FENDT MAN D 0836 LE Instruction manual

Werkstatthandbuch
Workshopmanual
Manuel de réparation
Manuel d´atelier
Manuale per I´officina
Motor
Engine
Moteur
Motore
MAN D 0836 LE (Mechanical part)
X990.005.039.010

MAN D 0836 LE
Favorit 916 916/../3001-
Favorit 920 920/../3001-
Favorit 924 924/../3001-
Favorit 926 926/../3001-
Herausgegeben von der Abt. Kundendienst der Fa. ACGO GmbH & Co., Marktoberdorf
Alle Rechte vorbehalten –Printed inGermany. Diese Druckschrift darf ohne unsere schriftliche Genehmigung
Weder ganz noch auszugsweise vervielfältigt werden.
Published by the Service Divisionof ACGO GmbH & Co., Marktoberdorf
Copyright –Allrights reserved – Printed inGermany. Rproduction of this publication, in whole or parts,
without our prior authorisation, is prohibited.
Peblié par le ServiceAprés-vente de ACGO GmbH & Co., Marktoberdorf
Tous droits réservés –Printed in Germany Cette brochure ne peut être reproduite, ni totalement,
ni par extraitssans notre autorisation écrite.
Pubblicato dal reparto tecnico della ACGO GmbH & Co., Marktoberdorf
Tutti idirette riservati – Printed inGermany La riproduzione diequesto 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 derAGCO-Corp.
Maschinen- und Schlepperfabrik, Marktoberdorf / Bayern Germany
Postfachadresse: D-87609 Marktoberdorf, Postfach 1155
Telefon [phone] Telefax (0 83 42) 77-2 22 (Kundendienst)
Bestell-Nr.
X 990.005.039.010
2672 C - en EKI 09/01 © Printed in Germany – All rights reserved

VORWORT
Das vorliegende Werkstatthandbuch wurde für die
Reparaturwerkstätten unserer Vertretungen zusam-
mengestellt und enthält alle Demontage- und Mon-
tagevorgänge, die im Zusammenhang mit Ein-
stellarbeiten und der Auswechselung von Teilen
erforderlich ist.
Sind Teile auszuwechseln, so dürfen nur Original-
Ersatzteile verwendet werden. Teile-Bestellungen
bitten wir unter Angabe der Fahrgestell-Nummer nach
den jeweils gültigen Ersatzteilunterlagen aufzugeben.
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 Pflege-
und Wartungsarbeiten verweisen wir auf die Be-
triebsanleitungen.
Von den Werkstätten sind ie Technischen Daten zu
beachten.
Die einschlägigen Unfallverhütungsvorschriften sowie
die sonstigen allgemeinen anerkannten si-
cherheitstechnischen und arbeitsmedizinischen
Regelnsind einzuhalten.
Dieses Werkstatthandbuch unterliegt keinem Ände-
rungsdienst, wir weisen aus diesem Grunde auf die
zusätzlich herauskommenden technischen Rund-
schreiben 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 Vervielfältigung
jeglicher Art, auch auszugsweise, bedarf unserer
schriftlichen Genehmigung.
FOREWORD
This workshop manual was compiled for our agent´s
repair workshops and contains allthe dismantling and
assembly procedures necessary in connection with
adjustments and replacement of parts.
If parts have tobe 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 thismanual.
Please refer tothe Operating Instructions for details of
generalmaintenance and care operations.
Workshopsmust observe the technical data.
The accident prevention regulations and all other
generally recognized regulations on safety and
occupational medicine are tobe 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 allthe 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 inwhole, aresubject toour written approval.
de/en

AVANT PROPOS
Le présent Manuel deRéparation a été concupour
les Ateliers deRéparation de nos dépositaires et il
contient toutes les instructions dedémontage et de
montage nécessitées par les travauc deréglade et
de remplacement despiéces.
Dés qu´il s´agit deremplacer des piéces, il faut
utiliser uniquement despiéces de rechange
originales. Pour commander les piéces de
rechange, nous prions denous indiquer le numéro
du chassis et le numéro deréférence 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 desoutils
classiques et del´appareillage équipant
normalement un atelier.
Les outils spéciaux ont été réduits au strct
nécessaire et ilssont énumérés la fin dumanuel.
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 deprévention 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 detoutes lesmodification nécessaires.
Sous féserve de modifications techniques
nécessaires á lámélioration des produits présentés
par des illustrations et des indications référencées
dans ce Manueld´Atelier.
Réimpression et reproductionmeme partielle, quelle
qu´en soit la nature, interdtes sans l´autorisation
écrite denosservice.
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 otrabajos 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 derepuestons 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
necesariay 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 losdatos técnicos.
Se cumplirán las normas aplicables para la
prevención deaccidentes 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, seirán 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 ilustracionesy datos contenidos en este Manual
de Taller. La reimpresión del presente libro o
cualquiera forma de reproducción, aunque sea
parcial, requiere nuestra autorización por escrito.
fr/es

PREMESSA
Il presente manuale è stato redatto per le
officine dei nostri concessionari e contiene
tutte le indicazioni relative allo smontaggio ed
al montaggio che si rendono necessari per la
registrazione e la sostituzione di ricambi.
Se ci sono parti da sostituire devono essere
utilizzati assolutamente ricambi originali. I
ricambi devono venire ordinati indicando il
numero di telaio, secondo la documentazione
ricambistica in vigore.
E‘ necessario che questi lavori vengano
effettuati da personale specializzato, perciò le
riparazioni generalmente note non sono
descritte in questo manuale.
Si presuppone la presenza degli attrezzi
necessari e di dispositivi in generale che fanno
parte della dotazione di un‘officina.
Attrezzi speciali sono limitati al minimo
indispensabile e vengono elencati alla fine di
questo manuale. Per quanto riguarda la
manutenzione si prega di consultare le
istruzioni per l‘uso.
Le officine devono osservare i dati tecnici.
Rispettare le norme antinfortunistiche nonché
le generali norme tecniche sulla sicurezza e di
medicina sul lavoro.
Questo manuale non è soggetto a nessun
servizio di aggiornamento, per questo motivo
rimandiamo ad ulteriori comunicazioni
tecniche. In caso di aggiornamento di un
manuale si tiene conto delle variazioni, che
vengono poi incluse nella nuova versione.
Ci riserviamo il diritto di apportare modifiche
rispetto ad illustrazioni ed indicazioni di questo
manuale, che si rendono necessarie per il
miglioramento del prodotto. Stampa e
riproduzione di ogni genere, anche parziale, di
questo manuale solo previa nostra
autorizzazione scritta.
it

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 A
Généralités
Fav 900 from chassis number 23/3001and up
12/03/2001 2000 000005
A
a1/1 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 1175 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. 113°C (235°F)

Fav 900 Engine / Generalities
Service Data A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b1/14 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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b2/14 Capitel Docu-No.
Index
Date Version Page Service Data
Crankshaft
PM-Picturemodule
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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b3/14 Capitel Docu-No.
Index
Date Version Page Service Data
Main bearing
PM-Picturemodule
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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b4/14 Capitel Docu-No.
Index
Date Version Page Service Data
Text-module
Connecting rod
PM-Picturemodule
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 Fitcon-rodbearingcaps(withoutshells).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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b5/14 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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b6/14 Capitel Docu-No.
Index
Date Version Page Service Data
Text-module
Cylinder head
PM-Picturemodule
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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b7/14 Capitel Docu-No.
Index
Date Version Page Service Data
Valves
PM-Picturemodule
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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b8/14 Capitel Docu-No.
Index
Date Version Page Service Data
Valve operation
PM-Picturemodule
PM-Picturemodule
PM-Picturemodule
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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b9/14 Capitel Docu-No.
Index
Date Version Page Service Data
PM-Picturemodule
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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b10/14 Capitel Docu-No.
Index
Date Version Page Service Data
Engine lubrication
Text-module
Oil pump
PM-Picturemodule
Text-module
Text-module
Valve 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 A
General
Fav 900 chassis number 23/3001and up
13/03/2001 2000 000006
A
b11/14 Capitel Docu-No.
Index
Date Version Page Service Data
Cooling system
PM-Picturemodule
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).