FENDT MAN D 0836 LE Workshop Manual

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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

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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.

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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.

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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

Fav 900

Engine / Cylinder head

Checking compression

Testing

Fav 900 chassis number 23/3001and up

20.2.2001

2010 000001

1/1

Capitel Docu-No.

Index

Date Version

Page

Checking compression

PM-Picturemodule

PMTAB_Picture

● Warm up engine until coolant temperature

reaches 60 to 80°C (140 - 176°F).

● Check valves clearance and adjust.

● Remove all injectors and injector holders.

● See values of compression in chapter "Service

Data".

Starting with the 1st cylinder, ﬁt new seal and tighten. Install test adaptor of compression recorder with threaded union and tighten.

PMTAB_Picture

Screw compression recorder onto test adaptor and insert test sheet.

Using the starter motor, turn engine until the indicator no longer deﬂects.

Connect compression recorder with test adapter to the other cylinders and proceed as above.

PMTAB_Picture

Depending on the design of the compression recorder, the engine can also be cranked directly from the compression recorder.

To do this, the starter has to be connected to the appropriate electrical leads.

PMTAB_Picture

Compare data and remove compression recorder and test adapter. Apply "Never Seeze" to contact faces of injector holders.

Fit injector holder and injectors using a new seal. Screw on union nut and tighten to speciﬁed torque.

Re-connect injection and leak-oil lines.

Note: The union nut can be tightened with an open end wrench without removing the injection pipe.

Fav 900

Engine / Cylinder head

Checking valve timing

Setting and Calibration

Fav 900 chassis number 23/3001and up

20.2.2001

2010 000002

1/1

Capitel Docu-No.

Index

Date Version

Page

Checking valve timing

Text-module

Checking valve timing

Shifting of the camshaft drive gear can result in severe engine damage. It is therefore necessary to ensure a correct ﬁt by checking the valve timing after repair. The above takes into consideration that tappet push rods are not distorted! Proceed as follows:

Bullet-List

● Fit engine actuation device to ﬂywheel housing.

● Remove crankcase venting pipe.

● Accurately set valve play of 1st cylinder.

● Actuate engine against rotating direction to approx. 40°C before TDP.

● Set dial gauge onto intake valve spring retainer of 1st cylinder and set at "0".

● Slowly turn crankshaft in rotating direction and watch the pointer:

● Immediatey when the pointer moves, the intake valve opens.

● Take reading from graded scale on ﬂywheel and compare with valve timing.

Note: By ﬁtting a dial gauge to both intake and exhaust valve spring retainers of the 1st cylinder, it is possible to check all valve timings and the valve stroke by continued turning of the engine. V alve stroke desired value: 5,0 to 5,7 mm (.197 - .224").

Fav 900

Engine / Cylinder head

Setting valve clearance

Setting and Calibration

Fav 900 chassis number 23/3001 and up

15.2.2001

2010 000003

1/2

Capitel Docu-No.

Index

Date Version

Page

Setting valve clearance

PM-Picturemodule

Text-module

Setting valves clearance:

Valves overlap on cylinder:

PM-Picturemodule

PMTAB_Picture

Engine must be cold for adjusting valve clearance. (max. coolant temperature 50° C (122°F)) Setting valve clearance.

PMTAB_Picture

Rotate crankshaft using turning device until the piston of the cylinder to be set is at top dead centre ( TDC ) and the rocker arms are not loaded.

The valves of the synchronous cylinder are now overlapping.

153624 624153

PMTAB_Picture

Layout of cylinder sequence and position of valves I Fan end II Flywheel end A Exhaust valve E Intake valve

Fav 900

Engine / Cylinder head

Setting valve clearance

Setting and Calibration

Fav 900 chassis number 23/3001 and up

15.2.2001

2010 000003

2/2

Capitel Docu-No.

Index

Date Version

Page

Setting valve clearance

PM-Picturemodule

PMTAB_Picture

● Insert gauge between valve shaft and rocker .

● With valve setting tool loosen lock nut and turn

setting screw until gauge can be moved with a slight resistance.

● Tighten lock nut.

● Check clerance again.

● Reﬁt cylinder head covers.

● Tighten screws and bolts to adequate torque.

Fav 900

Engine / Cylinder head

Reassembling and reﬁtting intake pipe

Repair

Fav 900 chassis number 23/3001 and up

15.2.2001

2010 000002

1/1

Capitel Docu-No.

Index

Date Version

Page

Reassembling and refitting intake pipe

PM-Picturemodule

PMTAB_Picture

Removing intake pipe Note:

T o avoid engine damage, always ensure clean conditions when working on intake system.

● Disconnect pressure sensor for intercooler

● Disconnect wiring to ﬂame booster plug, to

solenoid switch ant to the temperature sensors.

● Remove fuel lines to ﬂame booster plug and to

solenoid valve.

● Remove wiring harness.

● Remove fuel ﬁlter.

● Remove fuel pre ﬁlter with manual lifting pump

● Remove collars of the injection lines and of the

fuel lines wich are ﬁtted onto the intake manifold.

PMTAB_Picture

Loose and remove intake pipe ﬁxing bolts on the cylinder head.

Detach intake pipe, remove traces of gasket residue from sealing faces of intake pipe and cylinder head.

Note: Do not allow dirt particles to enter the inlet ports.

PMTAB_Picture

Reﬁtting intake pipe

Position intake pipe using new gaskets. Insert ﬁxing bolts. Watch proper positionning of the gasket. Tighten to speciﬁed torque. replace all parts wich have been removed before Purge fuel system.

Fav 900

Engine / Cylinder head

Removing and reﬁtting turbocharger

Repair

Fav 900 chassis number 23/3001 and up

15.02.2001

2010 000004

1/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting turbocharger

PM-Picturemodule

PMTAB_Picture

Removing turbocharger

Remove crankcase venting (pressure control valve).

Remove air intake pipe from compressor to intake manifold.

Remove air intake manifold.

PMTAB_Picture

Remove oil return line and feed line.

PMTAB_Picture

Remove heat protection panel

PMTAB_Picture

Unscrew the turbocharger. Remove turbocharger.

Note: Shut all inlet and outlet ports in order to prevent particle contamination.

Fav 900

Engine / Cylinder head

Removing and reﬁtting turbocharger

Repair

Fav 900 chassis number 23/3001 and up

15.02.2001

2010 000004

2/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting turbocharger

PM-Picturemodule

PMTAB_Picture

Reﬁtting the turbocharger

Check intake pipe and exhaust manifold for eventual foreign objects.

Examine oil feed and return lines for eventual damage, jamming and leaks.

Replace all gaskets. Reﬁtting the turbocharger occurs in the inversed

sequence as the removing For reﬁtting use new gaskets and new locking

nuts. Before connecting oil feed line, ﬁll bearing case

with clean engine oil. Check all connection fot tightness and absence of

mecanical stress.

PMTAB_Picture

Note: The clamped section of the hose must always be behind the collar of the hose.

1. Pipe

2. Gap

3. Hose

4. Collar

5. Hose clip

Note: Use only clean water as a lubricant.

Fav 900

Engine / Cylinder head

Removing and reﬁtting exhaust manifold

Repair

Fav 900 Chassis number 23/3001 and up

15.02.2001

2010 000003

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting exhaust manifold

PM-Picturemodule

PMTAB_Picture

Removing the exhaust manifold

Remove turbocharger.

Note: Protect exhaust port on turbocharger from contamination.

Unscrew and remove nuts from exhaust manifold.

PMTAB_Picture

Guidance pins (visible on photograph) may be used.

Remove manifold.

PMTAB_Picture

Reﬁtting the exhaust manifold

Clean sealing faces of both, cylinder head and manifold.

Bumped side (1) of gasket facing the cylinderhead (2), depression facing the manifold (3).

PMTAB_Picture

Insert screws and tighten to adequate torque. Reﬁt the turbocharger.

Fav 900

Engine / Cylinder head

Removing and reﬁtting cylinder head

Repair

Fav 900 chassis number 23/3001 and up

16.02.2001

2010 000006

1/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting cylinder head

PM-Picturemodule

PMTAB_Picture

Removing the rocker

Remove cylinder head cover.

PMTAB_Picture

Loosen clamping bolts and remove rocker arm. Dismantling, overhauling and reassembling rocker

assembly.

Removing the cylinder head

● Drain coolant,

● remove lines from injection nozzles,

● Remove intake pipe,

● Remove exhaust manifold,

● Remove coolant pipe.

PMTAB_Picture

Remove push rods.

PMTAB_Picture

Loosen cylinder head bolts in reverse sequence of tightening (for tightening torque values refer to chap 2000 Reg A).

Note: Cylinder head bolts must not be re-used.

Remove cylinder head and lay down in such way to prevent damage.

Remove cylinder head gasket.

Fav 900

Engine / Cylinder head

Removing and reﬁtting cylinder head

Repair

Fav 900 chassis number 23/3001 and up

16.02.2001

2010 000006

2/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting cylinder head

PM-Picturemodule

PMTAB_Picture

Before reﬁtting the cylinder head :

● Clean all the parts which have been removed.

● Clean sealing faces of cylinder head and

crankcase, and blow out tapped holes in crankcase.

● In the event of repeated leaking, use the

straight edge to chek the sealing faces of cranskcase and cylinder head for distortion.

● Uneven cylinder heads can be surface ground

by up to 1 mm.

● Remachined sealing surfaces are measured in

relation to the bore centre of the cranskshaft bearing.

Note: Sealing surface of the cylinder head and crankcase may only be cleaned manually by scraper and slight sandpaper on a polishing block.

PMTAB_Picture

Insert two 6h 8x10 DIN 7 straight pins per head into the leading surface of the crankshaft housing to locate the cylinder heads

PMTAB_Picture

If these straight pins need replacing, observe the max. projection of 4,5mm.

Fav 900

Engine / Cylinder head

Removing and reﬁtting cylinder head

Repair

Fav 900 chassis number 23/3001 and up

16.02.2001

2010 000006

3/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting cylinder head

PM-Picturemodule

PMTAB_Picture

Reﬁtting the cylinder head Note:

Cylinder head gasket must always be replaced.

Install a dry new gasket carefully positioned according to the hole pattern . Fit cylinder head.

PMTAB_Picture

Note: To prevent distortion between cylinder heads and manifolds, we recommend the following steps :

● Reﬁt cylinder heads using guidance bolts.

● Oil the new cylinder head bolts and their rest

surface with "Optimoly Withe T" paste.

● Hand tighten new cylinder head bolts.

● Mount rectiﬁed ruler (Special tool) onto the

exhaust side. Tighten screws at 20 Nm. If no ruler is available, ﬁt exhaust pipe and tighten at 20 Nm.

PMTAB_Picture

● Tighten progressively cylinder head bolts in the

indicated sequence at the prescribed torque.

● Remove the rectiﬁed ruler.

PMTAB_Picture

Reﬁtting the rocker assembly

Check push rods for distortion and wear in the ball sockets.

When inserting the push rods ensure correct ﬁt in the socket of the valve tappets.

Fit rocker arm bracket.

Fav 900

Engine / Cylinder head

Removing and reﬁtting cylinder head

Repair

Fav 900 chassis number 23/3001 and up

16.02.2001

2010 000006

4/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting cylinder head

PM-Picturemodule

PMTAB_Picture

Tighten bolts slightly and align rocker arms with valves.

Subsequently tighten bolts to speciﬁed torque.

PMTAB_Picture

● Set valve clearance, chap 2010 Reg F

● Reﬁt coolant pipe,

● Reﬁt exhaust manifold,

● Reﬁt intake pipe,

● Reﬁt the injectors lines.

PMTAB_Picture

Reﬁt cylinder head cover with a dry new gasket. Insert screws and tighten.

Fill up with coolant. Tighten cylinder head bolts once more.

Fav 900

Engine / Cylinder head

Dismantling and reassembling the rocker arm assembly

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000007

1/2

Capitel Docu-No.

Index

Date Version

Page

Dismantling and reassembling the rocker arm assembly

PM-Picturemodule

PMTAB_Picture

Dismantling the rocker arm assembly

Remove rocker arm assembly Clamp rocker bearing bracket in a vise (use

non-metallic jaws).

PMTAB_Picture

Remove circlip.

PMTAB_Picture

Remove parts separately from the rocker shaft. 1 Central spring 2 Stop washer 3 Rocker arm 4 Rocker bearing bracket 5 Circlip 6 Outside spring 7 Rocker shaft

PMTAB_Picture

Note: If the rocker bearing bushes need replacing, use new or reconditioned ready-to-install rocker arms.

Fav 900

Engine / Cylinder head

Dismantling and reassembling the rocker arm assembly

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000007

2/2

Capitel Docu-No.

Index

Date Version

Page

Dismantling and reassembling the rocker arm assembly

PM-Picturemodule

PMTAB_Picture

Reassembling the rocker arm assembly

Coat rocker bushes with "Optimol White T"paste. Reﬁt circlip on the rocker shaft. Coat rockershaft and bearing bracket bore with

"Optimol White T" paste. Slide stop washer, outer spring, stop washer,

rocker arm (end ﬂush with bushing facing the bearing bracket) and bearing bracket into the rocker shaft.

When clamping the assembled rocker shaft into the bearing bracket, ensure that the shaft end is supported. (Use non-metallic jaws).

PMTAB_Picture

Fit parts in the sequence shown, compressing springs, and insert circlip.

Reﬁt rocker arm assembly , see chapter 2010 Reg G - Cylinder head removing and reﬁtting.

Fav 900

Engine / Cylinder head

Removing and reﬁtting valves

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000008

1/3

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting valves

PM-Picturemodule

PMTAB_Picture

Removing valves

Remove rocker arm assembly and cylinder head (Chapter 2010 Reg G).

Note: Valve springs and spring plates can be replaced without removing the cylinder head. This requires the appropriate piston to be at TDC. The use of a valve ﬁtting tool is necessary.

● Place ﬁtting lever to cylinder head.

● Turn screw (1) until the lever (2) is slightly

raised.

PMTAB_Picture

Note: If a valve bench is available, this can be used for the above operations.

● Push valve ﬁtting lever down and remove valve

collets.

● Lift lever and swing to one side Caution:

Beware of spring tension. Danger of injury !

● Remove upper spring plate (2), valve spring (3)

and washer (4).

● Turn cylinder head over and extract intake (5)

exhaust (6) valve.

● Check valves for damage and replace weak

springs.

● Measure valve spring and replace weak

springs.

● Check valve stem and guides for scoring and

wear; if necessary , measure guides with a plug gauge.

● Check valve seats for severe wear and signs of

burning, if necessary reseat valves or replace the insert.

● Remachine valve seat (following grinding

machine manufaturer's instructions), or replace.

PMTAB_Picture

Reﬁtting valves

Lubricate valve stems and insert into valve guides.

Note: Minor valve seating damage can be removed by reseating using a valve grinding paste. When ﬁtting new valves these must be reseated so that uniform seating is attained, if necessary machine the valve seat insert.

Fav 900

Engine / Cylinder head

Removing and reﬁtting valves

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000008

2/3

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting valves

PM-Picturemodule

PMTAB_Picture

Turn cylinder head over. Place valve ﬁtting lever. Fit washer, valve spring and upper spring plate.

PMTAB_Picture

Compress spring with ﬁtting lever and insert collets.

Note: Make sure collets ﬁt properly: they can cause severe damage by springing out.

PMTAB_Picture

Measuring valve recess

● Position gauge holder with dial gauge at the

cylinder head.

● Press tip of gauge onto cylinder head.

● Set dial gauge at "0".

● Swing gauge towards valve head and read

recess.

PMTAB_Picture

If after skimming the cylinder head faces, valve recess is inadequte or valve projection is excessive, the valve seat insert must be re-ground.

1 Valve recess

Note:

- When skimming the cylinder head sealing face, the max. dimension must not exceed 1 mm (0.039“).

- After skimming, observe injection nozzle projection. Replace standard - copper sealing ring with a thicker one.

Fav 900

Engine / Cylinder head

Removing and reﬁtting valves

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000008

3/3

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting valves

PM-Picturemodule

PMTAB_Picture

1= Copper - Sealing ring 2 = Injection nozzle projection (2,68 - 3,47mm). Available sealing ring thicknesses : 0,5 / 1,0 / 1,5 /

2,0 / 2,5 / 3,0 mm (.020 / .039 / .059 / .079 / .098 / .118")

Fav 900

Engine / Cylinder head

Removing and reﬁtting valve guides.

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000009

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting valve guides.

PM-Picturemodule

PMTAB_Picture

Removing the valve guide

Removing and reﬁtting the cylinder head. Removing and reﬁtting the valves. Position cylinder head on a press with the

combustion chamber side facing upwards. Use a mandrel to press out the valve guide.

PMTAB_Picture

Reﬁtting the valve guide

Lubricate new valve guides and using a mandrel and spacer sleeve, press in form the rocker arm side.

PMTAB_Picture

Valve guides differ in length only. 1 Exhaust = shorter guide 2 Intake = longer guide 3 Press-in depth (see Servicing Data) Press-in depth is governed by the spacer sleeve.

Note: After replacing the valve guides it is necessary to re-grind the valve seats ( see Servicing Data and instructions by the manufacturer of the valve lathe used in your workshop).

Fav 900

Engine / Cylinder head

Replacing valve seat insert

Repair

Fav 900 chassis number 23/3001and up

19.02.2001

2010 000010

1/2

Capitel Docu-No.

Index

Date Version

Page

Replacing valve seat insert

Text-module

Remove valve seat insert

Note: When replacing valve seat inserts, it is advisable to replace valve guides, since this is the only way to guarantee precise reseating of the new inserts. A tool was therefore designed with which valve guidance and valve seat inserts can only be replaced together, or alternately the valve guides alone.

PM-Picturemodule

PMTAB_Picture

Using a valve lathe machine a 3 - 4 mm (.118-.157") wide groove in the valve valve seat inserts.

Insert internal extractor claw in the machined groove and tighten.

PMTAB_Picture

Note: To prevent damage to the cylinder head face, insert a washer (1) or other suitable object underneath the feet (4) of the support legs.

Screw spindle (2) into extractor (5), align support legs (4) and extract valve seat insert by turning the nut (3).

Clean contact surface of insert in the cylinder head.

PMTAB_Picture

If a valve lathe is not available, proceed as follows:

● Using an arc-welder, apply two welding beads

to the valve seat (arrowed).

● Extract valve seat insert.

● Clean insert contact surface in the cylinder

head.

Fav 900

Engine / Cylinder head

Replacing valve seat insert

Repair

Fav 900 chassis number 23/3001and up

19.02.2001

2010 000010

2/2

Capitel Docu-No.

Index

Date Version

Page

Replacing valve seat insert

PM-Picturemodule

Text-module

Note: After cooling down: re-machine valve seats. After re-machining: clean cylinder head and check for leaks with a cylinder detector. Overheating of the cylinder head (above +200°C / 392°F ) causes the core plugs to become loose, and they must be replaced. To do this, clean core holes, blow out ducts and press in new core plugs using a mandrel and "LOCTITE 270".

PMTAB_Picture

Replacing valve seat insert

Immerse cylinder head in a hot water bath and heat up to approx. 80°C (176°F).

Supercool new insert to approx -200°C (-328°F) and insert into the cylinder head.

When the temperature has equalized, check by pressing in a mandrel to the end position.

Reﬁt valve guides.

Note: When replacing the valve seat inserts, it is necessary to re-machine valve seats.

Fav 900

Engine / Cylinder head

Re-machining the valve seats

Repair

Fav 900 chassis number 23/3001and up

19.02.2001

2010 000011

1/3

Capitel Docu-No.

Index

Date Version

Page

Re-machining the valve seats

PM-Picturemodule

PMTAB_Picture

Re-machining the valve seat

(with Mira-Precision tvalve seat re-machining tool)

1. Crank

2. Rocker switch

3. Hand grip

4. Lubricating nipple

5. Mains supply

6. Solenoid valve with coil

7. Guide tube

8. Swivel arm

9. Guide mandrel

10.Cutter

11.Allen screw

12.Chuck

13.Lubricating nipple

14.Clamping lever

15.Guide ball

16.Thrust nut with mm-dial

PMTAB_Picture

Select suitable guide mandrel, insert with open-end wrench (SW 12) and tighten.

Note: For maximum precision, the guide mandrel must have a perfect ﬁt.

Select cutting with appropriate valve face with a seat angle and insert.

PMTAB_Picture

Adjust cutter with setting gauge and secure with Allen screw.

Using a guide mandrel insert tool into valve guide.

Fav 900

Engine / Cylinder head

Re-machining the valve seats

Repair

Fav 900 chassis number 23/3001and up

19.02.2001

2010 000011

2/3

Capitel Docu-No.

Index

Date Version

Page

Re-machining the valve seats

PM-Picturemodule

PMTAB_Picture

Release clamping lever, ﬁt solenoid ﬂange on clamping plate, adjust the height to ensure the cutter is clear of valve seat.

Set rocker switch at position 1. Tighten clamping lever.

PMTAB_Picture

Re-machine valve seat by evenly turning the crank handle in clockwise direction, this moving the thurst nut at the same time.

Note: Turn the crank ﬁrmly and evenly but never in anticlockwise direction since this could cause the carbide cutting edge to break out.

PMTAB_Picture

When the re-machining process is completed, reduce working pressure of the cutter for a further 2-3 turns without thrust.

While still turning, reverse the thrust nut by 2-3-turns.

Switch into position 2 : to eliminate magnetic ﬁeld. Now pull the entire Mira-tool out and insert into the

next valve guide where the centering process is to be repeated.

The cutter setting remains the same for all intake exhaust valve seats.

Fav 900

Engine / Cylinder head

Re-machining the valve seats

Repair

Fav 900 chassis number 23/3001and up

19.02.2001

2010 000011

3/3

Capitel Docu-No.

Index

Date Version

Page

Re-machining the valve seats

PM-Picturemodule

PMTAB_Picture

Observe speciﬁed seat angle.

PMTAB_Picture

Note: When re-machining the valve seat inserts, only the minimum of material should be removed. Reference value will be value of valve recess.

If the cylinder head faces are re-machined (max.1 mm (.039")), it is necessary also to re-machine the inserts in order to obtain the correct valve recess: When ﬁtting new valves and inserts, machine out cylinder head to amount relative to the skimming of the cylinder head face.

Having skimmed the cylinder head face and machined the valve seat insert, the theoretical valve seat may have become too deep in the cylinder head or the seat surface may be too wide.

PMTAB_Picture

In this event the valve seat insert must be replaced.

Always observe the correct value for valve recess.

Fav 900

Engine / Cylinder head

Reseating valves

Repair

Fav 900 chassis number 23/3001 and up

19.02.2001

2010 000012

1/1

Capitel Docu-No.

Index

Date Version

Page

Reseating valves

PM-Picturemodule

PMTAB_Picture

Reseating valves

Apply grinding paste to the valve seating face. Lubricate valve guide and insert valve. With a valve grinding tool, regrind valve seat with

spinning movements.

Note: Do not allow grinding paste to come into contact with the valve stem and guide.

PMTAB_Picture

The re-grinding process of the valve seat must produce a perfect, closed grinding pattern.

The width of the grinding pattern is the result of a correctly machined valve seat insert.

1. Valve cone face

2. valve seat

PMTAB_Picture

1. Valve seat insert

2. Valve

3. Valve seat - too wide

4. Valve seat - correct

Note: Excessively wide valve seats are favoring carbon deposits,

- Valve may leak Excessively narrow valve seats prevent rapid heat transfer from the valve to the cylinder head.

- Valves become scorched-

Fav 900

Engine /Cooling system

Replacing engine coolant

Repair

Fav 900 chassis number 23/3001 and up

08.02.2001

2050 000001

1/2

Capitel Docu-No.

Index

Date Version

Page

Replacing engine coolant

Text-module

Draining the coolant

Drain coolant only on a cooled down engine as described: Note:

Collect coolant in a pan and dispose of it properly!

PM-Picturemodule

Caution: Hot coolant may cause severe burns during draining!

PMTAB_Picture

● Open shortly cover from expansion tank in

order release pressure.

PMTAB_Picture

● Unscrew draining screws from Oil cooler case

● Then unscrew cover

● Drain coolant using a container with sufﬁcient

capacity

Fav 900

Engine /Cooling system

Replacing engine coolant

Repair

Fav 900 chassis number 23/3001 and up

08.02.2001

2050 000001

2/2

Capitel Docu-No.

Index

Date Version

Page

Replacing engine coolant

PM-Picturemodule

PMTAB_Picture

Filling Coolant

(only on a cooled down engine) Fill in an adequate mixture of tap water and

antifreeze based on Ethylene - Glykol and corrosion preventer.

Refer to Lubricants - Chapter l 0000 Reg. A Use a proper ratio water / Antifreeze.

● Tighten screw on oil ﬁlter body using a new

gasket.

● Fill in slowly coolant mixture up to the adequate

coolant level

● Put in place screw cap

● After a short engine operation time , check

coolant level again

Caution: If coolant level needs to be checked , the engine being at operating temperature, ﬁrst open cover vith safety valve to release pressure - then open carefully.

Fav 900

Engine / Cooling

Removing and reﬁtting the thermostatic valve

Repair

Fav 900 chassis number 23/3001and up

09.02.2001

2050 000002

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the thermostatic valve

PM-Picturemodule

PMTAB_Picture

Removing the thermostatic valve

● Drain coolant, chapter G 2050 Reg G

Disconnect coolant hose from thermostatic valve. Unscrew and remove the two screws (SW) and

remove thermostat housing.

PMTAB_Picture

Remove thermostatic valve.

Check correct operation of thermostat as following:

● Place thermostatic valve in pot ﬁlled with water

● Heat water

● Measure opening temperature with an

adequate thermometer

● Measure opening distance

Replace faulty thermostatic valve

PMTAB_Picture

Reﬁtting thermostatic valve

Fit thermostatic valve with new O-seal "ensuring that the ball valve is pointing upwards" (TOP).

Note: Never run engine without a thermostatic valve or bybass inserts.

Fit thermostat housing cover, insert screws and tighten. attach feed hose to radiator. Fill up with coolant.

PMTAB_Picture

Replacing temperature sensor

Disconnect connections Unscrew temperature sensor from coolant pipe. Screw in temperature sensor using "Loctite 648"

and tighten to speciﬁed torque.

Fav 900

Engine /Cooling system

Removing and reﬁtting water pump

Repair

Fav 900 chassis number 23/3001 and up

14.2.2001

2050 000003

1/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting water pump

PM-Picturemodule

PMTAB_Picture

Removing the pump lift section

● Drain coolant.

● Unscrew fan

● Remove feed and drain lines.

● Remove V-belt.

● Remove cooling lines to air compressor

● Remove generator belt tensioner screw (1) top

left

● Remove generator pod (2) on the top left

● Remove hub of Viscosity clutch

PMTAB_Picture

Unsrew and remove pump lift section. Clean sealing faces of pump lift- and delivery

sections.

PMTAB_Picture

Removing the pump lift section

Remove three screws (arrows) and remove the pump lift section.

PMTAB_Picture

Clean sealing faces of pump lift section and engine block.

Reﬁtting the water pump lift section

Install pump lift section with new gasket. Tighten screws to speciﬁed torque.

Fav 900

Engine /Cooling system

Removing and reﬁtting water pump

Repair

Fav 900 chassis number 23/3001 and up

14.2.2001

2050 000003

2/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting water pump

PM-Picturemodule

PMTAB_Picture

Reﬁtting the water pump

Replace seals on connecting pipe. Install water pump with new gasket. Tighten fscrews to speciﬁed torque. Put all removed parts back into place Fill up coolant.

PMTAB_Picture

Overhauling the water pump.

1. Impeller

2. Sliding ring gasket.

3. Water pump bearing.

4. Pump housing.

5. Circlip

6. V-belt pulley Remove water pump

PMTAB_Picture

Clamp water pump lift section in a vise (use non-metallic jaws).

Remove V-belt pulley with pulling device. Remove circlip from pump housing. Invert water pump and ﬁt into hydraulic press Using a suitable mandrel (same as bearing shaft)

press out bearing.

Note: When the bearing is pressed out, the pump impeller is released.

PMTAB_Picture

Using a suitable mandrel, press out and replace sliding ring gasket.

Reassambling the water pump

Using pressing bush (special tool) press in a new sliding ring gasket as far as possible.

See notes

on ﬁtting gasket !

Fav 900

Engine /Cooling system

Removing and reﬁtting water pump

Repair

Fav 900 chassis number 23/3001 and up

14.2.2001

2050 000003

3/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting water pump

PM-Picturemodule

Text-module

PMTAB_Picture

Using a pressinf bush, press bearing into pump housing until contact is made.

Insert circlip. Press pulley into shaft ﬂush with the plate

PMTAB_Picture

Invert water pump and let it rest on hub and bearing shaft.

Fit impeller to bearing shaft.

PMTAB_Picture

Gradually press impeller onto bearing shaft, using gauge to check for correct clearance.

Rotate impeller and check clearance at several points.

Fav 900

Engine /Cooling system

Removing and reﬁtting water pump

Repair

Fav 900 chassis number 23/3001 and up

14.2.2001

2050 000003

4/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting water pump

When reparing do not replace pump unless a leak has been found.

Depending on design, the sliding ring gasket of the water pump may allow small amounts of coolant to leak which may lead to water marks underneath the drain hole.

This does not call for a pump replacement. It is advisable to check out the following points before replacing or repairing the pump:

Bullet-List

● Is there a visible and repeated loss of water from the coolant on the circuit.

● Whether the loss is caused by discharge from the expansion tank (e.g. too full) or by leakages from

the hoses, radiators etc. Water pump needs to be replaced only if water is dripping while the engine is running or after it is switched off.

Text-module

Fitting instructions for sliding ring gasket :

The ring gasket must be mounted "wet". Coat the shaft and sleeve (4) with a mixture of 50 % W ater und 50 % alcohol or 35 % to 50 % antifreeze.

Text-module

Do not use any other lubricant

Fit gasket "wet", i.e. coat retaining collar (1) and pump shaft (2) with a mixture of 50% water and 50% alcohol or a mixture of water and 35 to 50 % antifreeze to MAN in-house standard 324.

If there are any signs of scoring however slight, or other minor damage, apply a bead of Dirko Transparent sealing agent.

Position gasket with plastic cap (3) on shaft (1) and using assembly tool, press into housing until tool makes contact with the housing. Remove plastic cap.

PM-Picturemodule

Text-module

Note: Investigations have shown that in most cases pump damage is caused by the use of unsuitable coolants. For trouble free operation use only radiator anti-corrosives by Fendt .

PMTAB_Picture

Fav 900

Engine / Cooling system

Removing and reﬁtting coolant pipe

Repair

Fav 900 chassis number 23/3001 and up

14.02.2001

2050 000004

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting coolant pipe

PM-Picturemodule

PMTAB_Picture

Removing the coolant pipe

Drain coolant while engine is cold. Use a clean pan with sufﬁcient capacity

● Remove injection lines

● Remove intake pipe

● Disconnect temperature sensor

PMTAB_Picture

Unscrew and remove coolant pipe. Remove gasket and clean all sealing faces.

PMTAB_Picture

Reﬁtting the coolant pipe

Replace O-Rings of connecting pipe. Fit coolant pipe using new gaskets.

PMTAB_Picture

Insert screws and tighten to speciﬁed torque.

Note: Insert the longer screws into the brackets for injectors.

● Reconnect temperature sensor,

● Reﬁt intake pipe.

● Reﬁt injection lines.

● Fill up with coolant.

Fav 900

Engine / Fuel system

Layout of fuel system

Documents and Diagrams

Fav 900 chassis number 23/3001and up

09.03.2001

2060 000002

1/1

Capitel Docu-No.

Index

Date Version

Page

Layout of fuel system

PM-Picturemodule

Text-module

ETNum-list

PMTAB_Picture

1.Pre-ﬁlter with manual fuel lift pump

2.Fuel lift pump

3.Fuel ﬁlter

4.Measuring point for fuel pressure.

5.Injection pump

6.Return line from injection pump

7.Line to injector

8.Return tank

9.Line to heater plug

10.Fuel tank

Fav 900

Engine / Fuel supply system

Fuel pre ﬁlter / Cartrige

Repair

Fav 900 chassis number 23/3001 and up

08.02.2001

2060 000002

1/2

Capitel Docu-No.

Index

Date Version

Page

Fuel pre filter / Cartrige

PM-Picturemodule

PMTAB_Picture

Cleaning pre - ﬁlter

Disassemble pre - ﬁlter:

● Unscrew ﬁlter body

PMTAB_Picture

● Clean Filter body (1) and Sieve (2) with clean

diesel fuel and dry it with compressed air

● Re - assemble with a new gasket

● Tighten ﬁlter body

PMTAB_Picture

● Actuate manual pump until overﬂow valve

toward injection pump opens audibly.

● Start engine

● Check Pre - ﬁlter for eventual leaks

Note: Purge air from fuel supply system - Chapter 2060 Reg. G

Fav 900

Engine / Fuel supply system

Fuel pre ﬁlter / Cartrige

Repair

Fav 900 chassis number 23/3001 and up

08.02.2001

2060 000002

2/2

Capitel Docu-No.

Index

Date Version

Page

Fuel pre filter / Cartrige

PM-Picturemodule

PMTAB_Picture

Removing and reﬁtting main fuel ﬁlter

Disconnect fuel lines (1) . Remove scews (2) and take off fuel ﬁlter. Reassemble in reversed order and connect fuel

lines with new sealing rings. Purge air from fuel supply system.

PMTAB_Picture

Replace ﬁlter element

● Loosen ﬁlter element with chocking wrench and

unscrew element manually

● Wet gaskets of replacement element with fuel.

● Screw in replacement element and tighten

ﬁrmly by hand.

● Purge air from fuel supply system - Chapter

2060 Reg. G

PMTAB_Picture

Note: Used fuel ﬁlters are hazardous waste

Fav 900

Engine / Fuel Supply System

Purging Air from Fuel Supply System

Repair

Fav 900 Chassis Number 23/3001

02.11.2000

2060 000001

1/1

Capitel Docu-No.

Index

Date Version

Page

Purging Air from Fuel Supply System

PM-Picturemodule

Text-module

Important: Start engine an run it idle for apprx. 30 sec in order to allow the complete system to purge residual air.

Caution: Fuel runs within the lines! Any fuel spill must be cleaned up with rags . Be aware of safety and

environmental regulations!

PMTAB_Picture

For Operating EDC Injection System, careful purging of the fuel Supply system is compulsory!

Unscrew purging screw of the fuel ﬁlter by one to two turns.

PMTAB_Picture

Actuate manual fuel lifting pump until fuel ﬂows without any bubbles.

Repeat this procedure on the second purging screw

Check for leaks within the fuel supply system.

PMTAB_Picture

If air reaches the high pressure section of the injection pump (Type VP 44), a further purging

step is to be carried out: Purging the high pressure system becomes

necessary when the engine does not start any more or if the tank went dry.

On steep slopes and with little fuel in the tank, air may be aspirated by the injection pump eventually. (Failure Code)

or after repairs on the fuel supply system. Following steps must be carried out on at least 3

following cylinders :

● Loosen nut of the injection line on the injection

valve approx 1/2 turn.

● Crank engine with starter motor until fuel runs

out of .

● Tighten Nut (10 Nm) then for 60° angle.

Fav 900

Engine / Cold start booster

Removing and reﬁtting heater plug

Repair

Fav 900 chassis number 23/3001 and up

08.02.2001

2180 000001

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting heater plug

PM-Picturemodule

PMTAB_Picture

Remove heater plug

Disconnect the heater plug. Unscrew threaded union of fuel line. Release lock nut of heater plug and remove plug.

PMTAB_Picture

Reﬁtting heater plug

Unscrew the lock nut on the heater plug as far as possible. Wetten threads with "Curil T" sealant

Screw in heater plug to the end position of the lock nut and align with fuel line.

Reconnect fuel line and electrical connections. Tighten lock nut.

PMTAB_Picture

Checking solenoid valve for leaks

Remove fuel line from heater plug: Make sure there are no fuel leaks when the engine is running and warm.

Removing the solenoid valve

● Remove fuel line.

● Remove electrical connection from valve.

● Unscrew both screws and remove solenoid

valve The valve cannot be repaired. Damaged valves must be replaced.

Reﬁtting the solenoid valve

● Fit valve bracket.

● Connect fuel lines using new seals.

● Re- connect solenoid valve.

Fav 900

Engine / Short block

Power - belts

Repair

Fav 900 chassis number 23/3001and up

26.02.2001

2210 000016

1/3

Capitel Docu-No.

Index

Date Version

Page

Power - belts

PM-Picturemodule

PMTAB_Picture

Generator right Checking condition

Power belt is maintenance free

● Check belts for cracks, oiling-up, and signs of

overheating and wear.

● Replace damaged belt.

PMTAB_Picture

Checking tension

Tensioning device (arrow) keeps permanently a constant tension on the power belt.

PMTAB_Picture

Tensioner must be adjusted as follows:

1. New tensioner: distance (A) = 92 ±1 mm

(3.62" ±.04").

2. If distance (A) = 100 mm (3.94"), turn excenter

to right to reach a distance of (A) = 92 ± 1 mm (3.62" ±.04"), at least that the excenter (1) allows a reduction of A down to min 92 mm (3.62").

3. If the distance reaches (A) = 100 mm (3.94")

and the excenter (1) is at the end position, the power belt must be replaced. Adjust a new power belt according to Point 1.

PMTAB_Picture

The replacement of the powerbelt becomes necessary if the tensionning lever comes to rest on console (Arrow).

Note: Distance of 100 mm (3.94") may cause a total failure of the belt drive because of insufﬁcient tension.

Fav 900

Engine / Short block

Power - belts

Repair

Fav 900 chassis number 23/3001and up

26.02.2001

2210 000016

2/3

Capitel Docu-No.

Index

Date Version

Page

Power - belts

PM-Picturemodule

PMTAB_Picture

Replacing the powerbelt

● Place adequate tool onto square shaft.

● Release tension from tensioner

● and remove powerbelt from the pulley .

Reﬁtting :

● Place powerbelt onto pulleys of crankshaft ,

generator and coolant pump.

● Set tensioner completely back.

● Place powerbelt onto pulley , release tensioner ,

remove special tool.

PMTAB_Picture

Grease the greasing point.

PMTAB_Picture

Alternator left Checking Powerbelt condition

● Check belts for cracks, oiling-up, and signs of

overheating and wear.

● Replace damaged belt.

PMTAB_Picture

Checking tension

For checking V-belt tension, use V-belt tension gauge.

● Press indicator arm (1) in the scale.

Fav 900

Engine / Short block

Power - belts

Repair

Fav 900 chassis number 23/3001and up

26.02.2001

2210 000016

3/3

Capitel Docu-No.

Index

Date Version

Page

Power - belts

PM-Picturemodule

Text-module

Determining the span force

Bullet-List

● Read tension force at the point of intersection of the upper side of the indicator arm (1) and the scale.

● Before reading the values make sure that the indicator arm remains in its position.

If the value does not agree with the speciﬁed setting, the Powerbelt tension must be reajusted.

PM-Picturemodule

PMTAB_Picture

● Position tension gauge (2) in the center

between the generator pulleys and the

crankshaft.

● Slowly push pressure pad (3) down until the

spring snaps out audibly and the indicator arm

moves upwards. Continued pressing after the spring has snapped

out will result in an incorrect reading!

Span forces measured on the kg-scale of instrument

Belt width Poly V 790 K 4 Newly ﬁtted When ﬁtting 60

After 10 minutes running 45-50

Minimal span force 30

Re adjust tension if minimum

tension is reached.

PMTAB_Picture

Tensioning / replacing powerbelt

● Release clamping bolts(1).

● Loosen counternut (3).

● Adjust checking nut (2) for correct powerbelt

tension.

● Retighten counternut and clamping bolts.

When replacing powerbelts, slacken checking nut (3) and swing alternator inwards.

Fav 900

Engine / Short block

Removing and reﬁtting the starter engine

Repair

Fav 900 chassis number 23/3001and up

26.02.2001

2210 000014

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the starter engine

PM-Picturemodule

Text-module

Check ﬂywheel ring gear for wear and damage by actuating the crankshaft by hand. Check in particular the points which ﬁnal engine oscillations occur ; i.e. when turned off, there are

points where the engine comes to rest. The starter engine pinion engages in these positions during start up. On 6-cylinder engines these points are staggered by 180° ; i.e. threre are 3 points. To replace the starter ring gear see chapter 2000 Reg G.

PM-Picturemodule

PMTAB_Picture

Removing the starter

Disconnect earth terminal from battery. Remove cables terminal 30 (thick cable) and

terminal 50 from the starter.

PMTAB_Picture

Unscrew the screws and a nut from the starter motor ﬂange and remove the starter motor.

Clean exterior of starter engine and check for damage.

PMTAB_Picture

Reﬁtting the starter

Reﬁt the starter in reverse order of removing, making sure cables are connected correctly. Observe torque values.

Reconnect battery. On completion, check starter for correct

functionning.

Fav 900

Engine / Short block

Removing and reﬁtting generator

Repair

Fav 900 chassis number 23/3001and up

26.02.2001

2210 000015

1/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting generator

PM-Picturemodule

PMTAB_Picture

Generator right Removing generator

Disconnect earth cable from the battery. Remove connections B+, D+ and W from the

generator.

PMTAB_Picture

Remove V-belts. Unscrew bolts (arrows). Remove generator.

PMTAB_Picture

Reﬁtting generator.

● Reﬁt the generator.

● Check, and if necessary, correct cable

connections.

● Tighten ﬁxing bolts to speciﬁed torque.

● Tension V-belt.

● Fixing cables on generator.

After completion check generator for correct functioning.

Check voltage and charging current .

PMTAB_Picture

Remove generator, left Remove generator

Disconnect earth cable from the battery. Remove connections B+, D+ and W from the

generator.

Fav 900

Engine / Short block

Removing and reﬁtting generator

Repair

Fav 900 chassis number 23/3001and up

26.02.2001

2210 000015

2/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting generator

PM-Picturemodule

PMTAB_Picture

Loosen bolts(1), (3) and (4) from the generator and unscrew tensioning nut (2).

● Push generator toward the engine and take off

the power belt.

● Unscrew the upper screws(3).

● Unscrew the lower screws (4).

● Remove generator.

● Check screw and guide for damage (i.e.

cracks, bends, etc.) replace if necessary.

PMTAB_Picture

Reﬁtting generator

● Reﬁt the generator.

● Check, and if necessary, correct connections.

● Tighten ﬁxing to speciﬁed torque.

● Tension V-belt.

● Fixing cables on generator.

After completion check generator for correct functioning.

Check voltage and charging current .

Fav 900

Engine / Short block

Removing and reﬁtting air compressor

Repair

Fav 900 Chassis number 23/3001 and up

23.2.2001

2210 000013

1/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting air compressor

PM-Picturemodule

PMTAB_Picture

Removing the compressor

Remove hydraulic pump or rear end cover, Unscrew fan frame support bracket. Remove oil feed line, air intake line and

compressed-air line.

Note: For ease of assembly, mark position of excentric bearing support on timing case.

PMTAB_Picture

To remove air compressor :

PMTAB_Picture

Unscrew the four screws and remove compressor.

PMTAB_Picture

Replace compressor

To remove compressor drive gear (1) losen nuts (2).

Note: Do not swage compressor drive gear into a vise (Even with soft jaws) for tightening or loosening the nut of the compressor drive gear. Risk of damaging drive gear! For this reason, use mounting plate (3) (Special Tool), as shown.

Fav 900

Engine / Short block

Removing and reﬁtting air compressor

Repair

Fav 900 Chassis number 23/3001 and up

23.2.2001

2210 000013

2/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting air compressor

PM-Picturemodule

PMTAB_Picture

Tighten compressor drive gear (1) with 4 screws (4) on mounting plate (3) to 30 Nm (22.13 lbf-ft).

Loosen nut (2) . Press out drive gear, ﬁt mounting plate (3) with 4

screws (4) at the bottom side of the drive gear (2).

PMTAB_Picture

Screw (5) to be screwed into central threaded hole until drive gear comes loose.

Remove drive gear and mounting plate.

PMTAB_Picture

Release eccentric ﬂange (1) from compressor body with a soft hammer.

Remove ﬂange from body. Unscrew connecting ﬁttings of coolant as well as

of compressed air.

PMTAB_Picture

Clean eccentric ﬂange (1) . Replace and put silicon grease on O-Rings (2) . Put ﬂange (1) into compressor body.

Fav 900

Engine / Short block

Removing and reﬁtting air compressor

Repair

Fav 900 Chassis number 23/3001 and up

23.2.2001

2210 000013

3/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting air compressor

PM-Picturemodule

PMTAB_Picture

Place compressor drive gear (1) onto compressor crankshaft using mounting plate (2) (Special Tool).

Note: Drive gear must be mounted free of grease or oil.

Tighten drive gear nut (3) at 200-250 Nm (148 184 lb-ft.).

PMTAB_Picture

Remove screws (2) of mounting plate (1) out of drive gear.

Remove mounting plate. Screw and tighten connection ﬁttings for coolant

and compressed air using new gaskets into the cylinder.

PMTAB_Picture

Reﬁtting the compressor

Thoroughly clean sealing faces in compressor control timing case cover.

Use new gaskets and Oil O-rings with silicon oil. O-Rings on eccentric ﬂange must be replaced and greased with silicon oil.

Position ﬂywheel into "TDP" position. Place lever from the compressor excenter ﬂange

onto the highest position.

PMTAB_Picture

Position compressor crankshaft in such a manner that "TDP" mark on top and the upper edge of the drive fork (1) in positon (2) remains about 15° before the unmachined lowlaying part (3) .

Place compressor into timing case using a new O-Ring .

Fav 900

Engine / Short block

Removing and reﬁtting air compressor

Repair

Fav 900 Chassis number 23/3001 and up

23.2.2001

2210 000013

4/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting air compressor

PM-Picturemodule

PMTAB_Picture

Due to the slanting teeth cut of the drive gear , the crankshaft will turn by approx 15° by placing the compressor into the timing case. In ﬁnal position, the upper edge of the drive fork (1) must be in position (4) - ﬂush with the unmachined lowlaying part (3) .

If this posiition cannot be reached, the compressor must be removed and the crankshaft must be turned consequently.

PMTAB_Picture

Place 4 screws and tighten them in such a manner that the control eccentric can still be moved.

Screw in the screws of the rear side. Place eccentric into the marked position of the

compressor body. Consult following pages for avoiding high wear by

narrow clearance and excessive noise by excessive clearance, pinion clearance must be precisely adjusted.

PMTAB_Picture

Tighten in 3 steps the rear screws at the prescribed torque.

Connect coolant tubes. Connect lubrication line, intake tube and

compressed air line. Complete coolant and check oil level within the

engine. Fit hydraulic pump or place the substitution cover . Check all connections for leaks.

PMTAB_Picture

Check pinion clearance

Check can only be performed by completely mounted Timing Gear drive and by cold engine.

● Remove hydraulic pump or substitution cover.

Fav 900

Engine / Short block

Removing and reﬁtting air compressor

Repair

Fav 900 Chassis number 23/3001 and up

23.2.2001

2210 000013

5/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting air compressor

PM-Picturemodule

PMTAB_Picture

● Mount dial gauge onto the rear part of the

compressor.

● Place shaft extension with dial gauge lever

onto drive fork and tighten it in such a manner that the scanning ﬁnger of the dial gauge rests without clearance on the gauge lever.

● Turn softly lever with slight pressure axially

toward the compressor shaft from one end to the other.

The pinion clearance can be read on the dial gauge.

If the pinion clearance is not OK , then it needs to be adjusted.

PMTAB_Picture

Checking backlash

Check backlash between drive wheel and camshaft timing gear by manually turning the knurled collar.

Read off result on the gauge and compare with admissible value.

● Unscrew screws as long as the bearing ﬂange

and position over drive shaft until the compressor can be actuated easily by turning the ﬂange on the lever .

● By turning the eccentric the pinion clearance

must be adjusted between 0,1 - 0,15 mm .

Note: Position of level upper = max clearance down = minimum clearance

PMTAB_Picture

● Screw in 3 front screws and rear screws in

three steps at the speciﬁed torque.

● Reﬁt oil feed line, air intake line and

compressor air line. Screw the frame support bracket. Reﬁt hydraulic pump or rear end cover.

Fav 900

Engine / Short block

Replacing crankshaft front seal

Repair

Fav 900 chassis number 23/3001 and up

15.2.2001

2210 000002

1/1

Capitel Docu-No.

Index

Date Version

Page

Replacing crankshaft front seal

PM-Picturemodule

PMTAB_Picture

Removing vibration damper

Remove fan frame. Remove power belt. Unscrew vibration damper, remove vibration

damper. Check vibration damper and washer for damage;

replace if necessary. Remove oil splash ring.

PMTAB_Picture

Replacing crankshaft front seal

Lever out rotary shaftt with special tool.

PMTAB_Picture

Apply multi-purpose grease to sealing lips. Fit new shaft sealing ring.

Note: Do not damage sealing lips.

Use press-in plate to drive shaft sealing ring into timing case until ﬂush with recess .

PMTAB_Picture

Reﬁtting the vibration damper

With surfaces free of grease and oil, position vibration damper including oil splash ring, insert screws and tighten to speciﬁed torque.

Reﬁt power belt. Place screws and tighten.

Fav 900

Engine / Short block

Removing and reﬁtting ﬂywheel

Repair

Fav 900 chassis number 23/3001 and up

15.02.2001

2210 000004

1/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting flywheel

PM-Picturemodule

PMTAB_Picture

Remove ﬂywheel

Loosen screws, holding starter ring gear in place with a large screwdriver, if necessary.

Unscrew and remove two screws on opposite side, replace with two guide mandrels (special tool).

Unscrew all screws and remove clutch ﬂange. Using two M10, ease off the ﬂywheel. Remove clutch ﬂange and disc.

Danger: The ﬂywheel is very heavy.

Use suitable hoisting gear.

PMTAB_Picture

Clean and check ﬂywheel.

PMTAB_Picture

Reﬁtting ﬂywheel.

Position ﬂywheel on two guide mandrels, observing the correct aligment between centering pin (arrowed) and ﬂywheel bore hole: Reﬁt disc and clutch ﬂange. Push on ﬂywheel to end position.

Apply a small amount of oil to the screws. Insert and tighten to speciﬁed torque, alternating

sides.

Fav 900

Engine / Short block

Removing and reﬁtting ﬂywheel

Repair

Fav 900 chassis number 23/3001 and up

15.02.2001

2210 000004

2/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting flywheel

PM-Picturemodule

PMTAB_Picture

Replacing the starter ring gear

Remove ﬂy wheel. Drill starter ring gear and force open with a chisel.

Warning: Do not damage the ﬂywheel.

PMTAB_Picture

Note: Since the maximal permissible axial run-out of the starter ring gear must not be exceeded, it is advisable to determine ﬂywheel deviation at ring gear contact face, before ring gear is shrunk on. If this is in excess of the speciﬁed value, the ﬂywheel must be replaced.

Clamp ﬂywheel to the hub. Fit dial gauge to contact face of starter ring gear. Rotate ﬂywheel severals turns by hand and

observe gauge reading.

PMTAB_Picture

Heat new starter ring gear to approx. 220° to 240°C (428° - 464°F) and press on as far as possible.

Warning: Watch the position of chamer (arrowed).

Check maximal deviation.

Fav 900

Engine / Short block

Removing and reﬁtting crankshshaft seal (ﬂywheel).

Repair

Fav 900 chassis number 23/3001 and up

15.2.2001

2210 000003

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting crankshshaft seal (flywheel).

PM-Picturemodule

PMTAB_Picture

Rermoving shaft seal

Remove ﬂywheel. Lever out sealing ring with special tool.

PMTAB_Picture

Reﬁtting the shaft seal

Apply a thin coat of multi-purpose grease to lips of new sealing ring.

Fit seal with open side facing the crankshaft using an expanding mandrel - drive in until properly aligned.

Reﬁt the ﬂywheel.

Fav 900

Engine / Short block

Removing and reﬁtting ﬂywheel housing.

Repair

Fav 900 chassis number 23/3001 and up

15.2.2001

2210 000005

1/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting flywheel housing.

PM-Picturemodule

PMTAB_Picture

Removing ﬂywheel housing

Unscrew and remove the two screws (M16).

PMTAB_Picture

Then remove the two screws (M8), screw into the ﬂywheel housing.

PMTAB_Picture

Unscrew screws which are ﬁtted right and left on ﬂywheel housing.

Fav 900

Engine / Short block

Removing and reﬁtting ﬂywheel housing.

Repair

Fav 900 chassis number 23/3001 and up

15.2.2001

2210 000005

2/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting flywheel housing.

PM-Picturemodule

PMTAB_Picture

Remove starter. Remove ﬂywheel. Unscrew and remove the ﬁxing bolts.

Note: For easy assembly use two fairly long guide pins.

Remove ﬂywheel housing.

Caution: The ﬂywheel is very heavy. Use suitable hoisting gear.

Remove gasket residues from ﬂywheel housing and crankcase.

PMTAB_Picture

Note: If the replacement guide pins are ﬁtted, their projection must not exceed 30 mm: if this is exceeded, they will be in contact to ﬂywheel throught the housing.

PMTAB_Picture

Reﬁtting the ﬂywheel housing.

Coat ﬂywheel sealing face with sealing compound "Terostat 63" and position on crankcase.

Insert screws (including those to the oil pan) and tighten to speciﬁed torque.

Reﬁt ﬂywheel. Reﬁt starter.

Fav 900

Engine / Short block

Removing and reﬁtting the timing case.

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000006

1/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the timing case.

PM-Picturemodule

PMTAB_Picture

Removing case cover

Remove fan frame, vibration damper and air compressor.

Remove screws of timing case cover. Remove cover.

PMTAB_Picture

1. Crankshaft timing gear

(observe "2-2-2" on intermediate gear)

2. Intermediate gear

3. Injection pump drive gear.

4. Oil pump drive gear.

5. Crankshaft timing gear

(observe "*-*-1" on intermediate gear).

Note: For easy reassembly mark timing gear appropriately before removing.

PMTAB_Picture

Removing intermediate gear

Remove injection pump Unscrew hex screw, remove thrust washer and

pull off intermediate gear by hand.

PMTAB_Picture

Removing crankshaft timing gear

● Lock up gear with a large screw-driver and

remove screws. Avoid damage to the tooth

ﬂanks.

● Remove crankshaft timing gear.

Fav 900

Engine / Short block

Removing and reﬁtting the timing case.

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000006

2/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the timing case.

PM-Picturemodule

PMTAB_Picture

Replacing crankshaft axial stop

If necessary, replace cranshaft axial stop (thrust washer).

PMTAB_Picture

Removing timing case

Unscrew and remove screws (SW13) between oil pan and timing case.

PMTAB_Picture

Unscrew and remove all other screws. Remove timing case.

PMTAB_Picture

Reﬁtting timing case

Fit new gaskets to crankshaft housing. Install timing case

Note: Replacement studs of the injection pump must be inserted with "Loctite 648".

Insert screws and tighten to speciﬁed torque.

Note: Ensure correct ﬁt of gasket.

Fav 900

Engine / Short block

Removing and reﬁtting the timing case.

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000006

3/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the timing case.

PM-Picturemodule

PMTAB_Picture

Reﬁtting crankshaft timing gear

Slide crankshaft timing gear onto the centering pin.

After ﬁtting the intermediate gear tighten screws at the speciﬁed torque.

PMTAB_Picture

Reﬁtting intermediate gear

Position intermediate gear. Align camshaft and crankshaft with appropriate

markings, insert intermediate gear.

Note: Position of crankshaft timing gear in relation to intermediate gear is marked with "*-*-1". Position of camshaft timing gear in relation to intermediate gear is marked with"2-2-2".

PMTAB_Picture

Fit thrust washer and insert screws . Tighten screws of intermediate gear and camshaft

gear at speciﬁed torque. Reﬁt injection pump gear. Reﬁt injection pump

PMTAB_Picture

Note: Replacement centering pin must be driven in as far as possible; maximal projection is 24 mm. Shorten if necessary.

Fav 900

Engine / Short block

Removing and reﬁtting the timing case.

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000006

4/4

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the timing case.

PM-Picturemodule

PMTAB_Picture

Reﬁt timing case cover with new gasket. Insert screws and tighten.

Reﬁt vibration damper, Centaﬂex-coupling, front axle support, trunnion, alternator, Visco-fan and Power-belt.

Set valve clearance. Reﬁt cylinder head cover with a new dry gasket,

insert screws and tighten.

Fav 900

Engine / Short block

Removing and reﬁtting camshaft

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000007

1/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting camshaft

PM-Picturemodule

PMTAB_Picture

Removing camshaft

● Remove oil pan

● Remove timing case cover, idler gear and

camshaft gear.

● Remove ﬂywheel housing

● Remove rocker arm assembly and pushrods.

Unscrew axial stop screws and remove axial stop.

Note: Following photographs show the driving gears and timig case removed. The camshaft can be replaced without removing these parts.

PMTAB_Picture

Put engine upside down in order to have the pushrods sliding toward the cylinder head in such a manner that they will not disturb the removing operation of the camshaft!

With a special mandrel push out camshaft from the timing case end, at the same time guiding it at the ﬂywheel end.

PMTAB_Picture

Check tappets, replace if necessary.

PMTAB_Picture

Replacing camshaft bearings

Using a mandrel, drive out camshaft bushes.

Note: Crankshaft must be removed.

Note: On the new bushes the notch must be facing the fan end, and the oil channels should be aligned with those in the timing case.

Fav 900

Engine / Short block

Removing and reﬁtting camshaft

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000007

2/2

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting camshaft

PM-Picturemodule

PMTAB_Picture

Using a mandrel and in new bushes towards fan until ﬂush with the crankcase.

Note: Bearing bushes must be machined to the required size. The crankcase must be cleaned with compressed air (oil channels) after this operation.

PMTAB_Picture

Reﬁtting the camshaft

Slide guide mandrel into crankcase, insert camshaft in mandrel and reﬁt camshaft into the crankcase.

PMTAB_Picture

Reﬁt axial stop, insert screws and tighten at speciﬁed torque.

Measure end clearance; if necessary replace thrust water.

PMTAB_Picture

● Reﬁt timing gear.

● Reﬁt timing case.

● Reﬁt oil pan and idler gear.

● Reconnect pushrod and reﬁt rocker arm

assembly.

Fav 900

Removing and reﬁtting intermediate ﬂange

Repair

Fav 900 chassis number 23/3001 and up

14.2.2001

2210 000001

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting intermediate flange

PM-Picturemodule

PMTAB_Picture

Removing intermediate ﬂange

Unscrew and renove dispstick guide tube and undo oil ﬂiter cap.

Place a jack, unscrew and remove screws (1)

PMTAB_Picture

Insert 2 (M8x60) screws (arrowed) and carefully separate oil pan and intermediate ﬂange.

Clean ﬂange. Remove all gasket residue from ﬂange and

crankcase.

PMTAB_Picture

Reﬁtting the intermediate ﬂange

Coat ﬂange sealing surface with sealant Terostat

63. Using a jack, slowly raise the ﬂange to the

crankcase and insert screws.

PMTAB_Picture

Tighten screws at the speciﬁed torque. Reﬁt oil pan and oil intake line. Screw on the ﬂange.

Fav 900

Engine / Short block

Removing and reﬁtting con-rod bearing shells

Repair

Fav 900 chassis number 23/3001 and up

22.02.2001

2210 000011

1/1

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting con-rod bearing shells

PM-Picturemodule

PMTAB_Picture

Remove piston and con-rod assembly.

Note: Con-rod bearing shells of open bearings can be used again as long as they produce perfect running.

PMTAB_Picture

Note: When repairing con-rod bearing journals, use bearing shells of the relevant repair size.

Check spread of new bearing shells : Place bearing shells together on a level surface. Measure and note dimension "A". Measure and note dimension "B". Spread= A - B

PMTAB_Picture

Fit new bearing shells to con-rod big-end and bearing caps.

Note: Avoid damaging the running-in coating of the shells.

Apply a thin oil ﬁlm to running surfaces of bearing shells.

Reﬁt piston and con-rod assembly.

PMTAB_Picture

Note: Never re-use con-rod bolts.

Tighten con-rod bolts only with bearings in place. Insert new con-rod bolts and gradually tighten to

speciﬁed torque. Use torque angle indicator for ﬁnal tightening

process.

Fav 900

Engine / Short block

Removing and reﬁtting the crankshaft

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000008

1/3

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the crankshaft

PM-Picturemodule

PMTAB_Picture

Removing and reﬁtting the crankshaft

● Remove oil pan, oil line and idler gear.

● Remove timing case and ﬂywheel housing.

● Remove cylinder head.

● Remove piston and con-rod.

PMTAB_Picture

Gradually loosen screws of crankshaft bearing caps from the center outwards and remove: Take off bearing caps and arrange in order of assembly.

Note: Bearing cap positions in relation to the crankcase are identiﬁed by numbers: bearing number 1 is at the fan end.

Remove bearing shells from bearing caps. If they have not been marked, identify bearing shells and caps appropriately.

PMTAB_Picture

Remove the lower part of the axial stop washer.

PMTAB_Picture

Lift crankshaft out of crank case using a rope or leather strap.

Note: Do not use a steel cable as this could damage the bearing faces of the crakshaft journals.

Remove bearing shells from crankcase. If they have not been marked, identify bearing

shells and bearing caps appropriately. Clean parts and check for wear; replace if

necessary.

Fav 900

Engine / Short block

Removing and reﬁtting the crankshaft

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000008

2/3

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the crankshaft

PM-Picturemodule

PMTAB_Picture

Checking bearing shell spread

Place bearing shells together on a level surface. Measure and note dimension "A",repeat for "B".

Spread= A - B.

PMTAB_Picture

Reﬁtting the cranshaft

Clean oil ducts in crankcase and camshaft with dry compressed air.

PMTAB_Picture

Thoroughly clean bearing shells and journals. Insert bearings shells in crankcase, observing identiﬁcation numbers.

Stick the upper part of the axial to washer with grease onto crankcase.

Note: When using new bearing shells, observe relevant repair size.

PMTAB_Picture

Lubricate running surfaces of bearing shells and ﬁt crankshaft.

Fav 900

Engine / Short block

Removing and reﬁtting the crankshaft

Repair

Fav 900 chassis number 23/3001and up

20.2.2001

2210 000008

3/3

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting the crankshaft

PM-Picturemodule

PMTAB_Picture

Match bearing caps to relevant bearing shells. Lubricate running surfaces of bearing shells and

ﬁt caps. Insert bearing cap screws and gradually tighten

from the center outwards at speciﬁed torque.

Note: Faulty bearing caps cannot be replaced uniquely.

PMTAB_Picture

Checking end play Note:

The end play of the crankshaft is determined by the condition of the main bearing.

● Position gauge holder with dial on the

crankshaft.

● Press scanning tip of gauge onto ﬂywheel

ﬂange or crankshaft.

● Press crankshaft back and forwards and read

off end play on the dial gauge.

● If the maximal permissible end play is

exceeded, all main bearings must be replaced.

PMTAB_Picture

Assembling the engine

● Reﬁt piston and con rod assembly

● Check crankshaft for free running.

● Reﬁt cylinder heads.

● Reﬁt timing case, ﬂywheel housing and

ﬂywheel.

● Reﬁt oil pan, oil line and balancer gear.

Fav 900

Engine / Short block

Removing and reﬁtting con-rod

Repair

Fav 900 chassis number 23/3001 and up

21.2.2001

2210 000009

1/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting con-rod

PM-Picturemodule

PMTAB_Picture

Removing piston from con-rod

● Remove oil pan, suction line and intermediate

ﬂange.

● Remove cylinder head.

Remove con-rod bearing cap bolts.

PMTAB_Picture

Remove con-rod bearing caps and bearing shells, applying light knocks with a plastic hammer if necessary.

Note: Con-rod bearing caps are numbered to match the big-end and crankcase. Arrange in appropriate order.

PMTAB_Picture

Using a piece of hard wood, remove combustion residue (coking) from upper edge of cylinders.

Note: Do not damage cylinder running surface.

Push con-rod on piston upwards.

Note: Do not damage cooling oil - nozzle.

Place piston and con-rod next to the matching bearing cap. If available, use the special tray.

Carry out a visual check on piston and piston rings.

Note: Repair pistons with a 0,2; 0,4 and 0,6 (.008", .016" and .024") increase in compression height are available for remachined crankcase sealing faces.

Fav 900

Engine / Short block

Removing and reﬁtting con-rod

Repair

Fav 900 chassis number 23/3001 and up

21.2.2001

2210 000009

2/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting con-rod

PM-Picturemodule

PMTAB_Picture

Determining piston play

Measure cylinder inside diameter with an internal micrometer at three levels (top to bottom) and radially at 45° to each other. make a note of the values. Veriﬁy diameter of the new piston from the piston crown. Determine diameter of used pistons with an external micrometer (measured from lower edge of piston at right angles to pistons axis; for dimension see Service data). Make a note, subtract piston diameter from largest measured cylinder diameter.

The resulting value is the piston clearance. If clearance ist excessive cylinder liner and piston must be replaced.

PMTAB_Picture

Reﬁtting piston and con-rod Note:

If, for whatever reason, pistons need to be replaced, measure the piston diameter or read dimension on piston crown to ﬁnd out if replacement pistons were ﬁtted previously. If so, use oversize pistons.

Apply a thin oil ﬁlm to cylinder walls and pistons.

Note: Use new con-rod shells. Measure spread.

Thinly oil con-rod bearing shells and insert them into con-rod big end.

Offset piston ring gaps by 120°, Slide on piston ring clamp and compress piston

rings.

PMTAB_Picture

Insert piston and con-rod onto the cylinder, making sure that piston, conrod and cooling oil nozzle are assemled correctly.

Fav 900

Engine / Short block

Removing and reﬁtting con-rod

Repair

Fav 900 chassis number 23/3001 and up

21.2.2001

2210 000009

3/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting con-rod

PM-Picturemodule

PMTAB_Picture

Guide con-rod and insert piston until big end makes contact with the bearing journal.

PMTAB_Picture

Fit con-rod bearing shells into bearing caps. Fit bearing caps, making sure the numbers are

matching.

Note: Numbers on bearing cap and big end must be on the same side. Chamfered side (Arrow) on con- rod cap must show toward cooling oil nozzle.

PMTAB_Picture

Note: Never reuse con-rod bearing bolts .

Insert new con-rod bearing bolts and gradually tighten to speciﬁed torque.

Use torque angle indicator for ﬁnal tightening process.

PMTAB_Picture

Removing piston from con-rod

Remove piston with con-rod. Clamp con-rod in a vise, using non-metallic jaws. Remove piston pin circlips.

Fav 900

Engine / Short block

Removing and reﬁtting con-rod

Repair

Fav 900 chassis number 23/3001 and up

21.2.2001

2210 000009

4/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting con-rod

PM-Picturemodule

PMTAB_Picture

Press out piston pin, securely holding the piston. Remove piston and depose it safely.

Note: If the con-rod needs replacing, use ready-to-ﬁt new bush or reconditioned con-rod.

PMTAB_Picture

Measuring big-end con-rod bore

Screw on con-rod bearing caps (without bearing shells).

Mesure bore diameter with an internal micrometer.

Replace con-rod if this is in excess of the permissible variation.

PMTAB_Picture

Reﬁtting piston to con-rod

Fit piston to con-rod, inserting piston pin, and ﬁt circlips.

PMTAB_Picture

When reassembling, make sure that piston, con-rod and cooling oil nozzles are assembled correctly.

Fav 900

Engine / Short block

Removing and reﬁtting con-rod

Repair

Fav 900 chassis number 23/3001 and up

21.2.2001

2210 000009

5/5

Capitel Docu-No.

Index

Date Version

Page

Removing and refitting con-rod

PM-Picturemodule

PMTAB_Picture

Measuring the piston projection

Remove the cylinder heads. Turn relevant piston to TDC. Position gauge holder with dial on crankcase

sealing face. Set gauge at "0".

PMTAB_Picture

Carefully move dial gauge holder , lifting the gauge tip at the same time.

Lower tip onto piston crown and check dial reading for piston projection.

FENDT MAN D 0836 LE Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual