Service Maual of DDE 1013 Engine

大连道依茨 1013 系列发动机维修手册
880*1230 mm 16 开本 18 印张
2014 年 3 月第 1 版第 1 次印刷
山东临工工程机械有限公司
地址：山东省临沂经济开发区临工工业园
电话：0539-8785688 传真：0539-8785698
邮编：276023 网址：www.sdlg.cn
服务电话：8008607999 4006587999 0539-8785800
服务传真：0539-8785671
BFM1013 维修手册
鉴于不断的改进及更改，本手册中的技术条件及图例会经常改动改动。任何全部或
部分的翻译及再版须经过我们的书面批准。
In view of continuous design improvements or changes, the technical data and illustrations contained in
this Workshop Manual are subject to alteration. Reprinting and reproduction, in part or in whole, are
subject to our written approval.
修订：20201229
几个特殊的故障代码说明 P154A ;P154B;P154C;U0000
Revision: 20201229
Several special fault code descriptions P154A ;P154B;P154C;U0000
1
前言
发动机可靠的运转取决于适宜的维修及调整调整。
本维修手册描述了对于发动机各零部件维修及调整的正确操作，假定这些工作是由合格的人员操
作的。
本手册的布置可保证对内容的正确解释，那就是，在每个说明文字的旁边都有插图可以清晰的表
明操作过程。
有关有关操作及日常保养的内容，请参阅“备件手册”。
有关备件的需求，请参阅备件手册。
本手册在下一版之前一直有效，且不随工程更改而改变。
因此，在维修操作中，请参考工程技术更改通知。
一般性通告：
·请仔细阅读并遵照本手册中的指导以保证您的发动机正常可靠的工作,避免发生异常。
·确保所有维修及调整的操作可以在手册中迅速查到，并且对每部分都有正确的理解。
·任何不按手册中维修指导的操作都可能导致发动机故障及损坏，以及人员的伤害，所有这些制
造厂商不承担法律责任。
·应遵守事故预防准则及其它公认的安全规定以及职业医学的规定。
·必须的设备、手册及专用工具、以及正确的操作步骤是成功维修的必要条件。
·只有在使用“道依茨大柴”的纯正零件，才可获得发动机最佳的经济性、可靠性及耐久性。
·须小心处理发动机如弹簧、卡箍、锁环等零件，否则可引起伤害。
·发动机的维修必须按照设备制造商规定的既定用途进行，相应的，只有在经“道依茨一汽（大
连）柴油机有限公司”批准后，方可使用特种用途的零件。
2
FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work. on the
engine and engine components. It is presumed that this work will be carried out by qualified personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise text
passages are accompanied by pictographs to illustrate the relevant operation.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.
General information:
- Please read carefully and observe the instructions given in this Workshop Manual to avoid accidents
and ensure that your engine always functions properly and reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out repairs or
adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine damage as well as
personal injuries for which the manufacturer shall not accept any liability.
- The accident prevention regulations and all other generally recognized regulations on safety and
occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special tools are available
and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be ensured when genuine
parts of DEUTZ (DALIAN) are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not handled with care.
- Engine repairs must be carried out in accordance with intended use as defined by the equipment
manufacturer. For conversions, only parts approved by DEUTZ (DALIAN) ENGINE CO., LTD for a
specific purpose should be used.
3
目录Table of Contents
1. 技术参数/符号注释 Specification data / Key to symbols

2. 检查机调整 Control and adjustment
3. 零部件维修 Repair of components
4. 发动机拆装 Disassembly and re-assembly of complete engine
4
1.技术参数页码
技术参数---------------------------------------------------------------------5
气门间隙调整图解-------------------------------------------------------------8
缸盖螺栓拧紧顺序-------------------------------------------------------------9
波许喷油泵喷油提前角调整垫片厚度---------------------------------------------10
BFM1013 维修时标准长度 L0=143 ㎜的波许喷油泵喷油提前角调整垫片厚度------------13
确定波许喷油泵修正的安装长度以及 EP 代码 -------------------------------------14
符号注解 --------------------------------------------------------------------15
1. Specification data Page

Specification data---------------------------------------------------------------5
Schematic for valve clearance adjustment--------------------------------------------8
Tightening order for cylinder head bolts---------------------------------------------9
Determining commencement of delivery---------------------------------------------10
Determining shim thickness for commencement of delivery injection pump replacement in case of
service. Basic dimension L0 = 143 mm----------------------------------------------13
Determining corrected installation dimension and EP code for injection pump---------------14
Key to symbols-----------------------------------------------------------------15
5
技术参数 Specification data
BF4M 1013 BF4M 1013E BF6M 1013 BF6M 1013E
发动机型号含冷却系不含冷却系含冷却系不含冷却系
Engine type Cooling system Without cooling Cooling system Without cooling
system system
发动机重量㎏(近似) 480 BFM1013 430 BFM1013E 635 570 BFM1013E
Engine weight acc. to DIN BFM1013
70020 – A approx. kg
发动机排量 cm3 4764 7146
Engine swept volume cm3
缸径 mm 108
Bore mm
行程 mm 130
Stroke mm
旋转方向面向飞轮时,逆时针方向
Direction of rotation When facing flywheel counter-clockwise
额定转速 r/pm 2300
Rated speed max. rpm
最低怠速转速 rpm 600
Minimum idle speed rpm
工作循环 4 冲程柴油机
Working cycle Four-stroke diesel
燃烧系统直喷式
Combustion system Direct injection
压缩比 17.6：1
Compression ratio
缸压 Bar 30-38
Compression pressure bar
各缸工作顺序 1-3-4-2 1-5-3-6-2-4
Fiing order
最大长度 mm 945 862 1239 1146
Max. length mm
最大宽度 mm 685 616 760 622
Max. width mm
最大高度 mm 818 844 868 852
Max. height mm
上止点前进气门开启提 46.5
前角°
Inlet opens before TDC
degree
下止点前进气门关闭延 55.5
迟角°
Inlet closes after BDC
degrees
下止点前排气门开启提 100.5
前角°
Exhaust opens before
BDC degrees
6
上止点后排气门关闭延 51.5
迟角°
Exhaust closes after TDC
degrees
机油压力 Bar 6±0.75 10±1
Pressurestat bar
怠速时最低机油压力
SAE 15W/40 油温约 120 0.8
℃3
Lube oil pressure at low
Idling Temperature
approx. 120　C oil SAE
15W/40 min. bar
7
气门间隙调整图解 Schematic for valve clearance adjustment
曲轴位置 1 曲轴位置 2
Crankshaft position 1 Crankshaft position 1
发动机翻转到 1 号气缸气门重叠，还不可以调进一步翻转发动机 360º，可以调整。
整。
Turn engine until valves of cylinder No.1 overlap. Turn engine further by one complete revolution
(360°)
不可调整气门 Not ready for adjustment 可调整气门 Ready for adjustment
8
缸盖螺栓拧紧顺序 Tightening order for cylinder head bolts
BF4M1013
歧管侧 Manifold side
BF6M1013
岐管侧 Manifold side
9
确定喷油提前角的调整垫片厚度,
Determining shim thickness for commencement of delivery.Bosch injection
pump 表 1 Table1
机型喷油提前角（FB）凸轮轴类预行程名义值预行程修正系数喷油泵标准长度
Engine type （上止点前曲轴型（Vh）（mm）（mm/°曲轴转（L0）(mm)
转角°） Camshaft Pre-stroke 角） Standard
Commencement type (Vh) Pre-stroke dimensions
of delivery(FB) Nom. value correction factor inj. pump
(　C/A BTDC) (mm) (mm/　C/A) (Lo) (mm)
BFM 1013 4 6.20 0.1 143
BFM 1013 4.5 6.11 0.1 143
BFM 1013 5 6.02 0.1 143
BFM 1013 5.5 5.93 0.1 143
BFM 1013 6 5.84 0.1 143
BFM 1013 6.5 5.75 0.1 143
BFM 1013 7 5.66 0.1 143
BFM 1013 7.5 5.58 0.1 143
BFM 1013 8 5.49 0.1 143
表 2 Table2
调整垫片理论厚度垫片实际厚度调整垫片理论厚度垫片实际厚度
“TS”(mm) “Ss”(mm) “TS”(mm) “Ss”(mm)
Theor. thickness Shim-thickness Theor. thickness Shim-thickness
"TS" (mm) "SS" (mm) "TS" (mm) "SS"(mm)
0.95-1.049 1.0 2.45-2.549 2.5
1.05-1.149 1.1 2.55-2.649 2.6
1.15-1.249 1.2 2.65-2.749 2.7
1.25-1.349 1.3 2.75-2.849 2.8
1.35-1.449 1.4 2.85-2.949 2.9
1.45-1.549 1.5 2.95-3.049 3.0
1.55-1.649 1.6 3.05-3.149 3.1
1.65-1.749 1.7 3.15-3.249 3.2
1.75-1.849 1.8 3.25-3.349 3.3
1.85-1.949 1.9 3.35-3.449 3.4
1.95-2.049 2.0 3.45-3.549 3.5
2.05-2.149 2.1 3.55-3.649 3.6
2.15-2.249 2.2 3.65-3.749 3.7
2.25-2.349 2.3 3.75-3.850 3.8
2.35-2.449 2.4
注意98D电控单体泵的发动机，此单体泵统一带1111068B52D单体泵调整垫（2.4厚），无EP数值
Notice! Electricity control fuel pump use 1111068B52D shim ,without ED value
10
计算举例：Calculation example
缸号.Cylinder No 0 1 2 3
喷油泵号 Injection pump No. XXX
FB测量值℃/A FB measured 　C/A 10
从表1查到FB名义值℃/A FB nom. from table 1 C/A 10
从表1查到Vh修正系数mm/℃/A 0.1
Vh corr. factor from table 1 mm/　C/A
从表1查到Vh名义值 mm 5.31
Vh nom. from table 1 mm
从表1查到L0名义值mm 143
L0 nom. from table 1 mm
喷油泵A/100mm 1.33
A/100 of inj. pump mm
L测量值mm 152.22
L measured mm
E1=FB(测量值)－FB（名义值）℃/A 0
E1 = FB act. - FB nom 　C/A
E2=E1×Vh修正系数mm 0
E2 = E1 x Vh corr. factor mm
E3=E2+Vh名义值mm 5.31
E3 = E2 + Vh nom. mm
E4=E3+L0mm 148.31
E4 = E3 + L0 mm
E5=E4+A/100mm 149.64
E5 = E4 + A/100 mm
Ts=L-E5mm 2.58
TS = L - E5 mm
从表2查到“SS”mm 2.6
"SS" from table 2 mm
11
BFM1013 维修时标准长度 L0＝143mm 的波许喷油泵喷油提前角调整垫片厚度的确定
injection pump replacement in case of service. Basic dimension L0 = 143mm
在这种情况下不需要旧的喷油泵及垫片。
The old injection pump with shim is not required for such purpose.
举例：一台 BFM 1013 发动机更换 3 缸喷油泵。
Example: The injection pump of cylinder 3 is to be replaced on a BFM 1013 engine.
步骤：从铭牌中“EP”栏中读取 3 缸的 EP 代码，比如说：397
(读取顺序：第一行＝1 缸，第二行＝2 缸，依此类推)。
根据 EP 代码从表 5 中读取喷油泵修正后的安装尺寸（EK）,比如说：146.9mm。
Procedure: Read off EP code for cylinder 3 from nameplate under column „EP“, e.g. 397.
(Reading sequence: line 1=cyl.1, line 2 = cyl.2, etc.
Take corrected injection pump installation dimension (EK) from table 5 according to EP code,
e.g. 146.9 mm.
表 3 Table3
EK(mm) EP 代 EK(mm) EP 代 EK(mm) EP 代 EK(mm) EP 代 EK(mm) EP 代
码码码码码
code code code code code
144.5 145.1 145.7 349 146.36 373 146.9 397
144.525 145.125 145.725 350 146.325 374 146.925 398
144.55 145.15 145.75 351 146.35 375 146.95 399
144.575 145.175 145.775 352 146.375 376 146.975 400
144.6 145.2 145.8 353 146.4 377 147.0 401
144.625 145.225 145.825 354 146.425 378 147.025
144.65 145.25 145.85 355 146.45 379 147.05
144.675 145.275 145.875 356 146.475 380 147.075
144.7 145.3 145.9 357 146.5 381 147.1
144.725 145.325 145.925 358 146.525 382 147.125
144.75 145.35 335 145.95 359 146.55 383 147.15
144.775 145.375 336 145.975 360 146.575 384 147.175
144.8 145.4 337 146.0 361 146.6 385 147.2
144.825 145.425 338 146.025 362 146.625 386 147.225
144.85 145.45 339 146.05 363 146.65 387 147.25
144.875 145.475 340 146.075 364 146.675 388 147.275
144.9 145.5 341 146.1 365 146.7 389 147.3
144.925 145.525 342 146.125 366 146.725 390 147.325
144.95 145.55 343 146.15 367 146.75 391 147.35
144.975 145.575 344 146.175 368 146.775 392 147.375
145.0 145.6 345 146.2 369 146.8 393 147.4
145.025 145.625 346 146.225 370 146.825 394 147.425
145.05 145.65 347 146.25 371 146.85 395 147.45
145.075 145.675 348 146.275 372 146.875 396 147.475
从新喷油泵上读取喷油泵(A)的代码，比如说：133。
Take code for injection pump length (A) from new injection pump, e.g. 133.
从表 1 中喷油泵标准长度（L0），比如说：143mm。
Take standard dimension of injection pump (Lo) from table 1, e.g. 143 mm.
确定垫片的理论厚度（Ts）：Determine theoretical shim thickness (Ts)：
Ts＝EK-(L0+A/100)
Ts=146.9mm-(143mm+133/100mm)
Ts=2.57mm
12
按照表 2 选取调整垫片厚度（Ss）：
Select shim thickness (Ss) according to table 2.
Ts2.57mm=Ss2.6mm
确定波许喷油泵修正的安装长度（EK）以及 EP 代码
Determining corrected installation dimension and EP code for injection pump.
当更换曲轴箱、凸轮轴或滚轮挺柱时，必须重新确定修正后的安装尺寸（EK），同时名牌上相关
的 EP 代码必须重新更新。
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be
determined once again and the relevant EP code on the nameplate must be changed.
使用的表格见表 1，表 2，表 3。
For tables see table 1,table 2,table 3.
计算举例：Calculation example:
缸号Cylnder No. 0 1 2 3
表1中L0名义值L0 nom. from table 1 mm 143
FB测量值℃/AFB measured 　C/A 10
表中FB名义值℃/AFB nom. from table 　C/A 10
表1中Vh修正系数mm/℃/A 0.1
Vh corr.factor from tab.1 mm/　C/A
表1中Vh名义值mm Vh nom. from table 1 mm 5.31
L测量值mm L measured mm 152.22
E1=FB(测量值)- FB(名义值) ℃/A E1 = FB actual - FB nom 0
　C/A
E2=E1×Vh 修正系数 mm E2 = E1 x Vh corr.factor mm 0
E3=E2+Vh名义值mm E3 = E2 + Vh nom. mm 5.31
EK=L-E3mm 146.91
Ek 对称四舍五入 EK symm.rounded mm 146.9
从表 3 中查到 EP 代码 EP code from table 5 397
13
符号注释
总成拆解注意操作安全
总成再装配注意零件损伤
拆除相关零件支撑
相关零件再装配涂机油
特别注意涂润滑油
检查－调整，如转作标记，拆卸前做标
矩、尺寸、压力等。记要遵照标记再装配
专用工具平衡
消除所有的不平衡
加注
注意安装方向
如油、冷却水等。
排出
目视检查
如油、冷却水等。
或许还可以修理松开
必要时更换如松开夹紧装置
每次重装时都要更锁紧
新如拧紧卡紧装置
锁紧零件拆解通风
如打开销钉，锁片等
涂密封剂
机加工
如液体密封剂
14
Key to Symbols
Disassembly Guard against personal

of assembly groups injury Indication of
hazard
Reassembly Guard against material
to form assembly group damage Damage to
parts
Remove Prop up - Support -
obstructing parts Hold
Reinstall - Remount Oil

parts which had
obstructed disassembly
Attention! Important Grease
otice!
Check - Adjust Mark

e. g.torque dimensions, before disassembly,
observe marks when
pressures, etc. reassembling
Special tool Balance

Eliminate any
imbalance
Note direction of Filling - Topping up –
installation Refilling e. g. oil,
cooling water, etc.
Visual inspection Drain off

e. g. oil, cooling water,
etc.
Possibly still service Loosen - Release
able Renew if necessary e. g. loosening a
clamping device
Renew at each Tighten - Clamp
reassembly e. g. tightening a
clamping device
Unlock – Lock e. g. Vent
split pin, locking plate,
etc.
Lock – Adhere e. g. Machining process
with liquid sealant
15
检查与调整 Checking and adjusting
2.检查与调整 Checking and adjusting 页码 Page
气门间隙 Valve clearance-----------------------------------------------------------------------------16
气缸压力 Compression pressure---------------------------------------------------------------------19
喷油器 Injector------------------------------------------------------------------------------------------22
16
气门间隙 Valve clearance
调整气门间隙时，发动机须处于冷态，冷车在 0.5 小时以上，机油温度≤80℃。
with engine cold or warm after cooling down for at least 0.5 h. Oil temperature ≤80　C.
注意：每次更换气缸垫后，气门间隙会增加 0.1mm，运转 50-150 小时后应重新调整。
Note: The valve clearance is to be increased by 0.1 mm at every cylinder head gasket renewal.
The standard valve clearance is to be adjusted after completion of 50-150 hours of operation.
拆除气门室罩和曲轴箱呼吸器
Cylinder head cover and crankcase breather have
been removed
1、转动发动机至 1 缸气门重叠
1. Turn engine until valves of cyl. No. 1 overlap.
参见技术参数中气门间隙调整图解。
See specification data for valve clearance.
adjustment schematic.
注：气门重叠表示：排气门即将关闭，进气门
即将打开，在此位置推杆不能转动。
Note: Valves overlapping means:Exhaust valve
about to close. Inlet valve about to open. Neither
pushrod can be turned in this position.
气门间隙每1500h检查，如有需要，则调整
Valve clearance check and adjustment(if
needed) is added in routine maintenance, the
cycle is 500h
2、用塞片调整各缸气门间隙
Adjust valve clearance on respective cylinder
with feeler gauge.
注意：进气门间隙：0.3mm
排气门间隙：0.5mm
Note: Inlet valve clearance: 0.3 mm
Exhaust valve clearancee: 0.5 mm
3、拧紧锁定螺母至 20±2Nm
Tighten locknut with a torque of20±2Nm.
Recheck the adjustment with feeler gauge.
17
4、安装气门室罩衬垫。
Position gasket in place.
5、安装气门室罩，拧紧螺栓至 9±1 Nm
Fit cylinder head cover and cover plate.
Tighten bolts with a torque of 9±1 Nm.
6、安装曲轴箱呼吸器，拧紧螺栓至 9±1 Nm
Fit crankcase breather. Tighten bolts with a
torque of 9 ±1 Nm.
18
气缸压力：Compression pressure
通用工具：
Commercial tools required:
压力计：8005
Compression tester 8005
E 型专用套筒：8189
Torx tool kit 8189
专用工具：
Special tool required:
测压计接头：100110
Connector 100 110
气门间隙调整完毕，拆除喷油器。
Injectors have been removed, valve
clearance has been checked.
1、将带新的专用密封圈的接头插入气缸内。
Insert connector with new specialseal.
2、安装压板，拧紧螺栓。
Fit clamping pad. Tighten bolt.
3、必要时，在接头上加拧一个接头。
If necessary, screw on adapter for
connector.
19
4、接连压力计，用起动机拖动发动机
Connect compression tester.
Turn engine with starter.
缸压： 30-38 bar
Compression pressure: 30-38 bar
缸压的测量结果与测量过程中起动机转速
以及发动机所处的海拔高度有很大关系，
因此，很难规定精确的限值，测量缸压的
目的仅在于比较同一台发动机各缸压力，
如果各缸缸压差超过 15％应该拆解该缸
有关零件确定原因。
The measured compression pressure is
dependent on the starting speed during the
measuring process and also on the altitude of the
engine site. Therefore it is difficult to specify
precise limit values. It is recommended to use the
compression pressure measurement only for
comparison of compression pressures of all
cylinders in one engine. If a difference in
pressure in excess of 15% is determined, the
cylinder unit concerned should be dismantled to
establish the cause.
注：安装喷油器须使用新的专用密封圈，安压
板并拧入螺栓。安装新的高压油管，用手指拧
紧锁紧螺母。密封圈锥面必须配合紧密。高压
油管只能使用一次，不允许再弯曲。拧紧压板
螺栓至 16+5 N.m。预紧喷油管到油泵锁定螺母
以及到喷油器锁定螺母至 5 N.m,之后拧紧至
30+3.5N.m。一般使用新的回油管。拧紧气门
室罩螺栓至 9±1N.m。
Note: Fit injectors with new special seals.
Position clamping pads and start bolts. Fit new
injection lines. Screw on cap nuts fingertight. The
sealing cones must match precisely. Rebending is
not permissible.The injection lines may not be
used twice. Tighten bolts of clamping pads with a
torque of 16 + 5 Nm. Preload cap nuts of
injection lines on injection pumps and injectors
with a torque of approx. 5 Nm. Thereafter tighten
cap nuts with a torque of 25 + 3.5 Nm. Leakage
fuel lines must always be renewed. Tighten
cylinder head cover with a torque of 9 ±1 Nm.
20
喷油器 Injector
通用工具：Commercial tools required:
喷嘴测试仪：8008 Nozzle tester ：8008
长套管：8012 Long socket：8012
专用工具：Special tool required:
喷油器压板：110110 Assembly tool :110 110
注意：在对喷油设备检修时，必须保证最大限
度的清洁，在检测喷油器时只能使用符合
ISO4113 规定的纯净测试油，或者清洁的柴油。
Note: Utmost cleanliness must be ensured when
working on the injection equipment. For testing
the injector use only pure test oil to ISO 4113 or
clean diesel fuel.
特别注意：
谨防喷油器的油喷，燃油渗入皮下组织，引起
血液中毒。
Caution:
Beware of injection nozzle fuel jet. The fuel
penetrates deeply into the skin tissue and may
cause blood poisening.
1、将喷油器连接到喷嘴测试仪上。
Connect injector to nozzle tester.
2、检查开启压力
开启测压计，慢慢压下喷油器杠杆，在压力指
针停止或突然下降点的压力即为开启压力。开
启压力检测值为以下值时，喷油器可继续使用。
250 +8bar
Checking opening pressure With pressure gauge
switched on, slowly press down lever of nozzle
tester. The pressure at which thegauge pointer
stops or suddenly drops, is the opening pressure.
Opening pressure check value for possible reuse:
250 +8 bar
21
3、喷油器开启压力的调整
Adjusting the opening pressure on the injector
松开螺旋护套，拆除所有零件。
Unscrew cap nut and remove all parts.
拆除顺序
Sequence of parts disassembly
1、螺旋护套 Cap nut
2、喷油器喷嘴 Injection nozzle
3、弹簧座 Adapter
4、止推销 Thrust pin
5、压力弹簧 Compression spring
6、调整垫片 Shim
4、通过选择合适的调整垫片调节压力，
调整垫片越厚则开启压力越大。拧紧螺
旋护套至 40-50 N.m,在喷嘴测试仪上重
新检测开启压力。
Adjust pressure by selecting appropriate shim.
A thicker shim increases the opening pressure.
Tighten cap nut with a torque of 40 - 50 Nm.
Recheck injector on nozzle tester
5、紧固检查
Checking for tightness
用压缩空气吹干喷油器及外壳，按下测压
计手柄直至压力达到比上一次开启压力读
数低约 20 bar
Dry nozzle and nozzle holder – blow out with
compressed air. Press down handlever of tester
until a pressure of up to about 20 bar below the
previous opening pressure reading is attained.
22
6、如在 10 秒内没有滴漏现象，表明喷油器紧
固正常。
Nozzle is tight if there is no dripping within a
period of 10 seconds.
7、在有滴漏的情况下，喷油器必须拆解并清洗
干净以防滴漏，如这样还不能防止滴漏，则此
喷油器必须更换。
In case of a drip, the injector must be dismantled
and cleaned to remedy the leak. If this does not
cure the leak, the injector must be replaced
并且不允许重新操作规程。
Reworking is not permissible.
8、打压及喷雾试验
Buzzing and spray pattern test
关闭检测计的压力针。
Switch off pressure gauge of tester.
打压试验可以通过听到的声音简易地检查针阀
在阀座中的运动，新的喷油器会发出与使用过
的喷油器不同的蜂鸣声，由于针阀在针阀座中
的磨损可以引起损坏，如果尽管清洗后喷油器
仍不能发出正常的蜂鸣声，其必须被更换。
The buzzing test permits an audible check of the
ease of movement of the nozzle needle in the
nozzle body. New injectors emit a different
buzzing sound as compared to used injectors. It
deteriorates due to wear in the needle seat area. If
an injection nozzle does not buzz despite cleaning,
it must be renewed.
一个正常使用的喷油器，在手柄快速的运动中，
应发出清晰的蜂鸣声，同时应呈现出良好的喷
雾形式。新的喷油器和旧的喷油器喷雾形式会
有显著的不同。
A used injector should buzz clearly during rapid
actuation of the handlever, while exhibiting a
well atomized spray pattern. The spray pattern
may differ noticeably from that of a new injector.
23
零部件维修 Repair of components
24
3.零部件的维修 Repair of components
总成分组名称页码
Assembly Group Description Page
01 曲轴箱及缸体总成 27
Crankcase
01 前盖及机油泵 38
Front cover / Lube oil pump
01 正时齿轮罩盖 42
Timing case
05 曲轴 45
Crankshaft
05 飞轮及齿圈 48
Starter ring gear / flywheel
06 连杆 50
Connecting rod
07 活塞 56
Piston
08 气缸盖 59
Cylinder head
10 凸轮轴 65
Camshaft
11 摇臂支架 67
Rocker arm bracket
17 输油泵 69
Fuel pump
19 喷油器 71
Injector
27 控制齿条 75
Control rod
38 节温器 78
Thermostat
38 冷却水泵 80
Coolant pump
83 液压泵驱动装置 82
Hydraulic pump drive
83 液压泵与连接法兰 86
Hydraulic pump with
fastening flange
25
曲轴箱及缸体总成 Crankcase with integrated cylinder liners
26
曲轴箱及缸体总成
Crankcase with integrated cylinder liners
通用工具 Commercial tools required:
高强度内六角扳头 Screw driver socket－8112
内径百分表 Internal dial gauge
专用工具：Special tools required:
凸轮轴套拆装工具：143810
Assembly tool for camshaft sleeves：143810
控制齿条拆装工具：110480
Assembly tool forcontrol rod sleeves：110480
缸套安装工具：150100
Assembly tool for cylinder liners ：150100
拉拔器：150800
Extractor ：150800
1、清洗曲轴箱，并检查损伤。
Clean crankcase and inspect fordamage.
注意：在测量前，按规定拧紧主轴承螺栓。
初始锁紧力矩：50 Nm
Note: Prior to measurement tighten main
bearing caps as specified. Initial tightening
torque: 50 Nm
第一次拧紧转角：60°
1st tightening angle: 60
第二次拧紧转角：60°
2nd tightening angle: 60　
2、设定内径百分表 108mm
Set internal dial gauge.108 mm
27
3.测量缸筒
Gauge cylinders
缸径：108±0.02mm
Cylinder bore：108±0.02mm
磨损极限：108.1mm
Wear limit: 108.1mm
3.1 测量方向沿发动机纵向“a”和横向“b”。
In the engine’s longitudinal axis”a” and
transverse axis “b”
3.2 测量位置在平面 1-3 内

And in planes 1-3.
4.拆下缸套。
Remove cylinder liners
28
4.1 检查缸套定位凸缘并在圆周一圈之内多点
测量“X”值，以确定该缸套可否今后继续使
用。“X”＝9-0.02mm
With cylinder liners fit for further use inspect
liner collar seating and measure at several points
on the circumference. Dimension “X” = 9 -
0.02 mm.
注：如缸套有损伤或尺寸超差，必须更换缸套。
Note: Renew cylinder liner in case of damage or
dimensional deviation.
5.检查曲轴箱缸套定位凸缘座及密封表面。
分别测量每一气缸在圆周内不同点的缸套凸
缘座高度＝8.92+0.03mm
Inspect liner collar seating and sealing surface
for cylinder liners. Measure liner collar seating=
8.92 + 0.03 mm per cylinder at several points on
the circumference.
注：如有损伤或尺寸超差，必须更换曲轴箱。
Note: Renew crankcase in case of damage or
dimensional deviation.
如测量结果与缸套的规定值相一致，需对曲轴
箱进行必要的修理。
If the measured data correspond to the values
specified for the liners, the crankcase may be
repaired as necessary.
6.拆下螺塞，检查油道是否通畅。
Remove screw plugs. Check oil ducts for free
passage.
凸轮轴轴套
Camshaft bearing bushes
7.设定内径百分表
Set internal dial gauge: 65mm
29
8.图中表示出轴套测量平面“a”、“b”
及其中的测量点 1、2。
Schematic for gauging the bearing bushes
at points 1 and 2 in planes “a” and “b”.
9.测量轴套，必要时加以更换。
Gauge bearing bushes, renew ifnecessar
内径：65＋0.054mm
Inner diameter:65＋0.054mm
Wear limit: 65.080mm
10.拆下轴套
Remove bearing bushes.
注意：在拆卸前在轴套上做出标记以对应装配
新的轴套。
Note: Mark bearing bushes prior to removal and
adopt marking to new bearing bushes.
30
11.图中表示出在飞轮端轴套的安装位置。
Schematic: determining installation position of
bearing bush at flywheel end.
12.安装新的轴套
Position new bearing bush.
注意：机油孔必须对准。
Note: Lube oil bores must be lined up.
13.插入轴套
Insert bearing bush.
31
控制齿条导套
14.对于 BF4/6M 发动机从前端取出导套。
With BF4/6M engines drive out guide sleeve at
front end.
15.对于 BF6M 发动机从飞轮端取出导套。

With BF6M engines drive out guide sleeve at
flywheel end.
16.将短安装导杆插入中心孔。
Introduce short assembly arbor in centering
bore.
32
17.在安装导杆上安放轴套，将有导角端指向
曲轴箱。
Position guide sleeve on assembly arbor
with chamfer pointing towards crankcase.
18.将组合导杆紧固在曲轴箱上。
Secure centering bore with assembly arbor on
crankcase.
19.尽可能深的砸入导套。
Drive in guide sleeve as far as it will go.
20.对于BF6M机型使用长组合导杆在飞轮端
按同16-19的步骤砸入导套。
With BF6M engines drive in guide sleeve
at flywheel end as under items 16-19, using
however long assembly arbor.
33
21.用Φ6.7mm钻头在限压阀上钻孔。
Bore out bore in pressure holding valve with
drillΦ6.7 mm dia.
22.用 M8 丝锥攻丝。
Tap thread M8.
23.拧入拉拔器取出限压阀。
Screw in extractor and drive out pressure
holding valve.
24.在新的限压阀上涂 Deutz DW71 密封胶。

Apply locking compound Deutz DW 71 to new
pressure holding valve.
34
25.使用自制工具装入限压阀。
Drive in pressure holding valve with self-made
tool.
26.按以下要求拧紧螺塞对第 4,13,17 和 21
号螺塞使用新的密封圈在 24 号螺塞上涂
Deutz DW72 密封胶。
Tighten screw plugs as specified. Use new Cu
seals for items 4, 13, 17 and 21.Insert item 24
with locking compound Deutz W 72.
4＝ 35±3.5 N.m
6＝ 95±9.5N.m
7＝ 65±6.5N.m
8＝ 35±3.5N.m
13＝ 35±3.5N.m
17＝ 29N.m
21＝ 9±4N.m
24＝ 10±2N.m
注：6，7，8 号拆除后一般应换用新件。（7）
已被 24 代替。
Note: Always renew items 6,7 and 8 after
removal. Item (7) in brackets has been
superseded by item 24.
气缸套 Cylinder liners
27.应确保凸缘座及密封面保持绝对清洁。
Make sure that collar seating and sealing surface
are absolutely clean.
35
28.安装 O 形密封圈。
Fit O-seals.
注：装配之前在曲轴箱及缸套的“X”区域涂
少许润滑油。
Note: Prior to assembly oil crankcase and
cylinder liner in the area X.
29.尽可能深的压入缸套。
Press in cylinder liner as far as it will go.
36
前盖/机油泵 Front cover/ Lube oil pump
37
前盖/机油泵 Front cover/ Lube oil pump
通用工具：Commercial tool required:
使用气门弹簧拆装压杆拆装泄压阀。
Use valve spring assembly lever for pressure
control valve on
曲轴前油封安装工具：142920
Assembly tool : 142920
泄压阀安装工具： 150110
Assembly tool for pressure control valve 150110
1.砸出曲轴前油封。
Drive out shaft seal.
2.检查前盖，必要时更换。
Inspect front cover, replace if necessary.
注意：转子必须可以自由转动。
Note: Rotors must turn freely.
3.拆下机油泵及泄压阀清洗前盖。
For cleaning front cover remove lube oil
pump and pressure control valve.
38
3.1 泄压阀：将安装工具对准弹簧。安装气门
弹簧压杆。
Pressure control valve: Position assembly tool
on compression spring.
Fit valve spring tensioning device.
3.2 压下限压弹簧，取出限位片。
Press down compession spring and remove
holding plate.
4.在单一部件有可见的磨损或损坏时，更换
整个前盖。
Replace complete front cover in case of visible
wear or damage to individual components.
5.安装机油泵，拧紧至 8-9 N.m

Install lube oil pump and secure with a torque of
8 - 9 Nm.
39
6.安装泄压阀：压下限压弹簧，插入限位片。
Fit pressure control valve: Press down
compression spring and insert holding plate.
注意：仔细观察限位片是否到位。
Note: Watch out that holding plate is properly
seated
7.用曲轴前油封安装工具安装曲轴前油封。
Fit shaft seal with assembly tool.
注：装配前在油封上涂一些干燥润滑剂。
Note: Prior to assembly apply dehydrated
lubricant onto shaft seal.
40
正时齿轮罩盖 Timing chest
41
正时齿轮罩盖 Timing chest
曲轴后油封安装工具：142910
Assembly tool：142910
1.砸出曲轴后油封。
Drive out shaft seal.
2.压出端盖。
Press out cover.
注意：仔细观察定位销套。
Note: Watch out for spacer sleeves.
3.如有则拆除转速传感器。
Remove speed sensor if any.
42
4.检查正时齿轮罩盖必要时加以更换。
Inspect timing chest, replace if necessary.
5.用曲轴后油封安装工具安装曲轴后油封。
Fit shaft seal with assembly tool
注意：装配前在油封上涂一些干燥润滑剂。
Note: Prior to assembly apply dehydrated
onto shaft seal lubricant.
6.如有则安装转速传感器。拧紧力矩
为 9±1 Nm。
Install speed sensor, if any. Tight bolt with a
torque of 9±1 Nm.
43
曲轴 Crankshaft
44
曲轴 Crankshaft
1.将曲轴放在曲轴测量台架上。
Chuck crankshaft up on prism stand.
2.图中表示出主轴颈测量平面“a”、 “b”及其
中测量点“1”、“2”。
Schematic for gauging main bearing journals at
points “1” and “2” in planes “a” and ” b”.
主轴颈直径 Journal diameter：84.98~85.00 mm
每级减小 Each undersize： 0.25mm
最小级Limit for undersize： 84.48~84.50 mm
磨损极限Wear limit：
轴颈椭圆度 Journal ovality：0.01mm
3.测量主轴颈宽度。
Gauge thrust bearing journal width.
轴颈宽度 Journal width：38.00~38.06mm
每级加大 1st oversize stage：0.4mm
最大级 Limit for oversize：38.46mm
4.测量连杆轴颈。
Gauge crankpins.
连杆轴颈直径Crankpin diameter：
67.98~68.00 mm
每级减小 Each undersize： 0.25mm
最小级Limit for undersize： 37.48~67.50 mm
磨损极限 Wear limit：
轴颈椭圆度 Crankpin ovality：0.01mm
45
5.检查曲轴圆跳动。
Check crankshaft for true running.
最大不圆度 Out of roundness max：
BF4M = 0.07 mm
BF6M = 0.10 mm
6.检查曲轴端密封表面圆跳动。
Inspect running surfaces of shaft seals.
46
飞轮齿圈 Starter ring gear
47
飞轮齿圈 Starter ring gear
1.在齿圈上打孔。
Drill ring gear apart.
注：确保不损伤飞轮。
Note: Make sure not to damage flywheel.
2.拆除齿圈。
Remove ring gear.
3.清洗飞轮并检查支承法兰。
Clean flywheel and inspect at supporting flange.
4.加热齿圈最高至 210℃，将齿圈安装入位与
法兰平面贴紧。
Heat ring gear to max. 210℃,Placering gear in
position and bring to stop at flange.
48
连杆 Connecting rod
49
连杆 Connecting rod
小头轴套装配工具：131090
Assembly tool for small end bush：131090
1.设定内径百分表：
Set internal dial gauge: Φ42mm
2.在“a”、 “b”平面内“1”、 “2”点测量连杆

小头轴套。
Gauge small end bush at points “1” and “2” in
planes “a” and “b”.
3.测量。
Gauge.
0.05
压入后小头轴套规定值：42  0.04 mm
Small end bush pressed in Specified value ：
0.05
42 mm
 0.04
磨损极限：Wear limit:
小头轴套间隙：0.08mm
Small end bush clearance 0.08mm
4.必要时更换小头轴套。
Replace small end bush if necessary.
连杆小头内径：45.5+0.02mm
Bore for small end bush: 45.5+0.02mm
0.12
小头套外径：45.5  0.08 mm
0.12
Small end bush Outer diameter: 45.5 mm
 0.08
50
5.压入小头轴套。
Press in small end bush flush.
注意：小头轴套与连杆油道孔必须对准。
Note: Lube oil bores of small end bush and
connecting rod must be in line.
6.压入后研磨小头轴套。42 00..05 04 mm
After pressing in, precision-bore small end bush

on a fine boring mill.42 00..05
04 mm
7.确保盖与连杆配套使用。
Make sure that cap mates with connecting rod.
注意：确保定位销入位。
Note: Make sure that dowel pins are fitted.
8.安装轴承盖，按规定拧紧螺栓。
Mount bearing cap. Tighten bolts in accordance
with specification.
初始拧紧力矩：30 Nm
Initial tightening torque: 30 Nm
1st tightening angle 60°　
2nd tightening angle60°
51
9．设定内径百分表：
Set internal dial gauge: Φ72.5 mm
10.图中表示出连杆大头轴孔的测量平面“a”、
“b”及其中“1”、“2”两测量点。
大头内径：72.5+0.02mm
Schematic for gauging big end bearing bore at
points “1” and”2” in planes “a” and “b”.
Bore for big end bearing: 72.5 + 0.02 mm
11.如果测量读数符合规定的要求，则在安装
连杆轴瓦后可获得必要的预载荷。
If the gauge readings conform to the specified
values, the necessary preload will be obtained
after fitting the bearing shells.
注意：如测量只有一点超差，在装入新轴瓦后
再测量一次。
Note: If the measured values deviate only
slightly, additional measurements are to be
carried out with new bearing shells fitted.
12.拆下轴承盖，安装新的轴瓦。重新安装轴
承盖，并按以下要求拧紧螺母。
Remove bearing cap and fit new bearing shells.
Refit bearing cap. Tighten nuts in accordance
with specification.
初始拧紧力矩：30 Nm
Initial tightening torque: 30 Nm
1st tightening angle 60°
2nd tightening angle 60°
52
13.设定内径百分表，在“a”、“b”平面的
“1”、“2”测量轴瓦内径。
Set internal dial gauge. Gauge bearing shells at
Points “1” and “2” in planes “a” and “b”.
大头轴瓦内径：68.036-68.076 mm
每级减小：0.25mm
Big end bearing shells Inner diameter:
68.036-68.076 mm
Each undersize 0.25 mm
最小级：67.536-67.576mm
Limit for undersize: 67.536-67.576mm
磨损极限：Wear limit:
大头轴瓦径向间隙：0.12mm
Clearance of big end bearing ：0.12 mm
注：如果读数不超过公差范围 0.015mm，
连杆可以继续使用，如果超过磨损极限，
则需要更换连杆。
Note: If the readings do not exceed bearing
tolerances by more than 0.015 mm, the rod can
be used further. If the limit value is exceeded,
replace the connecting rod.
14.在连杆测试仪上检查不带轴承的连杆。
Check connecting rod without bearing shells
on connecting rod tester.
14.1 平行度检查：Parallelism check：
允许值：Permissible
公差： a=0.05mm
长度范围： x=100mm
tolerance a = 0.05 mm
over a distance of x = 100 mm
14.2 垂直度检查。
在 x=100mm 的长度范围内“A”相对于“B”
的允许公差＝0.05mm
Squareness check:
Permissible tolerance „A“ relative to „B“ = 0.05
mm over a distance of x = 100 mm
53
连杆与活塞的装配
Assembling connecting rod with piston
15.安装一端的卡簧入位。
Bring one circlip into correct position and fit.
注意：卡簧的开口必须朝向活塞顶端。
Note: Ring gaps of circlips must face towards
piston crown.
16.装配活塞与连杆。活塞上的飞轮标记必须
与连杆上的标记销处在同一侧。
Install piston together with connecting rod.
Flywheel symbol on the piston and dowel pins
of the connecting rod must be located on the
same side.
17.安装另一端卡簧入位
Bring second circlip into correct position and fit.
54
活塞 Piston
55
活塞 Piston
活塞环卡钳：130 300
Piston ring pliers: 130 300
1.拆除卡簧，取出活塞销。
Remove circlip. Take out piston pin.
2.调整活塞环卡钳至活塞直径，拆除活塞环。
Adjust piston ring pliers to piston diameter.
Remove piston rings.
3.清洗并检查活塞及活塞环槽。
Clean and inspect piston and ring grooves
4.用塞尺测量活塞环开口间隙。
Measure ring gap with feeler gauge.
磨损极限：Wear limits:
1 道环间隙：0.30-0.55mm
2 道环间隙：1.5-2.0mm
3 道环间隙：0.3-0.6mm
1st ring gap：0.30-0.55mm
2nd ring gap：1.5-2.0mm
3rd ring gap：0.3-0.6mm
56
5.用塞尺测量活塞环槽与活塞环的间隙。
Measure ring grooves with feeler gauge.
注意：测量时使用新的活塞环。
Note: Measurement to be made with new piston
rings.
1 道环轴向：梯形环槽
2 道环轴向：0.17mm
3 道环轴向：0.10mm
axial play 1st ring keystone groove
axial play 2nd ring 0.17 mm
axial play 3rd ring 0.10 mm
6.检查活塞销的磨损。
Check piston pin for wear.
活塞销直径：42-0.006mm
Piston pin diameter: 42 - 0.006 mm
7.活塞环的顺序及位置。
Order and position of piston rings:
1.梯形环顶面朝向燃烧室。
keystone ring, top facing combustion chamber
2.锥面压缩环，顶面朝向燃烧室。
tapered compression ring, top facing combustion
chamber
3.刮油环。
Bevelled-edge slotted oil control ring
8.安装活塞环。
Fit piston rings.
注意：刮油环的衬簧开口须相对刮油环开口偏
置 180°
Note: Spring gap of bevelled-edge ring to be
offset by 180 relative to ring gap.
57
缸盖 Cylinder head
58
磁性测量平台
Magnetic measuring stand
气门弹簧拆装杠杆：9017
Valve spring assembly lever :9017
气门研磨工具
Valve reseating tool
固定支架：120 900
Clamping stand : 120 900
固定平台：120 910
Clamping plate:120 910
1.将缸盖安装在卡具上。
Mount cylinder head on fixture.
2.如有，松开预热塞或堵塞。
Unscrew blanking parts or penciltype
glow plugs if any.
59
3.取出锥形锁片、气门弹簧座、气门弹簧及气
门。
Remove cone clamp, valve spring cap,
valve springs and valves.
4.取出气门导杆密封圈。
Remove valve stem seal.
5.清洗缸盖并进行损伤检查。
Clean cylinder head and inspect for damage.
6.测量气门导杆间隙。
进气门：0.10mm
排气门：0.13mm
Gauge valve stem clearance.
Inlet valve：0.10 mm
Exhaust valve：0.13 mm
60
7.检查并测量气门。
Inspect valves and gauge them.
标准气门导杆直径：
Valve stem diameter: standard
进气门:8.98-0.015mm
Inlet valve: 8.98 - 0.015 mm
排气门:8.96-0.015mm
Exhaust valve: 8.96 - 0.015 mm
7.1 气门凸缘厚度。
Valve rim thickness
进气门：2.1mm
排气门：1.8mm
Inlet valve: 2.1 mm
Exhaust valve: 1.8 mm
7.2 气门直径。
Valve disc diameter
进气门：48.0±0.1mm
Inlet valve:48.0±0.1 mm
排气门：48.0±0.1mm
Exhaust valve: 42.0±0.1 mm
8.检查气门座圈。
Inspect valve seat inserts and check wear
tolerances.
气门座圈宽度的磨损极限：
Wear limit of valve, seat width:
进气门 Inlet valve： 2.8mm
排气门 Exhaust valve： 2.2mm
61
9.用量规测量气门中心到缸盖密封表面的间
隙。
Gauge valve clearance between valve disc center
and cylinder head sealing surface.
气门下沉量。
Valve penetration into cylinder head
Wear limit: 1.5mm
10.测量气门弹簧的长度。
Gauge length of valve spring.
不加载标准长度：Unloaded length, standard:
64.7±1.3mm n＝2300r/min
66.2mm n=2600r/min
11.使用气门研磨工具修理气门座宽度和角
度。
Correct valve seat using valve reseating tool.
12.二次加工气门座圈。
Reworking valve seat insert
气门座角度进气门排气门
30° 45°
气门座圈最大宽度：
2.8mm 2.2mm
Valve seat angle Inlet Exhaust
30°　 45°　
Valve seat width max.: 2.8mm 2.2mm
注意：对气门座圈进行二次加工之后，再次
测量气门下沉量。
Note: Measure valve penetration into cylinder
head once again after reworking of valve seat
insert.
62
13.插入气门导杆密封圈。
Insert valve stem seal
14.装配气缸盖：
Assemble cylinder head:
气门弹簧及气门弹簧座。
Position valve spring and valve spring cap.
注意：在进气门及排气门导杆上涂一些润滑
油，特别是在有环槽的区域内，慢慢转动气门
导杆，轻轻的将气门压入气门导管内。
Note: Oil valve stem of inlet and exhaust valves,
especiallyin the area of keyseats. Press valves
into valve stem guide with a slight turn and
applying a slight pressure.
15.安装气门弹簧安装杠杆，装入锥型锁片。
Fit valve spring assembly lever, insert cone
clamp.
16.安装堵塞并拧紧至 10±5 Nm
Fit blanking parts and tighten with a torque of
10 ± 5 Nm.
63
凸轮轴 Camshaft
64
凸轮轴 Camshaft
1.检查凸轮及轴磨损情况。
Inspect cams and bearing journals for wear.
2.检查凸轮轴齿轮磨损情况。
Inspect camshaft gear for wear.
65
摇臂支座 Rocker arm bracket
66
摇臂支座 Rocker arm bracket
1.拆解摇臂支座。
Dismantle rocker arm bracket.
2.逐项检查磨损，在必要时加以更换。
Check for wear and replace if necessary:
－轴颈 Journals
－调整螺钉 Adjusting screw,
－摇臂接触面 Rocker arm contact face
－摇臂轴孔 Bore
3.检查油孔是否通畅。
Check oil duct for free passage.
4.重新组装摇臂支座，安装锁环。
Reassemble rocker arm bracket. Fit circlips.
67
输油泵 Fuel pump
68
输油泵 Fuel pump
1.拆下压板，检查输油泵及压板，在必要时
加以更换。
Remove clamping plate. Inspect fuel pump
/clamping plate and replace if necessary.
2.安装压板，拧紧螺栓至 22±2Nm。
Fit clamping plate and tighten bolts with a
torque of 22±2 Nm.
69
喷油器 Injector
70
喷油器 Injector
通用工具：Commercial tool required:
长套管：15 8012
Long socket, serrated, a/flats 15 8012
喷油器压板：110 110
Assembly tool：110 110
1.松开螺旋护套。
Unscrew cap nut.
2.零件拆解次序：
Sequence of parts disassembly
1.螺旋护套 Cap nut
2.喷油嘴 Injection nozzle
3.弹簧座Adapter
4.止推销 Thrust pin
5.调压弹簧 Compression spring
6.调（压）垫片 Shim
用干净的柴油将所有零件清洗干净并用压缩
空气吹干。
Wash all parts in clean diesel fuel and blow out
with compressed air.
3.喷油嘴针阀及针阀座是一套精密配合偶件，
不能搞乱也不可互换，不要用手指触摸针阀，
当针阀座保持于垂直位置时，针阀应可以以自
重慢慢自行滑进针阀座内。
Nozzle needle and nozzle body are lapped
together and must neither be confused nor
exchanged individually. Do not touch nozzle
needles with your fingers. When nozzle body is
held in upright position, nozzle needle should by
its own weight slide down slowly and smoothly
on its seating.
注意：如果针阀不能平顺地滑落，须再次用柴
油清洗喷油嘴，在必要时加以更换，新的喷油
嘴必须同样用干净柴油清洗。
Note: If nozzle needle does not slide down
smoothly, wash injectionnozzle again in diesel
fuel. Renew, if necessary. New injection nozzle
must likewise be washed in clean diesel fuel.
71
4.检查弹簧座接触表面的磨损情况，确保中心
销装配无误。
Check seating surfaces of adapter for wear.
Make sure that centering pins are fitted.
5.插入调压垫片。
Insert shim.
注意：喷油压力取决于调压垫片。
Note: The injection pressure is dependent
on the shim thickness.
6.插入调压弹簧。
Insert compression spring.
7.插入止推调销，中心销面向调压弹簧。
Insert thrust pin with centering collar facing
towards compression spring.
72
8.插入弹簧座，中心销插入针阀座孔内。
Insert adapter with centering pins into the bores
of the nozzle holder.
注意：凹点对准止推销。
Note: The recess points to the thrust pin.
9.安装喷油嘴，中心孔要与弹簧座的中心销相
配。
Fit injection nozzle with center bores mating
with the centering pins of the adapter.
注意：小心不要使针阀从针阀座中掉出来。
Note: Take care that nozzle needle does not fall
out of nozzle body.
10.拧上螺旋护套。
Screw on cap nut.
11.拧紧螺旋护套至 40-50Nm
Tighten cap nut with a torque of 40 - 50 Nm.
喷油器的测试及调整部分见第 2 章。
For testing and adjusting injector see
chapter 2.
73
控制尺条 Control rod
74
控制尺条 Control rod
1.检查控制尺条并更换有损伤的零件。
Inspect control rod and renew any damaged
parts.
2.在导套上钻孔取出定位销，拆解控制尺条。
Drill guide sleeve apart at dowel pin and remove
注意：在拆解控制尺条时，一般应更换导套及
定位销。
Note: When disassembling the control rod
always renew guide sleeve and dowel pin.
3.装配顺序：
Order of assembly
1.控制尺条
Control rod
2.定位销
Dowel pin
3.导套
Guide sleeve
4.压缩弹簧
Compression spring
4.注意观察控制尺条相于导套的安装方向。
Watch installation direction of control rod
relative to guide sleeve.
75
5.插入定位销，并使开口方向处于相对控制
尺条的横向位置。
Insert dowel pin so that opening points in
transverse Position towards control rod.
6.尽可能深地压入定位销。
Press in dowel pin as far as it will go.
76
节温器 Thermostat
77
节温器 Thermostat

节温器装配工具：170 090
Assembly tool for coolant thermostat:170 090
1.压下节温器，从节温器壳中取出节温器。
Press down thermostat and take out of
thermostat housing.
2.检查每一个零件，在必要时加以更换。
Inspect all single parts and replace if necessary.
3.压下节温器，装入节温器壳。
Press down thermostat and turn into thermostat
housing.
注意：卡箍必须嵌入节温器壳内。
Note: Clamping yoke must engage in thermostat
housing.
78
冷却水泵 Coolant pump
79
冷却水泵 Coolant pump
1.拆下 V－皮带轮。
Remove V-belt pulley.
2.检查每一个零件，必要时加以更换。
Inspect all single parts and replace
if necessary.
3.安装 V－皮带轮，拧紧螺栓至 21Nm。

Fit V-belt pulley. Tighten bolts with
a torque of 21 Nm.
80
81
液压泵驱动装置 Hydraulic pump drive
1.拆下定位垫圈。
Remove stop washer
2.检查每一个零件，必要时加以更换或修复。
Inspect all single parts and replace/repair if
necessary.
3.在“a”、 “b”平面内的“1”、 “2”两点测量

轴承套。
Gauge bearing bushes at points “1” and “2” in
planes “a” and “b”.
内径：60+0.054mm
Inner diameter: 60 + 0.054 mm
磨损极限：60+0.080mm
Wear limit: 60 + 0.080 mm
82
4.必要时更换轴套。
Renew bushes if necessary
5.图中表示出了轴套的安装尺寸及安装方向。
Schematic: Installation dimensions and
installation position of bearing bushes.
6.按照第 5 项的例图所示压入轴套。
Press in bearing bushes according to schematic,
item 5.
7.在齿轮轴及轴套上轻涂一些润滑油，并装
配。
Lightly oil gear shaft and bushes with motor oil
and install.
83
8.按照限位垫圈入位。
Position stop washer in place
9.拧紧螺栓至 8.5±1mm。
Tighten bolts with a torque of 8.5 ±1 Nm.
10.安装新的 O 型密封圈。
Fit new O-seal
84
液压泵与联结法兰
1.拆下齿轮。
Remove gear.
2.拔出齿轮。
Pull off gear
3.逐一检查每一个零件，必要时加以更换。
Inspect all single parts and replace if necessary.
4.安装新的密封圈。
Fit new O-seal
85
5.在液压泵上安装新的衬垫及联结法兰。
Place new gasket together with fastening flange
on hydraulic pump.
6.安装齿轮。
Mount gear.
注意：确保销键已安装入位。
Note: Make sure that key is inserted.
7.拧紧螺母至 80N.m。
Tighten nut with a torque of 80 Nm.
86
整机的拆装 Disassembly and reassembly of complete engine
4、整机的拆装 Disassembly and reassembly of complete engine 页码 Page
整机拆解 Dismantling engine-----------------------------------------------------------------------89~103
整机装配：Reassembling engine:
机油喷嘴 Oil spray nozzles------------------------------------------------------------------------------104
挺柱与凸轮轴 Tappets/camshaft------------------------------------------------------------------------105
曲轴轴承 Crankshaft bearings---------------------------------------------------------------------------105
驱动齿轮/调速器 Drive gear/governor-----------------------------------------------------------------109
控制尺条 Control rod -------------------------------------------------------------------------------------109
正时齿轮罩盖 Timing chest cover-----------------------------------------------------------------------110
前盖 Front cover--------------------------------------------------------------------------------------------110
活塞与连杆 Piston with connecting rod-----------------------------------------------------------------112
安装喷油泵 Installing injection pump-------------------------------------------------------------------114
飞轮/V 型皮带轮 Flywheel/V-belt pulley---------------------------------------------------------------123
缸盖 Cylinder head------------------------------------------------------------------------------------------124
喷油器/高压油管 Injector/injection lines----------------------------------------------------------------128
进排气岐管 Air intake/exhaust manifold----------------------------------------------------------------129
气门室罩 Cylinder head cover-----------------------------------------------------------------------------130
机油冷却器 Lube oil cooler--------------------------------------------------------------------------------131
冷却液泵 Coolant pump-------------------------------------------------------------------------------------132
输油泵 Fuel pump--------------------------------------------------------------------------------------------134
集油管/油底壳 Oil suction pipe/oil pan-------------------------------------------------------------------134
调速器 Governor---------------------------------------------------------------------------------------------137
飞轮壳 Adapter housing-------------------------------------------------------------------------------------140
起动机 Starter-------------------------------------------------------------------------------------------------141
机油进油管 Breather pipe----------------------------------------------------------------------------------142
曲轴箱呼吸器 Crankcase breather-------------------------------------------------------------------------142
废气涡轮增压器 Exhaust turbocharger-------------------------------------------------------------------143
机油回油管/机油输油管 Oil return pipe/pressure oil pipe--------------------------------------------144
进气弯头 Intake elbow--------------------------------------------------------------------------------------146
进气弯管 Charge air elbow---------------------------------------------------------------------------------147
机油尺 Oil dipstick-------------------------------------------------------------------------------------------148
发动机 Alternator--------------------------------------------------------------------------------------------149
张紧 V 型皮带 Tensioning V-belt--------------------------------------------------------------------------149
发动机支架/软垫 Engine mounting/mounting feet-----------------------------------------------------151
整机更换曲轴油封 Replacing shaft seals on complete engine
正时齿轮罩盖飞轮端 Timing chest cover flywheel end-----------------------------------------------156
前端盖 Front cover-------------------------------------------------------------------------------------------157
空气压缩机的拆装 Removing and refitting air compressor-------------------------------------------159
动力转向泵的拆装 Removing and refitting power steering pump -----------------------------------161
维修时喷油泵的更换 Replacing injection pumps in case of service---------------------------------162
- 87 -
整机拆解 Dismantling engine
E 型扳头：8189，E14，E18，E20
Torx socket wrench E：8189，E14，E18，E20
弹簧卡钳：798-10
Spring clamp pliers：798-10
弹簧卡钳：2465
Spring clamp pliers：2465
预热塞导线接头辅助工具：114010
Plug cable coupler：114010
发动机装配台架：
Engine assembly stand：6066
联接支架：6066/158
Angled clamping plate: 6066/158
滤清器拆卸工具：170050
filter cartridges 170 050
本章中所论及的维修程序针对的是标准技
术参数，也就是说按特别要求定制的发动机
组件不包括在内。
The repair procedure outlined in this chapter
refers to the standard specification, i.e.
components for customizing the engine are not
shown.
1.将发动机固定在发动机装配台架上，校正
并拧紧螺栓。
Clamp engine in double-sided swivelling
assembly stand and align. Tighten bolts.
放掉并收集机油及冷却液，并根据环保
原则妥善处置。
Drain and catch remaining oil and coolant
and dispose of in accordance with
anti-pollution regulations.
- 88 -
2.将发动机固定在双面旋转的装配台架上，
校正并拧紧螺栓。
Chuck engine in double sided swivel-type
assembly stand 6066 and align Tighten bolts.
放掉并收集机油及冷却液，并根据环保原则
妥善处理。
Drain and collect residual oil and coolant and
dispose of properly in accordance with
拆除泄压阀，发动机旋转 180°。收集所有
的机油及冷却液，并根据环保原则妥善处
置。
In case of parts assembly and turning of engine
by 180 the pressure control valve is to be
removed. Catch any remaining oil and coolant
and dispose of in accordance with
3.拆下发电机。
Remove alternator.
4.松开燃油泵，拆下 V 型皮带。
Loosen fuel pump. Remove V-belt.
- 89 -
5.拆下支架。
Remove bracket.
6.拆下冷却液管。
Remove coolant pipe
7.用专用的弹簧卡钳拆下呼吸器联接管。
Remove breather pipe using special spring
clamp pliers.
8.拆下进气软管。
Remove intake hose
注意：盖住废气增压的开口。
Note: Cover up opening of exhaust
turbo charger.
- 90 -
9.拆下机油输油管、机油回油、进气弯头及
废气涡轮增压器。更换有损伤的增压器。
Remove oil pressure pipe, oil return pipe,
charge air elbow and exhaust turbocharger.
Replace damaged turbocharger.
10.拔出各种堵塞。
Pull out plug-in element
11.将泄压阀及软管一起拆下。
Remove pressure control valve together
with hose.
12.拆下到进气压力补偿器的进气管。
Remove air pipe to manifold presssure
compensator and breather pipe.
- 91 -
13.拆下起动机。
Remove starter.
14.拆下吊耳。
Remove lifting lugs.
15.拆下调速器。
Remove governor.
16.用专用工具拆下燃油及机油滤清器。
Remove fuel and oil filter using special
device
for filter cartridges.
收集所有残余的机油燃油及燃油，
并根据环保原则妥善处置。
Dispose of remaining oil and fuel
in accordance with anti-pollution
regulations.
- 92 -
17.如有则拆下机油加注管。
Remove oil filler neck if any.
18.拆下输油管。
Remove fuel lines.
19.拆下输油泵及固定支架。
Remove fuel pump with clamping plate.
20.拆下机油冷却器，如有则同时拆下导线接
头固定卡子。
Remove lube oil cooler. Remove also retainer
for cable connector if any.
- 93 -
21.拆下冷却液泵及节温器壳。
Remove coolant pump together with
thermostat housing.
22.如有则拆开预热塞导线接头。进行此操作
时，用辅助工具小心地插入橡胶环内，不要
有任何转动，拔出导线。
Disconnect glow plug cable coupler if any. For
such purpose Introduce auxiliary tool carefully
into rubber grommet without turning it in any
way and disconnect cable.
23.拆下气门室罩，如有则同时拆下各种线
束。
Remove cylinder head cover. Remove cabling
as well if any
24.拆下回油管及溢流阀。
Remove back leakage pipe together with
overflow valve.
- 94 -
25.拆下停车电磁阀。
Remove shutdown solenoid.
26.拆下全部高压油管及橡胶密封圈。
Remove injection lines complete with
sealing rubber.
注意：盖住开口。
.Note: Cover up openings.
27.拆下喷油器。
Remove injectors.
注意：如发生粘连，使用拆解工具 NO.150
800 以
及拔取装置 NO.110 030。
Note: If sticking, use disassembly tool
No. 150 800 with extractor
No. 110 030.
28.如有则拆下预热塞。
Remove glow plugs if any.
- 95 -
29.拆下摇臂支架。
Remove rocker arm brackets.
30.取出推杆。
Take out pushrods.
31.拆下进气岐管。
Remove charge air pipe.
32.拆下排气岐管。
Remove exhaust manifold.
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33.拆下气缸盖，取下缸垫。
Remove cylinder head. Take off gasket.
注意：使用 E14/18 高强板头。
Note: Use E14/E18 Torx tool.
34.拆下喷油泵。
Remove injection pumps.
注意：特别注意调整垫片。
Note: Watch out for shims.
35.取出滚轮挺柱及调整垫片。
Take out roller tappets together with shims.
36.拔出机油尺。
Pull out oil dipstick.
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37.拆下盖板，将旋转 180°。
Remove cover plate.Turn engine by 180.
注意：收集所有漏出的机油并按照环保原则
妥善处置。
Note: Catch any escaping oil and dispose of in
accordance with anti-pollution regulations.
38.将发动机旋转 90°，拆下离合器壳。
Turn engine by 90°, Remove adapter
housing.
注意：使用 E20 及 E14 高强扳头。
Note: Use Torx tools E20 and E14.
39.将发动机旋转 90°，拆下油底壳。
Turn engine by 90°. Remove oil pan.
注意：标记油底壳的按照位置。
Note: Mark installation position of oil sump.
40.拆下集油管。
Remove oil suction pipe.
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41.拆下活塞及连杆。
Remove piston complete with connecting rod.
42.拆下 V 型皮带轮。
Remove V-belt pulley.
注意：使用 E20 高强板头。
Note: Use Torx tool E20.
43.拆下前盖。
Remove front cover
44.拆下飞轮。
Remove flywheel
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45.拆下正时齿轮罩盖。
Remove timing chest cover.
46.拆下主轴承盖。
Remove main bearing caps.
47.取出曲轴。
Lift out crankshaft.
48.取出止推环及轴瓦。
Take out thrust rings and bearing shell halves.
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49.拆下调速器的驱动齿轮。
Remove drive gear for governor.
50.取出凸轮轴。
Take out camshaft.
51.拆下导套，取出控制尺条。
Remove guide sleeve. Take out control rod.
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54.取出挺柱。
Take out tappets.
55.取出机油喷嘴，检查油道是否通畅。
Press out oil spray nozzles. Check oil ducts for
free passage.
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发动机的装配：Reassembling engine:
高强套管组件：8189
Torx tool set ：8189
加长高强套管：E14：8113、E18：8116、E20：8114
Torx socket wrench：E14：8113、E18：8116、E20：8114
扭力扳头：8117
Serrated wrench for turning I.P. :8117
软管卡钳：9090、9080
Hose clamp pliers: 9090、9080
V 型皮带张紧量规：8115
V-belt tension gauge: 8115
卡钳：8011
Cobra clamp pliers: 8011
百分表 M2T：100 400
Dial gauge M2T: 100 400
活塞顶隙测量专用工具：100 750
Measuring device: 100 750
标准筒：100 840
Measuring device: 100 840
控制尺条测量限位板：100 800
Measuring device/locking device for control rod: 100 800
分度盘：101 020
Graduated disc: 101 020
分度盘适配器：101 030
Adapter for graduated disc: 101 030
分度盘指针：101 300
Pointer: 101 300
活塞环引套：130 640
Piston ring compressor: 130 640
机油喷嘴 Oil spray nozzles

1.尽可能深地压入机油喷嘴。
Press in oil sprays nozzles as far as they will
go.
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挺柱及凸轮轴 Tappets/camshaft
2.插入挺柱。
Insert tappet
3.插入凸轮轴。
Introduce camshaft.
曲轴轴承 Crankshaft bearings
4.设定内径百分表：38mm
Set internal gauge: 38mm
5.测量曲轴止推轴颈宽度并记录尺寸“a”。
Gauge width of crankshaft thrust bearing
journal and record. Dimension “a”
标准轴颈宽度：38+0.06mm
Standard journal width: 38+0.06mm
加大极限：38.4+0.06mm
Limit for oversize: 38.4+0.06mm
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6.放入主轴承瓦。
Insert bearing shells.
7.在主轴承盖上放入主轴承瓦。
Insert bearing shells in main bearing caps.
8.将半边止推环片放在止推轴承盖上，测量
并记录宽度尺寸“b”。
Place half thrust rings on thrust bearing cap,
gauge and record width. Dimension “b”
9.确定端部游隙。
Determine end float.
端部游隙的允许值：0.10－0.30mm
Permissible end float for: 0.10－0.30mm
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10.在装配之前在曲轴上作出标记。
Mark crankshaft prior to installation.
11.在凸轮轴上作出标记并按照入位。
Mark camshaft and place in position.
12.对准标记，按照曲轴。
Introduce crankshaft. Marks must be in line.
13.插入没有凸起的半片止推环片。
Insert half thrust rings without lug.
注意：有涂层的工作面必须面向曲拐
Note: Running layer of thrust rings must face
towards crankweb.
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14.用一些润滑脂将半片带有凸起的止推环
粘在止推轴承盖上。
Stick half thrust rings with lug to thrust
bearing cap using some grease.
注意：止推环有涂层的工作面必须面向曲
拐。
Note: Running layer of thrust rings must face
towards crankweb.
15.安装止推轴承盖。
Mount thrust bearing cap.
注意：1 号主轴承盖在飞轮一端。
Note: Bearing cap No. 1 at flywheel end.
16.安装主轴承盖，注意编号。
Mount main bearing caps, paying attention to
the numbering.
17.按以下规定拧紧主轴承螺栓：
Tighten main bearing bolts according to
specification.
初始锁紧力矩：50N.m
Initial tightening torque：50N.m
第一次锁紧转角：60°
1st tightening angle ： 60　
第二次锁紧转角：60°
2nd tightening angle： 60　
注意：正常情况下，主轴承螺栓最多可以使
用 3 次。
Note: Bolts may be used 3x if evidence can be
provided concerning their use.
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驱动齿轮/调速器
Drive gear/governor
18.插入调速器驱动齿轮及轴承轴颈。
Insert governor drive gear complete with
bearing journal
19.插入螺栓并拧紧至 21N.m。
Insert bolt and tighten with a torque of 21 Nm.
控制尺条
Control rod
20.安装控制齿条及导套。
Fit control rod complete with guide sleeve.
21.在螺栓涂 Deutz DW71 密封胶，拧紧至

10+2N.m。
Apply Deutz DW 71 locking compound to bolt
and tighten with a torque of 10 + 2 Nm.
- 108 -
正时齿轮罩盖 Timing chest cover
22.在正时齿轮盖密封面上涂 Deutz DW67 密

封胶。
Apply Deutz DW 67 sealing compound to
sealing surface of timing chest cover.
23.安装正时齿轮罩盖，拧上螺栓，校正正时
齿轮盖与油底壳密封表面的相对位置。
Mount timing chest cover. Start bolts and align
timing chest cover relative to oil pan sealing
surface.
24.拧紧螺栓至 21±2N.m。
Tighten bolts with a torque of 21±2 Nm.
前盖
Front cover
25.在前盖转子上涂少量润滑油。
Lightly oil rotors in front cover
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26.用些润滑脂将衬垫粘在前盖上。
Stick gasket to front cover using some grease.
转动发动机 180°，油底壳密封面必须向下。
Turn engine by 180°,Oil pan sealing surface
must point downward.
27.转子一面面向曲轴。
Position rotor relative crankshaft.
28.安装前端，向上轻推前盖，使之与油底壳
密封面对齐，拧上螺栓。
Mount front cover, press cover upward and
align relative to oil pan sealing surface. Start
bolts.
29.拧紧前盖螺栓至 21±2N.m。
Tighten bolts for front cover with a torque of
21±2 Nm.
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活塞与连杆
Piston complete with connecting rod
30.在连杆大头中放入轴瓦。
Insert bearing shells in connecting rod.
31.活塞环开口必须相隔 90°—120°。
Piston ring gaps must be staggered
by 90-120°.　
32.将活塞及连杆插入缸体内。
Introduce piston complete with connecting rod
into crankcase with integrated cylinder liners.
注意：飞轮标记必须指向飞轮。
Note: Flywheel symbol must point towards
flywheel.
33.将连杆大头压在曲轴连杆轴颈上，安装大
头盖。
Press connecting rod against crankpin. Fit
pertinent big end bearing cap.
- 111 -
34.按以下规定拧紧新的连杆螺栓。
Tighten new conrod bolts in accordance with
specification.
初始拧紧力矩：30N.m
Initial tightening torque: 30N.m
第一次转角：60°
1st tightening angle :60　
第二次转角：60°
2nd tightening angle: 60　
35.检查连杆是否可以连杆轴颈上来回平顺
地转动。
Check that connecting rods can be easily
movedback and forth on the crankpin.
注：转动发动机曲轴 180°
Note: Turn engine by 180　
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安装喷油泵 Installing injection pumps
在安装喷油泵之前，测量控制尺条的行程。
Gauging control rod travel without
injection pumps installed
36.安装控制尺条限位板。
Fit control rod locking device.
37.测量限位板到控制尺条停车位置的距离。
Gauge from locking device to stop position of
control rod.
38-1.测量限位板到控制尺条起动位置的距
离。控制尺条起动位置与停车位置的位移差
值即是控制尺条的行程。
Gauge from locking device to start position of
control rod. Difference between start and stop
positions equals control rod travel.
举例：Example:
停车位置 stop position＝30.7mm
起动位置 start position＝13.4mm
控制尺条行程 control rod travel＝17.3mm
规定的行程
Specified dimension＝17.0-17.5mm
39.转动限位板，用手拧动滚花头定位螺钉
把控制尺条压到停车位置。
Turn locking device. Press control rod in stop
position by hand with knurled-head setscrew.
- 113 -
40.在飞轮法兰上安装分度盘。
Fit graduated disc to flywheel flange.
41.安装并拧紧分度头指针。
Fit pointer.
确定与喷油泵正时相对应的活塞上止点
Determining TDC of piston pertaining to
injection pump to be timed.
42.安装上止点测量棒与垫板，按发动机旋转
方向转动曲轴直到百分表指针达到其回转
点，设置百分表为“0”。
Position TDC measuring bar together with
spacing washers. Turn crankshaft in direction
of engine rotation until pointer of dial gauge
has reached its reversal point. Set dial gauge to
“0”.
43.按照发动机旋转方向转动曲轴约约 90°，
然后反向转动曲轴，直到在上止点（百分表
回转点）前 8mm，设置分度盘为“0”。
Turn crankshaft by about 90　in direction of
engine rotation. Thereafter turn again in
opposite direction of engine rotation until 8
mm before TDC (reversal point of dial gauge).
Set graduated disc to “0”.
- 114 -
44.按发动机旋转方向转动曲轴约 90°，
之后反方向转动曲轴，直到上止点（百分表
指针回转点）前 8mm，记录读数。
例如：50°
Turn crankshaft by about 90　in direction of
engine rotation. Thereafter turn again in
opposite direction of engine rotation until 8
mm before TDC (reversal point of dial gauge).
Read off determined value.
Example: 50°
45.这个值的平分值就等于上止点的角度。
Halve the value determined. The halved value
equals TDC.
如：（0°＋50°）/2=25°实际值
Example: = 25　
转动曲轴，直到达到这一数值。
Turn crankshaft until halved value is reached.
46.停止转动曲轴，松开两个限位螺栓，
设置分度盘为“0”。
Stop turning crankshaft. Loosen 2 nurled-head
screws and set graduated disc to “0”.
47.插入滚轮挺柱。
Insert roller tappet.
- 115 -
确定博世波许喷油泵的喷油提前角
Determining commencement of delivery
with Bosch injection pump
喷油提前角及从 1996 年 7 月以后的凸轮轴
类型都打印在铭牌上。
The commencement of delivery and since
about 07.96 also the type of camshaft are
stamped on the rating plate.
48.在预载荷为 0 时，设定测量装置的百分
表。
et dial gauge of measuring device under
preload to 0. Set value: 150mm
49.在凸轮轴的基圆上安装将被正时的喷油
泵滚轮挺柱，为此按发动机旋转反方向转动
曲轴约 180°。
Position roller tappet of the injection pump to
be timed on base circle. For that purpose turn
crankshaft by about 180　opposite to direction
of engine rotation.
50.小心地插入测量装置。
Insert measuring device carefully.
51.测量“L”值，并填进第 1 章中的表 1。
easure dimension „L“, and enter
in table 1, chapter 1.
例如：152.22mm
Example:152.22mm
- 116 -
52.设定百分表外圈指针为“0”。
Set pointer of dial gauge to 0 with outer ring.
注意：当达到预行程位置时，旋转方向不
得有任何的改动。
Note: The direction of rotation must not be
changed anymore when the pre-stroke position
has been reached.
53.按发动机旋转方向转动曲轴直到百分
表指针达到预行程刻度，见表 1。
Turn crankshaft in direction of engine rotation
until dial gauge indicates pre-stroke dimension,
see table 1.
例如：Example：
喷油提前角 Commencement of delivery 5°
凸轮轴类型 Camshaft type
预行程 Pre-stroke：6.02mm
54.读取实际喷油提前角并填进第 1 章表格
中。
例如：10°
Read off ACTUAL commencement of delivery
and enter in table, chapter 1.
Example:10　
55.读取“A”值＝喷油泵长度代号，填进第
1 章表格中。
Read off dimension “A” = code for injection
pump length and enter in table, chapter 1.
例如：133
Example: 133
- 117 -
56.拆掉测量装置。
Remove measuring device.
确定调整Determine shims.
见第1章See chapter 1.
57.安装选好的垫片和滚轮挺柱。
Position selected shim on roller tappet.
注意：第 48-57 项中的测量步骤是针对一个
喷油泵进行的。
Note: The measuring procedures under items
48-57 is to be carried out for each injection
pump.
喷油泵
Injection pump
58.转动喷油泵的连接杠杆到停车位置。
并设定指示的角度。
Turn injection pump linkage lever to approx.
middle position.
59.在凸轮轴基圆位置装入各缸相关的滚轮
挺柱，在曲轴箱接触孔壁及喷油泵的 O 型密
封圈上稍稍涂些机油。
小心地将喷油泵连接杠杆插入控制尺条当
中，不要让喷油泵有任何转动。装配从 6 缸
或 4 缸开始直到 1 缸。
Position roller tappet of relevant cylinder on
base circle. Lightly oil receiving bore in
crankcase and “O”seals of injection pump.
Carefully introduce. Injection pump linkage
lever into control rod.
- 118 -
60.安装喷油泵压盘。
Position flange.
注意：倒角一面必须面向喷油泵体。
Note: Chamfer must face injection pump body.
61.在螺栓上涂上一些润滑油，均匀拧紧至
5N.m。
Lightly oil bolts and tighten uniformly with a
torque of 5 Nm.
62.之后松开螺栓至 60°。
Loosen bolts again by 60　.
63.用测扭力扳手及喷油泵旋转扳手逆时针
方向转动喷油泵直到转不动为止，同时确定
摩擦力矩（Rm）。
Turn injection pump with wrench carefully
counter-clockwise until tangible stop.
- 119 -
64. 按确定的摩擦力矩 Rm ＝
3.5N.m+1N.m=4.5N.m 反时针方向转动喷油
泵，并保持在此位置。拧紧螺栓到 60°并交
替拧紧至 7 N.m，10 N.m，30 N.m。
Tighten bolts by 60°and then alternately with
a torque of 7 Nm, 10 Nm and 30 Nm.
注意：先从远离飞轮一端的螺栓开始（见箭
头）
Note: Start with the outer bolt, remote of the
flywheel (see arrow).
喷油泵安装后测量控制尺条行程
Gauging control rod travel with injection
pumps installed
65.从限位板松开限位螺钉，转动限位板。
Undo setscrew from locking device. Turn
locking device.
66.测量从限位板到控制齿条停车位置的距
离。
Gauge from locking device to stop position of
control rod.
66.1 测量从限位板到控制齿条起动位置的距
离。其差就是控制齿条的行程。
Gauge from locking device to start position of
control rod.Difference between stop and start
positions equals control rod travel.
例如：Example:
停车位置 stop position＝30.5mm
起动位置 start position＝13.4mm
控制齿条行程 control rod travel＝17.1mm
控制齿条最小行程
Min. control rod travel：16.8mm
- 120 -
67.拆掉限位板，分度头及分度盘。
Remove locking device, pointer and graduated
disc.
68.检查控制齿杆的灵活性。
Checking ease of movement of control rod
为调速器调整测量控制齿条行程
Gauging control rod travel for governor
adjustment
69.测量从正时齿轮罩盖表面到控制齿条停
车位置的距离。当更换或者维修调速器时
，必须确定这一尺寸。
Gauge control rod travel from surface of
timing chest cover to stop position. It is
mandatory to indicate the dimension
determined when replacing or repairing the
governor.
- 121 -
飞轮/V 型皮带轮
Flywheel/V-belt pulley
70.用自制心轴安装飞轮，用手指拧入螺栓。
Position flywheel, using a selfmade guide
mandrel. Secure bolts fingertight.
71.固定飞轮位置，按以下要求拧紧飞轮。
Retain etain flywheel. Tighten bolts according
to specification.
初始拧紧力矩：Initial tightening torque
30-45mm 长螺栓：20-30 Nm
Bolts 30 - 45 mm long 20-30 Nm
50-85mm 长螺栓：30-40 Nm
Bolts 50 - 85 mm long 30-40 Nm
第1次拧紧转角：1st tightening angle
30-85mm 长螺栓：60°
bolts 30 - 85 mm long : 60°　
第2次拧紧转角：2nd tightening angle
30mm 长螺栓：30°
bolts 30 mm long:30　
35-85mm 长螺栓：60°
bolts 35-85 mm long : 60　
72.安装 V 型皮带轮，保持飞轮位置，按以
下规定拧紧螺栓：
Fit V-belt pulley and retain against flywheel.
Tighten bolts according to specifications:
初始拧紧力矩：40-50 N.m
Initial tightening torque 40-50 Nm
第1次拧紧转角：1st tightening angle:
60mm、80mm 长螺栓：60°
bolts 60 mm、80 mm long:60°　
第2次拧紧转角：2nd tightening angle:
bolts 60 mm long: 30°　
bolts 80 mm long: 60°　
注意：使用离强扳头 E20。正常情况下，螺
栓最多可以使用 5 次。
Note: Use Torx socket wrench E20. Bolts may
be used max. 5x if evidence can be furnished
concerning their use.
- 122 -
73.确定气缸垫厚度。
Determine cylinder head gasket.
74.在装好缸套的曲轴箱密封表面安放
测量棒及垫块，设定百分表“0”点。
Place spacers on sealing surface of crankcase
with integrated liners and set dial gauge to”0”.
75.把百分表放在活塞测量点上，确定活塞
最大的凸出量。
Position dial gauge on piston at gauge points
and
determine max.piston projection.
注意：所有的活塞都要测量。
Note: All pistons must be gauged.
76.活塞上的测量点：
Watch gauge points：95mm
- 123 -
77.根据最大值，按表中所列数据确定适当的
缸垫。
Compare max. value with table and determine
appropriate cylinder head gasket.
0.28－＜0.54mm 1孔
0.54－＜0.64mm 2孔
0.64－＜0.75mm 2孔
Piston Marking of
Projection cylinder head gasket
0.28 - < 0.54 mm 1 hole
0.54 - < 0.64 mm 2 holes
0.64 - 0.75 mm 3 holes
78.安装气缸垫。
Position cylinder head gasket.
注意：气缸垫的密封表面必须清洁，无油。
注意定位销套。
Note: Sealing surfaces for cylinder head
gasket must be clean and free of oil. Watch out
for dowel sleeves.
气缸盖配气机构
Cylinder head with valve gear
79.安装气缸盖，在缸盖螺栓上涂油并拧入。
Position cylinder head. Lightly oil and start
cylinder head bolts.
注意：如果一切情况表明使用情况正常，缸
盖螺栓最多可以使用 5 次。
Note: Cylinder head bolts may beusedmax. 5x
if Evidence can be furnished concerning their
use.
- 124 -
80.按以下规定拧紧缸盖螺栓。
Tighten cylinder head bolts according to
specification.
初始拧紧力矩：Initial tightening torque:
第 1 步 1st stage：50 N.m
第 2 步 2nd stage：120 N.m
拧紧转角 Tightening angle：120°
注：缸盖螺栓的拧紧顺序，见技术参数。
Note: Observe tightening order for cylinder
head bolts. See Specification Data.
81.插入推杆。
Insert pusrods.
82.安装摇臂轴座，并校准与推杆及
气门的相对位置。
Fit rocker arm bracket and align towards
pushrods/valves.
83.拧紧螺栓至 21 N.m。
Tighten bolt with a torque of 21 Nm.
注：调整气门间隙，见第 2 章。
Note: Adjust valve clearance, see chapter 2.
- 125 -
84.安装笔状预热塞或堵塞。
Fit pencil-type glow plugs or blanking parts.
85.拧紧预热塞或堵塞至 20±2 N.m。

Tighten pencil-type glow plugs or blanking
parts with a torque of 20 ±2 Nm.
86.将控制齿条压至停车位置，并保持在此位
置，安装停车电磁阀，安装时使用新的 O 型
密封圈。
Press control rod into stop position and hold in
Place Fit shutdown solenoid with new O-seal.
注意：在 O 型圈上涂少许润滑油。
Note: Lightly oil O-seal.
87.拧紧螺栓至 21 N.m。
Tighten bolts with a torque of 21 Nm.
- 126 -
喷油泵/高压油管
Injector/injection lines
88.用一些润滑脂将新的密封圈装在喷油器
上，插入喷油器。
Slide new seal over injector using some grease
and insert injector.
注意：回油管必须向排气岐管一侧。
Note: leakage fuel line connection must face
the exhaust side.
89.安装压板，拧入螺栓。
Position clamping pads. Start bolt.
90.安装新的高压油管及密封胶圈，用手
拧紧锁定螺母。
Fit new injection line with sealing rubber.
Screw on cap nuts fingertight.
注：当安装高压油管时，密封锥面必须
紧密配合。
喷油管只能使用一次，不允许再弯曲。
Note: When fitting the injection lines, the
sealing cones must match pecisely.
Rebending is not permissible.The injection
lines must not be used twice.
91.拧紧压板螺栓至 16±5 Nm。

Tighten bolt of clamping pads with a torque
of 16 + 5 Nm.
- 127 -
92.预紧高压油管与喷油泵及喷油器的锁定
螺母至约 5 N.m，然后拧紧至 30+3.5 Nm。
Preload cap nuts of injection line on injection
pump and injector with a torque of approx. 5
Nm. Thereafter tighten cap nuts with a torque
of 25 + 3.5 Nm.
93.通过密封橡胶插入并安装回油管。
Fit leakage fuel line and introduce through
Sealing rubber.
注意：回油管一般必须更换。
Note: Leaage fuel lines must always be
replaced.
94.安装油管时，全部用新的铜垫。
95.安装溢流阀，安装时使用新的铜垫。
Fit overflow valve with new Cuseals and
leakage fuel line
进排气岐管 Air intake/exhaust manifold

96.安装进气岐管，使用新的密封垫。
Mount air intake manifold with new gaskets.
- 128 -
97.拧紧进气岐管螺栓至 11±1 Nm。
Tighten bolts for charge air pipe with a torque
of 11±1 Nm.
98.安装排气岐管，使用新的密封垫。密封垫
有皱纹一面必须向着气缸盖。
Mount exhaust manifold with new gaskets.
The gasket bead must point towards the
cylinder head.
注意：涂用 Deutz S1 密封胶，但不要粘到
双头螺栓上。
Note: Apply Deutz S1 Never Seize paste to
studs.
99.拧紧排气岐管螺母至 25±2.5 Nm。

Tighten nuts for exhaust manifold with a
torque of 25±2.5 Nm.
缸盖罩盖 Cylinder head cover

100.安装密封垫。
Position gasket
- 129 -
101.安装缸盖罩盖及线束，拧紧螺栓至
9±1 Nm。
Fit cylinder head cover together with cover
plate and cable harness. Tighten bolts with a
torque of 9±1 Nm.
机油冷却器 Lube oil cooler
102.安装机油冷却器，安装时使用新的垫圈。
Mount lube oil cooler with new gasket.
103.拧紧螺栓至 21±2 N.m。

注意：如有则同时安装线束接头固定卡子。
Note: Fit retainer for cable connector
as well if any.
104.安装输油管，使用铜垫。
Fit both screw plugs with new Cu seals.
- 130 -
105.拧紧螺母至 50±5 N.m。
Tighten nut with a torque of 50 ±5 Nm.
106.在燃油滤清器垫上涂少许润滑油，用手
拧紧机油机油滤清器。
Lightly oil fuel filter gasket. Secure fuel filter
cartridge fingertight.
107.在机油滤清器上涂少许润滑油，用手拧
紧机油滤清器。
Lightly oil oil filter gasket. Secure oil filter
cartridge fingertight.
冷却液泵
Coolant pump
108.装入堵塞，套上 O 型圈。
Plug-in element Slide on O-seals.
注：在 O 型圈上涂 AP25N 润滑脂。
Note: Apply lubricant AP25N to O-seals.
- 131 -
109.将节温器压入节温器壳及冷却液泵内。
Press plug-in element into thermostat housing
and coolant pump.
110.在 O 型圈放入节温器壳。
Insert new O-seals into thermostat housing.
注：在 O 型圈上涂 AP25N 润滑脂。
Note: Apply lubricant AP25N to O-seals.
111.安装预先装配好的冷却液泵，使用新的
衬垫。
Mount preassembled coolant pump with new
gasket.
112.交替拧紧螺栓至 21±2 N.m。

Tighten bolts alternately with a torque of 21
±2 Nm.
- 132 -
113.安装冷却液温度传感器，使用新密封圈，
拧紧至 18±2 Nm。
Fit coolant temperature sensor with new seal
and insulating hose, if any, and tighten with a
torque of 18±2 Nm.
输油泵
Fuel pump
114.安装输油泵。
Fit fuel pump.
注：拧入螺栓。
Note: Start bolts.
115.安装输油管，使用新的铜垫。
Fit fuel lines with new Cu seals.Use Cobra
clamp pliers.
注意：输油泵进油管接头螺纹规
格 M16×1.5。
Note: Attention - thread for feed line
connection on fuel pump is M16x1.5.
集油管/油底壳
Oil suction pipe/oil pan
116.将发动机旋转 180°，安装集油管，使
用密封圈垫。
Turn engine by 180°. Fit oil suction pipe with
new gasket.
注：同时安装固定支架，不要拧紧螺栓。
Note: Fit retainer as well. Do not tighten bolts.
- 133 -
117.拧紧顺序。
Order of tightening.
1.椭圆法兰盘螺栓。
2.集油管固定支架：力矩 21±2 Nm。
1. Bolts of oval flange
2. Retainer of oil suction pipe with a torque of
21±2 Nm.
118.剪掉凸出的衬垫。
Cut off projecting gasket
119.在油底壳密封表面接合处填充 Deutz
DW47 密封胶。
Fill up joints of oil pan sealing surface with
Deutz DW 47.
120.在曲轴箱上安放新的密封垫。
Position new gasket on crankcase.
- 134 -
121.在金属薄板油底壳密封垫所有凹槽内涂
Deutz DW47 密封胶。
Fill up all recesses in the gasket for the sheet
metal oil pan with Deutz DW 47.
122.安装金属薄板油底壳。
With sheet metal oil pan: Mount oil pan.
注意：注意查看安装位置标记。
Note: Watch marked installation position.
123.安装铸造油底壳，校准与正时齿轮
罩盖的相对位置。
With cast oil pan:Mount oil pan and align
relative to timing chest cover.
124.交替均匀地拧紧螺栓，对于薄板油底壳
21±2Nm，对于铸造油底壳 29±2 Nm。
Tighten bolts uniformly/alternately with a
torque of 21±2 Nm with sheet metal oil pan
or with 29±2 Nm with cast oil pan.
- 135 -
调速器 Governor
125.在调速器上涂 Deutz DW48 密封胶，密
封带宽度 1.5±0.5 mm。
Apply sealing compound Deutz DW 48 to
governor. Sealing string dia: 1.5 + 0.5 mm
注意：密封表面不得粘有机油或润滑脂。
Note: Sealing surface must be free of oil and
grease.
126.将发动机旋转 180°，安装调速器。
Turn engine by 180°, mount governor.
127.如图 1-2-3-4-5 顺序，拧紧螺栓至 17±1.5

Nm。
Tighten bolts in the order 1-2-3-4-5 with a
torque of 17 ±1.5 Nm.
129.在端盖上安装 O 型密封环并涂少许润滑
脂。
Fit new O-seal to cover and grease lightly.
- 136 -
130.安装端盖。Fit cover.
注意：注意导套。
Note: Watch out for spacer sleeves.
131.拧紧螺栓至 21±2 Nm。

132.安装调速器固定垫板。
Fit retaining plate to governor.
133.拧紧螺栓至 21±2 Nm。

- 137 -
134.安装调速器导线接头。
Fit cable lug to governor.
135.安装停车电磁阀导线接头。
Fit cable lug to shutdown solenoid.
136.连接预热塞导线接头。
Put together glow plug cable couplers.
- 138 -
飞轮壳 Adapter housing
137.将发动机转动 90°，安装飞轮壳。
Turn engine by 90°，Mount adapter housing.
注意：确保中心导套已安装。
Note: Make sure that centering sleeve are
fitted.
138.按以下规定拧紧螺栓：
Tighten bolts according to specification.
M12=99±10Nm
M16=243±25Nm
注：使用加长高强套管 E14，E20。
Note: Use Torx tool. E 14、E 20 ong version
139.安装盖板。
Mount cover plate.
- 139 -
起动机
Starter
140.安装起动机，拧紧螺栓至 70N.m。
Mount starter. Tighten bolts with torque of 70
Nm.
注：如有则拧紧带垫螺母至 40N.m。
Note: Tighten collar nut, if any, with a torque
of 40 Nm.
141.安装导线，拧紧线卡。
Fit cable and fastening clips.
曲轴箱呼吸管 Breather pipe

142.安装呼吸管，使用新的铜垫。
Fit breather pipe with new Cu eals.
143.紧固呼吸管螺栓，拧紧力矩 11±1Nm。
Tighten bolts for breather pipe ith a torque
of 11 ±1 Nm.
- 140 -
144.安装至岐管压力调节器（LDA）空气管。
Fit air pipe to manifolf pressure compensator
(LDA)
145.安装起重吊耳，拧紧螺栓至 47±4N.m。
Fit lifting lugs. Tighten bolts with torque of
47±4 Nm.
146.安装导线接头至冷却器传感器。
Fit cable lug to coolant temperature sensor.
机油压力开关
Oil pressure switch
147.安装机油压力开关，使用新的铜垫，
拧紧力矩 18±2N.m。
Fit oil pressure switch with new u seal and
tighten with a torque f 18 ±2 Nm.
- 141 -
148.安装导线接头至机油压力开关。
Fit cable lug to oil pressure switch.
曲轴箱呼吸器 Crankcase breather

149.装配曲轴箱呼吸器。
Assemble crankcase breather.
零件装配顺序：Order of parts assembly:
1.O 型密封环 Seal
2.压力控制阀 Pressure control valve
3.橡胶软管 Rubber sleeve
150.把压力控制阀安装到缸盖上。
Fit pressure control valve to cylinder head.
151.拧紧螺栓至 8.5±1N.m。
Tighten bolts with a torque of 8,5±1 Nm.
- 142 -
冷却液管 Coolant pipe
152.安装冷却液管，使用Deutz DW67密封
胶，拧紧螺栓至21±2Nm。
Mount coolant pipe with sealing compound
Deutz DW 67.Tighten bolts with a torque
of 21 ±2 Nm.
废气涡轮增压器 Exhaust turbocharger
153.安装废气涡轮增压器，使用新的衬垫。
Mount exhaust turbocharger with new gasket.
注：涂用 Deutz S1，但不要粘在双头螺栓上。
Note: Apply Deutz S1 Never Seize paste to
bolts.
154.按以下规定拧紧螺栓：
M8 螺栓 21±2Nm
或 M10 螺栓 40.5±4Nm
Bolts M8 21 ±2 Nm
or Bolts M10 40.5±4 Nm
机油输油管/机油回油管
Pressure oil pipe/oil return pipe
155.安装机油输油管，使用新的密封垫。
Mount pressure oil pipe with new gasket.
- 143 -
156.拧紧螺栓至 21±2Nm。
157. 安装新的铜垫，拧紧螺栓至 39±3Nm。

Fit banjo bolt with new Cu seals and tighten
with a torque of 39±3 Nm.
158.涂少许润滑干燥剂，安装 O 型圈。
Slide on new O-seals and apply dehydrated
lubricant.
159.安装机油回油管，使用新衬垫。
Mount oil return pipe with new gasket.
注意：在曲轴箱接合孔壁涂少许干燥润滑
剂。
Note: Apply dehydrated lubricant to receiving
bore in crankcase.
- 144 -
161.安装卡箍。
Fit clamping yoke.
进气弯头 Intake elblow
162.安装进气弯头（软管）。
Mount intake elbow (hose).
注：先不要锁紧软管卡子。
Note: Do not tighten hose clip yet.
163.安装通气管与保持架。
Mount breather pipe with retainer free of
stress.
- 145 -
164.安装弹簧卡箍。
Fit spring-loaded clamp.
注：使用弹簧卡钳。
Note: Use spring clamp pliers.
165.锁紧软管卡子。
Secure hose clip.
进气弯管 Charge air elbow

166.装入内部元件。
Press in plug-in element.
注：在密封区域及接合孔壁涂润滑脂。
Note: Apply lubricant to sealing section and
receiving bore.
177.安装进气弯管，使用新密封垫。
Mount charge air elbow with new seal.
- 146 -
Tighten bolts with a torque of 22 ±2 Nm.
169.如有则安装机油加注管及新密封垫，拧
紧至 21±2Nm。
Fit oil filler neck, if any, complete with new
seal and tighten with a torque of 21±2 Nm.
机油尺 Oil dipstick

170.装入新油封。
Slide on new O-seal.
171.尽可能深地插入机油尺。
Press in oil dipstick as far as it will go.
- 147 -
发电机 Alternator
172.安装发电机支架，拧紧螺栓
至 21±2Nm。
Fit alternator bracket. Tighten bolts with a
torque of 21±2 Nm.
173.安装发电机，拧入六角螺栓。
Mount alternator. Start hex. bolt.
174.安装调节支架及销套，拧入六角螺栓。
Fit clamping plate together with spacer bushes.
Start hex. bolts.
张紧 V 型皮带 Tensioning V-belt
175.安装皮带。
Position V-belt.
- 148 -
176.张紧皮带，拧紧螺栓至 21±2N.m。
Tension V-belt. Tighten bolts with a torque
of 21±2 Nm.
177.用皮带张紧量规检查 V 型皮带张紧度。
Check V-belt tension with belt and Tension
gauge.
10mm 宽度皮带 Belt back width 10 mm
初装配 Initial assembly： 450±50N
15 分钟负载运转后，测量：300±50N
Check value after 15 min of operation under
load 300 ±50 N.
使用过的皮带测量： 300±50N
When reusing belt : 300 ±50 N
13mm宽度皮带：Belt back width 13 mm
初装配： 550±50N
Initial assembly ____ 550 ±50 N
Check value after 15 min of operation under
load 400 ±50 N
使用过的皮带测量： 400±50N
When reusing belt __ 400 ±50 N
178.安装 V 型皮带。
Position V-belt.
179.张紧 V 型皮带，拧紧螺栓至 30 N.m。

Tension V-belt. Tighten bolts with a torque of
30 Nm.
- 149 -
180.用皮带张紧量规检查 V 型皮带张紧度。
Check V-belt tension with belt tension gauge.
初装配 Initial assembly： 450±50N
Check value after 15 min. of operation under
load 300 ±50 N
使用过的皮带测量：300±50N
When reusing belt :300 ±50 N
181.皮带张紧之后，拧紧固定螺栓，连接导
线。从装配台架上拆下发动机。
After tensioning of belt tighten remaining bolts
and connect cables. Remove engine from
assembly stand.
发电机支承支架/软垫
Engine mounting/mounting feet
182.安装发动机支架，拧紧螺栓至 260Nm。
Fit engine mounting. Tighten bolts with a
torque of 260 Nm.
183.安装发动机软垫，拧紧螺栓至 95Nm。
Fit mounting feet. Tighten bolts with a torque
of 95 Nm.
- 150 -
重装各零部件 Refitting components:
机油压力开关/冷却液温度传感器
Oil pressure switch/Coolant temperature
sensor
1. 安装机油压力开关，使用新铜垫，拧紧
力矩 18±2 Nm。
Fit oil pressure switch with new Cu seal and
tighten with a torque of 18±2 Nm.
2.安装冷却液温度传感器，使用新铜垫，
拧紧力矩 18±2 N.m。
Fit coolant temperature sensor with new Cu
seal and tighten with a torque of 18±2 Nm.
导线线束
Cable harness
3.安装导线线束。
Fit cable harness.
4.按规定拧紧螺栓，拧紧力矩 21±2 Nm。

Tighten fastening bolts with a torque
of 21 ±2 Nm.
- 151 -
5.安放导线线束。
Lay cable harness and fasten with holding
straps.
减振器/V 型皮带轮
Vibration damper/V-belt pulley
10.安装 V 型皮带轮及减振器。
Fit V-belt pulley and vibration damper.
11.固定 V 型皮带轮，拧紧螺栓至 61±6 Nm。

Fit V-belt pulley and retain against flywheel.
初装扭矩：40-50 Nm。
Initial tightening torque: 40-50 Nm
第1次扭紧角度：1st tightening angle
60mm 长螺栓 bolts 60 mm long ：60°
80mm 长螺栓 bolts 80 mm long：60°
第2次扭紧角度2nd tightening angle：
12.安装燃油泵。
Fit fuel pump loosely.
- 152 -
13.安装 V 型皮带轮，拧紧螺栓至 21±2N.m。
Position V-Belt in place and tension. Tighten
bolts with a torque of 21±2 Nm.
14.用张紧量规测量 V 型皮带张紧度。
皮带宽度 Belt back width 10 mm
初装配 Initial assembly：450±50N
Check value after 15 min.of operation under
load：300±50N
使用后的皮带测量：300±50N
When reusing belt 300±50N
皮带宽度 Belt back width 13 mm
Check value after 15 min. of operation under
load 400±50N
When reusing belt 400±50N
15.安装发电机支架，紧固力矩 60 N.m。
Fit alternator bracket and secure within a
torque of 60 Nm.
16.安装发电机，拧入螺栓。
Mount alternator. Start bolts.
- 153 -
17.安装 V 型皮带并张紧，螺栓拧紧
力矩 31 Nm。
Position V-belt in place and tension.
Tighten bolts with a torque of 31 Nm.
18.用张紧量规测量 V 型皮带张紧度。
Check value after 15 min.of
operation under load : 300±50 N
When reusing belt : 300±50 N
19.按标记从盖板中插入导线，安装导线和盖
板。
Fit cable.
20.安装冷却液温度传感器导线。
Fit cable for coolant temperature sensor.
- 154 -
整机更换曲轴油封
Replacing shaft seals on complete engine
曲轴油封拆卸工具：142 710
Extractor for shaft seals： 142 710
后油封装配工具：142 910
Assembly tool rear：142 910
前油封装配工具：142 920
Assembly tool, front：142 920
飞轮端正时齿轮罩盖
Timing chest cover flywheel end
拆下飞轮。
Flywheel has been removed.
1.将拆卸工具压入曲轴油封。
Press extractor into shaft seal.
2.用拉拔器从正时齿轮罩盖中取出曲轴油
封。
Lift shaft seal with extractor out of timing chest
cover.
3.安装导套。
Fit guide sleeve.
155
4.注意安装深度。
Pay attention to the installation depth.
1)表示是初始安装深度。
2)是最大安装深度。
Item 1 installation depth initial assembly
Item 2 maximum installation depth
4.1 在密封环上涂机油，用装配工具安装曲轴
油封，密封环面对曲轴。
Oil sealing lips. Fit shaft seal with assembly tool.
Sealing lip faces crankshaft.
－前盖－
- Front cover -
拆下 V 型皮带轮
V-belt pulley has been removed.
1.将拉拔器压入曲轴油封。
Press extractor into shaft seal.
2.用拉拔器从正时齿轮罩盖中取出曲轴油封。
Lift shaft seal with extractor out of front cover.
156
3.安装导套。
Fit guide sleeve.
4.注意安装深度。
Pay attention to the installation depth.
1)是表示初始安装深度。
2)是最大安装深度。
Item 1 installation depth initial assembly
Item 2 maximum installation depth
4.1 在密封环上涂机油，用装配工具安装曲
轴油封，密封环面对曲轴。
Oil sealing lips. Fit shaft seal with assembly tool.
Sealing lip faces crankshaft.
157
拆卸及重新安装空气压缩机
Removing and refitting air compressor
1.拆下空气压缩机和机油输油管。
Remove air compressor and oil pressure pipes.
注：检查每一零件，必要时加以更换。
Note: Inspect all single parts and replace if
necessary.
2.安装新 O 型圈。
Fit new O-seal.
3.在空气压缩机安装前，安装机油输油管，使
用新铜垫。
Fit oil pressure pipe together with new Cu seals
Prior to mounting air compressor.
注：先必要拧紧对接螺栓。
Note: Do not yet tighten banjo bolt.
4.安装空气压缩机。
Mount air compressor.
在螺栓上涂 Deutz DW72 密封胶，插入螺栓，
拧紧螺栓至 61±6 Nm。
Insert bolts with locking compound Deutz DW
72 and tighten with a torque of 61±6 Nm.
158
5.安第 2 个机油输油管，使用新铜垫。
Fit 2nd oil pressure pipe with new Cu seals.
6.在曲轴箱及空气压缩机上锁紧机油输
油管。
Secure oil pressure pipes on crankcase and air
compressor.
159
动力转向泵的拆装
Removing and refitting hydraulic pump
1.从液压泵上拧下螺栓。
Unscrew bolts from hydraulic pump.
2.从连接法兰上拧下螺栓，拆下液压泵及连接
法兰。
Unscrew bolts from guide flange. Remove
hydraulic pump complete with guide flange.
注：检查每一零件，必要时加以更换。
Note: Inspect all single parts and replace if
necessary.
3.安装预先装配好的液压泵及连接法兰，拧紧
法兰螺栓至 21±2 Nm。
Mount preassembled hydraulic pump together
with guide flange. Tighten guide flange bolts
with a torque of 21 ±2 Nm.
注：在 O 型圈及接合孔壁涂干燥润滑剂。
Note: Apply dehydrated lubricant to
seal/receiving bore.
4.将衬垫放入安装位置，拧紧液压泵螺栓
至 50±10 Nm。
Move gasket into installation position.
Tighten hydraulic pump bolts with a torque of
50 ±10 Nm.
160
维修时更换喷油泵
Replacing injection pump in case of service
本维修方法仅针对喷油泵的更换，如果同时进
行其它零部件的维修，如滚轮挺柱，调速器等，
其步骤请按第 4 章“喷油泵的安装”。
This repair method only refers to the
replacement of injection pumps. If other
components are to be replaced as well, e.g. roller
tappets, governor, etc., proceed
according to chapter 4 Installing injection pump
“.
专用工具 Special tool required:
控制齿条的压装工具：100 830
Press-on device for control rod：100 830
拉拔器 Extracting device：150 800
喷油器拉拔器 Extractor for injector：110 030
1.拆掉曲轴箱呼吸器及缸盖气门室罩。
Remove crankcase breather and cylinder head
cover.
2.拔出导线塞。
Pull off cable plug.
拆下停车电磁阀或螺塞。
Remove shutdown solenoid or screw plug.
3.压下停车拉杆接控制齿条压入停车位置，插
入压装工具并拧紧。
Press control rod with shutdown lever into stop
position. Insert press-on device and screw on.
161
4.用滚花头限位螺钉将控制齿条压进停车位
置。
Press control rod with knurled head setscrew
into stop position.
注意：用手拧紧滚花头螺钉。
Note: Tighten knurled-head setscrew by hand.
5.将要被拆卸的喷油泵对应的气缸转至点火
上止点，反方向旋转发动机曲轴约 120°。
注意：左侧图示是面对飞轮方向。
Move cylinder of injection pump to be removed
to firing TDC. Turn crankshaft about 120°
against direction of engine rotation.
Note: Flywheel is faced on the illustration at the
left.
6.拆下高压油管，输油管及喷油泵。
Remove injection line and injection pump.
7.用磁棒小心地取出调整垫片。
Carefully take out shim using bar magnet.
注：确定新调整垫片厚度。
Note: Determine new shim,
162
8.将预先确定的垫片安放在滚轮挺柱上。
Position new shim previously determined on
roller tappet.
9.拆下喷油器。
Remove injector.
注意：如果喷油器卡住，使用拉拔器150800
及110030。
Note: If jammed, use extracting device No. 150
800
10.拧回滚花头调节螺钉，拆下压装工具。
Turn back knurled-head setscrew. Remove
press-on device.
注：驱动调速器的停车拉杆，检查控制齿条能
否从起动到停车位置自由移动。
Note: Check whether control rod moves easily
from stop to start position. For this purpose
actuate shutdown lever of governor.
11.用停车拉杆将控制齿条压到停车位置，安
装停车电磁阀，使用新 O 型圈。
Press control rod with shutdown lever into stop
position. Fit shutdown solenoid with new O-
seal.
注：在 O 型圈上涂少许机油。
Note: Lightly oil O-seal.
163
12.拧紧螺栓至 9±1 Nm，安装导线塞。
Tighten bolts with a torque of 9±1 Nm
Fit cable plug.
13.安装气门室罩，拧紧螺栓至 9±1 Nm。

Fit cylinder head cover. Tighten bolts with a
torque of 9 ±1 Nm.
注意：必要时更换密封垫。
Note: Renew gasket if necessary.
14.在 O 型圈上涂少许机油，安装曲轴呼吸
起，拧紧螺栓至 9±1 Nm。
Lightly oil O-seal. Fit crankcase breather.
注意：必要时更换 O 型密封圈。
Note: Renew O-seal if necessary.
164

Service Maual of DDE 1013 Engine

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大连道依茨 1013 系列发动机维修手册

1. 技术参数/符号注释 Specification data / Key to symbols

1. Specification data Page

不可调整气门 Not ready for adjustment 可调整气门 Ready for adjustment

喷油泵号 Injection pump No. XXX

FB测量值℃/A FB measured C/A 10

从表1查到FB名义值℃/A FB nom. from table 1 C/A 10

Disassembly Guard against personal

Reinstall - Remount Oil

Check - Adjust Mark

Special tool Balance

Visual inspection Drain off

3.2 测量位置在平面 1-3 内

15.对于 BF6M 发动机从飞轮端取出导套。

24.在新的限压阀上涂 Deutz DW71 密封胶。

气缸套 Cylinder liners

5.安装机油泵，拧紧至 8-9 N.m

2.在“a”、 “b”平面内“1”、 “2”点测量连杆

After pressing in, precision-bore small end bush

Reassemble rocker arm bracket. Fit circlips.

专用工具：Special tool required:

3.安装 V－皮带轮，拧紧螺栓至 21Nm。

3.在“a”、 “b”平面内的“1”、 “2”两点测量

机油喷嘴 Oil spray nozzles

曲轴轴承 Crankshaft bearings

21.在螺栓涂 Deutz DW71 密封胶，拧紧至

22.在正时齿轮盖密封面上涂 Deutz DW67 密

85.拧紧预热塞或堵塞至 20±2 N.m。

91.拧紧压板螺栓至 16±5 Nm。

进排气岐管 Air intake/exhaust manifold

99.拧紧排气岐管螺母至 25±2.5 Nm。

缸盖罩盖 Cylinder head cover

机油冷却器 Lube oil cooler

103.拧紧螺栓至 21±2 N.m。

112.交替拧紧螺栓至 21±2 N.m。

127.如图 1-2-3-4-5 顺序，拧紧螺栓至 17±1.5

131.拧紧螺栓至 21±2 Nm。

133.拧紧螺栓至 21±2 Nm。

曲轴箱呼吸管 Breather pipe

曲轴箱呼吸器 Crankcase breather

废气涡轮增压器 Exhaust turbocharger

157. 安装新的铜垫，拧紧螺栓至 39±3Nm。

进气弯头 Intake elblow

进气弯管 Charge air elbow

机油尺 Oil dipstick

张紧 V 型皮带 Tensioning V-belt

179.张紧 V 型皮带，拧紧螺栓至 30 N.m。

4.按规定拧紧螺栓，拧紧力矩 21±2 Nm。

11.固定 V 型皮带轮，拧紧螺栓至 61±6 Nm。

13.安装气门室罩，拧紧螺栓至 9±1 Nm。

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FB测量值℃/A FB measured 　C/A 10