine E
● ● ● Leaking injection line P
● ● ● ● ● ● ● Injection valve defective P/W
Engine Preservation
8
8.1 Preservation
73 9929en
Engine Preservation 8.1 Preservation
8.1.1 Preserving Engine 8.1.2 Removing Engine

8 Preservatives
If the engine is to remain idle for an extended period ● Clean engine using high-pressure equipment ● Remove anti-corrosion agent from grooves in
of time, it is necessary to take protective measures to (or with cold-cleansing agent in emergency). V-belt pulleys.
prevent rusting. The preservative measures described ● Run engine until warm, then turn off. ● Install V-belt, retension after brief operation if
here will protect the engine for up to 6 months. ● Drain engine oil (see 6.1.2) and fill with anti- necessary, see 6.5.
The procedure will have to be reversed before the corrosion oil. ● Remove covers from intake port and exhaust
engine is recommissioned. ● If necessary, clean oil bath cleaner (see 6.4.3) port.
● Anti-corrosion oils to specification: and fill with anti-corrosion oil. ● Commission engine, see also 5.1, note 2.
MIL-L-21260B ● Drain fuel tank.
TL 9150-037/2 ● Make up a mixture of 90% diesel fuel and 10%
Nato Code C 640 / 642 anti-corrosion oil, and refill fuel tank.
● Anti-corrosion media for exterior protection only ● Allow engine to run for approx. 10 mins.
to specification: ● Switch off engine.
Nato Code C 632 ● Turn engine over manually several times to pre-
● Recommended cleaning agent to remove preserve cylinders and combustion chamber.
servatives: ● Remove V-belts and store in wrapped condition.
Petroleum benzine ● Spray grooves on V-belt pulleys with anti-corro-
(hazardous materials class A3) sion spray.
● Close intake ports and exhaust ports.
74 9929en
Technical Specifications
9
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
73
73 Gerade
Technical Specifications 9.1 Engine Specifications and Settings
Model
9 Numbers of cylinders
—— F2L 1011F —— F3L 1011F ————— F4L 1011F — F4L 1011FL* ——
——— 2 —————— 3 ————————— 4 ————— 4 ————
Cylinder arrangement ————————————— vertical in line ——————————————
Bore [mm] ———————————————— 91 ————————————————
Stroke [mm] ——— 105 ———— 105 ———————— 105 ————— 112 ————
Total displacement [cm3] ——— 1366 ———— 2049 ——————— 2732 ——— 2912 ———
Compression ratio [ε] ——————————————— 18,5 ————————————————
Working cycle ———————————— 4-stroke diesel engine ————————————
Combustion system ——————————— naturally aspirated engine with direct injection ————
Direction of rotation ————————————— counter clockwise —————————————
Weight incl. integrated cooling system as per DIN 70020-A
(without starter, with alternator) ca.[kg] ——— 167 ———— 208 ———————— 249 ————— 250 ————
Engine power [kW (PS)] 1)
———————————————— ———————————————————
Speed [1/min] ———————————————— 1) ———————————————————
Lubrication ———————————— pressure lubrication —————————————
SAE oil
—————————————— 20 W 20 ———————————————
Max. oil temperature in oil sump [°C]
——————————————— 130 ————————————————
Min. oil pressure in warm condition, oil temperature 110 °C 3)
at: 900/min (low idling speed) [bar] ——————————————— 1,4 ——————————————————
1800 /min [bar] ——————————————— 2,2 3) ——————————————————
max. 3300 /min, *max. 3000 /min [bar] ——————————————— 3 3) ——————————————————
2) 2) 2) 2)
Oil change quantity (oil sump) ca. [ltr.] ——— 6 ———— 5,5 ————————— 10 ————— 10 ————
Oil change quantity with filter (Standard 0.5 ltr.) ca. [ltr.] ——— 6,5 2) ————— 6 2) ———————— 10,5 2) ——— 10,5 2) ———
Valve clearance with cold engine [mm] ——————————————— inlet 0.3 ———————————————
(Engine cooling time at least 30 Min.: Oil temperature below 80°C)[mm] —————————————— exhaust 0.5 ——————————————
Start of delivery [°crank angle b TDC] ———————————————— 1) ———————————————————
Injector opening pressure: vehicle/genset engine [bar] —————————————— 210 / 250+8 ————————————————
Firing order of the engine ——— 1 - 2 ——— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 — 1 - 3 - 4 - 2 ——
V-Belt tension: Pretension / Retension
(after the engine has been running under load for 15 mins): [N] ————————————— 450 / 350 ±20 ——————————————
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative.
3)
Values for engines without engine oil heating.
74
Model ——— BF3L 1011F/L ———————— BF4L 1011F/FT ——

Number of cylinders ————— 3 ———————————— 4 —————— 9
Cylinder arrangement —————————— vertical in line ———————————
Bore [mm] ———————————— 91 —————————————
Stroke [mm] ———— 105/112 ——————————— 105 —————
Total displacement [cm3] ———— 2184 ——————————— 2732 —————
Compression ratio [ε] ———————————— 17 —————————————
Working cycle / Combustion system ——— 4-stroke diesel with turbocharging and direct injection ——
Direction of rotation ————————— counter clockwise ——————————
Weight without cooling system [kg] ————————— Refer to head-office —————————
Weight without starter, with alternator as per DIN 70020-A ca. [kg] ————— 233 ———————————— 256 —————
Engine power [kW (PS)] ———————————— 1) ———————————————
1)
Speed [1/min] —————————————————————— ———————————————
Lubrication ————————— pressure lubrication —————————
SAE oil ——————————— 20 W 20 ————————————
Max. oil temperature in the oil sump [°C] ———————————— 130 ————————————
at: 900/min (low idling speed) [bar] ——————————— 1,4 3) ——————————————
1800 /min [bar] ——————————— 2,2 3) ——————————————
max. 3000 /min [bar] ———————————— 3 3) ——————————————
2)
Oil change quantity (oil sump without cooling system) ca. [ltr.] ————— 7,5 ———————————— 10 ——————
2)
Oil change quantity with filter (Standard 0.5 ltr.) ca. [ltr.] ————— 8 ——————————— 10,5 ——————
Valve clearance with cold engine
(Engine cooling time at least 30 mins.: oil temperature below 80°C) [mm] ——————— inlet 0,3 + 0,1 / exhaust 0,5 + 0,1 ————————
+8
Injector opening pressure: vehicle/genset engine [bar] —————————— 210 / 250 ————————————
1)
Start of delivery [°crank angle b TDC] —————————————— ———————————————
Firing order of the engine ———— 1 - 2 - 3 —————————— 1-3-4-2 —————
V-Belt tension: Pretension / Retension (after the engine has been running under load for 15 mins):[N] —————————— 450 / 350 ±20 ——————————
1)
2)
Ca. value can vary depending on oil sump and or coolor design (external cooling system). The upper oil dipstick marking should always be taken as authoritative.
3)
75
75 Gerade
Technical Specifications
Model ——— F3M 1011F ———————— F4M 1011F ——

9 Number of cylinders ————— 3 ———————————— 4 ———— 9
Cylinder arrangement —————————— vertical in line ————————
Bore [mm] ———————————— 91 ———————————
Stroke [mm] ————— 112 ———————————— 112 ———
Total displacement [cm3] ———— 2184 ——————————— 2912 ———
Compression ratio [e] ———————————— 18,5 —————
Working cycle ———————— 4-stroke diesel engine ———————
Combustion system ————— naturally aspirated engine with direct injection
Direction of rotation ————————— counter clockwise ————————
Weight without cooling system ———————— Rückfrage Stammhaus ———————
(without starter, with generator) ca. [kg] ————— 200 ———————————— 242 ———
Engine power [kW (PS)] ———————————— 1) ———————————
Speed [1/min] ———————————— 1) ———————————
Lubrication ———————— Druckumlaufschmierung ——————
SAE oil ——————————— 20 W 20 ——————————
Maximum oil temperature in the oil sump [°C] ———————————— 130 ——————————
Minimum oil pressure in warm condition, oil temperature 110 °C,
at: 900/min (low idling speed) [bar] ——————————— 1,4 3) ——————————
1800 /min [bar] ——————————— 2,2 3) ——————————
max. 3000 /min [bar] ———————————— 3 3) ——————————
Engine with Thermostat
Oil change quantity without external cooler (see 3.1.1.2)/ without filter approx. [ltr.] ———— 5,5 2) ——————————— 10 2) ———
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement [ltr.] ————— 6 2) ——————————— 10,5 2) ———
(Standard 0.5 litre) approx.
Genset engine without Thermostat:
Oil change quantity including cooler (see 3.1.1.3)/ without filter approx. [ltr.] ———— 8,5 2) ——————————— 13 2) ———
Oil change quantity including cooler (see 3.1.1.3) + filter replacement [ltr.] ————— 9 2) ——————————— 13,5 2) ———
(Standard 0.5 litre) approx. —————————————
Valve clearance at cold engine —————————————
+ 0,1 + 0,1
(Engine cooling time at least 30 mins.: oil temperature below 80°C) [mm] —————— inlet 0,3 / exhaust 0,5 ————
Start delivery [°crank angle b TDC] ———————————— 1) ———————————
+8
Injector opening pressure: vehicle/genset engine [bar] —————————— 210 / 250 —————————
Firing order of the engine ———— 1 - 2 - 3 ————————— 1 - 3 - 4 - 2 ——
V-Belt tension: Pretension / Retension(after the engine has been running under load for 15 mins):[N] —————— 450 / 350 ±20 ————————
1) / 2.1.
Engine power, speed, start of delivery are stamped on engine rating plate, see also ———
2)
Ca. value can vary depending on oil sump and or coolor design (external cooling system).The upper oil dipstick marking should always be taken as authoritative.
3)
76
76 76 Gerade
Model ——— BF3M 1011 F ———————— BF4M 1011 F ———

Number of cylinders
Cylinder arrangement
————— 3 ———————————— 4 ——
—————————— vertical, in line ——————————
9
Bore [mm] ———————————— 91 —————————————
Stroke [mm] ———————————— 112 ————————————
Working cycle —————————— 4-stroke diesel ——————————
Combustion system —————— turbocharging and direct injection ———————
Direction of rotation ————————— counter clockwise ——————————
Weight without cooling system ————————— Refer to head-office —————————
(without starter, with generator) ca. [kg] ————— 226 ———————————— 249 —————
Engine power [kW (PS)] ———————————— 1) —————————————
Speed [1/min] ———————————— 1) —————————————
Lubrication ————————— pressure lubrication —————————
SAE oil ——————————— 20 W 20 ————————————
Maximum oil temperature in the oil sump [°C] ———————————— 130 ————————————
Minimum oil pressure in warm condition, oil temperature 110 °C,
at: 900/min (low idling speed) [bar] ———————————— 1,4 3) ————————————————————
1800 /min [bar] ———————————— 2,2 3) ————————————————————
max. 2800 /min [bar] ———————————— 3 3) —————————————————————
Oil change quantity without external cooler (see 3.1.1.2)/ without filter approx. [ltr.] ————— 7,5 ———————————— 10 2) —————————
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement [ltr.] ————— 8 ——————————— 10,5 2) ————————
Genset engine without Thermostat:
Oil change quantity including cooler (see 3.1.1.3)/ without filter approx. [ltr.] ————— 11 ——————————— 13,5 2) ————————
Oil change quantity including cooler (see 3.1.1.3) + filter replacement [ltr.] ————— 11,5 ——————————— 14 2) —————————
Valve clearance at cold engine
(Engine cooling time at least 30 mins.: oil temperature below 80°C) [mm] ——————— inlet 0,3 +0,1 / exhaust 0,5 +0,1 ————————
Start delivery [°crank angle b TDC] ———————————— 1) —————————————
Injector opening pressure: vehicle/genset engine [bar] —————————— 210 / 250 +8 ———————————
Firing order of the engine ———— 1-2-3 —————————— 1-3-4-2 —————
V-Belt tension: Pretension / Retension (after the engine has been running under load for 15 mins):[N] —————————— 400 / 300 ±20 ——————————
1)
2)
Ca. value can vary depending on oil sump and or coolor design (external cooling system).The upper oil dipstick marking should always be taken as authoritative.
3)
77
77 Gerade
Technical Specifications 9.2 Torque Wrench Settings
9 Preload [Nm] Torquing Load [Nm]

Location Total [Nm] Remarks
1st 2nd 3rd 1st 2nd 3rd 4th
Stage Stage Stage Stage Stage Stage Stage
Rocker cover 8,5
Rocker arm set screw 21
Air intake manifold 8,5

21
Exhaust manifold 40
22
Oil drain plug 55
Injector mounting 21 TORX
Injector line mounting 22

30
Oil pan (cast iron) 31
Oil pan (sheet metal) 21
78
9.3 Tools Technical Specifications
TORX V-belt Tension Gauge

9
25899 0 26002 0
A TORX wrench set (order number 8189) is used The V-belt tension gauge can be obtained under
with engines in the 1011 series. order number 91 107 from:
This system was chosen because of the many
advantages it offers: COMPANY WILBÄR
Postfach 14 05 80
● Outstanding accessibility to bolts. D-42826 Remscheid
● High load transfer when loosening and tightening.
● Almost impossible for socket to slide off or
break.
TORX tools can be ordered from:

COMPANY WILBÄR
Postfach 14 05 80
D-42826 Remscheid
79
79 Gerade
Notes
en Warnings to Place on Equipment Warning in the Manual
CALIFORNIA CALIFORNIA
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Diesel engine exhaust and some of its
constituents are known to the State of constituents are known to the State of
California to cause cancer, birth California to cause cancer, birth
defects, and other reproductive harm. defects, and other reproductive harm.
or
CALIFORNIA
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Notes
CALIFORNIA PROPOSITION 65 INFORMATION en

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.
The warning must appear in one of the following locations:

● Inside The front cover
● Inside the back cover
● Outside the front cover
● Outside the back cover
● As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
Notes
80
Service
Knowing it’s DEUTZ Order-No.: 0312 0806 10

en DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manu-
facturer, we offer — worldwide — a com-
prehensive 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 Order-No.: 0312 0807 (CD-ROM)
of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the DEUTZ AG
range of services provided. But even when no direct Deutz-Mülheimer Str. 147-149
product responsibility is mentioned, your DEUTZ D-51057 Köln
partner will be happy to help you with expert advice.
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Obtainable from the local service Partner reponsible Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. for you or from: Telex: 8812-0 khd d
http://www.deutz.de
DEUTZ AG — at your service.

14143 ET-Liste Umschlag 18.03.2002 11:30 Uhr Seite 1
Ersatzteilliste
Spare Parts Catalogue
Catalogue de Pièces de
Rechange
Lista de Piezas de Repuesto
B/F M 1011/F
Die in dieser Ersatzteilliste aufgeführten Bauteile sind nur für is resultantes da inobservãncia das instruções corresponde- Fagmessig innmontering av reservedeler er utførlig beskrevet
Reparatur von Deutz Motoren der bezeichneten Baureihe zu tes. i instruksjonsboken (vedlikeholdsarbeid) og verkstedshånd-
verwenden (bestimmungsgemäßer Gebrauch). boken (reparasjonsarbeid). Produsenten påtar seg ikke ansvar
Über den fachgerechten Einbau von Ersatzteilen informieren I componenti elencati in questa lista di pezzi di ricambio devo- for materielle skader eller personskader som skyldes at de
die Betriebsanleitung (Wartungsarbeiten) und das Werkstatt- no essere utilizzati soltanto per la riparazione di motori Deutz relevante anvisningene ikke har blitt fulgt.
handbuch (Reparaturarbeiten) ausführlich. Für Schäden oder della serie denominata (uso conforme alla destinazione).
Verletzungen von Personen, die aus der Nichtbeachtung der Il libretto di istruzioni (lavori di manutenzione) ed il manuale T· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÓÔ ·Ó·Ê¤ÚÔÓÙ·È ÔÙÔÓ ·ÚfiÓÙ· Î·Ù¿ÏÔÁÔ Ú¤ÂÈ
entsprechenden Anleitung führen, übernimmt der Hersteller per officine (lavori di riparazione) forniranno delucidazioni Ó· ¯ÚËÔÈÌÔÔÈÔ‡ÓÙ·È ÌfiÓÔ ÁÈ· ÙËÓ ÂÈÔÎÂ˘‹ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ ˚fi‘ÒÒ
keine Haftung. dettagliate sul montaggio corretto dei pezzi di ricambio. Il fab- ÙË˜ ÛÂÈÚ¿˜ ÌÔÓÙ¤ÏˆÓ ÔÙËÓ ÔÔãÈ ·Ó·Ê¤ÚÔÓÙ·È (¯Ú‹ÔË Û‡ÊˆÓ· ÌÂ
bricante non si assume nessuna responsabilità per danni o le- ÙÔÓ ÚÔÔÚÈÔÌfi ÙÔ˘˜).
The parts contained in this Catalogue are type-specific and sioni a persone dovuti all’inosservanza delle relative istruzioni. TÔ ·ˆÔÙfi ÌÔÓÙ¿ÚÈÛÌ· ÙˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ·˘ÙÒÓ ÂÚÈÁÚ¿ÊÂÙ·È
shall be used only for repairing engines belonging to the ÂÈÔÙ·Ì¤Ó· ÔÙÈ˜ √‰ËÁãÈÂ˜ §ÂÈÙÔ˘ÚÁãÈ·˜ (ÎÂÊ¿Ï·È: ∂ÚÁ·ÔãÈÂ˜
DEUTZ engine family given on the cover. De constructiedelen in deze onderdelenlijst mogen alleen wor- ·˘ÓÙ‹ÚËÔË˜) Î·È ÔÙÔ ÂÁ¯ÂÈÚãÈ‰ÈÔ Û¤Ú‚È˜ ÂÈÔÎÂ˘ÒÓ (ÎÂÊ¿Ï·È:
Full particulars for the correct installation of parts are to be den gebruikt worden reparatie van Deutz motoren uit de ver- ∂ÚÁ·ÔãÈÂ˜ ÂÙÈÔÎÂ˘Ë˜). √ Î·Ù·ÛÎÂ˘·ÔÙ‹˜ ‰ÂÓ ¤¯ÂÈ Â˘ı‡ÓÂ˜ ÁÈ· ˙ËÌãÈÂ˜
found in the relevant Operating (maintenance work) and melde bouwserie (gebruik volgens de voorschriften). ÛÂ ˘ÏÈÎfi Î·È ·Ù˘¯‹Ì·Ù· ÚÔÔˆÈÎÔ‡ ‹ ·Ó·ÏˆÙÒ/¯ÚËÔÙÒÓ, Ô˘
Workshop Manuals (repair). The engine builder shall not be Uitvoerige informatie over de correcte inbouw van onderdelen ÚÔ¤Ú¯ÔÓÙ·È ·fi ÙËÓ ÌË Ô˘ÌÌfiÚÊˆÔË ÚÔ˜ ÙÈ˜ ·Ó¿ÏÔÁÂ˜ Ô‰Ë ÁãÈÂ˜.
liable for any damage or injury resulting from non-compliance is te vinden in de gebruiksaanwijzing (onderhoudswerkzaam-
with guidelines given in the manuals. heden) en de werkplaatshandleiding (reparaties). Voor schade Yedek parça listesinde belirtilmiş olan parçalar, yalnızca ilgili
of persoonlijk letsel dat te wijten is aan niet-naleving van de Deutz motorlarının yapi grubu için geçerlidir ve yalnızca bu tip
Le présent Catalogue des pièces de rechange énumère les desbetreffende voorschriften, is de fabrikant niet aansprakelijk. motorların tamirinde kullanılacaktır (kullanım amacına uygun
composants à utiliser uniquement à des fins de réparation kullanım).
pour moteurs Diesel de la série indiquée (utilisation spécifi- De i denna reservdelslista upptagna komponenter ska endast Yedek parçaların talimatlara göre doğru şekilde tmonte
que). användas vid reparationer på Deutz-motorer av angiven typ. edilmesini gösteren bilgiler, kullanım kılavuzu (bakım
Les Instructions de service (travaux d’entretien) et le Manuel Ur instuktionsboken framgår utförligt hur reservdelarna ska çalışmaları) ve atölye el kitabında (tamir çalişmaları) ayrıntılı
d’atelier (travaux de réparation) apportent de plus amples monteras. För motor- och personskador som orsakas av fel- olarak açıklanmıstır. Talimatlara aykırı yapılan çalışmalardan
informations sur le montage approprié des pièces. Le fabricant montering ansvaras ej. doğacak hasar ve yaralanmalardan imalatçı firma sorumlu
décline toute responsabilité découlant de dommages ou de değildir.
blessures aux personnes résultant du non-respect des pré- De i denne reservedelsliste angivne komponenter må kun
sentes instructions. anvendes til reparation af Deutz motorer i den anførte serie Privedennye v nastoä wem spiske qapasnyx hasteí
(formålsrelevant anvendelse). detali doløny ispolæqovatæsä tolæko dlä remonta
Los componentes indicados en esta lista de repuestos se Detaljer vedrørende den korrekte montering af reservedele dvigatelej £dojtc“ ukaqannogo konstruktivnogo
emplearán exclusivamente para la reparación de motores fremgår af instruktionsbogen (service) samt værkstedshånd- rä da (ispolæqovanie po naqnaheniœ).
Deutz de la serie indicada (uso conforme a la finalidad). bogen (reparation). Producenten påtager sig intet ansvar for Podrobnaä informaciä o pravplænoj vstrojke
Respecto al correcto montaje de los repuestos, véanse los skader på personer eller ting som følge af, at bestemmelserne
manuales de instrucciones de manejo (trabajos de manteni- i den relavante vejledning ikke er overholdt.
qapasnyx hastej soderøitså v rukovodstve po
miento) y el manual de taller (trabajos de reparación). El fabri- qkspluatacii (raboty po texniheskomu obsluøivaniœ)
cante no responderá por daños o lesiones de personas resul- Tässä varaosaluettelossa lueteltuja komponentteja tulee i v spravohnike remontnoj masterskoj (remontnye
tantes de la inobservancia de la instrucción correspondiente. käyttää vain ilmoitetun tyyppisten Deutz-moottoreiden kor- raboty). Iqgotovitelæ ne perenmaet otvetstven-
jaustöissä (käyttötarkoituksen mukainen käyttö). nosti qa povreødeniä ili travmy personala,
As peças e partes componentes relacionadas nesta lista de Käyttöohjeesta (kohdasta Huoltotyöt) ja korjaamokäsikirjasta vyzvannye nesoblœdeniem sootvetstvuœwix
peças sobresselentes serão utilizadas (uso a que se destinam) (kohdasta Korjaustyöt) käy yksityiskohtaisesti ilmi, kuinka instrukcij.
somente para a reparação de motores Deutz da série desi- varasoat asennetaan asianmukaisesti. Valmistaja ei vastaa
gnada. vahingoista tai henkilöiden loukkaantumisista, jotka johtuvat
O manual de instruções de serviço (trabalhos de manutenção) siitä, että vastaavaa ohjetta ei ole noudatettu.
e o manual de oficina (trabalhos de reparação) proporcionam
informações pormenorizadas quanto à montagem tecnica- Komponenter som er oppført på denne reservedelslisten, er
mente correcta de peças sobresselentes. O fabricante não as- bare beregnet til reparasjon av DEUTZ motorer som tilhører de
sume qualquer responsabilidade por danos ou lesões pessoa- serier som er angitt (forskriftsmessing bruk).
12538 ET-Liste 1011/F 18.03.2002 12:29 Uhr Seite 01
Ersatzteilliste
Catalogue de Pièces de Rechange
Lista de peças sobresselentes
Listino parti di ricambio
Onderdelenlijst
Reservdelslista
Reservedelsliste
Varaosaluettelo
Reservedelsliste
∫·Ù¿ÏÔÁo˜ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
Yedek parça Listesi
Spisok zapasnyx hastej
Ersatzteilliste
B/F M 1011/F
Händlerstempel
0297 7780
Motornummer:
Bitte tragen Sie hier die Motornummer ein. Sie er-

leichtern hierdurch die Abwicklung bei Kunden-
dienst-, Reparatur- und Ersatzteilfragen.
Gegenüber Darstellungen und Angaben dieser Er-

satzteilliste sind technische Änderungen, die zur
Verbesserung der Motoren notwendig werden, vor-
behalten. Nachdruck und Vervielfältigung jeglicher
Art, auch auszugsweise, bedarf unserer schrift-
lichen Genehmigung.
1
Vorwort
de
Sehr geehrter Kunde,
die luft-/ flüssigkeitsgekühlten Motoren der Marke

DEUTZ sind für ein breites Anwendungsspektrum
entwickelt. Dabei wird durch ein umfangreiches An-
gebot von Varianten sichergestellt, daß die jeweiligen
speziellen Anforderungen erfüllt werden.
Ihr Motor ist dem Einbaufall entsprechend ausge-

rüstet, das heißt, nicht alle in dieser Ersatzteilliste
dargestellten Bauteile und Komponenten sind an
Ihrem Motor dargestellt.
Obwohl die Grafiken weitgehend nicht mit allen

Details dargestellt sind, können die einzelnen Vari-
anten deutlich unterschieden werden, so daß das
für Ihren Motor relevante Ersatzteil leicht heraus-
zufinden ist. Über Positions-, Baugruppen- und
Motornummer wird in jedem Fall das richtige
Ersatzteil ermittelt.
Bitte beachten Sie bei der Ersatzteilbestellung unsere

Bestellhinweise, damit wir Ihnen schnell und zu-
verlässig die benötigten Ersatzteile in der jeweils
dem letzten Änderungsstand entsprechenden Aus-
führung liefern können.
Für Rückfragen stehen wir Ihnen gerne beratend zur

Verfügung.
Ihre
DEUTZ AG
2
Vorwort
DEUTZ Dieselmotoren Original DEUTZ Teile DEUTZ Austauschkomponenten de
sind das Produkt jahrelanger Forschung und Ent- unterliegen den gleichen strengen Qualitätsanfor- DEUTZ Austauschkomponenten
wicklung. Das dadurch gewonnene fundierte know derungen wie die DEUTZ Motoren. Weiterentwick- sind eine preiswerte Alternative.
how in Verbindung mit hohen Qualitätsanforde- lungen, zur Verbesserung der Motoren werden Selbstverständlich gelten auch
rungen ist die Garantie für die Herstellung von Mo- selbstverständlich auch bei den Original DEUTZ hier wie für Neuteile höchste
toren mit langer Lebensdauer, hoher Zuverlässig- Teilen eingeführt. Nur die Verwendung von nach Qualitätsmaßstäbe. In Funktion
keit und geringem Kraftstoffverbrauch. Es ist neuesten Erkenntnissen gefertigten Original DEUTZ und Zuverlässigkeit sind DEUTZ Austausch-
selbstverständlich, daß auch die hohen Anforde- Teilen bietet die Gewähr einwandfreier Funktion komponenten den Original DEUTZ Teilen gleich-
rungen zum Schutz der Umwelt erfüllt werden. und hoher Zuverlässigkeit. wertig.
SERVICE Vorsicht bei laufendem Motor Asbest
Wenden Sie sich bei Betriebsstörungen und Er- Wartungsarbeiten oder Reparaturen nur bei abge- Bei diesem Motor verwendete
satzteilfragen an eine unserer zuständigen Service- stelltem Motor durchführen. Evtl. entfernte Schutz- Dichtungen sind asbestfrei. Bitte
Vertretungen. Unser geschultes Fachpersonal sorgt vorrichtungen nach Abschluß der Arbeiten wieder verwenden Sie bei Wartungs- und
im Schadensfall für eine schnelle und fachgerechte montieren. Bei Arbeiten am laufenden Motor soll die Reparaturarbeiten entsprechende
Instandsetzung unter Verwendung von Original Arbeitskleidung fest anliegen. Nur bei abgestelltem Ersatzteile.
DEUTZ Teilen. Motor tanken. Motor nie in geschlossenen Räumen
laufen lassen – Vergiftungsgefahr.
3
Motorbeschreibung
de 1. Firmenschild 2. Lage des Firmenschildes 3. Motornummer
Die Bauart A, die Motornummer B sowie die Lei- Das Firmenschild C ist auf der Ventilabdeckhaube Die Motornummer D ist auf dem Kurbelgehäuse
stungsdaten sind auf dem Firmenschild eingestem- angebracht. sowie auf dem Firmenschild eingestempelt.
pelt.
Bei der Ersatzteilbeschaffung müssen Bauart und
Motornummer angegeben werden.
4
Ersatzteilbestellung
de
5
Service
de
6
B/F M 1011/F
Dealer’s stamp
0297 7780
Engine
Serial No:
Please enter here the serial No. of your engine. This

will facilitate dealing with your questions concern-
ing after-sales service, repair and spare parts.
This Spare Parts Catalogue is subject to engineering

changes necessary for engine advancement. All
rights reserved. No part of this publication may be
reproduced or multiplied in any form, without our
prior permission in writing.
7
Preface
Dear Customer,
en
watercooled DEUTZ diesel engines are developed to
meet the requirements of a wide range of applica-
tions. An extensive program of variant options gives
them their high flexibility.
Your engine is custom-made, i.e. specifically equipped

for your requirement, which means that not all of
the components and assemblies contained in this
Catalogue are fitted to your engine.
The greater part of the illustrations does not depict all

details, and yet you will find it easy to differentiate bet-
ween versions and thus to identify the parts
pertaining to your engine model. Fig. Item No.,
Assembly Group No. Engine Serial No. are the
codes that infallibly lead to selection of the correct
parts.
When placing your order, please observe our ordering

hints. This will allow speedy and reliable delivery
of the required parts that are based on latest
engineering standards.
If there are any questions, please do not hesitate to

contact us.
Sincerely,
DEUTZ AG
8
Preface
DEUTZ Diesel Engines Genuine DEUTZ Parts DEUTZ Exchange Components
are products based on long-standing research and are subject to equally stringent quality require- are a cheap alternative. Of course,
en
development. The deep funds of acquired know- ments as the engines themselves. Improvements in they are subject to the same high
how in conjunction with high quality requirements engine design certainly also pass into the genuine quality requirements as new
guarantee that engines leaving our works achieve a DEUTZ parts. To ensure that your engine will parts. And as regards functions
long life, high reliability and excellent fuel eco- retain its functions and high reliability, you should and reliability, DEUTZ exchange
nomy. Naturally, they also attain best ratings as reuse genuine DEUTZ parts only. components equal genuine DEUTZ parts.
gards environmental protection.
SERVICE Beware of the Running Engine Asbestos
In case of operational trouble with your equipment Be sure to shut down the engine before performing Gaskets used for this engine do not
or queries about spare parts please turn to your maintenance or repair work. After repair, put back contain asbestos. Please use suit-
nearest service dealership. Our skilled staff of ser- in place any removed panels and guards. When able spare parts when carrying out
vice experts will trace and remedy any defect doing work on the running engine, working clothes maintenance and repair work.
quickly, using genuine DEUTZ parts. should fit tightly so that loose ends cannot get
caught. Do not run the engine in enclosed rooms
– poison hazard.
9
Description of Engine
1. Maker’s Nameplate 2. Position of Nameplate 3. Engine Serial No.
en
Engine model designation A, Engine Ser. No. B The rating plate C is attached to the valve cover. The engine serial number D is stamped on the
and the power rating are given on the maker’s crankcase as well as the rating plate.
nameplate. Be sure to state engine model and engine
serial number when writing out a parts order.
10
Spare Parts Orders
en
11
Service
en
12
B/F M 1011/F
Cachet du concessionnaire
0297 7780
Numéro
du moteur:
Veuillez incrire dans les cases correspondantes le

numéro du moteur. Vous facilitez ainsi le règlement
des questions du Service après-vente ainsi que tous
les problèmes de réparation et de pièces de re-
change.
Nous nous réservons le droit dans le présent Ma-

nuel, de procéder à toutes modifications techniques
utiles visant à améliorer la qualité des moteurs.
Toute réimpression ou reproduction du présent
Manual, faite même à titre exceptionnel, exige
notre autorisation spéciale.
13
Avant-propos
Cher client,
les moteurs refroidis par liquide de la marque DEUTZ

fr ont été développés pour les applications les plus
variées. Il existe un grand choix de variantes répon-
dant aux exigences spéciales demandées dans cha-
que cas.
Votre moteur est équipé pour les cas d’application

envisagée, ce qui signifie que toutes les pièces et
composants représentés dans votre Catalogue de
pièces de rechange ne sont pas montés sur votre
moteur.
Bien que les graphiques ne représentant pas tous les

détails, les variantes se distinguent nettement les
unes des autres, si bien que vous trouverez sans pro-
blème la pièce de rechange correspondant à votre
moteur. Les numéros de référence, de l’organe et
du moteur permettent en tout cas de retrouver la
pièce de rechange que vous cherchez.
Lors de votre commande de pièces de rechange

veuillez respecter nos indications de commande, afin
que nous puissons vous fournir rapidement et sûre-
ment les pièces de rechange demandées dans la ver-
sion correspondante réactualisée.
Pour toutes questions complémentaires nous restrons

à votre endière disposition.
DEUTZ AG
14
Avant-propos
Les moteurs Diesel DEUTZ Pièces d’orgine DEUTZ Composants de rechange DEUTZ
sont le fruit de longues recherches et d’un déve- Elles sont soumises aux même niveau d’exigence Les composants de rechange
loppment continu. Le solide savoir-faire ainsi ac- de qualité que les moteurs DEUTZ. Toute progrès DEUTZ sont une alternative. Lá
quis conjugué à des exigences élevées en matière visant à améliorer les moteurs est naturellement aussi, de même que pour les fr
de qualité est la garantie de fabrication de moteurs immédiatement adpotée pour les pièces d’orgine pièces neuves, on applique des
à longue durée de vie, haute fiabilité et faible DEUTZ. Seule l’utilisation de pièces d’orgine normes de qualité élevées. Du
consommation en combustible. Il va de soi que les DEUTZ d’origine fabriquées selon des méthodes point de vue fonctionnement et fiabilité les com-
moteurs doivent aussi respecter des exigences ultramodernes garantit un fonctionnement irrépro- posants de rechange DEUTZ sont équivalents aux
élevées en matiére de protection de l’environne- chable et une haute fiabilité. pièces d’orgine DEUTZ.
ment.
SERVICE Précaution à prendre quand Amiante

le moteur marche
En cas de panne d’exploitation et pour toute ques- Les rondelles d’étanchéité utili-
tion relative à des pièces de rechange veuillez vous N’effectuer les travaux d’entretien ou les répara- sées pour ces moteurs sont
adresser à notre point de service responsable pour tions qu’à l’arrêt du moteur. A la fin des travaux exemptes d’amiante. Veuillez em-
votre secteur. Notre personnel qualifié et averti as- penser à remonter les dispositifs de protection ployer, lors des travaux dèntretien
sure une remise en état rapide et appropriée de vo- ayant été déposés. Lors de travaux à faire sur le et de réparation, les pièces de
tre moteur en n’utilisant que des piéces d’origine moteur en marche, les vêtements de travail doi- rechange correspondantes.
DEUTZ. vent bien coller au corps. Ne faire le plein que lors-
que le moteur est arrêté. Ne jamais faire fonctionner
les moteurs dans des locaux fermes. Danger
d’asphyxie!
15
Description du moteur
1. Plaque du constructeur 2. Emplacement de la plaque du 3. Numéro du moteur
constructeur
fr
Le type A, le numéro du moteur B ainsi que les in- La plaque du constructeur C est fixée sur le Le numéro du moteur D se trouve gravé sur le bloc
dications de puissance sont gravés sur la plaque du cache-culbuteurs. moteur et figure aussi sur la plaque du con-
constructeur. structeur.
Pour toute commande de pièce de rechange, veuil-
lez indiquer le type et le numéro du moteur.
16
Commande de pièces de rechange
fr
17
Service
fr
18
B/F M 1011/F
Sello del distribuidor
0297 7780
No. de motor:
Sírvase registrar en estas casillas el No. de motor.

Así facilita la tramitación de cuestiones de servicio
postventa, reparaciones y repuestos.
Nos reservamos el derecho de efectuar, frente a las

representaciones e indicaciones de esta Lista de re-
puestos, las modificaciones técnicas necesarias
para perfeccionar los motores. Para la reimpresión
y reproducción en cualquier forma, también en la de
extractos, se require nuestra autorización por es-
crito.
19
Prefacio
Estimado cliente:
Los motores de la marqua DEUTZ con enfriamiento por

líquido han desarrollado para una amplia gama de apli-
caciones. Una extensa oferta de variantes garantiza que
se cumplen las exigencias especiales de cada caso.
es
Su motor se ha equipado de acuerdo con el respectivo
caso de equipo, o sea que no están montados en el
motor de Ud. todos las partes constructivas y compo-
nentes representados en su Lista de repuestos.
Pese a que la mayoría de los gráficos no contiene

todos los detalles, se pueden distinguir bien las dife-
rentes variantes de modo que resulta fácil identificar
el repuesto correspondiente a su motor. E repuesto
correcto para cada caso se determina a través de los
números de posición, de grupo constructivo y de
motor.
Le rogamos tenga en cuenta nuestras indicaciones

al confeccionar su pedido de repuestos para que le
podamos suministrar rápida y seguramente los
repuestos requeridos en la ejecución de acuerdo
con el último estado de modificación.
En caso de dudas, estamos gustosamente a su dis-

posición para asesorarle.
DEUTZ AG
20
Prefacio
Motores diesel DEUTZ Repuestos orginales DEUTZ Componentes reacondicionados DEUTZ
son el producto de trabajos de investigación y de- están sometidos a las mismas severas exigencias Componentes reacondiconados
sarrollo de largos años. El fundado know how así respecto a la calidad que los motores DEUTZ. De- DEUTZ constituyen una alterna-
logrado conjuntamente con altas exigencias de ca- sarrollos ulteriores para perfeccionar los motores tiva económica frente a repuestos
lidad es la garantía para la fabricación de motores son introducidos desde luego también en los repu- originales DEUTZ.
de larga duración, gran fiabilidad y bajo consumo
de combustible. Se sobreentiende que se cumplen
estos orginales DEUTZ. Sólo el emplo de repues-
tos originales DEUTZ farbricados según los
Naturalmente rigen también aquí,
igual que para piezas nuevas, elevadísimas ex-
es
también las elevadas exigencias para le protección conocimientos más recientes garantiza un funcio- igencias de calidad. Los repuestos reacondiciona-
del ambiente. namiento impecable y alta fiabilidad. dos DEUTZ equivalen a los repuestos originales en
cuanto a funcionamiento y fiabilidad.
SERVICE Atención a motor en marcha Amianto
En caso de anomalías en el funcionamiento y cues- Realizar trabajos de mantenimiento o reparación Las juntas utilizadas en este motor
tiones de repuestos, sírvase dirigirse a uno de nues- únicamente a motor parado. Remontar una vez son exentas de amianto (asbesto).
tros Servicíos Oficioles. Nuestro personal especiali- terminados los trabajos los dispositivos de protec- Para trabajos de mantenimiento y
zado y entrenado se ocupará de subsanar efecien- ción quitados eventualmente. En caso de que se reparacion sírvase utilizar los re-
temente y con rapidez cualquier desperfecto, utili- tengan que efectuar trabajos en el motor en mar- puestos correspondientes.
zando repuestos originales DEUTZ. cha, la ropa de trabajo debe tocar al cuerpo para
evitar accidentes. Hacer el repostado sólo a motor
parado. No hacer funcionar nunca el motor en lo-
cales cerrados – peligro de intoxicación.
21
Descripción del motor

1. Placa del fabricante 2. Situación de la placa del fabricante 3. No. de motor
es
El tipo A, el No. de motor B así como los datos de La placa del fabricante C está montada sobre la El No. de motor D va estampado en el cárter y en la
potencia van estampados en la placa del fabri- tapa de válvulas. placa del fabricante.
cante. El tipo y el No. de motor se han de indicar en
los pedidos de repuestos.
22
Pedido de repuestos
es
23
Servicio
es
24
B/FM 1011/F
Carimbo do vendedor
0297 7780
Número
do motor:
Inscreva aqui, por favor, o número do motor. Facili-

tará, com isso, o andamento das questões relacio-
nadas com a assistência técnica, reparações e
peças sobresselentes.
Reservamo-nos o direito proceder a alterações de

ordem técnica na representação e nos dados desta
lista de peças sobresselentes que se tornem neces-
sárias para o aperfeiçoamento dos motores. Toda e
qualquer reimpressão e reprodução, mesmo só em
parte, requere a nossa autorização por escrito.
25
Prefácio
Prezado cliente:
Os motores refrigerados à agua DEUTZ foram desen-

volvidos para um espectro de aplicação vasto. Asse-
gura-se ao mesmo tempo um atendimento das exi-
gências particulares correspondentes através da
ampla oferta de variantes.
O Seu motor encontra-se equipado de acordo com o

pt caso de montagem, isto é, não estão embutidas no
mesmo todas as peçass e partes componentes repre-
sentadas na Sua lista de peças sobresselentes.
Embora os gráficos não se encontrem amplamente

representados com todos os pormenores, é possível
distinguir claramente cada uma das variantes, de
forma a encontrar-se facilmente a peça sobresselen-
te de importância para o Seu motor. A devida peça
sobresselente é localizável em qualquer caso pelos
números do item, do grupo constructivo e do
motor.
Quando do pedido de encomenda de peças sobresse-

lentes queira, por favor, observar as nossas
instruções para encomenda, a fim de podermos
fornecer-lhe rápida e seguramente as peças sobres-
selentes requeridas de acordo com o tipo corres-
pondente à última alteração actualizada.
Encontramo-nos com prazer a Sua disposição para

um aconselhamento no caso de quaisquer pedidos
de informação que nos dirigir.
A Sua
DEUTZ AG
26
Prefácio
Os motores diesel DEUTZ Peças e partes originais Peças e partes componentes
substituíveis DEUTZ
são produto de longos anos de pesquisas e desen- estão sujeitasàs mesmas exigências severas de As peças e as partes componen-
volvimento. O „know how“ consolidado assim ad- qualidade para os motores DEUTZ. Naturalmente tes substituíveis DEUTZ são uma
quirido constitui, aliado às grandes axigências de que se introduzem aperfeiçoamentos também nas alternativa económica para as
qualidade, a garantia para a fabricação de motores peças e partes originais para o melhora-mento peças e partes originais.
com uma vida útil longa e um consumo reduzido dos motores. Somente o emprego de peças e Naturalmente que vigoram aqui,
de combustível. É compreensível que se deva partes originais fabricadas de acordo com os con- também, como para as peças novas, os padrões
obedecer também aos elevados requisitos de pre- hecimentos mais modernos poderá garantir um mais elevados de qualidade.
servação do meio ambiente. funcionamento perfeito e elevada confiabilidade. As peças e partes componentes substituíveis pt
DEUTZ são equivalentes na sua função e confiabili-
dade às peças e partes originais.
SERVICE Precaução com o motor em Amianto

funcionamento
No caso da acorréncia de uma avaria operacional e Proceder aos trabalhos de manutenção e às repa- As vedações utilizadas neste
de possíveis consultas relacionadas com peças e rações apenas com o motor parado. Após termina- motor encontram-se isentas de
partes sobressalentes, queira dirigir-se a uma das dos os trabalhos haverá que montar de novo os di- amianto. Empregue, por favor, as
nossas representantes autorizadas do Service. O spositivos protectores eventulamente removidos. correspendentes peças e partes
nosso pessoal especialízado e bem treinado procu- No caso de trabalhos com o motor em funciona- sobressalentes quando dos traba-
rara, em caso de uma avaria, proceder a uma repa- mento, a roupa de trabalho deverá estar bem aju- lhos de manutenção e conserto.
ração rápida e tecnicamente eficiente, empregando stada ao corpo. Nunca se deverá deixar o motor a
peças e partes originais. trabalhar num recinto fechado, porque existe o pe-
rigo de intoxicação.
27
Descrição do motor
1. Placa do fabricante 2. Localização da placa do fabricante 3. Número de motor
pt
O modelo A, o número do motor B e os dados de po- A placa do fabricante C encontra-se fixada na O número do motor D encontra-se gravado no
tência encontram-se gravados na placa do fabri- capa de revestimento da válvula. cárter e na placa do fabricante.
cante. Quando da aquisição de peças sobresselentes
deverão ser indicados o modelo e o número do mo-
tor.
28
Pedido de encomenda de peças sobresselentes
pt
29
Service
pt
30
B/F M 1011/F
Timbro del concessionario
0297 7780
Numero del
motore:
Voglia annotare qui il numero del motore. In questo

modo faciliterà il disbrigo in caso di questioni relative
all’assistenza tecnica, alla riparazione ed ai pezzi di
ricambio.
Rispetto all’illustrazione ed alle indicazioni di questa

lista dei pezzi di ricambio, ci si riserva quelle modifi-
che tecniche che sono necessarie per migliorare i
motori. Per la ristampa e la riproduzione di qualsiasi
tipo è necessaria la nostra autorizzazione scritta.
31
Prefazione
Egregio cliente,
i motori DEUTZ raffreddati ad agua sono stati svilup-

pati per un ampio spettro d’uso. Grazie ad una vasta
offerta di varianti viene garantito che verrà fatto fron-
te alle rispettive esigenze particolari.
Il Suo motore è allestito secondo lo specifico caso di

montaggio, vale a dire che non tutti gli elementi ed i
componenti illustrati nel Suo listino dei pezzi di
ricambio sono integrati nel Suo motore.
it
Nonostante i grafici non siano illustrati con tutti i det-
tagli, si possono distinguere chiaramente le singole
varianti, così che è facile trovare con facilità il pezzo
di ricam-bio importante per il Suo motore. In ogni
caso verrà rilevato il pezzo di ricambio giusto trami-
te numero di posizione, di gruppo di assemblaggio
e di motore.
Per l’ordinazione di pezzi di ricambio voglia osservare

le nostre indicazioni per l’ordinazione al fine di per-
metterci di fornirle in modo celere e sicuro i pezzi di
ricambio necessari nella relativa versione, conforme
all’ultima modifica.
Siamo a Vs. completa disposizione per eventuali

chiarimenti.
Sua
DEUTZ AG
32
Prefazione
I motori Diesel DEUTZ I pezzi di ricambio originali Componenti intercambiali DEUTZ
sono il prodotto di numerosi anni di ricerca e svi- sono soggetti alle stesse severe esigenze quali- I componenti intercambiabili
luppo. Il solido know how così ottenuto in combi- tative poste ai motori DEUTZ. I perfezionamenti atti DEUTZ sono un’alternativa eco-
nazione con elevate esigenze qualitative è la garan- a migliorare i motori vengono naturalmente intro- nomica ai pezzi di ricambio origi-
zia per la fabbricazione di motori aventi lunga du- dotti anche per i pezzi di ricambio originali. Soltan- nali.
rata, elevata affidabilità ed un basso consumo di to l’uso di pezzi di ricambio originali, fabbricati Naturalmente anche qui, come
combustibile. E’naturale che si faccia fronte anche secondo le più attuali conoscenze, offre la garan- per i pezzi nuovi, valgono massimi criteri quali-
alle elevate esigenze a favore della protezione am- zia di un perfetto funzionamento e di elevata af- tativi. I componenti intercambiabili DEUTZ sono
bientale. fidabilità. equivalenti ai pezzi di ricambio per ciò che concer-
ne il loro funzionamento ed affidabilità.
it
SERVICE Prudenza con il motore acceso Amianto
In caso di avarie o richieste di ricambi, rivolgersi im- Eseguire i lavori di manutenzione o di riparazione Le guarnizioni utilizzate per questo
mediatamente ai nostri Centri di Assistenza autoriz- solo con motore spento. Al termine dei lavori ri- motore sono senti da amianto. Per
zati. Per non diminuire la sicurezza di funziona- montare i dispositivi di sicurezza eventualmente i lavori di manutenzione e di ripa-
mento, tutti i lavori devono essere effettuati da per- asportati. Per lavori da eseguire con il motore ac- razione fate uso degli appositi
sonale specializzato servendosi dell’impiego di ri- ceso, l’abbigliamento da lavoro deve aderire bene ricambi.
cambi originali. al corpo. Fare rifornimento di combustibile solo
con motore spento. Non lasciare il motore acceso in
locali chiusi – pericolo di avvelenamento.
33
Descrizione del motore

1. Targhetta di fabbricazione 2. Posizione della targhetta di 3. Numero del motore
fabbricazione
it
Il tipo di costruzione A, il numero del motore B ed i La targhetta di fabbricazione C è fissata sul Il numero del motore D è stampigliato sia sull’inca-
dati tecnici sono stampigliati sulla targhetta di fabbri- coperchio delle valvole. stellatura come pure sulla targhetta di fabbricazione.
cazione. Per l’acquisto di pezzi di ricambio, bisogna
indicare il tipo di costruzione ed il numero del mo-
tore.
34
Ordinazione di pezzi di ricambio
it
35
Service
it
36
Onderdelenlijst
B/F M 1011/F
Stempel handelaar
0297 7780
Motornummer:
Geeft u hier a.u.b. het motornummer aan. De behan-

deling van klantenservice-, reparatie- en onderde-
lenkwesties wordt daardoor vereenvoudigd.
Wat de betreft de tekeningen en gegevens in deze on-

derdelenlijst blijven technische veranderingen die ter
verbetering van de motoren noodzakelijk worden,
voorbehouden. Elke vorm van nadruk of vermenig-
vuldiging, ook bij wijze van uittreksel, mag uitslui-
tend met onze schriftelijke toestemming plaatsvin-
den.
37
Voorwoord
Geachte klant,
de vattengekoelde DEUTZ-motoren zijn ontwikkeld

voor een breed spectrum aan toepassingsmogelijk-
heden. Daarbij wordt door een uitgebreid aanbod
variaties gewaarborgd, dat steeds kan worden
voldaan aan de desbetreffende speciale vereisten.
Uw motor is voor de individuele inbouwsituatie uitge-

rust. Dat wil zeggen dat niet alle onderdelen uit de lijst
en niet alle componenten voor uw motor van toepas-
sing zijn.
Hoewel de grafieken niet met alle details weeggege-

nl ven zijn, kunnen de verschillende uitvoeringen dui-
delijk onderscheiden worden, zodat u het voor uw
motor rele-vante onderdeel gemakkelijk kunt vin-
den. Via positie-, constructie- en motornummer
wordt in ieder geval het juiste onderdeel bepaald.
Let u bij de bestelling van onderdelen a.u.b. op onze

bestelgegevens. Dan kunnen wij u snel en betrouw-
baar de nodige onderdelen op de meest actuele stand
in over-eenstemming met de uitvoering leveren.
Voor nadere inlichtingen staan we U graag met raad

en daad terzijde.
Met vriendelijke groeten

DEUTZ AG
38
Voorwoord
DEUTZ-Dieselmotoren Orignele onderdelen DEUTZ tweedehands componenten
zijn het produkt van vele jaren research en enginee- ondergaan dezelfde strenge kwaliteitscontroles als Tweedehands DEUTZ componen-
ring. Het hierdoor gewonnen, gefundeerde know de DEUTZ motoren. Nieuwe ontwikkelingen ter ten vormen een voordelig alterna-
how in verbinding met hoge kwaliteitseisen is de verbetering van de motoren vinden natuurlijk ook tief voor originele onderdelen.
garantie voor de vervaardiging van motoren met hun neerslag bij vervangende originele onderde- Natuurlijk gelden ook hier, net als
een lange levensduur, hoge betrouwbaarheid en len. Alleen het gebruik van originele onderdelen die bij nieuwe onderdelen, zeer hoge
een laag brandstofverbruik. Het is vanzelfsprekend aan de nieuwste ontwikkelingen zijn aangepast, kwaliteitsmaatstaven. Wat functie en betrouw-
dat ook aan de hoge eisen met betrekking tot de garanderen een onberispelijke functie en een hoge baarheid betreft, zijn tweedehands DEUTZ compo-
milieubescherming voldaan wordt. betrouwbaarheid. nenten gelijkwaardig aan nieuwe onderdelen.
nl
SERVICE Voorzichtig bij draaiende motor Asbest
Wendt U zich bij berijfsstoringen en bij vragen om- Onderhoudswerkzaamheden en reparaties alleen De pakkingen in deze motor bevat-
trent reserveonderdelen tot een van onze Service- bij uitgeschakelde motor doorvoeren. Eventueel ten geen asbest. Gebruikt u bij
vertegenwoordigingen. Ons geschoold vakperso- verwijderde beschermplaten enz. moeten na de onderhouds en reparatiewerk-
neel zorgt in geval van defecten voor snelle en vak- werkzaamheden weer gemonteerd worden. Bij zaamheden a.u.b. onderdelen van
kundige reparatie met originele onderdelen. werken aan de draaiende motor moet nauw slui- dezelfde kwaliteit.
tende werkkleding worden gedragen. Motor nooit
in gesloten ruimten laten lopen – vergiftigingsge-
vaar.
39
Beschrijving van de motor

1. Firmaplaat 2. Plaat van de firmaplaat 3. Motornummer
nl
De constructievorm A, het motornummer B en de De firmaplaat C is aangebracht op de kleppenaf- Het motornummer D is op de carter en op de firma-
vermogensgegevens zijn op de firmaplaat gestem- dekkap. plaat gestempeld.
peld. Bij bestelling van onderdelen moeten construc-
tieserie en motornummer worden aangegeven.
40
Bestelling van onderdelen
nl
41
Service
nl
42
Reservdelslista
B/F M 1011/F
Närmaste DEUTZ-representant
0297 7780
Motornumret:
För in motornumret här. Du underlättar härigenom

lösning av service-reparations- och reservdelsfrå-
gor.
Vi förbehållar oss rätt till förbättringar av motorerna

utan att därför ändra i denna reservdelslista. För ef-
tertryck och kopiering av något slag fordras vårt
skriftliga medgivande.
43
Förord
Bäste kund,
DEUTZ vaterkylda motorer har utvecklats för ett

stort användningsområde. Därvid har genom
många varianter säkerställts att olika speciella for-
dringar uppfylls.
Din motor är utrustad för motsvarande inbyggnad,

d v s alla i reservdelslistan upptagna komponenter
finns ej med på Din motor.
Trots att alla detaljer inte framgår kan de olika varian-

terna urskiljas så att delarna för Din motor lätt går att
hitta. Med komponentbild- och motornummer får
man i varje fall fram rätt reservdel.
sv Observera vid beställning av reservdelar våra anvis-

ningar så att dessa snabbt och säkert kan levereras i
senaste utförande.
Vid förfrågningar står vi gärna förfogande.
DEUTZ AG
44
Förord
DEUTZ-dieselmotorer Originalreservdelar DEUTZ-utbyteskomponenter
är produkter av årslånga forskningar och utveck- underkastas lika stränga kvalitetsfordringar som Deutz utbyteskomponenter är ett
lingar. Därigenom vunnet know how tillsammans DEUTZ-motorerna. Vidareutveckling för förbätt- prisvärt alternativ till original-
med höga kvalitetsfordringar är garanti för tillver- ring av motorerna görs naturligtvis också på ori- reservdelar. Här gäller självklart
kning av motorer med lång livslängd, hög tillförlit- ginalreservdelar. Bara användning av de senaste öckså som för nya delar högsta
lighet och låg bränsleförbrukning. Självklart upp- originalreservdelar garanterar rätt funktion och kvalitet. DEUTZ-utbyteskompo-
fylls också kraven på miljöskydd. hög tillförlitlighet. nenter är i funktion och tillförlitlighet likvärdiga
med Deutz reservdelar.
SERVICE Försiktighet vid motor som är igång Asbest sv

Vänd er till en av våra servicerepresentanter vid Skötsel eller reparationer får bara utföras vid stilla- Tätningar som används i denna
störningar och reservdelsproblem. Vår specialutbil- stående motor. Montera ev borttagna skydd efter motor är asbestfria. Använd så-
dade personal reparerar snabbt och riktigt med ori- avslutat arbete. Se vid arbete med motor som är dana reservdelar även vid under-
ginalreservdelar vid behov. igång till att arbetskläder ej sitter löst. hålls- och reparationsåtgärder.
Tanka alltid vid stillastående motor. Kör aldrig mo-
tor i slutna rum – förgiftningsrisk.
45
Motorbeskrivning
1. Typskylten 2. Typskyltens placering 3. Motornummer
sv
Typen A, motornumret B och motordata finns på Typskylten C sitter på ventilkåpan. Motornumret D är instämplat på vevhuset och på
typskylten. Vid reservdelsbeställning måste typ och typskylten.
motornummer anges.
46
Reservdelbeställning
sv
47
Service
sv
48
Reservedelsliste
B/F M 1011/F
Forhandlerens stempel
0297 7780
Motornummer:
Notér motornummeret her. Derved lettes afvik-

lingen i forbindelse med serviceværksted, repara-
tion og bestilling af reservedele.
Ret til tekniske ændringer, som bliver nødvendige til

forbedring af motorerne, forbeholdes. Eftertryk og
mangfoldiggørelse af enhver art, også i uddrag, kun
tilladt med vores skriftlige samtykke.
49
Forord
Kære kunde!
De væskekølede motorer fra firmaet DEUTZ er udviklet

til et bredt anvendelsesspektrum. Derved sikres det på
grund af det omfattende udbud af varianter, at de indi-
viduelle specielle krav kan opfyldes.
Deres motor er udstyret, så den svarer til brugstil-

fældet; d.v.s. at ikke alle elementer og komponenter,
som er afbildet i denne reservedelsliste, er monteret
på Deres motor.
Selv om de grafiske afbildninger ikke kan vises med

alle detaljer, kan man tydeligt se forskel på de enkelte
varianter, så De let kan finde de reservedele, som er
relevante til Deres motor. Ved hjælp of positions-,
type- og motornummeret kan man altid finde frem
til den rigtige reservedel.
da Første gang De bestiller reservedele, bedes De

bemærke vore bestillingshenvisninger, så vi hurtigt
og korrekt kan finde frem til de nødvendige reserve-
dele i den udførelse, som svarer til den nyeste
ændringstilstand.
Vi står gerne til rådighed, hvis De har spørgsmål.
Deres
DEUTZ AG
50
Forord
DEUTZ-dieselmotorer Originale dele DEUTZ-udskiftningskomponenter
er produktet af mange års forskning og udvikling. underligger de samme strenge kvalitetskrav som DEUTZ-udskiftningskomponenter
Det velunderbyggede knowhow, vi dermed har vun- DEUTZ-motorerne. Videreudviklinger til forbedring er et prisbilligt alternativ til origi-
det, i forbindelse med høje kvalitetskrav er Deres af motorerne bliver naturligvis også anvendt ved nale dele. Selvfølgelig gælder
garanti for en produktion af motorer med lang leve- originale dele. Kun hvis man anvender originale også her de højeste kvalitetskrav
tid, høj pålidelighed og lavt brændstofforbrug. Det dele, som er udfærdiget efter de nyeste erkendels- – som ved de nye dele. DEUTZ-
er en selvfølge, at de høje krav mht. beskyttelsen af er, har man sikkerhed for en upåklagelig funktion udskiftningskomponenter fungerer lige så godt og
miljøet også opfyldes. og høj pålidelighed. er lige så pålidelige som originale dele.
SERVICE Forsigtig, når motoren løber Asbest
da
I tilfælde af driftsforstyrrelser og ved reservedels- Vedligeholdelsesarbejder og reparationer må kun Pakningerne, som er anvendt til
spørgsmål kan De henvende Dem til en af vores an- gennemføres, når motoren er slået fra. Evt. fjernede denne motor, er asbestfrie. An-
svarlige service-repræsentationer. Vores skolede beskyttelsesanordninger skal atter monteres på, vend venligst ved vedligehol-
fagpersonale sørger i tilfælde af skader for en hurtig når arbejderne er afsluttet. Ved arbejder med løb- delses- og reparationsarbejde
og faglig korrekt istandsættelse under anvendelse ende motor må man ikke bære løsthængende tøj. tilsvarende reservedele.
af originale dele. Der må kun fyldes brændstof på med motoren slået
fra. Lad aldrig motoren løbe i lukkede rum – fare for
forgiftning.
51
Motorbeskrivelse
1. Firmaskilt 2. Firmaskiltets placering 3. Motornummer
da Typen A, motornummeret B og ydelsesdataene er Firmaskiltet C er anbragt på ventilkappen. Motornummeret D er stemplet ind på krumtaphuset
stemplet ind på firmaskiltet. og på firmaskiltet.
Ved bestilling af reservedele skal man angive type
og motornummer.
52
Reservedelsbestilling
da
53
Service
da
54
Varaosaluettelo
B/F M 1011/F
Liikkeen leima
0297 7780
Mottorinumero:
Merkitse tähän moottorinumero. Sen ilmoittaminen

helpottaa asioiden käsittelyä huolto-, korjaus- ja
varaosakysymyksien yhteydessä.
Tämän varaosaluettelon kuvauksien ja tietojen suh-

teen pidätämme oikeuden muutoksiin, jotka ovat
tarpeellisia moottorin teknisen kehityksen kannalta.
Kaikenlaiseen jälkipainosten ja kopioiden tekoon,
myös osittain, tarvitaan kirjallinen lupamme.
55
Esipuhe
Hyvä asiakas
Ilmajäähdytteiset DEUTZ-moottorit on kehitetty laajaa

käyttäjäkuntaa silmälläpitäen. Niinpä tarjolla on laaja
valikoima moottorivaihtoehtoja, jotka täyttävät asiak-
kaiden vaihtelevat moottoritarpeet.
Moottorinne on toimitettu tietyin varustein, eivätkä

kaikki tässä varaosaluettelossa esiintyvät osat vält-
tämättä kuulu moottorinne varusteisiin.
Vaikka kaaviokuvat eivät sisällä kaikkia yksityiskoh-

tia, eri vaihtoehdot on kuitenkin helppo erottaa toi-
sistaan moottorillenne tärkeiden varaosien tunnista-
miseksi. Positio, rakenneryhmä- ja moottorinu-
meron avulla pystytään joka tapauksessa toimitta-
maan oikea varaosa.
Varaosia tilattessa on noudatettava annettuja tilau-

sohjeita, jotta pystymme nopeasti ja varmasti toimit-
tamaan tarvittavat, kyseisen mallin viimeisintä tek-
nistä kehitystä vastaavat varaosat.
fn
Annamme mielellään lisätietoja ja vastaamme
kysymyksiinne
DEUTZ AG
56
Esipuhe
DEUTZ dieselmoottorit DEUTZ-varaosat DEUTZ-vaihto-osat
ovat monien vuosien tutkimuksen ja kehittelyn tu- täyttävät samat, tiukat laatuvaatimukset kuin DEUTZ-vaihto-osat ovat edullinen
los. Näin saavutettu know-how yhdistyneenä kor- DEUTZ-moottoritkin. Moottorien parantamiseen vaihtoehto alkuperäisille DEUTZ-
keisiin laatuvaatimuksiin on tae pitkäikäisten, luo- käytettyä kehitystä sovelletaan myös DEUTZ- varaosille.
tettavien ja vähän polttoainetta kuluttavien mootto- varaosiin. Moitteeton toiminta ja luotettavuus on On myös itsestään selvää, että
reiden valmistukselle. On itsestään selvää, että taattu käyttämällä ainoastaan viimeisimmän teknii- näille osille asetetaan samat kor-
myös tarkat ympäristön suojelua koskevat mää- kan mukaan valmistettuja alkuperäisiä DEUTZ- keat laatuvaatimukset kuin uusille osillekin. Toi-
räykset on otettu huomioon. varaosia. minnaltaan ja luotettavuudeltaan DEUTZ-vaihto-
osat ovat samanarvoisia DEUTZ-varaosien kanssa.
SERVICE Varo moottorin käydessä Asbesti
Käyntihäiriöissä ja varaosakysymyksissä käänty- Huolto- tai korjaustyöt saa suorittaa ainoastaan Tässä moottorissa käytetyissä tii-
kää DEUTZ-edustajanne puoleen. Vauriotapauk- moottorin ollessa pysäytettynä. Mahdollisesti irro- visteissä ei ole asbestia.
sessa koulutettu henkilökunta huolehtii nopeasta ja tetut suojalaitteet on asennettava töiden päätyttyä Huolto- ja korjaustöissä pyy- fn
asianmukaisesta korjauksesta käyttämällä DEUTZ- jälleen paikoilleen. Huollettaessa käyvää moottoria dämme käyttämään vastaavia va-
osia. työvaatetus ei saa olla liian väljä. Moottori on py- raosia.
säytettävä tankkauksen ajaksi. Moottoria ei saa
koskaan käyttää suljetuissa tiloissa – myrkytys-
vaara.
57
Moottorin kuvaus
1. Tyyppikilpi 2. Tyyppikilven paikka 3. Moottorinumero
Moottorimalli A, moottorinumero B ja tehoarvot on Tyyppikilpi C on kiinnitetty venttiilien kanteen. Moottorinumero D on stanssattu sekä kampikam-
stanssattu tyyppikilpeen. mioon että tyyppikilpeen.
fn Varaosia tilattaessa on moottorimalli ja moottorinu-
mero ilmoitettava tilauksen vastaanottajalle.
58
Varaosien tilaus
fn
59
Service
fn
60
Reservedelsliste
B/F M 1011/F
Forhandlerstempel
0297 7780
Motornummer:
Vennligst skriv op motornummeret her. Dette gjør

behandlingen av spørsmål angående service,
reparasjoner og reservedeler enklere (se punkt 2.1).
Vi forbeholder oss tekniske foranderinger i våre

beskrivelser og opplysninger i denne instruksjons-
boka som er nødvendig for forbedring av motorene.
Ettertrykk og kopiering på enhver måte, også delvis,
må ikke gjøres uten vår skriftlige tillatelse.
61
Allment
Kjære kunde,
Væskekølte motorer av merket DEUTZ er utviklet med

tanke på mange forskjellige bruksområder. Et bredt
spekter av varianter sikrer at mange forskjellige spe-
sielle krav kan oppfylles.
Din motor er utstyrt for det aktuelle bruksområde.

Derfor vil ikke alle deler og komponenter som er opp-
ført på denne reservedelslsiten, være montert på din
motor.
Selv om bildene ikke alltid viser alle detaljer, kan de

enkelte variantene tydelig skilles fra hverandre slik at
det er lett å finne frem til de relevante reservedelene
til din motor. Ved hjelp av posisjonsnummer, kom-
ponentgruppenummer og motornummer kan du i
hvert enkelt tilfelle finne frem til riktig reservedel.
Vi ber deg vennligst følge våre anvisninger ved bestil-

ling av reservedeler slik at vi kan levere de reservede-
lene du har bruk for, raskt og sikkert og ifølge de
no seneste endringer.
Vi står gjerne til din disposisjon hvis du har ytterlige-

re spørsmål.
Vennlig hilsen
DEUTZ
62
Allment
DEUTZ-Dieselmotoren Originaldeler DEUTZ byttekomponenter
er resulotatet av mangeårig forskning og utvikling. Et er underkastet strenge kvalitetskrav på linje med DEUTZ byttekomponenter er et
omfattende know-how i forbindelse med høye DEUTZ motorer. Videreutvikling for å forbedre billig alternativ til originaldeler.
kvalitetskrav er garantien for fremstillingen av mo- våre motorer blir selvfølgelig fulgt opp med forbe- Selvfølgelig gjelder også her de
torer med lang levetid, stor pålitelighet og lavt dringer på originaldeler. Bruk derfor bare original- høyeste kvalitetskrav på samme
drivstofforbruk deler som er fremstilt etter de nyeste erfaringer for måte som for nye deler. Når det
Det er en selvfølge at de store kravene når det å være sikker på feilfri funksjon og høy pålitelighet. gjelder funksjon og pålitelighet, er DEUTZ bytte-
gjelder miljøvern, blir oppfylt. komponenter likeverdige med originaldeler „O“.
SERVICE Vær forsiktig med motor i drift! Asbest
Ta kontakt med en av våre ansvarlige service- Vedlikeholdsarbeid og reparasjoner skal bare utføres Pakningene som benyttes i denne
representanter ved driftsforstyrrelser og spørsmål med avslått motor. Vær sikker på at motoren ikke motoren, er asbestfrie. Bruk reserve-
angående reservedeler. Vårt utdannete fagpersonal kan starte uten oppsikt. Fare for ulykker! deler uten asbest ved vedlike-
sørger for rask og fagmessig reparasjon med Monter eventuelt fjernete beskyttelsesanordninger holds- og reparasjonsarbeid.
DEUTZ orignaldeler. på igjen etter avsluttet arbeid.
Tank bare med avslått motor.
no
Ta hensyn til arbeidsbeskyttelsesbestemmelsene
ved motordrift i lukkete rom eller ved arbeid under
jorda.
63
Motorbeskrivelse
1. Firmaskilt 2. Firmaskiltets plassering 3. Motornummer
Type A, motornummer B samt tytelsesdata er Firmaskiltet C er festet på ventilkåpan. Motornummer D er stemplet inn både veivhuset og
stemplet inn på firmaskiltet. på firmaskiltet.
Type og motornummer må angis når reservedeler
bestilles.
no
64
no
65
Service
no
66
B/F M 1011/F
™ÊÚ·Á›‰· ÙÔ˘ ÂÌfiÚÔ˘
0297 7780
∞ÚÈıÌfi˜ ÎÈÓËÙ‹Ú·:
™ËÌÂÈÒÛÙÂ Û·˜ ·Ú·Î·ÏÔ‡ÌÂ Â‰Ò ÙÔÓ ·ÚÈıÌfi ÙÛ˘

ÎÈÓËÙ‹Ú· Û·˜. ªÂ ÙÔÓ ÙÚfiÔ ·˘Ùfi ‰ÈÂ˘ÎÔÏ‡ÓÂÙÂ
ÙËÓ ÂÍ¤ÏÈÍË ÙˆÓ ‰È·‰ÈÎ·ÛÈÒÓ ÂÍ˘ËÚ¤ÙËÛË˜
ÂÏ·ÙÂ›·˜, ÂÈ‰ÈÔÚıÒÛÂˆÓ Î·È ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ.
¢È·ÙËÚÔ‡ÌÂ ÙÔ ‰ÈÎ·›ˆÌ·, Ó· ÚÔ‚·›ÓÔ˘ÌÂ ÛÂ ÙÂ¯ÓÈÎ¤˜

·ÏÏ·Á¤˜ Â› ÙˆÓ ·ÂÈÎÔÓ›ÛÂˆÓ Î·È ÂÓ‰Â›ÍÂˆÓ ÙÔ˘
Î·Ù·ÏfiÁÔ˘ ·˘ÙÔ‡ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, ÂÊfiÛÔÓ ÔÈ
·ÏÏ·Á¤˜ ·˘Ù¤˜ ·Ô‚Ï¤Ô˘Ó ÛÂ ‚ÂÏÙ›ˆÛË ÙˆÓ
ÎÈÓËÙ‹ÚˆÓ. ∏ ·Ó·Ù‡ˆÛË Î·È Ë ·ÓÙÈÁÚ·Ê‹ Î¿ıÂ
Â›‰Ô˘˜, ¤ÛÙˆ Î·È Î·Ù¿ Ì¤Úo˜, Ùo˘ Î·Ù·ÏfiÁo˘
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ÂÈÙÚ¤oÓÙ·È ÌfiÓo ÌÂÙ¿ ·fi
¤ÁÁÚ·ÊË ¤ÁÎÚÈÛ‹ Ì·˜.
67
∂ÈÛ·ÁˆÁÈÎ¤˜ ·Ú·ÙËÚ‹ÛÂÈ˜
∞ÍÈfiÙÈÌÂ ÂÏ¿ÙË, ¶ÚÔÛ¤ÍÙÂ Û·˜ ·Ú·Î·ÏÔ‡ÌÂ Î·Ù¿ ÙËÓ ·Ú·ÁÁÂÏ›·

·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ÙÈ˜ Ô‰ËÁ›Â˜ Ì·˜, Ô˘ ¤¯Ô˘Ó Û¯¤ÛË
ÔÈ ˘ÁÚfi„˘ÎÙÔÈ ÎÈÓËÙ‹ÚÂ˜ ÙË˜ Ì¿ÚÎ·˜ DEUTZ ÌÂ ÙÈ˜ ·Ú·ÁÁÂÏ›Â˜ ·˘Ù¤˜, ÚÔ˜ ÙÔ ÛÎÔfi fiˆ˜
ÂÍÂÏ›¯ıËÛ·Ó ÙÂ¯ÓÈÎ¿ ÁÈ· ÂÊ·ÚÌÔÁ‹ ÛÂ ¤Ó·Ó Â˘Ú‡ Â›Ì·ÛÙÂ ÛÂ ı¤ÛË Ó· Û·˜ Î¿ÓÔ˘ÌÂ Û‡ÓÙÔÌË Î·È
ÙÔÌ¤· ÂÊ·ÚÌÔÁÒÓ. ∫·Ù¿ ÙËÓ ÚÔÛ¿ıÂÈ¿ Ì·˜ ·˘Ù‹ ÂÌÈÛÙÂ˘ÙÈÎ‹ ·Ú¿‰ÔÛË ÙˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Ô˘
ÂÍ·ÛÊ·Ï›ÛÙËÎÂ Ì¤Ûˆ Ì›·˜ ÔÏ˘ÏËıÔ‡˜ ¯ÚÂÈ¿˙ÂÛÙÂ, ÛÙËÓ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹ ·Ú·ÏÏ·Á‹, Ë
ÚÔÛÊÔÚ¿˜ Î·Ù·ÛÎÂ˘·ÛÙÈÎÒÓ ·Ú·ÏÏ·ÁÒÓ, ÒÛÙÂ ÔÔ›· ·ÓÙ·ÔÎÚ›ÓÂÙ·È ÂÎ¿ÛÙÔÙÂ ÛÙËÓ ÙÂÏÂ˘Ù·›·
Ó· ÂÎÁËÚÒÓÔÓÙ·È fiÏÂ˜ ÔÈ ÂÈ‰ÈÎ¤˜ ··ÈÙ‹ÛÂÈ˜ ÙˆÓ ÛÙ¿ıÌË ÌÂÙ·ÙÚÔÒÓ.
ÂÏ·ÙÒÓ Ì·˜.
µÚÈÛÎfiÌ·ÛÙÂ ¿ÓÙÔÙÂ ÛÙË ‰È¿ıÂÛ‹ Û·˜, ·Ó ¤¯ÂÙÂ
√ ÎÈÓËÙ‹Ú·˜ Û·˜ ·˘Ùfi˜ Â›Ó·È ÂÊÔ‰È·ÛÌ¤ÓÔ˜ ÁÈ· ÂÚˆÙ‹Ì·Ù·, ÚÔÛÊ¤ÚÔÓÙ¿˜ Û·˜ Î·È ÙÈ˜ ·Ó·ÁÎ·›Â˜
ÂÊ·ÚÌÔÁ‹ ÙÔ˘ ÛÂ Ì›· ÂÈ‰ÈÎ‹ ÂÚ›ÙˆÛË, Î·È ·˘Ùfi Û˘Ì‚Ô˘ÏÂ˘ÙÈÎ¤˜ ˘ËÚÂÛ›Â˜.
ÛËÌ·›ÓÂÈ fiÙÈ Ù· ÛÙÔÈ¯Â›· ÌË¯·ÓÒÓ, Ù· ÔÔ›·
ÂÚÈÏ·Ì‚¿ÓÔÓÙ·È ÛÙÔÓ Î·Ù¿ÏÔÁÔ ·˘Ùfi ∏ ÂÙ·ÈÚÂ›· Û·˜
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Î·È Ù· ˘fiÏÔÈ· Û˘ÛÙ·ÙÈÎ¿ DEUTZ AG
ÌË¯·ÓÈÎ¿ ÛÙÛÈ¯Â›· ‰ÂÓ Â›Ó·È ÂÍ ÔÏÔÎÏ‹ÚÔ˘
ÂÊ·ÚÌÔÛÌ¤Ó· Î·È ÛÙÔÓ ÎÈÓËÙ‹Ú· Û·˜.
∞Ó Î·È ÔÈ ÁÚ·ÊÈÎ¤˜ ·Ú·ÛÙ¿ÛÂÈ˜ ‰ÂÓ Â›Ó·È

‰È·ÌÔÚÊˆÌ¤ÓÂ˜ ÌÂ fiÏÂ˜ ÙÈ˜ ÏÂÙÔÌ¤ÚÂÈÂ˜, ÌÔÚÂ›
ÂÓÙÔ‡ÙÔÈ˜ Ó· ÚÔÎ‡„ÂÈ ‰È·¯ˆÚÈÛÌfi˜ ÌÂÙ·Í‡ ÙˆÓ
ÌÂÌÔÓˆÌ¤ÓˆÓ Î·Ù·ÛÎÂ˘·ÛÙÈÎÒÓ ·Ú·ÏÏ·ÁÒÓ Î·Ù¿
Û·Ê‹ ÙÚfiÔ, Ô‡Ùˆ˜ ÒÛÙÂ Ó· ÌÔÚÂ›ÙÂ Ó· ‚ÚÂ›ÙÂ
ÌÂ Â˘ÎÔÏ›· Ù· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÎÂ›Ó·, Ù· ÔÔ›·
·ÊÔÚÔ‡Ó ÙÔÓ ÎÈÓËÙ‹Ú· Û·˜. ª¤Ûˆ ÙÔ˘ ·ÚÈıÌÔ‡
ı¤ÛË˜, oÌ¿‰·˜ ÂÍ·ÚÙËÌ¿ÙˆÓ Î·È ÎÈÓËÙ‹Ú· ÌÔÚÂ›
Ó· ‰È·ÈÛÙˆıÂ› ÛÂ Î¿ıÂ ÍÂ¯ˆÚÈÛÙ‹ ÂÚ›ÙôË ÙÔ
ÛˆÛÙfi ·ÓÙ·ÏÏ·ÎÙÈÎfi.
el
68
√È ÓÙÈ˙ÂÏÔÎÈÓËÙ‹ÚÂ˜ DEUTZ ∆· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ∞ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜ DEUTZ
·ÔÙÂÏÔ‡Ó ÚÔ›fiÓ Ì·ÎÚÔ¯ÚfiÓÈ·˜ ÂÈÛÙËÌÔÓÈÎ‹˜ YfiÎÂÈÓÙ·È ÛÙÈ˜ ›‰ÈÂ˜ ·˘ÛÙËÚ¤˜ ··ÈÙ‹ÛÂÈ˜ ∆· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜
¤ÚÂ˘Ó·˜ Î·È ÙÂ¯ÓÈÎ‹˜ ÂÍ¤ÏÈÍË˜. ∏ ·ÔÎÙËıÂ›Û· ÔÈfiÙËÙ·˜ fiˆ˜ ÔÈ ÎÈÓËÙ‹ÚÂ˜ Deutz. ∏ DEUTZ ·ÔÙÂÏÔ‡Ó ÌÈ· ÔÈÎÔÓÔÌÈÎ¿
ÙÂ¯ÓÔ‰ÔÛ›·, Ô˘ ÚÔ¤Î˘„Â ·fi ÙÈ˜ ÂÚÁ·Û›Â˜ Ì·˜ ÂÚ·ÈÙ¤Úˆ ÂÍ¤ÏÈÍË ÁÈ· ÙË ‚ÂÏÙ›ˆÛË ÙˆÓ Û˘ÌÊ¤ÚÔ˘Û· ÂÓ·ÏÏ·ÎÙÈÎ‹ Ï‡ÛË
·˘Ù¤˜, ·ÔÙÂÏÂ› ÛÂ Û˘Ó‰˘·ÛÌfi ÌÂ ˘„ËÏ¤˜ ÔÈÔÙÈÎ¤˜ ÎÈÓËÙ‹ÚˆÓ ‰ÈÂÍ¿ÁÂÙ·È ‚Â‚·›ˆ˜ Î·È ÛÙ· ÁÓ‹ÛÈ· ¤Ó·ÓÙÈ ÛÙ· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿.
··ÈÙ‹ÛÂÈ˜ ÙËÓ ÂÁÁ‡ËÛË ÁÈ· ÙËÓ Î·Ù·ÛÎÂ˘‹ ÎÈÓËÙ‹ÚˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎ¿. ªfiÓÔ Ë ¯Ú‹ÛË ÙˆÓ ÁÓ‹ÛÈˆÓ º˘ÛÈÎ¿ ÈÛ¯‡Ô˘Ó Î·È Â‰Ò Ù·
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ÌÈÎÚ‹ Î·Ù·Ó¿ÏˆÛË Î·˘Û›ÌˆÓ. ∂›Ó·È ·˘ÙÔÓfiËÙÔ, fiÙÈ Û‡ÌÊˆÓ· ÌÂ ÙÔ ÙÂÏÂ˘Ù·›Ô Â›Â‰Ô ÙË˜ Î·ÈÓÔ‡ÚÁÈ· ÂÍ·ÚÙ‹Ì·Ù·. ∆· ·ÓÙ·ÏÏ·ÎÙÈÎ¿
ÂÎÏËÚÔ‡ÓÙ·È ÛÙÔ˘˜ ÎÈÓËÙ‹ÚÂ˜ Ì·˜ Î·È ÔÈ ˘„ËÏ¤˜ ÙÂ¯ÓÔÏÔÁ›·˜, ·Ú¤¯ÂÈ ÂÁÁ‡ËÛË ÁÈ· ·ÚfiÛÎÔÙË ÂÍ·ÚÙ‹Ì·Ù· ÙË˜ DEUTZ Â›Ó·È ÈÛ¿ÍÈ· ÌÂ Ù· ÁÓ‹ÛÈ·
··ÈÙ‹ÛÂÈ˜ ÚÔÛÙ·Û›·˜ ÙÔ˘ ÂÚÈ‚¿ÏÏÔÓÙÔ˜. ÏÂÈÙÔ˘ÚÁ›· Î·È ˘„ËÏ‹ ·ÍÈÔÈÛÙ›·. ·ÓÙ·ÏÏ·ÎÙÈÎ¿ fiÛÔÓ ·ÊÔÚ¿ ÙË ÏÂÈÙÔ˘ÚÁ›· Î·È ÙËÓ
·ÍÈÔÈÛÙ›· ÙÔ˘˜.
™∂ƒµπ™ ¶ÚÔÛÔ¯‹ Î·Ù¿ ÙË ‰È¿ÚÎÂÈ· ÙË˜ ∞Ì›·ÓÙÔ˜

ÏÂÈÙÔ˘ÚÁ›·˜ ÙÔ˘ ÎÈÓËÙ‹Ú·
∞ÔÙ·ÓıÂ›ÙÂ ÛÂ ÂÚ›ÙˆÛË ÏÂÈÙÔ˘ÚÁÈÎÒÓ ‚Ï·‚ÒÓ √È ÂÚÁ·Û›Â˜ Û˘ÓÙ‹ÚËÛË˜ ‹ ÂÈÛÎÂ˘‹˜ ÂÈÙÚ¤ÂÙ·È ∆· ÛÙÂÁ·ÓˆÎ¿ ÂÍ·ÚÙ‹Ì·Ù·, Ù·
Î·È ÛÂ ÂÚ›ÙˆÛË Ô˘ ¯ÚÂÈ¿˙ÂÛÙÂ ·ÓÙ·ÏÏ·ÎÙÈÎ¿ Ó· ‰ÈÂÓÂÚÁÔ‡ÓÙ·È ÌfiÓÔ ÂÊfiÛÔÓ Ô ÎÈÓËÙ‹Ú·˜ ¤¯ÂÈ ÔÔ›· ÂÊ·ÚÌfi˙ÔÓÙ·ÈÛ ·˘ÙfiÓ ÙÔÓ
ÛÙÈ˜ ·ÚÌfi‰ÈÂ˜ ·ÓÙÈÚÔÛˆÂ›Â˜ Ì·˜, Ô˘ ‰È·ı¤ÙÔ˘Ó ÙÂıÂ› ÂÎÙfi˜ ÏÂÈÙÔ˘ÚÁ›·˜. ™Â ÂÚ›ÙˆÛË, Î·Ù¿ ÙËÓ ÎÈÓËÙ‹Ú·, ‰ÂÓ ÂÚÈ¤¯Ô˘Ó ·Ì›·ÓÙÔ.
˘ËÚÂÛ›Â˜ Û¤Ú‚È˜ ÂÏ·ÙÂ›·˜. ∆Ô ÂÍÂÈ‰ÈÎÂ˘Ì¤ÓÔ Ì·˜ ÔÔ›· Î·Ù¤ÛÙË ·Ó·ÁÎ·›Ô Ó· ·ÔÌ·ÎÚ‡ÓÂÙÂ ·fi ÙÔÓ ™Â ÂÚÈÙÒÛÂÈ˜ ÂÚÁ·ÛÈÒÓ Û˘Ó-
ÚÔÛˆÈÎfi ÊÚÔÓÙ›˙ÂÈ ÛÂ Î¿ıÂ ÂÚ›ÙˆÛË ‚Ï·‚ÒÓ ÎÈÓËÙ‹Ú· Û·˜ ÔÚÈÛÌ¤ÓÂ˜ ÚÔÛÙ·ÙÂ˘ÙÈÎ¤˜ Û˘ÛÎÂ˘¤˜ Ù‹ÚËÛË˜ Î·È ÂÈ‰ÈfiÚıˆÛË˜ ÂÊ-
ÁÈ· Ì›· Û‡ÓÙÔÌË Î·È ÂÍÂÈ‰ÈÎÂ˘Ì¤ÓË ÂÈ‰ÈfiÚıˆÛË ÌÂ Î·Ù¿ ÙË ‰È¿ÚÎÂÈ· ÂÚÁ·ÛÈÒÓ ÂÈ‰ÈfiÚıˆÛË˜, Ú¤ÂÈ ·ÚÌfi˙ÂÙÂ, Û·˜ ·Ú·Î·ÏÔ‡ÌÂ
¯ÚËÛÈÌÔÔ›ËÛË ÁÓËÛ›ˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ÙÔ˘ Ó· ÊÚÔÓÙ›ÛÂÙÂ ÒÛÙÂ Ó· Í·Ó·ÂÊ·ÚÌÔÛÙÔ‡Ó ÔÈ ·Ó¿ÏÔÁ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿.
ÂÚÁÔÛÙ·Û›Ô˘ Ì·˜. Û˘ÛÎÂ˘¤˜ ·˘Ù¤˜ ÌÂÙ¿ ÙÔ Ù¤ÏÔ˜ ÙË˜ ÂÈ‰ÈfiÚıˆÛË˜.
∫·Ù¿ ÙË ‰È¿ÚÎÂÈ· ÂÚÁ·ÛÈÒÓ ÛÂ ÎÈÓËÙ‹Ú·, Ô˘
‚Ú›ÛÎÂÙ·È ÛÂ ÏÂÈÙÔ˘ÚÁ›·, Ú¤ÂÈ Ó· ÊÔÚ¿ÙÂ ÛÙÂÓ¿
el
ÂÚÁ·ÙÈÎ¿ ÚÔ‡¯·. ¶ÚÔ‚·›ÓÂÙÂ ÛÂ Á¤ÌÈÛÌ· ÙÔ˘
ÚÂ˙ÂÚ‚Ô˘¿Ú ÙÔ˘ ÎÈÓËÙ‹Ú· ÌÂ Î·‡ÛÈÌ· ÌfiÓÔ ·ÊÔ‡
ÚÔËÁÔ˘Ì¤Óˆ˜ ¤¯ÂÙÂ ı¤ÛÂÈ ÙÔÓ ÎÈÓËÙ‹Ú· ÂÎÙfi˜
ÏÂÈÙo˘ÚÁ›·˜. ªËÓ ·Ê‹ÓÂÙÂ oÙ¤ Ó· ÏÂÈÙÔ˘ÚÁÂ› Ô
ÎÈÓËÙ‹Ú·˜ Ì¤Û· ÛÂ ÎÏÂÈÛÙÔ‡˜ ¯ÒÚÔ˘˜, ÁÈ·Ù›
˘¿Ú¯ÂÈ Î›Ó‰˘ÓÔ˜ ‰ËÏËÙËÚ›·ÛË˜.
69
¶ÂÚÈÁÚ·Ê‹ ÙÔ˘ ÎÈÓËÙ‹Ú·

1. ¶ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ 2. £¤ÛË ÙË˜ ÈÓ·Î›‰·˜ ÙÔ˘ 3. ∞ÚÈıÌfi˜ ÙÔ˘ ÎÈÓËÙ‹Ú·
Î·Ù·ÛÎÂ˘‹˜ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜
∏ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹ ·Ú·ÏÏ·Á‹ ∞, Ô ·ÚÈıÌfi˜ ÙÔ˘

ÎÈÓËÙ‹Ú· µ Î·ıÒ˜ Â›ÛË˜ Î·È Ù· ÙÂ¯ÓÈÎ¿ ÛÙÔÈ¯Â›·
ÈÛ¯‡Ô˜ ÙÔ˘ ÎÈÓËÙ‹Ú· ¤¯Ô˘Ó ÛÊÚ·ÁÈÛÙÂ› Â¿Óˆ ÛÙËÓ
ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜.
∫·Ù¿ ÙËÓ ·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ Ú¤ÂÈ Ó·
Á›ÓÂÙ·È ·Ó·ÊÔÚ¿ ÙË˜ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹˜ ·Ú·ÏÏ·Á‹˜
Î·È ÙÔ˘ ·ÚÈıÌÔ‡ ÙÔ˘ ÎÈÓËÙ‹Ú·.
el
70
¶·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
el
71
™∂Pµπ™
el
72
Yedek parça listesi
B/F M 1011/F
Bayi kaşesi
0297 7780
Motor numarası:
Lütfen buraya motor numarasıını yazın. Böylece

müşteri hizmetleri, tamir ve yedek parça ile ilgili
konularda kolaylık sağlanır.
Yedek parça listesinde gösterilen şekiller ve teknik

bilgilerin, motorlarda yapılacak geliştirmeler
nedeniyle değiştirilmesi hakkı saklıdır. Firmamızın
yazılı izni olmaksızın, kısmen de olsa her türlü
çoğaltma ve kopyalama yasaktır.
73
Önsöz
Sayın müşterimiz,
DEUTZ Marka hava/su soğutmalı motorlar geniş

kullanım alanları için geliştirilmiştir. Sunulan geniş
model ve tip çeşitleri ile her türlü kullanım alanının
gerektirdiği özel şartlar yerine getirilebilmektedir.
Sahip olduğunuz motor bağli olduğu kullanım

amacı ile donatılmış olduğundan, yedek parça
listesinde gösterilmiş olan tüm eleman ve parçalar
motorunuzda bulunmaz.
Gösterilmiş olan grafikler tüm detayları kapsamasa

da, motorunuz tipi için geçerli olan yedek parça
kolayca tespit edilebilir. Pozisyon, yapı grubu
ve motor numarası üzerinden her halukarda,
motorunuz ile ilgili doğru yedek parça tespit
edilebilir.
Yedek parça siparişinde, ihtiyacınız olan yedek

parçayı en kısa zamanda, güvenilir ve son değişiklik
tipinde sevk edebilmemiz için sipariş bilgilerine
dikkat ediniz.
Sormak istediğiniz sorular olduğunda bize her

zaman başvurabilirsiniz.
tr
DEUTZ AG
74
Önsöz
DEUTZ Dizel motorları Orijinal DEUTZ Yedek Parça DEUTZ Değiştirme komponentleri
DEUTZT Marka dizel motorları, uzun yıllardıı yapılan Orijinal yedek parçalar aynı DEUTZ motorlarında DEUTZ Değiştirme komponentleri
araştırma ve geliştirmenin ürünüdür Bu araştırma ve olduğu gibi yüksek kalite standartlarına göre (üniteleri) uygun fiyatlı bir alter-
geliştirmelerden elde ediler know how ve üretimde üretilir. Motorların iyileştirilmesi için yapılan natifdir.. Aynı yeni yedek parçalarda
uygulanan yüksek kalite standartları, uzun ömürlü, geliştirme çalışmalarında olduğu gibi yedek parçalar olduğu gibi bu parçalar için de
yüksek dayanıklı ve düşük yakıt sarfiyatlı motorların üzerinde de geliştirmeler yapılır. Yalnızca en son yüksek kalite standartları geçerlidir.
üretilmesin sağlamıştır. Aynı zamanda çevre koruma teknolojiye göre üretilmiş olan orijinal DEUTZ yedek DEUTZ Değiştirme komponentlerinin fonksiyon ve
ile ilgili tüm yükümlülükler de yerine getirilmiştir. parçaları, motorların mükemmel fonksiyonunu, yük- güvenilirliği orijinal DEUTZ yedek parçalarına eşittir.
sek dayanıklılık ve güvenilirliğini sağlar.
SERViS Motor çalışırken dikkatli olun Asbest
Arıza durumları ve yedek parça konularında bilgi Bakım ve onarım çalışmaları yalnızca motor dururken Bu motorda kullanılan contalarda
edinmek için yetkili servislerimize başvurunuz. Bu yapılacaktır. Muhtemelen sökülmüş olan kuruma asbest malzemesi bulunmaz.
durumlarda eğitimli kalifiye personelimiz, orijinal düzenleri, bakım ve tamir çalışmalarından sonra Bakım ve onarım çalışmalarında
DEUTZ parçalar kullanarak tamir çalışmalarını yerine tekrar monte edilecektir. Motor çalışırken yapılan lütfen uygun yedek parça kullanın.
getireceklerdir. çalışmalarda bol iş elbisesi giyilmeyecektir. Yakit
dolumu yalnızca motor dururken yapılacaktır.
Motoru kesinlikle kapalı mekanlarda çalıştırmayın –
Zehirlenme tehlikesi.
tr
75
Önsöz
1. Uretici etiketi 2. Uretici etiketi pozisyonu 3. Motor numarası
Yapı türü A, motor numarası B ve motor gücü Üretici etiketi C karter silindir bloğunda bağlıdır. Motor numarası D karter silindir bloğuna dövülmüş
verileri üretici etiketinde yazılıdır. ve üretici etiketine yazılmışdır.
Yedek parça siparişinde yapı türü ve motor
numarası belirtilecektir.
tr
76
Yedek parça siparişi
Sipariş bilgileri Yedek parça siparişi

Orijinal DEUTZ yedek parça siparişlerinde
aşağıdaki bilgilerin belirtilmesi gereklidir:
– Motor-Nr.
Sira no. Adet Kod Nr. Not
– Kod Nr.
Yap
– Adet ı gr
ubu
Po
Dokümantasyon yapısı
zis
yo
– Yedek parça listesindeki şekiller ve çizimler
n
motor gruplarına göre ayrılmıştır
– Her bölümün önünde yapı grubu listesi bulunur
– 08/01 Kod numarası örneğin:

(örnek 08) nolu yapı grubu (örnek 01) nolu
pozisyondan olusşur.
tr
77
Servis
Bilmek gerekir, bu DEUTZ’dur. Sipariş no.: 0297 7444
Motor yapımında çığır açan gelişmeler demek

DEUTZ demektir. Biz, bağımsız motor üreticisi
olarak dünya genelinde 4 ile 7.400 kW gücündeki
dizel ve gaz motorlarını palet halinde
sunmaktayız. Ürünlerimiz müşterilerimizin
beklentileri için biçilmiş kaftandır.
Bugün dünya genelinde 1,4 milyondan daha fazla

sayıda DEUTZ motoru hizmet vermektedir.
Motorlarımızın etkinliğini ve bununla birlikte
müşterilerimizin memnuniyetini sürdürmek
istiyoruz.
Bu nedenle bütün dünyada, yayılımları motorlarımızın
bölgesel dağılımına uygun olan yetkin temsilciler
bizleri temsil etmektedir.
DEUTZ, bu şekilde sadece motorlar için yaratıcılık

ruhuna sahip bir isim değil, bunun yanında motorla
ilgili tam bir hizmet paketi ve güvenebileceğiniz
bir servis demektir.
Sipariş no: 0297 7445 (CD-ROM)
Sales & Service cetveli size DEUTZ’un en
yakınınızdaki temsilcileri, onların ürün yetkileri ve
servis hizmetleri hakkında bilgi verir. Direk olarak
ürün yetkisi olmasa da DEUTZ temsilcisi size
danışma hizmeti vererek yardım eder. Bulunduğunuz yerdeki yetkili servisinizden veya DEUTZ AG
yandaki adresimizden edinebilirsiniz: Deutz-Mülheimer Str. 147-149
Cetvel sürekli olarak güncel hale getirilir. D-51057 Köln
Yakınınızdaki DEUTZ temsilcisinden yeni baskıyı
isteyiniz. Telefon: 0049-221-822-0
Telefaks: 0049-221-822-5304
tr Teleks: 8812-0 khd d
Sizin DEUTZ’unuz. http://www.deutz.de
78
Spisok zapasnyx hastej
B/F M 1011/F
‚tamp torgovca
0297 7780
Nomer
dvigatelä:
UkaΩite, poΩalujsta, zdes´ nomer

dvigatelä. Ztim Vy obleghite razre-
wenie voprosov po texniheskomu
obsluΩivaniü, remontu i zapasnym
hastä m.
V izobraΩeniä i dannye nastoä wego

spiska zapasnyx hastej my ostavlä em
za soboj pravo vnosit´ texniheskie
izmeneniä, esli oni neobxodimy v
celä x uluh‚eniä dvigatelej. Perepe-
hatka i razmnoqenie v lübom vide,
takΩe i vyderΩkami, dopuskaütsä
tol´ko posle poluheniä na‚ego pis´-
men- nogo razre‚eniä.
79
Predislovie
UvaΩaemyj Pokupatel´, Zakazyvaä zapasnye hasti, soblüdajte,

poΩalujsta, naπi ukazaniä, s tem htoby
dvigateli £DOJTC“ s vozdπnym oxlaΩ- trebuemy Vami zaphasti mogli by byt´
deniem prednaznaheny dlä πirokoj postav-leny nami bystro i nadeΩno, v
oblasti primeneniä. V svä zi s ztim ispolnenii, v ispolnenii, v kotorom
daetsä bol´πoj assortiment ix razlih- uhteny vse vvedennye nami za poslednee
nyx variantov, pozvolä üwij vypolnä t´ vremä izmene- niä.
vse predßä vlä emye k nim osobye trebo-
vaniä. Pri vsex Vaπix zaprosax my otxotno goto-
vy Vam pomoh´ texniheskoj konsul´taciej.
Priobretennyj Vami dvigatel´ osnawen
sootvetstvenno voznikπim pri ego DEUTZ AG
montaΩe trebovaniä m, t.e. ne vse uka-
zannye v Vaπem spiske zapasnyx hastej
detali i uzly vstroeny v nego.
Xotä na sxeme predstavleny ne vse deta-

li dvigatelej, vse-e vozmono hetko razli-
hat´ otdelńye ix varianty, blagodarä
hemu moΩno legko najti trebuüwuüsä
dlä Vaπego dvigatelä zaphast´. Pri
pomowi nomera pozicii, uzla i dvigatelä
v lübom sluhae moΩno najti pravilńuü
zaphast´.
ru
80
Predislovie
Dizelńye dvigateli £DOJTC“ Оригинальные части Сменные компоненты фирмы
ДОЙТч
ä vlä ütsä rezul´tatom mnogoletnix Для них действуют те же самые строгие Сменные компоненты фир-
is- sledovanij i razrabotok. Priobre- требования по качеству, что и для мы ДОЙТЦ представляют
ten- noe двигателей фирмы ДОЙТЦ. Mepы пo собой недорогую аль-
vsledstvie ztogo processa solidnoe ycoвepшeнcтвaнию, нaправленные на тернативу оригинальным
£nou-xau“, v sohetanii s vysokimi trebo- улучшение двигателей, разумеется, частям. Конечно, и в этом случае
vaniä mi, predßä vlä emymi k kahestvu, осуществляются также для оригинал- прилагаются самые высокие мерила
– zalog izgotovleniä dvigatelej s pro- ьных частей. Только использование качества, что и для новых частей. В
dolΩitelńym srokom sluΩby, vysokoj оригинальных частей, изготовленных в отношении функции и надежности
nadeΩnost´ü i nizkim rasxodom top- соответствии с современным уровнем сменные компоненты фирмы ДОЙТЦ
liva. Samo soboj razumeetsä, hto техники, гарантирует безупречную ра- эквивалентны оригинальным частям.
vypolnä ütsä i vse vysokie trebova- боту и высокую надежность двигателей.
niä, predßä lä emye s tohki zreniä
zawity okruΩaüwej sredy.
SERVIS OSTOROˇNO PRI RABO-

TAÜWEM DVIGATELE Asbest
V sluhaä x texniheskix naruπenij i po Raboty po texniheskomu obsluΩivaniü ispol´zuemye v ztom dvi-
voprosam zapasnyx detalej pros´ba ili remontu sleduet provodit´ tol´ko gatele uplotneniä mogut
obratit´sä v odno iz naπix sootvetst- pri otklühennom dvigatele. Po okonha- soderΩat´ asbest.
vuüwix predstavitel´stv po texnihes- nii ztix rabot neobxodimo vnov´ posta- Pri provedenii remontnyx
komu obsluΩivaniü. Naπi specialisty vit´ na svoj mesta snä tye, vozmoΩno, rabot obrawajte vnimanie
v sluhaä x texniheskix naruπenij provo- zawitnye prisposobleniä. Pri prove- na promakrirovannye buk-
dä t bystryj i kvalificirovannyj denii rabot na rabotaπüem dvigatele voj £a“ zapasnye hasti.
remont s primenenim originalńyx de- rabohaä odeΩda dolΩna plotno prile-
talej. gat´ k telu. Zapravku proizvodit´ tol´ko
pri otklühennom dvigatele. Nikogda ne
dopuskat´ rabotu dvigatelä v zakrytyx
pomeweniä x – ugroza otravleniä. ru
81
Opisanie dvigatelä
1. Firmennaä tablihka 2. Mesto zakrepleniä 3. Nomer dvigatelä
firmennoj tablihki
Konstruktivnoe ispolnenie A, nomer

dvigatela B, a takΩe rabohie xarakte-
pistiki, ukazany na Ffrmennoj tablih-
ke. V zakazax na zapasnye hasti dolΩny
ukazyvat´sä model´ i nomer dvigatelä.
ru
82
Zakaz na zapasnye hasti
ru
83
Servis
ru
84
B/F M 1011/F
0297 7780
Motornummer:
Bitte tragen Sie hier die Motornummer ein. Sie er-

leichtern hierdurch die Abwicklung bei Kunden-

Verbesserung der Motoren notwendig werden, vor-
behalten. Nachdruck und Vervielfältigung jeglicher
Art, auch auszugsweise, bedarf unserer schrift-
lichen Genehmigung.
85
DEUTZ AG
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Planscher
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sekiller
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Illüstracii
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DEUTZ AG
Service-Technik
Servicedokumentation
Deutz-Mülheimer Str. 147-149
D-51057 Köln
Telefon: 02 21-8 22-0
Fax: 02 21-8 22-53 58
http: //www.deutz.de
Printed in Germany
All rights reserved
8th Edition, © 02/01
Knowing it’s DEUTZ. Order No. 0297 7780
(07.01)
Werkstatthandbuch
Workshop Manual
Manuel d’Atelier
Manual de Taller 1011 F
0297 7423
Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind

technische Änderungen, die zur Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeglicher Art, auch auszugsweise,
bedarf unserer schriftlichen Genehmigung.
In view of continuous design improvements or changes, the technical spe-

cifications and the illustrations shown in this Workshop Manual are subject to
alteration. Reprinting and reproduction, in part or in whole, are subject to our
written approval.
Sous réserve de modifications techniques nécessaires à l’amélioration des

moteurs présentés par des illustrations et des indications référencées dans ce
Manuel d’Atelier. Réimpression et reproduction même partielle, quelle qu’en
soit la nature, interdites sans l’autorisation écrite de nos service.
Nos reservamos el derecho de introducir modificaciones técnicas necesarias

para el mejoramiento de motores, aunque difieran de las ilustraciones y datos
contenidos en este Manual de Taller. La reimpresión del presente libro o
cualquiera forma de reproducción, aunque sea parcial, requiere nuestra
autorización por escrito.
VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.
In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparatur-

und Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, daß die
Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.
Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der
Inhalte zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den
jeweils behandelten Arbeitsgang visualisieren.
Betriebs- und Wartungshinweise sind der entsprechenden Betriebsanleitung zu entnehmen.
Zur Ersatzteilbestellung ist die jeweilige Ersatzteilliste zugrunde zu legen.
Das vorliegende Werkstatthandbuch unterliegt keinem Änderungsdienst. Änderungen werden

jeweils bei Neuauflage eingearbeitet.
Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.
Allgemeine Hinweise:
- Lesen und beachten Sie die Informationen dieses Werkstatthandbuches. Sie

vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten
Motor.
- Stellen Sie sicher, daß dieses Werkstatthandbuch jedem an Reparatur- oder

Einstellarbeiten Beteiligten zur Verfügung steht und daß der Inhalt verstanden wird.
- Die Nichtbeachtung dieser Reparaturanleitung kann zu Funktionsstörungen und

Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller
keine Haftung übernommen wird.
- Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen

anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzu-
halten.
- Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderli-
chen Ausrüstungen, Hand- und Spezialwerkzeuge, sowie deren einwandfreier
Zustand.
- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei

Verwendung von Original Teilen der DEUTZ AG sichergestellt.
- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.
- Die Instandsetzung des Motors muß der bestimmungsgemäßen Verwendung -

definiert durch den Gerätehersteller - entsprechen. Bei Umbauten dürfen nur von der
DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt
werden.
FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work
on the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise
text passages are accompanied by pictographs to illustrate the relevant operation.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next
issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.
General information:
- Please read carefully and observe the instructions given in this Workshop Manual
to avoid accidents and ensure that your engine always functions properly and
reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out
repairs or adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine
damage as well as personal injuries for which the manufacturer shall not accept any
liability.
- The accident prevention regulations and all other generally recognized regulations
on safety and occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special
tools are available and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be
ensured when genuine parts of DEUTZ AG are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not
handled with care.
- Engine repairs must be carried out in accordance with intended use as defined by
the equipment manufacturer. For conversions, only parts approved by DEUTZ AG
for a specific purpose should be used.
PRÉFACE
Un fonctionnement fiable du moteur suppose l’exécution en bonne et due forme des travaux de
réparation et de réglage.
Le présent Manuel d’atelier décrit la suite des travaux de réparation et de réglage à effectuer sur
le moteur et ses éléments. Cela suppose que les travaux sont réalisés par un personnel spécialisé
et qualifié.
En vue d’une compréhension rapide du contenu, le manuel d’atelier comporte, en plus des textes
brefs, des symboles visualisant l’opération à réaliser.
Les indications relatives au service et à l’entretien figurent dans les instructions de service
correspondantes.
Pour la commande de pièces de rechange, il convient de se baser sur la liste des pièces de rechange
correspondante.
Le présent manuel d’atelier n’est soumis à aucun service de modifications. Les modifications
seront incorporées à chaque réédition du Manuel.
Pour les réparations, veuillez respecter les indications de nos circulaires techniques.
Remarques générales:
- Veuillez lire attentivement les informations du présent Manuel d’ Atelier et en tenir

compte. Vous éviterez ainsi des accidents et disposerez en même temps d’ un
moteur fonctionnel et en parfait état de marche.
- Assurez-vous que chaque personne chargée des travaux de réparation et de mise

au point dispose bien de ce Manuel d’ Atelier et en comprenne bien le contenu.
- Le non-respect de ces instructions de réparation peut entraîner des pannes, avaries

de moteur et accidents de personnes, pour lesquels le constructeur ne peut en aucun
cas assumer la responsabilité.
- Il convient de respecter les consignes générales de sécurité et de prévention des

accidents en vigueur.
- La condition préalable de la bonne exécution des réparations est la mise à disposition

de tous les équipements, outillages manuels et spéciaux requis, en parfait état de
fonctionnement.
- Seule l’utilisation de pièces de rechange d’origine DEUTZ AG garantit une rentabilité

et fiabilité optimales ainsi qu’une longue durée de vie.
- Les éléments du moteur notamment les ressorts, attaches, bagues élastiques etc.,
peuvent entraîner, en cas de non-respect des prescriptions, des blessures graves.
- La remise en état du moteur doit répondre à son utilisation propre, définie par le
constructeur de l’engin. En cas de modification, seules les pièces autorisées par
DEUTZ AG dans le cas de l’application concernée, peuvent être utilisées.
PROLOGO
Una ejecución competente de trabajos de reparación y ajuste es requisito fundamental para un
funcionamiento seguro del motor.
En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para
reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los
trabajos serán realizados por personal técnico especializado.
Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado
símbolos significativos a los textos explicatorios, visualizando así el trabajo a realizar.
Informaciones con respecto al manejo y al servicio de entretenimiento del motor, se encuentran

en el Manual de Instrucciones de Servicio correspondiente.
Para pedidos de repuestos servirá de base el respectivo catálogo de repuestos.
El presente manual para talleres no está sujeto a un servicio continuado de modificaciones e

innovaciones. Cada nueva edición incluye todas las modificaciones del caso.
Al efectuar reparaciones, aconsejamos asimismo tomar en cuenta las advertencias pertinentes de

nuestras circulares técnicas.
Advertencias generales:
- Le recomendamos la detenida lectura y observancia de las informaciones con-

tenidas en este Manual de taller. Así evitará accidentes y dispondrá de un motor
que funciona perfectamente.
- Haga lo necesario para que este Manual esté a disposición de toda persona que
participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el
contenido.
- Al no tenerse en cuenta estas instrucciones de reparación, podrán surgir

perturbaciones en el funcionamiento y averías en el motor así como lesiones de
personas para las cuales el fabricante no asume responsabilidad alguna.
- Se cumplirán las normas aplicables para la prevención de accidentes así como todas
las demás normas de seguridad y medicina laboral generalmente aceptadas.
- Es condición para la correcta reparación que estén disponibles todos los requeridos
equipos, herramientas manuales y especiales en perfecto estado.
- Máxima rentabilidad, fiabilidad y larga duración quedan garantizadas únicamente al

emplearse repuestos originales de DEUTZ AG.
- Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. ,
aumentan en caso de tratamiento incorrecto el peligro de lesiones.
- El reacondicionado del motor deberá corresponder al empleo previsto definido por

el fabricante del equipo. En caso de transformaciones, se deberán emplear
únicamente piezas admitidas por DEUTZ AG para el respectivo uso previsto.
Inhalts-Verzeichnis
Table of Contents
Sommaire
Indice
Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols
Caractéristiques techniques / Légende des symbols
Datos técnicos / Leyenda de símbolos
Prüfen und Einstellen

Checking and adjusting
Contrôle et réglage
Verificación y ajustes
Bauteile instand setzen

Repair of components
Mise en état des composants
Reparación de componentes
Demontage und Montage, Motor komplett

Disassembly and reassembly of complete engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor
Werkzeuge
Tools
Outils
Herramientas
5
Technische Daten
Specification data
Caractéristiques techniques
Datos técnicos 1011 F
Hinweis zum Gebrauch des Werkstatthandbuches

In diesem Werkstatthandbuch sind alle technischen Daten, Einstellwerte und
Anziehvorschriften den Stellen zugeordnet, wo sie bei Servicearbeiten, De- und
Montage am Motor benötigt werden.
Notes for the user of this Workshop Manual

In this Workshop Manual all specification data, adjustment values and
tightening specifications are allocated to those parts where they are needed for
service work, disassembly and reassembly on the engine.
Remarque quant à l’utilisazion du Manuel d’atelier

Dans le présent Manuel d’atelier, toutes les caractéristiques techniques, valeurs
de réglage et préconisations de serrage nécessaires se trouvent dans les
chapitres correspondant aux travaux de service après-vente et montage et
démontage du moteur.
Indicación para el uso del manual de taller

En este manual de taller se indican todos los datos técnicos, valores de ajuste y
prescripciones de apriete en los puntos donde son requeridos para la realización
de trabajos de servicio, desmontaje y montaje en el motor.
Inhalts-Verzeichnis Technische Daten
Table of Contents Specification data
Sommaire Caractéristiques techniques
Indice Datos técnicos
Deutsch Werkstatthandbuch 1011 F
1. Technische Daten Seite
Techn. Daten _______________________________________ 1.00.02 - 1.00.07

Ventilspieleinstellschema _______________________________________ 1.00.09
Reihenfolge beim Anziehen der Zylinderkopfschrauben ____________________ 1.00.11
Bildzeichenerklärung _______________________________________ 1.00.13 1
English
1. Specification data Page
Specification data _______________________________________ 1.00.02 -1.00.07

Schematic for valve clearance adjustment _______________________________ 1.00.09
Tightening order for cylinder head bolts ________________________________ 1.00.11
Key to symbols _______________________________________ 1.00.13
Français
1. Caractéristiques techniques Page
Caractéristiques techniques _______________________________________ 1.00.02 - 1.00.07

Schéma de réglage des soupapes _____________________________________ 1.00.09
Ordre à respecter lors du serrage dàpproche de définitif des fis de cul. ________ 1.00.11
Explication des légendes _______________________________________ 1.00.13
Español
1. Datos técnicos Página
Datos técnicos _______________________________________ 1.00.02 - 1.00.07

Esquema para el ajuste del juego de válvulas ____________________________ 1.00.09
Sucesión de los trabajos al apretar los tornillos de culata ___________________ 1.00.11
Leyenda de símbolos _______________________________________ 1.00.13
Technische Daten
Specification data
Datos técnicos
Werkstatthandbuch 1011 F
Deutsch English Français Español
Motorgewicht Engine weight Poids du moteur Peso del motor

ohne Starter, without starter sans démarreur sin arrancador,
1 mit Generator with generator avec génératrice con generador
ca. kg approx. kg approx. kg aprox. kg
Gesamthubvolumen Engine swept volume Cylindrée totale Cilindrada total
cm3 cm3 cm3 cm3
Bohrung Bore Alésage Calibre
mm mm mm mm
Hub Stroke Course Carrera
mm mm mm mm
Drehrichtung Direction of rotation Sens de rotation Sentido de giro
Nenndrehzahl Rated speed Régime nominal Régimen nominal
max. 1/min max. rpm maxi tr/mn máx. r/min
Niedrigste Minimum Ralenti extrême Régimen mín.

Leerlaufdrehzahl idle speed en vacío
1/min rpm tr/mn r/min
Arbeitsweise Working cycle Principe de fonction- Sistema de trabajo

nement
1.00.02
Technische Daten
Specification data
Datos técnicos
F2 - 4L 1011 F BF4L 1011 F F3 - 4M 1011 F BF4M 1011 F
F2L = 167
F3L = 208 F3M = 200
F4L = 250 257 F4M = 243 249
1
F2L = 1366
F3L = 2049 F3M = 2184
F4L = 2732 2732 F4M = 2912 2912
91
105 112
auf Schwungrad gesehen links

When facing flywheel counter-clockwise
Vu sur volant à gauche
Mirándose sobre el volante a izquierdas
3300 3000 3000 2800
900 ± 50
Viertakt - Diesel
Four-stroke diesel
Diesel 4 temps
Diesel a 4 tiempos
1.00.03
Technische Daten
Specification data
Datos técnicos
Verbrennungs- Combustion Principe de Sistema de

verfahren system combustion combustión
1
Verdichtungs- Compression Taux de Relación de

verhältnis ratio compression compresión
Kompressionsdruck Compression pressure Compression Pressión de

compresión
bar bar bars bar
Zündfolge Firing order Ordre d’allumage Orden de

encendido
Abmessungen des Dimensions of Dimensions du Dimensiones del

Motors mit engine incl. moteur avec volant motor con
Anschlußgehäuse standard flywheel standard volante
(normal) (normal)
größte Länge Max. length Longueur HT Longitud máx.
mm mm mm mm
größte Breite Max. width Largeur HT Anchura máx.
mm mm mm mm
größte Höhe Max. height Hauteur HT Altura máx.
mm mm mm mm
1.00.04
Technische Daten
Specification data
Datos técnicos
F2 - 4L 1011 F BF4L 1011 F F3-4M 1011 F BF4M 1011 F
Direkteinspritzung
Direct injection
Injection directe 1
Inyección directa
18,5 17 18,5 17
1-2
1 -2 - 3 1 -2 - 3
1 -3 - 4 - 2 1 -3 - 4 - 2 1 -3 - 4 - 2 1 -3 - 4 - 2
F2L = 487
F3L = 599 F3M = 599
F4L = 710 710 F4M = 710 710
451 495 451 495
F2L = 683
F3L = 678 F3M = 678
F4L = 703 703 F4M = 703 703
1.00.05
Technische Daten
Specification data
Datos técnicos
Steuerzeiten ohne Valve timing without Calage distribution sans Cotas de reglaje sin
Stößel- und Ventilspiel valve clearance jeu aux culbuteurs juegos de válvulas y
réglé de empujadores
1
Einlaß öffnet Inlet opens Admission ouvre Admisión abre

vor OT before TDC avant PMH a. PMS
Grad degrees degrés grados
Einlaß schließt Inlet closes Admission ferme Admisión cierra

nach UT after BDC après PMB t. PMI
Auslaß öffnet Exhaust opens Echappement ouvre Escape abre

vor UT before BDC avant PMB a. PMI
Auslaß schließt Exhaust closes Echappement ferme Escape cierra

nach OT after TDC après PMH t. PMS
Schmieröldruck in Lube oil pressure at low Pression d’huile au bas Presión de aceite lubri-
niedrigem Leerlauf idling ralent cante a marcha lenta
Temperatur ca. 110° C Temperature approx. température ca. 110° C en vacío Tempera-
Öl SAE 20W/20 110° C oil SAE 20W/20 huile SAE 20W/20 tura aprox. 110° C
aceite SAE 20W/20
Minimum bar min. bar mini bars mín. bar
Absteuerventil Pressurestat Clapet régulateur Válvula reguladora

final final
bar bar bars bar
1.00.06
Technische Daten
Specification data
Datos técnicos
F2 - 4L 1011 F BF4L 1011 F F3 - 4M 1011 F BF4M 1011 F
45 47 45 47
65 63 65 63
76 99,5 76 99,5
44 51,5 44 51,5
1,4
F2 -3L = 6,5 7 F3L = 6,5 7

F4L = 7 F4L = 7
1.00.07
Technische Daten
Specification data
Datos técnicos
1
Ventilspieleinstellschema
Schematic for valve clearance adjustment
Schéma de réglage des soupapes
Esquema para el ajuste de holgura de válvulas
English Français Español
Crankshaft position 1 Position de l’arbre à cames 1 Posición del cigüeñal 1
Kurbelwellenstellung 11 Kurbelwellenstellung 2 1 1 Turn engine until valves of cylinder

No. 1 overlap.
Virer le moteur jusqu'au chevau-
chement des soupapes au cylindre 1.
Gírese el motor, hasta que las válvulas
del cilindro N° 1 coincidan en su
posición momentánea.
Motor bis zum Erreichen der Ventilüber- Motor um eine volle Umdrehung (360°)
Not ready for adjustment. non réglable no ajustable
schneidung am Zyl. Nr. 1 durchdrehen. weiterdrehen.
Crankshaft position 2: Position de l’arbre à cames 2 Posición del cigüeñal 2
nicht einstellbar einstellbar Turn engine further by one complete Tourner le moteur d’un tour complet Continuese girando el motor por una
revolution (360°). (360°) rotación completa (360°)
Ready for adjustment. réglable ajustable
1 2 1 2
1 2 3 1 2 3
1 2 3 4 1 2 3 4
1.00.09 1.00.09
Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening order for cylinder head bolts
Ordre à respecter lors du serrage d’approche et définitif des vis de cul.
Sucesión de los trabajos al apretar los tornillos de culata
Krümmerseite,Manifold side, Krümmerseite,Manifold side,

Coté coudes, Lado codo Coté coudes, Lado codo
1 1
➝
2-Zylinder 2-Zylinder
4 2 6 2-cylinder 4 2 6 2-cylinder
2-cylindres 2-cylindres
2 cilindros 2 cilindros
5 1 3 5 1 3

➝
➝
7 3 4 6 3-cylinder 7 3 4 6 3-cylinder
5 1 2 8 5 1 2 8

➝
➝
8 6 4 5 9 4-cylinder 8 6 4 5 9 4-cylinder
10 3 1 2 7 10 3 1 2 7
© 2001 / 0297 9959 1.00.11 1.00.11 © 2001 / 0297 9959

Bildzeichenerklärung
Bildzeichenerklärung Bildzeichenerklärung
Zerlegen Personenschäden verhüten Zerlegen Personenschäden verhüten
von Baugruppen Hinweis auf Gefahrenstelle von Baugruppen Hinweis auf Gefahrenstelle
1 1
Zusammenbauen Materialschaden verhüten Zusammenbauen Materialschaden verhüten
zu einer Baugruppe Teilbeschädigung zu einer Baugruppe Teilbeschädigung
Abbauen - Ausbauen Unterbauen - Abstützen - Abbauen - Ausbauen Unterbauen - Abstützen -

Abfangen Abfangen
behindernder Teile behindernder Teile
Einbauen - Anbauen Einölen Einbauen - Anbauen Einölen
Teile, die beim Ab-/ Ausbau hinderten Teile, die beim Ab-/ Ausbau hinderten
Achtung, wichtiger Hinweis Einfetten Achtung, wichtiger Hinweis Einfetten
Prüfen - Einstellen Markieren Prüfen - Einstellen Markieren

vor dem Zerlegen, beachten beim vor dem Zerlegen, beachten beim
z. B. Drehmomente, Maße, Drücke usw. Zusammenbau z. B. Drehmomente, Maße, Drücke usw. Zusammenbau
Spezialwerkzeug Wuchten Spezialwerkzeug Wuchten
Ausgleichen von Unwuchten Ausgleichen von Unwuchten
Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen
z. B. Öl, Kühlwasser usw. z. B. Öl, Kühlwasser usw.
Kontrollieren - Prüfen Ablassen Kontrollieren - Prüfen Ablassen
Sichtprüfung z. B. Öl, Kühlwasser usw. Sichtprüfung z. B. Öl, Kühlwasser usw.
Bedingt wiederverwendbar Lösen Bedingt wiederverwendbar Lösen
Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung
Beim Zusammenbau immer Spannen Beim Zusammenbau immer Spannen

erneuern erneuern
z. B. Anziehen einer Spanneinrichtung z. B. Anziehen einer Spanneinrichtung
Entsichern - Sichern Entlüften Entsichern - Sichern Entlüften
z. B. Splint, Sicherungsblech usw. z. B. Splint, Sicherungsblech usw.
Sichern - Kleben Spanabhebende Bearbeitung Sichern - Kleben Spanabhebende Bearbeitung
z. B. Dichtmittel flüssig z. B. Dichtmittel flüssig
1.00.13 1.00.13
Key to Symbols
Key to Symbols Key to Symbols

Disassembly Guard against personal injury Disassembly Guard against personal injury
of assembly groups Indication of hazard of assembly groups Indication of hazard

1 1
Reassembly Guard against material damage Reassembly Guard against material damage
to form assembly group Damage to parts to form assembly group Damage to parts
Remove Prop up - Support - Hold Remove Prop up - Support - Hold
obstructing parts obstructing parts
Reinstall - Remount Oil Reinstall - Remount Oil
parts which had obstructed disassembly parts which had obstructed disassembly
Attention! Impartant notice! Grease Attention! Impartant notice! Grease
Check - Adjust Mark Check - Adjust Mark

before disassembly, observe marks when before disassembly, observe marks when
e. g. torque dimensions, pressures, etc. reassembling e. g. torque dimensions, pressures, etc. reassembling
Special tool Balance Special tool Balance
Eliminate any imbalance Eliminate any imbalance
Note direction of installation Filling - Topping up - Refilling Note direction of installation Filling - Topping up - Refilling
e. g. oil, cooling water, etc. e. g. oil, cooling water, etc.
Visual inspection Drain off Visual inspection Drain off
Possibly still serviceable Loosen - Release Possibly still serviceable Loosen - Release
Renew if necessary e. g. loosening a clamping device Renew if necessary e. g. loosening a clamping device
Renew at each reassembly Tighten - Clamp Renew at each reassembly Tighten - Clamp
e. g. tightening a clamping device e. g. tightening a clamping device
Unlock - Lock Vent Unlock - Lock Vent
e. g. split pin, locking plate, etc. e. g. split pin, locking plate, etc.
Lock - Adhere Machining process Lock - Adhere Machining process
e. g. with liquid sealant e. g. with liquid sealant
1.00.13 1.00.13
Légende des symboles
Légende des symboles Légende des symboles

Déassemblage Prévention aux accidents profession Déassemblage Prévention aux accidents profession
d’un ensemble constructif attirer l’attention sur un risque eventuel d’un ensemble constructif attirer l’attention sur un risque eventuel
d’ accident d’ accident
1 1
Assemblage Prévention à la détérioration de Assemblage Prévention à la détérioration de
matériels matériels
des composants d’un ensemble constructif Risque d’endommager des piéces des composants d’un ensemble constructif Risque d’endommager des piéces
Démontage Monter sur tréteaux - freiner par Démontage Monter sur tréteaux - freiner par
sabots - immobiliser par un moyen sabots - immobiliser par un moyen
d’eléments entravant l’accés quelconque d’eléments entravant l’accés quelconque
Remontage - Remise en place Huiler Remontage - Remise en place Huiler
d’eléments qui entravaient l’accés d’eléments qui entravaient l’accés
Remarque importante! Graisser Remarque importante! Graisser
employer lubrificant plastique employer lubrificant plastique
Utilisation impérative Repérage en cours de démontage Utilisation impérative Repérage en cours de démontage
p. ex.: couple-moteur, cotes, pressions etc. permet un remontage correct! p. ex.: couple-moteur, cotes, pressions etc. permet un remontage correct!
Utilisation impérative Equilibrer Utilisation impérative Equilibrer
d’un outil specialise éliminer le balourd d’un outil specialise éliminer le balourd
Respecter l’ordre de montage Premier garnissage - remplissage - Respecter l’ordre de montage Premier garnissage - remplissage -
garnissage d’appoint garnissage d’appoint
p. ex.: Huile eau de refroidissement etc. p. ex.: Huile eau de refroidissement etc.
Vérification - Contrôle Vidanger - soutirer Vérification - Contrôle Vidanger - soutirer
à vue p. ex.: Huile eau de refroidissement etc. à vue p. ex.: Huile eau de refroidissement etc.
Réutilisation sous certaines Desserrer Réutilisation sous certaines Desserrer

conditions conditions
à remplacer,si besoin est p. ex.: desserrage d’un dispositiv à remplacer,si besoin est p. ex.: desserrage d’un dispositiv
A remplacer systématiquement Serrer A remplacer systématiquement Serrer
lors de remontage p. ex.: serrage entre un dispositif lors de remontage p. ex.: serrage entre un dispositif
Arracher la goupille - goupiller Faire la purge d’air Arracher la goupille - goupiller Faire la purge d’air
freiner par tôle-arrétoir freiner par tôle-arrétoir
Freiner - coller Usinage par enlèvement de copeaux Freiner - coller Usinage par enlèvement de copeaux
p. ex. avec páte hermétique, ou frein liquide p. ex. avec páte hermétique, ou frein liquide
1.00.13 1.00.13
Leyenda de símbolos
Leyenda de símbolos Leyenda de símbolos

Desarmar Evitar accidentes Desarmar Evitar accidentes
grupos de construcción indica puntos de peligro grupos de construcción indica puntos de peligro
1 1
Rearmar Evitar daños materiales Rearmar Evitar daños materiales
un grupo de construcción averia de piezas un grupo de construcción averia de piezas
Desmontar Calzar - Apoyar Desmontar Calzar - Apoyar
partes que puedan estorbar partes que puedan estorbar
Montar - Incorporar Aceitar Montar - Incorporar Aceitar

partes que puedan estorbar en partes que puedan estorbar en
el desmontaje el desmontaje
!Atención! Indicación importante Engrasar !Atención! Indicación importante Engrasar
Verificar - Graduar - Ajustar Marcar Verificar - Graduar - Ajustar Marcar

antes del desmontaje - controlar la marcación antes del desmontaje - controlar la marcación
(p. ej. pares, medidas, presiones) en el remontaje (p. ej. pares, medidas, presiones) en el remontaje
Herramienta especial Equilibar Herramienta especial Equilibar
Aeliminar desequilibros o excentricidad Aeliminar desequilibros o excentricidad
Observar la dirección de montaje Lienar - Rellenar - Completar Observar la dirección de montaje Lienar - Rellenar - Completar
p. ej. aceite, agua refrigerante, etc. p. ej. aceite, agua refrigerante, etc.
Control Evacuar - Vaciar Control Evacuar - Vaciar
verificación visual p. ej. aceite, agua refrigerante, etc. verificación visual p. ej. aceite, agua refrigerante, etc.
Re-utilización condicional Soltar Re-utilización condicional Soltar
sustituir en caso necesario p. ej. un sistema de fijación o tensado sustituir en caso necesario p. ej. un sistema de fijación o tensado
Sustituir en cada montaje Tensar - Apretar Sustituir en cada montaje Tensar - Apretar
p. ej. un sistema de fijación o tensado p. ej. un sistema de fijación o tensado
Desafianzar - Afianzar (mecánicamente) Purgar el aire Desafianzar - Afianzar (mecánicamente) Purgar el aire
(p. ej. pasador de aletas, chapa de seguridad, (p. ej. pasador de aletas, chapa de seguridad,
etc.) etc.)
Afianzar - Pegar Mecanización con arranque de Afianzar - Pegar Mecanización con arranque de
virutas virutas
p. ej. con medio liquido p. ej. con medio liquido
1.00.13 1.00.13
Verificación y ajustes 1011 F
Inhalts-Verzeichnis Prüfen und Einstellen
Table of Contents Checking and adjusting
Sommaire Contrôle et réglage
Indice Verificación y ajustes
2. Prüfen und Einstellen Seite
Ventilspiel _______________________________________________________ 2.00.01 - 2.00.02

Kompressionsdruck ________________________________________________ 2.00.03 - 2.00.04
Einspritzventil ____________________________________________________ 2.00.05 - 2.00.07
Einspritzpumpe ___________________________________________________ 2.00.09 - 2.00.10
English
2. Checking and adjusting Page
Valve clearance ___________________________________________________ 2.00.01 - 2.00.02

Compression pressure______________________________________________ 2.00.03 - 2.00.04 2
Injector _________________________________________________________ 2.00.05 - 2.00.07
Injection pump ___________________________________________________ 2.00.09 - 2.00.10
Français
2. Contrôle et réglage Page
Jeu aux soupapes _________________________________________________ 2.00.01 - 2.00.02

Taux de compression ______________________________________________ 2.00.03 - 2.00.04
Soupape injectrice _________________________________________________ 2.00.05 - 2.00.07
Pompe d’injection _________________________________________________ 2.00.09 - 2.00.10
Español
2. Verificación y ajustes Pagina
Juego de válvulas _________________________________________________ 2.00.01 - 2.00.02

Presión de compresión _____________________________________________ 2.00.03 - 2.00.04
Inyector _________________________________________________________ 2.00.05 - 2.00.07
Bomba de inyección _______________________________________________ 2.00.09 - 2.00.10
Prüfen und Einstellen Ventilspiel
Checking and adjusting Valve clearance
Contrôle et réglage Jeu de soupapes
Verificación y ajustes Juego de válvulas
The standard valve clearance can be Le réglage standard du jeu des El ajuste del juego estándar de válvulas
adjusted: soupapes est possible es posible:
with engine cold or warm after cooling sur moteur froid ou chaud après une Con el motor frío o con el motor
down for at least 0.5 h. période de refroidissement d’au moins caliente después de un período de
30 minutes. enfriamiento de por lo menos
media hora.
Oil temperature ≤ 80°C. Température de l’huile ≤ 80˚C. Temperatura del aceite: ≤ 80°C.
Note: The valve clearance is to be in- Nota: à chaque changement du joint de Nota: El juego de válvulas debe
creased by 0.1 mm at every cy- culasse augmenter le jeu aux aumentarse por 0,1␣ mm a cada
linder head gasket renewal. soupapes de 0,1 mm. cambio de la junta de culata,.
The standard valve clearance is Après 500 heures de marche Tras 500 horas de servicio se
to be adjusted after completion procéder au réglage standard du ajustará el juego estándar.
of 500 hours of operation. jeu des soupapes.
Cylinder head cover has been removed. Le cache-culbuteurs a été déposé. La tapa de culata está desmontada.
2
1. Turn engine until valves of cyl. No. 1. Virer le moteur jusqu’à ce que les 1. Girar el cigüeñal hasta que se
1 overlap. soupapes soient en bascule, cyl. no. 1. crucen las válvulas en el cilindro 1.
For valve clearance adjustment Schéma de réglage du jeu aux Para el esquema de ajuste del juego
schematic see Specification Data. soupapes voir caractéristiques de válvulas, véanse los Datos
techniques. Técnicos.
Note: Valves overlapping means: Nota: le chevauchement des soupapes Nota: Cruce de válvulas significa: La
Exhaust valve about to close. signifie: soupape d’échappement válvula de escape aún no está
Inlet valve about to open. pas encore fermée et soupape cerrada y la de admisión
Neither pushrod can be turned d’admission commence à comienza a abrirse. En esta
in this position. s’ouvrir. Les deux tiges de posición, no es posible girar las
culbuteurs ne peuvent plus dos varillas de empuje.
tourner.
2. Adjust valve clearance on respec- 2. Régler le jeu des soupapes au 2. Ajustar el juego de válvulas en el
tive cylinder with feeler gauge. cylindre correspondant avec une cilindro correspondiente mediante
jauge d’épaisseur. la galga de espesores.
Note: Inlet valve clearance: 0.3 mm Nota: Jeu soupape ADM: 0,3 mm Nota: Juego de válvulas
Exhaust valve clearance: 0.5 mm Jeu soupape ECH: 0,5 mm - admisión: 0,3 mm
- escape: 0,5 mm
3. Tighten locknut. 3. Serrer le contre-écrou 3. Apretar la contratuerca.
Tightening specification: 20 ±2 Nm Consigne de serrage 20 ± 2 Nm Prescripción de apriete: 20 ± 2 Nm.
Recheck the adjustment with feeler Effectuer un nouveau contrôle du Comprobar nuevamente el ajuste
gauge. serrage avec une jauge d’épaisseur. efectuado, mediante la galga de
espesores.
2.00.01
Ventilspiel Prüfen und Einstellen
Valve clearance Checking and adjusting
Jeu de soupapes Contrôle et réglage
Juego de válvulas Verificación y ajustes
Die Standard-Ventilspieleinstellung ist möglich:
Am kalten- oder am warmen Motor nach einer

Abkühlzeit von mindestens 0,5 h.
Öltemperatur ≤ 80° C
Hinweis: Bei jedem Zylinderkopf-Dichtungswech-

sel ist das Ventilspiel um 0,1 mm zu er-
höhen.
Nach 500 Bh ist das Standard-Ventil-
spiel einzustellen.
Zylinderkopfhaube ist abgebaut
1. Motor durchdrehen bis zum Erreichen der

9
Ventilüberschneidung, Zyl. Nr. 1.
2
siehe Techn. Daten
Hinweis: Ventilüberschneidung bedeutet:

Auslaßventil ist noch nicht geschlos-
sen, Einlaßventil beginnt zu öffnen.
9
Dabei sind beide Stoßstangen nicht
drehbar. 5
2. Ventilspieleinstellung am entsprechenden Zy-

linder mit Fühlerlehrenblatt einstellen. 6
Hinweis: Ventilspiel Einlaß:
Ventilspiel Außlaß:
0,3 mm
0,5 mm
5
3. Kontermutter festdrehen.
Anziehvorschrift: 20 ± 2 Nm
Einstellung nochmals mit Fühlerlehrenblatt

überprüfen.
2.00.01
Contrôle et réglage Jeu de soupapes
Werkstatthandbuch 1011 F Deutsch
4. Dichtung aufsetzen.
4
0
5. Zylinderkopfhaube montieren. Schrauben

4 festdrehen.
2 6 Anziehvorschrift: 8,5 Nm
2.00.02
Jeu de soupapes Contrôle et réglage
4. Put gasket in place. 4. Mettre en place le joint. 4. Colocar la junta.
5. Fit cylinder head cover. Tighten 5. Monter le cache-culbuteurs. 5. Montar la tapa de culata. Apretar
bolts. Bloquer les vis. los tornillos.
Tightening specification: 8.5 Nm Consigne de serrage: 8,5 Nm. Prescripción de apriete: 8,5 Nm.
2
2.00.02
Prüfen und Einstellen Kompressionsdruck
Checking and adjusting Compression pressure
Contrôle et réglage Taux de compression
Verificación y ajustes Presión de compresión
Commercial tools required: Outillage usuel: Herramientas comerciales:
Compression tester __________ 8005 Compressiomètre ___________ 8005 Compresímetro _____________ 8005
Torx tool kit ________________ 8189 Jeu d’outils Torx ____________ 8189 Juego de herramientas Torx ___ 8189
Special tools required: Outil spécial: Herramientas especiales:
Connector ______________ 100 120 Pièce de raccordement ____ 100 120 Pieza de empalme ________ 100 120
Special wrench Clé spéciale pour Llave especial para
for injection line __________ 110 490 conduite d’injection _______ 110 490 tubo de inyección ________ 110 490
Injectors have been removed, valve Les injecteurs ont été déposés et le Los inyectores están desmontados y
clearance has been checked. jeu des soupapes contrôlé. el juego de válvulas está controlado.
1. Insert connector with new special 1. Mettre en place la pièce de 1. Introducir la pieza de empalme con
2 seal. raccordement avec un joint spécial la junta especial nueva.
neuf.
2. Fit clamping pad. Tighten bolt. 2. Placer la griffe de serrage et serrer 2. Colocar la garra de sujeción.
le boulon. Apretar el tornillo.
3. If necessary, screw on adapter for 3. Si nécessaire mettre en place 3. De ser necesario, enroscar el
connector. l’adaptateur de la pièce de adaptador para la pieza de
raccordement. empalme.
2.00.03
Kompressionsdruck Prüfen und Einstellen
Compression pressure Checking and adjusting
Taux de compression Contrôle et réglage
Presión de compresión Verificación y ajustes
Handelsübliche Werkzeuge:
Kompressionsdruckprüfer ___________ 8005

Torx-Werkzeugsatz ________________ 8189
Spezialwerkzeuge:
Anschlußstück _________________ 100 120

Spezialschlüssel für Einspritzleitung __ 110 490
Einspritzventile sind ausgebaut, Ventilspiel

ist kontrolliert. 4
1. Anschlußstück mit neuer Spezialdichtung
einsetzen. 7 2
0
2. Spannpratze aufsetzen. Schraube festdrehen.

4
3. Falls notwendig Adapter für Anschlußstück

aufschrauben. 4
2.00.03
Contrôle et réglage Taux de compression
4. Kompressionsdruckprüfer anschließen.
4 Motor mit Starter durchdrehen.
Kompressionsdruck:
6 F 1011 F
BF 1011 F
25-30 bar
22-27 bar
Der gemessene Kompressionsdruck ist abhän-

9 gig von der Anlaßdrehzahl während des Meß-
vorganges und der Höhenlage des Motorauf-
2 5 stellortes.
Grenzwerte sind daher nicht genau festlegbar.
Empfohlen wird die Kompressionsdruckmessung
nur als Vergleichsmessung aller Zylinder eines
Motors untereinander anzusehen. Sind mehr als
15% Abweichung ermittelt worden, sollte durch
die Demontage der betroffenen Zylindereinheit
die Ursache ermittelt werden.
Hinweis: Einspritzventil mit neuer Spezialdich-

tung einsetzen und festdrehen.
Anziehvorschrift: 21 Nm
Einspritzleitungen festdrehen.
Anziehvorschrift: 22 + 2 Nm
Die Leckölleitung ist grundsätzlich zu erneuern.
2.00.04
Taux de compression Contrôle et réglage
4. Connect compression tester. Turn 4. Brancher le compressiomètre. 4. Conectar el compresímetro. Girar el

engine with starter. Virer le moteur au démarreur motor con ayuda del arrancador.
Compression pressure: Pression de compression Presión de compresión:
F engine 25-30 bar Moteur F 25-30 bars Motor F 25 - 30 bar
BF engine 22-27 bar Moteur BF 22-27 bars Motor BF 22 - 27 bar
The measured compression pressure Le taux de compression mesuré El valor de compresión medido
is dependent on the starting speed dur- dépend de la vitesse de démarrage depende de la velocidad de arranque
ing the measuring process and also on durant le relevé des mesures, et de durante la medición y de la altitud del
the altitude of the engine site. There- l’altitude du lieu d’implantation du lugar de instalación del motor.
fore it is difficult to specify precise moteur. Por tanto, no es posible fijar valores 2
limit values. It is recommended to use Des valeurs limites précises ne límite exactos. La medición de
the compression pressure measure- peuvent donc pas être fixées. Il est compresión se aconseja solamente
ment only for comparison of compres- conseillé de considérer la mesure du como una medida de comparación
sion pressures of all cylinders in one taux de compression uniquement entre todos los cilindros de un mismo
engine. If a difference in pressure in comme mesure comparative pour tous motor. Si se verifican diferencias
excess of 15 % is determined, the les cylindres d’un moteur. En cas superiores al 15%, es conveniente
cylinder unit concerned should be d’écart supérieur à 15 %, la cause buscar la causa, desmontando la
dismantled to establish the cause. pourra être déterminée en démontant unidad de cilindro afectada.
l’unité cylindre concernée.
Note: Fit injector with new special seal Nota: monter l’injecteur avec un joint Nota: Montar el inyector con una junta
and tighten. spécial et serrer. especial nueva y apretar.
Tightening specification: 21 Nm Consigne de serrage: 21 Nm. Prescripción de apriete: 21 Nm.
Tighten injection lines. Serrer les tuyauteries d’injection. Apretar las tuberías de inyección.
Tightening Consigne Prescripción

specification: 22 + 2 Nm de serrage 22 + 2 Nm. de apriete: 22 + 2 Nm.
The leakage fuel line must always be Toujours remplacer la tubulure de La tubería de combustible sobrante
renewed. retour de fuites. deberá ser sustituida, en todos los
casos, por otra nueva.
2.00.04
Prüfen und Einstellen Einspritzventil
Checking and adjusting Injector
Contrôle et réglage Soupape injectrice
Verificación y ajustes Inyector
Nozzle tester _______________ 8008 Banc d’essais d’injecteurs _____ 8008 Comprobador para inyectores __ 8008
Long socket a/flats 15 ________ 8021 Clé à douille longue de 15 _____ 8021 Llave de vaso largo de 15 _____ 8021
Special tool required: Outillage spécial: Herramientas especiales:
Retainer for injector _______ 110 110 Dispositif d’immobilisation Soporte de inyectores _____ 110 110
pour injecteur ___________ 110 110
Note: Utmost cleanliness must be en- Nota: tous les travaux à effectuer sur Nota: Al trabajar en el equipo de
sured when working on the in- les injecteurs doivent être inyección, se deberá observar
jection equipment. For testing réalisés dans de parfaites máxima limpieza. Para la prueba
the injector use only pure test oil conditions de propreté. Pour de los inyectores sólo se
2 to ISO 4113 or clean diesel fuel. contrôler les injecteurs n’utiliser utilizará aceite de ensayo puro
que du gazole d’essai pur selon según ISO 4113 o combustible
ISO 4113 ou du combustible diesel limpio.
diesel parfaitement propre.
Caution! Attention! Atención:
Beware of injection nozzle fuel jet. The Tenir les mains à l’écart des jets de No acercar nunca las manos a los
fuel penetrates deeply into the skin gazole, la force de pénétration de ceux- chorros del inyector, pues el
tissue and may cause blood poisening. ci est telle qu’ils peuvent créer des combustible se introduce en la carne y
blessures graves et amener un destruye los tejidos. Si llega a la
empoisonnement du sang. sangre, produce grave intoxicación.
1. Connect injector to nozzle tester. 1. Monter l’injecteur sur la pompe 1. Empalmar el inyector al
d’essais d’injecteurs. comprobador.
2. Checking opening pressure 2. Contrôle de la pression d’ouverture 2. Comprobación de la presión

de apertura
With pressure gauge switched on, Le manomètre étant branché, Con el manómetro conectado,
slowly press down lever of nozzle appuyer lentement sur le levier de empujar la palanca del
tester. The pressure at which the la pompe d’essai d’injecteurs. La comprobador lentamente hacia
gauge pointer stops or suddenly pression à laquelle l’aiguille s’arrête abajo. La presión a la que la aguja
drops, is the opening pressure. ou chute brusquement, est la se detiene o cae repentinamente, es
pression maxi ou pression la presión de apertura.
d’ouverture. Presión de apertura para el nuevo
Opening pressure for initial setting: Valeur de contrôle de pression ajuste en motores:
Genset engines = 250 + 8 bar d’ouverture pour nouveau tarage : para grupos
Automotive engines = 210 + 8 bar Moteurs de groupe: 250 + 8 bars electrógenos = 250 + 8 bar.
Moteurs de véhicule: 210 + 8 bars para vehículos = 210 + 8 bar.
2.00.05
Einspritzventil Prüfen und Einstellen
Injector Checking and adjusting
Soupape injectrice Contrôle et réglage
Inyector Verificación y ajustes
Düsenprüfgerät ____________________ 8008

5
Lange Stecknuß SW 15 ______________ 8021
Spezialwerkzeug:
Halter für Einspritzventil __________ 110 110
Hinweis: Bei Arbeiten an der Einspritzausrüstung

auf größte Sauberkeit achten. Zur
Prüfung der Einspritzventile nur rei-
nes Prüföl nach ISO 4113 oder saube-
ren Dieselkraftstoff verwenden. 2
Achtung !
Hände weg vom Düsenstrahl. Der Kraftstoff

e
dringt tief in das Fleisch ein und kann zur Blut-
vergiftung führen. 4
1. Einspritzventil an das Düsenprüfgerät an-
bauen.
2. Prüfung des Öffnungsdruckes
Hebel des Düsenprüfgerätes bei zugeschal-

6
tetem Manometer langsam niederdrücken.
Der Druck bei dem der Zeiger stehen bleibt
oder plötzlich abfällt, ist der Öffungsdruck.
Öffnungsdruck für die Neueinstellung:

Aggregat - Motoren = 250 + 8 bar
Fahrzeug - Motoren = 210 + 8 bar
2.00.05
3. Einstellen des Öffnungsdruckes am

1 Einspritzventil
7 Überwurfmutter abschrauben, alle Teile aus-

bauen.
Folge der Einzeldemontage

8 1. Überwurfmutter
2. Einspritzdüse
2 r 3. Zwischenstück
4. Druckbolzen
5. Druckfeder
6. Ausgleichscheiben
4. Durch Auswahl der erforderlichen Scheibe

6 Druck einstellen. Stärkere Scheibe ergibt hö-
heren Öffnungsdruck. Einspritzventil zusam-
menbauen. Überwurfmutter festdrehen.
Einspritzventil auf dem Düsenprüfgerät er-

neut prüfen.
5. Prüfung auf Dichtheit

6 Düse und Düsenhalter abtrocknen - mit Luft
trockenblasen. Handhebel des Prüfgerätes
langsam niederdrücken, bis ca. 20 bar un-
terhalb des vorher abgelesenen Öffnungs-
druckes erreicht werden.
2.00.06
3. Adjusting the opening pressure on 3. Tarage de la pression d’ouverture 3. Ajuste de la presión de apertura
the injector sur injecteur en el inyector
Unscrew cap nut and remove Dévisser l’écrou-raccord et déposer Desenroscar la tuerca de unión y
all parts toutes les pièces. desmontar todas las piezas.
Sequence of parts disassembly Suite du démontage des pièces Secuencia del despiece
1. Cap nut 1. Ecrou-raccord 1. Tuerca de unión

2. Injection nozzle 2. Injecteur 2. Inyector propiamente dicho
3. Adapter 3. Pièce intermédiaire 3. Pieza intermedia 2
4. Thrust pin 4. Tige poussoir 4. Perno de presión
5. Compression spring 5. Ressort de pression 5. Muelle de presión
6. Shims 6. Rondelles d’épaisseur 6. Arandelas de reglaje
4. Adjust pressure by selecting appro- 4. Régler la pression en prenant le 4. Ajustar la presión eligiendo la
priate shim. A thicker shim in- nombre de rondelles nécessaires. arandela adecuada. Una arandela
creases the opening pressure. Re- Des rondelles plus épaisses más gruesa da una presión de
assemble injector. Tighten cap nut. entraînent une pression d’ouverture apertura más elevada. Rearmar el
plus grande. Remonter l’injecteur inyector. Apretar la tuerca de unión.
et serrer l’écrou-raccord.
Prescripción
Tightening specification: 45 ± 5 Nm Consigne de serrage: 45 ± 5 Nm de apriete: 40 ± 5 Nm.
Recheck injector on nozzle tester. Contrôler à nouveau l’injecteur Volver a ensayar el inyector sobre
à l’aide de la pompe d’essai el comprobador.
d’injecteurs.
5. Checking for tightness 5. Contrôle de l’étanchéité 5. Comprobación de estanqueidad
Dry nozzle and nozzle holder - blow Sécher l’injecteur et le porte- Secar el inyector y el portainyector,
out with compressed air. Press injecteur par jet d’air. Appuyer soplándolos con aire comprimido.
down handlever of nozzle tester lentement sur le levier de la pompe Empujar la palanca de mano del
slowly until a pressure of about d’essai jusqu’à obtention d’environ comprobador lentamente hacia
20 bar below the previous opening 20 bars en-dessous de la pression abajo hasta alcanzar un valor de
pressure reading is attained. d’ouverture lue auparavant. aprox. 20 bar por debajo de la
presión de apertura leída
previamente.
2.00.06
6. Nozzle is tight if there is no 6. L’injecteur est étanche lorsqu’il ne 6. El inyector es estanco si, pasados
dripping within a period of 10 goutte plus durant 10 secondes. 10␣ segundos, no sale ni una gota
seconds. de líquido.
7. In case of a drip, the injector must 7. Si l’injecteur goutte, le déposer et le 7. Si cae una gota, el inyector debe
be dismantled and cleaned to reme- nettoyer pour supprimer le manque ser desarmado y limpiado para
dy the leak. If this does not cure the d’étanchéité. En cas d’échec, eliminar la falta de estanqueidad. Si
leak, the injector must be replaced. remplacer l’injecteur. esto no surte efecto, es necesario
2 reemplazar el inyector.
Reworking is not permissible. Ne jamais rectifier l’injecteur. No están permitidos trabajos de

repaso.
8. Buzzing and spray pattern test 8. Contrôle du crissement 8. Comprobación del ronquido y
caractéristique de l’injecteur chorro
Switch off pressure gauge of tester. Débrancher le manomètre de la Desconectar el manómetro del
pompe d’essai. comprobador.
The buzzing test permits an audible Le contrôle du crissement permet La comprobación del ronquido
check of the ease of movement of un contrôle audible de l’injecteur permite controlar acústicamente la
the nozzle needle in the nozzle dont l’aiguille doit retomber d’elle- facilidad de movimiento de la aguja
body. New injectors emit a differ- même dans son logement. Les dentro del cuerpo del inyector.
ent buzzing sound as compared to injecteurs neufs présentent par Inyectores nuevos tienen un
used injectors. It deteriorates due rapport aux injecteurs usagés un ronquido diferente de los usados.
to wear in the needle seat area. If crissement différent. L’usure se El desgaste en la zona de asiento
an injection nozzle does not buzz produisant au niveau du siège de de la aguja lo empeora. Si el
despite cleaning, it must be l’aiguille entraîne une dégradation inyector no produce el ronquido
renewed. du crissement. Si, après nettoyage, característico del mismo a pesar de
l’injecteur refuse de crisser, il faut su limpieza anterior, es necesario
le remplacer. sustituirlo por otro nuevo.
A used injector should buzz clearly Un injecteur usagé doit, après Un inyector usado tiene que roncar
during rapid actuation of the actionnement rapide du levier de de forma audible y producir un
handlever, while exhibiting a well commande, émettre un crissement chorro bien pulverizado si se
atomized spray pattern. The spray audible et pulvériser de manière acciona la palanca rápidamente. La
pattern may differ noticeably from bien homogène. La forme du jet forma del chorro puede diferir, en
that of a new injector. peut alors, à la différence d’un tal caso, claramente de la
injecteur neuf, être tout à fait producida por un inyector nuevo.
différente.
2.00.07
6. Düse ist dicht, wenn innerhalb 10 Sekunden

kein Tropfen abfällt.
9
7. Fällt ein Tropfen ab, ist das Einspritzventil zu

zerlegen und die Undichtigkeit durch Reini-
gen zu beseitigen. Ist das nicht erfolgreich,
9
muß die Einspritzdüse erneuert werden.
2
Nacharbeit ist nicht zulässig.
8. Schnarr- und Strahlprüfung
Manometer des Prüfgerätes abschalten.

9
Die Schnarrprüfung ermöglicht eine hörbare
Prüfung der Leichtgängigkeit der Düsen-
nadel im Düsenkörper. Neue Einspritzventile
haben gegenüber gebrauchten ein geänder-
tes Schnarrverhalten.
Durch Verschleiß im Nadelsitzbereich ver-
schlechtert es sich. Schnarrt eine Einspritz-
düse trotz Reinigung nicht, muß sie durch
eine neue ersetzt werden.
Ein gebrauchtes Einspritzventil muß bei

schneller Hebeltätigkeit hörbar schnarren
und dabei gut zerstäubt abspritzen. Das
Strahlbild kann dabei gegenüber dem eines
neuen Einspritzventils deutlich unterschied-
lich sein.
2.00.07
Prüfen und Einstellen Einspritzpumpe
Checking and adjusting Injection pump
Contrôle et réglage Pompe d'injection
Verificación y ajustes Bomba de inyección
Commercial tool required: Outillage usuel: Herramienta comercial:

Injection pump tester _________ 8006 Appareil de contrôle de la pompe Comprobador de bombas
d’injection _________________ 8006 de inyección _______________ 8006
Special tool required: Outillage spécial: Herramienta especial:

Special wrench Clé spéciale pour Llave especial para
for injection line __________ 110 490 conduite d’injection ________ 110490 tuberías de inyección ______ 110 490
The following inspection for injection Dans le cas des pompes à injection portant Si se tatra de bombas de inyección con el
pumps with parts no 0417 9573 and le numéro de pièce 0417 9573 et 0417 9981 N° de pieza 0417 9573 y 0417 9981 (con
0417 9981 (with con-stant pressure (avec soupape de pression constante), il est válvula de presión constante) no es posible
valve). impossible d’effecteur le contrôle décrit ciaprès. Ilevar a cabo la siguiente prueba.
The injection pump is tested on the engine Le contrôle de la pompe d’injection se fait sur La bomba de inyección es ensayada sobre el
to make sure that the delivery valve and le moteur même au niveau de l’étanchéité de motor en cuanto a estanqueidad de la válvula
pump element are not leaking. For the test, la soupape de refoulement et de l’élément de de presión y del elemento de bomba.
it is essential that the fuel feed system is pompe. Ce contrôle suppose une alimentation Condición previa para la comprobación es
operating properly and that there is no air en combustible irréprochable et l’absence que el abastecimiento del combustible sea
in the fuel system. d’air dans le système d’injection. impecable y no exista aire en el sistema de
combustible.
2
Injection lines have been removed. Les conduites d’injection sont Las tuberías de inyección están
déposées. desmontadas.
1. Connect injection pump tester to 1. Raccorder l’appareil de contrôle de 1. Conectar el comprobador de

delivery valve holder. la pompe d’injection au support de bombas de inyección al soporte de
la soupape de refoulement. la válvula de presión.
2. Turn crankshaft via V-belt pulley, 2. Virer le vilebrequin par la poulie à 2. Girar el cigüeñal a través de la
while bleeding tester at the screw gorge et purger l’appareil de polea de correa trapezoidal,
plug. contrôle par le bouchon obturateur. purgando de aire el comprobador
en el tapón roscado.
3. Turn crankshaft until a pressure of 3. Virer le vilebrequin jusqu’à 3. Girar el cigüeñal hasta que la
150 bar is applied to the delivery obtention d’une pression de 150 válvula de presión cuente con una
valve. The pressure may drop by 10 bars à la soupape de refoulement. presión de 150 bar, admitiéndose
bar within one minute. Cette pression peut tomber de 10 una caída de presión de 10 bar
bars en l’espace d’une minute. dentro de un minuto.
2.00.09
Einspritzpumpe Prüfen und Einstellen
Injection pump Checking and adjusting
Pompe d'injection Contrôle et réglage
Bomba de inyección Verificación y ajustes
Handelsübliches Werkzeug:
Einspritzpumpenprüfgerät ___________ 8006
Spezialwerkzeug:
Bei Einspritzpumpen mit Teile-Nr. 0417 9573

und 0417 9981 (mit Gleichdruckventil) ist fol-
gende Prüfung nicht möglich.
Die Einspritzpumpe wird am Motor auf Dicht-
heit des Druckventils und Pumpenelementes
geprüft. Voraussetzung für die Prüfung ist ein-
wandfreie Kraftstoffversorgung und keine Luft
im Kraftstoffsystem.
Einspritzleitungen sind abgebaut.
1. Einspritzpumpenprüfgerät am Druckventil-
4
halter anschließen.
2
2. Kurbelwelle über die Keilriemenscheibe

durchdrehen, dabei das Prüfgerät an dem
Verschlußstopfen entlüften.
d
3. Kurbelwelle durchdrehen, bis das Druck-

ventil mit einem Druck von 150 bar beauf-
schlagt ist. Der Druck darf in einer Minute
6
um 10 bar abfallen.
2.00.09
Prüfen und Einstellen Einspritzpumpe
Checking and adjusting Injection pump
Contrôle et réglage Pompe d'injection
Verificación y ajustes Bomba de inyección
4. Kurbelwelle um 5 Umdrehungen weiter

6 durchdrehen, dabei müssen 300 bar erreicht
werden. Ist der Sollwert nicht erreichbar,
Einspritzpumpe austauschen.
5. Einspritzpumpenprüfgerät abbauen.
3
2
6. Einspritzleitungen anbauen und festdrehen.

4 Anziehvorschrift: 22 + 2 Nm
7
6
7. Luftführungshaube anbauen. Schrauben

4 festdrehen.
2.00.10
Einspritzpumpe Prüfen und Einstellen
Injection pump Checking and adjusting
Pompe d'injection Contrôle et réglage
Bomba de inyección Verificación y ajustes
4. Turn crankshaft further by 5 revolu- 4. Continuer à virer le vilebrequin de 5 4. Seguir girando el cigüeñal unas 5
tions until a pressure of 300 bar is tours jusqu’à obtention de 300 bars. vueltas más, debiéndose alcanzar
attained. If the specified value Si cette valeur de consigne ne peut 300 bar. Si no se puede alcanzar el
cannot be reached, replace the pas être atteinte, remplacer la pompe valor prescrito, hay que sustituir la
injection pump. d’injection. bomba de inyección por otra nueva.
5. Remove injection pump tester. 5. Démonter l’appareil de contrôle de 5. Desmontar el comprobador de

la pompe d’injection. bombas de inyección.
6. Fit injection lines and tighten. 6. Monter les conduites d’injection et 6. Montar las tuberías de inyección y
serrer. apretar.

specification: 22 + 2 Nm de serrage 22 + 2 Nm. de apriete: 22 + 2 Nm
7. Fit air cowling. Tighten bolts. 7. Monter la hotte de guidage d’air 7. Montar la manga guía de aire.
puis serrer les vis. Apretar los tornillos.
2.00.10
2

Reparación de componentes 1011 F
Inhalts-Verzeichnis Bauteile instand setzen
Table of Contents Repair of components
Sommaire Mise en état des composants
Indice Reparación de componentes
Deutsch
3. Bauteile instand setzen
Baugruppe Benennung Seite

01 Zylinderkurbelgehäuse 3.01.01 - 3.01.12
01 Hinterer Deckel 3.01.17 - 3.01.18
05 Kurbelwelle 3.05.23 - 3.05.24
05 Starterkranz / Schwungrad 3.05.29
06 Pleuelstange 3.06.33 - 3.06.37
07 Kolben 3.07.41 - 3.07.43
08 Zylinderkopf 3.08.47 - 3.08.52
10 Nockenwelle 3.10.57
11 Kipphebelbock 3.11.61
19 Einspritzventil 3.19.65 - 3.19.67
27 Vorderer Deckel 3.27.71 - 3.27.86
39 Kühlgebläse 3.39.91 - 3.39.96
39 Keilriemenpannrolle 3.39.101
39 Lüfterantrieb 3.39.105 - 3.39.109
83 Hydraulikpumpenkonsole 3.83.113 - 3.83.117
English
3. Repair of components 3
Assembly Group Description Page
01 Crankcase with integrated cylinder liners 3.01.01 - 3.01.12
01 Rear cover 3.01.17 - 3.01.18
05 Crankshaft 3.05.23 - 3.05.24
05 Starter ring gear / flywheel 3.05.29
06 Connecting rod 3.06.33 - 3.06.37
07 Piston 3.07.41 - 3.07.43
08 Cylinder head 3.08.47 - 3.08.52
10 Camshaft 3.10.57
11 Rocker arm bracket 3.11.61
19 Injector 3.19.65 - 3.19.67
27 Front cover 3.27.71 - 3.27.86
39 Blower 3.39.91 - 3.39.96
39 Idler pulley 3.39.101
39 Fan drive 3.39.105 - 3.39.109
83 Hydraulic pump bracket 3.83.113 - 3.83.117
Bauteile instand setzen Inhalts-Verzeichnis
Repair of components Table of Contents
Mise en état des composants Sommaire
Reparación de componentes Indice
Français
3. Mise en état des composants
Groupe Désignation Page

01 Bloc moteur 3.01.01 - 3.01.12
01 Couvercle arriére 3.01.17 - 3.01.18
05 Vilebrequin 3.05.23 - 3.05.24
05 Couronne du volant / volant 3.05.29
06 Bielle 3.06.33 - 3.06.37
07 Piston 3.07.41 - 3.07.43
08 Culasse 3.08.47 - 3.08.52
10 Arbre à cames 3.10.57
11 Support de culbuteurs 3.11.61
19 Injecteur 3.19.65 - 3.19.67
27 Couvercle avant 3.27.71 - 3.27.86
39 Turbine de refroidissement 3.39.91 - 3.39.96
39 Galet tendeur 3.39.101
39 Entraînement ventilateur 3.39.105 - 3.39.109
83 Console de pompe hydraulique 3.83.113 - 3.83.117
Español
3 3. Reparación de componentes
Grupo de construcción Denominación Página

01 Bloque de cilindros 3.01.01 - 3.01.12
01 Tapa trasera 3.01.17 - 3.01.18
05 Cigüeñal 3.05.23 - 3.05.24
05 Corona del volante / volante 3.05.29
06 Biela 3.06.33 - 3.06.37
07 Pistón 3.07.41 - 3.07.43
08 Culata 3.08.47 - 3.08.52
10 Arbol de levas 3.10.57
11 Soporte de balancines 3.11.61
19 Inyector 3.19.65 - 3.19.67
27 Tapa frontal 3.27.71 - 3.27.86
39 Ventilador de refrigeración 3.39.91 - 3.39.96
39 Polea tensora 3.39.101
39 Accionamiento del ventilador 3.39.105 - 3.39.109
83 Soporte de la bomba hidráulica 3.83.113 - 3.83.117
Zylinderkurbelgehäuse Bauteile instand setzen
Crankcase with integrated cylinder liners Repair of components
Bloc moteur Mise en état des composants
Bloque de cilindros Reparación de componentes
3
Bauteile instand setzen Zylinderkurbelgehäuse
Repair of components Crankcase with integrated cylinder liners
Mise en état des composants Bloc moteur
Reparación de componentes Bloque de cilindros

Screw driver socket __________ 8112 Embout de tournevis _________ 8112 Punta recambiable de
Internal dial gauge Appareil de mesure destornillador ______________ 8112
Micrómetro de interiores
Special tools required: Outillage spécial: Herramientas especiales:

Assembly tool for Outil de montage pour douille de Herramienta de montaje para
control rod bush _________ 110 140 crémaillère ______________ 110 140 manguitos de cremallera ___ 110 140
Assembly tool for Outil de montage pour Herramienta de montaje para
camshaft bush ___________ 143 820 bague d’arbre à cames ____ 143 820 casquillos de árbol de levas _ 143 820
Puller for pipe ___________ 150 140 Extracteur de tube ________ 150 140 Extractor para tubos ______ 150 140
Assembly arbor for pipe ___ 150 150 Mandrin de montage Mandril de montaje
pour tube _______________ 150 150 para tubos ______________ 150 150
1. Clean crankcase and inspect for 1. Nettoyer le bloc moteur et contrôler 1. Limpiar el bloque motor y
damage. visuellement s’il ne présente pas de examinarlo visualmente en cuanto
détérioration. a daños.
Note: Prior to measurement tighten Nota: avant de procéder au relevé des Nota: Antes de proceder a la medición
main bearing caps as specified. mesures serrer les chapeaux de es necesario apretar las tapas de
paliers de vilebrequin selon les los cojinetes del cigüeñal según
préconisations de serrage. prescripción.
Tightening specification: Consigne de serrage: Prescripción de apriete:

Initial tightening torque 50 Nm Valeur de préserrage: 50 Nm Apriete inicial 50 Nm
1st tightening angle 60° Valeur de Reapriete1ª fase 60°
2nd tightening angle 45° serrage à l’angle: 1re phase: 60° 2ª fase 45°
2e phase: 45°
3 2. Set internal dial gauge to 91 mm. 2. Régler l’appareil de mesure à 91 2. Ajustar el micrómetro de interiores
mm. a 91␣ mm.
3. Gauge cylinders. 3. Effectuer un relevé des cotes du 3. Medir los cilindros -

cylindre
Cylinder bore: 91+ 0.02 mm Alésage du cylindre: 91+ 0,02 mm calibre de cilindro: 91+ 0,02 mm
Wear limit: 91.1 mm Limite d’usure: 91,1 mm límite de desgaste: 91,1 mm
3.01.01
Schraubendrehereinsatz _____________ 8112
Innenmeßgerät
Spezialwerkzeuge:
Montagewerkzeug für
Regelstangenbuchse _____________ 110 140
Nockenwellenbuchse _____________ 143 820
Ausziehwerkzeug für Rohr _________ 150 140
Montagedorn für Rohr ____________ 150 150
1. Kurbelgehäuse reinigen und auf Beschädi-

gung sichtprüfen.
9
Hinweis: Vor der Messung sind die Kurbelwel-
lenlagerdeckel nach Anziehvorschrift 5
festzudrehen.
Anziehvorschrift:
Vorspannwert 50 Nm
Nachspannwinkel 1. Stufe 60°
2. Stufe 45°
2. Innenmeßgerät auf 91 mm einstellen.

6
3
3. Zylinder messen-
Zylinderbohrung: 91 + 0,02 mm
6
Verschleißgrenze: 91,1 mm
3.01.01
3.1 - in der Motorlängsachse „a“ und Motor-

9 quer-achse „b“
95-3.4
3.2 - und in der Ebene 1-3.

9
4. Bei verschlissener Zylinderlaufbahn besteht

9 die Möglichkeit in unseren Service-Centern
ein aufgebohrtes mit neuen Laufbuchsen
3 (Slipfit-Buchsen) ausgerüstetes Zylinder-
kurbelgehäuse zu beziehen.
5. Bei Vorhandensein der Slipfit-Buchsen im

1 Zylinderkurbelgehäuse
-Slipfit-Buchsen herausziehen.
3.01.02
3.1 - in the engine’s longitudinal axis 3.1. dans l’axe longitudinal „a“ et dans 3.1 -␣ en los ejes longitudinal „a““ y
„a“ and transverse axis „b“ l’axe transversal „b“ transversal „b“ del motor.
3.2 - and in planes 1-3. 3.2 et sur le plan 1-3. 3.2 - y en los planos 1-3.
4. If the cylinder working surfaces 4. Lorsque la surface de frottement 4. Si la superficie de roce del cilindro
are worn out, it is possible to du cylindre est usée, il est possible está desgastada, existe la
obtain from our Service Centers a de se procurer, en s’adressant à posibilidad de aquirir, en nuestros
rebored crankcase with new liners nos Service Centers, un bloc Centros de Servicio, un bloque 3
(slip fit liners). moteur alésé avec chemises motor con los cilindros
neuves (chemises dites slipfit). mandrinados y equipados con
nuevas camisas (slipfit).
5. If slip fit liners are installed, pull 5. En présence de chemises slipfit 5. Si el bloque de cilindros lleva
them out. dans le bloc moteur camisas slipfit,
- retirer ces dernières. -␣ sacar estas camisas.
3.01.02
6. Inspect receiving bores and liner 6. Contrôle visuel des alésages de 6. Examinar visualmente los
seating surface. positionnement et de la collerette alojamientos de las camisas y el
d’appui. asiento para el reborde de las
mismas.
7. Press in new slip fit liners as far as 7. Enfoncer les chemises neuves 7. Introducir a presión, hasta el tope,
they will go. slipfit jusqu’en position de butée. las camisas slipfit nuevas.
Note: To be used only with new Nota: utilisation prévue uniquement Nota: Se admite su uso tan sólo en
standard pistons. avec des pistons de série. conjunto con los pistones
nuevos de serie.
If the measured data correspond to Si le relevé des cotes des chemises Si los valores medidos de las camisas
the values specified for the liners, the correspond aux valeurs indiquées, au corresponden a los especificados, se
crankcase may be repaired as besoin remettre en état le bloc reacondicionará el bloque de cilindros
3 necessary. moteur. en la medida necesaria.
8. Remove screw plugs. Check oil 8. Dévisser les vis filetées. Vérifier si 8. Desenroscar los tapones de cierre.
ducts for free passage. les canalisations d’huile ne sont Comprobar si los conductos de
pas obstruées. aceite están despejados.
3.01.03
6. Aufnahmebohrungen und Bundauflage

sichtprüfen.
9
7. Neue Slipfit-Buchsen bis Anlage eindrücken.
Hinweis: Verwendung nur mit neuen Serienkol-

2
ben.
5
Entsprechen die Messungen der Laufbuchsen

den angegebenen Werten, ist nach Bedarf das
Zylinderkurbelgehäuse instandzusetzen.
1
9 3
8. Verschlußschrauben herausschrauben. Ölka-
näle auf freien Durchlaß prüfen.
95-3.10
3.01.03
Nockenwellenlagerbuchsen
6 9. Innenmeßgerät auf 54 mm einstellen.
10. Schema zum Vermessen der Lagerbuchsen

9 an den Punkten 1 und 2 in der Ebene "a" und
"b".
95-3.12
11. Lagerbuchsen messen, ggf. auswechseln.

6 Nockenwellenlagerbuchse
3
Innendurchmesser: 54 + 0,054 mm
12. Lagerbuchsen ausbauen.

1
7
3.01.04
Camshaft bearing bushes Bagues de paliers d’arbre à cames Casquillos del árbol de levas
9. Set internal dial gauge to 54 mm. 9. Régler l’appareil de mesure 9. Ajustar el micrómetro de interiores
à 54 mm. a 54␣ mm.
10. Schematic for gauging the bearing 10. Schéma de relevé des mesures 10. Esquema para efectuar la medición
bushes at points 1 and 2 in planes des bagues de paliers aux points 1 de los casquillos de soporte en los
„a“ and „b“. et 2 dans l’axe „a“ et „b“. puntos 1 y 2 de los planos „a“ y „b„.
11. Gauge bearing bushes, renew if 11. Faire un relevé des cotes des 11. Verificar las medidas de los
necessary. bagues de palier, les remplacer le casquillos, sustituyéndolos en
cas échéant. caso necesario.
3
Camshaft bearing bush Bague de palier d’arbre à cames Casquillo del árbol de levas
Inner diameter: 54 + 0.054 mm Diamètre intérieur: 54 + 0,054 mm Diámetro interior: 54 + 0,054 mm

Wear limit:^ 54.080 mm Limite d’usure: 54,080 mm Límite de desgaste: 54,080 mm
12. Remove bearing bushes. 12. Déposer les bagues de palier. 12. Desmontar los casquillos.
3.01.04
13. Schematic: Installation dimensions 13. Schéma: cotes d’insertion des 13. Esquema: Medidas de
of bearing bushes. bagues de paliers. introducción de los casquillos.
A B A B A B
2-Cyl. 2.5 mm 0.5 mm 2 cyl. 2,5 mm 0,5 mm 2 cil. 2,5 mm 0,5 mm
117.1 mm 117,1 mm 117,1 mm
3-Cyl. 2.5 mm 0.5 mm 3 cyl 2,5 mm 0,5 mm 3 cil. 2,5 mm 0,5 mm
118.9 mm 117.1 mm 118,9 mm 117,1 mm 118,9 mm 117,1 mm
118.9 mm 117.1 mm 118,9 mm 117,1 mm 118,9 mm 117,1 mm
228.1 mm 228,1 mm 228,1 mm
14. Schematic: Installation direction of 14. Schéma: sens de montage du joint 14. Esquema: dirección de montaje de
joint in the bearing bush. de la bague de palier. la junta de tope del casquillo.
15. Position new bearing bush. 15. Placer une nouvelle bague de palier. 15. Posicionar el casquillo nuevo.
Note: Lube oil bores must be lined up. Nota: veiller à ce que les trous de Nota: Prestar atención a la coincidencia
3 graissage correspondent. de los orificios de lubricación.
16. Insert bearing bush. 16. Introduire la bague de palier. 16. Introducir el casquillo.
3.01.05
13. Schema: Einziehmaße der Lagerbuchsen.
2 Zyl.
A
2,5 mm
B
0,5 mm
9
117,1 mm
3 Zyl. 2,5 mm 0,5 mm
118,9 mm 117,1 mm
4 Zyl. 2,5 mm 0,5 mm
118,9 mm 117,1 mm
228,1 mm
95-3.15
14. Schema: Einbaurichtung der Stoßfuge in

der Lagerbuchse.
9
15. Neue Lagerbuchse ansetzen.
Hinweis: Auf Übereinstimmung der Schmieröl-

2
3
bohrungen achten.
8
5
16. Lagerbuchse einziehen.

2
7
3.01.05
Regelstange und Führungsbuchsen

1 17. Zylinderstift austreiben.
18. Regelstange mit Feder herausnehmen.

1
19. Verschlußdeckel ausbauen.

1
3
20. Rohr mit einem Bohrer ø 5,5 mm einseitig

f durchbohren.
5 Hinweis: Nach dem Bohren ist das Kurbelge-

häuse gründlich zu reinigen.
3.01.06
Control rod and guide bushes Crémaillère et douille de guidage Cremallera y manguitos de guía
17. Drive out parallel pin. 17. Chasser la goupille cylindrique. 17. Desmontar golpeando el pasador
cilíndrico.
18. Remove control rod together with 18. Retirer la crémaillère et le ressort. 18. Retirar la cremallera con resorte.
spring.
19. Remove cover. 19. Déposer le couvercle. 19. Desmontar la tapa de cierre.
20. Pierce pipe on one side with a drill 20. Percer d’un côté tube à l’aide d’un 20. Abrir un taladro en un lado del tubo
of 5.5 mm dia. foret Ø 5,5 mm. mediante un macho Ø 5,5 mm.
Note: Carefully clean crankcase after Nota: après avoir percé nettoyer Nota: Terminado el taladrado, es
drilling. soigneusement le bloc moteur. indispensable limpiar a fondo el
bloque motor.
3.01.06
21. Insert puller until pin engages in 21. Mettre en place l’outil de montage 21. Introducir el extractor hasta que el
bore. jusqu’à encrantement du boulon perno se enclave en el taladro.
dans l’alésage.
22. Position spacer bush in place. Pull 22. Mettre en place douille 22. Colocar el casquillo distanciador.
out pipe from lower press fit. d’écartement. Retirer le tube du Extraer el tubo del ajuste forzado
logement inférieur. inferior.
Note: Do not pull out pipe completely. Nota: ne pas retirer entièrement le tube. Nota: No extraer el tubo totalmente.
23. Press pin in until it does no longer 23. Enfoncer le boulon de manière à 23. Introducir a presión el perno hasta
project beyond the pipe. Now pull ce que, après contrôle visuel, il ne que ya no se vea ningún resalto en
out pipe completely. dépasse plus au niveau du tube. el tubo. Hecho esto, extraer el tubo
3 Retirer entièrement le tube totalmente.
maintenant.
24. Drive out guide bush at front end. 24. Extraire à la partie avant douille de 24. Desmontar golpeando el manguito
guidage. de guía hacia adelante.
3.01.07
21. Ausziehwerkzeug einsetzen, bis der Bolzen

in die Bohrung einrastet.
2
9
7
22. Abstandsbuchse aufsetzen. Rohr aus dem

unteren Preßsitz herausziehen. 2
Hinweis: Rohr nicht ganz herausziehen.
1
7
5
23. Bolzen soweit eindrücken, bis kein Über-

stand am Rohr sichtbar ist. Jetzt Rohr ganz
herausziehen.
1
3
9
24. Führungsbuchse vorn austreiben.

1
7
3.01.07
25. Montagedorn mit Abstandsbuchse in Zen-

2 trierung schieben.
26. Führungsbuchse auf den Montagedorn, mit

2 der Anfasung zum Kurbelgehäuse weisend,
aufsetzen.
27. Zentrierung mit Montagedorn und Führungs-

2 buchse an Kurbelgehäuse festdrehen.
28. Führungsbuchse vorn bis Anlage eintreiben.

2
3.01.08
25. Introduce assembly arbor with 25. Insérer dans centrage mandrin de 25. Introducir en el dispositivo de
spacer bush into centering. montage avec douille d’écartement. centraje el mandril de montaje con
el casquillo distanciador puesto.
26. Position guide bush on assembly 26. Placer la douille de guidage sur le 26. Colocar el manguito de guía sobre
arbor with chamfer pointing mandrin de montage en orientant el mandril, con el bisel indicando
towards crankcase. le chanfrein vers le bloc moteur. hacia el bloque motor.
27. Secure centering with assembly 27. Au niveau du bloc moteur bloquer 27. Fijar al bloque motor el dispositivo
arbor and guide bush on crankcase. centrage avec mandrin de de centraje con el mandril de
montage et douille de guidage. montaje y manguito de guía.
3
28. Drive in guide bush at front end as 28. Introduire douille de guidage AV 28. Introducir a golpes el manguito de
far as it will go. jusqu’en position de butée. guía hasta el tope.
3.01.08
29. Remove centering. 29. Déposer le centrage. 29. Desmontar el dispositivo de

centraje.
30. Drive out guide bush at flywheel 30. Côté volant moteur extraire douille 30. Desmontar golpeando el manguito
end. de guidage. de guía en el lado del volante.
31. Introduce assembly arbor without 31. Introduire dans centrage mandrin 31. Introducir en el dispositivo de
spacer bush into centering. de montage sans douille centraje el mandril de montaje sin
d’écartement. casquillo distanciador.
3
32. Position guide bush on assembly 32. Placer douille de guidage sur le 32. Colocar el manguito de guía sobre
arbor with chamfer pointing mandrin de montage en orientant el mandril, con el bisel indicando
towards crankcase. le chanfrein vers le bloc moteur. hacia el bloque motor.
3.01.09
29. Zentrierung abbauen.

1
30. Führungsbuchse schwungradseitig austrei-

ben.
1
7
31. Montagedorn ohne Abstandsbuchse in Zen-

trierung schieben.
2
3
7
32. Führungsbuchse auf den Montagedorn, mit

der Anfasung zum Kurbelgehäuse weisend,
aufsetzen.
2
8
3.01.09
33. Zentrierung mit Montagedorn und Führungs-

2 buchse an Kurbelgehäuse festdrehen.
34. Führungsbuchse schwungradseitig bis An-

2 lage eintreiben.
35. Zentrierung abbauen.

1
3
36. Neues Rohr mit Montagedorn bis Anlage

2 eindrücken.
3.01.10
33. Secure centering with assembly 33. Bloquer sur bloc moteur centrage 33. Fijar al bloque motor el dispositivo
arbor and guide bush on crankcase. avec mandrin de montage et con el mandril de montaje y
douille de guidage. manguito de guía.
34. Drive in guide bush at flywheel end 34. Insérer côté volant moteur douille 34. Introducir a golpes, hasta el tope,
as far as it will go. de guidage jusqu’en position de el manguito de guía en el lado del
butée. volante.
35. Remove centering. 35. Déposer centrage. 35. Desmontar el dispositivo de

centraje.
36. Press in new pipe with assembly 36. A l’aide du mandrin de montage 36. Introducir forzadamente, hasta el
arbor as far as it will go. introduire tube neuf jusqu’en tope, el tubo nuevo utilizando el
position de butée. mandril de montaje.
3.01.10
37. Apply locking compound DEUTZ 37. Enduire de pâte de frein DEUTZ 37. Aplicar pegamento de seguridad
DW 72 to new cover. DW 72 le couvercle neuf. DEUTZ DW 72 a la tapa de cierre
nueva.
38. Drive in cover flush with 38. Insérer le couvercle jusqu’à 38. Colocar golpeando la tapa hasta
crankcase. affleurement dans bloc moteur. que quede a ras en el bloque motor.
39. Insert control rod with starter 39. Mettre en place dans les douilles 39. Introducir la cremallera con el
spring into guide bushes. de guidage crémaillère avec resorte de arranque en los
ressort du démarreur. manguitos de guía.
3
Note: Check for free movement. Nota: veiller à ce qu’il n’y ait aucun Nota: Prestar atención a su fácil
point dur. movimiento.
40. Compress starter spring. Drive 40. Comprimer le ressort du démarreur 40. Comprimir el resorte de arranque e
parallel pin into recess for control puis insérer jusqu’à affleurement la introducir a presión en la escotadura
rod travel limitation. Check that it goupille cylindrique dans l’évidement para la limitación del recorrido de
is flush with surface. de la limite de déplacement du regulación el pasador cilíndrico
réglage. hasta que quede a ras.
3.01.11
37. Neuen Verschlußdeckel mit Sicherungsmittel

DEUTZ DW 72 bestreichen.
w
38. Verschlußdeckel bündig zum Kurbel-

gehäuse eintreiben.
2
9
39. Regelstange mit Starterfeder in die

Führungsbuchsen einsetzen. 2
3
Hinweis: Auf Leichtgängigkeit achten.
5
40. Starterfeder zusammendrücken, Zylinderstift

in die Aussparung für Regelwegbegrenzung
bündig eintreiben.
2
9
3.01.11
Kolbenkühlöldüsen
1 41. Kolbenkühlöldüsen herausdrücken.
5 Hinweis: Vor Einbau der neuen Kolbenkühlöldü-

sen müssen die Bohrungen im Zylinder-
kurbelgehäuse sauber sein.
42. Neue Kolbenkühlöldüsen bis Anlage ein-

2 drücken.
43. Verschlußschrauben festdrehen.

2 Anziehvorschrift: Pos. 5 = 50 Nm
3
6 Pos. 7 =
Pos.10 =
95 Nm
56 Nm
Pos.15 = 50 Nm
5 Pos.17 = 26 Nm
Hinweis: Nach Demontage der Pos. 5 - 17 sind

diese grundsächlich zu erneuern.
95-3.45
3.01.12
Piston cooling oil nozzles Gicleurs d’huile de refroidissement Toberas de refrigeración de pistones
des têtes de pistons
41. Press out piston cooling oil 41. Extraire les gicleurs d’huile. 41. Desmontar a presión las toberas
nozzles. de refrigeración de pistón.
Note: Before installing new piston Nota: avant de monter les nouveaux Nota: Los orificios existentes en el
cooling oil nozzles, check that gicleurs d’huile veiller à ce que bloque motor deben estar
the bores in the crankcase are l’alésage se trouvant dans le limpios antes de montar las
clean and free of oil. bloc moteur soit parfaitement toberas nuevas.
propre.
42. Press in new piston cooling oil 42. Visser les nouveaux gicleurs 42. Introducir a presión, hasta el tope,
nozzles as far as they will go. d’huile jusqu’en position de butée. las toberas nuevas.
43. Tighten screw plugs. 43. Bloquer les vis filetées. 43. Apretar los tapones de cierre.
Tightening specification: Consigne de serage: Prescripción de apriete:

Item 5 = 50 Nm rep. 5 = 50 Nm. No. 5 = 50 Nm 3
Item 7 = 95 Nm rep. 7 = 95 Nm. No. 7 = 95 Nm
Note: Always renew items 5 - 17 after Nota: après leur démontage toujours Nota: Tras cada desmontaje de los
removal. renouveller les vis des rep. 5 à tapones Nos. 5␣ -␣ 17, es
17. necesario reemplazarlos por
otros nuevos.
3.01.12
Bauteile instand setzen Vorderer Deckel
Repair of components Front cover
Mise en état des composants Couvercle avant
Reparación de componentes Tapa delantera
3
Hinterer Deckel Bauteile instand setzen
Rear cover Repair of components
Couvercle arrière Mise en état des composants
Tapa trasera Reparación de componentes
3
Bauteile instand setzen Hinterer Deckel
Repair of components Rear cover
Mise en état des composants Couvercle arrière
Reparación de componentes Tapa trasera
Special tool required: Outil spécial Herramienta especial:
Assembly tool ___________ 142 860 Outil de montage _________ 142 860 Herramienta de montaje ___ 142 860
1. Drive out shaft seal. 1. Chasser le joint d’arbre. 1. Sacar el retén.
2. Inspect cover, replace if necessary. 2. Effectuer un contrôle visuel du 2. Examinar visualmente la tapa,
couvercle, au besoin le changer. sustituyéndola en caso necesario.
3. Installation depth of shaft seal. 3. Profondeur de montage du joint 3. Profundidad de montaje del retén.
d’arbre.
3.01.17
Spezialwerkzeug
Montagewerkzeug _______________ 142 860
1. Wellendichtring austreiben.
1
2. Deckel sichtprüfen, ggf. austauschen.

9
3
0
3. Einbautiefe des Wellendichtringes.

9
95-3.48
3.01.17
4. Wellendichtring ungeölt mit Montagevor-

2 richtung montieren.
ß
7
3.01.18
4. Fit shaft seal with assembly tool 4. Monter le joint d’arbre sans huile 4. Montar el retén sin aceitar utilizando
without using oil. avec le dispositif de montage. el dispositivo de montaje.
3.01.18
3
Kurbelwelle Bauteile instand setzen
Crankshaft Repair of components
Vilebrequin Mise en état des composants
Cigüeñal Reparación de componentes
3
Bauteile instand setzen Kurbelwelle
Repair of components Crankshaft
Mise en état des composants Vilebrequin
Reparación de componentes Cigüeñal
1. Chuck crankshaft up on prism 1. Serrer le vilebrequin sur un support 1. Colocar el cigüeñal sobre soportes
stand. prismatique. prismáticos.
Reworking sizes are marked on the Le repère des phases de retouche La marcación de las medidas de
outer contour of the cast-on counter- se fait sur les contours extérieurs rectificado se efectúa en el contorno
weight at flywheel end. du contre-poids rapporté côté exterior del contrapeso colocado en
volant moteur. fundición, en el lado del volante.
H = ground main bearing journals H = tourillon rectifié H = muñones de apoyo rectificados

P = ground crankpins P = maneton rectifié P = muñequillas rectificadas
2. Schematic for gauging journals at 2. Schéma de relevé des cotes des 2. Esquema para la verificación de las
points „1“ and „2“ in planes „a“ tourillons aux points „1“ et „2“ medidas de los muñones de apoyo
and „b“. dans l’axe „a“ et „b“. en los puntos „1“ y „2“ de los
planos „a“ y „b„.
Journal diameter 70 -0.01

-0.03 mm Diamètre des soies 70 -0,01
-0,03 mm Diámetro de muñón -0,01
70 -0,03 mm
Each undersize 0.25 mm Cote de rectification 0,25 mm Cada inframedida 0,25 mm
-0.01
Limit for undersize 69.5 -0.03 mm Cote limite Límite de
Wear limit: de rectification: 69,5 -0,01
-0,03 mm inframedida -0,01
69,5 -0,03 mm
Journal ovality 0.008 mm Limite d’usure Límite de desgaste:
ovalisation des soies 0,008 mm ovalización del muñón 0,008 mm
3. Gauge thrust bearing journal width. 3. Relever la largeur du tourillon du 3. Medir el ancho del muñón del
palier d’ajustage. cojinete de empuje
3 Journal width 35 +0.04 mm Largeur maneton 35 + 0,04 mm Diámetro de muñón 35 + 0,04 mm

Cote de
Each oversize 0.4 mm rectification respective 0,4 mm Cada sobremedida 0,4 mm
Limit for oversize 35.44 mm Cote limite de rectification 35,44 mm Límite de sobremedida 35,44 mm
4. Gauge crankpins. 4. Effectuer un relevé des cotes des 4. Medir la muñequilla.

manetons.
Diámetro
Pin diameter 55 -0.01
-0.03 mm Diamètre des soies -0,01
55 -0,03 mm de muñequilla -0,01
55 -0,03 mm
Cote limite Límite
Limit for undersize 54.5 -0.01
-0.03 mm de rectification 54,5 -0,01
-0,03 mm de inframedida 54,5 -0,01
-0,03 mm
Wear limit: Limite d’usure Límite de desgaste:
Pin ovality 0.01 mm ovalisation des soies 0,01 mm ovalización del muñón 0,01 mm
3.05.23
1. Kurbelwelle in Prismen aufnehmen.
Die Kennzeichnung der Nacharbeitsstufen

t
er-folgt auf der Außenkontur des angegosse-
nen, schwungradseitigen Gegengewichtes. 9
H = geschliffene Hauptlagerzapfen
P = geschliffene Pleuellagerzapfen
2. Schema zum Vermessen der Hauptlager-

zapfen an den Stellen „1“ und „2” in der
Ebene „a“ und „b“.
6
Zapfendurchmesser 70 -- 0,01
0,03 mm
Untermaß je Stufe 0,25 mm
Grenzmaß für
Untermaßstufe 69,5 -- 0,01
0,03 mm
Verschleißgrenze:
Zapfenunrundheit 0,008 mm
95-3.51
3. Breite des Paßlagerzapfens messen
Zapfenbreite 35 + 0,04 mm
6
Übermaß je Stufe 0,4 mm 3
Grenzmaß für Übermaßstufe 35,44 mm
4. Hubzapfen messen
6
- 0,01
Zapfendurchmesser 55 - 0,03 mm
Grenzmaß für
Untermaßstufe 54,5 -- 0,01
0,03 mm
Verschleißgrenze:
3.05 .23
5. Kurbelwelle auf Rundlauf prüfen

6 Abweichung max. 0,05 mm
6. Laufflächen der Wellendichtringe sichtprüfen.

9 Hinweis: Bei verschlissener Kurbelwelle besteht
5 die Möglichkeit die Kurbelwelle in unse-

ren Service - Centern instand setzen zu
lassen.
3.05.24
5. Check crankshaft for true running. 5. Vérifier la concentricité du 5. Verificar el giro en redondo del
vilebrequin. cigüeñal.
Out of roundness max. 0.05 mm Ecart maxi 0,05 mm Desviación máx. 0,05 mm
6. Inspect running surfaces of shaft 6. Contrôle visuel des surfaces de 6. Examinar visualmente las
seals. frottement des joints d’arbre. superficies de roce de los retenes.
Note: If crankshaft is worn, it is possib- Nota: en cas d’usure du vilebrequin Nota: Si el cigüeñal está desgastado,
le to have it reconditioned at our vous pouvez le faire remettre en existe la posibilidad de hacerlo
Service Centers. état dans un de nos Service reparar en uno de nuestros
Centers. Centros de Servicio.
3.05.24
3
Starterzahnkranz / Schwungrad Bauteile instand setzen
Starter ring gear / flywheel Repair of components
Couronne du volant / volant Mise en état des composants
Corona del volante / volante Reparación de componentes
3
Bauteile instand setzen Starterzahnkranz / Schwungrad
Repair of components Starter ring gear / flywheel
Mise en état des composants Couronne du volant / volant
Reparación de componentes Corona del volante / volante
1. Drill ring gear apart. 1. Percer la couronne dentée. 1. Abrir taladrando la corona dentada.
Note: Make sure not to damage Nota: ne pas endommager le volant Nota: Cuidar de no dañar el volante.
flywheel. moteur.
2. Remove ring gear. 2. Oter la couronne. 2. Quitar la corona dentada.
3. Clean flywheel and inspect at 3. Nettoyer le volant moteur et 3. Limpiar el volante y examinar
supporting flange. contrôler visuellement la collerette visualmente el collar de asiento.
d’appui.
3
4. Heat ring gear to max. 220°C. Place 4. Réchauffer la couronne dentée à 4. Calentar la corona a 220°C como
ring gear in position and bring to 220˚C maximum. máximo. Colocarla en el volante y
stop at flange. La mettre en place de manière à ce dejarla asentada en el collar.
qu’elle soit en position d’appui sur
la collerette.
3.05.29
Couronne du volant / volant Mise en état des composants
1. Zahnkranz aufbohren
Hinweis: Schwungrad nicht beschädigen.

f
5
2. Zahnkranz entfernen.
1
3. Schwungrad reinigen und am Auflagebund

sichtprüfen.
9
3
4. Zahnkranz auf max. 220° C erwärmen.

Zahnkranz auflegen und am Bund zur Anlage
bringen.
2
e
3.05.29
3
Pleuelstange Bauteile instand setzen
Connecting rod Repair of components
Bielle Mise en état des composants
Biela Reparación de componentes
3
Bauteile instand setzen Pleuelstange
Repair of components Connecting rod
Mise en état des composants Bielle
Reparación de componentes Biela
Special tools required: Bielle Mise en état des éléments Herramientas especiales:
Assembly tool for Outillage spécial: Herramienta de montaje para

small end bush 26 mm dia. __ 131 340 Dispositif de montage de bague casquillos de pie
Assembly tool for small end de pied de bielle Ø 26 mm __ 131 340 de biela Ø 26 mm ________ 131 340
bush 30 mm dia. _________ 131 350 Dispositif de montage de bague Herramienta de montaje para
de pied de bielle Ø 30 mm __ 131 350 casquillos de pie
de biela Ø 30 mm ________ 131 350
1. Set internal dial gauge. 1. Régler l’appareil de contrôle. 1. Ajustar el micrómetro de interiores.
F 1011 F 26 mm dia. F 1011F Ø 26 mm F 1011 F Ø 26 mm

BF 1011 F 30 mm dia. BF 1011 F Ø 30 mm BF 1011 F Ø 30 mm
2. Gauge small end bush at points „1“ 2. Procéder à un relevé des cotes de 2. Verificar las medidas del casquillo
and „2“ in planes „a“ and „b“ - la bague de pied de bielle aux points de pie de biela en los puntos „1“ y
„1“ et „2“ sur les axes „a“ et „b“. „2“ de los planos „a“ y „b„.
3. - Gauge 3. 3. Verificación.
Specified value, small end bush Valeur de consigne de la bague Valor prescrito casquillo
3 pressed in: de pied de bielle serrée introducido a presión:
F 1011 F 26 ++ 0.035
0.025 mm F 1011 F 26 ++ 0,035
0,025 mm F 1011 F 26 ++ 0,035
0,025 mm
BF 1011 F 30 ++ 0.035
0.025 mm BF 1011 F 30 ++ 0,035
0,025 mm BF 1011 F 30 ++ 0,035
0,025 mm
Wear limit:
Small end Limite d’usure jeu Límite de desgaste:
bush clearance 0.08 mm dans la bague 0,08 mm juego del bulón 0,08 mm
4. Replace small end bush if 4. Au besoin remplacer la bague de 4. Reemplazar el casquillo de pie de
necessaray. pied de bielle. biela, si es necesario.
Bore for small end bush: Alésage de bague de pied de bielle: Alojamiento del casquillo:
F 1011 F 29 +0.02 mm F 1011 F 29 +0.02 mm F 1011 F 29 +0.02 mm
BF 1011 F 33 +0.02 mm BF 1011 F 33 +0.02 mm BF 1011 F 33 +0.02 mm
Outer diameter Bague de pied de bielle diamètre Diámetro exterior del casquillo de
of small end bush: extérieur: pie de biela:
+ 0.10 + 0,10 + 0,10
F 1011 F 29 + 0.06 mm F 1011 F 29 + 0,06 mm F 1011 F 29 + 0,06 mm
BF 1011 F 33 ++ 0.110
0.070 mm BF 1011 F 33 ++ 0,110
0,070 mm BF 1011 F 33 ++ 0,110
0,070 mm
3.06.33
Spezialwerkzeug:
Montagevorrichtung für Kolben-

6
bolzenbuchse ø 26 mm ___________ 131 340
Montagevorrichtung für Kolben-
bolzenbuchse ø 30 mm ___________ 131 350
1. Innenmeßgerät einstellen.
F 1011 F ø 26 mm
BF 1011 F ø 30 mm
2. Kolbenbolzenbuchse an den Punkten „1“ und

„2“ in der Ebene „a“ und „b“ - 6
95-3.61
3. - messen.
Sollwert Kolbenbolzenbuchse eingepreßt:

6
F 1011 F 26 ++ 0,035
0,025 mm 3
BF 1011 F 30 ++ 0,035
0,025 mm
Verschleißgrenze:
Kolbenbolzenspiel 0,08 mm
4. Bei Bedarf Kolbenbolzenbuchse auswech-

seln. 1
Bohrung für Kolbenbolzenbuchse:
F 1011 F 29 + 0,02 mm
7
BF 1011 F 33 + 0,02 mm
2
Kolbenbolzenbuchse Außendurchmesser:
+ 0,10
F 1011 F 29 + 0,06 mm
BF 1011 F 33 ++ 0,110
0,070 mm
3.06.33
5. Kolbenbolzenbuchse bündig einpressen.

2 Hinweis: Schmierölbohrung der Kolbenbolzen-
9 buchse und der Pleuelstange müssen

übereinstimmen.
5
8
6. Kolbenbolzenbuchse nach dem Einpressen

f ausspindeln.
+ 0,035
F 1011 F 26 + 0,025 mm
+ 0,035
BF 1011 F 30 + 0,025 mm
7. Pleuellagerdeckel zuordnen.
9
3
8
8. Pleuellagerdeckel montieren. Muttern mit

2 12 kant-Steckschlüssel festdrehen.
6 Anziehvorschrift:
Vorspannwert 30 Nm
1. Nachspannwinkel 60°
r 2. Nachspannwinkel 60°
3.06.34
5. Press in small end bush flush. 5. Insérer jusqu’à affleurement bague 5. Insertar a ras el casquillo de pie de
de pied de bielle. biela.
Note: Lube oil bores of small end bush Nota: les trous de passage d’huile de la Nota: Los orificios de lubricación
and connecting rod must be in bague de pied de bielle et de la existentes en el casquillo de pie
line. bielle doivent correspondre. de biela y en la biela deben
coincidir.
6. After pressing in, precision-bore 6. Après l’avoir insérée usiner à la 6. Una vez insertado, mecanizar el
small end bush on a fine boring broche la bague du pied de bielle. casquillo de pie de biela en
mill. mandrinadora de precisión.
+ 0,035 + 0.035 + 0,035
F 1011 F 26 + 0,025 mm F 1011 F 26 + 0.025 mm F 1011 F 26 + 0,025 mm
BF 1011 F 30 ++ 0,035
0,025 mm BF 1011 F 30 ++ 0.035
0.025 mm BF 1011 F 30 ++ 0,035
0,025 mm
7. Make sure that cap mates with 7. Bien positionner selon le numéro 7. Elegir la tapa de biela que
connecting rod. repère le chapeau de bielle. corresponda.
8. Fit bearing cap. Tighten nuts with 8. Monter le chapeau de bielle. Serrer 8. Montar la tapa de biela. Apretar las
dodecagonal socket wrench. les écrous avec la clé à douille 12 tuercas utilizando la llave de vaso
pans selon les préconisations de de doce cantos.
serrage.

1st tightening angle 60° 1er serrage à l’angle 60˚ 1er ángulo de reapriete 60°
2nd tightening angle 60° 2e serrage à l’angle 60˚ 2o ángulo de reapriete 60°
3.06.34
9. Set internal dial gauge. 9. Mettre en place l’appareil de 9. Ajustar el micrómetro de

mesure. interiores.
Dia. 58.5 mm Ø 58,5 mm Ø 58,5 mm
10. Schematic for gauging big end 10. Schéma de mesurage de l’alésage 10. Esquema para la verificación de las
bearing bore at points „1“ and „2“ de coussinet de bielle aux points medidas de alojamiento de los
in planes „a“ and „b“. „1“ et „2“ du plan „a“ et „b“ cojinetes de cabeza de biela, en los
puntos „1“ y „2“ de los planos „a“
y „b„.
Bore for Alésage des Alojamiento para

big end bearing 58.5 +0.02 mm coussinets de bielle 58,5 + 0,02 mm cojinetes de biela 58,5 + 0,02 mm
11. If the gauge readings conform to 11. Si les mesures correspondent aux 11. Si los valores medidos
the specified values, the necessary valeurs indiquées, c’est que après corresponden a los especificados,
preload will be obtained after montage des coussinets la los semicojinetes recibirán la
3 fitting the bearing shells. précontrainte est établie. pretensión necesaria después de
su montaje.
Note: If the measured values deviate Nota: Si, en revanche, les valeurs Nota: Si, en cambio, los valores
only slightly, additional measure- enregistrées ne s’écartent que medidos sólo difieren insignifi-
ments are to be carried out with faiblement, procéder à de cantemente, es necesario
new bearing shells fitted. nouvelles mesures avec des realizar mediciones adicionales
coussinets neufs. con semicojinetes nuevos.
12. Remove bearing cap and fit new 12. Déposer le chapeau de bielle et 12. Desmontar la tapa de biela e
bearing shells. Refit bearing cap. mettre en place des coussinets introducir los semicojinetes
Tighten nuts. neufs. Monter le chapeau de bielle. nuevos. Volver a montar la tapa y
Serrer les écrous selon les apretar las tuercas.
préconisations de serrage.

1st tightening angle 60° 1er serrage à l’angle 60° 1er ángulo de reapriete 60°
2nd tightening angle 60° 2e serrage à l’angle 60° 2o ángulo de reapriete 60°
3.06.35
9. Innenmeßgerät einstellen.
ø 58,5 mm 6
10. Schema zum Vermessen der Pleuellager-

bohrung an den Punkten „1“ und „2“ der
Ebene „a“ und „b“.
6
Bohrung für Pleuellager 58,5 + 0,02 mm
95-3.69
11. Entsprechen die Messungen den angegebe-

nen Werten, ist nach dem Einbau von Lager-
schalen die Vorspannung vorhanden.
6
3
Hinweis: Weichen die Meßwerte nur geringfü- 5
gig ab, sind zusätzliche Messungen mit
neuen Lagerschalen durchzuführen.
12. Pleuellagerdeckel abbauen und neue Lager-

schalen einsetzen. Pleuellagerdeckel mon-
tieren. Muttern festdrehen.
1
Anziehvorschrift: 2
Vorspannwert 30 Nm
1. Nachspannwinkel 60° 6
r
3.06.35
13. Innenmeßgerät einstellen. Lagerschalen an

6 den Punkten „1“ und „2“ in den Ebenen „a“
und „b“ messen.
5 Pleuellagerschalen
Innendurchmesser 55,004 - 55,04 mm
Grenzmaß für
Untermaßstufe 54,504 - 54,54 mm
Verschleißgrenze:
Pleuellager Radialspiel 0,12 mm
Hinweis: Liegen die Werte bis. max. 0,015 mm

über den Lagertoleranzen, kann die
Pleuelstange weiter verwendet wer-
den. Wird der Grenzwert überschrit-
ten, Pleuelstange austauschen.
14. Pleuelstange ohne Lagerschalen auf einem

6 Pleuelprüfgerät prüfen.-
3 14.1 auf Parallelität:
Zulässige Abweichung a = 0,10 mm bei

einem Abstand von x = 100 mm
14.2 auf Winkligkeit:

6 Zulässige Abweichung „A“ zu „B“= 0,05 mm
3.06.36
13. Set internal dial gauge. Gauge 13. Régler l’appareil de contrôle. 13. Ajustar el micrómetro de
bearing shells at points „1“ and Effectuer le relevé des cotes des interiores. Verificar las medidas de
„2“ in planes „a“ and „b“. coussinets aux points „1“ et „2“ au los semicojinetes en los puntos
niveau des plans „a“ et „b“. „1“ y „2“ de los planos „a“ y „b„.
Inner diameter of big end Coussinets de bielle diamètre Diámetro interior cojinetes
bearing shells 55.004 - 55.04 mm intérieur 55,004 - 55,04 mm de biela 55,004 - 55,04 mm
Limit for Cote limite pour cote de Límite de
undersize 54.504 - 54.54 mm rectification 54,504 - 55,54 mm inframedida 54,504 - 54,54 mm
Wear limit: Radial clearance Limite d’usure coussinets Límite de desgaste:
of big end bearing 0.12 mm de bielle jeu radial 0,12 mm juego radial cojinete 0,12 mm
Note: If the readings do not exceed Nota : Si les valeurs dépassent au Nota: Si los valores medidos no
bearing tolerances by more than maximum de 0,015 mm les sobrepasan en más de
0.015 mm , the rod can be used tolérances du coussinet, la bielle 0,015 mm las tolerancias del
further. If the limit value is peut rester en service. Dans le cojinete, la biela puede seguir
exceeded, replace the cas contraire, la remplacer. utilizándose. En caso contrario,
connecting rod. reemplazar la biela.
14. Check connecting rod without 14. Contrôler toute bielle sans 14. Comprobar la biela desprovista de
bearing shells on connecting rod coussinet sur un appareil de los semicojinetes sobre un
tester. - contrôle notamment aparato para la comprobación de
bielas: 3
14.1 Parallelism check: 14.1 au niveau du parallélisme 14.1 Prueba de paralelismo:
Permissible Ecart admissible a = 0,10 mm Desviación

tolerance a = 0.10 mm pour un admisible a = 0,10 mm
over a distance of x = 100 mm écartement de x = 100 mm a la distancia de x = 100 mm
14.2 Squareness check: 14.2 et de l’équerrage 14.2 Prueba de la perpendicularidad:
Permissible tolerance Ecart admissible Desviación admisible

„A“ relative to „B“ = 0.05 mm „A“ par rapport „B“ = 0,05 mm „A“ respecto a „B“ = 0,05 mm
3.06.36
Assembling connecting rod with Compléter l’ensemble bielle-piston Unión de la biela y pistón
piston
15. Fit circlip. 15. Mettre en place un premier circlip. 15. Colocar uno de los anillos de
retención.
Note: Ring gaps of circlips must face Nota: les coupes des circlips doivent Nota: Los cortes de los anillos de
piston crown. être orientées dans le sens de la retención deben indicar hacia la
tête du piston. cabeza del pistón.
16. Install piston together with 16. Monter l’ensemble piston-bielle. 16. Unir el pistón con la biela. El
connecting rod. Flywheel symbol Le symbole du volant moteur símbolo del volante que figura en
on the piston must point to the left figurant sur le piston doit être el pistón debe indicar hacia la
3 and identification number on orienté vers la gauche et le chiffre izquierda y el número de
connecting rod must be visible. de la bielle doit être bien visible. identificación de la biela debe ser
visible.
17. Fit second circlip and bring into 17. Placer et ajuster le deuxième 17. Introducir el segundo anillo de
correct position. circlip. retención y alinearlo.
3.06.37
Pleuelstange mit Kolben komplettieren
15. Einen Sicherungsring einsetzen.

2
q
Hinweis: Ringstöße der Sicherungsringe müs-

sen zum Kolbenboden zeigen.
5
9
16. Kolben mit der Pleuelstange montieren.

Das Schwungradsymbol auf dem Kolben
muß nach links zeigen und die Kennziffer
2
3
der Pleuelstange muß sichtbar sein.
8
9
17. Zweiten Sicherungsring einsetzen und aus-

richten. 2
q
9
3.06.37
Bauteile instand setzen Kolben
Repair of components Piston
Mise en état des composants Piston
Reparación de componentes Pistón
3
Kolben Bauteile instand setzen
Piston Repair of components
Piston Mise en état des composants
Pistón Reparación de componentes
3
Special tool required: Outillage spécial: Herramienta especial:
Piston ring pliers _________ 130 300 Pince à monter les Alicates para montar
segments de piston _______ 130 300 aros de pistón ___________ 130 300
1. Remove circlip. Take out piston pin. 1. Enlever le circlip et retirer l’axe du 1. Quitar el anillo de retención. Sacar
piston. el bulón del pistón.
2. Adjust piston ring pliers to piston 2. Régler la pince à monter les 2. Ajustar los alicates para aros de
diameter. Remove piston rings. segments sur le diamètre du pistón al diámetro del pistón y
piston. Déposer les segments. desmontar los aros.
3
3. Clean and inspect piston and ring 3. Nettoyer le piston et les gorges 3. Limpiar y examinar visualmente el
grooves. annulaires puis faire un contrôle pistón y las ranuras para los aros.
visuel.
3.07.41
Spezialwerkzeug:
Kolbenring-Auflegezange: _________ 130 300
1. Sicherungsring entfernen. Kolbenbolzen

herausnehmen.
1
q
2. Kolbenring-Auflegezange auf den Kolben-

durchmesser einstellen. Kolbenringe abbauen. 1
3
6
7
3. Kolben und Ringnuten reinigen und sicht-

prüfen. 9
3.07.41
4. Kolbenringstoßspiel mit Fühlerlehre mes-

6 sen.
Verschleißgrenzen:
Stoßspiel 1. Ring 0,8 mm
Stoßspiel 3. Ring F 1011 F 1,2 mm
Stoßspiel 3. Ring BF 1011 F 0,9 mm
5. Kolbenringnuten mit Fühlerlehre messen.

6 Hinweis: Messung mit neuen Kolbenringen
5 durchführen.
Verschleißgrenzen:
Axialspiel 1. Ring F 1011 F 0,2 mm
Axialspiel 1. Ring BF 1011 F --
Axialspiel 2. Ring 0,16 mm
Axialspiel 3. Ring 0,12 mm
6. Kolbenbolzen auf Verschleiß prüfen.

6 Kolbenbolzendurchmesser:
3
F 1011 F 26 - 0,005 mm
BF 1011 F 30 - 0,005 mm
7. Reihenfolge und Lage der Kolbenringe:

9 1. F 1011 F, Rechteckring, Top zum Brenn-
raum weisend.
1. BF 1011 F, Doppeltrapezring, Top zum
Brennraum weisend.
2. Minutenring, Top zum Brennraum wei-
send.
3. Ölschlitz-Dachfasenring
3.07.42
4. Measure ring gap with feeler gauge. 4. Mesurer le jeu à la coupe avec une 4. Medir la distancia entre las puntas
jauge d’épaisseur. de los aros mediante una galga de
espesores.
Wear limits: Limites d’usure: Jeu à la coupe Límites de desgaste:

1st ring gap 0.8 mm 1er segment 0,8 mm distancia 1er aro 0,8 mm
2nd ring gap 1.8 mm 2e segment 1,8 mm distancia 2o aro 1,8 mm
3rd ring gap F 1011 F 1.2 mm 3e segment F 1011 F 1,2 mm distancia 3er aro F 1011 F 1,2 mm
3rd ring gap BF 1011 F 0.9 mm 3e segment BF 1011 F 0,9 mm distancia 3er aro BF 1011 F 0,9 mm
5. Measure ring grooves with feeler 5. Relever les cotes des gorges de 5. Medir las ranuras para aros
gauge. segments avec une jauge mediante una galga de espesores.
d’épaisseur.
Note: Measurement to be made with Nota: Effectuer Les mesures avec des Nota: Realizar la medición con aros
new piston rings. segments neufs. nuevos.
Wear limits: Limites d’usure: jeu axial Límites de desgaste:

axial play 1st ring F 1011 F 0.2 mm 1er segment F 1011 F 0,2 mm juego axial 1er aro F 1011 F 0,2 mm
axial play 1st ring BF 1011 F - - 1er segment BF 1011 F -- juego axial 1er aro BF 1011 F - -
axial play 2nd ring 0.16 mm 2e segment 0,16 mm juego axial 2o aro 0,16 mm
axial play 3rd ring 0.12 mm 3e segment 0,12 mm juego axial 3er aro 0,12 mm
6. Check piston pin for wear. 6. Contrôler l’usure de l’axe du piston. 6. Verificar el bulón en cuanto a
desgaste.
Piston pin diameter: Diamètre de l’axe du piston Diámetro del bulón: 3

F 1011 F 26 -0.005 mm F 1011 F 26 -0,005 mm F 1011 F 26 -0,005 mm
BF 1011 F 30 -0.005 mm BF 1011 F 30 -0,005 mm BF 1011 F 30 -0,005 mm
7. Order and position of piston rings: 7. Ordre et position des segments: 7. Orden de sucesión y posición de
los aros:
1. F 1011 F, rectangular ring, top 1. F 1011 F, segment à section 1. F 1011 F, aro de sección
facing combustion chamber rectangulaire,top orienté vers la rectangular, con „Top“ indicando
1. BF 1011 F, keystrone ring, top chambre de combustion hacia la cámara de combustión
facing combustion chamber 1. BF 1011 F segment trapézoïdal 1. BF 1011 F, aro de doble cuña,
2. tapered compression ring, top double, top orienté vers la con „Top“ indicando hacia la
facing combustion chamber chambre de combustion cámara de combustión
3. bevelled-edge slotted oil control 2. segment biseauté, top orienté 2. Aro con bisel de pequeño
ring vers la chambre de combustion ángulo, con „Top“ indicando
3. segment racleur à double hacia la cámara de combustión.
chanfrein 3. Aro ranurado de aceite con
chaflán
3.07.42
8. Fit piston rings 8. Monter les segments de piston. 8. Montar los aros de pistón.
Note: Spring gap of bevelled-edge ring Nota: décaler la coupe du ressort du Nota: Desplazar el corte del muelle del
to be offset by 180° relative to segment racleur de 180˚ par aro achaflanado ranurado de
ring gap. rapport à la coupe de segment. aceite por 180° con respecto al
corte del aro.
Note: With FL engines, regular pro- Nota: Les moteurs FL sont équipés de Nota: En los motores FL están
duction pistons are installed with série de pistons présentant les incorporados, de serie, pistones
the following compression heights taux de compression suivants: con las alturas de compresión
hKH A = 55.17 mm hKH A = 55,17 mm hKH A = 55,17

hKH B = 55.27 mm hKH B = 55,27 mm hKH B = 55,27
hKH C = 55.37 mm hKH C = 55,37 mm hKH C = 55,37
and with FM engines with the quant aux moteurs FM, leurs y en los motores FM, pistones
compression heights taux de compression sont les con las alturas de compresión
suivants:
hKH A = 51.67 mm hKH A = 51,67 mm hKH A = 51,67

hKH B = 51.77 mm hKH B = 51,77 mm hKH B = 51,77
hKHC = 51.87 mm hKH C = 51,87 mm. hKH C = 51,87
The identification numbers of Les différents modèles de piston Las variantes de pistón se
the piston variants are stamped sont marqués sur la tête du identifican en la cabeza del
on the piston crown. When ex- piston. pistón.
changing a piston, make sure A chaque changement de piston A cada cambio de un pistón
that a piston with the same veiller à toujours réutiliser la debe cuidarse de que el pistón
compression height is installed. même catégorie de taux de montado tenga la misma clase
When replacing the crankshaft compression du piston. de altura de compresión.
3 or crankcase, the distance En cas de remplacement du Cada vez que se cambie el
between „top edge of crankpin vilebrequin ou du bloc moteur, bloque de cilindros o el cigüeñal,
in TDC and cylinder head gasket pour déterminer la catégorie de es necesario, para la
seating surface“ has to be meas- compression, faire un relevé des determinación de la clase de
ured again to determine the cotes d’écartement entre l’arête altura de compresión de los
piston compression height. supérieure du maneton au PMH pistones. medir nuevamente la
See Chapter 4. et le plan de joint de culasse. distancia entre „el canto
Voir chapitre 4. superior de la muñequilla a PMS
y la superficie de asiento de la
With BF engines, the measure- Pour les moteurs BF il n’est pas junta de culata„.
ment is not necessary for deter- nécessaire d’effectuer un relevé Ver capítulo 4.
mining the piston compression de mesures pour déterminer la
height as only pistons with the catégorie de compression du fait En los motores BF no hace falta
compression height hKH A = que l’on utilise exclusivement des efectuar la medición para la
55.17 mm are installed in BFL pistons d’un niveau de compres- determinación de la clase de
engines and hkH A = 51.67 mm sion hKH A = 55,17 mm pour les altura de compresión de los
in BFM engines. moteurs BFL et hKH A = 51,67 mm pistones, dado que en los
pour les moteurs BFM. motores BFL están montados
exclusivamente pistones con la
altura de compresión hKH A =
55,17 mm y en los motores
BFM, pistones con la altura de
compresión hKH A = 51,67 mm.
3.07.43
8. Kolbenringe montieren.
Hinweis: Federstoß des Dachfasenringes um

2
180° zum Ringstoß versetzen.
7
5
Hinweis: Bei FL-Motoren sind in der Serie Kol-

ben mit den Kompressionshöhen 5
hKH A = 55,17 mm
hKH B = 55,27 mm 9
hKH C = 55,37 mm
und bei FM-Motoren Kolben mit den

Kompressionshöhen
hKH A = 51,67 mm
hKH B = 51,77 mm
hKH C = 51,87 mm
eingebaut.
Die Kolbenvarianten sind auf dem
Kolbenboden gekennzeichnet.
Bei jedem Kolbentausch ist sicherzu- 3
stellen, daß die gleiche Kolbenkom-
pressions-Höhenklasse wieder ver-
wendet wird.
Bei Kurbelwellen- oder Zylinder-
kurbelgehäusetausch muß zur Be-
stimmung der Kolbenkompressions-
Höhenklasse der Abstand „Hub-
zapfenoberkante OT bis Zylinderkopf-
dichtungsauflage“ neu ermittelt wer-
den.
Siehe Kapitel 4.
Bei BF-Motoren muß die Messung zur

Bestimmung der Kolbenkompressions
-Höhenklasse nicht durchgeführt wer-
den, da ausschließlich Kolben mit der
Kompressionshöhe hKH A = 55,17 mm
bei BFL-Motoren und hKH A = 51,67
mm bei BFM-Motoren eingebaut sind.
3.07.43
3
Zylinderkopf Bauteile instand setzen
Cylinder head Repair of components
Culasse Mise en état des composants
Culata Reparación de componentes
3
Bauteile instand setzen Zylinderkopf
Repair of components Cylinder head
Mise en état des composants Culasse
Reparación de componentes Culata
Magnetic measuring stand Support magnétique Soporte magnético de medición

Valve spring Levier de montage Palanca de montaje
assembly lever ___________ 210 450 pour ressorts de soupape __ 210 450 para resortes de válvula ____ 210 450
Valve reseating tool Appareil d’usinage pour sièges de Aparato para rectificar
soupape asientos de válvula
Special tools required: Outillage usuel: Herramientas especiales:
Clamping stand __________ 120 900 Chevalet d’ablocage _______ 120 900 Soporte de fijación ________ 120 900
Clamping plate ___________ 120 910 Plaque d’ablocage ________ 120 910 Placa de fijación __________ 120 910
Sleeve for fitting Douille de montage pour Manguito de montaje para
valve stem seal __________ 121 410 joint de tige de soupape ____ 121 410 juntas de vástago de válvula __ 121 410
1. Mount cylinder head on fixture. 1. Monter la culasse dans le dispositif. 1. Montar la culata al dispositivo.
2. Remove cone clamp, valve spring 2. Déposer les clavettes, les coupelles, 2. Desmontar los semiconos, los
cap, valve springs and valves. les ressorts de soupape et les platillos de retención de resorte, los
soupapes. resortes de válvula y las válvulas.
3.08.47
Magnet-Meßstativ
Ventilfedermontagehebel __________ 210 450
Ventilsitzbearbeitungsgerät
Spezialwerkzeuge:
Aufspannbock __________________ 120 900

Aufspannplatte __________________ 120 910
Montagehülse für
Ventilschaftabdichtung ___________ 121 410
1. Zylinderkopf an Vorrichtung anbauen.

2
7 3
2. Klemmkegel, Ventilfederteller, Ventilfedern

und Ventile ausbauen. 1
3.08.47
3. Ventilschaftabdichtung ausbauen.
1
4. Zylinderkopf reinigen und auf Beschädigung

1 prüfen.
5. Ventilschaftspiel messen.
6 Verschleißgrenzen:
3
Einlaßventil 0,12 mm
Auslaßventil 0,15 mm
6. Ventile sichtprüfen und vermessen.

9 Ventilschaftdurchmesser: normal
6 Einlaßventil 7,98 - 0,015 mm
Auslaßventil 7,96 - 0,015 mm
95-3.93
3.08.48
3. Remove valve stem seal. 3. Déposer le joint de tige de soupape. 3. Retirar la junta del vástago de
válvula.
4. Clean cylinder head and inspect for 4. Nettoyer la culasse et vérifier si elle 4. Limpiar la culata y examinarla en
damage. n’est pas endommagée. cuanto a daños.
5. Gauge valve stem clearance. 5. Relever le jeu à la tige de soupape. 5. Verificar el juego del vástago de
válvula.
Wear limits: Limites d’usure: Límites de desgaste: 3

Inlet valve 0.12 mm Soupape ADM 0,12 mm Válvula de admisión 0,12 mm
Exhaust valve 0.15 mm Soupape ECH 0,15 mm Válvula de escape 0,15 mm
6. Inspect valves and gauge them. 6. Contrôler les soupapes et faire un 6. Examinar visualmente las válvulas
relevé des cotes. y verificar sus medidas.
Valve stem diameter: standard Diamètre de la tige de soupape Diámetro de vástago de válvula:
valeur normale normal
Inlet valve 7.98 -0.015 mm Soupape ADM 7,98 -0,015 mm Válvula de admisión 7,98 -0,015 mm
Exhaust valve 7.96 -0.015 mm Soupape ECH 7,96 -0,015 mm Válvula de escape 7,96 -0,015 mm
3.08.48
6.1 Valve rim thickness 6.1. Epaisseur du bord de soupape: 6.1 Espesor de borde de la cabeza de
válvula
Wear limits F 1011 F: Limites d’usure moteurs F 1011 F: Límites de desgaste F 1011 F:

Wear limits BF 1011 F: Limites d’usure moteurs BF 1011 F: Límites de desgaste BF 1011 F:

6.2 Valve disc diameter 6.2 Diamètre de tête de soupape 6.2 Diámetro de la cabeza de válvula
F 1011 F: F 1011 F: F 1011 F:

Inlet valve 40.1 ±0.1 mm Soupape ADM 40,1 ± 0,1 mm Válvula de admisión 40,1 ± 0,1 mm
Exhaust valve 34.9 ±0.1 mm Soupape ECH 34,9 ± 0,1 mm Válvula de escape 34,9 ± 0,1 mm
BF 1011 F: BF 1011F: BF 1011 F:

Inlet valve 40.5 ±0.1 mm Soupape ADM 40,5 ± 0,1 mm Válvula de admisión 40,5 ± 0,1 mm
Exhaust valve 34.9 ±0.1 mm Soupape ECH 34,9 ± 0,1 mm Válvula de escape 34,9 ± 0,1 mm
7. Inspect valve seat inserts and 7. Contrôle visuel des sièges 7. Examinar visualmente los asientos
check wear tolerances. rapportés. Vérifier les cotes de válvula postizos. Controlar las
d’usure. medidas de desgaste.
3
Valve seat width: Largeur du siège moteur: Ancho del asiento postizo:
F 1011 F: F 1011 F: F 1011 F:

Inlet valve 1.7 ± 0.4 mm Soupape ADM 1,7 ± 0,4 mm Válvula de admisión 1,7 ± 0,4 mm
Exhaust valve 1.7 ± 0.4 mm Soupape ECH 1,7 ± 0,4 mm Válvula de escape 1,7 ± 0,4 mm
BF 1011 F: BF 1011 F: BF 1011 F:

Inlet valve 1.58 ± 0.4 mm Soupape ADM 1,58 ± 0,4 mm Válvula de admisión 1,58 ± 0,4 mm
Exhaust valve 1.7 ± 0.4 mm Soupape ECH 1,7 ± 0,4 mm Válvula de escape 1,7 ± 0,4 mm
8. Gauge valve clearance between 8. Relever le retrait de soupape du 8. Medir el retroceso de la válvula
valve disc center and cylinder head centre de la tête de soupape desde el centro de la cabeza de
sealing surface. jusqu’au plan de joint de culasse. válvula hasta la superficie de
asiento de la junta de culata.
Wear limit, valve penetration into Limites d’usure, cote de retrait de Límite de desgaste, retroceso de
cylinder head soupape válvula
F 1011 F 1.53 mm F 1011 F 1,53 mm F 1011 F 1,53 mm

BF 1011 F 1.3 mm BF 1011 F 1,3 mm BF 1011 F 1,3 mm
3.08.49
6.1 Ventilrandstärke
Verschleißgrenzen F 1011 F:
6
Verschleißgrenzen BF 1011 F:
95-3.94
6.2 Ventiltellerdurchmesser
F 1011 F:
6
Einlaßventil 40,1 ± 0,1 mm
Auslaßventil 34,9 ± 0,1 mm
BF 1011 F:
95-3.95
7. Ventilsitzringe sichtprüfen. Verschleißmaße

kontrollieren. 9
3
Ventilsitzbreite:
6
F 1011 F
BF 1011 F
8. Ventilrückstand von der Mitte, Ventilteller

zur Zylinderkopfdichtfläche messen. 6
Verschleißgrenze, Ventilrückstehmaß
F 1011 F 1,53 mm
BF 1011 F 1,3 mm
3.08.49
8.1 Bei verschlissenen Ventilsitzringen, Ventil-

9 führungen oder beschädigter Zylinderkopf-
dichtfläche besteht die Möglichkeit den
Zylin-derkopf in unseren Service-Centern
instand setzen zu lassen.
9. Länge der Ventilfeder messen.

6 Länge ungespannt normal:
Ventilfeder Draht- ø 3,35 mm 38,9 mm

oder
Ventilfeder Draht- ø 3,40 mm 39,3 mm
Ein gemischter Einbau ist zulässig.
10. Korrekturen der Ventilsitzbreite und Ventil-

f freistellung mit Ventilsitz-Bearbeitungs-
gerät durchführen.
3
10.1 Ventilsitzringbearbeitung
f Ventilsitzwinkel Einlaß Auslaß
6 F 1011 F
BF 1011 F
45°
30°
45°
45°
5 Ventilsitzbreite:
F 1011 F 1,7 ± 0,4 mm
BF 1011 F 1,58 ± 0,4 1,7 ± 0,4
Hinweis: Nach Ventilsitzringbearbeitung noch-

mals Ventilrückstand messen.
3.08.50
8.1 If valve seats, valve guides are 8.1 Quand les sièges de soupape ou les 8.1 Si los asientos postizos o guías de
worn out or cylinder head sealing guides de soupape sont usés et que las válvulas están desgastados o si
surface is damaged, it is possible le plan d’appui de culasse est endom- la superficie de asiento de la junta
to have the cylinder head recondi- magé, il est possible de remettre en de culata está dañada, existe la
tioned in our Service Centers. état la culasse dans l’un de nos points posibilidad de hacer reparar la
de service après-vente. culata en uno de nuestos Centros
de Servicio.
9. Gauge length of valve spring. 9. Relever les cotes de longueur du 9. Verificar la longitud de los resortes
ressort de soupape. de válvula.
Unloaded length, standard: Longueur normale non tendue Longitud normal en estado no
tensado:
Valve spring fil ressort
wire dia. 3.35 mm 38.9 mm de soupape Ø 3,35 mm 38,9 mm Resorte de válvula
or ou - Ø de alambre 3,35 mm 38,9 mm
Valve spring fil ressort ó
wire dia. 3.40 mm 39.3 mm de soupape Ø 3,40 mm 39,3 mm Ø de alambre 3,40 mm 39,3 mm
Mixed installation is permissible. Un montage mixte est admis. Se admiten montajes mixtos.
10. Correct seat width and relief using 10. Effectuer les corrections de la 10. Realizar correcciones en el ancho
valve reseating tool. largeur de portée du siège de del asiento de válvula y en el
soupape et le dégagement de destalonado de la válvula mediante
soupape avec l’appareil d’usinage el aparato para rectificar asientos 3
de siège de soupape. de válvula.
10.1 Reworking valve seat insert 10.1 Usinage du siège de soupape 10.1 Rectificado de asientos postizos
de válvula
Angle du siège
Valve seat angle Inlet Exhaust de soupape ADM ECH Angulo asiento Admisión Escape
F 1011 F 45° 45° F 1011 F 45˚ 45˚ F 1011 F 45° 45°
BF 1011 F 30° 45° BF 1011 F 30˚ 45˚ BF 1011 F 30° 45°
Largeur de portée du siège

Valve seat width: de soupape ADM ECH Ancho asiento de válvula:
F 1011 F 1.7 ± 0.4 mm F 1011 F 1,7 ± 0,4 mm F 1011 F 1,7 ± 0,4 mm
BF 1011 F 1.58 ± 0.4 1.7 ± 0.4 BF 1011 F 1,58 ± 0,4 1,7 ± 0,4 BF 1011 F 1,58 ± 0,4 1,7 ± 0,4
Note: Measure valve penetration into Nota: après usinage du siège de Nota: Verificar de nuevo el retroceso de
cylinder head once again after soupape faire un nouveau relevé la válvula después del rectificado
reworking of valve seat insert. du retrait de soupape. del asiento postizo de la misma.
3.08.50
11. Insert and retain valve. Slide pro- 11. Mettre en place et maintenir la 11. Introducir la válvula y retenerla.
tective sleeve onto valve stem. soupape. Insérer la douille de Colocar el manguito protector
protection sur la tige de soupape. sobre el vástago de la válvula.
Note: Before fitting valve stem seal,
valve splines must be covered Nota: avant chaque montage du joint Nota: Antes de montar la junta en el
by the protective sleeve or de tige de soupape recouvrir les vástago de válvula es siempre
masking tape. rainures de clavette d’une douille necesario cubrir las ranuras de
de protection ou d’une feuille chaveta de válvula mediante el
collante. manguito protector o una lámina
adhesiva.
12. Slide valve stem seal onto 12. Insérer la douille de protection sur 12. Colocar la junta de vástago de
protective sleeve. le joint de tige de soupape. válvula, pasándola por encima del
manguito protector.
13. Remove protective sleeve. Press in 13. Oter la douille de protection. 13. Quitar el manguito protector.
valve stem seal as far as it will go. Enfoncer le joint de la tige de Introducir a presión la junta hasta
soupape jusqu’en position de el tope.
3 butée.
14. Assemble cylinder head: 14. Compléter l’assemblage de la culasse 14. Completar la culata:
Position valve spring and valve en montant les ressorts de soupape Colocar el resorte de válvula y su
spring cap. et les coupelles de ressort. platillo de retención.
3.08.51
11. Ventil einsetzen und gegenhalten. Schutz-

hülse auf den Ventilschaft stecken. 2
Hinweis: Vor jeder Montage der Ventilschaftab-
dichtung sind die Ventil-Keilnuten mit 5
der Schutzhülse oder einer Klebefolie
abzudecken. r
12. Ventilschaftabdichtung über die Schutz-

hülse schieben.
2
13. Schutzhülse entfernen. Ventilschaftabdich-

tung bis Anschlag eindrücken.
2
3
8
7
14. Zylinderkopf komplettieren:

Ventilfeder und Ventilfederteller aufsetzen. 2
8
3.08.51
15. Ventilfedermontagehebel aufbauen, Klemm-

2 kegel einsetzen.
3.08.52
15. Fit valve assembly lever, insert 15. Mettre en place le levier de montage 15. Montar la palanca de montaje para
cone clamp. des ressorts de soupape ainsi que resortes de válvula e introducir los
les clavettes demi-cône. semiconos.
3.08.52
Bauteile instand setzen Nockenwelle
Repair of components Camshaft
Mise en état des composants Arbre à cames
Reparación de componentes Arbol de levas
3
Nockenwelle Bauteile instand setzen
Camshaft Repair of components
Arbre à cames Mise en état des composants
Arbol de levas Reparación de componentes
3
1. Inspect cams and bearing journals 1. Contrôle visuel de l’usure des 1. Examinar visualmente las levas y
for wear. cames et tourillons. los muñones de apoyo en cuanto a
desgaste.
3.10.57
1. Nocken und Lagerzapfen auf Verschleiß

sichtprüfen
9
3.10.57
Bauteile instand setzen Kipphebelbock
Repair of components Rocker arm bracket
Mise en état des composants Support de culbuteur
Reparación de componentes Soporte de balancines
3
Kipphebelbock Bauteile instand setzen
Rocker arm bracket Repair of components
Support de culbuteur Mise en état des composants
Soporte de balancines Reparación de componentes
3
1. Dismantle rocker arm bracket. 1. Démonter le support de culbuteurs. 1. Desarmar el soporte de balancines.
2. Check for wear and replace if 2 Contrôle de l’usure et au besoin 2. Examinar en cuanto a desgaste y
necessary: remplacement reemplazar, si es necesario:
Journals des tourillons, los muñones de apoyo,
Adjusting screw de la vis de réglage, el tornillo de reglaje,
Rocker arm contact face de la surface de frottement des la superficie de deslizamiento del
Bore culbuteurs balancín y
et de l’alésage. el alojamiento.
3. Check oil duct for free passage. 3. Vérifier le libre passage des 3. Comprobar si el conducto de aceite
conduits de graissage. está despejado.
4. Reassemble rocker arm bracket. 4. Compléter l’assemblage du support 4. Completar el soporte de balancines.
Fit circlips. de culbuteurs. Monter les circlips. Montar los anillos de retención.
3.11.61
1. Kipphebelbock zerlegen.
1
q
2. Auf Verschleiß prüfen ggf. austauschen:

Lagerzapfen
Einstellschraube
9
Kipphebelgleitfläche
Bohrung 0
3. Ölkanal auf Durchgang prüfen.

9
3
4. Kipphebelbock komplettieren. Sicherungs-

ringe montieren. 2
8
q
3.11.61
Bauteile instand setzen Einspritzventil
Repair of components Injector
Mise en état des composants Soupape injectrice
Reparación de componentes Inyectór
3
Einspritzventil Bauteile instand setzen
Injector Repair of components
Soupape injectrice Mise en état des composants
Inyectór Reparación de componentes
3
Commercial tool required: Outillage usuel: Herramientas comerciales:

Long socket a/flats 15 ________ 8021 Clé à douille longue de 15 _____ 8021 Llave de vaso largo de 15 _____ 8021
Special tool required: Outillage spécial : Herramienta especial:

Retainer Dispositif d’immobilisation pour Soporte
for injector ______________ 110 110 injecteur ________________ 110 110 de inyectores ____________ 110 110
1. Unscrew cap nut. 1. Dévisser l’écrou-raccord. 1. Desenroscar la tuerca de unión.
2. Sequence of parts disassembly: 2. Ordre de démontage des pièces 2. Secuencia del despiece de
componentes:
1. Cap nut 1. Ecrou-raccord
2. Injection nozzle 2. Injecteur 1. Tuercas de unión
3. Adapter 3. Pièce intermédiaire 2. Inyector
4. Thrust pin 4. Tige poussoir 3. Pieza intermedia
5. Compression spring 5. Ressort de pression 4. Perno de presión
6. Shims 6. Rondelles d’épaisseur 5. Muelle de presión
6. Arandelas de reglaje
Wash all parts in clean diesel fuel and Nettoyer toutes les pièces dans du
blow out with compressed air. combustible Diesel et les sécher au jet Lavar todas las piezas en combustible
d’air comprimé. diesel limpio y soplarlas con aire
comprimido.
3. Nozzle needle and nozzle body are 3. L’aiguille et la buse de l’injecteur 3. El cuerpo y la aguja del inyector
lapped together and may neither be sont appariées et rodées ensemble, son piezas perfectamente her-
confused nor exchanged indivi- elles ne doivent pas être inter- manadas por lapeado y, por tanto,
3 dually. Do not touch nozzle needles verties ni changées séparément. Ne no está permitido emparejarlas con
with your fingers. When nozzle pas prendre l’aiguille avec les doigts. otras o cambiarlas individualmente.
body is held in upright position, L’injecteur étant tenu verticalement No tocar la aguja con los dedos.
nozzle needle should by its own l’aiguille doit retomber d’elle-même Con el cuerpo del inyector en
weight slide down slowly and lentement dans son logement. posición vertical, la aguja debe
smoothly on its seating. bajar por su propio peso lenta y
progresivamente, deslizándose
hasta alcanzar su posición final de
asiento.
Note: If nozzle needle does not slide Nota: Si l’aiguille de l’injecteur ne Nota: Si el deslizamiento de la aguja
down smoothly, wash injection glisse pas librement dans son no es progresivo, el inyector
nozzle again in diesel fuel. logement la laver une nouvelle debe lavarse otra vez en
Renew, if necessary. New injection fois, si nécessaire renouveller combustible diesel o cambiarse
nozzle must likewise be washed l’injecteur. por otro nuevo, según el caso.
in clean diesel fuel. Penser à laver tout injecteur Lavar el inyector nuevo
neuf dans du gazole propre. igualmente en combustible
diesel limpio.
3.19.65
Lange Stecknuß SW 15 ______________ 8021
1
Spezialwerkzeug:
Halter für Einspritzventil __________ 110 110 7
1. Überwurfmutter abschrauben.
2. Folge der Einzeldemontage
1. Überwurfmutter
1
2. Einspritzdüse
3. Zwischenstück 0
4. Druckbolzen
5. Druckfeder
6. Ausgleichscheiben
Sämtliche Teile in sauberem Dieselkraftstoff reini-

gen und mit Druckluft ausblasen.
3. Düsennadel und Düsenkörper sind zusam-

men geläppt und dürfen weder vertauscht
noch einzeln ausgetauscht werden.
9
3
Düsennadel nicht mit den Fingern berühren.
Die Düsennadel muß bei senkrecht gehalte- 0
nem Düsenkörper durch ihr Eigengewicht
langsam und ruckfrei auf ihren Sitz gleiten. 5
Hinweis: Bei ruckweisem Abgleiten der Düsen-

nadel die Einspritzdüse erneut in
Dieselkraftstoff auswaschen, bei Be-
darf erneuern.
Neue Einspritzdüse ebenfalls in sau-
berem Dieselkraftstoff reinigen.
3.19.65
4. Sitzflächen des Zwischenstückes auf Ver-

9 schleiß prüfen. Auf Vorhandensein der Zen-
trierstifte achten.
5. Ausgleichscheiben einsetzen.
2 Hinweis: Der Abspritzdruck ist von den Aus-
5 gleichscheiben abhängig.
6. Druckfeder einsetzen.
2
3
7. Druckbolzen mit dem Zentrierbund zur

2 Druckfeder weisend einsetzen.
3.19.66
4. Check seating faces of adapter for 4. Vérifier l’usure des surfaces 4. Examinar las superficies de asiento
wear. Make sure that centering pins portantes de la pièce intermédiaire. de la pieza intermedia en cuanto a
are fitted. Veiller à ce que les pions de desgaste. Prestar atención a la
centrage soient bien en place. existencia de las espigas de
centraje.
5. Insert shims. 5. Intercaler des rondelles d’épaisseur. 5. Colocar las arandelas de reglaje.
Note: The ejection pressure is Nota: la pression de tarage dépend des Nota: La presión de descarga depende
dependent on the shims. rondelles d’épaisseur. de las arandelas de reglaje.
6. Insert compression spring. 6. Placer le ressort de pression. 6. Introducir el muelle de presión.
7. Insert thrust pin with centering 7. Placer la tige poussoir en orientant 7. Colocar el perno de presión con el
collar facing towards compression la collerette de centrage vers le collarín de centraje indicando hacia
spring. ressort. el muelle de presión.
3.19.66
8. Insert adapter with centering pins 8. Placer la pièce intermédiaire avec 8. Introducir la pieza intermedia con
into the bores of the nozzle holder. les pions de centrage dans les las espigas de centraje en los
alésages du porte-injecteur. taladros del portainyector.
Note: The spot facing points to the Nota: le lamage doit être orienté vers Nota: El rebaje debe indicar hacia el
thrust pin. la tige poussoir. perno de presión.
9. Fit injection nozzle with center 9. Placer l’injecteur avec les alésages 9. Asentar el inyector con los taladros
bores mating with the centering de centrage sur les pions de cent- de centraje sobre las espigas de
pins of the adapter. rage de la pièce intermédiaire. centraje de la pieza intermedia.
Note: Take care that nozzle needle Nota: ne pas faire tomber l’aiguille de Nota: La aguja no debe caer fuera del
does not fall out of nozzle body. l’injecteur. cuerpo del inyector.
10. Screw on cap nut. 10. Visser la vis raccord. 10. Enroscar la tuerca de unión.
11. Tighten cap nut. 11. Bloquer la vis-raccord. 11. Apretar la tuerca de unión.

specification: 45 ± 5 Nm de serrage: 45 ± 5 Nm de apriete: 45 ± 5 Nm
For testing and adjusting injector see Pour vérifier et caler l’injecteur, voir Para la verificación y el ajuste del
Chapter 2. chapitre 2. inyector, ver cap. 2.
3.19.67
8. Zwischenstück mit den Zentrierstiften in die

Bohrungen des Düsenhalters einsetzen.
2
Hinweis: Die Ansenkung weist zum Druckbol-
zen. 5
8
9. Einspritzdüse mit den Zentrierbohrungen

auf die Zentrierstifte des Zwischenstückes
aufsetzen.
2
Hinweis: Die Düsennadel darf nicht aus dem 8
Düsenkörper fallen.
5
r
10. Überwurfmutter aufschrauben.

2
3
11. Überwurfmutter festdrehen.
2
Einspritzventil prüfen und einstellen, siehe 6
Kapitel 2.
3.19.67
3
Vorderer Deckel Bauteile instand setzen
Front cover Repair of components
Couvercle avant Mise en état des composants
Tapa delantera Reparación de componentes
3
Assembly tool ___________ 142 850 Dispositif de montage _____ 142 850 Dispositivo de montaje ____ 142 850
Assembly tool ___________ 142 050 Dispositif de montage _____ 142 050 Dispositivo de montaje ____ 142 050
Measuring device for Règle de mesure pour Aparato de medición para
governor shaft arbre du régulateur et el eje del regulador y
and piston protrusion _____ 100 750 dépassement de piston ____ 100 750 saliente de pistón _________ 100 750
1. Remove engine shutdown device, if 1. Si le moteur en est équipé d’un 1. Si existe, desmontar el dispositivo
any. déposer le dispositif d’arrêt. de parada del motor.
2. Detach governor spring. 2. Décrocher le ressort du régulateur. 2. Descolgar el resorte regulador.
3. Remove governor lever shaft. 3. Déposer l’arbre du levier du 3. Desmontar el eje de palanca de
régulateur. regulador.
3.27.71
Spezialwerkzeug:
Montagevorrichtung _____________ 142 850

Montagevorrichtung _____________ 142 050
Meßgerät für Reglerwelle
und Kolbenüberstand ____________ 100 750
1. Falls vorhanden, Motorabstellung abbauen.

1
2. Reglerfeder aushängen.
1
3
3. Reglerhebelwelle abbauen.
1
3.27.71
4. Ausgleichsscheiben unter der Reglerhebel-

1 welle abnehmen.
5. Fliehkraftregler herausnehmen.
1
6. Wellendichtring für Nockenwelle austreiben.

1
3
7. Wellendichtring für Kurbelwelle austreiben.

1
3.27.72
4. Take off shims below governor 4. Retirer les cales de réglage se 4. Sacar las arandelas de ajuste por
lever shaft. trouvant sous l’arbre du régulateur. debajo del eje de palanca de
regulador.
5. Remove centrifugal governor. 5. Retirer le régulateur centrifuge. 5. Retirar el regulador centrífugo.
6. Drive out camshaft seal. 6. Chasser le joint d’arbre à cames. 6. Desmontar golpeando el retén para
el eje de levas.
7. Drive out crankshaft seal. 7. Chasser le joint d’arbre du 7. Desmontar golpeando el retén para
vilebrequin. el cigüeñal
3.27.72
8. Detach spring. 8. Décrocher le ressort. 8. Descolgar el resorte.
9. Drive out dowel sleeve. 9. Chasser la douille de serrage. 9. Desmontar golpeando el casquillo
de sujeción.
10. Remove shutdown lever together 10. Retirer le levier d’arrêt avec les 10. Retirar la palanca de parada con
with spacer bushes. douilles d’écartement. los casquillos distanciadores.
11. Remove shaft together with spacer 11. Oter l’arbre avec la douille 11. Retirar el eje con el casquillo
bush and spring. d’écartement et le ressort. distanciador y resorte.
3.27.73
8. Feder aushängen.
1
9. Spannhülse austreiben.
1
10. Abstellhebel mit Abstandsbuchsen heraus-

nehmen. 1
3
11. Welle mit Abstandsbuchse und Feder her-

ausnehmen. 1
3.27.73
12. Runddichtring herausnehmen.

1
13. Verschlußdeckel abbauen.

1
14. Spannhülse austreiben.

1
3
15. Bolzen heraushebeln.

1 Hinweis: Dichtfläche nicht beschädigen.
5
3.27.74
12. Take out O-seal. 12. Retirer le joint torique. 12. Quitar el anillo tórico.
13. Remove cover. 13. Déposer le couvercle. 13. Desmontar la tapa de cierre.
14. Drive out dowel sleeve. 14. Chasser la douille de serrage. 14. Desmontar golpeando el casquillo
de sujeción.
15. Lever out pin. 15. Décoller le boulon. 15. Sacar el perno, haciendo palanca.
Note: Make sure not to damage Nota: ne pas endommager le plan Nota: Cuidar de no dañar la superficie
sealing surface. d’appui. de cierre.
3.27.74
16. Remove speed control lever 16. Retirer le levier de réglage de 16. Retirar la palanca de ajuste de
together with spacer bush. vitesse avec la douille velocidad con el casquillo
d’écartement. distanciador.
17. Take out O-seal. 17. Retirer le joint torique. 17. Quitar el anillo tórico.
18. Remove full-load stop. 18. Déposer la butée de pleine charge. 18. Desmontar el tope de plena carga.
19. Remove clamping pad, if any. 19. Si le moteur en est équipé d’une, 19. Si existe, quitar la garra de
Unscrew torque control. ôter la patte de serrage. Retirer le sujeción. Desenroscar el
correcteur de débit. mecanismo corrector de par.
3.27.75
16. Drehzahlverstellhebel mit Abstandsbuchse

herausnehmen. 1
17. Runddichtring herausnehmen.

1
18. Vollastanschlag ausbauen.

1
3
19. Falls vorhanden, Spannpratze entfernen.

Angleichung herausschrauben. 1
3.27.75
20. Entlüftungsventil ausbauen.

1
21. Vorderen Deckel sichtprüfen ggf. austau-

9 schen.
22. Vollastanschlag mit Dichtring einbauen.

9
3
0
23. Abstand der Vollastanschlagschraube ein-

2 stellen. Kontermutter festdrehen.
6 Anziehvorschrift: 4,5 Nm
95-3.145
3.27.76
20. Remove vent valve. 20. Déposer la vanne de purge. 20. Desmontar la válvula de purga de
aire.
21. Inspect front cover and replace if 21. Contrôler visuellement le couvercle 21. Examinar visualmente la tapa
necessary. avant, au besoin le remplacer. delantera, sustituyéndola en caso
necesario.
22. Install full-load stop together with 22. Monter la butée de pleine charge 22. Montar el tope de plena carga con
O-seal. avec la bague d’étanchéité. la junta anular.
23. Adjust distance of full-load stop 23. Régler l’espace de la vis de pleine 23. Ajustar la distancia del tornillo de
screw. Tighten locknut. charge. Bloquer le contre-écrou. tope de plena carga. Apretar la
contratuerca.
Tightening specification: 4.5 Nm Consigne de serrage: 4,5 Nm Prescripción de apriete: 4,5 Nm
3.27.76
24. Inspect individual components of 24. Contrôler visuellement les diverses 24. Si existen, examinar visualmente
torque control, if any, and replace pièces du correcteur de débit, au los componentes del mecanismo
if necessary. besoin les remplacer. corrector de par, sustituyéndolos
en caso necesario.
25. Preassemble torque control. 25. Préassembler le correction de 25. Prearmar el mecanismo corrector
Turn item 1 as far as it will go into débit. de par.
item 2. Then unsrew by 1 + 0.5 turns. Insérer jusqu’en position de butée Enroscar la pieza 1 en la pieza 2
Tighten item 3. le repère 1 dans le repère 2. hasta el tope. A continuación,
Ensuite desserrer d’un tour et demi. desenroscaria una vuelta y media.
Bloquer le repère 3. Apretar la pieza 3.

specification: 16 ± 1.6 Nm de serrage 16 ± 1,6 Nm de apriete: 16 ± 1,6 Nm
26. Turn item 4 as far as it will go into 26. Insérer rep. 4 jusqu’en butée de 26. Introducir girando la pieza 4 en la
item 5. Then unscrew by 1 turn. rep. 5. Ensuite dévisser d’un tour. pieza 5 hasta el tope. Luego,
Tighten item 6. Serrer ensuite rep. 6. girarla 1 vuelta entera en sentido
3 contrario.
Apretar la pieza 6.

specification: 6 ± 0.6 Nm de serrage: 6 ± 0,6 Nm de apriete: 6 ± 0,6 Nm
27. Turn in torque control. 27. Monter et visser le correcteur de 27. Enroscar el mecanismo corrector
débit. de par.
3.27.77
24. Falls vorhanden, Einzelteile der Angleichung

sichtprüfen. Ggf. austauschen.
9
0
95-3.146
25. Angleichung vormontieren.

Pos. 1 bis Anschlag in Pos. 2 hineindrehen,
Anschließend 1 + 0,5 Umdrehungen her-
2 1 2 3
ausdrehen.
Pos. 3 festdrehen. 6
Anziehvorschrift: 16 ± 1,6 Nm
95-3.147
26. Pos. 4 bis zur Anlage an Pos 5 hineindrehen.

Anschließend 1 Umdrehung herausdrehen.
Pos. 6 festdrehen.
2 5 4 6
3
Anziehvorschrift: 6 ± 0,6 Nm 6
95-3.148
27. Angleichung hineindrehen.

2
3.27.77
28. Einschraubtiefe messen: 6,4 ± 0,5 mm

6
29. Spannpratze auflegen.

2
30. Spannmutter festdrehen.

2 Anziehvorschrift: 10 ± 1 Nm
3 6 Hinweis: Zur exakten Angleicheinstellung ist
5 ein Prüfstandslauf erforderlich.
31. Wellendichtring für Nockenwelle ungeölt

2 einpressen.
ß
7
3.27.78
28. Gauge thread reach: 6.4 ± 0.5 mm 28 Faire un relevé de la profondeur de 28. Medir la profundidad de
vissage: 6,4 ± 0,5 mm. enroscado: 6,4 ± 0,5 mm.
29. Position clamping pad. 29. Placer une patte de serrage. 29. Colocar la garra de sujeción.
30. Tighten clamping nut. 30. Serrer l’écrou de serrage 30. Apretar la tuerca de fijación.

specification: 10 ± 1 Nm de serrage: 10 ± 1 Nm. de apriete: 10 ± 1 Nm 3
Note: Bench test required for precise Nota: pour effectuer une correction de Nota: Para el ajuste exacto de la
adjustment of torque control. débit très précise il faut procéder asimilación se necesita una
à une marche au banc d’essais. marcha en el banco de pruebas.
31. Press in camshaft seal without 31. Monter à la presse joint d’arbre à 31. Introducir a presión y sin aceitar el
using oil. cames sans l’huiler. retén para el eje de levas.
3.27.78
32. Press in crankshaft seal without 32. Monter à la presse le joint de 32. Introducir a presión y sin aceitar el
using oil. vilebrequin sans l’huiler. retén para el cigüeñal.
33. Adjust distance of shutdown stop 33. Régler l’écartement de la vis de 33. Ajustar la distancia del tornillo del
screw and tighten: butée de stop et serrer. tope de parada y apretarlo.
34. Adjust distance of min. speed 34. Régler l’écartement de la vis 34. Ajustar la distancia del tornillo de
setscrew and tighten. d’accélération min puis serrer. velocidad mínima y apretarlo.
3 Tightening specification: 4.5 Nm Consigne de serrage: 4,5 Nm Prescripción de apriete: 4,5 Nm
Note: The above adjustment data rep Nota: les précisions de réglage Nota: En los datos de ajuste
resent basic values. It is neces- précitées sont des valeurs de precitados se trata de valores
sary to carry out a bench test for base. Pour le réglage de la básicos. Para el ajuste de la
setting engine power and speed. puissance et de la vitesse de potencia y de la velocidad se
rotation, il est nécessaire de requiere una marcha en el banco
procéder à une marche au banc de pruebas.
d’essais.
35. Slide spacer bush and spring 35. Glisser la douille d’écartement sur 35. Colocar sobre el eje de parada el
onto shutdown shaft. l’arbre d’arrêt. casquillo distanciador y el resorte.
3.27.79
32. Wellendichtring für Kurbelwelle ungeölt ein-

pressen.
2
ß
7
33. Abstand der Stop-Anschlagschraube ein-

stellen und festdrehen.
2
Anziehvorschrift: 4,5 Nm
6
95-3.155
34. Abstand der min. Drehzahlschraube einstel-

len und festdrehen. 2
6 3
Hinweis: Die vorgenannten Einstellangaben
sind Grundwerte. Zur Leistungs- und 5
Drehzahleinstellung ist ein Prüfstands-
lauf erforderlich.
95-3.156
35. Abstandsbuchse und Feder auf Abstellwelle

schieben. 2
3.27.79
36. Abstellwelle einbauen.

2
95-3.158
37. Eingefetteten Runddichtring auf die Welle

2 schieben.
u
ß
38. Abstandsbuchse aufschieben.

2
3
39. Abstellhebel mit Spannhülse montieren.

2
3.27.80
36. Install shutdown shaft. 36. Monter l’arbre d’arrêt. 36. Montar el eje de parada.
37. Slide greased O-seal onto shaft. 37. Introduire le joint d’arbre enduit 37. Colocar el anillo tórico engrasado
de graisse sur l’arbre. sobre el eje.
38. Slide on spacer bush. 38. Insérer la douille d’écartement. 38. Colocar el casquillo distanciador.
39. Assemble shutdown lever with 39. Monter le levier d’arrêt avec la 39. Montar la palanca de parada y el
dowel sleeve. douille de serrage. casquillo de sujeción.
3.27.80
40. Fit greased O-seal. 40. Monter un joint torique enduit de 40. Montar el anillo tórico engrasado.
graisse.
41. Fit spacer bush to speed control 41. Monter et enfoncer la douille 41. Montar el casquillo distanciador
shaft and press in. d’écartement sur l’arbre de réglage sobre el eje de velocidad e
de vitesse. introducirlo a presión.
Note: Watch direction of installation of Nota: tenir compte du sens de montage Nota: Prestar atención a la dirección
speed control lever. du levier de réglage de vitesse. de montaje de la palanca de
ajuste de velocidad.
3
42. Assemble speed control lever with 42. Monter le levier de réglage de 42. Montar la palanca de ajuste de
dowel sleeve. vitesse avec la douille de serrage. velocidad con casquillo de
sujeción.
3.27.81
40. Eingefetteten Runddichtring montieren.

2
u
ß
41. Abstandsbuchse auf Drehzahlwelle montie-

ren und eindrücken.
2
Hinweis: Einbaurichtung des Drehzahlverstell-

hebels beachten. 5
8 3
95-3.164
42. Drehzahlverstellhebel mit Spannhülse mon-

tieren. 2
3.27.81
43. Bolzen eintreiben.

2 Hinweis: Nut der Drehzahlverstellwelle muß mit
5 Bohrung für Bolzen auf Überdeckung

stehen.
44. Fliehkraftregler auf Verschleiß sichtprüfen,

9 ggf. austauschen.
45. Reglerteller sichtprüfen, ggf. austauschen.

9
3
0
46. Reglerteller mit Fliehkraftregler montieren.

2 Hinweis: Einbaurichtung beachten.
5
8
3.27.82
43. Drive in pin. 43. Introduire boulon. 43. Introducir a golpes el perno.
Note: Groove of speed control shaft Nota: la rainure de l’arbre de réglage Nota: La ranura del eje de ajuste de
must be in line with pin bore. de vitesse doit correspondre à velocidad tiene que coincidir con
l’alésage du boulon. el taladro para el perno.
44. Inspect centrifugal governor for 44. Contrôler visuellement l’usure du 44. Examinar visualmente el regulador
wear and replace if necessary. régulateur centrifuge, au besoin le centrífugo en cuanto a desgaste,
remplacer. sustituyéndolo en caso necesario.
45. Inspect governor plate and replace 45. Contrôler visuellement le disque 45. Examinar visualmente el plato de
if necessary. du régulateur, au besoin le regulador, sustituyéndolo en caso
remplacer. necesario.
3
46. Assemble governor plate with 46. Monter le disque du régulateur 46. Unir el plato con el regulador
centrifugal governor. avec le régulateur centrifuge. centrífugo.
Note: Watch direction of installation. Nota: tenir compte du sens de Nota: Prestar atención a la dirección
montage. de montaje.
3.27.82
47. Install centrifugal governor in front 47. Poser le régulateur centrifuge dans 47. Colocar el regulador centrífugo en
cover. le couvercle avant. la tapa delantera.
Note: Be careful not to damage sealing Nota: ne pas détériorer la lèvre Nota: No dañar el labio de obturación
lip of shaft seal. d’étanchéité du joint d’arbre. del retén.
48. Inspect roller lever, shaft and 48. Contrôle visuel du levier à galets, 48. Examinar visualmente la palanca
idling lever and replace if de l’arbre et du levier de ralenti, les de rodillos, el eje y la palanca de
necessary. remplacer au besoin. marcha en vacío, sustituyéndolos
en caso necesario.
49. Insert shims of at least 0.3 mm 49. Au cas où il y aurait des cales de 49. Colocar en los puntos „K“ y „L“
thickness at points „K“ and „L“. compensation, intercaler aux arandelas de ajuste de por lo
points „K“ et „L“ une épaisseur menos 0,3 mm.
3 d’au moins 0,3 mm.
50. Install governor lever shaft without 50. Monter l’arbre du levier du 50. Montar el eje de palanca de
idling lever. Tighten bolts. régulateur sans levier de ralenti. regulador sin la palanca de marcha
Serrer les vis. en vacío. Apretar los tornillos.
Tightening specification: 9.2 Nm Consigne de serrage 9,2 Nm. Prescripción de apriete: 9,2 Nm
3.27.83
47. Fliehkraftregler in vorderen Deckel einset-

zen.
2
Hinweis: Dichtlippe des Wellendichtringes nicht
beschädigen. 5
r
48. Rollenhebel, Welle und Leerlaufhebel sicht-

prüfen, ggf. austauschen.
9
0
49. Ausgleichscheiben an den Stellen „K“ und

„L“ mindestens 0,3 mm unterlegen. 2
3
6
50 Reglerhebelwelle ohne Leerlaufhebel ein-

bauen. Schrauben festdrehen. 2
6
3.27.83
Parallelität des Rollenhebels messen:

2 51. Gemessen wird unter leichtem Andruck des
7 Rollenhebels auf dem Kugellager Pos. 1
Hinweis: Meßuhr auf Null stellen.

6
5
52. Meßuhr auf Pos. 2 setzen. Abweichung no-

2 tieren.
Zum Erreichen der geforderten Toleranz von
6 0,05 mm kann an einer Stelle „K oder L“ zu-

sätzlich max. 0,5 mm unterlegt werden.
53. Rollenhebel mit Leerlaufhebel und Welle

2 montieren.
3 5 Hinweis: Einbaurichtung beachten.
54. Reglerhebelwelle kompl. in vorderen Deckel

2 einbauen. Schrauben festdrehen.
3.27.84
Measuring parallelism of roller lever: Relevé du parallélisme du levier à Medición del paralelismo de la
galet: palance de rodillos:
51. Measure on ball bearing, item 1, 51. La mesure se fait en appuyant 51. La medición se realiza presionando
by lightly pressing roller lever. légèrement sur le levier à galets au la palanca de rodillos ligeramente
niveau du roulement à billes (1). a nivel del cojinete de bolas 1.
Note: Set dial gauge to zero. Nota: régler le comparateur sur zéro. Nota: Ajustar el comparador a cero.
52. Place dial gauge on item 2. Note 52. Placer le comparateur sur rep. 2. 52. Colocar el comparador sobre 2.
deviation. Relever l’écart. Anotar la desviación.
To attain the required tolerance of Pour obtenir la tolérance voulue de Para alcanzar la tolerancia exigida
0.05 mm, it is possible to insert an 0,05 mm il est possible de 0,05 mm, se puede colocar
additional shim of max. 0.5 mm d’intercaler en plus au point „K ou adicionalmente una arandela de
either at point „K“ or „L“. L“ une épaisseur maxi de 0,5 mm. hasta 0,5 mm en uno de los
puntos „K“ o „L„.
53. Assemble roller lever with idling 53. Monter le levier à galets avec le 53. Unir la palanca de rodillos con la
lever and shaft. levier de ralenti et l’arbre. palanca de marcha en vacío y con
el eje.
3
Note: Watch direction of installation. Nota: tenir compte du sens de Nota: Observar la dirección de
montage. montaje.
54. Install complete governor lever 54. Monter arbre de levier du 54. Montar el eje de palanca de
shaft in front cover. Tighten bolts. régulateur complet dans couvercle regulador completo en la tapa
avant. Serrer les vis. delantera. Apretar los tornillos.
3.27.84
55. Hook up governor spring. 55. Accrocher le ressort du régulateur. 55. Enganchar el resorte regulador.
56. Mount cover with new gasket. 56. Monter le couvercle en 56. Montar la tapa con una junta
Tighten bolts. renouvellant le joint. nueva. Apretar los tornillos.
Tightening specification: 4.5 Nm Consigne de serrage 4,5 Nm Prescripción de apriete: 4,5 Nm
57. If engine shutdown device is pro- 57. Au cas où le moteur est équipé 57. Si existe un dispositivo de parada
vided, position O-seal and grease. d’un dispositif d’arrêt placer un del motor: colocar y engrasar el
joint torique enduit de graisse. anillo tórico.
3
58. Install engine shutdown device 58. Monter dispositif d’arrêt moteur et 58. Montar el dispositivo de parada y
and tighten bolts. serrer vis. apretar los tornillos.
Tightening specification: 9 Nm Consigne de serrage: 9 Nm Prescripción de apriete: 9 Nm
Note: Watch direction of installation. Nota: respecter le sens de montage. Nota: Observar la dirección de
montaje.
3.27.85
55. Reglerfeder einhängen.

2
56. Deckel mit neuer Dichtung montieren.

Schrauben festdrehen.
2
ß
6
57. Falls Motorabstellung vorhanden.

Runddichtring auflegen und einfetten. 2
u 3
58. Motorabstellung einbauen und Schrauben

festdrehen. 2
6
Hinweis: Einbaurichtung beachten.
5
8
3.27.85
60. Neuen Runddichtring auflegen.

2
ß
61. Kurbelgehäuseentlüftung montieren.

2 Schraube festdrehen.
62. Falls vorhanden, Leerlaufkapsel mit neuem

2 Runddichtring bis Innenkante vorderer
Deckel bündig einschrauben. Sechskant-
3
ß schraube festdrehen.
Anziehvorschrift: 4,6 ± 0,4 Nm

5
6
3.27.86
60. Position new O-seal. 60. Placer un joint torique neuf. 60. Colocar un anillo tórico nuevo.
61. Fit crankcase breather. Tighten 61. Monter évent de carter. Serrer les 61. Montar el elemento de ventilación
bolts. vis. del cárter. Apretar el tornillo.
62. Screw in idle-speed casting, if any, 62. Si le moteur en est équipé d’une, 62. Si existe, enroscar a ras, hasta el
with new O-seal flush with inner visser à fleur, jusqu’au bord canto interior de la tapa delantera,
edge of front cover. Tighten hex. intérieur du couvercle avant, la cápsula de marcha en vacío
bolt. capsule de ralenti avec un joint provista de un anillo tórico nuevo. 3
torique neuf. Apretar el tornillo hexagonal.
Bloquer la vis hexagonale.

specification: 4.6 ± 0,4 Nm de serrage: 4,6 ± 0,4 Nm de apriete: 4,6 ± 0,4 Nm
3.27.86
Bauteile instand setzen Kühlgebläse
Repair of components Blower
Mise en état des composants Turbine de refroidissement
Reparación de componentes Ventilador de refrigeración
3
Kühlgebläse Bauteile instand setzen
Blower Repair of components
Turbine de refroidissement Mise en état des composants
Ventilador de refrigeración Reparación de componentes
3
1. Remove blower jacket inlet. 1. Déposer entrée de l’enveloppe de la 1. Desmontar la entrada envolvente
turbine. del ventilador.
2. Remove air duct. 2. Déposer gaine d’air. 2. Desmontar el canal de aire.
3. Unscrew fastening nut. Remove 3. Dévisser écrou de fixation et 3. Desenroscar la tuerca de fijación.
washer. extraire la rondelle. Quitar la arandela.
4. Remove V-belt pulley and rotor. 4. Retirer la poulie à gorge et la roue à 4. Quitar la polea de correa
aube. trapezoidal y el rotor.
3.39.91
1. Gebläsemantel-Einlauf abbauen.
1
2. Luftkanal abbauen.
1
3. Befestigungsmutter abschrauben. Scheibe

abnehmen. 1
3
4. Keilriemenscheibe und Laufrad abnehmen.

1
3.39.91
5. Distanzscheibe abnehmen.
1
6. Führungsscheibe abnehmen.
1
7. Befestigungsmutter abschrauben.
1
3
8. Generator herausdrücken.
1
3.39.92
5. Remove spacer. 5. Retirer le disque d’écartement. 5. Quitar la arandela distanciadora.
6. Remove guide disc. 6. Retirer le disque de guidage. 6. Quitar el disco de guía.
7. Unscrew fastening nut. 7. Dévisser l’écrou de fixation. 7. Desenroscar la tuerca de fijación.
8. Press out alternator. 8. Extraire l’alternateur. 8. Desmontar a presión el alternador.
3.39.92
9. Inspect all single parts and replace 9. Contrôler visuellement toutes les 9. Examinar visualmente todas las
if necessary. pièces, au besoin les changer. piezas, sustituyéndolas en caso
necesario.
10. Introduce alternator into blower. 10. Placer l’alternateur dans la turbine 10. Colocar el alternador en el
de refroidissement. ventilador.
3 Note: Watch direction of installation. Nota: respecter le sens de montage. Nota: Observar la dirección de
montaje.
11. Position washers, tighten nuts. 11. Placer des rondelles de 11. Colocar las arandelas de calce y
compensation puis bloquer les apretar las tuercas.
écrous.
3.39.93
9. Alle Teile sichtprüfen, ggf. auswechseln.

9
0
9
0
10. Generator in Kühlgebläse einsetzen.

2
3
5
11. Unterlegscheiben auflegen, Muttern festdre-

hen. 2
6
3.39.93
12. Führungsscheibe auflegen.

2 Hinweis: Abgesetzte Seite muß zum Generator
5 weisen.
13. Distanzscheibe auflegen.

2
14. Laufrad einbauen.

2
3
15. Keilriemenscheibe auflegen.

2
3.39.94
12. Position guide disc. 12. Placer une rondelle de guidage. 12. Colocar el disco de guía.
Note: Shouldered side must face Nota: côté à épaulement doit être Nota: La cara escalonada debe indicar
alternator. orienté vers l’alternateur. hacia el alternador.
13. Position spacer. 13. Placer une rondelle intercalaire. 13. Colocar la arandela distanciadora.
14. Install rotor. 14. Monter la roue à aube. 14. Montar el rotor.
15. Position V-belt pulley. 15. Placer la poulie à gorge. 15. Colocar la polea de correa
trapezoidal.
3.39.94
16. Position washer. 16. Placer une rondelle. 16. Colocar la arandela.
17. Screw on fastening nut and 17. Poser écrou de fixation et serrer. 17. Enroscar la tuerca de fijación y
tighten. apretarla.
18. Position blower jacket inlet. 18. Mettre en place entrée de 18. Colocar la entrada envolvente del
l’enveloppe de la turbine. ventilador.
19. Tighten fastening bolts. 19. Serrer vis de fixation. 19. Apretar los tornillos de fijación.
3.39.95
16. Scheibe auflegen.

2
17. Befestigungsmutter aufschrauben und fest-

drehen.
2
6
18. Gebläsemantel-Einlauf aufsetzen.

2
3
19. Befestigungsschrauben festdrehen.
2
6
3.39.95
20. Spaltmaß zwischen Laufrad und Gebläse-

6 mantel-Einlauf messen.
min. = 0,2 mm
max. = 0,8 mm
21. Zur Korrektur entsprechende Distanzschei-

1 be verwenden.
2 Hinweis: Es stehen Distanzscheiben von 5,0 -

7,5 mm zur Verfügung.
22. Luftkanal anbauen.

3.39.96
20. Gauge clearance between rotor 20. Mesurer le jeu d’entrefer entre la 20. Medir la holgura entre el rotor y la
and blower jacket inlet. roue à aube et l’entrée de entrada envolvente del ventilador.
l’enveloppe de la turbine.
min. = 0.2 mm Minimum 0,2 mm mín. = 0,2 mm

max. = 0.8 mm Maximum 0,8 mm máx. = 0,8 mm
21. Use relevant spacer for correction. 21. Pour corriger utiliser des rondelles 21. Para la corrección usar una
intercalaires appropriées. arandela distanciadora que
corresponda.
Note: Spacers with 5.0 - 7.5 mm thick- Nota: il existe des rondelles inter- Nota: Están disponibles arandelas
ness are available. calaires comprises entre 5,0 distanciadoras de 5,0 - 7,5 mm.
et 7,5 mm
22. Mount air duct. Tighten bolt. 22. Remonter la gaine d’air et serrer la 22. Montar el canal de aire. Apretar el
vis. tornillo.
3.39.96
Bauteile instand setzen Spannrolle
Repair of components Idler pulley
Mise en état des composants Galet tendeur
Reparación de componentes Polea tensora
3
Spannrolle Bauteile instand setzen
Idler pulley Repair of components
Galet tendeur Mise en état des composants
Polea tensora Reparación de componentes
3
1. Remove clamping plate. 1. Déposer la patte de serrage. 1. Desmontar la corredera.
2. Replace damaged idler pulley. 2. Remplacer galet tendeur 2. Sustituir la polea tensora
défectueux. defectuosa.
3. Fit clamping plate, Tighten bolt. 3. Reposer la patte de serrage et 3. Montar la corredera. Apretar el
bloquer la vis. tornillo.
3 Tightening specification: 21 Nm Consigne de serrage: 21 Nm Prescripción de apriete: 21 Nm
3.39.101
1. Spannlasche abbauen.
1
2. Schadhafte Spannrolle austauschen.

9
0
3. Spannlasche anbauen. Schraube festdrehen.
2
6 3
3.39.101
Bauteile instand setzen Lüfterantrieb
Repair of components Fan drive
Mise en état des composants Entraînement ventilateur
Reparación de componentes Accionamiento del ventilador
3
Lüfterantrieb Bauteile instand setzen
Fan drive Repair of components
Entraînement ventilateur Mise en état des composants
Accionamiento del ventilador Reparación de componentes
3
Commercial tools required: Entraînement ventilateur Herramientas comerciales:
Torx tool kit ________________ 8189 Outillage Torx ______________ 8189 Juego de herramientas Torx ___ 8189
Internal puller Extracteur intérieur Extractor
1. Undo cheese-head bolt, pull drive 1. Dévisser vis à tête cylindrique, 1. Desenroscar el tornillo de cabeza
hub from bearing carrier. extraire le moyeu d’entraînement cilíndrica. Separar a presión el
du porte-roulement. cubo de accionamiento del
portacojinetes.
2. Take out fastening bolts. 2. Retirer vis de fixation. 2. Retirar los tornillos de fijación.
3. Remove V-belt pulley from drive 3. Déposer poulie à gorge du moyeu. 3. Desmontar la polea de correa
hub. trapezoidal del cubo de
accionamiento.
3.39.105
Handelübliche Werkzeuge:
Torx-Werkzeugsatz _________________ 8189

Innenauszieher
1. Zylinderschraube herausdrehen, Antriebs-

nabe von dem Lagerträger abdrücken.
1
2. Befestigungsschrauben herausnehmen.
1
3
3. Keilriemenscheibe von Antriebsnabe abbauen.

1
3.39.105
4. Vier Sechskantschrauben herausschrau-

1 ben, Scheibe und Zylinderschraube mit
Scheibe herausdrücken.
5. Äußeres Rillenkugellager herausziehen.

1 Hinweis: Das Rillenkugellager ist grundsätz-
5 lich zu erneuern.
6. Sicherungsring aus der Antriebsnabe her-

1 ausnehmen.
3
q
7. Inneres Rillenkugellager aus der Antriebs-

1 nabe herausziehen.
5 Hinweis: Das Rillenkugellager ist bedingt wie-

derverwendbar.
3.39.106
4. Undo four hexagon bolts, press out 4. Dévisser les quatre vis hexagonales 4. Desenroscar los cuatro tornillos
disc and cheese-head screw with puis extraire rondelle et vis à tête hexagonales. Desmontar a presión
washer. cylindrique avec rondelle. el disco y el tornillo de cabeza
cilíndrica con arandela.
5. Pull out outer grooved ball bearing. 5. Retirer le roulement rainuré à billes 5. Extraer el cojinete de bolas fijo
extérieur. exterior.
Note: The grooved ball must always be Nota: changer systématiquement le Nota: El cojinete deberá ser sustituido
renewed. roulement rainuré à billes. siempre por otro nuevo.
6. Take out circlip from drive hub. 6. Extraire le circlip du moyeu. 6. Sacar el anillo de retención del
cubo de accionamiento.
7. Pull out inner grooved ball bearing 7. Extraire le roulement rainuré à 7. Extraer el cojinete de bolas fijo
from drive hub. billes du moyeu. interior del cubo de accionamiento.
Note: The grooved ball bearing is pos- Nota: le roulement à billes n’est qu’en Nota: El cojinete es reutilizable
sibly still fit for further use. partie réutilisable. condicionalmente.
3.39.106
8. Press in inner grooved ball bearing 8. Enfoncer roulement rainuré à billes 8. Introducir a presión el cojinete de
via outer race as far as it will go. intérieur par la bague extérieure bolas fijo interior, a través del anillo
jusqu’en position de butée. exterior, hasta el tope.
9. Insert circlip in drive hub. 9. Insérer circlip sur le moyeu. 9. Colocar el anillo de retención en el
cubo de accionamiento.
10. Press in outer grooved ball bearing 10. Enfoncer roulement rainuré à billes 10. Introducir a presión el cojinete de
via outer race as far as it will go. extérieur par la bague extérieure bolas fijo exterior, a través del
jusqu’en position de butée. anillo exterior, hasta el tope.
3
11. Fit V-belt pulley. Tighten bolts. 11. Monter poulie à gorge. Serrer les 11. Montar la polea de correa
vis. trapezoidal. Apretar los tornillos.
Note: Watch direction of installation. Nota: respecter le sens de montage. Nota: Observar la dirección de
montaje.
3.39.107
8. Inneres Rillenkugellager über den Außen-

ring bis zur Anlage eindrücken.
2
9. Sicherungsring in die Antriebsnabe einset-

zen.
2
q
10. Äußeres Rillenkugellager über den Außen-

ring bis zur Anlage eindrücken. 2
3
11. Keilriemenscheibe anbauen. Schrauben fest-

drehen. 2
6
5
8
3.39.107
12. Drei Befestigungsschrauben in Lagerträger

2 einstecken.
13. Lagerfläche für äußeres Rillenkugellager

2 mit Sicherungsmittel DEUTZ DW 55 be-
streichen.
14. Zylinderschraube mit Scheibe einsetzen

2 und festdrehen.
3 6 Anziehvorschrift: 21 Nm
Antriebsnabe auf den Lagerträger aufsetzen.
15. Scheibe mit Führungsbund nach außen wei-

2 send einsetzen.
3.39.108
12. Insert three fastening bolts in 12. Introduire les trois vis dans le 12. Meter los tres tornillos de fijación
bearing carrier. porte-roulement. en el portacojinetes.
13. Apply locking compound DEUTZ 13. Enduire surface du roulement 13. Aplicar DEUTZ DW 55 a la
DW 55 to bearing surface of outer rainuré à billes extérieur de pâte superficie de soporte del cojinete
grooved ball bearing. d’étanchéité DEUTZ DW 55. de bolas fijo exterior.
14. Insert cheese-head screw together 14. Placer vis à tête cylindrique avec 14. Montar el tornillo de cabeza
with washer and tighten. rondelle et serrer. cilíndrica con arandela y apretarlo.
Tightening specification: 21 Nm Consigne de serrage: 21 Nm Prescripción de apriete: 21 Nm 3

Place drive hub on bearing carrier. Placer moyeu sur le porte- Colocar el cubo de accionamiento
roulement. sobre el portacojinetes.
15. Insert washer with guide collar 15. Placer rondelle avec collerette de 15. Introducir la arandela con el
pointing to the outside. guidage orientée vers l’extérieur. collarín de guía indicando hacia el
exterior.
3.39.108
16. Screw in four hexagon bolts, grade 16. Introduire les quatre vis hexagona- 16. Enroscar los cuatro tornillos
10.9, and tighten. les type 10.9 et serrer. hexagonales, calidad 10.9, y
apretarlos.
With mounted fan: Pour montage de ventilateur: En caso de montaje del ventilador:
Tightening specification: 30 Nm consigne de serrage: 30 Nm Prescripción de apriete: 30 Nm
3.39.109
16. Vier Sechskantschrauben Qualität 10.9 ein-

schrauben und festdrehen. 2
Bei Lüfteranbau:
Anziehvorschrift: 30 Nm 6
3.39.109
1
2
5
2
3
Hydraulikpumpen-Konsole Bauteile instand setzen
Hydraulic pump bracket Repair of components
Console de pompe hydraulique Mise en état des composants
Soporte de la bomba hidráulica Reparación de componentes
3
Bauteile instand setzen Hydraulikpumpen-Konsole
Repair of components Hydraulic pump bracket
Mise en état des composants Console de pompe hydraulique
Reparación de componentes Soporte de la bomba hidráulica
1. Take out coupling sleeve 1. Retirer la douille d’accouplement. 1. Sacar el manguito de acoplamiento.
2. Remove circlip. 2. Oter le circlip. 2. Retirar el anillo de retención.
3. Remove circlip. 3. Oter le circlip. 3. Retirar el anillo de retención.
4. Press out hydraulic pump gear. 4. Chasser le pignon de pompe 4. Desmontar a presión el engranaje
hydraulique. de la bomba hidráulica.
3.83.113
1. Kupplungshülse herausnehmen.
1
2. Sicherungsring entfernen
1
q
3. Sicherungsring entfernen.
1
3
q
4. Hydraulikpumpenzahnrad herausdrücken.
1
3.83.113
5. Verschlußdeckel abheben.
1
6. Zahnwelle herausdrücken.
1
7. Sicherungsring entfernen
1
3 q
8. Sicherungsring entfernen.
1
q
3.83.114
5. Lift off cover. 5. Soulever le couvercle. 5. Quitar la tapa de cierre.
6. Press out toothed shaft. 6. Chasser l’arbre cannelé. 6. Desmontar por presión el eje
dentado.
7. Remove circlip. 7. Oter le circlip. 7. Quitar el anillo de retención.
8. Remove circlip. 8. Oter le circlip. 8. Quitar el anillo de retención.
3.83.114
9. Press out ball bearing. 9. Extraire le roulement à billes. 9. Desmontar por presión el cojinete
de bolas.
10. Inspect component parts. 10. Contrôle visuel des différentes 10. Examinar visualmente los
pièces. componentes.
Note: Renew component parts, if Nota: au besoin renouveller les pièces. Nota: Sustituir los componentes en
necessary. caso necesario.
11. Press in ball bearing. 11. Introduire le roulement à billes. 11. Introducir a presión el cojinete de
bolas.
12. Insert circlip. 12. Mettre en place le circlip. 12. Introducir el anillo de retención.
3.83.115
9. Kugellager herausdrücken.
1
10. Einzelteile sichtprüfen.
Hinweis: Einzelteile ggf. erneuern.

9
0
11. Kugellager eindrücken.

2
3
12. Sicherungsring einsetzen.

2
q
3.83.115
13. Sicherungsring auf Zahnwelle einsetzen.

2
q
14. Zahnwelle mit Graphitfett eindrücken.

2 Hinweis: Auf Sicherungsring achten.
u
5
q
15. Hydraulikpumpenzahnrad eindrücken.

2
3

2
q
3.83.116
13. Place circlip on toothed shaft. 13. Placer circlip sur l’arbre cannelé. 13. Montar el anillo de retención sobre
el eje dentado.
14. Press in toothed shaft with 14. Introduire l’arbre cannelé avec de 14. Introducir a presión, con grasa
graphite grease. la graisse au graphite. grafitada, el eje dentado.
Note: Pay attention to circlip. Nota: attention au circlip! Nota: Prestar atención al anillo de
retención.
15. Press in hydraulic pump gear. 15. Introduire le pignon de la pompe 15. Introducir a presión el engranaje
hydraulique. de la bomba hidráulica.
16. Insert circlip. 16. Mettre en place le circlip. 16. Montar el anillo de retención.
3.83.116
17. Press cover down. 17. Enfoncer le couvercle. 17. Montar a presión la tapa de cierre.
18. Insert circlip. 18. Placer le circlip. 18. Montar el anillo de retención.
19. Insert coupling sleeve with 19. Mettre en place la douille 19. Introducir el manguito de
graphite grease. d’accouplement avec de la graisse acoplamiento con grasa grafitada.
au graphite.
3
3.83.117
17. Verschlußdeckel aufdrücken.

2

2
q
19. Kupplungshülse mit Graphitfett einsetzen.

2
3
u
3.83.117
1
2
5
2
3

Despiece y ensamblado conjunto de moteur
1011 F
Inhalts-Verzeichnis Demontage und Montage, Motor komplett
Table of Contents Disassembly and reassembly of complete engine
Sommaire Démontage et montage moteur complet
Indice Despiece y ensamblado conjunto de motor
Deutsch
4. Demontage und Montage, Motor komplett
Benennung Seite
Motor zerlegen ___________________________________ 4.00.01 - 4.00.16
Motor zusammenbauen: ___________________________________
Thermostat / Öldruckregelventil / Öldruckschalter _________________________ 4.00.17 - 4.00.19
Stößel / Nockenwelle ___________________________________ 4.00.20 - 4.00.21
Kurbelwellenlagerung ___________________________________ 4.00.21 - 4.00.24
Hinterer Deckel ___________________________________ 4.00.24
Kolbenklassenbestimmung ___________________________________ 4.00.24 - 4.00.25
Kolben mit Pleuel ___________________________________ 4.00.25 - 4.00.26
Vorderer Deckel ___________________________________ 4.00.27
Kurbelwellenzahnriemenrad ___________________________________ 4.00.27 -4.00.30
Nockenwellenzahnriemenrad ___________________________________ 4.00.30
Schmierölpumpe ___________________________________ 4.00.31
Zahnriemeneinstellung / Spannrolle ___________________________________ 4.00.31 - 4.00.35
Steuerzeiten-Kontrolle ___________________________________ 4.00.35 - 4.00.37
Zylinderkopf / Ventiltrieb ___________________________________ 4.00.38 - 4.00.40
Luftansaugrohr / Abgassammelrohr ___________________________________ 4.00.41 - 4.00.42
Einspritzpumpe ___________________________________ 4.00.42 - 4.00.46
Einspritzventile ___________________________________ 4.00.47
Kühlgebläse ___________________________________ 4.00.48
Kraftstoffleitung / Einspritzleitungen ___________________________________ 4.00.48 - 4.00.49
Kraftstofförderpumpe /Kraftstoffiltererkonsole / Kraftstoffilter / Ölfilter _________ 4.00.50 - 4.00.52
Luftführung / Ölkühler ___________________________________ 4.00.52 - 4.00.54
Anschlußgehäuse / Schwungrad ___________________________________ 4.00.54 - 4.00.55
Hydraulikpumpenkonsole ___________________________________ 4.00.55 - 4.00.57
Hydraulikpumpe ___________________________________ 4.00.58
Zahnriemenschutzgehäuse / Keilriemenscheibe / Keilriemen _________________ 4.00.59 - 4.00.60
Luftpresser ___________________________________ 4.00.61 - 4.00.63
Ölansaugrohr / Ölwanne ___________________________________ 4.00.63 - 4.00.66
Starter / Aufstellfuß ___________________________________ 4.00.66 - 4.00.67
Austausch der Wellendichtringe am kompletten Motor _____________________ 4.00.69 - 4.00.71
Abgasturbolader ab- und anbauen ___________________________________ 4.00.73 - 4.00.76
Generator und Lüfterantrieb ab- und anbauen ____________________________ 4.00.77 - 4.00.79
Generator ab- und anbauen ___________________________________ 4.00.79 - 4.00.81
Ladedruckabhängiger Vollastanschlag __________________________________ 4.00.82
Kurbelgehäuseentlüftung ___________________________________ 4.00.82
4
Demontage und Montage, Motor komplett Inhalts-Verzeichnis
Disassembly and reassembly of complete engine Table of Contents
Démontage et montage moteur complet Sommaire
Despiece y ensamblado conjunto de motor Indice
English
4. Disassembly and reassembly of complete engine
Description Page
Dismantling engine ___________________________________ 4.00.01 - 4.00.16
Reassembling engine: ___________________________________
Thermostat / oil pressure control valve / oil pressure switch 4.00.17 - 4.00.19
Tappets / camshaft ___________________________________ 4.00.20 - 4.00.21
Crankshaft bearings ___________________________________ 4.00.21 - 4.00.24
Rear cover ___________________________________ 4.00.24
Determining the piston class ___________________________________ 4.00.24 - 4.00.25
Piston with connecting rod ___________________________________ 4.00.25 - 4.00.26
Front cover ___________________________________ 4.00.27
Crankshaft toothed belt gear ___________________________________ 4.00.27 -4.00.30
Camshaft toothed belt gear ___________________________________ 4.00.30
Lube oil pump ___________________________________ 4.00.31
Toothed belt adjustment / idler pulley __________________________________ 4.00.31 - 4.00.35
Valve timing check ___________________________________ 4.00.35 - 4.00.37
Cylinder head / valve gear ___________________________________ 4.00.38 - 4.00.40
Air intake manifold / exhaust manifold __________________________________ 4.00.41 - 4.00.42
Injection pump ___________________________________ 4.00.42 - 4.00.46
Injectors ___________________________________ 4.00.47
Blower ___________________________________ 4.00.48
Fuel line / injection lines ___________________________________ 4.00.48 - 4.00.49
Fuel feed pump / fuel filter bracket / fuel filter / oil filter ____________________ 4.00.50 - 4.00.52
Air ducting / oil cooler ___________________________________ 4.00.52 - 4.00.54
Adapter housing / flywheel ___________________________________ 4.00.54 - 4.00.55
Hydraulic pump bracket ___________________________________ 4.00.55 - 4.00.57
Hydraulik pump ___________________________________ 4.00.58
Toothed belt guard / V-belt pulley / V-belt _______________________________ 4.00.59 - 4.00.60
Air compressor ___________________________________ 4.00.61 - 4.00.63
Oil suction pipe / oil pan ___________________________________ 4.00.63 - 4.00.66
Starter / mounting foot ___________________________________ 4.00.66 - 4.00.67
Renewing shaft seals on complete engine _______________________________ 4.00.69 - 4.00.71
Removing and refitting exhaust turbocharger ____________________________ 4.00.73 - 4.00.76
Removing and refitting alternator and fan drive ___________________________ 4.00.77 - 4.00.79
Removing and refitting alternator ___________________________________ 4.00.79 - 4.00.81
Manifold-pressure compensator ___________________________________ 4.00.82
Crankcase breather ___________________________________ 4.00.82
4
Sommaire Démontage et montage moteur complet
Français
4. Démontage et montage moteur complet
Désignation Page
Démontage du moteur ___________________________________ 4.00.01 - 4.00.16
Assemblage du moteur: ___________________________________
Thermostat / soupape de régulation de pression d’huile /
interrupteur de pression d’huile ___________________________________ 4.00.17 - 4.00.19
Poussoir / arbre à cames ___________________________________ 4.00.20 - 4.00.21
Paliers de vilebrequin ___________________________________ 4.00.21 - 4.00.24
Couvercle arrière ___________________________________ 4.00.24
Détermination de la catégorie de piston _________________________________ 4.00.24 - 4.00.25
Piston avec bielle ___________________________________ 4.00.25 - 4.00.26
Couvercle avant ___________________________________ 4.00.27
Pignon de courroie crantée du vilebrequin ______________________________ 4.00.27 -4.00.30
Pignon de courroie crantée d’arbre à cames _____________________________ 4.00.30
Pompe à huile de graissage ___________________________________ 4.00.31
Réglage de la courroie crantée / galet tendeur ____________________________ 4.00.31 - 4.00.35
Contrôle du calage de la distribution ___________________________________ 4.00.35 - 4.00.37
Culasse / commande des soupapes ___________________________________ 4.00.38 - 4.00.40
Collecteur d’admission / collecteur d’échappement _______________________ 4.00.41 - 4.00.42
Pompe d’injection ___________________________________ 4.00.42 - 4.00.46
Inyecteurs ___________________________________ 4.00.47
Turbine de refroidissement ___________________________________ 4.00.48
Conduite d’alimentation / conduites de refoulement _______________________ 4.00.48 - 4.00.49
Pompe d’alimentation / console de filtre à combustible /
filtre à combustible / filtre à huile ___________________________________ 4.00.50 - 4.00.52
Gaine de guidage d’air / radiateur à huile ________________________________ 4.00.52 - 4.00.54
Carter d’adaptation / volant ___________________________________ 4.00.54 - 4.00.55
Console de pompe hydraulique ___________________________________ 4.00.55 - 4.00.57
Pompe hydraulique ___________________________________ 4.00.58
Carter cache-courroie / courroie à gorge / courroie ________________________ 4.00.59 - 4.00.60
Compresseur d’air ___________________________________ 4.00.61 - 4.00.63
Tube d’aspiration d’huile / carter d’huile ________________________________ 4.00.63 - 4.00.66
Démarreur / Pied de fixation ___________________________________ 4.00.66 - 4.00.67
Remplacement des joints d’arbre sur moteur complet _____________________ 4.00.69 - 4.00.71
Dépose et repose du turbocompresseur d’échappement ____________________ 4.00.73 - 4.00.76
Déposer et reposer alternateur et entraînement du ventilateur _______________ 4.00.77 - 4.00.79
Déposer et reposer l’alternateur ___________________________________ 4.00.79 - 4.00.81
Correcteur de débit ___________________________________ 4.00.82
Event de carter ___________________________________ 4.00.82
4
Démontage et montage moteur complet Sommaire
Español
4. Despiece y ensamblado conjunto de motor
Denominación Página
Desarmado del motor ___________________________________ 4.00.01 - 4.00.16
Rearmado del motor: ___________________________________
Termostato / válvula de presión de aceite / interruptor de presión aceite _______ 4.00.17 - 4.00.19
Empujadores / árbol de levas ___________________________________ 4.00.20 - 4.00.21
Apoyos del cigüeñal ___________________________________ 4.00.21 - 4.00.24
Tapa trasera ___________________________________ 4.00.24
Determinación de la clase de pistón ___________________________________ 4.00.24 - 4.00.25
Pistón con biela ___________________________________ 4.00.25 - 4.00.26
Tapa delantera ___________________________________ 4.00.27
Rueda de correa dentada en el cigüeñal ________________________________ 4.00.27 -4.00.30
Rueda de correa dentada del árbol de levas ______________________________ 4.00.30
Bomba de aceite lubricante ___________________________________ 4.00.31
Ajuste de la correa dentada / polea tensora ______________________________ 4.00.31 - 4.00.35
Control de las cotas de reglaje ___________________________________ 4.00.35 - 4.00.37
Culata / accionamiento de las válvulas __________________________________ 4.00.38 - 4.00.40
Colector de admisión / colector de escape ______________________________ 4.00.41 - 4.00.42
Bomba de inyección ___________________________________ 4.00.42 - 4.00.46
Inyectores ___________________________________ 4.00.47
Ventilador de refrigeración ___________________________________ 4.00.48
Tubería de combustible / tuberías de inyección ___________________________ 4.00.48 - 4.00.49
Bomba de alimentación de combustible / consola del filtro de
combustible / filtro de combustible / filtro de aceite _______________________ 4.00.50 - 4.00.52
Conducción de aire / refrigerador de aceite ______________________________ 4.00.52 - 4.00.54
Cárter de adaptación / volante ___________________________________ 4.00.54 - 4.00.55
Soporte de la bomba hidráulica ___________________________________ 4.00.55 - 4.00.57
Bomba hidráulica ___________________________________ 4.00.58
Cubierta protectora de correas dentadas / polea de correa trapezoidal /
correa trapezoidal ___________________________________ 4.00.59 - 4.00.60
Compresor de aire ___________________________________ 4.00.61 - 4.00.63
Tubo de aspiración de aceite / cárter de aceite ___________________________ 4.00.63 - 4.00.66
Arrancador / pata de colocación ___________________________________ 4.00.66 - 4.00.67
Sustitución de los retenes en el motor completo __________________________ 4.00.69 - 4.00.71
Desmontaje y montaje del turbocompresor ______________________________ 4.00.73 - 4.00.76
Desmontaje y montaje del alternador y accionamiento del ventilador __________ 4.00.77 - 4.00.79
Desmontaje y montaje del alternador __________________________________ 4.00.79 - 4.00.81
Tope de plena carga dependiente de la presión de sobrealimentación __________ 4.00.82
Ventilación del cárter ___________________________________ 4.00.82
4
4
Dismantling engine Démontage du moteur Desarmado del motor
Torx tools _________________ 8189 Outils Torx _________________ 8189 Herramental Torx ____________ 8189
Cobra clamp pliers ___________ 8011 Pince à ressorts Cobra _______ 8011 Alicates Cobra
Multipower tool _____________ 8049 Multiplicateur de couple ______ 8049 para abrazaderas ____________ 8011
Socket a/flats 32 ____________ 8036 Clé à douille de 32 __________ 8036 Multiplicador de fuerza _______ 8049
Llave de vaso _______________ 8036
Special tools required: Outillage usuel: Herramientas especiales:
Engine assembly stand _______ 6067 Chevalet de Caballete de

Angled clamping plate ____ 6067/115 montage de moteur __________ 6067 montaje de motores __________ 6067
Adjusting pin ____________ 100 700 Support d’ablocage ______ 6067/115 Soporte de fijación _______ 6067/115
Special wrench Pige de réglage __________ 100 700 Perno de ajuste __________ 100 700
for injection line __________ 110 490 Clé spéciale pour Llave especial para
Puller _________________ 143 100 conduite d’injection _______ 110 490 tuberías de inyección ______ 110 490
Dolly _________________ 143 420 Outil à chasser ___________ 143 100 Dispositivo de
Intermediate disc _________ 143 430 Dispositif d’immobilisation __ 143 420 separación por presión ____ 143 100
Dolly for camshaft gear ____ 144 130 Disque intermédiaire ______ 143 430 Contrasoporte ___________ 143 420
Special wrench Dispositif d’imobilisation Arandela intermedia _______ 143 430
for oil pressure sensor ____ 170 110 pour pignon Contrasoporte para la rueda
d’arbre à cames __________ 144 130 dentada en el árbol de levas _ 144 130
Clé spéciale pour capteur Llave especial para transmisores
de pression d’huile _______ 170 110 de presión de aceite _______ 170 110
The repair procedure outlined in this Les travaux de réparation indiqués ne Los trabajos de reparación ilustrados
chapter refers to the standard specifi- tiennent pas compte de la diversité des no consideran los diversos volúmenes
cation, i.e. components for customi- volumes de livraison des clients, c’est- de suministro según pedidos de
zing the engine are not shown. à-dire que les pièces annexes différen- clientes, o sea, elementos que difieren
tes du modèle standard ne sont pas de la versión normal no se muestran.
présentées dans le présent Manuel.
1. Remove mounting foot. 1. Déposer le pied de fixation. 1. Desmontar la pata de colocación.
4.00.01
Motor zerlegen
Torx-Werkzeuge ____________________ 8189

Cobraklemmenzange ________________ 8011
Kraftvervielfältiger __________________ 8049
Stecknuß _________________________ 8036
Spezialwerkzeuge:
Motor-Montagebock ________________ 6067

Aufspannhalter ________________ 6067/115
Einstellbolzen ___________________ 100 700
Abdrückvorrichtung ______________ 143 100
Gegenhalter ____________________ 143 420
Zwischenscheibe ________________ 143 430
Gegenhalter für Nockenwellenrad ___ 144 130
Spezialschlüssel für Öldruckgeber ___ 170 110
Bei dem gezeigten Reparaturablauf sind unter-

schiedliche Kundenumfänge nicht berücksich-
tigt, d.h. von der Standard-Ausführung abwei-
chende Anbauteile werden nicht gezeigt.
1. Aufstellfuß abbauen.
3 4
4.00.01
2. Ladestromleitung und Starter abbauen.

3
3. Aufspannhalter anbauen. Schrauben fest-

4 drehen.
4. Motor an schwenkbaren Montagebock mon-

4 tieren.
7 Hinweis: Richtige Aufhängevorrichtung verwen-

den.
5. Öl bzw. Restöl ablassen, auffangen und vor-
4 ü schriftsmäßig entsorgen.
4.00.02
2. Remove charging current line and 2. Déposer la conduite de courant de 2. Desmontar el cable de corriente de
starter. charge et le démarreur. carga y el arrancador.
3. Mount angled clamping plate. 3. Monter le support d’ablocage et 3. Montar el soporte de fijación.
Tighten bolts. bloquer les vis. Apretar los tornillos.
4. Mount engine to swivelling 4. Monter le moteur sur le chevalet de 4. Montar el motor sobre el caballete
assembly stand. montage pivotable. de montaje orientable.
Note: Use proper suspension device. Nota: utiliser le bon dispositif de Nota: Usar el correcto dispositivo de
manutention. suspensión.
5. Drain, catch remaining oil and 5. Vidanger l’huile ou l’huile restante 5. Evacuar el aceite o aceite residual,
dispose of in accordance with anti- et s’en débarrasser selon la recogerlo y eliminarlo en forma
pollution regulations. réglementation antipollution. reglamentaria. 4
4.00.02
6. Remove hose elbow and V-belt pul- 6. Déposer la tubulure flexible, la 6. Desmontar el codo de manguera y
ley together with shims. Take off V- poulie à gorge et les rondelles de la polea de correa trapezoidal con
belt. compensation. Retirer la courroie arandelas de compensación.
trapézoïdale.
7. Remove lube oil pipe and air 7. Déposer la canalisation d’huile et le 7. Desmontar la tubería de aceite
compressor. compresseur d’air. lubricante y el compresor de aire.
8. Remove hydraulic pump. 8. Déposer la pompe hydraulique. 8. Desmontar la bomba hidráulica.
9. Remove V-belt idler pulley. Take off 9. Déposer le galet tendeur de 9. Desmontar la polea tensora de
V-belt. courroie et retirer cette dernière. correa trapezoidal. Quitar la correa.
4
4.00.03
6. Schlauchkrümmer und Keilriemenscheibe

mit Ausgleichscheiben abbauen. Keilriemen
abnehmen.
3
7. Schmierölleitung und Luftpresser abbauen.

3
8. Hydraulikpumpe abbauen.
3
9. Keilriemenspannrolle abbauen. Keilriemen

abnehmen. 3 4
4.00.03
10. Luftführungshaube abbauen.

3
11. Standblech abbauen.

3
12. Ölkühler abbauen. Falls Steckstücke im Kur-

3 belgehäuse verbleiben, Steckstücke heraus-
nehmen.
5 Hinweis: Auslaufendes Öl auffangen und vor-
schriftsmäßig entsorgen.
Bei B/FM - Motoren.
4 3 13. Ölkühleranschlüsse abbauen.
4.00.04
10. Remove air cowling. 10. Déposer la hotte de guidage d’air. 10. Desmontar la manga guía de aire.
11. Remove stay plate. 11. Déposer la tôle verticale. 11. Desmontar la chapa vertical.
12. Remove oil cooler. If plug-in ele- 12. Déposer le radiateur à huile. Au 12. Desmontar el refrigerador de
ments have remained in the crank- cas où des pièces intercalées aceite. Retirar las piezas de
case, take them out. seraient restées dans le bloc enchufe que hayan quedado en el
moteur, les retirer. bloque motor.
Note: Catch any escaping oil and Nota: Recueillir l’huile qui s’écoule et Nota: Recoger el aceite que sale y
dispose of in accordance with s’en débarrasser selon la eliminarlo en forma
anti-pollution regulations. réglementation antipollution. reglamentaria.
With B/FM engines: Pour moteurs B/FM En motores B/FM:
13. Remove oil cooler connections. 13. Déposer les raccords du radiateur 13. Desmontar los racores del 4
à huile. refrigerador de aceite.
4.00.04
14. Remove air ducting. 14. Déposer le guidage d’air. 14. Desmontar la conducción de aire.
15. Remove blower with alternator and 15. Déposer la turbine de 15. Desmontar el ventilador de
charging current line. refroidissement avec générateur et refrigeración con el alternador y
conduite de courant de charge. cable de corriente de carga.
16. Remove exhaust manifold and air 16. Déposer le collecteur 16. Desmontar los colectores de
intake manifold. d’échappement et le collecteur escape y de admisión.
d’admission.
17. Remove injection lines. 17. Déposer les conduites d’injection. 17. Desmontar las tuberías de
inyección.
4
4.00.05
14. Luftführung abbauen.

3
15. Kühlgebläse mit Generator und Ladestrom-

leitung abbauen. 3
16. Abgassammelrohr und Luftansaugrohr ab-

bauen. 3
17. Einspritzleitungen abbauen.

3 4
7
4.00.05
18. Leckölleitung abbauen.

3
19. Spannpratzen entfernen. Einspritzventile

3 ausbauen.
5 Hinweis: Anschlüsse verschließen.
20. Profilgummi entfernen.

3
21. Kraftstoffleitungen abbauen. Ölmeßstab
4 3 entfernen.
5 Hinweis: Cobraklemmenzange benutzen.
4.00.06
18. Remove leakage fuel pipe. 18. Déposer la tubulure de 18. Desmontar la tubería de
récupération des fuites. combustible sobrante.
19. Remove clamping pads. Remove 19. Oter les pattes de serrage et 19. Quitar las garras de sujeción.
injectors. déposer les injecteurs. Desmontar los inyectores.
Note: Cover up connections. Nota: boucher les orifices. Nota: Cerrar las aberturas.
20. Remove rubber profile. 20. Oter le caoutchouc profilé. 20. Quitar los perfiles de goma.
21. Remove fuel lines. Remove oil 21. Déposer les conduites 21. Desmontar las tuberías de
dipstick. d’alimentation et retirer la jauge combustible. Retirar la varilla para
d’huile. la medición del nivel de aceite. 4
Note: Use Cobra clamp pliers. Nota: utiliser une pince à ressorts Nota: Usar los alicates Cobra para
Cobra pour tuyaux. abrazaderas.
4.00.06
22. Remove oil filter. 22. Déposer le filtre à huile. 22. Desmontar el filtro de aceite.
Note: Catch any escaping oil and dis- Nota: recueillir l’huile qui s’écoule et Nota: Recoger el aceite que sale y
pose of in accordance with anti- s’en débarrasser selon la eliminarlo en forma
pollution regulations. réglementation antipollution. reglamentaria.
23. Remove fuel filter. 23. Déposer le filtre à combustible. 23. Desmontar el filtro de
combustible.
Note: Catch any escaping fuel and dis- Nota: recueillir l’huile qui s’écoule et Nota: Recoger el combustible que sale
pose of in accordance with anti- assurer son élimination selon la y eliminarlo en forma
pollution regulations. réglementation antipollution. reglamentaria.
24. Remove fuel filter bracket and fuel 24. Déposer console du filtre à 24. Desmontar la consola del filtro de
feed pump. combustible et pompe combustible y la bomba de
d’alimentation. alimentación de combustible.
25. Remove mounting foot. 25. Déposer pied de fixation. 25. Desmontar la pata de colocación.
4.00.07
22. Ölfilter abbauen.
Hinweis: Auslaufendes Öl auffangen und vor-

3
5
23. Kraftstoffilter abbauen.
Hinweis: Auslaufender Kraftstoff auffangen

3
und vorschriftsmäßig entsorgen.
5
24. Kraftstoffilterkonsole und Kraftstofförder-

pumpe abbauen. 3
25. Aufstellfuß abbauen.

3 4
4.00.07
26. Öldruckgeber und Verschlußschraube her-

3 ausschrauben.
27. Zylinderkopfhaube abbauen.

3
28. Kipphebelböcke abbauen.

3
29. Stoßstangen herausnehmen.
4 3
4.00.08
26. Unscrew oil pressure sensor and 26. Dévisser capteur d’huile de 26. Desenroscar el transmisor de
screw plug. pression et vis filetée. presión de aceite y el tapón.
27. Remove cylinder head cover. 27. Déposer la culasse. 27. Desmontar la tapa de culata.
28. Remove rocker arm brackets. 28. Déposer les supports de 28. Desmontar los soportes de
culbuteurs. balancines.
29. Take out pushrods. 29. Retirer les tiges de culbuteurs. 29. Sacar las varillas de empuje.
4.00.08
30. Remove cylinder head. 30. Déposer la culasse. 30. Desmontar la culata.
31. Remove injection pumps. 31. Déposer les pompes d’injection. 31. Desmontar las bombas de
inyección.
32. Take out roller tappets for injection 32. Retirer le poussoir à galets de la 32. Sacar el empujador de rodillo de la
pump (using outer circlip pliers). pompe d’injection (à l’aide de la bomba de inyección (con ayuda de
pince d’extérieur). unos alicates de seguridad exterior).
33. Remove thermostat. 33. Déposer le thermostat. 33. Desmontar el termostato.
4.00.09
30. Zylinderkopf abbauen.

3
31. Einspritzpumpen ausbauen.

3
32. Rollenstößel für Einspritzpumpe (mit Hilfe

einer Außensicherungszange) herausneh-
men.
3
33. Thermostat ausbauen.

3 4
4.00.09
34. Öldruckventil ausbauen.

3
35. Verschlußschrauben herausschrauben.

3 Falls Heizungsanschluß vorhanden, Öldruck-
ventile herausnehmen.
36. Riemenscheibe abbauen.

3
37. Zahnriemenschutzgehäuse abbauen.
4 3
4.00.10
34. Remove oil pressure control valve. 34. Déposer la soupape de régulation 34. Desmontar la válvula de presión de
de pression d’huile. aceite.
35. Unscrew screw plugs. If heater 35. Dévisser les vis filetées. En 35. Desenroscar los tapones.
connection is provided, take out oil présence d’un raccord de Si existe un empalme de
pressure control valves. chauffage, retirer les soupapes de calefacción, retirar las válvulas de
régulation de pression d’huile. presión de aceite.
36. Remove belt pulley. 36. Monter la poulie à gorge. 36. Desmontar la polea de correa
trapezoidal.
37. Remove toothed belt guard. 37. Déposer le carter cache-courroie. 37. Desmontar la cubierta protectora
de correas dentadas.
4
4.00.10
38. Take off intermediate disc. 38. Retirer la poulie intermédiaire. 38. Quitar la arandela intermedia.
39. Remove hydraulic pump bracket. 39. Déposer la console de la pompe 39. Desmontar el soporte de la bomba
Remove toothed belt. hydraulique et ôter la courroie hidráulica. Quitar la correa
dentée. dentada.
40. Remove idler pulley. Remove 40. Déposer le galet tendeur et ôter la 40. Desmontar la polea tensora. Quitar
toothed belt. courroie dentée. la correa dentada.
41. Remove camshaft gear. 41. Déposer le pignon d’arbre à cames. 41. Desmontar la rueda dentada del
árbol de levas.
4
4.00.11
38. Zwischenscheibe abnehmen.

3
39. Hydraulikpumpenkonsole abbauen. Zahn-

riemen entfernen. 3
40. Spannrolle abbauen. Zahnriemen entfernen.

3
41. Nockenwellenzahnrad abbauen.

3 4
7
4.00.11
42. Zwischenscheibe aufsetzen.

4
7
43. Gegenhalter für Kurbelwellenzahnrad an-

4 bauen und Schrauben festdrehen.
44. Kraftvervielfälltiger mit Stecknuß (60 IMP)

4 ansetzen.
45. Kraftvervielfälltiger gegenhalten und Zentral-
4 3 schraube lösen. Zahnräder abnehmen.
4.00.12
42. Position intermediate disc. 42. Placer la poulie intermédiaire. 42. Colocar la arandela intermedia.
43. Fit dolly for crankshaft gear and 43. Monter le dispositif 43. Montar el contrasoporte de la
tighten bolts. d’immobilisation du pignon du rueda dentada situada en el
vilebrequin puis bloquer les vis. cigüeñal y apretar los tornillos.
44. Position multipower tool with 44. Placer le multiplicateur de couple 44. Posicionar el multiplicador de
socket (60 IMP). avec la douille (60 IMP). fuerza con la llave de vaso (60
IMP) puesta.
45. Retain multipower tool and loosen 45. Placer et maintenir le multipli- 45. Retener el multiplicador de fuerza
central bolt. Take off gears. cateur de force. Desserrer la vis y soltar el tornillo central.
centrale. Déposer les pignons. Desmontar las ruedas dentadas. 4
4.00.12
46. Remove lube oil pump. 46. Déposer la pompe à huile. 46. Desmontar la bomba de aceite
lubricante.
Note: Catch any escaping oil and Nota: recueillir l’huile qui s’écoule et Nota: Recoger el aceite que sale y
dispose of in accordance with assurer son élimination selon la eliminarlo en forma
anti-pollution regulations. réglementation antipollution. reglamentaria.
47. Turn engine by 180°. Take off oil 47. Virer le moteur de 180° et déposer 47. Girar el motor 180°. Desmontar el
pan. le carter d’huile. cárter de aceite.
48. Remove oil suction pipe. 48. Déposer le tube d’aspiration 48. Desmontar el tubo de aspiración
d’huile. de aceite.
49. Remove piston complete with 49. Déposer l’ensemble piston-bielle. 49. Desmontar el pistón con la biela.
connecting rod.
4
Note: Loosen conrod nut with Nota: desserrer l’écrou de la bielle à Nota: Soltar las tuercas de biela con
dodecagonal socket wrench. l’aide la clé à douille à 12 pans. ayuda de una llave de vaso de
12 cantos.
4.00.13
46. Schmierölpumpe abbauen.

3
5
47. Motor um 180° drehen. Ölwanne abbauen.

3
48. Ölansaugrohr abbauen.

3
49. Kolben mit Pleuel ausbauen.
Hinweis: Pleuelmuttern mit

3 4
12- kant Steckschlüssel lösen.
5
4.00.13
50. Vorderen Deckel abbauen.

3
51. Schwungradschrauben lösen und entfernen.

3 Hinweis: Selbstgefertigten Führungsdorn ver-
5 wenden.
52. Falls Schwungrad festsitzt, Schwungrad-

4 abzieher anbauen. Schwungrad abdrücken.
7
3
53. Aufstellfüße abbauen.
4 3 Hinweis: Falls vorhanden, Anschlußgehäuse ab-

5 bauen.
4.00.14
50. Take off front cover. 50. Déposer le couvercle avant. 50. Desmontar la tapa delantera.
51. Undo and remove flywheel bolts. 51. Desserrer et ôter les vis du volant 51. Soltar y quitar los tornillos del
moteur. volante.
Note: Use self-made pilot bar. Nota: utiliser un mandrin de guidage Nota: Usar el mandril de guía de
de fabrication locale. confección propia.
52. If flywheel is stuck, fit flywheel 52. Si le volant moteur est bloqué, 52. En caso de firme asiento del
puller. Press off flywheel. monter un extracteur pour chasser volante, montar el dispositivo de
le volant. extracción. Separar por presión el
volante.
53. Remove mounting feet. 53. Déposer les pieds de fixation. 53. Desmontar las patas de colocación.
Note: Remove adapter housing, if any. Nota: si le moteur en est équipé d’un, Nota: Si existe, desmontar el cárter de 4
déposer le carter d’adaptation. adaptación.
4.00.14
54. Remove starter bracket. 54. Déposer la console du démarreur. 54. Desmontar la consola para el
arrancador.
55. Take off rear cover. 55. Déposer le couvercle arrière. 55. Desmontar la tapa trasera.
56. Screw in adjusting pin for cam- 56. Introduire la pige de réglage de 56. Enroscar el perno de ajuste del
shaft. Take off thrust washer for l’arbre à cames. árbol de levas. Desmontar la
camshaft. Déposer la rondelle de butée de arandela de tope del árbol de
l’arbre à cames. levas.
57. Remove camshaft. 57. Déposer l’arbre à cames. 57. Sacar el árbol de levas.
4.00.15
54. Konsole für Starter abbauen.

3
55. Hinteren Deckel abbauen.

3
56. Einstellbolzen für Nockenwelle einschrauben.

Anlaufscheibe für Nockenwelle abbauen. 4
7
3
57. Nockenwelle ausbauen.

3 4
4.00.15
58. Hauptlagerdeckel ausbauen. Kurbelwelle

3 herausnehmen.
59. Stößel herausnehmen.

3
4.00.16
58. Remove main bearing caps. 58. Déposer les chapeaux de paliers 58. Quitar las tapas de los cojinetes de
puis retirer le vilebrequin. apoyo. Sacar el cigüeñal.
59. Take out tappets. 58. Retirer les poussoirs. 59. Retirar los empujadores.
4.00.16
Reassembling engine Assemblage du moteur Rearmado del motor
Torx tools _________________ 8189 Outils Torx _________________ 8189 Herramental Torx ____________ 8189
Hose clamp pliers ___________ 9088 Pince à tuyaux flexibles _______ 9088 Alicates para abrazaderas
Cobra clamp pliers ___________ 8011 Pince à ressorts Cobra de mangueras ______________ 9088
V-belt tension gauge _________ 8115 pour tuyaux ________________ 8011 Alicates Cobra
Multipower tool _____________ 8049 Appareil de mesure para abrazaderas ____________ 8011
Socket a/flats 32 ____________ 8036 de la tension de courroie ______ 8115 Verificador de tensión
Spring clamp pliers __________ 9090 Multiplicateur de force ________ 8049 de correas trapezoidales ______ 8115
Douille de 32 _______________ 8036 Multiplicador de fuerza _______ 8049
Pince à ressorts _____________ 9090 Llave de vaso _______________ 8036
Alicates para
Special tools required: Outillage spécial: abrazaderas de resorte _______ 9090
Adjusting pin ____________ 100 700 Pige de calage ___________ 100 700 Herramientas especiales:
Adjusting pin ____________ 100 710 Pige de calage ___________ 100 710
Toothed belt tension gauge __ 100 720 Appareil de mesure de Perno de ajuste __________ 100 700
Locking wire tension de courroie crantée __ 100 720 Perno de ajuste __________ 100 710
for injection pump ________ 100 870 Fil d’arrêt pour Verificador de tensión
Locking wire pompe d’injection ________ 100 870 de correas dentadas ______ 100 720
for injection pump ________ 100 880 Fil d’arrêt pour Alambre de sujeción
Gauge _________________ 100 750 pompe d’injection ________ 100 880 p. bombas inyección ______ 100 870
Test template for I.P. gasket _ 103 020 Appareil de mesure _______ 100 750 Alambre de sujeción
Special wrench Gabarit de contrôle pour p. bombas inyección ______ 100 880
for injection line __________ 110 490 joint de pompe d’injection ___ 103 020 Dispositivo de medición ___ 100 750
Piston ring compressor ____ 130 510 Clé spéciale Plantilla para
Dolly _________________ 143 420 pour conduite d’injection ___ 110 490 comprobar juntas de b.i. ___ 103 020
Intermediate disc _________ 143 430 Sangle à comprimer Llave especial para
Dolly for camshaft gear ____ 144 130 les pistons ______________ 130 510 tuberías de inyección ______ 110 490
Tensioning device Outil de maintien _________ 143 420 Compresor de aros de pistón _ 130 510
for toothed belt __________ 144 600 Rondelle intermédiaire _____ 143 430 Contrasoporte ___________ 143 420
Special wrench Outil de maintien Arandela intermedia _______ 143 430
for oil pressure sensor ____ 170 110 de pignon d’arbre à cames __ 144 130 Contrasoporte para la rueda
Dispositif de serrage dentada en el árbol de levas _ 144 130
pour courroie crantée _____ 144 600 Tensor de correas dentadas _ 144 600
Clé spéciale pour capteur Llave especial para trans-
de pression d’huile _______ 170 110 misores de presión de aceite __ 170 110
Thermostat Thermostat Termostato
1. Fit thermostat with compression 1. Monter le thermostat avec le 1. Instalar el termostato con muelle
spring. ressort de pression. de presión.
4
2. Tighten screw plug with new O-seal. 2. Serrer la vis filetée en utilisant un 2. Apretar el tapón con un anillo
joint torique neuf. tórico nuevo.
Note: For fitting the O-seal cover Nota: pour le montage du joint torique Nota: Para el montaje del anillo tórico
thread with assembly sleeve. recouvrir le filet avec la douille hay que cubrir la rosca mediante
de montage. el manguito de montaje.
4.00.17
Motor zusammenbauen
Torx-Werkzeuge ____________________ 8189

Schlauchklemmen-Zange ____________ 9088
Cobraklemmenzange ________________ 8011
Keilriemenspannungs-Meßgerät _______ 8015
Kraftvervielfältiger __________________ 8049
Stecknuß _________________________ 8036
Federklemmenzange ________________ 9090
Spezialwerkzeuge:
Einstellbolzen ___________________ 100 700

Einstellbolzen ___________________ 100 710
Zahnriemenspannungs-Meßgerät ___ 100 720
Arretierungsdraht für Einspritzpumpe _ 100 870
Arretierungsdraht für Einspritzpumpe _ 100 880
Meßgerät ______________________ 100 750
Prüfschablone für E.P.-Dichtung ____ 103 020
Spezialschlüssel für Einspritzleitung _ 110 490
Kolbenringspannband ____________ 130 510
Gegenhalter ____________________ 143 420
Zwischenscheibe ________________ 143 430
Gegenhalter für Nockenwellenrad ___ 144 130
Spannvorrichtung für Zahnriemen ___ 144 600
Spezialschlüssel für Öldruckgeber ___ 170 110
Thermostat
4
1. Thermostat mit Druckfeder einbauen.
2. Verschlußschraube mit neuem Runddicht-

ring festdrehen. 4 4
ß
Hinweis: Für Montage des Runddichtringes Ge-
winde mit Montagehülse abdecken. 6
5
4.00.17
Öldruckventil (ohne Heizungsanschluß)

4 3. Öldruckventil mit Druckfeder (3 bar, grüne
Farbmarkierung) einbauen.
4. Verschlußschrauben mit neuen Cu-Dicht-

4 ringen festdrehen.
ß Anziehvorschrift: 111 Nm
Öldruckventil mit Heizungsanschluß

4 (falls vorhanden)
8 5. Öldruckventile mit Druckfedern einbauen.
Hinweis: Auf Einbaurichtung der Ventile und

5 unterschiedliche Druckfedern achten.
Pos. 5 Druckfeder 1,0 bar, gelbe Farbmarkierung

Pos. 6 Druckfeder 1,7 bar, rote Farbmarkierung
Pos. 7 Druckfeder 0,3 bar, blaue Farbmarkierung
95-4.64
6. Verschlußschrauben mit neuen Cu-Dichtun-
4 4 gen festdrehen.
95-4.65
4.00.18
Oil pressure control valve Soupape de régulation de pression Válvula de presión de aceite
(without heater connection) d’huile (sin empalme de calefacción)
(sans racord pour chauffage)
3. Fit oil pressure control valve with 3. Monter la soupape de régulation de 3. Instalar la válvula de presión de
compression spring (3 bar, green pression d’huile avec le ressort de aceite con muelle de presión (3 bar,
colour marking). pression (3 bars, repérage vert). marcación de color verde).
4. Tighten screw plugs with new Cu 4. Insérer vis filetées avec un joint au 4. Apretar los tapones provistos de
seals. Cu neuf. juntas de cobre nuevas.
Oil pressure control valve with heater Soupape de régulation de pression Válvula de presión de aceite con
connection d’huile avec raccord de chauffage empalme de calefacción
(if any) (si le moteur en est équipé d’un) (si existe)
5. Fit oil pressure control valves with 5. Monter les soupapes de régulation 5. Instalar las válvulas de presión de
compression springs. de pression avec les ressorts de aceite con los muelles de presión.
pression.
Note: Watch direction of installation of Nota: veiller au sens de montage des Nota: Observar la dirección en que se
valves and different compres- soupapes et aux différents monten las válvulas y tener en
sion springs. ressorts de pression. cuenta los diferentes tipos de
muelles.
Item 5, compr. spring 1.0 bar, yellow rep. 5 ressort de pression 1,0 bar, No. 5 muelle 1,0 bar, marca de color
colour marking repérage jaune amarillo
Item 6, compr. spring 1.7 bar, red rep. 6 ressort de pression 1,7 bar, No. 6 muelle 1,7 bar, marca de color
colour marking repérage rouge rojo
Item 7, compr. spring 0.3 bar, blue rep. 7 ressort de pression 0,3 bar, No. 7 muelle 0,3 bar, marca de color
colour marking repérage bleu azul
6. Tighten screw plugs with new Cu 6. Monter vis filetées avec des joints 6. Apretar los tapones provistos de
seals. en Cu neufs. una junta de cobre nueva.
4
4.00.18
7. Fit O-seals in such a manner to 7. Monter des bagues d’étanchéité 7. Colocar juntas anulares nuevas
swadged nipples that the spot neuves sur les embouts de réduction sobre las boquillas de empalme,
facing points towards the de manière à ce que le lamage soit de modo que el rebaje indique
crankcase. dirigé vers le vilebrequin. hacia el bloque motor.
Tighten swadged nipple, item 1, Bloquer embout de réduction (1) et Apretar la boquilla de empalme 1 y
and swadged nipple with valve embout de réduction avec logement la boquilla de empalme con
seat, item 2. de soupape (2). asiento de válvula 2.

specification 111 Nm ± 11 Nm de serrage: 111 ± 11 Nm de apriete: 111 ± 11 Nm
8. Tighten screw plugs with new Cu 8. Serrer vis filetée avec joints 8. Apretar los tapones provistos de
seals. d’étanchéité neufs en Cu. una junta anular nueva de cobre.
Tightening specification 50 Nm Consigne de serrage: 50 Nm Prescripción de apriete: 50 Nm
9. Tighten screw plug with new Cu 9. Serrer vis filetée avec joints 9. Apretar el tapón provisto de una
seal. d’étanchéité neufs en Cu. junta anular nueva de cobre.
Tightening specification 50 Nm Consigne de serrage: 50 Nm Prescripción de apriete: 50 Nm
9.1 Tighten oil pressure switch. 9.1 Bloquer interrupteur de pression 9.1 Apretar el interruptor de presión
4
specification 13 ± 1.5 Nm de serrage: 13 ± 1,5 Nm de apriete: 13 ± 1,5 Nm
4.00.19
7. Neue Dichtringe so auf die Übergangsnippel

montieren, daß die Ansenkung zum Kurbel-
gehäuse weist.
4
Übergangsnippel Pos. 1 und Übergangsnip-
pel mit Ventilsitz Pos. 2 festdrehen. ß
Anziehvorschrift: 111 ± 11 Nm 8
6
95-4.66
8. Verschlußschrauben mit neuen Cu-Dicht-

ringen festdrehen.
4
ß
6
95-4.67
9. Verschlußschraube mit neuem Cu-Dichtring

festdrehen. 4
ß
6
9.1 Öldruckschalter festdrehen.
4 4
6
4.00.19
10. Verschlußschraube mit neuem Cu-Dicht-

4 ring festdrehen.
ß
6
Stößel/Nockenwelle
4 11. Stößel einsetzen.
12. Nockenwelle einsetzen.

4
8
z
13. Anlaufscheibe montieren.
4 4 Hinweis: Schmiernut der Anlaufscheibe muß
8 zum Kurbelgehäuse weisen.
4.00.20
10. Tighten screw plug with new Cu 10. Serrer vis filetée avec joint 10. Apretar el tapón con una junta
seal. d’étanchéité neufs en Cu. anular nueva de cobre.
Tappets/camshaft Poussoir/arbre à cames Empujadores/árbol de levas
11. Insert tappets. 11. Mettre en place le poussoir. 11. Introducir los empujadores.
12. Introduce camshaft. 12. Mettre en place l’arbre à cames. 12. Introducir el árbol de levas.
13. Fit thrust washer. 13. Monter la rondelle de butée. 13. Montar la arandela de tope.
Note: Lubricating groove of thrust Nota: la rainure de graissage de la Nota: La ranura de lubricación de la 4
washer must face crankcase. bague de butée doit être orientée arandela de tope debe indicar
vers le bloc moteur. hacia el cárter del motor.
4.00.20
14. Screw in adjusting pin for 14. Visser la pige de réglage de l’arbre 14. Enroscar el perno de ajuste del
camshaft. Tighten bolt. à cames puis bloquer la vis. árbol de levas. Apretar el tornillo.
Note: Unscrew adjusting pin again. Nota: dévisser et extraire la pige de Nota: Desenroscar el perno de ajuste.
réglage.
Crankshaft bearings Paliers de vilebrequin Apoyos del cigüeñal
15. Insert bearing shells. 15. Mettre en place les coussinets. 15. Colocar los semicojinetes.
16. Insert bearing shells in main 16. Mettre an place les coussinets 16. Colocar los semicojinetes en las
bearing cap. dans le chapeau du palier tapas de los cojinetes de apoyo.
principal.
17. Fit thrust washers to thrust 17. Appliquer les demi-flasques de 17. Colocar las medias arandelas de
bearing cap and gauge width. butée sur le couvercle du palier tope contra la tapa del cojinete de
4 d’ajustage et relever la largeur. empuje y medir el ancho.
4.00.21
14. Einstellbolzen für Nockenwelle einschrau-

ben. Schraube festdrehen.
4
7
Hinweis: Einstellbolzen wieder herausschrauben.
6
5
Kurbelwellenlagerung
15. Lagerschalen einsetzen.

4
8
16. Lagerschalen in Hauptlagerdeckel einsetzen.

4
8
17. Anlaufscheiben am Paßlagerdeckel anlegen

und Breite messen. 4 4
8
6
4.00.21
18. Innenmeßgerät auf 35 mm einstellen.

6
19. Paßlagerzapfenbreite der Kurbelwelle mes-

6 sen.
Axialspiel ermitteln.
Zapfenbreite normal: 35 + 0,04 mm

Grenzmaß für Übermaßstufe: 35,44 mm
Axialspiel:
Normal: 0,1 - 0,273 mm

Hinweis: Bei Bedarf neue Anlaufscheiben zuord-

nen.
20. Paßhülsen einsetzen.
4 4
4.00.22
18. Set internal dial gauge to 35 mm. 18. Régler l’appareil de mesure 18. Ajustar el micrómetro de interiores
d’intérieur sur une valeur a 35␣ mm.
de 35 mm.
19. Gauge thrust bearing journal width 19. Relever la largeur des tourillons du 19. Medir el ancho de muñón para el
of crankshaft. palier d’ajustage du vilebrequin. cojinete de empuje del cigüeñal.
Determine axial play. Mesurer le jeu axial. Determinar el juego axial.
Journal Largeur normale Ancho de

width standard: 35 + 0.04 mm du tourillon: 35 + 0,04 mm muñón normal: 35 + 0,04 mm
Limit Cote limite Límite
for oversize: 35.44 mm de réparation 35,44 mm de sobremedida: 35,44 mm
Axial play: Juego axial:
standard: 0.1 - 0.273 mm Jeu axial: 0,1 - 0,273 mm Normal: 0,1 - 0,273 mm
wear limit: 0.4 mm Limite d’usure: 0,4 mm Límite de desgaste: 0,4 mm
Note: Use new thrust washers if Nota: au besoin placer des flasques de Nota: De ser necesario, colocar otras
necessary. butée neuves. arandelas nuevas.
20. Insert locating sleeves. 20. Mettre en place les douilles 20. Meter los casquillos de ajuste.
d’ajustage.
4
4.00.22
21. Introduce crankshaft. 21. Monter le vilebrequin. 21. Colocar el cigüeñal.
22. Stick half thrust washers with lug 22. Avec un peu de graisse coller sur 22. Pegar con un poco de grasa contra
to thrust bearing cap using some le chapeau de palier d’ajustage les la tapa del cojinete de empuje las
grease. flasques de butée avec le taquet de medias arandelas de tope con
guidage. talón de guía.
Note: Running layer of thrust washers Nota: les flasques de butée avec leur Nota: Las arandelas de tope deben
must face crankweb. face de roulement doivent être indicar con su capa de roce
orientées vers la joue du hacia la cara lateral de la
vilebrequin. manivela del cigüeñal.
23. Mount thrust bearing cap. 23. Monter le chapeau du palier 23. Montar la tapa del cojinete de
d’ajustage. empuje.
Note: Bearing cap No. 1 at flywheel Nota: le chapeau de palier no. 1 est du Nota: La tapa de cojinete No. 1 está en
end. Chamfer must point côté du volant moteur. el lado del volante. El bisel debe
towards flywheel end. La partie chanfreinée en indicar hacia el lado opuesto al
revanche doit être orientée dans del volante.
le sens inverse au volant moteur.
24. Mount bearing caps, paying 24. Monter le chapeau de palier 24. Montar las tapas de los cojinetes
attention to the numbering. principal en respectant la de apoyo según la numeración.
4 numérotation.
4.00.23
21. Kurbelwelle einsetzen.

4
8
z
22. Anlaufscheiben mit Führungsnase am Paß-

lagerdeckel mit etwas Fett ankleben. 4
Hinweis: Anlaufscheiben müssen mit der Lauf-
schichtseite zum Wangenspiegel der u
Kurbelwelle weisen.
8
5
23. Paßlagerdeckel aufbauen.
Hinweis: Lagerdeckel Nr. 1 ist schwungrad-

4
seitig. Anschrägung muß entgegen
der Schwungradseite weisen. 8
5
9
24. Hauptlagerdeckel entsprechend der Nume-

rierung montieren. 4 4
9
4.00.23
25. Hauptlagerschrauben festdrehen.

4 Anziehvorschrift:
6 Vorspannwert
1. Nachspannwinkel
50 Nm
60°
Hinterer Deckel
4 26. Hinteren Deckel mit DEUTZ DW 67 bestrei-
w chen.
27. Deckel komplett mit Wellendichtring anbau-

4 en. Deckel zur Ölwannendichtfläche aus-
richten. Schrauben festdrehen .
9 Anziehvorschrift: 21 Nm
Abstand Hubzapfenoberkante OT bis Zylinder-
4 6 kopfdichtfläche messen.
(Nur FL- und FM - Motoren)
28. Abstand Hubzapfenoberkante OT bis Zylin-

derkopfdichtfläche an jedem Zylinder mes-
sen.
4.00.24
25. Tighten main bearing bolts. 25. Bloquer les vis des paliers 25. Apretar los tornillos de los
principaux. cojinetes de apoyo.

Initial tightening torque 50 Nm Valeur de préserrage 50 Nm Apriete inicial 50 Nm
Rear cover Couvercle arrière Tapa trasera
26. Apply sealing compound DEUTZ 26. Enduire le couvercle arrière de 26. Aplicar DEUTZ DW 67 a la tapa
DW 67 to rear cover. pâte d’étanchéité DEUTZ DW 67. trasera.
27. Fit cover complete with shaft seal. 27. Monter le couvercle complet avec 27. Montar la tapa completa con retén.
Align cover relative to oil pan le joint d’arbre. Aligner le couvercle Alinear la tapa con respecto a la
sealing surface. Tighten bolts. par rapport à la surface d’étanchéité superficie de cierre del cárter de
du carter d’huile. Bloquer les vis. aceite. Apretar los tornillos.
Gauge distance between top edge of Mesurer espace entre arête supérieure Medición de la distancia entre el canto
crankpin in TDC and cylinder head du maneton au PMH et plan de joint de superior de la muñequilla a PMS y la
sealing surface. (Only FL and FM la culasse (uniquement pour moteurs superficie de asiento de la junta de 4
engines) FL et FM). culata. (Sólo motores FL y FM)
28. Gauge on every cylinder distance 28. Mesurer à chaque cylindre espace 28. Medir en cada cilindro la distancia
between top edge of crankpin in TDC entre arête supérieure du maneton que media entre el canto superior
and cylinder head sealing surface. au PMH et plan de joint de la de la muñequilla a PMS y la superficie
culasse. de asiento de la junta de culata.
4.00.24
28.1 28.1 28.1
FL 1011 F FL 1011 F FL 1011 F:

specified dimension x Piston class Valeur prescrite x Catégorie de piston Medida teórica x Clase de pistón
x1 = 199.890 - 199.99 A x1 = 199,890 - 199,99 A x1 = 199,890 - 199,99 A

x2 = 199.991 - 200.09 B x1 = 199,991 - 200,09 B x1 = 199,991 - 200,09 B
x3 = 200.091 - 200.19 C x3 = 200,091 - 200,19 C x3 = 200,091 - 200,19 C
FM 1011 F FM 1011 F FM 1011 F:

specified dimension x Piston class Valeur prescrite x Catégorie de piston Medida teórica x Clase de pistón
x1 = 196.390 - 196.49 A x1 = 196,390 - 196,49 A x1 = 196,390 - 196,49 A

x2 = 196.491 - 196.59 B x1 = 196,491 - 196,59 B x1 = 196,491 - 196,59 B
x3 = 196.591 - 196.59 C x3 = 196,591 - 196,69 C x3 = 196,591 - 196,69 C
28.2 Compare actual dimension with the 28.2 Comparer les valeurs réelles avec 28.2 Comparar la medida real con la
specified dimensions in the table. les valeurs de consigne figurant sur teórica especificada en la tabla.
Select piston class per cylinder. le tableau. Choisir la catégorie du Elegir la clase de pistón de cada
See Chapter. 3. piston en fonction du cylindre. cilindro. Ver cap. 3.
Voir Chap. 3.
Note: In the case of crankshaft Nota: en cas de cotes de réparation Nota: En caso de inframedidas del
undersizes, 0.125 mm must be vilebrequin sous-dimensionnées cigüeñal han de añadirse 0,125
added to the dimension ajouter aux valeurs figurant sur le mm a la respectiva medida
indicated in the table. tableau à chaque fois 0,125 mm. indicada en la tabla.
29. Insert bearing shells into connecting 29. Monter les coussinets dans la bielle. 29. Montar los semicojinetes en la biela.
rod.
30. Piston ring gaps must be staggered. 30. Tiercer les coupes de segments. 30. Desplazar entre sí los cortes de los
aros de pistón.
4
4.00.25
28.1
FL 1011 F Sollmaß x Kolbenklasse

x1 = 199,890 - 199,99 A
x2 = 199,991 - 200,09 B
x3 = 200,091 - 200,19 C
FM 1011 F Sollmaß x Kolbenklasse

x1 = 196,390 - 196,49 A
x2 = 196,491 - 196,59 B
x3 = 196,591 - 196,69 C
28.2 Istmaß mit den in der Tabelle aufgeführten

Sollmaßen vergleichen. Kolbenklasse je
Zylinder auswählen. Siehe Kap. 3.
9
Hinweis: Bei Untermaßstufen der Kurbelwelle 5
sind zu den in der Tabelle aufgeführ-
ten Maßen jeweils 0,125 mm hinzu-
zuzählen.
29. Pleuellagerschalen in Pleuelstange einbauen.

4
8
30. Kolbenringstöße zueinander versetzt anord-

nen. 9 4
4.00.25
31. Kolben komplett mit Pleuel in das Zylinder-

4 kurbelgehäuse einschieben.
z Hinweis: Schwungradsymbol auf dem Kolben

muß zum Schwungrad weisen.
7
9
32. Pleuelstange gegen den Hubzapfen drücken.

4 Dazugehörigen Pleuellagerdeckel montieren.
z Hinweis: Pleuelschrauben können bei Nachweis-

barkeit max. 5 mal wiederverwendet
werden.
5
9
33. Pleuelmuttern mit 12 kant-Steckschlüssel

4 festdrehen.
6 Anziehvorschrift:
Vorspannwert 30 Nm
34. Pleuelstangen kontrollieren, ob sie sich auf
4 9 dem Hubzapfen leicht verschieben lassen.
4.00.26
31. Introduce piston complete with 31. Introduire l’ensemble piston-bielle 31. Introducir el pistón completo con
connecting rod into crankcase with complet dans le bloc moteur. la biela en el bloque de cilindros.
integrated cylinders.
Note: Flywheel symbol must point Nota: le symbole figurant sur le volant Nota: El símbolo del volante en el
towards flywheel. moteur doit être orienté vers le pistón debe indicar hacia el
volant. volante.
32. Press connecting rod against 32. Enfoncer la bielle sur le maneton en 32. Presionando la biela contra la
crankpin. Fit pertinent big end montant le chapeau de bielle corres- muñequilla, montar la tapa de biela
bearing cap. pondant. Monter les chapeaux de correspondiente.
palier de bielle correspondants.
Note: Conrod bolts may be used max. Nota: ne pas utiliser les boulons de Nota: Los pernos de biela pueden ser
5 x if evidence can be provided bielle plus de 5 fois. reutilizados hasta 5 veces si esto
concerning their use. es comprobable.
33. Tighten conrod nuts with 33. Serrer les écrous de bielle avec 33. Apretar las tuercas de biela utilizan-
dodecagonal socket wrench. une clé à douille à 12 pans selon do una llave de vaso de 12 cantos.
les préconisations de serrage.

Intitial tightening torque 30 Nm Valeur de préserrage 30 Nm Apriete inicial 30 Nm
34. Check that connecting rods can be 34. Contrôler si les bielles glissent 34. Controlar si las bielas pueden
easily moved back and forth on the facilement sur les manetons. moverse fácilmente sobre la
crankpin. muñequilla. 4
4.00.26
Front cover Couvercle avant Tapa delantera
35. Apply sealing compound DEUTZ 35. Enduire la surface d’étanchéité du 35. Aplicar sellante DEUTZ DW 67 a la
DW 67 to front cover sealing couvercle avant de pâte d’étanchéité superficie de cierre de la tapa
surface. DEUTZ DW 67. delantera.
Note: Camshaft/centrifugal governor Nota: la liaison entre l’arbre à cames et Nota: La unión entre árbol de levas y
connection must be clean and le régulateur centrifuge doit être regulador centrífugo debe estar
free of oil. parfaitement propre et exempte limpia y exenta de aceite.
d’huile.
36. Fit front cover together with shaft 36. Monter le couvercle avant complet 36. Montar la tapa delantera completa
seals and align relative to oil pan avec les joints d’arbre et l’ajuster con los retenes y alinearla con
sealing surface. par rapport à la surface respecto a la superficie de cierre
d’étanchéité du carter d’huile. del cárter de aceite.
Note: When fitting cover pay attention Nota: au montage veiller au joint Nota: Al montar, prestar atención al
to crankshaft seal. d’étanchéité du vilebrequin. retén para el cigüeñal.
37. Tighten bolts. 37. Bloquer les vis. 37. Apretar los tornillos.
Crankshaft toothed belt gear Pignon de courroie crantée du Rueda de correa dentada en el
vilebrequin cigüeñal
4
38. Slide on crankshaft toothed belt 38. Introduire le pignon de courroie 38. Colocar la rueda de correa dentada
gear. crantée du vilebrequin. en el cigüeñal.
Note: All connecting surfaces must be Nota: toutes les surfaces de liaison Nota: Todas las superficies de unión
clean and free of oil. doivent être parfaitement deben estar limpias y exentas de
propres et exemptes d’huile. aceite.
4.00.27
Vorderer Deckel
35. Dichtfläche des vorderen Deckels mit Dicht-

4
mittel DEUTZ DW 67 bestreichen.
w
Hinweis: Verbindung zwischen Nockenwelle
und Fliehkraftregler muß sauber und 5
ölfrei sein.
36. Vorderen Deckel komplett mit Wellendicht-

ringe montieren und zur Ölwannen-
dichtfläche ausrichten.
4
Hinweis: Bei Montage auf Kurbelwellendichtring 5
achten.
37. Schrauben festdrehen.
4
6
Kurbelwellenzahnriemenrad
38. Kurbelwellenzahnriemenrad aufschieben.

4 4
Hinweis: Alle Verbindungsflächen müssen sau- 5
ber und ölfrei sein.
4.00.27
39. Falls vorhanden, Kurbelwellenzahnriemen-

4 rad für Hydraulikpumpe in die Zentrierung
einsetzen.
8 Hinweis: Ohne Hydraulikpumpenanbau wird an

Stelle des Zahnrades ein Zwischen-
5 stück verwendet.
40. Zentralschraube leicht andrehen.

4
41. Verschlußschraube herausschrauben. Ein-

3 stellbolzen für Kurbelwelle bis Anlage ein-
schrauben. Kurbelwelle im Uhrzeigersinn
4 gegen den Anschlag drehen.
Hinweis: Kolben am vorderen Deckel ist in OT.

7
5
42. Zentralschraube vorspannen.
6
4.00.28
39. Insert crankshaft toothed belt gear 39. Si le moteur en est équipé d’un, 39. Si existe, introducir en el centraje
for hydraulic pump, if any, in placer sur le centrage le pignon de la rueda de correa dentada del
centering. la courroie dentée du vilebrequin cigüeñal para la bomba hidráulica.
de la pompe hydraulique
Note: If no hydraulic pump is Nota: sans montage de pompe Nota: Si no se monta la bomba
mounted, a spacer is used hydraulique utiliser en lieu et hidráulica, se coloca una pieza
instead of the gear. place du pignon une pièce intermedia en lugar de la rueda
intermédiaire. dentada.
40. Start central bolt. 40. Serrer légèrement la vis centrale. 40. Apretar ligeramente el tornillo
central.
41. Undo screw plug. Screw in adjusting 41. Dévisser la vis filetée. Visser la pige 41. Desenroscar el tapón. Enroscar el
pin for crankshaft as far as it will de calage du vilebrequin jusqu’en perno de ajuste del cigüeñal hasta
go. Turn crankshaft in clockwise butée. Virer le vilebrequin dans le que se asiente. Girar el cigüeñal en
direction against stop. sens horaire jusqu’en position de el sentido de las agujas del reloj
butée. contra el tope.
Note: Piston at front cover is in TDC. Nota: le piston se trouvant près du Nota: El pistón cerca de la tapa
chapeau avant est au PMH. delantera está en el PMS.
42. Initially tighten central bolt. 42. Préserrer la vis centrale. 42. Apretar el tornillo central con un
par previo.
4
4.00.28
43. Position intermediate disc. 43. Placer le disque intermédiaire. 43. Colocar la arandela intermedia.
Note: Remove adjusting pin for Nota: ôter la pige de calage du Nota: Retirar el perno de ajuste del
crankshaft. vilebrequin. cigüeñal.
44. Fit dolly and tighten. 44. Monter et serrer la contre-butée. 44. Montar el contrasoporte y apretar.
45. Insert multipower tool with socket 45. Insérer le multiplicateur de couple 45. Meter en el contrasoporte el
in dolly. avec la douille dans la contre-butée. multiplicador de fuerza con la llave
de vaso puesta.
46. Retain multipower tool and tighten 46. Maintenir le multiplicateur de 46. Retener el multiplicador de fuerza
central bolt. couple et serrer la vis centrale. y apretar definitivamente el tornillo
4 central.

specification: 210° + 10° de serrage: 210° + 10° de apriete: 210°+10°
4.00.29
Hinweis: Einstellbolzen für Kurbelwelle entfernen.

4
7
8
44. Gegenhalter anbauen und festdrehen.

4
7
45. Kraftvervielfältiger mit Stecknuß in den Ge-

genhalter einsetzen. 4
46. Kraftvervielfältiger gegenhalten und Zentral-

schraube festdrehen. 4 4
Anziehvorschrift: 210° + 10°
6
4.00.29
47. Rasterknopf drücken. Kraftvervielfältiger

4 entlasten.
Kraftvervielfältiger, Gegenhalter und Zwi-
5 schenscheibe abbauen.
Hinweis: Einstellbolzen für Kurbelwelle wieder

bis zur Anlage einschrauben.
Kurbelwelle im Uhrzeigersinn gegen
den Anschlag drehen. Kolben am vor-
deren Deckel ist in O.T.
Nockenwellenzahnriemenrad
3 48. Verschlußschraube herausschrauben. Ein-
4 stellbolzen für Nockenwelle in das Kurbel-

gehäuse bis zur Anlage einschrauben.
7 Hinweis: Bohrung der Nockenwelle muß mit

der Bohrung im Kurbelgehäuse in
5 Überdeckung stehen.
49. Zahnriemenrad, Scheibe und Schraube auf-

4 setzen.
5 Hinweis: Alle Verbindungsflächen müssen sau-

ber und ölfrei sein.
50. Nockenwellenzentralschraube handfest an-
4 4 drehen.
5 Hinweis: Nockenwellenzahnrad muß noch dreh-

bar sein.
4.00.30
47. Depress detent knob. Unload 47. Enfoncer le bouton à crans et 47. Oprimir el botón reticulado.
multipower tool. soulager le multiplicateur de Descargar el multiplicador de
Remove multipower tool, dolly and couple. fuerza.
intermediate disc. Déposer ensuite le multiplicateur Desmontar el multiplicador de
de couple, la contre-butée et le fuerza, el contrasoporte y la
disque intermédiaire. arandela intermedia.
Note: Screw adjusting pin for Nota: visser la pige de réglage de Nota: Enroscar de nuevo el perno de
crankshaft back in again as far vilebrequin jusqu’en position ajuste del cigüeñal hasta que se
as it will go. d’appui. asiente. Girar el cigüeñal en el
Turn crankshaft in clockwise Virer le vilebrequin dans le sens sentido de las agujas del reloj
direction against stop. Piston at horaire jusqu’en butée. Le piston contra el tope. El pistón cerca de
front cover is in TDC. du couvercle avant est en position la tapa delantera está en su PMS.
de PMH.
Camshaft toothed belt gear Pignon de courroie crantée d’arbre à Rueda de correa dentada del árbol de
cames levas
48. Undo screw plug. Screw camshaft 48. Dévisser et retirer vis filetée. 48. Desenroscar el tapón. Enroscar el
adjusting pin into crankcase as far Visser la pige de réglage de l’arbre perno de ajuste del árbol de levas
as it will go. à cames jusqu’en position d’appui. en el bloque motor hasta que se
asiente.
Note: Bore of camshaft must overlap Nota: l’alésage de l’arbre à cames doit Nota: El orificio del árbol de levas y el
with bore in crankcase. correspondre à celui du bloc existente en el bloque motor
moteur. deben coincidir.
49. Position toothed belt gear, washer 49. Mettre en place le pignon de courroie 49. Colocar la rueda de correa dentada,
and bolt. crantée, la rondelle et la vis. arandela y tornillo.
Note: All connecting surfaces must be Nota: toutes les surfaces de liaison Nota: Todas las superficies de unión
clean and free of oil. doivent être parfaitement propres deben estar limpias y exentas de
et sans huile. aceite.
50. Secure camshaft central bolt 50. Bien serrer à la main la vis centrale 50. Apretar a mano el tornillo central
fingertight. de l’arbre à cames. del árbol de levas.
4
Note: Camshaft gear must still turn Nota: le pignon d’arbre à cames doit Nota: La rueda dentada del árbol de
freely. pouvoir encore tourner. levas debe poderse girar
todavía.
4.00.30
Lube oil pump Pompe à huile de graissage Bomba de aceite lubricante
51. Position gasket. 51. Placer un joint. 51. Colocar la junta.
52. Mount oil pump. 52. Monter la pompe à huile. 52. Montar la bomba de aceite
lubricante.
Note: Pay attention to dowel sleeves. Nota: attention aux douilles d’ajustage. Nota: Prestar atensión a los casquillos
de sujeción.
53. Tighten bolts. 53. Serrer les vis. 53. Apretar los tornillos.
Toothed belt adjustment Réglage de la courroie crantée Ajuste de la correa dentada
4 54. Position new toothed belt. 54. Mettre en place une courroie 54. Colocar una correa dentada nueva.
crantée neuve.
Note: Hold crankshaft against stop Nota: durant le réglage de la courroie Nota: Mientras se efectúa el ajuste de la
while adjusting toothed belt. crantée maintenir le vilebrequin correa dentada, es necesario
en butée. retener el cigüeñal contra el tope.
4.00.31
Schmierölpumpe
51. Dichtung auflegen.

4
ß
52. Schmierölpumpe anbauen.
Hinweis: Auf Spannhülsen achten. 4

6
4
6
Zahnriemeneinstellung
54. Neuen Zahnriemen auflegen

4 4
Hinweis: Während der Zahnriemeneinstellung ß
ist die Kurbelwelle gegen den An-
schlag zu halten. 5
4.00.31
55. Neue Zahnriemenspannrolle anbauen und

4 handfest andrehen. Alle Verbindungsflächen
müssen sauber und ölfrei sein. Das Sechs-
ß kantloch muß zur Ölwannendichtfläche zei-

gen.
5 Hinweis: Für Einstellarbeiten ist der Deckel zu

entfernen.
8
56. Zahnriemen so ausrichten, daß ein gleich-

4 mäßiger Abstand vom Deckel von 8 bis 9 mm
vorhanden ist.
57. Zahnriemenspannungs-Meßgerät aufsetzen.

4 Hinweis: Zahnriemenspannungs-Meßgerät darf
7 nur den Zahnriemen berühren.
58. Zahnriemen vorspannen. Spannrolle entge-
4 4 gen dem Uhrzeigersinn drehen, so daß ein

Skalenwert von 3,0 - 3,5 erreicht wird.
s Schraube von Spannrolle festdrehen.
6
4.00.32
55. Fit new toothed belt idler pulley and 55. Monter galet tendeur de courroie 55. Montar una polea tensora nueva
secure fingertight. All connecting crantée neuf et bien serrer à la para la correa dentada y apretar a
surfaces must be clean and free of main. Toutes les surfaces de mano. Todas las superficies de
oil. The hexagon bore must point liaison doivent rester parfaitement unión deben estar limpias y
towards oil pan sealing surface. propres et sans huile. Le trou exentas de aceite. El hexágono
hexagonal doit être dirigé vers le interior debe indicar hacia la super-
plan de joint du carter d’huile. ficie de cierre del cárter de aceite.
Note: Remove cover for adjustment Nota: pour les travaux de réglage ôter Nota: Para los trabajos de ajuste hay
work. le couvercle. que quitar la tapa.
56. Align toothed belt so as to ensure 56. Ajuster la courroie crantée de 56. Alinear la correa dentada, de modo
an equal distance from cover manière à avoir une distance que tenga una distancia uniforme
between 8 and 9 mm. uniforme par rapport au couvercle de 8 a 9 mm a la tapa.
de l’ordre de 8 à 9 mm.
57. Position toothed belt tension 57. Mettre en place l’appareil de mesure 57. Colocar el verificador de tensión
gauge. de tension de la courroie crantée. para correas dentadas.
Note: Gauge may only have contact Nota: l’appareil de mesure de tension Nota: El verificador sólo debe entrar
with toothed belt. de la courroie crantée ne doit être en contacto con la correa
en contact qu’avec la courroie dentada.
crantée.
58. Initially tighten toothed belt. Turn 58. Soumettre la courroie crantée à 58. Pretensar la correa dentada. Girar
idler pulley in anti-clockwise direc- une précontrainte. Virer le galet la polea tensora en contra del
tion to obtain a scale reading of tendeur dans le sens antihoraire sentido de las agujas del reloj 4
3.0 - 3.5. Tighten bolt of idler pulley. jusqu’à obtention de 3,0 - 3,5 sur hasta que se alcance un valor de
l’échelle de valeurs. 3,0 - 3,5 en la escala. Apretar el
Serrer la vis du galet tendeur. tornillo de la polea.
4.00.32
59. Retain centering washer. Initially 59. Maintenir le disque de centrage et 59. Retener el disco de centraje,
tighten camshaft central bolt. serrer la vis de centrage de l’arbre apretar el tornillo central del árbol
à cames. de levas con el par previo
prescrito.
60. Mark camshaft central bolt and 60. Repérer la vis de l’arbre à cames et 60. Marcar el tornillo central del árbol
centering washer. Tighten bolt. marquer le disque de centrage. de levas y el disco de centraje.
Serrer la vis. Apretar el tornillo definitivamente.
Tightening specification: Consigne de serrage Prescripción de apriete:

Tightening angle 210° à l’angle 210° Angulo de reapriete: 210°
61. Take off toothed belt tension gauge. 61. Retirer l’appareil de mesure de ten- 61. Retirar el verificador de tensión.
Remove adjusting pins for camshaft sion de courroie crantée et ôter la Quitar los pernos de ajuste del
and crankshaft. pige de calage de l’arbre à cames árbol de levas y cigüeñal.
et du vilebrequin.
62. Mark camshaft gear and opposite 62. Repérer le pignon d’arbre à cames 62. Marcar la rueda dentada del árbol
bolt. et la vis située en regard. de levas y el tornillo opuesto.
4
4.00.33
59. Zentrierscheibe gegenhalten, Nockenwellen-

zentralschraube vorspannen.
4
7
6
60. Nockenwellenzentralschraube und Zentrier-

scheibe kennzeichnen. Schraube fest-
drehen.
4
Anziehvorschrift: 6
Nachspannwinkel 210°
61. Zahnriemenspannungs-Meßgerät abnehmen.

Einstellbolzen für Nocken- und Kurbelwelle
entfernen.
3
62. Nockenwellenzahnrad und gegenüberlie-

gende Schraube markieren. i 4
4.00.33
63. Kurbelwelle 4 Umdrehungen in Motordreh-

6 richtung drehen, bis Markierungen in Über-
deckung stehen.

4 Riemenspannung messen.
6 Sollwert: Skalenwert 6,5 - 9,5
65. Wenn der geforderte Skalenwert nicht er-

6 reicht wird, muß mit Hilfe der Spannrolle
korrigiert werden.
66. Einstellbolzen für Kurbel-und Nockenwelle
4 4 wieder bis zum Anschlag einschrauben.
4.00.34
63. Make four complete crankshaft 63. Virer le vilebrequin de 4 tours dans le 63. Darle al cigüeñal 4 vueltas en el
revolutions in direction of engine sens de rotation du moteur jusqu’à sentido de giro normal del motor
rotation until marks coincide. ce que les repères correspondent. hasta que coincidan las marcas.
64. Position toothed belt tension 64. Placer l’appareil de mesure de 64. Colocar el verificador de tensión
gauge. Gauge belt tension. tension de courroie crantée. para correas dentadas. Medir la
Relever la valeur de tension de la tensión de la correa.
courroie.
Specified Valeur de consigne sur échelle Valor prescrito:

scale reading: 6.5 - 9.5 graduée: 6,5 - 9,5 valor de escala 6,5 - 9,5
65. If the specified scale reading is not 65. Si la valeur requise sur l’échelle 65. Si no se alcanza el valor de escala
obtained, readjust with idler pulley. n’est pas atteinte, corriger à l’aide exigida, hay que corregir con ayuda
du galet tendeur. de la polea tensora.
66. Screw adjusting pins for crankshaft 66. Visser à nouveau la pige de calage 66. Enroscar de nuevo los pernos de
and camshaft back in again as far du vilebrequin et de l’arbre à cames ajuste del cigüeñal y árbol de levas
as they will go. jusqu’en butée. hasta que tengan contacto. 4
4.00.34
67. Slacken idler pulley and turn in anti- 67. Desserrer le galet tendeur et virer 67. Soltar la polea tensora y girarla en
clockwise direction to obtain a scale dans le sens antihoraire jusqu’à contra del sentido de las agujas del
reading of 5 - 6. obtention d’une valeur de 5 - 6 sur reloj hasta que se alcance un valor
Tighten bolt of idler pulley again. l’échelle. de 5␣ -␣ 6 en la escala.
Serrer la vis du galet tendeur. Volver a apretar el tornillo de la
polea tensora.
68. Remove adjusting pins and toothed 68. Oter la pige de calage et l’appareil 68. Retirar los pernos de ajuste y el
belt tension gauge. Make 4 crankshaft de mesure de tension puis virer le verificador de tensión. Darle al
revolutions in direction of engine vilebrequin de 4 tours dans le sens cigüeñal 4 vueltas en el sentido de
rotation. de rotation du moteur. giro normal del motor.
Note: Pay attention camshaft marking. Nota: attention au repère porté sur Nota: Prestar atención a la marca
l’arbre à cames. puesta en la rueda dentada del
árbol de levas.
69. Fit toothed belt tension gauge. 69. Monter l’appareil de mesure de 69. Montar el verificador de tensión
Specified scale reading: 6.5 - 9.5 tension de courroie crantée. para correas dentadas.
Remove toothed belt tension gauge. Valeur de consigne sur échelle Valor prescrito: valor de escala
graduée: 6,5 - 9,5 6,5␣ -␣ 9,5
Déposer l’appareil de mesure de Desmontar el verificador de tensión.
tension de courroie.
Valve timing check Contrôle du calage de la distribution Control de las cotas de reglaje
4 70. Screw camshaft adjusting pin into 70. Visser jusqu’en butée la pige de 70. Enroscar el perno de ajuste del
crankcase as far as it will go. l’arbre à cames pour le calage de árbol de levas en el bloque motor
la distribution. hasta que se asiente.
Note: Bore for camshaft must overlap Nota: l’alésage de l’arbre à cames doit Nota: El orificio para el árbol de levas
with bore in crankcase. correspondre à celui du bloc y el orificio existente en el
moteur. bloque motor deben coincidir.
4.00.35
67. Spannrolle lösen und entgegen dem Uhr-

zeigersinn drehen, so daß ein Skalenwert
von 5 - 6 erreicht wird. a
Schraube von Spannrolle wieder fest-
drehen. 6
Anziehvorschrift: 45 Nm s
68. Einstellbolzen und Zahnriemenspannungs-

meßgerät entfernen. Kurbelwelle 4 Umdre-
hungen in Motordrehrichtung drehen.
3
Hinweis: Auf Markierung der Nockenwelle ach- 5
ten.
i
69. Zahnriemenspannungs-Meßgerät montieren.

Sollwert: Skalenwert 6,5 - 9,5
Zahnriemenspannungs-Meßgerät abbauen.
4
6
3
Steuerzeiten-Kontrolle
70. Einstellbolzen für Nockenwelle in das

4 4
Kurbelgehäuse bis Anlage einschrauben.
7
Hinweis: Bohrung für Nockenwelle muß mit der
Bohrung im Kurbelgehäuse in Über- 5
deckung stehen.
4.00.35
71. Zentralschraube mit Drehmomentschlüssel

6 in Motordrehrichtung 40 Nm spannen,
Drehmomentschlüssel wieder entlasten.
5 Hinweis: Kurbelwellenstellung nicht mehr ver-

drehen.
72. Einstellbolzen für Kurbelwelle einschrauben

4 bis er die Kurbelwelle leicht berührt.
i Einstellbolzen-Stellung zeichnen.
73. Die richtige Einstellung ist dann gegeben,

6 wenn sich der Einstellbolzen noch 0,75 bis
2,25 Umdrehungen bis zur Anlage ins
Kurbelgehäuse eindrehen läßt.
Hinweis: Wird die Einschraubtiefe des Einstell-

bolzens an das Kurbelgehäuse nicht
4 erreicht, ist die Nockenwellengrund-
einstellung zu wiederholen.
Hierzu Nockenwellenzahnriemenrad
und Spannrolle lösen.
Vorgang ab Punkt 55 wiederholen.
4.00.36
71. Tighten central bolt with torque 71. A l’aide de la clé dynamométrique 71. Utilizando la llave dinamométrica,
wrench 40 Nm in direction of serrer la vis centrale à 40 Nm dans apretar el tornillo central con 40
engine rotation, unload torque le sens de rotation du moteur, Nm en el sentido de giro normal
wrench again. ensuite soulager à nouveau la clé del motor. Volver a descargar la
dynamométrique. llave dinamométrica.
Note: Do not change crankshaft Nota: ne plus modifier la position du Nota: A partir de este momento,
position anymore. vilebrequin. mantener inalterada la posición
del cigüeñal.
72. Screw in crankshaft adjusting pin 72. Visser la pige de calage du 72. Enroscar el perno de ajuste del
until it has slight contact with vilebrequin jusqu’à ce qu’elle soit cigüeñal hasta que tenga ligero
crankshaft. en contact avec le vilebrequin. contacto con éste.
Mark position of adjusting pin. Repérer la position de la pige de Marcar la posición del perno de
réglage. ajuste.
73. The setting is correct when the ad- 73. Le bon calage est obtenu au mo- 73. El ajuste es correcto, si se puede
justing pin can still be screwed into ment où l’on peut encore tourner seguir girando el perno en el
the crankcase another 0.75 to 2.25 dans le bloc moteur la pige de bloque motor unas 0,75 a 2,25
turns until stop. 0,75 à 2,25 tours jusqu’en butée. vueltas hasta que se asiente.
Note: If the adjusting pin cannot be Nota: si la profondeur de vissage de la Nota: Si no se alcanza la profundidad
screwed into crankcase over its pige de calage n’est pas atteinte, de penetración del perno de
full effective length, the basic refaire le calage de base de ajuste en el bloque motor, es 4
camshaft setting has to be redone. l’arbre à cames. preciso repetir el ajuste básico
del árbol de levas.
Release camshaft toothed belt Pour cela desserrer le pignon de la
gear again for this purpose. courroie dentée de l’arbre à cames A tal objeto hay que soltar la
Repeat procedure as from et le galet tendeur. rueda de correa dentada del
point 55. Répéter opérations à partir du árbol de levas y la polea tensora.
pt. 55. Repetir la operación a partir del
punto 55.
4.00.36
74. Remove adjusting pins for cam- 74. Oter la pige de calage de l’arbre à 74. Quitar los pernos de ajuste del
shaft and crankshaft. cames et du vilebrequin. árbol de levas y cigüeñal.
74.1 Tighten screw plug with new Cu 74.1 Bloquer vis filetée en utilisant un 74.1 Apretar el tapón provisto de una
seal. joint d’étanchéité neuf en Cu. junta anular nueva de cobre.

Note: Use thin socket a/flats 14. Nota: utiliser douille de 14. Nota: Usar una llave de vaso delgado
de 14.
74.2 Tighten screw plug with new Cu 74.2 Bloquer vis filetée en utilisant un 74.2 Apretar el tapón provisto de una
seal. joint d’étanchéité neuf en Cu. junta anular nueva de cobre.

74.3 Refit cover together with gasket. 74.3 Remonter le couvercle avec un 74.3 Volver a montar la tapa con junta.
Tighten bolts. joint neuf. Serrer les vis. Apretar los tornillos.
4
4.00.37
74. Einstellbolzen für Nocken- und Kurbelwelle

entfernen.
3
74.1 Verschlußschraube mit neuem Cu-Dicht-

ring festdrehen.
4
ß
Hinweis: Dünne Stecknuß SW 14 verwenden.
5
74.2 Verschlußschraube mit neuem Cu-Dicht-

ring festdrehen. 4
ß
74.3 Deckel mit Dichtung wieder montieren.

Schrauben festdrehen. 4 4
6
4.00.37
Zylinderkopf
4 75. Zylinderkopfdichtung bestimmen
6 75.1 Abstandsplättchen auf die Dichtfläche des

Zylinderkurbelgehäuses legen und Meßuhr
5 auf „0“ stellen.
9 Hinweis: Bei Vorhandensein der Slip-fit-Buchsen

Abstandsplättchen nicht auf den Buch-
senbund auflegen.
75.2 Meßuhr an den Meßstellen auf den Kolben

4 setzen und den größten Kolbenüberstand
ermitteln.
6 Hinweis: Alle Kolben müssen vermessen wer-

den.
5
75.3 Meßpunkte beachten.

9
76. Größten Wert mit der Tabelle vergleichen
4 9 und entsprechende Zylinderkopfdichtung

ermitteln.
Kolbenüberstand Kennzeichnung der

Zylinderkopfdichtung
0,530 - 0,69 mm 1 Kerbe
0,691 - 0,76 mm 2 Kerben
0,761 - 0,83 mm 3 Kerben
4.00.38
Cylinder head Culasse Culata
75. Determine cylinder head gasket. 75. Déterminer le joint de culasse. 75. Determinación de la junta de
culata.
75.1 Place spacers on sealing surface 75.1 Poser des plaquettes d’écartement 75.1 Colocar las plaquitas distanciadoras
of crankcase with integrated liners sur la surface d’étanchéité du bloc sobre la superficie de cierre del
and set dial gauge to „0“. moteur et mettre le comparateur à bloque de cilindros y poner el
„0“. comparador a „0“.
Note: If slip fit liners are installed do Nota: en présence de chemises slip-fit Nota: Si existen camisas slipfit, cuidar
not place any spacers on liner ne pas placer de plaquettes de no colocar las plaquitas sobre
seating. d’écartement sur la collerette. el reborde de estas camisas.
75.2 Position dial gauge on piston at 75.2 Placer le comparateur sur le piston 75.2 Colocar el comparador en los
gauge points and determine max. aux points de mesure et déterminer puntos de medición sobre el pistón
piston projection. la cote de dépassement la plus y determinar el saliente de pistón
grande du piston. más grande.
Note: All pistons must be gauged. Nota: le relevé des cotes doit être fait Nota: Esta medición deberá hacerse en
sur tous les pistons. todos los pistones.
75.3 Pay attention to gauge points. 75.3 Respecter les points de mesure. 75.3 Observar los puntos de medición.
76. Compare max. value with table and 76. Comparer la plus grande valeur 76. Comparar el valor más grande
determine appropriate cylinder head avec le tableau et définir le joint con la tabla y definir la junta de
gasket. de culasse correspondant culata correspondiente. 4
Piston projection Marking of cylin- Dépassement Identification du Saliente Marcación de la
der head gasket de piston joint de culasse de piston junta de culata
0.590 - 0.69 mm 1 notch 0,590 - 0,69 mm 1 encoche 0,590 - 0,69 mm 1 encoche

0.691 - 0.76 mm 2 notches 0,691 - 0,76 mm 2 encoches 0,691 - 0,76 mm 2 encoches
0.761 - 0.83 mm 3 notches 0,761 - 0,83 mm 3 encoches 0,761 - 0,83 mm 3 encoches
4.00.38
77. Make sure that dowel pins are 77. Veiller à la présence des goupilles 77. Prestar atención a que existan los
fitted. de serrage. pasadores de ajuste.
78. Position cylinder head gasket. 78. Placer le joint de culasse. 78. Colocar la junta de culata.
Note: Sealing surfaces for cylinder head Nota: les surfaces d’étanchéité du joint Nota: Las superficies de cierre o asiento
gasket must be free of oil. de culasse doivent être exemptes de la junta de culata deben estar
d’huile. exentas de aceite.
79. Install cylinder head. Oil cylinder 79. Monter la culasse. Huiler 79. Montar la culata. Untar con un
head bolts lightly. légèrement les vis de culasse. poco de aceite los tornillos de
culata.
Note: Standard length of cylinder head Nota: longueur normale d’une vis de Nota: Longitud del tornillo de culata
bolt: 185 ± 0.8 mm culasse: 185 ± 0,8 mm normal: 185 ± 0,8 mm
79.1 Tighten cylinder head bolts. 79.1 Serrer les vis de culasse. 79.1 Apretar los tornillos de culata.

4 Initial tightening torque: Valeur de préserrage: Apriete inicial:
1st stage 30 Nm 1re phase 30 Nm 1er fase 30 Nm
2nd stage 80 Nm 2e phase 80 Nm 2o fase 80 Nm
3rd stage 160 Nm 3e phase 160 Nm 3er fase 160 Nm
Tightening angle: 90° Serrage à l’angle 90° Angulo de reapriete: 90°
Note: Observe tightening order for Nota: respecter l’ordre de serrage des Nota: Observar el orden de sucesión
cylinder head bolts. See vis de culasse. Voir chapitre en el apriete de los tornillos de
Specification Data. Caractéristiques techniques. culata.
Ver Datos técnicos.
4.00.39
77. Auf Vorhandensein der Spannstifte achten.

9
78. Zylinderkopfdichtung auflegen.
Hinweis: Dichtflächen für die Zylinderkopfdich-

4
tung müssen ölfrei sein.
5
9
79. Zylinderkopf montieren.

Zylinderkopfschrau-ben leicht einölen. 4
Hinweis: Länge der Zylinderkopfschraube nor-
mal: 150 ± 0,8 mm z
5
79.1 Zylinderkopfschrauben festdrehen.
Anziehvorschrift:
4 4
Vorspannwert: 1. Stufe
2. Stufe
30 Nm
80 Nm
6
3. Stufe 160 Nm
Nachspannwinkel: 90° 5
Hinweis: Reihenfolge beim Anziehen der Zylin-
derkopfschrauben beachten.
SieheTechn. Daten
4.00.39
Ventiltrieb
4 80. Stoßstangen einsetzen.
81. Kipphebelbock montieren und zu den Stoß-

4 stangen/Ventilen ausrichten.

6 Hinweis: Ventilspiel einstellen siehe Kapitel 2.
4 4
0
4.00.40
Valve gear Commande des soupapes Accionamiento de las válvulas
80. Insert pushrods. 80. Mettre en place les tiges de 80. Introducir las varillas de empuje.
culbuteurs.
81. Fit rocker arm bracket and align 81. Monter support de culbuteurs et 81. Montar el soporte de balancines y
relative to pushrods/valves. l’ajuster par rapport aux tiges de alinearlo con respecto a las varillas
culbuteurs et soupapes. de empuje/válvulas.
Tightening specification: 21 Nm Consigne de serrage 21 Nm Prescripción de apriete: 21 Nm
Note: Adjust valve clearance - see Nota: réglage du jeu aux soupapes voir Nota: Ajustar el juego de válvulas, ver
Chapter 2. chapitre 2. cap.␣ 2.
83. Place on gasket. 83. Placer un joint. 83. Colocar la junta.
4.00.40
84. Fit cylinder head cover. Tighten 84. Monter le cache-culbuteurs. Serrer 84. Montar la tapa de culata: Apretar
bolts. les vis. los tornillos.
Air intake manifold/exhaust manifold Collecteur d’admission/collecteur Colector de admisión/colector de

d’échappement escape
85. Mount air intake manifold with 85. Monter le collecteur d’admission 85. Montar el colector de admisión
new gaskets. avec des joints neufs. con juntas nuevas.
87. Mount exhaust manifold with new 87. Monter le collecteur d’échappement 87. Montar el colector de escape con
gaskets. en utilisant des joints neufs. juntas nuevas.
4
Note: Apply DEUTZ S1 Never Seize Nota: enduire les vis de pâte DEUTZ Nota: Aplicar pasta DEUTZ S1 Never
paste to bolts. S1 Never Seize. Seize a los tornillos.
4.00.41
84. Zylinderkopfhaube montieren. Schrauben

festdrehen.
4
6
Luftansaugrohr/Abgassammelrohr
85. Luftansaugrohr mit neuen Dichtungen an-

4
bauen.
ß
4
6
87. Abgassammelrohr mit neuen Dichtungen

anbauen. 4 4
Hinweis: Schrauben mit DEUTZ S1 Never Seize
Paste einstreichen. ß
5
4.00.41

Einspritzpumpe
3 89. Verschlußschraube am Kurbelgehäuse her-
ausschrauben.
90. Regelstange in Mittelstellung bringen.

9 Einstellbolzen für Regelstange in das Kurbel-
gehäuse bis Anlage einschrauben.
4
7
91. Nockenwelle drehen, bis Stößelhub des je-
4 4 weiligen Zylinders auf UT steht.
4.00.42
Injection pump Pompe d’injection Bomba de inyección
89. Undo screw plug on crankcase. 89. Dévisser la vis filetée du bloc 89. Desenroscar el tapón del bloque
moteur. motor.
90. Bring control rod in central 90. Placer la crémaillère en position 90. Situar la cremallera en posición
position. milieu. Visser la pige de réglage de media.
Screw adjusting pin for control rod la crémaillère dans le bloc moteur Enroscar el perno de ajuste de la
into crankcase as far as it will go. jusqu’en position de butée. cremallera en el bloque motor hasta
que se asiente.
91. Rotate camshaft until tappet stroke 91. Virer l’arbre à cames jusqu’à ce 91. Girar el árbol de levas hasta que
of respective cylinder is at BDC. que le poussoir du cylindre la carrera del empujador del
considéré soit au PMB. respectivo cilindro se encuentre 4
en PMI.
4.00.42
92. Fit injection pump tappet. 92. Monter le poussoir de la pompe 92. Montar el empujador de la bomba
d’injection. de inyección.
Note: Use flexible magnetic lifter. Nota: utiliser un extracteur magnétique Nota: Usar el elevador magnético
souple. flexible.
93. Determining compensating gasket 93. Détermination des cales de réglage 93. Determinación de la junta de
compensación.
93.1 Gauge depth dimension „A“ bet- 93.1 Relever la cote „A“ entre le plan 93.1 Determinar la medida de profundidad
ween crankcase contact surface d’appui du joint et le plan d’appui „A„ desde el asiento en el bloque
and spring plate contact surface de la cuvette du ressort au niveau motor hasta el asiento del plato
of tappet. du poussoir. de resorte en el empujador.
94. Installation dimension „X“ of 94. Cote de montage „X“ de la pompe 94. Medida de montaje „X„ de la
injection pump d’injection bomba de inyección.
4
B/FL 1011 F engines installation B/FL 1011 F - cote de montage B/FL 1011 F valor „X“ = 58 mm
dimension „X“ = 58 mm „X“ = 58 mm B/FM 1011 F valor„X“ = 59 mm
B/FM 1011 F engines installation B/FM 1011 F - cote de montage
dimension „X“ = 59 mm „X“ = 59 mm
Note: The installation dimension „X“ Nota: la cote de montage „X“ sert Nota: La medita de montaje „X“ sirve
only serves for calculation of uniquement au calcul des cales solamente para la determinación
shims. d’épaisseur. de las arandelas de compensación.
4.00.43
92. Einspritzpumpenstößel montieren.
Hinweis: Biegsamen Magnetheber verwenden. 4

5
93. Ermittlung der Ausgleichdichtung.

6
93.1 Tiefenmaß „A“ von der Kurbelgehäuse-

auflage bis Federtellerauflage am Stößel
messen.
6
94. Einbaumaß „X“ der Einspritzpumpe.
B/FL 1011 F Einbaumaß „X“ = 58 mm

9 4
B/FM 1011 F Einbaumaß „X“ = 59 mm
5
Hinweis: Das Einbaumaß „X“ dient nur zur
Berechnung der Ausgleichscheiben .
4.00.43
95. Differenz zwischen Einbaumaß „X“ und

Tiefenmaß „A“ ermitteln.
Beispiel: Einbaumaß „X“ = 58,00 mm

- Tiefenmaß „A“ = 57,35 mm
Differenz = 0,65 mm
96. Ausgleichdichtung nach Tabelle entspre-

9 chend der Kennzeichnung auswählen.
Ermittelte Maß der

Differenz Kennzeichnung
bis 0,4 mm 9 mm
0,401 - 0,5 mm 12 mm
0,501 - 0,6 mm 15 mm
0,601 - 0,7 mm 18 mm
0,701 - 0,8 mm 21 mm
0,801 - 0,9 mm 24 mm
95-4.166 0,901 - 1,0 mm 27 mm
96.1 Da die Teile-Nr. und die Dichtungsdicke auf

9 der Ausgleichdichtung nicht angegeben ist
kann mit Hilfe des Werkzeuges die Dich-
7 tungsdicke nachgeprüft werden.
95-4.167
97. Entsprechende Ausgleichdichtung auflegen.
4 4 Hinweis: Einbaulage beachten.
4.00.44
95. Determine difference between 95. Calculer la différence entre la 95. Determinar la diferencia entre la
installation dimension „X“ and valeur de montage „X“ et la cote medida de montaje „X„ y la de
depth dimension „A“. de profondeur „A“. profundidad „A“.
Example: Exemple: Ejemplo:

Installation dimension „X“ = 58.00 mm valeur de montage „X“ = 58,00 mm Medida de montaje „X“ = 58,00 mm
- Depth dimension „A“ = 57.35 mm - cote de profondeur „A“ = 57,35 mm - profundidad „A“ = 57,35 mm
Difference = 0.65 mm différence = 0,65 mm Diferencia = 0,65 mm
96. Select compensating gasket from 96. Sélectionner selon la liste ci-après 96. Elegir la junta de compensación
table according to marking. et conformément au repérage la según la tabla y medida de
cale de réglage voulue. identificación.
Determined Marked Calcul de la Cote de Diferencia Medita de

difference dimension différence repérage determinada identificación
up to 0.4 mm 9 mm jusqu’à 0,4 mm 9 mm jusqu’à 0,4 mm 9 mm
0.401 - 0.5 mm 12 mm 0,401 - 0,5 mm 12 mm 0,401 - 0,5 mm 12 mm
0.501 - 0.6 mm 15 mm 0,501 - 0,6 mm 15 mm 0,501 - 0,6 mm 15 mm
0.601 - 0.7 mm 18 mm 0,601 - 0,7 mm 18 mm 0,601 - 0,7 mm 18 mm
0.701 - 0.8 mm 21 mm 0,701 - 0,8 mm 21 mm 0,701 - 0,8 mm 21 mm
0.801 - 0.9 mm 24 mm 0,801 - 0,9 mm 24 mm 0,801 - 0,9 mm 24 mm
0.901 - 1.0 mm 27 mm 0,901 - 1,0 mm 27 mm 0,901 - 1,0 mm 27 mm
96.1 As the part No. and gasket thick- 96.1 Comme le numéro des pièces et 96.1 Dado que el número de pieza y el
ness are not indicated on the l’épaisseur de la cale ne sont pas espesor de la junta de compen-
compensating gasket the gasket indiqués sur la cale contrôler sación no están indicados en ésta,
thickness can be rechecked with l’épaisseur à l’aide de l’outil. se puede comprobar el espesor
the tool. con ayuda de la herramienta
adecuada.
97. Place on appropriate 97. Placer la cale de réglage 97. Colocar la junta de compensación
compensating gasket. correspondante. que corresponda.
4
Note: Watch installation position. Nota: veiller au sens de montage. Nota: Observar la posición de montaje.
4.00.44
98. Remove blanking pin from 98. Retirer le pion obturateur de la 98. Sacar el pasador de cierre de la
injection pump. pompe d’injection. bomba de inyección.
99. Before fitting injection pump, 99. Avant de monter la pompe 99. El alambre de sujeción debe estar
make sure that locking wire is d’injection veiller à ce que le fil enclavado en la palanca de
engaged in control lever. d’arrêt soit bien inséré dans le articulación antes de montar la
levier articulé. bomba de inyección.
100. Fit injection pump in place. Then 100. Monter la pompe d’injection. La 100. Montar la bomba de inyección y
press pump down to its seat, baisser en la centrant jusqu’en presionarla céntricamente hacia
taking care that it is accurately position de butée. Serrer les abajo hasta que se asiente.
centered. Tighten nuts. écrous Apretar las tuercas.
101. Take locking wire out. 101. Retirer le fil d’arrêt. 101. Retirar el alambre de sujeción.
4.00.45
98. Verschlußstift aus der Einspritzpumpe her-

ausnehmen.
3
99. Vor Montage der Einspritzpumpe ist darauf

zu achten, daß der Arretierungsdraht in den
Anlenkhebel eingerastet ist.
4
100 870
7 100 880
95-4.170
100. Einspritzpumpe montieren. Einspritzpumpe

zentrisch bis Auflage hinunterdrücken. Mut-
tern festdrehen.
4
101. Arretierungsdraht herausziehen.

3 4
4.00.45
102. Bohrung mit Verschlußstift verschließen.

4
103. Einstellbolzen für Regelstange entfernen.

3
104. Verschlußschraube mit neuem Cu-Dicht-

4 ring festdrehen.
4.00.46
102. Blank bore with pin. 102. Obturer l’alésage à l’aide du pion. 102. Cerrar el orificio mediante el
pasador de cierre.
103. Remove adjusting pin for control 103. Oter la pige de réglage de la 103. Retirar el perno de ajuste de la
rod. crémaillère. cremallera.
104. Tighten screw plug with new 104. Serrer vis filetée en renouvellant 104. Apretar el tapón provisto de una
Cu seal. bague d’étanchéité en Cu. junta anular nueva de cobre.
4.00.46
Injectors Injecteurs Inyectores
105. Slide sealing ring over injector 105. En l’enduisant d’un peu de graisse 105. Colocar la junta anular con un
using some grease. glisser le joint d’étanchéité sur poco de grasa sobre el inyector.
l’injecteur.
106. Insert injector. 106. Mettre en place l’injecteur. 106. Introducir el inyector.
Note: Leakage fuel connection must Nota: raccord conduite de récupération Nota: El empalme de combustible
point towards exhaust side. doit être dirigé vers la partie sobrante debe indicar hacia el
échappement. lado de escape.
107. Fit clamping pad. 107. Placer la griffe de serrage. 107. Colocar la garra de sujeción.
Note: Watch installation position of Nota: veiller au sens de montage de la Nota: Observar la posición de montaje
clamping pad. patte de serrage. de la garra.
108. Tighten bolt. 108. Serrer la vis. 108. Apretar el tornillo.
4.00.47
Einspritzventile
105. Dichtring mit etwas Fett auf das Einspritz-

4
ventil aufschieben.
ß
u
106. Einspritzventil einsetzen.
Hinweis: Leckölanschluß muß zur Abgasseite

4
weisen.
5
107. Spannpratze aufsetzen.
Hinweis: Einbaulage der Spannpratze beachten.

4
5
108. Schraube festdrehen.
4 4
6
4.00.47
Kühlgebläse
4 109. Ladestromleitung an Anschluß B+ montie-
6 ren. Mutter festdrehen. Gummimuffe an-

bauen.
110. Kühlgebläse anbauen. Schrauben festdre-

4 hen.
111. Ladestromleitung verschellen.

4
Kraftstoffleitung / Einspritzleitungen
4 4 112. Profilgummi auf Spannstifte aufschieben
4.00.48
Blower Turbine de refroidissement Ventilador de refrigeración
109. Fit charging current line to con- 109. Monter conduite de courant de 109. Acoplar el cable de corriente de
nection B+. Tighten nut. Fit rubber charge au branchement B+. Serrer carga a la conexión B+. Apretar la
sleeve. écrou et monter manchon en tuerca. Montar el manguito de
caoutchouc. goma.
110. Mount blower. Tighten bolts. 110. Monter turbine de refroidissement. 110. Montar el ventilador de refrige-
Serrer les vis. ración. Apretar el tornillo.
111. Secure charging current line with 111. Fixer conduite de courant de 111. Fijar el cable de corriente de carga
clips. charge à l’aide d’un collier. mediante abrazaderas.
Fuel line/injection lines Conduite d’alimentation/conduites de Tubería de combustible/tuberías de

refoulement inyección
4
112. Slide on rubber profile on dowel 112. Insérer caoutchouc profilé sur 112. Colocar el perfil de goma sobre
pins. goupilles de serrage. los pasadores de sujeción.
4.00.48
113. Mount fuel line with new Cu seals. 113. Monter conduite avec joints 113. Montar la tubería de combustible
Tighten banjo bolts. d’étanchéité neufs en Cu. Serrer con juntas anulares nuevas de cobre.
les vis creuses. Apretar los tornillos racores.

114. Mount injection lines and tighten. 114. Monter et serrer conduites de 114. Montar las tuberías de inyección y
refoulement. apretar.

specification: 22 + 2 Nm de serrage: 22 + 2 Nm de apriete: 22 + 2 Nm
115. Mount new leakage fuel line. 115. Monter une tubulure de retour 115. Montar una tubería de combustible
des fuites neuve. sobrante nueva.
Note: The leakage fuel line must Nota: toujours remplacer la tubulure Nota: La tubería de combustible so-
always be renewed. de retour de fuites. brante deberá ser sustituida, en
todos los casos, por otra nueva.
115.1 Fasten overflow line to fuel line 115.1 Utiliser la pince Cobra pour fixer 115.1 Sujetar la tubería de rebose a la
using Cobra clamp pliers. le conduit de trop-plein sur la de combustible por medio de
4 conduite d’alimentation de una abrazadera Cobra.
combustible.
Note: Use Cobra clamp pliers. Nota: utiliser la pince de serrage Cobra. Nota: Utilizar las tenzas Cobra.
4.00.49
113. Kraftstoffleitung mit neuen Cu-Dichtringen

anbauen. Hohlschrauben festdrehen.
4
ß
6
Anziehvorschrift: 22 + 2 Nm
4
6
7
115. Neue Leckölleitung anbauen.
Hinweis: Die Leckölleitung ist grundsätzlich zu

4
erneuern.
5
ß
115.1 Überströmleitung an Kraftstoffleitung mit

Cobraklemme befestigen. 4 4
Hinweis: Cobraklemmenzange benutzen.
5
4.00.49
Kraftstofförderpumpe / Kraftstoffilter
4 116. Neuen Runddichtring auflegen.
117. Nockenwellenexenter für Kraftstofförder-

9 pumpe auf UT stellen.
118. Kraftstofförderpumpe anbauen. Schrauben

4 wechselseitig bis zur Anlage einschrauben.
4.00.50
Fuel feed pump/fuel filter Pompe d’alimentation/filtre à Bomba de alimentación de com-

combustible bustible/filtro de combustible
116. Position new O-seal. 116. Placer un joint torique neuf. 116. Colocar un anillo tórico nuevo.
117. Set camshaft eccentric for fuel 117. Régler excentrique de l’arbre à 117. Poner la excéntrica del árbol de
feed pump to BDC. cames pour pompe d’alimentation levas para la bomba de alimentación
sur PMB. de combustible en PMI.
118. Mount fuel feed pump. Screw in 118. Monter pompe d’alimentation. 118. Montar la bomba de alimentación
bolts alternately as far as they will Visser alternativement les vis de combustible. Enroscar
go. jusqu’en position de butée. alternando los tornillos hasta que
se asienten.
4.00.50
120. Screw in plug for oil filler neck. 120. Visser bouchon obturateur de 120. Enroscar la tapa de cierre en la
jauge d’huile. boca de llenado de aceite.
121. Fit fuel filter bracket. Tighten 121. Monter console de filtre à 121. Montar la consola para el filtro de
bolts. combustible. Serrer les vis. combustible. Apretar los tornillos.
122. Lightly oil fuel filter gasket. 122. Huiler légèrement joint de filtre à 122. Untar con un poco de aceite la
Secure fuel filter cartridge combustible. Serrer à la main junta del filtro de combustible.
fingertight. cartouche de filtre à combustible. Apretar a mano el cartucho del
filtro de combustible.
123. Mount fuel lines. 123. Monter conduites d’alimentation. 123. Montar las tuberías de
combustible.
4
Note: Use Cobra clamp pliers. Nota: utiliser pince à ressorts Cobra Nota: Usar los alicates Cobra para
pour tuyaux. abrazaderas.
4.00.51
120. Verschlußdeckel für Öleinfüllung ein-

schrauben.
4
121. Kraftstoffilterkonsole anbauen. Schrauben

festdrehen.
4
6
122. Kraftstoffilterdichtung leicht einölen. Kraft-

stoffilterpatrone handfest andrehen. 4
z
123. Kraftstoffleitungen anbauen.
Hinweis: Cobraklemmenzange benutzen.

4 4
5
4.00.51
124. Ölfilterdichtung leicht einölen. Filter-

4 patrone handfest andrehen.
Luftführung / Ölkühler
4 125. Luftführung anbauen. Schrauben festdre-
6 hen.
126. Steckstücke auf sichtbare Beschädigungen

9 prüfen.
127. Steckstücke bis Anlage eindrücken.
4 4
4.00.52
124. Lightly oil oil filter gasket. Secure 124 Huiler légèrement joint de filtre à 124. Untar con un poco de aceite la
oil filter cartridge fingertight. huile. Bien serrer à la main junta del filtro de aceite. Apretar a
cartouche du filtre. mano el cartucho filtrante.
Air ducting/oil cooler Gaine de guidage d’air/radiateur à Conducción de aire/refrigerador de

huile aceite
125. Mount air ducting. Tighten bolts. 125. Monter le guidage d’air. Serrer les 125. Montar la conducción de aire.
vis. Apretar los tornillos.
126. Inspect plug-in elements for 126. Vérifier que les pièces insérées 126. Examinar las piezas de enchufe en
visual damage. ne présentent pas de dommages cuanto a daños visibles.
visibles.
127. Press in plug-in elements as far 127. Enfoncer les pièces insérées 127. Introducir a presión, hasta el
as they will go. jusqu’en position de butée. tope, las piezas de enchufe.
4
4.00.52
With B/FM engines: Moteurs B/FM En los motores B/FM:
127.1 Fit new O-seals to oil cooler con- 127.1 Monter joints neufs sur les 127.1 Colocar las juntas anulares
nections to that spot facing raccords du radiateur à huile de nuevas sobre los racores del
points towards crankcase. See manière à ce que le chanfrein refrigerador de aceite, de modo
illustration. soit orienté vers le bloc moteur. que el rebaje indique hacia el
Fit oil cooler connections. Voir figure en coupe. bloque motor. Ver el detalle.
Tighten bolts. Monter les raccords du Montar los racores para el
radiateur. Serrer les vis. refrigerador de aceite. Apretar
los tornillos.
128. Position oil cooler. 128. Placer le radiateur. 128. Colocar el refrigerador de aceite
en su sitio.
129. Fit stay plate. Tighten bolts. 129. Monter tôle verticale et serrer les 129. Montar la chapa vertical. Apretar
vis. los tornillos.
130. Tighten oil cooler fastening bolts. 130. Serrer les vis de fixation du 130. Apretar los tornillos que fijan el
radiateur. refrigerador de aceite.
4
Tightening specification. 21 Nm Consigne de serrage: 21 Nm Prescripción de apriete: 21 Nm
4.00.53
Bei B/FM - Motoren.
127.1 Neue Dichtringe so auf die Ölkühler-

4
anschlüsse montieren, daß die Ansenkung
zum Kurbelgehäuse weist. Siehe Bildaus- ß
schnitt.
Ölkühleranschlüsse anbauen. Schrauben
festdrehen.
8
6
128. Ölkühler aufsetzen.

4
129. Standblech anbauen. Schrauben festdrehen.
4
6
130. Ölkühlerbefestigungsschrauben festdrehen.
4 4
6
4.00.53
131. Luftführungshaube anbauen. Schrauben

4 festdrehen.
132. Aufstellfüße / Halter anbauen. Schrauben

4 festdrehen.
6 Anziehvorschrift:
Vorspannwert 106 Nm
133. Konsole für Starter anbauen. Schrauben

4 festdrehen.
6
Hinweis: Auf vorhandensein der Zentrierhülsen
5 achten.
134. Falls vorhanden, Anschlußgehäuse anbau-
4 4 en. Schrauben festdrehen.
6 Anziehvorschrift:
Schrauben M 12 106 Nm
4.00.54
131. Mount air cowling. Tighten bolts. 131. Monter hotte de guidage d’air. 131. Montar la manga guía de aire.
Serrer les vis. Apretar los tornillos.
132. Fit mounting feet/retainer. Tighten 132 Monter pieds de fixation / 132. Montar las patas de colocación /
bolts. support. Serrer les vis. los soportes. Apretar los tornillos.

Initial tightening torque 106 Nm Valeur de préserrage 106 Nm Apriete inicial 106 Nm
Tightening angle 30° Serrage à l’angle 30° Angulo de reapriete 30°
133. Mount starter bracket. Tighten 133. Monter console du démarreur. 133. Montar la consola para el
bolts. Serrer les vis. arrancador. Apretar los tornillos.

specification: 75 ±7 Nm de serrage: 75 ± 7 Nm de apriete: 75 ± 7 Nm
Note: Make sure that centering sleeves Nota: veiller à la présence des douilles Nota: Prestar atención a que existan
are installed. de centrage. los casquillos de centraje.
134. Mount adapter housing, if any. 134. Monter carter d’adaptation si le 134. Si existe, montar el cárter de
Tighten bolts. moteur en a un. Serrer les vis. adaptación. Apretar los tornillos.
4
Tightening specifiation: Consigne de serrage: Prescripción de apriete:
bolts M 12 106 Nm Vis M 12 106 Nm tornillos M 12 106 Nm
bolts M 14 180 Nm Vis M 14 180 Nm tornillos M 14 180 Nm
4.00.54
135. Position flywheel, using a self- 135. Mettre en place le volant moteur 135. Montar el volante, utilizando un
made pilot bar. en utilisant un mandrin de mandril de guía de confección
guidage de fabrication locale. propia.
Note: Use new bolts. Nota: utiliser des vis neuves. Nota: Usar tornillos nuevos.
136. Retain flywheel. Tighten bolts. 136. Maintenir le volant moteur et 136. Retener el volante. Apretar los
serrer les vis. tornillos.

Initial tightening torque 30 Nm Valeur de préserrage: 30 Nm Apriete inicial: 30 Nm
Tightening angle 60° Serrage à l’angle: 60° Angulo de reapriete: 60°
Tightening angle 30° Serrage à l’angle: 30° Angulo de reapriete: 30°
Hydraulic pump bracket Console de pompe hydraulique Soporte de la bomba hidráulica
137. Insert new O-seals. 137. Placer des joints toriques neufs. 137. Introducir anillos tóricos nuevos.
138. Mount hydraulic pump bracket. 138. Monter console de pompe 138. Montar el soporte de la bomba
Start fastening bolts. hydraulique. Serrer légèrement hidráulica. Apretar ligeramente los
4 vis de fixation. tornillos de fijación.
4.00.55
135. Schwungrad unter Verwendung eines

selbstgefertigten Führungsdornes aufsetzen.
4
Hinweis: Neue Schrauben verwenden.
5
136. Schwungrad gegenhalten. Schrauben fest-

drehen. 4
Anziehvorschrift:
Vorspannwert: 30 Nm 6
Nachspannwinkel: 60°
Hydraulikpumpenkonsole
137. Neue Runddichtringe einsetzen.

4
ß
138. Hydraulikpumpenkonsole anbauen. Befe-

stigungsschrauben leicht andrehen. 4 4
4.00.55
139. Zahnriemen aufsetzen.

4 Auf dem Kurbelwellenzahnrad bis gegen
den hinteren Führungsbord und auf dem
9 Hydraulikpumpenzahnrad mit ca. 4 mm

Rückstand zur Vorderkante.
140. Spannvorrichtung ansetzen.

4
7

4
7
142. Zahnriemen über die Spannvorrichtung
4 s vorspannen, so daß ein Skalenwert von

10,5 bis 11,5 erreicht wird.
6 Spannungs-Meßgerät entfernen.
4.00.56
139. Position toothed belt. 139. Mettre en place la courroie 139. Colocar la correa dentada.
On crankshaft gear as far as rear crantée. Sobre la rueda dentada del
guide plate and on hydraulic Sur le pignon du vilebrequin cigüeñal hasta contra el borde
pump gear with approx. 4 mm jusqu’au bord de guidage arrière trasero de guía y sobre la rueda
distance from front edge. et sur le pignon de la pompe dentada de la bomba hidráulica
hydraulique retrait d’environ 4 con un retroceso de aprox. 4 mm
mm par rapport à l’arête avant. con respecto al canto delantero.
140. Position tensioning device. 140. Mettre en place le dispositif 140. Colocar el tensor.
tendeur.
141. Position toothed belt tension 141. Mettre en place l’appareil de 141. Colocar el verificador de tensión
gauge. vérification de la tension de la para correas dentadas.
courroie crantée.
142. Tension toothed belt with tension- 142. Avec le dispositif tendeur tendre 142. Pretensar la correa dentada
ing device so as to attain a scale la courroie crantée jusqu’à obten- mediante el tensor hasta que se
reading between 10.5 and 11.5. tion sur l’échelle d’une valeur de alcance un valor de 10,5 a 11,5 4
Remove tension gauge. 10,5 à 11,5. en la escala.
Enlever l’appareil de vérification Retirar el verificador de tensión.
de la tension.
4.00.56
143. Tighten fastening bolts of bracket. 143. Serrer les vis de fixation de la 143. Apretar los tornillos de fijación del
console. soporte.
144. Remove tensioning device. 144. Oter le dispositif tendeur. 144. Quitar el tensor.
Turn crankshaft one revolution in Virer le vilebrequin d’un tour dans le Darle al cigüeñal 1 vuelta en el
direction of engine rotation. sens de rotation du moteur. sentido de giro normal del motor.
145. Position toothed belt tension 145. Placer l’appareil de vérification de 145. Colocar el verificador de tensión
gauge. la tension de courroie crantée. para correas dentadas. Medir la
Gauge belt tension. Mesurer la tension. tensión de la correa.
Specified scale reading: Valeur de consigne sur l’échelle Valor prescrito: valor de escala
10 to 12 10 à 12 10 a 12
146. If the specified scale reading is 146. Si la valeur de consigne indiquée 146. Al no alcanzarse el valor de escala
not attained, repeat procedure. sur l’échelle graduée n’est pas exigida, hay que repetir la
4 atteinte, répéter le réglage. operación de ajuste.
4.00.57
143. Befestigungsschrauben der Konsole fest-

drehen.
4
6
144. Spannvorrichtung entfernen.

Kurbelwelle 1 Umdrehung in Motordreh-
richtung drehen.
a
3
145. Zahnriemenspannungs-Meßgerät aufset-

zen. Riemenspannung messen. 4
Sollwert: Skalenwert 10 bis 12
7
6
146. Wenn der geforderte Skalenwert nicht er-

reicht wird, ist die Einstellung zu wiederho-
len.
6 4
4.00.57
Hydraulikpumpe
4 147. Zahnwelle mit Graphitfett bestreichen.
u Kupplungshülse aufschieben.
148. Befestigungsschrauben mit Scheiben ein-

4 setzen. Vorstehmaß der Schrauben mes-
sen.
6 Hinweis: Das max. Vorstehmaß von 15 mm

darf nicht überschritten werden.
5
149. Zahnwelle der Hydraulikpumpenkonsole

4 mit Graphitfett bestreichen. Hydraulik-
pumpe anbauen.
u
4.00.58
Hydraulic pump Pompe hydraulique Bomba hidráulica
147. Apply graphite grease to toothed 147. Enduire arbre-pignon de graisse 147. Aplicar grasa grafitada al eje
shaft. Slide on coupling sleeve. au graphite. Insérer douille dentado. Colocar sobre el eje el
d’accouplement. manguito de acoplamiento.
148. Insert fastening bolts together 148. Placer les vis de fixation avec les 148. Meter los tornillos de fijación con
with washers. Measure bolt rondelles. Mesurer la cote de sus arandelas. Medir la medida
projection. dépassement des vis. que sobresalen.
Note: The max. projection of 15 mm Nota: la cote de dépassement maxi ne Nota: Esta medida no debe ser
must not be exceeded. doit pas dépasser 15 mm. superior a 15 mm.
149. Apply graphite grease to toothed 149. Enduite l’arbre-pignon de la 149. Aplicar grasa grafitada al eje
shaft of hydraulic pump bracket. console de la pompe hydraulique dentado del soporte de la bomba
Mount hydraulic pump. de graisse au graphite puis hidráulica. Montar la bomba
monter la pompe hydraulique. hidráulica.
4.00.58
151. Position intermediate disc with 151. Placer la rondelle intermédiaire en 151. Colocar la arandela intermedia
flattened side facing the engine. orientant le côté plat vers le moteur. con la cara aplanada indicando
hacia el motor.
152. Mount toothed belt guard. 152. Monter le carter cache-courroie. 152. Montar la cubierta protectora de
correas dentadas.
Tightening specification. 8.5 Nm Consigne de serrage: 8,5 Nm Prescripción de apriete: 8,5 Nm
154. Fit V-belt pulley. Tighten bolts. 154. Monter la courroie à gorge et 154. Montar la polea de correa
serrer les vis. trapezoidal. Apretar los tornillos.
4
4.00.59
151. Zwischenscheibe mit der abgeflachten Sei-

te zum Motor weisend aufsetzen.
4
8
152. Zahnriemenschutzgehäuse anbauen.

4
4
6
154. Keilriemenscheibe anbauen. Schrauben

festdrehen. 4 4
6
4.00.59
155. Keilriemenspannrolle anbauen.

4 Hinweis: Schrauben leicht festdrehen.
156. Keilriemen auflegen.

4
157. Keilriemen spannen. Schrauben festdrehen.

s
6
158. Keilriemenspannung mit Spannungsmeß-
4 6 gerät prüfen.
Erstmontage: 400 ± 20 N
Kontrollwert nach
15 Minuten Lauf unter Last: 300 ± 20 N
4.00.60
155. Fit V-belt idler pulley. 155. Monter galet tendeur de courroie. 155. Montar la polea tensora de la
correa trapezoidal.
Note: Start bolts. Nota: serrer légèrement les vis. Nota: Apretar ligeramente los tornillos.
156. Position V-belt. 156. Placer la courroie. 156. Colocar la correa trapezoidal.
157. Tension V-belt. Tighten bolts. 157. Tendre la courroie et serrer les 157. Tensar la correa trapezoidal.
vis. Apretar los tornillos.
158. Check V-belt tension with tension 158. A l’aide de l’appareil de mesure 158. Comprobar la tensión de la correa
gauge. vérifier la tension de courroie. trapezoidal utilizando el verificador
de tensión correspondiente. 4
Initial assembly: 400 ± 20 N Premier montage: 400 ± 20 N Primer montaje: 400 ± 20 N
Check value after Valeur de contrôle Valor de control
15 min. operation après une marche tras marcha
under load: 300 ± 20 N de 15 minutes de 15 minutos
sous charge: 300 ± 20 N bajo carga: 300 ± 20 N
4.00.60
Air compressor Compresseur d’air Compresor de aire
159. Insert new O-seal using some 159. Placer un joint torique neuf avec 159. Colocar el anillo tórico nuevo con
grease. un peu de graisse. un poco de grasa.
160. Position air compressor and 160. Monter le compresseur et enfoncer 160. Montar el compresor de aire y
press down as far as it will go in jusqu’en position d’appui dans le presionarlo en dirección de la
direction of arrow. sens de la flèche. flecha hasta que se asiente.
162. Mount lube oil pipe together with 162. Monter tuyauterie d’huile avec des 162. Montar la tubería de aceite
new Cu seals. Tighten bolts. bagues en Cu neuves. Serrer les lubricante con anillos nuevos de
4 vis. cobre. Apretar los tornillos.
4.00.61
Luftpresser
159. Neuen Runddichtring mit etwas Fett ein-

4
setzen.
ß
u
160. Luftpresser aufbauen und in Pfeilrichtung

auf Anlage drücken. 4
4
6
162. Schmierölleitung mit neuen Cu-Ringen an-

bauen. Schrauben festdrehen. 4 4
ß
6
4.00.61
163. Schlauchkrümmer anbauen. Schlauch-

4 schellen festdrehen.
164. Herausgenommene Ausgleichscheiben

4 beilegen.
165. Keilriemen und äußere Keilriemenscheibe

4 montieren.
166. Falls vorhanden, restliche Ausgleichscheiben
4 4 aufsetzen. Schrauben einschrauben.
4.00.62
163. Fit hose elbow. Secure hose clips. 163. Monter tubulure flexible et serrer 163. Montar el codo de manguera.
colliers de fixation. Apretar las abrazaderas de
manguera.
164. Place back removed shims. 164. Intercaler cales de compensation 164. Colocar las arandelas de
retirées. compensación que se haya
desmontado.
165. Fit V-belt and outer V-belt pulley. 165. Monter courroie trapézoïdale et 165. Colocar la correa trapezoidal y la
poulie à gorge extérieure. polea exterior.
166. Position remaining shims, if 166. Placer le cas échéant les cales de 166. Si existen, colocar las arandelas
provided. Screw in bolts. compensation restantes. Serrer de compensación restantes.
les vis. Enroscar los tornillos. 4
4.00.62
167. Tighten bolts while continuously 167. Serrer les vis tout en virant 167. Girando constantemente el
turning the engine. constamment le moteur. cigüeñal, apretar los tornillos.
168. Check V-belt tension. 168. Vérifier la tension de courroie. 168. Verificar la tensión de la correa
If specified scale reading is not Si la valeur de consigne n’est pas trapezoidal.
attained, repeat procedure. atteinte, répéter l’opération de Al no alcanzarse el valor prescrito,
tension. es necesario repetir la operación
de tensado.
V-belt tension: Tension de courroie: Tensión de correa trapezoidal:

Initial assembly: 500 + 50 N première monte 500 + 50 N Primer montaje: 500 + 50 N
under load 410 + 50 N de 15 minutes de 15 minutos
sous charge: 410 + 50 N bajo carga: 410 + 50 N
Note: Turn engine by 180°. Nota: virer le moteur de 180°. Nota: Girar el motor 180°.
Oil suction pipe Tube d’aspiration d’huile Tubo de aspiración de aceite
169. Apply sealing compound DEUTZ 169. Enduire de pâte d’étanchéité 169. Aplicar sellante DEUTZ DW 67 a
DW 67 to sealing surface of oil DEUTZ DW 67 le plan de joint du la superficie de cierre del tubo de
suction pipe. tube d’aspiration d’huile. aspiración de aceite.
Note: Make sure that no sealing Nota: veiler à ce que le produit Nota: No debe llegar ningún sellante al
compound penetrates into the d’étanchéité ne coule pas dans interior del tubo de aspiración
oil suction pipe. le tube d’aspiration. de aceite.
170. Mount oil suction pipe. Tighten 170. Monter le tube d’aspiration. 170. Montar el tubo de aspiración de
bolts. Serrer les vis. aceite. Apretar los tornillos.
4
4.00.63
167. Schrauben unter ständigem Durchdrehen

des Motors festdrehen.
4
6
168. Keilriemenspannung prüfen.

Wenn der Sollwert nicht erreicht wird,
Spannvorgang wiederholen.
6
Keilriemenspannung: s
Erstmontage: 500 + 50 N
Kontrollwert nach 5
15 Minuten Lauf unter Last: 410 + 50 N
Hinweis: Motor um 180° drehen.
Ölansaugrohr
169. Dichfläche des Ölansaugrohres mit Dicht-

4
w
Hinweis: Darauf achten, daß kein Dichtmittel in
das Ölansaugrohr fließt. 5
170. Ölansaugrohr anbauen. Schrauben fest-

drehen. 4 4
6
4.00.63
171. Dichfläche der Ölwanne mit Dichtmittel

4 DEUTZ DW 47 bestreichen. Ölwanne anbau-
en. Eckschrauben „X“ jeweils mit 0,5 Nm
w vorspannen. Alle Schrauben nach Anzieh-

reihenfolge, siehe Skizzen, festdrehen.
171.1 4-Zylinder
4 Anziehvorschrift:
6 Blechölwanne
Schrauben M 8 x 16 mm -8.8 21 Nm
Gußölwanne
95-4.244
171.2 4-Zylinder
4 Anziehvorschrift:
6 Gußölwanne
Zylinderkopfschrauben 180 Nm
171.3 3-Zylinder
4 4 Anziehvorschrift:
6 Blechölwanne
4.00.64
171. Apply sealing compound DEUTZ 171. Enduire le plan d’appui du carter 171. Aplicar sellante DEUTZ DW 47 a la
DW 47 to sealing surface of oil pan. d’huile de pâte d’étanchéité superficie de cierre del cárter de
Mount oil pan. Initially tighten DEUTZ DW 47. Monter le carter aceite. Montar el cárter de aceite.
corner bolts „X“ with 0.5 Nm d’huile. Préserrer les vis „X“ Apretar cada uno de los tornillos
each. Tighten all bolts according situées dans le coins d’une valeur de esquina con un par previo de
to tightening order, see sketches respective correspondant à 0,5 0,5 Nm. Apretar todos los tor-
below. Nm. Ensuite bloquer toutes les vis nillos según el orden de sucesión
selon les préconisations de correspondiente, ver los croquis.
serrage, voir croquis.
171.1 4-Cylinder 171.1 4 cylindres 171.1 4 cilindros
Sheet metal oil pan Carter d’huile en tôle Cárter de aceite, de chapa
Bolts Vis Tornillos
M 8 x 16 mm -8.8 21 Nm M 8 x 16 mm -8.8 21 Nm M 8 x 16 mm -8.8 21 Nm
Cast oil pan Carter d’huile en fonte Cárter de aceite, de fundición

Bolts Vis Tornillos
Bolts Vis Tornillos
Cast oil pan Carter d’huile en fonte Cárter de aceite, de fundición

Bolts Vis Tornillos
Bolts Vis Tornillos
Cylinder head bolts 180 Nm Vis de culasse 180 Nm Tornillos de culata 180 Nm
Tightening specification: Consigne de serrage Prescripción de apriete: 4

Bolts Vis Tornillos
4.00.64
Bolts Vis Tornillos
172. Screw oil drain plug back in with 172. Placer bouchon de vidange d’huile 172. Enroscar el tornillo de salida de
new Cu seal and tighten. neuf avec une bague d’étanchéité aceite provisto de una junta anular
neuve en Cu et bloquer. nueva de cobre y apretarlo.

173. If adapther housing is provided, 173. En présence d’un carter 173. Si existe un cárter de adaptación,
mount cover plate. Tighten bolts. d’adaptation, monter tôle de montar la chapa de recubrimiento.
recouvrement. Serrer les vis. Apretar los tornillos.

specification: 9 Nm de serrage: 9 Nm de apriete: 9 Nm
Note: Turn engine by 180°. Nota: virer le moteur de 180°. Nota: Girar el motor 180°.
174. Fit new O-seal. 174. Insérer un joint torique neuf. 174. Colocar un anillo tórico nuevo.
4.00.65
171.4 2-Zylinder
Anziehvorschrift:
4
Blechölwanne 6
172. Ölablaßschraube mit neuem Cu-Dichtring

einschrauben und festdrehen. 4
ß
6
173. Falls Anschlußgehäuse, Abdeckblech an-

6
Hinweis: Motor um 180° drehen.
5
174. Neuen Runddichtring aufziehen.

4 4
ß
4.00.65
175. Ölmeßstab bis Anschlag eindrücken.

4
176. Aufstellfuß anbauen. Schrauben festdrehen.

6 Hinweis: Motor vom Montagebock und Auf-

spannhalter abbauen.
5
177. Starter anbauen. Schrauben festdrehen.

6
178. Ladestromleitung an Starter anbauen und
4 4 verschellen.
4.00.66
175. Press in oil dipstick as far as it 175. Enfoncer jauge d’huile jusqu’en 175. Introducir hasta el tope la varilla
will go. position de butée. de medición del nivel de aceite.
176. Fit mounting foot. Tighten bolts. 176. Monter pied de fixation puis 176. Montar la pata de colocación.
serrer les vis. Apretar los tornillos.
Tightening Consigne Prescripción de apriete: 200 Nm

specification: 200 Nm de serrage: 200 Nm
Note: Remove engine from assembly Nota: monter moteur sur le chevalet de Nota: Desmontar el motor del caballete
stand and angled clamping plate. montage et déposer le dispositif de montaje y soporte de fijación.
d’ablocage.
177. Mount starter. Tighten bolts. 177. Déposer le démarreur et serrer les 177. Montar el arrancador. Apretar los
vis. tornillos.
178. Fit charging current line to starter 178. Monter la conduite de courant de 178. Unir el cable de corriente de carga
and secure with clips. charge sur le démarreur et fixer à al arrancador y fijarlo mediante
l’aide d’un collier. abrazaderas. 4
4.00.66
179. Fit mounting foot. Tighten bolts. 179. Monter pied de fixation et serrer 179. Montar la pata de colocación.
les vis. Apretar los tornillos.
4.00.67
179. Aufstellfuß anbauen. Schrauben festdrehen.
4
6
4.00.67
Renewing shaft seals on complete Remplacement des joints d’arbre sur Sustitución de los retenes en el motor
engine moteur complet completo
Special tools required: Outillage spécial Herramientas especiales:
Puller for shaft seals ______ 142 710 Extracteur de joints d’arbre __ 142 710 Extractor de retenes _______ 142 710
Assembly tool front _______ 142 850 Dispositif de montage AV __ 142 850 Dispositivo de
Assembly tool front _______ 142 050 Dispositif de montage AV __ 142 050 montaje delantero ________ 142 850
Assembly tool rear ________ 142 860 Dispositif de montage AR __ 142 860 Dispositivo de
montaje delantero ________ 142 050
Dispositivo de
montaje trasero __________ 142 860
- Cover flywheel end - - Couvercle côté volant - - Tapa, lado de volante -
Flywheel has been removed. Le volant moteur a été déposé. El volante está desmontado.
1. Press angle hook into shaft seal. 1. Insérer le crochet d’extraction dans 1. Introducir a presión el gancho
le joint d’arbre. extractor en el retén.
2. Lever shaft seal out of cover using 2. Oter le joint d’arbre du couvercle 2. Haciendo palanca con el extractor,
puller. avec le dispositif d’extraction. desmontar el retén de la tapa.
3. Fit shaft seal with assembly tool 3. Monter le joint d’arbre non huilé 3. Montar sin aceitar el retén con
without using oil. Sealing lip points avec le dispositif à emmancher. La ayuda del dispositivo de montaje.
4 towards crankshaft. lèvre d’étanchéité doit être dirigée El labio obturante debe indicar
vers le vilebrequin. hacia el cigüeñal.
4.00.69
Austausch der Wellendichtringe am

kompletten Motor
Spezialwerkzeug
Ausziehvorrichtung für
Wellendichtringe ________________ 142 710
Montagevorrichtung vorn _________ 142 850
Montagevorrichtung vorn _________ 142 050
Montagevorrichtung hinten ________ 142 860
- Deckel Schwungradseite -
Schwungrad ist abgebaut

4
1. Abziehhaken in den Wellendichtring eindrük- 7
ken.
2. Wellendichtring mit Ausziehvorrichtung aus

dem Deckel hebeln. 3
7
3. Wellendichtring ungeölt mit Montagevorrich-

tung montieren. Die Dichtlippe weist zur
Kurbelwelle.
4 4
8
7
4.00.69
-Vorderer Deckel-
4 Zahnriemenschutzgehäuse, Nockenwellen- und
7 Kurbelwellenzahnrad sind abgebaut.
1. Abziehhaken in den Wellendichtring

-Nockenwelle-
-Kurbelwelle eindrücken-
4
7
2. Wellendichtring für Nockenwelle-

3
7
-und Kurbelwelle mit Ausziehvorrichtung
4 3 aushebeln.
4.00.70
- Front cover - - Couvercle avant - - Tapa delantera -
Toothed belt guard/camshaft and crank- Le carter protège courroie crantée ainsi El cárter protector de correas dentadas
shaft gears have been removed. que les carters de l’arbre à cames et du así como las ruedas dentadas en el árbol
vilebrequin ont été déposés. de levas y en el cigüeñal están desmon-
tados.
1. Press angle hook into seal of 1. Enfoncer le crochet d’extraction 1. Introducir a presión el gancho
- camshaft - dans le joint de l’arbre à cames extractor en el retén para
- árbol de levas -
- crankshaft -. - dans le joint du vilebrequin - - cigüeñal -
2. Lever out shaft seal for camshaft 2. Décoller le joint de l’arbre à cames 2. Haciendo palanca con el extractor,
desmontar el retén para el árbol de
levas -
- and crankshaft using puller. - et du vilebrequin avec le dispositif - y para el cigüeñal.

d’extraction.
4
4.00.70
3. Fit seal for camshaft with assembly 3. Monter avec le dispositif de montage, 3. Montar sin aceitar el retén del árbol
tool without using oil. Sealing lip sans l’huiler, le joint d’arbre à cames. de levas, utilizando el dispositivo
points towards camshaft. La lèvre d’étanchéité est dirigée vers de montaje. El labio de obturación
l’arbre à cames. indica hacia el árbol de levas.
4. Fit seal for crankshaft with assembly 4. Monter avec le dispositif de 4. Montar sin aceitar el retén para el
tool without using oil. Sealing lip montage, sans l’huiler, le joint du cigüeñal, utilizando el dispositivo
points towards crankshaft. vilebrequin. La lèvre d’étanchéité de montaje. El labo de obturación
est dirigée vers le vilebrequin. indica hacia el cigüeñal.
Note: After having fitted shaft seals basic Nota: après montage des joints d’arbre Nota: Una vez montados los retenes
setting of „camshaft relative to procéder à nouveau au réglage de es preciso efectuar el ajuste
crankshaft“ has to be carried out. base de „l’arbre à cames par básico „árbol de levas con
(See page 4.00.27) rapport au vilebrequin“. respecto al cigüeñal“.
(Voir page 4.00.27) (Ver pág. 4.00.27)
4.00.71
3. Wellendichtring für Nockenwelle ungeölt mit

Montagevorrichtung montieren. Die Dichtlip-
pe weist zur Nockenwelle.
4
8
7
4. Wellendichtring für Kurbelwelle ungeölt mit

Montagevorrichtung montieren. Die Dicht-
lippe weist zur Kurbelwelle.
4
Hinweis: Nach der Montage der Wellendicht- 8
ringe ist die Grundeinstellung „Nok-
kenwelle zur Kurbelwelle“ durchzu-
führen.
7
(siehe Seite 4.00.27)
5
4.00.71
Removing and refitting exhaust Dépose et repose du turbocompresseur Desmontaje y montaje del
turbocharger d’échappement turbocompresor
1. Take down oil return pipe. 1. Déposer la conduite de retour 1. Desmontar el tubo de retorno de
d’huile. aceite.
2. Take down lube oil pipe. 2. Déposer la tuyauterie d’huile. 2. Desmontar la tubería de aceite
lubricante.
3. Release spring band clips and push 3. Desserrer les colliers en feuillard et 3. Soltar las abrazaderas de fleje de
upwards. les pousser vers le haut. acero y correrlas hacia arriba.
Note: Replace damaged rubber sleeve. Nota: remplacer manchon en Nota: Sustituir el manguito de goma
caoutchouc défectueux. defectuoso.
4. Remove turbocharger. 4. Déposer turbocompresseur 4. Desmontar el turbocompresor.

d’échappement.
4
Note: Replace turbocharger if damaged. Nota: remplacer tout turbocompresseur Nota: Sustituir el turbocompresor
défectueux. defectuoso.
4.00.73
Abgasturbolader ab- und anbauen
1. Ölrücklaufrohr abbauen.
3
2. Schmierölleitung abbauen.
3
3. Federbandschellen lösen und nach oben

schieben. 3
Hinweis: Schadhafte Gummimuffe austauschen.
5
4. Abgasturbolader abbauen.
Hinweis: Schadhaften Abgasturbolader austau-

3 4
schen.
5
4.00.73
5. Glühwendelkerze ausbauen.
3
6. Ladeluftkrümmer abbauen.
3
7. Ladeluftkrümmer mit neuer Dichtung anbau-

4 en. Schrauben festdrehen.
8. Glühwendelkerze anbauen.
4 4
4.00.74
5. Remove glow-plug filament. 5. Déposer la bougie à filament 5. Desmontar la bujía de filamento

boudiné. incandescente.
6. Remove charge air elbow. 6. Déposer la tubulure d’air de 6. Desmontar el codo de aire de
suralimentation. sobrealimentación.
7. Mount charge air elbow with new 7. Monter tubulure d’air de suralimen- 7. Montar el codo de aire de sobre-
seal. Tighten bolts. tation avec joint neuf. Serrer les vis. alimentación con una junta nueva.
Apretar los tornillos.
8. Fit glow-plug filament. 8. Reposer la bougie à filament 8. Montar la bujía de filamento

boudiné. incandescente.
4
4.00.74
9. Tighten glow-plug filament. 9. Serrer la bougie à filament boudiné. 9. Apretar la bujía de filamento
incandescente.
10. Position rubber sleeve and push 10. Placer manchon en caoutchouc et 10. Colocar el manguito de goma y
spring band clips upwards. pousser vers le haut les colliers en correr hacia arriba las abrazaderas.
feuillard.
11. Mount turbocharger together with 11. Monter turbocompresseur 11. Montar el turbocompresor
new gasket. d’échappement avec joint neuf. provisto de una junta nueva.
Note: Apply Never Seize paste DEUTZ Nota: enduire les goujons de pâte Nota: Aplicar pasta Never Seize DEUTZ
S1 to studs. Never Seize DEUTZ S1. S1 a los espárragos.
12. Tighten nuts. 12. Serrer les écrous. 12. Apretar las tuercas.
4.00.75
9. Glühwendelkerze festdrehen.
4
6
10. Gummimuffe aufsetzen und Federband-

schellen nach oben schieben. 4
11. Abgasturbolader mit neuer Dichtung an-

bauen. 4
Hinweis: Stiftschrauben mit Never Seize Paste
DEUTZ S1 bestreichen. ß
5
12. Muttern festdrehen.
4 4
6
4.00.75
13. Federbandschellen montieren.

4
14. Schmierölleitung mit neuen Cu-Dichtringen

4 anbauen.
15. Hohlschrauben festdrehen.

6
16. Ölrücklaufrohr mit neuem Runddichtring
4 4 anbauen. Überwurfmutter Pos. 1 fest-

drehen. Haltebügel anbauen und Schraube
ß Pos. 2 festdrehen.
Anziehvorschrift: Pos. 1 60 ± 3 Nm
6 Pos. 2 8,5 Nm
4.00.76
13. Fit spring band clips. 13. Monter les colliers. 13. Montar las abrazaderas.
14. Fit lube oil pipe with new Cu seals. 14. Monter conduite d’huile avec bague 14. Montar la tubería de aceite
d’étanchéité neuves en Cu. lubricante con juntas anulares
nuevas de cobre.
15. Tighten banjo bolts. 15. Serrer les vis creuses. 15. Apretar los tornillos racores.
16. Fit oil return pipe with new O-seal. 16. Monter tube de retour avec joint 16. Montar el tubo de retorno de aceite
Tighten cap nut, item 1. Fit retainer torique neuf. Serrer écrou-raccord con un anillo tórico nuevo. Apretar
and tighten bolt, item 2. (1). Monter étrier de maintien et la tuerca de empalme (1). Montar 4
serrer vis (2). el estribo de soporte y apretar el
tornillo (2).

specification: item 1 60 ± 3 Nm de serrage: rep.1 60 ± 3 Nm de apriete: (1) 60 ± 3 Nm
item 2 8.5 Nm rep 2 8,5 Nm (2) 8,5 Nm
4.00.76
Different assembly variants Diverses variantes de montage Diversas variantes de adosamiento de

elementos
Removing and refitting alternator and Déposer et reposer alternateur et Desmontaje y montaje del alternador
fan drive entraînement du ventilateur y accionamiento del ventilador
Commercial tool required: Herramienta comercial:
V-belt tension gauge _______ 91 107 Appareil de mesure de Verificador de tensión

tension de courroie _________ 91107 para correas trapezoidales ____ 91107
1. Remove alternator. Take off V-belt. 1. Déposer alternateur. Retirer la 1. Desmontar el alternador. Quitar la
courroie. correa trapezoidal.
2. Remove bracket. 2. Déposer la console. 2. Desmontar la consola.
3. Remove complete fan drive. 3. Déposer entraînement du 3. Desmontar el accionamiento

ventilateur complet. completo del ventilador.
4
4.00.77
Verschiedene Anbauvarianten
Generator und Lüfterantrieb ab- und anbauen
Keilriemenspannungs-Meßgerät ______ 91107
1. Generator abbauen. Keilriemen abnehmen.

3
2. Konsole abbauen.
3
3. Lüfterantrieb komplett abbauen.

3 4
4.00.77
4. Konsole für Generator anbauen. Schrauben

4 festdrehen.
5. Generator anbauen. Schrauben leicht andre-

4 hen.
6. Lüfterantrieb komplett mit Keilriemen-

4 scheibe anbauen. Schrauben festdrehen.
s
6
4.00.78
4. Fit bracket for alternator. Tighten 4. Monter console de l’alternateur. 4. Montar la consola para el
bolts. Serrer légèrement les vis. alternador. Apretar los tornillos.
5. Fit alternator. Start bolts. 5. Monter alternateur. Serrer 5. Montar el alternador. Apretar
légèrement les vis. ligeramente los tornillos.
6. Fit fan drive complete with V-belt 6. Monter entraînement de l’alternateur 6. Montar el accionamiento completo
pulley. Tighten bolts. complet avec poulie à gorge. Serrer del ventilador con polea de correa
les vis. trapezoidal. Apretar los tornillos.
7. Tension V-belt. Tighten bolts. 7. Serrer la courroie et les vis. 7. Tensar la correa trapezoidal.
4
4.00.78
8. Check V-belt tension with tension 8. Vérifier la tension de courroie à 8. Comprobar la tensión de la correa
gauge. l’aide de l’appareil de contrôle. trapezoidal mediante el verificador
de tensión.
Initial assembly: 400 ± 20 N Première monte 400 ± 20 N Primer montaje: 400 ± 20 N

under load: 300 ± 20 N de 15 minutes de 15 minutos
sous charge: 300 ± 20 N bajo carga 300 ± 20 N
Removing and refitting alternator Déposer et reposer l’alternateur Desmontaje y montaje del alternador
Commercial tool required: Outil usuel: Herramienta comercial:
V-belt tension gauge _______ 91 107 Appareil de mesure Verificador de tensión

de tension de courroie _______ 91107 para correas trapezoidales ____ 91107
9. Remove alternator. Take off V-belt. 9. Déposer alternateur. Retirer la 9. Desmontar el alternador. Quitar la
courroie. correa trapezoidal.
10. Remove bracket. 10. Déposer la console. 10. Desmontar la consola.
4.00.79

gerät prüfen.
6
Kontrollwert nach
Generator ab- und anbauen
Keilriemenspannungs-Meßgerät ______ 91107
9. Generator abbauen. Keilriemen abnehmen.

3
10. Konsole abbauen.

3 4
4.00.79
11. Konsole anbauen. Schrauben leicht andre-

4 hen.
12. Generator anbauen. Schrauben leicht an-

4 drehen.

6
4 4
4.00.80
11. Fit bracket. Start bolts. 11. Monter console. Serrer légèrement 11. Montar la consola. Apretar
les vis. ligeramente los tornillos.
12. Fit alternator. Start bolts. 12. Déposer alternateur et serrer les 12. Montar el alternador. Apretar
vis modérément. ligeramente los tornillos.
14. Position V-belt. 14. Placer la courroie. 14. Colocar la correa trapezoidal.
4.00.80
15. Tension V-belt. 15. Tendre la courroie. 15. Tensar la correa trapezoidal.
16. Check V-belt tension with tension 16. Vérifier la tension de courroie à 16. Comprobar la tensión de la correa
gauge. l’aide de l’appareil de contrôle. trapezoidal mediante el verificador
de tensión.
Initial assembly: 400 ± 20 N Première monte 400 ± 20 N Primer montaje: 400 ± 20 N

15 min. operation après marche tras marcha
under load 300 ± 20 N de 15 minutes de 15 minutos
sous charge: 300 ± 20 N bajo carga 300 ± 20 N
17. After completed belt tensioning, 17. Avoir avoir tendu la courroie serrer 17. Terminado el tensado de la correa
tighten remaining bolts. les autres vis. trapezoidal, deberán apretarse los
tornillos restantes.

specification: item 1 43.5 Nm de serrage: Rep. 1 43,5 Nm de apriete: (1) 43,5 Nm
item 2 22 Nm Rep. 2 22 Nm (2) 22 Nm
item 3 31 Nm Rep. 3 31 Nm (3) 31 Nm
4.00.81
15. Keilriemen spannen.

4
s

gerät prüfen.
6
Kontrollwert nach
17. Nach dem Keilriemenspannen sind die übri-

gen Schrauben festzudrehen. 4
Anziehvorschrift: Pos. 1
Pos. 2
43,5 Nm
22 Nm 6
Pos. 3 31 Nm
4.00.81
Ladedruckabhängiger Vollastanschlag (LDA)

4 1. Einbaulage des ladedruckabhängigen Voll-
lastanschlages mit Schlauchleitung.
2. Einbaulage LDA-Schlauchleitung.
4 Hinweis: Bei Austausch durch Gummimuffe
5 führen.
Kurbelgehäuse-Entlüftung
4 3. Einbaulage Kurbelgehäuse-Entlüftung.
0 Bei Bedarf Gummimuffe austauschen.
4.00.82
Manifold-pressure compensator (LDA) Correcteur de débit (LDA) Tope de plena carga dependiente de la
presión de sobrealimentación (LDA)
1. Installation position of LDA with 1. Sens de montage du correcteur de 1. Posición de montaje del tope de
hose line. débit avec conduite flexible. plena carga dependiente de la
presión de sobrealimentación con
manguera.
2. Installation position of LDA hose 2. Sens de montage de la conduite 2. Posición de montaje de la

line. flexible du LDA. manguera del LDA.
Note: When replacing LDA introduce Nota: pour changer la conduite la faire Nota: En caso de sustitución pasarla
through rubber sleeve. passer à travers le manchon en por el manguito de goma.
caoutchouc.
Crankcase breather Event de carter Ventilación del cárter
3. Installation position of crankcase 3. Sens de montage de l’évent de 3. Posición de montaje del sistema de
breather. Renew rubber sleeve if carter.Au besoin changer manchon ventilación del cárter. Sustituir el
necessary. en caoutchouc. manguito de goma, si es necesario.
4.00.82
Werkzeuge
Tools
Outils
Herramientas 1011 F
Wir bitten Sie, alle Bestellungen von Spezialwerkzeugen direkt an die
Fa. Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92,
zu richten.
Please order all your special tools direct from

Messr.Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92
Nous vous prions de passer directement toutes vos commandes

d’outillage spécial auprès de la société:
Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92
Rogamos dirigir todos los pedidos de herramientas especiales directamente

a la casa Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92
Handelsübliche Werkzeuge
Commercial tools
Outils usuels
Herramientas comerciales
Deutsch English Français Español No. Werkstatthandbuch 10111 F
Torx-Werkzeugsatz 8189
Torx tool kit
Jeu d’outils Torx
Juego de herramientas Torx
Kompressionsdruckprüfer 8005
Compression tester
Compressiomètre
Compresímetro
Einspritzpumpenprüfgerät 8006
Injection pump tester
Appareil de contrôle de la pompe d’injection
Comprobador para bombas de inyección
Düsenprüfgerät 8008
Nozzle tester
Banc d’essais d’injecteurs
Comprobador para inyectores
5.00.01
5
Commercial tools
Outils usuels
Werkstatthandbuch 1011 F No. Deutsch English Français Español
8115 Keilriemenspannungsmeßgerät
V-belt tension gauge
Appareil de mesure de la tension de courroie
Verificador de tensión de correas trapezoidales
9088 Schlauchklemmenzange
Hose clip pliers
Pince à tuyaux flexibles
Alicates para abrazaderas de mangueras
9090 Federklemmenzange
Spring clamp pliers
Pince à ressorts
Alicates para abrazaderas de resorte
8011 Cobraklemmenzange
Cobra clamp pliers
Pince à ressorts Cobra pour tuyaux
Alicates Cobra para abrazaderas
5.00.02
5
Commercial tools
Outils usuels
Deutsch English Français Español No. Werkstatthandbuch 10111 F
Kraftvervielfältiger für Zentralschraube 8049
Multipower tool for central bolt
Multiplicateur de force pour vis centrale
Multiplicador de fuerza
Stecknuß SW 32 8036
Socket a/flats 32
Clé à douille de 32
Llave de vaso de 32
Lange Stecknuß SW 15 8021
Long socket a/flats 15
Clé à douille longue de 15
Llave de vaso largo de 15
Ventilfedermontagehebel 9017
Valve spring assembly lever
Levier de montage pour ressorts de soupape
Palanca de montaje para resortes de válvula
5.00.03
5
Commercial tools
Outils usuels
8112 Schraubendrehereinsatz 1/2" SW 17
Screw driver socket 1/2" a/flats 17
Embout tournevis 1/2" de 17
Punta recambiable de destornillador,

1/2" SW 17
5.00.04
5
Spezialwerkzeuge
Special tools
Outils spéciaux
Herramientas especiales
Deutsch English Français Español No. Werkstatthandbuch BFM 1011 F
Anschlußstück für Kompressionsdruckprüfer 100 120
Adapter for compression tester
Raccord pour compressiomètre
Pieza de empalme para el compresímetro
Einstellbolzen für Kurbel- und Nockenwelle 100 700
Adjusting pin for crankshaft and camshaft
Pige de calage pour vilebrequin et arbre à

cames
Pernos de ajuste para el cigüeñal y árbol de

levas
Einstellbolzen für Einspritzpumpenregelstange 100 710
Adjusting pin for injection pump control rod
Pige de calage pour crémaillère de pompe

d’injection
Perno de ajuste para la barra cremallera de la

bomba de inyección
Zahnriemenspannungsmeßgerät 100 720
Toothed belt tension gauge
Appareil de mesure de tension de courroie

crantée
Verificador de tensión de correas dentadas
5.00.05
5
Spezialwerkzeuge
Special tools
Outils spéciaux
100 750 Meßgerät mit Abstandsscheiben für Kolben-

überstand und vorderen Deckel
Gauge with spacers for piston projection and

front cover
Appareil de mesure du retrait de piston et

couvercle avant avec rondelles d’écartement
Dispositivo de medición con arandelas

distanciadoras para saliente de pistón y tapa
delantera
100 870 Arretierungsdraht für Anlenkhebel Einspritz-

880 pumpe
Locking wire for control lever, injection pump
Fil d’arrêt pour levier articulé de pompe

d’injection
Alambre de sujeción para la palanca arti-

culada, bomba de inyección
103 020 Prüfschablone für E.P.-Dichtung

0417 8522 0,4
8523 0,5 Test template for I.P. gasket
8524 0,6
8525 0,7
8526 0,8 Gabarit de contrôle pour joint de pompe
8527 0,9
8528 1,0 d’injection
Plantilla para comprobar juntas de b.i.
110 110 Halter für Einspritzventil
Retainer for injector
Dispositif d’immobilisation pour injecteur
Soporte de inyectores
5.00.06
5
Spezialwerkzeuge
Special tools
Outils spéciaux
Montagewerkzeug für Regelstangenbuchse 110 140
Assembly tool for control rod bush
Outil de montage pour douille de crémaillère
Herramienta de montaje para manguitos de

cremallera
Spezialschlüssel für Einspritzleitung 110 490
Special wrench for injection line
Clé spécial pour conduite d’injection
Llave especial para tuberías de inyección
Aufspannbock für Zylinderkopf 120 900
Clamping stand for cylinder heads
Chevalet d’ablocage pour culasse
Soporte de fijación para culatas
Aufspannplatte für No 120 900 120 910
Clamping plate for 120 900
Plaque d’ablocage pour no. 120 900
Placa de fijación para 120 900
5.00.07
5
Spezialwerkzeuge
Special tools
Outils spéciaux
121 410 Montagewerkzeug für Ventilschaftabdichtung
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
Util de montaje para juntas de vástago de

válvula
130 300 Universal-Kolbenring-Auflegezange
Universal piston ring pliers
Pince universelle à monter les segments de

piston
Alicates universales para montar aros de pistón
130 510 Kolbenringspannband
Piston ring compressor
Collier à comprimer les segments de piston
Compresor de aros de pistón
131 340 Montagevorrichtung für Kolbenbolzenbuchse

131 350
Assembly tool for small end bush
Dispositif de montage de bague de pied de

bielle
Herramienta de montaje para casquillos de pie

de biela
5.00.08
5
Spezialwerkzeuge
Special tools
Outils spéciaux
Ausziehvorrichtung für Kurbelwellendichtringe 142 710
Puller for crankshaft seals
Extracteur pour bagues d’étanchéité de

vilebrequin
Dispositivo de extracción para retenes del

cigüeñal
Montagevorrichtung für Nockenwellendichtring 142 050
Assembly tool for camshaft seals
Dispositif de montage pour bagues

d’étanchéité d’arbre à cames
Dispositivo de montaje para retenes del árbol

de levas
Montagevorrichtung für Kurbelwellendichtring, 142 850

vorne
Assembly tool for crankshaft seals,front
Dispositif de montage de bague d’étanchéité

avant de vilebrequin
Dispositivo de montaje para el retén delantero

del cigüeñal
Montagevorrichtung für Kurbelwellendichtring, 142 860

hinten
Assembly tool for crankshaft seals, rear
Dispositif de montage pour bague d’étanchéité

arrière de vilebrequin
Dispositivo de montaje para el retén trasero del

cigüeñal
5.00.09
5
Spezialwerkzeuge
Special tools
Outils spéciaux
143 100 Abdrückvorrichtung für Schwungrad
Puller for flywheel
Dispositif pour extraction de volant-moteur
Dispositivo de separación para el volante
143 420 Gegenhalter für Kraftvervielfältiger
Dolly for multipower tool
Dispositif de maintien du multiplicateur de

force.
Contrasoporte para el multiplicador de fuerza
143 430 Zwischenscheibe für Gegenhalter

143 420
Intermediate disc for dolly

143 420
Disque intercalaire pour outil de maintien

143 430
Arandela intermedia para el contrasoporte

143 420
143 820 Montagevorrichtung für Nockenwellenbuchse
Assembly tool for camshaft bush
Outil de montage pour bague d’arbre à cames
Dispositivo de montaje para casquillos de árbol

de levas
5.00.10
5
Spezialwerkzeuge
Special tools
Outils spéciaux
Gegenhalter für Nockenwellenrad 144 130
Dolly for camshaft gear
Outil de maintien de pignon d’arbre à cames
Contrasoporte para la rueda dentada en el

árbol de levas
Spannvorrichtung für Zahnriemen Hydraulik- 144 600

pumpe
Tensioning device for toothed belt, hydraulic

pump
Dispositif à serrer les courroies crantées de

pompes hydrauliques
Tensor de correa dentada, bomba hidráulica
Ausziehwerkzeug für Rohr 150 140
Puller for pipe
Extracteur de tube
Extractor para tubos
Montagedorn für Rohr 150 150
Assembly arbor for pipe
Mandrin de montage pour tube
Mandril de montaje para tubos
5.00.11
5
Spezialwerkzeuge
Special tools
Outils spéciaux
170 110 Spezialschlüssel für Öldruckgeber
Special wrench for oil pressure sensor
Clé spécial pour capteur de pression d’huile
Llave especial para transmisores de presión de

aceite
6067 Motormontagebock
Engine assembly stand
Chevalet de montage de moteur
Caballete de montaje de motores
6067/115 Aufspannhalter
Angled clamping plate
Support d’ablocage
Soporte de fijación
5.00.12
5
Operation Manual
2011
C 2000
1 9929en
Safety guidelines / Accident prevention
● Please read and observe the information

given in this Operation Manual. This will ● Unauthorized engine modifications will in-
enable you to avoid accidents, preserve the validate any liability claims against the manu-
manufacturer’s warranty and maintain the facturer for resultant damage.
engine in peak operating condition. Manipulations of the injection and regulating
system may also influence the performance
● This engine has been built exclusively for of the engine, and its emissions. Adherence
the application specified in the scope of to legislation on pollution cannot be guaran-
supply, as described by the equipment manu- teed under such conditions.
facturer and is to be used only for the
intended purpose. Any use exceeding that ● Do not change, convert or adjust the cooling
scope is considered to be contrary to the air intake area to the blower.
intended purpose. The manufacturer will The manufacturer shall not be held respon-
not assume responsibility for any damage sible for any damage which results from
resulting therefrom. The risks involved are such work.
to be borne solely by the user.
● When carrying out maintenance/repair op-
● Use in accordance with the intended pur- erations on the engine, the use of DEUTZ
pose also implies compliance with the con- original parts is prescribed. These are spe-
ditions laid down by the manufacturer for cially designed for your engine and guaran-
operation, maintenance and servicing. The tee perfect operation.
engine should only be operated by person- Non-compliance results in the expiry of the
nel trained in its use and the hazards in- warranty!
volved.
● Maintenance and cleaning of the engine
● The relevant accident prevention guidelines should only be carried out when the engine
and other generally accepted safety and is switched off and has cooled down.
industrial hygiene regulations must be ob- You must ensure that the electrical systems
served. have been switched off and the ignition key
has been removed.
● When the engine is running, there is a risk of Accident prevention guidelines concerning
injury through: electrical systems (e.g. VDE-0100/-0101/-
- turning/hot components 0104/-0105 Electrical protective measures
- engines with positive ignition against dangerous touch voltage) are to be
- ignition systems (high electrical voltage) observed.
You must avoid contact at all times! When cleaning with fluids, all electrical com-
ponents are to be covered impermeably.
00_GB.p65 2 04.02.2002, 14:23

Operation manual
2011
0297 9929 en
Engine Serial
Number:
Please enter the engine serial number here. This

number should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see
Section 2.1).
Technical modifications required to improve our

engines are reserved with regard to specification
data and other technical information contained in
this Operation Manual. No parts of this Manual may
C 2000
be reproduced in any form or by any means without
our written approval.
3 9929en
Foreword
Dear Customer,
Liquid-cooled Deutz engines are designed for a

large number of applications. Consequently, a wide
range of variants is offered to meet the requirements
of specific cases.
Your engine is appropriately equipped for the

installation concerned, which means that not all of
the components described in this Operation Manu-
al are necessarily fitted to your engine.
We have endeavoured to highlight any differences

so that you will be able to locate the operating and
maintenance instructions relevant to your engine
quickly and easily.
Please read this Manual before starting your engine,

and always observe the operating and maintenance
instructions.
We are available to help with any additional inquiries
Sincerely,
DEUTZ AG
9929en
4
Contents
1. General 3. Engine Operation 6. Service and Maintenance

3.1 Commissioning 6.1 Lubrication System
2. Engine Description 3.1.1 Adding Engine Oil 6.1.1 Oil Change Intervals
2.1 Model 3.1.2 Adding Fuel 6.1.2 Check Oil Level, Change Engine Oil
2.1.1 Rating Plate 3.1.3 Other Preperations 6.1.3 Changing Oil Filter
2.1.2 Position of the Rating Plate 3.1.4 Additional Maintenance Work 6.1.4 Clean/Replace Oil Filter (Cup)
2.1.3 Engine Serial Number 3.2 Starting 6.2 Fuel System
2.1.4 Cylinder Numbering 3.2.1 Electric Starting 6.2.1 Replace Fuel Filter
2.1.5 Fuel Delivery Lock 3.3 Monitoring Operation 6.2.2 Clean/Replace Fuel Filter (Cup)
2.2 Engine Illustrations 3.3.1 Engine Oil Pressure 6.2.3 Clean Stainer of Fuel Filter
2.2.1 Operation Side: 3.3.2 Engine Temperature 6.2.4 Change Fuel Leakage Line
Example FL 2011 3.4 Shutting Off 6.3 Cooling System
2.2.2 Exhaust Side: 3.4.1 Mechanical Shut-Off 6.3.1 Cleaning Intervals
Example FL 2011 3.4.2 Electric Shut-Off 6.4 Combustion Air Filter
2.2.3 Operation Side: 3.5 Operating Conditions 6.4.1 Cleaning Intervals
Example BF4L 2011 3.5.1 Winter Operation 6.4.2 Emptying Cyclone-Type Precleaner
2.2.4 Exhaust Side: 3.5.2 High Ambient Temperature, High Altitude 6.4.3 Dry Type Air Cleaner
Example BF4L 2011 6.5 Belt Drives
2.2.5 Operation Side: 4. Operating Media 6.5.1 Check V-belt
Example FM 2011 4.1 Lube Oil 6.5.2 Tensioning Alternator Belts
2.2.6 Exhaust Side: 4.1.1 Quality 6.5.3 Changing Alternator Belts
Example FM 2011 4.1.2 Viscosity 6.6 Adjustments
2.2.7 Operation Side: 4.2 Fuel 6.6.1 Check Valve Clearance, adjust if necessary
Example BFM 2011 4.2.1 Quality 6.6.1.1 Valve Clearance Adjustment Schematic
2.2.8 Exhaust Side: 4.2.2 Winter-Grade Fuel 6.7 Accessories
Example BFM 2011 6.7.1 Battery
2.3 Oil Circuit 5. Service 6.7.2 Rotary Current Alternator
2.3.1 Lube Oil Circuit Schematic 5.1 Service Plan 6.7.3 Transportation Shackles
2.4 Fuel System Schematic 5.2 Scheduled Maintenance Plan 6.8 Engine Cleaning
2.4.1 Fuel System 5.3 Maintenance Chart 6.8.1 Engine Cleaning
2.5 Coolant System 5.4 Maintenance Work Completed
2.5.1 Coolant Plan
5 9929en
Contents
7. Faults, Causes and Remedies

7.1 Fault Table
8. Engine Preservation
8.1 Preservation
8.1.1 Preserving Engine
8.1.2 Removing Engine Preservatives
9. Technical Specification
9.3 Tools
10. Service
C 2000
6 9929en
C 2000
7 9929en
General
DEUTZ Diesel Engines Care and Maintenance Service

1
are the product of many years of research and Sound care and maintenance practices will ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or for
with stringent quality standards, guarantee their placed on it. Recommended service intervals must spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance work carry out repairs quickly and professionally, using
consumption. carried out conscientiously. only genuine spare parts.
It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced
meet the highest standards for environmental demanding operating conditions. in accordance with state-of-the-art technology.
protection. Please turn to the end of this manual for further
service information.
Beware of Running Engine Safety

California
Shut the engine down before carrying out mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
DEUTZ original parts are asbestos-

free.
7 Gerade
9689en_K01_neu 7 30.09.1999, 15:45 Uhr
1
8
9689en_K01_neu 8 30.09.1999, 15:45 Uhr
Engine Description
2
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
C 2001
9 9929en
Engine Description 2.1 Model
2.1.1 Rating Plate 2.1.2 Position of the Rating Plate 2.1.3 Engine Serial Number
2
C
A B
© 26 332 2 © 31 864 0 © 31 865 0
The model A, the engine serial number B and the The rating plate C is attached to the valve cover. The engine serial number B is stamped on the
performance data are stamped on the rating plate. crankcase D as well as the rating plate.
The model and engine serial number must be given
when ordering parts.
C 2001
10 9929en
2.1 Model Engine Description
2.1.4 Cylinder Numbering 2.1.5 Fuel Delivery Lock

2
1 2 3 4
© 26 431 0 © 26 387 0
Cylinders are numbered consecutively, beginning The manufacturer shall not be held liable for dam-
at the flywheel. ages resulting from adjustments made to the regu-
lator by the operator.
The lock screws are protected in order to prevent
this:
1. with locking paint on model:
with torque balancer
2. with plastic protective cap on model:
without torque balancer.
Adjustments to the regulator are to

be carried out only by authorised
C 2001
! DEUTZ SERVICE specialists
11 9929en
Engine Description 2.2 Engine Illustration
2.2.1 Operation Side

2 FL 2011

1 3 Fan with integrated generator
21 4 Narrow V-belt
5 Tractive electromagnet
2 6 Wheel-house cover
20 7 V-belt pulley on crankshaft
8 Oil pan
3 9 Shut-off lever
11 Oil dipstick
19 4 12 Oil drain plug
13 Crankcase
5 15 Fuel pump
18 16 Easy-change fuel filter
18 Lube oil replacement filter
17 20 Injection pumps
6 21 Oil cooler
16
7
15
C 2001
14 13 12 11 10 9 8
© 31 873 1
12 9929en
2.2 Engine Illustration Engine Description
2.2.2 Exhaust Side

FL 2011 2
22 Date plate
23 Optional attachment of an SAE housing
25 Starter
26 Front cover
27 Crankcase
28 Exhaust manifold
29 29 Air intake pipe
22
28
27
23
26 24
26
C 2001
© 31 874 1
13 9929en

2 Example: BF4L 2011

21 1 2 3 Fan with integrated generator
4 Narrow V-belt
3 6 Wheel-house cover
8 Oil pan
20 9 Shut-off lever
11 Oil dipstick
19 12 Crankcase
4 14 Fuel pump
17 Charge-pressure-dependent full-load stop
17 5 (CPD)
20 Injection pumps
16 21 Oil cooler
6
15
14 7
C 2001
13 12 11 10 9 8
© 31869 1
14 9929en
2.2.4 Exhaust Side

Example: BF4L 2011 2
22 Cylinder head
23 Exhaust manifold line
32 24 Flywheel with ring gear
25 Starter
26 Crankcase
27 Lube oil feed line to turbocharger
31 28 Lube oil return line from turbocharger
29 Induction pipe
22 30 Turbocharger (TC)
31 Intake manifold
29 32 Charge-air line
23
27
30 24
28
26
25
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© 31 868 1
15 9929en

2 FM 2011

21 1 3 Alternator
4 Narrow V-belt
20 2 6 Timing belt cover
8 Oil pan
19 9 Shut-off lever
3 10 Speed control lever
11 Oil dipstick
18 12 Oil drain plug
4 13 Oil fill point (on side of crankcase)
12 Crankcase
17 14 Fuel pump
5 16 Connecting facility for oil heater
18 Injection pump(s)
6 19 Oil cooler connection
21 Injection valve(s)
15
7
14 13 12 11 10 9 8
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© 31 875 0
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2.2.6 Exhaust Side

FM 2011 2
22 Cylinder head
23 Exhaust manifold
25 Starter
26 Starter guard (optional)
27 Crankcase
28 Air intake pipe
28 22
23
24
27
26 25
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© 31876 0
17 9929en

2 BFM 2011
1 Air-intake pipe
2 Fan wheel
18 3 V-belt pulley on crankshaft
4 Narrow V-belt
1 5 Tractive electromagnet
17 6 Timing belt cover
7 Shut-off lever
2 8 Speed control lever
16 9 Oil fill point (on side of crankcase)
10 Oil dipstick
11 Fuel pump
14 15 Injection pump(s)
16 Oil cooler connection
17 Injection valve(s)
12
3
11
4
10 9 8 7 6 5
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© 31 861 0
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2.2.8 Exhaust Side

BFM 2011 2
19 Crankcase ventilation (optional)
20 Cylinder head cover
21 Exhaust manifold
28
22 SAE housing
23 Starter
24 Crankcase
19 25 Turbocharger
27 26 Generator with cover
27 Charge-air line
28 Oil filler neck
20
26
25
24
21
22
23
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© 31 862 0
19 9929en
Engine Description 2.3 Oil Circuit
2.3.1 Lube Oil Circuit Schematic

2
1 Oil pan
2 Oil-intake pipe
9 15 8 11 19 3 Oil pump
4 Main oil duct
5 Oil-cooled cylinders
10 18 6 Cylinder head cooling neck
7 Oil duct for rocker arm lubrication
8 Rocker arm
12 7 9 Oil manifold for the thermostat
10 Intake to external engine oil cooler
11 Return from external engine oil cooler
6 12 Thermostat housing with slide thermostat
13 Oil duct to oil filter
14 Oil filter
13 5 15 Oil duct to cam, con-rod and crankshaft bear
ings
20 16
17
Spray nozzle for piston cooling
Oil return via crankcase to oil pan
18 Lube oil intake to turbocharger
19 Turbocharger
20 Return from turbocharger to oil pan
1
C 2001
14 17 18 16 2 3 4
© 31877 0
20 9929en
2.4 Fuel System Schematic Engine Description
2.4.1 Fuel System

2
1 Fuel line from tank to fuel pump
2 Fuel pump
11 10 9 3 Fuel line from fuel pump to easy-change fuel
filter
5 Fuel line from filter to injection pump
6 Injection pump
7 Fuel distributor line
12 8 Injection line
9 Injection valves
10 Fuel leakage line
11 Fuel overflow pipe
12 Fuel return line to tank
The installation of a fuel pre-filter/

hand pump between the fuel tank
! and the engine is prescribed to
C 2001
1 2 3 6 protect the engines against dirt in
© 31 863 0
the fuel.
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2
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Engine Operation
3
3.1 Commissioning
3.2 Starting
3.3 Monitoring Operation
3.4 Shutting Off
3.5 Operating Conditions
23 9929en
3.1.1 Adding Engine Oil 3.1.1.2 Initial Engine Oil Fill-Up

3 3.1.1.1 Initial Engine Oil Fill-Up for
B/FL 2011 B/FM 2011
● Fill oil into oil pan up to "Max." mark on engine ● Fill oil into oil pan up to "Min." mark on engine
dipstick (for oil quantity see 9.1). dipstick.
OIL ● Start engine and allow to run at low idling speed ● In addition, top up oil quantity of supply hoses
for approx. 2 mins. and of external oil cooler (according to manufac-
● Switch off engine. turer’s specifications).
● Check oil level, if necessary, top up oil to "Max." ● Allow engine to run warm until thermostat opens
mark. (at approx. 95°C).
● Allow engine to run for approx. 2 mins.
● Switch off engine.
● Check oil level, and if necessary, top up oil to
"Max." mark.
© 26 432 0
As a rule, engines are delivered without oil.

Pour lube oil into the oil filler neck (arrow).
For oil grade and viscosity, see 4.1.
If the person operating the engine does not run up

the engine until the thermostat opens, the oil level
may lie above the "Max." mark on the engine
dipstick when delivered. The level can then only be
assessed after the engine has been run up.
24 9929en
3.1 Commissioning Engine Operation
3.1.2 Adding Fuel

3.1.1.3 Initial Engine Oil Fill-Up 3
B/FM 2011 Genset Engine
● Fill oil into oil pan up to "Max." mark on engine
dipstick (for oil quantity see 9.1).
● Start engine and allow to run at low idling speed
for approx. 2 mins.
FUEL
● Check oil level and fill up with oil up to upper
"Max." mark.
© 26 398 0
Use only commercial-grade diesel fuel. For fuel

grade, see 4.2. Use summer or winter-grade fuel,
depending on the ambient temperature.
Never fill the tank while the engine

is running.
! Ensure cleanliness!
Do not spill fuel!
25 9929en
3.1.3 Other Preparations 3.1.4 Additional Maintenance Work

3
● Check battery and cable connectors, When commissioning new and reconditioned en-
see 6.7.1. gines, the following additional maintenance work
must be carried out:
● Transport hooks
Remove if fitted (see 6.7.3) ● Change lube oil,
see 6.1.1. + 6.1.2.
● Trial run
After engine has been prepared, let it run for ● Change oil filter cartridge,
about 10 minutes without being loaded. see 6.1.3.
During and after trial run ● Change fuel filter cartridge,

- Check engine for leaks. see 6.2.1.
After engine has been turned off
- Check oil level, ● Check V-belts and retension as necessary,
see 6.1.2. see 6.5.
Top up with oil, if necessary,
see 3.1.1. ● Check engine for leaks
- Retension V-belt,
see 6.5). ● Check engine mounts, retighten if necessary,
see 9.2.
● Check valve clearance, adjust if necessary,

see 5.1. + 6.6.1.
26 9929en
3
27 9929en
Engine Operation 3.2 Starting
3.2.1 Electric starting

3 Without cold start assistance
Before starting, make sure that no-

body is standing in the immediate
vicinity of the engine or driven ma- 2
! chine.
After repair work:
Check that all guards have been
replaced and that all tools have been removed from
the engine.
When starting with glow plugs, do not use any other
starter substance (e.g. injection with start pilot).
Risk of accident!
Caution: If the speed regulator has been re- 1
moved, the engine must not be tested under any
circumstances.
Disconnect the battery!
© 26 423 0 © 25 746 2
● Where possible, disengage clutch to separate ● Insert key

engine from any driven parts. - Position 0 = no operating voltage
● Move speed control lever 1 into idle position. ● Turn key clockwise
● Move shut-off handle 2 into operating position. - Position 1 = operating voltage
- Pilot lights come on
● Push key in and turn further clockwise against
spring pressure.
- Position 2 = no function
- Position 3 = start
- Pilot lights go out.
Do not actuate the starter for more than 20 sec-
onds. If the engine does not catch, wait a minute
then try again.
If the engine does not catch after two attempts,
refer to the Fault Table (see 7.1).
28 9929en
3.2 Starting Engine Operation
With cold start assistance 3

- Glow plug
© 25 746 2
● Insert key
- Position 0 = no operating voltage
● Turn key clockwise
- Position 1 = operating voltage
- Pilot lights come on
● Push key in and turn further clockwise against
spring pressure.
- Position 2 = preheat, hold for approx. 1 minute.
- Preheat lamp comes on
- Position 3 = start
- Pilot lights go out
29 9929en
Engine Operation 3.3 Monitoring Operation
3.3.1 Engine Oil Pressure

3 Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge
© 25 752 1 © 25 753 0 © 25 754 0
● Oil pressure pilot light comes on with operating ● Pointer must remain in green sector over entire ● Pointer must indicate minimum oil pressure
voltage on and engine off. operating range. (see 9.1).
● Oil pressure pilot light should go out when
engine is running.
30 9929en
3.3 Monitoring Operation Engine Operation
3.3.2 Engine Temperature

Engine Temperature Gauge
3
© 24 985 0
● Engine temperature gauge pointer should re-

main in green sector most of time. It should
rarely enter yellow-green sector. If pointer enters
orange sector, engine is overheating. Turn off
and establish cause from Fault Table (see 7.1).
31 9929en
Engine Operation 3.4 Shutting Off
3.4.1 Mechanical Shut-Off 3.4.2 Electric Shut-Off

3 (Ignition Key)
© 26 424 0 © 25 746 2
● Move speed adjustment lever 1 to low idle. ● Turn key anticlockwise (to position 0) and re-
● Move shut-off lever 2 until engine comes to a move. Pilot lights will go out.
stop.
Charge pilot light and oil pressure pilot light will
come on when engine stops.
● Turn key anticlockwise (to position 0) and re-
move. Pilot lights will go out.
If possible, do not suddenly switch off engine when

under full load.
32 9929en
3.5 Operating Conditions Engine Operation
3.5.1 Winter Operation

3
● Lube Oil Viscosity ● Battery
- Select oil viscosity (SAE grade) according to - Efficient cold starting requires that battery is
ambient temperature before starting engine, well-charged, see 6.7.1.
see 4.1.2. - Starting limit temperatures can be lowered by
- Increase oil change frequency when operating 4-5°C by heating battery up to about +20°C. (To
below -10°C, see 6.1.1. do so, remove battery and store in warm place).
● Diesel Fuel
- Use winter-grade diesel fuel for operation be
low 0°C, see 4.2.2.
● Additional Maintenance Work

- Drain sludge from fuel tank once a week (undo
sludge drain screw).
- If necessary, allow oil in oil bath air cleaner and
engine oil to settle at ambient temperature.
© 26 248 0
- Below -20°C, after removing starter if neces
sary, smear ring gear on flywheel via pinion
bore from time to time with cold-resistant
grease.
(e.g. Bosch grease FT 1 V 31).
● Cold Start Assistance

- At temperatures near or below freezing point,
use glow plugs if necessary, see 3.2.1.
This not only lowers starting limit temperature,
but provides easier starting at temperatures
normally not requiring a starting aid.
33 9929en
Engine Operation 3.5 Operating Conditions
3.5.2 High Ambient Temperature,

3 High Altitude
● Air density decreases as altitude or ambient
temperature increases. As a result of this, the
engine’s maximum output, quality of exhaust
gas, temperature level and, in extreme cases,
starting behaviour, are impaired. Engine can be C F
used at altitudes up to 1000 m and temperatures
up to 30°C for mobile operations. If the engine is
to operate under more severe conditions (at
higher altitudes or temperatures), it will be nec-
essary to reduce the injected fuel quantity and
thus engine power. 0 32
● If you have any doubts about engine operation
under these or similar conditions, ask your en-
gine or equipment supplier whether the engine
has been derated in the interests of reliability,
service life and exhaust gas quality (smoke).
Otherwise contact DEUTZ SERVICE. 25 901 1
34 9929en
Operating media
4.1 Lube Oil

4.2 Fuel
C 2000
35 9929en
Operating Media 4.1 Lube Oil
4.1.1 Quality 4.1.2 Viscosity

4
Lube oils are differentiated according to their per- As the viscosity of the lube oil is dependent on
formance and quality class. In common use are temperature, the choice of SAE grade should be
specifications named after the API (American Pe- governed by the ambient temperature prevailing at
troleum Institute) and ACEA European Engine Oil the engine operating site. Optimum operating be-
Sequences. haviour will be attained if you take the accompany-
ing oil viscosity diagram as a guide.
Approved API Oils: Should the temperature fall temporarily below the
Minimum: CF-4 limits of SAE grade selected, cold starting may be
affected but the engine will not be damaged. In
Approved ACEA Oils: order to keep wear to a minimum, do not exceed
Minimum: E1-96 application limits for extended periods of time.
Oil changes dictated by the seasons can be avoided
by using multi-grade lube oils. Multi-grade oils,
particularly light-flowing oils, also reduce fuel con-
sumption.
C 2001
*Oil change intervals, see 6.1.1

Oil capacities, see 9.1 Only with engine
pre-heater © 30 298 1
36 9929en
4.2 Fuel Operating Media
4.2.1 Quality 4.2.2 Winter-Grade Fuel

4
Use commercially available diesel fuel with less Waxing may occur at low temperatures, clogging
+32 0
than 0.5% sulphur content. If the sulphur content is the fuel system and reducing engine efficiency. If I
higher, oil change intervals should be reduced (see the ambient temperature is less than 0°C, winter- +23 -5
6.1.1). grade fuel (suitable down to -15°C) should be used.
(This fuel is usually available from filling stations
+14 - 10
The following fuel specifications / standards are well in advance of the cold months). Diesel fuel
approved: containing additives (Super diesel) is often on sale
+ 5 - 15
as well, for use down to -20°C.
● DIN EN 590
● At temperatures below -15°C to -20°C, kerosene - 4 - 20
● BS 2869 should be added to the diesel fuel. The relevant
percentages are given in the adjacent diagram. - 13 - 25
● ASTM D 975-96; 1-D and 2-D II
If summer-grade diesel fuel must be used at tem- - 22 - 30
● NATO Code F-54 / F-34 / F-44 and XF 63 peratures below 0°C, up to 60% kerosene can be 0 10 20 30 40 50 60 %
added (see diagram). °F °C B
Exhaust emission values which may be determined A
© 26 441
26441 11
in the case of type approval tests always refer to the In most cases, adequate resistance to cold can also
reference fuel prescribed by the authorities for the be obtained by adding a flow improver (additive).
type approval test. Please inquire at DEUTZ SERVICE. Legend:
I Summer-grade diesel fuel

II Winter-grade diesel fuel
A Ambient temperature
B Percentage of kerosene added
Diesel fuels must never be mixed Mix in tank only! Fill with the ap-
with petrol (Normal and Super propriate amount of kerosene first,
C 2000
! grades)!
! then add the diesel fuel.
37 9929en
4
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38 9929en
Service
5
5.1 Service Plan
5.2 Scheduled Maintenance Plan
5.3 Maintenance Chart
5.4 Maintenance Work Completed
39 9929en
Service 5.1 Service Plan
Deutz maintenance and service schedule = E check = z adjust = clean = V replace = Industrial engines Section
5 prior to or during 1st trial run, check 2x daily during the breaking-in phase or The specified engine maintenance intervals are
when commissioning new and overhauled engines permissible recommended maximums. Depending
on usage, reduced maintenance intervals may be
every 10 operating hours or daily necessary (comply with the unit manufacturer’s
in operating hours (OH) every operating instructions).
E10 E20 E25 E30 E40 E50 E60 E70 Years # Maintenance must only be carried out by authorise
500 1000 3000 5000 6000 12000 1 2 Operation service personnel
z z Top lube oil up if necessary 6.1.2/3.1.4
FL 2011 lube oil, see TC 0199-99-3002 6.1.1/ 6.1.2
BFL 2011 lube oil, see TC 0199-99-3002 6.1.1/ 6.1.2
z V Oil bath (lube oil quality, see TC 0199-99-3002 / Dry type filter 6.4
Oil filter cartridge FL 2011 6.1.3
Oil filter cartridge BFL 2011 6.1.3
Fuel filter cartridge
V Change fuel pump/strainer if necessary 6.2.2
z Flexible fuel leakage lines, see TC 0138-21-9300 6.2.1/ 6.2.3
z Injection valve #
z V Fuelpre-cleaner 4.2
z Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3 /6.4.4
z Battery and cable connectors 6.7.1
z z Engine monitoring system, warning system (replace if necessary) 3.3 #
Valveclearance 6.6.1#
V-belt 6.5.#
z Crankcase pressure vent valve #
Timing belt, extreme-duty, see adjacent table #
Timing belt, heavy-duty, see adjacent table #
Timing belt, light-duty, see adjacent table #
z Check engine for leaks (visual inspection) –
z Engine mount (replace if damaged) 9.2
Basic overhaul #
40 9929en
5.1 Service Plan Service
Timing belt change intervals Engine application Engine/ application/operating parameters

Guideline values in OH Example: Example:
5
6000 or max. 5 years Generating sets 1500/1800 rpm; pump units, low speed; moderate ambient temperature;
lowspeed;platformlifts;refrigerationunitsetc. lowdustexposure
5000ormax.5years compressors;rollers;forklifttrucks;weldingunits; wheelloaders;mediumtohighvariablespeed;highambient

small dumpers; ski-steer loaders etc. temperature moderate dust exposure
3000 or max. 5 years agricultural machinery; ski-steer loaders; wheel loaders; drillinghigh speed; impact loads; extreme ambient
temperature;
41 9929en
equipment; trench-cutting machines; joint cutters; bulldozers etc. high dust exposure
5 Service
5.2 Scheduled Maintenance Plan
5.2.1 Scheduled Maintenance Plan
Intervals Deutz maintenance Operation Carried out by:
at/after and service schedule
50 OH E10 After commissioning and E 50-E 70 Authorisedspecialists
Daily E20 Dailycheck Operator
250 OH E25 Inspection Authorisedspecialists
500 OH E30 Extendedinspection Authorisedspecialists
1000 OH E40 Interim overhaul Authorisedspecialists
3000 OH E50 Extendedinterimoverhaul Authorisedspecialists
6 000 OH E60 Partialoverhaul Authorisedspecialists
12000 OH E70 Basicoverhaul Authorisedspecialists
42 9929en
5.3 Maintenance Chart Service
5
The maintenance chart shown here is supplied as a in. 0,3 mm
self-adhesive label with each engine. It should be 1 0.012 in. 1 4 h/Bh
a 0,5 mm
affixed where it can be seen clearly on the engine or ex. 0.020 in.
ex.
driven equipment. 2
in. 1000 125 ñ 2000
Check that this is the case.
3 BFM/BFL 4
If necessary, ask your engine or equipment supplier 500
OIL
for a fresh supply of labels. 5
2 BFM/BFL FM/FL
Routine work should be carried out according to the 500 1000
6
schedule in 5.1. B/FM 2011 5
FM/FL
OIL
1000
1 4 10 OIL
max.
3 2 6
1000
FU
EL 1000
6
2011 5 B/FL 2011
0297 9935 0

43 9929en
5.4 Maintenance Work Completed Service
Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5
50-150* -
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
* Following commissioning of new and overhauled engines
Duly completed maintenance jobs can be recorded and signed off in the above chart.
9929en
Quelle:45 /MUS_Kap5.3/de # BA Seite
45
Service 5.4 Maintenance Work Completed

5
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750

46 9929en
5.4 Maintenance Work Completed Service

5
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
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47
Service 5.4 Maintenance Work Completed

5

48 9929en
6
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling system
6.4 Combustion Air Filter
6.5 Belt Drives
6.6 Adjustments
6.7 Accessories
6.8 Engine Cleaning
C 2001
49 9929en
6.1.1 Oil Change Intervals

6 Engines for installation
Lube oil change intervals in OH

● Oil change intervals are dependent on engine API-specification CF-4/ CG-4 / CH-4 CF-4 CG-4 / CH-4
application and quality of lube oil. Lube quality
ACEA-specification E1-E3/96+ E4-98 E1-E2/96 E3-96+ E4-98
● If engine runs fewer hours during year than
stated in table, oil should be changed at least Normal duty oil, e.g.:
once a year.
road vehicles, cranes, construction machinery, ships, 1000 250 500
● Table refers to following conditions:
- sulphur content max. 0.5% by weight for diesel generating sets, pumps, rail vehicles.
fuel
- continuous ambient temperature to
-10°C (+14°F).
Heavy duty for oil, e.g.: 500 125 250
● If sulphur content is > 0.5 to 1% or continuous
ambient temperature below -10°C (+14°F), in- combine harvesters, emergency pumps, underground
tervals between oil changes should be halved. mining units, sweeping machines, winter maintenance
equipment, emergency generators.
● In case of fuels containing more than 1% sul-
phur, contact your service representative.
Lube oil change intervals in km
Vehicle engines
API specification CF-4/ CG-4 / CH-4 CF-4 CG-4 / CH-4

Lube oil quality
ACEA specification E1-E3/96+ E4-98 E1-E2/96 E3-96+ E4-98
Annual usage km Average driving
Service group speed approx. km/h
I < 30 000 20 20 000 5 000 10 000
II 30 000 – 100 000 40 40 000 10 000 20 000

Change oil with engine off but still warm (lube oil
C 2001
temperature approx. 80°C). III > 100 000 60 60 000 15 000 30 000
50 9929en
6.1.2 Check Oil Level /

Change Engine Oil 6
6.1.2.1 Check Oil Level 6.1.2.2 Change Engine Oil
© 25 729 0 © 26 022 0 © 26 023 0
● Switch engine off before checking oil level. ● Allow engine to warm up. ● Place oil tray under engine.
● Ensure that engine or vehicle is level. ● Ensure that engine or vehicle is level. ● Unscrew oil drain plug.
● Remove oil dipstick. - Lube oil temperature approx. 80°C. ● Drain oil.
● Wipe dipstick with non-fibrous, clean cloth. ● Switch off engine. ● Fit oil drain plug with new seal ring and tighten
● Insert it to stop and remove again. firmly (for torque, see 9.2)
● Check oil level, and if necessary, top up to "MAX" ● Pour in lube oil
mark. - For grade / viscosity, see 4.1
- If oil level is only just above "MIN" mark, more - For quantity, see 9.1
oil must be added. ● Check oil level, see 6.1.2.1.
Caution when draining hot oil: Risk

of scalding!
! Do not let used oil run into the soil
but collect it in a container!
C 2001
Dispose of this in accordance with
The level must not fall below the "MIN" mark. environmental regulations!
51 9929en
6.1.3 Changing Oil Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
● Undo lube oil filter cartridge using commercial ● Clean any dirt from filter carrier sealing surface. ● Tighten lube oil filter cartridge with another half-
tool and spin off. turn.
● Lightly oil rubber gasket of new lube oil filter
● Catch any escaping oil. cartridge. ● Check oil level, see 6.1.2.
● Manually screw in new cartridge until gasket is ● Check oil pressure, see 3.3.1.
flush.
● Check lube oil filter cartridge seal for leaks.
Caution is required in case of hot

oil: Risk of scalding!
C 2001
52 9929en
6.1.4 Clean / Replace

Oil Filter (Cup) 6
4
© 30 074 0
● Switch off engine. ● Replace and lightly oil rubber gasket 2.

● Loosen lube oil filter cover 1 and unscrew in ● Carefully insert new paper filter cartridge 3 into
anticlockwise direction. guide 4.
● Carefully loosen paper filter cartridge 3 upwards ● Tighten lube oil filter cover 1 in clockwise direc-
from guide 4. tion (25 Nm).
● Catch any escaping oil. ● Start engine.
● Replace paper filter cartridge 3. ● Check oil level, see 6.1.2.
● Clean any dirt from sealing surface of filter carrier ● Check oil pressure, see 3.3.1.
and lube oil filter cover 1 and from guide 4. ● Check lube oil filter attachment for leaks.
Caution is required in case of hot

oil:
C 2001
! Risk of scalding!
53 9929en
6.2.1 Replace Fuel Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
● Close fuel shut-off valve. ● Clean any dirt from filter carrier sealing surface. ● Tighten fuel filter cartridge with final half-turn.
● Undo fuel filter cartridge with commercial tool ● Apply light film of oil or diesel fuel to rubber ● Open fuel shut-off valve.
and spin off. gasket of new fuel filter cartridge.
● Check for leaks.
● Catch any escaping fuel. ● Manually screw in new cartridge until gasket is
flush.
Keep naked flames away

when working on the fuel
C 2001
! system. Do not smoke! The fuel system does not need to be bled.
54 9929en
6.2 Fuel System Service and Maintenance
6.2.2 Clean / Replace

Fuel Filter (Cup) 6
4
© 30 074 0
● Switch off engine. ● Replace and lightly oil rubber gasket 2.

● Loosen fuel oil filter cover 1 and unscrew in ● Carefully insert new paper filter cartridge 3 into
anticlockwise direction. guide 4.
● Carefully loosen paper filter cartridge 3 upwards ● Tighten fuel filter cover 1 in clockwise direction
from guide 4. (25 Nm).
● Catch any escaping fuel. ● Start engine.
● Replace paper filter cartridge 3. ● Check fuel filter attachment for leaks.
● Clean any dirt from sealing surface of filter
carrier and fuel filter cover 1 and from guide 4.

ing on the fuel system. Do not
!
C 2001
smoke!
55 9929en
6.2.3 Clean Strainer of Fuel Filter 6.2.4 Change Fuel Leakage Line
6
4 2
2 3
3
1
1
© 26 436 0 © 31 867 0
● Close fuel shut-off valve. ● Mount fuel strainer cover 2. ● Close fuel shut-off valve.
● Loosen and unscrew hexagonal nut 1. ● Tighten hexagonal screw 1. ● Disconnect rubber hoses 3 from injection valves.
● Remove fuel strainer cover 2 (cover and strainer, ● Check for leaks. ● Disconnect rubber hose 1 from fuel tank.
one unit). ● Disconnect rubber hoses 4, 3 and 1 from unions
● Clean fuel strainer 2 with diesel fuel. Replace if 2 and dispose of in an environmentally friendly
necessary. manner.
● Place seal 3 in position. ● Connect new rubber hoses 4, 3 and 1 to unions 2.
● Connect rubber hoses 3 to injection valves.
● Connect rubber hose 1 to fuel tank.
● Open fuel shut-off valve.
● Check for leaks after start-up.

ing on the fuel system. Do not
C 2001
! smoke!
56 9929en
6.3 Cooling System Service and Maintenance

6
● Amount of contamination in cooling system
depends on engine application. Checking or cleaning intervals
Guideline values OH Engine application
● Oil and fuel residues on engine increase risk of
contamination. Therefore pay special attention 2000 Ships, generating sets in enclosed areas, pumps.
to leaks if engine is used in dusty environments.
● Serious contamination can occur, for example: 1000 Vehicles on paved roads
- on construction sites where there is a high
level of air-borne dust. 500 Tractors, fork-lift trucks, mobile generating sets
- in harvesting applications where there are high
concentrations of chaff and chopped straw in 250 Vehicles on construction sites and unpaved roads, construc-
vicinity of machine.
tion machines, compressors, underground mining units
● Because applications vary, cleaning intervals
have to be determined from case to case. Clean- 125 Agricultural machines, tractors in harvesting applications
ing intervals given in table on right can be used
as a guide.
57 9929en
Service and Maintenance 6.4 Combustion Air Filter
6.4.1 Cleaning Intervals 6.4.2 Emptying Cyclone-Type

6 Precleaner
● Amount of dirt in air cleaner depends on amount

of dust in air and size of air cleaner used. If high
level of dust is anticipated, cyclone-type
precleaner can be fitted to air cleaner.
● Cleaning intervals will have to be determined

from case to case.
● If dry type air filters are used, cleaning should

only be carried out according to service indicator
or service switch.
● Air cleaner servicing is needed when:

- Service indicator
red signal 1 is fully visible when engine is off.
- Service switch
© 25 885 1 © 25 886 0
yellow pilot light comes on when engine is
running.
● Undo wing nut 1 and remove cover 2.
● pressing button on service indicator. Service ● Remove collector bowl 3 from lower section 4
indicator is now ready for operation again. and empty. Clean leaves, straw and other foreign
matter from lower section of pre-cleaner.
● Reposition collector bowl 3 onto lower section 4,
fasten cover 2 in place by tightening wing nut 1.
Never fill collector bowl with oil. Replace collector

bowl if damaged.
58 9929en
6.4 Combustion Air Filter Service and Maintenance
6.4.3 Dry Type Air Cleaner

Discharge Valve Filter Cartridges 6
© 25 888 1 © 25 889 0
● Empty dust discharge valve 1 by pressing apart ● Undo clip fasteners 1. ● After five cleaner services or after two years at
lips of discharge slot as indicated by arrows. ● Take off hood 2 and remove cartridge 3. latest, replace safety cartridge 4 (never clean).
● Clean discharge slot from time to time. ● Clean cartridge, replace at least once a year. To do so:
● Remove any caked dirt by pressing together ● Clean cartridge 3. - Undo hex nut 5 and remove cartridge 4.
upper section of valve. Using dry compressed air (max. 5 bar), blow out - Install new cartridge, fit and tighten hex nut.
from inside to outside (or in difficult cases, tap ● Install cartridge 3, replace hood 2 and do up clip
out, taking care not to damage cartridge, or wash fasteners 1.
according to manufacturer’s instructions).
● Gaskets on filter cartridge can become damaged
through regular removal and replacement. Check
paper filter (light showing through) and gaskets
for damage.
Replace if necessary. Never clean filter cartridge with pet-
rol or hot fluids.
!
59 9929en
Service and Maintenance 6.5 Belt Drives
6.5.1 Check V-belt

6
© 31 866 0 © 26 261 0
● Visually inspect entire V-belt for damage. - Carefully remove gauge without altering posi-
● Replace damaged V-belts. tion of indicator arm 1.
● After installing new belts, run engine for 15 - Read off value where black indicator arm 1
minutes, then check belt tension. intersects scale 5 (arrow). For settings, see
● To check tension of V-belt, use tension gauge 9.1.
(see 9.3). - If necessary, retension belt and measure again.
- Place indicator arm 1 into gauge.
- Position guide 3 on V-belt 2, midway between
pulleys, with stop against edge of belt.
- Push slowly on black pad 4 at right angles to V-
belt 2 until spring is heard or felt to trigger.

only with engine off. Refit belt guard,
! if provided. After installing new belts, run engine for 15 min-
utes, then check belt tension.
60 9929en
6.5 Belt Drives Service and Maintenance
6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts

6
3 5 3 5
1 1
4 4
2 2
© 31 859 0 © 31 860 0
● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1, 2 and 3.

● Adjust alternator 4 in direction of arrow by
● Adjust alternator 4 in direction of arrow by turning bolt 3.
turning bolt 3 until correct belt tension is achieved. ● Remove and replace belt.
● Adjust alternator 4 against direction of arrow by
● Retighten bolts 1, 2 and 3. turning bolt 3, until correct belt tension is
achieved.
● Retighten bolts 1, 2 and 3.

only with engine off. Refit belt guard,
! if provided.
61 9929en
Service and Maintenance 6.6 Adjustments
6.6.1 Check Valve Clearance, adjust

6 if necessary
© 19 691 2 © 25 893 0
● Remove cylinder head cover. ● Adjust valve clearance if necessary:

● Position crankshaft as per schematic, see 6.6.1.1. - Release locknut 4.
● Before adjusting valve clearance, allow engine to - Use Allan key 7 to turn setscrew 5 so that
cool down for at least 30 minutes. Oil tempera- correct clearance is attained after locknut 4 has
ture should be below 80°C. been tightened.
● Check valve clearance 1 between rocker arm / ● Check and adjust valve clearance on all cylin-
tappet contact face 2 and valve stem 3 with feeler ders.
gauge 6 (there should be only slight resistance ● Reinstall cylinder head cover, with new gasket if
when feeler blade is inserted). necessary.
For permissible valve clearance, see 9.1.
62 9929en
6.6 Adjustments Service and Maintenance
6.6.1.1 Valve Clearance Adjust 6

ments Schematic
● Crankshaft Position 1:
1 Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance of valves marked
in black on schematic. Mark respective rocker
1 2 1 2 3 1 2 3 4 arm with chalk to show that adjustment has been
carried out.
2 ● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in black on
schematic.
1 2 1 2 3 1 2 3 4
© 25 894 4
63 9929en
6.7.1 Battery
6 6.7.1.1 Check Battery and Cable 6.7.1.2 Check Electrolyte Level 6.7.1.3 Check Electrolyte Density
Connectors
© 25 895 0 © 24 232 3 © 25 896 0
● Keep battery clean and dry. ● Remove sealing caps 1. ● Measure electrolyte density of individual cells
● Undo dirty clamps. ● If testers 2 are present: with commercial hydrometer.
● Clean terminal posts (+ and -) and clamps of Electrolyte level should reach base of these.
battery, and grease with acid-free and acid- ● Without testers: Hydrometer reading (see table on following page)
resistant grease. Electrolyte level should be 10-15 mm above top indicates battery’s state of charge.
● When reassembling, ensure that clamps make of plates. During measurement, temperature of electrolyte
good contact. Tighten clamp bolts hand-tight. ● If necessary, top up with distilled water. should preferably be +20°C.
● Screw sealing caps back in.
64 9929en
Electrolyte density
in [kg/ l] in [°Bé (Baumé scale)*] Charge status
Normal Tropical Normal Tropical
1.28 1.23 32 27 well charged
1.20 1.12 24 16 semi-charged, re-charge
1.12 1.08 16 11 discharged, immediately charge
*Measurement of electrolyte density in °Bé (Baumé

scale) is out of date and rarely used today.
The gases emitted by the battery

are explosive! Keep sparks and na-
! ked flames away from the battery!
Do not allow battery acid to come
into contact with skin or clothing!
Wear protective goggles!
Do not rest tools on the battery!
65 9929en
6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

6
Notes on the three-phase system:
● Never disconnect cables between battery, alter-
nator and regulator while engine is running.
● If, however, it is necessary to start and operate
engine without battery, disconnect regulator from
alternator before starting.
● Be sure not to confuse battery terminals. 1
● Replace defective charge pilot lamp bulb imme-
diately.
● When washing engine, cover up alternator and
regulator.
● Touching lead against frame to check whether it 2
is live must not, under any circumstances, be
carried out with three-phase electrical systems.
● In case of electric welding, connect ground ter-
minal on welder directly to piece being welded.
© 31 871 0 © 31 870 0
● Always use proper lifting tackle 1 when trans-

porting engine.
● After transportation and before commissioning
of engine: remove attachment eyes 2.
Use only correct lifting gear.
66 9929en
6.8 Engine Cleaning Service and Maintenance
6.8.1 Engine Cleaning

6
Preperation
● Remove engine covers and cooling air hood.
Replace them after cleaning and before test run.
● Cover electrical / electronic components and
connections (e.g. alternator, starter, governor,
solenoid).
Using compressed air
● Blow air through engine, taking particular care
not to damage cooler and cooling fins (begin to
blow through air from exhaust side).
Remove dirt which has blown into interior space.
Using cold-cleaning compound
● Spray engine with commercial cold-cleaning
compound and allow to react for approx. 10
mins.
● Spray-clean engine with strong water jet, repeat
if necessary.
● Allow engine to run warm so that remaining
water evaporates.
Using high-pressure device
● Clean engine with steam jet (max. spray pres-
sure of 60 bar, max. steam temperature of 90ºC).
● Allow engine to run warm so that remaining
water evaporates.
Clean the engine only when the en-

gine is switched off.
!
67 9929en
6
68 9929en
Faults, Causes and Remedies
7.1 Fault Table
69 9929en
Faults, Causes and Remedies 7.1 Fault Table
7
● Faults are often caused by engine not being
properly operated or maintained.
● Each time fault occurs, check whether all operat-

ing and servicing regulations have been com-
plied with.
● Corresponding fault table can be found on adja-

cent page.
● If you cannot ascertain cause of a fault or cannot

rectify fault, please contact DEUTZ SERVICE.
70 9929en
7.1 Fault Table Faults, Causes and Remedies
Faults Measures
Engine does not start or is difficult to start Check Ch 7
Engine starts, but runs irregularly or fails Adjust A
Engine becomes excessively hot. Temperature warning system responds Replace Rp
Engine output is deficient Clean Cl
Engine does not run on all cylinders Top up T
Engine oil pressure is non-existent or excessively low Reduce Rd
Engine smokes - blue
- white
- black
Cause Section
● Not declutched (where possible) Engine Operation Ch
● ● Below starting limit temperature Ch
● ● Oil level too low T
● ● ● ● Oil level too high Ch
● ● ● Excessive inclination of engine Rd
● ● Incorrect lube oil SAE class or quality Operating media Rp
● ● ● ● Fuel quality not as per operating manual Rp
● ● ● Air cleaner clogged / turbocharger defective Combustion air Ch / Rp
● ● ● Air cleaner service switch / indicator defective Ch / Rp
● CPD * defective Ch
● ● Charge air line leaking Ch
● Oil cooler panels clogged Ch / Cl
● Cooling fan defective, split or loose V-belt Cooling system Ch / Rp
● Cooling air temperature rise / heating short circuit Ch
● Resistance in cooling system too great / through-flow quantity too small Ch
● Battery defective or discharged Electrics Ch / T
*CPD = Charge pressure-dependent full-load stop
71 9929en
Faults, Causes and Remedies 7.1 Fault Table
Faults Measures
7 Engine does not start or is difficult to start Check Ch
Engine starts, but runs irregularly or fails Adjust A
Engine becomes excessively hot. Temperature warning system responds Replace Rp
Engine output is deficient Clean Cl
Engine does not run on all cylinders Top up T
Engine oil pressure is non-existent or excessively low Reduce Rd
Engine smokes - blue
- white
- black
Cause Section
● Electric cable connections to starter electrical system loose or oxidised Electrics Ch
● Starter defective or pinion does not engage Ch
● Solenoid defective (release switch) Ch
● ● ● ● ● Incorrect valve clearance Engine A
● ● ● Injection line leaks Ch
● ● ● ● ● ● ● Injection valve defective Ch / Rp
72 9929en
Engine Preservation
8
8.1 Preservation
73 9929en
Engine Preservation 8.1 Preservation
8.1.1 Preserving Engine 8.1.2 Removing Engine

8 Preservatives
If the engine is to remain idle for an extended period ● Clean engine using high-pressure equipment ● Remove anti-corrosion agent from grooves in
of time, it is necessary to take protective measures to (or with cold-cleansing agent in emergency). V-belt pulleys.
prevent rusting. The preservative measures described ● Run engine until warm, then turn off. ● Install V-belt, retension after brief operation if
here will protect the engine for up to 6 months. ● Drain engine oil (see 6.1.2) and fill with anti- necessary, see 6.5.
The procedure will have to be reversed before the corrosion oil. ● Remove covers from intake port and exhaust
engine is recommissioned. ● If necessary, clean oil bath cleaner (see 6.4.3) port.
● Anti-corrosion oils to specification: and fill with anti-corrosion oil. ● Commission engine, see also 5.1, note 2.
MIL-L-21260B ● Drain fuel tank.
TL 9150-037/2 ● Make up a mixture of 90% diesel fuel and 10%
Nato Code C 640 / 642 anti-corrosion oil, and refill fuel tank.
● Anti-corrosion media for exterior protection only ● Allow engine to run for approx. 10 mins.
to specification: ● Switch off engine.
Nato Code C 632 ● Turn engine over manually several times to pre-
● Recommended cleaning agent to remove preserve cylinders and combustion chamber.
servatives: ● Remove V-belts and store in wrapped condition.
Petroleum benzine ● Spray grooves on V-belt pulleys with anti-corro-
(hazardous materials class A3) sion spray.
● Close intake ports and exhaust ports.
74 9929en
Technical Specification
9
9.3 Tools
75 9929en
Technical Specification 9.1 Engine Specifications and Settings
Model
9 Number of cylinders
———— F2L 2011 ————— F3L 2011 —————— F4L 2011 ————
————— 2 ————————— 3 ———————— 4 ——————
Cylinder arrangement ————————————— vertical in line ——————————————
Bore [mm] ———————————————— 94 ————————————————
Stroke [mm] ——————————————— 112 ————————————————
Total displacement [cm3] ———— 1554 ——————— 2331 ———————— 3108 —————
Compression ratio [ε] ———————————————— 19 ————————————————
Working cycle ———————————— 4-stroke diesel engine ————————————
Combustion system ——————— Naturally aspirated engine with direct injection ————————
Direction of rotation —————————— On left when looking at flywheel ——————————
Weight incl. integral cooling system to DIN 70020-A
(without starter, with alternator) approx. [kg] ————— 175 ———————— 217 ———————— 256 —————
Engine output [kW (hp)] ———————————————— 1) ———————————————————
Speed [rpm] ———————————————— 1) ———————————————————
Lubrication ———————————— Pressure lubrication —————————————
SAE oil —————————————— 20 W 20 ———————————————
Maximum oil temperature in oil pan [°C] ——————————————— 130 ————————————————
Min. oil pressure in warm condition, oil temperature 110°C
at: 900 rpm (low idling speed) [bar] ——————————————— 1.4 3) ——————————————————
1800 rpm [bar] ——————————————— 2.2 3) ——————————————————
max. 2800 rpm [bar] ——————————————— 3 3) ——————————————————
Oil change quantity (oil pan) approx. [l] ————— 6 2) ————————— 5.5 2) ————————— 10 2) ——————
Oil change quantity with filter (standard 0.5 l) approx. (l) ———— 6.5 2) ————————— 6 2) ———————— 10.5 2) ——————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————————— Inlet 0.3 +0.1 / Exhaust 0.5 +0.1 ———————————
Start of feed [°crankshaft BTDC] ———————————————— 1) ———————————————————
Injector opening pressure: vehicle/unit [bar] ——————————————— 210 +8 ——————————————————
Firing order of engine ————— 1 - 2 ——————— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 ————
V-belt tension: pretension / retension (after engine has been running under load for 15 mins)[N] ————————————— 450 / 350 ±20 ——————————————
1)
2)
Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.
3)
76 9929en
9.1 Engine Specifications and Settings Technical Specification
Model
Number of cylinders
——— BF3L 2011 ————————— BF4L 2011 ————
————— 3 ———————————— 4 ——————
9
Bore [mm] ———————————— 94 —————————————
Stroke [mm] ———————————— 112 ————————————
Compression ratio [ε] ———————————— 17.5 ————————————
Working cycle / Combustion system ——— Four-stroke diesel with turbocharging and direct fuel injection ——
Direction of rotation —————— On left when looking at flywheel ———————
Weight without cooling system
Weight without starter, with alternator as per DIN 70020-A approx. approx. [kg] ————— 222 ———————————— 257 —————
Engine output [kW (hp)] —————————————— 1)
—————————————
Speed [rpm] ———————————— 1) —————————————
Lubrication ————————— Pressure lubrication —————————
SAE oil ——————————— 20 W 20 ————————————
Maximum oil temperature in oil pan [°C] ———————————— 130 ————————————
at: 900 rpm (low idling speed) [bar] ———————————— 1.4 3) ——————————————
1800 rpm [bar] ———————————— 2.2 3) ——————————————
max. 2800 rpm [bar] ———————————— 3 3) ——————————————
Oil change quantity (oil pan without cooling system) ca. [l] ————— 7.5 ———————————— 10 2) ——————
Oil change quantity with filter (Standard 0.5 l) approx. (l) ————— 8 ——————————— 10.5 2) ——————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————— Inlet 0.3 + 0.1 / Exhaust 0.5 + 0.1 ———————
Injector opening pressure: vehicle/unit [bar] ——————————— 210 + 8 ———————————
Start of feed [°crankshaft BTDC] —————————————— 1)
————————————
Firing order of engine ———— 1 - 2 - 3 —————————— 1-3-4-2 —————
V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N] —————————— 450 / 350 ±20 ——————————
1)
2)
3)
77 9929en
Technical Specification 9.1 Engine Specifications and Settings
Model — F2M 2011 ————— F3M 2011 ———— F4M 2011 ——

9 Number of cylinders ——— 2 ———————— 3 ———————— 4 ————
Bore [mm] ———————————— 94 —————————————
Stroke [mm] ———————————— 112 ————————————
Total displacement [cm3] —— 1554 ——————— 2331 —————— 3108 ———
Working cycle ———————— 4-stroke diesel engine —————————
Combustion system ————— Naturally aspirated engine with direct injection —————
Direction of rotation ——————— On left when looking at flywheel ——————
(without starter, with alternator) approx. approx. [kg] —— 169 ——————— 210 —————— 248 ———
Engine output [kW (hp)] ———————————— 1) ———————————————
Speed [rpm] ———————————— 1) ———————————————
SAE oil ——————————— 20 W 20 ————————————
Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar] ———————————— 1.4 3) ——————————————
1800 rpm [bar] ———————————— 2.2 3) ——————————————
max. 2800 rpm [bar] ———————————— 3 3) ——————————————
Oil change quantity without external cooler (see 3.1.1.2)/without filter approx. [l] —————— 5.5 2) ————————— 10 2) ————————
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre) approx. [l] ——————— 6 2) ————————— 10.5 2) ————————
Genset Engine without Thermostat:
Oil change quantity including external cooler (see 3.1.1.3)/without filter approx. [l] —————— 8.5 2) ————————— 13 2) ————————
Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l] ——————— 9 2) ————————— 13.5 2) ————————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————— Inlet 0.3 +0.1 / Exhaust 0.5 +0.1 ———————
Start of feed [°crankshaft BTDC] ———————————— 1) ———————————————
Injector opening pressure: vehicle/unit [bar] ——————————— 210 +8 ————————————
Firing order of engine —— 1-2 —————— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 ——
V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N] —————————— 450 / 350 ±20 ——————————
1)
2)
3)
78 9929en
9.1 Engine Specifications and Settings Technical Specification
Model ————— BF3M 2011 ————— BF4M 2011 ——————
Number of cylinders ——————— 3 ————————— 4 ———————— 9
Bore [mm] ———————————— 94 —————————————
Stroke [mm] ———————————— 112 ————————————
Total displacement [cm3] —————— 2331 ———————— 3108 ———————
Compression ratio [ε] ———————————— 17.5 ————————————
Working cycle ———————— 4-stroke diesel engine —————————
Combustion system ——————— Turbocharging and direct injection ————————
Direction of rotation ——————— On left when looking at flywheel ——————
(without starter, with alternator) approx. [kg] —————— 215 ———————— 250 ———————
Engine output [kW (hp)] ———————————— 1) ————————————
Speed [rpm] ———————————— 1) ————————————
SAE oil ——————————— 20 W 20 ————————————
Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar] ———————————— 1.4 3) ————————————
1800 rpm [bar] ———————————— 2.2 3) ————————————
max. 2800 rpm [bar] ———————————— 3 3) —————————————
Oil change quantity without external cooler (see 3.1.1.2) / without filter approx. [l] ——————— 7.5 ———————— 10 2) ———————
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre) approx. [l] ——————— 8 ———————— 10.5 2) ———————
Genset Engine without Thermostat:
Oil change quantity including external cooler (see 3.1.1.3) / without filter approx. [l] ——————— 11 ———————— 13.5 2) ———————
Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l] —————— 11.5 ———————— 14 2) ———————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————— Inlet 0.3 +0.1 / Exhaust 0.5 +0.1 ———————
Start of feed [°crankshaft BTDC] ———————————— 1) —————————————
Injector opening pressure: vehicle/unit [bar] ——————————— 210 +8 ————————————
Firing order of engine —————— 1-2-3 —————— 1-3-4-2 ——————
V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N] ————————— 450 / 350 ±20 ———————————
1)
2)
3)
79 9929en
Tecnical Specification 9.2 Torque Wrench Settings
9 Installation location Pre-tension [Nm] Re-tension [Nm] Total Comments
1st stage 2nd stage 3rd stage 1st stage 2nd stage 3rd stage 4th stage [Nm]
Cylinder head cover 8.5
Cylinder head cover 8.5
Rocker arm adjustment screw 21
Intake manifold 8.5
Foot Rigid suspension 30 45
Foot Elastic suspension 106
Air intake pipe 21
Exhaust manifold 22
Oil drain plug 55
Oil pan (sheet metal) 21
Oil pan (cast) 31
Injection line attachment 30
Injection valve attachment 21 TORX
Lube oil filter cartridge 27 on engine or separate
Threaded pipe union 4
80 9929en
9.3 Tools Technical Specification
TORX V-belt tension gauge

9
25899 0 26002 0
A TORX BN. 8189 screw set is used with engines in The V-belt tension gauge can be obtained under
the 1011 series. order number 8115 from:
This system was chosen because of the many
advantages it offers: FA.WILBÄR
Postfach 14 05 80
● Outstanding accessibility to bolts. D-42826 Remscheid
● High load transfer when loosening and tighten-
ing.
● Almost impossible for socket to slide off or
break, thereby practically ruling out risk of in-
jury.
TORX tools can be ordered from:
FA.WILBÄR
Postfach 14 05 80
D-42826 Remscheid
81 9929en
Notice
Notes
en Warnings to Place on Equipment Warning in the Manual
CALIFORNIA CALIFORNIA
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Diesel engine exhaust and some of its
constituents are known to the State of constituents are known to the State of
California to cause cancer, birth California to cause cancer, birth
defects, and other reproductive harm. defects, and other reproductive harm.
or
CALIFORNIA
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Notes
CALIFORNIA PROPOSITION 65 INFORMATION en

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.
The warning must appear in one of the following locations:

● Inside The front cover
● Inside the back cover
● Outside the front cover
● Outside the back cover
● As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
Service

requirements.


means reliable service and comprehensive support Order-No.: 0312 0807 (CD-ROM)
This index Sales & Service offers you an overview

products for which they are responsible and the Obtainable from the local service Partner reponsible DEUTZ AG
range of services provided. But even when no direct for you or from: Deutz-Mülheimer Str. 147-149
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. Telex: 8812-0 khd d
http://www.deutz.de
englisch
Beschnitt Beschnitt
Ersatzteilliste
Catalogue de Pièces de
Rechange
2011
U1_Titel_2012_0297 9957
Beschnitt CYAN = HKS 49K MAGENTA = HKS 14K SCHWARZ Beschnitt

Ersatzteilliste
2011
Händlerstempel
0297 9934
Motornummer:
Bitte tragen Sie hier die Motornummer ein. Sie

erleichtern hierdurch die Abwicklung bei Kunden-

Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeg-
licher Art, auch auszugsweise, bedarf unserer
schriftlichen Genehmigung.
1 de © 2000
© 2000
Rechts 1
Vorwort
de
en Sehr geehrter Kunde Die in dieser Ersatzteilliste aufgeführten Bauteile
sind nur für Reparatur von DEUTZ Motoren der
fr die flüssigkeitsgekühlten Motoren der Marke
DEUTZ sind für ein breites Anwendungsspektrum
bezeichneten Baureihe zu verwenden (bestim-
mungsgemäßer Gebrauch).
entwickelt. Dabei wird durch ein umfangreiches Über den fachgerechten Einbau von Ersatzteilen
es Angebot von Varianten sichergestellt, daß die je-
weiligen speziellen Anforderungen erfüllt werden.
informieren die Betriebsanleitung (Wartungs-
arbeiten) und das Werkstatthandbuch (Reparatur-
pt Ihr Motor ist dem Einbaufall entsprechend ausge-
arbeiten) ausführlich. Für Schäden oder Verletzun-
gen von Personen, die aus der Nichtbeachtung der
rüstet, das heißt nicht alle in dieser Ersatzteilliste entsprechenden Anleitung führen, übernimmt der
it dargestellten Bauteile und Komponenten sind an
Ihrem Motor dargestellt.
Hersteller keine Haftung.
nl Obwohl die Grafiken weitgehend nicht mit allen

Details dargestellt sind, können die einzelnen
sv Varianten deutlich unterschieden werden, so daß
das für Ihren Motor relevante Ersatzteil leicht
herauszufinden ist. Über Positions-, Baugruppen-
da und Motornummer wird in jedem Fall das richtige
Ersatzteil ermittelt.
fn Bitte beachten Sie bei dieser Ersatzteilbestellung

unsere Bestellhinweise, damit wir Ihnen schnell
no und zuverlässig die benötigten Ersatzteile in der
jeweils dem letzten Änderungsstand entsprechen-
den Ausführung liefern können.
el Für Ihre Rückfragen stehen wir Ihnen gerne
beratend zur Verfügung.
tr
ru Ihre
DEUTZ AG
ar
pl
© 2000 2 de
2 Links
Vorwort
de
DEUTZ Dieselmotoren Original DEUTZ Teile DEUTZ Austauschkomponenten en
fr
sind das Produkt jahrelanger Forschung und Ent- unterliegen den gleichen strengen Qualitätsan- DEUTZ Austauschkomponenten sind
wicklung. Das dadurch gewonnene fundierte know
how in Verbindung mit hohen Qualitätsanfor-
forderungen wie die DEUTZ Motoren. Weiter-
entwicklungen, zur Verbesserung der Motoren
eine preiswerte Alternative. Selbst-
verständlich gelten auch hier wie
es
derungen ist die Garantie für die Herstellung von
Motoren mit langer Lebensdauer, hoher Zuverläs-
werden selbstverständlich auch bei den Original
DEUTZ Teilen eingeführt. Nur die Verwendung
für Neuteile höchste Qualitätsmaß-
stäbe. In Funktion und Zuverlässigkeit pt
sigkeit und geringem Kraftstoffverbrauch. Es ist von nach neuesten Erkenntnissen gefertigten sind DEUTZ Austauschkomponenten den Original
selbstverständlich, daß auch die hohen Anforde-
rungen zum Schutz der Umwelt erfüllt werden.
Original DEUTZ Teilen bietet die Gewähr einwand-
freier Funktion und hoher Zuverlässigkeit.
DEUTZ Teilen gleichwertig. it
nl
sv
da
SERVICE Vorsicht bei laufendem Motor Asbest
fn
Wenden Sie sich bei Betriebsstörungen und Ersatz- Wartungsarbeiten oder Reparaturen nur bei abge- Bei diesem Motor verwendete
no
teilfragen an eine unserer zuständigen Service- stelltem Motor durchführen. Evtl. entfernte Schutz- Dichtungen sind asbestfrei. Bitte
Vertretungen. Unser geschultes Fachpersonal
sorgt im Schadensfall für eine schnelle und fach-
vorrichtungen nach Abschluß der Arbeiten wieder
montieren. Bei Arbeiten am laufenden Motor soll
verwenden Sie bei Wartungs- und
Reparaturarbeiten entsprechende
el
gerechte Instandsetzung unter Verwendung von
Original DEUTZ Teilen.
die Arbeitskleidung fest anliegen. Nur bei abge-
stelltem Motor tanken. Motor nie in geschlossenen
Ersatzteile.
tr
Räümen laufen lassen – Vergiftungsgefahr.
ru
ar
pl
3 de © 2000
Rechts 3
Motorbeschreibung
de
en 1. Firmenschild 2. Lage des Firmenschild 3. Motornummer
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 1
fn
Die Bauart A, die Motornummer B sowie die Das Firmenschild C ist am Ventildeckel Die Motornummer ist auf dem Kurbelgehäuse
no Leistungsdaten sind auf dem Firmenschild ein-
gestempelt.
befestigt. sowie auf dem Firmenschild eingestempelt.
Bei der Ersatzteilbeschaffung müssen Bauart und

el Motornummer angegeben werden.
tr
ru
ar
pl
© 2000 4 de
4 Links
Ersatzteilbestellung
de
Bestellangaben en
Bei der Bestellung von Original DEUTZ Teilen sind
folgende Angaben erforderlich:
Ersatzteilbestellung fr
- Motor-Nr. Motor-Nr.: es
- Ident-Nr. Lfd. Nr. Stück Ident-Nr. Bemerkung Baugruppe pt
- Stückzahl
it
Dokumentationsaufbau
nl
- Die Bildtafeln dieser Ersatzteilliste sind nach
Motor-Baugruppen sortiert. sv
- Die Baugruppen sind in der Motorübersicht
aufgeführt. da
- Die Ident-Nr. 06/59 besteht aus Baugruppe
(z.B. 06) und Position (z.B. 59).
Position
fn
Symbolerklärungen
no
-06- Baugruppennummer (z.B. 06) el
000 Änderungsziffer (z.B. 000)
tr
96 Seitennummer (z.B. 96)
Querverweiß auf Fortsetzungsseite

ru
94 (z.B. 94)
ar
A Anschlußsymbol
- tritt immer mindestens paarweise auf
(z.B. A-A, B-B, C-C etc.)
pl
5 de © 2000
Rechts 5
Service
Zu wissen, es ist DEUTZ. Bestell-Nr.: 0312 0806 10

de Seit jeher steht DEUTZ für bahnbrechende Ent-
wicklungen im Motorenbau. Als unabhängiger
Motorenhersteller bieten wir weltweit eine kom-
plette Palette von Diesel- und Gasmotoren im
Leistungsbereich von 4 bis 7.400 kW an. Unsere
Produkte sind auf die Anforderungen unserer
Kunden perfekt zugeschnitten.
Weltweit verrichten mehr als 1,4 Millionen DEUTZ

Motoren zuverlässig ihren Dienst. Die Einsatz-
bereitschaft unserer Motoren und damit die
Zufriedenheit unserer Kunden wollen wir erhalten.
Daher sind wir weltweit mit einem Netz von
kompetenten Partnern vertreten, dessen Dichte der
regionalen Verteilung unserer Motoren entspricht.
So ist DEUTZ nicht nur der Name für Motoren mit

Erfindungsgeist. Sondern auch für ein komplettes
Leistungspaket rund um den Motor und einen
Service, auf den Sie sich verlassen können.
Das Register Sales & Service bietet Ihnen einen

Überblick über die DEUTZ Partner in ihrer Nähe,
über deren Produkt-Zuständigkeiten und Service- Bestell-Nr.: 0312 0807 (CD-ROM)
Leistungen. Aber auch wenn keine direkte Produkt-
Zuständigkeit vermerkt ist, hilft Ihnen der DEUTZ DEUTZ AG
Partner mit kompetenter Beratung weiter. Deutz-Mülheimer Str. 147-149
D-51057 Köln
Das Register wird permanent aktualisiert; fragen Beziehbar über Ihren zuständigen Service-Partner
Sie Ihren DEUTZ Partner nach der neuesten vor Ort oder bei: Telefon: 0049-221-822-0
Auflage. Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
Ihre DEUTZ AG
2011
Dealer’s stamp
0297 9934
Engine
Serial No.:
Please enter here the serial No. of your engine. This

will facilitate dealing with your questions
concerning after-sales service, repair and spare
parts.
This Spare Parts Catalogue is subject to enginee-

ring changes necessary for engine advancement.
All rights reserved. No part of this publication may
be reproduced or multiplied in any form, without
our prior permission in writing.
1 en © 2000
© 2000
Rechts 1
Preface
de
en Dear Customer The parts contained in this Catalogue are type-
specific and shall be used only for repairing
fr liquid DEUTZ diesel engines are developed to meet
the requirements of a wide range of applications.
engines belonging to the DEUTZ engine family
on the cover).
An extensive program of variant options gives them Full particulars for the correct installation of parts
es their high flexibility. are to be found in the relevant Operating
(maintenance work) and Workshop Manual
pt Your engine is custom-made, i.e. specifically equip-
ped for your requirement, which means that not all
(repair). The engine builder shall not be liable
for any damage or injury resulting from non-
of the components and assemblies contained in compliance with guidelines given in the manual.
it this Catalogue are fitted to your engine.
The greater part of the illustrations does not depict

nl all details, and yet you will find it easy to differentia-
te between versions and thus to identify the parts
sv pertaining to your engine model. Fig. Item No.,
Assembly Group No. Engine Serial No. are the
codes that infallibly lead to selection of the correct
da parts.
When placing your order, please observe our

fn ordering hints. This allow speedy and reliable
delivery of the required parts that are based on
no latest engineering standards.
If there are any questions, please do not hesitate to

el contact us.
tr Sincerely,
DEUTZ AG
ru
ar
pl
© 2000 2 en
2 Links
Preface
de
DEUTZ Diesel Engines Genuine DEUTZ Parts DEUTZ Exchange Components en
fr
are products based on long-standing research and are subject to equally stringent quality require- are a cheap alternative. Of course,
development The deep funds of acquired know-
how in conjunction with high quality requirements
ments as the engines themselves. Improvements
in engine design certainly also pass into the
they are subject to the same high
quality requirements as new parts.
es
guarantee that engines leaving our works achieve a
long life, high reliability and excellent fuel eco-
genuine DEUTZ parts. To ensure that your engine
will retain its functions and high reliability, you
And as regards functions and
reliability, DEUTZ exchange components equal pt
nomy. Naturally, they also attain best ratings as should use genuine DEUTZ parts only. genuine DEUTZ parts.
regards environmental protection. it
nl
sv
da
SERVICE Beware of the Running Engine Asbestos
fn
In case of operational trouble with your equip- Be sure to shut down the engine before performing Gaskets used for this engine do not
no
ment or queries about spare parts please turn to maintenance or repair work. After repair, put back contain asbestos. Olease use suit-
your nearest service dealership. Our skilled staff of
service exoerts will trace and remedy any defect
in place any removed panels and guards. When
doing work on the running engine, working clothes
able spare parts when carrying out
maintenance and repair work.
el
quickly, using genuine DEUTZ parts. should fit tightly so that loose ends cannot get
caught. Do not run the engine in enclosed rooms tr
– poison hazard.
ru
ar
pl
3 en © 2000
Rechts 3
Description of Engine
de
en 1. Maker’s Nameplate 2. Position of Nameplate 3. Engine Serial No.
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Engine model designation A, Engine Ser. No. B The nameplate C is attached to the crankcase. The engine serial No. is stamped on the crankcase
no and the power rating are given on the maker’s
nameplate.
and also on nameplate..
Be sure to state engine model and engine serial

el number when writing out a parts order.
tr
ru
ar
pl
© 2000 4 en
4 Links
Ordering spare parts
de
Order information en
Please specify the following information when
ordering original DEUTZ parts:
Ordering spare parts fr
- Engine no. Engine no.: es
- Ident no. Item Qty. Ident. no. Comments Assembly group pt
- Quantity
it
Document structure
nl
- The picture diagrams in this spare list are sorted
according to engine assembly groups. sv
- The assemblies are listed in the engine
overview. da
- The ident no. 06/59 is made up of the assembly
group (e.g. 06) and item number (e.g. 59).
Item number
fn
Explanation of symbols
no
-06- assembly No. (e.g. 06) el
000 revision level (e.g. 000)
tr
96 page number (e.g. 96)
cross reference on continuation page

ru
94 (e.g. 94)
ar
A A connection symbol
- always occurs at least in pairs
(z.B. A-A, B-B, C-C etc.)
pl
5 en © 2000
Rechts 5
Service

requirements.


means reliable service and comprehensive support
This index Sales & Service offers you an overview Order-No.: 0312 0807 (CD-ROM)
products for which they are responsible and the DEUTZ AG
range of services provided. But even when no direct Deutz-Mülheimer Str. 147-149
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Obtainable from the local service Partner reponsible Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. for you or from: Telex: 8812-0 khd d
http://www.deutz.de

2011
Cachet du concessionnaire
0297 9934
Numéro
du moteur:
Veuillez incrire dans les cases correspondantes

le numéro du moteur. Vous facilitez ainsi le
règlement des questions du Service après-vente
ainsi que tous les problèmes de réparation et
de pièces de rechange.
Nous nous réservons le droit dans le présent

Manuel, de procéder à toutes modifications
techniques utiles visant à améliorer la qualité des
moteurs. Toute réimpression ou reproduction du
présent Manual, faite même à titre exceptionnel,
exige notre autorisation spéciale.
1 fr © 2000
© 2000
Rechts 1
Avant-propos
de
en Cher client, Le présent Catalogue des pièces de rechange
énumère les composants à utiliser uniquement
fr les moteurs refroidis par liquide de la marque
DEUTZ ont été développés pour les applications les
à des fins de réparation pour moteurs Diesel de
la série indiquée (utilisation spécifique).
plus variées. Il existe un grand choix de variantes Les Instructions de service (travaux d’entretien)
es répondant aux exigences spéciales demandées
dans chaque cas.
et le Manuel d’atelier (travaux de réparation)
apportent de plus amples informations sur le mon-
pt Votre moteur est équipé pour les cas d’application
tage approprié des pièces. Le fabricant décline
toute responsabilité découlant de dommages ou de
envisagée, ce qui signifie que toutes les pièces et blessures aux personnes résultant du non-respect
it composants représentés dans votre Catalogue de
pièces de rechange ne sont pas montés sur votre
des présentes instructions.
moteur.
nl Bien que les graphiques ne représentant pas tous
sv les détails, les variantes se distinguent nettement
les unes des autres, si bien que vous trouverez sans
problème la pièce de rechange correspondant à
da votre moteur. Les numéros de référence, de
l’organe et du moteur permettent en tout cas de
retrouver la pièce de rechange que vous cherchez.
fn Lors de votre commande de pièces de rechange
no veuillez respecter nos indications de commande,
afin que nous puissons vous fournir rapidement
et sûrement les pièces de rechange demandées
el dans la version correspondante réactualisée.
Pour toutes questions complémentaires nous

tr restrons à votre endière disposition.
ru DEUTZ AG
ar
pl
© 2000 2 fr
2 Links
Avant-propos
de
Les moteurs Diesel DEUTZ Pièces de rechange DEUTZ Composants de rechange DEUTZ en
fr
sont le fruit de longues recherches et d’un Elles sonts soumises aux même niveau d’exigence Les composants de rechange
développment continu. Le solide savoir-faire ainsi
acquis conjugué à des exigences élevées en
de qualité que les moteurs DEUTZ. Toute progrès
visant à améliorer les moteurs est naturellement
DEUTZ sont une alternative. Lá
aussi, de même que pour les
es
matière de qualité est la garantie de fabrication
de moteurs à longue durée de vie, haute, fiabilité
immédiatement adpotée pour les pièces de
d’orgine DEUTZ. Seule l’utilisation de pièces de
pièces neuves, on applique des
normes de qualité élevées. Du pt
et faible consommation en combustible. Il va de soi d’origine DEUTZ d’origine fabriquées selon des point de vue fonction nement et fiabilité les
que les moteurs doivent aussi respecter des
exigences élevées en matiére de protection de
méthodes ultramodernes garantit un fonction-
nement irréprochable et une haute fiabilité.
composants de rechange DEUTZ sont équivalents
aux pièces de rechange DEUTZ.
it
l’environnement.
nl
sv
da
SERVICE Précaution à prendre quand
le moteur marche Amiante fn
En cas de panne d’exploitation et pour toute ques- N’effectuer les travaux d’entretien ou les répara-
Les rondelles d’étanchéité utili-
sées pour ces moteurs sont
no
tion relative à des pièces de rechange veuillez vous tions qu’à l’arrêt du moteur. A la fin des travaux exemptes d’amiante. Veuillez em-
adresser à notre point de service responsable pour
votre secteur. Notre personnel qualifié et averti
penser à remonter les dispositifs de protection
ayant été déposés. Lors de travaux à faire sur le
ployer, lors des travaux dèntretien
et de réparation, les pièces de
el
assure une remise en état rapide et appropriée de
votre moteur en n’utilisant que des piéces d’origine
moteur en marche, les vêtements de travail
doivent bien coller au corps. Ne faire le plein que
rechange correspondantes.
tr
DEUTZ. lorsque le moteur est arrêté. Ne jamais faire
fonctionner les moteurs dans des locaux fermes.
Danger d’asphyxie!
ru
ar
pl
3 fr © 2000
Rechts 3
Description du moteur
de
en 1. Plaque du constructeur 2. Emplacement de la plaque 3. Numéro du moteur
fr du constructeur
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Le type A, le numéro du moteur B ainsi que les La plaque du constructeur C est fixée sur le bloc Le numéro du moteur se trouve gravé sur le
no indications de puissance sont gravés sur la
plaque du constructeur.
moteur. bloc moteur et figure aussi sur la plaque du
constructeur.
Pour toute commande de pièce de rechange, veuil-
el lez indiquer le type et le numéro du moteur.
tr
ru
ar
pl
© 2000 4 fr
4 Links
Commande de pièces de rechange
de
Indications de commande en
Commande de pièce
Lors d’une commande de pièces détachées
originales de DEUTZ, il est nécessaire de fournir déatachée fr
les indication:
N° de moteur es
- n° de moteur
Nom- N° d’identi-
- n° d’identification
N° bre fication Observation numéro de groupe pt
- nombre it
Structure de la documentation
nl
- Les tableaux illustrés de cette liste de pièces
détachées sont classés par groupe de moteur. sv
- Les groupes constitutifs figurent dans
récapitulatif moteur moteur. da
- Le n° d’identification 06/59 est constitué
du n° de groupe (p.ex. 06) et du n° de position
position
fn
(p.ex. 59).
Symbolerklärungen
no
-06- Numéro de groupe constitutif (p. ex. 06) el
000 Indice de modification (p. ex. 000)
tr
96 Numéro de page (p. ex. 96)
94 Renvoi à la page (p. ex. 94)

ru
A Symbol d’assemblage ar
- se présente toujours par paire
(p. ex. A-A, B-B, C-C)
pl
5 fr © 2000
Rechts 5
Service
Qu’on se le dise: c’est du DEUTZ! Référence de commande: 0312 0806 10

fr DEUTZ est depuis toujours synonyme d’innovation
dans le domaine de la construction de moteurs.
C’est un fabricant indépendant qui offre une
gamme complète de moteurs diesel et à gaz d’une
puissance de 4 à 7 400 kW sur l’ensemble de la
planète. Nous fournissons des produits parfai-
tement adaptés aux exigences de nos clients.
Aujourd’hui, plus de 1,4 million de moteurs DEUTZ

tournent dans le monde entier. Notre double
objectif est d’assurer la fiabilité de nos moteurs et
de garantir la satisfaction de nos clients. C’est
pourquoi nous sommes représentés aux quatre
coins de la planète par un réseau de partenaires
compétents qui correspond à la répartition
régionale de nos moteurs.
DEUTZ, ce n’est donc pas seulement une marque

innovatrice de moteurs. C’est aussi une gamme
complète de services autour du moteur, c’est aussi
un nom sur lequel vous pouvez toujours compter.
Le registre Sales & Service vous donne un aperçu

des partenaires DEUTZ les plus proches, de leurs
compétences techniques et des services qu’ils Référence de commande: 0312 0807 (CD-ROM)
vous offrent. Et même s’il n’est pas directement
spécialisé dans le produit qui vous intéresse, votre DEUTZ AG
partenaire DEUTZ pourra vous conseiller avec Deutz-Mülheimer Str. 147-149
compétence. D-51057 Köln
Le registre est constamment actualisé. N’hésitez Peut être commandé en vous adressant à votre Téléphone: 0049-221-822-0
pas à demander la dernière version en date à votre partenaire service local ou auprès de: Téléfax: 0049-221-822-5304
partenaire DEUTZ. Téléx: 8812-0 khd d
http://www.deutz.de
Votre DEUTZ AG
2011
Sello del distribuidor
0297 9934
No. de motor:
Sírvase registrar en estas casillas el No. de motor.

Así facilita la tramitación de cuestiones de servicio
postventa, reparaciones y repuestos.
Nos reservamos el derecho de efectuar, frente a las

representaciones e indicaciones de esta Lista de
repuestos, las modificaciones técnicas necesarias
para perfeccionar los motores. Para la reimpresión
y reproducción en cualquier forma, también en la
de extractos, se require nuestra autorización por
escrito.
1 de © 2000
© 2000
Rechts 1
Prefacio
de
en Estimado cliente: Los componentes indicados en esta lista de
repuestos se emplearán exclusivamente para la
fr Los motores de la marqua DEUTZ con enfriamiento
por líquido han desarrollado para una amplia gama
reparación de motores Deutz de la serie indicada
(uso conforme a la finalidad).
de aplicaciones. Una extensa oferta de variantes Respecto al correcto montaje de los repuestos,
es garantiza que se cumplen las exigencias especiales
de cada caso.
véanse los manuales de instrucciones de manejo
(trabajos de mantenimiento) y el manual de
pt Su motor se ha equipado de acuerdo con el respec-
taller (trabajos de reparación). El fabricante no
responderá por daños o lesiones de personas
tivo caso de equipo, o sea que no están montados resultantes de la inobservancia de la instrucción
it en el motor de Ud. todos las partes constructivas
y componentes representados en su Lista de
correspondiente.
repuestos.
nl Pese a que la mayoría de los gráficos no contiene
sv todos los detalles, se pueden distinguir bien las
diferentes variantes de modo que resulta fácil
identificar el repuesto correspondiente a su motor.
da E repuesto correcto para cada caso se determina a
través de los números de posición, de grupo
constructivo y de motor.
fn Le rogamos tenga en cuenta nuestras indicaciones
no al confeccionar su pedido de repuestos para que le
podamos suministrar rápida y seguramente los
repuestos requeridos en la ejecución de acuerdo
el con el último estado de modificación.
En caso de dudas, estamos gustosamente a su

tr disposición para asesorarle.
ru DEUTZ AG
ar
pl
© 2000 2 es
2 Links
Prefacio
de
Motores diesel DEUTZ Repuestos DEUTZ Componentes reacondicionados DEUTZ en
fr
son el producto de trabajos de investigación y de- están sometidos a las mismas severas exigencias Componentes reacondiconados
sarrollo de largos años. El fundado know how así
logrado conjuntamente con altas exigencias de ca-
respecto a la calidad que los motores DEUTZ.
Desarrollos ulteriores para perfeccionar los
DEUTZ constituyen una alterna-
tiva económica frente a repuestos
es
lidad es la garantía para la fabricación de motores
de larga duración, gran fiabilidad y bajo consumo
motores son introducidos desde luego también
en los repuestos DEUTZ. Sólo el emplo de
originales DEUTZ.
Naturalmente rigen también aquí, pt
de combustible. Se sobreentiende que se cumplen repuestos DEUTZ originales farbricados según igual que para piezas nuevas, elevadísimas ex-
también las elevadas exigencias para le protección
del ambiente.
los conocimientos más recientes garantiza un
funcionamiento impecable y alta fiabilidad.
igencias de calidad. Los repuestos reacondiciona-
dos DEUTZ equivalen a los repuestos originales
it
DEUTZ en cuanto a funcionamiento y fiabilidad.
nl
sv
da
SERVICE Atención a motor en marcha Amianto
fn
En caso de anomalías en el funcionamiento y Realizar trabajos de mantenimiento o reparación Las juntas utilizadas en este motor
no
cuestiones de repuestos, sírvase dirigirse a uno únicamente a motor parado. Remontar una vez son exentas de amianto (asbesto).
de nuestros Servicíos Oficioles. Nuestro personal
especializado y entrenado se ocupará de subsanar
terminados los trabajos los dispositivos de protec-
ción quitados eventualmente. En caso de que se
Para trabajos de mantenimiento
y reparacion sírvase utilizar los
el
efecientemente y con rapidez cualquier desper-
fecto, utilizando repuestos originales DEUTZ.
tengan que efectuar trabajos en el motor en
marcha, la ropa de trabajo debe tocar al cuerpo para
repuestos correspondientes.
tr
evitar accidentes. Hacer el repostado sólo a motor
parado. No hacer funcionar nunca el motor en lo-
cales cerrados – peligro de intoxicación.
ru
ar
pl
3 es © 2000
Rechts 3
Descripción del motor
de
en 1. Placa del fabricante 2. Situación de la placa del fabricante 3. No. de motor
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
El tipo A, el No. de motor B así como los datos de La placa del fabricante C va fijada en el cárter. El No. de motor va estampado en el cárter y en la
no potencia van estampados en la placa del fabri-
cante. El tipo y el No. de motor se han de indicar
placa del fabricante.
en los pedidos de repuestos.

el
tr
ru
ar
pl
© 2000 4 es
4 Links
Pedido de repuestos
de
Indicaciones para el pedido: en
Al solicitar piezas originales de DEUTZ será
necesario indicar los siguientes datos:
Pedido de repuestos fr
- Nº de Motor: Nº de Motor: es
N° de
- Nº de identificatión N° Pos. Cant. ident. Anotación: Groupo de construcción pt
- Cantidad de piezas
it
Estructuración de la documentación
- Las tablas con las ilustraciones de dichas piezas
nl
de repuesto están clasificadas de acuerdo con el
grupo constructivo de los motores. sv
- Los grupos constructivos se indican en el
resumen correspondiente del motor.
da
- El Nº de identificación 06/59 consta del grupo
(v.g. 06) y de la posición (v.g. 59).
Posición
fn
Leyenda
no
-06- número del grupo constructivo (z.B. 06) el
000 índice de modificación (z.B. 000)
tr
96 número de página (p.ej. 96)
referencia recíproca a la página de

ru
94 continuación (p.ej. 94)
ar
A símbolo de enlace
- aparece siempre, por lo menos, como
pareja (p.ej. A-A, B-B, C-C, etc.)
pl
5 es © 2000
Rechts 5
Service
La confianza de saber que es DEUTZ No. Pedito: 0312 0806 10

es DEUTZ siempre ha estado a la vanguardia de la
industria de fabricación de motores. Como marca
independiente, ofrecemos, a escala mundial, una
gama muy completa de motores diesel y de gas,
con potencias comprendidas entre 4kW y 7400kW.
Nuestros productos están estudiados para
satisfacer plenamente las exigencias de nuestros
clientes.
Más de 1.400.000 motores DEUTZ funcionan con
toda fiabilidad en distintas partes del mundo.
Estamos resueltos a mantener las elevadas pres-
taciones de nuestros motores y, por consiguiente,
la confianza y satisfacción de nuestros clientes. Por
ello, contamos con una red mundial de centros de
asitencia, cuya densidad corresponde a la
distribución de motores en las distintas regiones.
Así pues, DEUTZ no es tan sólo el nombre de un
motor fruto del genio creador. DEUTZ también
significa un paquete de servicios de apoyo para
garantizar un funcionamiento óptimo del motor y
una asistencia técnica en la que puede Ud. confiar.
El registro Sales & Service le ofrece una panorá-
mica de los centros DEUTZ en su zona geográfica, No. Pedito.: 0312 0807 (CD-ROM)
detallando, en particular, los productos de los que
se ocupa cada centro y la gama de servicios dispo-
nibles. Pero incluso cuando no se mencione un DEUTZ AG
producto determinado, puede Ud. estar seguro que Deutz-Mülheimer Str. 147-149
su centro de asistencia DEUTZ tendrá mucho gusto D-51057 Köln
en asesorarle y ayudarle en todo lo que pueda.
Téléfono: 0049-221-822-0
El registro se actualiza periódicamente. No dude en Obtenible a través de su servicio local corres- Telefax: 0049-221-822-5304
solicitar la última edición a su centro de asistencia pondiente o de: Telex: 8812-0 khd d
DEUTZ. http://www.deutz.de
DEUTZ AG
A su servicio.
2011
Carimbo do vendedor
0297 9934
Número
do motor:
Inscreva aqui, por favor, o número do motor.

Facilitará, com isso, o andamento das questões
relacionadas com a assistência técnica, repa-
rações e peças sobresselentes.
Reservamo-nos o direito proceder a alterações

de ordem técnica na representação e nos dados
desta lista de peças sobresselentes que se tornem
neces-sárias para o aperfeiçoamento dos motores.
Toda e qualquer reimpressão e reprodução,
mesmo só em parte, requere a nossa autorização
por escrito.
1 pt © 2000
© 2000
Prefácio
de
en Prezado cliente: As peças e partes componentes relacionadas nesta
lista de peças sobresselentes serão utilizadas
fr Os motores refrigerados à agua DEUTZ foram
desenvolvidos para um espectro de aplicação
(uso a que se destinam) somente para a reparação
de motores Deutz da série designada.
vasto. Assegura-se ao mesmo tempo um O manual de instruções de serviço (trabalhos de
es atendimento das exigências particulares corres-
pondentes através da ampla oferta de variantes.
manutenção) e o manual de oficina (trabalhos de
reparação) proporcionam informações pormeno-
pt O Seu motor encontra-se equipado de acordo com o
rizadas quanto à montagem tecnicamente correcta
de peças sobresselentes. O fabricante não assume
caso de montagem, isto é, não estão embutidas no qualquer responsabilidade por danos ou lesões
it mesmo todas as peçass e partes componentes
representadas na Sua lista de peças sobresselentes.
pessoais resultantes da inobservãncia das
instruções correspondetes.
nl Embora os gráficos não se encontrem amplamente

representados com todos os pormenores, é possível
sv distinguir claramente cada uma das variantes, de
forma a encontrar-se facilmente a peça sobresse-
lente de importância para o Seu motor. A devida peça
da sobresselente é localizável em qualquer caso pelos
números do item, do grupo constructivo e do motor.
fn Quando do pedido de encomenda de peças sobres-

selentes queira, por favor, observar as nossas
no instruções para encomenda, a fim de podermos
fornecer-lhe rápida e seguramente as peças
sobresselentes requeridas de acordo com o tipo
el correspondente à última alteração actualizada.
Encontramo-nos com prazer a Sua disposição para

tr um aconselhamento no caso de quaisquer pedidos
de informação que nos dirigir.
ru
A Sua
ar DEUTZ
pl
© 2000 2 pt
Prefácio
de
Os motores diesel DEUTZ Peças e partes originais Peças e partes componentes en
substituíveis DEUTZ
fr
são produto de longos anos de pesquisas e desen- estão sujeitasàs mesmas exigências severas de As peças e as partes componentes
volvimento. O „know how“ consolidado assim ad-
quirido constitui, aliado às grandes axigências de
qualidade para os motores DEUTZ. Naturalmente
que se introduzem aperfeiçoamentos também nas
substituíveis DEUTZ são uma alter-
nativa económica para as peças
es
qualidade, a garantia para a fabricação de motores
com uma vida útil longa e um consumo reduzido
peças e partes originais para o melhora-mento
dos motores. Somente o emprego de peças e
sobresselentes originais DEUTZ.
Naturalmente que vigoram aqui, pt
de combustível. É compreensível que se deva partes originais fabricadas de acordo com os con- também, como para as peças novas, os padrões
obedecer também aos elevados requisitos de pre-
servação do meio ambiente.
hecimentos mais modernos poderá garantir um
funcionamento perfeito e elevada confiabilidade.
mais elevados de qualidade.
As peças e partes componentes substituíveis
it
DEUTZ são equivalentes na sua função e confiabili-
dade às peças sobresselentes DEUTZ. nl
sv
da
SERVICE Precaução com o motor em Amianto
funcionamento
fn
No caso da acorréncia de uma avaria operacional e Proceder aos trabalhos de manutenção e às repa- As vedações utilizadas neste
no
de possíveis consultas relacionadas com peças e rações apenas com o motor parado. Após termina- motor encontram-se isentas de
partes sobressalentes, queira dirigir-se a uma das
nossas representantes autorizadas do Service. O
dos os trabalhos haverá que montar de novo os di-
spositivos protectores eventulamente removidos.
amianto. Empregue, por favor, as
correspendentes peças e partes
el
nosso pessoal especialízado e bem treinado procu-
rara, em caso de uma avaria, proceder a uma repa-
No caso de trabalhos com o motor em funciona-
mento, a roupa de trabalho deverá estar bem aju-
sobressalentes quando dos trabal-
hos de manutenção e conserto. tr
ração rápida e tecnicamente eficiente, empregando stada ao corpo. Nunca se deverá deixar o motor a
peças e partes originais. trabalhar num recinto fechado, porque existe o pe-
rigo de intoxicação.
ru
ar
pl
3 pt © 2000
Descrição do motor
de
en 1. Placa do fabricante 2. Localização da placa do fabricante 3. Número de motor
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
O modelo A, o número do motor B e os dados de po- A placa do fabricante C encontra-se fixada ao O número do motor encontra-se gravado no cárter
no tência encontram-se gravados na placa do fabri-
cante. Quando da aquisição de peças sobres-
cárter. e na placa do fabricante.
selentes deverão ser indicados o modelo e o

el número do motor.
tr
ru
ar
pl
© 2000 4 pt
Encomenda de peças sobressalentes
de
Dados necessários para a encomenda: en
Encomenda de peças
Para encomendar as peças originais DEUTZ é
necessário indicar os seguintes dados: sobressalentes fr
- Nº do motor Nº do motor es
Nº de
- Nº de identificação Num. peças Nº - ident. Observações Módulo pt
- Nº de peças
Organização dos documentos

it
- As figuras representativas das peças sobres- nl
salentes estão agrupadas pelos módulos do
motor. sv
- Os elementos comostos são aprentados na
vista de conjunto do motor. da
- O Nº de identifiçao 06/59 é formado a partir do
número do módulo (por ex. 06) e da posição
Posição
fn
(por ex. 59):
Explicação dos símbolos

no
-06- Número dos elemento (p.ex. 06) el
000 Algarismo de mudança (p.ex. 000)
tr
96 Número de página (p.ex. 96)
Indicação transversal referente à página

ru
94 de continuação (p.ex. 94)
ar
A Símbolo de ligação
- introduzir sempre, no mínímo, em pares
(p.ex. A-A, B-B, C-C etc.)
pl
5 pt © 2000
Service
de
en A saber, é a DEUTZ. Nº de encomenda: 0312 0806
fr Desde sempre que a DEUTZ é responsável por

progressos revolucionários na construção de
motores. Como fabricante de motores indepen-
es dente oferecemos em todo o mundo uma completa
paleta de motores a Diesel e a gás numa gama de
pt potência de 4 a 7.400 kW. Os nossos produtos são
perfeitamente cortados à medida exacta das
exigências dos nossos clientes.
it Em todo o mundo mais de 1,4 milhões de motores
DEUTZ executam o seu serviço com segurança.
nl Queremos conservar a disponibilidade de aplicação
dos nossos motores e com ela a satisfação dos
sv nossos clientes. É por isso que estamos
representados em todo o mundo com uma rede de
associados competentes cuja consistência corresponde
da à distribuição regional dos nossos motores.
Deste modo, DEUTZ é não só o nome de motores com

fn espírito inventivo, como também de um completo
conjunto de serviços relacionados com o motor e de Nº de encomenda: 0312 0807 (CD-ROM)
no uma assistência técnica na qual você pode confiar.
O catálogo Sales & Service oferece-lhe um

el panorama sobre o associado da DEUTZ mais perto
de si, acerca das suas competências de produtos e A adquirir directamente no seu serviço de DEUTZ AG
da prestação de assistência técnica. Mas também assistência técnica ou na: Deutz-Mülheimer Str. 147-149
tr quando não se observa nenhuma competência
directa de produtos, o associado da DEUTZ continua
D-51057 Köln
ru a ajudá-lo com um aconselhamento competente. Telefone: 0049-221-822-0

Fax: 0049-221-822-5304
O catálogo é permanentemente actualizado; peça Telex: 8812-0 khd d
ar ao seu associado da DEUTZ a edição mais recente. http://www.deutz.de
A sua Deutz AG
pl
© 2000 6 pt
2011
Timbro del concessionario
0297 9934
Numero del
motore:
Voglia annotare qui il numero del motore. In questo

modo faciliterà il disbrigo in caso di questioni
relative all’assistenza tecnica, alla riparazione ed
ai pezzi di ricambio.
Rispetto all’illustrazione ed alle indicazioni di

questa lista dei pezzi di ricambio, ci si riserva
quelle modifiche tecniche che sono necessarie
per migliorare i motori. Per la ristampa e la
riproduzione di qualsiasi tipo è necessaria la
nostra autorizzazione scritta.
1 it © 2000
© 2000
Rechts 1
Prefazione
de
en Egregio cliente, I componenti elencati in questa lista di pezzi di
ricambio devono essere utilizzati soltanto per la
fr i motori DEUTZ raffreddati ad agua sono stati svi-
luppati per un ampio spettro d’uso. Grazie ad una
riparazione di motori Deutz della serie denominata
(uso conforme alla destinazione).
vasta offerta di varianti viene garantito che verrà Il libretto di istruzioni (lavori di manutenzione) ed
es fatto fronte alle rispettive esigenze particolari. il manuale per officine (lavori di riparazione)
forniranno delucidazioni dettagliate sul montaggio
pt Il Suo motore è allestito secondo lo specifico caso
di montaggio, vale a dire che non tutti gli elementi
corretto dei pezzi di ricambio. Il fabbricante non si
assume nessuna responsabilità per danni o lesioni
ed i componenti illustrati nel Suo listino dei pezzi di a persone dovuti all’inosservanza delle relative
it ricambio sono integrati nel Suo motore. istruzioni.
Nonostante i grafici non siano illustrati con tutti i

nl dettagli, si possono distinguere chiaramente le
singole varianti, così che è facile trovare con facilità
sv il pezzo di ricam-bio importante per il Suo motore.
In ogni caso verrà rilevato il pezzo di ricambio
giusto tramite numero di posizione, di gruppo di
da assemblaggio e di motore.
Per l’ordinazione di pezzi di ricambio voglia osserva-

fn re le nostre indicazioni per l’ordinazione al fine di
permetterci di fornirle in modo celere e sicuro i
no pezzi di ricambio necessari nella relativa versione,
conforme all’ultima modifica.
el Siamo a Vs. completa disposizione per eventuali

chiarimenti.
tr Sua
ru DEUTZ AG
ar
pl
© 2000 2 it
2 Links
Prefazione
de
I motori Diesel DEUTZ I pezzi di ricambio DEUTZ Componenti intercambiali DEUTZ en
fr
sono il prodotto di numerosi anni di ricerca e sono soggetti alle stesse severe esigenze quali- I componenti intercambiabili DEUTZ
sviluppo. Il solido know how così ottenuto in
combinazione con elevate esigenze qualitative è la
tative poste ai motori DEUTZ. I perfezionamenti
atti a migliorare i motori vengono naturalmente
sono un’alternativa economica ai
pezzi di ricambio originali.
es
garanzia per la fabbricazione di motori aventi
lunga durata, elevata affidabilità ed un basso
introdotti anche per i pezzi di ricambio originali.
Soltanto l’uso di pezzi di ricambio originali, fab-
Naturalmente anche qui, come per i
pezzi nuovi, valgono massimi criteri pt
consumo di combustibile. E’naturale che si faccia bricati secondo le più attuali conoscenze, offre la qualitativi. I componenti intercambiablili DEUTZ
fronte anche alle elevate esigenze a favore della
protezione ambientale.
garanzia di un perfetto funzionamento e di elevata
affidabilità.
sono equivalenti ai pezzi di ricambio per ciò che
concerne il loro funzionamento ed affidabilità.
it
nl
sv
da
SERVICE Prudenza con il motore acceso Ambianto
fn
In caso di avarie o richieste di ricambi, rivolgersi Eseguire i lavori di manutenzione o di riparazione Le guarnizioni utilizzate per questo
no
immediatamente ai nostri Centri di Assistenza solo con motore spento. Al termine dei lavori ri- motore sono senti da amianto.
autorizzati. Per non diminuire la sicurezza di
funzionamento, tutti i lavori devono essere
montare i dispositivi di sicurezza eventualmente
asportati. Per lavori da eseguire con il motore ac-
Per i lavori di manutenzione e di
riparazione fate uso degli appositi
el
effettuati da personale specializzato servendosi
dell’impiego di ricambi originali.
ceso, l’abbigliamento da lavoro deve aderire bene
al corpo. Fare rifornimento di combustibile solo
ricambi.
tr
con motore spento. Non lasciare il motore acceso
in locali chiusi – pericolo di avvelenamento. ru
ar
pl
3 it © 2000
Rechts 3
Descrizione del motore
de
en 1. Targhetta di fabbricazione 2. Posizione della targhetta di 3. Numero del motore
fr fabbricazione
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Il tipo di costruzione A, il numero del motore B ed La targhetta di fabbricazione C è fissata all’incastel- Il numero del motore è stampigliato sia
no i dati tecnici sono stampigliati sulla targhetta di
fabbricazione. Per l’acquisto di pezzi di ricambio,
latura. sull’incastellatura come pure sulla targhetta di
fabbricazione.
bisogna indicare il tipo di costruzione ed il numero
el del motore.
tr
ru
ar
pl
© 2000 4 it
4 Links
Ordinazione di pezzi di ricambio
de
Dati di ordinazione en
Ordinazione di pezzi
Per l’ordinazione di pezzi di ricambio originali
DEUTZ, indicare sempre i seguenti dati:
di ricambio fr
- No. del motore No. del motore: es
- Codice d’identificazione No. Cod.
- Unità
progr. Unitá d’identif. Note Gruppo construttivo pt
Struttura della docomentazione it
- Le tavole di questa lista dei pezzi di ricambio
sono suddivise secondo i gruppi costruttivi nl
dei motori
- Gli elementi costruttivi sono specificati nella

sv
vista panoramica del motore
- Il codice d’identificazione 06/59 è costituito dal

da
gruppo costruttivo (per es. 06) e dalla posizione
(per es. 59)
Posizione
fn
Legenda no
Numero dell’elemento costruttivo
-06- (ad esempio 06) el
000 Numero variabile (ad esempio 000)
Numero della pagina (ad esempio. 96)

tr
96
94
Riferimento incrociato alla pagina di ru
continuazione (ad esempio 94)
Simbolo di collegamento
ar
A - compare sempre almeno a coppie
(ad esempio A-A, B-B, C-C, ecc.) pl
5 it © 2000
Rechts 5
Service
DEUTZ: un nome che vuol dire eccellenza! No. d’ordine 0312 0806 10
DEUTZ, da sempre sinonimo di innovazione nel
settore della fabbricazione dei motori, è un
fabbricante indipendente che offre sul mercato
mondiale una gamma completa di motori diesel ed
a gas di potenza compresa fra 4 e 7400 kW. Noi
forniamo prodotti perfettamente adatti alle
specifiche esigenze dei nostri clienti.
Oggi, più di 1,4 milioni di motori DEUTZ sono in

attività in tutto il mondo. Noi perseguiamo un
duplice obiettivo: garantire la massima affidabilità
dei nostri prodotti e garantire un elevato livello di
soddisfazione ai nostri clienti. Ecco perché
abbiamo istituito una rete mondiale di partner, la cui
densità è funzione diretta del numero di motori in
attività in ciascuna regione.
DEUTZ non è solamente un marchio innovatore di

motori, ma anche una gamma completa di servizi in
grado di accentuare le loro caratteristiche di affi-
dabilità ed un nome su cui potrete sempre contare.
Il registro Sales & Service vi fornisce una pano-

ramica dei partner DEUTZ più vicini, inclusa la
No. d’ordine 0312 0807 (CD-ROM)
gamma di servizi offerti e le famiglie di prodotti per
cui essi possono assicurarvi una manutenzione DEUTZ AG
specializzata. Qualora non potessero fornirvi un Deutz-Mülheimer Str. 147-149
aiuto diretto, potranno in ogni caso consigliarvi con D-51057 Köln
competenza.
Telefono: 0049-221-822-0
Il registro è sottoposta ad un regolare aggior- Reperibile attraverso il Vostro Partner Service Telefax: 0049-221-822-5304
namento. Se necessario, potrete ottenerne l‘edizione locale oppure presso la: Telex: 8812-0 khd d
più recente rivolgendovi al vostro partner DEUTZ. http://www.deutz.de
Il Vostro DEUTZ AG
Onderdelenlijst
2011
Stempel handelaar
0297 9934
Motornummer:
Geeft u hier a.u.b. het motornummer aan. De behan-

deling van klantenservice-, reparatie- en onderde-
lenkwesties wordt daardoor vereenvoudigd.
Wat de betreft de tekeningen en gegevens in deze

onderdelenlijst blijven technische veranderingen
die ter verbetering van de motoren noodzakelijk
worden, voorbehouden. Elke vorm van nadruk of
vermenigvuldiging, ook bij wijze van uittreksel,
mag uitsluitend met onze schriftelijke toestemming
plaatsvinden.
1 nl © 2000
© 2000
Rechts 1
Voorwoord
de
en Geachte klant, De constructiedelen in deze onderdelenlijst mogen
alleen worden gebruikt worden reparatie van Deutz
fr de vattengekoelde DEUTZ-motoren zijn ontwikkeld voor
een breed spectrum aan toepassingsmogelijkheden.
motoren uit de vermelde bouwserie (gebruik
volgens de voorschriften).
Daarbij wordt door een uitgebreid aanbod variaties Uitvoerige informatie over de correcte inbouw van
es gewaarborgd, dat steeds kan worden voldaan aan
de desbetreffende speciale vereisten.
onderdelen is te vinden in de gebruiksaanwijzing
(onderhoudswerkzaamheden) en de
pt Uw motor is voor de individuele inbouwsituatie uit-
werkplaatshandleiding (reparaties). Voor schade
of persoonlijk letsel dat te wijten is aan niet-
gerust. Dat wil zeggen dat niet alle onderdelen uit de naleving van de desbetreffende voorschriften, is de
it lijst en niet alle componenten voor uw motor van
toepassing zijn.
fabrikant niet aansprakelijk.
nl Hoewel de grafieken niet met alle details weeggege-

ven zijn, kunnen de verschillende uitvoeringen
sv duidelijk onderscheiden worden, zodat u het voor uw
motor rele-vante onderdeel gemakkelijk kunt vinden.
Via positie-, constructie- en motornummer wordt
da in ieder geval het juiste onderdeel bepaald.
Let u bij de bestelling van onderdelen a.u.b. op

fn onze bestelgegevens. Dan kunnen wij u snel en
betrouwbaar de nodige onderdelen op de meest
no actuele stand in overeenstemming met de
uitvoering leveren.
el Voor nadere inlichtingen staan we U graag met

raad en daad terzijde.
tr Met vriendelijke groeten

ru DEUTZ AG
ar
pl
© 2000 2 nl
2 Links
Voorwoord
de
DEUTZ-Dieselmotoren DEUTZ Onderdelen DEUTZ tweedehands componenten
en
fr
zijn het produkt van vele jaren research en enginee- ondergaan dezelfde strenge kwaliteitscontroles als Tweedehands DEUTZ componen-
ring. Het hierdoor gewonnen, gefundeerde know
how in verbinding met hoge kwaliteitseisen is de
de DEUTZ motoren. Nieuwe ontwikkelingen ter
verbetering van de motoren vinden natuurlijk ook
ten vormen een voordelig alter-
natief voor originele onderdelen.
es
garantie voor de vervaardiging van motoren met
een lange levensduur, hoge betrouwbaarheid en
hun neerslag bij vervangende DEUTZ onderdelen.
Alleen het gebruik van originele DEUTZ onderdelen
Natuurlijk gelden ook hier, net als
bij nieuwe onderdelen, zeer hoge kwaliteitsmaat- pt
een laag brandstofverbruik. Het is vanzelfsprekend die aan de nieuwste ontwikkelingen zijn aangepast, staven. Wat functie en betrouwbaarheid betreft, zijn
dat ook aan de hoge eisen met betrekking tot de
milieubescherming voldaan wordt.
garanderen een onberispelijke functie en een hoge
betrouwbaarheid.
tweedehands DEUTZ componenten gelijkwaardig
aan nieuwe onderdelen.
it
nl
sv
da
SERVICE Voorzichtig bij draaiende motor Asbest
fn
Wendt U zich bij berijfsstoringen en bij vragen om- Onderhoudswerkzaamheden en reparaties alleen De pakkingen in deze motor bevat-
no
trent reserveonderdelen tot een van onze Service- bij uitgeschakelde motor doorvoeren. Eventueel ten geen asbest. Gebruikt u bij
vertegenwoordigingen. Ons geschoold vakperso-
neel zorgt in geval van defecten voor snelle en
verwijderde beschermplaten enz. moeten na de
werkzaamheden weer gemonteerd worden. Bij
onderhouds en reparatiewerk-
zaamheden a.u.b. onderdelen van
el
vakkundige reparatie met originele onderdelen. werken aan de draaiende motor moet nauw slui-
tende werkkleding worden gedragen. Motor nooit
dezelfde kwaliteit.
tr
in gesloten ruimten laten lopen – vergiftigingsge-
vaar.
ru
ar
pl
3 nl © 2000
Rechts 3
Beschrijving van de motor
de
en 1. Firmaplaat 2. Plaat van de firmaplaat 3. Motornummer
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
De constructievorm A, het motornummer B en de De firmaplaat C is aangebracht aan de carter. Het motornummer is op de carter en op de firma-
no vermogensgegevens zijn op de firmaplaat
gestempeld. Bij bestelling van onderdelen moeten
plaat gestempeld.
constructieserie en motornummer worden aan-

el gegeven.
tr
ru
ar
pl
© 2000 4 nl
4 Links
Bestelling von onderdelen
de
Bestelgegevens en
Bestellen van
Bij bestelling van originele DEUTZ onderdelen
dienen de volgende gegevens verstrekt te worden: onderdelen fr
- motornummer Motornr.: es
- identificatienummer Nr. Stuks Ident.nr. Opmerking module pt
- aantal
it
Gebruiksaanwijzing voor documentatie
- De afbeeldingen in deze onderdelenlijst zijn
nl
geordend naar deelsamenstelling.
sv
- De constructiegroepen zijn in het overzicht van
de motoren vermeld.
da
- Het identificatienummer (bijv. 06/59) is
opgebouwd uit de deelsamenstelling (bijv. 06),
gevolgd door de positie (bijv. 59).
positic
fn
Verklaring van de symbolen
no
-06- Nummer van de constructiegroep (b.v. 06) el
000 Modificatie cijfer (b.v. 000)
tr
96 Paginanummer (b.v. 96)
Kruisverwijzing naar de volgende pagina

ru
94 (b.v. 94)
ar
A Anslutningssymbol
- verschijnt altijd ten minste paarsgewijs
(b.v. A-A, B-B, C-C etc.)
pl
5 nl © 2000
Rechts 5
Service
Te weten, het is DEUTZ. Bestelnr.: 0312 0806 10

nl Van oudsher staat Deutz in verband met baan-
brekende ontwikkelingen in de motorconstructie.
Als onafhankelijke motorenfabrikant bieden wij
wereldwijd een compleet assortiment van diesel-
en gas-motoren met een vermogen van 4 tot
7.400 kW aan. Onze producten zijn voortreffelijk op
de eisen van onze klanten afgestemd.
Wereldwijd verrichten meer dan 1,4 miljoen DEUTZ

motoren precies hun functie. Wij willen de
bedrijfsvaardigheid van onze motoren en daardoor
de tevredenheid van onze klanten bewaren. Om die
redenen zijn wij wereldwijd vertegenwoordigd met
een net van competente partners waarvan de
dichtheid met de regionale distributie van onze
motoren overeenstemt.
Zo is DEUTZ niet alleen de naam voor inventieve

motoren maar ook voor een compleet prestatie-
pakket omtrent de motor en een service waarop u
kunt vertrouwen.
Het register Sales & Service geeft u een overzicht

over de DEUTZ partners in uw buurt, over hun
product-competenties en serviceprestaties. Maar Bestelnr.: 0312 0807 (CD-ROM)
ook als er geen directe product-competentie is
vermeldt, helpt de DEUTZ partner u verder met een DEUTZ AG
competent advies. Deutz-Mülheimer Str. 147-149
D-51057 Köln
Het register wordt permanent geactualiseerd; Verkrijgbaar via uw competente servicepartner ter
vraag bij uw DEUTZ partner naar de meest recente plaatse of bij: Tel.: 0049-221-822-0
uitgave. Fax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
Uwe DEUTZ AG
Reservdelslista
2011
Närmaste DEUTZ-representant
0297 9934 sv
Motornumret:
För in motornumret här. Du underlättar härigenom

lösning av service-reparations- och reservdelsfrå-
gor.
Vi förbehållar oss rätt till förbättringar av motorerna

utan att därför ändra i denna reservdelslista. För ef-
tertryck och kopiering av något slag fordras vårt
skriftliga medgivande.
1 sv © 2000
© 2000
Rechts 1
Förord
de
en Bäste kund, De i denna reservdelslista upptagna komponenter
ska endast användas vid reparationer på Deutz-
fr DEUTZ vaterkylda motorer har utvecklats för ett
stort användningsområde. Därvid har genom
motorer av angiven typ.
Ur instuktionsboken framgår utförligt hur
många varianter säkerställts att olika speciella for- reservdelarna ska monteras. För motor- och
es dringar uppfylls. personskador som orsakas av felmontering
ansvaras ej.
pt Din motor är utrustad för motsvarande inbyggnad,
d v s alla i reservdelslistan upptagna komponenter
finns ej med på Din motor.
it Trots att alla detaljer inte framgår kan de olika vari-
anterna urskiljas så att delarna för Din motor lätt går
nl att hitta. Med komponentbild- och motornummer
får man i varje fall fram rätt reservdel.
sv Observera vid beställning av reservdelar våra anvis-
ningar så att dessa snabbt och säkert kan levereras
da i senaste utförande.
Vid förfrågningar står vi gärna förfogande.

fn
DEUTZ AG
no
el
tr
ru
ar
pl
© 2000 2 sv
2 Links
Förord
de
DEUTZ-dieselmotorer DEUTZ-reservdelar DEUTZ utbyteskomponenter en
fr
är produkter av årslånga forskningar och utveck- underkastas lika stränga kvalitetsfordringar som Deutz utbyteskomponenter är ett
lingar. Därigenom vunnet know how tillsammans
med höga kvalitetsfordringar är garanti för tillver-
DEUTZ-motorerna. Vidareutveckling för förbätt-
ring av motorerna görs naturligtvis också på ori-
prisvärt alternativ till original-
reservdelar. Här gäller självklart
es
kning av motorer med lång livslängd, hög tillförlit-
lighet och låg bränsleförbrukning. Självklart upp-
ginal reservdelar. Bara användning av de senaste
originalreservdelar garanterar rätt funktion och
öckså som för nya delar högsta
kvalitet. DEUTZ utbyteskomponen- pt
fylls också kraven på miljöskydd. hög tillförlitlighet. ter är i funktion och tillförlitlighet likvärdiga med
Deutz reservdelar. it
nl
sv
da
SERVICE Försiktighet vid motor som är igång Asbest
fn
Vänd er till en av våra servicerepresentanter vid Skötsel eller reparationer får bara utföras vid stilla- Tätningar som används i denna
no
störningar och reservdelsproblem. Vår specialutbil- stående motor. Montera ev borttagna skydd efter motor är asbestfria. Använd så-
dade personal reparerar snabbt och riktigt med
originalreservdelar vid behov.
avslutat arbete. Se vid arbete med motor som är
igång till att arbetskläder ej sitter löst.
dana reservdelar även vid under-
hålls- och reparationsåtgärder.
el
Tanka alltid vid stillastående motor. Kör aldrig mo-
tor i slutna rum – förgiftningsrisk. tr
ru
ar
pl
3 sv © 2000
Rechts 3
Motorbeskrivning
de
en 1. Typskylten 2. Typskyltens placering 3. Motornummer
fr
es
pt
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 1
fn
Typen A, motornumret B och motordata finns på Typskylten C är fäst på vevhuset. Motornumret är instämplat på vevhuset och på
no typskylten. Vid reservdelsbeställning måste typ och
motornummer anges.
typskylten.
el
tr
ru
ar
pl
© 2000 4 sv
4 Links
Beställning av reservdelar
de
Beställningsuppgifter en
För beställning av DEUTZ original reservdelar krävs
följande uppgifter:
Reservdelsbeställning fr
- Motor-nr. Motornr.: es
- Id-nr. Löpnr. Aantal Id-nr. Anmärkning Funktionsgrupp pt
- Antal
it
Dokumentationens uppbyggnad
nl
- Illustrationerna i denna reservdelslista är
sorterade enligt motorns funktionsgrupper. sv
- Konstruktionsgrupperna kommer fram i motor-
listan. da
- Id-numret 06/59 består av funktionsgrupp
(t.ex. 06) och position (t.ex.59).
Position
fn
Symbolerförklaring
no
-06- Konstruktionsgruppnummer (t.ex. 06) el
000 Förändringsnummer (t.ex. 000)
tr
96 Sidnummer (t.ex. 96)
Korsreferens på fortsättningssidan
ru
94 (t.ex. 94)
ar
A Anslutningssymbol
- kommer alltid fram parvis
(t.ex. A-A, B-B, C-C, o.s.v.)
pl
5 sv © 2000
Rechts 5
Service
Att veta, det är DEUTZ. 10

Sedan länge står DEUTZ för banbrytande Beställningsnr: 0312 0806
utveckling inom motorkonstruktion. Som
oberoende tillverkare av motorer erbjuder vi ett
komplett urval av diesel- och gasmotorer inom ett
effektområde på 4 till 7 400 kW över hela världen.
Våra produkter är perfekt anpassade efter våra
kunders krav.
I hela världen gör fler än 1,4 miljoner motorer från

DEUTZ sin trogna tjänst. Vi vill behålla våra
motorers användningsberedskap och därmed
våra kunders belåtenhet. Därför representeras vi
över hela världen via ett nät av kompetenta
partners, så tätt att det motsvarar den regionala
spridningen av våra motorer.
På så vis är DEUTZ inte bara namnet på motorer

med uppfinningslust. Utan även för ett komplett
tjänstepaket runt om hela motorn och en service
som går att lita på.
Registret Sales & Service erbjuder en överblick

över DEUTZ partners i din egen närhet, över deras
produktansvar och servicetjänster. Men även om
inget direkt produktansvar finns, så hjälper DEUTZ Beställningsnr: 0312 0807 (CD-ROM)
partner till med kompetent rådgivning.
Registret uppdateras ständigt; fråga din DEUTZ Kan beställas hos er lokala Deutz-partner eller hos: DEUTZ AG
partner efter den senaste versionen. Deutz-Mülheimer Str. 147-149
D-51057 Köln
Ihre DEUTZ AG Telefon: 0049-221-822-0

Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
Reservedelsliste
2011
Forhandlerens stempel
0297 9934
Motornummer:
Notér motornummeret her. Derved lettes afvik-

lingen i forbindelse med serviceværksted, repara-
tion og bestilling af reservedele.
Ret til tekniske ændringer, som bliver nødvendige til

forbedring af motorerne, forbeholdes. Eftertryk og
mangfoldiggørelse af enhver art, også i uddrag, kun
tilladt med vores skriftlige samtykke.
1 da © 2000
© 2000
Forord
de
en Kære kunde! De i denne reservedelsliste angivne komponenter
må kun anvendes til reparation af Deutz motorer i
fr De væskekølede motorer fra firmaet DEUTZ er udvik-
let til et bredt anvendelsesspektrum. Derved sikres
den anførte serie (formålsrelevant anvendelse).
Detaljer vedrørende den korrekte montering af
det på grund af det omfattende udbud af varianter, reservedele fremgår af instruktionsbogen (service)
es at de indivi-duelle specielle krav kan opfyldes. samt værkstedshåndbogen (reparation). Produ-
centen påtager sig intet ansvar for skader på
pt Deres motor er udstyret, så den svarer til brugstil-
fældet; d.v.s. at ikke alle elementer og komponenter,
personer eller ting som følge af, at bestemmelserne
i den relavante vejledning ikke er overholdt.
som er afbildet i denne reservedelsliste, er monteret
it på Deres motor.
Selv om de grafiske afbildninger ikke kan vises med

nl alle detaljer, kan man tydeligt se forskel på de enkelte
varianter, så De let kan finde de reservedele, som er
sv relevante til Deres motor. Ved hjælp of positions-,
type- og motornummeret kan man altid finde frem
til den rigtige reservedel.
da Første gang De bestiller reservedele, bedes De
bemærke vore bestillingshenvisninger, så vi hurtigt
fn og korrekt kan finde frem til de nødvendige reserve-
dele i den udfø-relse, som svarer til den nyeste
no ændringstilstand.
Vi står gerne til rådighed, hvis De har spørgsmål.

el
Deres
tr DEUTZ AG
ru
ar
pl
© 2000 2 da
Forord
de
DEUTZ-dieselmotorer Original dele DEUTZ udskiftningskomponenter en
fr
er produktet af mange års forskning og udvikling. underligger de samme strenge kvalitetskrav som DEUTZ-udskiftningskomponenter
Det velunderbyggede knowhow, vi dermed har vun-
det, i forbindelse med høje kvalitetskrav er Deres
DEUTZ-motorerne. Videreudviklinger til forbedring
af motorerne bliver naturligvis også anvendt ved
er et prisbilligt alternativ til origi-
nale dele. Selvfølgelig gælder
es
garanti for en produktion af motorer med lang leve-
tid, høj pålidelighed og lavt brændstofforbrug. Det
original dele. Kun hvis man anvender originale
dele, som er udfærdiget efter de nyeste erkendels-
også her de højeste kvalitetskrav
– som ved de nye dele. DEUTZ- pt
er en selvfølge, at de høje krav mht. beskyttelsen af er, har man sikkerhed for en upåklagelig funktion udskiftningskomponenter fungerer lige så godt
miljøet også opfyldes. og høj pålidelighed. og er lige så pålidelige som originale dele. it
nl
sv
da
SERVICE Forsigtig, når motoren løber Asbest
fn
I tilfælde af driftsforstyrrelser og ved reservedels- Vedligeholdelsesarbejder og reparationer må kun Pakningerne, som er anvendt til
no
spørgsmål kan De henvende Dem til en af vores an- gennemføres, når motoren er slået fra. Evt. fjernede denne motor, er asbestfrie. An-
svarlige service-repræsentationer. Vores skolede
fagpersonale sørger i tilfælde af skader for en hurtig
beskyttelsesanordninger skal atter monteres på,
når arbejderne er afsluttet. Ved arbejder med løb-
vend venligst ved vedligehol-
delses- og reparationsarbejde
el
og faglig korrekt istandsættelse under anvendelse
af originale dele.
ende motor må man ikke bære løsthængende tøj.
Der må kun fyldes brændstof på med motoren slået
tilsvarende reservedele.
tr
fra. Lad aldrig motoren løbe i lukkede rum – fare for
forgiftning. ru
ar
pl
3 da © 2000
Motorbeskrivelse
de
en 1. Firmenskilt 2. Firmaskiltets placering 3. Motornummer
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Typen A, motornummeret B og ydelsesdataene er Firmaskiltet C er fastgjort på krumtaphuset. Motornummeret er stemplet ind på krumtaphuset
no stemplet ind på firmaskiltet.
Ved bestilling af reservedele skal man angive type
og på firmaskiltet.
og motornummer.
el
tr
ru
ar
pl
© 2000 4 da
Bestillingsangivelser
de
Bestillingsangivelser en
Ved bestillingen af originale DEUTZ-dele er det
nødvendigt med følgende angivelser:
Bestillingsangivelser fr
- motor-nr. Motor-nr.: es
- ident.-nr lb. nr. antal ident.-nr. anmærkning komponent pt
- antal
it
Dokumentationens opbygning nl
- Billederne i denne reservedelsliste er sorteret
efter motor-komponenter. sv
- Delmontagerne findes i motoroversigten.
da
- Ident-nr. 06/59 er opbygget af komponent
(f.eks. 06) og position (f.eks. 59).
position
fn
Symbolforklaring
no
-06- delmontagenummer (f.eks. 06) el
000 ændringsciffer (f.eks. 000)
tr
96 sidenummer (f.eks. 96)
krydshenvisning til næste side

ru
94 (f.eks. 94)
ar
A tilslutningssymbol
- optræder altid mindst parvis
(f.eks. A-A, B-B, C-C osv.) pl
5 da © 2000
Service
de
en Man ved, det er DEUTZ. Bestillings-nr.: 0312 0806
fr Fra tidernes morgen har DEUTZ været

ensbetydende med banebrydende udviklinger
inden for fremstillingen af motorer. Som uafhængig
es motorfabrikant tilbyder vi over hele verden et
komplet spektrum af diesel- og gasmotorer med en
pt effekt på 4 til 7.400 kW. Vore produkter er perfekt
skræddersyet efter vore kunders behov.
it Over hele verden udretter mere end 1,4 millioner

DEUTZ-motorer deres arbejde til alles tilfredshed.
Vi ønsker at bevare vore motorers
nl anvendelsesberedskab og dermed også vore
kunders tilfredshed. Derfor er vi over hele verden
sv repræsenteret af et helt net af kompetente partnere,
hvis tæthed svarer til vore motorers regionale
fordeling.
da Således er DEUTZ ikke kun navnet på motorer til
stadig nye opgaver, men også på en komplet
fn servicepakke med hensyn til alt, hvad der har med
motorer at gøre, og med en service, De kan stole på. Bestillings-nr.: 0312 0807 (CD-ROM)
no Registret Sales & Service giver Dem et overblik
over DEUTZ-partnerne i Deres egn, over disses
el produkt-kompetancer og service-ydelser. Men
selvom der ikke direkte er angivet nogen produkt- Kan købes over Deres ansvarlige service-partner på DEUTZ AG
kompetance, hjælper DEUTZ-partneren Dem videre stedet eller over: Deutz-Mülheimer Str. 147-149
tr med en kompetent rådgivning. D-51057 Köln
ru Registret bliver hele tiden aktualiseret; bed Deres

DEUTZ-partner om den nyeste udgave.
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
ar Deres DEUTZ AG
http://www.deutz.de
pl
© 2000 6 da
Varaosaluettelo
2011
Liikkeen leima
0297 9934
Mottorinumero:
Merkitse tähän moottorinumero. Sen ilmoittaminen

helpottaa asioiden käsittelyä huolto-, korjaus- ja
varaosakysymyksien yhteydessä.
Tämän varaosaluettelon kuvauksien ja tietojen suh-

teen pidätämme oikeuden muutoksiin, jotka ovat
tarpeellisia moottorin teknisen kehityksen kannalta.
Kaikenlaiseen jälkipainosten ja kopioiden tekoon,
myös osittain, tarvitaan kirjallinen lupamme.
1 fn © 2000
© 2000
Rechts 1
Esipuhe
de
en Hyvä asiakas Tässä varaosaluettelossa lueteltuja komponentteja
tulee käyttää vain ilmoitetun tyyppisten Deutz-
fr Ilmajäähdytteiset DEUTZ-moottorit on kehitetty
laajaa käyttäjäkuntaa silmälläpitäen. Niinpä tarjolla
moottoreiden korjaustöissä (käyttötarkoituksen
mukainen käyttö).
on laaja valikoima moottorivaihtoehtoja, jotka Käyttöohjeesta (kohdasta Huoltotyöt) ja
es täyttävät asiakkaiden vaihtelevat moottoritarpeet. korjaamokäsikirjasta (kohdasta Korjaustyöt) käy
yksityiskohtaisesti ilmi, kuinka varasoat
pt Moottorinne on toimitettu tietyin varustein, eivätkä
kaikki tässä varaosaluettelossa esiintyvät osat vält-
asennetaan asianmukaisesti. Valmistaja ei vastaa
vahingoista tai henkilöiden loukkaantumisista,
tämättä kuulu moottorinne varusteisiin. jotka johtuvat siitä, että vastaavaa ohjetta ei ole
it Vaikka kaaviokuvat eivät sisällä kaikkia yksityiskoh-
noudatettu.
tia, eri vaihtoehdot on kuitenkin helppo erottaa toi-

nl sistaan moottorillenne tärkeiden varaosien tunni-
stamiseksi. Positio, rakenneryhmä- ja moottorinu-
sv meron avulla pystytään joka tapauksessa toimitta-
maan oikea varaosa.
da Varaosia tilattessa on noudatettava annettuja tilau-

sohjeita, jotta pystymme nopeasti ja varmasti toimit-
tamaan tarvittavat, kyseisen mallin viimeisintä tek-
fn nistä kehitystä vastaavat varaosat.
no Annamme mielellään lisätietoja ja vastaamme

kysymyksiinne
el DEUTZ AG
tr
ru
ar
pl
© 2000 2 fn
2 Links
Esipuhe
de
DEUTZ dieselmoottorit DEUTZ varaosat DEUTZ vaihto-osat en
fr
ovat monien vuosien tutkimuksen ja kehittelyn tu- täyttävät samat, tiukat laatuvaatimukset kuin DEUTZ-vaihto-osat ovat edullinen
los. Näin saavutettu know-how yhdistyneenä kor-
keisiin laatuvaatimuksiin on tae pitkäikäisten, luo-
DEUTZ-moottoritkin. Moottorien parantamiseen
käytettyä kehitystä sovelletaan myös DEUTZ
vaihtoehto alkuperäisille DEUTZ
varaosille.
es
tettavien ja vähän polttoainetta kuluttavien mootto-
reiden valmistukselle. On itsestään selvää, että
varaosiin. Moitteeton toiminta ja luotettavuus on
taattu käyttämällä ainoastaan viimeisimmän teknii-
On myös itsestään selvää, että
näille osille asetetaan samat kor- pt
myös tarkat ympäristön suojelua koskevat mää- kan mukaan valmistettuja alkuperäisiä DEUTZ keat laatuvaatimukset kuin uusille osillekin. Toi-
räykset on otettu huomioon. varaosia. minnaltaan ja luotettavuudeltaan DEUTZ vaihto-
osat ovat samanarvoisia DEUTZ varaosien kanssa.
it
nl
sv
da
SERVICE Varo moottorin käydessä Asbesti
fn
Käyntihäiriöissä ja varaosakysymyksissä käänty- Huolto- tai korjaustyöt saa suorittaa ainoastaan Tässä moottorissa käytetyissä tii-
no
kää DEUTZ-edustajanne puoleen. Vauriotapauk- moottorin ollessa pysäytettynä. Mahdollisesti irro- visteissä ei ole asbestia.
sessa koulutettu henkilökunta huolehtii nopeasta ja
asianmukaisesta korjauksesta käyttämällä DEUTZ-
tetut suojalaitteet on asennettava töiden päätyttyä
jälleen paikoilleen. Huollettaessa käyvää moottoria
Huolto- ja korjaustöissä pyy-
dämme käyttämään vastaavia va-
el
osia. työvaatetus ei saa olla liian väljä. Moottori on py-
säytettävä tankkauksen ajaksi. Moottoria ei saa
raosia.
tr
koskaan käyttää suljetuissa tiloissa – myrkytys-
vaara. ru
ar
pl
3 fn © 2000
Rechts 3
Moottorin kuvaus
de
en 1. Tyyppikilpi 2. Tyyppikilven paikka 3. Moottorinumero
fr
es
pt
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Moottorimalli A, moottorinumero B ja tehoarvot on Tyyppikilpi C on kiinnitetty kampikammioon. Moottorinumero on stanssattu sekä kampikam-
no stanssattu tyyppikilpeen.
Varaosia tilattaessa on moottorimalli ja moottorinu-
mioon että tyyppikilpeen.
mero ilmoitettava tilauksen vastaanottajalle.

el
tr
ru
ar
pl
© 2000 4 fn
4 Links
Varaosatilaus
de
Tilaustiedot en
Alkuperäisten DEUTZ-varaosien tilauksen
yhteydessä on ilmoitettava seuraavat tiedot:
Varaosatilaus fr
- moottori-nro Moottori-nro: es
- ident.-nro Jks.nro Kpl Ident.-nro Huomautus Rakenneryhmä pt
- kappalemäärä
it
Dokumentaation rakenne
- Tämän varaosaluettelon kuvat on ryhmitelty
nl
moottorin rakenneryhmien mukaan.
sv
- Rakenneryhmät käyvät selville moottorin
listasta.
da
- Identifioimis- eli tunnistusnumero 06/59
koostuu rakenneryhmästä (esim. 06) ja
osanumerosta (esim. 59).
Osanumero
fn
Symbooliselvitys
no
-06- Rakennerymänumero (esim. 06) el
000 Muutosnumero (esim. 000)
tr
96 Sivunumero (esim. 96)
Ristivittaus jatkosivulla
ru
94 (esim. 94)
ar
A Liitäntäsymbooli
- ilmenee aina vähintään parittain
(esim. A-A, B-B, C-C, j.n.e.)
pl
5 fn © 2000
Rechts 5
Service
de
en Hyvä tietää, se on DEUTZ. Tilaus-nro: 0312 0806
fr DEUTZ on edustanut jo ammoisista ajoista saakka

uraauurtaavia uudistuksia moottorinrakennus-
alalla. Puolueettomana moottorinvalmistajana tarjo-
es amme ympäri maailmaa kokonaisen valikoiman
diesel- ja kaasumoottoreita, joiden suorituskyky
pt vaihtelee välillä 4 - 7.400 kW. Tuotteemme on
sovitettu täydellisesti asiakkaittemme vaatimusten
mukaan.
it Yli 1,4 miljoonaa DEUTZ-moottoria täyttää
ympäri maailmaa luotettavasti tehtävänsä.
nl Tarkoituksenamme on säilyttää moottoreidemme
käyttövalmius ja täten asiakkaittemme
sv tyytyväisyys. Tästä syystä olemme edustettuina
ympäri maailmaa asiantuntevien edustajien
muodostamalla verkolla, jonka tiheys vastaa
da moottoreidemme alueellista levinneisyyttä.
DEUTZ-nimi ei merkitse näin vain keksijähenkisiä

fn moottoreita. Vaan myös kokonaista moottoreihin
liittyvää suorituspakettia ja palvelua, johon voit Tilaus-nro: 0312 0807 (CD-ROM)
no luottaa.
Sales & Service -rekisteri antaa yleiskuvan lähelläsi

el olevista DEUTZ-edustajista, heidän edustamistaan
tuotteista ja palveluista. Ja vaikka yksilöllistä tuote- Voit tilata paikallisesta sopimushuoltoliikkeestä DEUTZ AG
edustusta ei olisikaan mainittu, DEUTZ-edustaja tai osoitteesta: Deutz-Mülheimer Str. 147-149
tr auttaa sinua eteenpäin asiantuntevalla neuvon-
nalla.
D-51057 Köln
ru Rekisteriä päivitetään jatkuvasti: tiedustele DEUTZ-

Puh.: 0049-221-822-0
Telefax: 0049-221-822-5304
edustajaltasi uusinta painosta. Telex: 8812-0 khd d
ar http://www.deutz.de
DEUTZ AG
pl
© 2000 6 fn
6 Links
Reservedelsliste
2011
Forhandlerstempel
0297 9934
Motornummer:
Vennligst skriv op motornummeret her. Dette gjør

behandlingen av spørsmål angående service,
reparasjoner og reservedeler enklere.
Vi forbeholder oss tekniske foranderinger i våre

beskrivelser og opplysninger i denne instruksjons-
boka som er nødvendig for forbedring av motorene.
Ettertrykk og kopiering på enhver måte, også delvis,
må ikke gjøres uten vår skriftlige tillatelse.
1 no © 2000
© 2000
Allment
de
en Kjære kunde, Komponenter som er oppført på denne reser-
vedeslisten, er bare beregnet til reparasjon av
fr Væskekølte motorer av merket DEUTZ er utviklet
med tanke på mange forskjellige bruksområder.
DEUTZ motorer som tilhører de serier som er
angitt (forskriftsmessig bruk).
Et bredt spekter av varianter sikrer at mange Fagmessig innmontering av reservedeler er utførlig
es forskjellige spesielle krav kan oppfylles. beskrevet i instruksjonsboken (vedlikeholdsarbeid)
og verkstedshåndboken (reparasjonsarbeid).
pt Din motor er utstyrt for det aktuelle bruksområde.
Derfor vil ikke alle deler og komponenter som er
Produsenten påtar seg ikke ansvar for materielle
skader eller personskader som skyldes at de
oppført på denne reservedelslisten, være montert relevante anvisningene ikke har blitt fulgt.
it på din motor.
Selv om bildene ikke alltid viser alle detaljer, kan

nl de enkelte variantene tydelig skilles fra hverandre
slik at det er lett å finne frem til de relevante
sv reservedelene til din motor. Ved hjelp av
posisjonsnummer, komponentgruppenummer
og motornummer kan du i hvert enkelt tilfelle finne
da frem til riktig reservedel.
Vi ber deg vennligst følge våre anvisninger ved

fn bestilling av reservedeler slik at vi kan levere de
reservedelene du har bruk for, raskt og sikkert og
no ifølge de seneste endringer.
Vi står gjerne til din disposisjon hvis du har

el ytterligere spørsmål.
Vennlig hilsen
tr DEUTZ AG
ru
ar
pl
© 2000 2 no
Allment
de
DEUTZ-Dieselmotoren Originaldeler DEUTZ byttekomponenter en
fr
er resulotatet av mangeårig forskning og utvikling. er underkastet strenge kvalitetskrav på linje med DEUTZ byttekomponenter er et
Et omfattende know-how i forbindelse med høye
kvalitetskrav er garantien for fremstillingen av
DEUTZ motorer. Videreutvikling for å forbedre
våre motorer blir selvfølgelig fulgt opp med for-
billig alternativ til originaldeler.
Selvfølgelig gjelder også her de
es
motorer med lang levetid, stor pålitelighet og lavt
drivstofforbruk Det er en selvfølge at de store
bedringer på originaldeler. Bruk derfor bare ori-
ginaldeler som er fremstilt etter de nyeste erfarin-
høyeste kvalitetskrav på samme
måte som for nye deler. Når det pt
kravene når det gjelder miljøvern, blir oppfylt. ger for å være sikker på feilfri funksjon og høy gjelder funksjon og pålitelighet, er DEUTZ bytte-
pålitelighet. komponenter likeverdige med originaldeler „O“. it
nl
sv
da
SERVICE Vær forsiktig med motor i drift! Asbest
fn
Ta kontakt med en av våre ansvarlige service- Vedlikeholdsarbeid og reparasjoner skal bare Pakningene som benyttes i denne
no
representanter ved driftsforstyrrelser og spørsmål utføres med avslått motor. Vær sikker på at motoren motoren, er asbestfrie. Bruk reserve-
angående reservedeler. Vårt utdannete fagpersonal
sørger for rask og fagmessig reparasjon med
ikke kan starte uten oppsikt. Fare for ulykker!
Monter eventuelt fjernete beskyttelsesanordninger
deler uten asbest ved vedlike-
holds- og reparasjonsarbeid.
el
DEUTZ orignaldeler. på igjen etter avsluttet arbeid.
Tank bare med avslått motor. tr
Ta hensyn til arbeidsbeskyttelsesbestemmelsene
ved motordrift i lukkete rom eller ved arbeid under
jorda.
ru
ar
pl
3 no © 2000
Motorbeskrivekse
de
en 1. Firmaskilt 2. Firmaskiltets plassering 3. Motornummer
fr
es C
pt A B
it
nl
sv
da © 26 332 2 © 31 864 0 © 31 865 0
fn
Type A, motornummer B samt tytelsesdata er Firmaskiltet C er festet på veivhuset. Motornummer er stemplet inn både veivhuset og
no stemplet inn på firmaskiltet.
Type og motornummer må angis når reservedeler
på firmaskiltet.
bestilles.
el
tr
ru
ar
pl
© 2000 4 no
de
Bestillingsangivelser en
Bestilling av
Ved bestilling av originale DEUTZ deler er følgende
angivelser nødvendig. reservedeler fr
- Motor-nr. Motor-nr.: es
- Ident-nr. Nr. Stykk Ident.nr. Anmärkning Konstrukstionsgruppe pt
- Stykktall
it
Dokumentasjonsoversikt nl
- Illustrasjonene i denne reservedelslisten er
sortert etter motor-konstruksjonsgruppe. sv
- Delegruppen vises på motortegningen.
da
- Ident-nr. 06/59 består av konstruksjonsgruppe
(f.eks 06) og posisjon (f.eks 59)
Posisjon
fn
Symbolforklaring
no
-06- Delenummer (f.eks. 06) el
000 Endringnummer (f.eks. 000)
tr
96 Sidenummer (f.eks. 96)
Kryssreferanse på fortsettelsessiden.
ru
94 (f.eks. 94)
ar
A Koblingssymbol
- Føres alltid opp parvis
(f.eks. A-A, B-B, C-C osv.)
pl
5 no © 2000
Service
de
en Å vite at det er Deutz Bestillings-nr.: 0312 0806
fr Deutz har alltid stått for en banebrytende utvikling

av motorer. Som uavhengig motorprodusent tilbyr
vi verden over et komplett utvalg av diesel- og
es gassmotorer med en effekt på 4 til 7.400 kW. Våre
produkter er perfekt tilpasset våre kunders krav.
pt Verden over arbeider mer enn 1,4 millioner DEUTZ
motorer pålitelig. Vi vil sørge for å opprettholde
it motorenes driftsklarhet og dermed våre kunders
tilfredshet. Derfor er vi verden over representert
med et nett av kompetente partnere som er tilpasset
nl den regionale fordelingen av våre motorer.
sv DEUTZ er dermed ikke bare et navn for innfalsrike

motorer, men også for en komplett pakke med
ytelser for alt som har med motorer å gjøre og for
da en service du kan stole på.
Registeret Sales & Service gir deg en oversikt over

fn DEUTZ partnere i din nærhet, over deres produkt-
kompetanse og service-ytelser, Og selv om en Bestillings-nr.: 0312 0807 (CD-ROM)
no direkte produkt-kompetanse ikke er merket av,
hjelper DEUTZ-partneren deg med kompetente råd.
el Registeret blir permanent aktualisert; spør din

DEUTZ partner om nyeste versjon. Bestilles hos din lokale service-partner eller hos: DEUTZ AG
tr DEUTZ AG
D-51057 Köln
ru Telefon:
Telefax:
0049-221-822-0
0049-221-822-5304
Telex: 8812-0 khd d
pl
© 2000 6 no
2011
™ÊÚ·Á›‰· ÙÔ˘ ÂÌfiÚÔ˘
0297 9934
∞ÚÈıÌfi˜
ÎÈÓËÙ‹Ú·:
™ËÌÂÈÒÛÙÂ Û·˜ ·Ú·Î·ÏÔ‡ÌÂ Â‰Ò ÙÔÓ ·ÚÈıÌfi ÙÛ˘

ÎÈÓËÙ‹Ú· Û·˜. ªÂ ÙÔÓ ÙÚfiÔ ·˘Ùfi ‰ÈÂ˘ÎÔÏ‡ÓÂÙÂ ÙËÓ
ÂÍ¤ÏÈÍË ÙˆÓ ‰È·‰ÈÎ·ÛÈÒÓ ÂÍ˘ËÚ¤ÙËÛË˜ ÂÏ·ÙÂ›·˜,
ÂÈ‰ÈÔÚıÒÛÂˆÓ Î·È ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ.
¢È·ÙËÚÔ‡ÌÂ ÙÔ ‰ÈÎ·›ˆÌ·, Ó· ÚÔ‚·›ÓÔ˘ÌÂ ÛÂ ÙÂ¯ÓÈÎ¤˜

·ÏÏ·Á¤˜ Â› ÙˆÓ ·ÂÈÎÔÓ›ÛÂˆÓ Î·È ÂÓ‰Â›ÍÂˆÓ ÙÔ˘
Î·Ù·ÏfiÁÔ˘ ·˘ÙÔ‡ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, ÂÊfiÛÔÓ ÔÈ ·ÏÏ·Á¤˜
·˘Ù¤˜ ·Ô‚Ï¤Ô˘Ó ÛÂ ‚ÂÏÙ›ˆÛË ÙˆÓ ÎÈÓËÙ‹ÚˆÓ.
∏ ·Ó·Ù‡ˆÛË Î·È Ë ·ÓÙÈÁÚ·Ê‹ Î¿ıÂ Â›‰Ô˘˜, ¤ÛÙˆ
Î·È Î·Ù¿ Ì¤Úo˜, Ùo˘ Î·Ù·ÏfiÁo˘ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
ÂÈÙÚ¤oÓÙ·È ÌfiÓo ÌÂÙ¿ ·fi ¤ÁÁÚ·ÊË ¤ÁÎÚÈÛ‹ Ì·˜.
1 el © 2000
© 2000
de
en ∞ÍÈfiÙÈÌÂ ÂÏ¿ÙË, ¶ÚÔÛ¤ÍÙÂ Û·˜ ·Ú·Î·ÏÔ‡ÌÂ Î·Ù¿ ÙËÓ T· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÓÔ ·Ó·Ê¤ÚÔÓÙ·È ÔÙÔÓ
·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ ÙÈ˜ Ô‰ËÁ›Â˜ Ì·˜, ·ÚfiÓÙ· Î·Ù¿ÏÔÁÔ Ú¤ÂÈ Ó· ¯ÚËÔÈÌÔÔÈÔ‡ÓÙ·È
fr ÔÈ ˘ÁÚfi„˘ÎÙÔÈ ÎÈÓËÙ‹ÚÂ˜ DEUTZ ÂÍÂÏ›¯ıËÛ·Ó
ÙÂ¯ÓÈÎ¿ ÁÈ· ÂÊ·ÚÌÔÁ‹ ÛÂ ¤Ó·Ó Â˘Ú‡ ÙÔÌ¤·
Ô˘ ¤¯Ô˘Ó Û¯¤ÛË ÌÂ ÙÈ˜ ·Ú·ÁÁÂÏ›Â˜ ·˘Ù¤˜,
ÚÔ˜ ÙÔ ÛÎÔfi fiˆ˜ Â›Ì·ÛÙÂ ÛÂ ı¤ÛË Ó·
ÌfiÓÔ ÁÈ· ÙËÓ ÂÈÔÎÂ˘‹ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ ˚fi‘ÒÒ ÙË˜
ÛÂÈÚ¿˜ ÌÔÓÙ¤ÏˆÓ ÔÙËÓ ÔÔãÈ ·Ó·Ê¤ÚÔÓÙ·È
ÂÊ·ÚÌÔÁÒÓ. ∫·Ù¿ ÙËÓ ÚÔÛ¿ıÂÈ¿ Ì·˜ ·˘Ù‹ Û·˜ Î¿ÓÔ˘ÌÂ Û‡ÓÙÔÌË Î·È ÂÌÈÛÙÂ˘ÙÈÎ‹ (¯Ú‹ÔË Û‡ÊˆÓ· ÌÂ ÙÔÓ ÚÔÔÚÈÔÌfi ÙÔ˘˜).
es ÂÍ·ÛÊ·Ï›ÛÙËÎÂ Ì¤Ûˆ Ì›·˜ ÔÏ˘ÏËıÔ‡˜
ÚÔÛÊÔÚ¿˜ Î·Ù·ÛÎÂ˘·ÛÙÈÎÒÓ ·Ú·ÏÏ·ÁÒÓ,
·Ú¿‰ÔÛË ÙˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Ô˘ ¯ÚÂÈ¿˙ÂÛÙÂ,
ÛÙËÓ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹ ·Ú·ÏÏ·Á‹, Ë ÔÔ›·
TÔ ·ˆÔÙfi ÌÔÓÙ¿ÚÈÛÌ· ÙˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
·˘ÙÒÓ ÂÚÈÁÚ¿ÊÂÙ·È ÂÈÔÙ·Ì¤Ó· ÔÙÈ˜ √‰ËÁãÈÂ˜
pt ÒÛÙÂ Ó· ÂÎÁËÚÒÓÔÓÙ·È fiÏÂ˜ ÔÈ ÂÈ‰ÈÎ¤˜
··ÈÙ‹ÛÂÈ˜ ÙˆÓ ÂÏ·ÙÒÓ Ì·˜.
·ÓÙ·ÔÎÚ›ÓÂÙ·È ÂÎ¿ÛÙÔÙÂ ÛÙËÓ ÙÂÏÂ˘Ù·›·
ÛÙ¿ıÌË ÌÂÙ·ÙÚÔÒÓ.
§ÂÈÙÔ˘ÚÁãÈ·˜ (ÎÂÊ¿Ï·È: ∂ÚÁ·ÔãÈÂ˜ ·˘ÓÙ‹ÚËÔË˜)
Î·È ÔÙÔ ÂÁ¯ÂÈÚãÈ‰ÈÔ Û¤Ú‚È˜ ÂÈÔÎÂ˘ÒÓ (ÎÂÊ¿Ï·È:
∂ÚÁ·ÔãÈÂ˜ ÂÙÈÔÎÂ˘Ë˜). √ Î·Ù·ÛÎÂ˘·ÔÙ‹˜
it √ ÎÈÓËÙ‹Ú·˜ Û·˜ ·˘Ùfi˜ Â›Ó·È ÂÊÔ‰È·ÛÌ¤ÓÔ˜
ÁÈ· ÂÊ·ÚÌÔÁ‹ ÙÔ˘ ÛÂ Ì›· ÂÈ‰ÈÎ‹ ÂÚ›ÙˆÛË,
µÚÈÛÎfiÌ·ÛÙÂ ¿ÓÙÔÙÂ ÛÙË ‰È¿ıÂÛ‹ Û·˜, ·Ó
¤¯ÂÙÂ ÂÚˆÙ‹Ì·Ù·, ÚÔÛÊ¤ÚÔÓÙ¿˜ Û·˜ Î·È ÙÈ˜
‰ÂÓ ¤¯ÂÈ Â˘ı‡ÓÂ˜ ÁÈ· ˙ËÌãÈÂ˜ ÛÂ ˘ÏÈÎfi Î·È
·Ù˘¯‹Ì·Ù· ÚÔÔˆÈÎÔ‡ ‹ ·Ó·ÏˆÙÒ/¯ÚËÔÙÒÓ,
Î·È ·˘Ùfi ÛËÌ·›ÓÂÈ fiÙÈ Ù· ÛÙÔÈ¯Â›· ÌË¯·ÓÒÓ, ·Ó·ÁÎ·›Â˜ Û˘Ì‚Ô˘ÏÂ˘ÙÈÎ¤˜ ˘ËÚÂÛ›Â˜. Ô˘ ÚÔ¤Ú¯ÔÓÙ·È ·fi ÙËÓ ÌË Ô˘ÌÌfiÚÊˆÔË ÚÔ˜
nl Ù· ÔÔ›· ÂÚÈÏ·Ì‚¿ÓÔÓÙ·È ÛÙÔÓ Î·Ù¿ÏÔÁÔ ·˘Ùfi
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Î·È Ù· ˘fiÏÔÈ· Û˘ÛÙ·ÙÈÎ¿ ∏ ÂÙ·ÈÚÂ›· Û·˜
ÙÈ˜ ·Ó¿ÏÔÁÂ˜ Ô‰Ë ÁãÈÂ˜.
sv ÌË¯·ÓÈÎ¿ ÛÙÛÈ¯Â›· ‰ÂÓ Â›Ó·È ÂÍ ÔÏÔÎÏ‹ÚÔ˘

ÂÊ·ÚÌÔÛÌ¤Ó· Î·È ÛÙÔÓ ÎÈÓËÙ‹Ú· Û·˜.
DEUTZ AG
da ∞Ó Î·È ÔÈ ÁÚ·ÊÈÎ¤˜ ·Ú·ÛÙ¿ÛÂÈ˜ ‰ÂÓ Â›Ó·È

‰È·ÌÔÚÊˆÌ¤ÓÂ˜ ÌÂ fiÏÂ˜ ÙÈ˜ ÏÂÙÔÌ¤ÚÂÈÂ˜,
ÌÔÚÂ› ÂÓÙÔ‡ÙÔÈ˜ Ó· ÚÔÎ‡„ÂÈ ‰È·¯ˆÚÈÛÌfi˜
fn ÌÂÙ·Í‡ ÙˆÓ ÌÂÌÔÓˆÌ¤ÓˆÓ Î·Ù·ÛÎÂ˘·ÛÙÈÎÒÓ
·Ú·ÏÏ·ÁÒÓ Î·Ù¿ Û·Ê‹ ÙÚfiÔ, Ô‡Ùˆ˜ ÒÛÙÂ Ó·
no ÌÔÚÂ›ÙÂ Ó· ‚ÚÂ›ÙÂ ÌÂ Â˘ÎÔÏ›· Ù· ·ÓÙ·ÏÏ·ÎÙÈÎ¿
ÂÎÂ›Ó·, Ù· ÔÔ›· ·ÊÔÚÔ‡Ó ÙÔÓ ÎÈÓËÙ‹Ú· Û·˜.
ª¤Ûˆ ÙÔ˘ ·ÚÈıÌÔ‡ ı¤ÛË˜, oÌ¿‰·˜ ÂÍ·ÚÙËÌ¿ÙˆÓ
el Î·È ÎÈÓËÙ‹Ú· ÌÔÚÂ› Ó· ‰È·ÈÛÙˆıÂ› ÛÂ Î¿ıÂ
ÍÂ¯ˆÚÈÛÙ‹ ÂÚ›ÙôË ÙÔ ÛˆÛÙfi ·ÓÙ·ÏÏ·ÎÙÈÎfi.
tr
ru
ar
pl
© 2000 2 el
de
√È ÓÙÈ˙Â ÏÔÎÈÓËÙ‹ÚÂ˜ DEUTZ ∆· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ∞ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜ DEUTZ en
fr
·ÔÙÂÏÔ‡Ó ÚÔ›fiÓ Ì·ÎÚÔ¯ÚfiÓÈ·˜ ÂÈÛÙËÌÔÓÈÎ‹˜ YfiÎÂÈÓÙ·È ÛÙÈ˜ ›‰ÈÂ˜ ·˘ÛÙËÚ¤˜ ··ÈÙ‹ÛÂÈ˜ ÔÈfiÙËÙ·˜ ∆· ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÂÍ·ÚÙ‹Ì·Ù· ÙË˜
¤ÚÂ˘Ó·˜ Î·È ÙÂ¯ÓÈÎ‹˜ ÂÍ¤ÏÈÍË˜. ∏ ·ÔÎÙËıÂ›Û·
ÙÂ¯ÓÔ‰ÔÛ›·, Ô˘ ÚÔ¤Î˘„Â ·fi ÙÈ˜ ÂÚÁ·Û›Â˜ Ì·˜
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·ÓÙ·ÏÏ·ÎÙÈÎÒÓ, Ô˘ ¤¯Ô˘Ó Î·Ù·ÛÎÂ˘·ÛÙÂ› Û‡ÌÊˆÓ·
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DEUTZ Â›Ó·È ÈÛ¿ÍÈ· ÌÂ Ù· ÁÓ‹ÛÈ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿
it
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sv
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fn
Î·È ÛÂ ÂÚ›ÙˆÛË Ô˘ ¯ÚÂÈ¿˙ÂÛÙÂ ·ÓÙ·ÏÏ·ÎÙÈÎ¿ ÛÙÈ˜
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ÔÔ›· ÂÊ·ÚÌfi˙ÔÓÙ·ÈÛ ·˘ÙfiÓ ÙÔÓ
ÎÈÓËÙ‹Ú·, ‰ÂÓ ÂÚÈ¤¯Ô˘Ó ·Ì›·ÓÙÔ. ™Â no
˘ËÚÂÛ›Â˜ Û¤Ú‚È˜ ÂÏ·ÙÂ›·˜. ∆Ô ÂÍÂÈ‰ÈÎÂ˘Ì¤ÓÔ Ì·˜ Î·Ù¤ÛÙË ·Ó·ÁÎ·›Ô Ó· ·ÔÌ·ÎÚ‡ÓÂÙÂ ·fi ÙÔÓ ÎÈÓËÙ‹Ú· ÂÚÈÙÒÛÂÈ˜ ÂÚÁ·ÛÈÒÓ Û˘ÓÙ‹ÚËÛË˜
ÚÔÛˆÈÎfi ÊÚÔÓÙ›˙ÂÈ ÛÂ Î¿ıÂ ÂÚ›ÙˆÛË ‚Ï·‚ÒÓ
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·Ú·Î·ÏÔ‡ÌÂ ·Ó¿ÏÔÁ· ·ÓÙ·ÏÏ·ÎÙÈÎ¿.
el
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tr
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ÚÔ‡¯·. ¶ÚÔ‚·›ÓÂÙÂ ÛÂ Á¤ÌÈÛÌ· ÙÔ˘ ÚÂ˙ÂÚ‚Ô˘¿Ú ÙÔ˘ ru
ÎÈÓËÙ‹Ú· ÌÂ Î·‡ÛÈÌ· ÌfiÓÔ ·ÊÔ‡ ÚÔËÁÔ˘Ì¤Óˆ˜ ¤¯ÂÙÂ
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ar
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pl
3 el © 2000
¶ÂÚÈÁÚ·Ê‹ ÙÔ˘ ÎÈÓËÙ‹Ú·
de
en 1. ¶ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ 2. £¤ÛË ÙË˜ ÈÓ·Î›‰·˜ ÙÔ˘ 3. ∞ÚÈıÌfi˜ ÙÔ˘ ÎÈÓËÙ‹Ú·
fr Î·Ù·ÛÎÂ˘‹˜ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
∏ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹ ·Ú·ÏÏ·Á‹ ∞, Ô ·ÚÈıÌfi˜ ÙÔ˘ ∏ ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜ C √ ·ÚÈıÌfi˜ ÙÔ˘ ÎÈÓËÙ‹ÚÔ˜ Â›Ó·È ÛÊÚ·ÁÈÛÌ¤Óo˜
no ÎÈÓËÙ‹Ú· µ Î·ıÒ˜ Â›ÛË˜ Î·È Ù· ÙÂ¯ÓÈÎ¿ ÛÙÔÈ¯Â›·
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ÛÙÚÔÊ¿ÏÔ˘.
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Î·È Â¿Óˆ oÙËÓ ÈÓ·Î›‰· ÙÔ˘ Î·Ù·ÛÎÂ˘Ë˜.
ÛÙËÓ ÈÓ·Î›‰· ÙÔ˘ ÂÚÁÔÛÙ·Û›Ô˘ Î·Ù·ÛÎÂ˘‹˜.
el ∫·Ù¿ ÙËÓ ·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ Ú¤ÂÈ
Ó· Á›ÓÂÙ·È ·Ó·ÊÔÚ¿ ÙË˜ Î·Ù·ÛÎÂ˘·ÛÙÈÎ‹˜
tr ·Ú·ÏÏ·Á‹˜ Î·È ÙÔ˘ ·ÚÈıÌÔ‡ ÙÔ˘ ÎÈÓËÙ‹Ú·.
ru
ar
pl
© 2000 4 el
¶·Ú·ÁÁÂÏ›· ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
de
™ÙÔÈ¯Â›· ·Ú·ÁÁÂÏ›·˜ en
¶·Ú·ÁÁÂÏ›·
∫·Ù¿ ÙËÓ ·Ú·ÁÁÂÏ›· ÙˆÓ ÁÓ‹ÛÈˆÓ ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ
DEUTZ ¯ÚÂÈ¿˙ÔÓÙ·È Ù· ·ÎfiÏÔ˘ı· ÛÙÔÈ¯Â›·: ·ÓÙ·ÏÏ·ÎÙÈÎÒÓ fr
- ∞Ú. ∫ÈÓËÙ‹Ú· ∞Ú. ∫ÈÓËÙ‹Ú· : es
- ∞Ú. ∞Ó·ÁÓÒÚÈÛË˜ TÂÌ ¶ÔÛÔÙ. ∞Ú. ∞v·Áv. ¶·Ú·ÙËÚ. ™˘ÁÎÚfiÙÌ· ∫ÈÓËÙ‹Ú· pt
- ∞Ú. ∆ÂÌ·¯›ˆÓ
it
¢È¿Ù·ÍË ÙÂÎÌËÚ›ˆÛË˜
- √È ›Ó·ÎÂ˜ ÌÂ ÂÈÎfiÓÂ˜ ·˘ÙÔ‡ ÙÔ˘ Î·Ù·ÏfiÁÔ˘
nl
·ÓÙ·ÏÏ·ÎÙÈÎÒÓ Â›Ó·È Ù·ÍÈÓÔÌËÌ¤ÓÔÈ Û‡ÌÊˆÓ·
ÌÂ Ù· Û˘ÁÎÚÔÙ‹Ì·Ù· ÎÈÓËÙ‹ÚˆÓ. sv
- ™Â Î¿ıÂ Ì¤ÚÔ˜ ˘¿Ú¯ÂÈ
Û˘ÁÎÚÔÙ‹Ì·ÙÔ˜ ÎÈÓËÙ‹Ú·
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da
- √ ·Ú. ∞Ó·ÁÓÒÚÈÛË˜ 06/59 ·ÔÙÂÏÂ›Ù·È ·fi
Û˘ÁÎÚfiÙËÌ· (.¯. 06) Î·È ı¤ÛË (.¯. 59)
∞Ú. ∆ÂÌ·¯›Ô˘
fn
no
-06- el
000
96
tr
94 ru
A
ar
pl
5 el © 2000
™∂ƒµπ™
de
en ¶Ú¤ÂÈ Ó· ÁÓˆÚ›˙ÂÙÂ, Â›Ó·È DEUTZ AÚ. ¶·Ú·ÁÁÂÏ›·˜: 0312 0806
fr ∂‰Ò Î·È ¯ÚfiÓÈ· ÙÔ fiÓÔÌ· DEUTZ Â›Ó·È Û˘ÓÒÓ˘ÌÔ ÙˆÓ
ÚÈ˙ÔÛ·ÛÙÈÎÒÓ ÂÍÂÏ›ÍÂˆÓ ÛÙËÓ Î·Ù·ÛÎÂ˘‹ ÎÈÓËÙ‹ÚˆÓ.
ø˜ ·ÓÂÍ¿ÚÙËÙÔ˜ Î·Ù·ÛÎÂ˘·ÛÙ‹˜ ÎÈÓËÙ‹ÚˆÓ
es ÚÔÛÊ¤ÚÔ˘ÌÂ ·ÁÎÔÛÌ›ˆ˜ Ì›· Ï‹ÚË ÁÎ¿Ì·
ÂÙÚÂÏ·ÈÔÎÈÓËÙ‹ÚˆÓ Î·È ÎÈÓËÙ‹ÚˆÓ ÌÂ ·¤ÚÈÔ ÛÙËÓ
pt ÂÚÈÔ¯‹ ÈÛ¯‡Ô˜ ·fi 4 ¤ˆ˜ Î·È 7400kW. ∆· ÚÔ˚fiÓÙ·
Ì·˜ Â›Ó·È Ù¤ÏÂÈ· ÚÔÛ·ÚÌÔÛÌ¤Ó· ÛÙÈ˜ ··ÈÙ‹ÛÂÈ˜ ÙˆÓ
ÂÏ·ÙÒÓ Ì·˜.
it ¶·ÁÎÔÛÌ›ˆ˜, ÂÚÈÛÛfiÙÂÚÔÈ ·fi 1,4 ÂÎ·ÙÔÌÌ‡ÚÈ·
ÎÈÓËÙ‹ÚÂ˜ DEUTZ ÂÎÙÂÏÔ‡Ó ·ÍÈfiÈÛÙ· ÙÈ˜ ˘ËÚÂÛ›Â˜
nl ÙÔ˘˜. £· ı¤Ï·ÌÂ Ó· ‰È·ÙËÚ‹ÛÔ˘ÌÂ ÙËÓ ÂÙÔÈÌfiÙËÙ·
¯Ú‹ÛË˜ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ Ì·˜ Î·È ÙËÓ ÈÎ·ÓÔÔ›ËÛË ÙˆÓ
sv ÂÏ·ÙÒÓ Ì·˜. °È· ·˘Ùfi ÙÔ ÏfiÁÔ ÂÎÚÔÛˆÔ‡Ì·ÛÙÂ
·ÁÎÔÛÌ›ˆ˜ ÌÂ ¤Ó· ‰›ÎÙ˘Ô Î·Ù¿ÏÏËÏˆÓ Û˘ÓÂÚÁ·ÙÒÓ, Ë
˘ÎÓfiÙËÙ· ÙˆÓ ÔÔ›ˆÓ ·ÓÙÈÛÙÔÈ¯Â› ÛÙËÓ ÂÚÈÊÂÚÂÈ·Î‹
da Î·Ù·ÓÔÌ‹ ÙˆÓ ÎÈÓËÙ‹ÚˆÓ Ì·˜.
ŒÙÛÈ Ë DEUTZ ‰ÂÓ Â›Ó·È ÌfiÓÔ ÙÔ fiÓÔÌ· ÁÈ· ÎÈÓËÙ‹ÚÂ˜ ÌÂ

fn ÓÂ‡Ì· ·Ó·Î¿Ï˘„Ë˜, ·ÏÏ¿ Î·È ÁÈ· ¤Ó· ÔÏÔÎÏËÚˆÌ¤ÓÔ
·Î¤ÙÔ ·ÚÔ¯ÒÓ Á‡Úˆ ·fi ÙÔÓ ÎÈÓËÙ‹Ú· Î·È ¤Ó· AÚ. ¶·Ú·ÁÁÂÏ›·˜: (CD-ROM) 0312 0807
no Û¤Ú‚È˜, ÙÔ ÔÔ›Ô ÌÔÚÂ›ÙÂ Ó· ÂÌÈÛÙÂ˘fiÛ·ÛÙÂ.
√ Î·Ù¿ÏÔÁÔ˜ Sales & Service Û·˜ ÚÔÛÊ¤ÚÂÈ Ì›·

el Û˘ÓÔÙÈÎ‹ ÂÈÎfiÓ· ÁÈ· ÙÔ˘˜ Û˘ÓÂÚÁ¿ÙÂ˜ ÙË˜ DEUTZ
ÛÙËÓ ÂÚÈÔ¯‹ Û·˜, ÁÈ· Ù· ÚÔ˚fiÓÙ· Ô˘ Â›Ó·È ·ÚÌfi‰ÈÔÈ ¶ÚÔÌËıÂ‡ÂÙ·È Ì¤Ûˆ ÙÔ˘ ·ÚÌfi‰ÈÔ˘ Û˘ÓÂÚÁ¿ÙË Service DEUTZ AG
Î·È ÁÈ· ÙÈ˜ ˘ËÚÂÛ›Â˜ Û¤Ú‚È˜. ∞ÏÏ¿ ·ÎfiÌË ÎÈ fiÙ·Ó ‰ÂÓ ÙË˜ ÂÚÈÔ¯‹˜ ‹ ·fi: Deutz-Mülheimer Str. 147-149
tr ÛËÌÂÈÒÓÂÙ·È Î¿ÔÈ· ¿ÌÂÛË ·ÚÌÔ‰ÈfiÙËÙ· ÚÔ˚fiÓÙÔ˜, Ô
Û˘ÓÂÚÁ¿ÙË˜ ÙË˜ DEUTZ ı· Û·˜ ‚ÔËı‹ÛÂÈ ÌÂ
D-51057 Köln
ru Î·Ù¿ÏÏËÏÂ˜ Û˘Ì‚Ô˘Ï¤˜. TËÏ¤ÊˆÓÔ: 0049-221-822-0

º·Í: 0049-221-822-5304
√ Î·Ù¿ÏÔÁÔ˜ ·Ó·ÓÂÒÓÂÙ·È ÛÂ ÌfiÓÈÌË ‚¿ÛË. ƒˆÙ‹ÛÙÂ ÙÔ T¤ÏÂÍ: 8812-0 khd d
ar ‰ÈÎfi Û·˜ Û˘ÓÂÚÁ¿ÙË ÙË˜ DEUTZ ÁÈ· ÙË Ó¤· ¤Î‰ÔÛË. http://www.deutz.de
∏ ‰ÈÎ‹ Û·˜ DEUTZ AG

pl
© 2000 6 el
Yedek parça listesi
2011
0297 9934
Motor numarası:
Lütfen buraya motor numarası nı yazın. Böylece

müşteri hizmetleri, tamir ve yedek parça ile ilgili
konularda kolaylık sağlanır.
Yedek parça listesinde gösterilen şekiller ve teknik

bilgilerin, motorlarda yapılacak geliştirmeler
nedeniyle değiştirilmesi hakkı saklıdır. Firmamızın
yazılı izni olmaksızın, kısmen de olsa her türlü
çoğaltma ve kopyalama yasaktır.
1 tr © 2000
© 2000
Önsöz
de
en Sayın müşterimiz, Yedek parça listesinde belirtilmiş olan parçalar,
yalnızca ilgili Deutz motorlarının yapı grubu için
fr DEUTZ Marka hava/su soğutmalı motorlar geniş
geçerlidir ve yalnızca bu tip motorların tamirinde
kullanılacaktır (kullanım amacına uygun kullanım).
kullanım alanları için geliştirilmiştir. Sunulan geniş Yedek parçaların talimatlara göre doğru şekilde
es model ve tip çeşitleri ile her türlü kullanım alanının
gerektirdiği özel şartlar yerine getirilebilmektedir.
tmonte edilmesini gösteren bilgiler, kullanım kılavuzu
(bakım çalışmaları) ve atölye el kitabında (tamir
pt Sahip olduğunuz motor bağlı olduğu kullanım amacı
çalışmaları) ayrıntılı olarak açıklanmıştır. Talimatlara
aykırı yapılan çalışmalardan doğacak hasar ve
ile donatılmış olduğundan, yedek parça listesinde yaralanmalardan imalatçı firma sorumlu değildir.
it gösterilmiş olan tüm eleman ve parçalar motorunuzda
bulunmaz.
nl Gösterilmiş olan grafikler tüm detayları kapsamasa

da, motorunuz tipi için geçerli olan yedek parça
sv kolayca tespit edilebilir. Pozisyon, yapı grubu ve
motor numarası üzerinden her halukarda, motorunuz
ile ilgili doğru yedek parça tespit edilebilir.
da Yedek parça siparişinde, ihtiyacınız olan yedek
parçayı en kısa zamanda, güvenilir ve son değişiklik
fn tipinde sevk edebilmemiz için sipariş bilgilerine dikkat
ediniz.
no Sormak istediğiniz sorular olduğunda bize her zaman
başvurabilirsiniz.
el
DEUTZ AG
tr
ru
ar
pl
© 2000 2 tr
Önsöz
de
DEUTZ Dizel motorları Orijinal DEUTZ Yedek Parça DEUTZ Değiştirme komponentleri en
fr
DEUTZT Marka dizel motorları, uzun yıllardır yapılan Orijinal yedek parçalar aynı DEUTZ motorlarında DEUTZ Değiştirme komponentleri
araştırma ve geliştirmenin ürünüdür. Bu araştırma ve
geliştirmelerden elde edilen know how ve üretimde
olduğu gibi yüksek kalite standartlarına göre üretilir.
Motorların iyileştirilmesi için yapılan geliştirme
(üniteleri) uygun fiyatlı bir alternatifdir.
Aynı yeni yedek parçalarda olduğu
es
uygulanan yüksek kalite standartları, uzun ömürlü,
yüksek dayanıklı ve düşük yakıt sarfiyatlı motorların
çalışmalarında olduğu gibi yedek parçalar üzerinde
de geliştirmeler yapılır. Yalnızca en son teknolojiye
gibi bu parçalar için de yüksek
kalite standartları geçerlidir. DEUTZ pt
üretilmesini sağlamıştır. Aynı zamanda çevre koruma göre üretilmiş olan orijinal DEUTZ yedek parçaları, Değiştirme komponentlerinin fonksiyon ve
ile ilgili tüm yükümlülükler de yerine getirilmiştir. motorların mükemmel fonksiyonunu, yüksek
dayanıklılık ve güvenilirliğini sağlar.
güvenilirliği orijinal DEUTZ yedek parçalarına eşittir. it
nl
sv
da
SERVİS Motor çalışırken dikkatli olun Asbest
fn
Arıza durumları ve yedek parça konularında bilgi Bakım ve onarım çalışmaları yalnızca motor dururken Bu motorda kullanılan contalarda
no
edinmek için yetkili servislerimize başvurunuz. Bu yapılacaktır. Muhtemelen sökülmüş olan koruma asbest malzemesi bulunmaz.
durumlarda eğitimli kalifiye personelimiz, orijinal
DEUTZ parçaları kullanarak tamir çalışmalarını
düzenleri, bakım ve tamir çalışmalarından sonra
tekrar monte edilecektir. Motor çalışırken yapılan
Bakım ve onarım çalışmalarında
lüften uygun yedek parça kullanın.
el
yerine getireceklerdir. çalışmalarda bol iş elbisesi giyilmeyecektir. Yakıt
dolumu yalnızca motor dururken yapılacaktır. Motoru tr
kesinlikle kapalı mekanlarda çalıştırmayın -
Zehirlenme tehlikesi. ru
ar
pl
3 tr © 2000
Motorun tanımlanması
de
en 1. Üretici etiketi 2. Üretici etiketi pozisyonu 3. Motor numarası
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Yapı türü A, motor numarası B ve motor gücü verileri Üretici etiketi C karter silindir bloğunda bağlıdır. Motor numarası, karter silindir bloğuna dövülmüş
no üretici etiketinde yazılıdır.
Yedek parça siparişinde yapı türü ve motor numarası
ve üretici etiketine yazılmıştır.
belirtilecektir.
el
tr
ru
ar
pl
© 2000 4 tr
Yedek parça siparişi
de
Sipariş bilgileri en
Orijinal DEUTZ yedek parça siparişlerinde aşağıdaki
bilgilerin belirtilmesi gereklidir:
Yedek parça siparişi fr
- Motor-Nr. Motor-Nr.: es
S ra
- Kod Nr.
no. Adet Kod Nr. Not Yap grubu pt
- Adet
it
Dokümantasyon yapısı
nl
- Yedek parça listesindeki şekiller ve çizimler
motor gruplarına göre ayrılmıştır sv
- Her bölümün önünde yapı grubu listesi bulunur
- 06/59 Kod numarası örneğin:

da
(örnek 06) nolu yapı grubu (örnek 59) nolu
pozisyondan oluşur.
Pozisyon
fn
Sembol açiklamasi
no
-06- Yapi grubu numarasi (Örn. 06) el
000 Değişim kudo (Örn. 000)
tr
96 Sayfa numarasi (Örn. 96)
Izleyen sayfa üzerindeki referans (Örn. 94 )

ru
94
ar
A Bağlanti semolü
- Her saman en az ikili sembol olarak
(Örn. A-A, B-B, C-C vs.gibi)
pl
5 tr © 2000
Servis
de
en Bilmek gerekir, bu DEUTZ’dur. Sipariş no: 0312 0806
fr Motor yapımında çığır açan gelişmeler demek DEUTZ
demektir. Biz, bağımsız motor üreticisi olarak dünya
genelinde 4 ile 7.400 kW gücündeki dizel ve gaz
es motorlarını palet halinde sunmaktayız. Ürünlerimiz
müşterilerimizin beklentileri için biçilmiş kaftandır.
pt
Bugün dünya genelinde 1,4 milyondan daha fazla
it sayıda DEUTZ motoru hizmet vermektedir.
Motorlarımızın etkinliğini ve bununla birlikte
müşterilerimizin memnuniyetini sürdürmek istiyoruz.
nl Bu nedenle bütün dünyada, yayılımları motorlarımızın
bölgesel dağılımına uygun olan yetkin temsilciler
sv bizleri temsil etmektedir.
DEUTZ, bu şekilde sadece motorlar için yaratıcılık

da ruhuna sahip bir isim değil, bunun yanında motorla
ilgili tam bir hizmet paketi ve güvenebileceğiniz bir
servis demektir.
fn Sales & Service cetveli size DEUTZ’un en Sipariş no: (CD-ROM) 0312 0807
no yakınınızdaki temsilcileri, onların ürün yetkileri ve
servis hizmetleri hakkında bilgi verir. Direk olarak ürün
yetkisi olmasa da DEUTZ temsilcisi size danışma
el hizmeti vererek yardım eder.
Bulunduğunuz yerdeki yetkili servisinizden veya DEUTZ AG
Cetvel sürekli olarak güncel hale getirilir. Yakınınızdaki yandaki adresimizden edinebilirsiniz: Deutz-Mülheimer Str. 147-149
tr DEUTZ temsilcisinden yeni baskıyı isteyiniz. D-51057 Köln
ru Sizin DEUTZ’unuz.
Telefon: 0049-221-822-0
Telefaks: 0049-221-822-5304
Teleks: 8812-0 khd d
pl
© 2000 6 tr
2011
0297 9934
1 ru © 2000
© 2000
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
© 2000 2 ru
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
3 ru © 2000
de
en
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
no
el
tr
ru
ar
pl
© 2000 4 ru
Заказ на запасные части
de
Данные для заказа en
Заказ на запасные
При заказе подлинных частей фирмы ДОЙЦ
требуется указать следующие данные: части fr
- Двигатель № Двигатель № es
Пор. Шт. Идент
- Идент. №
№ № Примечание Конструктивная группа pt
- Количество
Устройство ведомости для заказа

it
- Изображения этой ведомости nl
запасных частей сортированы согласно
конструктивным группам двигателя. sv
- Для каждого раздела вначале представлен
обзор конструктивных групп. da
- Идент. № 06\59 состоит из
конструктивной группы (например, 06)
Позиция
fn
и позиции (например, 59).
no
el
tr
ru
ar
pl
5 ru © 2000
Cepис
de
en Зная - это ДОЙЦ! Заказ № 0312 0806
Индекс сбыта и сервиса
fr С давних пор ДОЙЦ - это олицетворение
новаторского развития в изготовлении
двигателей. В качестве независимого
es производителя двигателей мы предлагаем по
всему миру комплектный ассортимент
дизельных и газовых двигателей в диапазоне
pt мощности от 4 до 7400 кВт. Наша продукция в
совершентсве припасована к требованиям
it наших заказчиков.
По всему миру надежно служат более чем 1,4
миллиона двигателей “ДОЙЦ“. Мы желаем
nl сохранить готовность наших двигателей к
эксплуатации и этим - удовлетворенность
sv наших клиентов. Для этого мы представлены по
всему миру сетью компетентных партнеров,
количество которых соответствует региональному
da распределению наших двигателей.
Таким образом, ДОЙЦ является не только
fn именем для двигателей с духом
изобретательства. Но также и для комплекса
услуг по всем вопросам, касающимся Заказ № (CD-ROM) 0312 0807
no двигателей, и сервиса, на который можно
положиться.
Индекс сбыта и сервиса
el “Индекс сбыта и услуг“ дает Вам обзор

партнеров ДОЙЦа, находящихся недалеко от Заказ производится через соответствующего DEUTZ AG
Вас, и их компетентности относительно местного партнера по сервису или на фирме: Deutz-Mülheimer Str. 147-149
tr двигателей и сервисных услуг. Но даже если их
компетентность не охватывает требующегося
D-51057 Köln
ru объема частей по определенному двигателю,

партнер ДОЙЦа всегда поможет Вам
Телефон: +49-221-822-0
Телефакс: +49-221-822-5304
компетентным советом. Телекс: 8812-0 khd d
ar Индекс постоянно актуализируется - запросите
у партнера ДОЙЦа новейшее издание.
http://www.deutz.de
pl Ваше АО ДОЙЦ
© 2000 6 ru
2011
0297 9934
1 ar © 2000
© 2000
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
© 2000 2 ar
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
3 ar © 2000
de
en
fr
es C
pt
it
nl
sv
da
© 31 865 0 © 31 864 0 © 26 232 1
fn
no
el
tr
ru
ar
pl
© 2000 4 ar
de
en
fr
es
pt
it
nl
sv
da
fn
no
el
tr
ru
ar
pl
5 ar © 2000
de
en 0312 0806
fr
es
pt
it
nl
sv
da
fn
no 0312 0807
el DEUTZ AG
tr D-51057 Köln
ru 0049-221-822-0
0049-221-822-5304
ar 8812-0 khd d
http://www.deutz.de
pl
© 2000 6 ar
Lista części zamiennych
2011
Pieczątka handlowca
0297 9934
Numer silnika:
Prosimy wpisać numer silnika. W ten sposób

ułatwiacie Państwo załatwienie spraw serwisu,
napraw i części zamiennych.
W opisie i danych, zawartych w niniejszej Liście

części zamiennych zastrzegamy sobie prawo
wprowadzenia zmian technicznych koniecznych
do ulepszenia silnika. Przedruk i powielanie w
jakikolwiek sposób, także w postaci wyciągów,
wymaga naszej pisemnej zgody.
1 pl © 2001
© /2000
0297 7547
Wprowadzenie
de
en Szanowny odbiorco, Elementy wymienione w niniejszej Liście części
zamiennych należy stosować jedynie do naprawy
fr chłodzone cieczą silniki marki DEUTZ zostały
opracowane dla szerokiego zakresu zasto-
wymienionego szeregu konstrukcyjnego silników
marki Deutz (użycie zgodnie z przeznaczeniem).
sowania. Bogata oferta różnych wariantów Szczegółowe informacje o prawidłowej zabu-
es zapewnia możliwość spełnienia wymagań
specjalnych w poszczególnych przypadkach.
dowie części zamiennych zawiera instrukcja
eksploatacji (czynności obsługi technicznej)
pt Wyposażenie silnika zamówionego przez
oraz książka warsztatowa (prace remontowe).
Wykonawca nie przejmuje odpowiedzialności za
Państwo odpowiada przypadkowi określonemu szkody i obrażenia osób powstałe w wyniku
it w zamówieniu, t.zn. nie wszystkie części
zamienne i części składowe z niniejszej Listy
nieprzestrzegania odpowiednich instrukcji.
części zamiennych zostały przedstawione w

nl Państwa silniku.
sv Mimo, że załączone rysunki nie zawierają wielu

szczegółów, są Państwo w stanie wyraźnie
rozróżnić poszczególne warianty tak, że
da znalezienie części zamiennych do Państwa
konkretnego silnika nie sprawi trudności.
Poszukiwana część zamienna może być w
fn każdym przypadku bezbłędnie znaleziona na
podstawie numeru pozycji, numeru pod-
no zespołu i numeru silnika.
Przy zamawianiu części zamiennych prosimy

el przestrzegać naszych wskazówek do zamó-
wienia. Zapewni nam to możliwość szybkiego i
niezawodnego dostarczenia potrzebnych części
tr zamiennych z każdorazowym uwzględnieniem
ostatnio wprowadzonych zmian.
ru Na zapytania Państwa udzielimy zawsze chętnie
odpowiedzi.
ar Z uszanowaniem
pl DEUTZ AG
© 2000 2 pl
Wprowadzenie
de
Silniki Diesla marki DEUTZ Oryginalne części zamienne Części zastępcze marki DEUTZ en
marki DEUTZ
fr
zostały opracowane w wyniku wieloletnich podlegają tym samym surowym wymaganiom Części zastępcze marki DEUTZ
badań i rozwoju. Zdobyte w wyniku tego solidne
know how stanowi w połączeniu ze spełnieniem
jakości, jak i silniki marki DEUTZ. W celu poprawy
jakości silników podlegają stałemu rozwojowi
stanowią alternatywę korzystniejszą
cenowo. Oczywiście obowiązują
es
wysokich wymogów jakości gwarancję produkcji
silników o długiej żywotności, wysokiej nie-
oczywiście także oryginalne części zamienne
marki DEUTZ. Tylko zastosowanie oryginalnych
tu, jak i w stosunku do elementów
nowych, najwyższe wymagania pt
zawodności i niskim zużyciu paliwa. Oczywiście części zamiennych marki DEUTZ, wykonanych z jakościowe. Części zastępcze marki DEUTZ są co
zostały także spełnione wysokie wymagania
ochrony środowiska. Umwelt erfüllt werden.
wykorzystaniem najnowszej wiedzy, zapewnia
nienaganne działanie i wysoką niezawodność
do działania i jakości równoważne oryginalnym
częściom zamiennym marki DEUTZ.
it
pracy.
nl
sv
da
SERVIS Środki ostrożności przy
pracującym silniku
Azbest
fn
W przypadkach zakłóceń eksploatacyjnych oraz Czynności obsługowe i naprawy należy wyko- Uszczelnienia zastosowane w tym
no
w sprawach części zamiennych prosimy zwrócić nywać tylko przy zatrzymanym silniku. Ewen-
się do jednego z naszych właściwych przed-
stawicielstw serwisowych. Nasi wyszkoleni
tualnie usunięty osprzęt ochronny należy po
zakończeniu prac ponownie zamontować.
silniku są wolne od azbestu. Do
prac obsługowych i napraw el
prosimy używać odpowiednich
specjaliści postarają się w przypadkach usz-
kodzeń o szybką i fachową naprawę z użyciem
Podczas prac przy pracującym silniku odzież
robocza powinna ściśle przylegać do ciała.
części zamiennych.
tr
oryginalnych części zamiennych marki DEUTZ. Silnik można tankować tylko po jego
zatrzymaniu. Silnik nie może w żadnym
przypadku pracować w zamkniętym
ru
pomieszczeniu – niebezpieczeństwo zatrucia.
ar
pl
3 pl © 2000
Opis silnika
de
en 1. Tabliczka firmowa 2. Położenie tabliczki firmowej 3. Numer silnika
fr
es C
pt A B
it
nl
sv
da
© 26 332 2 © 31 864 0 © 31 865 0
fn
Typ A, numer silnika B, jak i dane odnośnie mocy Tabliczka firmowa C jest zamocowana na Numer silnika jest odciśnięty na kadłubie silnika
no zostały odciśnięte na tabliczce firmowej.
Przy zamawianiu części należy podać typ i numer
kadłubie silnika. oraz na tabliczce firmowej.
silnika.
el
tr
ru
ar
pl
© 2000 4 pl
Zamówienie części zamiennych
de
Dane zamówieniowe en
Zamówienie części
Przy zamawianiu oryginalnych części zamien-
nych marki DEUTZ należy podać następujące zamiennych fr
dane:
Numer silnika: es
- Numer silnika (Motor-Nr.)
Nr Nr
- Numer identyfikacyjny (Ident-Nr.) porz. Ilość identyf. Uwagi Podzespół pt
- Ilość it
Układ dokumentacji nl
- Tabele zawierające rysunki części zamiennych
są uszeregowane według podzespołów silnlka. sv
- Podzespoły są zestawione w liście elementów
silnika.
da
- Numer identyfikacyjny (Ident-Nr.) 06/59 składa
się z podzespołu (np. 06) i z pozycji (np. 59).
Pozycja
fn
Objaśnienia symboli
no
-06- Numer podzespołu (np. 06) el
000 Cyfra zmiany
tr
96 Numer strony (np. 96)
Odsyłacz do strony z dalszym ciągiem

ru
94 (np. 94)
ar
A Symbol połączenia
- występuje zwykle w parze
(np. A-A, B-B, C-C itd.)
pl
5 pl © 2000
Servis
de
en Wiadomo, to jest DEUTZ. Numer zamówienia: 0312 0806
fr Z nazwą DEUTZ kojarzy się od dawna otwierający
nowe horyzonty rozwój w dziedzinie budowy
silników. Jako niezależny wytwórca silników
es dostarczamy na całym świecie całą gamę silni-
ków Diesla i silników gazowych o mocy od 4 do
7400 kW. Nasze wyroby odpowiadają dokładnie
pt wymaganiom naszych odbiorców.
Na całym świecie wykonuje niezawodnie swoje
it zadanie ponad 1,4 miliona silników firmy DEUTZ.
Jesteśmy zainteresowani w utrzymaniu wysokiej
gotowości do pracy naszych silników, a tym
nl samym w utrzymaniu zadowolenia naszych
odbiorców. Dlatego też jesteśmy
sv reprezentowani w całym świecie przez sieć
kompetentnych przedstawicieli, których
gęstość rozmieszczenia odpowiada
da regionalnemu rozmieszczeniu naszych silników.
Nazwa DEUTZ jest równoznaczna nie tylko z
fn pojęciem silników o duchu wynalazczości. Oz-
nacza ona też kompletny pakiet świadczeń we
wszystkich dotyczących silników dziedzinach Numer zamówienia: (CD-ROM) 0312 0807
no oraz serwis, któremu Państwo mogą zaufać.
Wykaz Sales & Service zawiera przegląd
el przedstawicielstw firmy DEUTZ w pobliżu
Państwa, informacje o ich kompetencjach i Do nabycia poprzez Państwa właściwe przed- DEUTZ AG
świadczeniach serwisowych. Także w przy- stawicielstwo serwisowe na miejscu albo pod Deutz-Mülheimer Str. 147-149
tr padkach, kiedy nie wymieniono wprost okre-
ślonych kompetencji, przedstawiciel firmy
adresem: D-51057 Köln
ru DEUTZ udzieli Państwu kompetentnej porady.

Wykaz ten jest stale aktualizowany, prosimy
Telefon: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
ar pytać w przedstawicielstwach firmy DEUTZ o
najnowsze wydanie.
http://www.deutz.de
Z uszanowaniem DEUTZ AG
pl
© 2000 6 pl
Bildtafeln de
Illustrations en
Figures fr
Grabados es
Quadros de figuras pt
Tavole it
Afbeeldingen nl
Planscher sv
Illustrationer da
Bilder fn
Kuvat no
¢È·ÁÚ¿ÌÌ·Ù· el
sekiller tr
Иллюст ации ru
ar
Tabela z rysunkami pl
© 2000
Rechts 3
Beschnitt Beschnitt
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
D-51057 Köln
Tel.: ++49 (0)2 21-8 22-0
Fax: ++49 (0)2 21-8 22-53 58
U4_Impr_2012_9957
http: //www.deutz.de
Printed in Germany
All rights reserved
1st Edition, © 04/01
We move your world. Order No.: 0297 9934
Beschnitt MAGENTA = HKS 14K SCHWARZ Beschnitt

Werkstatthandbuch
Workshop Manual
Manuel d’Atelier
Manual de Taller 2011
0297 9959
Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind

technische Änderungen, die zur Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeglicher Art, auch auszugsweise,
bedarf unserer schriftlichen Genehmigung.
In view of continuous design improvements or changes, the technical spe-

cifications and the illustrations shown in this Workshop Manual are subject to
alteration. Reprinting and reproduction, in part or in whole, are subject to our
written approval.
Sous réserve de modifications techniques nécessaires à l’amélioration des

moteurs présentés par des illustrations et des indications référencées dans ce
Manuel d’Atelier. Réimpression et reproduction même partielle, quelle qu’en
soit la nature, interdites sans l’autorisation écrite de nos service.
Nos reservamos el derecho de introducir modificaciones técnicas necesarias

para el mejoramiento de motores, aunque difieran de las ilustraciones y datos
contenidos en este Manual de Taller. La reimpresión del presente libro o
cualquiera forma de reproducción, aunque sea parcial, requiere nuestra
autorización por escrito.
© 2001 / 0297 9959

VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.
In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparatur-

und Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, dass
die Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.
Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der Inhalte
zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den jeweils
behandelten Arbeitsgang visualisieren.
Betriebs- und Wartungshinweise sind der entsprechenden Betriebsanleitung zu entnehmen.
Zur Ersatzteilbestellung ist die jeweilige Ersatzteilliste zugrunde zu legen.
Das vorliegende Werkstatthandbuch unterliegt keinem Änderungsdienst. Änderungen werden jeweils

bei Neuauflage eingearbeitet.
Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.
Allgemeine Hinweise:
- Lesen und beachten Sie die Informationen dieses Werkstatthandbuches. Sie

vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten
Motor.
- Stellen Sie sicher, dass dieses Werkstatthandbuch jedem an Reparatur- oder

Einstellarbeiten Beteiligten zur Verfügung steht und dass der Inhalt verstanden wird.
- Die Nichtbeachtung dieser Reparaturanleitung kann zu Funktionsstörungen und

Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller
keine Haftung übernommen wird.
- Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen

anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzu-
halten.
- Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderli-
chen Ausrüstungen, Hand- und Spezialwerkzeuge, sowie deren einwandfreier
Zustand.
- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei Ver-
wendung von Original Teilen der DEUTZ AG sichergestellt.
- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.
- Die Instandsetzung des Motors muß der bestimmungsgemäßen Verwendung -

definiert durch den Gerätehersteller - entsprechen. Bei Umbauten dürfen nur von
der DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt
werden.
© 2001 / 0297 9959

FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work
on the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise
text passages are accompanied by pictographs to illustrate the relevant operation.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.
General information:
- Please read carefully and observe the instructions given in this Workshop Manual
to avoid accidents and ensure that your engine always functions properly and
reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out
repairs or adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine
damage as well as personal injuries for which the manufacturer shall not accept any
liability.
- The accident prevention regulations and all other generally recognized regulations
on safety and occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special tools
are available and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be ensured
when genuine parts of DEUTZ AG are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not
handled with care.
- Engine repairs must be carried out in accordance with intended use as defined by
the equipment manufacturer. For conversions, only parts approved by DEUTZ AG for
a specific purpose should be used.
© 2001 / 0297 9959

PRÉFACE
Un fonctionnement fiable du moteur suppose l’exécution en bonne et due forme des travaux de
réparation et de réglage.
Le présent Manuel d’atelier décrit la suite des travaux de réparation et de réglage à effectuer sur
le moteur et ses éléments. Cela suppose que les travaux sont réalisés par un personnel spécialisé
et qualifié.
En vue d’une compréhension rapide du contenu, le manuel d’atelier comporte, en plus des textes
brefs, des symboles visualisant l’opération à réaliser.
Les indications relatives au service et à l’entretien figurent dans les instructions de service
correspondantes.
Pour la commande de pièces de rechange, il convient de se baser sur la liste des pièces de rechange
correspondante.
Le présent manuel d’atelier n’est soumis à aucun service de modifications. Les modifications
seront incorporées à chaque réédition du Manuel.
Pour les réparations, veuillez respecter les indications de nos circulaires techniques.
Remarques générales:
- Veuillez lire attentivement les informations du présent Manuel d’ Atelier et en tenir

compte. Vous éviterez ainsi des accidents et disposerez en même temps d’un
moteur fonctionnel et en parfait état de marche.
- Assurez-vous que chaque personne chargée des travaux de réparation et de mise au point
dispose bien de ce Manuel d’ Atelier et en comprenne bien le contenu.
- Le non-respect de ces instructions de réparation peut entraîner des pannes, avaries

de moteur et accidents de personnes, pour lesquels le constructeur ne peut en aucun
cas assumer la responsabilité.
- Il convient de respecter les consignes générales de sécurité et de prévention des

accidents en vigueur.
- La condition préalable de la bonne exécution des réparations est la mise à disposition

de tous les équipements, outillages manuels et spéciaux requis, en parfait état de
fonctionnement.
- Seule l’utilisation de pièces de rechange d’origine DEUTZ AG garantit une rentabilité

et fiabilité optimales ainsi qu’une longue durée de vie.
- Les éléments du moteur notamment les ressorts, attaches, bagues élastiques etc.,
peuvent entraîner, en cas de non-respect des prescriptions, des blessures graves.
- La remise en état du moteur doit répondre à son utilisation propre, définie par le
constructeur de l’engin. En cas de modification, seules les pièces autorisées par
DEUTZ AG dans le cas de l’application concernée, peuvent être utilisées.
© 2001 / 0297 9959

PROLOGO
Una ejecución competente de trabajos de reparación y ajuste es requisito fundamental para un
funcionamiento seguro del motor.
En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para
reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los
trabajos serán realizados por personal técnico especializado.
Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado
símbolos significativos a los textos explicatorios, visualizando así el trabajo a realizar.
Informaciones con respecto al manejo y al servicio de entretenimiento del motor, se encuentran en el

Manual de Instrucciones de Servicio correspondiente.
Para pedidos de repuestos servirá de base el respectivo catálogo de repuestos.
El presente manual para talleres no está sujeto a un servicio continuado de modificaciones e

innovaciones. Cada nueva edición incluye todas las modificaciones del caso.
Al efectuar reparaciones, aconsejamos asimismo tomar en cuenta las advertencias pertinentes de

nuestras circulares técnicas.
Advertencias generales:
- Le recomendamos la detenida lectura y observancia de las informaciones con-

tenidas en este Manual de taller. Así evitará accidentes y dispondrá de un motor que
funciona perfectamente.
- Haga lo necesario para que este Manual esté a disposición de toda persona que
participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el contenido.
- Al no tenerse en cuenta estas instrucciones de reparación, podrán surgir

perturbaciones en el funcionamiento y averías en el motor así como lesiones de
personas para las cuales el fabricante no asume responsabilidad alguna.
- Se cumplirán las normas aplicables para la prevención de accidentes así como todas
las demás normas de seguridad y medicina laboral generalmente aceptadas.
- Es condición para la correcta reparación que estén disponibles todos los requeridos
equipos, herramientas manuales y especiales en perfecto estado.
- Máxima rentabilidad, fiabilidad y larga duración quedan garantizadas únicamente al

emplearse repuestos originales de DEUTZ AG.
- Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. , aumentan
en caso de tratamiento incorrecto el peligro de lesiones.
- El reacondicionado del motor deberá corresponder al empleo previsto definido por

el fabricante del equipo. En caso de transformaciones, se deberán emplear
únicamente piezas admitidas por DEUTZ AG para el respectivo uso previsto.
© 2001 / 0297 9959

Inhalts-Verzeichnis
Table of Contents
Sommaire
Indice
Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols
Caractéristiques techniques / Explication des symboles
Datos técnicos / Leyenda de símbolos



Démontage et montage, moteur complet
Werkzeuge
Tools
Outils
Herramientas
© 2001 / 0297 9959
5
Technische Daten
Specification data
Datos técnicos 2011
Hinweis zum Gebrauch des Werkstatthandbuches

In diesem Werkstatthandbuch sind alle technischen Daten, Einstellwerte und
Anziehvorschriften den Stellen zugeordnet, wo sie bei Servicearbeiten, De- und
Montage am Motor benötigt werden.
Notes for the user of this Workshop Manual

In this Workshop Manual all specification data, adjustment values and
tightening specifications are allocated to those parts where they are needed for
service work, disassembly and reassembly on the engine.
Remarque quant à l’utilisazion du Manuel d’atelier

Dans le présent Manuel d’atelier, toutes les caractéristiques techniques, valeurs
de réglage et préconisations de serrage nécessaires se trouvent dans les
chapitres correspondant aux travaux de service après-vente et montage et
démontage du moteur.
Indicación para el uso del manual de taller

En este manual de taller se indican todos los datos técnicos, valores de ajuste y
prescripciones de apriete en los puntos donde son requeridos para la realización
de trabajos de servicio, desmontaje y montaje en el motor.
© 2001 / 0297 9959

Inhalts-Verzeichnis Technische Daten
Table of Contents Specification data
Sommaire Caractéristiques techniques
Indice Datos técnicos
Deutsch Werkstatthandbuch 2011
1. Technische Daten Seite
Techn. Daten __________________________________________ 1.00.02 - 1.00.07

Ventilspieleinstellschema __________________________________________ 1.00.09
Reihenfolge beim Anziehen der Zylinderkopfschrauben _________________________ 1.00.11
Bildzeichenerklärung __________________________________________ 1.00.13 1
English
1. Specification data Page
Specification data __________________________________________ 1.00.02 -1.00.07

Schematic for valve clearance adjustment ____________________________________ 1.00.09
Tightening order for cylinder head bolts ______________________________________ 1.00.11
Key to symbols __________________________________________ 1.00.13
Français
1. Caractéristiques techniques Page
Caractéristiques techniques __________________________________________ 1.00.02 - 1.00.07

Schéma de réglage des soupapes __________________________________________ 1.00.09
Ordre de serrage des vis de culasse ________________________________________ 1.00.11
Explication des symboles __________________________________________ 1.00.13
Español
1. Datos técnicos Página
Datos técnicos __________________________________________ 1.00.02 - 1.00.07

Esquema para el ajuste del juego de válvulas _________________________________ 1.00.09
Sucesión de los trabajos al apretar los tornillos de culata ________________________ 1.00.11
Leyenda de símbolos __________________________________________ 1.00.13
© 2001 / 0297 9959

Technische Daten
Specification data
Datos técnicos
Werkstatthandbuch 2011
Motorgewicht Engine weight Poids du moteur Peso del motor

ohne Starter, without starter sans démarreur sin arrancador,
1 mit Generator with generator avec génératrice con generador
ca. kg approx. kg approx. kg aprox. kg
Gesamthubvolumen Engine swept volume Cylindrée totale Cilindrada total
cm3 cm3 cm3 cm3
Bohrung Bore Alésage Calibre
mm mm mm mm
Hub Stroke Course Carrera
mm mm mm mm
Drehrichtung Direction of rotation Sens de rotation Sentido de giro
Nenndrehzahl Rated speed Régime nominal Régimen nominal
max. 1/min max. rpm maxi tr/mn máx. r/min
Niedrigste Minimum Ralenti extrême Régimen mín.

Leerlaufdrehzahl idle speed en vacío
1/min rpm tr/mn r/min
Arbeitsweise Working cycle Principe de fonction- Sistema de trabajo

nement
© 2001 / 0297 9959 1.00.02

Technische Daten
Specification data
Datos técnicos
F2 - 4L 2011 BF3-4L 2011 F2 - 4M 2011 BF3-4M 2011
inklusive Kühlsystem inklusive Kühlsystem ohne Kühlsystem ohne Kühlsystem

incl. cooling system incl. cooling system without cooling system without cooling system
y compris système de refroid. y compris système de refroid. sans système de refroid. sans système de refroid.
incl. sistema de refrige. incl. sistema de refrige. sin sistema de refrige. sin sistema de refrige
F2L = 175 F2M = 169 1
F3L = 217 BF3L = 222 F3M = 210 BF3M = 215
F4L = 256 BF4L = 257 F4M = 248 BF4M = 250
F2L = 1554 F2M = 1554

F3L = 2331 BF3L = 2331 F3M = 2331 BF3M = 2331
F4L = 3108 BF4L = 3108 F4M = 3108 BF4M = 3108
94
112
auf Schwungrad gesehen links

When facing flywheel counter-clockwise
Vu sur volant à gauche
Visto sobre el volante a izquierdas
2800
900
Viertakt - Diesel
Four-stroke diesel
Diesel 4 temps
Diesel a 4 tiempos
1.00.03 © 2001 / 0297 9959

Technische Daten
Specification data
Datos técnicos
Verbrennungs- Combustion Principe de Sistema de

verfahren system combustion combustión
1
Verdichtungs- Compression Taux de Relación de

verhältnis ratio compression compresión
Kompressionsdruck Compression pressure Compression Presión de

compresión
bar bar bars bar
Zündfolge Firing order Ordre d’allumage Orden de

encendido
Abmessungen des Dimensions of Dimensions du Dimensiones del

Motors mit engine incl. moteur avec carter motor con cárter
Anschlußgehäuse standard flywheel d’adaptation de adaptación
(normal) standard (normal)
größte Länge Max. length Longueura HT Longitud máx.
mm mm mm mm
größte Breite Max. width Largeur HT Anchura máx.
mm mm mm mm
größte Höhe Max. height Hauteur HT Altura máx.
mm mm mm mm
© 2001 / 0297 9959 1.00.04

Technische Daten
Specification data
Datos técnicos
F2 - 4L 2011 BF3-4L 2011 F2-4M 2011 BF3-4M 2011
Direkteinspritzung
Direct injection
Injection directe 1
Inyección directa
19 17,5 19 17,5
FL/M = 25 - 30
BFL/M = 22 - 27
1-2 1-2
1-2-3 1-2-3 1-2-3 1-2-3
1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
F2L = 501 F2M = 508

F3L = 612 BF3L = 612 F3M = 619 BF3M = 619
F4L = 724 BF4L = 724 F4M = 731 BF4M = 731
F2L = 510 F2M = 510

F3L = 509 BF3L = 569 F3M = 525 BF3M = 631
F4L = 523 BF4L = 556 F4M = 523 BF4M = 556
F2L = 683 F2M = 683

F3L = 678 BF3L = 695 F3M = 678 BF3M = 695
F4L = 707 BF4L = 707 F4M = 707 BF4M = 707
1.00.05 © 2001 / 0297 9959

Technische Daten
Specification data
Datos técnicos
Steuerzeiten ohne Valve timing without Calage distribution sans Cotas de reglaje sin
Stößel- und Ventilspiel valve clearance jeux des poussoirs juegos de válvulas y
et soupapes de empujadores
1
Einlaß öffnet Inlet opens Admission ouvre Admisión abre

vor OT before TDC avant PMH a. PMS
Einlaß schließt Inlet closes Admission ferme Admisión cierra

nach UT after BDC après PMB t. PMI
Auslaß öffnet Exhaust opens Echappement ouvre Escape abre

vor UT before BDC avant PMB a. PMI
Auslaß schließt Exhaust closes Echappement ferme Escape cierra

nach OT after TDC après PMH t. PMS
Mindestöldruck bei warmem Minimum oil pressure during Pression d’huile mini sur Presión mín. de aceite a
Motor, warm motor, moteur chaud, motor caliente, temperatura
Öltemperatur 110 °C Oil temperature 110 °C, température d’huile 110 °C, del aceite 110 °C,
Öl SAE 20/20 Oil SAE 20/20 huile SAE 20/20, SAE 20/20,
bei: during: à: a:
900/min (niederer Leerlauf) 900/min (lower no-load) 900 tr/mn (ralenti mini) 900 r/min (régimen bajo en
1800/min 1800/min 1800 tr/mn vacío)
max. 2800/min max. 2800/min 2800 tr/mn maxi 1800 r/min
máx. 2800 r/min
*) Angaben für Motoren *) Data related to motors *) Indications pour moteurs *) Datos para motores sin
ohne Motoröl-Heizung without motor oil heating sans chauffage par huile calefacción por el aceite
moteur del motor
bar bar bars bar
Absteuerventil Pressurestat Clapet de décharge Válvula reguladora

final
bar bar bars bar
© 2001 / 0297 9959 1.00.06

Technische Daten
Specification data
Datos técnicos
F2 - 4L 2011 BF3-4L 2011 F2 - 4M 2011 BF3-4M 2011
45 47 45 47
65 63 65 63
76 99,5 76 99,5
44 51,5 44 51,5
1,4 *)
2,2 *)
3 *)
F2 - 3L = 6,5 BF3L = 6,5 F2 - 3M = 6,5 BF3M = 6,5

F4L = 7 BF4L = 7 F4M =7 BF4M = 7
1.00.07 © 2001 / 0297 9959

Technische Daten
Specification data
Datos técnicos
© 2001 / 0297 9959


1 1
Kurbelwellenstellung 1 Kurbelwellenstellung 2 Turn engine until valves of cylinder No. 1
overlap.
Virer le moteur jusqu'au chevau-chement
des soupapes au cylindre 1.
del cilindro N° 1 coincidan en su posición
momentánea.
1 2 1 2
1 2 3 1 2 3
1 2 3 4 1 2 3 4
© 2001 / 0297 9959 1.00.09 1.00.09 © 2001 / 0297 9959


1 1
Kurbelwellenstellung 1 Kurbelwellenstellung 2 Turn engine until valves of cylinder No. 1
overlap.
Virer le moteur jusqu'au chevau-chement
des soupapes au cylindre 1.
del cilindro N° 1 coincidan en su posición
momentánea.
1 2 1 2
1 2 3 1 2 3
1 2 3 4 1 2 3 4
© 2001 / 0297 9959 1.00.09 1.00.09 © 2001 / 0297 9959

Krümmerseite, Manifold side, Krümmerseite, Manifold side,

1 1
5 1 3 5 1 3

5 1 2 8 5 1 2 8

10 3 1 2 7 10 3 1 2 7
© 2001 / 0297 9959 1.00.11 1.00.11 © 2001 / 0297 9959


1 1
5 1 3 5 1 3

5 1 2 8 5 1 2 8

10 3 1 2 7 10 3 1 2 7
© 2001 / 0297 9959 1.00.11 1.00.11 © 2001 / 0297 9959

1 1

Abfangen Abfangen


erneuern erneuern
© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

1 1

Abfangen Abfangen


erneuern erneuern
© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Key to Symbols


1 1

© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Key to Symbols


1 1

© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Explication des symboles

Déassemblage Prévention de dommages corporels Déassemblage Prévention de dommages corporels
d’ensemble constructifs Signalisation de danger d’ensemble constructifs Signalisation de danger

1 1
Assemblage Prévention de dommages Assemblage Prévention de dommages
d’un ensemble constructif Endommagement de pièces d’un ensemble constructif Endommagement de pièces
Démontage - Dépose Supporter - Etayer Démontage - Dépose Supporter - Etayer
de pièces entravant l’accès de pièces entravant l’accès
Remontage - Repose Huiler Remontage - Repose Huiler
de pièces qui entravaient la dépose de pièces qui entravaient la dépose
Attention, remarque importante Graisser Attention, remarque importante Graisser
Contrôler - régler Repérer Contrôler - régler Repérer

avant désassemble, respecteur au avant désassemble, respecteur au
p. ex. couples, cotes, pressions etc. réassemblage p. ex. couples, cotes, pressions etc. réassemblage
Outillage spécial Equilibrer Outillage spécial Equilibrer
éliminer le balourds éliminer le balourds
Respecter le sens de montage Remplir - Faire l’appoint Respecter le sens de montage Remplir - Faire l’appoint
p. ex. huile, eau de refroidissement p. ex. huile, eau de refroidissement
Contrôle - Vérifier Vidange Contrôle - Vérifier Vidange
Contrôle visuel p. ex. huile, eau de refroidissement Contrôle visuel p. ex. huile, eau de refroidissement
Réutilisation conditionnelle Desserrer Réutilisation conditionnelle Desserrer
Remplacer le cas échéant p. ex. desserrer un dispositiv de tension Remplacer le cas échéant p. ex. desserrer un dispositiv de tension
Toujours remplacer au remontage Serrer Toujours remplacer au remontage Serrer
p. ex. serrer un dispositif de tension p. ex. serrer un dispositif de tension
Débloquer - Arrêter Purge d’air Débloquer - Arrêter Purge d’air
p. ex. goupille, tôle d’arrêt etc. p. ex. goupille, tôle d’arrêt etc.
Freiner - Coller Usinage par enlèvement de copeaux Freiner - Coller Usinage par enlèvement de copeaux
p. ex. produit d’étanchéité liquide p. ex. produit d’étanchéité liquide
© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Explication des symboles

Déassemblage Prévention de dommages corporels Déassemblage Prévention de dommages corporels
d’ensemble constructifs Signalisation de danger d’ensemble constructifs Signalisation de danger

1 1
Assemblage Prévention de dommages Assemblage Prévention de dommages
d’un ensemble constructif Endommagement de pièces d’un ensemble constructif Endommagement de pièces
Démontage - Dépose Supporter - Etayer Démontage - Dépose Supporter - Etayer
de pièces entravant l’accès de pièces entravant l’accès
Remontage - Repose Huiler Remontage - Repose Huiler
de pièces qui entravaient la dépose de pièces qui entravaient la dépose
Attention, remarque importante Graisser Attention, remarque importante Graisser
Contrôler - régler Repérer Contrôler - régler Repérer

avant désassemble, respecteur au avant désassemble, respecteur au
p. ex. couples, cotes, pressions etc. réassemblage p. ex. couples, cotes, pressions etc. réassemblage
Outillage spécial Equilibrer Outillage spécial Equilibrer
éliminer le balourds éliminer le balourds
Respecter le sens de montage Remplir - Faire l’appoint Respecter le sens de montage Remplir - Faire l’appoint
p. ex. huile, eau de refroidissement p. ex. huile, eau de refroidissement
Contrôle - Vérifier Vidange Contrôle - Vérifier Vidange
Contrôle visuel p. ex. huile, eau de refroidissement Contrôle visuel p. ex. huile, eau de refroidissement
Réutilisation conditionnelle Desserrer Réutilisation conditionnelle Desserrer
Remplacer le cas échéant p. ex. desserrer un dispositiv de tension Remplacer le cas échéant p. ex. desserrer un dispositiv de tension
Toujours remplacer au remontage Serrer Toujours remplacer au remontage Serrer
p. ex. serrer un dispositif de tension p. ex. serrer un dispositif de tension
Débloquer - Arrêter Purge d’air Débloquer - Arrêter Purge d’air
p. ex. goupille, tôle d’arrêt etc. p. ex. goupille, tôle d’arrêt etc.
Freiner - Coller Usinage par enlèvement de copeaux Freiner - Coller Usinage par enlèvement de copeaux
p. ex. produit d’étanchéité liquide p. ex. produit d’étanchéité liquide
© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Leyenda de los pictogramas Leyenda de los pictogramas

Desarmar Prevención de daños personales Desarmar Prevención de daños personales
grupos de construcción Aviso a puntos de peligro grupos de construcción Aviso a puntos de peligro
1 1
Ensamblar Prevención de daños materiales Ensamblar Prevención de daños materiales
un grupo de construcción Daños en partes o piezas un grupo de construcción Daños en partes o piezas
Desmontar Colocar sobre caballete Desmontar Colocar sobre caballete

- apoyar - sostener - retener - apoyar - sostener - retener
elementos estorbantes elementos estorbantes
Remontar Aceitar Remontar Aceitar

elementos que habían estorbado elementos que habían estorbado
en el desmontaje en el desmontaje
Atención: Indicación importante Lubricar con grasa Atención: Indicación importante Lubricar con grasa
Verificar - ajustar Marcar Verificar - ajustar Marcar

antes de desarmar, observar las marcas antes de desarmar, observar las marcas
p.ej. pares motor, medidas, presiones, etc. al remontar p.ej. pares motor, medidas, presiones, etc. al remontar
Eliminar desequilibrios Eliminar desequilibrios
Dirección de montaje Llenar - reponer - rellenar Dirección de montaje Llenar - reponer - rellenar
p.ej. aceite, agua de refrigeración, etc. p.ej. aceite, agua de refrigeración, etc.
Inspección visual Evacuar Inspección visual Evacuar
Reutilizable en determinadas Soltar Reutilizable en determinadas Soltar

condiciones condiciones
Sustituir, si es necesario p.ej. aflojar un dispositivo de sujeción Sustituir, si es necesario p.ej. aflojar un dispositivo de sujeción
Renovar en cada montaje Fijar Renovar en cada montaje Fijar
p.ej. apretar un dispositivo de sujeción p.ej. apretar un dispositivo de sujeción
Quitar - colocar elementos Purgar de aire Quitar - colocar elementos Purgar de aire
de seguridad de seguridad
p.ej. pasador de aletas, chapa de seguridad, etc. p.ej. pasador de aletas, chapa de seguridad, etc.
Frenar - pegar Mecanizado con arranque de virutas Frenar - pegar Mecanizado con arranque de virutas
p.ej. utilizando pasta sellante p.ej. utilizando pasta sellante
© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Leyenda de los pictogramas Leyenda de los pictogramas

Desarmar Prevención de daños personales Desarmar Prevención de daños personales
grupos de construcción Aviso a puntos de peligro grupos de construcción Aviso a puntos de peligro
1 1
Ensamblar Prevención de daños materiales Ensamblar Prevención de daños materiales
un grupo de construcción Daños en partes o piezas un grupo de construcción Daños en partes o piezas
Desmontar Colocar sobre caballete Desmontar Colocar sobre caballete

- apoyar - sostener - retener - apoyar - sostener - retener
elementos estorbantes elementos estorbantes
Remontar Aceitar Remontar Aceitar

elementos que habían estorbado elementos que habían estorbado
en el desmontaje en el desmontaje
Atención: Indicación importante Lubricar con grasa Atención: Indicación importante Lubricar con grasa
Verificar - ajustar Marcar Verificar - ajustar Marcar

antes de desarmar, observar las marcas antes de desarmar, observar las marcas
p.ej. pares motor, medidas, presiones, etc. al remontar p.ej. pares motor, medidas, presiones, etc. al remontar
Eliminar desequilibrios Eliminar desequilibrios
Dirección de montaje Llenar - reponer - rellenar Dirección de montaje Llenar - reponer - rellenar
Inspección visual Evacuar Inspección visual Evacuar
Reutilizable en determinadas Soltar Reutilizable en determinadas Soltar

condiciones condiciones
Sustituir, si es necesario p.ej. aflojar un dispositivo de sujeción Sustituir, si es necesario p.ej. aflojar un dispositivo de sujeción
Renovar en cada montaje Fijar Renovar en cada montaje Fijar
p.ej. apretar un dispositivo de sujeción p.ej. apretar un dispositivo de sujeción
Quitar - colocar elementos Purgar de aire Quitar - colocar elementos Purgar de aire
de seguridad de seguridad
p.ej. pasador de aletas, chapa de seguridad, etc. p.ej. pasador de aletas, chapa de seguridad, etc.
Frenar - pegar Mecanizado con arranque de virutas Frenar - pegar Mecanizado con arranque de virutas
p.ej. utilizando pasta sellante p.ej. utilizando pasta sellante
© 2001 / 0297 9959 1.00.13 © 2001 / 0297 9959 1.00.13

Verificación y ajustes 2011
© 2001 / 0297 9959

Inhalts-Verzeichnis Prüfen und Einstellen
Table of Contents Checking and adjusting
Sommaire Contrôle et réglage
Indice Verificación y ajustes
2. Prüfen und Einstellen Seite
Ventilspiel _____________________________________________________________ 2.00.01 - 2.00.02

Kompressionsdruck _____________________________________________________ 2.00.03 - 2.00.04
Einspritzventil __________________________________________________________ 2.00.05 - 2.00.07
English
2. Checking and adjusting Page
Valve clearance ________________________________________________________ 2.00.01 - 2.00.02

Compression pressure ___________________________________________________ 2.00.03 - 2.00.04 2
Injector _______________________________________________________________ 2.00.05 - 2.00.07
Français
2. Contrôle et réglage Page
Jeu des soupapes ______________________________________________________ 2.00.01 - 2.00.02

Pression de compression _________________________________________________ 2.00.03 - 2.00.04
Injecteur ______________________________________________________________ 2.00.05 - 2.00.07
Español
2. Verificación y ajustes Pagina
Juego de válvulas _______________________________________________________ 2.00.01 - 2.00.02

Presión de compresión ___________________________________________________ 2.00.03 - 2.00.04
Inyector _______________________________________________________________ 2.00.05 - 2.00.07
© 2001 / 0297 9959

Contrôle et réglage Jeu des soupapes
The standard valve clearance can be Un réglage standard du jeu des soupapes El juego estándar de válvulas se puede
adjusted: peut se faire : ajustar:
with engine cold or warm after cooling sur moteur froid ou chaud après une durée A motor frío o a motor caliente tras un
down for at least 0.5 h. de refroidissement d’au moins 0,5 h. período de enfriamiento de, por lo menos,
media hora (0,5 h).
Oil temperature ≤ 80°C. Température d’huile ≤ 80 °C. Temperatura del aceite: ≤ 80 °C
Note: The valve clearance is to be in- Nota: Après chaque remplacement Nota: Cada vez que se cambia la junta
creased by 0.1 mm at every cy- de joint de culasse, le jeu des de culata, es necesario aumentar
linder head gasket renewal. soupapes est à augmenter de el juego de válvulas en 0,1 mm.
After 1000 Bh , the standard 0,1 mm. Tras 1000 horas de funcionamiento
valve clearance is to be adjusted. Après 1000 h de marche, régler le hay que ajustar el juego estándar
jeu de soupape standard. de válvulas.
Cylinder head cover has been removed. La cache-culbuteurs est déposé La tapa de culata está desmontada.
2 1. Turn engine until valves of cyl. No. 1 1. Virer le moteur jusqu’à ce que les sou- 1. Girar el cigüeñal hasta que se crucen
overlap. papes du cylindre n° 1 soient en bascule. las válvulas en el cilindro No. 1.
For valve clearance adjustment Schéma de réglage du jeu des Para el esquema de ajuste del juego de
schematic see Specification Data. soupapes, voir Caractéristiques válvulas, ver Datos técnicos.
techniques.
Note: Valves overlapping means: Nota: Soupapes en bascule signifie: Nota: Por cruce de válvulas se entiende:
Exhaust valve about to close. soupape d’échappement pas La válvula de escape aún no está
Inlet valve about to open. encore fermée, soupape cerrada y la de admisión empieza
Neither pushrod can be turned d’admission commence à s’ouvrir. a abrirse, sin que se puedan girar
in this position. Les deux tiges de culbuteur ne se las dos varillas de empuje en esta
laissent pas tourner alors. posición.
2. Adjust valve clearance on respective 2. Régler le jeu des soupapes du 2. Ajustar el juego de válvula en el
cylinder with feeler gauge. cylindre correspondant avec une cilindro correspondiente mediante la
jauge d’épaisseur. galga de espesores.
Note: Inlet valve clearance: 0.3 mm Nota: Jeu de soupape Admission 0,3 mm Nota: Juego de válvula admisión: 0,3 mm
Exhaust valve clearance: 0.5 mm Jeu de soupape Juego de válvula escape: 0,5 mm
Echappement 0,5 mm
3. Tighten locknut. 3. Serrer le contre-écrou. 3. Apretar la contratuerca.
Tightening specification: 20 ± 2 Nm Prescription de serrage: 20 ± 2 Nm Prescripción de apriete: 20 ± 2 Nm
Recheck the adjustment with Vérifier encore une fois le réglage Verificar otra vez el ajuste efectuado,
feeler gauge. avec la jauge d’épaisseur. mediante la galga de espesores.
© 2001 / 0297 9959 2.00.01

Jeu des soupapes Contrôle et réglage
Die Standard-Ventilspieleinstellung ist möglich:
Am kalten- oder am warmen Motor nach einer

Abkühlzeit von mindestens 0,5 h.
Öltemperatur ≤ 80 °C
Hinweis: Bei jedem Zylinderkopf-Dichtungswech-

sel ist das Ventilspiel um 0,1 mm zu er-
höhen.
Nach 1000 Bh ist das Standard-Ventil-
spiel einzustellen.
Zylinderkopfhaube ist abgebaut
1. Motor durchdrehen bis zum Erreichen der

9
Ventilüberschneidung, Zyl. Nr. 1.
2
siehe Techn. Daten
33762 ©
Hinweis: Ventilüberschneidung bedeutet:

Auslassventil ist noch nicht geschlossen,
Einlassventil beginnt zu öffnen.
9
Dabei sind beide Stoßstangen nicht
drehbar. 5
33763 ©
2. Ventilspieleinstellung am entsprechenden
Zylinder mit Fühlerlehrenblatt einstellen. 6
Hinweis: Ventilspiel Einlass:
Ventilspiel Außlass:
0,3 mm
0,5 mm
5
3. Kontermutter festdrehen.
Einstellung nochmals mit Fühlerlehrenblatt

überprüfen. 33764 ©
2.00.01 © 2001 / 0297 9959

Contrôle et réglage Jeu des soupapes
Werkstatthandbuch 2011 Deutsch
4
0
33765 ©
5. Neue Gummischläuche an Überströmleitung

4 und Einspritzventile bis Anschlag aufschieben.
Zylinderkopfhaube und Überströmleitung mon-
2 6 tieren. Schrauben festdrehen.
33766 ©
© 2001 / 0297 9959 2.00.02

Jeu des soupapes Contrôle et réglage
4. Put gasket in place. 4. Mettre en place le joint. 4. Colocar la junta.
5. Insert New rubber tubes at the 5. Emmancher des flexibles en caout- 5. Colocar mangueras de goma
cross-over pipe and injection valves chouc neufs sur la rampe de décharge nuevas sobre la tubería de rebose
until the end stop. et les injecteurs jusqu’en butée. y los inyectores hasta el tope.
Mount the cylinder head cover and Monter le cache-culbuteurs et la Montar la tapa de culata y la tubería
the cross-over pipe. Tighten bolts. rampe de décharge. Serrer les vis. de rebose. Apretar los tornillos. 2
Tightening specification: 8.5 Nm Prescription de serrage: 8,5 Nm Prescripción de apriete: 8,5 Nm
2.00.02 © 2001 / 0297 9959

Contrôle et réglage Pression de compression
Commercial tools required: Outillage standard: Herramientas comerciales:
Compression tester _____________ 8005 Compressiomètre ______________ 8005 Compresímetro ________________ 8005
Glaw key _____________________ 8018 Clé à griffes ___________________ 8018 Llave de garra _________________ 8018
Torx tool kit ___________________ 8189 Jeu d’outils Torx _______________ 8189 Juego de herramientas Torx ______ 8189
Connector __________________ 100 120 Elément raccord _____________ 100 120 Pieza de empalme ___________ 100 120
Injectors have been removed, valve Les injecteurs sont déposés, le jeu des Los inyectores están desmontados, el
clearance has been checked. soupapes est contrôlé. juego de válvulas está verificado.
1. Insert connector with new special seal. 1. Insérer l’élément raccord avec le joint 1. Introducir la pieza de empalme con
2 spécial. una junta especial.
2. Fit clamping pad. Tighten bolt. 2. Mettre en place la patte de serrage. 2. Colocar la garra de sujeción. Apretar
Serrer la vis. el tornillo.
3. If necessary, screw on adapter for 3. Si nécessaire, visser une pièce 3. De ser necesario, enroscar el
connector. d’adaptation pour l’élément raccord adaptador para la pieza de empalme.
© 2001 / 0297 9959 2.00.03

Pression de compression Contrôle et réglage
Kompressionsdruckprüfer _______________ 8005

Klauenschlüssel ______________________ 8018
Torx-Werkzeugsatz ____________________ 8189
Spezialwerkzeuge:
Anschlussstück _____________________ 100 120
Einspritzventile sind ausgebaut, Ventilspiel ist

kontrolliert. 4
1. Anschlussstück mit Spezialdichtung einsetzen.
7 2
0
33767 ©
2. Spannpratze aufsetzen. Schraube festdrehen.

4
33768 ©
3. Falls notwendig Adapter für Anschlußssstück

aufschrauben. 4
33769 ©
2.00.03 © 2001 / 0297 9959

Contrôle et réglage Pression de compression
4. Kompressionsdruckprüfer anschließen.
4 Motor mit Starter durchdrehen.
Kompressionsdruck:
6 FL/M
BFL/M
25 - 30 bar
22 - 27 bar
33770 ©
Der gemessene Kompressionsdruck ist abhängig

9 von der Anlassdrehzahl während des Mess-
vorganges und der Höhenlage des Motorauf-
2 5 stellortes.
Grenzwerte sind daher nicht genau festlegbar.
Empfohlen wird die Kompressionsdruckmessung
nur als Vergleichsmessung aller Zylinder eines
Motors untereinander anzusehen. Sind mehr als
15% Abweichung ermittelt worden, sollte durch
die Demontage der betroffenen Zylindereinheit die
Ursache ermittelt werden.
33771 ©
Hinweis: Einspritzventile mit neuer Spezialdich-

tung einsetzen und festdrehen.
Einspritzleitungen anbauen und fest-

drehen.
Neue Gummischläuche an Überström-

leitung und Einspritzventile bis Anschlag
aufschieben.
Überströmleitung anbauen.
© 2001 / 0297 9959 2.00.04

Pression de compression Contrôle et réglage
4. Connect compression tester. Turn 4. Brancher le compressiomètre. Virer le 4. Conectar el compresímetro. Girar el
engine with starter. moteur à l’aide du démarreur. motor mediante el arrancador.
Compression pressure: Pression de compression: Presión de compresión:
Fl/M 25 - 30 bar FL/M 25 à 30 bars FL/M 25 - 30 bar
BFL/M 22 - 27 bar BFL/M 22 à 27 bars BFL/M 22 - 27 bar
The measured compression pressure is La pression de compression mesurée La presión de compresión medida
dependent on the starting speed during dépend de la vitesse de démarrage depende de la velocidad de arranque
the measuring process and also on the durant le relevé et de l’altitude du site al hacer la medición y de la altitud
altitude of the engine site. Therefore it is d’installation du moteur. del lugar de instalación del motor.
difficult to specify precise limit values. It Des valeurs limites précises ne peuvent Por eso, no se pueden fijar valores 2
is recommended to use the compression donc pas être fixées. Le relevé de la límite exactos. Se recomienda con-
pressure measure-ment only for compression de compression doit uniquement siderar la medición de la compresión
parison of compression pressures of all être considéré comme relevé comparatif tan sólo como una medición de
cylinders in one engine. If a difference in pour l’ensemble des cylindres d’un moteur. comparación entre todos los cilindros
pressure in excess of 15% is determined, Si l’écart relevé est supérieur à 15%, il de un motor. Si las diferencias son
the cylinder unit concerned should be faut en déterminer la cause par démontage superiores al 15%, es conveniente
dismantled to establish the cause. des unités de cylindre en question. buscar la causa desmontando la
unidad de cilindro afectada.
Note: Fit injector with new special seal Nota: Remonter les injecteurs avec un Nota: Introducir los inyectores con una
and tighten. joint spécial neuf et les serrer. junta especial nueva y apretar.
Tightening specification: 21 Nm Prescription de serrage: 21 Nm Prescripción de apriete: 21 Nm
Attach the injection pipes and fix Remonter les tuyauteries d’injection Montar las tuberías de inyección y
them firmly. et les serrer. apretar.
Tightening specification: 2 ± 2.5 Nm Prescription de serrage: 25 ± 2,5 Nm Prescripción de apriete: 25 ± 2,5 Nm
Insert New rubber tubes at the Emmancher des flexibles en caout- Colocar mangueras de goma
cross-over pipe and injection valves chouc neufs sur la rampe de décharge nuevas sobre la tubería de rebose
until the end stop. et les injecteurs jusqu’en butée. y los inyectores hasta el tope.
Attach the cross-over pipe. Monter la rampe de décharge. Montar la tubería de rebose.
2.00.04 © 2001 / 0297 9959

Contrôle et réglage Injecteur
Nozzle tester __________________ 8008 Pompe d’essai des injecteurs _____ 8008 Comprobador para inyectores ____ 8008
Long socket a/flats 15 ___________ 8021 Douille longue de 15 ____________ 8021 Llave de vaso largo de 15 ________ 8021
Retainer for injector ___________ 110 110 Dispositif de blocage d’injecteur _ 110 110 Retenedor para inyector _______ 110 110
Note: Utmost cleanliness must be en- Nota: Lors de travaux sur le système Nota: Para cualquier trabajo a realizar en
sured when working on the in- d’injection, veiller à la plus grande el equipo de inyección se
jection equipment. For testing the propreté. Pour le contrôle des observará la máxima limpieza.
injector use only pure test oil to injecteurs, n’utiliser que du fuel Para la comprobación de los
ISO 4113 or clean diesel fuel. d’essai pur selon ISO 4113 ou du inyectores se utilizará solamente
gasoil propre. aceite de prueba puro según ISO
4113 ó combustible diesel limpio.
Caution! Attention! Atención:

No acercar nunca las manos al chorro
Beware of injection nozzle fuel jet. The Tenir les mains hors du jet des injecteurs. del inyector, pues el combustible penetra
fuel penetrates deeply into the skin tissue Le combustible peut pénétrer profundamente en los tejidos y puede
and may cause blood poisening. profondément dans la chair et provoquer causar una intoxicación de la sangre.
un empoisonnement du sang.
1. Connect injector to nozzle tester. 1. Monter l’injecteur sur la pompe d’essai 1. Montar el inyector en el comprobador.
des injecteurs.
2. Checking opening pressure 2. Contrôle de la pression d’ouverture 2. Comprobación de la presión de

apertura
With pressure gauge switched on, Le manomètre étant branché, Con el manómetro conectado, tirar
slowly press down lever of nozzle abaisser lentement le levier de la de la palanca del comprobador
tester. The pressure at which the pompe d’essai. La pression à lentamente hacia abajo. La presión
gauge pointer stops or suddenly laquelle l’aiguille s’immobilise ou a la que la aguja se detenga o caiga
drops, is the opening pressure. chute brusquement est la pression bruscamente es la presión de
d’ouverture. apertura.
Opening pressure for initial setting: Pression d’ouverture Presión de apertura

Genset engines = 210 + 8 bar pour un nouveau réglage: 210 + 8 bars para el nuevo ajuste: 210 + 8 bar
© 2001 / 0297 9959 2.00.05

Injecteur Contrôle et réglage
Düsenprüfgerät _______________________ 8008

5
Lange Stecknuss SW 15 ________________ 8021
Spezialwerkzeug:
Halter für Einspritzventil ______________ 110 110
Hinweis: Bei Arbeiten an der Einspritzausrüs-

tung auf größte Sauberkeit achten. Zur
Prüfung der Einspritzventile nur reines
Prüföl nach ISO 4113 oder sauberen
Dieselkraftstoff verwenden. 2
Achtung !
Hände weg vom Düsenstrahl. Der Kraftstoff dringt

e
tief in das Fleisch ein und kann zur Blutvergiftung
führen. 4
1. Einspritzventil an das Düsenprüfgerät anbauen.
33772 ©
2. Prüfung des Öffnungsdruckes
Hebel des Düsenprüfgerätes bei zugeschal-

6
tetem Manometer langsam niederdrücken.
Der Druck bei dem der Zeiger stehen bleibt oder
plötzlich abfällt, ist der Öffungsdruck.
Öffnungsdruck
für die Neueinstellung: 210 + 8 bar
33773 ©
2.00.05 © 2001 / 0297 9959

3. Einstellen des Öffnungsdruckes am

1 Einspritzventil
7 Überwurfmutter abschrauben, alle Teile aus-

bauen.
33774 ©
Folge der Einzeldemontage

8 1. Überwurfmutter
2 r 2. Einspritzdüse
3. Zwischenstück
4. Druckbolzen
5. Druckfeder
6. Ausgleichscheibe
33775 ©
4. Durch Auswahl der erforderlichen Scheibe

6 Druck einstellen. Stärkere Scheibe ergibt hö-
heren Öffnungsdruck. Einspritzventil zusam-
menbauen. Überwurfmutter festdrehen.
Einspritzventil auf dem Düsenprüfgerät erneut

prüfen.
33776 ©
5. Prüfung auf Dichtheit

6 Düse und Düsenhalter abtrocknen - mit Luft
trockenblasen. Handhebel des Prüfgerätes
langsam niederdrücken, bis ca. 20 bar unter-
halb des vorher abgelesenen Öffnungsdruckes
erreicht werden.
33777 ©
© 2001 / 0297 9959 2.00.06

3. Adjusting the opening pressure on 3. Réglage de la pression d’ouverture 3. Ajuste de la presión de apertura en
the injector sur l’injecteur el inyector
Unscrew cap nut and remove all parts Dévisser l’écrou-raccord, démonter Desenroscar la tuerca de unión y
toutes les pièces. desmontar todas las piezas
Sequence of parts disassembly Ordre de démontage des pièces Secuencia del despiece
1. Cap nut 1) Ecrou-raccord 1. Tuerca de unión

2. Injection nozzle 2) Injecteur 2. Inyector o tobera
3. Adapter 3) Pièce intermédiaire 3. Pieza intermedia 2
4. Thrust pin 4) Poussoir 4. Perno de presión
5. Compression spring 5) Ressort 5. Resorte de presión
6. Shims 6) Rondelles de réglage 6. Arandelas de reglaje
4. Adjust pressure by selecting appro- 4. Régler la pression en choisissant la 4. Ajustar la presión eligiendo la
priate shim. A thicker shim increases rondelle adéquate. Une rondelle arandela adecuada. Una arandela
the opening pressure. Reassemble plus épaisse donne une pression más gruesa aumenta la presión
injector. Tighten cap nut. d’ouverture plus élevée. Remonter de apertura. Ensamblar el inyector.
l’injecteur. Serrer l’écrou-raccord. Apretar la tuerca de unión.
Recheck injector on nozzle tester. Contrôler à nouveau l’injecteur sur Comprobar el inyector de nuevo
la pompe d’essai sobre el comprobador.
5. Checking for tightness 5. Contrôle d’étanchéité 5. Comprobación de estanqueidad
Dry nozzle and nozzle holder - blow Sécher l’injecteur et le porte-injecteur Secar el inyector (tobera) y portain-
out with compressed air. Press down au jet d’air. Abaisser lentement le yector, soplándolos con aire com-
handlever of nozzle tester slowly until levier de la pompe d’essai jusqu’à env. primido. Tirar de la palanca del
a pressure of about 20 bar below the 20 bars au-dessous de la pression comprobador lentamente hacia
previous opening pressure reading is d’ouverture relevée précédemment. abajo hasta que se alcance una
attained. presión en aprox. 20 bar inferior a
la de apertura leída anteriormente.
2.00.06 © 2001 / 0297 9959

6. Nozzle is tight if there is no dripping 6. L’injecteur est étanche si aucune goutte 6. El inyector es estanco si, pasados
within a period of 10 seconds. ne s’écoule pendant 10 secondes. 10 segundos, no sale ni una gota.
7. In case of a drip, the injector must be 7. Si l’injecteur goutte, il doit être 7. Si sale una gota, es necesario despie-
dismantled and cleaned to remedy démonté et la fuite éliminée par zar y limpiar el inyector para eliminar
the leak. If this does not cure the leak, nettoyage. En cas d’échec, la falta de estanqueidad. Si esto no
the injector must be replaced. remplacer l’injecteur. surte el efecto deseado, hay que
2 sustituir el inyector por otro nuevo.
Reworking is not permissible. Ne jamais rectifier l’injecteur. No está permitido rectificar el

inyector.
8. Buzzing and spray pattern test 8. Contrôle du crissement et du jet 8. Comprobación del ronquido y la
pulverización
Switch off pressure gauge of tester. Débrancher le manomètre de la Desconectar el manómetro del
pompe d’essai. comprobador.
The buzzing test permits an audible Le contrôle du crissement est un La comprobación del ronquido
check of the ease of movement of the contrôle acoustique du mouvement de permite verificar audiblemente el fácil
nozzle needle in the nozzle body. l’aiguille dans le corps de l’injecteur. movimiento de la aguja dentro del
New injectors emit a different buzzing Les injecteurs neufs présentent un cuerpo del inyector. Un inyector nuevo
sound as compared to used injectors. comportement de crissement différent tiene un ronquido distinto del de un
It deteriorates due to wear in the par rapport aux injecteurs usagés. inyector usado.
needle seat area. If an injection nozzle Par suite de l’usure du logement El ronquido disminuye con el des-
does not buzz despite cleaning, it d’aiguille, il se détériore. Si malgré gaste en la zona de asiento de la
must be renewed. nettoyage, un injecteur ne crisse plus, aguja. Si un inyector deja de emitir el
il doit être remplacé par un injecteur ronquido característico pese a su
neuf. limpieza anterior, hay que sustituirlo
por otro nuevo.
A used injector should buzz clearly Un injecteur usagé doit présenter un A rápido accionamiento de la palanca,
during rapid actuation of the crissement audible lorsque le levier un inyector usado debe roncar de
handlever, while exhibiting a well est actionné rapidement et bien forma audible y dar un chorro bien
atomized spray pattern. The spray pulvériser alors. La forme du jet peut pulverizado, pudiendo variar la
pattern may differ noticeably from that alors être nettement différente de celle pulverización claramente de la de un
of a new injector. d’un injecteur neuf. inyector nuevo.
© 2001 / 0297 9959 2.00.07

6. Düse ist dicht, wenn innerhalb 10 Sekunden

kein Tropfen abfällt.
9
33778 ©
7. Fällt ein Tropfen ab, ist das Einspritzventil zu

zerlegen und die Undichtigkeit durch Reinigen
zu beseitigen. Ist das nicht erfolgreich, muss die
9
Einspritzdüse erneuert werden.
2
Nacharbeit ist nicht zulässig.
33779 ©
8. Schnarr- und Strahlprüfung
Manometer des Prüfgerätes abschalten.

9
Die Schnarrprüfung ermöglicht eine hörbare
Prüfung der Leichtgängigkeit der Düsennadel im
Düsenkörper. Neue Einspritzventile haben ge-
genüber gebrauchten ein geändertes Schnarr-
verhalten.
Durch Verschleiß im Nadelsitzbereich ver-
schlechtert es sich. Schnarrt eine Einspritzdüse
trotz Reinigung nicht, muß sie durch eine neue 33780 ©
ersetzt werden.
Ein gebrauchtes Einspritzventil muss bei

schneller Hebeltätigkeit hörbar schnarren und
dabei gut zerstäubt abspritzen. Das Strahlbild
kann dabei gegenüber dem eines neuen
Einspritzventils deutlich unterschiedlich sein.
2.00.07 © 2001 / 0297 9959

© 2001 / 0297 9959

Reparación de componentes 2011
© 2001 / 0297 9959

© 2001 / 0297 9959
Inhalts-Verzeichnis Bauteile instand setzen
Table of Contents Repair of components
Sommaire Mise en état des composants
Indice Reparación de componentes
Deutsch
3. Bauteile instand setzen
Baugruppe Benennung Seite

01 Zylinderkurbelgehäuse 3.01.01 - 3.01.11
01 Hinterer Deckel 3.01.15 - 3.01.16
05 Kurbelwelle 3.05.19 - 3.05.20
05 Starterkranz / Schwungrad 3.05.23
06 Pleuelstange 3.06.27 - 3.06.31
07 Kolben 3.07.35 - 3.07.38
08 Zylinderkopf 3.08.41 - 3.08.46
10 Nockenwelle 3.10.49
11 Kipphebelbock 3.11.53
19 Einspritzventil 3.19.57 - 3.19.59
27 Vorderer Deckel 3.27.63 - 3.27.78
39 Kühlgebläse 3.39.81 - 3.39.86
39 Keilriemenspannrolle 3.39.89
39 Lüfterantrieb 3.39.93 - 3.39.95
English
3. Repair of components 3
Assembly Group Description Page
01 Crankcase with integrated cylinder liners 3.01.01 - 3.01.11
01 Rear cover 3.01.15 - 3.01.16
05 Crankshaft 3.05.19 - 3.05.20
05 Starter ring gear / flywheel 3.05.23
06 Connecting rod 3.06.27 - 3.06.31
07 Piston 3.07.35 - 3.07.38
08 Cylinder head 3.08.41 - 3.08.46
10 Camshaft 3.10.49
11 Rocker arm bracket 3.11.53
19 Injector 3.19.57 - 3.19.59
27 Front cover 3.27.63 - 3.27.78
39 Blower 3.39.81 - 3.39.86
39 Idler pulley 3.39.89
39 Fan drive 3.39.93 - 3.39.95
© 2001 / 0297 9959

Bauteile instand setzen Inhalts-Verzeichnis
Repair of components Table of Contents
Mise en état des composants Sommaire
Reparación de componentes Indice
Français
3. Mise en état des composants
Groupe Désignation Page

01 Bloc-cylindres 3.01.01 - 3.01.11
01 Couvercle arriére 3.01.15 - 3.01.16
05 Vilebrequin 3.05.19 - 3.05.20
05 Couronne de démarrage / volant 3.05.23
06 Bielle 3.06.27 - 3.06.31
07 Piston 3.07.35 - 3.07.38
08 Culasse 3.08.41 - 3.08.46
10 Arbre à cames 3.10.49
11 Support de culbuteurs 3.11.53
19 Injecteur 3.19.57 - 3.19.59
27 Couvercle avant 3.27.63 - 3.27.78
39 Ventilateur de refroidissement 3.39.81 - 3.39.86
39 Galet tendeur 3.39.89
39 Entraînement ventilateur 3.39.93 - 3.39.95
Español
3 3. Reparación de componentes
Grupo de construcción Denominación Página

01 Bloque motor 3.01.01 - 3.01.11
01 Tapa trasera 3.01.15 - 3.01.16
05 Cigüeñal 3.05.19 - 3.05.20
05 Corona del volante / volante 3.05.23
06 Biela 3.06.27 - 3.06.31
07 Pistón 3.07.35 - 3.07.38
08 Culata 3.08.41 - 3.08.46
10 Arbol de levas 3.10.49
11 Soporte de balancines 3.11.53
19 Inyector 3.19.57 - 3.19.59
27 Tapa frontal 3.27.63 - 3.27.78
39 Turbina de refrigeración 3.39.81 - 3.39.86
39 Polea tensora 3.39.89
39 Accionamiento del ventilador 3.39.93 - 3.39.95
© 2001 / 0297 9959

Bloc-cylindres Mise en état des composants
Bloque motor Reparación de componentes
© 2001 / 0297 9959

Mise en état des composants Bloc-cylindres
Reparación de componentes Bloque motor
Commercial tools required: Outillage standard Herramientas comerciales:

Screw driver socket _____________ 8112 Embout de tournevis ____________ 8112 Punta de destornillador __________ 8112
Internal dial gauge Appareil de mesure d’intérieur Micrómetro de interiores
Special tools required: Outillage spécial Herramientas especiales:

Assembly tool for Outil de montage de douille Herramienta de montaje para
control rod bush _____________ 110 140 de crémaillère _______________ 110 140 casquillos de cremallera _______ 110 140
Assembly tool for Outil de montage de douille Herramienta de montaje para
camshaft bush _______________ 143 820 d’arbre à cames _____________ 143 820 casquillos de árbol de levas ____ 143 820
Puller for pipe _______________ 150 140 Extracteur de tube ____________ 150 140 Extractor de tubos ____________ 150 140
Assembly arbor for pipe _______ 150 150 Mandrin de montage de tube ___ 150 150 Mandril de montaje para tubos __ 150 150
1. Clean the crankcase with 1. Nettoyage et examen visuel du 1. Limpieza e inspección del bloque
integrated cylinder liners and bloc-cylindres. motor.
carry out a visual check.
1.1 Remove the locking screws. 1.1 Dévisser les bouchons filetés. 1.1 Desenroscar los tapones. Limpiar
Clean the crankshaft casing and Nettoyer le bloc-cylindres et el bloque motor e inspeccionarlo
carry out a visual check for damage. l’examiner quant à des endommage- en cuanto a daños. Comprobar los
Check the oil channels for leakage. ments. Contrôler le libre passage conductos de aceite en cuanto a
des canaux d’huile. libre paso.
2. Measure the main 2. Mesure des alésages de paliers 2. Medición de los alojamientos /
bearing bores / bearing shells principaux / coussinets de paliers cojinetes de apoyo del cigüeñal
(if necessary) (le cas échéant). (si es necesario)
3
2.1 Mount on the crankshaft bearing 2.1 Monter les chapeaux de paliers de 2.1 Montar las tapas de cojinete /
cover / bearing shells and tighten vilebrequin / coussinets de paliers et cojinetes del apoyo. Apretar los
the screws firmly. serrer les vis. tornillos.
Torque specification: Prescription de serrage: Prescripción de apriete:

Pretension value 50 Nm Couple de préserrage 50 Nm Apriete inicial 50 Nm
Restress angle plate 1. stage 60° Angle de Reapriete 1a fase 60°
2. stage 45° serrage définitif 1e passe 60° 2a fase 45°
2e passe 45°
2.2 Measure the bearing bores / bearing 2.2 Mesurer les alésages de paliers/ 2.2 Sirviéndose del micrometro de
shells at the positions 1 and 2 the coussinets de paliers aux points 1 et interiores, medir los alojamientos /
level ”a“ and ”b“ with a measuring 2 dans les plans « a » et « b » avec cojinetes de apoyo en los puntos
instrument. un appareil de mesure d’intérieur. 1 y 2 de los planos ”a“ y ”b“.
Bearing bores nominal Cote nominale d’alésage Alojamientos medida

dimension 75.0 - 75.019 mm de palier 75,0 - 75,019 mm nominal 75,0 - 75,019 mm
Bearing shells nominal Cote nominale de coussinet Cojinetes medida
dimension 70.02 - 70.055 mm de palier 70,02 - 70,055 mm nominal 70,02 - 70,055 mm
Main bearing clearance nominal Cote nominale du jeu Juego de cojinete
dimension 0.03 - 0.085 mm de palier principal 0,03 - 0,085 mm medida nominal 0,03 - 0,085 mm
© 2001 / 0297 9959 3.01.01

Schraubendrehereinsatz ________________ 8112
Innenmessgerät
Spezialwerkzeuge:
Regelstangenbuchse ________________ 110 140
Nockenwellenbuchse ________________ 143 820
Ausziehwerkzeug für Rohr ____________ 150 140
Montagedorn für Rohr ________________ 150 150
1. Zylinderkurbelgehäuse reinigen und sicht-

prüfen. 1
1.1 Verschlussschrauben herausschrauben.
Kurbelgehäuse reinigen und auf Beschädigung 9
sichtprüfen. Ölkanäle auf freien Durchlass
prüfen.
33783 ©
2. Hauptlagerbohrungen / Lagerschalen
messen ( bei Bedarf) 2
3
2.1 Kurbelwellenlagerdeckel / Lagerschalen mon-
tieren und Schrauben festdrehen. 6
Anziehvorschrift:
Vorspannwert 50 Nm
Nachspannwinkel 1. Stufe 60°
2. Stufe 45°
33784 ©
2.2 Lagerbohrungen / Lagerschalen an den Punk-

ten 1 und 2 in der Ebene „a“ und „b“ mit
Innenmessgerät messen.
6
Lagerbohrungen Nennmaß 75,0 - 75,019 mm
Lagerschalen Nennmaß 70,02 - 70,055 mm
Hauptlagerspiel Nennmaß 0,03 - 0,085 mm
33785 ©
3.01.01 © 2001 / 0297 9959

3. Zylinder messen
9 Zum Messen der Zylinder müssen die Kurbel-
wellenlagerdeckel ordnungsgemäß montiert sein.
3.1 Zylinder mit Innenmessgerät
- in der Motorlängsachse „a“ und Motor-

querachse „b“
33786 ©
- und in der Ebene 1-3 messen.

9
33787 ©
3.2 Innendurchmesser der Zylinder:

6 Nennmaß 94,0 - 94,02 mm
3 Verschleißgrenze 94,1 mm
Übermaßstufe 94,5- 94,52 mm

Verschleißgrenze 94,6 mm
33788 ©
Entsprechen die Messungen der Zylinder den ange-

gebenen Werten, kann das Zylinderkurbelgehäuse
weiterverwendet werden.
Bei verschlissenen Zylindern kann das Zylinder-
kurbelgehäuse in unseren Service-Centern auf
Übermaßzylinder Ø 94,5 mm aufgehont werden.
© 2001 / 0297 9959 3.01.02

3. Gauge cylinders. 3. Mesure des cylindres 3. Medición de los cilindros
In order to measure the cylinder, the Pour mesurer les cylindres, les Las tapas de cojinete del cigüeñal
crankshaft bearing cover must be properly chapeaux de paliers de vilebrequin deben estar montadas correctamente
mounted. doivent être correctement montés. para la medición de los cilindros.
3.1 Cylinder with a measuring 3.1 Mesurer les cylindres avec 3.1 Sirviéndose del micrómetro de
instrument l’appareil de mesure d’intérieur interiores, medir los cilindros
- in the motor longitudinal axis ”a“ - dans l’axe longitudinal « a » et l’axe - en los ejes longitudinal ”a“ y
and motor transverse axis ”b“ transversal « b » du moteur, transversal ”b“ del motor
- and measure at the level 1-3. - et dans les plans 1 à 3. - así como en los planos 1 a 3.
3.2 Inside diameter of the cylinder: 3.2 Diamètre intérieur des cylindres: 3.2 Diámetro interior de los cilindros:
Cylinder bore 94.0 - 94.02 mm Cote nominale 94,0 - 94,02 mm Medida nominal 94,0 - 94,02 mm
Wear limit 94.1 mm Limite d’usure 94,1 mm Límite de desgaste 94,1 mm 3
Oversized stage 94.5 - 94.52 mm Cote surdimensionnée 94,5 - 94,52 mm Sobremedida 94,5 - 94,52 mm
Wear limit 94.6 mm Limite d’usure 94,6 mm Límite de desgaste 94,6 mm
If the measurements of the cylinders Si les relevés sur les cylindres sont Si los valores medidos de los cilindros
correspond to the indicated values, the conformes aux cotes indiquées, le bloc- corresponden a los especificados, puede
crankcase with integrated cylinder liners. cylindres peut être réutilisé. seguirse utilizando el bloque motor.
In case of worn cylinders, the cylinder En cas d’usure des cylindres, le bloc- Si los cilindros están desgastados, existe
crankshaft casing can be grooved at our cylindres peut être rodé à la cote la posibilidad de hacer repasarlos por
service center to an oversize cylinder surdimensionnée Ø 94,5 mm par bruñido a la sobremedida Ø 94,5 mm en
Ø 94,5 mm. pierrage dans notre Centre de Service. uno de nuestros Centros de Servicio.
3.01.02 © 2001 / 0297 9959

4. Measure the camshaft bearing 4. Mesure des bagues de palier 4. Medición de los casquillos del
bushes d’arbre à cames árbol de levas
4.1 Measure the camshaft bearing 4.1 Mesurer les bagues de palier d’arbre 4.1 Sirviéndose del micrómetro de
bushes with an internal measuring à cames avec l’appareil de mesure interiores, medir los casquillos del
device at the points 1 and 2 at the d’intérieur aux points 1 et 2 et dans árbol de levas en los puntos 1 y 2
level ”a“ and ”b“. les plans « a » et « b ». de los planos ”a“ y ”b“.
4.2 Inside diameter of the camshaft 4.2 Diamètre intérieur des bagues de 4.2 Diámetro interior de los casquillos del
bearing bushes: palier d’arbre à cames: árbol de levas:
Cylinder bore 54.0 - 54.054 mm Cote nominale 54,0 - 54,054 mm Medida nominal 54,0 - 54,054 mm
Wear limit 54.080 mm Limite d’usure 54,080 mm Límite de desgaste 54,080 mm
5. Exchange the camshaft 5. Remplacement des bagues de 5. Sustitución de los casquillos del
bearing bushes palier d’arbre à cames árbol de levas
3 5.1 Remove the bearing bushings. 5.1 Démonter les bagues de palier. 5.1 Desmontar los casquillos.
5.2 Place a new bearing bushing. 5.2 Mettre en place les nouvelles 5.2 Presentar el casquillo nuevo.
bagues de palier.
Note: Observe the fitting of the Nota: Veiller à ce que les alésages Nota: Prestar atencion a la coincidencia
lubricating oil drillings. d’huile coïncident. de los orificios de lubricación.
© 2001 / 0297 9959 3.01.03

4. Nockenwellenlagerbuchsen messen
4.1 Nockenwellenlagerbuchsen mit Innenmess- 6

gerät an den Punkten 1 und 2 in der Ebene
„a“ und „b“ messen.
33789 ©
4.2 Innendurchmesser der Nockenwellenlager-

buchsen:
6
Nennmaß
Verschleißgrenze
54,0 - 54,054 mm
54,080 mm 0
33790 ©
5. Nockenwellenlagerbuchsen austauschen
5.1 Lagerbuchsen ausbauen.

1
3
7
33791 ©
5.2 Neue Lagerbuchse ansetzen.
Hinweis: Auf Übereinstimmung der Schmieröl-

2
bohrungen achten.
8
5
33792 ©
3.01.03 © 2001 / 0297 9959

5.3 Schema: Einbaurichtung der Stoßfuge in der

9 Lagerbuchse.
33793 ©
5.4 Schema: Einziehmaße der Lagerbuchsen.

9 A B
2 Zyl. 2,5 mm 0,5 mm
117,1 mm
3 Zyl. 2,5 mm 0,5 mm
118,9 mm 117,1 mm
4 Zyl. 2,5 mm 0,5 mm
118,9 mm 117,1 mm
228,1 mm
33794 ©
5.4 Lagerbuchse einziehen.

2
3 7
33795 ©
© 2001 / 0297 9959 3.01.04

5.3 Schematic: Installation direction of 5.3 Schéma: sens de montage de la 5.3 Esquema: Dirección de montaje de
joint in the bearing bush. coupe de joint dans la bague de la junta del casquillo.
palier.
5.4 Schematic: Installation dimensions of 5.4 Schéma: Cote d’insertion des bagues 5.4 Esquema: Medidas de introducción
bearing bushes. de palier. de los casquillos.
A B A B A B
117.1 mm 117,1 mm 117,1 mm
118.9 mm 117.1 mm 118,9 mm 117,1 mm 118,9 mm 117,1 mm
118.9 mm 117.1 mm 118,9 mm 117,1 mm 118,9 mm 117,1 mm
228.1 mm 228,1 mm 228,1 mm
5.5 Insert bearing bush. 5.5 Insérer la bague de palier. 5.5 Introducir el casquillo.
3.01.04 © 2001 / 0297 9959

6. Exchange the adjusting rod and 6. Remplacement de la crémaillère et 6. Sustitución de la cremallera y los
guide bushes de la douille de guidage casquillos de guía
6.1. Drive out parallel pin. 6.1 Chasser la goupille cylindrique. 6.1 Desmontar golpeando el pasador
cilíndrico.
6.2 Remove control rod together with 6.2 Extraire la crémaillère avec ressort. 6.2 Retirar la cremallera con el resorte.
spring.
6.3 Remove cover. 6.3 Démonter le couvercle d’obturation. 6.3 Desmontar la tapa de cierre.
6.4 Pierce pipe on one side with a drill of 6.4 Percer le tube d’un côté avec un foret 6.4 Abrir un taladro en un lado del tubo
5.5 mm dia. Ø 5,5 mm. mediante una broca de Ø 5,5 mm.
Note: Carefully clean crankcase after Nota: Après le perçage, nettoyer Nota: Terminado el taladrado, hay qud
drilling. soigneusement le bloc-cylindres. limpiar a fondo bloque motor.
3.01.06
© 2001 / 0297 9959 3.01.05

6. Regelstange und Führungsbuchsen aus-

tauschen
1
6.1 Zylinderstift austreiben.
33796 ©
6.2 Regelstange mit Feder herausnehmen.

1
33797 ©
6.3. Verschlussdeckel ausbauen.

1
3
33798 ©
6.4. Rohr mit einem Bohrer ø 5,5 mm einseitig

durchbohren. f
Hinweis: Nach dem Bohren ist das Kurbelgehäuse
gründlich zu reinigen. 5
33799 ©
3.01.05 © 2001 / 0297 9959

6.5 Ausziehwerkzeug einsetzen, bis der Bolzen in

2 die Bohrung einrastet.
9
7
33800 ©
6.6 Abstandsbuchse aufsetzen. Rohr aus dem

2 unteren Preßsitz herausziehen.
1 Hinweis: Rohr nicht ganz herausziehen.
7
5
33801 ©
6.7. Bolzen soweit eindrücken, bis kein Überstand

1 am Rohr sichtbar ist. Jetzt Rohr ganz heraus-
ziehen.
3 9
33802 ©
6.8 Führungsbuchse vorn austreiben.

1
7
33803 ©
© 2001 / 0297 9959 3.01.06

6.5 Insert puller until pin engages in bore. 6.5 Insérer l’extracteur jusqu’à ce que le 6.5 Introducir el extractor hasta que el
boulon s’encrante dans l’alésage. pasador encaje en el taladro.
6.6 Position spacer bush in place. Pull 6.6 Monter la douille entretoise. Extraire 6.6 Colocar el casquillo distanciador.
out pipe from lower press fit. le tube du logement inférieur. Extraer el tubo de su alojamiento
inferior.
Note: Do not pull out pipe completely. Nota: Ne pas sortir complètement le tube. Nota: No extraer el tubo totalmente.
6.7 Press pin in until it does no longer 6.7 Enfoncer le boulon jusqu’à ce qu’il 6.7 Presionar adentro el pasador hasta
project beyond the pipe. Now pull out ne dépasse plus du tube. Maintenant, que visiblemente quede a ras
pipe completely. extraire complètement le tube. con el tubo. Luego, extraer el tubo
totalmente. 3
6.8 Drive out guide bush at front end. 6.8 Chasser la douille de guidage par 6.8 Desmontar golpeando el casquillo de
l’avant. guía en el lado delantero.
3.01.06 © 2001 / 0297 9959

6.9 Introduce assembly arbor with 6.9 Pousser le mandrin de montage 6.9 Introducir en el dispositivo de
spacer bush into centering. avec douille entretoise dans le centraje el mandril de montaje con el
centrage. casquillo distanciador.
6.10 Position guide bush on assembly 6.10 Monter la douille de guidage sur le 6.10 Colocar sobre el mandril de montaje
arbor with chamfer pointing towards mandrin de montage avec le chan- el casquillo de guía con el bisel
crankcase. frein orienté vers le bloc-cylindres. indicando hacia el bloque motor.
6.11 Secure centering with assembly 6.11 Bloquer le centrage avec le mandrin 6.11 Fijar en el bloque motor el dispo-
arbor and guide bush on crankcase. de montage et la douille de guidage sitivo de centraje con el mandril
sur le bloc-cylindres. de montaje y el casquillo de guía
3 puestos.
6.12 Drive in guide bush at front end as 6.12 Enfoncer la douille de guidage à 6.12 Introducir golpeando el casquillo de
far as it will go. l’avant jusqu’en application. guía en el lado delantero hasta que
haga tope.
© 2001 / 0297 9959 3.01.07

6.9 Montagedorn mit Abstandsbuchse in Zentrie-

rung schieben.
2
7
33804 ©
6.10 Führungsbuchse auf den Montagedorn, mit

der Anfasung zum Kurbelgehäuse weisend,
aufsetzen.
2
8
33805 ©
6.11 Zentrierung mit Montagedorn und Führungs-

buchse an Kurbelgehäuse festdrehen.
2
3
33806 ©
6.12 Führungsbuchse vorn bis Anlage eintreiben.

2
33807 ©
3.01.07 © 2001 / 0297 9959

6.13 Zentrierung abbauen.

1
33808 ©
6.14 Führungsbuchse schwungradseitig austrei-

1 ben.
33809 ©
6.15. Montagedorn ohne Abstandsbuchse in

2 Zentrierung schieben.
3
7
33810 ©
6.16 Führungsbuchse auf den Montagedorn, mit

2 der Anfasung zum Kurbelgehäuse weisend,
aufsetzen.
8
33811 ©
© 2001 / 0297 9959 3.01.08

6.13 Remove centering. 6.13 Démonter le centrage. 6.13 Desmontar el dispositivo de centraje.
6.14 Drive out guide bush at flywheel end. 6.14 Chasser la douille de guidage par le 6.14 Desmontar golpeando el casquillo de
côté volant. guía en el lado del volante.
6.15 Introduce assembly arbor without 6.15 Pousser le mandrin de montage 6.15 Introducir en el dispositivo de
spacer bush into centering. sans douille entretoise dans le centraje el mandril de montaje sin el
centrage. casquillo distanciador.
3
6.16 Position guide bush on assembly 6.16 Monter la douille de guidage sur le 6.16 Colocar sobre el mandril de montaje
arbor with chamfer pointing towards mandrin de montage avec le chan- el casquillo de guía con el bisel
crankcase. frein orienté vers le bloc-cylindres. indicando hacia el bloque motor.
3.01.08 © 2001 / 0297 9959

6.17 Secure centering with assembly 6.17 Serrer à bloquer le centrage avec le 6.17 Fijar en el bloque motor el dispo-
arbor and guide bush on crankcase. mandrin de montage et la douille de sitivo de centraje con el mandril de
serrage sur le bloc-cylindres. montaje y casquillo de guía puestos.
6.18 Drive in guide bush at flywheel end 6.18 Enfoncer la douille de guidage du 6.18 Introducir golpeando el casquillo de
as far as it will go. côté volant jusqu’en application. guía en el lado del volante hasta que
haga tope.
6.19 Remove centering. 6.19 Démonter le centrage. 6.19 Desmontar el dispositivo de centraje.
6.20 Press in new pipe with assembly 6.20 Enfoncer le tube neuf avec le 6.20 Sirviéndose del mandril de montaje,
arbor as far as it will go. mandrin de montage jusqu’en introducir a presión hasta el tope un
application. tubo nuevo.
© 2001 / 0297 9959 3.01.09

6.17 Zentrierung mit Montagedorn und Führungs-

buchse an Kurbelgehäuse festdrehen.
2
33812 ©
6.18 Führungsbuchse schwungradseitig bis Anlage

eintreiben.
2
33813 ©
6.19 Zentrierung abbauen.

1
3
33814 ©
6.20 Neues Rohr mit Montagedorn bis Anlage

eindrücken. 2
7
33815 ©
3.01.09 © 2001 / 0297 9959

6.21 Neuen Verschlussdeckel mit Sicherungsmittel

w DEUTZ DW 72 bestreichen.
33816 ©
6.22 Verschlussdeckel bündig zum Kurbelgehäuse

2 eintreiben.
33817 ©
6.23 Regelstange mit Starterfeder in die Führungs-

2 buchsen einsetzen.
3
5 Hinweis: Auf Leichtgängigkeit achten.
33818 ©
6.24 Starterfeder zusammendrücken, Zylinderstift

2 in die Aussparung für Regelwegbegrenzung
bündig eintreiben.
9
33819 ©
© 2001 / 0297 9959 3.01.10

6.21 Apply locking compound 6.21 Enduire un nouveau couvercle 6.21 Aplicar líquido sellador
DEUTZ DW 72 to new cover. d’obturation de produit de freinage DEUTZ DW 72 a la tapa de
DEUTZ DW 72. cierre nueva.
6.22 Drive in cover flush with crankcase. 6.22 Enfoncer le couvercle à fleur dans 6.22 Introducir golpeando la tapa de
le bloc-cylindres. cierre hasta que quede a ras con
el bloque motor.
6.23 Insert control rod with starter spring 6.23 Insérer la crémaillère avec le 6.23 Introducir en los casquillos de
into guide bushes. ressort de démarreur dans la guía la cremallera con el resorte
douille de guidage. de arranque.
3
Note: Check for free movement. Nota: Veiller à ce qu’il n’y ait aucun Nota: Prestar atención a que entre
point dur. fácilmente.
6.24 Compress starter spring. Drive 6.24 Comprimer le ressort de démarreur, 6.24 Comprimir el resorte de arranque e
parallel pin into recess for control introduire la goupille cylindrique à introducir golpeando el pasador
rod travel limitation. Check that fleur dans l’évidement pour la cilíndrico en la escotadura para la
it is flush with surface. limitation de la course de réglage. limitación del recorrido de regulación
hasta que quede a ras.
3.01.10 © 2001 / 0297 9959

7. Exchange the piston cooling oil 7. Remplacement des gicleurs d’huile 7. Sustitución de las toberas de aceite
nozzles de refroidissement des pistons para la refrigeración de los pistones
7.1 Press out piston cooling oil nozzles. 7.1 Chasser les gicleurs d’huile de 7.1 Sacar a presión las toberas de aceite.
refroidissement.
Note: Before installing new piston cooling Nota: Avant de monter les nouveaux Nota: Los taladros existentes en el
oil nozzles, check that the bores gicleurs, veiller à ce que les bloque motor deben estar limpios
in the crankcase are clean and free alésages dans le bloc-cylindres antes de montar las toberas de
of oil. soient propres. aceite nuevas.
7.2 Press in new piston cooling oil 7.2 Enfoncer les gicleurs neufs jusqu’en 7.2 Introducir a presión las toberas de
nozzles as far as they will go. application. aceite nuevas, hasta el tope.
8. Mount the plug screws 8. Monter les bouchons filetés 8. Montaje de los tapones roscados
8.1 Screw in the locking screws and 8.1 Insérer les bouchons filetés et 8.1 Enroscar los tapones y apretarlos.
3 tighten them. les serrer.
Tightening Couple Prescripción

specification: Item 5 = 50 Nm de serrage: Rep. 5= 50 Nm de apriete: No. 5= 50 Nm
Item 7 = 95 Nm Rep. 6= 26 Nm No. 6= 26 Nm
Item 10 = 56 Nm Rep. 7= 95 Nm No. 7= 95 Nm
Item 15 = 50 Nm Rep. 10 = 56 Nm No. 10 = 56 Nm
Item 17 = 26 Nm Rep. 15 = 50 Nm No. 15 = 50 Nm
Note: After dismantling the position 5, 7, Nota: Après démontage des Rep. 5, 7, Nota: Renovar siempre los tapones
10 and 17, these are to be basi- 10 et 17, ceux-ci doivent toujours Nos. 5, 7, 10 y 17, una vez que
cally renewed. Pos. 6 with new être remplacés. Rep. 6 avec un se hayan desmontado. El tapón
sealing ring. joint neuf. No. 6 con junta anular nueva.
© 2001 / 0297 9959 3.01.11

7. Kolbenkühlöldüsen austauschen
7.1 Kolbenkühlöldüsen herausdrücken.

1
Hinweis: Vor Einbau der neuen Kolbenkühl- 5
öldüsen müssen die Bohrungen im
Zylinderkurbelgehäuse sauber sein.
33820 ©
7.2 Neue Kolbenkühlöldüsen bis Anlage ein-

drücken.
2
33821 ©
8. Verschlussschrauben montieren
8.1 Verschlußschrauben einschrauben und fest-

2
3
drehen.
6
Anziehvorschrift: Pos. 5= 50 Nm
Pos. 6= 26 Nm 5
Pos. 7= 95 Nm
Pos. 10 = 56 Nm
Pos. 15 = 50 Nm
33822 ©
Hinweis: Nach Demontage der Pos. 5, 7, 10 und
17 sind diese grundsächlich zu erneuern.
Pos. 6 mit neuem Dichtring.
3.01.11 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

Special tool required: Outillage spécial Herramienta especial
Assembly tool _______________ 142 860 Outil de montage _____________ 142 860 Herramienta de montaje _______ 142 860
If the crankshaft density has a lead-in Si le plan de joint du vilebrequin présente Si la superficie de contacto del cigüeñal
spiral, a new shaft seal ring set, une rainure de roulement, à la place d’un presenta una huella de roce, es necesario
consisting of rotary shaft seal and a joint d’arbre neuf, utiliser un jeu de joints utilizar, en lugar del retén nuevo, un nuevo
rotating ring is to be used instead of d’arbre neufs comprenant joint d’arbre et juego de retén, compuesto de un retén y
a new shaft seal ring. bague de roulement. un anillo de roce.
For the assembly of the shaft seal ring set, Pour le montage du jeu de joints d’arbre, Para el montaje del juego de retén, ver
see chapter 4 voir chapitre 4. capítulo 4.
1. Drive out shaft seal. 1. Chasser le joint d’arbre. 1. Desmontar golpeando el retén.
2. Inspect cover, replace if necessary. 2. Examen visuel du couvercle, le cas 2. Inspeccionar la tapa, sustituyéndola
échéant, le remplacer. en caso necesario.
3. Installation depth of shaft seal. 3. Profondeur de montage du joint 3. Profundidad de montaje del retén.
d’arbre.
© 2001 / 0297 9959 3.01.15

Spezialwerkzeug
Montagewerkzeug ___________________ 142 860
Hat die Kurbelwellendichtfläche eine Einlaufrille, ist

anstatt eines neuen Wellendichtringes ein neuer
Wellendichtringsatz, bestehend aus Wellendicht-
ring und Laufring, zu verwenden.
Montage des Wellendichtringsatzes siehe Kapitel 4
1. Wellendichtring austreiben.
1
33825 ©
2. Deckel sichtprüfen, ggf. austauschen.

9
3
0
33826 ©
3. Einbautiefe des Wellendichtringes.

9
33827 ©
3.01.15 © 2001 / 0297 9959

4. Wellendichtring ungeölt mit Montagevorrichtung

2 montieren.
ß
7
33828 ©
© 2001 / 0297 9959 3.01.16

4. Fit shaft seal with assembly tool 4. Monter le joint d’arbre sans huile avec 4. Montar el retén sin aceitar utilizando el
without using oil. le dispositif de montage. dispositivo de montaje.
3.01.16 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

1. Measure the crankshaft 1. Mesurer le vilebrequin 1. Medición del cigüeñal

1.1 Placer le vilebrequin sur des prismes. 1.1 Colocar el cigüeñal sobre soportes
1.1 Chuck crankshaft up on prism stand.
prismáticos.
Reworking sizes are marked on the Le repérage des degrés de rectification se Las medidas de rectificado se encuentran
outer contour of the cast-on counter- fait sur le contour extérieur du contrepoids marcadas en el contorno exterior del
weight at flywheel end. rapporté du côté vilebrequin. contrapeso colocado en fundición, en el
H = ground main bearing journals H = tourillon lado del volante.
P = ground crankpins P = maneton H = muñón de apoyo
P = muñón de biela o muñequilla
If crankshaft is worn, it is possible to En cas d’usure du vilebrequin, celui-ci Si el cigüeñal está desgastado, se ofrece
have it reconditioned at our Service peut être remis en état par notre Centre la posibilidad de hacerlo reparar en uno
Centers. de Service. de nuestros Centros de Servicio.
1.2 Measure the main bearing pins at 1.2 Mesurer les tourillons aux points 1.2 Medir los muñones de apoyo en
the positions ”1“ and ”2“ at the level « 1 » et « 2 » dans les plans « a » et los puntos ”1“ y ”2“ de los planos ”a“
”a“ and ”b“. « b ». y ”b“.
Nominal dimension 69.97 - 69.99 mm Cote nominale 69,97 - 69,99 mm Medida nominal 69,97 - 69,99 mm
Cote sous-dimensionnée
Each undersize 0.25 mm par degré 0,25 mm Cada inframedida 0,25 mm
Limit for Valeur limite de cote Límite para
undersize 69.47 mm sous-dimensionnée 69,47 mm inframedida 69,47 mm
Wear limit: Limite d’usure: Límite de desgaste:
Journal ovality 0.008 mm ovalisation de tourillon 0,008 mm ovalización del muñón 0,008 mm
1.3 Gauge thrust bearing journal width. 1.3 Mesurer la largeur du tourillon de 1.3 Medir el ancho del muñón del
palier d’ajustage cojinete de empuje
3
Journal width 35.0 - 35.04 mm Cote nominale 35,0 - 35,04 mm Medida nominal 35,0 - 35,04 mm
Cote surdimensionnée
Each oversize 0.4 mm par degré 0,4 mm Cada sobremedida 0,4 mm
Valeur limite de cote

Limit for oversize 35.44 mm surdimensionnée 35,44 mm Límite para sobremedida 35,44 mm
1.4 Gauge crankpins. 1.4 Mesurer les manetons 1.4 Medir los muñones de biela
Pin diameter 54.97 - 54.99 mm Cote nominale 54,97 - 54,99 mm Medida nominal 54,97 - 54,99 mm
Valeur limite de Límite para

Limit for undersize 54.47 mm cote sous-dimensionnée 54,47 mm inframedida 54,47 mm

Pin ovality 0,01 mm ovalisation de maneton 0,01 mm ovalización del muñón 0,01 mm
© 2001 / 0297 9959 3.05.19

1. Kurbelwelle messen
1.1 Kurbelwelle in Prismen aufnehmen.
t
Die Kennzeichnung der Nacharbeitsstufen erfolgt
auf der Außenkontur des angegossenen, 9
schwungrad-seitigen Gegengewichtes.
H = Hauptlagerzapfen
P = Pleuellagerzapfen
Bei verschlissener Kurbelwelle besteht die Möglich-

keit die Kurbelwelle in unseren Service - Centern
instand setzen zu lassen. 33830 ©
1.2 Hauptlagerzapfen an den Stellen „1“ und „2”

in der Ebene „a“ und „b“ messen.
6
Nennmaß 69,97 - 69,99 mm
Grenzmaß für
Untermaßstufe 69,47 mm
Verschleißgrenze:
Zapfenunrundheit 0,008 mm 33831 ©
1.3 Breite des Passlagerzapfens messen
Nennmaß 35,0 - 35,04 mm

6
3
Übermaß je Stufe 0,4 mm
Grenzmaß für Übermaßstufe 35,44 mm
33832 ©
1.4 Hubzapfen messen
Nennmaß 54,97 - 54,99 mm

6
Grenzmaß für
Untermaßstufe 54,47 mm
Verschleißgrenze:
33833 ©
3.05.19 © 2001 / 0297 9959

1.5 Kurbelwelle auf Rundlauf prüfen

6 Abweichung max. 0,05 mm
33834 ©
2. Dichtflächen sichtprüfen
9 2.1 Dichtflächen der Wellendichtringe sichtprüfen.
5 Hinweis: Ist auf den Dichtflächen eine Einlauf-

rille steht zur Kurbelwellenabdichtung
ein Wellendichtringsatz, bestehend aus
Wellendichtring und Laufring, zur Ver-
fügung.
Montage des Wellendichtringsatzes
siehe Kapitel 4.
33835 ©
© 2001 / 0297 9959 3.05.20

1.5 Check crankshaft for true running. 1.5 Vérifier la concentricité du 1.5 Comprobar el cigüeñal en cuanto
vilebrequin. a excentricidad.
Out of roundness max. 0.05 mm Ecart maxi 0,05 mm. Excentricidad máx. 0,05 mm
2. Check visually the sealing 2. Examen visuel des plans de joint. 2. Inspección de las superficies de
surfaces contacto
2.1 Check visually the sealing surfaces 2.1 Examen visuel des plans de joint 2.1 Inspeccionar las superficies de
of the shaft seal rings d’arbre. contacto para los retenes.
Note: If a lead-in spiral is placed on the Nota: Si les plans de joint présentent une Nota: Si las superficies de contacto
sealing surfaces, a shaft seal ring rainure de roulement, il existe un presentan huellas de roce, está
set, consisting of a shaft seal ring jeu de joints d’arbre comprenant disponible un juego de retén,
and a rotating ring will be at the joint d’arbre et bague de roulement compuesto de un retén y un
disposal of the crankshaft seal. pour assurer l’étanchéité de l’arbre. anillo de roce, para la
Assembly of the shaft seal ring set, Pour le montage du jeu de joints hermetización del cigüeñal.
see chapter 4. d’arbre, voir chapitre 4. Para el montaje del juego de
retén, ver capítulo 4.
3.05.20 © 2001 / 0297 9959

© 2001 / 0297 9959

Couronne de démarrage / volant Mise en état des composants
© 2001 / 0297 9959

Bauteile instand setzen Starterzahnkranz / Schwungrad
Repair of components Starter ring gear / flywheel
Mise en état des composants Couronne de démarrage / volant
Reparación de componentes Corona del volante / volante
1. Exhange drill ring gear 1. Remplacement de la couronne 1. Sustitución de la corona dentada

dentée.
1.1 Drill ring gear apart. 1.1 Dégager la couronne dentée par 1.1 Abrir taladrando la corona.
perçage.
Note: Make sure not to damage flywheel. Nota: Ne pas endommager le volant. Nota: Cuidar de no dañar el volante.
1.2 Remove ring gear. 1.2 Enlever la couronne dentée. 1.2 Quitar la corona.
3. Clean flywheel and inspect at 1.3 Nettoyer le volant et faire un contrôle 1.3 Limpiar el volante e inspeccionar su
supporting flange. visuel du collet d’appui. borde de asiento.
4. Heat ring gear to max. 220 °C. Place 1.4 Chauffer la couronne dentée à 1.4 Calentar la corona a 220 °C, como
ring gear in position and bring to stop 220 °C maxi. máximo, y ponerla en su sitio,
at flange. Poser la couronne dentée et la dejándola asentada en el borde.
mettre en application sur le collet.
© 2001 / 0297 9959 3.05.23

Couronne de démarrage / volant Mise en état des composants
1. Zahnkranz austauschen
1.1 Zahnkranz aufbohren

f
Hinweis: Schwungrad nicht beschädigen. 5
33837 ©
1.2 Zahnkranz entfernen.

1
33838 ©
1.3 Schwungrad reinigen und am Auflagebund

sichtprüfen.
9
3
33839 ©
1.4 Zahnkranz auf max. 220 °C erwärmen.

Zahnkranz auflegen und am Bund zur Anlage
bringen.
2
e
33840 ©
3.05.23 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

Assembly tool for Outil de montage de bague Herramienta de montaje para casquillos
small end bush 26 mm dia. _____ 131 340 de pied de bielle Ø 26 mm _____ 131 340 de pie de biela Ø 26 mm _______ 131 340
Assembly tool for small end Outil de montage de bague Herramienta de montaje para casquillos
bush 30 mm dia. _____________ 131 350 de pied de bielle Ø 30 mm _____ 131 350 de pie de biela Ø 30 mm _______ 131 350
1. Measure the connecting rod bearing 1. Mesurer l’alésage des coussinets 1. Medición del taladro del cojinete
drilling de bielle. de cabeza de biela
1.1 Make sure that cap mates with 1.1 Assortir le chapeau de bielle 1.1 Elegir la tapa que corresponda a
connecting rod. correspondant la biela.
1.2 Fit bearing cap. Tighten nuts with 1.2 Monter le chapeau de bielle. Serrer 1.2 Montar la tapa de biela. Apretar las
dodecagonal socket wrench. les écrous avec une clé à douille 12 tuercas mediante una llave de vaso
pans. bihexagonal.
Tightening specification: Prescription de serrage: Prescripción de apriete

Initial tightening torque 30 Nm Couple de préserrage 30 Nm Apriete inicial 30 Nm
1st tightening angle 60° 1er angle de serrage définitif 60° 1er ángulo de reapriete 60°
2nd tightening angle 60° 2e angle de serrage définitif 60° 2° ángulo de reapriete 60°
1.3 Connecting rod bearing drilling with a 1.3 Mesurer l’alésage de coussinet de 1.3 Sirviéndose del micrómetro de interio-
measuring instrument at the positions bielle avec un appareil de mesure res, medir el taladro del cojinete de
“1” and “2” of the level “a” and “b” d’intérieur aux points « 1 » et « 2 » cabeza de biela en los puntos ”1“ y
3 des plans « a » et « b ». ”2“ de los planos ”a“ y ”b“.
- Measure
Nominal dimension 58.5 - 58.52 mm Valeur nominale 58,5 - 58,52 mm Medida nominal 58,5 - 58,52 mm
Note: If the gauge readings conform to Nota: Si les relevés correspondent aux Nota: Si los valores medidos corres-
the specified values, the necessary valeurs indiquées, le préserrage ponden a los especificados, los
preload will be obtained after fitting est assuré après le montage des semicojinetes recibirán la preten-
the bearing shells. coussinets. sión necesaria después de su
If the measured values deviate En cas d’écart minimal des valeurs, montaje.
only slightly, additional measure- effectuer des relevés supplémentai- Si los valores medidos difieren
ments are to be carried out with res avec de nouveaux coussinets aunque insignificantemente, es
new bearing shells fitted. de bielle. necesario realizar mediciones
adicionales con semicojinetes
nuevos.
© 2001 / 0297 9959 3.06.27

Spezialwerkzeug:
Montagewerkzeug für Kolben-

9
bolzenbuchse ø 26 mm _______________ 131 340
Montagwerkzeug für Kolben- 8
bolzenbuchse ø 30 mm _______________ 131 350
1. Pleuellagerbohrung messen
1.1. Pleuellagerdeckel zuordnen.

33842 ©
1.2 Pleuellagerdeckel montieren. Muttern mit

12 kant-Steckschlüssel festdrehen. 2
Anziehvorschrift:
Vorspannwert 30 Nm 6
2. Nachspannwinkel 60° r
33843 ©
1.3 Pleuellagerbohrung mit Innenmessgerät an

den Punkten „1“ und „2“ der Ebene „a“ und „b“ - 6
3
33844 ©
- messen.
Nennmaß 58,5 - 58,52 mm

6
Hinweis: Entsprechen die Messungen den ange- 5
gebenen Werten, ist nach dem Einbau
von Lagerschalen die Vorspannung vor-
handen.
Weichen die Messwerte nur geringfügig
ab, sind zusätzliche Messungen mit neu-
en Lagerschalen durchzuführen.
33845 ©
3.06.27 © 2001 / 0297 9959

1.4 Pleuellagerdeckel abbauen und neue Lager-

1 schalen einsetzen. Pleuellagerdeckel montie-
ren. Muttern festdrehen.
2 Anziehvorschrift:
Vorspannwert 30 Nm
6 1. Nachspannwinkel
2. Nachspannwinkel
60°
60°
r
33846 ©
1.5 Lagerschalen mit Innenmessgerät an den

6 Punkten „1“ und „2“ in den Ebenen „a“ und „b“ -
33847 ©
- messen.
6 Nennmaß 55,024 - 55,055 mm
3
5 Untermaß je Stufe 0,25 mm
Grenzmaß für
Untermaßstufe 54,524 - 54,555 mm
Verschleißgrenze:
Pleuellagerspiel 0,12 mm
33848 © Hinweis: Liegen die Werte bis. max. 0,015 mm

über den Lagertoleranzen, kann die
Pleuelstange weiter verwendet werden.
Wird der Grenzwert überschritten,
Pleuelstange austauschen.
© 2001 / 0297 9959 3.06.28

1.4 Remove bearing cap and fit new 1.4 Démonter le chapeau de bielle et 1.4 Desmontar la tapa de biela y colocar
bearing shells. Refit bearing cap. monter des coussinets de bielle los semicojinetes nuevos. Montar la
Tighten nuts. neufs. Serrer les écrous. tapa de biela. Apretar las tuercas.
Tightening specification: Prescription de serrage: Prescripción de apriete

1st tightening angle 60° 1er angle de serrage définitif 60° 1er ángulo de reapriete 60°
2nd tightening angle 60° 2e angle de serrage définitif 60° 2° ángulo de reapriete 60°
1.5 Bearing shell with a measuring 1.5 Mesurer les coussinets avec un 1.5 Sirviéndose del micrómetro de
instrument at the positions “1” and “2” appareil de mesure d’intérieur aux interiores, medir el cojinete en los
of the level “a” and “b” – points « 1 » et « 2 » des plans « a » puntos ”1“ y ”2“ de los planos ”a“
et « b ». y ”b“.
- Measure
Nominal dimension 55.024 - 55.055 mm Valeur nominale 55,024 - 55,055 mm Medida nominal 55,024 - 55,055 mm
3
Limit for Valeur limite de cote sous- Límite para

undersize 54.524 - 54.555 mm dimensionnée 54,524 - 54,555 mm inframedida 54,524 - 54,555 mm
Wear limit: Radial clearance Limite d’usure: Límite de desgaste:

of big end bearing 0.12 mm jeu des coussinets de bielle 0,12 mm Juego del cojinete 0,12 mm
Note: If the readings do not exceed Nota: Si les valeurs dépassent les Nota: Si los valores medidos no superan
bearing tolerances by more tolérances jusqu’à 0,015 maxi, las tolerancias del cojinete en más
than 0.015 mm , the rod can la bielle peut être réutilisée. de 0,015 mm, puede seguirse
be used further. If the limit Si a valeur limite est dépassée, utilizando la biela. Al sobrepasarse
value is exceeded, replace remplacer la bielle. el valor límite, hay que sustituir la
the connecting rod. biela por otra nueva.
3.06.28 © 2001 / 0297 9959

2. Measure the piston pin bushing 2. Mesurer la bague de pied de bielle 2. Medición del casquillo de pie de biela
2.1 Piston pin bushing with a 2.1 Mesurer la bague de pied de 2.1 Sirviéndose del micrómetro de
measuring instrument bielle avec un appareil de mesure interiores, medir el casquillo de pie
d’intérieur de biela
- at the positions “1” and “2” of - aux points « 1 » et « 2 » dans en los puntos ”1“ y ”2“ de los planos
the level “a” and “b” – les plans « a » et « b » - ”a“ y ”b“.
- Measure.
Nominal dimension Valeur nominale Medida nominal

FL/M 2011 26.025 - 26.035 mm FL/M 2011 26,025 - 26,035 mm FL/M 2011 26,025 - 26,035 mm
BFL/M 2011 30.025 - 20.035 mm BFL/M 2011 30,025 - 20,035 mm BFL/M 30,025 - 30,035 mm

Small end bush clearance 0.08 mm jeu d’axe de piston 0,08 mm Juego del bulón 0,08 mm
Replace small end bush if Le cas échéant, remplacer la bague De ser necesario, sustituir el casquillo
necessaray. de pied de bielle. de pie de biela por otro nuevo.
3. Measure the alignment of the 3. Mesurer le parallélisme des 3. Medición del paralelismo de los
bearing bores. alésages de bielle. taladros.
3 3.1 Permissible tolerance „a“ = 0.03 mm 3.1 Ecart admissible « a » = 0,03 mm 3.1 Desviación admisible ”a“ = 0,03 mm
over a distance of „x“ = 100 mm pour une distance « x » de 100 mm. a una distancia de ”x“ = 100 mm
3.2 Permissible tolerance „A“ relative 3.2 Ecart admissible de « A » par rapport 3.2 Desviación admisible de ”A“ respecto
to „B“ = 0.03 mm over a distance à « B » = 0,03 mm pour une distance a ”B“ = 0,03 mm a una distancia de
of „x“ = 100 mm « x » de 100 mm. ”x“ = 100 mm
Note: The adjustment of the connecting Nota: Il n’est pas admissible de redresser Nota: No es admisible enderezar la biela.
rod is not permissible. la bielle
© 2001 / 0297 9959 3.06.29

2. Kolbenbolzenbuchse messen
2.1 Kolbenbolzenbuchse mit Innenmessgerät

6
- an den Punkten „1“ und „2“ in der Ebene
„a“ und „b“ -
33849 ©
- messen.
Nennmaß
6
FL/M 2011 26,025 - 26,035 mm
BFL/M 2011 30,025 - 30,035 mm
Verschleißgrenze:
Kolbenbolzenspiel 0,08 mm
Bei Bedarf Kolbenbolzenbuchse auswechseln.
33850 ©
3. Parallelität der Lagerbohrungen messen.
3.1 Zulässige Abweichung „a“ = 0,03 mm

6
bei einem Abstand „x“ von 100 mm 3
33851 ©
3.2 Zulässige Abweichung „A“ zu „B“ = 0,03 mm

bei einem Abstand „x“ von 100 mm 6
Hinweis: Richten der Pleuelstange ist nicht 5
zulässig.
33852 ©
3.06.29 © 2001 / 0297 9959

4. Kolbenbolzenbuchse auswechseln
1 4.1 Kolbenbolzenbuchse ausziehen.
7 Bohrung für Kolbenbolzenbuchse:

FL/M 2011 29,0 - 29,02 mm
BFL/M 2011 33,0 - 33,02 mm
Kolbenbolzenbuchse Außendurchmesser:
FL/M 2011 29,06 - 29,10 mm
BFL/M 2011 33,07 - 33,11 mm
33853 ©
4.2 Kolbenbolzenbuchse bündig einziehen.

2 Hinweis: Schmierölbohrung der Kolbenbolzen-
7 buchse und der Pleuelstange müssen
übereinstimmen.
33854 ©
4.3 Kolbenbolzenbuchse nach dem Einpressen

f ausspindeln.
3 Nennmaß:
FL/M 2011 26,025 - 26,035 mm
BFL/M 2011 30,025 - 30,035 mm
33855 ©
5. Pleuelstange mit Kolben komplettieren

2 5.1 Einen Sprengring einsetzen.
q
33856 ©
© 2001 / 0297 9959 3.06.30

4. Exchange the piston pin bushing. 4. Remplacer la bague de pied 4. Sustitución del casquillo de pie
de bielle de biela
4.1 Withdraw the piston pin bushing. 4.1 Extraire la bague de pied de bielle. 4.1 Extraer el casquillo del pie de biela.
Bore for small end bush: Alésage de bague de pied de bielle: Taladro para casquillo de pie de biela:
BFL/M 2011 33.0 - 33.02 mm BFL/M 2011 33,0 - 33,02 mm BFL/M 2011 33,0 - 33,02 mm
Outer diameter Diamètre extérieur de bague de pied Diámetro exterior del casquillo de pie
of small end bush: de bielle: de biela:
4.2 Pull in flush the piston pin bushing. 4.2 Insérer la bague de pied de bielle à 4.2 Insertar a ras el casquillo de pie de
fleur. biela.
Note: Lube oil bores of small end bush Nota: Les alésages d’huile de la Nota: Deben coincidir los orificios de
and connecting rod must be in line. bague de pied de bielle et de la lubricación del casquillo y de la
bielle doivent coïncider. biela.
4.3 After pressing in, precision-bore small 4.3 Brocher la bague de pied de bielle 4.3 Después de insertado, repasar el
end bush on a fine boring. après le montage à la presse. casquillo de pie de biela mediante
mandrinadora de precisión.
3
Nominal dimension Valeur nominale Medida nominal
5. Assembling connecting rod with 5. Compléter l’ensemble bielle/piston 5. Unión de la biela y pistón
piston
5.1 Put in place a spring ring. 5.1 Insérer un circlip. 5.1 Montar uno de los anillos de
retención.
3.06.30 © 2001 / 0297 9959

Note: Ring gaps of circlips must face Nota: Les coupes des circlips sont à Nota: Los cortes de los anillos deben
piston crown. diriger vers la tête de piston. indicar hacia la cabeza del pistón.
5.2 Install piston together with connecting 5.2 Assembler le piston et la bielle. 5.2 Unir el pistón con la biela.
rod. Flywheel symbol on the piston Le symbole de volant sur le piston El símbolo del volante que figura
must point to the left and identification doit montrer vers la gauche et le en el pistón debe indicar hacia la
number on connecting rod must be chiffre repère de la bielle doit être izquierda y el número de identifi-
visible. visible. cación de la biela debe ser visible.
5.3 Fit in and align a second spring ring. 5.3 Insérer un second circlip et aligner. 5.3 Montar el segundo anillo de retención
y orientarlo correctamente.
© 2001 / 0297 9959 3.06.31

Hinweis: Ringstöße der Sicherungsringe müssen

zum Kolbenboden zeigen. 5
9
33857 ©
5.2 Kolben mit der Pleuelstange montieren.

Das Schwungradsymbol auf dem Kolben muss
nach links zeigen und die Kennziffer der Pleuel-
2
stange muß sichtbar sein.
8
9
33858 ©
5.3 Zweiten Sprengring einsetzen und ausrichten.

2
3
q
9
33859 ©
3.06.31 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

Piston ring pliers _____________ 130 300 Pince à segments de piston ____ 130 300 Alicates especiales
Trapezoidal slot wear gauge: ___ 130 420 Jauge d’usure de rainure para aros de pistón: __________ 130 300
Disassembling tool trapézoïdale ________________ 130 420 Calibre para ranura trapezoidal __ 130 420
for spring ring: _______________ 131 100 Outils de démontage de circlip __ 131 100 Herramienta de desmontaje
para anillos de retención: ______ 131 100
1. Completion connecting rod – 1. Défaire l’assemblage bielle / piston 1. Separación del conjunto biela-pistón
disassembling piston
1.1 Fit the auxiliary tool into the piston 1.1 Insérer l’outil auxiliaire dans l’axe 1.1 Introducir la herramienta auxiliar en el
pin. Remove the spring ring. Pull out piston. Enlever le circlip. Extraire bulón. Quitar los anillos de retención.
the piston pin. l’axe de piston. Sacar el bulón del pistón.
Note: Without auxiliary tools, there is a Nota: Sans outil auxiliaire, il y a risque de Nota: Sin la herramienta auxiliar existe el
risk of injury due to a spring ring blessure si le circlip saute. peligro de lesionarse por la salida
jumping off. brusca de los anillos de retención.
1.2 Adjust piston ring pliers to piston 1.2 Régler la pince à segment au 1.2 Ajustar los alicates especiales para
diameter. Remove piston rings. diamètre du piston. Démonter les aros de pistón al diámetro del pistón.
segments de piston. Desmontar los aros.
3
2. Check and measure the piston 2. Contrôler et mesurer le piston 2. Inspección y medición del pistón
3.1 Clean and inspect piston and ring 2.1 Nettoyer le piston et les gorges 2.1 Limpiar e inspeccionar el pistón y las
grooves. de segment et les soumettre à un ranuras para los aros.
examen visuel.
© 2001 / 0297 9959 3.07.35

Spezialwerkzeuge:
Kolbenring-Auflegezange: _____________ 130 300

Trapeznut-Verschleißlehre: ____________ 130 420
Demontagewerkzeug für Sprengring: ____ 131 100
1. Komplettierung Pleuelstange - Kolben

zerlegen
1
1.1 Hilfswerkzeug in den Kolbenbolzen einsetzen.
Sprengring entfernen. Kolbenbolzen heraus- q
nehmen.
Hinweis: Ohne Hilfswerkzeug besteht Verlet-

e
zungsgefahr durch abspringenden
Sprengring.
7
5 33861 ©
1.2 Kolbenring-Auflegezange auf den Kolben-

durchmesser einstellen. Kolbenringe abbauen. 1
3
6
7
33862 ©
2. Kolben prüfen und messen
2.1. Kolben und Ringnuten reinigen und sicht-

9
prüfen.
33863 ©
3.07.35 © 2001 / 0297 9959

2.2 Kolbenringstoßspiel mit Fühlerlehre messen.

6 Verschleißgrenzen:
Stoßspiel 3. Ring FL/M 2011 1,2 mm
Stoßspiel 3. Ring BFL/M 2011 1,1 mm
33864 ©
2.3 Axialspiel der Kolbenringe in den Kolbenring-

6 nuten mit Fühlerlehre messen.
5 Hinweis: Messung mit

durchführen.
neuen Kolbenringen
Verschleißgrenzen:
1. Ring FL/M 2011 0,20 mm
1. Ring BFL/M 2011 Trapeznut
2. Ring 0,20 mm
3. Ring 0,15 mm
33865 ©
2.4 Trapeznut mit Trapeznut-Verschleißlehre

6 messen.
3 7
33866 ©
2.5 Ist zwischen Trapeznut-Verschleißlehre und

6 Kolben ein Abstand „S“ vorhanden, so ist der
Kolben weiter verwendbar.
33867 ©
© 2001 / 0297 9959 3.07.36

2.2 Measure ring gap with feeler gauge. 2.2 Mesurer le jeu à la coupe des 2.2 Medir, mediante una galga de
segments de piston espesores, la distancia entre las
puntas de los aros de pistón.
Wear limits: Limites d’usure:
1st ring gap 0.8 mm Jeu à la coupe 1er segment 0,8 mm Límites de desgaste - distancia entre
2nd ring gap 2.5 mm Jeu à la coupe 2e segment 2,5 mm puntas:
3rd ring gap FL/M 2011 1.2 mm Jeu à la coupe 3e segment 1er aro 0,8 mm
3rd ring gap BFL/M 2011 1.1 mm FL/M 2011 1,2 mm 2° aro 2,5 mm
Jeu à la coupe 3e segment 3er aro FL/M 2011 1,2 mm
BFL/M 2011 1,1 mm 3er aro BFL/M 2011 1,1 mm
2.3 Measure the axial clearance of the 2.3 Mesurer le jeu axial des segments 2.3 Medir, mediante una galga de
piston rings in the piston ring grooves de piston dans les gorges avec une espesores, el juego axial de los
with a feeler gage. jauge d’épaisseur. aros en las ranuras del pistón.
Note: Carry out a measurement with Nota: Effectuer le relevé avec des Nota: Realizar la medición con aros
new piston rings. segments de piston neufs. nuevos.
Wear limits: Limites d’usure: Límites de desgaste:

1. Ring FL/M 2011 0.20 mm 1er segment FL/M 2011 0,20 mm 1er aro 0,20 mm
1. Ring BFL/M 2011 Trapezoidal slot 1er segment BFL 2011 gorge trapézoïdale 2° aro ranura trapezoidal
2. Ring 0.20 mm 2e segment 0,20 mm 3er aro FL/M 2011 0,20 mm
3. Ring 0.15 mm 3e segment 0,15 mm 3er aro BFL/M 2011 0,15 mm
2.4 Measure the trapezoidal slot with 2.4 Mesurer la gorge trapézoïdale 2.4 Medir la ranura trapezoidal
trapezoidal slot wear gauge. avec une jauge d’usure de gorge mediante el correspondiente
trapézoïdale. calibre de desgaste.
3
2.5 If a distance „S“ is present between 2.5 S’il existe un espace « S » entre la 2.5 Si entre el calibre de desgaste y el
the trapezoidal slot wear gauge and jauge d’usure de gorge trapézoïdale pistón media una distancia de ”S“,
the piston, then the piston can be et le piston, le piston peut être puede seguirse utilizando el pistón.
still used. réutilisé.
3.07.36 © 2001 / 0297 9959

2.6 If the trapezoidal slot wear gauge 2.6 Si la jauge d’usure de gorge 2.6 Si el calibre de desgaste entra en
rests against the piston, then the trapézoïdale est en application sur le contacto con el pistón, es necesario
piston is to be exchanged. piston, celui-ci doit être remplacé. sustituir el pistón por otro nuevo.
2.7 Measure the outside diameter of the 2.7 Mesurer le diamètre extérieur de l’axe 2.7 Medir el diámetro exterior del bulón.
piston pin de piston
Nominal dimension: Valeur nominale: Medida nominal:

3. Complete the piston 3. Compléter le piston 3. Completación del pistón
3.1 Order and position of piston rings: 3.1 Ordre et position des segments: 3.1 Orden y posición de los aros de pistón:
3 1. Rectangular ring with FL/M 2011, 1e Segment rectangulaire sur 1er aro de sección rectangular p.
top facing combustion chamber FL/M 2011, top orienté vers la FL/M 2011, TOP indicando hacia la
1. Double trapezoidal washer chambre de combustion. cámara de combustión
with BFL/M 2011, top facing 1e Segment trapézoïdal double sur 1er aro de doble cuña p. BFL/M 2011,
combustion chamber BFL/M 2011, top orienté vers la TOP indicando hacia la cámara de
2. tapered compression ring, chambre de combustion. combustión
top facing combustion chamber 2e Segment biseauté, top orienté vers la 2° aro biselado, TOP indicando hacia la
3. bevelled-edge slotted oil control chambre de combustion. cámara de combustión
ring 3e Segment racleur à double chanfrein 3er aro achaflanado ranurado de aceite
3.2 Fit piston rings 3.2 Monter les segments de piston. 3.2 Montar los aros de pistón.
Note: Spring gap of bevelled-edge ring to Nota: Décaler la coupe du ressort de Nota: Desplazar 180° entre sí el corte
be offset by 180° relative to ring segment à double chanfrein de del aro achaflanado ranurado de
gap. 180° par rapport à la coupe du aceite y el corte de su muelle.
segment.
© 2001 / 0297 9959 3.07.37

2.6 Liegt die Trapeznut-Verschleißlehre am Kolben

an. so ist der Kolben auszutauschen.
6
33868 ©
2.7 Außendurchmesser des Kolbenbolzens

messen
6
Nennmaß:
FL/M 2011 25,995 - 26,0 mm
BFL/M 2011 29,995 - 30,0 mm
33869 ©
3. Kolben komplettieren
3.1 Reihenfolge und Lage der Kolbenringe:

9
3
1. Rechteckring bei FL/M 2011,
Top zum Brennraum weisend.
1. Doppeltrapezring bei BFL/M 2011,
2. Minutenring,
3. Ölschlitz-Dachfasenring
33870 ©
3.2. Kolbenringe montieren.
Hinweis: Federstoß des Dachfasenringes um

2
180° zum Ringstoß versetzen.
7
5
33871 ©
3.07.37 © 2001 / 0297 9959

4. Hinweis zu den Kolbenklassen der Kolben

5 Die Kolben sind durch unterschiedliche
9 Kompressionshöhen in Kolbenklassen einge-

teilt. Die Kolbenklassen sind auf dem Kolben-
boden gekennzeichnet.
4.1 FL/M 2011

Für FL- und FM- Motoren stehen Kolben mit
unterschiedlichen Kompressionshöhen zur
Verfügung.
33872 ©
Kolbenklasse A
= Kompressionshöhe 51,67 mm
Kolbenklasse B
= Kompressionshöhe 51,77 mm
Bei jedem Kolbentausch ist sicherzustellen, daß

die gleiche Kolbenklasse wieder verwendet
wird.
Bei Kurbelwellen- oder Zylinderkurbelgehäuse-

tausch muss zur Bestimmung der Kolbenklasse
der Abstand „Hubzapfenoberkante OT bis
Zylinderkopfdichtungsauflage“ neu ermittelt
werden.
Siehe Kapitel 4.
4.2 BFL/M 2011

Bei BFL- und BFM- Motoren werden aus-
schließlich Kolben der Kolbenklasse A ver-
3 wendet.
© 2001 / 0297 9959 3.07.38

4. Note to the piston classes of 4. Indication relative aux classes de 4. Observación con respecto a las
the pistons pistons categorías de pistón
The pistons are grouped into Les pistons sont subdivisés en A razón de sus diferentes alturas de
different compression heights in classes en fonction des différentes compresión, los pistones están
piston classes. The piston classes hauteurs de compression. Les clasificados en categorías. Estas son
are marked at the piston head. classes de piston sont repérées sur identificables en la cabeza del pistón.
le sommet du piston.
4.1 FL/M 2011 4.1 FL/M 2011 4.1 FL/M 2011

For FL and FM motors, pistons Pour les moteurs FL et FM, il existe Para los motores FL y FM están
with different compression heights des pistons pour différentes hauteurs disponibles pistones con diferentes
are available. de compression. alturas de compresión.
Piston class A Classe A Categoría A

= Compression height 51.67 mm = hauteur de compression 51,67 mm = altura de compresión 51,67 mm
Piston class B Classe B Categoría B
= Compression height 51.77 mm = hauteur de compression 51,77 mm = altura de compresión 51,77 mm
With each piston exchange, it must A chaque remplacement de piston, A cada cambio de pistón deberá
be ensured that the same piston il faut veiller à utiliser la même classe asegurarse de que se siga utilizando
class is again used. de piston. la misma categoría que antes.
With the exchange of the crankshaft En cas de remplacement du carter En caso de sustitución del cigüeñal
or the crankcase with integrated de vilebrequin ou du bloc-cylindres, il o bloque motor, es necesario, para
cylinder liners, the distance „stroke faut mesurer à nouveau la distance determinar la categoría de compre-
tap upper edge TDC to cylinder head entre « bord supérieur de maneton sión, medir la distancia entre el
gasket support“ must again be PMH et appui de joint de culasse » ”canto superior del muñón de biela
determined for the determination of pour déterminer la classe de piston. en PMS y la superficie de asiento
the piston class. See chapter 4. Voir chapitre 4. de la junta de culata“.
Ver capítulo 4.
3
4.2 BFL/M 2011 4.2 BFL/M 2011 4.2 BFL/M 2011
With the BFL and BFM motors, Sur les moteurs BFL et BFM, Para los motores BFL y BFM se
pistons excluding those of the uniquement utiliser la classe utilizan exclusivamente pistones
piston class A are used de piston A. de la categoría A.
3.08.38 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959


Magnetic measuring stand Support magnétique de mesure Soporte magnético de medición
Dial gauge Comparateur Comparador
Valve stem gasket pliers _________ 8024 Pince à joint de tige de soupape ___ 8024 Alicates para juntas de vástago
Valve spring Levier de démontage de ressort de válvula ____________________ 8024
assembly lever ________________ 9017 de soupape ___________________ 9017 Palanca de montaje para
Valve reseating tool Appareil à rectifier les sièges de soupape resortes de válvula _____________ 9017
Aparato para rectificar asientos de válvula

Clamping stand ______________ 120 900 Chevalet de fixation __________ 120 900 Soporte de sujeción __________ 120 900
Clamping plate ______________ 120 910 Plaque de fixation ____________ 120 910 Placa de sujeción ____________ 120 910
Sleeve for fitting Douille de montage pour Manguito de montaje para
valve stem seal ______________ 121 410 joint de tige de soupape _______ 121 410 juntas de vástago de válvula ____ 121 410
1. Preparation 1. Préparatifs 1. Preparativos
1. Mount cylinder head on fixture. 1.1 Monter la culasse sur le dispositif. 1.1 Montar la culata en el dispositivo.
2. Remove the valves 2. Démonter les soupapes 2. Desmontaje de válvulas
2.1 Remove cone clamp, valve spring 2.1 Démonter clavettes, coupelles, 2.1 Desmontar los semiconos, los
3 cap, valve springs and valves. ressorts de soupape et soupapes. platillos de retención de resorte, los
resortes de válvula y las válvulas.
2.2 Remove valve stem seal. 2.2 Démonter le joint de tige 2.2 Desmontar la junta del vástago
de soupape. de válvula.
Note: Use the valve stem gasket Nota: Utiliser la pince à joint de tige de Nota: Utilizar los alicates 8024 para
pliers 8024 soupape 8024. juntas de vástago de válvula
© 2001 / 0297 9959 3.08.41

Magnet-Messstativ
Messuhr
Ventilschaftdichtungszange _____________ 8024
Ventilfedermontagehebel _______________ 9017
Ventilsitzbearbeitungsgerät
Spezialwerkzeuge:
Aufspannbock ______________________ 120 900
Aufspannplatte _____________________ 120 910
Montagehülse für
Ventilschaftabdichtung _______________ 121 410
1. Vorbereitung
1.1 Zylinderkopf an Vorrichtung anbauen.

2
7
33874 ©
2. Ventile ausbauen
2.1 Klemmkegel, Ventilfederteller, Ventilfedern und

1
Ventile ausbauen. 3
33875 ©
2.2 Ventilschaftdichtung ausbauen.
Hinweis: Ventilschaftdichtungszange 8024 ver-

1
wenden
5
33876
33572 ©
3.08.41 © 2001 / 0297 9959

3. Ventile beurteilen
9 3.1 Ventile reinigen und sichtprüfen.
6 3.2 Ventilschaftdurchmesser messen.
Einlassventil 7,965 - 7,98 mm

Auslassventil 7,945 - 7,96 mm
33877 ©
3.3 Ventilrandstärke messen

6 Verschleißgrenzen FL/M:
Einlassventil 0,8 mm
Auslassventil 1,2 mm
Verschleißgrenzen BFL/M:
33878 ©
4. Zylinderkopf beurteilen
1 4.1 Zylinderkopf reinigen und auf Beschädigung
3
9 sichtprüfen.
33879 ©
4.2 Ventilsitzringe sichtprüfen. Ventilsitzbreite

9 messen.
6 FL/M
BFL/M
33880 ©
© 2001 / 0297 9959 3.08.42

3. Check the valves 3. Examen de l’état des soupapes 3. Calificación de las válvulas
3.1 Clean the valves and carry out a 3.1 Nettoyer les soupapes et les 3.1 Limpiar e inspeccionar las
visual inspection soumettre à un examen visuel. válvulas.
3.2 Measure the 3.2 Mesurer le diamètre de la tige 3.2 Medir el diámetro de los vástagos
valve stem diameter de soupape. de válvula.
Inlet valve 7.965 - 7.98 mm Soupape d’admission 7,965 - 7,98 mm Válvula de admisión 7,965 - 7,98 mm
Exhaust valve 7.945 - 7.96 mm Soupape d’échappement 7,945 - 7,96 mm Válvula de escape 7,945 - 7,96 mm
3.3. Measure the strength of the 3.3 Mesurer l’épaisseur de bord de 3.3 Medir el espesor de borde de la
valve edge soupape válvula
Wear limits FL/M: Limite d’usure FL/M: Límites de desgaste FL/M:
Inlet valve 0.8 mm Soupape d’admission 0,8 mm Válvula de admisión 0,8 mm

Exhaust valve 1.2 mm Soupape d’échappement 1,2 mm Válvula de escape 1,2 mm
Wear limits BFL/M: Limite d’usure BFL/M: Límites de desgaste BFL/M:

4. Check the cylinder head 4. Examen de l’état de la culasse 4. Calificación de la culata
4.1 Clean cylinder head and inspect for 4.1 Nettoyer la culasse et la soumettre 4.1 Limpiar la culata y examinarla
damage. à un examen visuel quant aux visualmente en cuanto a daños. 3
endommagements.
4.2 Check visually the valve seat rings. 4.2 Effectuer un examen visuel des 4.2 Examinar visualmente los
Measure the valve seat width sièges de soupape. Mesurer la asientos de válvula. Medir el
largeur de siège. ancho del asiento de válvula.
FL/M: FL/M FL/M

Inlet valve 1.7 ± 0.4 mm Soupape d’admission 1,7 ± 0,4 mm Válvula de admisión 1,7 ± 0,4 mm
Exhaust valve 1.7 ± 0.4 mm Soupape d’échappement 1,7 ± 0,4 mm Válvula de escape 1,7 ± 0,4 mm
BFL/M: BFL/M BFL/M

Inlet valve 1.58 ± 0.4 mm Soupape d’admission 1,58 ± 0,4 mm Válvula de admisión 1,58 ± 0,4 mm
Exhaust valve 1.7 ± 0.4 mm Soupape d’échappement 1,7 ± 0,4 mm Válvula de escape 1,7 ± 0,4 mm
3.08.42 © 2001 / 0297 9959

4.3 Fit in the valves and measure the 4.3 Insérer les soupapes et mesurer le 4.3 Introducir las válvulas y medir el
valve stem clearance. jeu de tige de soupape. juego del vástago de válvula.
Wear limits: Limites d’usure: Límites de desgaste:

Note: For measuring the valve stem Nota: Pour mesurer le jeu de tige de Nota: Para la medición del juego del
clearance, the valve shaft-end soupape, l’extrémité de la tige doit vástago de válvula es necesario
must close with the valve guide. se trouver à hauteur du guide de que el extremo de vástago termine
soupape. a ras con la guía de válvula.
4.4 Measure the valve arrears from 4.4 Mesurer le retrait de la soupape 4.4 Medir el retroceso de válvula entre
the valve disk to the cylinder head entre tête de soupape et plan de la cabeza de válvula y la superficie
sealing surface. joint de la culasse. de asiento de la junta de válvula.
Wear limits: Limite d’usure: Límite de desgaste:
FL/M 1.53 mm FL/M 1,53 mm FL/M 1,53 mm

BFL/M 1.3 mm BFL/M 1,3 mm BFL/M 1,3 mm
5. Check the cylinder head 5. Rectification de la culasse 5. Rectificado de la culata
5.1 If the wear dimension of the valve 5.1 Si les cotes d’usure de siège de 5.1 Si todavía no se han alcanzado las
seat and the valve arrears are not soupape et de retrait de soupape medidas de desgaste del asiento
yet reached, then work on the valve ne sont pas encore atteintes, de válvula ni del retroceso de válvula,
seat with the aid of a valve-seat rectifier le siège de soupape avec proceder al rectificado del asiento
grinding device. l’appareil à rectifier les sièges de de válvula utilizando el aparato para
soupape. rectificar asientos de válvula.
© 2001 / 0297 9959 3.08.43

4.3 Ventile einsetzen und Ventilschaftspiel messen.
Verschleißgrenzen:
6
Hinweis: Zum Messen des Ventilschaftspiels muss

das Ventilschaftende mit der Ventilführung
abschließen.
33881
33548 ©
4.4 Ventilrückstand von Ventilteller zur Zylinderkopf-

dichtfläche messen. 6
Verschleißgrenze:
FL/M 1,53 mm
BFL/M 1,3 mm
33882
33549 ©
5. Zylinderkopf bearbeiten
5.1 Sind die Verschleißmaße von Ventilsitz und

f
Ventilrückstand noch nicht erreicht,
Bearbeitung des Ventilsitzes mit Ventilsitz-
Bearbeitungsgerät durchführen.
33884 ©
3.08.43 © 2001 / 0297 9959

5.2 Ventilsitzring bearbeiten

f Ventilsitzwinkel Einlass Auslass
6 FL/M
BFL/M
45°
30°
45°
45°
Ventilsitzbreite:
FL/M 1,7 ± 0,4 mm
BFL/M 1,58 ± 0,4 mm 1,7 ± 0,4 mm
33885 ©
5.3 Ventilrückstand von Ventilteller zur Zylinder-

6 kopfdichtfläche messen.
Verschleißgrenze:
FL/M 1,53 mm
BFL/M 1,3 mm
33886 ©
5.4 Bei verschlissenen Ventilsitzringen, Ventil-

9 führungen oder beschädigter Zylinderkopf-
dichtfläche besteht die Möglichkeit den Zylin-
3 derkopf in unseren Service-Centern instand
setzen zu lassen.
33887 ©
6. Ventilfedern beurteilen
6 6.1 Länge der Ventilfeder messen.
Länge ungespannt normal:
Ventilfeder Draht- Ø 3,35 mm 38,9 mm

oder
Ventilfeder Draht- Ø 3,40 mm 39,3 mm
Ein gemischter Einbau ist zulässig.

33888 ©
© 2001 / 0297 9959 3.08.44

5.2 Reworking valve seat insert 5.2 Rectification du siège de soupape 5.2 Rectificar el asiento postizo de
válvula
Valve seat angle Inlet Exhaust Angle de siège Admission Echappement Angulo de asiento Admisión Escape
FL/M 45° 45° FL/M 45° 45° de válvula
BFL/M 30° 45° BFL/M 30° 45° FL/M 45° 45°
BFL/M 30° 45°
Valve seat width: Largeur de siège: Ancho de asiento de válvula:

FL/M 1.7 ± 0.4 mm FL/M 1,7 ± 0,4 mm FL/M 1,7 ± 0,4 mm
BFL/M 1.58 ± 0.4 1.7 ± 0.4 BFL/M 1,58 ± 0,4 mm 1,7 ± 0,4 mm BFL/M 1,58 ± 0,4 mm 1,7 ± 0,4 mm
5.3 Measure the valve arrears from 5.3 Mesurer le retrait de soupape entre 5.3 Medir el retroceso de válvula entre
the valve disk to the cylinder head tête de soupape et plan de joint de cabeza de válvula y superficie de
sealing surface. culasse. asiento de la junta de culata.
Wear limits: Limite d’usure: Límite de desgaste
FL/M 1.53 mm FL/M 1,53 mm FL/M 1,53 mm

BFL/M 1.3 mm BFL/M 1,3 mm BFL/M 1,3 mm
5.4 If valve seats, valve guides are worn 5.4 En cas d’usure des sièges, guides de 5.4 Si los asientos postizos de válvula y
out or cylinder head sealing surface soupapes ou de plan de joint de guías de válvula están desgastados
is damaged, it is possible to have the culasse endommagé, il est possible o la superficie de asiento de la junta
cylinder head reconditioned in our de faire remettre la culasse en état à de culata está dañada, se ofrece la 3
Service Centers. notre Centre de Service. posibilidad de hacer reacondicionar
la culata en uno de nuestros Centros
de Servicio.
6. Check the valve springs 6. Examen de l’état des ressorts 6. Calificación de los resortes
de soupape de válvula
6.1 Gauge length of valve spring 6.1 Mesurer la longueur des ressorts 6.1 Medir la longitud del resorte
de soupape. de válvula.
Unloaded length,standard. Longueur normale non bandée: Longitud normal sin comprimir:
Valve spring Fil de ressort Alambre del resorte
wire dia. 3.35 mm 38.9 mm de soupape Ø 3,35 mm 38,9 mm de válvula Ø 3,35 mm 38,9 mm
or ou ó
Valve spring Fil de ressort Ø 3,40 mm 39,3 mm
wire dia. 3.40 mm 39.3 mm de soupape Ø 3,40 mm 39,3 mm
Mixed installation is permissible. Un montage mixte est admissible. Se admite un montaje mixto.
3.08.44 © 2001 / 0297 9959

7. Install the valves 7. Montage des soupapes 7. Montaje de las válvulas
7.1 Insert and retain valve. Slide 7.1 Mettre en place la soupape et la 7.1 Introducir la válvula y retenerla.
protective sleeve onto valve stem. maintenir. Placer la douille de Colocar el manguito protector sobre
protection sur la tige de soupape. el vástago de la válvula.
Note: Before fitting valve stem seal, valve Nota: Avant tout montage du joint de Nota: Antes de montar la junta de
splines must be covered by the tige de soupape, les rainures de vástago es necesario recubrir las
protective sleeve or masking tape. clavetage doivent être recouvertes ranuras para los semiconos con el
d’une douille de protection ou d’un manguito protector o una lámina
film adhésif. adhesiva.
7.2 Insert a new valve stem gasket 7.2 Pousser le nouveau joint de tige 7.2 Colocar una junta de vástago
through the protective sleeve. de soupape par-dessus la douille de de válvula nueva sobre el manguito
protection. protector.
7.3 Remove protective sleeve. Press in 7.3 Enlever la douille de protection. 7.3 Quitar el manguito protector.
valve stem seal as far as it will go. Enfoncer le joint de tige de soupape Presionar la junta de vástago hasta
jusqu’en butée. que haga tope.
3
8. Dismount the front cover 8. Compléter la culasse 8. Completación de la culata
8.1 Assemble cylinder head: 8.1 Compléter la culasse: 8.1 Completar la culata:
Position valve spring and valve Monter les ressorts de soupape Colocar el resorte de válvula
spring cap. et les coupelles. y su platillo de retención.
© 2001 / 0297 9959 3.08.45

7. Ventile einbauen
7.1 Ventil einsetzen und gegenhalten. Schutz-

2
hülse auf den Ventilschaft stecken.
5
Hinweis: Vor jeder Montage der Ventilschaftab-
dichtung sind die Ventil-Keilnuten mit r
der Schutzhülse oder einer Klebefolie
abzudecken.
33889 ©
7.2 Neue Ventilschaftdichtung über die Schutz-

hülse schieben.
2
33890 ©
7.3 Schutzhülse entfernen. Ventilschaftdichtung

bis Anschlag eindrücken.
2
3
8
7
33891 ©
8. Zylinderkopf komplettieren
8.1 Zylinderkopf komplettieren:

2
Ventilfeder und Ventilfederteller aufsetzen.
8
33892 ©
3.08.45 © 2001 / 0297 9959

8.2 Ventilfedermontagehebel aufbauen, Klemm-

2 kegel einsetzen.
33893 ©
© 2001 / 0297 9959 3.08.46

8.2 Fit valve assembly lever, insert cone 8.2 Monter le levier de montage 8.2 Montar la palanca de montaje
clamp. de ressort de soupape, insérer para resortes de válvula, meter
les clavettes. los semiconos.
3.08.46 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

1. Inspect cams and bearing journals 1. Effectuer un examen visuel des 1. Examinar visualmente las levas y
for wear. cames et tourillons quant à leur usure. muñones de apoyo en cuanto a
desgaste.
© 2001 / 0297 9959 3.10.49

1. Nocken und Lagerzapfen auf Verschleiß

sichtprüfen
9
33895 ©
3.10.49 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

1. Dismantle rocker arm bracket. 1. Démonter le support de culbuteur. 1. Despiezar el caballete de balancines.
2. Check for wear and replace if 2. Faire un contrôle d’usure, le cas 2. Inspeccionar en cuanto a desgaste
necessary: échéant remplacer: y sustituir, si es necesario:
Journals tourillon los muñones de soporte,
Adjusting screw vis de réglage el tornillo de reglaje,
Rocker arm contact face surface de glissement du culbuteur la superficie de deslizamiento del
Bore alésage balancín,
el taladro.
3. Check oil duct for free passage. 3. Contrôler le libre passage du canal 3. Comprobar el libre paso del conducto
4. Reassemble rocker arm bracket. 4. Compléter le support de culbuteur, 4. Completar el soporte de balancines.
Fit circlips. monter les circlips. Montar los anillos de retención.
© 2001 / 0297 9959 3.11.53

1. Kipphebelbock zerlegen.
1
q
33897 ©
2. Auf Verschleiß prüfen ggf. austauschen:

Lagerzapfen
Einstellschraube
9
Kipphebelgleitfläche
Bohrung 0
33898 ©
3. Ölkanal auf Durchgang prüfen.

9
3
33899 ©
4. Kipphebelbock komplettieren. Sicherungsringe

montieren. 2
8
q
33900 ©
3.11.53 © 2001 / 0297 9959

© 2001 / 0297 9959

Injecteur Mise en état des composants
© 2001 / 0297 9959

Mise en état des composants Injecteur
Commercial tool required: Outillage standard: Herramienta comercial:

Long socket a/flats 15 ___________ 8021 Clé à douille longue de 15 _______ 8021 Llave de vaso largo de 15 ________ 8021
Special tool required: Outillage spécial Herramienta especial:

Retainer for injector ___________ 110 110 Outil de maintien d’injecteur ____ 110 110 Retenedor de inyector _________ 110 110
1. Unscrew cap nut. 1. Dévisser l’écrou-raccord. 1. Desenroscar la tuerca de unión.
2. Sequence of parts disassembly: 2. Ordre de démontage 2. Secuencia del despiece
1. Cap nut 1. Ecrou-raccord 1. Tuerca de unión

2. Injection nozzle 2. Injecteur 2. Inyector o tobera
3. Adapter 3. Pièce intermédiaire 3. Pieza intermedia
4. Thrust pin 4. Poussoir 4. Perno de presión
5. Compression spring 5. Ressort 5. Resorte de presión
6. Shim 6. Rondelle de réglage 6. Arandela de reglaje
Wash all parts in clean diesel fuel and Nettoyer toutes les pièces dans du Limpiar todas las piezas en
blow out with compressed air. gasoil propre et les sécher au jet d’air combustible diesel limpio y soplarlas
comprimé con aire comprimido.
3. Nozzle needle and nozzle body are 3. Aiguille et corps d’injecteur sont rodés 3. El cuerpo y la aguja del inyector son
lapped together and may neither be ensemble, ils ne doivent pas être piezas perfectamente hermanadas por
confused nor exchanged individually. intervertis ou remplacés séparément. lapeado y, por tanto, no está permitido
3 Do not touch nozzle needles with your Ne pas toucher l’aiguille d’injecteur emparejarlas con otras o cambiarlas
fingers. When nozzle body is held in avec les doigts. Le corps d’injecteur individualmente.
upright position, nozzle needle should étant tenu en position verticale, No tocar la aguja con los dedos.
by its own weight slide down slowly l’aiguille doit tomber lentement et sans Con el cuerpo del inyector en posición
and smoothly on its seating. à-coups sur son siège par l’effet de vertical, la aguja debe bajar por su
son propre poids. peso propio lenta y progresivamente,
deslizándose hasta alcanzar su
posición final de asiento.
Note: If nozzle needle does not slide Nota: Si l’aiguille descend par à-coups, Nota: Si el deslizamiento de la aguja
down smoothly, wash injection nettoyer à nouveau l’injecteur no es progresivo, el inyector debe
nozzle again in diesel fuel. Renew, dans du gasoil, le cas échéant, lavarse otra vez en combustible
if necessary. New injection nozzle le remplacer. diesel o sustituirse por otro nuevo,
must likewise be washed in clean Nettoyer également l’injecteur según el caso.
diesel fuel. neuf dans du gasoil propre. Lavar el inyector nuevo igualmente
en combustible diesel limpio.
© 2001 / 0297 9959 3.19.57

Lange Stecknuss SW 15 ________________ 8021
1
Spezialwerkzeug:
Halter für Einspritzventil ______________ 110 110 7
1. Überwurfmutter abschrauben.
33902 ©
2. Folge der Einzeldemontage
1. Überwurfmutter
1
2. Einspritzdüse
3. Zwischenstück 0
4. Druckbolzen
5. Druckfeder
6. Ausgleichscheibe
Sämtliche Teile in sauberem Dieselkraftstoff reinigen

und mit Druckluft ausblasen.
33903 ©
3. Düsennadel und Düsenkörper sind zusammen

geläppt und dürfen weder vertauscht noch
einzeln ausgetauscht werden.
9
3
Düsennadel nicht mit den Fingern berühren. Die
Düsennadel muß bei senkrecht gehaltenem 0
Düsenkörper durch ihr Eigengewicht langsam
und ruckfrei auf ihren Sitz gleiten. 5
33904 ©
Hinweis: Bei ruckweisem Abgleiten der Düsen-

nadel die Einspritzdüse erneut in
Dieselkraftstoff auswaschen, bei Bedarf
erneuern.
Neue Einspritzdüse ebenfalls in sau-
berem Dieselkraftstoff reinigen.
3.19.57 © 2001 / 0297 9959

4. Sitzflächen des Zwischenstückes auf Ver-

9 schleiß prüfen. Auf Vorhandensein der Zen-
trierstifte achten.
33905 ©
5. Ausgleichscheibe einsetzen.
2 Hinweis: Der Abspritzdruck ist von der Dicke der
5 Ausgleichscheibe abhängig.
33906 ©
6. Druckfeder einsetzen.
2
3
33907 ©
7. Druckbolzen mit dem Zentrierbund zur Druck-

2 feder weisend einsetzen.
33908 ©
© 2001 / 0297 9959 3.19.58

4. Check seating faces of adapter for 4. Contrôler les surfaces de logement 4. Examinar las superficies de asiento
wear. Make sure that centering pins de la pièce intermédiaire quant à de la pieza intermedia en cuanto a
are fitted. l’usure. Veiller à la présence des desgaste. Cuidar de que existan las
ergots de centrage. espigas de centraje.
5. Insert shim. 5. Insérer les rondelle de réglage. 5. Colocar las arandela de reglaje.
Note: The ejection pressure is dependent Nota: La pression d’ouverture dépend Nota: La presión de descarga depende
on the shim. des rondelle d’épaisseur. de las arandela de reglaje.
6. Insert compression spring. 6. Insérer le ressort. 6. Introducir el resorte de presión.
7. Insert thrust pin with centering collar 7. Insérer le poussoir avec collet de 7. Introducir el perno de presión con el
facing towards compression spring. centrage orienté vers le ressort. collarín de centraje indicando hacia el
resorte de presión.
3.19.58 © 2001 / 0297 9959

8. Insert adapter with centering pins into 8. Insérer la pièce intermédiaire 8. Introducir la pieza intermedia con
the bores of the nozzle holder. avec les ergots de centrage dans las espigas de centraje en los
les alésages du porte-injecteur. taladros del portainyector.
Note: The spot facing points to the Nota: Le lamage doit être orienté vers Nota: El rebaje debe indicar hacia
thrust pin. le poussoir. el perno de presión.
9. Fit injection nozzle with center bores 9. Placer l’injecteur avec les alésages 9. Colocar el inyector con los taladros
mating with the centering pins of the de centrage sur les ergots de de centraje sobre las espigas de
adapter. centrage de la pièce intermédiaire. centraje de la pieza intermedia.
Note: Take care that nozzle needle does Nota: Ne pas laisser s’échapper l’aiguille Nota: La aguja no debe caer fuera del
not fall out of nozzle body. du corps d’injecteur. cuerpo del inyector.
10. Screw on cap nut. 10. Visser l’écrou-raccord. 10. Enroscar la tuerca de unión.
11. Tighten cap nut. 11. Bloquer l’écrou-raccord 11. Apretar la tuerca de unión.
For testing and adjusting injector see Pour le contrôle et le calage de Para la verificación y el ajuste del
Chapter 2. l’injecteur, voir chapitre 2. inyector, ver capítulo 2.
© 2001 / 0297 9959 3.19.59

8. Zwischenstück mit den Zentrierstiften in die

Bohrungen des Düsenhalters einsetzen.
2
Hinweis: Die Ansenkung weist zum Druckbolzen.
5
8
33909 ©
9. Einspritzdüse mit den Zentrierbohrungen auf

die Zentrierstifte des Zwischenstückes auf-
setzen.
2
Hinweis: Die Düsennadel darf nicht aus dem 8
Düsenkörper fallen.
5
r
33910 ©
10. Überwurfmutter aufschrauben.

2
3
33911 ©
11. Überwurfmutter festdrehen.
2
Einspritzventil prüfen und einstellen, siehe 6
Kapitel 2.
33912 ©
3.19.59 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

Assembly tool _______________ 142 850 Dispositif de montage _________ 142 850 Dispositivo de montaje ________ 142 850
Assembly tool _______________ 142 050 Dispositif de montage _________ 142 050 Dispositivo de montaje ________ 142 050
Measuring device for Appareil de mesure Equipo medidor para
governor shaft d’arbre de régulateur eje de regulador
and piston protrusion _________ 100 750 et de dépassement de piston ___ 100 750 y saliente de pistón ___________ 100 750
1. Dismount the front cover 1. Démontage du couvercle avant 1. Despiece de la tapa delantera
1.1 Remove engine shutdown device, 1.1 Le cas échéant, démonter le dispositif 1.1 Desmontar el dispositivo de parada
if any. d’arrêt du moteur. del motor, si lo hay.
1.2 Detach governor spring. 1.2 Décrocher le ressort de régulateur. 1.2 Descolgar el resorte del regulador.
1.3 Remove governor lever shaft. 1.3 Démonter l’arbre du levier de 1.3 Desmontar el eje de palancas del
régulateur. regulador.
© 2001 / 0297 9959 3.27.63

Spezialwerkzeug:
Montagevorrichtung _________________ 142 850

Montagevorrichtung _________________ 142 050
Messgerät für Reglerwelle
und Kolbenüberstand ________________ 100 750
1. Vorderen Deckel zerlegen
1.1 Falls vorhanden, Motorabstellung abbauen.

1
33914 ©
1.2 Reglerfeder aushängen.

1
3
33915 ©
1.3 Reglerhebelwelle abbauen.

1
33916 ©
3.27.63 © 2001 / 0297 9959

1.4 Ausgleichscheiben unter der Reglerhebelwelle

1 abnehmen.
33917 ©
1.5 Messwerk herausnehmen.

1
33918 ©
1.6 Wellendichtring für Nockenwelle austreiben.

1
3
33919 ©
1.7 Wellendichtring für Kurbelwelle austreiben.

1
33920 ©
© 2001 / 0297 9959 3.27.64

1.4 Take off shims below governor lever 1.4 Enlever les cales sous l’arbre de 1.4 Retirar las arandelas de reglaje
shaft. levier de régulateur. que se encuentran bajo el eje de
palancas del regulador.
1.5 Remove the measuring element 1.5 Extraire le régulateur. 1.5 Retirar el mecanismo de medición.
1.6 Drive out camshaft seal. 1.6 Chasser le joint d’arbre à cames. 1.6 Desmontar golpeando el retén para
el árbol de levas.
1.7 Drive out crankshaft seal. 1.7 Chasser le joint d’arbre de 1.7 Desmontar golpeando el retén para
vilebrequin. el cigüeñal.
3.27.64 © 2001 / 0297 9959

1.8 Detach spring. 1.8 Décrocher le ressort. 1.8 Desenganchar el resorte.
1.9 Drive out dowel sleeve. 1.9 Chasser la douille de serrage. 1.9 Desmontar golpeando el casquillo
de sujeción.
1.10 Remove shutdown lever together 1.10 Sortir le levier d’arrêt avec douilles 1.10 Retirar la palanca de parada con
with spacer bushes. entretoises. los casquillos distanciadores.
1.11 Remove shaft together with spacer 1.11 Sortir l’arbre avec douille entretoise 1.11 Sacar el eje con el casquillo
bush and spring. et ressort. distanciador y resorte.
© 2001 / 0297 9959 3.27.65

1.8 Feder aushängen.

1
33921 ©
1.9 Spannhülse austreiben.

1
33922 ©
1.10 Abstellhebel mit Abstandsbuchsen heraus-

nehmen. 1
3
33923 ©
1.11 Welle mit Abstandsbuchse und Feder heraus-

nehmen. 1
33924 ©
3.27.65 © 2001 / 0297 9959

1.12 Runddichtring herausnehmen.

1
33925 ©
1.13 Verschlussdeckel abbauen.

1
33926 ©
1.14 Spannhülse austreiben.

1
3
33927 ©
1.15 Bolzen heraushebeln.

1 Hinweis: Dichtfläche nicht beschädigen.
5
33928 ©
© 2001 / 0297 9959 3.27.66

1.12 Take out O-seal. 1.12 Sortir le joint torique. 1.12 Retirar el anillo tórico.
1.13 Remove cover. 1.13 Démonter le couvercle d’obturation. 1.13 Desmontar la tapa de cierre.
1.14 Drive out dowel sleeve. 1.14 Chasser la douille de serrage. 1.14 Desmontar golpeando el casquillo
de sujeción.
1.15 Lever out pin. 1.15 Décoller le boulon. 1.15 Sacar, haciendo palanca, el pasador.
Note: Make sure not to damage sealing Nota: Ne pas endommager le plan Nota: No dañar la superficie de cierre.
surface. de joint.
3.27.66 © 2001 / 0297 9959

1.16 Remove speed control lever together 1.16 Extraire le levier de variation de 1.16 Quitar la palanca de ajuste
with spacer bush. vitesse avec douille entretoise. de velocidad con el casquillo
distanciador.
1.17 Take out O-seal. 1.17 Extraire le joint torique. 1.17 Retirar el anillo tórico.
1.18 Remove full-load stop. 1.18 Démonter la butée de pleine charge. 1.18 Desmontar el tope de plena carga.
1.19 Remove clamping pad, if any. 1.19 Le cas échéant, enlever la patte 1.19 Quitar las garras de sujeción, si
Unscrew torque control. de serrage. Dévisser le correcteur de las hay. Desenroscar el mecanismo
débit. corrector de par.
© 2001 / 0297 9959 3.27.67

1.16 Drehzahlverstellhebel mit Abstandsbuchse

herausnehmen. 1
33929 ©
1.17 Runddichtring herausnehmen.

1
33930 ©
1.18 Vollastanschlag ausbauen.

1
3
33931 ©
1.19 Falls vorhanden, Spannpratze entfernen.

Angleichung herausschrauben. 1
33932 ©
3.27.67 © 2001 / 0297 9959

1.20 Entlüftungsventil ausbauen.

1
33933 ©
2. Einzelteile sichtprüfen
9 2.1 Vorderen Deckel sichtprüfen ggf. austauschen.
33934 ©
2.2 Messwerk auf Verschleiß sichtprüfen, ggf.

9 austauschen.
3
0
33935 ©
2.3 Muffe sichtprüfen, ggf. austauschen.

9
0
33936 ©
© 2001 / 0297 9959 3.27.68

1.20 Remove vent valve. 1.20 Démonter la soupape de purge d’air. 1.20 Desmontar la válvula de ventilación.
2. Check visually the single 2. Examen visuel des pièces 2. Inspección de las piezas
components
2.1 Inspect front cover and replace if 2.1 Effectuer un examen visuel du 2.1 Examinar visualmente la tapa
necessary. couvercle avant, le cas échéant, delantera, sustituyéndola en caso
le remplacer. necesario.
2.2 Check visually the measuring 2.2 Contrôler le régulateur quant à 2.2 Examinar visualmente si el
element for wear, exchange if l’usure, le cas échéant, le remplacer. mecanismo de medición está
necessary. desgastado, sustituyéndolo en
caso necesario. 3
2.3 Check visually the pipe coupling, 2.3 Effectuer un examen visuel 2.3 Inspeccionar el manguito, sustituyén-
exchange if necessary. du manchon, le cas échéant, le dolo en caso necesario.
remplacer.
3.27.68 © 2001 / 0297 9959

2.4 Carry out a visual check for the roller 2.4 Effectuer un examen visuel du levier 2.4 Examinar visualmente la palanca
lever, shaft and and no-load operation à galet, arbre et levier de ralenti, le de rodillos, el eje y la palanca de
lever, exchange if necessary. cas échéant, les remplacer. marcha en vacío, sustituyéndolos
en caso necesario.
3. Complete the front cover 3. Compléter le couvercle avant 3. Completación de la tapa delantera
3.1 Install full-load stop together with 3.1 Monter la butée de pleine charge 3.1 Montar el tope de plena carga con
O-seal. avec bague d’étanchéité. junta anular.
3.1 Adjust distance of full-load stop 3.1 Régler la distance de la vis de 3.1 Ajustar la distancia del tornillo
screw. Tighten locknut. butée de pleine charge. Serrer le de tope de plena carga. Apretar la
contre-écrou. contratuerca.
3
Tightening specification: 4.5 Nm Prescription de serrage: 4,5 Nm. Prescripción de apriete: 4,5 Nm
3.2 Inspect individual components of 3.2 En présence d’un correcteur de 3.2 Controlar visualmente las piezas del
torque control, if any, and replace if débit, effectuer un examen visuel mecanismo corrector de par, si lo hay.
necessary. des pièces de celui-ci. Le cas Sustituirlas en caso necesario.
échéant, les remplacer.
© 2001 / 0297 9959 3.27.69

2.4 Rollenhebel, Welle und Leerlaufhebel sicht-

prüfen, ggf. austauschen.
9
0
33937 ©
3. Vorderen Deckel komplettieren
3.1 Vollastanschlag mit Dichtring einbauen.

9
0
33938 ©
3.1 Abstand der Vollastanschlagschraube ein-

stellen. Kontermutter festdrehen. 2
3
6
33939 ©
3.2 Falls vorhanden, Einzelteile der Angleichung

sichtprüfen. Ggf. austauschen. 9
0
33940 ©
3.27.69 © 2001 / 0297 9959

3.3 Angleichung vormontieren.

2 Pos. 1 in Pos. 2 bis Anschlag mit max. 1 Nm
hineindrehen. Anschließend 1 + 0,5 Umdreh-
6 ungen herausdrehen.
Pos. 3 festdrehen.
33941 ©
3.4 Pos. 4 bis zur Anlage an Pos 5 hineindrehen.

2 Anschließend 1 Umdrehung herausdrehen.
Pos. 6 festdrehen.
6 Anziehvorschrift: 6 ± 0,6 Nm
33942 ©
3.5 Angleichung hineindrehen.

2
3
33943 ©
3.6 Einschraubtiefe messen: 6,4 ± 0,5 mm

6
33944 ©
© 2001 / 0297 9959 3.27.70

3.3 Preassemble torque control. 3.3 Préassembler le correcteur. 3.3 Premontaje del mecanismo corrector
Pre-mount the adjustment. Turn Visser le Rep. 1 jusqu’en butée de par.
Pos. 1 in Pos. 2 until the end dans le Rep. 2 à 1 Nm maxi. Enroscar, con a lo sumo 1 Nm, la
stop with max. 1 Nm. Then, turn Ensuite dévisser de 1 + 0,5 tour. pieza (1) en la pieza (2) hasta el
out 1 + 0,5 rotations. Serrer à bloc le Rep. 3. tope. A continuación, desenroscarla
Firmly tighten Pos. 3. una vuelta y media.
Apretar la pieza (3).
Tightening
specification: 16 ± 1.6 Nm Prescription de serrage: 16 ± 1,6 Nm. Prescripción de apriete: 16 ± 1,6 Nm
3.4 Turn item 4 as far as it will go into 3.4 Visser le Rep. 4 jusqu’en butée sur 3.4 Enroscar la pieza (4) hasta que haga
item 5. Then unscrew by 1 turn. le Rep. 5. Ensuite dévisser de 1 tour. tope en la pieza (5). A continuación,
Tighten item 6. Serrer à bloc le Rep. 6. desenroscarla una vuelta.
Apretar la pieza (6).
Tightening
specification: 6 ± 0.6 Nm Prescription de serrage: 6 ± 0,6 Nm. Prescripción de apriete: 6 ± 0,6 Nm
3.5 Turn in torque control. 3.5 Visser le correcteur. 3.5 Enroscar el mecanismo corrector
de par.
3.6 Gauge thread reach: 3.6 Mesurer la profondeur de vissage: 3.6 Medir la profundidad de enroscar:
6.4 ± 0.5 mm 6,4 ± 0,5 mm 6,4 ± 0,5 Nm
3.27.70 © 2001 / 0297 9959

3.7 Position clamping pad. 3.7 Poser la patte de serrage. 3.7 Colocar la garra de sujeción.
3.8 Tighten clamping nut. 3.8 Serrer à bloc l’écrou de serrage 3.8 Apretar la tuerca de sujeción.
Note: Bench test required for precise Nota: Pour le réglage exact de la Nota: Para el ajuste exacto del corrector
adjustment of torque control. correction de débit, un passage sur de par se requiere una marcha en
banc d’essai est nécessaire. el banco de pruebas.
3.9 Press in unlubricated the new shaft 3.9 Enfoncer un joint d’arbre neuf non 3.9 Introducir a presión el retén para el
seal ring for the cam shaft. huilé pour l’arbre à cames. árbol de levas, sin aceitarlo.
3.10 Press in crankshaft seal without 3.10 Enfoncer un joint d’arbre neuf non 3.10 Introducir a presión el retén para el
using oil. huilé pour le vilebrequin. cigüeñal, sin aceiterlo.
Note: If the crankshaft sealing surface Nota: Si le plan de joint du vilebrequin Nota: Si la superficie de contacto del
has a lead-in spiral, a new shaft présente une rainure de roulement, cigüeñal presenta una huella de
seal ring set, consisting of rotary à la place d’un joint d’arbre neuf, roce, es necesario utilizar, en lugar
shaft seal and a rotating ring is to monter un jeu de joints d’arbre neuf de un retén nuevo, un nuevo juego
be used instead of a new shaft comprenant joint d’arbre et bague de retén, compuesto por un retén
seal ring. For the assembly of the de roulement. Montage du jeu de y un anillo de roce. Para el montaje
shaft seal ring set, see chapter 4. joints d’arbre, voir chapitre 4. del juego de retén, ver capítulo 4.
© 2001 / 0297 9959 3.27.71

3.7 Spannpratze auflegen.

2
33945 ©
3.8 Spannmutter festdrehen.
2
Hinweis: Zur exakten Angleicheinstellung ist ein 6
Prüfstandslauf erforderlich.
5
33946 ©
3.9 Neuen Wellendichtring für Nockenwelle un-

geölt einpressen.
2
3
ß
7
33947 ©
3.10 Neuen Wellendichtring für Kurbelwelle un-

geölt einpressen. 2
Hinweis: Hat die Kurbelwellendichtfläche eine
Einlaufrille, ist anstatt eines neuen ß
Wellendichtringes ein neuer Wellen-
dichtringsatz, bestehend aus Wellen- 7
dichtring und Laufring, zu verwenden.
Montage des Wellendichtringsatzes
siehe Kapitel 4.
5
33948 ©
3.27.71 © 2001 / 0297 9959

3.11 Stop-Anschlagschraube so einschrauben,

2 dass Kontermutter mit dem Schrauben-
ende bündig abschließt.
33949 ©
3.12 Abstand der min. Drehzahlschraube einstellen

2 und festdrehen.
Hinweis: Die vorgenannten Einstellangaben sind

5 Grundwerte. Zur Leistungs- und Dreh-
zahleinstellung ist ein Prüfstandslauf
erforderlich.
33950 ©
3.13 Hülse und Feder auf Abstellwelle schieben.

2
3
33951 ©
3.14 Abstellwelle einbauen.

2
33952 ©
© 2001 / 0297 9959 3.27.72

3.11 Screw in the stop screw in such 3.11 Visser la vis de butée d’arrêt de 3.11 Enroscar el tornillo del tope de
a way that the counter nut closes sorte que le contre-écrou et parada de forma tal que la
flush fitting with the bolt end. l’extrémité de vis soient à fleur. contratuerca termine a ras con
el extremo del tornillo.
3.12 Adjust distance of min. speed 3.12 Régler l’écartement de la vis de 3.12 Ajustar la distancia del tornillo para
setscrew and tighten. régime mini et serrer à bloc. velocidad mínima y apretar.
Note: The above adjustment data rep Nota: Les valeurs de réglage indiquées Nota: Los precitados datos de ajuste
resent basic values. It is neces- ici sont des valeurs de base. son valores base. Para el ajuste
sary to carry out a bench test for Pour le réglage de la puissance de la potencia y velocidad se
setting engine power and speed. et du régime, un passage sur requiere una marcha en el banco
banc d’essai est nécessaire. de pruebas.
3.13 Push the sleeve and the spring 3.13 Emmancher la douille et le ressort 3.13 Colocar el casquillo y el resorte
onto storage shaft. sur l’arbre d’arrêt. sobre el eje de parada.
3.14 Install shutdown shaft. 3.14 Monter l’arbre d’arrêt. 3.14 Montar el eje de parada.
3.27.72 © 2001 / 0297 9959

3.15 Slide greased O-seal onto shaft. 3.15 Emmancher un joint torique graissé 3.15 Colocar el anillo tórico untado con
sur l’arbre. grasa sobre el eje.
3.16 Insert the sleeve. 3.16 Emmancher la douille. 3.16 Colocar el casquillo.
3.17 Assemble shutdown lever with dowel 3.17 Monter le levier d’arrêt avec la 3.17 Montar la palanca de parada con
sleeve. douille de serrage. el casquillo de sujeción.
3.18 Fit greased O-seal. 3.18 Monter le joint torique graissé. 3.18 Montar el anillo tórico untado con
grasa.
© 2001 / 0297 9959 3.27.73

3.15 Eingefetteten Runddichtring auf die Welle

schieben.
2
u
ß
33953 ©
3.16 Hülse aufschieben.

2
33954 ©
3.17 Abstellhebel mit Spannhülse montieren.

2
3
33955 ©
3.18 Eingefetteten Runddichtring montieren.

2
u
ß
33956 ©
3.27.73 © 2001 / 0297 9959

3.19 Hülse auf Drehzahlwelle montieren und

2 eindrücken.
33957 ©
Hinweis: Einbaurichtung des Drehzahlverstell-

5 hebels beachten.
33958 ©
3.20 Drehzahlverstellhebel mit Spannhülse mon-

2 tieren.
33959 ©
3.21 Bolzen eintreiben.

2 Hinweis: Nut der Drehzahlverstellwelle muß mit
5 Bohrung für Bolzen auf Überdeckung
stehen.
33960 ©
© 2001 / 0297 9959 3.27.74

3.19 Mount and push in the sleeve on the 3.19 Monter la douille sur l’arbre de 3.19 Colocar el casquillo sobre el eje
rotational speed shaft. variation de vitesse et l’enfoncer. de velocidad, dejándolo encajado.
Note: Watch direction of installation of Nota: Respecter le sens de montage Nota: Observar la dirección de
speed control lever. du levier de variation de vitesse. montaje de la palanca de ajuste
de velocidad.
3.20 Assemble speed control lever with 3.20 Monter le levier de variation de 3.20 Montar la palanca de ajuste
dowel sleeve. vitesse avec la douille de serrage. de velocidad con el casquillo de
sujeción.
3
3.21 Drive in pin. 3.21 Enfoncer le boulon. 3.21 Montar golpeando el pasador.
Note: Groove of speed control shaft must Nota: La rainure de l’arbre de variation Nota: La ranura del eje de ajuste de
be in line with pin bore. de vitesse doit coïncider avec velocidad debe coincidir con el
l’alésage du boulon. taladro de alojamiento del pasador.
3.27.74 © 2001 / 0297 9959

3.22 Complete the measuring element 3.22 Compléter le régulateur avec le 3.22 Completar el mecanismo de
with the pipe coupling. manchon. medición con el manguito.
Note: Watch direction of installation. Nota: Respecter le sens de montage. Nota: Observar la dirección en que se
monte.
3.23 Fit the measuring element in the 3.23 Introduire le régulateur dans le 3.23 Meter el mecanismo de medición en
front cover. couvercle avant. la tapa delantera.
Note: Be careful not to damage sealing Nota: Ne pas endommager la lèvre du Nota: Cuidar de no deteriorar el labio de
lip of shaft seal. joint d’arbre. obturación del retén.
3.24 Support the compensating shim 3.24 Placer des cales de compensation 3.24 Colocar en los puntos “K“ y “L“
washer at the positions „K“ and „L“ d’au moins 0,3 mm aux points « K » arandelas de calce de por lo menos
using at least 0.3 mm. et « L ». 0,3 mm de espesor.
3
3.25 Install governor lever shaft without 3.25 Monter l’arbre de levier de régulateur 3.25 Montar el eje de palancas del
idling lever. Tighten bolts. sans levier de ralenti. Serrer les vis. regulador sin la palanca de marcha
en vacío. Apretar los tornillos.
© 2001 / 0297 9959 3.27.75

3.22 Messwerk mit Muffe komplettieren.

2
5
8
33961 ©
3.23 Messwerk in vorderen Deckel einsetzen.
Hinweis: Dichtlippe des Wellendichtringes nicht

2
beschädigen.
5
r
33962 ©
3.24 Ausgleichscheiben an den Stellen „K“ und „L“

von mindestens 0,3 mm unterlegen. 2
3
6
33963 ©
3.25 Reglerhebelwelle ohne Leerlaufhebel ein-

6
33964 ©
3.27.75 © 2001 / 0297 9959

Parallelität des Rollenhebels messen:

2 3.26 Reglerhebel an der Stelle X so unterlegen,
7 dass die Kugellager nicht auf der Muffe auf-

liegen.
Gemessen wird unter leichtem Andruck des
6 Rollenhebels gegen die Reglerhebelwelle.
Messuhr auf Kugellager Pos. 1 setzen und
Zeiger auf Null einstellen.
33965 ©
3.27 Messuhr auf Kugellager Pos. 2 setzen. Ab-

2 weichung zu Kugellager Pos. 1 notieren.
6 Zum Erreichen der geforderten Toleranz von

0,05 mm kann an einer Stelle „K oder L“ max.
0,5 mm zusätzlich unterlegt werden.
33966 ©
3.28 Rollenhebel mit Leerlaufhebel und Welle

2 montieren.
3 5 Hinweis: Einbaurichtung beachten.
33967 ©
3.29 Reglerhebelwelle kompl. in vorderen Deckel

2 einbauen. Schrauben festdrehen.
33968 ©
© 2001 / 0297 9959 3.27.76

Measuring parallelism of roller lever: Mesurer le parallélisme du levier à Medición del paralelismo de la palanca
galet: de rodillos
3.26 Support the regulator levers at the 3.26 Placer une cale sous le levier de 3.26 Calzar la palanca del regulador en
position x in such a way that the ball régulateur au point x de sorte que el punto x, de modo que los
bearings do not rest upon the pipe le roulement à bille ne repose pas cojinetes de bolas no se asienten
coupling. sur le manchon. en el manguito.
It is measured under a light pressure Mesurer sous légère pression du La medición se realiza presionando
of the roller lever against the regulator levier à galet contre l’arbre de la palanca de rodillos ligeramente
lever shaft. levier de régulateur. contra el eje de palancas del regu-
Place the dial gauge on the ball Placer le comparateur sur le lador.
bearing Pos. 1 and set the pointer to roulement à billes Rep. 1 et mettre Colocar el comparador sobre el
l’aiguille sur zéro. cojinete de bolas (1) y ajustar la
aguja a cero.
3.27 Place the dial gauge on the ball 3.27 Placer le comparateur sur le 3.27 Colocar el comparador sobre el
bearing Pos. 2. Note the deviation roulement à billes Rep. 2. Noter cojinete de bolas (2) y apuntar la
to the ball bearing Pos. 1. l’écart par rapport au roulement desviación con respecto al cojinete
à billes Rep. 1. de bolas (1).
To attain the required tolerance
of 0.05 mm, it is possible to insert Pour respecter la tolérance exigée Para obtener la tolerancia solicitada
an additional shim of max. 0.5 mm de 0,05 mm, il est possible de placer de 0,05 mm es posible calzar
either at point ”K“ or ”L“. une cale de maxi 0,5 mm en un adicionalmente uno de los puntos
point « K » ou « L ». ”K“ o ”L“ con 0,5 mm, como máximo.
3.28 Assemble roller lever with idling 3.28 Monter le levier à galet avec le levier 3.28 Ensamblar la palanca de rodillos
lever and shaft. de ralenti et l’arbre. con la palanca de marcha en vacío
y el eje.
3
Note: Watch direction of installation. Nota: Respecter le sens de montage. Nota: Observar la dirección de montaje.
3.29 Install complete governor lever shaft 3.29 Monter l’arbre de levier de régulateur 3.29 Montar el eje de palancas del
in front cover. Tighten bolts. complet dans le couvercle avant. regulador por completo en la tapa
Serrer les vis. delantera. Apretar los tornillos.
3.27.76 © 2001 / 0297 9959

3.30 Hook up governor spring. 3.30 Accrocher le ressort de régulateur. 3.30 Enganchar el resorte del regulador.
3.31 Mount cover with new gasket. 3.31 Monter le couvercle avec un joint 3.31 Montar la tapa provista de una junta
Tighten bolts. neuf. Serrer les vis. nueva. Apretar los tornillos.
3.32 If engine shutdown device is 3.32 En présence d’un dispositif d’arrêt 3.32 Si el motor está equipado con
provided, position O-seal and du moteur, placer un joint torique et un dispositivo de parada:
grease. graisser. Colocar un anillo tórico y untarlo
3 con grasa.
3.33 Install engine shutdown device and 3.33 Monter le dispositif d’arrêt du moteur 3.33 Montar el dispositivo de parada y
tighten bolts. et serrer les vis. apretar los tornillos.
© 2001 / 0297 9959 3.27.77

3.30 Reglerfeder einhängen.

2
33969 ©
3.31 Deckel mit neuer Dichtung montieren.

2
ß
6
33970 ©
3.32 Falls Motorabstellung vorhanden.

Runddichtring auflegen und einfetten. 2
u 3
33971 ©
3.33 Motorabstellung einbauen und Schrauben

festdrehen. 2
6
5
8
33972 ©
3.27.77 © 2001 / 0297 9959

3.34 Neuen Runddichtring auflegen.

2 Entlüftungsventil reinigen und neuen Rund-
ß dichtring aufziehen.
33973 ©
3.35 Kurbelgehäuseentlüftung montieren.

33974 ©
3.36 Falls vorhanden, Leerlaufkapsel mit neuem

2 Runddichtring bis Innenkante vorderer Deckel
bündig einschrauben. Sechskantschraube
3
ß festdrehen.
Anziehvorschrift: 4,6 ± 0,4 Nm

5
6
33975 ©
© 2001 / 0297 9959 3.27.78

3.34 Position new O-seal. 3.34 Poser un joint torique neuf. 3.34 Colocar un anillo tórico nuevo.
3.35 Fit crankcase breather. 3.35 Monter l’évent de carter. 3.35 Montar el dispositivo de ventilación
Tighten bolts. Serrer les vis. del cárter.
Apretar el tornillo.
3.36 Screw in idle-speed casting, 3.36 En présence d’une capsule de 3.36 Si existe, enroscar la cápsula de
if any, with new O-seal flush ralenti, visser celle-ci avec un joint marcha en vacío provista de un
with inner edge of front cover. torique neuf jusqu’à fleur du bord anillo tórico nuevo, dejándola
Tighten hex. bolt. intérieur de couvercle avant. Serrer enrasada con el canto interior de la 3
la vis hexagonale. tapa delantera. Apretar el tornillo
hexagonal.
Tightening Prescription Prescripción

specification: 4.6 ± 0.4 Nm de serrage: 4,6 Nm ± 0,4 Nm de apriete: 4,6 ± 0,4 Nm
3.27.78 © 2001 / 0297 9959

© 2001 / 0297 9959

Ventilateur de refroidissement Mise en état des composants
Turbina de refrigeración Reparación de componentes
© 2001 / 0297 9959

Mise en état des composants Ventilateur de refroidissement
Reparación de componentes Turbina de refrigeración
1. Dismount the cooling fan 1. Démonter le ventilateur 1. Despiece de la turbina de

refrigeración
1.1 Remove blower jacket inlet. 1.1 Démonter l’entrée d’enveloppe de 1.1 Desmontar la entrada de la
ventilateur. envolvente de turbina.
1.2 Remove air duct. 1.2 Dévisser l’écrou de fixation. Enlever 1.2 Desenroscar la tuerca de fijación.
la rondelle. Quitar la arandela.
1.3 Unscrew fastening nut. Remove 1.3 Enlever la poulie à gorge et la roue 1.3 Desmontar la polea acanalada y
washer. à aubes. el rotor.
1.4 Remove V-belt pulley and rotor. 1.4 Enlever la bague d’écartement. 1.4 Quitar la arandela distanciadora.
© 2001 / 0297 9959 3.39.81

1. Kühlgebläse zerlegen
1.1 Gebläsemantel-Einlauf abbauen.

1
33977 ©
1.2 Befestigungsmutter abschrauben. Scheibe

abnehmen.
1
33978 ©
1.3 Keilriemenscheibe und Laufrad abnehmen.

1
3
33979 ©
1.4 Distanzscheibe abnehmen.

1
33980 ©
3.39.81 © 2001 / 0297 9959

1.5 Führungsscheibe abnehmen.

1
33981 ©
1.6 Befestigungsmutter abschrauben.

1
33982 ©
1.7 Generator herausdrücken.

1
3
33983 ©
© 2001 / 0297 9959 3.39.82

1.5 Remove guide disc. 1.5 Enlever la bague de guidage. 1.5 Quitar el disco de guía.
1.6 Unscrew fastening nut. 1.6 Dévisser l’écrou de fixation 1.6 Desenroscar la tuerca de fijación.
1.7 Press out alternator. 1.7 Chasser l’alternateur 1.7 Desmontar a presión el alternador.
3.39.82 © 2001 / 0297 9959

2. Check visually the single 2. Examen visuel de toutes les 2. Inspección de las piezas
components pièces.
2.1 Inspect all single parts and replace 2.1 Effectuer un examen visuel de toutes 2.1 Controlar visualmente todas las
if necessary. les pièces, le cas échéant, les piezas, sustituyéndolas en caso
remplacer. necesario.
3. Complete the cooling fan 3. Compléter le ventilateur 3. Completación de la turbina de

refrigeración
3.1 Introduce alternator into blower. 3.1 Monter l’alternateur dans le 3.1 Introducir el alternador en la turbina.
3 ventilateur.
3.2 Position washers, tighten nuts. 3.2 Mettre en place les cales, serrer les 3.2 Colocar las arandelas de calce.
écrous. Apretar las tuercas.
© 2001 / 0297 9959 3.39.83

2. Einzelteile sichtprüfen
2.1 Alle Teile sichtprüfen, ggf. auswechseln.

9
0
33984 ©
9
0
33985 ©
3. Kühlgebläse komplettieren
3.1 Generator in Kühlgebläse einsetzen.

2
3
Hinweis: Einbaurichtung beachten. 5
33986 ©
3.2 Unterlegscheiben auflegen, Muttern fest-

drehen. 2
6
33987 ©
3.39.83 © 2001 / 0297 9959

3.3 Führungsscheibe auflegen.

2 Hinweis: Abgesetzte Seite muß zum Generator
5 weisen.
33988 ©
3.4 Distanzscheibe auflegen.

2
33989 ©
3.5 Laufrad einbauen.

2
3
33990 ©
3.6 Keilriemenscheibe auflegen.

2
33991 ©
© 2001 / 0297 9959 3.39.84

3.3 Position guide disc. 3.3 Mettre en place la bague de 3.3 Colocar el disco de guía.
guidage.
Note: Shouldered side must face
alternator. Nota: Le côté à épaulement doit être Nota: La cara escalonada debe indicar
dirigé vers l’alternateur. hacia el alternador.
3.4 Position spacer. 3.4 Mettre en place la bague 3.4 Poner la arandela distanciadora
d’écartement. en su sitio.
3.5 Install rotor. 3.5 Monter la roue à aubes. 3.5 Montar el rotor.
3.6 Position V-belt pulley. 3.6 Poser la poulie à gorge. 3.6 Colocar la polea acanalada.
3.39.84 © 2001 / 0297 9959

3.7 Position washer. 3.7 Mettre en place la rondelle. 3.7 Colocar la arandela
3.8 Screw on fastening nut and tighten. 3.8 Visser l’écrou de fixation et le serrer. 3.8 Enroscar la tuerca de fijación y
apretarla.
3.9 Position blower jacket inlet. 3.9 Mettre en place l’entrée d’enveloppe 3.9 Colocar la entrada a la envolvente
de ventilateur. de turbina.
3.10 Tighten fastening bolts. 3.10 Serrer les vis de fixation. 3.10 Apretar los tornillos de fijación.
© 2001 / 0297 9959 3.39.85

3.7 Scheibe auflegen.

2
33992 ©
3.8 Befestigungsmutter aufschrauben und fest-

drehen.
2
6
33993 ©
3.9 Gebläsemantel-Einlauf aufsetzen.

2
3
33994 ©
3.10 Befestigungsschrauben festdrehen.
2
6
33995 ©
3.39.85 © 2001 / 0297 9959

3.11 Spaltmaß zwischen Laufrad und Gebläse-

6 mantel-Einlauf messen.
min. = 0,2 mm
max. = 0,8 mm
33996 ©
3.12 Zur Korrektur entsprechende Distanz-scheibe

1 verwenden.
2 Hinweis: Es stehen Distanzscheiben von 5,0 - 7,0

mm zur Verfügung.
33997 ©
© 2001 / 0297 9959 3.39.86

3.11 Gauge clearance between rotor and 3.11 Mesurer le jeu entre roue à aubes et 3.11 Medir la holgura radial entre
blower jacket inlet. entrée d’enveloppe de ventilateur. rotor y entrada a la envolvente
de la turbina.
min. = 0.2 mm mini = 0,2 mm mín. = 0,2 mm

max. = 0.8 mm maxi = 0,8 mm máx. = 0,8 mm
3.12 Use relevant spacer for correction. 3.12 Pour corriger le jeu, utiliser une 3.12 Para corregir utilizar la arandela
bague d’écartement correspondante. distanciadora correspondiente.
Note: Spacers with 5.0 - 7.0 mm Nota: Il existe des bagues d’écartement Nota: Están disponibles arandelas
thickness are available. de 5,0 à 7,0 mm. distanciadoras entre 5,0 y 7,0 mm.
3.39.86 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

1. Remove clamping plate. 1. Démonter l’éclisse de serrage. 1. Desmontar la corredera.
2. Replace damaged idler pulley. 2. Remplacer le galet tendeur 2. Sustituir la polea tensora defectuosa
défectueux. por otra nueva.
3. Fit clamping plate, Tighten bolt. 3. Remonter l’éclisse de serrage. Serrer 3. Montar la corredera. Apretar el tornillo
la vis.
3 Tightening specification: 21 Nm Prescription de serrage: 21 Nm Prescripción de apriete: 21 Nm
© 2001 / 0297 9959 3.39.89

1. Spannlasche abbauen.
1
33999 ©
2. Schadhafte Spannrolle austauschen.

9
0
34400 ©
3. Spannlasche anbauen. Schraube festdrehen.
2
6 3
34001 ©
3.39.89 © 2001 / 0297 9959

© 2001 / 0297 9959

© 2001 / 0297 9959

Torx tool kit ___________________ 8189 Jeux d’outils Torx _______________ 8189 Juego de herramientas Torx ______ 8189
1. Remove V-belt pulley from drive hub. 1. Démonter la poulie à gorge du moyeu 1. Desmontar la polea acanalada del
d’entraînement. cubo de accionamiento.
2. Remove the locking ring. 2. Extraire le circlip. 2. Quitar el anillo de retención.
3. Press out the grooved ball bearing 3. Chasser le roulement à billes rainuré 3. Desmontar a presión el cojinete rígido
and the shaft. et l’arbre. de bolas y el eje.
© 2001 / 0297 9959 3.39.93

Torx-Werkzeugsatz ____________________ 8189
1. Keilriemenscheibe von Antriebsnabe abbauen.

1
34005 ©
2. Sicherungsring herausnehmen.
1
3
34006 ©
3. Rillenkugellager und Welle herausdrücken.

1
34007 ©
3.39.93 © 2001 / 0297 9959

4. Rillenkugellager abziehen.
1 Hinweis: Die Rillenkugellager sind grundsätzlich
5 zu erneuern.
34008 ©
5. Inneres Rillenkugellager über den Außenring bis

2 Anlage eindrücken.
34009 ©
6. Welle bis Anlage in Rillenkugellager eindrücken.

2 Hinweis: Innenring des Rillenkugellagers abstützen.
3
5
34010 ©
7. Äußeres Rillenkugellager über Außen- und

2 Innenring bis Anlage eindrücken.
34011 ©
© 2001 / 0297 9959 3.39.94

4. Pull off the grooved ball bearing 4. Extraire le roulement à billes rainuré. 4. Extraer los cojinetes rígidos de bolas.
Note: Basically, the grooved ball bearings Nota: Les roulements à billes doivent Nota: Hay que renovar siempre los
are to be renewed. toujours être remplacés. cojinetes rígidos de bolas.
5. Press in inner grooved ball bearing via 5. Enfoncer le roulement à billes interne 5. Presionando sobre el anillo exterior
outer race as far as it will go. par-dessus la bague extérieure introducir el cojinete rígido de bolas
jusqu’en application. interior hasta el tope.
6. Push the shaft to unit into the grooved 6. Enfoncer l’arbre dans le roulement à 6. Introducir a presión el eje hasta
ball bearings. billes jusqu’en application. que haga tope en el cojinete rígido
de bolas.
3
Note: Support the inner ring of the Nota: Etayer la bague intérieure du Nota: Apoyar el anillo interior del cojinete
grooved ball bearing roulement à billes. rígido de bolas.
7. Press in outer grooved ball bearing via 7. Enfoncer le roulement à billes 7. Presionando sobre los anillos exterior
outer race as far as it will go. extérieur par-dessus la bague e interior introducir el cojinete rígido
extérieure et intérieure jusqu’en de bolas exterior hasta el tope.
application.
3.39.94 © 2001 / 0297 9959

8. Insert circlip in drive hub. 8. Insérer le circlip dans le moyeu 8. Montar el anillo de retención en el
d’entraînement. cubo de accionamiento.
9. Fit V-belt pulley. Tighten bolts. 9. Monter la poulie à gorge. Serrer les 9. Montar la polea acanalada. Apretar
vis. los tornillos.
10. With mounted fan: 10. Pour le montage du ventilateur 10. Para montaje del ventilador:
Tightening regulations of the screws: Prescription de serrage des vis: Prescripción de apriete para tornillos:
3 Screw 8.8 22 Nm Vis 8.8 22 Nm tornillos 8.8 22 Nm
Screw 10.9 30 Nm Vis 10.9 30 Nm tornillos 10.9 30 Nm
© 2001 / 0297 9959 3.39.95

8. Sicherungsring in die Antriebsnabe einsetzen.

2
34012 ©

drehen.
2
7
34013 ©
10. Bei Lüfteranbau.
Anziehvorschrift der Schrauben:

2
3
Schrauben 8.8
Schrauben 10.9
22 Nm
30 Nm 7
34014 ©
3.39.95 © 2001 / 0297 9959

1
2
5
2
3
© 2001 / 0297 9959

Despiece y ensamblado conjunto de moteur
2011
© 2001 / 0297 9959

Sommaire Démontage et montage, moteur complet
Deutsch
4. Demontage und Montage, Motor komplett
Benennung Seite
Motor zerlegen ______________________________________ 4.00.01 - 4.00.16
Motor zusammenbauen:
Thermostat ______________________________________ 4.00.17
Öldruckventil ______________________________________ 4.00.18 - 4.00.19
Öldruckgeber/ -schalter ______________________________________ 4.00.19 - 4.00.20
Stößel / Nockenwelle ______________________________________ 4.00.20 - 4.00.21
Kurbelwellenlagerung ______________________________________ 4.00.21 - 4.00.24
Hinterer Deckel ______________________________________ 4.00.24
Kolbenklassen bestimmen ______________________________________ 4.00.25
Kolben mit Pleuel ______________________________________ 4.00.25 - 4.00.26
Vorderer Deckel ______________________________________ 4.00.27
Kurbelwellenzahnriemenrad ______________________________________ 4.00.27 - 4.00.30
Nockenwellenzahnriemenrad ______________________________________ 4.00.30 - 4.00.31
Schmierölpumpe ______________________________________ 4.00.31
Zahnriemeneinstellung ______________________________________ 4.00.31 - 4.00.34
Steuerzeiten-Kontrolle ______________________________________ 4.00.35 - 4.00.37
Zylinderkopf ______________________________________ 4.00.38 - 4.00.39
Ventiltrieb ______________________________________ 4.00.40 - 4.00.41
Entlüftungsventil ______________________________________ 4.00.41
Luftansaugrohr / Abgassammelrohr ______________________________________ 4.00.41 - 4.00.42
Abgasturbolader ______________________________________ 4.00.42 - 4.00.43
Einspritzpumpe ______________________________________ 4.00.44 - 4.00.48
Öleinfüllung ______________________________________ 4.00.48
Einspritzventile ______________________________________ 4.00.49
Kühlgebläse / Kabelbaum ______________________________________ 4.00.50
Kraftstoffleitungen / Einspritzleitungen ______________________________________ 4.00.51 - 4.00.52
Kraftstoffförderpumpe / Kraftstofffilter ______________________________________ 4.00.52 - 4.00.54
Ölfilter ______________________________________ 4.00.54
Luftführung / Ölkühler ______________________________________ 4.00.55 - 4.00.56
Anschlußgehäuse / Konsole ______________________________________ 4.00.56 - 4.00.57
Schwungrad ______________________________________ 4.00.57
Hydraulikpumpenkonsole / Schutzhauben ____________________________________ 4.00.58 - 4.00.61
Hydraulikpumpe ______________________________________ 4.00.61 - 4.00.63
Keilriemenscheibe / Spannrolle / Keilriemen __________________________________ 4.00.63 - 4.00.64
Ölansaugrohr / Ölwanne ______________________________________ 4.00.65 - 4.00.67
Ölmessstab ______________________________________ 4.00.67
Starter ______________________________________ 4.00.67 - 4.00.68
Ölrücklaufrohr (bei BF-Motoren) ______________________________________ 4.00.68 4
Austausch der Wellendichtringe am kompletten Motor __________________________ 4.00.69 - 4.00.74
Verschiedene Lüfterantriebanbauten ______________________________________ 4.00.75 - 4.00.76
© 2001 / 0297 9959

Démontage et montage, moteur complet Sommaire
English
4. Disassembly and reassembly of complete engine
Description Page
Dismantling engine ______________________________________ 4.00.01 - 4.00.16
Reassembling engine:
Thermostat ______________________________________ 4.00.17
Oil pressure valve ______________________________________ 4.00.18 - 4.00.19
Oil pressure transmitter /-switch ______________________________________ 4.00.19 - 4.00.20
Tappets / camshaft ______________________________________ 4.00.20 - 4.00.21
Crankshaft bearings ______________________________________ 4.00.21 - 4.00.24
Rear cover ______________________________________ 4.00.24
Determine the piston classes ______________________________________ 4.00.25
Piston with connecting rod ______________________________________ 4.00.25 - 4.00.26
Front cover ______________________________________ 4.00.27
Crankshaft toothed belt gear ______________________________________ 4.00.27 - 4.00.30
Camshaft toothed belt gear ______________________________________ 4.00.30 - 4.00.31
Lube oil pump ______________________________________ 4.00.31
Toothed belt adjustment ______________________________________ 4.00.31 - 4.00.34
Valve timing check ______________________________________ 4.00.35 - 4.00.37
Cylinder head ______________________________________ 4.00.38 - 4.00.39
Valve gear ______________________________________ 4.00.40 - 4.00.41
Vent valve ______________________________________ 4.00.41
Air intake manifold / exhaust manifold ______________________________________ 4.00.41 - 4.00.42
Exhaust-driven turbosupercharger ______________________________________ 4.00.42 - 4.00.43
Injection pump ______________________________________ 4.00.44 - 4.00.48
Oil filling ______________________________________ 4.00.48
Injectors ______________________________________ 4.00.49
Cooling fan / cable trunk ______________________________________ 4.00.50
Fuel line / injection lines ______________________________________ 4.00.51 - 4.00.52
Fuel feed pump / fuel filter ______________________________________ 4.00.52 - 4.00.54
Oil filter ______________________________________ 4.00.54
Air ducting / oil cooler ______________________________________ 4.00.55 - 4.00.56
Connection housing /console ______________________________________ 4.00.56 - 4.00.57
Flywheel ______________________________________ 4.00.57
Hydraulic pump bracket / Protective covers ___________________________________ 4.00.58 - 4.00.61
Hydraulikpumpe ______________________________________ 4.00.61 - 4.00.63
V-belt pulley / idler pulley / V-belt ______________________________________ 4.00.63 - 4.00.64
Oil suction pipe / oil trough ______________________________________ 4.00.65 - 4.00.67
Oil measuring stick ______________________________________ 4.00.67
Starter ______________________________________ 4.00.67 - 4.00.68
4 Oil return pipe (with BF motors) ______________________________________ 4.00.68
Exchanging the shaft seal rings at the entire engine ____________________________ 4.00.69 - 4.00.74
Different fan drive attachments ______________________________________ 4.00.75 - 4.00.76
© 2001 / 0297 9959

Sommaire Démontage et montage, moteur complet
Français
4. Démontage et montage, moteur complet
Désignation Page
Démontage du moteur ______________________________________ 4.00.01 - 4.00.16
Montage du moteur
Thermostat ______________________________________ 4.00.17
Soupape de régulation de pression d’huile ___________________________________ 4.00.18 - 4.00.19
Transmetteur de pression d’huile / manocontact d’huile _________________________ 4.00.19 - 4.00.20
Poussoir / arbre à cames ______________________________________ 4.00.20 - 4.00.21
Paliers de vilebrequin ______________________________________ 4.00.21 - 4.00.24
Couvercle arrière ______________________________________ 4.00.24
Détermination des classes de piston ______________________________________ 4.00.25
Piston avec bielle ______________________________________ 4.00.25 - 4.00.26
Couvercle avant ______________________________________ 4.00.27
Pignon de courroie dentée de vilebrequin ____________________________________ 4.00.27 - 4.00.30
Pignon de courroie dentée d’arbre à cames __________________________________ 4.00.30 - 4.00.31
Pompe à huile ______________________________________ 4.00.31
Réglage de la courroie dentée ______________________________________ 4.00.31 - 4.00.34
Contrôle du calage de la distribution ______________________________________ 4.00.35 - 4.00.37
Culasse ______________________________________ 4.00.38 - 4.00.39
Commande des soupapes ______________________________________ 4.00.40 - 4.00.41
Soupape de purge d’air ______________________________________ 4.00.41
Collecteur d’admission d’air / collecteur d’échappement _________________________ 4.00.41 - 4.00.42
Turbocompresseur à gaz d’échappement ____________________________________ 4.00.42 - 4.00.43
Pompe d’injection ______________________________________ 4.00.44 - 4.00.48
Remplissage d’huile ______________________________________ 4.00.48
Injecteurs ______________________________________ 4.00.49
Ventilateur / faisceau de câbles ______________________________________ 4.00.50
Tuyauteries à combustible / tuyauteries d’injection _____________________________ 4.00.51 - 4.00.52
Pompe d’alimentation en combustible / filtre à combustible _______________________ 4.00.52 - 4.00.54
Filtre à huile ______________________________________ 4.00.54
Guidage d’air / refroidisseur d’huile ______________________________________ 4.00.55 - 4.00.56
Carter d’adaptation / console ______________________________________ 4.00.56 - 4.00.57
Volant ______________________________________ 4.00.57
Console de pompe hydraulique / capots de protection __________________________ 4.00.58 - 4.00.61
Pompe hydraulique ______________________________________ 4.00.61 - 4.00.63
Poulie à gorges / galet tendeur / courroie trapézoïdale __________________________ 4.00.63 - 4.00.64
Tuyau d’aspiration d’huile / carter d’huile _____________________________________ 4.00.65 - 4.00.67
Jauge d’huile ______________________________________ 4.00.67
Démarreur ______________________________________ 4.00.67 - 4.00.68
Conduite de retour d’huile (sur moteurs BF) __________________________________ 4.00.68 4
Remplacement des joints d’arbre sur moteur complet ___________________________ 4.00.69 - 4.00.74
Différentes variantes de montage d’entraînement de ventilateur ___________________ 4.00.75 - 4.00.76
© 2001 / 0297 9959

Démontage et montage, moteur complet Sommaire
Español
4. Despiece y ensamblado conjunto de motor
Denominación Página
Despiece del motor ______________________________________ 4.00.01 - 4.00.16
Ensamblado del motor:
Termostato ______________________________________ 4.00.17
Válvula reguladora de presión de aceite _____________________________________ 4.00.18 - 4.00.19
Transmisor / interruptor de presión de aceite __________________________________ 4.00.19 - 4.00.20
Empujadores / árbol de levas ______________________________________ 4.00.20 - 4.00.21
Apoyos del cigüeñal ______________________________________ 4.00.21 - 4.00.24
Tapa trasera ______________________________________ 4.00.24
Determinación de la categoría de pistón _____________________________________ 4.00.25
Pistón con biela ______________________________________ 4.00.25 - 4.00.26
Tapa delantera ______________________________________ 4.00.27
Rueda de correa dentada del cigüeñal ______________________________________ 4.00.27 - 4.00.30
Rueda de correa dentada del árbol de levas __________________________________ 4.00.30 - 4.00.31
Bomba de aceite lubricante ______________________________________ 4.00.31
Ajuste de la correa dentada ______________________________________ 4.00.31 - 4.00.34
Control de las cotas de reglaje ______________________________________ 4.00.35 - 4.00.37
Culata ______________________________________ 4.00.38 - 4.00.39
Mando de las válvulas ______________________________________ 4.00.40 - 4.00.41
Válvula de ventilación ______________________________________ 4.00.41
Colector de admisión / colector de escape ___________________________________ 4.00.41 - 4.00.42
Turbocompresor ______________________________________ 4.00.42 - 4.00.43
Bomba de inyección ______________________________________ 4.00.44 - 4.00.48
Boca de llenado de aceite ______________________________________ 4.00.48
Inyectores ______________________________________ 4.00.49
Turbina de refrigeración / mazo de cables ____________________________________ 4.00.50
Tuberías de combustible / tuberías de inyección _______________________________ 4.00.51 - 4.00.52
Bomba de alimentación de combustible / filtro de combustible ____________________ 4.00.52 - 4.00.54
Filtro de aceite ______________________________________ 4.00.54
Conducción de aire / refrigerador de aceite ___________________________________ 4.00.55 - 4.00.56
Cárter de adaptación / consola ______________________________________ 4.00.56 - 4.00.57
Volante ______________________________________ 4.00.57
Consola de bomba hidráulica / cubiertas protectoras ___________________________ 4.00.58 - 4.00.61
Bomba hidráulica ______________________________________ 4.00.61 - 4.00.63
Polea acanalada / polea tensora / correa trapezoidal ___________________________ 4.00.63 - 4.00.64
Tubo de aspiración de aceite / cárter de aceite ________________________________ 4.00.65 - 4.00.67
Varilla medidora de nivel de aceite ______________________________________ 4.00.67
Arrancador ______________________________________ 4.00.67 - 4.00.68
4 Tubo de retorno de aceite (en los motores BF) ________________________________ 4.00.68
Sustitución de los retenes en el motor completo _______________________________ 4.00.69 - 4.00.74
Diversos montajes del accionamiento del ventilador 4.00.75 - 4.00.76
© 2001 / 0297 9959

© 2001 / 0297 9959

Dismantling engine Démontage du moteur Despiece del motor
Torx tools _____________________ 8189 Outils Torx ____________________ 8189 Herramental Torx _______________ 8189
Clip pliers ____________________ 8011 Pince pour colliers ______________ 8011 Alicates para abrazaderas _______ 8011
Claw key _____________________ 8018 Clé à griffes ___________________ 8018 Llave de garra _________________ 8018
Socket a/flats 32 _______________ 8036 Douille _______________________ 8036 Llave de vaso _________________ 8036
Multipower tool ________________ 8049 Multiplicateur de couple _________ 8049 Multiplicador de fuerza __________ 8049
Hose clip pliers ________________ 9088 Pince à tuyaux souples __________ 9088 Alicates para
Spring clamp pliers _____________ 9090 Pince à ressort ________________ 9090 abrazaderas de manguera _______ 9088
Special bit ______________ 9120 or 9122 Embout de tournevis Alicates para
spécial ________________ 9120 ou 9122 abrazaderas de resorte __________ 9090
Bit especial _____________ 9120 ó 9122
Special tools required: Outillage spécial: Herramientas especiales
Engine assembly stand __________ 6067 Chevalet de montage moteur _____ 6067 Caballete de montaje del motor ___ 6067
Angled clamping plate ________ 6067/115 Support de fixation __________ 6067/115 Soporte de fijación __________ 6067/115
Adjusting pin ________________ 100 700 Pige d’ajustage ______________ 100 700 Perno de ajuste ______________ 100 700
Puller ______________________ 143 100 Extracteur __________________ 143 100 Dispositivo de separación ______ 143 100
Dolly ______________________ 143 420 Dispositif de blocage __________ 143 420 Dispositivo de retención _______ 143 420
Intermediate disc _____________ 143 430 Entretoise __________________ 143 430 Arandela intermedia __________ 143 430
Dolly for camshaft gear ________ 144 130 Dispositif de blocage de Dispositivo de retención para
Special wrench for pignon d’arbre à cames _______ 144 130 rueda del árbol de levas _______ 144 130
filter cartridges ______________ 170 050 Clé spéciale pour Llave especial para
Special wrench for cartouches de filtre ___________ 170 050 catuchos filtrantes ____________ 170 050
oil pressure sensor ___________ 170 110 Clé spéciale pour transmetteur Llave especial para
de pression d’huile ___________ 170 110 transmisor de presión de aceite _ 170 110
The repair procedure outlined in this Dans les travaux de réparation décrits, il Los trabajos de reparación descritos no
chapter refers to the standard specifi- n’est pas tenu compte des différentes consideran la diversidad de los volúmenes
cation, i.e. components for customizing spécifications du matériel, c’est-à-dire que de suministro de los clientes, es decir,
the engine are not shown. les composants qui diffèrent par rapport à no se muestran los elementos adosados
la version standard ne sont pas montrés. que difieran la versión estándar.
1. With BF motors. 1. Sur Moteurs BF. 1. En los motores BF.

Disassemble the oil-return pipe. Démonter la conduite de retour d’huile Desmontar la tubería de retorno
4 de aceite.
© 2001 / 0297 9959 4.00.01

Motor zerlegen
Torx-Werkzeuge ______________________ 8189

Klemmenzange _______________________ 8011
Stecknuss ___________________________ 8036
Kraftvervielfältiger _____________________ 8049
Schlauchklemmenzange ________________ 9088
Federklemmenzange __________________ 9090
Spezial-Bit ___________________ 9120 oder 9122
Spezialwerkzeuge:
Motor-Montagebock ___________________ 6067

Aufspannhalter ____________________ 6067/115
Einstellbolzen ______________________ 100 700
Abdrückvorrichtung __________________ 143 100
Gegenhalter _______________________ 143 420
Zwischenscheibe ___________________ 143 430
Gegenhalter für Nockenwellenrad ______ 144 130
Spezialschlüssel für Filterpatronen ______ 170 050
Spezialschlüssel für Öldruckgeber ______ 170 110
Bei dem gezeigten Reparaturablauf sind unter-

schiedliche Kundenumfänge nicht berücksichtigt,
d.h. von der Standard-Ausführung abweichende
Anbauteile werden nicht gezeigt.
1. Bei BF-Motoren.
Ölrücklaufleitung abbauen. 3 4
34015 ©
4.00.01 © 2001 / 0297 9959

2. Ladestromleitung und Starter abbauen.

3
34016 ©
3. Aufspannhalter anbauen. Schrauben festdre-

4 hen.
34017 ©
4. Motor an schwenkbaren Montagebock mon-

4 tieren.
7 Hinweis: Richtige Aufhängevorrichtung verwen-

den.
34018 ©
5. Öl bzw. Restöl ablassen, auffangen und vor-
4 ü schriftsmäßig entsorgen.
34019 ©
© 2001 / 0297 9959 4.00.02

2. Remove charging current line and 2. Démonter le câble de courant de 2. Desmontar el cable de corriente de
starter. charge et le démarreur. carga y el arrancador.
3. Mount angled clamping plate. Tighten 3. Monter le support de fixation. Serrer 3. Montar el soporte de fijación. Apretar
bolts. les vis. los tornillos.
4. Mount engine to swivelling assembly 4. Monter le moteur sur le chevalet de 4. Montar el motor en el caballete de
stand. montage pivotant. montaje orientable.
Note: Use proper suspension device. Nota: Utiliser le dispositif de suspension Nota: Utilizar el dispositivo de suspensión
correct. correcto.
5. Drain, catch remaining oil and 5. Vidanger l’huile ou l’huile résiduelle, 5. Evacuar el aceite o aceite
dispose of in accordance with anti- la recueillir soigneusement et l’éliminer restante, recogerlo y eliminarlo
pollution regulations. conformément aux réglementations en forma reglamentaria. 4
antipollution.
4.00.02 © 2001 / 0297 9959

6. Remove hydraulic pump. 6. Démonter la pompe hydraulique. 6. Desmontar la bomba hidráulica.
7. Remove V-belt idler pulley. Take off 7. Démonter le galet teneur de courroie. 7. Desmontar la polea tensora. Quitar la
V-belt. Enlever la courroie. correa trapezoidal.
8. Remove air cowling. 8. Démonter manche d’air. 8. Desmontar la manga guía de aire.
9. Remove stay plate. 9. Démonter la tôle verticale. 9. Desmontar la chapa vertical.
© 2001 / 0297 9959 4.00.03

6. Hydraulikpumpe abbauen.
3
34020 ©
7. Keilriemenspannrolle abbauen. Keilriemen ab-

nehmen.
3
34021 ©
8. Luftführungshaube abbauen.
3
34022 ©
9. Standblech abbauen.
3 4
34023 ©
4.00.03 © 2001 / 0297 9959

10. Ölkühler abbauen. Falls Steckstücke im Kur-

3 belgehäuse verbleiben, Steckstücke heraus-
nehmen.

34024 ©
11. Bei B/FM - Motoren

3 Ölkühleranschlüsse abbauen.
34025 ©
12. Luftführung abbauen.

3
34026 ©
13. Steckverbindung abbauen. Leitungen kenn-
4 3 zeichnen und mit Profilgummi abnehmen
34027 ©
© 2001 / 0297 9959 4.00.04

10. Remove oil cooler. If plug-in ele- 10. Démonter le refroidisseur d’huile. Si 10. Desmontar el refrigerador de aceite.
ments have remained in the crank- des cales sont restées dans le carter Retirar las piezas de enchufe que
case, take them out. moteur, les enlever. hayan quedado en el bloque motor.
Note: Catch any escaping oil and Nota: Recueillir l’huile qui s’écoule Nota: Recoger el aceite que salga y
dispose of in accordance with et l’éliminer conformément aux eliminarlo en forma reglamentaria.
anti-pollution regulations. réglementations antipollution.
11. With B/FM engines: 11. Sur moteurs B/FM 11. En los motores B/FM
Remove oil cooler connections. Démonter les raccords de Desmontar los racores para el
refroidisseur d’huile. refrigerador de aceite.
12. Remove air ducting. 12. Démonter la manche d’air. 12. Desmontar la conducción de aire.
13. Disassemble the plug-in connection. 13. Défaire les connexions. Repérer les 13. Separar la unión de enchufe. Marcar
Mark the lines and remove with the câbles et les enlever avec le los cables y retirarlos con la goma
profile rubber caoutchouc profilé. perfilada. 4
4.00.04 © 2001 / 0297 9959

14. Disassemble the cooling fan with 14. Démonter le ventilateur avec 14. Desmontar la turbina de refrigeración
the generator, induction system and alternateur, câble de courant de con el alternador, cable de corriente
cable trunk. charge et faisceau de câbles. de carga y mazo de cables.
15. With BF motors. 15. Sur moteurs BF 15. En los motores BF

Disassemble the vent pipe, reducer, Démonter le tuyau de purge d’air, Desmontar el tubo de ventilación,
lube oil line and the exhaust-driven le raccord de réduction, la conduite la pieza reductora, tubería de aceite
turbosupercharger. d’huile et le turbocompresseur. lubricante y el turbocompresor.
Note: Use the hose clip pliers 9088 and Nota: Utiliser la pince à tuyau souple Nota: Utilizar los alicantes 9088 para
the spring clamp pliers 9090. 9088 et la pince à ressort 9090. abrazaderas de manguera y 9090
para mangueras de resorte.
16. Remove exhaust manifold and 16. Démonter le collecteur 16. Desmontar el colector de escape
air intake manifold. d’échappement et le collecteur y el colector de admisión.
d’admission d’air.
17. Disassemble the cross-over pipe, the 17. Démonter la rampe de décharge, 17. Desmontar la tubería de rebose, la
fuel line and the injection lines. la tuyauterie à combustible et les tubería de combustible y las tuberías
4 tuyauteries d’injection. de inyección.
Note: Use the claw key 8018 for the
injection lines. Nota: Pour les tuyauteries d’injection, Nota: Utilizar la llave de garra 8018
Close off the connections of the utiliser la clé à griffes 8018. para las tuberías de inyección.
injection pumps and the injection Boucher les orifices de pompes Cerrar los orificios en las bombas
valves. d’injection et d’injecteurs. de inyección e inyectores.
© 2001 / 0297 9959 4.00.05

14. Kühlgebläse mit Generator, Ladeleitung und

Kabelbaum abbauen.
3
34028 ©
15. Bei BF-Motoren

Entlüftungsrohr, Reduzierstück, Schmieröl-
leitung und Abgasturbolader abbauen.
3
Hinweis: Schlauchklemmenzange 9088 und Feder- 5
klemmenzange 9090 verwenden.
34029 ©
16. Abgassammelrohr und Luftansaugrohr ab-

bauen. 3
34030 ©
17. Überströmleitung, Kraftstoffleitung und Ein-

spritzleitungen abbauen. 3 4
Hinweis: Für Einspritzleitungen Klauenschlüssel
8018 verwenden. 5
Anschlüsse von Einspritzpumpen und
Einspritzventile verschließen.
34031 ©
4.00.05 © 2001 / 0297 9959

18. Spannpratzen entfernen. Einspritzventile aus-

3 bauen.
34032 ©
19. Kraftstoffleitungen abbauen. Ölmessstab ent-

3 fernen.
34033 ©
20. Ölfilter abbauen.

7 schriftsmäßig entsorgen.
34034 ©
21. Kraftstofffilter abbauen.
4 3 Hinweis: Auslaufender Kraftstoff auffangen und
7 vorschriftsmäßig entsorgen.
34035 ©
© 2001 / 0297 9959 4.00.06

18. Remove clamping pads. 18. Enlever les pattes de serrage, 18. Quitar las garras de sujeción.
Remove injectors. Démonter les injecteurs. Desmontar los inyectores.
19. Remove fuel lines. Remove oil 19. Démonter les tuyauteries à 19. Desmontar las tuberías de
dipstick. combustible. Enlever la jauge d’huile. combustible. Sacar la varilla
medidora del nivel de aceite.
20. Remove oil filter. 20. Démonter le filtre à huile. 20. Desmontar el filtro de aceite.
Note: Catch any escaping oil and dispose Nota: Recueillir l’huile qui s’écoule et Nota: Recoger el aceite que salga y
of in accordance with anti-pollution l’éliminer conformément aux eliminarlo en forma reglamentaria.
regulations. réglementations antipollution.
21. Remove fuel filter. 21. Démonter le filtre à combustible. 21. Desmontar el filtro de combustible.
Note: Catch any escaping fuel and Nota: Recueillir l’huile qui s’écoule et Nota: Recoger el combustible que 4
dispose of in accordance with l’éliminer conformément aux salga y eliminarlo en forma
anti-pollution regulations. réglementations antipollution. reglamentaria.
4.00.06 © 2001 / 0297 9959

22. Remove fuel filter bracket and fuel 22. Démonter la console de filtre 22. Desmontar la consola de filtro
feed pump. à combustible et la pompe de combustible y la bomba de
d’alimentation en combustible. alimentación de combustible.
23. Remove the temperature transmitter, 23. Dévisser le transmetteur de 23. Desenroscar el transmisor de
the oil pressure switch and the température, le manocontact d’huile temperatura, interruptor de presión
locking screw or the oil pressure et le bouchon fileté ou transmetteur de aceite y tapón roscado o el
transmitter. de pression d’huile. transmisor de presión de aceite.
Note: Use a special key for the oil Nota: Utiliser la clé spéciale pour le Nota: Utilizar la llave especial para
pressure transmitter. transmetteur de pression d’huile. transmisores de presión de aceite.
24. Disassemble the vent valve. 24. Démonter la soupape de purge d’air. 24. Desmontar la válvula de ventilación.
(With BF4L/M motors) (Sur Moteurs BF4L/M) (En los motores BF4L/M)
25. Remove cylinder head cover. 25. Démonter le cache-culbuteurs. 25. Desmontar la tapa de culata.
© 2001 / 0297 9959 4.00.07

22. Kraftstofffilterkonsole und Kraftstoffförder-

pumpe abbauen.
3
34036 ©
23. Temperaturgeber, Öldruckschalter und Ver-

schlussschraube oder Öldruckgeber heraus-
schrauben.
3
Hinweis: Für Öldruckgeber Spezialschlüssel ver- 5
wenden.
34037 ©
24. Entlüftungsventil abbauen.

(Bei BF4L/M-Motoren) 3
34038 ©
25. Zylinderkopfhaube abbauen.

3 4
5
34039 ©
4.00.07 © 2001 / 0297 9959

26. Kipphebelböcke abbauen.

3
34040 ©
27. Stoßstangen herausnehmen.

3
34041 ©
28. Zylinderkopf abbauen.

3
34042 ©
29. Einspritzpumpen ausbauen.
4 3
34043 ©
© 2001 / 0297 9959 4.00.08

26. Remove rocker arm brackets. 26. Démonter les supports de culbuteurs. 26. Desmontar los soportes de
balancines.
27. Take out pushrods. 27. Extraire les tiges de culbuteurs. 27. Retirar las varillas de empuje.
28. Remove cylinder head. 28. Démonter la culasse. 28. Desmontar la culata.
29. Remove injection pumps. 29. Démonter les pompes d’injection. 29. Desmontar las bombas de inyección.
4.00.08 © 2001 / 0297 9959

30. Take out roller tappets for injection 30. Extraire les poussoirs à galet pour 30. Retirar el empujador o taqué de
pump (using outer circlip pliers). la pompe d’injection (à l’aide d’une rodillo para la bomba de inyección
pince à circlip extérieur). (sirviéndose de unos alicates para
anillos de retención exteriores).
31. Remove thermostat. 31. Démonter le thermostat. 31. Desmontar el termostato.
32. Remove oil pressure control valve. 32. Démonter la soupape de régulation 32. Desmontar la válvula reguladora de
de pression d’huile. presión de aceite.
33. Unscrew screw plugs. If heater 33. Dévisser les bouchons filetés. 33. Desenroscar los tapones roscados.
connection is provided, take out En présence d’un branchement de Si existe una conexión para
4 oil pressure control valves. chauffage, extraire les soupapes calefacción, retirar las válvulas
de régulation de pression d’huile. reguladoras de presión de aceite.
© 2001 / 0297 9959 4.00.09

30. Rollenstößel für Einspritzpumpe (mit Hilfe einer

Außensicherungszange) herausnehmen.
3
34044 ©
31. Thermostat ausbauen.

3
34045 ©
32. Öldruckventil ausbauen.

3
34046 ©
33. Verschlussschrauben herausschrauben.

Falls Heizungsanschluß vorhanden, Öldruck-
ventile herausnehmen.
3 4
34047 ©
4.00.09 © 2001 / 0297 9959

34. Riemenscheibe abbauen.

3
34048 ©
35. Schleuderscheibe abnehmen. Schutzhaube ab-

3 bauen.
34049 ©
36. Zwischenstück abnehmen.

3
34050 ©
37. Spannrolle abbauen. Zahnriemen abnehmen.
4 3
34051 ©
© 2001 / 0297 9959 4.00.10

34. Remove belt pulley. 34. Démonter la poulie à gorge. 34. Desmontar la polea acanalada.
35. Remove the centrifuge disk. 35. Enlever le disque protecteur. 35. Desmontar el disco centrífugo. Quitar
Disassemble the protective cover. Démonter le capot de protection. la cubierta protectora.
36 Take off intermediate disc. 36. Enlever la pièce intermédiaire. 36. Quitar la pieza intermedia.
37. Remove idler pulley. Remove 37. Démonter le galet tendeur. Enlever 37. Desmontar la polea tensora. Quitar
toothed belt. la courroie dentée. la correa dentada.
4
4.00.10 © 2001 / 0297 9959

38. Disassemble the protective cover. 38. Démonter les capots de protection. 38. Desmontar las cubiertas protectoras.
Note: For the locking screw (Pos. X), Nota: Pour la vis de blocage (Rep. x), Nota: Utilizar el bit especial 9120 ó 9122
use the special bit 9120 or 9122. utiliser l’embout de tournevis para el tornillo de seguridad (x).
spécial 9120 ou 9122
39. Remove the hydraulic pump console. 39. Démonter la console de pompe 39. Desmontar la consola de bomba
hydraulique. hidráulica.
40. Remove idler pulley. Remove 40. Démonter le galet tendeur. Enlever 40. Desmontar la polea tensora. Quitar
toothedbelt. la courroie dentée. la correa dentada.
41. Remove camshaft gear. 41. Démonter le pignon d’arbre à cames. 41. Desmontar la rueda dentada del
árbol de levas.
4
© 2001 / 0297 9959 4.00.11

38. Schutzhauben abbauen.
Hinweis: Für die Sicherungsschraube (Pos. x) Spe-

3
zial-Bit 9120 oder 9122 verwenden.
5
34052 ©
39. Hydraulikpumpenkonsole abbauen.

3
34053 ©
40. Spannrolle abbauen. Zahnriemen abnehmen.

3
34054 ©
41. Nockenwellenzahnrad abbauen.

3 4
7
34055 ©
4.00.11 © 2001 / 0297 9959


3
7
34056 ©
43. Gegenhalter für Kurbelwellenzahnrad anbauen

4 und Schrauben festdrehen.
34057 ©
44. Kraftvervielfälltiger mit Stecknuss (8036) an-

4 setzen.
34058 ©
45. Kraftvervielfälltiger gegenhalten und Zentral-
4 3 schraube lösen. Zahnräder abnehmen.
34059 ©
© 2001 / 0297 9959 4.00.12

42. Position intermediate disc. 42. Mettre en place l’entretoise. 42. Colocar la arandela intermedia.
43. Fit dolly for crankshaft gear and 43. Monter le dispositif de blocage 43. Montar el dispositivo de retención
tighten bolts. pour pignon de vilebrequin et serrer de la rueda dentada del cigüeñal y
les vis. apretar los tornillos.
44. Position multipower tool with socket 44. Mettre en place le multiplicateur de 44. Aplicar el multiplicador de fuerza
(8036). couple avec douille (8036). con llave de vaso (8036).
45. Retain multipower tool and loosen 45. Maintenir le multiplicateur de couple 45. Retener el multiplicador de fuerza
central bolt. Take off gears. et desserrer la vis centrale. Enlever y soltar el tornillo central. Quitar las
les pignons. ruedas dentadas. 4
4.00.12 © 2001 / 0297 9959

46. Remove lube oil pump. 46. Démonter la pompe à huile. 46. Desmontar la bomba de aceite
lubricante.
Note: Catch any escaping oil and dispose Nota: Recueillir l’huile qui s’écoule et Nota: Recoger el aceite que salga y
of in accordance with anti-pollution l’éliminer conformément aux eliminarlo en forma reglamentaria.
regulations. réglementations antipollution.
47. Turn engine by 180°. Take off oil pan. 47. Tourner le moteur de 180°. Démonter 47. Girar el motor 180° y desmontar el
le carter d’huile. cárter de aceite.
48. Remove oil suction pipe. 48. Démonter le tube d’aspiration d’huile. 48. Desmontar el tubo de aspiración de
aceite.
49. Remove piston complete with 49. Démonter le piston avec la bielle. 49. Desmontar el conjunto de biela-
connecting rod. pistón.
4
Note: Loosen conrod nut with Nota: Défaire les boulons de bielle avec Nota: Soltar las tuercas de biela con
dodecagonal socket wrench. une clé à douille à 12 pans. ayuda de una llave de vaso
bihexagonal.
© 2001 / 0297 9959 4.00.13

46. Schmierölpumpe abbauen.

3
5
34060 ©
47. Motor um 180° drehen. Ölwanne abbauen.

3
34061 ©
48. Ölansaugrohr abbauen.

3
34062 ©
49. Kolben mit Pleuel ausbauen.
Hinweis: Pleuelmuttern mit 12- kant Steckschlüssel

3 4
lösen.
5
34063 ©
4.00.13 © 2001 / 0297 9959

50. Vorderen Deckel abbauen.

3
5
34064 ©
51. Schwungradschrauben lösen und heraus-

3 drehen.
34065 ©
52. Schwungrad abnehmen.

4 Falls Schwungrad festsitzt, Schwungradab-
zieher anbauen. Schwungrad abdrücken.
7 Hinweis: Selbstgefertigten Führungsdorn eindre-
3 hen.
34066 ©
53. Anschlussgehäuse abbauen.
4 3
34067 ©
© 2001 / 0297 9959 4.00.14

50. Take off front cover. 50. Démonter le couvercle avant. 50. Desmontar la tapa delantera.
51. Loosen the flywheel screws and 51. Desserrer les vis du volant et les 51. Aflojar y desenroscar los tornillos
remove them. sortir. del volante.
52. Remove the flywheel. 52. Enlever le volant. 52. Quitar el volante.
If flywheel is stuck, fit flywheel puller. Si le volant est bloqué, monter En caso de firme asiento del volante,
Press off flywheel. un extracteur de volant. Chasser montar el extractor para éste y
le volant. separar el volante.
Note: Use self-made pilot bar. Nota: Insérer un mandrin de guidage Nota: Enroscar el mandril de guía de
spécialement confectionné à confección propia.
cet effet.
53. Disassemble the connection housing. 53. Démonter le carter d’adaptation. 53. Desmontar el cárter de adaptación.
4.00.14 © 2001 / 0297 9959

54. In the case of motors without a 54. Sur moteurs sans carter d’adaptation. 54. En motores sin cárter de adaptación.
connection housing, remove the Démonter la console du démarreur. Desmontar la consola para el
console for the starter. arrancador.
55. Take off rear cover. 55. Démonter le couvercle arrière. 55. Desmontar la tapa trasera.
56. Screw in adjusting pin for camshaft. 56. Visser la pige d’ajustage dans 56. Enroscar el perno de ajuste para el
Take off thrust washer for camshaft. l’arbre à cames. Démonter la bague árbol de levas. Desmontar la
de butée d’arbre à cames. arandela de tope del árbol de levas.
57. Remove camshaft. 57. Démonter l’arbre à cames. 57. Sacar el árbol de levas.
© 2001 / 0297 9959 4.00.15

54. Bei Motoren ohne Anschlussgehäuse.

Konsole für Starter abbauen.
3
34068 ©
55. Hinteren Deckel abbauen.

3
34069 ©

Anlaufscheibe für Nockenwelle abbauen. 4
7
3
34070 ©
57. Nockenwelle ausbauen.

3 4
34071 ©
4.00.15 © 2001 / 0297 9959

58. Hauptlagerdeckel ausbauen. Kurbelwelle

3 herausnehmen.
34072 ©
59. Stößel herausnehmen.

3
34073 ©
© 2001 / 0297 9959 4.00.16

58. Remove main bearing caps. 58. Démonter le chapeau de palier 58. Desmontar las tapas de los cojinetes
Lift out crankshaft. principal. Extraire le vilebrequin. de apoyo. Retirar el cigüeñal.
59. Take out tappets. 59. Enlever les poussoirs. 59. Retirar los empujadores o taqués.
4.00.16 © 2001 / 0297 9959

Reassembling engine Montage du moteur Ensamblado del motor
Torx tools _____________________ 8189 Outils Torx ____________________ 8189 Herramental Torx _______________ 8189
Hose clip pliers ________________ 9088 Pince à tuyaux souples __________ 9088 Alicates para
Cobra clamp pliers _____________ 8011 Pince pour colliers ______________ 8011 abrazaderas de manguera _______ 9088
V-belt tension gauge ____________ 8115 Appareil de mesure de Alicates para abrazaderas _______ 8011
Multipower tool ________________ 8049 tension des courroies ___________ 8115 Verificador de tensión
Socket a/flats 32 _______________ 8036 Clé à griffes ___________________ 8018 de correas trapezoidales _________ 8115
Spring clamp pliers _____________ 9090 Multiplicateur de couple _________ 8049 Llave de garra _________________ 8018
Special bit ______________ 9120 or 9122 Douille _______________________ 8036 Multiplicador de fuerza __________ 8049
Pince à ressort ________________ 9090 Llave de vaso _________________ 8036
Embout de tournevis spécial 9120 ou 9122 Alicates para
abrazaderas de resorte __________ 9090
Bit especial _____________ 9120 ó 9122
Adjusting pin ________________ 100 700 Pige d’ajustage ______________ 100 700 Perno de ajuste ______________ 100 700
Adjusting pin ________________ 100 710 Pige d’ajustage ______________ 100 710 Pernnde ajuste ______________ 100 710
Gauge _____________________ 100 750 Appareil de mesure ___________ 100 750 Dispositivo de medición _______ 100 750
Locking wire Fil d’arrêt pour Alambre de fijación para
for injection pump ____________ 100 880 pompe d’injection ____________ 100 880 bomba de inyección __________ 100 880
Test template for I.P. gasket ____ 103 020 Gabarit de contrôle Plantilla de prueba
Piston ring compressor ________ 130 630 de joint pompe d’injection ______ 103 020 para juntas de bomba inyectora _ 103 020
Dolly ______________________ 143 420 Collier à segments ___________ 130 630 Compresor de aros de pistón ___ 130 630
Intermediate disc _____________ 143 430 Dispositif de blocage __________ 143 420 Dispositivo de retención _______ 143 420
Dolly for camshaft gear ________ 144 130 Entretoise __________________ 143 430 Arandela intermedia __________ 143 430
Special wrench Dispositif de blocage Dispositivo de retención para
for oil pressure sensor ________ 170 110 de pignon d’arbre à cames _____ 144 130 rueda del árbol de levas _______ 144 130
Clé spéciale pour transmetteur Llave especial para
de pression d’huile ___________ 170 110 transmisor de presión de aceite _ 170 110
Thermostat Thermostat Termostato
1. Fit thermostat with compression 1. Monter le thermostat avec le ressort. 1. Instalar el termostato con el resorte de
spring. presión.
2. Tighten screw plug with new O-seal. 2. Serrer à bloc le bouchon fileté avec un 2. Apretar el tapón roscado provisto de
joint torique neuf. un anillo tórico nuevo.
4
Note: For fitting the O-seal cover thread Nota: Pour le montage du joint torique, Nota: Para el montaje del anillo tórico
with assembly sleeve. recouvrir le filetage d’une douille cubrir la rosca con el casquillo
de montage. de montaje.
© 2001 / 0297 9959 4.00.17

Motor zusammenbauen
Torx-Werkzeuge ______________________ 8189

Schlauchklemmenzange ________________ 9088
Klemmenzange _______________________ 8011
Keilriemenspannungs-Messgerät _________ 8115
Kraftvervielfältiger _____________________ 8049
Stecknuss ___________________________ 8036
Federklemmenzange __________________ 9090
Spezial-Bit ___________________ 9120 oder 9122
Spezialwerkzeuge:
Einstellbolzen ______________________ 100 700

Einstellbolzen ______________________ 100 710
Messgerät _________________________ 100 750
Arretierungsdraht für Einspritzpumpe ____ 100 880
Prüfschablone für E.P.-Dichtung ________ 103 020
Kolbenringspannband ________________ 130 630
Gegenhalter _______________________ 143 420
Zwischenscheibe ___________________ 143 430
Gegenhalter für Nockenwellenrad ______ 144 130
Spezialschlüssel für Öldruckgeber ______ 170 110
Thermostat
1. Thermostat mit Druckfeder einbauen.

4
34074 ©
2. Verschlussschraube mit neuem Runddichtring

festdrehen. 4 4
ß
Hinweis: Für Montage des Runddichtringes Ge-
winde mit Montagehülse abdecken. 6
5
34075 ©
4.00.17 © 2001 / 0297 9959

Öldruckventil (ohne Heizungsanschluss)

4 3. Öldruckventil mit Druckfeder (3 bar, grüne
Farbmarkierung) einbauen.
34076 ©
4. Verschlussschrauben mit neuen Cu-Dichtringen

4 festdrehen.
34077 ©
Öldruckventil mit Heizungsanschluss

4 (falls vorhanden)
8 5. Öldruckventile mit Druckfedern einbauen.
Hinweis: Auf Einbaurichtung der Ventile und unter-

5 schiedliche Druckfedern achten.
Pos. 5 Druckfeder 1,0 bar, gelbe Farbmarkierung

Pos. 6 Druckfeder 1,7 bar, rote Farbmarkierung
Pos. 7 Druckfeder 0,3 bar, blaue Farbmarkierung
34078 ©
6. Verschlussschrauben mit neuen Cu-Dichtungen
4 4 festdrehen.
34079 ©
© 2001 / 0297 9959 4.00.18

Oil pressure control valve (without Soupape de régulation de pression Válvula reguladora de presión de
heater connection) d’huile (sans raccord de chauffage) aceite (sin conexión de calefacción)
3. Fit oil pressure control valve with 3. Monter la soupape de régulation 3. Instalar la válvula reguladora de
compression spring (3 bar, green de pression d’huile avec le ressort presión de aceite con el resorte de
colour marking). (3 bars, repère de couleur verte). presión (3 bar, marca de color verde).
4. Tighten screw plugs with new 4. Serrer les bouchons filetés avec un 4. Apretar los tapones roscados
Cu seals. joint de cuivre neuf. provistos de juntas anulares de
cobre nuevas
Oil pressure control valve with heater Soupape de régulation de pression Válvula reguladora de presión de
connection d’huile avec raccord de chauffage aceite con conexión de calefacción
(if any) (pour autant que prévu) (si existe)
5. Fit oil pressure control valves with 5. Monter les soupapes de régulation de 5. Instalar las válvulas reguladoras
compression springs. pression d’huile avec les ressorts. de presión de aceite con resortes
de presión.
Note: Watch direction of installation of Nota: Respecter le sens de montage Nota: Observar la dirección de montaje
valves and different compression des soupapes et tenir compte des de las válvulas y los diferentes
springs. différences de ressorts. resortes de presión.
Item 5, compr. spring 1.0 bar, Rep. 5 Ressort 1,0 bar, de couleur jaune (5) Resorte de presión 1,0 bar, marca de
yellow colour marking Rep. 6 Ressort 1,7 bar, de couleur rouge color amarillo
Item 6, compr. spring 1.7 bar, Rep. 7 Ressort 0,3 bar, de couleur bleue (6) Resorte de presión 1,7 bar, marca de
red colour marking color rojo
Item 7, compr. spring 0.3 bar, (7) Resorte de presión 0,3 bar, marca de
blue colour marking color azul
6. Tighten screw plugs with new Cu 6. Serrer les bouchons filetés avec un 5. Apretar los tapones roscados
seals. joint de cuivre neuf. provistos de juntas anulares de
cobre nuevas. 4
4.00.18 © 2001 / 0297 9959

7. Fit O-seals in such a manner to 7. Monter les joints neufs sur les 7. Colocar juntas anulares nuevas
swadged nipples that the spot facing raccords de réduction de sorte sobre los racores de enlace de
points towards the crankcase. que le lamage soit dirigé vers forma tal que el rebaje indique
Tighten swadged nipple, item 1, le carter moteur. hacia el bloque motor.
and swadged nipple with valve seat, Serrer le raccord de réduction Rep. 1 Apretar el racor de enlace (1) y
item 2. et le raccord de réduction avec siège el racor de enlace con asiento de
de soupape Rep. 2. válvula (2).
Tightening
specification: 111 Nm ± 11 Nm Prescription de serrage: 111 ± 11 Nm Prescripción de apriete: 111 ± 11 Nm
8. Tighten screw plugs with new 8. Serrer les bouchon filetés avec des 8. Apretar los tapones roscados
Cu seals. joints de cuivre neufs. provistos de juntas anulares de
cobre nuevas.
Oil pressure transmitter /-switch Transmetteur de pression d’huile, Transmisor de presión de aceite,
manocontact d’huile interruptor de presión de aceite
9. Tighten screw plug with new Cu seal. 9. Serrer le bouchon fileté avec un joint 9. Apretar el tapón roscado provisto de
de cuivre neuf. una junta anular de cobre nueva.
Tightening specification 50 Nm Prescription de serrage: 50 Nm Prescripción de apriete: 50 Nm
Note: If the oil pressure transmitter Nota: En cas de montage d’un trans- Nota: Si el transmisor de presión de
is installed: firmly tighten the metteur de pression d’huile: aceite está montado:
oil pressure transmitter with Serrer le transmetteur de pression Apretar el transmisor de presión de
a special key. d’huile avec la clé spéciale. aceite mediante la llave especial.
Tightening regulations 20 ± 2 Nm Prescription de serrage: 20 ± 2 Nm Prescripción de apriete: 20 ± 2 Nm
9.1 Tighten oil pressure switch. 9.1 Serrer à bloc le manocontact d’huile. 9.1 Apretar el interruptor de presión de
aceite.
4
Tightening specification 13 ± 1.5 Nm Prescription de serrage: 13 ± 1,5 Nm Prescripción de apriete: 13 ± 1,5 Nm
© 2001 / 0297 9959 4.00.19

7. Neue Dichtringe so auf die Übergangsnippel

montieren, dass die Ansenkung zum Kurbel-
gehäuse weist.
4
Übergangsnippel Pos. 1 und Übergangsnippel
mit Ventilsitz Pos. 2 festdrehen. ß
6
34080 ©
8. Verschlussschrauben mit neuen Cu-Dichtringen

festdrehen.
4
ß
6
34081 ©
Öldruckgeber, Öldruckschalter
9. Verschlussschraube mit neuem Cu-Dichtring

4
festdrehen.
ß
6
Hinweis: Falls Öldruckgeber angebaut:
Öldruckgeber mit Spezialschlüssel fest-
drehen.
5
34082 ©
9.1 Öldruckschalter festdrehen.
4 4
6
34083 ©
4.00.19 © 2001 / 0297 9959

10. Öltemperaturgeber anbauen und festdrehen.

4 Anziehvorschrift: 25 ± 2,5 Nm
6 Hinweis: Bei Motoren ohne Öltemperaturgeber.

Verschlussschraube mit neuem Cu-Dicht-
5 ring festdrehen.
34084 ©
Stößel/Nockenwelle
4 11. Stößel einsetzen.
34085 ©
12. Nockenwelle einsetzen.

4
8
z
34086 ©
13. Anlaufscheibe montieren.
4 4 Hinweis: Schmiernut der Anlaufscheibe muss zum
8 Kurbelgehäuse weisen.
34087 ©
© 2001 / 0297 9959 4.00.20

10. Fit and tighten oil temperature 10. Monter le transmetteur de 10 Montar y apretar el transmisor de
regulator. température d’huile et le serrer. temperatura de aceite.
Note: In the case of motors without Nota: Sur moteurs sans transmetteur Nota: En motores sin transmisor de
oil temperature regulator. de température d’huile. temperatura de aceite.
Firmly tighten the locking screw Serrer le bouchon fileté avec un Apretar el tapón roscado
with a new Cu seal ring. joint de cuivre neuf. provisto de una junta anular
Tightening specification: 28 Nm Prescription de serrage: 28 Nm de cobre nueva.
Prescripción de apriete; 28 Nm
Tappets/camshaft Poussoir / arbre à cames Empujadores / árbol de levas
11. Insert tappets. 11. Mettre en place le poussoir. 11. Introducir los empujadores o taqués.
12. Introduce camshaft. 12. Mettre en place l’arbre à cames. 12. Introducir el árbol de levas.
13. Fit thrust washer. 13. Monter la bague de butée. 13. Montar la arandela de tope.
Note: Lubricating groove of thrust washer Nota: La rainure de graissage de la Nota: La ranura de lubricación de la 4
must face crankcase. bague de butée doit être dirigée arandela de tope debe indicar
vers le carter moteur. hacia el bloque motor.
4.00.20 © 2001 / 0297 9959

14. Screw in adjusting pin for camshaft. 14. Visser la pige d’ajustage d’arbre à 14. Enroscar el perno de ajuste para el
Tighten bolt. cames. Serrer la vis. árbol de levas. Apretar el tornillo.
Note: Unscrew adjusting pin again. Nota: Dévisser et extraire la pige Nota: Desenroscar el perno de ajuste.
d’ajustage.
Crankshaft bearings Paliers de vilebrequin Apoyos del cigüeñal
15. Insert bearing shells. 15. Mettre en place les coussinets. 15. Colocar los semicojinetes.
16. Insert bearing shells in main bearing 16. Mettre en place les coussinets dans 16. Colocar los semicojinetes en las
cap. le chapeau de palier principal. tapas de los cojinetes de apoyo.
17. Fit thrust washers to thrust bearing 17. Appliquer les bagues de butée sur les 17. Aplicar las medias arandelas de tope
cap and gauge width. chapeaux de palier d’ajustage et contra la tapa del cojinete de empuje
4 mesurer la largeur. y medir el ancho.
© 2001 / 0297 9959 4.00.21


Schraube festdrehen.
4
7
Hinweis: Einstellbolzen wieder herausschrauben.
6
5
34088 ©
Kurbelwellenlagerung
15. Lagerschalen einsetzen.

4
8
34089 ©
16. Lagerschalen in Hauptlagerdeckel einsetzen.

4
8
34090 ©
17. Anlaufscheiben am Paßlagerdeckel anlegen

und Breite messen. 4 4
8
6
34091 ©
4.00.21 © 2001 / 0297 9959

18. Innenmessgerät auf 35 mm einstellen.

6
34092 ©
19. Passlagerzapfenbreite der Kurbelwelle mes-

6 sen.
Axialspiel ermitteln.
Zapfenbreite normal: 35 + 0,04 mm

Übermaß je Stufe 0,40 mm
Grenzmaß für Übermaßstufe: 35,44 mm
34093 ©
Axialspiel:
Normal: 0,1 - 0,273 mm

Hinweis: Bei Bedarf neue Anlaufscheiben zuordnen.
20. Passhülsen einsetzen.
4 4
34094 ©
© 2001 / 0297 9959 4.00.22

18. Set internal dial gauge to 35 mm. 18. Régler l’appareil de mesure 18. Ajustar el micrómetro de interiores a
d’intérieur à 35 mm. 35 mm.
19. Gauge thrust bearing journal width of 19. Mesurer la largeur de tourillon de 19. Medir el ancho del muñón para el
crankshaft. palier d’ajustage du vilebrequin. cojinete de empuje del cigüeñal.
Determine axial play. Déterminer le jeu axial. Determinar el juego axial.
Journal Largeur normale Ancho normal

width standard: 35 + 0.04 mm de tourillon: 35 + 0,04 mm del muñón: 35 + 0,04 mm
Cote surdimensionnée
Each oversize: 0.40 mm par degré: 0.40 mm Cada sobremedida: 0.40 mm
Limit Cote surdimensionnée
for oversize: 35.44 mm limite: 35,44 mm Límite de sobremedida: 35,44 mm
Axial play: Jeu axial: Juego axial:
standard: 0.1 - 0.273 mm Normal: 0,1 - 0,273 mm Normal: 0,1 - 0,273 mm

wear limit: 0.4 mm Limite d’usure: 0,4 mm Límite de desgaste: 0,4 mm
Note: Use new thrust washers if Nota: Le cas échéant déterminer des Nota: De ser necesario, asignar nuevas
necessary. bagues de butée neuves. arandelas de tope.
20. Insert locating sleeves. 20. Mettre en place les douilles 20. Meter los casquillos de ajuste.
d’ajustage.
4
4.00.22 © 2001 / 0297 9959

21. Introduce crankshaft. 21. Mettre en place le vilebrequin. 21. Colocar el cigüeñal.
22. Stick half thrust washers with lug 22. Avec un peu de graisse, coller les 22. Pegar con un poco de grasa las
to thrust bearing cap using some bagues de butée avec le nez de medias arandelas de tope con talón
grease. guidage sur le chapeau de palier de guía contra la tapa del cojinete
d’ajustage. de empuje.
Note: Running layer of thrust washers Nota: Le côté revêtu des bagues de Nota: Las arandelas de tope deben
must face crankweb. butée doit être dirigé vers la joue indicar con su cara de roce hacia
de vilebrequin. la cara lateral de la manivela del
cigüeñal.
23. Mount thrust bearing cap. 23. Monter le chapeau de palier 23. Montar las tapas de cojinete de
d’ajustage. empuje.
Note: Bearing cap No. 1 at flywheel Nota: Chapeau de palier n° 1 du côté Nota: La tapa de cojinete No. 1 se
end. Chamfer must point towards volant. Le chanfrein doit se trouver encuentra en el lado del volante.
flywheel end. du côté opposé au côté volant. El bisel debe indicar hacia el
lado opuesto al del volante.
24. Mount bearing caps, paying attention 24. Monter les chapeaux de 24. Montar las tapas de cojinete
to the numbering. paliers principaux en respectant de apoyo teniendo en cuenta la
4 la numérotation. numeración.
© 2001 / 0297 9959 4.00.23

21. Kurbelwelle einsetzen.

4
8
z
34095 ©
22. Anlaufscheiben mit Führungsnase am Pass-

lagerdeckel mit etwas Fett ankleben. 4
Hinweis: Anlaufscheiben müssen mit der Lauf-
schichtseite zum Wangenspiegel der u
Kurbelwelle weisen.
8
5
34096 ©
23. Passlagerdeckel aufbauen.
Hinweis: Lagerdeckel Nr. 1 ist schwungrad-

4
seitig. Anschrägung muß entgegen
der Schwungradseite weisen. 8
5
9
34097 ©
24. Hauptlagerdeckel entsprechend der Nume-

rierung montieren. 4 4
9
34098 ©
4.00.23 © 2001 / 0297 9959

25. Hauptlagerschrauben festdrehen.

4 Anziehvorschrift:
6 Vorspannwert
1. Nachspannwinkel
50 Nm
60°
34099 ©
Hinterer Deckel
4 26. Hinteren Deckel mit DEUTZ DW 67 bestrei-
w chen.
34100 ©
27. Deckel komplett mit ungeölten Wellendicht-

4 ring anbauen. Deckel zur Ölwannendicht-
fläche ausrichten. Schrauben in der Anzieh-
9 reihenfolge 1 bis 8 festdrehen.
6
34101 ©
© 2001 / 0297 9959 4.00.24

25. Tighten main bearing bolts. 25. Serrer les vis des paliers 25. Apretar los tornillos de los cojinetes
principaux. de apoyo.
Tightening specification: Prescription de serrage Prescripción de apriete:

1st tightening angle 60° 1er angle de serrage définitif 60° 1er reapriete 60°
2nd tightening angle 45° 2ème angle de serrage définitif 45° 2° reapriete 45°
Rear cover Couvercle arrière Tapa trasera
26. Apply sealing compound 26. Enduire le couvercle arrière de 26. Aplicar pasta DEUTZ DW 67 a la
DEUTZ DW 67 to rear cover. DEUTZ DW 67. tapa trasera.
27. Remove the cover completely 27. Monter le couvercle complet avec 27. Montar la tapa completa con el retén
with unlubricated shaft seal ring. joint d’arbre non huilé. Diriger le sin aceitar. Alinear la tapa con
Align cover relative to oil pan sealing couvercle vers le plan de joint de respecto a la superficie de contacto
surface. Firmly tighten the srews carter d’huile. Serrer les vis dans del cárter de aceite. Apretar los
in the tightening sequence 1 to 8. l’ordre de serrage 1 à 8. tornillos en el orden de 1 a 8.
Tightening specification: 21 Nm Prescription de serrage: 21 Nm. Prescripción de apriete: 21 Nm
4.00.24 © 2001 / 0297 9959

Determine the piston class. Détermination de la classe des pistons. Determinación de la categoría de
(Only FL and FM engines) (Seulement moteurs FL et FM) pistón. (Sólo en motores FL y FM)
28. Gauge on every cylinder distance 28. Mesurer la distance entre bord 28. Medir en cada cilindro la distancia
between top edge of crankpin in TDC supérieur de maneton au PMH entre el canto superior del muñón
and cylinder head sealing surface. et plan de joint de culasse pour de biela en PMS y la superficie de
chaque cylindre. asiento de la junta de culata.
FL/M 2011 Piston FL/M 2011 Classe FL/M 2011 categoría

specified dimension x class cote de consigne x de piston medida teórica x de pistón
x1 = 196.390 - 196.49 A x1 = 196,390 - 196,49 A x1 = 196,390 - 196,49 A
x2 = 196.491 - 196.69 B x2 = 196,491 - 196,69 B x2 = 196,491 - 196,69 B
28.1 Compare actual dimension with the 28.1 Comparer la valeur effective avec 28.1 Comparar la medida real con las
specified dimensions in the table. les valeurs de consigne du tableau. medidas teóricas indicadas en la
Select piston class per cylinder. See Choisir la classe de piston par tabla. Elegir la categoría de pistón
Chapter. 3. cylindre. Voir chapitre 3. para cada cilindro. Ver cap. 3.
Note: In the case of crankshaft under- Nota: Pour les cotes sous-dimension- Nota: En caso de inframedidas del
sizes, 0.125 mm must be added nées, ajouter respectivement cigüeñal es necesario adicionar a
to the dimension indicated in the 0,125 mm aux valeurs du tableau. las medidas indicadas en la tabla
table. cada vez 0,125 mm.
Piston with a connecting rod Piston avec bielle Pistón con biela
29. Insert bearing shells into connecting 29. Monter les coussinets dans la bielle. 29. Colocar los semicojinetes en la biela.
rod.
30. Piston ring gaps must be staggered. 30. Tiercer les coupes des segments 30. Disponer los aros de pistón con
de pistons sus cortes desplazados entre sí.
4
© 2001 / 0297 9959 4.00.25

Kolbenklasse bestimmen.
(Nur FL- und FM - Motoren)
6
28. Abstand Hubzapfenoberkante OT bis Zylin-
derkopfdichtfläche an jedem Zylinder messen.
FL/M 2011 Sollmaß x Kolbenklasse

x1 = 196,390 - 196,49 A
x2 = 196,491 - 196,69 B
34102 ©
28.1 Istmaß mit den in der Tabelle aufgeführten

Sollmaßen vergleichen. Kolbenklasse je Zy-
linder auswählen. Siehe Kap. 3.
9
Hinweis: Bei Untermaßstufen der Kurbelwelle 5
sind zu den in der Tabelle aufgeführ-
ten Maßen jeweils 0,125 mm hinzuzu-
zählen.
34103 ©
Kolben mit Pleuelstange
29. Pleuellagerschalen in Pleuelstange einbauen.

4
8
34104 ©
30. Kolbenringstöße zueinander versetzt anord-

nen. 9 4
34105 ©
4.00.25 © 2001 / 0297 9959

31. Kolben komplett mit Pleuel in das Zylinder-

4 kurbelgehäuse einschieben.
z Hinweis: Schwungradsymbol auf dem Kolben

muß zum Schwungrad weisen.
7
9
34106 ©
32. Pleuelstange gegen den Hubzapfen drücken.

4 Dazugehörigen Pleuellagerdeckel montieren.
z Hinweis: Pleuelschrauben können bei Nachweis-

barkeit max. 5 mal wiederverwendet
werden.
5
9
34107 ©
33. Pleuelmuttern mit 12 kant-Steckschlüssel

4 festdrehen.
6 Anziehvorschrift:
Vorspannwert 30 Nm
34108 ©
34. Pleuelstangen kontrollieren, ob sie sich auf
4 9 dem Hubzapfen leicht verschieben lassen.
34109 ©
© 2001 / 0297 9959 4.00.26

31. Introduce piston complete with 31. Insérer le piston couplet avec bielle 31. Introducir el pistón completo con la
connecting rod into crankcase with dans le bloc-cylindres. biela en el bloque motor.
integrated cylinders.
Note: Flywheel symbol must point Nota: Le symbole de volant sur le piston Nota: El símbolo del volante puesto
towards flywheel. doit être orienté vers le volant. sobre el pistón debe indicar hacia
el volante.
32. Press connecting rod against 32. Presser la bielle contre le maneton. 32. Presionar la biela contra su
crankpin. Fit pertinent big Monter le chapeau de bielle muñequilla. Montar la tapa
end bearing cap. correspondant. correspondiente.
Note: Conrod bolts may be used Nota: Les boulons de bielles peuvent Nota: Los pernos de biela pueden
max. 5 x if evidence can be être réutilisés au maximum 5 fois, ser utilizados hasta 5 veces,
provided concerning their use. ce qui devra être consigné chaque siempre y cuando su uso quede
fois. comprobable.
33. Tighten conrod nuts with 33. Serrer les écrous de bielle avec une 33. Apretar las tuercas de biela mediante
dodecagonal socket wrench. clé à douille 12 pans. la llave bihexagonal.
Tightening specification: Prescription de serrage Prescripción de apriete:

Intitial tightening torque 30 Nm Couple de préserrage 30 Nm Apriete inicial 30 Nm
1st tightening angle 60° 1er angle de serrage définitif 60° 1er reapriete 60°
2nd tightening angle 60° 2ème angle de serrage définitif 60° 2° reapriete 60°
34. Check that connecting rods can be 34. Contrôler si les bielles se laissent 34. Controlar si las bielas pueden
easily moved back and forth on the déplacer légèrement sur le maneton. moverse fácilmente sobre su
crankpin. muñequilla. 4
4.00.26 © 2001 / 0297 9959

Front cover Couvercle avant Tapa delantera
35. Apply sealing compound 35. Enduire le plan de joint du 35. Aplicar sellante DEUTZ DW 67
DEUTZ DW 67 to front couvercle avant de produit a la superficie de contacto de
cover sealing surface. d’étanchéité Deutz DW 67. la tapa delantera.
Note: Camshaft/centrifugal governor Nota: Le plan de joint entre l’arbre à Nota: La unión entre árbol de levas y
connection must be clean and cames et le régulateur centrifuge regulador centrífugo debe estar
free of oil. doit être propre et exempte d’huile. limpia y exenta de aceite.
36. Mount completely the front cover 36. Monter le couvercle avant complet 36. Montar la tapa delantera completa
with unlubricated shaft seal rings avec joints d’arbre non huilés et con los retenes sin aceitar y alinearla
and align it to the oil trough sealing l’orienter vers le plan de joint du con respecto a la superficie de
surface. carter d’huile. contacto del cárter de aceite.
Note: When fitting cover pay attention Nota: Au montage, veiller au joint d’arbre Nota: Al montar prestar atención al retén
to crankshaft seal. du vilebrequin. del cigüeñal.
37. Firmly tighten the screws in the 37. Serrer les vis dans l’ordre de serrage 37. Apretar los tornillos siguiendo el
tightening sequence 1 to 11. 1 à 11. orden de 1 a 11.
Tightening specification: 21 Nm Prescription de serrage: 21 Nm. Prescripción de apriete: 21 Nm
Crankshaft toothed belt gear Pignon de courroie dentée de Rueda de correa dentada del cigüeñal
vilebrequin
4
38. Slide on crankshaft toothed belt gear. 38. Emmancher le pignon de courroie 38. Colocar la rueda de correa dentada
dentée du vilebrequin. del cigüeñal.
Note: All connecting surfaces must be Nota: Tous les plans de joint doivent Nota: Todas las superficies de unión
clean and free of oil. être propres et exempts d’huile. deben estar limpias y exentas
de aceite.
© 2001 / 0297 9959 4.00.27

Vorderer Deckel
35. Dichtfläche des vorderen Deckels mit Dicht-

4
w
Hinweis: Verbindung zwischen Nockenwelle und
Fliehkraftregler muß sauber und ölfrei 5
sein.
34110 ©
36. Vorderen Deckel komplett mit ungeölten

Wellendichtringen montieren und zur Öl-
wannendichtfläche ausrichten.
4
Hinweis: Bei Montage auf Kurbelwellendichtring 5
achten.
34111 ©
37. Schrauben in der Anziehreihenfolge 1 bis 11

festdrehen. 4
6
34112 ©
Kurbelwellenzahnriemenrad
38. Kurbelwellenzahnriemenrad aufschieben.

4 4
Hinweis: Alle Verbindungsflächen müssen sauber 5
und ölfrei sein.
34113 ©
4.00.27 © 2001 / 0297 9959

39. Falls vorhanden, Kurbelwellenzahnriemen-

4 rad für Hydraulikpumpe in die Zentrierung
einsetzen.
8 Hinweis: Ohne Hydraulikpumpenanbau wird an

Stelle des Zahnrades ein Zwischenstück
5 verwendet.
34114 ©
40. Zentralschraube leicht andrehen.

4
34115 ©
41. Verschlussschraube herausschrauben. Ein-

3 stellbolzen für Kurbelwelle bis Anlage ein-
schrauben. Kurbelwelle im Uhrzeigersinn
4 gegen den Anschlag drehen.
Hinweis: Kolben am vorderen Deckel ist in OT.

7
5
34116 ©
42. Zentralschraube vorspannen.
6
34117 ©
© 2001 / 0297 9959 4.00.28

39. Insert crankshaft toothed belt gear for 39. Le cas échéant, insérer le pignon de 39. Si existe, introducir en el centraje la
hydraulic pump, if any, in centering. courroie dentée de vilebrequin pour rueda de correa dentada del cigüeñal
pompe hydraulique dans le centrage. para la bomba hidráulica.
Note: If no hydraulic pump is mounted, a Nota: A défaut de montage de pompe Nota: Si no está montada una bomba
spacer is used instead of the gear. hydraulique, utiliser une pièce hidráulica, se utiliza en lugar de
intermédiaire à la place du pignon. la rueda dentada una pieza
intermedia.
40. Start central bolt. 40. Serrer légèrement la vis centrale. 40. Apretar ligeramente el tornillo central.
41. Undo screw plug. Screw in adjusting 41. Dévisser le bouchon fileté. Visser la 41. Desenroscar el tapón roscado.
pin for crankshaft as far as it will go. pige d’ajustage pour le vilebrequin Enroscar el perno de ajuste para
Turn crankshaft in clockwise direction jusqu’en butée. Virer le vilebrequin el cigüeñal hasta el tope. Girar
against stop. dans le sens horloger contre la butée. el cigüeñal en el sentido de las
agujas del reloj contra el tope.
Note: Piston at front cover is in TDC. Nota: Le piston côté couvercle avant est Nota: El pistón cerca de la tapa delantera
au PMH. está en PMS.
42. Initially tighten central bolt. 42. Préserrer la vis centrale. 42. Apretar el tornillo central con un
par inicial.
4
4.00.28 © 2001 / 0297 9959

43. Position intermediate disc. 43. Monter l’entretoise. 43. Colocar la arandela intermedia.
Note: Remove adjusting pin for Nota: Enlever la pige d’ajustage du Nota: Quitar el perno de ajuste para el
crankshaft. vilebrequin. cigüeñal.
44. Fit dolly and tighten. 44. Monter le dispositif de blocage et le 44. Montar el dispositivo de retención y
serrer. apretar.
45. Insert multipower tool with socket in 45. Insérer le multiplicateur de couple 45. Insertar el multiplicador de fuerza
dolly. avec douille dans le dispositif de con la llave de vaso en el dispositivo
blocage. de retención.
46. Retain multipower tool and tighten 46. Bloquer le multiplicateur de couple et 46. Retener el multiplicador de fuerza y
central bolt. serrer la vis centrale. apretar el tornillo central.
4
Tightening specification: 210° Prescription de serrage: 210° Prescripción de apriete: 210°
© 2001 / 0297 9959 4.00.29

Hinweis: Einstellbolzen für Kurbelwelle entfernen.

4
7
8
34118 ©
44. Gegenhalter anbauen und festdrehen.

4
7
34119 ©
45. Kraftvervielfältiger mit Stecknuss in den Ge-

genhalter einsetzen. 4
34120 ©
46. Kraftvervielfältiger gegenhalten und Zentral-

schraube festdrehen. 4 4
Anziehvorschrift: 210°
6
34121 ©
4.00.29 © 2001 / 0297 9959

47. Rasterknopf drücken. Kraftvervielfältiger entla-

4 sten.
Kraftvervielfältiger, Gegenhalter und Zwi-
5 schenscheibe abbauen.
Hinweis: Einstellbolzen für Kurbelwelle wieder bis

zur Anlage einschrauben.
Kurbelwelle im Uhrzeigersinn gegen den
Anschlag drehen. Kolben am vorderen
Deckel ist in O.T.
34122 ©
Nockenwellenzahnriemenrad
3 48. Verschlussschraube herausschrauben. Ein-
4 stellbolzen für Nockenwelle in das Kurbel-

gehäuse bis zur Anlage einschrauben.
7 Hinweis: Bohrung der Nockenwelle muss mit der

Bohrung im Kurbelgehäuse in Über-
5 deckung stehen.
34123 ©
49. Zahnriemenrad, Scheibe und Schraube auf-

4 setzen.
5 Hinweis: Alle Verbindungsflächen müssen sauber

und ölfrei sein.
34124 ©
50. Nockenwellenzentralschraube handfest an-
4 4 drehen.
5 Hinweis: Nockenwellenzahnrad muss noch dreh-

bar sein.
34125 ©
© 2001 / 0297 9959 4.00.30

47. Depress detent knob. Unload 47. Enfoncer le bouton cranté. Délester 47. Oprimir el botón reticulado.
multipower tool. le multiplicateur de couple. Descargar el multiplicador de fuerza.
Remove multipower tool, dolly Démonter le multiplicateur de couple, Desmontar el multiplicador de
and intermediate disc. le dispositif de blocage et l’entretoise. fuerza, el dispositivo de retención y
la arandela intermedia.
Note: Screw adjusting pin for crankshaft Nota: Visser à nouveau la pige d’ajustage Nota: Volver a enroscar el perno de ajuste
back in again as far as it will go. du vilebrequin jusqu’en butée. para el cigüeñal hasta el tope.
Turn crankshaft in clockwise Virer le vilebrequin dans le Girar el cigüeñal en el sentido de
direction against stop. Piston at sens horaire contre la butée. las agujas del reloj contra el tope.
front cover is in TDC. Le piston proche du couvercle El pistón cerca de la tapa delantera
avant est au PMH. está en PMS.
Camshaft toothed belt gear Pignon de courroie dentée d’arbre Rueda de correa dentada del árbol
à cames de levas
48. Undo screw plug. Screw camshaft 48. Dévisser le bouchon fileté. Visser la 48. Desenroscar el tapón roscado.
adjusting pin into crankcase as far pige d’ajustage d’arbre à cames dans Enroscar el perno de ajuste para el
as it will go. le carter moteur jusqu’en butée. árbol de levas en el bloque motor
hasta el tope.
Note: Bore of camshaft must overlap Nota: L’alésage de l’arbre à cames Nota: El taladro para el árbol de levas
with bore in crankcase. doit coïncider avec celui du carter debe coincidir con el taladro
moteur. existente en el bloque motor.
49. Position toothed belt gear, washer 49. Monter le pignon de courroie dentée, 49. Colocar la rueda de correa dentada,
and bolt. la rondelle et la vis. la arandela y el tornillo.
Note: All connecting surfaces must be Nota: Tous les plans de joint doivent Nota: Todas las superficies de unión
clean and free of oil. être propres et exempt d’huile. deben estar limpias y exentas
de aceite.
50. Secure camshaft central bolt 50. Préserrer la vis centrale d’arbre à 50. Apretar con la mano el tornillo
fingertight. cames. central del árbol de levas.
4
Note: Camshaft gear must still turn freely. Nota: Le pignon d’arbre à cames doit Nota: La rueda dentada del árbol de
encore se laisser tourner. levas aún debe poderse girar.
4.00.30 © 2001 / 0297 9959

Lube oil pump Pompe à huile Bomba de aceite lubricante
51. Position gasket. 51. Poser le joint. 51. Colocar la junta.
52. Mount oil pump. 52. Monter la pompe à huile. 52. Montar la bomba de aceite lubricante.
Note: Pay attention to dowel sleeves. Nota: Veiller aux douilles de serrage. Nota: Prestar atención a los casquillos
de sujeción.
Toothed belt adjustment Réglage de la courroie dentée. Ajuste de la correa dentada
4 54. Position new toothed belt. 54. Mettre en place une courroie dentée 54. Colocar una correa dentada nueva.
neuve.
Note: Hold crankshaft against stop while Nota: Durant le réglage de la courroie Nota: Al ajustar la correa dentada es
adjusting toothed belt. dentée, bloquer le vilebrequin necesario mantener aplicado el
contre la butée. cigüeñal contra el tope.
© 2001 / 0297 9959 4.00.31

Schmierölpumpe
51. Dichtung auflegen.

4
ß
34126 ©
52. Schmierölpumpe anbauen.
Hinweis: Auf Spannhülsen achten.

4
6
34127 ©
4
6
34128 ©
Zahnriemeneinstellung
54. Neuen Zahnriemen auflegen

4 4
Hinweis: Während der Zahnriemeneinstellung ist ß
die Kurbelwelle gegen den Anschlag
zu halten. 5
34129 ©
4.00.31 © 2001 / 0297 9959

55. Neue Spannrolle mit der Grundplatten-

4 Führungsgabel in den Führungsstift einhän-
gen.
ß Hinweis: Auf unterschiedliche Spannrollen achten.

Breite der Rolle für Nockenwellenantrieb
30 mm.
8 Breite der Rolle für Hydraulikpumpen-
antrieb 35 mm.
5
34130 ©
56. Exzenter-Einsatz mit Innensechskant in 6:00

4 Uhr Position bringen und Spannrolle anbauen.
Schraube mit 8 + 2 Nm vorspannen.
9
6
34131 ©
57. Zahnriemen so ausrichten, dass ein gleichmä-

4 ßiger Abstand vom Deckel von 8 bis 9 mm
vorhanden ist.
6
34132 ©
58. Arretierstift entfernen.
4
3
34133 ©
© 2001 / 0297 9959 4.00.32

55. Place the new tension roller with 55. Accrocher le galet tendeur neuf par la 55. Enganchar la polea tensora nueva
the base plate guide clevis onto the fourche de guidage de la plaque con la horquilla de guía de la placa
guide pin. d’assise dans l’ergot de guidage. base en el pasador de guía.
Note: Pay attention to the various Nota: Veiller aux différentes tailles de Nota: Tener en cuenta que hay diferentes
tension rollers. Width of the roller galet tendeur. versiones de polea tensora.
for the camshaft drive 30 mm. Largeur de galet d’entraînement El ancho de la polea para el
Width of the roller for the hydraulic d’arbre à cames: 30 mm accionamiento del árbol de levas
pump drive 35 mm. Largeur de galet d’entraînement de es de 30 mm.
pompe hydraulique: 35 mm. El ancho de la polea para el
accionamiento de la bomba
hidráulica es de 35 mm.
56. Set the eccentric cam arrangement 56. A l’aide d’une clé à six pans creux 56. Situar el elemento excéntrico con el
with the hex socket to 6:00 hour placer l’élément excentrique en hexágono interior en la posición de
position and mount on the tension position de 6.00 h et monter le galet 6 horas y montar la polea tensora.
roller. Pretension the screw with tendeur. Préserrer la vis à 8 + 2 Nm. Apretar el tornillo con el par inicial
8 + 2 Nm. de 8 + 2 Nm.
57. Align toothed belt so as to ensure 57. Aligner la courroie dentée de sorte 57. Alinear la correa dentada, de modo
an equal distance from cover qu’elle se trouve à une distance égale que tenga una distancia uniforme a
between 8 and 9 mm. du couvercle de 8 à 9 mm. la tapa de 8 a 9 mm.
58. Remove the locking pin. 58. Enlever la goupille d’arrêt. 58. Retirar el pasador de fijación.
4.00.32 © 2001 / 0297 9959

59. Rotate the eccentric cam 59. Tourner l’élément excentrique à 59. Sirviéndose de una llave Allen, girar
arrangement with the aid of an Allen l’aide d’une clé à six pans creux dans el elemento excéntrico en el sentido
key in arrow direction until the pointer le sens de la flèche jusqu’à ce que de la flecha hasta que el indicador
corresponds with the groove in the l’aiguille coïncide avec l’entaille dans coincida con la muesca existente en
base plate. Firmly tighten the screw. la plaque d’assise. Serrer la vis à bloc. la placa base. Apretar el tornillo.
60. Retain centering washer. Initially 60. Bloquer la bague de centrage, 60. Retener el disco de centraje, apretar
tighten camshaft central bolt. préserrer la vis centrale d’arbre à el tornillo central del árbol de levas
cames. con el par inicial.
61. Back-up the centering disc, firmly 61. Bloquer la bague de centrage, serrer 61. Retener el disco de centraje, apretar
tighten the camshaft central screw. à la vis centrale d’arbre à cames. el tornillo central del árbol de levas
en definitiva.
Tightening specification: Prescription de serrage: Prescripción de apriete:

Tightening angle 210° Angle de serrage définitif 210° Angulo de reapriete: 210°
62. Unscrew the adjusting pins for the 62. Dévisser les piges d’ajustage d’arbre 62. Desenroscar los pernos de ajuste
cam and crankshaft. à cames et de vilebrequin. para el árbol de levas y el cigüeñal.
4
© 2001 / 0297 9959 4.00.33

59. Exzenter-Einsatz mit Hilfe eines Inbusschlüssel

in Pfeilrichtung drehen bis Zeiger mit der Kerbe
in der Grundplatte übereinstimmt. Schraube
4
festdrehen.
s
9
6
34134 ©

zentralschraube vorspannen.
4
7
6
34135 ©

zentralschraube festdrehen. 4
Anziehvorschrift:
Nachspannwinkel 210° 7
6
34136 ©

herausdrehen. 3 4
7
34137 ©
4.00.33 © 2001 / 0297 9959

63. Nockenwellenzahnrad und gegenüberliegende

i Schraube markieren.
34138 ©
64. Kurbelwelle 2 Umdrehungen in Motordreh-

4 richtung drehen, bis Markierungen wieder in
Überdeckung stehen.
34139 ©
65. Position des Zeigers kontrollieren.

9
5
34140 ©
Hinweis: Wenn der Zeiger nicht mit der Kerbe
4 4 übereinstimmt, muss mit dem Exzenter-

Einsatz korrigiert werden.
9 Schraube lösen und wieder mit 8 + 2 Nm
vorspannen. Exzenter-Einsatz mit Hilfe
eines Inbusschlüssel in Pfeilrichtung dre-
s hen bis Zeiger mit der Kerbe in der
Grundplatte übereinstimmt. Schraube
6 mit 21 + 2 Nm festdrehen.
34141 ©
© 2001 / 0297 9959 4.00.34

63. Mark camshaft gear and opposite 63. Repérer le pignon d’arbre à cames et 63. Marcar un diente de la rueda
bolt. la vis opposée. dentada del árbol de levas y el
tornillo enfrente.
64. Make two complete crankshaft 64. Virer le vilebrequin de 2 tours dans 64. Darle al cigüeñal 2 vueltas en el
revolutions in direction of engine le sens de rotation du moteur jusqu’à sentido de giro normal del motor
rotation until marks coincide. ce que les repères coïncident à hasta que las marcas vuelvan a
nouveau. coincidir.
65. Check the position of the pointer 65. Contrôler la position de l’aiguille. 65. Controlar la posición del indicador.
Note: If the pointer does not correspond Nota: Si l’aiguille ne coïncide pas Nota: Si el indicador no coincide con
with the groove, it must be corrected avec l’entaille, il faut corriger avec la muesca, hay que corregir con
with the eccentric cam arrangement. l’élément excentrique. ayuda del elemento excéntrico. 4
Loosen the screw and pretension Défaire la vis et la préserrer de Soltar el tornillo y apretarlo de
again with 8 + 2 Nm. Rotate the nouveau à 8 + 2 Nm. Tourner nuevo con el par inicial 8 + 2 Nm.
eccentric cam arrangement with l’élément excentrique à l’aide Girar el elemento excéntrico
the aid of an Allen key in arrow d’une clé à six pans creux dans mediante la llave Allen en el
direction until the pointer corres- le sens de la flèche jusqu’à ce sentido de la flecha hasta que
ponds with the groove in the base que l’aiguille coïncide avec el indicador coincida con la
plate. Firmly tighten the screw with l’entaille sur la plaque d’assise. muesca de la placa base. Luego,
21 + 2 Nm. Serrer à bloc la vis à 21 + 2 Nm. apretar el tornillo con 21 + 2Nm.
4.00.34 © 2001 / 0297 9959

Valve timing check Contrôle du calage de la distribution Control de las cotas de reglaje
66. Screw camshaft adjusting pin into 66. Visser la pige d’ajustage d’arbre à 66. Enroscar el perno de ajuste para el
crankcase as far as it will go. cames dans le carter moteur jusqu’en árbol de levas en el bloque motor
butée. hasta el tope.
Note: Bore for camshaft must overlap Note: L’alésage de l’arbre à cames Nota: El taladro para el árbol de levas
with bore in crankcase. doit coïncider avec celui du carter debe coincidir con el taladro
moteur. existente en el bloque motor.
67. Tension the central bolt with the 67. Serrer la vis centrale avec la clé 67. Apretar con 40 Nm el tornillo central
torque spanner in motor direction dynamométrique à 40 Nm. Décharger en el sentido de giro del motor
of rotation with 40 Nm. Release uniformément la clé dynamométrique mediante la llave dinamométrica.
evenly the torque spanner again, et non par à-coups. Descargar la llave uniformemente y
but not abruptly.. no a tirones.
Note: Do not change crankshaft position Nota: Ne plus modifier la position du Nota: Mantener inalterada la posición
anymore. vilebrequin. del cigüeñal.
68. Screw in crankshaft adjusting 68. Visser la pige d’ajustage de 68. Enroscar el perno de ajuste para
pin until it has slight contact with vilebrequin jusqu’à ce qu’elle touche el cigüeñal hasta que toque éste
4 crankshaft. légèrement le vilebrequin. ligeramente.
Mark position of adjusting pin. Repérer la position de la pige Marcar la posición del perno de
d’ajustage. ajuste.
© 2001 / 0297 9959 4.00.35

Steuerzeiten-Kontrolle
66. Einstellbolzen für Nockenwelle in das Kurbel-

4
7
Hinweis: Bohrung für Nockenwelle muss mit der
Bohrung im Kurbelgehäuse in Über- 5
deckung stehen.
34142 ©
67. Zentralschraube mit Drehmomentschlüssel in

Motordrehrichtung mit 40 Nm spannen. Dreh-
momentschlüssel wieder gleichmäßig entla-
6
sten, nicht ruckartig.
5
Hinweis: Kurbelwelle nicht mehr verdrehen.
34143 ©
68. Einstellbolzen für Kurbelwelle einschrauben bis

er die Kurbelwelle leicht berührt. 4 4
Einstellbolzen-Stellung zeichnen. i
34144 ©
4.00.35 © 2001 / 0297 9959

69. Die richtige Einstellung ist dann gegeben, wenn

6 sich der Einstellbolzen noch 0,75 bis 2,25 Um-
drehungen bis zur Anlage ins Kurbelgehäuse
eindrehen lässt.
34145 ©
Hinweis: Wird die Einschraubtiefe des Einstell-

bolzens an das Kurbelgehäuse nicht
erreicht, ist die Nockenwellengrund-
einstellung zu wiederholen.
Hierzu Nockenwellenzahnriemenrad und

Spannrolle lösen.
Vorgang ab Punkt 56 wiederholen.

3 entfernen.
34146 ©
70.1 Verschlussschraube mit neuem Cu-Dichtring
4 4 festdrehen.
ß Anziehvorschrift: 18 ± 2 Nm
34147 ©
© 2001 / 0297 9959 4.00.36

69. The setting is correct when the ad- 69. Le réglage correct est obtenu lorsque 69. El ajuste es correcto si el perno de
justing pin can still be screwed into la pige d’ajustage se laisse encore ajuste puede ser girado adentro otras
the crankcase another 0.75 to 2.25 visser de 0,75 à 2,25 tours jusqu’en 0,75 a 2,25 vueltas hasta que haga
turns until stop. butée dans le carter moteur. tope en el bloque motor.
Note: If the adjusting pin cannot be Nota: Si la profondeur de vissage de Nota: Si al enroscar el perno de ajuste
screwed into crankcase over its la pige d’ajustage dans le carter no se alcanza la profundidad
full effective length, the basic moteur n’est pas atteinte, requerida en el bloque motor,
camshaft setting has to be redone. recommencer le réglage de hay que repetir el ajuste básico
base de l’arbre à cames. del árbol de levas.
Release camshaft toothed belt
gear again for this purpose. Pour cela, desserrer le pignon de Para ello, soltar la rueda de
Repeat procedure as from courroie dentée d’arbre à cames et correa dentada del árbol de levas
point 56. le galet tendeur. y la polea tensora.
Recommencer les opérations à Repetir las operaciones a partir
partir du point 56. del punto 56.
70. Remove adjusting pins for cam-shaft 70. Enlever les piges d’ajustage d’arbre à 70. Retirar los pernos de ajuste para el
and crankshaft. cames et de vilebrequin. árbol de levas y el cigüeñal.
70.1 Tighten screw plug with new Cu 70.1 Serrer le bouchon fileté avec un joint 70.1 Apretar el tapón roscado provisto de
seal. en cuivre neuf. una junta anular de cobre nueva.
4
Tightening specification: 18 ± 2 Nm Prescription de réglage: 18 ± 2 Nm Prescripción de apriete: 18 ± 2 Nm
4.00.36 © 2001 / 0297 9959

70.2 Tighten screw plug with new Cu 70.2 Serrer le bouchon fileté avec un joint 70.2 Apretar el tapón roscado provisto de
seal. en cuivre neuf. una junta anular de cobre nueva.
Tightening specification: 18 ± 2 Nm Prescription de réglage: 18 ± 2 Nm Prescripción de apriete: 18 ± 2 Nm
© 2001 / 0297 9959 4.00.37

70.2 Verschlussschraube mit neuem Cu-Dichtring

festdrehen.
4
ß
34148 ©
4.00.37 © 2001 / 0297 9959

Zylinderkopf
4 71. Zylinderkopfdichtung bestimmen
9 71.1 Abstandsplättchen auf die Dichtfläche des

Zylinderkurbelgehäuses legen und Messuhr
6 auf „0“ stellen.
34149 ©
71.2 Messuhr an den Messstellen auf den Kolben

4 setzen und den größten Kolbenüberstand er-
mitteln.
6 Hinweis: Alle Kolben müssen vermessen werden.
34150 ©
71.3 Messpunkte beachten. Die Messpunkte dürfen

9 nicht im Bereich der Beschriftung liegen.
34151 ©
72. Größten Wert mit der Tabelle vergleichen und
4 9 entsprechende Zylinderkopfdichtung ermitteln.
Kolbenüberstand Kennzeichnung der

Zylinderkopfdichtung
0,530 - 0,69 mm 1 Kerbe
0,691 - 0,76 mm 2 Kerben
0,761 - 0,83 mm 3 Kerben
34152 ©
© 2001 / 0297 9959 4.00.38

Cylinder head Culasse Culata
71. Determine cylinder head gasket. 71. Déterminer le joint de culasse. 71. Determinación de la junta de culata.
71.1 Poser les pastilles d’écartement 71.1 Colocar plaquitas distanciadoras

71.1 Place spacers on sealing surface of sur le plan de joint du bloc-cylindres sobre la superficie de asiento
crankcase with integrated liners and et mettre le comparateur à « 0 ». del bloque motor y ajustar el
set dial gauge to “0”. comparador a “0”.
71.2 Position dial gauge on piston at 71.2 Placer le comparateur aux points de 71.2 Poner el comparador sobre el pistón
gauge points and determine max. mesure du piston et déterminer le en los puntos de medición y
piston projection. plus grand dépassement du piston. determinar el saliente de pistón más
grande.
Note: All pistons must be gauged. Nota: Le relevé doit être fait sur tous les Nota: Esta medición deberá repetirse en
pistons. todos los pistones.
71.3 Pay attention to gauge points. 71.3 Respecter les points de mesure. 71.3 Prestar atención a los puntos de
Ceux-ci ne doivent pas se trouver medición. No deben encontrarse en
dans la zone comportant des la zona de rotulación.
marquages.
72. Compare max. value with table and 72. Comparer la valeur la plus grande 72. Comparar el valor más grande con
determine appropriate cylinder head avec celles du tableau et déterminer la tabla y definir la junta de culata
gasket. le joint de culasse correspondant. correspondiente. 4
Piston projection Marking of cylinder Dépassement Marquage du joint Saliente Identificación de
head gasket de piston de culasse de pistón la junta de culata
0.530 - 0.69 mm 1 notch 0,530 - 0,69 mm 1 entaille 0,530 - 0,69 mm 1 muesca
0.691 - 0.76 mm 2 notches 0,691 - 0,76 mm 2 entailles 0,691 - 0,76 mm 2 muescas
0.761 - 0.83 mm 3 notches 0,761 - 0,83 mm 3 entailles 0,761 - 0,83 mm 3 muescas
4.00.38 © 2001 / 0297 9959

73. Make sure that dowel pins are fitted. 73. Veiller à la présence des goupilles 73. Cuidar de que existan los pasadores
de serrage. de sujeción.
74. Position cylinder head gasket. 74. Poser le joint de culasse. 74. Colocar la junta de culata.
Note: Sealing surfaces for cylinder head Nota: Les plans d’étanchéité du joint Nota: Las superficies de asiento para la
gasket must be free of oil. de culasse doivent être exempts junta de culata deben estar libres
75. Install cylinder head. Oil cylinder 75. Monter la culasse. 75. Montar la culata.
head bolts lightly. Huiler légèrement les boulons de Untar con un poco de aceite los
culasse. tornillos de culata.
Note: Standard length of cylinder head Nota: Longueur normale de boulon de Nota: Longitud normal del tornillo de
bolt: 150 ± 0.8 mm culasse: 150 ± 0,8 mm culata: 150 ± 0,8 mm
75.1 Tighten cylinder head bolts. 75.1 Serrer à bloc les boulons de culasse. 75.1 Apretar los tornillos de culata.
4 Tightening specification: Prescription de serrage: Prescripción de apriete:

Initial tightening torque: Préserrage: 1e passe 30 Nm Apriete inicial: 1a fase 30 Nm
1st stage 30 Nm 2e passe 80 Nm 2a fase 80 Nm
2nd stage 80 Nm 3e passe 160 Nm 3a fase 160 Nm
3rd stage 160 Nm Angle de serrage définitif: 90° Reapriete: 90°
Tightening angle: 90°
Note: Observe tightening order for Nota: Respecter l’ordre de serrage des Nota: Observar el orden de apriete de
cylinder head bolts. boulons de culasse. los tornillos de culata.
See Specification Data. Voir caractéristiques techniques. Ver Datos técnicos.
© 2001 / 0297 9959 4.00.39

73. Auf Vorhandensein der Spannstifte achten.

9
34153 ©
74. Zylinderkopfdichtung auflegen.
Hinweis: Dichtflächen für die Zylinderkopfdichtung

4
müssen ölfrei sein.
5
9
34154 ©
75. Zylinderkopf montieren.

Zylinderkopfschrauben leicht einölen. 4
Hinweis: Länge der Zylinderkopfschraube normal:
150 ± 0,8 mm z
5
34155 ©
75.1 Zylinderkopfschrauben festdrehen.
Anziehvorschrift:
4 4
Vorspannwert: 1. Stufe
2. Stufe
30 Nm
80 Nm 6
3. Stufe 160 Nm
Hinweis: Reihenfolge beim Anziehen der Zylinder-
kopfschrauben beachten.
SieheTechn. Daten
34156 ©
4.00.39 © 2001 / 0297 9959

Ventiltrieb
4 76. Stoßstangen einsetzen.
34157 ©
77. Kipphebelbock montieren und zu den Stoß-

4 stangen/Ventilen ausrichten.
34158 ©

6 Hinweis: Ventilspiel einstellen siehe Kapitel 2.
34159 ©
4 4
0
34160 ©
© 2001 / 0297 9959 4.00.40

Valve gear Commande des soupapes Mando de las válvulas
76. Insert pushrods. 76. Mettre en place les tiges de 76. Meter las varillas de empuje.
culbuteur.
77. Fit rocker arm bracket and align 77. Monter le support de culbuteur et 77. Montar el soporte de balancines
relative to pushrods/valves. l’aligner par rapport aux tiges de y alinearlo con respecto a las
culbuteurs/soupapes. varillas de empuje / válvulas.
Note: Adjust valve clearance - see Nota: Réglage du jeu des soupapes, Nota: Para el ajuste de válvulas,
Chapter 2. voir chapitre 2. ver capítulo 2.
79. Place on gasket. 79. Poser le joint. 79. Colocar la junta.
4.00.40 © 2001 / 0297 9959

80. Fit cylinder head cover. 80. Monter le cache-culbuteurs. Serrer 80. Montar la tapa de culata. Apretar los
Tighten bolts. les vis. tornillos.
Vent valve Soupape de purge d’air Válvula de ventilación

(With BF4L/M motors) (Sur Moteurs BF4L/M) (En los motores BF4L/M)
81. Clean the vent valve and mount a 81. Nettoyer la soupape de purge d’air et 81. Limpiar la válvula de ventilación y
new O-ring type sealing ring. monter un joint torique neuf. colocar un anillo tórico nuevo.
82. Attach a vent valve. Firmly tighten 82. Monter la soupape de purge d’air. 82. Montar la válvula de ventilación.
the screw. Serrer les vis. Apretar el tornillo.
Air intake manifold / exhaust manifold Collecteur d’admission d’air / Colector de admisión / colector de
collecteur d’échappement escape
4
83. Mount air intake manifold with new 83. Monter le collecteur d’admission 83. Montar el colector de admisión
gaskets. d’air avec des joints neufs. utilizando juntas nuevas.
© 2001 / 0297 9959 4.00.41

80. Zylinderkopfhaube montieren. Schrauben fest-

drehen.
4
6
34161 ©
Entlüftungsventil (Bei BF4L/M - Motoren)
81. Entlüftungsventil reinigen und neuen Rund-

2
dichtring aufziehen.
ß
34162 ©
82. Entlüftungsventil anbauen. Schraube fest-

drehen. 4
6
34163 ©
Luftansaugrohr / Abgassammelrohr
83. Luftansaugrohr mit neuen Dichtungen anbauen.

4 4
ß
34164 ©
4.00.41 © 2001 / 0297 9959

83.1 Schrauben festdrehen.

34165 ©
83.2 Abgassammelrohr mit neuen Dichtungen

4 anbauen.
34166 ©

6
34167 ©
Abgasturbolader
4 4 85. Abgasturbolader mit Gummimuffe, Federband-

ß schellen und neuer Dichtung anbauen
5
Hinweis: Federklemmenzange 9090 verwenden.
34168 ©
© 2001 / 0297 9959 4.00.42

83.1 Tighten bolts. 83.1 Serrer les vis. 83.1 Apretar los tornillos.
83.2 Mount exhaust manifold with new 83.2 Monter le collecteur d’échappement 83.2 Montar el colector de escape
gaskets. avec des joints neufs. utilizando juntas nuevas.
Exhaust-driven turbosupercharger Turbocompresseur à gaz Turbocompresor

d’échappement
4
85. Attach an exhaust-driven turbo- 85. Monter le turbocompresseur avec 85. Montar el turbocompresor con
supercharger with a rubber sleeve, manchon en caoutchouc, colliers de manguito de goma, abrazaderas
spring steel clips and a new seal serrage à ressort et joints neufs. de fleje de acero-resorte y una
junta nueva.
Note: Use a spring clamp pliers 9090. Nota: Utiliser la pince à ressort 9090. Nota: Utilizar los alicates 9090 para
abrazaderas de resorte.
4.00.42 © 2001 / 0297 9959

87. Mount on a reducer loosely. 87. Monter lâchement le raccord de 87. Montar la pieza reductora, dejándola
réduction. suelta.
88. Adjust the reducer and mount on 88. Aligner le raccord de réduction et 88. Alinear la pieza reductora y montar
the vent pipe with a new seal. monter le tube de purge d’air avec el tubo de ventilación con una junta
Firmly tighten the screws and the un joint neuf. Serrer les vis et le nueva. Apretar los tornillos y la
hose clip. collier de serrage. abrazadera de manguera.

regulations Pos. 1 8.5 Nm de serrage Rep. 1 8,5 Nm de apriete: (1) 8,5 Nm
Pos. 2 4 ± 1 Nm Rep. 2 4 ± 1 Nm (2) 4 ± 1 Nm
Note: Use the hose clip pliers 9088. Nota: Utiliser la pince à tuyaux Nota: Utilizar los alicates 9088 para
souples 9088. abrazaderas de manguera.
89. Mount on the lube oil line with new 89. Monter la conduite d’huile de 89. Montar la tubería de aceite lubricante
seal rings. Firmly tighten the hollow graissage avec des joints neufs. utilizando juntas anulares nuevas.
4 screws. Serrer les vis creuses. Apretar los tornillos racor.
© 2001 / 0297 9959 4.00.43

4
6
34169 ©
87. Reduzierstück lose anbauen.

4
34170 ©
88. Reduzierstück ausrichten und Entlüftungsrohr

mit neuer Dichtung anbauen. Schrauben und
Schlauchschelle festdrehen.
4
Anziehvorschrift: Pos. 1 8,5 Nm ß
Pos. 2 4 ± 1 Nm
6
Hinweis: Schlauchklemmenzange 9088 verwen-
den. 5
34171 ©
89. Schmierölleitung mit neuen Dichtringen an-

bauen. Hohlschrauben festdrehen. 4 4
ß
6
34172 ©
4.00.43 © 2001 / 0297 9959

Einspritzpumpe
3 90. Verschlussschraube am Kurbelgehäuse her-
ausschrauben.
34173 ©
91. Regelstange in Mittelstellung bringen.

9 Einstellbolzen für Regelstange in das Kurbel-
4
7
34174 ©
92. Nockenwelle drehen, bis Stößelhub des je-
4 4 weiligen Zylinders auf UT steht.
34175 ©
© 2001 / 0297 9959 4.00.44

Injection pump Pompe d’injection Bomba de inyección
90. Undo screw plug on crankcase. 90. Dévisser le bouchon fileté du carter 90. Desenroscar el tapón roscado del
moteur. bloque motor.
91. Bring control rod in central position. 91. Placer la crémaillère en position 91. Situar la cremallera en posición
Screw adjusting pin for control rod médiane. media.
into crankcase as far as it will go. Visser la pige d’ajustage dans la Enroscar el perno de ajuste para la
crémaillère jusqu’en butée. cremallera en el bloque motor hasta
el tope.
92. Rotate camshaft until tappet stroke of 92. Virer l’arbre à cames jusqu’à ce que 92. Girar el árbol de levas hasta que la
respective cylinder is at BDC. la course de poussoir du cylindre leva para la elevación del empujador
respectif soit au PMB. o taqué del cilindro en cuestión se 4
encuentre en PMI.
4.00.44 © 2001 / 0297 9959

93. Fit injection pump tappet. 93. Monter le poussoir de pompe 93. Montar el empujador de la bomba de
d’injection. inyección.
Note: Use flexible magnetic lifter. Nota: Utiliser un extracteur magnétique Nota: Utilizar un levantador magnético
souple. flexible.
94. Determining compensating gasket 94. Déterminer les joints de 94. Determinación de la junta de
compensation. compensación.
94.1 Gauge depth dimension “A” 94.1 Relever la cote de profondeur « A » 94.1 Medir la profundidad “A” del asiento
between crankcase contact surface entre plan d’appui de carter moteur en el bloque motor al asiento del
and spring plate contact surface et plan d’appui de cuvette de ressort plato de resorte en el empujador.
of tappet. du poussoir.
95. Installation dimension “X” of injection 95. Cote de montage « X » de la pompe 95. Medida de montaje “X” de la bomba
pump = 60 mm. d’injection = 60 mm. de inyección = 60 mm
4
Note: The fitting dimension ”X” serves Nota: La cote de montage « X » ne Nota: La medida de montaje “X” sólo
only for the calculation of sert qu’au calcul des joints de sirve para el cálculo de las
compensating shim washers and compensation et ne peut pas arandelas de compensación y
cannot not be measure at the être mesurée sur la pompe no puede ser medida en la bomba
disassembled injection pump. d’injection démontée. de inyección desmontada.
© 2001 / 0297 9959 4.00.45

93. Einspritzpumpenstößel montieren.
Hinweis: Biegsamen Magnetheber verwenden. 4

5
34176 ©
94. Ermittlung der Ausgleichdichtung.

6
34177 ©
94.1 Tiefenmaß „A“ von der Kurbelgehäuse-

auflage bis Federtellerauflage am Stößel
messen.
6
34178 ©
95. Einbaumaß „X“ der Einspritzpumpe = 60 mm

9 4
Hinweis: Das Einbaumaß „X“ dient nur zur
Berechnung der Ausgleichdichtung und
kann an der ausgebauten Einspritz-
5
pumpe nicht gemessen werden.
34179 ©
4.00.45 © 2001 / 0297 9959

96. Differenz zwischen Einbaumaß „X“ und Tiefen-

maß „A“ ermitteln.
Beispiel: Einbaumaß „X“ = 60,00 mm

- Tiefenmaß „A“ = 59,35 mm
Differenz = 0,65 mm
97. Ausgleichdichtung nach Tabelle entsprechend

9 der Kennzeichnung auswählen.
Ermittelte Maß der

Differenz Kennzeichnung
bis 0,4 mm 9 mm
0,401 - 0,5 mm 12 mm
0,501 - 0,6 mm 15 mm
0,601 - 0,7 mm 18 mm
0,701 - 0,8 mm 21 mm
0,801 - 0,9 mm 24 mm
34180 © 0,901 - 1,0 mm 27 mm
97.1 Da die Teile-Nr. und die Dichtungsdicke auf der

9 Ausgleichdichtung nicht angegeben ist kann
mit Hilfe des Werkzeuges die Dichtungsdicke
7 nachgeprüft werden.
34181 ©
98. Entsprechende Ausgleichdichtung auflegen.
4 4 Hinweis: Einbaulage beachten.
34182 ©
© 2001 / 0297 9959 4.00.46

96. Determine difference between 96. Déterminer la différence entre cote 96. Determinar la diferencia entre la
installation dimension “X” and depth de montage « X » et cote de medida de montaje “X” y la
dimension “A”. profondeur « A ». profundidad “A”.
Example: Exemple: Ejemplo:

Installation dimension “X” = 60.00 mm Cote de montage « X » = 60,00 mm Medida de montaje “X” = 60,00 mm
- Depth dimension “A” = 59.35 mm - cote de profondeur « A » = 59,35 mm - profundidad “A” = 59,35 mm
Difference = 0.65 mm Différence = 0,65 mm Diferencia = 0,65 mm
97. Select compensating gasket from 97. Choisir le joint de compensation 97. Elegir la junta de compensación
table according to marking. selon le tableau conformément à la según la tabla conforme a la
cote repère. identificación.
Determined Marked Différence Cote Diferencia Medida de

difference dimension déterminée repère determinada identificación
up to 0.4 mm 9 mm jusqu’à 0,4 mm 9 mm hasta 0,4 mm 9 mm
0.401 - 0.5 mm 12 mm 0,401 - 0,5 mm 12 mm 0,401 - 0,5 mm 12 mm
0.501 - 0.6 mm 15 mm 0,501 - 0,6 mm 15 mm 0,501 - 0,6 mm 15 mm
0.601 - 0.7 mm 18 mm 0,601 - 0,7 mm 18 mm 0,601 - 0,7 mm 18 mm
0.701 - 0.8 mm 21 mm 0,701 - 0,8 mm 21 mm 0,701 - 0,8 mm 21 mm
0.801 - 0.9 mm 24 mm 0,801 - 0,9 mm 24 mm 0,801 - 0,9 mm 24 mm
0.901 - 1.0 mm 27 mm 0,901 - 1,0 mm 27 mm 0,901 - 1,0 mm 27 mm
97.1 As the part No. and gasket thickness 97.1 Etant donné que le n° de pièce et 97.1 Como sea que en la junta de
are not indicated on the compen- l’épaisseur ne figurent pas sur le compensación no se indica el
sating gasket the gasket thickness joint de compensation, l’épaisseur número de pieza ni el espesor
can be rechecked with the tool. de joint de compensation peut être de la junta, éste puede ser com-
vérifiée à l’aide d’un outil. probado mediante la herramienta.
98. Place on appropriate compensating 98. Monter le joint de compensation 98. Colocar la junta de compensación
gasket. adéquat. que corresponda.
4
Note: Watch installation position. Nota: Respecter la position de montage. Nota: Observar la posición de montaje.
4.00.46 © 2001 / 0297 9959

99. Remove blanking pin from injection 99. Extraire la goupille d’obturation de 99. Retirar el pasador de cierre de la
pump. la pompe d’injection bomba de inyección.
100. Before fitting injection pump, make 100. Avant le montage de la pompe 100. Antes de montar la bomba de
sure that locking wire is eng†ged in d’injection, veiller à ce que le fil inyección hay que asegurarse de
control lever. d’arrêt soit engagé dans le levier que el alambre de fijación haya
articulé. encajado en la palanca articulada.
101. Fit injection pump in place. Then 101. Monter la pompe d’injection. 101. Montar la bomba de inyección.
press pump down to its seat, taking Enfoncer la pompe d’injection Presionar la bomba céntricamente
care that it is accurately centered. centralement jusqu’en butée. hacia abajo hasta el tope. Apretar
Tighten nuts. Serrer les écrous. las tuercasl
102. Take locking wire out. 102. Extraire le fil d’arrêt. 102. Sacar el alambre de fijación.
© 2001 / 0297 9959 4.00.47

99. Verschlussstift aus der Einspritzpumpe heraus-

nehmen.
3
34183 ©
100. Vor Montage der Einspritzpumpe ist darauf zu

achten, dass der Arretierungsdraht in den
Anlenkhebel eingerastet ist.
4
7
34184 ©
101. Einspritzpumpe montieren. Einspritzpumpe

zentrisch bis Auflage hinunterdrücken. Muttern
festdrehen.
4
34185 ©
102. Arretierungsdraht herausziehen.

3 4
34186 ©
4.00.47 © 2001 / 0297 9959

103. Bohrung mit Verschlussstift verschließen.

4
34187 ©
104. Einstellbolzen für Regelstange entfernen.

3
34188 ©
105. Verschlussschraube mit neuem Cu-Dichtring

4 festdrehen.
34189 ©
Öleinfüllung
4 4 106. Verschlussdeckel für Öleinfüllung einschrau-

ben.
34190 ©
© 2001 / 0297 9959 4.00.48

103. Blank bore with pin. 103. Reboucher l’alésage avec goupille 103. Cerrar el taladro con el pasador de
d’obturation. cierre.
104. Remove adjusting pin for control rod. 104. Enlever la pige d’ajustage de la 104. Quitar el perno de ajuste para la
crémaillère. cremallera.
105. Tighten screw plug with new 105. Serrer le bouchon fileté avec un joint 105. Apretar el tapón roscado
Cu seal. en cuivre neuf. provisto de una junta anular de
cobre nueva.
Oil filling Remplissage d’huile Boca de llenado de aceite
106. Fit in the closure cover for oil filling. 106. Visser le bouchon de remplissage 106. Enroscar la tapa en la boca de 4
d’huile. llenado de aceite.
4.00.48 © 2001 / 0297 9959

Injectors Injecteurs Inyectores
107. Slide sealing ring over injector using 107. Emmancher le joint avec un peu de 107. Colocar con un poco de grasa la
some grease. graisse sur l’injecteur. junta anular sobre el inyector.
108. Insert injector. 108. Insérer les injecteurs. 108. Introducir los inyectores.
Note: Leakage fuel connection must point Nota: Le raccord des fuites de Nota: El racor de combustible
towards exhaust side. combustible soit être orienté sobrante debe indicar hacia
du côté échappement. el lado de escape.
109. Fit clamping pad. 109. Poser les pattes de serrage. 109. Colocar las garras de sujeción.
Note: Watch installation position of Nota: Respecter la position de montage Nota: Observar la posición de montaje de
clamping pad. des pattes de serrage. las garras de sujeción.
110. Tighten bolt. 110. Serrer les vis. 110. Apretar los tornillos.
4 Tightening specification: 21 Nm Prescription de serrage: 21 Nm Prescripción de apriete: 21 Nm
© 2001 / 0297 9959 4.00.49

Einspritzventile
107. Dichtring mit etwas Fett auf das Einspritzventil

4
aufschieben.
ß
u
34191 ©
108. Einspritzventile einsetzen.
Hinweis: Leckkraftstoffanschluss muß zur Abgas-

4
seite weisen.
5
34192 ©
109. Spannpratzen aufsetzen.
Hinweis: Einbaulage der Spannpratzen beachten.

4
5
34193 ©
4 4
6
34194 ©
4.00.49 © 2001 / 0297 9959

Kühlgebläse / Kabelbaum
4 111. Steckergehäuse von Kabelbaum in Gebläse-
6 mantel einsetzen. Leitungen wie gekennzeich-

net montiren.
a) Ladeleitung B+
i Sechskantmutter mit 5,5 - 7 Nm festdrehen.
Gummimuffe einsetzen.
b) Leitung G1.D+
Sechskantmutter mit 4,5 ± 0,8 Nm festdrehen.
c) Leitung G1. W
34195 ©
112. Kühlgebläse anbauen. Schrauben festdrehen.

34196 ©
113. Ladeleitung verschellen. Schrauben festdrehen.

4 Anziehvorschrift: Pos. 1 14 Nm
6 Pos. 2 8,5 Nm
34197 ©
114. Steckverbindung an Motorabstellung anbauen.
4 4 Schraube festdrehen.
Anziehvorschrift: 0,5 + 0,1 Nm
6 Leitungen wie gekennzeichnet montieren.

a) Leitung B3. G Temperaturgeber
i b) Leitung B3. WK Temperaturgeber
c) Leitung F1/B6. WK Druckschalter/ -geber
Leitung B6. G Druckgeber

(falls angebaut)
34198 ©
© 2001 / 0297 9959 4.00.50

Cooling fan / cable trunk Ventilateur de refroidissement / Turbina de refrigeración / mazo de

faisceau de câbles cables
111. Fit the plug casing of the cable 111. Insérer le boîtier de connexion du 111. Insertar la caja de enchufe del
trunk into the blower shell. Mount faisceau de câbles dans l’enveloppe mazo de cables en la envolvente
the lines as indicated. du ventilateur. Monter les câbles de turbina. Montar los cables
a) Induction system B+ conformément au repérage. según marcación.
firmly tighten the hex nut a) Câble de charge B+ a) Cable de carga B+
with 5.5 - 7 Nm. Serrer l’écrou hexagonal Apretar la tuerca hexagonal
Fit in the rubber sleeve à 5,5 - 7 Nm. Mettre en place con 5,5 - 7 Nm.
b) Line G1.D+ le manchon en caoutchouc. Colocar el manguito de goma.
firmly tighten the hex nut b) Câble G1.D+ b) Cable G1.D+
with 4.5 ± 0,8 Nm Serrer l’écrou hexagonal Apretar la tuerca hexagonal
c) Line G1.W à 4,5 ± 0,8 Nm. con 4,5 ± 0,8 Nm.
c) Câble G1.W c) Cable G1.W
112. Mount blower. Tighten bolts. 112. Monter le ventilateur. Serrer les vis. 112. Montar la turbina de refrigeración.
113. Load the induction system. Tighten 113. Fixer le câble de charge par collier. 113. Fijar el cable de carga mediante
the screws firmly. Serrer les vis. grapas. Apretar los tornillos.

specification: Pos. 1 14 Nm de serrage: Rep. 1 14 Nm de apriete: (1) 14 Nm
Pos. 2 8.5 Nm Rep. 2 8,5 Nm (2) 8,5 Nm
114. Mount on the plug-in connection at 114. Monter la connexion sur le 114. Establecer la unión de enchufe en
motor disconnection. Firmly tighten dispositif d’arrêt moteur. el dispositivo de parada del motor.
the screw. Serrer la vis. Apretar el tornillo. 4
Tightening specification: 0.5 + 0.1 Nm Prescription de serrage: 0,5 + 0,1 Nm Prescripción de apriete: 0,5 + 0,1 Nm
Mount the lines as indicated. Monter les câbles conformément aux repérages. Instalar los cables según marcación.
a) Line B3. G Temperature transmitter a) Câble B3.G Transmetteur de température a) cable B3.G transmisor de temperatura
b) Line B3. WK Temperature transmitter b) Câble B3.WK Transmetteur de température b) cable B3.WK transmisor de temperatura
c) Line F1/B6 WK Pressure switch/ c) Câble F1/B6.WK Manocontact/transmetteur c) cable F1/B6.WK interruptor/transmisor
transducer de pression de presión
Line B6. G Pressure transducer Câble B6.G Transmetteur de pression cable B6.G transmisor de presión
(if installed) (pour autant que prévu) (si está montado)
4.00.50 © 2001 / 0297 9959

Fuel line/injection lines Tuyauteries à combustible / tuyauteries Tuberías de combustible / tuberías de

d’injection inyección
115. Mount fuel line with new Cu seals. 115. Monter les tuyauteries à combustible 115. Montar la tubería de combustible
Tighten banjo bolts. avec des joints en cuivre neufs. utilizando juntas anulares de cobre
Serrer les vis creuses. nuevas. Apretar los tornillos racor.
116. Guide the cable trunk and the fuel 116. Enfiler le faisceau de câbles et la 116. Pasar el mazo de cables y la tubería
piping through the profile rubber tuyauterie à combustible à travers de combustible por la goma perfilada
and push the profile rubber onto the le profilé en caoutchouc et pousser y colocar ésta sobre los pasadores
split pins. le profilé en caoutchouc sur des de sujeción.
goupilles élastiques.
117. Mount injection lines and tighten. 117. Monter les tuyauteries d’injection et 117. Montar las tuberías de inyección y
les serrer. apretar.
Note: Use the claw key 8018. Nota: Utiliser la clé à griffes 8018. Nota: Utilizar la llave de garra 8018.
118. Mount on the cross-over pipe with 118. Monter la rampe de décharge avec 118. Montar la tubería de rebose con
new rubber tubes. Fasten the holder des flexibles en caoutchouc neufs. mangueras de goma nuevas. Fijar
4 with the screws of the cylinder head Fixer l’attache avec les vis du cache- los sujetadores con los tornillos de
cover. Engage the drain pipe into culbuteurs. Insérer la conduite de la tapa de culata. Encajar la tubería
the mounting slots of the cylinder retour dans les rainures de montage de retorno en las ranuras de montaje
head cover. du cache-culbuteurs. existentes en la tapa de culata.
Note: Basically, the rubber tubes are to Nota: Toujours remplacer les flexibles Nota: Renovar siempre las mangueras
be renewed. en caoutchouc. de goma.
© 2001 / 0297 9959 4.00.51

Kraftstoffleitungen / Einspritzleitungen
115. Kraftstoffleitung mit neuen Cu-Dichtringen an-

4
bauen. Hohlschrauben festdrehen.
ß
6
34199 ©
116. Kabelbaum und Kraftstoffleitung durch den

Profilgummi führen und Profilgummi auf
Spannstifte aufschieben
4
34200 ©
4
Hinweis: Klauenschlüssel 8018 verwenden. 6
5
34201 ©
118. Überströmleitung mit neuen Gummischläu-

chen anbauen. Halter mit Schrauben von Zy-
linderkopfhaube befestigen. Rücklaufleitung
4 4
in die Montagenuten der Zylinderkopfhaube
einrasten. ß
Anziehvorschrift: 8,5 Nm 6
Hinweis: Die Gummischläuche sind grundsätzlich
zu erneuern.
5
34202 ©
4.00.51 © 2001 / 0297 9959

119. Neuen Gummischlauch an Kraftstoffleitung

4 mit Schlauchschelle anbauen.
Schutzschlauch auf Gummischlauch aufzie-
ß hen.
Hinweis: Klemmenzange 8011 benutzen.
34203 ©
120. Gummischlauch an Überströmleitung mit

4 Schlauchschelle anbauen und mit Halteband
befestigen
5 Hinweis: Klemmenzange 8011 benutzen.
34204 ©
Kraftstoffförderpumpe / Kraftstofffilter
4 121. Gummischlauch an Kraftstoffleitung mit
5 Schlauchschelle anbauen.
Hinweis: Klemmenzange 8011 benutzen.
34205 ©
122. Neuen Runddichtring auflegen.
4 4
ß
34206 ©
© 2001 / 0297 9959 4.00.52

119. Mount a new rubber tube onto 119. Monter le flexible en caoutchouc 119. Unir a la tubería de combustible
the fuel line with a hose clip. neuf sur la tuyauterie à combustible una manguera de goma nueva
Put a protecting cover on the par collier de serrage. mediante la abrazadera adecuada.
rubber tube Emmancher la gaine de protection Colocar la manguera protectora
sur le flexible en caoutchouc. sobre la manguera de goma.
Note: Use a clamp 8011. Nota: Utiliser la pince pour colliers 8011. Nota: Utilizar los alicates 8011 para
abrazaderas.
120. Attach a rubber tube to the 120. Monter le flexible en caoutchouc 120. Unir una manguera de goma a
cross-over pipe with a hose clip sur la rampe de décharge par collier la tubería de rebose mediante la
and a fastening strip. de serrage et le fixer par sangle abrazadera adecuada y fijarla
d’attache. utilizando fleje ata-manguera.
abrazaderas.
Fuel feed pump / fuel filter Pompe d’alimentation en combustible / Bomba de alimentación de combustible /
filtre à combustible filtro de combustible
121. Mount a rubber tube onto the fuel 121. Monter le flexible en caoutchouc 121. Unir una manguera de goma a la
line with the hose clip. sur la tuyauterie à combustible par tubería de combustible mediante
collier de serrage. la abrazadera adecuada.
abrazaderas.
122. Position new O-seal. 122. Poser un joint torique neuf. 122. Colocar un anillo tórico nuevo.
4.00.52 © 2001 / 0297 9959

123. Set camshaft eccentric for fuel feed 123. Placer l’excentrique d’arbre à 123. Ajustar la excéntrica del árbol de
pump to BDC. cames pour la pompe d’alimentation levas para la bomba de alimentación
en combustible au PMB. de combustible a PMI.
124. Mount fuel feed pump. Fit in alter- 124. Monter la pompe d’alimentation en 124. Montar la bomba de alimentación
nately the screws up to the unit. combustible. Visser alternativement de combustible. Enroscar alternativa-
les vis jusqu’en application. mente los tornillos hasta que se
apoyen.
124.1 Tighten bolts. 124.1 Serrer les vis. 124.1 Apretar los tornillos
125. Fit fuel filter bracket. 125. Monter la console de filtre à 125. Montar la consola de filtro de
Tighten bolts. combustible. Serrer les vis. combustible. Apretar los tornillos.
4
© 2001 / 0297 9959 4.00.53

123. Nockenwellenexenter für Kraftstoffförder-

pumpe auf UT stellen.
9
34207 ©
124. Kraftstoffförderpumpe anbauen. Schrauben

wechselseitig bis zur Anlage einschrauben. 4
34208 ©
4
6
34209 ©
125. Kraftstofffilterkonsole anbauen. Schrauben

festdrehen. 4 4
6
34210 ©
4.00.53 © 2001 / 0297 9959

126. Kraftstofffilterdichtung leicht einölen. Neue

4 Kraftstoffilterpatrone handfest andrehen.
ß
z
34211 ©
127. Gummischlauch von Kraftstoffleitung an Kraft-

4 stofffilter mit Schlauchschelle anbauen.
5 Hinweis: Klemmenzange 8011 benutzen.
34212 ©
128. Neuen Gummischlauch von Kraftstoffförder-

4 pumpe zum Kraftstofffilter mit Schlauch-
schellen anbauen.
ß Hinweis: Klemmenzange 8011 benutzen.
34213 ©
Ölfilter
4 4 129. Ölfilterdichtung leicht einölen. Neue Filter-

ß patrone handfest andrehen.
34214 ©
© 2001 / 0297 9959 4.00.54

126. Lightly oil fuel filter gasket. Turn on 126. Huiler légèrement le joint de filtre à 126. Untar con un poco de aceite la
manually a new fuel filter cartridge. combustible. Serrer manuellement la junta del filtro de combustible.
cartouche de filtre à huile neuve. Enroscar con la mano el cartucho
filtrante de combustible.
127. Mount on a rubber tube of the 127. Fixer le flexible en caoutchouc de la 127. Unir la manguera de goma de
fuel line onto the fuel filter with tuyauterie à combustible sur le filtre la tubería de combustible al filtro
the hose clip. à combustible par collier de serrage. de combustible mediante una
abrazadera de manguera.
abrazaderas.
128. Mount on a new rubber tube of 128. Monter le flexible en caoutchouc 128. Unir una manguera de goma
the fuel transfer pump to the fuel neuf entre pompe d’alimentation en nueva a la bomba de alimentación
filter with the hose clips. combustible et filtre à combustible de combustible y al filtro de
par colliers de serrage. combustible mediante abrazaderas
de manguera.
abrazaderas.
Oil filter Filtre à huile Filtro de aceite
129. Lightly oil oil filter gasket. Secure 129. Huiler légèrement le joint de filtre à 129. Untar con un poco de aceite el 4
new oil filter cartridge fingertight. huile. Serrer manuellement la filtro de aceite. Enroscar con la
cartouche de filtre à huile neuve. mano el cartucho filtrante nuevo.
4.00.54 © 2001 / 0297 9959

Air ducting/oil cooler Guidage d’air / refroidisseur d’huile Conducción de aire / refrigerador de aceite
130. Mount on an air guide. First, 130. Monter le guidage d’air. Préserrer 130. Montar la conducción de aire.
pretension the screw at the cylinder d’abord à 3 Nm la vis sur culasse, Primero, apretar el tornillo situado
head with 3 Nm, then tighten firmly puis serrer définitivement les vis sur en la culata con 3Nm iniciales,
the screws at the cooling fan and le ventilateur et la culasse. luego apretar los tornillos en la
the cylinder head. turbina de refrigeración y la culata.
131. Inspect plug-in element for visual 131. Vérifier que les éléments d’insertion 131. Inspeccionar las piezas de enchufe
damage. ne présentent pas d’endommage- en cuanto a daños visibles,
ments visibles, le cas échéant, les sustituyéndolas en caso necesario.
remplacer.
132. Press in plug-in elements as far as 132. Enfoncer les éléments d’insertion 132. Introducir a presión las piezas de
they will go. jusqu’en application. enchufe hasta el tope.
132.1 With B/FM motors: 132.1 Pour moteurs B/FM 132.1 En los motores B/FM.
Fit new O-seals to oil cooler Monter les joints neufs sur les Montar juntas anulares nuevas
4 connections to that spot facing raccords de refroidisseur d’huile en los racores del refrigerador de
points towards crankcase. de sorte que le lamage soit orienté aceite, de forma tal que el rebaje
See illustration. vers le carter moteur. Voir figure. indique hacia el bloque motor. Ver
Fit oil cooler connections. Monter les raccords de el encuadre.
Tighten bolts. refroidisseur d’huile. Serrer les vis. Montar los racores del refrigerador
de aceite. Apretar los tornillos.
© 2001 / 0297 9959 4.00.55

Luftführung / Ölkühler
130. Luftführung anbauen. Zuerst Schraube am

4
Zylinderkopf mit 3 Nm vorspannen, dann
Schrauben am Kühlgebläse und Zylinderkopf 6
festdrehen.
34215 ©
131. Steckstücke auf sichtbare Beschädigungen

prüfen ggf. austauschen. 9
0
34216 ©
132. Steckstücke bis Anlage eindrücken.

4
34217 ©
132.1 Bei B/FM - Motoren.

Neue Dichtringe so auf die Ölkühler-
anschlüsse montieren, dass die Ansenkung
4 4
zum Kurbelgehäuse weist. Siehe Bildaus-
schnitt.
ß
Ölkühleranschlüsse anbauen. Schrauben
festdrehen. 8
34218 ©
4.00.55 © 2001 / 0297 9959

133. Ölkühler lose anbauen.

4
34219 ©
134. Standblech anbauen. Schrauben in der Reihen-

4 folge a, b und c festdrehen.
Hinweis: Auf Länge der Schrauben achten.

5
34220 ©
135. Luftführungshaube anbauen. Schrauben fest-

4 drehen.
34221 ©
Anschlussgehäuse / Konsole
4 4 136. Anschlussgehäuse anbauen. Schrauben fest-

6 drehen.
5 Anziehvorschrift:
Hinweis: Auf Vorhandensein der Spannbuchsen

achten.
34222 ©
© 2001 / 0297 9959 4.00.56

133. Mount on loosely the oil cooler. 133. Monter lâchement le refroidisseur 133. Montar el refrigerador de aceite,
d’huile dejándolo suelto.
134. Mount on the cooling air cowling. 134. Monter la tôle verticale. 134. Montar la chapa vertical.
Firmly tighten the screws in the Serrer les vis dans l’ordre Apretar los tornillos en el orden
order a, b and c. a, b et c. a, b y c.
Note: Pay attention to the length of the Nota: Veiller à la longueur des vis. Nota: Tener en cuenta la longitud de
screws. los tornillos.
135. Mount air cowling. Tighten bolts. 135. Monter la hotte de guidage d’air. 135. Montar la manga guía de aire.
Serrer les vis. Apretar los tornillos.
Connection housing / console Carter d’adaptation / console Cárter de adaptación / consola
136. Mount on the connection housing. 136. Monter le carter d’adaptation. 136. Montar el cárter de adaptación. 4
Tighten bolts. Serrer les vis. Apretar los tornillos.

bolts M 12 106 Nm Vis M 12 106 Nm Tornillos M12 106 Nm
bolts M 14 180 Nm Vis M 14 180 Nm Tornillos M14 180 Nm
Note: Make sure that the collets are Nota: Veiller à la présence des douilles Nota: Cuidar de que existan los
available. de serrage. casquillos de sujeción.
4.00.56 © 2001 / 0297 9959

137. In the case of motors without 137. Sur les moteurs sans carter 137. En motores sin cárter de adaptación.
connection housing. d’adaptation. Montar la consola para el
Mount on the console for the starter. Monter la console du démarreur. arrancador. Apretar los tornillos.
Tighten the screws firmly. Serrer les vis.
Note: Make sure that the collets are Nota: Veiller à la présence des douilles Nota: Cuidar de que existan los
available. de serrage. casquillos de sujeción.
Flywheel Volant Volante
138. Position flywheel, using a self-made 138. Monter le volant en utilisant un 138. Poner el volante en su sitio
pilot bar. mandrin de guidage confectionné à utilizando el mandril de guía de
cet effet. confección propia.
139. Fit in new screws. Back-up the 139. Visser les vis neuves. Immobiliser le 139. Enroscar tornillos nuevos. Retener
flywheel and firmly tighten the volant et serrer les boulons. el volante y apretar los tornillos.
screws.

Initial tightening torque 30 Nm Préserrage: 30 Nm Apriete previo: 30 Nm
Tightening angle 60° Angle de serrage définitif: 60° Reapriete: 60°
Tightening angle 30° Angle de serrage définitif: 30° Reapriete: 30°
© 2001 / 0297 9959 4.00.57

137. Bei Motoren ohne Anschlussgehäuse.

Konsole für Starter anbauen. Schrauben fest-
drehen.
4
Hinweis: Auf Vorhandensein der Spannbuchsen
achten.
5
34223 ©
Schwungrad
138. Schwungrad unter Verwendung eines selbst-

4
gefertigten Führungsdornes aufsetzen.
34224 ©
139. Neue Schrauben eindrehen. Schwungrad

gegenhalten und Schrauben festdrehen. 4
Anziehvorschrift:
Vorspannwert: 30 Nm ß
32225 ©
4.00.57 © 2001 / 0297 9959

Hydraulikpumpenkonsole / Schutzhauben
4 140. Neuen Runddichtring einsetzen.
34226 ©
141. Hydraulikpumpenkonsole anbauen.

4 Hinweis: Auf Vorhandensein der Spannstifte achten.
34227 ©
142. Schrauben von Hydraulikpumpenkonsole fest-

4 drehen.
34228 ©
143. Schutzhauben sichtprüfen, ggf. Dichtprofile
4 9 erneuern.
34229 ©
© 2001 / 0297 9959 4.00.58

Hydraulic pump bracket / Console de pompe hydraulique / Consola para bomba hidráulica /
protective cover capots de protection cubiertas protectoras
140. Insert new O-seal. 140. Mettre en place un joint torique neuf. 140. Introducir un anillo tórico nuevo.
141. Mount hydraulic pump bracket. Start 141. Monter la console de pompe 141. Montar la consola para bomba
fastening bolts. hydraulique. hidráulica.
Note: Make sure that the split pins are Nota: Veiller à la présence des goupilles Nota: Cuidar de que existan los
available. de centrage. pasadores de sujeción.
142. Firmly tighten the screws of the 142. Serrer les vis de la console de 142. Apretar los tornillos de la consola
hydraulic pump console. pompe hydraulique. para bomba hidráulica.
143. Check visually the protective 143. Soumettre les capots de protection 143. Inspeccionar las cubiertas
covers, replace the sealing profiles, à un examen visuel, le cas échéant, protectoras, renovando las juntas
if necessary. remplacer les profilés en caoutchouc. perfiladas, si es necesario. 4
4.00.58 © 2001 / 0297 9959

144. Mount on and align the protective 144. Monter les capots de protection, les 144. Montar la cubierta protectora,
cover and firmly tighten the screws. aligner et serrer les vis. alinearla y apretar los tornillos.
145. Mount on the protective cover and 145. Monter le capot de protection et 145. Montar la cubierta protectora y
firmly tighten the screws. serrer les vis. apretar los tornillos.
Note: For the locking screw (Pos. x), Nota: Pour la vis de fixation (Rep. x), Nota: Utilizar el bit especial 9120 ó 9122
use the special bit 9120 or 9122. utiliser l’embout de tournevis para el tornillo de seguridad (x).
spécial 9120 ou 9122.
146. Place the new tension roller with 146. Accrocher le galet tendeur neuf avec 146. Enganchar la polea tensora nueva
the base plate guide clevis onto the la fourche de guidage de plaque con la horquilla de guía de la placa
guide pin. d’assise dans l’ergot de guidage. base en el pasador de guía.
Note: Pay attention to the various tension Nota: Tenir compte des différentes Nota: Tener en cuenta que hay diferentes
rollers. Width of the roller for the dimensions de galet tendeur. versiones de polea tensora.
hydraulic pump drive 35 mm. Largeur de galet tendeur El ancho de la polea para el
Width of the roller for the camshaft d’entraînement de pompe accionamiento de la bomba
drive 30 mm hydraulique 35 mm. hidráulica es de 35 mm.
Largeur de galet tendeur El ancho de la polea para el
d’entraînement d’arbre à accionamiento del árbol de
cames 30 mm. levas es de 30 mm.
147. Set the eccentric cam arrangement 147. Mettre l’élément excentrique en 147. Situar el elemento excéntrico con
with the hex socket to 12:00 hour position de 12.00 h avec un six el hexágono interior en la posición
4 position and mount on the tension pans creux et monter le galet de 12 horas y montar la polea
roller. tendeur. tensora. Apretar el tornillo con
Pretension the screw with 8 + 2 Nm. Préserrer la vis à 8 + 2 Nm. 8 + 2 Nm iniciales.
© 2001 / 0297 9959 4.00.59

144. Schutzhaube anbauen, ausrichten und

4
9
6
34230 ©
145. Schutzhaube anbauen und Schrauben fest-

drehen.
4
6
Hinweis: Für die Sicherungsschraube (Pos. x) Spe-
zial-Bit 9120 oder 9122 verwenden. 5
34231 ©
146. Neue Spannrolle mit der Grundplatten-

Führungsgabel in den Führungsstift ein-
hängen.
4
Hinweis: Auf unterschiedliche Spannrollen achten. ß
8
Breite der Rolle für Hydraulikpumpenan-
trieb 35 mm.
Breite der Rolle für Nockenwellenantrieb
30 mm. 5
34232 ©
147. Exzenter-Einsatz mit Innensechskant in 12.00

Uhr Position bringen und Spannrolle anbauen.
Schraube mit 8 + 2 Nm vorspannen.
4 4
9
6
34233 ©
4.00.59 © 2001 / 0297 9959

148. Neuen Zahnriemen auflegen und ausrichten.

4 Auf dem Kurbelwellenzahnrad bis gegen den
hinteren Führungsbord und auf dem Hydraulik-
ß pumpenzahnrad mit ca. 4 mm Rückstand zur

Vorderkante.
34234 ©
149. Arretierstift entfernen.

3
34235 ©
150. Exzenter-Einsatz mit Hilfe eines Inbusschlüssels

4 in Pfeilrichtung drehen bis Zeiger mit der Kerbe
in der Grundplatte übereinstimmt. Schraube
s festdrehen.
9
6
34236 ©
151. Kurbelwelle 2 Umdrehungen in Motordrehrich-
4 4 tung drehen. Position des Zeigers kontrollieren.
9 Hinweis: Wenn der Zeiger nicht mit der Kerbe über-

einstimmt, muss mit dem Exzenter-
Einsatz korrigiert werden.
s Schraube lösen und wieder mit 8 + 2 Nm
vorspannen. Exzenter-Einsatz mit Hilfe
6 eines Inbusschlüssels in Pfeilrichtung
drehen bis Zeiger mit der Kerbe in der
Grundplatte übereinstimmt. Schraube mit
34237 © 21 + 2 Nm festdrehen.
© 2001 / 0297 9959 4.00.60

148. Place and adjust a new toothed belt. 148. Mettre en place une courroie 148. Colocar la correa dentada nueva
On crankshaft gear as far as rear dentée neuve et l’aligner: sur le y alinearla.
guide plate and on hydraulic pump pignon de vilebrequin, contre le Sobre la rueda dentada del
gear with approx. 4 mm distance bord de guidage arrière et sur le cigüeñal, tocando el borde de
from front edge. pignon de pompe hydraulique, guía trasero y sobre la rueda
avec un retrait d’env. 4 mm par dentada de la bomba hidráulica,
rapport au bord avant. retrocediendo unos 4 mm del
canto delantero.
149. Remove the locking pin 149. Enlever la goupille d’arrêt. 149. Retirar el pasador de fijación.
150. Rotate the eccentric cam arrange- 150. Tourner l’élément excentrique à 150. Sirviéndose de una llave Allen,
ment with the aid of an Allen key in l’aide d’une clé à six pans creux girar el elemento excéntrico en
arrow direction until the pointer dans le sens de la flèche jusqu’à el sentido de la flecha hasta que
corresponds with the groove in the ce que l’aiguille coïncide avec el indicador coincida con la
base plate. Firmly tighten the screw. l’entaille dans la plaque d’assise. muesca existente en la placa
Serrer la vis à bloc. base. Apretar el tornillo.
151. Turn the crankshaft 2 rotations in 151. Virer le vilebrequin de 2 tours dans le 151. Darle al cigüeñal 2 vueltas en
motor direction of rotation. Check sens de rotation du moteur jusqu’à ce el sentido de giro normal del
the position of the pointer. que les repères coïncident à nouveau. motor. Controlar la posición del
Contrôler la position de l’aiguille. indicador.
Note: If the pointer does not correspond Nota: Si l’aiguille ne coïncide pas avec Nota: Si el indicador no coincide con
with the groove, it must be corrected l’entaille, il faut corriger avec la muesca, hay que corregir con 4
with the eccentric cam arrangement. l’élément excentrique. ayuda del elemento excéntrico.
Loosen the screw and pretension Défaire la vis et la préserrer de Soltar el tornillo y apretarlo de
again with 8 + 2 Nm. Rotate the nouveau à 8 + 2 Nm. Tourner nuevo con 8 + 2 Nm iniciales.
eccentric cam arrangement with l’élément excentrique à l’aide Girar el elemento excéntrico
the aid of an Allen key in arrow d’une clé à six pans creux dans mediante la llave Allen en sentido
direction until the pointer corres- le sens de la flèche jusqu’à ce de la flecha hasta que el indi-
ponds with the groove in the base que l’aiguille coïncide avec cador coincida con la muesca de
plate. Firmly tighten the screw with l’entaille sur la plaque d’assise. la placa base. Apretar el tornillo
21 + 2 Nm. Serrer à bloc la vis à 21 + 2 Nm. finalmente con 21 +2Nm.
4.00.60 © 2001 / 0297 9959

152. Put on the intermediate piece with 152. Poser la pièce intermédiaire avec le 152. Colocar la pieza intermedia con la
the flattened side pointing to the côté aplati dirigé vers la courroie cara achaflanada indicando hacia la
toothed belt. dentée. correa dentada.
153. Mount on the protective cover and 153. Monter le capot de protection. Serrer 153. Montar la cubierta protectora.
firmly tighten the screws. les vis. Apretar los tornillos.
Hydraulic pump Pompe hydraulique Bomba hidráulica
154. Check visually the coupling sleeve 154. Contrôler la douille d’accouplement 154. Examinar visualmente el casquillo
and the collars for damage, et les manchettes quant à des de acoplamiento y los manguitos
exchange completely, if necessary. endommagements, le cas échéant, en cuanto a daños, sustituyendo
les remplacer complètement. el conjunto por completo, si es
necesario.
155. During further use of the 155. En cas de réutilisation de la 155. En caso de reutilización del
coupling sleeve, fill the teeth douille d’accouplement, casquillo de acoplamiento,
4 area with graphite grease remplir l’espace d’endentement llenar el recinto de dentado
G 500 (20 gram of tube). de graisse graphitique G 500 con grasa grafitada G 500
(tube de 20 grammes). (tubo de 20 gramos).
© 2001 / 0297 9959 4.00.61

152. Zwischenstück mit der abgeflachten Seite zum

Zahnriemen weisend aufsetzen. 4
8
34238 ©
153. Schutzhaube anbauen. Schrauben festdrehen.
4
6
34239 ©
Hydraulikpumpe
154. Kupplungshülse und Manschetten auf Be-

9
schädigung sichtprüfen, ggf. komplett aus-
tauschen. 0
34240 ©
155. Bei Weiterverwendung der Kupplungshülse

den Verzahnungsraum mit Grafitfett G 500
(20 Gramm Tube) befüllen.
u 4
34241 ©
4.00.61 © 2001 / 0297 9959

156. Die Verzahnung der Manschetten mit der Ver-

2 zahnung der Kupplungshülse in Überdeckung
bringen.
34242 ©
157. Zahnwelle mit Grafitfett G 500 einfetten. Kupp-

4 lungshülse auf die Zahnwelle aufschieben.
34243 ©
158. Schrauben mit Scheiben einsetzen und Vor-

4 stehmaß der Schrauben messen.
6 Hinweis: Das max. Vorstehmaß von 18 mm darf

nicht überschritten werden.
34244 ©
159. Zahnwelle des Hydraulikpumpenantriebes mit
4 u Grafittett DEUTZ G 500 einfetten. Hydraulik-

pumpe anbauen.
4
34245 ©
© 2001 / 0297 9959 4.00.62

156. Bring in cover the toothing of 156. Faire chevaucher l’endentement 156 Hacer coincidir el dentado de
the collars with the toothing of the des manchettes et celui de la douille los manguitos con el dentado del
coupling sleeve. d’accouplement. casquillo de acoplamiento.
157. Grease the tooth shaft with graphite 157. Enduire l’arbre denté de graisse 157. Lubricar con grasa grafitada G 500
grease G 500. Push the coupling graphitique G 500. Emmancher la el eje dentado o estriado. Colocar el
sleeve onto the tooth shaft. douille d’accouplement sur l’arbre casquillo de acoplamiento sobre el
denté. eje estriado.
158. Fit in the screws with washers and 158. Insérer les vis avec rondelles et 158. Meter los tornillos con arandelas
measure the foregoing dimension of mesurer le dépassement des vis. y medir la medida por la que
the screws. sobresalen.
Note: The max. dimension of 18 mm may Nota: Le dépassement maximum ne Nota: Los tornillos no deben salir por
not be exceeded. doit pas excéder 18 mm. más de 18 mm.
159. Grease the tooth shaft of the 159. Enduire l’arbre denté de l’entraîne- 159. Untar con grasa grafitada
hydraulic pump drive with graphite ment de pompe hydraulique de DEUTZ G 500 el eje estriado
grease DEUTZ G 500. Attach the graisse graphitique G 500. Monter del accionamiento de la bomba 4
hydraulic pump. la pompe hydraulique. hidráulica. Montar la bomba
hidráulica.
4.00.62 © 2001 / 0297 9959

V belt pulley / idler pulley / V belt Poulie à gorges / galet tendeur / Polea acanalada / polea tensora /
courroie trapézoïdale correa trapezoidal
161. Put on the centrifuge disk. 161. Monter le disque protecteur. 161. Colocar el disco centrífugo.
162. Fit V-belt pulley. Tighten bolts. 162. Monter la poulie à gorge. Serrer les 162. Montar la polea para correa
vis. trapezoidal. Apretar los tornillos
163. Fit V-belt idler pulley. 163. Monter le galet tendeur 163. Montar la polea tensora
de courroie. correspondiente.
4
Note: Start bolts. Nota: Serrer légèrement les vis. Nota: Apretar los tornillos ligeramente.
© 2001 / 0297 9959 4.00.63

4
6
34246 ©
Keilriemenscheibe / Spannrolle / Keilriemen
161. Schleuderscheibe aufsetzen.

4
8
34247 ©

drehen. 4
6
34248 ©
163. Keilriemenspannrolle anbauen.
Hinweis: Schrauben leicht festdrehen.

4 4
5
34249 ©
4.00.63 © 2001 / 0297 9959


4
34250 ©

s
6
34251 ©
166. Keilriemenspannung mit Spannungsmess-

6 gerät 8115 prüfen.
Kontrollwert nach
Wenn der Sollwert nicht erreicht wird, Spann-

vorgang wiederholen.
34252 ©
© 2001 / 0297 9959 4.00.64

164. Position V-belt. 164. Mettre en place la courroie 164. Colocar la correa trapezoidal.
trapézoïdale.
165. Tension V-belt. Tighten bolts. 165. Tendre la courroie. Serrer les vis. 165. Tensar la correa trapezoidal. Apretar
los tornillos.
166. Check V-belt tension with tension 166. Vérifier la tension de courroie à 166. Verificar la tensión de la correa
gauge 8115. l’aide de l’appareil de mesure de trapezoidal mediante el verificador
tension 8115. de tensión 8115.
Initial assembly: 450 ± 50 N Premier montage: 450 ± 50 Nm Primer montaje: 450 ± 50 N

Check value after Valeur de contrôle après Valor de control tras una
15 min. operation 15 mn de marche marcha de 15 minutos
under load: 300 ± 20 N sous charge: 300 ± 20 Nm bajo carga: 300 ± 20 N
If specified scale reading is not Si la valeur de consigne n’est pas Si no se alcanza el valor teórico,
attained, repeat procedure. atteinte, recommencer l’opération repetir la operación de tensado.
de tension.
4.00.64 © 2001 / 0297 9959

Oil suction pipe / Tuyau d’aspiration d’huile / Tubo de aspiración de aceite /

oil trough carter d’huile cárter de aceite
Rotate the motor by 180°. Tourner le moteur de 180°. Girar el motor 180°.
167. Apply the sealant DEUTZ DW 74 for 167. Appliquer la pâte d’étanchéité 167. Aplicar al bloque motor pasta
the oil suction pipe and the oil trough DEUTZ DW 74 pour le tuyau sellante DEUTZ DW 74 para el
to the crankcase with integrated d’aspiration d’huile et le carter montaje del tubo de aspiración
cylinder liners. d’huile sur le bloc-cylindres. de aceite y cárter de aceite.
Note: Make sure that no sealing Nota: Veiller à ce que la pâte Nota: Cuidar de que no llegue
compound penetrates into the d’étanchéité ne s’écoule pas pasta sellante alguna al interior
oil suction pipe. dans le canal d’huile. del conducto de aceite.
168. Attach the oil suction pipe. Firmly 168. Monter le tube d’aspiration d’huile. 168. Montar el tubo de aspiración de
tighten the screws. Serrer les vis. aceite. Apretar los tornillos.
169. Mount on the oil trough. Pretension 169. Monter le carter d’huile. Préserrer 169. Montar el cárter de aceite. Apretar
the corner screws “X” with 0,5 Nm les vis des coins « X » à 0,5 Nm cada uno de los tornillos de esquina
in each case. Firmly tighten all respectivement. Serrer définitive- “X” con 0,5 Nm iniciales. Apretar
screws according to the tightening ment toutes les vis dans l’ordre de todos los tornillos siguiendo el
sequence, see sketches. serrage selon croquis. orden establecido para su apriete,
ver croquis.
169.1 Tightening sequence 4-cylinder 169.1 Ordre de serrage moteurs à 4 169.1 Orden de apriete motor de 4
cylindres cilindros
4
Sheet metal oil pan Carter d’huile en tôle Cárter de aceite de chapa
Bolts M 8 x 16 mm -8.8 21 Nm Vis M 8 x 16 mm 21 Nm Tornillos M 8 x 16 mm 21 Nm
Cast oil pan Carter d’huile en fonte Cárter de aceite de fundición

© 2001 / 0297 9959 4.00.65

Ölansaugrohr / Ölwanne
Motor um 180° drehen.
4
167. Dichtungsmasse DEUTZ DW 74 für Ölansaug-
rohr und Ölwanne auf Zylinderkurbelgehäuse w
auftragen.
Hinweis: Darauf achten, dass keine Dichtungs-

5
masse in den Ölkanal fließt.
34253 ©
168. Ölansaugrohr anbauen. Schrauben festdrehen.
4
6
34254 ©
169. Ölwanne anbauen. Eckschrauben „X“ jeweils

mit 0,5 Nm vorspannen. Alle Schrauben nach
Anziehreihenfolge, siehe Skizzen, festdrehen.
4
6
34255 ©
169.1 Anziehreihenfolge 4-Zylinder
Anziehvorschrift:
4 4
Blechölwanne
6
Schrauben M 8 x 16 mm 21 Nm
Gussölwanne
34256 ©
4.00.65 © 2001 / 0297 9959


4 Gussölwanne mit Zylinderkopfschrauben
6 Anziehvorschrift:
Gussölwanne mit Zylinderkopfschrauben

Zylinderkopfschrauben 180 Nm
34257 ©

4 Anziehvorschrift:
6 Blechölwanne
34258 ©

4 Anziehvorschrift:
6 Blechölwanne
34259 ©
170. Ölablassschraube mit neuem Cu-Dichtring
4 4 einschrauben und festdrehen.
ß Anziehvorschrift: 55 ± 5 Nm
34260 ©
© 2001 / 0297 9959 4.00.66

169.2 Tightening sequence 169.2 Ordre de serrage moteurs à 169.2 Orden de apriete motor de
4-cylinder 4 cylindres 4 cilindros
Casting oil pan with cylinder Carter d’huile en fonte avec vis Cárter de aceite de fundición
head bolts à tête cylindrique con tornillos de cabeza cilíndrica
Casting oil pan with Carter d’huile en fonte avec vis à Cárter de aceite de fundición con
cylinder head bolts tête cylindrique tornillos de cabeza cilíndrica
Cylinder head bolts 180 Nm Vis à tête cylindrique 180 Nm Tornillos de cabeza cilíndrica 180 Nm
170. Screw oil drain plug back in with 170. Revisser le bouchon de vidange 170. Enroscar el tornillo de salida de
new Cu seal and tighten. d’huile avec un joint de cuivre neuf aceite provisto de una junta anular
et le serrer. de cobre nueva y apretarlo. 4
4.00.66 © 2001 / 0297 9959

171. In case of motors with a connection 171. Sur les moteurs avec carter 171 En motores con cárter de
housing, mount on a cover plate. d’adaptation, monter la tôle adaptación. Montar la chapa de
Tighten bolts. d’habillage. Serrer les vis. recubrimiento. Apretar los tornillos.
Oil measuring stick Jauge d’huile Varilla medidora de nivel de aceite

Rotate the motor by 180°. Tourner le moteur de 180°. Girar el motor 180°.
172. Fit new O-seal. 172. Emmancher un joint torique neuf. 172. Colocar un anillo tórico nuevo sobre
la varilla.
173. Press in oil dipstick as far as it will 173. Introduire la jauge d’huile jusqu’en 173. Introducir la varilla medidora hasta
go. butée. el tope.
Starter Démarreur Arrancador

Remove engine from assembly stand Démonter le moteur du chevalet de Desmontar el motor del caballete de
4 and angled clamping plate. montage et du support de fixation. montaje y soporte de fijación.
174. Mount starter 174. Monter le démarreur. 174. Montar el arrancador.

Tighten bolts. Serrer les vis. Apretar los tornillos.
© 2001 / 0297 9959 4.00.67

171. Bei Motoren mit Anschlussgehäuse,

Abdeckblech anbauen. Schrauben festdrehen.
4
6
34261 ©
Ölmessstab
Motor um 180° drehen. 6
172. Neuen Runddichtring aufziehen.
s
34262 ©
173. Ölmessstab bis Anschlag eindrücken.

4
34263 ©
Starter
Motor von Montagebock und Aufspannhalter ab-
bauen.
4 4
174. Starter anbauen. Schrauben festdrehen. 6
34264 ©
4.00.67 © 2001 / 0297 9959

175. Ladeleitung an Starter anbauen und verschel-

4 len. Sechskantmutter festdrehen.
6 Anziehvorschrift: max. 15 Nm
34265 ©
Ölrücklaufrohr (bei BF-Motoren)

4 176. Einschraubstutzen mit neuem Cu-Dichtring
ß einschrauben und festdrehen. Neuen Rund-

dichtring aufziehen.
34266 ©
177. Ölrücklaufrohr mit neuem Runddichtring an-

4 bauen. Halteblech anbauen und Schraube
festdrehen.
ß Anziehvorschrift: 8,5 Nm
34267 ©
© 2001 / 0297 9959 4.00.68

175. Mount on and load the induction 175. Monter le câble de charge sur le 175. Unir el cable de carga al arrancador
system at the starter. Firmly tighten démarreur et le fixer par colliers. y fijarlo con grapas. Apretar la tuerca
the hex nut. Serrer l’écrou hexagonal. hexagonal.
Tightening specification: 15 Nm max. Prescription de serrage: 15 Nm maxi Prescripción de apriete: máx. 15 Nm
Return pipe Conduite de retour d’huile Tubo de retorno de aceite

(with BF motors) (sur moteurs BF) (en los motores BF)
176. Fit in the threaded connections 176. Visser la tubulure avec un joint 176. Enroscar el racor de rosca exterior
with new Cu-sealing ring and tighten de cuivre neuf et serrer. Monter provisto de una junta anular de
firmly. Attach a new O-ring type un joint torique neuf. cobre nueva y apretarlo. Colocar un
sealing ring. anillo tórico nuevo.
177. Attach an oil return pipe with a new 177. Monter la conduite de retour d’huile 177. Montar el tubo de retorno de aceite
O-ring type sealing ring. Mount on a avec un joint torique neuf. Monter la con un anillo tórico nuevo. Montar la
locking plate and tighten the screw tôle de retenue et serrer la vis. chapa de soporte y apretar el
firmly. tornillo.
4.00.68 © 2001 / 0297 9959

Exchanging the shaft seal rings at Remplacement des joints d’arbre sur Sustitución de los retenes en el motor
the entire engine moteur complet completo
Special tools required: Outillage spécial Herramientas especiales
Puller for shaft seals __________ 142 710 Extracteur de joints d’arbre _____ 142 710 Extractor para retenes ________ 142 710
Assembly tools front __________ 142 050 Outil de montage avant ________ 142 050 Herramienta de montaje delante _ 142 050
Assembly tools rear __________ 142 690 Outil de montage arrière _______ 142 690 Herramienta de montaje atrás __ 142 690
Assembly tools rear __________ 142 860 Outil de montage arrière _______ 142 860 Herramienta de montaje atrás __ 142 860
- Cover flywheel end - - Couvercle côté volant – - Tapa, lado de volante -
Flywheel has been removed. Le volant est démonté. El volante está desmontado.
1. Remove shaft seal 1. Démontage du joint d’arbre 1. Desmontaje del retén
1.1 Press angle hook into shaft seal. 1.1 Presser le crochet d’extraction dans 1.1 Introducir a presión el gancho
le joint d’arbre. extractor en el retén.
1.2 Pull the shaft seal ring with a 1.2 Extraire le joint d’arbre du couvercle 1.2 Sirviéndose del extractor, quitar el
withdrawal device out of the cover. à l’aide de l’extracteur. retén de la tapa.
Check visually the contact surface of Soumettre la surface de roulement Inspeccionar la superficie de
the shaft seal ring on the crankshaft. du joint d’arbre sur le vilebrequin à contacto del retén en el cigüeñal.
un examen visuel.
Note: If the contact surface does not Nota: Si la surface de roulement ne Nota: Si la superficie de contacto todavía
yet have a lead-in spiral, a new présente pas de rainure de no presenta una huella de roce,
shaft seal ring can be built in. roulement, il peut être monté se puede montar un retén nuevo.
If a lead-in spiral is available, un joint d’arbre neuf. Si existe una huella de roce,
a new shaft seal ring must be En présence d’une rainure de hay que montar un retén nuevo
built in with a rotating ring. roulement, il faut monter un con anillo de roce.
joint d’arbre neuf avec bague
de roulement.
2. Fit new shaft seal 2. Montage du joint d’arbre neuf 2. Montaje del retén nuevo
4 2.1 Fit new shaft seal with assembly 2.1 Monter le joint d’arbre neuf non huilé 2.1 Montar el retén nuevo sin aceite
tool without using oil. Sealing lip avec le dispositif de montage. La mediante el dispositivo de montaje.
points towards crankshaft. lèvre d’étanchéité étant orientée vers El labio de obturación debe indicar
le vilebrequin. hacia el cigüeñal.
© 2001 / 0297 9959 4.00.69

Austausch der Wellendichtringe am

kompletten Motor
Spezialwerkzeug
Ausziehvorrichtung für
Wellendichtringe ____________________ 142 710
Montagewerkzeug vorn _______________ 142 050
Montagewerkzeug hinten _____________ 142 690
Montagewerkzeug hinten _____________ 142 860
- Deckel Schwungradseite -
Schwungrad ist abgebaut.

4
1. Wellendichtring ausbauen 7
1.1 Abziehhaken in den Wellendichtring eindrücken.
34268 ©
1.2 Wellendichtring mit Ausziehvorrichtung aus dem

Deckel herausziehen.
Lauffläche des Wellendichtringes auf der Kur-
3
belwelle sichtprüfen.
7
Hinweis: Hat die Lauffläche noch keine Einlauf-
rille kann ein neuer Wellendichtring ein- 9
gebaut werden.
Ist eine Einlaufrille vorhanden muss ein
neuer Wellendichtring mit Laufring einge-
5
baut werden.
34269 ©
2. Neuen Wellendichtring montieren
2.1 Neuen Wellendichtring ungeölt mit Montage-

4 4
vorrichtung montieren. Die Dichtlippe weist zur
Kurbelwelle.
ß
8
7
34270 ©
4.00.69 © 2001 / 0297 9959

3. Neuen Wellendichtring mit Laufring mon-

9 tieren
3.1 Einbaumaße des Wellendichtring-Satzes
34271 ©
3.2 Führung an Kurbelwelle anbauen. Schrauben

4 leicht andrehen.
34272 ©
3.3 Neuen Wellendichtring gemeinsam mit Laufring

4 in die Zentrierung der Montagehülse einsetzen.
ß Hinweis: Außen-Ø des Wellendichtringes und

Innen-Ø des Laufringes leicht ölen.
8
7
34273 © 5
3.4 Wellendichtring-Satz mit Montagehülse über
4 4 die Führung schieben.
34274 ©
© 2001 / 0297 9959 4.00.70

3. Mount a new shaft seal ring with 3. Montage du joint d’arbre neuf avec 3. Montaje del retén nuevo con
a rotating ring bague de roulement anillo de roce (juego de retén)
3.1 Fitting dimension of the shaft seal 3.1 Cotes de montage du jeu de joints 3.1 Medidas de montaje del juego de
ring set d’arbre. retén
Wellendichtring = shaft seal ring Wellendichtring: Joint d’arbre ; Wellendichtring = retén

Laufring = rotating ring Laufring: Bague de roulement Laufring = anillo de roce
3.2 Attach the guide at the crankshaft. 3.2 Monter le guidage sur le vilebrequin. 3.2 Montar el dispositivo de guía en
Turn the screws slightly. Serrer légèrement les vis. el cigüeñal. Apretar los tornillos
ligeramente.
3.3 Insert a new shaft seal ring together 3.3 Insérer le joint d’arbre neuf ensemble 3.3 Introducir el retén nuevo con el
with a rotating ring into the centering avec la bague de roulement dans le anillo de roce en el centraje del
of the mounting sleeve. centrage de la douille de montage. casquillo de montaje.
Note: Lubricate slightly the outer Ø of Nota: Huiler légèrement le diamètre Nota: Untar con un poco de aceite
the shaft seal ring and inner Ø of extérieur du joint d’arbre et le el diámetro exterior del retén y
the rotating ring. diamètre intérieur de la bague el diámetro interior del anillo
de roulement. de roce.
3.4 Insert the shaft seal ring set with the 3.4 Pousser le jeu de joints d’arbre avec 3.4 Colocar el juego de retén con
mounting sleeve over the guide. la douille de montage par-dessus le el casquillo de montaje sobre el
guidage. dispositivo de guía. 4
4.00.70 © 2001 / 0297 9959

3.5 Push in the mounting sleeve up to 3.5 Enfoncer la douille de montage 3.5 Introducir a presión el casquillo
the unit. The shaft seal ring and jusqu’en butée. de montaje hasta el tope.
the rotating ring are then in their Le joint d’arbre et la bague de El retén y anillo de roce quedan
correct position. roulement sont alors dans leur posicionados correctamente.
position correcte.
© 2001 / 0297 9959 4.00.71

3.5 Montagehülse bis zur Anlage eindrücken.

Wellendichtring und Laufring sind dann in ihrer
richtigen Position.
4
9
34275 ©
4.00.71 © 2001 / 0297 9959

- Vorderer Deckel -
4 Zahnriemenschutzgehäuse, Nockenwellen- und
7 Kurbelwellenzahnrad sind abgebaut.

Nach der Montage der Wellendichtringe ist die
Grundeinstellung „Nockenwelle zur Kurbelwelle“
durchzuführen. (siehe Seite 4.00.27)
1. Wellendichtringe ausbauen
1.1 Abziehhaken in den Wellendichtring

34276 © -Nockenwelle-
-Kurbelwelle eindrücken-
4
7
34277 ©
1.2 Wellendichtring für Nockenwelle-

3
7
9
34278 ©
-und Kurbelwelle mit Ausziehvorrichtung her-
4 3 ausziehen.
Lauffläche der Wellendichtringe sichtprüfen.
7 Hinweis: Hat die Lauffläche auf der Kurbelwelle
9
noch keine Einlaufrille kann ein neuer
Wellendichtring eingebaut werden.
Ist eine Einlaufrille vorhanden muss ein
5 neuer Wellendichtring mit Laufring ein-
gebaut werden.
34279 ©
© 2001 / 0297 9959 4.00.72

- Front cover - - Couvercle avant – - Tapa delantera -

Toothed belt guard/camshaft and crank- La protection de courroie dentée, les Están desmontadas la caja protectora de
shaft gears have been removed. pignons d’arbre à cames et de vilebrequin la correa dentada y las ruedas dentadas
After having fitted shaft seals basic setting sont démontés. del árbol de levas y del cigüeñal.
of “camshaft relative to crankshaft” has to Après le montage des joints d’arbre, Terminado el montaje de los retenes,
be carried out. (See page 4.00.27) procéder au réglage de base « Arbre à hay que realizar el ajuste básico “árbol
cames par rapport au vilebrequin ». de levas con respecto al cigüeñal”.
(voir page 4.00.27) (Ver pág. 4.00.27)
1. Remove shaft seals 1. Démontage des joints d’arbre 1. Desmontaje de los retenes
1. Press angle hook into seal of 1.1 Enfoncer le crochet d’extraction dans 1.1 Introducir a presión el
- camshaft - le joint d’arbre gancho extractor en el retén
- d’arbre à cames – - árbol de levas -
- crankshaft -. - de vilebrequin – - cigüeñal -
1.2 Withdraw the shaft seal ring for 1.2 Extraire le joint d’arbre à cames 1.2 Sirviéndose del extractor, quitar
the cam shaft el retén
- para el árbol de levas -
- and the crankshaft with the aid of a et de vilebrequin avec l’extracteur. - para el cigüeñal.
withdrawal device. Soumettre la surface de roulement Examinar visualmente la superficie
- Check visually the contact surface of des joints d’arbre sur le vilebrequin de contacto de los retenes.
the shaft seal rings on the crankshaft. à un examen visuel.
4
Note: If the contact surface does not Nota: Si la surface de roulement sur Nota: Si la superficie de contacto del
yet have a lead-in spiral on the le vilebrequin ne présente pas cigüeñal todavía no presenta
crankshaft, a new shaft seal ring encore de rainure de roulement, una huella de roce, se puede
can be built in. il peut être monté un joint montar un retén nuevo.
If a lead-in spiral is available, a d’arbre neuf. Si existe una huella de roce,
new shaft seal ring must be built En présence d’une rainure de hay que montar un retén nuevo
in with a rotating ring. roulement, il faut monter un con anillo de roce.
joint d’arbre neuf avec bague
de roulement.
4.00.72 © 2001 / 0297 9959

2. Fit in new shaft seal rings 2. Montage des joints d’arbre neufs 2. Montaje de los retenes nuevos
2.1 Fit new seal for camshaft with 2.1 Monter le joint d’arbre neuf non huilé 2.1 Montar el retén nuevo sin aceite
assembly tool without using oil. pour l’arbre à cames avec le dispositif para el árbol de levas mediante el
Sealing lip points towards camshaft. de montage. La lèvre d’étanchéité dispositivo de montaje. El labio
étant orientée vers l’arbre à cames. de obturación debe indicar hacia
el árbol de levas.
2.2. Fit new seal for crankshaft with 2.2 Monter le joint d’arbre neuf non huilé 2.2 Montar el retén nuevo sin aceite para
assembly tool without using oil. pour le vilebrequin avec le dispositif el cigüeñal mediante el dispositivo de
Sealing lip points towards crankshaft. de montage. La lèvre d’étanchéité montaje. El labio de obturación debe
étant orientée vers le vilebrequin. indicar hacia el cigüeñal.
3. Mount on a new shaft seal ring 3. Montage du joint d’arbre neuf 3. Montaje del retén nuevo con anillo
with a rotating ring for the avec bague de roulement pour le de roce para el cigüeñal
crankshaft vilebrequin
3.1 Fitting dimension of the shaft seal 3.1 Cotes de montage du jeu de joints 3.1 Medidas de montaje del juego de
ring set d’arbres. retén
Wellendichtring = shaft seal ring Wellendichtring: Joint d’arbre; Wellendichtring = retén

Laufring = rotating ring Laufring: Bague de roulement) Laufring = anillo de roce
3.2 Place a guide onto the crankshaft. 3.2 Monter le guidage sur le vilebrequin. 3.2 Colocar el dispositivo de guía sobre
el cigüeñal.
4
© 2001 / 0297 9959 4.00.73

2. Neue Wellendichtringe montieren
2.1 Neuen Wellendichtring für Nockenwelle ungeölt

4
mit Montagevorrichtung montieren. Die Dicht-
lippe weist zur Nockenwelle. ß
8
7
34280 ©
2.2 Neuen Wellendichtring für Kurbelwelle ungeölt

mit Montagevorrichtung montieren. Die Dicht-
lippe weist zur Kurbelwelle.
4
ß
8
7
34281 ©
3. Neuen Wellendichtring mit Laufring für

Kurbelwelle montieren 9
3.1 Einbaumaße des Wellendichtring-Satzes
34282 ©
3.2 Führung auf Kurbelwelle aufsetzen.

4 4
7
34283 ©
4.00.73 © 2001 / 0297 9959

3.3 Neuen Wellendichtring gemeinsam mit Laufring

4 in die Zentrierung der Montagehülse einsetzen.
ß HInweis: Außen-Ø des Wellendichtringes und

Innen-Ø des Laufringes leicht ölen.
8
7
34284 © 5
3.4 Wellendichtring-Satz mit Montagehülse über
4 die Führung schieben.
34285 ©
3.5 Montagehülse bis zur Anlage eindrücken.

4 Wellendichtring und Laufring sind dann in ihrer
richtigen Position.
9
34286 ©
© 2001 / 0297 9959 4.00.74

3.3 Insert a new shaft seal ring together 3.3 Insérer le joint d’arbre neuf ensemble 3.3 Introducir el retén nuevo junto
with a rotating ring into the centering avec la bague de roulement dans le con el anillo de roce en el centraje
of the mounting sleeve. centrage de la douille de montage del casquillo de montaje.
Note: Lubricate slightly the outer Ø of Nota: Huiler légèrement le diamètre Nota: Untar con un poco de aceite
the shaft seal ring and inner Ø of extérieur du joint d’arbre et le el diámetro exterior del retén y
the rotating ring. diamètre intérieur de la bague el diámetro interior del anillo
de roulement. de roce.
3.4 Insert the shaft seal ring set with the 3.4 Pousser le jeu de joints d’arbre avec 3.4 Colocar el juego de retén con
mounting sleeve over the guide. la douille de montage par-dessus le el casquillo de montaje sobre el
guidage. dispositivo de guía.
3.5 Push in the mounting sleeve 3.5 Enfoncer la douille de montage 3.5 Introducir a presión el casquillo
up to the unit. jusqu’en butée. de montaje hasta el tope.
The shaft seal ring and the rotating Le joint d’arbre et la bague de El retén y anillo de roce quedan
ring are then in their correct position. roulement sont alors dans leur posicionados correctamente.
position correcte.
4.00.74 © 2001 / 0297 9959

Different fan drive attachments Différentes variantes de montage de Diversos montajes del accionamiento
ventilateur del ventilador
1. High-built fan drive 1. Entraînement de ventilateur 1. Accionamiento elevado del

(aggregate design) surhaussé (version de groupe ventilador (versión para grupos
électrogène) electrógenos)

V-belt tension Appareil de mesure de tension de courroie Verificador de tensión
measuring instrument ___________ 8115 trapézoïdale __________________ 8115 de correas trapezoidales _________ 8115
1.1 Mount on the console (1), 1.1 Monter la console (1), l’entraînement 1.1 Montar la consola (1), el accionamiento
fan drive (2), generator (3) and de ventilateur (2), l’alternateur (3) et del ventilador (2), el alternador (3) y
guard plates (4). les tôles de protection (4). las chapas protectoras (4).

specification: a = 34 Nm de serrage: a = 34 Nm de apriete: a = 34 Nm
b = Pretension 30 Nm b = préserrage 30 Nm b = apriete inicial 30 Nm
Restress angle de serrage reapriete 49°
angle plate 49° définitif 49° c = apriete inicial 30 Nm
c = Pretension 30 Nm c = préserrage 30 Nm reapriete 120°
Restress angle de serrage
angle plate 120° définitif 120°
1.3 Place and tighten the V-belt. Firmly 1.3 Poser et tendre la courroie. 1.3 Colocar la correa trapezoidal y
tighten the screws. Serrer les vis. tensarla. Apretar los tornillos.

specification: d = 22 Nm de serrage: d = 22 Nm de apriete: d = 22 Nm
e = 22 Nm e = 22 Nm e = 22 Nm
f = 34 Nm f = 34 Nm f = 34 Nm
Check the V-belt tensioning with a Contrôler la tension des courroies Controlar la tensión de la correa
stress measuring instrument 8115. trapézoïdales avec l’appareil de trapezoidal mediante el verificador
mesure de tension de courroie 8115. de tensión 8115.
Initial assembly: 450 ± 50 Nm Premier montage: 450 ± 50 Nm Primer montaje: 450 ± 50 N

Control value after Valeur de contrôle après Valor de control tras una
after 15 minutes 15 mn de marche s marcha de 15 minutos
running on load: 300 ± 20 Nm ous charge: 300 ± 20 Nm bajo carga: 300 ± 20 N
4
If the set value is not reached, Si la valeur de consigne n’est pas Si no se alcanza el valor teórico,
repeat the tightening operation. atteinte, recommencer l’opération repetir la operación de tensado.
de tension.
© 2001 / 0297 9959 4.00.75

Verschiedene Lüfterantriebanbauten
1. Hochgebauter Lüfterantrib (Aggregateaus-

4
führung)
1.1 Konsole (1), Lüfterantrieb (2), Generator (3)

und Schutzbleche (4) anbauen.
34287 ©
Anziehvorschrift: a = 34 Nm
4
b = Vorspannen 30 Nm
Nachspannwinel 49° 6
c = Vorspannen 30 Nm
34288 ©
1.3 Keilriemen auflegen und spannen. Schrauben

festdrehen.
Anziehvorschrift: d = 22 Nm
4
e = 22 Nm
f = 34 Nm s
Keilriemenspannung mit Spannungsmessgerät 6
8115 prüfen.
Kontrollwert nach
15 Minuten Lauf unter Last: 300 ± 20 N 34289 ©

4.00.75 © 2001 / 0297 9959

2. Hochgebauter Lüfterantrieb (Baumaschinen-

4 ausführung)
2.1 Konsole (1), Lüfterantrieb (2) und Generator (3)

anbauen.
34290 ©

4 Anziehvorschrift: a = 30 Nm
6 b = Vorspannen 30 Nm
34291 ©
2.3 Keilriemen auflegen und spannen. Schrauben

4 festdrehen.
Anziehvorschrift: c = 21 Nm
s d = 30 Nm
6 Keilriemenspannung mit Spannungsmessgerät

8115 prüfen.
Kontrollwert nach
34292 © 15 Minuten Lauf unter Last: 300 ± 20 N

© 2001 / 0297 9959 4.00.76

2. High-built fan drive 2. Entraînement de ventilateur 2. Accionamiento elevado del

(construction machine design) surhaussé (version matériel de BTP) ventilador (versión para máquinas
de construcción)

V-belt tension Appareil de mesure de tension de courroie Verificador de tensión
measuring instrument ___________ 8115 trapézoïdale __________________ 8115 de correas trapezoidales _________ 8115
2.1 Mount on the console (1), fan drive 2.1 Monter la console (1), l’entraînement 2.1 Montar la consola (1), el accionamiento
(2) and generator (3). de ventilateur (2) et l’alternateur (3). del ventilador (2) y el alternador (3).

specification: a = 30 Nm de serrage: a = 30 Nm de apriete: a = 30 Nm
b = Pretension 30 Nm b = préserrage 30 Nm b = apriete inicial 30 Nm
Restress angle de serrage reapriete 120°
angle plate 120° définitif 120°
2.3 Place and tighten the V-belt. Firmly 2.3 Poser et tendre la courroie. 2.3 Colocar la correa trapezoidal y
tighten the screws. Serrer les vis. tensarla. Apretar los tornillos.

specification: c = 21 Nm de serrage: c = 21 Nm de apriete: c = 21 Nm
d = 30 Nm d = 30 Nm d = 30 Nm
Check the V-belt tensioning with a Contrôler la tension de courroie Controlar la tensión de la correa
stress measuring instrument 8115. trapézoïdale avec l’appareil de trapezoidal mediante el verificador
mesure de tension de courroie 8115. de tensión 8115.
Initial assembly: 450 ± 50 Nm Premier montage: 450 ± 50 Nm Primer montaje: 450 ± 50 N

Control value after Valeur de contrôle après Valor de control tras una
after 15 minutes 15 mn de marche marcha de 15 minutos
running on load: 300 ± 20 Nm sous charge: 300 ± 20 Nm bajo carga: 300 ± 20 N
If the set value is not reached, Si la valeur de consigne n’est pas Si no se alcanza el valor teórico, 4
repeat the tightening operation. atteinte, recommencer l’opération repetir la operación de tensado.
de tension.
4.00.76 © 2001 / 0297 9959

© 2001 / 0297 9959

Werkzeuge
Tools
Outils
Herramientas 2011
© 2001 / 0297 9959

Wir bitten Sie, alle Bestellungen von Spezialwerkzeugen direkt an die
Fa. Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92,
zu richten.
Please order all your special tools direct from

Messr.Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92
Nous vous prions de passer directement toutes vos commandes

d’outillage spécial auprès de la société:
Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92
Rogamos dirigir todos los pedidos de herramientas especiales directamente

a la casa Wilbär, D-42826 Remscheid, Postfach 14 05 80, Fax 02191 / 8 10 92
Commercial tools
Outils usuels
Deutsch English Français Español No. Werkstatthandbuch 2011
Kompressionsdruckprüfer 8005
Compression tester
Compressiomètre
Compresímetro
Düsenprüfgerät 8008
Nozzle tester
Banc d’essais d’injecteurs
Comprobador para inyectores
Klemmenzange 8011
Clip pliers
Pince pour colliers
Alicates para abrazaderas
Klauenschlüssel 8018
Claw key
Clé à griffes
Llave de garra
5.00.01 © 2001 / 0297 9959

5
Commercial tools
Outils usuels
Werkstatthandbuch 2011 No. Deutsch English Français Español
8021 Lange Stecknuss SW 15
Long socket a/flats 15
Clé à douille longue de 15
Llave de vaso largo de 15
8024 Ventilschaftdichtungszange
Valve stem gasket pliers
Pince à joint de tige de soupape
Alicates para juntas de vástago de válvula
8036 Stecknuss SW 32
Socket a/flats 32
Clé à douille de 32
Llave de vaso de 32
8049 Kraftvervielfältiger für Zentralschraube
Multipower tool for central bolt
Multiplicateur de force pour vis centrale
Multiplicador de fuerza para tornillo central
© 2001 / 0297 9959 5.00.02

5
Commercial tools
Outils usuels
Schraubendrehereinsatz 1/2" SW 17 8112
Screw driver socket 1/2" a/flats 17
Embout tournevis 1/2" de 17
Punta de destornillador 1/2" de 17
Keilriemenspannungsmessgerät 8115
V-belt tension gauge
Appareil de mesure de la tension de courroie
Verificador de tensión de correas trapezoidales
Torx-Werkzeugsatz 8189
Torx tool kit
Jeu d’outils Torx
Juego de herramientas Torx
Ventilfedermontagehebel 9017
Valve spring assembly lever
Levier de montage pour ressorts de soupape
Palanca de montaje para resortes de válvula
5.00.03 © 2001 / 0297 9959

5
Commercial tools
Outils usuels
9088 Schlauchklemmenzange
Hose clip pliers
Pince à tuyaux flexibles
Alicates para abrazaderas de mangueras
9090 Federklemmenzange
Spring clamp pliers
Pince à ressorts
Alicates para abrazaderas de resorte
9120 Torx Spezial- Bit 70 mm lang
Torx special bit 70 mm long
Embout de tournevis spécial Torx 70 mm de long
Bit especial Torx de 70 mm de longitud
9122 Torx Spezial- Bit 25 mm lang
Torx special bit 25 mm long
Embout de tournevis spécial Torx 25 mm de long
Bit especial Torx de 25 mm de longitud
© 2001 / 0297 9959 5.00.04

5
Spezialwerkzeuge
Special tools
Outils spéciaux
Anschlussstück für Kompressionsdruckprüfer 100 120
Adapter for compression tester
Raccord pour compressiomètre
Pieza de empalme para el compresímetro
Einstellbolzen für Kurbel- und Nockenwelle 100 700
Adjusting pin for crankshaft and camshaft
Pige de calage pour vilebrequin et arbre à cames
Pernos de ajuste para el cigüeñal y árbol de levas
Einstellbolzen für Einspritzpumpenregelstange 100 710
Adjusting pin for injection pump control rod
Pige de calage pour crémaillère de pompe

d’injection
Perno de ajuste para la barra cremallera de la

bomba de inyección
Messgerät mit Abstandsscheiben für Kolben- 100 750

überstand und vorderen Deckel
Gauge with spacers for piston projection and front

cover
Appareil de mesure du retrait de piston et

couvercle avant avec rondelles d’écartement
Dispositivo de medición con arandelas distancia-

doras para saliente de pistón y tapa delantera
©
5.00.05 © 2001 / 0297 9959

5
Spezialwerkzeuge
Special tools
Outils spéciaux
100 880 Arretierungsdraht für Anlenkhebel Einspritz-

pumpe
Locking wire for control lever, injection pump
Fil d’arrêt pour levier articulé de pompe d’injection
Alambre de sujeción para la palanca arti-

culada, bomba de inyección
103 020 Prüfschablone für E.P.-Dichtung
Test template for I.P. gasket
Gabarit de contrôle pour joint de pompe d’injection
Plantilla para comprobar juntas de b.i.
110 110 Halter für Einspritzventil
Retainer for injector
Dispositif d’immobilisation pour injecteur
Retenedor para inyector
110 140 Montagewerkzeug für Regelstangenbuchse
Assembly tool for control rod bush
Outil de montage pour douille de crémaillère
Herramienta de montaje para manguitos de

cremallera
© 2001 / 0297 9959 5.00.06

5
Spezialwerkzeuge
Special tools
Outils spéciaux
Aufspannbock für Zylinderkopf 120 900
Clamping stand for cylinder heads
Chevalet d’ablocage pour culasse
Soporte de fijación para culatas
Aufspannplatte für No 120 900 120 910
Clamping plate for 120 900
Plaque d’ablocage pour no. 120 900
Placa de fijación para 120 900
Montagewerkzeug für Ventilschaftdichtung 121 410
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
Util de montaje para juntas de vástago de válvula
Universal-Kolbenring-Auflegezange 130 300
Universal piston ring pliers
Pince universelle à monter les segments de piston
Alicates universales para montar aros de pistón
5.00.07 © 2001 / 0297 9959

5
Spezialwerkzeuge
Special tools
Outils spéciaux
130 420 Trapeznut - Verschleißlehre
Trapezoidal groove wear gauge
Jauge d'usure pour gorge trapézoïdale
Calibre de desgaste para ranuras trapezoidales
130 630 Kolbenringspannband
Piston ring compressor
Collier à comprimer les segments de piston
Compresor de aros de pistón
131 100 Demontagewerkzeug für Sprengring
Disassembling tool for spring ring
Outil de démontage de circlips
Herramienta de desmontaje para anillos

de seguridad
131 340 Montagewerkzeug für Kolbenbolzenbuchse

131 350
Assembly tool for small end bush
Dispositif de montage de bague de pied de bielle
Herramienta de montaje para casquillos de pie

de biela
© 2001 / 0297 9959 5.00.08

5
Spezialwerkzeuge
Special tools
Outils spéciaux
Montagewerkzeug für Nockenwellendichtring 142 050
Assembly tool for camshaft seals
Dispositif de montage pour bagues d’étanchéité

d’arbre à cames
Dispositivo de montaje para retenes del árbol

de levas
Montagewerkzeug für Dichtringsatz, hinten 142 680
Assembly tools for the sealing ring set, rear
Outil de montage de jeu de joints, arrière
Herramienta de montaje para juego de

retén trasero
Montagewerkzeug für Dichtringsatz, vorne 142 690
Assembly tools for the sealing ring set, front
Outil de montage de jeu de joints, avant
Herramienta de montaje para juego de

retén delantero
Ausziehvorrichtung für Kurbelwellendichtringe 142 710
Puller for crankshaft seals
Extracteur pour bagues d’étanchéité de vilebrequin
Dispositivo de extracción para retenes del cigüeñal
5.00.09 © 2001 / 0297 9959

5
Spezialwerkzeuge
Special tools
Outils spéciaux
142 850 Montagewerkzeug für Kurbelwellendichtring,

vorne
Assembly tool for crankshaft seals,front
Dispositif de montage de bague d’étanchéité avant

de vilebrequin
Dispositivo de montaje para el retén delantero del

cigüeñal
142 860 Montagewerkzeug für Kurbelwellendichtring,

hinten
Assembly tool for crankshaft seals, rear
Dispositif de montage pour bague d’étanchéité

arrière de vilebrequin
Dispositivo de montaje para el retén trasero del

cigüeñal
143 100 Abdrückwerkzeug für Schwungrad
Puller for flywheel
Dispositif pour extraction de volant-moteur
Dispositivo de separación para el volante
143 420 Gegenhalter für Kraftvervielfältiger
Dolly for multipower tool
Dispositif de maintien du multiplicateur de force
Dispositivo de retención para multiplicador

de fuerza
© 2001 / 0297 9959 5.00.10

5
Spezialwerkzeuge
Special tools
Outils spéciaux
Zwischenscheibe für Gegenhalter 143 420 143 430
Intermediate disc for dolly 143 420
Disque intercalaire pour outil de maintien 143 420
Arandela intermedia para dispostivo de

retención 143 420
Montagewerkzeug für Nockenwellenbuchse 143 820
Assembly tool for camshaft bush
Outil de montage pour bague d’arbre à cames
Dispositivo de montaje para casquillos de árbol

de levas
Gegenhalter für Nockenwellenrad 144 130
Dolly for camshaft gear
Outil de maintien de pignon d’arbre à cames
Dispositivo de retención para rueda dentada

del árbol de levas
Ausziehwerkzeug für Rohr 150 140
Puller for pipe
Extracteur de tube
Extractor para tubos
5.00.11 © 2001 / 0297 9959

5
Spezialwerkzeuge
Special tools
Outils spéciaux
150 150 Montagedorn für Rohr
Assembly arbor for pipe
Mandrin de montage pour tube
Mandril de montaje para tubos
170 050 Spezialschlüssel zum Abschrauben der

Filterpatrone
Special key for filter cartridges
Clé spéciale pour cartouches de filtre
Llave especial para cartuchos filtrantes
170 110 Spezialschlüssel für Öldruckgeber
Special wrench for oil pressure sensor
Clé spécial pour capteur de pression d’huile
Llave especial para transmisores de presión de

aceite
6067 Motormontagebock
Engine assembly stand
Chevalet de montage de moteur
Caballete de montaje de motores
© 2001 / 0297 9959 5.00.12

5
Spezialwerkzeuge
Special tools
Outils spéciaux
Aufspannhalter 6067/115
Angled clamping plate
Support d’ablocage
Soporte de fijación
5.00.13 © 2001 / 0297 9959

5
Spezialwerkzeuge
Special tools
Outils spéciaux
© 2001 / 0297 9959

5
Vendor Publication:
D2011 L04 (Tier IVi) Engine

Spare Parts Catalog
®
DEUTZ
ETL no.: 0511 4903 Generator mounting Constr. Group: 44 SERPIC © 08.08
Equipment: 00010873250 Engine type: D 4L2011
Output: 0000036,4 kW Speed: 2500 1/min
ETL scope: EU553323
Item Material Kit MS VS Quant UnitOrd Designation (en) Designation (de) Remark
1 04102232 Kit ? 1 ST Bracket Konsole

2 01111176 Kit ? 3 ST Hexagon bolt Sechskantschraube
4 04172296 Kit ? 1 ST Clamping strap Spannlasche
7 01216101 Kit ? 2 ST Plain washer Scheibe
8 01112824 Kit ? 1 ST Hexagon nut Sechskantmutter
®
DEUTZ
ETL no.: 0506 3447 Narrow v-belt Constr. Group: 39 SERPIC © 08.08
ETL scope: EU553323
1 01179565 Kit ? 1 ST Narrow v-belt Schmalkeilriemen 1125 mm

®
DEUTZ
ETL no.: 0507 9131 Generator Constr. Group: 44 SERPIC © 08.08
ETL scope: EU553323
1 01340485 Kit ? 1 ST Gasket set Dichtungssatz

2 01181859 Kit ? 1 ST Fan Luefter
3 01182187 Kit ? 1 ST V-grooved pulley Keilriemenscheibe
4 01182961 Kit ? 1 ST Generator Generator R 14V 95A
WITH ITEM....
(1,2,5-8)
5 01182906 Kit ? 90 90 1 ST Voltage regulator Spannungsregler
8 01182010 Kit ? 90 90 1 ST Supporting ring Stuetzscheibe
®
DEUTZ
ETL no.: 0507 4209 Protection hood Constr. Group: 83 SERPIC © 08.08
ETL scope: EU553323
25 04280352 Kit ? 1 ST Protection hood Schutzhaube WITH ITEM....

(27)
26 01123749 Kit ? 20 20 5 ST Hexagon bolt Sechskantschraube
27 01398414 Kit ? 90 90 1 M Sealing section Dichtprofil
®
DEUTZ
ETL no.: 0507 9110 Accessories Constr. Group: 83 SERPIC © 08.08
ETL scope: EU553323
9 02931482 Kit ? 1 ST Repair kit Reparatursatz

20 01179424 Kit ? 2 ST Torx-head bolt Torx-Schraube
21 01153887 Kit ? 1 ST O-seal Runddichtring
25 04280529 Kit ? 1 ST Clutch sleeve Kupplungshuelse
201 01016126 Kit ? 1 ST Graphite grease Graphitfett
®
DEUTZ
ETL no.: 0507 4273 Clutch sleeve Constr. Group: 83 SERPIC © 08.08
ETL scope: EU553323
1 04280529 Kit ? 1 ST Clutch sleeve Kupplungshuelse

201 01016126 Kit ? 1 ST Graphite grease Graphitfett
®
DEUTZ
ETL no.: 0506 7710 Heater connection Constr. Group: 16 SERPIC © 08.08
ETL scope: EU553323
1 04178390 Kit ? 90 90 3 ST Valve Ventil

2 04178399 Kit ? 1 ST Compression spring Druckfeder
3 01100483 Kit ? 90 90 2 ST Screw plug Verschlussschraube
4 01118748 Kit ? 2 ST Sealing ring Dichtring
7 04178229 Kit ? 1 ST Adapter nipple Uebergangsnippel
8 04178233 Kit ? 90 90 1 ST Adapter nipple Uebergangsnippel
9 01151441 Kit ? 2 ST Screw plug Verschlussschraube
®
DEUTZ
ETL no.: 0511 4527 Camshaft Constr. Group: 10 SERPIC © 08.08
ETL scope: EU553323
1 04173067 Kit ? 1 ST Thrust washer Anlaufscheibe

3 04287944 Kit ? 1 ST Camshaft Nockenwelle
®
DEUTZ
ETL no.: 0507 7881 Connecting rod Constr. Group: 06 SERPIC © 08.08
ETL scope: EU553323
1 04272080 Kit ? 90 90 1 ST Connecting rod Pleuelstange WITH ITEM....

(2,4)
2 04280016 Kit ? 2 ST Big end bolt Pleuelschraube M10x1x58,5mm
4 02108088 Kit ? 1 ST Big end bush Pleuelbuchse STANDARD (A)MM RD, FOR
OVERSIZE SEE ITEM (B)
A 29,06-29,10
B 953
5 04286649 Kit ? 1 ST Connecting rod Pleuelstange WITH ITEM....
(2,4)
6 04287601 Kit ? 1 ST Connecting rod Pleuelstange WITH ITEM....
(4,7)
7 04286942 Kit ? 2 ST Big end bolt Pleuelschraube M10x1x55mm
953 02108089 Kit ? 70 1 ST Big end bush Pleuelbuchse OVERSIZE
29,31-29,35MM
®
DEUTZ
ETL no.: 0506 8138 Crankshaft Constr. Group: 05 SERPIC © 08.08
ETL scope: EU553323
1 04270236 Kit ? 1 ST Crankshaft Kurbelwelle SPAREPART (NEW),

REMANUFACTURED PART
SEE ITEM (A) COMPL. WIT
H
ITEM
(2-4)
(A) 950
2 04270238 Kit ? 5 ST Main bearing Kurbelwellenlager STANDARD (A)MM RD, FOR
UNDERSIZE SEE ITEM (B)
A 70,00
B 951,952
3 02928961 Kit ? 1 ST Thrust washer Anlaufscheibe STANDARD (A)MM, FOR OVE
RSIZE
SEE ITEM (B)
(A) 2,4
(B) 953
4 04270255 Kit ? 4 ST Big end bearing Pleuellager STANDARD (A)MM RD, FOR
UNDERSIZE SEE ITEM (B)
(A) 55,0
(B) 954, 955
®
DEUTZ
ETL no.: 0506 8138 Crankshaft Constr. Group: 05 SERPIC © 08.08
ETL scope: EU553323
6 06218864 Kit ? 1 ST Threaded insert Gewindeeinsatz

950 02929801 Kit ? AR 1 ST Exch. crankshaft At-Kurbelwelle REMANUFACTURED PART,
NEW PART SEE ITEM (A)
COMPL. WITH ITEM
A1
B 951,953,954
951 04270242 Kit ? 5 ST Main bearing Kurbelwellenlager 1ST UNDERSIZE
69,75 MM RD
952 04270247 Kit ? 5 ST Main bearing Kurbelwellenlager 2ND UNDERSIZE
69,50 MM RD
953 02928962 Kit ? 1 ST Thrust washer Anlaufscheibe 1ST OVERSIZE
2,6 MM
954 04270259 Kit ? 4 ST Big end bearing Pleuellager 1ST UNDERSIZE
54,75 MM RD
955 04270263 Kit ? 4 ST Big end bearing Pleuellager 2ND UNDERSIZE
54,50 MM RD
®
DEUTZ
ETL no.: 0507 4232 Cylinder head Constr. Group: 08 SERPIC © 08.08
ETL scope: EU553323
1 04280268 Kit ? 1 ST Cylinder head Zylinderkopf SPAREPART (NEW),

REMANUFACTURED PART
SEE ITEM (A) COMPL. WIT
H
ITEM
(2-3,8-13)
(A) 952
2 04280047 Kit ? 90 90 4 ST Valve seat insert Ventilsitzring EXHAUST VALVE,STANDARD(
A)MM R
FOR OVERSIZE SEE ITEM(B
)
A) 37.07
B) 951
3 04280023 Kit ? 90 90 4 ST Valve seat insert Ventilsitzring INLET VALVE,STANDARD.(A
)MM RD
FOR OVERSIZE SEE ITEM (
B)
A) 42.67
®
DEUTZ
ETL no.: 0507 4232 Cylinder head Constr. Group: 08 SERPIC © 08.08
ETL scope: EU553323
B) 950
8 04280350 Kit ? 4 ST Inlet valve Einlassventil
9 04280049 Kit ? 4 ST Exhaust valve Auslassventil
10 04153728 Kit ? 8 ST Valve stem seal Ventilschaftdichtg
12 04280025 Kit ? 90 90 8 ST Spring cap Federteller
13 02108102 Kit ? 16 ST Valve collet Ventilkegelstueck
950 04272032 Kit ? 4 ST Valve seat insert Ventilsitzring INLET VALVE, 1ST OVERSI
ZE
42,87 MM
951 02108643 Kit ? 4 ST Valve seat insert Ventilsitzring EXHAUST VALVE, 1ST OVER
SIZE
37,27 MM
952 04280284 Kit ? AO 1 ST Cylinder head Zylinderkopf REMANUFACTURED PART,
NEW PART SEE ITEM (A)
(A) POS.1
953 04272011 Kit ? 8 ST Valve guide Ventilfuehrung
®
DEUTZ
ETL no.: 0507 4224 Fastenings Constr. Group: 08 SERPIC © 08.08
ETL scope: EU553323
1 04270815 Kit ? 10 ST Cylinder head bolt Zyl.Kopfschraube

2 04178611 Kit ? 2 ST Spiral pin Spiral-Spannstift GASKET THICKNESS DEPEND
ING
ON MEASUREMENT RESULT
-DELIVERY COND. (A)=...
MM
-INSTALLATION COND. (B)
=...MM
DIFF.THICKNESSES SEE IT
EM (C)
3 04280816 Kit ? 50 50 1 ST Cylind.head gasket Zyl.Kopfdichtung GASKET THICKNESS DEPEND
ING
MM
=...MM
®
DEUTZ
ETL scope: EU553323
EM (C)
A = 1,56 +/- 0.04
B = 1,48
C = POS.4,5
ING
MM
=...MM
EM (C)
A = 1,61 +/- 0.04
B = 1,55
C = POS.3,5
ING
MM
=...MM
EM (C)
A=1.74 +/- 0.05
B=1.60
C= POS. 3.4
®
DEUTZ
ETL no.: 0506 7789 Dipstick guide Constr. Group: 01 SERPIC © 08.08
ETL scope: EU553323
1 04270617 Kit ? 20 20 1 ST Guide tube Fuehrungsrohr

5 04102141 Kit ? 1 ST Bracket Halter
6 04270656 Kit ? 1 ST Pipe clamp Rohrschelle
®
DEUTZ
ETL no.: 0506 7762 Dipstick Constr. Group: 01 SERPIC © 08.08
ETL scope: EU553323
1 01180586 Kit ? 1 ST Dipstick Oelmessstab WITH ITEM....

(2)
®
DEUTZ
ETL no.: 0507 9159 Engine block Constr. Group: 01 SERPIC © 08.08
ETL scope: EU553323
1 04281940 Kit ? 1 ST Engine block Zyl.Kurbelgehaeu.. WITH ITEM....

(2-19)
2 04178155 Kit ? 2 ST Wrapped bear. bush Lagerbuchse
3 04178154 Kit ? 3 ST Wrapped bear. bush Lagerbuchse
4 04287999 Kit ? 2 ST Guide sleeve Fuehrungshuelse
11 04178218 Kit ? 1 ST Tube Rohr
12 04270312 Kit ? 1 ST Screw plug Verschlussschrau.. WITH ITEM....
(40)
13 04281325 Kit ? 1 ST Plug Verschlussstopfen
14 01182090 Kit ? 8 ST Stud Stiftschraube
17 03362279 Kit ? 10 ST Bush Buchse
18 04179928 Kit ? 90 90 1 ST Thermostat Thermostat WITH ITEM....
(19)
25 04178452 Kit ? 8 ST Piston cool.nozzle Kolbenkuehlduese
26 01148153 Kit ? 1 ST Cover Verschlussdeckel
®
DEUTZ
ETL no.: 0507 9159 Engine block Constr. Group: 01 SERPIC © 08.08
ETL scope: EU553323

189 01016125 Kit ? 20 20 0,010 KG Safety/lock.agent Sicherungsmittel
®
DEUTZ
ETL no.: 0506 4190 Flange Constr. Group: 41 SERPIC © 08.08
ETL scope: EU553323
1 04173758 Kit ? 1 ST Flange Flansch

2 01122477 Kit ? 20 20 3 ST Hexagon nut Sechskantmutter
3 04174032 Kit ? 1 ST Gasket Dichtung
®
DEUTZ
ETL no.: 0506 9181 Exhaust manifold Constr. Group: 41 SERPIC © 08.08
ETL scope: EU553323
1 04271252 Kit ? 1 ST Exhaust manifold Abgassammelrohr

3 01181006 Kit ? 90 90 8 ST Torx-head bolt Torx-Schraube
169 01016116 Kit ? 20 20 1 KG Fitting compound Montagemittel
®
DEUTZ
ETL no.: 0506 4134 Power take-off Constr. Group: 05 SERPIC © 08.08
ETL scope: EU553323
1 04173227 Kit ? 1 ST V-grooved pulley Keilriemenscheibe

4 04270814 Kit ? 1 ST Flanged hub Flanschnabe
®
DEUTZ
ETL no.: 0507 4151 Flywheel Constr. Group: 05 SERPIC © 08.08
ETL scope: EU553323
1 04272425 Kit ? 1 ST Flywheel Schwungrad WITH ITEM....

(2)
2 04272421 Kit ? 1 ST Gear rim Zahnkranz
3 02109988 Kit ? 8 ST Screw/bolt Schraube
®
DEUTZ
ETL no.: 0505 1756 Cover plate Constr. Group: 52 SERPIC © 08.08
ETL scope: EU553323
1 04172349 Kit ? 1 ST Cover plate Abdeckblech

3 01151016 Kit ? 20 20 3 ST Plain washer Scheibe
®
DEUTZ
ETL no.: 0506 9152 Adapter housing Constr. Group: 52 SERPIC © 08.08
ETL scope: EU553323
1 04270979 Kit ? 1 ST Adapter housing Zwischengehaeuse

2 02109066 Kit ? 2 ST Clamping bush Spannbuchse
®
DEUTZ
ETL no.: 0507 9145 Front cover/govern Constr. Group: 27 SERPIC © 08.08
ETL scope: EU553323
1 04286243 Kit ? 1 ST Metering unit Messwerk

5 04271828 Kit ? 1 ST Tension spring Zugfeder
6 04287201 Kit ? 90 90 1 ST Lever/arm Hebel
8 04175629 Kit ? 3 ST Sleeve Huelse
10 04175950 Kit ? 1 ST Lever/arm Hebel
17 04178839 Kit ? 1 ST Profile washer Profildichtung
18 01179835 Kit ? 3 ST Cheese head screw Zylinderschraube
21 04280156 Kit ? 1 ST Lever shaft Regelhebelwelle
23 04287491 Kit ? 1 ST Roller lever Rollenhebel WITH ITEM....
(24-26)
24 01137646 Kit ? 2 ST Ball bearing Rillenkugellager
25 01180059 Kit ? 90 90 2 ST Clevis pin Bolzen
26 01115316 Kit ? 1 ST Notched nail Kerbnagel
27 04178202 Kit ? 1 ST Axle Achse
28 04179754 Kit ? 90 90 1 ST Lever/arm Hebel
®
DEUTZ
ETL no.: 0507 9145 Front cover/govern Constr. Group: 27 SERPIC © 08.08
ETL scope: EU553323

31 01115434 Kit ? 2 ST Straight pin Spannstift
33 04270491 Kit ? 1 ST Sleeve Muffe
36 04281898 Kit ? 1 ST Torsion spring Drehfeder
40 01151181 Kit ? 20 20 1 ST Set screw Gewindestift
46 01105091 Kit ? 1 ST Parallel pin Zylinderstift
47 04281188 Kit ? 1 ST Front cover Vorderer-Deckel
49 04178572 Kit ? 1 ST Breather valve Entlueftungsventil
50 04175435 Kit ? 1 ST Rot.shaft lip seal Rad.Well.Dichtring
61 04175581 Kit ? 1 ST Pin Zugbolzen
66 04178895 Kit ? 1 ST Cover Deckel
70 01125637 Kit ? 1 ST Straight pin Spannstift
®
DEUTZ
ETL no.: 0506 9150 Fuel filter Constr. Group: 20 SERPIC © 08.08
ETL scope: EU553323

2 01174696 Kit ? 1 ST Spin-on fuel filt. Kraftstoffwe.Filt.
®
DEUTZ
ETL no.: 0507 9015 High pressure pipe Constr. Group: 21 SERPIC © 08.08
ETL scope: EU553323
1 04281876 Kit ? 90 90 1 ST High pressure pipe Einspritzleitung

®
DEUTZ
ETL no.: 0507 9099 Fuel line Constr. Group: 20 SERPIC © 08.08
ETL scope: EU553323
1 01177045 Kit ? 20 20 1 ST Rubber hose Gummischlauch

2 01180014 Kit ? 2 ST Hose clip Schlauchschelle
3 01404943 Kit ? 90 90 1 ST Hose Schlauch
4 01176435 Kit ? 1 ST Clamping band Halteband
®
DEUTZ
ETL scope: EU553323
1 01398209 Kit ? 1 ST Rubber hose Gummischlauch LONG

1000 MM
®
DEUTZ
ETL no.: 0511 3639 Fuel inject. pump Constr. Group: 17 SERPIC © 08.08
ETL scope: EU553323
1 04287049 Kit ? 90 1 ST Fuel inject. pump Einspritzpumpe WITH ITEM....

(2)
2 01340402 Kit ? 1 ST O-ring O-Ring
10 01340378 Kit ? 1 ST Fuel inject. pump Einspritzpumpe Pumpenklasse - A -
11 01340379 Kit ? 1 ST Fuel inject. pump Einspritzpumpe Pumpenklasse - B -
12 01340380 Kit ? 1 ST Fuel inject. pump Einspritzpumpe Pumpenklasse - C -
13 01340381 Kit ? 1 ST Fuel inject. pump Einspritzpumpe Pumpenklasse - D -
®
DEUTZ
ETL no.: 0507 9013 Fuel injector Constr. Group: 19 SERPIC © 08.08
ETL scope: EU553323
1 04286251 Kit ? 1 ST Fuel injector Einspritzventil WITH ITEM....

(6)
3 04281147 Kit ? 1 ST Claw Pratze
6 04281859 Kit ? 1 ST Nozzle element Duesenelement
®
DEUTZ
ETL no.: 0511 3678 Fuel supply pump Constr. Group: 20 SERPIC © 08.08
ETL scope: EU553323
1 04287258 Kit ? 1 ST Fuel supply pump Kr.Stoff-Foerd.Ppe WITH ITEM....

(2,4-6)
5 02111897 Kit ? 1 ST Hand pump Handpumpe
6 01340488 Kit ? 1 ST Repair kit Reparatursatz
®
DEUTZ
ETL no.: 0506 7616 Control rod Constr. Group: 27 SERPIC © 08.08
ETL scope: EU553323
1 04179809 Kit ? 90 90 1 ST Control rod Regelstange

2 04176057 Kit ? 1 ST Locating pin Fixierstift
®
DEUTZ
ETL scope: EU553323
2 04281429 Kit ? 20 20 1 ST Fuel line Kraftstoffleitung WITH ITEM....

(10,11)
3 01177045 Kit ? 20 20 1 ST Rubber hose Gummischlauch
4 01182135 Kit ? 1 ST Connecting piece Verbindungsstueck
8 01176435 Kit ? 1 ST Clamping band Halteband
10 01119241 Kit ? 4 ST Hollow screw Hohlschraube
®
DEUTZ
ETL scope: EU553323
1 04102954 Kit ? 1 ST Fuel line Kraftstoffleitung WITH ITEM....

(2,3)
®
DEUTZ
ETL no.: 0507 7823 Gasket set Constr. Group: 90 SERPIC © 08.08
ETL scope: EU553323
1 02931435 Kit ? 1 ST Gasket set Dichtungssatz The gasket set may not
contain all
gaskets, see SM 0199-99
-9449
®
DEUTZ
ETL no.: 0507 4134 Control unit Constr. Group: 48 SERPIC © 08.08
ETL scope: EU553323
1 04271688 Kit ? 1 ST Gl.time contr.unit Gluehzeitst.Geraet

3 04271983 Kit ? 1 ST Base/pedestal Sockel
®
DEUTZ
ETL no.: 0511 3645 Torge adapter Constr. Group: 27 SERPIC © 08.08
ETL scope: EU553323
1 04174250 Kit ? 1 ST Claw Pratze

4 04286902 Kit ? 1 ST Control system Getrieberegelung WITH ITEM....
(5-14)
5 04270758 Kit ? 1 ST Limit stop Anschlag
6 01107803 Kit ? 1 ST Circlip Sicherungsring
8 04286950 Kit ? 1 ST Setting screw Verstellschraube
10 04286899 Kit ? 1 ST Set screw Gewindestift
11 04286951 Kit ? 1 ST Setscrew Feststellschraube
12 04286901 Kit ? 1 ST Adjusting screw Einstellschraube
®
DEUTZ
ETL scope: EU553323
1 04103289 Kit ? 1 ST Roller tappet Rollenstoessel

4 04287618 Kit ? 1 ST Shim Ausgleichscheibe GASKET THICKNESS DEPEND
ING
ON MEASUREMENT RESULT (
A)= MM
EM (B)
A = 0,35 mm
B = 950-965
950 04287619 Kit ? 1 ST Shim Ausgleichscheibe ....MM THICKNESS
0,40 mm
0,45 mm
0,50 mm
0,55 mm
®
DEUTZ
ETL scope: EU553323

0,60 mm
0,65 mm
0,70 mm
0,75 mm
0,80 mm
0,85 mm
0,90 mm
0,95 mm
1,00 mm
1,05 mm
1,10 mm
1,15 mm
1,20mm
1,30mm
®
DEUTZ
ETL no.: 0506 3365 Glow plug Constr. Group: 26 SERPIC © 08.08
ETL scope: EU553323
1 01179016 Kit ? 1 ST Glow plug Gluehwendelkerze

®
DEUTZ
ETL no.: 0507 4094 Suction pipe Constr. Group: 22 SERPIC © 08.08
ETL scope: EU553323

3 04272207 Kit ? 1 ST Intake manifold Luftansaugrohr
®
DEUTZ
ETL no.: 0505 1624 Flange Constr. Group: 22 SERPIC © 08.08
ETL scope: EU553323

2 04172821 Kit ? 1 ST Flange Flansch
®
DEUTZ
ETL no.: 0506 3419 Blanking parts Constr. Group: 22 SERPIC © 08.08
ETL scope: EU553323

®
DEUTZ
ETL no.: 0506 3389 Air filter fitment Constr. Group: 22 SERPIC © 08.08
ETL scope: EU553323

2 01108080 Kit ? 3 ST Square nut Vierkantmutter
4 04271942 Kit ? 1 ST Hose nipple Schlauchstutzen
®
DEUTZ
ETL no.: 0506 7612 Filler cap Constr. Group: 08 SERPIC © 08.08
ETL scope: EU553323
1 04281390 Kit ? 1 ST Filler cap Einfuellverschluss

®
DEUTZ
ETL no.: 0507 7896 Bracket Constr. Group: 15 SERPIC © 08.08
ETL scope: EU553323
1 04287677 Kit ? 1 ST Bracket Filterkonsole WITH ITEM....

(4-8)
2 04281205 Kit ? 90 90 1 ST Gasket Dichtung
5 04258757 Kit ? 1 ST Control valve Regelschieber
6 04258759 Kit ? 1 ST Temperature sensor Temperaturfuehler
®
DEUTZ
ETL no.: 0506 4400 Lubric. oil filter Constr. Group: 15 SERPIC © 08.08
ETL scope: EU553323
1 01174416 Kit ? 1 ST Spin-on oil filter Wechselfilter

®
DEUTZ
ETL no.: 0506 8145 Radiator connect. Constr. Group: 16 SERPIC © 08.08
ETL scope: EU553323
1 04179775 Kit ? 10 10 2 ST Radiator connect. Kuehleranschluss

®
DEUTZ
ETL no.: 0506 7625 Oil suction line Constr. Group: 16 SERPIC © 08.08
ETL scope: EU553323
1 04178205 Kit ? 10 10 1 ST Oil suction pipe Oelsaugrohr

234 01016024 Kit ? 1 ST Packing compound Dichtungsmasse
®
DEUTZ
ETL no.: 0507 4179 Oil pan Constr. Group: 02 SERPIC © 08.08
ETL scope: EU553323
1 02931263 Kit ? 1 ST Oil pan Oelwanne WITH ITEM....

(4-6)
10 01017932 Kit ? 10 L Engine oil Motorenoel Material no.: only for
quantity
calculation
®
DEUTZ
ETL no.: 0511 3697 Pilot line Constr. Group: 15 SERPIC © 08.08
ETL scope: EU553323
2 04287842 Kit ? 1 ST Pilot line Steuerleitung WITH ITEM....

(10,11)
®
DEUTZ
ETL no.: 0511 4881 Lubricat. oil pump Constr. Group: 14 SERPIC © 08.08
ETL scope: EU553323
1 04102478 Kit ? 1 ST Lubricat. oil pump Schmieroelpumpe WITH ITEM....

(2,3)
2 01148815 Kit ? 1 ST Set screw Gewindestift
5 04178612 Kit ? 2 ST Spiral pin Spiral-Spannstift
6 04178989 Kit ? 1 ST Sealing ring Formdichtring
®
DEUTZ
ETL no.: 0511 3694 Temper.transmitter Constr. Group: 51 SERPIC © 08.08
ETL scope: EU553323
1 01182876 Kit ? 1 ST Temper.transmitter Temperaturgeber WITH ITEM....

(2)
®
DEUTZ
ETL no.: 0507 9273 Piston Constr. Group: 07 SERPIC © 08.08
ETL scope: EU553323
1 04281445 Kit ? 1 ST Piston Kolben COMPLETE

KOMPRESSIONSHOEHENKLASS
E "A"
2 02108066 Kit ? 1 ST Piston pin Kolbenbolzen
3 04272875 Kit ? 2 ST Snap ring Sprengring
4 04280565 Kit ? 1 ST Set of pist. rings Kolbenringsatz
8 04281447 Kit ? 1 ST Piston Kolben COMPLETE
E "B"
950 04281451 Kit ? 1 ST Piston Kolben OVERSIZE
E "A" UEBERMASS
951 04281453 Kit ? 1 ST Piston Kolben OVERSIZE
E "B" UEBERMASS
952 04281113 Kit ? 1 ST Set of pist. rings Kolbenringsatz OVERSIZE
®
DEUTZ
ETL no.: 0506 7617 Valve drive Constr. Group: 11 SERPIC © 08.08
ETL scope: EU553323
1 02109085 Kit ? 2 ST Pushrod Stossstange

2 04178075 Kit ? 2 ST Valve tappet Ventilstoessel
®
DEUTZ
ETL no.: 0507 9188 Rear end cover Constr. Group: 01 SERPIC © 08.08
ETL scope: EU553323
1 04286869 Kit ? 90 90 1 ST Rear end cover Hinterer Deckel WITH ITEM....

(3)
®
DEUTZ
ETL no.: 0505 1930 Rocker arm bracket Constr. Group: 11 SERPIC © 08.08
ETL scope: EU553323
1 01107727 Kit ? 2 ST Circlip Sicherungsring

2 02109628 Kit ? 2 ST Rocker arm Kipphebel
3 02109636 Kit ? 2 ST Adjusting screw Einstellschraube
6 01181417 Kit ? 50 2 ST Torx-head bolt Torx-Schraube
7 04174058 Kit ? 1 ST Rocker arm bracket Kipphebelbock WITH ITEM....
(1-4)
®
DEUTZ
ETL no.: 0507 9141 Connecting pipe Constr. Group: 48 SERPIC © 08.08
ETL scope: EU553323
1 04213069 Kit ? 1 ST Connecting pipe Verbindungsleitung

®
DEUTZ
ETL no.: 0507 9085 Shutdown device Constr. Group: 56 SERPIC © 08.08
ETL scope: EU553323

7 04175724 Kit ? 1 ST Tension spring Zugfeder
12 04287583 Kit ? 1 ST Shutdown device Motorabstellung WITH ITEM....
(7)
®
DEUTZ
ETL no.: 0511 9144 Starter Constr. Group: 44 SERPIC © 08.08
ETL scope: EU553323
1 04300287 Kit ? 1 ST Starter Starter R 12V 4KW

®
DEUTZ
ETL no.: 0505 1745 Fan Constr. Group: 39 SERPIC © 08.08
ETL scope: EU553323
1 04172166 Kit ? 1 ST Suction fan Saugluefter

®
DEUTZ
ETL no.: 0511 3695 Camshaft drive Constr. Group: 10 SERPIC © 08.08
ETL scope: EU553323
1 04286428 Kit ? 1 ST Synchr.belt pulley Zahnriemenrad

2 04270070 Kit ? 1 ST Hexagon screw Sechskantschraube
10 02931485 Kit ? 20 20 1 ST Repair kit Reparatursatz
®
DEUTZ
ETL scope: EU553323

4 02112403 Kit ? 1 ST Locking screw Sicherungsschraube
®
DEUTZ
ETL no.: 0507 9198 Protection hood Constr. Group: 10 SERPIC © 08.08
ETL scope: EU553323

(3+5)
(3,4,7)
3 01398465 Kit ? 1 M Sealing section Dichtprofil
4 04280144 Kit ? 1 ST Rubber grommet Gummituelle
5 04280126 Kit ? 1 ST Shaped packing Formdichtung
®
DEUTZ
ETL no.: 0511 9034 Valve mechan.cover Constr. Group: 08 SERPIC © 08.08
ETL scope: EU553323
1 04270206 Kit ? 1 ST Cyl.head/hd.cover Zyl.-Kopf/-Haube

C6
AUTOMATIC
TRANSMISSION
PARTS LIST
Revised December 2005

C6 Automatic Transmission Parts List
TABLE OF CONTENTS
Figure 1. Park Brake Assembly..........................................................................................................4
Figure 2. Converter, Pan, and Output Shaft Assembly ......................................................................6
Figure 3. Direct Clutch Assembly .......................................................................................................8
Figure 4. Forward and Reverse Clutch Assembly ............................................................................10
Figure 5. Intermediate Band Servo ..................................................................................................14
Figure 6. Parking Pawl, Throttle, and Manual Control Linkage .......................................................16
Figure 7. Valve Body Assembly ........................................................................................................18
Page 3
December 2005
Parts List C6 Automatic Transmission
7 4
6 5
8 4A
9 3
10
11 2
1
12
13
14 29
16
28 25
24
27 23 25
15
26 37
17 38
18
22
19 17
20 36
33
34
35
21 31
30 32
Figure 1. Park Brake Assembly
Page 4
December 2005
Table 1. Park Brake Assembly
Fig & Ford Part Tug Part

Description Qty
Ind Number Number
1-1 386034-S100 TPG-386034-S100 Nut, Slotted 9/16-18 1
1-2 ------ 1/8 x 1 Pin, Cotter Ø 1/8" x 1" Long 1
1-3 44880-S2 TPG-44880-S2 Washer, Flat 9/16" ID 1
1-4 D3TZ-2A663D TPG-D3TZ-2A663D Bellcrank, COM 1
1-4A ------ T6-8205-107 Bellcrank, Diesel 1
Screw, Hex Washer Head Ø
1-5 380207-S 3/8-16 x 1½ 6
3/8-16 x 1½" Long
1-6 D0TZ-7A039B D0TZ-7A039B Housing, Tail Shaft (C6) 1
1-7 D0TZ-7086A D2AZ-7086A Gasket, Extension Housing 1
1-8 B9TZ-2A710D TPG-B9TZ-2A710D Cam & Lever Assembly 1
1-9 380952-S2 ------ Nut, Hex 4
1-10 34794-S2 34794-S2 Washer, Lock 4
1-11 C8HZ-7A002A TPG-C8HZ-7A002A Plug, Speedometer Gear Inlet 1
1-12 D0TZ-7085A T6-8005-129 Housing, Flange 1
1-13 D1TZ-17285A TPG-D1TZ-17285A Spacer, Speedometer Gear 1
1-14 E1ZZ-7065A E1ZZ-7065A Bearing Assembly with Retainer Ring 1
1-15 D5TZ-7070A D5TZ-7070A Ring, Snap 1
1-16 D0TZ-7A011A D0TZ-7A011A Seal, Transmission 1
1-17 ------ T6-8005-143 Shoe, Park Brake (C6) 2
1-18 B9T-2634B T6-8005-147 Spring, Park Brake Assembly (C6) 2
1-19 58675-S2 TPG-58675-S2 Bolt, Hex Head Ø ½-13 x 1½" Long 4
1-20 B9TZ-2A636A T6-8005-135 Plate, Park Brake 1
1-21 B9T-2749A T6-8005-149 Spring, Park Brake Assembly (C6) 1
1-22 D6TZ-2A703A TPG-D6TZ-2A703A Shield, Park Brake 1
1-23 ------ MD-CB21-115 Pin, Clevis, COM 2
1-24 D3TZ-2857A TPG-D3TZ-2857A Clevis, Parking Brake 1
1-25 ------ 1/8 x 1 Pin, Cotter Ø 1/8" x 1" Long 2
1-26 D3TA-2A701AA TPG-D3TA-2A701AA Pipe, Parking Brake Drain 1
1-27 ------ 3/8-24 Nut, Hex 3/8-24 4
1-28 ------ 3/8 Washer, Lock 3/8" ID 4
1-29 385554-S2 TPG-385554-S2 Stud Ø 9/16-12 x 2.28" Long 1
1-30 382884-S TPG-382884-S Bolt Ø 5/16-24 x 1" Long 4
1-31 ------ ¼ Washer, Lock ¼" ID 4
1-32 C6TZ-4A254B TPG-C6TZ-4A254B Saddle, U-Joint 2
1-33 371887-S2 TPG-371887-S2 Nut, Lock 1-20 1
1-34 ------ ½-13 Nut, Top Lock Hex ½-13 4
1-35 D3TZ-2614A TPG-D3TZ-2614A Drum, Parking Brake 1
1-36 D3TZ-7089B TPG-D3TZ-7089B Flange, Output 1
1-37 385524-S2 TPG-385524-S2 Bolt Ø ½-13 x 1½" Long 4
1-38 C1TT-2857L TPG-C1TT-2857L Clevis 1
Page 5
December 2005
2 1
3
4 5 8 9
6 7
5
4 15 10
13 12 11
21
14
20
4 22
24
19 25 23
16
17
18
Figure 2. Converter, Pan, and Output Shaft Assembly
Page 6
December 2005
Table 2. Converter, Pan, and Output Shaft Assembly

Description Qty
Ind Number Number
2-1 C6AZ-7086A C6AZ-7086A Gasket 1
2-2 D6TZ-7060A D6TZ-7060A Shaft Assembly, Output (C6) 1
2-3 (See Note) (See Note) Bushing 1
2-4 87650-S ------ Plug, Dry Seal 1/8-27 4
2-5 E0UZ-7D273A ------ Connector Assembly - Oil Tube 2
2-6 C6AZ-7D029C ------ Vent Assembly - Case 1
2-7 58618-S2 ------ Screw, Hex Head Ø 5/16-18 x IR 4
2-8 387035-S5 ------ Ring 1
2-9 34805-S8 ------ Screw 4
2-10 ------ U3660B Governor Assembly 1
2-11 C7AZ-7D220A ------ Body (Governor Oil Collector) 1
2-12 C4AZ-7D011A ------ Ring (Governor Housing Seal) 3
2-13 C6AZ-7C232A ------ Sleeve (Oil Distributor) 1
2-14 C6AZ-7D000B C6AZ-7D000B Tube (Oil Distributor) 1
2-15 C6AZ-7D000A C6AZ-7D000A Tube (Oil Distributor) 1
2-16 E5TZ-7060A E5TZ-7060-A Converter Assembly 1
2-17 E5TZ-7A194D E5TZ-7A194D Pan, Transmission Oil (C6) 1
2-18 378782-S ------ 17
5/16-18 x 17/32" Long
2-19 C6AZ-7A191B C6AZ-7A191B Gasket, Oil Pan (C6) 1
2-20 D5AZ-7D080A ------ Valve, Primary Throttle 1
2-21 D3AZ-7F006B D3AZ-7F006B Clip, Modulator Valve 1
2-22 378782-S ------ 1
5/16-18 x 17/32" Long
2-23 F1TZ-7F013A ------ Shield, Heat 1
2-24 DATZ-7A377A DATZ-7A377-A Diaphragm Assembly (Black Band) 1
2-25 D8AZ-7A380A D8AZ-7A380-A Rod, Throttle Control 1
2- D5TZ-6375A TPG-D5TZ-6375A Flywheel Assembly (C6) 1
Note: Replace using C6 Automatic Transmission Overhaul Kit (P/N D6AZ-7C391A).
Page 7
December 2005
7 9 10
6
1 5
3
8
4
2 20
18 19
16
14
12 15
Direct Clutch
17
11a-e 13
lu tch
ct C 28
Dire
26
24
29a-e
(select fit)
27
25
23
22
21
Figure 3. Direct Clutch Assembly
Page 8
December 2005
Table 3. Direct Clutch Assembly

Description Qty
Ind Number Number
3-1 87650-S ------ Plug, Dry Seal 1/8-27 1
3-2 E5TZ-7060A E5TZ-7060A Converter Assembly 1
3-3 D2AZ-7017A ------ Shaft, Input 1
3-4 C2AZ-7A248A C2AZ-7A248A Seal, Shaft 1
3-5 C6AZ-7B258A ------ Bushing, Front Oil Pump (C6) 1
3-6 58619-S2 ------ Screw, Hex Head Ø 5/16-18 x 1¼" Long 7
3-7 C6AZ-7A248B C6AZ-7A248B Ring, Seal 1
3-8 C8AZ-7A103B C8AZ-7A103B Pump Assembly, Front Oil (C6) 1
3-9 C9AZ-7A108A ------ Support Assembly, Front Pump 1
3-10 20346-S8 ------ Screw, Hex Head Ø 5/16-18 x ¾" Long 5
3-11A C6AZ-7D014A ------ Washer, Thrust - Front Pump Support (0.057" Thick) 1
3-11B C6AZ-7D014B ------ Washer, Thrust - Front Pump Support (0.078" Thick) 1
3-11C C6AZ-7D014C C6AZ-7D014C Washer, Thrust - Front Pump Support (0.094" Thick) 1
3-11D C6AZ-7D014D ------ Washer, Thrust - Front Pump Support (0.114" Thick) 1
3-11E C6AZ-7D014E ------ Washer, Thrust - Front Pump Support (0.119" Thick) 1
3-12 C6AZ-7A248B C6AZ-7A248B Ring, Seal 1
3-13 C6AZ-7D025A C6AZ-7D025-A Seal, Intermediate Brake Drum 2
3-14 C6AZ-7A136A ------ Gasket, Front Oil Pump to Case 1
3-15 C6AZ-7D029C ------ Strut, Intermediate Brake Band 1
3-16 D9AZ-7D034B D9AZ-7D034-B Band Assembly 1
3-17 C6AZ-7D430C ------ Strut 1
3-18 C9AZ-7D044A ------ Drum Assembly, Intermediate Brake 1
3-19 C8AZ-7C099A C8AZ-7C099-A Seal, Oil - Clutch Piston 1
3-20 C8AZ-7A548C C8AZ-7A548-C Seal, Oil - Clutch Piston 1
3-21 C9AZ-7A262B ------ Piston Assembly, Clutch 1
3-22 C7ZZ-7B488A ------ Spring, Direct Clutch Piston 10
3-23 C6AZ-7A527A ------ Retainer, Direct Drive Clutch Spring 1
3-24 377136-9 ------ Ring, Retainer 1
3-25 E9TZ-7B442E E9TZ-7B442E Plate, External Spline Steel A/R
3-26 D6AZ-7B164A D6AZ-7B164A Plate, Internal Spline Friction A/R
3-27 C6AZ-7B066B C6AZ-7B066-B Plate, Direct Clutch Pressure 1
3-28 C6AZ-76096A ------ Bearing Assembly 1
3-29A 377126-S ------ Ring, Retainer (0.067" Thick) A/R
3-29B 377127-S ------ Ring, Retainer (0.076" Thick) A/R
3-29C 377128-S ------ Ring, Retainer (0.085" Thick) A/R
3-29D 377437-S ------ Ring, Retainer (0.058" Thick) A/R
3-29E 385044-S ------ Clutch, Reverse (7 1/8" Dia.) A/R
3- D7AZ-7153A D7AZ-7153-A Gasket & Oil Seal Kit (Items #4 & 14) 1
Page 9
December 2005
14a-e
(select fit)
13
11
8 9 10
6
3 5 7
2 4
1
12
h
lutc
34 35
ar dC
F orw
32 33
30 29
28 29
26 27
20 23
18 19 21
16 31
25 49
22 24 25 48
47
46
44
17 41 43
15
39
37
45
42
40 h
Clutc
38 ers e
36 Rev
50
54
53
52
51
Figure 4. Forward and Reverse Clutch Assembly
Page 10
December 2005
Table 4. Forward and Reverse Clutch Assembly

Description Qty
Ind Number Number
4-1 C6AZ-7D019A ------ Seal, Cylinder - Forward Clutch 2
4-2 E9TZ-7A360A ------ Cylinder Assembly - Forward Clutch 1
4-3 D6AZ-7A548A D6AZ-7A548-A Seal, Clutch - Outer 1
4-4 E9TZ-7A548F E9TZ-7A548-F Seal, Clutch - Inner 1
4-5 D6AZ-7A262A D6AZ-7A262A Piston Assembly - Forward Clutch 1
4-6 C6AZ-7D256B ------ Ring, Forward Clutch Piston Spring 1
4-7 D9AZ-7B070A ------ Spring, Forward Clutch Piston Disc 1
4-8 377127-S ------ Ring, Retainer 1
4-9 36243A ------ Washer, Thrust - Input Shell 1
4-10 D6AZ-7E085B D6AZ-7E085-B Spring, Clutch Pressure - Forward Clutch 1
4-13 C6AZ-7B066A C6AZ7B066A Plate, Forward Clutch Pressure 1
4-14A 377127-S ------ Ring, Retainer (0.076" Thick) A/R
4-14B 377437-S ------ Ring, Retainer (0.058" Thick) A/R
4-14C 377444-S ------ Ring, Retainer (0.094" Thick) A/R
4-14D 386841-S ------ Ring, Retainer (0.112" Thick) A/R
4-14E 386842-S ------ Ring, Retainer (0.130" Thick) A/R
4-15 C9AZ-7D090A ------ Washer, Thrust - Forward Clutch Hub 1
4-16 377132-S ------ Retainer 1
4-17 D6AZ-7B067A ------ Hub, Clutch 1
4-18 D6AZ-7D392A D6AZ-70392-A Gear, Forward Ring 1
4-19 C6AZ-7A166B C6AZ-7A166-B Washer, Bearing Assembly 1
4-20 D5AZ-7D398A ------ Planet Assembly - Forward 1
4-21 C6AZ-7D236A C6AZ-7D236-A Race, Bearing - Sun Gear 1
4-22 C6AZ-7D234B C6AZ-7D234-B Bearing Assembly - Sun Gear 1
4-23 C6AZ-7D235A C6AZ-7D235-A Race, Bearing - Sun Gear 1
4-24 C6AZ-7D063A ------ Gear Assembly, Sun 1
4-25 377300-S ------ Ring, Retainer 2
4-26 C6AZ-7D064A ------ Shell 1
4-27 C6AZ-7D066A ------ Washer, Thrust - Input Shell 1
4-28 377155-S ------ Ring, Retainer 1
4-29 C6AZ-7A166B ------ Washer, Bearing Assembly 2
4-30 C6AZ-7D006B ------ Planet Assembly - Reverse 1
Page 11
December 2005
14a-e
(select fit)
13
11
8 9 10
6
3 5 7
2 4
1
12
h
34 35lutc
ar dC
F orw
32 33
30 29
28 29
26 27
20 23
18 19 21
16 31
25 49
22 24 25 48
47
46
44
17 41 43
15
39
37
45
42
40 h
Clutc
38 ers e
36 Rev
50
54
53
52
51
Figure 4. Forward and Reverse Clutch Assembly (Cont'd)
Page 12
December 2005
Table 4. Forward and Reverse Clutch Assembly (Cont'd)

Description Qty
Ind Number Number
4-31 387031-S5 ------ Ring, Retainer 1
4-32 C6AZ-7A153A ------ Ring, Gear - Output Shaft 1
4-33 C9AZ-7D164A ------ Hub - Output Shaft 1
4-34 377132-S ------ Retainer 1
4-35 36254B ------ Bearing Assembly 1
4-36 U36576 ------ Hub, Reverse Clutch 1
4-37 377135-S ------ Ring, Retainer 2
4-38 A36654D ------ Sprag Kit, Rear 1
4-39 U36892 ------ Ring, Snap - Reverse Clutch 1
4-40 C6AZ-7B066C C6AZ7B066C Plate, Reverse Clutch Pressure 1
4-43 D8AZ-7E085A ------ Spring, Clutch Pressure 1
4-44 CM-7D403A CM-7D403-A Seal, Outer - Reverse Clutch 1
4-45 F3TZ-7D404A F3TZ-7D404-A Seal, Inner - Reverse Clutch 1
4-46 A36664E ------ Race, Over Running Clutch (1.013" Thick) 1
A36664B ------ Race, Over Running Clutch (1.040" Thick) 1
A36664A ------ Race, Over Running Clutch (1.089" Thick) 1
4-47 E6TZ-7D406A ------ Retainer and Spring Assembly 1
4-48 D8AZ-7D402A D8AZ7D402A Piston Assembly - Reverse Clutch 1
4-49 C6AZ-7D167A ------ Bolt, Case - Reverse Clutch 5
4-50 E8TZ-7005H E8TZ-7005H Case, Transmission (See Note 2) 1
4-51 D3TZ-7B368A ------ Washer 1
4-52 D6TZ-7A233A ------ Gear - Parking 1
4-53 (See Note 1) (See Note 1) Bushing 1
4-54 D6TZ-7060A D6TZ-7060A Shaft, Output (C6) 1
Note 1: Replace using C6 Automatic Transmission Overhaul Kit (P/N D6AZ-7C391A).
Note 2: Transmission Case (P/N E8TZ-7005H) includes the following parts:
Ford Part
Qty Description
Number
1 C7AZ-7E206A Retainer (Fig. 5-11)
2 E0UZ-7D273A Connector Assembly (Fig. 2-5)
1 E6TZ-7D406A Retainer and Spring Assembly
1 C6AZ-7D433A Shaft (Fig. 5-10)
Page 13
December 2005
17
2 16
3 4
1 7
5
6
15 12
14
8
11 10 9
13
Figure 5. Intermediate Band Servo
Page 14
December 2005
Table 5. Intermediate Band Servo

Description Qty
Ind Number Number
5-1 57633-S2 ------ Screw, Hex Head Ø 5/16-18 x ¾" Long 4
5-2 D3AZ-7D027A ------ Cover - Intermediate Band Servo 1
5-3 D5TZ-7D024B ------ Seal - Intermediate Band Servo 1
5-4 D4AZ-7D026A ------ Gasket - Intermediate Band Servo 1
Piston and Rod Assembly -
5-5 F2TZ-7D021B F2TZ-7D021B 1
Intermediate Band Servo
5-6 A36906 ------ Spring - Intermediate Band Servo 1
5-7 E8TZ-7005H E8TZ-7005H Case, Transmission (See Note) 1
5-8 C6AZ-7A178A ------ Screw, Reverse Band Adjusting 1
5-9 375185-S100 ------ Nut and Washer - Seal Type 9/16-12 1
5-10 C6AZ-7D433A ------ Shaft - Intermediate Band Actuating Lever 1
5-11 C7AZ-7E206A ------ Retainer - Intermediate Band Servo Lever 1
5-12 E0TZ-7330A ------ Lever - Intermediate Band Servo 1
5-13 C6AZ-7D430C ------ Strut - Intermediate Band Anchor 1
5-14 C6AZ-7D029C ------ Strut - Intermediate Band Anchor 1
5-15 D9AZ-7D034B D9AZ-7D034-B Band Assembly 1
5-16 D8TZ-7A228B ------ Dipstick and Filler Tube 1
5-17 E7TZ-7A020D TPG-E7TZ-7A020D Dipstick Indicator (C6) 1
Note: Transmission Case (P/N E8TZ-7005H) includes the following parts:
Ford Part
Qty Description
Number
Page 15
December 2005
3 4 5 6
1 2
8
7
9 10 12
14
28
24
27
20
21 19 18
25 22 17
23
Figure 6. Parking Pawl, Throttle, and Manual Control Linkage
Page 16
December 2005
Table 6. Parking Pawl, Throttle, and Manual Control Linkage

Description Qty
Ind Number Number
6-1 E8TZ-7005H E8TZ-7005H Case, Transmission (See Note 2) 1
6-2 D3TZ-7B368A ------ Washer, Thrust - Output Shaft (Rear) 1
6-3 D6TZ-7A233A ------ Gear, Parking - Output Shaft (See Note 1) 1
6-4 C6AZ-7D071A ------ Shaft - Parking Pawl 1
6-5 EOTZ-7A441A ------ Pawl, Parking 1
6-6 C6AZ-7D070B ------ Spring, Parking Pawl Return 1
6-7 U36995 ------ Plate 1
6-8 379058-S7-8 ------ Screw (Band Adjuster) 1
6-9 DSAZ-7B498A ------ Seal Assembly - Manual Control Lever 1
6-10 EOTZ-7A256B ------ Lever Assembly, Manual Control 1
6-11 Discontinued -- No Longer Used
6-12 DBTZ-7A247A ------ Switch, Neutral Safety Trans. Mount 1
6-14 55651-S2 ------ Screw 2
6-17 C9AZ-7D417A ------ Spring - Park Plate Torsion 1
6-18 C9AZ-7D414A ------ Plate Assembly - Park Rod Support 1
6-19 C9AZ-7D418A ------ Shaft - Parking Plate 1
6-20 EAA-6572A ------ Cup, 0.536" Dia. Plus 1
6-21 56501-S2 ------ Screw 1
6-22 EOTZ-7A261A ------ Spring, Manual Control Valve Detent Lever 1
6-23 CTR-C6-100 ------ Lever 1
6-24 U36991A ------ Rod 1
6-25 33848-S8 ------ Nut 1
6-27 353079-S ------ Ball, Detent ½" Dia. 1
6-28 380505-S ------ Ring, Retainer 1
Note 1: Output Shaft Parking Gear (P/N D6TZ-7A233A) includes Thrust Washer (P/N D3TZ-7B368A) (Item 2).
Note 2: Transmission Case (P/N E8TZ-7005H) includes the following parts:
Ford Part
Qty Description
Number
Page 17
December 2005
3
2
1 5
1a
6
7
9 10
10 11
Figure 7. Valve Body Assembly
Page 18
December 2005
Table 7. Valve Body Assembly

Description Qty
Ind Number Number
7-1 E0UZ-7A100A T6-1008-123 Body Assembly, Valve - 3 Speed 1
7-1a D9FP-7A100AA ------ Body Assembly, Valve - 2 Speed 1
7-2 C4AZ-7D227A ------ Retainer, Throttle Pressure 1
7-3 E0TZ-7326D ------ Rod, Gear Selector Valve 1
7-4 D0AZ-7E387A ------ Screen, Main Control Pump Inlet 1
7-5 D6AZ-7D100A ------ Gasket, Valve Body Separator Plate 1
7-6 ------ ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long (Body to Case) 6
7-7 C6AZ-7E062A ------ Gasket, Oil Pan Screen 1
7-8 D5AZ-7A098B D5AZ-7A098B Screen, Oil Pan w/ Gasket 1
7-9 ------ ¼-20 x 1½ Bolt, Hex Head Ø ¼-20 x 1½" Long (Body to Case) 2
7-10 ------ 10-24 x 1¼ Bolt, Oil Screen #10-24 x 1¼" Long 8
7-11 ------ 10-24 x 1 5/8 Bolt, Oil Screen #10-24 x 1 5/8" Long 1
Page 19
December 2005
Page 20
December 2005
Engineering Repair/Authorization No. Rev.
15-567680-03 Original
Title: Tug M1A Horn Button Hazard Elimination File Code
Sheet 1 of 5
0960-03-15

The intent of this Engineering Authorization (EA) is to provide instructions and authorization necessary to modify the
mounting technique for the steering column mounted horn button on Tug M1A Baggage Tractors. Knee
injuries/lacerations have occurred as a result of sharp edges on the mounting hardware. Following the instructions
contained in this EA will greatly reduce the risk of such injuries.
As Tug M1A Units are inspected during PMI, there are only two acceptable locations for the Horn Activation Button:
Location #1 is the original location, on the center of the steering wheel. If operational, no action required.
Location #2 is aftermarket “button” located on the steering column with the button facing to the left. (From Operators
view) Buttons in this location often have the hazard identified and require the instructions in this EA to be followed.
N/A
At Next Check
EFFECTIVITY
All Delta owned/maintained Tug Model M1A Baggage Tractors. Effectivity list will be provided with the distribution of
this EA and stored in Supporting Documents folder.
Total (1686) Units
NOTES
1. EA Planner Create EBIS notifications for this EA to be completed at next PMI visit of each unit
per the effectivity list provided.
2. Technical Publications Create an EA Appendix at the end of each manual and add this EA to the Appendix.
There is no need to reference this EA throughout the manuals as it pertains to an
aftermarket (non-OEM) part and will be referenced in the PMI document only.
Insert into the following manuals: pdf 1196, 2026, 2128, and 2253
3. Technical Analyst Notify all affected GSE Managers and supply effectivity list with the distribution of
this EA.
4. Material Planner Upon release of this EA, create increased stock levels of materials specified in all
three NAPA IBS locations.
5. Engineer Modify E-PMI form to reference this EA in conjunction with testing horn function.
MATERIALS (Read notes before ordering parts)

NOTE: Two clamp sizes listed, use smaller, # 72303 whenever possible.
NOTE: Order Horn Button ONLY IF REPLACEMENT IS REQUIRED.
QTY PART NUMBER DESCRIPTION MFG SUPPLIER
2 72303 Hose Clamp #16, 13/16 -1 1/2" Imperial NAPA IBS
2 72304 Hose Clamp #20, 13/16 -1 3/4" Imperial NAPA IBS
1 (as needed) HB6018 Button, Horn universal, misc. Echlin NAPA IBS
15-567680-03 Original
Sheet 2 of 5
0960-03-15
INSTRUCTIONS
1. Identify the hazard as shown in figures A & B.
2. If horn button is located on steering wheel and functions properly, write “Horn on steering wheel” in the
corrective action box and close out the Ebis work order.
THE BRACKETS
AND LONG
MOUNTING
SCREWS CIRCLED
HAVE RESULTED
IN INJURIES TO
THE OPERATOR’S
KNEE AREA.
Figure A Figure B
3. If this hazard does exist, continue with the following steps.
4. Disconnect the vehicle battery and utilize proper PPE as necessary.
5. Remove attachment screws and retaining band from existing horn button and discard. (Fig. C&D)
NOTE: If horn button shown (part # HB6018) is not operational, order replacement # HB6018 from NAPA IBS.
Discard this hardware
HB6018
Figure C Figure D Figure E

15-567680-03 Original
Sheet 3 of 5
0960-03-15
6. Acquire two Hose clamps (part # 72303) and get each clamp started around the steering column leaving them
very loose. Arrange the clamps so that the screw head is facing to the right as pictured. (Fig. F)
NOTE: If larger clamps are required, use part # 72304 or equivalent.
7. Turn the horn button 90 degrees and hold firmly against steering column. (Fig. G)
8. Slide the clamps over the mounting flanges on the button assembly, ensure that screw housing is located on top
of steering column and begin to tighten. (Fig. H)
CAUTION: Be sure that wiring is not pinched under clamps and that terminals are not shorted against column.
Figure F Figure G Figure H

9. When satisfied with horn button position and clamp location, tighten securely.
NOTE. Use only specified clamps to avoid having excess clamp as shown in figure I below.
10. Figures J & K show examples of proper repair with hazard eliminated.
AVOID CREATING A NEW

HAZARD! USE SPECIFIED
CLAMPS.
Figure I Figure J Figure K
15-567680-03 Original
Sheet 4 of 5
0960-03-15
11. After installation is complete, re-connect the vehicle battery and test horn function.
12. Once complied with, close only the EBIS Work Order card that was generated for this EA. DGS and Contract
Stations submit closeout notifications to the Control Work Center (CWC) via fax at (404)773-2790.
DRAWINGS/ATTACHMENTS
15-567680-03 Original
Sheet 5 of 5
0960-03-15
General Information
Equipment
Type
Signature Information
Revision Author Author Approved Approved
Date Date
Original Ardrey, Brian 04/30/18 Swalwel, Bryan 04/30/18
Checker Information
CheckerName CheckDate
Distribution
15-581593-03 A
Title: M1A Electronic Transmission Upgrade File Code Sheet 1 of
0960-03-15-01-01 54

The intent of this Engineering Authorization (EA) is to provide instructions and authorization necessary to
upgrade Delta’s TUG M1A Baggage Tractors from the C-6 mechanical transmission to the GM Gen 3
electronic transmission. The conversion process will include replacement of the transmission, cooler and
cooling lines, driveshaft, parking brake assembly, electrical wiring harness, throttle pedal, and shifter assembly
with all associated piece parts.
The primary reason for this upgrade is to improve the safety of the M1A tractors. By removing the mechanical
linkages between the shifter and transmission the potential for uncommanded movement due to shifter
maladjustment is eliminated. In addition to the safety enhancement, the upgrade will create other significant
reliability improvements such as a shift enable function and transmission fault light. This will prevent operators
from accidentally damaging the transmission through improper actions. The M1A Bag Tractor fleet will
eventually be fully upgraded to the GM Gen 3 electronic transmission through either this EA upgrade or by
zero-time overhaul and retrofit.
REVISION
Rev A – Revised the wiring instructions for the starter circuit under “Dash Power Harness Installation” and
added a new wiring diagram to clarify the final configuration.
15-1095 M1A Throttle Pedal Extension Plate
Execution of this EA will be managed by a project schedule and coordinated with GSE Planning and the
affected GSE Station Managers.
EFFECTIVITY
The effectivity list is stored in the supporting documents folder.
NOTES
1. EA Planner Create EBIS work orders for this EA to be completed according to the project
schedule provide by GSE Engineering.
2. Technical Publications Update the following manual(s) both on the GSE webpage and in EBis.
o Create an EA Appendix at the end of the/each manual
o Place this EA in the EA Appendix
o Create a bookmark for the EA Appendix
o Create a bookmark for the EA (within the EA Appendix)
 Manual # 1196, e-Page # 94, 108, 121, & 171
 Manual # 2062, e-Page # 61, 77, 93, & 167
 Manual # 2128, e-Page # 61, 67, 74, 90, & 145
 Manual # 2253, e-Page # 61, 142, & 963
3. Technical Analyst Update the Bag Tractor PMI to include diagnostic checks of the electronic
transmission (if installed).
15-581593-03 A
0960-03-15-01-01 54
4. Material Planner Assemble EA kits as outlined in the parts list. Quantities of kits needed per
station will be communicated by GSE Engineering. Ship to stations in
accordance with the project schedule provided by GSE Engineering.
5. Engineer Distribute to all GSE managers affected by this EA.
PARTS LIST
Important: Order only one kit # 1558159303KIT & Transmission # TRN5347 per unit to be completed. The
kit is inclusive of all parts needed to complete this EA. All kit parts and quantities are listed in the full BOM
under the DRAWINGS/ATTACHMENTS section for reference or future replacement purposes. Contact NAPA
IBS for any missing components.
ITEM QTY PART DESCRIPTION MFG SUPPLIER
NUMBER
1 1 TRN5347 PCS 4LHD Electronic Transmission PCS NAPA
2 1 1558159303KIT PCS Electronic Transmission Install Kit PCS NAPA
GENERAL INSTRUCTIONS
1. Obtain the Transmission and Install Kit shipped to the station by Napa/IBS.
2. Perform lockout/tagout procedures. Utilize appropriate PPE as necessary.
3. Turn off Tractor and disconnect the battery cables.
4. Secure the Tractor in place with chocks. Do not raise it on jacks yet.
DISASSEMBLY INSTRUCTIONS
1. Remove and retain the transmission cover “doghouse”, center firewall panel, and the dash cover plate to
gain access as shown in Figure 1.
Figure 1
15-581593-03 A
0960-03-15-01-01 54
2. Open and support the seat panel with the prop rod. Remove and discard the shifter assembly and old
shifter-tower by disconnecting the shifter cable from the shifter and disconnect/cut wiring from neutral
safety switch. Discard these components, none will be reused. Reference Figures 2 & 3.
3. Cut the seat switch wiring 24” from underside of seat panel as shown in Figure 4.
Figure 2 Figure 3 Figure 4

4. Remove the seat pan assembly from Tractor and set aside.
5. Remove the power wire from the back-up alarm under the driver side frame just forward of seat pan.
Leave the alarm ground wire in place.
6. Disconnect the parking brake cable from the drum brake as shown in Figure 5.
7. Remove and retain the chassis junction plate (parking brake plate). Retain the clevis and clevis-pin(s)
hardware with the brake cable to be reinstalled.
Figure 5
15-581593-03 A
0960-03-15-01-01 54
8. Remove the left front engine compartment side panel and retain with the 4 bolts per Figure 6.
9. Remove and discard the driveshaft (4 rear bolts) from the rear differential per Figure 7.
Figure 6 Figure 7
10. Place a catch-pan under the transmission.

11. Disconnect the modulator “kick-down” cable from the accelerator pedal. Will be completely removed
and discarded as shown in Figure 8.
12. Remove the old trans cooler, hoses, & lines from the vehicle, Ref Figure 9. Discard all removed parts.
Plug the transmission cooler ports on the old transmission for storage or shipping.
13. Cut any wires connected to the transmission pressure switch.
Figure 8 Figure 9
15-581593-03 A
0960-03-15-01-01 54
14. Raise the unit and place on approved jack-stands as shown in Figure 10.
15. Remove the transmission mount (x2) nuts on the rear underside of the transmission shown in Figure 11.
16. Using an overhead crane or an engine hoist, support and lift the transmission as shown in Figure 12, then
remove the torque converter (x4) nuts.
17. Support the rear of engine from above or below. Engine hoist shown in Figure 13.
Figure 10 Figure 11 Figure 12 Figure 13
18. Remove the bellhousing bolts (x6) and separate the transmission from the engine and remove from
vehicle as shown in Figure 14 & 15.
CAUTION: The torque-converter is now unsupported and can fall out. Keep transmission level.
19. Remove the old transmission mount bracket and discard as shown in Figure 16.
NOTE: Ensure C-6 transmission is fully drained prior to crating for shipment. The new casing from the
GM electronic transmission can be used for shipping the old C-6 transmission.

15-581593-03 A
0960-03-15-01-01 54
20. Remove discard the C6 flex-plate, flywheel/flex-plate adapter, and bellhousing adapter, per Figure 17 &
18.
21. Inspect the starter ring gear condition per Figure 19 & 20. “Teeth” should not be worn down. Replace if
necessary.
THESE TEETH DO NOT
MESH WITH STARTER
INSPECT
RING GEAR
TEETH FOR
CONDITION
22. Disconnect the throttle cable from the throttle pedal assembly. Remove the throttle pedal assembly and
discard as shown in Figure 21.
NOTE: Throttle cable will remain in unit.
23. Remove the anti-restart relay “ice cube relay” from behind the dash panel as shown in Figure 22 & 23.
a. Completely remove wire # 93A from terminal 2 on the relay base to start terminal on ignition
switch and discard wire.
b. Cut wire # 93 from terminal 3 on the relay base. Route wire out of the way.
c. All additional wires on relay base can be removed (cut-off) and tied back.
d. Remove the relay base from dash housing and discard.

15-581593-03 A
0960-03-15-01-01 54
24. Move 50-amp breaker from current location up one bolt hole and re-secure. If no hole exists, move the
breaker up so that the bottom hole is aligned with the old top hole. Mark the new top hole location and
drill a new 1/4” hole. Re-secure with existing hardware. Reference Figure 24.
25. Unbolt and remove the brake pedal assembly as shown in Figure 25, and set aside for later reinstallation.
a. Note: This component needs to be removed for drill access to the left throttle housing plate.
Figure 24 Figure 25
ASSEMBLY INSTRUCTIONS
NOTE: All drive line bolts require RED lock-tight unless bolts already come with pre-applied lock-tight.
NOTE: For fastener torque specs reference the PCS chart under the DRAWINGS/ATTACHMENTS section.
Preparing the Engine/Frame to Receive the Transmission
1. Prep PCS Flywheel Adaption Kit (TRN8200) for installation as shown in Figure 26 & 27.
a. Attach the engine spacer (TRN8200 Item #2) to the Flywheel adaption plate (TRN8200 Item #1),
using the shorter flanged hex bolts (x8) Item #3. Coat all nuts with RED Lock tight.
2. Install new Flywheel adaption plate with engine spacer onto the unit flywheel as shown in Figure 28.
Ensure all 8 bolts are coated in RED Lock tight. Start all bolts by hand before tightening.
3. Install the flex plate (TRN8350). Start all (x8) TRN7502 bolts by hand before tightening. Ensure flange
is pointed in the correct direction as shown in Figure 29.

15-581593-03 A
0960-03-15-01-01 54
4. Install the new transmission mount bracket (TM1-2-8080) to the cross-member, using (x4) TRN7553
nuts and (x4) TRN0250 bolts as shown in Figure 30.
Figure 30
Preparing the Transmission for Installation
1. Hoist Transmission to a comfortable height using overhead hoist or crane.
2. Cut the right-hand upper bell housing hole flange to allow for dip stick installation in following step as
shown in Figure 31.
CAUTION: Do not remove plug from transmission dip stick port before cutting the flange to ensure no
metal shavings / debris falls into the transmission port.
3. Install the heat shield on the left side using (2x) bolts in TRN7012 kit as shown in Figure 32.
4. Install the transmission mount (620-1543) to the rear of the transmission using (2x) TRN7527 bolts as
shown in Figure 33.

15-581593-03 A
0960-03-15-01-01 54
5. Remove the plug from the engine rpm bore hole in the left side of bell housing as shown in Figure 34.
6. Install the speed sensor (SNS1025) by inserting the sensor sleeve into the bore and then inserting the
sensor into the sleeve as shown in Figure 35.
Figure 34 Figure 35
7. Install the TCM mounting bracket (TRN7008) to the left side of the transmission using (x2) TRN7506
bolts as shown in Figure 36.
8. Install the caliper plate (TRN0274) on the rear of the transmission secured with (x2) TRN7500 bolts as
shown in Figure 37.
9. Install the Brake Lever Bracket (TRN0280) on the right rear end of the transmission using (x2)
TRN7500 bolts in the positions shown as shown in Figure 38.

10. Before installing the disc brake “bell-crank” apply arm (TRN0283), lubricate the linkage sleeve with
anti-seize grease and insert into the apply arm. Install onto the brake lever bracket with (x1) TRN7528
bolt through the apply arm and sleeve as shown in Figure 39 & 40.
Figure 39 Figure 40
15-581593-03 A
0960-03-15-01-01 54
11. Move transmission into position to slowly lower into the Tractor. Remove the torque converter shipping
bracket and discard. Ensure torque converter spins freely inside the transmission.
CAUTION: The torque converter WILL fall out of transmission if the transmission does not remain level.
Transmission Assembly in Unit

1. Align and install the transmission to the bell housing using (x9) TRN7501 bolts as shown in Figure 41.
Do not fully tighten the 9, 11, 1, or 3 o’clock bolts since there will be other components installed behind
them in following steps.
NOTE: Hole at the 10 o’clock position is unused.
2. Install the transmission mount nut (1x) TRN7508 at the rear of the transmission, Ref Figure 42.
Figure 41 Figure 42
3. Prior to installing torque converter (x3) TRN7503 bolts, push torque converter rearward towards
transmission and measure gap per Figure 43.
a. Verify gap to be 1/8” with 1/16” tolerance (1/16” – 3/16”).
b. Install the torque converter (x3) TRN7503 bolts through the flex plate to the torque converter.
Rotate crank as necessary to reach all bolt holes per Figure 44.
Figure 43 Figure 44
15-581593-03 A
0960-03-15-01-01 54
Disc Parking Brake and Drive Shaft Assembly

1. Install the brake disc (BRK0230) and drive shaft (722938) onto the rear transmission flange with (x4)
TRN7531 bolts using red lock-tight as shown in Figure 45.
2. Install aft end of drive shaft on the rear differential using (x4) TRN7551 bolts, and (x4) TRN7552 nuts
as shown in Figure 46. May need to rotate the drive shaft 90 degrees if bolts do not easily align.
Figure 45 Figure 46
3. Install the brake caliper with pads (TRN7035) to the caliper plate using (x2) caliper bolts (TRN0275) as
shown in Figure 47 & 48.
CAUTION: The caliper body adjustment set screw on top of the caliper is not high strength and can
shear if over-tightened, Ref Figure 48. Stop tightening when snug.
NOTE: Coat non-threaded portion of bolt with anti-seize, and threads with red lock-tight before
installing, Ref Figure 47.
NOTE: The caliper piston can be tightened using the caliper arm as tool. When hand tight, back off one
quarter turn, Ref Figure 49.
Caliper arm
Caliper adjustment
set screw

15-581593-03 A
0960-03-15-01-01 54
4. Install park brake sensor flag arm on the caliper arm bolt, then secure arm and flag with (x1) nut as
shown in Figure 50.
NOTE: The flag will be required for future maintenance adjustments of brake caliper.
5. Install the park brake sensor assembly as shown in Figure 51.
a. Install park brake sensor bracket (VHW0052) to the top of the Brake Lever Bracket using (x2)
TRN7556 bolts, and (x2) HDW9010) nuts. Ensure bracket is positioned so the proximity switch
will be aligned directly with center of the clevis pin.
b. Install proximity sensor (VHW0051) into the brake sensor bracket facing aft, secured with two
large jam nuts. Final adjustment will be done in a later step.
Caliper Sensor Flag
Figure 50 Figure 51
6. Install the male end of clevis fitting (TRN0285) into female end of clevis fitting (TRN0284). Then
install the male clevis fitting onto the caliper arm with pin and secure with cotter key. Install lower
female clevis fitting onto the disc brake “bell-crank” apply arm upper hole as shown in Figure 52 & 53.
NOTE: The small bronze coated clevis fitting included in Kit is not used for Delta installation, it can be
discarded. Only the 2 larger silver clevis fittings will be needed.
Not Used
Figure 52 Figure 53
15-581593-03 A
0960-03-15-01-01 54
7. Reinstall the center body cross-member (using existing hardware), with park brake lever assy mounted
to it as shown in Figure 54.
8. Route the existing park brake cable over the transmission housing to attach the end fitting to the brake
lever as follows.
a. Remove existing cable end clevis and slide cable through the bracket hole, then secure with jam
nut as shown in Figure 55.
b. Install park brake cable spring (VHW0059) and spring-retention washer (TRN7550) to the cable
end, then reinstall clevis fitting as shown in Figure 56.
c. Attach cable end clevis to the lower hole of “bell crank” apply arm with pin and cotter key.
Note: ensure heat shield doesn’t interfere with the clevis pin on lower apply arm hole. If so, bend
the heat shield out away from the apply arm to create clearance shown in Figure 56 & 57.
d. Adjust the parking brake cable by twisting brake handle until sufficient caliper brake pressure is
applied when lifting the park brake lever handle. Secure brake handle adjustment with proper
cold shrink.
Bent Out

15-581593-03 A
0960-03-15-01-01 54
Cooler, Hoses, and Line Assembly

1. Install the (x2) new transmission cooler hard lines utilizing existing fender (frame) mounting bolt holes
as shown in Figure 58.
a. Use new (x4) P-Clamps to secure both the hard lines to the frame at both aft mount hole
locations.
b. Use new (x1) P-Clamp to secure the forward end of the longer hard line only, to the frame at the
forward mount hole location.
Forward mount hole

for single P-Clamp
Figure 58
2. Remove the top bellhousing bolt at 11 o’clock position and install (x1) bellhousing bracket (VHW0063),
then reinstall bellhousing bolt, as shown in Figure 59.
3. Install the (x2) Transmission cooler hoses to the right-side fittings on transmission. The fittings on the
transmission (shown in Figure 60) must be replaced with larger diameter adapter fittings. Two sets of
fittings are supplied in the kit. You will have to determine which set to use by inspecting the fittings that
you remove from the transmission. If O-Ring style removed, use larger O-Ring style adapters. If Pipe
Thread style removed, use larger Pipe Thread style adapters.
4. Secure the cooler hoses to the bellhousing bracket using (x2) P-Clamps, as shown in Figure 60.
Figure 59 Figure 60
15-581593-03 A
0960-03-15-01-01 54
5. Remove the oil cooler mounting nuts but do not remove the oil hoses. Then displace the oil cooler.
6. Install the new transmission cooler assembly behind the front grill by attaching it to the front surface of
the oil cooler assembly as shown in Figure 61. Ensure the trans cooler is installed with the flow in the
correct direction, routing upper Transmission port line to upper Cooler port and lower Transmission port
line to lower Cooler port. Removal of the oil cooler may be necessary for this step.
7. Attach the transmission cooler lines to the new transmission cooler assembly using new hoses as shown
in Figure 62.
Figure 61 Figure 62
8. Install the dipstick Kit (7011)

a. Install the dipstick bracket (TRN7013) to the bell housing at 3 o’clock bolt, per Figure 63.
b. Remove the dipstick plug in transmission using care not to allow dust / debris into the
transmission.
c. Route dipstick tube down behind the engine exhaust pipe and into the trans hole per Figure 64.
d. Screw the rubber insulator provided in dipstick kit to the bellhousing bracket.
e. Secure the dipstick tube to the bellhousing bracket with (x1) M8125 flanged bolt per Figure 65.

15-581593-03 A
0960-03-15-01-01 54
9. Install the overflow vent hose with the transmission vent “Y-fitting” tube to top of transmission vent
tube as shown in Figure 66.
a. The lower open end of hose should route down below brake caliper to allow draining below the
tractor per Figure 67. Zip tie hose at bottom without pinching the hose.
b. Upper end of hose atmospheric vent cap will be routed up to mount later to the forward side of
the fire wall with a p-clamp.
Figure 66 Figure 67
10. Install brake pressure switch
a. If unit has in line brake pressure switch already installed for the brake light, remove and install a
new brake pressure switch (VHW0048), provided in Kit. Reference Figure 68.
b. If unit is equipped with mechanical brake light switch under the dash, installation of a Tee-fitting
in the brake line will be required in order to install the new brake pressure switch
(LM2A40REP), provided in Kit.
Figure 68
15-581593-03 A
0960-03-15-01-01 54
Dash Components Installation

1. Enlarge both holes for throttle pedal pivot arm to 1/2” diameter.
a. Enlarge the upper existing holes for throttle pedal pivot arm bearing blocks to ¼” on both sides
of the pedal retention housing as shown in Figure 69.
b. Use a 3/8”D x 6.5”L rod as a guide tool to position the bearing blocks on either side of housing
and align upper holes that were just enlarged and insert bolts temporarily. Ref Figure 70.
c. Mark the location for the new lower holes to be drilled to 1/4”.
d. Remove the bearing blocks and rod, then drill the 1/4” lower holes at marked locations per
Figure 71.

2. Drill new holes for the TPS Arm (throttle positioning sensor arm) on the throttle pedal retention plate as
shown in Figure 72.
NOTE: These holes may already be present in some kits, and if so skip to next step.
3. Prior to installing the Throttle pedal, fit check it in the dash housing. If new pedal assembly interferes
with the dash housing bolt, cut clearance angle as needed as shown in Figure 73.
NOTE: The clearance angle may already be cut in some pedals, and if so skip to next step.
Figure 72 Figure 73
15-581593-03 A
0960-03-15-01-01 54
4. Install new M1A Throttle Pedal Kit (VHM2005)

a. Sand down the throttle pivot rod (if necessary) on the new M1A Throttle Pedal (HVW0054) to
install bearing blocks
b. Install the (x1) pedal bearing block (VHW0055) on the long side of the pivot rod, Ref Figure 74
c. Insert the pedal into the dash and the rod into the pre-drilled ½” holes on outboard side of
housing.
d. Push the bearing block till it touches the housing and secure with (x2) bolts (HDW0777), Ref
Figure 75
e. Place the remaining (x1) pedal bearing block on the short side of the pivot rod on the inboard
side of the housing and insert the rod through the bearing and the housing.
f. Secure rod and bearing with (x2) bolts (HDW0777).
g. Ensure there is enough of the rod sticking out of the housing on each side to secure with (x2)
cotter pins, Ref Figure 76.

h. Test pedal to ensure it moves freely.
5. Install the new throttle cable extended mounting plate (P/N: 15-1095) to the top 2 holes of the throttle
pedal assembly and secure with original hardware as shown in Figure 77.
NEW THROTTLE
EXTENSION PLATE
Figure 77
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a. Locate the proper position hole on the throttle pedal vertical arm for the new throttle return
spring retention Pin (TRN7559) and Post (TRN7560) to ensure the spring will not interfere with
throttle cable or firewall per Figure 78.
NOTE: If necessary, mark new post position on the throttle pedal vertical arm for drilling. Drill
a 13/64” hole at the marked location and install the throttle return spring binding post.
b. Install dual throttle return spring (P/N: 6755177). Route the spring through the hole in the
firewall. Secure it with a cotter pin to the existing hole in the brake booster weldment as shown
in Figure 79.
NOTE: If no hole exists in the brake booster weldment, drill a 1/4” hole as shown below.
Figure 78 Figure 79
6. Reinstall the original brake pedal assembly, reusing original hardware.

7. Install the Remote Mount TPS Adaptor kit (TCM6045) to the dash housing
a. Remove the existing throttle stop bracket temporarily. Drill 1/4” bit through existing hole to
remove internal threads.
b. Align the forward TPS mounting hole with throttle stop bracket hole. Mark aft TPS mounting
hole position. Remove TPS sensor prior to drilling 1/4” hole.
CAUTION: Do not allow metal shavings near the sensor.
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c. Place throttle stop bracket back in position and place TPS on top. Add the spacer nut (TRN7558)
underneath aft TPS mount hole to compensate for stop bracket height difference. Secure with
(x2) 1/4-20X1.25 Bolts (TRN7557), (x2) 1/4-20 Nylock nuts (HDW9010), and (x2) 1/4 washers
(MCM90126A029). Reference Figure 80.
d. Assemble the TPS adjustment arm bracket to the throttle assembly using (x2) bolts (HDW0336)
and (x2) nuts (HDW9002) as shown in Figure 81.
e. Install the TPS linkage between the TPS and the adjustment arm bracket per the instructions
below and using the upper hole on each arm as shown in Figure 82.
1) Remove the rod ends from the linkage rod and set aside with their hardware.
2) Cut the threaded rod to 2-5/8” end to end.
3) Reattach the rod ends to secure the linkage between the TPS arm and the adjustment
bracket using the hardware previously removed.
4) Ensure linkage adjustment results in 3-1/2” measurements between upper holes in the
TPS and adjustment arm bracket as shown in Figure 82.
3-1/2” hole to hole
Spacer Nut Throttle Stop
f. Test throttle pedal to ensure it has full range of motion.
8. Replace the ball joints on both ends of the existing throttle cable with (x2) (6101 IMPERIAL)
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9. Attach the throttle cable end to the new throttle cable extension plate (15-1095) and secure with (x1) nut
(12509 IMPERIAL) as shown in Figure 83.
10. Tighten the jam nuts on the throttle cable connection at the brake booster weldment, ref Figure 85.
NOTE: Ensure throttle cable retention bracket near alternator is P/N: TM115033 as shown in Figure 84.
If non-standard bracket exists, replace with correct bracket. Otherwise, the throttle cable will
not align properly.

11. Ensure that when the throttle pedal assembly rests fully against the firewall, the engine throttle lever is
fully resting on the idle screw. If not, make proper adjustments to the throttle cable.
12. Locate an unused hole in LH side of dash panel and remove plug per Figure 86. Enlarge hole using a
stepper bit to 11/16”. Insert the Trans Fault light (TRN1250) through the “Trans Fault” Placard and then
secure it to the dash panel per Figure 87.
13. Locate an unused hole in RH side of dash panel and remove plug. Enlarge hole using a stepper bit to
11/16”. Insert the Shift Enable light (TRN1260) through the “Shift Enable” Placard and secure it to the
dash panel per Figure 87.
Figure 86 Figure 87
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Dash Power Harness Installation

1. Visually inspect ignition switch for condition and replace as needed. (Parts not included in kit)
2. Install new Dash power harness (in TCM4880 bag) per the following instructions.
a. Use an existing hole in the dash panel near the throttle linkage to attach the harness fuse block
mounting bracket (attached to the fuse block). Allow for best clearance of fuse box, Ref Figure
88. Mark location for any new holes on the outside of the dash panel as a drill will not fit in dash.
b. Drill marked holes for ¼” bolts. Clean any resulting burs so bracket will lay flat.
CAUTION: Use care not to drill into wiring behind the dash housing.
c. Secure fuse box bracket inside the dash housing with (x2) bolts (TRN7556) and (x2) nuts
(HDW9010) as shown in Figure 89.
d. Insert the fuse box on the Dash power harness into the bracket per Figure 90. Ensure it is fully
seated.
e. Insert the throttle positioning sensor connector (labeled) into the TPS module per Figure 91.

A 3. Plug wiring connectors for Shift Enable light and Trans Fault light into the PCS dash power harness.
4. Remove Ignition Switch from dash housing and unmount the Seat Switch Cut-Off Relay for easy access
to wiring on both components.
a. Remove and discard existing Seat Switch Cut-Off Relay. It will be replaced with Relay from kit
NOTE: Reference “M1A E-Trans Ignition and Cut-Off Circuit Diagram” in the Attachments section to
confirm the following connections are correct.
5. Route the red & blue wires from the PCS Dash Harness to ignition switch as shown in Figure 92 & 93.
a. Connect red B+ 12V wire from PCS Dash Harness to the BAT (B+) terminal on ignition switch.
b. Move the red wire from the B+ terminal on ignition switch that goes to Pin 30 on Seat Switch
Cut-Off Relay, and connect it to the “IGN” terminal on ignition switch. (Hot in Run position)
c. Locate the original vehicle B+ wire from vehicle main circuit breaker (CB-1) and attach to B+
terminal on ignition switch. It may be required to add length or make a new wire.
d. Remove existing start signal wire from the “ST” (start) terminal of ignition switch (not reused).
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A e. Connect blue start signal wire from PCS Dash Harness to the “ST” terminal on ignition switch.
NOTE: If ignition switch has spade connectors, it may be necessary to remove the ring terminals
and splice the Red and Blue wires as shown in Figure 93.
6. Route the yellow wire of PCS Dash harness to the seat switch cut-off relay behind dash and add to
existing wires coming from terminal 87 of the cut-off relay. This may require use of butt connector
instead of ring terminal as shown in Figure 94.

7. Install new Seat Switch Cut-Off Relay (AR143) from kit and discard original seat cut-off relay. While
appearance is the same, one has an internal diode that causes a 20A fuse to blow.
NOTE: Final wire connection in dash area will be completed in Step 18 of “Main Harness Installation”.
Main Harness Installation
1. Install the TCM (Transmission control module) on TCM bracket located on the transmission with (x3)
bolts (in TRN8360 Kit) as shown in Figure 95.
2. Insert the TCM connector from Main harness to the TCM on left side of transmission per Figure 95.
3. Route main harness across transmission and connect large round grey “Transmission Connector” (C-1)
into the transmission on right side per Figure 96.
4. Connect the black two-pin “Output shaft speed sensor” connector (C-2) to the rear transmission output
speed sensor Per Figure 97.

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5. Connect short 4-pin deutsch “Park Brake Connector” (C-8) to the park brake position proximity sensor
wire connector.
a. Coil excess gray prox sensor wire and secure to park brake cable bracket as shown in Figure 98.
6. Connect the short 4” black two-pin “E RPM” connector (C-3) to the forward trans speed sensor wire.
Sensor located in bell housing per Figure 99.
Figure 98 Figure 99
7. Route the remaining long harness section, including black 12 pin “Shifter” connector (C-7) towards the
rear of the vehicle along the left side of frame.
a. Note the harness wire with 4 pin Deutsch “Inching Option” connector (C-9) that is capped will not
be used and will need to be tied back/secured once the harness is installed per Figure 101.
8. Route the 16” leg with green & black wires to the reverse alarm under driver seat area. Connect the
green wire ring terminal to (+) terminal on the reverse alarm. Connect the black wire ring terminal to the
(-) terminal on reverse alarm as shown in Figure 100.
NOTE: The reverse alarm wiring leg may be mis-labeled on the harness as “Reverse Light”.
Figure 100 Figure 101

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9. Install the timer relay to the inside of the rear left frame wall above axle, Ref Figure 102.
a. Dill a ¼” hole into the frame and secure the timer with (x1) bolt (1/4-20 x 2”)
b. Ensure terminal 8 is orientated at the top when installed.
NOTE: Reference “M1A E-Trans Ignition and Cut-Off Circuit Diagram” in the Attachments section to
ensure the following connections are correct.
10. Route the short 3 individual wires on main PCS harness (red, black & black/purple) to the cut-off circuit
timer, located inside frame above left rear axle.
a. Connect the 2 female spade terminals on red wire to terminals 1 & 2 on timer (position selection
does not matter), Ref Figure 102.
b. Connect female spade terminal on solid black wire to terminal 3 on timer unit, Ref Figure 102.
c. Connect female spade terminal on black/purple wire to terminal 8 on timer unit, Ref Figure 102.
11. Route short green and black wires with spade terminals to connectors on the rear reverse lights as shown
in Figure 103. The harness may be mis-labeled as “Reverse Alarm” on these wires.
a. Disconnect the existing TUG harness from existing rear reverse lights.
b. The new green wire goes to existing red wire and the new black wire goes to existing white wire.
c. Secure wires with zip ties to the old harness as shown in Figure 103.

12. Reinstall the Seat Pan Assembly and prop open with rod.
13. Reconnect the seat switch wires to the cut-off circuit timer unit as shown in Figure 102.
a. Install 2 female spade connectors to the cut ends of the existing yellow and white seat switch
wires.
b. Connect the white wire to terminal 4 on timer unit
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c. Connect the yellow wire to terminal 5 on the timer unit.

14. Route forward long leg of PCS main harness up the engine-side of firewall along existing harness, Ref
Figure 103.
15. Connect the “Ground Chassis” wire large eyelet terminal to the transmission bell-housing bolt at 9
o’clock position as shown in Figure 104.
16. Route the 12 pin “Dash Bulkhead Connector” (C-6), and the single black/violet wire through the firewall
and connect to the PCS Dash Power Harness 12 pin connector as shown in Figure 105.

17. Remove the existing yellow wire/terminal from the “seat switch cutoff relay base” terminal 85. Yellow
wire is now unused and can be completely removed or tied back.
18. Install the black/violet wire from the PCS main harness (next to the dash bulkhead connector) to pin 85
in the “Seat Switch Cutoff Relay Base” as shown in Figure 106.
19. Reinstall the ignition switch and re-mount the Seat Switch Cut-off Relay. Then use wire ties to properly
retain all wiring behind the dash panel.
NOTE: Important to check throttle linkage travel to ensure no interference with wiring in the dash area.
20. Route the “Laptop Calibration Connector” over brake booster and down, then secure with zip ties as
shown in Figure 107. This connector will be used for maintenance diagnostic checks.

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21. Route the long “Brake Pressure Switch” & “Start” wires. (May require removing 8-10 inches of the wire
loom)
a. Connect blue “Start” wire ring terminal to ST80 Start Relay “S” terminal and remove existing wire
from the “S” terminal and tie it back (now unused). Ref Figure 108.
NOTE: on tractors with dual ST80 Relays, identify the correct relay as start circuit relay
b. Connect brown/black “Brake Pressure Switch” ring terminal to the brake pressure switch output
signal. Ref Figure 109.

Shifter Assembly
1. Install the new shifter tower housing (VHW0058) on seat pan reusing the original shift tower bolts and
nuts per Figure 110.
2. Install new PCS Electronic shifter (IES2030) by inserting into the new tower housing and align the side
mounting bolt holes to install 4 each 1/4-20 X 3/4” Bolts (P/N: 20102), using a 1/4” flat washer (P/N:
87611) and 1/4” lock washer (P/N: 76121) on each bolt. Then secure hardware as shown in Figure 111.
Note: Fit is very tight but DO NOT hit with mallet to fit. Ensure shifter is seated fully in the housing and
the “R” gear indicator is facing forward.
3. Connect the 12 pin Deutsch connector on PCS Main harness to the connector on the underside of the
electronic shifter assembly as shown in Figure 112.

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Programing and Calibration

1. Reconnect the battery and turn ignition switch to “RUN” position to ensure the unit powers on properly,
but do not start the engine.
2. Shifter and TCM are pre-programmed by PCS.
3. TPS calibration process:
a. Connect the diagnostic data cable to the diagnostic port labeled “Laptop Calibration Connector”
under the hood near brake booster. Connect other end of cable to USB port on TDD6000 Laptop.
b. Turn ignition switch to “RUN” position, DO NOT START THE ENGINE.
c. Open the PCS “TCM Serial Diagnostics” by clicking on desktop icon. Diagnostic Dashboard
Screen, Figure 113 should appear.
d. Ensure that throttle linkage is in full closed/idle position. From the “Analog Inputs” box on the
LH side of the screen, (Figure 114) take note of TPS voltage with throttle closed in idle position.
Write this value down on a notepad. (example 1.89 V)
e. Press the throttle pedal down fully two or three times, then hold down pedal in wide open throttle
position and take note of TPS voltage (Figure 115). Write this value down on a notepad.
(example 3.88 V)
f. Close the “TCM Serial Diagnostics” program.
Diagnostic Dashboard Screen

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g. Notepad Calculations: (see example in Figure 116)

1) Add .07 to the MIN (idle) reading from step “d” to obtain the adjusted value to be used in
step “m1”.
2) Subtract .07 from MAX (full throttle) reading from step “e” to obtain the adjusted value
to be used in step “m2”.
EXAMPLE:
Throttle at IDLE position your reading 1.47
ADD .07 to your IDLE reading 0.07
Insert this value for “TPS Voltage Closed Throttle” box 1.54
Throttle at WIDE OPEN position your reading 3.80

SUBTRACT .07 from your WIDE-OPEN reading 0.07
Insert this value for “TPS Voltage Full Throttle” box 3.73
Figure116
h. Open the TPS “Configurable Tuning Software” (icon with picture of transmission), gray
“Scratch Pad” screen shown in Figure 117 should appear.
i. Click “Go Online” in the toolbar to connect to the TCM. If connection is successful, the
background to the software will turn from gray to blue as shown in Figure 118.
j. Click the “Read Cal” toolbar button shown in Figure 119 to read the calibration from the
controller. This step is only necessary to get the calibration tree view to show up on the left-
hand side of the screen. You can open an existing calibration to get the same thing but DO NOT
WRITE THE CALIBARATION TO THE CONTROLLER.
k. On the left side of the software screen in the folder view, click to select “Hardware Setup”, then
“Analog Inputs”, then “TPS Calibration” as shown in Figure 120.
l. TPS Calibration box shown in Figure 121 should appear.
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m. The only 2 values that need to change are “TPS Voltage Closed Throttle” and “TPS Voltage Full
Throttle. If the software has a blue background when they are changed, they will be written to
the controller when the change is made. (Figure 121)
1) Delete the existing value and insert the closed throttle/idle adjusted value from step “g1”
into the “TPS Voltage Closed Throttle” box.
2) Delete the existing value and insert full throttle adjusted value from step “g2” into the
“TPS Voltage Full Throttle” box.
n. Click “Write Cal” button on the toolbar. If a previous file exists, you may be asked if you want
to overwrite, click Yes.
INSERT
ADJUSTED
VALUES
HERE
CLICK
CLICK
CLICK
o. When completed, close the “Configurable Tuning Software” program.

p. Disconnect vehicle battery for a minimum of 15 seconds. The controller will not use the new
TPS settings until it has been disconnected from constant 12 volts.
q. Reconnect vehicle battery.
r. Turn ignition switch to “RUN” position (do not start the engine), then open the “TCM Serial
Diagnostics” program.
s. TPS Meter should read “0%” and the “MIN TPS voltage” should match the value that you input
in step “m1”. (within +/- .01)
t. Depress the throttle pedal all the way. TPS Meter should read 100% and the “MAX TPS
voltage” should match the value that you input in step “m2”. (within +/- .01)
u. Confirm that it is safe to do so, then start the vehicle engine and ensure that the RPM Meter on
the display is functioning.
v. Depress the throttle slowly all the way to full throttle position while observing the RPM Meter to
ensure that signal is steady. If RPM reading is erratic or drops off, this indicates a faulty signal
from the Speed Sensor installed in the transmission bell housing. If reading is fairly smooth and
remains constant while holding the throttle full open for several seconds, signal from the Speed
Sensor is good.
w. Confirm also that Battery Voltage on the display is good. (12.5 to 14.2 volts)
x. Shut unit off, exit the “TCM Serial Diagnostics” program and disconnect the TDD6000 Laptop.
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4. Adjust park brake proximity switch and caliper flag, as necessary.

a. The park brake proximity sensor face should be 1/4” from the caliper flag arm. Adjust 2 jam nuts
on either side of proximity sensor bracket to obtain the 1/4” spacing, then tighten nuts.
b. Loosen the caliper arm nut to adjust the flag, using feedback from the sensor’s indicator light,
test and adjust the flag arm until the light reliably turns on when the brake is disengaged (and
light is off when brake is engaged).
Close Up and Testing
1. Replace all panels
a. Reinstall the center firewall panel. Ensure no harness wires are being pinched and are retained
away from moving components and exhaust.
i. Attach upper end of trans vent hose atmospheric vent cap to the forward side of the fire
wall with a p-clamp. Ensure hose is vertical.
b. Reinstall the transmission cover “doghouse”.
c. Reinstall the dash panel cover. Ensure no harness wires are being pinched and are retained away
from moving components.
d. Reinstall the left front engine compartment panel.
e. Close and secure the hood and seat pan assembly.
2. Add Dexron VI transmission fluid prior to starting engine, using 4 ½ Quarts.
3. Start the engine and idle tractor while checking trans dip stick for proper fluid level. Add more fluid as
needed. Check for fluid leaks.
4. Testing the PCS Shifter (Note: The PCS Shifter has a built-in interlock actuated by the brake pressure
circuit)
a. Turn ignition switch to “Run” position to power up the electronics (Do not start the engine),
Confirm the PCS Shifter gear indicator lights illuminate as shown in Figure 122.
Figure 122
b. Confirm the Shift Enable light illuminates on the dash panel when the brake pedal is depressed.
c. Confirm the shifter interlock is released when the Shift Enable light is on the dash panel.
d. Start the tractor ignition.
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e. Confirm that the shifter engages the transmission in both reverse gear and forward gear, and
check the gear indicator lights change color on the shifter as each gear is selected as shown in
Figure 123 and Figure 124.

5. Test drive the tractor in forward and reverse gear.
6. Test drive the unit. Confirm that all the safety features are functional.
a. Test the seat switch to ensure that when you get off the unit WITHOUT turning off the ignition,
the engine completely shuts down after a duration of two seconds.
b. Test the back-up alarm by shifting into reverse gear.
c. Test the park brake lever adjustment by disengaging the park brake lever, move the shifter into
gear, and then reapply the park brake lever. The park brake should hold the tractor from moving.
7. Once complied with, close only the EBIS Work Order card that was generated for this EA.
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DRAWINGS/ATTACHMENTS
M1A E-Trans Ignition and Cut-Off Circuit Diagram

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DELTA M1A DEUTZ BILL OF MATERIALS POWERTRAIN CONTROL SOLUTIONS

DESCRIPTION
BOM SUB PCS P/N VNDR P/N QTY NOTES SUPPLIER
1 MECH DISC PARKING BRAKE KIT (RH) BRK2050 N/A 1 PCS
*SEE PCS DRAWING FOR SUBCOMPONENTS
2 4LHD TCM BRACKET KIT TRN8360 N/A 1 PCS
3 TRANSMISSION CONTROLLER TCM2800 N/A 1 PCS
*NO SUBCOMPONENTS
4 TRANSMISSION HARNESS, DELTA M1A MLC A-TCM4880 N/A 1 PCS
5 INDUSTRIAL ELECTRONIC SHIFTER (FNR) IES2030 N/A 1 PCS
*NO SUBCOMPONENTS
6 4LHD FLEXPLATE KIT, SAE TRN8350 N/A 1 PCS
7 FLYWHEEL ADAPTION KIT TRN8200 N/A 1 "DEUTZ", 41.9mm DEPTH, M10X1.5 BOLTS PCS
8 4LHD DIPSTICK KIT TRN7011 N/A 1 PCS
9 SAE4 DIPSTICK BRACKET TRN7013 N/A 1 PCS
10 4LHD OVERFLOW VENT KIT TRN7006 N/A 1 PCS
*NO SUBCOMPONENTS
11 4LHD HEAT SHIELD KIT TRN7012 N/A 1 PCS
12 ENGINE RPM SENSOR SNS1025 N/A 1 PCS
*NO SUBCOMPONENTS
13 REMOTE MOUNT TPS ADAPTER KIT (M1A) TCM6045 N/A 1 PCS
14 DRIVE SHAFT KIT, M1A FOR 4LHD DISC BRAKE VHW2000 N/A 1
1 DRIVE SHAFT, M1A FOR 4LHD DISC BRAKE VHW0030 TUG 722938 1 TUG
2 BOLT, REAR DRIVESHAFT TRN7551 MCM 92620A656 4 3/8-24x1.25" HEX PCS
3 NUT, REAR DRIVESHAFT TRN7552 MCM 97135A235 4 3/8-24 NYLOCK PCS
15 TRANSMISSION MOUNT VHW0046 NAPA 6201543 1 NAPA NAPA
*NO SUBCOMPONENTS
16 TRANSMISSION MOUNT BRACKET KIT VHW2002 N/A 1 PCS
1 TRANSMISSION MOUNT BRACKET VHW0047 TUG TM1-2-8080 1 EXISTING PART FROM TUG TUG
2 BOLT, MOUNT BRACKET TO FRAME TRN0250 MCM 92620A716 4 1/2-13X1.5" HEX PCS
3 NUT, MOUNT BRACKET TO FRAME TRN7553 MCM 97135A250 4 1/2-13 NYLOCK PCS
4 WASHER, MOUNT BRACKET TO FRAME TRN7554 MCM 90126A033 8 1/2" ID PCS
5 NUT, MOUNT TO BRACKET TRN7508 N/A 1 M10X1.5 FLANGED HEX PCS
6 BOLT, MOUNT TO TRANSMISSION TRN7527 N/A 2 M10X1.5X20mm FLANGED HEX PCS
17 PARKING BRAKE SENSOR KIT VHW2004 N/A 1 PCS
1 PROXIMITY SENSOR W/ CONNECTOR VHW0051 TUG ELE-10046 1 TURCK Bl15-G30K-AP6X-1 2M-DT04-4PM4 TUG
2 BRACKET, PROXIMITY SENSOR VHW0052 TUG TM1-4-5518 1 TUG
3 SENSOR BRACKET BOLTS TRN7556 MCM92979A118 2 1/4-20X0.75" FLANGED HEX PCS
4 SENSOR BRACKET NUTS HDW9010 MCM 91831A029 2 1/4-20 LOCKNUT PCS
5 PROXIMITY SENSOR FLAG VHW0053 N/A 1 PCS
18 M1A THROTTLE PEDAL KIT VHW2005 N/A PCS
1 M1A THROTTLE PEDAL VHW0054 TUG 726042 1 GREEN PAINT AND 2 ADDED HOLES FOR TPS TUG
2 PEDAL BEARING BLOCK VHW0055 EFOI06R 2 NAPA NAPA
3 BOLT, THROTTLE BEARING BLOCK HDW0777 MCM 92865A540 4 1/4-20X0.75" HEX PCS
4 NUT, THROTTLE BEARING BLOCK HDW9010 91831A029 4 1/4-20 NYLOCK PCS
6 BOLT, PEDAL TO TPS HDW0336 MCM 91251A196 2 #8-32X0.625" SHCS PCS
7 NUT, PEDAL TO TPS HDW9002 MCM 90631A009 2 #8-32 NYLOCK PCS
8 BOLT, TPS TO DASH TRN7557 92240A544 2 1/4-20X1.25" HEX PCS
9 NUT, TPS TO DASH HDW9010 91831A029 2 1/4-20 NYLOCK PCS
10 WASHER, TPS TO DASH TRN7555 MCM 90126A029 5 1/4 THICK WASHER PCS
11 SPACER, TPS TO DASH TRN7558 94831A030 1 EQUIVELANT TO 44108 IMPERIAL PCS
12 SPRING 1, PEDAL TO CABLE VHW0056 7321114 1 NAPA NAPA
13 PEDAL EXTENSION PLATE NA 151095 1 NAPA
14 THROTTLE PEDAL POSTIONING TOOL NA 1 METAL ROD - 3/8" DIA. x 6.5" LONG DELTA
Table 1: Full BOM of Install Kit # 1558159303KIT
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DELTA M1A DEUTZ BILL OF MATERIALS POWERTRAIN CONTROL SOLUTIONS

DESCRIPTION
BOM SUB PCS P/N VNDR P/N QTY NOTES SUPPLIER
19 M1A TRANS UPGRADE PRINTED GUIDE DOC0003 N/A 1 LAMINATED 6 PAGE QRG WILL COME WITH THE PCS / DELTA
*NO SUBCOMPONENTS DIAGNOSTIC TOOL KIT
20 M1A DEUTZ TRANS UPGRADE HARDWARE KIT VHW2006 N/A 1 PCS
1 BELLHOUSING BOLT TRN7501 N/A 10 M10X1.5X30 FLANGED HEX PCS
2 SHIFTER TOWER VHW0058 49922398 1 A & B Metal Fab (Delta Supplier) A&B
3 SHIFTER TOWER BOLTS HDW0777 MCM 92865A540 6 1/4-20X0.75" HEX PCS
4 SHIFTER TOWER LOCK WASHERS HDW0204 MCM 91102A750 4 1/4" SPLIT LOCK WASHER PCS
5 SHIFTER WASHERS TRN7555 MCM 92141A029 6 1/4" FLAT WASHER, OR EQUIVELANT PCS
6 SHIFTER TOWER NUTS HDW9010 91831A029 2 1/4-20" NYLOCK PCS
7 SPRING, PARKING BRAKE CABLE VHW0059 LCM125HK 04 M 1 LEE SPRING
8 SPRING RETENTION WASHER TRN7550 N/A 1 PCS
9 SPRING, THROTTLE PEDAL RETURN 7321114 1 NAPA NAPA
10 THROTTLE SPRING RETENTION PIN TRN7559 98338A480 1 IMPERIAL 70726 PCS
11 THROTTLE SPRING RETENTION POST TRN7560 99637A302 1 Z4406SS NAPA
12 THROTTLE WASHER TRN7561 92141A011 1 76053 PCS
13 THROTTLE SCREW TRN7562 92949A242 1 18489 PCS
14 SEAT SWITCH RELAY AR143 1 NAPA NAPA
15 BOLT, FUSE BLOCK TRN7556 MCM92979A118 2 PCS
16 NUT, FUSE BLOCK HDW9010 91831A029 2 PCS
17 M1A Dash Label - Shift Enable VHW0065 1 CANTON GRAPHICS CANTON
18 M1A Dash Label - Trans Fault VHW0066 1 CANTON GRAPHICS CANTON
19 P-CLIP HDW1205 3225T25 1 PCS
20 BOLT, OVERFLOW VENT TRN7556 MCM92979A118 1 PCS
21 NUT, OVERFLOW VENT HDW9010 MCM 91831A029 1 PCS
22 BOLT, TIMER MOUNT GMS0215 MCM 91247A546 1 1/4-20X1.5" FLANGED HEX BOLT PCS
23 NUT, TIMER MOUNT HDW9010 MCM 91831A029 1 1/4-20" HEX NUT PCS
24 RUBBER DIPSTICK SPACER VHW0057 NAPA 65011 1 NAPA
21 LIGHT, RED "CHECK TRANS" TRN1250 N/A 1 W/ DT CONNECTOR PCS
*NO SUBCOMPONENTS
22 LIGHT, GREEN "SHIFT OK" TRN1260 N/A 1 W/ DTM CONNECTOR PCS
*NO SUBCOMPONENTS
23 M1A TRANSMISSION COOLER KIT VHW2001 N/A 1
1 STANDALONE TRANSMISSION COOLER VHW0040 NAPA 18437 1 NAPA
2 M1A TRANS COOLER HOSE TO UPPER COOLER VHW0041 M1AZTUPCLR 1 NAPA/APPLIED
3 M1A TRANS COOLER HOSE TO LOWER COOLER VHW0042 M1AZTLWRCLR 1 NAPA/APPLIED
4 M1A TRANS COOLER HOSE TO LOWER TRANS VHW0043 M1AZTLWRTRNS 1 NAPA/APPLIED
5 M1A TRANS COOLER HOSE TO UPPER TRANS VHW0044 M1AZTUPTRNS 1 NAPA/APPLIED
6 M1A TRANS HARD LINE VHW0045 M1AZT001TL 1 NAPA/APPLIED
7 M1A TRANS HARD LINE M1AZT002TL 1 NAPA/APPLIED
7 ADAPTER 240300806 2 NAPA/APPLIED
8 ADAPTER FOR EARLY VERSION TRANS 24040804 2 NAPA/APPLIED
9 ADAPTER FOR METRIC O-RING TRANS 640008060 2 NAPA/APPLIED
10 ADAPTER 24030808 1 NAPA/APPLIED
11 BELLHOUSING BRACKET TM1-1-8158 2 NAPA/TUG
12 P CLIPS SOFT LINE 75071 2 NAPA/IMPERIAL
13 P-CLIPS HARD LINES 75079 5 NAPA/IMPERIAL
14 BOLT P CLIP HARD LINE 20102 3 NAPA/IMPERIAL
15 BOLT, COOLER LINES TO BELL NA 20104 3 NAPA/IMPERIAL
16 NUT, COOLER LINES TO BELL NA 42106 3 NAPA/IMPERIAL
17 WASHER, COOLER LINES TO BELL NA 76102 2 NAPA/IMPERIAL
24 BRAKE PRESSURE SWITCH KIT VHW2003 1 PCS
1 BRAKE PRESSURE SWITCH LM2A40REP 1 NAPA NAPA
2 FITTING, BRAKE PRESSURE SWITCH ADAPTER VHW0049 EATON 202X3 1 PCS
3 SPACER, BRAKE TEE FITTING TRN7555 MCM 90126A029 2 PCS
4 BRAKE PRESSURE SWITCH TEE FITTING MJND8010 3TU 1 NAPA NAPA
5 BOLT, BRAKE TEE FITTING 1 PCS
6 NUT, BRAKE TEE FITTING 1 PCS
Table 1: Full BOM of Install Kit # 1558159303KIT (Cont’d)
15-581593-03 A
0960-03-15-01-01 54
Table 2: PCS Torque Specs

15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
Dash Light Placards – Fabricated by Canton Graphics

15-581593-03 A
0960-03-15-01-01 54
Delta Drawing # 15-1095 for M1A Throttle Pedal Extension Plate

15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
15-581593-03 A
0960-03-15-01-01 54
General Information
Equipment Type
Signature Information
Revision Author Author Date Approved Approved Date
A Swalwel, Bryan 01/16/20 Booth, Andrew 01/21/20
Checker Information
CheckerName Check Date
Ardrey, Brian, 01/16/20
Distribution

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1196 Tug M1 M1a

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TECHNICAL INSTRUCTION REVISION

STEVEN SCHWERTFEGER 4/22/15 3-1549 Steven Schwertfeger

PUBLICATION: OPERATIONS MAINTENANCE AND MFG. / PUB. NO:

REV. NO: 20 EQUIPMENT:

REMOVE & DESTROY INSERT REMOVE & DESTROY INSERT

NOTE: Check revision log in front of manual

EA 15-581593-03 REV A M1A Electronic Transmission Upgrade

FOR INFORMATION ONLY

LYNN BURNS 10-14-11 4-1150 Lynn Burns

UNIT: TUG – LOW PROFILE TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT

NOTE: Check revision record in front of manual

ENTIRE CONTENTS *ENTIRE CONTENTS

*NOTE - ALL DAL PAPERWORK IS TO REMAIN IN MANUAL

REMARKS: Manual revised to incorporate vendor revision 10.

FOR INFORMATION ONLY

LYNN BURNS 11-27-06 4-1150 Lynn Burns

UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT

NOTE: Check revision record in front of manual

DAL LEP DAL LEP

REMARKS: Manual revised to incorporate Tech Tip TU 41 Alterntor.

FOR INFORMATION ONLY

LYNN BURNS 7-24-06 4-1150 Lynn Burns

UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT

NOTE: Check revision record in front of manual

ENTIRE CONTENTS *ENTIRE CONTENTS

REMARKS: Manual revised to add vendor revision 9.

FOR INFORMATION ONLY

LYNN BURNS 5-17--06 4-1150 Lynn Burns

UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT

NOTE: Check revision record in front of manual

DAL LEP DAL LEP

FOR INFORMATION ONLY

LYNN BURNS 1-26-06 4-1150 Lynn Burns

UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT

NOTE: Check revision record in front of manual

ENTIRE CONTENTS *ENTIRE CONTENTS

*NOTE: PLEASE DO NOT REMOVE DAL PAPERWORK.

REMARKS: Manual revised to incorporate latest revision per manufacturer.

FOR INFORMATION ONLY

LYNN BURNS 11-4-04 4-1150 Lynn Burns

UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT INSERT

NOTE: Check revision record in front of manual

DATA PAGE DATA PAGE

DAL LEP DAL LEP

REMARKS: Manual revised to incorporate EA 15-085652-03, Rev. A -- Deutz

FOR INFORMATION ONLY

LYNN BURNS 8-20-04 4-1150 Lynn Burns

UNIT: TUG – TOW TRACTOR MFR: TUG, INC.

PUBLICATION: OPERATION, MAINTENANCE & PARTS MFG. / PUB.

REMOVE & DESTROY INSERT INSERT

NOTE: Check revision record in front of manual