TBG 632, WH, en

0297
4. 6.

3.

Workshop Manual
5. TBG 632
Workshop Manual
1. TBG 632
2.
This page intentionally left blank.
Workshop manual
TBG 632
0299 8710 en
Engine Number:
Please enter your engine number here. This will help us to serve you
better in questions of repairs, spare parts and after-sales service
generally.
We reserve the right to make technical alterations to the drawings and

particulars in this documentation package, if this should be-come
necessary to improve the engines. Reprints and duplication of any
kind, either in whole or in part, require our written permission.
TBG 632
This documentation is intended for the following engine.
Engine type:
Application:
System name:
Rating: kW
Speed: / min
Commissioning on:
Please enter the relevant data. This will make it easier for us to help you in questions involving repairs,
spare parts and after-sales service in general.
This documentation package is to be presented to the Service Partner responsible every time a service
job is carried out.
Imprint:
DEUTZ AG
Service-Technik
Servicedokumentation
Deutz-Mlheimer Strae 147149
D-51063 Cologne
Tel.: (+49 2 21) 8 22-0
Fax: (+49 2 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
(1) 0103
Ordering No. 0299 8710 en
Page II 0299 6307-0179 0103

Engines
Please read all the information contained in this manual, and follow the instructions carefully. You will avoid
accidents, retain the manufacturers warranty, and will be able to use a fully functional and operational
engine.
This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined
by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The
manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely
by the user.
The term intended use shall also include compliance with the operating, maintenance and repair
conditions specified by the manufacturer. The engine may be used, maintained and repaired only by
persons who are familiar with the work concerned and who have been properly informed of the risks
involved.
Make sure that these operating instructions are available to everyone involved in operating, maintaining,
and repairing the engine, and that they have all understood the contents.
Non-compliance with these operating instructions may result in engine malfunctions and even damage or
injury to persons; the manufacturer will accept no liability in such cases.
Proper maintenance and repair work depends on the availability of all requisite equipment, tools and
special implements, all of which must be in perfect condition.
Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled
properly.
The relevant accident prevention regulations and other generally recognized rules relating to safety
engineering and health and safety at work must all be complied with.
Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are
used.
Engine repairs must correspond to the intended use. In the event of modification work, only parts approved
by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will
preclude any liability of the manufacturer for resultant damage.
0100 0299 3235-0199 Page III

Forword Engines
Dear customer,
The engines of the DEUTZ brand have been developed for a broad spectrum of applications. A
comprehensive range of different variants ensures that special requirements can be met for the
individual case involved.
Your engine has been equipped to suit your own particular installation, and accordingly not all of the
devices and components described in these operating instructions will actually be fitted to your
engine.
We have endeavoured to present the differences involved as clearly as possible, to make it easier
for you to find the operating and maintenance instructions you need for your own particular engine.
Please read this manual before you start up your engine, and follow the operating and maintenance
instructions meticulously.
If you have any questions, just get in touch with us, and we will be pleased to answer them for you.
Yours sincerely,
DEUTZ AG
Page IV 0299 3235-0199 0100

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

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

Carry out maintenance or repair jobs only when the engine is at a standstill. If you remove any
protective features, fit them back in position after completing your work. Always wear tight-fitting
clothing if you are working on the engine while it is running.
Safety
You will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safety
instructions to your operating staff as well. In addition, comply with the statutory general safety and
accident prevention regulations applying in your country.
Instruction
You will find this symbol next to instructions of a general nature.
Follow these instructions carefully.
Asbestos
The seals and gaskets used in this engine are asbestos-free. Please use the appropriate spare parts
for maintenance and repair jobs.
0100 0299 3235-0199 Page V

Quick Introduction Engines and Systems
QUICK INTRODUCTION (FOR TRAINED AND QUALIFIED PERSONNEL)
GETTING OPERATING INSTRUCTIONS

Chap. 1 Advice to users
STARTED

Chap. 2 Description

Chap. 3 Operation

Chap. 4 Expendables

Chap. 10 Test reports
NORMAL OPERATING INSTRUCTIONS

OPERATION Chap. 3 Operation

Chap. 4 Expendables
MAINTENANCE OPERATING INSTRUCTIONS


Chap. 4 Expendables

Chap. 5 Maintenance and
Servicing

Chap. 8 Technical data

Chap. 9 Maintenance work

SPARE PARTS CATALOGUE
Spare parts

DEUTZ Service
Page VI 0299 3232-0199 0100

Engines and Systems Quick Introduction
SERVICING OPERATING INSTRUCTIONS


Chap. 5 Maintenance and
Servicing


WORKSHOP MANUAL
Servicing work

SPARE PARTS CATALOGUE
Spare parts

DEUTZ Service
MALFUNCTIONS IN OPERATING INSTRUCTIONS

OPERATION
Chap. 6 Operational disturbances
causes, corrective action


Chap. 10 Test reports

WORKSHOP MANUAL
Chap. 9 Maintenance work Servicing work

SPARE PARTS CATALOGUE SPARE PARTS CATALOGUE
Spare parts Spare parts

DEUTZ Service DEUTZ Service
0100 0299 3232-0199 Page VII

Engines and Systems
Page VIII 0299 3232-0199 0100

TBG 632 Contents
0 Introduction
Imprint, foreword, quick introduction, contents
1 Advice to users
1.1 General remarks
1.2 Regulations
1.2.1 Safety instructions / Accident prevention
1.2.2 Disposal regulations
1.3 Operating Instructions and Workshop Manual
1.4 Job cards
1.5 Spare parts
8 Technical data
8.1 General engine data
8.1.1 Basic data
8.1.2 Control data
8.1.3 Dimensions
8.1.4 Weights
8.2 Operating data
8.2.1 Fill quantities
8.2.2 Temperatures
8.2.3 Pressures
8.2.4 Emission data
8.3 Engine peripheral data
8.3.1 Start system
8.3.2 Speed gov ernor
8.3.3 RI flow diagrams
8.3.3.1 BHKW system (example)
8.3.3.2 Lube oil supply
8.3.3.3 Legend
8.4 Tightening instructions
8.4.1 For all regular maintenance tasks
8.4.1.1 Engines without Integrated Front-End (IFE)
8.4.1.2 Engines with Integrated Front-End (IFE)
10 Sundry other instructions
Service
0103 0299 8717-0179 Page IX

Contents TBG 632
Page X 0299 8717-0179 0103

Engines and Systems Advice to users
1 Advice to users 1
1.1 General remarks
1.2 Regulations
1.2.2 Disposal regulations
1.4 Job cards
1.5 Spare parts
0602 0299 3245-0199 Chapter 1 - Page 1

Advice to users Engines and Systems
1 1 Advice to users
1.1 General remarks

The maintenance and servicing jobs specified in this manual must be carried out punctually and completely.
The maintenance and servicing staff must possess the necessary technical knowledge required for doing their
jobs properly. Any safety and protective features which had to be removed during maintenance and servicing
work must be fitted back in place after completion.
The accident prevention and safety regulations must by always be complied with throughout all
maintenance and servicing work.
Also note the special safety instructions for the various servicing groups which are listed in
detail as job cards in the Chapter Job Cards see also Chapter 1.2.1).
The maintenance and servicing intervals are given in the maintenance and servicing schedule, which also
provides information on the jobs required.
The job cards (Chapter 9) give technical instructions on how to actually perform the jobs.
1.2 Regulations
For various servicing groups, detailed safety advice has have been drawn up in the form of job cards;
they are listed before the job cards of the respective servicing groups.
The statutory accident prevention regulations have to be complied with (obtainable from professional
associations or in specialized bookshops). They depend on the installation site, the operating mode and
the expendables and auxiliary materials used.
Special protective arrangements dependent on the particular jobs are indicated and marked in the job
description.
In general, the following applies:
for the personnel:
- Only trained personnel may operate or maintain the engine. Unauthorized persons are not
allowed to enter the machine room.
- When the engine is in operation, wear only tight-fitting clothes and ear muffs in the machine room.
- Use only professionally qualified staff for repair work.
for the machine room:

- Ensure sufficient ventilation (do not cover air shafts).
- Provide first-aid kit and suitable fire extinguishers and check their contents and serviceability at
regular intervals.
- Only store combustible materials in the machine room if they are necessary for the operation of
the system.
- Smoking and open flames are not allowed in the machine room.
for operation and maintenance of the engine:

- Only start the engine when all protective devices have been installed and the turning device has
been removed. Make sure that there is nobody in the danger area.
- Only carry out any cleaning, maintenance and repair work when the motor is shut down and
secured against starting.
Chapter 1 - Page 2 0299 3245-0199 0602

1.2.2 Disposal regulations 1

The procedures described in the Operating Instructions and the Workshop Manual specify, for example, when
certain parts and expendables have to be replaced. These replaced parts/expendables must be stored,
transported and disposed of in compliance with the relevant regulations. The client himself bears responsibility
for this.
The term disposal covers both the recycling and the dumping/destruction of parts/expendables, though
recycling should be given preference.
Details on disposal procedures and their monitoring are governed by regional, national and international laws
and ordinances, which it is the clients responsibility to comply with.

In order to provide a user-specific information structure, the service documentation has been divided into the
Operating Instructions and the Workshop Manual.
The Operating Instructions include a general description as well as instructions for all necessary maintenance
jobs.
They contain the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Engine description
3 Operating the engine
4 Instructions for expendables
5 Maintenance and servicing
6 Operational malfunctions, their causes and how to correct them
7 Engine conservation
8 Technical particulars
9 Job Cards, arranged by Job Card Numbers
10 Sundry other instructions (if not included in the appendix or in separate files)
After-sales service
The Workshop Manual presopposes knowledge of the contents of the Operating Instructions. This particularly
applies to the safety instructions. It describes easy repair jobs and emergency measures on components, which
are more elaborate to peform, and require appropriately qualified professional staff.
It contains the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2-7 See Operating Instructions
8 Technical particulars
9 Job Cards, arranged by Job Card Numbers
10 Sundry other instructions (if not included in the appendix or in separate files)
After-sales service
1.4 Job cards

The Job cards are divided into maintenance Job Cards of Operating instructions, for example B 1-1-1 and
servicing Job Cards of the Workshop Manual, for example W 4-5-1.
For the numbering please refer to Fig. 101.
The structure of a Job Card is shown in Fig. 102.
0602 0299 3245-0199 Chapter 1 - Page 3

1
Type of documentation
The letter at the front signifies the type of documentation involved.
B = Operating Instructions
W = Workshop Manual
Maintenance Group (the same for all engines)
0 General remarks / cross-category jobs 8 Lube oil system

1 Cylinder head 9 Coolant system
2 Drive mechanism 10 Compressed air system
3 Crankcase 11 Monitoring system
4 Engine control 12 Other components
5 Governor 13 Electrical system
6 Exhaust gas system / Charging
7 Fuel system
Subsystem (component)
The subsystems are distinguished by maintenance groups.
Generally valid:
0 Cross-subsystem or Safety Regulations
1 System parameters or general checks
Serial Number
Counting per subsystem (component)
Various jobs per subsystem (component)
Version differences
B 3-3-3 80301 2
Fig. 101 Numbering of the Job Cards
Chapter 1 - Page 4 0299 3245-0199 0602

1
1 2 3
4
13
5
12
6
11
10 9 8
80300 4
Fig. 102 Structure of the Job Cards
1 DEUTZ AG, 10 Date of issue of the Job Cards

editor of the service documentation
11 Sequence of operations, work procedure
2 Engine type to which the Job Card refers
12 Safety instructions and general hints
3 Short title of the Job Card
13 Full title of the Job Card
4 Number of the Job Card
If you have any questions on the Job Card,
5 Necessary tools, equipment, and please always state the engine type 2, the
spare parts number 4, the page 8, the date of issue 10 or,
as an alternative, the Internal part number 9.
6 Reference to further Job Cards,
instructions, etc.
7 Explanatory diagrams
8 Present page of total number of pages
9 Internal part number of the Job Card
0602 0299 3245-0199 Chapter 1 - Page 5

1 1.5 Spare parts

You will receive spare parts from Messrs. DEUTZ AG. You will find a list of the spare parts in the engines spare
parts list.
Chapter 1 - Page 6 0299 3245-0199 0602

Gas engines Description of engine
2-7 See Operating Instructions 2
0602 0299 8370-0199 Chapter 2 - Page 1

Description of engine Gas engines
2 This page intentionally left blank.
Chapter 2 - Page 2 0299 8370-0199 0602

TBG 632 Technical data
8 Technical data 8
8.1.1 Basic data
8.1.2 Control data
8.1.3 Dimensions
8.1.4 Weights
8.2 Operating data
8.2.2 Temperatures
8.2.3 Pressures
8.2.4 Emission data
8.3 Engine peripheral data
8.3.1 Start system
8.3.3 RI flow diagrams
8.3.3.2 Lube oil supply
8.3.3.3 Legend
8.4 Tightening instructions
8.4.1 Regular maintenance tasks until E 40
8.4.1.2 Engines with Integrated Front-End (IFE)
0203 0299 3767-0179 Chapter 8 - Page 1

Technical data TBG 632
Chapter 8 - Page 2 0299 3767-0179 0203

8 Technical data 8
8.1.1 Basic data
Type designation TBG632

V12 V16 1) V16 2)
Working mode Four-stroke
Lean-mixture combustion
Mixture exhaust-gas turbocharging
Mixture cooling
Cylinder configuration V-engine, 45 V-angle
No. of cylinders 12 16 16
Bore mm 260
Stroke mm 320
Capacity per cylinder dm 3
17
Total swept volume dm3 204 272 272
Compression 12 10 resp. 12 10,5
Speed control DEUTZ TEM system
Output control DEUTZ TEM system with control commands acting on governor
Gas mixture control DEUTZ TEM system acting on servomotor at mixer ect.,as per
combustion chamber temperatures
8.1.2 Control data
Valve control times (at valve clearance cold) TBG632 without integrated front end (IFE)
V12 V16 1) V16 2)
Inlet opens CA 28.4 b.TDC 28.4 b.TDC 28.4 b.TDC
Inlet closes CA 7.6 b.BDC 7.6 b.BDC 38.4 a.BDC
Exhaust opens CA 40.2 b.BDC 40.2 b.BDC 40.2 b.BDC
Exhaust closes CA 8.2 a.TDC 8.2 a.TDC 8.2 a.TDC
Valve control times (at valve clearance cold) TBG632 with integrated front end (IFE)
Inlet opens CA 25.3 b.TDC
Inlet closes CA 13.7 b.BDC
Exhaust opens CA 37.5 b.BDC
Exhaust closes CA 4.4 a.TDC
Firing order
V12: A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
V16: A1 B3 A3 B7 A7 B5 A5 B8 A8 B6 A6 B2 A2 B4 A4 B1
Sparking plugs Chamber plug
Valve clearance with cold engine
Inlet valve mm 0.3 + 00.1
Exhaust valve mm 1.3 + 00.1
1) TBG 632 V16 with exhaust gas turbocharger TPS57

2) TBG 632 V16 with exhaust gas turbocharger RR221
0203 0299 3767-0179 Chapter 8 - Page 3

8 8.1.3 Dimensions
Aggregate Length Width Height
TBG 632 V12 without IFE mm 7.500 2.800 3.900
TBG 632 V16 without IFE mm 8.700 2.800 3.900
TBG 632 V12 with IFE mm 7.600 2.700 3.700
TBG 632 V16 with IFE mm 8.700 2.700 3.700
8.1.4 Weights
Designation Weight in kg 1)
V12 V16
Engine, dry 18,500 23,000
Unit, dry 35,300 45,800
Crankcase - 5,900
Service Unit 455 455
Cylinder head 190 190
Strongback 82 82
Cylinder liner 85 85
Piston with connecting-rod 98 98
Crankshaft 1,730 2,215
Flywheel 848 848
Turbocharger 270 270
Mixture cooler 282 282
1)
all particulars are approximate values
Chapter 8 - Page 4 0299 3767-0179 0203

8.2 Operating data 8

V12 V16
Lube oil content of the oil pan (app.)
min. litres 1,300 1,650
max. litres 1,450 1,850
Engine shuts down at litres 1,710 2,160
Coolant content, engine litres 430 570
Mixture coolant content, engine litres 51 51
8.2.2 Temperatures
V12 V16
Coolant temperature, engine
Inlet / outlet C 79 / 90 79 / 90
with Glycol C 77 / 88 77 / 88
Intake air temperature
Minimum 1) C 0 0
Dimensioning as specified in project
1)
with intake air preheating fitted as standard
8.2.3 Pressures
Gas pressure fluctuations
in % of setting value % < 10
at fluctuation frequency of h-1 < 10
Max. exhaust gas counterpressure mbar 50
8.2.4 Emission data

V12 V16
Noise
Air-borne noise measured dB(A) app. 104 app. 105
at 1m distance from engine
(n = 1,000 min-1)
Exhaust noise emissions dB(A) app. 124 app. 125
without silencer
0203 0299 3767-0179 Chapter 8 - Page 5

8 8.3 Engine peripheral data

8.3.1 Start system
Compressed air before controlled system
(compressed air supply)
Air pressure min. bar 16
Air pressure max. bar 30
Contents of air bottle litres 2,000

Type designation - actuator StG 30 - 01
Angle of rotation
on the governor output shaft 42
Max. torque on the governor
output shaft (stop direction) Nm (app.) 28
Holding torque in the
current limiter Nm (app.) 14
Run-up time 0-100 % without load ms (app.) 170
Power consumption of
complete governor:
In steady-state condition A (app.) 1
During load changes A (app.) 3-4
Max. current A (app.) 4.5
Restricted current A (app.) 2.5
Bearing temperature C -55 to +110
Ambient temperature during operation C -25 to +90
Ambient temperature
special design C -40 to +90
Air humidity % up to 100
Type of protection IP 44
Weight kg (app.) 12.3
Chapter 8 - Page 6 0299 3767-0179 0203

8.3.3 RI flow diagrams 8

83915 0
Fig. 802 BHKW system (example)

1 Combustion gas 6 Lube oil feed and outlet
2 Air 7 Heating water return line
3 Gas/air mixture 8 Return line booster
4 Exhaust gas 9 Heating water inlet
5 Compressed air
0203 0299 3767-0179 Chapter 8 - Page 7

8 8.3.3.2 Lube oil supply
LICSA
234
PISA+
145
TISA+
208
PISA-
196
M 1 4
2 5
12
LS+ LSA+ LSA++

8530 9511 M 9520
LS- LA- LSA+
8531 9510 9521
1 2
3
83572 0
Fig. 803 Lube oil supply
1 Fresh-oil tank
2 Used-oil tank
3 Day tank
4 DEUTZ standard unit
5 System (from client)
6 Unit 2-n
Chapter 8 - Page 8 0299 3767-0179 0203

8.3.3.3 Legend 8
Shutoff valve
Ballcock
Three-way valve
Throttle valve
Non-return valve
Air/gas filter
Liquid filter
Safety valve
Safety corner valve
Compensator
Expansion tank
Motorised actuator
Electromagnetic actuator
Recirculation pump
Diaphragm actuator
Exhaust gas turbocharger
Local display
Generator
Stack
Catalytic converter
Gas park ignition engine
Silencer
Preheater
Breather
Gas-air mixer
Heat exchanger
Table cooler
Flame penetration guard
0203 0299 3767-0179 Chapter 8 - Page 9

Chapter 8 - Page 10 0299 3767-0179 0203

8.4 Tightening instructions 8

8.4.1 For all regular maintenance tasks
Code Screw connection** Dimension Strength Tightening type, sequence Remark

No.* Material St H V1 V2
01/1 Cylinder head M36x2x703 10.9 200 Stud
Crankcase see also 08/1
W 1-4-5
01/2 Camshaft bearing M16x120 10.9 + 115 250 Cylinder-head s.
cover - Crankcase
01/3 Main bearing cover M45x2x650 12.9 200 Stud
Crankcase W 2-4-5
01/4 Main bearing cover M27x2x290 10.9 Cylinder-head s.
Crankcase cross bracing
W 2-4-5
01/5 Camshaft cover M12x55 10.9 + - 80 Hexagon head s.
Crankcase M12 10.9 + - 80 Hexagon nut
M12x45 8.8 50 + - Stud
01/6 Bolt M12x40 8.8 + - 80 Hexagon head s.
Crankcase
01/7 Wheel case cover M10x35 10.9 + - 60 Hexagon head s.
Crankcase M10x70
02/1 Oil pan M16x70 10.9 + 115 290 Cylinder-head

Crankcase / IFE M16x140 screw
04/1 Cylinder jacket (old) - M12x45 10.9 + - 125 Cylinder-head s.

Crankcase M12x50
04/2 Cylinder jacket (new) - M12x60 10.9 + - 125 Cylinder-head s.
Crankcase M12x70 Cylinder-head s.
M12x60 Dodecagon head s.
05/1 Flywheel M30x2x180 10.9 + 800 1500 Hexagon head s.

Coupling flange M30 Hexagon nut
05/2 Flywheel M16x50 10.9 + 115 260 Cylinder-head s.
Crown gear
06/1 Con-rod cover M36x2x245 12.9 200 Stud

Connecting rod M36x2 10.9 - Nut
W 2-5-5
08/1 Cylinder head M36x2 10.9 - Nut

Crankcase W 1-4-5
08/2 Sleeve for spark plug M33x2 M10S20K 300 Sleeve
Cylinder head
08/3 Sleeve for spark plug M60x2 Ck35 300 Sleeve
Cylinder head
08/4 Cylinder head cover M10x125 10.9 + - 15 Stud/
Cylinder head Cap nut
1228 1738 / 14.06.02
St = tightening torque of sleeves / stud bolt Nm 10 percent

H = tightening by hand with standard wrench (+ = execute)
V1 = tightening with use of torque wrench (partial) ... Nm
V2 = tightening to fulltorque ... Nm 10 percent
*Code No. = No. group / ser. No.

**Connection featuring several screws: tighten alternately diagonally or opposite or in diagonally opposite sequence
s. = screw
Lubricant: Oil or tallow/red lead
0203 0299 8784-0179 Chapter 8 - Page 11

08/5 Cylinder head cover M10x200 10.9 + - 30 Cylinder-head s.
Cylinder head
09/1 Intermediate wheel hub M27x2x220 10.9 + - 1500 Cylinder-head s.
Crankcase
10/1 Camshaft A1-A2 to M14x1.5x50 10.9 + 50 180 Cylinder-head s.

Camshaft B7-B8
11/1 Toggle lever block M16x160 12.9 + 135 360 Dodecagon head s.
Cylinder head
Cylinder head
11/3 Toggle lever M20x1.5 + - 100 Nut
Setting screw/nut
11/4 Valve bridge M16x1.5 + - 80 Nut
Setting screw
14/1 Toothed wheel M16x115 10.9 + - 290 Hexagon head s.

oil pump
14/2 Oil pump M16x40 10.9 + 115 290 Hexagon head s.
damper housing
15/1 Oil filter M10x150 8.8 + - 45 1. - 8. Engine

(short CC)
15/2 Oil filter M10x155 8.8 + - 45 from 9th engine
(low CC)
15/3 Bracket for oil filter M12x25 8.8 + - 80 1. - 8. Engine
M12x30 (short CC)
15/4 Bracket for oil filter from 9th engine
(low CC)
26/1 Spark plug M18x1.5 50 Spark plug

sleeve for spark plug M22x1.5
27/1 Console for actuator / M10x160 8.8 45 Natural gas

gas pipe M10x65
27/2 Console for actuator / M10x35 10.9 65 Natural and pit gas
gas pipe M10x125 Pit gas
34/1 Pendulum damper M30x2x75 + 400 1650 Hexagon head s.

Crankshaft
34/2 Drive wheel M24x130 10.9 + 300 970 Cylinder-head s.
Crankshaft
1228 1738 / 14.06.02


s. = screw
Chapter 8 - Page 12 0299 8784-0179 0203

34/3 Damper housing M12x60 10.9 + 50 115 Cylinder-head s.
Crankcase M12x120
38/1 Cylinder head M10x25 10.9 + - 60 Cylinder-head s.

Water outlet
41/1 Exhaust manifold M12x35 NiCr20TiAl 50 + - 60 Stud
Cylinder head M12 Self-locking
nut
41/2 Exhaust manifold M16x65 21CrMoV5 + - 140 Hexagon head s.
before ATL M16 24CrMoV5 Self-locking
(exhaust gas turbocharger) Nut
after ATL M12 Self-locking
41/4 Fastening clip exhaust G3/8 - 16 25
Compensator M10 27
41/5 Cladding for M10x20 10.9 + - 60 Cylinder-head s.
Exhaust pipe (bottom part)
41/6 Cladding for M12x30 10.9 + - 100 Cylinder-head s.
43/1 ATL console M14x65 10.9 + 50 170

Crankcase
43/2 ATL console M20x50 8.8 + 100 400
Console for mix cooler M20x85
43/3 ATL bracket RR 221 M20x100 10.9 + 160 540
ATL console
43/4 ATL RR 221 - M24x85 8.8 + 625
ATL bracket M24x120
43/5 ATL RR 221 see RR 221 Operating Instructions
43/6 Cladding M8x15 8.8 + 22
ATL RR 221
43/7 ATL bracket TPS 57 - M20x60 8.8 + 100 400
ATL console
43/8 ATL TPS 57 - M20x270 10.9 + 160 540
ATL bracket
43/9 ATL TPS 57 see TPS 57 Operating Instructions
44/1 Bracket for starter M27x2x160 10.9 + 1400 Cylinder-head s.

44/2 Starter M16x50 10.9 + - 260
45 Cover instead of M16x35 8.8 180 Hexagon head s.

water pump
cover for aux. drive
1228 1738 / 14.06.02


s. = screw
0203 0299 8784-0179 Chapter 8 - Page 13

46/3 Engine claw M27x2x160 10.9 1. - 8. Engine

Crankcase M27x2x500 (short CC)
W 2-7-4
46/4 Engine claw M20x2x100 10.9 + 560 from 9th engine
Crankcase M20x2x80 (low CC)
48/1 Knocking sensor M8x30 8.8 20 5

58/1 Mix cooler mounted
58/2 Mix cooler M10x20 10.9 50* * only for spare
flame filter Cylinder-head s.
58/3 Mix cooler M12x35 10.9 + - 115
Console for mix cooler M12x50
64/1 Gas mixer M12xx25 8.8 80

64/2 Bracket for M10x40 8.8 + - 45
Gas mixer M12x180 8.8 + - 80
64/3 Gas pipe inlet M10x20 8.8 + - 45 Hexagon head s.
M10x28
64/4 Gas pipe - mixer M12x35 8.8 50 + - 80 Stud
M12 10.9 Hexagon nut
64/5 Console M16 180 Hexagon nut
gas pipe pit gas
87/1 Mix pipe M14 8.8 + - 125 Stud

Console for mix cooler
87/2 Mix pipe (old) M12x70 8.8 + - 80
Crankcase
87/3 Mix pipe (new) M16x160 10.9 + 100 260
Crankcase
87/4 Mix pipe M10 10.9 + - 65
Mix pipe all lengths
87/5 Mix pipe M12x45 8.8 + - 80
Mix pipe M12x35
87/6 Cover for M10x35 10.9 + - 65
Mix pipe
87/7 Cover for M8x30 8.8 + - 22
Mix pipe
87/8 Console for mix cooler M16x75 10.9 + 100 260
Crankcase
87/9 Hood for pressure
compensation M10x35 10.9 + - 60 Cylinder-head s.
1228 1738 / 14.06.02


s. = screw
Chapter 8 - Page 14 0299 8784-0179 0203

87/10 Cover for flame filter M10x25 10.9 + - 60 Torx screw
insert mix pipe
87/11 Flame filter insert M8x35 8.8 12 Hexagon head
screw
flange
87/12 Flange with flame filter M10x20 10.9 + - 50 Cylinder screw
cover
1228 1738 / 14.06.02


s. = screw
0203 0299 8784-0179 Chapter 8 - Page 15
8 8.4.1.2 Engines with Integrated Front-End (IFE)

01/1 Cylinder head M36x2x703 10.9 200 Stud

crankcase see also 08/1
W 1-4-5
01/2 Camshaft bearing cover M16x120 10.9 + 115 250 Cylinder head s.
crankcase
01/3 Main bearing cover M45x2x650 12.9 200 Stud
crankcase W 2-7-4
01/4 Main bearing cover M27x2x290 10.9 Cylinder head s.
crankcase Cross bracing
W 2-7-4
01/5 Camshaft cover M12x55 10.9 + - 80 Hexagon head s.
crankcase M12 10.9 + - 80 Hexagon nut
M12x50 8.8 50 + - Stud
01/6 Bolt M12x40 8.8 + - 80 Hexagon head s.
crankcase
01/7 Wheel case cover M10x35 10.9 + - 60 Hexagon head s.
crankcase M10x70
01/8 Housing CC bleeding M16x60 8.8 + - 180 Hexagon head s.
crankcase
01/9 Bracket Racor filter M8x28 8.8 + - 22 Hexagon head s.
IFE
01/10 Racor filter M10x25 8.8 + - 45 Hexagon head s.
Bracket Racor filter
02/1 Oil pan M16x70 10.9 + 115 290 Cylinder-head s.

Crankcase / IFE M16x140
04/2 Cylinder jacket M12x60 10.9 + - 125 Cylinder head s.

crankcase
05/1 Flywheel M30x2x180 10.9 + 800 1500 Hexagon head s.

coupling flange M30 Hexagon nut
05/2 Flywheel M16x50 10.9 + 115 260 Cylinder head s.
crown gear
05/3 Counterweight M30x2x200 10.9 Dodecagon head s.
crankshaft Pre-tensioning torque: 800 Nm, post-tensioning angle: 60
06/1 Con-rod cover M36x2x245 12.9 200 Stud

con-rod M36x2 10.9 - Nut
W 2-5-5
08/1 Cylinder head M36x2 10.9 - Nut

crankcase W 1-4-5
08/2 Sleeve for spark plug M33x2 M10S20K 300 Sleeve
cylinder head
1238 0032 / 14.06.02


s. = screw
Chapter 8 - Page 16 0299 8784-0179 0203

08/3 Sleeve for spark plug M60x2 Ck35 300 Sleeve
cylinder head
08/4 Cylinder head cover M10x60 10.9 + - 30 Cylinder head s.
cylinder head
08/5 Cylinder head cover M10x200 10.9 + - 30 Cylinder head s.
cylinder head
09/1 Intermediate wheel hub M27x2x220 10.9 + - 1500 Cylinder-head s.
10/1 Camshaft A1-A2 to M14x1.5x50 10.9 + 50 180 Cylinder-head s.

Camshaft B7-B8
Cylinder head
Cylinder head
11/3 Toggle lever M20x1.5 + - 100 Nut
Setting screw/nut
11/4 Valve bridge M16x1.5 + - 80 Nut
Setting screw
14/1 Toothed wheel M16x115 10.9 + - 290 Hexagon head s.

oil pump
14/2 Oil pump M16x50 10.9 + 115 290 Hexagon head s.
IFE cover
15/1 Oil filter fastening M16x230 10.9 + 115 290 Hexagon head s.
on IFE
15/2 Bracket for oil filter M12x35 10.9 + - 80 Cylinder head s.
on IFE
15/3 Bracket for oil filter M10x30 10.9 + - 60 Cylinder head s.
on filter M10x40
M10x60
26/1 Spark plug M22x1.5 50 Spark plug

sleeve for spark plug M18x1.5
34/1 Pendulum damper M30x2x75 8.8 + 400 1650 Hexagon head s.

crankshaft
34/2 Drive wheel M24x130 10.9 + 300 970 Cylinder head s.
crankshaft
38/1 Water outlet M10x25 10.9 + - 60 Cylinder head s.

cylinder head
1228 1738 / 14.06.02


s. = screw
0203 0299 8784-0179 Chapter 8 - Page 17


cylinder head M12 Self-locking
nut
41/2 Exhaust manifold M16x50 21CrMoV5 + - 140 Hexagon head s.
before ATL M16 24CrMoV5 Self-locking
after ATL M12 Self-locking
(exhaust gas turbocharger) nut
41/4 Fastening clip exhaust G3/8 - 16 25
Compensator M10 27
41/5 Cladding for M10x20 10.9 + - 60 Cylinder head s.
41/6 Cladding for M12x30 10.9 + - 100 Cylinder head s.
43/1 ATL bracket M16x55 10.9 + 115 290

crankcase
43/2 ATL TPS 57 - M20x270 10.9 + 160 540
Bracket
43/3 ATL TPS 57 see TPS 57 Operating Instructions
44/1 Bracket for starter M27x2x160 10.9 + 1400 Cylinder-head s.

44/2 Starter M16x50 10.9 + - 260
45/1 Cover for auxiliary drive M12x60 10.9 + - 80 Cylinder-hea s.

IFE housing
45/2 Cover instead of M16x35 8.8 + 50 180 Hexagon head s.
water pump
cover for aux. drive
46/4 Engine claw M20x2x80 10.9 + 560 Cylinder head s.

crankcase
48/1 Knocking sensor M8x30 8.8 20 5
58/1 IFE housing M14x80 10.9 + 50 180

crankcase M14x180
58/2 IFE housing M14x45 10.9 + 50 180
Mix pipe M14x70
58/3 Mix cooler (mounted) M12x65 10.9 + 50 120 Dodecagon head s.
IFE housing M12x70
M12x150
M12x165
1228 1738 / 14.06.02


s. = screw
Chapter 8 - Page 18 0299 8784-0179 0203

58/4 Mix cooler M12x40 10.9 + 50 120 Dodecagon head s.
mix cooler cover M12x160
64/1 Gas mixer add-on M12x25 10.9 120

M12x30 8.8 80
M12x45 8.8 80
64/2 Fastening / gas pipe M16x30 8.8 100 + 80 200 Stud
join M16 10.9 Hexagon nut
64/3 Fastening / gas pipe M10x20 10.9 + - 70 Hexagon head s.
on join M10x28
64/4 Fastening / gas pipe M12x35 8.8 50 + - 80 Stud
on mixer M12 10.9 Hexagon nut
69/1 Turning device M10x35 10.9 + - 45 Hexagon head s.

M10x70 8.8
M10x130 8.8
87/3 Mix pipe M16x160 12.9 + 100 260

crankcase
87/4 Mix pipe M10x55 10.9 + - 65
Mix pipe M10x155
87/5 Mix pipe M12x45 10.9 + - 120
Mix pipe M12x35 8.8 + - 80
M12x30 8.8 + - 80
87/6 Cover for M10x35 10.9 + - 65
Mix pipe
87/7 Cover for M8x30 8.8 + - 22
Mix pipe
87/8 Console for mix cooler M16x75 10.9 + 100 260
crankcase
87/9 Hood for pressure
compensation M10x35 10.9 + - 60 Cylinder head
screw
87/10 Cover flame filter insert M10x25 10.9 60 Torx screw
mix pipe
87/11 Flame filter insert M10x20 10.9 50 Cylinder head s.
mix pipe cover
1228 1738 / 14.06.02


s. = screw
0203 0299 8784-0179 Chapter 8 - Page 19
Chapter 8 - Page 20 0299 8784-0179 0203

TBG 632 Job Cards
9 Job Cards 9
9.1 Overviews
9.1.1 Arranged alphabetically
9.1.2 Arranged by Job Card Numbers
9.1.3 Explanation of symbols
9.2 Job Cards arranged by Job Card Numbers
0103 0299 6309-0179 Chapter 9 - Page 1

Job Cards TBG 632
9 9 Job Cards
9.1 Overviews
9.1.1 Arranged alphabetically
Jobs Job Card
Check axial clearance of the camshaft W 4-1-4
Check axial play of the crankshaft W 2-1-4
Check bearing spread W 2-1-1
Check cylinder liner W 3-3-1
Check piston bolt play W 2-12-3
Check piston rings, grooves W 2-10-3
Check wheel drive (drive side) W 4-4-4
Check wheel drive (free side) W 4-4-2
Check, remove and install valve stem guide W 1-6-1
Checking the crank web breathing W 2-1-5
Checking the engine mounting W 3-7-1
Checking the torsional backlash W 4-4-6
Clean flame filter W 6-7-1
Clean pre-control cartridge W 8-11-4
Cleaning mix cooler (on air side) in installed condition in engines without IFE W 6-4-6
Cleaning the mixture cooler (water and air sides) W 6-4-4
Connecting rod bearing cover, assembly specification, HTI hydraulic tool W 2-5-5
Connecting-rod bearing cover, mounting instructions, hydraulic tool Lerbs W 2-5-5
Crack inspection with the diffusion liquid procedure W 0-3-2
Cylinder head, mounting instructions, hydraulic tool HTI W 1-4-5
Cylinder head, mounting instructions, hydraulic tool Lerbs W 1-4-5
Endoscoping the combustion compartment W 0-2-7
Filling and venting the hydraulic clamping device W 0-0-1
Inlet and exhaust valves W 1-5-1
Installing and removing pistons and connecting rod assembly W 2-9-3
Installing and removing the gear drive (drive side) W 4-4-3
Instructions for Work on the Electrical Equipment W 13-0-1
Main bearing cap on crankcase, assembly specification, Lerbs hydraulic tool W 2-7-4
Main bearing cap, Assembly specification, HTI hydraulic tool W 2-7-4
Remove and install cylinder head W 1-4-4
Remove and install cylinder liner W 3-3-2
Remove and install main bearing W 2-7-2
Remove and install piston bolt W 2-12-4
Remove and install, clean frequency pick ups, 2 pcs. W 5-3-13
Removing and installing exhaust gas turbocharger W 6-6-4
Removing and installing mix cooler on engines without IFE W 6-4-7
Removing and installing the cylinder jacket (Strongback) W 3-4-1
Removing and installing the gear train (Free End) W 4-4-1
Removing and installing the piston rings W 2-10-1
Removing and installing the unit W 0-4-1
Removing and installing the wearing ring halves of the crankshaft W 2-7-3
Removing, installing and checking the camshaft bearings W 4-1-1
Chapter 9 - Page 2 0299 6309-0179 0103

TBG 632 Job Cards
Removing, installing and checking the lower valve mechanism W 4-2-1

Repair discharge valves W 1-5-7
Repair intake valves (narrow seat) W 1-5-6
Repair intake valves (wide seat) W 1-5-6
Repair lube oil pump, Rickmeier make W 8-4-1
Repair pressure limiting valve of the lube oil pump W 8-4-2
Replace compensators W 12-3-1
Running-In Instructions W 0-1-3
Safety rules for working on the drive mechanism W 2-0-1
Use of liquid nitrogen W 0-3-1
Visual inspection of the bearing shells W 2-1-6
0103 0299 6309-0179 Chapter 9 - Page 3

Job Cards TBG 632
9.1.2 Arranged by Job Card Numbers

Job Card Jobs
W 0-0-1 Filling and venting the hydraulic clamping device
W 0-1-3 Running-In Instructions
W 0-2-7 Endoscoping the combustion compartment
W 0-3-1 Use of liquid nitrogen
W 0-3-2 Crack inspection with the diffusion liquid procedure
W 0-4-1 Removing and installing the unit
W 1-4-4 Remove and install cylinder head
W 1-4-5 Cylinder head, mounting instructions, hydraulic tool Lerbs
W 1-4-5 Cylinder head, mounting instructions, hydraulic tool HTI
W 1-5-1 Inlet and exhaust valves
W 1-5-6 Repair intake valves (wide seat)
W 1-5-6 Repair intake valves (narrow seat)
W 1-5-7 Repair discharge valves
W 1-6-1 Check, remove and install valve stem guide
W 2-0-1 Safety rules for working on the drive mechanism
W 2-1-1 Check bearing spread
W 2-1-4 Check axial play of the crankshaft
W 2-1-5 Checking the crank web breathing
W 2-1-6 Visual inspection of the bearing shells
W 2-5-5 Connecting-rod bearing cover, mounting instructions, hydraulic tool Lerbs
W 2-5-5 Connecting rod bearing cover, assembly specification, HTI hydraulic tool
W 2-7-2 Remove and install main bearing
W 2-7-3 Removing and installing the wearing ring halves of the crankshaft
W 2-7-4 Main bearing cap on crankcase, assembly specification, Lerbs hydraulic tool
W 2-7-4 Main bearing cap, Assembly specification, HTI hydraulic tool
W 2-9-3 Installing and removing pistons and connecting rod assembly
W 2-10-1 Removing and installing the piston rings
W 2-10-3 Check piston rings, grooves
W 2-12-3 Check piston bolt play
W 2-12-4 Remove and install piston bolt
W 3-3-1 Check cylinder liner
W 3-3-2 Remove and install cylinder liner
W 3-4-1 Removing and installing the cylinder jacket (Strongback)
W 3-7-1 Checking the engine mounting
W 4-1-1 Removing, installing and checking the camshaft bearings
W 4-1-4 Check axial clearance of the camshaft
W 4-2-1 Removing, installing and checking the lower valve mechanism
W 4-4-1 Removing and installing the gear train (Free End)
W 4-4-2 Check wheel drive (free side)
W 4-4-3 Installing and removing the gear drive (drive side)
W 4-4-4 Check wheel drive (drive side)
W 4-4-6 Checking the torsional backlash
Chapter 9 - Page 4 0299 6309-0179 0103

TBG 632 Job Cards
W 5-3-13 Remove and install, clean frequency pick ups, 2 pcs.

W 6-4-4 Cleaning the mixture cooler (water and air sides)
W 6-4-6 Cleaning mix cooler (on air side) in installed condition in engines without IFE
W 6-4-7 Removing and installing mix cooler on engines without IFE
W 6-6-4 Removing and installing exhaust gas turbocharger
W 6-7-1 Clean flame filter
W 8-4-1 Repair lube oil pump, Rickmeier make
W 8-4-2 Repair pressure limiting valve of the lube oil pump
W 8-11-4 Clean pre-control cartridge
W 12-3-1 Replace compensators
W 13-0-1 Instructions for Work on the Electrical Equipment
0103 0299 6309-0179 Chapter 9 - Page 5

Job Cards TBG 632
9 9.1.3 Explanation of symbols

You will find there are various symbols used on the Job Cards, in order to designate information not relating
directly to the actual work sequence involved.
Tools:
- The tools normally required are listed against this symbol.
Equipment:
- Things like pressure gauges, lube oil and hydraulic oil
Spare parts:
- Seals, locking parts, etc.
Cross-references:
- Documents, reports or Job Cards to which reference is made in the Job Card concerned.
9.2 Job Cards arranged by Job Card Numbers
Chapter 9 - Page 6 0299 6309-0179 0103

General
Engines Job Card
W 0-0-1
Filling and venting the hydraulic clamping device

Aids:
Safety instructions for the - Hydraulic oil 6.088.801.1011.8
hydraulic clamping device.
Before fitting the hydraulic clamping device,
clean and lubricate the threads and contact
areas.
Lubricant:tallow /red lead or lube oil
(Molycote forbidden).
Before commencing any work on the
pressurized hydraulic clamping device,
check all pressurized hoses and seals.
When working on the pressurized hydraulic
clamping device wear face protection and
gloves,since hydraulic oil escaping from For the hydraulic clamping device to
leaks would penetrate under the skin due to operate properly,the entire piping/hose
the high pressure involved. system must be air-free.
Repairs to the hydraulic clamping device are But carry out a venting procedure only
forbidden. when necessary,since normally the
automatically closing safety coupling
Because of the accident risk,all parts of the halves will prevent oil escaping and air
hydraulic clamping device,particularly the penetrating.
high-pressure hoses,must be in perfect
condition.
For safety reasons,always close off
Do not kink,sharply bend or pull the high- unconnected but pressurized hoses with
pressure hoses. closure nipple.
Components of the clamping device

1 High-pressure pump
2 Oil tank
3 Pump lever
4 Filling aperture with threaded plug
5 Handwheel for return valve
6 Pressure gauge
7 High-pressure hose
8 Manifold
9 Safety coupling half 1 2 3 4
10 Hydro tension element
11 Safety coupling half (mating component)
12 Venting aperture with grub screw 80228 0
13 Closure nipple
Ill. 1 High-pressure pump
0101 0299 4545-0199 Page 1 of 4
General
Job Card Engines
W 0-0-1
8 13
6
mm
7
150
rmin =
5
80229 0
Ill. 2 Pressure gauges, hoses, connections
11 10 12
80230 0
Ill. 3 Hydro tension element
How the clamping device works

With the aid of high-pressure pump 1, oil pressure is The normal operating configuration of the high-
passed via high-pressure hoses 7 into the hydro pressure pump 1 is horizontal, but it can also run in a
tension elements 10. vertical position, with the hose connection facing
downwards.
The oil pressure is limited by a safety valve.
The oil pressure specified for tightening the screw
connection is read off at pressure gauge 6. To reduce
the oil pressure in the piping/hose system, turn
handwheel 5 in its opening direction.
The high-pressure hoses 7 are connected to the
hydro tension elements 10 and the manifold 8 via
safety coupling halves 9 and 11.
If fewer than four hydro tension elements are connected
at the same time, the coupling halves 9 located at the
unused hoses will close these in a pressure-tight
configuration (see also the instructions on Page 1).
Page 2 of 4 0299 4545-0199 0101

General
Engines Job Card
W 0-0-1
Filling and venting the clamping device Malfunctions

Fill the high-pressure pump 1 only with hydraulic In the event of malfunctions at the hydraulic clamping
oil 6.088.801.1011.8, or if this is not available, with device, e.g. no or inadequate pressure build-up or
one of the hydraulic oils listed below: pressure drop, proceed as follows:
BP Energol Hydraulic 50 If the high-pressure pump 1 is in a vertical position
Mobil Hydraulic-Oil L (hose connection facing downwards), operate
BV High-Performance Oil (Hochleistungsl) E 100 pump lever 3 rapidly several times, while alternately
opening and closing the return valve by means of
Shell Oil AB 1 handwheel 5.
Esso Zerice 36
Vent high-pressure hoses and hydro tension
Shell Tellus Oil 15
elements.
Gasolin Special AS
Viscobil Oil Sera I When necessary, you should check that
Viscobil Oil CL40 pressure gauge 6 is indicating accurately by
comparing it with a calibrated pressure gauge.
Using other oils may cause malfunctions due to
The reserve pressure gauge is fitted with a
swelling of the seals.
safety coupling half 11 for connection to one
Completely unsuitable substances include of the high-pressure hoses 7.
brake fluid, shock-absorber oil, diesel oil,
kerosene and petrol.
Filter the oil from time to time. When you do this,
flush out the oil tank as well.
Work sequence
Place high-pressure pump in a horizontal position.
At the fill opening 4 of the oil tank 2, fill high-
pressure pump 1 with not less than 1.5 litres of
hydraulic oil.
Connect high-pressure pump 1, pressure gauge
holder 6, manifold 8 and hydro-tension elements
10 to the high-pressure hoses.
Unscrew grub screw 12 of the hydro tension
elements 10, and operate pump lever 3 until
hydraulic oil exits without bubbles from vent
aperture 12.
During this procedure, the hydro tension elements
10 should be positioned at a higher level than high-
pressure pump 1 and held at an angle to vent
aperture 12, in order to make sure the annular
compartment in the hydro tension element 10 is
vented completely.
Tighten grub screw 12.
0101 0299 4545-0199 Page 3 of 4

General
Job Card Engines
W 0-0-1
Page 4 of 4 0299 4545-0199 0101

General
TBG 632 Job Card
W 0-1-3
Running-In Instructions
Tools:
- Ignition light pistol
Cross-references:
- Test stand acceptance protocol
- Job Card W 0-2-7
Preparations Run the engine for 10 minutes at 25 % of the

nominal capacity.
Install measuring points
Then raise the capacity by 5 % every 15 minutes
The following pressures are to be measured during
until the engine is running at full load.
insertion and to be noted at 50 %, 75 %, 90 % and
100 %: The second load point must lie slightly above
30 % (approx. 30.2 30.5 %).
- Mixing pressure after thickener
Run engine for 2 hours at full load. When steady
- Mixing pressure in the receiver tube
speed has been reached, set the controller filling
- Exhaust pressure after turbine (depending on to 70 - 80 % (Longitudinal hole in the controller
engine at A or B side) levers).
Set the ignition angle (TEM EVO-parameters 11301 Check that the differential pressure A to B
and 21319) to the value given in the test stand side is below 50 mbar.
protocol, check with an ignition light pistol and
correct if necessary. After Running-In
Endoscope all the combustion chambers and
Running-In inspect for scoring or similar damage,
The above-mentioned settings must be see Job Card W 0-2-7.
controlled or carried out before running-in.
Do not run engine longer than 15 minutes at
30 % load, otherwise TEM will switch the
engine off.
If the running-in program is to be interrupted,
then the load point last used must be repeated.
Start engine.
Set the mixture on the gas mixture and the zero
pressure regulator such that the engine runs
satisfactorily.
Control the differential pressure receiver A side to
B side during idling. The differential pressure must
not exceed 30 mbar, if necessary adjust by altering
the length of the regulating rods.
0402 0299 8294-0179 Page 1 of 2

General
Job Card TBG 632
W 0-1-3
Page 2 of 2 0299 8294-0179 0402

General
Engines Job Card
W 0-2-7
Endoscoping the combustion compartment

Endoscopy is a method enabling you to examine the Tools:
combustion compartment (piston, cylinder liner, - Endoscope
cylinder head, valves) for its wear-and-tear status
without having to remove the cylinder head
beforehand. This means you can exploit the wear
Cross-references:
limits more effectively, and thus cut your maintenance - Job Cards B 7-7-2, B 13-5-1, B 13-5-4
costs.
When handling the endoscope, always follow the
manufacturers instructions!
The endoscope image may be laterally transposed or
upside down, depending on how you are looking into
the lens.
Examinign the combustion

compartment
In the case of diesel engines, remove the injection
valve, see Job Card B 7-7-2.
In the case of gas engines, remove the sparking
plugs, see Job Card B 13-5-1 or B 13-5-4.
Place the piston of the cylinder you want to examine
in its bottom dead centre position.
Connect the endoscope, switch it on, and insert it
cautiously through the injection valve or the
sparking plug borehole.
Carry out your examination using the eyepiece
and the cold light source.
To enable the inlet and exhaust valves to be
checked, the engine has to be turned
appropriately. Be very careful to ensure that
the endoscope is not damaged.
Light reflections may lead to faulty diagnoses.
You will also find it helpful to swivel the
endoscope during your examinations, and tilt
it alternatively from side to side, making sure
that the fibre-optic cable is not damaged.
0100 0299 4270-0199 Page 1 of 2

General
Job Card Engines
W 0-2-7
If you find clearly recognizable damage (e.g. break-

outs, notches, scoring), remove the cylinder head.
Always be on the lookout for drip formation at the
bottom of the cylinder head. This indicates a
possible leak at the seal of the injection valve or the
sparking plug guard tube.
Evaluation of normal wear phenomena, and
specification of the next endoscoping date
can be performed only by properly trained
experts.
Carefully take out the endoscope.
In the case of diesel engines, install the injection
valve, see Job Card B 7-7-2 and Installation
Instructions W 7-7-6.
In the case of gas engines, install the sparking
plugs, see Job Card B 13-5-1.
80967 0
Ill. 1 Checking with an endoscope
Page 2 of 2 0299 4270-0199 0100

General
Engines Job Card
W 0-3-1
Use of liquid nitrogen
Never touch liquid nitrogen and

undercooled parts:
Risk of injury!
When placing the components into

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

concentric containers into each other and fill the
clearance between the two containers with glass
wool, cork meal or sand.
Pour the nitrogen from the containers, in which it is
delivered, into the special basin and then dip the metal
parts into this liquid.
Use a suitable tool for placing the components
into and taking them out of the container.
The start of the undercooling process is indicated by
heavy boiling. Bubbles will form until the metal parts
have assumed the nitrogen temperature (-196 C).
Once no more bubbles form, the parts are ready for
installation.
Quantity of nitrogen needed

Under normal conditions, one kilogram of metal to be
cooled from +15 C to -196 C requires the following
quantity of liquid nitrogen:
0.60 l for steel
0.66 l for cast iron
0.45 l for bronze, copper, brass
0.96 l for aluminium
0100 0299 4271-0199 Page 1 of 2

General
Job Card Engines
W 0-3-1
Page 2 of 2 0299 4271-0199 0100

General
Engines Job Card
W 0-3-2
Crack inspection with the diffusion liquid procedure
When working with trichloroethylene:

Aids:
- Cleaning agent (trichloroethylene)
Risk of poisoning! - Diffusion liquid (red)
- Developer (white)
- Dry cloth
- Protective goggles
- Protective gloves
- Extractor device
Cleaning the components

Wear protective goggles and protective gloves!
Make sure the room is properly ventilated!
Make sure the vapours are extracted. Never inhale
them!
Use cleaning agent to degrease the component.
Allow the cleaning agent to act for 10 - 15 minutes.
Rub down the surface you want to check with a dry
cloth. This will get rid of all the grease residues
which might otherwise fill in and cover up any
cracks present, see Fig. 1.
Applying the diffusion liquid

Apply diffusion liquid, see Fig. 2. Use a spray can,
a spray gun, or a brush to do this, or immerse the
component in the diffusion liquid.
Allow the liquid to act for the time period specified
by the manufacturer.
Clean the component with water, until the diffusion
liquid has been washed off the surface, and remains
only in the cracks, see Fig. 3.
Rub the surface thoroughly with a cloth to dry it.
Allow the component to finish drying.
Appling the developer

Use a spray gun or a brush to apply a thin film of
developer. (Avoid applying twice to the same
area).
Allow the developer to dry for 1 - 2 minutes.
Due to the blotting paper effect of the 25495 0
developer, the diffusion liquid is sucked out of
the crack, and thus becomes visible, see Ill. 1 Diffusion liquid procedure
Fig. 4.
0100 0299 4272-0199 Page 1 of 2
General
Job Card Engines
W 0-3-2
Assessment
- It may happen that very thin cracks do not become
visible until several hours have passed.
- Due to the diffusion liquid being sucked upwards,
red points will form in the white developer coating
wherever there are cracks or other surface
irregularities.
- Red lines indicate cracks.
- Red dots indicate pitting and porosity.
- A dotted red line will appear in the case of:

- very fine cracks,
- metal fatigue,
- an only partial rupture.
Page 2 of 2 0299 4272-0199 0100

General
DEUTZ MWM Job Card
TBG 632 W 0-4-1
Removing and installing the unit

Tools:
The safety instructions for work on the
! drive mechanism must be complied with
- Set of tools 1215 0000
- Lifting tackle
as detailed in Job Card W 2-0-1.
from special basic kit:
- Bolt drawer fro connecting-rod screws
- Slide rail for mounting the connecting-
rod bearing cover
Comply with the tightening instructions
- Device for fixing the connecting rod to
given in the Operating Manual,
the cylinder liner
Chapter 8, Technical Data.
- Device for fixing the roller tappets
- Lift-off device for unit
from hydraulic tools:
- Tools for loosening the connecting-rod
and cylinder-head nuts
Aids:
- Cleaning agent
Cross-references:
- Job Cards W 0-1-3, B 1-1-1,
W 1-4-5, W 2-0-1, W 2-3-2,
W 2-5-5
- Operating Instructions, Chapter 8,
Tightening Instructions
Removing the unit

l Disconnect the cables.
l Remove clips 1 at exhaust gas pipe 2. 2
l Remove fixing nuts at exhaust gas pipe 2.
l Take off exhaust gas pipe 2.
l Take off guard caps 3.
1
l Remove cylinder head hood.
80789 0
Fig. 1 Exhaust gas pipe / guard caps

1097 0299 6311-0179 Page 1 of 8
General
Job Card DEUTZ MWM
W 0-4-1 TBG 632
l Remove coolant overflow 1.

l Remove inspection hole cover and camshaft cover
of the cylinder involved. 1
81176 0
Fig. 2 Coolant overflow
l Turn the engine until the tappets 11 are at their

highest point. 11
l Fit holding device 10 for tappets 11.
10
80871 0
Fig. 3 Holding device for tappets
Page 2 of 8 0299 6311-0179 1097

General
DEUTZ MWM Job Card
TBG 632 W 0-4-1
l Use four screws 8, tightened in diagonally opposite

sequence, to connect cylinder jacket 7 to cylinder 1
head 1.
l Bolt device 3 for fixing the piston-connecting-rod
unit to cylinder liner 2.
l Turn the engine in such a way that the hydraulic
tensioning device can be fitted to the stud bolts of
the connecting-rod cover.
l Hydraulically loosen connecting-rod nuts 6,
see Job Card W 2-5-5.
l Use the slide rail to support the connecting-rod 8
cover 4.
l Unscrew connecting-rod nuts 6 and stud bolts 5. 7
l Lower connecting-rod cover 4, and take it out.
6
81174 0
Fig. 4 Unit
l Loosen nuts 1 for cylinder head mounting, and

unscrew them, 1
81178 0
Fig. 5 Cylinder head

1097 0299 6311-0179 Page 3 of 8
General
Job Card DEUTZ MWM
W 0-4-1 TBG 632
81166 0
Fig. 6 Fixing screws for cylinder jacket (for a better view shown without the cylinder head)
l Remove the eight fixing screws 1.

l Fit unit lift-off device.
l Lift the unit out of the crankcase with tilted lift-off
device and a crane.
l Make sure that the stroke journal and the top
connecting-rod bearing shell are not damaged.
l Lower the unit carefully into the device.
l To complete the removed unit, fit connecting-rod
bearing cover with connecting-rod bearing shell
and cylinder-head hood.
l Remove old O-sealing rings and seals at the
cylinder block.
Page 4 of 8 0299 6311-0179 1097

General
DEUTZ MWM Job Card
TBG 632 W 0-4-1
Installing the unit

l Clean the sealing surfaces, removing all residues
of old seals.
Make sure that no seals or seal residues drop
into the crankcase.
l Place new O-sealing rings 1 over the stud bolts
onto the crankcase.
81164 0
Fig. 7 O-sealing rings for dowel pins
81165 0
Fig. 8 Sealing the crankcase
l Seal the coolant channel with a beading of sealant

1 on the crankcase. Fit new cylinder jacket seal 3.
Seal coolant channel with a beading of sealant 2
on seal 3. Check centering sleeve 4 for damage
and correct seat; see Fig. 8.
l Check sealing rings of the cylinder liner for correct
seat, and grease them.
l Fit tilted lift-off device at the units exhaust gas
pipe, and use crane to raise it.
Install the unit with the connecting-rod union
facing towards the camshaft side.
l Grease turned groove 1 and O-ring for intake pipe.
Clean coolant overflow flange 2, Fig. 9.
81177 0
Fig. 9 Intake pipe

1097 0299 6311-0179 Page 5 of 8
General
Job Card DEUTZ MWM
W 0-4-1 TBG 632
l Oil slide layers of the connecting-rod bearing shells.

l Use crane to carefully insert the unit into the
crankcase aperture.
Make sure that the sealing rings of the cylinder
liner are not damaged or twisted. Be careful
with the centering sleeve.
l Turn the engine in such a way that the hydraulic
tensioning device can be fitted to the connecting-
rod bearing cover stud bolts.
l Place top bearing shell 6a on the crank journal 10.
l Insert bottom bearing shell 6b into device. Bearing
shell 6b is fixed in position using pin 11.
l Position connecting rod shortly before top bearing
shell. Turn bearing shell mounting device until
surface X is flush against the bottom connecting- 80899 0
rod surface. Fig. 10 Mounting the connecting-rod bearing

Guide lugs 13 of the two bearing shells 6 must
be aligned on each other!
l Place connecting rod with piston in bearing shell
6a, and remove bearing shell mounting device.
l Use bolt drawer to screw in the stud bolts; tightening
torque 200 20 Nm. Remove bolt drawer.
l Push slide rail into assembly aperture, and insert
connecting-rod bearing cover. 23
80796 0
Fig. 11 Mounting the connecting-rod bearing,

fixing pin I
Make sure that the connecting-rod bearing
shells are in the correct axial position. The
bottom bearing shell must fit into pin 23.
80900 0
Fig. 12 Mounting the connecting-rod bearing,

fixing pin II
Page 6 of 8 0299 6311-0179 1097
General
DEUTZ MWM Job Card
TBG 632 W 0-4-1
l Lift connecting-rod bearing cover over stud bolts,

and screw in connecting-rod nuts until they are 1
hand-tight.
l Hydraulically tighten connecting-rod nuts;
l Install the eight fixing screws for the cylinder jacket;
for tightening torque, see Operating Instructions,
Chapter 8, Tightening Instructions.
l Tighten nuts 1 with washers fro securing the cylinder
head until they are hand-tight.
l Tighten nuts 1 for securing the cylinder head,
81178 0
l Remove device 3 for fixing the piston/connecting-

rod unit to the cylinder liner 2. 1
l Remove the four fixing screws 8.
l Turn the engine until the cams are overlapping at
their topmost point, then remove the device at the
roller tappets.
l Fit new seals to the inspection hole cover and
camshaft cover of the cylinder involved.
l Connect cables.
l Install coolant overflow.
8
l Install exhaust gas pipe.
l Fit clips at exhaust gas pipe. 7
l Adjust the valve clearance,
see Job Card B 1-1-1.
l Run in the engine,
l After starting up the engine, immediately check the
supply of lube oil to the valve lifters. 2
6
81174 0
Fig. 14 Unit
1097 0299 6311-0179 Page 7 of 8
General
Job Card DEUTZ MWM
W 0-4-1 TBG 632
Page 8 of 8 0299 6311-0179 1097

Cylinder Head
TBG 632 Job Card
W 1-4-4
Remove and install cylinder head

Tools:
The safety instructions for work on the - Standard tools
drive mechanism must be complied with - Hydraulic tool for loosening and
as detailed in Job Card W 2-0-1. tightening the cylinder head nuts
- Mounting plate for cylinder head
- Lifting device for cylinder head
Never touch liquid nitrogen and - Lifting gear
undercooled parts:
Risk of injury! Auxiliary equipment:
- Cleaning agent
given in the Chapter 8, Technical Data. Spare parts:
- Seals and round sealing rings
Cross references:
- Job Card B 1-1-1, W 1-4-5, W 2-0-1
- Chapter 8, Tightening specifications
Remove cylinder head

Clean the work area before starting work.
Remove exhaust pipe cladding.

Disconnect cables.
Remove cylinder head hood 1.
Remove protective caps 2.
1
80840 0
Fig. 1 Cylinder head cover

0103 0299 6312-0179 Page 1 of 4
Cylinder Head
Job Card TBG 632
W 1-4-4
Loosen the fastening clips 3, unscrew the four nuts

4 and remove the exhaust pipe 5. 3
80838 0
Fig. 2 Exhaust pipe
Remove the cooling fluid overflow 6.
80839 0
Fig. 3 Cooling fluid overflow
Remove toggle lever block 10, loosen the four

screws 8 to do so.
Remove the fenders 9.
Loosen the four cylinder head nuts 7 hydraulically,
see job card W 1-4-5.
Remove the cylinder head nuts 7 with washers.
Attach the lifting device to the cylinder head and lift
the cylinder head carefully from the cylinder jacket.
To avoid damaging the cylinder head, place this on
the mounting plate.

Page 2 of 4 0299 6312-0179 0103
Cylinder Head
TBG 632 Job Card
W 1-4-4
Remove cylinder head

Remove leftover gasket, clean the contact and
sealing surfaces.
Renew all gaskets.
Insert round sealing ring in the groove 11 of the
manifold with grease. Clean flange 12 for cooling
fluid overflow.
Fig. 5 Manifold
Attach the lifting device to the cylinder head and lift

the cylinder head carefully from the cylinder jacket.
Fit washers with cylinder head nuts 7 hand tight.
Tighten cylinder head nuts 7 hydraulically,
Place protective caps on the cylinder head nuts.
Insert fenders 9 in the cylinder head.
Mount toggle lever block 10 and tighten the four
screws 8 according to the tightening specifications.
Attach cooling fluid overflow.
Attach exhaust pipe.
Set valve play,
see job card B 1-1-1.
Attach cylinder head cover.
Attach cabling. Fig. 6 Cylinder head
Mount exhaust pipe cladding.
0103 0299 6312-0179 Page 3 of 4

Cylinder Head
Job Card TBG 632
W 1-4-4
Page 4 of 4 0299 6312-0179 0103

Cylinder head
TBG 632 Job Card
W 1-4-5
Cylinder head, mounting instructions, hydraulic tool Lerbs
The safety instructions for the hydraulic

Tools:
clamping device as laid down in Job - Hydraulic clamping device
Card W 0-0-1 must be complied with. - Tightening tool HV 1945/32
The hydraulic system may be pressurized

Cross-references:
only when it has been completely assembled.
- Job Card W 0-0-1
Lubricant:tallow/red lead or oil (Molycote
prohibited).
Repairs to the hydro screw pretensers are
prohibited.
If there is pressure at the tension elements,
keep away from the area above the hydro
screw pretensers.
Work sequence for unscrewing the Work sequence for tightening the
connection connection
Fit hydro screw pretensioner onto the 4 screws. Tighten hexagonal nuts (4 of them) hand-tight in
diagonal sequence with a box spanner.
Screw puller bolt of the tightening tool onto the stud
bolts as far as it will go. Nut (spanner size 65) must Fit hydro screw pretensioner onto the 4 screws.
be loose.
Screw puller bolt of the tightening tool onto the stud
Connect hydraulic lines. Open valve at the pressure bolts as far as it will go. Nut (spanner size 65) must
pump and bring the hydro tensioning elements be loose.
with the hexagonal nuts (spanner size 65) into the
Connect hydraulic lines. Open valve at the pressure
initial position. Loosen hexagonal nuts (spanner
pump and bring the hydro tensioning elements
size 65) by 9 sixth-circles (make sure that the
with the hexagonal nuts (spanner size 65) into the
puller bolts do not turn as well).
initial position. When doing this, align pressure
Close valve at the pressure pump, and while the sleeves (support pipe) at the outer diameter of the
pressure s being built up align pressure sleeves washers.
(support pipes) at the outer diameter of the washers.
Close valve at the pressure pump, pump pressure
Pump pressure up to 550 bar. Use 8 mm arbor
up to 200 bar, and tighten hexagonal nuts hand-
to loosen hexagonal nuts via a box spanner with a
tight with 8 mm arbor via a box spanner.
turn of 420.
Increase pressure to 525 bar, and tighten hexago-
Bleed off pressure, remove the hydro screw
nal nuts hand-tight with a 8 mm arbor, while
pretensioners; the cylinder head has now been
checking the tightening angle.
unscrewed.
The position of the hexagonal nuts after
tightening with 200 bar is the beginning of
counting. It must be possible to tighten the
hexagonal nuts by 240 15 or 4 sixth-circles
1/4 sixth-circle ( corresponds to 1 hole
8 mm). If the tolerance bands for the screw
connections are not complied with, the fault
must be found (for example, mounting error,
material defect, device defective).
Bleed off pressure, remove the hydro-screw
pretensioners: the cylinder head has now been
fitted.
1000 0299 5947-0179 Page 1 of 4

Cylinder head
Job Card TBG 632
W 1-4-5
1 Stud bolt M36x2 10.9

2 Washer
3 Nut M36x2 10.9
4 Hexagonal nut spanner jaw size 65
5 Tension element
6 Ring
7 Screw
8 Box spanner
9 Tension blot
10 Support tube
11 Flexible hose
12 Manifold, quadruple
13 Transport frame
Page 2 of 4 0299 5947-0179 1000

Cylinder head
TBG 632 Job Card
W 1-4-5
10
11
12
13
82115 0
Fig. 1 Tightening tool for cylinder head

1000 0299 5947-0179 Page 3 of 4
Cylinder head
Job Card TBG 632
W 1-4-5
Page 4 of 4 0299 5947-0179 1000

Cylinder head
TBG 632 Job Card
W 1-4-5
Cylinder head, mounting instructions, hydraulic tool HTI

Before using the hydraulic clamping device, the Tools:
safety instructions must be read, understood, and - Normal tools
complied with. - Hydraulic clamping device HTI
The hydraulic pressures specified for loosening
and tightening the screw union relate only to the Cross-references:
application case with the HTI hydraulic clamping - HTI Operating Instructions *
device. - HTI Safety Instructions *
Before using the hydraulic clamping device, make * Is included in the HTI toolbox
sure that the numbers 7.66 sq.in. (49.4 cm2) are
stamped into the surface of the piston head.
Safety instructions
The hydraulic clamping device is operated using - Do not lift or move the hydraulic clamping
hydraulic oil under high pressure. In order to device at the hydraulic hoses or quick-release
avoid injuries, the following instructions must be connection pieces.
meticulously complied with at all times: - The two hydro screw tensioners may, when
- Before using the hydraulic clamping device, they have been correctly mounted on the stud
the safety instructions and the operating bolts, be pressurised only simultaneously.
instructions from the tools manufacturers must - When the hydraulic clamping device is
have been read in their entirety and understood. pressurised, no part of the operators or
- The hydraulic clamping device may be used assistants body may be located in the direction
only by qualified specialist staff. of bolt pull.
- For operating or servicing the hydraulic - A pressurised hydraulic system must not be
clamping device, safety goggles and gloves left without an operator. The pressure must be
must be worn. bled off, the air supply switched off, and the
needle valve for the tank return must be
- It is not permitted to exceed the specified
completely open.
pressures.
- While the pressure is being built up in the
hydraulic system, the pressure indicator must
be kept under observation; once the requisite
pressure has been reached, stop increasing
the pressure IMMEDIATELY.
- The largest stroke on the hydraulic clamping
device has been reached when a yellow line
becomes visible on the pulling device. This
yellow marking must not be exceeded.
- Make sure that a length of at least one thread
diameter is protruding above the nuts.
- Make sure that all quick-release connection
pieces are firmly connected before building up
the pressure.
- Close off the pump outlet with a plug or connect
to a hose.
1000 0299 8019-0179 Page 1 of 4

Cylinder head
Job Card TBG 632
W 1-4-5
Instructions for tightening the cylinder Instructions for loosening the cylinder
head head
1.1 Before using the tightening tools, comply with 2.1 Before using the tightening tools, comply with
the HTI operating and safety instructions! the HTI operating and safety instructions!
1.2 Apply clean machine oil to the cylinder head 2.2 Make sure that the threads, after removal of the
bolts, the threads and the contact surfaces of guard caps from the cylinder bolts, are clean
the nuts and the washer. Do not use any and free from residues.
lubricant on a molybdenum basis, like Molyko-
2.3 Mount hydraulic tightening tool for the cylinder
te!
head in compliance with HTIs mounting
1.3 Mount hydraulic tightening tool for the cylinder instructions. Important: in order to avoid damage
head in compliance with HTIs mounting to the engine and to the hydraulic tightening
instructions. Important: in order to avoid damage tool, the mounting instructions given in the HTI
to the engine and to the hydraulic tightening manual must be meticulously complied with.
tool, the mounting instructions given in the HTI
2.4 Remove the inlet and exhaust shock-absorber
manual must be meticulously complied with.
rods, so that these do not raise the cylinder
1.4 Increase pressure to 380 bar, and tighten the head after the cylinder head bolts have been
four hexagonal nuts with a 9/16" box cap wrench. loosened.
1.5 Increase hydraulic pressure to 1005 bar, and 2.5 Increase hydraulic pressure to 1050 bar, and
tighten hexagonal nuts with a 8 mm arbor, loosen the hexagonal nuts with a turn of 420.
while checking the tightening angle.
2.6 Remove hydraulic tightening tool after bleeding
The position of the hexagonal nuts after Point off the pressure.
1.4 marks the beginning of counting. It must
be possible to tighten the hexagonal nuts by
240 15 or 4 sixth-circles 1/4 sixth-circles
( corresponds to 1 hole 8 mm). If the
tolerance bands for the screw union are not
complied with, the fault must be found (e.g.
mounting error, material defect, device
defective).
1.6 Remove hydraulic tightening tool after bleeding
off the pressure.
Page 2 of 4 0299 8019-0179 1000

Cylinder head
TBG 632 Job Card
W 1-4-5
4 5
A B
3
6
7
2
8
11
1 9
10
12
13
11
14
9
7
10
16 15
82374 2
Fig. 1 Hydraulic clamping device for cylinder head

A Cylinder head B Hydraulic clamping device
1 Tie-rod 4 Adjuster screw
2 Washer 5 Pulling device bolt
3 Hexagonal nut 6 Pulling device nut
7 Sleeve
8 Bridge
9 Tie-rod
10 Hexagonal nut
11 Bridge
12 Manifold block
13 Nipple
14 Hydraulic pipe
15 Turn indicator angle
16 Lift arm
1000 0299 8019-0179 Page 3 of 4

Cylinder head
Job Card TBG 632
W 1-4-5
Page 4 of 4 0299 8019-0179 1000

Cylinder head
TBG 632 Job Card
W 1-5-1
Inlet and exhaust valves

Tools:
- Normal tools
- Mounting device for inlet and exhaust
valves
Aids:
- Cleaning agent
Spare parts:
- Round sealing rings
- Valves, if necessary
- Valve clamping cones, if necessary
- Valve springs, if necessary
Cross-references:
- Job Cards W 1-4-4, W 1-5-6, W 1-5-7,
W 1-6-1
Removing the valves Installing the valves

See next pages for illustrations of inlet and Before installing overhauled or new valves, always
exhaust valves. replace the round sealing rings 9 in valve guides 7.
Remove cylinder head, Apply a light film of oil to valves 5, and insert into the
see Job Card W 1-4-4. cylinder head from below.
Place cylinder head on a wooden board, so that the Place cylinder head on a wooden board, so that the
valves do not move aside when spring plate 1 is valves do not move aside when spring plate 1 is
pressed down. pressed down.
Fit mounting device. Fit mounting device.
Push spring plate 1 in the direction of the arrow, and Fit spring plate 1 with valve springs 4 and valve
remove valve clamping cone 2. rotating device 3.
Take off spring plate 1 with valve springs 4 and Press spring plate 1 in the direction of the arrow,
valve rotating device 3. and insert valve clamping cone 2.
Withdraw valves 5 downwards from the cylinder Make sure that the valve clamping cones are
head. in the correct position.
Check valve clamping cones and shaft surface of Fit the cylinder head,
the valves for surface damage; replace if necessary. see Job Card W 1-4-4.
Check valve springs 4 for damage; replace if
necessary.
Clean inlet and exhaust channels, and the valves
themselves.
If you find any signs of wear and tear or damage at
valve sealing surfaces 6, valve guides 7 or valve
seat rings 8, further work is then required:
- Repair inlet valves,
- Repair exhaust valves,
- Check valve guide, remove and install,
0201 0299 6313-0179 Page 1 of 4

Cylinder head
Job Card TBG 632
W 1-5-1
Diagram of inlet valves in the cylinder head
1 5 2
4 1 2 5
7
9
8 6 8
80842 1
Ill. 1 Inlet valves in the cylinder head
1 Spring plate
2 Valve clamping cone
3 Valve rotating device
4 Valve springs
5 Inlet valve
6 Valve sealing surfaces
7 Valve guide
8 Valve seat rings
9 Round sealing rings
Page 2 of 4 0299 6313-0179 0201

Cylinder head
TBG 632 Job Card
W 1-5-1
Diagram of exhaust valves in the cylinder head
1 5 2
4 1 2 5
8 6 8 7
80843 1
Ill. 2 Exhaust valves in the cylinder head
1 Spring plate
2 Valve clamping cone
3 Valve rotating device
4 Valve springs
5 Exhaust valve
6 Valve sealing surfaces
7 Valve guide
8 Valve seat rings
9 Round sealing rings
0201 0299 6313-0179 Page 3 of 4

Cylinder head
Job Card TBG 632
W 1-5-1
Page 4 of 4 0299 6313-0179 0201

Cylinder Head
TBG 632 Job Card
W 1-5-6
Repair intake valves (wide seat)

Tools:
from special basic equipment:
- Valve grinding tools:
Valve cone grinding machine
Auxiliary equipment:
- Cleaning agent
- Marking ink
Cross references:
- Job Card W 1-5-1
Reworking valve conical seats and

valve seat rings
Remove valves, A
Grind the valve conical seat on the valve cone
grinding machine (seat angle see fig. 1) until the 72,84
min. 6,3
surface of the seat is clean.
5'
_
When wear dimension 6.3 mm as in fig. 1 is
30
reached or if the chrome layer is broken
through at the valve shaft, install a new valve.
Have valve seat 1 reworked by the DEUTZ 6
8 1
,0
Service with a valve seat turning tool. Valve
seat ring may be reworked up to diameter
88 mm. The seat angle must be retained. 8,0
0, 3 A
Check with marking ink whether a continuous, 83754 1
surrounding carry is guaranteed at the greatest
valve cone diameter between the valve cone and Fig. 1 Valve cone of the intake valves
the valve seat ring (external carry).
Run the test without inserting round sealing ring in
the valve stem guide. 1
,0
74 1
Clean the valves after the test with distilled fuel, do
not switch over the valves.
If the dimension 88.0 mm as in fig. 2 is reached,
A
10'
change the valve seat ring. Contact DEUTZ

Service or an authorised workshop in this
30 12'
case.
Install valves,
see job card W 1-5-1. 0,15
neu/new 9,58
max. 8
0,2 A R z 4
83755 1
Fig. 2 Valve seat ring for intake valve

0602 0299 6314-0179 Page 1 of 2
Cylinder Head
Job Card TBG 632
W 1-5-6
Page 2 of 2 0299 6314-0179 0602

Cylinder Head
TBG 632 Job Card
W 1-5-6
Repair intake valves (narrow seat)

Tools:
- Cleaning agent
- Marking ink
Cross references:
- Job Card W 1-5-1

valve seat rings
Remove valves, A
grinding machine (seat angle see fig. 1) until the 59, 7
min. 6,3
10'
_
30
Have valve seat 1 reworked by the DEUTZ 86 1
,0
88 mm. The seat angle must be retained. 8
,0
0, 3 A
surrounding carry is guaranteed at the greatest
valve cone diameter between the valve cone and Fig. 1 Valve cone of the intake valves
the valve stem guide. + 0,1
7 1
Clean the valves after the test with distilled fuel, do
change the valve seat ring. Contact DEUTZ A
+10'
Service or an authorised workshop in this

case.
30 2'
Install valves,
see job card W 1-5-1. + 0,1
neu/new 86
max. 88
0,2 A Rz 4
80850 1
Fig. 2 Valve seat ring for intake valve

0602 0299 8705-0179 Page 1 of 2
Cylinder Head
Job Card TBG 632
W 1-5-6
Page 2 of 2 0299 8705-0179 0602

Cylinder Head
TBG 632 Job Card
W 1-5-7
Repair discharge valves

Tools:
- Cleaning agent
- Marking ink
Cross references:
- Job Card W 1-5-1

valve seat rings
Remove valves, A
grinding machine (seat angle see fig. 1) until the 67,18
min. 6,3
5'
_
30
Have valve seat 1 reworked by the DEUTZ 80 0,1
82 mm. The seat angle must be retained. 0,8
0,03 A
surrounding carry is guaranteed at the greatest Fig. 1 Valve cone of the discharge valves
valve cone diameter between the valve cone and
the valve stem guide.
1
Clean the valves after the test with distilled fuel, do B
change the valve seat ring. Contact DEUTZ
30 2' +10'
Service or an authorised workshop in this A

case.
Install valves,
68 -0,1
neu/new 80 + 0,1
max 82
0,02 AB Rz 4
80847 3
Fig. 2 Valve seat ring for discharge valve

0602 0299 6315-0179 Page 1 of 2
Cylinder Head
Job Card TBG 632
W 1-5-7
Page 2 of 2 0299 6315-0179 0602

Cylinder Head
TBG 632 Job Card
W 1-6-1
Check, remove and install valve stem guide

Tools:
Never touch liquid nitrogen and
- Insertion and removal pin for valve stem
undercooled parts:
guide
Risk of injury!
Spare parts:
- Round rubber rings
- Valve stem guides
Cross references:
- Job Card W 0-3-1, W 1-5-1
Check, remove and install valve stem A B

guide
2 3
Remove valves,
Remove round rubber ring 3.
Check valve stem guides.
mm
Wear limit B of the valve stem guide 2
0,5
max. 17.2 mm.
This can be checked with a barrel gauge
X = 53,5
( 17.2 mm) in the direction of the arrow. This may
not be insertable in the guide by more than 10 mm.
C
If it is, use a new valve stem guide.
Press valve stem guides 2 out of the cylinder head
R
with insertion and removal pin.

16
80844 1
If pressing out the valve stem guides 2 reveals
heavy marks in the drill holes C, the holes C must Fig. 1 Valve stem guides
be reamed to the next repair stage with a reamer,
see table 1.
In table 1 the appropriate repair valve stem guides
and part numbers are listed.
Cool valve stem guides 2 in liquid nitrogen to
approx. -196 C and press into the cylinder head
up to dimension X according to Ill. 1.
Install new round rubber rings.
Install valves,
[mm] Series Rep. stage 1 Rep. stage 2 Rep. stage 3

Valve stem guide A 28.022 28.035 28.222 28.235 28.422 28.435 28.622 28.635
Part number 1228 1914 nn nn nn
Hole C 28.000 28.013 28.200 28.213 28.400 28.413 28.600 28.613
Tab. 1
0200 0299 6316-0179 Page 1 of 2

Cylinder Head
Job Card TBG 632
W 1-6-1
Page 2 of 2 0299 6316-0179 0200

Drive mechanism
Engines Job Card
W 2-0-1
Safety rules for working on the drive mechanism

When you are performing any work on the
drive mechanism, you MUST always
comply with the following rules.
Danger of burst!
Before starting work During the work

Shut down the engine, and secure it against being Make sure that no dirt can penetrate into the drive
started up again. compartment.
If necessary, drain off lube oil and/or coolant, and Before turning the crankshaft, check that:
collect it for re-use. Caution: risk of scalding!
- the turning device has engaged properly,
With diesel engines, open the indexing cocks.
- there are no persons working in or at the engine,
With gas engines, remove the spark plugs.
- no tools are impeding the crankshaft from turning
If it is fitted on your engine, open the inspection
and might thus cause damage,
hole cover 10 minutes at the earliest AFTER the
engine has been shut down, and after oil circulation - the drive mechanism is not being put out of
has been interrupted. equilibrium by the removal o drive mechanism
parts.
Do not perform any other work on the drive
mechanism until the engine has cooled down Make sure that the engine cannot turn uninten-
sufficiently. The engine must have cooled down tionally.
enough to ensure that there is no longer any risk of
burns. After finishing work
When working on the exhaust gas system, Before you close the engine, check whether you
remember that in spite of long cooldown ties some have removed all tools, cleaning cloths, etc. from
components may still be hot. Heat guard plates the crank compartment.
can have sharp edges, so wear protective gloves.
Fit inspection hole cover (if any), with new seals.
Do not start the work until a sufficient ventilation
Before starting up, turn the engine with open
period has elapsed.
indexing cocks or (in the case of gas engines) with
Make sure that the environment is clean in which spark plugs not installed.
the engine is going to be opened up.
With diesel engines, close indexing cocks. With
gas engines, install spark plugs.
Fill with lube oil. Top up coolant, vent cooling
system, and check for leaks.
0100 0299 6317-0199 Page 1 of 2

Drive mechanism
Job Card Engines
W 2-0-1
Page 2 of 2 0299 6317-0199 0100

Crankcase
TBG 632 Job Card
W 2-1-1
Check bearing spread

The bearing shell should have a positive spread so Tool:
that it lies perfectly in the take-up hole in the installed - Caliper gauge
condition.
All new bearing shells have a positive spread unless
they have been improperly handled, e.g. during
transportation.
Definition a
Positive spread:
Dimension a is greater than dimension D
measured at room temperatures.
Negative spread:
Dimension a smaller than dimension D.
Assessment
D
If a run bearing exhibits a negative spread, this may be

a sign that the bearing is deformed in shape due to
overheating and thus has lost its pre-tension if no
other reasons can be discovered.
Bearing shells with negative spread may no longer be
used.
80227 0
A correction is not possible because there is
a danger that the bearing metal peels off the Fig. 1 Spread
supporting shell or deformation occurs on the
bearing. This damage could lead to serious
faults during operation.
Setpoints
mm Main bearing Main bearing Main bearing Con-rod bearing
Series Overdimension 0.5 Overdimension 1.00 Series
Hole D 265 + 00.032 265.5 + 00.032 266 + 0.032
0
216 + 0.029
0
Spread a 265.8 + 02.0 266.3 + 02.0 266.8 + 2.0

0
216.6 + 2.0
0
1202 0299 6318-0179 Page 1 of 2

Crankcase
Job Card TBG 632
W 2-1-1
Page 2 of 2 0299 6318-0179 1202

Crankcase
TBG 632 Job Card
W 2-1-4
Check axial play of the crankshaft

Tools:
drive mechanism must be complied with - Measuring dial with magnetic stand
as detailed in Job Card W 2-0-1. - Feeler gauge
Cross references:
- Work card W 2-7-3, B 3-1-4
Check axial play of the crankshaft

Remove inspection hole cover 1 of cylinder A1 or
B1.
Press the crankshaft with narrow mounting lever in
the direction of the drive or free side to the stop.
Place the measuring dial on the crankshaft, pre-
tension 3 mm, set to zero.
Press the crankshaft in the opposite direction.
Read and note the measured value.
Repeat the process 2 to 3 times.
If the axial play is greater than 0.84 mm, change
the wearing ring halves 2.
see work card W 2-7-3.
81186 0
Fig. 1 Inspection hole cover

Axial bearing play (mm) New max. permiss.
Snug fit bearing 0.4 0.6 0.84
Check the gasket of the inspection hole cover 1 for

damage and replace if necessary,
see work card B 3-1-4.
Attach the inspection hole cover 1.
80798 0
Fig. 2 Wearing ring halves
0103 0299 6319-0179 Page 1 of 2

Crankcase
Job Card TBG 632
W 2-1-4
Page 2 of 2 0299 6319-0179 0103

Drive mechanism
TBG 632 Job Card
W 2-1-5
Checking the crank web breathing

Tools:
The safety instructions for work on the - see in the cross-references listed
drive mechanism must be complied with
Cross-references:
- Job Card W 2-0-1
- Alignment Specification
>> Service-Bulletin in preparation
- Specification
Checking the crank web breathing

Power generating sets:
- Aligning power generating sets, diesel engine
and generator,
see Alignment Specification
Permissible values:
- Permissible crank web breathing a,
see Specification
0103 0299 6320-0179 Page 1 of 2

Drive mechanism
Job Card TBG 632
W 2-1-5
Page 2 of 2 0299 6320-0179 0103

Drive mechanism
Gas engines Job Card
W 2-1-6
Visual inspection of the bearing shells

Please take the precise point in time when to inspect Tools:
the connecting-rod and crankshaft bearings from the - Magnifier, 8-fold magnification, better
operating instructions, Maintenance and Servicing. magnifier with 10-fold magnification or
pocket microscope with 35-fold
magnification
Cross-references:
- Job Cards W 2-1-1, W 2-7-2, W 2-9-3
- Operating instructions
How to proceed:
You must check the bearing shells by means of a
visual inspection and by checking the bearing shell
spread.
Under a basic overhaul routine (for precise intervals
see operating instructions Maintenance and
servicing), connecting-rod and crankshaft bearings
must always be replaced.
Removing the bearing shells

Remove piston with connecting rod,
Remove main bearing,
Check bearing spread,
see Job Card W 2-1-1
Visual inspection of the slide bearings

Running pattern of the bearing shells
Material: steel/aluminium alloy
Depending on the number of operating hours and on
the operating conditions involved, used bearing shells
will exhibit different running patterns. The essential
differences can often be recognized only by a properly
trained and specialized expert. If in doubt, we
recommend you to consult DEUTZ service for the
assessment of the bearing shells concerned.
If the inspection reveals a poor running pattern on the
connecting-rod bearings and/or deep dirt scoring or a
lot of embedded dirt, then you must additionally check
a crankshaft bearing.
0102 0299 6321-0199 Page 1 of 10

Drive mechanism
Job Card Gas engines
W 2-1-6
81148 0
Fig. 1 Bearing shell, can be re-used
The contact pattern is evenly formed over the entire

width of the bearing. As practical experience has
shown, the dirt scoring caused by a foreign body in the
lube oil has no significant effect on the slide bearings
further operational dependability.
The bearing shells contact pattern is faultless.
This bearing shell can be re-used. Illustration 1.
Page 2 of 10 0299 6321-0199 0102

Drive mechanism
W 2-1-6
81149 0
Fig. 2 Bearing shell, can be re-used
81191 0
Fig. 3 Detail for Fig. 2

width of the bearing.
The bearing shells contact pattern is impeccable.
This bearing shell can be re-used. Illustrations 2
and 3.
0102 0299 6321-0199 Page 3 of 10

Drive mechanism
W 2-1-6
81192 0
Fig. 4 Bearing shell, can be re-used if appropriate
81150 0
Fig. 5 Detail for Fig. 4

width of the bearing. The radial-configuration scoring
is caused by fine solid particles contained in the lube
oil.
If the depth of this scoring can neither be measured
nor felt, the bearing shell in question may be re-used.
If the depth of such scoring reaches or even exceeds
the lube-oil films order of magnitude, the bearing shell
must be replaced. Illustrations 4 and 5.
Page 4 of 10 0299 6321-0199 0102

Drive mechanism
W 2-1-6
81151 0
Fig. 6 Bearing shell, cannot be re-used
The contact pattern shows a marked edge carrier with

traces of scoring in the slide layer made of aluminium
alloy.
You must find out what caused this slide-bearing
damage, and eliminate the cause. Illustration 6.
This bearing shell cannot be re-used.
0102 0299 6321-0199 Page 5 of 10

Drive mechanism
W 2-1-6
81152 0
The contact pattern exhibits large-area damage with

varying degrees of scoring.
You must find out what caused this slide-bearing
damage, and eliminate the cause. Illustration 7.
This bearing shell cannot be re-used.
The loaded area of the bearing shell exhibits broken-

off bearing metal pieces. Some broken-off pieces are
lying around loose in the fatigue zone.
These have been caused by fatigue in the slide layer
of the aluminium alloy. The surface structure at the
bottom of the break-out indicates good bonding
between steel and aluminium alloy.
This bearing shell cannot be re-used. Illustration 8.
81153 0

Page 6 of 10 0299 6321-0199 0102
Drive mechanism
W 2-1-6
81154 0
This bearing shell exhibits broken-off bearing metal

pieces.
These have been caused by fatigue in the slide layer
of the aluminium alloy. The surface structure at the
bottom of the break-out indicates good bonding
between steel and aluminium alloy.
This bearing shell cannot be re-used. Illustration 9.
0102 0299 6321-0199 Page 7 of 10

Drive mechanism
W 2-1-6
Visual inspection of the deep-groove

bearings
Running pattern of the bearing shells
Material: steel/aluminium alloy
In its as-new condition, the contact surface exhibits
approx. 75 % electroplated contact layer and
approx. 25 % of bearing metal.
Use a magnifier to assess the wear-and-tear status
of the contact surface (magnification not less than
8x). Contact surface is visible as the dark zone and
the bearing metal rib as the light-coloured zone.
Crucial for wear-and-tear status:
- Ratio of width of bearing metal rib and width of
groove, plus
- extent of the worn surface.
Each time you are assessing groove states, you
must adduce the contact surface in the less loaded
area (in most cases groove status as new) as a
comparison.
1 Groove with overlay, ~ 75 %

2 Bearing metal, ~ 25 %
3 Nickel dam, max. 5 %
82333 2
Fig. 10 Deep-groove bearing, cross-section

Page 8 of 10 0299 6321-0199 0102
Drive mechanism
W 2-1-6
2 4
1 3
=5
80231 2
Fig. 11 Bearing shell (deep-groove bearing) Case 1, can be re-used if appropriate
A distinction must be made between the following Assessment

cases: In places, the bearing is worn to such an extent that
the bearing metal ribs and the grooves in the contact
Case 1 (Illustration 11):
layer have reached a ratio of 1 : 1. The width of the
Definition of the contact-surface areas bearing metal ribs has increased from 25 % (as-new
1 Max. 30 % of the shells circumference condition) to 50 %. There is still some contact layer left
in the grooves.
2 Max. 70 % of the width
If a wear-and-tear status as described in
3 Max. 50 % of the shells circumference Case 2 below must be anticipated within the
4 Max. 35 % of the width next inspection interval, then the bearing must
be replaced.
5 Wear-and-tear 1 : 1
0102 0299 6321-0199 Page 9 of 10

Drive mechanism
W 2-1-6
1 3 5 6
2 4
=7 =8
80232 2
Fig. 12 Bearing shell (deep-groove bearing) Case 2, cannot be re-used
Case 2 (Illustration 12): Assessment

The bearing metal ribs are worn in places.
Definition of the contact-surface areas
When this wear-and-tear status has been
reached, the bearing must be replaced.
2 Max. 5 % of the shells circumference
4 Max. 35 % of the shells circumference
6 Comb wear
7 Wear and tear 1 : 1
8 Bearing metal ribs worn
Page 10 of 10 0299 6321-0199 0102

Drive mechanism
TBG 632 Job Card
W 2-5-5
Connecting-rod bearing cover, mounting instructions,

hydraulic tool Lerbs
Tools:
- Hydraulic clamping device
- Tightening tool HV 1945/30
clamping device as laid down in Job
Card W 0-0-1 must be complied with. Cross-references:
- Job Card W 0-0-1
prohibited).
prohibited.
screw pretensers.
Job sequence when loosening the Job sequence when tightening the
connection connection
Screw in the tightening tools puller bolt onto the The stud bolts have been screwed in with 200 Nm.
stud bolts as far as the contact surface. Make sure
Fit the connecting-rod cover, and use a wrench to
that the nut (wrench size 65) is loose.
tighten the hexagonal nuts handtight.
Connect the hydraulic lines, open the valve at the
Mount the 2 hydro bolt pretensers onto both screws.
pressure pump and move the hydro tension
elements with the hexagonal nuts (wrench size Screw in the tightening tools puller bolt onto the
65) to their initial position. Loosen the hexagonal stud bolts as far as the contact surface. Make sure
nuts (wrench size 65) by 9 sixth-circles (making that the nut (wrench size 65) is loose.
sure that the puller bolts do not turn simultaneously). Connect the hydraulic lines. Open the valves at the
Close the valve at the pressure pump and align the pressure pump and move the hydro tension
thrust sleeves (support pipes) (averaging out the elements with the hexagonal nuts (wrench size
clearance) while the pressure is being built up. 65) to their initial position, aligning the thrust sleeves
Pump the pressure up to 860 bar. Use an arbor (support pipes) (averaging out the clearance).
8 mm to loosen the hexagonal nut with the Close the valve at the pressure pump. Pump the
socket wrench by 5 hole pitches, which corresponds pressure up to 250 bar and use a 8 mm arbor to
to 300. tighten the hexagonal nuts with the socket wrench
Release the pressure, remove the hydro bolt handtight.
pretensers; the connection has now been loosened. Increase the pressure to 850 bar and use an arbor
to tighten the hexagonal nuts handtight, checking
the tightening angle.
The hexagonal nuts position after being
tightened with 250 bar is the start for counting.
Make sure that the hexagonal nuts can be
tightened by 120 15 or 2 sixth-circles 1/4
sixth-circle ( corresponds to 1 hole 8 mm).
If the tolerance ranges are exceeded, you
have to look for the fault involved (e.g.
assembly faults, material defects, defective
device).
Release the pressure, remove the hydro bolt
pretensers; the connecting rod has now been
mounted.
1101 0299 5946-0179 Page 1 of 2

Drive mechanism
Job Card TBG 632
W 2-5-5
1 Stud bolt
2 Hexagonal nut
3 Support pipe 3
4 Puller bolt
5 Socket wrench 4
6 Cylinder screw
5
7 Tension element
8 Hexagonal nut, wrench size 65 6
82113 0
Fig. 1 Tightening tool for the connecting-rod

bearing cover
Page 2 of 2 0299 5946-0179 1101

Crankcase
TBG 632 Job Card
W 2-5-5
Connecting rod bearing cover, assembly specification, HTI hydraulic

tool
Tools:
- Standard tools
Before using the hydraulic clamping device please - HTI hydraulic clamping device
read the safety instructions, make sure you und-
erstand them and follow them. Cross references:
The hydraulic pressures listed for slackening and - HTI directions for use *
tightening screws and bolts refer solely to the use - HTI safety directions *
of this HTI hydraulic clamping device. * Forms part of the HTI toolbox
Before using the hydraulic clamping device, make
sure that the numbers 9.39 sq in (60.6 cm2) are
stamped on the surface of the piston head.
Safety instructions
The hydraulic clamping device is operated with - Do not lift or move the hydraulic clamping
hydraulic oil under high pressure. In order to device by the hydraulic hoses or quick-release
prevent injuries, the following instructions must couplings.
be explicitly adhered to:
- Both hydraulic screw coiled piston rings may
- Before using the hydraulic clamping device, be pressurized simultaneously only if they are
please read the safety instructions and mounted correctly on the stud bolts.
directions for use published by the manu-
- If the hydraulic clamping device is under
facturers of this tool completely and make sure
pressure, no part of the body of the operator or
you understand them.
any other person must be in the way of the stud
- The hydraulic clamping device must be used hoist.
solely by qualified and authorised personnel.
- A pressurized hydraulic system must not be
- When operating or carrying out maintenance left unattended. The pressure must be let off,
on the hydraulic clamping device, safety the air feed switched off and the needle valve
goggles and gloves must be worn at all times. for tank backflow must be fully open.
- It is not permitted to exceed the prescribed
pressure.
- While the pressure in the system is building up,
observe the pressure indicator; if the system
reaches the required pressure, stop the
pressure build-up immediately.
- The hydraulic clamping device has reached its
highest elevation when a yellow line becomes
visible on the extracting device. This yellow
mark must not be exceeded.
- Make sure that there is a length of at least one
thread diameter visible above the nut.
- Make sure that all quick-release couplings are
securely connected before building up the
pressure.
- Close the pump outlet with a bung or connect
it to a hose.
1101 0299 8262-0179 Page 1 of 4

Crankcase
Job Card TBG 632
W 2-5-5
Procedure when tightening the con-rod

con-rod cover connection:
1.1 Apply a thin layer of thread lubricant to the The clamping device has reached its
thread and nut surfaces (tallow, red lead oxide highest permitted value, if the yellow line
or oil). Moly based lubricant such as Molykote appears during suspension on the
must not be used. extracting device: The pump must be
switched off immediately. Open the tank
1.2 Mount stud bolts to the con-rod housing and
valve flowback and ready the piston for a
tighten to a torque of 200 Nm.
new elevation, holding the stud with an
1.3 Mount the con-rod cover on the con-rod and open-end spanner (SW 70 mm). Repeat
hand tighten the hexagonal nut with an open- step 1.7.
end spanner.
1.9 Release the hydraulic pressure from the pump.
1.4 Screw a hydraulic clamping device over the Remove the hydraulic hoses first and then the
nuts on both stud bolts. Continue the process hydraulic clamping device.
until the clamping device bridge comes into
contact with the surface of the stud bolts.
1.5 In doing so, make sure that both pistons are
fully pressed down (the piston shoulder must
be approx. 1 mm away from the top of the
housing). If the pistons are not in this fully
pressed down position, connect the hoses
and open the pumps flow-back channel to the
tank pump. Then push the pistons further
down by screwing down the stud bolt with an
open-end spanner (SW 70 mm).
1.6 Connect the hydraulic hoses to the hydraulic
clamping device.
1.7 Close the valve on the hydraulic pump and
pump up the hydraulic pressure to 390 bars.
Tighten the hexagonal nut by rotating the
sleeve with the adjusting rod.
1.8 Raise the pressure to 1,320 bars and tighten
the hexagonal nut by rotating the sleeve with
the adjusting rod. Count the number of
hexagon surfaces turned, beginning at the
position reached in step 1.7. The hexagonal
nut must be turned two (2) sides plus or minus
of one side (120 plus or minus 15). If the
hexagonal nuts cannot be turned this much,
the cause must be established. Faulty fitting,
incorrect parts or a problem with the hydraulic
clamping device are possible causes.
Page 2 of 4 0299 8262-0179 1101

Crankcase
TBG 632 Job Card
W 2-5-5
82375 0
Fig. 1 Hydraulic clamping device for con-rod bearing cover
A Con-rod bearing cover B Hydraulic clamping device

1 Stud 3 Piston
2 Hexagonal nut 4 Housing
5 Bridge
6 Nipple
7 Adjusting slot
8 Inner square for ratchet
1101 0299 8262-0179 Page 3 of 4

Crankcase
Job Card TBG 632
W 2-5-5
Procedure when slackening the

connecting rod connecting rod cover
connection
2.1 Screw a hydraulic clamping device over the
nuts on both stud bolts. Continue the process
contact with the surface of the stud.
2.2 In doing so, make sure that both pistons are
fully pressed down (the piston shoulder must
be approx. 1 mm away from the top of the
open-end spanner (SW 70 mm).
2.3 Unscrew the clamping device a full turn. This
prevents the clamping device getting stuck
after the stud nuts have been unscrewed.
One turn is sufficient in general. If the clamping
device is stuck on the stud after the pressure
release process, read the note after point 2.6.
2.4 Connect the hydraulic hoses to the pump and
clamping gear.
2.5 Close the valve on the hydraulic pump and
increase the pressure to 1,345 bars. Unscrew
the hexagonal nut nine (9) sides (1.5 turns).
2.6 Release the hydraulic pressure on the pump.
Remove the hydraulic hoses and then the
clamping device.
The pressure must not be raised further if
the nut cannot be turned for whatever
reason (such as corrosion or damaged
thread). Additional hydraulic pressure will
have no effect if the clamping device has
lifted the nuts from the contact surface.
If a clamping device is stuck on a stud, the
hydraulic pressure should be increased
until the nut turns. Tighten the nut until it
comes into contact with the stud bolt and
then release the hydraulic pressure. Repeat
steps 2.2 to 2.6; in step 2.3, the clamping
device should however be unscrewed 1
turns.
Page 4 of 4 0299 8262-0179 1101

Crankcase
TBG 632 Job Card
W 2-7-2
Remove and install main bearing

Tools:
Die Sicherheitsvorschriften fr - Standard tools
Crankcasesarbeiten gem Job Card - Hydraulic clamping device
W 2-0-1 sind einzuhalten. - Lowering device for main bearing cover
- Carrier
Die Anziehvorschriften gem Kapitel 8, Auxiliary equipment:

Technische Daten, sind einzuhalten.
- Lubricating oil
Cross references:
- Job Card W 0-1-3, W 2-0-1, W 2-1-5, W
2-1-6, W 2-7-4, B 3-1-4
Remove main bearing

Only remove every second main bearing. Do not
remove two bearings next to each other at the same
time. The removal of one main bearing is described in
this job card. Proceed accordingly for the others.
Remove inspection hole cover on both sides.
Remove wheelhouse cover on both sides.
Remove the temperature sensor of the main
bearing temperature monitor is available.
Loosen fastening screws 1 on both sides and
loosen fastening nuts 2,
Insert lowering device 3 in the oil pan and support
the main bearing cover 4. Unscrew the fastening
nuts 2 and lower the main bearing cover 4. 81172 0
Remove the lower bearing shell 5. To remove the Fig. 1 Cross bracing
upper bearing shell 7, insert the carrier 6 in the oil
hole of the crankshaft and turn the motor until the
carrier 6 has pressed the bearing shell 7 out of the
bearing seats.
Remove bearing shell 7.
Check the main bearing shell for wear,
81173 0
Fig. 2 Main bearing screw fitting

1102 0299 6322-0179 Page 1 of 2
Crankcase
Job Card TBG 632
W 2-7-2
Install main bearing

Clean the bearing journal 8 of the crankshaft,
clean the bearing seat in the crankcase and main
bearing cover. Oil the bearing journal 8.
Make sure no oil gets onto the back of the
bearing.
Insert the upper bearing shell 7 so that the bearing
shell can be pushed from the B side lug 9 first into
the crankcase seat.
The guide lug 9 must be on the A side after
pushing in.
If it is not possible to push in bearing shell 7:
Insert carrier 6 in the lube oil hole of the crankshaft
and press the bearing shell 7 into the seat by
turning from the B side to the A side. 80898 0
Turn back the crankshaft and remove the carrier 6. Fig. 3 Bearing shells with guide lugs
Insert the bottom bearing shell 5 in the main
bearing cover 4, pay attention to guide lugs 10. Lift
the main bearing cover 4 with lowering device 3. 8 7
Screw on fastening nuts 2 and fix with pin.
Tighten fastening screws 1 on both sides and
tighten fastening nuts 2,
Remove the temperature sensor of the main
bearing temperature monitor if available.
Check crank arm breathing,
6
Attach inspection hole and wheelhouse cover with
new seals,
5
Run in engine after drive mechanism work,
80882 1
Fig. 4 Lowering device for main bearing cover
Page 2 of 2 0299 6322-0179 1102

Drive mechanism
TBG 632 Job Card
W 2-7-3
Removing and installing the wearing ring halves of the crankshaft

Tools:
Spare parts:
- Wearing ring halves
Cross-references:
- Job Card W 2-0-1, W 2-7-2
Removing the wearing ring halves

Remove main bearing cover 3,
The main bearing covers have identity
markings - be careful not to get them mixed
up.
Turn the two wearing ring halves 4 radially by 180,
and remove them.
80807 0
Fig.1 Main bearing cover
0900 0299 6323-0179 Page 1 of 2

Drive mechanism
Job Card TBG 632
W 2-7-3
Installing the wearing ring halves

Oil the new wearing ring halves 4, and install them
in the opposite sequence.
Make sure that the oil pockets 6, as shown in
Fig. 3, are facing towards spur toothed gear 5.
Install main bearing cover 3,
80877 0
Fig.2 Wearing ring half
80808 0
Fig.3 Spur toothed gear
80878 0
Fig. 4 Installation position

Page 2 of 2 0299 6323-0179 0900
Crankcase
TBG 632 Job Card
W 2-7-4
Main bearing cap on crankcase, assembly specification, Lerbs

hydraulic tool
Tools:
- Hydraulic clamping device
- HV 1945/31 Draw in tool
clamping device as laid down in Job
Card W 0-0-1 must be complied with.
Cross references:
- Job Card W 0-0-1
prohibited).
prohibited.
screw pretensers.
Procedure when loosening coupling

Slacken transverse screws 4 and 7 (short
crankcase).
Screw in the draw in bolts of the draw in tool on the
stud bolts up to the unit. The nut (spanner width 70)
must be loose.
Connect the hydraulic lines. Open the valve on the
pressure pump and install the hydraulic strength
members, fitted with hexagonal nuts (spanner
width 70) to the exit. Slacken the hexagonal nuts
(spanner width 70) by 10 turns (make sure that the
draw in screws do not turn at the same time).
Close the valve on the pressure pump and pump
the pressure up to 820 bars.
If this forms part of an overhaul (Bearing row
treatment), pump the pressure up to 900 bars.
Place the round nuts with Lathe mandrel 8 mm
to the draw in screws, then screw back 2 hole
sections.
Blow off the pressure, detach the hydraulic screw
tightener. The main bearing cap is free.
0103 0299 5945-0179 Page 1 of 4

Crankcase
Job Card TBG 632
W 2-7-4
Procedure when tightening the coupling

Begin with main bearing cap 1 on the drive side.
Tighten the draw in screw 1 in the crankcase to a Blow off the pressure, detach the hydraulic screw
torque of 200Nm. tightener.
Hand tighten round nut 3 with lathe mandrel 8 Then tighten cross brace screws 4, 6 and 7 as
mm. follows:
Screw in the screws 4 to cross brace with washers Pre-tighten screws 4, 6 and 7 to a torque of 500
5 and screws 7 (short crankcase). First tighten all Nm, first on cylinder side A, beginning with bearing
screws on the A side, then all screws on the B side, 1 10 as seen from the drive side, then on cylinder
to a torque of 200 Nm. side B, beginning with bearing 10 1 as seen from
the free side.
Screw in the draw in tool draw in screws to the stud
bolts up to the unit. The nut (spanner width 70) Tighten screw 6 120 30, screw 4 150 30 and
must be loose. screw 7 180 30, to 1,600 Nm. First on cylinder
side A, beginning with bearing 1 10 as seen from
Connect the hydraulic lines. Open the valve on the
the drive side, then on cylinder side B, beginning
pressure pump and fit the hydro-strength members
with bearing 10 1 as seen from the free side.
with hexagonal nuts (spanner width 70) to the exit.
In doing so, align the ferrules (struts) with the outer
diameter of the washers.
1 Stud
Close the valve on the pressure pump. Pump the
2 Washer
pressure up to 250 bars and hand tighten the
round nuts. 3 Round nut
Slacken the screws 4 and 7 (cross bracing) on 4 Cylinder-head screw
both sides, so that they are merely hand tight. 5 Washer
Raise the pressure to 820 bars and hand tighten 6 Cylinder-head screw
the round nuts.
7 Cylinder-head screw
The round nuts must be at 330 to 360 (5
to 6 hole sections). 8 Ferrule
The following values apply in the case of an overhaul 9 Draw in screw

(Bearing row treatment): 10 Strength member
Raise the pressure to 900 bars and hand tighten 11 Hexagonal nut, spanner width 70
the round nuts.
The round nuts must be at 390 to 420 (6
to 7 hole sections) to each other.
Page 2 of 4 0299 5945-0179 0103

Crankcase
TBG 632 Job Card
W 2-7-4
A B
4 5 1
10
11
82114 1
Fig. 1 Main bearing cap draw in tool
0103 0299 5945-0179 Page 3 of 4

Crankcase
Job Card TBG 632
W 2-7-4
Page 4 of 4 0299 5945-0179 0103

Crankcase
TBG 632 Job Card
W 2-7-4
Main bearing cap, Assembly specification, HTI hydraulic tool

Before using the hydraulic clamping device please Tools
read the safety instructions, make sure you und- - Standard tools
erstand them and follow them. - Hydraulic clamping device
The hydraulic pressures listed for slackening and
tightening screws and bolts refer solely to the use Cross references
of this HTI hydraulic clamping device. - HTI operating instructions*
Before using the hydraulic clamping device, make - HTI safety instructions*
sure that the numbers 14.7 sq in (94.8 cm2) are * forms part of the HTI toolbox
stamped on the surface of the piston head.
Safety instructions
The hydraulic clamping device is operated with - Both hydraulic screw coiled piston rings may be
hydraulic oil under high pressure. In order to pressurized simultaneously only if they are
prevent injuries, the following instructions must mounted correctly on the stud bolts.
be explicitly adhered to:
- If the hydraulic clamping device is under pressure,
- Before using the hydraulic clamping device, please the operator must not put any part of his/her body
read the safety instructions and directions for use or that of any other person in the way of the stud
published by the manufacturers of this tool hoist.
completely and make sure you understand them.
- A pressurized hydraulic system must not be left
- The hydraulic clamping device must be used solely unattended. The pressure must be let off, the air
by qualified and authorised personnel. feed switched off and the needle valve for tank
- When operating or carrying out maintenance on backflow must be fully open.
the hydraulic clamping device, safety goggles and
gloves must be worn at all times.
- It is not permitted to exceed the prescribed
pressure.
- While the pressure in the system is building up,
observe the pressure indicator; if the system does
not reach the required pressure, stop the pressure
build-up immediately.
- The hydraulic clamping device has reached its
highest elevation when a yellow line becomes
visible on the extracting device. This yellow mark
must not be exceeded.
- Make sure that there is a length of at least one
thread diameter visible above the nut.
- Make sure that all quick-release couplings are
tightly connected before building up pressure.
- Close the pump outlet with a bung or connect it to
a hose.
- Do not lift or move the hydraulic clamping device
by the hydraulic hoses or quick-release couplings.
0103 0299 8260-0179 Page 1 of 4

Crankcase
Job Card TBG 632
W 2-7-4
Tightening the screws and bolts in the 1.10 Raise the pressure to 1,175 bars and hand
main bearing cap tighten the round nuts by turning the adjusting
rod. Define the turn in degrees, beginning with
1.1 Apply a thin layer of thread lubricant to the the position established in point 1.8. The
thread and nut surfaces (tallow, red lead oxide round nuts must be at 330 to 360 (5 to 6
or oil). Moly based lubricant such as Molykote hole sections) to each other. If the round nuts
must not be used. cannot be rotated this much, establish the
1.2 Mount stud bolts to the crankcase and tighten cause. Faulty fitting, incorrect parts or a
to a torque of 200 Nm. problem with the hydraulic clamping device
are possible causes.
1.3 Mount the main bearing cap and the round
nuts with the adjusting rod and hand tighten. In the case of an overhaul (Lagergassen
treatment), the pressure must be raised to
1.4 Screw in screws 4 to cross brace with washers 1,290 bars; the round nuts must be at 390 to
5 and screws 7 (short crankcase). First tighten 420 (6 to 7 hole sections) to each other.
all screws on the A side and then all screws on
the B side. Tighten to a torque of 200 Nm. The clamping device has reached its highest
permitted load, if the yellow line appears
1.5 Screw a hydraulic clamping device over the during suspension on the extracting device:
nuts on both stud bolts. Continue the process The pump must be switched off im-
until the clamping device bridge comes into mediately. Open the tank valve flowback on
contact with the surface of the washer. the pump and ready the piston for a new
1.6 In doing so, make sure that both pistons are elevation, holding the stud with an open-
fully pressed down (the piston shoulder must end spanner (SW 70 mm). Repeat step 1.8.
be approx. 1 mm away from the top of the 1.11 Release the hydraulic pressure from the pump.
housing). If the pistons are not in this fully Remove the hydraulic hoses first and then the
pressed down position, connect the hoses hydraulic clamping device. The screws 4 for
and open the pumps flow-back channel to the cross bracing must not be too tight to twist by
tank pump. Then push the pistons further hand.
open-end spanner (SW 70 mm). 1.12 Then tighten the cross bracing screws as
follows:
1.7 Connect the hydraulic hoses to the hydraulic
clamping device. 1.12.1 Pre-tension screws 4, 6 and 7 to a torque of
500 Nm; first on cylinder side A, beginning
1.8 Connect the valve to the hydraulic pump and with bearing 1 10 as seen from the drive
slowly raise the pressure to 360 bars. Tighten side, then on cylinder side B, beginning with
the round nuts by turning the adjusting rod. bearing 10 1 seen from the free side.
1.9 Slacken screws 4 and 7 (cross-bracing) on 1.12.2 Then turn screw 6 120 30, screw 4 150
both sides, so that they are hand tight. 30 and screw 7 180 30, tightening to a
torque of 1,600 Nm. Follow the order as in
1.12.1.
Page 2 of 4 0299 8260-0179 0103

Crankcase
TBG 632 Job Card
W 2-7-4
5 5
7
4 4
1 3 2
2
3
60
10
11
82376 3
Fig. 1 Hydraulic clamping device for main bearing cap
Main bearing cap Hydraulic clamping device

1 Hoist 2 Washer
2 Washer 3 Round nut
3 Round nut 8 Bridge
4 Cylinder-head screw 9 Housing
5 Washer 10 Piston
6 Cylinder-head screw 11 connecting piece
7 Cylinder-head screw
0103 0299 8260-0179 Page 3 of 4

Crankcase
Job Card TBG 632
W 2-7-4
Slackening the main bearing cap

screws and bolts
2.1 Slacken cross bracing screws 4 and 7 (short
crankcase).
2.2 Screw a hydraulic clamping device over the
nuts on both stud bolts. Continue the process
contact with the surface of the washer.
2.3 Make sure that both pistons are fully pressed
down (the shoulder of the piston must be
approx. 1 mm away from the top of the
down by screwing down the stud bolt with an 82837 0
open-end spanner (SW 70 mm). Fig. 2 Hydraulic pump (example)

2.4 Unscrew the clamping device a full turn. This
prevents the clamping device getting stuck The pressure must not be raised further if
after the stud nuts have been unscrewed. the nut cannot be turned for whatever
One turn is sufficient in general. If the clamping reason (such as corrosion or damaged
device is stuck on the stud after the pressure thread). Additional hydraulic pressure will
release process, read the note after point 2.7. have no effect if the clamping device has
2.5 Connect the hydraulic hoses to the pump and lifted the nuts from the contact surface.
clamping gear. If a clamping device is stuck on a stud, the
2.6 Close the valve on the hydraulic pump and hydraulic pressure should be increased
pump up the pressure to 1,175 bars. Unscrew until the nut turns. Tighten the nut until it
the round nuts two turns. comes into contact with the stud bolt and
In the case of an overhaul (Lagergassen then release the hydraulic pressure. Repeat
treatment), the pressure must be pumped up steps 2.3 to 2.7; in step 2.4, the clamping
to 1,290 bars. device should however be unscrewed 1
turns.
2.7 Release the hydraulic pressure on the pump.
Remove the hydraulic hoses and then the
clamping devices. The main bearing cap bolts
and screws are now free.
Page 4 of 4 0299 8260-0179 0103

Crankcase
TBG 632 Job Card
W 2-9-3
Installing and removing pistons and connecting rod assembly

Tools:
drive mechanism must be complied with - Thread cutter M12
as detailed in Job Card W 2-0-1. - Lifting gear
- Stud bolt screwdriver for con-rod stud
bolt
When removing or installing the engine - Lifting gear for pistons and connecting
or its components, always make sure rods
that approved lifting tackle in faultless - Assembly device for con-rod bearing
condition appropriate to the weight shells
involved is used. - Protective cap for cylinder liner
- Piston installation ring
Comply with the tightening instructions - Hydraulic clamping device
given in the Chapter 8, Technical Data.
- Grinding paste
- Cleaning agent
- Lubricating oil
- UNIMOLY C 220 lubricant
Cross references:
- Job Card W 0-0-1, W 0-1-3, W 1-4-4, W
2-0-1, W 2-1-6, W 2-5-5, B 3-1-4
Removing pistons and connecting rod

assembly
Remove cylinder head,
Crank the engine sufficiently, so that the blank
sliding face in the cylinder liner is concealed by the
upper surface of the piston. Seal the gap between
the piston base and cylinder liner with grease.
Scrape away any coke deposits in the cylinder
liner.
Inspect the edge at the upper inversion point of the
first sealing ring created after considerable running
time. If this edge is so strong that the piston rings
can attach themselves to it, it must be filed down.
0103 0299 6324-0179 Page 1 of 4

Crankcase
Job Card TBG 632
W 2-9-3
Remove all dirt and grease.

Label pistons with cylinder number for later re- 3 7
installation.
Remove the inspection hole cover of the relevant
piston as well as the opposite inspection hole
cover.
Crank the engine sufficiently, so that the hydraulic
clamping device can be fitted to the con-rod bearing
cover stud bolts.
Slacken the con-rod screw fitting 2, 9
Re-cut threaded hole 3 (M12) in the piston base,
mount the piston lifting gear 4 (fig. 2) and attach the
lifting gear.
Unscrew the con-rod nuts 2.
Lower the con-rod bearing cover 1 and remove it.
Unscrew the stud bolts 5.
Using the lifting gear, carefully lift the piston 7, and
push the con-rod free of the crank pin.
Slacken the retaining clips of the con-rod bearing
6
shells, e.g. with a screwdriver. Brace the bearing
shells. 6 2
Place the protective cap in the upper stud bolt hole.
Lift the piston 7 and con-rod assembly, holding it
steady, up to the opening and then pull it out of the 10 5
cylinder liner 9.
Make sure that the crank pin 10 and cylinder
liner 9 do not get damaged. 1
Place the piston and con-rod assembly carefully in
a device. When mounting the piston, protect the 2 5
con-rod and crank pin from dirt and damage. 80833 1
Check the bearing shells,

Fig. 1 Piston and con-rod assembly
83988 0
Fig. 2 Piston lifting gear

Page 2 of 4 0299 6324-0179 0103
Crankcase
TBG 632 Job Card
W 2-9-3
Installing pistons and con-rod assembly

As per the label allocate the piston to the correct Kr2
cylinder.
Make sure that the label 12 is aligned to the
camshaft. 120 120
The piston ring stop of sealing ring Kr1, oil ring Kr2
and scraper ring Kr3 must each be installed at an
angle of 120 from each other, see fig. 3. Make
sure that the hose spring stop is offset 180 to the
ring stop scraper ring.
Oil the cylinder liner, piston, piston rings and crank
pin. Kr1 CAM Kr3
Crank the engine sufficiently, so that the hydraulic
clamping device can be fitted to the con-rod bearing 12
cover stud bolts. 82188 0
Using the piston lifting gear 4, carefully lower the Fig. 3 Ring stop setting
piston and con-rod assembly into the cylinder liner
using mounting ring 8 for piston rings, fig. 4.
Remove the protective cover from the upper stud
bolt hole.
Spray the sliding face and con-rod bearing shell
stop with UNIMOLY C 220 lubricant.
Attach the bearing shells 6a and 6b to the crank pin
with retainer clips correctly.
The guide lug 13 must abut both bearing
shells 6.
Apply the bearing shell assembly device. Pin 11
must fit in the lower bearing shell 6b.
Position the con-rod so it is just below the upper
bearing shell. Turn the bearing shell assembly
device, until face X abuts the lower con-rod face Y.
Move the con-rod and piston assembly to bearing 83989 0
shell 6a and remove the bearing shell assembly
device. Fig. 4 Piston installation ring
Screw in the stud bolts with a screwdriver to a

torque of 200 20 Nm.
80899 0
Fig. 5 Con-rod bearing shells

0103 0299 6324-0179 Page 3 of 4
Crankcase
Job Card TBG 632
W 2-9-3
Insert the con-rod bearing cover.

Make sure that the con-rod bearing shells
have the correct axial alignment. The lower
bearing shell must fit into pin 23.
Lift the con-rod bearing cover over the stud bolts
and screw on the con-rod nuts hand-tight.
Then tighten them hydraulically,
Fit new gaskets to the inspection hole cover, see
job card B 3-1-4.
Install cylinder head,
If new pistons/piston rings were fitted, the engine
must be run in again.
see job card W 0-1-3. 80900 1
Fig. 6 Bearing shell fixing pin
23
80796 1
Fig. 7 Bearing shell fixing pin
Page 4 of 4 0299 6324-0179 0103

Drive mechanism
TBG 632 Job Card
W 2-10-1
Removing and installing the piston rings

Tools:
The safety instructions for work on the - Piston ring pliers
Aids:
- Alkaline cleaning agent
Cross-references:
- Job Card W 2-0-1, W 2-10-3, W 2-12-4
Removing the piston rings

Remove the piston pin,
Use piston ring pliers to remove piston rings 15, 15
and mark them for identification.
Use cleaning agent to clean piston 16 and piston
rings 15.
Check piston and piston rings,
see Job Card W 2-10-3. 16 13
14
13
17
18
4
10
81171 0
Fig. 1 Drive mechanism parts
0900 0299 6325-0179 Page 1 of 2

Drive mechanism
Job Card TBG 632
W 2-10-1
Installing the piston rings

TO P
Use piston ring pliers to mount piston rings at the
piston in accordance with the piston ring
configuration illustrated in Fig. 2. Kr1
Kr1 Compression ring Kr2
Rectangular ring, identified on the ring edge with
TO P
GOE MKP81A TOP. Kr3
When installing, make sure that the TOP side is
facing upwards.
Kr2 Oil scraper ring
Tapered compression piston ring, chromium-
plated, identified on the rings edge with GOE
TOP.
When installing, make sure that the TOP side is
facing upwards.
Kr3 Oil wiper ring 81170 0
Narrow-land drain oil control ring, chromium- Fig. 2 Fitting the piston rings
plated (with hose spring), identified on the ring
edge with GOE.
Install piston pin,
If new piston rings have been installed, run in
the engine,
Page 2 of 2 0299 6325-0179 0900

Crankcase
TBG 632 Job Card
W 2-10-3
Check piston rings, grooves

Tools:
- Feeler gauge / gauge blocks
Cross references:
- Job Card W 2-10-1
Check piston ring groove for wear

Remove piston rings,
see job card W 2-10-1. 2
Measure axial play S between new piston ring
and lower edge of the piston ring groove at 4
positions offset 90 (fig. 1). 1
The new piston ring 1 must be pressed against the
bottom of the groove 2 in the area of the measuring
point during the measurement. 3
It is recommended to mark the measuring depth
on the feeler gauge.
S
If the feeler gauge 3 with a thickness of 0.3 mm can
be inserted in the ring groove, the piston must be 3 mm
changed.
Please contact the DEUTZ SERVICE in this 80853 0
case. Fig. 1 Piston ring groove
0102 0299 6326-0179 Page 1 of 2

Crankcase
Job Card TBG 632
W 2-10-3
Check piston ring for wear

The piston ring wear is assessed according to the
stroke play.
To measure the stroke play X, insert the piston
ring at right angles in a new cylinder liner and
measure the stroke play with a feeler gauge.
Wear limit for stroke play:
ring New part max. permissible
[mm] [mm]
1 0.71.0 1.4
2 1.51.8 2.2
3 0.81.15 1.5
If one ring has reached the limit value, change the
whole set. To do this, have the cylinder liners re-
80185 0
honed. Please contact the DEUTZ SERVICE in
this case. Fig. 2 Piston ring
Install piston rings,
Page 2 of 2 0299 6326-0179 0102

Crankcase
TBG 632 Job Card
W 2-12-3
Check piston bolt play

If it is determined after the piston bolt play that the Tools:
wear limits have been reached, please contact your - Feeler gauge
DEUTZ SERVICE.
Cross references:
- Job Card W 2-12-4
Check piston bolt play

Remove piston bolts,
Set con-rod 3 upright. Insert the cleaned piston s 1
bolt 1 into the cleaned connecting rod bushing 2
until an even protrusion a of the piston bolt 1 is
available on both sides. 2
Measure bearing play s with a feeler gauge.
On reaching the max. permissible play, the parts
a a 3
must be measured off singly and the wearable
parts exchanged.
Install piston bolts,
80235 0
Fig. 1 Piston bolt play
Bearing play New play max. permissible play

Piston bolt -
Connecting rod bushing 0.121 0.192 0.28
Piston bolt -
Piston bolt eye 0.010 0.035 0.06
Diameter New dimension max. permissible dimension
Bushing (internal diameter) 110 ++ 0,121
0.177
110.257
(con-rod)
Piston bolt 110 0.015 109.975
Piston bolt eye 110.3 +0.2
110.55
0103 0299 6327-0179 Page 1 of 2

Crankcase
Job Card TBG 632
W 2-12-3
Page 2 of 2 0299 6327-0179 0103

Crankcase
TBG 632 Job Card
W 2-12-4
Remove and install piston bolt

Tools:
The safety instructions for work on the - Pliers for piston bolt locking ring
- Cleaning agent
- Lubricating oil
Cross references:
- Job Card W 2-0-1, W 2-9-3, W 2-12-3
Remove piston bolt

Remove piston with con-rod,
15
Before removing the piston bolt, check whether
the piston 16, con-rod shank 17 and con-rod
bearing cover are labelled by a cylinder number,
attach one if necessary.
16 13
Locking rings are under tension!
Remove locking rings 13 with pliers and push the
14
piston bolts 14 out carefully, lift the con-rod slightly
if necessary.
Clean the piston and piston bolt with a cleaning 13
agent.
Check piston bolt play,
17
Install piston bolt
Oil all parts.
Insert a locking ring 13 in piston 16 with the
opening facing down (6 oclock).
Mount the connecting rod 17 on the piston in such 18
a way that the label of the con-rod and the label of
the piston face the same way.
Push in the piston bolt 14 and insert second
locking ring 13.
Pay attention to the correct fit of the locking 4
rings (openings at bottom, position correctly
in the groove). 10
Install piston with con-rod,
see job card W 2-9-3. 81171 0
Fig. 1 Drive mechanism parts
1102 0299 6328-0179 Page 1 of 2

Crankcase
Job Card TBG 632
W 2-12-4
Page 2 of 2 0299 6328-0179 1102

Crankcase
TBG 632 Job Card
W 3-3-1
Check cylinder liner

Tools:
- Inside micrometer
Cross references:
- Job Card W 0-1-3, W 2-9-3, W 2-10 1
Check cylinder liner for wear

Measure diameter of the cylinder liner in longitudi-
nal and transverse direction of the motor. If a heel
is tangible on the bottom edge of the top dead point
of the 1st ring, place the measuring points directly
below the heel. The measuring points are defined
in the measuring sheet on the next page (copy
form).
Reworking (honing) of the cylinder liner is
necessary when:
- more than 50% of the liner running surface
without honing pattern or
- heavy marking,
- ovality greater than 0.25 mm,
- new piston rings inserted.
The reworking (honing) of the cylinder liner
must always be performed by the DEUTZ
Service because honing and assessment of
the result (honing pattern, cleanliness)
requires special know-how.
If a measured value has reached the wear limit of
260.20 mm, the cylinder liner must be replaced.
When using re-honed or new cylinder liners, install
new piston rings, see job card W 2-10-1.
Run in engine after honing,
0301 0299 6329-0179 Page 1 of 2

Measuremetn sheet for cylinder liners 260 +0.05 mm (nominal dimension)
Page 2 of 2
W 3-3-1
Customer: Engine type: Op. hours: Date:

Job Card
Crankcase
Engine No.: Order No.: Measured:
(Name)
Coupling end
Cylinder: A1 A2 A3 A4 A5 A6 A7 A8
Meas. direction X Y X Y X Y X Y X Y X Y X Y X Y
H in mm 35
50
0299 6329-0179
TBG 632
150
250
Cylinder: B1 B2 B3 B4 B5 B6 B7 B8
Meas. direction X Y X Y X Y X Y X Y X Y X Y X Y
H in mm 35
50
150
250
0301
Crankcase
TBG 632 Job Card
W 3-3-2
Remove and install cylinder liner

If a new or re-processed (honed) cylinder liner is Tools:
installed, new piston rings must be used. In addition - Assembly device for cylinder liner
the engine must be run in again, see work card W 0- - Alignment device for cylinder liner
1-3. - Lifting gear
- Acid-free grease
Spare parts:
Cross references:
- Job card W 0-1-3, W 2-9-3
Removing cylinder liner

Attach assembly device to the cylinder liner.
Remove the cylinder liner with an appropriate tool.
Clean cylinder jacket and cylinder head in the
vicinity of the cylinder liner contact surfaces.
If the contact surfaces of the cylinder jacket or
cylinder liner are damaged, please contact
DEUTZ SERVICE.
82323 0
Fig. 1 Assembly device
Labelling a cylinder liner:

6 Company logo
7 Date of manufacture
8 Cylinder number
9 Leak test
80828 1
Fig. 2 Labelling of a cylinder liner

0103 0299 6330-0179 Page 1 of 2
Crankcase
Job Card TBG 632
W 3-3-2
Installing cylinder liner

On the cylinder jacket (Strongback) make a mark
precisely in the centre point between both stud
bolts on the cylinder head fastening on the camshaft
side.
Grease the cylinder liner in the vicinity of the round
sealing rings.
Use acid-free grease.
Grease new round sealing rings and pull on from
below.
- The two thicker round sealing rings 2 at the top,
- the thinner round sealing ring 3 at the bottom.
Make sure that the rings are not installed
twisted.
Grease the cylinder liner in the vicinity of the round
sealing rings again.
Transpose the position of the threaded holes 1 at
the bottom end of the cylinder liner using the
aligning device 4 onto the collar of the top end
(chalk).
Insert the cylinder liner with assembly device (fig. 1)
carefully in the cylinder liner. The transposed mark
5 at the top end of the cylinder liner must be on the
camshaft side.
The transposed mark 5 at the top end of the
cylinder liner and the mark on the cylinder
jacket go together.
Remove the assembly device.
83983 0
Fig. 3 Cylinder liner
81162 0
Fig. 4 Threaded holes

Page 2 of 2 0299 6330-0179 0103
Crankcase
DEUTZ MWM Job Card
TBG 632 W 3-4-1
Removing and installing the cylinder jacket (Strongback)

Tools:
- Set 1215 0000
- Set 1215 0001
- Scraper
- Mounting device for cylinder jacket
- Holding device for tappets
- Appropriate lifting tackle
Chapter 8, Technical Data. Aids:
- Lube grease
- Cleaning agent
Cross-references:
- Job Cards W 2-0-1, W 3-3-3
Removing the cylinder jacket with

tappet
l Remove the cylinder liner,
l Remove camshaft inspection hole cover 1 of the
cylinder involved.
81169 0
Fig. 1 Camshaft inspection hole cover
l Install holding device 10 for tappets 11.

11
10
80871 0

1097 0299 6331-0179 Page 1 of 4
Crankcase
Job Card DEUTZ MWM
W 3-4-1 TBG 632
81166 0
Fig. 3 Eight fixing screws for the cylinder jacket
l Remove the eight fixing screws 1.

l Fit mounting device for cylinder jacket, and use
appropriate lifting tackle to lift it upwards.
l Remove holding device 10, and take off tappets 11
downwards.
Make sure you dont get the tappets mixed up.
l Clean the sealing surfaces; remove all residues of
old seals.
80891 0
Fig. 4 Lifting off the cylinder jacket
Page 2 of 4 0299 6331-0179 1097

Crankcase
DEUTZ MWM Job Card
TBG 632 W 3-4-1
Installing the cylinder jacket with tappet

l When using a new cylinder jacket, install grub
screws 1, 2 and 3.
l Install the closure cover of the injection pump and
the screw plug.
l Insert tappet, and secure with holding device.
l Coat slide points with grease.
81163 0
Fig. 5 Grub screws
l Place new O-sealing rings 1 over the stud bolts on

the crankcase.
81164 0
Fig. 6 O-sealing rings for stud bolts
1097 0299 6331-0179 Page 3 of 4

Crankcase
Job Card DEUTZ MWM
W 3-4-1 TBG 632
l Seal the coolant channel with a sealant beading 1

on the crankcase. Fit new cylinder jacket seal 3.
Seal coolant channel with a sealant beading 2 on
seal 3. Check centering sleeve 4 for damage and
correct seat.
81165 0
Fig. 7 Cylinder jacket seal
l Fit the mounting device for the cylinder jacket, and

use appropriate lifting tackle to place the cylinder
jacket on the crankcase.
l Install the eight fixing screws for the cylinder jacket,
using the tightening torque specified in the
Operating Instructions, Chapter 8, Tightening
Instructions.
l Remove holding device for tappet.
l Fit camshaft inspection hole cover, with a new
seal.
l Install cylinder liner;
80891 0
Fig. 8 Fitting the cylinder jacket
Page 4 of 4 0299 6331-0179 1097

Crankcase
TBG 632 Job Card
W 3-7-1
Checking the engine mounting

Since the foundation may alter due to thermal effects Tools:
and stresses, the fixing screws must be checked for - Normal tools
any loosening. This is particularly essential during the
initial operating hours.
Checking the engine mounting

Check the shims with rigid mounting configurations,
or the pads in the case of an elastic mounting, by
tapping them (including those which are difficult to
access, e.g. because pipes run over them).
When you tap, a metallic sound indicates a
firm connection.
Tighten any loose screws 1, following the tightening
instructions specified by the system erector.
Check the alignment.
Make sure everything is meticulously clean;
in particular, keep oil and water away from the
foundation.
81184 0
Fig. 1 Engine bracket
0900 0299 6332-0179 Page 1 of 2

Crankcase
Job Card TBG 632
W 3-7-1
Page 2 of 2 0299 6332-0179 0900

Engine control
DEUTZ MWM Job Card
TBG 632 W 4-1-1
Removing, installing and checking the camshaft bearings

Tools
- Set 1215 0000
- Torque wrench
- 8 retention pins
- Mirror and lamp
- Camshaft removal device
- Holding device for tappets
Aids
- liquid sealant
Cross-references:
- Job Cards B 1-1-1, W 2-0-1,
W 2-1-6, W 4-1-4
Removing the camshaft
l Remove lube oil lines 1 and 2, collecting the lube 2
oil as it flows out.
80866 0
Fig. 1 Lube oil lines, engine inlet
l Remove gear cover 1 and all camshaft covers on

the appropriate side.
81185 0
Fig. 2 Cover for assembly apertures

1097 0299 6333-0179 Page 1 of 6
Engine control
Job Card DEUTZ MWM
W 4-1-1 TBG 632
l Turn the engine until Cylinder A 1 is in ignition

TDC. The marking bores 15 must be located at the
outer edge of the crankcase, as shown in Figs. 4 5
and 10. Fix this position with the assembly device,
as shown in Fig. 10 Pos. 14, in the drive
compartment aperture B 1.
A
l If you are using tool 14 for the first time use a
hammerblow to mark fixed point X at the crankcase,
drive compartment aperture B 1.
l Markings A must be aligned on each other.
6
80868 0
Fig. 3 Installation marking
l Check that marking bores 15 are located at the

outer edge of the crankcase. 11
5
21
7
15
80901 0
Fig. 4 Installation markings
l Remove all valve lifter brackets 8, and take out

shock-absorber rods 9.
8
9
80870 0
Fig. 5 Valve lifter bracket

Page 2 of 6 0299 6333-0179 1097
Engine control
DEUTZ MWM Job Card
TBG 632 W 4-1-1
l Fit holding devices 10 for tappets 11.

11
10
80871 0
l Fit camshaft removal device to camshaft 21, and

tense slightly with lifting tackle.
l Remove all camshaft bearing covers 7, and lift
camshaft 21, together with bearing shells 22, from
the thrust bearings.
l Remove circlips 16 from the bearing shells 22, and
take bearing shells 22 off camshaft 21.
Bearing covers 7 and bearing shells 22 are
identified, so dont get them mixed up.
80902 0
Fig. 7 Camshaft
1097 0299 6333-0179 Page 3 of 6

Engine control
Job Card DEUTZ MWM
W 4-1-1 TBG 632
l If you find any traces of corrosion or severe signs

of wear and tear on wearing rings 17, replace
them.
80812 0
Fig. 8 Wearing rings
Checking the camshaft bearings

l Check bearing shells,
Installing the camshaft

l Oil all slide points. 19
- Mount bearing shells 22 with circlip 16 on camshaft
21, taking care not to interchange the bearing
shells.
l Circlips 16 must be mounted towards the 18
gearwheel, compare Fig. 7.
l Use installation device to insert camshaft 21 into
the thrust bearings.
The marked teeth of camshaft gearwheel 5 20
and idler gear 6 must mesh with each other.
The markings shown in Figs. 4 and 10 must
coincide.
l Place bearing covers 7 on bearings shells 22 in
accordance with the numbering (at the side), 80875 0
aligning with pin 18. Fig. 9 Fixing the bearing

Page 4 of 6 0299 6333-0179 1097
Engine control
DEUTZ MWM Job Card
TBG 632 W 4-1-1
l Tighten bearing cover screws 20.

l Remove tool 14.
l Measure the axial clearance as detailed in Job
Card W 4-1-4.
l Measure the radial clearance; tolerance range
0.096 mm to 0.172 mm.
l Seal bearing cover against the crankcase with
sealing compound in ring groove 19.
l Lower all tappets into camshaft 21.
l Fit remaining parts in the opposite sequence
l Turn to check for free movement.
l Adjust the valve clearance,
1097 0299 6333-0179 Page 5 of 6

Engine control
Job Card DEUTZ MWM
W 4-1-1 TBG 632
80893 0
Fig. 10 Tool for fixing the crankshaft

Page 6 of 6 0299 6333-0179 1097
Engine control
TBG 632 Job Card
W 4-1-4
Check axial clearance of the camshaft

Tools:
drive mechanism must be complied with - Measuring dial with magnetic stand
as detailed in Job Card W 2-0-1. - Feeler gauge
Comply with the tightening instructions Cross references:

given in the Chapter 8, Technical Data. - Job Cards W 2-0-1, B 3-1-4, W 4-1-1
Measure axial clearance of the camshaft

Remove camshaft cover 1 of cylinder A1 or B1.
Press the camshaft 2 with mounting lever in the
direction of the drive or free side to the stop.
Place the measuring dial on the cam 3, pre-tension
3 mm, set to zero.
Press the camshaft 2 in the opposite direction
Read and note the measured value.
Repeat the process 2 to 3 times.
If the axial clearance is greater than 0.9 mm,
change the wearing ring halves 4.
83986 0
Axial bearing Fig. 1 Camshaft cover (cylinder side B)

clearance (mm) New max. permissible
Snug fit bearing 0.2 0.75 0.9
Attach camshaft cover 1 with new gasket, see job
card B 3-1-4.
80800 0
Fig. 2 Camshaft
0103 0299 6334-0179 Page 1 of 2
Engine control
Job Card TBG 632
W 4-1-4
80801 0
Fig. 3 Wearing ring
Page 2 of 2 0299 6334-0179 0103

Engine control
TBG 632 Job Card
W 4-2-1
Removing, installing and checking the lower valve mechanism

Tools
drive mechanism must be complied with - Torque wrench
as detailed in Job Card W 2-0-1. - Holding device for tappets
Comply with the tightening instructions Cross-references:

given in Chapter 8, Technical Data. - Job Cards W 0-4-1, B 1-1-1, W 2-0-1,
B 3-1-4, W 4-1-1
- Chapter 8, Tightening Instructions
Checking the tappet roller

Remove camshaft cover 1.
Turn the engine, and inspect tappet roller 2 and
cam track 3 for traces of corrosion or other damage.
If you find any traces of corrosion on the
tappet roller, replace the entire tappet
concerned. Slight traces of corrosion on the
cam can be eliminated by fine working.
81169 0
Fig. 1 Camshaft cover
80861 0
Fig. 2 Cam and tappet roller

0103 0299 6335-0179 Page 1 of 2
Engine control
Job Card TBG 632
W 4-2-1
If one tappet fails

If there is any damage to the tappets of a
cylinder station, remove the unit, 7 6 7
After you have removed the unit, remove valve
lifter bracket 8 from it, and take out shock-absorber
rods 9.
Remove holding device 6, and take out tappet 7 5
downwards.
Install the new tappet in the opposite sequence.
Oil all slide points.
Adjust valve clearance,
Fit a new gasket to camshaft cover 1 and attach it, 80863 1
If more than one tappet fails

If the tappets of more than one cylinder station
are damaged, it is more effective to remove the
camshaft,
When the camshaft 5 has been removed, take off
the valve lifter brackets 8 at the cylinder stations
involved, and take out the shock-absorber rods 9.
Remove holding device 6 at the damaged tappets,
and take out tappets 7 downwards.
Install the new tappets 7 in the opposite sequence.
Oil all slide points.
Adjust valve clearance,
Fit a new gasket to camshaft cover 1 and attach it,
see job card B 3-1-4. Fig. 4 Valve lifter bracket
Page 2 of 2 0299 6335-0179 0103

Engine control
TBG 632 Job Card
W 4-4-1
Removing and installing the gear train (Free End)

Tools:
The safety instructions for work on the - Normal tools
drive mechanism must be complied with - Removal device
Spare parts:
- Gearwheels
- Screws
- Seals
Cross-references:
- Job Card W 2-0-1, W 4-4-6, W 8-4-1
Removing and installing the gearwheels

Remove lube oil pump 3,
1 2
At the lube oil pump, unscrew the size-M16 screw.
Use the removal device to remove gearwheel 1.
Replace gearwheel, and tighten in position with a
new screw.
Remove gear box 6.
81187 0
Ill. 1 Gearwheels
81188 0
Ill. 2 Free end

0900 0299 6336-0179 Page 1 of 2
Engine control
Job Card TBG 632
W 4-4-1
Unscrew screws 7, and take off gearwheel 2.

Replace gearwheel 2, and tighten in position with
new screws.
Re-pin gearwheel 2, bore 10 H7.
Fit gear box 6.
Fit lube oil pump 3,
Use new seals. 2
Check torsional backlash,
80881 0
Ill. 3 Crankshaft gearwheel
Page 2 of 2 0299 6336-0179 0900

Engine control
TBG 632 Job Card
W 4-4-2
Check wheel drive (free side)

The lube oil pump is flanged to the end face cover on Tools:
the free side. A mire gear mounted on the crankshaft - Standard tools
drives the lube oil pump. - Hand lamp
- Collecting tray
Spare parts:
- any gaskets
Cross references:
- Job Card W 4-4-1
Visual inspection
Remove lube oil line to compensator 1, collect
draining lube oil.
Unscrew the eight hexagon head screws 2 and
remove cover 3 with compensator 1 and gasket.
Check the teeth edges of the toothed wheels
through the opening with the hand lamp. Turn the
motor at least one turn so that the teeth edges can
be checked round the whole circumference of the
toothed wheels.
Visibly worn wheels with grooves, pitting or
considerable reduction of teeth edges must
be changed.
Assembly
Fig. 1 Cover
Assembly takes place in reverse order, check the
gaskets, renew if necessary.
Observe the tightening torques.
0103 0299 8759-0179 Page 1 of 2

Engine control
Job Card TBG 632
W 4-4-2
Page 2 of 2 0299 8759-0179 0103

Engine control
TBG 632 Job Card
W 4-4-3
Installing and removing the gear drive (drive side)

Tools:
drive mechanism must be complied with - Assembly device for intermediate gears
Spare parts:
Comply with the tightening instructions - Round sealing rings
given in the Chapter 8, Technical Data. - Intermediate gears
- Camshaft toothed wheel
Cross references:
- Job Card W 2-0-1, B 3-1-4, W 4-1-1,
W 4-4-6
General
Change visibly worn gears with grooves, pitting or
considerable reduction of teeth edges.
Removing intermediate gears

Remove inspection hole cover 1 and gear housing
cover 2.
Crank the engine until cylinder A1 is in TDC
position. The marker holes 15 must be in the
position shown in fig. 4 on the exterior of the
crankcase.
Marks A + B are positioned as in fig. 7 relative to
one another.
A Intermediate toothed wheel camshaft toothed
wheel 81189 0
B Intermediate toothed wheel crankshaft Fig. 1 Inspection hole and gear housing cover
toothed wheel
Slacken hexagon socket head screw 3, but do not
unscrew it. 8
Install the assembly device for removal of
intermediate gears 8.
10
Unscrew hexagon socket head screw 3 and pull
out hub 10 in the direction of the arrow. Replace O-
rings 11.
3
Roll intermediate gears 8 completely out of the
mounting and lift.
11 11
80884 0
Fig. 2 Intermediate gears

1202 0299 6337-0179 Page 1 of 4
Engine control
Job Card TBG 632
W 4-4-3
Installing intermediate gears

Prior to installation oil all running faces.
Replace intermediate gears 8 and install them in
reverse order of removal. Marks A + B must be
positioned as in fig. 7 relative to each other.
Marker holes 15 are on the exterior of the
crankcase, see fig. 4.
Tighten screw 3.
Check circumferential backlash,
Fit new seals to inspection hole cover 1 and gear
housing cover 2,
80822 0
Fig. 3 Intermediate gear attachment
Fig. 4 Marker holes
Removing camshaft toothed wheel

Remove camshaft,
Using a grinder, cut and remove the toothed wheel
at two opposite places.
Do not damage the surface of the seat on the
camshaft.
Page 2 of 4 0299 6337-0179 1202

Engine control
TBG 632 Job Card
W 4-4-3
Installing camshaft toothed wheel

Heat the new camshaft toothed wheel 7 to approx.
270 C and position it on the camshaft 12 as shown
in fig. 5.
Danger of burst!
Allow the camshaft toothed wheel 7 to cool.

Install camshaft,
Check circumferential backlash,
7 12 7 30 13
80885 0
Fig. 5 Camshaft
Removing and installing crankshaft

toothed wheel
If the crankshaft toothed wheel 9 is worn, this
generally means that the engine has had a
long service life. Remove the crankshaft to
change the toothed wheel. As it is very costly
to remove the crankshaft, it is better to overhaul
the engine.
80809 0
Fig. 6 Crankshaft toothed wheel

1202 0299 6337-0179 Page 3 of 4
Engine control
Job Card TBG 632
W 4-4-3
7 7
A A
8 8
8 8
B B
80886 0
Fig. 7 Gear drive
Page 4 of 4 0299 6337-0179 1202

Engine control
TBG 632 Job Card
W 4-4-4
Check wheel drive (drive side)

Tools:
- Standard tools
Spare parts:
- Gasket
Cross references:
- Job Cards B 3-1-4, W 4-4-3
Visual inspection after removing the

wheel house cover
Unscrew fastening nuts and screws 1 and remove
wheel house cover 2.
Check the toothed wheels of the wheel drive for
damage, turn the motor 2 turns to be able to check
the whole circumference of the toothed wheels.
Visibly worn wheels with grooves, pitting or
considerable reduction of teeth edges must
be changed.
Rough teeth edges and a too great edge play
increase the running noise.
82318 0
Fig. 1 Wheel house cover
Assembly
The wheel house cover is assembled in reverse
order, observe tightening torques according to
Operating Instructions, chapter 8.
Use new gasket for the wheel house cover,
0103 0299 8762-0179 Page 1 of 2

Engine control
Job Card TBG 632
W 4-4-4
Page 2 of 2 0299 8762-0179 0103

Engine control
TBG 632 Job Card
W 4-4-6
Checking the torsional backlash

Tools:
- Feeler gauge
Checking the torsional backlash

Illustration on the next page.
0902 0299 6338-0179 Page 1 of 2

Engine control
Job Card TBG 632
W 4-4-6
X Y
1 5 6
S d
2
S d
S d
4 3
S d
81190 0
Fig. 1 Torsional backlash sd
Torsional backlash sd= 0.15 0.35 mm

X Drive end
1 Camshaft
2 Idler gear, small
3 Idler gear, large
4 Crankshaft
Y Free end
5 Lube oil pressure pump
6 Crankshaft
Page 2 of 2 0299 6338-0179 0902

Governor
TBG 632 Job Card
W 5-3-13
Remove and install, clean frequency pick ups, 2 pcs.

An incorrectly set gap between the frequency pick-up Tools:
and the ring gear of the flywheel or the pulse screw on - Standard tools
the camshaft toothed wheel, as well as metal particles
on the permanent magnet of the frequency pick-up
can affect the pulse output to the control electronics.
The frequency pick-up is set in the factory and should
not be removed unless absolutely necessary.
Removing frequency pick-up

Loosen screw 8 and remove connector 3.
Loosen lock nuts 2 and unscrew frequency pick-
up 1 by hand.
Check frequency pick-up for metal particles or dirt
and clean if necessary.
80951 1
Fig. 1 Distance X after turning back
Install frequency pick up on flywheel

housing
Screw in frequency pick-up 1 by hand until it is
aligned with a tooth head on the flywheel ring gear
4 of flywheel 9, see Fig. 1.
Turn back the frequency pick up 1 turn to set the
distance X then back to mark 5 of the frequency
pick up 1 in running direction of the flywheel 9.
Tighten locknut 2
Insert connector 3 into frequency pick-up 1 and
tighten screw 8.
82308 0
Fig. 2 Frequency pickup on flywheel.
1102 0299 5294-0179 Seite 1 von 2

Governor
Job Card TBG 632
W 5-3-13
Install frequency pick up to camshaft

toothed wheel
Turn motor until the pulse screw is visible in the
threaded hole of the frequency pick up, fig. 3
Screw in the frequency pick up by hand until it is
touching the pulse screw.
Turn back the frequency pick up 1 three turns, then
back further to mark 5 in running direction (6
oclock) of the camshaft toothed wheel.
Tighten locknut 2
Insert connector 3 into frequency pick-up 1 and
tighten screw 8.
After installing the frequency pick up to the
camshaft toothed wheel, the ignition time
82309 0
must be tested.
The camshaft offset (TEM evolution) may Fig. 3 Frequency pickup to camshaft toothed
have to be corrected. wheel
If the motor is operated with the wrong values

for the camshaft offset, this can lead to
destruction of the motor!
82434 0
Fig. 4 Marking
Seite 2 von 2 0299 5294-0179 1102

Exhaust gas system/Charging
TBG 632 Job Card
W 6-4-4
Cleaning the mixture cooler (water and air sides)

Tools:
- Normal tools
given in Chapter 8, Technical Data.
- Tube cleaner (plastic round brush)
Aids:
- Cleaning agent
- Neutralizing agent
Spare parts:
- Seals
Cross-references:
- Job Card W 6-4-7
- Chapter 8, Tightening Instructions
Cleaning the mixture cooler (water side)

Mechanical cleaning
Remove the mixture cooler and dismantle it into its
individual parts,
Soft deposits:
Push the plastic round brush through the cooler
tubes, and then rinse with a powerful jet of water.
Hard deposits in the tubes:
NEVER drill these out. A chemical cleaning
procedure is required here.
Assemble the mixture cooler with new seals.
1202 0299 8041-0179 Page 1 of 4

Job Card TBG 632
W 6-4-4
Chemical cleaning
For cleaning agent, see next section.
2 1 5
A cleaning solution is pumped through the detached
mixture cooler (closure covers are fitted).
Key to Fig. 1:
1 Tube inner diameter 1"
2 Recirculation pump
3 Tank, 0.5 - 1 m3
4 Heater, 5 kW
5 Mixture cooler
Make sure that the cleaning tank 3 is located higher
than the cooler, so that when the pump is switched off
the cooler cannot dry empty and be left dry. 3 4
Chemical cleaning agents 80252 0
Powder-form acids on a sulphide basis are used, Fig. 1 Chemical cleaning

strongly inhibited in order to avoid corrosion on the
metal parts:
Check the tube sheets and closure covers for wash-
P3 - T1166 Messrs. Henkel KGAA outs, and rework as necessary. The damaged point
P3 - croni (neutraliser) 40191 Dsseldorf
Follow manufacturers must be filled up with a commercially available
instructions for treatment corrosion-proof two-component filler (e.g. Belzona
from Messrs Molecular Conservation Ltd., Clare Road,
SAF-Acid (only calcium solutizer) Messrs. Drew Ameroid Harrogate/Yorkshire, England, German agency: F.
Deutschl. GmbH
Concentration: 5 % 21107 Hamburg Wolfgang Bastian, Rothenbaumchaussee 185, D-
Temperature: 55 C - 75 C 20149 Hamburg). After this has set, the tube sheet
surface must be equalized.
Porodox Messrs. Collardi GmbH
Concentration: 2 % - 10 % 50825 Kln Leaking tubes can in emergencies be sealed up with
Temperature: 20 C - 60 C a slightly conical plug made of a corrosion-proof
Treatment time: max. 16 hours
material (e.g. CuNi or GSnBz).
Comply with protection regulations!

Use protective goggles, rubber or plastic
gloves, and acid-proof protective clothing!
The mixture cooler must NEVER be cleaned
with hydrochloric acid.
After use, the cleaning solution must be
neutralized with caustic soda solution. (En-
vironmental protection!)
After cleaning, circulate a weakly alkaline
solution (caustic soda solution) through
the mixture cooler for neutralization, or
leave this solution in place for not less
than one hour.
Page 2 of 4 0299 8041-0179 1202

TBG 632 Job Card
W 6-4-4
Cleaning the mixture cooler (air side)

Place the cooler block in a trough (see Fig. 2 for
fill level).
Use a cleaning solution to soften up dirt.
The following cleaning agents can be used:
ACC 9 Messrs. Drew Ameroid
Deutschl. GmbH
21107 Hamburg
Vecom B 85 Messrs. Vecom GmbH

21107 Hamburg
P3T-5308 Messrs. Henkel KGAA

40191 Dsseldorf
Follow the manufacturers instructions.

50687 0
The soak time will depend on the degree of soiling Fig. 2 Cleaning the air side
involved. Then thoroughly rinse the cooler block with
fresh water. Clean any corroded guide plates, frames
or internal fittings, and coat them with a thermally
stable (approx. 200 C) zinc-dust paint.
The best cleaning effect is achieved with an ultra-
sonic cleaning device. Follow the instructions provided
by the manufacturer of the ultra-sonic troughs involved.
Fitting the mixture cooler

Straighten out any bent cooling plates.
Re-assemble in the opposite sequence to that
detailed above,
Tighten the fixing screws as detailed in Chapter 8,
Tightening Instructions.
After filling with coolant, vent at the venting screws.
1202 0299 8041-0179 Page 3 of 4

Job Card TBG 632
W 6-4-4
Page 4 of 4 0299 8041-0179 1202

TBG 632 Job Card
W 6-4-6
Cleaning mix cooler (on air side) in installed condition in engines

without IFE
Tools:
- Standard tools
Carry out this work only when the engine Auxiliary equipment:
has been shut down.
- Alkaline cleaner
Secure engine against start-up. - Fluid container
- Grease
Spare parts:
- any seals
Cleaning mix cooler (air side)

Remove control rod 1.
Unscrew the three hexagonal screws 2 and remove
them with washers 3.
Carefully pull up the rotary disk valve 4.
82346 0
Fig. 1 Control rods
82817 0
Fig. 2 Rotary disk valve

0201 0299 8129-0179 Page 1 of 4
Job Card TBG 632
W 6-4-6
Unscrew the intake screw 5.

Fill the opening created by unscrewing the intake
screw 5 with alkaline cleaner.
82816 0
Fig. 3 Intake screw
Above the opening of the rotary disk valve, fig. 4,

check the level of the cleaner.
The level of the cleaner must not be higher than the
edge 6, otherwise cleaner will enter the suction
pipe.
Allow the cleaner approx. 24 hours to work in.
82818 0
Fig. 4 Rotary disk valve opening
Unscrew the drain screws 7 and 8 on both mix

coolers. Collect the drained cleaner and dispose
of it as directed.
82819 0
Fig. 5 Drain screw
Page 2 of 4 0299 8129-0179 0201

TBG 632 Job Card
W 6-4-6
Check the sealing rings 9 and replace if necessary.

Mount the rotary disk valve 4 and fit control rod 1.
82820 0
Fig. 6 Drain screw
82821 0
Fig. 7 Sealing rings
0201 0299 8129-0179 Page 3 of 4

Job Card TBG 632
W 6-4-6
Page 4 of 4 0299 8129-0179 0201

TBG 632 Job Card
W 6-4-7
Removing and installing mix cooler on engines without IFE

Tools:
When removing or installing the engine
- Standard tools
or its components, always make sure
- Pick-up
that approved lifting tackle in faultless
- 2 extension spring eyes
condition appropriate to the weight
- Scraper
involved is used.
Comply with the tightening instructions - Crane
given in the Chapter 8, Technical Data. - Liquid sealing compound
- Fluid container
Spare parts:
- Seals
Cross references:
- Job Card W 6-4-4, W 6-6-4
Removing mix cooler

Remove exhaust turbocharger,
Drain cooling fluid and collect for re-use.
Remove air lines 1 and gas lines 2.
Remove manifold 3 and compensators 4.
Label and pull out cable plug 5.
82800 0
Fig. 1 Lines
0201 0299 8131-0179 Page 1 of 8
Job Card TBG 632
W 6-4-7
Remove attachment bracket 6 of cable 7 and

swing cable 7 away to cable harness 8.
82801 0
Fig. 2 Cables
Remove rods 9 and electronic controller 10.

Remove lube oil lines to 11 and 12, collect draining
lube oil.
82802 0
Fig. 3 Electronic controller
82803 0
Fig. 4 Lube oil line and cables

Page 2 of 8 0299 8131-0179 0201
TBG 632 Job Card
W 6-4-7
Suspend mixer 13 and eye 14 from crane.
82804 0
Fig. 5 Mixer
Unscrew attachment screws on brackets 15 and

16 and remove spacer bush 17.
Use the crane to lift mixer 13 and manifold 18 and
set them on a wooden surface.
82805 0
Fig. 6 Mixer bracket
0201 0299 8131-0179 Page 3 of 8

Job Card TBG 632
W 6-4-7
Remove air vent lines 19 and 20.
82806 0
Fig. 7 Vent line
Remove drain line 21.
82807 0
Fig. 8 Drain line
Remove the cooling fluid line 22.

Unscrew all attachment bolts on bracket 23 and lift
bracket 23 off with the crane.
82808 0
Fig. 9 Turbocharger bracket

Page 4 of 8 0299 8131-0179 0201
TBG 632 Job Card
W 6-4-7
Mark and remove the lube oil and cooling fluid lines
24, collect draining lube oil and cooling fluid.
82809 0
Fig. 10 Lines
82810 0
Fig. 11 Lines
82811 0
Fig. 12 Lines
0201 0299 8131-0179 Page 5 of 8

Job Card TBG 632
W 6-4-7
Unscrew the attachment screws between housing

25 and the intake pipe.
Fit the lifting device 26.
Run a rope through eye 27 and suspend on the
crane.
Unscrew the attachment screws on housing 25
and lift off housing 25 with both mix coolers 28
using the crane and set them on a wooden surface.
82812 0
Fig. 13 Lifting device
Unscrew the attachment screws on housing 29

and remove housing 29 from mix cooler 28.
82813 0
Fig. 14 Mix cooler housing
Fit two eyes 30 to the left and right sides of the mix
cooler 28, run a rope through them and suspend
the cooler on the crane.
82822 0
Fig. 15 Suspension eye

Page 6 of 8 0299 8131-0179 0201
TBG 632 Job Card
W 6-4-7
Slacken all attachment bolts 31 and lift up the mix

cooler 28.
Clean all sealing surfaces.
If necessary clean the mix cooler,
82814 0
Fig. 16 Mix cooler
Installing mix cooler

The mix cooler 28 is installed in reverse order of
removal.
Replace all seals, grease O-rings prior to
installation.
Apply liquid sealing compound to sealing rings 32
at the fit 33 on both sides.
82815 0
Fig. 17 Mix cooler seals
0201 0299 8131-0179 Page 7 of 8

Job Card TBG 632
W 6-4-7
Page 8 of 8 0299 8131-0179 0201

TBG 632 Job Card
W 6-6-4
Removing and installing exhaust gas turbocharger

Tools:
Carry out this work only when the engine
- Standard tools
has been shut down.
Secure engine against start-up. Auxiliary equipment:
- Crane
The room ventilation system must be
switched on before any work is carried Spare parts:
out of the gas line. - Seals
Smoking an use of open flames are strictly
prohibited. Cross references:
- Job Card W 13-0-1
Explosion hazard!
When removing or installing the engine

or its components, always make sure
involved is used.

Removing turbocharger
Close fuel cock.
Interrupt the monitoring current.
Switch on the air admitter/vent.
Remove exhaust pipe 1.
Unscrew hexagonal nuts 2 and remove hexagonal
screws.
Unscrew hexagonal screws 3.
Unscrew hexagonal nuts 4 and remove hexagonal
screws.
Run a rope through the extension spring eye 5 and
tighten slightly with the crane.
Unscrew both hexagonal screws 6 and remove
82633 0
along with washers 7.
Fig. 1 Exhaust pipe attachment
0103 0299 8765-0179 Page 1 of 2
Job Card TBG 632
W 6-6-4
Lift the turbocharger 8 with the crane and set it on

a wooden surface.
Collect draining lube oil.
Close off the opening of the turbocharger 8.
Installing turbocharger
Replace all seals.
Install the turbocharger 8 in the reverse order of
removal.
If a new turbocharger is installed, the setting
can be skewed by slackening the brackets 9
and 10.
82634 0
Fig. 2 Manifold attachment
Page 2 of 2 0299 8765-0179 0103

TBG 632 Job Card
W 6-7-1
Clean flame filter

The flame filter is cleaned at the intervals specified in Tools:
the maintenance plan and at unscheduled removal of - Standard tools
the cylinder head.
Comply with the tightening instructions - Compressed air
given in the Chapter 8, Technical Data. - Tray
- Grease dissolving cleaning agent
- Brake cleaner
- Sealing compound DIRKO-HT
Spare parts:
- gaskets if necessary
Cross references:
- Job Card W 1-4-4
Remove cylinder heads

see job card W 1-4-4
Remove flame filter

Unscrew hexagon socket head screws or Torx
screws 1 and remove cover 2 with flame filters.
Clean all sealing surfaces.
Clean flame filter

Place the cover 2 with flame filters 3 facing upwards
(see fig. 2) in a bath with a grease dissolving
cleaner and soak for 24 hours.
Remove cover 2 with flame filters 3 from the bath
and spray with brake cleaner.
Blow out cover 2 with flame filters 3 with compressed
air against the flow direction.
83577 0
Fig. 1 Cover with flame filters
1002 0299 8768-0179 Page 1 von 2

Job Card TBG 632
W 6-7-1
Mount flame filter

Coat sealing surfaces 4 all round with DIRKO-HT
sealing compound.
Mount cover 2 in reverse order.
Observe the tightening regulations.
Assemble cylinder heads

see job card W 1-4-4
83578 0
Fig. 2 Cover with flame filters, rear
Page 2 von 2 0299 8768-0179 1002

Lube oil system
TBG 632 Job Card
W 8-4-1
Repair lube oil pump, Rickmeier make

Tools:
- Standard tools
has been shut down.
- Pull off device
Secure engine against start-up.
When draining off hot lube oil: - Crane
- Collecting tray
risk of scalding!
Spare parts:
When removing or installing the engine - Seals
or its components, always make sure - O rings
involved is used. Cross references:
- Job Card W 8-4-2
Comply with the tightening instructions Tightening specifications
R 95/1400 FL-K-DB-SO
Remove lube oil pump

Unscrew hexagon head screws 2 and lube oil line
1. Collect draining lube oil.
Loosen lube oil line on the screw fitting, see fig. 2.
Hang the lube oil pump 5 to a crane by a rope and
tighten the rope slightly.
Unscrew screws 4 and lift the lube oil pump.
82823 0
Fig. 1 Lube oil pump with lines
0103 0299 8771-0179 Page 1 of 4

Lube oil system
Job Card TBG 632
W 8-4-1
82824 0
Fig. 2 Lube oil line
Dismantle and test lube oil pump

Unscrew screw 6 and remove with washer 7.
Pull off toothed wheel 8 with pull off device.
Tighten the lube oil pump 5 at the drive flange 9,
pressure limiting valve 10 up.
Remove connecting line 11.
Unscrew cylinder head screws 12 and remove the
pressure limiting valve 10.
Overhaul the pressure limiting valve 10, see
job card W 8-4-2.
Unscrew cylinder head screws 13 and remove the
wheelhouse 14.
Remove the drive wheel shaft 15 and running
wheel axis 16 from the drive flange 9. 82825 0
Clean the dismantled parts thoroughly. Fig. 3 Connecting line

Check the teeth edges for pitting and wear.
Examine the drive flange 9 and wheel house 14 for
damage.
Check bearing journals 17 and liners 18 for wear.
Page 2 of 4 0299 8771-0179 0103

Lube oil system
TBG 632 Job Card
W 8-4-1
Exchange criteria of the lube oil pump Assemble lube oil pump
Bearing journal diameter 17 > 0.2 (comparison The lube oil pump 5 is assembled accordingly in
with bearing journal diameter 17 outside the sliding reverse order.
bearing range 19).
Pay attention to optimum cleanliness, residue
Surface roughness of the bearing journal 17 paint must be removed from the separating
Rz > 5 m. surfaces. All O rings must be renewed.
Groove percentage on the bearing journal 17 Tighten cylinder head screws 12 and 13 with
> 5 %. 410 41 Nm.
Revealed bronze layer of the sliding bearing For the screws 4 and 6 the tightening
1/3 of the sliding bearing circumference. specifications must be observed according to
Operating Instructions, chapter 8, Technical
Groove percentage in the sliding bearing liner
Data.
> 5 %.
8 17 18 9 19 15 10 12
6 7 18 17 13 16 14 12
82826 0
Fig. 4 Lube oil pump

0103 0299 8771-0179 Page 3 of 4
Lube oil system
Job Card TBG 632
W 8-4-1
Page 4 of 4 0299 8771-0179 0103

Lube oil system
TBG 632 Job Card
W 8-4-2
Repair pressure limiting valve of the lube oil pump

The pressure limiting valve prevents the lube oil Tools:
pressure exceeding a maximum limit. The valve piston - Standard tools
loaded with the valve spring opens when the maximum - 2 cylinder head screws M8x100
value is exceeded. As a result the lube oil can flow - 2 washers
from the pressure side of the lube oil pump to the
suction side or into the oil pan.
- Collecting tray
- Compressed air
- Lapping paper, grain 630
Spare parts:
- O ring
Cross references:
- Job Card W 8-11-4
Dismantle the pressure limiting valve

Unscrew the hollow screws 1 and remove the
connecting line 2 with sealing rings.
Loosen the lube oil line 3 at the screw fitting 4,
collect draining lube oil.
82827 0
Fig. 1 Connecting line
82828 0
Fig. 2 Lube oil line

0103 0299 8774-0179 Page 1 of 2
Lube oil system
Job Card TBG 632
W 8-4-2
Unscrew two opposite cylinder head screws 5.

Turn in and tighten two cylinder head screws
M8x100 with screwed in nuts and washers.
Turn in nuts and washers to the stop.
Unscrew the other four cylinder head screws 5.
Accident risk!
Springs are under tension.
The pressure spring 6 is pre-tensioned with a

force F = 524 N, pre-tension distance 46 mm.
Relieve the pressure spring 6 by simultaneously
unscrewing the two nuts, the cylinder head screws
may not turn as well.
Unscrew the two cylinder head screws and remove 82829 0
the cover 7. Fig. 3 Cover for pressure limiting valve
Remove the pressure spring 6 and piston 8 from
the housing 9.
Clean the piston 8, piston seat and piston stem
guide with a soft, clean cloth and check for damage.
Smooth off minor surface damage with lapping
paper, grain 630.
The complete pressure limiting valve must be
renewed in the case of more serious damage.
Blow out control oil panel 10 with compressed air.
Mounting the pressure limiting valve

The pressure limiting valve is mounted in reverse
order.
Install new O-Ring 11.
Tightening torques:
Hollow screws 1 = 28 2.8 Nm
Cylinder head screws 5 = 25 2.5 Nm
Bleed lube oil line 3
Set lube oil pressure,
82830 0
Fig. 4 Pressure limiting valve
Page 2 of 2 0299 8774-0179 0103

Lube oil system
TBG 632 Job Card
W 8-11-4
Clean pre-control cartridge

Tools:
- Standard tools
has been shut down.
Secure engine against start-up.
When draining off hot lube oil: - Fuel
- Collecting tray
risk of scalding!
- Compressed air
- Wire
Spare parts:
- Gasket
Clean pre-control cartridge

Stop the engine and secure against restarting. 1
Remove the protective cap 1.
Loosen and unscrew the pre-control cartridge at 6
the hexagon 3.
Clean the pre-control cartridge 2 and seat of the 3
pre-control cartridge with fuel and blow out with
compressed air. 2
5
Push through the hole 4 with wire.
Screw in and tighten pre-control cartridge 2 with
new gasket 5.
Let the engine run and check the lube oil pressure
before the engine.
The nominal lube oil pressure is 5.5 0.3 bar. If 82457 0
this lube oil pressure is not reached, it can be

Fig. 1 Protective cap
adjusted on the square bar 6.
Replace the protective cap 1.
6
4
5
82458 0
Fig. 2 Pre-control cartridge

0103 0299 8777-0179 Page 1 of 2
Lube oil system
Job Card TBG 632
W 8-11-4
82460 0
Fig. 3 Pre-control cartridge
Page 2 of 2 0299 8777-0179 0103

Other components
TBG 632 Job Card
W 12-3-1
Replace compensators
Tools:
Arbeiten nur bei abgestelltem Motor
- Standard tools
durchfhren.
Motor gegen Starten sichern! Auxiliary equipment:
- Collecting vessel for cooling fluid
Beim Ablassen of heiem Schmierl: - Collecting vessel for lube oil
Verbrhungsgefahr !
Spare parts:
- Self-locking hexagon nut
- Compensators
Remove compensators
The arrangement of the compensators
depends on the version of the engine. A TBG
632 with integrated front-end housing (IFE) is
shown in figure 3.
Drain cooling fluid and collect for recycling.
Remove bracket 1.
Remove earthing cable 2.
Unscrew self-locking hexagon nuts 3 from all
compensators 4 and remove with hexagon head
screws 6.
Collect draining lube oil.
Remove all compensators 4 and dispose of
properly.
Fig. 1 Compensator (vertical attachment)
Fig. 2 Compensator (horizontal attachment)

0103 0299 8780-0179 Page 1 of 2
Other components
Job Card TBG 632
W 12-3-1
Attach compensators
Attach new compensators 4 accordingly in reverse
order, follow the assembly instructions on the next
page.
Gaskets are unnecessary, the surfaces 5 of
the compensators 4 serve as a seal. All self-
locking hexagon nuts 3 must be replaced.
Assembly instructions
- Check the compensators for damage, e.g. from
transportation, before installation.
- Keep bellows free from foreign bodies, e.g. dirt or
insulating material, on the inside and outside and
check after assembly.
- Do not damage the bellows, do not allow rough
vibrations or knocks, do not throw.
- Do not attach chains or ropes to the bellows part.
- The sealing surfaces of the flange must be level
and clean.
- Torsional stress (twisting) during assembly (and
later during operation) must be avoided at all cost.
- Compensators may not be mechanically stressed.
- Further pipelines must be secured properly.
- Protect the bellows when welding, cover with non-
conductive material.
- Do not paint the bellows, do not attach insulation.
- Do not exceed the permissible test pressure.
Fig. 3 Arrangement of compensators

(example: TBG 632 with IFE)
82834 0
Fig. 4 Sealing surfaces

Page 2 of 2 0299 8780-0179 0103
Electrical system
Engines Job Card
W 13-0-1
Instructions for Work on the Electrical Equipment
The gases emitted by the battery are

explosive.
Avoid sparks and open flames in the vicinity
of the battery.
Do not allow any acid to get on your skin or
clothing.
Wear protective goggles.
Do not place any tools on the battery.
The following instructions must be

observed when working on the
electrical equipment:
Battery (if installed)
Disconnect the negative lead!
Dispose of batteries in a manner preventing envi-
ronmental pollution!
Other power supply

Interrupt the power supply to the engine!
Cable
Observe cross sections and lengths in accordance
with the generally accepted safety regulations.
0100 0299 4343-0199 Page 1 of 2

Electrical system
Job Card Engines
W 13-0-1
Page 2 of 2 0299 4343-0199 0100

Gasengines Sundry other
instructions
10 Sundry other instructions 10
0200 0299 3284-0199 Chapter 10 - Page 1

Sundry other Gasengines
instructions
Chapter 10 - Page 2 0299 3284-0199 0200

Service
Knowing its DEUTZ
DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry.
As an independent motor manufacturer, we offer worldwide a comprehensive range of diesel and gas
motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers individual
requirements.
Over 1.4 million DEUTZ motors do their job reliably all over the world. We are determined to preserve the high
standard of performance and dependability of our motors, thus keeping our customers satisfied at all times.
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This index Sales & Service offers you an overview of the DEUTZ partners in your vicinity, including the products
for which they are responsible and the range of services provided. But even when no direct product
responsibility is mentioned, your DEUTZ partner will be happy to help you with expert advice.
The Index is constantly updated. Please ask your DEUTZ service partner for the latest edition.
DEUTZ AG at your service.
Obtainable from the local service Partner reponsible for you or from: DEUTZ AG
Deutz-Mlheimer Str. 147-149
D-51063 Kln
Phone: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
Service http://www.deutz.de
1102 0297 7474-0199 Service

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0297

We reserve the right to make technical alterations to the drawings and

This documentation is intended for the following engine.

Ordering No. 0299 8710 en

Page II 0299 6307-0179 0103

0100 0299 3235-0199 Page III

Page IV 0299 3235-0199 0100

Care and maintenance

Careful when the engine is running!

0100 0299 3235-0199 Page V

QUICK INTRODUCTION (FOR TRAINED AND QUALIFIED PERSONNEL)

GETTING OPERATING INSTRUCTIONS

NORMAL OPERATING INSTRUCTIONS

MAINTENANCE OPERATING INSTRUCTIONS

Page VI 0299 3232-0199 0100

SERVICING OPERATING INSTRUCTIONS

MALFUNCTIONS IN OPERATING INSTRUCTIONS

0100 0299 3232-0199 Page VII

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Page VIII 0299 3232-0199 0100

1.4 Job cards

1.5 Spare parts

10 Sundry other instructions

0103 0299 8717-0179 Page IX

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Page X 0299 8717-0179 0103

1.4 Job cards

1.5 Spare parts

0602 0299 3245-0199 Chapter 1 - Page 1

1.1 General remarks

for the machine room:

for operation and maintenance of the engine:

Chapter 1 - Page 2 0299 3245-0199 0602

1.2.2 Disposal regulations 1

1.3 Operating Instructions and Workshop Manual

1.4 Job cards

0602 0299 3245-0199 Chapter 1 - Page 3

Maintenance Group (the same for all engines)

0 General remarks / cross-category jobs 8 Lube oil system

Fig. 101 Numbering of the Job Cards

Chapter 1 - Page 4 0299 3245-0199 0602

Fig. 102 Structure of the Job Cards

1 DEUTZ AG, 10 Date of issue of the Job Cards

0602 0299 3245-0199 Chapter 1 - Page 5

1 1.5 Spare parts

Chapter 1 - Page 6 0299 3245-0199 0602

2-7 See Operating Instructions 2

0602 0299 8370-0199 Chapter 2 - Page 1

2 This page intentionally left blank.

Chapter 2 - Page 2 0299 8370-0199 0602

0203 0299 3767-0179 Chapter 8 - Page 1

8 This page intentionally left blank.

Chapter 8 - Page 2 0299 3767-0179 0203

Type designation TBG632

8.1.2 Control data

1) TBG 632 V16 with exhaust gas turbocharger TPS57

0203 0299 3767-0179 Chapter 8 - Page 3

Chapter 8 - Page 4 0299 3767-0179 0203

8.2 Operating data 8

8.2.4 Emission data

0203 0299 3767-0179 Chapter 8 - Page 5

8 8.3 Engine peripheral data

8.3.2 Speed gov ernor

Chapter 8 - Page 6 0299 3767-0179 0203