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4.
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3.
Workshop manual
5.
Workshop manual
1.
2.
Workshop manual
0299 6277 en
Engine Number:
Please enter your engine number here. This will help us to serve you
better in questions of repairs, spare parts and after-sales service
generally.
Engine manufacturer:
Motoren-Werke Mannheim AG
(DEUTZ MWM)
Carl-Benz-Str. 5
D-68167 Mannheim
Tel.
Tx.
Fax
DEUTZ MWM
TBG 620/TBG 620K
This documentation is intended for the following engine.
Engine type:
Application:
System name:
Rating:
kW
Speed:
/ min
Commissioning on:
19
Please enter the relevant data. This will make it easier for us to help you in questions involving repairs,
spare parts and after-sales service in general.
This documentation package is to be presented to the Service Partner responsible every time a service
job is carried out.
Imprint:
DEUTZ AG
Service-Technik
Servicedokumentation
Deutz-Mlheimer Strae 147149
D-51057 Cologne
Tel.: (+49 2 21) 8 22-0
Fax: (+49 2 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
(1) 0997
Ordering No. 0299 6277 en
Page II
0299 3923-0122
0997
DEUTZ MWM
Engines
Please read all the information contained in this manual, and follow the instructions carefully. You will avoid
accidents, retain the manufacturers warranty, and will be able to use a fully functional and operational
engine.
This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined
by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The
manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely
by the user.
The term intended use shall also include compliance with the operating, maintenance and repair
conditions specified by the manufacturer. The engine may be used, maintained and repaired only by
persons who are familiar with the work concerned and who have been properly informed of the risks
involved.
Make sure that these operating instructions are available to everyone involved in operating, maintaining,
and repairing the engine, and that they have all understood the contents.
Non-compliance with these operating instructions may result in engine malfunctions and even damage or
injury to persons; the manufacturer will accept no liability in such cases.
Proper maintenance and repair work depends on the availability of all requisite equipment, tools and special
implements, all of which must be in perfect condition.
Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled
properly.
The relevant accident prevention regulations and other generally recognized rules relating to safety
engineering and health and safety at work must all be complied with.
Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are
used.
Engine repairs must correspond to the intended use. In the event of modification work, only parts approved
by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will
preclude any liability of the manufacturer for resultant damage.
0997
0299 3235-0199
Page III
Forword
DEUTZ MWM
Engines
Dear customer,
The engines of the DEUTZ MWM brand have been developed for a broad spectrum of applications.
A comprehensive range of different variants ensures that special requirements can be met for the
individual case involved.
Your engine has been equipped to suit your own particular installation, and accordingly not all of the
devices and components described in these operating instructions will actually be fitted to your engine.
We have endeavoured to present the differences involved as clearly as possible, to make it easier for
you to find the operating and maintenance instructions you need for your own particular engine.
Please read this manual before you start up your engine, and follow the operating and maintenance
instructions meticulously.
If you have any questions, just get in touch with us, and we will be pleased to answer them for you.
Yours sincerely,
DEUTZ AG
Page IV
0299 3235-0199
0997
DEUTZ MWM
Engines
General
0997
0299 3235-0199
Page V
Quick Introduction
DEUTZ MWM
Engines and Systems
OPERATING INSTRUCTIONS
Chap. 1
Chap. 2
Chap. 3
Chap. 4
Chap. 10
NORMAL
OPERATION
OPERATING INSTRUCTIONS
Chap. 3
Chap. 4
MAINTENANCE
Advice to users
Description
Operation
Expendables
Test reports
Operation
Expendables
OPERATING INSTRUCTIONS
Chap. 1
Chap. 4
Chap. 5
Chap. 8
Chap. 9
Advice to users
Expendables
Maintenance and
Servicing
Technical data
Maintenance work
DEUTZ Service
Page VI
0299 3232-0199
0997
DEUTZ MWM
Quick Introduction
Engines and Systems
SERVICING
OPERATING INSTRUCTIONS
Chap. 1
Chap. 5
Chap. 8
Advice to users
Maintenance and
Servicing
Technical data
WORKSHOP MANUAL
Servicing work
DEUTZ Service
MALFUNCTIONS IN
OPERATION
OPERATING INSTRUCTIONS
Chap. 6 Operational disturbances
causes, corrective action
Chap. 8
Technical data
Chap. 10
Test reports
WORKSHOP MANUAL
0997
Servicing work
Spare parts
Spare parts
DEUTZ Service
DEUTZ Service
0299 3232-0199
Page VII
DEUTZ MWM
Engines and Systems
This page intentionally left blank.
Page VIII
0299 3232-0199
0997
DEUTZ MWM
TBG 620/TBG 620K
0
Contents
Introduction
Imprint, foreword, quick introduction, contents
Advice to users
1.1
General remarks
1.2
1.3
1.4
Job cards
1.5
Spare parts
Job Cards
2.1
2.1.1
2.1.2
2.1.3
Overviews
Arranged alphabetically
Arranged by Job Card Numbers
Explanation of symbols
2.2
Service
0997
0299 3920-0122
Page IX
Contents
DEUTZ MWM
TBG 620/TBG 620K
Please note:
Operating instructions for DEUTZ MWM TEM System are a separate documentation
and has to be ordered separately.
Page X
0299 3920-0122
0997
DEUTZ MWM
Engines and Systems
0997
Advice to users
Advice to users
1.1
General remarks
1.2
1.3
1.4
Job cards
1.5
Spare parts
0299 3245-0199
Chapter 1 - Page 1
Advice to users
Advice to users
1.1
General remarks
DEUTZ MWM
Engines and Systems
The maintenance and servicing jobs specified in this manual must be carried out punctually and completely.
The maintenance and servicing staff must possess the necessary technical knowledge required for doing their
jobs properly. Any safety and protective features which had to be removed during maintenance and servicing
work must be fitted back in place after completion.
The accident prevention and safety regulations must by always be complied with throughout
all maintenance and servicing work.
Also note the special safety instructions for the various servicing groups which are listed
in detail as job cards in the Chapter Job Cards see also Chapter 1.2).
The maintenance and servicing intervals are given in the maintenance and servicing schedule, which also
provides information on the jobs required.
The job cards (Chapter 9) give technical instructions on how to actually perform the jobs.
1.2
For various servicing groups, detailed safety advice has have been drawn up in the form of job cards;
they are listed before the job cards of the respective servicing groups.
The statutory accident prevention regulations have to be complied with (obtainable from professional
associations or in specialized bookshops). They depend on the installation site, the operating mode and
the expendables and auxiliary materials used.
Special protective arrangements dependent on the particular jobs are indicated and marked in the job
description.
In general, the following applies:
Only trained personnel may operate or maintain the engine. Unauthorized persons are not
allowed to enter the machine room.
When the engine is in operation, wear only tight-fitting clothes and ear muffs in the machine room.
Use only professionally qualified staff for repair work.
Only start the engine when all protective devices have been installed and the turning device has
been removed. Make sure that there is nobody in the danger area.
Only carry out any cleaning, maintenance and repair work when the motor is shut down and
secured against starting.
Chapter 1 - Page 2
0299 3245-0199
0997
DEUTZ MWM
Engines and Systems
1.3
Advice to users
In order to provide a user-specific information structure, the service documentation has been divided into the
Operating Instructions and the Workshop Manual.
The Operating Instructions include a general description as well as instructions for all necessary maintenance
jobs.
In detail, they contain the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Engine description
3 Operating the engine, with
- Work routines before initial start-up and after every inspection
- Work routines before start-up
- Start-up
- Operational monitoring
- Shutting down the engine
- Emergency operation if components fail (if necessary and possible).
4 Instructions for expendables
5 Maintenance and servicing, with
- Tools and equipment overview
- Maintenance and servicing schedules
6 Operational malfunctions, their causes and how to correct them
7 Engine conservation
8 Technical particulars
9 Job Cards, arranged by Job Card Numbers
10 Sundry other instructions (if not included in the appendix or in separate files)
After-sales service
Global service directory.
The Workshop Manual presopposes knowledge of the contents of the Operating Instructions. This particularly
applies to the safety instructions. It describes easy repair jobs and emergency measures on components, which
are more elaborate to peform, and require appropriately qualified professional staff.
It contains the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Job Cards, arranged by Job Card Numbers
After-sales service
Global service directory.
1.4
Job cards
The Job cards are divided into maintenance Job Cards of Operating instructions, for example B 1-1-1 and
servicing Job Cards of the Workshop Manual, for example W 4-5-1.
For the numbering please refer to Fig. 101.
The structure of a Job Card is shown in Fig. 102.
0997
0299 3245-0199
Chapter 1 - Page 3
Advice to users
DEUTZ MWM
Engines and Systems
1
Type of documentation
The letter at the front signifies the type of documentation involved.
B = Operating Instructions
W = Workshop Manual
8
9
10
11
12
13
Subsystem (component)
The subsystems are distinguished by maintenance groups.
Generally valid:
0 Cross-subsystem or Safety Regulations
1 System parameters or general checks
Serial Number
Counting per subsystem (component)
Various jobs per subsystem (component)
Version differences
B 3-3-3
80307 0
Chapter 1 - Page 4
0299 3245-0199
0997
DEUTZ MWM
Engines and Systems
Advice to users
80300 1
0997
0299 3245-0199
Chapter 1 - Page 5
Advice to users
1.5
DEUTZ MWM
Engines and Systems
Spare parts
Chapter 1 - Page 6
0299 3245-0199
0997
DEUTZ MWM
TBG 620/TBG 620K
Job Cards
Job Cards
2.1
2.1.1
2.1.2
2.1.3
Overviews
Arranged alphabetically
Arranged by Job Card Numbers
Explanation of symbols
2.2
B 0-1-2
B 3-3-3
W 2-1-4
0997
0299 3921-0122
Chapter 2 - Page 1
Job Cards
Job Cards
2.1
Overviews
2.1.1
Jobs
Arranged alphabetically
DEUTZ MWM
TBG 620/TBG 620K
Job Card
Chapter 2 - Page 2
0299 3921-0122
W 2-2-1
W 2-2-3
W 2-1-3
W 2-1-1
W 4-1-1
W 4-5-2
W 4-5-1
W 2-5-2
W 2-5-1
W 2-3-1
W 9-9-1
W 9-0-1
W 0-3-2
W 2-2-2
W 2-2-4
W 1-4-2
W 1-4-0
W 1-4-4
W 3-3-4
W 3-3-1
W 3-3-3
W 3-3-2
W 2-0-2
W 2-1-0
W 2-0-1
W 0-1-3
W 12-6-1
W 3-7-1
W 5-3-13
W 4-8-1
W 4-4-1
W 0-0-1
W 13-0-1
W 0-3-1
W 6-4-5
W 6-4-4
W 8-11-2
0997
DEUTZ MWM
TBG 620/TBG 620K
Job Cards
2
Arranged alphabetically
Jobs
Job Card
0997
0299 3921-0122
W 2-15-1
W 2-12-2
W 2-12-4
W 2-9-3
W 2-10-3
W 2-10-1
W 1-10-2
W 12-1-4
W 1-2-3
W 1-6-1
W 1-2-2
W 4-2-1
W 1-3-1
W 1-7-3
W 1-7-2
W 1-7-1
W 1-5-1
Chapter 2 - Page 3
Job Cards
DEUTZ MWM
TBG 620/TBG 620K
2.1.2
Arranged by Job Card Numbers
Job Card
Jobs
W 0-0-1
W 0-1-3
W 0-3-1
W 0-3-2
W 1-2-2
W 1-2-3
W 1-3-1
W 1-4-0
W 1-4-2
W 1-4-4
W 1-5-1
W 1-6-1
W 1-7-1
W 1-7-2
W 1-7-3
W 1-10-2
W 2-0-1
W 2-0-2
W 2-1-0
W 2-1-1
W 2-1-3
W 2-2-1
W 2-2-2
W 2-2-3
W 2-2-4
W 2-3-1
W 2-5-1
W 2-5-2
W 2-9-3
W 2-10-1
W 2-10-3
W 2-12-2
W 2-12-4
W 2-15-1
W 3-3-1
W 3-3-2
W 3-3-3
W 3-3-4
W 3-7-1
Chapter 2 - Page 4
0299 3921-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Job Cards
0997
0299 3921-0122
Chapter 2 - Page 5
Job Cards
DEUTZ MWM
TBG 620/TBG 620K
2.1.3
Explanation of symbols
You will find there are various symbols used on the Job Cards, in order to designate information not relating
directly to the actual work sequence involved.
Tools:
-
Equipment:
-
Spare parts:
-
Cross-references:
-
2.2
Documents, reports or Job Cards to which reference is made in the Job Card concerned.
Chapter 2 - Page 6
0299 3921-0122
0997
General
Job Card
W 0-0-1
DEUTZ MWM
Engines
Filling and venting the hydraulic clamping device
!
Equipment:
80228 0
Fig. 1
0299 4545-0199
High-pressure pump
Page 1 of 4
General
Job Card
W 0-0-1
DEUTZ MWM
Engines
13
rmin =
150 m
m
9
7
80229 0
Fig. 2
11
10
12
80230 0
Fig. 3
The normal operating configuration of the highpressure pump 1 is horizontal, but it can also run in a
vertical position, with the hose connection facing
downwards.
0299 4545-0199
1197
DEUTZ MWM
Engines
3. Filling and venting the clamping
device
General
Job Card
W 0-0-1
5. Malfunctions
4. Work sequence
Place high-pressure pump in a horizontal position.
At the fill opening 4 of the oil tank 2, fill highpressure pump 1 with not less than 1.5 litres of
hydraulic oil.
Connect high-pressure pump 1, pressure gauge
holder 6, manifold 8 and hydro-tension elements
10 to the high-pressure hoses.
Unscrew grub screw 12 of the hydro tension
elements 10, and operate pump lever 3 until
hydraulic oil exits without bubbles from vent
aperture 12.
During this procedure, the hydro tension elements
10 should be positioned at a higher level than highpressure pump 1 and held at an angle to vent
aperture 12, in order to make sure the annular
compartment in the hydro tension element 10 is
vented completely.
Tighten grub screw 12.
1197
0299 4545-0199
Page 3 of 4
General
Job Card
W 0-0-1
DEUTZ MWM
Engines
Page 4 of 4
0299 4545-0199
1197
General
Job Card
W 0-1-3
DEUTZ MWM
Gas engine
Running in the engine
The engines have been run in at the manufacturers
facility, therefore any further running-in instructions
can be dispensed with. If maintenance work has been
performed on bearings, pistons, cylinder liners, or any
of these have been replaced, then the engine must be
run in anew.
Cross-references:
-
30 min.
50 % power
Stage 2
15 min.
75 % power
Stage 3
15 min.
100 %
power
1097
0299 6310-0179
Page 1 of 2
General
Job Card
W 0-1-3
DEUTZ MWM
Gas engine
Page 2 of 2
0299 6310-0179
1097
General
Job Card
W 0-2-7
DEUTZ MWM
Engines
Endoscoping the combustion compartment
Endoscopy is a method enabling you to examine the
combustion compartment (piston, cylinder liner,
cylinder head, valves) for its wear-and-tear status
without having to remove the cylinder head beforehand.
This means you can exploit the wear limits more
effectively, and thus cut your maintenance costs.
Tools:
-
Endoscope
Cross-references:
-
1197
0299 4270-0199
Page 1 of 2
General
Job Card
W 0-2-7
DEUTZ MWM
Engines
If you find clearly recognizable damage (e.g. breakouts, notches, scoring), remove the cylinder head.
Always be on the lookout for drip formation at the
bottom of the cylinder head. This indicates a
possible leak at the seal of the injection valve or the
sparking plug guard tube.
Evaluation of normal wear phenomena, and
specification of the next endoscoping date
can be performed only by properly trained
experts.
Carefully take out the endoscope.
In the case of diesel engines, install the injection
valve, see Job Card B 7-7-2 and Installation
Instructions W 7-7-6.
In the case of gas engines, install the sparking
plugs, see Job Card B 13-5-1.
80967 0
Fig. 1
Page 2 of 2
0299 4270-0199
1197
DEUTZ MWM
Engines
General
Job Card
W 0-3-1
1197
0299 4271-0199
Page 1 of 2
General
Job Card
W 0-3-1
DEUTZ MWM
Engines
Page 2 of 2
0299 4271-0199
1197
General
Job Card
W 0-3-2
DEUTZ MWM
Engines
Crack inspection with the diffusion liquid procedure
!
Aids:
risk of poisoning!
25495 0
Fig.
1197
0299 4272-0199
General
Job Card
W 0-3-2
DEUTZ MWM
Engines
Assessment
- It may happen that very thin cracks do not become
visible until several hours have passed.
-
metal fatigue,
Page 2 of 2
0299 4272-0199
1197
Cylinder head
Job Card
W 1-2-2
DEUTZ MWM
TBG 620/TBG 620K
Valve lifter and valve lifter bracket: removing, checking and installing
Tools:
Normal tools
Special pliers for sparking plug connector
Feeler gauge
Caliper gauge
Cross-references:
-
New clearance
[mm]
Clearance between
bearing journal and
valve lifter bore
Table 1
0.050 0.091
0.130
Clearance
0997
0299 3899-0122
Page 1 of 2
Cylinder head
Job Card
W 1-2-2
DEUTZ MWM
TBG 620/TBG 620K
50736 0
Fig. 1
Page 2 of 2
0299 3899-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-2-3
Tools:
Normal tools
Extractor
Risk of injury!
Aids:
-
Nitrogen (liquid)
Cross-references:
-
Fig. 1
0997
0299 3898-0122
Valve actuator
Page 1 of 2
Cylinder head
Job Card
W 1-2-3
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3898-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-3-1
Normal tools
Cross-references:
-
0997
0299 3897-0122
Page 1 of 2
Cylinder head
Job Card
W 1-3-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3897-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-4-0
Tools:
-
Special tools
Hydraulic clamping device
Aids:
-
Lube oil
Cross-references:
-
Preparations
Fill and vent the hand pump,
see Job Card W 0-0-1.
Oil the anti-fatigue stud bolts 4; do not lubricate
with Molykote.
When mounting the cylinder head, tighten cylinder
head nuts 5 in diagonally opposite sequence until
they are hand-tight.
Fit support tubes 3.
They must be easy to turn, and must not be
supported on the adjoining cylinder heads.
Fit socket wrenches 2 onto cylinder head nuts 5.
The marking rings 7 must be flush with the
upper edges of the arbors 1 and the bores of
socket wrenches 2.
Fit tension elements 8. Check the centering support
by turning it.
Screw the puller bolts 6 onto the stud anti-fatigue
bolts.
50475 0
Fig. 1
0997
0299 3894-0122
Hydraulic element
Page 1 of 2
Cylinder head
Job Card
W 1-4-0
DEUTZ MWM
TBG 620/TBG 620K
50477 0
Fig. 2
Hand pump
50476 1
Fig. 3
Page 2 of 2
0299 3894-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-4-2
Tools:
-
Normal tools
Endoscope
Cross-references:
-
Install valves,
see Job Card W 1-5-1.
Fit cylinder head,
see Job Card W 1-4-1.
0997
0299 3891-0122
Page 1 of 2
Cylinder head
Job Card
W 1-4-2
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3891-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-4-4
Tools:
-
Aids:
-
Normal tools
Mounting device for lifting off the cylinder
head
Rail for aligning the cylinder heads
Lube grease
Cross-references:
-
0997
0299 3895-0122
Page 1 of 4
Cylinder head
Job Card
W 1-4-4
DEUTZ MWM
TBG 620/TBG 620K
50671 0
Fig. 1
50741 0
Fig. 2
Page 2 of 4
0299 3895-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-4-4
0.6 to 1.25 mm
50673 0
Fig. 3
0997
0299 3895-0122
Page 3 of 4
Cylinder head
Job Card
W 1-4-4
DEUTZ MWM
TBG 620/TBG 620K
Page 4 of 4
0299 3895-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-5-1
Tools:
-
Normal tools
Removal and installation lever for valve
springs
Aids:
-
Wooden board
Lube oil
Cross-references:
-
Removing valves
Remove cylinder head,
see Job Card W 1-4-4.
Place cylinder head with combustion-compartment
side on something soft (e.g. wood).
Remove valve lifters and valve lifter brackets,
see Job Card W 1-2-2.
Take off valve actuator bridges.
Screw the removal lever for valve springs onto the
bolt for the valve lifter bracket mounting.
Accident risk!
Springs are under tension.
50667 0
Fig. 1
0997
0299 3896-0122
Page 1 of 2
Cylinder head
Job Card
W 1-5-1
DEUTZ MWM
TBG 620/TBG 620K
50738 0
Fig. 2
50739 1
Fig. 3
Page 2 of 2
0299 3896-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-6-1
Tools:
-
Normal tools
Digital caliper gauge
Press-out mandrel
Press-in mandrel
Single-stroke honing tool
Inside calipers
Aids:
-
Engine oil
Nitrogen (liquid)
Cross-references:
-
50740 1
Fig. 1
Valve guide
0997
0299 3884-0122
Page 1 of 2
Cylinder head
Job Card
W 1-6-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3884-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-7-1
Tools:
-
Normal tools
Digital caliper gauge
Magnifying glass (at least 4-fold magnification)
Aids:
-
Distillate fuel
Cross-references:
-
no corrosion scars,
Install valves,
see Job Card W 1-5-1.
0997
0299 3887-0122
Page 1 of 2
Cylinder head
Job Card
W 1-7-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3887-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-7-3
Tools:
-
Normal tools
Electric welding unit
Inside calipers
Digital caliper gauge
Press
Aids:
-
Nitrogen (liquid)
Cross-references:
-
Inlet
Exhaust
60 +0.019
-0
58 +0.019
-0
Hole depth
+0.02
15 +0.05
15 +0.02
+0.05
Table 1 Dimensions
0997
0299 3900-0122
Page 1 of 2
Cylinder head
Job Card
W 1-7-3
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3900-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Cylinder head
Job Card
W 1-10-2
Normal tools
Special nut for removing the bottom guard
sheath
Aids:
-
Screw-locking compound
Cross-references:
-
81066 0
Fig. 1
0997
0299 3901-0122
Page 1 of 2
Cylinder head
Job Card
W 1-10-2
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3901-0122
0997
DEUTZ MWM
Engines
Drive mechanism
Job Card
W 2-0-1
Danger of burst!
!
Before starting work
1097
0299 6317-0199
Page 1 of 2
Drive mechanism
Job Card
W 2-0-1
DEUTZ MWM
Engines
Page 2 of 2
0299 6317-0199
1097
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-1-0
Tools:
-
Normal tools
Turning device
Cross-references:
-
0997
0299 3886-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-1-0
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3886-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-1-1
Tools:
-
Slide gauge
1. Definition
Positive spread:
Measured at room temperatures, Dimension a is
greater than Dimension D.
Negative spread:
2. Assessment
If a used bearing shows negative spread, this may (if
no other reasons can be detected) be an indication
that the bearing has undergone plastic deformation
due to overheating and has thus lost its initial tension.
80227 0
Fig. 1
Spread
3. Setpoint values
[mm]
Conn. rod b.
Spread a
135.025
0997
+ 0.4
0299 3885-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-1-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3885-0122
0997
Drive mechanism
Job Card
W 2-1-6
DEUTZ MWM
Gas engines
Visual inspection of the bearing shells
Please take the precise point in time when to inspect
the connecting-rod and crankshaft bearings from the
operating instructions, Maintenance and Servicing.
Tools:
-
Cross-references:
-
How to proceed:
You must check the bearing shells by means of a
visual inspection and by checking the bearing shell
spread.
Under a basic overhaul routine (for precise intervals
see operating instructions Maintenance and
servicing), connecting-rod and crankshaft bearings
must always be replaced.
0997
0299 6321-0199
Page 1 of 10
Drive mechanism
Job Card
W 2-1-6
DEUTZ MWM
Gas engines
81148 0
Fig. 1
Page 2 of 10
0299 6321-0199
0997
DEUTZ MWM
Gas engines
Drive mechanism
Job Card
W 2-1-6
81149 0
Fig. 2
81191 0
Fig. 3
0997
0299 6321-0199
Page 3 of 10
Drive mechanism
Job Card
W 2-1-6
DEUTZ MWM
Gas engines
81192 0
Fig. 4
81150 0
Fig. 5
Page 4 of 10
0299 6321-0199
0997
DEUTZ MWM
Gas engines
Drive mechanism
Job Card
W 2-1-6
81151 0
Fig. 6
0997
0299 6321-0199
Page 5 of 10
Drive mechanism
Job Card
W 2-1-6
DEUTZ MWM
Gas engines
81152 0
Fig. 7
The loaded area of the bearing shell exhibits brokenoff bearing metal pieces. Some broken-off pieces are
lying around loose in the fatigue zone.
These have been caused by fatigue in the slide layer
of the aluminium alloy. The surface structure at the
bottom of the break-out indicates good bonding
between steel and aluminium alloy.
This bearing shell cannot be re-used. Fig. 8.
81153 0
Fig. 8
Page 6 of 10
0299 6321-0199
0997
DEUTZ MWM
Gas engines
Drive mechanism
Job Card
W 2-1-6
81154 0
Fig. 9
0997
0299 6321-0199
Page 7 of 10
Drive mechanism
Job Card
W 2-1-6
DEUTZ MWM
Gas engines
Assessment
In places, the bearing is worn to such an extent that
the bearing metal ribs and the grooves in the contact
layer have reached a ratio of 1 : 1. The width of the
bearing metal ribs has increased from 25 % (as-new
condition) to 50 %. There is still some contact layer left
in the grooves.
If a wear-and-tear status as described in Case
2 below must be anticipated within the next
inspection interval, then the bearing must be
replaced.
Use a magnifying glass to assess the wear-andtear status of the contact surface (magnification at
least 5-fold). Contact surface is visible as the dark
zone and the light-metal rib as the light-coloured
zone.
Crucial for wear-and-tear status:
- Ratio of width of light-metal rib and width of
groove, plus
- extent of the worn surface.
Each time you are assessing groove states, you
must adduce the contact surface in the less loaded
area (in most cases groove status as new) as a
comparison.
A distinction must be made between the following
cases:
Case 1 (Fig. 10):
Definition of the contact-surface areas
1 Max. 30 % of the shells circumference
2 Max. 70 % of the width
3 Max. 50 % of the shells circumference
4 Max. 35 % of the width
5 Wear-and-tear 1 : 1
=5
80231 1
Fig. 10
Page 8 of 10
0299 6321-0199
0997
DEUTZ MWM
Gas engines
Drive mechanism
Job Card
W 2-1-6
Assessment
The bearing metal ribs are worn in places.
When this wear-and-tear status has been reached,
the bearing must be replaced.
=7
=8
80232 1
Fig. 11
0997
Page 9 of 10
Drive mechanism
Job Card
W 2-1-6
DEUTZ MWM
Gas engines
Page 10 of 10
0299 6321-0199
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-2-1
Tools:
Normal tools
Sealant Hylomar
Cross-references:
-
Bearing race
Apply sealant.
0997
0299 3930-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-2-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3930-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-2-2
Tools:
Normal tools
Sealant Loctite 574
Cross-references:
-
50756 1
Fig. 1
0997
0299 3929-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-2-2
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3929-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-2-3
Tools:
Normal tools
Sealant Hylomar
Cross-references:
-
Fig. 1
Bearing race
0997
0299 3928-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-2-3
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3928-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-2-4
Tools:
Normal tools
Sealant Loctite 574
Cross-refeences:
-
50324 1
Fig. 1
0997
0299 3511-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-2-4
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3511-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-3-1
Tools:
-
Normal tools
Two-step measuring instrument
Caliper gauge
Cross-references:
-
b a
50745 0
Fig. 1
Normal
125.099 - 125.155
max. 125.190
Rep. Stage 1
124.699 - 124.755
max. 124.790
Rep. Stage 2
124.299 - 124.355
max. 124.390
Rep. Stage 3
123.899 - 123.955
max. 123.990
Bearing clearance
(Bearing shells / crankshaft)
0997
max. 0.04
max.
0.065
0.095 - 0.185
max.
0.230
0299 3904-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-3-1
DEUTZ MWM
TBG 620/TBG 620K
b a
50689 0
Fig. 2
135.000 - 135.025
134.980 - 135.060
Conicity
max. 0.012
max. 0.020
Roundness (Out-of-roundness)
max. 0.012
max. 0.040
Page 2 of 2
0299 3904-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-5-1
Tools:
Normal tools
Cross-references:
-
50 746 0
Fig. 1
0997
0299 3888-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-5-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3888-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-5-2
Tools:
Normal tools
Cross-references:
-
Preparation
Clean all parts thoroughly.
Check the surface condition of the lift journal
meticulously, and smooth out any impact points with
an oil stone.
0997
0299 3889-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-5-2
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3889-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-9-3
Tools:
-
Normal tools
Lifting tackle
Lift-out plate
Piston support device
Tightening strap or mounting pliers
Aids:
-
Wooden wedges
Engine oil
Cross-references:
-
0997
0299 3905-0122
Page 1 of 4
Drive mechanism
Job Card
W 2-9-3
DEUTZ MWM
TBG 620/TBG 620K
50710 0
Fig. 1
50749 0
Fig. 2
50702 0
Fig. 3
Page 2 of 4
0299 3905-0122
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-9-3
50701 0
Fig. 4
150 Nm
250 Nm
30
30
0997
0299 3905-0122
Page 3 of 4
Drive mechanism
Job Card
W 2-9-3
DEUTZ MWM
TBG 620/TBG 620K
Page 4 of 4
0299 3905-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-10-1
Tools:
-
Cross-references:
-
Fig. 1
TOP
1
TOP
2
3
4
50695 0
Fig. 2
0997
0299 3903-0122
Drive mechanism
Job Card
W 2-10-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3903-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-10-3
Feeler gauge
Micrometer
Cross-references:
-
50618 1
Fig. 1
Fig. 2
50696 1
0997
0299 3902-0122
Drive mechanism
Job Card
W 2-10-3
DEUTZ MWM
TBG 620/TBG 620K
Install piston,
see Job Card W 2-9-3.
80185 0
Fig. 3
Joint clearance
(mm)
As-new
condition
(mm)
max. perm.
Ring
3.313 - 3.333
0.50 - 0.75
1.20
Groove
3.415 - 3.445
---
---
Ring
3.475 - 3.490
0.90 - 1.15
1.50
Groove
3.560 - 3.580
---
---
Ring
5.975 - 5.990
0.50 - 0.80
1.00
Groove
6.060 - 6.080
---
---
(mm)
1.
2.
3.
Page 2 of 2
0299 3902-0122
Axial clearance
As-new
condition
(mm)
max. perm.
(mm)
0.082 - 0.132
0.180
0.070 - 0.105
0.150
0.070 - 0.105
0.150
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-12-2
Normal tools
Press
Inside callipers
Micrometer
Aids:
-
Nitrogen
Cross-references:
-
Checking the
Remove piston pin,
see Job Card W 2-12-4.
Check that the piston pin bushes are firmly seated.
Check that the position of the oil bores in the
connecting-rod eye and the piston pin bush still
coincide. (When a 6 mm test mandrel can no
longer be inserted, replace the bush).
Check piston pin bush for even contact pattern,
surface quality and scoring.
Measure piston pin bush.
Replace any scored, worn connecting-rod
bushes, or any with a poor contact pattern.
Tolerances
Piston bush
Conn. rod
0997
Nominal dimension
in mm
Wear limit
in mm
Diameter
after installation
65.056...65.099
65.140
Conicity after
installation at right
angles to force direction
65.060...65.120
65.140
0.020
Clearance between
piston pin and piston
pin bush
0.056...0.107
0.120
0.180...0.740
1.000
0299 3907-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-12-2
DEUTZ MWM
TBG 620/TBG 620K
Fig. 1
Page 2 of 2
0299 3907-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-12-4
Normal tools
Pliers for circlips
Inside callipers
Micrometer
Aids:
-
Engine oil
Cross-references:
-
50709 0
Fig. 1
0997
0299 3906-0122
Page 1 of 2
Drive mechanism
Job Card
W 2-12-4
DEUTZ MWM
TBG 620/TBG 620K
50747 0
Fig. 2
Insert the circlip for the piston pin on the other side
of the piston.
Install piston,
see Job Card W 2-9-3.
Page 2 of 2
0299 3906-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-15-1
Tools:
-
Normal tools
Lamp and mirror
Aligning tool for piston cooling oil jets
Cross-references:
You have to remove the piston cooling-oil jets for any
major overhauls or erection jobs, before all cylinder
liners are removed. You must also remove them is
there is severe soiling due to damage, or if the lube oil
circuit is soiled. Removing these jets is not essential
if you are only going to be removing and installing
individual pistons, connecting rods and cylinder liners.
0997
0299 3908-0122
Page 1 of 4
Drive mechanism
Job Card
W 2-15-1
DEUTZ MWM
TBG 620/TBG 620K
50750 0
Fig. 1
Page 2 of 4
0299 3908-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Drive mechanism
Job Card
W 2-15-1
50751 0
Fig. 2
0997
0299 3908-0122
Page 3 of 4
Drive mechanism
Job Card
W 2-15-1
DEUTZ MWM
TBG 620/TBG 620K
Page 4 of 4
0299 3908-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Crankcase
Job Card
W 3-3-1
Tools:
Inside micrometer
Turning device
Cross-references:
-
170 +0.025 mm
170.340 mm
24873 1
Fig. 1
0.051 mm
50657 0
Fig. 2
0299 3910-0122
Page 2 of 2
0299 3910-0122
250
150
50
H in mm 35
Meas. direction
Cylinder:
250
150
50
H in mm 35
Meas. direction
Cylinder:
Customer:
B1
A1
B2
A2
B3
Y
B4
A4
B5
A5
Order No.:
Engine No.:
A3
Op. hours:
Engine type:
B6
A6
B7
A7
Measured:
Date:
B8
A8
Coupling end
(Name)
Crankcase
Job Card
W 3-3-1
DEUTZ MWM
TBG 620/TBG 620K
0997
DEUTZ MWM
TBG 620/TBG 620K
Crankcase
Job Card
W 3-3-3
Tools:
Normal tools
Pull-out device for cylinder liners
Cross-references:
-
50708 0
Fig. 1
0997
0299 3911-0122
Crankcase
Job Card
W 3-3-3
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3911-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Crankcase
Job Card
W 3-3-4
Tools:
Normal tools
Aids:
-
Abrasive paste
Acid-free grease
Cross-references:
-
Fig. 1
50706 0
Fig. 2
0997
0299 3912-0122
Crankcase
Job Card
W 3-3-4
DEUTZ MWM
TBG 620/TBG 620K
50705 0
Fig. 3
50704 0
Fig. 4
Page 2 of 2
0299 3912-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Crankcase
Job Card
W 3-7-1
Foundation bolts
Since the foundation may alter, due to the effects of
heat and distortion, you have to check the foundation
bolts to see if they have worked loose. This is
particularly important after the first few operating
hours.
Tools:
-
Normal tools
0997
0299 3909-0122
Page 1 of 2
Crankcase
Job Card
W 3-7-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3909-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Engine control
Job Card
W 4-1-1
Tools:
Normal tools
Press-out device
Two-step measuring instrument
Cross-references:
Dimensions in mm
Nominal dimension
Wear limit
Location hole
in crankcase
68,000...68,030
68.035
59.996...60.050
60.120
0.064...0.156
0.240
Fig. 1
0997
0299 3509-0122
Engine control
Job Card
W 4-1-1
DEUTZ MWM
TBG 620/TBG 620K
50184 0
Fig. 2
Page 2 of 2
0299 3509-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Engine control
Job Card
W 4-2-1
Tools:
Normal tools
Cross-references:
-
50755 1
Fig. 1
0997
0299 3913-0122
Page 1 of 2
Engine control
Job Card
W 4-2-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3913-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Engine control
Job Card
W 4-4-1
Normal tools
Special tools
Cross-references:
-
Fig. 1
Gear train
0997
0299 3933-0122
Page 1 of 2
Engine control
Job Card
W 4-4-1
DEUTZ MWM
TBG 620/TBG 620K
81063 0
Fig. 2
81062 0
Fig. 3
Page 2 of 2
0299 3933-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Engine control
Job Card
W 4-5-1
Tools:
Normal tools
Insertion and removal mandrels for
camshaft
Prism / dial gauge
Micrometer
Cross-references:
-
81064 0
Fig. 1
50698 0
Fig. 2
0997
0299 3507-0122
Engine control
Job Card
W 4-5-1
DEUTZ MWM
TBG 620/TBG 620K
Dimensions in mm
Nominal dimension
Wear limit
Diameter
Camshaft bearings
59.94...59.40
59.880
Axial clearance
0.120...0.210
0.300
17.840...17.880
17.770
Meas. point
V8
V12
V16
0.06
0.08
0.09
II
0.06
0.06
IIl
0.04
0.04
0.04
Table 2
50300 0
Fig. 3
Page 2 of 2
0299 3507-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Engine control
Job Card
W 4-5-2
Tools:
Normal tools
Insertion and removal mandrels for
camshaft
Aids:
-
Lube oil
Cross-references:
-
50699 0
Fig. 1
81064 0
Fig. 2
0997
0299 3508-0122
Engine control
Job Card
W 4-5-2
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3508-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Engine control
Job Card
W 4-8-1
Tools:
Normal tools
Feeler gauge
Dial gauge
Cross-references:
-
[mm]
Meas. point
Nominal dimension
Wear limit
Face clearance
0.050...0.300
0.380
44.959...44.975
44.955
Radial clearance
Idler gear axle bearing bush
0.035...0.091
0.100
Axial clearance
0.080...0.192
0.300
34.959...34.975
34.955
0.025...0.083
0.120
Radial clearance
Idler gear axle bearing bush
Table 1
0997
0299 3932-0122
Page 1 of 2
Engine control
Job Card
W 4-8-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3932-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Governor
Job Card
W 5-3-13
Tools:
-
Normal tools
Feeler gauge
81073 0
Fig. 1
50758 0
Fig. 2
0997
0299 3934-0122
Governor
Job Card
W 5-3-13
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3934-0122
0997
Tools:
-
Normal tools
Round brush
Wooden rod
Spare parts:
-
Cross-references:
-
50760 0
Fig. 1
0997
0299 3935-0122
Mixture cooler
Page 1 of 2
Page 2 of 2
0299 3935-0122
0997
Normal tools
Lifting tackle
Cleaning agent
Spare parts:
-
Cross-references:
-
0997
0299 3936-0122
Page 1 of 2
Page 2 of 2
0299 3936-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Tools:
-
Normal tools
Special wrench for removing the oil
pressure control valve
Measuring tools
Cross-references:
-
4 0.3 bar.
100 mm.
0.085 mm.
1.500 mm.
81065 0
Fig. 1
0997
0299 3955-0122
Page 1 of 2
DEUTZ MWM
TBG 620/TBG 620K
50776 0
Fig. 2
Page 2 of 2
0299 3955-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Coolant system
Job Card
W 9-0-1
Tools:
Aids:
Normal tools
Cross-references:
Operating Instructions, Chapter 4
Operating Instructions, Chapter 7
81072 0
Fig. 1
81068 0
Fig. 2
0997
0299 3937-0122
Coolant system
Job Card
W 9-0-1
DEUTZ MWM
TBG 620/TBG 620K
81069 0
Fig. 3
After all the coolant has drained off, close the drain
plugs, drain valves and pipes again. Use new seals
and sealing rings. Re-use the coolant you have
collected, or dispose of it in a eco-friendly manner.
81070 0
Fig. 4
Page 2 of 2
0299 3937-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Coolant system
Job Card
W 9-9-1
Tools:
-
Normal tools
Aids:
-
Cleaning
0997
0299 3938-0122
Page 1 of 2
Coolant system
Job Card
W 9-9-1
DEUTZ MWM
TBG 620/TBG 620K
81071 0
Fig. 1
Preheater
Page 2 of 2
0299 3938-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Other components
Job Card
W 12-1-4
Tools:
-
Normal tools
Lifting tackle
Aids:
-
Spare parts:
-
Cross-references:
-
50784 0
0997
Fig. 1
0299 3939-0122
Page 1 of 2
Other components
Job Card
W 12-1-4
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3939-0122
0997
DEUTZ MWM
TBG 620/TBG 620K
Other components
Job Card
W 12-6-1
Tools:
Normal tools
Flywheel mounting mandrels
Lifting tackle
Cross-references:
-
50700 0
FIg. 1
Mounting mandrels
0997
0299 3510-0122
Page 1 of 2
Other components
Job Card
W 12-6-1
DEUTZ MWM
TBG 620/TBG 620K
Page 2 of 2
0299 3510-0122
0997
DEUTZ MWM
TBD 616
Electrical system
Job Card
W 13-0-1
1197
0299 4343-0199
Page 1 of 2
Electrical system
Job Card
W 13-0-1
DEUTZ MWM
TBD 616
Page 2 of 2
0299 4343-0199
1197
DEUTZ MWM
Engines and Systems
Service
Service
Welt
incl.
Wirtschaftsraum I
DEUTZ AG
Deutz-Mlheimer Strae 107
Postfach 80 05 09
D - 51057 Kln
Asien Pazifik
Wirtschaftsraum II
Wirtschaftsraum III
+
+
+
D
0997
GB
J
E
RUS
0299 3113-0199
Service