DEUTZ-FAHR SERIE 1000 3-4-6 cylinders ENGINE EURO 2 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
DEUTZ-FAHR SERIE 1000 3-4-6 cylinders ENGINE EURO 2 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 170
Downloadable : Yes
File Type : PDF
Size: 10.1 MB
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
DEUTZ-FAHR SERIE 1000 3-4-6 cylinders ENGINE EURO 2 Workshop Manual – PDF DOWNLOAD
HOW TO CONSULT THE MANUAL:
1. Removal and refitting of assembled units
(1) For the removal or refitting of assembled units, the sequence of operations and the methods to be applied are described
in the removal procedure; if the refitting sequence of operations is the exact reverse of the removal procedure,
it is not described.
(2) All special techniques that apply only to the refitting procedure are indicated by the symbol ; this same
symbol appears at the end of each major step in the removal procedure to indicate the parts for which special
techniques are to be applied during refitting.
TABLE OF CONTENTS:
DEUTZ-FAHR SERIE 1000 3-4-6 cylinders ENGINE EURO 2 Workshop Manual – PDF DOWNLOAD
IMPORTANT PRELIMINARY
INFORMATION… …………………………………………………. 1
HOW TO CONSULT THE MANUAL……………………….. 3
HOW TO USE AND UPDATE THE MANUAL ………….. 4
LIFTING INSTRUCTIONS……………………………………… 5
STANDARD TIGHTENING TORQUES FOR NUTS
AND BOLTS ………………………………………………………… 6
THREADLOCKERS, ADHESIVES, SEALANTS
AND LUBRICANTS………………………………………………. 7
SPECIAL TOOLS …………………………………………………. 9
CONVERSION FACTORS …………………………………… 10
ENGINE TYPE IDENTIFICATION AND
SERIAL NUMBERS…………………………………………….. 11
IDENTIFICATION OF INJECTORS AND
INJECTION PUMPS …………………………………………… 13
DETERMINING THE INJECTION
ADVANCE ANGLE……………………………………………… 14
ENGINE DISASSEMBLY
1. PRELIMINARY REMOVAL OPERATIONS …………….15
2. REMOVAL OF THE COOLING AND INTAKE PIPES 18
3. REMOVAL OF THE CYLINDER HEADS………………..20
• 3.1 Dismantling the cylinder heads …………………..28
• 3.2 Dismantling the rocker arm supports…………..29
4. REMOVAL AND TESTING OF THE
THERMOSTATS………………………………………………….30
• 4.1 REMOVAL ……………………………………………….30
• 4.2 TESTING THE THERMOSTATS ………………….31
5. REMOVAL OF THE COOLANT PUMP ………………….32
• 5.1 3- AND 4-CYLINDER VERSIONS………………..32
• 5.2 6-CYLINDER VERSIONS……………………………32
6. REMOVAL OF THE UNIT PUMPS, ACTUATOR AND
FUEL LIFT PUMP ……………………………………………….33
7. OVERHAUL OF THE MECHANICAL GOVERNOR
DRIVE ………………………………………………………………..38
• 7.1 DISASSEMBLY ………………………………………….38
• 7.2 ASSEMBLY ……………………………………………….40
8. OVERHAUL OF THE MECHANICAL GOVERNOR
(STANDARD AND WITH L.D.A.) …………………………..44
• 8.1. DISASSEMBLY OF THE STANDARD
GOVERNOR …………………………………………….44
• • 8.1.1 Separation of the lower and
upper housings……………………………………. 44
• • 8.1.2 Assembly of the lower housing…….. 49
• • 8.1.3 Adjusting the height of the lever
control bush………………………………………… 50
• • 8.1.5 Assembly of the upper housing ……. 54
• • 8.1.6 Assembly of the governor housing .. 54
• 8.2 DISASSEMBLY OF THE GOVERNOR
WITH L.D.A. VALVE…………………………………..55
• • 8.2.1 Separating the upper and lower
housings …………………………………………….. 55
• • 8.2.2 Renewal of the membrane…………… 56
• • 8.2.3 Completion of the disassembly ……. 57
• • 8.2.4 Assembly of the governor with
L.D.A. valve…………………………………………. 59
• 8.3 BENCH ADJUSTMENT OF L.D.A. VALVE…….61
• • 8.3.1 Adjusting the length of the tie-rod … 61
• • 8.3.2 Adjusting the spring load …………….. 61
• • 8.3.3 Adjusting the membrane travel…….. 62
• 8.4 FINAL ADJUSTMENTS ……………………………….62
• • 8.4.1 Adjusting the fuel flow rate ………….. 62
• • 8.4.2 Calibration for mechanical
governors……………………………………………. 63
• • 8.4.3 Adjusting the maximum speed …….. 64
• • 8.4.4 Hunting adjustment…………………….. 64
• • 8.4.5 Adjusting the idle speed ……………… 65
• • 8.4.6 Sealing the governor…………………… 65
9. ADJUSTMENT OF THE ELECTRONIC
ACTUATOR………………………………………………………..66
• 9.1 CALIBRATION OF ELECTRONIC
ACTUTAORS……………………………………………67
10. REMOVAL OF THE INJECTION PUMP
CONTROL ROD………………………………………………….68
11. REMOVAL AND DISASSEMBLY OF THE HEAT
EXCHANGER
(For 4- and 6-cylinder versions) ………………………….69
12.DISMANTLING THE VALVE TIMING DRIVE………….70
13.DISMANTLING THE CRANKSHAFT …………………….73
• 13.1 REMOVAL OF THE HARMONIC BALANCER
(4-cylinder versions when fitted) …………………75
• 13.2 OVERHAUL OF THE HARMONIC BALANCER
(when fitted)……………………………………………..75
• • 13.2.1 Disassembly …………………………….. 75
• • 13.2.2 Assembly …………………………………. 76
• 13.3 REMOVAL OF THE CRANKSHAFT……………..76
• 13.4 DISMANTLING THE OIL PUMP ………………….79
• • 13.4.1 3- and 4-cylinder versions …………… 79
• • 13.4.2 6-cylinder version……………………….. 80
CONTENTS
30-ii
14. REMOVAL OF THE PISTONS AND CYLINDER
LINERS …………………………………………………………….. 81
• 14.1 SEPARATING THE PISTON-CONNECTING
ROD ASSEMBLY…………………………………….. 81
15. RENEWAL OF THE REAR CRANKSHAFT
OIL SEAL………………………………………………………….. 83
16. TESTS – TECHNICAL DATA AND DIMENSIONS….. 84
• 16.1 CYLINDER HEADS – VALVES –
ROCKER ASSEMBLIES……………………………. 84
• • 16.1.1 Inspection and renewal of valve
guides………………………………………………….84
• • 16.1.2 Renewal of the valve guides …………84
• • 16.1.3 Inspecting the valve seats…………….84
• • 16.1.4 Inspecting the valves……………………85
• • 16.1.5 Inspecting the valve springs………….85
• • 16.1.6 Testing the valve seals …………………86
• • 16.1.7 Checking injector protrusion …………86
• • 16.1.8 Renewal of the copper bushes ……..87
• • 16.1.9 Inspecting the rocker arms and
pivot posts……………………………………………87
• • CYLINDER HEADS – VALVE GUIDES –
VALVE SEATS ………………………………………88
• • VALVES – VALVE SPRINGS ……………………89
• • ROCKER ARMS – ROCKER PIVOT
POSTS – TAPPETS………………………………..90
• 16.2 INJECTORS – INJECTION PUMPS ……………. 91
• • 16.2.1 Testing the injectors …………………….91
• • INJECTOR TECHNICAL DATA –
NATURALLY ASPIRATED ENGINES………..92
• CALIBRATION METHOD…………………………………. 93
• • INJECTOR TECHNICAL DATA –
TURBOCHARGED ENGINES………………….94
• • INJECTOR TECHNICAL DATA –
INTERCOOLER ENGINES………………………96
• 16.3 PISTONS – CONNECTING RODS ……………… 98
• • 16.3.1 Inspection of the pistons and piston
rings…………………………………………..98
• • 16.3.2 Inspecting the connecting rods
– gudgeon pins ……………………………99
• 16.4 INSPECTION OF THE BIG-END
CAP BOLTS100
• • PISTONS code 0.013.1456.0
(3-4-6 cylinder W engines) ……………………101
• • PISTON RINGS …………………………………..101
• • PISTONS code 0.012.8912.0
( 3- cylinder WT engines)………………………102
• • PISTON RINGS …………………………………..102
• • PISTONS code 0.012.8913.0
( 4-6 cylinder WT engines)…………………….103
• • PISTON RINGS …………………………………..103
• • PISTONS code 0.012.8483.4/20
(4-6 cylinder WTI engines)…………………….104
• • PISTON RINGS …………………………………..104
• • CONNECTING RODS
(FOR PISTONS W-WT)…………………………105
• • CONNECTING RODS
(FOR PISTONS WTI)…………………………….106
• 16.5 CRANKSHAFT………………………………………. 107
• • CRANKSHAFT (3-CYLINDER VERSION) .109
• • CRANKSHAFT (4-CYLINDER VERSION) ..110
• • CRANKSHAFT (6-CYLINDER VERSION) ..111
• 16.6 ENGINE BLOCK – CYLINDER LINERS …….. 112
• • 16.6.1 Engine block……………………………. 112
• • 16.6.2 Inspection of the cylinder liners….. 112
• • ENGINE BLOCK – CYLINDERS……………. 114
• 16.7 CAMSHAFT ………………………………………….. 115
• • CAMSHAFT (13° STATIC ADVANCE)……. 116
• • CAMSHAFT (16° STATIC ADVANCE)……. 117
• 16.8 TIMING GEARS…………………………………….. 118
• • 16.8.1 Removal of the gear shaft …………. 118
• • TIMING GEARS …………………………………. 119
• 16.9 HARMONIC BALANCER
(For 4 cylinder engines only)……………………. 120
• • HARMONIC BALANCER …………………….. 121
• 16.10 FLYWHEEL…………………………………………. 122
ENGINE ASSEMBLY
17. FITTING THE PISTON COOLING NOZZLES………. 123
18. FITTING THE CYLINDER LINERS,
PISTONS AND CONNECTING RODS………………… 124
19. FITTING THE CAMSHAFT-CRANKSHAFT AND
CONNECTING ROD BIG-ENDS………………………… 126
20. ASSEMBLY OF THE HARMONIC BALANCER
(For 4-cylinder engines only, only when fitted) …. 130
21. REFITTING THE OIL PUMP – SUMP PAN………….. 131
• 21.1 3- AND 4-CYLINDER VERSIONS…………….. 131
• 21.2 6-CYLINDER VERSION………………………….. 131
• 21.3 ASSEMBLY OF THE ENGINE OIL SUMP …. 132
22.CALCULATING THE THICKNESSES OF THE
HEAD GASKETS AND REFITTING THE
CYLINDERHEADS…………………………………………… 133
23. REFITTING THE CYLINDER HEADS…………………. 134
24. REFITTING THE INJECTION PUMP
CONTROL ROD………………………………………………. 136
25. REFITTING THE MECHANICAL GOVERNOR DRIVE
AND THE ELECTRONIC GOVERNOR SUPPORT . 137
26. ADJUSTMENT OF THE TIMING GEARS……………. 138
27. VALVE TIMING………………………………………………… 140
• 27.1 Checking the camshaft timing…………………. 141
28. TIMING THE INJECTION PUMPS …………………….. 142
29.REFITTING THE ROCKER ASSEMBLIES ………….. 147
30. ADJUSTMENT OF VALVE CLEARANCES –
INJECTOR ASSEMBLY……………………………………. 148
• 30.1 Valve clearance adjustment ……………………. 148
• 30.2 Injector assembly ………………………………….. 148
31. FINAL ENGINE ASSEMBLY OPERATIONS ……….. 149
32. FINAL ENGINE ASSEMBLY – REAR END………….. 161
33. ENGINE TESTS……………………………………………….. 164
• 33.1 Initial start-up and oil pressure check ………. 164
• 33.2 Synchronizing the injection pumps. …………. 165
• • 33.2.1 Test………………………………………… 165
• • 33.2.2 Angular adjustment of the
injection pumps ……………………….. 165
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V