Workshop Manual 170 PDF

Workshop manual
TCG 2020
0299 9195 EN, 10/2008
Engine number:
Please enter the engine serial numb er here. This will simplify the handling of customer service, repair and
spare parts queries.
Technical modifications required to improve our engines are reserved with regard to specification data and
other technical information contained in this documentation. No parts of this document may be reproduced
in any form or by any means without our written approval.
This is a translation of the German original. In case of argument the German original version is bind-
ing.
Workshop manual
This documentation is intended for the following engine
 Engine type:
 Type of application:
 System name:
 Power: kW
 Speed: rpm
 Commissioned on:
Please enter data. This will make it a lot easier for us to process after-sales support, repair work and spare
parts orders.
The documentation should be presented to the responsible service partner for every service assignment.
Note
Changes in this document only concern our current layout. The content corresponds to
the date of issue 02/2008.
Imprint:
MWM GmbH
Service Documentation
Carl-Benz-Strasse 1
D-68167 Mannheim
Phone: +49 (0) 6 21 3 84-0
Fax: +49 (0) 6 21 3 84-88 41
www.mwm.net
Printed in Germany
All rights reserved
Date of issue:
© MWM GmbH 10/2008
Order number:
0299 9195
OBJ_DOKU-26011-001.fm 2 © MWM GmbH 10/2008

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Introduction
0
Introduction
Please read and keep in mind...
z Read and keep to the information in this documentation. You will avoid accidents, re-
tain the manufacturer’s warranty and have a f ully functional, ready-to-use engine at
your disposal.
z This engine is built exclusively for the purpose intended according to the scope of de-
livery as 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 will bear the sole risk in this case.
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 it and instructed in the dan-
gers.
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 Non-compliance with this documentation package may lead to malfunctions and dam-
age to your engine, or even injuryto persons, for which the manufacturer will not accept
any liability.
z A prerequisite for proper ma intenance and repair is the av ailability of all necessary
equipment, hand tools and special tools. All equipment and tools must be in perfect
working condition.
z Engine parts such as s prings, clamps, elastic retaining rings etc. constitute an in-
creased risk of injury when not used properly.
z The relevant rules for the prevention of accidents and other generally recognised safe-
ty and industrial medicine rules must be followed.
z Maximum cost-effectiveness, reliability and long life is only guaranteed when MWM
GmbH original parts are used.
z Repair of the engine must comply with use for the intended purpose. Only parts re-
leased for the purpose by the manufacturer may be used for conversion work. Unau-
thorised modifications to the engine exclude manufacturer liability for resulting
damages.

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Introduction
Take care when the engine is running

Carry out maintenance or repair work only when the engine is at a standstill. If you remove
any protective features, fit them back in place on completion of the work concerned. When
working on the running engine, work clothing must be close-fitting.
Safety
You will find this symbol next to all safety instructions. Follow these meticulously. The at-
tention of operating personnel should be drawn to these safety instructions. I n addition,
general statutory safety and accident prevention regulations applying in your country must
be complied with.
Note
You will find this symbol next to instructions of a general nature.

Follow these meticulously.

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Introduction
0
Foreword
Dear Customer,
MWM engines are designed for a large number of applications. A wide range of variants
ensures that the special requirements of each customer are met.
Your engine is appropriately equipped for your requirements, which means that not all of
the components described in this manual are necessarily fitted to your engine.
We have endeavoured to highlight any differences so that you will be able to locate the op-
erating and maintenance instructions relevant to your engine quickly and easily.
Please read this documentation before starting your engine, and always follow the operat-
ing and maintenance instructions.
We are at your service for any questions you may have.
Your
MWM Service
The engines of MWM GmbH

MWM GmbH engines are the product of many years of research and development. The
profound know-how gained in connection with high-quality requirements is our guarantee
for the manufacture of engines w ith a long life, hi gh reliability and low fuel consumption.
Naturally the high requirements for environmental protection are also met.
Maintenance and care

Good service and maintenance will ensure that the engine continues to satisfy your require-
ments. Recommended service intervals must be observed and maintenance work carried
out conscientiously. If the engine becomes difficult to operate, or if operating conditions de-
viate from normal, it is particularly important to take steps to find out the cause.
MWM Service
Please consult one of our service representatives responsible for operating faults and ques-
tions on spare parts. Our trained specialist personnel ensures fast, professional repairs us-
ing original parts in the event of damage.
Original parts from MWM are always manufactured according to the latest standards in
technology.
Information about our service can be found at the end of this manual.

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Introduction

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Content
Content
0 Introduction
Please read and keep in mind... ......................................................................................................... 3
Take care when the engine is running ................................................................................................ 4
Foreword............................................................................................................................................. 5
The engines of MWM GmbH .............................................................................................................. 5
Maintenance and care ..................................................................................................................... 5
MWM Service .................................................................................................................................. 5
1 User notes
General ............................................................................................................................................. 13
Regulations ....................................................................................................................................... 13
Safety Regulations / Rules for Accident Prevention ...................................................................... 13
Rules for disposal .......................................................................................................................... 14
Competence classes ........................................................................................................................ 15
Operating manual and workshop manual ......................................................................................... 17
Operating Manual .......................................................................................................................... 17
Workshop manual.......................................................................................................................... 18
Job cards .......................................................................................................................................... 19
Spare parts ....................................................................................................................................... 20
2 Description
Design and designations .................................................................................................................. 23
Type designation ........................................................................................................................... 23
Rating plate.................................................................................................................................... 24
Location on engine ..................................................................................................................... 24
Figure rating plate....................................................................................................................... 25
Designation of sides of engine, cylinder numbering and direction of engine rotation.................... 26
Figures of engine and units .............................................................................................................. 27
Power unit...................................................................................................................................... 27
Left side ......................................................................................................................................... 28
Right side....................................................................................................................................... 30
Design and function .......................................................................................................................... 32
Cylinder head................................................................................................................................. 32
Channel guide................................................................................................................................ 33
Drive system .................................................................................................................................. 33
Crankcase...................................................................................................................................... 33
Control system............................................................................................................................... 34
Speed governing............................................................................................................................ 34
Actuator ...................................................................................................................................... 35
V12 and V16 engine with StG 30................................................................................................ 35
V20 engine with StG 2080 .......................................................................................................... 36
Governor linkage ........................................................................................................................ 37
Installation location ..................................................................................................................... 38
Exhaust system / Charging............................................................................................................ 39
Functional description................................................................................................................. 39
Schematic diagram of the turbocharging .................................................................................... 41
OBJ_BUCH-1169-001IVZ.fm 7 © MWM GmbH TCG 2020

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Content
Compressor bypass....................................................................................................................... 42
Gas unit ......................................................................................................................................... 44
Gas control system ..................................................................................................................... 44
Automatic switch off process ...................................................................................................... 44
Fitting and testing ....................................................................................................................... 45
Notes on fitting............................................................................................................................ 45
Gas-air mixer, formation of mixture ............................................................................................ 46
Lubricating oil system .................................................................................................................... 47
Lube oil level switch....................................................................................................................... 47
Crankcase bleed valve .................................................................................................................. 48
Model Dynapure AS 200 / AS 500.............................................................................................. 48
Model UPF 55............................................................................................................................. 49
Cooling system .............................................................................................................................. 49
Compressed air system ................................................................................................................. 50
Compressed air starter ............................................................................................................... 50
Electrical system............................................................................................................................ 51
Electrical system......................................................................................................................... 51
Spark plug................................................................................................................................... 52
Electric starter............................................................................................................................. 53
Electrical components................................................................................................................. 54
3 Operation
Work before commissioning for the first time and after every service .............................................. 61
General .......................................................................................................................................... 61
Filling up coolant............................................................................................................................ 61
Filling lubrication oil ....................................................................................................................... 61
Pre-lubrication................................................................................................................................ 62
Gas supply..................................................................................................................................... 62
Note for all heat exchangers.......................................................................................................... 62
Exhaust gas side ........................................................................................................................... 62
Commissioning / starting .................................................................................................................. 63
Start the engine. ............................................................................................................................ 63
Warming up ................................................................................................................................... 63
Ventilation of rooms ....................................................................................................................... 63
Lubricating oil system .................................................................................................................... 63
Turbocharger ................................................................................................................................. 64
Operation monitoring ........................................................................................................................ 64
Inspections immediately after commissioning ............................................................................... 64
Unit monitoring............................................................................................................................... 64
Engine peripheral systems ............................................................................................................ 64
Reverse power............................................................................................................................... 65
Coolant circuit ................................................................................................................................ 65
Batteries......................................................................................................................................... 65
Shutting down ................................................................................................................................... 66
4 Operating media
General ............................................................................................................................................. 69
Product selection .............................................................................................................................. 69
Mixability ........................................................................................................................................... 69

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Content
Guarantee ......................................................................................................................................... 70
Fuel gas ............................................................................................................................................ 70
Lube oil ............................................................................................................................................. 70
Engine coolant .................................................................................................................................. 70
Auxiliary materials............................................................................................................................. 71
Packing compound ........................................................................................................................ 71
Locking agent ................................................................................................................................ 72
Activator......................................................................................................................................... 74
Adhesive ........................................................................................................................................ 74
Hardener........................................................................................................................................ 74
Lubricant ........................................................................................................................................ 75
Commercially available products ................................................................................................... 76
Conservation agents...................................................................................................................... 76
Cleaning agents............................................................................................................................. 77
Water treatment agents ................................................................................................................. 78
5 Maintenance
Maintenance schedule as separate documentation ......................................................................... 81
Tools for competence class 1 ........................................................................................................... 83
Address of order ............................................................................................................................ 83
Tools sorted according to order numbers ...................................................................................... 83
6 Troubleshooting
Explanation of tabular representation ............................................................................................. 105
Troubleshooting remedies .............................................................................................................. 106
7 Corrosion protection
General ........................................................................................................................................... 117
8 Technical data
Test and setting values ................................................................................................................... 121
Tightening specifications ................................................................................................................ 127
Nominal and wear dimensions........................................................................................................ 135
9 Job cards
Symbol description ......................................................................................................................... 169
Job card list..................................................................................................................................... 170
Service

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Content

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User notes
1

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User notes

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User notes
1
User notes
General
The maintenance and service work prescribed in the operating manual and the workshop
manual must be performed on schedule and in full.
The maintenance and repair personnel must have the necessary technical knowledge to
perform the work. Safety and protection devices which may have to be removed during
maintenance and repair work must be replaced afterwards.
The rules for the prevention of accidents and the safety regulations must be ob-
served at all times during maintenance and service work.
Please also observe the special safety regulations for the various service groups
which are listed in detail as job cards in the Job Cards chapter (cf. also chapter 1
Safety Regulations / Rules for Accident Prevention).
See the maintenance schedules for the maintenance intervals. These also provide informa-
tion about the work to be performed.
The job cards provide technical hints for performing the work.
Regulations
Safety Regulations / Rules for Accident Prevention

Detailed safety instructions have been compiled for various service groups in the
form of job cards, these precede the job cards of the respective service groups.
The legally prescribed rules for accident prevention (available from the appropriate
associations or technical publishers) must be observed. These will depend on the lo-
cation, the operating mode and the supplies and expendables used.
Special safety measures dependent on the respective work are specified and high-
lighted in the work description.
It generally applies among other things:
z for personnel:
- Only instructed personnel may operate or maintain the engine. Unauthor-
ized persons must not enter the engine room.
- Wear tight fitting clothing and ear protectors in the engine room when en-
gines are running.
- Only employ qualified personnel for repairs or service work.
z for the engine room:

- Make sure it is properly ventilated (do not cover the ventilation shafts).
- Provide a first aid kit and suitable fire extinguishers. Check filling and oper-
ational readiness at regular intervals.
- Only store inflammable materials in the engine room which are necessary
for operating the system.
- Smoking and naked lights are prohibited in the engine room.

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User notes
z for operation and maintenance of the engine:

- Only start the engine when all safety devices have been fitted and the turn-
ing gear has been removed. Make sure there is no-one in the danger zone.
- Only perform cleaning, maintenance and re pair work when the engine is
switched off and secured against starting up.
Rules for disposal

The work described in the operation manual and workshop manual necessitate the renewal
of parts and operating media among other things. These renewed parts / operating media
must be properly stored, transported and disposed of. The owner is responsible for this.
Disposal includes recycling and disposal of parts / operating media whereby recycling has
priority.
The details of disposal and its supervision are governed by regional, national and interna-
tional laws and decrees which the plant owner is responsible for observing.

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User notes
1
Competence classes
The competence classes 1 to 3, see also SIT 07010, have been introduced to be able to
supply all contract partners with the appropriate information.
These are closely related to the respective partner contract and a number of conditions
such as:
z Training
z Spare parts stores
z Workshop equipment etc.
The following competence classes, hereinafter referred to as CC, are defined:
CC 1 Technical skilled qualified personnel

Maintenance stages 20, 30, 40
Work Operation and maintenance
Documents B job cards
- Regular maintenance according to the maintenance schedules in the operating
manuals
- Visual inspections, cleaning work
- Testing and replacing maintenance parts and operating media
- Minor repairs with conventional tools
- Test run and function test
CC 2 Authorised qualified personnel

Maintenance stages (10), 45, 50, 55
Work Inspection
Test and adjustment work
Repair work
Documents W job cards
- Testing the actual condition of the engine and engine components
- Error analysis
- Comparison of nominal / actual condition and determining of the resulting repair
measures
- Repair work on the engine periphery
- Components, including cylinder head, disassembly and assembly / replacement
- Testing of the parts and components for reusability and repair / replacement without
re-machining mechanically
- Adjustment work resulting from the repair

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User notes
CC 3 Authorised qualified personnel

Maintenance stages 60, 70
Work Intermediate overhaul
Major overhaul
Extensive diagnosis, test and adjustment work on the whole engine
Mechanical rework on engine parts (without removal of material)
Documents W job cards
- Extensive engine diagnosis
- Complete disassembly, examination, repair and reassembly of the engine
- Engine adjustment
- Function and performance test on the test bench or in the drive system
- Extensive, know-how intensive maintenance work on the drive assembly, parts and
components including mechanical rework (without removal of material) according
to maintenance documents

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User notes
1
Operating manual and workshop manual

To structure the information to suit the user, the service documentation is divided into op-
erating manual and workshop manual.
Operating Manual
The operating manual contains a general description as well as instructions for necessary
maintenance measures among other things. The maintenance measures described in the
operating manual may be carried out by technically skilled personnel.
The chapters of the operating manual have the following contents:
Operating Manual
Engine type
Order number
0 Introduction
Index
1 User notes
2 Description (description of the engine and components)
3 Opeation (operation of the engine)
4 Operating media and aids (operating media regulations - see Technical
Circular)
5 Maintenance (maintenance schedules as separate documentation,
tools for competence class 1)
6 Troubleshooting
7 Corrosion protection (corrosion protection regulations - see Technical
Circular)
8 Technical data (test and setting values and tightenening specifications
for competance class 1)
9 Job cards (symbol explanation, job card list, job cards for maintenance
work for competance class 1)
Service
Technical Circular
General safety regulations

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User notes
Workshop manual
The workshop manual contains all the chapters of the operating manual plus all the instruc-
tions that are required for maintenance work as of MWM GmbH maintenance and service
schedule E40. The maintenance measures from MWM GmbH maintenance and service
schedule E40 onwards described in the workshop manual may only be carried out by
trained specialist personnel.
The chapters of the workshop manual have the following contents:
Workshop manual
Engine type
Order number
0 Introduction
Index
1 User notes
2 Description (description of the engine and components)
3 Opeation (operation of the engine)
4 Operating media and aids (operating media regulations - see Technical
Circular)
5 Maintenance (maintenance schedules as separate documentation,
tools for competence class 1 to 3)
6 Troubleshooting
7 Corrosion protection (corrosion protection regulations - see Technical
Circular)
8 Technical data (test and setting values, tightening specifications and
nominal and wear dimensions for competance class 1 to 3)
9 Job cards (symbol explanation, job card list, job cards for maintenance
work for competance class 1 to 3)
Service
Technical Circular
Technical specification
General safety regulations

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User notes
1
Job cards
Every job card has a job card number which is linked to a defined work process. Explana-
tions about the structure of the numbering are shown in the summary below. The structure
of the job card is shown in the following diagram.
Differentiation of job cards

The first letter refers to the level of training required for carrying out the maintenance task.
B Operating manual (competance class 1)
W Workshop manual (competance class 2 or 3)
Maintenance group
0 General
1 Cylinder head
2 Power train
3 Crankcase
4 Control system
5 Speed governing
6 Exhaust system / Charging
7 Fuel system
8 Lube oil system
9 Coolant system
10 Compressed air system
11 Monitoring system
12 Other components
13 Electrical system
Sub group of maintenance group

The sub group differs, depending on the maintenance group
Consecutive number
Consecutive number within the sub group
T 1-1

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User notes
A 1-1
For inquiries about job cards please always give the engine type or system 1, the number
of the job card 2 and the date of issue 7.
1 Engine type or system

2 Job card number
3 Title of the job card
4 Tools, auxiliary material, spare parts and references
5 Safety instructions
6 General notes
7 Date of issue of the job card
Spare parts
Spares are available from Service. You will find a list of spares in the spare parts list of the
engine or the system. You will find further information in the Service chapter at the end of
the Operation Manual or Workshop Manual.

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Description
2
1 2 3 4

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Description

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Description
2
Description
Design and designations

The engines of this series are water-cooled high powered four stroke spark ignited gas en-
gines which can be used in a wide variety of areas making use of the coolant and exhaust
heat in heat-power coupling processes. So as to protect the environment a combustion
process with particularly low exhaust emissions was developed.
Type designation
See also the rating plate
T C G 2020 V -
Turbocharger
Mixture charge cooling
Gas engine
Series
V-engine
Number of cylinders

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Description
Rating plate
Location on engine
The rating plate is fixed to the engine. In addition the engine number is embossed.
The rating plate 1 and the engine serial number 2 are in the following positions.
A 2-1
A 2-2

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Description
2
Figure rating plate
A 2-3
1 Engine design designation

2 Year of manufacture
3 Engine number
4, 5, 6 Performance code according to DIN ISO 3046 Part 7 and code for the type
of gas.
Performance code
b = Bio-gas
n = Natural gas
s = Sewage gas
l = Landfill gas
m = Marsh gas
p = Propane
A * or ** in front of the performance code indicates the relevant NOx emis-
sion, see 13,14.
7, 8, 9 Numerical value of output in kW
10, 11, 12 Engine speed at rpm
13, 14 NOx emission in mg
15 Height above sea level (corresponds normally to zero) in m (conditions at
installation site)
16 Air pressure px in mbar (conditions at installation site)
17 Charging air coolant temperature tx in °C (conditions at installation site)
18 Relative humidity Φx in % (conditions at installation site)
19 Mixture coolant temperature tcx in °C (conditions at installation site)
20 Performance of lubricating oil pump F in kW (numeric value)

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Description
Designation of sides of engine, cylinder numbering and direction of engine rotation

The designations in this operating manual comply with DIN ISO 1204.
A 2-4
Engine sides:
1 Drive side Flywheel, driving end
2 Left side Cylinder side A
3 Free side Front side, free end
4 Right side Cylinder side B
Cylinder designation:
Each individual cylinder is designated with a combination of a letter and a number.
Seen from the drive side counting on the left side starts with cylinder A1 and on the right
side with cylinder B1.
Engine rotational direction:
Seen from the drive side the engine turns in an anti-clockwise direction.

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Description
2
Figures of engine and units
Power unit
A 2-5

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Description
Left side
V12 and V16 engine
A 2-6
1 Air intake filter

2 Mixture cooler
3 Starter
4 Charging mixture pipe
5 Crankcase breather connection
6 Engine mounting
7 Prelubrication pump
8 Coolant inlet (high temperature circuit)
9 Coolant outlet (high temperature circuit)
10 Exhaust gas compensator
11 Actuator

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Description
2
V20 engine
A 2-7
1 Air intake filter

2 Mixture cooler
3 Generator
4 Actuator
5 Starter
6 Charging mixture pipe
7 Engine mounting
8 Lube oil level switch
10 Crankcase breather
11 Vibration damper
12 Exhaust gas compensator
13 Gas-air mixer

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Description
Right side
V12 and V16 engine
A 2-8
1 Gas-air mixer
2 Turbocharger
3 Crankcase breather connection
6 Lubricating oil cooler
7 Lube oil filter
8 Coolant inlet (low temperature circuit)
9 Coolant outlet (low temperature circuit)

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Description
2
V20 engine
A 2-9
1 Gas-air mixer
2 Turbocharger
3 Crankcase breather
6 Lubricating oil cooler
7 Lube oil filter
8 Coolant inlet (low temperature circuit)
9 Coolant outlet (low temperature circuit)

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Description
Design and function
Cylinder head
The cylinder heads are made from a special alloyed casting like the crankcase. One single
cylinder head is installed per cylinder. Thanks to the excellent access and optimized design,
the single cylinder head can be replaced in a very short time.
The cylinder heads are liquid-cooled and integrated into the engine cooling system.
The cylinder heads are multi-valve heads, i.e. each cylinder has two inlet valves for opti-
mum filling and two outlet valves for fast expulsion of exhaust gases. The high-temperature
resistant valves sit in th e pressed in and so easily exchangeable valve seat inserts. The
valves are controlled with a proven valve bridge technology. The valve bridge control is par-
ticularly wear-resistant and is very maintenance-friendly.
A 2-10
1 Inlet rocker arm

2 Outlet rocker arm
3 Pushrods
4 Valve bridge
5 Spark-plug shaft
6 Valve
7 Valve spring
8 Valve head

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Description
2
Channel guide
The channel guide is based on the cross current principle. The cylinder heads are supplied
with the combusion gas through the charge mixture pipe from the one side. The two inlet
channels 2 and 3 have different manifolds in the cylinder heads. They are divided into a fill-
ing channel 2 and a twist channel 3. These ensure, by their shape, a combustion gas flow
into the combustion chamber which greatly improves the filing. The outlet channels 1 end
in the exhaust system in which the exhaust gas energy is not lost but recycled.
A 2-11
Drive system
The machined crankshaft with bolted on counterweights is suspended in the crankcase.
The bearing covers are held vertically by two studs and are fastened horizontally by two
additional screws for cross bracing. The engine has forged light metal pistons which are
cooled by lube-oil injection nozzles and double T-shank con-rods. The lube oil supply to the
main bearing and con-rod bearing is provided by a lube oil pump which sucks the lube oil
from the oil pan.
Crankcase
The crank case is sphero-cast with suspended crankshaft bearings and wet cylinder liners.
Lateral drive gear assembly openings enable fast access to the crank gear.

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Description
Control system
A 2-12
1 Gear wheel crankshaft (59 teeth)

2 Idler gear (59 teeth)
3 Idler gear (33 teeth)
4 Camshaft gear wheel, B-side (66 teeth)
5 Camshaft gear wheel, A-side (66 teeth)
6 Idler gear to the lubricating oil pump (52 teeth)
7 Gear wheel lubricating oil pump drive (40 teeth)
Speed governing
The speed governing has the task of controlling the engine speed by adjusting the throttle
valve position.
This control is carried out electronically through the TEM system. With an electronic speed
governing the actual speed is picked up using a flywheel sensor. This sensor signal is sent
to the TEM system and compared with the set rated speed. Speed fluctuations are control-
led by the TEM system and the actuator.
The actuator is connected to the throttle valve or the rotary valve and so it can adjust the
speed.

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Description
2
Actuator
The V12 and V16 engines are equipped with the actuator StG 30, two actuators StG 2080
are fitted to the V20 engine.
The actuators are distinguished by:
- high adjustment forces acting in both directions

- low power consumption
- Insensitivity at slow voltage change in the power supply, sudden changes lead to con-
troller faults.
V12 and V16 engine with StG 30

A DC motor transmits the torque to the regulator output shaft via an idler gear. The position
of the regulator output shaft is scanned by the return probe without contact at the return cam
and transferred to the TEM system.
On reaching an end stop, the current limiter is triggered after approx. 20 seconds and re-
duces the actuator current accordingly.
A 2-13
1 DC motor
2 Gearbox
3 Output shaft
4 Probe
5 Return cams

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Description
V20 engine with StG 2080

A multipole magnetised permanent magnet is fitted to the actuator shaft. A coil assembly
with the operating coils is mounted opposite the permanent magnet. If current is applied to
the operating coils, a torque is generated in one direction, reversing the polarity of the cur-
rent generates the torque for the opposite direction.
A recoil spring is mounted on the regulator output shaft the force of which is normally suffi-
cient to pull the actuato r into the stop position when the current fails. The position of th e
regulator output shaft is scanned by the return probe without contact at the return cam and
transferred to the TEM system.
On reaching an end stop the current limiter is triggered after approx. 20 seconds and re-
duces the actuator current accordingly.
A 2-14
1 Working coil
2 Output shaft
3 Permanent magnet
4 Probe
5 Return cams
6 Return spring

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Description
2
Governor linkage
A 2-15
1 Actuator
2 Control lever
3 Idle position
4 Adjusting angle
5 Full-load position
6 Connecting linkage
7 Lever for throttle adjustment

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Description
Installation location
Position 1 shows the actuator in the V12 and V16 engine.
Position 2 shows the actuator of the engine A-side in the V20 engine.
A 2-16
A 2-17

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Description
2
Exhaust system / Charging

The engine is fitted with a turbocharger and a liquid cooled mixture cooler. The charging of
the mixture achieves a higher level of output while at the same time reducing the pollutant
emissions.
The turbocharger supplies the air volume required for operation of the engine and gener-
ates the necessary charging pressure.
The turbocharger may only be maintained by trained and authorised personnel.

Work on mechanical components such as bearings or rotors may only be carried out by
qualified personnel of the manufacturer.
Functional description
The turbocharger consists of two flow machines, a radial turbine and a radial compressor
which are mounted on a common shaft (rotor).
The exhaust gases of the engine flow through the inlet housing and the nozzle ring to the
turbine wheel.
The turbine wheel uses the energy in the exhaust gas to drive the compressor wheel.
The exhaust gases pass through the exhaust pipe connected to the gasoutlet flange to then
outside.
The air or gas-air mixture required for operation of the e ngine passes through the intake
nozzle to the compressor wheel.
The air or gas-air mixture is pre-compressed by the compressor wheel and pressed through
the diffusor and the pressure nozzles on the compressor housing into the manifold.
The rotor runs in two sliding bearings which are located in the bearing bushes between the
compressor and the turbine. The axial bearing is between the radial sliding bearings.
The bearings are connected to a central lubricating oil duct which is connected to the en-
gine's lubricating oil circuit. The lubricating oil outlet is always at the lowest point on the
bearing housing.

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Description
A 2-18
1 Gas-air inlet
2 Radial compressor / compressor wheel
3 Radial turbine / turbine wheel
4 Exhaust gas inlet
5 Exhaust gas outlet
6 Gas-air outlet
7 Sliding bearing / radial bearing
8 Lubricating oil duct

TCG 2020
Description
2
Schematic diagram of the turbocharging
A 2-19
1 Intake air
2 Air filter
3 Filtered air
4 Gas-air mixer
5 Gas
6 Mixture to the compressor
7 Centrifugal impeller
8 From the compressor to the mixture cooler
9 Mixture cooler
10 Cooled mixture
11 Inlet valve
12 Exhaust valve
13 To the exhaust turbine
14 Turbine wheel
15 To the silencer

TCG 2020
Description
Compressor bypass
When adapting the turbocharger, the com bustion behaviour of the gas (energy content,
combustion velocity etc.) mu st be taken into account. Landfill or sewage gas may v ary
greatly in composition. This results in great changes in the combustion behaviour. At de-
creasing calorific value and high inert gas content the combustion velocity is reduced which
leads to a higher exhaust gas temperature. This in turn leads to a higher boost pressure at
the same performance and the compressor of the turbocharger starts pumping.
An adjustable compressor bypass on the turbocharger avoids another turbocharger speci-
fication being necessary depending on the gas composition. Optimum adaptation to the ex-
isting gas quality is possible at any time without conversions.
The bypass is set during commissioning or as required (e.g. in case of great changes in the
gas quality at landfills) by your service partner.
Two different variants are in use
A 2-20
1 Bypass pipe
2 Setting screw
3 Mixture pipe in front of turbocharger
4 Charging mixture pipe after turbocharger

TCG 2020
Description
2
A 2-21
1 Bypass pipe
2 Setting screw
3 Mixture pipe in front of turbocharger
4 Charging mixture pipe after turbocharger

TCG 2020
Description
Gas unit
Gas control system

Set up and function
The gas control system's control and safety units ensure danger-free and safe gas supply
to the engine. The gas pressure regulator matches the gas pressure on the network side to
the gas engine's needs.
Incorrect fitting, adjustment, alteration, operation or maintenance can cause injury

or damage to property.
Fitting, adjusting and maintenance only by authorised personnel.
Read instructions before fitting and using.
The units must be fitted in accordance with the applicable regulations.
The electricity and gas supply companies' local regulations must be observed.
Example gas control system
A 2-22
1 Shut-off system (ball valve)

2 Pressure gauge
3 Gas filter
4 Pressure switch
5 Safety cut-off valve, magnetic
6 Only for gas group 2 - flame penetration safety system
7 Gas pressure controller
Automatic switch off process

So as to purge the engine when switching off, the gas supply is closed off before the ingni-
tion is interrupted. This method is part of the automatic process by the TEM system.

TCG 2020
Description
2
Fitting and testing

For installation G 600 (DVGW-TRGI), G 490 and G 495 apply to the supply up to the cut-
off system to be fitted on the building side.
The components of the gas control system are tested by the manufacturer for strength and
seal. The completely fitted unit must undergo a final seal test with air or inert gas at 1.2
times the maximum permissible operating pressure (set outlet pressure at the controller),
but at least 150 mbar.
- The inlet pressure (network side) must always be the same as or greater than the outlet
pressure (engine side).
- Always create pressure build-up from the inlet side, reduce pressure always upstream
of the outlet side (adjust pressure slowly!).
- The gas control system may only be fitted horizontally.
- The gas control system must be protected from careless damage, especially when fit-
ted in a low position.
- No vibration may pass from the engine to the gas line.
- The operating elements must be easily accessible and easy to read.
Notes on fitting
Depending on the type of gas, the engine requires the right kind of gas control system.
If aggressive gases are used, nonferrous metal (brass) may not be used for parts carrying
gas.
The gas control system must be positioned in the same room as the gas engine. This en-
sures that the gas control system is subject to the same air pressures as the engine.
Blow-off lines must be led into the open air with adequate diameter.
Pressure control and control units and pipes must be fitted without tension. Pressure control
and control units must always be fitted in accordance with the manufacturer's instructions.
The direction of flow must be observed.
The gas control system must be fitted as close to the engine as possible. The distance be-
tween the gas control system outlet and the gas mixer inlet must not exceed 3 m and be
designed with max. three 90° bends.
Flame flashovers can occur with fuel gas mixtures whose components may also contain ox-
ygen. The gas control systems contain endurance burning flame flashover protection de-
vices with temp erature monitoring to prevent flashovers in th e gas-carrying line. Here a
maximum distance between the engine and the gas control system of 40x the gas line's di-
ameter is permissible. If the distance is greater, permanently fire-proof detonation protec-
tion must be fitted instead of the flame flashover protection.
Example: Line diameter = 10 cm

40 x 10 cm = 400 cm
max. permissible distance = 4m

TCG 2020
Description
Gas-air mixer, formation of mixture

The mixing of gas and air to a combustible mixture takes place immediately upstream of the
turbocharger, in the so-called mixer.
The mixer is a venturi pipe, i.e. flow-beneficial narrowing of the pipe which widens up again
gradually. The design causes only very slight loss of pressure to the flow and thus minimal
reduction of filling into the cylinders. At the narrowest point the flow is at its highest speed.
The underpressure created over a ring-shaped gap makes the gas mix into the main flow
radially from outside. This way of mixing has the advantage that the ratio of gas and air re-
mains almost constant even if the mixture sucked through changes considerably, and only
leaves the so-called lambda window, in which the engine operates safely and economically,
for short periods.
The adjustable gas gap serves to adjust the gas-air mixture.
The mixture volume is regulated by means of the throttle valve or rotary disk valve.
A 2-23
1 Gas inlet
2 Air inlet
3 Gas-air mixture outlet
4 Connection linkage to the stepper motor
5 Gas gap

TCG 2020
Description
2
Lubricating oil system

The lube oil reduces the friction of the components which rub against each other and feeds
heat away from the rubbing positions, the piston head and the turbocharger. A film of lube
oil on the running surfaces of the cylind ers reduces the sliding friction of the pistons and
piston rings. Furthermore, the lube oil keeps impurities in suspension and carries them to
the lube oil filter.
The lube oil pump sucks the lube oil from the lube oil sump, feeds it through the lube oil
cooler and the lube oil filter into the engine's lube oil circuit.
The lube oil pressure in the engine circuit is set by a lube oil control valve. The bypass valve
is fitted so as to avoid the flow of lube oil being interrupted when the lube oil filter is dirty. If
the lube oil pr essure is so high that the lube oil pump is at risk, the overpressure valve
opens and allows the excess lube oil carried flow back into the lube oil sump.
Lube oil level switch

The engine is fitted with a lube oil level switch. It passes various information about the level
of lube oil in the engine to the TEM system.
The lube oil is thus topped up automatically by the TEM system. If there is still too little lube
oil, the TEM system switches off the engine.
Likewise the lube oil level switch changes the lube oil automatically in conjunction with the
TEM system. The lube oil level switch reports the various lube oil levels to the TEM system.
A 2-24

TCG 2020
Description
Crankcase bleed valve
Model Dynapure AS 200 / AS 500

The crankcase bleed valve is equipped with an oil mist trap. The sucked in air/oil mixture is
spun and accelerated in the oil mist trap by a rotating drum so strongly that the micro-fine
oil mist particles form small droplets and are separated from the air in the rotating filter drum
by the sieving and inertia effect. The oil gained in this w ay flows back into the oil pan
through the drain.
A 2-25
1 Intake pipe 3 Oil mist trap

2 Air return line to the air filter 4 Drain pipe
A 2-26
1 Air outlet, the cleaned air is returned

2 Rotating filter drum with turbo wheel
3 Intake pipe
4 Drain for separated oil

TCG 2020
Description
2
Model UPF 55
The crankcase breather UPF 55 has been developed for separating oily air.
The oil mist sucked in from the crankcase is fed from the inside to the outside through two
filter stages. The fine oil particles are separated in the filter stages.
A 2-27
1 Venting inlet from the engine (flow direction)

2 Measuring connections
3 Venting outlet
4 Outer filter insert
5 Inner filter insert
6 Process stage 1
7 Process stage 2
Cooling system
During combustion the chemical energy in the gas is converted into heat energy. Only some
of this can be converted into mechanical energy in the engine. The remaining residual heat
is mainly led away with the exhaust gas and the coolant.
The engine has a two circuit coo ling system. The lube oil cooler, mixture cooler, water-
cooled exhaust pipe and cylinder cooler are integrated in the engine cooling circuit.
The low-temperature mixture cooler is cooled through a separate cooling circuit. That way
the mixture temperature could be lowered and the engine output increased.
Both conventional cooling and expansion to combined heat and power is possible.
The temperature of the coolant is controlled and monitored automatically. If the tempera-
tures exceed the maximum set values the engine is turned off by the TEM system.

TCG 2020
Description
Compressed air system
Compressed air starter

The V20 engine is equipped with a compressed air starter or an electric starter depending
on the version.
Triggered by the TEM system control air presses the starter pinion into the flywheel ring
gear, the operating air then rotates the engine up to starting speed. When the engine has
fired, the TEM system tracks out the starter and blocks further starts when the machine is
running.
The compressed air starter generates a sufficiently high starting speed for ignition through
the flywheel.
A 2-28
A 2-29
1 Air starter
2 Pressure reducing starter valve - Input pressure: max. 30 bar
- Back pressure: 1 to 10 bar
3 Solenoid valve 24V
4 Safety valve - Pressure setting: 12 bar
5 Pressure gauge
6 Dirt trap
7 High-pressure hose (air supply)

TCG 2020
Description
2
Electrical system
Electrical system
The engine is fitted with a microprocessor controlled ignition system which is supplied with
24V power by the TEM system.
A gear rim fitted on the flywheel is scanned by an electronic sensor and enables the precise
crank angle time to be established. The selection of the correct process phase for the igni-
tion spark in the four stroke process is carried out by an additional sensor on the camshaft.
The electronic control unit sends medium voltage pulses to the i gnition coils allocated to
each cylinder. From there a high voltage cable leads to the spark plugs. An extremely fast
increase in voltage ensures a powerful and short ignition spark which has a gentle effect on
the spark plug electrodes.
Setting on the ignition device are made exclusively by your service partner, e.g. adjustment
of the ignition time.
For work on the ignition system such as changing parts, e.g. spark plugs, ignition cables
and ignition coils, the ignition need not be switched off because the TEM system switches
off safely anyway when the ignition is at standstill.
A 2-30

TCG 2020
Description
Spark plug
The spark plug is designed as a prechamber spark plug. The ignition spark is created within
prechamber 1, the rays of flame pass through the holes 2 to the end face of the prechamber
into the combustion chamber.
The advantages of this design are the improved more even spread of the flame front across
the entire combustion chamber and lower wear and consequent longer service life of the
spark plug.
A 2-31
A 2-32

TCG 2020
Description
2
Electric starter
The engines TCG 2020 V12 and V16 are equipped with an electric starter, the engine TCG
2020 V20 either with an air starter or an electric starter.
The starter accelerates the engine crankshaft to ignition speed.
An electric motor drives the starter pinion to the ring gear of the flywheel via an axially mov-
able multi-disc clutch and thus drives the crankshaft. The multi-disc clutch only transmits
the full starter torque after the starter pinion has engaged in to avoid damaging the teeth
flanks. When the engine starts, the multi-disc clutch is released by the steep thread and the
starter pinion disengaged.
A 2-33

TCG 2020
Description
Electrical components
V12 and V16 engine
A 2-34
1 Coolant temperature sensor in front of mixture cooler

2 Knocking sensor
One sensor per cylinder
3 Combustion chamber temperature sensor
4 Starter
5 Starter relay
6 Crankcase pressure sensor
7 Lube oil level switch
9 Lube oil pressure sensor
10 Camshaft pulse sensor
11 Multi-function rail cylinder bank A
12 Gas-air mixer proximity switch
13 Suction air temperature sensor
V16 engine
V12 engine
15 Ignition coil
One ignition coil per cylinder

TCG 2020
Description
2
V12 and V16 engine
A 2-35
1 Multi-function rail cylinder row B

2 Coolant temperature sensor (engine outlet)
3 Charge mixture temperature sensor
4 Coolant temperature sensor (engine inlet)
5 Lube oil temperature sensor
7 Knocking sensor
9 Flywheel pulse sensor
10 Ignition control unit
11 Actuator
12 Stepper motor gas-air mixer
13 Ignition coil
14 Turbocharger speed sensor
15 Exhaust gas turbocharger temperature sensor

TCG 2020
Description
V20 engine
A 2-36
1 Starter
2 Starter relay
3 Knocking sensor
5 Crankcase pressure sensor
6 Camshaft pulse sensor
7 Exhaust gas turbocharger temperature sensor
8 Multi-function rail cylinder bank A
10 Ignition coil

TCG 2020
Description
2
V20 engine
A 2-37
1 Coolant temperature sensor (engine outlet)

2 Charge mixture temperature sensor
3 Coolant temperature sensor (engine inlet)
4 Lube oil temperature sensor
6 Knocking sensor
8 Actuator
9 Flywheel pulse sensor
10 Coolant temperature sensor in front of mixture cooler
11 Ignition control unit
12 Ignition coil
13 Multi-function rail cylinder row B
14 Gas-air mixer proximity switch
15 Stepper motor gas-air mixer
16 Turbocharger speed sensor

TCG 2020
Description

TCG 2020
Operation
3

TCG 2020
Operation

TCG 2020
Operation
3
Operation
Work before commissioning for the first time and after every service
General
Before commissioning for the first time, after the engine has been standing still for a long
time and after servicing and maintenance work the following tasks must be carried out:
z Check all leads and connections for the following media:

- Gas
- Lube oil
- Coolant
- Intake air
- Exhaust gas
z Check the speed transmitter for smooth action.
z Check the function of the monitoring, shut-off and remote control devices.
z Check that the electric wiring is in perfect condition.
z Check control cables and sensors usint the TEM system self-test facility.
Filling up coolant
Close the coolant drain cocks on the engine and the cooling devices.
The coolant is filled through a filler connection.
For specifications of the quality to be used see chapter 4, Operating media or Technical Cir-
cular
The coolant chambers are vented by a venting pipe with the coolant pump running.
Then check the coolant level again and top up the coolant if necessary.
Filling lubrication oil

Fill in lubricating oil through the pre-lubrication pump.
For specifications of the quality to be used see chapter 4, Operating media or Technical Cir-
cular
The lubrication oil level is monitored during oepration by the TEM system. The approximate
lubrication oil level can be checked with a dipstick or inspection glass. After topping up lu-
brication oil this must be done in conjunction with the TEM system.
If the lubrication oil level is too low thee monitoring system switches to non-release of the
starting process or to stopping the engine.

TCG 2020
Operation
Pre-lubrication
An electric pre-lubrication pump is fitted onto the engine.
Before the engine is started the TEM system switches on the pre-lubrication pump. The pre-
lubrication process runs for a fixed length of time. Only when the pre-lubrication process
has been completed is it possible to start the engine.
On engines which are on stand-by the engine is lubricated by the electric pre-lubrication
pump at regular intervals. Pre-lubrication must be completed before the engine is started.
Gas supply
Danger of explosion !
Before carrying out any work on the gas line, the room ventilation must be turned on.
Smoking and naked lights are prohibited.
The entire line leading to the engine (if appropriate, also the desulphurizer, gas compres-
sor, cooler, gas pressure controller and shut-off devices) must be cleaned from the inside
before commissioning. All parts of the line must be dry, clean and free of welding beads,
scale and other dirt particles.
The seals of the connections must be checked by spraying on soap suds or a leakage seek-
ing spray.
Note for all heat exchangers

When filling the water side of heat exchangers they must be permanently vented (if they are
not properly vented gas bubbles can be formed which cause damage to the boilers).
Particular care must be taken to avoid dirt in the heating water. Mud and corrosion products
from older boilers and residue from roller and welding can ge deposited and cause over-
heating, voltage spikes and material breaks because of the local isolation effect.
For this reason the heating water side must be checked and if necessary cleaned after the
first 10 hours and every additional 100 hours. Mud extraction nozzles and filters make this
task easier.
Exhaust gas side

Before closing the isolation all bolts on the pipe and container flanges of the exhaust system
must be tightened. This measure is neccessary because of the settling behaviour of tghe
seals.
It is essential that the tightening process is repeated after about 100 operating hours or af-
ter 14 Days.
If this is not carried out no guarantee can be made for leaky seals or escaping ehaust gas-
es.

TCG 2020
Operation
3
Commissioning / starting
Before every commissioning / starting of the engine
- Check the coolant level, correct if necessary.

- Check the lubricating oil level, correct if necessary.
Start the engine.

The intake air temperature levels must be adhered to - see Chapter 8, Technical Data
The following functions are performed automatically by the engine management TEM sys-
tem one after another after starting.
1 Run mixer to the starting position for the type of gass concerned
2 Check readiness of all module components for starting
3 Switch on starter (engine runs, air and exhaust system is purged)
4 Switch on ignition
5 Open gas valve (engine starts)
6 Turn off starter when adequate speed is adequate and disconnect
7 Engine speed is increased to set speed
8 Unit is ready for synchronisation
Warming up
The engines can be kept at operating temperature, even when standing, by using separate
coolant heating (resistance heating or heating with pump operation).
After starting the engines usually reach operating temperature quickly by return increase of
the warm water flow, independently of the temperature in the heating system. In most cases
the working temperature is the same as the set heating flow temperature.
Ventilation of rooms
When engines are fitted in closed rooms, a check must be made after they have started that
the automatic room ventilation is working properely and that the fans re running.
Inadequate engine room ventilation leads to high room temperatures and to a correspond-
ing loss of performance due to the engine and generator protection in the TEM system.
Lubricating oil system

The lubrication oil pressure is monitored and re corded in the TE M system and normally
does not have to be checked any more by the operator.
Checking the lubrication oil level and the lubrication oil supply in the day tank regularly is
very important. It should be check ed when the engine is standing still, during regular
checks, or when running constantly, every 24 hours. If there is not enough lubrication oil is
switched off automatically and has to be unlocked manually at the switchboard after the lu-
brication oil has been filled up.
The pre-lubrication process takes about 20 minutes. It is not possible to start the engine
before then.

TCG 2020
Operation
Turbocharger
The lubricants and pastes used in installation liquefy or evaporate and may emerge as an
oily fluid in the first few hours after commissioning.
If other oily fluid emerges after this, the cause must be found and eliminated immediately.
The lubricating oil supply to the turbocharger must be checked first. If this is okay consult
your service partner or the manufacturer.
The turbocharger may only be maintained by trained and authorised personnel.

Work on mechanical components such as bearings or rotors may only be carried out by
qualified personnel of the manufacturer.
Operation monitoring
Inspections immediately after commissioning

Check engine for smooth running and noise.
Check the entire engine for leaks.
For further information about the visual inspection of the system - see job card B 0-1-5.
Unit monitoring
All important parameters of the engine, the generator and the connected heat utilization unit
are constantly monitored by the TEM system.
The unit's operating data must be checked using the printouts from the TEM system at reg-
ular operating hour intervals (daily when running continuously).
If there is a warning or a fault in the unit, these must be recorded before resetting. This pro-
vides the oppurtinity to print out the appropriate history or the operating daybook from the
TEM system.
Danger of destruction !
Never reset warning/fault reports before the cause has been ascertained.
Continuing to operate the engine when there is a warning or restarting after a fault
without eliminating the cause can lead to damage and total loss of the engine.
If the engine is restarted without fixing the cause of the warning or fault, the manu-
facturer's guarantee becomes invalid.
Engine peripheral systems

The temperatures, pressures and other relevant conditions are monitored automatically,
the operating data is stored continuously in the TEM system's module control.
When the set limit values are reached, a warning is first given out. If the limit value is passed
again the TEM system stops the engine.

TCG 2020
Operation
3
Reverse power
If the unit is switched off by the TEM system while it is running parallel to the network and
it does not open the generator circuit breaker because of a fault, the unit goes into reverse
power. By switching off in the TEM system the solenoid valves are closed and the ignition
is turned off. No further combustion takes place.
Depending on the type of control the generator section switch is automatically cut off from
the power network. If this does not happen, the power fed in causes the generator to run as
a electric motor and it continues to run at the set speed.
If the Emergency Stop switch is operated in this situation, all electric pumps stop. The me-
chanical friction in the engine will continue to generate heat, but it will not be dissipated
through the cooling system. This can lead to the engine overheating and being written off.
If it gose into reverse flow the generator circuit breaker must be switched off or the
network section track must be disconnected from the power.
Coolant circuit
The coolant must not be topped up while the engine is runnning.
This may be topped up with small amounts after shutting down the engine. In case of fre-
quent refilling, make sure that it contains sufficient corrosion protection agent and/or anti-
freeze - see job card B 9-1-1.
Batteries
If the engine has an electric starter motor, its batteries and the chargers must be checked
weekly.
Please observe:
The TEM system operating instructions are a separate document and must be re-
quested separately.

TCG 2020
Operation
Shutting down
If the engine is shut down for a longer period of time, the work steps listed below must be
performed.
Shutting down the engine for up to 3 months:
- Close the shut-off valve of the gas control line.

- Close the shut-off valves before and after the cooling devices.
- Switch on the pre-heating devices for the coolant, if available, in case of risk of frost.
If the pre-heating device is not switched on, anti-freeze must be added to the coolant.
If this is not possible, the cooling system must be emptied - see job card B 9-0-4.
- During engine standstill, turn over the engine at least two turns of the crankshaft once
a week. Pre-lubricate the engine first.
Shutting down the engine for 3 months or longer:
- Close the shut-off valve of the gas control line.

- Close the shut-off valves before and after the cooling devices.
- Drain the cooling system - see job card B 9-0-4.
- Drain lubricating oil from the engine, mounted parts, pipes and fittings.
- Check the exhaust pipe in front of the turbocharger for combustion residue or foreign
bodies, clean if necessary.
- Fill the engine with corrosion protection agent - see chapter 7 Corrosion protection.

TCG 2020
Operating media
4
GAS

TCG 2020
Operating media

TCG 2020
Operating media
4
Operating media
General
Activities described in the operating and workshop manuals necessitate the use of operat-
ing and auxiliary materials.
All operating and auxiliary materials must be stored, transported and disposed of properly.
The owner is responsible for this.
Disposal includes recycling and disposal of operating and auxiliary materials whereby re-
cycling has priority.
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.
It is essential that notes from the supplier on the packaging or in the form of enclosed leaf-
lets be observed.
These include, for example:
- Safety instructions
- Personal protection equipment
- Proper use
- Proper disposal
- Best before date
- Storage / transport
Product selection
Due to the large number of products in national and international quality and availability and
as a result of the constant further development, it is not possible for us to test all suitable
products and to name them, we therefore cannot accept any responsibility for these prod-
ucts.
The supplier of the operating materials is solely responsible for the world-wide consistent
quality of the products listed here and for products not listed here additionally for meeting
the listed requirements for operating media and their operational safety. This also applies
for the event that the manufacturer develops the listed products further.
The operating media (reference products) listed here are just a selection of a few manufac-
turers and their products. Other operating media not listed here may be used if they meet
the specified requirements. That means these operating media must be at least equal or
better in all criteria. The operating media named in this specification are to be used as ref-
erence products for comparison. The respective operating media suppliers can provide in-
formation about this and should confirm the suitability accordingly.
Mixability
Mixing different expendable types together, e.g. different lube oils with each other, different
coolant additives with each other, may lead to malfunctions.
In any case the product supplier’s consent must be obtained before mixing and he must
take over the responsibility. This also applies for other additives to the operating media.

TCG 2020
Operating media
Guarantee
If unsuitable operating media are used or if it is not possible to produce evidence that the
operating media used are suitable for the requirements, no guarantee of faultless operation
is accepted by the m anufacturer of the e ngine. This also applies to inadequate mainte-
nance of the engines and the operating media.
The most important operating media are shown in the accompanying operating media reg-
ulations. The data given in them are binding unless the engine or unit-specific contracts
state otherwise.
Fuel gas
see technical circular TR 0199-99-3017.
Lube oil
Engine coolant

TCG 2020
Operating media
4
Auxiliary materials
Packing compound
DW 43
Solvent free, rubber-based soft-elastic hardening, fast skin formation.
Temperature range 30 °C to 100 °C
For sealing narrow joints
DW 47
Silicone rubber, tenacious elastic, easily dissolvable.
Temperature range max. 180 °C, lube oil max 150 °C
For sealing of rough and uneven surfaces
DW 48
Silicone rubber, tenacious elastic, high adhesion strength.
Temperature range -65 °C to 265 °C
For sealing of rough and uneven surfaces
DW 49
Mixed polymerisate of vinyl and acrylic compounds, high adhesion strength and perma-
nent elasticity.
For sealing core hole plugs
DW 50
Liquid, hardening artificial resin, compatible with flat gaskets.
For sealing housings
DW 51
Physically dry artificial resin, permanently elastic and vibration free.
For sealing surfaces
DW 63
Anaerobic solvent-free single-component substance hardening upon metal contact when
excluding oxygen, low strength, high viscosity, thixothropic.
For sealing surfaces up to a max. gap width of 0.10 mm

TCG 2020
Operating media
DW 67
For sealing surfaces up to a max. gap width of 0.50 mm
DW 68
For sealing surfaces up to a max. gap width of 0.50 mm, locking and sealing threads up
to R2"
Locking agent
DW 55
excluding oxygen, high strength, low viscosity.
Locking and sealing threads up to M12, joints up to a max. gap width of 0.15 mm
DW 56
excluding oxygen, high strength, high viscosity.
Locking and sealing threads up to R2"
DW 57
excluding oxygen, low strength, low viscosity.
Locking and sealing threads up to M12
DW 59
excluding oxygen, high strength, medium viscosity.
DW 60
excluding oxygen, medium strength, low viscosity.
Locking and sealing threads up to M56 or R2"

TCG 2020
Operating media
4
DW 62
Joints up to a maximum gap width of 0.12 mm
DW 64
Locking and sealing threads up to M80 or R3"
DW 65
excluding oxygen, high strength, high viscosity.
Joints up to a maximum gap width of 0.25 mm
DW 66
excluding oxygen, low strength, high viscosity.
Locking and sealing threads up to R3"
DW 69
excluding oxygen, low strength, low viscosity.
DW 70
DW 71

TCG 2020
Operating media
DW 72
Activator
DW 61
Accelerates and enables full hardening of anaerobic substances in passive materials
Adhesive
KL 1
Two-part epoxy resin based, water, lube oil and diesel fuel resistant. Mixing ratio 1:1, ad-
hesive KL 1 and hardener KL 2
Temperature range max. 150 °C
Sticks steel, aluminium, brass and plastics such as plexiglass, polyethylene etc. with
themselves and with each other
Hardener
KL 2
Two-part epoxy resin based, water, lube oil and diesel fuel resistant. Mixing ratio 1:1, ad-
hesive KL 1 and hardener KL 2
Temperature range max. 150 °C
Sticks steel, aluminium, brass and plastics such as plexiglass, polyethylene etc. with
themselves and with each other

TCG 2020
Operating media
4
Lubricant
S1
Prevents burning of screw connections in exhaust pipes
S2
Spray medium, prevents friction and wear on poorly accessible sliding surfaces. Provides
an emergency lubrication and prevents jolting.
S3
Spray medium, prevents friction and wear. Provides an emergency lubrication and pre-
vents jolting.
S4
Preferably for pre-treating components with a high operational temperature. After evapo-
ration of the carrier oil (at 200 °C) a more effective lubricant solid film is left behind. Com-
patible with natural rubber and plastics.
S5
For long-term lubrication of rolling and plain bearings with high bearing pressures. Water-
resistant, good emergency lubrication.
S6
For long-term lubrication of roller and plain bearings with medium bearing pressures and
higher temperatures. Water-resistant, good emergency lubrication.
Grease
Consistent grease for lubricating rolling bearings, plain bearings and sliding surfaces. For
example, for filling the tooth coupling between the injection pumps.

TCG 2020
Operating media
Commercially available products

Below is a reference list of auxiliary media used w ith which best results have been
achieved. Equivalent products can be used whereby the supplier must guarantee the suit-
ability of the product for the application.
Conservation agents
Manufacturer: BP Hamburg
SAE30W-30, BP- Run-in conservation oil for conserving the lube oil system and 15%
MEK 30 part distilled fuel for fuel systems
Manufacturer: Kuhbier Chemie GmbH, 58566 Kierspe

Puriton 3956 For corrosion protection of the coolant system
Manufacturer: Reicon Chemie, 04103 Leipzig

ODACON Z For corrosion protection of the coolant system
Manufacturer: Deutsche Castrol, 76829 Landau

Gerserol Super For protecting bare exterior surfaces and parts (wax-like)
Manufacturer: Fuchs Europe, 68169 Mannheim

Renolit MP2 Protective grease for control linkages and joints
Manufacturer: Silbermann GmbH & Co. KG, 86456 Gablingen

Talcum fine, white For rubber parts

TCG 2020
Operating media
4
Cleaning agents
Manufacturer: Henkel KGAA, 40191 Düsseldorf

P3 Standard For enging cooling system, powder
P3 Cold cleaner For engine parts, liquid
P3 - croni Neutralising agent for raw water circuit and charge air cooler, water
side
P3T - 288 For enging cooling system, powder
P3T - 1166 Neutralising agent for raw water circuit and charge air cooler, water
side
P3T - 5308 For charge air cooler, air side
Manufacturer: Vecom GmbH, 21107 Hamburg

Vecom B 14 For tank systems, liquid
Vecom B 24 B For engine parts and tank systems, liquid
Vecom B 85 For charge air cooler, air side
Vecom BA-S For enging cooling system, powder
Vecom BA-30 For enging cooling system, liquid
Manufacturer: Drew Ameroid Deutschland GmbH, 21107 Hamburg

ACC 9 For charge air cooler, air side
SAF-Acid Limescale remover for engine cooling system, raw water circuit and
charge air cooler, water side, liquid, concentration 5%, temperature
range 55 °C to 75 °C
HDE-777 For enging cooling system, liquid
Carbon remover For engine parts, liquid
Tank cleaner No. 4 For tank systems, liquid
Ameroid ACC-9 For engine parts, liquid
Manufacturer: Collardi GmbH, 50825 Köln

Porodox For raw water circuit and charge air cooler, water side, treatment time
max. 16 hours, concentration 2% to 10%, temperature range 20 °C to
60 °C
Manufacturer: Haug-Chemie GmbH, 74889 Sinsheim

Eskapon S 255 For removal of conservation agent
Manufacturer: Fuchs Europe, 68169 Mannheim

Reponal B150 Thinners and removers of wax-like conservation agents

TCG 2020
Operating media
Water treatment agents
Manufacturer: E. Merck KGAA, 64293 Darmstadt

Aquamerk Art. No. Hardness determiner for cooling water, order no. 1215 8292
11129
Manufacturer: Vecom GmbH, 21107 Hamburg

Vecom CN Coolant hardener, powder
Manufacturer: Benckiser GmbH, 67001 Ludwigshafen

Trisodium phos- Coolant softener, powder
phate

TCG 2020
Maintenance
5
E20
E30
E40
E50
E60
E70

TCG 2020
Maintenance

TCG 2020
Maintenance
5
Maintenance
Maintenance schedule as separate documentation

To ensure the operating reliability of the engine and the components fitted to the engine,
the maintenance measures must b e carried out according to the maintenance schedule or
the manufacturer documentation.
The maintenance schedule adapted to the engine is enclosed or available as a separate
documentation.
When operating the engine without observing the maintenance measures listed in
the maintenance schedule, the engine could be damaged or destroyed.
The manufacturer will not be liable if the engine is operated without performing the
prescribed maintenance work.

TCG 2020
Maintenance

TCG 2020
Tools
5
Tools for competence class 1
Address of order
You can buy the tools through your service partner.
Tools sorted according to order numbers
Name Figure
1 Description / Use (The illustrations are examples)
2 Module
3 Order number / Order from ...
Torque wrench
1 Measuring range 0-210 Nm (0-21 kpm)
2 00 General
3 1203 0350 / Service partner
Tool kit
1 Standard set
2 00 General
consisting of: 1203 0366 Tool case

1203 0375 Open-end spanner 46
0115 1236 Open-end spanner 36 x 41
0115 1247 Socket 22 x 12.5
0115 1248 Socket 24 x 20
0115 1249 Socket 27 x 20
0115 1250 Socket 30 x 20
0115 1251 Socket 32 x 20
1203 0376 Socket key size 36, extra deep
1205 0717 Socket key, inside size 17
1203 0354 Slider CH 1772/39

TCG 2020
Tools
Name Figure
2 Module
1203 0348 Extension CH 1772/38

1203 0356 Extension CH 1915/7
1203 0360 Extension D 601/602
0115 1239 Adapter A 20 x 12.5
1203 0350 Torque wrench 0-210 Nm (0-21 kpm)
1203 0346 Extension for torque wrench
1203 0362 Ratchet 1/2“
1203 0352 Ratchet 3/4"
1205 1887 Extension for 3/4" slider
0115 1262 Right angle screwdriver 5
0111 0476 Right angle screwdriver, gunmetal 5
1203 0377 Pin wrench 3/16”
0115 1253 Pliers A 10
0115 1254 Pliers A 19
0115 1256 Pliers C 40
1203 0369 Brush
1203 0364 Handle D 601/602
12003 0358 Feeler gauge 0.05 - 0.5 mm
1203 0373 Pin for loosening the retaining bolts
1203 0378 Ring spanner size 22
1203 0370 Extension for brushes for pipe cooler
1203 0371 Round brush CH 1988/2
1203 0374 Round brush CH 1988/4
1213 5586 Wrench (starter wrench) 27

TCG 2020
Tools
5
Name Figure
2 Module
Tool kit
1 Standard set
2 00 General
consisting of: 1218 9924 Socket wrench 3/8“, No.33

0703 7936 Socket 16 x 12.5
0703 7935 Wrench B 16
1215 8153 Strip key
1214 1829 Pliers, valve stem seal
1221 7605 Spark plug spanner

TCG 2020
Tools
Name Figure
2 Module
Tool kit
1 Standard set
2 00 General
consisting of: 1215 8074 Tool case

0112 4755 Ring spanner 13 x 17
0115 4367 Set of feeler gauges 0.05 - 1.0 x 100
0110 3964 Socket 10 x 12.5
0110 3965 Socket 13 x 12.5
0110 3966 Socket 14 x 12.5
0110 3967 Socket 17 x 12.5
0110 3968 Socket 19 x 12.5
0110 2416 Socket 22 x 12.5
0115 2905 T-handle A 12.5
0110 2415 Extension B 12.5 x 250
0115 4232 Universal joint C 12.5
0110 3385 Screwdriver A 0.8 x 4.0
0110 4281 Screwdriver A 1 x 5.5

TCG 2020
Tools
5
Name Figure
2 Module
Strobe light
1 For checking the ignition time
2 13 Electrics
Acid tester
1 For checking the battery fluid density
2 13 Electrics
Lubricating oil filter key

1 For loosening the lubricating oil filter cartridge
2 08 Lubricating oil system
Test set for cooling water

1 To determine the water values for fresh water and cooling
water
2 09 Cooling system
3 1215 8292 / Service Partner
Replaces test case 1213 0382

TCG 2020
Tools
Name Figure
2 Module
Valve wear measuring device

1 For mounting on the cylinder head for the valve wear
measurement
2 01 Cylinder head
Depth gauge
1 For measuring the valve wear
2 01 Cylinder head
Spark plug spanner

1 For removing and installing the spark plugs with integrat-
ed ignition cable
2 13 Electrics
Locking wrench for setting screws of the valve bridges

1 For tightening the locking nuts in the valve bridge setting
2 01 Cylinder head

TCG 2020
Tools
5
Name Figure
2 Module
Hexagon wrench for cylinder head nuts

1 For loosening and tightening the cylinder head nuts
2 01 Cylinder head
Tool set for PEARL exhaust gas system

1 For removing and installing the exhaust gas pipes in the
PEARL exhaust gas system
2 06 Exhaust system / Charging

TCG 2020
Tools
Name Figure
2 Module
Hydraulic clamping device for cylinder head nuts with

hydraulic hand pump (compact design)
1 For clamping the pin bolts
2 01 Cylinder head
consisting of: Mock no.:

4x 1221 7450 (HV 1999/1) Clamping device for cylinder head
1x 1213 5816 (HV 6012-1/49) Hydraulic hand pump
5x 0703 7812 High pressure hose
1x 0703 7813 Copies to
2x 0111 0403 Lathe mandrel
1x 1206 9457 Spare hydraulic oil
1x Tool kit
1x Operating instructions
Compressed air hydraulic pump

1 Can be ordered additionally for the hydraulic clamping
device 1221 7454 or 1221 7448
2 01 Cylinder head or 02 driving gear

TCG 2020
Tools
5
Name Figure
2 Module
Cover plate for crankcase

1 To close the crankcase when working on the cylinder
2 03 Crankcase
Disassembly and assembly device for cylinder head

1 For disassembling and assembling the cylinder head
2 01 Cylinder head
Measuring tap for charging mixture pressure measure-

ment
1 For installation in the charging mixture pipe for pressure
measurement
2 06 Exhaust system / Charging
The measuring taps can remain installed in the charging mixture pipe after the measurement.
Shim for cylinder head assembly

1 For positioning the cylinder head during assembly
2 01 Cylinder head

TCG 2020
Tools

TCG 2020
Tools
5
Name Figure
2 Module
Assembly tool for coolant overflow

1 For knocking in the coolant overflow
2 01 cylinder head
3 0297 7278 / Service Partner
Assembly pliers for piston assembly

1 For clamping the piston rings when inserting the pistons
in the cylinder liner
2 01 Cylinder head
Press-in pin for valve stem guide

1 For pressing in the inlet and outlet valve stem guide
2 01 Cylinder head

TCG 2020
Tools
Name Figure
2 Module
Press-out pin for valve stem guide

1 For pressing out the inlet and outlet valve stem guide
2 01 Cylinder head
Holding device for piston

1 For removing and installing the pistons
2 02 Drive unit
Disassembly and assembly lever for valve spring

1 For clamping the valve springs when removing and in-
stalling the valves
2 01 Cylinder head
Dial gauge
1 For measuring stand and plate
2 01 Cylinder head

TCG 2020
Tools
5
Name Figure
2 Module
Measuring tripod
1 For clamping and fixing the dial gauge
2 00 General
Disassembly tool for cylinder liners

1 For removing the cylinder liners from the crankcase
2 03 Crankcase
Inspection device for piston cooling nozzle

1 For testing the alignment of the piston cooling nozzle
2 02 Driving gear
Disassembly pin for main bearing

1 For removing the main bearing with the crankshaft in-
stalled
2 02 Driving gear

TCG 2020
Tools
Name Figure
2 Module
Plug gauge for cylinder liner fitting

1 For checking the upper cylinder liner fit in the crankcase
2 03 Crankcase
Hydraulic clamping device for cylinder head and main

bearing nuts with hydraulic hand pump (compact de-
sign)
1 For clamping the pin bolts
2 01 Cylinder head or 02 driving gear
consisting of:
4x 1221 7450 (HV 1999/1) Clamping device for cylinder head
2x 1221 7452 (HV 1999/2) Clamping device for main bearing
1x 1213 5816 (HV 6012-1/49) Hydraulic hand pump
1x 0703 7813 Copies to
2x 0111 0403 Lathe mandrel
1x 1206 9457 Spare hydraulic oil
1x Tool kit
1x Operating instructions
If the hydraulic clamping device 1221 7454 (competence class 2) is available, only the two clamping
devices (HV 1999/2) for the main bearing must be ordered for completion !

TCG 2020
Tools
5
Name Figure
2 Module
Lathe tool for cylinder liner fit

1 For reworking the cylinder liner fit in the crankcase
2 03 Crankcase
Disassembly device for con-rod liner

1 For removing the con-rod liners from the con-rod
2 02 Driving gear
Piston ring pliers (diameter 170 mm)

1 For removing and installing the piston rings in the pistons
2 02 Driving gear
Disassembly and assembly pin for camshaft

1 For removing and installing the camshaft
2 04 Engine control

TCG 2020
Tools
Name Figure
2 Module
Disassembly and assembly device for roller tappets

1 For removing and installing the roller tappets
2 04 Engine control
Disassembly and assembly tool for camshaft bearing

1 For removing and installing the camshaft bearing in the
crankcase
2 04 Engine control
Test shaft for bearing race bore

1 For testing the bearing race bore
2 03 Crankcase
Lifting device for valve tappet

1 For lifting the valve tappet when removing the camshaft
2 04 Engine control

TCG 2020
Tools
5
Name Figure
2 Module
Guide pin for vibration damper and flywheel flange

1 For positioning the vibration damper and flywheel flange
2 12 Other components

TCG 2020
Tools

TCG 2020
Troubleshooting
6
STOP

TCG 2020
Troubleshooting

TCG 2020
Troubleshooting
6
Troubleshooting
The following table is a list of faults which may occur during engine operation and their pos-
sible causes. It does not claim to be a full list.
The causes of the faults are listed in ascending order of effort required to localise them.
The tables listed below contain measures which may help to eliminate the fault. If the fault
persists even after carrying out the measures, please contact your Service Partner.
Never reset warning/fault reports before the cause has been ascertained.
Continuing to operate the engine when there is a warning or restarting after a fault
without eliminating the cause can lead to damage and total loss of the engine.
If the engine is restarted without fixing the cause of the warning or fault, the manu-
facturer's guarantee becomes invalid.
Explanation of tabular representation
Fault type
TEM message
Plain text entry
Possible cause of the fault

Troubleshooting

TCG 2020
Troubleshooting
Troubleshooting remedies
Engine fails to start
TEM message
Engine does not start
Gas shutoff fittings closed

Open gas shutoff fittings
Gas pipe not bled

Bleed gas line
Discharged or defective battery

Check battery, recharge / renew if necessary
Starter defective
Check the starter, renew if necessary
Power supply to the terminal box unit interrupted

Check the cable harness, repair / renew if necessary
Ignition system defective

Check the ignition system

TCG 2020
Troubleshooting
6
Engine does not reach the prescribed performance or speed
TEM message
none
No valve clearance
Set the valve clearance
TEM message
Gas pressure
Gas shutoff fittings not fully open

Fully open the gas shut-off fittings / check gas filter and renew if necessary
Too little gas

Check gas pressure
Suction air intake filter blocked

Check the suction air intake filter, renew if necessary
TEM message
Gas mixer stop
Gas-air mixture defective (too lean / too rich)

Checking the setting of the gas-air mixer

TCG 2020
Troubleshooting
Engine fires irregularly
TEM message
Engine misfires
Note: The smooth run detector of the TEM system can be used to diagnose the
misfiring
Ignition control unit defective

Check the ignition control unit, renew if necessary
Ignition coils defective

Check the ignition coils, renew if necessary
Electrode spacing at spark plug too big

Check the spark plug, reset / renew if necessary
Spark plugs defective

Check the spark plugs, renew if necessary
Frequency sensor (camshaft or flywheel) has too big a spacing / or are in

range of limit
Check the setting, adjust if necessary

TCG 2020
Troubleshooting
6
Engine bangs and runs irregularly
TEM message
none
Inlet and outlet valves leaking

Check inlet or outlet valves
Oil carbon residue on pistons or outlet valves

Check parts, clean if necessary
TEM message
Engine does not start
Ignition cable defective

Check the ignition cable, renew if necessary
Ignition coil defective

Check the ignition coil, renew if necessary

range of limit
Gas pipe not bled

Bleed gas line

TCG 2020
Troubleshooting
Engine stops suddenly or is switched off by TEM after a fault
TEM message
none
Ignition failed (cable broken)

Check the cable harness, repair / renew if necessary
Ignition control unit defective

Check the ignition control unit, renew if necessary

range of limit
Gas supply interrupted

Check the gas pipe
Gas pressure regulator sticks

Check the gas pressure regulator, repair or renew if necessary
TEM message
Gas mixer stop lean
Gas pressure too high

Check gas pressure on the gas pressure regulator and correct it if necessary
TEM message
Overspeed
Speed governor defective

Ask an authorised expert to check the speed governor and have it repaired
if necessary
TEM message
Fault cooling water pump

TCG 2020
Troubleshooting
6
Coolant pump defective (pump shaft broken, bearing defective)

Check the coolant pump, repair and renew if necessary
TEM message
Overtemperature cooling water
Coolant system sludged or blocked by scale

Clean the coolant system
TEM message
Low cooling water
Too little coolant

Check coolant level and correct if necessary, eliminate cause of the coolant
loss
Coolant leaks from the coolant pump

Check axial sealing rings of the coolant pump and renew if necessary
TEM message
Lubricating oil level too low / overtemperature lubricating oil
Lube oil level too low

Check the lube oil level and refill if necessary

TCG 2020
Troubleshooting
Engine gets too hot or TEM message lack of coolant
TEM message
none
Three-way valve secondary heating circuit defective

Check the three-way valve secondary heating circuit, renew if necessary
Heat transmission (from primary circuit to secondary circuit) defective

Clean sludged elements of the heat transformer
TEM message
Fault cooling water pump
Coolant pump defective (pump shaft broken, bearing defective)

Check the coolant pump, repair and renew if necessary
TEM message
Overtemperature cooling water
Coolant system sludged or blocked by scale

Clean the coolant system
TEM message
Low cooling water
Too little coolant

Check coolant level and correct if necessary, eliminate cause of the coolant
loss
Coolant leaks from the coolant pump

Check axial sealing rings of the coolant pump and renew if necessary

TCG 2020
Troubleshooting
6
Lack of lubricating oil pressure or TEM message lubricating oil pressure too low or
lubricating oil level too low
TEM message
none
Lube oil pressure gauge defective

Check the lube oil pressure gauge, renew if necessary
Pressure control valve defective

Checking, repairing and, if necessary, renewing the pressure control valve
Bearing clearance of the crankshaft or con-rod bearings too great (wear)

Check bearing clearances, renew components if necessary
TEM message
Lube oil filter dirty
Lube oil filter dirty

Replace lubricating oil filter
TEM message
Lubricating oil level too low / overtemperature lubricating oil
Lube oil level too low

Check the lube oil level and refill if necessary
TEM message
Lube oil pressure too low

TCG 2020
Troubleshooting
Manifold to lube oil pump soiled

Check and clean the manifold
Lube oil pump heavily worn

Check the lube oil pump, repair and renew if necessary
Safety valve on the lube oil pump leaking

Check the safety valve, repair and renew if necessary
Coolant in lube oil
TEM message
none
Cylinder liner seal in crankcase leaking

Remove the cylinder liner and seal it again, analyse the lubricating oil sam-
ple
Lube oil in coolant
TEM message
none
Lube oil cooler leaking

Check the lube oil cooler, renew if necessary

TCG 2020
Corrosion protection
7

TCG 2020

TCG 2020
7
General
Engines and spare parts are protected against corrosion at the Mannheim factory before
delivery. The duration of the corrosion protection depends on the type of corrosion protec-
tion, the packing and the storage conditions.
If the engine is taken out of operation for 3 months or longer, it must be protected against
corrosion appropriately.
A distinction is made between corrosion protection of engines which have already been run-
ning (inside and outside corrosion protection), reapplication of corrosion protection and re-
moval of corrosion protection.
For further information about the corrosion protection - see Technical Circular TR 0199-99-
2116.

TCG 2020

TCG 2020
Technical data
8

TCG 2020
Technical data

TCG 2020
Technical data
8
Technical data
Test and setting values
General
Work procedure
Otto four-stroke engine with four-valve technology
Mixture charging
Turbocharging with mixture cooling
Mixture cooler (liquid cooled)
Cylinder arrangement
V-engine with 90° cylinder angle
No. of cylinders
12, 16 and 20
Engine control
TEM Evolution System
Actuator
V12 and V16 engine Heinzmann StG 30 - 01
V20 engine Heinzmann StG 2080 - 01
Combustion gas type

Gases of gas group 1 and gas group 2
Bore
170 mm
Stroke
195 mm
Capacity per cylinder

4.426 dm3
Total displacement
V12 engine 53.1 dm3
V16 engine 70.8 dm3
V20 engine 88.5 dm3
Compression ratio
13.5 : 1
Ignition sequence
V12 engine A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6
V16 engine A1 B2 A6 B5 A8 B7 A3 A7 B6 A4 B8 A2 B3 A5 B1 B4
V20 engine A1 B7 A2 B5 A4 B3 A6 B1 A8 B2 A10 B4 A9 B6 A7 B8 A5 B10 A3 B9

TCG 2020
Technical data
Dimensions
Length V12 engine 4.700 mm
V16 engine 5.700 mm
V20 engine 6.300 mm
Width V12 engine 1.750 mm
V16 engine 1.750 mm
V20 engine 1.750 mm
Height V12 engine 2.500 mm
V16 engine 2.500 mm
V20 engine 2.550 mm
Weights (all data are approximate values)

Engine V12 engine 4.200 kg
V16 engine 5.800 kg
V20 engine 7.800 kg
Power unit V12 engine 10.500 kg
V16 engine 13.500 kg
V20 engine 17.580 kg
Cylinder head, complete 54 kg
Cylinder liner 16 kg
Piston, complete 10 kg
Con rod, complete 15 kg
Camshaft V12 engine 19 kg
V16 engine 25 kg
V20 engine 35 kg
Crankshaft with coun- V12 engine 511 kg
terweights
V16 engine 452 kg
V20 engine 611 kg
Main bearing cover 16 kg
Oil pan V12 engine 90 kg
V16 engine 100 kg
V20 engine 340 kg
Flywheel 316 kg
Vibration damper V20 engine 42 kg
Mixture cooler without V12 engine 75 kg
cover
V16 engine 75 kg
V20 engine 113 kg
Lubricating oil pump, V12 engine 37 kg
complete
V16 engine 42 kg
V20 engine 42 kg
TCG 2020
Technical data
8
Coolant content
V12 engine 139 dm3
V16 engine 179 dm3
V20 engine 262 dm3
Coolant temperatures
Engine max. Inlet / outlet 80 / 92 °C
with Glycol Inlet / outlet 80 / 92 °C
Intake air temperature

min. 20 °C
Design Project-related
Cylinder head
Control times (with 2 mm valve clearance)

Inlet opens after TDC 7° 04’ (7,06°)
Inlet closes before BDC 31° 04’ (31,06°)
Outlet opens before BDC 33° 19’ (33,31°)
Outlet closes before TDC 3° 43’ (3,71°)
Valve bridge
0.05 mm
Valve clearance (Gas group 1 and 2)

Inlet 0.3 mm
Outlet 0.7 mm
Valve lag with fitted cylinder head

Inlet Nominal dimension 74.7 mm
Wear limit 71.2 mm
Outlet Nominal dimension 74.7 mm
Wear limit 71.2 mm
Crankcase
Crankcase breather (model Dynapure)

Imbalance of the drum 50 Hz, 2,810 rpm max. 7.0 mm/s

TCG 2020
Technical data
Speed controller
Set the camshaft sensor (Jaquet)

Turn the engine until the pulse screw is visible
Turn in the frequency sensor to the stop
Unscrew 1 rotation (360°)
Set the flywheel sensor (Jaquet)

Turn in the frequency sensor up to the system
Continue unscrewing until the marking is in running direction
Actuator (Heinzmann StG 30-1)

Controller output shaft
Angle of rotation 42°
max. torque 28 Nm
Holding torque 14 Nm
Throughput time 170 ms
Power consumption
Steady condition 1A
at load change 3-4A
max. current 4.5 A
limited current 2.5 A
Storage temperature -55 to +110 °C
Ambient temperature
Standard -25 to +90 °C
Special version -40 to +90 °C
Humidity up to 100%
Type of protection Housing IP 44
Weight 12.3 kg

TCG 2020
Technical data
8
Actuator (Heinzmann StG 2080-1)

Controller output shaft
Angle of rotation 36°
max. torque 11 Nm
Holding torque 5.5 Nm
Throughput time 60 ms
Power consumption
Steady condition 1A
at load change 3-4 A
max. current 4.5 A
limited current 2.5 A
Storage temperature -55 to +110
Ambient temperature
Standard -25 to +90
Special version -40 to +90
Humidity up to 100%
Type of protection Housing IP 44
Weight 6.6 kg
Charge mixture pressures - synchronisation of cylinder row A and B (only V20 engine)
DZR actuator type (parameter 11 107)
Setting value 5
Offset actuator B-A at 0% load (parameter 11 110)
Differential pressure less than 30 mbar
Fuel system / gas system
Gas pressure of the gas control system

see acceptance documents

TCG 2020
Technical data
Lube oil system
Lube oil content

V12 engine 630 dm3
V16 engine 865 dm3
V20 engine 1.080 dm3
Lubricating oil pump

Press-in depth of the intermediate 44.10 - 44.15 mm
wheel axis
Distance valve housing - lubricating oil 21.40 - 22.40 mm
pump housing
Electrical system
Ignition point
according to TEM system parameter 11301
Starter (electric)
Supply voltage 24 V
Power consumption V12 engine 9 kW
V16 engine 15 kW
V20 engine 18 kW
Starter (compressed air)

Supply pressure min. 16 bar
max. 30 bar
Air bottle content 2.000 dm3
Battery
Voltage 12 V
Capacity V12 engine 4 x 143 Ah
V16 engine 4 x 215 Ah
V20 engine 6 x 215 Ah
Battery acid density

Charge status Normal Tropical
well charged 1.28 kg/l 1.23 kg/l
semi-charged (re-charge) 1.20 kg/l 1.12 kg/l
discharged (recharge, renew if neces- 1.12 kg/l 1.08 kg/l
sary)

TCG 2020
Technical data
8
Tightening specifications
General
Nuts / bolts, standard values complying with H 0385-1, screw connection class II *
8.8 10.9 12.9
M4 2.5 3.5 4.5 Nm
M5 5.0 7.5 8.5 Nm
M6 8.5 13 15 Nm
M8 20 30 36 Nm
M10 42 60 70 Nm
M12 70 110 120 Nm
M14 110 170 200 Nm
M16 180 260 300 Nm
M18 260 360 420 Nm
M20 360 500 600 Nm
M22 480 700 800 Nm
M24 600 850 1000 Nm
M27 900 1300 1500 Nm
M30 1200 1700 2000 Nm
Caution !
* Use only if no component-specific torque values are specified.
Compensator on flange
DN 40 / 50 15 Nm
DN 65 / 80 / 100 / 125 20 Nm
DN 150 25 Nm
Cylinder head
Cylinder head on the crankcase

see job card W 1-4-4
Lock nut of the valve bridge

M10x1 40 Nm
Lock nut on the rocker arm

M12x1.5 45 Nm

TCG 2020
Technical data
Rocker arm bracket on cylinder head

M16x1.5 - 10.9 1. Stage 30 Nm
2. Stage 120°
Protective tube for spark plug on cylinder head

M27x2 200 Nm
Cylinder head cover on cylinder head

M8x55 / 85 25 Nm
Drive gear
Big end bearing cover on connecting rod

(renew screws) M20x2 - 10.9 1. Stage 125 Nm
2. Stage 250 Nm
3. Stage 30°
4. Stage 30°
Main bearing cover on crankcase

Cross bracing on main bearing cover

Counterweight on crankshaft
M20x2x120 - 10.9 1. Stage 150 Nm
2. Stage 60°
Coat threads and screw head contact surfaces with lubricant.
Check with minimum inspection tightening torque 460 Nm !
Flywheel flange on crankshaft

Observe tightening order !
Tighten screws in the order 1, 6, 2, 7, 3, 8, 4, 9, 5, 10.
Assignment of screws - see job card W 2-2-9.
(renew screws) M27x2x140 - 12.9 1. Stage 100 Nm
2. Stage 300 Nm
3. Stage 120°
Vibration damper flange on crankshaft

M27x2x195 - 10.9 1. Stage 300 Nm
2. Stage 600 Nm
3. Stage 60°
4. Stage 30°
Piston cooling nozzle on crankcase

M8x50 - 10.9 25 Nm

TCG 2020
Technical data
8
Crankcase
Cover for lubricating oil duct on crankcase

M8x40 - 10.9 25 Nm
Cover for cooling water duct on crankcase

M8x40 - 10.9 25 Nm
Cover in place of injection pump

M8x25 - 10.9 35 Nm
Hatch cover on the crankcase

M8x20 - 8.8 25 Nm
Engine holder on crankcase (engine mounting)

M16x40 - 10.9 190 Nm
Engine holder on base frame (engine mounting)

M16x40 - 10.9 210 Nm
Lubricating oil pan on crankcase

M8x70 - 8.8 25 Nm
Lid on gearcase cover

M8x20 - 8.8 25 Nm
Gearcase cover on crankcase

M8x80 - 10.9 35 Nm
M10x65/80 - 10.9 50 Nm
Rear cover on crankcase (drive side)

M8x20/25/50 - 8.8 25 Nm
Engine control
Camshaft on bearing flange

(renew screw) M10x110 - 12.9 1. Stage 60 Nm
2. Stage 90°
Camshaft toothed gear on bearing flange

2. Stage 60°
Camshaft toothed gear on ring

M10x40 - 10.9 60 Nm
Idler gear on shaft (wear disc)

M16x50 - 10.9 200 Nm
Cover on camshaft bearing housing

M8x18 - 8.8 25 Nm

TCG 2020
Technical data
Front cover on camshaft bearing housing

M8x16 - 10.9 35 Nm
Speed governing
Actuator on retainer plate

M8x28 - 8.8 25 Nm
Lever impulse transmitter linkage on actuator

M6x35 - 8.8 10 Nm
Knocking sensor on crankcase

M8x30 - 8.8 20 Nm
Exhaust pipe (Pearl) on cylinder head

M10x48 60 Nm
Clamp on exhaust pipe (Pearl)

M8 15 Nm
Support for mixture cooler on face plate

M16x90 - 10.9 295 Nm
Holder for mixture cooler on angle bracket (A side)

M10x20 - 8.8 49 Nm
Holder for mixture cooler on mixture cooler (A side)

M12x25/30 - 10.9 125 Nm
Holder for mixture cooler on crankcase (A side)

M12x80 - 10.9 125 Nm
Holder for mixture cooler on mixture cooler (B side)

M12x60 - 10.9 125 Nm
Holder for mixture cooler on crankcase (B side)

M12x65 - 10.9 125 Nm
Compensator on turbocharger (inlet)

M10 40 Nm
Compensator on turbocharger (outlet)

M8 25 Nm
Exhaust manifold to turbocharger

M20x70 250 Nm
Holder on exhaust manifold

M10x25 70 Nm

TCG 2020
Technical data
8
Holder turbocharger on crankcase

M12x30 120 Nm
Holder turbocharger on crankcase (free side)

M10x95 - 10.9 69 Nm
Holder turbocharger TPS 48

M16 400 Nm
Turbocharger TPS 52 on holder

M20x2x200 455 Nm

M16x1.5x190 230 Nm
Turbine housing TPS 48 on gas outlet flange

M8 25 Nm

M8 45 Nm
Turbine housing TPS 48 on compressor housing

M8 35 Nm

M8 70 Nm
Turbocharger on charge mixture pipe

M12x40 - 8.8 86 Nm
Charge mixture pipe to cylinder head

M12x30/45 - 10.9 90 Nm
Charge mixture pipe to compensator

M8x40 - 8.8 25 Nm
Retainer plate for air intake filter housing

M8x20 - 8.8 25 Nm
Air intake filter housing on retainer plate

M6x60 - 8.8 10 Nm
Clamping clip on air intake filter housing

M8x100 - 10.9 35 Nm
Retainer plate on air intake filter housing

M8x100 - 10.9 35 Nm

TCG 2020
Technical data
Fuel system / gas system
Lock nut proximity switch

10 Nm
Cover of gas filter housing

8 Nm
Holder gas mixer on crankcase

M10x30 - 8.8 49 Nm
Gas mixing valve on holder

M10x45 - 8.8 49 Nm
Lube oil system
Cover on housing lubricating oil pump

M10x70 - 8.8 50 Nm
Drive gear lubricating oil pump on pump wheel

M12x95 - 10.9 123 Nm
Idler gear lubricating oil pump on gear shaft

M10x100 - 10.9 68 Nm
M8x50 - 10.9 35 Nm
Lubricating oil pump on crankcase

M10x80/90 - 8.8 48 Nm
Valve cover on valve housing

M42x1.5 70 Nm
Lubricating oil cooler cover on lubricating oil cooler insert

M8x90 - 10.9 27 Nm
Lubricating oil cooler cover on lubricating oil cooler housing

M8x80/90 - 10.9 27 Nm
Lubricating oil cooler housing on crankcase

M8x30/90 - 10.9 27 Nm
Lubricating oil filter console on crankcase

M8x30/80 - 10.9 27 Nm
Lube oil filter on console

25 Nm

TCG 2020
Technical data
8
Cooling system
Coolant pipes (union nut)

6 mm 35 Nm
8 mm 45 Nm
10 mm 60 Nm
12 mm 75 Nm
Coolant pipes (hollow screws)
M10 x 1 18 Nm
M12 x 1.5 29 Nm
M14 x 1.5 39 Nm
M16 x 1.5 49 Nm
Other components
Flywheel on flywheel flange

M16x45 1. Stage 120 Nm
2. Stage 160 Nm
3. Stage 280 Nm
Coupling on flywheel
according to system documentation
Generator on coupling
Generator on base frame

Electrical system
Mounting bracket - starter holder (electric starter)

45 Nm
Starter holder - crankcase (electric starter)

25 Nm
Compressed air starter on console

42 Nm
Spark plug on cylinder head

M18x1.5 52 Nm
Combustion chamber temperature sensor

M12x1 hand tight

TCG 2020
Technical data

TCG 2020
Technical data
8
Nominal and wear dimensions
General
DN40 DN50 DN65 DN80 DN100 DN125 DN150
without position
Nominal pressure 25 25 25 25 25 10 10 bar
Position 1
Outer pipe diameter 42 50 60 80 100 120 159 mm
Position 2
Internal diameter 34 43 63 75 95 120 145 mm
Position 3
Outer diameter sealing 73 85 104 117 136 165 190 mm

surface
Position 4
Hole circle diameter 84 96 116 126 148 176 202 mm
Position 5
Outer diameter flange 108 120 140 150 172 200 226 mm
Position 6
Total length 175 175 175 200 200 200 200 mm
Position 7
Length 125 125 125 150 150 150 150 mm
Position 8
Flange thickness 16 16 16 18 18 18 18 mm
OBJ_DOKU-26026-001.fm 135 © MWM GmbH 2010-05

TCG 2020
Technical data
Cylinder head
Position 1
Bore diameter for valve guide

Nominal dimension 18.000 – 18.019 mm
Position 2
Bore diameter for valve seat ring

Inlet Nominal dimension 60.000 – 60.019 mm
Outlet Nominal dimension 58.000 – 58.019 mm
Position 3
Bore depth for valve seat ring

Position 4
Height of cylinder head


TCG 2020
Technical data
8
Valve guide / valve seat ring
Inlet valve stem guide
Position 1
Internal diameter
Position 2
Protrusion
Position 3
External diameter
Position 4
Length
Position 5
Outer chamfer
Position 6
Inner chamfer
Position 7
Inner diameter of inner chamfer


TCG 2020
Technical data
Outlet valve stem guide
Position 1
Internal diameter
Position 2
Protrusion
Position 3
External diameter
Position 4
Length
Position 5
Inner chamfer
Position 6
Inner diameter of inner chamfer


TCG 2020
Technical data
8
Valve seat ring
Position 1
Valve seat ring (External diameter)

Position 2
Valve seat width

Inlet Nominal dimension no specification
Outlet Nominal dimension no specification
Position 3
Valve seat angle

Inlet Nominal dimension 30 °
Outlet Nominal dimension 30 °
without position

Wear limit 71.2 mm
Wear limit 71.2 mm

TCG 2020
Technical data
Valve
Position 1
Shaft diameter
Position 2
Edge thickness
Position 3
Plate diameter
Position 4
Valve seat width

Inlet Nominal dimension no specification
Outlet Nominal dimension no specification
without position
Standback dimension*
Inlet Nominal dimension 0 – 0.4 mm
Outlet Nominal dimension 0 – 0.4 mm
* measured from centre of valve disc to cylinder head sealing surface

TCG 2020
Technical data
8
Valve spring
Position 1
Length (unstretched)
Nominal dimension 59.5 mm
Guide pin valve bridge
Position 1
Overhang setting screw

Nominal dimension at least 2.5 mm
Position 2
Installation dimension

TCG 2020
Technical data
Rocker arm block / rocker arm shaft
Position 1
Rocker arm axis (External diameter)

without position
Rocker arm bearing clearance

Wear limit 0.130 mm
Position 1
Fastening screw rocker arm block

Wear limit max. 80.8 mm
Position 1
Rocker arm (Internal diameter)


TCG 2020
Technical data
8
Crankshaft
Position 1
Main bearing pin (Diameter)

Wear limit 151.960 mm
Position 2
Main bearing pin (Width)

Nominal dimension 68.000 – 68.046 mm*
*axial bearing, first bearing pin on the drive side
Position 3
Lifting journal (Diameter)

Position 4
Lifting journal (Width)

without position
Crankshaft bearing clearance (Axial)

Wear limit 0.5 mm

TCG 2020
Technical data
Crankshaft
Runout accuracies main bearing pin
Pos. to AB V12 V16 V20

1 0.02 mm 0.02 mm 0.02 mm
2 0.03 mm 0.03 mm 0.03 mm
3 0.05 mm 0.04 mm 0.04 mm
4 0.08 mm 0.06 mm 0.06 mm
5 0.05 mm 0.08 mm 0.08 mm
6 0.03 mm 0.06 mm 0.10 mm
7 0.02 mm 0.04 mm 0.08 mm
8 0.03 mm 0.06 mm
9 0.02 mm 0.04 mm
10 0.03 mm
11 0.02 mm

TCG 2020
Technical data
8
Crankshaft
Main bearing pin
Position 1
Parallelism
to A and B Nominal dimension 0.01 mm
to all others 1 Nominal dimension 0.01 mm
Straightness*
over 10 mm length of the reference area Nominal dimension 0.0025 mm
over the whole length of the reference area Nominal dimension 0.0065 mm
* The specifications for straightness according to DIN ISO 1101.
Lifting journal
Position 2
Parallelism
to A, B, C and 1 Nominal dimension 0.01 mm
to all others 2 Nominal dimension 0.01 mm
Straightness*
over 10 mm length of the reference area Nominal dimension 0.0025 mm
over the whole length of the reference area Nominal dimension 0.0125 mm
* The specifications for straightness according to DIN ISO 1101.
without position
Roundness*
Nominal dimension 0.001 mm per 10°
* The roundness must be tested according to test specification 0162 0022 except in the area of the lubricating oil
bores.

TCG 2020
Technical data
Stop discs
Position 1
Stop disc thickness

Wear limit 8.850 mm

TCG 2020
Technical data
8
Main bearing shell
Position 1
Main bearing shell (Internal diameter)

Position 2
Main bearing shell (Width)

Position 3
Main bearing shell (Spread)

without position
Main bearing clearance

radial Nominal dimension 0.132 – 0.212 mm
Wear limit 0.260 mm
axial Nominal dimension 0.15 – 0.35 mm

TCG 2020
Technical data
Con rod
Position 1
Big end bearing bore

Diameter Nominal dimension 135.000 – 135.025 mm
Wear limit 134.980 – 135.060 mm
Cylindricity Nominal dimension 0.025 mm
Position 2
Con rod liner bore

Diameter Nominal dimension 73.000 - 73.025 mm
without position
Con rod liner bearing clearance

Wear limit 0.120 mm

TCG 2020
Technical data
8
Con rod
Parallelism of the big end bearing bore to the con rod liner
Measuring direction 1 to A Nominal dimension 0.03 mm

Measuring direction 2 to A Nominal dimension 0.05 mm

TCG 2020
Technical data
Con rod bearing shell
Position 1
Big end bearing (Internal diameter)

Position 2
Big end bearing (Width)

Position 3
Big end bearing shell (Spread)

without position
Big end bearing clearance (Radial)

Wear limit 0.215 mm
Assembly temperature
Minimum temperature difference 200 °C
Con rod liner min. -160 °C
Con rod min. 100 °C

TCG 2020
Technical data
8
Con rod liner
Position 1
Con rod liner (Measuring direction 1)

Position 2
Con rod liner (Measuring direction 2)


TCG 2020
Technical data
Piston bolt
Position 1
Length
Position 2
External diameter
without position
Piston bolt bearing clearance

Wear limit 0.120 mm
Wear limit 1.000 mm

TCG 2020
Technical data
8
Piston
Position 1
Height
Position 2
Piston bolt bore

without position
Piston standback (at compression ratio 13.5:1)

1.8 – 2.45 mm
Piston ring groove height

1. Piston ring groove Nominal dimension 3.6 mm
2. Piston ring groove Nominal dimension 3.560 - 3.580 mm
3. Piston ring groove Nominal dimension 6.06 - 6.08 mm

TCG 2020
Technical data
Piston rings
Position 1
Joint clearance
1. Piston ring Wear limit 0.90 mm
Position 2
Angle of twist of the piston ring joints

120 °
without position
Piston ring thickness

1. Piston ring Nominal dimension 3.5 mm
2. Piston ring Nominal dimension 3.475 - 3.490 mm
3. Piston ring Nominal dimension 6.975 - 6.990 mm

TCG 2020
Technical data
8
Bearing bores in the crankcase
without position
Bores for camshaft bearing (Diameter)

Bores for main bearing (Diameter)

Bores for valve tappets (Diameter)

Upper cylinder liner fit

max. deviation Wear limit 198.100 mm

TCG 2020
Technical data
Cylinder liner
Position 1
Outer diameter top

Position 2
Internal diameter
Position 3
Height to collar rest

Position 4
Height of collar
without position
Unroundness of the cylinder liner

Wear limit 0.051 mm

TCG 2020
Technical data
8
Camshaft
Position 1
Camshaft bearing pin (Diameter)

without position
Camshaft stroke
Inlet 8.5 mm
Outlet 8.5 mm
Camshaft bearing clearance

Wear limit 0.240 mm
Wear limit 0.35 mm
Stop disc thickness


TCG 2020
Technical data
Camshaft
Runout
Item V12 V16 V20

1 0.08 mm 0.09 mm 0.09 mm
2 0.06 mm 0.06 mm 0.06 mm
3 0.04 mm 0.04 mm 0.04 mm

TCG 2020
Technical data
8
Camshaft bearing liner
Position 1
Camshaft bearings (Internal diameter)

Position 2
Camshaft bearings (Width)

Nominal dimension no specification

TCG 2020
Technical data
Valve tappet
Position 1
Valve tappet (External diameter)

38.050 – 38.075 mm
Position 2
Valve tappet (Height)

89.5 mm

TCG 2020
Technical data
8
Wheel drive
Position 1
Crankshaft gear 59 teeth
Position 2
Intermediate wheel 59 / 33 teeth

Gear axle Nominal dimension 44.959 – 44.975 mm
Radial clearance Nominal dimension 0.034 – 0.099 mm
Wear limit 0.140 mm
Axial clearance Nominal dimension 0.100 – 0.250 mm
Wear limit 0.300 mm
Position 3
Camshaft gear A-side 66 teeth
Position 4
Camshaft gear B-side 66 teeth
Position 5
Intermediate wheel 52 teeth

Gear axle Nominal dimension 34.959 – 34.975 mm
Radial clearance Nominal dimension 0.025 – 0.083 mm
Wear limit 0.120 mm
Position 6
Lubricating oil pump wheel 40 teeth

TCG 2020
Technical data
Position 7
Tooth edge clearance between
Gear 1 and gear 2
Crankshaft gear and intermediate gear camshaft

0.163 -0.362 mm
Gear 2 and gear 3
Intermediate gear and camshaft gear A side

0.084 -0.291 mm
Gear 3 and gear 4
Camshaft gear A side and camshaft gear B side

0.148 -0.276 mm
Gear 1 and gear 5
Crankshaft gear and intermediate gear lubricating oil pump

0.125 -0.319 mm
Gear 5 and gear 6
Intermediate gear lubricating oil pump and lubricating oil pump wheel
0.162 -0.324 mm

TCG 2020
Technical data
8
Idler gear camshaft
Position 1
Bearing axis idler gear (external diameter)

Nominal dimension 59.951 - 59.970 mm
Position 2
Bearing liner, idler gear (internal diameter)


TCG 2020
Technical data
Lube oil pump
Position 1
Press-in depth bearing liner idler gear

Nominal dimension X 0.35 - 0.95 mm
Nominal dimension Y 0.5 mm
Position 1
Bearing axis idler gear (external diameter)

Position 2
Bearing liner, idler gear (internal diameter)


TCG 2020
Technical data
8
Starter
Position 1
Distance between starter pinion and crown gear flywheel

Nominal dimension 2 mm

TCG 2020
Technical data

TCG 2020
Job cards
9

TCG 2020
Job cards

TCG 2020
Job cards
9
Job cards
Symbol description
Tools
- List of necessary tools and special tools.
Auxiliary material
- List of necessary sealing compounds, locking agents, adhesives, lubricants, cleaning
agents etc.
Spare parts
- List of maintenance and repair parts which must always or sometimes be renewed.
References
- List of chapters, job cards, logs etc. to which this job card makes reference.
You will find this symbol next to all safety instructions. Follow these meticulously. The at-
tention of operating personnel should be drawn to these safety instructions. In addition,
general statutory safety and accident prevention regulations applying in your country must
be complied with.
You will find this symbol next to instructions of a general nature.

Follow these meticulously.

TCG 2020
Job cards
Job card list

The job cards are listed in two lists on the following pages.
- According to job card title

- According to job card number

TCG 2020
Job cards
9
Job cards
Auxiliaries test using TEM System (TEM Evolution with Touch Screen, BRT) B 0-1-6
Changing lube oil B 8-1-2
Checking and adjusting ignition timing W 13-5-3
Checking and adjusting inlet and outlet valve clearance B 1-1-1
Checking and measuring control times W 4-4-11
Checking and replacing the starter motor pinion and ring gear on flywheel W 12-6-4
Checking bearing shells W 2-1-6
Checking camshaft W 4-5-6
Checking camshaft axial clearance W 4-1-4
Checking crankcase W 2-1-7
Checking crankshaft axial clearance W 2-1-4
Checking cylinder liner W 3-3-1
Checking cylinder liner fit W 3-10-4
Checking engine mounting W 3-7-1
Checking intermediate gear mounting W 4-4-8
Checking percentage of corrosion protection agent or antifreeze in coolant B 9-1-1
Checking piston W 2-9-7
Checking the crankcase pressure B 3-1-2
Checking the gas pressure in the gas regulator line B 7-20-1
Checking the speed governor linkage B 5-4-2
Checking valve lag (cylinder head fitted) B 1-7-10
Checking, removing and installing piston cooling nozzle W 2-15-2
Cleaning the engine B 0-3-6
Combustion Gas Sampling B 7-18-1
Drain air bottle (starter air container) and fill B 10-7-1
Drive gear inspection W 2-1-0
Empty and fill cooling system B 9-0-4
Endoscope examination of combustion chamber W 0-2-7
Installing, removing and actuating engine turning gear B 4-6-1
Lifting and setting down the engine W 0-5-1
Maintenance crankcase breather (Dynapure AS 200 / AS 500) B 3-1-9
Maintenance crankcase breather (Model UPF 55) B 3-1-9
Overhaul pressure limiting valve of the pre-lube pump B 8-4-11
Overhauling cylinder head W 1-4-6
Overhauling gas pressure regulator (model Donkin) W 7-20-6
Overhauling gas valve (model RMG) W 7-20-7
OBJ_BUCH-1169-001EAL.fm 171 © MWM GmbH TCG 2020

TCG 2020
Job cards
Overhauling gas-air mixer (V12 and V16 engines) W 7-22-3

Overhauling gas-air mixer (V20 engine) W 7-22-3
Overhauling lube oil pump W 8-4-1
Overhauling pressure regulating valve (lube oil cooler) W 8-11-15
Overhauling pressure regulating valve (lube oil pump) W 8-11-16
Overhauling rotary disc valve (V20 engine) W 5-4-8
Overhauling throttle valve W 7-23-2
Regulations for cutting, grinding, soldering and welding work B 0-0-4
Remove and install con rod liner W 2-3-3
Removing and installing actuator (V12 and V16 engine) W 5-4-5
Removing and installing actuator (V20 engine) W 5-4-5
Removing and installing ball race (drive side) W 2-2-1
Removing and installing ball race (free side) W 2-2-3
Removing and installing camshaft W 4-5-5
Removing and installing charge mixture pipe (V12 and V16 engine) W 6-2-7
Removing and installing charge mixture pipe (V20 engine) W 6-2-7
Removing and installing compensator of exhaust pipe W 6-1-11
Removing and installing coolant housing (lube oil cooler crankcase) W 9-6-5
Removing and installing coolant overflow (cylinder head) W 9-6-2
Removing and installing crankshaft W 2-4-1
Removing and installing crankshaft sealing ring (drive side) W 2-2-2
Removing and installing crankshaft sealing ring (free side) W 2-2-4
Removing and installing cylinder head W 1-4-4
Removing and installing cylinder liner W 3-3-2
Removing and installing exhaust gas turbocharger (V12 and V16 engine) W 6-6-4
Removing and installing exhaust gas turbocharger (V20 engine) W 6-6-4
Removing and installing exhaust pipe W 6-1-9
Removing and installing flywheel flange W 2-2-9
Removing and installing frequency sensor (Jaquet model - camshaft) W 5-7-1
Removing and installing gear housing cover W 4-4-9
Removing and installing ignition control unit W 13-9-1
Removing and installing lube oil filter console W 8-10-9
Removing and installing lube oil pressure sensor W 8-2-4
Removing and installing lube oil temperature sensor W 8-2-5
Removing and installing lube oil tray W 3-5-1
Removing and installing lubricating oil pump W 8-4-5
Removing and installing piston with con rod W 2-9-3

TCG 2020
Job cards
Removing and installing rear cover (drive side) W 3-9-1

Removing and installing rocker arm and rocker arm block W 1-2-2
Removing and installing spark plugs, checking ignition cable B 13-5-4
Removing and installing suction air intake filter housing (V12 and V16 engine) W 6-3-8
Removing and installing swivel head for speed governor linkage (V12 and V16 engine) W 5-4-6
Removing and installing the flywheel W 12-6-1
Removing and installing the flywheel sensor (model Jaquet) W 5-7-1
Removing and installing the gear drive (free side) W 4-4-1
Removing and installing the spark plug protective tube W 1-10-2
Removing and installing the starter (compressed air starter) W 13-3-2
Removing and installing the starter (electric starter) W 13-3-2
Removing and installing throttle valve (V12 and V16 engine) W 7-23-1
Removing and installing torsional vibration dampers (V20 engine) W 12-1-4
Removing and installing, cleaning mixture cooler (V12 and V16 engine) W 6-4-7
Removing and installing, cleaning mixture cooler (V20 engine) W 6-4-7
Removing, installing and checking camshaft bearing W 4-1-1
Removing, installing and checking hose pipes, vibration dampers and flexible pipes W 0-3-4
Removing, installing and checking piston rings W 2-10-1
Removing, installing and checking rubber compensators W 12-3-1
Removing, installing and checking valve tappet W 4-2-3
Removing, installing and cleaning the lube oil cooler W 8-8-2
Removing, installing and testing big end bearing W 2-5-3
Renewing gas filter insert B 7-21-1
Renewing inspection hole cover gasket B 3-1-4
Renewing lube oil filter cartridge B 8-10-4
Renewing the suction air intake filter B 6-3-6
Running-in instructions W 0-1-3
Safety regulations for drive unit work W 2-0-1
Safety regulations for handling components made of elastomers containing fluoride (e.g. B 0-0-3
Viton)
Safety regulations for hydraulic clamping device W 0-0-5
Servicing the battery B 13-4-1
Setting speed governor linkage W 5-4-7
Setting stepper motor of the gas-air mixer (V20 engine) W 7-20-2
Settting stepper motor of the gas-air mixer (V12 and V16 engines) W 7-20-2
Taking lube oil samples B 8-1-1
Tear inspection by diffusion liquid method W 0-3-2

TCG 2020
Job cards
Testing and setting charge mixture pressure (V20 engines) W 6-7-2

Testing mixture cooler (endoscope) W 6-4-11
Use of liquid nitrogen W 0-3-1
Visual inspection of camshaft W 4-5-8
Visual inspection of cylinder liner (cylinder liner installed) W 3-3-9
Visual inspection of the system B 0-1-5

TCG 2020
Job cards
B 0-0-3 Safety regulations for handling components made of elastomers containing fluoride (e.g.
Viton)
B 0-0-4 Regulations for cutting, grinding, soldering and welding work
B 0-1-5 Visual inspection of the system
B 0-1-6 Auxiliaries test using TEM System (TEM Evolution with Touch Screen, BRT)
B 0-3-6 Cleaning the engine
B 1-1-1 Checking and adjusting inlet and outlet valve clearance
B 1-7-10 Checking valve lag (cylinder head fitted)
B 3-1-2 Checking the crankcase pressure
B 3-1-4 Renewing inspection hole cover gasket
B 3-1-9 Maintenance crankcase breather (Dynapure AS 200 / AS 500)
B 3-1-9 Maintenance crankcase breather (Model UPF 55)
B 4-6-1 Installing, removing and actuating engine turning gear
B 5-4-2 Checking the speed governor linkage
B 6-3-6 Renewing the suction air intake filter
B 7-18-1 Combustion Gas Sampling
B 7-20-1 Checking the gas pressure in the gas regulator line
B 7-21-1 Renewing gas filter insert
B 8-1-1 Taking lube oil samples
B 8-1-2 Changing lube oil
B 8-4-11 Overhaul pressure limiting valve of the pre-lube pump
B 8-10-4 Renewing lube oil filter cartridge
B 9-0-4 Empty and fill cooling system
B 9-1-1 Checking percentage of corrosion protection agent or antifreeze in coolant
B 10-7-1 Drain air bottle (starter air container) and fill
B 13-4-1 Servicing the battery
B 13-5-4 Removing and installing spark plugs, checking ignition cable
W 0-0-5 Safety regulations for hydraulic clamping device
W 0-1-3 Running-in instructions
W 0-2-7 Endoscope examination of combustion chamber
W 0-3-1 Use of liquid nitrogen
W 0-3-2 Tear inspection by diffusion liquid method
W 0-3-4 Removing, installing and checking hose pipes, vibration dampers and flexible pipes
W 0-5-1 Lifting and setting down the engine
W 1-2-2 Removing and installing rocker arm and rocker arm block
W 1-4-4 Removing and installing cylinder head
W 1-4-6 Overhauling cylinder head

TCG 2020
Job cards
W 1-10-2 Removing and installing the spark plug protective tube

W 2-0-1 Safety regulations for drive unit work
W 2-1-0 Drive gear inspection
W 2-1-4 Checking crankshaft axial clearance
W 2-1-6 Checking bearing shells
W 2-1-7 Checking crankcase
W 2-2-1 Removing and installing ball race (drive side)
W 2-2-2 Removing and installing crankshaft sealing ring (drive side)
W 2-2-3 Removing and installing ball race (free side)
W 2-2-4 Removing and installing crankshaft sealing ring (free side)
W 2-2-9 Removing and installing flywheel flange
W 2-3-3 Remove and install con rod liner
W 2-4-1 Removing and installing crankshaft
W 2-5-3 Removing, installing and testing big end bearing
W 2-9-3 Removing and installing piston with con rod
W 2-9-7 Checking piston
W 2-10-1 Removing, installing and checking piston rings
W 2-15-2 Checking, removing and installing piston cooling nozzle
W 3-3-1 Checking cylinder liner
W 3-3-2 Removing and installing cylinder liner
W 3-3-9 Visual inspection of cylinder liner (cylinder liner installed)
W 3-5-1 Removing and installing lube oil tray
W 3-7-1 Checking engine mounting
W 3-9-1 Removing and installing rear cover (drive side)
W 3-10-4 Checking cylinder liner fit
W 4-1-1 Removing, installing and checking camshaft bearing
W 4-1-4 Checking camshaft axial clearance
W 4-2-3 Removing, installing and checking valve tappet
W 4-4-1 Removing and installing the gear drive (free side)
W 4-4-8 Checking intermediate gear mounting
W 4-4-9 Removing and installing gear housing cover
W 4-4-11 Checking and measuring control times
W 4-5-5 Removing and installing camshaft
W 4-5-6 Checking camshaft
W 4-5-8 Visual inspection of camshaft
W 5-4-5 Removing and installing actuator (V12 and V16 engine)
W 5-4-5 Removing and installing actuator (V20 engine)

TCG 2020
Job cards
W 5-4-6 Removing and installing swivel head for speed governor linkage (V12 and V16 engine)
W 5-4-7 Setting speed governor linkage
W 5-4-8 Overhauling rotary disc valve (V20 engine)
W 5-7-1 Removing and installing the flywheel sensor (model Jaquet)
W 5-7-1 Removing and installing frequency sensor (Jaquet model - camshaft)
W 6-1-9 Removing and installing exhaust pipe
W 6-1-11 Removing and installing compensator of exhaust pipe
W 6-2-7 Removing and installing charge mixture pipe (V12 and V16 engine)
W 6-2-7 Removing and installing charge mixture pipe (V20 engine)
W 6-3-8 Removing and installing suction air intake filter housing (V12 and V16 engine)
W 6-4-7 Removing and installing, cleaning mixture cooler (V12 and V16 engine)
W 6-4-7 Removing and installing, cleaning mixture cooler (V20 engine)
W 6-4-11 Testing mixture cooler (endoscope)
W 6-6-4 Removing and installing exhaust gas turbocharger (V12 and V16 engine)
W 6-6-4 Removing and installing exhaust gas turbocharger (V20 engine)
W 6-7-2 Testing and setting charge mixture pressure (V20 engines)
W 7-20-2 Settting stepper motor of the gas-air mixer (V12 and V16 engines)
W 7-20-2 Setting stepper motor of the gas-air mixer (V20 engine)
W 7-20-6 Overhauling gas pressure regulator (model Donkin)
W 7-20-7 Overhauling gas valve (model RMG)
W 7-22-3 Overhauling gas-air mixer (V12 and V16 engines)
W 7-22-3 Overhauling gas-air mixer (V20 engine)
W 7-23-1 Removing and installing throttle valve (V12 and V16 engine)
W 7-23-2 Overhauling throttle valve
W 8-2-4 Removing and installing lube oil pressure sensor
W 8-2-5 Removing and installing lube oil temperature sensor
W 8-4-1 Overhauling lube oil pump
W 8-4-5 Removing and installing lubricating oil pump
W 8-8-2 Removing, installing and cleaning the lube oil cooler
W 8-10-9 Removing and installing lube oil filter console
W 8-11-15 Overhauling pressure regulating valve (lube oil cooler)
W 8-11-16 Overhauling pressure regulating valve (lube oil pump)
W 9-6-2 Removing and installing coolant overflow (cylinder head)
W 9-6-5 Removing and installing coolant housing (lube oil cooler crankcase)
W 12-1-4 Removing and installing torsional vibration dampers (V20 engine)
W 12-3-1 Removing, installing and checking rubber compensators
W 12-6-1 Removing and installing the flywheel

TCG 2020
Job cards
W 12-6-4 Checking and replacing the starter motor pinion and ring gear on flywheel
W 13-3-2 Removing and installing the starter (electric starter)
W 13-3-2 Removing and installing the starter (compressed air starter)
W 13-5-3 Checking and adjusting ignition timing
W 13-9-1 Removing and installing ignition control unit

TCG 2020
B 0-0-3
Safety regulations for ha ndling components made of elastomers con-

taining fluoride (e.g. Viton)
References
- Chapter 1, Rules for disposal
General information
Seals, O-seals and shaped parts for high thermic loads are made in part of elastomers con-
taining fluoride (FPM).
If unplanned temperatures exceed 315°C (e.g. caused by engine fire) the material decom-
poses and forms caustic acids. The remains are sticky and have a black appearance.
If damage has occurred to seals or O-seals caused by high temperatures, proceed as fol-
lows:
z Check all seals visually which have been subjected to the effects of heat.
z Put on gloves (neoprene).
z Remove residual material and dispose of,
- see Chapter 1, disposal regulations.
z Destroy clothing that has come into contact with the remains of the seals.
Risk of injury !
Touching material remains with the human skin, even after they have cooled down,
can be harmful to health.

TCG 2020
B 0-0-3

TCG 2020
B 0-0-4
Regulations for cutting, grinding, soldering and welding work
References
- Accident prevention regulations
General information
Welding may only be carried out by authorised personnel.

A welding supervisor with the appropriate qualifications must be consulted for protection of
the system.
The contractor of cutting, grinding, soldering and welding work must alert the persons en-
listed to do the work to the dangers and ensure that the points listed below are observed
and complied with.
Persons entrusted with cutting, grinding, soldering and welding work must be familiar with
and observe the valid regulations and specifications, especially the rules for accident pre-
vention of the respective national legislations.
The following points must be observed in addition to the specified regulations and specifi-
cations.
Electrics / electronics
The following points apply for work where electrical and electronic components may be at
risk due to heat or electrical short-circuiting.
z Disconnect the battery ground and remove and stow away the battery safely if neces-
sary.
z Pull out the cable set plugs of electrical and electronic components (e.g. switch cabi-
net, junction box, control unit, sensors).
z Remove electrical and electronic components in the immediate vicinity of the working
area.
z Always connect the ground terminal of the welding gear in the immediate vicinity of the
welding point to avoid vagrant currents. Make sure there is a perfect ground connec-
tion, remove varnish in the area of the ground terminal if necessary.
Failure to do so can lead to serious damage to the engine electronics.

TCG 2020
B 0-0-4
Sparks / danger of fire
z Keep all inflammable materials away from the danger area.

z Inflammable objects (e.g. cables, compensators) must be covered with non-conduc-
tive, non-flammable material or must be removed.
z Sensitive surfaces (e.g. air filter) must be covered with non-conductive and non-flam-
mable material.
z Openings on the engine must be sealed or covered.
z Seal off and cover openings to other work areas.
z Keep a sufficient number of fire extinguishers close by.
Danger of explosion
z Work which could lead to a strong development of heat on gas or fuel pipes and ves-
sels may only be carried out when these have been completely emptied and bled or
flushed.
z Shut off gas pipes and fuel pipes.
Health hazard
z Air well, draw off fumes and dust particles.

z Screen off the working area during arc welding to protect bystanders against the harm-
ful effects of optical radiation.

TCG 2020
B 0-1-5
Visual inspection of the system
Tools
- Commercially available tools
References
- B 6-3-6 Renewing the suction air intake filter
- B 7-20-1 Checking the gas pressure in the gas regulator line
- B 7-21-1 Renewing gas filter insert
- B 13-4-1 Servicing the battery
General information
Danger of burning !
When working on hot engine.
Daily check
Engine monitoring
z Check display values and warning lamps in the switchboard.

- Observe engine monitoring operating manual.
z The operating values must be taken from the engine monitoring system and compared
with the values in the commissioning report.
- If the values are outside the range of tolerance the cause must be sought and re-
paired immediately.
Engine
z Check engine for smooth running and noise.

- If the engine is not running smoothly or if abnormal sounds can be heard the cause
must be found and repaired immediately.
Lube oil system
z Check the tightness of the lube oil circuit and all connected components.
- If leaks are discovered, find the causes and eliminate immediately.
Coolant system
z Check the tightness of the coolant circuits and all connected components.

TCG 2020
B 0-1-5
Intake air system
z Check maintenance display of intake air cleaner visually.

- If necessary the intake air cleaner must be replaced.
- Replace intake air cleaner - see job card B 6-3-6.
Gas system
z Check gas pressure in the gas control system - see job card B 7-20-1.
- If necessary the gas filter insert must be replaced.
- Replace gas filter insert - see job card B 7-21-1.
z Check the tightness of the gas system and all connected components.
Pneumatic system
z Drain water from the air bottle - see job card B 10-7-1.
z Check the tightness of the pneumatic system and all connected components.
If the engine is out of operation, the following additional tests can be made.
Exhaust system
z Check the firm sit and tightness of the exhaust system and all connected components.
- If faults are discovered, they must be rectified immediately.

TCG 2020
B 0-1-6
Auxiliaries test using TEM System (TEM Evolution with Touch Screen,
BRT)
References
- TEM system operating manual
General information
If one of the test items listed below is not performed correctly, please contact your service
partner.
Depending on the engine version and equipment, some of the following tests described
may not be carried out.
Only auxiliaries which are set in the parameters and have been released are tested.
It is not possible to start the engine in test mode.

The test mode serves for checking individual auxiliaries for control by the TEM Evolution
control unit. The test can only be carried out with the engine standing still, manual operation
and without the emergency stop activated.
Individual auxiliaries (e.g. starter) can for safety reasons only be controlled with the button
keys. The auxiliary only stays switched on while the button remains pressed, it is not pos-
sible to turn it on and off.
Auxiliaries (e.g. gas mixer, emergency cooler) which are actuated by servo motors can be
checked as follows.
Cell 1 shows the auxiliary. Here positive adjustment can be made (e.g. rich, warmer) or neg-
ative (e.g. lean, cooler).
Cell 2 shows the currently calculated position of the auxiliary's servo motor.
Cell 3 shows the limit stops and the intermediate positions.
A1
A2

TCG 2020
B 0-1-6
Test results and measured values are shown as follows:
- Red lightning flash Test result not OK.
- Green checkmark Test result OK.
- Blue plus sign Servo motor has reached plus stop (e.g. rich, warm)
- Blue minus sign Servo motor has reached minus stop (e.g. lean, cold)
- Blue double arrow Servo motor is moving or standing between the two limit
stops.
Carrying out the tests
z Select Service 1 mask.

z Select auxiliaries 2 mask.
- Select appropriate sub-menu.
z Select test mode ON 3.
- All auxiliaries are automatically switched off.
A3

TCG 2020
B 0-1-6
Engine auxiliary test
A4
Ignition
z Switch on ignition.
- The ignition carries out a self-test and gives the result after about 10 seconds.
- Check wiring, supply voltage and communications

- Repeat test
z Switch off ignition

TCG 2020
B 0-1-6
Starter
On engines with electric starters the mains starting device is actuated and so the function
is checked automatically.
On engines with compressed air starter the start air prepressure must be set and the starter
throttled in before the starter is operated.
While checking the starter the engine is turned as when starting the engine normally.
Therefore the engine's pre-lubrication pump and if appropriate the generator must
be switched on manually 3 minutes before the test.
When commissioning the engine's pre-lubrication pump must be switched on man-
ually 20 minutes before the test.
After changing the lube oil the automatic pre-lubrication is turned on automatically
by the TEM system. Here the engine's pre-lubrication pump is switched on for 20
minutes.
z Go to starter.
- Check function, speed and lube oil pressure.
Speed governor
z Switch on speed governor.

- The impulse transmitter runs a calibration sequence. It runs from 0% to 100% and
back for this.
- The control voltage of the throttle valve is displayed in Volts.
z Change from the engine mask to the governor mask.
z Select test mode ON.
z Set the set position to 20%.
z Accept adjustment value.
z Read off display on actuator.
- The mechanical display on the actuator and the set nominal position must be iden-
tical.
z Also check set position at 50%, 75% and 90%.
z Select test mode OFF.
z Change from the governor mask to the engine mask.
z Turn off speed governor.

TCG 2020
B 0-1-6
Anti-knock control
z Switch on anti-knock control.

- The ignition carries out a self-test and gives the result after about 10 seconds.
- Check wiring, supply voltage and communications

- Repeat test
z Switch off anti-knock control.
Pre-lubrication pump
z Switch on pre-lubrication pump.

- Check direction of rotation.
- Lube oil pressure must rise.
z Switch off pre-lubrication pumps.
Gas mixer A
A5
z Switch on gas mixer A rich (cell 1).

- If the gas mixer is at the stop lean (cell 3 minus sign) after a few steps the stop
must move into the double arrow.
- The gas mixer must move a maximum of 4000 steps from the starting position to-
wards rich (Zelle 2). Here the mathematical leading sign in the starting position
must be observed. If the star ting position is, for example, -400 steps, the maxi-
mum value must not exceed 3600 steps.
- Make sure that gas mixer really does move towards rich.
z Switch on gas mixer A lean (cell 1).
- The gas mixer goes back to the stop lean (cell 3 minus sign).
- Check the v ision panel t o make sure th at gas mixer really does move towards
lean.
Gas mixer B
z Perform test in the same way as for gas mixer A.

TCG 2020
B 0-1-6
Gas mixer A starting position
z Go to gas mixer A starting position.

- The gas mixer moves to starting position (cell 2 - 0 steps).
- Reaching the starting position is displayed with a green hook.
Gas mixer A stop position
z Switch on gas mixer A stop position.

- The gas mixer goes to the stop lean (cell 3 minus sign).
- A negative value must be shown in cell 2.
Auxiliary test gas
A6
Gas valve A1
z Go to gas valve A1.

- It is possible to feel and hear the solenoid valve switching.
Gas valve A2
z Go to gas valve A2

TCG 2020
B 0-1-6
Filling with lube oil
With this function the lube oil supply filler valves can be tested.
However. there is no report back in the mask.
Depending on the design of the unit different numbers of various valves may be fitted.
z Go to fill lube oil.

During the test the engine's lube oil circuit is filled with lube oil.
Auxiliary test cooling / heating circuit
A7
Motor cooling circuit pump
z Switch on motor cooling circuit pump (green hook is shown).

z If a green hook is shown in the next column, the system is OK.
Heating circuit pump
z Switch on heating circuit pump (green hook is shown).

Emergency cooling circuit pump
z Switch on emergency cooling circuit pump (green hook is shown).


TCG 2020
B 0-1-6
Mixture cooling circuit pump
z Switch on mixture cooling circuit pump (green hook is shown).

Pre-heating
Danger of burning !
Before testing the pre-heating, ensure that it is completely filled with coolant.
When testing the pre-heating, components can get hot.
z Switch on pre-heating.
- Check whether the coolant pipes heat up.
z Switch off pre-heating.
Heating water cooler / hotter
z Switch on hot water heater.

- The actuator moves to the hot stop.
- If the servo motor stands at the cold limit stop, after a few steps the display in the
stop cell should change to the double arrow.
- During this adjustment process the percentage should change accordingly.
z Switch on hot water to cooler.
- The servo motor moves back to the cold stop.
Emergency cooler hotter / cooler
z Carry out test analogous with heating water hotter / colder.
Mixture cooler hotter / cooler
z Carry out test analogous with heating water hotter / colder.

TCG 2020
B 0-1-6
Auxiliary test table cooler
A8
Depending on the system fitted, the fan speed can be actuated either variably or step by
step.
NK table cooler
z NK table cooler hotter/step 3

- The fan lowers the speed.
z NK table cooler cooler/step 4
- The fan increases the speed.
GK table cooler
z Carry out test analogous with NK table cooler.

TCG 2020
B 0-1-6
Auxiliary test air/oil
A9
Room ventilation
z Control room ventilation and check function visually.
The auxiliary test hydrostatic pump A and B is only available with generators with lube oil
pressure pumps.
Hydrostatic pump A
z Actuate pump. Pump must run.
Hydrostatic pump B
z Actuate pump. Pump must run.

TCG 2020
B 0-1-6
Auxiliary test controller
A 10
In the controller mask two controllers which can be parameterised can be selected.
By actuating Output + the controller opens.
By actuating Output - the controller closes.
Release parameterisable controller 1
z Release parameterisable controller 1.

- Switch on controller 1.
z Parameterisable controller 1 output +.
- Controller 1 opens.
z Parameterisable controller 1 output -.
- Controller 1 closes.
Release paramterisable controller 2
z Release paramterisable controller 2.

- Switch on controller 2
z Parameterisable controller 2 output +.
- Controller 2 opens.
z Parameterisable controller 2 output -.
- Controller 2 closes.

TCG 2020
B 0-1-6

TCG 2020
B 0-3-6
Cleaning the engine
Auxiliary material
- Cleaning agents
- Plugs, covers
- Compressed air
References
- Chapter 4, Auxiliary materials
General information
Risk of injury !
Only carry out work when the engine is stopped.
Secure engine to prevent it starting.
Danger of poisoning !
Ensure adequate ventilation.
Suck off vapours, do not inhale.
Risk of injury !
Wear protective glasses and gloves.
Preparation
z Turn off engine and allow to cool down.

z Select cleaning agent, see Chapter 4, Auxiliary materials.
z Remove protective covers.
z Remove heat protection covers from exhaust lines.
z Seal engine openings (e.g. air inlet) or fit waterproof cover.
If the engine is partially dismantled, openings in housings must be sealed or have water-
proof covers fitted.

TCG 2020
B 0-3-6
Cleaning
The following must not be cleaned with pressure cleaning systems:
- Sensitive components (e.g. filters, sensors, rubber grommets, sealing rings, wires) as
these could be damaged.
- Joints and bearings which are covered with lubricant or filled with grease.
z Spray cleaning agent onto engine.

- Allow time to take effect as specified by the manufacturer.
z Spray off engine with powerful jet of water or wash off.
If the required level of cleanliness is not achieved, repeat process.

Dismantled protective covers and heat protection covers must be cleaned separately.
Reworking
It is essential that protective covers and heat protection covers are dried before fit-
ting.
Otherwise there is a danger of fire from the formation of gases or deflagration inside
the casing covers.
z Blow off accumulations of water with compressed air.

z Remove covers from electric and electronic components.
z Remove covers and seals from openings in the engine.
z Dry and fit exhaust line heat protection covers.
z Dry and fit protective covers.

TCG 2020
B 1-1-1
Checking and adjusting inlet and outlet valve clearance
Tools
- Feeler gauge
- Spark plug key
- Torque wrench
Spare parts
- Sealing rings
- poss. moulded gasket for cylinder head cover
References
- B 4-6-1 Installing, removing and actuating engine turning gear
Technical data
Valve bridge
0.05 mm
Valve clearance (Gas group 1 and 2)

Inlet 0.3 mm
Outlet 0.7 mm

M10x1 40 Nm

M12x1.5 45 Nm

M8x55 / 85 25 Nm
General information
Inlet and outlet valves will only form a seal when closed if the specified clearance is avail-
able in the valve drive between the camshaft and the valve shaft.
If the valve clearance is too small the valves are only closed briefly or not at all.
This results in a drop in performance for to the subsequent compression loss.
The valve seat and valve head may burn due to overheating. There is also a danger of an
engine fire to to flashover in the exhaust or suction intake channel.
If the valve clearance is too great, the valves open later and close earlier.
Because the valves are only fully open briefly, the filling level of the engine drops. Drop in
performance is the result.
TCG 2020
B 1-1-1
This also causes considerable wear in the valve control.

Exact setting and observation of the valve clearance prolongs the life and increases the op-
erational reliability of the engine.
A large valve clearance determined in the test is due to wear in the valve drive.
Depending on the difference between the actual value and the reference value, the valve
clearance curve of the respective cylinder must be monitored and the cause investigated
immediately.
The actual values must be noted in the “Valve clearance actual values table“. A copy of the
table is enclosed.
Test and setting sequence

When setting the valves the inlet and outlet valve of the cylinder to be set must be com-
pletely closed, i.e. the valve drive must be on the base circle of the cam. This is guaranteed
when the cylinder firing 360° KW before the cylinder to be set is in valve overlap, i.e. the
outlet valve closes whilst the inlet valve opens.
The setting is made according to the order of ignition, starting with cylinder A1. Specified in
the figure below are the ignition order, ignition spacings in degrees of crankshaft and the
overlap cylinder assigned to every firing cylinder. For determining the correct position of the
cylinder to be set, the attached overlapping cylinder is monitored whilst turning slowly. It
must be turned until the valves just go into overlap. The whole overlap range of the overlap
cylinder is suitable for the valve setting of the firing cylinder.
The whole valve setting can be made with 2 revolutions of the crankshaft (Step 1 and Step
2).
Shown in the schematic engine figure below are the positions of the firing cylinders and the
overlapping cylinders for the first and second crankshaft revolution. The figure only shows
the position: the order is determined by the firing order.

TCG 2020
B 1-1-1
12-cylinder engine
Ignition angle offset
Ignition TDC
A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6
Overlap
A6 B5 A2 B3 A4 B6 A1 B2 A5 B4 A3 B1
T1

TCG 2020
B 1-1-1
16-cylinder engine
Ignition TDC
A1 B2 A6 B5 A8 B7 A3 A7 B6 A4 B8 A2 B3 A5 B1 B4
Overlap
B6 A4 B8 A2 B3 A5 B1 B4 A1 B2 A6 B5 A8 B7 A3 A7
T2

TCG 2020
B 1-1-1
20 cylinder engine
Ignition TDC
A1 B7 A2 B5 A4 B3 A6 B1 A8 B2 A10 B4 A9 B6 A7 B8 A5 B10 A3 B9
Overlap
A10 B4 A9 B6 A7 B8 A5 B10 A3 B9 A1 B7 A2 B5 A4 B3 A6 B1 A8 B2
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Step 1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Step 2
© 84586-0
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
T3 Test and setting order V20

TCG 2020
B 1-1-1
z Remove cylinder head cover.

- Pull off the spark plug connector.
- Unscrew screws and remove cylinder head cover with gasket.
Only check and set the valve clearance compensation and valve clearance when the en-
gine is cold.
Follow the correct test and setting sequence.
z Install engine turning gear - see job card B 4-6-1.

z Turn the engine in rotation direction until cylinder A1 is in the ignition TDC range.
Check valve bridge
A1
z Insert feeler gauges between valve stem and valve bridge (arrows) on both valves on
one valve bridge at the same time.
z Push rocker arm onto valve bridge with the finger.
- It must be possible to pull out the feeler gauges evenly without too much resist-
ance.
- If this is not the case, the valve bridge must be adjusted again.

TCG 2020
B 1-1-1
Adjust valve bridge
A2
z Loosen nut 1.
z Insert feeler gauges between valve stem and valve bridge (arrows) on both valves on
one valve bridge at the same time.
z Push rocker arm onto valve bridge with the finger.
z Adjust valve bridge with screw 2.
- It must be possible to pull out the feeler gauges evenly without too much resist-
ance.
z Tighten nut 1.
- Hold against screw 2.
z Check valve bridge again with feeler gauge.
- If there are any variations, adjust valve bridge again.

TCG 2020
B 1-1-1
Checking valve clearance
A3
z Push feeler gauge between the valve bridge and the toggle lever (arrow).
- The feeler gauge must be insertable and removable with little resistance.
- The valve clearance must be set if not.
Setting valve clearance
A4
z Loosen nut 1.
z Push feeler gauge between the valve and the rocker arm (arrow).
z Set the valve clearance with screw 2.
- It must be possible to push in and pull out the feeler gauge without too much re-
sistance.

TCG 2020
B 1-1-1
z Tighten nut 1.
- Hold against screw 2.
z Check the valve clearance again with the feeler gauge.
- Reset the valve clearance in case of deviations.
z Turn engine in direction of rotation until next cyllinder is at TDC.
z Repeat the test and setting procedure until the valve clearance is set on all cylinders.
z Remove engine turning gear - see job card B 4-6-1.
z Attach cylinder head hood.
- Check the gasket of the cylinder head hood and renew if necessary.
- Mount cylinder head hoods with gasket.
- Tighten screws.
- Plug in spark plug connector.

TCG 2020
B 1-1-1
Table of actual values of valve clearance

The total adjustment time can be determined by the actual value data.
This can tell you something about the previous wear in the valve drive.
Legend for the tables on the following pages.
A5
1: inlet-side gas-air mixture

2: outlet-side exhaust gas
X: short channel
Y: long channel
The following table is applicable for all series and number of cylinders available till date.

TCG 2020
B 1-1-1
Enclosure: Engine type:

Name: Engine no.:
Remark:
Operating hours
Inlet X
A1 Y
Outlet X
Inlet X
A2 Y
Outlet X
Inlet X
A3 Y
Outlet X
Inlet X
A4 Y
Outlet X
Inlet X
A5 Y
Outlet X
Inlet X
A6 Y
Outlet X
Inlet X
A7 Y
Outlet X
Inlet X
A8 Y
Outlet X

TCG 2020
B 1-1-1
Inlet X
A9 Y
Outlet X
Inlet X
A10 Y
Outlet X

Name: Engine no.:
Remark:
Operating hours
Inlet X
B1 Y
Outlet X
Inlet X
B2 Y
Outlet X
Inlet X
B3 Y
Outlet X
Inlet X
B4 Y
Outlet X
Inlet X
B5 Y
Outlet X
Inlet X
B6 Y
Outlet X

TCG 2020
B 1-1-1
Inlet X
B7 Y
Outlet X
Inlet X
B8 Y
Outlet X
Inlet X
B9 Y
Outlet X
Inlet X
B10 Y
Outlet X

TCG 2020
B 1-1-1

TCG 2020
B 1-7-10
Checking valve lag (cylinder head fitted)
Tools
- Spark plug key
- Torque wrench
- Special tool according to chapter 5
- Measuring device for valve wear
- Depth gauge
Spare parts
- Sealing rings
- Shaped gasket for cylinder head cover, if necessary
References
Technical data

Wear limit 71.2 mm
Wear limit 71.2 mm

M8x55 / 85 25 Nm

M18x1.5 52 Nm

TCG 2020
B 1-7-10
General information
By measuring the valve lag regularly it is poss ible to ascertain the wear behaviour of the
valve cones and valve seats.
If the maximum permissible valve lag is exceeded, all valves and valve seat inserts of the
cylinder head concerned must be replaced.
The measurement must be taken after every valve clearance setting on all inlet and outlet
valves.
Care must be taken here to ensure that the valves are completely closed when measuring.
The measurements must be taken in order of ignition sequence, starting with cylinder A1 -
see job card B 1-1-1, test and setting order.
The actual values must be noted in the valve lag actual value table. The table is attached
as a copy form.
Checking valve lag
A1
z Pull ignition cable 1 from ignition coil 2.

z Check the spark plug shaft for dirt.
z Blow out spark plug shaft with compressed air.
Risk of injury !
Dirt particles can cause injury when cleaning with compressed air.
Wear protective glasses and clothing.
z Remove spark plug.

z Unscrew screws and remove cylinder head cover with gasket.
z Install engine turning gear - see job card B 4-6-1.

TCG 2020
B 1-7-10
A2
z Installing measuring device 3.

- Tighten screws.
z Insert depth gauge 4 in measuring device.
The figure shows measuring at the inlet valves

Proceed accordingly at the outlet valves.
Position numbers X and Y are to aid orientation and are repeated on the copy form.
Before taking measurements it is essential to ensure that the cylinder head cover
gasket is no longer lying on the cylinder head as otherwise the measured results
could be inaccurate.
z Check valve lag on both inlet and outlet valves.

- Measure with the depth gauge from the top of the valve spring plate to the meas-
uring device.
z Turn engine in direction of rotation until next cyllinder is at TDC.
z Repeat the process until the valve lag is established on all cylinders.
z Remove engine turning gear - see job card B 4-6-1.
z Fit cylinder head cover with gasket and tighten screws.
z Renew the sealing ring of the spark plug.
z Insert and tighten spark plug.
z Plug the ignition cable to the ignition coil.

TCG 2020
B 1-7-10
Valve lag actual value table

The total wear value can be determined by the actual value data.
This can tell you something about the previous wear in the valve drive.
Legend for the tables on the following pages.
A3
1: inlet-side gas-air mixture

2: outlet-side exhaust gas
X: short channel
Y: long channel
The following table is applicable for all series and number of cylinders available till date.

TCG 2020
B 1-7-10

Name: Engine no.:
Remark:
Operating hours
Inlet X
A1 Y
Outlet X
Inlet X
A2 Y
Outlet X
Inlet X
A3 Y
Outlet X
Inlet X
A4 Y
Outlet X
Inlet X
A5 Y
Outlet X
Inlet X
A6 Y
Outlet X
Inlet X
A7 Y
Outlet X
Inlet X
A8 Y
Outlet X

TCG 2020
B 1-7-10
Inlet X
A9 Y
Outlet X
Inlet X
A10 Y
Outlet X

Name: Engine no.:
Remark:
Operating hours
Inlet X
B1 Y
Outlet X
Inlet X
B2 Y
Outlet X
Inlet X
B3 Y
Outlet X
Inlet X
B4 Y
Outlet X
Inlet X
B5 Y
Outlet X
Inlet X
B6 Y
Outlet X

TCG 2020
B 1-7-10
Inlet X
B7 Y
Outlet X
Inlet X
B8 Y
Outlet X
Inlet X
B9 Y
Outlet X
Inlet X
B10 Y
Outlet X

TCG 2020
B 1-7-10

TCG 2020
B 3-1-2
Checking the crankcase pressure
References
- B 3-1-9 Maintenance crankcase breather (Dynapure AS 200 / AS 500)
General information
The pressure in the crankcase is checked by the TEM system while the engine is running.
If the specified set value is not reached the crankcase breather must be serviced - see job
card B 3-1-9.

TCG 2020
B 3-1-2

TCG 2020
B 3-1-4
Renewing inspection hole cover gasket
Tools
- Scraper
Spare parts
- Gasket for hatch cover
Technical data

M8x20 - 8.8 25 Nm
General information
Risk of injury !
OBJ_DOKU-26036-001.fm 223 © MWM GmbH 1007

TCG 2020
B 3-1-4
Removing/installing the inspection hole cover
A1
z Remove line 1 if necessary.

z Unscrew screws 2.
z Remove hatch cover 3 with gasket.
z Clean the sealing surface.
z Mount hatch cover 3 with gasket.
z Tighten screws 2.
z Mount line 1 if necessary.

TCG 2020
B 3-1-9
Maintenance crankcase breather (Dynapure AS 200 / AS 500)
Tools
- Special tools available from:
- Fa. Umwelt Technik 99 AG, Sunnehof, CH-8493 Saland, Switzerland
- Fitting tool, order no. 909 -190500
- Dismantling tool, order no. 909- 190501
- Vibration measuring instrument for imbalance check
Spare parts
- Filter insert
- Basic filter
- Filter disc
- Aluminium grille
- Cover seal
- Engine gaskets
Technical data
Crankcase breather (model Dynapure)

General information
The sucked in mixture is swirled and accellerated so hard using a rotating drum that the
micro-fine lubricating oil mist particles combine into droplets and are separated from the air
by the sieve and inertia effect in the rotating filter drum.
The lubricating oil recovered in this manner flows through the outlet back into the engine
room or lubricating oil tank.
Risk of injury !
Risk of injury !
When working on crankcase venting, disconnect the electric motor from the mains
supply.

TCG 2020
B 3-1-9
Remove filter insert and basic filter
A1
z Loosen locking collar 1.

z Remove case lid 2 with seal 3.
Danger of imbalance !
Mark interface of filter insert 4 in the drum 5.
z Remove filter insert.

z Check basic filter for dirt, if necessary replace.
By changing the basic filter 6 the drum 5 can become unbalanced.

Balancing the drums is absolutely essential.
Install filter insert and basic filter
z Fit filter insert 4.

- Pay attention to marking.
z Fit case lid 2 with seal 3.
z Close locking collar 1.
z Check crankcase venting for seal and function.

TCG 2020
B 3-1-9
Remove filter disc with aluminium grid
A2
z Loosen locking collar 1.

z Remove case lid 2 with seal 3.
z Undo screws 7 and remove turbo wheel 8.
z Pull off drum 5 from electric motor shaft with dismantling tool.
z Undo screws 9 and remove retaining drum 10.
z Remove filter disc 11 and aluminium grid.
z Check wire grid 13 and renew if necessary.
Install filter disc with aluminium grid
z Fit wire grid 13, aluminium grid 12, filter disc 11 a nd retaining drum 10, and tighten
screws 9.
z Push drum 5 on the electric motor shaft up to the stop with assembly tool.
z Fit turbo wheel 8 and tighten screws 7.
z Fit case lid 2 with seal 3.
z Close locking collar 1.
z Check crankcase venting for seal and function.

TCG 2020
B 3-1-9

TCG 2020
B 3-1-9
Maintenance crankcase breather (Model UPF 55)
Tools
- Measuring instrument for separating quality, e.g. Dust Trak TM Model 8520
- Hose for water column
- Measuring instrument for blowby volume
Auxiliary material
- Acid-free grease
Spare parts
- Inner filter insert
- Outer filter insert
- Gaskets, if necessary
Technical data
Differential pressure UPF 55 (at full load)

Complete filter max. 200 mmWS
(max. 20 mbar)
1. stage (inner filter insert) max. 80 mmWS
(max. 8 mbar)
2. stage (outer filter insert) max. 120 mmWS
(max. 12 mbar)
Separating quality UPF 55 (measured at full load with Dust Trak TM Model 8520)
after 1st stage (inner filter insert) max. 20 mg/m3
after 2nd stage (outer filter insert) max. 5 mg/m3
Clamping clip UPF filter M8x60 hand tight
General information
The crankcase breather must be maintained when the maintenance intervals specified in
the maintenance schedule are reached.
The pressure regulator is set to a fixed value at the factory and cannot be adjusted. Chang-
es to the pressure regulator are not permissible.
Observe the regulations for disposal !

Collect operating materials and dispose of them properly in accordance with nation-
al regulations.

TCG 2020
B 3-1-9
Cleaning the filter elements is not permissible and can damage the engine.
Renewal of the filter elements must be documented in the certificate of execution according
to the maintenance schedule.
All the filter elements of the crankcase breather must be renewed if coolant penetrates the
lubricating oil system.
Remove filter cartridge
A1
z Unscrew nut 1.
z Unscrew screw 2.
Loosen screw 2 on the opposite side.
z Remove clamp.
A2
z Remove filter cover 3.

TCG 2020
B 3-1-9
A3
z Remove outer filter cartridge 4.
A4
z Remove inner filter cartridge 5.

TCG 2020
B 3-1-9
A5
z Check the rubber seal 6 for damage and renew if necessary.
Make sure the drain holes are not blocked.
Fit filter cartridge
A6
z Insert inner filter cartridge 5.

TCG 2020
B 3-1-9
A7
z Insert outer filter cartridge 4.
A8
z Wet rubber seal 6 with acid-free grease.
Make sure that the sealing rubber 6 fits correctly on the filter housing.
z Fit filter cover 3.

z Turn on nut 1.
- Centre filter cover.
z Tighten nut 1.
- until filter cover is lying on the rubber seal 6 and is centred.

TCG 2020
B 3-1-9
A9
z Install clamp 7.
Make sure that the clamp 7 is sitting correctly on the rubber seal 6 and the filter housing 3.
A 10
z Tighten screw 2.
Make sure the screws are tightened evenly.

TCG 2020
B 3-1-9
A 11
After tightening the clamp, check fit of nut 1, tighten hand tight if necessary.

TCG 2020
B 3-1-9
Check filter function
Visual inspection
z Remove filter cover.

z After the second filter stage the filter housing should be dry inside or only be slightly
wet with lubricating oil or condensation.
If there is lubricating oil or condensation in the filter housing, the connecting hose between
the pressure regulator and the engine must be removed and cleaned.
z Fit filter cover.
Measure the differential pressure
Use a water column as a measuring device.

The water column must be attached to two measuring taps, do not measure against the
atmosphere.
The measurement is made in full load operation if possible.
A 12
z Connect the measuring device to the measuring connections required for the measure-
ment.
z Measure the differential pressure
Position 1 - of complete filter
Position 2 - 1st stage (inner filter insert)
Position 3 - 2nd stage (outer filter insert)
The sum of the differential pressures of the first and second stage must correspond to the
differential pressure of the complete filter.
z Remove the measuring device.

TCG 2020
B 3-1-9
Measuring the separating quality
A 13
A measuring instrument, e.g. Dust Trak TM Model 8520 is necessary for the measurement.
A 14
z Measuring point 1
- after 1st stage (inner filter insert)
z Measuring point 2
- after second stage (outer filter insert)
It is not possible to measure the separating quality with the Dust Trak TM in front of the
crankcase breather because the range of the measuring instrument is inadequate.

TCG 2020
B 3-1-9
Measure blowby volume
A measuring instrument with the following parameters is required for the measurement:
z Measuring range 0 to 1000 l/min

z Temperature range 20 to 100 °C

TCG 2020
B 3-1-9
Measuring sheet for crankcase breather (model UPF)
Date
Name
Enclosure
Engine type
Engine serial number
Lubricating oil make
Filter housing type
Type of 1st filter stage
Type of 2nd filter stage
Operating hours
Total engine
1. Filter stage
2. Filter stage
Lubricating oil
Unit 1 2 3 4 5
Engine performance P (electric) kW
Load %
Crankcase pressure TEM display* mbar
Total differential pressure filter mmWS
Differential pressure 1st filter stage mmWS
(inner filter)
Differential pressure 2nd filter stage mmWS
(outer filter)
Blowby temperature in tank °C
Blowby volume l/min
Optional measurement if measuring instrument available

Separating quality after 1st filter mg/m3
stage (pre-filter)
Separating quality after 2nd filter mg/m3
stage (fine filter)
* In units with Huba-Control pressure switches, the crankcase pressure must be measured
with a water column.

TCG 2020
B 3-1-9

TCG 2020
B 4-6-1
Installing, removing and actuating engine turning gear
Tools
- Engine turning gear if applicable
General information
If no turning gear is available, the engines can be turned with a suitable bar on the flywheel
after removing the protective covers.
Always turn the engine in the direction of rotation to avoid damage.
Risk of injury !
Using the engine turning device
The engine turning gear is spring loaded for safety reasons.

To turn the engine, press in the hexagon and turn.

TCG 2020
B 4-6-1
A1
A2
A3

TCG 2020
B 5-4-2
Checking the speed governor linkage
Tools
Auxiliary material
- Lubricant, see section 4, Auxiliary materials
General information
The throttle valve must always be checked for leaks in connection with checking the im-
pulse transmitter linkage.
The throttle valve shaft must be che cked for sucking noises and leakage with the engine
running for this.
Risk of injury !
Check speed governor linkage, V12 and V16 engines
A1
z Push lever 1 to full load stop.
While pushing an even resistance must be felt.

When releasing, the actuator must return automatically to the zero position.
z Move connecting rod 2 in direction of arrow and check swivel heads for play.

TCG 2020
B 5-4-2
If irregular resistance can still be felt, there is probably a defect in the actuator or the rotary
valve.
If the swivel heads do have any play, they can be replaced.
For this contact your service partner.
Check speed governor linkage, V20 engines

The V20 engine is equipped with two actuators the output shafts of which act directly on the
rotary disk valves.
A2
z Turn shaft 3 to full load stop.
An even resistance must be tangible when turning.

If irregular resistance can still be felt, there is probably a defect in the actuator or the rotary
valve.

TCG 2020
B 6-3-6
Renewing the suction air intake filter
Tools
Spare parts
- Air intake filter
General information
Risk of injury !
Renew the suction air intake filters when
- the underpressure limit value has been reached (observe maintenance display).
- there is any damage or leaks (e.g. holes caused by outside factors).
- the maintenance intervals have been reached.
Renewing air intake filter, V12 and V16 engines
Removing air intake filter
A1
z Unscrew wing nut 1.

z Remove cover from housing of air intake filter.

TCG 2020
B 6-3-6
A2
z Unscrew nut 2.
z Remove suction air intake filter.
z Clean air intake filter housing on the inside with cleaning rags.
Installing air intake filter
z Insert new suction air intake filter.

z Tighten nut 2.
z Mount housing cover on the air intake filter.
z Tighten wing nut 1.

TCG 2020
B 6-3-6
Renewing air intake filter, V20 engines
Removing air intake filter
A3
z Open catches 3 and lift up cover 4 from housing of the air intake filter.
z Remove suction air intake filter 5.
z Clean air intake filter housing on the inside with cleaning rags.
Installing air intake filter
z Insert new air intake filter and push together (arrow).
Observe direction of flow through the intake air cleaner.
z Close housing cover of the air intake filter and close catches 3.

TCG 2020
B 6-3-6

TCG 2020
B 7-18-1
Combustion Gas Sampling
Tools
- Sample bag (polyvinylfluoride)
Auxiliary material
- Sampling valve (stainless steel or nickel-plated brass)
- Sampling tube of PTFE (teflon), diameter 6 x 1 mm, maximum length 0.5 m
- Adapter for connecting the bag
- Additionally for non-natural gas:
- Pressure measuring instrument
- Temperature measuring instrument
- Humidity measuring instrument
General information
The proper combustion gas sampling should be performed with the sample bag. A Tedlar
bag is recommended. Tedlar® is the trade name of the DuPont™ company for polyvinylflu-
oride.
Below you will find some general hints which apply both for taking samples of natural gas
and all types of special gases as well as special instructions for the analysis of special gas-
es.
A1

TCG 2020
B 7-18-1
Selection of the sampling point

The sampling point must be in a section of the line with a continious gas flow and be free
from condensation.
Falling or rising pipes are suited best.
A2
A - wrong
B - correct
In horizontal pipes 1, the sampling point 2 must located in the upper half of the pipe.
Otherwise condensation will collect in the sampling tube.
The condensation also falsifies the measurement if it was drained previously and the gas
is optically dry.
Combustion gas sampling

The combustion gas supply must have been in steady operation for at least 3 hours.
The gas volume flow must be at least 75 % of the nominal volume flow rate which occurs
at full load operation of the gas engine system. Flares may have to be put into operation
(for plants still in planning).
For landfill plants it must be ensured that the suction pressure during this time is of a similar
value as the suction pressure in full load operation.
The sampling in landfill facilities is only useful from the main line. Sampling of individual gas
wells does not give useful results.
Deviations from these requirements must be indicated in the sampling log which is submit-
ted with each sample.
The sampling point must be in the high pressure section of the combustion gas pipe leading
to the gas engine.
In gas pip es which o nly have a low flow du ring sampling, there is a risk of an incorrect
measurement due to condensation of trace components on cold surfaces.
The gas temperature in the pipe must be below 50 °C (or 120°F). If the ambient temperature
is much lower than the gas temperature in the pipe, the sampling fittings must be heated to
app. 30°C (or 85°F) to avoid condensation forming. The same applies to fittings that were
TCG 2020
B 7-18-1
exposed to low temperatures during transport to the sampling point.

No changes to the current gas compressor system should be made during sampling so that
a largely steady trace component composition can be assumed.
All fittings which come into contact with the sample gas have to be made of stainless steel
or nickel-plated brass.
The least influence of the gas trace components is to be expected from PTFE tubes. There-
fore the connecting tube between the sampling point and the Tedlar bag must be made of
PTFE (teflon). No other plastics or materials containing silicon may be used.
The surface having contact with the gas should be kept as small as possible and of residue
(dirt, condensation).
The tube should react with the trace gas components as little as possible to avoid absorp-
tion, adsorption and carry-over effects. Therefore the sampling tube should be kept as short
as possible.
Gas analysis
Recognised laboratories
Gas analyses will only be evaluated by MWM when accompanied by a filled in sampling
log.
MWM recommends the laboratories listed below.
The analysis of silicon-organic compounds (VOSiC) should be done exclusively by these
laboratories:
CAU Analytik GmbH

Daimlerstr. 23
D-63303 Dreieich
Phone: +49 (0)6103 - 485698-0
Fax: +49 (0)6103 - 485698-99
E-mail: info@cau-analytik.de
Umweltanalytik RUK GmbH

Im Paesch
D-54340 Longuich
Phone: +49 (0)6502 - 9339-0
Fax: +49 (0)6502 - 9339-29
E-mail: ruk@umweltueberwachung.de

TCG 2020
B 7-18-1
Contact data, certification number and analysis methods must be specified for analyses by
other laboratories.
In case of fo reign language analyses, please submit the original even if a translation is
available.
Approved methods of analysis

The following methods should be used:
Main components DIN 51872-04-A (GC-WLD)

Sum, chlorine, fluoride, sulphur DIN EN 38409 H8 (Wickboldcombustion), DIN EN
10304 (IC)
VOSiC i.A. VDI 3865 Bl.4 (GC-MS)
Ammonia VDI 2461 p.2 (colorimetric)
Hydrogen sulphide DIN 51855-4 (colorimetric)
Hydrocarbons VDI 3865 p.4 (GC-FID)
BTEX, Halogeniated HCs VDI 3865 p.4 (GC-MS)
Analysis values
Gas analyses must be clearly labelled and should contain a selection of the following anayl-
sis values adapted to the gas type:
Please contact your DPS partner if you are unsure with regard to the necessary scope of
analysis for your gas type.
z Sample description (see accompanying sampling log)
z Main components
- Methane (Vol-%)
- Carbon dioxide (Vol-%)
- Oxygen (Vol-%)
- Nitrogen (Vol-%)
z Inorganic trace gases

- Ammonia (mg/m3N)
- Hydrogen sulphide (mg/m3N)
z Hydrocarbons
- greater n-Pentane, less than or equal n-Decane (C5 H12 ... C10 H22) (mg/m3N)
- greater than n-Decane ( C10 H22) (mg/m3N)
z Total CI, F, S content (Wickbold)

- Total Chlorine (mg/m3N)
- Total Fluoride (mg/m3N)
- Total Sulphur (mg/m3N)

TCG 2020
B 7-18-1
z Halogenated hydrocarbons
- Dichlorodifluoromethane (F12) (mg/m3N)
- Vinylchlorid (mg/m3N)
- Trichlorofluoromethane (F11) (mg/m3N)
- 1.1-Dichloroethene (mg/m3N)
- Dichloromethane (mg/m3N)
- 1,1,2-Trichloro-1,2,2-Trifluoroethane (mg/m3N)
- Trans-1,2-Dichloroethene (mg/m3N)
- 1,1-Dichloroethane (mg/m3N)
- Cis-1,2-Dichloroethan (mg/m3N)
- Trichloromethane (mg/m3N)
- 1.2-Dichloroethane (mg/m3N)
- 1,1,1-Trichloroethane (mg/m3N)
- Tetrachloromethane (mg/m3N)
- Trichloroethene (mg/m3N)
- 1,1,2-Trichloroethane (mg/m3N)
- Tetrachloroethene (mg/m3N)
- 1,1,1,2-Tetrachloroethane (mg/m3N)
z BTEX
- Benzene (mg/m3N)
- Toluene (mg/m3N)
- Ethylbenzene (mg/m3N)
- m-/p-Xylene (mg/m3N)
- o-Xylene (mg/m3N)
z VOSiC
- Tetramethylsilane (mg/m3N)
- Trimethylsilanol (mg/m3N)
- Hexamethyldisiloxane (L2) (mg/m3N)
- Hexamethylcyclotrisiloxane (D3) (mg/m3N)
- Octamethyltrisiloxane (L3) (mg/m3N)
- Octamethylcyclotetrasiloxane (D4) (mg/m3N)
- Decamethyltetrasiloxane (L4) (mg/m3N)
- Decamethylcyclopentasiloxane (D5) (mg/m3N)
- Sum VOSiC (calc.) (mg/m3N)
- Sum silicon (calc.) (mg/m3N)

TCG 2020
B 7-18-1
z Gases with long-chained hydrocarbons (e.g. associated gas)

- Ethene C2H4 (Vol.-%)
- Ethane C2H6 (Vol.-%)
- Propane C3H8 (Vol.-%)
- Butane C4H10 (Vol.-%)
- Pentane C5H12 (Vol.-%)
- Hexane C6H14 (Vol.-%)
z Gases with a high H2-content (more than 30 Vol-%, e.g. coke oven gas)
- Hydrogen H2 (Vol.-%)
- Naphthalene (mg/m3N)
- Benzene (mg/m3N)
- Tar (mg/m3N)

TCG 2020
B 7-18-1
Accompanying certificate for combustion gas sample
Gas type
Natural gas Bio-gas Landfill gas
Desired scope of analysis

N.C.V. analysis (1 ltr. Tedlar bag)
Standard analysis and Wickbold (10 ltr. Tedlar bag)
Sampler
Name: Date:
Phone: Time:
Sample no.: Order no.:
Plant data
Plant name: Project / engine no.:
Person: Engine type:
Phone: Number of engines:
Fax no.: Nominal electrical output:
Description of sampling point
Ambient conditions
Ambient temperature in °C: Precipitation:
Outside temperature in °C: Relative humidity in %:
Time that the plant was in operation prior to sample extraction:
Gas pipes exposed to sunlight?
If yes, how long?
Comments / Peculiarities
The sample bag must not be exposed to direct sunlight.

The manufacturer's transport conditions must be observed.

TCG 2020
B 7-18-1

TCG 2020
B 7-20-1
Checking the gas pressure in the gas regulator line
References
- B 7-21-1 Renewing gas filter insert
Technical data
Gas pressure of the gas control system

see acceptance documents
General information
The correct gas pressure for the unit is to be found in the commissioning report.
The gas pressure applied to the gas control system is read from the pressure gauge. This
is supplied by the pre-pressure control system and depends on the type and quality of gas.
A pressure check can only be made when the engine is running.
Checking the gas pressure in the gas regulator line
A1
z Press confirmation button 1 and read off gas pressure.
If the specified level has not been reached, the gas filter insert must be renewed - see job
card B-7-21-1.

TCG 2020
B 7-20-1

TCG 2020
B 7-21-1
Renewing gas filter insert
Tools
Spare parts
- Gasket
- Filter insert
References
- B 7-20-1 Checking the gas pressure in the gas regulator line
Technical data
Cover of gas filter housing

8 Nm
General information
Remove gas filter insert
A1
z Disconnect gas supply by closing the ballcock (arrow).

z Unscrew screws 1.
z Remover cover from gas filter housing 2.
TCG 2020
B 7-21-1
A2
z Remove filter insert 3 from cover 4.

z Clean cover and gas filter housing.
Fit gas filter insert
A3
z Replace seal 5.
z Mount new filter insert 3 on cover 4.
Note positioning of filter insert on the cover (arrow).

TCG 2020
B 7-21-1
A4
z Place cover with filter insert 6 in gas filter housing.
Note positioning of filter insert on the gas filter housing (arrow).
z Fasten screws and tighten crosswise.

z Restore gas supply by opening the ballcock.
z Check the cover and gas filter housing for leaks.
- To do this, spray the cover with leak search spray or soap suds and watch for for-
mation of bubbles.

TCG 2020
B 7-21-1

TCG 2020
B 8-1-1
Taking lube oil samples
Tools
- Lube oil sample container
Auxiliary material
- Lubricating oil according to operating media specifications, chapter 4, Auxiliary mate-
rials
General information
Trouble-free operation and wear behaviour depend to a large extent on the state of the lube
oil. Therefore checking the lube oil is one of the most important maintenance jobs.
An analysis by the lube oil manufacturer is necessary since a detailed examination can only
be carried out in a laboratory. If there is no alternative, MWM will carry out the analysis
for reimbursement of expenses.
The necessary data for lube oil analysis are:
- Brand and type of lube oil.

- Reading on the operating hours counter.
- Lube oil consumption since the last sample was taken.
If the analysis proves negative, the lube oil must be replaced.
The lube oil sample must be taken from the lube oil circuit with the engine running and at
operating temperature.
Risk of scalding !
When working with hot operating materials.
Lube oil tap
A1

TCG 2020
B 8-1-1
A2
z Start engine and bring up to operating temperature (lube oil temperature above 60°C).
z Push coupling piece 1 with hose pipe until it clicks in to lube oil removal valve.
Risk of scalding !
When the coupling piece has clicked in, hot lube oil immediately flows out under
pressure.
z Drain the required amount of lube oil into the lube oil sample container.
z Unlock lube oil removal valve 1 and pull off coupling piece 2 with hose pipe 3.

TCG 2020
B 8-1-2
Changing lube oil
Tools
Spare parts
- Lubricating oil according to running material specifications
References
- Chapter 4, Operating media
- TEM System Operating Manual
- Technical Circular TR 0199-99-2105.
General information
The lube oil change is performed in connection with the TEM System.
The lube oil change should be performed on the warm engine.
Depending on the system version, there is an option for remote oil change which enables
control of two solenoid valves for automatic switching between the pre-lubrication and
pumping modes. Lube oil can then be changed via modem.
Risk of injury !
Risk of scalding !
Observe the disposal regulations !

Collect operating materials and dispose of properly according to the national regu-
lations.

TCG 2020
B 8-1-2
Position of the 3-way taps
A1
z Empty lubricating oil pan.
A2
z Empty base frame.
A3
z Prelubricate unit
TCG 2020
B 8-1-2
A from lube oil tray

B from base frame
C to waste oil tank
D to engine lube oil circuit
1 Three-way cock, suction connection

2 Three-way cock, pressure connection
3 Stop cock, base frame
4 Stop cock, lube oil tray
Pump off lube oil
z Switch three-way valve 1, 2, 3 and 4 on the pre-lubrication pump so that the waste oil
can be pumped out of the engine or the base frame.
z In the TEM system
- Select menu item Service.
- Select menu item Oil change.
- Select menu item Pump out oil - (pumping out process starts and finishes after
the time programmed in the TEM).
If the lube oil tray is not empty after the programmed time (pre-lube pump stops), the pump-
ing out process must continue with menu item Pump out oil.
If the lube oil tray is empty before the programmed time (pre-lube pump is sucking air), the
pre-lube pump can be turned off under menu item Oil sump empty.
z Switch the three-way valves 1, 2, 3 and 4 on the pre-lubrication pump back to engine
operation.
Pour in lube oil
z In the TEM system

- Select menu item Refill - (fresh oil starts to fill).
The filling process is controlled automatically by the TEM system.

When the filling level is reached the lube oil level switch ends the filling process automati-
cally.
z At the end of fresh oil filling

- Select menu item Pre-lubrication - (pre-lubrication process starts).
The pre-lubrication process takes about 20 minutes. It is not possible to start the engine
before then.

TCG 2020
B 8-1-2

TCG 2020
B 8-4-11
Overhaul pressure limiting valve of the pre-lube pump
Tools
- Caliper gauge
- Torque wrench
Spare parts
- Sealing rings (DIN 7603-A 21x26-Cu)
- poss. control piston
- poss. compression spring
Technical data
Pressure limiting valve pre-lubricating pump

Cap nut 70 Nm
General information
Risk of injury !
Dirt particles may collect on the c ontrol piston of the pre-lube pump's pressure limiting
valve. The control piston is then no longer fully in contact with the piston seat and leaks.
Some of the pumped lube oil is taken off directly due to this leak. The lube oil pressure re-
quired for pre-lurication is then no longer achieved.

TCG 2020
B 8-4-11
Overhaul pressure limiting valve of the pre-lube pump
Dismantle the pressure limiting valve
A1
z Unscrew the cap nut.
A2
z Determine dimension X with caliper gauge and note for later installation.
- measured from the top of the setting screw to the lock nut.

TCG 2020
B 8-4-11
A3
z Loosen lock nut and unscrew setting screw.
A4
z Remove compression spring and control piston.

z Clean the seat on the control piston (arrows) and in the housing of the pressure control
valve.
Check components (compression spring, control piston) for wear, renew if necessary.
Assemble pressure limiting valve
z Insert control piston and compression spring.

z Renew sealing ring and screw in setting screw with lock nut.

TCG 2020
B 8-4-11
A5
z Turn in setting screw to dimension X.
The dimension X determined when removing must be retained otherwise the set lube oil
pressure will be changed.
A6
z Tighten the lock nut.
Hold at the setting screw.

After tightening the lock nut, check the dimension X again with the depth measuring appli-
ance, loosen the lock nut again if necessary and reset the dimension X.
z Renew sealing ring and tighten cap nut.

TCG 2020
B 8-10-4
Renewing lube oil filter cartridge
Tools
- Lubricating oil filter key
Aids
- Collecting tray for old oil
Spare parts
- Lubricating oil according to operating media specifications
- Lubricating oil filter cartridge
References
- TEM System Operating Manual
Technical data

25 Nm
General information
Risk of injury !
Risk of scalding !

lations.

TCG 2020
B 8-10-4
Removing the lubricating oil filter cartridge
A1
z Place collection tray underneath.

z Unscrew and remove the lube oil filter cartridge with commercially available strip key.
When unscrewing the lube oil cartridge fine plastic chips are produced when the catch is
released. These chips do not get into the lube oil system and pose no danger.
Install lube oil filter cartridge
A2

z Wet the gasket of the new lubricating oil filter cartridge with lubricating oil.

TCG 2020
B 8-10-4
A3
z Mount and tighten lube oil filter cartridge.

z Check lube oil filter cartridge for leaks.
- build up oil pressure with pre-lube pump.

TCG 2020
B 8-10-4

TCG 2020
B 9-0-4
Empty and fill cooling system
Tools
Auxiliary material
- Collecting tray for coolant
Spare parts
- Gaskets
References
- B 9-1-1 Checking percentage of corrosion protection agent or antifreeze in coolant
General information
For various work, e.g. on the cylinder head, crankcase, heat exchanger and pipes, the cool-
ant must be partially or totally drained.
If no antifreeze is added, the coolant must be drained totally from the engine and the attach-
ment parts when shutting down the engine for a longer time and in case of frost.
Danger of burning !
When corrosion protection is not in its hardened state, it is a fire hazard.
Risk of injury !

lations.

TCG 2020
B 9-0-4
Emptying the cooling system
A1
A2
A3
In order to empty the engine completely, coolant must be drained from various points in the
cooling system.
A collecting tray must be placed underneath the appropriate places.
z Shut off the coolant pipes from and to the engine.

z Open drain screws, drain valves or pipes and drain coolant.
z Close drain screws, drain valves and pipes again after complete drainage.
- Use new gaskets and sealing rings.

TCG 2020
B 9-0-4
Filling the cooling system
Use the required quality of coolant as described in chapter 4, Operating materials.

Use the right percentage of corrosion protection agent or antifreeze as set out in job card
B 9-1-1.
z Fill the engine cooling system with the prepared coolant.

z The filled cooling system bleeds automatically. When refilling, it is necessary to bleed
the coolant pipe at the highest point.
- Loosen the hollow screw until the coolant comes out without bubbles.
z Open coolant pipe from and to the engine.
z After filling, check pipes, connecting elements and engine for tightness and renew de-
fective components if necessary.
z Check the coolant level again, top up if necessary.

TCG 2020
B 9-0-4

TCG 2020
B 9-1-1
Checking percentage of corrosion protection agent or antifreeze in

coolant
Tools
- Test set for cooling water
Spare parts
- Anti-corrosion agent or antifreeze if necessary
References
General information
In order to protect coolant chambers from corrosion anti-corrosion is added to the coolant.
This protection only exists, though, if the content of anti-corrosion agent does not go below
a certain amount. If more anti-corrosion agent than is necessary is in the coolant, the cool-
ing effect is reduced.
If antifreeze is mixed into the coolant , this must also have anti-corrosive properties. In this
case, no anti-corrosion agent has to be added. For those reasons the antifreeze content
must be measured accordingly.
If the cooling system has to be topped up, the antifreeze or anti-corrosion agent content in
the coolant must be checked. Then the coolant must be corrected as described below.
Danger of burning !
When corrosion protection is not in its hardened state, it is a fire hazard.
Checking the percentage of corrosion protection agent or antifreeze
z Take a coolant sample from the radiator, expansion tank or drain tap.
z Check the additive content with the measuring instrument - see TR 0199-99-2091.

TCG 2020
B 9-1-1
Correct the corrosion protection agent and antifreeze content
If additive content is too low:
z Calculate additive content.

A = B x (C - D) / 100
A= Quantity of extra additive needed

B= Total filling quantity
C= Nominal value
D= Measured value
z Drain off enough coolant.
z Mix the quantity of additive to be topped up well with the drained coolant.
z Fill the mixture.
If the additive content is too high:
z Calculate additive content.

A = (1 - B / C) x D
A= Coolant to be drained
B= Nominal value
C= Measured value
D= Total filling quantity
z Drain off necessary coolant.

z Fill cooling system with pure water.
Observe water quality - see chapter 4, Operating media
z Bleed cooling system.

TCG 2020
B 10-7-1
Drain air bottle (starter air container) and fill
Tools
z Open drain 1 valve slowly until water comes out. When no more water comes out, close
drain valve again.
z Fill air bottle to 30 bar every time before stopping engine.
Do not open drain valve too far because if the flow speed is too great the water is displaced
and only air comes out. When air bottles are fitted vertically a rising pipe 2 is fitted. The air
pressure in the air bottle pushes the water through the rising pipe into the outside air.
If no water comes out over several service intervals, have air bottle checked.
' 80122-1
A1

TCG 2020
B 10-7-1

TCG 2020
B 13-4-1
Servicing the battery
Tools
- Acid tester
Auxiliary material
- Distilled water
- Acid protection grease
- Rags
Technical data
Battery acid density

Charge status Normal Tropical
well charged 1.28 kg/l 1.23 kg/l
semi-charged (re-charge) 1.20 kg/l 1.12 kg/l
discharged (recharge, renew if neces- 1.12 kg/l 1.08 kg/l
sary)
General information
The gases emitted by the battery are explosive.
Avoid sparks and naked flames.
Danger of burns !
Do not allow battery acid to come into contact with skin or clothing.
Danger of short-circuit !
Do not rest tools on the battery.
Cover the battery poles.
Risk of injury !

TCG 2020
B 13-4-1
Keep battery clean and dry.
Check battery and cable connectors
A1
z Remove dirty clamps.

z Clean the battery poles and clamps.
z Plug on and tighten clamps.
z Grease clamps with acid-proof grease.
z When reassembling, ensure that clamps make good contact. Tighten clamp bolts
hand-tight.
Make sure the clamps have good contact.

TCG 2020
B 13-4-1
Check acid level
A2
z Unscrew and remove sealing caps 1.

z Visually check the acid level.
- without control inserts 2: liquid level 10 - 15 mm above top edge of plate.
- with control inserts 2: liquid level up to their floor.
Only use distilled water for refilling.
Check acid density
A3
z Measure the acid density with a commercially available acid tester.
During measurement, temperature should preferably be 20 °C.

TCG 2020
B 13-4-1
If the battery is recharged, all the stoppers must be removed before charging.
Check the acid level after charging and correct if necessary.
Correct the acid density
z if acid density too low:

A = B x (C - D) / (E - D)
A= Amount of acid to be refilled

B= Cell content
C= Nominal density
D= Acid density in the cell
E= Density of acid to be refilled
- Suck amount of acid to be refilled from the battery.

- Fill determined amount of battery acid into the battery.
z if acid density too high:

A = B x (C - D) / (C - 1)
A= Amount of water to be refilled

B= Cell content
C= Acid density in the cell
D= Nominal density
- Suck amount of water to be refilled from the battery.

- Fill determined amount of water into the battery.

TCG 2020
B 13-5-4
Removing and installing spark plugs, checking ignition cable
Tools
- Spark-plug wrench
- Torque wrench
Auxiliary material
- Compressed air
- Safety goggles
Spare parts
- Sealing rings for spark plugs
- Spark plugs if necessary
Technical data

52 Nm
General information
Spark plugs and ignition cables are one component and cannot be separated.
Risk of injury !
Danger of death !
When working on the high voltage ignition system.

TCG 2020
B 13-5-4
Removing the spark plug
A1

Risk of injury !
Checking the ignition cable
z Visually inspect the ignition cable for damage and renew if necessary.
Installing the spark plug
If the spark plug is renewed, the new spark plug must be checked for damage.
If the removed spark plugs are re-fitted, the sealing ring must be replaced.


TCG 2020
W 0-0-5
Safety regulations for hydraulic clamping device
References
- Accident prevention regulations
- Manufacturer documents
General information
Only the manufacturer is allowed to do repairs to the hydraulic clamping device.
Because of the danger of accidents, all parts of the claping device, especially the high pres-
sure hoses, must be in perfect condition.
Do not kink, crush or overheat the high pressure hoses. The minimum bending radius 1 may
not be smaller than 150 mm.
A1
Clean the thread and contact surfaces and wet with Talg-Mennige or lube oil before mount-
ing the clamping device. Do not use Molykote.
In cylinder assembly only all four hydraulic elements and in con rod or main bearing assem-
bly only both hydraulic elements may be put under pressure simultaneously.
z Before working with the clamping device,

- check all the hoses and gaskets to which pressure is applied.
z While working with the clamping device,

- wear a face mask and gloves because hydraulic oil spaying from leaks can pene-
trate the skin due to the high pressure.
- Never stand in pulling direction behind or above the clamping device.
- Seal unconnected hoses with caps for safety reasons.
- Do not apply pressure to the clamping device for longer than necessary.

TCG 2020
W 0-0-5
For perfect operation of the hydraulic clamping device, the whole pipe system must be free
of air.
However, venting is only necessary when required because the automatically closing safety
coupling halves normally prevent oil from escaping and air from entering.
In order to guarantee the operational reliability and functionality of the hydraulic system, it
is recommended to change the hydraulic oil every 12 months and the highly stressed gas-
kets every 300 operating hours.

TCG 2020
W 0-1-3
Running-in instructions
References
General information
New engines are run in at the factory, so it is not necessary to run them in again.
After maintenance work on main or con rod bearings, pistons, piston rings and cylinder lin-
ers, or after their replacement, the engine will need to be run in again.
The engine must be run in according to the run-in program.
The engine commissioning log should be used as a basis for the setting values.
If the commissioning log is no longer available, the test bench acceptance documents can
be used.
Do not operate the engine for longer than 15 minutes under 30% power (increased oil in
cylinder at low load).
If the run-in program is interrupted, the last load point should be run again.
The data should be monitored during running-in and noted at 100% load.
If work has been done on the gear train the TDC must be checked, and redefined if neces-
sary.

TCG 2020
W 0-1-3
Running-in program
z Install measuring points

- Mixed pressure after turbocharger (compressor side)
before throttle valve or rotary disk valve and in the charge mixture pipe
- Exhaust gas pressure after turbocharger (turbine side)
z Start engine.
z Check the ignition angle with a stroboscopic lamp. Correct if necessary.
z Set the mixture with the gas mixer or the zero-pressure regulator until the engine is
idling satisfactorily.
z Operate the engine for 10 minutes at 25% of the rated power.
z Then increase the power by 25% every 10 minutes until full load is reached.
z Run the engine for 60 minutes on full load.
z Set the characteristic by measuring pollutants.

TCG 2020
W 0-2-7
Endoscope examination of combustion chamber
Tools
- Endoscope
- Torque wrench
- Spark plug key
Spare parts
Technical data

52 Nm
General information
Using endoscopy, it is possible to inspect the state of wear of the combustion chamber (pis-
ton, cylinder liner, cylinder head, valves) without having to remove the cylinder head. The
wear limits can be better exploited and maintenance costs reduced as a result.
Observe the manufacturer specifications for handling the endoscope.
Evaluation of normal signs of wear and determination of the next endoscopy date can only
be carried out by trained personnel.
The endoscope image can also be projected inverted or upside down depending on the
view of the lens.

TCG 2020
W 0-2-7
Endoscope examination of combustion chamber
A1
z Remove spark plugs.

z Turn engine until the piston of the cylinder to be inspected is in the lower dead centre.
z Connect endoscope, switch on and feed carefully through the spark plug bore.
In order to be able to test the outlet and inlet valves, the engine must be turned accordingly.
Make sure that the endoscope is not damaged during this process.
Light reflections can lead to diagnostic errors. Swivel and alternately tilt the endoscope dur-
ing the examination. Make sure that the glass fibre cable does not get damaged during this
process.
z In case of clear signs of damage (e.g. breakouts, notches, grooves), the cylinder head
or cylinder liner must be removed.
z Watch out for drip formation on the floor of the cylinder head.
- This may be an indication of leaks or tears in the cylinder head.
z Remove the endoscope carefully.
z Install spark plugs.
- Renew sealing rings.

TCG 2020
W 0-3-1
Use of liquid nitrogen
General information
Risk of injury !
Do not touch liquid nitrogen or supercooled parts.
When the components are placed in liquid nitrogen, drops of liquid may splash out.
Wear protective glasses, snugly-fitting clothing and gloves.
For occasional brief periods of work with liquid nitrogen place two concentric containers one
inside the other for the immersion bath and fill the gap with glass wool, cork dust or sand.
The liquid nitrogen is poured as needed from the containers in which it is delivered into the
immersion bath, into which the components are inserted if necessary.
At the beginning of the metal cooling, the liquid nitrogen "boils" strongly. The bubbling per-
sists until the metal parts reach the temperature of the liquid nitrogen (-196 °C). If the bbub-
bling stops, the parts are ready for installation.
Use a suitable tool for inserting the components into the container and removing them.
Liquid nitrogen consumption

Under normal conditions, the following amount is required for cooling 1 kg of metal from
+15 °C to -196 °C:
z 0.60 l for steel

z 0.66 l for cast iron
z 0.45 l for bronze, copper, brass
z 0.96 l for aluminium

TCG 2020
W 0-3-1

TCG 2020
W 0-3-2
Tear inspection by diffusion liquid method
Aids
- Cleaning agent (trichlorethylene)
- Diffusion liquid (red)
- Developer (white)
- Dry cloth
- Safety goggles
- Protective gloves
- Suction device
General information
When working with trichlorethylene.
Risk of injury !
Cleaning component
A1
z Remove grease from component with cleaning agent.

z Allow cleaning agent to work for 10 - 15 minutes.
z Rub down the surface to be tested thoroughly with a dry cloth.
- This removes all residue grease which might fill in and cover any tears.

TCG 2020
W 0-3-2
Apply diffusion liquid
A2
z Applying diffusion liquid

- This is done with a spray can, spray gun, brush or by immersing the component in
the diffusion liquid.
Observe exposure time according to the manufacturer's specifications.
A3
z Clean component with water.

- Wash off the diffusion liquid thoroughly from the surface until it only remains in the
tears.
z Rub the surface dry thoroughly with a cloth.
z Let the component dry.
Applying developer.
A4
z Apply developer thinly with a spray can or brush.

- Avoid applying twice to the same surface.
z Let the developer dry for 1 - 2 minutes.
The diffusion liquid is drawn out of the tear by the developer (acting as blotting paper) and
therefore becomes visible.

TCG 2020
W 0-3-2
Evaluation
z Very thin tears may only become visible after several hours.
z Red areas in the white developer layer appear in the areas of the tears and other sur-
face irregularities because of the diffusion liquid being drawn up.
z Red lines indicate tears.
z Red dots indicate recesses and porosity.
z A red dotted line occurs with:
- very fine tears
- metal fatigue
- an only partial rupture

TCG 2020
W 0-3-2

TCG 2020
W 0-3-4
Removing, installing and checking hose pipes, vibration dampers and

flexible pipes
Tools
Spare parts
- poss. hose pipes
- poss. vibration dampers
- poss. flexible pipes
Technical data
Vibration dampers on pipes

according to manufacturer's specifications
General information
Due to the wide variety of applications and variants, these instructions do not cover every
single version.
If leaks, tears, porosity or other damage are visible, the corresponding components must
be renewed.
A1

TCG 2020
W 0-3-4
A2
Removing and installing hose pipe and flexible pipe
z Remove clips and fastening nuts.

z Remove components.
z Clean connection nozzles.
z Insert and position new parts.
z Position and tighten clips or fastening nuts.
z Start engine and check components for leaks.
- Leaks must be eliminated.
Removing and installing vibration dampers
z Unscrew nuts and screws.

z Clean contact surface.
z Insert and position new parts.
z Tighten nuts and screws.
z Start engine and visually inspect vibration dampers.

TCG 2020
W 0-5-1
Lifting and setting down the engine
Tools
Auxiliary material
- Lifting gear
General information
If the generator and engine have been separated, check the alignment of the gener-
ator to the engine and correct if necessary !
The engine must be moved, lifted and set down to be able to perform certain work steps.
This is the case for example during a general overhaul or work on the lubricating oil system.
Danger of death !
Note the breaking strains of the ropes and hoist unit.
Lifting and setting down the engine
z Drain lube oil.

z Drain the coolant.
z Disconnect the pipes from the engine to the system.
z Remove the exhaust pipe.
z Disconnect electric cables.
z Separate the generator from the engine.
A cross-member must be used between the central hook of the lifting crane and the
suspending ropes. The cross-member must guarantee that the suspending ropes are
tensioned vertically upwards !

TCG 2020
W 0-5-1
A1
z Fix suspending rope to engine transport eyes.
A2
z Remove the base frame screw connection.

z Lift engine with hoist unit.
z Set engine down carefully on appropriately high, firm and safe support.

TCG 2020
W 1-2-2
Removing and installing rocker arm and rocker arm block
Tools
- Spark plug key
Spare parts
References
- B 1-1-1 Checking and adjusting inlet and outlet valve clearance
Technical data
Rocker arm (Internal diameter)

Rocker arm axis (External diameter)

Rocker arm bearing clearance

Wear limit 0.130 mm

M16x1.5 - 10.9 1. Stage 30 Nm
2. Stage 120°

M10x1 40 Nm

M12x1.5 45 Nm

M8x55 / 85 25 Nm
General information
To remove and install the rocker arm block, the engine must be turned so that the valve
drive is not under spring tension. That means both inlet and outlet valves are closed.

TCG 2020
W 1-2-2
Removing rocker arm and rocker arm block
A1

Particles of dirt can cause injury when cleaning with compressed air.
Wear safety glasses and close-fitting clothing.

z Unscrew screws.
A2
z Turn the engine until all the valves are closed.

z Unscrew screw 3.
TCG 2020
W 1-2-2
z Remove rocker arm block with rocker arm.
A3
z Pull the rocker arm off the rocker arm block (direction of arrow).
z Clean all components.
z Check lube oil bores for free passage.
z Check all components for wear.
- Visually inspect setting screw and renew if necessary.
- Measure rocker arm bore with internal measuring device.
- Measure the diameter of the rocker arm axis with a micrometer gauge.
If the wear limit is reached, the components must be renewed.

TCG 2020
W 1-2-2
Install rocker arm and rocker arm block
z Wet all components with lube oil.
A4
Note installation position.

The inlet and outlet rocker arms are different.
Short rocker arm - outlet side.
Long rocker arm - inlet side.
z Push the rocker arm onto the rocker arm shaft.
A5
z Measure screw of toggle lever block and renew if necessary.

z Insert rocker arm block with rocker arm.
Make sure that the ball heads of the rocker arms are in the pushrods.

TCG 2020
W 1-2-2
A6
z Tighten screw 3.
- Tighten screws.
z Renew the sealing ring of the spark plug.
z Checking and adjusting inlet and outlet valve clearance - see job card B 1-1-1.

TCG 2020
W 1-2-2

TCG 2020
W 1-4-4
Removing and installing cylinder head
Tools
- Feeler gauges
- Torque wrench
- Depth gauge
- Shim package
- Hydraulic tool MOCK / LERBS
1x 1206 9494 or
1x 1221 7454 or
1x 1221 7448
- Hydraulic tool SCHAAF
1x 1230 0218 or
1x 1230 5662
Auxiliary material
- Lube oil
Spare parts
- Gasket exhaust manifold on cylinder head
- Gasket charge mixture pipe on cylinder head
- Cylinder head sealing ring
- Shaped gasket for cylinder head
- Gasket cylinder head hood, if necessary
- Cylinder head nut, if necessary
- Screw for toggle lever block, if necessary
References
- B 9-0-4 Empty and fill cooling system
- W 0-0-5 Safety regulations for hydraulic clamping device

TCG 2020
W 1-4-4
Technical data
Cylinder head fastening, installation specification

Pay attention to hole spacing!
Pin wrenches with 6 holes (60°) and 8 holes (45°) hole spacing have been delivered.
Loosen cylinder head

Mount clamping device until touching - then loosen 1 turn
Build up pressure Mock 1206 9494 (HV 1995/5) 730 bar
1221 7454 (HV 1999/1) 1000 bar
1221 7448 (HV 1999/1) 1000 bar
Schaaf 1230 0218 (A 3957 0000) 2350 bar
1230 5662 (A 5556 0000) 1850 bar
Loosen cylinder head nut Mock Turn out 6 or 8 holes 360 °
Schaaf Turn out 6 holes 360 °
Relieve pressure 0 bar
Tighten cylinder head
Tighten cylinder head nuts diagonally 100 Nm
Loosen cylinder head nuts (approx. 1/6) 60 °
Align cylinder head on charging mixture pipe
Pre-tighten cylinder head nuts diagonally 100 Nm
Mount clamping device until touching - then loosen 1/4 turn
1. Build up pressure Mock 1206 9494 (HV 1995/5) 150 - 160 bar
1221 7454 (HV 1999/1) 210 - 220 bar
1221 7448 (HV 1999/1) 210 - 220 bar
Schaaf 1230 0218 (A 3957 0000) 400 bar
1230 5662 (A 5556 0000) 400 bar
Tighten cylinder head nut hand tight, all cylinder head nuts must be tightenable by the same
amount
2. Build up pressure Mock 1206 9494 (HV 1995/5) 730 bar
1221 7454 (HV 1999/1) 1000 bar
1221 7448 (HV 1999/1) 1000 bar
Schaaf 1230 0218 (A 3957 0000) 2350 bar
1230 5662 (A 5556 0000) 1850 bar
Tighten cylinder head nut hand tight, all cylinder head nuts must be tightenable by the same
amount

TCG 2020
W 1-4-4

M10x48 60 Nm
Combustion chamber temperature sensor

M12x1 hand tight

M16x1.5 - 10.9 1. Stage 30 Nm
2. Stage 120°

M12x30/45 - 10.9 90 Nm

M8x55 / 85 25 Nm
Fastening screw rocker arm block

Wear limit max. 80.8 mm
General information
Observe the order of work strictly to avoid damage.
The pressures of the different tools must be observed.
See also TR 0122-49-6447.
Risk of injury !
The safety regulations for the hydraulic clamping device must be observed - see job
card W-0-0-5.
All maintenance work on the clamping device must be performed according to man-
ufacturer specifications, the operating manual must also be observed.
Correct loosening and tightening of the cylinder head nuts is only possible with the hydraulic
clamping device.
To avoid jamming of the cylinder heads, the cylinder head nuts must be tightened in two
steps.
Due to the cylinder angle of 45°, the mounted cylinder heads slip towards the charge mix-
ture pipe when the engine is in the installation position. Therefore the cylinder head must
be positioned with shims. The cylinder head is pressed 0.1 mm towards the V-chamber.
The gap which forms between the cylinder head and the charge mixture pipe leads to ma-
terial tension when tightening. These are compensated by the elastic deformation of the
charge mixture pipe.
TCG 2020
W 1-4-4
If the crankcase is clamped in a rotary vice and can be swivelled 45° (cylinder liners verti-
cal), the alignment with the positioning aids can be omitted. In this case the cylinder head
can be aligned to the charge mixture pipe.
Removing cylinder head
z Drain the cooling system - see job card B 9-0-4.
A1
z Pull off spark plug cables from ignition coils.

z Disconnect all cable set plugs from the multifunction rail 1.
z Unscrew nuts (arrows).
z Remove clip.
z Remove multifunction rail 1.
A2
z Disconnect coolant pipe from coolant line 2.

TCG 2020
W 1-4-4
z Unscrew screws (arrows) and remove with washers.

z Remove top part of the fastening clips.
z Pull coolant pipe 2 up out of the coolant overflow.
The screws of the exhaust pipe must only be unscrewed on the cylinder head to be re-
moved.
z Remove exhaust pipe - see job card W 6-1-9.

z Loosen all the screws of the charge mixture pipe.
z Unscrew screws of the charge mixture pipe of the cylinder head concerned.
z Remove gaskets.
A3
z Turn the engine until all the valves are closed.

z Unscrew screw 3.
z Remove rocker arm block with rocker arm.

TCG 2020
W 1-4-4
A4
z Remove valve bridges 4.

z Remove the stop rods 5.
Loosen the cylinder head nuts with the hydraulic tool
A5
z Insert the hydraulic die 6 in the support pipe 7.

TCG 2020
W 1-4-4
A6
z Clean the pin bolts 8 and coat with lubricating oil.
Do not use Molykote !
z Mount the hydraulic element 9 on the pin bolts 8 and tighten.
Danger of destroying the cylinder head !

Make sure the support pipe fits properly. The flattened end of the support pipe 10
must be flush with the edge of the cylinder head.
A7
z Check whether the pin wrench is jammed with the lathe mandrel 11 through the assem-
bly opening.
- If the pin wrench is jammed, is touching the cylinder head nut, loosen the hydraulic
element and tighten again.

TCG 2020
W 1-4-4
z Turn the hydraulic element back one turn.
Do not turn the hydraulic element back further otherwise the permissible stroke will be ex-
ceeded.
If you turn back less, the hydraulic element may stick after relieving the pressure.
A8
z Mount three other hydraulic elements accordingly.
A9
z Connect all hydraulic elements to the pump by high pressure hoses 12 and distributors
13.
Only all four hydraulic elements may be pressurized at the same time mounted !
z Apply pressure to the hydraulic system.

TCG 2020
W 1-4-4
A 10
The stroke signals 14 are visible at the hydraulic elements when the pressure builds
up.
If the groove 15 becomes visible during pressure build-up with a stroke signal, the
pressure build-up must be aborted otherwise the hydraulic element will be de-
stroyed.
Relieve the pressure from the hydraulic system slowly, find and eliminate the cause.
A 11
z Insert the lathe mandrel 27.94 cm the pin wrench and loosen the cylinder head nuts.
If this is not possible,
- drain pressure,
- find cause (e.g. thread damaged, assembly fault),
- eliminate the cause.

TCG 2020
W 1-4-4
z Drain the pressure totally from the hydraulic system slowly.

- Wait for the piston recoil. The stroke signals sink completely into the hydraulic el-
ements.
z Remove the high pressure hoses from the hydraulic elements.
z Remove the hydraulic elements from the pin bolts.
z Unscrew the cylinder head nuts from the pin bolts and remove together with the wash-
ers.
A 12
z Mount holding plate on cylinder head.

z Tighten screw.
z Attach the holding plate to the crane.
z Lift up the cylinder head with crane from the crankcase.
- Do not damage the pin bolts.
A 13
z Remove cylinder head sealing ring 17.

TCG 2020
W 1-4-4
z Remove shaped gaskets 18 and 19.

z Check all components and gaskets and renew if necessary.
Mounting cylinder head
A 14
z Clean the sealing surfaces.

z Mount shaped gaskets 18 and 19.
z Mount new cylinder head sealing ring 17.
Make sure the sealing ring fits properly.

Do not move the sealing ring when you mount the cylinder head.
A 15
z Place the cylinder head carefully on the crankcase with the crane.
- Do not damage the pin bolts.
z Unhook the crane, unscrew the screw and remove the holding plate 16.
TCG 2020
W 1-4-4
z Press the cylinder head in the direction of the V-chamber.

- The cylinder head must be felt to snap into the centering of the liner.
A 16
z Tighten the cylinder head nuts crosswise with 100 Nm.

z Check the correct fit of the cylinder head sealing ring.
- Measure the distance from the crankcase to the contact surface of the cylinder
head nut with a depth measuring appliance 20 on all four pin bolts.
- The measuring results may not deviate by more than 0.1 mm.
- In case of greater deviations, lift the cylinder head and eliminate the cause.
for installation of one cylinder head:
z Loosen cylinder head nuts approx. 1 notch (approx. 60°).

z Tighten charge mixture pipe with gasket on at least two adjacent cylinder heads with
30 Nm.
A 17

TCG 2020
W 1-4-4
z Align the cylinder head.
The cylinder head is aligned without the gasket of the charge mixture pipe.
- Turn in the screws 21.

- Align the cylinder head parallel to the charge mixture pipe by turning in the screws
21. To do this, turn in the screw at the bigger gap dimension until the gap is par-
allel.
- Unscrew screws.
- Check the parallelism of the gap with feeler gauges 22.
- Determine the gap dimension with feeler gauges (alternatively the shims can be
used to determine the gap dimension).
A 18
z Determine the necessary shim thickness 23.

- Determined gap dimension plus 0.1 mm.
Example:
Determined gap dimension 1.6 mm
+ 0.1 mm
Required shim thickness 1.7 mm
z Loosen the charge mixture pipe on the adjacent cylinder heads until the shims of the
required thickness can be pushed in.
z Tighten the charge mixture pipe on the adjacent cylinder heads with 30 Nm.
- This presses the cylinder head towards the V-chamber.
z Tighten the cylinder head nuts crosswise with 100 Nm.
z Remove the shims and unscrew the screws 21 of the charge mixture pipe.
z Mount the gasket of the charge mixture pipe and tighten the screws 21.

TCG 2020
W 1-4-4
for installation of several cylinder heads:
At least three cylinder heads must be installed next to each other, whereby two of them are
used for fastening the charge mixture pipe.
z Tighten the cylinder head nuts crosswise with 100 Nm on two cylinder heads.
z Loosen cylinder head nuts of another cylinder head approx. 1 notch (approx. 60°).
z Mount the charge mixture pipe with gasket in the two cylinder heads which have not
been loosened and tighten with 30 Nm.
z Align and tighten the cylinder head as described in the single installation.
Repeat the process until all cylinder heads have been mounted.
Tighten the cylinder head with the hydraulic tool
z Mount the hydraulic element on the pin bolt and tighten.
Danger of destroying the cylinder head !

Make sure the support pipe fits properly. The flattened end of the support pipe 10
must be flush with the edge of the cylinder head.
z Check whether the pin wrench is jammed with the lathe mandrel 11 through the assem-
bly opening.
- If the pin wrench is jammed, is touching the cylinder head nut, loosen the hydraulic
element and tighten again.
z Turn the hydraulic element back one quarter turn.
ceeded.
z Mount three other hydraulic elements accordingly.

z Connect hydraulic elements to the pump by high pressure hoses and distributors.
Only all four hydraulic elements may be pressurized at the same time mounted !
up.
stroyed.
z Apply pressure to the hydraulic system - 1st step.

z Insert the lathe mandrel in the pin wrench and tighten all nuts hand tight.
- All nuts must be tightenable by the same angle.
TCG 2020
W 1-4-4

ements.
z Apply pressure to the hydraulic system - 2nd step.
- drain pressure,

ements.
A 19
z Insert the stop rods 5.

z Coat valve bridges 4 with lube oil and insert.

TCG 2020
W 1-4-4
A 20
z Measure screw of toggle lever block and renew if necessary.

z Insert rocker arm block with rocker arm.
Make sure that the ball heads of the rocker arms are in the pushrods.
z Tighten screw 3.
z Checking and adjusting inlet and outlet valve clearance - see job card B 1-1-1.
- Tighten screws.
z Tighten all the screws of the charge mixture pipe.
z Install exhaust pipe - see job card W 6-1-9.
A 21
z Insert coolant pipe 2 in coolant overflows.

z Insert top part of the fastening clips.
TCG 2020
W 1-4-4
z Tighten screws (arrows).

z Mount coolant line on coolant pipe 2.
z Install multifunction bar.
z Install spark plugs.
z Connect all cable set plugs.
z Fill up cooling system - see job card B 9-0-4.

TCG 2020
W 1-4-4

TCG 2020
W 1-4-6
Overhauling cylinder head
Tools
- Welding gear
- Press
- Knocking hammer
- Drilling machine
- Thread cutter
- Spark plug key
- Press-in pin for inlet and outlet valve seat ring
- Press-out pin for valve stem guide
- Press-in pin for valve stem guide
- Assembly lever for valve spring
Auxiliary materials
- Liquid nitrogen
Spare parts
- Sealing rings
- Inlet and outlet valve seat rings
- Inlet and outlet valves
- Inlet and outlet valve stem guides
- Guide bolts for valve bridges
- Spark plug protective tube
- poss. valve barring gears
- poss. valve springs
- poss. valve clamping cone
- poss. spring plate
References
- W 0-3-1 Use of liquid nitrogen
- W 1-4-4 Removing and installing cylinder head
- W 1-10-2 Removing and installing the spark plug protective tube
Technical data

M27x2 200 Nm

TCG 2020
W 1-4-6
- see chapter 8, nominal and wear dimensions
General information
The cylinder head is removed and cleaned.
New valves, valve seat rings and valve stem guides must always be installed when over-
hauling the cylinder head.
Dismantling the cylinder head
Removing inlet and outlet valves
Risk of injury !
The component is under spring pressure.
A1
z Install assembly lever for valve springs.

z Press down the valve spring plate with assembly lever.
z Remove the valve clamping cone.
z Release the tension on the valve spring carefully.
z Remove valve spring plate, valve spring and valve barring gear or spacer disc.
z Remove assembly lever for valve springs.
z Turn cylinder head 180°.
z Pull valve out of valve guide.
z Remove all the other valves accordingly.
Removing valve seat ring
z Unscrew valve head about 5 mm.

z Insert valve in cylinder head.
TCG 2020
W 1-4-6
A2
When welding (arrow), do not weld the valve to the valve seat ring.
z Weld seam (arrow) to valve seat ring.

- Welding electrode diameter 2 mm
- Current strength maximum 130 Ampere
Do not set a higher current, or damage may occur to the cylinder head.

z Remove the valve seat ring from the cylinder head by hitting the valve stem.
Removing valve guide
A3
z Place cylinder head under the press.

TCG 2020
W 1-4-6
z Press the valve stem guide out of the cylinder head with the press-out pin.
Note the press-out direction.

The valve guide must be pressed out in the direction of the combustion chamber.
Removing the guide bolts for valve bridges
The work steps are described on the guide bolt.

Proceed accordingly if the cylinder pin is renewed.
z Centre punch the guide bolt.
A4
z Drill out the guide bolt.
A5
z Cut the thread in the guide bolt.

TCG 2020
W 1-4-6
A6
z Turn the hammer into the thread.

z Knock the guide bolt out of the cylinder head.
Checking cylinder head
The dismantled cylinder head must be checked for various criteria.

These include visual inspection, tear testing and leak testing.
z Clean and check all components.

TCG 2020
W 1-4-6
Assembling the cylinder head
Installing guide bolts for valve bridges
A7
z Cool guide bolts in liquid nitrogen.

z Dry guide bolts, i.e. without oil, then insert into the holding bore of the cylinder head.
Do not force it in.
Observe installation dimension X.
Installing valve guide
The valve stem guide is nitrided and may never be reworked !
Since the sealing ring in the valve stem guide may also be supercooled, the valve may not
be inserted until the valve stem guide has heated up to room temperature.
The protrusion dimension X must be observed when pressing in the valve stem guide.
Use the press-in pin for this.

TCG 2020
W 1-4-6
A8
z Supercool the valve guide in nitrogen.

z Insert valve stem guide with press-in pin in the cylinder head.
Pay attention to the position of the sealing ring 1.
z Press in the valve stem guide until it is touching the cylinder head.
Installing valve seat ring
To guarantee a permanent firm seat in the cylinder head, the valve seat ring must be
pressed with a force of 12,000 N (1200 kp) for at least 15 seconds.
z Supercool the valve seat ring with nitrogen.

z Place cylinder head under the press.
z Insert valve seat ring in cylinder head.
z Press valve seat ring into cylinder head.
Installing inlet and outlet valves
z Wet the valve stem and valve stem guide with lube oil.
z Insert valve in cylinder head.
Do not damage the sealing ring in the valve stem guide.

z Install assembly lever for valve springs.
z Insert the valve barring gear or spacer disc, valve spring and valve spring plate.

TCG 2020
W 1-4-6
A9
z Press down the valve spring plate with assembly lever.

z Insert valve clamping cone 1 and 2.
Make sure the valve clamping cone fits properly.
Never release the tension on the valve spring plate if the valve clamping cone 1 is
not sitting correctly in the valve stem.
z Relieve the tension on the assembly levers for valve springs carefully.
z Remove assembly lever for valve springs.
z Install all the other valves accordingly.
z Mount cylinder head - see job card W 1-4-4.

TCG 2020
W 1-10-2
Removing and installing the spark plug protective tube
Tools
- Spark plug key
Spare parts
- Sealing rings
- Spark plug protective tube
References
- W 1-2-2 Removing and installing rocker arm and rocker arm block
Technical data

M27x2 200 Nm
General information
The seal between the protective tube and the cylinder head is made by chamfering the pro-
tective tube.
The protective tube must be renewed every time it is removed.
Removing the spark plug protective tube

z Remove the rocker arm and the rocker arm block - see job card W 1-2-2.
A1

TCG 2020
W 1-10-2
z Remove valve bridges 1.
A2
z Remove O-ring, sealing ring and compression spring (arrow).

Risk of injury !
A3
z Unscrew the spark plug protective tube 2.
Make sure that no coolant runs into the combustion chamber.

TCG 2020
W 1-10-2
Installing the spark plug protective tube
A4
z Renew the sealing rings (arrow).

z Wet the sealing rings (arrows) with acid-free grease.
z Insert and tighten new protective tube.
z Install compression spring, sealing ring and O-ring.
z Place valve bridges on guide bolts.
z Install the rocker arm and the rocker arm block - see job card W 1-2-2.

TCG 2020
W 1-10-2

TCG 2020
W 2-0-1
Safety regulations for drive unit work
General information
Before starting work
z Stop the engine and secure against restarting.

z Danger of burns!
- If necessary, drain lube oil or coolant and collect for re-use.
- Do not perform other drive unit work until the engine is sufficiently cool.
- When working on the exhaust system, remember that components may still be hot
despite a long cooling time.
z Wear protective glasses and gloves!
- Heat guards may have sharp edges.
z Do not start work until enough time has been allowed for ventilation.
z Make sure that the environment in which the engine is opened is clean.
During work
z Make sure no dirt gets into the crankcase.

z Before turning the crankshaft, check that
- the turning gear is properly engaged.
- no persons are working in or on the engine.
- no tools obstruct turning of the crankshaft, as this could result in damage.
- the drive unit is not unbalanced by the removal of parts of the drive unit.
z Make sure the crankshaft cannot be turned unintentionally.

TCG 2020
W 2-0-1
After finishing work
z Check that all tools, cleaning cloths etc. have been removed from the crankcase.
z Turn over the engine with spark plugs removed before commissioning.
z Install spark plugs with new sealing rings.
z Pour in lube oil.
z Top up coolant.
z Start engine and check components for leaks.

TCG 2020
W 2-1-0
Drive gear inspection
Tools
- Temperature measuring instrument (e.g. infrared temperature measuring instru-
ment)
- Engine turning gear
General information
Pay attention to the piston cooling nozzle when working on the crankcase.
If the piston cooling nozzle is not OK, the complete piston cooling nozzle unit must be re-
newed. Rebending is not permitted.
Carrying out a drive gear inspection
z Remove the hatch cover from the crankcase.

- Only cylinder side A (remove starter if necessary)
Check the storage temperature
z Measure the temperature of all con rods on the short con rod arm in the area of the
joint and the temperature of the main bearing at the joint with the crankcase.
- Permissible temperature differences max. 5°C.
Carrying out clearance check of the con rods
z The con rods must move easily on the crank pin.
Visually inspecting the crankcase
z Pay attention to metal particles in the crankcase, leaked bearing metal or other irregu-
larities.
z Check for corrosion and water leaks.
Checking the lube oil supply

z Switch on pre-lubrication pump.
z Check whether lube oil emerges visibly from all bearing points of the crankshaft.
z Check whether lube oil emerges visibly from all bearing points of the valve drive.
z Set the pre-lube pump to Automatic.
z Mount the hatch cover on the crankcase.

TCG 2020
W 2-1-0

TCG 2020
W 2-1-4
Checking crankshaft axial clearance
Tools
- Internal measuring device
- Micrometer gauge
- Mounting iron
- Magnetic measuring stand with dial gauge.
Technical data
Crankshaft bearing clearance (Axial)

Wear limit 0.5 mm
General information
The axial clearance can be determined with the crankschaft installed.
If the crankshaft axial clearance is exceeded, the wearing rings must be renewed. Use the
appropriate thickness when renewing the wearing rings.
Checking crankshaft axial clearance
Crankshaft installed
z Remove flywheel guard if present.

z Attach magnetic measuring stand and insert dial gauge.
z Using the mounting iron, press flywheel to stop in the direction of the drive side.
z Adjust dial gauge to 0.
z Using the mounting iron, press flywheel to stop in the direction of the free side.
z Read the dial gauge.
Repeat the measurement several times and compare the measured values.
z Remove magnetic measuring stand and dial gauge.

z Install flywheel guard if present.

TCG 2020
W 2-1-4

TCG 2020
W 2-1-6
Checking bearing shells
Tools
- Caliper gauge
References
- Service Information System (Global SIS)
Technical data
Main bearing shell (Spread)

Big end bearing shell (Spread)

General information
Run bearing shells exhibit different running profiles depending on the number of operating
hours and operating conditions. The basic differences can often only be detected by trained
personnel. If in doubt, we recommend that you contact your service partner for an evalua-
tion.
Further information can be found in the Global SIS in the SD - Special Documentation sec-
tion.

TCG 2020
W 2-1-6
Checking bearing spread
z All components are removed and cleaned.
A1
1 Bearing spread
2 Bearing shell outer diameter
z Measure bearing spread 1 with caliper gauge.
The bearing spread 1 is always greater than the bearing shell outer diameter 2.
Correction of the bearing shell is not permissible.
Renew the bearing shells if the measured dimensions deviate from the nominal dimen-
sions.

TCG 2020
W 2-1-7
Checking crankcase
Tools
- Micrometer gauge
- Prisms
- Magnetic measuring stand with dial gauge.
Auxiliary material
- Cleaning agents
References
- W 0-3-2 Tear inspection by diffusion liquid method
Technical data
Data on tightening specifications, dimensions, position and form tolerances can be found
in chapter 8, Technical Data.
The technical test specifications listed in the text 0162 0000

0162 0022
0162 0030
can be found in the appendix, Technical Test Specifications.
Counterweight on crankshaft
M20x2x120 - 10.9 1. Stage 150 Nm
2. Stage 60°
Coat threads and screw head contact surfaces with lubricant.
Check with minimum inspection tightening torque 460 Nm !
General information
In case of slight running marks at the bearing points, it is possible to have the crankshaft
polished at our service centres.
Regrinding of the bearing points is not permissible.
Realigning the crankshaft is not permissible.
If a nominal value of a component is not observed, the component must be renewed.

TCG 2020
W 2-1-7
If the counterweights of the crankshaft need to be removed, the screws must be renewed.
Pay attention to the numbering, positioning and tightening torques when installing the coun-
terweights.
Checking crankcase
Cleaning
z Remove crankshaft - see job card W 2-4-1.
A1
z Cleaning the crankshaft.

- Remove oil
- Wash off with cleaning agent - see chapter 4.
z Blow crankshaft dry with compressed air.
z Rub the bearing points dry thoroughly with rags.
Tear test
z Carry out tear test by magnetic test method according to test specification 0162 0000
or diffusion liquid method - see job card W 0-3-2.
z Check the running surfaces of the main bearing pin for marks.
z Check the running surfaces of the lifting journal for marks.
Checking roundness
The roundness of main bearing pin and lifting journal must be checked according to the
Technical Test Specification 0162 0022.

TCG 2020
W 2-1-7
Checking the bearing pin
Mounting
A2
z Mount the crankshaft fixed on the outer main bearing pins and additionally on at least
two inner main bearing pins with floating prisms.
z Max. difference in height of the bearing points 0.01 mm.

TCG 2020
W 2-1-7
Diameter of the bearing pins
Do not measure in the area of the lubricating oil bores.
A3
z Measuring schematic of the main bearing pin diameter at points a and b in the levels 1
and 2.
A4
z Measuring schematic of the lifting journal diameter at points a and b in the levels 1, 2,
3 and 4.

TCG 2020
W 2-1-7
A5
z Measure diameter with micrometer gauge.
Straightness of the bearing pins
A6
A7
z Attach magnetic measuring stand and insert dial.

z Place the stylus on the bearing pin under pre-tension.
z Move the dial gauge (arrow).
TCG 2020
W 2-1-7
z Check parallelism.
z Mount the dial gauge on all other bearing pins.
z Repeat procedure.
Run-out of the bearing pins
A8

z Turn the crankshaft.
z Check the runout.
z Mount the dial gauge on all remaining bearing pins.
z Repeat procedure.

TCG 2020
W 2-1-7
Special feature of the lifting journal
A9
z Do not turn the crankshaft but make the measurement once at three o'clock and once
at zero hundred hours.
z Repeat procedure.
Check parallelism

The parallelism of the main bearing and pin bearings to each other and the pin bearing and
main bearing in relation to each other must be checked!
Do NOT readjust the dial gauge for measurements!
A 10
z Attach magnetic measuring stand and insert dial at the first main bearing pin.
z Mount the dial gauge on all remaining main bearing pins (arrow).

TCG 2020
W 2-1-7
A 11
z Turn the lifting journal respectively to the measuring position.

z Repeat the measurement with all lifting journals.

TCG 2020
W 2-2-1
Removing and installing ball race (drive side)
Tools
Auxiliary material
- DW 62
- Cleaning agents
Spare parts
- Ball race
- Crankshaft sealing ring
References
- W 2-2-2 Removing and installing crankshaft sealing ring (drive side)
- W 2-2-9 Removing and installing flywheel flange
- W 12-6-1 Removing and installing the flywheel
General information
In case of a leaking crankshaft sealing ring, check whether a groove has been scored in the
ball race.
The ball race must be renewed if it is too heavily worn.
The shaft sealing ring must always be renewed when the ball race is renewed.
Removing the ball race (drive side)
z Remove flywheel - see job card W 12-6-1.

z Remove flywheel flange - see job card W 2-2-9.
A1
z Remove ball race from flange.

TCG 2020
W 2-2-1
Separate ball race in longitudinal crankshaft direction with a flat chisel if necessary.
Do not damage the flange.
Installing the ball race (drive side)
A2
The components must be free of oil and grease.
z Wet the contact surface of the ball race on the flange with locking agent.
z Heat up the ball race to150 - 160 °C.
z Mount the ball race on the flange.
- Until touching the flange.
The components must join without using force.
z Install flywheel flange - see job card W 2-2-9.

z Install flywheel - see job card W 12-6-1.

TCG 2020
W 2-2-2
Removing and installing crankshaft sealing ring (drive side)
Tools
- Angled wrench
- Guide pins for flywheel flange
Auxiliary material
- DW 75
Spare parts
- Gasket
References
- W 2-2-1 Removing and installing ball race (drive side)
- W 2-2-9 Removing and installing flywheel flange
Technical data

M8x20/25/50 - 8.8 25 Nm
General information
ball race.
Remove and install ball race (drive side) - see job card W 2-2-1.
If the rear cover is removed the crankshaft sealing ring must always be renewed.

TCG 2020
W 2-2-2
Removing crankshaft sealing ring

z Remove flywheel flange - see job card W 2-2-9.
Do not damage the crankshaft and rear cover.
Do not damage the sealing surfaces.
A1
z Unscrew screws (arrows).

z Remove rear cover.
- Position 1.
z Remove crankshaft sealing ring with a suitable tool.
- Position 2.
z Check the running surfaces of the ball race for marks.
- Renew ball race if necessary.

TCG 2020
W 2-2-2
Installing crankshaft sealing ring
The crankshaft sealing ring must be installed evenly and without skew.

z Clean all sealing surfaces.
z Wet the outside of the crankshaft sealing ring with locking agent.
A2
z Install crankshaft sealing ring with a suitable tool.

- Until touching the edge of the cover (arrow).
A3
z Renew gasket.
z Apply sealant to the crankcase in the area of the lube oil tray.
z Mount rear cover.
- Position 1.
TCG 2020
W 2-2-2
z Screw in screws (arrows) evenly.

Wet the sealing lip of the crankshaft sealing ring with lube oil, never use grease.


TCG 2020
W 2-2-3
Removing and installing ball race (free side)
Tools
Auxiliary material
- DW 62
- Cleaning agents
Spare parts
- Ball race
References
- W 2-2-4 Removing and installing crankshaft sealing ring (free side)
- W 12-1-4 Removing and installing torsional vibration dampers (V20 engine)
Technical data

M27x2x195 - 10.9 1. Stage 300 Nm
2. Stage 600 Nm
3. Stage 60°
4. Stage 30°
General information
ball race.
The shaft sealing ring must always be renewed when the ball race is renewed.
Removing ball race (free side)
z Remove torsional vibration damper - see job card W 12-1-4.

z Remove flange from crankshaft.

TCG 2020
W 2-2-3
A1
z Remove ball race 1 from flange 2.
Separate ball race in longitudinal crankshaft direction with a flat chisel if necessary.
Do not damage the flange.
Installing ball race (free side)
A2
z Wet the contact surface of the ball race on the flange with locking agent.
z Heat up the ball race to150 - 160 °C.
TCG 2020
W 2-2-3
z Mount ball race 1 on flange 2.

- Until touching the flange.
The components must join without using force.
z Mount flange.
z Install crankshaft sealing ring (free side) - see job card W 2-2-4.
z Install torsional vibration damper - see job card W 12-1-4.

TCG 2020
W 2-2-3

TCG 2020
W 2-2-4
Removing and installing crankshaft sealing ring (free side)
Tools
Auxiliary material
- DW 75
Spare parts
References
Technical data

M27x2x195 - 10.9 1. Stage 300 Nm
2. Stage 600 Nm
3. Stage 60°
4. Stage 30°
General information
ball race.
The installation position of the sealing ring is determined by the step in the front cover.
There is no possibility for installing the sealing ring in different positions.

TCG 2020
W 2-2-4
Removing crankshaft sealing ring
z Remove torsional vibration damper - see job card W 12-1-4.

- Unscrew screws (arrows).
A1
z Remove flange torsional vibration damper.
A2
z Loosen crankshaft sealing ring in its seat using a mandrel.

- Position 1.
z Lever out crankshaft sealing ring with suitable tool, e.g. assembly lever.

TCG 2020
W 2-2-4
Installing crankshaft sealing ring
The installation position of the sealing ring is determined by the step in the front cover.
Press in the sealing ring to the stop (arrows) in the gear housing cover.
A3
z Apply sealant.
z Install crankshaft sealing ring.
- Position 1.
A4
z Insert flange torsional vibration damper.

z Install torsional vibration damper - see job card W 12-1-4.
- Tighten screws (arrows).

TCG 2020
W 2-2-4

TCG 2020
W 2-2-9
Removing and installing flywheel flange
Tools
- Torque wrench
- Guide pins for flywheel flange
- Force multiplier
- Pin wrench insert (12-edge)
- Stop for force multiplier
Auxiliary material
- Lube oil
Spare parts
- Screws
- poss. intermediate ring
- poss. flywheel flange
References
Technical data

2. Stage 160 Nm
3. Stage 280 Nm
Flywheel flange on crankshaft

Observe tightening order !
Tighten screws in the order 1, 6, 2, 7, 3, 8, 4, 9, 5, 10.
Assignment of screws - see job card W 2-2-9.
(renew screws) M27x2x140 - 12.9 1. Stage 100 Nm
2. Stage 300 Nm
3. Stage 120°

TCG 2020
W 2-2-9
General information
The job card describes removal and installation with 12-edge screws.
If the version with hexagon head screws is installed on the flange, this must be converted
to 12-edge screws with an intermediate ring.
See also SM 0122-05-6534/0.
The flange surfaces must be oil and grease free during installation to ensure trans-
mission of the torque prescribed for surface pressing.
It is essential to observe the tightening order to avoid consequential damage.
A1
The screws are numbered clockwise in the job card for better understanding.
The screws, the intermediate ring and the flywheel flange must be marked accordingly be-
fore removing to be able to assign them correctly in the later component analysis.
The screws for fastening the flywheel flange may only be used once and must be renewed
for every assembly.
Suitable cleaning agents can be found in chapter 4, Auxiliary materials.
Visually inspect all parts.
If wear is detected, the components must be renewed.

TCG 2020
W 2-2-9
Removing the flywheel flange
A2
z Install stop for force multiplier
A3
z Fit pin wrench insert (12-edge) and force multiplier.
The clip of the force multiplier must be flush with the stop.
z Loosen screws.
z Remove stop for force multiplier.
z Unscrew and remove screws.

TCG 2020
W 2-2-9
A4
z Remove intermediate ring.
A5
z Turn in the guide pins.
Leave screw holes 1, 4 and 7 free for installation when inserting the guide pins.

TCG 2020
W 2-2-9
A6
z Remove flywheel flange.

z Clean components, check and renew if necessary.
Installing the flywheel flange
Clean and check the threaded bores in crankshaft.

The flange faces of the crankshaft and flywheel flange must be free from oil and grease.
A7
z Mount the flywheel flange.
Make sure that the clamping pin in the flywheel flange is in line with the hole in the flywheel.

TCG 2020
W 2-2-9
A8
z Insert intermediate ring.
A9
z Insert and tighten screws dry.

- Screw position 1, 4 and 7.
- Tighten screws according to technical specification, 1st step.
z Unscrew guide pins.
z Wet the other screws with lube oil.
z Screw in and tighten screws.
- Screw position 2, 3, 5, 6, 8, 9 and 10.

TCG 2020
W 2-2-9
A 10
z Unscrew screws.
z Wet screws with lube oil.
z Tighten screws.
- All screws in the order 1, 6, 2, 7, 3 ,8, 4, 9, 5 ,10.
- Tighten screws according to technical specification, 2nd step.
A 11
The markings on the screw neck correspond to a tightening angle of 60 degrees.
z Mark screw on neck.

TCG 2020
W 2-2-9
z Mark position of screw in relation to flywheel flange.
A 12
z Install stop for force multiplier
A 13
z Fit pin wrench insert (12-edge) and force multiplier.
The clip of the force multiplier must be flush with the stop.
z Tighten screws.
- All screws in the order 1, 6, 2, 7, 3 ,8, 4, 9, 5 ,10.
- Tighten screws according to technical specification, 3rd step.
z Mark screw with oil-resistant paint after tightening.
z Remove stop for force multiplier.

TCG 2020
W 2-3-3
Remove and install con rod liner
Tools
- Circlip pliers
- Micrometer gauge
- Dial gauge
- Disassembly device for con rod liner
Auxiliary material
- Liquid nitrogen
References
- W 2-9-3 Removing and installing piston with con rod
Technical data
- see chapter 8, nominal and wear dimensions
Con rod liner bore

Diameter Nominal dimension 73.000 - 73.025 mm
Con rod liner bearing clearance

Wear limit 0.120 mm
General information
All components are removed and cleaned.
The installation procedure must take place rapidly due to the necessary temperature differ-
ence of the individual components. For this reason, we recommend that you read this job
card carefully and practise the necessary actions before installation.
Risk of injury !

TCG 2020
W 2-3-3
Removing the con rod liner
z Remove the piston with con rod - see job card W 2-9-3.
z Remove the con rod liner - see job card W 2-9-7.
A1
Grind a continuous groove of approx. 2.5 mm on the long side of the con rod liner to loosen
the con rod liner.
Do not damage the con rod.
z Place the disassembly device so that the liner can be pressed down and out.
A2
z Insert the con rod in the disassembly device.
Pay attention to the correct resting and position of the con rod in the disassembly device.

TCG 2020
W 2-3-3
Knocking out the con rod is not permitted.
z Fix the con rod by screwing the pin 3 into the lube oil bore.
z Press the con rod liner out by turning the spindle 4.

Installing the con rod liner
When inserting the supercooled con rod liner in the con rod, pay careful attention to the po-
sitioning of the lube oil bore.
It is not permissible to press in the con rod liner with the disassembly device.
z Supercool con rod liner in liquid nitrogen.

z Insert the con rod liner dry, i.e. without lubricant, in the con rod without using force.
z Position the con rod liner.
- Pay attention to the lube oil bore.
- Align the con rod liner in the centre.
z Check the diameter of the con rod liner - see chapter 8, Technical Data.
z Check the smooth action of the piston bolt in the con rod liner.
The con rod liner is ready to install and may not be reworked after shrinking in.
z Mount the con rod on the piston - see job card W 2-9-7.
z Install the piston with con rod - see job card W 2-9-3.

TCG 2020
W 2-3-3

TCG 2020
W 2-4-1
Removing and installing crankshaft
Tools
- Torque wrench
- Hydraulic tool MOCK / LERBS
- 1x 1206 7448
- Hydraulic tool SCHAAF
- 1x 1230 0218 or
- 1x 1230 5662 (service variant)
Auxiliary material
- Lube oil
- Lifting gear
Spare parts
- Gasket
- Nuts for main bearing if necessary (required amount)
References
- W 0-0-5 Safety regulations for hydraulic clamping device
- W 2-1-6 Checking bearing shells
- W 3-5-1 Removing and installing lube oil tray
- W 3-9-1 Removing and installing rear cover (drive side)
- W 4-4-9 Removing and installing gear housing cover
- W 4-4-11 Checking and measuring control times
- W 8-4-5 Removing and installing lubricating oil pump

TCG 2020
W 2-4-1
Technical data
Main bearing fastening, installation specification

Always loosen main bearing nuts from the outside in-
wards (1).
Always tighten main bearing nuts from the inside out-
wards (2).
Always tighten cross screw connection first on the right
side in the order L1, L2, L3 etc..
Loosen the main bearing cover

Loosen cross screw connection on the left side (cylinder row A)
Loosen cross screw connection on the right side (cylinder row B)
Unscrew and remove all cross screw connections
Mount clamping device until touching - then loosen one and a half turns
Build up pressure Mock 1221 7448 (HV 1999/2) 1360 bar
Schaaf 1230 0218 or 1230 5662 (A 4171 0000) 2350 bar
Loosen main bearing nuts Mock Turn out 5 holes 300 °
Schaaf Turn out 6 holes 300 °
Tighten main bearing cover
Pre-tighten main bearing nuts 30 Nm
Insert and tighten all cross screw connections
Tighten cross screw connection on the right side (cylinder row B) 30 Nm
Tighten cross screw connection on the left side (cylinder row A) 30 Nm
Mount clamping device until touching - then loosen 1/4 turn
Schaaf 1230 0218 or 1230 5662 (A 4171 0000) 400 bar
Tighten main bearing nuts hand tight, all main bearing nuts must be tightenable by the
same amount
Schaaf 1230 0218 or 1230 5662 (A 4171 0000) 2350 bar
Tighten main bearing nuts hand tight, all main bearing nuts must be tightenable by the
same amount
Tighten cross screw connection on the right side (cylinder row B) 200 Nm
Tighten cross screw connection on the left side (cylinder row A) 200 Nm
Retighten cross screw connection on the right side (cylinder row B) 120 °
Retighten cross screw connection on the left side (cylinder row A) 120 °

TCG 2020
W 2-4-1
General information
Observe the order of work strictly to avoid damage.
The pressures of the different tools must be observed.
Risk of injury !
The safety regulations for the hydraulic clamping device must be observed - see job
card W-0-0-5.
All maintenance work on the clamping device must be performed according to man-
ufacturer specifications, the operating manual must also be observed.
Correct loosening and tightening of the main bearing nuts is only possible with the hydraulic
clamping device.
To avoid jamming of the crankshaft, the main bearing nuts must be tightened in several
steps.
If the first main bearing on the free side is to be rmoved, the lube oil pump must be removed.
To make the work easier, it is an advantage to clamp the crankcase in a rotary vice and turn
it 180°.
Removing crankshaft
z Remove lube oil tray - see job card W 3-5-1.

z in V20 engines
- Remove torsional vibration damper - see job card W 12-1-4.
z Remove gear housing cover - see job card W 4-4-9.
z Remove the flywheel flange.
z Remove lube oil pump - see job card W 8-4-5.
z Remove rear cover (drive side) - see job card W 3-9-1.
The cross screw connection is always loosened on the left side first (cylinder side A).
z Unscrew cross screw connection on the left hand side (cylinder side A).
z Unscrew cross screw connection on the right hand side (cylinder side B).

TCG 2020
W 2-4-1
Loosen the main bearing nuts with the hydraulic tool
A1
z Unscrew screw 1.
z Remove intermediate gear 2.
A2
The hydraulic die consists of two individual components.

Hydraulic element 3
Support tube 4

TCG 2020
W 2-4-1
A3
z Clean the pin bolts and coat with lube oil.
Do not use Molykote !
z Mount the support tube 4 on the main bearing cover and fix.
Make sure that the support tube is not jammed on the main bearing nut.
A4
z Mount the hydraulic element on the pin bolts and tighten.

z Turn the hydraulic element back one and a half turns.

TCG 2020
W 2-4-1
ceeded.
z Mount second hydraulic element as described above.

z Connect both hydraulic elements to the pump with high pressure hoses.
Only both hydraulic elements may be pressurized at the same time mounted.
z Apply pressure to the hydraulic system.
A5
up.
stroyed.
A6

TCG 2020
W 2-4-1
z Insert the lathe mandrel 7 in the pin wrench and loosen the main bearing nuts.
- drain pressure,

ements.
z Unscrew the main bearing nuts from the pin bolts and remove together with the wash-
ers.
A7
z Remove main bearing cover 8.

- Loosen main bearing cover if necessary by hitting lightly with a plastic hammer.
Do not damage the components.
z Remove the main bearing shells from the main bearing covers.
z Remove fit bearing cover with wearing ring halves.
Lay out all the components according to the installation position, note the identification.

TCG 2020
W 2-4-1
A8
z Hang the crankshaft 9 with hoist unit on crane.

z Remove crankshaft 9.
A9
z Remove wearing ring halves (arrows) and all bearing shells.
Lay out all the components according to the installation position, note the identification.

z Check bearing shells - see job card W 2-1-6.

TCG 2020
W 2-4-1
Installing crankshaft
The rear of the bearing shells must be oil and grease free.
A 10
z Insert main bearing shell with lube oil bore in the crankcase.
- Pay attention to positioning of the torsion lock and alignment of the lube oil bore.
z Insert main bearing shell without lube oil bore in the main bearing cover.
- Pay attention to positioning of the twist protection.
A 11
z Wet wearing ring halves with lubricating oil.
The stepped edge or the lube oil groove (arrow) of the wearing ring halves must face the
crank web.

TCG 2020
W 2-4-1
z Stick the two wearing ring halves with a little grease.
A 12
z Wet the lifting journal and main bearing pin with lube oil.
z Insert crankshaft 9 in crankcase.
z Unhook hoist unit.
A 13
z Insert fit bearing and main bearing cover.
Note assignment and installation position.

Insert the main bearing cover labelled with 1 on the drive side.
The labels on the main bearing cover and the crankcase must be identical and opposite
each other in assembly.
z Insert and turn the main bearing screws and cross screw connection.

TCG 2020
W 2-4-1
The cross screw connection is always tightened on the right side (cylinder side B)
first.
z Turn over the crankshaft and check for easy action.

z Check axial clearance of the crankshaft - see job card W 2-1-4.
Tighten the main bearing nuts with the hydraulic tool
z Mount the support tube on the main bearing cover and fix.
z Mount the hydraulic element on the pin bolts and tighten.
z Turn the hydraulic element back one quarter turn.
ceeded.
z Mount second hydraulic element as described above.

z Connect both hydraulic elements to the pump with high pressure hoses.
Only both hydraulic elements may be pressurized at the same time mounted.
z Apply pressure to the hydraulic system - 1st step.

ements.
z Apply pressure to the hydraulic system - 2nd step.
- drain pressure,

ements.

TCG 2020
W 2-4-1
z Tighten cross screw connection.

- Tighten cross screw connection on the right side (cylinder row B) in the order L1,
L2, L3 etc..
- Tighten cross screw connection on the left side (cylinder row A) in the order L1,
L2, L3 etc..
z Turn over the crankshaft and check for easy action.
A 14
The control times must be set when installing the intermediate gear - see job card W 4-4-11.
z Insert intermediate gear.

z Tighten screw.
z Install rear cover (drive side) - see job card W 3-9-1.
z Install lube oil pump - see job card W 8-4-5.
z in V20 engines
- Install torsional vibration damper - see job card W 12-1-4.
z Install gear housing cover - see job card W 4-4-9.
z Install lube oil tray - see job card W 3-5-1.

TCG 2020
W 2-5-3
Removing, installing and testing big end bearing
Tools
- Angled wrench
Spare parts
- Big end bearing screws (amount - as required)
- poss. big end bearing shells (set)
- Gaskets
References
- W 2-1-6 Checking bearing shells
Technical data

2. Stage 250 Nm
3. Stage 30°
4. Stage 30°

M8x20 - 8.8 25 Nm
General information
It is possible to remove and install the big end bearing without having to remove the pistons
and the crankshaft.
This procedure is described here.
If the big end bearings are to be renewed with the piston removed - see job card W 2-9-3.

TCG 2020
W 2-5-3
A1
The identification (arrow) on the con rod and the big end bearing cover must be identical
and be opposite when assembled.
If the label is no longer legible, it must be restored by suitable means (e.g. oil-proof paint).
If the old big end bearings are to be re-installed, these must be labelled as well.
Removing the big end bearing
A2
z Turn the crankshaft until the big end bearing screws of the respective cylinder are ac-
cessible.
z Unscrew screws.
z Remove con rod bearing cover.

TCG 2020
W 2-5-3
Make sure that no components and tools fall into the lube oil tray.
When removing several big end bearings, lay the components down in order.
z Turn the crankshaft slowly until the con rod base is free from the big end bearing pin.
z Remove the upper bearing shell from the con rod.
Run bearing shells exhibit different running profiles depending on the number of operating
hours and operating conditions. The basic differences can often only be detected by trained
personnel. If in doubt, we recommend that you contact your service partner for an evalua-
tion.
Installing the big end bearing
A3
The bearing shells, the con rod and the big end bearing cover must be free of oil and grease
when assembling.
z Insert con rod bearing shells in con rods and con rod bearing covers.
z Wet big end bearing pins with lube oil.
z Turn the crankshaft slowly until the con rod base is setting in the big end bearing pin.
- Make sure that the con rod does not damage the big end bearing pin.
The con rod screws must be renewed for every assembly.
z Mount the con rod bearing cover and tighten the screws.
TCG 2020
W 2-5-3
The con rods must move easily on the crank pin.

- Remove big end bearing cover

z Tighten screws with angled wrench.


TCG 2020
W 2-9-3
Removing and installing piston with con rod
Tools
- Angled wrench
- Holding tool for piston
- Assembly pliers for piston assembly
Spare parts
- Big end bearing screws (amount - as required)
- poss. big end bearing shells (set)
- Gaskets
References
- W 2-15-2 Checking, removing and installing piston cooling nozzle
Technical data

2. Stage 250 Nm
3. Stage 30°
4. Stage 30°
Cylinder head on the crankcase


M10x1 40 Nm

M12x1.5 45 Nm

M16x1.5 - 10.9 1. Stage 30 Nm
2. Stage 120°

M8x55 / 85 25 Nm

M8x20 - 8.8 25 Nm

TCG 2020
W 2-9-3
General information
Before removing the pistons the combustion residue must be removed from the cylinder lin-
ers.
Always check the alignment of the piston cooling nozzle before installing the piston - see
job card W 2-15-2.
Removing/installing the piston with con rod
z Remove cylinder head - see job card W 1-4-4.

A1
z Turn the crankshaft until the piston of the respective cylinder is in TDC position.
z Mount holding device for piston
- Clean the thread in the piston base if necessary.
A2

TCG 2020
W 2-9-3
z Turn the crankshaft until the big end bearing screws of the respective cylinder are ac-
cessible.
z Unscrew screws.
z Remove con rod bearing cover.
Make sure that no components and tools fall into the lube oil tray.
A3
z Pull the piston with con rod out of the cylinder liner.
- When removing several cylinders, lay the components down in order.

TCG 2020
W 2-9-3
Installing piston with con rod
A4
z Insert con rod bearing shells in con rods and con rod bearing covers.
z Arrange piston ring joints offset by about 120°.
z Secure piston rings with assembly tool.
A5
Make sure that the recess in the piston is on the piston cooling nozzle side.
Note the cylinder assignment of the pistons.

Always wet the piston and the cylinder liner with lube oil. Never install the components dry.

TCG 2020
W 2-9-3
z Insert the piston with con rod into the cylinder liner until it touches the assembly tool.
- Make sure that the con rod does not damage the big end bearing pin.
z Push the piston into the cylinder liner.
- Do not damage the piston ring.
- Do not damage the piston cooling nozzle.
A6
The identification (arrow) on the con rod and the con rod bearing cover must be identical
and be opposite when assembled.
The con rod screws must be renewed for every assembly.
z Mount the con rod bearing cover and tighten the screws.
The con rods must move easily on the crank pin.

- Remove big end bearing cover

z Tighten screws with angled wrench.


TCG 2020
W 2-9-3

TCG 2020
W 2-9-7
Checking piston
Tools
- Circlip pliers
- Micrometer gauge
- Dial gauge
References
Technical data
Piston bolt bearing clearance

Wear limit 0.120 mm
Wear limit 1.000 mm
Piston
Piston bolt bore

Height
Piston bolt
External diameter
General information


TCG 2020
W 2-9-7
Checking piston
Removing piston from con rod
A1
z Remove locking ring with Seeger ring pliers.

z Push piston pin out of piston.
- place piece of wood underneath if necessary and drive out with light knocks of the
hammer.
z Remove con rod from piston.
Checking the piston bolt bore
A2
z Measuring schematic of the piston bolt bore at points a and b in the levels 1 and 2.
z Prepare and adjust internal measuring instrument.
z Measure piston pin bore with internal measuring device.
TCG 2020
W 2-9-7
Checking piston pin
A3
z Measuring schematic of the piston bolt diameter at points a and b in the levels 1, 2 and
3.
z Measure piston bolt diameter with micrometer gauge.
The clearance of the piston pin in the piston is calculated from the dimensions piston pin
bore - piston pin diameter.
Mounting piston on con rod
A4
z Install circlip with circlip pliers on one side of the piston.

- Make sure the circlip fits properly.

TCG 2020
W 2-9-7
A5
z Insert con rod in piston.
Pay attention to the position of the recess for the piston cooling nozzle.
The recess for the piston cooling nozzle is on the con rod screw side near the bolt.
The arrow mark on the piston points to the inlet side.
z Push piston bolt into piston.

z Install locking ring with Seeger ring pliers.
- Make sure the circlip fits properly.

TCG 2020
W 2-10-1
Removing, installing and checking piston rings
Tools
- Piston ring pliers
Spare parts
- poss. piston ring set
References
Technical data
Joint clearance
General information
If a piston ring is worn or defective, the complete piston ring set must be renewed (do not
renew single piston rings).
If the piston or the cylinder liner is renewed, the piston rings must always be renewed.
The piston rings may only be removed and installed with the listed piston ring pliers, other-
wise the piston rings may be overstretched.

TCG 2020
W 2-10-1
Removing piston rings
A1
z Remove piston rings with piston ring pliers.
Cleaning pistons
A2
z Clean pistons and piston ring grooves

- Select cleaning fluid - see operating manual chapter 4.
- Place piston in cleaning fluid (see manufacturer's instructions for exposure time).
The piston ring groove has a steel mounting ring.

The piston ring grooves 2 and 3 are machined directly in the piston. Clean carefully here so
that no piston material is worn away.

TCG 2020
W 2-10-1
Checking the piston ring joint clearance
A3
Do not check the piston ring joint clearance in wear area 5, or the wear on the cylinder liner
will measured at the same time.
Insert piston rings in the wear-free area 6.
z Clean cylinder liner.
A4
z Insert piston ring in cylinder liner.

- Insert piston ring horizontally, do not jam.
z Check joint clearance with feeler gauge.

TCG 2020
W 2-10-1
Installing piston rings.
A5
z Install hose spring 4 in piston.

- Assemble hose spring 4.
z Mount piston rings 3 on piston with piston ring pliers.
- Move the joint 7 of the hose spring 180° to joint 8 of the piston ring.
A6
z Mount piston rings 2 and 1 on piston with piston ring pliers.
The TOP label must face the bottom of the piston.

TCG 2020
W 2-10-1
A7
z Align piston ring joints.

- Offset the joint of piston rings 1, 2 and 3 by 120° to each other.

TCG 2020
W 2-10-1

TCG 2020
W 2-15-2
Checking, removing and installing piston cooling nozzle
Tools
- Torque wrench
- Inspection device for piston cooling nozzle
Spare parts
- gasket piston cooling nozzle unit, if necessary
- piston cooling nozzle unit, if necessary
References
Technical data
Piston cooling nozzle on crankcase

M8x50 - 10.9 25 Nm
General information
Danger of destruction of the piston cooling nozzle!

If the piston cooling nozzle is not in order, it must be renewed. Rebending the piston
cooling nozzle is not permissible.
Use of a test pin is not permitted. The precision nozzle may be damaged by inserting the
test pin.
The piston cooling nozzle should be checked whenever the accessibility allows.
The alignment is important because piston cooling is not fully guaranteed if the lubricating
oil jet is incorrect and the engine may be destroyed as a result.

TCG 2020
W 2-15-2
Checking the piston cooling nozzle
A1
z Screw the positioning pin 2 into the inspection device 1.

A2
z Insert inspection device in cylinder liner.

- Make sure the positioning pin is in the right place in the coolant channel.

TCG 2020
W 2-15-2
A3
z Check alignment of the piston cooling nozzle.

- The piston cooling nozzle must be in the centre of the bore. It may not be at the
edge of the bore.
Removing piston cooling nozzle
A4
z Unscrew screws 3.
z Remove piston cooling nozzle unit 4 with gasket.
- The crankshaft is removed for clarity.

TCG 2020
W 2-15-2
Installing the piston cooling nozzle

z Mount piston cooling nozzle unit with gasket.
z Tighten screws 3.
- Pay attention to the fixing pin.
Check the alignment of the piston cooling nozzle after installing a new piston cooling nozzle
unit.

TCG 2020
W 3-3-1
Checking cylinder liner
Tools
- Micrometer gauge
- Dial gauge
Auxiliary material
- Commercially available grinding paste
Spare parts
- Cylinder liner if necessary
- Sealing rings
References
- W 3-3-2 Removing and installing cylinder liner
Technical data
Outer diameter top

Internal diameter
Height of collar

Wear limit 0.051 mm
General information
Run cylinder liners exhibit different running appearances depending on the number of op-
erating hours and operating conditions. The basic differences can often only be recognised
by trained experts. In cases of doubt we recommend you to consult your service partner for
assessment.
If the cylinder liner is renewed, the piston rings must always be renewed.
Regrinding of the cylinder liner is not permissible.
TCG 2020
W 3-3-1
Checking cylinder liner
The cylinder liner must be installed in the crankcase for the measurement.
It is possible to measure the cylinder liner with the piston installed.
The test dimension of measuring level 4 is omitted.
A1
z Measuring schematic of the cylinder liner at points a and b in the levels 1 - 4.

A2
z Measure cyliner liner with internal measuring device.

- Balance internal measuring device at the given measuring points and read off the
measured values.
In case of damage or deviations in measurements, the cylinder liner must be renewed.

TCG 2020
W 3-3-1
In case of re-usable cylinder liners
z Remove cylinder liner - see job card W 3-3-2.
A3
z Visually inspect collar surfaces.

- In area X.
A4
z Clean and visually inspect collar rest and sealing surface for cylinder liner.
In case of rust or suspicion of leaks in the cylinder liners in the area of the collar rest, this
can easily be repaired with new or re-usable cylinder liners.

TCG 2020
W 3-3-1
A5
z Grind collar rest surface of the cylinder liner with ordinary grinding paste.
Insert the cylinder liners in the crankcase without sealing rings for correction grinding.
z Insert cylinder liner and turn until there is an even contact pattern.
z Remove the cylinder liner from the crankcase.
z Clean the cylinder liner and crankcase thoroughly.
z Install cylinder liner - see job card W 3-3-2.

TCG 2020
W 3-3-1
Measuring sheet for cylinder liners
Customer: Order no.:

Engine type: Engine no.:
Operating hours: Signature:
Date:
Nominal dimension 170 - 170.025 mm

Measuring heights 1= 25 mm
2= 50 mm
3= 150 mm
4= 250 mm
1 2 3 4
A1 a/b
A2 a/b
A3 a/b
A4 a/b
A5 a/b
A6 a/b
A7 a/b
A8 a/b
A9 a/b
A10 a / b
B1 a/b
B2 a/b
B3 a/b
B4 a/b
B5 a/b
B6 a/b
B7 a/b
B8 a/b
B9 a/b
B10 a / b

TCG 2020
W 3-3-1

TCG 2020
W 3-3-2
Removing and installing cylinder liner
Tools
- Disassembly tool for cylinder liner
Auxiliary material
- Acid-free grease
- Spotting paste
Spare parts
- Sealing rings
References
- W 3-3-1 Checking cylinder liner
Technical data
Internal diameter

Wear limit 0.051 mm
Height of collar
General information
If the cylinder liner is renewed, the piston rings must always be renewed.

TCG 2020
W 3-3-2
Removing cylinder liner
A1
z Mount disassembly tool for cylinder liner

- Position tension plate so that the contact surfaces touch the bottom of the cylinder
liner.
- Place counterholder on the crankcase.
The counterweights of the crankshaft of the respective cylinder must face down.
Pay attention to the piston cooling nozzle when working on the crankcase.
A2
z Pull out cylinder liner with disassembly tool.

z Remove cylinder liner from crankcase.
z Check cylinder liner - see job card W 3-3-1.

TCG 2020
W 3-3-2
Installing the cylinder liner
The cxylinder liner contact in the crankcase must be checked before installing new cylinder
liners.
z Wet the contact surfacer of the cylinder all round lightly with spotting paste.
z Insert cylinder liner without sealing rings in the crankcase.
The cylinder liner must be easily insertable and turnable by hand.
z Turn the cylinder liner half a turn.

z Pull the cylinder liner back out.
z Check the contact surface of the cylinder liner and the cylinder liner rest.
- There must be a uniform bearing face.
If there is no uniform bearing face, please contact your service partner.
z Remove spotting paste.

z Renew sealing rings.
z Wet the sealing rings with acid-free grease.
z Wet the sealing surface of the sealing rings in the crankcase with acid-free grease.
A3
z Insert cylinder liner in the crankcase.

z Press the cylinder liner in until it touches.

TCG 2020
W 3-3-2

TCG 2020
W 3-3-9
Visual inspection of cylinder liner (cylinder liner installed)
Tools
- Micrometer gauge
- Dial gauge
References
Technical data
Internal diameter

Wear limit 0.051 mm
General information
Run cylinder liners exhibit different running appearances depending on the number of op-
erating hours and operating conditions. The basic differences can often only be recognised
by trained experts. In cases of doubt we recommend you to consult your service partner for
assessment.
Regrinding of the cylinder liner is not permissible.

TCG 2020
W 3-3-9
Visual inspection of cylinder liner (cylinder liner installed)

z Turn the crankshaft so that the piston of the respective cylinder is in BDC position.
A1
z Visually inspect cylinder liner.

- Grinding pattern, valleys, paint flaws, corrosion.
The cylinder liner must be installed in the crankcase for the measurement.
It is possible to measure the cylinder liner with the piston installed.
The test dimension of measuring level 4 is omitted.
A2
z Measuring schematic of the cylinder liner at points a and b in the levels 1 - 4.


TCG 2020
W 3-3-9
A3
z Measure cyliner liner with internal measuring device.

measured values.

TCG 2020
W 3-3-9
Measuring sheet for cylinder liners

Date:
Nominal dimension 170 - 170.025 mm

Measuring heights 1= 25 mm
2= 50 mm
3= 150 mm
4= 250 mm
1 2 3 4
A1 a/b
A2 a/b
A3 a/b
A4 a/b
A5 a/b
A6 a/b
A7 a/b
A8 a/b
A9 a/b
A10 a / b
B1 a/b
B2 a/b
B3 a/b
B4 a/b
B5 a/b
B6 a/b
B7 a/b
B8 a/b
B9 a/b
B10 a / b

TCG 2020
W 3-5-1
Removing and installing lube oil tray
Tools
Auxiliary material
- DW 43
Spare parts
- Gaskets
References
- B 8-1-2 Changing lube oil
- W 0-5-1 Lifting and setting down the engine
Technical data

M8x70 - 8.8 25 Nm
General information
Risk of injury !
Secure the engine against starting up.
Risk of scalding !

TCG 2020
W 3-5-1
Removing lube oil tray
z Pump off lube oil - see job card B 8-1-2.

z Lift engine - see job card W 0-5-1.
A1

z Remove the lube oil line 1 of the pre-lube pump from the lube oil tray.
- Remove the pre-lube pump if necessary.
A2
Secure the lubricating oil pan against falling out by suitable means before loosening the
screws.
z Unscrew screws and remove with washers.

z Remove lube oil tray from crankcase.
z Remove gasket.

TCG 2020
W 3-5-1

Install lube oil tray
A3
z Stick lube oil tray gasket with lube grease to the lube oil tray.
- Do not grease the transitional joint of the individual gasket parts.
z Wet the transitional joint of the lube oil tray gasket with sealant.
- Joints must be sealed completely with sealant.
z Mount lube oil tray on crankcase.
- Mount the pre-lube pump if necessary.
z Mount the lube oil line of the pre-lube pump.
z Set down engine - see job card W 0-5-1.
z Fill up lube oil - see job card B 8-1-2.

TCG 2020
W 3-5-1

TCG 2020
W 3-7-1
Checking engine mounting
Tools
Technical data
Engine holder on crankcase (engine mounting)

M16x40 - 10.9 190 Nm
Engine holder on base frame (engine mounting)

M16x40 - 10.9 210 Nm
General information
Since the base frame can change due to the effect of heat and tension, the fastening screws
must be checked for loosening.
This is particularly necessary after the first few hours of operation.

TCG 2020
W 3-7-1
Checking engine mounting
A1
z Check mating pieces in rigid mounting and enclosures in elastic mounting by knocking
(including those which are difficult to access due to pipes running above them).
A metallic sound indicates a tight connection.
z Tighten screws.
Fuel, lube oil, water and coolant must not come into contact with the elastic mountings.

TCG 2020
W 3-9-1
Removing and installing rear cover (drive side)
Tools
Auxiliary material
- DW 47
- DW 67
Spare parts
- Gasket
References
- W 2-2-2 Removing and installing crankshaft sealing ring (drive side)
Technical data

M8x20/25/50 - 8.8 25 Nm
General information

TCG 2020
W 3-9-1
Removing rear cover (drive side)
A1
z Remove drain hose.

- Position 1.
- Position 2.
- Position 3.
The removal of the bottom rear cover is described in the job card W 2-2-2 Removing and
installing crankshaft sealing ring.

- Position 4.

TCG 2020
W 3-9-1
Installing rear cover (drive side)
A2

z Renew all gaskets.
The installation of the bottom rear cover is described in the job card W 2-2-2 Removing and
installing crankshaft sealing ring.
z Install rear cover.

- Position 4.
z Mount rear cover.
- Position 2.
- Position 3.
z Install drain hose.
- Position 1.
- Install flywheel - see job card W 12-6-1.

TCG 2020
W 3-9-1

TCG 2020
W 3-10-4
Checking cylinder liner fit
Tools
- Dial gauge
- Plug gauge for cylinder liner fit
- Extraction tool for cylinder liner fit
References
Technical data
Upper cylinder liner fit

max. deviation Wear limit 198.100 mm
General information
The upper and lower cylinder liner fit must be cleaned and checked every time the cylinder
liner is removed. This applies for every cylinder liner.
Testing with the plug gauge is a test procedure and not a measurement. It is only checked
which cylinder liner fit needs to be repaired.
If the plug gauge fits into the upper cylinder liner fit without jamming, the cylinder liner can
be installed - see job card W 3-3-2.
If the plug gauge does not fit into the cylinder liner fit, the cylinder liner fit must be measured
and documented. Then the cylinder liner fit must be repaired and measured again.
If the lower cylinder liner fit is worn, it is possible to rework the crankcase.

TCG 2020
W 3-10-4
Checking cylinder liner fit
z Clean upper and lower cylinder liner fit.

z Insert plug gauge into the cylinder liner fit without pressure.
If the plug gauge fits into the upper cylinder liner fit without jamming, the cylinder liner can
be installed - see job card W 3-3-2.
If the plug gauge does not fit into the cylinder liner fit, it must be measured.
A1
z Schematic for measuring the cylinder liner fit in the levels 1 - 4.

z Measure cylinder liner fit with internal measuring instrument.
measured values.
A locally limited deviation A according to the technical data is permissible.

TCG 2020
W 3-10-4
Measuring sheet for cylinder liner fit

Date:
Upper cylinder liner fit B Nominal dimension 198.000 - 198.046 mm

Locally limited deviation A Wear limit 198.300 mm
1 2 3 4 A
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10

TCG 2020
W 3-10-4

TCG 2020
W 4-1-1
Removing, installing and checking camshaft bearing
Tools
- Dial gauge
- Insertion and extraction device for camshaft bearing
Auxiliary material
- Molykote
Spare parts
- Gaskets
- Camshaft bearing if necessary
- Screws
References
- W 4-5-5 Removing and installing camshaft
Technical data

Wear limit 0.240 mm
Wear limit 0.35 mm
Stop disc thickness



M8x20 - 8.8 25 Nm

TCG 2020
W 4-1-1

M8x80 - 10.9 35 Nm
M10x65/80 - 10.9 50 Nm

M8x20/25/50 - 8.8 25 Nm

2. Stage 60°

M10x40 - 10.9 60 Nm

M8x18 - 8.8 25 Nm

M8x16 - 10.9 35 Nm

2. Stage 160 Nm
3. Stage 280 Nm
General information
All gaskets, sealing rings and circlips must be renewed.
Risk of injury !
Danger of burning !
When working with the insertion and extraction device for camshaft bearings, make sure
that the camshaft bearings and the camshaft bearing seats are not damaged.

TCG 2020
W 4-1-1
Insertion and extraction device for camshaft bearing

Component overview
A1
1 Hexagonal nut M20 2 pieces

2 Washer Diameter 80.0 mm
3 Spacer tube 4 pieces - 105, 179, 240 and 275 mm
4 Fitting Diameter 59.5 mm x height 40.0 mm
5 Threaded rod 3 pieces
6 Square bar Holding when extracting and inserting
8 Conical fitting Diameter 67.0 mm x height 60.0 mm
10 Muffs 2 connections of the threaded rods
Depending on the engine type and camshaft storage location, several threaded rods and
spacer tubes are available in different lengths for the insertion and extraction device.
The insertion and extraction device can be adapted individually by the threaded rods and
the spacer tubes.

TCG 2020
W 4-1-1
Checking the camshaft bearings.
A2
z Remove camshaft - see job card W 4-5-5.

z Remove cylinder liner - see job card W 3-3-2.
z Measuring schematic of the camshaft bearing diameter at points a and b in the levels
1 and 2.
z Measure camshaft bearings with internal measuring device.
measured values.

TCG 2020
W 4-1-1
Removing camshaft bearings
The camshaft bearings are always pulled out of the crankcase to the free side.
A3
1 Hexagonal nut M20

2 Washer
3 Spacer tube
4 Fitting diameter 59.5 x height 40
5 Threaded rod
6 Square bar for holding when extracting the camshaft bearing
7 Fitting diameter 59.5 x height 30.0
z Insertion and extraction device for camshaft bearings.
- A - free side
- B - drive side
- Arrow - pull direction of the threaded rod for extracting the camshaft bearing.
the spacer tubes.

TCG 2020
W 4-1-1
A4
z Insert fitting 4.
- Insert fitting (diameter 59.5 mm x height 40.0 mm) from the wheel side into the
front camshaft bearing.
z Insert threaded rod 5.
- Insert threaded rod from the free side into the camshaft bearing race.
z Push on spacer tube 3.
- Assemble the spacer tubes individually for the camshaft bearings to be pressed
out and plug onto the threaded bar 5.
z Push washer onto threaded rod 5.
z Turn on nut 1.
A5
z Insert fitting 7.
- Insert fitting (diameter 59.5 mm x height 30.0 mm) from the free side into the cam-
shaft bearing to be pressed out.

TCG 2020
W 4-1-1
z Turn on nut 1.
z Hold with open-end wrench (arrow).
- Hold with open-end wrench at square bar 6 of the threaded rod 5.
A6
z Tighten nut 1.
- Turn nut (arrow) until the camshaft bearing is pressed out.
z Unscrew nut 1.
z Remove insertion and extraction tool.
z Remove camshaft bearing.
z Remove all other camshaft bearings as described above.

TCG 2020
W 4-1-1
Install camshaft bearing
The camshaft bearings are always pulled into the crankcase to the drive side.
A7
1 Hexagonal nut M20

2 Washer
3 Spacer tube
5 Threaded rod
6 Square bar for holding when pulling in the camshaft bearing
7 Fitting diameter 59.5 x height 30.0
8 Conical fitting diameter 67.5 x height 60
z Insertion and extraction device for camshaft bearings.
- A - free side
- B - drive side
- Arrow - pull direction of the threaded rod for pulling in the camshaft bearing.
- The tool asembly illustrated in figure A7 is only for installation of a camshaft bear-
ing for example.
the spacer tubes.
When working with the insertion and extraction device for camshaft bearings, make sure
that the camshaft bearings and camshaft bearing seats are not damaged.

TCG 2020
W 4-1-1
A8
z Mount fitting 9.
- Mount fitting (diameter 67.5 mm x height 30.0 mm) in front of the first camshaft
bearing on the drive side.
- Insert threaded rod from the drive side into the camshaft bearing race.
z Push on spacer tube 3.
- Assemble the spacer tubes individually for the camshaft bearings to be pressed
out and plug onto the threaded bar 5.
z Push washer onto threaded rod 5.
z Turn on nut 1.
A9
z Insert fitting 4.
- Insert fitting (diameter 59.5 mm x height 40.0 mm) into the bearing before the cam-
shaft bearing to be pressed in.

TCG 2020
W 4-1-1
A 10
z Insert conical fitting 8.

- Insert conical fitting (diameter 67.5 mm x height 60.0 mm) into the camshaft bear-
ing seat of the camshaft bearing to be pressed in.
A 11
z Push on camshaft bearing 11.

- Push camshaft bearing onto fitting 7 (diameter 59.5 mm x height 30.0 mm).
z Grease half of camshaft bearing 11.
- Grease the camshaft bearing side pulled into the camshaft bearing seat first up to
the ring groove with Molykote 12.
When positioning the camshaft bearing, make sure that the notch in the camshaft bearing
is facing the top.

TCG 2020
W 4-1-1
A 12
z Position camshaft bearing.

- The new camshaft bearing must be mounted so that the notch in the camshaft
bearing is facing the top (arrow) when installed.
A 13
z Mount the fitting 7 with camshaft bearing 11.

- Insert fitting (diameter 59.5 mm x heig ht 30.0 mm) with camshaft bearing in the
crankcase.
z Turn on nut 1.

TCG 2020
W 4-1-1
A 14
z Hold with open-end wrench (arrow).

- Hold with open-end wrench at square bar 6 of the threaded rod 5.
A 15
z Tighten nut 1.
- Turn the nut until the fitting 7 is touching the crankcase.
z Unscrew nut 1.
z Remove insertion and extraction tool.
z Remove all other camshaft bearings one after another as described above.
z Install cylinder liner - see job card W 3-3-2.
z Install camshaft - see job card W 4-5-5.

TCG 2020
W 4-1-1
Measuring sheet for camshaft bearing

Date:
Internal diameter
1 2
1 a/b
2 a/b
3 a/b
4 a/b
5 a/b
6 a/b
7 a/b
8 a/b
9 a/b
10 a/b
11 a/b

TCG 2020
W 4-1-1

TCG 2020
W 4-1-4
Checking camshaft axial clearance
Tools
- Angled wrench
- Magnetic measuring stand
- Dial gauge
Auxiliary material
- DW 47
Technical data

Wear limit 0.240 mm
Wear limit 0.35 mm
Stop disc thickness

General information

TCG 2020
W 4-1-4
Checking camshaft axial clearance
z Remove the rocker arm and the rocker arm block - see job card W 1-2-2.
A1
z Unscrew screws 1.
z Remove the cover.
A2
z Unscrew screws 2.

TCG 2020
W 4-1-4
A3
z Turn in two screws M10x100 (arrows).

A4
z Apply stylus to the screw with pre-tension.

z Pull forward camshaft on gear as far as possible.
z Push back camshaft gear as far as possible.
z Read axial clearance on dial gauge.
If the axial clearance is out of tolerance, the axial disc must be renewed, see work proce-
dure - renewing axial disc of camshaft.
Then repeat the measurement.

z Unscrew two screws.
TCG 2020
W 4-1-4
A5

z Tighten screws 2.
A6
z Apply packing compound to the sealing surface.

z Mount cover.
z Tighten screws 1.
z Install the rocker arm and the rocker arm block - see job card W 1-2-2.

TCG 2020
W 4-1-4
Renewing axial disc of camshaft
A7
z Unscrew screws 1.
z Remove cover 2.
A8
z Unscrew screws 3.
z Remove wear discs.

TCG 2020
W 4-1-4
A9
z Remove axial disc 4.

z Insert new axial disc 4.
Pay attention to the positioning of the camshaft axial guide.
A 10
z Insert wear disc.

z Tighten screws 3.
- Tighten screws with angled wrench.

TCG 2020
W 4-1-4
A 11
z Fit cover 2 and tighten screws 1.

TCG 2020
W 4-1-4

TCG 2020
W 4-2-3
Removing, installing and checking valve tappet
Tools
- Disassembly and assembly device for roller tappets
References
Technical data
Bores for valve tappets (Diameter)

Valve tappet (External diameter)

38.050 – 38.075 mm
General information
If the tappet bore in the crankcase is worn, you can have a liner inserted at one of our Serv-
ice Centres.

TCG 2020
W 4-2-3
Removing valve tappets
A1
z Remove pushrods.
z Unscrew screw 1.
- Remove with sealing ring.
A2
z Loosen knurled nut 2 on tool.

TCG 2020
W 4-2-3
A3
z Insert tool 3 in roller tappet 4.

z Tighten knurled nut 2.
z Remove roller tappet 4 from crankcase.
- Lay out the components in order of installation, note order of cylinders.

Checking the valve tappet and valve tappet bore
z Measure the valve tappet diameter at the specified positions with micrometer gauge.
z Measure valve tappet bore with internal measuring device.
Installing valve tappet

z Insert tool 3 in roller tappet 4.
z Tighten knurled nut 2.
z Insert roller tappet in crankcase with assembly tool.
- Pay attention to order of installation and cylinder arrangement.

TCG 2020
W 4-2-3
A4
The valve tappet has a guide groove 5 so thta it cannot twist in engine operation.
The screw 1 must fit in the guide groove 5.
z Insert screw 1 with sealing ring.

- Move the roller tappet up and down to ensure that the screw is in the guide groove.
z Tighten screw 1.
After tightening the screw, the action of the valve tappet must be checked again.
If the valve tappet is stuck, the screw must be unscrewed and an additional sealing
ring fitted.

z Remove tool.
z Insert pushbars.

TCG 2020
W 4-4-1
Removing and installing the gear drive (free side)
Tools
- Torque wrench
Auxiliary material
- Lube oil
References
Technical data

2. Stage 90°

2. Stage 60°

M10x40 - 10.9 60 Nm

M16x50 - 10.9 200 Nm
Crankshaft gear and intermediate gear camshaft

0.163 -0.362 mm
Intermediate gear and camshaft gear A side

0.084 -0.291 mm
Camshaft gear A side and camshaft gear B side

0.148 -0.276 mm

0.125 -0.319 mm
0.162 -0.324 mm

TCG 2020
W 4-4-1
Removing the gear drive
A1
z Unscrew screw 1.
A2
z Remove wear disc 2.

TCG 2020
W 4-4-1
A3
z Remove intermediate wheel 3.
A4
z Unscrew screws 4.
z Removing the camshaft wheel

TCG 2020
W 4-4-1
A5
z Unscrew screws 5.
z Removing the camshaft wheel
Installing the gear drive
A6
z Pay attention to the position of the locking pin.

TCG 2020
W 4-4-1
A7
z Mount camshaft wheel on camshaft.

z Tighten screws 5.
A8
Make sure that the toothed wheel markings are in line when mounting the camshaft wheel.
The marking with a dot 6 faces the camshaft wheel on the A side.
The marking with two dots 7 faces the intermediate wheel.

TCG 2020
W 4-4-1
A9
z Mount camshaft wheel on camshaft.

z Tighten screws 4.
A 10
z Set camshaft wheels to marking 8.

z Turn the crankshaft so that the marking 9 face up.
z Push intermediate wheel into the toothing of the camshaft and crankshaft.
Make sure that the markings 10 match up.

Pull off the intermediate wheel if necessary so far that the tooth edges no longer engage.
Turn the camshaft or crankshaft until the marking match up.

TCG 2020
W 4-4-1
A 11
z Mount wear disc 2.
A 12
z Tighten screw 1.
z Check and measured control times - see job card W 4-4-11.

TCG 2020
W 4-4-1
Check tooth edge clearance
The measuring process is described on a camshaft wheel.

Proceed accordingly for the other toothed wheels.
A 13
z Attach magnetic measuring stand and insert dial.

z Check tooth edge clearance.
- Turn the camshaft wheel to one side if possible (arrow).
- Adjust dial gauge to 0.
- Turn the camshaft wheel to the other side if possible (arrow).
- Read the tooth edge clearance from the dial.
If the tooth edge clearance is out of tolerance, the camshaft wheel must be renewed.
Then repeat the measurement.


TCG 2020
W 4-4-8
Checking intermediate gear mounting
Tools
- Angled wrench
Auxiliary material
- DW 68
Spare parts
- Sealing rings
References
Technical data

M16x50 - 10.9 200 Nm
General information
All gaskets and sealing rings must be renewed.
Risk of injury !

TCG 2020
W 4-4-8
Overview gear train
A1
1 Intermediate gear
2 Camshaft gears
3 Crankshaft wheel
4 Intermediate gear lube oil pump
Checking intermediate gear mounting
A2

z Unscrew screw (arrow).
z Remove intermediate gear.
- Position 1.

TCG 2020
W 4-4-8
A3
z Check intermediate gear mounting for wear.
If wear is detected, please contact your service partner in this matter.
Make sure the cylindrical pin on the gear wheel and the corresponding fit bore are in line
when assembling.
A4

z Check and set control times - see job card W 4-4-11.
- Position 1.
Only wet screw with sealant on the contact surface, not on the thread.

TCG 2020
W 4-4-8
z Tighten screw (arrow).


TCG 2020
W 4-4-9
Removing and installing gear housing cover
Tools
- Lifting gear
- Angled wrench
- Dial gauge
Auxiliary material
- Acid-free grease
- Guide pins M10x120
- DW 47
Spare parts
- Gaskets
- Sealing rings
References
- W 4-5-6 Checking camshaft
Technical data

M8x70 - 8.8 25 Nm

M8x20 - 8.8 25 Nm

M8x80 - 10.9 35 Nm
M10x65/80 - 10.9 50 Nm

2. Stage 90°

M8x18 - 8.8 25 Nm

M8x16 - 10.9 35 Nm

TCG 2020
W 4-4-9
Nominal and wear dimensions

Wear limit 0.240 mm
Wear limit 0.35 mm
General information
A1
Pay attention to different screw lengths.

Item 1 - 2x screws M10x65

TCG 2020
W 4-4-9
Removing gear housing cover
A2
z If present, remove torsional vibration damper - see job card W 12-1-4.

z Remove bracket 1.
z Remove lube oil filter 2 with brackets and pipes.
z Remove camshaft pulse sensor 3.
z Remove pipe 4.
A3

z Remove cover.

TCG 2020
W 4-4-9
A4

z Remove heat guard 5.
A5

z Remove bracket turbocharger.
- Position 6.

TCG 2020
W 4-4-9
A6

z Remove lid 7.
z Remove lid 8.
A7

TCG 2020
W 4-4-9
A8

z Remove lid 9.
A9

z Remove axial discs.
- Position 10.

TCG 2020
W 4-4-9
A 10

z Remove bearing housing 11.
A 11

TCG 2020
W 4-4-9
A 12
z Hang gear housing cover on suitable hoist unit.

- Position 12.
A 13
Do not damage the sealing surfaces.
z Lift gear housing cover with hoist unit (arrow).

- Position 12.

TCG 2020
W 4-4-9
Mounting gear housing cover
Only use approved cleaning agents - see chapter 4.

Observe the manufacturer's specifications.
Clean all sealing surfaces.
A 14
z Clean gear housing cover.

- Position 12.
z Apply sealant.
- Apply sealant evenly to the sealing surface (arrows) of the gear housing cover 12.
A 15
z Apply sealant.
- Apply sealant to the gates (arrows) for the screws.
TCG 2020
W 4-4-9
- Apply sealant to the crankcase in the area of the lube oil tray.
A 16
z Screw guide pins into crankcase.

- Use guide pins M10x120.
- To guide the gear housing cover (arrows).
z Loosen the lube oil tray and renew the lube oil tray gasket if necessary.
A 17
z Mount gear housing cover.

- With hoist unit on crankcase.
- Pay attention to cylinder pins (arrows).
TCG 2020
W 4-4-9
A 18
z Screw on screws (arrows).

z Align gear housing cover.
- Align gear housing cover to the crankcase and lube oil tray.
A 19
z Insert bearing housing 11.

- If the camshaft flange cannot be inserted or is difficulkt to insert, the gear housing
cover must be aligned accordingly.
z Remove bearing housing 11.

TCG 2020
W 4-4-9
A 20
z Mount gear housing cover.

- Position 12.
- Tighten screws (arrows).
z Remove hoist unit.
A 21

TCG 2020
W 4-4-9
A 22
z Renew the sealing rings (arrow).

A 23
z Insert bearing housing 11.

z Check axial clearance of the camshaft - see job card W 4-5-6.

TCG 2020
W 4-4-9
A 24
z Insert axial discs.

z Position 10.
A 25

z Insert cap 8.
z Insert cap 7.

TCG 2020
W 4-4-9
A 26
z Install bracket turbocharger.

- Position 6.
A 27

z Install heat guard 5.

TCG 2020
W 4-4-9
A 28
z Renew sealing ring.

z Wet the sealing ring with acid-free grease.
z Mount cover.
A 29
z Mount pipe 4.
z Install camshaft pulse sensor 3.
z Install lube oil filter 2 with brackets and pipes.
z Mount bracket 1.
z If present, install torsional vibration damper - see job card W 12-1-4.

TCG 2020
W 4-4-11
Checking and measuring control times
Tools
- Tape measure
- Pocket calculator
References
- W 4-4-1 Removing and installing the gear drive (free side)
Technical data
Control times (with 2 mm valve clearance)

Inlet opens after TDC 7° 04’ (7,06°)
Inlet closes before BDC 31° 04’ (31,06°)
Outlet opens before BDC 33° 19’ (33,31°)
Outlet closes before TDC 3° 43’ (3,71°)
General information
The work procedure is described on a valve.
Proceed accordingly if the other valves also have to be checked.
The ignition mark is in different places depending on the engine.
A1
Position 1 = ignition mark V12 and V16 engine

Position 2 = ignition mark V20 engine
TCG 2020
W 4-4-11
Checking control times
Visually inspecting gear wheel marks
A2
z Turn the engine.

- until the gear marks are one above the other.
z Check toothed wheel markings.
If the toothed wheel markings are not in line, the control times must be set.
Removing and installing the gear drive - see job card W 4-4-1.
Measuring control times
z Calculate arc dimension for flywheel

L = d x Pi x °KW / 360°
L= Calculated arc dimension in mm

d= Flywheel diameter in mm
Pi = Circle number
°KW = Control time in °KW (according to technical data)
Calculation example
d= 750 mm
Pi = 3,14
°KW = 33,31°
L = d x Pi x °KW / 360
L = 750 mm x 3.14 x 33.31° / 360°
L = 217.90 mm

TCG 2020
W 4-4-11
A3
1= Ignition marks on crankcase or flywheel

X= Marking direction for values before TDC
Y= Marking direction for values after TDC
A4
z Turn the engine.

- until the appropriate cylinder is in ignition TDC.
The ignition marks 1 on the flywheel and the crankcase are in line.

z Set inlet and outlet valve clearance - see job card B 1-1-1.
- to 2 mm valve clearance.
z Transfer calculated arc dimension to flywheel at position 2.

TCG 2020
W 4-4-11
A5
z Turn engine in direction of rotation.

- until marking of arc dimension 2 is in line with the TDC marking on crankcase 3.
In this position the rocker arm must just begin to press open the valve.
This is the case when the pushrod of the valve concerned can no longer be turned by hand.
Before starting engine
Set inlet and outlet valve clearance - see job card B 1-1-1.

TCG 2020
W 4-5-5
Removing and installing camshaft
Tools
- Assembly tool for camshafts
Auxiliary material
- Lube oil
Spare parts
- Gaskets
- Sealing rings
- Screws
References
- W 4-2-3 Removing, installing and checking valve tappet
- W 4-4-1 Removing and installing the gear drive (free side)
Technical data

M8x20 - 8.8 25 Nm

M8x80 - 10.9 35 Nm
M10x65/80 - 10.9 50 Nm

M8x20/25/50 - 8.8 25 Nm

2. Stage 60°

M10x40 - 10.9 60 Nm

M8x18 - 8.8 25 Nm

TCG 2020
W 4-5-5

M8x16 - 10.9 35 Nm

2. Stage 160 Nm
3. Stage 280 Nm

Camshaft stroke
Inlet 8.5 mm
Outlet 8.5 mm

Wear limit 0.240 mm
Wear limit 0.35 mm
Stop disc thickness

General information

TCG 2020
W 4-5-5
Assembly tool for camshafts
The assembly tool for camshafts serves as a guide for the camshaft when removing and
installing.
The camshafts can be removed and installed both in drive side and free side direction de-
pending on the local space conditions.
z Mount assembly tool on the free side.
A1
z Mount assembly tool on the drive side.
A2
1 Guide sleeve
2 Fastening screw
3 Hexagon socket head wrench
4 Centring pin

TCG 2020
W 4-5-5
Removing camshaft
The removal of the camshaft with the assembly tool in the direction of the free side is de-
scribed.

z Removing the valve tappet - see job card W 4-2-3.
A3
z Unscrew screws.
z Remove rear cover 1.
z Removing the gear drive - see job card W 4-4-1.

TCG 2020
W 4-5-5
A4
z Mount the assembly tool on the camshaft.
A5
When applying the assembly tool, make sure that there is no offset between the assemby
tool and the camshaft.

TCG 2020
W 4-5-5
A6
z Pull camshaft out of crankcase (arrow).

z Remove the assembly tool from the camshaft.
Installing camshaft
A7
The camshafts are marked by A or B on the drive side.

The identification serves to assign the camshaft to the appropriate row of cylinders.

TCG 2020
W 4-5-5
z Mount the assembly tool on the camshaft.
A8
When applying the assembly tool, make sure that there is no offset between the assemby
tool and the camshaft.

z Wet assembly tool with lube oil.
A9
z Insert camshaft in of crankcase (arrow).

z Push camshaft into crankcase.

TCG 2020
W 4-5-5
A 10
z Remove the assembly tool from the camshaft.

z Installing the gear drive - see job card W 4-4-1.
A 11
z Mount rear cover 1.

z Tighten screws.
z Install valve tappet - see job card W 4-2-3.

TCG 2020
W 4-5-6
Checking camshaft
Tools
- Micrometer gauge
- Prisms
- Dial gauge
- Magnetic measuring stand
References
- W 0-3-2 Tear inspection by diffusion liquid method
- W 4-5-5 Removing and installing camshaft
Technical data
Data on the runout accuracy can be found in chapter 8, Technical Data.

Camshaft stroke
Inlet 8.5 mm
Outlet 8.5 mm

General information

TCG 2020
W 4-5-6
Tear test
z Carry out tear test by magnetic test method according to test specification 0162 0000
or diffusion liquid method - see job card W 0-3-2.
z Check the running surfaces of the bearings and cams for marks.
Check diameter of camshaft bearing pin
A1
z Measuring schematic of the camshaft bearing pin diameter at points a and b in the lev-
els 1 and 2.
z Check diameter of camshaft bearing pin with micrometer gauge.

TCG 2020
W 4-5-6
Checking camshaft run-out
A2
z Place camshaft on prism.

- Contact points according to graphic.
z Turn camshaft.
z Check the runout.
z Repeat procedure.

TCG 2020
W 4-5-6
Measuring sheet for camshaft

Date:
Internal diameter
1 2
1 a/b
2 a/b
3 a/b
4 a/b
5 a/b
6 a/b
7 a/b
8 a/b
9 a/b
10 a/b
11 a/b

TCG 2020
W 4-5-8
Visual inspection of camshaft
Tools
References
- W 4-2-3 Removing, installing and checking valve tappet
Visual inspection of camshaft

z Removing the valve tappet - see job card W 4-2-3.
A1
z Visually inspect cams through tappet bore.
Turn the camshaft until the whole running surface has been checked.
The camshaft must be removed if there is any visible damage.
z Install valve tappet - see job card W 4-2-3.


TCG 2020
W 4-5-8

TCG 2020
W 5-4-5
Removing and installing actuator (V12 and V16 engine)
Tools
Spare parts
- Lock washers
- Hexagonal nuts
References
- W 5-4-7 Setting speed governor linkage
- W 6-3-8 Removing and installing suction air intake filter housing (V12 and V16 engine)
Technical data
General
Actuator on retainer plate

M8x28 - 8.8 25 Nm
General information
The setting of the speed governor linkage is based in this job card on marking of the previ-
ous position of the ball heads in the elongated holes. If the speed governor linkage needs
to be set - see job card W 5-4-7.
Risk of injury !
Danger of burning !

TCG 2020
W 5-4-5
Removing actuator
A1
z Loosen clamps 1.
z Remove clamps (arrows) from suction air intake filter housing.
z Remove suction air intake filter housing.
z Remove rubber sleeves.
A2
z Mark linkage setting 2.

TCG 2020
W 5-4-5
A3

- Hold at the nut.
z Swing the speed governor linkage to the side.
- Remove washers.
z Remove cable set plug.
- From the actuator.
A4

z Remove actuator 3.

TCG 2020
W 5-4-5
Installing actuator
A5
z Insert the pushrods 3.

A6
z Mount speed governor linkage.

- Mount washers.
z Set linkage to mark 2.
z Insert screw.
- Use new lock washer and new nut.
z Turn on nut.

TCG 2020
W 5-4-5
A7

z Install cable set plug.
- On actuator.
A8
z Insert rubber sleeves.

z Insert suction air intake filter housing.
z Mount clamps (arrows) on suction air intake filter housing.
z Tighten clamps 1.

TCG 2020
W 5-4-5

TCG 2020
W 5-4-5
Removing and installing actuator (V20 engine)
Tools
- Locking pin
Auxiliary material
- Acid-free grease
Spare parts
- Sealing ring
- possibly actuator
General information
The actuators must be checked for jolt-free smooth action before assembly by moving the
pointer manually.
The smooth action should be checked again after assembly. If manual movement of the
pointer has become very difficult, the actuator must be removed and installed again.
The permissible average throttle valve current is 3.5 A.
The difference between minimum and maximum current may be 1.5 A.
The individual throttle valve currents should not differ by more than 1.5 A on average.

TCG 2020
W 5-4-5
Removing actuator
If the work for one engine side described below is also to be carried out for the opposite
engine side, proceed accordingly.
A1

z Remove actuator complete with rotary disk valve.
A2
z Loosen fixing screw 1.
The fastening screw is accessible through the side bore.

TCG 2020
W 5-4-5
A3

z Remove actuator upwards.
Installing actuator
The same actuator is installed on both sides of the engine.

On the side mounted on the support, the display elements must be removed from the actu-
ator.
A4
z Note installation position.

- Cylinder side A - connection for cable set plug mounted towards the support.
- Cylinder side B - connection for cable set plug mounted away from the support.

TCG 2020
W 5-4-5
A5
z Remove wedge 9.
z Remove pointer 10 with spacer discs.
z Insert wedge 9.
z Unscrew screws.
z Remove indicator scale 11.
A6
Do not switch the supports 2 of the cylinder sides A and B.

The cylinder side (A or B) is marked on the support.

TCG 2020
W 5-4-5
A7
z Coat clamping bore with grease.

z Mount actuator on support.
Make sure that the wedge 9 is sitting in the groove 12.
A8

TCG 2020
W 5-4-5
A9
z Tighten fixing screw 1.
A 10
When inserting the rotary disc valve the bore (arrow) must point towards the locking screw.

TCG 2020
W 5-4-5
A 11
z Unscrew locking screw (magnifying glass).

z Insert actuator complete with rotary disk valve.
A 12
z Screw in screws (arrows).

TCG 2020
W 5-4-5
A 13
z Insert locking pin 13.

- Into the bore (magnifying glass) of the locking screw through the bore in the rotary
disc valve.
The rotary disc valve is blocked by the locking pin.
A 14
z Set actuator.
- Turn actuator until the pointer on the scale is at 0 (zero).

TCG 2020
W 5-4-5
A 15

z Remove locking pin 13.
z Turn in locking screw.
z Tighten locking screw.

TCG 2020
W 5-4-5

TCG 2020
W 5-4-6
Removing and installing swivel he ad for speed governor linkage (V12

and V16 engine)
Tools
Spare parts
- Lock washers
- Hexagonal nuts
References
- W 5-4-7 Setting speed governor linkage
- W 6-3-8 Removing and installing suction air intake filter housing (V12 and V16 engine)
Technical data
General

M6x35 - 8.8 10 Nm
General information
The setting of the speed governor linkage is based in this job card on marking of the previ-
ous position of the ball heads in the elongated holes. If the speed governor linkage needs
to be set - see job card W 5-4-7.
Risk of injury !
Danger of burning !

TCG 2020
W 5-4-6
Removing swivel head for speed governor linkage
If the work for a joint head described below is also to be carried out for the opposite joint
head, proceed accordingly.
A1
z Removing the suction air intake filter housing - see job card W 6-3-8.
z Mark linkage setting 2.
A2

- Hold at the nuts.
z Swing the speed governor linkage to the side.
- Remove washers.

TCG 2020
W 5-4-6
A3
z Measure distance X between the swivel heads.

- Measured from hole centre to hole centre.
- Note determined dimension.
A4
z Unscrew swivel head 3.

- Loosen lock nut (arrow).
- Turn back lock nut (arrow) two turns.

TCG 2020
W 5-4-6
Installing swivel head for speed governor linkage
A5
z Screw on swivel head 3.

- Up to measured distance X.
- Tighten nut (arrow).
A6
z Mount speed governor linkage.

- Mount washers.
z Set linkage to mark 2.
z Insert screw.
- Use new lock washer and new nut.
z Turn on nut.

TCG 2020
W 5-4-6
A7

- Hold at the nut.
z Installing the suction air intake filter housing - see job card W 6-3-8.

TCG 2020
W 5-4-6

TCG 2020
W 5-4-7
Setting speed governor linkage
Tools
Technical data
General

M6x35 - 8.8 10 Nm
General information
Risk of injury !
Danger of burning !
Setting speed governor linkage
A1
z Loosen lock nut 1 of the swivel heads.

z Screw in swivel heads to the stop in the threaded rod.
z Loosen nuts 2.

TCG 2020
W 5-4-7
A2
z Set the swivel head on the lever of the speed governor.

- Insert swivel head in elongated hole with maximum distance X.
- Turn on nut.
z Set the swivel head on the lever of the throttle valve.
- Insert swivel head in elongated hole with maximum distance Y.
- Turn on nut.
Make sure that the throttle valve is closed and the speed governor is in the zero position.
A3
z Press the lever of the speed governor in full load.
If the throttle valve is not fully open or the speed governor is not on full load, the ball heads
in the elongated holes must be moved so that both these conditions are satisfied.

TCG 2020
W 5-4-8
Overhauling rotary disc valve (V20 engine)
Tools
- Assembly tool for sealing ring
- Assembly tool for sleeve
- Extractor
Auxiliary material
- Acid-free grease
Spare parts
- Sealing ring
- Sleeve if necessary
References
- W 5-4-5 Removing and installing actuator (V20 engine)
General information
Overhauling rotary disc valve
A1
z Remove support 2 from rotary disc valve 3.

TCG 2020
W 5-4-8
A2
z Renew the sealing ring (arrow).

z Remove shaft sealing ring 4.
A3
z Install shaft sealing ring 4 with suitable tool 5 up to stop in support 2.

TCG 2020
W 5-4-8
A4
z Pull off slip ring 6 with extractor.

z Remove sealing ring 7.
A5

z Insert sealing ring 7.
z Mount slip ring 6 with chamfer facing down on rotary disc valve.
z Press slip ring 6 with suitable tool 8 onto the rotary disc valve.

TCG 2020
W 5-4-8
A6
Do not switch the supports 2 of the cylinder sides A and B.

The cylinder side (A or B) is marked on the support.
A7
z Mount support 2 on rotary disc valve 3.

- Pay attention to correct positioning of bore to clamping screw 1.
z Coat clamping bore with grease.

TCG 2020
W 5-7-1
Removing and installing the flywheel sensor (model Jaquet)
Tools
Spare parts
- Flywheel sensor
Technical data
Set the flywheel sensor (Jaquet)

Turn in the frequency sensor up to the system
Continue unscrewing until the marking is in running direction
General information
If the gap the between the flywheel sensor sensor and the ring gear is not set correctly, it
affects the pulse output to the electronic control unit.
If the flywheel sensor is soiled, it must be removed and cleaned.
The flywheel sensor is mounted differently depending on the engine.
A1
Item 1 = flywheel sensor V12 and V16 engine

Item 2 = flywheel sensor V20 engine

TCG 2020
W 5-7-1
Removing the flywheel sensor
A2

z Loosen lock nut (arrow).
z Unscrew the flywheel sensor.
Installing the flywheel sensor
The flywheel sensor must be set to the fixed defined gap for the correct function.
A3
The mark on the sensor must always face in the running direction of the flywheel.
z Turn in the flywheel sensor to the stop.

TCG 2020
W 5-7-1
z Unscrew the flywheel sensor by the values specified in the technical data.
z Unscrew the flywheel sensor further until the marking is pointing in the running direc-
tion (see figure).
Check the installation position again after tightening the lock nut.
Function test
The function of the flywheel sensor must be checked using the TEM system after installa-
tion.
A4
z Select Service 1 mask.

z Select auxiliary unit engine.
z Select starter.
z Go to starter.
A speed display must appear in field 2 after actuating the starter.

TCG 2020
W 5-7-1

TCG 2020
W 5-7-1
Removing and installing frequency sensor (Jaquet model - camshaft)
Tools
Spare parts
- Frequency sensor
References
- W 13-5-3 Checking and adjusting ignition timing
Technical data
Set the camshaft sensor (Jaquet)

Turn the engine until the pulse screw is visible
Turn in the frequency sensor to the stop
General information
An incorrectly set frequency sensor for the camshaft offset or reset position can lead
to severe engine damage..
An incorrectly set distance of the frequency sensor influences the pulse emission to the
electronic control unit.
The frequency sensor is set in the factory and should not be removed unless absolutely
necessary.
Different frequency sensors are used.
A1
Version 1 - camshaft sensor, without connecting cable

Version 2 - camshaft sensor, with connecting cable
The frequency sensors are not interchangeable.

TCG 2020
W 5-7-1
Removing frequency sensor

z Loosen lock nut.
z Unscrew frequency sensor.
Installing frequency sensor
For correct functioning the frequency sensor must be set to the defined gap.
A2
z Turn engine until the pulse screw 1 is visible in the threaded hole of the frequency sen-
sor.
z Screw in frequency sensor to the stop.
z Unscrew the frequency sensor by the value specified in the Technical Data.
Danger of destroying the engine !

After installing the frequency sensor, check the ignition and set if necessary - see
job card W 13-5-3.

TCG 2020
W 6-1-9
Removing and installing exhaust pipe
Tools
- Tool set for PEARL exhaust gas system
Spare parts
- Gaskets for exhaust gas compensator
- Gasket exhaust pipe
- Clamps if necessary
Technical data

M10x48 60 Nm

M8 15 Nm
General information
The exhaust gas compensator is different on the two outer sides. It therefore has a specified
installation position.
A1
Position A - The open side faces towards the free side

Position B - The closed side faces towards the drive side
TCG 2020
W 6-1-9
Danger of burning !
Removing the exhaust pipe
A2

z Remove clip.
A3
z Press down the lock.

z Lift up the clip.

TCG 2020
W 6-1-9
A4
The cover must be removed to remove the exhaust cladding on the flywheel side.
Then push the exhaust cladding to the free side and remove from the top.
z Unscrew screws.
z Remove the cover.
z Remove exhaust pipe cladding.
A5
z Unscrew nuts 2.
z Loosen clamp from exhaust pipe and compensator.
z Push clamp to the side (arrow direction).

TCG 2020
W 6-1-9
A6
z Press together compensator (arrow direction).

z Remove compensator with gaskets upwards.
A7
z Unscrew nut 3.
z Unscrew screws 4.
- Remove spacer sleeves.
z Remove exhaust pipe 5.

TCG 2020
W 6-1-9
A8
z Remove gasket 6.
Installing exhaust pipe

z Renew gaskets.
The gaskets of the exhaust gas compensator must be installed dry.

Do not wet with grease or other agents.
z Insert gasket 6.
A9
z Insert exhaust pipe 5.

z Turn on screws 4 with spacer sleeves.
z Position clamp (arrow direction).

TCG 2020
W 6-1-9
z Tighten nut 3.
A 10

z Insert compensator.
A 11

z Tighten nuts 2.
z Tighten nuts 4.
z Install exhaust pipe cladding.
z Plug the spark plug cables to the ignition coils.

TCG 2020
W 6-1-11
Removing and installing compensator of exhaust pipe
Tools
Spare parts
- Gaskets for exhaust gas compensator
- Clamps if necessary
Technical data

M8 15 Nm
General information
The exhaust gas compensator is different on the two outer sides. It therefore has a specified
installation position.
A1
Position A - The open side faces towards the free side

Position B - The closed side faces towards the drive side
Danger of burning !

TCG 2020
W 6-1-11
Removing compensator of exhaust pipe
A2

z Remove clip.
A3

z Lift up the clip.

TCG 2020
W 6-1-11
A4
z Unscrew screws.
z Remove the cover.
A5
z Unscrew nuts 2.

TCG 2020
W 6-1-11
A6

z Remove compensator with gaskets upwards.
Installing compensator of exhaust pipe


A7

z Insert compensator.

TCG 2020
W 6-1-11
A8

z Tighten nuts 2.
z Plug the spark plug cables to the ignition coils.

TCG 2020
W 6-1-11

TCG 2020
W 6-2-7
Removing and installing charge mixture pipe (V12 and V16 engine)
Tools
Auxiliary material
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
Technical data

M12x30/45 - 10.9 90 Nm
General information
Risk of injury !
Danger of burning !

TCG 2020
W 6-2-7
Removing charge mixture pipe
A1
z Only for cylinder side B:

- Remove temperature sensor.
z Unscrew screws 4.
z Remove charging mixture pipe.
A2
z Unscrew screws 4.

TCG 2020
W 6-2-7
Installing charge mixture pipe

Renew all gaskets.
A3

z Insert charging mixture pipe.
z Tighten screws 4.
A4

z Tighten screws 4.
- Mount temperature sensor.

TCG 2020
W 6-2-7

TCG 2020
W 6-2-7
Removing and installing charge mixture pipe (V20 engine)
Tools
Auxiliary material
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
Technical data

M12x30/45 - 10.9 90 Nm
General information
Risk of injury !
Danger of burning !

TCG 2020
W 6-2-7
Removing charge mixture pipe
A1

- Remove temperature sensor.
z Unscrew screws 4.
A2
z Unscrew screws 4.

TCG 2020
W 6-2-7
A3
z Unscrew screws 4.
Installing charge mixture pipe

Renew all gaskets.
A4

z Tighten screws 4.

TCG 2020
W 6-2-7
A5

z Tighten screws 4.
A6

z Tighten screws 4.
- Mount temperature sensor.

TCG 2020
W 6-3-8
Removing and installing suction air intake filter housing (V12 and V16
engine)
Tools
General information
Danger of burning !
Risk of injury !
Removing suction air intake filter housing
A1
z Loosen clamps 1.
z Remove clamps (arrows) from suction air intake filter housing.
z Remove suction air intake filter housing.

TCG 2020
W 6-3-8
Installing suction air intake filter housing
A2
z Insert suction air intake filter housing.

z Mount clamps (arrows) on suction air intake filter housing.
z Tighten clamps 1.

TCG 2020
W 6-4-7
Removing and installing, cleaning mixture cooler (V12 and V16 engine)
Tools
- Lifting gear
- Round brush
Auxiliary material
- Cleaning agents
- Cleaning bath
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
References
- W 7-23-1 Removing and installing throttle valve (V12 and V16 engine)
- W 12-3-1 Removing, installing and checking rubber compensators
Technical data

M16x90 - 10.9 295 Nm

M10x20 - 8.8 49 Nm

M12x25/30 - 10.9 125 Nm

M12x80 - 10.9 125 Nm

M12x60 - 10.9 125 Nm

M12x65 - 10.9 125 Nm

M12x30/45 - 10.9 90 Nm

TCG 2020
W 6-4-7

M8x20 - 8.8 25 Nm

M6x60 - 8.8 10 Nm

M8x100 - 10.9 35 Nm

M8x100 - 10.9 35 Nm
General information
The best cleaning results are achieved with an ultrasonic cleaning device. The instructions
and regulations of the manufacturers of the ultrasonic cleaning equipment must be ob-
served.
Risk of injury !
Danger of burning !

Dispose of cleaning agents properly according to national regulations.

TCG 2020
W 6-4-7
Removing mixture cooler
A1

z Removing the suction air intake filter housing - see job card W 6-3-8.
z Pull all ignition cables 1 from ignition coil.
z Disconnect all cable set plugs from the multifunction rail.
z Disconnect the ground cable of the multifunction rail.
A2
z Unscrew nuts 3.
z Remove clip.

TCG 2020
W 6-4-7
A3
z Unscrew screws 4.
A4
z Remove temperature sensor from mixture cooler.

- Remove cable set plug.
z Unscrew screws 4.

TCG 2020
W 6-4-7
A5
z Remove all cable set plugs from ignition control unit 6.

- Remove ground cable.
z Remove ignition control unit.
A6
z Loosen cable set (magnifying glass) from rail 7.

z Remove rail 7.

TCG 2020
W 6-4-7
A7

z Remove bracket 8.
A8
z Remove rubber compensators - see job card W 12-3-1.

- Position 9.

TCG 2020
W 6-4-7
A9

z Remove connecting pipe 10.
A 10

- On the A and B side.
z Remove air filter console 11.

TCG 2020
W 6-4-7
A 11
z Unscrew screws.
z Remove bracket.
A 12

z Unscrew screws 12.

TCG 2020
W 6-4-7
A 13

z Remove connecting pipe.
A 14
z Remove throttle valve - see job card W 7-23-1.

z Remove locking screw on mixture cooler.
z Install bracket 14 on mixture cooler.
z Hang mixture cooler on suitable hoist unit (arrow).

TCG 2020
W 6-4-7
A 15
z Additionally only for mixture cooler cylinder side A:

- Remove valve cover.
- Remove bracket.
z Lift mixture cooler with hoist unit.

TCG 2020
W 6-4-7
Cleaning mixture cooler
A 16
z Set down mixture cooler on a strudy, clean work surface.

z Remove bracket 16.
A 17
z Unscrew screws.
- 24 screws from cover 17.
z Remove cover 17.
z Clean cover.

TCG 2020
W 6-4-7
A 18
z Unscrew screws.
z Remove cover 18.
z Clean cover.
A 19
z Pull out connecting pipe 19.

TCG 2020
W 6-4-7
A 20
z Unscrew screws.
z Remove cover 20.
z Clean cover.
A 21
z Unscrew screws.
z Remove cover 21.
z Clean cover.
z Clean mixture cooler.

TCG 2020
W 6-4-7
Only use approved cleaning agents - see operating manual chapter 4.

Risk of injury !
A 22
z Mixture cooler insert.

- Mixture side 22.
- Water side 23.
z Check mixture cooler insert and renew if necessary.
z Place the mixture cooler insert in the cleaning bath with cleaning fluid.
z Clean the lamellas 22 with a suitable brush.
z Clean the ducts 23 with a suitable brush.
z Remove mixture cooler insert from cleaning bath.
z Rinse mixture cooler insert with water.
z Dry mixture cooler insert with compressed air.
z Check mixture cooler insert again and renew if necessary.

The different screw length must be taken into account when assembling and installing.

TCG 2020
W 6-4-7
A 23
z Renew gasket.
z Mount cover 21.
z Tighten screws.
- 24 screws in cover 21.
A 24
z Renew gasket.
z Mount cover 20.
z Tighten screws.

TCG 2020
W 6-4-7
A 25
z Renew sealing ring 24.

z Install connecting pipe 19.
A 26
z Renew gasket.
z Mount cover 18.
z Tighten screws.

TCG 2020
W 6-4-7
A 27
z Renew gasket.
z Mount cover 17.
z Tighten screws.
A 28
z Mount bracket 16.


TCG 2020
W 6-4-7
Installing mixture cooler
A 29
z Mount mixture cooler.

z Additionally only for mixture cooler cylinder side A:
- Mount bracket.
- Install valve cover.
A 30
z Remove hoist unit (arrow).

z Remove holder 14.
z Turn in locking screw.
z Install throttle valve - see job card W 7-23-1.

TCG 2020
W 6-4-7
A 31

z Renew gaskets.
z Mount connecting pipe.
A 32
z Tighten screws 12.

z Renew gaskets.
z Mount connecting pipe 13.

TCG 2020
W 6-4-7
A 33
z Mount bracket.
z Tighten screws.
A 34
z Install air filter console 11.


TCG 2020
W 6-4-7
A 35
z Insert connecting pipe 10.

A 36

z Install rubber compensators - see job card W 12-3-1.
- Position 9.

TCG 2020
W 6-4-7
A 37
z Insert bracket 8.
A 38
z Insert rail 7.
z Fix cable set (magnifying glass) to rail 7.

TCG 2020
W 6-4-7
A 39
z Insert ignition control unit.

- Install ground cable.
z Install all cable set plugs in ignition control unit 6.
A 40

z Renew gaskets.
z Tighten screws 4.
z Mount temperature sensor on mixture cooler.
- Install cable set plug.

TCG 2020
W 6-4-7
A 41

z Renew gaskets.
z Tighten screws 4.
A 42
z Insert multifunction rail 2.

z Fit clip.
z Tighten nuts 3.

TCG 2020
W 6-4-7
A 43
z Connect the ground cable of the multifunction rail.

z Connect all cable set plugs from the multifunction rail.
z Plug in all ignition cables 1.
z Installing the suction air intake filter housing - see job card W 6-3-8.

TCG 2020
W 6-4-7

TCG 2020
W 6-4-7
Removing and installing, cleaning mixture cooler (V20 engine)
Tools
- Lifting gear
- Round brush
Auxiliary material
- Cleaning agents
- Cleaning bath
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
References
- W 12-3-1 Removing, installing and checking rubber compensators
Technical data

M16x90 - 10.9 295 Nm

M10x20 - 8.8 49 Nm

M12x25/30 - 10.9 125 Nm

M12x80 - 10.9 125 Nm

M12x60 - 10.9 125 Nm

M12x65 - 10.9 125 Nm

M12x30/45 - 10.9 90 Nm

M8x20 - 8.8 25 Nm
TCG 2020
W 6-4-7

M6x60 - 8.8 10 Nm

M8x100 - 10.9 35 Nm

M8x100 - 10.9 35 Nm

M18x1.5 52 Nm
General information
The best cleaning results are achieved with an ultrasonic cleaning device. The instructions
and regulations of the manufacturers of the ultrasonic cleaning equipment must be ob-
served.
Risk of injury !
Danger of burning !


TCG 2020
W 6-4-7
Removing mixture cooler
A1

z Pull all ignition cables 1 from ignition coil.
z Disconnect all cable set plugs from the multifunction rail.
z Disconnect the ground cable of the multifunction rail.
A2
z Unscrew nuts 3.
z Remove clip.

TCG 2020
W 6-4-7
A3

z Push back flange (arrow).
A4
z Remove rubber compensators - see job card W 12-3-1.

- Position 6.

TCG 2020
W 6-4-7
A5

z Remove temperature sensor from mixture cooler.
- Remove cable set plug.
A6
z Remove cable set (magnifying glass) from rail 8.

z Remove rail 8.

TCG 2020
W 6-4-7
A7
z Remove cable set bracket 10 from rail 9.

z Remove rail 9.
A8
z Remove all cable set plugs from ignition control unit.

z Unscrew screws 11.
z Remove bracket.

TCG 2020
W 6-4-7
A9
A 10

TCG 2020
W 6-4-7
A 11
A 12

z Lift mixture cooler with hoist unit.
z Set down mixture cooler on a strudy, clean work surface.

TCG 2020
W 6-4-7
Cleaning mixture cooler
A 13
z Unscrew screws.
z Remove cover 13.
z Clean cover.
A 14
z Unscrew screws.
z Remove cover 14.
z Clean cover.

TCG 2020
W 6-4-7
A 15
z Unscrew screws.
z Remove cover 15.
z Clean cover.
A 16
z Unscrew screws.
z Remove cover 16.
z Clean cover.

TCG 2020
W 6-4-7
Risk of injury !
A 17
z Mixture cooler insert.

- Mixture side 22.
- Water side 23.
z Check mixture cooler insert and renew if necessary.
z Place the mixture cooler insert in the cleaning bath with cleaning fluid.
z Clean the lamellas 22 with a suitable brush.
z Clean the ducts 23 with a suitable brush.
z Remove mixture cooler insert from cleaning bath.
z Rinse mixture cooler insert with water.
z Dry mixture cooler insert with compressed air.
z Check mixture cooler insert again and renew if necessary.

The different screw length must be taken into account when assembling and installing.

TCG 2020
W 6-4-7
A 18
z Renew gasket.
z Mount cover 16.
z Tighten screws.
A 19
z Renew gasket.
z Mount cover 15.
z Tighten screws.

TCG 2020
W 6-4-7
A 20
z Renew gasket.
z Mount cover 14.
z Tighten screws.
A 21
z Renew gasket.
z Mount cover 13.
z Tighten screws.

TCG 2020
W 6-4-7
Installing mixture cooler
A 22

z Mount mixture cooler.
A 23

z Remove hoist unit (arrow).

TCG 2020
W 6-4-7
A 24
z Renew gasket.
A 25
z Renew gaskets.

TCG 2020
W 6-4-7
A 26
z Mount bracket.
z Tighten screws 11.
z Install all cable set plugs in ignition control unit.
A 27
z Insert rail 9.
z Install cable set bracket 10 on rail.

TCG 2020
W 6-4-7
A 28
z Insert rail 8.
z Install cable set (magnifying glass) on rail 8.
A 29
z Mount temperature sensor on mixture cooler.

- Install cable set plug.

TCG 2020
W 6-4-7
A 30

z Install rubber compensators - see job card W 12-3-1.
- Position 6.
A 31
z Insert multifunction rail 2.

z Fit clip.
z Tighten nuts 3.

TCG 2020
W 6-4-7
A 32
z Push flange forward (arrow).

A 33
z Connect the ground cable of the multifunction rail.

z Connect all cable set plugs from the multifunction rail.
z Plug in all ignition cables 1.

TCG 2020
W 6-4-7

TCG 2020
W 6-4-11
Testing mixture cooler (endoscope)
Tools
- Endoscope
Spare parts
- Sealing ring
General information
By endoscopy, it is possible to inspect the state of soiling of the mixture cooler without hav-
ing to remove the mixture cooler first. The degree of soiling can be better determined and
maintenance costs reduced as a result.
Observe the manufacturer specifications for handling the endoscope.
The endoscopy pictures can usually only be evaluated by trained specialists.
The endoscope image can also be projected inverted or upside down depending on the
view of the lens.

TCG 2020
W 6-4-11
Testing mixture cooler (endoscope)
A1
z Unscrew plug.
z Connect endoscope, switch on and feed carefully through the threaded bore.
Make sure that the endoscope is not damaged.

Light reflections can lead to diagnostic errors. Swivel and alternately tilt the endoscope dur-
ing the examination. Make sure that the glass fibre cable does not get damaged during this
process.
z Determine and evaluate the degree of soiling.

z Remove the endoscope carefully.
z Tighten the stopper.

TCG 2020
W 6-6-4
Removing and installing exhaust gas turbocharg er (V12 and V16 en-
gine)
Tools
- Lifting gear
Auxiliary material
- Assembly paste
Spare parts
- Gaskets
- Sealing rings
Technical data

M10 40 Nm

M8 25 Nm

M20x70 250 Nm

M10x25 70 Nm

M12x30 120 Nm

M10x95 - 10.9 69 Nm

M20x2x200 455 Nm

M8 45 Nm

M8 70 Nm

M12x40 - 8.8 86 Nm

M8x40 - 8.8 25 Nm

TCG 2020
W 6-6-4
General information
Danger of burning !
Risk of injury !
Remove turbocharger
A1
z Remove exhaust gas temperature sensor.

- Position 1.
z Open clamps (arrows).
- On both sides.
z Remove top of housing.
- Position 2.
z Remove bottom of housing.
- Position 3.

TCG 2020
W 6-6-4
A2

z Remove heat guard 5.
A3

z Remove exhaust gas turbocharger speed sensor.
- Position 4.

TCG 2020
W 6-6-4
A4
z Hang turborcharger on suitable hoist unit (arrow).
A5

TCG 2020
W 6-6-4
A6
z Remove exhaust manifold.

- Hold at the nuts.
A7

TCG 2020
W 6-6-4
A8

z Lift turbocharger with hoist unit.
Renew turbocharger
Before installing a new turbocharger, the connections for the gas outlet manifold and the
charge air mixture pipe must be aligned.
A9
z Loosen screws (arrows).

z Turn the connections of the exhaust gas outlet flange 6 and the compressor housing 7
into position.

TCG 2020
W 6-6-4
Installing turbocharger

A 10

z Renew gaskets.
z Mount turbocharger with hoist unit.
A 11
z Renew gasket.

TCG 2020
W 6-6-4
A 12
z Renew gasket.
- Hold at the nuts.
z Install exhaust manifold
A 13

TCG 2020
W 6-6-4
A 14
z Install exhaust gas turbocharger speed sensor.

- Position 4.
A 15
z Install heat guard 5.


TCG 2020
W 6-6-4
A 16
z Mount bottom of housing.

- Position 3.
z Mount top of housing.
- Position 2.
z Lock clamps (arrows).
- On both sides.
z Install exhaust gas temperature sensor.
- Position 1.

TCG 2020
W 6-6-4
Removing and installing exhaust gas turbocharger (V20 engine)
Tools
- Lifting gear
Auxiliary material
- Assembly paste
Spare parts
- Gaskets
- Sealing rings
Technical data

M10 40 Nm

M8 25 Nm

M20x70 250 Nm

M10x25 70 Nm

M12x30 120 Nm

M10x95 - 10.9 69 Nm

M16x1.5x190 230 Nm

M8 25 Nm

M8 35 Nm

M12x40 - 8.8 86 Nm

M8x40 - 8.8 25 Nm

TCG 2020
W 6-6-4
General information
Danger of burning !
Risk of injury !
Remove turbocharger
The exhaust gas turbocharger of cylinder side B must be removed first.
If the work for a turbocharger described below is also to be carried out on the second tur-
bocharger, proceed accordingly.
A1
z Open clamps (arrows).

- On both sides and in the centre.
z Remove top of housing.
- Position 1.
- Position 2.

TCG 2020
W 6-6-4
A2

z Remove exhaust gas turbocharger speed sensor (arrow).
A3

z Remove exhaust manifold.

TCG 2020
W 6-6-4
A4
z Hang turborcharger on suitable hoist unit (arrow).
A5

z Lift turbocharger with hoist unit.

TCG 2020
W 6-6-4
A6
z Remove charge air mixture pipe 4 from turbocharger 3.
Renew turbocharger
Before installing a new turbocharger, the connections for the gas outlet manifold and the
charge air mixture pipe must be aligned.
A7
z Loosen exhaust gas outlet flange 5.

- Loosen nuts (arrows).
z Loosen compressor housing 6.
- Loosen screws (arrows).
z Turn the connections of the exhaust gas outlet flange 5 and the compressor housing 6
into position.

TCG 2020
W 6-6-4
z Tighten nuts (arrows).
Installing turbocharger
The exhaust gas turbocharger of cylinder side A must be installed first.

A8

z Renew gasket.
z Install charge air mixture pipe 4 on turbocharger 3.
A9

TCG 2020
W 6-6-4
A 10
z Mount turbocharger with hoist unit (arrow).
A 11


TCG 2020
W 6-6-4
A 12
z Renew gasket.
z Install exhaust manifold
A 13
z Install exhaust gas turbocharger speed sensor (arrow).


TCG 2020
W 6-6-4
A 14

- Position 2.
z Mount top of housing.
- Position 1.
z Lock clamps (arrows).
- On both sides and in the centre.

TCG 2020
W 6-6-4

TCG 2020
W 6-7-2
Testing and setting charge mixture pressure (V20 engines)
Tools
- Electronic measured value sensors, measuring range -1 to 5 bar,
quality class 0.5%
- Measuring connections for charging mixture pressure measurement
Auxiliary material
- TEM key stage 2
Spare parts
- O-rings for stoppers charge mixture pipe; Cu 18x24
References
- TEM-evolution, parameter description
Technical data
Charge mixture pressures - synchronisation of cylinder row A and B (only V20 engine)
DZR actuator type (parameter 11 107)
Setting value 5
General information
Before performing the work described below, you must have the necessary access rights.
The cylinder rows A and B must run in sync to ensure optimum running of the engine. It is
possible to adapt actuator B to actuator A with the TEM system, parameters 11110 und
11111 for this.
Example: Parameter 11110 = 5%

Actuator B is open 5% more than actuator A in idle operation.
The synchronisation of the charging mixture pressure is only possible with the TEM code
step 2.
The two measuring connections must always be in the same place in the charging mixture
pipe on the A and B side, e.g. between cylinders A1-A2 and B1-B2.

TCG 2020
W 6-7-2
The charging mixture pressure test may not be carried out with water columns.
Danger of burning !
Checking and setting charge mixture pressures
A1
z Check parameter 11107 DZR actuator type in TEM, set if necessary.
z In the TEM system

- Select menu item Parameter.
- Select menu item DZR setup.
- Select menu item Show group selection.
- Set parameter 11107 DZR actuator type.

TCG 2020
W 6-7-2
A2
A3
z Unscrew stopper.
z Insert and tighten connections for measuring instruments.
z Connect measuring instruments.
z Start the engine and run on idle.
Check charge mixture pressures - on idle or 0% load.
z Watch the pressure meters.

- The maximum permissible pressure difference between the A side and the B side
may not exceed the specified nominal value.

TCG 2020
W 6-7-2
Set charge mixture pressures - on idle or 0% load.
z In the TEM system

- Select parameter 11110 offset actuator B against A at 0%.
- Adjust the actuator in the menu window and save the entry.
- Read new charge mixture pressures from the pressure meters.
Repeat the setting until the difference between the two measured values is in the nominal
range.
The offset value is below 10% from experience.
If the value is greater than 10%, find and eliminate the cause.
Check the charge mixture pressures - at 100% load.
The load status of the engine must be greater than 90% for the test.
z Run engine up to full load in several steps and watch the pressure meters.
z Run the engine on full load.
- The maximum permissible pressure difference between the A side and the B side
may not exceed the specified nominal value.
Set the charge mixture pressures - at 100% load.
z In the TEM system

- Select parameter 11111 offset actuator B against A at 100%.
- Adjust the actuator in the menu window and save the entry.
- Read new charge mixture pressures from the pressure meters.
Repeat the setting until the difference between the two measured values is in the nominal
range.
The offset value is below 10% from experience.
If the value is greater than 10%, find and eliminate the cause.
z Run up the engine from idle to full load several times and watch the pressure meters.
z Repeat in case of difference values outside the nominal value setting.
z Switch off the engine.
z Remove measuring instruments.
z Unscrew connections for measuring instruments.
z Insert and tighten stoppers with new gaskets.

TCG 2020
W 7-20-2
Settting stepper motor of the gas-air mixer (V12 and V16 engines)
Tools
References
- W 7-22-3 Overhauling gas-air mixer (V12 and V16 engines)
Technical data

10 Nm
General information
The setting can only be made in the test mode of the TEM system.
Settting gas-air mixer (V12 and V16 engines)
A1

z Unscrew screws (arrow).
z Remove stepper motor.

TCG 2020
W 7-20-2
A2
z Check gas-air mixer for smooth action.

- Turn the drive shaft by hand.
If the drive shaft moves sluggishly, the gas-air mixer must be overhauled - see job card W
7-22-3.
A3

z Remove the protective cover.

TCG 2020
W 7-20-2
A4
z Insert drive shaft and turn into the stop.

- Figure A.
z Turn drive shaft a 3/4 turn (270°)
- Figure B.
A5

z Turn in the proximity switch until it touches the switching pin.
z Turn out the proximity switch one and a half turns (540°).

TCG 2020
W 7-20-2
A6
z Set proximity switch.
There are two different versions of the proximity switch.

If the distance from the switching pin is increased, the one version switches on the LED (ar-
row) and the other version switches the LED off.
- Screw the proximity switch in or out until the LED goes on or off.
- The switching point of the LED is the correct setting position.
- Hold against the proximity switch to avoid changing the setting.
z Check the setting of the proximity switch.
- Turn the drive shaft in to the stop.
- Turn the drive shaft out slowly until the LED switches.
At the switching point of the LED the drive shaft must have been turned out a three quarter
turn (270°).
Repeat the setting if necessary.

TCG 2020
W 7-20-2
A7
z Mount protective cover.

z Insert and tighten screws (arrows).
A8
z Mount stepper motor.

- The connection of the cable set plug faces down.

TCG 2020
W 7-20-2
A9
z Select gas-air mixer stop position 1 in the TEM system.

- The stepper motor moves in lean direction until the stop position is reached.
z Select start position 2 in the TEM system.
- The stepper motor moves in rich direction until the start position is reached.
z Select stop position 1 in the TEM system.

TCG 2020
W 7-20-2
Setting stepper motor of the gas-air mixer (V20 engine)
Tools
References
- W 7-22-3 Overhauling gas-air mixer (V20 engine)
Technical data

10 Nm
General information
Setting gas-air mixer (V20 engine)
A1


TCG 2020
W 7-20-2
A2

If the drive shaft moves sluggishly, the gas-air mixer must be overhauled - see job card W
7-22-3.
A3


TCG 2020
W 7-20-2
A4

- Figure A.
z Turn drive shaft a 3/4 turn (270°)
- Figure B.
A5

z Turn in the proximity switch until it touches the switching pin.
z Turn out the proximity switch one and a half turns (540°).

TCG 2020
W 7-20-2
A6
z Set proximity switch.
There are two different versions of the proximity switch.

If the distance from the switching pin is increased, the one version switches on the LED (ar-
row) and the other version switches the LED off.
- Screw the proximity switch in or out until the LED goes on or off.
- The switching point of the LED is the correct setting position.
- Hold against the proximity switch to avoid changing the setting.
z Check the setting of the proximity switch.
- Turn the drive shaft in to the stop.
- Turn the drive shaft out slowly until the LED switches.
At the switching point of the LED the drive shaft must have been turned out a three quarter
turn (270°).
Repeat the setting if necessary.

TCG 2020
W 7-20-2
A7

A8


TCG 2020
W 7-20-2
A9
z Select gas-air mixer stop position 1 in the TEM system.

z Select start position 2 in the TEM system.
- The stepper motor moves in rich direction until the start position is reached.
z Select stop position 1 in the TEM system.

TCG 2020
W 7-20-6
Overhauling gas pressure regulator (model Donkin)
Tools
- Torque wrench
Spare parts
- Set of gaskets
General information
Component overview
A1
Risk of injury !
Diaphragms must be held when removing and installing otherwise they will be de-
stroyed.

TCG 2020
W 7-20-6
Dismantling the gas pressure regulator
A2
z Unscrew screws 1.
- Hold at the nuts.
A3

TCG 2020
W 7-20-6
Dismantling the gas pressure regulator top part
A4
z Remove cover.
- Use a suitable tool.
Do not unscrew the nut without holding otherwise the diaphragms will turn too and
be destroyed.
A5
z Unscrew nut 2.
- Hold with open-end wrench on threaded bolt (magnifying glass).

TCG 2020
W 7-20-6
A6
Unscrew the screw 5 last because this fixes the upper diaphragm plate.
If screw 5 is unscrewed beforehand, the upper diaphragm plate can be turned. The upper
diaphragm may be destroyed.
z Unscrew screws 4.
z Unscrew screw 5.
Do not unscrew the guide pin without holding otherwise the diaphragms will turn too
and be destroyed.
A7
z Unscrew the guide pin 6.

- Hold with open-end wrench on threaded bolt 3.

TCG 2020
W 7-20-6
A8
- Guide pin 6 with plastic reinforcement 7
- Gasket 8
- Upper diaphragm 9
- Valve body 10
z Check components and repair or renew if necessary.
Dismantling the gas pressure regulator bottom part
A9
z Unscrew screws.
z Remove bottom part 11 of diaphragm housing 12.

TCG 2020
W 7-20-6
A 10
z Remove spring 13.

z Remove discs 14.
A 11
z Unscrew cover 15.

z Check components and repair or renew if necessary.

TCG 2020
W 7-20-6
Assembling gas pressure regulator
Assembling gas pressure regulator bottom part
A 12
z Mount cover 15.
A 13
z Insert discs 14.

z Insert spring 13.

TCG 2020
W 7-20-6
A 14
z Renew gasket.
z Install bottom part 11 of diaphragm housing 12.
z Tighten screws.
Assembling gas pressure regulator top part
Do not tighten the guide pin without holding otherwise the diaphragms will turn too
and be destroyed.
A 15
z Insert component.
- Valve body 10
- Upper diaphragm 9
- Gasket 8

TCG 2020
W 7-20-6
- Guide pin 6 with plastic reinforcement 7

z Tighten guide pin 6.
A 16
z Align the diaphragm plate on the hole circle.

z Tighten screw 5.
z Tighten screws 4.
Do not tighten the nut without holding otherwise the diaphragms will turn too and be
destroyed.
A 17
z Insert component.
z Tighten nut 2.
TCG 2020
W 7-20-6
A 18
z Mount cover.
- Use a suitable tool.
A 19

TCG 2020
W 7-20-6
A 20
z Tighten screws.
z Hold at the nuts.

TCG 2020
W 7-20-6

TCG 2020
W 7-20-7
Overhauling gas valve (model RMG)
Tools
- Torque wrench
Spare parts
- Set of gaskets
General information
Risk of injury !

TCG 2020
W 7-20-7
Dismantling gas valve
z Cut off the gas supply by closing the ballcock on the gas regulator line.
A1
z Unscrew screw 1.
z Remove cover 2.
A2
z Remove connecting cable.

- Position 3.
z Pull the cable set out of the housing in the direction of the arrow.
z Unscrew nut 4.

TCG 2020
W 7-20-7
A3
z Remove the housing from the magnetic coil from the top.
A4

z Remove valve body 5.

TCG 2020
W 7-20-7
A5
z Remove valve 6 from housing from above.
A6
z Remove both sealing bands 7 from the valve.

TCG 2020
W 7-20-7
A7
z Press together the spring and spring plate 8.

z Remove lock 9.
z Press out bolt in direction of arrow.
z Remove valve plate 10 from valve body.
A8


TCG 2020
W 7-20-7
Assemble gas valve
A9
z Remove sealing ring from housing.

z Renew gasket.
A 10
z Mount spring and spring plate 8 on valve.

z Press together the spring and spring plate 8.
z Mount valve plate 10.
- Pay attention to positioning of the bore.
z Insert bolt in direction of arrow.
z Fit lock 9.

TCG 2020
W 7-20-7
A 11
z Insert valve 6 in housing.
A 12
z Install valve body 5.


TCG 2020
W 7-20-7
A 13

z Mount housing of the magnetic coil.
A 14
z Turn on and tighten nut 4.

z Insert cable set in housing.
- Lay cable set free from chafing and strain.
z Install connecting cable.
- Position 3.

TCG 2020
W 7-20-7
A 15
z Fit cover 2 and tighten screws 1.

z Open ballcock to restore gas supply.

TCG 2020
W 7-20-7

TCG 2020
W 7-22-3
Overhauling gas-air mixer (V12 and V16 engines)
Tools
Auxiliary material
- Unimolly 220
References
- W 7-20-2 Settting stepper motor of the gas-air mixer (V12 and V16 engines)
Technical data

10 Nm
General information
A correct axial clearance measurement can only be made after dismantling and cleaning
the components.
Dismantling gas-air mixer (V12 and V16 engines)
A1

TCG 2020
W 7-22-3
A2
z Remove shaft coupling.

- Plug shaft coupling to stepper motor.
- Turn stepper motor with coupling side down and shake.
- The shaft coupling must stay attached to the stepper motor.
Both sides of the shaft coupling must be checked.
A3


TCG 2020
W 7-22-3
A4

A5

z Loosen lock nut.
z Turn out the proximity switch.

TCG 2020
W 7-22-3
A6

z Remove proximity switch housing with sealing ring.
A7

z Remove washer.

TCG 2020
W 7-22-3
A8
z Turn out drive shaft.

- Connection piece, shaft coupling, bearing, thread.
A9
z Unscrew switching pin.

TCG 2020
W 7-22-3
A 10
z Remove Venturi insert from housing.

Check components of the gas-air mixer, renew if necessary.
A 11
z Check Teflon tapes (arrows), renew if necessary.

TCG 2020
W 7-22-3
A 12
z Check drive shaft.

- Check guide bearing 1.
- Check thread 2 and wet with Unimolly 220.
If the guide bearing is worn, it must be renewed.
A 13
- Unscrew screws (arrows).

- Pull off shaft coupling 1.
- Pull off guide bearing 2.
Use suitable extractor if necessary.
- Press on new guide bearing to stop.

TCG 2020
W 7-22-3
- Plug on shaft coupling.

- Tighten screws.
z Check Venturi insert.
- Check running surface of the Teflon belts, clean if necessary.
- Check the threaded socket of the drive shaft for wear and firm fit.
- Check thread for switching pin for wear.
If the threaded bush for the drive shaft is worn, a new bush must be stuck in.
The thread inserts on the Venturi insert may not be retapped.
Assembling gas-air mixer
A 14
z Insert Venturi insert carefully.
Pay attention to the position of the thread for the switching pin.
Do not damage the Teflon belts.
Do not turn the Venturi insert when inserting.
z Wet the thread on the guide pin with screw locking agent.
z Insert and tighten the switching pin.

TCG 2020
W 7-22-3
A 15
A 16
z Insert disc.

TCG 2020
W 7-22-3
A 17
z Check axial clearance of the Venturi insert.

- Turn drive shaft out 2 turns.
- Move the Venturi insert backwards and forwards.
If there is a tangible axial clearance, the Venturi insert must be removed and the threaded
bus in the Venturi insert, the drive shaft and the guide bearing renewed.
A 18

z Mount proximity switch housing with sealing ring.

TCG 2020
W 7-22-3
A 19

Short screws - proximity switch housing.
Long screws - protective cover proximity switch.
A 20
z Install proximity switch.
Set proximity switch - see job card W 7-20-2.

TCG 2020
W 7-22-3
A 21

A 22


TCG 2020
W 7-22-3
Overhauling gas-air mixer (V20 engine)
Tools
Auxiliary material
- Unimolly 220
References
- W 7-20-2 Setting stepper motor of the gas-air mixer (V20 engine)
Technical data

10 Nm
General information
A correct axial clearance measurement can only be made after dismantling and cleaning
the components.
Dismantling gas-air mixer (V20 engines)
A1

TCG 2020
W 7-22-3
A2
z Remove shaft coupling.

- Plug shaft coupling to stepper motor.
- Turn stepper motor with coupling side down and shake.
- The shaft coupling must stay attached to the stepper motor.
Both sides of the shaft coupling must be checked.
A3


TCG 2020
W 7-22-3
A4

A5

z Loosen lock nut.
z Turn out the proximity switch.

TCG 2020
W 7-22-3
A6

z Remove proximity switch housing with sealing ring.
A7

z Remove washer.

TCG 2020
W 7-22-3
A8
z Turn out drive shaft.

- Connection piece, shaft coupling, bearing, thread.
A9
z Unscrew switching pin.

TCG 2020
W 7-22-3
A 10

z Separate gas-air mixer 1 and mixture pipe 2.
A 11
z Remove Venturi insert from housing.


TCG 2020
W 7-22-3
Check components of the gas-air mixer, renew if necessary.
A 12
z Check Teflon tapes (arrows), renew if necessary.
A 13
z Check drive shaft.

- Check guide bearing 1.
- Check thread 2 and wet with Unimolly 220.
If the guide bearing is worn, it must be renewed.

TCG 2020
W 7-22-3
A 14
- Unscrew screws (arrow).

- Pull off shaft coupling 1.
- Pull off guide bearing 2.
Use suitable extractor if necessary.
- Press on new guide bearing to stop.

- Plug on shaft coupling.
- Tighten screws.
z Check Venturi insert.
- Check running surface of the Teflon belts, clean if necessary.
- Check the threaded socket of the drive shaft for wear and firm fit.
- Check thread for switching pin for wear.
If the threaded bush for the drive shaft is worn, a new bush must be stuck in.
The thread inserts on the Venturi insert may not be retapped.

TCG 2020
W 7-22-3
Assembling gas-air mixer
A 15
z Insert Venturi insert carefully.
Pay attention to the position of the thread for the switching pin.
Do not damage the Teflon belts.
Do not turn the Venturi insert when inserting.
A 16

z Mount gas-air mixer 1 on mixture pipe 2.

TCG 2020
W 7-22-3
A 17
z Wet the thread on the guide pin with screw locking agent.
z Insert and tighten the switching pin.
A 18
z Insert disc.

TCG 2020
W 7-22-3
A 19
z Check axial clearance of the Venturi insert.

- Turn drive shaft out 2 turns.
- Move the Venturi insert backwards and forwards.
If there is a tangible axial clearance, the Venturi insert must be removed and the threaded
bus in the Venturi insert, the drive shaft and the guide bearing renewed.
A 20

z Mount proximity switch housing with sealing ring.

TCG 2020
W 7-22-3
A 21

Short screws - proximity switch housing.
Long screws - protective cover proximity switch.
A 22
z Install proximity switch.
Set proximity switch - see job card W 7-20-2.

TCG 2020
W 7-22-3
A 23

A 24


TCG 2020
W 7-22-3

TCG 2020
W 7-23-1
Removing and installing throttle valve (V12 and V16 engine)
Tools
General information
Removing throttle valve
z Remove air intake filter housing.
A1
The multifunction bar and the exhaust pipe cladding must be removed on the A and B side.

z Remove clip.

TCG 2020
W 7-23-1
A2

z Lift up the clip.
A3

TCG 2020
W 7-23-1
A4
The installation position must be marked for later mounting before loosening the connection
linkage.
z Unscrew nut.
z Remove screw with washer.
A5
z Remove clamps 2.
z Remove compensator 3.

TCG 2020
W 7-23-1
A6
z Unscrew screws.
z Remove throttle valve with mixture pipe.
A7

z Separate mixture pipe and throttle valve.

TCG 2020
W 7-23-1
Installing throttle valve

A8
Note direction of flow.

The arrow indicates the flow direction of the mixture.
z Mount mixture pipe on throttle valve.

z Tighten screws.
A9
z Insert throttle valve with mixture pipe.


TCG 2020
W 7-23-1
A 10

z Insert compensator 3.
z Mount clip 2.
A 11
Note installation position of the connection linkage.
z Install connection linkage.

- Insert screws with washers.
- Tighten nut (arrow).
TCG 2020
W 7-23-1

z Install air intake filter housing.

TCG 2020
W 7-23-1

TCG 2020
W 7-23-2
Overhauling throttle valve
Tools
Auxiliary material
- DW 70
References
- W 7-23-1 Removing and installing throttle valve (V12 and V16 engine)
General information
If the throttle valve is sluggish or knocked out, it is possible to renew the mounting of the
throttle valve shaft.
Dismantling the throttle valve
z Remove throttle valve - see job card W 7-23-1.
A1

z Remove valve.

TCG 2020
W 7-23-2
A2
z Pull throttle valve shaft out of housing (arrow).
A3
z Remove circlip 1 from housing.

TCG 2020
W 7-23-2
A4
z Place housing under the press.

z Press out both needle bearings from the inside to the outside (direction of arrow).
- Use suitable press-out pin.
Assembling throttle valve
A5
z Place housing under the press.

z Mount needle bearing vertically on bore.
z Press in both needle bearings from the outside to the inside (direction of arrow).
- Until touching the housing.
z Install circlip in housing.

TCG 2020
W 7-23-2
A6
z Push throttle valve shaft into housing.
The guide pin 2 must fit in the recess in the housing.
A7
z Insert valve in housing.
The far side (arrows) faces the mixture cooler side.

TCG 2020
W 7-23-2
A8
z Insert screws (arrows) with locking agent.

z Tighten screws.
z Install throttle valve - see job card W 7-23-1.

TCG 2020
W 7-23-2

TCG 2020
W 8-2-4
Removing and installing lube oil pressure sensor
Tools
Auxiliary material
Spare parts
- Pressure sensor
- Sealing ring
General information
The pre-lubrication pump must be out of op eration during the work process. The engine
must be stopped for this. The pre-lubrication pump will continue to run for a period of time
programmed into the TEM system. At the end of the run-on time the emergency stop must
be pressed. This switches off the periodic lube. This ensures that the pre-lubrication pump
will not start during the work process.
Risk of injury !
Risk of scalding !

lations.

TCG 2020
W 8-2-4
Removing and installing lube oil pressure sensor
A1

z Turn out lube oil pressure sensor 1.
z Tighten lube oil pressure sensor 1.

TCG 2020
W 8-2-5
Removing and installing lube oil temperature sensor
Tools
Auxiliary material
Spare parts
- Temperature sensor
- Sealing ring
General information
The pre-lubrication pump must be out of op eration during the work process. The engine
must be stopped for this. The pre-lubrication pump will continue to run for a period of time
programmed into the TEM system. At the end of the run-on time the emergency stop must
be pressed. This switches off the periodic lube. This ensures that the pre-lubrication pump
will not start during the work process.
Risk of injury !
Risk of scalding !

lations.

TCG 2020
W 8-2-5
Removing and installing lube oil temperature sensor
A1

z Turn out lube oil temperature sensor 1.
z Tighten lube oil temperature sensor 1.

TCG 2020
W 8-4-1
Overhauling lube oil pump
Tools
- Depth gauge
- Extractor
- Plastic wedge
Auxiliary material
- Liquid nitrogen
References
- W 8-4-5 Removing and installing lubricating oil pump
Technical data

M10x80/90 - 8.8 48 Nm
Cover on housing lubricating oil pump

M10x70 - 8.8 50 Nm
Drive gear lubricating oil pump on pump wheel

M12x95 - 10.9 123 Nm
Idler gear lubricating oil pump on gear shaft

M10x100 - 10.9 68 Nm
M8x50 - 10.9 35 Nm

M42x1.5 70 Nm

M8x70 - 8.8 25 Nm

TCG 2020
W 8-4-1

wheel axis
pump housing
Press-in depth bearing liner idler gear

Nominal dimension X 0.35 - 0.95 mm
Nominal dimension Y 0.5 mm
General information
The installation procedure must take place rapidly due to the necessary temperature differ-
ence of the individual components. For this reason, we recommend that you read this job
card carefully and practise the necessary actions before installation.
Risk of injury !
Dismantling lube oil pump
A1

z Remove lube oil pump - see job card W 8-4-5.

TCG 2020
W 8-4-1
A2

z Remove the cover.
- Position 2.
A3
z Block gears (arrows).

- With a wooden or plastic wedge.
z Unscrew screw 4.
z Unscrew screws 6.
z Remove hole disc (magnifying glass).

TCG 2020
W 8-4-1
A4
z Remove intermediate gear.

- Position 3.
z Remove gear (arrow).
- With extractor from gear shaft.
A5
z Pull out gear shafts (arrows).

TCG 2020
W 8-4-1
Renew bearing liners
A6
z Press out bearing liners (arrows) from cover 2.
A7

z Supercool bearing liners in liquid nitrogen.
z Insert bearing liners (arrows) in cover.
- Flus with the sealing surface of the cover.
- Note the position of the lubricating bores 6.
z Check lube oil bore for free passage.
- Blow through lube oil bores with compressed air.

TCG 2020
W 8-4-1
Renew bearing liner intermediate gear
A8
z Press out bearing liner from intermediate gear.

z Heat up intermediate gear.
A9
z Insert bearing liner 2 in intermediate gear 1.
Note installation dimension.
- according to technical data.

TCG 2020
W 8-4-1
Renew intermediate gear axis
A 10
z Press out intermediate gear axis 5.

- Position 5
A 11

z Insert intermediate gear axis.
- Position 5
z Press in intermediate gear axis (arrow).
- See test and setting values for press-in depth.

TCG 2020
W 8-4-1
A 12
z Check press-in depth.
Assembling lube oil pump
A 13

z Insert gear shafts (arrows).

TCG 2020
W 8-4-1
A 14

z Press gear (arrow) onto gear shaft.
- Position 3.
A 15
z Block gears (arrows).

- With a wooden or plastic wedge.
z Insert hole disc (magnifying glass).
z Tighten screws 6.
z Tighten screw 4.

TCG 2020
W 8-4-1
A 16
z Mount cover.
- Position 2.
A 17
z Install lube oil pump - see job card W 8-4-5.

- Position 1.

TCG 2020
W 8-4-5
Removing and installing lubricating oil pump
Tools
Auxiliary material
References
Technical data

0.125 -0.319 mm
0.162 -0.324 mm

M10x80/90 - 8.8 48 Nm

TCG 2020
W 8-4-5
Removing lube oil pump

A1
z Unscrew screws 2.
z Unscrew screws 1.
z Remove the lubricating oil suction intake pipe 3 with gasket.
A2
z Unscrew screws 4.
- From lubrication oil pressure pipe 5.
z Unscrew screw 6.
z Remove lubricating oil pump 7 downwards.
- Use suitable hoist unit.
z Remove gasket from lubricating oil pressure pipe 5.
TCG 2020
W 8-4-5
Install lube oil pump
A3

z Renew clamping sleeves.
z Insert gasket in lubricating oil pressure pipe 5.
z Insert lubricating oil pump 7 from below.
- Use suitable hoist unit.
z Tighten screws 6.
z Set tooth edge clearance.
- Check tooth edge clearance.
- Set tooth edge clearance by inserting shims at position 8 between the lubricating
oil pump and crankcase.
z Tighten screws 4 on lubricating oil pressure pipe 5.
z Insert the lubricating oil suction intake pipe 3 with gasket.

TCG 2020
W 8-4-5
A4
z Screw in screws 1.
z Screw in screws 2.
z Tighten screws 1.
z Tighten screws 2.

TCG 2020
W 8-8-2
Removing, installing and cleaning the lube oil cooler
Tools
Auxiliary material
- Cleaning fluid
- DW 60
Spare parts
- Set of gaskets
References
- W 6-2-7 Removing and installing charge mixture pipe (V12 and V16 engine)
- W 6-2-7 Removing and installing charge mixture pipe (V20 engine)
Technical data
Lubricating oil cooler cover on lubricating oil cooler insert

M8x90 - 10.9 27 Nm
Lubricating oil cooler cover on lubricating oil cooler housing

M8x80/90 - 10.9 27 Nm
Lubricating oil cooler housing on crankcase

M8x30/90 - 10.9 27 Nm
General information
Proceed accordingly for the version with a lubricating oil cooler.
The lube oil cooler must be checked for leaks after cleaning.
Risk of scalding !

lations.

TCG 2020
W 8-8-2
Risk of injury !
Two overpressure valves 1 are installed in the right hand lube oil filter cover.
Two stoppers 2 are installed in the left hand lube oil cover at this position.
The lube oil cooler covers may never be switched.
If a lube oil cooler cover is to be renewed, the overpressure valves or the stoppers
of the old lube oil coolercover must be moved to the new lubricating oil cooler cover.
Insert the components with DW 60.
A1

TCG 2020
W 8-8-2
Component overview
A2
1 Overpressure valves
2 Stoppers
3 Right lube oil pipe
4 Right lube oil cooler
5 Left lube oil cooler
6 Left lube oil pipe

TCG 2020
W 8-8-2
Removing lube oil cooler
z Turn off engine and allow to cool down.

z Remove all the necessary cable set plugs.
z Remove charge mixture pipe - see job card W 6-2-7.
- Right side.
A3

z Unscrew cap (arrow).
z Drain lube oil.
z Tighten caps with new gaskets.
A4
z Remove lubricating oil pressure pipe.

- Unscrew union nut (arrow).
z Remove lube oil pipe to lube oil filter.
TCG 2020
W 8-8-2
A5
z Remove lube oil pipe 7 to pre-lube pump.

- Unscrew union nuts (arrows).
- Unscrew union nut on lube oil pump.
A6
z Unscrew screws.
z Remove lube oil pipe 3.

TCG 2020
W 8-8-2
A7

z Remove lubricating oil pipe 6.
A8
z Attach lubricating oil cooler to hoist unit.

z Unscrew screws.
z Remove lube oil cooler.
- Both lube oil coolers as an assembly.

TCG 2020
W 8-8-2
A9
z Label lube oil cooler cover.

z Remove lube oil cooler cover.
z Remove lube oil cooler insert.

TCG 2020
W 8-8-2
Cleaning lube oil cooler insert

Check lube oil fine filter for leaks.
A 10
z Seal connections for lube oil with stoppers.

z Mix cleaning fluid according to manufacturer specifications.
z Place the lube oil cooler insert 9 in the cleaning bath with cleaning fluid.
z Soften dirt with a cleaning solution.
- The soaking time depends on the degree of soiling.
z Spray down the lubricating oil cooler insert 9 with a powerful water jet.
z Unscrew plug.
z Fill lube oil cooler insert 9 with fuel and rinse through.
z Dry components with compressed air.

TCG 2020
W 8-8-2
Mounting lube oil cooler
A 11
z Check components for damage.

A 12
z Insert lube oil cooler insert.

z Insert lube oil cooler cover.
- Note the identification of the lube oil cooler cover.

TCG 2020
W 8-8-2
z Check lube oil cooler for leaks.

- Close openings on the lube oil cooler.
- Check for leaks.
A 13
z Insert lube oil cooler.

- Both lube oil coolers as an assembly.
A 14
z Insert lube oil pipe 6.


TCG 2020
W 8-8-2
A 15
z Insert lubricating oil pipe 3.

z Tighten screws.
A 16
z Install lube oil pipe 7 to pre-lube pump.

- Tighten union nuts (arrows).
- Tighten union nut on lube oil pump.
- Install lube oil pipe to lube oil filter.

TCG 2020
W 8-8-2
A 17
z Install lubricating oil pressure pipe.

- Tighten union nut (arrow).
z Install all the necessary cable set plugs.
z Fill up lube oil.
z Install charge mixture pipe - see job card W 6-2-7.
- Right side.

TCG 2020
W 8-10-9
Removing and installing lube oil filter console
Tools
- Drain hose
Auxiliary material
Spare parts
- Lubricating oil according to running material specifications
- Set of gaskets
References
Technical data

M8x30/80 - 10.9 27 Nm

25 Nm
General information
Risk of scalding !

lations.

TCG 2020
W 8-10-9
Removing lube oil filter console
A1

z Unscrew screws 1.
A2
z Unscrew screws 2.
z Remove connecting pipe.

TCG 2020
W 8-10-9
A3

z Remove lube oil filter cartridges 3.
A4
z Unscrew screws 4.
z Remove left lube oil filter console.
- Pull out connecting pipes 5 from the side.

TCG 2020
W 8-10-9
A5
z Pull out connecting pipe 5.

- From right hand lube oil filter console (arrow direction).
A6
z Unscrew screws 6.

TCG 2020
W 8-10-9
A7
z Unscrew screws 8.
z Pull off right hand lubricating oil filter console.
Installing lube oil filter console
A8

TCG 2020
W 8-10-9
A9
z Insert right hand lube oil filter console.

z Tighten screws 8.
A 10

z Tighten screws 6.

TCG 2020
W 8-10-9
A 11
z Insert connecting pipe.

- In right hand lube oil filter console (arrow direction).
A 12
z Insert left hand lube oil filter console.

- In connecting pipe 5.
z Tighten screws 4.

TCG 2020
W 8-10-9
A 13
z Install lube oil filter cartridges 3.
A 14
z Insert connecting pipe.

z Tighten screws 2.

TCG 2020
W 8-10-9
A 15
z Tighten screws 1.
z Fill up lube oil.

TCG 2020
W 8-10-9

TCG 2020
W 8-11-15
Overhauling pressure regulating valve (lube oil cooler)
Tools
Auxiliary material
- Cleaning agents
Spare parts
- Set of gaskets
References
General information
Risk of injury!
Observe the regulations for disposal !

Collect operating materials and dispose of them properly in accordance with nation-
al regulations.
Risk of scalding !
When draining hot lube oil.
Remove lube oil pressure regulating valve.
A1
TCG 2020
W 8-11-15

z Unscrew screws 1.
A2
z Unscrew union nuts 2.

z Unscrew screws (magnifying glass).
z Remove lube oil pressure regulating valve.

TCG 2020
W 8-11-15
Cleaning the lube oil pressure regulating valve
Risk of injury !
The component is under spring pressure.
A3
z Close openings (arrows).

z Clean component from outside.
z Unscrew screws 3.
z Remove cover 4 from housing 8.
A4
3 Screws
4 Cover
5 Sealing ring
6 Springs

TCG 2020
W 8-11-15
7 Piston
8 Housing
9 Sealing ring
- Renew lube oil pressure regulating valve if necessary.
A5
z Insert piston 7 in housing 8.
A6
z Insert spring 6 in housing 8.

TCG 2020
W 8-11-15
A7

A8
z Mount cover 4 on housing 8.

z Tighten screws 3.

TCG 2020
W 8-11-15
Installing lube oil pressure regulating valve
Renew all gaskets.
A9
z Insert lube oil pressure regulating valve.

z Tighten screws (magnifying glass).
z Tighten union nut 2.
A 10
z Tighten screws 1.

TCG 2020
W 8-11-16
Overhauling pressure regulating valve (lube oil pump)
Tools
Auxiliary material
References
Technical data

M42x1.5 70 Nm

wheel axis
pump housing
General information
In lube oil trays with covers, the pressure regulating valve can be overhauled without re-
moving the lube oil tray.
Risk of injury !
Danger of burning !

TCG 2020
W 8-11-16
Overhauling pressure regulating valve
A1
z Unscrew overpressure valve (arrow).
A2
z Remove overpressure valve (arrow).

- Remove setting discs 1.

TCG 2020
W 8-11-16
A3
Lay out all components in the order of installation.
1 Setting discs
2 Valve housing
3 Ball
4 Washer
5 Compression spring
6 Spring guide pin
7 Valve cover
- Renew components if necessary.
A4
z Insert valve housing.

z Tighten valve housing.

TCG 2020
W 8-11-16
z Measure distance X from valve housing to lube oil pump housing.
A5
z Insert ball, washer, compression spring and spring guide pin in valve housing (arrow).
A6
z Tighten valve cover.


TCG 2020
W 9-6-2
Removing and installing coolant overflow (cylinder head)
Tools
- Assembly tool for coolant overflow
Auxiliary material
- Acid-free grease
References
General information
Risk of scalding !
Removing coolant overflow
A1

z Remove clip.

TCG 2020
W 9-6-2
A2
z Disconnect coolant pipe from coolant line 2.

z Unscrew screws (arrows) and remove with washers.
z Remove top part of the fastening clips.
z Pull coolant pipe 2 up out of the coolant overflow.
z Remove coolant overflow from cylinder head with pliers.
Installing coolant overflow
A3

- In the cylinder head.

TCG 2020
W 9-6-2
A4
z Knock coolant overflow into cylinder head with assembly tool.
A5


TCG 2020
W 9-6-2
A6
z Insert coolant pipe 2 in coolant overflows.

z Insert top part of the fastening clips.
z Mount coolant line on coolant pipe 2.

TCG 2020
W 9-6-5
Removing and installing coolant housing (lube oil cooler crankcase)
Tools
Auxiliary material
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
References
- W 8-10-9 Removing and installing lube oil filter console
Technical data

M8x30/80 - 10.9 27 Nm

25 Nm
General information
Danger of burning !
Risk of scalding !


TCG 2020
W 9-6-5
Removing coolant housing
A1

z Remove lube oil filter console - see job card W 8-10-9.
z Unscrew screws 2.
z Remove coolant housing 1.
A2
z Unscrew screws 4.
z Remove coolant housing 3.

TCG 2020
W 9-6-5
Install coolant housing
A3
z Remove connection nozzles.

z Clean connection nozzles.
z Mount connection nozzles.
A4
z Renew gasket.
z Mount coolant housing 3.

TCG 2020
W 9-6-5

z Tighten screws 4.
A5
z Renew gasket.
z Mount coolant housing 1.
z Tighten screws 2.
z Install lube oil filter console - see job card W 8-10-9.
z Fill up lube oil.

TCG 2020
W 12-1-4
Removing and installing torsional vibration dampers (V20 engine)
Tools
- Angled wrench
- Pin wrench insert (12-edge)
Technical data

M27x2x195 - 10.9 1. Stage 300 Nm
2. Stage 600 Nm
3. Stage 60°
4. Stage 30°
General information
Check the position of the TDC mark before removing the torsional vibration damper.
To do so, set cylinder A1 to TDC and check the TDC mark.
Make sure the marks are in line when mounting the torsional vibration damper.

TCG 2020
W 12-1-4
Install torsional vibration damper.
A1

z Remove housing cover 1.
A2

z Remove torsional vibration damper housing 3.

TCG 2020
W 12-1-4
A3

z Remove torsional vibration damper 2.
Mounting torsional vibration damper.
A4
Note TDC mark.
z Insert torsional vibration damper 2.


TCG 2020
W 12-1-4
A5
z Insert torsional vibration damper housing 3.

A6
z Insert housing cover 1.


TCG 2020
W 12-3-1
Removing, installing and checking rubber compensators
Tools
- Conventional tools
Technical data
DN 40 / 50 15 Nm
DN 65 / 80 / 100 / 125 20 Nm
DN 150 25 Nm
General information
Check the compensators for damage, e.g. from transport, before installation.
Keep both the inside and outside of the rubber bellows free from foreign bodies, e.g. dirt or
insulating material. Check this before and after assembly.
Do not damage the rubber bellows, do not allow rough vibrations or knocks, do not throw.
Do not attach chains or ropes to the rubber bellows part.
The sealing surfaces of the flanges must be level and clean.
Torsional stress (twisting) during assembly and later during operation must be avoided at
all costs.
Compensators must not be mechanically stressed.
Further pipelines must be secured properly.
Protect the rubber bellows when welding: cover with non-conductive material.
Do not paint the rubber bellows, and do not attach insulation.
Do not exceed the permissible test pressure.
Risk of scalding !
Risk of injury !

TCG 2020
W 12-3-1
Removing rubber compensators
A1
z Drain coolant or lube oil.

z Unscrew screws.
z Remove earthing cable.
z Loosen self-locking nuts on compensator diagonally.
z Unscrew screws.
z Remove compensator.
z Dispose of compensators properly.
Installing rubber compensators
To avoid damage to the rubber bellows from tools, the wrench must be held on the bellows
side and turned on the side of the opposite flange.

z Insert compensator and fix flange with screws and nuts.
- Renew all self-locking nuts.
- Attach earthing cable to a screw connection.
The flange faces of the compensators serve as seals.

Do not use any other sealing materials.

z Fill up coolant or lube oil.

TCG 2020
W 12-6-1
Removing and installing the flywheel
Tools
- Guide pins for flywheel
Auxiliary material
- Lifting gear
Technical data

2. Stage 160 Nm
3. Stage 280 Nm
Coupling on flywheel
Generator on coupling
Generator on base frame

General information
If the flywheel flange is to be removed, the screw connection of the flywheel flange must be
loosened before loosening the flywheel screw connection.
The flange surfaces must be oil and grease free during installation to ensure trans-
mission of the torque prescribed for surface pressing.

TCG 2020
W 12-6-1
Remove flywheel
A1
z Remove flywheel guard.

z Mark installation position 1.
A2
z Block flywheel.

TCG 2020
W 12-6-1
A3
z Remove coupling.
- Unscrew screws 2.
- Unscrew screws 3.
A4
Determine installation position and position of the generator.
z Unscrew screw 4.
- On both sides.

TCG 2020
W 12-6-1
Risk of injury !
Do not push the generator back too far otherwise it might tip from the base frame.
The generator must be secured in its end position, e.g. with straps.
The connecting cables may not be kinked or strained.
The connecting cables should be disconnected if this is not possible.
z Push back the generator on the base frame.

z Remove coupling.
A5
z Loosen screws.
z Unscrew two screws and screw in the guide pins.
z Unscrew the rest of the screws.
z Pull the flywheel off the flywheel flange.
z Remove flywheel with suitable hoist unit.

TCG 2020
W 12-6-1
Installing flywheel
A6
The flange faces of the flywheel and flywheel flange must be free from oil and grease.
Make sure the clamping pin is in the flywheel flange.
z Turn in the guide pins.

z Mount flywheel with suitable hoist unit on flywheel flange.
Make sure that the clamping pin in the crankshaft is in line with the bore in the flywheel.
A7
z Insert and tighten screws dry.

- Screw position 1 to 6.
TCG 2020
W 12-6-1
z Wet the other screws with lube oil.

z Insert and tighten the rest of the screws.
z Unscrew screws.
z Wet screws with lube oil.
A8
z Block flywheel.
z Tighten screws crosswise.
- Tighten screws according to technical specification, 2nd step.
- Tighten screws according to technical specification, 3rd step.
z Insert coupling.
Note installation position.
z Move the generator on the base frame.

z Screw in screws.
- From coupling.

TCG 2020
W 12-6-1
A9
z Align generator.
z Tighten screw 4.
A 10
z Install coupling.
- Tighten screws 3.
- Tighten screws 2.
z Mount flywheel guard.

TCG 2020
W 12-6-1

TCG 2020
W 12-6-4
Checking and replacing the starter mo tor pinion and ring gear on fly-
wheel
Tools
- Extractor
Auxiliary material
- DW 62
Spare parts
- Ring gear if necessary
- Starter pinion if necessary
References
Check components
A1
The the whole area of the teeth flanks.
z Turn starter shaft.

- Check teeth flanks on starter pinion 1.
z Turn the engine.
- Check teeth flanks on flywheel 2.

TCG 2020
W 12-6-4
Removing starter pinion
z Press starter pinion 1 into gear ring on flywheel 2.

z Unscrew nut 3.
z Remove starter pinion with extractor.
z Clean starter shaft.
Install starter pinion.
z Mount starter pinion 1 on starter shaft.

z Turn on nut 3.
z Press starter pinion 1 into gear ring on flywheel 2.
z Tighten nut 3.
Removing ring gear on flywheel
A2
z Unscrew screws 4.
z Remove ring gear on flywheel.
- Turn screws evenly into the three threaded bores 5 until ring gear2 is released
from flywheel.
Installing ring gear on flywheel
z Place ring gear 2 on the flywheel 6.

z Tighten screws 4 evenly crosswise.

TCG 2020
W 13-3-2
Removing and installing the starter (electric starter)
Tools
Technical data
Distance between starter pinion and crown gear flywheel

Nominal dimension 2 mm
Mounting bracket - starter holder (electric starter)

45 Nm
Starter holder - crankcase (electric starter)

25 Nm
General information
Risk of injury !
The unit must be out of operation during the work process. The engine must be shutdown
and locked by the TEM system for this. This guarantees that the unit cannot be started with-
out authorisation while work is in progress.
The flywheel guard must be removed for exact positioning of the starter to be installed to
the ring gear.

TCG 2020
W 13-3-2
Removing starter
A1
z Disconnect the battery.

z Remove cable set.
Terminal Designation
31 Battery minus (-)
50 Starter control
48 not occupied
30 Battery plus (+)
A2
z Remove flywheel cover part 1.

- Unscrew screws.
- Remove flywheel cover.

TCG 2020
W 13-3-2

- Unscrew screws.
A3
z Loosen screws (arrows).

z Pull out starter.

TCG 2020
W 13-3-2
Installing starter
z Insert starter.
A4
z Screw in screws.
A5
The starter must be positioned so that the starter pinion is in front of the flywheel's ring
gear.
z Align starter.
- Set gap 1.
- according to technical data.
z Tighten screws.

TCG 2020
W 13-3-2
A6
z Mount flywheel guard part 2.

- Insert flywheel cover.
- Tighten screw.
- Tighten screw.
A7
z Install cable set.
Terminal Designation
31 Battery minus (-)
50 Starter control
48 not occupied
30 Battery plus (+)
z Connect the battery.
TCG 2020
W 13-3-2

TCG 2020
W 13-3-2
Removing and installing the starter (compressed air starter)
Tools
Technical data
Compressed air starter on console

42 Nm
General information
Risk of injury !
Make sure the compressed air supply is disconnected before beginning work.
The unit must be out of operation during the work process. The engine must be shutdown
and locked by the TEM system for this. This guarantees that the unit cannot be started with-
out authorisation while work is in progress.
The compressed air system must be maintained before starting up the compressed air
starter.
Removing starter
A1
z Drain compressed air from compressed air line.

z Remove valve block.
TCG 2020
W 13-3-2
A2

- Unscrew screws.
- Unscrew screws.
A3

z Remove starter.

TCG 2020
W 13-3-2
Installing starter
A4
z Insert starter.
A5

- Tighten screw.
- Tighten screw.

TCG 2020
W 13-3-2
A6
z Renew gasket.
z Install compressed air line with flange.
z Reconnect compressed air supply.

TCG 2020
W 13-5-3
Checking and adjusting ignition timing
Tools
- Tape measure
- Pocket calculator
- Strobe light
Technical data
Ignition point
according to TEM system parameter 11301
General information
Adjustment or correction of the ignition time is only possible in conjunction with the service
software.
The ignition timing can only be adjusted at engine standstill and in small steps (max . 3°
crank angle).
The adjustment of the stroboscope lamp must be switched off to test and set the ignition
time.
The ignition mark is in different places depending on the engine.
A1
Position 1 = ignition mark V12 and V16 engine

Position 2 = ignition mark V20 engine

TCG 2020
W 13-5-3
Danger of death !
Checking ignition time
A2
z Read standard ignition angle from TEM system.

z Calculate arc dimension for flywheel
L = d x Pi x °KW / 360°
L= Calculated arc dimension in mm

d= Flywheel diameter in mm
Pi = Circle number
°KW = Ignition time in °KW
Calculation example
d= 750 mm
Pi = 3,14
°KW = 25°
L = d x Pi x °KW / 360°
L = 750 mm x 3.14 x 25° / 360°
L = 163.54 mm

TCG 2020
W 13-5-3
A3
z Find TDC mark 1 of cylinder A1 on the flywheel.

z Transfer calculated arc dimension 2 to flywheel.
z Connect the stroboscope lamp to the ignition cable of cylinder A1.
A4
z Start engine.
z Flash on the mark of the ignition time on the flywheel.

TCG 2020
W 13-5-3
Setting ignition timing
The ignition marks on the flywheel and the crankcase must be in line.
If not,
- Switch off the engine.

- adjust camshaft offset 3 in TEM system.
- Start engine.
- Check ignition time.
Repeat testing and setting until the ignition marks are in line.
A5
z Calculate new camshaft offset.

New camshaft offset = camshaft offset + (actual value - nominal value)
New camshaft offset = Calculated camshaft offset in °CA

Camshaft offset = From TEM system in °CA
Actual value = Value measured on the flywheel in °CA
Nominal value = Standard ignition angle according to TEM system in °CA
Calculation example
Camshaft offset = 102,0°

Actual value = 27°
Nominal value = 25°
New camshaft offset = camshaft offset + (actual value - nominal value)
New camshaft offset = 102.0° + (27° - 25°)
New camshaft offset = 104.0°

TCG 2020
W 13-9-1
Removing and installing ignition control unit
Tools
General information
Risk of injury !
Danger of death !
Switch off the power supply to the unit.
Removing the ignition control unit
A1
Installation position 1 - V12 and V16 engine

Installation position 2 - V20 engine
z Remove all cable set plugs from ignition control unit.


TCG 2020
W 13-9-1
Installing the ignition control unit

z Install all cable set plugs in ignition control unit.

TCG 2020
Service
Service
DEPIC
The MWM Parts Identification for Customers (DE-
PIC) offers you spare parts identification individually
adapted to your systems. DEPIC enables you to
generate an order list almost automatically, making
ordering your spare parts more efficient. Order no.:
on request (CD-ROM)
Tutorial programs
The degree of availability, reliability and service life
of equipment and drive assemblies are determined
to a great extent by professional operation and serv-
ice by qualified and experienced operators and
service technicians. The MWM GmbH also offers
service-related seminars for MWM products to the
staff of customers and operators. Apart from the
standard seminars, held in our Training Centre in
Mannheim, it is also possible to arrange special
seminars, either in the Training Centre or at another
location requested by the customer. Information
about the seminar program will be distributed in a
circular. Please ask your MWM Service representa-
tive.

TCG 2020
Service

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Workshop manual

0299 9195 EN, 10/2008

This documentation is intended for the following engine

OBJ_DOKU-26011-001.fm 2 © MWM GmbH 10/2008

Please read and keep in mind...

OBJ_DOKU-26012-001.fm 3 © MWM GmbH 02/2008

Take care when the engine is running

You will find this symbol next to instructions of a general nature.

OBJ_DOKU-26012-001.fm 4 © MWM GmbH 02/2008

The engines of MWM GmbH

Maintenance and care

OBJ_DOKU-26012-001.fm 5 © MWM GmbH 02/2008

OBJ_DOKU-26012-001.fm 6 © MWM GmbH 02/2008

OBJ_BUCH-1169-001IVZ.fm 7 © MWM GmbH TCG 2020

OBJ_BUCH-1169-001IVZ.fm 8 © MWM GmbH TCG 2020

OBJ_BUCH-1169-001IVZ.fm 9 © MWM GmbH TCG 2020

OBJ_BUCH-1169-001IVZ.fm 10 © MWM GmbH TCG 2020

OBJ_DOKU-26013-001.fm 11 © MWM GmbH 02/2008

OBJ_DOKU-26013-001.fm 12 © MWM GmbH 02/2008

Safety Regulations / Rules for Accident Prevention

z for the engine room:

OBJ_DOKU-26013-001.fm 13 © MWM GmbH 02/2008

z for operation and maintenance of the engine:

Rules for disposal

OBJ_DOKU-26013-001.fm 14 © MWM GmbH 02/2008

CC 1 Technical skilled qualified personnel

CC 2 Authorised qualified personnel

OBJ_DOKU-26013-001.fm 15 © MWM GmbH 02/2008

CC 3 Authorised qualified personnel

OBJ_DOKU-26013-001.fm 16 © MWM GmbH 02/2008

Operating manual and workshop manual

General safety regulations

OBJ_DOKU-26013-001.fm 17 © MWM GmbH 02/2008

General safety regulations

OBJ_DOKU-26013-001.fm 18 © MWM GmbH 02/2008

Differentiation of job cards

Sub group of maintenance group

OBJ_DOKU-26013-001.fm 19 © MWM GmbH 02/2008

1 Engine type or system

OBJ_DOKU-26013-001.fm 20 © MWM GmbH 02/2008

OBJ_DOKU-26014-001.fm 21 © MWM GmbH 02/2008

OBJ_DOKU-26014-001.fm 22 © MWM GmbH 02/2008

Design and designations

See also the rating plate

Mixture charge cooling

OBJ_DOKU-26014-001.fm 23 © MWM GmbH 02/2008

OBJ_DOKU-26014-001.fm 24 © MWM GmbH 02/2008

Figure rating plate

1 Engine design designation

OBJ_DOKU-26014-001.fm 25 © MWM GmbH 02/2008

Designation of sides of engine, cylinder numbering and direction of engine rotation

OBJ_DOKU-26014-001.fm 26 © MWM GmbH 02/2008

Figures of engine and units

OBJ_DOKU-26014-001.fm 27 © MWM GmbH 02/2008

1 Air intake filter

OBJ_DOKU-26014-001.fm 28 © MWM GmbH 02/2008

1 Air intake filter

OBJ_DOKU-26014-001.fm 29 © MWM GmbH 02/2008

OBJ_DOKU-26014-001.fm 30 © MWM GmbH 02/2008

OBJ_DOKU-26014-001.fm 31 © MWM GmbH 02/2008

Design and function

1 Inlet rocker arm

OBJ_DOKU-26014-001.fm 32 © MWM GmbH 02/2008