TBD 645, WH, en

0297 …
4. 6.
✂
3.
✂
Workshop Manual
5. TBD 645
✂
Workshop Manual
1. TBD 645
✂
✂
2.
This page intentionally left blank.
Workshop Manual
TBD 645
0299 6399 en
Engine number:
Please enter the engine number here. This will make it easier for us to
help you in questions of after-sales service, repairs and spare parts.
We reserve the right to make technical changes in the illustrations and

particulars given in these operating instructions if such changes are
necessary to improve the engines. Reprints and duplication of any
kind, even in excerpts, require our written permission.
Engine manufacturer:
Motoren-Werke Mannheim AG
(DEUTZ MWM)
Carl-Benz-Str. 5
D-68167 Mannheim
Tel. (06 21) 3 84-0

Tx. 462341
Fax (06 21) 3 84-83 86
DEUTZ MWM
TBD 645
This documentation is intended for the following engine
● Engine type:
● Applicaton:
● System name:
● Rating: kW
● Speed: / min
● Commissioned on : 19
Please enter the relevant data. This will make it easier for us to help you in questions of after-sales
service, repairs and spare parts.
These documentation must be presented to the responsible serviceperson every time any service work
is provided.
Imprint:
DEUTZ AG
Service-Technik
Servicedokumentation
Deutz-Mülheimer-Straße 147–149
D-51057 Köln
Tel.: (02 21) 8 22-0
Fax: (02 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
(1) 1197
Ordering No.: 0299 6399 en
Page II 0299 4668-0108 1197

DEUTZ MWM
Engines
● Please read all the information contained in this manual, and follow the instructions carefully. You will avoid
accidents, retain the manufacturer’s warranty, and will be able to use a fully functional and operational
engine.
● This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined
by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The
manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely
by the user.
● The term „intended use“ shall also include compliance with the operating, maintenance and repair
conditions specified by the manufacturer. The engine may be used, maintained and repaired only by
persons who are familiar with the work concerned and who have been properly informed of the risks
involved.
● Make sure that these operating instructions are available to everyone involved in operating, maintaining,
and repairing the engine, and that they have all understood the contents.
● Non-compliance with these operating instructions may result in engine malfunctions and even damage or
injury to persons; the manufacturer will accept no liability in such cases.
● Proper maintenance and repair work depends on the availability of all requisite equipment, tools and special
implements, all of which must be in perfect condition.
● Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled
properly.
● The relevant accident prevention regulations and other generally recognized rules relating to safety
engineering and health and safety at work must all be complied with.
● Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are
used.
● Engine repairs must correspond to the intended use. In the event of modification work, only parts approved
by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will
preclude any liability of the manufacturer for resultant damage.
0997 0299 3235-0199 Page III

Forword DEUTZ MWM
Engines
Dear customer,
The engines of the DEUTZ MWM brand have been developed for a broad spectrum of applications.
A comprehensive range of different variants ensures that special requirements can be met for the
individual case involved.
Your engine has been equipped to suit your own particular installation, and accordingly not all of the
devices and components described in these operating instructions will actually be fitted to your engine.
We have endeavoured to present the differences involved as clearly as possible, to make it easier for
you to find the operating and maintenance instructions you need for your own particular engine.
Please read this manual before you start up your engine, and follow the operating and maintenance
instructions meticulously.
If you have any questions, just get in touch with us, and we will be pleased to answer them for you.
Yours sincerely,
DEUTZ AG
Page IV 0299 3235-0199 0997

DEUTZ MWM General
Engines
DEUTZ MWM engines

are the culmination of long years filled with research and development work. The in-depth know-how
thus acquired, in conjunction with high standards of quality, is your guarantee for engines manufactured
for long lifetime, high reliability and low fuel consumption. And of course, stringent criteria of
environment-friendliness are met as well.
Care and maintenance

are crucial factors in ensuring that your engine satisfactorily meets the requirements involved.
Compliance with the specified maintenance intervals and meticulous performance of care and
maintenance work are therefore absolutely essential. Special attention must be paid to any more
critical operating conditions deviating from the norm.
DEUTZ AG
In the event of malfunctions, or if you need spare parts, please contact one of our responsible service
agencies. Our trained and qualified staff will ensure fast, professional rectification of any damage,
using original parts.
Original parts from DEUTZ AG have always been manufactured to the very latest state-of-the-art.
You will find details of our after-sales service at the end of these operating instructions.
Careful when the engine is running!

Carry out maintenance or repair jobs only when the engine is at a standstill. If you remove any
protective features, fit them back in position after completing your work. Always wear tight-fitting
clothing if you are working on the engine while it is running.
Safety
You will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safety
instructions to your operating staff as well. In addition, comply with the statutory general safety and
accident prevention regulations applying in your country.
Instruction
You will find this symbol next to instructions of a general nature.
Follow these instructions carefully.
Asbestos
The seals and gaskets used in this engine are asbestos-free. Please use the appropriate spare
parts for maintenance and repair jobs.
0997 0299 3235-0199 Page V

Quick Introduction DEUTZ MWM
Engines and Systems
QUICK INTRODUCTION (FOR TRAINED AND QUALIFIED PERSONNEL)
GETTING OPERATING INSTRUCTIONS

➠ Chap. 1 Advice to users
STARTED
⇓
Chap. 2 Description
⇓
Chap. 3 Operation
⇓
Chap. 4 Expendables
⇓
Chap. 10 Test reports
NORMAL OPERATING INSTRUCTIONS

OPERATION ➠ Chap. 3 Operation
⇓
Chap. 4 Expendables
MAINTENANCE OPERATING INSTRUCTIONS

➠ Chap. 1 Advice to users
⇓
Chap. 4 Expendables
⇓
Chap. 5 Maintenance and
Servicing
⇓
Chap. 8 Technical data
⇓
Chap. 9 Maintenance work
⇓
SPARE PARTS CATALOGUE
Spare parts
⇓
DEUTZ Service
Page VI 0299 3232-0199 0997

DEUTZ MWM Quick Introduction
Engines and Systems
OPERATING INSTRUCTIONS
SERVICING ➠ Chap. 1 Advice to users
⇓
Chap. 5 Maintenance and
Servicing
⇓
⇓
WORKSHOP MANUAL
Servicing work
⇓
SPARE PARTS CATALOGUE
Spare parts
⇓
DEUTZ Service
MALFUNCTIONS IN OPERATING INSTRUCTIONS

OPERATION
➠ Chap. 6 Operational disturbances
causes, corrective action
⇓
⇓
Chap. 10 Test reports
⇓ ⇓
WORKSHOP MANUAL
Chap. 9 Maintenance work Servicing work
⇓ ⇓
SPARE PARTS CATALOGUE SPARE PARTS CATALOGUE
Spare parts Spare parts
⇓ ⇓
DEUTZ Service DEUTZ Service
0997 0299 3232-0199 Page VII

DEUTZ MWM
Engines and Systems
Page VIII 0299 3232-0199 0997

DEUTZ MWM Contents
TBD 645
0 Introduction
Imprint, foreword, quick introduction, contents
1 Advice to users
1.1 General remarks
1.2 Safety instructions / Accident prevention
1.3 Operating instructions and Workshop manual
1.4 Job cards
1.5 Spare parts
2 Job Cards
2.1 Overviews
2.1.1 Arranged alphabetically
2.1.2 Arranged by Job Card Numbers
2.1.3 Description of symbols
2.2 Job Cards arranged by Job Card Numbers
Service
1197 0299 4669-0108 Page IX

Contents DEUTZ MWM
TBD 645
Page X 0299 4669-0108 1197

DEUTZ MWM Advice to users
Engines and Systems
1 Advice to users 1
1.1 General remarks
1.3 Operating instructions and Workshop manual
1.4 Job cards
1.5 Spare parts
0997 0299 3245-0199 Chapter 1 - Page 1

Advice to users DEUTZ MWM
Engines and Systems
1 1 Advice to users
1.1 General remarks

The maintenance and servicing jobs specified in this manual must be carried out punctually and completely.
The maintenance and servicing staff must possess the necessary technical knowledge required for doing their
jobs properly. Any safety and protective features which had to be removed during maintenance and servicing
work must be fitted back in place after completion.
The accident prevention and safety regulations must by always be complied with throughout
all maintenance and servicing work.
Also note the special safety instructions for the various servicing groups which are listed
in detail as job cards in the Chapter „Job Cards“ see also Chapter 1.2).
The maintenance and servicing intervals are given in the maintenance and servicing schedule, which also
provides information on the jobs required.
The job cards (Chapter 9) give technical instructions on how to actually perform the jobs.

For various servicing groups, detailed safety advice has have been drawn up in the form of job cards;
they are listed before the job cards of the respective servicing groups.
The statutory accident prevention regulations have to be complied with (obtainable from professional
associations or in specialized bookshops). They depend on the installation site, the operating mode and
the expendables and auxiliary materials used.
Special protective arrangements dependent on the particular jobs are indicated and marked in the job
description.
In general, the following applies:
● for the personnel:
- Only trained personnel may operate or maintain the engine. Unauthorized persons are not
allowed to enter the machine room.
- When the engine is in operation, wear only tight-fitting clothes and ear muffs in the machine room.
- Use only professionally qualified staff for repair work.
● for the machine room:

- Ensure sufficient ventilation (do not cover air shafts).
- Provide first-aid kit and suitable fire extinguishers and check their contents and serviceability at
regular intervals.
- Only store combustible materials in the machine room if they are necessary for the operation of
the system.
- Smoking and open flames are not allowed in the machine room.
● for operation and maintenance of the engine:

- Only start the engine when all protective devices have been installed and the turning device has
been removed. Make sure that there is nobody in the danger area.
- Only carry out any cleaning, maintenance and repair work when the motor is shut down and
secured against starting.
Chapter 1 - Page 2 0299 3245-0199 0997

Engines and Systems
1.3 Operating instructions and Workshop manual 1

In order to provide a user-specific information structure, the service documentation has been divided into the
Operating Instructions and the Workshop Manual.
The Operating Instructions include a general description as well as instructions for all necessary maintenance
jobs.
In detail, they contain the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Engine description
3 Operating the engine, with
- Work routines before initial start-up and after every inspection
- Work routines before start-up
- Start-up
- Operational monitoring
- Shutting down the engine
- Emergency operation if components fail (if necessary and possible).
4 Instructions for expendables
5 Maintenance and servicing, with
- Tools and equipment overview
- Maintenance and servicing schedules
6 Operational malfunctions, their causes and how to correct them
7 Engine conservation
8 Technical particulars
9 Job Cards, arranged by Job Card Numbers
10 Sundry other instructions (if not included in the appendix or in separate files)
After-sales service
• Global service directory.
The Workshop Manual presopposes knowledge of the contents of the Operating Instructions. This particularly
applies to the safety instructions. It describes easy repair jobs and emergency measures on components, which
are more elaborate to peform, and require appropriately qualified professional staff.
It contains the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Job Cards, arranged by Job Card Numbers
After-sales service
• Global service directory.
1.4 Job cards

The Job cards are divided into maintenance Job Cards of Operating instructions, for example B 1-1-1 and
servicing Job Cards of the Workshop Manual, for example W 4-5-1.
For the numbering please refer to Fig. 101.
The structure of a Job Card is shown in Fig. 102.
0997 0299 3245-0199 Chapter 1 - Page 3

Engines and Systems
1
Type of documentation
• The letter at the front signifies the type of documentation involved.
➠ B = Operating Instructions
W = Workshop Manual
Maintenance Group (the same for all engines)

➠ 0 General remarks / cross-category jobs 8 Lube oil system
1 Cylinder head 9 Coolant system
2 Drive mechanism 10 Compressed air system
3 Crankcase 11 Monitoring system
4 Engine control 12 Other components
5 Governor 13 Electrical system
6 Exhaust gas system / Charging
7 Fuel system
Subsystem (component)
• The subsystems are distinguished by maintenance groups.
• Generally valid:
➠ 0 Cross-subsystem or Safety Regulations
1 System parameters or general checks
Serial Number
• Counting per subsystem (component)
• Various jobs per subsystem (component)
• Version differences
B 3-3-3 80307 0
Fig. 101 Numbering of the Job Cards
Chapter 1 - Page 4 0299 3245-0199 0997

Engines and Systems
80300 1
Fig. 102 Structure of the Job Cards
1 DEUTZ AG, 10 Date of issue of the Job Cards

editor of the service documentation
11 Sequence of operations, work procedure
2 DEUTZ MWM, manufacturer, and
12 Safety instructions and general hints
engine type to which the Job Card refers
13 Full title of the Job Card
3 Short title of the Job Card
If you have any questions on the Job Card,
4 Number of the Job Card
please always state the engine type (2), the
5 Necessary tools, equipment, and number (4), the page (8), the date of issue
spare parts (10) or, as an alternative, the Internal part
number (9).
6 Reference to further Job Cards,
instructions, etc.
7 Explanatory diagrams
8 Present page of total number of pages
9 Internal part number of the Job Card
0997 0299 3245-0199 Chapter 1 - Page 5

Engines and Systems
1 1.5 Spare parts

You will receive spare parts from Messrs. DEUTZ AG.
You will find a list of the spare parts in the engine’s
spare parts list.
Chapter 1 - Page 6 0299 3245-0199 0997

DEUTZ MWM Job Cards
TBD 645
2 Job Cards 2
2.1 Overviews
2.1.2 Arranged by Job Card Numbers
2.1.3 Description of symbols
B 0-1-2
B 3-3-3
W 2-1-4
1197 0299 4670-0108 Chapter 2 - Page 1

Job Cards DEUTZ MWM
TBD 645
2 2 Job Cards
2.1 Overviews
Job Job Card
Bearing spread, checking W 2-1-1
Camshaft bearing, removing, installing and checking W 4-1-1
Camshaft’s vibration absorber, removing and mounting W 4-9-1
Combustion compartment, endoscoping W 0-2-7
Connecting-rod bearing, checking W 2-5-4
Control rod, adjusting after replacing the injection pump W 7-2-2
Coolant pump, reconditioning W 9-7-2
Cracks, checking for, applying the liquid method W 0-3-2
Crank web breathing, checking W 2-1-5
Crankshaft’s axial clearance, checking W 2-1-4
Crankshaft’s wearing ring halves, removing and installing W 2-7-3
Cylinder head, removing and fitting W 1-4-4
Cylinder liner, checking W 3-3-1
Deep-groove bearing, replacement criteria W 2-0-2
Delivery beginning, checking and adjusting W 7-6-1
Emergency operation in the event of a cylinder station breakdown W 0-2-2
Flywheel, removing and mounting W 12-6-1
Gear box (drive end), removing and mounting W 3-9-1
Gear train (drive end), checking W 4-4-4
Gear train (drive end), removing and installing W 4-4-3
Gear train (free end), removing and installing W 4-4-1
Hydraulic clamping device, filling and bleeding W 0-0-1
Injection pump drive, removing and installing W 7-4-7
Injection pump, checking W 7-4-4
Injection pump, reconditioning W 7-4-2
Injection pump, removing and mounting W 7-4-1
Inlet valve, checking W 1-5-2
Inlet valve, reconditioning W 1-5-6
Intercooler (water and air sides), cleaning W 6-4-3
Liquid nitrogen, jobs involving W 0-3-1
Lower valve actuator, removing, installing and checking W 4-2-1
Lube oil cooler, removing, mounting and cleaning W 8-8-2
Lube oil pump (6 cyl.), reconditioning W 8-4-3
Lube oil pump’s safety valve (6 cyl.), reconditioning W 8-4-4
Lube oil pump’s safety valve, reconditioning W 8-4-2
Lube oil pump, reconditioning W 8-4-1
Main bearing, removing and installing W 2-7-2
Oil pressure control valve, checking W 8-11-1
Outlet valve, checking W 1-5-3
Chapter 2 - Page 2 0299 4670-0108 1197

DEUTZ MWM Job Cards
TBD 645
Job Job Card

Outlet valve, reconditioning W 1-5-7
Piston pin clearance, checking W 2-12-3
Piston pin, removing and installing W 2-12-4
Piston rings and piston ring grooves, checking W 2-10-3
Piston rings, removing and installing W 2-10-1
Piston with connecting rod, removing and installing W 2-9-3
Piston, cleaning the top section W 2-9-6
Piston, replacing the top section W 2-9-5
Protective tube for the injection valve, removing and installing W 1-10-1
Running-in instructions W 0-1-3
Safety regulations for jobs at the drive mechanism W 2-0-1
Safety regulations for jobs at the electronic system W 13-0-1
1197 0299 4670-0108 Chapter 2 - Page 3

Job Cards DEUTZ MWM
TBD 645
2 2.1.2 Arranged by Job Card Numbers

Job Card Job
W 0-0-1 Hydraulic clamping device, filling and bleeding
W 0-1-3 Running-in instructions
W 0-2-2 Emergency operation in the event of a cylinder station breakdown
W 0-2-7 Combustion compartment, endoscoping
W 0-3-1 Liquid nitrogen, jobs involving
W 0-3-2 Cracks, checking for, applying the liquid method
W 1-4-4 Cylinder head, removing and fitting
W 1-5-2 Inlet valve, checking
W 1-5-3 Outlet valve, checking
W 1-5-6 Inlet valve, reconditioning
W 1-5-7 Outlet valve, reconditioning
W 1-10-1 Protective tube for the injection valve, removing and installing
W 2-0-1 Safety regulations for jobs at the drive mechanism
W 2-0-2 Deep-groove bearing, replacement criteria
W 2-1-1 Bearing spread, checking
W 2-1-4 Crankshaft’s axial clearance, checking
W 2-1-5 Crank web breathing, checking
W 2-5-4 Connecting-rod bearing, checking
W 2-7-2 Main bearing, removing and installing
W 2-7-3 Crankshaft’s wearing ring halves, removing and installing
W 2-9-3 Piston with connecting rod, removing and installing
W 2-9-5 Piston, replacing the top section
W 2-9-6 Piston, cleaning the top section
W 2-10-1 Piston rings, removing and installing
W 2-10-3 Piston rings and piston ring grooves, checking
W 2-12-3 Piston pin clearance, checking
W 2-12-4 Piston pin, removing and installing
W 3-3-1 Cylinder liner, checking
W 3-9-1 Gear box (drive end), removing and mounting
W 4-1-1 Camshaft bearing, removing, installing and checking
W 4-2-1 Lower valve actuator, removing, installing and checking
W 4-4-1 Gear train (free end), removing and installing
W 4-4-3 Gear train (drive end), removing and installing
W 4-4-4 Gear train (drive end), checking
W 4-9-1 Camshaft’s vibration absorber, removing and mounting
W 6-4-3 Intercooler (water and air sides), cleaning
W 7-2-2 Control rod, adjusting after replacing the injection pump
W 7-4-1 Injection pump, removing and mounting
W 7-4-2 Injection pump, reconditioning
W 7-4-4 Injection pump, checking
W 7-4-7 Injection pump drive, removing and installing
W 7-6-1 Delivery beginning, checking and adjusting
Chapter 2 - Page 4 0299 4670-0108 1197

DEUTZ MWM Job Cards
TBD 645
2
Job Card Job
W 8-4-1 Lube oil pump, reconditioning
W 8-4-2 Lube oil pump’s safety valve, reconditioning
W 8-4-3 Lube oil pump (6 cyl.), reconditioning
W 8-4-4 Lube oil pump’s safety valve (6 cyl.), reconditioning
W 8-8-2 Lube oil cooler, removing, mounting and cleaning
W 8-11-1 Oil pressure control valve, checking
W 9-7-2 Coolant pump, reconditioning
W 12-6-1 Flywheel, removing and mounting
W 13-0-1 Safety regulations for jobs at the electronic system
1197 0299 4670-0108 Chapter 2 - Page 5

Job Cards DEUTZ MWM
TBD 645
2 2.1.3 Description of symbols

There are various symbols used on the Job Cards, in order to designate information not directly related to the
actual work sequence involved.
Tools:
- The tools normally required are listed against this symbol.
Equipment:
- Things like pressure gauges, lube oil, hydraulic oil.
Spare parts:
- Seals, locking parts, etc.
Cross-references:
- Douments, reports or Job Cards to which reference is made in this Job Card.
Chapter 2 - Page 6 0299 4670-0108 1197

General
DEUTZ MWM Job Card
Engines W 0-0-1
Filling and venting the hydraulic clamping device
Safety instructions for the Equipment:

! - Hydraulic oil 6.088.801.1011.8
hydraulic clamping device.
● Before fitting the hydraulic clamping device,

clean and lubricate the threads and contact
areas.
● Lubricant: tallow / red lead or lube oil
(Molykote forbidden).
● Before commencing any work on the
pressurized hydraulic clamping device,
check all pressurized hoses and seals.
● When working on the pressurized hydraulic
clamping device wear face protection and
For the hydraulic clamping device to
gloves, since hydraulic oil escaping from ! operate properly, the entire piping/hose
leaks would penetrate under the skin due to
system must be air-free.
the high pressure involved.
But carry out a venting procedure only
● Repairs to the hydraulic clamping device are
when necessary, since normally the
forbidden.
automatically closing safety coupling
● Because of the accident risk, all parts of the halves will prevent oil escaping and air
hydraulic clamping device, particularly the penetrating.
high-pressure hoses, must be in perfect
condition.
For safety reasons, always close off
● Do not kink, sharply bend or pull the high- ! unconnected but pressurized hoses
pressure hoses.
with closure nipple.
1. Components of the clamping device

1 High-pressure pump
2 Oil tank
3 Pump lever
4 Filling aperture with threaded plug
5 Handwheel for return valve
6 Pressure gauge
7 High-pressure hose
8 Manifold
9 Safety coupling half
1 2 3 4
10 Hydro tension element
11 Safety coupling half (mating component)
12 Venting aperture with grub screw 80228 0
13 Closure nipple Fig. 1 High-pressure pump
1197 0299 4545-0199 Page 1 of 4

General
Job Card DEUTZ MWM
W 0-0-1 Engines
8 13
6
m
150 m
7
rmin =
5
80229 0
Fig. 2 Pressure gauges, hoses, connections
11 10 12
80230 0
Fig. 3 Hydro tension element
2. How the clamping device works

With the aid of high-pressure pump 1, oil pressure is The normal operating configuration of the high-
passed via high-pressure hoses 7 into the hydro pressure pump 1 is horizontal, but it can also run in a
tension elements 10. vertical position, with the hose connection facing
downwards.
The oil pressure is limited by a safety valve.
The oil pressure specified for tightening the screw
connection is read off at pressure gauge 6. To reduce
the oil pressure in the piping/hose system, turn
handwheel 5 in its opening direction.
The high-pressure hoses 7 are connected to the
hydro tension elements 10 and the manifold 8 via
safety coupling halves 9 and 11.
If fewer than four hydro tension elements are connected
at the same time, the coupling halves 9 located at the
unused hoses will close these in a pressure-tight
configuration (see also the instructions on Page 1).
Page 2 of 4 0299 4545-0199 1197

General
DEUTZ MWM Job Card
Engines W 0-0-1
3. Filling and venting the clamping 5. Malfunctions

device In the event of malfunctions at the hydraulic clamping
● Fill the high-pressure pump 1 only with hydraulic device, e.g. no or inadequate pressure build-up or
oil 6.088.801.1011.8, or if this is not available, with pressure drop, proceed as follows:
one of the hydraulic oils listed below: ● If the high-pressure pump 1 is in a vertical position
BP Energol Hydraulic 50 (hose connection facing downwards), operate
Mobil Hydraulic-Oil L pump lever 3 rapidly several times, while alternately
BV High-Performance Oil (Hochleistungsöl) E 100 opening and closing the return valve by means of
handwheel 5.
Shell Oil AB 1 ● Vent high-pressure hoses and hydro tension
Esso Zerice 36 elements.
Shell Tellus Oil 15
Gasolin Special AS When necessary, you should check that
Viscobil Oil Sera I pressure gauge 6 is indicating accurately by
Viscobil Oil CL40 comparing it with a calibrated pressure gauge.
The reserve pressure gauge is fitted with a
● Using other oils may cause malfunctions due to safety coupling half 11 for connection to one of
swelling of the seals. the high-pressure hoses 7.
Completely unsuitable substances include
brake fluid, shock-absorber oil, diesel oil,
kerosene and petrol.
● Filter the oil from time to time. When you do this,
flush out the oil tank as well.
4. Work sequence
● Place high-pressure pump in a horizontal position.
● At the fill opening 4 of the oil tank 2, fill high-
pressure pump 1 with not less than 1.5 litres of
hydraulic oil.
● Connect high-pressure pump 1, pressure gauge
holder 6, manifold 8 and hydro-tension elements
10 to the high-pressure hoses.
● Unscrew grub screw 12 of the hydro tension
elements 10, and operate pump lever 3 until
hydraulic oil exits without bubbles from vent
aperture 12.
● During this procedure, the hydro tension elements
10 should be positioned at a higher level than high-
pressure pump 1 and held at an angle to vent
aperture 12, in order to make sure the annular
compartment in the hydro tension element 10 is
vented completely.
● Tighten grub screw 12.
1197 0299 4545-0199 Page 3 of 4

General
Job Card DEUTZ MWM
W 0-0-1 Engines
Page 4 of 4 0299 4545-0199 1197

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

Engine load adjustable independently of the RPM
Running-in time in min. Engine RPM in % Engine output in %
of rated RPM of rated output
60 30 - 50 up to 5
30 50 5 - 10
60 100 up to 20
15 30 - 50 up to 5
45 100 30 - 40
15 100 up to 25
45 100 50 - 60 In the case of
15 100 20 - 30 propeller drives, may
45 100 80 - 90 not be run when the
15 100 30 - 40 ship is moored!
45 100 80 - 90
● Once you have finished the running-in program, check the engine’s operating values, and compare them with
the acceptance test report. If you find any significant divergences, ascertain the cause.
● During the following 24 operating hours, the engine must not be run with fitted injection pump blocking and
reduced speed, nor with overload.
You will reduce the stresses on your engine if you make sure that load changes are not made with abrupt
transitions.
1197 0299 4269-0199 Page 1 of 2

General
Job Card DEUTZ MWM
W 0-1-3 Engines
Page 2 of 2 0299 4269-0199 1197

General
DEUTZ MWM Job Card
TBD 645 W 0-2-2
Emergency operation in the event of a cylinder station breakdown

Tools:
- Set 1215 0000
- Tool for sealing the oil boreholes
Equipment:
- Cleaning agent
Cross-references:
- Job Cards B 7-2-1, W 1-4-4, W 2-9-3
Shutting down the cylinder station

involved
● Remove the cylinder head of the respective cylinder
station,
see Job Card W 1-4-4.
● Remove the piston and the connecting rod,
● Install tool 1 for sealing the oil boreholes at the
stroke journal and screw it handtight.
● Mount the cylinder head without shock-absorber
rods, 1
● Actuate the prelubrication pump and check the
stroke journal oil borehole for leaks.
80291 0
● Unscrew both screws 2.
Fig. 1 Tool for oil bore closure
80290 1
Fig. 2 Unscrew the screws of the strip

1197 0299 4671-0108 Page 1 of 2
General
Job Card DEUTZ MWM
W 0-2-2 TBD 645
● Lift the roller tappets and screw in screw 3 until

journal 4 engages in the borehole at tappet cup 5.
● Dimensions of screw 3, see Fig. 5. 4
● Use the turning device to turn the engine, and
make sure that tappet rollers 6 do not touch down
on the camshaft’s cams (distance between cams
and tappet roller 6 must be min. 1 mm). 5
● Raise the injection pump drive,
see Job Card B 7-2-1. 3
● Disengage the control rod at the injection pump,
and fix the injection pump’s control rod in stop
position.
To operate the engine while a cylinder station
is removed, the elastic engine mount must be 6
blocked by means of all rigid engine supports 80289 0
7 available.
Fig. 3 Raise roller tappet and fix in place
● The disengaged key 8 secured at motor support 7
must be loosened at hexagon head cap screws 9.
● Unscrew hexagon head cap screws 10 from engine 10
support 7 and remove the hose section below the
screw. 11
● Key 8 must be secured tightly between engine
bottom rail 11 and engine support 7. 9
● Tighten hexagon head cap screw 10 at 1150 Nm.
The elastic bearing elements have now been de- 8
activated.
When you re-install the cylinder station, you
must reactivate the elastic engine mount as
7
well. Install the cylinder station in the reverse
sequence. Make sure that there is a gap of 6
mm between the disengaged key 8 and the
bottom edge of the engine’s bottom rail 11.
80288 0
Fig. 4 Engine foot strip
M 10 Ø8
28
70
82100 0
Fig. 5 Fixing screw
Page 2 of 2 0299 4671-0108 1197

General
DEUTZ MWM Job Card
Engines W 0-2-7
Endoscoping the combustion compartment

Endoscopy is a method enabling you to examine the Tools:
combustion compartment (piston, cylinder liner, - Endoscope
cylinder head, valves) for its wear-and-tear status
without having to remove the cylinder head beforehand.
This means you can exploit the wear limits more
Cross-references:
effectively, and thus cut your maintenance costs. - Job Cards B 7-7-2, W 7-7-6, B 13-5-1
When handling the endoscope, always follow the

manufacturer’s instructions!
The endoscope image may be laterally transposed or
upside down, depending on how you are looking into
the lens.
Examining the combustion

compartment
● In the case of diesel engines, remove the injection
valve, see Job Card B 7-7-2.
● In the case of gas engines, remove the sparking
plugs, see Job Card B 13-5-1.
● Place the piston of the cylinder you want to examine
in its bottom dead centre position.
● Connect the endoscope, switch it on, and insert it
cautiously through the injection valve or the sparking
plug borehole.
● Carry out your examination using the eyepiece
and the cold light source.
To enable the inlet and exhaust valves to be
checked, the engine has to be turned
appropriately. Be very careful to ensure that
the endoscope is not damaged.
Light reflections may lead to faulty diagnoses.
You will also find it helpful to swivel the
endoscope during your examinations, and tilt
it alternatively from side to side, making sure
that the fibre-optic cable is not damaged.
1197 0299 4270-0199 Page 1 of 2

General
Job Card DEUTZ MWM
W 0-2-7 Engines
● If you find clearly recognizable damage (e.g. break-

outs, notches, scoring), remove the cylinder head.
● Always be on the lookout for drip formation at the
bottom of the cylinder head. This indicates a
possible leak at the seal of the injection valve or the
sparking plug guard tube.
Evaluation of normal wear phenomena, and
specification of the next endoscoping date
can be performed only by properly trained
experts.
● Carefully take out the endoscope.
● In the case of diesel engines, install the injection
valve, see Job Card B 7-7-2 and Installation
Instructions W 7-7-6.
● In the case of gas engines, install the sparking
plugs, see Job Card B 13-5-1.
80967 0
Fig. 1 Checking with an endoscope
Page 2 of 2 0299 4270-0199 1197

General
DEUTZ MWM Job Card
Engines W 0-3-1
Use of Liquid Nitrogen
Never touch liquid nitrogen and

! undercooled parts:
Risk of injury!
For occasional work of short duration, place two

concentric containers into each other and fill the
clearance between the two containers with glass
wool, cork meal or sand.
Pour the nitrogen from the containers, in which it is
delivered, into the special basin and then dip the metal
parts into this liquid. The start of the undercooling
process is indicated by heavy ”boiling“. Bubbles will
form until the metal parts have assumed the nitrogen
temperature (-196 °C). Once no more bubbles form,
the parts are ready for installation.
Quantity of Nitrogen needed

Under normal conditions, one kilogram of metal to be
cooled from +15°C to -196°C requires the following
quantity of liquid nitrogen:
● 0.60 l for steel
● 0.66 l for cast iron
● 0.45 l for bronze, copper, brass
● 0.96 l for aluminium
1197 0299 4271-0199 Page 1 of 2

General
Job Card DEUTZ MWM
W 0-3-1 Engines
Page 2 of 2 0299 4271-0199 1197

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

Aids:
When working with trichloroethylene:
! - Cleaning agent (trichloroethylene)
risk of poisoning! - Diffusion liquid (red)
- Developer (white)
- Dry cloth
- Protective goggles
- Protective gloves
- Extractor device
Cleaning the components

● Wear protective goggles and protective gloves!
● Make sure the room is properly ventilated!
● Make sure the vapours are extracted. Never inhale
them!
● Use cleaning agent to degrease the component.
● Allow the cleaning agent to act for 10 - 15 minutes.
● Rub down the surface you want to check with a dry
cloth. This will get rid of all the grease residues
which might otherwise fill in and cover up any
cracks present, see Fig. 1.
Applying the diffusion liquid

● Apply diffusion liquid, see Fig. 2. Use a spray can,
a spray gun, or a brush to do this, or immerse the
component in the diffusion liquid.
● Allow the liquid to act for the time period specified
by the manufacturer.
● Clean the component with water, until the diffusion
liquid has been washed off the surface, and remains
only in the cracks, see Fig. 3.
● Rub the surface thoroughly with a cloth to dry it.
● Allow the component to finish drying.
Appling the developer

● Use a spray gun or a brush to apply a thin film of
developer. (Avoid applying twice to the same area).
● Allow the developer to dry for 1 - 2 minutes.
Due to the “blotting paper” effect of the
developer, the diffusion liquid is sucked out of
the crack, and thus becomes visible, see 25495 0
Fig. 4.
Fig. Diffusion liquid procedure
1197 0299 4272-0199 Page 1 of 2
General
Job Card DEUTZ MWM
W 0-3-2 Engines
Assessment
- It may happen that very thin cracks do not become
visible until several hours have passed.
- Due to the diffusion liquid being sucked upwards,
red points will form in the white developer coating
wherever there are cracks or other surface
irregularities.
- Red lines indicate cracks.
- Red dots indicate pitting and porosity.
- A dotted red line will appear in the case of:

- very fine cracks,
- metal fatigue,
- an only partial rupture.
Page 2 of 2 0299 4272-0199 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-4-4
Cylinder head, removing and fitting
The safety instructions for the hydraulic Tools:

! clamping device as laid down in Job from special basic kit:
Card W 0-0-1 must be complied with. - Cylinder head lift-off device
● The hydraulic system may be pressurized - Socket wrench, Size 50, for cylinder
only when it has been completely head screws
assembled. - Insert, Size 50 x 25, extra-deep, for
● Lubricant: tallow/reed lead or oil (Molycote cylinder head screws
prohibited). - Wrench, Size 50, for starting air line -
cylinder head
● Repairs to the hydro screw pretensers are
prohibited. from hydraulics toolkit:
- Single-head wrench, Size 65
● If there is pressure at the tension elements, - Arbor, Ø 8
keep away from the area above the hydro
screw pretensers. - Hydro bolt pretenser for
cylinder head screws
- Hydraulic pump
- Pressure hoses
Equipment:
- Cleaning agent
Cross-references:
- Job Cards B 1-1-1, W 0-0-1
Removing the cylinder head

● Drain off water from the engine. 1
● Disconnect all pipes:
- Leakage fuel pipe
- Pipe to nozzle cooling
- Pipe to lubrication system
- Fuel high-pressure pipe
- Receiver pipe
- Coolant feed
- Coolant outlet
- Exhaust gas bend
● Remove rocker-arm bracket 1 (weight app. 50 kg).
2
● Withdraw shock absorber rods 2.
● Unscrew locking bolts 3. 14 9 5
80171 0
Fig. 1 Cylinder head with lever mechanism

1197 0299 4672-0108 Page 1 of 4
Cylinder head
Job Card DEUTZ MWM
W 1-4-4 TBD 645
● Screw the M 12 bolt into the threaded bore at the

shock absorber rod casing 4.
● Press the shock absorber rod casing downwards
as far as it will go.
● Loosen cylinder head screw union 5 hydraulically,
in accordance with the loosening instructions below:
- Mount 4 hydro bolt pretensers on every second
cylinder head screw union 5. 4
- Screw tension bolt 6 with socket wrench 7 and
support tube 8 onto stud bolt 9 as far as it will go.
- Plug on hydro tension element 10, and secure in
place with hexagonal nut 11.
- Connect pressure hoses.
- Open drain valve 12 at hydraulic pump 13, and
3
80172 0
pull hydro tension elements with hexagonal nut
into their starting position (use the Size-65 single- Fig. 2 Locking bolts
end wrench).
- Turn the tension bolt of the device back by half a
hexagon side. 11
- Turn the hexagonal nut back by 9 hexagon sides
(do not allow the tension bolt to turn also).
10
- Centre support tube on cylinder head bolt in a
clearance-centred configuration.
- Close drain valve at hydraulic pump, pump until 6
pressure p = 730 bar, and turn back cylinder head
nuts 14 with Ø 8 mm arbor using a socket wrench
as far as they will go (anti-clockwise), then tighten 8
again by 2 hexagon sides.
If the cylinder head nut 14 cannot be loosened, 9
7
the oil pressure can be increased to max. p = 5
750 bar.
14
- Bleed off the pressure slowly at the drain valve. 80173 0
- Now fit the hydro bolt pretenser onto the 4

Fig. 3 Hydro bolt prestresser
remaining cylinder head screw unions, and repeat
the procedure. The connection has now been
detached.
● Unscrew cylinder head nuts.
● Fit lift-off device to cylinder head.
- Screw 2 16x330 mm stud bolts with the short
thread into threaded bore 15.
- Fit 2 24x3x205 mm tubes over screwed-in stud
bolts and 1 28x3x249 mm tube over stud bolt 16.
Use M 16x1.5 nuts for M1 16 stud bolts.
● Lift off the cylinder head (weight approx. 390 kg).
● Check the anti-fatigue stud bolts 9 for corrosion
scars, and damage at the foot, and replace if
necessary. 12 13
80174 0
Fig. 4 Hydraulics pump
Page 2 of 4 0299 4672-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-4-4
Fitting the cylinder head

● Fit new cylinder head seal.
● Replace all O-rings, and before fitting them, first
coat them with vaseline, soft soap or a similar 16
agent.
● Fit cylinder head in place, and align it on the intake
pipe flange.
● Remove lift-off device (Fig. 5).
● Insert seal between intake bend and cylinder head.
- Screw in bolts, and tighten them for alignment.
- Screw on and tighten cylinder head nuts 14
handtight.
15
- Loosen intake pipe bolts again.
80175 0
● Tighten cylinder head nuts 5 hydraulically, in
accordance with the tightening instructions below: Fig. 5 Removal device for cylinder head
- Tighten cylinder head nuts 14 by hand in
diagonally opposite sequence, and then tighten
to 300 Nm in diagonally opposite sequence.
- Fit 4 hydro bolt pretensers to every second cylinder
head screw union 5.
- Connect pressure hoses.
- Screw in puller bolt 6 of the device as far as it will
go, and then unscrew it by half-one-sixth of a turn.
- Open the drain valve 12 at the hydraulic pump 13,
and use hexagonal nut 11 to pull hydro tension
elements 10 into their bottom end position (use
the Size 65 single-ended open-jawed wrench).
● Unscrew hexagonal nut 11 and tension bolt 6
together by 1/4 of a turn.
● Close drain valve 12.
● Centre support tube 8 on cylinder head screw
union 5 in a clearance-centred configuration.
● Pump until pressure p = 725 bar and tighten
cylinder head nuts 14 with Ø 8 mm arbor until they
are handtight, counting the number of hexes you
have turned.. The turn angle must be 285° ± 15° or
4 3/4 ±1/4 hexes. 1 hole diameter for the Ø 8 mm
arbor corresponds to approx. 1/4 hex. If this
tolerance band is not complied with, you must look
for the fault concerned (erection error, material
defect, equipment or pressure gauge defect, etc.).
● Bleed off pressure at the drain valve.
● Fit 4 hydro bolt pretensers onto the 4 remaining
cylinder screw unions 5, and repeat the procedure.
The connection has now been mounted.
● Unscrew the M12 bolt from the threaded bore at
the shock absorber rod casing 4.
1197 0299 4672-0108 Page 3 of 4

Cylinder head
Job Card DEUTZ MWM
W 1-4-4 TBD 645
● Press the M 12 bolt out of the threaded bore as far

as it will go, and screw in the locking bolt 3.
● Insert shock absorber rods 2 into the cylinder
head, and fit rocker-arm bracket 1.
● Fit all pipes removed back in place, make sure
seals are properly inserted, replace if necessary.
● Fill with coolant to the specified value.
● Adjusting valve clearance
see Job Card B 1-1-1.
Retightening the cylinder head union

Because of the settling behaviour displayed by the
cylinder head, the cylinder head union must be
retightened after commissioning or after any work on
the removed cylinder had.
The cylinder head union must be retightened after a
maximum of 100 operating hours.
All cylinder head unions must be retightened
at the same engine temperature.
● Fit 4 hydro screw pretensers onto every second
cylinder head union 5.
● Pump until pressure p = 725 bar, and use an 8-mm-
diameter arbor to tighten cylinder head nuts 14
until they are hand-tight.
● Bleed off pressure at exhaust valve.
● Transfer 4 hydro screw pretensers to the 4
remaining cylinder head unions 5, and repeat the
procedure. The union has now been retightened.
● Adjust valve clearance,
Page 4 of 4 0299 4672-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-2
Inlet valve, checking

Tools:
- Set 1215 0000
from special basic kit:
- Injection valve removal device
- Removal device for inlet valves
Equipment:
- Cleaning agent
Cross-references:
- Job Cards B 1-1-1, W 1-4-4, W 1-5-6
Removing the inlet valve

● Removing the cylinder head
● Place cylinder head on a wooden board to prevent
the valve cones from yielding when the spring is
pressed down.
● Fit removal device.
● Press down the valve rotating device and remove
cone pieces.
● Remove valve rotating device and valve spring.
● Withdraw inlet valve from the cylinder head.
80217 1
Fig. 1 Removal device parts for inlet valve
Checking the inlet valve

● Check cone pieces and shaft surfaces of the
valves for surface damage, replace if necessary.
● Check valve springs for damage, replace if
necessary.
● Clean inlet channels and valves.
● If you find any wear or damage to inlet valve cone
17, valve guide 24 or the valve seating, you must
perform the work described in Job Card W 1-5-6.
80108 1
Fig. 2 Removal device parts for inlet valve

1197 0299 4673-0108 Page 1 of 2
Cylinder head
Job Card DEUTZ MWM
W 1-5-2 TBD 645
Installing the inlet valves

● Before installing overhauled or new valves, always
replace round sealing ring 26 in the valve guide.
● Install inlet valve 17 in the reverse sequence.
● Tighten rocker-arm bracket 1 with nuts 30 until
handtight and then tighten to 410 Nm.
● Fitting the cylinder head,
80109 1
Fig. 3 Removal device for inlet valve, fitted
19 26
2 18
26 28
24 25
27 23
17 29
80014 0
Fig. 4 Cylinder head cross-section
30 19
20
20
30
80177 0
Fig. 5 Cylinder head plan view
Page 2 of 2 0299 4673-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-3
Checking the exhaust valves

Tools:
- Lift-off device
- Cylinder head lift-off device
- Valve cage removal device
- Socket wrench, Size 50, for cylinder head
bolts
- Insert, Size 50 x 25, extra deep, for
cylinder head bolts
Equipment:
- Cleaning agent
References:
- Job Card B 1-1-1, W 1-4-4, W 1-5-7
Removing the exhaust valves, cylinder

head removed 18
(Figs. 1 to 6) 21
● Removing the cylinder head,
see Job Card W 1-4-4. 23
Before removing the cylinder head, you have
to unscrew the nuts of the exhaust valve
housings. Unscrewing these nuts (high torque)
is necessary to prevent the cylinder head from
holding up.
● Place the cylinder head on a wooden board to
prevent the valves from yielding when the spring is 17
pressed down.
● Unscrew nuts 30 and take off rocker-arm bracket
with valve lifters. 80176 0
● Fit removal device (see Fig. 6). Fig. 1 Removing the exhaust valves
cone pieces.
● Remove valve rotating device and valve spring.
● Withdraw exhaust valves 18 from the cylinder
head.
● Check cone pieces and shaft surfaces of the
valves for surface damage, replace if necessary.
● Check valve springs for damage, replace if
necessary.
● Fit removal device (see Fig. 5) and use it to
withdraw the valve cage from the cylinder head.
Two different valve cages will be used (see
Fig. 2):
- short channel to the outlet
cast designation 645-3 645-3 ex 645-4
- long channel to the outlet 80948 0
cast designation 645-4 Fig. 2 Identification of the valve cages
1197 0299 5531-0108 Page 1 of 6

Cylinder head
Job Card DEUTZ MWM
W 1-5-3 TBD 645
● Clean outlet ducts, plus valves and valve cages.

● If you find any wear or damage to outlet valve 18, 19 26
valve guide 25 or valve cage 23, carry out the work
described in Job Card W 1-5-7.
2 18
26 28
24 25
Removing the exhaust valves, cylinder
head fitted 27 23
Procedure when lifting tackle is available
● Turn your engine until exhaust valves 18 are 17 29
closed (valve clearanceexisting at exhaust valve
80014 0
lifter 19).
● Use lifting tackle to lift exhaust valve lifter 19 at the Fig. 3 Cylinder head cross-section
short lever, and take off shock absorber rod 2. The
exhaust valves will now be freely accessible after
the valve lifter has been tilted. 30 19
20
Procedure if no lifting tackle is available
● Turn your engine until inlet and exhaust valves are
closed (valve clearance existing at both valve
lifters).
● Unscrew nuts 30, and take off valve lifter bracket
with valve lifters.
● Unscrew nuts 20, and use removal device 22 see
Fig. 5) to pull valve cage 23 out of the cylinder
head.
20
30
The crankcase contains 4 water shut-off
valves, which enable the coolant to remain in 80177 0
the engine. Fig. 4 Cylinder head plan view
● Clamp exhaust valve cone 18 with valve cage 23,
in a vice, protected by leaden jaws.
● Fit removal device (see Fig. 6).
26
22
28
23
29
80178 0
Fig. 5 Valve cage with device for removing

from the cylinder head
Page 2 of 6 0299 5531-0108 1197
Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-3

cone pieces.
● Remove valve rotating device, valve spring and
outlet valve.
25
● Clean outlet ducts, plus valves and valve cages.
● If you find any wear or damage to outlet valve 18,
valve guide 25 or valve cage 23, carry out the work
described in Job Card W 1-5-7.
18
23
80179 0
Fig. 6 Valve removal with device from the

valve cage
Installing the exhaust valves

● Before installing overhauled or new valves, always
replace round sealing ring 26 in the valve guide.
● Install outlet valve 18 in valve cage 23. 2
● Cover jacket area of the valve cage with a coating
of DEUTZ S1 grease according to KHD Standard
4
H 0685, Ordering No. 0100 7277, to prevent
sticking. 1
● Clean intake bore in the cylinder head.
● Install valve cage in the cylinder head, also installing
3
new round sealing ring 28 and sealing ring 29.
Grease groove for round sealing ring beforehand.
● Tightening instructions for exhaust valves
Tighten fixing nuts 1 to 4 in the sequence 1, 2,
3, 4 with 200 Nm, 1 stage. 82143 0
Then: Fig. 7 Tightening instruction

turn fixing nut 1 by another 60° (1 sixth-circle),
2nd stage,
turn fixing nut 2 by another 60° (1 sixth-circle), ● Use the lift-off device to lift outlet lever 19 at the
2nd stage, short lever and install shock absorber rod 2.
turn fixing nut 1 by another 60° (1 sixth-circle), ● If the rocker-arm bracket has been removed, tighten
3nd stage, rocker-arm bracket 1 handtight with nuts 30 and
turn fixing nut 2 by another 60° (1 sixth-circle), then tighten to 410 Nm.
3nd stage,
● Checking the valve clearance,
2nd stage,
2nd stage,
3nd stage,
3nd stage.
1197 0299 5531-0108 Page 3 of 6

Cylinder head
Job Card DEUTZ MWM
W 1-5-3 TBD 645
Identification of the exhaust valve cages
1 Exhaust valve cage (645-3) mounted in short

exhaust channel
2 Exhaust valve cage (645-4) mounted in long
exhaust channel
3 Serial No.
4 DEUTZ MWM-part-no.
5 Exhaust
1 2
4 5 4 3
80949 0
Fig. 7 Identification of the valve cages
Page 4 of 6 0299 5531-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-3
TBD 645 exhaust valves
If you have a complaint, please complete and Name:

attach it to the part concerned.
Date:
Name of the unit/site:
Engine no.:
component location
short exhaust channel long exhaust channel
Cylinder no.
serial no. of valve cage
DEUTZ MWM-part no.
Operating hours of overhauled

valves before installation
Date of assembly
Date of removal
Running time meter

at assembly
Running time meter

at removal
Working hours
Total valve hours
Removal on the basis of
1197 0299 5531-0108 Page 5 of 6

Cylinder head
Job Card DEUTZ MWM
W 1-5-3 TBD 645
Page 6 of 6 0299 5531-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-6
Reconditioning the inlet valves

Tools:
Never touch liquid nitrogen and - Installation and removal mandrel for the
! undercooled parts: valve guide
Risk of injury! from special basic kit:
- Valve grinding tool
Equipment:
- Cleaning agent
- Liquid nitrogen
Cross-references:
- Job Cards W 1-5-2, W 0-3-1
Reconditioning the inlet valves

When working at the valve seats, make sure Ø 99 27
that the exhaust valve cage and, while the
injection valve is not installed, the injection
valve’s sleeve nut are properly installed and
30 +10´
fastened tightly, so as to prevent the cylinder
head from becoming distorted.
Reworking the valve seat rings and

cone seats, using a grindstone
Always follow the instructions of the tools’
new Ø 108
manufacturer while performing jobs at the max. Ø 112
valve seat and the valve seat rings.
● Regrind the cone seats on a valve cone grinding
machine (for seat angle, see Fig. 2) until the seat 0.02 A Rz 4
80144 0 en
surface is clean.
When the wear dimension has been reached Fig. 1 Valve seat ring for inlet valves
or if large areas of the chromium coating at the
valve stem are damaged, install a new valve.
● Clamp the mandrel to accommodate the grinding
machine between two 15°-cones in the valve guide.
Regrind valve seat ring 27 until the seat surface is
clean. You may rework the valve seat ring as far as
a diameter of 112 mm. Make sure that you do not
30° ± 3’
alter the seat angle. Ø 95

10
When the dimension of 112.0 mm according

to Fig. 1 has been reached, you must replace
the valve seat ring.
● Make sure that there is a continuous, circular
contact pattern [between the valve and the cone Ø 108 -0.3
seat at the valve seat’s largest diameter (outer
contact pattern). Use the marking ink for checking,
contact pattern percentage: 10 - 30%. 0.02 A Rz 4 *
– 0.005 80180 0 en
Fig. 2 Valve disc of inlet valves

1197 0299 4674-0108 Page 1 of 2
Cylinder head
Job Card DEUTZ MWM
W 1-5-6 TBD 645
Replacing the valve guide

● Use the installation and removal mandrel to press 19 26
valve guides 24 out of the cylinder head.
Wear limit for the valve guide: max. 22.183 mm. 2 18
● Cool down the valve guide in liquid nitrogen to
approx. -200 C and press it into the cylinder head 26 28
as far as it will go.
● Jobs involving liquid nitrogen,
24 25
Exhaust valve guide is longer than the inlet
valve guide. 27 23
● Perform the appropriate jobs at the valve cone and
the valve seat ring (see Paragraph 1). 17 29
● Install a new O-ring seal 26. 80014 0
● For further assembly routines,

Fig. 3 Cylinder head cross-section
Page 2 of 2 0299 4674-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-7
Repairing the exhaust valves

Tools:
Never touch liquid nitrogen and - Installation/removal mandrel for valve
! undercooled parts: guide
Risk of injury! - Lifting tackle
- Valve cage removal device
- Valve grinding tool
Aids:
- Cleaning agent
- Liquid nitrogen
Cross-references:
- Job Cards W 0-3-1, W 1-5-3
Ø 35
31
Ø 21,93 -0,025
Ø 109 +0,1
-0,2
26
23 25
0,06 A
– 0,02
0,03
A
–2’
30 5’+
Ø 94
neu Ø 109+0,1
-0,2
Rz 6,3 *
max. Ø 111,5
Ø 109 +0,1
-0,2
82117 0
Fig. 1 Valve cage with valve guide for exhaust valve *ground
1197 0299 5948-0108 Page 1 of 4

Cylinder head
Job Card DEUTZ MWM
W 1-5-7 TBD 645
Reworking the cone seats and cage

seats of the exhaust valves with a
grindstone
Clamp the valve cage in the cylinder head and carry
out the reworking procedures described below only in
this clamped conditions. When you do this, clamp the
valve cage to the parts needed for the intallation job
concerned in accordance with the tightening
instructions, in each case fitting a new soft-iron ring
beforehand.
Two different valve cages are used (see
Fig. 2):
- short channel to the outlet
cast designation 645-3
- long channel to the outlet 645-3 ex 645-4
cast designation 645-4 80948 0
Reworking used valve cages Fig. 2 Valve cage designations

All work on the valve seat and the valve seat
rings must be carried out in accordance with
the tool manufacturer`s instructions.
● Clamp the mandrel for supporting the grinding
machine between two 15° cones in the valve
guide. Rework the valve seat 23 with a grindstone
until the seat surface is clean and free of cracks.
The valve seat may be rewoked down to a diameter
of 111.5 mm. Make sure the correct seat angle is
retained.
If the dimension of 111.5 mm as shown in fig.
1 has been reached, then the valve cage must
be reworked in the supplier`s facility.
Page 2 of 4 0299 5948-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-5-7
Regrind the cone seats of the exhaust valves on a

valve cone grinding machine (see Fig. 3 for the seat
angle involved) until the seat surface is clean. The
groove (indicated by the arrow in Fig. 4) must not be
ground at all.
30° ± 3’
If the groove (indicated by the arrow in Fig. 4)
has been ground at all, or the chrome layer at Ø 95
10
the valve stem has been broken through over
sizeable areas, or if the bottom of the disc
exhibits corrosion of more than 0.8 mm, install
a new valve.
Check reground or new cones together with the Ø 108 -0,3
clamped-in valve cage. Use marking ink to perform
this check routine, applied very thinly to the surface of
the valve cone. When you are marking, do not turn the 0,02 A Rz 4 *
cone by more than 16°. Between the valve cone and – 0,005
80180 1
the valve cage an uninterrupted circumferential contact
pattern at the maximum valve seat diameter with a Fig. 3 Valve disk of exhaust valves *ground
radial contact pattern content of 60 - 100% must be
assured (outside contact pattern).
Ø 93
Ø 95
Ø 93
Ø 95
82118 0
Fig. 4 Groove
Replacing the valve guide

● Use installation/removal mandrel 31 to press valve 19 26
guides 25 out of the valve cage.
Wear limit for the valve guide is max. 2 18
22.183 mm.
● Cool the valve guide down to approx. -194°C in 26 28
liquid nitrogen, and press it into the valve cage as
far as it will go.
24 25
The exhaust valve guide is longer than the
inlet valve guide.
● Carry out work on the valve cone and the valve 27 23
cage (see Para. 1).
● Fit new round sealing ring 26. 17 29
● For further assembly procedure, 80014 0
Fig. 5 Cross-section through the cylinder head
1197 0299 5948-0108 Page 3 of 4

Cylinder head
Job Card DEUTZ MWM
W 1-5-7 TBD 645
This page has been intentionally left blank.
Page 4 of 4 0299 5948-0108 1197

Cylinder head
DEUTZ MWM Job Card
TBD 645 W 1-10-1
Protective tube for the injection valve, removing and installing

Tools:
- Set of tools 1215 0000
- Mounting tool for injection valve sleeve
6.645.820.0026.L
Job Cards:
- B 7-7-2, W 1-4-4
Removing the cylinder head

4
Removing the injection valve 3
see Job Card B 7-7-2. 2
6
Removing protective tube 7 for the 5
injection valve 5
● Remove cooling oil and leakage oil lines from Pos.
3 and 4. 9
● Unscrew hexagon socket screw 2, and take off
sleeve 1.
● Use the special tool to unscrew fixing nut 6.
● Press out protective tube 7 for injection valve. 7
● Clean the location hole for protective tube 7 and
the seat for seal 8.
● Clean contact surface 5 of sleeve 1. 9
Installing the protective tube 7 for the

injection valve 10
● Fit a new seal 8.
● Fit new O-rings 9 onto new protective tube 7, and
coat with grease. 11
● Insert protective tube 7 into the location hole of the
cylinder head. Align boreholes 10 and 11 in relation
to each other. 9
● Insert mounting device 12 into protective tube 7 by
pressing spindle 13, until the centering bolt 14
engages in boreholes 10 and 11. 8
● Insert locking bolt 15 through borehole 11 in the
cylinder head as far as it will go, and lock protective 82151 0
tube 7 in place.
Fig. 1 Sleeve for injection valve seal
1197 0299 4675-0108 Page 1 of 2
Cylinder head
Job Card DEUTZ MWM
W 1-10-1 TBD 645
● Screw in fixing nut 6 with a special tool, and tighten

it with 80 Nm.
● Screw punch-out device 16 into locking bolt 15, 13
and punch out locking bolt 15.
● Take off mounting device 12 by pressing spindle
13.
● Fit sleeve 1 onto contact surface 5, and tighten
hexagon socket screw 2 until it is handtight. 12
Fitting the cylinder head

15
Installing the injection valve 16

● Tighten hexagon socket screw 2 with 70 Nm.
● Mount cooling oil and leakage oil lines 3 and 4,
starting from sleeve 1, making sure they are stress-
free.
14
80894 0
Fig.21 Protective tubel
Page 2 of 2 0299 4675-0108 1197

Drive mechanism
DEUTZ MWM Job Card
Engines W 2-0-1
Safety rules for working on the drive mechanism

When you are performing any work on the
! drive mechanism, you MUST always
comply with the following rules.
! Danger of burst!
!
Before starting work During the work
● Shut down the engine, and secure it against being ● Make sure that no dirt can penetrate into the drive
started up again. compartment.
● If necessary, drain off lube oil and/or coolant, and ● Before turning the crankshaft, check that:
collect it for re-use. Caution: risk of scalding!
- the turning device has engaged properly,
● With diesel engines, open the indexing cocks. With
- there are no persons working in or at the engine,
gas engines, remove the spark plugs.
- no tools are impeding the crankshaft from turning
● If it is fitted on your engine, open the inspection
and might thus cause damage,
hole cover 10 minutes at the earliest AFTER the
engine has been shut down, and after oil circulation - the drive mechanism is not being put out of
has been interrupted. equilibrium by the removal o drive mechanism
parts.
● Do not perform any other work on the drive
mechanism until the engine has cooled down ● Make sure that the engine cannot turn
sufficiently. The engine must have cooled down unintentionally.
enough to ensure that there is no longer any risk of
burns. After finishing work
● When working on the exhaust gas system, ● Before you close the engine, check whether you
remember that in spite of long cooldown ties some have removed all tools, cleaning cloths, etc. from
components may still be hot. Heat guard plates the crank compartment.
can have sharp edges, so wear protective gloves.
● Fit inspection hole cover (if any), with new seals.
● Do not start the work until a sufficient ventilation
● Before starting up, turn the engine with open
period has elapsed.
indexing cocks or (in the case of gas engines) with
● Make sure that the environment is clean in which spark plugs not installed.
the engine is going to be opened up.
● With diesel engines, close indexing cocks. With
gas engines, install spark plugs.
● Fill with lube oil. Top up coolant, vent cooling
system, and check for leaks.
1097 0299 6317-0199 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-0-1 Engines
Page 2 of 2 0299 6317-0199 1097

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-1-1
Checking the bearing spread

The bearing shell must exhibit a positive spread, so Tools:
that it is properly flush against the acceptance bore - Slide gauge
when it has been installed.
All new bearing shells exhibit a positive spread, unless
they have been incorrectly handled (e.g. in transit).
Definition
a
Positive spread:
Measured at room temperature, dimension “a” is
larger than dimension “D”.
Negative spread:
Dimension “a” is smaller than dimension “D”. D
Evaluation
If a run-in bearing shows a negative spread, and if
there are no other obvious reasons, this may be an
indication that the bearing has become plastically
deformed due to overheating and has thus lost some
of its prestress.
Bearing shells whose spread exceeds the limit value
80227 0
indicated below, i.e. is almost negative, must not be
used any more. Fig. 1 Spread
It is not permissible to correct the bearing
involved using makeshift means, since the
bearing metal is at risk of working loose from
the supporting shell or the bearing may become
deformed. Damage of this kind may cause
serious malfunctions during operation.
New values Limit values

Crankshaft bear. Conn. rod b. Crankshaft bear. Conn. rod b.
Bore „D“ Ø 340 +0 0.036 Ø 280 +0 0.032 Spread,

min. perm. 340.1 280.1
Spread „a“ 341 +0 2 Ø 280.8 +0 1.7
1197 0299 4676-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-1-1 TBD 645
Page 2 of 2 0299 4676-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 632 W 2-1-2
Replacement criteria for deep-groove bearing

In as-new condition, the contact surface exhibits Tools:
about 75 % galvanic running layer and about 25 % - Magnifying glass, 5-fold magnification
light metal.
Cross-refeences:
- Job Card W 2-1-1
Procedure
● Assess the wear condition of the contact surface
with a magnifying glass (magnification not less
than 5x). Running layer can be seen as a dark zone
and the light-metal rib as a light zone.
● Determinant factors for wear condition:
- Ratio between width of light-metal rib and width
of groove, plus
- extent of worn surface.
Every time you assess the state of the grooves,
you must compare them to the contact surface
in a less-stressed area (mostly with as-new
groove state).
● Check the spreading of the bearing shell (see Job
Card W 2-1-1)
Assessment
see next page
1197 0299 4286-0199 Page 1 of 4

Drive mechanism
Job Card DEUTZ MWM
W 2-1-2 TBD 632
2 4
1 3
=5
80231 1
Fig. 1 State 1
Assessment The bearing is locally worn insofar as the bearing

metal ribs and the running layer grooves have reached
You must distinguish between the following states:
a ratio of 1 : 1. The width of the bearing metal ribs has
State 1 (Fig. 1): increased from 25 % (as-new condition) to 50 %.
There is still running layer in the grooves.
1 Maximum 30% of the circumference of the
bearing shell If a wear condition as detailed in (2.) below
2 Maximum 70% of the bearing bush width can be anticipated within the next inspection
interval, you must replace the bearing.
bearing shell
4 Maximum 35% of the bearing bush width
5 Wear 1:1
Page 2 of 4 0299 4286-0199 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 632 W 2-1-2
1 3 5 6
2 4
=7 =8
80232 1
Fig. 2 State 2
State 2 (Fig. 2): The bearing metal ribs are locally worn.
1 Maximum 20% of the bearing bush width When this wear condition has been reached,
you must replace the bearing.
bearing shell
bearing shell
6 Cam wear
7 Wear 1:1
8 Bearing metal strip worn
1197 0299 4286-0199 Page 3 of 4

Drive mechanism
Job Card DEUTZ MWM
W 2-1-2 TBD 632
Page 4 of 4 0299 4286-0199 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-1-4
Checking the crankshaft’s axial clearance

Tools:
The safety instructions for work on the
! - Set of tools 1215 0000
drive mechanism must be complied with
- Dial gauge with magnetic stand
as detailed in Job Card W 2-0-1.
- Feeler gauge
Cross-references:
- Job Cards W 2-0-1, B 3-1-4, W 2-7-3
Measuring the crankshaft’s axial

clearance
● Remove the inspection hole cover of cylinders 1
and 2 at both ends.
● Use a narrow iron rod to press the crankshaft
towards the flywheel end or the operator side a far
as it will go.
● Place the dial gauge at the flywheel, prestress to 3
mm, reset to zero.
● Press the crankshaft to the opposite direction. 3
● Read the measured value and note it down.
1 1
● Repeat the routine 2 to 3 times.
● If the axial clearance is larger than 0.5 mm, replace 3 2
wearing ring halves 1, 80127 0
Fig. 1 Main bearing cover with wearing ring
● If there is not sufficient room for levering, you can halves
also determine the axial clearance by gauging it on
both sides, using the feeler gauge and adding the
measured values.
Mounting the inspection hole cover with

a sealing cord
● Check the sealing cord for damage and replacing
if necessary,
mm new max. perm.
Axial clearance
Fitting bearing 0,16 - 0,363 0,5
1197 0299 4677-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-1-4 TBD 645
Page 2 of 2 0299 4677-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-1-5
Checking the crank web breathing

Tools:
! - Set 1215 0000
Cross-references:
- Job Cards B 3-1-4, W 2-0-1, W 2-7-2
- see enclosure or request from DEUTZ
MWM:
1. Aligning generating sets, diesel engine
and generator
6.000.9.000.3304
2. Aligning diesel engines inside ships
6.000.9.000.3314
3. Permissible crank web breathing ∆a
1241 1401 UE
Measuring the crank web breathing

Generating sets: Cross-reference 1
Aligning generating sets, diesel engine and
generator
6.000.9.000.3304
Ship installation: Cross-reference 2
Aligning diesel engines inside ships
6.000.9.000.3314
Take ship’s loading condition into account. If
the limit values are exceeded, correct engine’s
distortion on the foundation, and recheck the
crank web breathing. If the alignment condition
is still unsatisfactory, check the main bearing
(see Job Card W 2-7-2), and if necessary
consult DEUTZ MWM.
Permissible values: Cross-reference 3
Permisisble crank web breathing ∆a
1241 1401 UE
Fitting the inspection hole cover with

sealing cord
● Check the sealing cord for damage, replace if
necessary,
1197 0299 4678-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-1-5 TBD 645
Page 2 of 2 0299 4678-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-5-4
Connecting-rod bearings, checking

The connecting-rod bearings should be checked Cross-references:
according to the same maintenance and servicing - W 2-0-2, W 2-1-1, W 2-9-3
interval that also applies to the checking of the pistons.
For that reason, the connecting-rod bearings do not
have to be removed separately.
● Removing the pistons,

● Assessing the wear state of the bearing shells
according to the running pattern,
● Checking the spreading of the bearing shell,
1197 0299 4679-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-5-4 TBD 645
Page 2 of 2 0299 4679-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-7-2
Main bearings, checking and replacing

! clamping device as laid down in Job - Set 1215 0000
Card W 0-0-1 must be complied with. - Set 1215 0001
● The hydraulic system may be pressurized - Hydraulic tightening device (with tandem
only when it has been completely cylinder)
assembled. - Lowering device for bearing cover
● Lubricant: tallow/reed lead or oil (Molycote - Cam
prohibited).
● Repairs to the hydro screw pretensers are Equipment:
prohibited. - Lube oil
● If there is pressure at the tension elements, - Hydraulic oil 6.088.801.1011.8 for
keep away from the area above the hydro topping up the hydraulic tightening device
screw pretensers.
Cross-references:
- Job Cards B 0-1-3, B 2-0-1, B 3-1-4,
The safety instructions for work on the W 0-0-1, W 2-0-2, W 2-1-5
! drive mechanism must be complied with
as detailed in Job Card B 2-0-1.
Removing main bearings

Always remove only every second bearing, and not
two adjacent bearings at the same time. 1
● Remove inspection hole cover on both sides.
● Unscrew bolts 1 for cross-tensioning of the bearing
covers.
● Remove lube oil line 2 to the main bearing involved,
and close the lube oil connections at the oil pipe.
● Remove temperature probe 16 of the main bearing
temperature monitor.
9 15
● Screw the puller bolts 3 of the hydraulic tightening
device onto the protruding stud bolts of the bearing
cover mounting, and tighten them lightly.
80128 0
Fig. 1 Hydraulics pump, transverse deformation 1 of

the bearing covers
1197 0299 4680-0108 Page 1 of 4
Drive mechanism
Job Card DEUTZ MWM
W 2-7-2 TBD 645
● Fit pressure sleeve 4 onto the puller bolts (latch 5

will engage), and attach hydraulic cylinder 6
(bayonet connection).
● Fit spacer sleeve 7 and the second hydraulic
cylinder 8 (bayonet connection). 11 5
● Connect the hydraulic system, and open drain 2 4
valve 9. Screw on flanged nut 10 and move the
hydraulic cylinder to its starting position by 3
tightening the flanged nut.
● Turn the flanged nut 10 back by one and a half 6
turns, and turn the puller bolt 3 (spanner size 32)
back by 1 hexagon side (60 degrees). When you 7
are turning puller bolt 3 back, be careful to hold
flanged nut 10 in position. 8
10
● Unscrew ventilation screw 15, check the oil filling 3
in the high-pressure pump, and top up if necessary. 80129 0
● Close drain valve 9, and build up the pressure to p Fig. 2 Hydraulic cylinder, main bearing cover
= 810 bar. Use the adjusting pin to unscrew the nuts
fixing nuts 11 through the adjuster slots; unscrew
them as far as they will go, then turn them back 2
slot widths. 14
● Bleed off pressure at drain valve 9, release latch 5,
move hydraulic cylinder onto the screws which are 13
still firmly in place, and loosen these screws as
described above.
● Insert lowering device 12 into the oil pan, and
support the bearing cover. When the engine
concerned is a 6-cylinder model, support 17 must
also be properly supported. Unscrew fixing nuts 16
11, and lower the bearing cover.
Fig. 3 A = 6-cylinder engine 12
B = 8+9-cylinder engine 17
● Take off the lower bearing shell 13. To remove the A B
80130 0
upper bearing shell, insert cam 14 into the oil bore
of the crankshaft, and turn the engine until the Fig. 3 Lowering device for main bearing cover
bearing shell has emerged from the thrust bearing.
● Take out the bearing shell.
Checking bearings for wear

● Deep-groove bearings are used, which because of
their construction have to be assessed against
special criteria; the wear condition is assessed by
means of the running pattern (Job Card W 2-0-2).
● The bearing shells must also be replaced if there
is severe scoring.
Page 2 of 4 0299 4680-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-7-2
Installing main bearings

● Clean the bearing journals of the crankshaft, the 11
bearing seat in the crankcase, and the bearing
cover. Coat the bearing journal with oil. 5 3
Make sure that no oil penetrates to the back of
the bearing. 4
● Insert the upper bearing shell, and push it as far as
possible into the seat in the crankcase, in order to 6
prevent it skewing. Align the bearing shell laterally
on the thrust bearing.
7
● Insert cam 14 in the lube oil bore of the crankshaft,
and turn so as to press the bearing shell into the 10
8
seat; then take off the cam.
● Insert lower bearing shell into the bearing cover, 3
taking care with the adjusting pin. Lift the bearing 80131 0
cover with lowering device 12.
Fig. 4 Hydraulic cylinder with round nut 11
● Screw on fixing nuts 11, and tighten with the
adjuster pin.
Always screw both inner screws at the main
bearing cover first and then the outer ones.
● Screw in puller bolt 3 (inner stud bolts), fit pressure
sleeve 4 and hydraulic cylinder 6 (latch 5 will
engage).
● Fit spacer sleeve 7 and the second hydraulic
cylinder 8 (bayonet connection).
● Screw on flanged nut 10. Connect hydraulic system,
open drain valve 9, and tighten flanged nut 10.
● Close drain valve 9. Pump pressure up to 325 bar,
check with a 0.05 mm feeler gauge whether the
bearing cover is completely flush with the seat in
the crankcase. If this is not the case, lower the
bearing cover again. When you raise it again,
make sure that the bearing cover does not become
skewed.
● Under a pressure of p = 325 bar, use the adjuster
pin to tighten fixing nuts 11 hand-tight.
● Bring pressure to p = 800 bar, and tighten fixing
nuts 11, counting the hole pitches tightened.
Setpoint value:
- outer bolts
3 1/2 hole pitches (210°)
- inner screws
4 hole pitches (240°)
Tolerance for both values:
1/4 hole pitch (approx. 1 hole diameter 8 mm).
If the values stated are violated upwards or
downwards, find out the cause (installation
error, defective pressure gauge, stud bolts
overelongated).
● Bleed off pressure. Press in latch 5. Take off
hydraulic cylinder, place it on the screws which are
still loose, and tighten the fixing nuts as described
above.
1197 0299 4680-0108 Page 3 of 4

Drive mechanism
Job Card DEUTZ MWM
W 2-7-2 TBD 645
● Screw in bolts 1 for cross-tensioning, pretension

with 600 Nm, then tighten by two hexagon sides
(120 degrees).
● Install temperature probe 16.
● Fit lube oil line 2, prime with lube oil, and check the
connections of lube oil line 2 for leaks.
● Check the crank web breathing
● Remove inspection hole cover (see Job Card B 3-
1-4 for how to replace the seal).
● After any work on the drive mechanism, the running-
in instructionsprovided in Job Card B 0-1-3 must
be meticulously complied with.
Page 4 of 4 0299 4680-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-7-3
Wearing ring halves, replacing

Tools:
! - Set 1215 0000
Cross-references:
- Job Cards B 2-0-1, B 3-1-4, W 2-1-4,
W 2-7-2
Replacing the wearing ring halves

● Lower main bearing cover 2 with the two wearing
ring halves
● Unscrew cheese-head botls 3, replace wearing
ring halves.
● Fit the main bearing cover back in place
see Job Card W 2-7-2
● Check the axial clearance,
Setpoint value : 0.16 ... 0.36 mm.
Divergences for the setpoint value indicate
wear and tear at the crankshaft.
Fitting the inspection hole cover with

sealing cord
● Check the sealing cord for damage, replace if
necessary
1 1
3 2
80127 0
Fig. 1 Main bearing cover with wearing ring halves

1197 0299 4681-0108 Page 1 of 2
Drive mechanism
Job Card DEUTZ MWM
W 2-7-3 TBD 645
Page 2 of 2 0299 4681-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-9-3
Piston with connecting rod, removing and installing

! clamping device as laid down in Job - Screw tap M12
Card W 0-0-1 must be complied with. - Hoist
● The hydraulic system may be pressurized from special basic kit:
only when it has been completely - Bolt remover for connecting rod stud
assembled. bolts
● Lubricant: tallow/reed lead or oil (Molycote - Clamp for installing and removing the
prohibited). piston
- Slide rail for connecting rod cover
● Repairs to the hydro screw pretensers are
prohibited. installation
- Piston ring pliers, piston ring clamp band
● If there is pressure at the tension elements, - Pliers for circlip (piston pin)
keep away from the area above the hydro
screw pretensers. from hydraulics toolkit:
- Single-end wrench, Size 65
- Arbor, Ø 8
- Hydro bolt pretensers for
! conn. rod bolts
- Hydraulic pump
as detailed in Job Card B 2-0-1.
- Pressure hoses
Equipment:
- Lapping compound
- Cleaning agent
- Assembly aid, with high temperature
stability, DEUTZ-S 1, 0100 7277
Cross-references:
- Job Cards W 0-0-1, W 0-1-3, W 1-4-4,
W 2-0-1, W 2-0-2, W 2-1-1
1197 0299 4682-0108 Page 1 of 6

Drive mechanism
Job Card DEUTZ MWM
W 2-9-3 TBD 645
Removing the piston with connecting

rod
(Fig. 1 to 5)
● Remove cylinder head,
● At the coke stripper ring 13, clean the three notches
for fitting the removal device 12.
● Fit the removal device 12 to the coke stripper ring
13.
● Turn the piston slowly upwards, and press out the
coke stripper ring 13. If you find any wear and tear
or damage, you must replace the coke stripper
ring.
82136 05
Fig. 1 Removal device 12
● Check the edge at the cylinder liner which is

formed after lengthy periods of running at the top
reversal point of the first compression ring. If this
10 3
edge is so pronounced that piston rings may catch
on it, it must be ground away.
● Depending on the direction of rotation involved, 4 1
turn the crankshaft to the following position:
- with anti-clockwise rotation, set to 40° crankshaft
before TDC, 2 5
- with clockwise rotation, set to 40° crankshaft
after TDC.
40° crankshaft ☞ approx. 360 mm from the
machined surface of the bearing cover, centre of
stud bolts to bottom outer edge of inspection 6
hole. (Hydraulic clamping device can still just be
mounted.)
80181 0
Fig. 2 Hydro bolt pretensers

Page 2 of 6 0299 4682-0108 1197
Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-9-3
● Loosen connecting rod screw union hydraulically,

following the loosening instructions below:
- Mount 2 hydro bolt pretensers for connecting
rods on connecting rod bolts in a diagonally 5
opposite configuration.
- Using socket wrench 2 and support tube 3, screw
puller bolt 1 onto connecting rod stud bolt 4 as far
6
as it will go (Fig. 2).
- Plug on hydro tension element 5, tighten with 1
hexagonal nut 6 (Fig. 3).
- Connect pressure hoses 7. 7
- Open relief valve 8 at hydraulic pump 9, and
press piston of the hydro tension element as far
as it will go into the cylinder by tightening the
hexagonal nut (wrench size 65) (see Figs. 3, 4). 80182 0
- Turn hexagonal nut back by 1 1/2 turns (9 hexagon Fig. 3 Mounted bolt pretensers
sides) (puller bolt must not be allowed to turn as
well).
- Unscrew puller bolt 1 by one hexagon side.
- Close relief valve at the hydraulic pump, pump
the pressure up to p = 760 bar, and turn back
connecting rod nuts 10 with the Ø 8 mm arbor
using a socket wrench as far as they will go (anti-
clockwise), then tighten them again by 2 hole
pitches. If you find the connecting rod nuts cannot
be loosened at 760 bar, increase the pressure
slowly 10 to 20 bar until the nuts can be loosened.
- Slowly bleed off the pressure at the relief valve.
- Transfer hydro bolt pretensers to the 2 remaining
connecting-rod bolts, and repeat the operation.
● Rethread the threaded bores (M12) in the piston 8 9
base, mount clamp 11 (Fig. 5) and attach the hoist
tackle. 80183 0
● Use a bolt drawer to unscrew 2 connecting-rod Fig. 4 Hydraulic pump

nuts and stud bolts at the bottom, and one at the
top.
● Mount device for removing the connecting rod
bearing cover at the left or right of the crankcase, 11
and support the bearing cover with the seat of the
device (Fig. 6).
14
80184 0
Fig. 5 Clamp for installing a. removing the piston

1197 0299 4682-0108 Page 3 of 6
Drive mechanism
Job Card DEUTZ MWM
W 2-9-3 TBD 645
● Unscrew the fourth connecting-rod nut and the

stud bolt.
● Lower bearing cover by means of spindle, and
swing it out.
The two bearing halves 18 are held on the lift
journal by the connecting rod.
● Use lifting tackle to slightly raise piston 14, while
pressing the connecting-rod eye free from the
stroke journal, from the exhaust gas side.
Support the bottom bearing shell, and turn the
top one out of the connecting-rod eye.
Check whether designation 12 (cylinder
number) is present; is necessary, use a punch
to punch in the number concerned.
● Holding the rest of the assembly in place, raise 80238 0
piston 14 with connecting rod (being careful not to Fig. 6 Supporting the bearing cover
touch the stroke journal) until it is suspended
freely, and then withdraw it from the engine.
● Place piston 14 with connecting rod safely in a
frame; if you are going to store it, close off the oil
borehole in the large connecting-rod eye against
dirt by means of opaque adhesive tape.
● Protect lift journal against dirt and damage with
adhesive tape, oiled paper or cloths.
● Assess wear state of the bearing shells 18 by the
running pattern,
● Check the spread of the bearing shell,
Installing the piston with connecting

left side
rod
(Fig. 7 to 11) Kr4 Kr2
● Replace coke stripper ring 13 by mounting ring 16
in the cylinder liner 15.
● Fit mounting bush 17 for piston installation into
cylinder liner 15.
● Check the designation 12 on the piston to make
sure it is the right cylinder number. If it is a new
piston, punch in the cylinder number concerned. Zyl
Kr1 Kr3
12
right side
80234 0
Fig. 7 Position of ring joints

Page 4 of 6 0299 4682-0108 1197
Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-9-3
● Align piston ring joints from plain compression ring

Kr1 to ventilated oil ring with bevelled outer edges
Kr4 (Fig. 7) in a congruent configuration. Make
sure that the spring joint of the hose spring is 180°
offset against the ring joint of the ventilated oil ring
with bevelled outer edges.
● Apply a film of oil to cylinder liner, piston, piston
rings and crankshaft journal.
● Insert piston slowly into the mounting bush 17.
Installing the piston with connecting rod,
connecting rod screw union to control shaft
side.
● Depending on the direction of rotation involved,
turn the crankshaft to the following position:
- with anti-clockwise rotation, set to 40° crankshaft 80237 0
before TDC,
- with clockwise rotation, set to 40° crankshaft Fig. 8 Positioning the conn. rod
after TDC.
40° crankshaft ⇒ approx. 360 mm from the
machined surface of the bearing cover, centre of
stud bolts to bottom outer edge of inspection
hole. (Hydraulic clamping device can still just be
mounted.)
● Insert piston with connecting rod in the engine. For
depositing on the journal, press against from the
left side (exhaust gas side) on the journal.
Be careful not to damage the contact area of
the crankshaft journal.
● Before fitting, insert top and bottom bearing shells
into the connecting rod, and position them with the
device provided (Fig. 8).
● Deposit connecting rod with the two bearing shells
on the crankshaft journal.
80238 0
● Mount device for installing the bearing cover at the
left or right of the crankcase, and place bearing Fig. 9 Mounting th bearing cover
cover in the seat in the correct installation position
(fixing pin).
● Screw a guide pin into an upper bore of the
connecting rod, and push the bearing cover lying
in the device onto the pin (Fig. 9).
Make sure the bottom bearing shell is in the
correct axial position.
● Use the device to press the connecting-rod bearing A
cover against the parting line, position in place with
the cap screw, and screw into the free, top borehole.
● Remove device and guide pin.
4
10
80188 0
Fig. 10 Stud bolt protrusion „A“ befor hydr.

tightening
1197 0299 4682-0108 Page 5 of 6
Drive mechanism
Job Card DEUTZ MWM
W 2-9-3 TBD 645
● Use a bolt drawer to screw in the connecting-rod - Increase pressure to p = 750 bar, and tighten
stud bolts, and tighten them until they are handtight; connecting-rod nuts with the Ø 8 mm arbor until
then use a wrench to tighten connecting-rod nuts they are handtight, counting the number of
10 until they are handtight.. hexagon sides by which you have turned. The
turning angle must be 120 ± 15° or 2 ± 1/4
● Measure stud bolt protrusion „A“ (see Fig. 10). This
hexagon sides. 1 hole diameter for the Ø 8 mm
is in order to check that connecting rod stud bolt 4
arbor corresponds to approx. 1/4 of a hexagon
has been properly screwed into the connecting rod
side. If this tolerance band is not complied with,
and that the bearing cover has been fitted in the
you must find the fault concerned (erection error,
correct configuration.
material defect, device or pressure gauge
Setpoint value: 26.4 ... 28.1 mm.
defective, etc.).
● Tighten the connecting-rod bolts hydraulically,
- Bleed off the pressure at the relief valve, transfer
following the tightening instructions below.
both hydro bolt pretensers to the 2 remaining
● Mount the 2 hydro bolt pretensers in diagonally connecting-rod bolts, and repeat the operation.
opposite sequence as follows. The connection has now been assembled..
- Screw in puller bolt 1 of the device as far as it will ● Remove mounting bush 17 and mounting ring 16.
go.
● Coat the outer surface of coke stripper ring 13 with
- Connect pressure hoses 7. DEUTZ-S 1 mounting compound, and inset it in
- Open relief valve 8 at hydraulic pump 9, and pull cylinder liner 15.
hydro tension elements 5 with hexagonal nut 6 ● Fitting the cylinder head,
into the bottom end position (use the Size-65 see Job Card W 1-4-4.
single-end wrench).
● If new piston parts, piston rings or connecting-rod
- Close relief valve. bearings have been installed, then run in the
- Center support tube 3 on connecting rod bolt in a engine as detailed in Job Card W 0-1-3.
centred-clearance configuration.
- Prestress pressure up to p = 300 bar, use the Ø 8
mm arbor to tighten connecting rod bolt 10
handtight with socket wrench 2.
17
16
15
82136 0
Fig. 11 Mounting bush and mounting ring

Page 6 of 6 0299 4682-0108 1197
Drive mechanism
DEUTZ MWM Arbeitskarte
TBD 645 W 2-9-5
Piston, replacing the top section

Tools:
- Torque wrench
- Feeler gauge
- Mandrel
Equipment:
- Molykote Paste G-n
Cross-references:
- Job Cards W 2-9-3, W 2-9-6
Replacing the top section of the piston

This work should be carried out only by DEUTZ 18 21
Service personnel.
● Unscrew nuts 17, and separate top section 16 from 22 16
bottom section 19 with mandrel through oil return
bore 18.
20 19
Examine piston cooling compartment, remove
any deposits.
23
● Remove stud bolts 20 and dowel pin 21 from top
section.
● Check stud bolts 20 by visual inspection for cracks. 17
● Turn new top section upside down and screw in
bolts 20 with 10 Nm. Insert dowel pin 21.
● Replace bottom part of round sealing ring 22. 80015 0
● Place bottom section loosely on top section (be Fig. 1 Assembled piston with cooling oil
careful with dowel pin 21), and insert shims 23 for compartment for flow cooling
adjustment against the top section.
● Coat threads and contact areas of the nuts with
„Molykote Paste G-n“. 16
● Tighten nuts in diagonally opposite sequence with
60 Nm. 22
21
● Unscrew nuts again.
● Check insertion of piston bolt in top section of
piston with 10 Nm. 19
20
23
17
80187 0
Fig. 2 Piston components
0997 0299 4683-0108 Page 1 of 2

Drive mechanism
Arbeitskarte DEUTZ MWM
W 2-9-5 TBD 645
● Check shoulder clearance 24 as shown in Fig. 3.

If the shoulder clearance is ≥ 0.15 mm, the piston
must be reworked by DEUTZ Service or must be
renewed.
● Tighten nuts in diagonally opposite sequence with 16
30 Nm.
● Turn the nuts further by 90° in diagonally opposite
19
sequence.
Check: at 60 Nm, the nut must not turn any further.
● Punch in cylinder number
see JC W 2-9-3.
24
80016 0
Fig. 3 Shoulder clearance between top and

bottom sections of the piston
Page 2 of 2 0299 4683-0108 0997

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-9-6
Piston, cleaning the top section

Equipment:
- Alkaline cleaning agent
- White gasoline
- Compressed air
Cross-references:
- Job Card W 2-9-5
Removing the top section of the piston

Remove the top section of the piston 1

● Immerse the removed top section of piston 1 in an
alkaline cleaning agent solution, with the opening
facing upwards towards the piston cooling
compartment.
● Make sure that the cleaning agent solution covers
the top section of the piston completely and acts on
it for a few hours, depending on the oil carbon’s
strength.
● Take top section 1 of the piston out of the cleaning
agent solution, clean it afterwards with white
gasoline, and blow it out with compressed air. 82149 0
Mounting the top section of the piston Fig. 1 Top section of the piston
0997 0299 4684-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-9-6 TBD 645
Page 2 of 2 0299 4684-0108 0997

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-10-1
Piston rings, removing and installing

Tools:
! from special basic kit:
- Piston ring pliers, ring for installng the
piston
Equipment:
- Cleaning agent
Cross-references:
- Job Cards W 0-1-3, W 2-0-1, W 2-9-3,
W 2-10-3, W 2-12-4
Removing the piston rings

● Removing the piston,
● Removing the piston pin, 15
● Use the piston ring pliers to remove piston rings 15,
and mark them.
● Clean piston and piston rings 15 with cold cleanign
agent, and check them, 16 13
14
13
17
18
4
10
80001 2
Fig. 1 Parts of drive mechanism

0997 0299 4685-0108 Page 1 of 2
Drive mechanism
Job Card DEUTZ MWM
W 2-10-1 TBD 645
Mounting the piston rings TOP

● Use the piston ring pliers to mount the piston rings
in the configuration shown in Fig. 2.
Kr1
Kr1, Kr2 Compression ring
Kr2
Square ring, chrome-plated, marked on ring flank
with “GOE“, “TOP“. Kr3
TOP
Install with “TOP“ side upwards.
Kr4
Kr3 Lugged ring
Tapered compression piston ring, chrome-plated,
marked on ring flank with “GOE“, “TOP“.
Install with “TOP“ side upwards.
Kr4 Oil stripper ring
Chamfered ring, chrome-plated (with hose spring),
marekd on ring flank with “GOECRO“.
● Installing the piston, 80233 1
Fig. 2 Configuration of piston rings
● Installing the piston pin,
Running in the engine

If new piston parts, piston rings or connecting-
rod bearings have been installed, then run in
the engine.
● Running in the engine,
Page 2 of 2 0299 4685-0108 0997

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-10-3
Checking piston rings, piston grooves

Tools:
- Feeler gauge / final dimensions
Cross-references:
- Job Card W 2-10-1
Checking piston rings, piston grooves

● Removing piston rings, 3mm
Measuring wear and tear at the piston “Y”

ring groove
At 3 points in the circumference, measure groove
height „Y“ at the outer diameter at a groove depth of
approx. 3 mm:
As-new dimension Wear-and-tear limit
mm mm
Groove 1 6.14 ... 6.17 6.50
Groove 2 & 3 5.09 ... 5.11 5.40
Groove 4 7.04 ... 7.06 7.40 80274 0
Number the grooves, starting from the piston’s top

Fig. 1 Piston ring grooves
end.
The wear-and-tear maximum is on the piston’s
pressure end.
If the value measured comes close to the
wear-and-tear limit, this latter may be exceeded
before the next maintenance routine. To avoid
any concomitant damage, it is essential to
have the piston top part replaced in good time.
For this purpose, please get in touch with your
DEUTZ Service.
● Replace piston rings. For this purpose, have the
cylinder liner honed. In this context, please get in
touch with your DEUTZ Service.
● Installing piston rings,
0997 0299 4686-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-10-3 TBD 645
Page 2 of 2 0299 4686-0108 0997

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-12-3
Piston pin clearance, checking

Tools:
Never touch liquid nitrogen and - Torque wrench
! undercooled parts: - Feeler gauge
Risk of injury!
Cross-references:
Since special tools are required when the - Job Cards W 0-3-1, W 2-12-4
piston pin bush is replaced, and the connecting
rod and piston have to be aligned as well,
bering bush replacement should be carried
out by DEUTZ-Service facilities.
Measuring the piston pin clearance

● Removing the piston pin,
● Place connecting rod 3 in a vertical position. Insert s 1
the cleaned piston pin 1 into the cleaned bush 2
until you have a uniform projection a of piston pin
1 on both sides. 2
● Measure bearing clearance s with a feeler gauge.
● When the maximum permissible clearance has
a a 3
been reached, you must measure the parts
individually, and replace any worn ones.
● Cool down new bush 2 in liquid nitrogen (approx.
-200 °C) , and insert with special tool.
● Working with liquid nitrogen,
see Job Card W 0-3-1. 80235 0
Fig. 1 Piston pin clearance
Bearing clearances As-new clearance max. perm. clearance

Piston pin -
piston pin bush 0.125 - 0.178 0.25
Piston pin -
piston pin eye 0.009 - 0.04 0.07
Diameter New dimension max. perm. dimension
Bush inner Ø
(conn. rod) 140.154 + 0.052 140.33
- 0.018
Piston pin Ø 140 139.97
Piston pin-
eye Ø 140 ++ 0.022
0.009 140.04
1197 0299 4687-0108 Page 1 of 2

Drive mechanism
Job Card DEUTZ MWM
W 2-12-3 TBD 645
Page 2 of 2 0299 4687-0108 1197

Drive mechanism
DEUTZ MWM Job Card
TBD 645 W 2-12-4
Piston pin, removing and installing

Tools:
! from special basic kit:
- Pliers for circlip (piston pin)
Equipment:
- Cleaning agent
Cross-references:
- Job Cards W 2-0-1, W 2-9-3, W 2-12-3
Removing the piston pin

● Removing the piston,
● Before removing the piston pin, first check whether
there are cylinder number identifications marked 15
on piston 16, connecting rod shannk 17 and
connecting rod bearing cover; if not mark them first
appropriately.
● Separate connecting rod from piston, removing
circlip 13 with pliers and pushing out piston pin 14 16 13
(lift the connecting rod slightly to do this).
14
● Clean piston and piston pin with cold cleaning
agent, and check them,
13
Installing the piston pin

17
● Insert a circlip 13 in piston 16.
● Mounting connecting rod 17 at piston 16 in such a
way that the connecting rod identification and the
piston identification are both facing in the same
direction. 18
● Push in piston pin 14 and fit second circlip 13.
The openings of the circlips must expose the
oil drain bores located in the groove.
● Installing the piston,
10
80001 2
Fig. 1 Drive mechanism parts

1197 0299 4688-0108 Page 1 of 2
Drive mechanism
Job Card DEUTZ MWM
W 2-12-4 TBD 645
Page 2 of 2 0299 4688-0108 1197

Crankcase
DEUTZ MWM Job Card
TBD 645 W 3-3-1
Checking the cylinder liner

Tools:
- Inside micrometer
from the basic special kit:
- Mounting and grinding device
Aids:
- Marking ink
- Type G grinding paste
- 2-component anti-corrosion agent
„Permatex K 326 green DB 601”
- Silicone rubber Elastosil A33
Cross-references:
- Job Cards W 0-1-3, W 2-9-3
Checking the cylinder liner for wear and

tear
89
152
Fig. 5
216
● Removing piston with connecting rod,
Re-hone cylinder liner if:
- more than 50 % of the contact surface is without
602
a honing pattern,
- there is serious scoring,
- the ovality is larger than 0.1 mm,
- new piston rings are used for installation. 1
Cylinder liner honing must always be 4
performed by DEUTZ Service or by a properly
authorized workshop on a machine intended 7
for the purpose.
80017 2
Measuring the cylinder liner
● Measure the cylinder liner’s diameter in the longi- Fig. 1 Measuring points at cylinder liner
tudinal and transverse directions of the engine
(measuring planes of Fig. 1). If an offset can be felt
at the bottom edge of the first ring’s top dead
centre, then place additional measuring points
directly above and below the offset.
● If any one measured value has reached the wear-
and-tear limit of 331.30 mm, replace the cylinder
liner.
● If one of the surfaces A, B or C is damaged, you
must always rework all surfaces A, B and C by the
same dimension. The permissible dimension for
reworking is 0.3 +0,1 mm.
Before mounting the cylinder head, you must
check the following for reworked cylinder liners:
● The top edge of coke stripper ring D must not
protrude beyond B, may however be set back by
0.4 mm. The newly installed cylinder head gasket 82167 0
must protrude beyond B by 0.4 - 0.6 mm.
Fig. 2 Rework surfaces
0997 0299 4689-0108 Page 1 of 4
Crankcase
Job Card DEUTZ MWM
W 3-3-1 TBD 645
Removing the cylinder liner

● Unscrew the four fixing screws 2 for the coolant
jacket.
● Take off coolant jacket 3.
● Fit removal device, Fig. 4. Pull cylinder liner 1 out
of crankcase 4 by the eyebolt.
Identifying a cylinder liner, Fig. 7:
13 Acceptance stamp from classification 2
society
14 Company logo
15 Number as you remove,
new or overhauled cylinder liners must
be identified with the cylinder No.
16 Date of manufacture 80018 0
17 Leak test
Fig. 3 Fixing of coolant jacket
18 Installation mark (recess) at exhaust-
gas pipe end
19 Left-hand side (exhaust gas side)
20 Longitudinal engine axis
21 Cup-type feet for connecting rod 1
Installing the cylinder liner

● Clean and degrease contact area 5 in the
crankcase.
● Check anti-corrosion paint coat in the crankcase
above the cylinder liner contact surface, and patch
up if necessary. For this purpose, use the „Permatex
K 326 green DB 601“ 2-component anti-corrosion
agent with hardener K 326 (mixing ratio 5: 1).
● Clean and degrease cylinder liner and crankcase
especially in the vicinity of the contact areas and of 80150 1
the liner groove 6.
Fig. 4 Removal device for cylinder liners
The anti-corrosion agent is inflammable
! in its non-hardened state!
3
● Coat O-ring seals 7 with vaseline, soft soap or
similar, and fit in place. Take special care not to 1
twist the rings during installation.
● Insert new ring, or used ring 8 from one of the
grooves in the bottom end of the cylinder liner as 10
filler ring in liner groove 6. 5 , 9
● Fill groove 6 with silicone rubber 12. Use a spatula
to flatten the bead and to remove any excess
paste. X
● Contact areas 5 and 9 must be free of sealing 4
paste (Fig. 6).
● After 15 minutes at the latest, install cylinder liner,
taking care to ensure that the installation mark is 80019 3
pointing towards the exhaust gas end (see Fig. 7).
Fig. 5 Coolant jacket - excerpt
Page 2 of 4 0299 6489-0108 0997
Crankcase
DEUTZ MWM Job Card
TBD 645 W 3-3-1
A- A
6 1
9 8
5 12
15 A
4
Z yl.N
-r. 14
16 A1
DE
UT
Z
M
80154 0
W
M
7
PT
Fig. 6 Excerpt X Fig. 5
xxx
17 13
x
● Load the cylinder liner with the cylinder head or a
press-in device, so as to make sure that the
silicone rubber is pressed into its final position
while still liquid.
● When you are using new or honed cylinder liners,
install new piston rings.
● Insert new sealing rings 10 into coolant jacket,
taking care not to twist the sealing rings as you 18 21
install them.
● Fix coolant jacket firmly in place on housing with A
hex. screws 2. 20
● Installing piston with connecting rod,
19
● Run in new cylinder liner as described in Job Card
W 0-1-3.
80146 2
Fig. 7 Identification of a cylinder liner
Setpoint value for piston clearance

● Clearance a between the piston’s top edge (piston 1 a
in TDC) and the liner’s top edge must measure
16.0 mm. 3
Fig. 8, Piston clearance a:
1 Cylinder liner
3 Coolant jacket
4 Crankcase
11
11 Piston in top dead centre
4
80020 2
Fig. 8 Piston clearance a
0997 0299 4689-0108 Page 3 of 4

Measurement sheet for cylinder liners, ø 330 mm mm (nominal dimension)
Page 4 of 4
W 3-3-1
Job Card
Customer: Engine type: Op. hours: Date:

Crankcase
Engine No.: Order No.: Measured:
(Name)
Cylinder: 1 2 3 4 5 6 7 8 9
Measuring direction X Y X Y X Y X Y X Y X Y X Y X Y X Y
H in mm 89
152
0299 6489-0108
TBD 645
216
DEUTZ MWM
602
89
152
X
216
Y
602
0997
Crankcase
DEUTZ MWM Job Card
TBD 645 W 3-9-1
Gear box (drive end), removing and mounting

Tools:
! - Set 1215 0000
- Scraper
Equipment:
- Liquid sealant 1215 1052
Comply with the tightening instructions
- Wick wool, 3 mm ø 0139 6832
given in the Operating Manual,
Chapter 8, „Technical Data“.
Removing the gear box (drive end)

● Remove the flywheel, 1
● Remove the components covering gear boxes 1 4
and 2 and those which might impede the removal
procedure.
2
● Remove the actuator with operating mechanism,
● Remove the fixing screws at gear boxes 1 and 2.
● Take off gear box 1 and pull off gear box 2 towards
the front.
● Clean all sealing surfaces, use a scraper to remove
any seal residues still adhering, and degrease the
sealing surfaces. 3
82140 0
● Pull off the dowel pins for aligning gear boxes 1 and
2. If the dowel pins are damaged, replace them. Fig. 1 Gear cover, complete
6 2
82141 0
Fig. 2 Camshaft cover

1197 0299 4690-0108 Page 1 of 2
Crankcase
Job Card DEUTZ MWM
W 3-9-1 TBD 645
Mounting the gear box (drive end)

● Unscrew the two hexagon socket screws 5 and
take the sealing ring off.
● Instead of the two hexagon socket screws 5, screw
in two grub screws with journal M8x50 DIN 417.
● Squeeze plain compression ring 6, with the joint
facing upwards, and use the two grub screws to
clamp it in place.
● Apply a film of liquid sealant to the oil pan’s sealing
surface and the lower sealing surface of gear box
2. Cover the entire length of the oil pan’s sealing
surface with wick wool (3 mm ø) and also apply a
film of liquid sealant to it.
● Carefully install gear box 2 over flange 7 and plain
compression ring 6, making sure not to displace 82142 0
the wick wool on the oil pan’s sealing surface.
Fig. 3 Screw plugs
● Install new seals 3 and 4 and strike in the dowel
pins. Screw gear box 2 in place.
● Unscrew the two grub screws for clamping plain
compression ring 6, and screw in hexagon socket
screws 5 with new sealing rings.
● Apply a film of liquid sealant to the top sealing
surface of gear box 2 and to the bottom sealing
surface of gear box 1.
● Install gear box 1, pin it together and screw it in
place.
● Mount the actuator with drive,
● Mount the flywheel,
● Mount the remaining components removed in the
reverse sequence.
Page 2 of 2 0299 4690-0108 1197

Engine control
DEUTZ MWM Job Card
TBD 645 W 4-1-1
Camshaft bearing, checking

Tools
- Torque wrench
per cylinder:
- 2 pins 7x70 for inlet and outlet tappet
arresting
- 2 Traverses for camshaft mounting
Equipment
- liquid sealing compound
Cross-references:
- Job Cards B 1-1-1, B 3-1-4, B 7-2-1,
W 7-6-1
Removing the camshaft

● Remove crank compartment venting feature.
● Remove the valve lifter blocks completely.
● Remove camshaft cover 1.
● Loosen the actuator rodding. When you do this,
mark the position of hte ocnnection on the actuator
output shaft.
● Remove actuator housing.
● Remove gear cover top 2.
● Check clearances (see Fig. 7, X and Y). If the
maximum values are exceeded, replace the two
bearing bushes 17 and/or the 2 bearing ring halves
(axial bearing ) at cylinder 2.
[mm] New cond. max. perm. 80115 1
Radial clearance X 0.1 - 0.165 0.25 Fig. 1 Camshaft cover

Axial clearance Y 0.2 - 0.6 0.8
80200 1
Fig. 2 Gear cover, complete

1197 0299 4691-0108 Page 1 of 4
Engine control
Job Card DEUTZ MWM
W 4-1-1 TBD 645
● Remove lube oil lines 4 to the bearing points 5,

remove distributor line 6.
● Loosen flanged bearing 7 on the drive end, press
it out of its seat.
● Unscrew non-drive-end cover 8. Remove shaped 12
flange 9 and flanged bearing 10 by unscrewing 14
screws 11.
● Raise inlet and outlet tappets (use the cams to
move each tappet to its topmost position).
4
● Arrest inlet and outlet tappets my menas of 7 mm 5
Ø pins in bore.
● Raise pump drive, 14
6
80202 1
Fig. 3 Camshaft and tappet roller
19
20
80253 0
Fig. 4 Drive-end gear train
Position the markings of camshaft gear and

intermediate shaft gear against each other
(do not turn the engine again until camshaft
installation has been completed).
● Fit the traverses.
● Unscrew bearing cover 13 and roll camshaft with
bearing out of the camshaft trough in the traverses.
80193 0
Fig. 5 Installation marking
Page 2 of 4 0299 4691-0108 1197

Engine control
DEUTZ MWM Job Card
TBD 645 W 4-1-1
Checking, replacing the camshaft

bearings.
● Remove spring ring 21 from the bearing shells 22,
and tske the bearing shells off the shaft.
● Check contact surfaces of bearing shells, install
new bearing shells if necessary.
● Oil the bearing shells, fit them on the camshaft 21 18
shank, and secure with a spring ring. (The bearings
are numbered consecutively from the gear side
with 1, 2, ....)
14
21 22
18
80086 1
Fig. 6 Camshaft bearing
Installing the camshaft. ● Fit flanged bearings, making sure the circlip
15 on the flywheel side is in the correct
● Clean the camshaft.
position, tighten screws 16 with 145 Nm.
● Push the camshaft into the camshaft trough on the Check clearances of the two flange mountings
traverses. (see above).
The marked teeth of camshaft gear 19 and ● Check tooth clearance,
idler gear 20 must mesh together. see Chapter 8.6).
● Fit bearing cover 13 onto bearing shells in ● Finish mounting procedure.
accordance with the numbering (at the side), and
● After fitting the valve lifter blocks, check valve
align. The protruding lube oil connection sockets
clearance,
are used to adjust the bearing shells. Tighten
bearing cover screws 14 handtight and then tighten
with 210 Nm. ● Turn to check the parts move freely.
● Check delivery inception,
15 Y 8
17 X
16 9
7
11
10
17
80087 1
Fig. 7 Camshaft installation clearances
1197 0299 4691-0108 Page 3 of 4

Engine control
Job Card DEUTZ MWM
W 4-1-1 TBD 645
Page 4 of 4 0299 4691-0108 1197

Engine control
DEUTZ MWM Job Card
TBD 645 W 4-2-1
Lower valve actuator, removing, installing and checking

Tools:
- Torque wrench
per cylinder:
- 2 pins 7x70 for inlet and outlet tappet
arresting
Equipment:
- Liquid sealing compound
Cross-references:
- Job Cards B 1-1-1, B 3-1-4
Checking the lower valve actuator

Checking the tappet roller:
● Remove camshaft cover 1,
● Turn the engine, and examine tappet roller 2 and
cam track 3 for scuffing or other damage.
If you find scuffing or traces of seizing on the
tappet roller, replace tappet 4 completely.
Remove any traces of scuffing/seizing on the
cam by fine reworking.
1
80115 1
Fig. 1 Camshaft cover
80192 1
Fig. 2 Camshaft and tappet roller

1197 0299 4692-0108 Page 1 of 2
Engine control
Job Card DEUTZ MWM
W 4-2-1 TBD 645
Tappet replacement:
● Set cylinder station in ignition TDC (both stop rods
destressed).
● Remove valve lifter block with valve lifter 5
completely.
● Take out stop rod 6.
● Remove screw 8 from housing 7. In the welded-on
threaded socket 9 of tappet tube 10, screw in an 4
M12 screw, and thus press the tappet tube
downwards.
● Unscrew the two hexagon-head screws 11, and
remove the husing with the tappet tube.
● Remove tappet guide 12, together with the tappet,
after unscrewing screws 13.
80198 1
● Replace the entire tappet.
Fig. 3 Tappet
Assembly in reverse sequence. Remember
the following points:
● Oil the sliding surfaces.
● Use new sealing rings 14.
5
● Adjust valve clearance,
see Job Card B 1-1-1 6
10
11 14
7
13 8 7 8
14
12
14
4
80201 1 80199 1
Fig. 4 Tappet guide Fig. 5 Valve control

Page 2 of 2 0299 4692-0108 1197
Engine control
DEUTZ MWM Job Card
TBD 645 W 4-4-1
Gear train (free end), removing and installing

Tools:
- Set 1215 0000
- Hand lamp
Cross-references:
- Job Cards W 8-4-1, W 9-7-2
Replacing Gears 1, 2, 3 and 4:

● When installing, apply a thin film of oil the
screws for securing the gears; do not use
Molykote, and tighten in diagonally opposite
sequence whenever this is specified.
Then check the torsional backlash (see Fig. 4).
Gear 1
● Remove the water pump with intermediate
flange; Gear 1 will come with it. 1 2
Follow the instructions given in Job Card
W 9-7-2.
4 3
80197 1
Fig. 1 Non-drive end (free end)
8 8
6
80137 1
Fig. 2 Cover for gearwheel check

1197 0299 4693-0108 Page 1 of 2
Engine control
Job Card DEUTZ MWM
W 4-4-1 TBD 645
Gear 2
● Remove water and lube oil pumps, plus end wall 8 8
cover 6.
● Detach Gear 2 by loosening twelve screws
7(Fig. 3).
● Replace Gear 2, tighten screws 7 by hand, and
then tighten further in diagonalyl opposite
seqeunce with a torque of 580 Nm (see Chapter
8).
Gears 3 and 4
● Gears 3 and 4 for the lube oil pumps are pulled
with the pumps out of the end wall cover.
● Tighten Gears 3 and 4 wth new Midgrip nuts, 6
and a torque of 140 Nm for M12 and 300 Nm for 80137 1
M16.
Fig. 3 Installation advice, Gear 2
Follow the instructions given in Job Card
W 8-4-1.
● Further assembly in the reverse sequence.
4 3 2 1
Sd = 0,2…0,27
Sd = 0,37…0,45
Sd = 0,2…0,27
Sd
82139 0
Fig. 4 Torsional backlash
Page 2 of 2 0299 4693-0108 1197

Engine control
DEUTZ MWM Job Card
TBD 645 W 4-4-3
Gear train (drive end), removing and installing

Visibly worn gears with scoring,. pitting or significant Tools:
shringage of the tooth flanks must be replaced as - Set 1215 0000
detailed in the next section. Rough tooth flanks and - see Fig. 8
excessive backlash will increase running noise (see - Centering screw 6.645.820.0085 L
Job Card B 4-4-4 for check procedure).
Job Cards:
- B 3-1-4, W 3-9-1, W 4-4-4
Replacing gears 7, 8 and 9

● Remove the gear box,
Here we mention just the most important of
the routines involved, to indicate the scope of
work required for replacing the gear wheels.
During assembly, make sure the installation
markings on the gear wheels are properly
10 9
aligned (Fig. 2), and follow the tightening
instructions (see Chapter 8).
Apply a thin film of oil to the screws for securing
the gear wheels (don’t use Molykote), and
tighten in diagonally opposite sequence where 11
appropriate. Then check the torsional backlash
(see Chapter 8).
80191 1
Fig. 1:
Fig. 1 Drive-end gear train
8 Camshaft
9 Idler gear, small
10 Idler gear, large
11 Crankshaft
Replacing gear wheel 7 (actuator)

● Unscrew locking screw 12.
● Unscrew hexagonal nut 13 (M30 x 1.5), and use a
removal device to take toothed gear wheel 7 off the
shaft.
● Mount in the opposite sequence, remembering the
following points:
● Screw on hexagonal nut 13 until it is handtight, and
tighten with 300 Nm.
● Screw in locking screw 12, and lock by a punch
80193 0
mark.
Fig. 2 Installation marking
1197 0299 4694-0108 Page 1 of 4

Engine control
Job Card DEUTZ MWM
W 4-4-3 TBD 645
Removing gears 9 and 10

(For tools, see also Fig. 8, for example)
● Measure delivery beginning, and make a note of it.
12
● Detach valve lifter brackets, and take off the shock-
absorber rods.
● Secure the roller tappets of the injection pumps in
TDC with the lock screw; see Job Card B 7-2-1.
● In the crankcase, remove the lube oil line and
threaded piece 19.
● Turn the engine (possible up to 13 times) until all 13
markings are properly aligned (see Fig. 4).
● Idler gears 9 and 10 can be removed together.
● Fit forcing device 38 with screw 37 (M20x50) at
7
tapered pin 14, and pull off the tapered pin. 80263 0
● Knock tapered pin 14 with a screwed-in shaft Fig. 3 Governor gear

hammer (M 12) from inside out of the crankcase,
but leave it in shaft 15.
● Unscrew screws 16 from the crankcase with
spanner 39.
● Screw removal device 31 with 2 hexagon-head
screws M 16 x 65 to the front of idler gear 10.
● Use a rope tackle block, suspended at ring bolt 42,
roll toothed gear wheels 9 and 10, shaft 15 and hub LM
18 together out of their position in the crankcase.
● Continue to remove the idler gears.
Gears 9 and 10: assembly in the

opposite sequence
remember the following points:
80278 0
● Fix gear 9, hub 18 and gear 10 I proper alignment
with each other using the centering screw Fig. 4 Installation markings
6.645.820.0085.L, as shown in Fig. 5 (markings),
and screw together with screws 16; tightening
torque 145 Nm. 35° 11' 31"
● Tighten the six M 24 screws 16 by hand.
● Insert idler gears 9 and 10 into the gear wheel
combination in such a way that the markings are
aligned with each other (see Fig. 4).
● Use tapered pin 14 to centre the idler gear.
● Use a torque wrench and a ring wrench insert 43
to tighten six M 24 screws 16 in 3 stages, in a
diagonally opposite sequence:
1. Pretighten with 150 Nm.
2. Continue tightening with 300 Nm.
3. Turn by another 1/2 hexagon-side (30°). !
80277 0
Fig. 5 Marking and angle

Page 2 of 4 0299 4694-0108 1197
Engine control
DEUTZ MWM Job Card
TBD 645 W 4-4-3
Replacing the camshaft gear 8

● Remove idler gears 9 and 10 10 9
● Detach camshaft gear 8 from the camshaft, by
unscrewing screws 20, and replace gear wheel 8
(Fig. 7). 16
Screws 20 must be replaced after every
dismantling routine.
● Assemble in the opposite sequence, remembering 14 19
the following points:
● Secure new gear wheel by tightening screws 20
handtight. 15
● Perform fine adjustment by turning wheel 8. The
fine adjustment routine includes checking the
delivery beginning, which must be the same as the 18
value noted down before removal of gear wheel 9. 80138 2
The 19 mm boreholes 21 in toothed gear wheel 8 Fig. 6 Installation hint for idler gears 9 and 10
permit fine adjustment in relation to the crankshaft
of ±2°CA.
● After adjusting the fuel cams, tighten screws 20
21
with 200 Nm.
Do NOT use the existing borehole of 12.5 mm
on the diameter of 280 mm in gear 8. Instead,
drill a new hole of 12.5 mm through gear wheel 20
8 and hub 22. Then ream them together to Ø
13H7, and pin them together with a dowel pin.
● Assemble the actuator housing in the opposite 22
sequence, complying with the specified tightening
torques.
● Use a new special-shape seal for the drive housing.
Replace the seal for the camshaft cover as detailed
in Job Card B 3-1-4.
● Fit the camshaft cover: 8
80196 2
● Pretighten in screws 5, tighten nuts 6 in sequence,
starting from the actuator operating mechanism, Fig. 7 Installation hint for camshaft gear 8
finish tightening screws 5.
● Fit the gear box,
1197 0299 4694-0108 Page 3 of 4

Engine control
Job Card DEUTZ MWM
W 4-4-3 TBD 645
31 32 33
18
100
70
43
170
48 35
34
42
35
1230
300
36
1170
1170
41
39
40 22
37 38
43
80
80656 0
Fig. 8 Tool for removing the idler gear
Tools in Fig. 8:
31 2 screws M 16 x 65 38 Forcing device, 20 mm thick, for tapered pin
32 Plate, 15 mm thick 39 Spanner
33 Pipe, flattened and welded at this point 40 Pipe, outer diameter 45 mm
34 Nut SW 36, 35 mm high 41 Pipe, inner diameter 38 mm
35 Nut welded to flat iron at this point 42 Ring bolt M 16
36 Flat iron 43 Ring spanner insert SW 36, CH 1932/36
37 Hexagon-head screw M 20 x 50
Page 4 of 4 0299 4694-0108 1197

Engine control
DEUTZ MWM Job Card
TBD 645 W 4-4-4
Checking the gear train (drive end)

Tools:
! - Set 1215 0000
Cross-references:
- Job Cards B 3-1-4, W 2-0-1, W 4-4-3
- Chapter 8, Technical Particulars
Comply with the tightening instructions
given in the Operating Manual,
Chapter 8, „Technical Data“.
Initial visual inspection

Rough tooth faces and an excessive face clearance
will increase noise emissions during operation. Visibly
worn gears with scoring, pitting or with distinctive
signs of wear at the faces must all be replaced. 1
● Removing and installing the gear train,
It is possible to perform an initial visual inspection
without removing the actuator by looking through the
flange at the actuator operating mechanism’s side.
● Check the gear train’s toothed gears for damage 1
while turning the engine by two revolutions so as to 2
be able to check the toothed gears’ entire
circumference.
80135 0
Fig. 1 Actuator and rodding mountings
1197 0299 4695-0108 Page 1 of 2

Engine control
Job Card DEUTZ MWM
W 4-4-4 TBD 645
Visual inspection of the entire gear train

Removing the actuator 6
● Unscrew the counternut of fixing screws 1, unscrew
fixing screws 1 and take off the control rod assembly. 3
5
● Remove the lube oil pipe for the actuator operating
mechanism. 6
● Detach the electric cables from the actuator.
● Unscrew fixing screws 2 and take the actuator with
the base plate off.
Place down the actuator in installation 2
configuration so as to prevent the oil filling
4
from draining off.
● Remove camshaft cover 3.
● Unscrew fixing nuts 4 and take the actuator 80136 0
operating mechanism off. Fig. 2 Camshaft cover and actuator operating

● Check the gear train’s toothed gears for damage mechanism
while turning the engine by two revolutions, so as
to be able to check the toothed gears’ entire
circumference. 1 2 3 4 5 6
Mounting the actuator
● Mount the actuator in the reverse sequence.
● Mounting the housing cover,
Tightening torques,
see Chapter 8, Technical Particulars
Sd = 0,4…0,5
Sd = 0,35…0,45
Sd = 0,28…0,35
Sd = 0,07…0,16
Sd
82138 0
Fig. 3 Torsional backlashes
Page 2 of 2 0299 4695-0108 1197

Engine control
DEUTZ MWM Job Card
TBD 645 W 4-9-1
Camshaft’s vibration absorber, removing and mounting

(9-cylinder engine)
Tools:
! Secure engine against start-up. Equipment:

- Cleaning agent
Removing the vibration absorber

● Remove the casing for the vibration absorber.
● Unscrew both hexagon head cap screws 1 and
take locking washer 2 off.
● Unscrew hexagon head cap screws 3 (6 pieces)
and take vibration absorber 4 with ring 5 and disk
6 off.
● Clean the seat surfaces for the vibration absorber.
80916 0
Fig. 1 Vibration absorber installation

1197 0299 4696-0108 Page 1 of 2
Engine control
Job Card DEUTZ MWM
W 4-9-1 TBD 645
Mounting the vibration absorber

● Mount the vibration absorber in the reverse
sequence.
● The tightening torque for screw 3 is 120 Nm.
Page 2 of 2 0299 4696-0108 1197

Exhaust gas system
DEUTZ MWM Job Card
TBD 645 W 6-4-3
Intercooler (water and air sides), cleaning

The water side must be cleaned at the latest when the Tools:
charging air temperature exceeds the temperature - Tool set 1215 0000
specified in the commissioning report by 7 °C. - 4 off M 12 eyebolts
If the pressure drop at the intercooler at full load has - Tube cleaner (plastic round brush)
risen by approx. 30 %, this means the air side has to - U-shaped pipe colum
be cleaned.
To measure the differential pressure, connect a Equipment:
commercially available U-pipe at measuring points - Cleaning agent
after compressor spiral A and after intercooler B (see - Neutralizing agent
Fig. 2). - Seals for cover and bend
Cross-references:
- Operating Instructions, Chapter 8,
“Tightening Instructions
Removing the intercooler

7
● Drain intercooler 2 through the engine’s coolant
drain, and collect the coolant for subsequent re-
use. After you have removed intercooler 2, pour
out the remaining liquid. 6
● Remove all coolant lines at the intercooler.
4
● Remove intake bend 3 between turbocharger and
intercooler 2.
3
● At intercooler 2, screw in four ring bolts and fit a
cable with lifting tackle.
● Unscrew screws 5, and use the lifting tackle to 5
raise intercooler 2.
● Cover up the openings at the intake pipe and the
turbocharger. 1 2
80088 2
Fig. 1 Intercooler
Cleaning the intercooler (water side)

Mechanical cleaning A B
● Remove both the intercooler’s 2 closure covers 6.
The cooling plates on the intercooler’s air
side are very sensitive, so be careful not be
bend them.
● Soft deposits:
● Push a round plastic brush through the cooler
pipes, and then rinse with a powerful jet of water.
● Solid deposits in the pipes:
NEVER drill out. A timely chemical cleaning
procedure is required here.
● Clean both closure covers 6.
82150 0
● Replace all seals.
Fig. 2 Measure the differential pressure
1197 0299 4697-0108 Page 1 of 4

Exhaust gas system
Job Card DEUTZ MWM
W 6-4-3 TBD 645
Chemical cleaning
See the next section for details of cleaning agents. 2 1 5
Pump a cleaning solution through the removed inter-
cooler (make sure closure covers are fitted).
Items in Fig. 2:
1 Pipe inner Ø 1"
2 Circulation pump
3 Tank 0.5 - 1 m3
4 Heater 5 kW
5 Intercooler
Make sure that the cleaning tank (3) is
positioned higher than the cooler, so that
3 4
when the pump is switched off the cooler is
80252 0
not drained and left dry.
Fig. 3 Chemical cleaning
Chemical cleaning agents

The agents used are pulverized acids with a sulfamic After cleaning, you must circulate a
base, severely inhibited, in order to avoid corrosion of weakly alkaline solution (e.g. caustic
the metal components: soda) through the cooler, or at least
“Porodox” leave it inside to stand for an hour. It is
Messrs Collardin GmbH Concentration: 2 - 10 % not permissible to flush the cooler out
Widdersdorfer Straße 215 Temperature: 20 - 60 °C overboard with raw water.
Treatment time : max. 16 Std.
50825 Köln Check the tube bottoms and closure covers for erosion,
Drew’s “SAF-Acid” (lime remover only) and rework if necessary. The damaged section must
Messrs Drew Chemical GmbH Concentration: 5% be filled up with a commercially available corrosion-
Börsenbrücke 4 Temperature: max. 75°C proof two-component filler (e.g. Belzona from Messrs
min. 55°C Molecular Conservation Ltd., Clare Road, Harrogate/
20457 Hamburg Yorkshire, England, German representatives: F. Wolf-
gang Bastian, Rothenbaumchaussee 185, 20149
“P3 - T1166”
Messrs Henkel & Cie GmbH Comply with manufacturer’s Hamburg). After hardening, the tube bottom surface
P.O. Box 1100 treatment instructions must be levelled out.
40002 Düsseldorf Leaking tubes can be sealed in an emergency with a

slightly conical plug made of a corrosion-resistant
Neutralizing agent “P3-croni”
Meesrs Henkel & Cie GmbH Comply with manufacturer’s material (e.g. CuNi or GSnBz).
P.O. Box 1100 treatment instructions
40002 Düsseldorf
Comply with the safety regulations!

Use protective goggles, rubber or
plastic gloves, and acid-resistant
protective clothing!
The intercooler must never be cleaned
with hydrochloric acid.
After you have used a cleaning solution,
neutralize it with caustic soda. (Eco-
friendliness!!)
Page 2 of 4 0299 4697-0108 1197

Exhaust gas system
DEUTZ MWM Job Card
TBD 645 W 6-4-3
Cleaning the intercooler (air side)

● Place cooler block in a trough (see Fig. 3 for fill
level).
● Soften any soiling with a cleaning solution.
You can use the following cleaning agents:
„ACC9“
Messrs Drew Chemical GmbH
Borsenbrücke 4
20457 Hamburg
„Vecom B85“
Messrs VECOM GmbH
Schlenzigstr. 7
21107 Hamburg
„P3T-5308“
Messrs Henkel & Cie GmbH
P.O. Box 1100
40002 Düsseldorf 50687 0
Fig. 4 Air-side cleaning

Comply with the manufacturers’
instructions.
The soaking time depends on the degree of soiling
involved. Then rinse coole block thorughly with fresh
water. Clean corroded baffle plates, frames or internals,
and paint then with a heatproof (approx.. 200 °C) zinc
dust paint.
The best cleaning effect is obtained with an ultra-
sonic cleaning unit. Comply with the instructions and
specifications provided by the manufacturers of the
ultra-sonic troughs.
Fitting the intercooler

● Straighten any bent cooling plates.
● Assembly in the reverse sequence to that described
above.
● After topping up with coolant, vent at venting
screws 7.
1197 0299 4697-0108 Page 3 of 4

Exhaust gas system
Job Card DEUTZ MWM
W 6-4-3 TBD 645
Page 4 of 4 0299 4697-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-2-2
Control rod, adjusting after replacing the injection pump

Afer lever 4 has been detached, you have to re-adjust Tools:
the set screw 6 (lead-sealed in the factory). - Tool set 1215 0000
- 2 off adjuster gauges SEP 28 (see Item 5)
The work procedures described below
! may be carried out by the operator only
in emergencies; otherwise they may
only be performed by authorized service
personnel.
● Loosen spring element at the regulating shaft.

● Turn regulating shaft 1 with pointer 2 so that poin-
ter 2 is located at 28 scale divisions on scale 3.
A correctly adjusted injection pump is needed
as a reference pump. Use an adjoining pump
if you can.
Adjusting the control rods by exhaust gas
temperatures is strictly prohibited.
80267 2
Fig. 1 Level at control rod
● Insert adjuster gauge 5 with the rated dimension of

54 mm as shown in Fig. 2 at the reference pump.
The setting of 28 scale divisions as specified in the
preceding workstep has to be retained. The set
screw 6 of the reference pump has to remain lead-
sealed.
80268 1
Fig. 2 Injection pump with fill level indicator

1197 0299 4698-0108 Page 1 of 2
Fuel system
Job Card DEUTZ MWM
W 7-2-2 TBD 645
● Install the second adjuster gauge at the pump you

want to re-adjust, between stop X and stop Y (Fig.
3). If you have not already done so, remove the
lead seal at set screw 6, and make fine adjustment
to 28 scale divisions or 54 + 0.05 mm.
● If further injection pumps are incorrectly adjusted,
re-adjust them accordingly. For this purpose
adjuster gauge 5 remains at the reference pump.
After adjustment has been completed, the

adjuster gauges must always be removed.
If the adjustment gauges are not removed,
speeds will be impermissibly high, and
then the engine will be destroyed.
80269 1
If the adjustments concerned have been made

Fig. 3 Control rod of injection pump
by the operator in an emergency, the work
must be checked by authorized service
personnel as soon as possible.
● The set screws 6 must be lead-sealed by authorized
service personnel.
Page 2 of 2 0299 4698-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-4-1
Removing and fitting the injection pump

Tools:
Before dismantling, shut off the fuel - Normal tools
! feed. - Lifting device for pump
(Lerbs No. CH 1932/3)
From Special Basic Kit Part 1:
The Fig. Numbers specified for the tools - Fig. No. 23 insert 24x20 DIN 3124
have been taken from the folders supplied - Fig. No. 24 extension B20x200
together with the toolbox. DIN 3123
- Fig. No. 25 sleeve
- Fig. No. 26 extension 20x750
Comply with the tightening instructions (Lerbs No. CH 1932/21)
given in the Operating Manual, From Special Basic Kit Part 2:
Chapter 8, „Technical Data“. - Fig. No. 10 ring wrench SW 24, offset
(Lerbs No. 1932/18)
- Wrench Al 36 for fuel pressure line
From Stand. Additional Kit B:
- Fig. No. 14 cardan joint C 20
Removing the injection pump - Fig. No. 18 torque wrench
1215 8139
● Take off the cylinder head hood.
- Fig. No. 19 extension lever
● Remove sealing washer 1 with light blows (plastic 1203 0346
hammer) upwards, Fig. 1. - Fig. No. 20 extension lever
● Detach fuel feed and return lines 1, Fig. 2. 1215 8145
- Fig. No. 21 pipe grip
● Detach fuel lines 2 from the injection pump, Fig. 2. 1215 8146
- Fig. No. 23 ratchet head
1215 8143
Cross-references:
- B 0-2-5, W 7-6-1
- Operating Instructions, Chapter 8,
Tightening Instructions
- Folders in toolbox
81080 0 81079 0
Fig. 1 Sealing washer Fig. 2 Injection pump peripherals

1197 0299 3956-0108 Page 1 of 4
Fuel system
Job Card DEUTZ MWM
W 7-4-1 TBD 645
● Remove circlip 1 and carefully push out bolt 2,

Fig. 3.
● Remove fuel pressure line 3.
Use wrench Al 36 for fuel pressure line, Fig. 4.
81081 0
Fig. 3 Control rodding, bolts
Removing the injection pump fixing screws 1,

Fig. 5.
● To unscrew the rear injection pump fixing screws,
you will need the following tools: 3
- Fig. No. 23 insert 24x20 DIN 124
- Fig. No. 24 extension B20x200 DIN 3123
- Fig. No. 14 cardan joint C 20
- Fig. No. 25 sleeve (Lerbs No. CH 1932/12)
- Fig. No. 26 extension 20x750
- Fig. No. 23 ratchet head
1215 8143
1215 8145
80245 0
Fig. 4 Fuel pressure line
1203 0346
- Fig. No. 21 pipe grip 1215 8146
● Assemble tools in the order of their listing, and fit
them onto the rear injection pump fixing screw
from above through the opening in the cylinder
head.
Make sure the tool engages properly with the
screw head, and that the sleeve is properly
located over the cardan joint. A slight tilt to the
tool when unscrewing the rear right-hand
fixing screw is inevitable given the design
involved. Using the sleeve makes it possible
for a single person to unscrew the fixing
screws.
● Unscrew rear fixing screws.
81078 0
Fig. 5 Injection pump fixing screws

Page 2 of 4 0299 3956-0108 1197
Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-4-1
● To unscrew the front injection pump fixing screws, ● Tighten the injection pump fixing screws in
you will need the following tools: diagonally opposite sequence.
- Fig. No. 10 ring wrench SW 24, offset ● Fit all fuel lines to the injection pump.
(Lerbs No. 1932/18)
● Fit the fuel pressure line to the injection pump and
- Fig. No. 20 extension lever the cylinder head.
1215 8145
● Fit the sealing washer with light blows (plastic
- Fig. No. 19 extension lever hammer) from above, with a new sealing ring.
1203 0346
● Fit the cylinder head hood.
- Fig. No. 21 pipe grip 1215 8146
● Connect the control rodding to the pump. For this
● Unscrew front fixing screws. purpose, insert bolt 2 and fit circlip.
If the pump rises when the screws are being ● Check that the control rodding is moving smoothly.
unscrewed, turn the engine until the fuel cam
● Measure the ignition pressure,
of the camshaft is no longer friction-locked.
● Remove fixing screws.
● Check commencement of delivery, correct it if
● Use the lifting device to withdraw the pump from necessary,
the pump dive. see Job Card W 7-6-1.
Fitting the injection pump

● Replace round sealing ring between injection pump
and injection pump drive.
● Insert pump in pump drive, and screw on injection
pump fixing screws by hand.
● Align injection pump with the aid of the low-pressure
fuel lines.
● To tighten the fixing screws, you need the same
tool assembly as for unscrewing them, with the
following exception:
The extension lever 1215 8145 and the pipe grip CH
1215 8146 must be replaced by:
- Fig. No. 18 Torque wrench
1215 8139
Make sure the tool engages properly with the
screw head, and that the sleeve is properly
located over the cardan joint. A slight tilt to the
tool when tightening the rear right-hand fixing
screw is inevitable given the design involved.
Using the sleeve makes it possible for a single
person to unscrew the fixing screws
1197 0299 3956-0108 Page 3 of 4

Fuel system
Job Card DEUTZ MWM
W 7-4-1 TBD 645
Page 4 of 4 0299 3956-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-4-2
Injection pump, reconditioning

Tools:
- Round and flat steel bars
- Wire
Cross-references:
- Job Card B 0-2-5
Dismantling the injection pump

● Clamp the pump in the vice, with the connector
piece pointing to the bottom.
● Use a levering effect (wire, round and flat steel
bars, see Fig. 1) to press down the pump piston
until you can take off circlip 18.
Accident risk!
!
Spring force in this position approx. 1,300 N.
● Remove the circlip. Slowly release the lever.

● Tappet spring 19 is now de-stressed.
● Withdraw from the pump, all together, piston 10,
with spacer ring 20 and piston bottom plate 21 - 80003 0
secured by circlip 23.
Fig. 1 Equipment for removing and installing
● Remove circlip 23 from the piston bottom plate. the locking ring
● Take tappet spring 19, spring plate 25 and
regulating sleeve 26 out of the pump.
● Clamp the pump so as to ensure that connector
piece 16 is facing upwards.
● Unscrew cylinder screws 27.
● Use connector piece 16 to pull the injection pump
element out of the pump.
1197 0299 4699-0108 Page 1 of 4

Fuel system
Job Card DEUTZ MWM
W 7-4-2 TBD 645
27 16
14 15 28
12 13
34 29
26 30
25 31
19 32
33 10
23 21
18 20
80021 1
Fig. 2 Cross section of the injection pump(Position 34: prestroke 8 mm)
80004 0
Fig. 3 Replacement parts
Page 2 of 4 0299 4699-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-4-2
Replacing the injection pump element

● Separate both parts by unscrewing cylinder screws
28. Unscrew the connector piece, and take it off so
as to ensure that no valve parts get lost.
● The parts listed below must be replaced (compare
Fig. 3):
10, 11 Pump element
12 Pressure valve cone
13 Pressure valve spring
14 Valve cone
15 Valve spring
16 Connector piece
● Use dowel pins to ensure a correct configuration
80226 0
during the assembly routine. Screw connector
piece 16 with the parts in positions 12 to 15 to Fig. 4 Installing the regulating sleeve and the
element bushing 11. Screw in the screws 28 in a piston
diagonally opposite sequence, and tighten them
with 90 Nm.
Mounting the injection pump

Cover all contact surfaces with a thin film of oil.
Grease the sealing rings.
● Put new O-ring seals 29, 30 and 31 on the element
bushing.
● Insert the element bushing (without piston) from
above into the pump, and use the connector piece
to attach it to the housing. Screw in the screws 27
in a diagonally opposite sequence, and tighten
them with 80 Nm.
● Clamp the pump again at the top.
● Insert the regulating sleeve so as to ensure that the
marked tooth engages between the marked teeth
of control rod 32 (see Fig. 4).
● Insert the spring plate and the tappet spring.
● Put the new piston, the piston bottom plate and the
spacer ring together, and insert them, secured by
a spring ring, into the pump, making sure that the
markings at piston lug are facing towards the
control rod.
● Press down the pump piston until you can insert
circlip 18 in the housing. While pressing down the
pump piston, make sure that the piston lug engages
in the regulating sleeve’s groove.
● Insert the circlip.
● Check the maximum combustion pressure at
P=100 %,
1197 0299 4699-0108 Page 3 of 4

Fuel system
Job Card DEUTZ MWM
W 7-4-2 TBD 645
Page 4 of 4 0299 4699-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-4-4
Injection pump, checking

Tools:
- Tool set 1215 0000
Cross-references:
- Job Cards W 7-4-1
Checking the injection pump

● Remove injection pump,
● Check wear parts, plus valves and valve seats in “A” “A”
the connection piece, for wear and tear; if
necessary, replace pressure valve cone 12,
pressure valve spring 13, valve cone 14, valve
spring 15 and connection piece 16 together. a b
● Check the pump piston
If control edge A (Fig. 1a) is undamaged, re-
assemble the injection pump as specified in
Para. 3. Make sure the pump piston is in the 33
correct configuration.
If you find any scoring, major erosion or
interruption in control edge A (Fig. 1b), replace 80216 1
pump element, consisting of piston 10 and
element bush 11 together. Fig. 1 Individual parts of the injection pump
● Mount injection pump,
80004 1
Fig. 2 Replacement parts

1197 0299 4700-0108 Page 1 of 2
Fuel system
Job Card DEUTZ MWM
W 7-4-4 TBD 645
Page 2 of 2 0299 4700-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-4-7
Removing and installing the injection pump drive

Cleaning will be necessary in cases like a suspended Tools:
injection pump drive. Overhaul only at the - Tool set 1215 0000
manufacturer’s facility.
Cross references:
- Job Card W 7-4-1
Removing the injection pump drive

● Taking off the injection pump,
● Unscrew the 4 fixing screws of the injection pump
drive 1.
● Pull the complete injection pump drive 1 out of the
guide in the cylinder crankcase, and clamp it 4
upside down in a vice.
● Use lever force (Fig. 1) to push tappet roller 2 with
tappet cup 3 downwards, until arresting screw 4
can be unscrewed.
● Destress lever 5 slowly, until tappet springs 6 have
relaxed. Take out complete tappet cup 3.
80243 1
Accident risk! Fig. 1 Removing the tappet cup arrester

!
Spring force in this position approx. 600 N.
11 14
● Use a Ø-3.mm pin to press in the arrester 8 in arrow 13 10

direction a, push roller bolt 9 in arrow direction b
out of tappet cup 3.
1 4
● Remove all parts, and clean them in gas oil.
● Blow out lube oil bores 10 with compressed air. 6 12
● Check all parts for wear and tear, and have any
damaged parts replaced. 10 3
● Replace sealing rings 11, 12 and 14.
9 b
8
2 a
80244 0
Fig. 2 Injection pump drive
1197 0299 4701-0108 Page 1 of 2

Fuel system
Job Card DEUTZ MWM
W 7-4-7 TBD 645
Installing the injection pump drive

● Clamp the housing of the injection pump drive 1 in
its installed configuration in a vice.
● Apply a thin film of oil to all parts.
● Insert tappet 13 from above
● Install tappet roller 2 with roller bolt 9 in tappet cup
3, making sure that the arrester pin 8 engages in
the corresponding bore in the tappet cup.
● Insert all remaining parts from above into the
tappet cup 3 (see Fig. 2), and insert tappet cup
from below into injection pump drive housing1.
● Use lever force (Fig. 1) to force the tappet roller 2
with tappet cup 3 downwards, until arrester screw
4 can be screwed in.
Accident risk!
!
Spring force in this position approx. 600 N.
● Insert complete injection pump drive 1 into the

guide in the cylinder crankcase.
● Prestress the 4 fixing screws of the injection pump
drive 1 in diagonally opposite sequence with 60
Nm, and then tighten with 120 Nm.
● Fitting the injection pump,
Page 2 of 2 0299 4701-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-6-1
Delivery beginning, checking and adjusting

Delivery inception must be checked if there are Tools:
divergences in ignition pressure, if work has been - Tool set Werkzeuge 1215 0000
performed on the camshaft or if there are divergences - Tool set 1215 0001
in exhaust gas temperature. - Device for adjusting delivery inception
- Lifting device for relief valve
- Tape measure
Cross-references:
- Job Cards B 0-2-5, B 3-1-4
- Acceptance test report
Checking delivery inception with the

overflow method 1
● Set the piston of the cylinder concerned to ignition
TDC (both valve lifters have valve clearance).
● Remove fuel pressure line.
3
● Remove adjusting screw 1 and clamp sleeve 2
with knurled nut 3 for the lifting device . Fit overflow
pice on the injection pump’s pressure connection. 2
● Turn knurled nut 3 back as far as it will go, and
insert clamp sleeve 2 into the pressure connection
as far as it will go. Screw in adjusting screw 1, and
tighten it lightly.
● Raise clamp sleeve 2 by screwing down the knurled
nut 3 (valve cone is lifted off the seat).
80072 0
● Measure the circumference of the flywheel, and
divide the measured value by 360. The figure thus Fig. 1 Lifting device
obtained corresponds to 1° crank angle on the
flywheel’s circumference.
● Remove the lifting device and fit the fuel pressure
Bring control rodding to full-load position. Turn line.
the flywheel against the direction of rotation
In the case of pump elements with a lengthy period of
beyond delivery inception. Open fuel cocks or
operation behind them, and worn control edges, the
run fuel delivery pump; a jet of fuel will exit at
inception of dripping may be poorly measured. In this
the overflow pipe.
case we recommend using the light gap method of
● Turn the flywheel slowly in the direction of rotation, measurement:
until the exiting fuel starts to drip. On the flywheel,
measure the distance from the TDC mark to the
pointer. Divide the measured value by the figure
determined in Paragraph 6, and compare the
result (delivery inception expressed in degrees of
crank angle) with the setpoint value from the test
report. If you find a significant divergence from the
test report, check whether the piston is in the
correct TDC, or if you have confused the direction
of rotation.
1197 0299 4702-0108 Page 1 of 4

Fuel system
Job Card DEUTZ MWM
W 7-6-1 TBD 645
Checking delivery inception with the

light gap method
● Set the piston of the cylinder concerned to TDC
(both valve lifters have valve clearance).
● Measure the circumference of the flywheel, and
divide the measured value by 360. The figure thus
obtained corresponds to 1° crank angle on the
flywheel’s circumference.
Close fuel cocks.
1 1
● Unscrew the lateral bafle screws 1 and
illuminate through the baffle screw opening wioth
very bright light (e.g. light source in an endoscope)
. Turn the engine in the direction of rotation, and
observe with a mirror until the plunger just closes
off the bore 2.
● On the flywheel, measure the distance from the
TDC mark to the pointer. Divide this measured 2 2
value by the figure determined in Paragraph 2, and
compare the result (delivery inception expressed
in degrees of crank angle) with the acceptance test
report. If there is a significant divergence, check
whether the piston is in the correct TDC, or if you
have confused the direction of rotation.
80266 0
Fig. 2 Delivery inception adjustment, light gap

method
Page 2 of 4 0299 4702-0108 1197

Fuel system
DEUTZ MWM Job Card
TBD 645 W 7-6-1
Adjusting delivery inception

4
● Remove camshaft cover.
● Cover up lube oil drain bore in camshaft
compartment.
● Fit traverse 4.
● Fit adjuster device between cam and traverse.
● Fit segment 8 with scale to fuel cam, and align it so
that the indicator points to “0”.
● Screw connection piece 9 into threaded bore (in
the cam), and tighten. Connect high-pressure pump
to connection piece.
8
● To vent, loosen connection at connection piece,
and pump until lube oil exits. Retighten connection. 5
● Pump the pressure up to 1300 to 1600 bar unitl oil 80074 1
exits between shaft and cam, then adjsut fuel cam Fig. 3 Measuring device for delivery inception
at screw 10. adjustment
● Bleed off pressure, check setting at indicator.
● Remove device for adjusting fuel cam, and measure 8
4
delivery inception as described above.
● Fit camshaft cover, remembering the seal.
● Replace the seal, if necessary,
Reference value for correcting delivery in-
ception:
4 bar ignition pressure differential at full load
correspond to a difference in delivery inception
of approx. 1 °KW.
Adjusting the fuel cam in direction of rotation: 9
Delivery inception earlier -> ignition pressure
rises. 10
Adjusting the fuel cam against the direction of 80075 1
rotation: Fig. 4 Cam adjuster

Delivery inception later -> ignition pressure
falls.
● After adjustment, perform engine diagnosis routine,

1197 0299 4702-0108 Page 3 of 4

Fuel system
Job Card DEUTZ MWM
W 7-6-1 TBD 645
Page 4 of 4 0299 4702-0108 1197

Lube oil system
DEUTZ MWM Job Card
TBD 645 W 8-4-1
Lube oil pump, reconditioning (8- and 9-cylinder engines)

R 95/800 FL-K-DB-SO Tools:
R 95/900 FL-K-DB-SO - Set 1215 0001
Spare parts:
- Seals
Cross-references:
- Job Card W 8-4-2
Removing the lube oil pump

● Remove lube oil pump 1 including intermediate
flange 17 from the engine.
Dismantling and checking the lube oil

pump
● Take off gear 18.
● Clamp pump at drive flange 4, with safety valve 2
(pressure-limiting valve) facing upwards.
● Unscrew screws 16 and remove safety valve 2.
Overhaul the safety valve,
20 19 17 1 2
● Take off gear housing 6.
● Take drive gear shaft 5 and impeller axle 7 out of 80160 0
drive flange 4, and check for pitting and signs of Fig. 1 Lube oil pump and safety valve 2
wear.
● Examine drive flange 4 and gear housing 6 for
damage, and check the bearing bores for gear
shaft 5 and gear axle 7.
If you find significant wear and tear, replace
the entire pump.
1197 0299 4703-0108 Page 1 of 2

Lube oil system
Job Card DEUTZ MWM
W 8-4-1 TBD 645
Assembling the lube oil pump Re-adjusting the tooth flank clearance
Assemble the pump in the reverse sequence, with a ● Loosen pump with intermediate flange 17 from end
tightening torque for screws 16 of wall cover, and shift until tooth flank clearance is
410 Nm. between 0.20 and 0.27 mm.
Make sure everything is scrupulously clean; ● Bolt pump firmly to end wall cover.
remove any paint residues from the interfaces.
● Re-pin intermediate flange 17 to end wall cover
Replace the O-rings. (not a through-bore!) (bore Ø 13H7 mm).
● Fit intermediate flange 17 with seal.
● Tighten gear 18 on the pump by means of screw 9
with a torque of 300 Nm.
● Fit pump to end wall cover, using a new seal.
● Unscrew nuts 20, and remove dummy flange 19;
check the toothe flank clearance through the
opening. The setpoint value is 0.20 to 0.27 mm.
18 4 5 2 16
11
9 7 6 16 10
21
22
13
14
15 12
80271 0
Fig. 2 Lube oil pump and safety valve 2 in cross-section, safety valve drawn turned by 90°.
Page 2 of 2 0299 4703-0108 1197
Lube oil system
DEUTZ MWM Job Card
TBD 645 W 8-4-2
Lube oil pump’s safety valve, reconditioning (8 and 9-cylinder engines)
The safety valve prevents the lube oil pressure Tools:

exceeding a maximum limit. The valve piston loaded - Tools set 1215 0001
with the valve spring will open if the maximum value
is exceeded, allowing the lube oil to flow off from the
pressure side of the lube oil pump to the intake side,
Equipment:
or into the oil pan. - Lube oil
- Cleaning agent
Safety valve 2 can be dismantled without removing it

from the pump.
● Unscrew cap nut 15 and take off the sealing ring;
then unscrew the nut below, and take off the next
sealing ring.
● Turn valve nut 13 back to cover 14 by turning the
valve spindle 12 (clockwise) as far as it will go.
While you are doing this, count the number of
spindle revolutions, and make a note of this number
for adjustment purposes.
Remove cover only when valve spring

! has been completely destressed.
● Remove cover 14, unscrew screws 21, remove

spacer 22, and then take valve piston 10 out of the
housing.
● Clean all parts. Check valve piston, valve seat and
valve guide in housing for wear and tear. Replace
any parts with visible signs of wear or damage.
Check valve piston 10 for smooth movement in the
housing, replace valve if necessary.
● Oil all sliding surfaces, fit new sealing rings and
seals. Assemble in the reverse sequence to that
described above.
● Turn valve spindle 12 anticlockwise by the number
of revolutions you counted during dismantling. Fit
nut and cap nut 15 together with new seals.
The next time the engine is run, check

the lube oil pressure, and correct it at valve
spindle 12 if necessary.
1197 0299 4704-0108 Page 1 of 2

Lube oil system
Job Card DEUTZ MWM
W 8-4-2 TBD 645
18 4 5 2 16
11
9 7 6 16 10
21
22
13
14
15 12
80271 1
Page 2 of 2 0299 4704-0108 1197

Lube oil system
DEUTZ MWM Job Card
TBD 645 W 8-4-3
Lube oil pump (6 cyl.), reconditioning

R 65/630 FL-K-DB-SO Tools:
- Set 1215 0001
Spare parts:
- Seals
Cross-references:
- Job Cards W 8-4-4
Removing the lube oil pump

● Remove lube oil pump 1, including intermediate
flange 17, from the engine.
Dismantling and checking the lube oil

pump
● Take off gear 18.
● Clamp pump at drive flange 4, with safety valve 2
(pressure-limiting valve) facing upwards.
● Unscrew screws 16, and take off safety valve 2.
Overhaul the safety valve as detailed in Job
Card W 8-4-4.
20 19 17 1 2
● Remove gear housing 6.
● Take drive gear shaft 5 and impeller axle 7 out of 80160 0
drive flange 4, and check for pitting and signs of Fig. 1 Lube oil pump and safety valve 2
wear.
● Examine drive flange 4 and gear housing 6 for
damage, and check the bearing bores for gear
shaft 5 and gear axle 7.
If you find serious wear and tear, replace the
entire pump.
Otherwise:
● Remove circlip and shaft sealing ring 8 from drive
flange 4.
1197 0299 4705-0108 Page 1 of 2

Lube oil system
Job Card DEUTZ MWM
W 8-4-3 TBD 645
Assembling the lube oil pump Re-adjusting the tooth flank clearance
Perform assembly in the reverse sequence. ● Loosen pump with intermediate flange 17 from the
end wall cover, and shift until the tooth flank
Make sure everything is scrupulously clean;
clearance is between 0.20 and 0.27 mm.
remove any paint residues from the interfaces.
● Bolt pump firmly to the end wall cover.
Replace the O-rings.
● Re-pin intermediate flange 17 to the end wall cover
● After the pump has been completely assembled,
(not a through-hole!) (bore Ø 13H7 mm).
insert the new shaft sealing ring 8 in the correct
position, using a protective sleeve.
● Fit intermediate flange 17 with seal.
● Use nut 9 to tighten gear 18 on the pump, with a
torque of 1600 Nm.
● Fit pump to the end wall cover, using a new seal.
● Unscrew nuts 20, and remove dummy flange 19;
check the tooth flank clearance through the
opening. The setpoint value is 0.20 to 0.27 mm.
18 4 5 2
10
11
9 8 7 6 12
13
2 14
15
80036 1
Page 2 of 2 0299 4705-0108 1197

Lube oil system
DEUTZ MWM Job Card
TBD 645 W 8-4-4
Lube oil pump’s safety valve (6 cyl.), reconditioning

The safety valve prevents the lube oil pressure Tools:
exceeding a maximum limit. The valve piston loaded - Tool set 1215 0001
with the valve spring will open if the maximum value
is exceeded, allowing the lube oil to flow off from the
pressure side of the lube oil pump to the intake side,
Equipment:
or into the oil pan. - Lube oil
- Cleaning agent
Safety valve 2 can be dismantled without removing it

from the pump.
● Unscrew cap nut 15 and take off the sealing ring;
then unscrew the nut below, and take off the next
sealing ring.
● Turn valve nut 13 back to cover 14 by turning the
valve spindle 12 (clockwise) as far as it will go.
While you are doing this, count the number of
spindle revolutions, and make a note of this number
for adjustment purposes.
Remove cover only when valve spring

! has been completely destressed.
● Remove cover 14, take valve spring 11 and valve

piston 10 out of the housing.
● Clean all parts. Check valve piston, valve seat and
valve guide in housing for wear and tear. Replace
any parts with visible signs of wear or damage.
Check valve piston 10 for smooth movement in the
housing, replace valve if necessary.
● Oil all sliding surfaces, fit new sealing rings and
seals. Assemble in the reverse sequence to that
described above.
● Turn valve spindle 12 anticlockwise by the number
of revolutions you counted during dismantling. Fit
nut and cap nut 15 together with new seals.
The next time the engine is run, check

the lube oil pressure, and correct it at valve
spindle 12 if necessary.
1197 0299 4706-0108 Page 1 of 2

Lube oil system
Job Card DEUTZ MWM
W 8-4-4 TBD 645
18 4 5 2
10
11
9 8 7 6 12
13
2 14
15
80036 1
Fig. 1 Lube oil pump and safety valve 2 in cross-section, safety valve drawn turned by 90°
Page 2 of 2 0299 4706-0108 1197

Lube oil system
DEUTZ MWM Job Card
TBD 645 W 8-8-2
Lube oil cooler, removing, mounting and cleaning

The built-on lube oil cooler is a shell-and-tube heat Tools:
exchanger, where the lube oil flows round the tubes - Tool set 1215 0000
and the coolant through the tube nest. - Pipe brush
If the lube oil temperature after the lube oil cooler has
risen by 5 K (degrees Kelvin) compared to the value Equipment:
recorded in the commissioning report, this means the - Cleaning agent
lube oil cooler has to be cleaned.
Cleaning the lube oil cooler

● Drain off coolant (drain point 1) and lube oil (drain
point 2) from the cooler.
● Remove lube oil and coolant lines. 3
● Remove lube oil cooler.
● Remove hoods 3 and pull tube nest out of the
housing in the direciton of the arrow.
● Clean all parts in cleaning agent solution. Clean
the tubes of the tube nest with a pipe brush.
● Re-assemble in the reverse sequence. Fit new
seals. Pump in lube oil and vent at vent screw 4. 1 2
After a brief period of running at operating
temperature, retighten the fixing screws of
hoods 3, in order to avoid leaks due to the 80089 0
seals settling.
Fig. 1 Lube oil cooler add-on
4 3
1
2
1
80090 0
Fig. 2 Individual parts of lube oil cooler

1197 0299 4707-0108 Page 1 of 2
Lube oil system
Job Card DEUTZ MWM
W 8-8-2 TBD 645
Page 2 of 2 0299 4707-0108 1197

Lube oil system
DEUTZ MWM Job Card
TBD 645 W 8-11-1
Oil pressure control valve, checking

The oil pressure control valve is used to adjust the Tools:
lube oil pressure after the filter to the requisite operating - Set of tools 1215 0000
pressure. The adjustment value is recorded in the
acceptance test report, and must not be changed
unless altered operating conditions necessitate a
Equipment:
change in the lube oil pressure to the setpoint value. - Grinding paste 1215 8051
- Cleaning agent
The lube oil pressure must be continually checked as
specified in Job Card B 0-1-2 „Checking operating
Spare parts:
values, Para. 1“. Within the framework of the trouble-
- Seals
shooting procedure detailed there, check the oil
pressure control valve as follows.
Cross-references:
- Job Card B 0-1-2
- Acceptance test report
● Shut down the engine.

● Remove the backwash filter from the engine (Fig. 1),
and collect the lube oil which drains off.
● Unscrew the oil pressure control valve 1 from the
filter, and withdraw from the mounting.
80203 0
Fig. 1 Backwash filter with oil pressure control

valve 1
1197 0299 4708-0108 Page 1 of 2
Lube oil system
Job Card DEUTZ MWM
W 8-11-1 TBD 645
● Loosen counternut 9.
● Loosen threaded piece 8 and unscrew it, including 8 9 10
adjuster screw 10.
● Take out spring plate 5, compression spring 3 and 7
valve cone 2.
● Check valve seating in housing 11 and valve cone
2 for soiling and damage. 6
● Grind damaged seatings with grinding paste
1215 8051. Replace the parts if necessary. 5
● Clean the parts thoroughly before installing.
● Assemble the oil pressure control valve, using a 4
new round seal 6 and a new sealing ring 7.
● Fit the oil pressure control valve, and when the 3 11
engine is at operational temperature adjust the
lube oil pressure in accordance with the acceptance
test report. 2
80204 0
Fig. 2 Oil pressure control valve 1
Page 2 of 2 0299 4708-0108 1197

Coolant system
DEUTZ MWM Job Card
TBD 645 W 9-7-2
Coolant pump, reconditioning

The open borehole 1 enables you to ascertain whether Tools:
the mechanical seal 2 and the radial sealing ring 3 are - Torque wrench
leaking. If the mechanical seal is defective, then water - Removal device
will exit from borehole 1; if the radial sealing ring is - Pipe section with an inside diameter of
defective, then lube oil will exit. In both cases, the 60 mm
pump has to be overhauled. - Seeger ring pliers 0115 2915
- Dial gauge with magnetic stand
Equipment:
- Lubricating grease
- Valve lapping compound No. 7
- Cleaning agent
Spare parts:
- Seals
Removing the coolant pump

● Drain off water from the pump at borehole 4.
● Unscrew nuts 5 and remove pump with intermediate
flange 6 from the end wall cover.
Replace mechanical seal 2 /

radial sealing ring 3
● Unscrew nuts 7, and separate flanged bearing 8
from pump housing 9.
● Unscrew cap nut 10, and remove impeller 11 and
washer 12 from shaft 13.
Unscrew nut 14, and remove gear wheel 15.
Be careful of the feather keys.
● Remove cup springs 16 and washer 17 from the
80209 0
shaft.
● Remove circlip 18, and pull spacer ring 19 off the Fig. 1 Coolant pump with gear
shaft. Push shaft with roller bearing 20 out of
flanged bearing 8. ● Replace the radial sealing ring: to do this, remove
● Replace the mechanical seal, always remembering circlip 22 and withdraw outer ring of roller bearing
to install a new washer 12 and a new round sealing 23 from the flanged bearing.
ring 21. - Press a new radial sealing ring into the flanged
- Use a screwdriver or mandrel to push the bearing (spring towards the bearing).
mechanical seal out of the flanged bearing. Press - Press the outer ring of the roller bearing into the
the new mechanical seal into the flanged bearing flanged bearing.
with a tube (inner diameter not less than 60 mm).
- Insert circlip 22.
Make sure you only touch the outer ring of the
seal with this pipe: it must not touch the carbon
or ceramic ring.
1197 0299 4709-0108 Page 1 of 2

Coolant system
Job Card DEUTZ MWM
W 9-7-2 TBD 645
Mounting the pump

Mount the pump in a configuration allowing you to
check the tooth flank clearance (see Para. 4).
● Clean all parts, and check the water-contacted
parts for corrosion and cavitation.
● Grease new sealing rings and the surface areas.
● Insert shaft with roller bearing into flanged bearing.
Insert spacer ring and circlip 18.

● Push washer 17 and cup springs 16 onto shaft 13.
● Fit gear wheel 15 onto the shaft, making sure
feather key is in the correct position.
● Fit washer 24 onto the shaft, and tighten nut 14
with 300 Nm. 80211 0
● Fit washer 12 with impeller 11 and washer 25 onto Fig. 2 Determining the tooth flank clearance
the shaft. When you are doing this, make sure that over the outer diameter of the impeller
the impeller and washer 12 are linked by the dowel
pin 26.
● Tighten cap nut 10 with 265 Nm.
Checking the tooth flank clearance

● Fit the pump to the end wall cover without pump
casing 9.
● Measure the tooth flank clearance at the outside
diameter of the impeller (Fig. 2). The setpoint value
at the outside diameter is 0.5 to 0.6 mm.
● Fit new round sealing ring 27 onto the flanged
bearing 8, and screw on pump casing with nuts 7.
● Check that the shaft can run freely.
Checking the tooth flank clearance

when fitting a new pump.
When fitting a new pump, check the tooth flank
clearance as described in Para. 4, but without replacing
the round sealing ring 27.
If the tooth flank clearance deviates from the setpoint
value, then you must re-adjust.
Re-adjusting the tooth flank clearance

● Remove the pinning.
● Fit the pump to the end wall cover without the
casing.
● Unscrew fixing nuts 5 from intermediate flange 6,
and move the pump until the setpoint value of 0.5
to 0.6 mm is achieved at the outer diameter of the
impeller.
● Tighten nuts 5 firmly, and re-pin flange 6 (bore Ø
10H7 tapped blind hole).
Page 2 of 2 0299 4709-0108 1197

Other components
DEUTZ MWM Job Card
TBD 645 W 12-6-1
Flywheel, removing and mounting

Tools:
! - Standard tools
- Flywheel mounting arbors
- Hoist
Comply with the tightening instructions Cross-references:

given in the Operating Manual, - Job Card W 2-0-1
Chapter 8, „Technical Data“. - Operating instructions, Chapter 8,
Tightening instructions
The flywheel must be removed if the starter toothed

gear has to be replaced or if the gear box has to be
removed.
Removing the flywheel

● Remove the components covering flywheel 2 and
those which might impede the removal procedure.
● Unscrew two opposite flywheel fixing screws 1 and
screw in mounting arbors instead.
● Mark flywheel 2 and the camshaft in relation to
each other, as indicated by the arrow.
● Use the hoist to support flywheel 2.
● Remove the remaining fixing screws 1 and carefully
pull flywheel 2 off. You will find it helpful to carefully
lever off flywheel 2 from two sides by means of two
turning rods.
82137 0
Fig. 1 Flywheel
Mounting the flywheel

● Mount the flywheel in the reverse sequence, also
using the two mounting arbors. Make sure that the
markings on flywheel 2 and on the camshaft are
properly aligned with each other when you install
the flywheel.
1197 0299 4710-0108 Page 1 of 2

Other components
Job Card DEUTZ MWM
W 12-6-1 TBD 645
Page 2 of 2 0299 4710-0108 1197

Electrical system
DEUTZ MWM Job Card
TBD 616 W 13-0-1
Instructions for Work on the Electrical Equipment
When working on the high-voltage

! ignition system:
life-threatening risk!
The gases emitted by the battery are

! explosive.
● Avoid sparks and open flames in the vicinity
of the battery.
● Do not allow any acid to get on your skin or
clothing.
● Wear protective goggles.
● Do not place any tools on the battery.
The following instructions must be

observed when working on the
electrical equipment:
Battery (if installed)
● Disconnect the negative lead!
● Dispose of batteries in a manner preventing envi-
ronmental pollution!
Other power supply

● Interrupt the power supply to the engine!
Cable
● Observe cross sections and lengths in accordance
with the generally accepted safety regulations.
1197 0299 4343-0199 Page 1 of 2

Electrical system
Job Card DEUTZ MWM
W 13-0-1 TBD 616
Page 2 of 2 0299 4343-0199 1197

DEUTZ MWM Service
Engines and Systems
Service
DEUTZ AG is represented in 150 countries ● „North/Central America and

throughout the world. Around 15,000 specialists Caribbean“
provide compe-tent servicing of DEUTZ and Order Nr. 0297 7101
DEUTZ MWM engines at approximately 3,000 Trading Area II
service bases. The service registers are adapted
to the structure of the trading area or the regional ● „Asia Pacific“
situation. Order Nr. 0297 7102
Trading Area III
As a result, quick updating is possible in the The Trading Area III will be supple-
event of regional changes. mented by the regional register
- Japan
In detail, the following registers are available (see
also the diagram below): All of the service registers can be obtained from
your local service agent or from DEUTZ in
● „World“ Cologne.
Order Nr. 0297 7099
Total overview of the service network
and Trading Area I.
The Trading Area I is complemented
by the regional registers DEUTZ AG
- Germany - Great Britain Deutz-Mülheimer Straße 107
- Italy - France Postfach 80 05 09
- Spain - Russia D - 51057 Köln
Welt Nord-/Mittelamerika und Karibik Asien Pazifik

incl.
Wirtschaftsraum I Wirtschaftsraum II Wirtschaftsraum III
+ +
+ +
D GB J
F E I RUS
0997 0299 3113-0199 Service

TBD 645, WH, en

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This documentation is intended for the following engine

Ordering No.: 0299 6399 en

Page II 0299 4668-0108 1197

0997 0299 3235-0199 Page III

Page IV 0299 3235-0199 0997

DEUTZ MWM engines

Care and maintenance

Careful when the engine is running!

0997 0299 3235-0199 Page V

QUICK INTRODUCTION (FOR TRAINED AND QUALIFIED PERSONNEL)

GETTING OPERATING INSTRUCTIONS

NORMAL OPERATING INSTRUCTIONS

MAINTENANCE OPERATING INSTRUCTIONS

Page VI 0299 3232-0199 0997

MALFUNCTIONS IN OPERATING INSTRUCTIONS

0997 0299 3232-0199 Page VII

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Page VIII 0299 3232-0199 0997

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

1197 0299 4669-0108 Page IX

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Page X 0299 4669-0108 1197

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

0997 0299 3245-0199 Chapter 1 - Page 1

1.1 General remarks

1.2 Safety instructions / Accident prevention

● for the machine room:

● for operation and maintenance of the engine:

Chapter 1 - Page 2 0299 3245-0199 0997

1.3 Operating instructions and Workshop manual 1

1.4 Job cards

0997 0299 3245-0199 Chapter 1 - Page 3

Maintenance Group (the same for all engines)

Fig. 101 Numbering of the Job Cards

Chapter 1 - Page 4 0299 3245-0199 0997

Fig. 102 Structure of the Job Cards

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

0997 0299 3245-0199 Chapter 1 - Page 5

1 1.5 Spare parts

Chapter 1 - Page 6 0299 3245-0199 0997

1197 0299 4670-0108 Chapter 2 - Page 1

Chapter 2 - Page 2 0299 4670-0108 1197

Job Job Card

1197 0299 4670-0108 Chapter 2 - Page 3

2 2.1.2 Arranged by Job Card Numbers

Chapter 2 - Page 4 0299 4670-0108 1197

1197 0299 4670-0108 Chapter 2 - Page 5

2 2.1.3 Description of symbols

2.2 Job Cards arranged by Job Card Numbers

Chapter 2 - Page 6 0299 4670-0108 1197

Filling and venting the hydraulic clamping device

Safety instructions for the Equipment:

● Before fitting the hydraulic clamping device,

1. Components of the clamping device

13 Closure nipple Fig. 1 High-pressure pump