Professional Documents
Culture Documents
9040 (404-03)
7045 (403-03)
7040 (402-03)
7030 (401-03)
6030 (400-01)
Repair Manual
The telehandlers described in this manual are to be used only for agricultural and related applications. This is the designated use they are
to be put to.
If the machine is modified without the prior written consent of CLAAS, or if it used in a way which does not correspond to the designated
use, or if the machine is not driven or serviced correctly, the firm shall not assume any responsibility whatsoever for injuries or damage
(both direct damage and consequential damage).
Strictly observe the procedures regarding operation and maintenance described in this manual.
Moreover, use original CLAAS spare parts only. In the event that no original spare parts are used, the machine guarantee shall be void in
case of damage resulting from failure to use original spare parts.
Exclusively built for CLAAS KGaA mbH by
KRAMER-WERKE GmbH Nussdorfer Str. 50 D-88662 Überlingen/Germany.
Table of contents
Table of contents
Table of contents
Machine specifications: overview 1
Machine outside view .............................................................................................. 1-1
Inside of cab: overview ............................................................................................ 1-2
Instrument panel, multifunctional lever, switch consoles: overview ......................... 1-3
Important information on this manual ...................................................................... 1-4
Abbreviations/symbols ....................................................................................... 1-4
Model and trade names: overview ........................................................................... 1-4
Type labels and component numbers ...................................................................... 1-5
Serial number .................................................................................................... 1-5
Cab number ....................................................................................................... 1-5
Engine number .................................................................................................. 1-5
Hydraulic pump number .................................................................................... 1-6
Variable displacement motor number ................................................................ 1-6
Variable displacement motor number (high speed option) ................................ 1-6
Front and rear axle numbers ............................................................................. 1-6
Frame ...................................................................................................................... 1-8
Engine ...................................................................................................................... 1-8
Oil/water cooling fan ................................................................................................ 1-9
Power train ............................................................................................................... 1-9
Variable displacement pump ............................................................................. 1-9
Variable displacement motor ............................................................................. 1-9
Axles ...................................................................................................................... 1-10
Front axle ......................................................................................................... 1-10
Rear axle ......................................................................................................... 1-10
Service and parking brake ..................................................................................... 1-11
Steering system ..................................................................................................... 1-11
Work hydraulics ..................................................................................................... 1-12
Hydraulic pump ................................................................................................ 1-12
Hydraulic ram protection .................................................................................. 1-12
Lift, tilt and push-out rams: velocity ................................................................. 1-13
Hydraulic pilot control ...................................................................................... 1-13
Additional control circuit (option) ..................................................................... 1-13
Electric system ....................................................................................................... 1-14
Fuses: overview ............................................................................................... 1-14
Electric components ........................................................................................ 1-15
Main fuse box with relays (88 kW diesel engine) ............................................ 1-16
Main fuse box with relays (103 kW diesel engine) .......................................... 1-16
Relays: overview ............................................................................................. 1-17
Tyres for models 400-01/401-03/402-03/403-03 ................................................... 1-18
Tyres for model 404-03 .......................................................................................... 1-18
Weights .................................................................................................................. 1-19
Noise levels ........................................................................................................... 1-19
Vibration ................................................................................................................. 1-19
Coolant compound table ........................................................................................ 1-19
Tightening torques ................................................................................................. 1-20
General tightening torques .............................................................................. 1-20
Specific tightening torques .............................................................................. 1-20
Trailer couplings: trailer weight/drawbar load ........................................................ 1-20
Payload: model 400-01 load diagram .................................................................... 1-21
Payload: models 401-03 load diagram .................................................................. 1-22
Payload: model 402-03 load diagram .................................................................... 1-23
Payloads: model 403 03 load diagram .................................................................. 1-24
14 Door arrester
Models: 404-03 3 4 5 6 7 8 9 23 10 11
15 Rear eye hook for strapping down the machine
16 Handle
7
17 Cab access
1 18 Battery (battery master switch option)
12
19 Front eye hook for towing/strapping down the machine
1 13 20 Right-hand side frame levelling ram on front axle (option) 404-03
15 1. Eye hooks are for removing the cab only, and may not be used for crane-lifting the machine
19 1 18 17 7 16 3
10 11 Accelerator pedal
12 Control lever (joystick)
41
13 Stop cock – control lever lock for road travel
11
14 Interior light
0
I
II
1 2
40
0
15 Switch panel – side console (right)
3
16 Drink holder
12
39 17 Storage net for
18 Prepared installation for radio (option)
38 19 Loudspeakers (option)
13
20 Air vent – rear window
37 21 Working light (standard on left/option on right)
22 Steering electronics
14
23 Drive electronics (Susmic)
36
24 Central electrics (relays, fuse box etc.)
25 Rear wiper
35 15
26 Rotating beacon
27 Aerial (option)
34 28 Proportional electronics
16
29 Rotary switch – fresh air/recirculated air
33 30 Fresh air filter
17 31 Seat belt
32 32 Hook
33 Brake fluid tank
18 34 Bracket for first aid kit
31
35 Tank – washer system
36 Seat
30
19 37 Roller sun-visor
38 Bracket for side window lock (upper door option)
29 39 Steering system
20 40 Brake/inching pedal
19 41 Lock on cab
42 Inside door lock
20 21 43 Multifunctional lever – turn indicators, headlights, wipers
402 02_0 3_b0 0.iso 44 Switch panel – side console (left)
45 Front working light (option)
21 28 27 26 25 24 23 22
59 60 61 62 63 64 65 66 67
1.3 Instrument panel, multifunctional lever, switch consoles: overview
51 52 53 68
84 Switch – quickhitch release
50 54 Instrument panel 85 Switch – working light on boom
46 Hour meter 86 Switch – Autohitch trailer coupling (option)
49 55 69
47 Telltale (yellow) – cold starter 87 Switch – front socket for electric attachments (option)
48 Telltale (blue) – high beam 88 Switch – additional rear control circuit (option)
48 56 49 Telltale (red) – coolant level 89 Switch – fuel preheater (option)
00000 00 h
70 77 50 Telltale (red) – hydraulic oil filter 90 Switch – heated rear window (option)
47 57 51 Telltale (yellow) – air filter 91 Switch – rotating beacon (option)
52 Telltale (red) – alternator charge function 92 Switch – rear working light
78
46 58 53 Telltale (red) – parking brake 93 Switch – front working light
54 Telltale (red) – engine oil pressure 94 Pressure gauge – air compressor (option)
79
1 2
55 Telltale (red) – 3rd control circuit continuous operation 95 Switch – machine lights (low beam and rear lights)
56 Telltale (green) – right/left turn indicators for rear attach- 96 Switch with lock – continuous operation of 3rd control circuit
3
Nr_7_2.iso
80 ments (option)
57 Telltale (green) – fuel/water separator 97 Switch – load stabiliser (option)
76 75 74 73 72 71
81 58 Fuel level indicator Right-hand side switch panel
Front instrument panel 98 Switch – diagonal steering (crab steering)
98 59 Telltale (red) – hydraulic system overheating 99 Switch – parking brake
82 83 84 85 86 87 88
60 Telltale (red) – hydraulic oil level 100 Switch – work range/speed range
99 61 Telltale (green) – differential lock 101 Switch with lock – 4 wheel/front axle steering
62 Telltale (green) – right/left turn indicators 102 Tip switch – steering synchronisation
63 Telltale (yellow) – hose burst valve 103 Switch – rear wiper
100
64 Telltale (green) – front axle steering 104 Switch – reversing fan operation (engine)
89
65 Telltale (green) – 4 wheel steering 105 Switch – air conditioning (option)
101 66 Telltale (green) – diagonal steering (crab steering) 106 Switch – hydraulic connection for tipping trailer (option)
67 Telltale (red) – steering synchronisation 107 Tip switch – hydraulically adjustable trailer coupling (Auto-
102 68 Telltale (green) – forwards driving direction hitch) or hydraulic connection for tipping trailer (option)
90
97 69 Telltale (green) – reverse driving direction 108 Switch – additional control circuit (option)
96 103 70 Speedometer (high speed option) 109 Switch – front axle frame levelling
95
71 Temperature indicator – diesel engine (only for telehandler model 404, option)
94 115
93 104 72 Manual throttle potentiometer (option) 110 Tip switch – rear axle hydraulic oscillating axle interlock
92 73 Instrument panel (only for telehandler model 404, option)
91 12 114 111 Switch with lock – disabling/enabling the lock function of the
74 Mark with telltale (red) drive interlock (option)
105 safe load indicator
75 Crawler gear potentiometer (option)
116 113 Control lever (joystick)
76 Tachometer (engine)
106 112 Tip switch – driving direction in neutral
77 Telltale (red) – disabling/enabling the lock function of the
112 safe load indicator 113 Switch – extend/retract telescopic boom
119 118 117 107 Heating switches 114 Not assigned (option)
78 Rotary switch – heating temperature 115 Switch – unlock/lock 3rd control circuit
108 79 Rotary switch – heater fan 116 Tip switch – differential lock
117 Switch – forwards/reverse driving direction
0
Abbreviations/symbols
• This symbol stands for a list
• Subdivision within lists or an activity. Follow the steps in the recommended sequence
☞ This symbol requires you to carry out the activity described
➥ Description of the effects or results of an activity
n. s. = not shown
“Option” = optional equipment
Stated whenever controls or other components of the machine are installed as an option.
This symbol shows the driving direction – for better orientation in figures and
graphics.
CLAAS
Telehandler CLAAS model designation
trade name
400-01 K01 6030
401-03 K02 7030
402-03 K04 7040
403-03 K04 7045
404-03 K05 9040
Cab number
The type label (arrow) is located in the cab, at the top right in driving direction.
Engine number
The type label is located on the cylinder-head cover (engine).
Example: Deutz TCD 2012 L04 2V
kW 88
1.7 Frame
Sturdy steel sheet frame, rubber-mounted engine
1.8 Engine
Telehandler model 400-01, 401-03, 402-03 403-03/404-03
Type TCD 2012 L04 2V
88 kW 103 kW
Output (as per ISO 9249) at 2400 rpm at 2400 rpm
with charge-air cooler with charge-air cooler
Max. torque 420 Nm 520 Nm
(counterclockwise rotation) 1500 rpm 1500 rpm
Specific minimum fuel con-
215 g/kWh 205 g/kWh
sumption
No. of cylinders 4
Displacement 4038 cm³
Bore and stroke 101 x 126 mm
Compression ratio 1:18
PDL DCR
Fuel injection system
(pump, line, nozzle) (Deutz Common Rail)
Firing order 1-3-4-2
Starting aid Glow plug
Max. lateral left/right inclination: 30° (57 %)
Max. inclined position (engine
Max. uphill/downhill inclination: 30° (57 %)
no longer supplied with oil)
Observe the tilting limit of the machine!
Oil pressure Forced feed lubrication
Intake valve 75°
Valve tip clearance1
Exhaust valve 120°
Control plunger play1 exhaust
Control plunger play 144°
gas recirculation
1. Adjust the play when the engine is cold
1.11 Axles
Front axle
400-01/401-03/402-03
Telehandler model 404-03
403-03
Planetary steering and drive axle, rigid screw connection
Design
with frame
Differential lock 100 % differential
King-pin inclination 0°
Camber 0°
Steering angle Max. 45° Max. 40°
Toe-in 0 mm
Track width 1920 mm
Rear axle
400-01/401-03/402-03
Telehandler model 404-03
403-03
Planetary steering and drive axle,
Design
oscillating bearing on frame
Differential lock No
King-pin inclination 0°
Camber 0°
Oscillation ±10°
Steering angle Max. 45° Max. 40°
Toe-in 0 mm
Track width 1920 mm
401-03
Telehandler 400-01 402-03, 403-03 404-03
402-03
Fixed displacement Variable displacement
Hydraulic pump
pump 44 cm³/rev pump 60 cm³/rev
Lift ram
Raise 10.5 sec 9.0 sec 12.5 sec
Lower 6.5 sec 7.0 sec 7.0 sec
Tilt ram
Tilt in 4.5 sec 4.5 sec 5.0 sec
Dump out 4.0 sec 4.0 sec 4.5 sec
Push-out ram
Retract 7.0 sec 9.0 sec 9.0 sec 13.0 sec
Extend 6.0 sec 8.0 sec 8.0 sec 12.0 sec
Electric components
Description Output
Alternator 12 V 95 A
Starter 12 V 3.0 kW
Battery 12 V/135 Ah
Relays: overview
The relays are located underneath the cover behind the seat.
Switching relay
Protected circuit
no.
K25
K1 High current relay
1.18 Weights
400-01,
Telehandler 402-03 403-03 404-03
401-03
Kerb weight1 7200 kg 78000 kg 8100 kg 8600 kg
Gross weight rating 10000 kg
Front/rear gross axle weight
6500 kg
rating
Max. authorised load (towing
4000 kg/drawbar load 1000 kg
facility)
1. Without attachment, with driver and full fuel tank
Important!
Measurement of sound power level according to EC Directive 2005/88 EC. Meas-
urements carried out on asphalted surface.
1.20 Vibration
Vibration
Effective acceleration value for the m
< 2.5 ------
upper extremities of the body s2
Important!
Payload indications with authorised tyres
Important!
Payload indications with authorised tyres
Important!
Payload indications with authorised tyres
Important!
Payload indications with authorised tyres
Important!
Payload indications with authorised tyres
Rigid front axle with mechanical or hydraulic oscillating axle interlock (rear axle)
Important!
Payload indications with authorised tyres
Front axle with frame levelling and without oscillating axle interlock (rear axle)
Important!
Payload indications with authorised tyres
Front axle with frame levelling and hydraulic oscillating axle interlock (rear axle)
Important!
Payload indications with authorised tyres
d
g
f 920
e e
a b c a b c
1710
2450
2650
45°
47 °
430 200
2850 1920
4760 2320
Fig. 12: Machine dimensions
1940 900
5690
a b a b
401-03,
Telehandler model 400-01 404-03
402-03, 403-03
Pallet forks pin height1 retracted 4700 mm 4900 mm 5850 mm
a
extended 6460 mm 7350 mm 9120 mm
Pallet height1, 2 retracted 4530 mm 4760 mm 5700 mm
b
extended 6250 mm 7100 mm 8950 mm
c Dump-in angle in transport position 2 20 °
2
d Dump-out angle 75 ° 70 °
2
Turning radius: with forks between walls 4550 mm 5250 mm
Turning radius with frame levelling:
–
With forks between walls2 5300 mm
1. With tyres 405/70-24 MPT01 (with tyres 425/75R20 and 405/70-20 (- 50mm) 17.5LR24,
400/80R24 and 460/70R24 (+ 20 mm), 15.5-25 and 15.5-80-24 (+ 40) 19.5LR24 and 500/70R24 (+ 60)
2. With pallet forks
Symbol Explanation
Before starting maintenance work, follow the safety instructions in the Operator's Manual!
Before starting maintenance work, read the “Maintenance” chapter in the Operator's Manual!
Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary!
Leakage check:
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections. Rectify if necessary!
Visual check!
Check wear parts and screw connections at regular intervals
Retighten loose connections immediately and replace worn wear parts!
Leakage check:
Check the fuel/water separator. Drain water if necessary!
Lubrication service:
Lubricate the assemblies concerned!
1000153091
Service and maintenance work
Travaux de maintenance
Täglich
Daily
Tous les jours
10 h
20 h
Täglich
Daily
Tous les jours
10 h P
20 h
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. MIL-L-2104C; API CD/CE/CF4; CCMC-D4
3. Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association)
4. DIN 51 524
5. Total capacity of hydraulic system about 170 l
6. DIN 51 601, min 45 cetane
7. Do not mix this brake fluid with other brake fluids (standards: B 71 2710 and ISO 7308)
8. Maintenance work must be carried out by trained staff only
9. Bear in mind the safety data sheet during maintenance work
10. SeeCoolant compound table on page 1-19
11. See manufacturer's indications on the packaging and bear in mind the antifreeze compound table
12. Replace the coolant every 2 years!
“A”
“B”
“C”
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
work
Delivery
at 100 s/h
inspection
attachment manufacturer as well.
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
2nd Inspection
1st Inspection1
Oil and filter changes ( ) (check the oil levels after a test run):
• Check the charge-air cooler for dirt, clean if necessary and drain condensation water8 ● ● ● ●
• When using biodegradable oil: drain the condensation water in the hydraulic oil tank 5 ● ●
3-4
3-5
3.4 Maintenance plan (overview)
“A”
“B”
“C”
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
work
Delivery
at 100 s/h
inspection
attachment manufacturer as well.
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
1st Inspection1
2nd Inspection
• Clean the dust receptacle on the air filter (option) ● ● ● ● ●
• V-belts: check condition and pre-tension, retighten and replace if necessary9 ● ● ● ● ● ●
• Fuel system ● ● ● ● ● ●
• Check the fuel/water separator. Drain water if necessary ● ● ● ● ●
• Check valve tip clearance (engine timing). Set if necessary ●
• Battery: check charge condition ● ●
Maintenance and servicing work
• Heating: clean fine-dust filter and recirculated-air filter, replace every 500 s/h if necessary10 ● ●
• Air conditioning (option) check coolant level, clean compressor and evaporator11 ● ● ● ● ● ●
• Check the multidisc brake of the service and parking brake ● ● ● ● ● ●
• Drain the water in the compressed-air tank (compressed-air brake option) ● ● ● ● ● ●
• Tyre check (damage, air pressure, tread depth) ● ● ● ● ● ●
• Trailer coupling (damage, wear) ● ● ● ● ● ●
• Check and readjust slide plates on telescopic boom. Replace if necessary 12 ● ● ● ● ● ●
Check screws and nuts or screw connections for tightness on the following assemblies/components. Retighten if necessary
• Engine and engine bearing ● ● ● ● ●
• Steering system ● ● ● ● ●
• Hydraulic system ● ● ● ● ●
• Telescopic boom (pin locking), quickhitch lock ● ● ● ● ●
• Axle mounting, axle suspension ● ● ● ● ●
• Counterweight (attachment) ● ● ● ● ●
• Fastening screws of cardan shafts ● ● ● ● ●
• Fastening screws of cab ● ● ● ● ●
• Wheel nuts ● ● ● ● ●
• Electric system: check electric and earth connections, chafing on wiring harness, battery terminals ● ● ● ● ●
“A”
“B”
“C”
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
work
Delivery
at 100 s/h
inspection
attachment manufacturer as well.
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
2nd Inspection
1st Inspection1
Lubrication service13 ( )
3-6
3-7
3.4 Maintenance plan (overview)
“A”
“B”
“C”
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
work
Delivery
at 100 s/h
inspection
attachment manufacturer as well.
once a year
(once a day)
Every 50 s/h
once a week
Maintenance
every 500 s/h2
every 1500 s/h
1st Inspection1
2nd Inspection
Leakage check ( ):
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
• Air intake line (air filter, turbocharger, engine charge-air cooler) ● ● ● ● ● ●
• Engine lubrication (engine – filter) ● ● ● ● ● ●
• Fuel lines14 ● ● ● ● ● ●
• Cooling system (engine – hydraulic oil) ● ● ● ● ● ●
Maintenance and servicing work
1. Work to be carried out once after the first 100 s/h. This work must be carried out by an authorised workshop for warranty claims to be acknowledged.
2. Work after the first 500 s/h (2nd Inspection) must be carried out by an authorised workshop for warranty claims to be acknowledged
3. Replace filter insert as indicated by the telltale, however at least every 12 months or 1500 s/h.
4. When working in an acidic environment, replace the filter every 300 s/h!
5. When using biodegradable oil: drain the condensation water in the hydraulic oil tank every 500 s/h, in any case before the cold season.
6. Replace the brake oil every 2 years
7. Depending on operation and dust conditions, it may be necessary to clean the radiator more frequently
8. Drain the condensation water every 1500 service hours
9. Replace the V-belts after 2 years at the latest
10. Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently
11. Replace the dehumidifier every 2 years or after maintenance and repair work on the refrigerating circuit
12. Minimum wear plate thickness (8 mm)
13. Lubricate attachment according to manufacturer's instructions!
14. Replace flexible fuel leak oil lines every 2 years
15. Replace flexible lines every 6 years (UVV, DIN 20066 part 5)
3.5 Introduction
Operational readiness and the service life of the telehandler are heavily dependent on
maintenance.
Maintenance work must be carried out by trained and qualified staff only.
☞ See “Maintenance plan (overview)” on page 3-4
Caution!
Before carrying out service and maintenance work, always read, understand
and follow the instructions given in
☞ chapter 2 “SAFETY INSTRUCTIONS” of this Operator's Manual
☞ the Operator's Manuals of the attachments
☞ Make sure the lift ram of the telescopic boom is secured with a prop so the
telescopic boom cannot be lowered unintentionally if you need to carry out
maintenance work with the telescopic boom raised
Refuelling
Filler inlet A of the fuel tank is located on the left in driving direction, behind the cab
Danger!
A All work involving fuel carries an increased
Danger of fire and poisoning!
☞ Do not refuel in closed rooms
☞ Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Fig. 1: Fuel filler inlet
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
☞ Never bleed the fuel system if the engine is hot!
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
☞ Proceed as follows:
• Switch off the engine
• Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
• Open the engine cover
• Place a container to collect the fuel
A • Remove the cover plate
• Unscrew drain plug B on sight glass A of the fuel prefilter
• Drain the water until the fuel that flows out is clean
B • Tighten drain plug B
Fig. 3: Checking the fuel/water separator • Test run the engine and check for leaks
• Mount the cover plate
Replace the fuel prefilter every 500 s/h (service hours)
☞ Proceed as follows:
• Place a container to collect the fuel
4
• Remove cable 1 from the plug on the water receptacle
• Remove water receptacle 2 (arrow)
3
• Remove filter cartridge 3 with a slight rotation
• Clean filter housing 4
2 • Insert a new filter cartridge 3
• Clean and install water receptacle 2
1 • Install cable 1 on the plug of the water receptacle
• Test run the engine and check for leaks
g. 4: Replacing the fuel/water separator • Mount the cover plate
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
A Danger of burns!
☞ Never bleed the fuel system if the engine is hot!
Environment!
Fig. 5: Fuel filter position
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
☞ Proceed as follows:
• Park the machine on level ground
• Lower the telescopic boom fully
B
• Apply the parking brake with the switch
A • Switch off the engine
• Switch off the ignition and remove the ignition key
• Open the engine cover
• Place a suitable container underneath the engine to collect the fuel as it drains
• Slacken and unscrew filter cartridge A with a commercially available filter spanner
• Clean the inside of the filter head
A • Apply a thin coat of fuel to rubber seal B of the new filter cartridge
• Tighten the new filter cartridge by hand until the gasket makes contact
Fig. 6: Replacing the fuel filter
• Tighten filter cartridge A by hand by about a further half revolution
• Bleed the fuel system – see Bleeding the fuel system on page 3-12
• Let the engine run and check the filter cartridge for leaks
Caution!
If the engine oil level is too low or if an oil change is overdue, this may cause
☞ Engine damage or loss of output!
☞ Drain the oil
☞ – see Maintenance plan (overview) on page 3-4
Important!
Caution!
Too much or incorrect engine oil may result in engine damage! For this reason:
☞ Do not add engine oil above the MAX mark of oil dipstick A
☞ Use only the specified engine oil
☞ – see Fluids and lubricants: overview on page 3-3
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in
an environmentally friendly manner!
☞ Clean the area around oil filler cap B with a lint-free cloth
OIL ☞ Open filler cap B
A B ☞ Raise oil dipstick A slightly to allow any trapped air to escape
☞ Fill in engine oil
➥ Wait a moment until all the oil has run into the oil sump
☞ Check the oil level
➥ – see Checking the engine oil level on page 3-13
☞ Fill up if necessary and check the oil level again
☞ Close filler cap B
☞ Push oil dipstick A back in as far as possible
Fig. 9: Filling up engine oil
☞ Completely remove all oil spills from the engine
Danger!
Caution when draining hot engine oil –
☞ Danger of burns!
+80 °C ☞ Wear protective gloves
☞ Use suitable tools
OIL Environment!
Fig. 10: Optimum engine oil temperature
Use a suitable container to collect the engine oil as it drains and dispose of it in
an environmentally friendly manner!
☞ Proceed as follows:
•Park the machine on level ground
•Lower the telescopic boom fully
•Apply the parking brake with the switch
•Let the engine run until it reaches its operating temperature (oil temperature
about 70 – 80 °C)
• Switch off the engine
• Switch off the ignition and remove the ignition key
• Open the engine cover
• Remove the cover plate
• Place a container (about 15 l capacity) under the opening to collect the oil as it drains
• Carefully unscrew the oil drain plug on the oil pan
☞ Once the oil is completely drained
• Screw the oil drain plug back onto the oil pan with a new sealing ring
• Replace the engine oil filter
– see Replacing the engine oil filter cartridge every 500 s/h (service hours) on
page 3-16
• Fill in engine oil – see Filling up engine oil on page 3-14
• Check the oil level – see Checking the engine oil level on page 3-13
• Start the engine and let it run briefly at low revs
• Check the engine oil pressure by means of the telltale
• Switch off the engine
• Wait a moment until all the oil has run into the oil sump
• Check the oil level again
• Fill up if necessary and check again
• Completely remove all oil spills from the engine
Replacing the engine oil filter cartridge every 500 s/h (service hours)
Danger!
Caution when handling hot engine oil –
H
Danger of burns!
☞ Wear protective gloves
Environment!
Fig. 11: Engine oil filter position Collect the drained engine oil in a suitable container. Dispose of used oil and
filters in an environmentally friendly manner!
Engine oil filter H is accessed via the maintenance flap in the rear right wheel well
☞ Proceed as follows:
• Park the machine on level ground
• Lower the telescopic boom fully
I
• Apply the parking brake with the switch
H • Switch off the engine
• Switch off the ignition and remove the ignition key
• Open the engine cover
• Remove the servicing lid
• Place a suitable container underneath the oil filter to collect the oil as it drains
• Slacken and unscrew oil filter cartridge H with a commercially available oil filter
H spanner
• Clean the inside of the filter head
Fig. 12: Replacing the engine oil filter
• Apply fresh engine oil to rubber seal I of the new oil filter cartridge and screw on the
filter cartridge by hand until the seal makes contact
• Tighten the oil filter cartridge to 15 – 17 Nm with a (commercially available) torque
wrench
• Drain the engine oil
– see Replacing the engine oil every 500 s/h (service hours) on page 3-15
Danger!
All work involving antifreeze carries an increased
Danger of poisoning and causticisation!
☞ Seek medical attention immediately if antifreeze has been swallowed
☞ Wear protective clothing and gloves
☞ Keep antifreeze out of reach of children
• Dirt on the radiator fins reduces the radiator's heat dissipation capacity! To avoid this:
• Clean the outside of the radiator at regular intervals. Refer to the maintenance plans
for the cleaning intervals
• In dusty or dirty work conditions, clean more frequently than indicated in the mainte-
nance plans
• An insufficient coolant level reduces the heat dissipation capacity as well and can lead
to engine damage! Therefore:
• Check the coolant level at regular intervals. Refer to the maintenance plans in the
appendix for the intervals
• If the coolant must be replace frequently, have the cooling system checked for leaks
by an authorised workshop!
• Never fill in cold water/coolant if the engine is warm!
• After filling the expansion tank, make a test run with the engine and check the coolant
level again after switching off the engine
• The use of the wrong coolant can destroy the engine and the radiator. Therefore:
• Add enough antifreeze to the coolant.
• Use brand-name antifreeze compounds with anticorrosion additives – see Fluids and
lubricants: overview on page 3-3
• Do not use radiator cleaning compounds if an antifreeze compound has been added
to the coolant – otherwise this causes sludge to form, which can damage the engine
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in
an environmentally friendly manner!
Important!
Check the coolant level every 10 s/h (service hours) or once a day.
We recommend checking it before starting the engine.
Check the antifreeze at regular intervals, especially at temperatures below 4 °C!
Replace the coolant every 2 years!
Filling up coolant
Danger!
Never open the coolant tank and never drain coolant if the warm engine is
running since the cooling system is under high pressure –
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Always actuate the safety valve in the filler cap of the expansion tank first.
To do this:
Unscrew the filler cap to the first notch and release the pressure
Draining coolant
Danger!
Never open the coolant tank and never drain coolant if the warm engine is
running since the cooling system is under high pressure –
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Open filler cap D to the first notch of the expansion tank and release the
pressure
Danger!
Warm engine –
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective goggles, gloves and clothing!
Caution!
Dirt on the radiator fins reduces the radiator's heat dissipation capacity and
can cause damage to the engine and the hydraulic system!
☞ Check and clean the outside of the radiator once a day. Refer to the main-
tenance plan for the cleaning intervals
☞ In dusty or dirty work conditions, clean more frequently than indicated in the
maintenance plan
Caution!
Fig. 16: Cleaning the radiator In order to ensure the radiator's optimal cooling capacity, do not damage the
radiator fins as you clean them with a compressed-air gun!
Caution!
A
Dirt on the radiator fins reduces the radiator's heat dissipation capacity and
can cause damage to the engine and the hydraulic system!
Tip switch T for the reversing fan is located on the instrument panel on the right.
☞ Press tip switch T briefly to position B
➥ The fan reverses its direction of rotation,
➥ the fan is in cleaning mode and the
A
➥ dirt is removed from the radiator
➥ This can be seen by the dust A blown out from the intake screen on the engine
cover
➥ The fan automatically switches back to cooling mode after about 1 minute
Fig. 17: Tip switch for reversing fan
Important!
When working in especially dusty environment, clean the radiator repeatedly and
more frequently!
D Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
periods of time. This risk is present for example in acid production facilities,
steel and aluminium mills, chemical plants and other nonferrous-metal plants.
☞ Replace filter cartridge D and safety cartridge F at the latest after 500 serv-
34001b520_02.iso ice hours!
F
Fig. 18: Air filter – dust valve
Caution!
Make sure the dust in the container has a minimum distance of 25 mm to the
Fig. 19: Air filter – dust valve cover otherwise the engine is damaged!
Caution!
G The filter cartridge will be damaged if it is washed or brushed out!
Bear in mind the following to avoid premature engine wear!
☞ Do not clean the filter cartridge
H
☞ Replace the filter cartridge when the telltale comes on
☞ Never reuse a damaged filter cartridge
307b0700.ai
☞ Ensure cleanliness when replacing the filter cartridge!
D
☞ Proceed as follows:
• Switch off the engine
• Apply the parking brake with the switch
• Switch off the ignition and remove the ignition key
• Open the engine cover
307b0710.ai
• Fold both locks G on lower housing section H to the outside
• Remove lower housing section H
D • Carefully remove filter cartridge D with slightly turning movements
In addition, every 3rd time the filter is replaced:
• Carefully remove safety cartridge F with slightly turning movements
• Make sure all contamination (dust) inside the upper and lower housing sections has
been removed
H
• Insert a new safety cartridge F into the upper housing section
F • Insert new filter cartridge D into the upper housing section
• Position lower housing section H (make sure it is properly seated)
Fig. 20: Removing the filter element
• Close both locks G
Danger!
Only check or retighten/replace the V-belts when the engine is switched off –
Danger of personal injury!
☞ Switch off the engine before carrying out inspection work in the engine
compartment!
Caution!
Cracked and stretched V-belts cause engine damage
☞ Have the V-belts replaced by an authorised workshop
Environment!
Use a suitable container to collect the gearbox oil as it drains and dispose of it
in an environmentally friendly manner!
Environment!
Use a suitable container to collect the gearbox oil as it drains and dispose of it
in an environmentally friendly manner!
Danger!
Careful when draining hot gearbox oil –
Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!
☞ Proceed as follows:
20 kph gearbox • Park the machine on level ground when the gearbox is at operating temperature
• Place a suitable container under the rear axle gearbox to collect the oil
• Oil filler and inspection plug A on the 20 kph gearbox, or
• Unscrew oil filler and inspection plug B on the 30 kph or 40 kph gearbox
A (Ecospeed)
• Unscrew oil drain plug C on the 20 kph gearbox or oil drain plug E on the 30 kph or
40 kph gearbox (Ecospeed)
C
Caution!
30 kph or 40 kph Do not unscrew oil drain plug D!
gearbox
☞ It is used for draining the hydraulic oil
Environment!
30 kph or 40 kph Use a suitable container to collect the gearbox oil as it drains and dispose of it
gearbox in an environmentally friendly manner!
Important!
Drain oil only after running the machine for a longer period of time (operating tem-
perature)!
Danger!
Careful when draining hot gearbox oil –
Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!
☞ Proceed as follows:
• Park the machine on level ground when the differential is at operating temperature
A
• Place an adequately sized container under the differential housing of the rear axle to
B collect the oil
• Clean and unscrew plugs A and B
• Unscrew oil drain plug C
• Completely drain the old gearbox oil
C
• Tighten drain plug C with a new sealing ring to make an oil-tight seal
• Fill in oil through opening A until it runs out of opening B
Fig. 27: Oil drain plug on rear axle differential If the oil level in the differential remains constant:
• Tighten plugs A and B with new sealing rings to make oil-tight seals
After carrying out a test run:
• Check the oil level again after about 5 minutes, and fill up if necessary
Important!
Drain oil only after running the machine for a longer period of time (operating tem-
A B perature)!
Danger!
C
Careful when draining hot gearbox oil –
Fig. 29: Oil filler and inspection plug on the differential
Danger of burns!
☞ Wear protective gloves
☞ Use suitable tools, e.g. for unscrewing the oil drain plug!
☞ Proceed as follows:
• Park the machine on level ground when it is at operating temperature
• Clean and unscrew plugs A and B
• Place a container under plug C to collect the oil
• Completely drain the old oil
• Tighten drain plug C with a new sealing ring to make an oil-tight seal
• Fill in fresh oil through opening A until it runs out of opening B
• Tighten oil filler and inspection plugs A/B with new sealing rings to make oil-tight
seals
Caution!
After carrying out a test run:
☞ Check the oil level again after about 5 minutes, and fill up if necessary
Important!
Drain oil only after running the machine for a longer period of time!
A
☞ Check the oil level
• Park the machine on level ground and secure it against rolling away
• Place plug A in the position shown in fig. 30 (plug must be at the top)
Fig. 30: Oil filler and inspection plug on planetary drive • Clean and unscrew plug A (to release possible overpressure)
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil –
Danger of severe damage to the hydraulic system!
☞ Take care to avoid contamination when working!
☞ Always fill in hydraulic oil using the filling screen!
☞ Only use authorised oils of the same type
☞ – see Fluids and lubricants: overview on page 3-3
☞ Always fill in hydraulic oil before the level gets too low
☞ If the hydraulic system is filled with biodegradable oil, then only use biode-
gradable oil of the same type for filling up – observe the sticker on the
hydraulic oil tank
☞ Have the hydraulic oil replaced by an authorised workshop only
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dis-
pose of drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in
charge of oil disposal before disposing of biodegradable oil.
Telltale 50 on the instrument panel can come on in cold weather immediately after starting
the engine. This is caused by increased oil viscosity.
In this case:
☞ Set the engine revs so that telltale 50 (on the instrument panel) goes out
☞ Bear in mind the instructions concerning warmup
Caution!
Any excess quantity of hydraulic oil in the tank escapes via the breather B as
soon as the temperature rises!
The oil level is no longer visible in the upper half of the oil level sight glass A!
☞ Drain hydraulic oil
Danger!
Caution when draining hot hydraulic oil and removing the filter element –
Danger of burns!
☞ Wear protective gloves
☞ Use an oil drain coupling with a sufficiently long hose
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dis-
pose of drained hydraulic oil by an ecologically safe method!
Always contact the relevant authorities or commercial establishments in
charge of oil disposal before disposing of biodegradable oil.
☞ Proceed as follows:
• Park the machine on level ground
• Retract all hydraulic rams. To do this:
• Lower the telescopic boom completely
• Tilt in the tilt ram fully
A • Switch off the engine and prevent the machine from rolling away
• Unscrew breather filter A to release the pressure in the hydraulic oil tank
– there must be no pressure in the system!
• Place a suitable container under the machine at the rear to collect the oil as it drains
(minimum capacity 110 l)
• Remove filler cap C of oil drain valve D
• Place the end of the hose connected with the oil drain coupling in the container
• Screw the oil drain coupling onto the oil drain valve D
➥ The oil drain valve opens and the oil flows into the container
• Fill up the hydraulic oil
• See “Checking the hydraulic oil”
D • Unscrew the oil drain coupling from oil drain valve D. Screw on filler cap C of oil drain
C valve D
• Screw on breather filter A. Use a new breather filter depending on the maintenance
interval if necessary
• Bear in mind the maintenance interval for the hydraulic oil filter insert H. Replace the
filter insert if necessary
Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
Danger of personal injury!
☞ Always consult a doctor immediately, even if the wound seems insignificant
– otherwise serious infections could set in!
☞ Always observe the following instructions:
• Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
• Never weld or solder damaged or leaking pressure lines and screw con-
nections. Replace damaged parts with new ones!
• Never search for leaks with your bare hands, but wear protective gloves!
• Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
• Have damaged flexible lines replaced by authorised workshops only!
Important!
A
The machine has an oscillation-type rear axle. Grease the bearing at the latest
after every 20 service hours or once a week.
Both lubrication points A are located on the rear left side of the frame and are
routed to the axle bearing via hoses.
A A
C D B C
Environment!
Use a suitable container to collect the brake fluid as it drains and dispose of it
in an environmentally friendly manner!
A Danger!
MAX
MAX An incorrect brake fluid grade or an insufficient brake fluid level may impair the
safety of the brake system –
Danger!
The brake system is under pressure (30 – 35 bar) –
Danger of personal injury!
☞ As you bleed the brake system:
• Open bleed valves carefully
Danger!
An incorrect brake fluid grade or an insufficient brake fluid level may impair the
safety of the brake system –
Danger of accidents!
☞ Use only LHM brake fluids
☞ – see Fluids and lubricants: overview on page 3-3
☞ Ensure cleanliness when bleeding/replacing the brake fluid
Caution!
Do not apply the parking brake when bleeding!
☞ Release the parking brake with the switch (on the right on the instrument
panel)
Caution!
Use only the two outside bleed valves on the front axle (service brake).
☞ Connect the bleed container with the hose onto the bleed valve
☞ Open the bleed valve until you can clearly see that new brake fluid is coming out and
that there are no more air bubbles
☞ Close the bleed valve
☞ Repeat the procedure on all bleed valves in the order mentioned above
☞ Check the brakes for tightness and test the brakes
Environment!
Use a suitable container to collect the brake fluid as it drains and dispose of it
in an environmentally friendly manner!
B
N
Connections
• P = pump
• T = tank
• N = reversing fan
• B = quick coupler (mounted at the rear)
• Y = pressure line from the service brake to Y Y P
☞ Bleed as follows:
• Start the diesel engine
• Fit a hose onto the bleed valve and make sure the other end is in the container used
for collecting the brake fluid as it drains
• Open the bleed valve
• Press the brake pedal repeatedly until the oil comes out free of air from the bleed
valve
• Close the bleed valve
• Check the brake system for leaks and correct function
Caution!
Do not apply the parking brake when bleeding!
☞ Release the parking brake with the switch (on the right on the instrument
panel)
☞ Fit a hose onto the bleed valve and make sure the other end is in the container used for
collecting the brake fluid as it drains
☞ Carefully open bleed valve P (inside on either side) of the front axle until there is no
more air in the bleed hose
☞ Close bleed valve P
☞ Check the parking brake for correct function
Danger!
Improper tyre repairs –
Danger of accidents!
☞ All repair work on tyres and rims may only be carried out by authorised
workshops
Important!
Changing wheels
Danger!
Use of wrong tyres or wheels –
Danger of accidents!
☞ Use only wheels and tyres authorised for your telehandler – see the Opera-
tor's Manual
☞ Check the wheel nuts for tightness after every wheel or tyre change
Caution!
The wheels are heavy and can damage the threads on the wheel studs if they
are handled incorrectly!
☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack
etc.
Danger!
Lines and hoses containing refrigerants and cooling fluids are under pressure
and can be hot!
Danger of burns!
☞ Avoid touching parts containing refrigerants.
☞ Switch off the air conditioning.
Soldering and welding work on the closed system –
Danger of explosion!
☞ Have repair work carried out by an authorised workshop with trained staff
only
Caution!
The air conditioning system must be checked and serviced twice a year by
C trained staff in an authorised workshop!
☞ Replace dehumidifier A every two years
Caution!
D
B Have the air conditioning system serviced
and repaired by authorised staff only!
Fig. 51: Air conditioning compressor
Alternator
Always observe the following instructions:
• Only test run the engine with the battery connected
• When connecting the battery, make sure the poles (+/–) are not inverted
• Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
• Replace defective charge telltales immediately
Danger!
If a lightweight or superlightweight material bucket (see table) is fitted onto the
machine, the headlights are covered by the buckets in transport position –
Danger of accidents!
☞ When using a lightweight or superlightweight material bucket on public
roads, the headlight on the right-hand side mirror bracket must be mounted
in a higher position with an extra bracket (order no. ). Also readjust both
headlights
☞ – see Adjusting the headlights when using a lightweight material bucket on
page 3-53
☞ Mounting the headlights in higher positions and readjusting them must be
carried out by an authorised workshop
B
A C a b c
1. With tyres 425/75R20 and 405/70-20 (- 50 mm) 17.5LR24, 400/80R24 and 460/70R24 (+ 20 mm),
15.5-25 and 15.5-80-24 (+ 40 mm) 19.5LR24 and 500/70R24 (+ 60 mm)
Danger!
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells –
Danger of explosion!
☞ Open the caps of the battery openings by half a revolution before recharg-
ing the battery
☞ Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
☞ Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode!
☞ Always disconnect the negative terminal (–) from the battery before starting
repair work on the electric system!
Battery acid is highly caustic!
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
The battery is located underneath the access, on the left in driving direction. The battery is
low in maintenance and no fluid needs to be refilled under normal operating conditions.
However have the battery checked at regular intervals to make sure the electrolyte level is
between the MIN and MAX marks.
+ Always follow the specific battery safety instructions!
-
Replacing the battery
☞ Apply the parking brake with the switch
A ☞ Switch off the ignition and remove the ignition key
☞ Remove the key from the battery master switch (option)
☞ Remove the battery lead from the negative terminal (-)
Fig. 53: Battery
☞ Remove the battery lead from the positive terminal (+)
☞ Remove battery brackets A
☞ Replace the battery with a new one
☞ Install the battery in the reverse order
Caution!
When installing the battery leads,
☞ install the positive lead (+) first
☞ and then the negative lead (-)
Caution!
Make sure the coupling pin is engaged in the trailer coupling before cleaning
with high-pressure equipment!
☞ Apply a little more grease to the coupling pin and the base ring once cleaning is over
☞ Apply grease to the grease nipple on the joint
Danger!
Worn coupling pins, too much play in the bearing or a worn base ring –
Danger of accidents!
☞ Check the trailer coupling for wear and play
☞ Apply grease to the base ring
B
☞ Measure wear by means of a slide gauge on the thickest section of the coupling pin C
➥ Diameter C may not drop below 36.5 mm
36.5 mm ➥ Height-wise play B max. 2.5 mm
☞ Otherwise replace the coupling pin
C
☞ Check pin play D in the base ring and thickness E of the base ring
➥ Pin play D max. 2.5 mm
➥ Thickness E of base ring min. 7 mm
2.5 mm
D
Caution!
E
Repair work on the trailer coupling must be carried out by an authorised
workshop only
7 mm
Caution!
Therefore always observe the following instructions!
Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure may
• penetrate into the electric system and cause short circuits and
• damage seals and disable the controls!
Danger!
Soiled automatic seat belts may affect and impair winding –
Danger of personal injury!
☞ Only wind the seat belt when it is dry!
Danger!
Clean the engine at engine standstill only –
Danger of personal injury!
☞ Switch off the engine before cleaning
☞ Remove the ignition key
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
Caution!
The humidity penetrating the electronics causes it to fail and leads to engine
damage!
When cleaning the engine with a water or steam jet
☞ The engine must be cold
☞ Do not point the jet directly at any of the electric sensors such as tempera-
ture and oil pressure switches or control valves.
☞ Protect all electric parts, such as the alternator, connectors etc. from
humidity
☞ If the water jet is unintentionally pointed at electric components, dry them
with compressed air and apply contact spray to them.
Important!
Correct maintenance and service is absolutely necessary for smooth and continu-
ous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments!
88 kW diesel engine electric system: electric diagram 88 kW diesel engine electric system: electric diagram
Engine
103 kW diesel engine electric system: 103 kW diesel engine electric system:
electric diagram electric diagram
Engine
Fuel preheater (option): electric diagram Fuel preheater (option): electric diagram
Engine
Engine
Reversing function
• Switching the reversing fan solenoid valve (Y37) diverts the oil flow.
➥ The fan rotates in the other direction
Socket housing X15 (3 pole) Socket housing X23 (15 pole) Socket housing X40 (6 pole)
Socket housing X41 Socket housing X49 Socket housing X100 Pin housing X100
(22 pole) (14 pole) (1 pole) (1 pole)
Socket housing X15 Socket housing Socket housing Socket housing X42
(3 pole) X23 (15 pole) X40 (6 pole) (14 pole)
Socket housing X45 Socket housing Socket housing X49 Socket housing X79
(12 pole) X48 (9 pole) (14 pole) (6 pole)
Socket housing
X100 (1 pole)
Pin housing
Socket housing X100 (1 pole)
X80 (3 pole)
Disconnect X5 (7 pole)
Engine
Oil cooler
Auxiliary output: work hydrau- Connection from Connection to sepa- Fuel filter
lics pump separate oil filter rate oil filter
Connection to expan-
sion tank
Starter 12 V/3.0 kW
Alternator 12 V/95 A Turbocharger
Thermostat
Important!
Only run the diesel engine of a specific machine with a control valve having the
same serial number as the diesel engine.
Control valves cannot be exchanged without re-programming them.
Fig. 1: Control valve on engine (initial delivery)
In the event of engine damage, the replacement engine is delivered with a new control
X 83 valve which must be installed on the machine instead of the old control valve.
The sensors do not require any calibration.
In case of a guarantee claim, the rejected engine must be shipped together with its control
valve.
X 82 X 81
Fig. 2: Control valve on machine
Diagnosis connector
1
• Win GPi (1)
• Claas CDS (2)
Manual throttle
A final resistance is located on the wiring underneath the instrument panel if a machine is
not equipped with a manual throttle.
☞ Remove the final resistance from the wiring harness when retrofitting a manual throttle
☞ Connect the manul throttle regulator onto the wiring harness
The accelerator pedal and the manual throttle do not require any re-calibration
when replacing them in the event of damage.
2 3 1
Example:
Flashing code 2-3-1 =>2 short (0.4 sec) – 3 long (0.8 sec) – 1 short (0.4 sec)
➥ Engine oil pressure = not enough or too much oil in the engine
Please contact your dealer if you require more information
1-2-6 Manual throttle Open wiring or short circuit, signal not plausible
1-3-3 Customer-specific temperature Not within specified system reaction range (temperature 1)
1-3-4 Rail pressure Positive regulator divergence (speed-sensitive) not within specified range
1-3-5 Fuel metering unit Flow rate not within specified range
1-4-2 Engine operation telltale Open wiring or internal error of control unit
1-4-3 Multiple position switch Open wiring or short circuit, input voltage not within specificed range (switch 1)
1-4-7 Rail pressure sensor Signal divergence when starting or after run, beyond specified range
2-1-2 Revs sensor Motor runs only with camshaft revs signal
2-1-3 Revs sensor Phase displacement of crankshaft and camshaft revs signals
2-1-6 Low fuel pressure Below specified range with system reaction
2-1-9 Engine brake flap (actuator) Engine brake flap (actuator): open wiring or short circuit
2-2-3 Charge-air pressure Not within specified range with system reaction
2-2-7 Fuel temperature sensor Fuel temperature sensor: open wiring or short circuit
2-3-2 Coolant temperature Not within specified range with system reaction
2-3-5 Coolant level Not within specified range with system reaction
2-7-1 CAN bus switched off Open wiring or short circuit, switched off (CAN bus A)
5-1-3 Diagnostics telltale Open wiring or short circuit, prevented by control unit
5-2-1 Machine speed signal Speed over specified range, missing signal or not plausible
5-2-6 CAN message Missing or value over specified range (message “DecV1” = pseudopedal)
5-2-8 Engine brake (internal) Internal engine brake: open wiring or short circuit
5-3-1 Solenoid valve dwell period Not within specified range or missing (cylinder 1)
5-3-2 Solenoid valve dwell period Not within specified range or missing (cylinder 2)
5-3-3 Solenoid valve dwell period Not within specified range or missing (cylinder 3)
5-3-4 Solenoid valve dwell period Not within specified range or missing (cylinder 4)
Caution!
Install the longer projecting side of the toothing
towards the flywheel mass of the engine
Fuel filter
4.22 Fuel system (88/103 kW): overview
Manual pump
4-36
Engine
Engine
1
Reflux line
Suction line
Bleed as follows:
• After removing and fitting the fuel filter, prefilter or the fuel lines back on again
• After running the fuel tank empty
• After running the engine again, after it has been out of service for a longer period of
time
☞ Apply the parking brake with the switch
☞ Switch off the ignition and remove the ignition key
☞ Fill the fuel tank
☞ Place the container under the engine
☞ Open the engine cover
☞ Slacken flexible line 1 and pump with manual pump 2 until the fuel comes out free of air
☞ Tighten the flexible line.
☞ Open pressure retaining valve 3 and pump with manual pump 2 until the fuel comes out
free of air
☞ Close pressure retaining valve 3
☞ Start the engine and check for leaks
Expansion tank
To hydraulic pump
4-38
Engine
4-39
B
Engine
Reversing valve block
Valve for speed control
Reversing valve ➥ Controlled by Susmic
➥ De-energised = full revs
T
A
P
4.25 Fan circuit with reversing fan
Changeover valve T
A P
Y37
Revs control
The temperature sensor of the oil cooler transmits the temperature values to the steering
electronics (Susmic). The revs control valve is energised (580 mA) when the machine is
started with cold oil (below 40 °C), i.e. the fan runs at minimum revs.
➥ at diesel engine idling speed = 500 rpm
➥ at diesel engine maximum speed = 800 rpm
The Susmic system starts controlling the fan revs after about 5 minutes and sends more or
less current to the fan valve depending on the temperature of the oil.
➥ Up to 40 °C = 580 mA low revs
➥ Over 90 °C = 0 mA full revs
A Cable connection
from Susmic
Caution!
A
Dirt on the radiator fins reduces the radiator's heat dissipation capacity and
can cause damage to the engine and the hydraulic system!
Tip switch T for the reversing fan is located on the instrument panel on the right.
☞ Press tip switch T briefly to position B
➥ The fan rotates the other way round with a certain delay,
A ➥ the fan is in cleaning mode and the
➥ dirt is removed from the radiator
➥ This can be seen by the dust A blown out from the intake screen on the engine
cover
Fig. 16: Tip switch for reversing fan ➥ The fan automatically switches back to cooling mode after about 1 minute
Important!
When working in especially dusty environment, clean the radiator repeatedly and
more frequently!
Revs curve
About 40 s Time
✂
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Werkstatthandbuch
2012
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Workshop Manual
2012
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0312 0361
Werkstatthandbuch
2012
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0312 0361
Workshop Manual
2012
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Manuel d’Atelier
2012
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Manual de Taller
2012
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0312 0361
Manuel d’Atelier
2012
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0312 0361
Manual de Taller
2012
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Werkstatthandbuch
Workshop Manual
Manuel d’Atelier
0312 0361
Printed in Germany
All rights reserved
3rd Edition, © 06/2004
The engine company. Order No. 0312 0361
VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.
Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der Inhalte
zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den jeweils
behandelten Arbeitsgang visualisieren.
Allgemeine Hinweise:
- Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderli-
chen Ausrüstungen, Hand- und Spezialwerkzeuge, sowie deren einwandfreier
Zustand.
- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei Ver-
wendung von Original Teilen der DEUTZ AG sichergestellt.
- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.
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 AG 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 AG for
a specific purpose should be used.
Le présent Manuel d’Atelier décrit les travaux de réparation et de réglage à effectuer sur le moteur
et ses composants. Il est entendu que ces travaux doivent être réalisés par des personnes de métier
et qualifiées.
En vue d’une compréhension rapide du contenu de ce Manuel d’Atelier, les textes descriptifs brefs
sont accompagnés de symboles visualisant l’opération respectivement traitée.
Pour la commande des pièces de rechange, se reporter à la Liste des pièces de rechange respective.
Le présent Manuel d’Atelier n’est soumis à aucun service de mise à jour. Les modifications seront
reportées lors d’une nouvelle édition.
Pour les réparations, reportez-vous à nos Circulaires Techniques.
Instructions générales:
- Pour une réparation selon les règles de l’art, il est indispensable de disposer de tous
les équipements, outils manuels et spéciaux requis et en parfait état.
- Les éléments de moteurs tels que ressorts, agrafes, bagues élastiques etc. constituent
en cas de maniement incorrect, un danger accru de blessure.
- La remise en état du moteur doit répondre à son usage conforme – défini par le
constructeur du matériel. En cas de transformations, seules doivent être utilisées les
pièces agréées par DEUTZ AG pour l’application respective.
En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para
reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los
trabajos serán realizados por personal técnico especializado.
Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado
pictogramas significativos a los textos explicatorios, visualizando así el trabajo a realizar.
Advertencias generales:
- Haga lo necesario para que este Manual esté a disposición de toda persona que
participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el contenido.
- Se cumplirán las normas aplicables para la prevención de accidentes así como todas
las demás normas de seguridad y medicina laboral generalmente aceptadas.
- Es condición para la correcta reparación que estén disponibles todos los requeridos
equipos, herramientas manuales y especiales en perfecto estado.
- Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. , aumentan
en caso de tratamiento incorrecto el peligro de lesiones.
Repair of
Werkzeuge
Tools
Outils
Herramientas
Specification data
Caractéristiques techniques
Deutsch
English
Français
Español
mm mm mm mm
mm mm mm mm
4 040 6 060
101
126
2500
800
Viertakt - Diesel
Four-stroke diesel
Diesel à 4 temps
Diesel de 4 tiempos
mm mm mm mm
mm mm mm mm
mm mm mm mm
Direkteinspritzung
Direct injection
1
Injection directe
Inyección directa
19
30 - 38
1-3-4-2 1-5-3-6-2-4
643 628
Steuerzeiten ohne Valve timing without Calage de la distribution Cotas de reglaje sin
1 Stößel- und Ventilspiel tappet and
valve clearance
sans jeu de poussoirs
et de soupapes
juegos de válvulas y
de empujadores
Schmieröldruck in Lube oil pressure at low Pression d’huile au ralenti Presión de aceite a
niedrigem Leerlauf idling mini température marcha lenta en vacío,
Temperatur ca. 120 °C Temperature approx. environ 120 °C temperatura aprox. 120 °C
Öl SAE 15W/40 120 °C oil SAE 15W/40 huile SAE 15W/40 aceite SAE 15W/40
46
56
96
50
4 ± 0,4
0,8
1
Kurbelwellenstellung 1 Kurbelwellenstellung 2
Motor bis zum Erreichen der Ventilüber- Motor um eine volle Umdrehung (360°) weiter-
schneidung am Zyl. Nr. 1 durchdrehen. drehen.
Turn engine further by one complete Virer encore le moteur d’un tour Continuar girando el cigüeñal
revolution (360°). complet (360°). una vuelta entera (360°)
4-Zylinder 1
4-cylinder
4 cylindres Krümmerseite, elbow side
4 cilindros Côté collecteur, costado codo de escape
14 6 4 12
18 10 2 8 16
17 9 1 7 15
13 5 3 11
6-Zylinder
6-cylinder
6 cylindres Krümmerseite, elbow side
6 cilindros Côté collecteur, costado codo de escape
22 14 6 4 12 20
26 18 10 2 8 16 24
25 17 9 1 7 15 23
21 13 5 3 11 19
1
7 L
Hinweis:
Auf dem Schriftfeld für den Förderbeginn ist auch der Nockenwellentyp K, L, H, Q oder P angegeben. Dies ist bei der
Grundeinstellung der Einspritzpumpen, siehe Tabelle 1, unbedingt zu berücksichtigen.
Note:
Camshaft type K, L, H, Q or P is also indicated in the inscription field for the commencement of delivery.
It is absolutely necessary to take this into account for the basic setting of the injection pumps, see table 1.
Nota:
Dans la case indiquant le début d’injection figure aussi le type d’arbre à came K, L, H, Q ou P.
Il faut impérativement en tenir compte lors du calage de base de la pompe d’injection, voir tableau 1.
Nota:
En la casilla de inscripción correspondiente al comienzo de alimentación se indica también el tipo de árbol de levas
K , L, H, Q ó P. Es imprescindible considerar este dato para el ajuste básico de las bombas de inyección, ver tabla 1.
Tabelle 1 Tabelle 2
Motortyp Förderbeginn Nockenwelle Vorhub Vorhub Grundmaß Theor. Dicke Ausgleich- Theor. Dicke Ausgleich-
(FB) (Vh) Korrektur- E-Pumpe „TS“ scheiben- „TS“ scheiben-
Nenn./Tol. Typ Nennwert faktor (L0) dicke „SS“ dicke „SS“
(° kW v. OT) (mm) (mm/° kW) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0,0 K 4,80 0,14 117,5 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 2012 1,0 K 4,62 0,14 117,5 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 2012 2,0 K 4,44 0,14 117,5
1,15 - 1,249 1,2 2,65 - 2,749 2,7 1
BFM 2012 3,0 K 4,27 0,14 117,5
1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 2012 4,0 K 4,11 0,14 117,5
BFM 2012 5,0 K 3,95 0,14 117,5 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 2012 2,0 L 5,14 0,14 117,5 1,45 - 1,549 1,5 2,95 - 3,049 3,0
BFM 2012 3,0 L 4,97 0,14 117,5 1,55 - 1,649 1,6 3,05 - 3,149 3,1
BFM 2012 4,0 L 4,80 0,14 117,5 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 2012 5,0 L 4,62 0,14 117,5
1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 2012 6,0 L 4,44 0,14 117,5
1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 2012 7,0 L 4,26 0,14 117,5
BFM 2012 8,0 L 4,11 0,14 117,5 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 2012 9,0 L 3,95 0,14 117,5 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 2012 1,0 H 5,52 0,14 117,5 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 2012 2,0 H 5,36 0,14 117,5 2,25 - 2,349 2,3
BFM 2012 3,0 H 5,20 0,14 117,5
2,35 - 2,449 2,4
BFM 2012 4,0 H 5,05 0,14 117,5
BFM 2012 5,0 H 4,89 0,14 117,5
BFM 2012 6,0 H 4,73 0,14 117,5
BFM 2012 7,0 H 4,58 0,14 117,5
BFM 2012 8,0 H 4,43 0,14 117,5
BFM 2012 2,0 Q 5,31 0,14 117,5
BFM 2012 3,0 Q 5,14 0,14 117,5
BFM 2012 4,0 Q 4,97 0,14 117,5
BFM 2012 5,0 Q 4,80 0,14 117,5
BFM 2012 6,0 Q 4,62 0,14 117,5
BFM 2012 7,0 Q 4,44 0,14 117,5
BFM 2012 8,0 Q 4,26 0,14 117,5
BFM 2012 9,0 Q 4,11 0,14 117,5
BFM 2012 10,0 Q 3,95 0,14 117,5
BFM 2012 2,0 P 5,23 0,14 117,5
BFM 2012 3,0 P 5,08 0,14 117,5
BFM 2012 4,0 P 4,92 0,14 117,5
BFM 2012 5,0 P 4,76 0,14 117,5
BFM 2012 6,0 P 4,61 0,14 117,5
BFM 2012 7,0 P 4,46 0,14 117,5
BFM 2012 8,0 P 4,31 0,14 117,5
BFM 2012 9,0 P 4,16 0,14 117,5
BFM 2012 10,0 P 4,01 0,14 117,5
Zylinder Nr. 0 1 2 3 4 5 6
E - Pumpen Nr. xxx
FB Ist gemessen °kW 8
1 FB Nenn aus Tabelle 1 °kW 7
Vh Korr.faktor aus Tab. 1 mm/°kW 0,14
Vh Nenn aus Tabelle 1 mm 4,26
L0 aus Tabelle 1 mm 117,5
A/100 von E.-Pumpe mm 0,29
L gemessen mm 125,28
Table 1 Table 2
Engine type Commencement Camshaft Pre-stroke Pre-stroke Basic Theor. thickness Shim Theor. thickness Shim
of delivery (Vh) correction dimension ”TS“ thickness ”TS“ thickness
nom./tol. type nom. value factor inj. pump ”SS“ ”SS“
(°C/A BTDC) (mm) (mm/°C/A) (L0) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0.0 K 4.80 0.14 117.5 0.95 - 1.049 1.0 2.45 - 2.549 2.5
BFM 2012 1.0 K 4.62 0.14 117.5 1.05 - 1.149 1.1 2.55 - 2.649 2.6
BFM 2012 2.0 K 4.44 0.14 117.5
1.15 - 1.249 1.2 2.65 - 2.749 2.7 1
BFM 2012 3.0 K 4.27 0.14 117.5
1.25 - 1.349 1.3 2.75 - 2.849 2.8
BFM 2012 4.0 K 4.11 0.14 117.5
BFM 2012 5.0 K 3.95 0.14 117.5 1.35 - 1.449 1.4 2.85 - 2.949 2.9
BFM 2012 2.0 L 5.14 0.14 117.5 1.45 - 1.549 1.5 2.95 - 3.049 3.0
BFM 2012 3.0 L 4.97 0.14 117.5 1.55 - 1.649 1.6 3.05 - 3.149 3.1
BFM 2012 4.0 L 4.80 0.14 117.5 1.65 - 1.749 1.7 3.15 - 3.249 3.2
BFM 2012 5.0 L 4.62 0.14 117.5
1.75 - 1.849 1.8 3.25 - 3.349 3.3
BFM 2012 6.0 L 4.44 0.14 117.5
1.85 - 1.949 1.9 3.35 - 3.449 3.4
BFM 2012 7.0 L 4.26 0.14 117.5
BFM 2012 8.0 L 4.11 0.14 117.5 1.95 - 2.049 2.0 3.45 - 3.549 3.5
BFM 2012 9.0 L 3.95 0.14 117.5 2.05 - 2.149 2.1 3.55 - 3.649 3.6
BFM 2012 1.0 H 5.52 0.14 117.5 2.15 - 2.249 2.2 3.65 - 3.749 3.7
BFM 2012 2.0 H 5.36 0.14 117.5 2.25 - 2.349 2.3
BFM 2012 3.0 H 5.20 0.14 117.5
2.35 - 2.449 2.4
BFM 2012 4.0 H 5.05 0.14 117.5
BFM 2012 5.0 H 4.89 0.14 117.5
BFM 2012 6.0 H 4.73 0.14 117.5
BFM 2012 7.0 H 4.58 0.14 117.5
BFM 2012 8.0 H 4.43 0.14 117.5
BFM 2012 2.0 Q 5.31 0,14 117.5
BFM 2012 3.0 Q 5.14 0.14 117.5
BFM 2012 4.0 Q 4.97 0.14 117.5
BFM 2012 5.0 Q 4.80 0.14 117.5
BFM 2012 6.0 Q 4.62 0.14 117.5
BFM 2012 7.0 Q 4.44 0.14 117.5
BFM 2012 8.0 Q 4.26 0.14 117.5
BFM 2012 9.0 Q 4.11 0.14 117.5
BFM 2012 10.0 Q 3.95 0.14 117.5
BFM 2012 2.0 P 5.23 0.14 117.5
BFM 2012 3.0 P 5.08 0.14 117.5
BFM 2012 4.0 P 4.92 0.14 117.5
BFM 2012 5.0 P 4.76 0.14 117.5
BFM 2012 6.0 P 4.61 0.14 117.5
BFM 2012 7.0 P 4.46 0.14 117.5
BFM 2012 8.0 P 4.31 0.14 117.5
BFM 2012 9.0 P 4.16 0.14 117.5
BFM 2012 10.0 P 4.01 0.14 117.5
Cylinder No. 0 1 2 3 4 5 6
Injection pump No. xxx
FB measured °C/A 8
1 FB nom. from table 1 °C/A 7
Vh corr. factor from table 1 mm/°C/A 0.14
Vh nom. from table 1 mm 4.26
L0 from table 1 mm 117.5
A/100 of inj. pump mm 0.29
L measured mm 125.28
Tableau 1 Tableau 2
Type de moteur Début d’injection Arbre à Course à Facteur de Cote de base Epaisseur Epaisseur Epaisseur Epaisseur
(FB) cames débit nul (Vh) correction ppe d’injection théor. cale de théor. cale de
nom./tol. type valeur nom. course à débit nul (L0) ”TS“ réglage ”SS“ ”TS“ réglage ”SS“
(°vil. av. PMH) (mm) (mm/°vil.) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0,0 K 4,80 0,14 117,5 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 2012 1,0 K 4,62 0,14 117,5 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 2012
BFM 2012
2,0
3,0
K
K
4,44
4,27
0,14
0,14
117,5
117,5
1,15 - 1,249 1,2 2,65 - 2,749 2,7 1
1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 2012 4,0 K 4,11 0,14 117,5
BFM 2012 5,0 K 3,95 0,14 117,5 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 2012 2,0 L 5,14 0,14 117,5 1,45 - 1,549 1,5 2,95 - 3,049 3,0
BFM 2012 3,0 L 4,97 0,14 117,5 1,55 - 1,649 1,6 3,05 - 3,149 3,1
BFM 2012 4,0 L 4,80 0,14 117,5 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 2012 5,0 L 4,62 0,14 117,5
1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 2012 6,0 L 4,44 0,14 117,5
1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 2012 7,0 L 4,26 0,14 117,5
BFM 2012 8,0 L 4,11 0,14 117,5 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 2012 9,0 L 3,95 0,14 117,5 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 2012 1,0 H 5,52 0,14 117,5 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 2012 2,0 H 5,36 0,14 117,5 2,25 - 2,349 2,3
BFM 2012 3,0 H 5,20 0,14 117,5
2,35 - 2,449 2,4
BFM 2012 4,0 H 5,05 0,14 117,5
BFM 2012 5,0 H 4,89 0,14 117,5
BFM 2012 6,0 H 4,73 0,14 117,5
BFM 2012 7,0 H 4,58 0,14 117,5
BFM 2012 8,0 H 4,43 0,14 117,5
BFM 2012 2,0 Q 5,31 0,14 117,5
BFM 2012 3,0 Q 5,14 0,14 117,5
BFM 2012 4,0 Q 4,97 0,14 117,5
BFM 2012 5,0 Q 4,80 0,14 117,5
BFM 2012 6,0 Q 4,62 0,14 117,5
BFM 2012 7,0 Q 4,44 0,14 117,5
BFM 2012 8,0 Q 4,26 0,14 117,5
BFM 2012 9,0 Q 4,11 0,14 117,5
BFM 2012 10,0 Q 3,95 0,14 117,5
BFM 2012 2,0 P 5,23 0,14 117,5
BFM 2012 3,0 P 5,08 0,14 117,5
BFM 2012 4,0 P 4,92 0,14 117,5
BFM 2012 5,0 P 4,76 0,14 117,5
BFM 2012 6,0 P 4,61 0,14 117,5
BFM 2012 7,0 P 4,46 0,14 117,5
BFM 2012 8,0 P 4,31 0,14 117,5
BFM 2012 9,0 P 4,16 0,14 117,5
BFM 2012 10,0 P 4,01 0,14 117,5
Cylindre n° 0 1 2 3 4 5 6
Pompe d’inj. n° xxx
FB réel mesuré °vil. 8
1 FB nom. selon tableau 1 °vil. 7
Fact. corr. Vh selon tableau 1 mm/°vil. 0,14
Vh nom. selon tableau 1 mm 4,26
L0 selon tableau 1 mm 117,5
A/100 de ppe d’inj. mm 0,29
L mesuré mm 125,28
Tabla 1 Tabla 2
Tipo de motor Comienzo Arbol de levas Precurso Factor de Medida básica Espesor teór. Espesor Espesor teór. Espesor
de alimentación Tipo (Vh) corrección Bomba iny. ”TS“ arandela de ”TS“ arandela de
(”FB“, en alemán)
V.nom./tol. Valor nom. precurso (L0) reglaje ”SS“ reglaje ”SS“
(°cig. a. PMS) (mm) (mm/°cig.) (mm) (mm) (mm) (mm) (mm)
BFM 2012 0,0 K 4,80 0,14 117,5 0,95 - 1,049 1,0 2,45 - 2,549 2,5
BFM 2012 1,0 K 4,62 0,14 117,5 1,05 - 1,149 1,1 2,55 - 2,649 2,6
BFM 2012
BFM 2012
2,0
3,0
K
K
4,44
4,27
0,14
0,14
117,5
117,5
1,15 - 1,249 1,2 2,65 - 2,749 2,7 1
1,25 - 1,349 1,3 2,75 - 2,849 2,8
BFM 2012 4,0 K 4,11 0,14 117,5
BFM 2012 5,0 K 3,95 0,14 117,5 1,35 - 1,449 1,4 2,85 - 2,949 2,9
BFM 2012 2,0 L 5,14 0,14 117,5 1,45 - 1,549 1,5 2,95 - 3,049 3,0
BFM 2012 3,0 L 4,97 0,14 117,5 1,55 - 1,649 1,6 3,05 - 3,149 3,1
BFM 2012 4,0 L 4,80 0,14 117,5 1,65 - 1,749 1,7 3,15 - 3,249 3,2
BFM 2012 5,0 L 4,62 0,14 117,5
1,75 - 1,849 1,8 3,25 - 3,349 3,3
BFM 2012 6,0 L 4,44 0,14 117,5
1,85 - 1,949 1,9 3,35 - 3,449 3,4
BFM 2012 7,0 L 4,26 0,14 117,5
BFM 2012 8,0 L 4,11 0,14 117,5 1,95 - 2,049 2,0 3,45 - 3,549 3,5
BFM 2012 9,0 L 3,95 0,14 117,5 2,05 - 2,149 2,1 3,55 - 3,649 3,6
BFM 2012 1,0 H 5,52 0,14 117,5 2,15 - 2,249 2,2 3,65 - 3,749 3,7
BFM 2012 2,0 H 5,36 0,14 117,5 2,25 - 2,349 2,3
BFM 2012 3,0 H 5,20 0,14 117,5
2,35 - 2,449 2,4
BFM 2012 4,0 H 5.05 0,14 117,5
BFM 2012 5,0 H 4,89 0,14 117,5
BFM 2012 6,0 H 4,73 0,14 117,5
BFM 2012 7,0 H 4,58 0,14 117,5
BFM 2012 8,0 H 4,43 0,14 117,5
BFM 2012 2,0 Q 5,31 0,14 117,5
BFM 2012 3,0 Q 5,14 0,14 117,5
BFM 2012 4,0 Q 4,97 0,14 117,5
BFM 2012 5,0 Q 4,80 0,14 117,5
BFM 2012 6,0 Q 4,62 0,14 117,5
BFM 2012 7,0 Q 4,44 0,14 117,5
BFM 2012 8,0 Q 4,26 0,14 117,5
BFM 2012 9,0 Q 4,11 0,14 117,5
BFM 2012 10,0 Q 3,95 0,14 117,5
BFM 2012 2,0 P 5,23 0,14 117,5
BFM 2012 3,0 P 5,08 0,14 117,5
BFM 2012 4,0 P 4,92 0,14 117,5
BFM 2012 5,0 P 4,76 0,14 117,5
BFM 2012 6,0 P 4,61 0,14 117,5
BFM 2012 7,0 P 4,46 0,14 117,5
BFM 2012 8,0 P 4,31 0,14 117,5
BFM 2012 9,0 P 4,16 0,14 117,5
BFM 2012 10,0 P 4,01 0,14 117,5
Cilindro No. 0 1 2 3 4 5 6
Bomba de inyección No. xxx
“FB” real, medido °cig. 8
1 “FB” nominal seg. tabla 1 °cig. 7
Factor corr. precurso seg. tabla 1 mm/°cig. 0,14
Precurso nominal seg. tabla 1 mm 4,26
L0 seg. tabla 1 mm 117,5
A/100 de la bomba iny. mm 0,29
L medido mm 125,28
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012
BFM 2012
3,0
4,0
Q
Q
5,150
4,975
-
-
111,15
111,15
4,675 - 4,7249
4,725 - 4,7749
4,70
4,75
5,625 - 5,6749
5,675 - 5,7249
5,65
5,70
1
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012 3,0 Q 5,150 - 111,15 4,675 - 4,7249 4,70 5,625 - 5,6749 5,65 1
BFM 2012 4,0 Q 4,975 - 111,15 4,725 - 4,7749 4,75 5,675 - 5,7249 5,70
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012
BFM 2012
3,0
4,0
Q
Q
5,150
4,975
-
-
111,15
111,15
4,675 - 4,7249
4,725 - 4,7749
4,70
4,75
5,625 - 5,6749
5,675 - 5,7249
5,65
5,70
1
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
BFM 2012 2,0 Q 5,325 - 111,15 4,625 - 4,6749 4,65 5,575 - 5,6249 5,60
BFM 2012
BFM 2012
3,0
4,0
Q
Q
5,150
4,975
-
-
111,15
111,15
4,675 - 4,7249
4,725 - 4,7749
4,70
4,75
5,625 - 5,6749
5,675 - 5,7249
5,65
5,70
1
4,775 - 4,8249 4,80 5,725 - 5,7749 5,75
BFM 2012 2,0 P 5,231 - 111,15 4,825 - 4,8749 4,85 5,775 - 5,8249 5,80
BFM 2012 3,0 P 5,074 - 111,15 4,875 - 4,9249 4,90 5,825 - 5,8749 5,85
4,925 - 4,9749 4,95 5,875 - 5,9249 5,90
4,975 - 5,0249 5,00 5,925 - 5,9749 5,95
5,025 - 5,0749 5,05 5,975 - 6,0249 6,00
5,075 - 5,1249 5,10 6,025 - 6,0749 6,05
5,125 - 5,1749 5,15 6,075 - 6,1249 6,10
5,175 - 5,2249 5,20 6,125 - 6,1749 6,15
5,225 - 5,2749 5,25 6,175 - 6,2249 6,20
5,275 - 5,3249 5,30 6,225 - 6,2749 6,25
5,325 - 5,3749 5,35 6,275 - 6,3249 6,30
5,375 - 5,4249 5,40 6,325 - 6,3749 6,35
5,425 - 5,4749 5,45 6,375 - 6,4249 6,40
5,475 - 5,5249 5,50
5,525 - 5,5749 5,55
Beispiel: An einem BF6M 2012 ist die Einspritzpumpe von Zylinder 3 zu ersetzen.
Vorgehensweise:
Vom Firmenschild in der Rubrik „EP“ den EP-Code für Zylinder 3 ablesen, z.B. 295.
(Lesefolge: Zeile 1 = Zyl.1, Zeile 2 = Zyl.2, u.s.w.) 1
Kennzahl für Einspritzpumpenlänge (A) von der neuen Einspritzpumpe ablesen, z.B. 42.
Grundmaß der Einspritzpumpe (L0 ) aus Tabelle 1 entnehmen, z.B. 117,5 mm.
The old injection pump with shim is not required for such purpose.
Take corrected injection pump installation dimension (EK) from table 3 according to EP code, e.g. 120.875 mm.
Table 3
Read off code for injection pump length (A) from new injection pump, e.g. 42.
Take basic dimension of injection pump (L0 ) from table 1, e.g. 117.5 mm
1.00.17
© 2004 / 0312 0361
Déterminer l’épaisseur de cale de réglage pour le début d’injection
lors d’un remplacement de pompe d’injection dans le cadre du Service.
Cote de base L0 = 117,5 mm
L’ancienne pompe d’injection et cale de réglage n’est pas nécessaire pour cela.
Méthode à suivre:
Sur la plaque signalétique relever sous « EP » le code EP pour le cylindre 3, p.ex. 295
(Lire: ligne 1 = cyl. 1, ligne 2 = cyl. 2 etc.) 1
Relever la cote corrigée d’adaptation de pompe d’injection (EK) du tableau 3 selon le code EP;
p.ex. 120,875 mm.
Tableau 3
Relever la caractéristique de longueur de pompe d’injection (A) pour la nouvelle pompe d’injection, p.ex. 42.
Relever la cote de base de la pompe d’injection (L0 ) du tableau 1, p.ex. 117,5 mm.
Modo de proceder:
Leer de la placa de fabricante, en la columna „EP“, el código EP para el cilindro 3, p.ej. 295.
(Secuencia de lectura: línea 1 = cil. 1, línea 2 = cil. 2, etc.) 1
Tomar de la tabla 3 la medida de montaje corregida (EK) que corresponde al código EP de la bomba de inyección,
p.ej. 120,875 mm.
Tabla 3
Tomar de la placa de características de la nueva bomba de inyección el código de longitud (A), p.ej. 42.
Tomar de la tabla 1 la medida básica (L0 ) de la bomba de inyección, p.ej. 117,5 mm.
Beispiel: An einem BF6M 2012 ist die Einspritzpumpe von Zylinder 3 zu ersetzen.
Vorgehensweise:
Vom Firmenschild in der Rubrik „EP“ den EP-Code für Zylinder 3 ablesen, z.B. 665.
(Lesefolge: Zeile 1 = Zyl.1, Zeile 2 = Zyl.2, u.s.w.)
1
Korrigiertes Einspritzpumpeneinbaumaß (EK) aus Tabelle 3.1 entsprechend dem EP-Code entnehmen,
z.B. 117,525 mm.
Tabelle 3.1
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Kennzahl für Einspritzpumpenlänge (A) von der neuen Einspritzpumpe ablesen, z.B. 42.
Grundmaß der Einspritzpumpe (L0 ) aus Tabelle 1.1 entnehmen, z.B. 111,15 mm.
The old injection pump with shim is not required for such purpose.
Procedure:
Read off EP code for cylinder 3 from name plate under column ”EP“, e.g. 665.
(Reading sequence: line 1 = cyl. 1, line 2 = cyl. 2, etc.) 1
Take corrected injection pump installation dimension (EK) from table 3.1 according to EP code, e.g. 117.525 mm.
Table 3.1
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Read off code for injection pump length (A) from new injection pump, e.g. 42.
Take basic dimension of injection pump (L0 ) from table 1.1, e.g. 111,15 mm
Déterminer l’épaisseur de cale de réglage pour le début d’injection lors d’un remplacement
de pompe d’injection dans le cadre du Service. Cote de base L0 = 111,15 mm
L’ancienne pompe d’injection et cale de réglage n’est pas nécessaire pour cela.
Méthode à suivre:
Sur la plaque signalétique relever sous « EP » le code EP pour le cylindre 3, p.ex. 665.
(Lire: ligne 1 = cyl. 1, ligne 2 = cyl. 2 etc.) 1
Relever la cote corrigée d’adaptation de pompe d’injection (EK) du tableau 3.1 selon le code EP;
p.ex. 117,525 mm.
Tableau 3.1
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Relever la caractéristique de longueur de pompe d’injection (A) pour la nouvelle pompe d’injection, p.ex. 42.
Relever la cote de base de la pompe d’injection (L0 ) du tableau 1.1, p.ex. 111,15 mm.
Modo de proceder:
Leer de la placa de fabricante, en la columna „EP“, el código EP para el cilindro 3, p.ej. 665.
(Secuencia de lectura: línea 1 = cil. 1, línea 2 = cil. 2, etc.) 1
Tomar de la tabla 3.1 la medida de montaje corregida (EK) que corresponde al código EP de la bomba de inyección,
p.ej. 117,525 mm.
Tabla 3.1
115,9 600 116,5 624 117,1 648 117,7 672 118,3 696
115,925 601 116,525 625 117,125 649 117,725 673 118,325 697
115,95 602 116,55 626 117,15 650 117,75 674 118,35 698
115,975 603 116,575 627 117,175 651 117,775 675 118,375 699
116 604 116,6 628 117,2 652 117,8 676
116,025 605 116,625 629 117,225 653 117,825 677
116,05 606 116,65 630 117,25 654 117,85 678
116,755 607 116,675 631 117,275 655 117,875 679
116,1 608 116,7 632 117,3 656 117,9 680
116,125 609 116,725 633 117,325 657 117,925 681
116,15 610 116,75 634 117,35 658 117,95 682
116,175 611 116,775 635 117,375 659 117,975 683
116,2 612 116,8 636 117,4 660 118 684
116,225 613 116,825 637 117,425 661 118,025 685
116,25 614 116,85 638 117,45 662 118,05 686
116,275 615 116,875 639 117,475 663 118,075 687
116,3 616 116,9 640 117,5 664 118,1 688
116,325 617 116,925 641 117,525 665 118,125 689
116,35 618 116,95 642 117,55 666 118,15 690
116,375 619 116,975 643 117,575 667 118,175 691
116,4 620 117 644 117,6 668 118,2 692
116,425 621 117,025 645 117,625 669 118,225 693
116,45 622 117,05 646 117,65 670 118,25 694
116,475 623 117,075 647 117,675 671 118,275 695
Tomar de la tabla 1.1 la medida básica (L0 ) de la bomba de inyección, p.ej. 111,15 mm.
Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muss das korrigierte Einbaumaß (EK) neu ermittelt und der
dazugehörende EP-Code auf dem Firmenschild geändert werden.
Tabellen siehe Seite 1.00.15. bis 1.00.17.1
1
Berechnungsbeispiel BFM 2012
Zylinder Nr. 0 1 2 3 4 5 6
L0 aus Tabelle 1 mm 117,5
FB Ist gemessen °KW 8
FB Nenn aus Tabelle 1 °KW 7
Vh Korr.faktor aus Tab. 1 mm/°KW -
Vh Nenn aus Tabelle 1 mm 4,26
L gemessen mm 125,13
- -
- -
- -
EK = L - Vh Nenn mm 120,87
EK symmetrisch gerundet mm 120,875
EP-Code aus Tabelle 3 295
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be determined once again
and the relevant EP code on the name plate must be changed.
For tables see pages 1.00.15 to 1.00.17.1
1
Calculation example: BFM 2012
Cylinder No. 0 1 2 3 4 5 6
L0 from table 1 mm 117,5
FB measured °C/A 8
FB nom. from table 1 °C/A 7
Vh corr. factor from table 1 mm/°C/A -
Vh nom. from table 1 mm 4,26
L measured mm 125,13
- -
- -
- -
EK = L - Vh nom. mm 120,87
EK symm. rounded mm 120,875
EP code from table 3 295
En cas de remplacement du bloc-moteur, de l’arbre à cames ou de poussoir à galet, il faut déterminer de nouveau la cote d’adaptation
corrigée (EK) et modifier le code EP correspondant sur la plaque signalétique.
Tableaux, voir pages 1.00.15 - 1.00.17.1
- -
- - -
- - -
EK = L - Vh nom. mm 120,87
EK symétriquement arrondi mm 120,875
Code EP selon tableau 3 295
Para la sustitución del bloque motor, árbol de levas o empujadores de rodillo es necesario determinar nuevamente la medida
de montaje corregida (EK) y modificar el correspondiente código EP en la placa de fabricante.
Para las tablas, ver págs. 1.00.15 - 1.00.17.1
1
Ejemplo de cálculo: BFM 2012
Cilindro No. 0 1 2 3 4 5 6
L0 seg. tabla 1 mm 117,5
“FB” real, medido °cig. 8
“FB” nominal seg. tabla 1 °cig. 7
Factor corr. precurso seg. tabla 1 mm/°cig. -
Precurso nominal seg. tabla 1 mm 4,26
L medido mm 125,13
- -
- -
- -
EK = L - Precurso nominal mm 120,87
EK redondeado simétricamente mm 120,875
Código EP seg. tabla 3 295
Bei Austausch von Kurbelgehäuse, Nockenwelle oder Rollenstößel muss das korrigierte Einbaumaß (EK) neu ermittelt und der
dazugehörende EP-Code auf dem Firmenschild geändert werden.
Tabellen siehe Seite 1.00.15. bis 1.00.17.1
1
Berechnungsbeispiel BFM 2012
Zylinder Nr. 0 1 2 3 4 5 6
L0 aus Tabelle 1.1 mm 111.15
FB Ist gemessen °KW 5
FB Nenn aus Tabelle 1.1 °KW 3
Vh Korr.faktor aus Tab. 1.1 mm/°KW -
Vh Nenn aus Tabelle 1.1 mm 5,15
L gemessen mm 122,67
- -
- -
- -
EK = L - Vh Nenn mm 117,52
EK symmetrisch gerundet mm 117,525
EP-Code aus Tabelle 3.1 665
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be determined once again
and the relevant EP code on the name plate must be changed.
For tables see pages 1.00.15 to 1.00.17.1
1
Calculation example: BFM 2012
Cylinder No. 0 1 2 3 4 5 6
L0 from table 1.1 mm 111,15
FB measured °C/A 5
FB nom. from table 1.1 °C/A 3
Vh corr. factor from table 1.1 mm/°C/A -
Vh nom. from table 1.1 mm 5,15
L measured mm 122,67
- -
- -
- -
EK = L - Vh nom. mm 117,52
EK symm. rounded mm 117,525
EP code from table 3.1 665
En cas de remplacement du bloc-moteur, de l’arbre à cames ou de poussoir à galet, il faut déterminer de nouveau la cote d’adaptation
corrigée (EK) et modifier le code EP correspondant sur la plaque signalétique.
Tableaux, voir pages 1.00.15 - 1.00.17.1
11
Exemple de calcul: BFM 2012
Cylindre n° 0 1 2 3 4 5 6
L0 selon tableau 1.1 mm 111,15
FB réel mesuré °vil. 5
FB nom. selon tableau 1.1 °vil 3
Fact. corr. Vh selon tableau 1.1 mm/°vil -
Vh nom. selon tableau 1.1 mm 5,15
L mesuré mm 122,67
- -
- -
- -
EK = L - Vh nom. mm 117,52
EK symétriquement arrondi mm 117,525
Code EP selon tableau 3.1 665
Para la sustitución del bloque motor, árbol de levas o empujadores de rodillo es necesario determinar nuevamente la medida
de montaje corregida (EK) y modificar el correspondiente código EP en la placa de fabricante.
Para las tablas, ver págs. 1.00.15 - 1.00.17.1
1
Ejemplo de cálculo: BFM 2012
Cilindro No. 0 1 2 3 4 5 6
L0 seg. tabla 1.1 mm 111,15
“FB” real, medido °cig. 5
“FB” nominal seg. tabla 1.1 °cig. 3
Factor corr. precurso seg. tabla 1.1mm/°cig. -
Precurso nominal seg. tabla 1.1 mm 5,15
L medido mm 122,67
- -
- -
- -
EK = L - Precurso nominal mm 117,52
EK redondeado simétricamente mm 117,525
Código EP seg. tabla 3.1 665