Operating Instructions
TBD 616 OEM
Operating Instructions
TBD 616 OEM
Operating Instructions
TBD 616 OEM
0299 8561 en
Engine Number:
Please enter your engine number here. This will help us to serve
you better in questions of repairs, spare parts and after-sales service generally.
We reserve the right to make technical alterations to the drawings
and particulars in this documentation package, if this should
become necessary to improve the engines. Reprints and duplication of any kind, either in whole or in part, require our written permission.
TBD 616 OEM
This documentation is intended for the following engine
● Engine type:
● Application:
● System name:
● Rating: kW
● Speed: min
-1
● Commissioning on:
Please enter the relevant data. This will make it easier for us to help you in questions involving
repairs, spare parts and after-sales service in general.
This documentation package is to be presented to the Service Partner responsible every time a service job is carried out.
Imprint:
DEUTZ AG
Service Information Systems
Deutz-Mülheimer-Straße 147–149
D-51063 Cologne
Tel.: (02 21) 8 22-0
Fax: (02 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reseved
(1) 0304 ©
Ordering No 0299 8561 en
Chapter 0- Page 4 300200039-en-00.fm © 0304
Introduction
Medium-sized and large engines
0Introduction
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.
0
Please read all ...● Please read all the information contained in this manual, and follow the
© 0303 300200002-en-00.fm Chapter 0 - Page 5
Introduction
Medium-sized and large engines
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.
Chapter 0 - Page 6 300200002-en-00.fm © 0303
Introduction
Medium-sized and large engines
The engines of the DEUTZ brand have been developed for a broad spectrum
of applications. A comprehensive range of differe nt variant s 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 th e diff erences involved as clearly as possible, to make it easier for you to find the operating an d 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
0
ForwordDear customer,
The in-depth know-how thus acquired, in conjunction with high standards of
quality, is your guarantee for engines manufactured for long lifetime , hig h re liability and low fuel consumption. And of course, stringent criteria of environment-friendliness are met as well.
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.
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.
DEUTZ enginesare the culmination of long years filled with research and development work.
Care and maintenanceare crucial factors in ensuring that your engine satisfactorily meets the
DEUTZ ServiceIn the event of malfunctions, or if you need spare p ar ts, please contact one of
© 0303 300200002-en-00.fm Chapter 0 - Page 7
Introduction
Medium-sized and large engines
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Chapter 0 - Page 8 300200002-en-00.fm © 0303
TBD 616 Marine
Contents
0Introduction
Please read all ..................................................................................................... 0-5
Careful when the engine is running!..................................................................... 0-6
Forword................................................................................................................. 0-7
DEUTZ engines.................................................................................................... 0-7
Care and maintenance...................................................................................... 0-7
DEUTZ Service.................................................................................................. 0-7
1User Guide
General................................................................................................................. 1-1
Regulations........................................................................................................... 1-1
Safety Regulations / Rules for Accident Prevention .......................................... 1-1
Rules for disposal.............................................................................................. 1-2
Operating Instructions and Workshop Manual...................................................... 1-2
Job cards .............................................................................................................. 1-4
Spares .................................................................................................................. 1-6
Contents
2 Description
Type and designations.......................................................................................... 2-1
Type designation ............................................................................................... 2-1
Rating plate........................................................................................................ 2-1
Position on the engine.................................................................................... 2-1
Figure rating plate........................................................................................... 2-2
Designation of the engine sides, cylinder and direction of rotation.................... 2-3
Direction of rotation......................................................................................... 2-3
Engine figures.................................................................................................... 2-4
Left side.......................................................................................................... 2-4
Right side........................................................................................................ 2-5
Drive side........................................................................................................ 2-6
Structure and function........................................................................................... 2-7
Crankcase.......................................................................................................... 2-7
Crankcase bleeding (Racor)........................................................................... 2-8
Crank drive and valve drive............................................................................. 2-10
Wheel drive...................................................................................................... 2-12
Mass compensation shaft (V8 engines only)................................................ 2-13
Cylinder head................................................................................................... 2-14
Structure....................................................................................................... 2-14
Valve control................................................................................................. 2-15
Charging.......................................................................................................... 2-16
Schematic diagram of the charge air circuit (with liquid-cooled charge air cooler)
2-18
Schematic diagram of the charge air circuit (air / air charge air cooler)....... 2-19
Exhaust gas system......................................................................................... 2-20
Exhaust system with the DEUTZ PEARL® System...................................... 2-20
Surge charging............................................................................................. 2-20
Fuel system ..................................................................................................... 2-21
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Contents
Emissions ..................................................................................................... 2-21
Injection .............................................. ... ... .................................................... 2-21
Fuel pipe system................ ... .... ... ... ................................................................. 2-22
Fuelpipe system V8 engine................ ... ... .................................................... 2-22
Fuel pipe system V12 engine ............................................. ... ... .... ................ 2-23
Fuel pipe system V 16 engine ............................................ ... ... .... ... ... ... ....... 2-24
Speed regulation .............................................................................................. 2-25
Electronic speed governing systems............................................................ 2-25
Lube oil system.................. ... ....................................... ... .... ... ... ... .... ... ............. 2-31
Cooling system ............ ... ... ... .... ... .................................................................... 2-31
Schematic representation of the dual-circu it coo ling ............................. ... .... 2-34
Starter............................................. ... .... ... ....................................................... 2-36
Electronic engine controller EMR2 ..................................... ... ... ....................... 2-37
Use and structure ..... ... ................................................................................. 2-37
Function.......... ... ... .... ... ... .............................................................................. 2-38
System functions ................................................ ... ... ... .... ... .......................... 2-39
Configuration and parameterization............................. ................................. 2-41
Diagnostic possibilities........................ .......................................................... 2-41
TBD 616 Marine
3 Operation
Work prior to commissioning................................................................................. 3-1
General.............................................................................................................. 3-1
Operating media................................................................................................ 3-2
Coolant ........................................................................................................... 3-2
Coolant level................................................................................................... 3-3
Fuel................................................................................................................. 3-3
Lubricant......................................................................................................... 3-5
Monitoring.......................................................................................................... 3-6
Starter system.................................................................................................... 3-6
Room ventilation................................................................................................ 3-6
Commissioning ..................................................................................................... 3-7
Starting the engine............................................................................................. 3-7
Monitoring operation.......................................................................................... 3-7
Shutting down.................................................................................................... 3-7
4 Expendables
General remarks................................................................................................... 4-1
Warranty............................................................................................................ 4-1
Product selection............................................................................................... 4-1
Mixability............................................................................................................ 4-1
Fuel....................................................................................................................... 4-1
Engine lube oil ...................................................................................................... 4-1
Engine coolant...................................................................................................... 4-1
Auxiliary materials................................................................................................. 4-3
Sealants and securing agents ........................................................................... 4-3
Gluing agents..................................................................................................... 4-5
Lubricants.......................................................................................................... 4-5
Other auxiliary materials.................................................................................... 4-6
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TBD 616 Marine
5 Maintenance
Continuous supervision ........................................................................................ 5-1
Maintenance schedule.......................................................................................... 5-1
General.............................................................................................................. 5-1
Selection and structure...................................................................................... 5-1
Deutz maintenance and service schedule......................................................... 5-2
Specific maintenance schedule performance group A1 ....................................... 5-3
Operating hour-independent maintenance work................................................ 5-4
Definition of activities in the maintenance schedule.......................................... 5-5
Operating hour-dependent maintenance work .................................................. 5-5
Overview of operating hour-independent maintenance work (copy form)......... 5-8
Overview of operating hour-dependent maintenance work (copy form)............ 5-9
Specific maintenance schedule performance group A2 ..................................... 5-13
Operating hour-independent maintenance work.............................................. 5-14
Definition of activities in the maintenance schedule........................................ 5-15
Operating hour-dependent maintenance work ................................................ 5-15
Overview of operating hour-independent maintenance work (copy form)....... 5-18
Overview of operating hour-dependent maintenance work (copy form).......... 5-19
Specific maintenance schedule performance group B ....................................... 5-21
Operating hour-independent maintenance work.............................................. 5-22
Definition of activities in the maintenance schedule........................................ 5-23
Operating hour-dependent maintenance work ................................................ 5-23
Overview of operating hour-independent maintenance work (copy form)....... 5-26
Overview of operating hour-dependent maintenance work (copy form).......... 5-27
Specific maintenance schedule performance group C....................................... 5-29
Operating hour-independent maintenance work.............................................. 5-30
Definition of activities in the maintenance schedule........................................ 5-31
Operating hour-dependent maintenance work ................................................ 5-31
Overview of operating hour-independent maintenance work (copy form)....... 5-34
Overview of operating hour-dependent maintenance work (copy form).......... 5-35
Tools for maintenance work up to E40............................................................... 5-37
Standard tool kits............................................................................................. 5-37
Small tool kit ................................................................................................. 5-37
Large tool kit................................................................................................. 5-38
Tool kit supplement I..................................................................................... 5-39
Tool kit supplement II.................................................................................... 5-39
Turning device.............................................................................................. 5-40
V-belt tension measuring instrument............................................................ 5-41
Tools for maintenance work from E50.................................................................. 5-1
Contents
6 Troubleshooting
Fault table............................................................................................................. 6-1
7Conservation
Conservation......................................................................................................... 7-1
8 Technical particulars
General engine data............................................................................................. 8-1
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Contents
TBD 616 Marine
Basic data.......................................................................................................... 8-1
Control data....................................................................................................... 8-1
Ignition sequence............................................................................................... 8-1
Dimensions........................................................................................................ 8-2
Weights.............................................................................................................. 8-2
Operating data...................................................................................................... 8-3
Filling volumes................................................................................................... 8-3
Temperatures .................................................................................................... 8-3
Pressures........................................................................................................... 8-3
Emission data.................................................................................................... 8-3
Start of pumping ................................................................................................ 8-3
Tightening specifications for maintenance work up to E40................................... 8-5
Tightening specifications for maintenance work from E50.................................... 8-1
9Job Cards
Explanation of symbols......................................................................................... 9-1
Overviews............................................................................................................. 9-2
Arranged alphabetically..................................................................................... 9-2
Arranged by Job Card Numbers........................................................................ 9-3
10 Other instructions
Index
Service
We move your world.................................... ... ... ......................................... Service-1
DEUTZ AG - at your service........ ... ... .... ... ... ... ... .... ... ............................... Service-1
Sales & Service Index.................. ... .......................................... ... ............ Service-1
DEPIC.......................... ... ... ... .......................................... .... ..................... Service-1
Seminar program .... .... ... ... ... .......................................... .... ..................... Service-1
Contents - Page 4 300200038-en-00IVZ.fm © 0103
User Guide
Engines and systems
1 User Guide
and the workshop manual must be performed on schedule and in full.
The maintenance and service personnel must have the necessary technical
knowledge to perform the work. Safety and protection devices which may
have to be removed during maintenance and service work must be replaced
afterwards.
The rules for the prevention of accidents and the safety regulations
must be observed at all times during maintenance and service work.
Please also observe the special safety regulations for the various service groups which are listed in detail as job cards in the job cards chapter (cf. also chapter 1 Safety Regulations / Rules for Accident
Prevention).
The maintenance and service intervals are listed in the maintenance and
service schedules. These also provide information about the work to be performed.
The job cards provide technical hints for performing the work.
1
GeneralThe maintenance and service work prescribed in the operating instructions
Detailed safety instructions have been compiled for various service
groups in the form of job cards, these precede the job cards of the
respective service groups.
The legally prescribed rules for accident prevention (available from the
appropriate associations or technical publishers) must be observed.
These depend on the installation site, the mode of operation and the
operating and auxiliary media being used.
Special safety measures depende nt on the respective work are spec ified and highlighted in the work description.
It generally applies among other things:
● for personnel:
- Only instructed personnel may operate or maintain the engine.
Unauthorised persons may not enter the engine room.
- Wear tight fitting clothing and ear protectors in the engine room
when engines are running.
- Only employ qualified personnel for repairs or service work.
● for the engine room:
- Ensure adequate fresh air and ventilation (do not cover ventila-
tion shafts).
- Provide first aid kits and suitable fire extinguishers. Check the fil-
ling and proper functioning regularly.
- Only store inflammable materials in the engine room which are
necessary for operating the system.
- Smoking and naked lights are prohibited in the engine room.
Regulations
Safety Regulations /
Rules for Accident Prevention
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User Guide
Engines and systems
● for operation and maintenance of the engine:
- Only start the engine when all safety devices have been fitted and
the turning gear has been removed. Make sure there is no-one in
the danger zone.
- Only perform cleaning, maintenance and repair work when the
engine is switched off and secured against starting up.
Rules for disposal The work described in the operating instructions and workshop manual
necessitates the renewal of parts and expendables among other things.
These renewed parts / e xpendables m ust be prope rly stored, tr ansp orted and
disposed of. The owner is responsible for this.
Disposal includes recycling and disposal of parts / expendables whereby
recycling has priority .
The details of disposal and its supervision are governed by regional, national
and international laws and decrees which the plant owner is responsible for
observing.
Operating Instructions and Workshop
Manual
The service documentation is divided in to the operating instructions an d the
workshop manual for a user-oriented organisation of the information content.
The Operating Instructions contain a general description as well as instructions for the necessary maintenance and service work which can be performed by a trained operator.
It contains the following chapters:
0 Introduction
Contents
1 User guide
2 Description (description of the engine and components)
3 Operation (operating the engine)
Expendables (operating media specifications and auxiliary materi-
4
als)
5 Maintenance
6 Troubleshooting
7 Conservation (conservation of the engine)
8 Technical particulars
9 Job cards (in order of job card numbers)
10 Sundry other instructions (if not in the appendix or separate folders)
Index
Service
Chapter 1 - Page 2 300200004-en-01.fm © 0303
User Guide
Engines and systems
The Workshop Manual assumes knowledge of the content of the operating
instructions, this applies especially to the safety regulations. Minor repairs
and emergency measures on components are described which require a
greater effort and appropriately qualified personnel.
It contains the chapters:
0 Introduction
Contents
1User guide
2-4 See operating instructions
5 Tools for service
6-7 See operating instructions
8 Technical particulars
9 Job cards (in order of job card numbers)
10 Sundry other instructions (if not in the appendix or separate folders)
Service
1
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User Guide
Engines and systems
Job cards
The Job cards are divided into Job cards of the operating instructions, e.g. B 1-1-1 and job cards of the
workshop manual, e.g. W 4-5-1.
● Please see Figure 1-1 for explanations of the numbering.
● The structure of the job card is shown in Figure 1-2.
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
1 Cylinder head
2 Drive mechanism
3 Crankcase
4 Engine control
5 Governor
6 Exhaust gas system / Charging
7 Fuel system
/ cross-category jobs
8 Lube oil system
9 Coolant system
10 Compressed air system
11 Monitoring system
12 Other components
13 Electrical system
Subsystem (component)
• The subsystems are distinguished by maintenance groups.
• Generally valid:
0 Cross-subsystem or Safety Regulations
1 System parameters or general checks
B 3-3-3
Figure 1-1 Numbering of the job cards
Serial Number
• Counting per subsystem (component)
• Various jobs per subsystem (component)
• Version differences
© 80301-3
Chapter 1 - Page 4 300200004-en-01.fm © 0303
User Guide
Engines and systems
12
1
3
4
5
6
7
111213
Figure 1-2 Numbering of the job cards
When making inquiries about the job card please always state the engine
type or the system 2, the number of the job card 3, the page number 11, the
date of issue 13 or alternatively the identification number of the job card.
DEUTZ Service, publisher of the service documen-
1
tation
8Figures
8
9
10
' 80300-5
2 Engine type or system 9 General notes
3 Number of the job card 10 Work sequence
4 Title of the job card 11 Page number
5 Tools, aids, spares and references 12 Identification number of the job card
6 Safety instructions 13 Date of issue of the job card
7 Sub-headings
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User Guide
Engines and systems
Spares Spares are available from DEUTZ Service. You will find a list of spares in the
spare parts list of the engine or the system. You will find further information in
Chapter Service, at the end of the operating instructions.
Chapter 1 - Page 6 300200004-en-01.fm © 0303
Description
TBD 616 OEM
2 Description
The engines in this series are water-cooled four-stroke diesel engines which
can be used for various powertrains.
See also rating plate (Figure 2-2, item 1)
Turbocharger T
Charge air cooler B
Diesel engine D
Series 616
V-engine V
TBD616V_
2
Type and designations
Type designation
No. of cylinders 8, 12 or 16
tionally.
Rating plate
Position on the engineThe rating plate is fixed to the engine. The engine number is punched addi-
Figure 2-1 Position of the rating plate and the engine number on the engine (example)
© 0103 300200040-en-00.fm Chapter 2 - Page 1
Description
Figure rating plate
TBD 616 OEM
Figure 2-2 Figure rating plate
1 Engine type designation
2 Year of manufacture
3 Engine number
Performance code according to DIN ISO 3046 Part 7
4, 5, 6
A * or ** is specified after the performance code if the available
performance is restricted to a certain time according to special
manufacturer specifications, see 13, 14.
7, 8, 9 Numeric value of the performance in kW
10, 11, 12 Engine speed in rpm
13, 14 Time limiting of the available performance in hours (h)
15 Height above sea level (conditions at installation site)
16 Air pressure p
Charge air coolant temperature t
17
tion site)
18 Relative humidity F
19 Air temperature t
in mbar (conditions at installation site)
x
in °C (conditions at installa-
cx
in % (conditions at installation site)
x
in °C (conditions at installation site)
x
20, 21, 22 Numeric value of an auxiliary device in kW (F, G, H)
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Description
TBD 616 OEM
Designation of the engine sides, cylinder and direction of rotation
The four sides of the engine normally carry the following designations in practice (see Figure 2-3):
The designation used in this operating manual is highlighted respectively in bold print and corresponds with
DIN ISO 1204.
2
A1
A2
A3
A4
1 3
B1
B2
B3
B4
2
4
Figure 2-3 Designation of the engine sides and cylinders
Engine sides
1 Drive side Flywheel, clutch side
2 Left side Cylinder side A
3 Free side End, damper, flui d pump, clutch opposite side
4 Right side Cylinder side B
Cylinder numbering
... counted and labelled from the drive side.
Direction of rotation
Looking towards the drive side in anticlockwise direction ”left-han d rotation”
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Description
Engine figures
Left side
TBD 616 OEM
Figure 2-4 Engine, left side
1 Charge air cooler 7 Oil pan
2 Suction air intake filter 8 Rotary current alternator
3 Crankcase bleed valve 9 Coolant pump of the charge air cooler
4 Exhaust gas turbocharger cylinder side A 10 Rotary vibration damper
5 Heat insulation cladding PEARL exhaust pipe 11 Coolant pump engine cooling circuit
6 Starter 12 Holder for attaching the engine (second holder
on the diagonally opposite side)
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Description
Right side
TBD 616 OEM
2
Figure 2-5 Engine, right side
1 Lube oil nozzle 5 Lube oil filter
2 Fuel filter 6 Fuel hand pump
3 Lube oil cooler 7 Heat insulation cladding PEARL exhaust pipe
4 Oil dipstick 8 Exhaust gas turbocharger cylinder side B
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Description
Drive side
TBD 616 OEM
Figure 2-6 Engine, drive side
1 Flywheel
2 Flywheel housing
3 Holder for attaching the engine (second holder on the diagonally opposite side)
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Description
TBD 616 OEM
Structure and function
Crankcase
The crankcase is made from a special alloyed casting. Torsional strength, breaking strength and casting
tightness which enable low weight and compactness distinguish this manufacturing method. The side walls
of the crankcase are pulled down below the center of the crankshaft and therefore guarantee additional torsional strength. The cylinder angle of 60° enables a narrow design which is demanded in ma ny applica tions.
2
Figure 2-7 Crankcase
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Description
TBD 616 OEM
Crankcase bleeding (Racor)
Fumes are produced in the crankcase during engine operation. To protect the environment these fumes are
not allowed to escape into the atmosphere but are fed into a closed crankcase bleeding system. In this
crankcase bleeding system the filter performs important functions.
The fumes flowing into the filter first pass the pressure control valve which is mounted centrally in the top
part of the filter system. After passing the filter element the purified residual gases are fed to the suction line
between the suction air intake filter and the turbocharger.
The pressure regulator consists of a diaphragm valve loaded both sides. It controls the crankcase pressure
while at the same time vacuum pressures from the suction intake system settle at an upper limit. Pulsating
pressure peaks are limited as a result.
An optical indicator signals it is time to change the filter element.
The exchangeable and recyclable filter element consists of a micro glass fibre structure with a filter effect up
to 0.3 µm. This can be changed without tools due to quick-change catches. The filtered oil particles collect in
the sump of the filter casing and are fed back into the oil circuit by a return line.
A floor valve prevents gas getting in through the return line. The oil returns on exceeding the pressure difference between the filter and crankcase or at engine standstill.
Figure 2-8 Crankcase bleed valve
1 Optical indicator for due change of filter element
2 Quick-release catches
3 Filter top with integrated pressure regulator
4 Powder-coated metal housing
5 Filter element
6 Round sealing ring
7 Round sealing ring
8 Floor insert
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Description
TBD 616 OEM
This crankcase bleeding system achieves that:
● the engine room and system are not contaminated by oil fumes,
● the smell in the immediate vicinity is reduced,
● environmental pollution is reduced,
● charge air cooler, turbocharger and inlet valves are better protected against soiling.
2
Figure 2-9 Schematic of the crankcase bleeding system
1 Sucked in air
2 Suction air intake filter
3 Turbocharger
4 Exhaust gas
5 Charge air cooler
6Engine
7 Line for fumes to the filter system
8 Line for filtered fumes into the suction line
9 Filter
10 Return to the oil pan
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Description
TBD 616 OEM
Crank drive and valve drive
The crank drive comprises crankshaft, con rod, piston, rotary vibration damper and the flywheel.
The drop-forged crankshaft 1 is hung in multilayer bearings in the crankcase 7. Every bearing cover is
secured by four studs. Multilayer be arings offer greater lubrication security and emergency running properties. The shaft and crank journals and the contact surfaces of the axial bearings are inductively hardened.
The counterweights 9 screwed to the crank webs serve to dissipate the internal mass effect and relieve the
crankshaft bearing. The rotary vibration damper and the flywheel ensure smooth running of the engine with
their structure calculated exactly for every application.
The double T-shank con rods 2 are divided at an angle. This allows removal of the piston with con rod up
through the cylinder liner 3. The con rods run on the crankshaft in sputter bearings. A liner is pressed into the
upper con rod eye in which the piston bolt 4 is mounted on a floating bearing.
The pistons 6 are cast from a lightweight metal. The piston rings 5 (trapeze ring, minute ring and a narrow
land drain oil control ring) are in cast steel beams. The pistons are supplied with cooling lube oil through a
spray nozzle 8. The lube oil flows through the cooling channels of the piston base where it emits heat.
The cylinder liners 3 are made by a spin casting technique. Special emphasis is placed on honing in the further processing. The cross grind ing an gle cr eated d uring hon ing is asy m metr ical is res pon se to th e dema nd
for low oil consumption and optimum run-in times . Th e cylin d er liner s to uc h th e cra n kca se and ar e gu id ed in
a collar at the top and bottom.
The use of wet cylinder liners enables fast and low cost exch an ge of a cylin de r un it.
Chapter 2 - Page 10 300200040-en-00.fm © 0103
Description
TBD 616 OEM
2
Figure 2-10Crank and valve drive
1 Crankshaft 6 Piston
2 Con rod 7 Crankcase
3 Cylinder liner 8 Oil injection nozzle
4 Piston bolt 9 Counterweights of the cranksha ft
5Piston rings
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Description
TBD 616 OEM
Wheel drive
The wheel drive serves for engine control and driving of sub-components.
Engine control unit
The toothed wheel 6 on the crankshaft drives the toothed wheel 3 on the camshaft.
Sub-components
The toothed wheel 3 on the camshaft drives the injection pump via toothed wheel 1. If hydraulic pumps are
attached to the engine, toothed wheel 2 or 10, these are driven by toothed wheel 1.
The lube oil pump 7 is driven by toothed wheel 6 on the crankshaft.
If a compressor is installed on the engine, toothed wheel 4, it is driven by the intermediate wheel 5, driven by
toothed wheel 6 on the crank sh aft.
The coolant pump, toothed wheel 9, is driven by the intermediate wheel 8, driven by toothed wheel 6 on the
crankshaft.
1
10
2
3
9
8
5
7
Figure 2-11 Wheel drive on the free side
Gear wheels:
1 Injection pump 6 Crankshaft
2 Hydraulic pump 7 Lube oil pump
3 Camshaft 8 Intermediate wheel
4 Compressor 9 Coolant pump
5 Intermediate wheel 10 Hydraulic pump
6
4
© 84131-0
Chapter 2 - Page 12 300200040-en-00.fm © 0103
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