DEUTZ TBD 616, WH, en

0297 …
4. 6.
✂
3.
✂
Workshop Manual
5. TBD 616
✂
Workshop Manual
1. TBD 616
✂
✂
2.
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Workshop Manual
TBD 616
0299 7321 en
Engine number:
Please enter the engine number here. This will make it easier for us to
help you in questions of after-sales service, repairs and spare parts.
We reserve the right to make technical changes in the illustrations and

particulars given in these operating instructions if such changes are
necessary to improve the engines. Reprints and duplication of any
kind, even in excerpts, require our written permission.
TBD 616
This documentation is intended for the following engine
● Engine type:
● Applicaton:
● System name:
● Rating: kW
● Speed: / min
● Commissioned on :
Please enter the relevant data. This will make it easier for us to help you in questions of after-sales
service, repairs and spare parts.
These operating instructions must be presented to the responsible serviceperson every time any service
work is provided.
Impressum:
DEUTZ AG
Servicedokumentation
Deutz-Mülheimer-Straße 147–149
D-51057 Cologne
Tel.: (02 21) 8 22-0

Fax: (02 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
(1) 0500 ©
Order No. 0299 7321 en
Page II 0299 4266-0120 © 0500

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

Forword DEUTZ
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 0199

DEUTZ General
Engines
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.
0199 0299 3235-0199 Page V

Quick Introduction DEUTZ
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. 1 Advice to users
⇓
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 0199

DEUTZ Quick Introduction
Engines and Systems
OPERATING INSTRUCTIONS
SERVICING ➠ Chap. 1 Advice to users
⇓
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
0199 0299 3232-0199 Page VII

DEUTZ
Engines and Systems
Page VIII 0299 3232-0199 0199

DEUTZ Contents
TBD 616
0 Introduction
Imprint, foreword, quick introduction, contents
1 Advice to users
1.1 General remarks
1.2 Safety instructions / Accident prevention
1.3 Operating instructions and Workshop manual
1.4 Job cards
1.5 Spare parts
2 Job Cards
2.1 Overviews
2.1.1 Arranged alphabetically
2.1.2 Arranged by Job Card Numbers
2.1.3 Explanation of symbols
2.2 Job Cards arranged by Job Card Numbers
Service
1099 0299 4267-0120 Page IX

Contents DEUTZ
TBD 616
Page X 0299 4267-0120 1099

DEUTZ Advice to users
Engines and Systems
1 Advice to users 1
1.1 General remarks
1.3 Operating instructions and Workshop manual
1.4 Job cards
1.5 Spare parts
0798 0299 3245-0199 Chapter 1 - Page 1

Advice to users DEUTZ
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).
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.

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 0798

Engines and Systems
1.3 Operating instructions and Workshop manual 1

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.
In detail, they contain the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Engine description
3 Operating the engine, with
- Work routines before initial start-up and after every inspection
- Work routines before start-up
- Start-up
- Operational monitoring
- Shutting down the engine
- Emergency operation if components fail (if necessary and possible).
4 Instructions for expendables
5 Maintenance and servicing, with
- Tools and equipment overview
- Maintenance and servicing schedules
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 Job Cards, arranged by Job Card Numbers
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 Ill. 101.
The structure of a Job Card is shown in Ill. 102.
0798 0299 3245-0199 Chapter 1 - Page 3

Engines and Systems
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 80307 0
Ill. 101 Numbering of the Job Cards
Chapter 1 - Page 4 0299 3245-0199 0798

Engines and Systems
1
1 2 3
4
13
5
12
6
11
10 9 8
80300 3
Ill. 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 DEUTZ, manufacturer, and
12 Safety instructions and general hints
engine type to which the Job Card refers
13 Full title of the Job Card
3 Short title of the Job Card
If you have any questions on the Job Card,
4 Number of the Job Card
please always state the engine type (2), the
5 Necessary tools, equipment, and number (4), the page (8), the date of issue (10)
spare parts 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
0798 0299 3245-0199 Chapter 1 - Page 5

Engines and Systems
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 engine’s
spare parts list.
Chapter 1 - Page 6 0299 3245-0199 0798

TBD 616 Job Cards
2 Job Cards 2
2.1 Overviews
2.1.3 Explanation of symbols
© 0500 0299 4268-0120 Chapter 2 - Page 1

Job Cards TBD 616
2 2 Job Cards
2.1 Overviews
Jobs Job Card
Camshaft, installation instructions W 4-5-3
Checking and adjusting the commencement of delivery W 7-6-1
Checking liquid-cooled exhaust gas pipes, liquid compartments W 6-1-3
Checking the bearing shells for wear W 2-1-3
Checking the bearing spread W 2-1-1
Checking the clearance at the injection pump drive W 7-4-12
Checking the compression pressure W 0-2-6
Checking the connecting-rod geometry W 2-3-5
Checking the coolant compartments W 9-0-3
Checking the coolant thermostat W 9-8-1
Checking the crankshaft W 2-1-7
Checking the curved-teeth coupling, and inserting a new grease filling W 7-4-9
Checking the cylinder head W 1-4-2
Checking the cylinder liner W 3-3-1
Checking the engine mount W 3-7-1
Checking the injection lines W 7-3-3
Checking the intercooler on the air side W 6-4-5
Checking the piston rings and piston ring grooves W 2-10-3
Checking the plate heat exchanger W 9-10-5
Checking the valves and valve seating rings W 1-7-1
Checking the waste gate valve function W 6-5-1
Checking, removing and fitting the coolant pump, 2nd cooling circuit W 9-7-9
Checking, removing and fitting the raw water pump, make DEUTZ W 9-7-10
Checking, removing and fitting the raw water pump, make Steimel W 9-7-10
Checking, removing and installing the guide pins for the valve actuation bridges W 1-2-3
Checking, removing and installing the piston cooling oil jets W 2-15-2
Checking, removing and installing the valve guides W 1-6-1
Cleaning the coolant compartments W 9-0-2
Cleaning the cooling plates W 9-10-4
Cleaning the intercooler (water and air sides) W 6-4-3
Connecting-rod bearing cover, installation instructions W 2-5-5
Crack inspection with the diffusion liquid procedure W 0-3-2
Cylinder head mounting, installation instructions W 1-4-5
Cylinder liner, installation instructions W 3-3-6
Dismantling and assembling the plate heat exchanger W 9-10-3
Draining the cooling system W 9-0-1
Drive mechanism check W 2-1-0
Endoscoping the combustion compartment W 0-2-7
Exhaust gas line, installation instructions W 6-1-2
Flywheel housing, installation instructions W 3-6-2
Flywheel, installation instructions W 12-6-2
Chapter 2 - Page 2 0299 4268-0120 © 0500

TBD 616 Job Cards
Jobs Job Card

Fuel delivery pump, installation instructions, make Rickmeier W 7-11-2
Injection pump mounting and drive, installation instructions W 7-4-10
Installing the camshaft W 4-5-2
Installing the connecting-rod bearing W 2-5-2
Installing the cylinder liner W 3-3-4
Instructions for Work on the Electrical Equipment W 13-0-1
Main bearing cover at crankcase, installation instructions W 2-7-4
Nozzle holder with nozzle, installation instructions W 7-7-6
Removing and checking the camshaft W 4-5-1
Removing and fitting the centrifugal lube oil filter W 8-13-3
Removing and fitting the compressor W 10-5-1
Removing and fitting the coolant pump W 9-7-8
Removing and fitting the electric speed fine adjuster W 5-3-3
Removing and fitting the lube oil pump W 8-4-5
Removing and fitting the manual speed fine adjuster W 5-3-4
Removing and fitting the oil pan W 3-5-1
Removing and fitting, checking the idler gear for the coolant pump W 9-7-5
Removing and fitting, checking the idler gears for the raw water pump W 9-7-6
Removing and fitting, replacing the flywheel housing W 3-6-1
Removing and installing the connecting-rod bushing W 2-3-3
Removing and installing the crankshaft sealing ring (drive end) W 2-2-2
Removing and installing the crankshaft sealing ring (non-drive end) W 2-2-4
Removing and installing the cylinder head W 1-4-4
Removing and installing the end wall cover (non-drive end) W 3-8-1
Removing and installing the flywheel W 12-6-1
Removing and installing the fuel delivery pump, make Rickmeier W 7-11-1
Removing and installing the guard tube for the injection valve W 1-10-1
Removing and installing the injection lines W 7-3-1
Removing and installing the injection pump and coupling, 16-cyl. W 7-4-6
Removing and installing the injection pump and the coupling, 8- and 12-cyl. W 7-4-6
Removing and installing the injection pump and the multi-disk clutch, 8 cyl. W 7-4-11
Removing and installing the injection pump drive W 7-4-7
Removing and installing the inlet and exhaust valves W 1-5-1
Removing and installing the main bearing W 2-7-2
Removing and installing the piston pin W 2-12-4
Removing and installing the piston rings W 2-10-1
Removing and installing the piston with connecting rod W 2-9-3
Removing and installing the plate heat exchanger W 9-10-2
Removing and installing the preheating system for the coolant W 9-9-1
© 0500 0299 4268-0120 Chapter 2 - Page 3

Job Cards TBD 616
Jobs Job Card

Removing and installing the thermostat inserts W 9-8-2
Removing and installing the thrust ring (drive end) W 2-2-1
Removing and installing the thrust ring (non-drive end) W 2-2-3
Removing and installing valve lifter and valve lifter bracket W 1-2-2
Removing and installing, checking the camshaft bearings W 4-1-1
Removing and installing, checking the mass balance shaft W 2-8-1
Removing and mounting the electric speed fine adjuster W 5-3-2
Removing and mounting the torsional vibration damper W 12-1-4
Removing the connecting-rod bearing W 2-5-1
Removing the cylinder liner W 3-3-3
Removing, installing and checking the lower valve mechanism W 4-2-1
Removing, installing and checking the valve seating ring W 1-7-3
Removing, installing and cleaning the frequency encoder, 1pc. W 5-3-13
Removing, installing and cleaning the lube oil cooler W 8-8-2
Repairing the coolant pump W 9-7-2
Repairing the fuel delivery pump, make Rickmeier W 7-11-4
Repairing the injection pump drive W 7-4-8
Repairing the raw water pump, make DEUTZ W 9-7-3
Repairing the raw water pump, make Steimel W 9-7-3
Replacement criteria for deep-groove bearing W 2-1-2
Replacing hose lines, vibration dampers and flexible lines W 0-3-4
Replacing the bypass valve W 8-11-5
Replacing the non-return valve in the leakage fuel line W 7-3-5
Replacing the oil pressure control valve W 8-11-3
Replacing the woven-mat insulation at the exhaust gas turbocharger W 6-6-3
Running-in instructions W 0-1-3
Safety rules for working on the drive mechanism W 2-0-1
Solid insulation to/from the exhaust gas turbocharger W 6-1-4
Torsional vibration damper, installation instructions, with central screw W 12-1-5
Torsional vibration damper, installation instructions, with screw plug W 12-1-5
Use of liquid nitrogen W 0-3-1
Valve mechanism, installation instructions, bridge control W 1-2-1
Valve mechanism, installation instructions, rod control W 1-2-1
Chapter 2 - Page 4 0299 4268-0120 © 0500

TBD 616 Job Cards

Job Card Jobs
W 0-1-3 Running-in instructions
W 0-2-6 Checking the compression pressure
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 0-3-4 Replacing hose lines, vibration dampers and flexible lines
W 1-2-1 Valve mechanism, installation instructions, rod control
W 1-2-1 Valve mechanism, installation instructions, bridge control
W 1-2-2 Removing and installing valve lifter and valve lifter bracket
W 1-2-3 Checking, removing and installing the guide pins for the valve actuation bridges
W 1-4-2 Checking the cylinder head
W 1-4-4 Removing and installing the cylinder head
W 1-4-5 Cylinder head mounting, installation instructions
W 1-5-1 Removing and installing the inlet and exhaust valves
W 1-6-1 Checking, removing and installing the valve guides
W 1-7-1 Checking the valves and valve seating rings
W 1-7-3 Removing, installing and checking the valve seating ring
W 1-10-1 Removing and installing the guard tube for the injection valve
W 2-0-1 Safety rules for working on the drive mechanism
W 2-1-0 Drive mechanism check
W 2-1-1 Checking the bearing spread
W 2-1-2 Replacement criteria for deep-groove bearing
W 2-1-3 Checking the bearing shells for wear
W 2-1-7 Checking the crankshaft
W 2-2-1 Removing and installing the thrust ring (drive end)
W 2-2-2 Removing and installing the crankshaft sealing ring (drive end)
W 2-2-3 Removing and installing the thrust ring (non-drive end)
W 2-2-4 Removing and installing the crankshaft sealing ring (non-drive end)
W 2-3-3 Removing and installing the connecting-rod bushing
W 2-3-5 Checking the connecting-rod geometry
W 2-5-1 Removing the connecting-rod bearing
W 2-5-2 Installing the connecting-rod bearing
W 2-5-5 Connecting-rod bearing cover, installation instructions
W 2-7-2 Removing and installing the main bearing
W 2-7-4 Main bearing cover at crankcase, installation instructions
W 2-8-1 Removing and installing, checking the mass balance shaft
W 2-9-3 Removing and installing the piston with connecting rod
W 2-10-1 Removing and installing the piston rings
W 2-10-3 Checking the piston rings and piston ring grooves
W 2-12-4 Removing and installing the piston pin
W 2-15-2 Checking, removing and installing the piston cooling oil jets
© 0500 0299 4268-0120 Chapter 2 - Page 5

Job Cards TBD 616
Job Card Jobs

W 3-3-1 Checking the cylinder liner
W 3-3-3 Removing the cylinder liner
W 3-3-4 Installing the cylinder liner
W 3-3-6 Cylinder liner, installation instructions
W 3-5-1 Removing and fitting the oil pan
W 3-6-1 Removing and fitting, replacing the flywheel housing
W 3-6-2 Flywheel housing, installation instructions
W 3-7-1 Checking the engine mount
W 3-8-1 Removing and installing the end wall cover (non-drive end)
W 4-1-1 Removing and installing, checking the camshaft bearings
W 4-2-1 Removing, installing and checking the lower valve mechanism
W 4-5-1 Removing and checking the camshaft
W 4-5-2 Installing the camshaft
W 4-5-3 Camshaft, installation instructions
W 5-3-2 Removing and mounting the electric speed fine adjuster
W 5-3-3 Removing and fitting the electric speed fine adjuster
W 5-3-4 Removing and fitting the manual speed fine adjuster
W 5-3-13 Removing, installing and cleaning the frequency encoder, 1pc.
W 6-1-2 Exhaust gas line, installation instructions
W 6-1-3 Checking liquid-cooled exhaust gas pipes, liquid compartments
W 6-1-4 Solid insulation to/from the exhaust gas turbocharger
W 6-4-3 Cleaning the intercooler (water and air sides)
W 6-4-5 Checking the intercooler on the air side
W 6-5-1 Checking the waste gate valve function
W 6-6-3 Replacing the woven-mat insulation at the exhaust gas turbocharger
W 7-3-1 Removing and installing the injection lines
W 7-3-3 Checking the injection lines
W 7-3-5 Replacing the non-return valve in the leakage fuel line
W 7-4-6 Removing and installing the injection pump and the coupling, 8- and 12-cyl.
W 7-4-6 Removing and installing the injection pump and coupling, 16-cyl.
W 7-4-7 Removing and installing the injection pump drive
W 7-4-8 Repairing the injection pump drive
W 7-4-9 Checking the curved-teeth coupling, and inserting a new grease filling
W 7-4-10 Injection pump mounting and drive, installation instructions
W 7-4-11 Removing and installing the injection pump and the multi-disk clutch, 8 cyl.
W 7-4-12 Checking the clearance at the injection pump drive
W 7-6-1 Checking and adjusting the commencement of delivery
W 7-7-6 Nozzle holder with nozzle, installation instructions
Chapter 2 - Page 6 0299 4268-0120 © 0500

TBD 616 Job Cards
Job Card Jobs

W 7-11-1 Removing and installing the fuel delivery pump, make Rickmeier
W 7-11-2 Fuel delivery pump, installation instructions, make Rickmeier
W 7-11-4 Repairing the fuel delivery pump, make Rickmeier
W 8-4-5 Removing and fitting the lube oil pump
W 8-8-2 Removing, installing and cleaning the lube oil cooler
W 8-11-3 Replacing the oil pressure control valve
W 8-11-5 Replacing the bypass valve
W 8-13-3 Removing and fitting the centrifugal lube oil filter
W 9-0-1 Draining the cooling system
W 9-0-2 Cleaning the coolant compartments
W 9-0-3 Checking the coolant compartments
W 9-7-2 Repairing the coolant pump
W 9-7-3 Repairing the raw water pump, make DEUTZ
W 9-7-3 Repairing the raw water pump, make Steimel
W 9-7-5 Removing and fitting, checking the idler gear for the coolant pump
W 9-7-6 Removing and fitting the idler gears for the raw water pump
W 9-7-8 Removing and fitting the coolant pump
W 9-7-9 Checking, removing and fitting the coolant pump, 2nd cooling circuit
W 9-7-10 Checking, removing and fitting the raw water pump, make DEUTZ
W 9-7-10 Checking, removing and fitting the raw water pump, make Steimel
W 9-8-1 Checking the coolant thermostat
W 9-8-2 Removing and installing the thermostat inserts
W 9-9-1 Removing and installing the preheating system for the coolant
W 9-10-2 Removing and installing the plate heat exchanger
W 9-10-3 Dismantling and assembling the plate heat exchanger
W 9-10-4 Cleaning the cooling plates
W 9-10-5 Checking the plate heat exchanger
W 10-5-1 Removing and fitting the compressor
W 12-1-4 Removing and mounting the torsional vibration damper
W 12-1-5 Torsional vibration damper, installation instructions, with screw plug
W 12-1-5 Torsional vibration damper, installation instructions, with central screw
W 12-6-1 Removing and installing the flywheel
W 12-6-2 Flywheel, installation instructions
W 13-0-1 Instructions for Work on the Electrical Equipment
© 0500 0299 4268-0120 Chapter 2 - Page 7

Job Cards TBD 616
2 2.1.3 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.
Aids:
- 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.
Chapter 2 - Page 8 0299 4268-0120 © 0500

General
DEUTZ Job Card
Diesel engines W 0-1-3
Running-in instructions
The engines have been run in at the manufacturer’s facility, so that no further running-in instructions are really
required. If maintenance work has been performed at bearings, pistons, bushes, or if these have been replaced,
the engine has to be run in again.
If available, run in the engine using running-in oil, which may remain inside the engine for up to 50 operating
hours.
● Run the engine at low speed for 5 minutes.
● Shut down the engine, and check the bearing and crank compartments. If any component is exhibiting
serious heat-up, find out the cause and eliminate it..
If everything is all right:
● Run the engine at low speed for 30 minutes.
● Check bearing and and crank compartments as above.
● Run in the engine by gradually increasing RPM/load:
Drive mode n = variable
Engine load determined mainly by the RPM
Running-in time in min. Engine RPM %
of rated RPM
60 35
30 45
60 55
15 35
45 70
15 55
45 80
15 65
45 90 In the case of propeller drives, may not be
15 70 run when the ship is moored!
45 95
Drive mode n = constant

Engine load adjustable independently of the RPM
Running-in time in min. Engine RPM in % Engine output in %
of rated RPM of rated output
60 30 - 50 up to 5
30 50 5 - 10
60 100 up to 20
15 30 - 50 up to 5
45 100 30 - 40
15 100 up to 25
45 100 50 - 60
15 100 20 - 30 In the case of propeller
45 100 80 - 90 drives, may not be run
15 100 30 - 40 when the ship is
45 100 80 - 90 moored!
● Once you have finished the running-in program, check the engine’s operating values, and compare them
with the acceptance test report. If you find any significant divergences, ascertain the cause.
● During the following 24 operating hours, the engine must not be run with fitted injection pump blocking and
reduced speed, nor with overload.
You will reduce the stresses on your engine if you make sure that load changes are not made with
abrupt transitions.
0499 0299 4269-0199 Page 1 of 2

General
Job Card DEUTZ
W 0-1-3 Diesel engines
Page 2 of 2 0299 4269-0199 0499

General
TBD 616 Job Card
W 0-2-6
Checking the compression pressure

When working on the valve mechanism, make Tools:
absolutely sure that everything is meticulously clean. - Normal tools
NEVER use magnetic tools. - Compression pressure gauge
- Connector piece with circlip
1231 3141
Aids:
- Compressed air
Cross-references:
- Job Cards W 1-4-2, W 1-7-1, W 2-10-3,
W 3-3-1, B 7-7-2
- Operating Instructions, Chapter 8,
Tightening Instructions
Checking the compression pressure

● Blow out the injection valve shaft thoroughly with
compressed air.
● Remove the injection valve,
see Job Card B 7-7-2.
● In place of the injection valve, fit connector piece
1 with sealing ring; use shim 2 to secure connector
piece 1 in position.
● Connect compression pressure gauge 3 to
connector piece 1.
● Extend the paper holder with transport level 4.
Clamp paper in the holder, make sure the adjuster
pin is in the correct position, and push the paper
holder back into the device.
● Turn the engine 3 - 5 revolutions with the starter 82078 0
system. Ill. 1 Cylinder head

But you MUST keep stop lever 5 at its stop
position; the engine must NOT fire.
● Take paper out of the holder, and evaluate the
measurement recorded.
If the compression pressure measured is
below 19 bar, you must check the following
components:
Cylinder head Job Card W 1-4-2
Inlet and exhaust valves Job Card W 1-7-1
Piston Job Card W 2-10-3
Cylinder lining Job Card W 3-3-1
● Remove connector piece 1 and for the injection
valve with a new sealing ring.
Follow the tightening instructions given in the
Operating Instructions, Chapter 8.
82079 0
Ill. 2 Compression pressure gauge

© 0200 0299 4273-0120 Page 1 of 2
General
Job Card TBD 616
W 0-2-6
The connector piece 1 can be made in

accordance with Ill. 3. Take circlip 6 from an
12,4 57 2,5 89 18
old injection valve.
R1/4"
ø 18,9
ø 21
ø 21
ø4
ø9
15°
,5
R2
184
82080 0
Ill. 3 Connector piece with circlip
Page 2 of 2 0299 4273-0120 © 0200

General
DEUTZ Job Card
Engines 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
manufacturer’s 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.
0299 0299 4270-0199 Page 1 of 2

General
Job Card DEUTZ
W 0-2-7 Engines
● 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 0299

General
DEUTZ Job Card
Engines 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
0299 0299 4271-0199 Page 1 of 2

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

General
DEUTZ Job Card
Engines W 0-3-2
Crack inspection with the diffusion liquid procedure

Aids:
When working with trichloroethylene:
! - 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
developer, the diffusion liquid is sucked out 25495 0
of the crack, and thus becomes visible, see
Fig.␣ 4. Ill. 1 Diffusion liquid procedure
0299 0299 4272-0199 Page 1 of 2
General
Job Card DEUTZ
W 0-3-2 Engines
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 0299

General
DEUTZ Job Card
TBD 616 W 0-3-4
Replacing hose lines, vibration dampers and flexible lines

The sheer multiplicity of applications (variants) makes Tools:
it impossible to depict all parts 1 to 3 which have to - Normal tools
be replaced under an intermediate overhaul routine
(E60) in Illustrations 1 to 13.
Spare parts:
- Hose lines
- Vibration dampers
- Flexible lines
● The parts, hose lines 1, vibration dampers 2 and

flexible lines 3 shown in Illustrations 1 to 13, plus
the flexible lines at the injection pump not shown,
must be replaced.
● If additional or other parts 1 to 3 have been
installed at the engine, then these parts must
likewise be replaced.
● Once installed, parts 1 to 3 must be checked for
leaks while the engine is running, and any leaks
found must be eliminated.
82546 0
Ill. 1 Exhaust gas turbocharger and air filter
82547 0
Ill. 2 Flexible adapters

0199 0299 7341-0120 Page 1 of 4
General
Job Card DEUTZ
W 0-3-4 TBD 616
82548 0 82551 0
Ill. 3 Air filter Ill. 6 Coolant pipe
82549 0 82552 0
Ill. 4 Exhaust gas turbocharger and ventilation Ill. 7 Air filter

feature
82550 0 82553 0
Ill. 5 Exhaust gas turbocharger Ill. 8 Flexible lines and coolant line
Page 2 of 4 0299 7341-0120 0199
General
DEUTZ Job Card
TBD 616 W 0-3-4
82554 0 82557 0
Ill. 9 Flexible lines and coolant line Ill. 12 Vibration dampers, air filter
82555 0 82558 0
Ill. 10 Flexible lines Ill. 13 Vibration dampers
82556 0
Ill. 11 Flexible lines

0199 0299 7341-0120 Page 3 of 4
General
Job Card DEUTZ
W 0-3-4 TBD 616
Page 4 of 4 0299 7341-0120 0199

Cylinder head
DEUTZ Job Card
TBD 616 W 1-2-1
Valve mechanism, installation instructions, bridge control

Tools:
- Normal tools
- Torque wrench
Aids:
- Oil-proof paint
Cross-references:
Technical Particulars
- Job Card B 1-1-1
● Push valve bridge onto guide pin, making sure it

can move freely.
● After tightening, mark screws and nuts with oil-
proof paint.
● After a trial run, check the valve clearance;
See next page for illustration.
No. Dimension Strength H V1 V2 V3 Other procedures /Remarks

1 M10x75 12.9 80+5 Cylinder-head bolts
2 M12x110 12.9 140+5 Cylinder-head bolts
3 M10 30+3 Hexagonal nuts
Table 1 Installation instructions
H ⇒ Use a normal tool to tighten by hand to... Nm

V1 ⇒ Use a torque wrench to pretighten to... Nm
V2 ⇒ Use a torque wrench to tighten to ... Nm
V3 ⇒ Use a normal tool and an angulometric disk to continue turning by the specified angle [ ° ]
0499 0299 4277-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-2-1 TBD 616
1 2
3 3
80943 0
Ill. 1 Valve mechanism bridge control
Page 2 of 2 0299 4277-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-2-1
Valve mechanism, installation instructions, rod control

Tools:
- Normal tools
- Torque wrench
Aids:
- Screw locking compound Loctite 270
- Oil-proof paint
Cross-references:
- Job Card B 1-1-1
● Before tightening the fixing screws, place the

valve lifter brackets in the direction of the arrow
against the shank of the screw.
● After tightening, mark screws and nuts with oil-
proof paint.
● After a trial run, check the valve clearance;
No. Dimension Strength H V1 V2 V3 Other procedures/Remarks

1 M8x60 12.9 50+2 Cylinder-head screws
3 M10x1,8 30+3 Hexagonal nuts
4 M6x16 10.9 10 Secure cylinder-head screws with
Loctite 270
5 M9x1 20+5 Hexagonal nuts

0499 0299 4274-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-2-1 TBD 616
1 2 3
6
80944 0
Ill. 1 Valve mechanism rod control
Page 2 of 2 0299 4274-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-2-2
Removing and installing valve lifter and valve lifter bracket

Tools:
- Standard tools
- Feeler gauge
- Caliper gauge
Cross-references:
- Job Card B 1-1-1, W 1-2-1
Removing valve lifter and valve lifter

bracket
● Remove fuel pressure line and cylinder head hood.
● Turn the engine so as to ensure that tappets 1 of
the valve mechanism of the cylinder unit concerned
are destressed and the valves are closed, i.e. the
piston is in ignition TDC.
5 2 3 5 4
● Unscrew fixing screws 2 of valve lifter bracket 3 4
and lift valve lifter bracket 3 together with valve
lifters 4.
Checking valve lifter and valve lifter

bracket 1
The inspection of the dismantled components includes
checking for passage through the lube oil channels in
valve lifters 4, the set screw 5 (clean if necessary), a 6
firm seat of the closure plugs for to these lube oil
channels, the wear at the contact areas of set screws
5, and the radial clearance between bearing journal
and valve lifter bore.
80964 0
If necessary replace the components concerned.
Ill. 1 Valve actuation, components
As-new clearance [mm] max. perm. clearance [mm]

radial radial
Valve lifter bearing 0.02 - 0.07 0.100
Installing valve lifter and valve lifter

bracket
● Screw valve lifter bracket 3 onto cylinder head, ● Adjust the valve clearance,
taking care to ensure concentricity 6. see Job Card B 1-1-1.
● You must follow the Tightening Instructions as ● Mount cylinder head hood and fuel pressure line.
per Assembly instructions,
Job Card W 1-2-1.
0499 0299 4275-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-2-2 TBD 616
Page 2 of 2 0299 4275-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-2-3
Checking, removing and installing the guide pins for the valve
actuation bridges
Tools:
Check the valve actuation bridges for a stable bearing. - Standard tools
If a clearance can be felt, replace the valve actuation - Pull-off device
bridges and/or the guide pins involved.
Aids:
Never touch liquid nitrogen and - (Liquid) nitrogen
! undercooled parts:
Risk of injury! Cross-references:
- Job Cards W 0-3-1, B 1-1-1, W 1-2-2
Removing the guide pins for the valve

actuation bridges
● Remove the valve lifter and valve lifter bracket, 2 1
see Job Card W 1-2-2.
● Remove valve actuation bridges 2. Clean the
parts.
● Check the valve actuation bridges, the thrust
pieces and guide pins 1 for traces of wear and
tear. Replace any damaged parts.
● Use the pull-off device to pull out the damaged
guide pin 1.
Installing the guide pins for the valve

X
actuation bridges
● Insert the pin after supercooling it in liquid nitrogen
(approx. -196␣ °C), without using any force.
● Observe the reference dimension X = 26 +- 0.2␣ mm.
● Lubricate all components of the valve mechanism.
● Place valve actuation bridge 2 onto guide pin 1.
● Install the valve lifter and valve lifter bracket,
● Adjust the valve clearance,
80965 0
Ill. 1 Valve actuator

0499 0299 4276-0120 Page 1 of 2
Cylinder head
Job Card DEUTZ
W 1-2-3 TBD 616
Page 2 of 2 0299 4276-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-4-2
Checking the cylinder head

Depending on the engine’ use and load, plus the Tools:
quality of the fuel and lube oil, the necessary check - Standard tools
intervals for cylinder heads may vary significantly. - Endoscope
Cross-references:
- Job Cards W 0-2-7, W 0-3-2, W 1-2-2,
W 1-3-1, W 1-4-4, W 1-5-1, W 1-6-1,
W 1-7-1, B 7-7-2
Checking the cylinder head

● Check the cylinder head using an endoscope,
If an endoscope is not available, a cylinder
head must be removed. (Do not remove a
cylinder head from the end of a cylinder
bank.)
● Check the cylinder head with the worst-looking
combustion compartment as follows.
● Remove the cylinder head,
● Remove injection valve;
● Use compressed air to check that the leakage fuel
bores 1 and 2 are free of obstructions. If they are 82932 0
blocked, eliminate the cause involved. Ill. 1 Leakage fuel bores

In this case, all other cylinder heads must be
checked as well.
● Check the cylinder head’s combustion
compart-ment end for cracks,
● Check the drain plug for leaks.
● Rinse the coolant compartment with cold cleaning
agent, clean thick boiler scales using a boiler
cleaning agent (follow the manufacturer’s
instructions).
1099 0299 4278-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-4-2 TBD 616
● Remove the valves,

● Check the valve lifter bearing for wear,
see Job Card W 1-2-2..
● Check the valve guide,
● Check the valves and valve seating rings,
see Job Card 1-7-1.
- If previous checks have produced a positive result,
checking the remaining cylinder heads may be
postponed until the next combustion compartment
check interval. At this time, the combustion
compartment has to be checked as described.
- If the result is positive again, checking all cylinder
heads may be postponed for another combustion
compartment check interval.
- If, however, the cylinder head checked shows
excessive wear, all remaining cylinder heads must
be checked, too, and reconditioned if necessary.
- The engine’s operating hours up to the time when
all cylinder heads must be checked for the first
time is the check interval for the cylinder heads.
● Install the valves,
● Install the cylinder head,
● Install injection valve;
Page 2 of 2 0299 4278-0120 1099

Cylinder head
DEUTZ Job Card
TBD 616 W 1-4-4
Removing and installing the cylinder head

Built-on components at the engine will differ according Tools:
to the customer specifications and the particular - Standard tools
application concerned. This may, for example, involve - Mounting device for taking the cylinder
the exhaust gas system, the turbocharger assembly head off
and the electrics. This is why there might be additio- - Rail for aligning the cylinder heads
nal work required. These job sequences are not - 2 guide pins, 1231 2705
described here.
Aids:
The safety instructions for work on the - Lube grease
! drive mechanism must be complied with
as detailed in Job Card W 2-0-1.
Cross-references:
- Job Cards W 1-2-2, W 1-4-2, W 1-4-5,
W 2-0-1, W 9-0-1,
Removing the cylinder head

● Drain off the coolant,
● Remove air intake pipe 1, exhaust gas collecting
pipe 2, fuel pressure pipes 3 and oil leakage pipes
4.
● Remove cylinder head hood 5.
● Remove valve lifter bracket 6 with valve lifter,
● Remove valve lifter actuation bridges 7.
● Remove fixing screws 8 for the cylinder head.
● Screw on the mounting device for taking the
cylinder head off.
● Use the mounting device to carefully take the 80907 0
cylinder head off.

Ill. 1 Fuel pressure pipes
● Remove cylinder head gasket and adapters 10
and 11, if fitted, always replace adapter Ill. 6 by
adapter Ill. 7, also replace seals when they show
signs of damage.
● Place the removed cylinder head on a wooden
support.
80913 0
Ill. 2 Intake and exhaust gas pipes

0499 0299 4279-0120 Page 1 of 4
Cylinder head
Job Card DEUTZ
W 1-4-4 TBD 616
Installing the cylinder head

● Completely clean the cylinder head. Remove any
remaining pieces of gasket.
● Check the cylinder head for damages,
● Check the threads of the four fixing screws 8 for
faultless condition, replace if necessary.
● Clean sealing surface 9 on the cylinder liner.
● Fit new cylinder head gasket.
● Clean the contact areas and seating surfaces of
the lube oil and coolant adapter pieces 10 and 11.
● Insert adapters 10 and 11 into the crankcase’s
bores as shown in Ill. 5 and 7, with Y facing
downwards. 80908 0
● Insert the 2 guide pins 12 diagonally into the

Ill. 3 Cylinder head
crankcase.
● Insert the 2 shock absorber rod guard pipes 13
into the crankshaft’s boreholes, see Ill. 8, page X
in the crankcase borehole.
In the event of previous leaks at guard pipes
13, they must be replaced.
● Apply a coat of grease to the 2 boreholes for
seating the shock absorber rod guard pipes 13 in
the cylinder head.
● Install the mounting device at the cylinder head
and lower the cylinder head via the 2 guide pins
12, carefully inserting shock absorber rod guard
pipes 13 from the bottom into the 2 boreholes in
the cylinder head.
● Place the cylinder head slowly and carefully onto
the crankcase.
● Take off the two guide pins 12. 80909 0
● Apply a coat of lube oil to cylinder head screws 8 Ill. 4 Guide pin and adapter pieces
at the head’s support and the thread.
● Deposit the cylinder head slowly and carefully on
the crankcase. 10b
● Manually screw on all four cylinder head screws 8
and evenly tighten them manually in a diagonally
opposite sequence.
● Remove the mounting device.
Align cylinder head by means of the flange
surface for the intake pipe. If you are mounting
several cylinder heads or the complete row,
you have to use a rail to align them. If you
mount only one or two cylinder heads, use
the intake pipe to align them. Do not use the 10a 10a
exhaust gas pipe for this purpose.
● Tighten cylinder head screws 8, see Assembly
Instructions, Job Card W 1-4-5. 11
80910 0
Ill. 5 Adapter pieces, configuration

Page 2 of 4 0299 4279-0120 0499
Cylinder head
DEUTZ Job Card
TBD 616 W 1-4-4
● Fit valve lifter actuation bridges 7.

● Install the valve lifter bracket 6 with valve lifter,
● Install fuel pressure pipes 3, oil leakage pipe 4,
exhaust gas collecting pipe 2, air intake pipe 1.
● If the seals of the exhaust gas or intake pipes are
damaged, replace them.
● Install cylinder head screw 5.
● Fill with coolant.
80911 0
Ill. 6 Adapter pieces, details (old version)
80911 1
Ill. 7 Adapter pieces, details (new version)
80912 0
Ill. 8 Shock absorber rod guard pipe

0499 0299 4279-0120 Page 3 of 4
Cylinder head
Job Card DEUTZ
W 1-4-4 TBD 616
Page 4 of 4 0299 4279-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-4-5
Cylinder head mounting, installation instructions

Tools:
- Normal tools
- Torque wrench
Cylinder head at cylinder block

● Coat head supports and screw threads with lube
1
oil.
● Pretighten screws 1 in diagonally opposite
sequence with 20 Nm.
● Continue to tighten screws in 3 steps:
- 1st step: 100 Nm
- 2nd step:200 Nm
- 3rd step: 400 Nm
with a max. toleranzce of +10 Nm.
● Then mark screws 1 with oil-proof paint.
1
80934 0
Ill. 1 Cylinder head fixing screws
0499 0299 4280-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-4-5 TBD 616
Page 2 of 2 0299 4280-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-5-1
Removing and installing the inlet and exhaust valves

Always ensure a maximum degree of cleanliness Tools:
when you are working at the valve mechanism. It is - Standard tools
not permissible to use magnetic tools. - Removing and installing lever for valve
springs, 1231 3140
Aids:
- Wooden board
- Lube oil
Cross-references:
- Job Cards W 1-2-2, W 1-4-4, W 1-7-1
Removing the valves

● Removing the cylinder head,
● Place the cylinder head on a soft base, e.g. wood,
with the combustion compartment end at the
bottom.
● Removing valve lifter and valve lifter bracket,
● Remove the valve actuation bridges.
● Screw the removing lever for valve springs onto
the valve lifter bracket attachment pin.
Accident risk!
!
Springs are under tension.
80970 0
Ill. 1 Removing and installing lever

● Place the thrust piece on the valve.
● Press the valve springs down.
● Remove the valve clamping cone.
● Release the valve springs.
● Take the valve spring plate and the valve springs
out.
● Turn the cylinder head to its side wall.
● Pull the inlet and exhaust valves out of the valve
guides.
0499 0299 4281-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-5-1 TBD 616
Checking the valve clamping cone and

the valve springs
● Check the valve clamping cone for signs of
expansion.
Expanded valve clamping cones no longer fit
tightly at the valve stem, so that a proper
wringing fit in the valve spring plate’s inner
cone is no longer assured. Replace any
clamping cones with drag marks, burring or
signs of wear.
● Check valve springs for damage (breaks, corrosion
marks, signs of wear) and fatigue.
● Check the valve spring length.
Setpoint length:Small spring < 46.5 +- 1.5 mm
Large spring < 49.0 +- 1.5 mm
50738 0
● If the setpoint length has been exceeded, the
valve spring must be replaced. Ill. 2 Valve clamping cone
Installing the valves

● Grease the valve stem and the valve guide.
● Carefully insert valves 1 so as to ensure that the O-
ring seal in the valve guide will not be damaged.
● Fit the valve springs and valve spring plate 3.
● Shim the cylinder head so as to ensure that the
valve disks are supported.
● Place thrust piece 5 onto valve spring plate 3.
● Press valve springs 4 down.
● Insert valve clamping cone 2.
● Release valve spring 4.
Never release the valve spring plate upwards
top while the valve spring is still tensioned, if 50739 1
valve clamping cones do not clamp tightly as
specified. (Y=correct, X=wrong) Ill. 3 Valve clamping system
Make sure that valve clamping cones 2 glide
into the valve spring plate’s inner cone, If the valve spring plate can be withdrawn from the
because they are then fixed in their correct valve clamping cones easily and without a jerk, this
position, see Ill. 3. means the latter had not been properly clamped
against the valve stem and must be replaced.
● Use a plastic hammer to briefly strike the valve
stem’s end surface. ● Fit the valve actuation bridge.
Do not strike the valve spring plate. ● Install valve lifter and valve lifter bracket,
● Install the cylinder head,
● To check the valve collets’ seating, use the thrust
piece to press the valve spring plate down.
It must be possible only with difficulty and
abruptly to withdraw the spring plate from the
valve collets; the valve clamping cones are
clamped against the valve stem (swellings in
the groove). Then destress the valve spring
plate again and once again use a plastic
hammer to briefly strike the valve stem’s end
surface.
Page 2 of 2 0299 4281-0120 0499
Cylinder head
DEUTZ Job Card
TBD 616 W 1-6-1
Checking, removing and installing the valve guides

When you recondition a cylinder head, you also have Tools:
to check the valve guides for wear. - Standard tools
- Digital caliper gauge
- Press-in mandrel, 6.226.0.690.004.4
- Press-out mandrel, 6.226.0.690.006.4
- Single-cut honing tool
- Inside calipers
Aids:
- Lube oil
- (Liquid) nitrogen
Cross-references:
- Job Cards W 0-3-1, W 1-5-1
Checking
If the valve guides’ inner diameter is greater than
9.022 mm, they have to be replaced. The same
applies if they are too severely scored.
Removing the valve guides

● Removing the valves,
● Use a press and a press-out mandrel to press the
valve guides out.
After pressing out the guide, check the seat
borehole in the cylinder head. If the borehole
is larger than 15.021 mm or damaged, the
cylinder head must be reworked in a DEUTZ
service workshop to the oversize level 80966 0
concerned in each case. (If the borehole
diameter is > 15.239 mm, the cylinder head Ill. 1 Valve guide
must be replaced.)
Installing the valve guides

● Supercool new valve guides in liquid nitrogen ● If it is impeded, you have to rework using a single-
(approx. -196 °C). Insert it in dry condition, i.e. cut honing tool. Never ream it!
without lube oil, and without applying any force,
● Apply a thin film of lube oil to new O-ring seal 2 and
into the cylinder head’s seat borehole, leading
insert it in valve guide 1.
with the end stepped in diameter by 1 mm. When
you are doing this, use the press-in mandrel for ● Install the valves,
guidance. Be careful to conform with the reference see Job Card W 1-5-1.
dimension “C” = 14 ± 0,1 mm from the cylinder
head’s top edge to the valve guide’s lower edge.
● Working with liquid nitrogen,
● To check, test whether a long mandrel moves
freely in the valve guide.
0499 0299 4282-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-6-1 TBD 616
Page 2 of 2 0299 4282-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-7-1
Checking the valves and valve seating rings

Inadequate engine condition engine, poor fuel and Tools:
poor cooling water processing, plus insufficient - Standard tools
preheating, impermissible torque operation (speed - Digital caliper gauge
drop in the event of a block), etc. can cause, among - Magnifying glass (with at least quadruple
other things, a premature breakdown of valves. magnification)
Aids:
- Distillate fuel
Cross-references:
- Job Card W 1-5-1, W 1-7-3
Checking the valves and valve seating Checking the valve seating rings
rings The valve seating rings can be further used, if the
following preconditions are met:
see Job Card W 1-5-1. - Seating surface without burnouts, blow-
throughs, cracks or traces of impacts.
● Clean seating surface to remove residues.
the valve seat rings exhibit coke impacts, scoring,
● Use a scraper to remove coking on the valve offsets or corrosion and similar phenomena, the valve
plates and valve seating rings and wash them with seat rings must be replaced.
distillate fuel.
● Removing and installing valve seat rings,
To ease the removal of water-soluble, sulphurous see Job Card W 1-7-3.
residues, the run valve cones can be placed in water
for some hours. ● Installing valves,
Checking the valves
The valve cones can be further used, if the following
preconditions are met:
- Seating surface without burnouts, blow-
throughs, cracks, or traces of impacts,
- no damage to the chromium layer,
- no corrosion pits,
- stem diameter min. 8.945 mm,
- no damage to the clamping cone groove.
The valves must be replaced when:

- the cleaned seating surface is not free from
coke impacts, blow-throughs, pitting and other
damage (check with a magnifying glass).
0499 0299 4283-0120 Page 1 of 2

Cylinder head
Job Card DEUTZ
W 1-7-1 TBD 616
Page 2 of 2 0299 4283-0120 0499

Cylinder head
DEUTZ Job Card
TBD 616 W 1-7-3
Removing, installing and checking the valve seating ring

If with new valves the max. permissible backset Tools:
dimension R for the bottom edge of the valve (inlet - Normal tools
and exhaust) against ring surface Z= 1.8 mm cannot - Electric welding unit
be complied with, the valve seating rings must be - Inside calipers
replaced. - Digital caliper gauge
- Press
! undercooled parts: Aids:
- (Liquid) nitrogen
Risk of injury!
Cross-references:
- Job Cards W 0-3-1, W 1-5-1, W 1-7-1
Removing the valve seating rings

● Use an electric welding electrode Ø 2 mm at 130␣ A
to go round the weld seam on the valve seating
ring. The deformation will cause the valve seating
ring to fall off.
Do not set a higher current intensity, so as to
ensure that the cylinder head will not be
damaged.
● Checking the reference dimensions for the valve
seating ring. Z R
82056 1
[mm] Inlet Outlet
Ill. 1 Ring surface Z and backset dimension R
Valve seating Ø 48 mm +0.016 Ø 45 mm +0.016
-0 -0
ring
Tab. 1 Seat borehole in the cylinder head
● If these values are exceeded or signs of damage

are perceptible in the seat borehole, you can
change over to a repair stage. If you want to do
this, please contact your DEUTZ Service partner
or an authorized specialist workshop.
Installing new valve seating rings

● Supercool the inlet or outlet valve seating rings in
liquid nitrogen (approx. -196 °C) and insert them
without using any force. (For how to use liquid
nitrogen, see Job Card W 0-3-1). Use a press to
press the valve seating rings in place and maintain
the pressure of 12000 N for at least 15 s.
● Install the valves,
0299 0299 4284-0120 Page 1 of 2
Cylinder head
Job Card DEUTZ
W 1-7-3 TBD 616
Page 2 of 2 0299 4284-0120 0299

Cylinder Head
DEUTZ Job card
TBD 616 W 1-10-1
Removing and installing the guard tube for the injection valve
Tools:
Comply with the tightening instructions
- Normal tools
given in the Operating Manual,
- Wrench for cap nut, 1215 815
Chapter 8, „Technical Data“.
- Hot-air device
Aids:
- Loctite 270
- Loctite 582
Cross-references:
- Job Cards W 1-2-2, W 1-4-4, B 7-7-2
- Operating instructions, Chapter 8
“Tightening instructions”
Removing the guard tube

● Remove cylinder head,
● Remove injection valve,
● Remove valve lifter bracket,
● Use hot-air device to warm up cap nut 3 all round,
and unscrew cap nut 3 with the cap nut wrench.
● Remove guard tube 2, ring 4 and O-ring 5.
● Recut thread 6 in the cylinder head; clean and
degrease seating surfaces X, guard tube 2 and
thread 6
Installing the guard tube

● Apply a thin coating of Loctite 279 to seating
surface X of guard tube 2, and insert guard tube 2
into the bore of the cylinder head.
● Insert new O-ring 5 and ring 4.
● Apply a thin coating of Loctite 582 to the thread of
cap nut 3, screw in cap nut 3, and tighten with
45+5␣ Nm.
Loctite must be allowed to harden for 42␣ hours.
● Fit valve lifter bracket,

● Install injection valve,
● Fit cylinder head,
0499 0299 6801-0120 Page 1 of 2

Cylinder Head
Job card DEUTZ
W 1-10-1 TBD 616
82169 0
Ill. 1 Guard tube for injection valve
Page 2 of 2 0299 6801-0120 0499

Drive mechanism
DEUTZ Job Card
Engines 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
sufficiently. The engine must have cooled down unintentionally.
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 have removed all tools, cleaning cloths, etc. from
some components may still be hot. Heat guard the crank compartment.
plates can have sharp edges, so wear protective
● Fit inspection hole cover (if any), with new seals.
gloves.
● Before starting up, turn the engine with open
● Do not start the work until a sufficient ventilation
indexing cocks or (in the case of gas engines) with
period has elapsed.
spark plugs not installed.
● Make sure that the environment is clean in which
● With diesel engines, close indexing cocks. With
the engine is going to be opened up.
gas engines, install spark plugs.
● Fill with lube oil. Top up coolant, vent cooling
system, and check for leaks.
0299 0299 6317-0199 Page 1 of 2

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

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-1-0
Drive mechanism check

Tools:
The safety instructions for work on the
! - Standard tools
drive mechanism must be complied with
- Turning device
Cross-references:
- Job Cards W 2-0-1, W 2-15-2
While performing these jobs, make sure

that the piston cooling system’s injection
nozzles do not get bent,
● Feel the crankshaft and connecting rod bearing

covers and find out whether they are at an even
temperature.
● Check the drive mechanism’s degree of soiling,
paying attention to whether there is any bearing
metal in the oil pan, and to signs of corrosion and
water leaks.
● Carefully check the drive compartment ends of
the cylinder liner contact surface and of the liner
seals. For this purpose, the pistons must each be
in TDC.
● Perform the lube oil check:
- If installed, actuate the prelubrication pump and
check whether lube oil visibly emerges at each
bearing.
- Take off the cylinder head hood. Perform the
check routine at the valve lifter bearings.
0499 0299 4287-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-1-0 TBD 616
Page 2 of 2 0299 4287-0120 0499

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-1-1
Checking the bearing spread

The bearing spread must have a positive spread so as Tools:
to ensure that it lies properly in the seat borehole - Caliper gauge
when installed.
All new bearing shells have a positive spread unless
they have been exposed to inexpert handling, e.g.
during transport.
Definition a
Positive spread:
Measured at room temperatures, dimension “a” is
larger than dimension “D”.
Negative spread:
Dimension “a” is smaller than dimension “D”. D
Crankshaft bearing:
Dimension “D” etched into the bearing shell’s
front end.
Connecting-rod bearing:
To be measured directly at the bearing cover.
Evaluation
If a run bearing has a negative spread, this may be, if 80227 0
there are no other apparent reasons, an indication
that the bearing has suffered plastic deformation due Ill. 1 Spread
to overheating and has thus lost its initial tension.
Bearing shells with a negative spread must
not be used any more.
It is not permissible to use tools to correct the spread,
because of the risk that the bearing metal will withdraw
from the support shell or that the bearing will suffer
deformation. This sort of damage may lead to serious
malfunctions during operation.
Setpoint values
[mm] Thrust and Connecting-
main bearings rod bearings
Spread “a” 113.332 +0.2 98.522 +0.2
0499 0299 4288-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-1-1 TBD 616
Page 2 of 2 0299 4288-0120 0499

Drive mechanism
DEUTZ Job Card
Engines W 2-1-2
Replacement criteria for deep-groove bearing

In as-new condition, the contact surface exhibits Tools:
about 75 % galvanic running layer and about 25 % - Magnifying glass, 5-fold magnification
light metal.
Cross-references:
- Job Card W 2-1-1
Procedure
● Assess the wear condition of the contact surface
with a magnifying glass (magnification not less
than 5x). Running layer can be seen as a dark zone
and the light-metal rib as a light zone.
● Determinant factors for wear condition:
- Ratio between width of light-metal rib and
width of groove, plus
- extent of worn surface.
Every time you assess the state of the grooves,
you must compare them to the contact surface
in a less-stressed area (mostly with as-new
groove state).
● Check the spreading of the bearing shell
(see Job Card W 2-1-1)
Assessment
see next pages
0199 0299 4286-0199 Page 1 of 4

Drive mechanism
Job Card DEUTZ
W 2-1-2 Engines
Visual inspection of the deep-groove

bearings 4 7
1 Ratio between width of groove and width of
bearing metal rib = 3 : 1 (as-new condition)
2 Ratio between width of groove and width of
bearing metal rib = 1 : 1
3 Bearing metal ribs worn
4 Groove with overlay
5 Aluminium
6 Steel
7 Nickelwall
5 6
25%
75%
1
50%
50%
2
82333 0
Ill. 1 Deep-groove bearing, cross-section
Page 2 of 4 0299 4286-0199 0199

Drive mechanism
DEUTZ Job Card
Engines W 2-1-2
2 4
1 3
=5
80231 1
Ill. 2 State 1
Assessment The bearing is locally worn insofar as the bearing

metal ribs and the running layer grooves have reached
You must distinguish between the following states:
a ratio of 1 : 1. The width of the bearing metal ribs has
State 1 (Illustration 2): increased from 25 % (as-new condition) to 50 %.
1 Maximum 30␣ % of the circumference of the There is still running layer in the grooves.
bearing shell If a wear condition as detailed in 2. below can
2 Maximum 70␣ % of the bearing bush width be anticipated within the next inspection
interval, you must replace the bearing.
3 Maximum 50␣ % of the circumference of the
bearing shell
4 Maximum 35␣ % of the bearing bush width
5 Wear 1 : 1
0199 0299 4286-0199 Page 3 of 4

Drive mechanism
Job Card DEUTZ
W 2-1-2 Engines
1 3 5 6
2 4
=7 =8
80232 1
Ill. 3 State 2
State 2 (Illustration 3): The bearing metal ribs are locally worn.
1 Maximum 20␣ % of the bearing bush width When this wear condition has been reached,
you must replace the bearing.
bearing shell
bearing shell
6 Cam wear
7 Wear 1 : 1
8 Bearing metal strip worn
Page 4 of 4 0299 4286-0199 0199

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-1-3
Checking the bearing shells for wear

Cross-references:
- Job Cards W 2-1-1, W 2-1-2
General preconditions
If the connecting-rod bearings’ check routine reveals
a poor running pattern or deep dirt scorings or lots of
embedded dirt, an additional crankshaft bearing must
be checked.
Within the framework of the general overhaul routine,
the connecting-rod and main bearings must always
be replaced. The running times involved will depend
on the output and can be found in the operating
instructions, Chapter 5, Maintenance.
Measurements - visual inspection

For checking bearing shells which are to be re-used,
the following guidelines apply:
- sufficient spread
see Job Card W 2-1-1
- faultless running pattern of the bearing shells:
Run bearing shells will have different running
patterns, depending on the number of their
operating hours and their operating condition.
The significant differences can often be noticed
only by a trained expert. In the event of doubt, we
recommend consulting the DEUTZ Service staff
to evaluate the bearing shells concerned.
0499 0299 4289-0120 Page 1 of 2

Drive mechanisml
Job Card DEUTZ
W 2-1-3 TBD 616
Page 2 of 2 0299 4289-0120 0499

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-1-7
Checking the crankshaft

Tools:
When working with trichloroethylene:
! - Device for electromagnetic crack test
risk of poisoning! - Micrometer for Ø 95 mm and Ø 105 mm
Aids:
- Cleaning agent (Trichloroethylene)
Wear protective goggles and gloves. - Protective gloves
Care for sufficient ventilation! - Protective goggles
- Extraction device
Exhaust vapours, do not inhale! - Dry cloths
Cross-references:
- Job Cards W 0-3-2, W 2-7-2
Checking the crankshaft for freedom

from cracks
● Degrease crankshaft with cleaning agent, and
clean it.
● Allow cleaning agent to act for 10 - 15 minutes.
● Rub down those surfaces you want to check
thoroughly with a dry cloth, thus removing all
grease residues which might otherwise fill and
cover any cracks.
● Use a device for electromagnetic crack testing to
check the surfaces involved (main bearing journal
1 and crank journal 2), following the instructions
given by the manufacturer. If the test reveals any
cracks, the crankshaft must be replaced.
● If you do not have a device for electromagnetic 82422 0
crack testing at your disposal, you may also follow
the instructions detailed in Job Card W 0-3-2 for Ill. 1 Bearing journal
how to perform a crack test.
0199 0299 6826-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-1-7 TBD 616
Checking the crankshaft for wear and

tear
● Use a micrometer to measure the bearing journal’s
diameter. If the maximum limit for wear and tear of
a bearing journal has been reached (see Table 1),
or if you can feel perceptible scoring with your
fingernail, the crankshaft must be replaced.
(mm) new Limit for

wear and
tear
Main bear-
ing journal 104.942 - 104.964 104.938
Crank journal 91.942 - 91.964 91.938
Tab. 1
Page 2 of 2 0299 6826-0120 0199

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-2-1
Removing and installing the thrust ring (drive end)

Tools:
! - Normal tools
Spare parts:
- Clamp sleeve
- Thrust ring
Cross-references:
- Job Cards W 2-0-1, W 2-2-2, W␣ 12-6-1
After a lengthy period of operation, a groove may

form on the thrust ring 2 underneath the sealing lip of
the shaft sealing ring. As long as the shaft sealing ring
is not replaced, this will mostly not be disadvantageous
for the sealing properties.
Fit the new shaft sealing ring 1 (see Job Card W␣ 2-2-2) 1
in the end wall cover approx. 3 mm axially offset, so
that it is clearly next to the old groove. In the case of
the drive-end end wall cover, this is possible only if
the distance between the old groove and the free end
2
of the thrust ring is at least 7.5 mm. Otherwise (and if
the shaft sealing ring 1 has already been relocated
once), you have to replace thrust ring 2.
3
Removing and fitting the flywheel
see Job Card W 12-6-1. 80988 0
Ill. 1 Thrust ring
Removing the thrust ring

● Take off thrust ring 2.
● Remove remainders of the old sealing agent, so
that the surface is left absolutely clean.
● Take off clamp sleeve 3.
Installing the thrust ring

● Tap in the new clamp sleeve 3.
● Fit the new thrust ring evenly and without jamming
it.
● Check that the introduction bevel for the shaft
sealing ring is in faultless condition.
● Fit the flywheel.
0599 0299 4290-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-2-1 TBD 616
Page 2 of 2 0299 4290-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-2-2
Removing and installing the crankshaft sealing ring (drive end)

Tools:
! - Normal tools
- Sealing agent Loctite 574
- Mounting ring, 1216 1633
Spare parts:
- Shaft sealing ring
Cross-references:
- Job Cards W 2-0-1, W 2-2-1, W 12-6-1
Removing and fitting the flywheel

Removing the crankshaft sealing ring

Replace shaft sealing ring 1 only if there is a 1
leak, or if (after removal) you find visible wear
and tear at the sealing lip (width greater than
1 mm).
● Check contact surface of the shaft sealing ring on 2
the thrust ring 2, and replace thrust ring if necessary,
Installing the crankshaft sealing ring 3

● Oil the shaft sealing rings thoroughly before fitting
80988 0
them.
● Fit only original DEUTZ shaft sealing rings, to Ill. 1 Shaft sealing ring
ensure a properly tight seal. Always install the
shaft sealing ring with the open side facing inwards.
1
Installation position for the crankshaft
sealing ring
● Seal the outer surface with Loctite 574.
4
You must press the shaft sealing ring into the
end wall cover evenly and without jamming
it, using mounting ring 4.
When installing shaft sealing rings with 3 mm

axial offset, a ring 3 mm thick must additionally
be inserted under mounting ring 4.
80989 0
Ill. 2 Mounting ring

0599 0299 4291-0120 Page 1 of 2
Drive mechanism
Job Card DEUTZ
W 2-2-2 TBD 616
Page 2 of 2 0299 4291-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-2-3
Removing and installing the thrust ring (non-drive end)

Tools:
! - Standard tools
Spare parts:
- Locking pin
- Thrust ring
Chapter 8, „Technical Data“. Cross-references:
- Job Cards W 2-0-1, W 2-2-4, W 12-1-4
- Operating instructions, Chapter 8,
Tightening instructions
Under unfavourable operating conditions and after a

lengthy period of operation, run-in grooves may form 2
under the sealing lip of shaft sealing ring 2 on thrust
ring 1. As long as shaft sealing ring 2 is not replaced,
this will usually not affect the sealing properties. 1
Install new shaft sealing ring 2, see Job Card W 2-2-
4, offset by approx. 3 mm to ensure that it seals 3
clearly next to the old run-in groove. If shaft sealing
ring 2 has already been offset once, thrust ring 1 must
be replaced. 5
80987 0
Ill. 1 Thrust ring
Removing and installing the torsional

vibration damper.
0599 0299 4292-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-2-3 TBD 616
Removing the thrust ring

● Unscrew cylinder head screws 3.
● Pull off driver pins 4.
● Pull off thrust ring 1 and locking pin 5.
● Remove remainders of the old sealing agent to
ensure an absolutely clean surface.
Installing the thrust ring

● Tap in new locking pin 5 and press thrust ring 1
onto it.
● Evenly press on the ring without jamming it (use a
“soft” interlayer). Make sure that the ring evenly
fits closely around the hub.
● Press in driver pins 4.
● Tighten cylinder screws 3 as per Tightening
Instructions.
● Install torsional vibration damper.
Page 2 of 2 0299 4292-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-2-4
Removing and installing the crankshaft sealing ring (non-drive end)

Tools:
! - Standard tools
- Installation device
Aids:
- Sealing agent Loctite 574
Spare parts:
- Shaft sealing ring
Cross-references:
- Job Cards W 2-0-1, W 2-2-3
Removing the crankshaft sealing ring

2
Replace shaft sealing ring 2 only in the event
of leakage or if (after removing it) there are
visible signs of wear at the sealing lip (more 1
than 1 mm wide).
● Check the shaft sealing ring’s contact surface on
thrust ring 1, replacing thrust ring 1 if necessary,
3
5
80987 0
Ill. 1 Shaft sealing ring
Installing the crankshaft sealing ring Installation position of the crankshaft

● Lubricate shaft sealing ring 2 well before you sealing ring
install it. ● Use Loctite 574 to seal the outer surface.
● Only install original DEUTZ shaft sealing rings to Make sure you press shaft sealing ring 2 into
ensure reliable sealing properties. Always install the end wall cover evenly and without
the open end of shaft sealing ring 2 pointing jamming it (if necessary, use a tool to help).
inwards.
When you install shaft sealing rings with an
axial offset of 3 mm, always use an
appropriate, graded device.
0599 0299 4293-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-2-4 TBD 616
Page 2 of 2 0299 4293-0120 0599

Drive mechanism
TBD 616 Job Card
W 2-3-3
Removing and installing the connecting-rod bushing

Tools:
! Danger of burst! - Press-out/press-in device for connec-
ting-rod bushing 1231 3294
- Drill, ø 6 mm
- Face cutter
! undercooled parts: Aids:
- Nitrogen (liquid)
Risk of injury! - Degreasing agent/cleaning agent
- Compressed air
- Heating oven
Spare parts:
- Connecting-rod bushing 1218 8037
Cross references:
- Job Cards W 0-3-1, W 1-4-4, W 2-3-5,
Preparatory work W 2-9-3, W 2-12-4, W 3-5-1
● Remove cylinder head,
● Remove oil pan,
● Remove piston with connecting rod,
● Remove piston,
1 Bushing
2 Sleeve, top part
3 Sleeve, bottom part
4 Bushing
5 Installation bushing
8 Wedge
81193 0
Ill. 1 Press-out/Press-in device

© 0200 0299 7346-0120 Page 1 of 4
Drive mechanism
Job Card TBD 616
W 2-3-3
Removing the connecting-rod bushing

● Fit press-out/press-in device to connecting-rod
bushing as shown in illustration 2.
● Use the press-out/press-in device to align
connecting rod horizontally under a press, and
compensate with spacer rings/bush.
● Press out connecting-rod bushing.
● Give the bushing bore a meticulous cleaning, and
degrease it.
81194 0
Ill. 2 Pressing out
Installing the connecting-rod bushing

● Heat up connecting rod with bottom parts (3 and
4, Ill. 1) of the press-out/press-in device for one
hour up to 200 °C.
● Align connecting rod with bottom parts (3 and 4,
Ill. 1) of the press-in device horizontally under a
press, and compensate with spacer rings/bush.
● Push back pin 7 at installation bushing 5 with a
wedge far enough to ensure that no contact is
made on the inner side with connecting-rod bus-
hing 6, and hold it in that position.
● Place new connecting-rod bushing 6 onto
installation bushing 5, and align to suit the bore
concerned (Ill. 3).
● Remove wedge 8, pin 7 will engage. 81195 0
● Immerse connecting-rod bushing 6 together with Ill. 3 Connecting-rod bushing with installation
installation bushing 5 (Ill. 3) in liquid nitrogen for 30 bushing
minutes, and seal.
● After heat-up and/or undercooling, bring
components in position and position connecting-
rod bushing 6 with installation bushing 5 so as to
ensure that the bores of connecting-rod bushing
6 and connecting-rod eye coincide.
● Operate press with a low contact pressure.
Connecting-rod bushing 6 with installation bus-
hing 5 will drop into the connecting-rod eye (Ill. 4).
It is still possible for a brief time to adjust the
oil bore.
● To remove installation bushing 5, push back pin 7
(Ill. 3) with wedge 8 far enough to ensure that no
contact is made on the inner side with connecting-
rod bushing 6 (damage to the bearing), and hold it
in that position.
81196 0
Ill. 4 Pressing in
Page 2 of 4 0299 7346-0120 © 0200
Drive mechanism
TBD 616 Job Card
W 2-3-3
Drilling an oil bore

● Drill a second oil bore 9 (ø 6 mm) and deburr its
inside, taking care to prevent damage to the
bearing (Ill. 5).
Use piston pin to perform a monitoring
measurement; if stiff, repeat procedure with
a new connecting-rod bushing.
Milling off the connecting-rod bushing

After having been pressed in, the new connecting-
rod bushing 6 must be matched to the connecting-
rod eye.
● Clamp connecting rod in place under a milling
machine, as shown in Ill. 6 (α = 9°).
You will need different spacer rings 10 for 81197 0
machining, since the two sides of the

Ill. 5 Oil bore
connecting rod are not symmetrical. The
machining direction X must be complied with
(Ill. 6).
The connecting-rod bushing is milled off in two steps:
● Use a face cutter to mill off connecting-rod bus-
hing 6, taking into account the machining direction
X, down to 0.3 mm in parallel to the connecting-
rod eye. Set the milling machine to high speed,
small advance.
● Use a face cutter to match connecting-rod bus-
hing 6 to the level of the connecting-rod eye 11,
taking into account the machining direction X
(Ill. 7). Set the milling machine to high speed, small
advance. Then deburr connecting-rod bushing 6
by 0.1…0.6x45°.
Do not cut into the connecting rod’s eye
when milling off the connecting rod’s bus-
81198 0
hing, so as not to weaken the eye’s cross-
section! Ill. 6 Milling set-up
● Repeat this procedure with the other side of the
connecting-rod bushing.
● Blow out oil bore.
Make sure everything is clean.
● Check the connecting-rod geometry,

● Fit piston,
● Fit piston with connecting rod,
● Fit oil pan,
● Fit cylinder head,
see Job Card W 1-4-4. 81199 0
Ill. 7 Milling off

© 0200 0299 7346-0120 Page 3 of 4
Drive mechanism
Job Card TBD 616
W 2-3-3
Page 4 of 4 0299 7346-0120 © 0200

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-3-5
Checking the connecting-rod geometry

Tools:
- Normal tools
- Two-position measuring instrument
- Caliper gauge
Cross-references:
- Job Cards W 2-3-3, W 2-5-1,
W 2-5-2, W 2-5-5
Checking the connecting-rod head bore

(connecting-rod foot/connecting-rod
bearing cover)
● Assemble connecting-rod shaft and connecting-
rod bearing cover with bearing shell 1,
see installation instructions, Job Card W 2-5-5.
● Approx. 10 mm from the edges of the connecting-
rod head, take the following measurements:
measure diameters “a”, “b” and “c”, Ill. 1.
● From the values measured, determine us
roundness (out-of-roundness) and conicity.
● If the limit values listed in Table 1 are exceeded,
install new connecting-rod bearing shells 2 , and
repeat the measurement routine described above.
If the limit values listed in Table 1 are still being
exceeded, replace the connecting rod.
Checking the connecting-rod bushing

bore
● Measure diameters “d” and “e”.
● From the values measured, determine roundness
(out-of-roundness). If the limit values listed in
Table 1 are exceeded, replace the connecting-rod
bushing (see Job Card W 2-3-3), and repeat the
measurement routine as described above. If the
limit values listed in Table 1 are still being exceeded,
replace the connecting rod.
82594 0
Ill. 1 Measuring points
0199 0299 7351-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-3-5 TBD 616
Connecting-rod bearing shells and connecting-rod bushing installed
State Nominal dimension [mm] Limit value [mm]

Connecting-rod head bore with bearing shell installed Ø 92.024 to 92.070 -
Roundness (out-of-roundness) - Ø 92.100
Connecting-rod bushing bore Ø 50.025 to 50.075 -
Roundness (out-of-roundness) - Ø 50.100
Table 1
Page 2 of 2 0299 7351-0120 0199

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-5-1
Removing the connecting-rod bearing

Tools:
! - Standard tools
Cross-references:
- Job Cards W 2-0-1, W 2-1-3, W 2-9-3
With piston removal

● Turn the crankshaft so as to ensure that connecting
rod bolts 1 can be unscrewed.
● Support connecting-rod bearing cover 2.
● Unscrew the connecting rod bolts completely.
● Lift connecting-rod bearing cover out of the
crankcase.
● Take the lower bearing shell out of the connecting-
rod bearing cover.
● When you remove the piston (see Job Card
W␣ 2-9-3), take the upper bearing shell out of the
connecting rod.
● Use a sticky tape (not a transparent “Sellotape”
product or similar) to protect the crankshaft journals 50 746 0
against dirt from the lube oil borehole, and wrap
them with a clean cleaning cloth or oiled paper. Ill. 1 Connecting-rod bearing
Without removing the piston

The upper bearing shell can also be removed while
the piston is installed.
● Remove connecting-rod bearing cover 2 as
described in “Job sequence with piston removal”.
● Slowly turn the piston with the crankshaft until the
connecting rod hangs freely.
● Take the upper bearing shell off.
Evaluating the bearing shells

0599 0299 4294-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-5-1 TBD 616
Page 2 of 2 0299 4294-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-5-2
Installing the connecting-rod bearing

Tools:
! - Standard tools
Spare parts:
- Connecting rod bolts
Evaluate the bearing shells as per Job Cards
W 2-1-2 and W 2-1-3 and replace if necessary. Cross-references:
Make sure that the bearing shells and bearing
- Job Cards W 2-0-1, W 2-1-2, W 2-1-3,
covers are not interchanged (deep-groove
W 2-5-5, W 2-9-3
bearing on top). The connecting-rod foot and
the bearing cover have been marked by
numbers to show which ones go together.
Check the stroke journal’s state. The
permissible run-out is 0.01 mm. Start
reworking, if necessary, after prior
consultation with DEUTZ Service staff.
Any connecting rod bolts, once loosened,
must always be replaced!
Preparation
Carefully clean all parts.
Check the stroke journal’s surface condition
meticulously, and use an oil stone to smooth out any
impact traces.
With the piston removed With the piston installed

● Insert the upper bearing shell into the connecting ● Insert the bearing shell into the connecting rod
rod and install the piston according to Job Card foot in the same way as with the piston removed.
W␣ 2-9-3. Slowly turn the lift journal into the connecting rod
foot.
The upper shell and the lower shell are diffe-
rent. Make sure that run bearing shells are ● Insert the bearing shell into the bearing cover.
reinserted in their original place and that the Lubricate the bearing shell’s running surface.
groove coincides with the positioning pin.
● Make sure that the bearing’s back and the parting
● Slowly lower the connecting rod with the piston lines are free from oil and grease.
onto the lift journal.
● Fit the connecting-rod bearing cover in place,
ensuring correct seating of the positioning pin
pressed into the connecting rod.
● Tighten the new connecting rod bolts as detailed
in the tightening instructions, see installation
instructions, Job Card W 2-5-5.
● Check the clearance between crankshaft and
connecting-rod bearing, max. 0.090...0.135 mm.
0599 0299 4295-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-5-2 TBD 616
Page 2 of 2 0299 4295-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-5-5
Connecting-rod bearing cover, installation instructions

Tools:
- Normal tools
- Torque wrench
Aids:
- Lube oil
- Oil-proof paint
● Coat the head supports and screw threads with

lube oil.
● After tightening, mark the screws with oil-proof
paint.

1 M16x1.5 12.9 90 60 Alternativ tighten 1 with
230 +10 Nm in 2 steps

80936 0
Ill. 1 Connecting-rod bearing cover

0599 0299 4296-0120 Page 1 of 2
Drive mechanism
Job Card DEUTZ
W 2-5-5 TBD 616
Page 2 of 2 0299 4296-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-7-2
Removing and installing the main bearing

Tools:
- Normal tools
- Crane
- Dial gauge
- Magnetic stand
Aids:
- Lube oil
Cross-references:
- Job Cards W 0-1-3, W 1-4-4, W 2-0-1,
W 2-1-2, W 2-1-7, W 2-7-4, W 2-9-3,
W 3-5-1, W 3-6-1, W 3-8-1, W 8-4-5
Preparatory work
● Remove cylinder heads,
● Remove piston,
● Remove end wall cover,
● Remove flywheel housing,
● Remove oil pan,
● Remove lube oil pump,
82412 0
Ill. 1 Main bearing installed
Removing the main bearing

● Turn engine, position crankshaft 4 and main bearing
1 facing upwards.
● Unscrew main bearing screws 2.
● Mark main bearing cover 1 together with bearing
shells 3, then remove them.
82413 0
Ill. 2 Main bearing removed

0199 0299 6821-0120 Page 1 of 4
Drive mechanism
Job Card DEUTZ
W 2-7-2 TBD 616
● Use lifting tackle to lift crankshaft 4 out of the

bearing lane, Ill. 4. During lifting, take care to
ensure that the crankshaft 4 does not jam or knock
against anything.
Wrap the bearing 6 with leather or a similar
protective material.
● Put down crankshaft 4 on wood.
● Mark upper bearing shell 7, then take it out of the
thrust bearings.
● Clean all bearing shells with fuel.
● Check all bearing shells,
● Check crankshaft,
82414 0
Ill. 3 Crankshaft
Installing the main bearing

● Clean bearing journal 6 of crankshaft 4, bearing
seat in the crankcase and main bearing cover 1.
Flush through lube oil bore of crankshaft 4 with
fuel.
Take care to ensure that no oil penetrates into
the rear of the bearing.
● Insert upper bearing shell 7 with continuous
lubrication groove and push it into its seat in the
crankcase. Make sure you adhere to the correct
sequence (markings); recess 9 for adjusting pin 10
must be on the left seen from the flywheel side
● Centre the bearing shells 8 in such a way as to
ensure that the lube oil bores 11 of the crankcase
and of the bearing shells 7 coincide.
82415 0
● The first main bearing 7 on the flywheel side is the
thrust bearing and possesses two lateral ribs for Ill. 4 Bearing lane
fixing the crankshaft in an axial direction; see Ill. 6.
● Apply a generous amount of oil to the main bearing
shells 7 in the crankcase. Remove the protective
material at the bearing journals 6, and push
crankshaft 4 carefully into the bearings, using the
lifting tackle. The tooth marked “0” of crankshaft
gear wheel 12 must mesh between the teeth
marked “0” of camshaft gear wheel 13, Ill. 7.
With the 8-cylinder engine, you must take
care to ensure the markings coincide as
shown in Ill. 8. It is only in the 8-cylinder
engine that a mass balance shaft has been
provided.
82416 0
Ill. 5 Main bearing

Page 2 of 4 0299 6821-0120 0199
Drive mechanism
DEUTZ Job Card
TBD 616 W 2-7-2
Measuring the axial clearance

● Fit dial gauge 14 with magnetic stand 15, and
place dial gauge 14 onto the end surface of
crankshaft 4, Ill. 9.
● Bring crankshaft 4 axially in one direction as far as
it will go. Pre-tense dial gauge with 2 mm and set
it to “0”.
● Now turn crankshaft 4 in the other direction as far
as it will go, and read off the axial clearance at dial
gauge 14.
● As from 0.4 mm axial clearance onwards, the
thrust bearing (first main bearing with lateral ribs
on the flywheel side must be replaced, Ill. 6.
● Insert main bearing shells 7 (without lubricating
groove 8!) into main bearing cover 1; the position 82417 0
is specified by positioning pin 10.
Ill. 6 Thrust bearing
● Apply oil to main bearing shells 7, and insert main
bearing cover 1 into the bearings.
Take care to ensure that no oil penetrates into
the rear of the bearing.
Adhere to the correct sequence as specified
by the markings.
B B
● Apply a layer of lube oil to the head supports and 0
to the threads of the fixing screws 2.
● Screw in the fixing screws 2 of the main bearing
covers 1, and evenly tighten the inner and outer
screws 2 until they are handtight.
● Tightening instructions for fixing screw 2, 0 0
see Job Card W 2-7-4. 0
When tightening the fixing screws 2, you

must proceed from the middle of the
crankcase and work outwards.
82418 0
After fixing screws 2 have been tightened, it
must be easy to turn crankshaft 4. If it is not, Ill. 7 0-markings on crankshaft gear wheel -
you must locate the fault involved, and camshaft gear wheel
eliminate it.
● To install the remaining components, proceed in
the reverse sequence to that detailed under
“Removing the main bearing”.
0
0
0
1
1 1
82418 0
Ill. 8 0-markings on crankshaft gear wheel -

intermediate gear wheel
0199 0299 6821-0120 Page 3 of 4
Drive mechanism
Job Card DEUTZ
W 2-7-2 TBD 616
82420 0
Ill. 9 Measuring axial clearance
Page 4 of 4 0299 6821-0120 0199

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-7-4
Main bearing cover at crankcase, installation instructions

Tools:
- Normal tools
- Torque wrench

oil.
paint.

1 BM18x165 12.9 200+10 90 Main bearing cover screws
2 BM18x165 12.9 200+10 90 Main bearing cover screws

● First tighten the inner fixing screws 1, then the

outer fixing screws 2 in accordance with V1 in
Table 1.
● In the same sequence, continue turning the fixing
screws with a retightening angle as per V3.
2
80935 0
Ill. 1 Bearing cover fixing screws
0599 0299 4297-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-7-4 TBD 616
Page 2 of 2 0299 4297-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-8-1
Removing and installing, checking the mass balance shaft

Tools:
! - Normal tools
Aids:
- Lube oil
- Cleaning agent
Cross-references:
- Job Cards W 2-0-1, W 3-5-1, W 3-6-1,
W 12-6-1
Tightening Instructions.
Removing the mass balance shaft

● Remove flywheel,
● Remove flywheel housing,
● Remove oil pan, see Job Card W 3-5-1.
● Unscrew fixing screws 1 of stop plate 2, and
remove stop plate 2, idler gear 3 and bearing
journal 4.
● Unscrew cylinder head screws 5, and take off
counterweights 6.
● Pull mass balance shaft 5 with gear wheel out of
the cylinder crankcase.
80990 0
Checking the mass balance shaft for
wear Ill. 1 Stop plate
● Measure the diameter of the bearings of the mass
balance shaft 5 and of the bearing journal 4. If the
wear limit of 59.91 mm has been reached, or if you
can feel scoring with your fingernail, replace mass
balance shaft 5.
● Check the bearing bushes in the cylinder crankcase
and in idler gear 3 by visual inspection. If the
bearing metal layer is worn, or there are continuous
scoring marks visible in the surface, replace the
bearing bush concerned. When installing the wide
bearing bush (first bearing bush at the drive end),
make sure that the lube oil boreholes of the
bearing bush and the of the cylinder crankcase are
above one another (use a wire to check).
● If you notice any damage or scoring at the faces of
the gear teeth, replace the gear wheel concerned.
● If the stop plate 2 is severely worn, replace it as 80991 0
well.
Ill. 2 Idler gear
0599 0299 4298-0120 Page 1 of 2
Drive mechanism
Job Card DEUTZ
W 2-8-1 TBD 616
Installing the mass balance shaft

● Clean all parts in fuel, and flush the lube oil
boreholes of mass balance shaft 5 thoroughly with
fuel; clean bearing and seat of the bearing journal
4 in the cylinder crankcase. Wet all bearings with
lube oil.
● Fit bearing journal 4 in idler gear 3 in such a way
that the tooth of the crankshaft gear marked with
“0” engages in the tooth gap between the teeth of
the idler gear marked with “0”, see Ill. 4.
● Screw in the fixing screws for adjustment.
● Install the mass balance shaft 5 in the cylinder
crankcase in such a way that the gear tooth
marked with “1” engages in the tooth gap between
the teeth of the idler gear marked with “1”,
80992 0
see Ill.␣ 4.
● Unscrew the fixing screws again. Make sure that Ill. 3 Counterweights
idler gear 3 with bearing journal 4 does not fall
down.
● Fit stop plate 2 in place with the fixing screws.
● Screw counterweights 6 in place with cylinder-
head screws 5.
● Tighten the seven fixing screws 1 in accordance
with the Operating Instructions, Chapter 8,
Tightening Instructions, Page 5.
Operating Instructions, Chapter 8.
● Fit flywheel housing, oil pan and flywheel back
in place,
see Job Cards W 3-5-1, W 3-6-1 and W 12-6-1.
82058 0
Ill. 4 Gear setting
Page 2 of 2 0299 4298-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-9-3
Removing and installing the piston with connecting rod

When you replace a piston or the piston rings, you Tools:
also have to replace the cylinder liner if its wear limits - Standard tools
have been exceeded. Cylinder liners still dimensionally - Hoist
correct must be rehoned. Call the DEUTZ Service - Piston removal device 1231 5954
staff to perform the honing jobs. - Piston deposit device
- Piston installation liner, 1227 5301 or
- Piston insertion pliers, 1215 8242
Aids:
- Wooden wedges
- Lube oil
Spare parts:
- Connecting rod bolts
- Piston (if necessary)
Cross-references:
- Job Cards W 0-1-3, W 1-4-4, W 2-5-5,
W 3-5-1
Removing the piston

● Remove the oil pan,
● Use a scraper to carefully remove the oil carbon
deposited at the upper part of the cylinder liner.
● Move the piston to TDC position.
● Scrape free the cylinder number (if any) at the
piston bottom.
If there is no cylinder number at the piston
bottom, mark the piston before you remove
it.
● The connecting-rod bearing cover and the
connecting rod have been marked by the same
number.
● Screw out the connecting rod bolts and take the
loose connecting-rod bearing cover off.
● Loosen the connecting rod from the crankshaft
and push it upwards.
● Pull the piston and the connecting rod out upwards.
Carefully pull out the piston so as to ensure
that connecting rod, cylinder liner and the
injection nozzle of the piston’s cooling system
do not get damaged.
0199 0299 4299-0120 Page 1 of 4

Drive mechanism
Job Card DEUTZ
W 2-9-3 TBD 616
Storing the pistons removed
50710 0
Ill. 1 Storing the pistons
1
Either use a connecting rod and two wooden
wedges (Ill. 1, left) to deposit the piston
removed upside down on the piston bottom
or store it suspended in a wooden device
(Ill.␣ 1, right).
Installing the piston

● Apply a thick film of lube oil to the piston, the
cylinder liner and the connecting-rod bearing
shells.
The pistons must be installed in the same
cylinder from which they have been removed.
● Before you install the piston, check that the piston’s 3 2
lower edge with the countersink has been mounted 82533 0
on the end of the injection nozzle.
Ill. 2 Arrangement of the piston rings’ joints
● Make sure that the joints of the piston rings 1 and
2 and of the narrow-land drain oil-control ring are
offset against each other by approximately 120°
when installed, see Ill. 2.
Installation with installation liner or insertion pliers
● Carefully insert the piston and the connecting rod
into the installation bush, see Ill. 3.
● Hold the connecting rod from the bottom and
guide it; slowly press the piston from the top to the
bottom until the connecting-rod bearing rests on
the crankshaft’s connecting-rod bearing journal.
80969 0
Ill. 3 Installing the piston with installation bush

Page 2 of 4 0299 4299-0120 0199
Drive mechanism
DEUTZ Job Card
TBD 616 W 2-9-3
Make sure that the connecting rod does not

touch the injection nozzles and does not
strike against the crankshaft. This would
damage the bearing journals and bend the
injection nozzles.
● Fit the connecting-rod bearing cover in place,
ensuring correct seating of the positioning pin
pressed into the connecting rod.
● Lubricate the thread and the contact areas.
● Tighten the connecting rod bolts,
see Assembly Instructions, Job Card W 2-5-5.
● Check the clearance between crankshaft and
connecting-rod bearing:
max. 0.052...0.127 mm.
● Installing the oil pan,
● Installing the cylinder head,
If new pistons with rings or cylinder liners
have been installed, the engine has to be
run in again,
0199 0299 4299-0120 Page 3 of 4

Drive mechanism
Job Card DEUTZ
W 2-9-3 TBD 616
Page 4 of 4 0299 4299-0120 0199

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-10-1
Removing and installing the piston rings

Whenever you have removed a piston, you must Tools:
replace the set of piston rings. Only in exceptional - Piston ring pliers, 1215 8170
cases and after careful inspection may sets of piston
rings be re-installed.
Spare parts:
- Piston rings
Cross-references:
- Job Card W 2-9-3, W 2-10-3
Removing the piston rings

● Removing the piston,
● Use the piston ring pliers to remove the piston
rings, see Ill.␣ 1.
● Check the piston ring groove and the piston
rings,
Installing the piston rings

● Use the piston ring pliers to install the piston rings.
Place “Top” onto the piston ring flange,
pointing upwards, see Ill. 2.
● Insert hose spring 4 of the narrow-land drain oil-
50694 0
control ring 3 into the piston ring groove, see Ill. 2.
Ill. 1 Piston ring pliers
Arrangement of the piston rings’ joints,
see Ill. 3.
TOP
TOP 2
82322 0
Ill. 2 Piston ring placement

0599 0299 4300-0120 Page 1 of 2
Drive mechanism
Job Card DEUTZ
W 2-10-1 TBD 616
3 2
82533 0
Ill. 3 Arrangement of the piston rings’ joints
Page 2 of 2 0299 4300-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-10-3
Checking the piston rings and piston ring grooves

Tools:
- Feeler gauge
- Micrometer
Cross-references:
- Job Cards W 2-9-3, W 2-10-1
Checking the axial clearance

● Removing the piston,
● Use the piston ring pliers to remove the old piston
rings from the piston.
● Clean the piston ring groove.
Place the piston in a cleaning bath, with the piston
bottom downwards. Make sure that all piston ring
grooves are immersed. Allow the cleaning agent
solution to act until the carbon residues in the ring
grooves are detached.
Make sure that the cleaning agent solution (in a
mixing ratio of 1:1 between alkaline cleaning agent
and water) is warm.
● Insert new piston rings, 50618 2
see Job Card W 2-10-1. Ill. 1 Measuring points for measuring the axial
● Check the piston rings’ axial clearance every 45°, clearance
see Ill. 1.
● While you are measuring the clearance, press the
piston ring at the measuring point against the
bottom of the groove, see Ill. 2.
If the permissible axial clearance is exceeded,
the piston has to be replaced.
● Dimensions for piston rings and piston ring
grooves, see next page.
50696 1
Ill. 2 Measuring procedure measuring the axial

clearance
0599 0299 4301-0120 Page 1 of 2
Drive mechanism
Job Card DEUTZ
W 2-10-3 TBD 616
Checking the joint dimension

● Insert the piston ring in its installation configuration
into the cleaned, non-worn-out upper part of the
cylinder liner.
Make sure that the piston ring is not jammed.
● Use the feeler gauge to measure joint dimension
“X” between the two piston ring joints, see Ill. 3.
If the maximum permissible joint clearance is
exceeded at one piston ring, you must replace
the complete set of piston rings.
● Install the piston,
’’X‘‘
80185 0
Ill. 3 Piston ring joint dimension
Set of piston rings

1. Keystone ring
2. Tapered compression piston ring
3. Narrow-land drain oil-control ring with hose spring
Dimensions for piston rings and piston ring grooves
Ring thickness and groove height Joint dimension X Axial clearance
New dimension New state max. perm. New state max. perm.
(mm) (mm) (mm) (mm) (mm)
Ring — 0.35 - 0.50 1.00 —-

1. —-
Groove —- —- —- —-
Ring 2.975 - 2.990 0.50 - 0.75 1.50

2. 0.070 - 0.105 0.150
Groove 3.060 - 3.080 —- —-
Ring 3.470 - 3.490 0.40 - 0.75 1.00

3. 0.030 - 0.070 0.100
Groove 3.520 - 3.540 —- —-
Page 2 of 2 0299 4301-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-12-4
Removing and installing the piston pin

Tools:
- Standard tools
- Pliers for circlips, 0115 3018
- Inside calipers
- Micrometer
Aids:
- Lube oil
Spare parts:
- Piston pin (if necessary)
Cross-references:
- Job Card W 2-9-3
Removing the piston pin

● Remove the piston,
● Clean oil carbon deposit from the piston pin
borehole’s sides.
● Remove the circlip in the piston, see Ill. 1.
● Push the piston pin out of the piston, if necessary
using a piece of wood or a hammer handle to
gently knock it out (no need to warm it).
Checking the piston pin clearance in

the piston
● Use the micrometer to measure the piston pin’s
diameter.
50709 0
● Use the inside calipers to measure the piston
Ill. 1 Removing or installing the piston pin
borehole.
circlips
The calculated clearance between piston pin
and piston pin borehole in the piston must not
exceed 0.02 mm.
Checking the piston pin clearance in

the connecting-rod eye
● Use the micrometer to measure the piston pin’s
diameter.
● Use the inside calipers to measure the connecting-
rod eye borehole.
The calculated clearance between piston pin
and connecting-rod eye borehole must not
exceed 0.20 mm.
If the permissible tolerance limits have been
exceeded, the components concerned must
be replaced.
0599 0299 4303-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-12-4 TBD 616
Installing the piston pin

● Insert a sealing ring in the piston.
Position the circlip’s opening facing upwards,
and make sure that the circlip is located
firmly in the groove provided for it, see Ill. 1.
● Generously lubricate all components.
When you assemble the piston and
connecting rod you must be careful with the
position of the recess for the injection nozzle
at the bottom in the piston shaft. The recess
for the injection nozzle is at the end of the
connecting rod bolt “next to the pin”, see
Ill.␣ 3.
Arrow marking 2 in Ill. 2 on the piston points
to the inlet end. 50747 0
● Insert the piston pin into the piston. Ill. 2 Piston alignment on the connecting rod
● Place the piston onto the connecting rod and push
the piston pin in as far as the circlip.
● Insert the circlip for the piston pin in the other side
of the piston.
Position the circlip’s opening facing upwards,
and make sure that the circlip is located firmly
in the groove provided for it, see Ill. 1.
80971 0
Ill. 3 Piston recess
Page 2 of 2 0299 4303-0120 0599

Drive mechanism
DEUTZ Job Card
TBD 616 W 2-15-2
Checking, removing and installing the piston cooling oil jets

Tools:
- Normal tools
- Lamp and mirror
- Aligning device for piston cooling oil jets
Cross-references:
At main overhauls or major installation jobs, after
- Job Card W 2-9-3
installing cylinder liners or pistons, you have to remove
the piston cooling oil jets. These also have to be
removed if there is excessive soiling due to some
damage, or if there is dirt in the lube oil circuit. It is not
essential to replace the jets if only individual pistons,
connecting rods and cylinder liners re being removed/
installed.
Removing the piston cooling oil jets

Be careful not to confuse the piston cooling
oil jets 5 between sides A and B.
● Unscrew the fixing screws of piston cooling oil
jets␣ 5.
● Carefully take out the piston cooling oil jets 5.
Cleaning the piston cooling oil jets

● Clean the piston cooling oil jets 5 with cleaning
agent, and rinse them through.
Installing the piston cooling oil jets

● Mount and align the piston cooling oil jets 5 for the
A and B sides respectively.
● Tighten new fixing screws.
0599 0299 4304-0120 Page 1 of 2

Drive mechanism
Job Card DEUTZ
W 2-15-2 TBD 616
Aliging the piston cooling oil jets (piston removed) Re-aligning the piston cooling oil jets
● Place aligning device 2 on cylinder crankcase. ● If there are any deviations, first check that the
The aligning device 2 with its fixing bushes must components are properly mounted and fixed in
be inserted into the threaded boreholes for securing the correct position.
the cylinder head.
Re-alignment will only be necessary when
● Secure the aligning device 2 in position with two the jets are bent. Never use the test rod 4 for
cylinder-head screws 1. this purpose; use a pipe, to make sure that
the mouth of the spray jet does not get
● Into the aligning device 2, through guide bush 3,
damaged.
insert test rod 4 cautiously into piston cooling oil
jet 5, and align and secure piston cooling oil jet 5. ● Re-align with a suitable-size pipe pushed over the
spray jet.
● Turn the engine, checking with the lamp and the
mirror whether the test rod 4 can be inserted into ● Tighten the fixing screws of the piston cooling oil
the piston’s cooling oil inlet borehole without jet 5; see Operating Instructions, Chapter 8,
touching the piston. Tightening Instructions.
82057 0
Ill. 1 Aligning the piston cooling oil jets (piston removed)

Page 2 of 2 0299 4304-0120 0599
Crankcase
DEUTZ Job Card
TBD 616 W 3-3-1
Checking the cylinder liner

Tools:
! - Inside micrometer
- Turning device
Cross-references:
- Job Cards W 1-4-4, W 2-0-1, W 3-3-3
Checking the cylinder liner

● Turn the crankshaft until the piston concerned is
in BDC position.
● Clean combustion residues from cylinder liner.
● Check the first piston ring’s wearing edge.
If it can be distinctly felt, this is a sign of
increased wear.
● Adjust the inside micrometer to the cylinder liner’s
inside diameter.
● Perform the measuring routine as per attached
measuring sheet in longitudinal and transverse
directions and in the different measuring levels. 80968 0
Ill. 1 Wearing edge of the first piston ring
Nominal diameter Ø 132 +0.025 mm
max. perm. wear dimension Ø 132.1 mm
max. perm. run-out 0.06 mm
Table 1 Cylinder liner dimensions

If one of the maximum permissible values
has been exceeded, the cylinder liner must
be replaced,
It may be possible to rehone a cylinder liner if
it is only slightly worn. For this purpose,
please contact your DEUTZ Service staff.
● Mount the cylinder head,
50657 0
Ill. 2 Measuring with inside micrometer

0599 0299 4305-0120 Page 1 of 2
Measurement sheet for cylinder liners, ø 132 +0.025 mm (nominal dimension)
Page 2 of 2
W 3-3-1
Job Card
Customer: Engine type: Op. hours: Date:

Crankcase
Engine No.: Order No.: Measured:
(Name)
Drive end
Cylinder: A1 A2 A3 A4 A5 A6 A7 A8
Measuring direction X Y X Y X Y X Y X Y X Y X Y X Y
H in mm 25
50
DEUTZ
0299 4305-0120
TBD 616
150
250
25
Cylinder: B1 B2 B3 B4 B5 B6 B7 B8
Measuring direction X Y X Y X Y X Y X Y X Y X Y X Y
H in mm 25
50
150
250
0599
Crankcase
DEUTZ Job Card
TBD 616 W 3-3-3
Removing the cylinder liner

Tools:
! - Standard tools
- Removal device for cylinder liners
1231 2708
Cross-references:
- Job Cards W 2-0-1, W 2-9-3
It is necessary to remove the cylinder liners if the wear

and tear measured exceeds the permissible limits,
the track shows a poor contact pattern or damage or
if it is too smooth (honing scores no longer visible).
The cylinder liner must also be removed if the piston
or the piston rings are replaced or when the housing’s
coolant compartments and the state of the liner’s
outer side containing the coolant are checked during
intermediate or major overhauls.
Make sure that no dirt whatsoever falls from
the coolant compartments onto the crankshaft
during the removal and installation routines.
This is why the drive compartment must be
properly covered.
Removing the cylinder liner

● Carefully cover the drive compartment.
● Use the removal device to pull the cylinder liner
out of the crankcase, see Ill. 1.
Do not damage the piston’s cooling oil
nozzles.
50791 0
Ill. 1 Removing the cylinder liners

0599 0299 4306-0120 Page 1 of 2
Crankcase
Job Card DEUTZ
W 3-3-3 TBD 616
Page 2 of 2 0299 4306-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-3-4
Installing the cylinder liner

Tools:
! - Standard tools
Aids:
- Grinding paste, 6.083.117.1013.1
- Acid-free grease
Cross-references:
- Job Card W 0-1-3, W 2-0-1, W␣ 2-15-2,
W 3-3-1, W 3-3-6
Installing the cylinder liner

● Check cylinder liners for wear,
● Before you install the new cylinder liner, clean the
contact area of cylinder liner 1 in crankcase 2 and
check it for possible damage.
When replacing a cylinder liner 1 we advise
replacing the associated piston as well, but
you absolutely MUST replace the piston rings.
● Manually position cylinder liner 1 without O-ring
seals in the cleaned crankcase 2. It must be
possible to inserted it easily and turn it manually.
Make sure you do not damage the piston’s
cooling oil nozzles.
80914 0
● Manually grind in the collar seat’s contact surface Ill. 1 Cylinder liner
using grinding paste until there is an even contact
pattern.
If you do not succeed in producing an even
contact pattern,
please call the DEUTZ Service staff.
● Lift out cylinder liner 1 again. 1
● Apply a thin film of acid-free grease to the new O-
ring seals. 2
● Insert the O-ring seals in grooves 3 of crankcase
2. 3
80915 0
Ill. 2 Crankcase
0599 0299 4307-0120 Page 1 of 2
Crankcase
Job Card DEUTZ
W 3-3-4 TBD 616
● Manually insert cylinder liner 1 until it touches the

contact surface.
Be careful not to damage the piston’s cooling
oil nozzles when you install cylinder liner 1.
● Check the alignment of the piston’s cooling oil
nozzles;
When you install cylinder liners 1 the O-ring
seals are at risk of getting jammed or twisted.
So install the cylinder liners carefully. Follow
the assembly instructions on Job Card
W 3-3-6.
● After installing new cylinder liners 1 or piston and
piston rings, your engine has to be run in anew,
Page 2 of 2 0299 4307-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-3-6
Cylinder liner, installation instructions

Tools:
- Dial gauge, 0710 6439
- Bridge for dial gauge
Aids:
- Tin-lead solder
To ensure a perfect fit for cylinder liner 2, the values

in the table below must be checked.
The items in illustration 1 are:
1 Cylinder head
2 Cylinder liner
3 Crankcase
4 Piston
80938 2
Ill. 1 Cylinder liner 2
Can be measured when cylinder head 1 has been removed

X Piston projection, seal surface mm 0.1-0.5
Y Piston recessed, fire protection collar mm 0.7-1.2
Can be measured * with cylinder head 1 still fitted

Z Compression distance mm 1.00-1.45
* To be measured with a tin-lead solder rod through the injection valve borehole.
0599 0299 4308-0120 Page 1 of 2

Crankcase
Job Card DEUTZ
W 3-3-6 TBD 616
This page has been intentionally left blank.
Page 2 of 2 0299 4308-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-5-1
Removing and fitting the oil pan

Tools:
When draining off hot lube oil: - Normal tools
!
risk of scalding! - Scraper
Collect the used oil, do not allow it to Aids:

! seep into the soil.
- Collecting trough for lube oil
Dispose of in accordance with the - Fuel, petroleum ether
relevant regulations.
Cross-references:
Carry out this work only when the - Operating Instructions, Chapter 8,
! engine has been shut down. Tightening Instructions
Expendables Specifications
Removing the oil pan

● Drain or pump off lube oil into a suitable collecting
trough.
● Unscrew all fixing screws (Ill. 1 arrows), and take
off the oil pan.
● Remove any seal remainders, clean and degrease
the sealing surfaces.
● Clean the oil pan thoroughly, using fuel or petroleum
ether.
82090 0
Ill. 1 Oil pan

0599 0299 4309-0120 Page 1 of 2
Crankcase
Job Card DEUTZ
W 3-5-1 TBD 616
Fitting the oil pan

● Fit new seals. OIL
● Screw oil pan in place with the fixing screws (Ill. 1
arrows).
● Pour lube oil into filling socket (Ill. 2, arrow) until it
reaches the upper dipstick marking, Ill. 3.
For particulars of quality and viscosity, please
consult the Operating Instructions, Chapter
4, Expendables Specifications.
● Activate the prelubrication pump, if any.
● Run the engine briefly.
● Shut down the engine, and check the lube oil level;
if necessary, top up as far as the upper dipstick
marking. 80681 0
Ill. 2 Lube oil filling socket
25729 0
Ill. 3 Dipstick marking
Page 2 of 2 0299 4309-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-6-1
Removing and fitting, replacing the flywheel housing

Tools:
! - Normal tools
- Plastic hammer
- Drill
- Drill bit, Ø 12mm
- Grindstone
- Magnetic stand with dial gauge
Aids:
- Degreasing agent
- Liquid sealant (silicone rubber)
- Loctite 270
- Compressed air
Spare parts:
- if necessary 2 centring pins Ø 12 mm
Cross-references:
- Job Cards W 3-5-1, W 3-6-2, W 12-6-1
Removing the flywheel housing

● Remove the flywheel, see Job Card W 12-6-1.
● Take off the oil pan, see Job Card W 3-5-1.
● Unscrew fixing screws 1 to 6, see Ill. 3.
● Use a plastic hammer to loosen the flywheel
housing, and then remove it carefully.
● Check centering pins 1 in the crankcase for faultless
condition; replace if necessary, see Ill. 1.
● Remove any remainders of old seals from the
sealing surfaces.
● Degrease the sealing surfaces.
82102 1
Ill. 1 Centering pins
1099 0299 4310-0120 Page 1 of 4

Crankcase
Job Card DEUTZ
W 3-6-1 TBD 616
Fitting the flywheel housing

● Apply sealing compound to the sealing surfaces,
as shown in Ill. 2.
● Align flywheel housing on the centering pins, and
place it on the crankcase.
● Insert fixing screws and tighten them,
● Fit the oil pan,
● Fit the flywheel,
82103 1
Ill. 2 Flywheel housing sealing surfaces
Replacing the flywheel housing

● Remove damaged flywheel housing, as described
above.
● Remove the two centring pins 11 for the crankcase.
● Remove seal residues from the sealing surfaces of
the crankcase, and degrease the sealing surfaces,
see Ill. 2.
● Use a grindstone to dress the sealing surfaces of
the new flywheel housing, and degrease them
with a degreasing agent.
● Screw locating pins 7 into the crankcase.
● Coat screws 8 with Loctite 270; affix plate 9 to
flywheel housing, and tighten screws 8 until they
are handtight.
82936 0
● Apply liquid sealant (silicone rubber) as shown in
Ill 2. Ill. 3 Magnetic stand with dial gauge
● Lift flywheel housing with a crane, and insert it
over the locating pins 7. Lightly tighten the three
screws 10.
● Affix magnetic stand with dial gauge to the
crankshaft, and set up dial gauge as shown in Ill.
3, set scale to “0”.
● By turning the crankshaft, measure the radial
runout of the flywheel housing.
● Using light taps with a plastic hammer, correct the
radial runout.
The radial runout must not exceed 0.25 mm.
● Remove magnetic stand with dial gauge and
locating pins.
Page 2 of 4 0299 4310-0120 1099

Crankcase
DEUTZ Job Card
TBD 616 W 3-6-1
● Insert all screws and tighten them;

● Drill the two bores for the centring pins 11 with a
Ø 12 mm bit, blow out with compressed air, and fix
in place with two new centring pins Ø 12 mm.
● Fit the oil pan,
● Fit the flywheel,
1 1 1 1 1 6
1
4
2 1
1 4
3 3
2 2 5 2 4
80947 0
Ill. 4 Fixing screws, flywheel housing

1099 0299 4310-0120 Page 3 of 4
Crankcase
Job Card DEUTZ
W 3-6-1 TBD 616
Page 4 of 4 0299 4310-0120 1099

Crankcase
DEUTZ Job Card
TBD 616 W 3-6-2
Flywheel housing, installation instructions

Tools:
- Normal tools
- Torque wrench
Aids:
- Oil-proof paint
● Afer tightening, mark screws with oil-proof paint.


3 M12x125 10.9 115+5 Hexagon-head screws

0599 0299 4311-0120 Page 1 of 2

Crankcase
Job Card DEUTZ
W 3-6-2 TBD 616
1 1 1 1 1 6
1
4
2 1
1 4
3 3
2 2 5 2 4
80947 0
Ill. 1 Flywheel housing
Page 2 of 2 0299 4311-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-7-1
Checking the engine mount

Since the foundation may change due to heat and Tools:
deformation phenomena, the fixing screws must be - Standard tools
checked for possible loosening. This is particularly
essential after the first operating hours.
Checking the engine mount

● Check shims in the case of rigid mounts or packings
in the case of elastic mounts, by tapping them
(including those which are not easily accessible,
e.g. due to superimposed pipes).
A metallic sound heard when tapping the
shims indicates that the connection is tight.
● Tighten loose screws as per Tightening Instructions
by the erection company involved.
● Check the alignment.
Ensure a maximized degree of cleanness; in
particular keep oil and water away from the
foundation.
0599 0299 4312-0120 Page 1 of 2

Crankcase
Job Card DEUTZ
W 3-7-1 TBD 616
Page 2 of 2 0299 4312-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-8-1
Removing and installing the end wall cover (non-drive end)

Tools:
! - Normal tools
- Scraper
- Plastic hammer
Carry out this work only when the Aids:

! engine has been shut down. - Collecting trough for coolant
- Cleaning agent
- Lithium-saponified grease
Comply with the tightening instructions - Lube oil
given in the Operating Manual, - Liquid sealing agent Deutz-DW 47
Cross-references:
- Job Cards W 2-0-1, W 2-2-3, W 2-2-4,
W 9-0-1, W 9-7-5, W 9-7-6, W 12-1-4
Removing the end wall cover

● Drain off the coolant, and collect it for re-use.
● Remove coolant pumps and lines, plus (if fitted)
heat exchanger with expansion tank, three-phase
current generator, fuel delivery pump, and V-belt
pulley with torsional vibration damper-
● Unscrew all screws, as shown in Ill. 2.
● Unscrew fixing screws of oil pan at the end wall
cover; see Ill. 1.
● Use light taps with a plastic hammer to detach the
outer end wall cover 10 from the seals.
82090 0
Ill. 1 Oil pan

0599 0299 5502-0120 Page 1 of 6
Crankcase
Job Card DEUTZ
W 3-8-1 TBD 616
4 4 4 4 4
4 4
6
5 5
7 2
3
2
9
3
8
3
3
3 1
82089 0
Ill. 2 Fixing screws
1 = Cyl.-head screw M8x65 (with seals)

2 = Cyl.-head screw M8x75
4 = Hex.-head screw M8x80
5 = Hex.-head screw M8x85
6 = Cyl.-head screw M10 x80
Page 2 of 6 0299 4313-0120 0599

Crankcase
DEUTZ Job Card
TBD 616 W 3-8-1
● Press off end wall cover 10 and remove it. ● Check bearing bush 16 by visual inspection. If the
bearing metal layer is worn away, or you can see
● Remove idler gears 11 and 12, or axles in place of
continuous scoring in the contact surface, replace
idler gears; see Job Cards W 9-7-5 and W 9-7-6.
bearing bush 16.
● Turn the engine until the markings of gears 13 and
14 are properly aligned with each other.
● Unscrew fixing screws of gears 13 and 14, and
take off the gears.
● Unscrew fixing screws of the rear end wall cover
15.
● Use light taps with a plastic hammer to detach end
wall cover 15, and remove it.
● If the oil pan seal is damaged, replace it.
● Remove all residues of the liquid seal, using a
scraper and cleaning agent, and degrease the
sealing surfaces.
82091 0
Ill. 3 Gear train

0599 0299 5502-0120 Page 3 of 6
Crankcase
Job Card DEUTZ
W 3-8-1 TBD 616
Fitting the end wall cover

● Use spray pistol 17 to apply liquid sealant DEUTZ-
DW 47 to rear end wall cover 15, as shown in Ill. 4.
● Place rear end wall cover 15 on crankcase; do not
tighten screws yet.
Be careful not to damage the oil pan seal!
● Fit idler gears 11 and 12, or axles in place of idler
gears. See Job Cards W 9-7-5 and W 9-7-6.
● End wall cover 15 has now been properly adjusted,
and can be secured in place.
● Fit gears 13 and 14. The markings must be properly
aligned, as shown in Ill. 6.
● On the installed rear end wall cover 15, as shown
in Ill. 3, use spray pistol 17 to apply liquid sealant 82092 0
DEUTZ-DW 47. The 3 boreholes 18 must likewise
be sealed with liquid sealant. Ill. 4 Apply liquid seal
Do NOT apply any sealant to the area indicated

by an arrow in Ill. 3.
● Coat axles 19 and boreholes 21 with lithium-
saponified grease.
● Wet camshaft 20 and bearing shell 22 with lube oil.
● On borehole 23, fit a new O-ring coated with
lithium-saponified grease.
● Seal boreholes 24 with liquid sealant DEUTZ-DW
47.
82093 0
Ill. 5 Spray pistol
0 0
0
0 0
0
80959 0
Ill. 6 Installation marking

Page 4 of 6 0299 4313-0120 0599
Crankcase
DEUTZ Job Card
TBD 616 W 3-8-1
● Place the front end wall cover 10 on the rear end

wall cover 15, and screw together. See Ill. 2 for the
screw configuration involved.
● Tighten the fixing screws for the oil pan; see Ill. 1.
● Fit all the components previously removed,
proceeding in the reverse sequence.
Comply with the tightening instructions given
in the Operating Instructions, Chapter 8.
82094 0
Ill. 7 End wall cover (non-drive end)

0599 0299 5502-0120 Page 5 of 6
Crankcase
Job Card DEUTZ
W 3-8-1 TBD 616
Page 6 of 6 0299 4313-0120 0599

Engine control
DEUTZ Job Card
TBD 616 W 4-1-1
Removing and installing, checking the camshaft bearings

Tools:
! - Normal tools
- Press-out device 1231 3142
- Two-point measuring instrument
You must replace the camshaft bearings if you notice Aids:

wear and tear after a visual inspection or a measuring - Compressed air
routine.
Spare parts:
- Bearing bush
Cross-references:
- Job Cards W 2-0-1, W 4-5-1, W 4-5-2
Removing the camshaft bearings

● Remove the camshaft,
Checking the camshaft bearings
● Check the bearing bushes for scoring and wear.
Dimensions in mm Nominal dimension Wear limit

Camshaft bushing pressed in,
inner diameter 54.92 - 54.94 55.040
Bearing clearance, camshaft - bearing 0.06 - 0.11 0.15
Table 1 Nominal dimensions

● Fit press-out device 1.
● Withdraw bearing bush 2 from crankcase 3.
Cleaning the components

● After removing scored or worn bearing bushes,
clean all lube oil boreholes very thoroughly, using 3
compressed air if at all possible. 15 26
If chips of metal have got into the lube oil 2
circuit or into the crankcase because of a
rework job at the crankcase or because of a
damaged bearing, the camshaft bearing
Ø 20 + 0,3
bushes (even if they are still in faultless

58,7
54,9
condition) must be removed, and the lube oil

borehole and lobe oil grooves must be
cleaned. We advise pressing in new bearing
bushes after this.
1
80963 0
Ill. 1 Removing the camshaft bearing
0599 0299 4314-0120 Page 1 of 2

Engine control
Job Card DEUTZ
W 4-1-1 TBD 616
Installing the camshaft bearings

Fit the first bearing bush at the non-drive end in such
a way that the distance between the bearing bush
and the outer edge of the crankcase is 7 mm. In all
other bearing positions, fit the bearing bushes centrally
(= flush) into the case walls.
● Fit bearing bush 1 in such a way that the lube oil
borehole 2 is facing downwards 3 towards the oil
pan. The lube oil borehole of the bearing 2 must
coincide precisely with the lube oil borehole in the
crankcase (you can check this with a wire, for
example).
1 2
● Push bearing bush 1 into the case borehole (taking 3
care not to jam bearing bush 1).
● Before pushing bearing bush 1 in fully, remove any
80962 0
chips from the pressing-in process at the outer
lube oil groove. Ill. 2 Lube oil borehole at the camshaft bearing
After installing new bearing bushes, you must
check the inner diameters with a two-point
measuring instrument (see Table 1).
Points to note during installation:
● Install the camshaft,
Page 2 of 2 0299 4314-0120 0599

Engine control
DEUTZ Job Card
TBD 616 W 4-2-1
Removing, installing and checking the lower valve mechanism

Tools:
! - Standard tools
- Tappet lifting device
1218 8097
Spare parts:
- Valve tappets
- Shock absorber rods (if necessary)
Cross-references:
- Job Cards B 1-1-1, W 1-2-2, W 2-0-1,
W␣ 4-5-1, W 4-5-2
Removing the shock absorber rods

● Remove valve lifter 1,
1
● Pull shock absorber rods 2 out upwards.
3
80953 0
Ill. 1 Valve tappets with shock absorber rod
Checking the shock absorber rods

● Check shock absorber rods 2 for eccentricity by
always turning two rods next to each other.
● Check shock absorber rod head 3 and shock
absorber rod foot 4 for wear and damage (cavities,
etc.).
Installing the shock absorber rods

● Carefully insert shock absorber rods 2 from the
top.
● Install valve lifter 1,
0599 0299 4315-0120 Page 1 of 2

Engine contro
Job Card DEUTZ
W 4-2-1 TBD 616
Removing the valve tappets

● Remove valve lifter 1,
Ø=X
● Pull out shock absorber rods 2 upwards.
● Remove the camshaft, 6
Ø=Y
● Take valve tappets 8 downwards out of the
crankcase’s bores.
7
80954 0
Checking the valve tappet Ill. 2 Valve tappets

● Check the valve tappets’ contact surface 5 for
pitting, and inner seat pan 6 for wear; replace if
necessary.
● Check lube oil bores 7 for free passage.
If checking valve tappets 8 reveals any
irregularities, you have to check the camshaft
and the camshaft bearings.
● Measure valve tappet bore X and valve tappet
outer diameter Y.
mm Original state Wear and tear limit
X 20.200...20.221 20.230
Y 20.159 20.180 20.130
When wear and tear limit X has been

reached, please contact your DEUTZ
80955 0
Service contact person.
When wear and tear limit Y has been Ill. 3 Valve tappets in the crankcase
reached, valve tappets 8 have to be
replaced.
Installing the valve tappets

● Insert valve tappets 8 in the crankcase’s bores
and fix them by means of the tappet lifting device
according to Ill. 4.
● Install the camshaft,
● Carefully insert the shock absorber rods from the
top.
● Mount the valve lifter,
● Adjust the valve clearance,
80305 0
Ill. 4 Tappet lifting device

Page 2 of 2 0299 4315-0120 0599
Engine control
DEUTZ Job Card
TBD 616 W 4-5-1
Removing and checking the camshaft

Tools:
! - Standard tools
- Installing and removal mandrel for
camshaft
- Prism/Dial gauge
- Micrometer
Usually it is not necessary to check the camshaft, its - Mounting trestle
bearings and its drive before the major overhaul is - Tappet lifting device 1218 8097
due, unless a check of the valve tappets has revealed
any irregularities. Cross-references:
- Job Card W 1-2-2, W 2-0-1, W 4-1-1,
W 4-2-1, W 4-4-1
Removing the camshaft

● Remove the cylinder head hood.
1
● Removing valve lifter 1,
● Take shock absorber rods 2 out upwards. 3
● Remove end wall cover 13.
● Turn the engine in the mounting trestle so that the
cylinder heads are pointing downwards. 2
The engine has to be brought in this position to
ensure that valve tappets 4 do not fall off.
If you want to remove the camshaft from the 4
dismantled engine, make sure that there is enough
room for the removal procedure.
Room required for: 80953 0
8-cylinder engine 795 mm Ill. 1 Valve tappet with shock absorber rod
12-cylinder engine 1133 mm
16-cylinder engine 1473 mm
● To pull camshaft 6 out of the crankcase, all valve
tappets 4 have to be lifted by means of tappet
lifting devices (see Ill. 2) and secured. Number of
tappet lifting devices = number of cylinders x 2.
80305 0
Ill. 2 Tappet lifting device

0599 0299 4316-0120 Page 1 of 4
Engine control
Job Card DEUTZ
W 4-5-1 TBD 616
● Unscrew fixing screws 5 of the camshaft toothed

gears 7 and take camshaft toothed gears 7 off.
● If there are signs of wear and tear, and if the
camshaft toothed gears’ face clearance is too
large, you must replace the camshaft toothed
gears.
● Measure axial clearance of camshaft 6. When the
wear and tear limit has been reached (see Table 1),
replace guide segment 8.
● Unscrew fixing screws 9 of guide segment 8
through bores 10 of camshaft flange 11 and take
off guide segment 8.
● Attach removal mandrel to camshaft 6, see Ill. 3.
● Carefully pull camshaft 6 out of the crankcase.
● Take valve tappets 4 out of the crankcase. 50698 0
● Check the lower valve mechanism, Ill. 3 Removing device for camshaft
13
12 1
Checking the camshaft bearing
11
● Visually examine the bearing shells of camshaft 6 6
in the crankcase. Worn bearing shells must be
replaced,
see Job Card W 4-1-1. 9
8 7
80961 0
Ill. 4 Mounting the camshaft
Checking the camshaft (camshaft

removed)
● Check the camshaft bearings’ diameter, see Table
1.
● Check guide segment 8 for wear, see Table 1.
● Check guide lug 12 at camshaft nub 11 for wear,
see Table 1.
80960 0
Ill. 5 Guide segment

Page 2 of 4 0299 4316-0120 0599
Engine control
DEUTZ Job Card
TBD 616 W 4-5-1
● Check cams and bearings of camshaft 6 for

scoring. If signs of wear and tear or severe scoring
0 0
are visible on the cam’s edges, replace camshaft
0
6 and valve tappet 4.
● Check radial eccentricity of camshaft 6, see
Table 2 and Ill. 7.
- Use a prism at the last-but-one outer
bearing on each side.
- Measure the radial eccentricity deviation by
means of a dial gauge at all the other
bearings.
0 0
0
80959 0
Ill. 6 Installation marking
Dimensions in mm Nominal size Wear and tear limit

Diameter
Camshaft bearings 54.920 … 54.940 54.860
Axial clearance 0.125 … 0.224 0.265
Radial clearance 0.06 … 0.11 0.205
Wear, guide segment 7.040 … 7.020 7.065
Wear, guide lug at 6.895 … 6.816 6.000
Camshaft nub
Table 1 Tolerances for measuring camshaft 6
Meas. point V8 V12 V16

I 0.04 0.04 0.04
II – 0.02 0.02
IIl 0.02 0.02 0.02
Table 2 Maximum values for the radial eccentricity of camshaft 6
50300 0
Ill. 7 Measuring the camshaft’s radial clearance

0599 0299 4316-0120 Page 3 of 4
Engine control
Job Card DEUTZ
W 4-5-1 TBD 616
Page 4 of 4 0299 4316-0120 0599

Engine control
DEUTZ Job Card
TBD 616 W 4-5-2
Installing the camshaft

Tools:
! - Standard tools
- Removal/installation device for camshaft
Aids:
- Lube oil
Spare parts:
- Camshaft (if necessary)
Cross-references:
- Job Card W 2-0-1, W 4-2-1, W 4-4-1,
W␣ 4-5-3
Installing the camshaft

● Give the components a thorough cleaning.
● Apply a thin film of lube oil to camshaft 6 and the
camshaft bearings.
● Mount installation device, see Ill. 1.
● Carefully feed the installation device with the
camshaft through the bearings, see Ill. 1.
● Fit guide segment 8 and bolt it in place through
bores 10 of hub 11.
● Mount camshaft drive wheels 7; the markings
must correspond, see Ill. 4.
● Install lower valve mechanism,
Follow the Tightening Instructions in 50698 0
accordance with the Assembly Instructions,
Ill. 1 Installation device with camshaft
Job Card W 4-5-3.
80960 0
Ill. 2 Guide segment of the camshaft

0599 0299 4317-0120 Page 1 of 2
Engine control
Job Card DEUTZ
W 4-5-2 TBD 616
13
12 1
11
6
8 7
80961 0
Ill. 3 Mounting the camshaft
0 0
0
0 0
0
80959 0
Ill. 4 Toothed gear markings
Page 2 of 2 0299 4317-0120 0599

Engine control
DEUTZ Job Card
TBD 616 W 4-5-3
Camshaft, installation instructions

Tools:
- Normal tools
- Torque wrench
Aids:
- Screw locking compound Loctite 270
- Oil-proof paint
● After tightening, mark screw with oil-proof paint.


1 M10x50 80 Cylinder-head screws lock with
Loctite 270
2 M8x20 30+5 Cylinder-head screws

0599 0299 4318-0120 Page 1 of 2

Engine control
Job Card DEUTZ
W 4-5-3 TBD 616
2
80942 0
Ill. 1 Camshaft
Page 2 of 2 0299 4318-0120 0599

Governor
DEUTZ Job Card
TBD 616 W 5-3-2
Removing and mounting the electric speed fine adjuster

Tools:
Carry out this work only when the
! - Normal tools
engine has been shut down.
Secure engine against start-up. Aids:
- Lube oil
Removing the electric speed fine

adjuster
● Unscrew cover 1 at the servomotor, detach cable
gland 2, and detach electrical cables, after first
labelling them; remove cable 3.
● Unscrew the four hexagon-head screws 4, and
detach the terminal box together with housing
cover 5.
● After first labelling them, remove cables at
microswitches 6 and take off terminal box with
cover and electrical cables.
● Loosen and unscrew counternuts of the two
setscrews 7.
● Mark the position of lever 8, and unscrew it.
Remove shaft with cam 9 and microswitches in
the direction indicated by the arrow.
● Unscrew the two micro-switches 6.
● Unscrew cap nut 10.
● Unscrew hexagon-head bolts 11 and take off
geared motor. Take the cup springs, the disk and
the driver off the square shaft of the geared motor.
● Unscrew threaded spindle 12 from housing 13.
82623 0
Ill. 1 Cross-sectional view

0199 0299 7356-0120 Page 1 of 2
Governor
Job Card DEUTZ
W 5-3-2 TBD 616
Mounting the electric speed fine

adjuster
● To fit the part in place, proceed in the opposite
sequence.
● Tighten the screw unions until they are handtight.
Before installation, oil threaded spindle 12
thoroughly. When fitting it in place, make
sure you keep to the right configuration for
the cup springs, as shown in Ill. 2.
When you feel resistance when screwing in
cap nut 10, continue screwing it in for approx.
one more turn.
82624 0
Ill. 2 Electric speed fine adjuster
Page 2 of 2 0299 7356-0120 0199

Governor
DEUTZ Job Card
TBD 616 W 5-3-3
Removing and fitting the electric speed fine adjuster

Tools:
! - Normal tools
- Cleaning cloth
Removing the electric speed fine

adjuster
● Disconnect grounding cable at the battery.
● Open cover 1 at terminal box, label electrical
conductors, and disconnect them. Loosen cable
gland 2 and remove cable.
● Unscrew nuts at both ball studs with tie rod socket
3, and take away the threaded rod, allowing for
right-hand and left-hand threads.
● Unscrew nut 13 and remove hexagon-head bolt
14.
● Unhitch tension spring 4.
● Unscrew nuts 5, and take off housing 12 together
with motor 6.
82625 0
● Unscrew the hexagon-head screws 7, and take off
the support. Ill. 1 Terminal box
● Clean all parts.
Fitting the electric speed fine adjuster

● To mount, proceed in the opposite sequence.
The stub bolts with tie rod socket 3 must,
after installation, be coated with lithium-
saponified grease.
0199 0299 7361-0120 Page 1 of 2

Governor
Job Card DEUTZ
W 5-3-3 TBD 616
Adjusting the speed fine adjuster

● Connect grounding cable to the battery.
● Start the engine.
● Unscrew the two setscrews 8 and 9 from the
housing. Bring engine RPM up to maximum
setpoint value and cautiously screw in setscrew 8
until perceptible resistance is encountered, then
turn setscrew + of a turn back, and lock in place.
● Following this adjustment, bring engine RPM to
minimum value, and repeat adjustment procedure
as above.
● Perform a check routine, and make any
correction(s) necessary.
If the distance for the lever 10 is not sufficient
for the upper or lower speed range, you can
change this by turning the threaded rod 11,
allowing for right-hand and left-hand thread
as appropriate.
82626 0
Ill. 2 Electric speed fine adjuster
Page 2 of 2 0299 7361-0120 0199

Governor
DEUTZ Job Card
TBD 616 W 5-3-4
Removing and fitting the manual speed fine adjuster

Tools:
! - Normal tools
- Molykote
- Fuel
- Cleaning cloth
Removing the manual speed fine

adjuster
● Loosen the two hexagonal nuts 1, noting right-
hand and left-hand threads, and unscrew threaded
rod 2.
● Unscrew fixing screws 3, and remove manual
speed fine adjuster 4.
● Remove ball studs with tie-rod sockets 5, and
check for wear and tear. If the ball-and-socket
joints are worn, replace ball studs with tie-rod
sockets 5, noting the appropriate right-hand and
left-hand threads.
● Clean all parts with fuel, and rub them dry with the
cleaning cloth.
82625 0
Fitting the manual speed fine adjuster
Ill. 1 Manual speed fine adjuster
● To mount the speed fine adjuster 4, proceed in the (Normal size on next page)
opposite sequence.
● Coat the ball studs with tie-rod sockets 5 with
lithium-saponified grease, and the threaded
spindle 6 with Molykote.
If the max, setpoint speed is not reached
when the engine is run, you can correct this
by turning threaded rod 2.
0199 0299 7366-0120 Page 1 of 2

Governor
Job Card DEUTZ
W 5-3-4 TBD 616
82626 0
Ill. 1 Manual speed fine adjuster
Page 2 of 2 0299 7366-0120 0199

Governor
DEUTZ Job Card
TBD 616 W 5-3-13
Removing, installing and cleaning the frequency encoder, 1 pc.

An incorrectly adjusted clearance between the Tools:
frequency encoder and the flywheel’s ring gear, plus - Standard tools
metal chips adhering to the frequency encoder’s
permanent magnet will affect how the pulse is passed
to the control electronics. The frequency encoder has
been preset in the factory, and should therefore not
be removed without a compelling reason.
Removing the frequency encoder

● Pull off connector 3.
● Loosen counternuts 2 and manually unscrew
frequency encoder 1.
● Check the frequency encoder for any metal chips
or dirt adhering, and clean it if necessary.
Installing the frequency encoder

● Manually screw in frequency encoder 1 until it fits
flush against a tip of a tooth of ring gear 4 or on the
flywheel’s pulse bump, see Ill. 1.
● To adjust clearance “X”, turn the frequency encoder
back by 270° (3/4 revolution); bore 5 of frequency
encoder 1 must point in or against the sense of
rotation of flywheel 6. 80951 0
● Tighten counternuts 2 Ill. 1 Screwing in until frequency encoder is flush

● Plug in connector 3 in frequency encoder 1.
80952 0
Ill. 2 Clearance X after turning back

0599 0299 4319-0120 Page 1 of 2
Governor
Job Card DEUTZ
W 5-3-13 TBD 616
Page 2 of 2 0299 4319-0120 0599

Exhaus gas system/Charging
DEUTZ Job Card
TBD 616 W 6-1-2
Exhaust gas line, installation instructions

Tools:
- Normal tools
Aids:
- Lube oil
- Oil-proof paint
- High-thermal-stability grease
Ordering No. 1215 1170
● Install seal 1 with bead 2 pointing towards the

cylinder head.
● Coat head supports and screw threads with high-
thermal-stability grease before inserting.
● After tightening, mark screws with oil-proof paint.
82935 0
Ill. 1 Seal
1099 0299 4320-0120 Page 1 of 2

Exhaus gas system/Charging
Job Card DEUTZ
W 6-1-2 TBD 616
II
3 3
III
4 4
80937 1
Ill. 2 Exhaust gas line
I 8-cylinder engine 3 Special disks

II 12-cylinder engine 4 Fixing bores
III 16-cylinder engine
Page 2 of 2 0299 4320-0120 1099

Exhaust gas system / Charging
DEUTZ Job Card
TBD 616 W 6-1-3
Checking liquid-cooled exhaust gas pipes, liquid compartments

An endoscope enables you to check the status of the - Tools:
liquid compartments without having to remove the - Normal tools
liquid-cooled exhaust gas pipe. - Endoscope
Follow the instructions issued by the manufacturer
concerned when handling the endoscope! Aids:
- Collecting vessel for coolant
- Cleaning trough
- Cleaning agent P3-T288, Messrs Hen-
kel Düsseldorf / Germany
Checking the liquid compartments

● Shut down the engine and secure it against starting.
● Drain off coolant into a collecting vessel for sub-
sequent re-use.
● Remove connecting flange 1.
● Connect endoscope, switch on, and insert it
carefully through aperture 2.
● Perform the check routines, using the eyepiece
and the cold light source, making sure you swivel
the endoscope during the procedure.
● When swivelling the endoscope, make sure that
the fibre-optic cable is not damaged.
● If there is clearly visible damage due to cavitation,
exhaust gas pipes 4 must be replaced, as must all 82564 0
seals.
Ill. 1 Liquid-cooled exhaust gas pipes
● If deposits are clearly visible, you must remove
exhaust gas pipes 4.
● Mix together cleaning agent solution in a trough,
following manufacturer’s instructions, and place
exhaust gas pipes 4 into this solution.
● Allow the cleaning agent to act for a few hours,
then rinse exhaust gas pipes through with clear
water.
● Re-install exhaust gas pipes, fit new seals.
● Tighten fixing screw as detailed in the operating
instructions, Chapter 8, Tightening Instructions.
● Install connecting flange 1.
● Refill with the coolant previously drained off.
● Perform a leak check routine while the engine is
running.
82565 0
Ill. 2 Liquid compartments

0199 0299 7371-0120 Page 1 of 2
Job Card DEUTZ
W 6-1-3 TBD 616
82566 0
Ill. 3 Check routine with endoscope
Page 2 of 2 0299 7371-0120 0199

DEUTZ Job Card
TBD 616 W 6-1-4
Solid insulation to/from the exhaust gas turbocharger

Tools:
- Normal tools
- Torque wrench
Cross-references:
- Job Card W 6-1-2
Checking the exhaust gas pipes’ solid

insulation
● Shut down the engine and secure it against starting.
● Allow engine to cool down.
● Check exhaust gas pipes 1 and bends 2 and 3
visually and by feeling them.
● If by feeling you find soft spots in the insulation,
you can continue to operate your engine, but you
will have to perform insulation check routines at
shorter intervals.
● If there are visible signs of disintegration at the
insulation, then the part concerned in each case
(exhaust gas pipe 1 or bend(s) 2 and 3 must be
completely replaced.
82561 0
● When installing new parts, you must always fit
new seals as well. Ill. 1 Exhaust gas pipe and bends
Please comply with the installation
instructions, see Job Card W 6-1-2.
82562 0
Ill. 2 Exhaust gas pipe, 16-cylinder engine

0199 0299 7376-0120 Page 1 of 2
Job Card DEUTZ
W 6-1-4 TBD 616
Page 2 of 2 0299 7376-0120 0199

Exhaust gas system/Charging
DEUTZ Job Card
TBD 616 W 6-4-3
Cleaning the intercooler (water and air sides)

If only minor soiling is involved, the water side can be Tools:
cleaned without removing the intercooler. If the soiling - Normal tools
concerned is severe, however, you will have to remove - Lifting tackle
the intercooler. Replace all seals, round sealing rings - Round plastic brush
and spring washers. - Wooden rod
Aids:
- Cleaning agent
- Neutralizing agent
Spare parts:
- Seals and spring washers
Cross-references:
- Job Card W 9-0-1
- Operating Instructions, Chapter 4
Cleanign the water side of the

intercooler (still mounted)
● Drain the engine, see Job Card W 9-0-1.
● Close off all the surrounding engine apertures.
● Cover up any parts sensitive to water.
● Remove coolant lines to the intercooler.
● Remove covers 1 and 3.
● Clean the inside (cooler insert 2) with a brush or a
wooden rod, and blow it out with compressed air.
● After cleaning, fit the covers.
● Fit coolant lines.
● Fill up with coolant, see Operating Instructions,
Chapter 4.
● Vent the coolant circuit.
Removing the intercooler

● Drain the engine, see Job Card W 9-0-1.
● Remove the intercooler’s built-on components.
● Detach the intercooler’s mounting parts.
● Carefully take off the intercooler, and pour out the
remaining water.
1 4
80956 0
Ill. 1 Intercooler
0599 0299 4321-0120 Page 1 of 4
Job Card DEUTZ
W 6-4-3 TBD 616
Cleaning the intercooler’s water side

(intercooler removed) 2 1 5
Mechanical cleaning
● Soft deposits:
Push through the cooler tubes with a round plastic
brush, and then rinse them through with a powerful
jet of water.
● Solid deposits in the tubes:
Do NOT drill them out. You MUST use a chemical
cleaning routine.
● Clean the closure covers.
Chemical cleaning
See the next section for cleaning agents.
3 4
Pump a cleaning agent solution through the removed 80252 0
intercooler (with closure covers fitted).
Ill. 2 Chemical cleaning
Items in Ill. 2:
1 Tube inner diameter Ø 1"
2 Recirculation pump
3 Container 0.5 - 1 m3
4 Heater, 5 kW
5 Intercooler
Make sure that the cleaning container 3 is
located higher than the cooler, so that when
the pump is switched off the cooler does not
run empty and stand dry.
Chemical cleaning agents
The agents used are pulverized acids on a sulphamic
basis, strongly inhibited so as to avoid corrosion of
the metal parts:
“Porodox“
Messrs. Collardin GmbH Concentration: 2 - 10 %
Widdersdorfer Straße 215 Temperature: 20 - 60 °C
Treatment time: max. 16
hours
D-50825 Cologne
Drew’s “SAF-Acid“ (lime remover only)
Messrs. Drew Chemical GmbH Concentration: 5%
Börsenbrücke 4 Temperature: max. 75°C
min. 55°C
D-20457 Hamburg
“P3 - T1166“
Messrs. Henkel & Cie GmbH Follow manufacturer’s
P.O. Box 1100 treatment instructions
D-40002 Düsseldorf
Neutralizinh Agent “P3-croni“
Messrs. Henkel & Cie GmbH Follow manufacturer’s
Postfach 1100 treatment instructions
D-40002 Düsseldorf
Page 2 of 4 0299 4321-0120 0599

DEUTZ Job Card
TBD 616 W 6-4-3
Comply with the safety instructions!

Use protective goggles, rubber or plastic
gloves, and acid-proof protective clothing!
The intercooler must NEVER be cleaned
with hydrochloric acid.
After use, neutralize the cleaning agent
solution with caustic soda (environmental
protection).
After cleaning, a weakly alkaline solution
(caustic soda) must be circulated through
the cooler, or at least left to stand in it for
not less than one hour. On ships, rinsing
with raw water overboard is not permitted.
Check tube bottoms and closure covers for
wash-outs, and rework if necessary. Fill in the
damaged area with a commercially available
corrosion-proof two-component filler (e.g. Belzona
from Messrs. Molecular Conservation Ltd., Clare
Road, Harrogate/Yorkshire, England, represented in
Germany by F. Wolfgang Bastian,
Rothenbaumchaussee 185, D-20149 Hamburg). Af-
ter hardening, level out the surface of the tube bottom.
Leaking tubes must in emergencies be closed up with
a slightly conical plug made of a corrosion-resistant
materials (e.g. CuNi or GSnBz).
0599 0299 4321-0120 Page 3 of 4

Job Card DEUTZ
W 6-4-3 TBD 616
Cleaning the intercooler’s air side

● Place cooler block in a trough (see Ill. 3 for fill level).
● Use a cleaning agent solution to soak off the dirt.
The following cleaning agents can be used:
“ACC9“
Messrs. Drew Chemical GmbH
Borsenbrücke 4
D-20457 Hamburg
“Vecom B85“
Messrs. VECOM GmbH
Schlenzigstr. 7
D-21107 Hamburg
“P3T-5308“
Messrs. Henkel & Cie GmbH
P.O. Box 1100
D-40002 Düsseldorf
50687 0
Ill. 3 Air-side cleaning
Follow the manufacturers’ instructions.
The soaking time will depend on the degree of soiling

involved. Then rinse the cooler block thoroughly with
fresh water. Clean any corroded baffle plates, frames
or internals, and coat them with a heat-resistant
(approx. 200 °C) zinc dust paint.
The best cleaning results will be obtained using an
ultra-sonic cleaning unit. Follow the instructions and
specifications given by the manufacturers of the
ultra-sonic troughs.
Fitting the intercooler

● Place the intercooler carefully in position.
● Fit the intercooler mounting parts.
● Mount the intercooler’s built-on components.
● Fill up with coolant, see Operating Instructions,
Chapter 4.
● Vent the coolant circuit.
Page 4 of 4 0299 4321-0120 0599

DEUTZ Job Card
TBD 616 W 6-4-5
Checking the intercooler on the air side

Tools:
! - Normal tools
- Charging pressure gauge
Secure engine against start-up.
Cross-references:
- Job Card W 6-4-3
● Shut down the engine.

● Install a charging pressure gauge downstream of
the intercooler, and restart your engine.
● Run engine at full load.
● Read off the figure at the charging pressure gauge
and compare it with the figure given in the
commissioning report and the value given in the
test-rig report.
● If the figure you have read off is approx. 100 mbar
lower, a cleaning procedure must be performed.
● Clean intercooler,
● Remove the charging pressure gauge after the
0199 0299 7381-0120 Page 1 of 2

Job Card DEUTZ
W 6-4-5 TBD 616
Page 2 of 2 0299 7381-0120 0199

DEUTZ Job Card
TBD 616 W 6-5-1
Checking the waste gate valve function

Tools:
- Normal tools
- Pressure reducing valve
Aids:
- Compressed-air system
Checking the waste gate valve function

● Remove hose line 8.
● Unscrew the three hexagon-socket screws 2 and
take off the charging pressure control valve 5 with
flat seal 1.
● At a compressed-air system, fit a pressure reducing
valve, and feed in compressed air.
● Set the pressure reducing valve to 2.5 bar, and
shut off the compressed air.
● Remove pressure hose 8 from the charging
pressure control valve.
● Connect charging pressure control valve 5 to
connection 3 with the pressure reducing valve.
● Feed compressed air into the charging pressure 82134 0
control valve 5 at the pressure preset at the
pressure reducing valve (2.5 bar). Ill. 1 Installing the idling control valve
● The adjustment dimension 6 between the flange
surface of the heat sink and the bottom edge of the
valve cone 7 must be 35.5 +- 0.1 mm. If adjustment
dimension 6 is not correct, you can correct this at
set screw 4.
If it is not possible to correct the setting
dimension, or if there are traces of corrosion
at valve stem 9, then you must replace the
charging pressure control valve 5.
82933 0
Ill. 2 Valve stem
1099 0299 6806-0120 Page 1 of 2

Job Card DEUTZ
W 6-5-1 TBD 616
● After you have made the correction, lock set

screw 4 in place with the counternut provided.
● Shut off the compressed air. Caution: risk of injury!
● Remove all parts from the compressed-air system.
● Clean valve seat and valve cone 7.
● Fit charging pressure control valve 5 in place with
a new seal 1. Tighten fixing screws 2 with 8.5 Nm.
● Fit pressure hose 8 to charging pressure control
valve.
After the charging pressure control valve 5
has been replaced, the charging pressure
must be fine-tuned during the first trial run.
Table 1 shows what charging pressure must
be set under what conditions.
82133 0
Ill. 3 Idling control valve

Cyl.- Propeller curve RPM Charging pressure
Number Load in % in min-1 in mbar
+30
12 100 2.165 1.850
+30
120 2.300 2.350
+30
16 100 2.165 1.950
+30
120 2.300 2.450
Tab. 1
The figures in mbar above must not be

exceeded, since otherwise the turbocharger
may be destroyed.
Page 2 of 2 0299 6806-0120 1099

DEUTZ Job Card
TBD 616 W 6-6-3
Replacing the woven-mat insulation at the exhaust gas turbocharger

Tools:
! Danger of burst! - Normal tools
Replacing the woven mats

● Shut down the engine and allow it to cool down.
● Disengage the two tension springs 1 and remove
the old woven mat 2.
● Remove residues of woven material from the
exhaust gas turbocharger.
● Fit new woven mat 2 and re-engage the two
tension springs 1 into the eyelets provided for this
purpose.
82559 0
Ill. 1 Woven mats fitted
82560 0
Ill. 2 Woven mats removed

0199 0299 7386-0120 Page 1 of 2
Job Card DEUTZ
W 6-6-3 TBD 616
Page 2 of 2 0299 7386-0120 0199

Fuel system
DEUTZ Job Card
- TBD 616 W 7-3-1
Removing and installing the injection lines

Tools:
- Normal tools
- Box spanner insert for injection lines
0704 1395
Aids:
- Cleaning cloth
Cross-references:
Removing the injection lines

● Shut down engine.
● Push rubber seals 1 upwards onto injection lines␣ 2.
● Unscrew screws 3 and take off bushings 4.
● Use box spanner, Ill. 3, to unscrew the screwed
unions at injection pump and injection valves.
Collecting any fuel exiting and make sure
everything is meticulously clean.
● Note down the assignment of line bundles 5
leading from injection pump to the injection valves.
● Remove complete line bundles 5 and dispose of
them.
Installing the injection lines 82543 0
● Fit new rubber seals 1 onto injection lines 2. Ill. 1 Injection lines
● Fit new line bundles 5 in the configuration you
have previously noted down.
● Tighten the line bundles’ screwed unions until
they are handtight, then tighten them properly
with the box spanner (Ill. 3), following the operating
instructions, Chapter 8, Tightening Instructions.
● Fit bushings 4 and tighten screws 3 until they are
handtight.
● Check all screwed unions of the injection lines at
injection pump and injection valves for leaks while
the engine is running.
● Insert rubber seals 1 into cylinder head hoods 6.
82544 0
Ill. 2 Supports for injection lines
0199 0299 7391-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-3-1 TBD 616
82545 0
Ill. 3 Box spanner
Page 2 of 2 0299 7391-0120 0199

Fuel system
DEUTZ Job Card
TBD 616 W 7-3-3
Checking the injection lines

Frequent removal, refitting and tightening of injection Tools:
lines 2 may cause deformations at cones 1 of the - Normal tools
injection lines 2, and thus result in leaks.
Aids:
- Compressed air
Comply with the tightening instructions - Ball ø 2 mm
given in the Operating Manual, - Cleaning cloth
Cross-references:
- Job Card W 7-3-1
- Operating Instructions, Chapter 8
“Tightening Instructions”
Checking the injection lines

● While the engine is running, check all the screw
connections of the injection lines at the injection
pump and injection valves for leaks. Use paint to
mark any screw connections which cannot be
rendered leakproof by retightening, and any bent
or otherwise damaged injection lines.
● Remove the complete line bundles, without
detaching the mounting brackets,
Collect any fuel escaping.
Make sure everything is meticulously clean.
● Use compressed air to blow a 2-mm-diameter ball
through the lines. Use paint to mark any injection 82156 0
lines where the ball does not pass through without
any resistance. Ill. 1 Injection lines
● Fit all line bundles back in place, tighten screw

connections by hand, and then finish tightening
them as detailed in the Operating Instructions.
Chapter 8, “Tightening Instructions.
● Detach the mounting brackets, and replace the
paint-marked lines. Then fit the mounting brackets
back in place.
● Tighten the screw connections as detailed in the
Operating Instructions, Chapter 8, “Tightening
Instructions”.
● While the engine is running, check all screw
connections of the injection lines at the injection
pump and injection valves for leaks.
0599 0299 6811-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-3-3 TBD 616
Page 2 of 2 0299 6811-0120 0599

Fuel system
DEUTZ Job Card
- TBD 616 W 7-3-5
Replacing the non-return valve in the leakage fuel line

Tools:
- Normal tools
Aids:
- Collecting trough
- Cleaning cloth
Removing the non-return valve

● Close the fuel shut-off valve.
● Unscrew hollow screw 1, collect any fuel exiting.
● If the non-return valve has been installed in a
vertical position, unscrew hollow screw 2, remove
sealing rings 3 and flexible lines 4, collecting any
fuel exiting.
● If the non-return valve has been installed in a
horizontal position, unscrew fuel line 5 and collect
any fuel exiting.
● Swivel support 6 upwards and unscrew non-
return valve 7.
82541 0
Ill. 1 Vertical position
Installing the non-return valve

● Screw in non-return valve 7 with new sealing ring
until it is handtight.
● Tighten fuel line 5 until it is handtight.
● Install flexible lines 4 using new sealing rings 3,
screw in hollow screws 1 and 2 until they are
handtight.
82542 0
Ill. 2 Horizontal position

0199 0299 7396-0120 Page 1 of 2
Fuel system
Job Card DEUTZ
W 7-3-5 TBD 616
Page 2 of 2 0299 7396-0120 0199

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-6
Removing and installing the injection pump and the coupling,

8- and 12-cyl.
Tools:
- Normal tools
- Pull-off device
Aids:
- Petroleum ether
- Safety cleaner MR 77
Messrs. MR-Chemie GmbH
D-59427 Unna-Massen
- Lube oil
Cross-references:
- Job Cards W 7-6-1, W 7-4-9, W 7-4-10
Removing the injection pump and the

curved-teeth coupling
● Remove fuel and lube oil lines.
● Unscrew unions 1 and 2.
● Unscrew fixing screws 3 of the injection pump,
and lift off the injection pump.
Be careful with the injection pump’s locating
sleeves.
● Unscrew hexagonal nuts 4, and use the pull-off
device to take off coupling halves 5. Remember to
mark all the coupling halves and their respective
cones for subsequent identification. Get all the
lube grease off the coupling parts, and clean them
thoroughly with petroleum ether.
82065 0
If there is a defect at the injection pump or the
curved-teeth coupling, have it corrected by Ill. 1 Curved-teeth coupling, 12-cylinder engine
DEUTZ Service.
82066 0
Ill. 2 Curved-teeth coupling, 8-cylinder engine
0599 0299 4322-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-4-6 TBD 616
Installing the injection pump and the

● Degrease coupling halves and shaft cone at the
connecting surfaces, and spray them all round
with safety cleaner MR 77; then allow them to dry.
● Fit the marked coupling halves with ring 6 onto the
shaft concerned in such a way that the end-face
hub line marking “X“ coincides with the middle of
the shaft groove or shaft marking.
● Tighten hexagonal nuts 4, making sure that the
coupling halves do not get twisted when you are
tightening the nuts.
● Lift the injection pump into the crankcase saddle
(V-space) and install coupling intermediate piece 7
between the coupling halves 5 in such a way that
82067 0
the “Y” markings facing upwards coincide.
Ill. 3 Injection pump mounting
● Secure injection pump in the crankcase saddle
with 4 screws, making sure the locating sleeves
are correctly positioned.
● Tighten screw connections 1 and 2 after first
having adjusted delivery commencement, see Job
Card W 7-6-1.
● Fit fuel and lube oil lines, plus intake pipes.
● Fill the curved-teeth coupling with the right amount
of grease, see Job Card W 7-4-9.
Follow the tightening instructions as given in
the Installation Instructions, Job Card
W␣ 7-4-10.
In the case of a new or repaired injection
pump, fill the injection pump with oil before
commissioning or a trial run on a test rig. See
Table 1 for the quantity of oil involved.
82068 0
Ill. 4 Marking for 12-cylinder engines
RP21
with built-on without
mechanical governor governor
V8 0.95 dm3 --
3
V12 1.3 dm --
RP25
with built-on with electronic
mechanical governor governor
V8 1.2 dm3 0.5 dm3
V12 1.7 dm3 0.9 dm3
Table 1 Oil filling quantity for injection pump
82069 0
Ill. 5 Marking for 8-cylinder engine
Page 2 of 2 0299 4322-0120 0599

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-6
Removing and installing the injection pump and coupling, 16-cyl.
Tools:
- Normal tools
- Pull-off device
Aids:
- Petroleum ether
Messrs MR-Chemie GmbH
D-59427 Unna-Massen
- Lube oil
Cross-references:
- Job Cards W 7-6-1, W 7-4-9, W 7-4-10
Removing injection pumps and curved-

teeth couplings
● Remove fuel and lube oil lines.
● Unscrew unions 1, 2 and 3.
● Loosen circlip 4, and together with sleeve 5 push
as far as it will go in the direction of the arrow.
● Loosen counternuts 6 (N.B.! right and left-handed
threads), and unscrew screw piece 7.
● Unscrew fixing screws 8 of the two injection
pumps, and (as shown on Ill. 7) use the suspension
device to lift off the combined injection pump
assembly.
Be careful with the injection pump’s locating
sleeves.
82106 0
● Unscrew hexagonal nut 9, and use the pull-off Ill. 1 Curved-teeth coupling
device to take off coupling halves 10. Remember
to mark all the coupling halves and their respective
cones for subsequent identification.
● Get all the lube grease off the coupling parts, and
clean them thoroughly with petroleum ether.
If there is a defect at the injection pumps,
have it corrected by DEUTZ Service.
82107 0
0599 0299 4323-0120 Page 1 of 4

Fuel system
Job Card DEUTZ
W 7-4-6 TBD 616
When replacing an injection pump

● If one of the two injection pumps is defective, then
in order to achieve equality between the two
injection pumps, the still-intact injection pump
must be measured on a pump test station at a
defined speed and control travel.
● The replacement injection pump must be precisely
adjusted to the value previously measured; see
also the values in the Bosch Test Sheet.
● Make sure delivery is equal at low idling speed.
pump, fill the injection pump with oil before
commissioning or a trial run on a test rig. See
Table 1 for the quantity of oil involved.
82108 0
Ill. 3 Control rod connection
Installing the injection pumps and the

curved-teeth couplings
● Fit the marked 4 coupling halves with ring 12 onto
the shaft concerned in such a way that the end-
face hub line marking “X“ coincides with the middle
of the shaft groove or shaft marking.
● Lift injection pump I into the crankcase saddle (V-
space) and install coupling intermediate piece 11
between the coupling halves 10 in such a way that
82109 0
the “Y” markings facing upwards coincide.
Ill. 4 Markings
● Secure injection pump I in the crankcase saddle
with 4 screws 8, making sure the locating sleeves
● Lift injection pump II into the crankcase saddle,
and install coupling intermediate piece 16 between
the coupling halves 10 in such a way that the “Y”
markings facing upwards coincide. Line markings
“X“ will then be 45° offset from each other.
● Secure injection pump II in the crankcase saddle
● Tighten screw connections 1, 2 and 3 after first
having adjusted delivery commencement, see Job
Card W 7-6-1.
82110 0
Ill. 5 Measuring device

Page 2 of 4 0299 4323-0120 0599
Fuel system
DEUTZ Job Card
TBD 616 W 7-4-6
Installing the control rod connection

● Unscrew the screw plug 13 at injection pump I,
and fit the measuring device and dial gauge from
Messrs. Bosch. The probe of the dial gauge must
be screwed into the control rod.
● Set control rod to “Stop” and dial gauge to zero.
● Screw in screw piece 7 one thread turn into the
joint piece 14. N.B.! Right and left-hand threads.
Screw in screw piece 7 into joint piece 15 until
control travel zero has been reached on dial gauge
18. The complete control travel must measure 21
mm. Remove measuring device 17 and dial gauge
18, and screw in screw plug 13.
● Tighten counternuts 6.
● Coat joint pieces and sealing rings 19 with a thin 82111 0
film of grease, and push sleeve 5 as far as it will go
against the circlip. Insert circlip 4 in the groove. Ill. 6 Screw plug for control rod
● Fit fuel and lube oil lines, plus the intake pipes.
of grease, Job Card W 7-4-9.
W␣ 7-4-10.
82061 0
Ill. 7 Suspension device
RP21 RP25
with built-on without with built-on with electronic
mechanical governor governor mechanical governor governor
with without both
V16 0.5 dm3 0.5 dm3 governor governor pumps
1.2 dm3 0.5 dm3 0.5 dm3
Table 1 Oil filling quantity for injection pump
0599 0299 4323-0120 Page 3 of 4

Fuel system
Job Card DEUTZ
W 7-4-6 TBD 616
Page 4 of 4 0299 4323-0120 0599

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-7
Removing and installing the injection pump drive

Tools:
- Normal tools
- Suspension device
- Pull-off device
- Grease gun
Aids:
- Fuel
- Liquid sealing compound DEUTZ-DW␣ 47
Cross-references:
- Job Cards W 3-8-1, W 7-6-1, W 7-4-10
Removing the injection pump drive

● Remove the end wall cover at the non-drive end,
● Turn the engine until all gear wheel markings in the
gear train are opposite each other. Unscrew all
hexagonal nuts 3, and take off screws 4; make a
note of marking 5.
● Remove fuel pressure lines and lube oil feed and
return lines of the injection pump. Unscrew the
fixing screws of the injection pump, and lift off the
injection pump.
● Secure the engine, and unscrew hexagonal nut 6.
● Remove coupling half 7, using the pull-off device.
● Unscrew hexagon-head screws 8, take off washer
9 and gear wheel 10. 82060 0
● Unscrew hexagonal nuts 11, and lift off the injection Ill. 1 Curved-teeth coupling,
pump drive. 12- and 16-cylinder engine
Installing the injection pump drive

● Replace round sealing ring 12, and fit it on the
injection pump drive, after first coating it with
lithium-saponified grease.
● In the area around the hexagonal nuts (area “X”),
coat the injection pump drive with liquid sealing
compound DEUTZ-DW 47, and screw it to the
cover plates 13.
● Mount gear wheel 10 and washer 9, making sure
that the gear wheel markings and position marking
14 coincide.
82061 0
0599 0299 4324-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-4-7 TBD 616
● To prevent the tapered-roller bearings running dry

when the engine is started up, fill compartments
“Y” with lube oil.
● Degrease all the surfaces marked with an “*”.
● Place coupling half 7 on the shaft cone in such a
way that the end -face hub line marking coincides
with shaft line marking 15.
● Tighten hexagonal nut 6, making sure that the line
markings 15 do not become offset.
● The rest of the installation procedure is as described
above, but of course in the reverse sequence.
When installing, set the same values as you
noted down previously during removal.
● Check delivery commencement,
see Job Card W 7-6-1. 82062 0
Follow tightening Instructions as per Installa- Ill. 3 Injection pump drive

tion Instructions, Job Card W 7-4-10.
82063 0
Ill. 4 Adjustment markings
4 15
5 6
7
* 82064 0

Page 2 of 2 0299 4324-0120 0599
Fuel system
DEUTZ Job Card
TBD 616 W 7-4-8
Repairing the injection pump drive

Tools:
- Normal tools
- Pull-off device
Aids:
- Fuel
- Loctite
- Liquid nitrogen
- Lube oil
- Oil bath
Spare parts:
- Tapered-roller bearing
- O-ring
- Radial sealing ring
Cross-references:
- Job Cards W 7-6-1, W 7-4-10
Removing the injection pump drive

● Unscrew cylinder-head screw 1 and clamp nut 2.
● Unscrew hexagon-head screws 3, and take off
cover plate 4.
● At the “F” surfaces, support the injection pump
drive on a hand press, and press shaft 5 out of the
housing in the direction indicated by the arrow.
● Remove circlip 6 and supporting ring 7; remove
ring 8 with O-ring 10.
● Use the pull-off device to remove radial sealing
ring 9, take away inner ring 11 of the tapered-roller
bearing, and remove outer ring 12 as well.
● Use the pull-off device to remove inner and outer
rings 14 and 13 from the housing and the shaft
respectively.
● Clean all parts in fuel.
● Check all parts for wear and tear, replace if
necessary.
In any case, always replace the tapered-roller
82059 0
bearing, the O-ring and the radial sealing ring.
Ill. 1 Injection pump drive
0599 0299 4325-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-4-8 TBD 616
Mounting the injection pump drive

● Fit circlip 6 and supporting ring 7 in the housing.
● Use the hand press to press the outer rings of the
tapered-roller bearings into the housing as far as
they will go, in the sequence first 12, then 13.
To make things easier, press in the outer rings
with liquid nitrogen.
● Fit inner ring 14 on shaft 5; to facilitate this, heat up
inner ring 14 to 150 °C.
● Place shaft 5 on the hand press, and fit the housing.
Use a pipe to press inner ring 11 (likewise heated
up to 150° C) onto shaft 5. The axial clearance
must be 1 - 2 mm.
● Use a suitable pipe to press radial sealing ring 9
into the housing, taking care not to jam it.
● Lightly grease radial sealing ring 9 and O-ring 9;
install O-ring 10 and ring 8 as far as they will go.
● Screw in clamp nut 2, and while continually turning
the bearings tighten it until an axial clearance of
0.01 to 0.05 mm has been achieved.
● Coat clamp nut 2 and cylinder-head screw 1 with
Loctite, and secure in place.
● The cover plate 4 must be coated with liquid
sealing compound DEUTZ-DW 47 in the area
where it comes into contact with the housing, and
then mounted.
Following the tightening instructions given in
W␣ 7-4-10.
To avoid the tapered-roller bearings running
dry when the engine is started up, fill the
compartments of the housing with approx.
2␣ cm3 of lube oil.
Page 2 of 2 0299 4325-0120 0599

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-9
Checking the curved-teeth coupling, and inserting a new grease filling

Tools:
- Normal tools
- Pull-off device 1231 3276
- 4 cylinder head screws
DIN 912 M6x65 - 12.9
- Grease gun
Aids:
- Lube greases as per Table 1
- Petroleum ether
Messrs. MR-Chemie GmbH
D- 59427 Unna-Massen
Cross-references:
- Job Cards W 7-6-1, W 7-4-6, W 7-4-10
Checking the curved-teeth coupling

● Remove injection pump and curved-teeth
coupling, see Job Card W 7-4-6.
● Mark curved-teeth coupling for identification before
removing it.
● Dismantle the curved-teeth coupling, and clean
all the parts with petroleum ether.
● If you find any signs of wear at the toothing 1,
replace the curved-teeth coupling concerned.
● Fit new seal 2. Degrease coupling halves and shaft
cone at the connecting surfaces, spray them all
the way round with safety cleaner, and allow them
to dry. Coat toothing with grease, and mount
coupling pieces (see identification markings).
● Install injection pump and curved-teeth coupling, 82104 0
see Job Card W 7-4-6. Ill. 1 Curved-teeth coupling,

● Adjust delivery commencement, 12- and 16-cylinder engines
Installation Instructions, Job Card W 7-4-10.
82105 0
0599 0299 5843-0120 Page 1 of 4

Fuel system
Job Card DEUTZ
W 7-4-9 TBD 616
● Unscrew the two cylinder head screws 3 of the

curved teeth coupling, located opposite each other,
and press in lube grease from the products listed
below into one of the filling apertures.
● After filling, screw the cylinder head screws 3 back
in.
82070 0
Ill. 3 Cylinder-head screw for grease filling

3
Lubricant quantity in dm
For injection No. of Curved teeth coupling Curved teeth coupling Curved teeth coupling
pump cylinders with marking* without marking* between the
Engine end Pump end injection pumps
RP 21 V8 – – 0.10 –
RP 21 V 12 0.10 0.09 0.50 –
RP 21 V 16 0.10 0.09 0.45 0.2
For injection No. of Curved teeth coupling Curved teeth coupling Curved teeth coupling
pump cylinders with marking* without marking* between the
Engine end Pump end injection pumps
RP 25 V 12 0.09 0.085 0.50 –

RP 25 V 16 0.09 0.085 0.45 0.2
* Marking for the smaller lubricant quantity, see Ill. 4

1 Engine end
2 Injection pump end
3 Marking groove for smaller lubricant quantity
4 Cover for smaller lubricant quantity
82168 0
Ill. 4 Curved teeth coupling with smaller grease filling

Page 2 of 4 0299 4326-0120 0599
Fuel system
DEUTZ Job Card
TBD 616 W 7-4-9
Lube greases for curved-teeth coupling

Lube greases for the temperature range from -20 °C to +80 °C.
You can also use lube greases (suitable for extreme pressure stresses with EP additives) from other brand-
name manufacturers.
We recommend lube greases to DIN 51825 of the consistency code 2K (usable up to 120°C). Never use
any greases with a solids content of higher than 3 %.
The mixability of lube greases can be determined from Table 2.
AGIP AGIP GR MU/EP 1

AGIP GR SLL
ARAL Aralub FDP 0
BP BP Energrease MM-EPO
BP Energrease LS-EPO 0
CASTROL Spheerol EPL 1
Spheerol EPL 2
CHEVRON Chevron Dura-Lith Grease EP O
ESSO Fliessfett S420
EP GREASE 350
FIBRAX EP 370
BEACON EP 1
FINA MARSON EPL 1
KLÜBER Lubrication Structovis BHD MF
GRAFLOSCON C SG 0
COSTRAK GL 1501
MOBIL Mobilplex 44
Mobiltemp SHC 460 Spezial
Sovarex Grease L1
Shell Shell Tiveal Compound A
Shell Alvania EP Fett 1
DEA Glissando EPO
TACKE TACKE - Longlife Grease for 25000 operating hours or 5 years
Wintershall Wiolub LFP 0
Elf Elf EPEXA 2
AVIA AVIANAT OEP AVIALUB Spezialfett 923
UK-Mineralölwerke
Wenzel und Weidmann GmbH UK-ECULIT B310
Table 1 Lube greases
0599 0299 5843-0120 Page 3 of 4

Fuel system
Job Card DEUTZ
W 7-4-9 TBD 616
Mixability of lube greases
Thickening- Ca-soap Ca-complex-Li-soap Na-soap Gels 1) Ba-complex- A1-complex-

agent (water-free) Soap Soap Soap
Ca-soap
(water-free) ✔ ✔ ✘ ✔ ✔ ✘
Ca-complex-
Seife ✔ ✔ ✘ ✔ ✔ ✘
Li-soap ✔ ✔ ✘ ✔ ✔ ✘
Na-soap ✔ ✔ ✔ ✔ ✔ ✘
Gels 1) ✔ ✔ ✔ ✔ ✔ ✘
Ba-complex-
Seife ✔ ✔ ✔ ✔ ✔ ✔
A1-complex-
Soap ✘ ✘ ✘ ✘ ✘ ✔
Ureas ✔ ✔ ✔ ✔ ✔ ✔ ✔
Table 2 Mixability
1)
Bentonite, silica gel
✔: mixable ✘: not mixable
Page 4 of 4 0299 4326-0120 0599

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-10
Injection pump mounting and drive, installation instructions

Tools:
- Normal tools
- Torque wrench
Aids:
- Oil-proof paint
Cross-references:
- Job Card W 7-4-6, W 7-4-9
● Fill with lube oil for injection pump,

● Insert grease for curved-teeth coupling, see Job
Card W 7-4-9.

1 In the vicinity of cylinder-head screws M12, seal intermediate flange and housing with liquid sealing
compound DEUTZ DW 47.
3 M10x35 67 Hexagona-head screws
4 M14x1.5 20+5 Hexagonal nuts
5 110+10 Pressure pipe connection at
injection pump RP21 and RP25
M10x100 10.9 25+5 Cylinder-head bolts
7 RP21:
M24x1,5 400+10 Hexagonal nuts
RP25:
M20x1.5 300+10 Hexagonal nuts
8 M24x1,5 400+10 Hexagonal nuts
9 M10x35 10.9 80 Cylinder-head screws

0599 0299 4327-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-4-10 TBD 616
2 3 3 4
8 7
80941 0
Ill. 1 Injection pump mounting and drive
Page 2 of 2 0299 4327-0120 0599

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-11
Removing and installing the injection pump and the multi-disk clutch,
8␣ cyl.
Tools:
- Normal tools
- Pull-off device
Aids:
- White gasoline
Messr MR-Chemie GmbH
D-59427 Unna-Massen
- Lube oil
Cross-references:
- Job Card W 7-6-1, W 7-4-10

multi-disk clutch
● Detach fuel and lube oil lines.
● Unscrew screw union 1 and take off segments 2.
● Unscrew fixing screws 3 of injection pump 4.
● Lift off injection pump 4 with clutch half 5 and take
off shim rings 6.
Be careful with the locating sleeves of the
injection pump.
82523 0
Ill. 1 Clutch
82524 0

0299 0299 7226-0120 Page 1 of 4
Fuel system
Job Card DEUTZ
W 7-4-11 TBD 616
● Unscrew hexagonal nuts 7 and 8.

● Use the pull-off device 10 to pull off clutch halves
5 and 9.
● Give the clutch halves a thorough cleaning with
white gasoline.
● Visually inspect disks 11: if any of them are
deformed, you have to replace the entire clutch.
Defective injection pumps may be repaired
ONLY by DEUTZ Service.
82525 0
Ill. 3 Clutch half at injection pump
82526 0
Ill. 4 Shim rings

multi-disk clutch
● Degrease clutch halves and shaft cone at the
connecting surfaces, and spray all round with
safety cleaner MR 77. Then allow to dry.
● Fit clutch half 9 onto the shaft in such a way that
the front-end line marking coincides with shaft
marking 12.
the front-end line marking is pointing to the centre
of groove 13.
● Tighten hexagonal nuts 7 and 8,* make sure when
tightening the nuts that the clutch halves to not
become distorted.
82527 0
Ill. 5 Clutch half, engine end

Page 2 of 4 0299 7226-0120 0299
Fuel system
DEUTZ Job Card
TBD 616 W 7-4-11
82528 0
Ill. 6 Pull-off device
82529 0
Ill. 7 Marking
● Install injection pump 4 with clutch half 5 without

shim rings 6: injection pump 4 is fixed in position
by means of locating sleeves.
● Lightly screw in fixing screws 3.
● Put together shim rings 6, and (as shown in Ill. 9)
push them into spacer slot 14. Increase the number
of shim rings 6 until they can be snugly moved in
spacer slot 14.
● Remove injection pump 4, degrease shim rings 6
and fit as shown in Ill. 4.
82530 0
Ill. 8 Marking
0299 0299 7226-0120 Page 3 of 4

Fuel system
Job Card DEUTZ
W 7-4-11 TBD 616
● Fit injection pump 4 as described above; markings

15 must be aligned on each other as shown in
Ill.␣ 10.
● Fit segments 2 and screw in hexagon-head
screws␣ 1:
Strength: Tightening torque:
8.8 87 Nm
10.9 117 Nm
● Tighten cylinder-head screws 3 *.
● Attach fuel and lube oil lines *.
* Follow tightening instructions as per installation
pump, before starting up or running on the
test rig, fill the injection pump with lube oil. 82531 0
See Table 1 for fill quantity.
Ill. 9 Shim ring bundle
82532 0
Ill. 10 Markings
RP21 RP25
mechanical controller controller mechanical controller controller
V8 0.95 dm3 — 1.2 dm3 0.5 dm3
3 3
V12 1.3 dm — 1.7 dm 0.9 dm3
with without both
V16 0.95 dm3 0.5 dm3 controller controller pumps
1.2 dm3 0.5 dm3 0.5 dm3
Table 1 Lube oil fill quantities for injection pump
● Set delivery inception,

Page 4 of 4 0299 7226-0120 0299

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-11
Removing and installing the injection pump and the multi-disk clutch,
12 cyl.
Tools:
- Normal tools
- Pull-off device
Aids:
- White gasoline
D-59427 Unna-Massen
- Lube oil
Cross-references:
- Job Card W 7-6-1, W 7-4-10

multi-disk clutch
● Unscrew fixing screws 3 of injection pump 4.
● Lift off injection pump 4 with coupling half 5 and
remove centre part 10.
injection pump.
82925 0
Ill. 1 Clutch
82926 0
Ill. 2 Coupling in cross-section

1099 0299 7606-0120 Page 1 of 4
Fuel system
Job Card DEUTZ
W 7-4-11 TBD 616

5 and 9.
white gasoline.
82525 0

multi-disk clutch
marking 12.
of groove 13.
● Tighten hexagonal nuts 7 and 8, make sure when
become distorted.
● Lightly attach coupling centre part 10 with the 82927 0
segments 2 and screws 1 M 12x35 to coupling half Ill. 4 Clutch half, engine end
5. Markings must be congruent.
82928 0
Ill. 5 Fitting the coupling centre part

Page 2 of 4 0299 7606-0120 1099
Fuel system
DEUTZ Job Card
TBD 616 W 7-4-11
● Unscrew hexagon-socket screws 14, and remove

centring flange 15 with shims 6.
● Fit centring flange 15 back in place without shims
6.
82929 0
Ill. 6 Centring flange
82529 0
Ill. 7 Marking
● Install injection pump 4 with coupling half 5 and

coupling centre part; injection pump 4 is fixed in
position by means of a locating sleeve.
push them into spacer slot. Increase the number
spacer slot.
● Remove injection pump 4, degrease shims 6, and
install the previously specified number of shims 6;
tighten the hexagon-socket screws 14 until they
are handtight.
Under the injection pump 4, two spacers with
9 mm thickness must have been installed.
82530 0
Ill. 8 Marking
1099 0299 7606-0120 Page 3 of 4
Fuel system
Job Card DEUTZ
W 7-4-11 TBD 616

15 must be aligned on each.
● Screw in hexagon-head screws 1:
8.8 87 Nm
10.9 117 Nm
test rig, fill the injection pump with lube oil.
82930 0
82931 0
Ill. 10 Tightening the fixing screws 1
RP21 RP25
V8 0.95 dm3 — 1.2 dm3 0.5 dm3
3 3
V12 1.3 dm — 1.7 dm 0.9 dm3
with without both
1.2 dm3 0.5 dm3 0.5 dm3

Page 4 of 4 0299 7606-0120 1099

Fuel system
TBD 616 Job Card
W 7-4-11
Removing and installing the injection pumps and the multi-disk clutch,
16 cyl.
Tools:
- Normal tools
- Pull-off device
- Suspension device for injection pumps
Aids:
- White gasoline
D-59427 Unna-Massen
- Lube oil
Cross-references:
- Job Card W 7-6-1, W 7-4-10
Removing the injection pumps and the

multi-disk clutch
● Unscrew fixing screws 3 of the two injection
pumps 4.
83523 0
Ill. 1 Clutch
82926 0
Ill. 2 Coupling in cross-section

© 0300 0299 7693-0120 Page 1 of 8
Fuel system
Job Card TBD 616
W 7-4-11
● Fit suspension device, Ill. 3, lift off injection pumps

4 with coupling half 5, an take off centre part 10.
injection pumps.
82061 1

5 and 9.
white gasoline.
83524 0
82927 0
Ill. 5 Clutch half, engine end

Page 2 of 8 0299 7693-0120 © 0300
Fuel system
TBD 616 Job Card
W 7-4-11
When replacing an injection pump

● Unscrew union 16.
● Loosen circlip 17, and together with sleeve 18
push as far as it will go in the direction of the arrow.
● Loosen counternuts 19 (N.B.! right and left-handed
threads), and unscrew screw piece 20.
● Unscrew hexagonal nut 21, and use the pull-off
device to take off coupling halves 22. Remember
to mark the coupling halves and their respective
cones for subsequent identification.
● Get all the lube grease off the coupling parts, and
clean them thoroughly with petroleum ether.
83525 0
Ill. 6 Control rod connection

© 0300 0299 7693-0120 Page 3 of 8
Fuel system
Job Card TBD 616
W 7-4-11
If one of the two injection pumps is defective,

then in order to achieve equality between the
two injection pumps, the still-intact injection
pump must be measured on a pump test
station at a defined speed and control travel.
The replacement injection pump must be
precisely adjusted to the value previously
measured; see also the values in the Bosch
Test Sheet.
Make sure delivery is equal at low idling
speed.
83526 0
Installing the injection pump I and the Ill. 7 Fitting the coupling centre part
multi-disk clutch
marking 12.
of groove 13.
● Tighten hexagonal nuts 7 and 8, make sure when
become distorted.
● Lightly attach coupling centre part 10 with the
segments 2 and screws 1 M 12x35 to coupling half
5. Markings must be congruent.
82929 0
Ill. 8 Centring flange
● Unscrew hexagon-socket screws 14, and remove

centring flange 15 with shims 6.
● Fit centring flange 15 back in place without shims
6.
82529 0
Ill. 9 Marking
Page 4 of 8 0299 7693-0120 © 0300
Fuel system
TBD 616 Job Card
W 7-4-11
● Install injection pump 4 with coupling half 5 and

coupling centre part; injection pump 4 is fixed in
position by means of a locating sleeve.
push them into spacer slot. Increase the number
spacer slot.
● Remove injection pump 4, degrease shims 6, and
install the previously specified number of shims 6;
tighten the hexagon-socket screws 14 until they
are handtight.
Under the injection pump 4, two spacers with
9 mm thickness must have been installed.
82530 0
Ill. 10 Marking

15 must be aligned on each.
82930 0
● Screw in hexagon-head screws 1(M 12x30):

10.9 117 Nm
82931 0
Ill. 12 Tightening the fixing screws 1

© 0300 0299 7693-0120 Page 5 of 8
Fuel system
Job Card TBD 616
W 7-4-11
Installing the injection pump II and the

● Fit the marked 2 coupling halves 22 with ring 23
onto the shaft concerned in such a way that the
end-face hub line marking “X“ coincides with the
middle of the shaft groove or shaft marking.
83527 0
Ill. 13 Markings
● Lift injection pump II into the crankcase saddle,

and install coupling intermediate piece 24 between
the coupling halves 23 in such a way that the “Y”
markings facing upwards coincide. Line markings
“X“ will then be 45° offset from each other.
● Secure injection pump II in the crankcase saddle
● Tighten screw connections 16 after first having
adjusted delivery commencement, see Job Card
W 7-6-1.
83528 0
Ill. 14 Measuring device
Page 6 of 8 0299 7693-0120 © 0300

Fuel system
TBD 616 Job Card
W 7-4-11
Installing the control rod connection

● Unscrew the screw plug 15 at injection pump I,
and fit the measuring device and dial gauge from
Messrs. Bosch. The probe of the dial gauge must
be screwed into the control rod.
● Set control rod to “Stop” and dial gauge to zero.
● Screw in screw piece 20 one thread turn into the
joint piece 26. N.B.! Right and left-hand threads.
Screw in screw piece 20 into joint piece 27 until
control travel zero has been reached on dial gauge
28. The complete control travel must measure
21 mm. Remove measuring device 29 and dial
gauge 28, and screw in screw plug 25.
● Tighten counternuts 30.
● Coat joint pieces and sealing rings 31 with a thin 83529 0
film of grease, and push sleeve 18 as far as it will
go against the circlip. Insert circlip 17 in the Ill. 15 Screw plug for control rod
groove.
● Fit fuel and lube oil lines, plus the intake pipes.
of grease, Job Card W 7-4-9.
W 7-4-10.

test rig, fill the injection pump with lube oil.
RP21 RP25
V8 0.95 dm3 — 1.2 dm3 0.5 dm3
V12 1.3 dm3 — 1.7 dm3 0.9 dm3
with without both
1.2 dm3 0.5 dm3 0.5 dm3

© 0300 0299 7693-0120 Page 7 of 8

Fuel system
Job Card TBD 616
W 7-4-11
Page 8 of 8 0299 7693-0120 © 0300

Fuel system
DEUTZ Job Card
TBD 616 W 7-4-12
Checking the clearance at the injection pump drive

Tools:
- Normal tools
- Dial gauge with magnetic stand
Aids:
- Loctite
Cross-references:
- Job Cards W 7-4-6, W 7-4-8, W 7-4-10
● Remove injection pump and clutch,

● Unscrew hexagon-head screws 1, remove was-
her 2 and gear wheel 3.
● Turn shaft 4 by one revolution. If chatter marks can
be felt while turning, the injection pump drive must
be repaired,
● Fit dial gauge and magnetic stand as shown in
Ill.␣ 2, push shaft 4 in the direction of the arrow, and
set dial gauge to 0.
● Push shaft 4 in the opposite direction to that
indicated by the arrow, and read off the axial
clearance; for setpoint value see table 1.
Clearance mm 82576 0
Axial 0.01 to 0.05 Ill. 1 Injection pump drive

Radial 0.00
Table 1
● If the setpoint value for axial clearance is exceeded,
loosen locking screw 5, and screw in hexagonal
nut 6 until the setpoint value has been reached.
● Measure the radial clearance of shaft 4. If shaft 4
exhibits clearance, this means the injection pump
drive must be repaired; see Job Card W 7-4-8. If
no radial clearance can be measured, screw in
locking screws 5 after you have coated them with
Loctite beforehand.
● Perform remaining steps of installation procedure
in the reverse sequence.
● Make sure you observe the tightening instructions,
82577 0
Ill. 2 Dial gauge with magnetic stand

0199 0299 7401-0120 Page 1 of 2
Fuel system
Job Card DEUTZ
W 7-4-12 TBD 616
82578 0
Ill. 3 Adjuster nut
Page 2 of 2 0299 7401-0120 0199

Fuel system
DEUTZ Job Card
TBD 616 W 7-6-1
Checking and adjusting the commencement of delivery

You have to check commencement of delivery if there Tools:
are deviations in ignition pressure, if work has been - Normal tools
done on the camshaft, or if you are encountering - Prestroke measuring device
deviations in the exhaust-gas temperature. 1231 3146
- Piston stroke measuring device
1231 3149
- Tappet
1231 3147
Cross-references:
- Job Card B 7-7-2, W 7-7-6
Checking the commencement of

delivery (dry)
● Remove pressure pipe connection 1 at the first
pump cylinder.
80999 0
Ill. 1 Pump cylinder 1
With injection pump RP25

● Tale off liner 3, compression spring 2 and pressure
valve piston 4. The valve body itself remains in the
injection pump. Replace sealing washer 5 every 1 1
time you loosen the pressure pipe connection 1.
With injection pump RP21
● Take off cone piece 6, compression spring 2 and 3 6
constant-pressure valve piston 7. The valve body
itself remains in the injection pump.
2 2
4
7
5
80996 0
Ill. 2 Pressure valves

1099 0299 4328-0120 Page 1 of 6
Fuel system
Job Card DEUTZ
W 7-6-1 TBD 616
● Assemble prestroke measuring device 8,

consisting of reworked pressure pipe connection
9, 30 mm long-stroke dial gauge 10 with 1/100
scale divisions, dial gauge extension 11 and pipe
clip Ø 10 mm 12 to the terminals of dial gauge 10,
and install in the first pump cylinder.
80995 0
Ill. 3 Prestroke measuring device, cpl.
10
12
11
80994 0
Ill. 4 Prestroke measuring device, individual

parts
Manufacturing the tool for the prestroke measuring
device 8 ø10
See Ill. 5 for rework routine on separate pressure pipe 1 ø8 X
connection 9 and manufacture of dial gauge extension
11.
1 Pressure pipe connection
11 Dial gauge extension
X After turning, make 4 slits in the circumference.
11
M 2,6
5
~35,0
81197 0
Ill. 5 Tool for prestroke measurement

Page 2 of 6 0299 4328-0120 1099
Fuel system
DEUTZ Job Card
TBD 616 W 7-6-1
● Turn your engine against its sense of rotation until

the pointer of the prestroke dial gauge 10 halts at
BDC of injection pump 13. In this position, set the
prestroke dial gauge to “zero”.
80998 0
Ill. 6 Dial gauge for prestroke fitted
● Turn your engine in its sense of rotation until

prestroke value 14 has been reached. The
prestroke value is punched in next to the first
pump cylinder.
80999 0
Ill. 7 Prestroke measured value punched in
If you do not find the prestroke value 14 punched in,

you can read off the pump designation on rating plate
15, and then determine the prestroke value from
Table 1.
80993 0
Ill. 8 Injection pump rating plate

1099 0299 4328-0120 Page 3 of 6
Fuel system
Job Card DEUTZ
W 7-6-1 TBD 616
● Detach fuel pressure line, and take off the cylinder

head hood. 17 19
● Remove the injection valve,
● Remove O-ring in the inside of the pressure sleeve
20 for the injection valve, and mount pressure
sleeve 20 back in position.
● When installing the injection valve, coat the O-ring
with lube oil, then insert it again.
● Place tool 16 on the piston through the injection
valve aperture; fit magnetic holder with dial gauge.
● Place dial gauge on the shank of tool 16, and set
18
the dial gauge to “zero”.
● Turn the engine further to TDC, and read off the
piston travel at the dial gauge. 80931 0
● In conjunction with Table 3, you can now determine Ill. 9 Injection pump coupling
the delivery commencement in °CA.
Adjusting the commencement of
delivery
● If the delivery commencement determined in 21
advance is not correct, you must again turn your
engine to the precise delivery commencement
value. 16
20
● Loosen hexagonal nuts 17 at the entire
circumference of curved-teeth coupling 18.
● Turn coupling part 19 at the injection pump side
until the correct prestroke value can be read off at
the injection pump’s dial gauge.
● Tighten hexagonal nuts 17.
For tightening instructions, consult the Installation
Instructions, Job Card W 7-7-6.
80932 0
● Perform the check routine for delivery
commencement again. Ill. 10 Tool for measuring piston stroke
● Remove prestroke measuring device 8,and install
the parts Ill. 2 in the reverse sequence. Tighten
pressure pipe connection with 110 Nm.
Make absolutely sure that when installing the
constant-pressure valve piston 7 the
cylindrically dressed end (Ill. 11, arrow) is
pointing downwards.
82912 0
Ill. 11 Constant-pressure valve piston

Page 4 of 6 0299 4328-0120 1099
Fuel system
DEUTZ Job Card
TBD 616 W 7-6-1
Manufacturing tools 16+21 for piston stroke

measurement
Manufacture part 16 as shown in Ill. 12.
Part 21 is manufactured from a standard pressure
sleeve 20, by milling off the upper part. ø 21 ø9
156 100
80933 0
Ill. 12 Tool for measuring piston stroke
Key data for delivery commencement adjustment using “prestroke”
Engine type: Pump type: Pump designation: Bosch-No.: Pre-stroke:

[TBD] [Size] [Type Formula] [Comb.-No.] [mm]
616-V8 RP.-25 PE8P120...7383 0402618808 4.55
616-V8 RP.-25 PE8P120...7384 0402678829 4.65
616-V8 RP.-25 PE8P120...7381 0402678828 4.55
616-V12 RP.-25 PE12P120...7376 0402610804 4.55
616-V12 RP.-25 PE12P120...7375 0402670810 4.55
616-V12 RP.-25 PE12P120...7385 0402670811 4.65
616-V12 RP.-21C PE12P120...1510 0401430015 4.95
616-V16 RP.-25 PE8P120...7377/7378 0402618/806-807 4.55
616-V16 RP.-25 PE8P120...7387 0402618809 4.65
616-V16 RP.-25 PE8P120...7386 0402678830 4.65
616-V16 RP.-21C PE8P120...1509/1508 0401408050/0401438015 4.95
Table 1
Delivery commencement adjustment

NOx
Injection Speed mg/Nm 3 Delivery start Piston clearance Pre-stroke
pump 1/min (ref. to °CA fr. TDC fr. TDC at delivery start mm
5% O2) mm
RP21 2300 _ 19+1 5.692-6.297 4.95
RP25 2100 _ 20+1 6.297-6.930 4.65
RP25 1800 _ 18+1 5.117-5.692 4.55
RP25 1800 2000 13+-0.5 2.485-2.895 4.55
RP25 1500 _ 15+1 3.568-4.054 4.55
RP25 1500 2000 9.5+-0.5 1.292-1.594 4.55
Table 2
1099 0299 4328-0120 Page 5 of 6

Fuel system
Job Card DEUTZ
W 7-6-1 TBD 616
Piston travel in dependence on crank angle
Crank angle Piston travel Crank angle Piston travel

°Ca mm °Ca mm
7.00 0.783 19.00 5.692

7.50 0.898 19.10 5.751
19.20 5.811
8.00 1.022 19.30 5.870
8.50 1.153 19.40 5.931
9.00 1.292 19.50 5.991
9.50 1.439 19.60 6.051
19.70 6.112
10.00 1.594 19.80 6.174
10.50 1.757 19.90 6.235
11.00 1.927 20.00 6.297
20.10 6.359
11.50 2.105
20.20 6.421
12.00 2.291 20.30 6.484
12.50 2.485 20.40 5.547
13.00 2.686 20.50 6.610
20.60 6.673
13.50 2.895
20.70 6.730
14.00 3.112 20.80 6.801
14.50 3.336 20.90 6.866
15.00 3.568 21.00 6.930
21.10 6.995
15.50 3.807 21.20 7.060
16.00 4.054 21.30 7.126
16.50 4.309 21.40 7.192
17.00 4.571 21.50 7.250

21.60 7.324
17.50 4.840 21.70 7.391
18.00 5.117 21.80 7.458
18.50 5.401 21.90 7.525
18.60 5.458 22.00 7.592
18.70 5.516 22.10 7.660
18.80 5.575 22.20 7.728
18.90 5.633 22.30 7.797
22.40 7.865
22.50 7.934
23.00 8.283
23.50 8.638
24.00 9.001
24.50 9.370
Table 3
Page 6 of 6 0299 4328-0120 1099

Fuel system
DEUTZ Job Card
TBD 616 W 7-7-6
Nozzle holder with nozzle, installation instructions

Tools:
- Normal tools
- Torque wrench
Spare parts:
- Sealing ring

1 M14x1.5 20+5 Hexagnal nut
3 48+2 Box nut
4 Sealing ring 3 mm thick. n <= 1500 min-1
5 Sealing ring 2 mm thick. n > 1500 min-1

1099 0299 4329-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-7-6 TBD 616
4
80940 0
Ill. 1 Nozzle holder with nozzle
Page 2 of 2 0299 4329-0120 1099

Fuel system
DEUTZ Job Card
TBD 616 W 7-11-1
Removing and installing the fuel delivery pump, make Rickmeier

Tools:
- Normal tools
- Scraper
- Vice
Spare parts:
- Clamping sleeves
Aids:
- Collecting vessel
- Cleaning cloth
- Emery cloth
- DEUTZ-DW 56-2 sealant
Cross-references:
- Job Cards W 7-11-2, W 7-11-4
Removing the fuel delivery pump

● Shut down the engine and close the fuel cocks
● Unscrew screwed unions 1 and collect any fuel
exiting.
● Unscrew hexagon-socket screws 2 and take off
fuel delivery pump 3 together with cover 4.
● Clamp gear wheel 5 into a vice, using leaden jaws.
● Unscrew hexagonal nut 6 and withdraw/remove
gear wheel 5.
● Unscrew the four hexagonal nuts 7 and take fuel
delivery pump 3 off cover 4.
If you detect friction rust or scoring on shaft cone 10,
as shown in Ill. 3, then the entire fuel delivery pump 3
and also gear wheel 5 must be replaced. 82588 0
Only in extreme emergencies may shaft cone

Ill. 1 Inspection bore
10 and gear wheel 5 be smoothed with a fine-
grained grinding paste.
After having thus been operated in an
emergency, fuel delivery pump 4 and gear
wheel 5 must be replaced without any further
delay.
● Clean sealing surfaces, if necessary rub down
with emery cloth, and degrease.
82591 0
Ill. 2 Gear wheel

0199 0299 7406-0120 Page 1 of 4
Fuel system
Job Card DEUTZ
W 7-11-1 TBD 616
82571 0
Ill. 3 Fuel delivery pump
Page 2 of 4 0299 7406-0120 0199

Fuel system
DEUTZ Job Card
TBD 616 W 7-11-1
Installing the fuel delivery pump

● To install the fuel delivery pump 3, proceed in the
reverse sequence.
● Coat one sealing surface in each case between
cover 4 and gear cover 8 and fuel delivery pump
3 and cover 4 with liquid sealant DEUTZ-DW 56-
2.
● Tap in new clamping sleeves 9.
● Vent the fuel system.
● Check whether any liquid is exiting from inspection
bore 19 while the engine is running; if this is the
case, the two shaft seals 11 must be replaced;
● Unscrew cap nut 12, loosen counter-nut 13.
82590 0
● Unscrew screw plug 14 at instrument gland 15,
and screw into instrument gland 15 a pressure Ill. 4 Shaft cone
gauge with a measuring range of 0 to 10 bar.
● Start the engine and run up to rated speed, reading
on pressure gauge must be 4 bar. If this is not the
case, set delivery pressure to 4 bar at adjuster
screw 16, and lock in place with nut 13.
● Shut down the engine and remove pressure gauge.
● Screw in screw plug 14 and cap nut 12.
82592 0
Ill. 5 Setting the delivery pressure

(here shown with pump removed)
0199 0299 7406-0120 Page 3 of 4

Fuel system
Job Card DEUTZ
W 7-11-1 TBD 616
Page 4 of 4 0299 7406-0120 0199

Fuel syste
DEUTZ Job Card
TBD 616 W 7-11-2
Fuel delivery pump, installation instructions, make Rickmeier

Tools:
- Normal tools
- Torque wrench
Spare parts:
- Sealing compound DEUTZ-DW 56-2
- Disk
1 Disk
2 Insert stud bolts M8x25 with sealing
compound. When you do this, make sure that
the set screws NEVER protrude out of the
sealing surface at the bottom of the cover.
3 Cylinder-head screws M10x25, strength 10.9
4 Hexagonal nut M10x1.25, tightening torque
25+5␣ Nm.
0599 0299 4330-0120 Page 1 of 2

Fuel system
Job Card DEUTZ
W 7-11-2 TBD 616
1 2
80939 0
Ill. 1 Rickmeier fuel pump
Page 2 of 2 0299 4330-0120 0599

Fuel system
DEUTZ Job Card
TBD 616 W 7-11-4
Repairing the fuel delivery pump, make Rickmeier

Tools:
- Normal tools
- Plastic hammer
Aids:
- Cleaning cloth
- Grinding paste
Cross-references:
- Job Card W 7-11-1
Removing the fuel delivery pump

● Clamp fuel delivery pump 1 into a vice.
● Unscrew cap nut 2 and counter-nut 3.
● Unscrew threaded piece 4, take off tension spring
5 and thrust piece 6.
● Unscrew the four hexagon-head screws 7 and
take off valve housing 8 together with O-ring 9.
82582 0
Ill. 1 Fuel delivery pump
82583 0
Ill. 2 Pressure-limiting valve

0299 0299 7411-0120 Page 1 of 4
Fuel system
Job Card DEUTZ
W 7-11-4 TBD 616
● Detach gear housing 10 by hammering lightly

against it with a plastic hammer from the bottom
towards the top, and lift it off.
82584 0
Ill. 3 Gear housing
● Lift off impellers 11 in an upward direction. Remove

O-ring 13 and withdraw dowel pins 12.
● Check the contact surfaces 14 of gear wheels 15
for signs of pitting over the entire circumference.
If you find severe pitting or wear, you must
replace the fuel delivery pump, s e e
Job Card W 7-11-1.
82585 0
Ill. 4 Impellers
● Use a pull-off device to remove shaft seal 16,

remove circlip 17 and pull off shaft seal 18.
● Clean all sealing surfaces.
● Flush all components with fuel and blow them out
with compressed air.
● Check whether inspection bore 19 has through-
clearance.
82608 0
Ill. 5 Seal
Page 2 of 4 0299 7411-0120 0299
Fuel system
DEUTZ Job Card
TBD 616 W 7-11-4
Installing the fuel delivery pump

● To install fuel delivery pump 1, proceed in the
reverse sequence.
● The configuration of shaft seals 16 and 18 is
shown in Ill. 6.
● Tighten hex.-head screws 7 with 14 Nm.
The “arrow” and “R” markings must be
congruent, see Ill. 9.
82607 0
Ill. 6 Shaft seals
82587 0
Ill. 7 Configuration of shaft seals
82588 0
Ill. 8 Inspection bore
0299 0299 7411-0120 Page 3 of 4

Fuel system
Job Card DEUTZ
W 7-11-4 TBD 616
82589 0
Ill. 9 Markings
Page 4 of 4 0299 7411-0120 0299

Lube oil system
DEUTZ Job Card
TBD 616 W 8-4-5
Removing and fitting the lube oil pump

Tools:
- Normal tools
Aids:
- Fuel
Cross-references:
- Job Cards W 3-5-1, W 3-8-1
Removing the lube oil pump

● Remove oil pan; see Job Card W 3-5-1.
● Remove end wall cover (non-drive end),
● Unscrew screws of mounting clip 1.
● Unscrew screws at suction pipe 2; remove suction
pipe 2 and seal.
● Unscrew the three screws 3, and remove lube oil
pump 4.
● Take O-ring out of pressure connection.
● Clean lube oil pump 4 and suction pipe 2 with fuel.
82097 0
Ill. 1 Lube oil pump
Fittig the lube oil pump

● Coat new O-ring with grease, and insert it into the
pressure connection of the lube oil pump.
● Mount lube oil pump 4, and fit all the parts
previously removed, in the opposite sequence.
0599
Lube oil system
Job Card DEUTZ
W 8-4-5 TBD 616
Page 2 of 2 0299 4331-0120 0599

Lube oil system
DEUTZ Job Card
TBD 616 W 8-8-2
Removing, installing and cleaning the lube oil cooler

Tools:
When draining off hot lube oil: - Normal tools
!
risk of scalding!
Aids:
Carry out this work only when the - Liquid sealant DW 47
! engine has been shut down. - Cleaning trough
- Collecting vessel
Secure engine against start-up. - Compressed air
- Fuel
Comply with the tightening instructions kel Düsseldorf, Germany
Removing the lube oil cooler

● Drain off coolant and collect for subsequent re-
use.
● Unscrew drain plug 1 and drain off coolant from
lube oil cooler 2; screw in drain plug 1 with a new
sealing ring.
● Unscrew drain plug 3, collect any lube oil exiting.
● Unscrew fixing screws 4 and lift fuel filter 5 together
with the flexible lines sideways to the right.
● Remove lube oil filter 6, collect any lube oil exiting.
● Unscrew screw 7 and take off bushing 8.
● Swivel dipstick 9 to one side.
82567 0
● Remove coolant line 10.
● Unscrew the twelve fixing screws 11 and take off/ Ill. 1 Screw unions at lube oil cooler
remove lube oil cooler 2.
● Unscrew the four cylinder-head screws 12 and
withdraw cooling insert 13.
82568 0
Ill. 2 Lube oil cooler

0199 0299 7416-0120 Page 1 of 2
Lube oil system
Job Card DEUTZ
W 8-8-2 TBD 616
Cleaning the cooling insert

● Close off the lube oil compartment of cooling
insert 13 with two seals and closure cover.
● In a cleaning trough, mix cleaning agent as per
manufacturer’s instructions, place cooling insert
13 into the solution and allow it to act for a few
hours.
● Take cooling insert 13 out of the cleaning trough
and rinse it with clear water.
● Take off again the closure cover with seals you
have previously fitted.
● Flush the lube oil compartment of cooling insert
13 with fuel, and blow it out thoroughly with
compressed air.
● Clean sealing surfaces 18. 82569 0
Ill. 3 Cooling insert with O-rings
Installing the lube oil cooler

● Replace all O-rings 14; coat new ones with grease
and then fit them in place.
● Coat sealing surface 18 of cooling insert 13 with
liquid sealant DW 47 all the way round.
● Insert cooling insert 13 into housing 15 and tighten
screws 12 until they are handtight.
● Apply liquid sealant DW 47 to sealing surface 16,
as shown in Ill. 4.
● Perform the remaining installation steps in the
reverse sequence.
● Make sure you comply with the tightening
instructions as given in the Operating Instructions,
Chapter 8, Technical Data.
82570 0
● Refill with the coolant you have previously drained
off. Ill. 4 Liquid sealant
● Pour the lube oil previously collected into lube oil
neck 17.
Page 2 of 2 0299 7416-0120 0199

Lube oil system
DEUTZ Job Card
TBD 616 W 8-11-3
Replacing the oil pressure control valve

Tools:
- Normal tools
Aids:
- Collecting trough
- Locking agent DEUTZ-DW 60-2
1215 1056
Removing the oil pressure control valve

● Unscrew cap nut 1 and remove it, together with
sealing ring 3 and compression spring 2.
● Collecting the escaping lube oil in the collecting
trough.
● Unscrew sleeve 4 with ball 5.
5
3 4
2 1
82088 0
Ill. 1 Oil pressure control valve
Installing the oil pressure control valve

● Replace the complete oil pressure control valve.
● Degrease thread in the lube oil cooler housing.
● Coat the thread of the new sleeve 4 with DEUTZ-
DW 60-2 locking agent.
● Screw in sleeve 4 with ball 5.
● Screw on cap nut 1 with new sealing ring 3 and
compression spring 2.
● Fill the lube oil cooler with the collected lube oil.
0599 0299 4332-0120 Page 1 of 2

Lube oil system
Job Card DEUTZ
W 8-11-3 TBD 616
Page 2 of 2 0299 4332-0120 0599

Lube oil system
DEUTZ Job Card
TBD 616 W 8-11-5
Replacing the bypass valve

Tools:
- Normal tools
Aids:
- Collecting trough
Removing the bypass valve

● Unscrew screw 1, remove sealing ring 3, tension
spring 2, washer 4 and valve 5.
● Collect any lube oil exiting in the collecting trough.
82539 0
Ill. 1 Bypass valve
Installing the bypass valve

● Completely replace the bypass valve.
● Clean the thread in the lube oil cooler housing.
● Refill the engine with the lube oil you have collected.
● Insert into screw 1 tension spring 2, washer 4 and
valve 5.
● Screw the complete bypass valve with a new
sealing ring 3 from below into the lube oil cooler
until it is handtight.
82540 0
Ill. 2 Bypass valve, detail
0199 0299 7421-0120 Page 1 of 2

Lube oil system
Job Card DEUTZ
W 8-11-5 TBD 616
Page 2 of 2 0299 7421-0120 0199

Lube oil system
DEUTZ Job Card
- TBD 616 W 8-13-3
Removing and fitting the centrifugal lube oil filter

Tools:
! - Normal tools
- Scraper
Aids:
When draining off hot lube oil: - Collecting trough
!
risk of scalding!
Spare parts:
- Round sealing rings
Collect the used oil, do not allow it to
! seep into the soil. - Specially shaped seals
Dispose of in accordance with the

relevant regulations. Cross-references:
- Job Card B 8-13-1
Removing the centrifugal lube oil filter

● Unscrew screw union 1, collecting the lube oil
which flows out.
● Unscrew hexagonal nut 2, and swivel away support
3 together with lube oil lines 4.
● Unscrew hollow screw 5, and remove together
with the two sealing rings, collect the lube oil
which flows out.
● Unscrew hexagonal nuts 6, and remove them
together with the spring washers.
● Lift off centrifugal lube oil filter 7 with seal.
● Unscrew hexagon-socket screw 8, and remove it
together with spring washers and support 9.
● Clean support 9 and all sealing surfaces. 82878 0
● Clean centrifugal lube oil filter,

Ill. 1 Centrifugal lube oil filter
Fitting the centrifugal lube oil filter

● Replace all seals.
● To fit, proceed in the opposite sequence as
appropriate.
● Tighten the screw unions until they are handtight.
82879 0
Ill. 2 Support
0499 0299 7426-0120 Page 1 of 2
Lube oil system
Job Card DEUTZ
W 8-13-3 TBD 616
Page 2 of 2 0299 7426-0120 0499

Coolant system
DEUTZ Job Card
TBD 616 W 9-0-1
Draining the cooling system

For various jobs, e.g. at the cylinder head, the Tools:
crankcase, the heat exchanger and the pipes, it is - Standard tools
necessary to drain the coolant partially or completely.
If no antifreeze has been added, the coolant must be Aids:
drained completely from the engine and the built-on - Collecting container for coolant
components if your engine is going to be shut down
for a lengthy period or if there is a risk of frost.
Cross-references:
If your engine is going to be shut down for a lengthy - Operating instructions, Chapter 4
period, conserve the engine as per Operating - Operating instructions, Chapter 7
Instructions, Chapter 7.
Draining the coolant

● Block off the coolant pipes from and to the engine.
● Place a collecting container underneath.
● Loosen drain plug 1 at the lube oil heat exchanger.
● If fitted, loosen preheating drain plug.
● If fitted, loosen drain plugs of the coolant pipes.
● Loosen drain plug 2 at the crankcase.
80973 0
Ill. 1 Lube oil heat exchanger drain plug
80972 0
Ill. 2 Crankcase drain plug

0599 0299 4333-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-0-1 TBD 616
● If fitted open drains 3 and 4 of the liquid-cooled

exhaust gas pipes.
● If fitted, drain raw water pump at drain plugs 5.
After the coolant has been completely drained off,
close drain plugs, drain valves or pipes again. Use
new seals and sealing rings. Re-use collected coolant
or arrange for eco-friendly disposal.
80974 0
Ill. 3 Exhaust gas pipe drain plug
80975 0
Ill. 4 Exhaust gas pipe drain plug
80976 0
Ill. 5 Raw water pump drain

Page 2 of 2 0299 4333-0120 0599
Coolant system
DEUTZ Job Card
TBD 616 W 9-0-2
Cleaning the coolant compartments

Because of dirt in the coolant, lime and corrosion, Tools:
deposits are formed on the walls of the coolant - Normal tools
compartments, and have to be removed.
This applies in the pure-water area only when, due to Aids:
preceding leaks, a coolant consumption has had to - Collecting trough for coolant
be compensated for by continuous topping up. - Cleaning agent P3-T288, from Messrs
Henkel, Düsseldorf, Germany
Cross-references:
- Job Card W 9-0-1
Cleaning the coolant compartments

● Drain off the coolant, see Job Card W 9-0-1.
● Mix the cleaning agent solution in accordance
with the manufacturer’s instructions, and fill the
engine compartments with it.
● Start up the engine briefly, then allow the cleaning
agent to act for 24 hours.
● Drain off the cleaning agent.
● Fill with clean water, and start up the engine
briefly. Then drain off the water, and repeat the
procedure without starting up the engine this time.
● Fill with new coolant. The coolant must come up
to the bottom X = “cold” mark in filling socket 1.
● If a separate pure-water circuit has been fitted for 82095 0
the intercooler, follow the same procedure for this.
Ill. 1 Filling socket at expansion tank
1
W
ar
m
Ka
lt
Cold
Kalt
Warm
82096 0
Ill. 2 Filling socket, recirculation cooling

0599 0299 4334-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-0-2 TBD 616
Page 2 of 2 0299 4334-0120 0599

Coolant system
DEUTZ Job Card
TBD 616 W 9-0-3
Checking the coolant compartments

When a basic overhaul is performed, the engine has Tools:
been dismantled, thus enabling all coolant - Endoscope
compartments (components through which water
flows) to be visually checked without any additional
outlay.
Aids:
- Cleaning trough
kel Düsseldorf
● Check all the engine’s surfaces and cavities visually

for deposits and cavitation; if necessary, with the
aid of an endoscope.
● If you find clearly visible damage caused by
cavitation, the components concerned must be
replaced.
● If you find clearly visible deposits, the components
concerned must be cleaned.
● Mix the cleaning agent solution in a trough,
following the manufacturer’s instructions, and
place the components waiting to be cleaned into
it.
● Allow the cleaning agent to act for a few hours,
then rinse the components thoroughly with clear
water.
0199 0299 7431-0120 Page 1 of 2

Coolant system
Job Card DEUTZ
W 9-0-3 TBD 616
Page 2 of 2 0299 7431-0120 0199

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-2
Repairing the coolant pump

If lube oil or coolant is escaping at the leakage bore Tools:
underneath the coolant pump shaft, this means the - Normal tools
coolant pump must be repaired. - Pull-off device
- Hot-air blower
- Mounting mandrel for ceramic ring
Comply with the tightening instructions - Mounting mandrel for mechanical face
given in the Operating Manual, seal
Chapter 8, „Technical Data“. - Press
Aids:
- Loctite 1215 1050
- Loctite 0100 7689
Cross-references:
- Job Card W 9-7-8
Repairing the coolant pump

● Remove coolant pump,
0599 0299 6816-0120 Page 1 of 4

Coolant system
Job Card DEUTZ
W 9-7-2 TBD 616
Removing the coolant pump

● Clamp coolant pump 13 at gear wheel 7 in a vice ● Screw in cap nut 3 completely, and use the press
with soft-metal jaws. to press shaft 2 out of the housing in the direction
indicated by the arrow.
● Use hot-air blower to warm up box nut 3 and nut
8, and then unscrew them. ● Remove seals 4, 5 and 12.
● Release coolant pump 13 from the vice, and use ● Remove angular ball bearing 10 and spacer ring
the pull-off device to remove gear wheel 7. 11 from shaft 2.
● Unscrew hexagon-socket screws 6, and take off ● Remove Loctite residues from shaft 2, nuts 3 and
cover 9. 8, and degrease.
● Use pull-off device to remove impeller 1. ● Remove any corrosion residues at housing 13 and
impeller 1.
● Place coolant pump 13 on a press, supporting it if
necessary at surfaces X.
10 11 10 12 13 1
9 2
D
D
8
3
B
C
X
7 6 5
82154 0
Ill. 1 Coolant pump

Page 2 of 4 0299 6816-0120 0599
Coolant system
DEUTZ Job Card
TBD 616 W 9-7-2
Mounting the coolant pump

● Use the mounting plate to press mechanical face
seal 12 into the housing.
Make sure the mechanical face seal 12 is
installed in precisely the correct configuration.
● Fit angular ball bearing 10 and spacer ring 11 onto
shaft 2.
Make sure the angular ball bearing 10 is
installed in precisely the correct configuration.
● Use mounting mandrel (Ill. 2, Pos. 2) to press the
mechanical face seal 5 at the outer ring into the
coolant pump’s housing. Coat surface A with
Loctite 1215 1050 beforehand.
The slide faces of the mechanical face seal
must be absolutely clean, dry, and free of
Loctite residues.
!
60 60
Ø 51,5
Ø 48
Ø 46
1 x 45° 15
1 2
82155 0
Ill. 2 Mounting mandrels
● Carefully insert shaft 2 with the angular ball bearings

10 into the housing, against the direction indicated
by the arrow.
● Screw cover 9 in place with screws 6, using a
tightening torque of 8.7 Nm.
● Use mounting mandrel (Ill. 2, Pos. 1) to press
ceramic ring 4 into impeller 1. Use only soap water
as a mounting aid for the O-ring.
● Apply a thin coating of Loctite 0100 7689 to
surface B of shaft 2.
● Press impeller 1 onto shaft 2 in the direction of the
arrow.
Make sure no Loctite gets into the mechanical
face seal 5.
0599 0299 6816-0120 Page 3 of 4

Coolant system
Job Card DEUTZ
W 9-7-2 TBD 616
● Apply a thin coating of Loctite 0100 7689 to

surface C of shaft 2.
● Press gear wheel onto shaft 2 against the direction
of the arrow.
Make sure no Loctite gets into the angular
ball bearings 10.
● Apply a thin coating of Loctite 0100 7689 to the
threads at Positions 3 and 8, and to surface D.
● Tighten nuts 3 and 8, using a tightening torque of
250 +30 Nm.
● Fit the coolant pump in place,
Page 4 of 4 0299 6816-0120 0599

Coolant system
TBD 616 Job Card
W 9-7-3
Repairing the raw water pump, make DEUTZ

Tools
- Normal tools
- Pull-off device
- Press-in sleeve
- Plastic hammer
Aids
- Hotplate
- Liquid sealant
- White spirit
- Lube oil
- Press
- Loctite 582 CVX
- Grease
- DEUTZ DW 69
Spare parts
- Shaft seals
- Mechanical face seal
- O-rings
- Ball bearing and roller bearing
- where appropriate stud bolt and cap nut
1230 4620, Pos. 26
- Round sealing ring 0115 3919, Pos. 27
Removing the raw water pump

● Unscrew hex.-head screw 12 and remove it
together with washer 11.
● Use a pull-off device to pull gear wheel 10 off shaft
14.
● Unscrew hex.-head nuts 25 and remove flanged
socket 19 together with O-ring 18.
●l Unscrew hexagon socket screw 22, and take it off
together with washer 23, scrap both parts, and
replace by parts 26 and 27.
● If the new version with cap nut and stud bolt 26, Ill.
1, is obstructed, unscrew cap nut with stud bolt 26
together, and take off O-ring 27. If cavitation
damage is found at the contact area of the cap nut,
replace cap nut and stud bolt 26 together. 82969 0
Ill. 1 Version with stud bolt and cap nut
© 0200 0299 7436-0120 Page 1 of 4

Coolant system
Job Card TBD 616
W 9-7-3
● Use a pull-off device to pull impeller 24 off shaft ● Remove circlip 9.

14.
● Via inner ring 13a, press shafts 14 with ball bearing
● Pull counter-ring 21 off impeller 24 together with 6 and raceway 5 out of the bearing housing 7 in the
O-ring. direction of the arrow, using a press-in sleeve.
● Unscrew hex.-head nuts 2, and pull spiral housing ● Pull parts 5, 6 and 13a off shaft 14.
1 off shaft 14 together with mechanical face seal
● Remove circlips 8 from bearing housing 7.
20.
● Press roller bearing (Part 13b) out of bearing
● Press mechanical face seal 20 out of spiral housing
housing 7.
1.
● Clean all parts thus removed and degrease them.
● Remove circlip 17 and unscrew hex.-head screws
3. Replace all seals, ball bearing and roller
bearings. Replace impeller if damaged, check
● Remove bearing cover 16.
cooling system for residues, and clean it.
● Remove O-ring 15 and radial shaft seal 4 from
bearing cover 16.
82866 0
Ill. 2 Raw water pump
Page 2 of 4 0299 7436-0120 © 0200

Coolant system
TBD 616 Job Card
W 9-7-3
Mounting the raw water pump

● Insert roller bearing (Part 13b) and circlips 8 into
bearing housing 7.
● Heat up ball bearing 6 and roller bearing (Part 13a)
to a temperature of 120 °C, push them onto shaft
14 as far as they will go, as shown in Ill. 2.
Risk of burns: please do wear gloves!
● Heat up raceway 5 to a temperature of 180 °C,

and push it onto shaft 14 as far as it will go; insert
circlip 17.
● Insert shaft 14 into bearing housing 7 towards
drive gear wheel 10.
● Press radial shaft seal 4 into bearing cover 16 as
far as it will go, making sure the installation direction
is correct.
● Coat O-Ring 15 with grease, then place it into
bearing cover 16, insert bearing cover 16 into
bearing housing 7 making sure it is aligned straight,
apply a thin coating of Loctite 582 CVX to screws
3 and tighten them in a diagonally opposite
sequence, tightening torque 8.5 Nm.
● Apply a thin coating of liquid sealant to the outer
sheet-metal jacket of the mechanical face seal
(Part 20), making absolutely sure that no sealant
gets as far as the rear face or onto the seal’s slide
face.
● Press the mechanical face seal (Part 20) into spiral
housing 1 as far as it will go, using a mounting
mandrel; clean slide face with white spirit.
● Press counter-ring 21 together with O-ring into
impeller 24 as far as it will go, making sure it is
aligned straight; you may only use a 1:1-mixture of
white spirit and water as a mounting aid; clean
slide face with white spirit.
● Insert spiral housing 1 into bearing housing 7, and
bolt together with hex.-head nuts 2.
● Push impeller 24 onto shaft 14, making sure oil
and grease have been removed.
● Insert round sealing ring 27 into cap nut 26, coat
the thread of the stud bolt with DEUTZ DW 69, and
tighten cap nut with stud bolt 26 together, using a
tightening torque of 100+10 Nm.
● Push gear wheel 10 onto shaft 14, fit washer 11 in
place, apply some oil to hexagon-socket screw
12, then screw it in, using a tightening torque of
100 +10 Nm.
● Grease O-ring 18 and fit in place on flange socket
19.
● Insert flange socket 19 into spiral housing 1 and
bolt together with hex.-head nuts 25.
© 0200 0299 7436-0120 Page 3 of 4

Coolant system
Job Card TBD 616
W 9-7-3
Page 4 of 4 0299 7436-0120 © 0200

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-3
Repairing the raw water pump, make Steimel

Tools:
- Normal tools
- Pull-off device
- Press-in sleeve
- Round rod Ø 5 mm
- Rubber hammer
Aids:
- Lube grease
- Sealing compound Curil K2
Messrs Elring Dichtungstechnik GmbH
D-Fellbach
- Hotplate
- Cold cleaning agent
- Compressed air
- Loctite 243
Spare parts:
- Ball bearing
- Cylindrical roller bearing
- Seals
- O-rings
- Hexagonal nut Pos. 35b, Part Number
0117 6651
- Radial shaft sealing rings
Dismantling the raw water pump

● Unscrew nut 35, and use removal device to remove
spur gear wheel 36 from shaft 7. If still obstructed,
scrap nut 35a with lock washer (see Ill. 4).
● Mark pump parts in relation to each other.
● Loosen grub screws 19.
● Unscrew ball bearing cover 15, and remove split
pin 16.
● Clamp shaft 7 in place, and unscrew castellated
nut 17.
● Loosen and unscrew hexagon socket screws 13
and nuts 27.
82620 0
Ill. 1 Spur toothed gear

1099 0299 7441-0120 Page 1 of 6
Coolant system
Job Card DEUTZ
W 9-7-3 TBD 616
● Use a pull-off device to remove cover 14. If

necessary, you can also use cover 15 and an M10
screw as a pull-off device.
● Remove mechanical face seal 25 from shaft 7.
● Press counter-ring 24 and cup leather 23 out of
cover 14.
● Unscrew nut 22 from cover 14, and use a pull-.off
device to remove ball bearing 18, take off spacer
disk 20, and press off radial shaft sealing ring 21.
● Take off cam disk 12.
● Loosen and take off clamp nut 11.
● Remove impeller 30 from shaft 7, and take off
impeller centre piece 9.
82621 0
Ill. 2 Ball bearing cover
82622 0
Page 2 of 6 0299 7441-0120 1099

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-3
● Loosen grub screw 34.

● Unscrew threaded disk 40, and take off radial
shaft sealing ring 38.
● Use a pull-off device to remove flange cover 3 and
raceway 39.
● Remove cylindrical roller bearing 1 and radial
shaft sealing ring 2.
● Take mechanical face seal 31 off shaft 7.
● Press counter-ring 32 and cup leather 33 out of
flange cover 3.
● Use light taps with a rubber hammer to drive shaft
7 in the direction indicated by the arrow; use a
pull-off device if appropriate.
● Mark impellers 5 and 8 for identification.
● Use ultra-fine emery cloth to remove traces of rust
and insertion on shaft 7, then give shaft 7 a
thorough cleaning.
● Clean impellers and housing sections with cold
cleaning agent, and blow out with compressed
air.
● Replace all seals, ball bearings and roller bearings.
● Replace damaged impellers, examine cooling
system for residues, and clean it.
1099 0299 7441-0120 Page 3 of 6

Coolant system
Job Card DEUTZ
W 9-7-3 TBD 616
Mounting the raw water pump. ● Screw in ball bearing cover 15 as far as it will go.
Replace grub screws 19 and 34. ● Insert new cup leather 33 and counter-ring 32 into
flange cover 3.
Before installing, apply Loctite 243 to cover
15, grub screws 19 and 34 and threaded disk ● Insert new radial shaft sealing ring 2.
40. ● Fit flange cover 3, in the opposite direction to that
● Clamp shaft 7 at drive end “A” in a vice, using indicated by the arrow, together with a new seal
leaden jaws. 29. Make sure markings are congruent, screw in
hexagon socket screw 13 and nuts 27, and tighten
● Pull impeller 30 with spacer washer 10 onto shaft
them lightly.
7 in the direction indicated by the arrow, as far as
it will go. ● Warm up new roller bearing to approx. 80 °C, and
press in, without the inner ring, as far as it will go,
● Screw in clamp nut 11, and tighten it with 350 Nm.
then press in the inner ring approx. 3/4 deep.
● Clamp shaft 7 into vice at other end “B”.
● Tighten hexagon socket screw 13 and nut 27 until
● Fit impeller 8 together with impeller centre piece 9 they are handtight.
and flat seal 29 in the opposite direction to that
● Screw in threaded disk 40, and tighten until it is
indicated by the arrow, as far as it will go.
handtight; use grub screw 34 to secure threaded
Flat seals 28 and 29 must be sealed on both disk 40.
sides with non-hardening sealing compound
(e.g. Curil K2 from Messrs Elring Dichtungs-
technik GmbH, Fellbach, Germany).
● Fit spacer piece 6 with flange and flat seals 29
onto shaft 7 as far as it will go.
● Press impeller 5 with spacer washer 4 onto shaft
7.
When installing the new mechanical face
seals 25 and 31, you MUST be careful not to
confuse them. The right-hand spring is located
on the “B” side and the left-hand spring on
the “A” side.
● Use a press-in sleeve to fit mechanical face seal
31 onto shaft 7 as far as it will go, being careful not
to damage the sealing lip.
● Clamp shaft 7 in a vice again at the drive end “A”,
using leaden jaws.
● Fit cam disk 12 with flat seal 28 in the direction
indicated by the arrow.
● Use a press-in sleeve to fit mechanical face seal
25 on shaft 7 as far as it will go, being careful not
to damage the sealing lip.
● Insert new cup leather 23 and counter-ring 24 in
cover 14.
● Screw nut 22 with new radial shaft sealing ring 21
into cover 14.
● Push cover 14 onto shaft 7, making sure markings
are congruent.
● Warm up new ball bearing 18 to approx. 80 °C,
and insert with spacer disk 20.
● Screw in castellated nut 17, tighten it until it is
handtight, and secure with new split pin 16.
Page 4 of 6 0299 7441-0120 1099

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-3
Adjusting the impellers

● Loosen ball bearing cover 15 by some turns.
● Screw in nut 22 as far as it will go, with a 5 mm
round rod through the leakage water slot 26, in the
opposite direction to that indicated by the arrow;
the impellers will be flush against the sides, and
shaft 7 cannot be moved.
● Screw in ball bearing cover 15 as far as it will go,
and mark its position; then loosen ball bearing
cover 15 by approx. three turns.
● Turn nut 22 approx. two turns in the direction
indicated by the arrow, and screw in ball bearing
cover 15 as far as it will go; the impellers are on the
other side – mark this position as well.
● Position ball bearing cover 15 in the middle of the 82934 0
two markings, and use grub screw 19 to secure it.
Ill. 4 Fixing nut old, new
● Screw in nut 22 in the opposite direction to that
indicated by the arrow as far as it will go, and
secure with grub screw 19. It must now be possible
to turn shaft 7 easily; and the impellers have been
centred.
● Press in the inner ring of cylindrical roller bearing
1 until there is approx. 0.2 mm of axial clearance.
● Warm up raceway 39 to approx. 80 °C, and push
it onto shaft 7, with a new O-ring.
● Press in new radial shaft sealing ring 38.
● Fit new O-ring 41 with grease.
● Fit gear wheel 36 to shaft 7, coat thread of nut 35b
with Loctite 243, screw on, and tighten with 250
Nm.
● Fill lubrication compartments with lube grease
through lubrication nipples 42 and 43.
1099 0299 7441-0120 Page 5 of 6

Coolant system
Job Card DEUTZ
W 9-7-3 TBD 616
Page 6 of 6 0299 7441-0120 1099

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-5
Removing and fitting, checking the idler gear for the coolant pump
Tools:
- Normal tools
- Pull-off device
Aids:
- Lube oil
! - Lithium-saponified grease
undercooled parts:
- Cleaning agent
Risk of injury! - Liquid sealing compound DEUTZ-DW␣ 47
- Liquid nitrogen
Cross-references:
- Job Cards W 3-8-1, W 4-8-1, W 9-7-8,
W 9-7-10
Removing the idler gear

● Remove raw water pump 1 and coolant lines 2,
● Remove coolant pump 4 and coolant lines 3,
● Remove end wall cover 5,
● Block gearwheel 6, and unscrew hex. nut 7, take
off gearwheel 6 and washer 11.
● Unscrew cylinder-head screw 8 and remove axle
9.
● If you find traces of wear and tear at the teeth of
gear wheel 6, replace it.
● Check bearing bush 10; if you find traces of severe 82071 0
wear and tear, replace bearing bush 10.
● Supercool new bearing bush 10 with liquid
nitrogen, and insert it in gear wheel 6 (this heated
up to 200␣ °C), without exerting any force.
Ensure a distance dimension X of 0.15 mm on
both sides (see Ill. 4).
82072 0
Ill. 2 End wall cover
0599 0299 4335-0120 Page 1 of 2

Coolant system
Job Card DEUTZ
W 9-7-5 TBD 616
Fitting the idler gear

8 6 9 7
● Secure axle 9 with cylinder-head screw 8, making
sure the lube oil borehole 14 is in the correct
position.
12
● Fit gear wheel 6 onto axle 9 as shown in Ill. 3, first
having coated bearing bush 10 thoroughly with
oil.
● Fit washer 11, and coat the contact area of hexa-
gonal nut 7 with liquid sealing compound DEUTZ-
DW 47.
● Block gear wheel 6.
● Tighten hexagonal nut 7. and coat it all the way
13
round with DEUTZ-DW 47 liquid sealing compound
13. 14 10 11
● Replace O-ring 12, and coat it with grease. 82073 0
● Check axial clearance of gear wheel 6: Ill. 3 Idler gear

setpoint value = 0.087- 0.2 mm.
● Fit the remaining built-on components in the
reverse sequence.
Follow the tightening instructions given in
Chapter 8 of the Operating Instructions.
82074 0
Ill. 4 Distance dimension
82075 0
Ill. 5 Gear train

Page 2 of 2 0299 4335-0120 0599
Coolant system
DEUTZ Job Card
TBD 616 W 9-7-6
Removing and fitting, checking the idler gears for the raw water pump
Tools:
- Normal tools
- Pull-off device
Aids:
- Liquid nitrogen
! - Hotplate
undercooled parts:
Risk of injury! - Lithium-saponified grease
Cross-references:
- Job Cards W 3-8-1, W 4-8-1, W 9-7-8,
W␣ 9-7-10
Removing the idler gears

● Remove raw water pump 1 and coolant lines 2,
● Remove coolant pump 4 and coolant lines 3,
● Remove end wall cover 5,
● Block gear wheels 6 and loosen cylinder-head
screw 8.
● Unscrew hexagonal nut 11, and remove together
with washer 12.
● Take off gear wheels 6 with hub 9.
● Take off cylinder-head screws 8 together with
washers 7 and gear wheels 6. 82071 0
● Remove cylinder-head screws 13 and axle 15

● If you find any traces of wear at the teeth of the
gear wheels 6, replace the gear wheels concerned.
● Check bearing bush 16; if you find traces of severe
wear and tear, replace bearing bush 16.
● Supercool new bearing bush 16 with liquid
nitrogen, and insert it in hub 9 (this first heated up
to 200␣ °C), without exerting any force.
You must make sure that bearing bushes do
not protrude on either of the two hub sides.
82072 0
Ill. 2 End wall cover

0599 0299 4336-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-7-6 TBD 616
Fitting the idler gears

● Secure axle 15 with cylinder-head screw 13,
making sure the lube oil borehole 14 is in the
correct position.
● Fit gear wheels 6 on hub 9, as shown in Ill. 4, and
screw them lightly together with cylinder-head
screws 8 and washers 7.
● Coat bearing bushes 16 thoroughly with oil, and fit
them on axle 15 together with gear wheels 6, as
shown in Ill. 4.
● Fit washer 12. Coat surface X of washer 12 and
thread X of hexagonal nut 11 with liquid sealing
compound DEUTZ-DW 47, and screw on hexago-
nal nut 11.
● Block gear wheels 6, and tighten hexagonal nuts 82076 0
11 and cylinder-head screws 8.
Ill. 3 Gear train
● Replace O-ring 10 and coat it with grease.
● Check the axial clearance of gear wheels 6:
setpoint value = 0.087- 0.2 mm. 15 16 6
Chapter 8 of the Operating Instructions. 7
8
14 9
10
11
13 12
82077 0
Ill. 4 Idler gears, cpl.
Page 2 of 2 0299 4336-0120 0599

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-8
Removing and fitting the coolant pump

Tools:
Carry out this work only when the - Normal tools
! engine has been shut down. - Dial gauge 0710 6439
- Magnetic stand 1215 8175

given in the Operating Manual, Aids:
Chapter 8, „Technical Data“. - Collecting trough
- Cleaning agent
Spare parts:
- Sealing
Cross-references:
- Job Card W 9-0-1

● Drain off coolant (see Job Card W 9-0-1), and
collect it in a suitable container for re-use.
● Unscrew screws 1 of coolant line 2.
● Take off the upper coolant line 2.
● Remove coolant line 3.
● Unscrew cylinder-head screws 4, and remove
coolant pump 5 frontwards.
● Take off the O-ring from coolant pump 5, and
clean the coolant pump.
0599 0299 4337-0120 Page 1 of 4

Coolant system
Job Card DEUTZ
W 9-7-8 TBD 616
82099 0
Ill. 1 Coolant pump
Fitting the coolant pump

● Coat a new O-ring with acid-free grease, and fit it
on coolant pump 5.
● Insert coolant pump 5 in end wall cover 6, and
tighten it lightly in place with the cylinder-head
screws 4.
● Unscrew cover 7, and block the gear wheels
through the opening
82098 0
Ill. 2 Coolant line

Page 2 of 4 0299 4337-0120 0599
Coolant system
DEUTZ Job Card
TBD 616 W 9-7-8
● Unscrew flange 8, and fit dial gauge 9 together

with magnetic holder 10, as shown in Ill. 3.
● Place the measuring probe of dial gauge 9 on an
impeller edge, and press the impeller in one
direction; set the dial gauge scale to zero. By
pressing in the other direction, you can now
determine the face clearance.
● With light blows of a hammer on the coolant
pump, alter the face clearance until a value of 0.12
to 0.23 mm has been achieved.
● Remove dial gauge 9 together with magnetic
holder 10.
● Take out the tool used to block the gear wheels,
and fit cover 7.
● Tighten cylinder-head screws 4, fit flange 8 together 82101 0
with an O-ring coated with acid-free grease, and
screw in place. Ill. 3 Dial gauge
● Mount the remaining components, proceeding in

the reverse sequence.
● Fill with coolant, and vent the cooling system.
Vent coolant pump 5 at screw 10.
Chapter 8 of the Operating Instructions.
0599 0299 4337-0120 Page 3 of 4

Coolant system
Job Card DEUTZ
W 9-7-8 TBD 616
Page 4 of 4 0299 4337-0120 0599

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-9
Checking, removing and fitting the coolant pump, 2nd cooling circuit
Tools:
- Normal tools
Aids:
- Collecting trough
Spare parts:
- Seal
Checking
● The coolant pump must be replaced if:
- shaft 8 of coolant pump 7 perceptibly possesses
bearing clearance, or
- coolant exits from the monitoring bore 9 while
the engine is operating.
82595 0
Ill. 1 Monitoring bore

● Remove the V-belt guard.
● Drain off coolant of the 2nd cooling circuit, and
collect it for re-use.
● At the generator 1, de-stress V-belt 2 and remove
it.
● Remove hose bend 3.
● Unscrew hexagon-socket screws 4, and take off
V-belt pulley 5.
● Unscrew hexagon-socket screws 6, and take off
coolant pump 7 plus seal.
82596 0
Ill. 2 Coolant pump

0199 0299 7446-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-7-9 TBD 616
Fitting the coolant pump

● To mount coolant pump 7, proceed in the opposite
sequence as appropriate; use a new seal.
● Tighten hexagon-head screws 6 with 25 Nm.
82597 0
Ill. 3 V-belt pulley
Page 2 of 2 0299 7446-0120 0199

Coolant system
TBD 616 Job Card
W 9-7-10
Checking, removing and fitting the raw water pump, make DEUTZ
Tools:
- Normal tools
Aids:
- Collecting vessels
Spare parts:
- Seals
- O-ring
Cross-references:
- Job Card W 9-7-3
Checking
● If raw water is exiting from the monitoring aperture
10, this means the raw water pump 6 needs
repairing,
82862 0
Ill. 1 Raw water lines

● Close the raw water cocks.
● Drain off raw water at drain plug 1; collect the raw
water which flows out.
● Remove raw water lines 2 and 3.
● Remove lube oil line 4; collect the lube oil which
flows out.
82863 0
Ill. 2 Lube oil line

© 0200 0299 7451-0120 Page 1 of 2
Coolant system
Job Card TBD 616
W 9-7-10
● Unscrew the four hexagonal nuts 5, and remove

the raw water pump 6 forwards.
● Flange 7 remains at end wall cover 8.
82864 0
82865 1
Ill. 4 Monitoring aperture
Fitting the raw water pump

● To fit the raw water pump, proceed in the opposite
sequence as appropriate.
● Fit new seals for raw water lines 2 and 3, and a new
O-ring 9.
● The face clearance is entailed by the flange 7.
Page 2 of 2 0299 7451-0120 © 0200

Coolant system
DEUTZ Job Card
TBD 616 W 9-7-10
Checking, removing and fitting the raw water pump, make Steimel
Tools:
- Normal tools
Aids:
- Collecting vessel
- Sealing compound DW 47
Cross-references:
- Job Card W 9-7-3
Checking
● If raw water exits from monitoring apertures 14,
this means the raw water pump 8 needs repairing,
82609 0

● Drain off raw water at the drain cocks 1.
● Unscrew hexagonal nuts 2 and 3, and remove
them, together with the spring washers.
● Remove bends 4 and 5, plus the associated
specially shaped seals.
● Close fuel cocks, and remove fuel lines 6, collect
the fuel which flows out.
● Unscrew hexagonal nuts 7 together with spring
washers, and take off raw water pump 8 together
with support 9.
● Unscrew hexagon-socket screw from flange 10,
and remove flange 10 from raw water pump 8;
clean sealing surfaces.
82610 0
Ill. 2 Raw water bend

0299 0299 7456-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-7-10 TBD 616
Fitting the raw water pump.

● Fit flange 10 to raw water pump 8.
● Apply sealing compound DW 47 to the sealing
surface of flange 10.
● Push raw water pump 8 onto stud bolts 11, and fit
support 9.
● Screw in hexagon socket screws 7 with new
spring washers, and tighten, using a tightening
torque of 67 Nm.
● Fit fuel lines 6, and vent fuel system.
● Fit bends 4 and 5, together with new seals.
● Unscrew hexagon socket screw 12 and fill raw
water pump with water through funnel 13.
● Screw in hexagon-socket screw 12. 82611 0
Ill. 3 Filling funnel
Page 2 of 2 0299 7456-0120 0299

Coolant system
DEUTZ Job Card
TBD 616 W 9-8-1
Checking the coolant thermostat

Aids:
- Water container
- Thermometer (measuring range up to
100␣ °C)
- Hotplate
Spare parts:
- Thermostat inserts if required
Cross-references:
- Job Card W 9-8-2
Preparatory work
● Removing and installing the thermostat inserts,
Checking the operating point of the

thermostat inserts
● Fill water container with water.
● Place thermostat inserts 6 and thermometer in
water container.
● Heat up water on hotplate, while checking
thermostat insert for expansion.
Opening must begin as per particulars on the

expandable working element 1, full opening 82522 0
as per Table 1.
Ill. 1 Opening commencement in °C
If this value is not reached, replace the
thermostat insert.
Opening to begin +- 2 °C 65 70 82
full opening
stroke min. 9.5 mm °C 78 83 95
max. perm. temperature °C 115 120 120
Tab. 1 Values of the expandable working 6
element
50992 0
Ill. 2 Thermostat insert

0199 0299 6775-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-8-1 TBD 616
Page 2 of 2 0299 6775-0120 0199

Coolant system
DEUTZ Job Card
TBD 616 W 9-8-2
Removing and installing the thermostat inserts

Tools:
Carry out this work only when the - Normal tools
! engine has been shut down. - Scraper
Comply with the tightening instructions Aids:

given in the Operating Manual, - Lithium-saponified grease
Chapter 8, „Technical Data“. - Liquid sealant
- Cleaning agent
Cross-references:
Removing the thermostat inserts

Carry out this work when the engine has
cooled down.
Remember that even when the outside of the
engine has cooled down, the coolant coming
out of the inside of the engine may still be hot.
● Drain off the coolant and collect for re-use.
● Unscrew hexagon-socket screws (Ill. 1, arrows).
● Swing the thermostat housing 1 downwards, and
take it off.
● Remove the second thermostat housing on the
opposite side in the same way as thermostat
housing 1.
● Take thermostats 2 and 6 out of the thermostat 82127 0
housings 1.
Ill. 1 Thermostat housing
● Remove any sealant residues at seal surfaces 7,
and degrease.
● Remove any dirt and incipient corrosion from the
seats of the thermostats inside the housing.
82128 0
Ill. 2 Thermostat
0599 0299 7461-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-8-2 TBD 616
Installing the thermostat inserts

● Use new O-rings 3, 4 and 5.
● Apply a thin coating of lithium-saponified grease
to all O-rings, and insert new thermostats into the
thermostat housings.
● Apply liquid sealant to the seal surfaces 7 of the
thermostat housings.
● Fit both thermostat housings in place in the reverse
sequence.
● Fill with coolant up to the “Cold” marking (see
Ill.␣ 4).
82129 0
Ill. 3 Thermostat
82130 0
Ill. 4 Filler neck
Page 2 of 2 0299 7461-0120 0599

Coolant system
DEUTZ Job Card
TBD 616 W 9-9-1
Removing and installing the preheating system for the coolant

A heating element 1 has been installed at the engine. Tools:
If you are going to clean only the heating element, it - Standard tools
is sufficient to remove it from the preheating system’s
housing.
Aids:
- Cleaning agent for boiler scale removal
- Collecting container for coolant
Removing the preheating system for the

coolant
● Switch off the power supply to heating element 1.
● Disconnect electric lines from heating element 1
and coolant pump 2.
● Unscrew coolant drain plug 3 and collect coolant
to be used again.
● Loosen union nuts 4 of coolant pipes 5.
● Remove fixing screws 7 of preheating system 6
and take out preheating system 6.
● Remove heating element 1.
Cleaning Installing the preheating system for the

● Immerse immersion heater in a bath with boiler coolant
cleaning agent until the boiler scale has dissolved ● Insert preheating system 6 and screw in fixing
off. Make sure the solvent does not affect any screws 7.
metal.
● Tighten union nuts 4.
Never use tools (e.g. a scraper) to remove the
boiler scrape by force. ● Screw in coolant drain plug 3 with a new seal.
● After completing the cleaning procedure, rub the ● Connect electric lines of heating element 1 and
immersion heater thoroughly, and rinse it in clean coolant pump 2.
water to ensure that no solvent gets into the ● Check preheating system for leaks.
engine’s coolant system.
● Fill with coolant.
0599 0299 4338-0120 Page 1 of 2

Coolant system
Job Card DEUTZ
W 9-9-1 TBD 616
80958 0
Ill. 1 Preheating system
Page 2 of 2 0299 4338-0120 0599

Coolant system
DEUTZ Job Card
TBD 616 W 9-10-2
Removing and installing the plate heat exchanger

Tools:
- Normal tools
Aids:
- Crane
- Collecting container for coolant
- Grease
Spare parts:
- Seals and O-rings
Cross-references:
- Job Card W 9-0-1
Removing the plate heat exchanger

● Drain off coolant,
● Detach and remove all lines at expansion tank 1.
● Remove the two retainer plates 2.
● Slightly tension expansion tank 1 with lifting tackle.
● Unscrew the four hexagon socket screws 3, and
lift off expansion tank 1.
● Remove elbow 4.
● Detach and remove coolant lines 5.
● Unscrew hexagonal nuts 6 at intake manifolds 7.
● Slightly tension plate heat exchanger 8 with lifting
tackle.
82491 0
● Unscrew the screws under plate heat exchanger
8, and lift off plate heat exchanger 8 frontwards. Ill. 1 Plate heat exchanger
● Deposit plate heat exchanger 8 on a wooden

board.
82492 0
Ill. 2 Screw union to expansion tank

0199 0299 6770-0120 Page 1 of 2
Coolant system
Job Card DEUTZ
W 9-10-2 TBD 616
82493 0
Ill. 3 Intake manifold and coolant lines
Fitting the plate heat exchanger

● Remove all seals and seal residues, and take off
the O-rings.
● Clean all sealing surfaces, smoothing them if
necessary with emery cloth.
● Fit new seals, coat new O-rings with grease, and
insert them.
● Fit plate heat exchanger, proceeding in the
opposite sequence to removal.
● Fill with coolant,
82494 0
Ill. 4 Intake manifold and raw water
82495 0
connection
Ill. 5 Raw water connections
Page 2 of 2 0299 6770-0120 0199
Coolant system
DEUTZ Job card
TBD 616 W 9-10-3
Dismantling and assembling the plate heat exchanger

Tools:
- Normal tools
- Screwdriver
- Press, approx. 15 t
- Press-off device
- 2 guide bolts (Ill. 10)
Aids:
- Cleaning agent P3-T288, Messrs. Hen-
kel, Düsseldorf
- Compressed air
- Crane
- Silicone sealing compound, DEUTZ Part
Number 0140 0735
- Grease
- Molykote
- Emery cloth, fine
Spare parts:
- Seals and O-rings
- Heat exchanger plates
Cross-references:
- Job Card W 9-8-1, W 9-10-2, W 9-10-4
- Instructions from the cleaning agent
manufacturer
Preparatory work
● Remove plate heat exchanger,
Dismantling the plate heat exchanger 1

● Unscrew stud bolts 2.
● Unscrew hexagon-head screws 3 at the raw water
connections 4.
● Unscrew all screws at the two thermostat housings
5, Ills. 2 and 3.
82496 0
Ill. 1 Plate heat exchanger

0199 0299 6765-0120 Page 1 of 10
Coolant system
Job Card DEUTZ
W 9-10-3 TBD 616
82497 0
Ill. 2 Unscrewing the thermostat housing

screws
● With light taps of a plastic hammer, detach the
thermostat housing 5 and remove it.
82498 0
Ill. 3 Detaching the thermostat housing
82499 0
Ill. 4 Cover plate

Page 2 of 10 0299 6765-0120 0199
Coolant system
DEUTZ Job card
TBD 616 W 9-10-3
● Withdraw raw water connections 4.

● Loosen the eight screws 6 in a diagonally opposite
sequence, and use screwdriver 7 to unscrew them
in a diagonally opposite sequence.
Caution!
Plate assembly 9 is under tension!
● Take off compression plate 8.

● Take off spacer bushes 8a.
82500 0
Ill. 5 Destressing the plate assembly
● Take off cooling plates 10.
82501 0
Ill. 6 Cooling plates
● Unscrew hexagon socket screws 11 of the two

thermostat housings 5.
82502 0
Ill. 7 Thermostat housing

0199 0299 6765-0120 Page 3 of 10
Coolant system
Job Card DEUTZ
W 9-10-3 TBD 616
● With light taps of the plastic hammer, separate

thermostat housings 5 and 23 from each other,
see Ill. 8.
● Remove thermostats 12 from the housings, and
clean them.
● Check thermostats 12,
● Clean all sealing surfaces, smoothing them with
emery cloth if necessary.
● Clean all housings with P3-T288 cleaning agent,
following the instructions provided by its
manufacturer.
● After cleaning, rinse housing with clear water.
82503 0
Ill. 8 Thermostat housing with thermostats
● Check seals 13 of cooling plates 10 for faultless

condition. If any of the seals 13 are damaged,
replace the cooling plate concerned. For Marking
Number, see Ill. 11, for DEUTZ Ordering No. see
Table 1.
● Clean cooling plates 10,
82504 0
Ill. 9 Seals
Assembling the plate heat exchanger

● Fit the two guide bolts 20.
20
SW 24 M 14
20 30
560
82507 0
Ill. 10 Guide bolt

Page 4 of 10 0299 6765-0120 0199
Coolant system
DEUTZ Job card
TBD 616 W 9-10-3
● First of all, insert end plate 14, Ills. 12 and 13, with
the seal facing downwards towards the housing,
then channel plates (A) 16 and channel plates (B)
17, always alternately, as shown in Ills. 6 and 13,
with the seal facing downwards. Finally, insert end
plate 18 and the compression plate 8.
The arrow direction of the plates must be
alternately opposite!
See also Ills. 9 and 13.
● Insert spacer bushes 8a.
● Coat all threads 8b with a thin film of Molykote.
82505 0
Ill. 11 Marking Number
82508 0
Ill. 12 End plate
Pos.Designation Marking DEUTZ No. off

Number Ord.-No. 8 12 16
-cyl.
14 End plate G 119025-0183 G 1227 6853 1 1 1
16 Channel plate A 119291-2103 A 1227 6857 21 33 39
17 Channel plate B 119291-3103 B 1227 6856 21 33 39
18 End plate A 119025-0116 A 1227 6854 1 1 1
Tab. 1 Plate information
82506 0
Ill. 13 How to install

0199 0299 6765-0120 Page 5 of 10
Coolant system
Job Card DEUTZ
W 9-10-3 TBD 616
● Tighten the eight screws 6 evenly in a diagonally

opposite sequence, see Ill. 14.
With new cooling plates 10, screws 6 will not
grip; then proceed as described below.
82509 0
Ill. 14 How to tighten
● Suspend plate heat exchanger from crane, and

deposit on a press; see Ill. 15.
82510 0
Ill. 15 Deposit plate heat exchanger on press
● Place first a plastic plate, then a metal plate 21 on

the compression plate 8.
● Operate press 22, and keep it at about 14 t; the
cooling plates 10 will be pressed together,. This
operation may take 20 minutes before screws 6
actually grip.
● Screw in screws 6 with screwdriver 7 in a diagonally
opposite sequence; see Ill. 14.
● Use a torque wrench to tighten screws 6 in a
diagonally opposite sequence; tightening torque
1320 Nm.
● Unscrew guide bolts 20.
82511 0
Ill. 16 How to use the press

Page 6 of 10 0299 6765-0120 0199
Coolant system
DEUTZ Job card
TBD 616 W 9-10-3
● Degrease all sealing surfaces.

● Grease seat of thermostats 12, and install
thermostats as shown in Ill. 8.
● Apply silicone sealing compound, as shown in Ill.
17; make sure vent bore 25 remains free of sealing
compound.
82512 0
Ill. 17 Liquid silicone seal
● Place thermostat housing 23 on thermostat

housing 5, and screw together lightly with screws
11.
82513 0
Ill. 18 Screwing the housing together
● Apply silicone sealing compound, as shown in Ill.

19; make sure vent bore 26 remains free of sealing
compound.
82514 0
Ill. 19 Liquid silicone seal

0199 0299 6765-0120 Page 7 of 10
Coolant system
Job Card DEUTZ
W 9-10-3 TBD 616
● Insert some sealing compound in the two threaded

bores 27.
82515 0
Ill. 20 Sealing surface of the plate heat

exchanger
● Insert new O-rigs 29, and coat O-rings 29 and
sealing surfaces 30 with grease.
● Fit the two raw water bends 3 and 4; tighten
screws 28 until they are hand-tight.
82516 0
Ill. 21 Raw water connections
● Screw thermostat housing 5 to plate heat

exchanger 1.
● Fit two washers 38 under screw 31.
● Tighten screws 30 and 31 until they are hand-
tight.
● Tighten screws 32 until they are hand-tight, and
loosen then again.
● Tighten screws 11 at thermostat housing 23 until
they are hand-tight, then tighten screws 32 until
they are hand-tight.
● Fit opposite thermostat housing as described
above; screw in all screws with only one washer.
82517 0
Ill. 22 Fitting the thermostat housing
Page 8 of 10 0299 6765-0120 0199

Coolant system
DEUTZ Job card
TBD 616 W 9-10-3
Leak check
● The cooling plates 10 must, as depicted in Ill. 23,
be in a honeycomb configuration.
82518 0
Ill. 23 Cooling plates
● Seal off openings 33 at heat exchanger 1 to

prevent leaks, and fit water connections 34.
● Unscrew water connections 35 seal off with screw
plugs to prevent leaks.
● Fill with water through the top water connection
until water is exiting from the openings 36, then
shut off the water and seal off openings 36 to
prevent any leaks.
● Fill with water until water is exiting from the
openings 37, then shut off the water, and seal off
openings 37 to prevent any leaks.
82519 0
Ill. 24 Plate heat exchanger
82520 0
Ill. 25 Screw plugs

0199 0299 6765-0120 Page 9 of 10
Coolant system
Job Card DEUTZ
W 9-10-3 TBD 616
● Close stopcock 36. and through the bottom water

connection apply a pressure of 5 bar to the plate
heat exchanger 1.
● The pressure must be retained for 1/2 hour, and
must not drop.
● If the pressure drops, replace leaking cooling
plate(s) 10.
● Bleed off the pressure, and drain off the water.
● Remove all closures and water connections.
● Fit coolant connections 35.
● Fit plate heat exchanger,
82521 0
Ill. 26 Stopcock
Page 10 of 10 0299 6765-0120 0199

Coolant system
DEUTZ Job Card
TBD 616 W 9-10-4
Cleaning the cooling plates

Tools:
- Soft brush
Aids:
- High-pressure water jet
- Cleaning trough
- Cleaning chemicals
- Compressed air
Spare parts:
- Cooling plate(s)
Cross-references:
- Job Cards W 9-10-2, W 9-10-3
- Instructions from the cleaning agent
manufacturer
Preparatory work
● Remove plate heat exchanger,
● Dismantle plate heat exchanger,
Cleaning the cooling plates

● If they are fouled or flogged, cooling plates 10
must be cleaned in accordance with Table 1.
● If cooling plates 10 are cleaned with chemical
agents, you must following the cleaning and
accident prevention instructions from the
manufacturer concerned.
Do not use a hydrochloric acid mixture for
cleaning purposes, since this would corrode 82501 0
the seals! Ill. 1 Cooling plates

● After chemical cleaning, rinse the cooling plates
10 with clear water, and blow them dry with
compressed air.
● Check all seals 13 for perfect condition; if you find
any damage, replace the cooling plates 10 involved.
● The DEUTZ Ordering Number can be defined in
terms of the Marking Number, Ill. 3 and Table 1 in
Job Card W 9-10-3.
82504 0
Ill. 2 Seals
0199 0299 6780-0120 Page 1 of 4
Coolant system
Job Card DEUTZ
W 9-10-4 TBD 616
● Assemble plate heat exchanger,

● Fit plate heat exchanger,
82505 0
Ill. 3 Marking number
Page 2 of 4 0299 6780-0120 0199

Coolant system
DEUTZ Job Card
TBD 616 W 9-10-4
Fouling and clogging Countermeasures

Sedimentation
The inlet and outlet openings of the cooling plates are Increased cooling water velocity
clogged up by large particles (> 3 mm), sand or mud.
Spülen
Mechanical cleaning after opening with water, a soft
brush, and a high-pressure water jet.
Be careful not to damage the seals!
Deposits
Carbonate deposits (calcium carbonate, calcium Increased cooling water velocity
sulphate and silicates) up to several millimetres.
Lower cooling water temperature, if possible
Addition of agents (= active substances)
Chemical cleaning of the cooling plate using:
- nitric acid *
- sulphamic acid *
- citric acid *
- phosphoric acid *
- sodium polyphosphates *
* concentration max. 4 %,
temperature max 60 °C
Coarse fouling
Fibres, marine plants and shells collect in the openings Backflush the unopened plate heat exchanger.
and the cooling plate inlet area.
Biological fouling
Mud deposits in the cooling plates up to 1 mm in Mechanical cleaning after opening with water, a soft
thickness, caused by bacteria and diatomic brush and a high-pressure water jet.
organisms.
Fouling due to shells.
Chemical cleaning of the cooling plates using:
- sodium hydroxide *
- sodium carbonate *
The cleaning effect can be substantially enhanced by
adding small quantities of hypochloride.
* concentration max. 4 %,
temperature max. 60 °C
Tab. 1 Malfunctions and countermeasures
0199 0299 6780-0120 Page 3 of 4

Coolant system
Job Card DEUTZ
W 9-10-4 TBD 616
Page 4 of 4 0299 6780-0120 0199

Coolant system
DEUTZ Job Card
TBD 616 W 9-10-5
Checking the plate heat exchanger

Tools:
! - Normal tools
- Torch
Aids:
- Collecting vessel
Cross-references:
- Job Cards W 9-10-2, W 9-10-3,
W 9-10-4
Checking the plate heat exchanger

● Shut down the engine, and secure it against being
started up.
● Drain off coolant as far as below bend 1.
● Collect coolant for re-use.
● Detach raw water line 3.
● Unscrew screws 2, remove bend 1.
● With a torch, check the cooling plates through the
opening.
● If you find substantial deposits, then the plate heat
exchanger has to be cleaned;
see Job Cards W 9-10-2, W 9-10-3 and W 9-10-4.
● Insert bend 1 again, with two new O-rings, and
tighten screws 2 until they are handtight. 82563 0
● Fill up again with the coolant drained off previously. Ill. 1 Bend
0199 0299 7471-0120 Page 1 of 2

Coolant system
Job Card DEUTZ
W 9-10-5 TBD 616
Page 2 of 2 0299 7471-0120 0199

Compressed air system
DEUTZ Job Card
- TBD 616 W 10-5-1
Removing and fitting the compressor

Tools:
! - Normal tools
- Pull-off device
Secure engine against start-up. - Scraper
Aids:
- Cleaning agent
- Liquid sealing compound
- Collecting vessel
Removing the compressor

● Remove air lines 1 and 2.
● Remove coolant lines 3 and 4, collect the coolant
which flows out.
● Remove lube oil line 5, collect the lube oil which
flows out.
82867 0
Ill. 1 Air and coolant lines
82868 0
Ill. 2 Lube oil line

0499 0299 7466-0120 Page 1 of 2
Compressed air system
Job Card DEUTZ
W 10-5-1 TBD 616
● Remove generator 6 and support 7.

● Through the opening now accessible, unscrew
the hexagonal nuts M 20 x 1.5.
● Use the pull-off device to remove the compressor
gear wheel.
● Unscrew the three hexagonal nuts 8, and remove
them, with the spring washers.
● Take off compressor 9 over stud bolts 10.
● Clean all sealing surfaces, remove seal residues
with a scraper
82869 0
Ill. 3 Generator
Fitting the compressor

● To fit the compressor 9, proceed in the opposite
sequence as appropriate.
● Coat sealing surfaces of compressor 9 and support
7 all the way round with liquid sealing compound.
● Tightening torque for hexagonal nut M 20 x 1.5 is
180 +- 20 Nm.
82870 0
Ill. 4 Compressor
Page 2 of 2 0299 7466-0120 0499

Other components
DEUTZ Job Card
TBD 616 W 12-1-4
Removing and mounting the torsional vibration damper

Tools:
! - Standard tools
- Hoist
Aids:
- Cleaning agent
Chapter 8, „Technical Data“. Spare parts:
- Clamping sleeves
Cross-references:
- Job Card W 2-0-1, W 12-1-5
Removing the torsional vibration

damper 1
● Remove protective covering.
3
● Unscrew the ten fixing screws 2.
● Take off both torsional vibration dampers 1, disk 2
3 and, if attached, the V-belt pulley.
● Pull off clamping sleeve 4. 4
● Unscrew cylinder screws 5 and remove connection
7
flange 6.
● Take off clamping sleeve 7. 5
● Clean all parts thoroughly.
6
80957 0
Ill. 1 Torsional vibration damper
Mounting the torsional vibration

damper
● If necessary, replace the torsional vibration
damper.
You mount the torsional vibration damper in the
reverse sequence, noting the following points:
- Replace clamping sleeves 4 and 7.
- Tightening and installation instructions,
0599 0299 4339-0120 Page 1 of 2

Other components
Job Card DEUTZ
W 12-1-4 TBD 616
Page 2 of 2 0299 4339-0120 0599

Other components
DEUTZ Job Card
TBD 616 W 12-1-5
Torsional vibration damper, installation instructions, with screw plug

Tools:
- Normal tools
- Torque wrench
Aids:
- Lube oil
- Oil-proof paint
- Loctite DEUTZ-DW 62
- Solvent

oil.
paint.

1 M27x2x95 10.9 1600+20 Insert hex.-head screw with
Loctite DEUTZ-DW 62
3 M16x1,5x80 12.9 380+10 60 Use new cylinder-head screws
4 M8x40 10.9 Cylinder-head screws
M16x120 10.9 310 Cylinder-head screws
M16x205 8.8 210 Hex.head screws

V2 ⇒ Use a torque wrench to tighten to... Nm
Assembly instructions and sequence of threaded connections 1 and 3:

- When screwing in the screws, do not allow any oil to penetrate into the flange joint.
- Clean end surface X between crankshaft and counter-flange at the flanges with residue-free solvent,
making sure it is free of grease.
- Tighten Pos. 3 eight times in diagonally opposite sequence.
- Tighten Pos. 1.
0199 0299 4340-0120 Page 1 of 2

Other components
Job Card DEUTZ
W 12-1-5 TBD 616
1 X
5 4 3 2
80946 1
Page 2 of 2 0299 4340-0120 0199

Other components
DEUTZ Job Card
TBD 616 W 12-1-5
Torsional vibration damper, installation instructions, with central screw

Tools:
- Normal tools
- Torque wrench
Aids:
- Lube oil
- Oil-proof paint
- Loctite DEUTZ-DW 62
● End surfaces of crankshaft X and counter-surface

at the hub must be cleaned with residue-free
solvent to render them clean and grease-free.
oil.
paint.
● Installation sequence for the cylinder head screws

1 M20x30 8.8 1600+20 Insert hex.-head screw with
Loctite DEUTZ-DW 62
3 M16x1,5x80 12.9 380+10 60 Cylinder-head screws*
4 M8x40 10.9 Cylinder-head screws
M16x120 10.9 310 Cylinder-head screws
M16x205 8.8 210 Hex.head screws

V2 ⇒ Use a torque wrench to tighten to... Nm
* Screws may only be used once.
0199 0299 4727-0120 Page 1 of 2

Other components
Job Card DEUTZ
W 12-1-5 TBD 616
5 4 3 2
80946 2
Page 2 of 2 0299 4727-0120 0199

Other components
DEUTZ Job Card
TBD 616 W 12-6-1
Removing and installing the flywheel

Tools:
! - Standard tools
- Flywheel mounting mandrels
- Hoist
Cross-references:
You have to remove the flywheel if the starter toothed - Job Cards W 2-0-1, W 12-6-2
gear has to be exchanged or if the thrust ring and the
shaft sealing ring need to be replaced.
Removing the flywheel

● Remove the components covering the flywheel.
● Unscrew two opposite flywheel fixing screws and,
screw in mounting mandrels in their place (see
Ill.␣ 1).
● Use the hoist to take the weight of the flywheel.
● Remove remaining fixing screws and carefully pull
the flywheel off, using two turning rods to lever off
the flywheel from two ends.
50700 0
Ill. 1 Mounting mandrels
Installing the flywheel

● Install the flywheel in the reverse sequence, also
using the two mounting mandrels. For tightening
instructions, see Assembly Instructions, Job Card
W 12-6-2.
0599 0299 4341-0120 Page 1 of 2

Other components
Job Card DEUTZ
W 12-6-1 TBD 616
Page 2 of 2 0299 4341-0120 0599

Other components
DEUTZ Job Card
TBD 616 W 12-6-2
Flywheel, installation instructions

Tools:
- Normal tools
- Torque wrench
Aids:
- Lube oil
- Oil-proof paint
● Coat the head supports and screw threads with

lube oil.
paint.
No. Dimensions Strength H V1 V2 V3 Other procedures/Remarks

1 M16x1.5x80 12.9 380+10 Cylinder-head screw

0599 0299 4342-0120 Page 1 of 2

Other components
Job Card DEUTZ
W 12-6-2 TBD 616
80945 0
Ill. 1 Flywheel
Page 2 of 2 0299 4342-0120 0599

Electrical system
DEUTZ Job Card
Engines 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.
0299 0299 4343-0199 Page 1 of 2

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

Service
Knowing it’s DEUTZ
DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry.
As an independent motor manufacturer, we offer — worldwide — a comprehensive range of diesel and gas
motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job reliably all over the world. We are determined to preserve the high
standard of performance and dependability of our motors, thus keeping our customers satisfied at all times.
Therefore we are represented worldwide through a network of highly competent service partners who will meet
the needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors which pack a lot of inventive genius. DEUTZ also means
reliable service and comprehensive support to enhance your motor’s performance.
This index Sales & Service offers you an overview of the DEUTZ partners in your vicinity, including the products
for which they are responsible and the range of services provided. But even when no direct product
responsibility is mentioned, your DEUTZ partner will be happy to help you with expert advice.
The Index is constantly updated. Please ask your DEUTZ service partner for the latest edition.
DEUTZ AG — at your service.
Order-No.: 0297 7444
Order-No.: 0297 7445 (CD-ROM)
Obtainable from the local service Partner reponsible for you or from: DEUTZ AG
Deutz-Mülheimer Str. 147-149
D-51057 Köln
Phone: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
Service http://www.deutz.de
0898 0297 7474-0199 Service

DEUTZ TBD 616, WH, en

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We reserve the right to make technical changes in the illustrations and

This documentation is intended for the following engine

Tel.: (02 21) 8 22-0

Order No. 0299 7321 en

Page II 0299 4266-0120 © 0500

0199 0299 3235-0199 Page III

Page IV 0299 3235-0199 0199

Care and maintenance

Careful when the engine is running!

0199 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 0199

MALFUNCTIONS IN OPERATING INSTRUCTIONS

0199 0299 3232-0199 Page VII

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Page VIII 0299 3232-0199 0199

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

1099 0299 4267-0120 Page IX

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Page X 0299 4267-0120 1099

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

0798 0299 3245-0199 Chapter 1 - Page 1

1.1 General remarks

1.2 Safety instructions / Accident prevention

● for the machine room:

● for operation and maintenance of the engine:

Chapter 1 - Page 2 0299 3245-0199 0798

1.3 Operating instructions and Workshop manual 1

1.4 Job cards

0798 0299 3245-0199 Chapter 1 - Page 3

Maintenance Group (the same for all engines)

Ill. 101 Numbering of the Job Cards

Chapter 1 - Page 4 0299 3245-0199 0798

Ill. 102 Structure of the Job Cards

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

0798 0299 3245-0199 Chapter 1 - Page 5

1 1.5 Spare parts

Chapter 1 - Page 6 0299 3245-0199 0798

© 0500 0299 4268-0120 Chapter 2 - Page 1

Chapter 2 - Page 2 0299 4268-0120 © 0500

Jobs Job Card

© 0500 0299 4268-0120 Chapter 2 - Page 3

Jobs Job Card

Chapter 2 - Page 4 0299 4268-0120 © 0500

2.1.2 Arranged by Job Card Numbers

© 0500 0299 4268-0120 Chapter 2 - Page 5

Job Card Jobs

Chapter 2 - Page 6 0299 4268-0120 © 0500

Job Card Jobs

© 0500 0299 4268-0120 Chapter 2 - Page 7

2 2.1.3 Explanation of symbols

2.2 Job Cards arranged by Job Card Numbers

Chapter 2 - Page 8 0299 4268-0120 © 0500

Drive mode n = constant