620 work shop manual

0297

"

5.

"

1.

"

3.

"

"

4. 6.

"

2.

Workshop manual

TBG 620/TBG 620K

Workshop manual

TBG 620/TBG 620K

0299 6277 en

Engine manufacturer:

Motoren-Werke Mannheim AG(DEUTZ MWM)Carl-Benz-Str. 5D-68167 Mannheim

Tel. (06 21) 3 84-0Tx. 462341Fax (06 21) 3 84-83 86

Workshop manual

TBG 620/TBG 620K

We reserve the right to make technical alterations to the drawingsand particulars in this documentation package, if this should be-come necessary to improve the engines. Reprints and duplication ofany kind, either in whole or in part, require our written permission.

Engine Number:

Please enter your engine number here. This will help us to serve youbetter in questions of repairs, spare parts and after-sales servicegenerally.

Page II 0299 3923-0122 0997

DEUTZ MWMTBG 620/TBG 620K

Imprint:DEUTZ AGService-TechnikServicedokumentationDeutz-Mlheimer Strae 147149D-51057 CologneTel.: (+49 2 21) 8 22-0Fax: (+49 2 21) 8 22-53 58http://www.deutz.de

Printed in GermanyAll rights reserved(1) 0997

Ordering No. 0299 6277 en

This documentation is intended for the following engine.

l Engine type:

l Application:

l System name:

l Rating: kW

l Speed: / min

l Commissioning on: 19

Please enter the relevant data. This will make it easier for us to help you in questions involving repairs,spare parts and after-sales service in general.

This documentation package is to be presented to the Service Partner responsible every time a servicejob is carried out.

0997 0299 3235-0199 Page III

DEUTZ MWMEngines

l Please read all the information contained in this manual, and follow the instructions carefully. You will avoidaccidents, retain the manufacturers warranty, and will be able to use a fully functional and operationalengine.

l This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as definedby the equipment manufacturer (intended use). Any other use shall be construed as not intended. Themanufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solelyby the user.

l The term intended use shall also include compliance with the operating, maintenance and repairconditions specified by the manufacturer. The engine may be used, maintained and repaired only bypersons who are familiar with the work concerned and who have been properly informed of the risksinvolved.

l 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.

l Non-compliance with these operating instructions may result in engine malfunctions and even damage orinjury to persons; the manufacturer will accept no liability in such cases.

l Proper maintenance and repair work depends on the availability of all requisite equipment, tools and specialimplements, all of which must be in perfect condition.

l Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handledproperly.

l The relevant accident prevention regulations and other generally recognized rules relating to safetyengineering and health and safety at work must all be complied with.

l Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG areused.

l Engine repairs must correspond to the intended use. In the event of modification work, only parts approvedby the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine willpreclude any liability of the manufacturer for resultant damage.

Page IV 0299 3235-0199 0997

DEUTZ MWMEngines

Forword

Dear customer,

The engines of the DEUTZ MWM brand have been developed for a broad spectrum of applications.A comprehensive range of different variants ensures that special requirements can be met for theindividual case involved.

Your engine has been equipped to suit your own particular installation, and accordingly not all of thedevices 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 foryou 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 maintenanceinstructions 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

0997 0299 3235-0199 Page V

DEUTZ MWMEngines

General

DEUTZ MWM enginesare the culmination of long years filled with research and development work. The in-depth know-howthus acquired, in conjunction with high standards of quality, is your guarantee for engines manufacturedfor long lifetime, high reliability and low fuel consumption. And of course, stringent criteria ofenvironment-friendliness are met as well.

Care and maintenanceare crucial factors in ensuring that your engine satisfactorily meets the requirements involved.Compliance with the specified maintenance intervals and meticulous performance of care andmaintenance work are therefore absolutely essential. Special attention must be paid to any morecritical operating conditions deviating from the norm.

DEUTZ AGIn the event of malfunctions, or if you need spare parts, please contact one of our responsible serviceagencies. 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 anyprotective features, fit them back in position after completing your work. Always wear tight-fittingclothing if you are working on the engine while it is running.

SafetyYou will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safetyinstructions to your operating staff as well. In addition, comply with the statutory general safety andaccident prevention regulations applying in your country.

InstructionYou will find this symbol next to instructions of a general nature.Follow these instructions carefully.

AsbestosThe seals and gaskets used in this engine are asbestos-free. Please use the appropriate spareparts for maintenance and repair jobs.

Page VI 0299 3232-0199 0997

DEUTZ MWMEngines and Systems

Quick Introduction

QUICK INTRODUCTION (FOR TRAINED AND QUALIFIED PERSONNEL)

GETTINGSTARTED

OPERATING INSTRUCTIONSChap. 1 Advice to users

Chap. 2 Description

Chap. 3 Operation

Chap. 4 Expendables

Chap. 10 Test reports

NORMALOPERATION

OPERATING INSTRUCTIONSChap. 3 Operation

Chap. 4 Expendables

MAINTENANCE OPERATING INSTRUCTIONSChap. 1 Advice to users

Chap. 4 Expendables

Chap. 5 Maintenance and

Servicing

Chap. 8 Technical data

Chap. 9 Maintenance work

SPARE PARTS CATALOGUESpare parts

DEUTZ Service

0997 0299 3232-0199 Page VII


Quick Introduction

SERVICING OPERATING INSTRUCTIONSChap. 1 Advice to users

Chap. 5 Maintenance and

Servicing


WORKSHOP MANUALServicing work

SPARE PARTS CATALOGUE

Spare parts

DEUTZ Service

MALFUNCTIONS INOPERATION

OPERATING INSTRUCTIONSChap. 6 Operational disturbances

causes, corrective action


Chap. 10 Test reports

Chap. 9 Maintenance work

SPARE PARTS CATALOGUESpare parts

DEUTZ Service

WORKSHOP MANUALServicing work

SPARE PARTS CATALOGUE

Spare parts

DEUTZ Service

Page VIII 0299 3232-0199 0997


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0997 0299 3920-0122 Page IX

DEUTZ MWM ContentsTBG 620/TBG 620K

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 Cards2.1 Overviews2.1.1 Arranged alphabetically2.1.2 Arranged by Job Card Numbers2.1.3 Explanation of symbols2.2 Job Cards arranged by Job Card Numbers

Service

Page X 0299 3920-0122 0997

Contents DEUTZ MWMTBG 620/TBG 620K

Please note:

Operating instructions for DEUTZ MWM TEM System are a separate documentationand has to be ordered separately.

0997 0299 3245-0199 Chapter 1 - Page 1

DEUTZ MWM Advice to usersEngines and Systems

11 Advice to users1.1 General remarks

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

Chapter 1 - Page 2 0299 3245-0199 0997

Advice to users DEUTZ MWMEngines and Systems

1 1 Advice to users

1.1 General remarksThe 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 theirjobs properly. Any safety and protective features which had to be removed during maintenance and servicingwork must be fitted back in place after completion.

The accident prevention and safety regulations must by always be complied with throughoutall maintenance and servicing work.Also note the special safety instructions for the various servicing groups which are listedin 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 alsoprovides information on the jobs required.The job cards (Chapter 9) give technical instructions on how to actually perform the jobs.

1.2 Safety instructions / Accident preventionFor 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 professionalassociations or in specialized bookshops). They depend on the installation site, the operating mode andthe expendables and auxiliary materials used.Special protective arrangements dependent on the particular jobs are indicated and marked in the jobdescription.In general, the following applies:l 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.

l 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.

l 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.

0997 0299 3245-0199 Chapter 1 - Page 3


11.3 Operating instructions and Workshop manualIn order to provide a user-specific information structure, the service documentation has been divided into theOperating Instructions and the Workshop Manual.The Operating Instructions include a general description as well as instructions for all necessary maintenancejobs.In detail, they contain the following chapters:

0 General remarks, Getting started, Contents1 Advice for the user2 Engine description3 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 expendables5 Maintenance and servicing, with

- Tools and equipment overview- Maintenance and servicing schedules

6 Operational malfunctions, their causes and how to correct them7 Engine conservation8 Technical particulars9 Job Cards, arranged by Job Card Numbers10 Sundry other instructions (if not included in the appendix or in separate files)

After-sales service Global service directory.

The Workshop Manual presopposes knowledge of the contents of the Operating Instructions. This particularlyapplies to the safety instructions. It describes easy repair jobs and emergency measures on components, whichare more elaborate to peform, and require appropriately qualified professional staff.It contains the following chapters:

0 General remarks, Getting started, Contents1 Advice for the user2 Job Cards, arranged by Job Card Numbers

After-sales service Global service directory.

1.4 Job cardsThe Job cards are divided into maintenance Job Cards of Operating instructions, for example B 1-1-1 andservicing Job Cards of the Workshop Manual, for example W 4-5-1.For the numbering please refer to Fig. 101.The structure of a Job Card is shown in Fig. 102.

Chapter 1 - Page 4 0299 3245-0199 0997


1Type of documentation

Subsystem (component)

Serial Number

Maintenance Group (the same for all engines)

The letter at the front signifies the type of documentation involved. B = Operating Instructions W = Workshop Manual

The subsystems are distinguished by maintenance groups. Generally valid: 0 Cross-subsystem or Safety Regulations 1 System parameters or general checks

Counting per subsystem (component) Various jobs per subsystem (component) Version differences

0 General remarks / cross-category jobs1 Cylinder head2 Drive mechanism3 Crankcase4 Engine control5 Governor6 Exhaust gas system / Charging7 Fuel system

8 Lube oil system9 Coolant system

10 Compressed air system11 Monitoring system12 Other components13 Electrical system

B 3-3-380307 0

Fig. 101 Numbering of the Job Cards

0997 0299 3245-0199 Chapter 1 - Page 5


1

80300 1

Fig. 102 Structure of the Job Cards

1 DEUTZ AG,editor of the service documentation

2 DEUTZ MWM, manufacturer, andengine type to which the Job Card refers

3 Short title of the Job Card4 Number of the Job Card5 Necessary tools, equipment, and

spare parts6 Reference to further Job Cards,

instructions, etc.7 Explanatory diagrams8 Present page of total number of pages9 Internal part number of the Job Card

10 Date of issue of the Job Cards11 Sequence of operations, work procedure12 Safety instructions and general hints13 Full title of the Job Card

If you have any questions on the Job Card,please always state the engine type (2), thenumber (4), the page (8), the date of issue(10) or, as an alternative, the Internal partnumber (9).

Chapter 1 - Page 6 0299 3245-0199 0997


1 1.5 Spare partsYou will receive spare parts from Messrs. DEUTZ AG.You will find a list of the spare parts in the enginesspare parts list.

0997 0299 3921-0122 Chapter 2 - Page 1

DEUTZ MWM Job CardsTBG 620/TBG 620K

2

B 0-1-2B 0-1-2B 3-3-3B 3-3-3

W 2-1-4W 2-1-4

2 Job Cards2.1 Overviews2.1.1 Arranged alphabetically2.1.2 Arranged by Job Card Numbers2.1.3 Explanation of symbols2.2 Job Cards arranged by Job Card Numbers

Chapter 2 - Page 2 0299 3921-0122 0997

Job Cards DEUTZ MWMTBG 620/TBG 620K

2 2 Job Cards

2.1 Overviews2.1.1 Arranged alphabeticallyJobs Job CardBearing race (drive end): removing and installing W 2-2-1Bearing race (free end): removing and installing W 2-2-3Bearing shells: checking for wear and tear W 2-1-3Bearing spread: checking W 2-1-1Camshaft bearings: removing and installing W 4-1-1Camshaft: installing W 4-5-2Camshaft: removing and checking W 4-5-1Connecting rod bearings: installing W 2-5-2Connecting rod bearings: removing W 2-5-1Connecting-rod bearings and connecting rod: checking for roundness and conicity W 2-3-1Coolant preheater: removing and installing W 9-9-1Coolant system: draining W 9-0-1Crack inspection with the diffusion liquid procedure W 0-3-2Crankshaft sealing ring (drive end): removing and installing W 2-2-2Crankshaft sealing ring (free end): removing and installing W 2-2-4Cylinder head: checking W 1-4-2Cylinder head nuts: hydraulically loosing and tightening W 1-4-0Cylinder head: removing and fitting W 1-4-4Cylinder liner: installing W 3-3-4Cylinder liner: measuring W 3-3-1Cylinder liner: removing W 3-3-3Cylinder liners: endoscoping W 3-3-2Deep-groove bearing: Replacement criteria W 2-0-2Drive mechanism: checking W 2-1-0Drive mechanism: Safety Instructions W 2-0-1Engine: running in W 0-1-3Flywheel: removing and fitting W 12-6-1Foundation bolts: checking W 3-7-1Frequency generator: removing, installing and checking W 5-3-13Gear train: checking W 4-8-1Gear train: removing and installing W 4-4-1Hydraulic clamping device: filling and venting W 0-0-1Instructions for Work on the Electrical Equipment W 13-0-1Liquid Nitrogen: use of W 0-3-1Mixture cooler: cleaning on the air side W 6-4-5Mixture cooler: cleaning on the water side W 6-4-4Oil pressure control valve, removing, installing and checking W 8-11-2

0997 0299 3921-0122 Chapter 2 - Page 3


2

Arranged alphabeticallyJobs Job Card

Piston cooling-oil jets: checking, removing and installing W 2-15-1Piston pin bush: removing and installing W 2-12-2Piston pin: removing and installing W 2-12-4Piston: removing and installing W 2-9-3Piston ring grooves and piston rings: checking W 2-10-3Piston rings: removing and installing W 2-10-1Sparking plug guard sheath: removing and installing W 1-10-2Torsional vibration damper: removing and fitting W 12-1-4Valve actuator bridges, guide bolts: removing and installing W 1-2-3Valve guides: checking, removing and installing W 1-6-1Valve lifter and valve lifter bracket: removing, checking and installing W 1-2-2Valve mechanism, bottom: removing, installing and checking W 4-2-1Valve rotating device: removing, checking, and installing W 1-3-1Valve seat ring: removing and installing W 1-7-3Valve seats: endoscoping W 1-7-2Valves and valve seat rings: checking W 1-7-1Valves: removing and installing W 1-5-1

Chapter 2 - Page 4 0299 3921-0122 0997


2 2.1.2 Arranged by Job Card NumbersJob Card Jobs

W 0-0-1 Hydraulic clamping device: filling and ventingW 0-1-3 Engine: running inW 0-3-1 Liquid Nitrogen: use ofW 0-3-2 Crack inspection with the diffusion liquid procedureW 1-2-2 Valve lifter and valve lifter bracket: removing, checking and installingW 1-2-3 Valve actuator bridges, guide bolts: removing and installingW 1-3-1 Valve rotating device: removing, checking, and installingW 1-4-0 Cylinder head nuts: hydraulically loosing and tighteningW 1-4-2 Cylinder head: checkingW 1-4-4 Cylinder head: removing and fittingW 1-5-1 Valves: removing and installingW 1-6-1 Valve guides: checking, removing and installingW 1-7-1 Valves and valve seat rings: checkingW 1-7-2 Valve seats: endoscopingW 1-7-3 Valve seat ring: removing and installingW 1-10-2 Sparking plug guard sheath: removing and installingW 2-0-1 Drive mechanism: Safety InstructionsW 2-0-2 Deep-groove bearing: Replacement criteriaW 2-1-0 Drive mechanism: checkingW 2-1-1 Bearing spread: checkingW 2-1-3 Bearing shells: checking for wear and tearW 2-2-1 Bearing race (drive end): removing and installingW 2-2-2 Crankshaft sealing ring (drive end): removing and installingW 2-2-3 Bearing race (free end): removing and installingW 2-2-4 Crankshaft sealing ring (free end): removing and installingW 2-3-1 Connecting-rod bearings and connecting rod: checking for roundness and conicityW 2-5-1 Connecting rod bearings: removingW 2-5-2 Connecting rod bearings: installingW 2-9-3 Piston: removing and installingW 2-10-1 Piston rings: removing and installingW 2-10-3 Piston ring grooves and piston rings: checkingW 2-12-2 Piston pin bush: removing and installingW 2-12-4 Piston pin: removing and installingW 2-15-1 Piston cooling-oil jets: checking, removing and installingW 3-3-1 Cylinder liner: measuringW 3-3-2 Cylinder liners: endoscopingW 3-3-3 Cylinder liner: removingW 3-3-4 Cylinder liner: installingW 3-7-1 Foundation bolts: checking

0997 0299 3921-0122 Chapter 2 - Page 5


2Arranged by Job Card NumbersJob Card Jobs

W 4-1-1 Camshaft bearings: removing and installingW 4-2-1 Valve mechanism, bottom: removing, installing and checkingW 4-4-1 Gear train: removing and installingW 4-5-1 Camshaft: removing and checkingW 4-5-2 Camshaft: installingW 4-8-1 Gear train: checkingW 5-3-13 Frequency generator: removing, installing and checkingW 6-4-4 Mixture cooler: cleaning on the water sideW 6-4-5 Mixture cooler: cleaning on the air sideW 8-11-2 Oil pressure control valve, removing, installing and checkingW 9-0-1 Coolant system: drainingW 9-9-1 Coolant preheater: removing and installingW 12-1-4 Torsional vibration damper: removing and fittingW 12-6-1 Flywheel: removing and fittingW 13-0-1 Instructions for Work on the Electrical Equipment

Chapter 2 - Page 6 0299 3921-0122 0997


2 2.1.3 Explanation of symbolsYou will find there are various symbols used on the Job Cards, in order to designate information not relatingdirectly to the actual work sequence involved.

Tools:- The tools normally required are listed against this symbol.

Equipment:- Things like pressure gauges, lube oil and hydraulic oil

Spare parts:- Seals, locking parts, etc.

Cross-references:- Documents, reports or Job Cards to which reference is made in the Job Card concerned.

2.2 Job Cards arranged by Job Card Numbers

1197 0299 4545-0199 Page 1 of 4

GeneralDEUTZ MWM Job Card

Engines W 0-0-1

1 2 3 4

Filling and venting the hydraulic clamping deviceEquipment:- Hydraulic oil 6.088.801.1011.8

80228 0

Fig. 1 High-pressure pump

1. Components of the clamping device1 High-pressure pump2 Oil tank3 Pump lever4 Filling aperture with threaded plug5 Handwheel for return valve6 Pressure gauge7 High-pressure hose8 Manifold9 Safety coupling half

10 Hydro tension element11 Safety coupling half (mating component)12 Venting aperture with grub screw13 Closure nipple

Safety instructions for thehydraulic clamping device.

l Before fitting the hydraulic clamping device,clean and lubricate the threads and contactareas.

l Lubricant: tallow / red lead or lube oil(Molykote forbidden).

l Before commencing any work on thepressurized hydraulic clamping device,check all pressurized hoses and seals.

l When working on the pressurized hydraulicclamping device wear face protection andgloves, since hydraulic oil escaping fromleaks would penetrate under the skin due tothe high pressure involved.

l Repairs to the hydraulic clamping device areforbidden.

l Because of the accident risk, all parts of thehydraulic clamping device, particularly thehigh-pressure hoses, must be in perfectcondition.

l Do not kink, sharply bend or pull the high-pressure hoses.

!

For the hydraulic clamping device tooperate properly, the entire piping/hosesystem must be air-free.But carry out a venting procedure onlywhen necessary, since normally theautomatically closing safety couplinghalves will prevent oil escaping and airpenetrating.

!

For safety reasons, always close offunconnected but pressurized hoseswith closure nipple.

!

of 4 0299 4545-0199 1197

GeneralJob Card DEUTZ MWMW 0-0-1 Engines

11 10 12

80230 0

Fig. 3 Hydro tension element

r min

= 1

50 m

m

5

6

8

7

9

13

Fig. 2 Pressure gauges, hoses, connections80229 0

2. How the clamping device worksWith the aid of high-pressure pump 1, oil pressure ispassed via high-pressure hoses 7 into the hydrotension elements 10.The oil pressure is limited by a safety valve.The oil pressure specified for tightening the screwconnection is read off at pressure gauge 6. To reducethe oil pressure in the piping/hose system, turnhandwheel 5 in its opening direction.The high-pressure hoses 7 are connected to thehydro tension elements 10 and the manifold 8 viasafety coupling halves 9 and 11.If fewer than four hydro tension elements are connectedat the same time, the coupling halves 9 located at theunused hoses will close these in a pressure-tightconfiguration (see also the instructions on Page 1).

The normal operating configuration of the high-pressure pump 1 is horizontal, but it can also run in avertical position, with the hose connection facingdownwards.

1197 0299 4545-0199 Page 3 of 4


Engines W 0-0-1

3. Filling and venting the clampingdevice

l Fill the high-pressure pump 1 only with hydraulicoil 6.088.801.1011.8, or if this is not available, withone of the hydraulic oils listed below:BP Energol Hydraulic 50Mobil Hydraulic-Oil LBV High-Performance Oil (Hochleistungsl) E 100

Shell Oil AB 1Esso Zerice 36Shell Tellus Oil 15Gasolin Special ASViscobil Oil Sera IViscobil Oil CL40

l Using other oils may cause malfunctions due toswelling of the seals.

Completely unsuitable substances includebrake fluid, shock-absorber oil, diesel oil,kerosene and petrol.

l Filter the oil from time to time. When you do this,flush out the oil tank as well.

5. MalfunctionsIn the event of malfunctions at the hydraulic clampingdevice, e.g. no or inadequate pressure build-up orpressure drop, proceed as follows:l If the high-pressure pump 1 is in a vertical position

(hose connection facing downwards), operatepump lever 3 rapidly several times, while alternatelyopening and closing the return valve by means ofhandwheel 5.

l Vent high-pressure hoses and hydro tensionelements.

When necessary, you should check thatpressure gauge 6 is indicating accurately bycomparing it with a calibrated pressure gauge.The reserve pressure gauge is fitted with asafety coupling half 11 for connection to one ofthe high-pressure hoses 7.

4. Work sequencel Place high-pressure pump in a horizontal position.l At the fill opening 4 of the oil tank 2, fill high-

pressure pump 1 with not less than 1.5 litres ofhydraulic oil.

l Connect high-pressure pump 1, pressure gaugeholder 6, manifold 8 and hydro-tension elements10 to the high-pressure hoses.

l Unscrew grub screw 12 of the hydro tensionelements 10, and operate pump lever 3 untilhydraulic oil exits without bubbles from ventaperture 12.

l During this procedure, the hydro tension elements10 should be positioned at a higher level than high-pressure pump 1 and held at an angle to ventaperture 12, in order to make sure the annularcompartment in the hydro tension element 10 isvented completely.

l Tighten grub screw 12.

of 4 0299 4545-0199 1197



1097 0299 6310-0179 Page 1 of 2

GeneralDEUTZ MWM Job CardGas engine W 0-1-3

The engines have been run in at the manufacturersfacility, therefore any further running-in instructionscan be dispensed with. If maintenance work has beenperformed on bearings, pistons, cylinder liners, or anyof these have been replaced, then the engine must berun in anew.

Running in the engine

Running in the enginel After starting the engine, perform a visual and

acoustic inspection. In the event of leaks, loose ordefective components, the engine must be shutdown and the appropriate repair routine performed.

Perform the running-in routine in three stagesTo reduce wear on the engine, we recommendperforming load changes not abruptly but allowing fora transitional period of 2 to 3 minutes between theindividual running-in stages for increasing the power.Stage 1 30 min. 50 % powerStage 2 15 min. 75 % powerStage 3 15 min. 100 % powerl During Stage 3 of the running-in program, check

the engines operational values, and comparethem with the acceptance test report. In the eventof major deviations, find the causes and eliminatethem.

l For lube-oil analysis and/or lube oil change, seeOperating Instructions, Chapter 4, TechnicalCircular 0199 - 99 - 2105.

Cross-references:- Operating instructions, Chapter 4,

Technical Circular 0199 - 99 - 2105

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GeneralJob Card DEUTZ MWMW 0-1-3 Gas engine

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1197 0299 4270-0199 Page 1 of 2


Engines W 0-2-7

Endoscoping the combustion compartment

Examining the combustioncompartmentl In the case of diesel engines, remove the injection

valve, see Job Card B 7-7-2.l In the case of gas engines, remove the sparking

plugs, see Job Card B 13-5-1.l Place the piston of the cylinder you want to examine

in its bottom dead centre position.l Connect the endoscope, switch it on, and insert it

cautiously through the injection valve or the sparkingplug borehole.

l Carry out your examination using the eyepieceand the cold light source.

To enable the inlet and exhaust valves to bechecked, the engine has to be turnedappropriately. Be very careful to ensure thatthe endoscope is not damaged.Light reflections may lead to faulty diagnoses.You will also find it helpful to swivel theendoscope during your examinations, and tiltit alternatively from side to side, making surethat the fibre-optic cable is not damaged.

Endoscopy is a method enabling you to examine thecombustion compartment (piston, cylinder liner,cylinder head, valves) for its wear-and-tear statuswithout having to remove the cylinder head beforehand.This means you can exploit the wear limits moreeffectively, and thus cut your maintenance costs.When handling the endoscope, always follow themanufacturers instructions!The endoscope image may be laterally transposed orupside down, depending on how you are looking intothe lens.

Tools:- Endoscope

Cross-references:- Job Cards B 7-7-2, W 7-7-6, B 13-5-1

of 2 0299 4270-0199 1197


l If you find clearly recognizable damage (e.g. break-outs, notches, scoring), remove the cylinder head.

l Always be on the lookout for drip formation at thebottom of the cylinder head. This indicates apossible leak at the seal of the injection valve or thesparking plug guard tube.

Evaluation of normal wear phenomena, andspecification of the next endoscoping datecan be performed only by properly trainedexperts.

l Carefully take out the endoscope.l In the case of diesel engines, install the injection

valve, see Job Card B 7-7-2 and InstallationInstructions W 7-7-6.

l In the case of gas engines, install the sparkingplugs, see Job Card B 13-5-1.

80967 0

Fig. 1 Checking with an endoscope

1197 0299 4271-0199 Page 1 of 2


Engines W 0-3-1

! Never touch liquid nitrogen andundercooled parts:Risk of injury!

Use of Liquid Nitrogen

For occasional work of short duration, place twoconcentric containers into each other and fill theclearance between the two containers with glasswool, cork meal or sand.Pour the nitrogen from the containers, in which it isdelivered, into the special basin and then dip the metalparts into this liquid. The start of the undercoolingprocess is indicated by heavy boiling. Bubbles willform until the metal parts have assumed the nitrogentemperature (-196 C). Once no more bubbles form,the parts are ready for installation.

Quantity of Nitrogen neededUnder normal conditions, one kilogram of metal to becooled from +15C to -196C requires the followingquantity of liquid nitrogen:l 0.60 l for steell 0.66 l for cast ironl 0.45 l for bronze, copper, brassl 0.96 l for aluminium

of 2 0299 4271-0199 1197



1197 0299 4272-0199 Page 1 of 2


Engines W 0-3-2

Crack inspection with the diffusion liquid procedure

Aids:- Cleaning agent (trichloroethylene)- Diffusion liquid (red)- Developer (white)- Dry cloth- Protective goggles- Protective gloves- Extractor device

Cleaning the componentsl Wear protective goggles and protective gloves!l Make sure the room is properly ventilated!l Make sure the vapours are extracted. Never inhale

them!l Use cleaning agent to degrease the component.l Allow the cleaning agent to act for 10 - 15 minutes.l Rub down the surface you want to check with a dry

cloth. This will get rid of all the grease residueswhich might otherwise fill in and cover up anycracks present, see Fig. 1.

Applying the diffusion liquidl Apply diffusion liquid, see Fig. 2. Use a spray can,

a spray gun, or a brush to do this, or immerse thecomponent in the diffusion liquid.

l Allow the liquid to act for the time period specifiedby the manufacturer.

l Clean the component with water, until the diffusionliquid has been washed off the surface, and remainsonly in the cracks, see Fig. 3.

l Rub the surface thoroughly with a cloth to dry it.l Allow the component to finish drying.

Appling the developerl Use a spray gun or a brush to apply a thin film of

developer. (Avoid applying twice to the same area).l Allow the developer to dry for 1 - 2 minutes.

Due to the blotting paper effect of thedeveloper, the diffusion liquid is sucked out ofthe crack, and thus becomes visible, seeFig. 4.

Fig. Diffusion liquid procedure25495 0

! When working with trichloroethylene:risk of poisoning!

of 2 0299 4272-0199 1197


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 coatingwherever there are cracks or other surfaceirregularities.

- 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.

0997 0299 3899-0122 Page 1 of 2

Cylinder headDEUTZ MWM Job Card

TBG 620/TBG 620K W 1-2-2

Valve lifter and valve lifter bracket: removing, checking and installing

Removing the valve lifter and the valvelifter bracketl Use the special pliers to withdraw the sparking

plug connector, and remove the cylinder headhood.

l Turn the engine so that the tappet of the valvemechanism at the cylinder unit concerned isdestressed, and the valves are closed, i.e. arepositioned at ignition TDC.

l Unscrew fixing nut 3 of the valve lifter bracket 2,and lift off the valve lifter bracket together with thevalve lifters 5 and 1.

New clearance Max. perm. clearance

Clearance betweenbearing journal andvalve lifter bore

0.050 0.091 0.130

Installing the valve lifter and the valvelifter bracketl Place the valve lifter bracket on the cylinder head,

positioning it by means of the centering bush andthe dowel pin.

l Screw on fixing nut and tighten .l Adjust valve clearance,

see Job Card B 1-1-1.

Tools:- Normal tools- Special pliers for sparking plug connector- Feeler gauge- Caliper gauge

Cross-references:- Job Card B 1-1-1- Operating Manual, Chapter 8, Tightening

instructions

Checking the valve lifter and the valvelifter bracketThe inspection routine for the removed parts coverschecking free passage of the lube oil ways in the valvelifter bracket and in the valve lifters themselves (cleanthem if necessary), checking proper fit of the screwplugs for these lube oil ways, checking for wear andtear at the contact areas of the clamping screws 4, andchecking the radial clearance between bearing journaland valve lifter bore (see table 1).Replace parts if necessary.

[mm]

Table 1 Clearance

Comply with the tightening instructionsgiven in the Operating Manual,Chapter 8, Technical Data.

of 2 0299 3899-0122 0997

Cylinder headJob Card DEUTZ MWMW 1-2-2 TBG 620/TBG 620K

50736 0

Fig. 1 Valve actuator, parts

0997 0299 3898-0122 Page 1 of 2


TBG 620/TBG 620K W 1-2-3

Valve actuator bridges, guide bolts: removing and installing

Check valve actuator bridges for zero-tilt mounting. Ifthere is perceptible play, replace valve actuator bridgesand/or guide bolts.

Removing the guide bolts for valveactuator bridgesl Remove valve lifter and valve lifter bracket,

see Job Card W 1-2-2.l Take off valve actuator bridges 2 with shims 3.

Clean the parts.l Check valve actuator bridges, shims and guide

bolt 1 for wear and tear and traces of scoring.Replace any damaged parts.

l Bore the damaged guide bolt 1 inside to 8.5 mm.Cut an M10 thread, and withdraw guide bolt 1.

50737 0

Tools:- Normal tools- Extractor

Aids:- Nitrogen (liquid)

Cross-references:- Job Card W 0-3-1, B 1-1-1, W 1-2-2

Installing the guide bolts for valveactuator bridgesl Supercool the bolt in liquid nitrogen (approx.

-190C), and insert it without using any force.l The top edge must lie 46-0.5 mm above the adjoining

cylinder head surface.l Oil all the components of the valve mechanism.l Fit valve actuator bridge onto the guide bolt with a

shim.l Install valve lifter and valve lifter bracket,

see Job Card W 1-2-2.l Adjust valve clearance,

see Job Card B 1-1-1.

Fig. 1 Valve actuator

! Never touch liquid nitrogen andundercooled parts:Risk of injury!

of 2 0299 3898-0122 0997



0997 0299 3897-0122 Page 1 of 2


TBG 620/TBG 620K W 1-3-1

Valve rotating device: removing, checking, and installing

Removing the valve rotating devicel Remove valves,

see Job Card W 1-5-1.l Take out valve rotating device.

Checking the valve rotating devicel Clean the valve rotating device.l Make a visual inspection to check for wear and

tear.

l Check by hand that it moves freely.If you find no defects after this check routine,you can continue to use the valve rotatingdevice. Otherwise replace the valve rotatingdevice.

Installing the valve rotating devicel Insert the valve rotating device.l Install valves,

see Job Card W 1-5-1.

Tools:- Normal tools

Cross-references:- Job Card W 1-5-1

of 2 0299 3897-0122 0997



0997 0299 3894-0122 Page 1 of 2


TBG 620/TBG 620K W 1-4-0

Cylinder head nuts: hydraulically loosening and tightening

Tools:- Special tools- Hydraulic clamping device

Aids:- Lube oil


Preparationsl Fill and vent the hand pump,

see Job Card W 0-0-1.l Oil the anti-fatigue stud bolts 4; do not lubricate

with Molykote.l When mounting the cylinder head, tighten cylinder

head nuts 5 in diagonally opposite sequence untilthey are hand-tight.

l Fit support tubes 3.They must be easy to turn, and must not besupported on the adjoining cylinder heads.

l Fit socket wrenches 2 onto cylinder head nuts 5.The marking rings 7 must be flush with theupper edges of the arbors 1 and the bores ofsocket wrenches 2.

l Fit tension elements 8. Check the centering supportby turning it.

l Screw the puller bolts 6 onto the stud anti-fatiguebolts.

The hydraulic clamping device makes it easier for youto loosen and tighten the cylinder head nuts.

! The safety instructions for the hydraulicclamping device as laid down in JobCard W 0-0-1 must be complied with.

l The hydraulic system may be pressurizedonly when it has been completelyassembled.

l Lubricant: tallow/reed lead or oil (Molycoteprohibited).

l Repairs to the hydro screw pretensers areprohibited.

l If there is pressure at the tension elements,keep away from the area above the hydroscrew pretensers.

50475 0

Fig. 1 Hydraulic element

of 2 0299 3894-0122 0997


Tightening and looseningl Tighten the puller bolts hand-tight.- When tightening the nuts, turn the puller bolts

back by 90.- When loosening the nuts, turn the puller bolts

back by 180.By tightening and then turning back the pullerbolts, you will prevent the puller bolts and thecylinder head nuts locking each other whenthe pressure is bled off in the clamping device.

l Connect clamping devices 1 to hand pump 2 viahigh-pressure hoses, see Fig. 2.

- Do NOT operate the hand pump beforethe high-pressure hoses have beenproperly secured!

- Never place yourself in the direction ofpull behind or above the hydraulicpreclamping device, for as long as it isunder pressure!

l Bring piston 9 of the tension elements into itsstarting position, see Fig. 1.

l Open vent screw 3 by one turn, see Fig. 2.l Close drain plug 4, see Fig. 2.l Operate pump lever 1, until 150....160 bar have

been reached, see Fig. 2.l Use arbor 1 to tighten all socket wrench and

cylinder head nuts hand-tight, see Fig. 1.l Slowly open drain plug 4, reduce pressure down to

0 bar, see Fig. 2.l Close the drain plug.l Operate pump lever until 720....730 bar have been

reached.l Use the arbor to tighten all socket wrench and

cylinder head nuts hand-tight, see Fig. 1.This hand-tight tightening procedure means3...3,5 holes which can be turned further. Ifthis is not the case, find and eliminate thecause (e.g. thread damaged, soiled with paint,erection error, device defective, etc.).

l Slowly open the drain plug, reduce pressure to0 bar.

l Remove clamping devices.

50477 0

50476 1

!

Fig. 2 Hand pump

Fig. 3 Hydraulic clamping device

0997 0299 3891-0122 Page 1 of 2


TBG 620/TBG 620K W 1-4-2

Cylinder head: checkingThe inspection intervals for cylinder heads can varywidely, depending on the engines operating conditionsand loading, and on the quality of the fuel and the lubeoil quality.

Tools:- Normal tools- Endoscope

Cross-references:- Job Card W 0-3-2, W 1-3-1, W 1-4-1,

W 1-5-1, W 1-6-1, W 1-7-1, W 1-7-2

Checking the cylinder headl Make your inspection in conjunction with an

endoscope,see Job Card W 1-7-2.

If you dont have an endoscope available, youwill have to remove a cylinder head. (Dontchoose one from the end of a cylinder row).

l Inspect the cylinder head with the worst-lookingcombustion compartment, following the proceduredescribed below.

l Remove the cylinder head,see Job Card W 1-4-1.

l Check the combustion-compartment side of thecylinder head for cracks,see Job Card W 0-3-2.

l Check the screw plug for leaks.l Flush the coolant compartment with cold cleaning

agent; if there are significant scale deposits, usescale-dissolving agents to remove them (followthe manufacturers instructions).

l Remove valves,see Job Card W 1-5-1.

l Check valve lifter mounting for wear and tear.l Check valve rotating device,

see Job Card W 1-3-1.l Check valve guide,


l Check valves and valve seat rings,see Job Card 1-7-1.

- If previous inspections have proved positive, theinspection routine for the other cylinder heads canbe postponed for another combustion-compartmentcheck interval. When this interval has elapsed,check the combustion compartments once moreas detailed above.

- If everything is again in order, then you can postponeinspection of all cylinder heads once more foranother combustion compartment inspectioninterval.

- If, however, you find excessive wear and tear at thecylinder head which you check, then you mustcheck all the other cylinder heads as well, andrepair them as necessary.

- The number of operating hours run by the engineup to the date when all cylinder heads have to bechecked for the first time is defined as the inspectioninterval for the cylinder heads.

l Install valves,see Job Card W 1-5-1.

l Fit cylinder head,see Job Card W 1-4-1.

of 2 0299 3891-0122 0997



0997 0299 3895-0122 Page 1 of 4


TBG 620/TBG 620K W 1-4-4

Cylinder head: removing and fittingAdd-on pieces fitted to the engine will vary, dependingon he options the client chooses, and the particularapplication concerned. This will, for example, apply tothe exhaust gas system, the turbocharger equipment,and the electrics. These features may entail additionalwork. The procedures involved are not describedhere.

Removing the cylinder headl Drain off the coolant,

see Job Card W 9-0-1.l Remove all requisite covers.l Take off air intake pipe. coolant drain pipe, exhaust

gas collecting pipe, oil pressure line (if any), and oilreturn line, and use special pliers to withdraw thesparking plug connector.

l Remove combustion-compartment temperatureprobe from cylinder head.

l Remove valve lifter and valve lifter bracket,see Job Card W 1-2-2.

l Take off valve lifter actuator bridges.l Remove fixing nuts for cylinder head. When using

a hydraulic clamping device,see Job Card, W 1-4-0.

l Screw mounting device for lifting off the cylinderhead onto the bolt of the valve lifter bracketmounting.

l Use the mounting device to carefully lift off thecylinder head.

Take special care to ensure that the stud boltsdo not get damaged.

l Once you have removed the cylinder head, placeit on a wooden board.

The safety instructions for work on thedrive mechanism must be complied withas detailed in Job Card W 2-0-1.

!

Tools:- Normal tools- Mounting device for lifting off the cylinder

head- Rail for aligning the cylinder heads

Aids:- Lube grease

Cross-references:- Job Card W 1-2-2, W 1-4-0, W 2-0-1,

W 9-0-1, W 1-4-2

of 4 0299 3895-0122 0997


Fitting the cylinder headl Clean the cylinder head completely. Remove any

remains of seals.l Check cylinder head for damage,

see Job Card W 1-4-2.l Check threads of the four stud bolts along their

entire length for faultless condition and easy nutmovement.

l Check nuts and washers, replace if necessary.l Clean the sealing surface on the cylinder liner.l Clean the contact areas and seat surfaces for

sealing rings and round sealing rings on the cylinder.l Grease all the round sealing rings before fitting

them.l Fit a new cylinder head gasket, Fig. 1.l Fit the two coolant transfer fittings 1 with new round

sealing rings. Remember the flow direction of thecoolant (chamfer), Fig. 2.

l Fit two new round sealing rings for the shock-absorber rod casing (if any) into the turned grooveof the cylinder head. Dont forget the grease!

l Also fit new (greased!) round sealing rings into thelower grooves of the shock-absorber rod casings.

l Insert casing with round sealing ring into the tappetbore of the crankcase.

l Fit the mounting device.l Place cylinder head onto the stud bolts.

Be careful not to damage the stud bolt threads.Insert the shock-absorber rod casings (withthe shock-absorber rods inside them!)carefully from below into the fitted roundsealing rings in the cylinder head.

l Lower the cylinder head slowly and carefully ontothe crankcase.

l Screw on by hand all four cylinder head nuts(smooth side facing downwards, marked side facingupwards), with washers, and tighten them evenlyby hand in a diagonally opposite sequence.

l Remove the mounting device.Align the cylinder head with the flange surfacefor the air collecting pipe. When more thanone cylinder head is being mounted (or theentire row), you have to use a rail or thisalignment procedure. If you are mountingonly one or two cylinder heads, use the aircollecting pipe for alignment purposes. Do notalign on the exhaust pipe.

50671 0

50741 0

!

Fig. 1 Cylinder head gasket

Fig. 2 Coolant transfer fitting

0997 0299 3895-0122 Page 3 of 4


TBG 620/TBG 620K W 1-4-4

l Tighten the cylinder head nuts- With hydraulic clamping device,

see Job Card W 1-4-0.The cylinder head must lie completely evenly flushagainst the sealing ring.To check, measure the gap dimension between thecylinder head and the crankcase, see Fig. 3.Gap dimension: 0.6 to 1.25 mm(same dimension 0.05 mm over the entirecircumference of a cylinder head).l Fit valve lifter actuator bridges.l Install valve lifter and valve lifter bracket,

see Job Card W 1-2-2.l Fit combustion compartment temperature probe at

cylinder head.l Fit oil pressure line (if any), oil return line, exhaust

gas collecting pipe, air intake pipe and coolantdrain pipe, and attach the sparking plug connector.

l Fill with coolant.l Fit covers.

50673 0

Fig. 3 Cylinder head gap dimension

of 4 0299 3895-0122 0997



0997 0299 3896-0122 Page 1 of 2


TBG 620/TBG 620K W 1-5-1

Valves: removing and installing

50667 0

When working on the valve mechanism, you musttake special care to keep everything absolutely clean.Never use magnetic tools.

Tools:- Normal tools- Removal and installation lever for valve

springs

Aids:- Wooden board- Lube oil

Cross-references:- Job Card W 1-2-2, W 1-4-4, W 1-7-1

l Fit shim on valve.l Press down the valve spring.l Remove the valve clamping cone.l Destress the valve spring.l Take out the valve spring disk, the valve spring and

the valve rotating device.l Lay the cylinder head lengthways.l Pull the inlet and exhaust valves out of the valve

guidesl Check valves and valve seat rings,


! Accident risk!Springs are under tension.

Removing valvesl Remove cylinder head,

see Job Card W 1-4-4.l Place cylinder head with combustion-compartment

side on something soft (e.g. wood).l Remove valve lifters and valve lifter brackets,

see Job Card W 1-2-2.l Take off valve actuator bridges.l Screw the removal lever for valve springs onto the

bolt for the valve lifter bracket mounting.

Fig. 1 Removal and installation lever

of 2 0299 3896-0122 0997


Installing the valvesl Replace the valve springs, clamping cones and

valve spring disks.l Oil the valve stem and valve guide.l Insert valves 1 carefully, making sure that the

round sealing ring in the valve guide does not getdamaged.

l Fit valve rotating device, valve spring and valvespring disk 3.

l Place supports underneath the cylinder head sothat the valve disks are flush.

l Fit shim 5 onto valve spring disk 3.l Press down the valve spring 4.l Insert the valve clamping cone 2.l Destress valve spring 4.

Never destress the valve spring disk upwardswhile the valve spring is still tensed, if thevalve clamping cones 2 are not clampingproperly in the specified configuration(X = wrong, Y = right).The valve clamping cones 2 must slide intothe inside cone of the valve spring disk, andare then fixed in position, see Fig. 3.

l Use a plastic hammer to tap briefly on the endsurface of the valve stem.

Dont tap the valve spring disk itself.l In order to check whether the valve cone pieces

are properly fitted, press the valve spring diskdownwards with the shim.

The spring disk must resist being detachedfrom the valve cone pieces, and when it doescome free, this must happen with a jerk, sincethe valve cone pieces clamp into the valvestem (bead into the groove). Then destressthe valve spring disk again, and tap on theend surface of the valve stem briefly oncemore with a plastic hammer.

If the valve spring disk can be easily detached from thevalve clamping cones easily and without a jerk, thismeans the cones were not fitting properly into thevalve stem, and have to be replaced.l Fit valve actuator bridge.l Install valve lifter and valve lifter bracket,

see Job Card W 1-2-2.l Fit the cylinder head,


50738 0

50739 1

!

!

Fig. 2 Valve clamping cone

Fig. 3 Valve clamping system

0997 0299 3884-0122 Page 1 of 2


TBG 620/TBG 620K W 1-6-1

Valve guides: checking, removing and installingWhen a cylinder head is being repaired, the valveguides must be checked for wear and tear.If the inside diameter of the valve guides is greaterthan 11.11 mm, they must be replaced. Likewise ifthere is excessive scoring.

Removing the valve guidesl Removing the valves,

see Job Card W 1-5-1.l Use a press and a press-out mandrel to press out

the valve guides.After pressing out the guide, check the locationhole in the cylinder head. If the hole is largerthan 18.018 mm or is damaged, the cylinderhead must be reworked in a DEUTZ MWMService to ensure the correct overdimension.(At a hole diameter of > 19.018 mm, thecylinder head must be replaced.)

Installing the valve guidesl Supercool the valve guides in liquid nitrogen

(approx. -190 C). Insert them dry (i.e. without oil),using no force, into the location hole of the cylinderhead, with the end stepped by 1 mm in diametergoing first. Use a press-in mandrel for guidance.Make sure the protruding dimensionC = 23.0 0.200 mm above the contact area of thevalve rotating device is correct.

l Working with liquid nitrogen,see Job Card W 0-3-1.

l To check, test whether a long mandrel movesfreely in the valve guide.

l If it does not move freely, you must rework with asingle-stroke honing tool. NEVER ream it!

l Wet new round sealing ring 2 with engine oil, andinsert in valve guide 1.


50740 1

Tools:- Normal tools- Digital caliper gauge- Press-out mandrel- Press-in mandrel- Single-stroke honing tool- Inside calipers

Aids:- Engine oil- Nitrogen (liquid)

Cross-references:- Job Card W 1-5-1, W 0-3-1

Fig. 1 Valve guide

of 2 0299 3884-0122 0997



0997 0299 3887-0122 Page 1 of 2


TBG 620/TBG 620K W 1-7-1

Valves and valve seat rings: checkingDefective engine condition, poor fuel and coolingwater conditioning, and inadequate preheating,impermissible torque operation (speed drop withongoing engine block), etc., may cause prematurefailure of valves.

Tools:- Normal tools- Digital caliper gauge- Magnifying glass (at least 4-fold magni-

fication)

Aids:- Distillate fuel


Checking the valves and valve seatringsl Remove the valves,

see Job Card W 1-5-1.l Clean the seat surface to remove any residues.l Use a scraper to remove any coking on the valve

disks and seat rings, and wash down with distillatefuel.

To make it easier to remove water-soluble residueswith a sulphur content, the run valve cones can beplaced in water for a few hours.

Checking the valve seat ringsThe valve seat rings can continue to be used, providedthe following preconditions are met:- seat surface without burn-outs, blow-throughs,

cracks or impact traces.If the valve seat rings exhibit coke impacts, scoring,stepping or corrosion, etc., the seat surfaces of thevalve seat rings must be repaired in their installedstate.


Reworking of the valve seat rings may becarried out only by an authorized workshop.

Checking the valvesThe valve cones can continue to be used, providedthe following preconditions are met:- seat surface without any burn-outs, blow-throughs,

cracks, or impact traces,- no damage to the chrome layer,- no corrosion scars,- stem diameter min. 10.93 mm,- no damage to the clamp cone groove.

The seat surface of the valve cone must be repairedif:- the cleaned seat surface is not free of coke impacts,

blow-throughs, pittings and other damage (checkwith a magnifying glass).

of 2 0299 3887-0122 0997



0997 0299 3900-0122 Page 1 of 2


TBG 620/TBG 620K W 1-7-3

Valve seat ring: removing and installingTools:- Normal tools- Electric welding unit- Inside calipers- Digital caliper gauge- Press

Aids:- Nitrogen (liquid)


If the damage involved cannot be eliminated within thepermissible reworking limits, or if the maximumpermissible residual dimension between bottom edgeof valve and the bottom of the cylinder head cannot becomplied with, even when new valves are fitted, thenthe valve seat rings must be replaced.

Removing the valve seat ringsl Remove the valves,

see Job Card W 1-5-1.l Check valves and valve seat rings,

see Job Card W 1-7-1.l Place a 2 mm electric welding electrode at 130 A

around the valve seat ring. The deformation willcause the valve seat ring to drop out.

Do not set a higher current, otherwise youmay damage the cylinder head.

Check reference dimensions for valve seat ring.- Location hole in the cylinder head, table 1.

Installing new valve seat rings:l Supercool inlet and exhaust valve seat rings in

liquid nitrogen (approx. -190C) and insert themwithout applying any force. Use a press to press inthe valve seat rings, using a force of 12000 N(approx. 1200 kp), and maintaining this pressureforce for not less than 15 seconds.

l Newly fitted valve seat rings must be ground intogether with the associated valves.


-0 -0

[mm] Inlet Exhaust

Valve seat ring 60 +0.019 58 +0.019

Hole depth 15 +0.02 15 +0.02+0.05

Table 1 Dimensions

+0.05

of 2 0299 3900-0122 0997



0997 0299 3901-0122 Page 1 of 2


TBG 620/TBG 620K W 1-10-2

Removing and installing the sparking plug guard sheathTools:- Normal tools- Special nut for removing the bottom guard

sheath

Aids:- Screw-locking compound

Cross-references:- Job Card W 1-2-2- Operating instructions, Chapter 8,

tightening instructions

Removing the guard sheathl Remove valve lifter and valve lifter bracket,

see Job Card W 1-2-2.l Take off valve actuator bridges.l Remove sparking plug.l Unscrew top guard sheath 1.l Remove bottom guard sheath.

Installing the guard sheathl Clean the bottom guard sheath, fit new seals,

apply screw-locking compound, insert sheath inthe cylinder head, and tighten.

l Screw the top guard sheath into the cylinder head,with screw-locking compound, and tighten.

l Install sparking plug.l Fit valve actuator bridges.l Install valve lifter and valve lifter bracket,


81066 0

Fig. 1 Sparking plug guard sheath


of 2 0299 3901-0122 0997



1097 0299 6317-0199 Page 1 of 2

Drive mechanismDEUTZ MWM Job Card

Engines W 2-0-1

Safety rules for working on the drive mechanism

Before starting workl Shut down the engine, and secure it against being

started up again.l If necessary, drain off lube oil and/or coolant, and

collect it for re-use. Caution: risk of scalding!l With diesel engines, open the indexing cocks. With

gas engines, remove the spark plugs.l If it is fitted on your engine, open the inspection

hole cover 10 minutes at the earliest AFTER theengine has been shut down, and after oil circulationhas been interrupted.

l Do not perform any other work on the drivemechanism until the engine has cooled downsufficiently. The engine must have cooled downenough to ensure that there is no longer any risk ofburns.

l When working on the exhaust gas system,remember that in spite of long cooldown ties somecomponents may still be hot. Heat guard platescan have sharp edges, so wear protective gloves.

l Do not start the work until a sufficient ventilationperiod has elapsed.

l Make sure that the environment is clean in whichthe engine is going to be opened up.

! When you are performing any work on thedrive mechanism, you MUST alwayscomply with the following rules.

During the workl Make sure that no dirt can penetrate into the drive

compartment.l Before turning the crankshaft, check that:

- the turning device has engaged properly,- there are no persons working in or at the engine,- no tools are impeding the crankshaft from turning

and might thus cause damage,- the drive mechanism is not being put out of

equilibrium by the removal o drive mechanismparts.

l Make sure that the engine cannot turnunintentionally.

After finishing workl Before you close the engine, check whether you

have removed all tools, cleaning cloths, etc. fromthe crank compartment.

l Fit inspection hole cover (if any), with new seals.l Before starting up, turn the engine with open

indexing cocks or (in the case of gas engines) withspark plugs not installed.

l With diesel engines, close indexing cocks. Withgas engines, install spark plugs.

l Fill with lube oil. Top up coolant, vent coolingsystem, and check for leaks.

!! Danger of burst!

of 2 0299 6317-0199 1097

Drive mechanismJob Card DEUTZ MWMW 2-0-1 Engines

This page has been intentionally left blank.

0997 0299 3886-0122 Page 1 of 2


TBG 620/TBG 620K W 2-1-0

Drive mechanism: checking


!Tools:- Normal tools- Turning device

Cross-references:- Job Card W 2-0-1, W 2-15-1

When you are doing this work, take care toensure that the spray jets of the pistoncooling systems do not get bent,see Job Card W 2-15-1.

l Feel the bearing covers at the crankshaft andconnecting rods, to check whether they areexhibiting a uniform temperature.

l Check the drive mechanism for soiling. Pay specialattention to checking for bearing metal in the oilpan, and for corrosion and water leaks.

l Make a careful check of the cylinder liner contactsurface an the liner seals on the drive compartmentside. Note that when you do this the pistons mustbe at TDC.

l Carry out a lubrication check:- Operate and check the prelubrication pump,

to see whether lube oil exits visibly at everybearing.

- Take off the cylinder head hood. Carry out acorresponding check at the valve lifter bearings.

of 2 0299 3886-0122 0997

Drive mechanismJob Card DEUTZ MWMW 2-1-0 TBG 620/TBG 620K


0997 0299 3885-0122 Page 1 of 2


TBG 620/TBG 620K W 2-1-1

a

D

Checking the bearing spreadThe bearing shell must exhibit a positive spread, sothat it is properly flush against the acceptance borewhen it has been installed.All new bearing shells exhibit a positive spread, unlessthey have been incorrectly handled (e.g. in transit).

Tools:- Slide gauge

80227 0

1. DefinitionPositive spread:

Measured at room temperatures, Dimension a isgreater than Dimension D.

Negative spread:Dimension a smaller than Dimension D.

Crankshaft bearing: Dimension D etched intothe end fact of the bearing shell,Connecting-rod bearing: must be measured directlyat the bearing cover.

2. AssessmentIf a used bearing shows negative spread, this may (ifno other reasons can be detected) be an indicationthat the bearing has undergone plastic deformationdue to overheating and has thus lost its initial tension.

Bearing shells with a negative spread must nolonger be used.

Do not attempt to correct with any tool, since there isa risk that the bearing metal will become detachedfrom the support shell, or that the bearing will bedeformed. This sort of damage can lead to seriousoperational malfunctions.

3. Setpoint values[mm] Conn. rod b.Spread a 135.025 + 0.4

Fig. 1 Spread

of 2 0299 3885-0122 0997



0997 0299 6321-0199 Page 1 of 10

Drive mechanismDEUTZ MWM Job CardGas engines W 2-1-6

Visual inspection of the bearing shellsPlease take the precise point in time when to inspectthe connecting-rod and crankshaft bearings from theoperating instructions, Maintenance and Servicing.

Tools:- Magnifying glass, 5-fold magnification

Cross-references:- Job Cards W 2-1-1, W 2-7-2,

W 2-9-1, W 2-9-3- Operating instructions

How to proceed:You must check the bearing shells by means of avisual inspection and by checking the bearing shellspread.Under a basic overhaul routine (for precise intervalssee operating instructions Maintenance andservicing), connecting-rod and crankshaft bearingsmust always be replaced.

Removing the bearing shellsl Remove piston with connecting rod,

see Job Card W 2-9-1 and/or W 2-9-3.l Remove main bearing,

see Job Card W 2-7-2.l Check bearing spread,

see Job Card W 2-1-1

Visual inspection of the slide bearingsRunning pattern of the bearing shellsMaterial: steel/aluminium alloyDepending on the number of operating hours and onthe operating conditions involved, used bearing shellswill exhibit different running patterns. The essentialdifferences can often be recognized only by a properlytrained and specialized expert. If in doubt, werecommend you to consult DEUTZ service for theassessment of the bearing shells concerned.If the inspection reveals a poor running pattern on theconnecting-rod bearings and/or deep dirt scoring or alot of embedded dirt, then you must additionally checka crankshaft bearing.

of 10 0299 6321-0199 0997

Drive mechanismJob Card DEUTZ MWMW 2-1-6 Gas engines

The contact pattern is evenly formed over the entirewidth of the bearing. As practical experience hasshown, the dirt scoring caused by a foreign body in thelube oil has no significant effect on the slide bearingsfurther operational dependability.The bearing shells contact pattern is faultless.This bearing shell can be re-used. Fig. 1.

81148 0

Fig. 1 Bearing shell, can be re-used

0997 0299 6321-0199 Page 3 of 10


81149 0

Fig. 2 Bearing shell, can be re-used

The contact pattern is evenly formed over the entirewidth of the bearing.The bearing shells contact pattern is impeccable.This bearing shell can be re-used. Figs. 2 and 3.

81191 0

Fig. 3 Detail for Fig. 2

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81150 0

Fig. 4 Bearing shell, can be re-used if appropriate

The contact pattern is evenly formed over the entirewidth of the bearing. The radial-configuration scoringis caused by fine solid particles contained in the lubeoil.If the depth of this scoring can neither be measurednor felt, the bearing shell in question may be re-used.If the depth of such scoring reaches or even exceedsthe lube-oil films order of magnitude, the bearing shellmust be replaced. Figs. 4 and 5.

81192 0

Fig. 5 Detail for Fig. 4

0997 0299 6321-0199 Page 5 of 10


81151 0

Fig. 6 Bearing shell, cannot be re-used

The contact pattern shows a marked edge carrier withtraces of scoring in the slide layer made of aluminiumalloy.You must find out what caused this slide-bearingdamage, and eliminate the cause. Fig. 6.This bearing shell cannot be re-used.

of 10 0299 6321-0199 0997


Fig. 7 Bearing shell, cannot be re-used

Fig. 8 Bearing shell, cannot be re-used81153 0

81152 0

The contact pattern exhibits large-area damage withvarying degrees of scoring.You must find out what caused this slide-bearingdamage, and eliminate the cause. Fig. 7.This bearing shell cannot be re-used.

The loaded area of the bearing shell exhibits broken-off bearing metal pieces. Some broken-off pieces arelying around loose in the fatigue zone.These have been caused by fatigue in the slide layerof the aluminium alloy. The surface structure at thebottom of the break-out indicates good bondingbetween steel and aluminium alloy.This bearing shell cannot be re-used. Fig. 8.

0997 0299 6321-0199 Page 7 of 10


Fig. 9 Bearing shell, cannot be re-used81154 0

This bearing shell exhibits broken-off bearing metalpieces.These have been caused by fatigue in the slide layerof the aluminium alloy. The surface structure at thebottom of the break-out indicates good bondingbetween steel and aluminium alloy.This bearing shell cannot be re-used. Fig. 9.

of 10 0299 6321-0199 0997


3

2

1

4

= 580231 1

Visual inspection of the deep-groovebearingsRunning pattern of the bearing shellsMaterial: steel/aluminium alloyIn its as-new condition, the contact surface exhibitsapprox. 75 % electroplated contact layer and approx.25 % of light metal.l Use a magnifying glass to assess the wear-and-

tear status of the contact surface (magnification atleast 5-fold). Contact surface is visible as the darkzone and the light-metal rib as the light-colouredzone.

l Crucial for wear-and-tear status:- Ratio of width of light-metal rib and width ofgroove, plus- extent of the worn surface.

l Each time you are assessing groove states, youmust adduce the contact surface in the less loadedarea (in most cases groove status as new) as acomparison.

A distinction must be made between the followingcases:

Case 1 (Fig. 10):Definition of the contact-surface areas

1 Max. 30 % of the shells circumference2 Max. 70 % of the width3 Max. 50 % of the shells circumference4 Max. 35 % of the width5 Wear-and-tear 1 : 1

Fig. 10 Bearing shell (deep-groove bearing) Case 1, can be re-used if appropriate

AssessmentIn places, the bearing is worn to such an extent thatthe bearing metal ribs and the grooves in the contactlayer have reached a ratio of 1 : 1. The width of thebearing metal ribs has increased from 25 % (as-newcondition) to 50 %. There is still some contact layer leftin the grooves.

If a wear-and-tear status as described in Case2 below must be anticipated within the nextinspection interval, then the bearing must bereplaced.

0997 0299 6321-0199 Page 9 of 10


4

3

2

5

= 7

61

= 880232 1

Case 2 (Fig. 11):Definition of the contact-surface areas

1 Max. 20 % of the width2 Max. 5 % of the shells circumference3 Max. 10 % of the width4 Max. 35 % of the shells circumference5 Max. 10 % of the width6 Comb wear7 Wear and tear 1 : 18 Bearing metal ribs worn

Fig. 11 Bearing shell (deep-groove bearing) Case 2, cannot be re-used

AssessmentThe bearing metal ribs are worn in places.When this wear-and-tear status has been reached,the bearing must be replaced.

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0997 0299 3930-0122 Page 1 of 2


TBG 620/TBG 620K W 2-2-1

Removing and installing the bearing race (drive end)

50756 1

Tools:- Normal tools- Sealant Hylomar

Cross-references:- Job Card W 2-0-1, W 2-2-2, W 12-6-1- Operating Instructions, Chapter 8,

Tightening Instructions

After a lengthy period of running, a lead-in groove onthe bearing race 2 will form underneath the sealing lipof the shaft sealing ring 1. Provided the shaft sealingring is not replaced, this will in most cases not impairthe sealing effect.Install a new shaft sealing ring, see Job CardW 2-2-2, in the end wall cover, axially offset by approx.3 mm, so that it effectively seals next to the old lead-in groove. In the case of the end wall cover at thecoupling-end, this is possible only if the distancebetween the old groove and the free end of the bearingrace is not less than 7.5 mm. Otherwise (and if theshaft sealing ring has already been repositioned once)you will have to replace the bearing race.

Removing and fitting the flywheel see Job Card W 12-6-1.

Installing the bearing racel Apply sealant.l Press the new bearing race on, with the larger

diameter at the front (the inner diameter of thebearing races is slightly conical).

l Press the ring on, evenly and without tilting it (usea soft interlayer). The shoulder of the flywheelflange must be evenly flush all the way round.

Fig. 1, X: flush with the worked outer surfaceAfter pressing on:l Check that the lead-in bevel for the shaft sealing

ring is in faultless condition.l Fit the flywheel flange, and tighten the anti-fatigue

bolts 4 as specified in the Operating Instructions,Chapter 8, Tightening Instructions.


!

Removing the bearing racel Remove flywheel flange 3.l Apply a thin welding bead or individual welding

spots at regular intervals on the bearing race.l Take off bearing race.

If necessary, cut through the bearing racewith a flat chisel, in the longitudinal direction ofthe crankshaft. Take care not to damage thecrankshaft.

l Remove the residues of the old sealant, to ensurean absolutely clean surface.

Fig. 1 Bearing race


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0997 0299 3929-0122 Page 1 of 2


TBG 620/TBG 620K W 2-2-2

50756 1

Removing and installing the crankshaft sealing ring (drive end)Tools:- Normal tools- Sealant Loctite 574


Different shaft sealing rings are fitted at theflywheel and vibration-absorber ends, andyou must be careful not to mix them up. Theones at the free end (= vibration-absorberend) have a right-hand twist, and the those atthe drive end (= vibration-absorber end) havea left-hand twist.

Removing and fitting the flywheelsee Job Card W 12-6-1.

Take note of the markingsThere is a directional arrow and letters readingSchwungradseite (flywheel end) and Schwing-ungsdmpferseite (vibration-absorber end) outsideon the dust lip.


!

Removing the crankshaft sealing ringRaplce shaft sealing ring 1 only if there is aleak or (after dismantling operations) if thereis visible wear and tear at the sealing lip (widthgreater than 1 mm).

l Check contact surface of the shaft sealing ring onthe bearing race 2; replace the bearing race ifnecessary, see Job Card W 2-2-1.

l After installing the bearing race, check that thelead-in bevel for the shaft sealing ring is in faultlesscondition.

Fig. 1 Crankshaft sealing ring

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Installing the crankshaft sealing ringl Oil the shaft sealing rings thoroughly before fitting

them.l Install only original DEUTZ-MWM shaft sealing

rings, so as to ensure a reliable sealing effect.Always install the shaft sealing ring with the openside facing inwards.

Installation position for the shaftsealing ringl Seal the outer surface with Loctite 574.

When you press the shaft sealing ring into theend wall cover, do it evenly and withouttilting (use a help device if necessary).When you are installing sealing rings with a3 mm axial offset, always use a suitable,stepped device (journal diameter of device214 mm).

Fig. 1, X: flush with worked outer surface

0997 0299 3928-0122 Page 1 of 2


TBG 620/TBG 620K W 2-2-3

Removing and installing the bearing race (free end)

50757 1

Tools:- Normal tools- Sealant Hylomar

Cross-references:- Job Card W 2-0-1, W 2-2-4, W 12-1-4- Operating Instructions, Chapter 8,

Tightening Instructions

Under unfavourable operating conditions, and after alengthy period of running, lead-in grooves on thebearing race 2 may form underneath the sealing lip ofthe shaft sealing ring 1. Provided the shaft sealing ringis not replaced, this will in most cases not impair thesealing effect.Install a new shaft sealing ring, see Job CardW 2-2-4, offset by approx. 3 mm, so that it effectivelyseals next to the old lead-in groove. If the shaft sealingring has already been repositioned once, you mustreplace the bearing race.

Removing and fitting the torsionalvibration absorber.

see Job Card W 12-1-4

Fig. 1 Bearing race

Installing the bearing racel Press the new bearing race on, with the larger

diameter at the front (the inner diameter of thebearing races is slightly conical)..

l Press the ring on, evenly and without tilting it (usea soft interlayer). The race must be evenly flushwith the hub all the way round.

Fig. 1, X: flush with the worked outer surfaceAfter pressing on:l Check that the lead-in bevel for the shaft sealing

ring is in faultless condition.l Mount vibration-absorber hub and fit vibration

absorber. Tighten anti-fatigue bolts 4 as specifiedin the Operating Instructions, Chapter 8, TighteningInstructions.

Removing the bearing racel Remove torsional vibration absorber flanges 3.l Apply a thin welding bead or individual welding

spots at regular intervals on the bearing race.l Take off bearing race.

If necessary, cut through the bearing racewith a flat chisel, in the longitudinal direction ofthe crankshaft. Take care not to damage thecrankshaft.

l Remove the residues of the old sealant, to ensurean absolutely clean surface.


!


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0997 0299 3511-0122 Page 1 of 2


TBG 620/TBG 620K W 2-2-4

Removing and installing the crankshaft sealing ring (free end)

50324 1

Tools:- Normal tools- Sealant Loctite 574

Cross-refeences:- Job Card W 2-0-1, W 2-2-3

At the flywheel and vibration absorber ends,you will find different shaft sealing rings, andyou must be very careful not to get thesemixed up. The one at the free end (vibrationabsorber end) has a right-hand twist, and theone at the drive end (flywheel end) has a left-hand twist.

Check the identifiersSense-of-rotation arrow and labelling Schwungrad-seite (= flywheel end) or Schwingungsdmpfer-seite (= vibration absorber end) outside on the dustlip.

Fig. 1 Crankshaft sealing ring


!

Removing the crankshaft sealing ringReplace the shaft sealing ring 2 only if there isa leak or (after removal) you find visible wearand tear at the dust lip (width greater than 1mm).

l Check the contact surface of the shaft sealing ringon the bearing race 1; replace the bearing race ifnecessary, see Job Card W 2-2-3.

l After installing the bearing race, check that thelead-in bevel for the shaft sealing is in faultlesscondition.

of 2 0299 3511-0122 0997


Installing the crankshaft sealing ringl Before fitting them oil the shaft sealing rings

thoroughly.l Install only original DEUTZ-MWM shaft sealing

rings, to ensure a reliable sealing effect. Alwaysmake sure the open side of the shaft sealing ringis facing inwards.

Installation position for the shaftsealing ringl Seal the outer surface with Loctite 574.

When pressing the shaft sealing ring into theend wall cover, make sure you do so evenlyand without tilting (use the help device ifnecessary).Wheninstalling shaft sealing ring with a 3 mmaxial offset, you must always use a suitable,stepped device (devices journal diameter214 mm).Fig. 1, X: flush with worked outer surface

0997 0299 3904-0122 Page 1 of 2


TBG 620/TBG 620K W 2-3-1

cb a

Checking connecting-rod bearings and connecting rod for roundnessand conicityThe connecting-rod bearing shells must be measuredin the associated, removed and already-measuredconnecting rod before being installed in your engine.

Checking the connecting-rod bearingshells in their installed conditionl Assess the bearing shells,

see Job Card W 2-1-3.l Check the bearing shells spread dimension,

see Job Card W 2-1-1.l Install bearing shells, and attach connecting-rod

bearing covers,Use the measured values obtained to determinethe roundness (out-of-roundness) and conicityW 2-5-2.

l Carry out the following check in the centre of thebearing:- measure diameters a, b and c.

l Use the measured values obtained to determineout-of-roundness and conicity.

If the limit values specified below areexceeded, remove the bearing shells and thebearing covers, and clean the gearing againthoroughly.

l Carry out check routine as described above.

Tools:- Normal tools- Two-step measuring instrument- Caliper gauge


50745 0

Designation: Nominal dimension in mm: Limit values in mm:

Conn. rod head, with bearing shells fitted

- Normal 125.099 - 125.155 max. 125.190

- Rep. Stage 1 124.699 - 124.755 max. 124.790

- Rep. Stage 2 124.299 - 124.355 max. 124.390

- Rep. Stage 3 123.899 - 123.955 max. 123.990

- Roundness (out-of-roundness) / conicity max. 0.04 max. 0.065

Bearing clearance 0.095 - 0.185 max. 0.230(Bearing shells / crankshaft)

Fig. 1 Bearing shell diameters

of 2 0299 3904-0122 0997


cb a

If the bearing shells pass all the above-mentionedchecks, they can be re-used.If the permissible values are not reached, you have tomeasure the connecting-rod head borehole.

Checking the connecting-rod headborehole (conn. rod foot / conn. rodbearing cover)l Assemble connecting-rod stem and connecting-

rod bearing covers without bearing shells, asdescribed in Job Card W 2-5-2.

l Carry out the following check in connecting-rodheads bearing centre:- measure diameters a, b and c.

l Enter your measured values in a record sheet,stating the operating hours, the date, and the No.of the connecting rod you have checked.

l Use the measured values obtained to determinethe roundness (out-of-roundness) and conicity

If the values detailed below are exceeded,replace the connecting rod concerned.

Designation: Rated dimension in mm: Limit values in mm:

- Conn. rod head, without bearing shells fitted

- Conn. rod head bore 135.000 - 135.025 134.980 - 135.060

- Conicity max. 0.012 max. 0.020

- Roundness (Out-of-roundness) max. 0.012 max. 0.040

50689 0

Fig. 2 Connecting-rod head borehole

0997 0299 3888-0122 Page 1 of 2


TBG 620/TBG 620K W 2-5-1

Connecting rod bearings: removingTools:- Normal tools


With piston removall Turn the crankshaft so that connecting rod screws

1 can be loosened.l Prop up the connecting rod bearing cover 2.l Unscrew the connecting rod screws completely.l Lift the connecting rod bearing cover out of the

crankcase.l Take the bottom bearing shell out of the connecting

rod bearing cover.l If you are removing the piston (see Job Card

W 2-9-1), take the top bearing shell out of theconnecting rod.

l Protect the crankshaft journal against soiling in theoil bore with adhesive tape (not with transparentsellotape), and wrap with a clean cloth or oiledpaper.


!

Without removing the pistonThe top bearing shell can be removed even while thepiston is still installed.l Remove the connecting rod bearing cover 2 as

described under Work sequence with piston rem-oval.

l Slowly turn the piston with the crankshaft, until theconnecting rod is hanging free.

l Take off the top bearing shell.

50 746 0

Assessing the bearing shellssee Job Card W 2-1-3.

Fig. 1 Connecting rod bearing

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0997 0299 3889-0122 Page 1 of 2


TBG 620/TBG 620K W 2-5-2

Connecting rod bearings: installingTools:- Normal tools

Cross-references:- Job Card W 2-0-1, W 2-1-3, W 2-14-1- Tightening Instructions

Assess bearing shells as described in JobCard W 2-1-3, and replace if necessary. Becareful not to get the bearing shells and bearingcovers mixed up. Piston, connecting rod footand bearing cover are all identified with thecylinder number in