大连道依茨 2012 系列发动机维修手册

880*1230 mm 16 开本 18 印张
2014 年 3 月第 1 版 第 1 次印刷

山 东 临 工 工 程 机 械 有 限 公 司
地址：山东省临沂经济开发区临工工业园
电话：0539-8785688 传真：0539-8785698
邮编：276023 网址：www.sdlg.cn
服务电话：8008607999 4006587999 0539-8785800
服务传真：0539-8785671
BFM2012 维修手册
鉴于不断地设计改进及更改，本手册中的技术条件及图例会有改动。任何全部或部分的翻版及
再版须经我们许可。
In view of continuous design improvements or changes, the technical data and
illustrations contained in this Workshop Manual are subject to alteration. Reprinting
and reproduction, in part or in whole, are subject to our written approval.

1
前 言
发动机的可靠运行取决于正确的修理和调整工作。
该“车间工作手册”对发动机和发动机零部件正确的修理和调整方法加以描述。但前提条件是
必须由合格人员执行。
该操作手册的设计旨在让您轻松快速的理解所述内容。所以，在简明的文字描述旁边都附有相
关操作的图解。
操作和维护部分包含在对应的“操作手册”中。
有关备用件的操作，请参考各备用件目录。
该“车间工作手册”不随技术设备的变动而更改，所以，有效期至下一版本的发行。
因此，修理设备时请参考我们的“技术通告”。
一般性通告：
 请仔细阅读和遵守“车间工作手册”中的操作指南，以免发生事故，同时确保发动机正常
可靠的运行。
 若没有遵守这些修理指南，将可能导致系统故障、发动机损坏以及人员伤害，制造商对此
不承担任何责任。
 要遵守事故预防条例和其他公认的安全条例以及职业病预防条例。
 只有真正使用 DDE 公司的零件，才能保证发动机的持久耐用和经济可靠。
 发动机部件（如弹簧、夹具、卡环等）如果操作不谨慎，可能导致人员伤害。
 必须按照设备制造商的设计目的操作各发动机零件。若要改装，应使用经道依茨一汽（大
连）有限公司许可的特殊零件。

2
 FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work. on
the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise text
passages are accompanied by pictographs to illustrate the relevant operation.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.

General information:
- Please read carefully and observe the instructions given in this Workshop Manual to avoid accidents
and ensure that your engine always functions properly and reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out repairs or
adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine damage as well
as personal injuries for which the manufacturer shall not accept any liability.
- The accident prevention regulations and all other generally recognized regulations on safety and
occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special tools are
available and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be ensured when
genuine parts of DEUTZ AG are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not handled with
care.
- Engine repairs must be carried out in accordance with intended use as defined by the equipment
manufacturer. For conversions, only parts approved by DEUTZ(DALIAN) ENGINE CO.,LTD for a
specific purpose should be used.

3
目录 Table of Contents
1．技术参数/符号注释 Specification data / Key to symbols
2．检查机调整 Control and adjustment
3．零部件维修 Repair of components
4．发动机拆装 Disassembly and re-assembly of complete engine

4
技术参数/符号注释 Specification data / Key to symbols
1．技术参数/符号注释 Specification data / Key to symbols
页码
技术参数 Specification data------------------------------------------------------------------------------6
气门间隙调整图解------------------------------------------------------------------------------------------7
缸盖螺栓拧紧顺序------------------------------------------------------------------------------------------8
BFM2012 维修时标准长度 L0=117.5mm 的波许喷油泵喷油提前角调整垫片厚度-----------11
确定波许喷油泵修正的安装长度以及 EP 代码-------------------------------------------------------12
符号注释------------------------------------------------------------------------------------------------------13

Schematic for valve clearance adjustment-----------------------------------------------------------------6

Tightening order for cylinder head bolts-------------------------------------------------------------------7
Determining commencement of delivery-------------------------------------------------------------------8
Determining shim thickness for commencement of delivery injection pump replacement in case of
service. Basic dimension L0 = 117.5 mm------------------------------------------------------------------11
Determining corrected installation dimension and EP code for injection pump----------------------12
Key to symbols-------------------------------------------------------------------------------------------------13

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 技术参数/符号注释 Specification data / Key to symbols
技术参数 Specification data
发动机型号 Engine type BF4M2012 BF6M2012
重量kg（近似） 380 495
Engine weight acc. to DIN 70020 -
Aapprox. kg
排量cm3 4040 6060
Engine swept volume cm3
缸径mm 101
Bore mm
行程 mm 126
Stroke mm
旋转方向 Direction of rotation 面向飞轮时，逆时针方向 When facing flywheel counter-clockwise
额定转速 Rated speed rpm 2500
最低怠速转速 Rated speed rpm 800
工作循环 Working cycle 4 冲程柴油机 Four-stroke diesel
燃烧系统 直喷式 Max. height
Combustion principle
压缩比 Compression ratio 19：1
缸压 Compression pressure bar 30-38
各缸工作顺序 Firing order 1-3-4-2 1-5-3-6-2-4
最大长度 Max. length mm BF4M 2012 910，BF4M 2012 BF6M 2012 C 1038
C 921
最大宽度 Max. width mm 643 628
最大高度 Max. height mm BF4M 2012 771，BF4M 2012 908
833
上止点前进气门开启提前角 Inlet 46
opens before TDC degrees
下止点前进气门关闭提前角 Inlet 56
closes after BDC degrees
下止点前排气门开提前角 96
Exhaust opens before BDC
degrees
上 止 点 前 排 气 门 关 闭 提 前 角 50
Exhaust closes after TDC degrees
机油压力 Pressure stat bar 4±0.4
怠 速 时 最 低 机 油 压 力 SAE 0.8
15W/40 120℃
Lube oil pressure at low idling
Temperature approx.
120 °C oil SAE 15W/40 min.
bar

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 技术参数/符号注释 Specification data / Key to symbols
气门间隙调整图解 Schematic for valve clearance adjustment
曲轴位置 1 曲轴位置 2
Crankshaft position 1 Crankshaft position 1
发动机翻转到 1 号气缸气门重叠，还不可以调 进一步翻转发动机 360º，可以调整。
整。
Turn engine until valves of cylinder No.1 overlap. Turn engine further by one complete revolution
(360°)

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

7
 技术参数/符号注释 Specification data / Key to symbols
缸盖螺栓拧紧顺序 Tightening order for cylinder head bolt

4M2012

歧管侧 elbow side

6M2012

歧管侧 elbow side

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 技术参数/符号注释 Specification data / Key to symbols
注意：
凸轮轴被分成 K、L、H、Q 或 P 类型的凸轮轴，以代表不同的喷油提前角。因此当确定
喷油泵的标准尺寸时，这一点要特别注意。
Notes:
Camshaft type K, L, H, Q or P is also indicated in the inscription field for the commencement of delivery.
It is absolutely necessary to take this into account for the basic setting of the injection pumps, see table 1.
表 1 Tabele 1 表 2 Tabele 2
发动机类型 供油始点 凸 轮 预 行 程 前冲程修正 喷射泵基 理论厚度 垫 片 理论厚度 垫片厚
标准/总共 轴 类 (Vh) 系数 本尺寸 “Ts” 厚度 “Ts” 度
(0C/A 型 标准值 (mm/0C/A) (L0)(mm) (mm) “Ss” (mm) “Ss”
BTDC) (mm) (mm) (mm)
Engine Commence Cam Pre-strok Pre-stroke Basic Theor. Shim Theor. Shim
type ment of shaft e(Vh) correction Dimensio Thickness Thick Thicknes Thick
delivery type nom. factor n inj. ”TS“ ness s ness
nom./tol. value(m (mm/°C/A Pump (mm) ”SS“ ”TS“ ”SS“
(0C/A m) ) (L0) (mm) (mm) (mm)
BTDC) (mm)
BFM 2012 0.0 K 4.80 0.14 117.5 0.95-1.049 1.0 2.45-2.549 2.5
BFM 2012 1.0 K 4.62 0.14 117.5 1.05-1.149 1.1 2.55-2.649 2.6
BFM 2012 2.0 K 4.44 0.14 117.5 1.15-1.249 1.2 2.65-2.749 2.7
BFM 2012 3.0 K 4.27 0.14 117.5 1.25-1.349 1.3 2.75-2.849 2.8
BFM 2012 4.0 K 4.11 0.14 117.5 1.35-1.449 1.4 2.85-2.949 2.9
BFM 2012 5.0 K 3.95 0.14 117.5 1.45-1.549 1.5 2.95-3.049 3.0
BFM 2012 2.0 L 5.14 0.14 117.5 1.55-1.649 1.6 3.05-3.149 3.1
BFM 2012 3.0 L 4.97 0.14 117.5 1.65-1.749 1.7 3.15-3.249 3.2
BFM 2012 4.0 L 4.80 0.14 117.5 1.75-1.849 1.8 3.25-3.349 3.3
BFM 2012 5.0 L 4.62 0.14 117.5 1.85-1.949 1.9 3.35-3.449 3.4
BFM 2012 6.0 L 4.44 0.14 117.5 1.95-2.049 2.0 3.45-3.549 3.5
BFM 2012 7.0 L 4.26 0.14 117.5 2.05-2.149 2.1 3.55-3.649 3.6
BFM 2012 8.0 L 4.11 0.14 117.5 2.15-2.249 2.2 3.65-3.749 3.7
BFM 2012 9.0 L 3.95 0.14 117.5 2.25-2.349 2.3
BFM 2012 1.0 H 5.52 0.14 117.5 2.35-2.449 2.4
BFM 2012 2.0 H 5.36 0.14 117.5
BFM 2012 3.0 H 5.20 0.14 117.5
BFM 2012 4.0 H 5.05 0.14 117.5
BFM 2012 5.0 H 4.89 0.14 117.5 注意！98D电控单体泵的发动机，
BFM 2012 6.0 H 4.73 0.14 117.5 此单体泵统一带1111068B52D单体泵
BFM 2012 7.0 H 4.58 0.14 117.5 调整垫（2.4厚），无EP数值
BFM 2012 8.0 H 4.43 0.14 117.5
BFM 2012 2.0 Q 5.31 0.14 117.5 Notice! Electricity control fuel pump
BFM 2012 3.0 Q 5.14 0.14 117.5 use 1111068B52D shim ,without ED
BFM 2012 4.0 Q 4.97 0.14 117.5 value
BFM 2012 5.0 Q 4.80 0.14 117.5
BFM 2012 6.0 Q 4.62 0.14 117.5
BFM 2012 7.0 Q 4.44 0.14 117.5
BFM 2012 8.0 Q 4.26 0.14 117.5
BFM 2012 9.0 Q 4.11 0.14 117.5
BFM 2012 10.0 Q 3.95 0.14 117.5
BFM 2012 2.0 P 5.23 0.14 117.5
BFM 2012 3.0 P 5.08 0.14 117.5
BFM 2012 4.0 P 4.92 0.14 117.5
BFM 2012 5.0 P 4.76 0.14 117.5
BFM 2012 6.0 P 4.61 0.14 117.5
BFM 2012 7.0 P 4.4 0.14 117.5
BFM 2012 8.0 P 4.31 0.14 117.5
BFM 2012 9.0 P 4.16 0.14 117.5
BFM 2012 10.0 P 4.01 0.14 117.5

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 技术参数/符号注释 Specification data / Key to symbols
计算举例：BFM2012
气缸号 0 1 2 3 4 5 6
喷射泵号 Xxx

铭牌上的提前角 0C/A
来自表 1 的 Vh 修正系数 mm/0C/A
来自表 1 的 Vh 标准值 mm
来自表 1 的 L0 mm
喷射泵的 A/100 mm
L 测量值 mm

mm
E3=Vh 标准值 mm
E4=E3+L0 mm
E5=E4+A/100 mm
TS=L-E5 mm
来自表 2 的 “SS” mm
Calculation example: BFM2012
Cylinder No. 1 2 3 4 5 6
Injection pump No.

INGETING TIMING
Vh corr. factor from table 1 mm/°C/A
Vh nom. from table 1 mm
L0 from table 1 mm
A/100 of inj. pump mm
L measured mm

E3 = Vh nom. mm
E4 = E3 + L0 mm
E5 = E4 + A/100 mm
TS = L - E5 mm
”SS“ from table 2 mm

10
 技术参数/符号注释 Specification data / Key to symbols
BFM2012 维修时标准长度 L0=117.5mm 的波许喷油泵喷油提前角调整垫片厚度的确定
injection pump replacement in case of service. Basic dimension L0 = 117.5 mm
对于具有垫片的旧喷射泵不作该要求。
The old injection pump with shim is not required for such purpose.
例如：气缸 3 的喷射泵在 BF6M2012 中被替换。
Example: The injection pump of cylinder 3 is to be replaced on a BF6M 2012.
程序：Procedure:
从名称图板的”EP”列中读取气缸 3 的 EP 码，如 295。
（读取次序：行 1＝气缸 1，行 2＝气缸 2 等等。）
Read off EP code for cylinder 3 from name plate under column ”EP“, e.g. 295.
(Reading sequence: line 1 = cyl. 1, line 2 = cyl. 2, etc.)

根据 EP 码，从表 3 中选择修正的泵安装尺寸（Ek），如 120.875mm。

Take corrected injection pump installation dimension (EK) from table 3 according to
EP code, e.g. 120.875 mm.
表 3 Table 3
Ek EP- Ek EP- Ek EP- Ek EP-
(mm) 码 (mm) 码 (mm) 码 (mm) 码
119.25 230 119.85 254 120.45 278 121.05 302
119.275 231 119.875 255 120.475 279 121.075 303
119.3 232 119.9 256 120.5 280 121.1 304
119.325 233 119.925 257 120.525 281 121.125 305
119.35 234 119.95 258 120.55 282 121.15 306
119.375 235 119.975 259 120.575 283 121.175 307
119.4 236 120.0 260 120.6 284 121.2 308
119.425 237 120.025 261 120.625 285 121.225 309
119.45 238 120.05 262 120.65 286 121.25 310
119.475 239 121.075 263 120.675 287 121.275 311
119.5 240 120.1 264 120.7 288 121.3 312
119.525 241 120.125 265 120.725 289 121.325 313
119.55 242 120.15 266 120.75 290 121.35 314
119.575 243 120.175 267 120.775 291 121.375 315
119.6 244 120.2 268 120.8 292
119.625 245 120.225 269 120.825 293
119.65 246 120.25 270 120.85 294
119.675 247 120.275 271 120.875 295
119.7 248 120.3 272 120.9 296
119.725 249 120.325 273 120.925 297
119.75 250 120.35 274 120.95 298
119.775 251 120.375 275 120.975 299
119.8 252 120.4 276 121.0 300
119.825 253 120.425 277 121.025 301

从新喷射泵读取旧喷射泵长度的代码（A）如 42。
Read off code for injection pump length (A) from new injection pump, e.g. 42.
从表 1 中选择喷射泵（L0）的基本尺寸，如 117.5mm。
Take basic dimension of injection pump (L0) from table 1, e.g. 117.5 mm
确定垫片的理论厚度（Ts）。
Determine theoretical shim thickness (TS).
TS=EK-(L0+A/100)
TS=120.875mm-(117.5mm+42/100mm)
TS=2.955mm
从表 2 中选择垫片厚度（Ss）。
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 技术参数/符号注释 Specification data / Key to symbols
Select shim thickness (SS) from table 2.
Ts 2.955mm=Ss 3.0mm
确定喷射泵的修正安装尺寸和 EP 码
Determining corrected installation dimension and EP code for injection pump.
更换曲轴箱、曲轴或挺柱时，必须反复确定修正安装尺寸（Ek），同一面板中的相关 EP 码也必须
随之更改。
When replacing crankcase, camshaft or roller tappets, the corrected installation dimension (EK) must be
determined once again and the relevant EP code on the name plate must be changed.
有关表格，请参见表 1、表 2、表 3。
For tables see table 1,table 2,table 3.
计算示例：BFM2012

气缸号 0 1 2 3 4 5 6
喷射泵号 Xxx

铭牌上的提前角 0C/A
来自表 1 的 Vh 修正系数 mm/0C/A
来自表 1 的 Vh 标准值 mm
来自表 1 的 L0 mm
喷射泵的 A/100 mm
L 测量值 mm

mm
E3=Vh 标准值 mm
E4=E3+L0 mm
E5=E4+A/100 mm
TS=L-E5 mm
来自表 2 的 “SS” mm
Calculation example: BFM2012
Cylinder No. 1 2 3 4 5 6
Injection pump No.

INGETING TIMING
Vh corr. factor from table 1 mm/°C/A
Vh nom. from table 1 mm
L0 from table 1 mm
A/100 of inj. pump mm
L measured mm

E3 = Vh nom. mm
E4 = E3 + L0 mm
E5 = E4 + A/100 mm
TS = L - E5 mm
”SS“ from table 2 mm

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技术参数/符号注释 Specification data / Key to symbols
符号的注释

总成拆解 注意操作安全

总成再装配 注意零件损伤

拆除相关零件 支撑

相关零件再装配 涂机油

特别注意 涂润滑油

检查－调整，如转 作标记，拆卸前做标

矩、尺寸、压力等。 记要遵照标记再装配

专用工具 平衡

消除所有的不平衡

加注
注意安装方向
如油、冷却水等。

排出
目视检查
如油、冷却水等。

或许还可以修理 松开

必要时更换 如松开夹紧装置

每次重装时都要更 锁紧
新 如拧紧卡紧装置

锁紧零件拆解 通风
如打开销钉，锁片等

涂密封剂
机加工
如液体密封剂

13
技术参数/符号注释 Specification data / Key to symbols
Key to Symbols
Disassembly Guard against personal
of assembly groups injury Indication of
hazard
Guard against material
Reassembly damage Damage to
to form assembly group parts

Remove Prop up - Support -

obstructing parts Hold
Reinstall - Remount
parts which had
obstructed disassembly Oil
Attention! Important

otice!
Grease
Check - Adjust Mark
e. g.torque dimensions, before disassembly,
observe marks when
pressures, etc. reassembling

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

Loosen - Release
Possibly still service e. g. loosening a
able Renew if necessary clamping device
Tighten - Clamp
Renew at each e. g. tightening a
reassembly clamping device

Unlock – Lock e. g.
split pin, locking plate,
etc. Vent

Lock – Adhere e. g.
with liquid sealant Machining process

14
技术参数/符号注释 Specification data / Key to symbols
2．检查与调整 Control and adjustment 页码 Page
气门间隙 Valve clearance--------------------------------------------------------------------------16
喷油器 Injector------------------------------------------------------------------------------------18
压缩压力 Compression pressure-------------------------------------------------------------------21
节温器 Thermostat--------------------------------------------------------------------------------23

15
检查与调整 Control and adjustment
气门间隙 Valve clearance
专用工具：Special tools:
旋转齿轮 Turning gear 100 320
起动装置 Cranking device 100 330
当发动机处于冷却或较温的状态下时可以调整
它的气门间隙，发动机至少可冷却 0.5h，油温
<80ºC
Valve clearance can be adjusted on the engine in
cold or warm condition allowing the engine to
cool down for 0.5 h at a minimum.
Oil temperature < 80 °C
注意：替换气缸盖垫圈的地方，需要将气门间
隙增加 0.1mm。
运转 1500 小时后设置标准的气门间隙。
Note: The valve clearance is to be increased by
0.1 mm at every cylinder head gasket renewal.
The standard valve clearance is to be adjusted
after completion of 50-150 hours of operation.

拆除气门室罩和曲轴箱呼吸器
Cylinder head cover and crankcase breather
have been removed

1．转动发动机至 1 缸气门重叠
Turn engine until valves of cyl. No. 1 overlap.

参见技术参数中气门间隙调整图解。
See specification data for valve clearance
adjustment schematic.

气门间隙每1500h检查，如有需要，则调整
Valve clearance check and adjustment(if
needed) is added in routine maintenance, the
cycle is 500h

注意：气门重叠表示：排气门即将关闭，
进气门即将打开，在此位置推杆不能转动。
Note: Valves overlapping means:Exhaust valve
about to close.Inlet valve about to open.Neither
pushrod can be turned in this position.

16
检查与调整 Control and adjustment
2．使用测隙规调整各个气缸的气门间隙。
Adjust valve clearance on respective cylinder with
feeler gauge.
进气门 Inlet valve clearance： 0.3mm
排气门 Exhaust valve clearancee: 0.5mm
3．拧紧防松螺母。
指定拧紧扭矩：20±2 Nm
使用测隙规反复检查气门间隙。
Tighten locknut with a torque of 20±2 Nm.
Recheck the adjustment with feeler gauge.

4．将新垫片安装在合适位置。
Position gasket in place.

5．安装气门室罩盖，拧紧螺栓至指定的拧紧扭
矩：11 Nm
Fit cylinder head cover and cover plate. Tighten
bolts with a torque of 11Nm.

17
检查与调整 Control and adjustment
喷油器 Injector

通用工具：Commercial tools required:

喷嘴测试仪Nozzle tester： 8008
长套管Long socket a/flats 15： 8012
专用工具：Special tool required:
喷油器压板：Assembly tool 110 110

注意：在对喷油设备检修时，必须确保最大限
度的清洁，在检测喷油器时只能使用符合 ISO
4113 规定的纯净测试油或者清洁的柴油。
Note: Utmost cleanliness must be ensured when
working on the injection equipment. For testing
the injector use only pure test oil to ISO 4113 or
clean diesel fuel.
特别注意：
谨防喷油器的油喷，燃油渗入皮下组织，可能
引起血液中毒。
Caution
Beware of injection nozzle fuel jet. The fuel
penetrates deeply into the skin tissue and may
cause blood poisoning.

1．将喷油器连接到喷嘴测试仪上。
Connect injector to nozzle tester.

2．检查开启压力。
开启测压计，慢慢压下喷油器杠杆，压力计
指针停止或突然下降点的压力即为开启压
力。
开启压力检测值为 250＋8bar 时，喷油器可
继续使用。
Checking opening pressure
With pressure gauge switched on, slowly press
down lever of nozzle tester. The pressure at which
the gauge pointer stops or suddenly drops,
is the opening pressure. Opening pressure check
value for possible reuse: 250 + 8 bar

18
检查与调整 Control and adjustment
3．喷油器开启压力的调整
松开螺旋护套，拆除所有零件。
Adjusting the opening pressure on the injector
Unscrew cap nut and remove all parts.

拆除顺序Sequence of parts disassembly

1. 螺旋护套 Cap nut
2. 喷油器喷嘴 Injection nozzle
3. 弹簧座 Adapter
4. 止推销 Thrust pin
5. 压力弹簧 Compression spring
6. 调整垫片 Shim

4．通过选择合适的调整垫片调节压力，调整垫
片越厚则开启压力越大，拧紧螺旋护套至 40
－50Nm，在喷嘴测试仪上重新检测开启压
力。
Adjust pressure by selecting appropriate shim.
A thicker shim increases the opening
pressure.Tighten cap nut with a torque of 40 -
50 Nm. Recheck injector on nozzle tester.

5．紧固检查 Checking for tightness

用压缩空气吹干喷油器及外壳，按下测压计
手柄直至压力达到比上一次开启压力读数
低约 20bar。
Dry nozzle and nozzle holder – blow out with
compressed air. Press down handlever of tester
until a pressure of up to about 20 bar below
the previous opening pressure reading is
attained.

19
检查与调整 Control and adjustment
6．如在 10 秒内没有滴漏现象，表明喷油器紧
固正常。
Nozzle is tight if there is no dripping within a
period of 10 seconds.

7． 在有滴漏的情况下，喷油器必须拆解并清晰
干净以防滴漏，如这样还不能防止滴漏，则
此喷油器必须更换。
In case of a drip, the injector must be dismantled
and cleaned to remedy the leak. If this does not
cure the leak, the injector must be replaced.
并且不允许重新操作。
Reworking is not permissible.

8．打压及喷雾试验
Buzzing and spray pattern test
关闭检测计的压力计。打压试验可以通过听
到的声音简易地检查针阀在针阀座中的运动，
新的喷油器会发出与使用过的喷油器不同的蜂
鸣声，由于针阀在针阀座中的磨损可引起损坏，
如果尽管清洗后喷油器仍不能发出正常的蜂鸣
声，其必须被更换。
Switch off pressure gauge of tester. The buzzing
test permits an audible check of the ease of
movement of the nozzle needle in the nozzle
body. New injectors emit a different buzzing
sound as compared to used injectors. It
deteriorates due to wear in the needle seat area. If
an injection nozzle does not buzz despite cleaning,
it must be renewed.
一个正常使用的喷油器，在手柄快速的运动
中，应发出清晰的蜂鸣声，同时应呈现良好的
喷雾形式，新的喷油器和旧的喷油器喷雾形式
会有显著的不同。
A used injector should buzz clearly during rapid
actuation of the hand lever, while exhibiting a
well atomized spray pattern. The spray pattern
may differ noticeably from that of a new injector.

20
检查与调整 Control and adjustment
气缸压力：Compression pressure

通用工具Commercial tools required:

Compression tester 压力计：2461
Torx tool kit E 型专用套筒：8189
专用工具Special tool required:
测压计接头 Connector：100110

气门间隙调整完毕，拆除喷油器。
Injectors have been removed, valve
clearance has been checked.

1．将带新的专用密封圈的接头插入气缸内。
Insert connector with new special seal.

2．安装压板，拧紧螺栓。
Fit clamping pad. Tighten bolt.

3．必要时，在接头上加拧一个接头。
If necessary, screw on adapter for
connector.

21
检查与调整 Control and adjustment
4．接连压力计，用起动机拖动发动机
缸压：30-38 bar
Connect compression tester. Turn engine with
starter.
Compression pressure:30-38bar
缸压的测量结果与测量过程中起动机转速
以及发动机所处的海拔高度有很大关系，因此，
很难规定精确的限值，测量缸压的目的仅在于
比较同一台发动机各缸压力，如果各缸缸压压
差超过 15％应该拆解该缸有关零件确定原因。
The measured compression pressure is dependent
on the starting speed during the measuring process
and also on the altitude of the engine site.
Therefore it is difficult to specify
precise limit values. It is recommended to use the
compression pressure measurement only for
comparison of compression pressures of all
cylinders in one engine. If a difference in
pressure in excess of 15% is determined, the
cylinder unit concerned should be dismantled to
establish the cause.
注意：安装喷油器须使用新的专用密封圈，安
压板并拧入螺栓。
安装新的高压油管，用手指拧紧锁定螺母。
密封圈锥面必须配合紧密。
高压油管只能使用一次，不允许再弯曲。
拧紧压板螺栓至 16＋5Nm
预紧喷油管到油泵锁定螺母以及到喷油器
锁定螺母至 5Nm，之后拧紧至 30＋3.5Nm。
一般使用新的回油管。
拧紧气门室罩盖螺栓至 9±1Nm。
Note: Fit injectors with new special seals. Position
clamping pads and start bolts. Fit new injection
lines. Screw on cap nuts finger tight.
The sealing cones must match precisely.
Rebending is not permissible. The injection lines
may not be used twice.
Tighten bolts of clamping pads with a torque of 16
+ 5 Nm.
Preload cap nuts of injection lines on injection
pumps and injectors with a torque of approx. 5
Nm. Thereafter tighten cap nuts with a torque of
25 +3.5 Nm.
Leakage fuel lines must always be renewed.
Tighten cylinder head cover with a torque of 9
±1 Nm.

22
检查与调整 Control and adjustment
节温器 Thermostat
在拆除状态下检查节温器
Check thermostat in removed condition
1. 节温器上的测量尺寸”a”。
Measure dimension “a” on the thermostat.
注意：”a”＝大约 83±2℃（T1）时开始的冲程
”b”＝大约 95℃（T2）时结束的冲程
Note:
“a” = stroke beginning at approx.83 ± 2°C
(T1)
“b” = stroke bending at approx. 95°C (T2)

2. 在水箱中加热节温器。
Heat up thermostat in the water bath.
为了精确确定开始点，读取温度时应尽可能
的靠近节温器，但是不要接触。
水必须不停搅拌，使温度分布均衡。温度上
升速度最大不能超过 1℃/分，否则，开始点
将相应延迟。
For a determination of the exact opening point,
the temperature reading should take place as
closely as possible to the thermostat, however,
without contacting the latter. The water must be
continuously stirred to arrive at a uniform
distribution of temperature. The rate of rise of
temperature should not exceed 1°C/min. at a
maximum otherwise opening will be delayed
correspondingly.

3. 节温器上的测量尺寸”b”。
在显示的温度（T2）下行程最小长度为 8mm。
Measure dimension “b” on the thermostat.
Stroke length at indicated temperature (T2) 8 mm
at a minimum.

23
零部件维修 Repair of components

24
零部件维修 Repair of components
3.零部件的维修 Repair of components
总成分组 名称 页码
Assembly Group Description Page
01 曲轴箱及缸体总成 26
Crankcase
01 前盖及机油泵 34
Front cover / Lube oil pump
05 曲轴 37
Crankshaft
05 飞轮及齿圈 40
Starter ring gear / flywheel
06 连杆 42
Connecting rod
07 活塞 48
Piston
08 气缸盖 51
Cylinder head
09 正时齿轮室 57
Timing case
10 凸轮轴 59
Camshaft
11 摇臂支架 61
Rocker arm bracket
19 喷油器 63
Injector
27 控制齿条 67
Control rod
33 空气压缩机 69
Air compressor
72 质量平衡轴 71
Mass balancing shaft
83 带有紧固凸缘的液压泵 73
Hydraulic pump with
fastening flange

25
零部件维修 Repair of components
曲轴箱 Crankcase

26
零部件维修 Repair of components
曲轴箱 Crankcase
通用工具：Commercially available tools
内径量表Internal dial gauge
外径千分尺 External screw type micrometer
专用工具：Special tools:
控制齿条拆装工具 110 470
Assembly tool for control rod sleeves 110 470
MAG 轴套的装配工具 143 780
MAG sleeves 143 780
曲轴轴套的装配工具 143 840
camshaft sleeves 143 840

1. 清洁曲轴箱并检查是否损坏
Clean crankcase and inspect for damage.
注意：测量前，按规定拧紧主轴承螺栓
Note: Prior to measurement tighten main bearing
caps as specified.
初始拧紧扭矩： 50Nm
第一个锁紧角度 90º
第二个锁紧角度 90º
Initial tightening torque:50 Nm
1st tightening angle: 90°　
2nd tightening angle: 90°　

2. 量规轴承座孔/轴瓦（如果必须）
Gauge bearing bores / bearing shells (if
necessary)
使用内径量表测量“a”和“b”平面上“1”
和“2”处的轴承座孔/轴瓦。
Use internal dial gauge for measuring bearing
bores / bearing shells at points “1” and “2”
on planes “a” and “b”.
公称孔径：Nominal bore diameter:
轴承座孔 Bearing bores： 9.0-89.022mm
轴瓦 Bearing shells： 84.3-84.072mm
间隙轴承/曲轴Clearance bearing /crankshaft：
0.03-0.092mm

27
零部件维修 Repair of components
3. 气缸的测量 Gauging of cylinders
若要测量气缸，必须正确安装轴承盖。
For cylinder gauging, bearing covers must
be properly installed.
3.1 将内径量表设定为 101 mm
Set internal dial gauge to 101 mm.

3.2 测量气缸之间：
Gauge cylinder diameter:
公称直径 Nominal diameter： 101+0.02mm
磨损极限 Wear limit: 101.1mm

3.3 在发动机纵轴“a”和横轴“b”方向测量
气缸
Gauge cylinders in the longitudinal axis “a”
and transversal axis “b” of engine

3.4 仍然在平面 1-3 中

and also in planes 1-3
如果气缸磨损，曲轴箱可以在我们的“维修中
心”磨制加大型气缸，直径为 Φ101.5mm。
Crankcases can be honed up to oversize
cylindersΦ101.5 mm in our Service Centers if
cylinders are worn out.

28
零部件维修 Repair of components
4. 测量凸轮轴轴承衬套
Gauge camshaft bearing bushes
4.1 将内径量表设定为 63mm。
Set internal dial gauge to 63 mm.

4.2 在“a”和“b”平面的 1 和 2 点测量轴承

衬的示意图。
Schematic drawing for gauging
bearing bushes at points 1 and 2 in
planes “a” and “b”.

4.3 测量轴承衬套，必要时更换新件。
Gauge bearing bushes, replace by
new ones, if necessary.
公称直径 Nominal diameter： 63+0.054mm
磨损极限 Wear limit：63.080mm

5. 更换凸轮轴轴承衬套
Replace camshaft bearing bushes
5.1 拆卸凸轮轴轴承衬套。
使用抽取工具 143 840
Remove camshaft bearing bushes.
Use extractor tool 143 840

29
零部件维修 Repair of components
5.2 在飞轮端安装新轴承衬套
Fit new bearing sleeve from the flywheel end.
注意：观察润滑油孔的正确位置。端轴承的润
滑油孔必须在一条直线上。
Note: Observe correct position of lube oil bores.
The lube oil bores of the bearing on the flywheel
end must be in line.

5.3 示意图：轴承衬套的安装位置。
Schematic drawing: Mounting position of the
bearing sleeves.

5.4 嵌入轴承衬套。
使用压入工具 143 840
Insert bearing sleeve.
Use press-in tool 143 840.

6. 质量平衡－测量轴承衬套
Mass balancing – gauge bearing sleeves
6.1 将内径量表设定为 54mm。
Set internal dial gauge to 54 mm.

30
零部件维修 Repair of components
6.2 显示如何在“a”和“b”平面的 1 和 2 处
测量轴承衬套的示意图。
Schematic drawing showing how bearing
sleeves are gauged at points 1 and 2 in planes
“a” and “b”.

6.3 测量轴承衬套，必要时更换新件。
Gauge bearing sleeves and replace as necessary
公称直径 Nominal diameter：54.06-54.105mm
磨损极限 Wear limit:： 54.125mm

7. 质量平衡－更换轴承平衡轴衬套
Mass balancing – replace bearing balancer
bushes
7.1 取出轴承衬套。
使用发动机平衡轴套筒的装配工具 143 780。
Pull out bearing bushes. Use assembly tool for
engine balancer bushes 143 780

7.2 安装新的轴承衬套，并相应标记，确保润
滑油孔/中心孔在一条直线上。使用装配工具
143 780。
Fit new bearing bush, mark accordingly and
make sure that lube oil bores/center bores are in
line. Use assembly tool 143 780.

31
零部件维修 Repair of components
7.3 嵌入轴承衬套。使用装配工具 143 780
Insert bearing bush. Use assembly tool 143 780

8. 更换控制杆的导向套
Replace guide bushes for control rod
8.1 取出前端导向套筒。
Knock out front guide bush.
注意：对发动机平衡器轴套使用较短的装配工
具 110 470。外径为Φ25mm。
Note: Use short assembly tool for engine
balancer bushes 110 470,outer Φ25 mm.

8.2 从 飞 轮 末 端 取 出 导 向 套 筒 （ 仅 适 用 于
BF6M 发动机）。
Knock guide bushing out from the flywheel end
(only for BF6M engines).
注意：对于导向套筒使用较长的装配工具 110
470，外径为Φ28mm。
Note: Use long assembly tool 110 470 for the
guide bushes, outer Φ28 mm.

8.3 将导向套筒放置到较短的装配工具 110

470，斜面面向曲轴箱。
Place guide bushes onto short assembly tool 110
470 with the chamfered side facing the
crankcase.

32
零部件维修 Repair of components
8.4 使用装配工具 110 470 将居中装置安装到
曲轴箱的前端。
Fit centering device to front side of crankcase
using assembly tool 110 470.

8.5 嵌入导向轴套直到即将运行。使用装配工
具 110 470。
Insert guide bushing as far as it will
go. Use assembly tool 110 470.

8.6 仅适用于 BF6M 发动机。

在飞轮末端嵌入导向套筒，如 8.3-8.4 所述，
但是，飞轮末端要使用长装配工具 110 470。
Only for BF6M engines.
Insert guide bush on the flywheel end
as described under items 8.3 – 8.4,
however, from the flywheel end using
the long assembly tool 110 470.

9. 安装螺旋塞
Mount screw plugs
9.1 检查输油管是否畅通。
拧紧螺旋塞。为 4 和 14 安装新的 O 形环。
Check oil ducts for free passage. Tighten screw
plugs. Provide for new O-rings for items
4 and 14..
指定拧紧扭矩：
Specified tightening torque:
Item6： 95±9.5Nm
Item7: 75±7.5Nm
Item4、8、14: 35±3.5Nm
Item18: 10±2Nm
注意：通常在拆卸后，要为6、7、8和18提供
新零件。
Note: Provide for new components
for items 6, 7, 8 and 18 after
disassembly as a rule.

33
零部件维修 Repair of components
前盖/机油泵 Front cover / lube oil pump

34
零部件维修 Repair of components
前盖/机油泵 Front cover / lube oil pump
1. 取出曲轴前油封。
Knock out shaft oil seal ring.

注意：有关新油封圈的安装，请参见第四章内
容。
Note: Refer to Chapter 4 for the installation of a
new shaft oil seal ring.

2. 目测检查前盖，必要时更换新件。
Visually inspect front cover and replace as
necessary.
注意：转子必须可以自由转动。
Note: Rotors must turn freely.

3. 拆下润滑油泵，清洁前盖。
Remove lube oil pump for cleaning of front
cover.

4. 如果个别部件有可见磨损或损坏，请更换
整个前盖。
Replace the complete front cover in the case of
visible wear or damage of individual
components.

35
零部件维修 Repair of components
5. 嵌入外部和内部转子。
Insert external and internal rotors.
注意：内部转子的凹槽必须朝向内侧。
Note: The groove at the internal rotor
must point to the inside.

6. 安装前盖。拧紧螺栓。
Put cover in place. Tighten bolts.
指定拧紧扭矩：8.5±1Nm
Specified tightening torque: 8.5 ± 1 Nm
注意：观察内部转子的安装方向。
Note: Observe the mounting direction of
the internal rotor.

36
零部件维修 Repair of components
曲轴 Crankshaft

37
零部件维修 Repair of components
曲轴 Crankshaft
磨损的曲轴可以在我们的“维修中心”修理。
A worn out crankshaft can be repaired in
our Service-Centers.
1. 用曲轴放在曲轴测量台架上。
Chuck crankshaft up on prism stand.

2. 图中表示出住轴颈测量平面“a”、“b”及
其中测量点“1”、“2”。
Schematic for gauging main bearing journals at
points “1” and“2” in planes “a” and “b”.

主轴颈直径 Journal diameter 83.98-84.00mm

每级减少 Each undersize 0.25mm
负公差尺寸极限 Limit for undersize 83.73mm
磨损极限Wear limit:
轴径椭圆度 Journal ovality： 0.01mm

3. 测量主轴颈宽度。
Gauge thrust bearing journal width

轴套宽度 Journal width 32.2-32.24mm

每级加工 1st oversize stage 0.4 mm
最大级 Limit for oversize 32.64mm

4. 测量连杆轴颈
Gauge crankpins.

曲柄销直径 Crankpin diameter 62.98-63.00mm

第级减小Each undersize 0.25mm
最小值 Limit for undersize 62.73mm

磨损极限Wear limit:
曲柄销椭圆度 Crankpin ovality 0.01mm

38
零部件维修 Repair of components
5. 检查真正运行的曲轴
Check crankshaft for true running.

最大圆度 Out of roundness max： 0.10mm

6. 目测检查轴端密封表面圆跳动。
Inspect running surfaces of shaft seals.

39
零部件维修 Repair of components
飞轮齿圈/飞轮 Starter ring gear / flywheel

40
零部件维修 Repair of components
1．在齿圈上打孔。
Drill ring gear apart.
注意：确保不损伤飞轮。
Note: Make sure not to damage flywheel.

2．拆除齿圈。
Remove ring gear.

3．清洗飞轮并检查支撑法兰。
Clean flywheel and inspect at supporting flange.

4．加热齿圈最高至210°C，将齿圈安装入位
与法兰平面贴紧。
Heat ring gear to max. 210°C. Place ring gear
in position and bring to stop at flange.

41
零部件维修 Repair of components
连杆 Connecting rod

42
零部件维修 Repair of components
连杆Connecting rod
专用工具：Special tool required:
小头轴套装配工具：131090
Assembly tool for small end bush：131090
1．设定内径百分表：Ф38mm
Set internal dial gauge:Ф38mm

2．在“a”，“b”平面内“1”，“2”点测量连
杆小头轴套。
Gauge small end bush at points “1” and “2”
in planes “a”and“b”.

3．测量。
Gauge.
压入后小头轴套规定值：
Small end bush pressed in Specified value
38.025-38.035mm
磨损极限：Wear limit:
小头轴套间隙：0.08 mm
Small end bush clearance 0.08mm

4．必要时更换小头轴套。

连杆小头内径：38.025–38.035 mm
Specified value:38.025–38.035 mm

43
零部件维修 Repair of components
5．压入小头轴套。
Press in small end bush flush.
注：小头轴套与连杆油道孔必须对准。
Note: Lube oil bores of small end bush and
connecting rod must be in line.

6. 压入后研磨小头轴套。
After pressing in, precision-bore small end bush
on a fine boring mill.

7. 确保盖与连杆配套使用。
Make sure that cap mates with connecting rod.
注意：确保定位销入位。
Note: Make sure that dowel pins are fitted.

8. 安装轴承盖，按规定拧紧螺栓。
Mount bearing cap. Tighten bolts in
accordance with specification.
初始拧紧力矩：30~40Nm
Initial tightening torque：30~40Nm
第一次拧紧转角： 60°
1st tightening angle 60
第二次拧紧转角： 30°
2nd tightening angle 30°

44
零部件维修 Repair of components
9.设定内径百分表：66.6mm
Set internal dial gauge:66.6mm

10.图中表示出连杆大头轴孔的测量平面“a”，
“b”及其中“1”，“2”两测量点。
大头内径：66.6-66.619mm
Schematic for gauging big end bearing bore at
points“1”and“2”in planes“a”，“ and “b”.
Bore for big end bearing: 66.6-66.619mm

11.如果测量读数符合规定的要求，则在安装
连杆轴瓦后可获得必要的预载荷。
If the gauge readings conform to the specified
values, the necessary preload will be obtained
after fitting the bearing shells.
注意：如果测量值仅是稍微偏离指定值，则应
该安装新的轴瓦，并再次测量。
Note: If the measured values deviate only lightly,
additional measurements are to be carried out
with new bearing shells fitted.

12.拆下轴承盖，安装新的轴瓦，重新安装轴
承盖，并按一下要求拧紧螺母。
Remove bearing cap and fit new bearing shells.
Refit bearing cap.Tighten nuts in accordance
with specification.

初始拧紧力矩： 30Nm
Initial tightening torque:30Nm
第一次拧紧转角： 60°
1st tightening angle 60°　
第二次拧紧转角： 30°
2nd tightening angle 30°

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零部件维修 Repair of components
13.设定内径百分表，在“a”， “b”平面的“1”，
“2”测量轴瓦内径。
Set internal dial gauge. Gauge bearing shells at
points „1“ and „2“ in planes „a“ and „b“.
Big end bearing shells
大头轴瓦内径Nominal diameter：
63,026 - 63,065 mm
每级减小Each undersize： 0.025mm
最小级undersize： 62,776 - 62,815mm
注：如果读数不超过公差范围0.015mm，连杆
可以继续使用，如果超过磨损极限，则需要更
换连杆。
Note: If the readings do not exceed bearing
tolerances by more than 0.015 mm, the rod can
be used further. If the limit value is exceeded,
replace the connecting rod.

14.在连杆测试仪上检查不带轴承的连杆。
Check connecting rod without bearing shells on
connecting rod tester.

14.1 平行度检查：
Parallelism check:
允许值：Permissible
公差tolerance： a＝0.05mm
长度范围over a distance of：x＝100mm

14.2垂直度检查。
Squareness check:
在x＝100mm的长度范围内“A”相对于“B”
的允许公差＝0.05mm。
Permissible tolerance „A“ relative to „B“ = 0.05
mm over a distance of x = 100 mm

46
零部件维修 Repair of components
连杆与活塞的装配Connecting rod

15.安装第一个弹性挡圈。
Bring one circlip into correct position and fit.

注意：卡簧的开口必须朝向活塞顶端。
Note: Ring gaps of circlips must face towards
piston crown.

16.装配活塞与连杆。
活塞上的飞轮标记必须与连杆上的标记销处
在同一侧。
Install piston together with connecting rod.
Flywheel symbol on the piston and dowel pins
of the connecting rod must be located on the
same side.

17.安装另一端卡簧入位。
Bring second circlip into correct position and fit.

47
零部件维修 Repair of components
活塞 Piston

48
零部件维修 Repair of components
活塞 Piston
专用工具：Special tools required:
活塞环卡钳：130300
Piston ring pliers:130300
1.用辅助工具拆卸卡簧，取出活塞销。
Remove circlip. Take out piston pin.
注意：不使用辅助工具，是危险操作。
Note: Risk of injury when not using auxiliary
tool.

2. 调整活塞环卡钳至活塞直径，拆除活塞环。
Adjust piston ring pliers to piston diameter.
Remove piston rings.

3.清洗并检查活塞及活塞环槽。
Clean and inspect piston and ring grooves.

4.用塞尺测量活塞环开口间隙。
Measure ring gap with feeler gauge.

1道环间隙：0.8mm
1st ring gap：0.8mm
2道环间隙：2.5mm
2nd ring gap：2.5mm
3道环间隙：1.5mm
3rd ring gap：1.15 mm

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零部件维修 Repair of components
5.用塞尺测量活塞环槽与活塞环的间隙。
Measure ring grooves with feeler gauge.
注意：测量时使用新的活塞环。
Note: Measurement to be made with new piston
rings.
磨损极限：Wear limits:
1道环间隙：梯形环槽
axial play 1st ring keystone groove
2道环间隙：0.17mm
axial play 2nd ring 0.17 mm
3道环间隙：0.10mm
axial play 3rd ring 0.10 mm

6.检查活塞销的磨损。
Check piston pin for wear.
活塞销直径：37.994- 38.00mm
Piston pin diameter：37.994- 38.00mm

7.活塞环的顺序及位置。
Order and position of piston rings:
1.梯形环顶面朝向燃烧室。
1.keystone ring, top facing
2.锥面压缩环，定面朝向燃烧室。
2. tapered compression ring, top combustion
chamber facing combustion chamber
3.刮油环。
3. bevelled-edge slotted oil control ring

8.安装活塞环。
Fit piston rings.
注意：刮油环的衬簧开口须对刮油环开口偏置
180°。
Note: Spring gap of bevelled-edge ring to be
offset by 180　relative to ring gap.

50
零部件维修 Repair of components
气缸盖 Cylinder

51
零部件维修 Repair of components
气缸盖 Cylinder
通用工具：Commercial tools required:
磁测量架Magnetic measuring stand
气门重置工具Valve reseating tool
气门密封钳 8024
气门弹簧装配杆 9017
Valve spring assembly lever 9017
专用工具：Special tools required:
指示表 100 400
夹紧架 Clamping stand 120 900
夹紧板 Clamping plate 120 910
安装气门导管油封 121 410

1. 预备测量
Preparatory measures
在夹具上安装气缸盖。使用夹紧架 120 900 和
夹紧板 120 910。
Mount cylinder head on fixture. Use clamping
stand 120 900 and clamping plate 120 910.

2. 拆卸气门
Remove valves
2.1 拆卸锥形锁块、气门弹簧盖、气门弹簧和
气门。使用气门弹簧装配杆 9017。
Remove cone clamp, valve spring cap, valve
springs and valves. Use valve spring assembly
lever 9017.
注意：排列拆下的零件，以避免混淆，便于重
新安装到同一位置。
Note: Arrange removed parts so as to prevent
confusion and facilitate re-fitting to the same
points.

2.2 拆卸气门油封
Remove valve stem sealing
注意：使用油封钳 8024。
Note: Use valve sealing pliers 8024.

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零部件维修 Repair of components
3. 评定气门状态
Assess valve condition
3.1 清洁气门，并目测检查。
Clean and visually inspect valves.
3.2 测量气门杆直径。
Gauge valve stem diameter.
进气门 Inlet valve： 7.965-7.98mm
排气门 Exhaust valve： 7.945-7.96mm

3.3 测量气门轮缘厚度：
Gauge valve rim thickness:
磨损极限：Wear limit:
进气门 Inlet valve： 1.8 mm
排气门 Exhaust valve： 1.1 mm

4. 评定气缸盖状态
Assess condition of cylinder head
4.1 清洁气缸盖，并目测检查其是否损坏。
Clean and visually inspect cylinder head for
damage.

4.2 目测检查气门座密封圈。测量气门座的宽
度。
Visually inspect valve seat inserts. Gauge width
of valve seats
磨损极限：Wear limit:
进气门 Inlet valve： 2.70 mm
排气门 Exhaust valve： 2.10 mm

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零部件维修 Repair of components
4.3 嵌入气门，测量导杆间隙。
Insert valves and gauge valve stem clearance.
磨损极限：Wear limit:
进气门 Inlet valve： 0.10 mm
排气门 Exhaust valve： 0.13 mm

注意：若要测量气门杆间隙，气门杆末端必须
停止用气门导向套筒冲洗。
Note: For measuring valve stem clearance, the
valve stem end must end up flush with the valve
guide bush.

4.4 测量气门中心到气缸盖密封表面的间隙。
Gauge valve recess between valve disc to
cylinder head seal surface.
气门下沉量。
磨损极限：
进气门： 1.40 mm
排气门： 1.40 mm

4.5 磨损的阀座密封圈、气门导套或汽缸盖垫
圈表面可以在我们的“维修中心”修理。
Worn out valve seat inserts, valve guides or
cylinder head gasketing surfaces can be repaired
in our Service Centers.

5. 气缸盖的再度使用
Reworking of cylinder head
5.1 如果气门座和气门杆凹槽还没有达到磨
损极限，可使用再加工气门座的专用工具，以
再度使用气门座。
Provided wear limits for valve seat and valve
recess have not yet been reached, re-work valve
seat using the special tool for the reworking of
valve seats.

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零部件维修 Repair of components
5.2 气门座圈的再度使用
Reworking of valve seat inserts
气门座角度 Valve seat angle：
进气门座 Inlet valve seat:30º
排气门座 Exhaust valve seat:45º

气门座宽度的极限尺寸：
Valve seat width limit dimension:
进气门座 Inlet valve seat:2.70mm
排气门座 Exhaust valve seat:2.10mm

5.3 测量从气门圆盘到气缸盖密封表面的气
门下沉量。
Measure valve recess from valve disc to cylinder
head seal surface.
磨损极限：Limit dimensions:
进气门 Inlet valve：1.4 mm
排气门 Exhaust valve：1.4 mm

6. 评定气门弹簧状态
Assess condition of valve springs
6.1 测量气门弹簧的长度。
Gauge length of valve spring.
零载荷标准长度，Zero load length,
标准值 standard 59±1.9mm

7. 安装气门导管密封圈及气门
Insert valve stem seal and valve

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零部件维修 Repair of components
9． 装配气缸盖 Assemble cylinder head

安装气门弹簧和气门弹簧座。
Assemble cylinder head: Position valve spring
and valve spring cap.
注意：在进气门及排气门导杆上涂一些润滑
油，特别是在有环槽的区域内，慢慢转动气门
导杆，轻轻的将气门压入气门导管内。
气门弹簧标为黄色的卷曲端必须朝向气缸盖。
Note: Oil valve stem of inlet and exhaust valves,
especially in the area of keyseats. Press valves
into valve stem guide with a slight turn and
applying a slight pressure.
The narrower coils must face towards cylinder
head.

9．安装气门弹簧安装杠杆，装入锥型锁片。
Fit valve spring assembly lever, insert cone
clamp.

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零部件维修 Repair of components
正时齿轮室罩盖 Timing case

57
零部件维修 Repair of components
1. 取出曲轴油封。
Knock out shaft oil seal ring.

2. 目测检查正时齿轮室罩盖，必要时更换新
件。
Visually inspect timing case and replace as
necessary.
注意：若要嵌入新的油封圈，请参见第四和第
五章内容。
Note: Insert new shaft oil seal ring, see Chapters
4 and 5.

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零部件维修 Repair of components
凸轮轴 Camshaft

59
零部件维修 Repair of components
凸轮轴 Camshaft
通用工具：
Commercially available tools:
外径千分尺
External screw type micrometer
1.目测检查凸轮及轴磨损情况。
Visually inspect bearing journals and
cams for wear, gauge – as necessary.
支承轴颈直径： 62.98-62.93mm
Bearing journal diameter: 62.98 – 62.93 mm
凸轮冲程：Cam stroke:
进气门 Inlet valve： 6.9±0.08mm
排气门 Exhaust valve： 7.0±0.08mm

2. 目测检查凸轮轴的齿轮是否磨损。
Visually inspect camshaft gears for wear.

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零部件维修 Repair of components
摇臂支架 Rocker arm bracket

61
零部件维修 Repair of components
摇臂支架 Rocker arm bracket

1. 拆除摇臂支架。
Dismantle rocker arm bracket.

2. 逐项检查磨损，必要时加以更换
Check for wear and replace if necessary:
－轴颈Journals
－调整螺钉Adjusting screw,
－摇臂接触面Rocker arm contact face
－摇臂轴孔Bore

3. 检查油孔是否通畅。
Check oil duct for free passage.

4. 重新组装摇臂支座，安装锁环。
Reassemble rocker arm bracket. Fit circlips.

62
零部件维修 Repair of components
喷油器 Injector

63
零部件维修 Repair of components
喷油器 Injection
通用工具：
Commercially available tools:
长套筒扳手尺寸 15 8012
Long socket size 15 ____________ 8012
专用工具：Special tools:
喷油器压板 110 110
Dolly for injector 110 110
1. 松开螺旋护套。
Unscrew cap nut.

2. 拆卸顺序：
Sequence of parts disassembly
1. 螺旋护套 Cap nut
2. 喷油嘴 Injection nozzle
3. 弹簧座 Adapter
4. 止推销 Thrust pin
5. 调压弹簧 Compression spring
6. 调压垫片 Shim
用干净的柴油将所有零件清洗干净并用压缩
空气吹干。
Wash all parts in clean diesel fuel and blow out
with compressed air.

3. 喷油嘴针阀及针阀座是一套精密配合偶
件，不能搞乱，也不可以互换，不要用手指触
摸针阀，当针阀座保持于竖直位置时，针阀应
可以以自重慢慢自行滑进针阀内。
Nozzle needle and nozzle body are lapped
together and may neither be confused nor
exchanged. Do not touch nozzle needles with
your fingers. When nozzle body is held in
upright position nozzle needle should slide down
by its own weight slowly and smoothly to its
seating.

注意：如果针阀不能平顺地滑落，须再次用柴
油清洗喷油嘴，在必要时加以更换，新的喷油
嘴必须同样用干净柴油清洗。
Note: If nozzle needle does not slide
down smoothly, wash injection
nozzle again in diesel fuel.
Renew, if necessary. New
injection nozzle must likewise be
washed in clean diesel fuel.

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零部件维修 Repair of components
4. 检查弹簧座接触表面的磨损情况，确保中
心销装配无误。
Check seating surfaces of adapter for wear.
Make sure that centering pins are fitted.

5. 嵌入垫片。
Insert shim.
注意：喷油压力取决于调压垫片。
Note: The injection pressure is dependent on the
shim thickness.

6. 嵌入调压弹簧。
Insert compression spring.

7. 插入止推销，中心销面向调压弹簧。
Insert thrust pin with centering
collar facing towards compression
spring.

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零部件维修 Repair of components
8. 插入弹簧座，中心销插入针阀座孔内。
Insert adapter with centering pins
into the bores of the nozzle holder.

注意：凹点对准止推销。
Note: The recess points to the thrust
pin.

9. 安装喷油嘴，中心孔摇与弹簧座的中心销
相配。
Fit injection nozzle with center
bores mating with the centering
pins of the adapter.
注意：不要使针阀从针阀座中掉出来。
Note: Take care that nozzle needle
does not fall out of nozzle body.

10. 旋上螺旋护套。
Screw on cap nut.

11. 拧紧螺旋护套至 30－40Nm。

Tighten cap nut with a torque of 30 -40 Nm.
喷油器的测试及调整部分见第二章。
For testing and adjusting injector see
chapter 2.

66
零部件维修 Repair of components
控制齿条 Control rod

67
零部件维修 Repair of components
1. 检查控制齿条并测量，必要时更换新件。
Visually inspect control rod and gauge or
replace as necessary.
控制齿条上的销凹槽 5.03-5.06mm
Groove for control lever pin 5.03–5.06 mm

68
零部件维修 Repair of components
空气压缩机 Air compressor

69
零部件维修 Repair of components
空气压缩机 Air compressor
专用工具：Special tools:
用于空气压缩机齿轮的顶把 170 630
Dolly for air compressor gear 170 630
1.将顶把170 630滑到齿轮上，松弛锁紧螺母。
Slide dolly 170 630 onto gear. Slacken retaining
nut.

2.使用双臂提取器取出齿轮。
Pull off gear using a commercially available
two-armed extractor.

3.安装齿轮，拧紧锁紧螺母。
Mount gear and tighten retaining nut.
注意：安装齿轮之前，要确保齿轮圆锥面和轴
绝对清洁，没有油脂和缺陷。
Note: Before mounting the gear make sure that
cones of gear and shaft are absolutely clean and
free from grease and defects.

4.顶把 170 630 滑到齿轮上，将锁紧螺母拧紧

到 200+50Nm 扭矩。
Slide dolly 170 630 onto gear and tighten
retaining nut to a torque of 200 + 50 Nm.

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零部件维修 Repair of components
质量平衡轴 Mass balancing shaft

71
零部件维修 Repair of components
通用工具：
Commercially available tools:
外径千分尺
External screw type micrometer
BF4M 2012
1. 检查轴颈的磨损情况。
Gauge bearing journal.
外径：53.98-54.00mm
Outer diameter: 53.98 – 54.00 mm

2. 检查齿轮的磨损情况。
Visually inspect gear for wear.

72
零部件维修 Repair of components
带有紧固凸缘的液压泵 Hydraulic pump with fastening flange

73
 零部件维修 Repair of components
带有紧固凸缘的液压泵
Hydraulic pump with fastening flange

1. 旋开锁紧螺母。
Unscrew retaining nut.
注意：齿轮夹具要使用保护性的铝夹具。
Note: Use protective aluminium jaws for gear
clamping.

2. 取出齿轮。
Pull off gear.

3. 目测检查所有零件，必要时更换新件。
Visually inspect all parts and replace
as necessary.

4. 安装新的 O 形圈。
Install new O-ring.

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 零部件维修 Repair of components
5. 为液压泵安装新垫圈和紧固凸缘。
Mount new gasket and fastening flange to
hydraulic pump.

6. 安装齿轮。
Mount gear.
注意：安装齿轮前要确保齿轮圆锥面和轴都是
干净的，没有油脂和缺陷。
Note: Before mounting the gear make sure that
cones of gear and shaft are clean and free from
grease and defects.

7. 拧紧锁紧螺母。
Tighten retaining nut.
指定拧紧扭矩为：80 Nm
Specified tightening torque: 80 Nm

注意：DEUTZ 指定的锁紧螺母类型要单独使
用。齿轮夹具要使用保护性的铝夹具。
Note: Retaining nut type specified by
DEUTZ to be used exclusively.
Use protective aluminium jaws
for gear clamping.

75
整机的拆装 Disassembly and re-assembly of complete engine
4.发动机整机的拆卸和重新组装 Disassembly and re-assembly of complete engine

发动机整机的拆卸和重新组装 Disassembly and re-assembly of complete engine Page

发动机的拆卸 Disassembly of engine 77
发动机的重新组装： Re-assembly of engine: 88
冷却油喷嘴 Cooling oil nozzles 88
质量平衡轴 Tappets, camshaft 93
惰轮（调速器） Crankshaft bearings 98
控制杆 Control rod 98
正肘齿轮室罩盖 Timing case cover 99
前盖 Front cover 99
前油封 Shaft sealing insert – front 101
后油封 Shaft sealing insert – flywheel end 101
带有连杆的活塞 Piston with connecting rod 103
喷油泵的安装 Installation of injection pumps 104
不带喷油泵的控制杆行程测量 Measurement of control rod travel path without injection pumps 104
活塞点火 TDC 的确定 Determination of piston firing TDC 105
供油始点的确定 Determination of the fuel delivery cut-in point 109
控制杆移动灵活性的检测 Test for ease of movement of the control rod 112
控制杆凹槽尺寸的测量 Measurement of the control rod recess dimension 112
飞轮 Flywheel 113
飞轮壳 Adapter housing 113
棱纹 V 带滑轮/减振器 Ribbed V-belt pulley / torsional vibration damper 113
气缸盖 Cylinder head 114
进气歧管 Charge air pipe 117
排气总管 Exhaust manifold 117
排气装置涡轮增压器 Exhaust turbocharger 118
回油管 Oil return pipe 118
起动机 Starter 119
调速器 Governor 120
喷油嘴/高压油管 Injector nozzles/injector lines 121
发动机停止装置 Engine stop device 122
机油冷却器盖板 Oil cooler housing 122
燃油滤清器/机油滤清器 Fuel filter/oil filter 123
气缸盖罩 Cylinder head cover 123
曲轴箱呼吸器 Pressure control valve 124
冷却液泵 Coolant pump 125
支架/发电机 Bracket / generator 125
燃油泵 Fuel pump 125
张紧轮 Tension pulley 126
风扇驱动器 Fan drive 126
棱纹 V 型带 Ribbed V-belt 126
油底壳 Oil pan 127

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整机的拆装 Disassembly and re-assembly of complete engine

发动机的拆解 Dismantling of engine

通用工具 Commercially available tools:：
爪形柄板手 Claw grip wrench 8018
torx 工具箱 Torx tool kit 8189
torx 板手套筒 Torx wrench socket E14 8113
torx 板手套筒 Torx wrench socket E20 8114
弹簧夹钳 Spring clamp pliers 9090
专用工具 Special tools：
发动机装配座 Engine assembly stand 6066
斜口夹紧盘 Angled clamping plate 6066/158
提取器 Extractor 110 030
专用板手 Special wrench 110 500
提取器 Extractor 120 680
减振器的顶把 vibration damper 144 800
提取器牵引装置
Extractor pulling device 150 800
中心螺母顶把，风扇 Dolly for center nut, fan 160 330
开口爪形板手 Open jawed wrench 160 340

1. 安装连接支架，安装斜口夹紧盘 6066/158。
Mount angled，clamping plate 6066/158.

2. 用夹盘将发动机夹在双面旋转型装配架
中，校正并拧紧螺栓。
Chuck engine in double sided swivel-type
assembly stand 6066 and align.
Tighten bolts.
排出并收集剩余机油和冷却液，并根据环保原
则妥善处理。
Drain and collect residual oil and coolant and
dispose of properly in accordance with
anti-pollution regulations.

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整机的拆装 Disassembly and re-assembly of complete engine

3．减轻滑轮 1 棱纹 V 型带在箭头方向的压力。
Relieve pressure of ribbed V-belt via
pulley 1 in direction of the arrow.
注意：首先卸下滑轮 2 棱纹 V 型带。
Remove ribbed V-belt via pulley 2 first.

4. 从发电机中取出电缆连接器，旋下接线端
子，拆下发电机。

Pull-off cable connector from generator set and

screw-off terminal end. And remove generator
set.

5.拆卸输油管和输油泵。
Remove fuel line and fuel pump.

6.拆卸风扇驱动连接盘。
Remove fan drive.

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整机的拆装 Disassembly and re-assembly of complete engine

7. 拆卸冷却液泵。
Remove coolant pump.

8. 拆卸张紧轮。
Remove tensioning pulley.

9. 拆卸支架和悬置板。
Remove bracket and suspension plate.

10. 拆卸通气管。使用弹簧夹钳 9090 箍松到

头。
Remove breather pipe. Slacken hose collar using
spring clamp pliers 9090 to this end. Remove
lube oil pipe, oil return pipe and exhaust
turbocharger

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整机的拆装 Disassembly and re-assembly of complete engine

11. 拆卸增压器润滑油管、回油管和废气涡轮
增压器。

12.拆卸起动机。
Slacken terminal on starter and pull-off. Remove
starter.

13 拆卸排气总管。
Remove exhaust manifold.

14 松开电缆连接器，拆卸传感器及电磁阀，
并拆除控制线路。
Release cable connector and pull off from all
sensors. Remove fixing clamp.

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整机的拆装 Disassembly and re-assembly of complete engine

15. 拆卸调速器。
Remove governor

16. 拆卸气门室罩盖，如有则同时拆下各种线
束。
Remove cover plate and inspection cover.

23. 拆卸进气管。
Remove retainer (arrow) and charge air pipe.

25. 拆卸机油尺。
Remove oil dip stick .

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整机的拆装 Disassembly and re-assembly of complete engine

26. 旋下柴油滤清器和机油滤清器。
Remove fuel filter housing and oil filter.
注意：收集燃油和机油，对其处理，使之符合
无污染规定。
Note: Collect fuel and oil. Dispose of in
accordance with anti-pollution regulations.

27. 拆卸机油冷却器。
Remove oil cooler housing.
注意：收集剩余机油和冷却液，对其处理，使
之符合无污染规定。
Note: Collect residual oil and coolant and
dispose of in accordance with anti-pollution
regulations.

28. 拆卸停油电磁阀。
Remove cut-off solenoid.
注意：拔开插头。
Note: Plug opening.

29. 拆卸高压油管。
Remove injection pipes
注意：使用爪形管子钳 8018。
Note: Use claw grip wrench 8018.

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整机的拆装 Disassembly and re-assembly of complete engine

30. 拆卸张力爪，取出喷油器
Remove tensioning claws and take out injector
valves
注意：如果堵塞，应同时使用提取器牵引装置
150 800 和工具 110 030。使用提出器 120 680
拔出密封圈。
Note: Use extractor pulling device 150 800 in
combination with tool 110 030 if jammed. Use
extractor 120 680 for pulling out the sealing
ring.

31. 拆卸摇臂，拆卸挺杆。
Remove rocker arms and lift out pushrods.

32. 拆卸气缸盖。
Remove cylinder head.
注意：使用 torx 板手套筒 E14,8113。
Note: Use Torx wrench socket E14, 8113.

33. 取出汽缸盖垫。拆卸喷油泵凸缘，取下喷
油泵。并取下挺柱和垫圈。
Take out cylinder head gasket. Remove injection
pump flange and pull out injection pumps
Pull out roller tappet together with shims.
注意：堵住喷油器孔。
Note: Plug openings.

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整机的拆装 Disassembly and re-assembly of complete engine

34. 用顶把 144 800 夹持减振器，并拆除。

Retain torsional vibration damper with
dolly 144 800 and remove.
注意：使用 torx 板手套筒 E20,8114。
Note: Use Torx wrench socket E20, 8114 .

35. 拆卸飞轮壳。保留飞轮，并拆除。
Remove adapter housing. Retain flywheel and
remove.
注意：使用 torx 板手套筒 E20，8114 和 E14，
8113。
Note: Use Torx wrench sockets E20, 8114
and E14, 8113.

36. 将发动机翻转 180º。拆卸油底壳。

Turn engine by 180°. Remove oil pan.
注意：收集剩余机油和冷却液，对其处理，使
之符合无污染规定。
Note: Collect residual oil and coolant and
dispose of in accordance with anti-pollution
regulations.

37. 拆卸前盖。.
Remove front cover.

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整机的拆装 Disassembly and re-assembly of complete engine

39.拆卸正时齿轮室罩盖。
Remove timing case cover.

40. 拆卸调速器驱动齿轮和导向套。并取出齿
条。
Remove idler gear and guide bushing. Take out
control rod.

41. 拆卸活塞和连杆。
Remove piston together with connecting rod.

42. 拆卸主轴承盖。取出曲轴、曲轴轴承和止
推片。
Remove main bearing cap. Take out crankshaft
together with crankshaft bearing and thrust
washers.

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整机的拆装 Disassembly and re-assembly of complete engine

43. 拆卸平衡轴的驱动齿轮（如果有）。
Remove drive gears for
compensation shafts, if any.

44. 拆卸平衡轴的止推盖（如果有）。
Remove thrust covers for
compensation shafts, if any.

45. 拆卸平衡轴（如果有）。
Remove compensation shafts, if any.

46. 按下所有挺杆。拆卸凸轮轴。
Press down all tappets. Remove
camshaft.
注意：若要进行该操作 ，需要将发动机斜着
安装到装配架上。
Note: Hook up engine on one side in
assembly stand for this purpose.

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整机的拆装 Disassembly and re-assembly of complete engine

47. 取出挺柱。
Take out tappets.

48. 将发动机翻转 180º。

Turn engine by 180°.
取出喷油嘴。检查油管是否畅通。
Press out oil jet nozzles.
Check oil ducts for free passage.

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 整机的拆装 Disassembly and re-assembly of complete engine
发动机整机的拆卸和重新组装
Disassembly and re-assembly of complete engine
发动机的重新组装
Re-assembly of engine
通用工具 Commercially available tools：
外径千分尺 External screw type micrometer
爪形管子钳 8018 Claw grip wrench 8018
torx 工具箱 8189 Torx tool kit 8189
torx 板手套筒 E14 Torx wrench socket E148113
torx 板手套筒 E20 Torx wrench socket E20 8114
旋转喷射泵的锯齿状板手 8117 Serrated wrench for turning injection pump 8117
弹簧夹钳 9090 Spring clamp pliers 9090
专用工具 Special tools：
百分表 100 400 M2TDial gauge M2T 100 400
测量杆 100 750 Measuring bar 100 750
测量和锁紧控制杆的装置 Device for measuring and locking control rod 100 800
质量平衡轴的调整销 Adjusting pin for mass balancing shafts 100 810
测量装置 100 890 Measuring device 100 890
分度盘 110 020 Graduated disk 110 020
分度盘联接盘 101 030 Adapter for graduated dis 101 030
分度盘指针 101 300 Pointer for graduated disk 101 300
固定锥面千分尺 101 910 Tightening angle dial indicator 101 910
高压油管专用板手 Special wrench for injection line 110 500
直径为 98mm 的活塞环引套 Piston ring compressor dia. 98 mm 130 660
直径为 101mm 的活塞环压缩器 Piston ring compressor dia. 101 mm 130 670
活塞环压缩器后端 142 660 Piston ring compressor rear 142 660
曲轴前油封装配工具 142 670 Piston ring compressor front 142 670
减振器顶把 144 800 Dolly for tensional vibration damper 144 800
中心螺母顶把，风扇 160 330 Dolly for center nut, fan 160 330
开口爪形板手 160 340 Open jawed wrench 160 340

机油喷油嘴
1. 尽可能地按下喷油嘴。
Press-in oil injection nozzles as far as they will
go.

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整机的拆装 Disassembly and re-assembly of complete engine
挺柱及凸轮轴 Tappets/camshaft
2. 嵌入挺柱。Insert tappets.

3. 插入凸轮轴。
Install camshaft
注意：若进行该操作，需要把发动机倾斜安装
在装配座上。
Note: Hook up engine on one side in assembly
stand for this purpose.

曲轴轴承 Crankshaft bearing

4. 将内径量表设置为 32.2mm。
Set internal dial gauge to 32.2 mm.

5. 测量曲轴止推轴承的宽度，记下尺寸“a”。
Gauge width of crankshaft thrust
bearing and note down dimension “a”.
标准轴径宽度： 32.2+0.04mm
Standard journal width: 32.2+0.04mm
尺寸极限： 32.6+0.04mm
Limit for oversize: 32.6+0.04mm

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整机的拆装 Disassembly and re-assembly of complete engine
6. 放入主轴瓦。
Insert bearing shells.

7. 把主轴瓦放入到主轴承盖中。
Insert bearing shell in main bearing cap.

8. 将半个止推片放置到止推轴承盖上。测量并
记下尺寸“b”。
Place half thrust rings on thrust bearing cap.
Gauge and note down width.
Dimension “b”.

9. 确定轴向窜量。
Determine end float.
例如：尺寸 a=32.23mm
Example: Dimension a = 32.23 mm
尺寸 b=32.37mm
Dimension b = 32.37 mm
尺寸 b－尺寸 a＝轴向移动
＝0.14mm
Dimension a – dimension b = end float
= 0.14 mm
轴向窜量允许范围：0.10-0.28mm
Allowable end float: 0.10 – 0.28 mm

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整机的拆装 Disassembly and re-assembly of complete engine
10. 安装前先标记曲轴。
Mark crankshaft prior to installation.

11. 在凸轮轴上作标记并安装入位。
Mark and position camshaft.

12. 插入曲轴
安装后标记必须恰好在一条线上。
Introduce crankshaft Marks must be exactly in
line after installation.

13. 插入没有凸起的半片止推瓦片。
Insert half thrust rings without guide nose.
注意：止推片带有涂层面必须朝向曲轴前端。
Note: The overlay sides of the thrust washers must
point towards the cheek surface of the crankshaft.

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整机的拆装 Disassembly and re-assembly of complete engine
14. 用一些润滑脂将半片带有凸起的止推环粘
在止推轴承盖上。
Bond thrust washer halves to the
locating bearing cap by means
of the guide nose using a small
quantity of grease.
注意：止推片带有涂层面，必须朝向曲轴止推
面。
Note: The overlay sides of the thrust
washers must point towards the
check surface of the crankshaft.

15. 安装止推轴承盖。
Mount thrust bearing cap.
注意：1 号主轴承盖在飞轮一端。
Note: Bearing cap No. 1 at flywheel end.

16. 安装主轴承盖，安装时要注意编号。
Mount main bearing caps paying
attention to the numbering.

17. 将主轴承螺栓拧紧到指定扭矩。
Tighten main bearing bolts to the
specified tightening torque:
初始拧紧扭矩： 50 Nm
Initial tightening torque: 50 Nm
第一次锁紧角度 90º
1st lock down angle _ 90°
第二次锁紧角度 90º
2nd lock down angle _________ 90°

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整机的拆装 Disassembly and re-assembly of complete engine
质量平衡轴 BF4M 2012（如果有）
Mass balancing shafts BF4M 2012
(if any)
将发动机翻转 180º。
Turn engine by 180º.
17.1 拧出螺塞。
17.1 Turn out plug bolts.

17.2 安装质量平衡轴。
17.2 Fit mass balancing shaft.
注意：配重端必须朝向油盘密封面。
Note: The load weight side must point towards the
oil pan sealing surface.

17.3 尽量深入将质量平衡轴的定位销 100 810

旋入曲轴箱。
Screw adjusting pin 100 810 for mass balancing
shafts into crankcase as far as it will go.
注意：质量平衡轴的轴孔必须和曲轴箱的锁孔
对齐。
Note: Bore of mass balancing shaft must be in line
with bore on crankshaft housing.

17.4 安装止推垫圈，校正轴向相对位置。拧紧
螺栓。
Fit thrust washer and align relative to shaft axis.
Tighten bolt.
指定拧紧扭矩：29Nm
Specified tightening torque: 29 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
17.5将曲轴调到 1 缸 TDC（供油始点）。一旦曲
轴上的标记和曲轴及凸轮轴的中心连线相
重合，即到达 TDC。
Set crankshaft cylinder 1 to TDC. TDC is reached
once the marking on the crankshaft coincides with
the connection line of the centre points of
crankshaft and camshaft.

17.6 安装惰轮，并轻轻压入曲轴齿轮的凹槽。
Fit idler gear and slightly press into recess of
crankshaft gear.

17.7 在对应的齿上做标记。
Mark opposite teeth.

17.8 将曲轴顺时针旋转 3 个齿。

Turn crankshaft clockwise passing 3 teeth.

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整机的拆装 Disassembly and re-assembly of complete engine
17.9 逆时针旋转曲轴，直到孔相重叠。
Turn crankshaft counter-clockwise
until bores overlap.

17.10 嵌入轴承轴颈。
Insert bearing journal.
注意：轻轻地来回转动曲轴，检查轴承轴颈是
否对准中心孔。
Note: Check centered position of bearing
journal in bore by alternate movement of the
crankshaft.

17.13 拧紧螺栓
Tighten bolt
指定拧紧扭矩：22Nm
Specified tightening torque: 22 Nm

17.14 安装第二个质量平衡轴
Install second mass balancing shaft
注意：配重端必须朝向油盘密封面。
Note: The load weight side must face the
oil pan sealing surface.

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整机的拆装 Disassembly and re-assembly of complete engine
17.15 尽量深地将质量平衡轴的调整销 100 810
旋入曲轴箱。
Screw adjusting pin 100 810 for mass balancing
shafts into crankcase as far as it will go.
注意：质量平衡轴的销孔必须和曲轴箱的销孔
对准。
Note: Bore of mass balancing shaft must overlap
with bore in crankcase.

17.16 安装止推片，校正轴向相对位置。
Mount thrust disk and align relative to axis of
shaft.

17.17 拧紧螺栓至 29Nm。

Tighten bolt. Specified tightening torque: 29 Nm

17.18 嵌入惰齿轮，使孔重叠。
Insert idler gear so as to make bores overlap.

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整机的拆装 Disassembly and re-assembly of complete engine
17.19 插入轴承轴颈，安装固定盘。
Insert bearing journals

17.21 拧紧螺栓。
指定拧紧扭矩：22 Nm
Tighten bolt Specified tightening torque: 22 Nm

17.22 拆卸两个调整螺栓。旋入螺旋塞和新铜垫
圈，并拧紧至 9+4 Nm。
Remove both adjusting bolts. Turn in screw plugs
together with new Cu sealing rings and tighten.
Specified tightening torque: 9 + 4 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
驱动齿轮/调速器 Idler gear / governor

18. 安装齿轮和支承轴径。
Fit gear wheel with bearing journal.
注意：轴承要轻微润滑。
Note: Bearing to be slightly oiled.

19. 拧紧螺栓。
Tighten bolt
指定拧紧扭矩：29 Nm
Specified tightening torque: 29 Nm

控制齿条
Control rod
20. 安装带导向套的控制齿条。
Fit control rod with guide bushing

21. 嵌入涂有 BEUTZ DW71 密封胶的螺栓，并

拧紧。
Insert bolt applying some DEUTZ DW 71
compound and tighten.
指定拧紧扭矩：10+2 Nm
Specified tightening torque: 10+2 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
正时齿轮罩盖 Timing case cover

22. 在正时齿轮盖密封面上涂 Deutz DW67 密封

胶。
Apply some DEUTZ DW 67 sealing compound to
sealing surface of timing case cover.

23. 安装正肘齿轮室罩盖。拧紧螺栓，使调速箱
盖和油底壳密封面对齐。
Fit timing case cover. Tighten bolts finger tight
and align timing case cover relative to oil pan
sealing surface.

24. 拧紧螺栓。
Tighten bolts.
指定拧紧扭矩：30±3 Nm
Specified tightening torque: 30 ± 3 Nm

前盖 Front cover

25. 在前盖转子上涂少量润滑油。
Slightly grease rotors in front cover.

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整机的拆装 Disassembly and re-assembly of complete engine
26. 使用润滑油将垫圈粘在前盖上。
Glue on gasket for front cover using some grease.
翻转发动机 180º。油底壳面必须朝下。
Make sure the tension bush is in place.

27. 转子一面面向曲轴。
Turn engine by 180°. Sealing surface of
oil pan must face downwards.

28. 将转子安装到曲轴上。
Position rotor relative to crankshaft.

29. 安装前端，向上轻推前盖，使之与油底壳密
封面对齐，拧上螺栓。
Fit front cover. Press cover upwards
and align relative to oil pan sealing
surface. Start bolts.

30.拧紧前盖螺栓至 30Nm。
Tighten bolts. Specified tightening torque: 30 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
曲轴油封 Shaft oil seal rings
-前油封--front-

31. 使用工具 142 670 安装导向套。

Fit guide bushing using tool 142 670

32. 轻微润滑密封边缘，谨慎安装新的轴油封。
根据安装深度放置隔离垫圈。
Slightly oil seal lip. Carefully fit new shaft seal
ring. Add spacer washers according to mounting
depth.
2 垫圈 初始安装
1 垫圈 第一次维修安装深度
无垫圈 最大安装深度
2 washers ___________ Initial installation
1 washer _____ 1st repair mounting depth
without washers __ max. mounting depth

33. 固定安装套筒，尽可能深地压入装置。
Fit mounting sleeve and press into device as far as
it will go.
注意：油封当前所处位置是预选择的安装深度。
Note: Shaft oil seal ring is now in its pre-selected
mounting depth.

-后油封-
- flywheel end -
34. 使用工具 142 660 安装导向套筒。
Fit guide bushing using tool 142 660

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整机的拆装 Disassembly and re-assembly of complete engine
35. 轻微润滑密封边缘。谨慎安装新的油封。根
据安装深度放置隔离垫圈。
Slightly oil seal lip. Carefully fit new shaft seal
ring. Add spacer washes according to mounting
depth.
2 垫圈 初始安装
1 垫圈 第一次维修安装深度
无垫圈 最大安装深度
2 washers ___________ Initial installation
1 washer _____ 1st repair mounting depth
without washers __ max. mounting depth

36. 固定安装套筒，尽可能深地压入装置。
Fit mounting sleeve and press into device as far as
it will go.
注意：油封当前所处位置是预选择的安装深度。
确保定心套筒处于正确位置，必要时嵌入。
Note: Shaft oil seal ring is now in its preselected
mounting depth.
Make sure the centering bush is in place, insert as
necessary.

活塞与连杆
Piston complete with connecting rod
37. 在连杆大头中放入轴套。
Incorporate big end bearing shells in
connecting rod.

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整机的拆装 Disassembly and re-assembly of complete engine
38. 活塞环间必须相互交错 90-120º。
Piston ring gaps must be staggered by 90-120°
relative to each other.

39.将发动机翻转 90º。把带连杆的活塞安装到
气缸曲轴箱。
Turn engine by 90°. Introduce piston complete
with connecting rod into cylinder crankcase.
使用尺寸与活塞直径相对应的活塞环引套。
Use piston ring compressor size according to
piston diameter.
活塞环 Piston ring
引套 compressor_98mm 130 660
活塞环 Piston ring
引套 compressor_101mm 130 670
注意：飞轮标识必须朝向飞轮。
Note: Flywheel symbol must face towards
flywheel.

40.连杆推至连杆轴颈。安装对应的大头轴承
盖。
Press connecting rod against crankpin. Fit
pertinent big-end bearing cap.

41.拧紧新安装的连杆螺栓。
Tighten new connecting rod bolts.
指定的拧紧扭矩 Specified tightening torque：
初始拧紧扭矩 Initial tightening torque： 30Nm
第一次锁紧角度 1st lock down angle 60º
第二次锁紧角度 2nd lock down angle 30º

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整机的拆装 Disassembly and re-assembly of complete engine
42. 确保连杆在连杆轴颈上可以前后自由运动。
Make sure that connecting rods can be easily
moved back and forth on the crankpin.

安装喷射泵 Install injection pumps

测量不带喷射泵的控制齿条行程
Gauge control rod travel path without
injection pumps
43.将发动机翻转 90º。
安装控制杆的测量装置 100 800。
Turn engine by 90°.
Fit measuring device 100 800 for control rod.

44.测量从测量装置到控制杆停止运动位置之
间的距离。
Measure distance from device to stop position of
control rod.

44.1 测量从测量装置到控制杆开始运动位置
之间的距离。
Measure distance from device to start position of
control rod.
开始和停止位置之间的距离即是控制杆行
程。
The difference start- to stop position is the control
rod travel path.
例如：Example:
停止位置 Stop position： 30.7mm
开始位置 Start position： 13.4mm
控制杆行程 Control rod travel path：17.3mm
标准行程 Specified size： 17.0mm-17.5mm

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整机的拆装 Disassembly and re-assembly of complete engine
45. 翻转测量装置。使用定位销钉将控制杆手动
按到停止位置。
Turn device. Use stop bolt for pressing control rod
manually into stop position.

46. 将分度盘 101 020 安装到飞轮凸缘。

Fit graduated disc 101 020 to flywheel flange.

47. 安装指针 101 300。

Fit pointer 101 300.

确定与即将安装的喷射泵相对应的活塞上止点
Determine firing TDC of piston corresponding
to the injection pump to be set

48. 带有垫片的活塞测量杆 100 750，测量 TDC

和活塞上止点。沿发动机的旋转方向转动曲
轴，直到指示表 100 400 的指针到达反转位
置。将百分表设置为“0”。
Position measuring bar 100 750 with spacers for
gauging TDC and piston projection. Turn
crankshaft in the sense of rotation of the engine
until the pointer of dial gauge 100 400 has
reached its point of reversal. Set dial gauge to
“0”.

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整机的拆装 Disassembly and re-assembly of complete engine
49. 沿发动机旋转的相反方向转动曲轴约 90º。
然后再沿发动机的旋转方向转动曲轴，直到
TDC（指示表反转位置）前 8mm 位置。
将分度盘设置为“0”。
Turn crankshaft by approx. 90° in opposite
direction to the sense of rotation of the engine.
Turn crankshaft then again in direction of the
sense of rotation of the engine until 8 mm
before TDC (dial gauge point of reversal). Set
graduated disc to “0”

50. .沿发动机的旋转方向转动曲轴约 90º，直到

TCD（指示表反转位置）前 8mm 位置。读
取指示值。
Turn crankshaft by approx. 90° in the sense of
rotation of the engine until 8 mm before TCD
(dial gauge point of reversal). Read-off indicated
value.
例如：50º
Example: 50º

51. 指示值除以 2。所得值即是 TCD 值。

Divide indicated value by 2. This
value is the TCD value.
0 0 ＋50 0
例如： ＝25 0 指定值
2
0 0 ＋50 0
＝25 0
Example： 2 specified value
将曲轴旋转到该值的一半。
Turn crankshaft to this halved value.

52. 不能再转动曲轴。松弛两个滚花头螺钉，将
刻度盘设置为“0”。
Crankshaft must not be moved any longer.
Slacken the 2 knurled head screws and set
graduated disc to “0”.

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整机的拆装 Disassembly and re-assembly of complete engine
53. 嵌入挺柱。
Insert roller tappets.
确定供油始点－喷射泵
Determine fuel delivery cut-in point –Bosch
injection pump
供油始点和凸轮轴的类型显示在铭片上。
The fuel delivery cut-in point and the type of
camshaft are indicated on the name plate.

54. 在预紧力作用下，测量装置 100 890 的指示

表 100 400 设置为 0。
参考尺寸：124mm
Set dial gauge 100 400 in measuring device 100
890 to 0 under pre-tension.
Reference dimension: 124 mm

55.把要调整的喷射泵挺柱设置为基圆尺寸。沿
发动机旋转的相反方向转动曲轴约 90°。
Set roller tappets corresponding to the injection
pump to be adjusted to base circle measurement.
Turn crankshaft by approx. 90° in opposite
direction of the engine rotation.

56. 小心嵌入测量装置。
Carefully insert measuring device.

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整机的拆装 Disassembly and re-assembly of complete engine
57. 测量尺寸“L”并记入表中，请参见第一章。
Gauge dimension “L” and note down
in the table, see Chapter 1.
例如：125.13 mm
Example: 125.13 mm

58. 使用外部环将百分表转到指针的零位置。
Turn dial gauge by means of the
external ring to zero position of the
pointer.
注意：如果预先设置了行程，将不再能够改变
旋转方向。
Note: When the pre-stroke has been set,
the sense of rotation may not be
changed any longer.

59. 沿发动机旋转方向转动曲轴，直到指示表指
示预行程尺寸。参见表 1。
Turn crankshaft in direction of
rotation of engine until dial gauge
indicates size of pre-stroke.
See Table 1.
例如：燃料供油始点：9°
曲轴类型 L
预行程 3.95mm
Example:Fuel delivery cut-in point: 9°
Camshaft type L
Pre-stroke 3.95 mm

60. 读取供油始点的真实值，并输入到表 1，参

见第一章。
Read off ACTUAL fuel delivery
cut-in point and enter in Table 1,
see Chapter 1.
例如 Example:：8°

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整机的拆装 Disassembly and re-assembly of complete engine
61. 读取尺寸“A”（喷射泵的长度代号），并输
入到表中，参见第一章。
Read-off size “A” = index for injection
pump length and enter in Table , see
Chapter 1.
例如：42
Example: 42

62．拆卸测量装置。
Remove measuring device.
确定垫片尺寸，参见第一章。
Determine shim size, see Chapter 1.

62. 将已确定的垫片安装到挺柱上。
Place shim as determined on roller
tappet.
注意：每个喷射泵都要进行 48－63 条目中描述
的测量操作。
Note: Measurements described under
items 48-63 to be carried out for
each injection pump.

喷射泵 Injection pump

64．将喷射泵控制杆旋转到中心位置附近。
Turn injection pump control lever
more or less to centre position.
注意：每个喷射泵都要执行 48-64 条目中描述
的装配步骤。
Note: Assembly steps described under
items 48-64 to be carried out for
each injection pump.

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整机的拆装 Disassembly and re-assembly of complete engine
65. 将相应气缸的挺柱放置在基圆。把 AP 1908
化合物涂到曲轴箱的安装孔和喷射泵的 O 形圈
上。将喷射泵转向杆谨慎嵌入到控制杆中。
Place roller tappets of corresponding cylinder on
base circle. Apply AP 1908 compound to
mounting bore in crankcase and O-rings of
injection pump. Insert injection pump steering
lever carefully into control rod.

66. 安装法兰。
Fit flange.
注意：倒角的一面必须朝向喷射泵体。
Note: Chamfered end must face to injection pump
body.

67. 轻微润滑螺栓，并统一拧紧到 5 Nm。

Slightly oil bolts and tighten uniformly to a
tightening torque of 5 Nm.

68. 再次松弛螺栓 60°。

Slacken bolts again by 60°.

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整机的拆装 Disassembly and re-assembly of complete engine
69. 使用板手，将喷油泵逆时针转动到明显停止
位置。
Carefully turn injection pump anti-clockwise up to
a noticeable stop using a wrench.

70. 再次旋入 60°，并逐渐拧紧到 7Nm、10Nm

和 30Nm 的拧紧扭矩。
Turn-in bolts again by 60° and gradually tighten
to a tightening torque of 7 Nm, 10 Nm and 30
Nm.
注意：从相应的外部螺栓开始，即距离飞轮最
远的螺栓。
Note: Start with the corresponding external bolt
– the one remotest from the flywheel.

测量控制杆行程
Gauge control rod travel path with injection
pumps
71. 从设备中拆下锁紧螺栓。转动设备。
Remove retaining bolt from device. Turn device.

72. 测量从设备到控制杆停止位置的距离。
Gauge distance from device to control rod stop
position.

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整机的拆装 Disassembly and re-assembly of complete engine
72.1 测量从设备到控制杆开始运动位置之间的
距离。开始和停止位置之间的距离即是控制杆
行程。
Gauge distance from device to control rod start
position. The difference between start and stop
positions is the control rod travel path.
例如 Example:
停止位置 Stop position： 30.5mm
开始位置 Start position： 13.4mm
控制杆行程 Control rod travel path： 17.1mm
控制杆最小行程Control rod travel path
minimum： 16.8mm

检查控制杆运动的灵活性
Check ease of movement of control rod
73.在任意位置松开控制杆，应弹回原位。
Slow insertion of the control rod may not give rise
to any irregular resistance. After release the
control rod must be pressed back into home
position from any other position.

74. 拆卸锁紧装置、指针和分度盘。
Remove retaining device, pointer and graduated
disc.

测量调速器的齿条凹槽尺寸
Gauge control rod recess dimension for governor
adjustment
75. 测量凹槽尺寸。
Gauge recess dimension timing case cover –
stop position.
必须测量该尺寸，更换和修理调速器。
This dimension must be indicated for a
replacement or repair of the governor.

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整机的拆装 Disassembly and re-assembly of complete engine
飞轮 Flywheel
76.使用自制的导向心轴安装飞轮。
锁紧飞轮。拧紧螺栓。
Fit flywheel, using a self-made guide mandrel.
Retain flywheel. Tighten bolts.
指定拧紧扭矩 Specified tightening torque：
初始拧紧扭矩 Initial tightening torque：
全部螺栓 All bolts： 30Nm
第一次锁紧角度 1st lock down angle：
全部螺栓 All bolts： 60°
第二次锁紧角度 2nd lock down angle：
30mm 长的螺栓 Bolts, 30 mm long： 30°
35－85mm 长的螺栓 Bolts 35–85 mm long：
60°
注意：如果螺栓适合使用，最多可以重复使用 5
次。
Note: Bolts if proven to be fit for use can be
re-used max. 5 times.
76.1 必要时将锁紧销插入螺纹孔。
Knock locking plugs into thread bores if
necessary.
飞轮壳 Adapter housing
77. 嵌入弹力衬套。
Insert tension bushings.
安装飞轮壳，交叉拧紧螺栓。
Fit adapter housing and tighten bolts cross-wise.
指定拧紧扭矩 Specified tightening torque:
螺栓 Bolts M12 99Nm
螺栓 Bolts M16 243Nm
注 意 ： 使 用 Torx 板 手 套 筒 E14 ， 8113 和
E20,8114。
Note: Use Torx wrench socket E14, 8113 and E20,
8114.
棱纹 V 型带滑轮/扭转振动阻尼器
Ribbed V-belt pulley / torsional vibration
damper

78. 必要时嵌入弹性衬套和弹性销。
Insert tension bushing and tension pin as
necessary.

79. 安装减振器时，曲轴和减振器上的标记必须
重叠。
When fitting the torsional vibration damper, the
markings on crankshaft and torsional vibration
damper must overlap.

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整机的拆装 Disassembly and re-assembly of complete engine
80. 安装减振器，使用顶把 144 800 固定。拧
紧螺栓。
Fit torsional vibration damper and retain using
dolly 144 800. Tighten bolts.
定拧紧扭矩 Specified tightening torque:
初始拧紧扭矩 Specified tightening torque:30Nm
第一次锁紧角度 1st lock down angle: 60°
第二次锁紧角度 2nd lock down angle :60°
注意：使用 Torx 板手套筒 8114。 如果螺栓适
合使用，最多可以重复使用 5 次。
Note: Use Torx wrench socket 8114. Bolts if
proven to be fit for use can be re-used 5 times.

气缸盖 Cylinder head

81. 选择气缸盖垫。
Select cylinder head gasket.

81.1 将带垫片 100 750 的测量杆放置到气缸表

面，并将百分表的 100 400 设置为“0” 。
Place measuring bar with spacers 100 750 on
sealing surface of cylinder crankcase and set dial
gauge 100 400 to “0”.
注意：所有的活塞都必须测量。
All pistons must be gauged.

81.2 观察参考点。
Observe reference points

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整机的拆装 Disassembly and re-assembly of complete engine
81.3 将最大值和表中的数值相比较，选取相应
的气缸缸盖垫。
Compare highest value with that of table and
select the corresponding cylinder head gasket.

活塞凸出量 气缸垫编码
Piston projection Code on cylinder
head gasket
0.33－0.55mm 1 孔 holes
0.56－0.65mm 2 孔 holes
0.66－0.76mm 3 孔 holes

82. 安装新的气缸盖垫。
Fit new cylinder head gasket.
注意：气缸盖垫的密封面必须清洁，没有任何
油脂。确认安装定位销套。
Note: Sealing surface of cylinder head gasket
must be clean and free from oil. Make sure
mounting sleeves are fitted.

83. 安装气缸盖。
Mount cylinder head.
注意：密封表面必须清洁，没有油脂。确保安
装定位销套。
气缸盖螺钉（如果适合使用）最多可重复使用 5
次。
Note: Sealing surfaces must be clean and free
from oil. Make sure tension pins are fitted.
Cylinder head screws (if proven to be fit for use)
can be re-used 5 times.

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整机的拆装 Disassembly and re-assembly of complete engine
84. 轻微润滑气缸盖短螺钉并用手拧紧，装入止
推杆。
Slightly oil short cylinder head screws, tighten
finger-tight and insert thrust rods.

85.安装摇臂支架，与推杆/气门对齐。
Mount rocker arm brackets and align relative to
thrust rods/ valves.

86. 轻微润滑汽缸盖长螺钉并用手拧紧，嵌入
止推杆。插入 M8 螺钉并拧紧。
Slightly oil long cylinder head screws, tighten
finger – tight and insert thrust rods. Insert M8
screws and tighten.
注意：汽缸盖螺钉（如果适合使用）最多可重
复使用5次。
Note: Cylinder head screws – if proven to be fit
for use - can be re-used 5 times.

87. 将 M8 螺栓拧紧到 21Nm 扭矩。

Tighten M8 bolts to a tightening torque to 21 Nm.

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整机的拆装 Disassembly and re-assembly of complete engine
88. 拧紧汽缸盖螺钉：
Tighten cylinder head screws:
指定拧紧扭矩 Specified tightening torque：
初始拧紧扭矩 Initital tightening torque：
第一阶段 1st stage 40 Nm
第二阶段 2nd stage 70Nm
再次拧紧角度 Re-tightening angle 180°
注意：观察汽缸盖螺钉的拧紧顺序，使用拧紧
角度千分表 101 910。
参见“技术数据”－第二章中的“气门间隙设
置”。
Note: Observe sequence for the tightening of the
cylinder head screws and use tightening angle
dial indicator 101 910.
See Technical Data – “Valve clearance setting”,
Chapter 2.

进气歧管 Charge air pipe

89. 安装进气歧管，使用新的密封垫。
Place charge air pipe with sealing surface showing
upwards. Insert bolts into the charge air pipe from
below and slide new gaskets onto screw thread.
注意：使用螺栓将垫片安装在合适位置。
Note: Gaskets are kept in place by
the bolts.
90. 将进气管和垫片安装到汽缸盖。
Place charge air pipe together with gaskets onto
cylinder head.
首先松开所有螺栓。Start all bolts first.
指定拧紧扭矩：11 Nm
Specified tightening torque: 11 Nm

排气总管
Exhaust manifold
91.安装带有新垫圈的排气总管。
Fit exhaust manifold with new gaskets.
注意：从定位孔（中心孔）开始拧紧螺母，依
次向外螺旋进行。使用 DEUTZ S1 涂抹螺母。
指定拧紧扭矩：25 Nm
Note: Tighten nuts starting from the location hole
bore (centric) and proceed in spiral form in
outward direction. Coat nuts with DEUTZ S1
Never Seize Compound.

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整机的拆装 Disassembly and re-assembly of complete engine
排气涡轮增压器 Exhaust gas turbocharger

92.安装带有新密封件的排气涡轮增压器。
Fit exhaust gas turbocharger
with new seal.
注意：使用 DEUTZ S1 涂抹螺母。
Note: Apply DEUTZ S 1 Never Seize
Compound to nuts.
指定拧紧扭矩：22 Nm
Specified tightening torque: 22 Nm

回油管
Oil return pipe
93.将带有新垫圈的回油管上端安装到涡轮增压
器，将其拧紧。
Mount upper part of oil return pipe with new
gasket to turbocharger and tighten.
指定拧紧扭矩：22 Nm
Specified tightening torque: 22 Nm

94.将新的 O 形圈安装到回油管的下端。
Mount new O-rings to lower part of oil return
pipe.
注意：将 AP1908 涂抹到 O 形圈。滑动回油管
部件。将回油管的下端按入曲轴箱。
Note: Apply AP1908 compound to O-rings.
Slide oil return pipe components together. Press
lower part of oil return pipe into crankcase.

95.使用固定支架将回油管的下端安装到曲轴
箱。
Fix lower part of oil return pipe to crankcase by
use of the mounting bracket.
指定拧紧扭矩：22 Nm
Specified tightening torque: 22 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
96.润滑油管。
Fit lube oil pipe.
注意：从加油口加入一些发动机机油，提前润
滑排气涡轮增压器。
Note: Pre-oil exhaust gas turbocharger by putting
some drops of engine oil into the oil feed bore.
安装带有 Cu 密封垫的空心螺钉。
Fit hollow screws with new Cu seals
指定拧紧扭矩：39Nm
Specified tightening torque: 39 Nm

97.安装并固定进、回油管支架。
Fix upper part of oil return pipe to lower part of
oil return pipe and mount lube oil line to oil return
line by screwing.
指定拧紧扭矩：22 Nm
Specified tightening torque: 22 Nm

起动机
Starter
98．安装起动机，起动和拧紧螺栓。
Mount starter, start and tighten bolts.
指定拧紧扭矩：70 Nm
Specified tightening torque: 70 Nm

99.安装接线器（接线端 50）。
Fix cable connector (terminal 50).
指定拧紧扭矩：1.3 Nm
Specified tightening torque: 1.3 Nm

注意：安装电缆（目的是不产生任何张应力）
并固定到夹具。
Note: Install cable so as to produce no tensile
stress and fix to holders.

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整机的拆装 Disassembly and re-assembly of complete engine
调速器 Governor
100.向调速箱凹槽涂抹大量的 BEUTZ DW73。
Apply ample quantities of DEUTZ DW 73 to
timing case grooves.
注意：密封面必须没有油脂和润滑油。
Note: Sealing surface must be free from oil and
grease.

101. 将 BEUTZ DW73 密封剂涂抹到调速器。

密封沿厚度为 1.5mm。
Apply DEUTZ DW 73 sealing compound to
governor. Thickness of sealing bead 1.5 mm.
注意：密封面必须没有油脂和润滑剂。若有必
要，需轻微旋转调速器齿轮，使其啮合。
Note: Sealing surface must be free from
oil and grease. Slightly turn governor gear, if
necessary, to permit meshing.

102. 安装调速器。
Fit governor.
注意：更换调速器时，新调速器上的尺寸必须
符合当前控制杆凹槽的尺寸。
Note: When replacing the governor, existing
dimension of control rod recess must be set on the
new governor.
指定拧紧扭矩
Specified tightening torque：17±1.5Nm
螺栓拧紧顺序
Bolt tightening sequence：1- 2 - 3 - 4 - 5。

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整机的拆装 Disassembly and re-assembly of complete engine
喷油器/高压油管
Injection valves / injection lines
103. 使用润滑油将新密封圈滑到喷射阀，并嵌
入喷射阀。
Slide new sealing ring to injection valve using
some grease and insert injection valve.
注意：喷油器接头的凹槽必须背向张力爪。
Note: The notch on the injection valve must face
away from the tensioning claw.

104. 安装爪形压板，并轻轻旋入。
Mount tensioning claw and slightly
screw in.

105. 安装带有橡胶密封件的新高压油管。用手
安装螺帽。
Fit new injection lines with sealing rubber
elements. Fit cap screw finger-tight.
注意：不允许再次弯曲。高压油管一定不能使
用两次。
Note: Re-bending is not allowed. Injection lines
must not be used twice.

106. 拧紧爪形压板。
Tighten bolts of claws.
指定拧紧扭矩
Specified tightening torque：16+5 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
107. 将喷射泵和喷油阀上高压油管的螺母预紧
到大约 5 Nm 拧紧扭矩。
Pre-tighten cap nuts of injection lines on injection
pump and injection valves to a tightening torque
of approx. 5 Nm.
拧紧螺母。
Tighten cap nuts now.
指定拧紧扭矩
Specified tightening torque：25+3.5 Nm
注意：使用爪形管子钳 8018
Note: Use claw grip wrench 8018

发动机制动装置 Engine stop device

108. 安装新的 O 形圈。

Mount new O-ring.
注意：轻微润滑 O 形圈。
Note: Slightly oil O-ring.

109. 使用制动杆将控制杆压入停止位置。安装
发动机制动装置。拧紧螺栓。
Press control rod into stop position using the stop
lever and retain. Install engine stop device.
Tighten bolts.
指定拧紧扭矩：21 Nm
Specified tightening torque: 21 Nm

机油冷却器盖板 Oil cooler casing

110. 安装新成形密封件。
Fit new profiled seals and a shaped seal.

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整机的拆装 Disassembly and re-assembly of complete engine
111. 安装机油冷却器盖板。
规定的螺栓扭矩：21+2 Nm
Tighten bolts with a torque of 21+2 Nm
注意：如有则同时安装线束接头固定卡子。
Note: Fit retainer for cable connector
as well if any.

燃油滤清器/机油滤清器
Fuel filter/oil filter
112. 并用手拧紧燃油滤清器和机油滤清器。
Secure fuel filer and oil filter cartridge fingertight.
注意：在滤清器垫上涂少许润滑油。
Note: Lightly oil filter gasket.

气缸罩盖 Inspection cover

113. 安装新垫圈并对齐。
Fit new gasket and align.

114. 安装检查盖和盖板。拧紧螺栓。
Fit inspection cover and cover plate. Tighten
bolts.
指定拧紧扭矩：11 Nm
Specified tightening torque: 11 Nm
注意：确保橡胶密封件正确安装在检查盖上。
Note: Make sure sealing rubber elements are
properly seated in inspection cover.

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整机的拆装 Disassembly and re-assembly of complete engine
曲轴箱呼吸器 Pressure control valve

115.安装带有新 O 形圈的控制阀。
Fit pressure control valve with a new O-ring.
指定拧紧扭矩：8.5 Nm
Specified tightening torque: 8.5 Nm

116. 安装通气管。
Fit bleeder hose.
注意：使用弹簧夹钳 9090
Note: Use spring clamp pliers 9090

117. 安装排液管。
Mount bleeder tube.
指定拧紧扭矩：8.5 Nm
Specified tightening torque: 8.5 Nm

119. 拧紧环箍。
Tighten pipe collar.
指定拧紧扭矩：30 Nm
Specified tightening torque: 30 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
冷却液泵 Coolant pump
128. 安装带有新密封环的冷却液泵。
Fit coolant pump with new sealing ring.
注意：将 AP 1908 密封胶涂抹到 O 形圈。观察
安装的正确位置。
Note: Apply AP 1908 mounting
compound to O-ring. Observe
proper position of installation.
Specified tightening torque: 30 Nm

支架/发电机
Bracket / generator
129. 安装支架、连接板和发电机。
Mount bracket, suspension plate
and generator.
指定拧紧扭矩：60 Nm
Specified tightening torque: 60 Nm

130. 安装电缆接头并固定电缆末端吊耳。
Fit flat plug pin and fix cable end ear.
指定拧紧扭矩：2 Nm
Specified tightening torque: 2 Nm

燃油泵 Fuel pump

131. 安装燃油泵

指定拧紧扭矩：30 Nm
Install fuel pump
Specified tightening torque: 30 Nm

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整机的拆装 Disassembly and re-assembly of complete engine
张紧轮 Tensioning pulley
133. 安装张紧轮。
Install tensioning pulley.
指定拧紧扭矩：80 Nm
Specified tightening torque: 80 Nm

风扇驱动器 Fan drive

134. 安装风扇联接盘。
Fit fan drive.
指定拧紧扭矩：60 Nm
Specified tightening torque: 60 Nm

棱纹 V 型带 Ribbed V-belt
135. 沿箭头方向按下张紧轮 1。在滑轮 2 上安
装棱纹 V 型带。
Press tensioning pulley 1 in
direction of the arrow. Mount ribbed
V-belt – last on pulley 2.
沿与箭头相反的方向松弛张紧轮，直到棱纹 V
型带处于张紧状态。
Release tensioning pulley in
opposite direction of the arrow until
ribbed V-belt is under tension.

136.如果再次使用棱纹 V 型带，要确保不超过
磨损极限。测量移动式张力臂前端和固定的张
紧轮箱停止点的距离“a”。
When re-using ribbed V-belt make
sure wear limits are not exceeded.
Gauge distance “a” between the
nose of the mobile tensioning arm
and the stop of the stationary
tensioner housing.
如果距离“a”大于 3 mm，需要更换新的棱纹
V 型带。
If distance “a” is inferior to 3 mm,
replace ribbed V-belt by a new one.

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整机的拆装 Disassembly and re-assembly of complete engine
138.连接电缆连接器，拆卸传感器及电磁阀，并
拆除控制线路。
Plug cable connector and pull off from all sensors.
Remove fixing clamp.

油底壳 Oil pan

将发动机翻转 180°。

140. 将 DEUTZ DW 74 密封剂涂抹到密封面和

凹口处。密封胶厚度为 3.6mm。

注意：密封剂一定不要溢到油孔内。

141. 放置新垫圈，安装油底壳。

注意：不要移动 O 形圈和密封垫圈。

142. 交替拧紧螺栓。

指定拧紧扭矩：30 Nm

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