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Workshop Manual

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TCD 2015

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.

0312 3514 en

Regarding copyright questions and licensing agreements


please contact :
VS-DI, Mr. Sonntag
Tel.:
+ 49 (0) 221 822-3053
EMail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostrae 1
D-51149 Kln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-Mail: info@deutz.com

The engine company.

Printed in Germany
All rights reserved
1st Edition, 06/2007
Order No. 0312 3514 en

TCD 2015
1

Foreword

General

User notes
3.1
3.2
3.2.1
3.2.2
3.3
3.4
3.5

General
Specifications
Safety regulations and rules for the prevention of accidents
Disposal regulations
Operating manual and workshop manual
Job cards
Explanation of symbols

Technical data
4.1
4.2

Testing and setting data


Tightening specifications

Job card overview


5.1
5.2
5.3

06/2006

Table of contents

Sorted alphabetically
Sorted numerically
Job card references

Job cards

Commercial tools

Special tools

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8141-001

TCD 2015

Table of contents

06/2006

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8141-001

DEUTZ engines

Foreword

05/2005

Foreword

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8142-001

DEUTZ engines

Foreword

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8142-001

DEUTZ engines

Foreword

z Read and observe the information in this documentation. You will avoid accidents, retain the
manufacturer's warranty and possess a fully
functional and ready to operate engine.
z This engine is built exclusively for purpose according to the scope of delivery - defined by the
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is considered improper use. The manufacturer will not
be liable for damages resulting from this. The
user bears the sole risk.

z Repair of the engine must correspond to its use


for the intended purpose. Only parts released by
the manufacturer for the respective purpose may
be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe
this will void the warranty!
z The engines made by DEUTZ are developed for
a wide range of applications. A wide range of variants ensures that the respective special requirements are met.
z The engine is equipped according to the installation case, i.e. not all the parts and components
described in this documentation are installed in
your engine necessarily.

z Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with this
and are aware of the risks involved.

z We have done our best to highlight the differences so that you can easily find the operating, maintenance and repair instructions relevant to your
engine.

z Make sure that this documentation is available to


everyone involved in the operation, maintenance
and repair and that they have understood the
contents.
z Failure to observe this documentation may lead
to malfunctions and engine damage as well as injury to persons for which the manufacturer will
not accept any liability.
z Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
z Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury
when handled incorrectly.
z The pertinent rules for the prevention of accidents and other generally recognised health and
safety regulations must be observed.

We are at your service for any questions you may


have in this matter.

z Maximum economy, reliability and long life is only


guaranteed when using DEUTZ original parts.
Your DEUTZ AG

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8142-001

DEUTZ engines

Foreword

05/2005

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8142-001

DEUTZ engines

General

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General

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DEUTZ engines

General

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8143-001

DEUTZ engines

General

DEUTZ engines are the product of years of research and development. The profound expertise
gained through this, in combination with high demands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability
and low fuel consumption. It goes without saying
that the high environmental protection requirements
are also met.

Maintenance and care are the only way the engine


can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particularly heeded.
Please consult one of our service representatives
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.

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DEUTZ engines

General

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8143-001

User notes

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User notes

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8144-001

User notes

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8144-001

User notes
3.2 Specifications

3.1 General
The documentation of the workshop manual has
been created based on the engine available at the
time of going to press.
There may be deviations in the descriptions, illustrations and parts due to further developments.
The maintenance work described in the operation
manual and in the workshop manual must be carried
out on schedule and completely. The maintenance
personnel must have the necessary technical
knowledge to perform the work. Safety and protection devices which are removed during maintenance
work must be replaced again afterwards.

3.2.1 Accident prevention and safety regulations


The legally prescribed rules for the prevention of accidents must be observed. These are available from
professional associations or from dealers. These
are dependent on the application site, operating
mode and the operating and auxiliary materials being used.
Special protection measures are specified depending on the work being carried out, and are identified
in the job description.
Among other things it generally applies that:

Caution!

z for the personnel:

The rules for the prevention of accidents and the


safety regulations must be observed during maintenance work.

Only briefed personnel may operate or maintain the engine. Unauthorised persons are
prohibited access to the machine room.

Reference is made in the workshop manual job


cards to the regulations in chapter 3.2. These must
be read before working on the engine and must be
strictly followed.

Wear close-fitting clothing and ear protectors


in the machine room when the engine is in operation.
Only deploy trained personnel to do repairs
and maintenance work.

The maintenance intervals and the work to be performed are specified in the maintenance schedule
of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

Do not work on the fuel system when the engine is running. The fuel system is under high
pressure - danger of death.
Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
Ensure adequate ventilation (do not cover air
shafts).
Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly.
Only store inflammable materials in the machine room if they are essential for operation
of the system.
Smoking and naked flames are prohibited in
the machine room.
z for operation, maintenance and repairs on the
engine:
Wait 30 seconds after switching off the engine
before working on the fuel sytem.
After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6.2 Fuel system.
Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
Cleaning, maintenance and repair work may
only be performed with the engine at a standstill and secured against starting.
Injection lines and high pressure pipes must
not be deformed.

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8144-001

User notes
z Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.

Damaged injection lines and high-pressure


pipes must be renewed.
Injection lines and high pressure fuel lines
must never be connected when the engine is
running.

z Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid
draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may
be kept or operated in the same room.

Do not place hands near to a leak in the high


pressure fuel system.
Also carefully check all high pressure components visually before performing tests on the
running engine. Wear suitable protective
clothing (for example protective glasses).
Leaks are a potential source of danger for
workshop personnel.

z Air currents which kick up dust, such as those


caused by brake repairs or the starting of engines, should be avoided.

Even if no leaks are discernible on the high


pressure fuel system, the workshop personnel
should avoid the immediate danger zone or
wear suitable protective clothing (such as protective glasses) when performing tests on the
running engine and during the first trial run.
Always stay out of range of a fuel jet, as it
could cause severe injury.

z For work such as removal and installation on defective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
z No general machine tools may be operated in
this room.

Smoking is strictly prohibited when working on


the fuel system.

z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating
fans should be minimised.

Do not work near to sparks and flames.


Never disconnect an injector when the engine
is running.

z Areas of the engine room from which particles of


dirt could be loosened (for example the bottom
part of the tipped driver cab) must be covered
with fresh clean film.

3.2.2 Cleanliness instructions and measures for handling the DEUTZ Common Rail System
The DEUTZ Common Rail system used in the
DEUTZ engines consists of high-precision components which are exposed to extreme stress. Great
attention must be paid to cleanliness when working
on the fuel system due to the high precision technology.
Notes and measures to be observed before
starting work on the fuel system

z Working materials and tools must be cleaned before work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.
Notes and measures to be observed during work
on the fuel system or with the fuel system open.
z Only work in clean overalls.
z Only lint-free cleaning cloths may be used for
work on the fuel system.

z The fuel system must be closed. Make a visual


inspection for leaks / damage to the fuel system.

z Remove loose parts (for example paint chips


from assembly work) with an industrial vacuum
cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.

z Clean the whole engine and engine room with the


system closed before starting work on the fuel
system.
z The engine must be dry when you start working
on the fuel system.
z Blowing (dry) with compressed air is only permissible with the fuel system closed.

z Working materials and tools must be cleaned before work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.

z When using a steam jet, first cover up the control


unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet
may not be pointed directly at them.

z Do not use used cleaning fluid or test fluid for


cleaning.

z Electrical plug connections must be plugged


when spraying.

z Work on removed components may only be performed at a suitably equipped workbench.

12/2005

4/8

z Compressed air must not be used for cleaning on


the open fuel system.

8144-001

User notes
z When removing and installing components, no
materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

operating materials among other things. The renewed parts / operating materials must be stored,
transported and disposed of according to regulations. The owner himself is responsible for this.

z Removed parts may only be rubbed down with


clean, lint-free cloths. No dirt particles may be
rubbed into the components.

Disposal includes recycling and the scrapping of


parts / operating materials, although recycling has
priority.

z Openings on the components and on the engine


must be closed immediately with suitable stoppers/caps.

Details of disposal and their monitoring are governed by regional, national and international laws
and directives which the system operator must observe on his own responsibility.

z The stoppers/caps may only be removed immediately before installing.


z Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
z Only remove new parts from the original packaging just before installation.
z Removed components must be kept in new, sealable bags or - if available - in the packaging of the
new parts.
z Always use the original packaging of the new part
to send back the removed components.
Notes and measures for the vehicle workshop
area
z For work such as removal and installation on defective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
z The workshop floor is sealed or tiled.
z No welding gear, grinders, general machine
tools, brakes or performance test benches may
be operated in this room.
z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating
fans should be minimised.
Notes and measures for workbench and tools in
the vehicle hall
z A special workbench must be set up for work on
removed components.
z Clean the removal and installation tools regularly
and keep them in a closed tool cabinet.
z Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device.
z Working materials and tools must be cleaned before work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.

3.2.3 Disposal regulations


The work described in the operation manual and
workshop manual necessitates renewal of parts and
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8144-001

User notes
3.3 Operation manual and workshop
manual

3.4 Job cards

To structure the information to suit the user, the


service documentation is divided into operation
manual and workshop manual.

The operation manual contains a general description and instructions for all other maintenance work.
It contains the following chapters:
1. Contents, General
2. Engine description
3. Operation
4. Operating media

The job cards are divided in the workshop manual


into "W" and "I" job cards.
The "W" job card documents standard repairs on the
engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
card.
The "I" job card additionally documents the appropriate work procedures for repairing the engine and/
or its components. The workshop must satisfy special conditions to perform these work procedures.
Special tools and machine tools must be available,
for example.

3.4.1 Numbering of job cards

5. Maintenance

The job card numbers follow the pattern W 02-0401. The individual parts of this pattern are explained
below:

6. Care and maintenance work


7. Faults, causes and remedies
8. Engine conservation

z W 02-04-01: Documentation type

9. Technical data

W.... Workshop manual

10.Service

I ...... Repair instructions

The workshop manual assumes knowledge of the


contents of the operation manual. This applies especially for the safety regulations. The workshop
manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

z W 02-04-01: Maintenance group


00 ... General / interdisciplinary activities
01 ... Cylinder head
02 ... Drive system
03 ... Crankcase
04 ... Engine control system
05 ... Speed governing
06 ... Exhaust system / Charging
07 ... Fuel system
08 ... Lube oil system
09 ... Cooling system
10 ... Compressed air system
11 ... Monitoring system
12 ... Other components
13 ... Electrical system
z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number

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8144-001

User notes
3.5 Explanation of symbols

3.4.2 Structure of a job card


1

Triebwerk
W 02-04-01

Danger!
of death or to health. Must be observed!
For example: The incorrect use or conversion of the turbocharger can lead to
serious injury.

4
5

16

15

Caution!
Danger to the component/engine. Noncompliance can lead to destruction of the
component/engine.
Must be observed!

14
8
13

12

Note
General notes on assembly, environmental protection etc. No potential danger for
man or machine.

11

10

Tool
Conventional and special tools required
for the work.
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)

1. DEUTZ AG,
publisher of service documentation

References
to important documents or job cards for
the work process.
For example: Job card W 04-05-05

2. Engine type (e.g. TCD 2013 4V)


3. Maintenance group
4. Job card number or topic
5. Title of job card

Reference
to a document or a job card within the
work process.

6. Reference to other job cards


7. Chapter

Test and setting data


The necessary values are specified here.
If several values are necessary, a cross
reference is given to the Test and Setting
Values table.
For example:
ID no. P01 61 = valve clearance, inlet

8. Graphic or photo
9. DEUTZ internal creation number
10.Page number
11.Date of issue of job card
12.Note
13.Danger / Important

Tightening specification
The necessary values are specified here.
If several values are necessary, a cross
reference is given to the Tightening Specifications table.
For example:
ID no. A01 001 = cylinder head screws

14.Work sequence
15.Special tools; auxiliary materials
16.Conventional tools

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8144-001

User notes

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8144-001

TCD 2015

Technical data

06/2006

Technical data

4.1

Testing and setting data

1/28

8145-001

Technical data
Testing and setting data

TCD 2015

06/2006

2/28

8145-001

06/2006

Name

3/28

Combustion process

Total volume

P00 20

P00 30

Bore

Working principle

P00 10

P00 31

Engine weight according to DIN 70020-A

Height of engine with connection housing

Height of engine

Width of engine with connection housing

Width of engine

Length of engine with connection housing

P00 04

P00 03

P00 02

P00 01

Length of engine

General engine data

ID no.

without operating media

about all data

about all data

about all data

Information

V08 1244
V06 920
V08 1160

TCD 2015
TCD 2015
(Railway)
TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

kg

V06 approx. 1020-1200

TCD 2015

132

V08 15874

mm

cm3

cm3

Direct injection
V06 11906

4 stroke

kg

kg

kg

mm

mm

mm

V08 837

V06 835

V06 1300

mm

mm

mm

mm

mm

mm

Unit

TCD 2015
(Railway)

TCD 2015
(Railway)

TCD 2015

V08 1120

V06 1125

TCD 2015
(Railway)
TCD 2015
(Railway)

V06 1200

TCD 2015

V08 1454

V06 1107

TCD 2015
(Railway)
TCD 2015
(Railway)

V06 1200

Value

TCD 2015

Series

TCD 2015
Technical data
Testing and setting data

8145-001

06/2006

Stroke

Compression ratio

Direction of rotation

Compression pressure

Spark gap

Ignition sequence

Cylinder and side view

P00 32

P00 40

P00 50

P00 51

P00 70

P00 71

P00 81

4/28

Valve seat insert, bore (outlet)

Valve seat insert, bore (inlet)

Valve seat insert, bore (outlet)

Valve guide, bore in cylinder head

Valve guide, bore in cylinder head

Valve guide, bore in cylinder head

Cylinder head, height

Cylinder head, height

P01 02

P01 03

P01 04

P01 05

P01 06

P01 07

P01 08

P01 09

P01 11

Valve guide, external diameter

Valve guide

Valve seat insert, bore (inlet)

P01 01

Cylinder head

Name

Standard

Undersize

Standard

2. oversize level

1. oversize level

Standard

1. oversize level

1. oversize level

Standard

Standard
fit H6

looking onto the flywheel

Information

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

V08

15.0

119.70

120

+0.0
44.500 0
+0.0
47.800 0
+0.0
44.300 0
+0.0
15.000 0
+0.0
15.100 0
+0.0
15.200 0

+0.0
47.500 0

T00 81

A1-B4-A4-B1-B3-A3B2-A2

V06 A1-B3-A3-B2-A2-B1

TCD 2015

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

kPa
(bar)

3200-3400
(32-34)
V06 120

mm

Unit

counter-clockwise

TCD 2015

TCD 2015

TCD 2015

16.5:1

17.5:1

TCD 2015
TCD 2015
(Railway)

145

Value

TCD 2015

Series

ID no.

Technical data
Testing and setting data
TCD 2015

8145-001

06/2006

Valve guide, external diameter

Valve guide, external diameter

Valve guide, inside diameter (inlet)

Valve guide, inside diameter (outlet)

P01 12

P01 13

P01 14

P01 15

Valve seat insert, outside diameter (inlet)

Valve seat insert, outside diameter (outlet)

P01 23

P01 24

5/28

Valve shaft clearance (outlet)

Valve edge thickness, valve head (inlet)

Valve edge thickness, valve head (outlet)

Valve head diameter (inlet)

Valve head diameter (outlet)

P01 34

P01 35

P01 36

P01 37

P01 38

P01 45

Valve stand back dimension (inlet)

Valve shaft clearance (inlet)

P01 33

Valve seat

Valve shaft diameter (outlet)

P01 32

P01 31

Valve shaft diameter (inlet)

Valve seat insert, outside diameter (outlet)

P01 22

Valve

Valve seat insert, outside diameter (inlet)

P01 21

Valve seat insert

Name

ID no.

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Series

Wear limit
(from the center of the valve head to the TCD 2015
cylinder head sealing surface)

Standard
(from the center of the valve head to the TCD 2015
cylinder head sealing surface)

Standard

Standard

Standard

Standard

Wear limit

Wear limit

Standard

Standard

1. oversize level

1. oversize level

Standard

Standard

Standard

Standard

2. oversize level

1. oversize level

Information

mm

0.14
+0.
1.9 -0.2
+0.
1.5 -0.2
+0.
46.0 -0.2
+0.
42.0 -0.2

mm

mm

2.5

1.20 - 1.60

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

Unit

0.12

+0.00
7.97 -0.00
+0.00
7.96 -0.00

+0.07
47.5 +0.06
+0.07
44.0 +0.06
+0.07
47.800 +0.06
+0.07
44.300 +0.06

8.030 +0.0
0
+0.0
8.030 0

15.2

15.1

Value

TCD 2015
Technical data
Testing and setting data

8145-001

06/2006

Valve stand back dimension (outlet)

P01 46

Valve spring wire diameter

Valve spring length

6/28

Valve clearance setting

P01 63

Rocker arm, bore, diameter (outlet)

Rocker arm, bore, diameter (inlet)

Rocker arm shaft (diameter)

Axial clearance of the toggle levers

P01 72

P01 73

P01 74

P01 75

Rocker arm/bracket

Valve clearance (outlet)

Valve clearance (inlet)

P01 62

P01 61

Valve clearance

P01 51

Valve spring

Name

Series

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Axial bearing clearance with cold engine TCD 2015

Valve overlap according to adjustment


schematic

with cold engine


with feeler gauge

with rotation angle disc

with cold engine


with feeler gauge

with rotation angle disc

untensioned, normal

Wear limit
(from the center of the valve head to the TCD 2015
cylinder head sealing surface)

Standard
(from the center of the valve head to the TCD 2015
cylinder head sealing surface)

Information

+1

+1

0.2 - 0.4

+0.02
28 0
+0.02
28 0
-0.04
28 -0.06

T01 63

+0.
0.30 0

108

+0.
0.25 0

90

4.25

58.7

1.25 - 1.65

2.4

Value

ID no.

mm

mm

mm

mm

mm

mm

mm

mm

mm

Unit

Technical data
Testing and setting data
TCD 2015

8145-001

06/2006

Roughness

P01 93

Main journal, diameter

Main journal, unroundness

Main journal, hardness

P02 04

P02 06

P02 07

7/28

Fit bearing, width

Fit bearing, width

P02 12

P02 13

Lifting journal, diameter

Lifting journal, unroundness

Radial run-out, crankshaft

P02 23

P02 25

P02 26

P02 34

Axial clearance of crankshaft

Main bearing

Lifting journal, diameter

P02 22

Lifting journal

Fit bearing, width

P02 11

Fit journal

Main journal, diameter

P02 03

Main journal

Crankshaft

Main running gear

Name

ID no.

permissible

maximum permissible deviation

Wear limit

Undersize stage
3 stages

Limit value for oversize stage

Oversize stage

Standard

Standard

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Undersize stage
3 stages
Wear limit

TCD 2015

Standard

TCD 2015

TCD 2015

Surface for cylinder head gasket

Surface for cylinder head cover

Series

Information

mm

0.25 each

mm

mm

0.205 - 0.392

mm
0.15

0.010

mm

0.25 each

mm

mm

+0.06

mm

mm

-0.01
91 -0.03

38.50

+0.06

+0.06
38.25

38

HRC

mm

mm

-0.01
108 -0.03

0.010
+6
50 0

[Rmax]

Rz

[Rmax]

Rz

Unit

20

16

20

10

Value

TCD 2015
Technical data
Testing and setting data

8145-001

06/2006

Thrust ring half, thickness

Thrust ring half, thickness

Thrust ring half, thickness

P02 35

P02 36

P02 37

8/28

Assembly temperature of the connecting rod

P02 47

Big end bearing shells, inside diameter

Big end bearing

Big end bearing, bore in connecting rod

Theoretical clearance between the big end bearing / lifting journal

Big end bearing clearance

P02 52

P02 54

P02 55

P02 56

P02 57

Big end bearing

Assembly temperature of the small end bush

P02 46

Small end bush, inside diameter

P02 43

Small end bush clearance between piston pin


and small end bush

Taper on periphery of the connecting rod

P02 42

P02 45

Parallelism of the connecting rod

P02 41

Connecting rod

Name

TCD 2015
TCD 2015

1. oversize stage=0.125 mm
(upper and lower half)
2. oversize stage=0.125 mm
(upper and lower half)

Wear limit

TCD 2015

0.17

0.060 - 0.136

+0.03
95 -0.00

after separation and re-assembly of rod


TCD 2015
and cover
TCD 2015

0.25 each

TCD 2015

Undersize stage
3 stages

+0.05
91.048 0

max. 220

approx. -40

0.04 - 0.063

mm

mm

mm

mm

mm

mm

mm

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

installed
identification (n) / top
lining spattered

heated up in hot-air oven to

cooled in coolant to

installed, unmachined

mm
+0.0
52.040 0

mm

mm

mm

mm

mm

mm

Unit

100

max. 0.10

Permissible deviation (A) to (B)


at a distance of (x)

100
TCD 2015

+0.05

max. 0.06

3.610

+0.05

+0.05

3.485

3.36

Value

at a distance of (x)

TCD 2015

TCD 2015

Standard
(upper and lower half)

Permissible deviation (a)

Series

Information

ID no.

Technical data
Testing and setting data
TCD 2015

8145-001

06/2006

Piston pin clearance

P02 62

9/28

Piston projection

Piston projection

Piston projection

Piston pin, bore

P02 75

P02 76

P02 77

P02 78

Closed gap, piston ring 1

Closed gap, piston ring 2

P02 84

P02 85

Piston rings

Piston, diameter

Piston, diameter

P02 72

P02 73

Piston, diameter

P02 71

Piston

Piston pin, diameter

Name

P02 61

Piston pin

ID no.

mm
mm
mm
mm

mm
mm
mm

-0.05 to 0.10
0.10 to 0.30
0.30 to 0.51
+0.0
52 +0.00

0.35 - 0.45
0.9
1.1 - 1.3
1.4

Standard
Wear limit
TCD 2015
(identification TOP in direction of piston
head)
Standard
Wear limit
TCD 2015
(identification TOP in direction of piston
head)

1.8 = 3 holes (cylinder head gasket)

1.6 = 2 holes (cylinder head gasket)

TCD 2015

TCD 2015

TCD 2015

mm

mm

+0.0
132 -0.01

Measuring point 3
at height 122.7 mm
TCD 2015
(Identification of the installation position
on the piston head)
TCD 2015

mm

+0.00
132 -0.00

Measuring point 2
at height 87.5 mm
TCD 2015
(Identification of the installation position
on the piston head)

1.4 = 1 hole (cylinder head gasket)

mm

+0.00
132 -0.00

mm

51.992 - 52.000

Measuring point 1
at height 22.5 mm
TCD 2015
(Identification of the installation position
on the piston head)

Unit

Value

mm

TCD 2015

TCD 2015

Series

0.09

Wear limit

Information

TCD 2015
Technical data
Testing and setting data

8145-001

06/2006

Closed gap, piston ring 3

Axial clearance, 1st piston ring

Axial clearance, 2nd piston ring

Axial clearance, 3rd piston ring

P02 86

P02 87

P02 88

P02 89

10/28

Tappet bores, diameter

Tappet bores, diameter

Installation depth of the crankshaft sealing ring


(rear cover)

Installation depth of the crankshaft sealing ring


(genset support)

P03 23

P03 24

P03 25

P03 26

P03 35

P03 31

Fitting depth for cylinder liner

Cylinder bore

Cylinder liners

Camshaft bearing liner, inside diameter

Camshaft bearing liner, wall thickness

Camshaft bearing liner, inside diameter

Camshaft bearing liner, outside diameter

Bore diameter for camshaft bearing liner in the


crankcase

P03 14

P03 13

P03 12

P03 11

Camshaft bearing

Crankcase

Name

Standard

Repairs

First assembly

Repairs

First assembly

Wear limit

Wear limit

Wear limit

Wear limit

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

+0.0
132 -0.0
+0.0
9.87 -0.0

mm

mm

mm

mm

mm

mm

mm

mm
25.050
+0.2
0.5 -0.2
+0.2
3.5 -0.2
+0.
3 -0.5
+0.
7 -0.5

mm
+0.03
25.000 0

mm

mm

mm

mm

mm

mm

70.100

+0.03
75.090 0
+0.05
69.990 0
+0.0
2.0493 0

+0.03
75.000 0

0.15

0.25

TCD 2015

Measure with trapezoidal groove wear


gauge

Wear limit

mm

1.2

mm

Unit

Wear limit
TCD 2015
(identification TOP in direction of piston
head)

Value
0.4 - 0.7

Series

Standard

Information

ID no.

Technical data
Testing and setting data
TCD 2015

8145-001

06/2006

Collar height of cylinder liner

Thickness of shim

Overhang of cylinder liner

P03 36

P03 37

P03 39

11/28

TCD 2015
TCD 2015
TCD 2015

Overhang of the parallel pin on the camshaft gear


wheel

Axial clearance of the camshaft for injection


pumps

Tooth edge clearance of the idler gear - idler gear


to camshaft gear wheel

P04 39

P04 43

P04 44

Tooth edge clearance between gear wheel of the


camshaft for injection pumps and camshaft gear
wheel

P07 20

P07 52

Nozzle opening pressure of the fuel injector

Injection valve

Plunger lift of the camshaft for injection pumps

P07 19

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Clearance between speed governor (camshaft)


and camshaft gear wheel

P05 92

Fuel system

TCD 2015

Clearance between speed governor (crankshaft)


and flywheel

P05 91

see name plate

TCD 2015

Thickness of the gasket for axial clearance setting

P04 37

Speed governing system

TCD 2015

Axial clearance of the camshaft

P04 35

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Series

Camshaft bearing pin diameter

Standard

Standard

Information

P04 31

Camshaft

Control system

Name

ID no.

mm

0.25 - 0.75

mm
mm

bar

0.04 - 0.3

280 - 288

mm

4.00

0.3 - 0.9

mm

mm

0.04 - 0.3

+0.

mm

0.2 - 0.45

1.0

mm

5.000

mm

mm

-0.06
70 -0.07

0.3

mm

mm

mm

Unit

0.09

Value
0
9.02 -0.0
+0.0
1.0 -0.0

TCD 2015
Technical data
Testing and setting data

8145-001

06/2006

Installation dimensions of the fuel shut-off valve

Installation angle of the fuel pipe

P07 91

P07 92

12/28

Thermostat, start opening (B-bank)

Thermostat, stroke distance

P09 12

P09 13

P13 66

P12 21

Venting notch top

Coloured marking black


venting notch top

0
60 -3

Screw-in height of the flame glow plug in connecdimension X


ting line

TCD 2015

+5
300 -50

TCD 2015

Tension of the single V-belt (generator, 55 Ampe- Check after 15 minutes running under
re)
load

+5
350 -50

Tension of the single V-belt (generator, 120 Am- Check after 15 minutes running under
pere)
load

500

at least 8

87

79

29.1

32

35

approx. 30

approx. 25

Value

+5
550 -50

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Series

Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device
rator, 55 Ampere)
8115

Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device
rator, 120 Ampere)
8115

Other components

Thermostat, start opening (A-bank)

P09 11

P12 11

for 3.00 bar

dimension X

dimension X

Information

Basic setting of the pressurestat when using new


for 3.50 bar
parts
for 4.00 bar

Cooling system

P08 63

Lube oil pressure

Lubricating oil system

Name

ID no.

mm

mm

mm

mm

Unit

Technical data
Testing and setting data
TCD 2015

8145-001

Technical data
Testing and setting data

TCD 2015
T00 81
Cylinder and side view
engine TCD 2015 V06

A2

A1

A3

B2

B1

B3

45418-0

T00 81
Cylinder and side view
engine TCD 2015 V08
A1

A2

A3

A4

B1

B2

B3

B4

45885-0

T01 63
Setting valve clearance
engine TCD 2015 V06
Ignition sequence: A1-B3-A3-B2-A2-B1
Valve overlap on cylinder
A1
B3
A3
B2
A2
B1

Setting on
cylinder
B2
A2
B1
A1
B3
A3

00000-0

06/2006

13/28

8145-001

Technical data
Testing and setting data

TCD 2015

T01 63
Setting valve clearance
engine TCD 2015 V08
Ignition sequence: A1-B4-A4-B1-B3-A3-B2-A2
Valve overlap on cylinder

A1
B4
A4
B1
B3
A3
B2
A2

Setting on
cylinder
B3
A3
B2
A2
A1
B4
A4
B1
00000-0

T13 054
Connection plan of the injection pumps
engine TCD 2015 V06
Item
1
2
3
4
5
6

Component
Y15.1
Y15.5
Y15.3
Y15.6
Y15.4
Y15.2

Cylinder assignment
A1
A2
A3
B1
B2
B3

6
40971-0

T13 054
Connection plan of the injection pumps
engine TCD 2015 V08
Item

Component
Y15.1
Y15.8
Y15.6
Y15.3
Y15.4
Y15.7
Y15.5
Y15.2

Cylinder assignment
A1
A2
A3
A4
B1
B2
B3
B4

00000-0

08/2008

14/28

8145-002

TCD 2015

Technical data

4.2

06/2006

Tightening specifications

15/28

8145-001

Technical data
Tightening specifications

TCD 2015

06/2006

16/28

8145-001

Name

Clamping bracket on crankcase

Clamping bracket on adapter for assembly block

Mounting feet/engine mounting on crankcase

Cylinder head on crankcase

Rocker arm bracket on cylinder head

Lock nut valve clearance setting screw

Cylinder head cover on cylinder head

Cylinder head cover on cylinder head hood

Counterweight on crankshaft

Main bearing cover, vertical screws

ID no.

A00 001

A00 002

A00 003

A01 001

A01 002

A01 003

A01 004

A01 005

06/2006

A02 001

A02 010

17/28
Screws with
washers

M8x30

Screw type

TCD 2015

Screw can be used a


max. 3 times, otherwise renew every time they are loosened.
Oil lightly

TCD 2015

TCD 2015

Screws can be used a


max. 3 times, otherwise renew every time they are loosened.
Oil lightly

TCD 2015

oil lightly
hexagonal socket
oil lightly

TCD 2015

oil lightly

TCD 2015

TCD 2015

TCD 2015

TCD 2015

rigid
oil lightly

elastic

TCD 2015

TCD 2015

TCD 2015

Mounting feet/engine mounting on crankcase, elastic


Mounting feet/engine mounting on crankcase, rigid
oil lightly

Series

Notes / Remarks

+120
+120
+60
50 Nm

+30
+60
+60
+60
+60
+120

50 Nm

50 Nm

22 Nm

22 Nm

20 Nm

61 Nm

+45

+45

Postclamping
value

30 Nm

106 Nm

90 Nm

30 Nm

106 Nm

Pre-clamping value

TCD 2015
Technical data
Tightening specifications

8145-001

06/2006

18/28

Crankcase breather

Breather pipe on intake elbow/oil separator

A03 060

A03 064

A03 069

Valve housing (pressurestat) on crankcase

A03 051

Pipe (crankcase breather) on cable harness rail

Breather pipe (holder) on cable harness rail

Connecting flange on lubricating oil pan

Lubricating oil pan on crankcase

A03 030

A03 035

Genset support on crankcase

A03 020

Half-flange on connecting flange

Rear cover on crankcase

A03 010

A03 034

Big end bearing cover on connecting rod

A02 020

Oil drain plug on lubricating oil pan

Main bearing cover, horizontal screws

A02 011

A03 031

Name

M10x20-10.9

M8x30-10.9

M10

Screw type

TCD 2015
TCD 2015

Renew screws every time


they are loosened.
Insert with locking agent
DEUTZ DW 59

Hose clip

Pipe clamp

oil lightly

oil lightly

Gasket steel beading


Observe tightening order

TCD 2015

Screws can be used a


max. 3 times, otherwise renew every time they are loosened.

30 Nm

TCD 2015
(Railway)

TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

20 Nm

20 Nm

6.5 Nm

8 Nm

50 Nm

30 Nm

TCD 2015
(Railway)

TCD 2015

120 Nm

120 Nm

24 Nm

28 Nm

55 Nm

21 Nm

50 - 60 Nm

80 Nm

Pre-clamping value

TCD 2015
(Railway)

TCD 2015

TCD 2015
(Railway)

TCD 2015

TCD 2015

Series

Notes / Remarks

ID no.

210 Nm

+60
+60

+30
+30

Postclamping
value

Technical data
Tightening specifications
TCD 2015

8145-001

06/2006

Camshaft gear wheel on idler gear

Gear wheel on camshaft for injection pumps

Plug of injection pump camshaft on crankcase

Fastening screw for idler gear on genset support

Screw plug for bolt idler gear

Screw for bolt idler gear

Pad thrust bearing on crankcase

A04 003

A04 004

A04 005

A04 011

A04 012

A04 013

A04 015

Connection housing to crankcase

A03 088

Stop cover (camshaft) on crankcase

Cover on connection housing

A03 085

A04 002

Connection housing to crankcase

A03 082

Central screw for camshaft gear wheel on camshaft

Connection housing to crankcase

A03 081

A04 001

Connection housing on lubricating oil pan

A03 080

Connection housing to crankcase

Pipe (crankcase breather)

A03 070

A03 089

Name

ID no.

19/28
M12x100

M12x175

M12x190

M8x16

M12x1.5x90

M12x1.5x35

Screw type

TCD 2015

TCD 2015

Insert with locking agent


DEUTZ DW 59
Insert with locking agent
DEUTZ DW 59

oil lightly

oil lightly

oil lightly

Fastening screw for diverter


stopper

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Insert with locking agent


DEUTZ DW 72
oil lightly

TCD 2015

oil lightly

TCD 2015

TCD 2015

Insert with locking agent


DEUTZ DW 59

Insert with locking agent


DEUTZ DW 59

TCD 2015

+60
+60
30 Nm

+150

50 Nm

30 Nm

70 Nm

79 Nm

80 Nm

8.5 Nm

30 Nm

30 Nm
+30

+60
+90
30 Nm

22 Nm

+60
+60
+60
30 Nm

21 Nm

+30
+30

Postclamping
value

30 Nm

70 Nm

6.5 Nm

TCD 2015
(Railway)
TCD 2015

Pre-clamping value

Series

Insert with locking agent


DEUTZ DW 59

Hose clip

Notes / Remarks

TCD 2015
Technical data
Tightening specifications

8145-001

06/2006

Cover (stop cover) on crankcase

Speed governor on connection housing (crankshaft)

Speed governor on cover (camshaft)

Exhaust pipe at cylinder head

Exhaust pipe on exhaust manifold

A04 022

A05 011

A05 012

A06 001

A06 002

20/28

Exhaust turbocharger to exhaust manifold

Intake elbow to exhaust turbocharger

Tubing connection to turbocharger

A06 021

A06 024

Exhaust manifold to exhaust line

A06 020

A06 010

Exhaust manifold to connection housing

Exhaust pipe on exhaust line

Gear case cover on crankcase

A04 020

A06 003

Name

Nut

Nut

M8x35
M8x45

Screw type

Hose clip

Hose clip
housing position of the hose
clip top
screw head rear

Insert with fitting compound


DEUTZ S1

Insert with fitting compound


DEUTZ S1

5 Nm

5 Nm

TCD 2015

TCD 2015
(Railway)

10 Nm

35 Nm

TCD 2015
TCD 2015
(Railway)

35 Nm

28 Nm

18 Nm

22 Nm

60 Nm

8 Nm

8 Nm

20 Nm

TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

Insert with fitting compound


DEUTZ S1
Insert with fitting compound
DEUTZ S1

TCD 2015

TCD 2015

TCD 2015

TCD 2015

21 Nm

21 Nm

TCD 2015
TCD 2015
(Railway)

Pre-clamping value

Series

Insert with fitting compound


DEUTZ S1

Insert with locking agent


DEUTZ DW 72

Notes / Remarks

ID no.

35 Nm

Postclamping
value

Technical data
Tightening specifications
TCD 2015

8145-001

06/2006

Screw plug on charge air pipe

Connecting elbow to charge air pipe

Connecting pipe to holder

Retaining plate on genset support

Fuel injector on cylinder head

Injection nozzle on fuel injector

Injection line on fuel injector/injection pump

Pipe clamp for injection pipe

Injection pump housing on crankcase

Injection pump on injection pump housing

A06 046

A06 056

A06 058

A07 001

A07 002

A07 003

A07 006

A07 009

A07 012

Holder on exhaust manifold

Joint plate on connecting pipe

Connection pipe to air intake pipe

Charge air pipe to air intake pipe

Charge air pipe to cylinder head

Name

A06 038

A06 034

A06 033

A06 030

ID no.

21/28
M6x12

Union nut

Nozzle cap
nut

Union screw

Stud

Nut

Nut

M10 x 85
M10 x 65

Screw type

oil lightly

oil lightly

without leak oil


Insert with fitting compound
DEUTZ S1

Notes / Remarks

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

TCD 2015
(Railway)

TCD 2015

60 Nm

60 Nm

10 Nm

25 Nm

40 - 50 Nm

70 Nm

20 Nm

20 Nm

20 Nm

4.5 Nm

20 Nm

34 Nm

20 Nm

57 Nm

20 Nm

20 Nm

TCD 2015
TCD 2015
(Railway)

60 Nm

20 Nm

Pre-clamping value

TCD 2015

TCD 2015

Series

Postclamping
value

TCD 2015
Technical data
Tightening specifications

8145-001

06/2006

22/28
Lock nut

Union nut

Ground cable on lock nut (flame glow plug)

Flame glow plug to connecting pipe

Connector (fuel pressure holding valve) to fuel


pipe

Overflow valve on connector

Screw-in nipple on fuel shut-off valve

A07 058

A07 059

A07 066

A07 067

A07 068

M45x1.5

Adapter (flame glow plug) on charge air pipe

Fuel pipe fastening

A07 057

A07 044

Fuel line on fuel supply pump

A07 034

SW50

Pipe clamp

Pipe clamp/holder
oil thread and head contact
surface.

Bearing housing (fuel supply pump) to genset


support

A07 024

Fuel pipe fastening

TCD 2015

Temperature transmitter on connector

A07 023

Hollow screw

TCD 2015

Fuel pipe to fuel shut-off valve (flame flow plugs) Union nut

A07 018

TCD 2015

18 Nm

39 Nm

39 Nm

TCD 2015
TCD 2015
(Railway)

42 Nm

TCD 2015
(Railway)

42 Nm

TCD 2015

7.5 Nm

TCD 2015
(Railway)

25 Nm

50 Nm

TCD 2015
(Railway)

TCD 2015

8.5 Nm

8.5 Nm

max.35 Nm

42 Nm

22 Nm

20 Nm

TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

TCD 2015
(Railway)
25 Nm

25 Nm

TCD 2015

Fuel pipe to injection pump housing

Pre-clamping value

Series

A07 015

Notes / Remarks

Name

Screw type

ID no.

Postclamping
value

Technical data
Tightening specifications
TCD 2015

8145-001

06/2006

Fuel shut-off valve (flame glow plug) on crankcase (thermostat housing)

Adapter on oil filter nozzle (genset support

Oil pressure pump on genset support

Plug on oil pump

Lubricating oil pipe to genset support

Lubricating oil pipe to fuel supply pump

A07 093

A08 002

A08 010

A08 011

A08 013

A08 014

23/28

Lubricating oil pipe on exhaust turbocharger

A08 040

Union nut
M14 x 1.5

Screw-in nipple (guide tube) on lubricating oil pan

A08 038

M8x16

Guide tube on screw-in nipple (lubricating oil pan Union nut

Holder on oil suction pipe

M8x25

M8x20

M8x16

Union nut

Hollow screw

M16x1.5

Screw type

A08 035

A08 016

Holder oil suction pipe on retaining plate (main


bearing cover)

Oil suction intake pipe on oil pump

Screw-in nipple on overflow valve

A07 069

A08 015

Name

ID no.

TCD 2015

Oil thread and head contact


surface.

TCD 2015

TCD 2015

TCD 2015

TCD 2015
(Railway)

TCD 2015

39 Nm

45 Nm

30 Nm

22 Nm

22 Nm

22 Nm

22 Nm

TCD 2015
TCD 2015
(Railway)

22 Nm

22 Nm

20 Nm

18 Nm

21 Nm

40.5 Nm

50 Nm

TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

20 Nm

42 Nm

TCD 2015
(Railway)
TCD 2015

Pre-clamping value

Series

Oil thread and head contact


surface.

Pipe clamp

Notes / Remarks

Postclamping
value

TCD 2015
Technical data
Tightening specifications

8145-001

06/2006

24/28

Inlet adapter on coolant pump

Temperature transmitter on thermostat housing

Flywheel on crankshaft

A09 011

A09 031

A12 001

Flanged hub (torsional vibration damper) on


crankshaft

Coolant pump on genset support

A09 010

A12 030

Outlet branch on thermostat housing

Holder on thermostat housing

A09 002

A09 001

Thermostat housing on crankcase

Oil pressure pick-up on oil cooler housing

Holder (lubricating oil pipe) on genset support/


gear case cover

A08 079

A08 091

Screw plug on valve housing (pressurestat)

A08 071

Relief valve of piston cooling nozzle on crankcase

Oil cooler on genset support

A08 051

A08 081

Oil cooler housing cover on genset support

Oil pressure pipe on genset support

A08 050

A08 045

Oil return pipe to turbocharger/crankcase

A08 044

Oil pressure pipe on gear case cover

Name

M16x70

M14 x 1.5

Screw type

oil lightly

Renew screws after every


loosening.
Oil lightly

oil lightly

oil lightly

Holder of pipe clamp (fuel


pipe)

Hexagon socket head

Pipe clamp

Pipe clamps

Notes / Remarks

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015
(Railway)

TCD 2015

30 Nm

50 Nm

22 nm

20 Nm

21 Nm

20 Nm

20 Nm

20 Nm

20 Nm

28 Nm

20 Nm

180 Nm

20 Nm

20 Nm

20 Nm

8.5 Nm

20 Nm

20 Nm

TCD 2015
TCD 2015
(Railway)

Pre-clamping value

Series

ID no.

+120

+30
+60
+60

Postclamping
value

Technical data
Tightening specifications
TCD 2015

8145-001

06/2006

25/28
M16x1.5
M6

Hollow screw pipe union

Pipe clamps, fuel pipe to connecting pipe

A12 092

A12 093

Clip (cable) on holder (central plug)

Fuel hose to air intake pipe

Hollow screw
M14x1.5

Hollow screw pipe union with ring piece

A12 090

A12 095

Fuel hose to connector (overflow valve/fuel shut- Hollow screw


off valve)
M10x1

M8

Union nut

Oil pressure pipe

A12 082

Union nut

Fuel pipe on flame glow plug

M8x16-10.9

A12 080

Heat shield on holder (gear case cover)

Holder on gear case cover

M10x210

Flange housing on bearing housing (hydraulic


pump drive)

A12 059

A12 071

oil lightly

M10x110

Flange housing on bearing housing (hydraulic


pump drive)

A12 058

M8x16-8.8

oil lightly

Bearing housing (hydraulic pump drive) on crankM10x55


case

A12 057

+180

30 Nm

TCD 2015

TCD 2015

Fule pipe on fuel pressure


holding valve

18 Nm

8.5 Nm

8.5 Nm

40 Nm

39 Nm

18 Nm

13 Nm

TCD 2015
TCD 2015
(Railway)

45 Nm

TCD 2015
(Railway)

39 Nm

TCD 2015

20 Nm

20 Nm

20 Nm

TCD 2015

Pipe clamp

+120

30 Nm

18 Nm

+60

Postclamping
value

30 Nm

30 Nm

Pre-clamping value

TCD 2015

TCD 2015

TCD 2015
(Railway)

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

Series

Breather pipe on oil cooler


cover

Pipe union with ring piece,


pipe 6 mm

oil lightly

oil lightly

V-belt pulley/torsional vibration damper on flanged hub

Notes / Remarks

A12 031

Screw type

Name

ID no.

TCD 2015
Technical data
Tightening specifications

8145-001

06/2006

Cable to pre-heating relay

Pressure sensor/temperature transmitter on connecting pipe

Cable to injection pump

A13 046

A13 054

Lock nut (V-belt) on generator holder

A13 017

A13 038

Generator on console

A13 015

Cable to pre-heating relay

Generator on plate (console)

A13 012

A13 037

Heat shield (starter) on crankcase

A13 006

Cable to flame glow plug

Starter on crankcase

A13 001

A13 035

Screw-in nipple (lubricating oil pipe) on exhaust


turbocharger

A12 098

Generator holder on genset support

Breather pipe on holder

A12 096

A13 018

Name

26/28
Nut M6

Nut M4

Nut M5

Screw
lock nut

5 Nm

1.0 Nm

TCD 2015
TCD 2015
(Railway)

9 Nm

7.5 Nm

2 Nm

TCD 2015

TCD 2015

TCD 2015

5 Nm

max. 5 Nm

TCD 2015
TCD 2015
(Railway)

42 Nm

hand tight

hand tight

hand tight

70 Nm

TCD 2015

TCD 2015

TCD 2015

TCD 2015

TCD 2015

M12x22
M12x28

30 Nm

45 Nm

30 Nm

TCD 2015
(Railway)
TCD 2015
(Railway)

Pre-clamping value

Series

TCD 2015

Pipe clamp

Notes / Remarks

Nut

Screw type

ID no.

42 Nm

20 Nm

20 Nm

+60
+60

Postclamping
value

Technical data
Tightening specifications
TCD 2015

8145-001

Name

Cable harness holder to connecting pipe

Cable harness rail on holder

Holder (cable harness) on connection housing

ID no.

06/2006

A13 090

A13 094

A13 098

M6x12
M6x16

8 Nm
70 Nm

TCD 2015
(Railway)

7.5 Nm

20 Nm

18 Nm

Pre-clamping value

TCD 2015
(Railway)

TCD 2015

M6

TCD 2015

Series

TCD 2015
(Railway)

Notes / Remarks

M8

M8 x 20
M8 x 16

Screw type

Postclamping
value

TCD 2015
Technical data
Tightening specifications

27/28

8145-001

Technical data
Tightening specifications

TCD 2015

06/2006

28/28

8145-001

TCD 2015

Job card overview

06/2006

Job card overview

5.1

Sorted alphabetically

1/22

8146-001

Job card overview


Sorted alphabetically

TCD 2015

06/2006

2/22

8146-001

TCD 2015

Job card overview

Activity

Job card

Maintenance group

Checking and setting fuel injectors

W 07-07-05

Fuel system

Checking and setting plunger lift of injection pumps W 07-06-04

Fuel system

Checking axial backlash of crankshaft (crankshaft


installed)

W 02-01-04

Drive system

Checking axial backlash of crankshaft (crankshaft


removed)

W 02-01-04

Drive system

Checking piston overhang

W 01-04-09

Cylinder head

Checking the camshaft

W 04-05-06

Engine control

Checking the compression pressure

W 00-02-06

General

Checking the con rod

W 02-03-01

Drive system

Checking the crankshaft

W 02-01-07

Drive system

Checking the overhang of the cylinder liner

W 03-03-08

Crankcase

Checking the piston

W 02-09-07

Drive system

Checking the piston rings and piston ring grooves

W 02-10-03

Drive system

Checking the valve guide

W 01-06-03

Cylinder head

Checking the valve lag

W 01-07-08

Cylinder head

Checking the valves

W 01-05-04

Cylinder head

Checking thermostat (removed state)

W 09-08-01

Cooling system

Disassembling, assembling and checking the rocker


W 01-02-06
arm and rocker arm bracket

Cylinder head

Dismantling and assembling fuel injector

W 07-07-02

Fuel system

Dismantling and assembling genset support

W 03-08-03

Crankcase

Grinding the cylinder head sealing surface

I 01-04-08

Cylinder head

Installing and removing turning gear

W 04-06-03

Engine control

Mounting engine on assembly block and demounting

W 00-05-01

General

Removing and installing charge air pipe (A-bank)

W 06-07-03

Exhaust system / Charging

Removing and installing charge air pipe (B-bank)

W 06-07-03

Exhaust system / Charging

Removing and installing connecting pipe

W 06-02-05

Exhaust system / Charging

Removing and installing connecting pipe


(Railway)

W 06-02-05

Exhaust system / Charging

Removing and installing coolant pump

W 09-07-08

Cooling system

Removing and installing crankcase breather (oil seW 03-01-11


parator)

Crankcase

Removing and installing exhaust line (A-bank)

W 06-01-05

Exhaust system / Charging

Removing and installing exhaust line (B-bank)

W 06-01-05

Exhaust system / Charging

Removing and installing exhaust manifold

W 06-01-07

Exhaust system / Charging

06/2006

3/22

8146-001

TCD 2015

Job card overview


Activity

Job card

Maintenance group

Removing and installing exhaust manifold (A-bank)


W 06-01-07
(Railway)

Exhaust system / Charging

Removing and installing exhaust manifold (B-bank)


W 06-01-07
(Railway)

Exhaust system / Charging

Removing and installing exhaust pipe (A-bank)

W 06-01-06

Exhaust system / Charging

Removing and installing exhaust pipe (B-bank)

W 06-01-06

Exhaust system / Charging

Removing and installing flame glow plug

W 07-01-02

Fuel system

Removing and installing flame glow plug (Railway)

W 07-01-02

Fuel system

Removing and installing flywheel

W 12-06-01

Other components

Removing and installing fuel pipes

W 07-10-06

Fuel system

Removing and installing fuel pipes (flame glow


plugs)

W 07-01-04

Fuel system

Removing and installing fuel pipes (flame glow


plugs) (Railway)

W 07-01-04

Fuel system

Removing and installing fuel pipes


(Railway)

W 07-10-06

Fuel system

Removing and installing fuel pressure holding valve W 07-13-01

Fuel system

Removing and installing fuel pressure holding valve


W 07-13-01
(Railway)

Fuel system

Removing and installing fuel shut-off valve (flame


glow plugs)

W 07-01-03

Fuel system

Removing and installing fuel shut-off valve (flame


glow plugs) (Railway)

W 07-01-03

Fuel system

Removing and installing gear case cover


(Railway)

W 04-04-09

Engine control

Removing and installing genset support

W 03-08-01

Crankcase

Removing and installing hydraulic pump drive

W 12-08-04

Other components

Removing and installing injection pump camshaft

W 04-05-07

Engine control

Removing and installing injection pumps (cylinder


A1)

W 07-04-01

Fuel system

Removing and installing injection pumps (cylinder


A2-B3)

W 07-04-01

Fuel system

Removing and installing lubricating oil pan


(Railway)

W 08-04-07

Lube oil system

Removing and installing oil pressure pick-up

W 08-11-09

Lube oil system

Removing and installing oil suction pipe


(Railway)

W 08-04-06

Lube oil system

Removing and installing pressure sensor/temperature sensor (charge air)

W 13-08-01

Electrical system

Removing and installing pressurestat

W 08-11-10

Lube oil system

Removing and installing rear cover

W 03-09-01

Crankcase

06/2006

4/22

8146-001

TCD 2015

Job card overview

Activity

Job card

Maintenance group

Removing and installing small end bush

I 02-03-03

Drive system

Removing and installing tappets, checking tappet


bores

W 04-02-02

Engine control

Removing and installing temperature transmitter

W 07-09-01

Fuel system

Removing and installing temperature transmitter

W 09-12-01

Cooling system

Removing and installing the cable harness

W 13-01-02

Electrical system

Removing and installing the camshaft

W 04-05-05

Engine control

Removing and installing the charge air line

W 06-02-03

Exhaust system / Charging

Removing and installing the connection housing

W 03-09-04

Crankcase

Removing and installing the crankshaft

W 02-04-01

Drive system

Removing and installing the cylinder head

W 01-04-04

Cylinder head

Removing and installing the cylinder liner

W 03-03-02

Crankcase

Removing and installing the fuel injectors

W 07-07-01

Fuel system

Removing and installing the fuel supply pump

W 07-11-01

Fuel system

Removing and installing the gearcase cover

W 04-04-09

Engine control

Removing and installing the generator (V-belt drive) W 13-02-03

Electrical system

Removing and installing the impulse transmitter


(camshaft)

W 05-07-03

Speed governing

Removing and installing the impulse transmitter


(crankshaft)

W 05-07-01

Speed governing

Removing and installing the lubricating oil pan

W 08-04-07

Lube oil system

Removing and installing the oil cooler

W 08-08-02

Lube oil system

Removing and installing the oil suction pipe

W 08-04-06

Lube oil system

Removing and installing the piston and con rod

W 02-09-03

Drive system

Removing and installing the piston cooling nozzle

W 02-15-01

Drive system

Removing and installing the rocker arm and rocker


arm bracket

W 01-02-02

Cylinder head

Removing and installing the starter

W 13-03-02

Electrical system

Removing and installing the valves

W 01-05-01

Cylinder head

Removing and installing thermostat

W 09-08-02

Cooling system

Removing and installing thermostat housing

W 09-08-04

Cooling system

Removing and installing torsional vibration damper

W 12-01-04

Other components

Removing and installing turbocharger

W 06-06-04

Exhaust system / Charging

Removing and installing turbocharger (A-bank)


(Railway)

W 06-06-04

Exhaust system / Charging

Removing and installing turbocharger (B-bank)


(Railway)

W 06-06-04

Exhaust system / Charging

Removing and installing, testing camshaft bearing

W 03-11-01

Crankcase

06/2006

5/22

8146-001

TCD 2015

Job card overview

Activity

Job card

Maintenance group

Renewing injection pipes (A-bank)

W 07-03-01

Fuel system

Renewing injection pipes (B-bank)

W 07-03-01

Fuel system

Renewing the crankshaft sealing ring (flywheel side) W 02-02-02

Drive system

Renewing the crankshaft sealing ring (opposite side


W 02-02-04
to flywheel)

Drive system

Renewing toothed starter flywheel ring

W 12-06-03

Other components

Renewing valve guide (oversize, pressed version)

I 01-06-04

Cylinder head

Repairing the collar rest of the cylinder liner

I 03-10-05

Drive system

Replacing valve seat insert (oversize)

I 01-07-09

Cylinder head

Setting valve clearance

W 01-01-01

Cylinder head

Testing the cylinder liner

W 03-03-01

Crankcase

06/2006

6/22

8146-001

Job card overview


Sorted numerically

TCD 2015

5
5.2

06/2006

Sorted numerically

7/22

8146-001

Job card overview


Sorted numerically

TCD 2015

06/2006

8/22

8146-001

TCD 2015

Job card overview

Job card

Activity

Maintenance group

I 01-04-08

Grinding the cylinder head sealing surface

Cylinder head

I 01-06-04

Renewing valve guide (oversize, pressed version)

Cylinder head

I 01-07-09

Replacing valve seat insert (oversize)

Cylinder head

I 02-03-03

Removing and installing small end bush

Drive system

I 03-10-05

Repairing the collar rest of the cylinder liner

Drive system

W 00-02-06

Checking the compression pressure

General

W 00-05-01

Mounting engine on assembly block and demounting

General

W 01-01-01

Setting valve clearance

Cylinder head

W 01-02-02

Removing and installing the rocker arm and rocker


arm bracket

Cylinder head

W 01-02-06

Disassembling, assembling and checking the rocker


Cylinder head
arm and rocker arm bracket

W 01-04-04

Removing and installing the cylinder head

Cylinder head

W 01-04-09

Checking piston overhang

Cylinder head

W 01-05-01

Removing and installing the valves

Cylinder head

W 01-05-04

Checking the valves

Cylinder head

W 01-06-03

Checking the valve guide

Cylinder head

W 01-07-08

Checking the valve lag

Cylinder head

W 02-01-04

Checking axial backlash of crankshaft (crankshaft


removed)

Drive system

W 02-01-04

Checking axial backlash of crankshaft (crankshaft


installed)

Drive system

W 02-01-07

Checking the crankshaft

Drive system

W 02-02-02

Renewing the crankshaft sealing ring (flywheel side) Drive system

W 02-02-04

Renewing the crankshaft sealing ring (opposite side


Drive system
to flywheel)

W 02-03-01

Checking the con rod

Drive system

W 02-04-01

Removing and installing the crankshaft

Drive system

W 02-09-03

Removing and installing the piston and con rod

Drive system

W 02-09-07

Checking the piston

Drive system

W 02-10-03

Checking the piston rings and piston ring grooves

Drive system

W 02-15-01

Removing and installing the piston cooling nozzle

Drive system

W 03-01-11

Removing and installing crankcase breather (oil seCrankcase


parator)

W 03-03-01

Testing the cylinder liner

Crankcase

W 03-03-02

Removing and installing the cylinder liner

Crankcase

W 03-03-08

Checking the overhang of the cylinder liner

Crankcase

06/2006

9/22

8146-001

TCD 2015

Job card overview

Job card

Activity

Maintenance group

W 03-08-01

Removing and installing genset support

Crankcase

W 03-08-03

Dismantling and assembling genset support

Crankcase

W 03-09-01

Removing and installing rear cover

Crankcase

W 03-09-04

Removing and installing the connection housing

Crankcase

W 03-11-01

Removing and installing, testing camshaft bearing

Crankcase

W 04-02-02

Removing and installing tappets, checking tappet


bores

Engine control

W 04-04-09

Removing and installing the gearcase cover

Engine control

W 04-04-09

Removing and installing gear case cover


(Railway)

Engine control

W 04-05-05

Removing and installing the camshaft

Engine control

W 04-05-06

Checking the camshaft

Engine control

W 04-05-07

Removing and installing injection pump camshaft

Engine control

W 04-06-03

Installing and removing turning gear

Engine control

W 05-07-01

Removing and installing the impulse transmitter


(crankshaft)

Speed governing

W 05-07-03

Removing and installing the impulse transmitter


(camshaft)

Speed governing

W 06-01-05

Removing and installing exhaust line (A-bank)

Exhaust system / Charging

W 06-01-05

Removing and installing exhaust line (B-bank)

Exhaust system / Charging

W 06-01-06

Removing and installing exhaust pipe (A-bank)

Exhaust system / Charging

W 06-01-06

Removing and installing exhaust pipe (B-bank)

Exhaust system / Charging

W 06-01-07

Removing and installing exhaust manifold

Exhaust system / Charging

W 06-01-07

Removing and installing exhaust manifold (A-bank)


Exhaust system / Charging
(Railway)

W 06-01-07

Removing and installing exhaust manifold (B-bank)


Exhaust system / Charging
(Railway)

W 06-02-03

Removing and installing the charge air line

Exhaust system / Charging

W 06-02-05

Removing and installing connecting pipe

Exhaust system / Charging

W 06-02-05

Removing and installing connecting pipe


(Railway)

Exhaust system / Charging

W 06-06-04

Removing and installing turbocharger

Exhaust system / Charging

W 06-06-04

Removing and installing turbocharger (A-bank)


(Railway)

Exhaust system / Charging

W 06-06-04

Removing and installing turbocharger (B-bank)


(Railway)

Exhaust system / Charging

W 06-07-03

Removing and installing charge air pipe (A-bank)

Exhaust system / Charging

W 06-07-03

Removing and installing charge air pipe (B-bank)

Exhaust system / Charging

W 07-01-02

Removing and installing flame glow plug

Fuel system

06/2006

10/22

8146-001

TCD 2015

Job card overview

Job card

Activity

Maintenance group

W 07-01-02

Removing and installing flame glow plug (Railway)

Fuel system

W 07-01-03

Removing and installing fuel shut-off valve (flame


glow plugs)

Fuel system

W 07-01-03

Removing and installing fuel shut-off valve (flame


glow plugs) (Railway)

Fuel system

W 07-01-04

Removing and installing fuel pipes (flame glow


plugs)

Fuel system

W 07-01-04

Removing and installing fuel pipes (flame glow


plugs) (Railway)

Fuel system

W 07-03-01

Renewing injection pipes (A-bank)

Fuel system

W 07-03-01

Renewing injection pipes (B-bank)

Fuel system

W 07-04-01

Removing and installing injection pumps (cylinder


A1)

Fuel system

W 07-04-01

Removing and installing injection pumps (cylinder


A2-B3)

Fuel system

W 07-06-04

Checking and setting plunger lift of injection pumps Fuel system

W 07-07-01

Removing and installing the fuel injectors

Fuel system

W 07-07-02

Dismantling and assembling fuel injector

Fuel system

W 07-07-05

Checking and setting fuel injectors

Fuel system

W 07-09-01

Removing and installing temperature transmitter

Fuel system

W 07-10-06

Removing and installing fuel pipes

Fuel system

W 07-10-06

Removing and installing fuel pipes


(Railway)

Fuel system

W 07-11-01

Removing and installing the fuel supply pump

Fuel system

W 07-13-01

Removing and installing fuel pressure holding valve Fuel system

W 07-13-01

Removing and installing fuel pressure holding valve


Fuel system
(Railway)

W 08-04-06

Removing and installing the oil suction pipe

Lube oil system

W 08-04-06

Removing and installing oil suction pipe


(Railway)

Lube oil system

W 08-04-07

Removing and installing the lubricating oil pan

Lube oil system

W 08-04-07

Removing and installing lubricating oil pan


(Railway)

Lube oil system

W 08-08-02

Removing and installing the oil cooler

Lube oil system

W 08-11-09

Removing and installing oil pressure pick-up

Lube oil system

W 08-11-10

Removing and installing pressurestat

Lube oil system

W 09-07-08

Removing and installing coolant pump

Cooling system

W 09-08-01

Checking thermostat (removed state)

Cooling system

W 09-08-02

Removing and installing thermostat

Cooling system

06/2006

11/22

8146-001

TCD 2015

Job card overview

Job card

Activity

Maintenance group

W 09-08-04

Removing and installing thermostat housing

Cooling system

W 09-12-01

Removing and installing temperature transmitter

Cooling system

W 12-01-04

Removing and installing torsional vibration damper

Other components

W 12-06-01

Removing and installing flywheel

Other components

W 12-06-03

Renewing toothed starter flywheel ring

Other components

W 12-08-04

Removing and installing hydraulic pump drive

Other components

W 13-01-02

Removing and installing the cable harness

Electrical system

W 13-02-03

Removing and installing the generator (V-belt drive) Electrical system

W 13-03-02

Removing and installing the starter

Electrical system

W 13-08-01

Removing and installing pressure sensor/temperature sensor (charge air)

Electrical system

06/2006

12/22

8146-001

Job card overview


Job card references

TCD 2015

5
5.3

06/2006

Job card references

13/22

8146-001

Job card overview


Job card references

TCD 2015

06/2006

14/22

8146-001

TCD 2015

Job card overview

00 General
Job card

Activity and additional job cards necessary for its execution


Checking the compression pressure

W 00-02-06
W 01-01-01

W 07-07-01

Mounting engine on assembly block and demounting


W 00-05-01
W 13-02-03

01 Cylinder head
Job card

Activity and additional job cards necessary for its execution


Setting valve clearance

W 01-01-01
W 04-06-03
Removing and installing the rocker arm and rocker arm bracket
W 01-02-02
W 01-01-01

W 04-06-03

W 07-03-01
(A-bank)

W 07-03-01
(B-bank)

Disassembling, assembling and checking the rocker arm and rocker arm bracket
W 01-02-06
W 01-02-02
Removing and installing the cylinder head
W 01-04-04

W 01-02-02

W 01-04-09

W 06-07-03
(B-bank)

W 07-07-01

W 06-01-05
(A-bank)

W 06-01-05
(B-bank)

W 06-07-03
(A-bank)

Grinding the cylinder head sealing surface


I 01-04-08
W 01-05-01
Checking piston overhang
W 01-04-09
W 01-04-04

W 04-06-03

Removing and installing the valves


W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
Checking the valve guide
W 01-06-03
W 01-05-01
Renewing valve guide (oversize, pressed version)
I 01-06-04
W 01-05-01

W 01-06-03

Checking the valve lag


W 01-07-08
W 01-04-04
Replacing valve seat insert (oversize)
I 01-07-09
W 01-05-01

06/2006

W 01-07-08

15/22

8146-001

TCD 2015

Job card overview

02 Drive system
Job card

Activity and additional job cards necessary for its execution


Checking axial backlash of crankshaft (crankshaft removed)

W 02-01-04
W 02-04-01
Checking axial backlash of crankshaft (crankshaft installed)
W 02-01-04
W 03-08-01

W 03-09-01

Checking the crankshaft

W 02-01-07
W 02-04-01
Renewing the crankshaft sealing ring (flywheel side)
W 02-02-02
W 12-06-01
Renewing the crankshaft sealing ring (opposite side to flywheel)
W 02-02-04
Checking the con rod
W 02-03-01
W 02-09-03
Removing and installing small end bush
I 02-03-03
Removing and installing the crankshaft
W 02-04-01
W 02-01-04

W 02-01-07

W 03-08-01

W 03-09-01

W 07-07-01

Removing and installing the piston and con rod


W 02-09-03
W 01-04-04

W 02-10-03

W 08-04-06

W 08-04-06
(Railway)

Checking the piston


W 02-09-07
W 02-09-03
Checking the piston rings and piston ring grooves
W 02-10-03
W 02-09-03
Removing and installing the piston cooling nozzle
W 02-15-01
W 02-09-03

03 Crankcase
Job card

Activity and additional job cards necessary for its execution


Removing and installing crankcase breather (oil separator)

W 03-01-11
Testing the cylinder liner
W 03-03-01
W 03-03-02
Removing and installing the cylinder liner
W 03-03-02
W 02-09-03

06/2006

W 03-03-01

W 03-03-08

16/22

8146-001

TCD 2015

Job card overview

03 Crankcase (continuation)
Job card

Activity and additional job cards necessary for its execution


Checking the overhang of the cylinder liner

W 03-03-08
W 01-04-04
Removing and installing genset support
W 03-08-01

W 02-02-04

W 06-07-03
(A-bank)

W 06-07-03
(B-bank)

W 08-04-06

W 09-07-08

W 09-08-04

Dismantling and assembling genset support


W 03-08-03
W 03-08-01
Removing and installing rear cover
W 03-09-01
W 02-02-02

W 03-09-04

W 08-04-07

Removing and installing the connection housing


W 03-09-04
W 05-07-01

W 06-01-07

W 12-06-01

W 13-03-02

Repairing the collar rest of the cylinder liner


I 03-10-05
W 03-03-02
Removing and installing, testing camshaft bearing
W 03-11-01
W 04-05-05

04 Engine control
Job card

Activity and additional job cards necessary for its execution


Removing and installing tappets, checking tappet bores

W 04-02-02
W 04-05-05
Removing and installing the gearcase cover
W 04-04-09
W 06-06-04
Removing and installing gear case cover
(Railway)
W 04-04-09
W 07-13-01
(Railway)
Removing and installing the camshaft
W 04-05-05

W 01-02-02

W 02-04-01

W 04-05-06

W 07-04-01
(cylinder A1)

W 07-04-01
(cylinder A2-B3)

W 07-06-04

W 05-07-03

W 06-06-04

Checking the camshaft


W 04-05-06
W 04-05-05
Removing and installing injection pump camshaft
W 04-05-07

06/2006

W 01-02-02

W 02-02-02

W 03-08-01

W 03-09-04

W 04-06-03

W 05-07-03

W 06-06-04

W 07-04-01
(cylinder A1)

W 07-04-01
(cylinder A2-B3)

W 07-06-04

17/22

8146-001

TCD 2015

Job card overview


04 Engine control (continuation)
Job card

Activity and additional job cards necessary for its execution


Installing and removing turning gear

W 04-06-03

05 Speed governing
Job card

Activity and additional job cards necessary for its execution


Removing and installing the impulse transmitter (crankshaft)

W 05-07-01
W 04-06-03
Removing and installing the impulse transmitter (camshaft)
W 05-07-03
W 04-06-03

W 06-06-04

06 Exhaust system / Charging


Job card

Activity and additional job cards necessary for its execution


Removing and installing exhaust line (A-bank)

W 06-01-05

W 06-01-06
(A-bank)
Removing and installing exhaust line (B-bank)

W 06-01-05

W 06-01-06
(B-bank)
Removing and installing exhaust pipe (A-bank)

W 06-01-06
Removing and installing exhaust pipe (B-bank)
W 06-01-06
Removing and installing exhaust manifold
W 06-01-07

W 06-01-06
(A-bank)

W 06-01-06
(B-bank)

W 06-06-04

Removing and installing exhaust manifold (A-bank)


(Railway)
W 06-01-07
W 06-06-04
(A-bank)
Removing and installing exhaust manifold (B-bank)
(Railway)
W 06-01-07
W 06-06-04
(B-bank)
Removing and installing the charge air line
W 06-02-03
Removing and installing connecting pipe
W 06-02-05
W 07-01-04

06/2006

18/22

8146-001

TCD 2015

Job card overview

06 Exhaust system / Charging (continuation)


Job card

Activity and additional job cards necessary for its execution


Removing and installing connecting pipe
(Railway)

W 06-02-05
W 07-01-04
(Railway)
Removing and installing the turbocharger
W 06-06-04
W 06-02-03

W 06-06-04

Removing and installing turbocharger (A-bank)


(Railway)

W 06-06-04

Removing and installing turbocharger (B-bank)


(Railway)

Removing and installing charge air pipe (A-bank)


W 06-07-03
W 03-01-11

W 06-02-05

W 07-03-01
(A-bank)

Removing and installing charge air pipe (B-bank)


W 06-07-03
(B-bank)

W 06-02-05

W 07-03-01
(B-bank)

07 Fuel system
Job card

Activity and additional job cards necessary for its execution


Removing and installing flame glow plug

W 07-01-02
W 07-01-04
Removing and installing flame glow plug (Railway)
W 07-01-02

W 07-01-04
(Railway)
Removing and installing fuel shut-off valve (flame glow plugs)

W 07-01-03
Removing and installing fuel shut-off valve (flame glow plugs) (Railway)
W 07-01-03
Removing and installing fuel pipes (flame glow plugs)
W 07-01-04
W 06-02-03
Removing and installing fuel pipes (flame glow plugs) (Railway)
W 07-01-04
Renewing injection pipes (A-bank)
W 07-03-01

06/2006

19/22

8146-001

TCD 2015

Job card overview


07 Fuel system (continuation)
Job card

Activity and additional job cards necessary for its execution


Renewing injection pipes (B-bank)

W 07-03-01
W 06-02-03
Removing and installing injection pumps (cylinder A1)
W 07-04-01
W 04-06-03

W 06-07-03
(A-bank)

W 07-10-06

W 07-10-06
(Railway)

Removing and installing injection pumps (cylinder A2-B3)

W 07-04-01

W 03-01-11

W 04-06-03

W 07-03-01
(A-bank)

W 07-03-01
(B-bank)

W 07-10-06

W 06-06-04
(B-bank)
(Railway)

W 07-04-01
(cylinder A1)

W 07-10-06
(Railway)
Checking and setting plunger lift of injection pumps

W 07-06-04

W 04-06-03

W 06-06-04

W 06-06-04
(A-bank)
(Railway)

W 07-04-01
(cylinder A2-B3)
Removing and installing the fuel injectors
W 07-07-01

W 07-03-01
(A-bank)

W 07-03-01
(B-bank)

W 07-07-05

Dismantling and assembling fuel injector


W 07-07-02
W 07-07-01

W 07-07-05

Checking and setting fuel injectors


W 07-07-05
W 07-07-01

W 07-07-02

Removing and installing temperature transmitter


W 07-09-01

W 06-07-03
(B-bank)
Removing and installing fuel pipes

W 07-10-06

W 07-10-06

W 06-07-03
(A-bank)

W 06-07-03
(B-bank)

Removing and installing fuel pipes


(Railway)

Removing and installing the fuel supply pump


W 07-11-01
Removing and installing fuel pressure holding valve
W 07-13-01

06/2006

W 06-07-03
(A-bank)

20/22

8146-001

TCD 2015

Job card overview

07 Fuel system (continuation)


Job card

Activity and additional job cards necessary for its execution

W 07-13-01

Removing and installing fuel pressure holding valve


(Railway)

08 Lube oil system


Job card

Activity and additional job cards necessary for its execution

Removing and installing the oil suction pipe


W 08-04-06
W 08-04-07
Removing and installing oil suction pipe
(Railway)
W 08-04-06
W 08-04-07
(Railway)
Removing and installing the lubricating oil pan
W 08-04-07
W 13-03-02

W 08-04-07

Removing and installing lubricating oil pan


(Railway)

Removing and installing the oil cooler


W 08-08-02

W 06-07-03
(A-bank)

W 09-08-04

Removing and installing oil pressure pick-up


W 08-11-09
Removing and installing pressurestat
W 08-11-10
W 03-01-11

W 06-07-03
(B-bank)

09 Cooling system
Job card

Activity and additional job cards necessary for its execution


Removing and installing coolant pump

W 09-07-08
Checking thermostat (removed state)
W 09-08-01
W 09-08-02
Removing and installing thermostat
W 09-08-02
W 09-08-01

W 09-08-04

Removing and installing thermostat housing


W 09-08-04
W 07-01-04

06/2006

21/22

8146-001

TCD 2015

Job card overview


09 Cooling system (continuation)
Job card

Activity and additional job cards necessary for its execution


Removing and installing temperature transmitter

W 09-12-01

12 Other components
Job card

Activity and additional job cards necessary for its execution


Removing and installing torsional vibration damper

W 12-01-04
Removing and installing flywheel
W 12-06-01
Renewing toothed starter flywheel ring
W 12-06-03
W 12-06-01
Removing and installing hydraulic pump drive
W 12-08-04

W 06-01-06
(A-bank)

13 Electrical system
Job card

Activity and additional job cards necessary for its execution


Removing and installing the cable harness

W 13-01-02
W 06-02-03
Removing and installing the generator (V-belt drive)
W 13-02-03
Removing and installing the starter
W 13-03-02
Removing and installing pressure sensor/temperature sensor (charge air)
W 13-08-01

06/2006

22/22

8146-001

DEUTZ engines

11/2005

Job cards

Job cards

1/2

8147-001

DEUTZ engines

Job cards

11/2005

2/2

8147-001

General
W 00-02-06

TCD 2015
Checking the compression pressure
Commercial available tools:
Compression pressure
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005

W 01-01-01
W 07-07-01

Special tools:
Connector . . . . . . . . . . . . . . . . . . 100130
Grooved nut wrench . . . . . . . . . . 110130

Checking the compression pressure


z Check and set valve clearance.
 W 01-01-01
z Removing fuel injectors.
 W 07-07-01

z Mount sealing ring (1).


Use sealing ring (1) for fuel injector.

z Insert connector (2).

40640-0

z Tighten union screw with grooved nut wrench.


 A07 001

40643-0

06/2006

1/4

8148-001

General
W 00-02-06

TCD 2015

z Connect adapter (1) to connector.


1

6
40641-0

z Mount the compression tester on the adapter.


z Turn over engine with starter.
 P00 51

40642-0

No.
Kompression in bar
Compression value in bar
Pression
en bar
Dat. _________
10 15 20 25
30 35 40

Zyl.

The measured compression pressure


depends on the starting speed during the
measuring process and the altitude of the
engine installation site. Therefore, limit
values cannot be determined exactly. The
compression pressure measurement is
only recommended as a reference measurement of all cylinders of an engine to each
other. If more than 15% deviation has been
determined, the cause should be determined by disassembling the cylinder unit concerned.

1
2
3
4
5
6
7
8
DBGM

Made in Germany

MOTOMETER
33771-5

06/2006

2/4

8148-001

General
W 00-02-06

TCD 2015
z Remove the compression pressure tester.
z Remove adapter (1).
1

6
40641-0

z Unscrew union screw with grooved nut wrench.

40643-0

z Remove connector (2).


z Remove sealing ring (1).
z Install fuel injectors.
 W 07-07-01
2

40640-0

06/2006

3/4

8148-001

General
W 00-02-06

TCD 2015

06/2006

4/4

8148-001

General
W 00-05-01

TCD 2015
Mounting engine on assembly block and demounting
Commercial available tools:
Lifting gear
Suspension ropes

W 13-02-03

Special tools:
Assembly block incl. adapter plates . . . . . . . . . . . . . . . . . . . . . 6066
Clamping bracket . . . . . . . . . . .6066/151

Different customer scopes are not taken


into account in the repair sequence shown
here, accessories which deviate from the
standard equipment are not shown.

Mounting engine on assembly block


z Remove generator.
 W 13-02-03
1

z Unscrew screws (1).

z Remove heat shield (2).

40644-1

z Screw in eyelet bolts (1).


z Hang engine on workshop crane.
1

40645-0

06/2006

1/6

8149-001

General
W 00-05-01

TCD 2015

z Unscrew all screws (1).


z Remove all mounting feet (2).
1

6
40652-0

z Mount all clamping brackets (1).


z Tighten screws (2).
 A00 001

2
1

2
40646-1

z Unscrew screws (1).


z Remove all mounting feet (2).

2
1
1

40651-0

06/2006

2/6

8149-001

General
W 00-05-01

TCD 2015
z Insert engine in engine block.
z Mount clamping bracket on the adapter plates.
z Align all clamping brackets (1) on the adapter
plates (2) of the assembly block.
z Tighten screws .
 A00 002

6
40649-0

z Align engine on engine block.


z Unhook the engine from the workshop crane.

40653-0

Demounting engine from assembly block


z Hang engine on workshop crane.
z Remove screws.
z Remove all clamping brackets (1) from the adapter
plates (2).
1

z Lift engine off the assembly block.

2
40649-0

06/2006

3/6

8149-001

General
W 00-05-01

TCD 2015

z Mount all mounting feet (1).


z Tighten screws (2).

 A00 003

6
40991-0

z Unscrew screws (2).


z Remove all clamping brackets (1).

2
1

2
40646-1

z Mount all mounting feet (2).


z Tighten all screws (1).
 A00 003

40652-0

06/2006

4/6

8149-001

General
W 00-05-01

TCD 2015
z Set down engine.
z Unhook the engine from the workshop crane.
z Unscrew eyelet bolts (1).

6
40645-0

z Mount heat shield (2).


z Tighten screws (1).
 A13 006
z Install generator.

1
2

 W 13-02-03

40644-1

06/2006

5/6

8149-001

General
W 00-05-01

TCD 2015

06/2006

6/6

8149-001

Cylinder head
W 01-01-01

TCD 2015
Setting valve clearance
Commercial available tools:
Rotation angle disc . . . . . . . . . . . . . 8190
Screwdriver insert for slotted screws. . . . . . . . . . . . . . . . . . . . 8191
Open wrench size 13 . . . . . . . . . . . 8196

W 04-06-03

Allow the engine to cool down for at least


30 minutes before setting the valve clearance. Engine oil temperature < 80 C

Locking agent
DEUTZ DW 59

The following work process describes setting of the valve clearance on an exhaust
valve. The setting procedure for an inlet
valve is analogous under consideration of
the specified rotation angle size.

z Unscrew screws (1).


z Remove cylinder head cover (2).
z Remove gasket.
z Attach turning gear.
 W 04-06-03
2

40627-0

Setting engine to valve overlap


z Turn crankshaft using the turning gear until the valve
overlap of cylinder A1 is reached.
 T01 63

40463-1

06/2006

1/4

8150-001

Cylinder head
W 01-01-01

TCD 2015

Valve overlap means:


The inlet valve starts opening,exhaust
valve closes.

6
40629-0

Arrangement of the inlet and exhaust valves.


IN = inlet valve
EX = exhaust valve

IN

IN

EX

EX

40630-0

Setting valve clearance


z Loosen lock nut (1).
z Press in the adjusting screw (2) to the stop.

2
1

40631-0

06/2006

2/4

8150-001

Cylinder head
W 01-01-01

TCD 2015
z Set the rotation angle disc with a screwdriver insert
at the adjusting screw.
z Fix magnet of rotation angle disc on cylinder head.
z Set rotation angle disc to "0".
Do not rotate adjusting screw.
 P01 61
P01 62

6
40632_1

z Turn the adjusting screw in the direction of the arrow.


 P01 62

40633-0

z Tighten lock nut (1) with open wrench.


 A01 003
Do not rotate adjusting screw.

z Remove rotation angle disc.


Set all other valves according to the valve
setting schematic T01 63.

1
40638_1

06/2006

3/4

8150-001

Cylinder head
W 01-01-01

TCD 2015

z Clean sealing surfaces.


z Mount new gasket (1).
1

Note installation position.


Position gasket over the profile washer (2).

6
40802-0

z Mount cylinder head cover.


Profile washer (1) may not be trapped
underneath the sealing surface (2) of the
cylinder head cover.

40803-0

z Lightly oil screws (1).


z Tighten screws (1).
 A01 005
z Remove turning gear.
 W 04-06-03
1

40804-0

06/2006

4/4

8150-001

Cylinder head
W 01-02-02

TCD 2015

Removing and installing the rocker arm and rocker arm bracket
Commercial available tools:
Feeler gauges

W 01-01-01
W 04-06-03
W 07-03-01 . . . . . . . . . . . . (A-bank)
W 07-03-01 . . . . . . . . . . . . (B-bank)

Locking agent
DEUTZ DW 59

Removing the rocker arm and rocker arm


bracket
1

z Removing high pressure pipes (A-bank).

 W 07-03-01
2

z Removing high pressure pipes (B-bank).


 W 07-03-01
z Unscrew screws (1).
z Remove cylinder head cowling (2).
z Remove gasket.

1
42215-1

z Unscrew screws (arrows).


Loosen screws evenly to avoid tension on
the rocker arm brackets.

z Remove rocker arms (1), (2) and rocker arm


brackets (3) together.

Lay out components in the order in which


they should be installed.

42217-1

06/2006

1/6

8151-001

Cylinder head
W 01-02-02

TCD 2015

z Remove push rods (1).


Lay out components in the order in which
they should be installed.

6
42219-1

z Visually inspect the components.

34824-2

Installing the rocker arm and rocker arm


bracket
z Insert stop rods (1).

Note assignment!

42219-1

06/2006

2/6

8151-001

Cylinder head
W 01-02-02

TCD 2015
The pushrod must be seated with the ball
head in the ladle of the tappet.
z Attach turning gear.
 W 04-06-03

6
40490-0

z Turn crankshaft until reaching the base circle position of inlet and exhaust cams of the respective cylinder.
z Mount rocker arm bracket.

Attention!

The longer side (1) must point upwards.


The ball heads (2) must be seated in the
ladles of the pushrods .

45805-0

z Align rocker arm to the pushrods/valves.


z Tighten screws (1) alternately.

45806-0

06/2006

3/6

8151-001

Cylinder head
W 01-02-02

TCD 2015

Checking axial backlash of the rocker arm


z Measure the axial backlash between the rocker arm
bracket (1) and rocker arm (2) with a feeler gauge.
 P01 75

The rocker arm (2) is on the opposite side


on the rocker arm bracket (3).
3

The setting is made by moving the rocker


arm brackets.

6
42221-1

z Tighten screws (1) alternately.


 A01 002
z Check and set valve clearance.
 W 01-01-01

42222-1

z Clean sealing surfaces.

z Mount new gasket.


z Mount cylinder head cover.
z Fasten screws.

Screw length:
M8 x 80 mm (1)
M8 x 70 mm (2)
M8 x 30 mm (3)

3
42216-1

06/2006

4/6

8151-001

Cylinder head
W 01-02-02

TCD 2015
z Tighten screws .
 A01 004
z Installing high pressure pipes (A-bank)
 W 07-03-01
z Installing high pressure pipes (B-bank)
 W 07-03-01
z Remove turning gear.
 W 04-06-03

6
42223-1

06/2006

5/6

8151-001

Cylinder head
W 01-02-02

TCD 2015

06/2006

6/6

8151-001

Cylinder head
W 01-02-06

TCD 2015

Disassembling, assembling and checking the rocker arm and rocker arm
bracket
Commercial available tools:
Internal measuring device
Micrometer gauge

W 01-02-02

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 170120

Disassembling the rocker arm bracket


z Remove rocker arm and rocker arm bracket.
 W 01-02-02

34824-2

Checking rocker arm (inlet valves)


z Prepare internal measuring device:
Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 28 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge to the reversal point of the pointer to
"0".

34768-2

06/2006

1/6

8152-001

Cylinder head
W 01-02-06

TCD 2015

z Measure rocker arm bore.


 P01 73
When the wear limit is reached the rocker
arm must be renewed.

6
34825-2

z Visually inspect the components.


z Check ball stud (1) and adjusting screws (2) for
wear.

The components must be renewed in case


of excessive wear.
z Check oil channel (3) for free passage.

36749-1

Renewing ball stud


z Place disassembly/assembly tool (1) underneath.
z Press out ball stud.

34827-3

06/2006

2/6

8152-001

Cylinder head
W 01-02-06

TCD 2015
z Mount new ball stud (1).
Notch (2) faces vertically to the rocker arm
shaft.

6
34828_3

z Place disassembly/assembly tool underneath.


z Press in ball stud (1).
z Check oil channel for free passage.

34829_3

Checking rocker arm (exhaust valves)


z Measure rocker arm bore.
 P01 72
When the wear limit is reached the rocker
arm must be renewed.

34830-2

06/2006

3/6

8152-001

Cylinder head
W 01-02-06

TCD 2015

z Visually inspect the components.


z Check ball stud (1) and adjusting screws (2) for
wear.

The components must be renewed in case


of excessive wear.

36750-1

Renewing ball stud


z Place disassembly/assembly tool (1) underneath.
z Press out ball stud.

34832_3

z Place disassembly/assembly tool (1) underneath.


z Press in new ball stud (2).

34833_3

06/2006

4/6

8152-001

Cylinder head
W 01-02-06

TCD 2015
Checking rocker arm shaft
z Measure diameter with micrometer gauge.
 P01 74
When the wear limit is reached the rocker
arm shaft must be renewed.
z Check oil channels for free passage.

6
34834-2

Assembling the rocker arm bracket


z Push rocker arm onto rocker arm shaft.

The oil bores (1) must face upwards and


the recess clearances (2) for the screws of
the rocker arm brackets to the adjusting
screws.

36751-1

z Push rocker arm brackets onto rocker arm shaft.

Attention!
The longer side (1) must point upwards.
The clamping grooves (2) must face the
adjusting screws (3) .
1

45385_1

06/2006

5/6

8152-001

Cylinder head
W 01-02-06

TCD 2015

z Insert all screws (1).


z Install rocker arm and rocker arm bracket.
 W 01-02-02
1

6
34837_3

06/2006

6/6

8152-001

Cylinder head
I 01-04-08

TCD 2015
Grinding the cylinder head sealing surface
Commercial available tools:
Surface milling machine
Roughness measuring unit
Depth-measuring
appliance

W 01-05-01

The relevant manufacturers specifications


must be observed when working with the
surface milling machine.

Prepare cylinder head


z Remove valves.
 W 01-05-01
z Deburr the upper face of the cylinder head.
The upper face of the cylinder head must
be burr-free and free of gasket remains to
guarantee correct clamping of the cylinder
head.

39757-1

Grinding cylinder head surface


z Clamp cylinder head on surface milling machine.
z Align cylinder head.
z Align tool of the surface milling machine with the cylinder head.

39758-1

06/2006

1/4

8153-001

Cylinder head
I 01-04-08

TCD 2015

z Grind cylinder head sealing surface.


z Check the cylinder head sealing surface.
If the cylinder head sealing surface is not
level, recognisable from differences in
colour of the machined surface, the surface must be reground.
The adjustment range of the tool is a
maximum 0.2 mm per grind.

6
39759-1

Checking the cylinder head sealing surface


z Visually inspect the cylinder head sealing surface.
z Visually inspect the combustion chamber surface.
z Measure the roughness of the cylinder head sealing
surface with the roughness measuring instrument.
 P01 93
If the measured value is out of tolerance,
the cylinder head sealing surface must be
remachined with different setting data for
the surface milling machine.

39760-1

z Measure cylinder head height with depth measuring


appliance.
 P01 08
P01 09
When the wear limit is reached, the cylinder head must be renewed.

39761-1

06/2006

2/4

8153-001

Cylinder head
I 01-04-08

TCD 2015
z Remove cylinder head from the surface milling machine.

6
39758-1

z Attach the repair date and company logo to the cylinder head.

Attention!
Do not mark identification on a sealing surface.
Mark the cylinder head after every repair.

z Install valves.
 W 01-05-01

39744-1

06/2006

3/4

8153-001

Cylinder head
I 01-04-08

TCD 2015

06/2006

4/4

8153-001

Cylinder head
W 01-04-04

TCD 2015
Removing and installing cylinder head
Commercial available tools:
Socket wrench insert . . . . . . . . . . . 8016
Rotation angle disc . . . . . . . . . . . . . 8190

W 01-02-02
W 01-04-09
W 06-01-05 . . . . . . . . . . . . (A-bank)
W 06-01-05 . . . . . . . . . . . . (B-bank)
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 06-07-03 . . . . . . . . . . . . (B-bank)
W 07-07-01

Removing the cylinder head


z Remove charge air pipe (A-bank).
 W 06-07-03
z Remove charge air pipe (B-bank).
 W 06-07-03
z Remove exhaust line (A-bank)
 W 06-01-05
z Remove exhaust pipe (B-bank)
 W 06-01-05

40578-0

z Remove rocker arm and rocker arm bracket.


 W 01-02-02
z Removing fuel injectors.
 W 07-07-01
Lay out components in the order in which
they should be installed.

42234-1

06/2006

1/4

8154-001

Cylinder head
W 01-04-04

TCD 2015

z Unscrew screws (1) with the socket wrench insert.


z Remove cylinder head.
z Remove gasket.
z Visually inspect the components.

42235-1

Installing the cylinder head


z Check piston overhang.
 W 01-04-09
Determine the cylinder head gasket separately for every cylinder.

45811_0

z Select new cylinder head gasket according to measured piston overhang.


 P02 75
P02 76
P02 77
Example: Piston overhang = 0.05 mm, corresponds to cylinder head gasket with
1 hole (arrow).

45811_1

06/2006

2/4

8154-001

Cylinder head
W 01-04-04

TCD 2015
z Clean sealing surfaces.
z Fit a new cylinder head gasket.
The sealing surfaces for the cylinder head
gasket must be clean and free of oil.
Label OBEN / TOP facing the cylinder
head.

6
45812_1

z Fit cylinder head.


z Oil the cylinder head screws slightly.

Attention!
Screws can be reused a maximum 3 times
with written documentation.
z Fasten screws.

34976-2

z Tighten screws alternately with rotation angle disc


and socket wrench insert.
 A01 001

40582-0

06/2006

3/4

8154-001

Cylinder head
W 01-04-04

TCD 2015

z Install rocker arm and rocker arm bracket.


 W 01-02-02
z Install fuel injectors.
 W 07-07-01
z Install charge air pipe (A-bank)
 W 06-07-03
z Install charge air pipe (B-bank)
 W 06-07-03
z Install exhaust pipe (A-bank)
 W 06-01-05

z Install exhaust pipe (B-bank)


 W 06-01-05

06/2006

40583-0

4/4

8154-001

Cylinder head
W 01-04-09

TCD 2015
Checking piston overhang
Commercial available tools:
Magnetic measuring stand

8190

W 01-04-04
W 04-06-03

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Measuring instrument with
measuring plate . . . . . . . . . . . . . 100850

Checking piston overhang


z Remove cylinder head.
 W 01-04-04
z Insert screws and washers (1) diagonally opposed.
z Tighten screws until they touch the cylinder liner.

Washers:
Maximum thickness 4 mm
Screw length:
M16 x 90

45424-0

z Attach turning gear.


 W 04-06-03
z Turn the crankshaft until the respective piston is just
in front of the top dead centre (arrow).

45763-0

06/2006

1/4

8155-001

Cylinder head
W 01-04-09

TCD 2015

z Make sure the clamping bushings (arrows) are in


place.

6
45766-0

z Place measuring instrument (1) on measuring


plate (2).

z Insert dial gauges (3) with pre-tension in the measuring instrument.


z Turn the dial until the pointer points to "0".

37242-0

z Place the measuring instrument over the clamping


bushings (arrows).
z Read off measured value of both dial gauges.
z 1st dial gauge:
Note measured value, dimension (a).
z 2nd dial gauge:
Note measured value, dimension (b).

45767-0

06/2006

2/4

8155-001

Cylinder head
W 01-04-09

TCD 2015
z Form and note average value.
Calculation example
Desired:
Dimension x (average value of both dial gauges)
Given:
Measured:
Dimension a (measured value 1st dial gauge)
Dimension b (measured value 2nd dial gauge)
Calculation:
Dimension x = (dimension a + dimension b) : 2
(0.39 mm + 0.45 mm) : 2
Result:
= 0.42 mm

 P02 75
P02 76
P02 77
z Remove measuring instrument.

6
45767-2

z Unscrew screws (1).


z Remove turning gear.
 W 04-06-03
z Install cylinder head.
 W 01-04-04

45424-0

06/2006

3/4

8155-001

Cylinder head
W 01-04-09

TCD 2015

06/2006

4/4

8155-001

Cylinder head
W 01-05-01

TCD 2015
Removing and installing the valves
Commercial available tools:
Slide gauge
Assembly pliers. . . . . . . . . . . . . . . . 8024
Assembly lever . . . . . . . . . . . . . . . . 9017

W 01-04-04

Special tools:
Support bracket . . . . . . . . . . . . . 120900
Base plate. . . . . . . . . . . . . . . . . . 120910
Assembly tool . . . . . . . . . . . . . . . 121410
Assembly sleeves . . . . . . . . . . . . 121420

Removing the valves

z Remove cylinder head.


 W 01-04-04
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.

42227-1

z Install assembly lever (1).


z Press down valve spring with assembly lever.
z Remove both tapper collets (2).

z Remove valve spring plates, valve springs and


valves.
z Remove assembly lever.

2
42337-1

06/2006

1/4

8156-001

Cylinder head
W 01-05-01

TCD 2015

z Disassemble valve stem gasket with assembly plier.

6
42336-1

z Clean cylinder head.


z Check cylinder head.
z Visually inspect the components.

42335-1

Installing the valves


z Measure valve spring length with slide gauge.
 P01 51
When the wear limit is reached, the valve
spring must be renewed.

35856-2

06/2006

2/4

8156-001

Cylinder head
W 01-05-01

TCD 2015
z Oil the valve stem lightly.
z Insert and hold valve.
z Push assembly sleeve (2) over the valve Vgrooves (1).
2

6
42334-1

z Push new valve stem seal onto valve guide over the
assembly sleeve with assembly tool (1).
z Remove assembly sleeve.

42332-1

z Insert valve spring (1).


z Insert valve spring plate (2).

42331-1

06/2006

3/4

8156-001

Cylinder head
W 01-05-01

TCD 2015

z Mount assembly lever.


z Press down the valve spring with the assembly lever
and insert both tapper collets (1).
Make sure the tapper collets fit correctly in
the valve keyway.

6
42330-1

z Remove assembly lever.


z Remove cylinder head from support bracket.
z Install cylinder head.
 W 01-04-04

42329-1

06/2006

4/4

8156-001

Cylinder head
W 01-05-04

TCD 2015
Checking the valves
Commercial available tools:
Micrometer gauge
Slide gauge

W 01-05-01

Clean valves before testing.


When the wear limit is reached, the valve
must be renewed.

Checking valve stem diameter


z Remove valves.
 W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
 P01 31
P01 32

42182-1

Checking valve edge thickness


z Measure valve edge thickness with slide gauge.
 P01 35
P01 36

42183-1

06/2006

1/2

8157-001

Cylinder head
W 01-05-04

TCD 2015

Checking valve head diameter


z Measure valve head diameter with slide gauge.
 P01 37
P01 38
z Install valves.
 W 01-05-01

6
42184-1

06/2006

2/2

8157-001

Cylinder head
W 01-06-03

TCD 2015
Checking the valve guide
Commercial available tools:
Magnetic measuring stand

W 01-05-01

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

New valves are used for testing.


When the wear limit is reached, the valve
guide must be renewed.

Checking the valve guide


z Remove valves.
 W 01-05-01
z Visually inspect valve guide for wear.

40713-0

Measure valve stem clearance


z Mount magnetic measuring stand.
z Insert dial gauge.
z Insert new valve.
z Place stylus under pre-tension on the valve
head (arrow).
z Turn the dial until the pointer points to "0".

40714-0

06/2006

1/2

8158-001

Cylinder head
W 01-06-03

TCD 2015

z Move valve back and forth in direction of arrow.


 P01 33
P01 34
The valve stem ends must be flush with the
valve guide.
The whole tilt distance must be taken into
account.

6
40715-0

z Remove magnetic measuring stand.


z Remove dial gauge.
z Install valves.
 W 01-05-01

40639-0

06/2006

2/2

8158-001

Cylinder head
I 01-06-04

TCD 2015
Renewing the valve guide
(oversize, pressed version)
Commercial available tools:
Reamers
Plug gauges
Cylinder head machining
tool
Press
Press-out pin
Press-in pin
Industrial vacuum cleaner

W 01-05-01
W 01-06-03

Nitrogen (liquid)

The press-in process must be carried out


without interruption as a result of the temperature difference between the cylinder
head and the valve seat insert.
The necessary work steps must be practised before pressing in.

Danger!
Danger of injury, do not touch supercooled
components or the liquid nitrogen!
Wear protective gloves and glasses!

Attention!

The relevant manufacturers specifications


must be observed when working with the
cylinder head machining tool.

Checking the valve guide


z Check valve guides.
 W 01-06-03
z Check valve guide with plug gauge (1).
1

 P01 14
P01 15
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.

39737-1

06/2006

1/6

8159-001

Cylinder head
I 01-06-04

TCD 2015

Pressing out valve guide


z Press out valve guide with press-out pin (1).
1

6
39749-1

Check housing bore for valve guide


z Visually inspect housing bore (arrow).
If the housing bore is heavily scored, the
housing bore must be reamed to the next
oversize dimension.

36630-1

z Check housing bore for valve guide with plug


gauge (1).
 P01 05
P01 06
P01 07

The target area of the plug gauge must be


able to move upwards and downwards with
light suction.
The no-go limit of the gauge plug must not
fit into the housing bore. If the no-go limit
fits, it must be reamed to the next oversize.
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.

39750-1

06/2006

2/6

8159-001

Cylinder head
I 01-06-04

TCD 2015
Prepare housing bore for the valve guide
(oversize)
z Clamp cylinder head on cylinder head machining
tool.
z Seal coolant channels.
z Align cylinder head.

6
39751-1

z Align bore unit and mandrin guide (1) with the housing bore.
The housing bores can have different diameters, a suitable mandrin guide for alignment with the bore unit must therefore be
selected. The mandrin guide must move
easily in the housing bore without noticeable resistance.

39752-1

z Ream housing bore to oversize level.


 P01 06
P01 07

Attention!
The reamer has a left twist and must
always be turned in or out in clockwise
direction. Never turn reamers anti-clockwise. The cuttings resulting from removing
the material can get stuck and damage the
cutting.
z Blow out housing bore with compressed air.

39753-1

06/2006

3/6

8159-001

Cylinder head
I 01-06-04

TCD 2015

z Check housing bore for valve guide with plug


gauge (1).
Use corresponding plug gauge.
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.

6
39750-1

The no-go limit of the gauge plug (1) must


not fit into the housing bore.
If the no-go limit fits, it must be reamed to
the next oversize.
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.

 P01 06
P01 07

39750-1

z Unclamp cylinder head.


z Blast cylinder head clean with compressed air.

39751-1

06/2006

4/6

8159-001

Cylinder head
I 01-06-04

TCD 2015
Press in valve guide
z Mount cylinder head.
z Select valve guide to fit housing bore.
 P01 11
P01 12
P01 13

6
39754-1

z Supercool valve guide in liquid nitrogen.


Use a suitable container for the liquid nitrogen and a suitable tool for inserting and
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
have reached the temperature of the liquid
nitrogen (-196 C).
The valve guide has the correct temperature if the bubbling up process of the nitrogen has finished.

36636-1

z Push valve guide (1) onto press-in pin (2).


Note post-assembly position of the valve
guide.
The remote side (arrow) must face the
press-in pin.

1
2

39755-1

06/2006

5/6

8159-001

Cylinder head
I 01-06-04

TCD 2015

z Press in valve guide until it touches the press-in pin.


z Remove the press-in pin.
z Remove the cylinder head.

6
39756-1

z Attach the repair date and company logo to the cylinder head.

Attention!
Do not mark identification on a sealing surface.
Mark the cylinder head after every repair.

z Install valves.
 W 01-05-01

39744-1

06/2006

6/6

8159-001

Cylinder head
W 01-07-08

TCD 2015
Checking the valve lag
Commercial available tools:
Depth-measuring
appliance

W 01-04-04

Special tools:
Support bracket . . . . . . . . . . . . . 120900
Base plate. . . . . . . . . . . . . . . . . . 120910

Attention!
When the wear limit is reached, the valve
seat insert and/or valve must be renewed.

Checking the valve lag


z Remove cylinder head.

 W 01-04-04
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.

40650_1

z Mount depth measuring appliance on cylinder head


sealing surface.
z Measure valve stand back.
 P01 45
P01 46

42228-1

06/2006

1/2

8160-001

Cylinder head
W 01-07-08

TCD 2015

z Remove cylinder head from support bracket (1).


z Remove support bracket from base plate (2).
1

z Install cylinder head.


 W 01-04-04

6
40650_1

06/2006

2/2

8160-001

Cylinder head
I 01-07-09

TCD 2015
Renewing valve seat insert
(oversize)
Commercial available tools:
Tenon milling machine,
10 mm
Internal measuring device
Slide gauge
Cylinder head machining
tool
Press
Industrial vacuum cleaner
Press-in pin
Upright drilling machine

W 01-05-01
W 01-07-08

Danger!
Danger of injury, do not touch supercooled
components or the liquid nitrogen!
Wear protective gloves and glasses!

Attention!
The press-in process must be carried out
without interruption as a result of the temperature difference between the cylinder
head and the valve seat insert.
The necessary work steps must be practised before pressing in.

Nitrogen (liquid)

The relevant manufacturers specifications


must be observed when working with the
cylinder head machining tool.
The respective valve guide must be available for replacing a valve seat insert.

z Check valve stand back.


 W 01-07-08
z Remove valves.
 W 01-05-01

40639-0

06/2006

1/8

8161-001

Cylinder head
I 01-07-09

TCD 2015

Checking valve seat insert


z Check valve seat inserts (1).
Ensure that the installation location is free
from faults.

6
39739-1

Removing valve seat insert


z Clamp in cylinder head.
z Align valve seat insert with tenon milling machine.

39740-1

z Mill valve seat insert on the sides (arrow) until it can


be removed without tension.

Attention!
Do not damage cylinder head.

39741-1

06/2006

2/8

8161-001

Cylinder head
I 01-07-09

TCD 2015
z Fit protective underlay (arrow).
z Lever valve seat insert out.

Attention!
Do not damage cylinder head.
z Unclamp cylinder head.

6
39742-1

Checking housing bore for valve seat insert


Diagram for measuring the housing bore at
the points "a" and "b", in the centre of
level "1".

36640-1

z Measure housing bore with internal measuring device.


Measuring points see diagram.

z Read off measured value.


 P01 01
P01 02
P01 03
P01 04
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.
39743-1

06/2006

3/8

8161-001

Cylinder head
I 01-07-09

TCD 2015

Alternatively, the diameter of the housing


bore can be determined with the aid of a
measuring guide ring (1).
The measuring guide ring can, for
example, be a valve seat insert turned to
half its size in height which is inserted in
the hole.

6
36641-1

Prepare housing bore for the valve seat


insert (oversize)
z Set cutting tool.
 P01 03
P01 04

36620-1

z Clamp cylinder head on cylinder head machining


tool.
z Seal coolant channels.
z Align cylinder head.

39745-1

06/2006

4/8

8161-001

Cylinder head
I 01-07-09

TCD 2015
The valve guides can have different diameters, a suitable mandrin guide for alignment
with the bore unit must therefore be selected. The mandrin guide must move easily
in the valve guide without noticeable resistance.

z Align bore unit and mandrin guide (1) with the housing bore.

6
39746-1

z Bore housing bore to oversize level.

Attention!
The valve seat insert support (arrow) must
not be machined with the cutting tool.
z Remove chips thoroughly.

36624-1

z Measure housing bore with internal measuring device.


 P01 03
P01 04

39747-1

06/2006

5/8

8161-001

Cylinder head
I 01-07-09

TCD 2015

Press in valve seat insert


z Mount cylinder head.
z Select valve seat insert to fit housing bore.
 P01 21
P01 22
P01 23
P01 24

6
39748-1

z Supercool valve seat insert in liquid nitrogen.


Use a suitable container for the liquid nitrogen and a suitable tool for inserting and
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
have reached the temperature of the liquid
nitrogen (-196 C).
The valve seat insert has the correct temperature if the bubbling up process of the
nitrogen has finished.

36623-1

z Push valve seat insert (1) onto press-in pin (2).


Note installation position.
The valve seat surface must point to the
press-in pin.

36643-1

06/2006

6/8

8161-001

Cylinder head
I 01-07-09

TCD 2015
z Press the valve seat insert (1) with press-in pin (2)
into the housing bore (3) until it is in position (arrow).
z Remove the cylinder head.

z Machine valve seat insert.

1
3

6
36633-1

z Attach the repair date and company logo to the cylinder head.

Attention!
Do not mark identification on a sealing surface.
Mark the cylinder head after every repair.

39744-1

z Install valves.
 W 01-05-01
z Check valve stand back.
 W 01-07-08

40639-0

06/2006

7/8

8161-001

Cylinder head
I 01-07-09

TCD 2015

06/2006

8/8

8161-001

Drive system
W 02-01-04

TCD 2015
Checking axial backlash of crankshaft
(crankshaft removed)
Commercial available tools:
Micrometer gauge
Internal measuring device

8190

W 02-04-01

Checking the axial backlash


z Remove crankshaft.
 W 02-04-01

40485-0

z Set micrometer gauge to 38 mm.


z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".

35825-2

06/2006

1/2

8162-001

Drive system
W 02-01-04

TCD 2015

z Measure locating bearing width


z Note measured value, dimension (a).
 P02 11
P02 12
P02 13

6
42324-1

z Place thrust ring halves on bearing caps (arrows).


z Measure width with micrometer gauge.
z Note measured value, dimension (b).
z Determine axial backlash.
Calculation example
Desired:
Axial backlash
Given:
Measured:
(a) = 38.6 mm
(b) = 38.4 mm
Calculation:
Axial backlash = dimension (a) - dimension (b)
38.6 mm - 38.4 mm
Result:
= 0.2 mm

 P02 34
With deviating axial backlash:
Set axial backlash by changing the thrust
ring halves.

40600-0

z Install crankshaft.
 W 02-04-01

40485-0

06/2006

2/2

8162-001

Drive system
W 02-01-04

TCD 2015
Checking axial backlash of crankshaft
(crankshaft installed)
Commercial available tools:
Magnetic measuring stand
Micrometer gauge
Socket wrench insert, size
24, reinforced
Socket wrench insert . . . . . . . . . . . 8035
Rotation angle disc . . . . . . . . . . . . . 8190

8190

W 03-08-01
W 03-09-01

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

Checking the axial backlash


z Remove genset support.
 W 03-08-01
z Remove rear cover.
 W 03-09-01

40479-0

z Mount magnetic measuring stand.


z Insert dial gauge.
z Apply stylus to the crankshaft end with pre-tension.
z Press crankshaft in direction of arrow.
z Turn the dial until the pointer points to "0".

40589-0

06/2006

1/6

8163-001

Drive system
W 02-01-04

TCD 2015

z Press crankshaft in direction of arrow.


z Read off measured value.
 P02 34
With deviating axial backlash:
Note measured value, dimension (a).
Set axial backlash by changing the thrust
ring halves.

6
40588-0

Changing thrust ring halves


z Unscrew screws (arrows) with the socket wrench
insert 8035.

40593-0

z Unscrew screws (1) with the socket wrench


insert size 24.

z Remove bearing cap (2).


z Remove lower bearing shell.
z Remove bottom thrust ring halves (arrows).
2

1
40594-0

06/2006

2/6

8163-001

Drive system
W 02-01-04

TCD 2015
z Remove top thrust ring halves (arrows).

6
40595-0

z Measure thickness of the top and bottom thrust ring


halves.
z Note measured value, dimension (b).
z Determine thickness of the new thrust ring halves.
 P02 35
P02 36
P02 37
Calculation example
Desired:
Thickness of the new thrust ring halves
Given:
(x) = thickness for standard, oversize
level 1 and 2
(y) = axial backlash (nominal)
(values from the technical data)
Measured:
(a) = 0.4 mm axial backlash (actual)
(b) = 3.26 mm (thickness of the old thrust ring
halves)
Calculation:
(x) - (b) = (c)
3.36 mm - 3.26 mm = 0.1 mm
Dimension (a) - Dimension (c)
Result:
= 0.3 mm
Value must be within the given axial
backlash (y).

43504-0

z Select new thrust ring halves according to calculated


value.

06/2006

3/6

8163-001

Drive system
W 02-01-04

TCD 2015

z Install upper thrust ring halves according to measured axial clearance.


Oil grooves (1) of the thrust ring halves
face the crankshaft web face (2).
Insert thrust ring halves between crankcase and crankshaft web (arrow).

6
40596-0

z Fix thrust ring halves with a little grease to the bearing cap.
z Install lower thrust ring halves according to measured axial backlash.
Use thrust ring halves with guide
lug (arrow).
The oil grooves (1) face the crankshaft web
face.
Bearing cap has identification 3.

40489-0

z Insert bearing cap (1).


The identification "3" on the bearing cap
must be legible from the flywheel side.
z Align bearing cap.
Press the crankshaft to the flywheel side
first and then in the opposite direction.

40598-0

06/2006

4/6

8163-001

Drive system
W 02-01-04

TCD 2015
z Tighten screws (arrows).

Attention!
Screws can be reused a maximum 3 times
with written documentation.

6
40597-0

z Lightly oil screws (1).


z Tighten screws (1).

Attention!
Screws can be reused a maximum 3 times
with written documentation.
1

40599-0

z Tighten screws (arrow) with the socket wrench


insert size 24 and rotation angle disc.
 A02 010

40491-0

06/2006

5/6

8163-001

Drive system
W 02-01-04

TCD 2015

z Tighten screws (arrow) with the socket wrench


insert 8035 and rotation angle disc.
 A02 011

6
40492-0

z Check axial backlash of crankshaft.


 P02 34

45417-0

z Remove magnetic measuring stand.


z Remove dial gauge.
z Install genset support.
 W 03-08-01
z Mount rear cover.
 W 03-09-01

40479-0

06/2006

6/6

8163-001

Drive system
W 02-01-07

TCD 2015
Checking the crankshaft
Commercial available tools:
Magnetic measuring stand
Micrometer gauge
Internal measuring device
Prisms
Hardness tester

W 02-04-01

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

z Remove crankshaft.
 W 02-04-01
z Place crankshaft on prism.

40485-0

z Pull off gear wheel (1).


z Remove friction disc.

40585-0

06/2006

1/6

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TCD 2015

z Visually inspect the components.

6
40586-0

z Position friction disc on parallel pin (2).


Use friction disc with locating hole.
1

z Mount gear wheel (1).

40587-0

z Visually inspect peripheral surfaces (1).


z Visually inspect gear wheel (2).
1

40584-0

06/2006

2/6

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Drive system
W 02-01-07

TCD 2015
z Put hardness tester on journal.

6
34754-2

z Raise stylus (1) and press release (2).


Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.

44445-0

z Read off displayed value (arrow) from hardness tester.


 P02 07
The measured value is to be converted
according to the table of the measuring
device.

43515-1

06/2006

3/6

8164-001

Drive system
W 02-01-07

TCD 2015

Diagram for measuring the journals at the


points 1 and 2 in the levels a and b.

6
36424-2

Checking the diameter of the main bearing


pins
z Measure main bearing pin with micrometer gauge.
 P02 03
P02 04
P02 06
Measuring points see diagram.

42327-1

Checking the diameter of the lifting journals


z Measure lifting journal with micrometer gauge.
 P02 22
P02 23
P02 25
Measuring points see diagram.

42326-1

06/2006

4/6

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Drive system
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TCD 2015
Checking the rotation
z Mount magnetic measuring stand.
z Insert dial gauge.
z Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
z Turn crankshaft evenly and check rotation.
 P02 26
z Remove magnetic measuring stand.
z Remove dial gauge.

6
42325-1

Measuring the fit bearing width


z Set micrometer gauge to 38 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".

35825-2

z Measure bearing width with internal measuring device between thelay-on surfaces of the thrust rings.
 P02 11
P02 12
P02 13

42324-1

06/2006

5/6

8164-001

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W 02-01-07

TCD 2015

z Install crankshaft.
 W 02-04-01

6
40485-0

06/2006

6/6

8164-001

Drive system
W 02-02-02

TCD 2015
Renewing the crankshaft sealing ring
(flywheel side)
Commercial available tools:
Depth-measuring
appliance
Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
Assembly lever . . . . . . . . . . . . . . . . 9017

W 12-06-01

Special tools:
Assembly tool . . . . . . . . . . . . . . . 142650
Self-tapping screw
Washer

Removing the crankshaft sealing ring


z Remove flywheel.
 W 12-06-01
z Loosen crankshaft sealing ring in its seat evenly with
a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.

Attention!
Do not damage the rear cover and crankshaft!

40656-0

z Turn in a self-tapping screw with washer.

42091-2

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Drive system
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TCD 2015

z Pull out the crankshaft sealing ring with assembly lever.

6
36764-1

z Visually inspect all running surfaces.

40657-0

Install crankshaft sealing ring


z Select shim (1).
Use the shim with identification "RepStage".

36756-2

06/2006

2/6

8165-001

Drive system
W 02-02-02

TCD 2015
z Mount shim (1).
Pay attention to alignment of the
clampingbushing (2) and locating hole (3).

2
1
3

6
36755-1

z Turn bolt (1) with thread (2) into crankshaft.


1

36757-1

Use new crankshaft sealing ring.

z Oil the sealing lip of the crankshaft sealing ring lightly.


z Place the crankshaft sealing ring carefully on the peripheral surface.
The sealing lip faces the crankcase.

36758-1

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3/6

8165-001

Drive system
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TCD 2015

z Place assembly sleeve (1) on bolt (2).


z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.
1

2
36759-1

z Push pressure cross-member (1) onto bolt (2).


z Mount washers.
z Screw on nuts.
2

36760-1

z Tighten screw (1) until the assembly sleeve (2) is


touching.
z Remove assembly tool.
2

36761-1

06/2006

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TCD 2015
z Check installation depth (1) with depth measuring
appliance.
 P03 25
z Install flywheel.
 W 12-06-01

6
40960-0

06/2006

5/6

8165-001

Drive system
W 02-02-02

TCD 2015

06/2006

6/6

8165-001

Drive system
W 02-02-04

TCD 2015
Renewing the crankshaft sealing ring
(opposite side to flywheel)
Commercial available tools:
Depth-measuring
appliance
Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
Assembly tool . . . . . . . . . . . . . . . 142640
Self-tapping screw
Washer

Removing the crankshaft sealing ring


z Unscrew all screws (1).
z Remove flanged hub with torsional vibration damper
and V-belt pulley.
Block flywheel with suitable tool.

40659-0

z Loosen crankshaft sealing ring in its seat evenly with


a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.

Attention!
Do not damage the genset support and
crankshaft!

40660-0

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1/6

8166-001

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TCD 2015

z Turn in a self-tapping screw with washer.

6
40661-0

z Pull out the crankshaft sealing ring with assembly lever.

40662-0

z Visually inspect all running surfaces.

40663-0

06/2006

2/6

8166-001

Drive system
W 02-02-04

TCD 2015
Install crankshaft sealing ring
z Select shim (1).
Use the shim with identification "RepStage".

6
37153-2

z Mount shim (1).

37211-1

z Turn bolt (1) with thread (2) into crankshaft.


1

37208-1

06/2006

3/6

8166-001

Drive system
W 02-02-04

TCD 2015

Use new crankshaft sealing ring.

z Oil the sealing lip of the crankshaft sealing ring lightly.


z Place the crankshaft sealing ring carefully on the peripheral surface.
The sealing lip faces the crankcase.

6
35203-2

z Place assembly sleeve (1) on bolt (2).


z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.
1

2
35204-2

z Push pressure cross-member (1) onto bolt (2).


z Mount washers.
z Screw on nuts.

1
35205-2

06/2006

4/6

8166-001

Drive system
W 02-02-04

TCD 2015
z Tighten screw (1) until the assembly sleeve (2) is
touching.
z Remove assembly tool.

6
35206-2

z Check installation depth (1) with depth measuring


appliance.
 P03 26

35201-3

z Remove flanged hub with torsional vibration damper


and V-belt pulley.
z Lightly oil screws (1).
Block flywheel with suitable tool.
1

z Tighten all screws (1) alternately.


 A12 030

40659-0

06/2006

5/6

8166-001

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W 02-02-04

TCD 2015

06/2006

6/6

8166-001

Drive system
W 02-03-01

TCD 2015
Checking the con rod
Commercial available tools:
Micrometer gauge
Internal measuring device
Con rod test device

W 02-09-03

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

z Remove piston and connecting rod.


 W 02-09-03

40592-0

Checking small end bush


z Prepare internal measuring device:
Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 52 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

34768-2

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1/10

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TCD 2015

Diagram for measuring the small end bush


at the points "a" and "b" in the
levels "1" and "2".

6
37239-1

z Insert internal measuring device.


z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
 P02 43
Measuring points see diagram.

z Note measured value, dimension (a).

34770-2

Checking piston pin


z Measure piston pin with micrometer gauge.
 P02 61
z Note measured value, dimension (b).

35908-2

06/2006

2/10

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Drive system
W 02-03-01

TCD 2015
Determining piston pin clearance
The piston pin clearance is given by the
difference between the internal diameter of
the small end bush (a) and the piston pin
diameter (b).
 P02 45
P02 62
Calculation example
Desired:
Piston pin clearance
Given:
Measured:
Internal diameter small end bush (a)
(a) = 52.040 mm
Diameter piston pin (b)
(b) = 52.000 mm
Calculation:
Dimension (a) - Dimension (b)
52.040 mm - 52.000 mm
Result:
= 0.040 mm

Checking the con rod bearing bore


z Mount big end bearing cap.

Attention!
Note the assignment of the big end bearing
cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.

34771-2

z Tighten screws .
 A02 020

34772-2

06/2006

3/10

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W 02-03-01

TCD 2015

z Prepare internal measuring device:


Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 95 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

6
36094-1

Diagram for measuring the con rod bearing


bore at the points "a" and "b" in the
levels "1" and "2".

37239-1

z Insert internal measuring device.


z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
 P02 55
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.

34775-2

06/2006

4/10

8167-001

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W 02-03-01

TCD 2015
Checking internal diameter of the con rod
bearing shells
2

z Remove screws.
z Remove the con rod bearing cover.
z Insert bearing shell in the con rod.

Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
anodised rear side (arrow) in the connecting rod.
The anti-rotation lock (1) must lock in
groove (2).

6
36768-1

z Insert bearing shell in the respective big end bearing


cap.

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

36769-1

z Mount big end bearing cap.

Attention!
1

Note the assignment of the big end bearing


cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.

34771-2

06/2006

5/10

8167-001

Drive system
W 02-03-01

TCD 2015

z Tighten screws .
 A02 020

6
34778-2

z Prepare internal measuring device:


Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 91 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

36094-1

Diagram for measuring the inside diameter


of the con rod bearing shells at the
points "a" and "b" in the levels "1" and "2".

37239-1

06/2006

6/10

8167-001

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W 02-03-01

TCD 2015
z Insert internal measuring device.
z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
z Note measured value, dimension (a).
 P02 52
P02 54
If the values up to maximum 0.015 mm are
above the bearing tolerances, the connecting rod can still be used.
When the limit value is reached, the connecting rod must be replaced.

6
34775-2

Checking the diameter of the lifting journals


Diagram for measuring the journals at the
points 1 and 2 in the levels a and b.

36424-2

z Measure lifting journal with micrometer gauge.


 P02 22
P02 23
P02 25
Measuring points see diagram.

z Note measured value, dimension (b).

45399-0

06/2006

7/10

8167-001

Drive system
W 02-03-01

TCD 2015

Determine big end bearing clearance


The big end bearing clearance is given by
the difference between the internal diameter of the big end bearing shell (a) and the
lifting journal diameter (b).
 P02 56
P02 57

Calculation example
Desired:
Big end bearing clearance
Given:
Measured:
Internal diameter big end bearing shell (a)
(a) =88.060 mm
Diameter lifting journal (b)
(b) = 88.000 mm
Calculation:
Dimension (a) - Dimension (b)
88.060 mm - 88.000 mm
Result:
= 0.60 mm

z Remove screws.
z Remove the con rod bearing cover.
z Remove con rod bearing shells.

34778-2

Checking the con rod


Attention!
Aligning the con rod is not permissible.
z Check that the con rod is parallel.
 P02 41
Check con rod without bearing shells on
the con rod test device.
Permissible deviation (a) at a
distance of (x).

35880-2

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TCD 2015
z Check the angle of the con rod.
 P02 42
Permissible deviation from (A) to (B) at a
distance of (x).

6
35881-2

z Install piston and connecting rod.


 W 02-09-03

40592-0

06/2006

9/10

8167-001

Drive system
W 02-03-01

TCD 2015

06/2006

10/10

8167-001

Drive system
I 02-03-03

TCD 2015
Removing and installing small end bush
Commercial available tools:
Press or threaded spindle

Danger!

Special tools:
Base plate. . . . . . . . . . . . . . . . . . 131200
Assembly tool kit. . . . . . . . . . . . . 131210

Danger of injury, do not touch supercooled


components or the liquid nitrogen!

Nitrogen (liquid)
Degreasing agent/cleaning
agent
Compressed air
Heating oven

Attention!

Danger of injury, do not touch hot parts!

Wear protective gloves and glasses!

The press-in process must be carried out


without interruption as a result of the temperature difference between the small end
bush and the connecting rod.
The necessary work steps must be practised before pressing in.
The pressing out of the small end bush is
shown with pneumatic press.
A threaded spilndle can also be used alternatively.

Removing the small end bush


Attention!

Never hammer out the small end bush!


z Insert big end bearing holder (3) in base plate (2).

z Insert removal gauge (1) in base plate.

Attention!
Do not confuse the removal gauge with the
installation gauge!
The groove (arrow) must face the big end
bearing holder.
Make sure the removal gauge is inserted
flush!

2
40404-0

06/2006

1/6

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I 02-03-03

TCD 2015

z Insert the bottom part of the assembly tool (3) into the
removal gauge from below.

z Place the connecting rod (1) on the base plate.

The flat side (arrow) of the connecting rod


must face down.
z Turn the bottom part (3) into the top part (2) of the assembly tool.

6
40403-0

z Align the top part (1) of the assembly tool and removal gauge (2).
The top part of the assembly tool and the
removal gauge are level with the angled
surfaces (arrows) of the big end bearing.
1

40401-0

z Screw the top part (1) and bottom part (2) of the assembly tool together.

2
40402-0

06/2006

2/6

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Drive system
I 02-03-03

TCD 2015
z Align the pneumatic press horizontally on the base
plate.
The press-out die is in the centre above
the top of the assembly tool.

6
36284-2

z Press out the small end bush with slight pressure.


z Clean the bush bore.
The bush bore must be free from grease
and dirt.

36285-2

Installing small end bush


z Insert big end bearing holder (3) in base plate (2).
z Insert installation gauge (1) in base plate.

The groove (arrow) must face the big end


bearing holder.

Make sure the installation gauge is inserted flush.

40405-0

06/2006

3/6

8168-001

Drive system
I 02-03-03

TCD 2015

z Heat up the connecting rod (1).


 P02 47
z Place the connecting rod on the base plate (2).

The flat side (arrow) of the connecting rod


must face down.

40406-0

z Cool down the small end bush (1) in liquid nitrogen.


 P02 46

36288-3

z Place supercooled small end bush (1) on installation


mandrel (3).
The index pin (2) is sitting correctly in the
groove (arrow) of the small end bush.

40407-0

06/2006

4/6

8168-001

Drive system
I 02-03-03

TCD 2015
z Insert installation mandrel (1) with small end bush (2)
in con rod bore.
The small end bush must be insertable in
the connecting rod bore with little force.
Note installation position of the small end
bush.

z Pull out the installation mandrel.


The small end bush may not slip.

6
36290-3

z Check installation position.


Position of the bush joint (arrow) looking at
the flat side of the connecting rod shank.

40968-1

Mechanical machining of the small end


bush is necessary after assembly work.
z Spindle the small end bush to dimension A.
Dimensions

Maximum
dimension

Bore of small
end bush
52.055 mm
dimension A
Piston pin dia52.000 mm
meter
Theoretical
0.063 mm
clearance

Minimum
dimension
52.040 mm
51.992 mm
0.040 mm

39730-2

06/2006

5/6

8168-001

Drive system
I 02-03-03

TCD 2015

06/2006

6/6

8168-001

Drive system
W 02-04-01

TCD 2015
Removing and installing the crankshaft
Commercial available tools:
Socket wrench insert, size
24, reinforced
Socket wrench insert, size
14, reinforced . . . . . . . . . . . . . . . . . 8015
Socket wrench insert, size
22, reinforced . . . . . . . . . . . . . . . . . 8035
Rotation angle disc . . . . . . . . . . . . . 8190

W 02-01-04 . . . . . . . . . . . . (crankshaft
removed)
W 02-01-04 . . . . . . . . . . . . (crankshaft
installed)
W 02-01-07
W 03-08-01
W 03-09-01
W 07-07-01

Special tools:
Turn-over gear . . . . . . . . . . . . . . 100350

Removing crankshaft
z Removing fuel injectors.
 W 07-07-01
z Remove genset support.
 W 03-08-01
z Remove rear cover.
 W 03-09-01

40479-0

z Fasten all screws (1).

40470-0

06/2006

1/14

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TCD 2015

z Mount turning gear (1).

6
40471-0

z Set the counterweights (1) of cylinders A1/B1 at bottom dead centre.

 T00 81
z Turn the crankshaft with the turning gear.
z Unscrew screws (2).
z Remove counterweights (1).
Lay out components in the order in which
they should be installed.

42140-1

z Set the counterweights (1) of cylinders A3/B3 at bottom dead centre.


z Unscrew screws (2).
z Remove counterweights (1).
Lay out components in the order in which
they should be installed.

40480-0

06/2006

2/14

8169-001

Drive system
W 02-04-01

TCD 2015
z Place lifting journal of the respective cylinder at bottom dead centre (BDC).

Attention!
Do not jam the con rods when turning the
crankshaft.

6
40496-0

z Unscrew screws (1) with the socket wrench


insert 8015.
z Remove all big end bearing caps (2).
z Remove bearing shell.
Lay out components in the order in which
they should be installed.
Note order of cylinders.
1

40481-0

Attention!
Do not jam the con rods when turning the
crankshaft.
Do not damage the big end bearing shells.
z Turn the crankshaft with the turning gear evenly.
The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).

1
40482-0

06/2006

3/14

8169-001

Drive system
W 02-04-01

TCD 2015

z Unscrew all screws (1) with the socket wrench


insert 8035.

z Unscrew all screws (2) with the socket wrench


insert size 24.

1
40483-1

z Remove bearing cap (1).


z Remove bearing shell.
z Remove bottom thrust ring halves (arrows).

z Remove all main bearing covers (2).

1 - 2724 A

Note order of cylinders.

2 - 2724 A

4 - 2724 A

Lay out components in the order in which


they should be installed.

3 - 2724 A

z Remove the main bearing shells.

42144-1

z Press the con rods carefully out of the lifting journal.

40484-0

06/2006

4/14

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Drive system
W 02-04-01

TCD 2015
z Remove turn-over gear.
z Lift out the crankshaft.
z Place crankshaft on prism.

6
42145-1

z Remove top thrust ring halves (arrows).


z Remove all main bearing shells (1).
z Remove all big end bearing shells (2).
z Visually inspect the components.
Lay out components in the order in which
they should be installed.

Note order of cylinders.

37041-1

z Check crankshaft.
 W 02-01-07
z Check axial backlash of crankshaft (crankshaft removed).
 W 02-01-04

40485-0

06/2006

5/14

8169-001

Drive system
W 02-04-01

TCD 2015

Installing the crankshaft


z Insert upper main bearing shells.

Attention!

Note the assignment of the bearing shells.


The anti-rotation lock (1) must lock in
groove (2).
2

6
37042-1

z Insert lower main bearing shells in the respective


main bearing cover.

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

37043-1

z Insert bearing shell in the con rod.

Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
anodised rear side in the connecting rod.
The anti-rotation lock (1) must lock in
groove (2).

37044-1

06/2006

6/14

8169-001

Drive system
W 02-04-01

TCD 2015
z Insert big end bearing shells in the respective big end
bearing cap.

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

6
36769-1

z Lightly oil bearing surfaces.

40488-0

z Insert the crankshaft carefully in the crankcase.

Attention!
Do not jam the con rods when inserting the
crankshaft!
z Set the crankshaft in line with the camshaft (1) .
The marking on the crankshaft gear wheel
must be between the marking points on the
camshaft gear wheel.
1

37045-1

06/2006

7/14

8169-001

Drive system
W 02-04-01

TCD 2015

z Fasten all screws (1).


z Mount the turning gear.

6
40470-0

z Install upper thrust ring halves according to measured axial clearance.


The oil grooves (1) face the crankshaft
web face (2).
2

Insert thrust ring halves between crankcase and crankshaft web (arrows).

42180-1

z Install lower thrust ring halves according to measured axial backlash.


z Fix thrust ring halves with a little grease to the bearing cap.
Use thrust ring halves with guide
lug (arrow).
Oil grooves (1) face the crankshaft web
face.
Bearing cap has identification 3.

40489-0

06/2006

8/14

8169-001

Drive system
W 02-04-01

TCD 2015
z Insert bearing cap (1).
z Insert main bearing covers (2).
Note assignment and installation position:

Assignment of the main bearing covers:

Identifications legible from the flywheel


side.

2 - 2724 A

3 - 2724 A

4 - 2724 A

With identification "4" = side opposite flywheel side.

1 - 2724 A

With identification "1" = flywheel side.

6
42146-2

z Fasten all screws (1).

Attention!

Screws can be used a maximum 3 times


with written documentation.

1
42147-1

z Oil the screws lightly.


z Fasten all screws (1).

Attention!
Screws can be used a maximum 3 times
with written documentation.
z Move the crankshaft axially to and fro.
The bearing is aligned in position as a
result.
1

42148-1

06/2006

9/14

8169-001

Drive system
W 02-04-01

TCD 2015

z Tighten all screws (arrow) with the socket wrench insert size 24 and rotation angle disc.
 A02 010

Attention!
Do not jam the main bearing cover.

6
40491-0

z Tighten all screws (arrow) with the socket wrench insert 8035 and rotation angle disc.
 A02 011

40492-0

z Check installation position of the connecting rods.


The flattened side (arrow) faces the flywheel on the A-bank and the genset support
on the B-bank.

37204-1

06/2006

10/14

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Drive system
W 02-04-01

TCD 2015
z Pull con rods carefully on to the lifting journal.

6
42151-1

z Place lifting journal of the respective cylinder at bottom dead centre (BDC).

Attention!
Do not jam the con rods when turning the
crankshaft.

40493-0

z Mount big end bearing cap.

Attention!
Note assignment and installation position:
The identification numbers (1) on the connecting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.
1

37055-1

06/2006

11/14

8169-001

Drive system
W 02-04-01

TCD 2015

z Tighten new screws with the socket wrench insert


8015 and rotation angle disc.
 A02 020

6
37056-1

z Place crankshaft web of the respective cylinder at


bottom dead centre (BDC).
z Pay attention to clamping bushing (1).

42152-1

Attention!
1

Note assignment and installation position:


Assignment of the counterweights:
Counterweight with
identification "1" = flywheel side.
Flattened sides (1) face the main bearing
cover.

37057-2

06/2006

12/14

8169-001

Drive system
W 02-04-01

TCD 2015

z Insert counterweights according to the identification.

6
42153-1

z Oil the screws lightly.


z Tighten screws .
 A02 001

42154-1

z Remove turning gear (1).

40471-0

06/2006

13/14

8169-001

Drive system
W 02-04-01

TCD 2015

z Unscrew all screws (1).

6
40470-0

z Check axial backlash of crankshaft (crankshaft installed).


 W 02-01-04

40494-0

z Mount rear cover.


 W 03-09-01
z Install genset support.
 W 03-08-01
z Install fuel injectors.
 W 07-07-01

40495-0

06/2006

14/14

8169-001

Drive system
W 02-09-03

TCD 2015
Removing and installing the piston and con rod
Commercial available tools:
Locking ring pliers
Socket wrench insert . . . . . . . . . . . 8015
Rotation angle disc . . . . . . . . . . . . . 8190

W 01-04-04
W 02-10-03
W 08-04-06
W 08-04-06 . . . . . . . . . . . . (Railway)

Special tools:
Piston ring compressor . . . . . . . . 130650

Removing the piston and con rod


z Remove cylinder head.
 W 01-04-04
z Insert screws and washers (1) diagonally opposed.
Washers:

Maximum thickness 4 mm
Screw length:
M16 x 90
z Tighten screws until they touch the cylinder liner.

40873-0

z Remove oil suction pipe


 W 08-04-06
z Remove oil suction pipe (Railway).
 W 08-04-06

40591-0

06/2006

1/8

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W 02-09-03

TCD 2015

z Set piston at bottom dead centre (BDC).


z Unscrew screws (1) with the socket wrench insert.

6
42375-1

z Remove big end bearing cover with bearing shell.


Lay out components in the order in which
they should be installed.
Note order of cylinders.
 T00 81
z Visually inspect the components.

40821-0

z Set piston at top dead centre (TDC).


z Remove bearing shell.
z Press out the piston and connection rod.

Attention!
Do not jam the connecting rod in the cylinder liner when removing!
Lay out components in the order in which
they should be installed.
Note order of cylinders.

42376-1

06/2006

2/8

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Drive system
W 02-09-03

TCD 2015
z Visually inspect the components.

6
40592-0

z Remove locking ring with locking ring pliers.


z Press out piston pin.
z Remove locking ring with locking ring pliers.
z Visually inspect the components.

Attention!
Make sure the surface of the piston is flawless.

42377-1

Installing the piston and con rod


z Insert new locking ring.
Ensure that the installation location is free
from faults.

42378-1

06/2006

3/8

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Drive system
W 02-09-03

TCD 2015

z Insert con rod.

Attention!
The concave surface (arrow) of the connecting rod must face the recess (1) for the
piston cooling nozzle on the piston.

6
40967-0

z Oil the piston bolt lightly.


z Insert piston pin in piston.
z Insert new locking ring.
Ensure that the installation location is free
from faults.

42379-1

Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
anodised rear side (arrow) in the connecting rod.
The anti-rotation lock (1) must lock in
groove (2).

z Insert bearing shell in the con rod.


1

36768-1

06/2006

4/8

8170-001

Drive system
W 02-09-03

TCD 2015
z Insert bearing shell in the respective big end bearing
cap.

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

6
36769-1

z Arrange the piston ring joints with an offset of


about 120 to each other.
z Check piston rings and piston ring grooves.
 W 02-10-03

42380-1

z Lightly oil cylinder running surface, piston, piston


rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.

36771-1

06/2006

5/8

8170-001

Drive system
W 02-09-03

TCD 2015

z Set lifting journal at bottom dead centre (BDC).


z Push piston and con rod completely into cylinder liner.
Note the cylinder assignment of the piston.
Note identification (1) of the installation
position on the piston base.
1

The arrow must point to the exhaust gas


side.
The piston ring compressor must lie flat on
the cylinder liner.

6
36772-1

z Check installation position of the connecting rods.

Attention!
The flattened side (1) must face the adjacent lifting crank web (2).

1
2

40964-1

z Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.
Do not damage the piston cooling nozzle.

42381-1

06/2006

6/8

8170-001

Drive system
W 02-09-03

TCD 2015
z Mount big end bearing cap.

Attention!
Note the assignment of the big end bearing
cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.

6
42382-1

z Tighten new screws with the socket wrench insert


and rotation angle disc.
 A02 020

42383-1

z Install oil suction pipe.


 W 08-04-06
z Install oil suction pipe (Railway).
 W 08-04-06

40591-0

06/2006

7/8

8170-001

Drive system
W 02-09-03

TCD 2015

z Unscrew screws with washers (1).


z Install cylinder head.
 W 01-04-04
1

6
40873-0

06/2006

8/8

8170-001

Drive system
W 02-09-07

TCD 2015
Checking the piston
Commercial available tools:
Micrometer gauge
Internal measuring device

W 02-09-03

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

When the piston wear limit is reached, the


piston must be renewed.

Checking the piston bolt bore


z Remove piston and connecting rod.
 W 02-09-03

42229-1

z Prepare internal measuring device:


Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 52 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

34768-2

06/2006

1/4

8171-001

Drive system
W 02-09-07

TCD 2015

Diagram for measuring the piston bolt bore


at the points "a" and "b" in the
levels "1" and "2".

6
37239-1

z Insert internal measuring device.


z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
 P02 78
Measuring points see diagram.

36484-2

Checking the piston diameter


Diagram for measuring the piston diameter
at the measuring points "1, 2 and 3", transverse to the piston bolt bore.

3
2
1

37244-1

06/2006

2/4

8171-001

Drive system
W 02-09-07

TCD 2015
z Measure diameter with micrometer gauge.
Measuring points see diagram.
 P02 71
P02 72
P02 73

6
40969-0

z Install piston and connecting rod.


 W 02-09-03

40592-0

06/2006

3/4

8171-001

Drive system
W 02-09-07

TCD 2015

06/2006

4/4

8171-001

Drive system
W 02-10-03

TCD 2015
Checking the piston rings and piston ring grooves
Commercial available tools:
Feeler gauges

W 02-09-03

Special tools:
Universal piston ring pliers . . . . . 130300
Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . . 130400

Checking the piston rings and piston ring


grooves
z Remove piston and connecting rod.
 W 02-09-03
z Set universal piston ring pliers to the piston diameter.
 P02 73
z Remove piston rings with universal piston ring pliers.

42323-1

z Clean piston.
z Clean piston ring grooves.
z Visually inspect the components.

42322-1

06/2006

1/4

8172-001

Drive system
W 02-10-03

TCD 2015

z Measure piston ring groove for first piston ring with


trapezoidal groove wear gauge.

6
33866-2

If there is a gap "S" between the trapezoidal groove wear gauge and piston, the
piston can be used again.

33867-2

If the trapezoidal groove wear gauge is


touching the piston (arrow), the piston
must be changed.

33868-2

06/2006

2/4

8172-001

Drive system
W 02-10-03

TCD 2015
Checking the piston ring joint clearance
z Insert the piston ring (1) in the cylinder.
z Align the piston ring in the cylinder by pushing the
piston.

6
42321-1

z Measure the piston ring joint clearance with a feeler


gauge.
 P02 84
P02 85
P02 86
When the wear limit is reached, the piston
ring must be renewed.

42320-1

Installing piston rings


Order and position of the piston rings as
seen from the piston base:

- Double-sided keystone ring (1)

- Taper-faced ring (2)


- Bevelland-edge oil control ring with coiled
spring expander (3)

Identification Top in (1) and (2) facing


combustion chamber

42319-1

06/2006

3/4

8172-001

Drive system
W 02-10-03

TCD 2015

z Install piston rings with universal piston ring pliers.


Set spring joint of the bevelland-edge oil
control ring 180 to the ring joint.

6
42318-1

Checking the piston ring axial clearance


Check with new piston rings.

z Check axial backlash with feeler gauge between piston ring and piston ring groove.
 P02 88
P02 89
When the piston wear limit is reached, the
piston must be renewed.

42317-1

z Install piston and connecting rod.


 W 02-09-03

40592-0

06/2006

4/4

8172-001

Drive system
W 02-15-01

TCD 2015
Removing and installing the piston cooling nozzle
Commercial available tools

W 02-09-03

Special tools:
Tester . . . . . . . . . . . . . . . . . . . . . 102560
Dipstick . . . . . . . . . . . . . . . . . . . . 102565

Removing the piston cooling nozzle


z Remove piston and connecting rod.
 W 02-09-03
z Unscrew relief valve (1).

z Remove piston cooling nozzle (2).

42353-1

Installing the piston cooling nozzle


z Mount piston cooling nozzle.
z Screw on the relief valve hand tight.
The flattened side (1) faces the cylinder
liner.
1

42354-1

06/2006

1/4

8173-001

Drive system
W 02-15-01

TCD 2015

Check the jet position of the piston cooling


nozzle.
Attention!
Do not damage the cylinder liner when
inserting the tester.

z Insert tester in cylinder liner.


z Set tester with the bores (1) over the clamping
bushings (2).

6
40787-0

z Insert dipstick (1) in the bores (2) of the tester.

42356-2

z Insert the tip of the dipstick (1) without using force


into the opening in the piston cooling nozzle (2).
The piston cooling nozzle must be turned.

Attention!
If it cannot be turned, the piston cooling
nozzle must be renewed!
The piston cooling nozzle may not be bent!
The piston cooling nozzle must be in line
with the dipstick!

42357-1

06/2006

2/4

8173-001

Drive system
W 02-15-01

TCD 2015
z Tighten the relief valve.
 A08 081

Attention!
Make sure the piston cooling nozzle is not
twisted!

6
42358-1

z Remove the dipstick.


z Remove the tester.
z Install piston and connecting rod.
 W 02-09-03

40992-0

06/2006

3/4

8173-001

Drive system
W 02-15-01

TCD 2015

06/2006

4/4

8173-001

Crankcase
W 03-01-11

TCD 2015
Removing and installing the crankcase breather
(oil separator)
Commercial available tools

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing the crankcase bleeding


z Unscrew screw (1).

40664-0

z Loosen hose clip (1).


z Loosen hose clip (2).
z Pull out pipe (3).
z Remove intake elbow (4).
1

45807-0

06/2006

1/6

8174-001

Crankcase
W 03-01-11

TCD 2015

z Loosen hose clips (1).

6
40667-0

z Loosen pipe clamp (1).

40668-0

z Pull out oil separator (1) together with pipe.

40669-0

06/2006

2/6

8174-001

Crankcase
W 03-01-11

TCD 2015
z Pull off pipe (1).
1

6
45401-0

z Visually inspect the components.

40671-0

Install crankcase bleeding


z Mount pipe (1).

z Fill oil syphon (2) with engine oil.

40670-0

06/2006

3/6

8174-001

Crankcase
W 03-01-11

TCD 2015

z Insert oil separator (1) in flanged pipe (2).


Do not move the spring (arrow).
1

2
40672-0

z Mount intake elbow (4).


Note installation position.

z Position hose clip (1).


z Tighten hose clip (1).

 A06 021
z Mount pipe (3).
z Position hose clip (2).
z Tighten hose clip (2).
 A03 064

45807-0

z Position pipe clamp (1).


z Tighten pipe clip (1).
 A03 060

45808-0

06/2006

4/6

8174-001

Crankcase
W 03-01-11

TCD 2015
z Position hose clips (1).
z Tighten hose clips (1).
 A03 064
1

6
40667-0

z Tighten screw (1).


 A03 069

40664-0

06/2006

5/6

8174-001

Crankcase
W 03-01-11

TCD 2015

06/2006

6/6

8174-001

Crankcase
W 03-03-01

TCD 2015
Testing the cylinder liner
Commercial available tools:
Depth-measuring
appliance
Micrometer gauge
Internal measuring device

W 03-03-02

The following work sequence must be carried out on every cylinder unit of a cylinder
bank.

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

Testing the cylinder liner


z Remove cylinder liner.
 W 03-03-02
z Visually inspect the cylinder running surface.

45423-0

z Prepare internal measuring device:


Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 42 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

36094-1

06/2006

1/4

8175-001

Crankcase
W 03-03-01

TCD 2015

Diagram for measuring the cylinder running surface at the points "a" and "b" in the
levels "1 - 4".
1

37238-1

z Remove shim ring (1).


z Visually inspect collar rest (arrow).

z Visually inspect sealing surface.

40677-0

z Insert internal measuring device.


z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
 P03 31
Measuring points see diagram.
When the wear limit is reached, the cylinder liner must be renewed.

42394-1

06/2006

2/4

8175-001

Crankcase
W 03-03-01

TCD 2015
z Measure collar height in area (X) with micrometer
gauge.
 P03 36

Carry out the measurement at several places on the collar rest.


z Install cylinder liner.
 W 03-03-02

6
42395-1

06/2006

3/4

8175-001

Crankcase
W 03-03-01

TCD 2015

06/2006

4/4

8175-001

Crankcase
W 03-03-02

TCD 2015
Removing and installing the cylinder liner
Commercial available tools:
Depth-measuring
appliance

W 02-09-03
W 03-03-01
W 03-03-08

Special tools:
Assembly device. . . . . . . . . . . . . 150120
Extraction tool . . . . . . . . . . . . . . . 150130
Fitting compound
DEUTZ AP1908

Removing the cylinder liner


z Remove piston and connecting rod.
 W 02-09-03

40826-0

z Mark installation position of the cylinder liner on the


crankcase.
z Mark cylinder liner with the cylinder designation.

51521-1

06/2006

1/6

8176-001

Crankcase
W 03-03-02

TCD 2015

z Fold back plate and insert puller.


Place the plate (1) with the lay-on surfaces against
the cylinder liner (2) and hold them together.
Mount the counter holder (3) on the crankcase (4) .

Attention!

Do not damage the peripheral surfaces


and the sealing surfaces.
Do not damage the piston cooling nozzle.
The counterweights of the crankshaft face
the lubricating oil pan.
4

6
36782-1

z Pull the cylinder liner up and out.


Turn the nut in the direction of the arrow.

z Remove the disassembly device.


z Pull the cylinder liner up and out.

42230-1

z Remove shim ring (1).


z Visually inspect collar rest (arrow).

z Visually inspect sealing surface.

40677-0

06/2006

2/6

8176-001

Crankcase
W 03-03-02

TCD 2015
z Remove both O-rings (arrows).
z Test the cylinder liners.
 W 03-03-01

6
42231-1

Install cylinder liner


z Insert new O-rings (arrows).
Pull the O-rings apart slightly to prevent
them falling out during assembly.

42231-1

z Measure collar rest with depth measuring appliance.


 P03 35
Carry out the measurement at several places on the collar rest.

42392-1

06/2006

3/6

8176-001

Crankcase
W 03-03-02

TCD 2015

z Insert shim ring (1).


1

A centring lug (2) points up.

6
39911-0

z Coat the cylinder liner in the "X" area with fitting compound.
Make sure that the liner surface and the
crankcase are absolutely clean before
installing the cylinder liner.

34932-1

z Insert the cylinder liner (1) in the crankcase.


1

39918-0

06/2006

4/6

8176-001

Crankcase
W 03-03-02

TCD 2015
z Screw in retaining pins (1).
Screw retaining pins into a threaded bore
for screws of the cylinder head.
z Mount pressure plate (2) on cylinder liner.
2

Make sure the pressure plate is fit evenly.

6
42232-1

z Press in cylinder liner to stop.


z Remove the assembly device.

42233-1

z Check the overhang of the cylinder liner.


 W 03-03-08
z Install piston and connecting rod.
 W 02-09-03

40583-0

06/2006

5/6

8176-001

Crankcase
W 03-03-02

TCD 2015

06/2006

6/6

8176-001

Crankcase
W 03-03-08

TCD 2015
Checking the overhang of the cylinder liner
Commercial available tools:
Magnetic measuring stand

W 01-04-04

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

Checking the overhang of the cylinder liner


z Remove cylinder head.
 W 01-04-04
z Insert screws and washers (1) diagonally opposed.

z Tighten screws until they touch the cylinder liner.


Washers:
Maximum thickness 4 mm
Screw length:
M16 x 90

45424-0

z Mount magnetic measuring stand.


z Insert dial gauge.
z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow).
z Turn the dial until the pointer points to "0".

45762-0

06/2006

1/2

8177-001

Crankcase
W 03-03-08

TCD 2015

z Loosen magnetic measuring stand.


z Turn the magnetic measuring stand carefully until the
stylus is touching the sealing surface of the cylinder
liner (arrow).
z Mount magnetic measuring stand.
z Read off measured value.
 P03 39
Make measurements at at least 3 other
points on the cylinder liner.

6
45761-0

z Unscrew screws (1).


z Install cylinder head.
 W 01-04-04

45424-0

06/2006

2/2

8177-001

Crankcase
W 03-08-01

TCD 2015
Removing and installing genset support
Commercial available tools:
Open wrench size SW 22

W 02-02-04
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 06-07-03 . . . . . . . . . . . . (B-bank)
W 08-04-06
W 09-07-08
W 09-08-04

Packing compound
DEUTZ DW 47

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing genset support


z Remove charge air pipe (A-bank).
 W 06-07-03
z Remove charge air pipe (B-bank).
 W 06-07-03
z Unscrew screws (1).
z Remove the holder (2).

2
1

40519-0

z Unscrew screw (1).


z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings (4).
1
2

40520-1

06/2006

1/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Unscrew nut (1).


z Remove the holder (2).

1
2

6
40521-0

z Unscrew hollow screw (1).


Hold overflow valve.

z Remove fuel pipe (3).


z Remove sealing rings (2).
1
3

45803_0

z Remove thermostat housing.


 W 09-08-04
z Remove coolant pump.
 W 09-07-08

z Unscrew all screws (1).


z Remove flanged hub with torsional vibration damper
and V-belt pulley.
Block flywheel with suitable tool.

40531-0

06/2006

2/14

8178-001

Crankcase
W 03-08-01

TCD 2015
z Remove cable tie (1).

6
40532-0

z Remove cable tie (1).

40533-0

z Remove cable tie (1).

40534-0

06/2006

3/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Remove oil suction pipe.


 W 08-04-06

6
40535-0

z Unscrew lock nut (1).


z Unscrew hollow screw (2).
z Remove lubricating oil pipe.
z Remove sealing rings.
1

40536-0

z Unscrew screws (1).


z Unscrew screws (2).
1

2
1
40538-0

06/2006

4/14

8178-001

Crankcase
W 03-08-01

TCD 2015
z Unscrew all screws (1).
z Remove holder.

6
40539-0

z Unscrew screws (1).


1

1
40540-0

z Unscrew screws (1).


z Unscrew screws (2).

40541-0

06/2006

5/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Unscrew screws (1).


z Remove genset support.
z Remove gasket.

Attention!
Do not damage the crankshaft journal
when removing the genset support.
The teeth of the oil pump gears and the
idler gear must grip the teeth of the crankshaft drive wheel.

Use suitable workshop crane.

6
40542-0

z Visually inspect the components.

40543-0

z Knock out crankshaft sealing ring (1).

Attention!
Do not damage sealing surface when
knocking out.

40544-0

06/2006

6/14

8178-001

Crankcase
W 03-08-01

TCD 2015
Installing genset support
z Clean sealing surfaces.
z Fix new O-rings (1) with a little grease.
1

6
40545-0

z Fix new gasket (1) to the crankcase with a little


grease.
The oil pan sealing surface on the crankcase must face upwards.

Make sure the parallel pins (arrows) are in


place.

40546-0

z Install genset support.


Use suitable workshop crane.

z Centre genset support above the parallel pins.


z Fix genset support with screws (1).
The teeth of the oil pump gears and the
idler gear must grip the teeth of the crankshaft drive wheel.
Screw length:
M10 x 150 mm

40547-0

06/2006

7/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Tighten screws (1) alternately.


Screw length:

M10 x 150 mm

6
40548-0

z Tighten screws alternately.


Screw length:
M10 x 65 mm (1)
M10 x 100 mm (2)
2

40541-0

z Tighten screws (1) alternately.


Screw length:

M10 x 110 mm
1

1
40540-0

06/2006

8/14

8178-001

Crankcase
W 03-08-01

TCD 2015
z Mount holder.
z Fasten all screws (1).
TIghten screws only after mounting the
connecting pipe.

6
40539-0

z Tighten screws alternately.


Screw length:
M10 x 70 mm (1)

M10 x 110 mm (2)

2
1
40538-0

z Tighten screws alternately.


 A03 020

40551-0

06/2006

9/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Cut off overhanging gasket (arrows) flush with the


sealing surface of the oil tray.

6
40549-0

z Mount new sealing rings.


z Mount the lubricating oil pipe.
z Screw on hollow screw (2).
z Screw on lock nut (1).
1

40536-0

z Tighten hollow screw (2).


 A08 013
z Tighten lock nut (1).
 A08 014

40536-0

06/2006

10/14

8178-001

Crankcase
W 03-08-01

TCD 2015
z Clean sealing surfaces.
z Install oil suction pipe.
 W 08-04-06
Before mounting the lubricating oil pan, fill
in the joints crankcase/genset support
(arrows) with packing compound.

6
40550-0

z Fix the cable strand with cable tie (1) without tension.

40534-0

z Fix the cable strand with cable tie (1) without tension.

40533-0

06/2006

11/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Fix the cable strand with cable tie (1) without tension.
z Install crankshaft sealing ring (opposite side to flywheel)
 W 02-02-04

6
40532-0

z Mount the torsional vibration damper.


z Tighten all screws (1) alternately.
 A12 030
Block flywheel with suitable tool.
1

z Install coolant pump.


 W 09-07-08
z Install thermostat housing.
 W 09-08-04

40531-0

z Insert new sealing rings (3).


z Mount fuel pipe (2).
z Screw on hollow screw (1).

1
3

45803_0

06/2006

12/14

8178-001

Crankcase
W 03-08-01

TCD 2015
z Oil the thread lightly.
z Mount holder (2).
z Screw on nut (1).

1
2

6
40521-0

z Mount new sealing rings (4).


z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1).

1
2

40520-1

z Tighten hollow screw (1).


Hold overflow valve.
 A12 093
z Tighten nut (2).

 A07 044
2

40565-0

06/2006

13/14

8178-001

Crankcase
W 03-08-01

TCD 2015

z Tighten screw (1).


 A07 044
z Tighten hollow screw (2).
 A12 092

1
2

6
40555-0

z Mount holder (2).


z Tighten screws (1).
 A07 044
z Install charge air pipe (A-bank)
 W 06-07-03
z Install charge air pipe (B-bank)
 W 06-07-03

2
1

40519-0

06/2006

14/14

8178-001

Crankcase
W 03-08-03

TCD 2015
Dismantling and assembling genset support
Commercial available tools

W 03-08-01

Dismantling genset support


z Remove genset support.
 W 03-08-01

z Unscrew screw (1).


z Remove thrust washer (2).

z Remove idler gear (3).

40556-0

z Unscrew screws (1).


z Unscrew screws (2).
z Remove lubricating oil pump (3).

2
3

40557-0

06/2006

1/10

8179-001

Crankcase
W 03-08-03

TCD 2015

z Pull out plug element (1).

6
40558-0

z Unscrew nut (1).


z Remove adapter (2).
z Remove O-rings.

2
45371_1

z Unscrew screws (1).


z Remove bearing housing (2).
The fuel supply pump, idler gear and fuel
pipes remain installed on the bearing housing.

z Remove O-ring.

40559-0

06/2006

2/10

8179-001

Crankcase
W 03-08-03

TCD 2015
z Unscrew screws (1).
z Remove ground cable (2).
z Remove holder (3).

1
1

6
40560_1

z Unscrew all screws (1).


z Remove holder.
1

40561-0

z Unscrew all screws (3).


z Unscrew screws (2).
z Remove holder (1).
z Remove oil cooler cover (4).
3

40562_1

06/2006

3/10

8179-001

Crankcase
W 03-08-03

TCD 2015

z Unscrew screws (1).


z Remove oil cooler (2).
z Remove O-rings.

6
40563-0

Assembling genset support


z Clean sealing surfaces.
z Insert new O-rings (1).
z Insert new O-rings (2).
1

40564-0

z Mount oil cooler (2).


z Tighten screws (1).
 A08 051

40563-0

06/2006

4/10

8179-001

Crankcase
W 03-08-03

TCD 2015
z Clean sealing surfaces.
z Mount new gasket.
z Mount oil cooler cover (4).
z Mount holder (1).
z Fasten all screws.

Screw length:
M8 x 35 mm (2)
M8 x 65 mm (3)
2

6
40562_1

z Mount holder (1).


z Fasten all screws (2).

40523-0

z Align oil cooler cover.


The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
1

Do not move gasket.


z Tighten all screws (1) alternately.
 A08 050

40524-0

06/2006

5/10

8179-001

Crankcase
W 03-08-03

TCD 2015

z Unscrew all screws (1).


z Remove holder.
The screws for both holders are not tightened until after mounting the connecting
pipe.

6
40525-0

z Mount holder (3).


z Mount ground cable (2).
z Tighten screws (1).

 A13 018

1
1

40560_1

z Insert new O-ring.


z Insert bearing housing (2).
z Tighten screws (1).
1

 A07 024
2

40559-0

06/2006

6/10

8179-001

Crankcase
W 03-08-03

TCD 2015
z Position O-rings.
z Mount adapter (2).
z Tighten nut (1).
 A08 002

2
45371_1

z Lightly oil O-ring.


z Mount new O-ring (1).
1

40526-0

z Insert plug element (1).

40527-0

06/2006

7/10

8179-001

Crankcase
W 03-08-03

TCD 2015

z Pay attention to clamping bushing (1).

6
40528-0

z Insert new O-ring.

34738-2

z Mount lubricating oil pump (3).


z Oil the screws lightly.
z Fasten screws.

Screw length:
M10 x 75 mm (1)
M8 x 45 mm (2).

2
3

40557-0

06/2006

8/10

8179-001

Crankcase
W 03-08-03

TCD 2015
z Tighten screws (1).
 A08 010
z Tighten screws (2).

 A08 011

2
1

6
40648-0

z Lightly oil journal (1).


z Lightly oil bearing bush (2).

z Mount idler gear (3).


The collar (arrow) of the idler gear faces
the genset support.

2
1

40529-0

z Mount thrust washer (2).


z Fasten screw (1).

The bevelled side (arrow) of the thrust


washer must face upwards.
2

40530-0

06/2006

9/10

8179-001

Crankcase
W 03-08-03

TCD 2015

z Tighten screw (1).


 A04 011
z Install genset support.

 W 03-08-01

6
40537-0

06/2006

10/10

8179-001

Crankcase
W 03-09-01

TCD 2015
Removing and installing rear cover
Commercial available tools

W 02-02-02
W 03-09-04
W 08-04-07

Locking agent
DEUTZ DW 59

Removing rear cover


z Remove connection housing.
 W 03-09-04
1

z Remove lubricating oil pan.


 W 08-04-07
z Unscrew all screws (1).
z Remove rear cover 2.

z Remove gasket.

40684-0

z Knock out crankshaft sealing ring (1).

Attention!
Do not damage the sealing surfaces.

37207-1

06/2006

1/4

8180-001

Crankcase
W 03-09-01

TCD 2015

z Visually inspect the components.

6
40685-0

Installing rear cover


z Clean sealing surfaces.
z Make sure the clamping bushings (arrows) are in
place.
The slots in the clamping bushings must
face downwards.

40686-0

z Insert new seal (1).

40687-0

06/2006

2/4

8180-001

Crankcase
W 03-09-01

TCD 2015
z Mount rear cover.
Use new sealing rings.
1

z Fasten screws.
z Insert screws (1) with locking agent.
Screw length:
M8 x 30 mm (1),(3)
M8 x 45 mm (2)

z Tighten screws alternately.

 A03 010
2

6
40688_1

The gasket (arrows) must be flush with the


sealing surface of the oil pan.

40689-0

z Install lubricating oil pan.


 W 08-04-07
z Install connection housing.
 W 03-09-04
z Renew crankshaft sealing ring (flywheel side).
 W 02-02-02

40655-0

06/2006

3/4

8180-001

Crankcase
W 03-09-01

TCD 2015

06/2006

4/4

8180-001

Crankcase
W 03-09-04

TCD 2015
Removing and installing the connection housing
Commercial available tools:
Rotation angle disc . . . . . . . . . . . . . 8190

W 05-07-01
W 06-01-07
W 12-06-01
W 13-03-02

Locking agent
DEUTZ DW 59

Removing the connection housing


z Install impulse transmitter (crankshaft).
 W 05-07-01
z Remove starter.
 W 13-03-02
z Remove exhaust manifold.
 W 06-01-07
z Remove flywheel.
 W 12-06-01

40690-0

z Unscrew screws (arrows).

40691-0

06/2006

1/6

8181-001

Crankcase
W 03-09-04

TCD 2015

z Unscrew screws (1).


z Unscrew screws (2).
z Remove flange housing (3).

3
40692-0

z Unscrew screws (1).


z Unscrew screws (arrows).

40693-0

z Unscrew all screws (1).


z Remove connection housing.

45394-0

06/2006

2/6

8181-001

Crankcase
W 03-09-04

TCD 2015
z Visually inspect the components.

6
40899-0

Installing the connection housing


z Clean contact surfaces.
z Coat connection housing on lay-on surface (arrow)
with locking agent.

42087-1

Make sure the parallel pins (arrows) are in


place.

40695-0

06/2006

3/6

8181-001

Crankcase
W 03-09-04

TCD 2015

z Mount connection housing.


Centre above the parallel pins.

z Fasten screws.

Insert screws with locking agent.


Note different screw lengths.
M12 x 35 mm (1)

M12 x 90 mm (2).
z Tighten screws (1).
 A03 081

6
40694-0

z Tighten screws (1) alternately.


 A03 082

40696-0

z Fasten screws.
Insert screws with locking agent.
Note different screw lengths.
M12 x 200 mm (1)
M12 x 175 mm (arrows).

z Tighten screws (1) alternately.


 A03 088

40693-0

06/2006

4/6

8181-001

Crankcase
W 03-09-04

TCD 2015
z Tighten screws (arrows).
 A03 089

6
40697-0

z Mount new O-ring (1).


z Coat lay-on surface (arrow) with locking agent.

45409-0

z Mount flange housing (3).


z Lightly oil screws (1).
z Tighten screws (1).
Screw length:
M10 x 110 mm

z Insert screws (2) with locking agent.


z Tighten screws (2).
Screw length:
M10 x 210 mm
z Tighten screws (1).

 A12 058
3

40692-0

06/2006

5/6

8181-001

Crankcase
W 03-09-04

TCD 2015

z Tighten screws (1).


 A12 059

6
40698-0

z Tighten screws (arrows).


 A03 080

40691-0

z Install flywheel.
 W 12-06-01
z Install starter.
 W 13-03-02
z Install impulse transmitter (crankshaft).
 W 05-07-01
z Install exhaust manifold.
 W 06-01-07

40451-0

06/2006

6/6

8181-001

Crankcase
I 03-10-05

TCD 2015
Repairing the collar rest of the cylinder liner
Commercial available tools

W 03-03-02

Special tools:
Tool kit. . . . . . . . . . . . . . . . . . . . . 150030

In case of coolant leakage or damage to


the sealing assembly crankcase/cylinder
liner/cylinder head, the collar rest of the
cylinder liner in the crankcase can be
repaired.

Repair kits
Fitting compound
DEUTZ AP 1908
Cleaning agent (e.g. commerically available brake
cleaner)

The following work sequence must be carried out on every cylinder unit of a cylinder
bank.

Grinding in collar rest surface


z Remove cylinder liner.

 W 03-03-02
z Seal the insides of the crankcase with cover
plates (1).

39914-0

z Clean collar rest (1).


z Clean inside of the crankcase.
Use cleaning agent.

1
39902-0

06/2006

1/8

8182-001

Crankcase
I 03-10-05

TCD 2015

Grinding for cleaning the collar rest


z Apply post-grinding paste (1) to the collar rest (2).

z Add a little clean water.

6
39908-0

z Mount the bracket and handles on the grinding/surface plate.


A

Note the different processing sides of the


grinding/surface plate:
A - grinding side
B - surface side
Grinding side A faces down.
z Place grinding side A on collar rest.

39904-0

z Turn the grinding/surface plate (1) forwards and


backwards evenly (approx. 180).
z Grind the collar rest lightly.
Note soft grinding noise.

z Clean the collar rest.

z Remove grind paste and grinding particles.


Use cleaning agent.

39906-0

06/2006

2/8

8182-001

Crankcase
I 03-10-05

TCD 2015
Check
z Move the bracket on the griding/surface plate.

Spotting side B facing downwards.

z Apply surface paste thinly to the surface side B.


Applying it too thickly makes it impossible
to detect recesses in the collar rest.

6
39916-0

z Place surface side B on collar rest.


Note the different processing sides of the
grinding/surface plate:
A - grinding side
B - surface side
z Surface the collar rest.

39906-1

The surfacing shows up recesses (1) in the


collar rest.
1

39913-0

06/2006

3/8

8182-001

Crankcase
I 03-10-05

TCD 2015

Grinding
z Move the bracket on the griding/surface plate.

Grinding side A faces down.

6
39904-0

z Apply pre-grinding paste (1) to the collar rest (2).


z Add a little clean water.

2
39907-0

z Place grinding side A on collar rest.


z Turn the grinding/surface plate (1) forwards and
backwards evenly (approx. 180).
Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
1

Note rough grinding noise.


z Remove grind paste and grinding particles.
z Clean the collar rest.
Use cleaning agent.

39906-0

06/2006

4/8

8182-001

Crankcase
I 03-10-05

TCD 2015
Check
z Check the contact pattern.
An even contact pattern must exist.
Otherwise, repeat the grinding and surface process.
z Clean the collar rest.

6
39912-0

Regrinding
z Move the bracket on the griding/surface plate.

Grinding side A faces down.

39904-0

z Apply post-grinding paste (1) to the collar rest (2).


z Add a little clean water.

2
39907-0

06/2006

5/8

8182-001

Crankcase
I 03-10-05

TCD 2015

z Turn the grinding/surface plate (1) forwards and


backwards evenly (approx. 180).
Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
Note soft grinding noise.
1

z Clean the collar rest.


z Remove grind paste and grinding particles.
Repeat the surface process to check.

6
39906-0

z Clean inside of the crankcase.


z Remove cover plates (1).
z Check the inside of the crankcase for cleanliness.

The tool set must be cleaned and the grinding/surface plate oiled slightly for corrosion protection.

39914-0

Assembly
z Insert new O-rings (1).
z Coat the O-rings with fitting compound.

39917-0

06/2006

6/8

8182-001

Crankcase
I 03-10-05

TCD 2015
z Insert shim ring (1).
1

A centring lug (2) points up.

6
39911-0

z Insert new cylinder liner (1).


 W 03-03-02
1

39918-0

06/2006

7/8

8182-001

Crankcase
I 03-10-05

TCD 2015

06/2006

8/8

8182-001

Crankcase
W 03-11-01

TCD 2015
Removing and installing, testing camshaft bearing
Commercial available tools:
Micrometer gauge
Internal measuring device

W 04-05-05

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Assembly tool . . . . . . . . . . . . . . . 143830

Testing camshaft bearing


z Remove camshaft.
 W 04-05-05

42126-1

z Prepare internal measuring device:


Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 70 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the meter at the reversal point of the pointer to "0".

34768-2

06/2006

1/8

8183-001

Crankcase
W 03-11-01

TCD 2015

Diagram for measuring the camshaft bearing at the points "a and b" in the
levels "1 and 2".

6
37239-1

z Insert internal measuring device.


z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
 P03 13
P03 14
Measuring points see diagram.
When the wear limit is reached, the camshaft bearing must be replaced.

42127-1

Removing camshaft bearing


z Insert spindle (1) with puller bush (2) on the opposite
side to the flywheel.

2
1
34711-2

06/2006

2/8

8183-001

Crankcase
W 03-11-01

TCD 2015
z Insert counter bearing (1) on the flywheel side.

1
34712-1

z Mount spacing sleeve (1).


z Mount ball bearing (2).
z Screw on nut.
1

34713-2

z Pull out the camshaft bearings one after another.


Do not pull out the camshaft bearing (flywheel side).

34714-2

06/2006

3/8

8183-001

Crankcase
W 03-11-01

TCD 2015

z Insert spindle with puller bush on flywheel side.


z Mount counter bearing (1) on flywheel side.
z Mount spacing sleeve.
z Mount ball bearing.
z Screw on nut.

z Pull out flywheel side camshaft bearing.

6
34716-2

Installing camshaft bearing


Diagram for the installation depth of the
camshaft bearings.

Measuring the depth from the flywheel side


A

mm

172,5

 0,2
 0,2

337,5

 0,2
 0,2

mm

502,5

 0,2
 0,2

mm

mm

45415-1

z Mount the new camshaft bearing (flywheel side) so


that the recess (1) faces the flywheel.
The diagram shows the camshaft bearing
in the installed state.
The camshaft bearing (flywheel side) has
two lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.
1
2
37179-1

06/2006

4/8

8183-001

Crankcase
W 03-11-01

TCD 2015
z Insert spindle with counter bearing on the opposite
side to the flywheel.
z Insert puller bush in camshaft bearing and push onto
the spindle.

6
34718-2

z Mount spacing sleeve.


z Mount ball bearing.
z Screw on nut.
z Press in camshaft bearing (flywheel side).
Installation depth, see diagram.

34720-2

z Check that the lubricating oil bores (1) are in line.


If the lubricating oil bore is not in line, the
camshaft bearing must be removed and reinstalled.

1
40900-0

06/2006

5/8

8183-001

Crankcase
W 03-11-01

TCD 2015

z Mount the new middle camshaft bearings on the opposite side to the flywheel so that the recess (1) faces the flywheel.
1

The diagram shows the camshaft bearing


in the installed state.
The middle camshaft bearings have three
lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.

6
37180-1

z Mount the new camshaft bearing (opposite side to


flywheel) so that the recess (1) faces the flywheel.
The diagram shows the camshaft bearing
in the installed state.

The camshaft bearing (opposite side to flywheel) has three lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.
1

37181-1

z Insert puller bush in camshaft bearing.


z Insert spindle with puller bush on flywheel side.

34723-2

06/2006

6/8

8183-001

Crankcase
W 03-11-01

TCD 2015
z Mount counter bearing.
z Mount spacing sleeve.
z Mount ball bearing.
z Screw on nut.
z Insert the camshaft bearings one after another.

Attention!
Do not damage the camshaft bearings
when moving the assembly tool!
Installation depth, see diagram.

6
34714-2

z Check that the lubricating oil bores (1) are in line.


If the lubricating oil bore is not in line, the
camshaft bearing must be removed and reinstalled.
z Install the camshaft.

 W 04-05-05

40901-0

06/2006

7/8

8183-001

Crankcase
W 03-11-01

TCD 2015

06/2006

8/8

8183-001

Engine control
W 04-02-02

TCD 2015
Remove and installing tappets, checking tappet bores
Commercial available tools:
Micrometer gauge
Internal measuring device

W 04-05-05

Removing tappets.
z Remove camshaft.
 W 04-05-05
z Remove tappets.
Lay out components in the order in which
they should be installed.
Note order of cylinders.

37198-1

z Visually inspect the components.

40699-0

06/2006

1/2

8184-001

Engine control
W 04-02-02

TCD 2015

Measuring tappet bores


z Set micrometer gauge to 25 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".

6
35825-2

z Measure tappet bore with internal measuring device.


 P03 23
P03 24

X
34707-4

Installing tappets
z Oil all tappets lightly.
z Insert all tappets.
Note the assignment of the tappets.

z Install the camshaft.


 W 04-05-05

37199-1

06/2006

2/2

8184-001

Engine control
W 04-04-09

TCD 2015
Removing and installing the gearcase cover
Commercial available tools

W 06-06-04

Packing compound
DEUTZ DW 48

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing the gearcase


z Remove turbocharger.
 W 06-06-04

40700-0

z Loosen hose clip (1).


z Pull off pipe (2).

1
2

40701-0

06/2006

1/6

8185-001

Engine control
W 04-04-09

TCD 2015

z Unscrew screws (1).

6
40702-0

z Unscrew screws (1).


z Remove spacing sleeves.
z Unscrew all screws (2).
z Remove heat shield (3).

40703-0

z Unscrew screws (1).


z Remove the holder (2).

40704-0

06/2006

2/6

8185-001

Engine control
W 04-04-09

TCD 2015
z Unscrew screw (1).
z Remove pipe clamp (2).

6
40705-0

z Unscrew all screws (1).


z Remove gear case cover (2).
1
2

40706-0

z Visually inspect the components.

40707-0

06/2006

3/6

8185-001

Engine control
W 04-04-09

TCD 2015

Installing the gearcase cover


Attention!
Do not damage the sealing surfaces.

z Clean sealing surfaces.

z Apply packing compound evenly to the sealing surface.


z Mount gear case cover (1).
z Mount holder (2).
z Tighten all screws (3) alternately.
3

 A04 020

6
40708-0

z Mount pipe clamp (2).


z Tighten screw (1).
 A08 045
2

40705-0

z Mount holder (2).


z Tighten screws (1).
 A12 071

40704-0

06/2006

4/6

8185-001

Engine control
W 04-04-09

TCD 2015
z Mount heat shield (3).
z Insert spacing sleeves with screws (1).
z Tighten screws (1).
z Fasten all screws (2).

z Tighten all screws.


 A12 071

6
40703-0

z Tighten screws (1).


 A13 094

40702-0

z Push on pipe (2).


z Tighten hose clip (1).
 A03 064
1
2

40701-0

06/2006

5/6

8185-001

Engine control
W 04-04-09

TCD 2015

z Install the turbocharger.


 W 06-06-04

6
40700-0

06/2006

6/6

8185-001

Engine control
W 04-04-09

TCD 2015 Railway


Removing and installing the gearcase cover
Commercial available tools

W 07-13-01 . . . . . . . . . . . . (Railway)

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing the gearcase


z Unlock cable plug (1) and remove.
z Remove cable tie (2).
z Lay cable bare.

1
2

42108-1

z Unscrew screws (1).


z Remove washers.
z Remove fuel pressure holding valve.
 W 07-13-01

45777-0

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W 04-04-09

TCD 2015 Railway

z Unscrew screw (1).


z Remove washer.

z Remove spacing sleeve (2).


z Loosen pipe clamp (3).

2
1

6
45775-0

z Unscrew screws (1).


z Remove washer.

z Remove the holder (2).


z Remove holder (3).

45776-0

z Unscrew all screws (1).


z Remove gear case cover (2).
z Remove gasket.

2
42416-2

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TCD 2015 Railway


z Visually inspect the components.

6
40707-0

Installing the gearcase cover


z Clean sealing surfaces.
z Mount new gasket.
z Mount gear case cover (1).
z Tighten screws (2) alternately.

 A04 020

2
42416-2

z Mount holder (3).


z Mount holder (2).

z Mount washer.
z Tighten screws (1).
 A12 071

45776-0

06/2006

3/6

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TCD 2015 Railway

z Position pipe clamp (3).


z Position spacing sleeve (2).

z Mount washer.
z Tighten screw (1).
 A12 096
2

6
45775-0

z Position cable harness rail with cable harness.


z Position pipe clamp (1).
z Mount washers.
z Fasten screws.

Note different screw lengths:


M6 x 12 mm (1)
M6 x 16 mm (2)
z Tighten screws .
 A13 094

45778-1

z Install fuel pressure holding valve.


 W 07-13-01

45779-1

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z Plug in the cable plug (1).
Ensure that the cables are connected properly.
z Fix cable with cable tie (2).

1
2

6
42108-1

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W 04-05-05

TCD 2015
Removing and installing the camshaft
Commercial available tools:
Lifting gear
Depth-measuring
appliance
Magnetic measuring stand
Rotation angle disc . . . . . . . . . . . . . 8190

W 01-02-02
W 02-04-01
W 04-05-06
W 05-07-03
W 06-06-04
W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
W 07-06-04

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Counter support . . . . . . . . . . . . . 144150
Packing compound
DEUTZ DW 48
Locking agent
DEUTZ DW 72

Removing the camshaft


z Remove rocker arm brackets.
 W 01-02-02
z Remove crankshaft.
 W 02-04-01
z Remove impulse transmitter (camshaft).
 W 05-07-03

40409-0

z Remove injection pumps (cylinder A1).


 W 07-04-01
z Remove injection pumps (cylinder A2-B3).
 W 07-04-01

Do not remove injection pump housing.


2

z Unscrew hollow screw (1).


z Place fuel hose (2) to one side.
z Remove sealing rings.

40458-0

06/2006

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TCD 2015

z Unscrew screws (1).


z Place cable harness rail (2) with cable harness to
one side.
1
2

6
40410-0

z Unscrew all screws (3).


z Remove spacing sleeves.

z Unscrew all screws (2).


z Remove heat shield (1).

40411-1

z Unscrew screws (1).


z Remove the holder (2).

1
40412-0

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TCD 2015
z Unscrew screw (1).
z Remove pipe clamp (2).

6
40413-0

z Unscrew all screws (1).


z Remove gear case cover (2).

40414-0

z Remove cable tie (1).

40415-0

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z Unscrew screws (1).


z Remove cover (2) .
z Remove cover (3).

3
2

6
40416-0

z Unscrew screws (1).


z Remove pad thrust bearing (2).

40417-0

z Unscrew all screws (1).


z Remove gear wheel (2).

Attention!

Make sure no parts fall into the crankcase!


Concealed screws can be accessed by
turning the crankshaft with the turning gear.
Press back the injection pump camshaft
carefully as far as it goes.

40418-0

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z Unscrew screw (1).

6
40419-0

z Unscrew screw (1).

40420-0

z Remove bolt (1).


z Remove idler gear (2).

40421-0

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TCD 2015

z Unscrew screw (1).

6
40422-0

z Unscrew screw (1).

40423-0

z Remove bolt (1).


z Remove idler gear (2).

40424-0

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z Unscrew all screws (1).
z Remove cover (2) .
z Remove gasket.

6
40425-0

z Insert counter support (1) in the toothing of the camshaft gear wheel.

40426-0

z Turn the camshaft gear wheel in the direction of


the A-bank.
z Block the camshaft gear wheel with the counter holder on the crankcase (arrow).

40427-0

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TCD 2015

z Loosen screw (1).


z Turn back the camshaft gear wheel.
z Remove counter holder (2).

6
40428-0

z Unscrew screw (1).


z Remove camshaft toothed wheel (2).
Press back the injection pump camshaft
carefully as far as it goes.
2

40429-0

z Turn engine 180.


z Press in all tappets.
z Hang engine on workshop crane.
z Unhook the engine from the assembly block on one
side.
z Pull out the camshaft (1) carefully to the flywheel
side.
1

40430-0

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z Check camshaft.
 W 04-05-06

6
36812-1

Installing the camshaft


z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
z Insert camshaft carefully.
The locating hole (1) of the camshaft faces
towards the lubricating oil pan.

37079-1

z Measure the overhang of the parallel pin with the


depth measuring appliance.
 P04 39
z Correct overhang.

40431-0

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z Insert camshaft gear wheel (2).


z Lightly oil screw (1).
z Fasten screw (1).
Make sure that the parallel pin on the
camshaft gear wheel and the locating hole
on the camshaft are in line.

6
40429-0

z Insert counter support (1) in the toothing of the camshaft gear wheel.
z Turn the camshaft gear wheel in the direction of
the B-bank.
z Block the camshaft gear wheel with the counter holder on the crankcase (arrow).

40432-0

z Tighten screw (arrow).


 A04 001
z Turn back the camshaft gear wheel.
z Remove counter holder.

40433-0

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TCD 2015
Determining axial backlash of the camshaft
z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
z Note measured value, dimension (a).

6
40434-0

z Mount new gasket (1).


z Measure the flange height from the running surfaces
to the lay-on surface with the depth measuring appliance (arrows).
z Note measured value, dimension (b).
z Determine axial backlash.
 P04 35
Calculation example
Desired:
Axial backlash
Given:
Measured:
(a) = 45.80 mm
(b) = 45.50 mm
Calculation:
Axial backlash = dimension (a) - dimension (b)
45.80 mm - 45.50 mm
Result:
= 0.30 mm

z Correct deviation with gaskets.

42273-2

 P04 37
z Mount cover (2).
Insert screws with locking agent.

z Fit new sealing rings.


z Tighten all screws (1).

 A04 002

40425-0

06/2006

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TCD 2015

z Mount new O-ring (1).


z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
40435-0

z Lightly oil bearing liner (1) with engine oil.


z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

40438-0

z Insert bolt (1).

40437-0

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z Lightly oil screw (1).
z Tighten screw (1).
 A04 013
Screw length:
M12 x 80 mm

6
40423-0

z Lightly oil screw (1).


z Tighten screw (1).
 A04 012

40422-0

z Mount new O-ring (1).


z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
40435-0

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z Lightly oil bearing liner (1) with engine oil.


z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

40436-0

z Insert bolt (1).

40439-0

z Lightly oil screw (1).


z Tighten screw (1).
 A04 013
Screw length:

M12 x 100 mm

40420-0

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z Lightly oil screw (1).
z Tighten screw (1).
 A04 012
1

6
40419-0

Checking the tooth edge clearance of the


idler gear (B-bank)
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

40440-0

z Turn idler gear in direction of arrow until it stops.


z Read off measured value.
 P04 44
Repeat the measuring process on several
tooth flanks.
z Remove magnetic measuring stand.
z Remove dial gauge.

40441-0

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Checking the tooth edge clearance of the


idler gear (A-bank)
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

6
40442-0

z Turn idler gear in direction of arrow until it stops.


z Read off measured value.
 P04 44
Repeat the measuring process on several
tooth flanks.
z Remove magnetic measuring stand.
z Remove dial gauge.

40443-0

z Position the injection pump camshaft.


The locating hole (arrow) faces upwards.

40444-0

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TCD 2015
z Position camshaft gear wheel.
The marking (1) faces towards the crankshaft.

6
42289-1

Overview of the gear train and the markings of the control times:

Injection pump camshaft gear wheel (1)


2

Camshaft gear wheel (2)


Idler gear (3).
Crankshaft gear wheel (4)
Marking injection pump camshaft / idler
gear (5)

Marking camshaft / crankshaft (6)

6
40445-1

z Position injection pump camshaft gear wheel.


The marking (1) faces the camshaft gear
wheel.

40446-0

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z Insert the injection pump camshaft gear wheel in the


camshaft gear wheel.
The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).

40447-0

Attention!
Make sure no parts fall into the crankcase!
z Fasten all screws (1).
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

40448-0

Checking the tooth edge clearance of the


injection pump camshaft gear wheel
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn gear wheel in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

40449-0

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z Turn gear wheel in direction of arrow until it stops.
z Read off measured value.
 P07 20
Repeat the measuring process on several
tooth flanks.
z Remove magnetic measuring stand.
z Remove dial gauge.

6
40450-0

z Install crankshaft.
 W 02-04-01
Do not install the turbocharger.

z Install rocker arm brackets.


 W 01-02-02
z Check and set plunger lift of injection pumps.
 W 07-06-04

40503-0

z Tighten all screws (1).


 A04 004
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

40464-0

06/2006

19/24

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W 04-05-05

TCD 2015

z Mount pad thrust bearing (2).


z Lightly oil screws (1).
z Tighten screws (1).

6
40989-0

Checking and setting axial backlash of the


injection pump camshaft
z Insert feeler gauge blade between gear wheel of the
injection pump camshaft and the pad thrust
bearing (arrow).

z Press the pad thrust bearing onto the feeler gauge


blade.
z Fasten screw (1).
z Check axial backlash.
 P04 43

40512-0

z Insert feeler gauge blade between gear wheel of the


injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1).

z Check axial backlash.


 P04 43

40513-0

06/2006

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TCD 2015
z Tighten screws (1).
 A04 015
z Check axial backlash again.
 P04 43
1

Check axial backlash on both sides between


pad thrust bearing and gear
wheel (arrows).

6
40514-0

z Clean sealing surfaces.


z Mount new O-ring (1).
z Lightly oil O-ring.

40515-0

z Press in the cover (3) to the stop.


z Mount cover (2).
Insert screws with locking agent.

z Tighten screws (1).

 A04 022

40460-0

06/2006

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z Fix cable tie (1).

6
40459-0

z Clean sealing surfaces.


z Apply packing compound evenly to the sealing surface of the gear case.
Use packing compound DEUTZ DW 48.
2

z Mount gear case cover (1).


z Mount holder (2).

z Tighten all screws (3) alternately.


 A04 020
3

40516-0

z Mount pipe clamp (2).


z Tighten screw (1).
 A08 045
2
1

40456-0

06/2006

22/24

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W 04-05-05

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z Mount holder (2).
z Tighten screws (1).
 A12 071

6
40455-0

z Mount heat shield (1).


1

z Insert screws (3) with spacing sleeves.


z Tighten screws (2).
z Tighten screws (2 and 3) alternately.
 A12 071

2
40517-0

z Tighten screws (1).


 A13 094
1

40453-0

06/2006

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TCD 2015

z Mount new sealing rings.


z Position fuel hose (2).
z Tighten hollow screw (1).
 A12 090
1
2

6
40458-0

z Install impulse transmitter (camshaft).


 W 05-07-03
z Install injection pumps (cylinder A1).
 W 07-04-01
z Install injection pumps (cylinder A2-B3).
 W 07-04-01
z Install the turbocharger.
 W 06-06-04

40518-0

06/2006

24/24

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W 04-05-06

TCD 2015
Checking the camshaft
Commercial available tools:
Depth-measuring appliance
Micrometer gauge

W 04-05-05

Checking the camshaft


z Remove camshaft.
 W 04-05-05
z Visually inspect cams and bearing pins for wear.
Repairing the camshaft is not permissible.
The camshaft must be renewed.
z Visually inspect the components.

36812-1

Diagram for measuring the journals at the


points 1 and 2 in the levels a and b.

36424-2

06/2006

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W 04-05-06

TCD 2015

z Measure the diameter of journals with the micrometer gauge.


 P04 31
Measuring points see diagram.
When the wear limit is reached, the camshaft must be renewed.

6
42128-1

Checking the camshaft gear wheel


z Unscrew all screws (1).
1

40601-0

z Remove idler gear (1).


z Visually inspect the idler gear (1) for wear.
2

z Visually inspect the camshaft gear wheel (2) for


wear.
1

40602-1

06/2006

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TCD 2015
z Insert parallel pin (1).
1

6
40603-0

z Measure the overhang of the parallel pin with the


depth measuring appliance.
 P04 39
z Correct overhang.

40604-0

z Place camshaft gear wheel on idler gear.


Note installation position.
2

The marking (1) on the idler gear faces the


camshaft gear wheel.
The markings (1) and (2) must be opposite
in line.

40605-1

06/2006

3/4

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z Lightly oil screws (1).


z Tighten screws (1) alternately.
 A04 003

z Install the camshaft.


 W 04-05-05

6
40601-0

06/2006

4/4

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Engine control
W 04-05-07

TCD 2015
Removing and installing injection pump camshaft
Commercial available tools:
Depth-measuring
appliance
Magnetic measuring stand

W 01-02-02
W 02-02-02
W 03-08-01
W 03-09-04
W 04-06-03
W 05-07-03
W 06-06-04
W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
W 07-06-04

Special tools:
Turn-over gear . . . . . . . . . . . . . . 100350
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Counter support . . . . . . . . . . . . . 144150
Packing compound
DEUTZ DW 48
Locking agent
DEUTZ DW 72

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing injection pump camshaft


z Remove impulse transmitter (camshaft).
 W 05-07-03
z Remove injection pumps (cylinder A1).
 W 07-04-01
z Remove injection pumps (cylinder A2-B3).
 W 07-04-01
z Remove genset support.
 W 03-08-01
z Remove turbocharger.
 W 06-06-04
40497-0

z Unscrew hollow screw (1).


z Place fuel hose (2) to one side.
z Remove sealing rings.
1
2

40458-0

06/2006

1/32

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TCD 2015

z Unscrew screws (1).

6
40453-0

z Unscrew all screws (3).


1

z Remove spacing sleeves.


z Unscrew all screws (2).
z Remove heat shield (1).

2
40517-0

z Unscrew screws (1).


z Remove the holder (2).

40455-0

06/2006

2/32

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W 04-05-07

TCD 2015
z Unscrew screw (1).
z Remove pipe clamp (2).

2
1

6
40456-0

z Unscrew all screws (1).


z Remove gear case cover (2).
1
2

40457-0

z Remove cable tie (1).

40459-0

06/2006

3/32

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TCD 2015

z Unscrew screws (1).


z Remove cover (2) .
z Remove cover (3).
3

6
40460-0

z Unscrew screws (1).


z Remove pad thrust bearing (2).

z Attach turning gear.


 W 04-06-03

40417-0

z Loosen all screws (1).


Concealed screws can be accessed by
turning the crankshaft with the turning gear.

40464-0

06/2006

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W 04-05-07

TCD 2015
z Turn over crankshaft until the valve overlap is
achieved on cylinder no. B2.
 T01 63
Valve overlap means:
The inlet valve starts opening,exhaust
valve closes.

6
40465-0

The locking pin of the turning gear must


snap into the tooth notch (1) of the starter
ring gear.
The second tooth notch (2) must face the
B-bank.

2
40466-0

Attention!
Make sure no parts fall into the crankcase!
z Unscrew screws (1).
z Pull locking pin.
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

40590-0

06/2006

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TCD 2015

z Turn over crankshaft until the valve overlap is


achieved on cylinder no. B2.
z Unscrew screws (1).
z Remove gear wheel (2).

Attention!

Make sure no parts fall into the crankcase!


Press back the injection pump camshaft
carefully as far as it goes.
z Remove turning gear.

 W 04-06-03

6
40467-0

z Remove rocker arm brackets.


 W 01-02-02
z Remove connection housing.
 W 03-09-04
1

z Remove crankcase sealing ring (flywheel side)


 W 02-02-02
z Unscrew screw (1).

40419-0

z Unscrew screw (1).

40420-0

06/2006

6/32

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z Remove bolt (1).
z Remove idler gear (2).

6
40421-0

z Unscrew screw (1).

40422-0

z Unscrew screw (1).

40423-0

06/2006

7/32

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W 04-05-07

TCD 2015

z Remove bolt (1).


z Remove idler gear (2).

6
40424-0

z Unscrew all screws (1).


z Remove cover (2) .
z Remove gasket.
1

40468-0

z Insert counter support (1) in the toothing of the camshaft gear wheel.

40469-1

06/2006

8/32

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TCD 2015
z Fasten all screws (1).

6
40470-0

z Mount turning gear (1).

40471-0

z Turn the camshaft gear wheel in the direction of


the A-bank.
z Block the camshaft gear wheel with the counter holder on the crankcase (arrow).

40472-0

06/2006

9/32

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TCD 2015

z Loosen screw (1).

6
40473-0

z Turn the crankshaft with the turning gear evenly.


The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).

z Remove counter holder.

40474-0

z Unscrew screw (1).


z Remove camshaft gear wheel (2)
Push back the camshaft carefully as far as
it goes.
2

45381-0

06/2006

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TCD 2015
z Tighten screws (1).
z Pull out the injection pump camshaft carefully.

Attention!
Do not damage the camshaft and camshaft
bearing!

6
40475-0

z Visually inspect the components.

40476-0

Installing injection pump camshaft


z Unscrew screw (1).

40993-0

06/2006

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TCD 2015

z Fasten screw (1).


z Pull out cover (2).

6
40994-0

z Oil camshaft bearing lightly.


z Oil cam shaft pin lightly.
z Insert the injection pump camshaft carefully.

40995-0

Attention!
Do not damage the camshaft and camshaft
bearing!
z Move the injection pump camshaft over the opposite
side to the flywheel.
Use a suitable tool.

40996-0

06/2006

12/32

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W 04-05-07

TCD 2015
z Unscrew screws (1).

6
40475-0

z Mount new O-ring (1).


z Lightly oil O-ring.

40997-0

z Mount cover (2).


z Unscrew screw (1).

40994-0

06/2006

13/32

8189-001

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W 04-05-07

TCD 2015

z Lightly oil screw (1).


z Tighten screw (1).
 A04 005

6
40993-0

Installing camshaft gear wheel


1

Overview of the gear train and the markings of the control times:

Injection pump camshaft gear wheel (1)


Camshaft gear wheel (2)
Idler gear (3).
Crankshaft gear wheel (4)

Marking injection pump camshaft / idler


gear (5)

Marking camshaft / crankshaft (6)

6
40445-1

z Measure the overhang of the parallel pin with the


depth measuring appliance.
 P04 39
z Correct overhang.

40431-0

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TCD 2015
z Insert camshaft gear wheel.
The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).

Make sure that the parallel pin on the


camshaft gear wheel and the locating hole
on the camshaft are in line.

6
40474-0

z Lightly oil screw (1).


z Fasten screw (1).

40473-0

z Insert counter support (1) in the toothing of the camshaft gear wheel.
z Turn the crankshaft evenly with the turning gear until
the counter holder blocks on the B-bank of the
crankcase (arrow).

40477-0

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15/32

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TCD 2015

z Tighten screw (1).


 A04 001

6
40473-0

z Turn the crankshaft with the turning gear evenly.


The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).

z Remove counter holder.

40474-0

Determining axial backlash of the camshaft


z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
z Note measured value, dimension (a).

40478-0

06/2006

16/32

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TCD 2015
z Mount new gasket (1).
z Measure the flange height from the running surfaces
to the lay-on surface with the depth measuring appliance (arrows).
z Note measured value, dimension (b).
z Determine axial backlash.
 P04 35
Calculation example
Desired:
Axial backlash
Given:
Measured:
(a) = 45.80 mm
(b) = 45.50 mm
Calculation:
Axial backlash = dimension (a) - dimension (b)
45.80 mm - 45.50 mm
Result:
= 0.30 mm

z Correct deviation with gaskets.

42273-2

 P04 37
z Mount cover (2).
Insert screws with locking agent.

z Fit new sealing rings.

z Tighten all screws (1).


 A04 002

40468-0

z Mount new O-ring (1).


z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
40435-0

06/2006

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z Lightly oil bearing liner (1) with engine oil.


z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

6
40438-0

z Insert bolt (1).

40437-0

z Lightly oil screw (1).


z Tighten screw (1).
 A04 013
Screw length:
M12 x 80 mm

40423-0

06/2006

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TCD 2015
z Lightly oil screw (1).
z Tighten screw (1).
 A04 012

6
40422-0

z Mount new O-ring (1).


z Lightly oil O-ring.
z Check oil channel (arrow) for free passage.

1
40435-0

z Lightly oil bearing liner (1) with engine oil.


z Insert idler gear (2).
The collar (arrow) faces the bearing bush.

1
40436-0

06/2006

19/32

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W 04-05-07

TCD 2015

z Insert bolt (1).

6
40439-0

z Lightly oil screw (1).


z Tighten screw (1).
 A04 013
Screw length:

M12 x 100 mm

40420-0

z Lightly oil screw (1).


z Tighten screw (1).
 A04 012
1

40419-0

06/2006

20/32

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Checking the tooth edge clearance of the
idler gear (B-bank)
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

6
40440-0

z Turn idler gear in direction of arrow until it stops.


z Read off measured value.
 P04 44
Repeat the measuring process on several
tooth flanks.
z Remove magnetic measuring stand.
z Remove dial gauge.

40441-0

Checking the tooth edge clearance of the


idler gear (A-bank)
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

40442-0

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z Turn idler gear in direction of arrow until it stops.


z Read off measured value.
 P04 44
Repeat the measuring process on several
tooth flanks.
z Remove magnetic measuring stand.
z Remove dial gauge.

6
40443-0

z Position the injection pump camshaft.


The locating hole (arrow) faces upwards.

40444-0

z Turn the crankshaft with the turning gear evenly.


The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).

40474-0

06/2006

22/32

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z Remove turning gear (1).

6
40471-0

z Unscrew all screws (1).

40470-0

z Position injection pump camshaft gear wheel.


The marking (1) faces the camshaft gear
wheel.

40446-0

06/2006

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W 04-05-07

TCD 2015

z Insert the injection pump camshaft gear wheel in the


camshaft gear wheel.
The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).

40447-0

z Tighten screws (1).

Attention!
Make sure no parts fall into the crankcase!
1

40498-0

Checking the tooth edge clearance of the


injection pump camshaft gear wheel
z Mount magnetic measuring stand.
z Insert dial gauge.
z Turn gear wheel in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".

40449-0

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z Turn gear wheel in direction of arrow until it stops.
z Read off measured value.
 P07 20
Repeat the measuring process on several
tooth flanks.
z Remove magnetic measuring stand.
z Remove dial gauge.

6
40450-0

z Install crankshaft sealing ring (flywheel side)


 W 02-02-02
z Install connection housing.
 W 03-09-04
Do not install the turbocharger.

z Attach turning gear.


 W 04-06-03

40690-0

Attention!
Make sure no parts fall into the crankcase!
z Fasten all screws (1).
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

40464-0

06/2006

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TCD 2015

z Install genset support.


 W 03-08-01
z Install rocker arm brackets.
 W 01-02-02
z Check and set plunger lift of injection pumps.
 W 07-06-04

6
40503-0

z Tighten all screws (1).


 A04 004
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

40464-0

z Mount pad thrust bearing (2).


z Lightly oil screws (1).
z Tighten screws (1).

40989-0

06/2006

26/32

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TCD 2015
Checking and setting axial backlash of the
injection pump camshaft
z Insert feeler gauge blade between gear wheel of the
injection pump camshaft and the pad thrust
bearing (arrow).

z Press the pad thrust bearing onto the feeler gauge


blade.
z Fasten screw (1).
z Check axial backlash.
 P04 43

6
40512-0

z Insert feeler gauge blade between gear wheel of the


injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1).

z Check axial backlash.


 P04 43

40513-0

z Tighten screws (1).


 A04 015
z Check axial backlash again.
 P04 43
1

Check axial backlash on both sides between


pad thrust bearing and gear
wheel (arrows).

40514-0

06/2006

27/32

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TCD 2015

z Clean sealing surfaces.


z Mount new O-ring (1).
z Lightly oil O-ring.

6
40515-0

z Press in the cover (3) to the stop.


z Mount cover (2).
Insert screws with locking agent.

z Tighten screws (1).

 A04 022

40460-0

z Fix cable tie (1).

40459-0

06/2006

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z Clean sealing surfaces.
z Apply packing compound evenly to the sealing surface of the gear case.
Use packing compound DEUTZ DW 48.

z Mount gear case cover (1).


z Mount holder (2).

z Tighten all screws (3) alternately.


 A04 020
3

6
40516-0

z Mount pipe clamp (2).


z Tighten screw (1).
 A08 045
2
1

40456-0

z Mount holder (2).


z Tighten screws (1).
 A12 071

40455-0

06/2006

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z Mount heat shield (1).


1

z Insert screws (3) with spacing sleeves.


z Tighten screws (2).
z Tighten screws (2 and 3) alternately.
 A12 071

40517-0

z Tighten screws (1).


 A13 094
1

40453-0

z Mount new sealing rings.


z Position fuel hose (2).
z Tighten hollow screw (1).
 A12 090
1
2

40458-0

06/2006

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TCD 2015
z Install injection pumps (cylinder A1).
 W 07-04-01
z Install injection pumps (cylinder A2-B3).
 W 07-04-01
z Install impulse transmitter (camshaft).
 W 05-07-03
z Install the turbocharger.
 W 06-06-04
z Remove turning gear.
 W 04-06-03

6
40518-0

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Installing and removing turning gear

The turning gear 100350 can be used at


the front end of the crankshaft depending
on the installation relations.

Commercial available tools


Special tools:
Turn-over gear . . . . . . . . . . . . . . 100300
Locking agent
DEUTZ DW 59

Attaching turning gear


z Unscrew screws (1).
z Remove cover (2).
z Remove gasket.

40461-0

z Insert turn-over gear (1).


z Insert centering pin (2) in threaded bore (3).

40462-0

06/2006

1/2

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TCD 2015

z Tighten screw (1).


 A03 085
Gear wheel of the turning gear grips the
starter gear ring.

6
40463-0

Removing turning gear


z Unscrew screw (1).
z Remove turn-over gear.

40463-0

z Clean sealing surfaces.


z Mount new gasket.
z Mount cover (2).
z Insert screws (1) with locking agent.
z Tighten screws (1).
 A03 085

40461-0

06/2006

2/2

8190-001

Speed control
W 05-07-01

TCD 2015
Removing and installing the impulse transmitter
(crankshaft)
Commercial available tools

W 04-06-03

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Dial gauge adapter . . . . . . . . . . . 101830
Turn-over gear . . . . . . . . . . . . . . 100300

Read out error memory of the motor control timer with SERDIA.

Fitting compound
DEUTZ AP1908

Removing the impulse transmitter


z Attach turning gear.
 W 04-06-03
z Unlock cable plug (1) and disconnect.

z Remove cable tie (2).

40710-0

z Remove cable tie (1).

40932-0

06/2006

1/6

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TCD 2015

z Unscrew screw (1).


z Remove impulse transmitter (2).
z Remove seals.

6
40711-0

z Visually inspect the components.


z Clean components.
z Clean sealing surfaces.

45879-1

Installing the impulse transmitter


z Turn the crankshaft with the turning gear evenly.
Through the installation opening of the
impulse transmitter, no bore (arrow) may
be visible on the flywheel.

45900-0

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2/6

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TCD 2015
z Insert dial gauge in adapter (1).

6
45897-0

z Insert adapter with dial gauge under pre-tension in


the base plate (1).
z Fix dial gauge in adapter.
z Turn the dial until the pointer points to "0".

45898-0

z Insert and press in adapter with dial gauge into the


connection housing until it stops.
The stylus of the dial gauge must touch the
level flywheel surface.
z Note measured value.
z Make 120 orientation marks on the vibration damper.

Attention!

Remove adapter and dial gauge before


turning the crankshaft.
z Turn the crankshaft to the next 120 mark in direction
of rotation.
z Note measured value.
z Select lowest measured value of 3 measurements,
dimension (a).

06/2006

3/6

45899-0

8191-001

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W 05-07-01

TCD 2015

z Measure distance, dimension (b).


 24

 0,1
 0,2

mm

z Note measured value.


z Calculate difference between dimension (a) and
dimension (b), dimension (y).

Calculation example
Desired:
Dimension (y)
Given:
Dial gauge adapter dimension = 24.00 mm
Measured:
Dimension (a) = dial gauge adapter dimension +
lowest measured value
Dimension (a) = 24.00 mm + 0.49 mm
Dimension (a) = 24.49 mm
Dimension (b) = 24.00 mm
Calculation:
Dimension (y) = dimension (a) - dimension (b)
Dimension (y) = 24.49 mm - 24.00 mm
Result:
Dimension (y) = 0.49 mm

45878-1

z Determine tightness of the impulse transmitter under


compliance with the permissible distance
dimension (c).
Calculation example
Desired:
Compliance with the permissible distance, dimension (c)
Gasket
Given:
MInimum distance dimension (c1) = 1.00 mm
Dimension (y)
Thickness of gasket = 0.30 mm
Thickness of gasket = 0.50 mm
Measured:
Calculation:
Dimension (c) = minimum
distance dimension (c1) dimension (y) + thickness of the gasket
Dimension (c) = 1.00 mm - 0.49 mm + 0.50 mm
Dimension (c) = 1.01 mm
Result:
Dimension (c) corresponds to the permissible distance, therefore a gasket with a thickness of
0.50 mm must be used.

c
1

2
45904-0

z Permissible distance (c) between flywheel (1) and


impulse transmitter (2).
 P05 91

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TCD 2015
z Select new gaskets.
Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by placing the appropriate number of gaskets
underneath.
z Remove dial gauge.

6
45882-0

z Mount new gasket(s) according to the determined


distance.
z Press in impulse transmitter (2).

Attention!
Do not damage the component.
z Tighten screw (1).
1

 A05 011
2

40711-0

z Fix cable tie (1).

40932-0

06/2006

5/6

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W 05-07-01

TCD 2015

z Plug cable plugs (1) together.


Ensure that the cables are connected properly.
z Fix cable tie (2).

z Remove turning gear.


 W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.
2

6
40710-0

06/2006

6/6

8191-001

Speed control
W 05-07-03

TCD 2015
Removing and installing the impulse transmitter
(camshaft)
Commercial available tools

W 04-06-03
W 06-06-04

Special tools:
Dial gauge adapter . . . . . . . . . . . 101830
Turn-over gear . . . . . . . . . . . . . . 100300

Read out error memory of the motor control timer with SERDIA.

Fitting compound
DEUTZ AP 1908
Locking agent
DEUTZ DW 72

Removing the impulse transmitter


z Attach turning gear.
 W 04-06-03
z Remove turbocharger.
 W 06-06-04

40700-0

z Unlock cable plug (1) and disconnect.

40717-0

06/2006

1/8

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W 05-07-03

TCD 2015

z Remove cable tie (1).

6
40718-0

z Unscrew screws (1).


z Remove cover (2) .

40719-0

z Unscrew screw (1).


z Remove impulse transmitter (2).
z Remove seals.
1

40720-0

06/2006

2/8

8192-001

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W 05-07-03

TCD 2015
z Remove protective foil.
z Unlock cable plug (1) and disconnect.
z Visually inspect the components.

z Clean components.

6
00000-0

Installing the impulse transmitter


z Turn the crankshaft with the turning gear evenly.
The pin (arrow) must be in the centre of the
installation opening.

45901-0

z Insert dial gauge in adapter (1).

45897-0

06/2006

3/8

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W 05-07-03

TCD 2015

z Insert adapter with dial gauge under pre-tension in


the base plate (1).
z Fix dial gauge in adapter.
z Turn the dial until the pointer points to "0".

6
45898-0

z Insert and press in adapter with dial gauge into the


connection housing until it stops.
The stylus of the dial gauge must touch the
pin of the camshaft gear.
z Note measured value.
z Make 120 orientation marks on the vibration damper.

Attention!

Remove adapter and dial gauge before


turning the crankshaft.
z Turn the crankshaft to the next 120 mark in direction
of rotation.
z Note measured value.
z Select lowest measured value of 3 measurements,
dimension (a).

45902-0

z Measure distance, dimension (b).


 24

 0,1
 0,2

mm

z Note measured value.


z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired:
Dimension (y)
Given:
Dial gauge adapter dimension = 24.00 mm
Measured:
Dimension (a) = dial gauge adapter dimension +
lowest measured value
Dimension (a) = 24.00 mm + 0.76 mm
Dimension (a) = 24.76 mm
Dimension (b) = 23.90 mm
Calculation:
Dimension (y) = dimension (a) - dimension (b)
Dimension (y) = 24.76 mm - 23.90 mm
Result:
Dimension (y) = 0.86 mm

45878-1

06/2006

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TCD 2015
z Determine tightness of the impulse transmitter under
compliance with the permissible distance
dimension (c).
Calculation example
Desired:
Compliance with the permissible distance, dimension (c)
Gasket
Given:
Minimum distance dimension (c1) = 0.30 mm
Dimension (y)
Thickness of gasket = 0.30 mm
Thickness of gasket = 0.50 mm
Measured:
Calculation:
Dimension (c) = minimum
distance dimension (c1) dimension (y) + thickness of the gasket
Dimension (c) = 0.30 mm 0.86 mm + (2x0.50 mm)
Dimension (c) = 0.44 mm
Result:
Dimension (c) corresponds to the permissible distance, therefore two gaskets with a thickness of
0.50 mm must be used.

c
1

2
45903-0

z Permissible distance (c) between camshaft gear


wheel (1) and impulse transmitter (2).
 P05 92

z Select new gaskets.


Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by placing the appropriate number of gaskets
underneath.

45882-0

06/2006

5/8

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W 05-07-03

TCD 2015

z Remove dial gauge.


z Mount new O-ring (1).
z Coat the O-ring (1) with fitting compound.

6
45878-2

z Plug cable plugs (1) together.


Ensure that the cables are connected properly.
1

z Wrap the cable plug in protective foil.

00000-0

z Clean sealing surfaces.


z Mount new gasket(s) according to the determined
distance.
z Press in impulse transmitter (2).

Attention!
Do not damage the component!

z Tighten screw (1).


 A05 012

40720-0

06/2006

6/8

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W 05-07-03

TCD 2015
z Mount cover (2).
z Insert screws (1) with locking agent.
z Tighten screws .
 A04 022
1

6
40719-0

z Fix cable tie (1).

40718-0

z Plug cable plugs (1) together.


Ensure that the cables are connected properly.
1

40717-0

06/2006

7/8

8192-001

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W 05-07-03

TCD 2015

z Install the turbocharger.


 W 06-06-04
Delete error entry in the error memory of
the motor control timer with SERDIA.

6
40716-0

06/2006

8/8

8192-001

Exhaust system/Charging
W 06-01-05

TCD 2015
Removing and installing exhaust line
(A-bank)
Commercial available tools

W 06-01-06 . . . . . . . . . . . . (A-bank)

Fitting compound
DEUTZ S1

Removing exhaust line


z Remove exhaust pipe (A-bank).
 W 06-01-06

40722-0

z Loosen screws (1).

40723-0

06/2006

1/4

8193-001

Exhaust system/Charging
W 06-01-05

TCD 2015

z Unscrew screws (1).


z Remove exhaust line (2).

2
45810-0

z Unscrew screws (1).


z Remove seals.

40725-0

z Visually inspect the components.

40726-0

06/2006

2/4

8193-001

Exhaust system/Charging
W 06-01-05

TCD 2015
Installing exhaust line
z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.
The strap (arrow) must face the cylinder
head cover.
z Coat the screws with fitting compound .
z Tighten screws (1).

6
45374-0

z Mount exhaust line (2).


z Coat the screws with fitting compound .
z Tighten screws (1).

2
45810-0

z Tighten all the screws (1) alternately from the centre


outwards.
 A06 001
1

40986-0

06/2006

3/4

8193-001

Exhaust system/Charging
W 06-01-05

TCD 2015

z Install exhaust pipe (A-bank).


 W 06-01-06

6
40722-0

06/2006

4/4

8193-001

Exhaust system/Charging
W 06-01-05

TCD 2015
Removing and installing exhaust line
(B-bank)
Commercial available tools

W 06-01-06 . . . . . . . . . . . . (B-bank)

Fitting compound
DEUTZ S1

Removing exhaust line


z Remove exhaust pipe (B-bank).
 W 06-01-06

z Loosen screws (1).

40727-0

z Unscrew screws (1).


z Remove exhaust line (2).

45809-0

06/2006

1/4

8194-001

Exhaust system/Charging
W 06-01-05

TCD 2015

z Unscrew screws (1).


z Remove seals.

6
40730-0

z Visually inspect the components.

40729-0

Installing exhaust line


z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.
The strap (arrow) must face the cylinder
head cover.
z Coat the screws with fitting compound .
z Tighten screws (1).

45375-0

06/2006

2/4

8194-001

Exhaust system/Charging
W 06-01-05

TCD 2015
z Mount exhaust line (2).
z Coat the screws with fitting compound .
z Tighten screws (1).

6
45809-0

z Tighten all the screws (1) alternately from the centre


outwards.
 A06 001
1

z Install exhaust pipe (B-bank).


 W 06-01-06

40985-0

06/2006

3/4

8194-001

Exhaust system/Charging
W 06-01-05

TCD 2015

06/2006

4/4

8194-001

Exhaust system/Charging
W 06-01-06

TCD 2015
Removing and installing exhaust pipe
(A-bank)
Commercial available tools

Fitting compound
DEUTZ S1

Removing exhaust pipe


z Unscrew nuts (arrows).

z Remove screws.
z Unscrew screws (1).
z Remove sealing rings.
z Remove exhaust pipe (2).

40733-0

Install exhaust pipe.

z Position exhaust pipe (1).


Note installation position.
1

z Insert sealing ring.


Note installation position.
The cone (arrow) faces the exhaust pipe.
z Mount flange (2) on exhaust manifold.
z Coat the screws with fitting compound .
z Fasten screws (3).

3
36795-1

06/2006

1/2

8195-001

Exhaust system/Charging
W 06-01-06

TCD 2015

z Insert sealing ring.


1

Note installation position.


The cone (arrow) faces the exhaust pipe.
z Mount flange (1) on exhaust line.
z Coat the screws with fitting compound .
z Tighten screws (2).
z Screw on nuts (3).

3
2

6
36796-1

z Tighten screws (1) alternately.


 A06 002
Ensure uniform distance (arrow) of flange
connection.

37216-1

z Tighten nuts (1) alternately.


 A06 003
Ensure uniform distance (arrow) of flange
connection.

40736-0

06/2006

2/2

8195-001

Exhaust system/Charging
W 06-01-06

TCD 2015
Removing and installing exhaust pipe
(B-bank)
Commercial available tools

Fitting compound
DEUTZ S1

Removing exhaust pipe


z Unscrew nuts (arrows).

z Remove screws.
z Unscrew screws (1).
z Remove sealing rings.
z Remove exhaust pipe (2).

40734-0

Install exhaust pipe.


z Position exhaust pipe (1).
Note installation position.
1

z Insert sealing ring.

Note installation position.


The cone (arrow) faces the exhaust pipe.
z Mount flange (2) on exhaust manifold.
z Coat the screws with fitting compound .
z Fasten screws (3).
3
36799-1

06/2006

1/2

8196-001

Exhaust system/Charging
W 06-01-06

TCD 2015

z Insert sealing ring.


1

Note installation position.


The cone (arrow) faces the exhaust pipe.
z Mount flange (1) on exhaust line.
z Coat the screws with fitting compound .
z Tighten screws (2).
z Screw on nuts (3).

3
36800-1

z Tighten nuts (1) alternately.


 A06 002
Ensure uniform distance (arrow) of flange
connection.

37218-1

z Tighten nuts (1) alternately.


 A06 003
Ensure uniform distance (arrow) of flange
connection.

40735-0

06/2006

2/2

8196-001

Exhaust system/Charging
W 06-01-07

TCD 2015
Removing and installing exhaust manifold
Commercial available tools

W 06-01-06 . . . . . . . . . . . . (A-bank)
W 06-01-06 . . . . . . . . . . . . (B-bank)
W 06-06-04

Removing exhaust manifold


z Remove turbocharger.
 W 06-06-04
z Remove exhaust pipe (A-bank).
 W 06-01-06
z Remove exhaust pipe (B-bank).
 W 06-01-06

40731-0

z Unscrew all screws (1).


z Remove exhaust manifold (2).
z Visually inspect the components.
1

40732-0

06/2006

1/2

8197-001

Exhaust system/Charging
W 06-01-07

TCD 2015

Installing exhaust manifold


z Mount exhaust manifold (2).
z Tighten all screws (1).

 A06 010

6
40732-0

z Install exhaust pipe (A-bank).


 W 06-01-06
z Install exhaust pipe (B-bank).
 W 06-01-06
z Install the turbocharger.
 W 06-06-04

40451-0

06/2006

2/2

8197-001

Exhaust system/Charging
W 06-01-07

TCD 2015 Railway


Removing and installing exhaust manifold
(A-bank)
Commercial available tools

W 06-06-04 . . . . . . . . . . . . (A-bank)

Fitting compound
DEUTZ S1

Removing exhaust manifold


z Remove turbocharger (A-bank).
 W 06-06-04
z Unscrew nuts (1).
z Remove screws.
z Remove the holder (2).
1

2
42079-1

z Unscrew nuts (1).


z Remove washers.
z Remove screws.
z Remove exhaust manifold (2).
z Visually inspect the components.
1

42081-2

06/2006

1/2

8198-001

Exhaust system/Charging
W 06-01-07

TCD 2015 Railway

Installing exhaust manifold


z Clean sealing surfaces.
z Mount exhaust manifold (2).
z Coat the screws with fitting compound .
z Insert screws.
z Mount washers.

z Tighten nuts (1).


 A06 010

6
42081-2

z Mount holder (2).


z Insert screws.
z Tighten nuts (1).
 A06 034
z Install turbocharger (A-bank).
 W 06-06-04
1

2
42079-1

06/2006

2/2

8198-001

Exhaust system/Charging
W 06-01-07

TCD 2015 Railway


Removing and installing exhaust manifold
(B-bank)
Commercial available tools

W 06-06-04 . . . . . . . . . . . . (B-bank)

Fitting compound
DEUTZ S1

Removing exhaust manifold


z Remove turbocharger (B-bank).
 W 06-06-04

42080-1

z Unscrew nuts (1).


z Remove washers.
z Remove screws.
z Remove exhaust manifold (2).
2

z Visually inspect the components.

1
42082-2

06/2006

1/2

8199-001

Exhaust system/Charging
W 06-01-07

TCD 2015 Railway

Installing exhaust manifold


z Clean sealing surfaces.
z Mount exhaust manifold (2).
z Coat the screws with fitting compound .

z Insert screws.
z Tighten nuts (1).
 A06 010

1
42082-2

z Install turbocharger (B-bank).


 W 06-06-04

42080-1

06/2006

2/2

8199-001

Exhaust system/Charging
W 06-02-03

TCD 2015
Remove and install the charge air line
Commercial available tools

Fitting compound
DEUTZ AP1908

Remove charge air line


z Unscrew screws (1).
z Remove charge air pipe (2) with plug.
2
1

40764-0

z Pull out plug element (1).

40765-1

06/2006

1/4

8200-001

Exhaust system/Charging
W 06-02-03

TCD 2015

z Unscrew nuts (1).


z Remove washers.
z Remove charge air manifold (2).
1

z Remove gasket.
z Visually inspect the components.

6
45403-0

Install charge air line


z Mount new gasket.
z Mount charge air manifold (2).

z Mount washers and screw on nuts.


z Tighten nuts (1).
 A06 046

45403-0

z Mount new O-rings (1).


z Coat the O-rings with fitting compound.
1

40767-0

06/2006

2/4

8200-001

Exhaust system/Charging
W 06-02-03

TCD 2015
z Insert plug element (1).

6
40768-1

z Clean sealing surfaces.


z Mount charge air line.
z Tighten screws .
 A06 030
Screw length:

M10 x 65 mm (1)

M10 x 85 mm (2)

40769-0

06/2006

3/4

8200-001

Exhaust system/Charging
W 06-02-03

TCD 2015

06/2006

4/4

8200-001

Exhaust system/Charging
W 06-02-05

TCD 2015
Removing and installing connecting pipe
Commercial available tools

W 07-01-04

Removing connecting pipe


z Remove fuel pipes (flame glow plugs).
 W 07-01-04

40737-0

z Unlock cable plug (1) and remove.

40738-0

06/2006

1/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015

z Unscrew nut (1).


Mark assignment of cables/connections
before removing.
z Remove cables (2) from both flame glow plugs.

6
40739-0

z Unscrew nuts (1).


z Remove the holder (2).
1

z Remove screws.

40740-0

z Unscrew screws (1).


z Place cable harness to one side.

40741-0

06/2006

2/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015
z Unscrew screws (1).

1
1

6
40742-0

z Unscrew nuts (1).


z Remove the holder (2).

1
2

40743-0

z Unscrew nuts (1).


z Remove the holder (2).

1
1

40744-0

06/2006

3/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015

z Unscrew nuts (1).


z Remove the holder (2).

2
1

6
40745-0

z Unscrew nuts (1).

40746-0

z Remove connecting pipe (1).


z Remove seals.

40747-0

06/2006

4/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015
z Visually inspect the components.

6
40748-0

Installing connecting pipe


z Clean sealing surfaces.
z Mount new gaskets.
z Mount connecting pipe (1).

40747-0

z Screw on nuts (1).

40746-0

06/2006

5/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015

z Mount holder (2).


z Screw on nuts (1).

2
1

6
40745-0

z Mount holder (2).


z Screw on nuts (1).

1
1

40744-0

z Mount holder (2).


z Screw on nuts (1).

1
2

40743-0

06/2006

6/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015
z Tighten screws (1).
 A06 056

1
1

6
40742-0

z Tighten nuts (arrows).


 A06 033

40749-0

z Lay cable.
z Tighten screws .
 A13 090
Screw length:

M8 x 20 mm (1)
M8 x 16 mm (2)
1

40750-0

06/2006

7/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015

z Unscrew screws (1).


z Remove end plate.
z Remove gasket.

6
40751-0

z Mount new gasket.


z Mount end plate.
z Insert screws.

Screw length:
M10 x 45 mm (1)
M10 x 55 mm (2)

40752-0

z Mount holder (1).


z Tighten nuts (arrows).
 A06 034

1
40950-0

06/2006

8/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015
z Plug cables (2) to both flame glow plugs.

Attention!
Note assignment and polarity of the electrical connections!
1

Connect cables according to marks made


before removing.
z Mount washer.
z Tighten nut (1).

 A13 035

6
40739-0

z Plug in the cable plug (1).

40738-0

z Install fuel pipes (flame glow plugs).


 W 07-01-04

40737-0

06/2006

9/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015

06/2006

10/10

8201-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway


Removing and installing connecting pipe
Commercial available tools

W 07-01-04 . . . . . . . . . . . . (Railway)

Ensure that the cables are connected properly.

Removing connecting pipe


z Unlock cable plug (1) and remove.

45926-0

z Unscrew screw (1).


z Remove spring washer.
z Remove ground cable.
Mark assignment of cables/connections
before removing.

45907-0

06/2006

1/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway

z Remove fuel pipes (flame glow plugs), (Railway).


 W 07-01-04

6
42025-2

z Unscrew nuts (1).


z Remove washers.

1
1

42185-2

z Remove cables (1).


Mark assignment of cables/connections
before removing.

42192-2

06/2006

2/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway


z Unscrew screw (1).
z Place fuel shut-off valve (2) to one side.

6
42186-1

z Unscrew screw (1).


z Place cable harness to one side.

42418-1

z Unscrew screws (1).


z Loosen the holder (2).

42419-1

06/2006

3/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway

z Unscrew screws (1).

1
1

6
42501-1

z Unscrew nuts (1).


z Remove washers.
z Remove holder.
z Place cables to one side.

45850-0

z Unscrew all nuts (1).


z Remove connecting pipe (2).
z Remove gasket.
z Visually inspect the components.
1

1
2

45851-1

06/2006

4/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway


Installing connecting pipe
z Clean sealing surfaces.
z Mount new gaskets.
z Mount connecting pipe (1).

6
42421-1

z Mount washers.
z Mount holder (1).
z Screw on nuts.

45850-0

z Screw on all nuts (1).

45852-1

06/2006

5/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway

z Tighten screws (1).


 A06 056

1
1

6
42501-1

z Tighten all nuts (1).


 A06 033

45852-1

z Position holder (2).


z Tighten screws (1).

 A13 090

42419-1

06/2006

6/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway


Attention!
Lay the cables free from chafing and tension.
z Tighten screw (1).
 A13 090

6
42418-1

z Mount fuel shut-off valve (2).


z Position pipe clamp.
z Fasten screw (1).
2

42186-1

z Position fuel shut-off valve.


 P07 91
Note installation dimensions (X).

45909-0

06/2006

7/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway

Attention!
Note assignment and polarity of the electrical connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Connect plus cable (R3.2) to flame glow plug (2).

z Mount washers.
z Screw on nuts.

6
45928-0

z Tighten nuts (1).


 A13 035
z Install fuel pipes (flame glow plugs), (Railway).
 W 07-01-04
1
1

42185-2

z Connect ground cable.


z Mount spring washer.
z Tighten screw (1).
 A07 058

45907-0

06/2006

8/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway


z Tighten screw (1).
 A13 090

6
42423-1

z Plug in the cable plug (1).


Ensure that the cables are connected properly.

45926-0

06/2006

9/10

8202-001

Exhaust system/Charging
W 06-02-05

TCD 2015 Railway

06/2006

10/10

8202-001

Exhaust system/Charging
W 06-06-04

TCD 2015
Removing and installing the turbocharger
Commercial available tools

W 06-02-03

Special tools:
Special wrench . . . . . . . . . . . . . . 170100

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Fitting compound
DEUTZ S1

Removing turbocharger
z Remove the charge air pipe.
 W 06-02-03

40753-0

z Unscrew lock nuts (1) with special wrench.


z Remove screw-in nipple.
z Remove sealing rings.

40754-0

06/2006

1/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015

z Unscrew screw (1).


z Remove holder (2).
z Remove lubricating oil pipe (3).

2
3

6
40755-0

z Unscrew screw (1).


z Loosen hose clips (2).
1

40756-0

z Pull off pipe.


z Remove intake elbow (1).
1

40757-0

06/2006

2/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015
z Unscrew screw (1).

6
40758-0

z Pull out oil return pipe (1).

40759-0

z Unscrew all screws (1).


z Remove turbocharger (2).

40760-0

06/2006

3/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015

z Unscrew screws (1).


z Remove oil return pipe (2).
z Remove gasket.

6
40761-0

z Visually inspect the components.

40762-0

Installing the turbocharger


z Mount new gaskets.

z Mount oil return pipe (2).


z Tighten screws (1).
 A08 044

40761-0

06/2006

4/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015
z Clean sealing surfaces.
z Mount turbocharger (2).
z Coat the screws with fitting compound .
z Tighten all screws (1).
 A06 020

6
40760-0

z Mount oil return pipe (1).

40759-0

z Tighten screw (1).


 A08 044

40758-0

06/2006

5/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015

z Mount intake elbow (1).


Note installation position.
1

z Insert pipe.

6
40757-0

z Position hose clips.


z Tighten hose clip (2).
 A03 064
z Tighten hose clip (3).

 A06 021

z Tighten screw (1).


 A03 069

45402-0

z Mount lubricating oil pipe (3).


z Position holder (2).
z Tighten screw (1).
 A08 079

45373-0

06/2006

6/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015
z Mount new sealing rings.
z Tighten screw-in nipple.
z Tighten both lock nuts (1) with a special wrench.
 A08 040

6
40763-0

z Install the charge air pipe.


 W 06-02-03

40753-0

06/2006

7/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015

06/2006

8/8

8203-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway


Removing and installing turbocharger
(A-bank)
Commercial available tools

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Fitting compound
DEUTZ S1

Removing turbocharger
z Unscrew screw (1).
z Loosen pipe clip (2).

42048-1

z Unscrew union nuts (1).


z Remove lubricating oil pipe (2).

2
1
1

42049-1

06/2006

1/6

8204-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway

z Unscrew screws (1).


z Remove oil return pipe (2).
z Remove gasket.

6
42050-1

z Loosen hose clip (1).


z Loosen hose clip (2).
1

2
42051-2

z Pull off tubing connection (1).


z Pull off bleeding hose (2).
2

z Remove breather pipe (3).

3
1

42052-2

06/2006

2/6

8204-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway


z Unscrew nuts (arrows).
z Remove turbocharger (1).

6
42053-1

z Unscrew screw-in nipple (1).


z Remove sealing ring.
z Visually inspect the components.

42054-1

Installing the turbocharger


z Mount new sealing ring.
z Tighten screw-in nipple (1).

 A12 098

42054-1

06/2006

3/6

8204-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway

z Clean sealing surfaces.


z Mount turbocharger (1).
z Tighten nuts (arrows).
 A06 020

6
42053-1

z Mount breather pipe (3).


z Plug in breather pipe (2).
2

z Plug in the tubing connection (1).

3
1

42052-3

z Position hose clip (1).


z Tighten hose clip (1).
 A03 070
1

z Position hose clip (2).


z Tighten hose clip (2).
 A06 024

2
42051-2

06/2006

4/6

8204-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway


z Mount new gasket.
z Mount oil return pipe (2).
z Tighten screws (1).

 A08 044

6
42050-1

z Mount lubricating oil pipe (2).


z Screw on union nuts (1).
 A12 082

2
1
1

42049-1

z Position pipe clamp (2).


z Tighten screw (1).
 A08 045

42048-1

06/2006

5/6

8204-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway

06/2006

6/6

8204-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway


Removing and installing turbocharger
(B-bank)
Commercial available tools

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Fitting compound
DEUTZ S1

Removing turbocharger
z Unscrew union nuts (1).
z Remove lubricating oil pipe (2).

1
2

1
42056-1

z Unscrew screws (1).


z Remove oil return pipe (2).

z Remove gasket.

42057-1

06/2006

1/6

8205-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway

z Loosen hose clip (1).


z Loosen hose clip (2).
1

6
42059-2

z Pull off tubing connection (1).


z Pull off bleeding hose (2).
z Remove breather pipe (3).

1
42058-2

z Unscrew nuts (arrows).


z Remove turbocharger (1).

42055-1

06/2006

2/6

8205-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway


z Unscrew screw-in nipple (1).
z Remove sealing ring.
z Visually inspect the components.

6
42054-1

Installing the turbocharger


z Mount new sealing ring.
z Tighten screw-in nipple (1).

 A12 098

42054-1

z Clean sealing surfaces.


z Mount turbocharger (1).
z Tighten nuts (arrows).
 A06 020
1

42055-1

06/2006

3/6

8205-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway

z Mount breather pipe (3).


z Plug in breather pipe (2).
z Plug in the tubing connection (1).

1
42058-2

z Position hose clip (1).


z Tighten hose clip (1).
1

 A03 070
z Position hose clip (2).
z Tighten hose clip (2).
 A06 024

42059-2

z Mount new gasket.


z Mount oil return pipe (2).

z Tighten screws (1).


 A08 044

42057-1

06/2006

4/6

8205-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway


z Mount lubricating oil pipe (2).
z Screw on union nuts (1).
 A12 082

1
2

1
42056-1

06/2006

5/6

8205-001

Exhaust system/Charging
W 06-06-04

TCD 2015 Railway

06/2006

6/6

8205-001

Exhaust system/Charging
W 06-07-03

TCD 2015
Removing and installing charge air pipe
(A-bank)
Commercial available tools

W 03-01-11
W 06-02-05
W 07-03-01 . . . . . . . . . . . . (A-bank)

Special tools:
Special wrench . . . . . . . . . . . . . . 110510

Removing charge air pipe


z Remove connecting pipe.
 W 06-02-05
z Removing high pressure pipes (A-bank).
 W 07-03-01

40552-0

z Removing the crankcase breather.


 W 03-01-11
z Unscrew screw (1).
1

40553-0

06/2006

1/6

8206-001

Exhaust system/Charging
W 06-07-03

TCD 2015

z Unscrew screws (1).


z Place fuel hose (2) to one side.

6
40554-0

z Unscrew all screws (1).


z Remove the holder (2).

40566-0

z Unscrew screws (1) with special wrench.


z Unscrew screws (2).

z Remove charge air pipe (3).


z Remove seals.
1

40567-0

06/2006

2/6

8206-001

Exhaust system/Charging
W 06-07-03

TCD 2015
z Visually inspect the components.

6
40568-0

Installing charge air pipe


z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.
1

z Turn in all screws (1) a few turns.


Screw length:
M8 x 65 mm

40574-0

z Insert charge air pipe.


z Fasten all screws (1).
Screw length:
M8 x 100 mm
1

40575-0

06/2006

3/6

8206-001

Exhaust system/Charging
W 06-07-03

TCD 2015

z Mount spacing sleeve (arrow).


z Mount holder.
z Fasten screw (1).
Screw length:
M8 x 120 mm

6
40576-0

z Tighten screw (1).


 A12 071

40553-0

z Tighten screws (1) alternately with special wrench.


 A06 030

40577-0

06/2006

4/6

8206-001

Exhaust system/Charging
W 06-07-03

TCD 2015
z Position fuel hose (2).
z Tighten screws (1).
 A12 095
z Install crankcase breather.
 W 03-01-11

6
40554-0

z Installing high pressure pipes (A-bank)


 W 07-03-01
z Install connecting pipe.
 W 06-02-05

40552-0

06/2006

5/6

8206-001

Exhaust system/Charging
W 06-07-03

TCD 2015

06/2006

6/6

8206-001

Exhaust system/Charging
W 06-07-03

TCD 2015
Removing and installing charge air pipe
(B-bank)
Commercial available tools

W 06-02-05
W 07-03-01 . . . . . . . . . . . . (B-bank)

Special tools:
Special wrench . . . . . . . . . . . . . . 110510

Removing charge air pipe


z Remove connecting pipe.
 W 06-02-05
z Removing high pressure pipes (B-bank).
 W 07-03-01

40552-0

z Unscrew all screws (1).

40569-0

06/2006

1/4

8207-001

Exhaust system/Charging
W 06-07-03

TCD 2015

z Unscrew screws (1) with special wrench.


z Unscrew screws (2).

z Remove charge air pipe (3).


z Remove seals.

1
1

6
40570-0

z Visually inspect the components.

40571-0

Installing charge air pipe


z Clean sealing surfaces.
z Mount new gaskets.
Note installation position.
1

z Turn in all screws (1) a few turns.


Screw length:
M8 x 65 mm

40572-0

06/2006

2/4

8207-001

Exhaust system/Charging
W 06-07-03

TCD 2015
z Insert charge air pipe.
z Fasten all screws (1).
Screw length:
M8 x 100 mm

6
40569-0

z Tighten screws (1) alternately with special wrench.


 A06 030
1
1

1
1

40573-0

z Installing high pressure pipes (A-bank)


 W 07-03-01
z Install connecting pipe.
 W 06-02-05

40552-0

06/2006

3/4

8207-001

Exhaust system/Charging
W 06-07-03

TCD 2015

06/2006

4/4

8207-001

Fuel system
W 07-01-02

TCD 2015
Removing and installing flame glow plug
Commercial available tools

W 07-01-04

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing flame glow plug


z Remove fuel pipes (flame glow plugs).
 W 07-01-04

z Unscrew nut (1).


z Remove cables (2).
Mark assignment of cables/connections
before removing.

40770-0

06/2006

1/4

8208-001

Fuel system
W 07-01-02

TCD 2015

z Loosen lock nut (1).


z Unscrew flame glow plug (2).
z Remove gasket.

6
40771-0

z Visually inspect the components.

40772-0

Installing flame glow plug


z Mount new gasket.
z Screw in flame glow plug.
 P13 66
Note screw-in height dimension (X).

45404-0

06/2006

2/4

8208-001

Fuel system
W 07-01-02

TCD 2015
z Install fuel pipes (flame glow plugs).
 W 07-01-04

6
40773-0

z Tighten lock nut (1).


 A07 059

40774-0

z Plug in cable lug (2).

Attention!

Note assignment and polarity of the electrical connections!


2

Connect cables according to marks made


before removing.
z Mount washer.
z Tighten nut (1).
 A13 035

40775-0

06/2006

3/4

8208-001

Fuel system
W 07-01-02

TCD 2015

06/2006

4/4

8208-001

Fuel system
W 07-01-02

TCD 2015 Railway


Removing and installing flame glow plug
Commercial available tools

W 07-01-04 . . . . . . . . . . . . (Railway)

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing flame glow plug


z Unscrew screw (1).
z Remove spring washer.
z Remove ground cable.
Mark assignment of cables/connections
before removing.

45907-0

06/2006

1/6

8209-001

Fuel system
W 07-01-02

TCD 2015 Railway

z Remove fuel pipes (flame glow plugs), (Railway).


 W 07-01-04

6
42025-2

z Unscrew nuts (1).


z Remove washers.

1
1

42185-2

z Remove cables (1).


Mark assignment of cables/connections
before removing.

42192-2

06/2006

2/6

8209-001

Fuel system
W 07-01-02

TCD 2015 Railway


z Loosen lock nut (2).
z Unscrew flame glow plug (1).
z Remove insulating washer (3).

2
3

6
42187-1

z Unscrew adapter (1).


z Remove sealing ring.

42188-1

z Unscrew lock nut.


z Visually inspect the components.

42191-2

06/2006

3/6

8209-001

Fuel system
W 07-01-02

TCD 2015 Railway

Installing flame glow plug


z Mount new gasket.
z Tighten adapter (1).
 A07 057
1

6
42188-1

z Screw on lock nut.

42191-2

z Mount insulating washer (1).


z Screw in flame glow plug (2).

2
1

42187-2

06/2006

4/6

8209-001

Fuel system
W 07-01-02

TCD 2015 Railway


z Position flame glow plug.
 P13 66
Note screw-in height dimension (X).
Screw-in nipple (1) faces crankshaft at a
right angle (90).

6
45911-0

z Tighten lock nut (1).


 A07 059

45927-0

Attention!
Note assignment and polarity of the electrical connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Connect plus cable (R3.2) to flame glow plug (2).

45928-0

06/2006

5/6

8209-001

Fuel system
W 07-01-02

TCD 2015 Railway

z Mount washers.
z Screw on nuts.
z Tighten nuts (1).
 A13 035
z Install fuel pipes (flame glow plugs), (Railway).

 W 07-01-04

6
42185-2

z Connect ground cable.


z Mount spring washer.
z Tighten screw (1).
 A07 058

45907-0

06/2006

6/6

8209-001

Fuel system
W 07-01-03

TCD 2015
Removing and installing fuel shut-off valve
(flame glow plugs)
Attention!

Commercial available tools

Pay attention to utmost cleanliness when


working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Removing fuel shut-off valve


z Unlock cable plug (1) and remove.
1

40951-0

06/2006

1/6

8210-001

Fuel system
W 07-01-03

TCD 2015

z Hold screw-in nipple.


z Unscrew lock nut (1).
z Hold screw-in nipple.
z Unscrew lock nut (2).
z Remove fuel pipe (3).

40776-0

z Unscrew screw (1).


z Remove spacing sleeve.
z Remove fuel shut-off valve (2).

z Remove pipe clamp.

40778-0

z Unscrew screw-in nipple (1).


z Visually inspect the components.

40779-0

06/2006

2/6

8210-001

Fuel system
W 07-01-03

TCD 2015
Installing fuel shut-off valve
1

z Tighten screw-in nipple (1).


 A07 068
1

6
40779-0

z Position pipe clamp.


z Screw on lock nut (1).

40780-0

z Screw on lock nut (1).

40781-0

06/2006

3/6

8210-001

Fuel system
W 07-01-03

TCD 2015

z Position spacing sleeve.


z Fasten screw (1).

6
40782-0

z Position fuel shut-off valve.


 P07 91

Note installation dimensions (X).

45406-0

z Tighten screw (1).


 A07 093
1

40783-0

06/2006

4/6

8210-001

Fuel system
W 07-01-03

TCD 2015
z Position fuel pipe.
 P07 92
Note installation angle, dimension (X).

X
6
45407-0

Attention!
Install fuel pipes tension free!
z Hold screw-in nipple.
z Tighten lock nuts (1).

 A07 018

40784-0

z Plug in the cable plug (1).

40951-0

06/2006

5/6

8210-001

Fuel system
W 07-01-03

TCD 2015

06/2006

6/6

8210-001

Fuel system
W 07-01-03

TCD 2015 Railway


Removing and installing fuel shut-off valve
(flame glow plugs)
Attention!

Commercial available tools

Pay attention to utmost cleanliness when


working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Removing fuel shut-off valve


z Unlock cable plug (1) and remove.

42020-2

06/2006

1/6

8211-001

Fuel system
W 07-01-03

TCD 2015 Railway

z Unscrew hollow screw (1).


z Remove sealing rings.
Collect draining fuel and dispose of according to regulations.
z Seal hose pipe (2).
z Place hose pipe (2) to one side.

6
42021-1

z Hold screw-in nipple.


z Unscrew lock nut (1).

1
42022-1

z Unscrew screw (1).


z Remove fuel shut-off valve (2).
z Remove pipe clamp.

1
2

42023-1

06/2006

2/6

8211-001

Fuel system
W 07-01-03

TCD 2015 Railway


z Unscrew screw-in nipple (1).
z Visually inspect the components.

6
45913-0

Installing fuel shut-off valve


z Tighten screw-in nipple (1).
 A07 068
z Mount pipe clamp (2).

45912-0

z Screw on lock nut (1).

1
42024-1

06/2006

3/6

8211-001

Fuel system
W 07-01-03

TCD 2015 Railway

z Position pipe clamp.


z Fasten screw (1).

6
42023-2

z Position fuel shut-off valve.


 P07 91
Note installation dimensions (X).

45909-0

z Tighten screw (1).


 A07 093

42023-2

06/2006

4/6

8211-001

Fuel system
W 07-01-03

TCD 2015 Railway


z Hold screw-in nipple.
z Tighten lock nuts (1).
 A07 018

Attention!
Install fuel pipes tension free!

6
42022-1

z Position hose pipe (2).

Attention!
Lay the hose pipe free from chafing and
tension.
z Mount new sealing rings.
z Tighten hollow screw (1).
 A12 090

42021-1

z Plug in the cable plug (1).


Ensure that the cables are connected properly.

42020-2

06/2006

5/6

8211-001

Fuel system
W 07-01-03

TCD 2015 Railway

06/2006

6/6

8211-001

Fuel system
W 07-01-04

TCD 2015
Removing and installing fuel pipes
(flame glow plugs)
Commercial available tools

W 06-02-03

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pipes


z Remove the charge air pipe.
 W 06-02-03
1

z Unscrew screw (1).


z Loosen pipe clip (2).

40785-0

06/2006

1/4

8212-001

Fuel system
W 07-01-04

TCD 2015

z Unscrew union nuts (1).

6
45378-0

z Remove fuel pipes (1).

45376-0

z Visually inspect the components.

45377-0

06/2006

2/4

8212-001

Fuel system
W 07-01-04

TCD 2015
Installing fuel pipes
z Mount fuel pipes (1).

6
45376-0

z Screw on union nuts (1).

45378-0

z Position pipe clamp (2).


z Fasten screw (1).

40785-0

06/2006

3/4

8212-001

Fuel system
W 07-01-04

TCD 2015

z Tighten lock nuts (1).


 A12 080

Attention!
Install fuel pipe tension free.
1

6
40952-0

z Tighten lock nuts (1).


 A12 080

Attention!
Install fuel pipe tension free.

40789-0

z Tighten screw (1).


 A07 044
z Install the charge air pipe.
 W 06-02-03

45379-0

06/2006

4/4

8212-001

Fuel system
W 07-01-04

TCD 2015 Railway


Removing and installing fuel pipes
(flame glow plugs)
Commercial available tools

Danger!

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Wait 30 seconds after switching off the


engine before working on the fuel system.

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pipes


z Remove cable tie (1).
z Unscrew screw (2).
z Loosen pipe clip.

42025-1

06/2006

1/4

8213-001

Fuel system
W 07-01-04

TCD 2015 Railway

z Unscrew union nuts (1).


z Remove fuel pipe (2).

6
42026-1

z Unscrew union nuts (1).


z Remove fuel pipe (2).
1

42028-1

z Hold screw-in nipple.


z Unscrew lock nut (1).
z Remove distributor (2).

z Visually inspect the components.

42029-1

06/2006

2/4

8213-001

Fuel system
W 07-01-04

TCD 2015 Railway


Installing fuel pipes
z Mount distributor (2).
Note installation position.

z Screw on lock nut (1).

6
42029-1

z Mount fuel pipe (2).


z Screw on union nuts (1).
1

42028-1

z Mount fuel pipe (2).


z Screw on union nuts (1).

42026-1

06/2006

3/4

8213-001

Fuel system
W 07-01-04

TCD 2015 Railway

Attention!
Install fuel pipe tension free.
z Tighten lock nuts (1).
 A12 080

6
42027-1

Attention!
Install fuel pipe tension free.
z Tighten lock nuts (1).

 A12 080
z Hold screw-in nipple.
z Tighten lock nut (2).
 A07 018
2

42030-1

z Position pipe clip.


z Tighten screw (2).
 A07 044
z Lay cable harness and fix with cable tie (1).

42025-1

06/2006

4/4

8213-001

Fuel system
W 07-03-01

TCD 2015
Renewing injection pipes
(A-bank)
Danger!

Commercial available tools:


Dog wrench. . . . . . . . . . . . . . . . . . . 8018

Wait 30 seconds after switching off the


engine before working on the fuel system.

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Injection pipes may not be bent.

Removing injection pipes


z Unscrew screws (1).
z Remove cylinder head cover (2).
z Remove gasket.
2

40627-0

06/2006

1/6

8214-001

Fuel system
W 07-03-01

TCD 2015

z Unscrew screw (1).


z Remove pipe clamp (2).

1
2

6
40792-0

z Unscrew lock nuts (1) with dog wrench.


z Remove injection line.
Lay out components in the order in which
they should be installed.
Note cylinder assignment.

40793-0

z Visually inspect the components.


z Renew damaged profile washers.

40796-0

06/2006

2/6

8214-001

Fuel system
W 07-03-01

TCD 2015
Installing injection pipes
z Mount new injection pipe.
z Screw on union nuts (1).

Attention!
Install injection pipes without tension!

Note assignment and installation position


of the injection lines.

6
40793-0

z Oil the injection pipe in the area of the profile


washer (1).
z Position profile washer (1).
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1

40634-0

z Tighten lock nuts (1) with dog wrench.


 A07 003

40800-0

06/2006

3/6

8214-001

Fuel system
W 07-03-01

TCD 2015

z Tighten lock nuts (1) with dog wrench.


 A07 003

6
40801-0

z Position pipe clamp (2).


z Tighten screw (1).
 A07 006
1
2

40792-0

z Clean sealing surfaces.


z Mount new gasket (1).
1

Note installation position.


Position gasket over the profile washer (2).

40802-0

06/2006

4/6

8214-001

Fuel system
W 07-03-01

TCD 2015
z Mount cylinder head cover.
Profile washer (1) may not be trapped
underneath the sealing surface (2) of the
cylinder head cover.

6
40803-0

z Lightly oil screws (1).


z Tighten screws (1).
 A01 005

40804-0

06/2006

5/6

8214-001

Fuel system
W 07-03-01

TCD 2015

06/2006

6/6

8214-001

Fuel system
W 07-03-01

TCD 2015
Renewing injection pipes
(B-bank)
Commercial available tools:
Dog wrench. . . . . . . . . . . . . . . . . . . 8018

W 06-02-03

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Injection pipes may not be bent.

Removing injection pipes


z Remove the charge air pipe.
 W 06-02-03
z Unscrew screws (1).
z Remove cylinder head cover (2).

z Remove gasket.

40791-0

06/2006

1/6

8215-001

Fuel system
W 07-03-01

TCD 2015

z Unscrew screw (1).


z Remove pipe clamp (2).
1

6
40794-0

z Unscrew lock nuts (1) with dog wrench.


z Remove injection line.
Lay out components in the order in which
they should be installed.

Note cylinder assignment.

40795-0

z Visually inspect the components.


z Renew damaged profile washers.

40796-0

06/2006

2/6

8215-001

Fuel system
W 07-03-01

TCD 2015
Installing injection pipes
z Mount new injection pipe.
z Screw on union nuts (1).

Attention!

Install injection pipes without tension!


Note assignment and installation position
of the injection lines.

6
40795-0

z Oil the injection pipe in the area of the profile


washer (1).
z Position profile washer (1).
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1

40634-0

z Tighten lock nuts (1) with dog wrench.


 A07 003

40797-0

06/2006

3/6

8215-001

Fuel system
W 07-03-01

TCD 2015

z Tighten lock nuts (1) with dog wrench.


 A07 003

6
40798-0

z Position pipe clamp (2).


z Tighten screw (1).
 A07 006

40794-0

z Clean sealing surfaces.


z Mount new gasket (1).
Note installation position.

Position gasket over the profile washer (2).

40635-0

06/2006

4/6

8215-001

Fuel system
W 07-03-01

TCD 2015
z Mount cylinder head cover.
Profile washer (1) may not be trapped
underneath the sealing surface (2) of the
cylinder head cover.

6
40636-0

z Lightly oil screws (1).


z Tighten screws (1).
 A01 005
z Install the charge air pipe.
 W 06-02-03

40637-0

06/2006

5/6

8215-001

Fuel system
W 07-03-01

TCD 2015

06/2006

6/6

8215-001

Fuel system
W 07-04-01

TCD 2015
Removing and installating injection pumps.
(Cylinder A1)
Commercial available tools:
Open wrench size SW 22

W 04-06-03
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 07-10-06
W 07-10-06 . . . . . . . . . . . . (Railway)

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!

Locking agent
DEUTZ DW 59

Pay attention to utmost cleanliness when


working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Read out error memory of the motor control timer with SERDIA.

Removing the fuel injector pump


z Remove charge air pipe (A-bank).
 W 06-07-03

40552-0

06/2006

1/10

8216-001

Fuel system
W 07-04-01

TCD 2015

z Unscrew screws (1).


z Remove the holder (2).

40808-0

z Unscrew screw (1).


z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings.
1
2

40520-0

z Unscrew nut (1).


z Remove the holder (2).

1
2

40521-0

06/2006

2/10

8216-001

Fuel system
W 07-04-01

TCD 2015
z Unscrew hollow screw (1).
Hold overflow valve.

z Remove fuel pipe (2).


z Remove sealing rings.
1
2

6
40522-0

z Loosen screws (1).


z Pull off cables (2).

1
2

40809-0

z Unscrew screws (1).


Loosen screws evenly to avoid jamming
the injection pump.
z Remove fuel injector pump(2).
1

Lay out components in the order in which


they should be installed.

45386-0

06/2006

3/10

8216-001

Fuel system
W 07-04-01

TCD 2015

z Pull out roller tappet (1).

Attention!
Do not damage the roller tappet!

Lay out components in the order in which


they should be installed.

6
40810-0

z Visually inspect the components.

40807-0

Removing injection pump housing


z Remove fuel pipes.
 W 07-10-06
z Remove fuel pipes (Railway).
 W 07-10-06

z Unscrew screws (1).


z Remove injection pump housing (2).
Lay out components in the order in which
they should be installed.

Note cylinder assignment.

45387-0

06/2006

4/10

8216-001

Fuel system
W 07-04-01

TCD 2015
z Visually inspect the components.

6
40812-0

Installing injection pump housing


z Clean contact surfaces.
z Mount new O-ring (1).

45390-1

z Oil the shank of the injection pump housing lightly.


z Press the injection pump housing into the stop in the
crankcase.
Note cylinder assignment.
The pilot pin (1) must lock in
groove (arrow).

1
40813-0

06/2006

5/10

8216-001

Fuel system
W 07-04-01

TCD 2015

z Lightly oil screws (1).


z Tighten screws (1).
 A07 009

6
45388-0

z Install fuel pipes.


 W 07-10-06
z Install fuel pipes (Railway).
 W 07-10-06
1

Do not install fuel pipe (1).


Do not install charge air pipe (A-bank).

45391-0

Installing the fuel injector pump


Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.

40807-0

06/2006

6/10

8216-001

Fuel system
W 07-04-01

TCD 2015
z Attach turning gear.
 W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).

6
42163-1

z Oil the roller tappet lightly.


z Insert roller tappet.
The pilot pin (1) must lock in
groove (arrow).
1

42164-1

z Mount new O-rings (1).


z Oil O-rings lightly.

42165-2

06/2006

7/10

8216-001

Fuel system
W 07-04-01

TCD 2015

z Insert injection pump (1).


The cable connections (3) of the injection
pumps must face the genset support.

z Lightly oil screws (2).


z Tighten screws (2).

6
40954-0

z Tighten screws (1) alternately.


 A07 012

Attention!
Do not turn the camshaft until all the injection pumps are installed. Danger of breaking the tappet!
1

40953-0

z Plug in cables (2).


 T13 054
Note assignment!

z Tighten screws (1).


 A13 054

1
2

40809-0

06/2006

8/10

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W 07-04-01

TCD 2015
z Mount new sealing rings.
z Mount fuel pipe (2).
z Screw on hollow screw (1).

1
2

6
40522-0

z Oil the thread lightly.


z Mount holder (2).
z Screw on nut (1).

1
2

40521-0

z Mount new sealing rings.


z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1).

1
2

40520-0

06/2006

9/10

8216-001

Fuel system
W 07-04-01

TCD 2015

z Tighten hollow screw (1).


Hold overflow valve.
 A12 093
z Tighten nut (2).

 A07 044
2

6
40565-0

z Tighten screw (1).


 A07 044
z Tighten hollow screw (2).
 A12 092

1
2

40555-0

z Mount holder (2).


z Tighten screws (1).
 A07 044
z Install charge air pipe (A-bank)
 W 06-07-03
z Remove turning gear.
 W 04-06-03
2

Delete error entry in the error memory of


the motor control timer with SERDIA.
1

40808-0

06/2006

10/10

8216-001

Fuel system
W 07-04-01

TCD 2015
Removing and installing injection pumps
(Cylinder A2-B3)
Commercial available tools

W 03-01-11
W 04-06-03
W 07-03-01 . . . . . . . . . . . . (A-bank)
W 07-03-01 . . . . . . . . . . . . (B-bank)
W 07-10-06
W 07-10-06 . . . . . . . . . . . . (Railway)

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Locking agent
DEUTZ DW 59

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Read out error memory of the motor control timer with SERDIA.

Removing injection pumps


z Removing the crankcase breather.
 W 03-01-11
z Removing high pressure pipes (A-bank).
 W 07-03-01

z Removing high pressure pipes (B-bank).

 W 07-03-01
z Unscrew screws (1).
z Place fuel hose (2) to one side.

40554-0

06/2006

1/8

8217-001

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W 07-04-01

TCD 2015

z Loosen screws (1).


z Pull off cables (2).

1
2

6
45384-0

z Unscrew screws (1).


Loosen screws evenly to avoid jamming
the injection pump.
z Remove fuel injector pump(2).
Lay out components in the order in which
they should be installed.

Note cylinder assignment.

40805-0

z Pull out roller tappet (1).

Attention!
Do not damage the roller tappet!
1

Lay out components in the order in which


they should be installed.
Note cylinder assignment.

40806-0

06/2006

2/8

8217-001

Fuel system
W 07-04-01

TCD 2015
z Visually inspect the components.

6
40807-0

Removing injection pump housing


z Remove fuel pipes.
 W 07-10-06
z Remove fuel pipes (Railway).
 W 07-10-06

z Unscrew screws (1).


z Remove injection pump housing (2).
Lay out components in the order in which
they should be installed.
Note cylinder assignment.

40811-0

z Visually inspect the components.

40812-0

06/2006

3/8

8217-001

Fuel system
W 07-04-01

TCD 2015

Installing injection pump housing


z Clean contact surfaces.
z Mount new O-ring (1).

6
42159-2

The injection pump housings differ.


Mount the injection pump housing with the
bevel (arrow) on the B-bank.

42160-1

z Oil the shank of the injection pump housing lightly.


z Press the injection pump housing into the stop in the
crankcase.
Note cylinder assignment.
The pilot pin (1) must lock in
groove (arrow).

1
45389-0

06/2006

4/8

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W 07-04-01

TCD 2015
z Lightly oil screws (1).
z Tighten screws (1).
 A07 009
z Install fuel pipes.
 W 07-10-06
z Remove fuel pipes (Railway).
 W 07-10-06

6
40814-0

Installing injection pumps


Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.

40807-0

z Attach turning gear.


 W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).

42163-1

06/2006

5/8

8217-001

Fuel system
W 07-04-01

TCD 2015

z Oil the roller tappet lightly.


z Insert roller tappet.
The pilot pin (1) must lock in
groove (arrow).
1

6
42164-1

z Mount new O-rings (1).


z Oil O-rings lightly.

42165-2

z Insert injection pump (1).


Note assignment!
A-bank:
The cable connections (3) of the injection
pumps must face the genset support.
B-bank:

The cable connections (3) of the injection


pumps must face the flywheel.
z Lightly oil screws (2).
z Tighten screws (2).

45382-0

06/2006

6/8

8217-001

Fuel system
W 07-04-01

TCD 2015
z Tighten screws (1) alternately.
 A07 012

Attention!
Do not turn the camshaft until all the injection pumps are installed. Danger of breaking the tappet!

6
45383-0

z Plug in cables (2).


 T13 054
Note assignment!

z Tighten screws (1).


 A13 054

1
2

45384-0

z Position fuel hose (2).


z Tighten screws (1).
 A12 095

40554-0

06/2006

7/8

8217-001

Fuel system
W 07-04-01

TCD 2015

z Installing high pressure pipes (A-bank)


 W 07-03-01
z Installing high pressure pipes (B-bank)
 W 07-03-01
z Install crankcase breather.
 W 03-01-11
z Remove turning gear.
 W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

6
40956-0

06/2006

8/8

8217-001

Fuel system
W 07-06-04

TCD 2015
Checking and setting plunger lift of injection pumps
Commercial available tools:
Feeler gauges

W 04-06-03
W 06-06-04
W 06-06-04 . . . . . . . . . . . . (A-bank,
Railway)
W 06-06-04 . . . . . . . . . . . . (B-bank,
Railway)
W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)

Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100410
Dial gauge holder
with stylus extension. . . . . . . . . . 103240
Measuring pin . . . . . . . . . . . . . . . 110180
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Packing compound
DEUTZ DW 48
Locking agent
DEUTZ DW 72

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Read out error memory of the motor control timer with SERDIA.

Checking plunger lift of injection pumps


z Remove injection pumps (cylinder A1).
 W 07-04-01
z Remove injection pumps (cylinder A2-B3).
 W 07-04-01
Do not remove injection pump housing.

z Attach turning gear.


 W 04-06-03

40495-0

06/2006

1/14

8218-001

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W 07-06-04

TCD 2015

z Turn over crankshaft until the valve overlap is


achieved on cylinder no. B2.
 T01 63
Valve overlap means:
Inlet valves begin to open and exhaust valves close.
Observe valve clearance setting diagram.

6
40465-0

In case of valve overlap of cylinder no. B2:


The locking pin of the turning gear must
snap into the tooth notch (1) of the starter
ring gear.
The second tooth notch (2) must face the
B-bank.

2
40466-0

z Pull locking pin (1).


z Turn crankshaft in the opposite direction to the engine rotation (arrow) a turn with the turning gear.
1

40501-0

06/2006

2/14

8218-001

Fuel system
W 07-06-04

TCD 2015
z Unscrew hollow screw (1).
z Place fuel hose (2) to one side.
z Remove sealing rings.

1
2

6
40458-0

The injection pump cams for cylinder


no. A1 must be on the base circle (arrow).

42163-1

z Oil the roller tappet lightly.


z Insert roller tappet.
Note the assignment of the roller tappet.
The pilot pin (1) must lock in
groove (arrow).
1

42164-1

06/2006

3/14

8218-001

Fuel system
W 07-06-04

TCD 2015

z Mount dial gauge holder (1).


z Tighten screws (2).
 A07 012
1
2

6
40499-0

z Insert dial gauge holder (1) with stylus extension.


z Mount stylus with 6 mm pre-tension on the roller tappet.
z Turn the crankshaft alternately in and against engine
direction.
z Check installation position of the dial gauge.

Dial gauge must run on the base circle of


the injection camshaft.
The display of the dial gauge may not
move.
z Adjust dial gauge to "0".

40500-0

z Set crankshaft with turning gear in engine direction of


rotation (arrow) to ignition TDC, cylinder no. A1.
The locking pin of the turning gear must
snap into the starter gear ring.

40502-0

06/2006

4/14

8218-001

Fuel system
W 07-06-04

TCD 2015
z Read and note the measured value.
 P07 19

6
40503-0

Setting plunger lift of injection pumps


All injection pumps must be removed.
1

z Remove turbocharger.
 W 06-06-04
z Remove turbocharger (A-bank, Railway).
 W 06-06-04
z Remove turbocharger (B-bank, Railway).
 W 06-06-04
z Unscrew screws (1).

40504-0

z Unscrew all screws (3).


1

z Remove spacing sleeves.


z Unscrew all screws (2).
z Remove heat shield (1).

2
40517-0

06/2006

5/14

8218-001

Fuel system
W 07-06-04

TCD 2015

z Unscrew screws (1).


z Remove the holder (2).

6
40506-0

z Unscrew screw (1).


z Remove pipe clamp (2).

2
1

40456-0

z Unscrew all screws (1).


z Remove gear case cover (2).

40507-0

06/2006

6/14

8218-001

Fuel system
W 07-06-04

TCD 2015
z Remove cable tie (1).

6
40459-0

z Unscrew screws (1).


z Remove cover (2) .
z Remove cover (3).
3

40460-0

z Unscrew screws (1).


z Remove pad thrust bearing (2).

40508-0

06/2006

7/14

8218-001

Fuel system
W 07-06-04

TCD 2015

z Loosen all screws (1).

6
40464-0

z Pull locking pin (1).


z Turn crankshaft in the opposite direction to the engine rotation (arrow) a turn with the turning gear.
1

Dial gauge must read "0" again.

40501-0

z Set crankshaft with turning gear in engine direction of


rotation (arrow) to ignition TDC, cylinder no. A1.
The locking pin of the turning gear must
snap into the starter gear ring.

40502-0

06/2006

8/14

8218-001

Fuel system
W 07-06-04

TCD 2015
z Turn the injection pump camshaft with the screws in
engine direction of rotation (arrow) until the prescribed plunger lift is reached.
 P07 19

6
40509-0

z Pre-tighten screws (1).


 A04 004
When pre-tightening the screws, press the
gear wheel lightly in the opposite direction
to engine rotation (arrow) against the tooth
flanks.
z Check the setting of the plunger lift again.

40510-0

z Remove dial gauge.


z Remove dial gauge holder.

40511-0

06/2006

9/14

8218-001

Fuel system
W 07-06-04

TCD 2015

z Tighten all screws (1).


 A04 004
z Pull locking pin.
Concealed screws can be accessed by
turning the crankshaft with the turning gear.

6
40464-0

z Mount pad thrust bearing (2).


z Lightly oil screws (1).
z Tighten screws (1).

40989-0

Checking and setting axial backlash of the


injection pump camshaft
z Insert feeler gauge blade between gear wheel of the
injection pump camshaft and the pad thrust
bearing (arrow).

z Press the pad thrust bearing onto the feeler gauge


blade.
z Fasten screw (1).
z Check axial backlash.
 P04 43

40512-0

06/2006

10/14

8218-001

Fuel system
W 07-06-04

TCD 2015
z Insert feeler gauge blade between gear wheel of the
injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge
blade.
z Fasten screw (1).

z Check axial backlash.


 P04 43

6
40513-0

z Tighten screws (1).


 A04 015
z Check axial backlash again.
 P04 43
1

Check axial backlash on both sides between


pad thrust bearing and gear
wheel (arrows).

40514-0

z Clean sealing surfaces.


z Mount new O-ring (1).
z Lightly oil O-ring.

40515-0

06/2006

11/14

8218-001

Fuel system
W 07-06-04

TCD 2015

z Press in the cover (3) to the stop.


z Mount cover (2).
Insert screws with safety agent
DEUTZ DW 72.
3

z Tighten screws (1).

 A04 022

6
40460-0

z Fix cables with cable ties (1).

40459-0

z Clean sealing surfaces.


z Apply packing compound evenly to the sealing surface of the gear case.
z Mount gear case cover (1).
z Mount holder (2).
z Tighten all screws (3) alternately.

 A04 020
1

40516-0

06/2006

12/14

8218-001

Fuel system
W 07-06-04

TCD 2015
z Mount pipe clamp (2).
z Tighten screw (1).
 A08 045
2

6
40456-0

z Mount holder (2).


z Tighten screws (1).
 A12 071

40455-0

z Mount heat shield (1).


1

z Insert screws (3) with spacing sleeves.


z Tighten screws (2).
z Tighten screws (2 and 3) alternately.
 A12 071

2
40517-0

06/2006

13/14

8218-001

Fuel system
W 07-06-04

TCD 2015

z Tighten screws (1).


 A13 094
z Install the turbocharger.
1

 W 06-06-04
z Install turbocharger (A-bank, Railway).
 W 06-06-04
z Install turbocharger (B-bank, Railway).
 W 06-06-04

6
40453-0

z Mount new sealing rings.


z Position fuel hose (2).
z Tighten hollow screw (1).
 A12 090
1
2

40458-0

z Install injection pumps (cylinder A1).


 W 07-04-01
z Install injection pumps (cylinder A2-B3).
 W 07-04-01
z Remove turning gear.
 W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

40518-0

06/2006

14/14

8218-001

Fuel system
W 07-07-01

TCD 2015
Removing and installing the fuel injectors
Commercial available tools:
Assembly pliers. . . . . . . . . . . . . . . . 8024

W 07-03-01 . . . . . . . . . . . . (A-bank)
W 07-03-01 . . . . . . . . . . . . (B-bank)
W 07-07-05

Special tools:
Puller. . . . . . . . . . . . . . . . . . . . . . 110030
Grooved nut wrench . . . . . . . . . . 110130
Disassembly tool. . . . . . . . . . . . . 110901
Extraction tool . . . . . . . . . . . . . . . 120660
Slide hammer . . . . . . . . . . . . . . . 150800
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Fitting compound
DEUTZ S1

Removing fuel injector


z Removing high pressure pipes (A-bank).
 W 07-03-01
z Removing high pressure pipes (B-bank).
 W 07-03-01

40957-0

06/2006

1/6

8219-001

Fuel system
W 07-07-01

TCD 2015

z Unscrew union screw with grooved nut wrench.

6
40643-0

z Pull out fuel injector (1) and sealing ring (arrow).

40815-0

Removing stuck fuel injectors


z Assembly sliding hammer (1) and puller (2).
z Tighten lock nut (3).
1

2
3

40958-0

06/2006

2/6

8219-001

Fuel system
W 07-07-01

TCD 2015
z Mount sliding hammer on fuel injector.
z Screw on lock nut (1).
z Pull out stuck fuel injector.

6
40816-0

z Grip a tight sealing ring (1) with the assembly


pliers (2) and pull off, turning slightly.

Attention!
Do not damage the nozzle tip!

1
2
43303-0

Removing a tightly fixed sealing ring from


the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.

45419-0

06/2006

3/6

8219-001

Fuel system
W 07-07-01

TCD 2015

z Turn in the spindle.


The sealing ring must be fixed on the puller.
Hold puller on hexagon.

z Mount adapter (1) and slide hammer (2) on extraction device.


z Remove tight sealing ring.
2

6
45420-0

z Remove the O-ring (1) with the disassembly tool.


1

40607-1

z Visually inspect the components.


z Check the fuel injector.
 W 07-07-05

45414-0

06/2006

4/6

8219-001

Fuel system
W 07-07-01

TCD 2015
Installing the fuel injector
z Insert new O-ring (arrow).
z Coat the thread (1) with fitting compound.

6
40818-0

z Coat the nozzle holder shaft in the (X) area with fitting compound.
z Coat the lay-on surface of the sealing ring (arrow)
with fitting compound.

z Mount new sealing ring (1) on fuel injector.


1

40819-0

z Push the union screw (1) in the direction of the arrow.

Attention!
Do not damage the O-ring!

40820-0

06/2006

5/6

8219-001

Fuel system
W 07-07-01

TCD 2015

z Insert fuel injector.


z Tighten union screw with grooved nut wrench.
 A07 001

6
40643-0

z Installing high pressure pipes (A-bank)


 W 07-03-01
z Installing high pressure pipes (B-bank)
 W 07-03-01

40957-0

06/2006

6/6

8219-001

Fuel system
W 07-07-02

TCD 2015
Dismantling and assembling fuel injector
Commercial available tools:
Socket wrench insert . . . . . . . . . . . 8017

W 07-07-01
W 07-07-05

Special tools:
Holder . . . . . . . . . . . . . . . . . . . . . 110110

Dismantling fuel injector


z Removing fuel injectors.
 W 07-07-01
z Check and set fuel injectors.
 W 07-07-05
z Insert fuel injector in holder.
z Unscrew nozzle cap nut with socket wrench insert.

36271-2

z Dismantle fuel injector.


Lay out components in the order in which
they should be installed.
6

z Visually inspect the components.


Shim (1)
Compression spring (2)

Thrust bolt (3)

Intermediate piece (4)


Injection nozzle (5)
Nozzle cap nut (6)
z Clean the parts in clean diesel fuel.
z Blow components dry with air.
36269-2

06/2006

1/6

8220-001

Fuel system
W 07-07-02

TCD 2015

Assembling fuel injector


z Check injection nozzle.

Attention!
Do not touch the nozzle needle with your
fingers!
Nozzle needle (1) and nozzle body (2) are
folded together and may not be switched or
changed individually!

1
2

6
33904-2

The nozzle needle (1) must slide slowly


and without jolting into its seat by the force
of its own weight with the nozzle body (2)
held vertically.
In case of abrupt sliding of the nozzle
needle, clean the injection nozzle again in
the diesel bath, renew if necessary.

1
2

Also clean the new injection nozzle in the


clean diesel bath.

33904-2

z Visually inspect the seat surfaces of the intermediate


piece for wear.
Make sure the centering pins (arrows) are
in place.

33905-2

06/2006

2/6

8220-001

Fuel system
W 07-07-02

TCD 2015
z Select shim for setting the opening pressure.
The opening pressure depends on the
thickness of the shim.
A thicker shim gives a higher opening pressure.
z Insert shim.

6
36274-2

z Insert compression spring.

33907-2

z Insert thrust bolt.

33908-2

06/2006

3/6

8220-001

Fuel system
W 07-07-02

TCD 2015

z Insert intermediate piece with the centering pins in


the bores of the nozzle holder.
The countersink must face the thrust bolt.

6
33909-2

z Mount the injection nozzle with the centre bores on


the centering pins of the intermediate piece.
The nozzle needle may not fall out of the
nozzle body.

33910-2

z Screw on the nozzle cap nut.

33911-2

06/2006

4/6

8220-001

Fuel system
W 07-07-02

TCD 2015
z Tighten nozzle cap nut.
 A07 002
z Remove fuel injector from holder.
z Check and set fuel injectors.
 W 07-07-05
z Install fuel injectors.
 W 07-07-01

6
33912-2

06/2006

5/6

8220-001

Fuel system
W 07-07-02

TCD 2015

06/2006

6/6

8220-001

Fuel system
W 07-07-05

TCD 2015
Checking and setting fuel injectors
Commercial available tools:
Socket wrench insert . . . . . . . . . . . 8017
Nozzle tester. . . . . . . . . . . . . . . . . . 8008

W 07-07-01
W 07-07-02

Special tools:
Holder . . . . . . . . . . . . . . . . . . . . . 110110

Danger!
Danger of injury when handling the nozzle
tester.
The fuel penetrates deep into the flesh
through the nozzle jet!
Caution, blood poisoning!
After about three or four actuations of the
hand lever, the spring space above the
nozzle needle in the injection valve fills up
with diesel fuel/test oil. Then it is no longer
possible to actuate the hand lever.
The nozzle cap nut must be loosened carefully before every test procedure to release
pressure from the spring space.
Only use pure test oil according to ISO
4113 or clean diesel fuel to test the fuel
injectors.

z Removing fuel injectors.


 W 07-07-01

45414-0

06/2006

1/6

8221-001

Fuel system
W 07-07-05

TCD 2015

Connecting the fuel injector to the nozzle


tester
z Insert fuel injector in holder.
z Loosen nozzle cap nut approx. 180 with socket
wrench insert (release pressure) and re-tighten.
 A07 002

6
36271-2

z Connect the fuel injector to the nozzle tester

35889-2

Checking opening pressure


z Press down the lever of the nozzle tester slowly with
the pressure gauge connected.
z Read off measured value.
The pressure at which the pointer stands
still or suddenly drops is the opening pressure.
Repeat test 3 times.

36293-2

06/2006

2/6

8221-001

Fuel system
W 07-07-05

TCD 2015
z Compare measured values.
 P07 52
The measured values of three tests must
match the test value.
z In case of deviations from the test value, the fuel injector must be dismantled or exchanged.
 W 07-07-02

6
36293-2

Checking tightness
z Blow the injection nozzle and nozzle holder dry with
air.
z Press the hand lever of the tester down slowly until
about 20 bar below the previously read opening
pressure are reached.

36293-2

Injection nozzle is tight if it does not drip


within 10 seconds.

36294-2

06/2006

3/6

8221-001

Fuel system
W 07-07-05

TCD 2015

z If the injection nozzle drips, the fuel injector must be


dismantled or exchanged.
 W 07-07-02

Attention!
Repairs are not permitted!

6
36295-2

Checking the easy action of the nozzle


needle
z Switch off the testers pressure gauge.
z Carry out chatter and jet test of the nozzle needle.
The easy action of the nozzle needle in the
nozzle body is checked by the acoustic
chatter test.
Increasing wear in the needle seat of the
fuel injectors changes the chatter behavior
of the injecton nozzle.
A used fuel injector must buzz audibly and
atomize the fuel finely when the lever is
actuated quickly.

36296-2

z If the injection nozzle does not buzz audibly, it must


be dismantled and cleaned.
 W 07-07-02
The injection nozzle must be changed if it
does not buzz after cleaning.
The jet profile may deviate considerably
from that of a new fuel injector.

36296-2

06/2006

4/6

8221-001

Fuel system
W 07-07-05

TCD 2015
Removing the fuel injector from the nozzle
tester
z Loosen nozzle cap nut approx. 180 with socket
wrench insert (release pressure) and re-tighten.
 A07 002

Attention!
The pressure in the spring space must be
reduced before installing the fuel injectors.
z Install fuel injectors.
 W 07-07-01

6
36271-2

06/2006

5/6

8221-001

Fuel system
W 07-07-05

TCD 2015

06/2006

6/6

8221-001

Fuel system
W 07-09-01

TCD 2015
Removing and installing temperature transmitter
Commercial available tools

W 06-07-03 . . . . . . . . . . . . (B-bank)

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Read out error memory of the motor control timer with SERDIA.

Removing temperaure transmitter


z Remove charge air pipe (B-bank).
 W 06-07-03

40822-0

06/2006

1/4

8222-001

Fuel system
W 07-09-01

TCD 2015

z Unlock cable plug (1) and remove.

6
40823-0

z Unscrew temperature transmitter (1).

40824-0

z Visually inspect the components.

40825-0

06/2006

2/4

8222-001

Fuel system
W 07-09-01

TCD 2015
Installing temperature transmitter
z Tighten temperature transmitter (1).
 A07 023

6
40824-0

z Plug in the cable plug (1).

40823-0

z Install charge air pipe (B-bank)


 W 06-07-03
Delete error entry in the error memory of
the motor control timer with SERDIA.

40822-0

06/2006

3/4

8222-001

Fuel system
W 07-09-01

TCD 2015

06/2006

4/4

8222-001

Fuel system
W 07-10-06

TCD 2015
Removing and installing fuel pipes
Commercial available tools:
Open wrench size SW 22

W 06-07-03 . . . . . . . . . . . . (A-bank)
W 06-07-03 . . . . . . . . . . . . (B-bank)

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Ensure that the cables are connected properly.

Removing fuel pipes


z Remove charge air pipe (A-bank).
 W 06-07-03
z Remove charge air pipe (B-bank).
 W 06-07-03

40606-0

06/2006

1/14

8223-001

Fuel system
W 07-10-06

TCD 2015

z Loosen screws (1).


z Pull the cables (2) off all injection pumps.
Mark assignment of cables/connections
before removing.

1
2

6
45384-0

z Remove cable tie (1).


z Unlock cable plug (2) and disconnect.

40608-0

z Unlock cable plug (1) and remove.

40609-0

06/2006

2/14

8223-001

Fuel system
W 07-10-06

TCD 2015
z Unlock cable plug (1) and remove.

6
40610-0

z Unscrew screws (1).

40611-0

z Unscrew nuts (1).


z Unscrew the nuts (2).
z Remove washers.
z Remove cables.
Mark assignment of cables/connections
before removing.

z Place cable harness rail with cable harness to one


side.

40612-0

06/2006

3/14

8223-001

Fuel system
W 07-10-06

TCD 2015

z Unscrew screws (1).


z Remove the holder (2).

2
1

6
40613-0

z Unscrew screw (1).


z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings.

1
2

40623-0

z Unscrew nut (1).


z Remove the holder (2).

40614-0

06/2006

4/14

8223-001

Fuel system
W 07-10-06

TCD 2015
z Unscrew hollow screw (1).
Hold overflow valve.

z Remove fuel pipe (2).


z Remove sealing rings.
1
2

6
40615-0

z Unscrew hollow screw (1).


z Remove sealing rings.
z Place fuel hose (2) to one side.
1

40616-0

z Unscrew nuts (1).


z Remove the holder (2).

40617-0

06/2006

5/14

8223-001

Fuel system
W 07-10-06

TCD 2015

z Unscrew lock nut (1).


z Remove fuel pipe (2).

6
40618-0

z Unscrew all screws (1).


z Remove fuel pipes (2).
z Remove seals.
1

40619-0

z Visually inspect the components.

40620-0

06/2006

6/14

8223-001

Fuel system
W 07-10-06

TCD 2015
Installing fuel pipes
z Mount new gaskets (1).
1

6
40621-0

Note assignment!
The lug (1) must lock in groove (2).

42115-1

z Mount fuel pipes (2).


z Tighten all screws (1).
 A07 015
Do not move the gaskets when mounting
the fuel pipes.

40619-0

06/2006

7/14

8223-001

Fuel system
W 07-10-06

TCD 2015

z Mount fuel pipe (2).


z Screw on lock nut (1).

6
40618-0

z Oil the thread lightly.


z Mount holder (2).
z Tighten nuts (1).
 A07 044

40617-0

z Tighten lock nut (1).


 A07 066

40622-0

06/2006

8/14

8223-001

Fuel system
W 07-10-06

TCD 2015
z Mount new sealing rings.
z Position fuel hose (2).
z Tighten hollow screw (1).
 A12 090

6
40616-0

z Mount new sealing rings.


z Mount fuel pipe (2).
z Screw on hollow screw (1).

1
2

40615-0

z Oil the thread lightly.


z Mount holder (2).
z Screw on nut (1).
1

40614-0

06/2006

9/14

8223-001

Fuel system
W 07-10-06

TCD 2015

z Mount new sealing rings.


z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.

z Fasten screw (1).

6
40623-0

z Tighten hollow screw (1).


Hold overflow valve.
 A12 093
1

z Tighten nut (2).


 A07 044

40625-0

z Tighten screw (1).


 A07 044
z Tighten hollow screw (2).

 A12 092

40624-0

06/2006

10/14

8223-001

Fuel system
W 07-10-06

TCD 2015
z Mount holder (2).
z Tighten screws (1).
 A07 044

2
1

6
40613-0

z Position cable harness rail with cable harness.


z Plug cables.

Attention!
Note assignment and polarity of the electrical connections!

Connect cables according to marks made


before removing.

z Mount washers.
z Tighten nuts (1).
 A13 037
z Tighten nuts (2).
 A13 038
40612-0

z Tighten screws (1).


 A13 094

40611-0

06/2006

11/14

8223-001

Fuel system
W 07-10-06

TCD 2015

z Plug in the cable plug (1).

6
40610-0

z Plug in the cable plug (1).

40609-0

z Plug together the cable plugs (2).


z Fix cable tie (1).

40608-0

06/2006

12/14

8223-001

Fuel system
W 07-10-06

TCD 2015
Clamp all injection pumps.

z Plug in cables (2).


 T13 054
z Tighten screws (1).
 A13 054

1
2

6
45384-0

z Install charge air pipe (A-bank)


 W 06-07-03
z Install charge air pipe (B-bank)
 W 06-07-03

40495-0

06/2006

13/14

8223-001

Fuel system
W 07-10-06

TCD 2015

06/2006

14/14

8223-001

Fuel system
W 07-10-06

TCD 2015 Railway


Removing and installing fuel pipes
Attention!

Commercial available tools

Pay attention to utmost cleanliness when


working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Ensure that the cables are connected properly.

Removing fuel pipes


z Loosen screws (1).
Mark assignment of cables/connections
before removing.
z Remove cables.

42107-2

06/2006

1/6

8224-001

Fuel system
W 07-10-06

TCD 2015 Railway

z Unlock cable plug (1) and remove.


z Remove cable tie (2).

1
2

6
42108-1

z Unlock cable plug (1) and remove.


z Unlock cable plug (2) and remove.

1
45854-0

z Unscrew screws (arrows).


z Place cable harness rail with cable harness to one
side.

42110-1

06/2006

2/6

8224-001

Fuel system
W 07-10-06

TCD 2015 Railway


z Unscrew hollow screw (1).
z Remove sealing rings.
z Place hose pipe (2) to one side.

1
2

6
42112-1

z Unscrew all screws (1).


z Remove fuel pipes (2).
z Remove seals.

2
1

45856-1

z Visually inspect the components.

40620-0

06/2006

3/6

8224-001

Fuel system
W 07-10-06

TCD 2015 Railway

Installing fuel pipes


z Mount new gaskets (1).

6
42114-2

Note assignment!
The lug (1) must lock in groove (2).

42115-1

z Mount fuel pipes (2).


z Tighten all screws (1).
 A07 015
Do not move the gaskets when mounting
the fuel pipes.
2
1

45856-1

06/2006

4/6

8224-001

Fuel system
W 07-10-06

TCD 2015 Railway


z Mount hose line (2).
z Mount new sealing rings.
z Screw on hollow screw (1).

1
2

6
42112-1

z Position cable harness rail with cable harness.


z Position pipe clamp (arrow).
z Fasten screws.
Note different screw lengths:
M6 x 12 mm (1)
1

M6 x 16 mm (2)
z Tighten screws .

 A13 094
2

42111-1

z Position hose line (1).


Observe installation angle dimension X =
10.

z Tighten hollow screw (2).


 A12 090

2
45910-2

06/2006

5/6

8224-001

Fuel system
W 07-10-06

TCD 2015 Railway

z Plug in the cable plug (1).


z Plug in the cable plug (2).

45854-0

z Plug cable plugs (1) together.


z Fix cable with cable tie (2).

1
2

42108-1

Clamp all injection pumps.

z Plug in cables (1).


 T13 054

Attention!
Note assignment and polarity of the electrical connections!

Connect cables according to marks made


before removing.
z Tighten screws .
 A13 054
45858-0

06/2006

6/6

8224-001

Fuel system
W 07-11-01

TCD 2015
Removing and installing the fuel supply pump
Attention!

Commercial available tools:


Magnetic measuring stand

Pay attention to utmost cleanliness when


working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Removing the fuel supply pump


z Unscrew screws (1).
z Remove holder (2).

40827-0

06/2006

1/6

8225-001

Fuel system
W 07-11-01

TCD 2015

z Unscrew hollow screws (1).


z Remove fuel pipes (2).
z Remove sealing rings.

6
40828-0

z Unscrew hollow screw (1).


z Unscrew lock nut (2).
z Remove lubricating oil pipe.

z Remove sealing rings.

40829-0

z Unscrew screws (1).


z Remove fuel supply pump (2).

40830-0

06/2006

2/6

8225-001

Fuel system
W 07-11-01

TCD 2015
z Visually inspect the components.

6
40961-0

Installing the fuel supply pump


z Mount new O-ring (1).
z Lightly oil O-ring.

42286-2

z Install fuel pump.


z Insert the driver (1) in the groove (2).

40831-0

06/2006

3/6

8225-001

Fuel system
W 07-11-01

TCD 2015

z Tighten screws (1).


 A07 024

6
40832-0

z Mount new sealing rings.


z Mount the lubricating oil pipe.
z Screw on hollow screw (1).

z Tighten lock nut (2).


 A08 014
z Tighten hollow screw (1).
 A08 013
2

40829-0

z Mount new sealing rings.


z Mount fuel pipes (2).
z Tighten hollow screws (1).
 A07 034
2

40828-0

06/2006

4/6

8225-001

Fuel system
W 07-11-01

TCD 2015
z Mount holder (2).
z Tighten screws (1).
 A07 044

6
40827-0

06/2006

5/6

8225-001

Fuel system
W 07-11-01

TCD 2015

06/2006

6/6

8225-001

Fuel system
W 07-13-01

TCD 2015
Removing and installing fuel pressure holding valve
Commercial available tools:
Open wrench size SW 22

W 06-07-03 . . . . . . . . . . . . (A-bank)

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing fuel pressure holding valve


z Remove charge air pipe (A-bank).
 W 06-07-03
z Unscrew screws (1).
z Remove the holder (2).

2
1

40519-0

06/2006

1/8

8226-001

Fuel system
W 07-13-01

TCD 2015

z Unscrew screw (1).


z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings.
1
2

6
40520-0

z Unscrew nut (1).


z Remove the holder (2).

1
2

40521-0

z Unscrew hollow screw (1).


Hold overflow valve.

z Remove fuel pipe (2).


z Remove sealing rings.
1
2

40522-0

06/2006

2/8

8226-001

Fuel system
W 07-13-01

TCD 2015
z Unscrew hollow screw (1).
z Remove sealing rings.
z Place hose pipe (2) to one side.

1
2

6
40948-0

z Hold the connector.


z Unscrew overflow valve (3).
z Remove sealing ring.
z Unscrew lock nut (1).
1

z Remove connector (2).

40949-0

z Visually inspect the components.

45848-0

06/2006

3/8

8226-001

Fuel system
W 07-13-01

TCD 2015

Installing fuel pressure holding valve


z Mount new sealing ring.
z Screw on overflow valve (1).

6
40947-0

z Insert connector (2).


Note installation position.
Connection of the hose line faces the heat
shield.
1

z Hold the connector.


z Tighten union nuts (1) with open wrench.
 A07 066

40949-0

z Hold the connector.


z Tighten overflow valve (1) with open wrench.
 A07 067

40949-0

06/2006

4/8

8226-001

Fuel system
W 07-13-01

TCD 2015
z Position hose line (1).
z Mount sealing rings (3).
z Tighten hollow screw (2).
 A12 090

Attention!
Lay the hose pipe free from chafing and
tension.

1
3

6
40948-1

z Mount new sealing rings.


z Mount fuel pipe (2).
z Screw on hollow screw (1).

1
2

40522-0

z Oil the thread lightly.


z Mount holder (2).
z Screw on nut (1).

1
2

40521-0

06/2006

5/8

8226-001

Fuel system
W 07-13-01

TCD 2015

z Mount new sealing rings.


z Screw on hollow screw (3).
z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1).

1
2

6
40520-0

z Tighten hollow screw (1).


Hold overflow valve.
 A12 093
z Tighten nut (2).

 A07 044
2

40565-0

z Tighten screw (1).


 A07 044
z Tighten hollow screw (2).
 A12 092

1
2

40555-0

06/2006

6/8

8226-001

Fuel system
W 07-13-01

TCD 2015
z Mount holder (2).
z Tighten screws (1).
 A07 044
z Install charge air pipe (A-bank)
 W 06-07-03

2
1

6
40519-0

06/2006

7/8

8226-001

Fuel system
W 07-13-01

TCD 2015

06/2006

8/8

8226-001

Fuel system
W 07-13-01

TCD 2015 Railway


Removing and installing fuel pressure holding valve
Attention!

Commercial available tools:


Open wrench size SW 22

Pay attention to utmost cleanliness when


working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Removing fuel pressure holding valve


z Hold overflow valve (1).
z Unscrew screw-in nipple (2).
z Remove sealing ring.

45925-1

06/2006

1/6

8227-001

Fuel system
W 07-13-01

TCD 2015 Railway

z Hold connector (1).


z Unscrew overflow valve (2).
z Remove sealing ring.

45915-1

z Unscrew screw (1).


z Remove washer.
1

z Loosen pipe clip.

45916-0

z Unscrew hollow screw (1).


z Remove sealing rings.
z Place hose pipe (2) to one side.
z Unscrew union nut (3).

z Remove connector.

1
45917-0

06/2006

2/6

8227-001

Fuel system
W 07-13-01

TCD 2015 Railway


z Visually inspect the components.

6
45769-0

Installing fuel pressure holding valve


z Mount new sealing ring.
z Screw on overflow valve (1).

40947-0

z Mount new sealing ring.


z Screw on screw-in nipple (1).

45770-0

06/2006

3/6

8227-001

Fuel system
W 07-13-01

TCD 2015 Railway

z Mount hose line (1).


z Mount new sealing rings.
z Screw on hollow screw (2).

1
2

6
45918-0

z Insert connector.
z Screw on lock nut (1).

45919-0

z Position connector (1).


Arrange hexagon area (1) horizontally.
The connection (2) faces approx. 45 to
the left.
1

45920-0

06/2006

4/6

8227-001

Fuel system
W 07-13-01

TCD 2015 Railway


z Hold connector (1).
z Tighten union nuts (2) with open wrench.
 A07 066

6
45921-1

z Hold connector (1).


z Tighten overflow valve (2) with open wrench.
 A07 067

45922-1

z Hold overflow valve (1).


z Tighten screw-in nipple (2).
 A07 069

45925-1

06/2006

5/6

8227-001

Fuel system
W 07-13-01

TCD 2015 Railway

z Position pipe clamp (1).


z Mount washer.
z Tighten screw (2).
2

 A13 094

6
45924-0

z Position hose line (1).


Observe installation angle dimension X =
10.

Attention!

Lay the hose pipe free from chafing and


tension.

z Tighten hollow screw (2).


 A12 090

2
45910-0

06/2006

6/6

8227-001

Lube oil system


W 08-04-06

TCD 2015
Removing and installing the oil suction pipe
Commercial available tools

W 08-04-07

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing the oil suction pipe


z Remove lubricating oil pan.
 W 08-04-07
z Unscrew screws (1).

z Remove oil suction pipe (2).


z Remove gasket.
1
2

40833-0

z Unscrew screws (1).


z Remove the holder (2).
z Visually inspect the components.

2
40834-0

06/2006

1/4

8228-001

Lube oil system


W 08-04-06

TCD 2015

Installing the oil suction pipe


z Mount holder (2).
z Tighten screws (1).

2
40834-0

z Clean sealing surfaces.


z Mount new gasket.
z Mount oil suction pipe (2).

Attention!
1

Ensure that the installation location is free


from faults.
Install tension-free.
z Tighten screws (1).
1
2

40833-0

z Tighten screws (1).


 A08 016

40835-0

06/2006

2/4

8228-001

Lube oil system


W 08-04-06

TCD 2015
z Tighten screws (1).
 A08 015
z Tighten screws (2).
 A08 016

z Install lubricating oil pan.


 W 08-04-07

6
40962-0

06/2006

3/4

8228-001

Lube oil system


W 08-04-06

TCD 2015

06/2006

4/4

8228-001

Lube oil system


W 08-04-06

TCD 2015 Railway


Removing and installing the oil suction pipe
Commercial available tools

W 08-04-07 . . . . . . . . . . . . (Railway)

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing the oil suction pipe


z Remove lubricating oil pan (Railway).
 W 08-04-07
z Unscrew screws (1).

z Remove oil suction pipe (2).


z Remove gasket.
1
1

45859-0

z Unscrew screws (1).


z Remove the holder (2).
z Visually inspect the components.

2
1

42171-1

06/2006

1/2

8229-001

Lube oil system


W 08-04-06

TCD 2015 Railway

Installing the oil suction pipe


z Mount holder (1).
z Tighten screws (2).
 A08 016
2
1

6
42171-1

z Clean sealing surfaces.


z Mount new gasket.
z Mount oil suction pipe.
z Fasten screws.
Ensure that the installation location is free
from faults.
Note different screw lengths:
M8 x 25 mm (1)
M8 x 20 mm (2)
1

42170-1

z Tighten screws (1).


 A08 015
z Tighten screws (2).
 A08 016

Attention!
Install tension-free!
z Install lubricating oil pan (Railway).
 W 08-04-07

42170-1

06/2006

2/2

8229-001

Lube oil system


W 08-04-07

TCD 2015
Removing and installing the lubricating oil pan
Commercial available tools

W 13-03-02

Packing compound
DEUTZ DW 47
Engine oil

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.

Removing the lubricating oil pan


z Remove starter.
 W 13-03-02
z Unscrew locking screw (1).
z Drain, collect and dispose of engine oil according to
regulations.

1
40836-0

z Oil the screw plug lightly.


z Mount new sealing ring.
z Tighten screw plug (1).
 A03 031

40836-0

06/2006

1/6

8230-001

Lube oil system


W 08-04-07

TCD 2015

z Pull out oil dipstick (1).


z Turn engine 180.

6
40837-0

z Unscrew screws (1).

40838-0

z Unscrew all screws (1).


z Remove cables (2).
The holders (3) remain on the cables.

2
3
40839-0

06/2006

2/6

8230-001

Lube oil system


W 08-04-07

TCD 2015
z Remove lubricating oil pan.
z Remove gasket (1).

6
40840-0

z Unscrew lock nut (1).


z Remove guide tube (2).
z Remove screw-in nipple.
z Visually inspect the components.

2
40841-0

Installing the lubricating oil pan


z Tighten screw-in nipple (1).
 A08 038

z Mount guide tube.


z Tighten union nut.
 A08 035

40842-0

06/2006

3/6

8230-001

Lube oil system


W 08-04-07

TCD 2015

z Clean sealing surfaces.


The sealing surfaces must be dry and free
from grease and dirt.
z Apply packing compound to the joints (arrows).

6
40843-0

z Select new gasket.

40844-0

z Mount gasket (1).


Strap (arrow) faces generator.
TOP label faces crankcase.

1
40845-0

06/2006

4/6

8230-001

Lube oil system


W 08-04-07

TCD 2015
z Mount lubricating oil pan.
z Align lubricating oil pan to crankcase.
Ensure that the installation location of the
gasket is free from faults.

6
40846-0

z Mount holder (3).


z Position cable (2).
z Tighten screws (1) alternately.

2
3
40839-0

z Tighten all screws.


 A03 030
24

See graphic for tightening sequence.

20 16

12

13

17

21

28

25

30

29

27

26

23

19

15

11

10

14

18

22

45421-1

06/2006

5/6

8230-001

Lube oil system


W 08-04-07

TCD 2015

z Tighten screws (1).


 A03 080
1

6
40838-0

z Turn engine 180.


z Insert oil dipstick (1).

40837-0

z Fill engine oil according to operating instructions.


z Install starter.
 W 13-03-02

40848-0

06/2006

6/6

8230-001

Lube oil system


W 08-04-07

TCD 2015 Railway


Removing and installing the lubricating oil pan

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.

Commercial available tools

Packing compound
DEUTZ DW 47
Fitting compound
DEUTZ AP1908
Engine oil

Removing the lubricating oil pan


z Unscrew locking screw (1).
z Drain, collect and dispose of engine oil according to
regulations.

42439-1

z Oil the screw plug lightly.


z Mount new sealing ring.
z Tighten screw plug (1).
 A03 031
z Turn engine 180.

1
45860-0

06/2006

1/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway

z Unscrew all screws (1).


z Remove washers.
z Remove all half-flanges (2).
z Remove both flanged sockets (3).

1
2

6
45867-0

z Unscrew screws (1).


z Remove connecting flange (2).
2

42441-1

z Unscrew screws (1).


z Remove the holder (2).
1
2

1
42442-1

06/2006

2/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway


z Unscrew all screws (1).
z Remove cables (2).
The holders (3) remain on the cables.

z Loosen lubricating oil pan.

6
45861-0

z Pull lubricating oil pan in direction of arrow.


z Remove lubricating oil pan.
z Remove gasket.
z Visually inspect the components.

45868-0

z Pull out plug elements (1).

1
45862-0

06/2006

3/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway

z Insert new O-rings (arrows).


z Coat the O-rings with fitting compound.

6
45863-0

z Insert plug elements (1).

1
45862-0

Mount lube oil tray with gasket.


z Clean sealing surfaces.
The sealing surfaces must be dry and free
from grease and dirt.
z Apply packing compound to the joints (arrows).

42445-1

06/2006

4/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway


z Mount new gasket (1).
The bright side of the gasket faces the
crankcase.
In case of metal bead seals, the beading
faces the crankcase.

6
45864-0

Mount lube oil tray with packing compound.


z Apply packing compound evenly to the sealing surface and in the beading of the lube oil tray.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
The position of the packing compound is
only partly illlustrated.

43451-0

z Mount lubricating oil pan.


z Push on lubricating oil pan in direction of arrow.

Attention!
Do not move or damage O-rings.

45869-0

06/2006

5/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway

z Align lubricating oil pan to crankcase.

Attention!
Do not move gasket/packing compound.
Do not move the gasket when mounting
the lubricating oil pan.

6
45865-0

z Mount holder (arrows).


z Position cable.
z Tighten screws alternately.

42447-1

z Tighten all screws.


 A03 030
24

See graphic for tightening sequence.

20 16

12

13

17

21

28

25

30

29

27

26

23

19

15

11

10

14

18

22

45421-1

06/2006

6/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway


z Insert new O-rings (arrows).
z Coat the O-rings with fitting compound.

6
37110-1

z Mount connecting flange (2).

Attention!
EX

The labels IN and EX on the connecting


flange and the lubricating oil pan must
match.

IN

z Tighten screws (1).


 A03 035

1
2

42448-1

z Insert new O-rings (arrows).


z Coat the O-rings with fitting compound.

37112-1

06/2006

7/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway

z Mount half-flange (1).


z Mount washers.
z Tighten screws (2).
z Insert flanged socket (3).
3
2

2
45870-0

z Mount half-flange (1).


z Mount washers.
z Tighten screws (2).

2
1

45871-0

z Mount half-flange (1).


z Mount washers.
z Tighten screws (2).

z Insert flanged socket (2).


z Align both flanged sockets centrally.

z Tighten all screws.


 A03 034

1
2

45872-0

06/2006

8/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway


z Mount holder (2).
z Tighten screws (1).
 A13 098

z Turn engine 180.


z Fill engine oil according to operating instructions.

1
42442-1

06/2006

9/10

8231-001

Lube oil system


W 08-04-07

TCD 2015 Railway

06/2006

10/10

8231-001

Lube oil system


W 08-08-02

TCD 2015
Removing and installing the oil cooler
Commercial available tools

W 06-07-03 . . . . . . . . . . . . (A-bank)
W 09-08-04
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing the oil cooler


z Remove charge air pipe (A-bank).
 W 06-07-03
z Remove thermostat housing.
 W 09-08-04

40849-0

z Unscrew screws (1).


z Remove the holder (2).

2
1

40519-0

06/2006

1/8

8232-001

Lube oil system


W 08-08-02

TCD 2015

z Unscrew screw (1).


z Remove the holder (2).

1
2

6
40850-0

z Unscrew nut (1).


z Remove the holder (2).

40851-0

z Unscrew hollow screw (1).


Hold overflow valve.

z Remove fuel pipe (2).


z Remove sealing rings.
1
2

40852-0

06/2006

2/8

8232-001

Lube oil system


W 08-08-02

TCD 2015
z Unscrew screws (1).

6
40853-0

z Unscrew all screws (1).


z Remove oil cooler cover (2).
z Remove gasket.
1

40854-0

z Unscrew screws (1).


z Remove oil cooler (2).
z Remove O-rings.

1
2

40855-0

06/2006

3/8

8232-001

Lube oil system


W 08-08-02

TCD 2015

z Visually inspect the components.

6
40856-0

Installing the oil cooler


z Clean sealing surfaces.
z Insert new O-rings (1).
z Insert new O-rings (2).

40857-0

z Mount oil cooler (2).


z Align oil cooler.
z Tighten screws (1).
 A08 051
1

1
2

40855-0

06/2006

4/8

8232-001

Lube oil system


W 08-08-02

TCD 2015
z Clean sealing surfaces.
z Mount new gasket.
z Mount oil cooler cover.
z Mount holder (1).
z Tighten screws (2).

Screw length:
M8 x 35 mm
z Fasten all screws (3).
2

Screw length:

M8 x 65 mm

3
40858-0

z Align oil cooler cover (2).


The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
Do not move gasket.

z Tighten all screws (1) alternately.


 A08 050

40854-0

z Tighten screws (1).


 A06 058
1

40853-0

06/2006

5/8

8232-001

Lube oil system


W 08-08-02

TCD 2015

z Mount new sealing rings.


z Mount fuel pipe (2).
z Screw on hollow screw (1).

1
2

6
40852-0

z Oil the thread lightly.


z Mount holder (2).
z Screw on nut (1).

40851-0

z Mount holder (2).


z Oil thread and head contact surface lightly.
z Fasten screw (1).
1
2

40850-0

06/2006

6/8

8232-001

Lube oil system


W 08-08-02

TCD 2015
z Mount holder (2).
z Tighten screws (1).
 A07 044

2
1

6
40519-0

z Tighten hollow screw (1).


 A12 093
Hold overflow valve.
1

z Tighten nut (2).

 A07 044

z Tighten screw (3).


 A07 044

40859-0

z Install thermostat housing.


 W 09-08-04
z Install charge air pipe (A-bank)
 W 06-07-03

40849-0

06/2006

7/8

8232-001

Lube oil system


W 08-08-02

TCD 2015

06/2006

8/8

8232-001

Lube oil system


W 08-11-09

TCD 2015
Removing and installing oil pressure pick-up

Read out error memory of the motor control timer with SERDIA.

Commercial available tools


Special tools:
Socket wrench insert . . . . . . . . . 110700

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing oil pressure pick-up


z Pull out cable plug (1).
1

40860-0

z Unscrew oil pressure pick-up (1) with the socket


wrench insert.
1

40861-0

06/2006

1/2

8233-001

Lube oil system


W 08-11-09

TCD 2015

z Visually inspect the components.

6
40862-0

Installing oil pressure pick-up


z Mount new gasket.
z Insert oil pressure pick-up (1).

z Tighten oil pressure pick-up with socket wrench insert.


 A08 091

40861-0

z Plug in the cable plug (1).


Delete error entry in the error memory of
the motor control timer with SERDIA.
1

40860-0

06/2006

2/2

8233-001

Lube oil system


W 08-11-10

TCD 2015
Removing and installing pressurestat
Commercial available tools:
Depth-measuring
appliance

W 03-01-11
W 06-07-03 . . . . . . . . . . . . (B-bank)
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing pressurestat
z Removing the crankcase breather.
 W 03-01-11
z Remove charge air pipe (B-bank).
 W 06-07-03

40863-0

z Remove cable tie (1).


z Unlock cable plug (2) and remove.

40608-0

06/2006

1/10

8234-001

Lube oil system


W 08-11-10

TCD 2015

z Unlock cable plug (1) and remove.

6
40609-0

z Unlock cable plug (1) and remove.

40864-0

z Unscrew screws (1).


z Remove the holder (2).

2
1

40613-0

06/2006

2/10

8234-001

Lube oil system


W 08-11-10

TCD 2015
z Unscrew nuts (1).
z Remove the holder (2).

6
40972-0

z Unscrew lock nut (1).


z Remove fuel pipe (2).
1

40973-0

z Unscrew locking screw (1).


z Remove sealing ring.

40865-0

06/2006

3/10

8234-001

Lube oil system


W 08-11-10

TCD 2015

z Unscrew valve housing (1).


z Remove sealing ring.
Do not move the adjusting bolt (2).
1

6
40866-0

If the same oil pressure is to be set again,


the overhang of the adjusting bolt must be
measured before removing.
z Measure overhang (X) from adjusting bolt (1) to
crankcase with the depth measuring appliance.
z Note measured value.
1

40867-0

z Unscrew adjusting bolt (1).


z Remove compression spring.
z Remove valve plunger.
1

40868-0

06/2006

4/10

8234-001

Lube oil system


W 08-11-10

TCD 2015
z Visually inspect the components.
Adjusting bolt (1).
Compression spring (2)
Valve plunger (3)

6
42460-1

Installing pressurestat
Overhang dimension (X) for basic setting
of adjusting bolt.
If the same oil pressure is to be set again,
the overhang dimension (X) noted before
removal must be reset.
 P08 63

35022-2

z Insert valve plunger.


z Insert compression spring.
z Screw in adjusting bolt (1).
 P08 63

Note overhang dimension of the adjusting


bolt.

40868-0

06/2006

5/10

8234-001

Lube oil system


W 08-11-10

TCD 2015

z Mount new sealing ring.


z Oil the thread valve housing lightly.
z Tighten valve housing (1).
 A03 051
Do not move the adjusting bolt (2).

1
2

6
40869-0

z Mount new sealing ring.


z Tighten screw plug (1).
 A08 071
1

40865-0

z Mount fuel pipe (2).


z Screw on lock nut (1).
1

40973-0

06/2006

6/10

8234-001

Lube oil system


W 08-11-10

TCD 2015
z Oil the thread lightly.
z Mount holder (2).
z Tighten nuts (1).
 A07 044

6
40972-0

z Tighten lock nut (1).


 A07 066
1

40990-0

z Mount holder (2).


z Tighten screws (1).
 A07 044

2
1

40613-0

06/2006

7/10

8234-001

Lube oil system


W 08-11-10

TCD 2015

z Plug in the cable plug (1).

6
40864-0

z Plug in the cable plug (1).

40609-0

z Plug in the cable plug (2).


z Fix cable tie (1).

40608-0

06/2006

8/10

8234-001

Lube oil system


W 08-11-10

TCD 2015
z Install charge air pipe (B-bank)
 W 06-07-03
z Install crankcase breather.
 W 03-01-11

6
40848-0

06/2006

9/10

8234-001

Lube oil system


W 08-11-10

TCD 2015

06/2006

10/10

8234-001

Cooling system
W 09-07-08

TCD 2015
Removing and installing the coolant pump

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Commercial available tools


Special tools:
Disassembly tool. . . . . . . . . . . . . 110901
Fitting compound
DEUTZ AP1908

Removing coolant pump


z Unscrew screws (1).
z Removing screw-in nipple (2).
z Remove gasket.
2

40870_1

z Visually inspect the components.

45393-0

06/2006

1/6

8235-001

Cooling system
W 09-07-08

TCD 2015

z Unscrew all screws (1).

6
40871-0

z Tighten screws (1).


Use three studs M8 to push the coolant
pump off the genset support.

z Press off the coolant pump.


z Remove gasket.

40872-0

z Remove screws.
z Remove the O-ring (1) with the disassembly tool.
z Remove the O-ring (2) with the disassembly tool.

36828_1

06/2006

2/6

8235-001

Cooling system
W 09-07-08

TCD 2015
z Visually inspect the components.

6
40874-0

Installing coolant pump


z Insert new O-rings.
O-rings:
75 x 3 mm (1)
80 x 3 mm (2)
1

z Coat the O-rings with fitting compound.

36828_1

z Clean sealing surfaces.


Check drainage holes (arrows) for free
passage.

40876-0

06/2006

3/6

8235-001

Cooling system
W 09-07-08

TCD 2015

z Screw in studs (1).


To fix the gasket and the coolant pump.
1

z Mount new gasket.

6
40877-0

z Insert coolant pump.


The gear wheel (1) must engage the toothing of the idler gear (2).

Attention!
Do not damage the gasket.
Do not move gasket.
1
2

40875-0

z Lightly oil screws (1).


z Fasten all screws (1).
z Unscrew studs (2).

40878-0

06/2006

4/6

8235-001

Cooling system
W 09-07-08

TCD 2015
z Lightly oil screws (1).
z Tighten screws (1).
z Tighten screws (1) alternately.
 A09 010

6
40879-0

z Clean sealing surfaces.


z Mount new gasket.
z Mount inlet adapter (2).
z Lightly oil screws (1).
z Tighten screws (1).
 A09 011

40870_1

06/2006

5/6

8235-001

Cooling system
W 09-07-08

TCD 2015

06/2006

6/6

8235-001

Cooling system
W 09-08-01

TCD 2015
Checking the thermostat when uninstalled
Commercial available tools:
Thermometer

W 09-08-02

Danger!
Risk of injury!
Hot water and hot thermostat.

Checking thermostat
z Remove thermostats.
 W 09-08-02
z Measure beginning of stroke, dimension (a).
z Note measured value, dimension (a).

34679-3

z Heat up the thermostat in the water bath.


z Determine beginning of opening.
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the thermostat.
Do not touch the thermostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1C/min. Otherwise the beginning of opening will be delayed accordingly.
 P09 11
P09 12
34680-2

06/2006

1/2

8236-001

Cooling system
W 09-08-01

TCD 2015

z Measure end of stroke, dimension (b).


z Note measured value, dimension (b).

6
34679-2

z Determine stroke.
Calculation example
Desired:
Stroke
Given:
Measured:
Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Dimension (b) - dimension (a)
Result:
= stroke

z Compare result with setpoint value.


 P09 13
z Install thermostats.
 W 09-08-02

34679-1

06/2006

2/2

8236-001

Cooling system
W 09-08-02

TCD 2015
Removing and installing thermostats
Commercial available tools

W 09-08-01
W 09-08-04

Fitting compound
DEUTZ AP1908

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing thermostats
z Remove thermostat housing.
2

 W 09-08-04
z Unscrew all screws (1).

z Remove outlet nozzle (2).

40880_1

z Remove thermostats (1).

40881-0

06/2006

1/4

8237-001

Cooling system
W 09-08-02

TCD 2015

z Visually inspect the components.


z Check thermostats.
 W 09-08-01

6
40882-0

Installing thermostats
z Select thermostats.

z Coat the sealing rings with fitting compound.


z Fit new sealing rings (1).
Note different opening
temperatures (arrows) of the thermostats.
 P09 11
P09 12

40883-0

Note installation position.


The markings (3) face upwards.
Note thermostat assignment.
z Insert thermostat (1).

 P09 12

z Insert thermostat (2).


 P09 11

40884_2

06/2006

2/4

8237-001

Cooling system
W 09-08-02

TCD 2015
z Mount outlet nozzle (2).
z Tighten all screws (1).
 A09 002

z Install thermostat housing.


1

 W 09-08-04

6
40880_1

06/2006

3/4

8237-001

Cooling system
W 09-08-02

TCD 2015

06/2006

4/4

8237-001

Cooling system
W 09-08-04

TCD 2015
Removing and installing the thermostat housing
Commercial available tools

W 07-01-04

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing thermostat housing


z Remove fuel pipes (flame glow plugs).
 W 07-01-04

40885-0

z Unscrew screws (1).

40886-0

06/2006

1/8

8238-001

Cooling system
W 09-08-04

TCD 2015

z Unscrew screws (1).


z Place holder (2) to one side.

2
1

6
40887-0

z Unscrew screw (1).


z Remove spacing sleeve.
z Place pipe to one side.

40888-0

z Unscrew hollow screw (1).


z Remove sealing rings.

40889-0

06/2006

2/8

8238-001

Cooling system
W 09-08-04

TCD 2015
z Unscrew screw (2).
z Remove holder (1).

z Unlock cable plug (3) and remove.

6
40890-0

z Unscrew screws (arrows).

40891-0

z Remove the thermostat housing (1).


z Unlock cable plug (2) and remove.
1

z Remove gasket.

40892-0

06/2006

3/8

8238-001

Cooling system
W 09-08-04

TCD 2015

z Visually inspect the components.

6
40893-0

Installing thermostat housing


z Clean sealing surfaces.

z Mount new gasket.


z Mount thermostat housing (1).
Do not move gasket.

z Plug in the cable plug (2).

40892-0

z Fasten screws.
Note different screw lengths.
M8 x 90 mm (1)
M8 x 65 mm (2)

2
40894-0

06/2006

4/8

8238-001

Cooling system
W 09-08-04

TCD 2015
z Mount holder (1).
z Fasten screw (2).

Screw length:
M8 x 140 mm.
TIghten screw only after mounting the fuel
pipes (flame glow plugs).

z Plug in the cable plug (3).

6
40890-0

z Tighten screws (1).


 A09 001
z Tighten screws (2).
 A09 001

40894-0

z Mount new sealing rings.


z Tighten hollow screw (1).
 A12 092

40889-0

06/2006

5/8

8238-001

Cooling system
W 09-08-04

TCD 2015

z Mount fuel pipe.


z Position spacing sleeve.
z Fasten screw (1).

6
40888-0

z Position fuel shut-off valve.


 P07 91

Note installation dimensions (X).

45406-0

z Tighten screw (1).


 A07 093

40888-0

06/2006

6/8

8238-001

Cooling system
W 09-08-04

TCD 2015
z Mount holder (2).
z Tighten screws (1).
 A09 001
Screw length:
M8 x 150 mm

2
1

6
40887-0

z Tighten screws (1).


 A13 094

40886-0

z Install fuel pipes (flame glow plugs).


 W 07-01-04

40956-0

06/2006

7/8

8238-001

Cooling system
W 09-08-04

TCD 2015

06/2006

8/8

8238-001

Cooling system
W 09-12-01

TCD 2015
Removing and installing temperature transmitter

Read out error memory of the motor control timer with SERDIA.

Commercial available tools

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Removing temperaure transmitter


z Unlock cable plug (1) and remove.

40895-0

z Unscrew temperature transmitter (1).

40896-0

06/2006

1/2

8239-001

Cooling system
W 09-12-01

TCD 2015

z Visually inspect the components.

6
44084-0

Installing temperature transmitter


z Tighten temperature transmitter (1).
 A09 031

40896-0

z Plug in the cable plug (1).


Delete error entry in the error memory of
the motor control timer with SERDIA.

40895-0

06/2006

2/2

8239-001

Other components
W 12-01-04

TCD 2015
Removing and installing torsional vibration damper
Commercial available tools

Removing the torsional vibration damper


z Unscrew all screws (1).
z Remove V-belt pulley (2).
1

40965-0

z Pull off torsional vibration damper (1).

Danger!

Risk of injury!

40897-0

06/2006

1/2

8240-001

Other components
W 12-01-04

TCD 2015

z Visually inspect the components.

6
40898-0

Installing the torsional vibration damper


z Mount torsional vibration damper (1).

40897-0

z Mount V-belt pulley (2).


z Lightly oil screws (1).
z Tighten all screws (1) alternately.
 A12 031

40965-0

06/2006

2/2

8240-001

Other components
W 12-06-01

TCD 2015
Removing and installing flywheel
Attention!

Commercial available tools:


Socket wrench insert . . . . . . . . . . . 8016
Rotation angle disc . . . . . . . . . . . . . 8190

Do not turn the crankshaft without screws/


mandrin guide.
The crankshaft gear wheel is positioned by
screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.

Special tools:
Self-made mandrin guide

Removing flywheel
z Unscrew all screws (1).
Block flywheel with suitable tool.
1

z Remove thrust washer (2).

40902_1

z Insert self-made mandrin guide.


z Remove flywheel.
z Remove friction disc.

Attention!
Do not turn the crankshaft without screws/
mandrin guide.
The crankshaft gear wheel is positioned by
screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.

34985-2

06/2006

1/2

8241-001

Other components
W 12-06-01

TCD 2015

z Visually inspect the components.

6
40903-0

Install flywheel
z Position friction disc.
Make sure the clamping bushing (1) is in
place.
z Mount flywheel.
Make sure the clamping bushing and locating hole are in line.

40966-0

z Insert thrust washer (2).


z Lightly oil screws (1).
z Fasten all screws (1).
z Remove self-made mandrin guide.
1

Attention!
Renew screws every time they are loosened.

z Tighten all screws (1) with the socket wrench insert.


 A12 001
Block flywheel with suitable tool.

40658_1

06/2006

2/2

8241-001

Other components
W 12-06-03

TCD 2015
Renewing toothed starter ring on the flywheel
Commercial available tools

W 12-06-01

Danger!
Danger of injury, do not touch hot parts!

Removing toothed starter ring


z Remove flywheel.
 W 12-06-01
z Check marking.
The marking (arrow) is on the flywheel and
exactly in the middle of the tooth notch of
the toothed starter ring.

40904-0

z Remove toothed starter ring with suitable tool.

34764-2

06/2006

1/4

8242-001

Other components
W 12-06-03

TCD 2015

z Visually inspect joint (arrow) and contact surface.


z Clean flywheel.
The joint and contact surface must be free
from grease and dirt.

6
34765-2

Install toothed starter ring


z Check marking of new toothed starter ring.
The marking (arrow) is on the flywheel and
exactly in the middle of the tooth notch of
the toothed starter ring.

40905-0

z Heat up toothed starter ring to 220 C.


z Place toothed starter ring on flywheel.
The markings on the flywheel and toothed
starter ring must match.
The toothed starter ring must lie evenly on
the joint of the flywheel.

40906-0

06/2006

2/4

8242-001

Other components
W 12-06-03

TCD 2015
z Install flywheel.
 W 12-06-01

6
40907-0

06/2006

3/4

8242-001

Other components
W 12-06-03

TCD 2015

06/2006

4/4

8242-001

Other components
W 12-08-04

TCD 2015
Removing and installing hydraulic pump drive
Commercial available tools

W 06-01-06 . . . . . . . . . . . . (A-bank)

Special tools:
Disassembly tool. . . . . . . . . . . . . 110901

Collect leaking operating substances in


suitable vessels and dispose of according
to regulations.

Fitting compound
DEUTZ AP1908
Locking agent
DEUTZ DW 59

Removing hydraulic pump drive


z Remove exhaust pipe (A-bank).
1

 W 06-01-06
z Unscrew screw (1).
z Unscrew lock nuts (2).
3

z Remove lubricating oil pipe (3).

40908-0

z Unscrew screws (1).


z Remove flange housing (2).

40909-0

06/2006

1/4

8243-001

Other components
W 12-08-04

TCD 2015

z Unscrew screws (1).


z Remove hydraulic pump drive (2).
1

6
40910-0

z Remove the O-ring (1) with the disassembly tool.


z Visually inspect the components.

42200-2

Installing hydraulic pump drive


z Mount new O-ring (1).
z Coat the O-ring with fitting compound.

42200-2

06/2006

2/4

8243-001

Other components
W 12-08-04

TCD 2015
z Insert hydraulic pump drive.
The gear wheel (1) must engage the toothing of the idler gear (2).

6
40913-0

z Lightly oil screws (1).


z Tighten screws (1).
 A12 057

40914-0

z Mount new O-ring (1).


z Coat lay-on surface (arrow) with locking agent.

45409-0

06/2006

3/4

8243-001

Other components
W 12-08-04

TCD 2015

z Mount flange housing (1).


z Lightly oil screws (2).
z Tighten screws (2).
Screw length:
1

M10 x 110 mm
z Insert screws (3) with locking agent.
z Fasten screws (3).
Screw length:
M10 x 210 mm

6
40915-0

z Tighten screws (1).


 A12 058
z Tighten screws (2).
 A12 059

45395-0

z Mount lubricating oil pipe (3).


z Fasten screw (1).
z Tighten lock nut (2).

 A12 082
z Tighten screw (1).
 A08 045

z Install exhaust pipe (A-bank).


 W 06-01-06
2

40908-0

06/2006

4/4

8243-001

Electrical system
W 13-01-02

TCD 2015
Removing and installing the cable harness
Commercial available tools

W 06-02-03

Attention!
Note assignment and polarity of the electrical connections!

Removing the cable harness


z Remove the charge air pipe.
 W 06-02-03

40916-0

z Disconnect the battery's negative terminal.


z Disconnect cables.

40917-0

06/2006

1/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Remove cable tie (1).

6
40534-0

z Remove cable tie (1).

40918-0

z Unlock cable plug (1) and remove.


1

40919-0

06/2006

2/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Unscrew nut (1).
z Remove washer.
z Remove cables (2).
Mark assignment of cables/connections
before removing.

6
40920-0

z Unlock cable plug (1) and remove.

40921-0

z Remove cable tie (1).

40922-0

06/2006

3/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Loosen screws (1).


z Pull cables off all injection pumps.
Mark assignment of cables/connections
before removing.

6
40923-0

z Remove cable tie (1).


z Unlock cable plug (2) and disconnect.

1
2

40924-0

z Unlock cable plug (1) and remove.

40925-0

06/2006

4/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Unlock cable plug (1) and remove.

6
40926-0

z Remove cable tie (1).

40927-0

z Unscrew nuts (1).


z Unscrew the nuts (2).

z Remove washers.
z Remove cables.
Mark assignment of cables/connections
before removing.

40928-0

06/2006

5/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Unscrew screws (1).

6
40929-0

Mark assignment of cables/connections


before removing.

z Unscrew nut (1).

z Remove washer.
z Remove cables (2).

40930-0

z Remove cable tie (1).

40931-0

06/2006

6/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Unscrew lock nut (1).

6
40933-0

z Unscrew lock nut (1).

40934-0

z Unscrew screw (1).


z Remove fuel pipe.

40935-0

06/2006

7/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Pull out cable plug (1).

6
40936-0

z Remove cable tie (1).


z Unlock cable plug (2) and disconnect.

40943-0

z Remove cable tie (1).

40532-0

06/2006

8/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Unlock cable plug (1) and remove.

6
40937-0

z Unscrew screws (1).

40938-0

z Unscrew screw (1).

40939-0

06/2006

9/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Unlock central plug (1) (arrow) and pull off from holder.
1

6
40940-0

z Visually inspect the components.

40941-0

Installing the cable harness


z Position the cable harness on the engine accordingly.
z Lay the cable plugs to the individual components.

40942-0

06/2006

10/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Push the central plug onto the holder until it snaps in.
z Tighten screw (1).
 A12 095

6
40939-0

z Tighten screws .
 A13 090
Screw length:
M8 x 20 mm (1)

M8 x 16 mm (2)
1

40987-0

z Plug in the cable plug (1).

40937-0

06/2006

11/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Lay cable harness and fix with cable ties (1).

6
40532-0

z Plug together the cable plugs (2).


z Lay cable harness and fix with cable ties (1).

40943-0

z Plug in the cable plug (1).

40936-0

06/2006

12/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Mount fuel pipe.
z Position pipe clip.
z Fasten screw (1).

6
40935-0

z Tighten lock nut (1).


 A12 080

Attention!

Install fuel pipe tension free.

40934-0

z Tighten lock nut (1).


 A12 080

40933-0

06/2006

13/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Tighten screw (1).


 A07 044

6
40935-0

z Lay cable harness and fix with cable tie (1).

40931-0

z Plug in cables (2).

Attention!

Note assignment and polarity of the electrical connections!

Connect cables according to marks made


before removing.
z Mount washer.
z Tighten nut (1).
 A13 035

40930-0

06/2006

14/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Tighten screws (1).
 A13 094

6
40929-0

z Plug cables.

Attention!

Note assignment and polarity of the electrical connections!


Connect cables according to marks made
before removing.
z Mount washers.
z Tighten nuts (1).
 A13 037

z Tighten nuts (2).


 A13 038

40928-0

z Lay cable harness and fix with cable ties (1).

40927-0

06/2006

15/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Plug in the cable plug (1).

6
40926-0

z Plug in the cable plug (1).

40925-0

z Plug together the cable plugs (2).


z Lay cable harness and fix with cable tie (1).

1
2

40924-0

06/2006

16/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Plug cables to all injection pumps.
 T13 054

Attention!
Note assignment and polarity of the electrical connections!
Connect cables according to marks made
before removing.
1

z Tighten screws (1).


 A13 054

6
40923-0

z Lay cable harness and fix with cable tie (1).

40922-0

z Plug in the cable plug (1).

40921-0

06/2006

17/20

8244-001

Electrical system
W 13-01-02

TCD 2015

z Plug in cables (2).

Attention!
Note assignment and polarity of the electrical connections!
Connect cables according to marks made
before removing.

z Mount washer.
z Tighten nut (1).

 A13 035

6
40920-0

z Plug in the cable plug (1).


1

40919-0

z Lay cable harness and fix with cable ties (1).

40918-0

06/2006

18/20

8244-001

Electrical system
W 13-01-02

TCD 2015
z Lay cable harness and fix with cable ties (1).

6
40534-0

z Connect cables.
z Connect the battery's negative terminal.

40917-0

z Install the charge air pipe.


 W 06-02-03

40956-0

06/2006

19/20

8244-001

Electrical system
W 13-01-02

TCD 2015

06/2006

20/20

8244-001

Electrical system
W 13-02-03

TCD 2015
Removing and installing the generator
(V-belt drive)
Commercial available tools:
V-belt tension measuring
device . . . . . . . . . . . . . . . . . . . . . . . 8115

Attention!
Only test / tighten / renew V-belts when the
engine is not running.
The V-belt tension of new V-belts must be
checked after they have been running for
15 minutes.

Removing the generator


z Disconnect the battery's negative terminal.
z Remove cable from generator.
1

Note assignment!
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+

3
45411-0

z Loosen screws (1).

40975-0

06/2006

1/8

8245-001

Electrical system
W 13-02-03

TCD 2015

z Loosen nut (1).

6
40976-0

z Loosen screw (1).

45412-0

z Press generator in direction of arrow.


z Remove V-belt (1).

40978-1

06/2006

2/8

8245-001

Electrical system
W 13-02-03

TCD 2015
z Unscrew screws (1).
Hold nuts.

z Remove generator (2).

2
40979-0

z Visually inspect the components.

40980-0

Installing the generator


z Mount generator.
z Insert screws.
Note different screw lengths:

M10 x 100 mm (1)


M10 x 120 mm (2)
z Fasten screws.
Hold nuts.

2
40988-1

06/2006

3/8

8245-001

Electrical system
W 13-02-03

TCD 2015

z Tighten screws (1).


 A13 015
Hold nuts.

6
45396-0

z Mount V-belt (1).

40978-0

z Tighten V-belt (1) by turning the clamping screw (2).


 A13 017
3

z Fasten screws (3).

40977-1

06/2006

4/8

8245-001

Electrical system
W 13-02-03

TCD 2015
Check V-belt tension with V-belt tension
measuring device
z Lower indicator arm (1) into V-belt tension measuring
device.

6
39582_2

z Mount V-belt tension measuring device on V-belt.


The V-belt must be between the
guides (arrow).

40981-0

z Press the V-belt measuring device against the V-belt


with the button (1) until you hear it click.

40982-0

06/2006

5/8

8245-001

Electrical system
W 13-02-03

TCD 2015

z Read measured value at the intersection (arrow) of


the indicator arm and scale.
 P12 11
P12 21
Note different units on the scale.

z If the nominal value is not reached, the tensioning


process must be repeated.

6
45413-0

z Tighten screws (1).


 A13 012

40983-0

z Tighten nut (1).


 A13 017

40984-0

06/2006

6/8

8245-001

Electrical system
W 13-02-03

TCD 2015
z Remove cable from generator.
Note assignment!
- (1) = terminal W
- (2) = terminal D+

- (3) = terminal B+
z Connect the battery's negative terminal.

3
45411-0

06/2006

7/8

8245-001

Electrical system
W 13-02-03

TCD 2015

06/2006

8/8

8245-001

Electrical system
W 13-03-02

TCD 2015
Removing and installing the starter
Commercial available tools

Fitting compound
DEUTZ AP1908

Removing the starter


z Disconnect the battery's negative terminal.
z Disconnect cables.

40917-0

z Unscrew nuts (1).


z Remove starter.

40944-1

06/2006

1/4

8246-001

Electrical system
W 13-03-02

TCD 2015

z Visually inspect the components.

6
40945-0

Installing the starter


z Insert new O-ring (arrow).
z Coat the O-ring with fitting compound.

42096-1

z Insert starter.
z Tighten nuts (1).
 A13 001

40944-1

06/2006

2/4

8246-001

Electrical system
W 13-03-02

TCD 2015
z Connect cables.
z Connect the battery's negative terminal.

6
40917-0

06/2006

3/4

8246-001

Electrical system
W 13-03-02

TCD 2015

06/2006

4/4

8246-001

Electrical system
W 13-08-01

TCD 2015

Removing and installing the pressure/temperature sensor


(charge air)
Commercial available tools

Read out error memory of the motor control timer with SERDIA.

Fitting compound
DEUTZ AP1908

Remove pressure/temperature sensor


z Unlock cable plug (1) and remove.

40919-0

z Unscrew screw (1).


z Remove pressure/temperature sensor
z Visually inspect the components.

40946-0

06/2006

1/2

8247-001

Electrical system
W 13-08-01

TCD 2015

Installing the pressure/temperature sensor


z Mount new O-ring (1).
z Lightly coat O-ring with fitting compound.

6
42002-2

z Insert pressure/temperature sensor.


z Tighten screw (1).
 A13 046

40946-0

z Plug in the cable plug (1).


Delete error entry in the error memory of
the motor control timer with SERDIA.

40919-0

06/2006

2/2

8247-001

TCD 2015

Standard tools

Standard tools
7

06/2006

1/8

8248-001

TCD 2015

Standard tools
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com

06/2006

2/8

8248-001

TCD 2015

Standard tools

8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure

35410-2

7
8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles

35411-2

8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe

39426-1

06/2006

3/8

8248-001

TCD 2015

Standard tools
8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.

37503-1

7
8016
Socket wrench insert
SW 17, reinforced
Unscrew and tighten flywheel screws.

37504-1

8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.

37506-1

06/2006

4/8

8248-001

TCD 2015

Standard tools

8024
Assembly pliers
e. g. removing valve stem seals

37509-4

7
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension

35416-3

8198
Pricker
Removing rotary shaft lip seal

43206-3

06/2006

5/8

8248-001

TCD 2015

Standard tools
8190
Rotation angle disc
with magnet (e. g. setting valve clearance)

42528-1

7
8191
Socket wrench insert
with slotted screwdriver insert (8x1.6)
(e. g. setting valve clearance)

43060-0

8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.

43197-0

06/2006

6/8

8248-001

TCD 2015

Standard tools

9017
Assembly lever
e. g. removing and installing valves

37511-1

06/2006

7/8

8248-001

TCD 2015

Standard tools

06/2006

8/8

8248-001

TCD 2015

Special tools

Special tools

06/2006

1/16

8249-001

TCD 2015

Special tools
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com

06/2006

2/16

8249-001

TCD 2015

Special tools

6066
Assembly block
Engine clamping, double-sidedmaximum load capacity
at middle centre of gravity approx. 1200 kg

35451-2

6066/151
Clamping bracket
(in conjunction with assembly block 6066)
Engine clamping, double-sided

37601-1

100130
Connector
(in conjunction with compression pressure tester 8005)

37602-1

06/2006

3/16

8249-001

TCD 2015

Special tools
100300
Turning gear
with mechanical TDC transmitter and degree scale for
start of pumping check
Turn crankshaft,
block engine

37603-1

100350
Turning gear
Turn crankshaft on the V-belt pulley.

37604-1

100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm

37605-1

06/2006

4/16

8249-001

TCD 2015

Special tools

100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm

43205-0

100850
Measuring instrument with measuring plate
Checking piston overhang

37606-1

101830
Dial gauge adapter
Measuring installation depth for impulse transmitter

45906-0

06/2006

5/16

8249-001

TCD 2015

Special tools
102560
Tester
Basic device with two dipsticks
Check radiation position of the piston cooling nozzle
(old version)

37608-1

102565
Dipstick
(in connection with tester 102560)
Check radiation position of the piston cooling nozzle
(new version)

37628-1

103240
Dial gauge holder
with stylus extension (diameter 5/95 mm)
Checking plunger lift of injection pumps

43927-3

06/2006

6/16

8249-001

TCD 2015

Special tools

110030
Puller
(in connection with sliding hammer 150800)
Removing fuel injector

35433-2

110110
Holder
SW11,
Clamp fuel injector in the vice

35434-2

110130
Slotted nut wrench
Unscrew and tighten union screw on the fuel injector.

37610-1

06/2006

7/16

8249-001

TCD 2015

Special tools
110500
Special wrench
Size 17
Removing and installing injection pipes

35436-1

110510
Special wrench
Removing and installing charge air pipe

43928-3

110700
Socket wrench insert
Size 27
long
Removing and installing oil pressure transmitter

42341-2

06/2006

8/16

8249-001

TCD 2015

Special tools

110901
Disassembly tool
Removing O-ring

45950-1

120660
Puller
(in connection with sliding hammer 150800)
Removing jammed fuel injector sealing ring

45421-0

120900
Support bracket
pivoting
Clamping cylinder head

35438-2

06/2006

9/16

8249-001

TCD 2015

Special tools
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)

35439-2

121410
Assembly tool
Assembling valve stem gasket

37614-1

121420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

43210-0

06/2006

10/16

8249-001

TCD 2015

Special tools

130300
Universal piston ring pliers
Removing and installing the piston rings

35441-2

130400
Trapezoidal groove wear gauge
Testing piston ring groove

36461-1

130650
Piston ring compressor
Removing and installing the piston rings

35443-2

06/2006

11/16

8249-001

TCD 2015

Special tools
131200
Base plate
(in connection with assembly tool kit 131210)
Pressing small end bush out and in

37616-1

131210
Assembly tool kit
(in connection with base plate 131200)
Pressing small end bush out and in

37617-1

142640
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)

37618-1

06/2006

12/16

8249-001

TCD 2015

Special tools

142650
Assembly tool
Installing crankshaft sealing ring
(flywheel side)

37619-1

143830
Assembly tool
Removing and installing camshaft bearing

37621-1

144150
Counter support
Blocking camshaft gear wheel

37622-1

06/2006

13/16

8249-001

TCD 2015

Special tools
150030
Tool kit
Repairing the collar rest of the cylinder liner

40221-0

150120
Assembly device
Installing cylinder liner

37624-1

150130
Puller
Removing cylinder liner

37625-1

06/2006

14/16

8249-001

TCD 2015

Special tools

150800
Slide hammer
Removing fuel injector

35449-2

170050
Special wrench
Unscrewing the filter cartridges

37629-1

170100
Special wrench
Removing and installing lubricating oil pipe turbocharger

37626-1

06/2006

15/16

8249-001

TCD 2015

Special tools
170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in

37627-1

170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

43663-0

06/2006

16/16

8249-001