FENDT MAN D 0836 LE Workshop Manual

Werkstatthandbuch Workshopmanual Manuel de réparation Manuel d´atelier Manuale per I´officina

Motor Engine

Moteur Motore

MAN D 0836 LE (Mechanical part)

X990.005.039.010

MAN D 0836 LE

Favorit 916 916/../3001Favorit 920 920/../3001Favorit 924 924/../3001Favorit 926 926/../3001-

Herausgegeben von der Abt. Kundendienst der Fa. ACGO GmbH & Co., Marktoberdorf Alle Rechte vorbehalten – Printed in Germany. Diese Druckschrift darf ohne unsere schriftliche Genehmigung Weder ganz noch auszugsweise vervielfältigt werden.

Published by the Service Division of ACGO GmbH & Co., Marktoberdorf Copyright –All rights reserved – Printed in Germany. Rproduction of this publication, in whole or parts, without our prior authorisation, is prohibited.

Peblié par le Service Aprés-vente de ACGO GmbH & Co., Marktoberdorf Tous droits réservés – Printed in Germany Cette brochure ne peut être reproduite, ni totalement, ni par extraits sans notre autorisation écrite.

Pubblicato dal reparto tecnico della ACGO GmbH & Co., Marktoberdorf Tutti i dirette riservati – Printed in Germany La riproduzione die questo libro, sia completa che in parte É vietata senza la nostra autorzzazione.

Redatto dal reparto assistenza della ditta ACGO GmbH & Co., Marktoberdorf Tutti i diritti riservati - printed in Germany. Laa riproduzione di questo opuscolo, parziale o integrale, non è ammessa senza autorizzazione scritta.

WERKSTATTHANDBUCH

WORKSHOPMANUAL

MANUEL D´ATELIER

MANUAL DE TALLER

MANUALE PER L‘OFFICINA

MOTOR / ENGINE / MOTEUR / MOTORE

MAN D 0836 LE

(Mechanical part)

Ausgabe 05/2001

Xaver FENDT GmbH & CO.

Ein Unternehmen der AGCO-Corp. Maschinen- und Schlepperfabrik, Marktoberdorf / Bayern Germany Postfachadresse: D-87609 Marktoberdorf, Postfach 1155 Telefon (0 83 42) 77-0 Telefax (0 83 42) 77-2 22 (Kundendienst)

Bestell-Nr.

X 990.005.039.010

VORWORT Das vorliegende Werkstatthandbuch wurde für die

Reparaturwerkstätten unserer Vertretungen zusammengestellt und enthält alle Demontage- und Montagevorgänge, die im Zusammenhang mit Einstellarbeiten und der Auswechselung von Teilen erforderlich ist.

Sind Teile auszuwechseln, so dürfen nur OriginalErsatzteile verwendet werden. Teile-Bestellungen bitten wir unter Angabe der Fahrgestell-Nummer nach den jeweils gültigen Ersatzteilunterlagen auf zugeben.

Es wird vorausgesetzt, daß diese Arbeiten von Fachleuten ausgeführt werden; daher wurde auf die Beschreibung allgemein bekannter Reparaturen verzichtet.

Handelsübliche Werkzeuge und allgemeines Gerät, das zur Ausrüstung einer Werkstatt gehört, wird hierbei vorausgesetzt.

Spezialwerkzeuge sind auf das notwendige Maß beschränkt und am Schluß des Buches in einer Zusammenfassung gezeigt. Hinsichtlich der Pflegeund Wartungsarbeiten verweisen wir auf die Betriebsanleitungen.

Von den Werkstätten sind ie Technischen Daten zu beachten.

Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzuhalten.

Dieses Werkstatthandbuch unterliegt keinem Änderungsdienst, wir weisen aus diesem Grunde auf die zusätzlich herauskommenden technischen Rundschreiben besonders hin. Bei Neuauflage eines Werkstatthandbuches werden alle Änderungen berücksichtigt und mit eingearbeitet.

Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind technische Änderungen, die zur Verbesserung des Produktes notwendig werden, vorbehalten. Nachdruck und Vervielfälti gung jeglicher Art, auch auszugsweise, bedarf unserer schriftlichen Genehmigung.

FOREWORD This workshop manual was compiled for our agent´s

repair workshops and contains all the dismantling and assembly procedures necessary in connection with adjustments and replacement of parts.

If parts have to be renewed, only original replacement parts may be used. Orders für parts must state the chassis number and be in line with the latest parts decomentation.

It is assumed that these repairs will be carried out by skilled mechanics; descriptions of routine repair work have, theerfore, been omitted.

It is furher assumed that the workshop concerned is equipped with standard tools and has the normal workshop facilities. The special tools are restricted to the essential minimum and are shown in a summery at the back of this manual.

Please refer to the Operating Instructions for details of general maintenance and care operations.

Workshops must observe the technical data. The accident prevention regulations and all other

generally recognized regulations on safety and occupational medicine are to be observed.

This workshop manual is not subject to an updating service. For this reason we draw your attention to the supplementary technical circulars which are published separately. New issues of a workshop manual incorporate all the latest changes.

In view of continuous desing improvements or changes, the technical specifications and the illustrations shown in this Workshop Manual are subject to alteration. Reprinting and reproduction, in part or in whole, are subject to our written approval.

de/en

AVANT PROPOS Le présent Manuel de Réparation a été concupour

les Ateliers de Réparation de nos dépositaires et il contient toutes les instructions de démontage et de montage nécessitées par les travauc de réglade et de remplacement des piéces.

Dés qu´il s´agit de remplacer des piéces, il faut utiliser uniquement des piéces de rechange originales. Pour commander les piéces de rechange, nous prions de nous indiquer le numéro du chassis et le numéro de référence de la piéce concernée.

On considére que ces travaux sont effectués par des spécialistes et c´est pourquoi les réparations courantes ne sont pas décrites.

On considére également que l´on dispose des outils classiques et de l´appareillage équipant normalement un atelier.

Les outils spéciaux ont été réduits au strct nécessaire et ils sont énumérés la fin du manuel.

En ce qui cincerne les travaux d´entretien, priére de consulter les Instructions de Service.

Les ateliers de réparation devront tenir compte des caractéristiques techniques.

Il convient de respecter les consignes générales de sécurité et de prévention des accidents en vigueur.

Le présent Manuel de Réparation n´est soumit á aucune midification, et c´est pourquoi il convient de consulter les Circulaires Techniques publiées par la suite. L´édition d´un nouveau Manuel de Réparation tient compte de toutes les modification nécessaires.

Sous féserve de modifications techniques nécessaires á lámélioration des produits présentés par des illustrations et des indications référencées dans ce Manuel d´Atelier. Réimpression et reproduction meme partielle, quelle qu´en soit la nature, interdtes sans l´autorisation écrite de nos service.

PROLOGO El presente Manual de Rparaciones ha sido

elaborado para los talleres de nuestros servicios oficiales y comprende todos los trabjos de montaje y desmontaje qu son necesarios para la sustitución de piezas o trabajos de ajuste.

Cuando se sustituyan piezas deberán utilizarse unicamente piezas de repuesto originales. Los pedidos de las piezas de repuesto, sirvanse hacerlos indicando el número de chasis y siguiende el catálogo de repuestons que tenga validenz.

Es una condición previa que los trabajos sean ilevados a cabo por personal especializado. Por este motivo, hemos desistido de describir reparaciones comúnmente conocidas.

Naturalmente, damos por sobreentendido que los talleres deberán estar equipados con herramientas y utillaje adecuado. La cantidad de herramientas especiales a utilizar ha sido reducida a la medida necesaria y van relacionadas al final de este libro.

Los puntos referentes a trabajos de mantenimiento y de conservación sirvanse consultar el Manual de Instrucciones. Los talleres están obligados a tener en cuenta los datos técnicos. Se cumplirán las normas aplicables para la prevención de accidentes asi como todas las demás normas de seguridad y medicina laboral generalmente aceptas.

Este Manual de Reparaciones no está sometido a modificaciones y, por lo tanto, les rogamos tengan especialmente en cuenta las circularse técnicas que, adicionalmente, se irán publicando. Cuando un Manual de Reparaciones sea editado de nuevo se tendrán en cuenta y serán introducidas todas las modificaciones.

Nos reservamos el derecho de introducir modificaciones técnicas necesarias para el mejoramiento de las productas, aunque difieran de las ilustraciones y datos contenidos en este Manual de Taller. La reimpresión del presente libro o cualquiera forma de reproducción, aunque sea parcial, requiere nuestra autorización por escrito.

fr/es

PREMESSA

Il presente manuale è stato redatto per le officine dei nostri concessionari e contiene tutte le indicazioni relative allo smontaggio ed al montaggio che si rendono necessari per la registrazione e la sostituzione di ricambi.

Se ci sono parti da sostituire devono essere utilizzati assolutamente ricambi originali. I ricambi devono venire ordinati indicando il numero di telaio, secondo la documentazione ricambistica in vigore.

E‘ necessario che questi lavori vengano effettuati da personale specializzato, perciò le riparazioni generalmente note non sono descritte in questo manuale.

Si presuppone la presenza degli attrezzi necessari e di dispositivi in generale che fanno parte della dotazione di un‘officina.

Attrezzi speciali sono limitati al minimo indispensabile e vengono elencati alla fine di questo manuale. Per quanto riguarda la manutenzione si prega di consultare le istruzioni per l‘uso.

Le officine devono osservare i dati tecnici. Rispettare le norme antinfortunistiche nonché

le generali norme tecniche sulla sicurezza e di medicina sul lavoro.

Questo manuale non è soggetto a nessun servizio di aggiornamento, per questo motivo rimandiamo ad ulteriori comunicazioni tecniche. In caso di aggiornamento di un manuale si tiene conto delle variazioni, che vengono poi incluse nella nuova versione.

Ci riserviamo il diritto di apportare modifiche rispetto ad illustrazioni ed indicazioni di questo manuale, che si rendono necessarie per il miglioramento del prodotto. Stampa e riproduzione di ogni genere, anche parziale, di questo manuale solo previa nostra autorizzazione scritta.

Table of contents Page

Specifications ............................................................................................................................... 9

Service data.................................................................................................................................10

Tightening torque values...............................................................................................................24

Turbocharger, troubleshooting......................................................................................................28

View of engine D 0836 LE 501......................................................................................................30

Checking compression .................................................................................................................31

Checking valve timing...................................................................................................................32

Setting valve clearance.................................................................................................................33

Reassembling and refitting intake pipe...........................................................................................35

Removing and refitting turbocharger..............................................................................................36

Removing and refitting manifold ....................................................................................................38

Removing and refitting cylinder head.............................................................................................39

Dismantling and reassembling the rocker arm assembly.................................................................43

Removing and refitting valves .......................................................................................................45

Removing and refitting valve guides ..............................................................................................48

Replacing valve seat insert ...........................................................................................................49

Re-machining the valve seat.........................................................................................................51

Reseating valves..........................................................................................................................54

Replacing engine coolant..............................................................................................................55

Removing and refitting the thermostatic valve ................................................................................57

Removing and refitting water pump...............................................................................................58

Removing and refitting coolant pipe ...............................................................................................62

Layout of fuel system ...................................................................................................................63

Fuel pre filter / Cartridge ...............................................................................................................64

Purging Air from Fuel Supply System............................................................................................66

Removing and refitting heater plug................................................................................................67

Power - belts ...............................................................................................................................68

Removing and refitting the starter engine .......................................................................................71

Removing and refitting generator...................................................................................................72

Removing and refitting air compressor ...........................................................................................74

Replacing crankshaft front seal .....................................................................................................79

Removing and refitting flywheel.....................................................................................................80

Removing and refitting crankshaft seal (flywheel) ...........................................................................82

Removing and refitting flywheel.....................................................................................................83

Removing and refitting the timing case..........................................................................................85

Removing and refitting camshaft ...................................................................................................89

Removing and refitting intermediate flange....................................................................................91

Removing and refitting the con-rod bearing shells ..........................................................................92

Removing and refitting the crankshaft............................................................................................93

Removing and refitting con-rod......................................................................................................96

Removing and refitting the piston rings ........................................................................................ 101

Table of contents Page

Replacing cylinder liners............................................................................................................. 103

Layout of engine lubrication ........................................................................................................ 104

Replacing oil filter.......................................................................................................................105

Removing and refitting oil cooler................................................................................................. 106

Removing and refitting oil pan..................................................................................................... 108

Removing and refitting oil pump ..................................................................................................111

Removing and refitting splash nozzle........................................................................................... 114

Checking Start of Delivery VP44 ................................................................................................. 115

Fuel Injection Pump VP 44 - Mounting - Dismounting ...................................................................122

Checking injection nozzles ..........................................................................................................132

Replacing Injection valve with needle Motion sensor..................................................................... 135

Special tools.............................................................................................................................. 138

Fav 900

Engine / Generalities

Speciﬁcations

Généralités

Fav 900 from chassis number 23/3001and up

12/03/2001

2000 000005

1/1

Chapitre Docu-No.

Reg.

Date Édition

Page

Specifications

Text-module

Engine Design In-line vertical

Principle of operation

4- Stroke Diesel with turbocharger and inter-

cooler Method Direct injection Number of cylinders 6

Compresssion ratio 18 : 1 Bore

108 mm (4.25")

125 mm (4.92")

Stroke Swept volume 6871 cm³ (419.29 in³) Firing sequence 1-5-3-6-2-4

Emission category MVEG 1 Max. output to ISO 1585 88/195 EWG

D 0836 LE 501 210 kW (285 PS) at 2250 rpm (281HP) D 0836 LE 502 186 kW (255 PS) at 2250 rpm (249HP) D 0836 LE 503 162 kW (220 PS) at 2150 rpm (217 HP) D 0836 LE 504 146 kW (200 PS) at 2150 rpm (196 HP)

Max. torque to ISO 1585 88/195 EWG D 0836 LE 501 1 175 Nm at 1400 rpm D 0836 LE 502 1070 Nm at 1400 rpm D 0836 LE 503 970 Nm at 1400 rpm D 0836 LE 504 880 Nm at 1400 rpm

Rotation in rpm Idling speed - Final speed D 0836 LE 501 / 502 800±30 ; 2250; 2420-2480 D 0836 LE 503 / 504 800±30 ; 2150; 2320-2380

Start of delivery Crankshaft angle before TDP D 0836 LE 501 / 502 / 503 / 504 0°±0,5° Engine number D 0836 LE 50. 164 9790 ... and up 5°±0,5°

Lubrication Forced feed lubrication method gear oil pump Quantities Quantities in oil pan min. 18 ltr . (19 qt.)

max. 23 ltr. (24.3 qt.) Oil change with ﬁlter 25,5 ltr. (27 qt.)

Cooling Liquid cooling Method Impeller pump Coolant temperature D 0836 LE 501 / 502 normal 102°C (215°F) momentary max. 108°C (226°F) D 0836 LE 503 / 504 normal 105°C (221°F) momentary max. 1 13°C (235°F)

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

1/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Text-module

Crankcase

PM-Picturemodule

Text-module

Cylinder liner

PM-Picturemodule

Text-module

PMTAB_Picture

1. 116,0-116,1 mm (4.4567 - 4.4570 ")

2. Standard size: 4,00-4,03 mm (.157 - .159") Oversize: 4,20-4,23 mm (.165 - .167")

3. Standard size: 111,50-111,52 mm (4.389 - 4.390")

Oversize 0,5 mm: 112,00-112,02 mm (4.409 - 4.410")

4. Max. permissible taper over length of cylinder

PMTAB_Picture

1. 115,74-115,88 mm (4.556 - 4.562")

2. Standard size 4,04-4,06 mm (.159 - .160") Oversize: 4,24-4,26 mm (.167 - .168")

3. 108,00-108,22 mm (4.252 - 4.260") max. wear limit: 0,1 (.039") above basic size

4. Max. permissible taper over length of cylinder

5.Standard size: 111,475-111,490 mm (4.388 - 4.389")

Oversize: 0,5 mm (.020"): 111,975-111,990 mm (4.408 - 4.409")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

2/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Crankshaft

PM-Picturemodule

Text-module

PMTAB_Picture

1. Dimensions: Standard: 76,981-77,000 mm (3.031 - 3.032“) Under size: 0,10 mm (.004"): 76,881-76,900 mm

(3.027 - 3.028")

2. Con-rod bearing journal diameter: Standard : 69,981-70,000 mm (2.755 - 2.756") Under size: 0,10 mm (.004"): 69,881-69,900 mm

(2.751 - 2.752")

PMTAB_Picture

1. For all crankshaft journals: maximal permissible runout maximal deviation from conical form

2. Thrust bearing journal width: Standard size: 34,000-34,062 mm

(1.339 - 1.341") Repair sizes: 34,500-34,562 mm (1.358 - 1.361")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

3/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Main bearing

PM-Picturemodule

Text-module

Flywheel

PM-Picturemodule

PMTAB_Picture

1. Standard size: 2,468-2,480 mm (.097 - .098") Oversize 0,10 mm (.004"): 2,518-2,530 mm

(.099 - .100")

2. Fitted bearing inner Ø for main bearing : Standard size : 77,040-77,086 mm

(3.033 - 3.035") Undersize 0,10mm (.004"): 76,940-76,986 mm

(3.029 - 3.031") Housing bore for main bearing: 82,000-82,022

mm (3.228 - 3.229") Axial play: 0,040-0,105 mm (.002 - .004") Spread of main spearing shells: 0,5-1,5 mm

(.020 - .059")

PMTAB_Picture

max permissible crankshaft axials play: 0,200-0,395 mm (.008 - .016")

1. Thrust bearing journal width thrust washer: Standard size: 2,850-2,900 mm (.112 - .114") Repair size: 3,100-3,150 mm (.122 - .124")

2. 27,967-28,000 mm (1.101 - 1.102")

PMTAB_Picture

1. Watch position of chamfer! Fitting temperature (Shrink-on temperature):

220-240°C (428-464°F)

2. Flywheel: 352,390-352,447 mm (13.874 - 13.876")

Ring gear (Internal): 351,671-351,760 mm (13.845 - 13.849")

m total. = 50,3 kg (110.89 lbs.) J total = 1,65 kgm²

3.Number of teeth : Z=125, Module 3 Mating gear (Z=11) Backlash : 0,4-0,7 mm (.016 - .020")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

4/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Text-module

Connecting rod

PM-Picturemodule

Text-module

Con-rod bearing

PM-Picturemodule

Text-module

PMTAB_Picture

1. 42,050-42,066 mm (1.655 - 1.656")

2. 32,78-32,88 mm (1.290 - 1.294") Con-rod journal width: 33,0-33,1mm

(1.299 - 1.303")

PMTAB_Picture

Fit con-rod bearing caps (without shells). Measure basic bore with an internal micrometer.

74,000-74,019 mm (2.913 - 2.914")

PMTAB_Picture

1. Standard size: 1,975-1,987 mm (.077 - .078") Oversize 0,10 mm (.004"): 2,025-2,037 mm

(.079 - .080") Spread of new bearing shells : 0,5-2,0 mm

(.020 - .079")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

5/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Piston

PM-Picturemodule

Text-module

Piston ring grooves

PM-Picturemodule

Text-modulePiston rings PM-Picturemodule

PMTAB_Picture

1. Compresion height: 63,90-64,00 mm (2.516 - 2.519")

with undersizes 0,2 mm (.008"): 63,70-63,80 mm (2.508 - 2.511")

with undersizes 0,4 mm (.016"): 63,50-63,60 mm (2.500 - 2.503")

Piston projection above crankcase: 0,0093-0,391 mm (.004 - .015")

2. 42,003-42,009 mm (1.6537 - 1.6539") Piston pin diameter: 41,994-42,000 mm

(1.6533 - 1.6535")

3. 107,891-107,900 mm (4.2477 - 4.2480")

PMTAB_Picture

1. 2,685 mm (.106")

2. 2,54-2,56 mm (.100 - .101")

3. 4,02-4,04 mm (.158 - .159")

Piston rings

PMTAB_Picture

1. Ring - keystone ring: Height: 2,429-2,463 mm (.096 - .097")

2. Ring - chamfered ring: Height: 2,478-2,490 mm (.097 - .098") Axial play: 0,050-0,082 mm (.002 - .003")

3. Ring - D-ring with spring: Height: 3,975-3,990 mm (.156 - .157") Axial play: 0,030-0,065 mm (.001 - .002")

4. End gap clearance:

1. Ring: 0,35-0,55 mm (.001 - .002")

2. Ring: 0,3-0,5 mm (.001 - .002")

3. Ring: 0,3-0,6 mm (.001 - .002")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

6/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Text-module

Cylinder head

PM-Picturemodule

Text-module

PMTAB_Picture

1. 10,000-10,015 mm (.3937 - .3942") at intake and exhaust valves

2. 14,1-14,15 mm (.555 - .557")

3. 97,8-98,0 mm (3.850 - 3.860")

Minimum: 96,8 mm (3.811") alpha = 60° Intake valve beta = 45° Exhaust valve

PMTAB_Picture

1. Valve guide bore in cylinder head:

Standard size: 16,000-16,018 mm (.630 - .631") Oversize: 16,250-16,268 mm (.640 - .641")

2. Valve guide outer diameter:

Standard size: 16,028-16,046 mm (.631 - .632") Oversize: 16,278-16,296 mm (.641 - .642")

3. Standard size:

Intake valve: 10,8-10,9 mm (.425 - .429") Exhaust valve: 11,0-11,1 mm (.433 - .437") Oversize: Intake valve: 11,0-11,1 mm (.433 - .437") Exhaust valve: 11,2-11,3 mm (.441 - .445")

4. Cylinder head basic bore:

Standard size: 51,00-51,03 mm (2.008 - 2.009") Oversize: 51,20-51,23 mm (2.016 - 2.017") Valve seat insert outer diameter: Standard size: 51,10-51,11 mm (2.011 - 2.012") Oversize: 51,30-51,31 mm (2.019 - 2.020")

5.Cylinder head basic bore:

Standard size: 44,000-44,025 mm (1.732 - 1.733")

Oversize: 44,200-44,225 mm (1.740 - 1.741") Valve seat insert outer diameter: Standard size: 44,10-44,11 mm (1.736 - 1.737") Oversize: 44,30-44,31 mm (1.744 - 1.745")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

7/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Valves

PM-Picturemodule

Text-module

PMTAB_Picture

1. Intake valve: 9,965-9,980 mm (.3923 - .3929")

Exhaust valve: 9,950-9,965 mm (.3917 - .3923") Wear limit: max. 0,1 mm (.0039")

2. Valve recess:

Intake valve : 0,25-0,71 mm (.010 - .028") Exhaust valve: 0,45-1,05 mm (.018 - .041")

PMTAB_Picture

Valve springs: Untensioned approx.: 59,5-61,0 mm

(2.343 - 2.401") Spring resistance L = 45 mm: 410-471 N

(92 - 106 lbs.) Spring resistance L = 33,5 mm: 744-825 N

(167 - 185 lbs.)

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

8/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Valve operation

PM-Picturemodule

PMTAB_Picture

Rocker arm

1. 20,000-20,001 mm (.78740 - .78744")

Diameter of rocker arm bearing: 19,957-19,970 mm (.7857 - 7862")

Wear limit: 0,08 mm (.003")

PMTAB_Picture

Valve tappets

1. Tappet housing bore:

Standard size: 20,000-20,021 mm (.787 - .788") Oversize: 20,250-20,271 mm (.797 - .798") Tappet outer diameter: Standard size: 19,944-19,965 mm (.785 - .786") Oversize: 20,194-20,215 mm (.795 - .796")

PMTAB_Picture

Camshaft

Camshaft bush inner diameter: 55,07-55,14 mm (2.168 - 2.170")

1. 1. 54,91-54,94 mm (2.162 - 2.163")

Camshaft axial diameter: 0,14-0,27 mm (.0055 - .0106")

Wear limit: 1,5 mm (.059")

PMTAB_Picture

Valve clearance

1. Adjust when engine is cold.

Intake valve: 0,5 mm (.020") Exhaust valve: 0,5 mm (.020")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

9/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

PM-Picturemodule

Text-module

Backlash between

Text-module

Compression pressures

Text-module

PMTAB_Picture

Valve timing

1. Engine direction of rotation

2. Intake valve opens 18° before TDC.

3. Exhaust valve closes 29° after TDC.

4. Exhaust valve opens 63° before TDC.

5. Intake valve closes 32° after bottom dead point.

6. Exhaust valve opening point 272°.

7. Intake valve opening point 230°.

Figures in degrees relate to the crankshaft angle.

PMTAB_Picture

Layout of engine timing

1. Crankshaft gear

2. Intermediate timing gear

3. Camshaft gear

4. Injection pump drive gear

5. Oil pump drive gear

6. Oil pump delivery gear

7. Power take off / air compression take off

Crankshaft gear and intermediate gear 0,000-0,465 mm (0 - .018") Intermediate gear and crankshaft gear 0,062-0,324 mm (.002 - .013") Intermediate gear and injection pump drive 0,10-0,27 mm (.004 - .010") Intermediate gear and oil pump drive 0,100-0,266 mm (.004 - .010") Oil pump delivery gears 0,10-0,22 mm (.004 - .009") Camshaft gear and hydraulic pump gear 0,10-0,15 mm (.004 - .006")

good above 30 bar (435 PSI) permissible 27 - 30 bar (391 - 435 PSI) needs repairing under 26 bar (377 PSI) pressure difference max. 4 bar (58 PSI)

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

10/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Engine lubrication

Text-module

Oil pump

PM-Picturemodule

Text-module

V alve opening pressures Bypass valve for full ﬂow oil ﬁlter 2-3 bar (29 - 44 PSI) Oil pump pressure relief valve 5-6 bar (73 - 87 PSI) Pressure valve of oil nozzles Opening pressure 1,9-2,1 bar (27.5 - 30.5 PSI) Closing pressure 1,4-1,6 bar (20.3 - 23.2 PSI)

Oil splash nozzle oriﬁce 1,75-1,85 mm (.069 - .073")

PMTAB_Picture

Oil pump drive gear

1. 16 mm (.630")

2. D 0836 LE 501/502: 31,925-31,950 mm

(1.257 - 1.258") D 0836 LE 503/504: 31,920-31,950 mm

(1.257 - 1.258") Housing depth: 32,000-32,039 mm

(1.260 - 1.261") Housing bore: 10000 N

3. Shaft: 15,94-15,95 mm (.627 - .628")

Housing bore: 16,000-16,018 mm (.630 - .631")

Oil pump delivery at pump speed (with SAE 20W/20 Oil, at 90°C (194°F) and p=6bar (87 PSI)) Gear spread 32 mm (1.260") at n = 1008 1/min (rpm 800 1/min) 17 ltr./min (4.5 GPM) at n = 2709 1/min (rpm 2150 1/min) 53,5 ltr./min (14 GPM) at n = 2835 1/min (rpm 2250 1/min) 56,5 ltr./min (15 GPM) ati n = 2961 1/min (rpm 2350 1/min) 59 ltr./min (15.5 GPM) at n = 3087 1/min (rpm2450 1/min) 62,5ltr./min (16.5 GPM)

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

11/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Cooling system

PM-Picturemodule

Text-module

PMTAB_Picture

Water pump (engine)

1. Gap between impeller and housing: 0,5-0,9 mm (.020 - .035")

2. Impeller diameter: 136 mm (5.354")

3. Bearing location in housing: 54,940-54,970 mm (2.163 - 2.164"). Bearing diameter: 54,981-54,994 mm (2.1646 - 2.1651")

4. Bore in hub: 25,000-25,013 mm (.984 - .985"). Bearing shaft diameter: 25,048-25,061 mm (.986 - .987").

5. Impeller bearing shaft bore: 16,000-16,018 mm (.630 - .631"). Bearing shaft diameter : 16,045-16,056 mm (.6316 - .6321).

PMTAB_Picture

Thermostat

Opening at 83°C (±2°) (181°F ±3.6°F). Fully open: 95°C (203°F).

1. Stroke: min 8 mm at 95°C (.315" at 203°F).

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

12/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Turbocharger

PM-Picturemodule

Text-module

Manufacturer KKK D 0836 LE 501/502/503/504 HX40-8274AW/H18W A8

PMTAB_Picture

Axial play

1. 0,038-0,093 mm (.0015 - .0037")

PMTAB_Picture

Radial play

1. 0,329-0,501 mm (.0130 - .0197")

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

13/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

Fuel system Injection nozzles

PM-Picturemodule

Manufacturer Bosch Type : DSLA 154 P 625 N° of oriﬁces 6 Nozzle opening pressure : Nozzle holder new : 320 + 8 bar (4641 +1 16 PSI) Nozzle holder used : 300 + 8 bar (4351 +1 16 PSI) Nozzle injection pump with vane-cell feed pump

and automatic pressure controlled injection timer

2,68-3,47 mm (.106 - .137")

Nozzle holder KDEL 82 P 55

PMTAB_Picture

Injection pump

Nozzle injection pump with vane pump and automatic pressure controlled injection timer

Manufacturer : Bosch. Type: VP 44.

Fav 900

Engine / Generalities

Service Data

General

Fav 900 chassis number 23/3001and up

13/03/2001

2000 000006

14/14

Capitel Docu-No.

Index

Date Version

Page

Service Data

PM-Picturemodule

Text-module

Power take-off for hydraulic pump / Air compressor

PM-Picturemodule

PMTAB_Picture

Starter

Manufacturer : Bosch Type : EV operationg method : pre-engaged drive Starter pinion gear Number of teeth: 11 Module: 3 Nominal voltage: 24 Volt Nominal output : 4 kW (5.36 HP)

PMTAB_Picture

Generator

Manufactured : Bosch Type : KC Operating method : 3_PHASE Nominal voltage : 14 Volt Max. current : 45-90 Ampere

Speed 0,97 * engine speed

PMTAB_Picture

Air compressor

Single cylinder air compressor Manufacturer: Knorr Lubrication: Circulatory system with pressure

compression Cooling: air-cooled Displacement: 213 cm³ (129 in³) Op speed: max. 3000 1/min Op presure: max 12,5 bar (181 PSI)

Fav 900

Engine / Generalities

Tightening Torque values

General

Fav 900 from chassis number 23/3001and up

13/03/2001

2000 000007

1/4

Capitel Docu-No.

Index

Date Version

Page

Tightening Torque values

Text-module

Note: All threaded unions not speciﬁed in this table must be tightened according to our works standard M 3059. Bolts and screws must be lightly oiled before tightening !

Plugs

Crankcase, crank gear

Cylinder head

Lubrication

DIN 908 M 14*1,5; M16*1,5 80 Nm (59,00 lbf-ft) M 18*1,5; M22*1,5 100 Nm (73,76 lbf-ft) M 24*1,5; M26*1,5 120 Nm (88,51 lbf-ft) M 30*1,5 150 Nm (1 10,63 lbf-ft) DIN 7604 AM 10*1; M12*1,5 50 Nm (36,88 lbf-ft) AM 14*1,5 80 Nm (59,00 lbf-ft)

Crankshaft bearing cap on and crankcase Initial torque 1 15 Nm (84,82 lbf-ft) Angular torque 90-100° Damper on crankshaft M14*1,5 10,9 Initial torque 150 Nm (1 10,63 lbf-ft) Angular torque 90-100° Damper on crankshaft M14*1,5 12,9 Initial torque 150 Nm (1 10,63 lbf-ft) Angular torque 90-100° Angular torque 90-100° Flywheel on crankshaft Initial torque 100 Nm (73,76 lbf-ft) Angular torque 90-100° Con-rod bearing caps Initial torque 50-60 Nm (36,88-44,25 lbf-ft) Angular torque 90-100°

For tightening and retightening of cylinder head bolts see following page Lock nut for valve adjusting screw 40 Nm (29,50 lbf-ft) Cheese-head screws with hexagonal socket for bolts of interme-

diate gear

1 15 Nm (84,82 lbf-ft)

Collar screw for crankshaft 65 Nm (47,94 lbf-ft) Rocker socket (T orx E12) 65 Nm (47,94lbf-ft)

Oil pressure valve for piston spray nozzle 38-42 Nm (28,03-30,98 lbf-ft) Oil pump drive gear on shaft 30 Nm (22,13 lbf-ft) Screw plug for pressure relief valve in crankcase 60Nm (44,25 lbf-ft) Oil pan drain plug 60Nm (44,25 lbf-ft) Screw plug for oil ﬁlter head (M 10*1) 20 Nm (14,75 lbf-ft) Threaded coupling for oil ﬁlter 40 Nm (29,50 lbf-ft) Screw plug in oil ﬁlter (M 18*1,5) 30 Nm (22,13 lbf-ft) Screw plug in oil ﬁlter (M 24*1,5) 30 Nm (22,13 lbf-ft) Screw plug in oil ﬁlter (M 30*1,5) 40 Nm (29,50 lbf-ft) OIl change ﬁlter 25 Nm (18,44 lbf-ft)

Fav 900

Engine / Generalities

Tightening Torque values

General

Fav 900 from chassis number 23/3001and up

13/03/2001

2000 000007

2/4

Capitel Docu-No.

Index

Date Version

Page

Tightening Torque values

Cooling system

Exhaust / Intake manifolds

Fuel system

Starter / Alternator /Compressor

Sensors

Screw plug in coolant pipe (M14*1,5) 20 Nm (14,75 lbf-ft) Hose clips : Clamping range 12 to 31 mm, 9 mm wide 3,6 Nm (2,66 lbf-ft) over 32 mm, 13 mm wide 5 Nm (3,69 lbf-ft)

Exhaust manifold on cylinder head Initial torque 50-55 Nm (36,88-40,75 lbf-ft) Angular torque 90-100° Banjo bolt of solenoid valve 10-15 Nm (7,38-1 1,06 lbf-ft) Knuckle pin clap of turbocharger 12 Nm (8,85 lbf-ft)

Nozzle holder in cylinder head 70 Nm (51,63 lbf-ft) Nozzle adjusting nut 45 Nm (33,19 lbf-ft) Banjo bolt for leak oil 10-12 Nm (7,38-8,86 lbf-ft) Pressure line at nozzle Initial torque 10 Nm (7,38 lbf-ft) Angular torque 60° Banjo bolt on oil ﬁlter 20-30 Nm (14,75-22,13 lbf-ft) Fuel ﬁlter 10-15 Nm (7,38-1 1,06 lbf-ft) Purge plug on fuel ﬁlter 8-10 Nm (5,90-7,38 lbf-ft)

Alternator pulley 75-85 Nm (55,32-62,69 lbf-ft) Compressor drive gear 200-250 Nm (147,51-184,39 lbf-ft)

Oil pressure sensor 80 Nm (59,00 lbf-ft) T emperature sensor switch 15 Nm (11,06 lbf-ft) Coolant T emperature sensor (EDC) 35 Nm (25,82 lbf-ft)

Fav 900

Engine / Generalities

Tightening Torque values

General

Fav 900 from chassis number 23/3001and up

13/03/2001

2000 000007

3/4

Capitel Docu-No.

Index

Date Version

Page

Tightening Torque values

Assembly tightening torques to works standard M 3059

External or internal hexagon nuts and bolts, heads without collar or ﬂange.

Tread size * Pitch Property class / Tightening torque in Nm (lbf-ft)

at 8,8/8 at 10,9/10 at 12,9/12 M4 2,5 (1,84) 4,0 (2,95) 4,5 (3,32) M5 5,0 (3,69) 7,5 (5,53) 9,0 (6,64) M6 9,0 (6,64) 13,0 (9,59) 15,0 (1 1,06) M7 14,0 (10,33) 20,0 (14,75) 25,0 (18,44) M8 22,0 (16,23) 30,0 (22,13) 35,0 (25,81) M8*1 23,0 (16,96) 35,0 (25,81) 40,0 (29,50) M10 45,0 (33,19) 65,0 (47,94) 75,0 (55,32) M10*1,25 45,0 (33,19) 65,0 (47,94) 75,0 (55,32) M10*1 50,0 (36,88) 70,0 (51,63) 85,0 (62,62) M12 75,0 (55,32) 105,0 (77,44) 125,0 (92,20) M12*1,5 75,0 (55,32) 1 10,0 (81,13) 130,0 (95,88) M12*1,25 80,0 (59,00) 1 15,0 (84,20) 135,0 (99,57) M14 1 15,0 (84,20) 170,0 (125,39) 200,0 (147,51) M14*1,5 125,0 (92,20) 185,0 (136,45) 215,0 (158,58) M16 180,0 (132,76) 260,0 (191,77) 310,0 (228,64) M16*1,5 190,0 (140,14) 280,0 (206,52) 330,0 (243,40) M18 260,0 (191,77) 370,0 (272,90) 430,0 (317,15) M18*2 270,0 (199,14) 290,0 (213,89) 450,0 (331,90) M18*1,5 290,0 (213,89) 410,0 (302,40) 480,0 (354,03) M20 360,0 (265,52) 520,0 (383,53) 600,0 (442,54) M20*2 380,0 (280,27) 540,0 (398,28) 630,0 (464,66) M20*1,5 400,0 (295,02) 570,0 (420,41) 670,0 (494,17) M22 490,0 (361,40) 700,0 (516,29) 820,0 (604,80) M22*2 510,0 (376,16) 730,0 (538,42) 860,0 (634,30) M22*1,5 540,0 (398,28) 770,0 (567,92) 900,0 (663,80) M24 620,0 (457,29) 890,0 (656,43) 1040,0 (767,06) M24*2 680,0 (501,54) 960,0 (708,06) 1130,0 (833,44) M24*1,5 740,0 (545,8) 1030,0 (759,69) 1220,0 (899,82)

Fav 900

Engine / Generalities

Tightening Torque values

General

Fav 900 from chassis number 23/3001and up

13/03/2001

2000 000007

4/4

Capitel Docu-No.

Index

Date Version

Page

Tightening Torque values

Cylinder head bolts Tightening cylinder head bolts following repair work (new engine)

Only for Torx-head screws. No tightening for Torx-head screws.

Tightening cylinder head bolts following repair work

(cold engine) Only for Torx-head screws.

PM-Picturemodule

Text-module

Tightening cylinder head bolts following repair work

Only for Torx-heads. No tightening for Torx-head screws.

PMTAB_Picture

Note: Only use new cylinder head bolts. do not re use.

before inserting bolts, lubricate threads (not the tapped bores) and the bolt heads with "Optimoly White T" paste. Do not use oils or additives containing MoS

-h. Tighten bolts by the torque

angle method following the diagram :

● 1.st initial stage = 10 Nm (7,38 lbf-ft).

● 2.nd initial stage = 80 Nm (59,00 lbf-ft).

● 3.rd initial stage = 150 Nm (110,63 lbf-ft).

● 4.tth initial stage = 90°.

● 5.th initial stage = 90°.

● Final stage = 90°.

Adjust valve play

PMTAB_Picture

Put on sticker number 51.97801-0150.

Fav 900

Engine / General system

Turbocharger, troubleshooting

Faults

Fav 900 chassis number 23/3001 and up

15.2.2001

2000 000003

1/2

Capitel Docu-No.

Index

Date Version

Page

Turbocharger, troubleshooting

Text-module

Before replacing the turbocharger, check the following:

Excessive engine oil consumption, lack of power and abnormal intake or exhaust noises are a frequent cause of unnecessary turbocharger replacement.

Examination of the allegedly defective parts by the manufacturer often shows the turbocharger to be in perfectly good working order.

To avoid this situation, the following checks must be performed :

Text-module

Excessive oil consumption

Bullet-List

● Check air ﬁlter contamination

● Check intake pipe for restricted cross section (e.g. damage, dirt)

Either are possible causes for increased oil consumption due to the higher pressure.

Bullet-ist

● Check turbocharger for external traces of oil

Excessive oil consumption of the turbocharger is due to bearing wear, quickly resulting in mechanical damage.

Text-module

Lack of power

For satisfactory power, observe correct settings for:

Bullet-

● start of fuel delivery

● valves clearance

● engine control (at full load)

● exhaust brake (must open fully).

Bullet-List

Also check:

● Cylinder compression

● air ﬁlter contamination

● intake system for restricted cross sections and leaks

● exhaust system for damage and leaks.

If none of these checks reveal the cause of poor performance, the turbocharger has to be also checked for:

Bullet-List

● Coking of turbine impedes easy rotation. (Axial movement may realese coking.)

● Dirt within compressor

● Damage by foreign objects

● Turbine wheel in contact with housing

Remove visible contamination of compresssor side and check bearing clearance.

Text-module

Note: Do not damage the compressor fan wheel.

Bullet-List

Abnormal intake and exhaust noises

● Check intake and exhaust system adjacent to the turbocharger assembly. Damaged gaskets must

be replaced (can mislead to failure diagnostic of turbocharger).

● If this does not eliminate the abnormal noises, the turbocharger is to be replaced. (A turbocharger in

good condition does not generate noise!)

Text-module

Fav 900

Engine / General system

Turbocharger, troubleshooting

Faults

Fav 900 chassis number 23/3001 and up

15.2.2001

2000 000003

2/2

Capitel Docu-No.

Index

Date Version

Page

Turbocharger, troubleshooting

Oil in intake pipes and intercooler

Oilspray within the intake system is necessary. It lubricates inlet valve seats. If too much oil is encountered to such an extent that puddles can be found within the air box of the

intercooler, there is a serious risk of engine "runaway", an uncontrolled increase of engine speed . Leaks must immediately be removed.

Possible origins:

Bullet-List

● Engine oil level too high - Check whether proper dipstick is used -

● Inadequate engine oil, check "Lubricants " schedule.

● Operation on not allowed high slanting angles

● High pressure within crankcase, e. g. Oil release valve failure (Crank case venting) or worn piston

rings

Text-module

Turbocharger compressor coking

Can occur by excessive intake air temperature, e.g. during constant full load opreation. Coking may result in reduced intake air pressure, there will not be a noticeable power reduction or a

diminished acceleration behavior. Coking may result in exhaust turbitidy.

If Turbocharger compressor coking occurs:

Bullet-List

● Disassemble compressor housing. Avoid compressor fan wheel damage which could result in

balancing problems and strong vibrations until complete destruction of the turbocharger.

● Use a solvent to remove coking from the compressor housing

Bullet-List

● In severe cases, use special oil with low coking risk.

Warning: Never inject solvent spray while the engine is running - Accident Hazard !!! -

Fav 900

Engine / Generalities

View of engine D 0836 LE 501

Component Location

Fav 900 chassis number 23/3001and up

09/03/2001

2000 000003

1/1

Capitel Docu-No.

Index

Date Version

Page

View of engine D 0836 LE 501

PM-Picturemodule

Text-module

PMTAB_Picture

1 Fuel injection pump (VP44) 7 Fuel ﬁlters 2 Lubricant cooler 8 Turbocharger 3 Lubricant ﬁlter 9 Lubrication oil turbocharger (pressure) 4 Oil ﬁlling socket, Oil level indicator 10 Lubrication oil return from turbocharger 5 B10 - Sensor , Engine 1 11 Air compressor 6 B1 1 - Sensor , Engine 2 12 Thermostat

+ 114 hidden pages

FENDT MAN D 0836 LE Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual