TCD 2015

Workshop Manual
competence level 3
TCD 2015
25 .IR
46 ft
9
01 So
0312 3514 en
12 ine
09 h
ac
M
This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
Downloaded from www.Manualslib.com manuals search engine

25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
Regarding copyright questions and licensing agreements

please contact :
VS-DI, Mr. Sonntag
Tel.: + 49 (0) 221 822-3053
EMail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostraße 1
D-51149 Köln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-Mail: info@deutz.com
Printed in Germany
All rights reserved
1st Edition, 06/2007
The engine company. Order No. 0312 3514 en

TCD 2015 Table of contents
1 Foreword
2 General
3 User notes
3.1 General
3.2 Specifications
3.2.1 Safety regulations and rules for the prevention of accidents
3.2.2 Disposal regulations
3.3 Operating manual and workshop manual
3.4 Job cards
3.5 Explanation of symbols
4 Technical data
4.1 Testing and setting data
25 .IR
4.2 Tightening specifications
5 Job card overview

46 ft
9
5.1 Sorted alphabetically
01 So
5.2 Sorted numerically
5.3 Job card references
12 ine
6 Job cards
7 Commercial tools
09 h
ac
8 Special tools
M
© 06/2006 1/2 8141-001

Table of contents TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/2 8141-001

DEUTZ engines Foreword
1 Foreword
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 05/2005 1/4 8142-001

Foreword DEUTZ engines
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 05/2005 2/4 8142-001

DEUTZ engines Foreword
z Read and observe the information in this docu- z Repair of the engine must correspond to its use
mentation. You will avoid accidents, retain the for the intended purpose. Only parts released by 1
manufacturer's warranty and possess a fully the manufacturer for the respective purpose may
functional and ready to operate engine. be used for conversion work. Unauthorised mod-
ifications to the engine exclude manufacturer lia-
z This engine is built exclusively for purpose ac-
bility for resulting damages. Failure to observe
cording to the scope of delivery - defined by the
this will void the warranty!
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is con- z The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications. A wide range of var-
be liable for damages resulting from this. The iants ensures that the respective special require-
user bears the sole risk. ments are met.
z Use for the intended purpose also includes ob- z The engine is equipped according to the installa-
servance of the operating, maintenance and re- tion case, i.e. not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this z We have done our best to highlight the differenc-
and are aware of the risks involved. es so that you can easily find the operating, main-
z Make sure that this documentation is available to tenance and repair instructions relevant to your
25 .IR
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
46 ft
z Failure to observe this documentation may lead
9
01 So
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
z Prerequisite for proper maintenance and repair is
12 ine
the availability of all the necessary equipment,

conventional and special tools and their perfect
condition.
09 h
z Engine parts such as springs, clamps, elastic re-

taining rings etc. pose an increased risk of injury
ac
when handled incorrectly.

z The pertinent rules for the prevention of acci-
M
dents and other generally recognised health and We are at your service for any questions you may
safety regulations must be observed. have in this matter.
z Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
Your DEUTZ AG
© 05/2005 3/4 8142-001

Foreword DEUTZ engines
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 05/2005 4/4 8142-001

DEUTZ engines General
2 General
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 11/2005 1/4 8143-001

General DEUTZ engines
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 11/2005 2/4 8143-001

DEUTZ engines General
DEUTZ engines are the product of years of re-

search and development. The profound expertise
gained through this, in combination with high de-
mands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability 2
and low fuel consumption. It goes without saying
that the high environmental protection requirements
are also met.
Maintenance and care are the only way the engine

can satisfy the demands you make on it. Compli-
ance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular-
ly heeded.
Please consult one of our service representatives
25 .IR
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
46 ft
Original spare parts from DEUTZ AG are always
9
01 So
manufactured according to the state of the art.
12 ine
09 h
ac
M
© 11/2005 3/4 8143-001

General DEUTZ engines
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 11/2005 4/4 8143-001

User notes
3 User notes
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 12/2005 1/8 8144-001

User notes
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 12/2005 2/8 8144-001

User notes
3.1 General 3.2 Specifications
The documentation of the workshop manual has

3.2.1 Accident prevention and safety regu-
been created based on the engine available at the lations
time of going to press. The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra- cidents must be observed. These are available from
tions and parts due to further developments. professional associations or from dealers. These
The maintenance work described in the operation are dependent on the application site, operating 3
manual and in the workshop manual must be carried mode and the operating and auxiliary materials be-
out on schedule and completely. The maintenance ing used.
personnel must have the necessary technical Special protection measures are specified depend-
knowledge to perform the work. Safety and protec- ing on the work being carried out, and are identified
tion devices which are removed during maintenance in the job description.
work must be replaced again afterwards. Among other things it generally applies that:
Caution! z for the personnel:
The rules for the prevention of accidents and the – Only briefed personnel may operate or main-
safety regulations must be observed during mainte- tain the engine. Unauthorised persons are
nance work.
25 .IR
prohibited access to the machine room.
Reference is made in the workshop manual job – Wear close-fitting clothing and ear protectors
cards to the regulations in chapter 3.2. These must in the machine room when the engine is in op-
be read before working on the engine and must be eration.
strictly followed.
46 ft – Only deploy trained personnel to do repairs
9
01 So
The maintenance intervals and the work to be per- and maintenance work.
formed are specified in the maintenance schedule
– Do not work on the fuel system when the en-
of the operation manual. The job cards contain tech-
gine is running. The fuel system is under high
nical documentation on the execution of mainte-
12 ine
pressure - danger of death.

nance work.
– Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
09 h
– Ensure adequate ventilation (do not cover air

ac
shafts).
– Provide first aid kit and suitable fire extinguish-
ers. Check the filling and readiness for opera-
M
tion regularly.
– Only store inflammable materials in the ma-
chine room if they are essential for operation
of the system.
– Smoking and naked flames are prohibited in
the machine room.
z for operation, maintenance and repairs on the
engine:
– Wait 30 seconds after switching off the engine
before working on the fuel sytem.
– After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6.2 Fuel system“.
– Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
– Cleaning, maintenance and repair work may
only be performed with the engine at a stand-
still and secured against starting.
– Injection lines and high pressure pipes must
not be deformed.
© 12/2005 3/8 8144-001

User notes
– Damaged injection lines and high-pressure z Remove loose parts (for example paint chips
pipes must be renewed. from assembly work) with an industrial vacuum
– Injection lines and high pressure fuel lines cleaner or other suction device. Only suction may
must never be connected when the engine is be used in assembly work on the open fuel sys-
running. tem.
– Do not place hands near to a leak in the high z Only work on the fuel system in a clean environ-
ment (no dust, no grinding or welding). Avoid
3 pressure fuel system.
draughts (dust). Clean the workshop floor regu-
– Also carefully check all high pressure compo-
larly. No brake or performance test benches may
nents visually before performing tests on the
be kept or operated in the same room.
running engine. Wear suitable protective
clothing (for example protective glasses). z Air currents which kick up dust, such as those
Leaks are a potential source of danger for caused by brake repairs or the starting of en-
workshop personnel. gines, should be avoided.
– Even if no leaks are discernible on the high z For work such as removal and installation on de-
pressure fuel system, the workshop personnel fective hydraulic components on the Common
should avoid the immediate danger zone or Rail System it is recommended to partition off a
wear suitable protective clothing (such as pro- separate workshop area in the factory. This must
tective glasses) when performing tests on the be separate from other areas in which general
25 .IR
running engine and during the first trial run. vehicle repairs such as brake repairs are carried
out.
– Always stay out of range of a fuel jet, as it
could cause severe injury. z No general machine tools may be operated in
46 ft
– Smoking is strictly prohibited when working on
this room.
9
z Regular cleaning of the workshop area is manda-
01 So
the fuel system.
tory. Draughts, ventilation systems and heating
– Do not work near to sparks and flames.
fans should be minimised.
– Never disconnect an injector when the engine
z Areas of the engine room from which particles of
12 ine
is running.
dirt could be loosened (for example the bottom
3.2.2 Cleanliness instructions and meas- part of the tipped driver cab) must be covered
ures for handling the DEUTZ Com- with fresh clean film.
mon Rail System
09 h
z Working materials and tools must be cleaned be-

The DEUTZ Common Rail system used in the fore work. Only use tools without damage to the
ac
DEUTZ engines consists of high-precision compo- chrome plating or tools which are not chrome-
nents which are exposed to extreme stress. Great plated.
attention must be paid to cleanliness when working Notes and measures to be observed during work
M
on the fuel system due to the high precision technol- on the fuel system or with the fuel system open.
ogy.
z Only work in clean overalls.
Notes and measures to be observed before
z Only lint-free cleaning cloths may be used for
starting work on the fuel system
work on the fuel system.
z The fuel system must be closed. Make a visual z Remove loose parts (for example paint chips
inspection for leaks / damage to the fuel system. from assembly work) with an industrial vacuum
z Clean the whole engine and engine room with the cleaner or other suction device. Only suction may
system closed before starting work on the fuel be used in assembly work on the open fuel sys-
system. tem.
z The engine must be dry when you start working z Working materials and tools must be cleaned be-
on the fuel system. fore work. Only use tools without damage to the
z Blowing (dry) with compressed air is only permis- chrome plating or tools which are not chrome-
sible with the fuel system closed. plated.
z When using a steam jet, first cover up the control z Do not use used cleaning fluid or test fluid for
unit, the cable plugs, all other electrical plug con- cleaning.
nections and the generator. Also, the steam jet z Compressed air must not be used for cleaning on
may not be pointed directly at them. the open fuel system.
z Electrical plug connections must be plugged z Work on removed components may only be per-
when spraying. formed at a suitably equipped workbench.
© 12/2005 4/8 8144-001

User notes
z When removing and installing components, no operating materials among other things. The re-
materials which can leave behind particles or fi- newed parts / operating materials must be stored,
bres (cardboard, wood, cloths) may be used. transported and disposed of according to regula-
z Removed parts may only be rubbed down with tions. The owner himself is responsible for this.
clean, lint-free cloths. No dirt particles may be Disposal includes recycling and the scrapping of
rubbed into the components. parts / operating materials, although recycling has
z Openings on the components and on the engine priority.
3
must be closed immediately with suitable stop- Details of disposal and their monitoring are gov-
pers/caps. erned by regional, national and international laws
z The stoppers/caps may only be removed imme- and directives which the system operator must ob-
diately before installing. serve on his own responsibility.
z Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
z Only remove new parts from the original packag-
ing just before installation.
z Removed components must be kept in new, seal-
25 .IR
able bags or - if available - in the packaging of the
new parts.
z Always use the original packaging of the new part
46 ft
to send back the removed components.
9
Notes and measures for the vehicle workshop
01 So
area
z For work such as removal and installation on de-
fective hydraulic components on the Common
12 ine
Rail System it is recommended to partition off a

separate workshop area in the factory. This must
be separate from other areas in which general
09 h
vehicle repairs such as brake repairs are carried

out.
ac
z The workshop floor is sealed or tiled.

z No welding gear, grinders, general machine
M
tools, brakes or performance test benches may

be operated in this room.
z Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
fans should be minimised.
Notes and measures for workbench and tools in
the vehicle hall
z A special workbench must be set up for work on
removed components.
z Clean the removal and installation tools regularly
and keep them in a closed tool cabinet.
z Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device.
z Working materials and tools must be cleaned be-
fore work. Only use tools without damage to the
chrome plating or tools which are not chrome-
plated.
3.2.3 Disposal regulations
The work described in the operation manual and
workshop manual necessitates renewal of parts and
© 12/2005 5/8 8144-001

User notes
3.3 Operation manual and workshop 3.4 Job cards

manual The job cards are divided in the workshop manual
To structure the information to suit the user, the into "W" and "I" job cards.
service documentation is divided into operation The "W" job card documents standard repairs on the
manual and workshop manual. engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
The operation manual contains a general descrip-
3 tion and instructions for all other maintenance work.
card.
The "I" job card additionally documents the appro-
It contains the following chapters: priate work procedures for repairing the engine and/
1. Contents, General or its components. The workshop must satisfy spe-
2. Engine description cial conditions to perform these work procedures.
3. Operation Special tools and machine tools must be available,
for example.
4. Operating media
3.4.1 Numbering of job cards
5. Maintenance
The job card numbers follow the pattern W 02-04-
6. Care and maintenance work
01. The individual parts of this pattern are explained
7. Faults, causes and remedies below:
25 .IR
8. Engine conservation z W 02-04-01: Documentation type
9. Technical data – W.... Workshop manual
10.Service – I ...... Repair instructions
46 ft
The workshop manual assumes knowledge of the z W 02-04-01: Maintenance group
9
contents of the operation manual. This applies es-
01 So
– 00 ... General / interdisciplinary activities
pecially for the safety regulations. The workshop
manual describes repairs to the engine and compo- – 01 ... Cylinder head
nents for which more effort and appropriately quali- – 02 ... Drive system
12 ine
fied technicians are required. – 03 ... Crankcase

– 04 ... Engine control system
– 05 ... Speed governing
09 h
– 06 ... Exhaust system / Charging

ac
– 07 ... Fuel system

– 08 ... Lube oil system
– 09 ... Cooling system
M
– 10 ... Compressed air system

– 11 ... Monitoring system
– 12 ... Other components
– 13 ... Electrical system
z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number
© 12/2005 6/8 8144-001

User notes
3.4.2 Structure of a job card 3.5 Explanation of symbols
1 2 3
Danger!
Triebwerk of death or to health. Must be observed!
W 02-04-01 4
For example: The incorrect use or con- 3
5 version of the turbocharger can lead to
16 serious injury.
6
Caution!
15
6 7 Danger to the component/engine. Non-
compliance can lead to destruction of the
14
component/engine.
8 Must be observed!
13
Note
General notes on assembly, environmen-
tal protection etc. No potential danger for
25 .IR
12
man or machine.
8
Tool
Conventional and special tools required
46 ft for the work.
9
01 So
Auxiliary materials
11 10 9 Working materials required in addition to
the tools for performing the work
1. DEUTZ AG,
12 ine
(e.g. greases, oils, adhesives, sealants)

publisher of service documentation
References
2. Engine type (e.g. TCD 2013 4V)
to important documents or job cards for
3. Maintenance group the work process.
09 h
4. Job card number or topic For example: Job card W 04-05-05

ac
5. Title of job card Reference

6. Reference to other job cards to a document or a job card within the
7. Chapter work process.
M
8. Graphic or photo Test and setting data

9. DEUTZ internal creation number The necessary values are specified here.
If several values are necessary, a cross
10.Page number
reference is given to the Test and Setting
11.Date of issue of job card Values table.
12.Note For example:
13.Danger / Important ID no. P01 61 = valve clearance, inlet
14.Work sequence Tightening specification
15.Special tools; auxiliary materials The necessary values are specified here.
If several values are necessary, a cross
16.Conventional tools
reference is given to the Tightening Spe-
cifications table.
For example:
ID no. A01 001 = cylinder head screws
© 12/2005 7/8 8144-001

User notes
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 12/2005 8/8 8144-001

TCD 2015 Technical data
4 Technical data
4.1 Testing and setting data
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 1/28 8145-001

Technical data
Testing and setting data TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/28 8145-001

ID no. Name Information Series Value Unit
© 06/2006
General engine data
Length of engine TCD 2015 V06 1200 mm
TCD 2015
V06 1107 mm
P00 01 about all data (Railway)
Length of engine with connection housing
TCD 2015
V08 1454 mm
(Railway)
M
TCD 2015
Width of engine TCD 2015 V06 1200 mm

TCD 2015
V06 1125 mm
Width of engine with connection housing
ac
TCD 2015
V08 1120 mm
(Railway)
09 h
Height of engine TCD 2015 V06 1300 mm
TCD 2015
V06 835 mm
3/28
12 ine
Height of engine with connection housing
TCD 2015
V08 837 mm
(Railway)
01 So
TCD 2015 V06 approx. 1020-1200 kg
46 ft
TCD 2015 V08 1244 kg
P00 04 Engine weight according to DIN 70020-A without operating media TCD 2015
V06 920 kg
(Railway)
25 .IR
TCD 2015
9 (Railway)
V08 1160 kg
P00 10 Working principle TCD 2015 4 stroke -

P00 20 Combustion process TCD 2015 Direct injection -
TCD 2015 V06 11906 cm3
P00 30 Total volume
TCD 2015 V08 15874 cm3
P00 31 Bore TCD 2015 132 mm
8145-001
Technical data
Testing and setting data
4
4
© 06/2006
P00 32 Stroke TCD 2015 145 mm
TCD 2015 17.5:1 -
P00 40 Compression ratio TCD 2015
16.5:1 -
(Railway)
Technical data
P00 50 Direction of rotation looking onto the flywheel TCD 2015 counter-clockwise -
3200-3400 kPa
P00 51 Compression pressure TCD 2015
M (32-34) (bar)

P00 70 Spark gap TCD 2015 V06 120 °
TCD 2015 V06 A1-B3-A3-B2-A2-B1 -

ac
P00 71 Ignition sequence A1-B4-A4-B1-B3-A3-
TCD 2015 V08 -
B2-A2
09 h
P00 81 Cylinder and side view TCD 2015 T00 81 -
Cylinder head
4/28
12 ine
Standard +0.0
P01 01 Valve seat insert, bore (inlet) TCD 2015 47.500 0 mm
fit H6
+0.0
01 So
P01 02 Valve seat insert, bore (outlet) Standard TCD 2015 44.500 0 mm
+0.0
P01 03 Valve seat insert, bore (inlet) 1. oversize level TCD 2015 47.800 0 mm
46 ft
+0.0
P01 04 Valve seat insert, bore (outlet) 1. oversize level TCD 2015 44.300 0 mm
+0.0
P01 05 Valve guide, bore in cylinder head Standard TCD 2015 15.000 0 mm
25 .IR
+0.0
P01 06 Valve guide, bore in cylinder head 1. oversize level
9 TCD 2015 15.100 0 mm
+0.0
P01 07 Valve guide, bore in cylinder head 2. oversize level TCD 2015 15.200 0 mm
P01 08 Cylinder head, height Standard TCD 2015 120 mm
TCD 2015
P01 09 Cylinder head, height Undersize TCD 2015 119.70 mm

Valve guide
P01 11 Valve guide, external diameter Standard TCD 2015 15.0 mm
8145-001
© 06/2006
P01 12 Valve guide, external diameter 1. oversize level TCD 2015 15.1 mm
P01 13 Valve guide, external diameter 2. oversize level TCD 2015 15.2 mm
P01 14 Valve guide, inside diameter (inlet) Standard TCD 2015 8.030 +0.0
0 mm
+0.0
P01 15 Valve guide, inside diameter (outlet) Standard TCD 2015 8.030 0 mm
Valve seat insert
+0.07
P01 21 Valve seat insert, outside diameter (inlet) Standard
M TCD 2015 47.5 +0.06 mm
TCD 2015

+0.07
P01 22 Valve seat insert, outside diameter (outlet) Standard TCD 2015 44.0 +0.06 mm
+0.07
P01 23 Valve seat insert, outside diameter (inlet) 1. oversize level TCD 2015 47.800 +0.06 mm
+0.07
ac
P01 24 Valve seat insert, outside diameter (outlet) 1. oversize level TCD 2015 44.300 +0.06 mm
Valve
09 h
+0.00
P01 31 Valve shaft diameter (inlet) Standard TCD 2015 7.97 -0.00 mm
+0.00
P01 32 Valve shaft diameter (outlet) Standard TCD 2015 7.96 -0.00 mm
5/28
12 ine
P01 33 Valve shaft clearance (inlet) Wear limit TCD 2015 0.12 mm
P01 34 Valve shaft clearance (outlet) Wear limit TCD 2015 0.14 mm
01 So
+0.
P01 35 Valve edge thickness, valve head (inlet) Standard TCD 2015 1.9 -0.2 mm
+0.
46 ft
P01 36 Valve edge thickness, valve head (outlet) Standard TCD 2015 1.5 -0.2 mm
+0.
P01 37 Valve head diameter (inlet) Standard TCD 2015 46.0 -0.2 mm
+0.
25 .IR
P01 38 Valve head diameter (outlet) Standard TCD 2015 42.0 -0.2 mm
Valve seat
9
Standard
(from the center of the valve head to the TCD 2015 2.5 mm
cylinder head sealing surface)
P01 45 Valve stand back dimension (inlet)
Wear limit
(from the center of the valve head to the TCD 2015 1.20 - 1.60 mm
8145-001
Technical data
4
4
© 06/2006
Standard
(from the center of the valve head to the TCD 2015 2.4 mm
P01 46 Valve stand back dimension (outlet)
Wear limit
(from the center of the valve head to the TCD 2015 1.25 - 1.65 mm
Technical data

Valve spring
Valve spring length
M
untensioned, normal 58.7

P01 51 TCD 2015 mm
Valve spring wire diameter 4.25
Valve clearance
ac
+1
with rotation angle disc 90 °
P01 61 Valve clearance (inlet) TCD 2015
09 h
with cold engine +0.
0.25 0 mm
with feeler gauge
+1
with rotation angle disc 108 °
6/28
12 ine
P01 62 Valve clearance (outlet) with cold engine TCD 2015 +0.
0.30 0 mm
with feeler gauge
01 So
Valve overlap according to adjustment
P01 63 Valve clearance setting TCD 2015 T01 63 -
schematic
46 ft
Rocker arm/bracket
+0.02
P01 72 Rocker arm, bore, diameter (outlet) TCD 2015 28 0 mm
25 .IR
+0.02
P01 73 Rocker arm, bore, diameter (inlet) 9 TCD 2015 28 0 mm
-0.04
P01 74 Rocker arm shaft (diameter) TCD 2015 28 -0.06 mm
P01 75 Axial clearance of the toggle levers Axial bearing clearance with cold engine TCD 2015 0.2 - 0.4 mm
TCD 2015
8145-001
© 06/2006
10 Rz
Surface for cylinder head gasket TCD 2015
20 [Rmax]
P01 93 Roughness
16 Rz
Surface for cylinder head cover TCD 2015
20 [Rmax]
Main running gear
Crankshaft M
TCD 2015

Main journal
-0.01
P02 03 Main journal, diameter Standard TCD 2015 108 -0.03 mm
ac
Undersize stage
P02 04 Main journal, diameter TCD 2015 0.25 each mm
3 stages
09 h
P02 06 Main journal, unroundness Wear limit TCD 2015 0.010 mm
+6
P02 07 Main journal, hardness Standard TCD 2015 50 0 HRC
7/28
12 ine
Fit journal
+0.06
P02 11 Fit bearing, width Standard TCD 2015 38 mm
01 So
+0.06
P02 12 Fit bearing, width Oversize stage TCD 2015 38.25 mm
+0.06
P02 13 Fit bearing, width Limit value for oversize stage TCD 2015 38.50 mm
46 ft
Lifting journal
-0.01
P02 22 Lifting journal, diameter TCD 2015 91 -0.03 mm
25 .IR
Undersize stage
P02 23 Lifting journal, diameter
3 stages
9 TCD 2015 0.25 each mm
P02 25 Lifting journal, unroundness Wear limit TCD 2015 0.010 mm

P02 26 Radial run-out, crankshaft maximum permissible deviation TCD 2015 0.15 mm
Main bearing
P02 34 Axial clearance of crankshaft permissible TCD 2015 0.205 - 0.392 mm
8145-001
Technical data
4
4
© 06/2006
Standard +0.05
P02 35 Thrust ring half, thickness TCD 2015 3.36 mm
(upper and lower half)
1. oversize stage=0.125 mm +0.05
2. oversize stage=0.125 mm +0.05
Technical data

Connecting rod M

Permissible deviation (a) max. 0.06 mm
P02 41 Parallelism of the connecting rod TCD 2015
at a distance of (x) 100 mm

ac
Permissible deviation (A) to (B) max. 0.10 mm
P02 42 Taper on periphery of the connecting rod TCD 2015
at a distance of (x) 100 mm
09 h
+0.0
P02 43 Small end bush, inside diameter installed, unmachined TCD 2015 52.040 0 mm
Small end bush clearance between piston pin
P02 45 TCD 2015 0.04 - 0.063 mm
8/28
12 ine
and small end bush
P02 46 Assembly temperature of the small end bush cooled in coolant to TCD 2015 approx. -40 °C
01 So
P02 47 Assembly temperature of the connecting rod heated up in hot-air oven to TCD 2015 max. 220 °C
Big end bearing
46 ft
installed
+0.05
P02 52 Big end bearing shells, inside diameter identification (n) / top TCD 2015 91.048 0 mm
lining spattered
25 .IR
P02 54 Big end bearing
9
Undersize stage
3 stages
TCD 2015 0.25 each mm
after separation and re-assembly of rod +0.03

P02 55 Big end bearing, bore in connecting rod TCD 2015 mm
TCD 2015
95 -0.00
and cover
Theoretical clearance between the big end bea-
P02 56 TCD 2015 0.060 - 0.136 mm
ring / lifting journal
P02 57 Big end bearing clearance Wear limit TCD 2015 0.17 mm
8145-001
© 06/2006
Piston pin
P02 61 Piston pin, diameter TCD 2015 51.992 - 52.000 mm
P02 62 Piston pin clearance Wear limit TCD 2015 0.09 mm
Piston
Measuring point 1
at height 22.5 mm +0.00
P02 71 Piston, diameter TCD 2015 132 -0.00 mm
(Identification of the installation position
M
TCD 2015

on the piston head)
Measuring point 2
ac
on the piston head)
09 h
Measuring point 3
9/28
12 ine
on the piston head)
P02 75 Piston projection 1.4 = 1 hole (cylinder head gasket) TCD 2015 -0.05 to 0.10 mm
01 So
P02 76 Piston projection 1.6 = 2 holes (cylinder head gasket) TCD 2015 0.10 to 0.30 mm
P02 77 Piston projection 1.8 = 3 holes (cylinder head gasket) TCD 2015 0.30 to 0.51 mm
46 ft
+0.0
P02 78 Piston pin, bore TCD 2015 52 +0.00 mm
Piston rings
25 .IR
Standard 0.35 - 0.45 mm
9
P02 84 Closed gap, piston ring 1 Wear limit TCD 2015
(identification TOP in direction of piston 0.9 mm
head)

head)
8145-001
Technical data
4
4
© 06/2006

head)
Measure with trape-
Technical data
P02 87 Axial clearance, 1st piston ring Wear limit TCD 2015 zoidal groove wear -
gauge
P02 88 Axial clearance, 2nd piston ring
M
Wear limit TCD 2015 0.25 mm

P02 89 Axial clearance, 3rd piston ring Wear limit TCD 2015 0.15 mm
Crankcase
ac
Camshaft bearing
09 h
Bore diameter for camshaft bearing liner in the +0.03
P03 11 TCD 2015 75.000 0 mm
crankcase
+0.03
P03 12 Camshaft bearing liner, outside diameter TCD 2015 75.090 0 mm
12 ine
10/28
+0.05
Camshaft bearing liner, inside diameter 69.990 0 mm
P03 13 TCD 2015 +0.0
Camshaft bearing liner, wall thickness 2.0493 0 mm
01 So
P03 14 Camshaft bearing liner, inside diameter Wear limit TCD 2015 70.100 mm
+0.03
46 ft
P03 23 Tappet bores, diameter TCD 2015 25.000 0 mm
P03 24 Tappet bores, diameter Wear limit TCD 2015 25.050 mm
25 .IR
+0.2
Installation depth of the crankshaft sealing ring First assembly 0.5 -0.2 mm
P03 25 TCD 2015
(rear cover)
9
Repairs
+0.2
3.5 -0.2 mm
+0.
Installation depth of the crankshaft sealing ring First assembly 3 -0.5 mm
P03 26 TCD 2015
TCD 2015
(genset support) +0.

Repairs 7 -0.5 mm
Cylinder liners
+0.0
P03 31 Cylinder bore Standard TCD 2015 132 -0.0 mm
+0.0
P03 35 Fitting depth for cylinder liner TCD 2015 9.87 -0.0 mm
8145-001
© 06/2006
0
P03 36 Collar height of cylinder liner TCD 2015 9.02 -0.0 mm
+0.0
P03 37 Thickness of shim Standard TCD 2015 1.0 -0.0 mm
P03 39 Overhang of cylinder liner TCD 2015 0.09 mm
Control system
Camshaft
-0.06
P04 31 Camshaft bearing pin diameter M Standard TCD 2015 70 -0.07 mm
TCD 2015

P04 35 Axial clearance of the camshaft TCD 2015 0.25 - 0.75 mm
Thickness of the gasket for axial clearance set-
P04 37 TCD 2015 0.3 mm
ting
ac
Overhang of the parallel pin on the camshaft gear
P04 39 TCD 2015 5.000 mm
wheel
09 h
Axial clearance of the camshaft for injection
P04 43 TCD 2015 0.2 - 0.45 mm
pumps
12 ine
11/28
Tooth edge clearance of the idler gear - idler gear
P04 44 TCD 2015 0.04 - 0.3 mm
to camshaft gear wheel
01 So
Speed governing system
Clearance between speed governor (crankshaft) +0.
P05 91 TCD 2015 1.0 mm
46 ft
and flywheel
Clearance between speed governor (camshaft)
P05 92 TCD 2015 0.3 - 0.9 mm
and camshaft gear wheel
25 .IR
Fuel system
9
P07 19 Plunger lift of the camshaft for injection pumps see name plate TCD 2015 4.00 mm
Tooth edge clearance between gear wheel of the
P07 20 camshaft for injection pumps and camshaft gear TCD 2015 0.04 - 0.3 mm
wheel
Injection valve
P07 52 Nozzle opening pressure of the fuel injector TCD 2015 280 - 288 bar
8145-001
Technical data
4
4
© 06/2006
P07 91 Installation dimensions of the fuel shut-off valve dimension X TCD 2015 approx. 25 mm
P07 92 Installation angle of the fuel pipe dimension X TCD 2015 approx. 30 °
Lubricating oil system
Lube oil pressure
Technical data
for 3.00 bar 35

Basic setting of the pressurestat when using new
P08 63 for 3.50 bar TCD 2015 32 mm
parts M

for 4.00 bar 29.1
Cooling system
ac
Coloured marking black
P09 11 Thermostat, start opening (A-bank) TCD 2015 79 °C
venting notch top
09 h
P09 12 Thermostat, start opening (B-bank) Venting notch top TCD 2015 87 °C
P09 13 Thermostat, stroke distance TCD 2015 at least 8 mm
12 ine
12/28
Other components
Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device
500 N
rator, 120 Ampere) 8115
01 So
P12 11 TCD 2015
Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device +5
550 -50 N
rator, 55 Ampere) 8115
46 ft
Tension of the single V-belt (generator, 120 Am- Check after 15 minutes running under +5
350 -50 N
pere) load
25 .IR
P12 21 TCD 2015
Tension of the single V-belt (generator, 55 Ampe- Check after 15 minutes running under
9 +5
300 -50 N
re) load
Screw-in height of the flame glow plug in connec- 0
P13 66 dimension X TCD 2015 60 -3 mm
TCD 2015
ting line
8145-001
Technical data
TCD 2015 Testing and setting data
T00 81
Cylinder and side view
engine TCD 2015 V06 A3
A2
A1
B3
B2
B1
© 45418-0
25 .IR
T00 81
Cylinder and side view
engine TCD 2015 V08
46 ft A3
A4
9
01 So
A2
A1 B4
B3
12 ine
B2
B1
09 h
ac
M
© 45885-0
T01 63
Setting valve clearance
engine TCD 2015 V06
Ignition sequence: A1-B3-A3-B2-A2-B1
Setting on
Valve overlap on cylinder
cylinder
A1 B2
B3 A2
A3 B1
B2 A1
A2 B3
B1 A3
© 00000-0
© 06/2006 13/28 8145-001

Technical data
Testing and setting data TCD 2015
T01 63
engine TCD 2015 V08
Ignition sequence: A1-B4-A4-B1-B3-A3-B2-A2
Setting on
Valve overlap on cylinder
cylinder
A1 B3
B4 A3
A4 B2
4 B1 A2
B3 A1
A3 B4
B2 A4
A2 B1
© 00000-0
25 .IR
T13 054
Connection plan of the injection pumps
engine TCD 2015 V06
46 ft
9
01 So
Item Component Cylinder assignment
1 Y15.1 A1
2 Y15.5 A2
12 ine
3 Y15.3 A3
1 2 3
4 Y15.6 B1
5 Y15.4 B2
6 Y15.2 B3
09 h
ac
4 5
M
6
© 40971-0
T13 054
Connection plan of the injection pumps
engine TCD 2015 V08
Item Component Cylinder assignment
Y15.1 A1
Y15.8 A2
Y15.6 A3
Y15.3 A4
Y15.4 B1
Y15.7 B2
Y15.5 B3
Y15.2 B4
© 00000-0
© 08/2008 14/28 8145-002

TCD 2015 Technical data
4.2 Tightening specifications
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 15/28 8145-001

Technical data
Tightening specifications TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 16/28 8145-001

Post-
Pre-clam-
© 06/2006
ID no. Name Screw type Notes / Remarks Series clamping
ping value
value
Mounting feet/engine moun-
TCD 2015 106 Nm
ting on crankcase, elastic
A00 001 Clamping bracket on crankcase Mounting feet/engine moun-
ting on crankcase, rigid TCD 2015 30 Nm +45°
oil lightly
A00 002 Clamping bracket on adapter for assembly block TCD 2015 90 Nm
M
TCD 2015

elastic TCD 2015 106 Nm
A00 003 Mounting feet/engine mounting on crankcase rigid
TCD 2015 30 Nm +45°
ac
oil lightly
Screw can be used a
09 h
max. 3 times, otherwise re- +120°
A01 001 Cylinder head on crankcase new every time they are loo- TCD 2015 50 Nm +120°
sened. +60°
12 ine
17/28
Oil lightly
A01 002 Rocker arm bracket on cylinder head TCD 2015 61 Nm
01 So
A01 003 Lock nut valve clearance setting screw TCD 2015 20 Nm
A01 004 Cylinder head cover on cylinder head oil lightly TCD 2015 22 Nm
46 ft
oil lightly
A01 005 Cylinder head cover on cylinder head hood M8x30 TCD 2015 22 Nm
hexagonal socket
25 .IR
9 +30°
A02 001 Counterweight on crankshaft oil lightly TCD 2015 50 Nm +60°
+60°
Screws can be used a
Screws with
A02 010 Main bearing cover, vertical screws new every time they are loo- TCD 2015 50 Nm +60°
washers
sened. +120°
Oil lightly
8145-001
Technical data
Tightening specifications
4
4
Post-
Pre-clam-
© 06/2006
ping value
value
Screws can be used a
A02 011 Main bearing cover, horizontal screws TCD 2015 80 Nm
new every time they are loo- +30°
sened.
Technical data
Renew screws every time +60°

A02 020 Big end bearing cover on connecting rod TCD 2015 50 - 60 Nm
they are loosened. +60°
M

Insert with locking agent
A03 010 Rear cover on crankcase TCD 2015 21 Nm
DEUTZ DW 59
A03 020 Genset support on crankcase M10 TCD 2015 55 Nm

ac
Gasket steel beading
TCD 2015 28 Nm
Observe tightening order
09 h
A03 030 Lubricating oil pan on crankcase
TCD 2015
24 Nm
(Railway)
12 ine
18/28
oil lightly TCD 2015 120 Nm
A03 031 Oil drain plug on lubricating oil pan TCD 2015
120 Nm
(Railway)
01 So
TCD 2015
A03 034 Half-flange on connecting flange M8x30-10.9 30 Nm
46 ft
(Railway)
TCD 2015
A03 035 Connecting flange on lubricating oil pan M10x20-10.9 30 Nm
(Railway)
25 .IR
A03 051 Valve housing (pressurestat) on crankcase 9 oil lightly TCD 2015 50 Nm 210 Nm
A03 060 Crankcase breather Pipe clamp TCD 2015 8 Nm
A03 064 Breather pipe on intake elbow/oil separator Hose clip TCD 2015 6.5 Nm
TCD 2015
Breather pipe (holder) on cable harness rail TCD 2015 20 Nm

A03 069 TCD 2015
Pipe (crankcase breather) on cable harness rail 20 Nm
(Railway)
8145-001
Post-
Pre-clam-
© 06/2006
ping value
value
TCD 2015
A03 070 Pipe (crankcase breather) Hose clip 6.5 Nm
(Railway)
A03 080 Connection housing on lubricating oil pan TCD 2015 70 Nm
Insert with locking agent +30°
A03 081 Connection housing to crankcase M12x1.5x35 TCD 2015 30 Nm
DEUTZ DW 59 +30°
M
TCD 2015

A03 082 Connection housing to crankcase M12x1.5x90 TCD 2015 30 Nm
DEUTZ DW 59 +60°
A03 085 Cover on connection housing M8x16 TCD 2015 21 Nm
DEUTZ DW 59
ac
+60°
09 h
A03 088 Connection housing to crankcase M12x190 TCD 2015 30 Nm +60°
DEUTZ DW 59
+60°
12 ine
A03 089 Connection housing to crankcase M12x175 TCD 2015 30 Nm
19/28
DEUTZ DW 59 +90°
Central screw for camshaft gear wheel on cams-
A04 001 oil lightly TCD 2015 50 Nm +150°
haft
01 So
A04 002 Stop cover (camshaft) on crankcase TCD 2015 22 Nm
46 ft
DEUTZ DW 72
A04 003 Camshaft gear wheel on idler gear oil lightly TCD 2015 30 Nm
25 .IR
A04 004 Gear wheel on camshaft for injection pumps TCD 2015 30 Nm +30°
A04 005 Plug of injection pump camshaft on crankcase

9 Fastening screw for diverter
TCD 2015 8.5 Nm
stopper
A04 011 Fastening screw for idler gear on genset support TCD 2015 80 Nm
A04 012 Screw plug for bolt idler gear oil lightly TCD 2015 79 Nm
A04 013 Screw for bolt idler gear M12x100 oil lightly TCD 2015 70 Nm
A04 015 Pad thrust bearing on crankcase oil lightly TCD 2015 30 Nm
8145-001
Technical data
4
4
Post-
Pre-clam-
© 06/2006
ping value
value
TCD 2015 21 Nm
A04 020 Gear case cover on crankcase M8x35 TCD 2015
21 Nm
M8x45 (Railway)
Technical data

A04 022 Cover (stop cover) on crankcase TCD 2015 20 Nm
DEUTZ DW 72
M
Speed governor on connection housing (cranks-

A05 011 TCD 2015 8 Nm
haft)
A05 012 Speed governor on cover (camshaft) TCD 2015 8 Nm

ac
Insert with fitting compound
A06 001 Exhaust pipe at cylinder head TCD 2015 60 Nm
DEUTZ S1
09 h
A06 002 Exhaust pipe on exhaust manifold TCD 2015 22 Nm
DEUTZ S1
12 ine
20/28
A06 003 Exhaust pipe on exhaust line Nut TCD 2015 18 Nm
DEUTZ S1
Exhaust manifold to connection housing TCD 2015 28 Nm
01 So
A06 010 Insert with fitting compound TCD 2015
Exhaust manifold to exhaust line 35 Nm
DEUTZ S1 (Railway)
46 ft
TCD 2015 35 Nm
A06 020 Exhaust turbocharger to exhaust manifold TCD 2015
25 .IR
Nut DEUTZ S1 10 Nm 35 Nm
9 (Railway)
Hose clip
housing position of the hose
A06 021 Intake elbow to exhaust turbocharger TCD 2015 5 Nm
clip top
TCD 2015
screw head rear

TCD 2015
A06 024 Tubing connection to turbocharger Hose clip 5 Nm
(Railway)
8145-001
Post-
Pre-clam-
© 06/2006
ping value
value
Charge air pipe to cylinder head TCD 2015 20 Nm
A06 030 M10 x 85
Charge air pipe to air intake pipe TCD 2015 60 Nm
M10 x 65
TCD 2015 20 Nm
A06 033 Connection pipe to air intake pipe TCD 2015
Nut
M 20 Nm
TCD 2015
(Railway)

Joint plate on connecting pipe TCD 2015 57 Nm
A06 034 TCD 2015
ac
Holder on exhaust manifold 20 Nm
(Railway)
A06 038 Screw plug on charge air pipe TCD 2015 34 Nm
09 h
Nut 20 Nm
A06 046 Connecting elbow to charge air pipe TCD 2015
Stud 4.5 Nm
12 ine
21/28
TCD 2015 20 Nm
A06 056 Connecting pipe to holder TCD 2015
01 So
20 Nm
(Railway)
A06 058 Retaining plate on genset support TCD 2015 20 Nm
46 ft
without leak oil
A07 001 Fuel injector on cylinder head Union screw Insert with fitting compound TCD 2015 70 Nm
25 .IR
DEUTZ S1
A07 002 Injection nozzle on fuel injector

9
Nozzle cap
TCD 2015 40 - 50 Nm
nut
A07 003 Injection line on fuel injector/injection pump Union nut TCD 2015 25 Nm
A07 006 Pipe clamp for injection pipe M6x12 TCD 2015 10 Nm
A07 009 Injection pump housing on crankcase oil lightly TCD 2015 60 Nm
A07 012 Injection pump on injection pump housing oil lightly TCD 2015 60 Nm
8145-001
Technical data
4
4
Post-
Pre-clam-
© 06/2006
ping value
value
TCD 2015 25 Nm
A07 015 Fuel pipe to injection pump housing TCD 2015
25 Nm
(Railway)
Technical data
A07 018 Fuel pipe to fuel shut-off valve (flame flow plugs) Union nut TCD 2015 20 Nm
A07 023 Temperature transmitter on connector M TCD 2015 22 Nm

Bearing housing (fuel supply pump) to genset
A07 024 TCD 2015 42 Nm
support
A07 034 Fuel line on fuel supply pump Hollow screw TCD 2015 max.35 Nm
ac
Pipe clamp/holder
Fuel pipe fastening oil thread and head contact TCD 2015 8.5 Nm
09 h
A07 044 surface.
TCD 2015
Fuel pipe fastening Pipe clamp 8.5 Nm
12 ine
(Railway)
22/28
TCD 2015
A07 057 Adapter (flame glow plug) on charge air pipe M45x1.5 SW50 50 Nm
(Railway)
01 So
TCD 2015
A07 058 Ground cable on lock nut (flame glow plug) 7.5 Nm
(Railway)
46 ft
A07 059 Flame glow plug to connecting pipe Lock nut TCD 2015 25 Nm
TCD 2015 42 Nm
25 .IR
Connector (fuel pressure holding valve) to fuel
A07 066 Union nut
9 TCD 2015
pipe 42 Nm
(Railway)
TCD 2015 39 Nm
TCD 2015
A07 067 Overflow valve on connector TCD 2015

39 Nm
(Railway)
A07 068 Screw-in nipple on fuel shut-off valve TCD 2015 18 Nm
8145-001
Post-
Pre-clam-
© 06/2006
ping value
value
TCD 2015
A07 069 Screw-in nipple on overflow valve M16x1.5 42 Nm
(Railway)
Fuel shut-off valve (flame glow plug) on crankca-
A07 093 Pipe clamp TCD 2015 20 Nm
se (thermostat housing)
A08 002 Adapter on oil filter nozzle (genset support TCD 2015 50 Nm
M
TCD 2015
Oil thread and head contact

A08 010 Oil pressure pump on genset support TCD 2015 40.5 Nm
surface.
Oil thread and head contact
A08 011 Plug on oil pump TCD 2015 21 Nm
surface.
ac
A08 013 Lubricating oil pipe to genset support Hollow screw TCD 2015 18 Nm
09 h
A08 014 Lubricating oil pipe to fuel supply pump Union nut TCD 2015 20 Nm
M8x16 TCD 2015 22 Nm
12 ine
23/28
A08 015 Oil suction intake pipe on oil pump TCD 2015
M8x20 22 Nm
(Railway)
01 So
TCD 2015 22 Nm
Holder oil suction pipe on retaining plate (main
M8x25 TCD 2015
bearing cover) 22 Nm
46 ft
(Railway)
A08 016
TCD 2015 22 Nm
25 .IR
Holder on oil suction pipe TCD 2015
M8x16 22 Nm
(Railway)
9
A08 035 Guide tube on screw-in nipple (lubricating oil pan Union nut TCD 2015 30 Nm
A08 038 Screw-in nipple (guide tube) on lubricating oil pan TCD 2015 45 Nm
Union nut
A08 040 Lubricating oil pipe on exhaust turbocharger TCD 2015 39 Nm
M14 x 1.5
8145-001
Technical data
4
4
Post-
Pre-clam-
© 06/2006
ping value
value
TCD 2015 20 Nm
A08 044 Oil return pipe to turbocharger/crankcase TCD 2015
20 Nm
(Railway)
Technical data
Oil pressure pipe on gear case cover Pipe clamps TCD 2015 8.5 Nm
A08 045 TCD 2015
Oil pressure pipe on genset support M Pipe clamp 20 Nm
(Railway)

A08 050 Oil cooler housing cover on genset support TCD 2015 20 Nm
A08 051 Oil cooler on genset support TCD 2015 20 Nm

ac
A08 071 Screw plug on valve housing (pressurestat) Hexagon socket head TCD 2015 180 Nm
09 h
Holder (lubricating oil pipe) on genset support/
A08 079 TCD 2015 20 Nm
gear case cover
Relief valve of piston cooling nozzle on crankca-
12 ine
A08 081 TCD 2015 28 Nm
24/28
se
A08 091 Oil pressure pick-up on oil cooler housing M14 x 1.5 TCD 2015 20 Nm
01 So
Thermostat housing on crankcase 20 Nm
A09 001 Holder of pipe clamp (fuel TCD 2015
46 ft
Holder on thermostat housing 20 Nm
pipe)
A09 002 Outlet branch on thermostat housing TCD 2015 20 Nm
25 .IR
A09 010 Coolant pump on genset support 9 oil lightly TCD 2015 21 Nm
A09 011 Inlet adapter on coolant pump oil lightly TCD 2015 20 Nm
A09 031 Temperature transmitter on thermostat housing TCD 2015 22 nm
TCD 2015
Renew screws after every +30°

A12 001 Flywheel on crankshaft M16x70 loosening. TCD 2015 50 Nm +60°
Oil lightly +60°
Flanged hub (torsional vibration damper) on
A12 030 oil lightly TCD 2015 30 Nm +120°
crankshaft
8145-001
Post-
Pre-clam-
© 06/2006
ping value
value
V-belt pulley/torsional vibration damper on flan-
A12 031 oil lightly TCD 2015 30 Nm
ged hub
Bearing housing (hydraulic pump drive) on crank-
A12 057 M10x55 oil lightly TCD 2015 30 Nm +60°
case
Flange housing on bearing housing (hydraulic
pump drive) M
TCD 2015

Flange housing on bearing housing (hydraulic
pump drive)
M8x16-8.8 TCD 2015 18 Nm
ac
Holder on gear case cover TCD 2015
A12 071 20 Nm
09 h
(Railway)
Heat shield on holder (gear case cover) M8x16-10.9 TCD 2015 20 Nm
12 ine
A12 080 Fuel pipe on flame glow plug Union nut TCD 2015 20 Nm
25/28
TCD 2015 39 Nm
A12 082 Oil pressure pipe Union nut
01 So
TCD 2015
45 Nm
(Railway)
46 ft
TCD 2015 13 Nm
Fuel hose to connector (overflow valve/fuel shut- Hollow screw
A12 090 Pipe union with ring piece, TCD 2015
off valve) M10x1 18 Nm
pipe 6 mm (Railway)
25 .IR
Hollow screw Breather pipe on oil cooler
A12 092 Hollow screw pipe union with ring piece
9
M14x1.5 cover
TCD 2015 39 Nm
Fule pipe on fuel pressure

A12 093 Hollow screw pipe union M16x1.5 TCD 2015 40 Nm
holding valve
Pipe clamps, fuel pipe to connecting pipe M6 8.5 Nm
A12 095 Fuel hose to air intake pipe Pipe clamp TCD 2015 8.5 Nm
Clip (cable) on holder (central plug) M8 18 Nm
8145-001
Technical data
4
4
Post-
Pre-clam-
© 06/2006
ping value
value
TCD 2015
A12 096 Breather pipe on holder Pipe clamp 30 Nm
(Railway)
Screw-in nipple (lubricating oil pipe) on exhaust TCD 2015
A12 098 45 Nm
Technical data
turbocharger (Railway)
+60°
A13 001 Starter on crankcase Nut TCD 2015 30 Nm
M +60°

M12x22
A13 006 Heat shield (starter) on crankcase TCD 2015 70 Nm
M12x28
A13 012 Generator on plate (console) TCD 2015 hand tight 20 Nm

ac
A13 015 Generator on console TCD 2015 hand tight 20 Nm
09 h
Screw
A13 017 Lock nut (V-belt) on generator holder TCD 2015 hand tight 42 Nm
lock nut
12 ine
A13 018 Generator holder on genset support TCD 2015 42 Nm
26/28
TCD 2015 max. 5 Nm
A13 035 Cable to flame glow plug Nut M5
01 So
TCD 2015
5 Nm
(Railway)
46 ft
A13 037 Cable to pre-heating relay Nut M4 TCD 2015 2 Nm
A13 038 Cable to pre-heating relay Nut M6 TCD 2015 7.5 Nm
25 .IR
Pressure sensor/temperature transmitter on con-
A13 046 TCD 2015 9 Nm
necting pipe
9
TCD 2015 1.0 Nm
A13 054 Cable to injection pump TCD 2015
TCD 2015
5 Nm
(Railway)
8145-001
Post-
Pre-clam-
© 06/2006
ping value
value
M8 x 20
TCD 2015 18 Nm
M8 x 16
A13 090 Cable harness holder to connecting pipe
TCD 2015
M8 20 Nm
(Railway)
M6 TCD 2015 7.5 Nm
A13 094 Cable harness rail on holder M
TCD 2015
M6x12 TCD 2015

8 Nm
M6x16 (Railway)
TCD 2015
A13 098 Holder (cable harness) on connection housing 70 Nm
(Railway)
ac
09 h
12 ine
27/28
01 So
46 ft
25 .IR
9
8145-001
Technical data
4
Technical data
Tightening specifications TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 28/28 8145-001

TCD 2015 Job card overview
5
5 Job card overview
5.1 Sorted alphabetically
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 1/22 8146-001

Job card overview
Sorted alphabetically TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/22 8146-001

Activity Job card Maintenance group

Checking and setting fuel injectors W 07-07-05 Fuel system
Checking and setting plunger lift of injection pumps W 07-06-04 Fuel system
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
installed)
removed)
Checking piston overhang W 01-04-09 Cylinder head
Checking the camshaft W 04-05-06 Engine control 5
Checking the compression pressure W 00-02-06 General
Checking the con rod W 02-03-01 Drive system
Checking the crankshaft W 02-01-07 Drive system
25 .IR
Checking the overhang of the cylinder liner W 03-03-08 Crankcase
Checking the piston W 02-09-07 Drive system
46 ft
Checking the piston rings and piston ring grooves W 02-10-03 Drive system
9
01 So
Checking the valve guide W 01-06-03 Cylinder head
Checking the valve lag W 01-07-08 Cylinder head
12 ine
Checking the valves W 01-05-04 Cylinder head

Checking thermostat (removed state) W 09-08-01 Cooling system
Disassembling, assembling and checking the rocker
09 h
W 01-02-06 Cylinder head

arm and rocker arm bracket
ac
Dismantling and assembling fuel injector W 07-07-02 Fuel system

Dismantling and assembling genset support W 03-08-03 Crankcase
M
Grinding the cylinder head sealing surface I 01-04-08 Cylinder head

Installing and removing turning gear W 04-06-03 Engine control
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
Removing and installing charge air pipe (A-bank) W 06-07-03 Exhaust system / Charging
Removing and installing charge air pipe (B-bank) W 06-07-03 Exhaust system / Charging
Removing and installing connecting pipe W 06-02-05 Exhaust system / Charging
Removing and installing connecting pipe
W 06-02-05 Exhaust system / Charging
(Railway)
Removing and installing coolant pump W 09-07-08 Cooling system
Removing and installing crankcase breather (oil se-
W 03-01-11 Crankcase
parator)
Removing and installing exhaust line (A-bank) W 06-01-05 Exhaust system / Charging
Removing and installing exhaust line (B-bank) W 06-01-05 Exhaust system / Charging
Removing and installing exhaust manifold W 06-01-07 Exhaust system / Charging
© 06/2006 3/22 8146-001

Job card overview TCD 2015

Removing and installing exhaust manifold (A-bank)
(Railway)
Removing and installing exhaust manifold (B-bank)
(Railway)
Removing and installing exhaust pipe (A-bank) W 06-01-06 Exhaust system / Charging
Removing and installing exhaust pipe (B-bank) W 06-01-06 Exhaust system / Charging
Removing and installing flame glow plug W 07-01-02 Fuel system
Removing and installing flame glow plug (Railway) W 07-01-02 Fuel system
5
Removing and installing flywheel W 12-06-01 Other components
Removing and installing fuel pipes W 07-10-06 Fuel system
Removing and installing fuel pipes (flame glow
W 07-01-04 Fuel system
plugs)
25 .IR
plugs) (Railway)
Removing and installing fuel pipes
46 ft W 07-10-06 Fuel system
9
(Railway)
01 So
Removing and installing fuel pressure holding valve W 07-13-01 Fuel system
Removing and installing fuel pressure holding valve
12 ine
(Railway)
Removing and installing fuel shut-off valve (flame
glow plugs)
09 h

ac
glow plugs) (Railway)

Removing and installing gear case cover
W 04-04-09 Engine control
(Railway)
M
Removing and installing genset support W 03-08-01 Crankcase

Removing and installing hydraulic pump drive W 12-08-04 Other components
Removing and installing injection pump camshaft W 04-05-07 Engine control
Removing and installing injection pumps (cylinder
A1)
A2-B3)
Removing and installing lubricating oil pan
W 08-04-07 Lube oil system
(Railway)
Removing and installing oil pressure pick-up W 08-11-09 Lube oil system
Removing and installing oil suction pipe
(Railway)
Removing and installing pressure sensor/tempera-
W 13-08-01 Electrical system
ture sensor (charge air)
Removing and installing pressurestat W 08-11-10 Lube oil system
Removing and installing rear cover W 03-09-01 Crankcase
© 06/2006 4/22 8146-001


Removing and installing small end bush I 02-03-03 Drive system
Removing and installing tappets, checking tappet
bores
Removing and installing temperature transmitter W 07-09-01 Fuel system
Removing and installing temperature transmitter W 09-12-01 Cooling system
Removing and installing the cable harness W 13-01-02 Electrical system
Removing and installing the camshaft W 04-05-05 Engine control
Removing and installing the charge air line W 06-02-03 Exhaust system / Charging 5
Removing and installing the connection housing W 03-09-04 Crankcase
Removing and installing the crankshaft W 02-04-01 Drive system
Removing and installing the cylinder head W 01-04-04 Cylinder head
25 .IR
Removing and installing the cylinder liner W 03-03-02 Crankcase
Removing and installing the fuel injectors W 07-07-01 Fuel system
46 ft
Removing and installing the fuel supply pump W 07-11-01 Fuel system
9
01 So
Removing and installing the gearcase cover W 04-04-09 Engine control
Removing and installing the generator (V-belt drive) W 13-02-03 Electrical system
12 ine
Removing and installing the impulse transmitter

W 05-07-03 Speed governing
(camshaft)
(crankshaft)
09 h
Removing and installing the lubricating oil pan W 08-04-07 Lube oil system
ac
Removing and installing the oil cooler W 08-08-02 Lube oil system
M
Removing and installing the oil suction pipe W 08-04-06 Lube oil system
Removing and installing the piston and con rod W 02-09-03 Drive system
Removing and installing the piston cooling nozzle W 02-15-01 Drive system
Removing and installing the rocker arm and rocker
arm bracket
Removing and installing the starter W 13-03-02 Electrical system
Removing and installing the valves W 01-05-01 Cylinder head
Removing and installing thermostat W 09-08-02 Cooling system
Removing and installing thermostat housing W 09-08-04 Cooling system
Removing and installing torsional vibration damper W 12-01-04 Other components
Removing and installing turbocharger W 06-06-04 Exhaust system / Charging
Removing and installing turbocharger (A-bank)
(Railway)
Removing and installing turbocharger (B-bank)
(Railway)
Removing and installing, testing camshaft bearing W 03-11-01 Crankcase
© 06/2006 5/22 8146-001


Renewing injection pipes (A-bank) W 07-03-01 Fuel system
Renewing injection pipes (B-bank) W 07-03-01 Fuel system
Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system
Renewing the crankshaft sealing ring (opposite side
to flywheel)
Renewing toothed starter flywheel ring W 12-06-03 Other components
Renewing valve guide (oversize, pressed version) I 01-06-04 Cylinder head
5 Repairing the collar rest of the cylinder liner I 03-10-05 Drive system
Replacing valve seat insert (oversize) I 01-07-09 Cylinder head
Setting valve clearance W 01-01-01 Cylinder head
Testing the cylinder liner W 03-03-01 Crankcase
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/22 8146-001

Job card overview
TCD 2015 Sorted numerically
5
5.2 Sorted numerically
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 7/22 8146-001

Job card overview
Sorted numerically TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/22 8146-001

Job card Activity Maintenance group

I 01-04-08 Grinding the cylinder head sealing surface Cylinder head
I 01-06-04 Renewing valve guide (oversize, pressed version) Cylinder head
I 01-07-09 Replacing valve seat insert (oversize) Cylinder head
I 02-03-03 Removing and installing small end bush Drive system
I 03-10-05 Repairing the collar rest of the cylinder liner Drive system
W 00-02-06 Checking the compression pressure General
W 00-05-01
Mounting engine on assembly block and demoun-
General 5
ting
W 01-01-01 Setting valve clearance Cylinder head
Removing and installing the rocker arm and rocker
arm bracket
25 .IR
Disassembling, assembling and checking the rocker
arm and rocker arm bracket
W 01-04-04
46 ft
Removing and installing the cylinder head Cylinder head
9
W 01-04-09 Checking piston overhang Cylinder head
01 So
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
12 ine
W 01-06-03 Checking the valve guide Cylinder head

W 01-07-08 Checking the valve lag Cylinder head
09 h

removed)
ac

installed)
M
W 02-01-07 Checking the crankshaft Drive system

W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system
Renewing the crankshaft sealing ring (opposite side
to flywheel)
W 02-03-01 Checking the con rod Drive system
W 02-04-01 Removing and installing the crankshaft Drive system
W 02-09-03 Removing and installing the piston and con rod Drive system
W 02-09-07 Checking the piston Drive system
W 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 02-15-01 Removing and installing the piston cooling nozzle Drive system
Removing and installing crankcase breather (oil se-
W 03-01-11 Crankcase
parator)
W 03-03-01 Testing the cylinder liner Crankcase
W 03-03-02 Removing and installing the cylinder liner Crankcase
W 03-03-08 Checking the overhang of the cylinder liner Crankcase
© 06/2006 9/22 8146-001


W 03-08-01 Removing and installing genset support Crankcase
W 03-08-03 Dismantling and assembling genset support Crankcase
W 03-09-01 Removing and installing rear cover Crankcase
W 03-09-04 Removing and installing the connection housing Crankcase
W 03-11-01 Removing and installing, testing camshaft bearing Crankcase
Removing and installing tappets, checking tappet
bores
5 W 04-04-09 Removing and installing the gearcase cover Engine control
(Railway)
W 04-05-05 Removing and installing the camshaft Engine control
25 .IR
W 04-05-06 Checking the camshaft Engine control
W 04-05-07 Removing and installing injection pump camshaft Engine control
W 04-06-03
46 ft
Installing and removing turning gear Engine control
9
01 So
(crankshaft)
12 ine
(camshaft)
W 06-01-05 Removing and installing exhaust line (A-bank) Exhaust system / Charging
W 06-01-05 Removing and installing exhaust line (B-bank) Exhaust system / Charging
09 h
W 06-01-06 Removing and installing exhaust pipe (A-bank) Exhaust system / Charging
ac
W 06-01-06 Removing and installing exhaust pipe (B-bank) Exhaust system / Charging
W 06-01-07 Removing and installing exhaust manifold Exhaust system / Charging
M

(Railway)
(Railway)
W 06-02-03 Removing and installing the charge air line Exhaust system / Charging
W 06-02-05 Removing and installing connecting pipe Exhaust system / Charging
(Railway)
W 06-06-04 Removing and installing turbocharger Exhaust system / Charging
(Railway)
(Railway)
W 06-07-03 Removing and installing charge air pipe (A-bank) Exhaust system / Charging
W 06-07-03 Removing and installing charge air pipe (B-bank) Exhaust system / Charging
W 07-01-02 Removing and installing flame glow plug Fuel system
© 06/2006 10/22 8146-001


W 07-01-02 Removing and installing flame glow plug (Railway) Fuel system
glow plugs)
glow plugs) (Railway)
plugs)
plugs) (Railway) 5
W 07-03-01 Renewing injection pipes (A-bank) Fuel system
W 07-03-01 Renewing injection pipes (B-bank) Fuel system
25 .IR
A1)
A2-B3)
W 07-06-04
46 ft
Checking and setting plunger lift of injection pumps Fuel system
9
01 So
W 07-07-01 Removing and installing the fuel injectors Fuel system
W 07-07-02 Dismantling and assembling fuel injector Fuel system
12 ine
W 07-07-05 Checking and setting fuel injectors Fuel system

W 07-09-01 Removing and installing temperature transmitter Fuel system
W 07-10-06 Removing and installing fuel pipes Fuel system
09 h

ac

(Railway)
W 07-11-01 Removing and installing the fuel supply pump Fuel system
M
W 07-13-01 Removing and installing fuel pressure holding valve Fuel system
(Railway)
W 08-04-06 Removing and installing the oil suction pipe Lube oil system
(Railway)
W 08-04-07 Removing and installing the lubricating oil pan Lube oil system
(Railway)
W 08-08-02 Removing and installing the oil cooler Lube oil system
W 08-11-09 Removing and installing oil pressure pick-up Lube oil system
W 08-11-10 Removing and installing pressurestat Lube oil system
W 09-07-08 Removing and installing coolant pump Cooling system
W 09-08-01 Checking thermostat (removed state) Cooling system
W 09-08-02 Removing and installing thermostat Cooling system
© 06/2006 11/22 8146-001


W 09-08-04 Removing and installing thermostat housing Cooling system
W 09-12-01 Removing and installing temperature transmitter Cooling system
W 12-01-04 Removing and installing torsional vibration damper Other components
W 12-06-01 Removing and installing flywheel Other components
W 12-06-03 Renewing toothed starter flywheel ring Other components
W 12-08-04 Removing and installing hydraulic pump drive Other components
W 13-01-02 Removing and installing the cable harness Electrical system
5 W 13-02-03 Removing and installing the generator (V-belt drive) Electrical system
W 13-03-02 Removing and installing the starter Electrical system
Removing and installing pressure sensor/tempera-
W 13-08-01 Electrical system
ture sensor (charge air)
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 12/22 8146-001

Job card overview
TCD 2015 Job card references
5
5.3 Job card references
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 13/22 8146-001

Job card overview
Job card references TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 14/22 8146-001

00 General
Job card Activity and additional job cards necessary for its execution
Checking the compression pressure
W 00-02-06
W 01-01-01 W 07-07-01
Mounting engine on assembly block and demounting
W 00-05-01
W 13-02-03
01 Cylinder head 5
W 01-01-01
W 04-06-03
25 .IR
Removing and installing the rocker arm and rocker arm bracket
W 01-02-02 W 07-03-01 W 07-03-01
W 01-01-01 W 04-06-03
(A-bank) (B-bank)
46 ft
9
Disassembling, assembling and checking the rocker arm and rocker arm bracket
01 So
W 01-02-06
W 01-02-02
Removing and installing the cylinder head
12 ine
W 06-01-05 W 06-01-05 W 06-07-03

W 01-02-02 W 01-04-09
W 01-04-04 (A-bank) (B-bank) (A-bank)
W 06-07-03
09 h
W 07-07-01
(B-bank)
ac
Grinding the cylinder head sealing surface

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

W 01-04-09
W 01-04-04 W 04-06-03
Removing and installing the valves
W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
Checking the valve guide
W 01-06-03
W 01-05-01
Renewing valve guide (oversize, pressed version)
I 01-06-04
W 01-05-01 W 01-06-03
Checking the valve lag
W 01-07-08
W 01-04-04
Replacing valve seat insert (oversize)
I 01-07-09
W 01-05-01 W 01-07-08
© 06/2006 15/22 8146-001

02 Drive system
Checking axial backlash of crankshaft (crankshaft removed)
W 02-01-04
W 02-04-01
Checking axial backlash of crankshaft (crankshaft installed)
W 02-01-04
W 03-08-01 W 03-09-01
Checking the crankshaft
W 02-01-07
5 W 02-04-01
Renewing the crankshaft sealing ring (flywheel side)
W 02-02-02
W 12-06-01
Renewing the crankshaft sealing ring (opposite side to flywheel)
25 .IR
W 02-02-04
Checking the con rod

W 02-03-01
W 02-09-03
46 ft
9
01 So
Removing and installing small end bush
I 02-03-03
12 ine
Removing and installing the crankshaft

W 02-04-01
W 02-01-04 W 02-01-07 W 03-08-01 W 03-09-01 W 07-07-01
Removing and installing the piston and con rod
09 h
W 02-09-03 W 08-04-06
W 01-04-04 W 02-10-03 W 08-04-06
ac
(Railway)
Checking the piston
W 02-09-07
M
W 02-09-03
Checking the piston rings and piston ring grooves
W 02-10-03
W 02-09-03
Removing and installing the piston cooling nozzle
W 02-15-01
W 02-09-03
03 Crankcase
Removing and installing crankcase breather (oil separator)
W 03-01-11
Testing the cylinder liner

W 03-03-01
W 03-03-02
Removing and installing the cylinder liner
W 03-03-02
W 02-09-03 W 03-03-01 W 03-03-08
© 06/2006 16/22 8146-001

03 Crankcase (continuation)
Checking the overhang of the cylinder liner
W 03-03-08
W 01-04-04
Removing and installing genset support
W 06-07-03 W 06-07-03
W 03-08-01 W 02-02-04 W 08-04-06 W 09-07-08
(A-bank) (B-bank)
W 09-08-04
W 03-08-03
Dismantling and assembling genset support 5
W 03-08-01
Removing and installing rear cover
W 03-09-01
W 02-02-02 W 03-09-04 W 08-04-07
25 .IR
Removing and installing the connection housing
W 03-09-04
W 05-07-01 W 06-01-07 W 12-06-01 W 13-03-02
I 03-10-05 46 ft
Repairing the collar rest of the cylinder liner
9
01 So
W 03-03-02
Removing and installing, testing camshaft bearing
W 03-11-01
W 04-05-05
12 ine
04 Engine control
09 h
ac
Removing and installing tappets, checking tappet bores

W 04-02-02
W 04-05-05
M
Removing and installing the gearcase cover

W 04-04-09
W 06-06-04
(Railway)
W 04-04-09
W 07-13-01
(Railway)
Removing and installing the camshaft
W 01-02-02 W 02-04-01 W 04-05-06 W 05-07-03 W 06-06-04
W 04-05-05
W 07-04-01 W 07-04-01
W 07-06-04
(cylinder A1) (cylinder A2-B3)
Checking the camshaft
W 04-05-06
W 04-05-05
Removing and installing injection pump camshaft
W 01-02-02 W 02-02-02 W 03-08-01 W 03-09-04 W 04-06-03
W 04-05-07
W 07-04-01 W 07-04-01
W 05-07-03 W 06-06-04 W 07-06-04
(cylinder A1) (cylinder A2-B3)
© 06/2006 17/22 8146-001

04 Engine control (continuation)

Installing and removing turning gear
W 04-06-03
05 Speed governing
Removing and installing the impulse transmitter (crankshaft)
5 W 05-07-01
W 04-06-03
Removing and installing the impulse transmitter (camshaft)
W 05-07-03
W 04-06-03 W 06-06-04
25 .IR
06 Exhaust system / Charging
46 ft
9
Removing and installing exhaust line (A-bank)
01 So
W 06-01-05 W 06-01-06
(A-bank)
12 ine
Removing and installing exhaust line (B-bank)

W 06-01-05 W 06-01-06
(B-bank)
09 h
Removing and installing exhaust pipe (A-bank)

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

M
W 06-01-06
Removing and installing exhaust manifold

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

W 06-02-05
W 07-01-04
© 06/2006 18/22 8146-001

06 Exhaust system / Charging (continuation)

(Railway)
W 06-02-05
W 07-01-04
(Railway)
Removing and installing the turbocharger
W 06-06-04
W 06-02-03
W 06-06-04 (Railway) 5

W 06-06-04 (Railway)
25 .IR
Removing and installing charge air pipe (A-bank)
W 06-07-03
W 03-01-11
46 ft
W 06-02-05
W 07-03-01
(A-bank)
9
01 So
Removing and installing charge air pipe (B-bank)
W 06-07-03
(B-bank) W 07-03-01
W 06-02-05
12 ine
(B-bank)
07 Fuel system
09 h
ac
Removing and installing flame glow plug

W 07-01-02
M
W 07-01-04
Removing and installing flame glow plug (Railway)
W 07-01-02 W 07-01-04
(Railway)
Removing and installing fuel shut-off valve (flame glow plugs)
W 07-01-03
Removing and installing fuel shut-off valve (flame glow plugs) (Railway)
W 07-01-03
Removing and installing fuel pipes (flame glow plugs)

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

W 07-03-01
© 06/2006 19/22 8146-001

07 Fuel system (continuation)

Renewing injection pipes (B-bank)
W 07-03-01
W 06-02-03
Removing and installing injection pumps (cylinder A1)
W 07-04-01 W 06-07-03 W 07-10-06
W 04-06-03 W 07-10-06
(A-bank) (Railway)
Removing and installing injection pumps (cylinder A2-B3)
5 W 03-01-11 W 04-06-03
W 07-03-01 W 07-03-01
W 07-10-06
W 07-04-01 (A-bank) (B-bank)
W 07-10-06
(Railway)
Checking and setting plunger lift of injection pumps
25 .IR
W 06-06-04 W 06-06-04
W 07-04-01
W 04-06-03 W 06-06-04 (A-bank) (B-bank)
W 07-06-04 (cylinder A1)
(Railway) (Railway)
W 07-04-01 46 ft
9
01 So
(cylinder A2-B3)
Removing and installing the fuel injectors
W 07-07-01
12 ine
W 07-03-01 W 07-03-01
W 07-07-05
(A-bank) (B-bank)
Dismantling and assembling fuel injector
W 07-07-02
09 h
W 07-07-01 W 07-07-05
ac
Checking and setting fuel injectors

W 07-07-05
W 07-07-01 W 07-07-02
M
Removing and installing temperature transmitter

W 07-09-01 W 06-07-03
(B-bank)
W 07-10-06 W 06-07-03 W 06-07-03
(A-bank) (B-bank)
Removing and installing the fuel supply pump

W 07-11-01

W 07-13-01 W 06-07-03
(A-bank)
© 06/2006 20/22 8146-001

07 Fuel system (continuation)

08 Lube oil system

Removing and installing the oil suction pipe 5
W 08-04-06
W 08-04-07
(Railway)
W 08-04-06
25 .IR
W 08-04-07
(Railway)
Removing and installing the lubricating oil pan
W 08-04-07
W 13-03-02 46 ft
9
01 So
12 ine
Removing and installing the oil cooler

W 08-08-02 W 06-07-03
W 09-08-04
09 h
(A-bank)
ac
Removing and installing oil pressure pick-up

W 08-11-09
M
Removing and installing pressurestat

W 08-11-10 W 06-07-03
W 03-01-11
(B-bank)
09 Cooling system
Removing and installing coolant pump
W 09-07-08
Checking thermostat (removed state)

W 09-08-01
W 09-08-02
Removing and installing thermostat
W 09-08-02
W 09-08-01 W 09-08-04
Removing and installing thermostat housing
W 09-08-04
W 07-01-04
© 06/2006 21/22 8146-001

09 Cooling system (continuation)

W 09-12-01
12 Other components
Removing and installing torsional vibration damper
5 W 12-01-04
Removing and installing flywheel

W 12-06-01
Renewing toothed starter flywheel ring
25 .IR
W 12-06-03
W 12-06-01
Removing and installing hydraulic pump drive
W 12-08-04
46 ft
9
W 06-01-06
01 So
(A-bank)
12 ine
13 Electrical system
Removing and installing the cable harness
09 h
W 13-01-02
W 06-02-03
ac
Removing and installing the generator (V-belt drive)

W 13-02-03
M
Removing and installing the starter

W 13-03-02
Removing and installing pressure sensor/temperature sensor (charge air)

W 13-08-01
© 06/2006 22/22 8146-001

DEUTZ engines Job cards
6 Job cards
6
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 11/2005 1/2 8147-001

Job cards DEUTZ engines
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 11/2005 2/2 8147-001

General
TCD 2015 W 00-02-06

Commercial available tools: – W 01-01-01
– Compression pressure – W 07-07-01
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
Special tools:
– Connector . . . . . . . . . . . . . . . . . . 100130
– Grooved nut wrench . . . . . . . . . . 110130
25 .IR
z Check and set valve clearance.
46 ft
9
W 01-01-01
01 So
z Removing fuel injectors.
W 07-07-01 2
12 ine
z Mount sealing ring (1).

Use sealing ring (1) for fuel injector.
09 h
z Insert connector (2). 1

ac
M
© 40640-0
z Tighten union screw with grooved nut wrench.

A07 001
© 40643-0
© 06/2006 1/4 8148-001

General
W 00-02-06 TCD 2015
z Connect adapter (1) to connector.
6
© 40641-0
25 .IR
z Mount the compression tester on the adapter.
z Turn over engine with starter.
P00 51 46 ft
9
01 So
12 ine
09 h
ac
M
© 40642-0
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the No.
engine installation site. Therefore, limit Kompression in bar
Compression value in bar
values cannot be determined exactly. The Pression en bar
compression pressure measurement is Dat. _________
10 15 20 25 30 35 40
only recommended as a reference measu-
Zyl.
rement of all cylinders of an engine to each

other. If more than 15% deviation has been 1
determined, the cause should be determi- 2
ned by disassembling the cylinder unit con- 3
cerned. 4
5
6
7
8
DBGM Made in Germany
MOTOMETER
© 33771-5
© 06/2006 2/4 8148-001

General
TCD 2015 W 00-02-06
z Remove the compression pressure tester.

z Remove adapter (1).
1
6
© 40641-0
25 .IR
z Unscrew union screw with grooved nut wrench.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40643-0
z Remove connector (2).

z Remove sealing ring (1).
z Install fuel injectors.
W 07-07-01
© 40640-0
© 06/2006 3/4 8148-001

General
W 00-02-06 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8148-001

General
TCD 2015 W 00-05-01
Mounting engine on assembly block and demounting

– Lifting gear
– Suspension ropes
Special tools: Different customer scopes are not taken
– Assembly block incl. adap- into account in the repair sequence shown
ter plates . . . . . . . . . . . . . . . . . . . . . 6066 here, accessories which deviate from the
– Clamping bracket . . . . . . . . . . .6066/151 standard equipment are not shown.
25 .IR
Mounting engine on assembly block
z Remove generator.
46 ft
9
W 13-02-03
01 So
z Unscrew screws (1). 1
z Remove heat shield (2). 2
12 ine
09 h
ac
1
M
© 40644-1
z Screw in eyelet bolts (1).

z Hang engine on workshop crane.
1 1
© 40645-0
© 06/2006 1/6 8149-001

General
W 00-05-01 TCD 2015
z Unscrew all screws (1).

z Remove all mounting feet (2).
6
© 40652-0
25 .IR
z Mount all clamping brackets (1).
z Tighten screws (2).
A00 001 46 ft
9
01 So
12 ine
2 2
1 1
09 h
ac
2 2
M
© 40646-1
z Unscrew screws (1).

z Remove all mounting feet (2).
1
1
© 40651-0
© 06/2006 2/6 8149-001

General
TCD 2015 W 00-05-01
z Insert engine in engine block.

z Mount clamping bracket on the adapter plates.
z Align all clamping brackets (1) on the adapter
plates (2) of the assembly block.
z Tighten screws .
A00 002 1
2
6
© 40649-0
25 .IR
z Align engine on engine block.
z Unhook the engine from the workshop crane.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40653-0
Demounting engine from assembly block

z Remove screws.
z Remove all clamping brackets (1) from the adapter
plates (2).
z Lift engine off the assembly block. 1
© 40649-0
© 06/2006 3/6 8149-001

General
W 00-05-01 TCD 2015
z Mount all mounting feet (1).

z Tighten screws (2). 1
A00 003
2 2
6
© 40991-0
25 .IR
z Remove all clamping brackets (1).
46 ft
9
01 So
12 ine
2 2
1 1
09 h
ac
2 2
M
© 40646-1
z Mount all mounting feet (2).

z Tighten all screws (1).
A00 003 1
© 40652-0
© 06/2006 4/6 8149-001

General
TCD 2015 W 00-05-01
z Set down engine.

z Unhook the engine from the workshop crane.
z Unscrew eyelet bolts (1). 1
1
6
© 40645-0
25 .IR
z Mount heat shield (2).
A13 006 46 ft
9
01 So
z Install generator. 1
W 13-02-03 2
12 ine
09 h
ac
1
M
© 40644-1
© 06/2006 5/6 8149-001

General
W 00-05-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8149-001

Cylinder head
TCD 2015 W 01-01-01

– Rotation angle disc . . . . . . . . . . . . . 8190
– Screwdriver insert for slot-
ted screws. . . . . . . . . . . . . . . . . . . . 8191 Allow the engine to cool down for at least
– Open wrench size 13 . . . . . . . . . . . 8196 30 minutes before setting the valve clea-
rance. Engine oil temperature < 80 °C
– Locking agent
DEUTZ DW 59 The following work process describes set-
ting of the valve clearance on an exhaust
valve. The setting procedure for an inlet
valve is analogous under consideration of
the specified rotation angle size.
25 .IR
z Remove cylinder head cover (2).
z Remove gasket.
46 ft
9
01 So
z Attach turning gear.
W 04-06-03
2
12 ine
09 h
1 1
ac
M
© 40627-0
Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder A1 is reached.
T01 63
© 40463-1
© 06/2006 1/4 8150-001

Cylinder head
W 01-01-01 TCD 2015
Valve overlap means:

The inlet valve starts opening,exhaust
valve closes.
6
© 40629-0
25 .IR
Arrangement of the inlet and exhaust val-
ves.
IN = inlet valve
46 ft
9
EX = exhaust valve
01 So
12 ine
IN IN
EX EX
09 h
ac
M
© 40630-0

z Loosen lock nut (1).
z Press in the adjusting screw (2) to the stop.
© 40631-0
© 06/2006 2/4 8150-001

Cylinder head
TCD 2015 W 01-01-01
z Set the rotation angle disc with a screwdriver insert

at the adjusting screw.
z Fix magnet of rotation angle disc on cylinder head.
z Set rotation angle disc to "0".
Do not rotate adjusting screw.
P01 61
P01 62
6
© 40632_1
25 .IR
z Turn the adjusting screw in the direction of the arrow.
P01 62
46 ft
9
01 So
12 ine
09 h
ac
M
© 40633-0
z Tighten lock nut (1) with open wrench.

A01 003
Do not rotate adjusting screw.
z Remove rotation angle disc.

Set all other valves according to the valve
setting schematic T01 63.
© 40638_1
© 06/2006 3/4 8150-001

Cylinder head
W 01-01-01 TCD 2015
z Clean sealing surfaces.

z Mount new gasket (1).
Note installation position. 1
Position gasket over the profile washer (2).
6
© 40802-0
25 .IR
z Mount cylinder head cover.
Profile washer (1) may not be trapped
46 ft
underneath the sealing surface (2) of the 2
9
01 So
cylinder head cover. 1
12 ine
09 h
ac
M
© 40803-0
z Lightly oil screws (1).

A01 005
z Remove turning gear.
W 04-06-03
1 1
© 40804-0
© 06/2006 4/4 8150-001

Cylinder head
TCD 2015 W 01-02-02
Removing and installing the rocker arm and rocker arm bracket
– Feeler gauges – W 04-06-03
– W 07-03-01 . . . . . . . . . . . . (A-bank)
– Locking agent – W 07-03-01 . . . . . . . . . . . . (B-bank)
DEUTZ DW 59
25 .IR
Removing the rocker arm and rocker arm
bracket
46 ft
z Removing high pressure pipes (A-bank). 1
9
1
01 So
W 07-03-01
z Removing high pressure pipes (B-bank). 2
12 ine
W 07-03-01
z Remove cylinder head cowling (2).
09 h
z Remove gasket.
ac
M
1
© 42215-1
z Unscrew screws (arrows).

Loosen screws evenly to avoid tension on
the rocker arm brackets. 1
z Remove rocker arms (1), (2) and rocker arm

brackets (3) together.
3
Lay out components in the order in which
they should be installed. 3 2
© 42217-1
© 06/2006 1/6 8151-001

Cylinder head
W 01-02-02 TCD 2015
z Remove push rods (1).

they should be installed. 1
6
© 42219-1
25 .IR
z Visually inspect the components.
46 ft
9
01 So
12 ine
09 h
ac
M
© 34824-2
Installing the rocker arm and rocker arm

bracket
1
z Insert stop rods (1).
Note assignment!
© 42219-1
© 06/2006 2/6 8151-001

Cylinder head
TCD 2015 W 01-02-02
The pushrod must be seated with the ball

head in the ladle of the tappet.

W 04-06-03
6
© 40490-0
25 .IR
z Turn crankshaft until reaching the base circle posi-
tion of inlet and exhaust cams of the respective cylin-
der.
46 ft
9
z Mount rocker arm bracket.
01 So
Attention! 2
The longer side (1) must point upwards.
12 ine
The ball heads (2) must be seated in the

ladles of the pushrods . 1
09 h
ac
M
© 45805-0
z Align rocker arm to the pushrods/valves.

z Tighten screws (1) alternately.
1 1
© 45806-0
© 06/2006 3/6 8151-001

Cylinder head
W 01-02-02 TCD 2015
Checking axial backlash of the rocker arm

z Measure the axial backlash between the rocker arm
bracket (1) and rocker arm (2) with a feeler gauge.
P01 75 1
The rocker arm (2) is on the opposite side
on the rocker arm bracket (3).
The setting is made by moving the rocker 3
arm brackets.
6
© 42221-1
25 .IR
A01 002
46 ft
9
z Check and set valve clearance.
01 So
W 01-01-01
1
1
12 ine
09 h
ac
M
© 42222-1

z Mount new gasket. 1
z Fasten screws. 2
2
Screw length:
M8 x 80 mm (1)
M8 x 70 mm (2)
M8 x 30 mm (3)
3
© 42216-1
© 06/2006 4/6 8151-001

Cylinder head
TCD 2015 W 01-02-02
z Tighten screws .
A01 004
z Installing high pressure pipes (A-bank)
W 07-03-01
z Installing high pressure pipes (B-bank)
W 07-03-01
W 04-06-03
6
© 42223-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8151-001

Cylinder head
W 01-02-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8151-001

Cylinder head
TCD 2015 W 01-02-06
Disassembling, assembling and checking the rocker arm and rocker arm
bracket
– Internal measuring device
– Micrometer gauge
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 170120
25 .IR
Disassembling the rocker arm bracket
z Remove rocker arm and rocker arm bracket.
46 ft
9
W 01-02-02
01 So
12 ine
09 h
ac
M
© 34824-2
Checking rocker arm (inlet valves)

z Prepare internal measuring device:
– Mount probe bolt for the appropriate measuring
range in the internal measuring device.
– Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
– Set micrometer gauge to 28 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge to the reversal point of the pointer to
"0".
© 34768-2
© 06/2006 1/6 8152-001

Cylinder head
W 01-02-06 TCD 2015
z Measure rocker arm bore.

P01 73
When the wear limit is reached the rocker
arm must be renewed.
6
© 34825-2
25 .IR
z Check ball stud (1) and adjusting screws (2) for
wear.
46 ft 1
9
01 So
The components must be renewed in case
of excessive wear.
z Check oil channel (3) for free passage.

12 ine
09 h
ac
3
2
M
© 36749-1
Renewing ball stud

z Place disassembly/assembly tool (1) underneath.
z Press out ball stud.
© 34827-3
© 06/2006 2/6 8152-001

Cylinder head
TCD 2015 W 01-02-06
z Mount new ball stud (1).

Notch (2) faces vertically to the rocker arm
shaft.
6
© 34828_3
25 .IR
z Place disassembly/assembly tool underneath.
z Press in ball stud (1).
z Check oil channel for free passage.
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 34829_3
Checking rocker arm (exhaust valves)

z Measure rocker arm bore.
P01 72
arm must be renewed.
© 34830-2
© 06/2006 3/6 8152-001

Cylinder head
W 01-02-06 TCD 2015

z Check ball stud (1) and adjusting screws (2) for 1
wear.
The components must be renewed in case
of excessive wear.
2
6
© 36750-1
25 .IR
Renewing ball stud
46 ft
9
z Press out ball stud.
01 So
12 ine
09 h
ac
1
M
© 34832_3

z Press in new ball stud (2).
© 34833_3
© 06/2006 4/6 8152-001

Cylinder head
TCD 2015 W 01-02-06
Checking rocker arm shaft

z Measure diameter with micrometer gauge.
P01 74
arm shaft must be renewed.
z Check oil channels for free passage.
6
© 34834-2
25 .IR
Assembling the rocker arm bracket
46 ft
z Push rocker arm onto rocker arm shaft.
1
9
The oil bores (1) must face upwards and
01 So
the recess clearances (2) for the screws of
the rocker arm brackets to the adjusting
screws.
12 ine
09 h
2
ac
M
© 36751-1
z Push rocker arm brackets onto rocker arm shaft.

Attention!
The longer side (1) must point upwards.
The clamping grooves (2) must face the
adjusting screws (3) .
1
2 3
© 45385_1
© 06/2006 5/6 8152-001

Cylinder head
W 01-02-06 TCD 2015
z Insert all screws (1).

z Install rocker arm and rocker arm bracket.
W 01-02-02
6
© 34837_3
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8152-001

Cylinder head
TCD 2015 I 01-04-08
Grinding the cylinder head sealing surface

– Surface milling machine
– Roughness measuring unit
– Depth-measuring The relevant manufacturer’s specifications
appliance must be observed when working with the
surface milling machine.
25 .IR
Prepare cylinder head
z Remove valves.
46 ft
9
W 01-05-01
01 So
z Deburr the upper face of the cylinder head.
The upper face of the cylinder head must
12 ine
be burr-free and free of gasket remains to

guarantee correct clamping of the cylinder
head.
09 h
ac
M
© 39757-1
Grinding cylinder head surface

z Clamp cylinder head on surface milling machine.
z Align cylinder head.
z Align tool of the surface milling machine with the cyl-
inder head.
© 39758-1
© 06/2006 1/4 8153-001

Cylinder head
I 01-04-08 TCD 2015
z Grind cylinder head sealing surface.

z Check the cylinder head sealing surface.
If the cylinder head sealing surface is not
level, recognisable from differences in
colour of the machined surface, the sur-
face must be reground.
The adjustment range of the tool is a
maximum 0.2 mm per grind.
6
© 39759-1
25 .IR
Checking the cylinder head sealing sur-
face
46 ft
z Visually inspect the cylinder head sealing surface.
9
01 So
z Visually inspect the combustion chamber surface.
z Measure the roughness of the cylinder head sealing
surface with the roughness measuring instrument.
12 ine
P01 93
If the measured value is out of tolerance,
the cylinder head sealing surface must be
09 h
remachined with different setting data for

ac
the surface milling machine.

M
© 39760-1
z Measure cylinder head height with depth measuring

appliance.
P01 08
P01 09
When the wear limit is reached, the cylin-
der head must be renewed.
© 39761-1
© 06/2006 2/4 8153-001

Cylinder head
TCD 2015 I 01-04-08
z Remove cylinder head from the surface milling ma-

chine.
6
© 39758-1
25 .IR
z Attach the repair date and company logo to the cylin-
der head.
Attention!
46 ft
9
01 So
Do not mark identification on a sealing sur-
face.
Mark the cylinder head after every repair.

12 ine
z Install valves.
09 h
W 01-05-01
ac
M
© 39744-1
© 06/2006 3/4 8153-001

Cylinder head
I 01-04-08 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8153-001

Cylinder head
TCD 2015 W 01-04-04
Removing and installing cylinder head

– Socket wrench insert . . . . . . . . . . . 8016 – W 01-04-09
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 06-01-05 . . . . . . . . . . . . (A-bank)
– W 06-01-05 . . . . . . . . . . . . (B-bank)
– W 06-07-03 . . . . . . . . . . . . (A-bank)
– W 06-07-03 . . . . . . . . . . . . (B-bank)
– W 07-07-01
25 .IR
Removing the cylinder head
z Remove charge air pipe (A-bank).
46 ft
9
W 06-07-03
01 So
z Remove charge air pipe (B-bank).
W 06-07-03
12 ine
z Remove exhaust line (A-bank)

W 06-01-05
09 h
z Remove exhaust pipe (B-bank)

W 06-01-05
ac
M
© 40578-0
z Remove rocker arm and rocker arm bracket.

W 01-02-02
W 07-07-01
they should be installed.
© 42234-1
© 06/2006 1/4 8154-001

Cylinder head
W 01-04-04 TCD 2015
z Unscrew screws (1) with the socket wrench insert.

z Remove cylinder head.
z Remove gasket.
z Visually inspect the components. 1
1
6
© 42235-1
25 .IR
Installing the cylinder head
z Check piston overhang.
46 ft
9
W 01-04-09
01 So
Determine the cylinder head gasket sepa-
rately for every cylinder.
12 ine
09 h
ac
M
© 45811_0
z Select new cylinder head gasket according to meas-

ured piston overhang.
P02 75
P02 76
P02 77
Example: Piston overhang = 0.05 mm, cor-
responds to cylinder head gasket with
1 hole (arrow).
© 45811_1
© 06/2006 2/4 8154-001

Cylinder head
TCD 2015 W 01-04-04

z Fit a new cylinder head gasket.
The sealing surfaces for the cylinder head
gasket must be clean and free of oil.
Label OBEN / TOP facing the cylinder
head.
6
© 45812_1
25 .IR
z Fit cylinder head.
z Oil the cylinder head screws slightly.
Attention! 46 ft
9
01 So
Screws can be reused a maximum 3 times
with written documentation.
z Fasten screws.
12 ine
09 h
ac
M
© 34976-2
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
A01 001
© 40582-0
© 06/2006 3/4 8154-001

Cylinder head
W 01-04-04 TCD 2015
z Install rocker arm and rocker arm bracket.

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

W 06-01-05
© 40583-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8154-001

Cylinder head
TCD 2015 W 01-04-09

8190
– Magnetic measuring stand – W 04-06-03

Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Measuring instrument with
measuring plate . . . . . . . . . . . . . 100850
25 .IR
46 ft
9
W 01-04-04
01 So
z Insert screws and washers (1) diagonally opposed.
z Tighten screws until they touch the cylinder liner. 1
12 ine
Washers:
Maximum thickness 4 mm
Screw length:
09 h
M16 x 90
ac
M
© 45424-0

W 04-06-03
z Turn the crankshaft until the respective piston is just
in front of the top dead centre (arrow).
© 45763-0
© 06/2006 1/4 8155-001

Cylinder head
W 01-04-09 TCD 2015
z Make sure the clamping bushings (arrows) are in

place.
6
© 45766-0
25 .IR
z Place measuring instrument (1) on measuring
plate (2). 3
46 ft
z Insert dial gauges (3) with pre-tension in the measur-
9
01 So
ing instrument.
z Turn the dial until the pointer points to "0".
12 ine
1
09 h
ac
2
M
© 37242-0
z Place the measuring instrument over the clamping

bushings (arrows).
z Read off measured value of both dial gauges.
z 1st dial gauge:
– Note measured value, dimension (a).
z 2nd dial gauge:
– Note measured value, dimension (b).
© 45767-0
© 06/2006 2/4 8155-001

Cylinder head
TCD 2015 W 01-04-09
z Form and note average value.

Calculation example
Desired: Dimension x (average value of both dial gauges)
Given: -
Measured: Dimension a (measured value 1st dial gauge)
Dimension b (measured value 2nd dial gauge)
Calculation: Dimension x = (dimension a + dimension b) : 2
(0.39 mm + 0.45 mm) : 2
Result: = 0.42 mm
P02 75
P02 76
P02 77
z Remove measuring instrument.
6
© 45767-2
25 .IR
W 04-06-03 46 ft
9
01 So
z Install cylinder head.
W 01-04-04 1
12 ine
09 h
ac
M
© 45424-0
© 06/2006 3/4 8155-001

Cylinder head
W 01-04-09 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8155-001

Cylinder head
TCD 2015 W 01-05-01
Removing and installing the valves

– Slide gauge
– Assembly pliers. . . . . . . . . . . . . . . . 8024
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Support bracket . . . . . . . . . . . . . 120900
– Base plate. . . . . . . . . . . . . . . . . . 120910
– Assembly tool . . . . . . . . . . . . . . . 121410
– Assembly sleeves . . . . . . . . . . . . 121420
25 .IR
Removing the valves
1
46 ft
9
W 01-04-04
01 So
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.
12 ine
09 h
ac
2
M
© 42227-1
z Install assembly lever (1).

z Press down valve spring with assembly lever.
z Remove both tapper collets (2). 1
z Remove valve spring plates, valve springs and
valves.
z Remove assembly lever.
© 42337-1
© 06/2006 1/4 8156-001

Cylinder head
W 01-05-01 TCD 2015
z Disassemble valve stem gasket with assembly plier.
6
© 42336-1
25 .IR
z Clean cylinder head.
z Check cylinder head.
46 ft
9
01 So
12 ine
09 h
ac
M
© 42335-1
Installing the valves

z Measure valve spring length with slide gauge.
P01 51
When the wear limit is reached, the valve
spring must be renewed.
© 35856-2
© 06/2006 2/4 8156-001

Cylinder head
TCD 2015 W 01-05-01
z Oil the valve stem lightly.

z Insert and hold valve.
z Push assembly sleeve (2) over the valve V-
grooves (1).
6
© 42334-1
25 .IR
z Push new valve stem seal onto valve guide over the
assembly sleeve with assembly tool (1).
z Remove assembly sleeve.
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 42332-1
z Insert valve spring (1).

z Insert valve spring plate (2).
2
© 42331-1
© 06/2006 3/4 8156-001

Cylinder head
W 01-05-01 TCD 2015
z Mount assembly lever.

z Press down the valve spring with the assembly lever
and insert both tapper collets (1).
Make sure the tapper collets fit correctly in
the valve keyway.
6
© 42330-1
25 .IR
z Remove assembly lever.
z Remove cylinder head from support bracket.
46 ft
9
01 So
W 01-04-04
12 ine
09 h
ac
M
© 42329-1
© 06/2006 4/4 8156-001

Cylinder head
TCD 2015 W 01-05-04
Checking the valves

– Slide gauge
Clean valves before testing.
must be renewed.
25 .IR
Checking valve stem diameter
z Remove valves.
46 ft
9
W 01-05-01
01 So
z Measure valve stem diameter with micrometer
gauge.
12 ine
P01 31
P01 32
09 h
ac
M
© 42182-1
Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
P01 35
P01 36
© 42183-1
© 06/2006 1/2 8157-001

Cylinder head
W 01-05-04 TCD 2015
Checking valve head diameter

z Measure valve head diameter with slide gauge.
P01 37
P01 38
z Install valves.
W 01-05-01
6
© 42184-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/2 8157-001

Cylinder head
TCD 2015 W 01-06-03

– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 New valves are used for testing.
guide must be renewed.
25 .IR
z Remove valves.
46 ft
9
W 01-05-01
01 So
z Visually inspect valve guide for wear.
12 ine
09 h
ac
M
© 40713-0
Measure valve stem clearance

z Mount magnetic measuring stand.
z Insert dial gauge.
z Insert new valve.
z Place stylus under pre-tension on the valve
head (arrow).
© 40714-0
© 06/2006 1/2 8158-001

Cylinder head
W 01-06-03 TCD 2015
z Move valve back and forth in direction of arrow.

P01 33
P01 34
The valve stem ends must be flush with the
valve guide.
The whole tilt distance must be taken into
account.
6
© 40715-0
25 .IR
z Remove magnetic measuring stand.
z Remove dial gauge.
z Install valves.
46 ft
9
01 So
W 01-05-01
12 ine
09 h
ac
M
© 40639-0
© 06/2006 2/2 8158-001

Cylinder head
TCD 2015 I 01-06-04
Renewing the valve guide

(oversize, pressed version)
– Reamers – W 01-06-03
– Plug gauges
– Cylinder head machining Danger!
tool
– Press Danger of injury, do not touch supercooled
– Press-out pin components or the liquid nitrogen!
– Press-in pin Wear protective gloves and glasses!
– Industrial vacuum cleaner
Attention!
– Nitrogen (liquid) The press-in process must be carried out
without interruption as a result of the tem-
perature difference between the cylinder 6
head and the valve seat insert.
The necessary work steps must be practi-
25 .IR
sed before pressing in.
The relevant manufacturer’s specifications

must be observed when working with the
46 ft cylinder head machining tool.
9
01 So
12 ine
09 h
ac
M

z Check valve guides.
W 01-06-03
z Check valve guide with plug gauge (1).
P01 14 1
P01 15
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.
© 39737-1
© 06/2006 1/6 8159-001

Cylinder head
I 01-06-04 TCD 2015
Pressing out valve guide

z Press out valve guide with press-out pin (1).
6
© 39749-1
25 .IR
Check housing bore for valve guide
46 ft
z Visually inspect housing bore (arrow).
9
If the housing bore is heavily scored, the
01 So
housing bore must be reamed to the next
oversize dimension.
12 ine
09 h
ac
M
© 36630-1
z Check housing bore for valve guide with plug

gauge (1).
P01 05
P01 06
P01 07
1
light suction.
The no-go limit of the gauge plug must not
fit into the housing bore. If the no-go limit
fits, it must be reamed to the next oversize.
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.
© 39750-1
© 06/2006 2/6 8159-001

Cylinder head
TCD 2015 I 01-06-04
Prepare housing bore for the valve guide

(oversize)
z Clamp cylinder head on cylinder head machining
tool.
z Seal coolant channels.
6
© 39751-1
25 .IR
z Align bore unit and mandrin guide (1) with the hous-
ing bore.
46 ft
The housing bores can have different dia-
9
01 So
meters, a suitable mandrin guide for align-
ment with the bore unit must therefore be
selected. The mandrin guide must move
easily in the housing bore without noticea-
12 ine
ble resistance.
1
09 h
ac
M
© 39752-1
z Ream housing bore to oversize level.

P01 06
P01 07
Attention!
The reamer has a left twist and must
always be turned in or out in clockwise
direction. Never turn reamers anti-clock-
wise. The cuttings resulting from removing
the material can get stuck and damage the
cutting.
z Blow out housing bore with compressed air.
© 39753-1
© 06/2006 3/6 8159-001

Cylinder head
I 01-06-04 TCD 2015
z Check housing bore for valve guide with plug

gauge (1).
Use corresponding plug gauge.
light suction.
1
6
© 39750-1
25 .IR
The no-go limit of the gauge plug (1) must
not fit into the housing bore.
46 ft
If the no-go limit fits, it must be reamed to
9
01 So
the next oversize.
be renewed. 1
12 ine
P01 06
P01 07
09 h
ac
M
© 39750-1
z Unclamp cylinder head.

z Blast cylinder head clean with compressed air.
© 39751-1
© 06/2006 4/6 8159-001

Cylinder head
TCD 2015 I 01-06-04
Press in valve guide

z Mount cylinder head.
z Select valve guide to fit housing bore.
P01 11
P01 12
P01 13
6
© 39754-1
25 .IR
z Supercool valve guide in liquid nitrogen.
Use a suitable container for the liquid nitro-
46 ft
gen and a suitable tool for inserting and
9
01 So
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
12 ine
have reached the temperature of the liquid

nitrogen (-196 °C).
The valve guide has the correct tempera-
09 h
ture if the bubbling up process of the nitro-

gen has finished.
ac
M
© 36636-1
z Push valve guide (1) onto press-in pin (2).

Note post-assembly position of the valve
guide.
The remote side (arrow) must face the
press-in pin.
© 39755-1
© 06/2006 5/6 8159-001

Cylinder head
I 01-06-04 TCD 2015
z Press in valve guide until it touches the press-in pin.

z Remove the press-in pin.
z Remove the cylinder head.
6
© 39756-1
25 .IR
der head.
Attention!
46 ft
9
01 So
face.

12 ine
z Install valves.
09 h
W 01-05-01
ac
M
© 39744-1
© 06/2006 6/6 8159-001

Cylinder head
TCD 2015 W 01-07-08

– Depth-measuring
appliance
Special tools: Attention!
– Support bracket . . . . . . . . . . . . . 120900 When the wear limit is reached, the valve
– Base plate. . . . . . . . . . . . . . . . . . 120910 seat insert and/or valve must be renewed.
25 .IR
46 ft 1
9
W 01-04-04
01 So
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.
12 ine
09 h
ac
2
M
© 40650_1
z Mount depth measuring appliance on cylinder head

sealing surface.
z Measure valve stand back.
P01 45
P01 46
© 42228-1
© 06/2006 1/2 8160-001

Cylinder head
W 01-07-08 TCD 2015
z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
z Install cylinder head. 1
W 01-04-04
2
6
© 40650_1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/2 8160-001

Cylinder head
TCD 2015 I 01-07-09
Renewing valve seat insert

(oversize)
– Tenon milling machine, – W 01-07-08
10 mm
– Internal measuring device Danger!
– Slide gauge
– Cylinder head machining Danger of injury, do not touch supercooled
tool components or the liquid nitrogen!
– Press Wear protective gloves and glasses!
– Industrial vacuum cleaner
– Press-in pin Attention!
– Upright drilling machine The press-in process must be carried out
– Nitrogen (liquid) perature difference between the cylinder 6
head and the valve seat insert.
25 .IR
sed before pressing in.
The relevant manufacturer’s specifications

must be observed when working with the
46 ft cylinder head machining tool.
9
01 So
The respective valve guide must be availa-
ble for replacing a valve seat insert.
12 ine
09 h
ac
M
z Check valve stand back.

W 01-07-08
z Remove valves.
W 01-05-01
© 40639-0
© 06/2006 1/8 8161-001

Cylinder head
I 01-07-09 TCD 2015
Checking valve seat insert

z Check valve seat inserts (1).
Ensure that the installation location is free 1
from faults.
6
© 39739-1
25 .IR
Removing valve seat insert
z Clamp in cylinder head.
46 ft
9
z Align valve seat insert with tenon milling machine.
01 So
12 ine
09 h
ac
M
© 39740-1
z Mill valve seat insert on the sides (arrow) until it can

be removed without tension.
Attention!
Do not damage cylinder head.
© 39741-1
© 06/2006 2/8 8161-001

Cylinder head
TCD 2015 I 01-07-09
z Fit protective underlay (arrow).

z Lever valve seat insert out.
Attention!
Do not damage cylinder head.
z Unclamp cylinder head.
6
© 39742-1
25 .IR
Checking housing bore for valve seat in-
sert
46 ft
9
Diagram for measuring the housing bore at
01 So
the points "a" and "b", in the centre of 1
level "1".
12 ine
09 h
ac
M
© 36640-1
z Measure housing bore with internal measuring de-

vice.
Measuring points see diagram.
z Read off measured value.

P01 01
P01 02
P01 03
P01 04
be renewed.
© 39743-1
© 06/2006 3/8 8161-001

Cylinder head
I 01-07-09 TCD 2015
Alternatively, the diameter of the housing

bore can be determined with the aid of a
measuring guide ring (1).
The measuring guide ring can, for
example, be a valve seat insert turned to
half its size in height which is inserted in
the hole.
6
© 36641-1
25 .IR
Prepare housing bore for the valve seat
insert (oversize)
z Set cutting tool. 46 ft
9
01 So
P01 03
P01 04
12 ine
09 h
ac
M
© 36620-1
z Clamp cylinder head on cylinder head machining

tool.
z Seal coolant channels.
© 39745-1
© 06/2006 4/8 8161-001

Cylinder head
TCD 2015 I 01-07-09
The valve guides can have different diame-

ters, a suitable mandrin guide for alignment
with the bore unit must therefore be selec-
ted. The mandrin guide must move easily
in the valve guide without noticeable resi- 1
stance.
z Align bore unit and mandrin guide (1) with the hous-
ing bore.
6
© 39746-1
25 .IR
z Bore housing bore to oversize level.
Attention!
46 ft
The valve seat insert support (arrow) must
9
01 So
not be machined with the cutting tool.
z Remove chips thoroughly.
12 ine
09 h
ac
M
© 36624-1
z Measure housing bore with internal measuring de-

vice.
P01 03
P01 04
© 39747-1
© 06/2006 5/8 8161-001

Cylinder head
I 01-07-09 TCD 2015
Press in valve seat insert

z Mount cylinder head.
z Select valve seat insert to fit housing bore.
P01 21
P01 22
P01 23
P01 24
6
© 39748-1
25 .IR
z Supercool valve seat insert in liquid nitrogen.
Use a suitable container for the liquid nitro-
46 ft
gen and a suitable tool for inserting and
9
01 So
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
12 ine
have reached the temperature of the liquid

nitrogen (-196 °C).
The valve seat insert has the correct tem-
09 h
perature if the bubbling up process of the

nitrogen has finished.
ac
M
© 36623-1
z Push valve seat insert (1) onto press-in pin (2).

Note installation position.
The valve seat surface must point to the 2
press-in pin.
© 36643-1
© 06/2006 6/8 8161-001

Cylinder head
TCD 2015 I 01-07-09
z Press the valve seat insert (1) with press-in pin (2)
into the housing bore (3) until it is in position (arrow).
z Remove the cylinder head.
z Machine valve seat insert. 2
6
© 36633-1
25 .IR
der head.
Attention!
46 ft
9
01 So
face.

12 ine
09 h
ac
M
© 39744-1
z Install valves.
W 01-05-01
z Check valve stand back.
W 01-07-08
© 40639-0
© 06/2006 7/8 8161-001

Cylinder head
I 01-07-09 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8161-001

Drive system
TCD 2015 W 02-01-04
Checking axial backlash of crankshaft

(crankshaft removed)
8190
25 .IR
Checking the axial backlash
z Remove crankshaft.
46 ft
9
W 02-04-01
01 So
12 ine
09 h
ac
M
© 40485-0
z Set micrometer gauge to 38 mm.

z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
© 35825-2
© 06/2006 1/2 8162-001

Drive system
W 02-01-04 TCD 2015
z Measure locating bearing width

z Note measured value, dimension (a).
P02 11
P02 12
P02 13
6
© 42324-1
25 .IR
z Place thrust ring halves on bearing caps (arrows).
z Measure width with micrometer gauge.
z Note measured value, dimension (b).
46 ft
9
01 So
z Determine axial backlash.
Calculation example
Desired: Axial backlash
12 ine
Given: -
Measured: (a) = 38.6 mm
(b) = 38.4 mm
Calculation: Axial backlash = dimension (a) - dimension (b)
09 h
38.6 mm - 38.4 mm
Result: = 0.2 mm
ac
P02 34
With deviating axial backlash:
M
Set axial backlash by changing the thrust

ring halves. © 40600-0
z Install crankshaft.
W 02-04-01
© 40485-0
© 06/2006 2/2 8162-001

Drive system
TCD 2015 W 02-01-04
Checking axial backlash of crankshaft

(crankshaft installed)
8190

– Socket wrench insert, size
24, reinforced
– Socket wrench insert . . . . . . . . . . . 8035
– Rotation angle disc . . . . . . . . . . . . . 8190
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
25 .IR
Checking the axial backlash
z Remove genset support.
46 ft
9
W 03-08-01
01 So
z Remove rear cover.
W 03-09-01
12 ine
09 h
ac
M
© 40479-0

z Apply stylus to the crankshaft end with pre-tension.
z Press crankshaft in direction of arrow.
© 40589-0
© 06/2006 1/6 8163-001

Drive system
W 02-01-04 TCD 2015
z Press crankshaft in direction of arrow.

P02 34
With deviating axial backlash:
Note measured value, dimension (a).
Set axial backlash by changing the thrust
ring halves.
6
© 40588-0
25 .IR
Changing thrust ring halves
46 ft
z Unscrew screws (arrows) with the socket wrench
insert 8035.
9
01 So
12 ine
09 h
ac
M
© 40593-0
z Unscrew screws (1) with the socket wrench

insert size 24.
z Remove bearing cap (2). 1
z Remove lower bearing shell.
z Remove bottom thrust ring halves (arrows).
© 40594-0
© 06/2006 2/6 8163-001

Drive system
TCD 2015 W 02-01-04
z Remove top thrust ring halves (arrows).
6
© 40595-0
25 .IR
z Measure thickness of the top and bottom thrust ring
halves.
46 ft
9
01 So
z Determine thickness of the new thrust ring halves.
P02 35
P02 36
12 ine
P02 37
Calculation example
09 h
Desired: Thickness of the new thrust ring halves

Given: (x) = thickness for standard, oversize
ac
level 1 and 2
(y) = axial backlash (nominal)
(values from the technical data)
M
Measured: (a) = 0.4 mm axial backlash (actual)

(b) = 3.26 mm (thickness of the old thrust ring
halves) © 43504-0
Calculation: (x) - (b) = (c)
3.36 mm - 3.26 mm = 0.1 mm
Dimension (a) - Dimension (c)
Result: = 0.3 mm
Value must be within the given axial
backlash (y).
z Select new thrust ring halves according to calculated
value.
© 06/2006 3/6 8163-001

Drive system
W 02-01-04 TCD 2015
z Install upper thrust ring halves according to meas-

ured axial clearance.
Oil grooves (1) of the thrust ring halves
face the crankshaft web face (2). 2
Insert thrust ring halves between crank-
case and crankshaft web (arrow).
6
© 40596-0
25 .IR
z Fix thrust ring halves with a little grease to the bear-
ing cap.
46 ft
z Install lower thrust ring halves according to meas-
9
01 So
ured axial backlash.
Use thrust ring halves with guide
lug (arrow).
12 ine
The oil grooves (1) face the crankshaft web

face.
Bearing cap has identification “3“.
09 h
ac
1
M
© 40489-0
z Insert bearing cap (1).

The identification "3" on the bearing cap
must be legible from the flywheel side.
z Align bearing cap.

Press the crankshaft to the flywheel side
first and then in the opposite direction.
© 40598-0
© 06/2006 4/6 8163-001

Drive system
TCD 2015 W 02-01-04
z Tighten screws (arrows).

Attention!
6
© 40597-0
25 .IR
Attention! 46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40599-0
z Tighten screws (arrow) with the socket wrench

insert size 24 and rotation angle disc.
A02 010
© 40491-0
© 06/2006 5/6 8163-001

Drive system
W 02-01-04 TCD 2015
z Tighten screws (arrow) with the socket wrench

insert 8035 and rotation angle disc.
A02 011
6
© 40492-0
25 .IR
z Check axial backlash of crankshaft.
P02 34
46 ft
9
01 So
12 ine
09 h
ac
M
© 45417-0

z Install genset support.
W 03-08-01
z Mount rear cover.
W 03-09-01
© 40479-0
© 06/2006 6/6 8163-001

Drive system
TCD 2015 W 02-01-07
Checking the crankshaft

– Prisms
– Hardness tester
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
25 .IR
W 02-04-01
46 ft
9
z Place crankshaft on prism.
01 So
12 ine
09 h
ac
M
© 40485-0
z Pull off gear wheel (1).

z Remove friction disc.
© 40585-0
© 06/2006 1/6 8164-001

Drive system
W 02-01-07 TCD 2015
6
© 40586-0
25 .IR
z Position friction disc on parallel pin (2).
Use friction disc with locating hole.
46 ft
9
1
01 So
z Mount gear wheel (1).
12 ine
09 h
ac
2
M
© 40587-0
z Visually inspect peripheral surfaces (1).

z Visually inspect gear wheel (2).
1 1
© 40584-0
© 06/2006 2/6 8164-001

Drive system
TCD 2015 W 02-01-07
z Put hardness tester on journal.
6
© 34754-2
25 .IR
z Raise stylus (1) and press release (2).
Stylus (1) falls down, briefly strikes the sur-
46 ft
face and jumps up to the measured value. 1
9
01 So
2
12 ine
09 h
ac
M
© 44445-0
z Read off displayed value (arrow) from hardness test-

er.
P02 07
The measured value is to be converted
according to the table of the measuring
device.
© 43515-1
© 06/2006 3/6 8164-001

Drive system
W 02-01-07 TCD 2015
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
6
© 36424-2
25 .IR
Checking the diameter of the main bearing
pins
46 ft
z Measure main bearing pin with micrometer gauge.
9
01 So
P02 03
P02 04
12 ine
P02 06
09 h
ac
M
© 42327-1
Checking the diameter of the lifting jour-

nals
z Measure lifting journal with micrometer gauge.
P02 22
P02 23
P02 25
© 42326-1
© 06/2006 4/6 8164-001

Drive system
TCD 2015 W 02-01-07
Checking the rotation

z Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
z Turn crankshaft evenly and check rotation.
P02 26
6
© 42325-1
25 .IR
Measuring the fit bearing width
46 ft
9
01 So
12 ine
09 h
ac
M
© 35825-2
z Measure bearing width with internal measuring de-

vice between thelay-on surfaces of the thrust rings.
P02 11
P02 12
P02 13
© 42324-1
© 06/2006 5/6 8164-001

Drive system
W 02-01-07 TCD 2015
W 02-04-01
6
© 40485-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8164-001

Drive system
TCD 2015 W 02-02-02
Renewing the crankshaft sealing ring

(flywheel side)
– Depth-measuring
appliance
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142650
– Self-tapping screw
– Washer
25 .IR
Removing the crankshaft sealing ring
z Remove flywheel.
46 ft
9
W 12-06-01
01 So
z Loosen crankshaft sealing ring in its seat evenly with
a mandrel.
12 ine
z Make a hole in the crankshaft sealing ring with a

pricker.
Attention!
Do not damage the rear cover and cranks-
09 h
haft!
ac
M
© 40656-0
z Turn in a self-tapping screw with washer.
© 42091-2
© 06/2006 1/6 8165-001

Drive system
W 02-02-02 TCD 2015
z Pull out the crankshaft sealing ring with assembly le-

ver.
6
© 36764-1
25 .IR
z Visually inspect all running surfaces.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40657-0
Install crankshaft sealing ring

z Select shim (1).
Use the shim with identification "Rep-
Stage". 1
© 36756-2
© 06/2006 2/6 8165-001

Drive system
TCD 2015 W 02-02-02
z Mount shim (1).

Pay attention to alignment of the
clampingbushing (2) and locating hole (3).
6
© 36755-1
25 .IR
z Turn bolt (1) with thread (2) into crankshaft.
46 ft 1
9
01 So
12 ine
09 h
2
ac
M
© 36757-1
Use new crankshaft sealing ring.
z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the pe-
ripheral surface.
The sealing lip faces the crankcase.
© 36758-1
© 06/2006 3/6 8165-001

Drive system
W 02-02-02 TCD 2015
z Place assembly sleeve (1) on bolt (2).

z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.
1
6 2
© 36759-1
25 .IR
z Push pressure cross-member (1) onto bolt (2).
z Mount washers.
z Screw on nuts.
46 ft
9
01 So
2
12 ine
09 h
ac
1
M
© 36760-1
z Tighten screw (1) until the assembly sleeve (2) is

touching.
z Remove assembly tool.
2
© 36761-1
© 06/2006 4/6 8165-001

Drive system
TCD 2015 W 02-02-02
z Check installation depth (1) with depth measuring

appliance.
P03 25
z Install flywheel.
W 12-06-01
6
© 40960-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8165-001

Drive system
W 02-02-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8165-001

Drive system
TCD 2015 W 02-02-04
Renewing the crankshaft sealing ring

(opposite side to flywheel)
Commercial available tools:
– Depth-measuring
appliance
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142640
– Self-tapping screw
– Washer
25 .IR
Removing the crankshaft sealing ring
46 ft
9
z Remove flanged hub with torsional vibration damper
01 So
and V-belt pulley.
Block flywheel with suitable tool. 1
12 ine
09 h
ac
M
© 40659-0
z Loosen crankshaft sealing ring in its seat evenly with

a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.
Attention!
Do not damage the genset support and
crankshaft!
© 40660-0
© 06/2006 1/6 8166-001

Drive system
W 02-02-04 TCD 2015
z Turn in a self-tapping screw with washer.
6
© 40661-0
25 .IR
z Pull out the crankshaft sealing ring with assembly le-
ver.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40662-0
z Visually inspect all running surfaces.
© 40663-0
© 06/2006 2/6 8166-001

Drive system
TCD 2015 W 02-02-04
Install crankshaft sealing ring

z Select shim (1).
Use the shim with identification "Rep-
Stage". 1
6
© 37153-2
25 .IR
z Mount shim (1).
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 37211-1
z Turn bolt (1) with thread (2) into crankshaft.
© 37208-1
© 06/2006 3/6 8166-001

Drive system
W 02-02-04 TCD 2015
Use new crankshaft sealing ring.
z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the pe-
ripheral surface.
The sealing lip faces the crankcase.
6
© 35203-2
25 .IR
z Place assembly sleeve (1) on bolt (2).
z Press on assembly sleeve.
46 ft
The assembly sleeve is evenly in contact
9
01 So
with the crankshaft sealing ring.
1
12 ine
09 h
ac
2
M
© 35204-2
z Push pressure cross-member (1) onto bolt (2).

z Mount washers.
z Screw on nuts.
© 35205-2
© 06/2006 4/6 8166-001

Drive system
TCD 2015 W 02-02-04
z Tighten screw (1) until the assembly sleeve (2) is

touching.
z Remove assembly tool. 2
1
6
© 35206-2
25 .IR
z Check installation depth (1) with depth measuring
appliance.
P03 26
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 35201-3

and V-belt pulley.
Block flywheel with suitable tool.
1
z Tighten all screws (1) alternately.
A12 030
© 40659-0
© 06/2006 5/6 8166-001

Drive system
W 02-02-04 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8166-001

Drive system
TCD 2015 W 02-03-01

– Con rod test device
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
25 .IR
z Remove piston and connecting rod.
W 02-09-03
46 ft
9
01 So
12 ine
09 h
ac
M
© 40592-0
Checking small end bush

the meter at the reversal point of the pointer to "0".
© 34768-2
© 06/2006 1/10 8167-001

Drive system
W 02-03-01 TCD 2015
Diagram for measuring the small end bush

at the points "a" and "b" in the
levels "1" and "2".
6
© 37239-1
25 .IR
z Insert internal measuring device.
z Balance the internal measuring device at the given
46 ft
measuring points and read off the measured value at
9
01 So
the reversal point of the pointer.
P02 43
12 ine

09 h
ac
M
© 34770-2
Checking piston pin

z Measure piston pin with micrometer gauge.
P02 61
© 35908-2
© 06/2006 2/10 8167-001

Drive system
TCD 2015 W 02-03-01
Determining piston pin clearance

The piston pin clearance is given by the
difference between the internal diameter of
the small end bush (a) and the piston pin
diameter (b).
P02 45
P02 62
Calculation example
Desired: Piston pin clearance
Given: -
Measured: Internal diameter small end bush (a)
(a) = 52.040 mm
Diameter piston pin (b)
(b) = 52.000 mm
Calculation: Dimension (a) - Dimension (b) 6
52.040 mm - 52.000 mm
Result: = 0.040 mm
25 .IR
Checking the con rod bearing bore
z Mount big end bearing cap.
46 ft 1
9
Attention!
01 So
Note the assignment of the big end bearing
cap.
The identification numbers (1) on the con
12 ine
rod and the big end bearing cap must be

identical and opposite to each other when
assembled.
09 h
ac
M
© 34771-2
z Tighten screws .
A02 020
© 34772-2
© 06/2006 3/10 8167-001

Drive system
W 02-03-01 TCD 2015

6
© 36094-1
25 .IR
Diagram for measuring the con rod bearing
bore at the points "a" and "b" in the
levels "1" and "2".
46 ft
9
01 So
12 ine
09 h
ac
M
© 37239-1

P02 55
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
© 34775-2
© 06/2006 4/10 8167-001

Drive system
TCD 2015 W 02-03-01
Checking internal diameter of the con rod

bearing shells
z Remove screws. 2
z Remove the con rod bearing cover.
z Insert bearing shell in the con rod.
Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
anodised rear side (arrow) in the connec-
ting rod. 1
The anti-rotation lock (1) must lock in
groove (2).
6
© 36768-1
25 .IR
z Insert bearing shell in the respective big end bearing
cap.
Attention!
46 ft
9
01 So
groove (2).
12 ine
2
09 h
ac
1
M
© 36769-1

Attention!
Note the assignment of the big end bearing 1
cap.
assembled.
© 34771-2
© 06/2006 5/10 8167-001

Drive system
W 02-03-01 TCD 2015
z Tighten screws .
A02 020
6
© 34778-2
25 .IR
46 ft
9
01 So
12 ine

09 h
ac
M
© 36094-1
Diagram for measuring the inside diameter

of the con rod bearing shells at the
points "a" and "b" in the levels "1" and "2".
© 37239-1
© 06/2006 6/10 8167-001

Drive system
TCD 2015 W 02-03-01

P02 52
P02 54
If the values up to maximum 0.015 mm are
above the bearing tolerances, the connec-
ting rod can still be used.
When the limit value is reached, the con-
necting rod must be replaced.
6
© 34775-2
25 .IR
Checking the diameter of the lifting jour-
nals
46 ft
9
01 So
12 ine
09 h
ac
M
© 36424-2
z Measure lifting journal with micrometer gauge.

P02 22
P02 23
P02 25
© 45399-0
© 06/2006 7/10 8167-001

Drive system
W 02-03-01 TCD 2015
Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diame-
ter of the big end bearing shell (a) and the
lifting journal diameter (b).
P02 56
P02 57
Calculation example
Desired: Big end bearing clearance
Given: -
Measured: Internal diameter big end bearing shell (a)
(a) =88.060 mm
Diameter lifting journal (b)
(b) = 88.000 mm
6 Calculation: Dimension (a) - Dimension (b)
88.060 mm - 88.000 mm
Result: = 0.60 mm
25 .IR
z Remove screws.
z Remove the con rod bearing cover.
z Remove con rod bearing shells.
46 ft
9
01 So
12 ine
09 h
ac
M
© 34778-2

Attention!
Aligning the con rod is not permissible.
z Check that the con rod is parallel.

P02 41
Check con rod without bearing shells on
the con rod test device.
Permissible deviation (a) at a
distance of (x).
© 35880-2
© 06/2006 8/10 8167-001

Drive system
TCD 2015 W 02-03-01
z Check the angle of the con rod.

P02 42
Permissible deviation from (A) to (B) at a
distance of (x).
6
© 35881-2
25 .IR
z Install piston and connecting rod.
W 02-09-03
46 ft
9
01 So
12 ine
09 h
ac
M
© 40592-0
© 06/2006 9/10 8167-001

Drive system
W 02-03-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 10/10 8167-001

Drive system
TCD 2015 I 02-03-03
Removing and installing small end bush

Commercial available tools: Danger!
– Press or threaded spindle Danger of injury, do not touch hot parts!
Special tools: Danger of injury, do not touch supercooled
– Base plate. . . . . . . . . . . . . . . . . . 131200 components or the liquid nitrogen!
– Assembly tool kit. . . . . . . . . . . . . 131210
Wear protective gloves and glasses!
– Nitrogen (liquid)
– Degreasing agent/cleaning
Attention!
The press-in process must be carried out
agent
– Compressed air
perature difference between the small end
– Heating oven
bush and the connecting rod.
sed before pressing in. 6
The pressing out of the small end bush is
shown with pneumatic press.
25 .IR
A threaded spilndle can also be used alter-
natively.
46 ft
9
01 So
12 ine
09 h
ac
M
Removing the small end bush

Attention! 3
Never hammer out the small end bush!
z Insert big end bearing holder (3) in base plate (2). 1

z Insert removal gauge (1) in base plate.
Attention!
Do not confuse the removal gauge with the
installation gauge!
The groove (arrow) must face the big end

bearing holder.
Make sure the removal gauge is inserted
flush! 2
© 40404-0
© 06/2006 1/6 8168-001

Drive system
I 02-03-03 TCD 2015
z Insert the bottom part of the assembly tool (3) into the
removal gauge from below. 1
z Place the connecting rod (1) on the base plate. 2
The flat side (arrow) of the connecting rod
must face down.
z Turn the bottom part (3) into the top part (2) of the as-
sembly tool.
6
© 40403-0
25 .IR
z Align the top part (1) of the assembly tool and remov-
al gauge (2).
46 ft
The top part of the assembly tool and the
9
01 So
removal gauge are level with the angled
surfaces (arrows) of the big end bearing.
1
12 ine
2
09 h
ac
M
© 40401-0
z Screw the top part (1) and bottom part (2) of the as-
sembly tool together.
© 40402-0
© 06/2006 2/6 8168-001

Drive system
TCD 2015 I 02-03-03
z Align the pneumatic press horizontally on the base

plate.
The press-out die is in the centre above
the top of the assembly tool.
6
© 36284-2
25 .IR
z Press out the small end bush with slight pressure.
z Clean the bush bore.
46 ft
The bush bore must be free from grease
9
01 So
and dirt.
12 ine
09 h
ac
M
© 36285-2
Installing small end bush

z Insert big end bearing holder (3) in base plate (2). 3
z Insert installation gauge (1) in base plate.
The groove (arrow) must face the big end
bearing holder.
1
Make sure the installation gauge is inser-
ted flush.
© 40405-0
© 06/2006 3/6 8168-001

Drive system
I 02-03-03 TCD 2015
z Heat up the connecting rod (1).

P02 47
z Place the connecting rod on the base plate (2). 1
The flat side (arrow) of the connecting rod
must face down.
2
6
© 40406-0
25 .IR
z Cool down the small end bush (1) in liquid nitrogen.
P02 46
46 ft
9
01 So
12 ine
9
09 h
ac
M
© 36288-3
z Place supercooled small end bush (1) on installation

mandrel (3).
The index pin (2) is sitting correctly in the
groove (arrow) of the small end bush. 1
2
3
© 40407-0
© 06/2006 4/6 8168-001

Drive system
TCD 2015 I 02-03-03
z Insert installation mandrel (1) with small end bush (2)

in con rod bore.
The small end bush must be insertable in
the connecting rod bore with little force.
Note installation position of the small end
1
bush.
z Pull out the installation mandrel.
The small end bush may not slip. 2
6
© 36290-3
25 .IR
z Check installation position.
Position of the bush joint (arrow) looking at
46 ft
the flat side of the connecting rod shank.
9
01 So
12 ine
09 h
ac
M
© 40968-1
Mechanical machining of the small end

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

Dimensions Maximum Minimum
dimension dimension
Bore of small
end bush 52.055 mm 52.040 mm
dimension A
Piston pin dia-
52.000 mm 51.992 mm
meter
Theoretical
0.063 mm 0.040 mm
clearance
© 39730-2
© 06/2006 5/6 8168-001

Drive system
I 02-03-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8168-001

Drive system
TCD 2015 W 02-04-01
Removing and installing the crankshaft

Commercial available tools: – W 02-01-04 . . . . . . . . . . . . (crankshaft
– Socket wrench insert, size removed)
24, reinforced – W 02-01-04 . . . . . . . . . . . . (crankshaft
– Socket wrench insert, size installed)
14, reinforced . . . . . . . . . . . . . . . . . 8015 – W 02-01-07
– Socket wrench insert, size – W 03-08-01
22, reinforced . . . . . . . . . . . . . . . . . 8035 – W 03-09-01
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 07-07-01
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100350
25 .IR
Removing crankshaft
46 ft
9
W 07-07-01
01 So
W 03-08-01
12 ine
z Remove rear cover.

W 03-09-01
09 h
ac
M
© 40479-0
z Fasten all screws (1).
© 40470-0
© 06/2006 1/14 8169-001

Drive system
W 02-04-01 TCD 2015
z Mount turning gear (1).
6
© 40471-0
25 .IR
z Set the counterweights (1) of cylinders A1/B1 at bot-
tom dead centre.
T00 81
46 ft 1
9
01 So
z Turn the crankshaft with the turning gear.
z Remove counterweights (1).
12 ine
Lay out components in the order in which 2

2
09 h
ac
M
© 42140-1
z Set the counterweights (1) of cylinders A3/B3 at bot-

tom dead centre.
z Remove counterweights (1).
they should be installed. 2 2
© 40480-0
© 06/2006 2/14 8169-001

Drive system
TCD 2015 W 02-04-01
z Place lifting journal of the respective cylinder at bot-

tom dead centre (BDC).
Attention!
Do not jam the con rods when turning the
crankshaft.
6
© 40496-0
25 .IR
z Unscrew screws (1) with the socket wrench
insert 8015.
46 ft
z Remove all big end bearing caps (2).
9
01 So
z Remove bearing shell.
12 ine
Note order of cylinders.

2 1
09 h
ac
M
© 40481-0
Attention!
crankshaft.
Do not damage the big end bearing shells.
z Turn the crankshaft with the turning gear evenly.
The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1
© 40482-0
© 06/2006 3/14 8169-001

Drive system
W 02-04-01 TCD 2015
z Unscrew all screws (1) with the socket wrench

insert 8035. 1
z Unscrew all screws (2) with the socket wrench
insert size 24.
6 1
© 40483-1
25 .IR
z Remove bearing cap (1).
46 ft
z Remove bottom thrust ring halves (arrows). 1
9
01 So
z Remove all main bearing covers (2).
z Remove the main bearing shells.
12 ine
1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A

09 h
ac
2
M
© 42144-1
z Press the con rods carefully out of the lifting journal.
© 40484-0
© 06/2006 4/14 8169-001

Drive system
TCD 2015 W 02-04-01
z Remove turn-over gear.

z Lift out the crankshaft.
z Place crankshaft on prism.
6
© 42145-1
25 .IR
z Remove top thrust ring halves (arrows).
z Remove all main bearing shells (1).
46 ft
z Remove all big end bearing shells (2).
9
01 So
12 ine
1
09 h
2
ac
M
© 37041-1
z Check crankshaft.
W 02-01-07
z Check axial backlash of crankshaft (crankshaft re-
moved).
W 02-01-04
© 40485-0
© 06/2006 5/14 8169-001

Drive system
W 02-04-01 TCD 2015
Installing the crankshaft

z Insert upper main bearing shells.
Attention! 1
groove (2).
6
© 37042-1
25 .IR
z Insert lower main bearing shells in the respective
main bearing cover. 1
Attention!
46 ft
9
01 So
groove (2).
12 ine
09 h
2
ac
M
© 37043-1

Attention!
Insert big end bearing shell with the black
1
anodised rear side in the connecting rod.
groove (2).
© 37044-1
© 06/2006 6/14 8169-001

Drive system
TCD 2015 W 02-04-01
z Insert big end bearing shells in the respective big end

bearing cap.
Attention!
groove (2).
6
© 36769-1
25 .IR
z Lightly oil bearing surfaces.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40488-0
z Insert the crankshaft carefully in the crankcase.

Attention!
Do not jam the con rods when inserting the
crankshaft!
z Set the crankshaft in line with the camshaft (1) .
must be between the marking points on the
camshaft gear wheel.
© 37045-1
© 06/2006 7/14 8169-001

Drive system
W 02-04-01 TCD 2015

z Mount the turning gear.
6
© 40470-0
25 .IR
z Install upper thrust ring halves according to meas-
ured axial clearance.
46 ft
The oil grooves (1) face the crankshaft
9
01 So
web face (2).
Insert thrust ring halves between crank- 2
case and crankshaft web (arrows).
12 ine
09 h
ac
1
M
© 42180-1
z Install lower thrust ring halves according to meas-

ured axial backlash.
z Fix thrust ring halves with a little grease to the bear-
ing cap.
Use thrust ring halves with guide
lug (arrow).
Oil grooves (1) face the crankshaft web
face.
Bearing cap has identification “3“.
© 40489-0
© 06/2006 8/14 8169-001

Drive system
TCD 2015 W 02-04-01
z Insert bearing cap (1).

z Insert main bearing covers (2).
Note assignment and installation position: 1
Assignment of the main bearing covers:
With identification "1" = flywheel side.
With identification "4" = side opposite flyw-
heel side.
1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A
Identifications legible from the flywheel
side.
2 2 2
6
© 42146-2
25 .IR
Attention! 1
46 ft
Screws can be used a maximum 3 times
9
01 So
12 ine
09 h
ac
M
1
© 42147-1
z Oil the screws lightly.

Attention!
Screws can be used a maximum 3 times
z Move the crankshaft axially to and fro.
The bearing is aligned in position as a
result.
1
© 42148-1
© 06/2006 9/14 8169-001

Drive system
W 02-04-01 TCD 2015
z Tighten all screws (arrow) with the socket wrench in-

sert size 24 and rotation angle disc.
A02 010
Attention!
Do not jam the main bearing cover.
6
© 40491-0
25 .IR
z Tighten all screws (arrow) with the socket wrench in-
sert 8035 and rotation angle disc.
A02 011
46 ft
9
01 So
12 ine
09 h
ac
M
© 40492-0
z Check installation position of the connecting rods.

The flattened side (arrow) faces the flyw-
heel on the A-bank and the genset support
on the B-bank.
© 37204-1
© 06/2006 10/14 8169-001

Drive system
TCD 2015 W 02-04-01
z Pull con rods carefully on to the lifting journal.
6
© 42151-1
25 .IR
z Place lifting journal of the respective cylinder at bot-
tom dead centre (BDC).
Attention!
46 ft
9
01 So
crankshaft.
12 ine
09 h
ac
M
© 40493-0

Attention!
Note assignment and installation position:
The identification numbers (1) on the con-
necting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.
© 37055-1
© 06/2006 11/14 8169-001

Drive system
W 02-04-01 TCD 2015
z Tighten new screws with the socket wrench insert

8015 and rotation angle disc.
A02 020
6
© 37056-1
25 .IR
z Place crankshaft web of the respective cylinder at
bottom dead centre (BDC).
46 ft
z Pay attention to clamping bushing (1).
9
01 So
12 ine
1 1
09 h
ac
M
© 42152-1
Attention!
Note assignment and installation position: 1 1 1
Assignment of the counterweights:
Counterweight with
identification "1" = flywheel side.
Flattened sides (1) face the main bearing
cover.
4
© 37057-2
© 06/2006 12/14 8169-001

Drive system
TCD 2015 W 02-04-01
z Insert counterweights according to the identification.
1
6
© 42153-1
25 .IR
z Tighten screws .
A02 001 46 ft
9
01 So
12 ine
09 h
ac
M
© 42154-1
z Remove turning gear (1).
© 40471-0
© 06/2006 13/14 8169-001

Drive system
W 02-04-01 TCD 2015
6
© 40470-0
25 .IR
z Check axial backlash of crankshaft (crankshaft in-
stalled).
W 02-01-04
46 ft
9
01 So
12 ine
09 h
ac
M
© 40494-0
z Mount rear cover.

W 03-09-01
W 03-08-01
W 07-07-01
© 40495-0
© 06/2006 14/14 8169-001

Drive system
TCD 2015 W 02-09-03
Removing and installing the piston and con rod

– Locking ring pliers – W 02-10-03
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 08-04-06 . . . . . . . . . . . . (Railway)
Special tools:
– Piston ring compressor . . . . . . . . 130650
25 .IR
Removing the piston and con rod
46 ft
9
W 01-04-04
01 So
z Insert screws and washers (1) diagonally opposed.
1
Washers:
12 ine
Screw length:
M16 x 90
09 h
z Tighten screws until they touch the cylinder liner.

ac
M
© 40873-0
z Remove oil suction pipe

W 08-04-06
z Remove oil suction pipe (Railway).
W 08-04-06
© 40591-0
© 06/2006 1/8 8170-001

Drive system
W 02-09-03 TCD 2015
z Set piston at bottom dead centre (BDC).

z Unscrew screws (1) with the socket wrench insert.
6
© 42375-1
25 .IR
z Remove big end bearing cover with bearing shell.
46 ft
9
01 So
T00 81
12 ine
09 h
ac
M
© 40821-0
z Set piston at top dead centre (TDC).

z Press out the piston and connection rod.
Attention!
Do not jam the connecting rod in the cylin-
der liner when removing!

© 42376-1
© 06/2006 2/8 8170-001

Drive system
TCD 2015 W 02-09-03
6
© 40592-0
25 .IR
z Remove locking ring with locking ring pliers.
z Press out piston pin.
46 ft
z Remove locking ring with locking ring pliers.
9
01 So
Attention!
Make sure the surface of the piston is flaw-
12 ine
less.
09 h
ac
M
© 42377-1
Installing the piston and con rod

z Insert new locking ring.
Ensure that the installation location is free
from faults.
© 42378-1
© 06/2006 3/8 8170-001

Drive system
W 02-09-03 TCD 2015
z Insert con rod.

Attention!
The concave surface (arrow) of the con-
necting rod must face the recess (1) for the
piston cooling nozzle on the piston.
1
6
© 40967-0
25 .IR
z Oil the piston bolt lightly.
z Insert piston pin in piston.
z Insert new locking ring.
46 ft
9
01 So
from faults.
12 ine
09 h
ac
M
© 42379-1
Attention!
Insert big end bearing shell with the black 2
anodised rear side (arrow) in the connec-
ting rod.
groove (2).
© 36768-1
© 06/2006 4/8 8170-001

Drive system
TCD 2015 W 02-09-03
z Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2).
6
© 36769-1
25 .IR
z Arrange the piston ring joints with an offset of
about 120° to each other.
46 ft
z Check piston rings and piston ring grooves.
9
01 So
W 02-10-03
12 ine
09 h
ac
M
© 42380-1
z Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.
© 36771-1
© 06/2006 5/8 8170-001

Drive system
W 02-09-03 TCD 2015
z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder lin-
er.
Note the cylinder assignment of the piston.
Note identification (1) of the installation
position on the piston base.
The arrow must point to the exhaust gas 1
side.
The piston ring compressor must lie flat on
the cylinder liner.
6
© 36772-1
25 .IR
z Check installation position of the connecting rods.
Attention!
46 ft
The flattened side (1) must face the adja-
9
01 So
cent lifting crank web (2). 1 1
2
12 ine
2
09 h
ac
M
© 40964-1
z Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.
Do not damage the piston cooling nozzle.
© 42381-1
© 06/2006 6/8 8170-001

Drive system
TCD 2015 W 02-09-03

Attention!
Note the assignment of the big end bearing
cap.
assembled.
6
© 42382-1
25 .IR
z Tighten new screws with the socket wrench insert
and rotation angle disc.
A02 020
46 ft
9
01 So
12 ine
09 h
ac
M
© 42383-1
z Install oil suction pipe.

W 08-04-06
z Install oil suction pipe (Railway).
W 08-04-06
© 40591-0
© 06/2006 7/8 8170-001

Drive system
W 02-09-03 TCD 2015
z Unscrew screws with washers (1).

W 01-04-04
6
© 40873-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8170-001

Drive system
TCD 2015 W 02-09-07
Checking the piston

Special tools: When the piston wear limit is reached, the
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 piston must be renewed.
25 .IR
Checking the piston bolt bore
46 ft
9
W 02-09-03
01 So
12 ine
09 h
ac
M
© 42229-1

© 34768-2
© 06/2006 1/4 8171-001

Drive system
W 02-09-07 TCD 2015
Diagram for measuring the piston bolt bore

at the points "a" and "b" in the
levels "1" and "2".
6
© 37239-1
25 .IR
46 ft
9
01 So
P02 78
12 ine
09 h
ac
M
© 36484-2
Checking the piston diameter

Diagram for measuring the piston diameter
at the measuring points "1, 2 and 3", trans-
verse to the piston bolt bore.
© 37244-1
© 06/2006 2/4 8171-001

Drive system
TCD 2015 W 02-09-07
z Measure diameter with micrometer gauge.

P02 71
P02 72
P02 73
6
© 40969-0
25 .IR
W 02-09-03
46 ft
9
01 So
12 ine
09 h
ac
M
© 40592-0
© 06/2006 3/4 8171-001

Drive system
W 02-09-07 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8171-001

Drive system
TCD 2015 W 02-10-03
Checking the piston rings and piston ring grooves

– Feeler gauges
Special tools:
– Universal piston ring pliers . . . . . 130300
– Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . . 130400
25 .IR
Checking the piston rings and piston ring
grooves
z Remove piston and connecting rod. 46 ft
9
01 So
W 02-09-03
z Set universal piston ring pliers to the piston diameter.
12 ine
P02 73
z Remove piston rings with universal piston ring pliers.
09 h
ac
M
© 42323-1
z Clean piston.
z Clean piston ring grooves.
© 42322-1
© 06/2006 1/4 8172-001

Drive system
W 02-10-03 TCD 2015
z Measure piston ring groove for first piston ring with

trapezoidal groove wear gauge.
6
© 33866-2
25 .IR
If there is a gap "S" between the trapezoi-
dal groove wear gauge and piston, the
piston can be used again.
46 ft S
9
01 So
12 ine
09 h
ac
M
© 33867-2
If the trapezoidal groove wear gauge is

touching the piston (arrow), the piston
must be changed.
© 33868-2
© 06/2006 2/4 8172-001

Drive system
TCD 2015 W 02-10-03
Checking the piston ring joint clearance

z Insert the piston ring (1) in the cylinder.
z Align the piston ring in the cylinder by pushing the
piston.
6
© 42321-1
25 .IR
z Measure the piston ring joint clearance with a feeler
gauge.
P02 84
46 ft
9
01 So
P02 85
P02 86
12 ine
When the wear limit is reached, the piston

ring must be renewed.
09 h
ac
M
© 42320-1
Installing piston rings

Order and position of the piston rings as 1
seen from the piston base:
- Double-sided keystone ring (1)
2
- Taper-faced ring (2)
- Bevelland-edge oil control ring with coiled
spring expander (3)
3
Identification “Top“ in (1) and (2) facing
combustion chamber
© 42319-1
© 06/2006 3/4 8172-001

Drive system
W 02-10-03 TCD 2015
z Install piston rings with universal piston ring pliers.

Set spring joint of the bevelland-edge oil
control ring 180° to the ring joint.
6
© 42318-1
25 .IR
Checking the piston ring axial clearance
46 ft
Check with new piston rings.
9
01 So
z Check axial backlash with feeler gauge between pis-
ton ring and piston ring groove.
12 ine
P02 88
P02 89
When the piston wear limit is reached, the
09 h
piston must be renewed.

ac
M
© 42317-1

W 02-09-03
© 40592-0
© 06/2006 4/4 8172-001

Drive system
TCD 2015 W 02-15-01
Removing and installing the piston cooling nozzle

Commercial available tools – W 02-09-03
Special tools:
– Tester . . . . . . . . . . . . . . . . . . . . . 102560
– Dipstick . . . . . . . . . . . . . . . . . . . . 102565
25 .IR
Removing the piston cooling nozzle
46 ft
9
W 02-09-03
01 So
z Unscrew relief valve (1). 2
1
z Remove piston cooling nozzle (2).
12 ine
09 h
ac
M
© 42353-1
Installing the piston cooling nozzle

z Mount piston cooling nozzle.
z Screw on the relief valve hand tight.
The flattened side (1) faces the cylinder
liner.
1
© 42354-1
© 06/2006 1/4 8173-001

Drive system
W 02-15-01 TCD 2015
Check the jet position of the piston cooling

nozzle.
Attention!
Do not damage the cylinder liner when
1
inserting the tester.
z Insert tester in cylinder liner.
z Set tester with the bores (1) over the clamping
bushings (2).
6
© 40787-0
25 .IR
z Insert dipstick (1) in the bores (2) of the tester.
46 ft
9
01 So
12 ine
09 h
ac
1
2
M
© 42356-2
z Insert the tip of the dipstick (1) without using force

into the opening in the piston cooling nozzle (2).
The piston cooling nozzle must be turned.
Attention!
If it cannot be turned, the piston cooling 1
nozzle must be renewed!
The piston cooling nozzle may not be bent!
The piston cooling nozzle must be in line 2
with the dipstick!
© 42357-1
© 06/2006 2/4 8173-001

Drive system
TCD 2015 W 02-15-01
z Tighten the relief valve.

A08 081
Attention!
Make sure the piston cooling nozzle is not
twisted!
6
© 42358-1
25 .IR
z Remove the dipstick.
z Remove the tester.
46 ft
9
01 So
W 02-09-03
12 ine
09 h
ac
M
© 40992-0
© 06/2006 3/4 8173-001

Drive system
W 02-15-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8173-001

Crankcase
TCD 2015 W 03-01-11
Removing and installing the crankcase breather

(oil separator)
Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
25 .IR
Removing the crankcase bleeding
z Unscrew screw (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40664-0
z Loosen hose clip (1).

z Pull out pipe (3).
z Remove intake elbow (4).
4
2 3
© 45807-0
© 06/2006 1/6 8174-001

Crankcase
W 03-01-11 TCD 2015
z Loosen hose clips (1).
6
© 40667-0
25 .IR
z Loosen pipe clamp (1).
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40668-0
z Pull out oil separator (1) together with pipe.
© 40669-0
© 06/2006 2/6 8174-001

Crankcase
TCD 2015 W 03-01-11
z Pull off pipe (1).
6
© 45401-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40671-0
Install crankcase bleeding

z Mount pipe (1).
1
z Fill oil syphon (2) with engine oil.
© 40670-0
© 06/2006 3/6 8174-001

Crankcase
W 03-01-11 TCD 2015
z Insert oil separator (1) in flanged pipe (2).

Do not move the spring (arrow).
1
6 2
© 40672-0
25 .IR
z Mount intake elbow (4).
46 ft
9
01 So
z Position hose clip (1).
z Tighten hose clip (1).
1
12 ine
A06 021
z Mount pipe (3).
09 h

ac
A03 064
4
2 3
M
© 45807-0
z Position pipe clamp (1).

z Tighten pipe clip (1).
A03 060
© 45808-0
© 06/2006 4/6 8174-001

Crankcase
TCD 2015 W 03-01-11
z Position hose clips (1).

z Tighten hose clips (1).
A03 064
6
© 40667-0
25 .IR
z Tighten screw (1).
A03 069
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40664-0
© 06/2006 5/6 8174-001

Crankcase
W 03-01-11 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8174-001

Crankcase
TCD 2015 W 03-03-01

– Depth-measuring
appliance
– Micrometer gauge The following work sequence must be car-
– Internal measuring device ried out on every cylinder unit of a cylinder
Special tools: bank.
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
25 .IR
z Remove cylinder liner.
46 ft
9
W 03-03-02
01 So
z Visually inspect the cylinder running surface.
12 ine
09 h
ac
M
© 45423-0

© 36094-1
© 06/2006 1/4 8175-001

Crankcase
W 03-03-01 TCD 2015
Diagram for measuring the cylinder run-

ning surface at the points "a" and "b" in the
levels "1 - 4".
4
6
© 37238-1
25 .IR
z Remove shim ring (1).
z Visually inspect collar rest (arrow).
z Visually inspect sealing surface.
46 ft 1
9
01 So
12 ine
09 h
ac
M
© 40677-0

P03 31
When the wear limit is reached, the cylin-
der liner must be renewed.
© 42394-1
© 06/2006 2/4 8175-001

Crankcase
TCD 2015 W 03-03-01
z Measure collar height in area (X) with micrometer

gauge.
P03 36
Carry out the measurement at several pla- X
ces on the collar rest.
z Install cylinder liner.

W 03-03-02
6
© 42395-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 3/4 8175-001

Crankcase
W 03-03-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8175-001

Crankcase
TCD 2015 W 03-03-02
Removing and installing the cylinder liner

– Depth-measuring – W 03-03-01
appliance – W 03-03-08
Special tools:
– Assembly device. . . . . . . . . . . . . 150120
– Extraction tool . . . . . . . . . . . . . . . 150130
– Fitting compound
DEUTZ AP1908
25 .IR
Removing the cylinder liner
46 ft
9
W 02-09-03
01 So
12 ine
09 h
ac
M
© 40826-0
z Mark installation position of the cylinder liner on the

crankcase.
z Mark cylinder liner with the cylinder designation.
© 51521-1
© 06/2006 1/6 8176-001

Crankcase
W 03-03-02 TCD 2015
z Fold back plate and insert puller.

– Place the plate (1) with the lay-on surfaces against
the cylinder liner (2) and hold them together.
– Mount the counter holder (3) on the crankcase (4) .
Attention! 1
3
Do not damage the peripheral surfaces
and the sealing surfaces.
Do not damage the piston cooling nozzle.
The counterweights of the crankshaft face

the lubricating oil pan.
4
2
6
© 36782-1
25 .IR
z Pull the cylinder liner up and out.
Turn the nut in the direction of the arrow.
46 ft
9
01 So
z Remove the disassembly device.
z Pull the cylinder liner up and out.
12 ine
09 h
ac
M
© 42230-1
z Remove shim ring (1).

z Visually inspect collar rest (arrow).
1
z Visually inspect sealing surface.
© 40677-0
© 06/2006 2/6 8176-001

Crankcase
TCD 2015 W 03-03-02
z Remove both O-rings (arrows).

z Test the cylinder liners.
W 03-03-01
6
© 42231-1
25 .IR
Install cylinder liner
z Insert new O-rings (arrows).
46 ft
9
Pull the O-rings apart slightly to prevent
01 So
them falling out during assembly.
12 ine
09 h
ac
M
© 42231-1
z Measure collar rest with depth measuring appliance.

P03 35
Carry out the measurement at several pla-
ces on the collar rest.
© 42392-1
© 06/2006 3/6 8176-001

Crankcase
W 03-03-02 TCD 2015
z Insert shim ring (1).

A centring lug (2) points up. 1
6
© 39911-0
25 .IR
z Coat the cylinder liner in the "X" area with fitting com-
pound.
46 ft
Make sure that the liner surface and the
9
01 So
crankcase are absolutely clean before
installing the cylinder liner.
12 ine
09 h
X
ac
M
© 34932-1
z Insert the cylinder liner (1) in the crankcase.
© 39918-0
© 06/2006 4/6 8176-001

Crankcase
TCD 2015 W 03-03-02
z Screw in retaining pins (1).

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

Make sure the pressure plate is fit evenly. 2 1
6
© 42232-1
25 .IR
z Press in cylinder liner to stop.
z Remove the assembly device.
46 ft
9
01 So
12 ine
09 h
ac
M
© 42233-1
z Check the overhang of the cylinder liner.

W 03-03-08
W 02-09-03
© 40583-0
© 06/2006 5/6 8176-001

Crankcase
W 03-03-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8176-001

Crankcase
TCD 2015 W 03-03-08
Checking the overhang of the cylinder liner

Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
25 .IR
Checking the overhang of the cylinder lin-
er
z Remove cylinder head. 46 ft
9
01 So
W 01-04-04
z Insert screws and washers (1) diagonally opposed. 1
12 ine
z Tighten screws until they touch the cylinder liner.

Washers:
09 h
Screw length:
ac
M16 x 90
M
© 45424-0

z Apply stylus of the dial gauge to the crankcase seal-
ing surface with pre-tension (arrow).
© 45762-0
© 06/2006 1/2 8177-001

Crankcase
W 03-03-08 TCD 2015
z Loosen magnetic measuring stand.

z Turn the magnetic measuring stand carefully until the
stylus is touching the sealing surface of the cylinder
liner (arrow).
P03 39
Make measurements at at least 3 other
points on the cylinder liner.
6
© 45761-0
25 .IR
W 01-04-04 46 ft
9
01 So
1
12 ine
09 h
ac
M
© 45424-0
© 06/2006 2/2 8177-001

Crankcase
TCD 2015 W 03-08-01
Removing and installing genset support

– Open wrench size SW 22 – W 06-07-03 . . . . . . . . . . . . (A-bank)
– W 06-07-03 . . . . . . . . . . . . (B-bank)
– Packing compound – W 08-04-06
DEUTZ DW 47 – W 09-07-08
– W 09-08-04
Collect leaking operating substances in

to regulations.
25 .IR
Removing genset support
46 ft
9
W 06-07-03
01 So
W 06-07-03
12 ine

z Remove the holder (2). 2
09 h
1
ac
M
© 40519-0

z Remove the holder (2).
z Unscrew hollow screw (3).
z Remove sealing rings (4).
1
2 3
© 40520-1
© 06/2006 1/14 8178-001

Crankcase
W 03-08-01 TCD 2015
z Unscrew nut (1).

6
© 40521-0
25 .IR
Hold overflow valve.
46 ft
9
01 So
z Remove fuel pipe (3).
z Remove sealing rings (2).
12 ine
1
3
09 h
ac
2
M
© 45803_0
z Remove thermostat housing.

W 09-08-04
z Remove coolant pump.
W 09-07-08
1
and V-belt pulley.
© 40531-0
© 06/2006 2/14 8178-001

Crankcase
TCD 2015 W 03-08-01
z Remove cable tie (1).
6
© 40532-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40533-0
© 40534-0
© 06/2006 3/14 8178-001

Crankcase
W 03-08-01 TCD 2015
z Remove oil suction pipe.

W 08-04-06
6
© 40535-0
25 .IR
z Unscrew lock nut (1).
z Remove lubricating oil pipe.
46 ft
9
01 So
z Remove sealing rings.
1
12 ine
09 h
2
ac
M
© 40536-0

2
1
© 40538-0
© 06/2006 4/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Remove holder.
6
© 40539-0
25 .IR
46 ft 1
9
01 So
1
12 ine
09 h
ac
1
M
© 40540-0

1
2
© 40541-0
© 06/2006 5/14 8178-001

Crankcase
W 03-08-01 TCD 2015

z Remove gasket.
1
Attention!
Do not damage the crankshaft journal
when removing the genset support.
The teeth of the oil pump gears and the

idler gear must grip the teeth of the cranks- 1
haft drive wheel.
Use suitable workshop crane.
6
© 40542-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40543-0
z Knock out crankshaft sealing ring (1).

Attention!
Do not damage sealing surface when
knocking out.
© 40544-0
© 06/2006 6/14 8178-001

Crankcase
TCD 2015 W 03-08-01
Installing genset support

z Fix new O-rings (1) with a little grease.
1 1
6
© 40545-0
25 .IR
z Fix new gasket (1) to the crankcase with a little
grease.
46 ft
The oil pan sealing surface on the crank-
9
1
01 So
case must face upwards.
Make sure the parallel pins (arrows) are in
place.
12 ine
09 h
ac
M
© 40546-0

Use suitable workshop crane.
1
z Centre genset support above the parallel pins.

z Fix genset support with screws (1).
The teeth of the oil pump gears and the
idler gear must grip the teeth of the cranks-
haft drive wheel.
Screw length:
M10 x 150 mm
© 40547-0
© 06/2006 7/14 8178-001

Crankcase
W 03-08-01 TCD 2015

Screw length:
1
M10 x 150 mm
6
© 40548-0
25 .IR
z Tighten screws alternately.
Screw length:
M10 x 65 mm (1) 46 ft
9
01 So
M10 x 100 mm (2)
1
2
12 ine
09 h
ac
M
© 40541-0

Screw length:
1
M10 x 110 mm
© 40540-0
© 06/2006 8/14 8178-001

Crankcase
TCD 2015 W 03-08-01
z Mount holder.
TIghten screws only after mounting the
connecting pipe.
6
© 40539-0
25 .IR
Screw length:
M10 x 70 mm (1) 46 ft
9
1
01 So
M10 x 110 mm (2)
12 ine
09 h
ac
2
1
M
© 40538-0

A03 020
© 40551-0
© 06/2006 9/14 8178-001

Crankcase
W 03-08-01 TCD 2015
z Cut off overhanging gasket (arrows) flush with the

sealing surface of the oil tray.
6
© 40549-0
25 .IR
z Mount new sealing rings.
z Mount the lubricating oil pipe.
z Screw on hollow screw (2).
46 ft
9
01 So
z Screw on lock nut (1).
1
12 ine
09 h
2
ac
M
© 40536-0
z Tighten hollow screw (2).

A08 013
z Tighten lock nut (1).
A08 014
1
© 40536-0
© 06/2006 10/14 8178-001

Crankcase
TCD 2015 W 03-08-01

z Install oil suction pipe.
W 08-04-06
Before mounting the lubricating oil pan, fill
in the joints crankcase/genset support
(arrows) with packing compound.
6
© 40550-0
25 .IR
z Fix the cable strand with cable tie (1) without tension.
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40534-0
© 40533-0
© 06/2006 11/14 8178-001

Crankcase
W 03-08-01 TCD 2015
z Install crankshaft sealing ring (opposite side to fly-
wheel)
W 02-02-04
6
© 40532-0
25 .IR
z Mount the torsional vibration damper.
A12 030 46 ft
9
01 So
1
12 ine
z Install coolant pump.

W 09-07-08
z Install thermostat housing.
09 h
W 09-08-04
ac
M
© 40531-0
z Insert new sealing rings (3).

z Mount fuel pipe (2).
1
3
© 45803_0
© 06/2006 12/14 8178-001

Crankcase
TCD 2015 W 03-08-01
z Oil the thread lightly.

z Mount holder (2).
z Screw on nut (1).
6
© 40521-0
25 .IR
z Mount new sealing rings (4).
z Mount holder (2).
46 ft
9
01 So
z Oil thread and head contact surface lightly.
z Fasten screw (1). 1
12 ine
2 3
4
09 h
ac
M
© 40520-1

A12 093
z Tighten nut (2).
1
A07 044
© 40565-0
© 06/2006 13/14 8178-001

Crankcase
W 03-08-01 TCD 2015

A07 044
A12 092
1
6
© 40555-0
25 .IR
z Mount holder (2).
A07 044 46 ft
9
01 So
W 06-07-03
12 ine

W 06-07-03 2
09 h
1
ac
M
© 40519-0
© 06/2006 14/14 8178-001

Crankcase
TCD 2015 W 03-08-03
Dismantling and assembling genset support

25 .IR
Dismantling genset support
46 ft
9
W 03-08-01 1
01 So
z Remove thrust washer (2). 2
12 ine
z Remove idler gear (3).

09 h
ac
3
M
© 40556-0

z Remove lubricating oil pump (3).
1
3 1
© 40557-0
© 06/2006 1/10 8179-001

Crankcase
W 03-08-03 TCD 2015
z Pull out plug element (1).
6
© 40558-0
25 .IR
z Unscrew nut (1).
z Remove adapter (2).
z Remove O-rings.
46 ft
9
01 So
12 ine
09 h
ac
1
M
2
© 45371_1

z Remove bearing housing (2).
The fuel supply pump, idler gear and fuel
pipes remain installed on the bearing hou- 1
sing.
z Remove O-ring. 2
© 40559-0
© 06/2006 2/10 8179-001

Crankcase
TCD 2015 W 03-08-03

z Remove ground cable (2).
z Remove holder (3). 2
3 1
1
6
© 40560_1
25 .IR
z Remove holder.
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40561-0

z Remove holder (1).
z Remove oil cooler cover (4).
3 4 1
2
2
© 40562_1
© 06/2006 3/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Remove oil cooler (2).
z Remove O-rings.
1
1
6
© 40563-0
25 .IR
Assembling genset support
46 ft
9
z Insert new O-rings (1).
01 So
1 1
12 ine
09 h
2 2
ac
M
© 40564-0
z Mount oil cooler (2).

A08 051
1
1
© 40563-0
© 06/2006 4/10 8179-001

Crankcase
TCD 2015 W 03-08-03

z Mount new gasket.
z Mount oil cooler cover (4).
z Mount holder (1).
z Fasten all screws. 3 4 1
Screw length:
M8 x 35 mm (2)
M8 x 65 mm (3)
2
2
6
© 40562_1
25 .IR
z Mount holder (1).
46 ft
9
01 So
12 ine
1
09 h
ac
2
M
© 40523-0
z Align oil cooler cover.

The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
Do not move gasket. 1

A08 050
© 40524-0
© 06/2006 5/10 8179-001

Crankcase
W 03-08-03 TCD 2015

z Remove holder.
The screws for both holders are not tighte-
ned until after mounting the connecting
pipe. 1
6
© 40525-0
25 .IR
z Mount holder (3).
z Mount ground cable (2).
46 ft 2
9
01 So
A13 018
12 ine
3 1
1
09 h
ac
M
© 40560_1
z Insert new O-ring.

z Insert bearing housing (2).
A07 024 1
© 40559-0
© 06/2006 6/10 8179-001

Crankcase
TCD 2015 W 03-08-03
z Position O-rings.
z Mount adapter (2).
z Tighten nut (1).
A08 002
2
6
© 45371_1
25 .IR
z Lightly oil O-ring.
z Mount new O-ring (1).
46 ft
9
1
01 So
12 ine
09 h
ac
M
© 40526-0
z Insert plug element (1).
© 40527-0
© 06/2006 7/10 8179-001

Crankcase
W 03-08-03 TCD 2015
z Pay attention to clamping bushing (1).
6
© 40528-0
25 .IR
z Insert new O-ring.
46 ft
9
01 So
12 ine
09 h
ac
M
© 34738-2
z Mount lubricating oil pump (3).

z Fasten screws.
Screw length: 1
M10 x 75 mm (1)
M8 x 45 mm (2).
3 1
© 40557-0
© 06/2006 8/10 8179-001

Crankcase
TCD 2015 W 03-08-03

A08 010
1
A08 011
6
© 40648-0
25 .IR
z Lightly oil journal (1).
z Lightly oil bearing bush (2).
z Mount idler gear (3).
46 ft 3
9
01 So
The collar (arrow) of the idler gear faces
the genset support.
12 ine
2
09 h
ac
1
M
© 40529-0
z Mount thrust washer (2).

The bevelled side (arrow) of the thrust
washer must face upwards.
© 40530-0
© 06/2006 9/10 8179-001

Crankcase
W 03-08-03 TCD 2015

A04 011
z Install genset support. 1
W 03-08-01
6
© 40537-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 10/10 8179-001

Crankcase
TCD 2015 W 03-09-01
Removing and installing rear cover

– W 03-09-04
– W 08-04-07
– Locking agent
DEUTZ DW 59
25 .IR
Removing rear cover
z Remove connection housing.
46 ft
9
W 03-09-04
01 So
z Remove lubricating oil pan. 1
W 08-04-07
12 ine

z Remove rear cover 2.
2
z Remove gasket.
09 h
ac
M
© 40684-0
z Knock out crankshaft sealing ring (1).

Attention!
Do not damage the sealing surfaces.
© 37207-1
© 06/2006 1/4 8180-001

Crankcase
W 03-09-01 TCD 2015
6
© 40685-0
25 .IR
Installing rear cover
46 ft
9
z Make sure the clamping bushings (arrows) are in
01 So
place.
The slots in the clamping bushings must
face downwards.
12 ine
09 h
ac
M
© 40686-0
z Insert new seal (1).
© 40687-0
© 06/2006 2/4 8180-001

Crankcase
TCD 2015 W 03-09-01
z Mount rear cover.

Use new sealing rings.
z Fasten screws. 1
z Insert screws (1) with locking agent.
Screw length:
M8 x 30 mm (1),(3)
M8 x 45 mm (2)
3 3
A03 010
2
6
© 40688_1
25 .IR
The gasket (arrows) must be flush with the
sealing surface of the oil pan.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40689-0
z Install lubricating oil pan.

W 08-04-07
z Install connection housing.
W 03-09-04
z Renew crankshaft sealing ring (flywheel side).
W 02-02-02
© 40655-0
© 06/2006 3/4 8180-001

Crankcase
W 03-09-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8180-001

Crankcase
TCD 2015 W 03-09-04
Removing and installing the connection housing

– Rotation angle disc . . . . . . . . . . . . . 8190 – W 06-01-07
– W 12-06-01
– Locking agent – W 13-03-02
DEUTZ DW 59
25 .IR
Removing the connection housing
46 ft
z Install impulse transmitter (crankshaft).
9
W 05-07-01
01 So
z Remove starter.
W 13-03-02
12 ine
z Remove exhaust manifold.

W 06-01-07
09 h
z Remove flywheel.
W 12-06-01
ac
M
© 40690-0
© 40691-0
© 06/2006 1/6 8181-001

Crankcase
W 03-09-04 TCD 2015

z Remove flange housing (3).
6 3
© 40692-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40693-0

© 45394-0
© 06/2006 2/6 8181-001

Crankcase
TCD 2015 W 03-09-04
6
© 40899-0
25 .IR
Installing the connection housing
z Clean contact surfaces.
46 ft
9
z Coat connection housing on lay-on surface (arrow)
01 So
with locking agent.
12 ine
09 h
ac
M
© 42087-1
Make sure the parallel pins (arrows) are in

place.
© 40695-0
© 06/2006 3/6 8181-001

Crankcase
W 03-09-04 TCD 2015
z Mount connection housing.

Centre above the parallel pins.
z Fasten screws.
1
Insert screws with locking agent.
Note different screw lengths.
M12 x 35 mm (1)
M12 x 90 mm (2). 2

A03 081
6
© 40694-0
25 .IR
A03 082
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40696-0
z Fasten screws.
M12 x 200 mm (1)
M12 x 175 mm (arrows).
1
A03 088
© 40693-0
© 06/2006 4/6 8181-001

Crankcase
TCD 2015 W 03-09-04

A03 089
6
© 40697-0
25 .IR
z Coat lay-on surface (arrow) with locking agent.
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 45409-0
z Mount flange housing (3).

Screw length:
M10 x 110 mm
1
Screw length:
M10 x 210 mm

2
A12 058
3
© 40692-0
© 06/2006 5/6 8181-001

Crankcase
W 03-09-04 TCD 2015

A12 059
6
© 40698-0
25 .IR
A03 080
46 ft
9
01 So
12 ine
09 h
ac
M
© 40691-0
z Install flywheel.
W 12-06-01
z Install starter.
W 13-03-02
z Install impulse transmitter (crankshaft).
W 05-07-01
z Install exhaust manifold.
W 06-01-07
© 40451-0
© 06/2006 6/6 8181-001

Crankcase
TCD 2015 I 03-10-05

Special tools:
– Tool kit. . . . . . . . . . . . . . . . . . . . . 150030
In case of coolant leakage or damage to
– Repair kits the sealing assembly crankcase/cylinder
– Fitting compound liner/cylinder head, the collar rest of the
DEUTZ AP 1908 cylinder liner in the crankcase can be
– Cleaning agent (e.g. com- repaired.
merically available brake The following work sequence must be car-
cleaner) ried out on every cylinder unit of a cylinder
bank.
25 .IR
Grinding in collar rest surface
z Remove cylinder liner.
46 ft 1
9
W 03-03-02
01 So
z Seal the insides of the crankcase with cover
plates (1).
12 ine
09 h
ac
M
© 39914-0
z Clean collar rest (1).

z Clean inside of the crankcase.
Use cleaning agent.
1
© 39902-0
© 06/2006 1/8 8182-001

Crankcase
I 03-10-05 TCD 2015
Grinding for cleaning the collar rest

z Apply post-grinding paste (1) to the collar rest (2). 1 2
z Add a little clean water.
6
© 39908-0
25 .IR
z Mount the bracket and handles on the grinding/sur-
face plate.
46 ft
Note the different processing sides of the A
9
01 So
grinding/surface plate:
A - grinding side
B - surface side
12 ine
Grinding side “A“ faces down.

z Place grinding side “A“ on collar rest.
09 h
ac
M
© 39904-0
z Turn the grinding/surface plate (1) forwards and

backwards evenly (approx. 180°).
z Grind the collar rest lightly.
Note soft grinding noise.
z Clean the collar rest. 1

z Remove grind paste and grinding particles.
Use cleaning agent.
© 39906-0
© 06/2006 2/8 8182-001

Crankcase
TCD 2015 I 03-10-05
Check
z Move the bracket on the griding/surface plate.
B
Spotting side “B“ facing downwards.
z Apply surface paste thinly to the surface side “B“.

Applying it too thickly makes it impossible
to detect recesses in the collar rest.
6
© 39916-0
25 .IR
z Place surface side “B“ on collar rest.
Note the different processing sides of the
grinding/surface plate:
46 ft
9
01 So
A - grinding side
B - surface side
z Surface the collar rest.
12 ine
09 h
ac
M
© 39906-1
The surfacing shows up recesses (1) in the

collar rest.
© 39913-0
© 06/2006 3/8 8182-001

Crankcase
I 03-10-05 TCD 2015
Grinding
A
6
© 39904-0
25 .IR
z Apply pre-grinding paste (1) to the collar rest (2).
46 ft 1
9
01 So
12 ine
09 h
ac
2
M
© 39907-0
z Place grinding side “A“ on collar rest.

Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
Note rough grinding noise. 1
z Clean the collar rest.
Use cleaning agent.
© 39906-0
© 06/2006 4/8 8182-001

Crankcase
TCD 2015 I 03-10-05
Check
z Check the contact pattern.
An even contact pattern must exist.
Otherwise, repeat the grinding and sur-
face process.
z Clean the collar rest.
6
© 39912-0
25 .IR
Regrinding
46 ft
A
9
01 So
12 ine
09 h
ac
M
© 39904-0
z Apply post-grinding paste (1) to the collar rest (2).

1
© 39907-0
© 06/2006 5/8 8182-001

Crankcase
I 03-10-05 TCD 2015

Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
Note soft grinding noise.
z Clean the collar rest. 1
Repeat the surface process to check.
6
© 39906-0
25 .IR
z Clean inside of the crankcase.
z Remove cover plates (1).
46 ft
z Check the inside of the crankcase for cleanliness. 1
9
01 So
The tool set must be cleaned and the grin-
ding/surface plate oiled slightly for corro-
sion protection.
12 ine
09 h
ac
M
© 39914-0
Assembly
z Coat the O-rings with fitting compound. 1
© 39917-0
© 06/2006 6/8 8182-001

Crankcase
TCD 2015 I 03-10-05
z Insert shim ring (1).

A centring lug (2) points up. 1
6
© 39911-0
25 .IR
z Insert new cylinder liner (1).
W 03-03-02
46 ft
9
1
01 So
12 ine
09 h
ac
M
© 39918-0
© 06/2006 7/8 8182-001

Crankcase
I 03-10-05 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8182-001

Crankcase
TCD 2015 W 03-11-01
Removing and installing, testing camshaft bearing

Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Assembly tool . . . . . . . . . . . . . . . 143830
25 .IR
Testing camshaft bearing
z Remove camshaft.
46 ft
9
W 04-05-05
01 So
12 ine
09 h
ac
M
© 42126-1

© 34768-2
© 06/2006 1/8 8183-001

Crankcase
W 03-11-01 TCD 2015
Diagram for measuring the camshaft bea-

ring at the points "a and b" in the
levels "1 and 2".
6
© 37239-1
25 .IR
46 ft
9
01 So
P03 13
P03 14
12 ine

When the wear limit is reached, the cams-
haft bearing must be replaced.
09 h
ac
M
© 42127-1
Removing camshaft bearing

z Insert spindle (1) with puller bush (2) on the opposite
side to the flywheel.
© 34711-2
© 06/2006 2/8 8183-001

Crankcase
TCD 2015 W 03-11-01
z Insert counter bearing (1) on the flywheel side.
1 6
© 34712-1
25 .IR
z Mount spacing sleeve (1).
z Mount ball bearing (2).
z Screw on nut.
46 ft
9
01 So
1
12 ine
09 h
ac
2
M
© 34713-2
z Pull out the camshaft bearings one after another.

Do not pull out the camshaft bearing (flyw-
heel side).
© 34714-2
© 06/2006 3/8 8183-001

Crankcase
W 03-11-01 TCD 2015
z Insert spindle with puller bush on flywheel side.

z Mount counter bearing (1) on flywheel side.
z Mount spacing sleeve.
z Mount ball bearing.
z Screw on nut.
z Pull out flywheel side camshaft bearing. 1
6
© 34716-2
25 .IR
Installing camshaft bearing
46 ft
Diagram for the installation depth of the
camshaft bearings.
9
01 So
12 ine
Measuring the depth from the flywheel side

A 0 mm
0,2 D C B A
B 172,5 mm
09 h
0,2
0,2
C 337,5 0,2 mm
ac
0,2
D 502,5 0,2 mm
M
© 45415-1
z Mount the new camshaft bearing (flywheel side) so

that the recess (1) faces the flywheel.
The diagram shows the camshaft bearing
in the installed state.
The camshaft bearing (flywheel side) has
two lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.
© 37179-1
© 06/2006 4/8 8183-001

Crankcase
TCD 2015 W 03-11-01
z Insert spindle with counter bearing on the opposite

z Insert puller bush in camshaft bearing and push onto
the spindle.
6
© 34718-2
25 .IR
z Screw on nut.
46 ft
9
01 So
z Press in camshaft bearing (flywheel side).
Installation depth, see diagram.
12 ine
09 h
ac
M
© 34720-2
z Check that the lubricating oil bores (1) are in line.

If the lubricating oil bore is not in line, the
camshaft bearing must be removed and re-
installed.
© 40900-0
© 06/2006 5/8 8183-001

Crankcase
W 03-11-01 TCD 2015
z Mount the new middle camshaft bearings on the op-

posite side to the flywheel so that the recess (1) fac-
es the flywheel.
The diagram shows the camshaft bearing 1
in the installed state.
The middle camshaft bearings have three
lubricating oil bores.
line.
6
© 37180-1
25 .IR
z Mount the new camshaft bearing (opposite side to
flywheel) so that the recess (1) faces the flywheel.
46 ft
The diagram shows the camshaft bearing
9
01 So
in the installed state. 2
The camshaft bearing (opposite side to fly-
wheel) has three lubricating oil bores.
12 ine

line.
09 h
1
ac
M
© 37181-1
z Insert puller bush in camshaft bearing.

z Insert spindle with puller bush on flywheel side.
© 34723-2
© 06/2006 6/8 8183-001

Crankcase
TCD 2015 W 03-11-01
z Mount counter bearing.

z Screw on nut.
z Insert the camshaft bearings one after another.
Attention!
Do not damage the camshaft bearings
when moving the assembly tool!
Installation depth, see diagram.
6
© 34714-2
25 .IR
z Check that the lubricating oil bores (1) are in line.
If the lubricating oil bore is not in line, the
46 ft
camshaft bearing must be removed and re-
9
01 So
installed.
1
z Install the camshaft.
W 04-05-05
12 ine
09 h
ac
M
© 40901-0
© 06/2006 7/8 8183-001

Crankcase
W 03-11-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8183-001

Engine control
TCD 2015 W 04-02-02
Remove and installing tappets, checking tappet bores

25 .IR
Removing tappets.
z Remove camshaft.
46 ft
9
W 04-05-05
01 So
z Remove tappets.
12 ine

09 h
ac
M
© 37198-1
© 40699-0
© 06/2006 1/2 8184-001

Engine control
W 04-02-02 TCD 2015
Measuring tappet bores

6
© 35825-2
25 .IR
z Measure tappet bore with internal measuring device.
P03 23
46 ft
9
P03 24
01 So
12 ine
X
09 h
ac
M
© 34707-4
Installing tappets
z Oil all tappets lightly.
z Insert all tappets.
Note the assignment of the tappets.

W 04-05-05
© 37199-1
© 06/2006 2/2 8184-001

Engine control
TCD 2015 W 04-04-09

– Packing compound Collect leaking operating substances in

DEUTZ DW 48 suitable vessels and dispose of according
to regulations.
25 .IR
Removing the gearcase
z Remove turbocharger.
46 ft
9
W 06-06-04
01 So
12 ine
09 h
ac
M
© 40700-0

z Pull off pipe (2).
1
2
© 40701-0
© 06/2006 1/6 8185-001

Engine control
W 04-04-09 TCD 2015
6
© 40702-0
25 .IR
z Remove spacing sleeves.
46 ft
9
1
01 So
z Remove heat shield (3).
2
12 ine
3
09 h
ac
M
© 40703-0

© 40704-0
© 06/2006 2/6 8185-001

Engine control
TCD 2015 W 04-04-09

z Remove pipe clamp (2).
6
© 40705-0
25 .IR
z Remove gear case cover (2).
46 ft
9
01 So
1
2
12 ine
09 h
ac
M
© 40706-0
© 40707-0
© 06/2006 3/6 8185-001

Engine control
W 04-04-09 TCD 2015
Installing the gearcase cover

Attention!
Do not damage the sealing surfaces.
1
2
z Clean sealing surfaces. 2
z Apply packing compound evenly to the sealing sur-
face.
z Mount gear case cover (1).
z Mount holder (2).
A04 020 3
6
© 40708-0
25 .IR
z Mount pipe clamp (2).
A08 045 46 ft
9
01 So
2
12 ine
1
09 h
ac
M
© 40705-0
z Mount holder (2).

A12 071
© 40704-0
© 06/2006 4/6 8185-001

Engine control
TCD 2015 W 04-04-09

z Insert spacing sleeves with screws (1).
z Fasten all screws (2). 1
2
z Tighten all screws.
A12 071
3
6
© 40703-0
25 .IR
A13 094
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40702-0
z Push on pipe (2).

A03 064
1
2
© 40701-0
© 06/2006 5/6 8185-001

Engine control
W 04-04-09 TCD 2015
z Install the turbocharger.

W 06-06-04
6
© 40700-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8185-001

Engine control
TCD 2015 Railway W 04-04-09

Commercial available tools – W 07-13-01 . . . . . . . . . . . . (Railway)

to regulations.
25 .IR
Removing the gearcase
z Unlock cable plug (1) and remove.
46 ft
9
01 So
z Lay cable bare.
12 ine
2
09 h
ac
M
© 42108-1

z Remove washers.
z Remove fuel pressure holding valve.
W 07-13-01 1
© 45777-0
© 06/2006 1/6 8186-001

Engine control
W 04-04-09 TCD 2015 Railway

z Remove washer.
3
z Remove spacing sleeve (2).
z Loosen pipe clamp (3).
6
© 45775-0
25 .IR
z Remove washer.
46 ft 3
9
01 So
12 ine
09 h
ac
1
2
M
© 45776-0

z Remove gasket.
© 42416-2
© 06/2006 2/6 8186-001

Engine control
6
© 40707-0
25 .IR
Installing the gearcase cover
46 ft
9
z Mount new gasket.
01 So
z Tighten screws (2) alternately. 1
12 ine
A04 020
09 h
ac
2
M
© 42416-2
z Mount holder (3).

z Mount holder (2).
z Mount washer. 3
A12 071
1
2
© 45776-0
© 06/2006 3/6 8186-001

Engine control

z Position spacing sleeve (2).
3
z Mount washer.
A12 096
6
© 45775-0
25 .IR
z Position cable harness rail with cable harness.
z Mount washers.
46 ft
9
01 So
z Fasten screws. 3 1
Note different screw lengths:
M6 x 12 mm (1)
12 ine
M6 x 16 mm (2)
z Tighten screws .
A13 094
09 h
2
ac
M
© 45778-1
z Install fuel pressure holding valve.

W 07-13-01
© 45779-1
© 06/2006 4/6 8186-001

Engine control
z Plug in the cable plug (1).

Ensure that the cables are connected pro-
perly.
z Fix cable with cable tie (2).
6
© 42108-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8186-001

Engine control
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8186-001

Engine control
TCD 2015 W 04-05-05
Removing and installing the camshaft

– Lifting gear – W 02-04-01
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
Special tools: – W 07-04-01 . . . . . . . . . . . . (Cylinder
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 A2-B3)
– Counter support . . . . . . . . . . . . . 144150 – W 07-06-04
– Packing compound
DEUTZ DW 48
– Locking agent
DEUTZ DW 72 6
25 .IR
Removing the camshaft
z Remove rocker arm brackets.
46 ft
9
W 01-02-02
01 So
W 02-04-01
12 ine
z Remove impulse transmitter (camshaft).

W 05-07-03
09 h
ac
M
© 40409-0
z Remove injection pumps (cylinder A1).

W 07-04-01
z Remove injection pumps (cylinder A2-B3).
W 07-04-01
1
Do not remove injection pump housing.
2
z Place fuel hose (2) to one side.
© 40458-0
© 06/2006 1/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Place cable harness rail (2) with cable harness to
one side.
6
© 40410-0
25 .IR
z Remove spacing sleeves. 1
46 ft
9
01 So
12 ine
3
09 h
ac
2
M
© 40411-1

© 40412-0
© 06/2006 2/24 8187-001

Engine control
TCD 2015 W 04-05-05

6
© 40413-0
25 .IR
46 ft
9
01 So
12 ine
1 2
09 h
ac
M
© 40414-0
© 40415-0
© 06/2006 3/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Remove cover (2) .
z Remove cover (3).
3
2
6
© 40416-0
25 .IR
z Remove pad thrust bearing (2).
46 ft 1
9
01 So
12 ine
09 h
ac
2
M
© 40417-0

z Remove gear wheel (2).
Attention!
2
Make sure no parts fall into the crankcase!
Concealed screws can be accessed by

turning the crankshaft with the turning gear.
Press back the injection pump camshaft
carefully as far as it goes.
© 40418-0
© 06/2006 4/24 8187-001

Engine control
TCD 2015 W 04-05-05
6
© 40419-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40420-0
z Remove bolt (1).

© 40421-0
© 06/2006 5/24 8187-001

Engine control
W 04-05-05 TCD 2015
6
© 40422-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40423-0
z Remove bolt (1).

© 40424-0
© 06/2006 6/24 8187-001

Engine control
TCD 2015 W 04-05-05

z Remove gasket.
6
© 40425-0
25 .IR
z Insert counter support (1) in the toothing of the cam-
shaft gear wheel.
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40426-0
z Turn the camshaft gear wheel in the direction of

the A-bank.
z Block the camshaft gear wheel with the counter hold-
er on the crankcase (arrow).
© 40427-0
© 06/2006 7/24 8187-001

Engine control
W 04-05-05 TCD 2015
z Loosen screw (1).

z Turn back the camshaft gear wheel.
z Remove counter holder (2).
1
6
© 40428-0
25 .IR
z Remove camshaft toothed wheel (2).
46 ft
9
01 So
2
12 ine
09 h
ac
1
M
© 40429-0
z Turn engine 180°.

z Press in all tappets.
z Unhook the engine from the assembly block on one
side.
z Pull out the camshaft (1) carefully to the flywheel
side.
© 40430-0
© 06/2006 8/24 8187-001

Engine control
TCD 2015 W 04-05-05
z Check camshaft.
W 04-05-06
6
© 36812-1
25 .IR
Installing the camshaft
z Oil camshaft bearing lightly.
46 ft
9
z Oil cam shaft pin lightly.
01 So
z Insert camshaft carefully.
The locating hole (1) of the camshaft faces
towards the lubricating oil pan.
12 ine
09 h
1
ac
M
© 37079-1
z Measure the overhang of the parallel pin with the

depth measuring appliance.
P04 39
z Correct overhang.
© 40431-0
© 06/2006 9/24 8187-001

Engine control
W 04-05-05 TCD 2015
z Insert camshaft gear wheel (2).

z Lightly oil screw (1).
z Fasten screw (1).
Make sure that the parallel pin on the
camshaft gear wheel and the locating hole
on the camshaft are in line. 2
6
© 40429-0
25 .IR
shaft gear wheel.
46 ft
9
01 So
the B-bank.
1
12 ine
09 h
ac
M
© 40432-0
z Tighten screw (arrow).

A04 001
z Turn back the camshaft gear wheel.
z Remove counter holder.
© 40433-0
© 06/2006 10/24 8187-001

Engine control
TCD 2015 W 04-05-05
Determining axial backlash of the cam-

shaft
z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
6
© 40434-0
25 .IR
z Measure the flange height from the running surfaces
46 ft
to the lay-on surface with the depth measuring appli-
9
01 So
ance (arrows).
12 ine
P04 35
Calculation example
09 h
Given: -
ac
(b) = 45.50 mm
45.80 mm - 45.50 mm
M
Result: = 0.30 mm
1
z Correct deviation with gaskets.
© 42273-2
P04 37
z Mount cover (2).

z Fit new sealing rings.

z Tighten all screws (1). 1
A04 002
© 40425-0
© 06/2006 11/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Check oil channel (arrow) for free passage.
6 1
© 40435-0
25 .IR
z Lightly oil bearing liner (1) with engine oil.
z Insert idler gear (2).
46 ft
The collar (arrow) faces the bearing bush.
9
01 So
12 ine
2
09 h
ac
1
M
© 40438-0
z Insert bolt (1).
© 40437-0
© 06/2006 12/24 8187-001

Engine control
TCD 2015 W 04-05-05

A04 013
Screw length:
M12 x 80 mm
6
© 40423-0
25 .IR
A04 012 46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40422-0

1
© 40435-0
© 06/2006 13/24 8187-001

Engine control
W 04-05-05 TCD 2015

1
6
© 40436-0
25 .IR
z Insert bolt (1).
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40439-0

A04 013
Screw length:
1
M12 x 100 mm
© 40420-0
© 06/2006 14/24 8187-001

Engine control
TCD 2015 W 04-05-05

A04 012
6
© 40419-0
25 .IR
Checking the tooth edge clearance of the
idler gear (B-bank)
z Mount magnetic measuring stand. 46 ft
9
01 So
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
12 ine
z Adjust dial gauge to "0".

09 h
ac
M
© 40440-0

P04 44
Repeat the measuring process on several
tooth flanks.

© 40441-0
© 06/2006 15/24 8187-001

Engine control
W 04-05-05 TCD 2015

idler gear (A-bank)
6
© 40442-0
25 .IR
P04 44 46 ft
9
01 So
tooth flanks.
12 ine

09 h
ac
M
© 40443-0
z Position the injection pump camshaft.

The locating hole (arrow) faces upwards.
© 40444-0
© 06/2006 16/24 8187-001

Engine control
TCD 2015 W 04-05-05
z Position camshaft gear wheel.

The marking (1) faces towards the cranks-
haft.
6
© 42289-1
25 .IR
Overview of the gear train and the mar-
kings of the control times: 1
46 ft
Injection pump camshaft gear wheel (1)
9
01 So
Camshaft gear wheel (2) 2
Idler gear (3).
Crankshaft gear wheel (4)
12 ine
Marking injection pump camshaft / idler

3
gear (5)
5
Marking camshaft / crankshaft (6)
09 h
ac
M
4
6
© 40445-1
z Position injection pump camshaft gear wheel.

The marking (1) faces the camshaft gear
wheel.
© 40446-0
© 06/2006 17/24 8187-001

Engine control
W 04-05-05 TCD 2015
z Insert the injection pump camshaft gear wheel in the

The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).
6 1
© 40447-0
25 .IR
Attention!
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40448-0

injection pump camshaft gear wheel
z Turn gear wheel in direction of arrow until it stops.
© 40449-0
© 06/2006 18/24 8187-001

Engine control
TCD 2015 W 04-05-05

P07 20
tooth flanks.

6
© 40450-0
25 .IR
W 02-04-01
46 ft
9
Do not install the turbocharger.
01 So
z Install rocker arm brackets.
12 ine
W 01-02-02
z Check and set plunger lift of injection pumps.
W 07-06-04
09 h
ac
M
© 40503-0

A04 004
© 40464-0
© 06/2006 19/24 8187-001

Engine control
W 04-05-05 TCD 2015
z Mount pad thrust bearing (2).

6
© 40989-0
25 .IR
Checking and setting axial backlash of the
injection pump camshaft
46 ft
z Insert feeler gauge blade between gear wheel of the
9
01 So
injection pump camshaft and the pad thrust
bearing (arrow). 1
z Press the pad thrust bearing onto the feeler gauge
12 ine
blade.
z Fasten screw (1).
z Check axial backlash.
09 h
P04 43
ac
M
© 40512-0

bearing (arrow).
blade.
P04 43
© 40513-0
© 06/2006 20/24 8187-001

Engine control
TCD 2015 W 04-05-05

A04 015
z Check axial backlash again.
P04 43
Check axial backlash on both sides bet- 1
ween
pad thrust bearing and gear
wheel (arrows).
6
© 40514-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40515-0
z Press in the cover (3) to the stop.

z Mount cover (2).

2
A04 022
© 40460-0
© 06/2006 21/24 8187-001

Engine control
W 04-05-05 TCD 2015
z Fix cable tie (1).
6
© 40459-0
25 .IR
face of the gear case.
46 ft
9
01 So
Use packing compound DEUTZ DW 48.
2
z Mount gear case cover (1). 2
12 ine
z Mount holder (2).

1
09 h
A04 020
ac
3
M
© 40516-0

A08 045
© 40456-0
© 06/2006 22/24 8187-001

Engine control
TCD 2015 W 04-05-05
z Mount holder (2).

A12 071
6
© 40455-0
25 .IR
z Insert screws (3) with spacing sleeves. 1
46 ft
9
01 So
z Tighten screws (2 and 3) alternately.
A12 071
12 ine
3
09 h
ac
2
M
© 40517-0

A13 094
© 40453-0
© 06/2006 23/24 8187-001

Engine control
W 04-05-05 TCD 2015

z Position fuel hose (2).
A12 090
1
6
© 40458-0
25 .IR
z Install impulse transmitter (camshaft).
W 05-07-03
46 ft
9
z Install injection pumps (cylinder A1).
01 So
W 07-04-01
z Install injection pumps (cylinder A2-B3).
12 ine
W 07-04-01
W 06-06-04
09 h
ac
M
© 40518-0
© 06/2006 24/24 8187-001

Engine control
TCD 2015 W 04-05-06

– Depth-measuring appli-
ance
25 .IR
z Remove camshaft.
46 ft
9
W 04-05-05
01 So
z Visually inspect cams and bearing pins for wear.
Repairing the camshaft is not permissible.
12 ine
The camshaft must be renewed.

09 h
ac
M
© 36812-1

© 36424-2
© 06/2006 1/4 8188-001

Engine control
W 04-05-06 TCD 2015
z Measure the diameter of journals with the microme-

ter gauge.
P04 31
When the wear limit is reached, the cams-
haft must be renewed.
6
© 42128-1
25 .IR
Checking the camshaft gear wheel
46 ft
9
1
01 So
12 ine
09 h
ac
M
© 40601-0

z Visually inspect the idler gear (1) for wear.
z Visually inspect the camshaft gear wheel (2) for 2
wear.
1
© 40602-1
© 06/2006 2/4 8188-001

Engine control
TCD 2015 W 04-05-06
z Insert parallel pin (1).
6
© 40603-0
25 .IR
P04 39
46 ft
9
01 So
z Correct overhang.
12 ine
09 h
ac
M
© 40604-0
z Place camshaft gear wheel on idler gear.

The marking (1) on the idler gear faces the 2
The markings (1) and (2) must be opposite
in line.
© 40605-1
© 06/2006 3/4 8188-001

Engine control
W 04-05-06 TCD 2015

A04 003 1
W 04-05-05
6
© 40601-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8188-001

Engine control
TCD 2015 W 04-05-07
Removing and installing injection pump camshaft

Special tools: – W 04-06-03
– Turn-over gear . . . . . . . . . . . . . . 100350 – W 05-07-03
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 – W 06-06-04
– Counter support . . . . . . . . . . . . . 144150 – W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
– W 07-04-01 . . . . . . . . . . . . (Cylinder
– Packing compound A2-B3)
DEUTZ DW 48 – W 07-06-04
– Locking agent
DEUTZ DW 72 Collect leaking operating substances in
suitable vessels and dispose of according 6
to regulations.
25 .IR
Removing injection pump camshaft
z Remove impulse transmitter (camshaft).
46 ft
9
W 05-07-03
01 So
W 07-04-01
12 ine

W 07-04-01
09 h

W 03-08-01
ac
W 06-06-04
M
© 40497-0

© 40458-0
© 06/2006 1/32 8189-001

Engine control
W 04-05-07 TCD 2015
6
© 40453-0
25 .IR
46 ft
9
01 So
12 ine
3
09 h
ac
2
M
© 40517-0

© 40455-0
© 06/2006 2/32 8189-001

Engine control
TCD 2015 W 04-05-07

6
© 40456-0
25 .IR
46 ft
9
1
01 So
2
12 ine
09 h
ac
M
© 40457-0
© 40459-0
© 06/2006 3/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Remove cover (3).
3
2
1
6
© 40460-0
25 .IR
46 ft 1
9
01 So
W 04-06-03
12 ine
09 h
ac
2
M
© 40417-0
z Loosen all screws (1).

© 40464-0
© 06/2006 4/32 8189-001

Engine control
TCD 2015 W 04-05-07
z Turn over crankshaft until the valve overlap is

achieved on cylinder no. B2.
T01 63
The inlet valve starts opening,exhaust
valve closes.
6
© 40465-0
25 .IR
The locking pin of the turning gear must
snap into the tooth notch (1) of the starter
ring gear.
46 ft
9
01 So
The second tooth notch (2) must face the
B-bank.
12 ine
09 h
ac
1
2
M
© 40466-0
Attention!

z Pull locking pin.
1 1
© 40590-0
© 06/2006 5/32 8189-001

Engine control
W 04-05-07 TCD 2015

z Remove gear wheel (2).
Attention! 2

z Remove turning gear. 1

W 04-06-03
6
© 40467-0
25 .IR
z Remove rocker arm brackets.
W 01-02-02
46 ft
9
01 So
W 03-09-04
z Remove crankcase sealing ring (flywheel side) 1
12 ine
W 02-02-02
09 h
ac
M
© 40419-0
© 40420-0
© 06/2006 6/32 8189-001

Engine control
TCD 2015 W 04-05-07
z Remove bolt (1).

1
6
© 40421-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40422-0
© 40423-0
© 06/2006 7/32 8189-001

Engine control
W 04-05-07 TCD 2015
z Remove bolt (1).

6
© 40424-0
25 .IR
z Remove gasket.
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40468-0

shaft gear wheel.
© 40469-1
© 06/2006 8/32 8189-001

Engine control
TCD 2015 W 04-05-07
6
© 40470-0
25 .IR
z Mount turning gear (1).
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40471-0

the A-bank.
© 40472-0
© 06/2006 9/32 8189-001

Engine control
W 04-05-07 TCD 2015
z Loosen screw (1).
6
© 40473-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40474-0

z Remove camshaft gear wheel (2)
Push back the camshaft carefully as far as
it goes.
2
© 45381-0
© 06/2006 10/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Pull out the injection pump camshaft carefully.
Attention!
Do not damage the camshaft and camshaft
bearing!
1
6
© 40475-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40476-0
Installing injection pump camshaft

© 40993-0
© 06/2006 11/32 8189-001

Engine control
W 04-05-07 TCD 2015
z Fasten screw (1).

z Pull out cover (2).
6
© 40994-0
25 .IR
z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
46 ft
z Insert the injection pump camshaft carefully.
9
01 So
12 ine
09 h
ac
M
© 40995-0
Attention!
Do not damage the camshaft and camshaft
bearing!
z Move the injection pump camshaft over the opposite
Use a suitable tool.
© 40996-0
© 06/2006 12/32 8189-001

Engine control
TCD 2015 W 04-05-07
6
© 40475-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40997-0
z Mount cover (2).

© 40994-0
© 06/2006 13/32 8189-001

Engine control
W 04-05-07 TCD 2015

A04 005
6
© 40993-0
25 .IR
Installing camshaft gear wheel
1
46 ft
Overview of the gear train and the mar-
kings of the control times:
9
01 So
Injection pump camshaft gear wheel (1) 2
Camshaft gear wheel (2)
Idler gear (3).
12 ine
Crankshaft gear wheel (4) 3

Marking injection pump camshaft / idler 5
gear (5)
09 h
Marking camshaft / crankshaft (6)

ac
M
4
6
© 40445-1

P04 39
z Correct overhang.
© 40431-0
© 06/2006 14/32 8189-001

Engine control
TCD 2015 W 04-05-07
z Insert camshaft gear wheel.

1
Make sure that the parallel pin on the
camshaft gear wheel and the locating hole
on the camshaft are in line.
6
© 40474-0
25 .IR
z Fasten screw (1).
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40473-0

shaft gear wheel.
z Turn the crankshaft evenly with the turning gear until
the counter holder blocks on the B-bank of the
crankcase (arrow).
© 40477-0
© 06/2006 15/32 8189-001

Engine control
W 04-05-07 TCD 2015

A04 001
6
© 40473-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40474-0
Determining axial backlash of the cam-

shaft
z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
© 40478-0
© 06/2006 16/32 8189-001

Engine control
TCD 2015 W 04-05-07

z Measure the flange height from the running surfaces
to the lay-on surface with the depth measuring appli-
ance (arrows).
P04 35
Calculation example
Given: -
(b) = 45.50 mm
45.80 mm - 45.50 mm
Result: = 0.30 mm
1
6
z Correct deviation with gaskets.
© 42273-2
P04 37
25 .IR
z Mount cover (2).
46 ft
9
01 So
z Fit new sealing rings.
1
12 ine
A04 002
09 h
2
ac
M
© 40468-0

1
© 40435-0
© 06/2006 17/32 8189-001

Engine control
W 04-05-07 TCD 2015

1
6
© 40438-0
25 .IR
z Insert bolt (1).
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40437-0

A04 013
Screw length:
M12 x 80 mm
© 40423-0
© 06/2006 18/32 8189-001

Engine control
TCD 2015 W 04-05-07

A04 012
6
© 40422-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
1
© 40435-0

© 40436-0
© 06/2006 19/32 8189-001

Engine control
W 04-05-07 TCD 2015
z Insert bolt (1).
1
6
© 40439-0
25 .IR
A04 013 46 ft
9
01 So
Screw length:
1
M12 x 100 mm
12 ine
09 h
ac
M
© 40420-0

A04 012
© 40419-0
© 06/2006 20/32 8189-001

Engine control
TCD 2015 W 04-05-07

idler gear (B-bank)
6
© 40440-0
25 .IR
P04 44 46 ft
9
01 So
tooth flanks.
12 ine

09 h
ac
M
© 40441-0

idler gear (A-bank)
© 40442-0
© 06/2006 21/32 8189-001

Engine control
W 04-05-07 TCD 2015

P04 44
tooth flanks.

6
© 40443-0
25 .IR
z Position the injection pump camshaft.
The locating hole (arrow) faces upwards.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40444-0

1
© 40474-0
© 06/2006 22/32 8189-001

Engine control
TCD 2015 W 04-05-07
z Remove turning gear (1).
6
© 40471-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40470-0
z Position injection pump camshaft gear wheel.

The marking (1) faces the camshaft gear
wheel.
© 40446-0
© 06/2006 23/32 8189-001

Engine control
W 04-05-07 TCD 2015
z Insert the injection pump camshaft gear wheel in the

The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).
6 1
© 40447-0
25 .IR
Attention!
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40498-0

injection pump camshaft gear wheel
© 40449-0
© 06/2006 24/32 8189-001

Engine control
TCD 2015 W 04-05-07

P07 20
tooth flanks.

6
© 40450-0
25 .IR
z Install crankshaft sealing ring (flywheel side)
W 02-02-02
46 ft
9
z Install connection housing.
01 So
W 03-09-04
Do not install the turbocharger.
12 ine

W 04-06-03
09 h
ac
M
© 40690-0
Attention!

© 40464-0
© 06/2006 25/32 8189-001

Engine control
W 04-05-07 TCD 2015

W 03-08-01
z Install rocker arm brackets.
W 01-02-02
z Check and set plunger lift of injection pumps.
W 07-06-04
6
© 40503-0
25 .IR
A04 004
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40464-0

© 40989-0
© 06/2006 26/32 8189-001

Engine control
TCD 2015 W 04-05-07

bearing (arrow). 1
blade.
z Fasten screw (1).
P04 43
6
© 40512-0
25 .IR
bearing (arrow).
46 ft
9
01 So
blade.
12 ine
P04 43
09 h
ac
M
© 40513-0

A04 015
P04 43
ween
wheel (arrows).
© 40514-0
© 06/2006 27/32 8189-001

Engine control
W 04-05-07 TCD 2015

6
© 40515-0
25 .IR
z Mount cover (2).
46 ft
9
01 So
2
12 ine
A04 022
09 h
ac
1
M
© 40460-0
© 40459-0
© 06/2006 28/32 8189-001

Engine control
TCD 2015 W 04-05-07

Use packing compound DEUTZ DW 48.
2
z Mount gear case cover (1). 2
z Mount holder (2).
1
A04 020
6
© 40516-0
25 .IR
A08 045 46 ft
9
01 So
2
12 ine
1
09 h
ac
M
© 40456-0
z Mount holder (2).

A12 071
© 40455-0
© 06/2006 29/32 8189-001

Engine control
W 04-05-07 TCD 2015

A12 071
2
6
© 40517-0
25 .IR
A13 094
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40453-0

A12 090
1
© 40458-0
© 06/2006 30/32 8189-001

Engine control
TCD 2015 W 04-05-07

W 07-04-01
W 07-04-01
z Install impulse transmitter (camshaft).
W 05-07-03
W 06-06-04
W 04-06-03
6
© 40518-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 31/32 8189-001

Engine control
W 04-05-07 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 32/32 8189-001

Engine control
TCD 2015 W 04-06-03
Installing and removing turning gear

Commercial available tools The turning gear 100350 can be used at
the front end of the crankshaft depending
Special tools: on the installation relations.
– Turn-over gear . . . . . . . . . . . . . . 100300
– Locking agent
DEUTZ DW 59
25 .IR
Attaching turning gear
46 ft
9
z Remove cover (2).
01 So
z Remove gasket.
12 ine
2
1
09 h
ac
M
© 40461-0
z Insert turn-over gear (1).

z Insert centering pin (2) in threaded bore (3).
1 2
© 40462-0
© 06/2006 1/2 8190-001

Engine control
W 04-06-03 TCD 2015

A03 085
Gear wheel of the turning gear grips the
starter gear ring.
6
© 40463-0
25 .IR
Removing turning gear
46 ft
9
z Remove turn-over gear.
01 So
12 ine
09 h
1
ac
M
© 40463-0

z Mount new gasket.
z Mount cover (2).
A03 085
2
1
© 40461-0
© 06/2006 2/2 8190-001

Speed control
TCD 2015 W 05-07-01

(crankshaft)
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Read out error memory of the motor con-
– Dial gauge adapter . . . . . . . . . . . 101830
trol timer with SERDIA.
– Turn-over gear . . . . . . . . . . . . . . 100300
DEUTZ AP1908
25 .IR
Removing the impulse transmitter
46 ft
9
W 04-06-03
01 So
z Unlock cable plug (1) and disconnect.
1
12 ine
09 h
2
ac
M
© 40710-0
© 40932-0
© 06/2006 1/6 8191-001

Speed control
W 05-07-01 TCD 2015

z Remove impulse transmitter (2).
z Remove seals.
6
© 40711-0
25 .IR
z Clean components.
46 ft
9
01 So
12 ine
09 h
ac
M
© 45879-1
Installing the impulse transmitter

Through the installation opening of the
impulse transmitter, no bore (arrow) may
be visible on the flywheel.
© 45900-0
© 06/2006 2/6 8191-001

Speed control
TCD 2015 W 05-07-01
z Insert dial gauge in adapter (1).
6
© 45897-0
25 .IR
z Insert adapter with dial gauge under pre-tension in
the base plate (1).
z Fix dial gauge in adapter.
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 45898-0
z Insert and press in adapter with dial gauge into the

connection housing until it stops.
The stylus of the dial gauge must touch the
level flywheel surface.
z Note measured value.

z Make 120° orientation marks on the vibration damp-
er.
Attention!
Remove adapter and dial gauge before
turning the crankshaft.
z Turn the crankshaft to the next 120° mark in direction
of rotation.
z Select lowest measured value of 3 measurements,
dimension (a). © 45899-0
© 06/2006 3/6 8191-001

Speed control
W 05-07-01 TCD 2015
z Measure distance, dimension (b).

0,1
24 0,2 mm
z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired: Dimension (y)
Given: Dial gauge adapter dimension = 24.00 mm
Measured: Dimension (a) = dial gauge adapter dimension + b
lowest measured value
Dimension (a) = 24.00 mm + 0.49 mm
Dimension (a) = 24.49 mm
Dimension (b) = 24.00 mm
Calculation: Dimension (y) = dimension (a) - dimension (b)
6
Dimension (y) = 24.49 mm - 24.00 mm
Result: Dimension (y) = 0.49 mm
© 45878-1
25 .IR
z Determine tightness of the impulse transmitter under
compliance with the permissible distance c
dimension (c).
46 ft
9
1
01 So
Calculation example
Desired: Compliance with the permissible distance, di-
mension (c)
Gasket
12 ine
Given: MInimum distance dimension (c1) = 1.00 mm

Dimension (y)
Thickness of gasket = 0.30 mm
09 h
Measured: -
Calculation: Dimension (c) = minimum
ac
distance dimension (c1) -

dimension (y) + thickness of the gasket
Dimension (c) = 1.00 mm - 0.49 mm + 0.50 mm 2
M
Dimension (c) = 1.01 mm

Result: Dimension (c) corresponds to the permissible di-
stance, therefore a gasket with a thickness of © 45904-0
0.50 mm must be used.
z Permissible distance (c) between flywheel (1) and

impulse transmitter (2).
P05 91
© 06/2006 4/6 8191-001

Speed control
TCD 2015 W 05-07-01
z Select new gaskets.

Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by pla-
cing the appropriate number of gaskets
underneath.
6
© 45882-0
25 .IR
z Mount new gasket(s) according to the determined
distance.
z Press in impulse transmitter (2).
46 ft
9
01 So
Attention!
Do not damage the component.

12 ine
A05 011 1
09 h
2
ac
M
© 40711-0
© 40932-0
© 06/2006 5/6 8191-001

Speed control
W 05-07-01 TCD 2015
z Plug cable plugs (1) together.

perly.

z Remove turning gear. 1
W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.
6
© 40710-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8191-001

Speed control
TCD 2015 W 05-07-03

(camshaft)
– W 06-06-04
Special tools:
– Dial gauge adapter . . . . . . . . . . . 101830
– Turn-over gear . . . . . . . . . . . . . . 100300
DEUTZ AP 1908
– Locking agent
DEUTZ DW 72
25 .IR
Removing the impulse transmitter
46 ft
9
W 04-06-03
01 So
W 06-06-04
12 ine
09 h
ac
M
© 40700-0
© 40717-0
© 06/2006 1/8 8192-001

Speed control
W 05-07-03 TCD 2015
6
© 40718-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40719-0

z Remove impulse transmitter (2).
z Remove seals.
1
© 40720-0
© 06/2006 2/8 8192-001

Speed control
TCD 2015 W 05-07-03
z Remove protective foil.

z Clean components. 1
6
© 00000-0
25 .IR
Installing the impulse transmitter
46 ft
9
The pin (arrow) must be in the centre of the
01 So
installation opening.
12 ine
09 h
ac
M
© 45901-0
z Insert dial gauge in adapter (1).
© 45897-0
© 06/2006 3/8 8192-001

Speed control
W 05-07-03 TCD 2015
z Insert adapter with dial gauge under pre-tension in

the base plate (1).
z Fix dial gauge in adapter.
6
© 45898-0
25 .IR
z Insert and press in adapter with dial gauge into the
connection housing until it stops.
46 ft
The stylus of the dial gauge must touch the
9
01 So
pin of the camshaft gear.

z Make 120° orientation marks on the vibration damp-
12 ine
er.
Attention!
Remove adapter and dial gauge before
09 h
turning the crankshaft.

ac
z Turn the crankshaft to the next 120° mark in direction

of rotation.
M
z Select lowest measured value of 3 measurements,

dimension (a). © 45902-0
z Measure distance, dimension (b).

0,1
24 0,2 mm
z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired: Dimension (y)
Given: Dial gauge adapter dimension = 24.00 mm
Measured: Dimension (a) = dial gauge adapter dimension + b
lowest measured value
Dimension (a) = 24.00 mm + 0.76 mm
Dimension (a) = 24.76 mm
Dimension (b) = 23.90 mm
Calculation: Dimension (y) = dimension (a) - dimension (b)
Dimension (y) = 24.76 mm - 23.90 mm
Result: Dimension (y) = 0.86 mm
© 45878-1
© 06/2006 4/8 8192-001

Speed control
TCD 2015 W 05-07-03
z Determine tightness of the impulse transmitter under

compliance with the permissible distance c
dimension (c).
Calculation example 1
Desired: Compliance with the permissible distance, di-
mension (c)
Gasket
Given: Minimum distance dimension (c1) = 0.30 mm
Dimension (y)
Measured: -
Calculation: Dimension (c) = minimum
distance dimension (c1) -
dimension (y) + thickness of the gasket
Dimension (c) = 0.30 mm - 2
0.86 mm + (2x0.50 mm)
Dimension (c) = 0.44 mm
6
Result: Dimension (c) corresponds to the permissible di- © 45903-0
stance, therefore two gaskets with a thickness of
25 .IR
0.50 mm must be used.
z Permissible distance (c) between camshaft gear
wheel (1) and impulse transmitter (2).
P05 92
46 ft
9
01 So
12 ine
09 h
ac
M
z Select new gaskets.

Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by pla-
cing the appropriate number of gaskets
underneath.
© 45882-0
© 06/2006 5/8 8192-001

Speed control
W 05-07-03 TCD 2015

z Coat the O-ring (1) with fitting compound.
6
© 45878-2
25 .IR
perly.
46 ft
9
01 So
1
z Wrap the cable plug in protective foil.
12 ine
09 h
ac
M
© 00000-0

z Mount new gasket(s) according to the determined
distance.
z Press in impulse transmitter (2).
1
Attention!
Do not damage the component!
z Tighten screw (1). 2

A05 012
© 40720-0
© 06/2006 6/8 8192-001

Speed control
TCD 2015 W 05-07-03
z Mount cover (2).

z Tighten screws .
A04 022
6
© 40719-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40718-0

perly.
© 40717-0
© 06/2006 7/8 8192-001

Speed control
W 05-07-03 TCD 2015

W 06-06-04
6
© 40716-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8192-001

Exhaust system/Charging
TCD 2015 W 06-01-05
Removing and installing exhaust line

(A-bank)
Commercial available tools – W 06-01-06 . . . . . . . . . . . . (A-bank)
DEUTZ S1
25 .IR
Removing exhaust line
z Remove exhaust pipe (A-bank).
46 ft
9
W 06-01-06
01 So
12 ine
09 h
ac
M
© 40722-0
z Loosen screws (1).
© 40723-0
© 06/2006 1/4 8193-001

W 06-01-05 TCD 2015

z Remove exhaust line (2).
6 2
© 45810-0
25 .IR
z Remove seals.
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40725-0
© 40726-0
© 06/2006 2/4 8193-001

TCD 2015 W 06-01-05
Installing exhaust line

z Mount new gaskets.
The strap (arrow) must face the cylinder
head cover.
z Coat the screws with fitting compound .
6
© 45374-0
25 .IR
z Mount exhaust line (2).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 45810-0
z Tighten all the screws (1) alternately from the centre

outwards.
A06 001
© 40986-0
© 06/2006 3/4 8193-001

W 06-01-05 TCD 2015
z Install exhaust pipe (A-bank).

W 06-01-06
6
© 40722-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8193-001

TCD 2015 W 06-01-05
Removing and installing exhaust line

(B-bank)
Commercial available tools – W 06-01-06 . . . . . . . . . . . . (B-bank)
DEUTZ S1
25 .IR
Removing exhaust line
z Remove exhaust pipe (B-bank).
46 ft
9
W 06-01-06
01 So
1
12 ine
09 h
ac
M
© 40727-0

z Remove exhaust line (2).
© 45809-0
© 06/2006 1/4 8194-001

W 06-01-05 TCD 2015

z Remove seals.
1
6
© 40730-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40729-0
Installing exhaust line

The strap (arrow) must face the cylinder
head cover.
© 45375-0
© 06/2006 2/4 8194-001

TCD 2015 W 06-01-05
z Mount exhaust line (2).

6
© 45809-0
25 .IR
z Tighten all the screws (1) alternately from the centre
outwards.
A06 001
46 ft
9
01 So
z Install exhaust pipe (B-bank). 1
W 06-01-06
12 ine
09 h
ac
M
© 40985-0
© 06/2006 3/4 8194-001

W 06-01-05 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8194-001

TCD 2015 W 06-01-06
Removing and installing exhaust pipe

(A-bank)
Commercial available tools
DEUTZ S1
25 .IR
Removing exhaust pipe
z Unscrew nuts (arrows).
46 ft 1
9
z Remove screws.
01 So
z Remove exhaust pipe (2). 2
12 ine
09 h
ac
M
© 40733-0
Install exhaust pipe.

2
z Position exhaust pipe (1).
1
z Insert sealing ring.
The cone (arrow) faces the exhaust pipe.
z Mount flange (2) on exhaust manifold.

z Fasten screws (3).
3
© 36795-1
© 06/2006 1/2 8195-001

W 06-01-06 TCD 2015

z Mount flange (1) on exhaust line.

z Screw on nuts (3).
3
2
6
© 36796-1
25 .IR
A06 002
46 ft
9
Ensure uniform distance (arrow) of flange
01 So
connection.
12 ine
1
09 h
ac
M
© 37216-1
z Tighten nuts (1) alternately.

A06 003
connection.
© 40736-0
© 06/2006 2/2 8195-001

TCD 2015 W 06-01-06
Removing and installing exhaust pipe

(B-bank)
DEUTZ S1
25 .IR
Removing exhaust pipe
46 ft 1
9
z Remove screws.
01 So
z Remove exhaust pipe (2).
12 ine
09 h
2
ac
M
© 40734-0
Install exhaust pipe.

z Position exhaust pipe (1).
1
z Insert sealing ring. 2

z Mount flange (2) on exhaust manifold.

3
© 36799-1
© 06/2006 1/2 8196-001

W 06-01-06 TCD 2015

z Mount flange (1) on exhaust line.

6 2 3
© 36800-1
25 .IR
A06 002
46 ft
9
01 So
connection.
12 ine
09 h
1
ac
M
© 37218-1

A06 003
connection.
© 40735-0
© 06/2006 2/2 8196-001

TCD 2015 W 06-01-07

– W 06-01-06 . . . . . . . . . . . . (B-bank)
– W 06-06-04
25 .IR
Removing exhaust manifold
46 ft
9
W 06-06-04
01 So
W 06-01-06
12 ine
z Remove exhaust pipe (B-bank).

W 06-01-06
09 h
ac
M
© 40731-0

z Remove exhaust manifold (2).
1
© 40732-0
© 06/2006 1/2 8197-001

W 06-01-07 TCD 2015
Installing exhaust manifold

z Mount exhaust manifold (2).
1
A06 010
6
© 40732-0
25 .IR
W 06-01-06
46 ft
9
z Install exhaust pipe (B-bank).
01 So
W 06-01-06
12 ine
W 06-06-04
09 h
ac
M
© 40451-0
© 06/2006 2/2 8197-001


(A-bank)
DEUTZ S1
25 .IR
z Remove turbocharger (A-bank).
46 ft
9
W 06-06-04
01 So
z Unscrew nuts (1).
z Remove screws.
12 ine
1
09 h
ac
M
2
© 42079-1
z Unscrew nuts (1).

z Remove washers.
z Remove screws.
© 42081-2
© 06/2006 1/2 8198-001


z Insert screws.
z Mount washers.
1
z Tighten nuts (1).
A06 010
6
© 42081-2
25 .IR
z Mount holder (2).
z Insert screws.
z Tighten nuts (1).
46 ft
9
01 So
A06 034
z Install turbocharger (A-bank).
12 ine
W 06-06-04
1
09 h
ac
M
2
© 42079-1
© 06/2006 2/2 8198-001


(B-bank)
DEUTZ S1
25 .IR
z Remove turbocharger (B-bank).
46 ft
9
W 06-06-04
01 So
12 ine
09 h
ac
M
© 42080-1
z Unscrew nuts (1).

z Remove washers.
z Remove screws.
© 42082-2
© 06/2006 1/2 8199-001


2
z Insert screws.
z Tighten nuts (1).
A06 010
6 1
© 42082-2
25 .IR
z Install turbocharger (B-bank).
W 06-06-04
46 ft
9
01 So
12 ine
09 h
ac
M
© 42080-1
© 06/2006 2/2 8199-001

TCD 2015 W 06-02-03
Remove and install the charge air line

DEUTZ AP1908
25 .IR
Remove charge air line
46 ft
9
z Remove charge air pipe (2) with plug.
01 So
2
12 ine
1
09 h
ac
1
M
© 40764-0
z Pull out plug element (1).
© 40765-1
© 06/2006 1/4 8200-001

W 06-02-03 TCD 2015
z Unscrew nuts (1).

z Remove washers.
z Remove charge air manifold (2).
z Remove gasket. 1
6
© 45403-0
25 .IR
Install charge air line
z Mount new gasket.
46 ft
9
z Mount charge air manifold (2).
01 So
1
z Mount washers and screw on nuts.
z Tighten nuts (1).
12 ine
A06 046
09 h
2
ac
M
© 45403-0
z Mount new O-rings (1).

z Coat the O-rings with fitting compound.
© 40767-0
© 06/2006 2/4 8200-001

TCD 2015 W 06-02-03
z Insert plug element (1).
6
© 40768-1
25 .IR
z Mount charge air line.
z Tighten screws .
46 ft
9
01 So
A06 030
Screw length:
1
12 ine
M10 x 65 mm (1)
M10 x 85 mm (2) 2
09 h
ac
M
© 40769-0
© 06/2006 3/4 8200-001

W 06-02-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8200-001

TCD 2015 W 06-02-05

25 .IR
Removing connecting pipe
46 ft
z Remove fuel pipes (flame glow plugs).
9
W 07-01-04
01 So
12 ine
09 h
ac
M
© 40737-0
© 40738-0
© 06/2006 1/10 8201-001

W 06-02-05 TCD 2015
z Unscrew nut (1).

Mark assignment of cables/connections
before removing.
z Remove cables (2) from both flame glow plugs. 1
6
© 40739-0
25 .IR
z Unscrew nuts (1).
z Remove screws.
46 ft 1
9
01 So
12 ine
09 h
ac
2
M
© 40740-0

z Place cable harness to one side.
© 40741-0
© 06/2006 2/10 8201-001

TCD 2015 W 06-02-05
1
1
6
© 40742-0
25 .IR
z Unscrew nuts (1).
46 ft
9
01 So
1
12 ine
2
09 h
ac
1
M
© 40743-0
z Unscrew nuts (1).

© 40744-0
© 06/2006 3/10 8201-001

W 06-02-05 TCD 2015
z Unscrew nuts (1).

6
© 40745-0
25 .IR
z Unscrew nuts (1).
46 ft
9
01 So
1
12 ine
09 h
1
ac
M
© 40746-0
z Remove connecting pipe (1).

z Remove seals.
© 40747-0
© 06/2006 4/10 8201-001

TCD 2015 W 06-02-05
6
© 40748-0
25 .IR
Installing connecting pipe
46 ft
9
01 So
z Mount connecting pipe (1).
1
12 ine
09 h
ac
M
© 40747-0
© 40746-0
© 06/2006 5/10 8201-001

W 06-02-05 TCD 2015
z Mount holder (2).

6
© 40745-0
25 .IR
z Mount holder (2).
46 ft
9
01 So
1
12 ine
1
09 h
2
ac
M
© 40744-0
z Mount holder (2).

© 40743-0
© 06/2006 6/10 8201-001

TCD 2015 W 06-02-05

A06 056
1
1
6
© 40742-0
25 .IR
z Tighten nuts (arrows).
A06 033
46 ft
9
01 So
12 ine
09 h
ac
M
© 40749-0
z Lay cable.
z Tighten screws .
A13 090
Screw length: 2
M8 x 20 mm (1)
M8 x 16 mm (2)
1
© 40750-0
© 06/2006 7/10 8201-001

W 06-02-05 TCD 2015

z Remove end plate.
z Remove gasket.
1
6
© 40751-0
25 .IR
z Mount new gasket.
z Mount end plate.
z Insert screws.
46 ft
9
1
01 So
Screw length:
M10 x 45 mm (1)
M10 x 55 mm (2)
12 ine
09 h
ac
2
M
© 40752-0
z Mount holder (1).

A06 034
1
© 40950-0
© 06/2006 8/10 8201-001

TCD 2015 W 06-02-05
z Plug cables (2) to both flame glow plugs.

Attention!
Note assignment and polarity of the electri-
cal connections!
Connect cables according to marks made 1

before removing.
z Mount washer.
z Tighten nut (1).
2
A13 035
6
© 40739-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40738-0
z Install fuel pipes (flame glow plugs).

W 07-01-04
© 40737-0
© 06/2006 9/10 8201-001

W 06-02-05 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 10/10 8201-001



perly.
25 .IR
Removing connecting pipe
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 45926-0

z Remove spring washer.
z Remove ground cable.
before removing.
© 45907-0
© 06/2006 1/10 8202-001

z Remove fuel pipes (flame glow plugs), (Railway).

W 07-01-04
6
© 42025-2
25 .IR
z Unscrew nuts (1).
z Remove washers.
46 ft
9
01 So
1
12 ine
1
09 h
ac
M
© 42185-2
z Remove cables (1).

before removing.
© 42192-2
© 06/2006 2/10 8202-001


z Place fuel shut-off valve (2) to one side.
6
© 42186-1
25 .IR
z Place cable harness to one side.
46 ft
9
01 So
12 ine
09 h
1
ac
M
© 42418-1

z Loosen the holder (2).
1 2
© 42419-1
© 06/2006 3/10 8202-001

6
© 42501-1
25 .IR
z Unscrew nuts (1).
z Remove washers.
z Remove holder.
46 ft
9
01 So
z Place cables to one side.
12 ine
1
1
09 h
ac
M
© 45850-0
z Unscrew all nuts (1).

z Remove connecting pipe (2).
z Remove gasket.
1
1
© 45851-1
© 06/2006 4/10 8202-001

Installing connecting pipe

z Mount connecting pipe (1).
6
© 42421-1
25 .IR
z Mount washers.
z Mount holder (1).
z Screw on nuts.
46 ft
9
01 So
12 ine
1
1
09 h
ac
M
© 45850-0
z Screw on all nuts (1).
1
1
© 45852-1
© 06/2006 5/10 8202-001


A06 056
6
© 42501-1
25 .IR
z Tighten all nuts (1).
A06 033
46 ft
9
01 So
1
1
12 ine
09 h
ac
M
© 45852-1
z Position holder (2).

1 2
A13 090
© 42419-1
© 06/2006 6/10 8202-001

Attention!
Lay the cables free from chafing and ten-
sion.
A13 090
6
© 42418-1
25 .IR
z Mount fuel shut-off valve (2).
z Position pipe clamp.
z Fasten screw (1).
46 ft
9
01 So
2
12 ine
09 h
ac
1
M
© 42186-1
z Position fuel shut-off valve.

P07 91
Note installation dimensions (X).
© 45909-0
© 06/2006 7/10 8202-001

Attention!
cal connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Mount washers. 1
z Screw on nuts.
6
© 45928-0
25 .IR
z Tighten nuts (1).
A13 035
46 ft
9
z Install fuel pipes (flame glow plugs), (Railway).
01 So
W 07-01-04
1
12 ine
1
09 h
ac
M
© 42185-2
z Connect ground cable.

z Mount spring washer.
A07 058
© 45907-0
© 06/2006 8/10 8202-001


A13 090
1
6
© 42423-1
25 .IR
perly.
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 45926-0
© 06/2006 9/10 8202-001

25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 10/10 8202-001

TCD 2015 W 06-06-04
Removing and installing the turbocharger

Special tools:
– Special wrench . . . . . . . . . . . . . . 170100
– Fitting compound suitable vessels and dispose of according
DEUTZ S1 to regulations.
25 .IR
Removing turbocharger
z Remove the charge air pipe.
46 ft
9
W 06-02-03
01 So
12 ine
09 h
ac
M
© 40753-0
z Unscrew lock nuts (1) with special wrench.

z Remove screw-in nipple.
1
© 40754-0
© 06/2006 1/8 8203-001

W 06-06-04 TCD 2015

z Remove lubricating oil pipe (3).
6
© 40755-0
25 .IR
z Loosen hose clips (2).
46 ft
9
01 So
1
12 ine
2
09 h
ac
M
© 40756-0
z Pull off pipe.

z Remove intake elbow (1).
© 40757-0
© 06/2006 2/8 8203-001

TCD 2015 W 06-06-04
6
© 40758-0
25 .IR
z Pull out oil return pipe (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40759-0

z Remove turbocharger (2).
© 40760-0
© 06/2006 3/8 8203-001

W 06-06-04 TCD 2015

z Remove oil return pipe (2).
z Remove gasket. 1
6
© 40761-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40762-0
Installing the turbocharger

z Mount oil return pipe (2). 1
A08 044
© 40761-0
© 06/2006 4/8 8203-001

TCD 2015 W 06-06-04

z Mount turbocharger (2).
A06 020 2
6
© 40760-0
25 .IR
z Mount oil return pipe (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40759-0

A08 044
© 40758-0
© 06/2006 5/8 8203-001

W 06-06-04 TCD 2015
z Mount intake elbow (1).

1
z Insert pipe.
6
© 40757-0
25 .IR
z Position hose clips.
A03 064 46 ft
9
01 So
1
A06 021
3
12 ine

A03 069
09 h
ac
2
M
© 45402-0
z Mount lubricating oil pipe (3).

z Position holder (2).
A08 079 1
© 45373-0
© 06/2006 6/8 8203-001

TCD 2015 W 06-06-04

z Tighten screw-in nipple.
z Tighten both lock nuts (1) with a special wrench.
A08 040
6
© 40763-0
25 .IR
z Install the charge air pipe.
W 06-02-03
46 ft
9
01 So
12 ine
09 h
ac
M
© 40753-0
© 06/2006 7/8 8203-001

W 06-06-04 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8203-001

Removing and installing turbocharger

(A-bank)
to regulations.
DEUTZ S1
25 .IR
46 ft
9
z Loosen pipe clip (2).
01 So
12 ine
2 1
09 h
ac
M
© 42048-1
z Unscrew union nuts (1).

© 42049-1
© 06/2006 1/6 8204-001


z Remove gasket.
1
6
© 42050-1
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
2
© 42051-2
z Pull off tubing connection (1).

z Pull off bleeding hose (2).
z Remove breather pipe (3). 2
© 42052-2
© 06/2006 2/6 8204-001


6
© 42053-1
25 .IR
z Unscrew screw-in nipple (1).
z Remove sealing ring.
46 ft
9
1
01 So
12 ine
09 h
ac
M
© 42054-1

z Mount new sealing ring.
z Tighten screw-in nipple (1).
1
A12 098
© 42054-1
© 06/2006 3/6 8204-001


A06 020
6
© 42053-1
25 .IR
z Mount breather pipe (3).
z Plug in breather pipe (2).
z Plug in the tubing connection (1).
46 ft 2
9
01 So
12 ine
3
09 h
1
ac
M
© 42052-3

A03 070
z Position hose clip (2). 1
A06 024
2
© 42051-2
© 06/2006 4/6 8204-001

z Mount new gasket.

1
A08 044
6
© 42050-1
25 .IR
z Screw on union nuts (1).
A12 082 46 ft
9
01 So
12 ine
2
09 h
1
ac
1
M
© 42049-1

A08 045
2 1
© 42048-1
© 06/2006 5/6 8204-001

25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8204-001

Removing and installing turbocharger

(B-bank)
to regulations.
DEUTZ S1
25 .IR
46 ft
9
01 So
1
2
12 ine
09 h
ac
M
© 42056-1

1
z Remove gasket.
© 42057-1
© 06/2006 1/6 8205-001


1
6
© 42059-2
25 .IR
z Pull off tubing connection (1).
z Pull off bleeding hose (2).
z Remove breather pipe (3).
46 ft
9
01 So
2
12 ine
3
09 h
ac
M
1
© 42058-2

© 42055-1
© 06/2006 2/6 8205-001


1
6
© 42054-1
25 .IR
46 ft
9
1
01 So
A12 098
12 ine
09 h
ac
M
© 42054-1

A06 020
1
© 42055-1
© 06/2006 3/6 8205-001

z Mount breather pipe (3).

z Plug in breather pipe (2).
z Plug in the tubing connection (1).
2
6
1
© 42058-2
25 .IR
A03 070 46 ft 1
9
01 So
12 ine
A06 024
09 h
ac
2
M
© 42059-2
z Mount new gasket.

1
A08 044
© 42057-1
© 06/2006 4/6 8205-001


A12 082
1
1 6
© 42056-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8205-001

25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8205-001

TCD 2015 W 06-07-03
Removing and installing charge air pipe

(A-bank)
– W 06-02-05
Special tools: – W 07-03-01 . . . . . . . . . . . . (A-bank)
– Special wrench . . . . . . . . . . . . . . 110510
25 .IR
Removing charge air pipe
z Remove connecting pipe.
46 ft
9
W 06-02-05
01 So
z Removing high pressure pipes (A-bank).
W 07-03-01
12 ine
09 h
ac
M
© 40552-0
z Removing the crankcase breather.

W 03-01-11
© 40553-0
© 06/2006 1/6 8206-001

W 06-07-03 TCD 2015

1 2
6
© 40554-0
25 .IR
46 ft
9
01 So
1
12 ine
2
09 h
ac
M
© 40566-0
z Unscrew screws (1) with special wrench.

3
z Remove charge air pipe (3).
z Remove seals.
1 2
© 40567-0
© 06/2006 2/6 8206-001

TCD 2015 W 06-07-03
6
© 40568-0
25 .IR
Installing charge air pipe
46 ft
9
01 So
12 ine
z Turn in all screws (1) a few turns. 1

Screw length:
M8 x 65 mm
09 h
ac
M
© 40574-0
z Insert charge air pipe.

Screw length:
M8 x 100 mm
1
© 40575-0
© 06/2006 3/6 8206-001

W 06-07-03 TCD 2015
z Mount spacing sleeve (arrow).

z Mount holder.
z Fasten screw (1).
Screw length:
M8 x 120 mm
6
© 40576-0
25 .IR
A12 071
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40553-0
z Tighten screws (1) alternately with special wrench.

A06 030
1 1
1 1
© 40577-0
© 06/2006 4/6 8206-001

TCD 2015 W 06-07-03

A12 095
z Install crankcase breather.
W 03-01-11
1 2
6
© 40554-0
25 .IR
W 07-03-01
46 ft
9
z Install connecting pipe.
01 So
W 06-02-05
12 ine
09 h
ac
M
© 40552-0
© 06/2006 5/6 8206-001

W 06-07-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8206-001

TCD 2015 W 06-07-03

(B-bank)
– W 07-03-01 . . . . . . . . . . . . (B-bank)
Special tools:
– Special wrench . . . . . . . . . . . . . . 110510
25 .IR
Removing charge air pipe
z Remove connecting pipe.
46 ft
9
W 06-02-05
01 So
z Removing high pressure pipes (B-bank).
W 07-03-01
12 ine
09 h
ac
M
© 40552-0
© 40569-0
© 06/2006 1/4 8207-001

W 06-07-03 TCD 2015
z Unscrew screws (1) with special wrench.

z Remove charge air pipe (3). 3
z Remove seals.
6
© 40570-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40571-0
Installing charge air pipe

1
z Turn in all screws (1) a few turns.
Screw length:
M8 x 65 mm
© 40572-0
© 06/2006 2/4 8207-001

TCD 2015 W 06-07-03
z Insert charge air pipe.

Screw length:
M8 x 100 mm
6
© 40569-0
25 .IR
z Tighten screws (1) alternately with special wrench.
A06 030
46 ft
9
01 So
1
1
12 ine
09 h
1
1
ac
M
© 40573-0

W 07-03-01
z Install connecting pipe.
W 06-02-05
© 40552-0
© 06/2006 3/4 8207-001

W 06-07-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8207-001

Fuel system
TCD 2015 W 07-01-02

Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
6
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
25 .IR
tely before assembling.
46 ft to regulations.
9
01 So
12 ine
09 h
ac
M
Removing flame glow plug

W 07-01-04
1
z Unscrew nut (1).
before removing. 2
© 40770-0
© 06/2006 1/4 8208-001

Fuel system
W 07-01-02 TCD 2015

z Unscrew flame glow plug (2).
z Remove gasket.
2 1
6
© 40771-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40772-0
Installing flame glow plug

z Mount new gasket.
z Screw in flame glow plug.
P13 66
Note screw-in height dimension (X).
© 45404-0
© 06/2006 2/4 8208-001

Fuel system
TCD 2015 W 07-01-02

W 07-01-04
6
© 40773-0
25 .IR
A07 059
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40774-0
z Plug in cable lug (2).

Attention! 1
cal connections!

before removing.
z Mount washer.
z Tighten nut (1).
A13 035
© 40775-0
© 06/2006 3/4 8208-001

Fuel system
W 07-01-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8208-001

Fuel system

Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
sed air.
6
25 .IR
9
01 So
12 ine
09 h
ac
M
Removing flame glow plug

z Remove spring washer.
z Remove ground cable.
before removing.
© 45907-0
© 06/2006 1/6 8209-001

Fuel system
z Remove fuel pipes (flame glow plugs), (Railway).

W 07-01-04
6
© 42025-2
25 .IR
z Unscrew nuts (1).
z Remove washers.
46 ft
9
01 So
1
12 ine
1
09 h
ac
M
© 42185-2

before removing.
© 42192-2
© 06/2006 2/6 8209-001

Fuel system

z Unscrew flame glow plug (1).
z Remove insulating washer (3).
2
3
6
© 42187-1
25 .IR
z Unscrew adapter (1).
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 42188-1
z Unscrew lock nut.

© 42191-2
© 06/2006 3/6 8209-001

Fuel system
Installing flame glow plug

z Mount new gasket.
z Tighten adapter (1).
A07 057
6
© 42188-1
25 .IR
z Screw on lock nut.
46 ft
9
01 So
12 ine
09 h
ac
M
© 42191-2
z Mount insulating washer (1).

z Screw in flame glow plug (2).
© 42187-2
© 06/2006 4/6 8209-001

Fuel system
z Position flame glow plug.

P13 66
Note screw-in height dimension (X).
Screw-in nipple (1) faces crankshaft at a
right angle (90°).
1
6
© 45911-0
25 .IR
A07 059
46 ft
9
01 So
12 ine
09 h
1
ac
M
© 45927-0
Attention!
cal connections!
1
© 45928-0
© 06/2006 5/6 8209-001

Fuel system
z Mount washers.
z Screw on nuts.
z Tighten nuts (1).
A13 035
z Install fuel pipes (flame glow plugs), (Railway).
1
W 07-01-04
1
6
© 42185-2
25 .IR
z Connect ground cable.
z Mount spring washer.
46 ft
9
01 So
A07 058
12 ine
09 h
ac
1
M
© 45907-0
© 06/2006 6/6 8209-001

Fuel system
TCD 2015 W 07-01-03
Removing and installing fuel shut-off valve

(flame glow plugs)
Commercial available tools Attention!
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
before removing.
sed air.
opening with new, clean plugs/caps. 6
25 .IR
to regulations.
46 ft
9
01 So
12 ine
09 h
ac
M
Removing fuel shut-off valve

© 40951-0
© 06/2006 1/6 8210-001

Fuel system
W 07-01-03 TCD 2015
z Hold screw-in nipple.

z Remove fuel pipe (3). 1
3
6
© 40776-0
25 .IR
z Remove spacing sleeve.
z Remove fuel shut-off valve (2).
46 ft
9
01 So
z Remove pipe clamp. 1
12 ine
2
09 h
ac
M
© 40778-0

© 40779-0
© 06/2006 2/6 8210-001

Fuel system
TCD 2015 W 07-01-03
Installing fuel shut-off valve

z Tighten screw-in nipple (1). 1
A07 068
6
© 40779-0
25 .IR
46 ft 1
9
01 So
12 ine
09 h
ac
M
© 40780-0
© 40781-0
© 06/2006 3/6 8210-001

Fuel system
W 07-01-03 TCD 2015
z Position spacing sleeve.

z Fasten screw (1).
6
© 40782-0
25 .IR
P07 91
46 ft X
9
01 So
12 ine
09 h
ac
M
© 45406-0

A07 093
© 40783-0
© 06/2006 4/6 8210-001

Fuel system
TCD 2015 W 07-01-03
z Position fuel pipe.

P07 92
Note installation angle, dimension (X).
6
© 45407-0
25 .IR
Attention!
Install fuel pipes tension free!
46 ft
9
01 So
z Tighten lock nuts (1).
1
A07 018
12 ine
09 h
ac
1
M
© 40784-0
© 40951-0
© 06/2006 5/6 8210-001

Fuel system
W 07-01-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8210-001

Fuel system
Removing and installing fuel shut-off valve

(flame glow plugs)
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
before removing.
sed air.
opening with new, clean plugs/caps. 6
25 .IR
to regulations.
46 ft
9
01 So
12 ine
09 h
ac
M
Removing fuel shut-off valve

© 42020-2
© 06/2006 1/6 8211-001

Fuel system

Collect draining fuel and dispose of accor-
ding to regulations.
z Seal hose pipe (2).

z Place hose pipe (2) to one side.
1
6
© 42021-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 42022-1

z Remove fuel shut-off valve (2).
z Remove pipe clamp.
1
2
© 42023-1
© 06/2006 2/6 8211-001

Fuel system

6
© 45913-0
25 .IR
Installing fuel shut-off valve
46 ft
9
A07 068
01 So
12 ine
09 h
ac
1 2
M
© 45912-0
1
© 42024-1
© 06/2006 3/6 8211-001

Fuel system

z Fasten screw (1).
6
© 42023-2
25 .IR
P07 91
46 ft
9
01 So
X
12 ine
09 h
ac
M
© 45909-0

A07 093
© 42023-2
© 06/2006 4/6 8211-001

Fuel system

A07 018
Attention!
Install fuel pipes tension free!
1
6
© 42022-1
25 .IR
z Position hose pipe (2).
Attention!
46 ft
Lay the hose pipe free from chafing and
9
01 So
tension.
12 ine
A12 090 1
09 h
ac
2
M
© 42021-1

perly.
© 42020-2
© 06/2006 5/6 8211-001

Fuel system
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8211-001

Fuel system
TCD 2015 W 07-01-04

(flame glow plugs)
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
before removing. 6
25 .IR
sed air.
46 ft opening with new, clean plugs/caps.
9
01 So
12 ine
to regulations.
09 h
ac
M
Removing fuel pipes

W 06-02-03
z Unscrew screw (1). 1
z Loosen pipe clip (2).
© 40785-0
© 06/2006 1/4 8212-001

Fuel system
W 07-01-04 TCD 2015
1
1
6
© 45378-0
25 .IR
z Remove fuel pipes (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 45376-0
© 45377-0
© 06/2006 2/4 8212-001

Fuel system
TCD 2015 W 07-01-04
Installing fuel pipes

z Mount fuel pipes (1).
6
© 45376-0
25 .IR
46 ft
9
01 So
1
1
12 ine
09 h
ac
M
© 45378-0

z Fasten screw (1).
© 40785-0
© 06/2006 3/4 8212-001

Fuel system
W 07-01-04 TCD 2015

A12 080
Attention!
Install fuel pipe tension free.
1
6
© 40952-0
25 .IR
A12 080
46 ft
9
Attention!
01 So
12 ine
09 h
1
ac
M
© 40789-0

A07 044
W 06-02-03
1
© 45379-0
© 06/2006 4/4 8212-001

Fuel system

(flame glow plugs)
Commercial available tools Danger!
Special tools: Wait 30 seconds after switching off the
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 engine before working on the fuel system.
Attention!
before removing.
sed air. 6
25 .IR
46 ft Collect leaking operating substances in
9
01 So
to regulations.
12 ine
09 h
ac
M
Removing fuel pipes

z Loosen pipe clip.
© 42025-1
© 06/2006 1/4 8213-001

Fuel system

1
1
6
© 42026-1
25 .IR
46 ft
9
01 So
1 2
12 ine
09 h
1
ac
M
© 42028-1

z Remove distributor (2).
2
© 42029-1
© 06/2006 2/4 8213-001

Fuel system

z Mount distributor (2).
6
© 42029-1
25 .IR
46 ft
9
01 So
1 2
12 ine
09 h
1
ac
M
© 42028-1

1
1
© 42026-1
© 06/2006 3/4 8213-001

Fuel system
Attention!

A12 080 1
6
© 42027-1
25 .IR
Attention!
46 ft
9
01 So
1
A12 080
12 ine

A07 018
2
09 h
ac
M
© 42030-1
z Position pipe clip.

A07 044
z Lay cable harness and fix with cable tie (1).
© 42025-1
© 06/2006 4/4 8213-001

Fuel system
TCD 2015 W 07-03-01
Renewing injection pipes

(A-bank)
Commercial available tools: Danger!
– Dog wrench. . . . . . . . . . . . . . . . . . . 8018 Wait 30 seconds after switching off the
Special tools: engine before working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
sed air. 6
25 .IR
46 ft Collect leaking operating substances in
9
01 So
to regulations.
Injection pipes may not be bent.
12 ine
09 h
ac
M
Removing injection pipes

z Remove gasket.
1 1
© 40627-0
© 06/2006 1/6 8214-001

Fuel system
W 07-03-01 TCD 2015

6
© 40792-0
25 .IR
z Unscrew lock nuts (1) with dog wrench.
z Remove injection line.
46 ft
9
01 So
Note cylinder assignment.
1
12 ine
09 h
1
ac
M
© 40793-0

z Renew damaged profile washers.
© 40796-0
© 06/2006 2/6 8214-001

Fuel system
TCD 2015 W 07-03-01
Installing injection pipes

z Mount new injection pipe.
Attention!
Install injection pipes without tension! 1
Note assignment and installation position

of the injection lines.
6
© 40793-0
25 .IR
z Oil the injection pipe in the area of the profile
washer (1).
z Position profile washer (1).
46 ft
9
01 So
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1
12 ine
09 h
ac
M
© 40634-0
z Tighten lock nuts (1) with dog wrench.

A07 003
© 40800-0
© 06/2006 3/6 8214-001

Fuel system
W 07-03-01 TCD 2015

A07 003
6
© 40801-0
25 .IR
A07 006 46 ft
9
01 So
1
2
12 ine
09 h
ac
M
© 40792-0

Position gasket over the profile washer (2).
© 40802-0
© 06/2006 4/6 8214-001

Fuel system
TCD 2015 W 07-03-01

underneath the sealing surface (2) of the 2
cylinder head cover. 1
6
© 40803-0
25 .IR
A01 005 46 ft
9
01 So
12 ine
1 1
09 h
ac
M
© 40804-0
© 06/2006 5/6 8214-001

Fuel system
W 07-03-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8214-001

Fuel system
TCD 2015 W 07-03-01
Renewing injection pipes

(B-bank)
– Dog wrench. . . . . . . . . . . . . . . . . . . 8018
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
before removing. 6
25 .IR
sed air.
9
01 So
12 ine
to regulations.
Injection pipes may not be bent.
09 h
ac
M
Removing injection pipes

W 06-02-03
2
z Remove gasket.
1
1
© 40791-0
© 06/2006 1/6 8215-001

Fuel system
W 07-03-01 TCD 2015

6
© 40794-0
25 .IR
z Unscrew lock nuts (1) with dog wrench.
z Remove injection line.
46 ft
9
01 So
Note cylinder assignment. 1
12 ine
09 h
ac
1
M
© 40795-0

z Renew damaged profile washers.
© 40796-0
© 06/2006 2/6 8215-001

Fuel system
TCD 2015 W 07-03-01
Installing injection pipes

z Mount new injection pipe.
Attention! 1
Install injection pipes without tension!
Note assignment and installation position

of the injection lines.
6
© 40795-0
25 .IR
z Oil the injection pipe in the area of the profile
washer (1).
z Position profile washer (1).
46 ft
9
01 So
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1
12 ine
09 h
ac
M
© 40634-0

A07 003
© 40797-0
© 06/2006 3/6 8215-001

Fuel system
W 07-03-01 TCD 2015

A07 003
6
© 40798-0
25 .IR
A07 006 46 ft
9
01 So
1
12 ine
2
09 h
ac
M
© 40794-0

Position gasket over the profile washer (2). 1
© 40635-0
© 06/2006 4/6 8215-001

Fuel system
TCD 2015 W 07-03-01

underneath the sealing surface (2) of the
cylinder head cover.
1
2
6
© 40636-0
25 .IR
A01 005 46 ft
9
01 So
W 06-02-03
12 ine
1
09 h
1
ac
M
© 40637-0
© 06/2006 5/6 8215-001

Fuel system
W 07-03-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8215-001

Fuel system
TCD 2015 W 07-04-01
Removing and installating injection pumps.

(Cylinder A1)
– Open wrench size SW 22 – W 06-07-03 . . . . . . . . . . . . (A-bank)
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 07-10-06 . . . . . . . . . . . . (Railway)
– Locking agent Attention!

DEUTZ DW 59 Pay attention to utmost cleanliness when
before removing.
sed air.
6
25 .IR
46 ft tely before assembling.
9
01 So
to regulations.

12 ine

09 h
ac
M
Removing the fuel injector pump

W 06-07-03
© 40552-0
© 06/2006 1/10 8216-001

Fuel system
W 07-04-01 TCD 2015

1
6
© 40808-0
25 .IR
46 ft
9
01 So
1
2
12 ine
3
09 h
ac
M
© 40520-0
z Unscrew nut (1).

© 40521-0
© 06/2006 2/10 8216-001

Fuel system
TCD 2015 W 07-04-01


6
© 40522-0
25 .IR
z Pull off cables (2).
46 ft
9
01 So
12 ine
1
09 h
2
ac
M
© 40809-0

Loosen screws evenly to avoid jamming
the injection pump.
z Remove fuel injector pump(2).

© 45386-0
© 06/2006 3/10 8216-001

Fuel system
W 07-04-01 TCD 2015
z Pull out roller tappet (1).

Attention!
Do not damage the roller tappet!
1
6
© 40810-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40807-0
Removing injection pump housing

z Remove fuel pipes.
W 07-10-06
z Remove fuel pipes (Railway).
W 07-10-06
2
z Remove injection pump housing (2).
© 45387-0
© 06/2006 4/10 8216-001

Fuel system
TCD 2015 W 07-04-01
6
© 40812-0
25 .IR
Installing injection pump housing
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 45390-1
z Oil the shank of the injection pump housing lightly.

z Press the injection pump housing into the stop in the
crankcase.
The pilot pin (1) must lock in
groove (arrow).
1
© 40813-0
© 06/2006 5/10 8216-001

Fuel system
W 07-04-01 TCD 2015

A07 009
6
© 45388-0
25 .IR
z Install fuel pipes.
W 07-10-06
46 ft
9
z Install fuel pipes (Railway).
01 So
W 07-10-06
Do not install fuel pipe (1). 1
12 ine
Do not install charge air pipe (A-bank).

09 h
ac
M
© 45391-0
Installing the fuel injector pump

Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.
© 40807-0
© 06/2006 6/10 8216-001

Fuel system
TCD 2015 W 07-04-01

W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).
6
© 42163-1
25 .IR
z Oil the roller tappet lightly.
z Insert roller tappet.
46 ft
9
01 So
groove (arrow).
1
12 ine
09 h
ac
M
© 42164-1

z Oil O-rings lightly.
© 42165-2
© 06/2006 7/10 8216-001

Fuel system
W 07-04-01 TCD 2015
z Insert injection pump (1).

The cable connections (3) of the injection
pumps must face the genset support.
1
3
6
© 40954-0
25 .IR
A07 012
46 ft
9
Attention!
01 So
Do not turn the camshaft until all the injec-
tion pumps are installed. Danger of brea-
king the tappet!
12 ine
1
09 h
ac
M
© 40953-0
z Plug in cables (2).

T13 054
Note assignment!

A13 054
1
© 40809-0
© 06/2006 8/10 8216-001

Fuel system
TCD 2015 W 07-04-01

6
© 40522-0
25 .IR
z Mount holder (2).
z Screw on nut (1).
46 ft
9
01 So
1
12 ine
2
09 h
ac
M
© 40521-0

z Mount holder (2).
2 3
© 40520-0
© 06/2006 9/10 8216-001

Fuel system
W 07-04-01 TCD 2015

A12 093
z Tighten nut (2).
1
A07 044
6
© 40565-0
25 .IR
A07 044
46 ft
9
01 So
A12 092
1
12 ine
2
09 h
ac
M
© 40555-0
z Mount holder (2).

A07 044
W 06-07-03
W 04-06-03
Delete error entry in the error memory of 2
© 40808-0
© 06/2006 10/10 8216-001

Fuel system
TCD 2015 W 07-04-01
Removing and installing injection pumps

(Cylinder A2-B3)
– W 04-06-03
Special tools: – W 07-03-01 . . . . . . . . . . . . (A-bank)
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 07-03-01 . . . . . . . . . . . . (B-bank)
– W 07-10-06
– Locking agent
– W 07-10-06 . . . . . . . . . . . . (Railway)
DEUTZ DW 59
Attention!
before removing.
6
sed air.
25 .IR
9
01 So
12 ine
to regulations.

09 h
ac
M
Removing injection pumps

W 03-01-11
W 07-03-01
1 2
W 07-03-01
© 40554-0
© 06/2006 1/8 8217-001

Fuel system
W 07-04-01 TCD 2015

z Pull off cables (2).
6
© 45384-0
25 .IR
Loosen screws evenly to avoid jamming
the injection pump.
46 ft
9
01 So
z Remove fuel injector pump(2).
1
12 ine

09 h
ac
2
M
© 40805-0
z Pull out roller tappet (1).

Attention!
Do not damage the roller tappet!
1
© 40806-0
© 06/2006 2/8 8217-001

Fuel system
TCD 2015 W 07-04-01
6
© 40807-0
25 .IR
Removing injection pump housing
z Remove fuel pipes.
46 ft
9
W 07-10-06
01 So
W 07-10-06
12 ine
2
z Remove injection pump housing (2).
09 h

ac

1
M
© 40811-0
© 40812-0
© 06/2006 3/8 8217-001

Fuel system
W 07-04-01 TCD 2015
Installing injection pump housing

6
© 42159-2
25 .IR
The injection pump housings differ.
Mount the injection pump housing with the
46 ft
bevel (arrow) on the B-bank.
9
01 So
12 ine
09 h
ac
M
© 42160-1
z Oil the shank of the injection pump housing lightly.

z Press the injection pump housing into the stop in the
crankcase.
groove (arrow).
1
© 45389-0
© 06/2006 4/8 8217-001

Fuel system
TCD 2015 W 07-04-01

A07 009
z Install fuel pipes.
W 07-10-06
W 07-10-06
6
© 40814-0
25 .IR
Installing injection pumps
46 ft
Note the assignment of the injection pump/
roller tappet when replacing the injection
9
01 So
pump and/or roller tappet.
12 ine
09 h
ac
M
© 40807-0

W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).
© 42163-1
© 06/2006 5/8 8217-001

Fuel system
W 07-04-01 TCD 2015

groove (arrow).
6
© 42164-1
25 .IR
z Oil O-rings lightly.
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 42165-2
z Insert injection pump (1).

Note assignment!
A-bank:
The cable connections (3) of the injection
pumps must face the genset support.
B-bank:
2
The cable connections (3) of the injection 3
pumps must face the flywheel.
© 45382-0
© 06/2006 6/8 8217-001

Fuel system
TCD 2015 W 07-04-01

A07 012
Attention!
Do not turn the camshaft until all the injec-
tion pumps are installed. Danger of brea-
king the tappet!
1
6
© 45383-0
25 .IR
T13 054
46 ft
9
Note assignment!
01 So
12 ine
A13 054
1
09 h
2
ac
M
© 45384-0

A12 095
1 2
© 40554-0
© 06/2006 7/8 8217-001

Fuel system
W 07-04-01 TCD 2015

W 07-03-01
W 07-03-01
W 03-01-11
W 04-06-03
6
© 40956-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8217-001

Fuel system
TCD 2015 W 07-06-04
Checking and setting plunger lift of injection pumps

– Feeler gauges – W 06-06-04
Special tools: – W 06-06-04 . . . . . . . . . . . . (A-bank,
– Dial gauge. . . . . . . . . . . . . . . . . . 100410 Railway)
– Dial gauge holder – W 06-06-04 . . . . . . . . . . . . (B-bank,
with stylus extension. . . . . . . . . . 103240 Railway)
– Measuring pin . . . . . . . . . . . . . . . 110180 – W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 – W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
– Packing compound
DEUTZ DW 48 Attention!
– Locking agent Pay attention to utmost cleanliness when
DEUTZ DW 72 working on the fuel system.
Remove residue paint and particles of dirt 6
before removing.
25 .IR
sed air.
46 ft Close all connections immediately after
9
01 So
12 ine

to regulations.

09 h

ac
M
Checking plunger lift of injection pumps

W 07-04-01
W 07-04-01
Do not remove injection pump housing.

W 04-06-03
© 40495-0
© 06/2006 1/14 8218-001

Fuel system
W 07-06-04 TCD 2015

T01 63
Inlet valves begin to open and exhaust val-
ves close.
Observe valve clearance setting diagram.
6
© 40465-0
25 .IR
In case of valve overlap of cylinder no. B2:
46 ft
snap into the tooth notch (1) of the starter
9
01 So
ring gear.
The second tooth notch (2) must face the
B-bank.
12 ine
09 h
ac
1
2
M
© 40466-0
z Pull locking pin (1).

z Turn crankshaft in the opposite direction to the en-
gine rotation (arrow) a ¼ turn with the turning gear.
1
© 40501-0
© 06/2006 2/14 8218-001

Fuel system
TCD 2015 W 07-06-04

6
© 40458-0
25 .IR
The injection pump cams for cylinder
no. A1 must be on the base circle (arrow).
46 ft
9
01 So
12 ine
09 h
ac
M
© 42163-1

Note the assignment of the roller tappet.
groove (arrow).
1
© 42164-1
© 06/2006 3/14 8218-001

Fuel system
W 07-06-04 TCD 2015
z Mount dial gauge holder (1).

A07 012
6
© 40499-0
25 .IR
z Insert dial gauge holder (1) with stylus extension.
z Mount stylus with 6 mm pre-tension on the roller tap-
pet.
46 ft
9
01 So
z Turn the crankshaft alternately in and against engine
direction.
1
z Check installation position of the dial gauge.
12 ine
Dial gauge must run on the base circle of

the injection camshaft.
The display of the dial gauge may not
move.
09 h

ac
M
© 40500-0
z Set crankshaft with turning gear in engine direction of

rotation (arrow) to ignition TDC, cylinder no. A1.
snap into the starter gear ring.
© 40502-0
© 06/2006 4/14 8218-001

Fuel system
TCD 2015 W 07-06-04
z Read and note the measured value.

P07 19
6
© 40503-0
25 .IR
Setting plunger lift of injection pumps
46 ft
All injection pumps must be removed.
9
1
01 So
W 06-06-04
12 ine
z Remove turbocharger (A-bank, Railway).

W 06-06-04
09 h
z Remove turbocharger (B-bank, Railway).

W 06-06-04
ac

M
© 40504-0

© 40517-0
© 06/2006 5/14 8218-001

Fuel system
W 07-06-04 TCD 2015

6
© 40506-0
25 .IR
46 ft
9
01 So
2
12 ine
1
09 h
ac
M
© 40456-0

1 2
© 40507-0
© 06/2006 6/14 8218-001

Fuel system
TCD 2015 W 07-06-04
6
© 40459-0
25 .IR
z Remove cover (3).
46 ft
9
01 So
3
2
12 ine
09 h
ac
1
M
© 40460-0

© 40508-0
© 06/2006 7/14 8218-001

Fuel system
W 07-06-04 TCD 2015
z Loosen all screws (1).
6
© 40464-0
25 .IR
z Pull locking pin (1).
z Turn crankshaft in the opposite direction to the en-
46 ft
gine rotation (arrow) a ¼ turn with the turning gear.
9
01 So
Dial gauge must read "0" again. 1
12 ine
09 h
ac
M
© 40501-0
z Set crankshaft with turning gear in engine direction of

rotation (arrow) to ignition TDC, cylinder no. A1.
snap into the starter gear ring.
© 40502-0
© 06/2006 8/14 8218-001

Fuel system
TCD 2015 W 07-06-04
z Turn the injection pump camshaft with the screws in

engine direction of rotation (arrow) until the pre-
scribed plunger lift is reached.
P07 19
6
© 40509-0
25 .IR
z Pre-tighten screws (1).
A04 004
46 ft
9
When pre-tightening the screws, press the
01 So
gear wheel lightly in the opposite direction
to engine rotation (arrow) against the tooth
flanks.
12 ine
z Check the setting of the plunger lift again.

09 h
ac
1
M
© 40510-0

z Remove dial gauge holder.
© 40511-0
© 06/2006 9/14 8218-001

Fuel system
W 07-06-04 TCD 2015

A04 004
z Pull locking pin.
6
© 40464-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
2
M
© 40989-0

bearing (arrow). 1
blade.
z Fasten screw (1).
P04 43
© 40512-0
© 06/2006 10/14 8218-001

Fuel system
TCD 2015 W 07-06-04

bearing (arrow).
blade.
P04 43
6
© 40513-0
25 .IR
A04 015
46 ft
9
01 So
P04 43
12 ine
ween
wheel (arrows).
09 h
ac
M
© 40514-0

© 40515-0
© 06/2006 11/14 8218-001

Fuel system
W 07-06-04 TCD 2015

z Mount cover (2).
Insert screws with safety agent
DEUTZ DW 72.

2
A04 022
1
6
© 40460-0
25 .IR
z Fix cables with cable ties (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40459-0

z Mount holder (2).
z Tighten all screws (3) alternately. 2
2
A04 020
1
© 40516-0
© 06/2006 12/14 8218-001

Fuel system
TCD 2015 W 07-06-04

A08 045
6
© 40456-0
25 .IR
z Mount holder (2).
A12 071 46 ft
9
01 So
2
12 ine
09 h
ac
1
M
© 40455-0

A12 071
© 40517-0
© 06/2006 13/14 8218-001

Fuel system
W 07-06-04 TCD 2015

A13 094
W 06-06-04 1
z Install turbocharger (A-bank, Railway).

W 06-06-04
z Install turbocharger (B-bank, Railway).
W 06-06-04
6
© 40453-0
25 .IR
46 ft
9
01 So
A12 090
1
12 ine
2
09 h
ac
M
© 40458-0

W 07-04-01
W 07-04-01
W 04-06-03
© 40518-0
© 06/2006 14/14 8218-001

Fuel system
TCD 2015 W 07-07-01
Removing and installing the fuel injectors

Commercial available tools: – W 07-03-01 . . . . . . . . . . . . (A-bank)
– Assembly pliers. . . . . . . . . . . . . . . . 8024 – W 07-03-01 . . . . . . . . . . . . (B-bank)
– Puller. . . . . . . . . . . . . . . . . . . . . . 110030
– Grooved nut wrench . . . . . . . . . . 110130 Danger!
– Disassembly tool. . . . . . . . . . . . . 110901 Wait 30 seconds after switching off the
– Extraction tool . . . . . . . . . . . . . . . 120660 engine before working on the fuel system.
– Slide hammer . . . . . . . . . . . . . . . 150800
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention!
– Fitting compound working on the fuel system.
DEUTZ S1 Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care- 6
sed air.
25 .IR

9
01 So
to regulations.
12 ine
09 h
ac
M
Removing fuel injector

W 07-03-01
W 07-03-01
© 40957-0
© 06/2006 1/6 8219-001

Fuel system
W 07-07-01 TCD 2015
z Unscrew union screw with grooved nut wrench.
6
© 40643-0
25 .IR
z Pull out fuel injector (1) and sealing ring (arrow).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40815-0
Removing stuck fuel injectors

z Assembly sliding hammer (1) and puller (2).
© 40958-0
© 06/2006 2/6 8219-001

Fuel system
TCD 2015 W 07-07-01
z Mount sliding hammer on fuel injector.

z Pull out stuck fuel injector.
6
© 40816-0
25 .IR
z Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
Attention!
46 ft
9
01 So
Do not damage the nozzle tip!
12 ine
09 h
ac
2
M
© 43303-0
Removing a tightly fixed sealing ring from

the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
© 45419-0
© 06/2006 3/6 8219-001

Fuel system
W 07-07-01 TCD 2015
z Turn in the spindle.

The sealing ring must be fixed on the pul-
ler.
Hold puller on hexagon.
1
z Mount adapter (1) and slide hammer (2) on extrac-
tion device.
z Remove tight sealing ring.
6
© 45420-0
25 .IR
z Remove the O-ring (1) with the disassembly tool.
46 ft
9
1
01 So
12 ine
09 h
ac
M
© 40607-1

z Check the fuel injector.
W 07-07-05
© 45414-0
© 06/2006 4/6 8219-001

Fuel system
TCD 2015 W 07-07-01
Installing the fuel injector

z Insert new O-ring (arrow).
z Coat the thread (1) with fitting compound.
6
© 40818-0
25 .IR
z Coat the nozzle holder shaft in the (X) area with fit-
ting compound.
46 ft
z Coat the lay-on surface of the sealing ring (arrow)
9
01 So
with fitting compound.
z Mount new sealing ring (1) on fuel injector. X
1
12 ine
09 h
ac
M
© 40819-0
z Push the union screw (1) in the direction of the arrow.

Attention!
Do not damage the O-ring!
© 40820-0
© 06/2006 5/6 8219-001

Fuel system
W 07-07-01 TCD 2015
z Insert fuel injector.

z Tighten union screw with grooved nut wrench.
A07 001
6
© 40643-0
25 .IR
W 07-03-01
46 ft
9
01 So
W 07-03-01
12 ine
09 h
ac
M
© 40957-0
© 06/2006 6/6 8219-001

Fuel system
TCD 2015 W 07-07-02
Dismantling and assembling fuel injector

Special tools:
– Holder . . . . . . . . . . . . . . . . . . . . . 110110
25 .IR
Dismantling fuel injector
46 ft
9
W 07-07-01
01 So
z Check and set fuel injectors.
W 07-07-05
12 ine
z Insert fuel injector in holder.

z Unscrew nozzle cap nut with socket wrench insert.
09 h
ac
M
© 36271-2
z Dismantle fuel injector.

6
5
– Shim (1) 4
3
– Compression spring (2) 2
– Thrust bolt (3) 1
– Intermediate piece (4)
– Injection nozzle (5)
– Nozzle cap nut (6)
z Clean the parts in clean diesel fuel.
z Blow components dry with air.
© 36269-2
© 06/2006 1/6 8220-001

Fuel system
W 07-07-02 TCD 2015
Assembling fuel injector

z Check injection nozzle.
Attention!
Do not touch the nozzle needle with your
1
fingers!
Nozzle needle (1) and nozzle body (2) are
folded together and may not be switched or 2
changed individually!
6
© 33904-2
25 .IR
The nozzle needle (1) must slide slowly
and without jolting into its seat by the force
46 ft
of its own weight with the nozzle body (2)
9
held vertically.
01 So
In case of abrupt sliding of the nozzle 1
needle, clean the injection nozzle again in
the diesel bath, renew if necessary.
12 ine
Also clean the new injection nozzle in the 2

clean diesel bath.
09 h
ac
M
© 33904-2
z Visually inspect the seat surfaces of the intermediate

piece for wear.
Make sure the centering pins (arrows) are
in place.
© 33905-2
© 06/2006 2/6 8220-001

Fuel system
TCD 2015 W 07-07-02
z Select shim for setting the opening pressure.

The opening pressure depends on the
thickness of the shim.
A thicker shim gives a higher opening pres-
sure.
z Insert shim.
6
© 36274-2
25 .IR
z Insert compression spring.
46 ft
9
01 So
12 ine
09 h
ac
M
© 33907-2
z Insert thrust bolt.
© 33908-2
© 06/2006 3/6 8220-001

Fuel system
W 07-07-02 TCD 2015
z Insert intermediate piece with the centering pins in

the bores of the nozzle holder.
The countersink must face the thrust bolt.
6
© 33909-2
25 .IR
z Mount the injection nozzle with the centre bores on
the centering pins of the intermediate piece.
46 ft
The nozzle needle may not fall out of the
9
01 So
nozzle body.
12 ine
09 h
ac
M
© 33910-2
z Screw on the nozzle cap nut.
© 33911-2
© 06/2006 4/6 8220-001

Fuel system
TCD 2015 W 07-07-02
z Tighten nozzle cap nut.

A07 002
z Remove fuel injector from holder.
z Check and set fuel injectors.
W 07-07-05
W 07-07-01
6
© 33912-2
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8220-001

Fuel system
W 07-07-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8220-001

Fuel system
TCD 2015 W 07-07-05
Checking and setting fuel injectors

– Nozzle tester. . . . . . . . . . . . . . . . . . 8008
Special tools: Danger!
– Holder . . . . . . . . . . . . . . . . . . . . . 110110 Danger of injury when handling the nozzle
tester.
The fuel penetrates deep into the flesh
through the nozzle jet!
Caution, blood poisoning!
After about three or four actuations of the

hand lever, the spring space above the
nozzle needle in the injection valve fills up 6
with diesel fuel/test oil. Then it is no longer
possible to actuate the hand lever.
25 .IR
The nozzle cap nut must be loosened care-
fully before every test procedure to release
pressure from the spring space.
46 ft Only use pure test oil according to ISO
9
4113 or clean diesel fuel to test the fuel
01 So
injectors.
12 ine
09 h
ac
M

W 07-07-01
© 45414-0
© 06/2006 1/6 8221-001

Fuel system
W 07-07-05 TCD 2015
Connecting the fuel injector to the nozzle

tester
z Insert fuel injector in holder.
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
A07 002
6
© 36271-2
25 .IR
z Connect the fuel injector to the nozzle tester
46 ft
9
01 So
12 ine
09 h
ac
M
© 35889-2
Checking opening pressure

z Press down the lever of the nozzle tester slowly with
the pressure gauge connected.
The pressure at which the pointer stands
still or suddenly drops is the opening pres-
sure.
Repeat test 3 times.
© 36293-2
© 06/2006 2/6 8221-001

Fuel system
TCD 2015 W 07-07-05
z Compare measured values.

P07 52
The measured values of three tests must
match the test value.
z In case of deviations from the test value, the fuel in-

jector must be dismantled or exchanged.
W 07-07-02
6
© 36293-2
25 .IR
Checking tightness
46 ft
z Blow the injection nozzle and nozzle holder dry with
air.
9
01 So
z Press the hand lever of the tester down slowly until
about 20 bar below the previously read opening
pressure are reached.
12 ine
09 h
ac
M
© 36293-2
Injection nozzle is tight if it does not drip

within 10 seconds.
© 36294-2
© 06/2006 3/6 8221-001

Fuel system
W 07-07-05 TCD 2015
z If the injection nozzle drips, the fuel injector must be

dismantled or exchanged.
W 07-07-02
Attention!
Repairs are not permitted!
6
© 36295-2
25 .IR
Checking the easy action of the nozzle
needle
46 ft
z Switch off the tester’s pressure gauge.
9
01 So
z Carry out chatter and jet test of the nozzle needle.
The easy action of the nozzle needle in the
nozzle body is checked by the acoustic
12 ine
chatter test.
Increasing wear in the needle seat of the
fuel injectors changes the chatter behavior
09 h
of the injecton nozzle.

A used fuel injector must buzz audibly and
ac
atomize the fuel finely when the lever is

actuated quickly.
M
© 36296-2
z If the injection nozzle does not buzz audibly, it must

be dismantled and cleaned.
W 07-07-02
The injection nozzle must be changed if it
does not buzz after cleaning.
The jet profile may deviate considerably
from that of a new fuel injector.
© 36296-2
© 06/2006 4/6 8221-001

Fuel system
TCD 2015 W 07-07-05
Removing the fuel injector from the nozzle

tester
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
A07 002
Attention!
The pressure in the spring space must be
reduced before installing the fuel injectors.
W 07-07-01
6
© 36271-2
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8221-001

Fuel system
W 07-07-05 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8221-001

Fuel system
TCD 2015 W 07-09-01

Attention!
before removing.
sed air.
6
25 .IR
9
01 So
12 ine
09 h
ac
M
Removing temperaure transmitter

W 06-07-03
© 40822-0
© 06/2006 1/4 8222-001

Fuel system
W 07-09-01 TCD 2015
6
© 40823-0
25 .IR
z Unscrew temperature transmitter (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40824-0
© 40825-0
© 06/2006 2/4 8222-001

Fuel system
TCD 2015 W 07-09-01
Installing temperature transmitter

z Tighten temperature transmitter (1).
A07 023
6
© 40824-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40823-0

W 06-07-03
© 40822-0
© 06/2006 3/4 8222-001

Fuel system
W 07-09-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8222-001

Fuel system
TCD 2015 W 07-10-06

– Open wrench size SW 22 – W 06-07-03 . . . . . . . . . . . . (B-bank)
Special tools:
before removing.
sed air.
6
25 .IR
9
01 So
perly.
12 ine
09 h
ac
M
Removing fuel pipes

W 06-07-03
W 06-07-03
© 40606-0
© 06/2006 1/14 8223-001

Fuel system
W 07-10-06 TCD 2015

z Pull the cables (2) off all injection pumps.
before removing.
6
© 45384-0
25 .IR
46 ft
9
01 So
1
12 ine
2
09 h
ac
M
© 40608-0
© 40609-0
© 06/2006 2/14 8223-001

Fuel system
TCD 2015 W 07-10-06
6
© 40610-0
25 .IR
46 ft
9
01 So
12 ine
1 1
09 h
ac
M
© 40611-0
z Unscrew nuts (1).

z Unscrew the nuts (2).
z Remove washers.
z Remove cables.
Mark assignment of cables/connections 2
before removing. 1
z Place cable harness rail with cable harness to one

side.
© 40612-0
© 06/2006 3/14 8223-001

Fuel system
W 07-10-06 TCD 2015

6
© 40613-0
25 .IR
46 ft
9
01 So
z Remove sealing rings. 1
2 3
12 ine
09 h
ac
M
© 40623-0
z Unscrew nut (1).

© 40614-0
© 06/2006 4/14 8223-001

Fuel system
TCD 2015 W 07-10-06


1
6
© 40615-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40616-0
z Unscrew nuts (1).

© 40617-0
© 06/2006 5/14 8223-001

Fuel system
W 07-10-06 TCD 2015

6
© 40618-0
25 .IR
z Remove seals.
46 ft
9
01 So
1
12 ine
09 h
ac
2
M
© 40619-0
© 40620-0
© 06/2006 6/14 8223-001

Fuel system
TCD 2015 W 07-10-06

z Mount new gaskets (1).
6
© 40621-0
25 .IR
Note assignment!
The lug (1) must lock in groove (2).
46 ft
9
01 So
12 ine
09 h
ac
2 1
M
© 42115-1

A07 015
Do not move the gaskets when mounting
the fuel pipes. 1
© 40619-0
© 06/2006 7/14 8223-001

Fuel system
W 07-10-06 TCD 2015

6
© 40618-0
25 .IR
z Mount holder (2).
z Tighten nuts (1).
46 ft
9
01 So
A07 044
1
12 ine
09 h
ac
2
M
© 40617-0

A07 066
© 40622-0
© 06/2006 8/14 8223-001

Fuel system
TCD 2015 W 07-10-06

A12 090
1
6
© 40616-0
25 .IR
46 ft
9
01 So
12 ine
2
09 h
ac
M
© 40615-0

z Mount holder (2).
z Screw on nut (1).
© 40614-0
© 06/2006 9/14 8223-001

Fuel system
W 07-10-06 TCD 2015

z Mount holder (2).
z Oil thread and head contact surface lightly. 1
z Fasten screw (1).
2 3
6
© 40623-0
25 .IR
46 ft
9
01 So
A12 093
z Tighten nut (2). 1
12 ine
A07 044
2
09 h
ac
M
© 40625-0

A07 044
1
A12 092
2
© 40624-0
© 06/2006 10/14 8223-001

Fuel system
TCD 2015 W 07-10-06
z Mount holder (2).

A07 044
6
© 40613-0
25 .IR
z Plug cables.
Attention! 46 ft
9
01 So
cal connections!
2
12 ine
before removing.
z Mount washers.
09 h
z Tighten nuts (1).

A13 037
ac
z Tighten nuts (2).

M
A13 038
© 40612-0

A13 094
1 1
© 40611-0
© 06/2006 11/14 8223-001

Fuel system
W 07-10-06 TCD 2015
6
© 40610-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40609-0
z Plug together the cable plugs (2).

© 40608-0
© 06/2006 12/14 8223-001

Fuel system
TCD 2015 W 07-10-06
Clamp all injection pumps.

T13 054
A13 054
1
6
© 45384-0
25 .IR
W 06-07-03
46 ft
9
01 So
W 06-07-03
12 ine
09 h
ac
M
© 40495-0
© 06/2006 13/14 8223-001

Fuel system
W 07-10-06 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 14/14 8223-001

Fuel system

Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
before removing.
sed air.
tely before assembling. 6
25 .IR
to regulations.

perly.
46 ft
9
01 So
12 ine
09 h
ac
M
Removing fuel pipes

before removing.
z Remove cables.
© 42107-2
© 06/2006 1/6 8224-001

Fuel system

6
© 42108-1
25 .IR
46 ft
9
01 So
12 ine
2
09 h
ac
1
M
© 45854-0

z Place cable harness rail with cable harness to one
side.
© 42110-1
© 06/2006 2/6 8224-001

Fuel system

1
6
© 42112-1
25 .IR
z Remove seals.
46 ft
9
01 So
2
12 ine
1
09 h
ac
M
© 45856-1
© 40620-0
© 06/2006 3/6 8224-001

Fuel system

z Mount new gaskets (1).
1 1
1 1
6
© 42114-2
25 .IR
Note assignment!
The lug (1) must lock in groove (2).
46 ft
9
01 So
12 ine
09 h
ac
2 1
M
© 42115-1

A07 015
Do not move the gaskets when mounting
the fuel pipes.
2
© 45856-1
© 06/2006 4/6 8224-001

Fuel system
z Mount hose line (2).

1
6
© 42112-1
25 .IR
z Position pipe clamp (arrow).
z Fasten screws.
46 ft
9
01 So
M6 x 12 mm (1)
M6 x 16 mm (2) 1
12 ine
z Tighten screws .
1
A13 094
09 h
2
ac
M
© 42111-1
z Position hose line (1).

Observe installation angle dimension X = 1
10°.

A12 090
1
2
© 45910-2
© 06/2006 5/6 8224-001

Fuel system

1
6
© 45854-0
25 .IR
z Fix cable with cable tie (2).
46 ft
9
01 So
12 ine
2
09 h
ac
M
© 42108-1
Clamp all injection pumps.

T13 054
Attention!
cal connections! 1
Connect cables according to marks made
before removing.
z Tighten screws .
A13 054
© 45858-0
© 06/2006 6/6 8224-001

Fuel system
TCD 2015 W 07-11-01
Removing and installing the fuel supply pump

Commercial available tools: Attention!
– Magnetic measuring stand Pay attention to utmost cleanliness when
Special tools: working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Remove residue paint and particles of dirt
before removing.
sed air.
25 .IR
to regulations.
46 ft
9
01 So
12 ine
09 h
ac
M
Removing the fuel supply pump

2
1
© 40827-0
© 06/2006 1/6 8225-001

Fuel system
W 07-11-01 TCD 2015
z Unscrew hollow screws (1).

6
© 40828-0
25 .IR
z Remove lubricating oil pipe.
46 ft
9
01 So
z Remove sealing rings. 1
12 ine
2
09 h
ac
M
© 40829-0

z Remove fuel supply pump (2).
© 40830-0
© 06/2006 2/6 8225-001

Fuel system
TCD 2015 W 07-11-01
6
© 40961-0
25 .IR
Installing the fuel supply pump
46 ft
9
z Lightly oil O-ring. 1
01 So
12 ine
09 h
ac
M
© 42286-2
z Install fuel pump.

z Insert the driver (1) in the groove (2).
© 40831-0
© 06/2006 3/6 8225-001

Fuel system
W 07-11-01 TCD 2015

A07 024
6
© 40832-0
25 .IR
z Mount the lubricating oil pipe.
46 ft
9
01 So
z Tighten lock nut (2). 1
A08 014
12 ine
A08 013
2
09 h
ac
M
© 40829-0

z Tighten hollow screws (1).
A07 034
© 40828-0
© 06/2006 4/6 8225-001

Fuel system
TCD 2015 W 07-11-01
z Mount holder (2).

A07 044
2
1
6
© 40827-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 5/6 8225-001

Fuel system
W 07-11-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8225-001

Fuel system
TCD 2015 W 07-13-01

– Open wrench size SW 22
Special tools:
before removing.
sed air.
6
25 .IR
9
01 So
12 ine
09 h
ac
M
Removing fuel pressure holding valve

W 06-07-03
© 40519-0
© 06/2006 1/8 8226-001

Fuel system
W 07-13-01 TCD 2015

1
2 3
6
© 40520-0
25 .IR
z Unscrew nut (1).
46 ft
9
01 So
1
12 ine
2
09 h
ac
M
© 40521-0


© 40522-0
© 06/2006 2/8 8226-001

Fuel system
TCD 2015 W 07-13-01

1
6
© 40948-0
25 .IR
z Hold the connector.
z Unscrew overflow valve (3).
46 ft
9
01 So
z Remove connector (2). 1
12 ine
3
09 h
2
ac
M
© 40949-0
© 45848-0
© 06/2006 3/8 8226-001

Fuel system
W 07-13-01 TCD 2015
Installing fuel pressure holding valve

z Screw on overflow valve (1).
1
6
© 40947-0
25 .IR
z Insert connector (2).
46 ft
Connection of the hose line faces the heat
9
01 So
shield.
z Hold the connector. 1
z Tighten union nuts (1) with open wrench.
12 ine
A07 066
09 h
2
ac
M
© 40949-0
z Hold the connector.

z Tighten overflow valve (1) with open wrench.
A07 067
© 40949-0
© 06/2006 4/8 8226-001

Fuel system
TCD 2015 W 07-13-01

z Mount sealing rings (3).
A12 090
2
Attention!
Lay the hose pipe free from chafing and 1
tension.
3
6
© 40948-1
25 .IR
46 ft
9
01 So
12 ine
2
09 h
ac
M
© 40522-0

z Mount holder (2).
z Screw on nut (1).
© 40521-0
© 06/2006 5/8 8226-001

Fuel system
W 07-13-01 TCD 2015

z Mount holder (2).
2 3
6
© 40520-0
25 .IR
46 ft
9
01 So
A12 093
z Tighten nut (2).
1
12 ine
A07 044
2
09 h
ac
M
© 40565-0

A07 044
A12 092
1
© 40555-0
© 06/2006 6/8 8226-001

Fuel system
TCD 2015 W 07-13-01
z Mount holder (2).

A07 044
W 06-07-03
6
© 40519-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 7/8 8226-001

Fuel system
W 07-13-01 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8226-001

Fuel system

– Open wrench size SW 22 Pay attention to utmost cleanliness when
Special tools: working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Remove residue paint and particles of dirt
before removing.
sed air.
25 .IR
to regulations.
46 ft
9
01 So
12 ine
09 h
ac
M
Removing fuel pressure holding valve

z Hold overflow valve (1).
2
1
© 45925-1
© 06/2006 1/6 8227-001

Fuel system
z Hold connector (1).

z Unscrew overflow valve (2).
1
6
© 45915-1
25 .IR
z Remove washer.
z Loosen pipe clip.
46 ft 1
9
01 So
12 ine
09 h
ac
M
© 45916-0

z Unscrew union nut (3).
2
z Remove connector.
3 1
© 45917-0
© 06/2006 2/6 8227-001

Fuel system
6
© 45769-0
25 .IR
Installing fuel pressure holding valve
46 ft
9
z Screw on overflow valve (1).
01 So
1
12 ine
09 h
ac
M
© 40947-0

z Screw on screw-in nipple (1).
© 45770-0
© 06/2006 3/6 8227-001

Fuel system
z Mount hose line (1).

6
© 45918-0
25 .IR
z Insert connector.
46 ft
9
01 So
12 ine
09 h
1
ac
M
© 45919-0
z Position connector (1).

Arrange hexagon area (1) horizontally.
The connection (2) faces approx. 45° to
the left.
© 45920-0
© 06/2006 4/6 8227-001

Fuel system

z Tighten union nuts (2) with open wrench.
A07 066
6
© 45921-1
25 .IR
z Tighten overflow valve (2) with open wrench.
A07 067 46 ft
9
01 So
12 ine
1
09 h
2
ac
M
© 45922-1
z Hold overflow valve (1).

A07 069
2
1
© 45925-1
© 06/2006 5/6 8227-001

Fuel system

z Mount washer.
A13 094 2
6
© 45924-0
25 .IR
Observe installation angle dimension X =
10°.
46 ft
9
01 So
Attention!
Lay the hose pipe free from chafing and 1
12 ine
tension.
z Tighten hollow screw (2). X
A12 090
09 h
ac
1
2
M
© 45910-0
© 06/2006 6/6 8227-001

Lube oil system
TCD 2015 W 08-04-06
Removing and installing the oil suction pipe


to regulations.
25 .IR
Removing the oil suction pipe
z Remove lubricating oil pan.
46 ft
9
W 08-04-07
01 So
1
z Remove oil suction pipe (2).
12 ine
z Remove gasket.
1
09 h
ac
2
M
© 40833-0

2
© 40834-0
© 06/2006 1/4 8228-001

Lube oil system
W 08-04-06 TCD 2015
Installing the oil suction pipe

z Mount holder (2).
6 2
© 40834-0
25 .IR
z Mount new gasket.
z Mount oil suction pipe (2).
46 ft
9
01 So
Attention!
Ensure that the installation location is free 1
from faults.
12 ine
Install tension-free.
1
09 h
ac
2
M
© 40833-0

A08 016
© 40835-0
© 06/2006 2/4 8228-001

Lube oil system
TCD 2015 W 08-04-06

A08 015
A08 016
z Install lubricating oil pan. 1
W 08-04-07
6
© 40962-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 3/4 8228-001

Lube oil system
W 08-04-06 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8228-001

Lube oil system
Removing and installing the oil suction pipe


to regulations.
25 .IR
Removing the oil suction pipe
46 ft
z Remove lubricating oil pan (Railway).
9
W 08-04-07
01 So
z Unscrew screws (1). 2
z Remove oil suction pipe (2).
12 ine
z Remove gasket.
1
09 h
1
ac
M
© 45859-0

© 42171-1
© 06/2006 1/2 8229-001

Lube oil system
Installing the oil suction pipe

z Mount holder (1).
A08 016
6
© 42171-1
25 .IR
z Mount new gasket.
z Mount oil suction pipe.
46 ft
9
01 So
z Fasten screws.
from faults.
12 ine

M8 x 25 mm (1)
M8 x 20 mm (2)
09 h
1 2
ac
M
© 42170-1

A08 015
A08 016
Attention!
Install tension-free!
z Install lubricating oil pan (Railway).

W 08-04-07 1 2
© 42170-1
© 06/2006 2/2 8229-001

Lube oil system
TCD 2015 W 08-04-07

– Packing compound Collect leaking operating substances in

DEUTZ DW 47 suitable vessels and dispose of according
– Engine oil to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.
25 .IR
Removing the lubricating oil pan
z Remove starter.
46 ft
9
W 13-03-02
01 So
z Unscrew locking screw (1).
z Drain, collect and dispose of engine oil according to
12 ine
regulations.
09 h
ac
1
M
© 40836-0
z Oil the screw plug lightly.

z Tighten screw plug (1).
A03 031
© 40836-0
© 06/2006 1/6 8230-001

Lube oil system
W 08-04-07 TCD 2015
z Pull out oil dipstick (1).

6
© 40837-0
25 .IR
46 ft
9
1
01 So
12 ine
09 h
ac
1
M
© 40838-0

The holders (3) remain on the cables.
© 40839-0
© 06/2006 2/6 8230-001

Lube oil system
TCD 2015 W 08-04-07

z Remove gasket (1).
1
6
© 40840-0
25 .IR
z Remove guide tube (2).
z Remove screw-in nipple.
46 ft
9
01 So
12 ine
1
09 h
ac
2
M
© 40841-0
Installing the lubricating oil pan

A08 038 1
z Mount guide tube.
z Tighten union nut.
A08 035
© 40842-0
© 06/2006 3/6 8230-001

Lube oil system
W 08-04-07 TCD 2015

The sealing surfaces must be dry and free
from grease and dirt.
z Apply packing compound to the joints (arrows).
6
© 40843-0
25 .IR
z Select new gasket.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40844-0
z Mount gasket (1).

Strap (arrow) faces generator.
“TOP“ label faces crankcase.
© 40845-0
© 06/2006 4/6 8230-001

Lube oil system
TCD 2015 W 08-04-07
z Mount lubricating oil pan.

z Align lubricating oil pan to crankcase.
Ensure that the installation location of the
gasket is free from faults.
6
© 40846-0
25 .IR
z Mount holder (3).
z Position cable (2).
46 ft
9
01 So
12 ine
1
09 h
2
ac
3
M
© 40839-0

A03 030
See graphic for tightening sequence. 24 20 16 12 8 4 1 5 9 13 17 21
28 25
30 29
27 26
23 19 15 11 7 3 2 6 10 14 18 22
© 45421-1
© 06/2006 5/6 8230-001

Lube oil system
W 08-04-07 TCD 2015

A03 080
6
© 40838-0
25 .IR
z Insert oil dipstick (1).
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40837-0
z Fill engine oil according to operating instructions.

z Install starter.
W 13-03-02
© 40848-0
© 06/2006 6/6 8230-001

Lube oil system

to regulations.
– Packing compound The appropriate operating manual should
DEUTZ DW 47 be observed for emptying and filling the
– Fitting compound engine.
DEUTZ AP1908
– Engine oil
25 .IR
Removing the lubricating oil pan
46 ft
9
z Drain, collect and dispose of engine oil according to
01 So
regulations.
12 ine
09 h
ac
1
M
© 42439-1
z Oil the screw plug lightly.

A03 031
© 45860-0
© 06/2006 1/10 8231-001

Lube oil system

z Remove washers.
z Remove all half-flanges (2).
z Remove both flanged sockets (3).
1
6
© 45867-0
25 .IR
z Remove connecting flange (2).
46 ft
9
01 So
2
1
12 ine
09 h
1
ac
M
© 42441-1

© 42442-1
© 06/2006 2/10 8231-001

Lube oil system

The holders (3) remain on the cables.
2 1
z Loosen lubricating oil pan.
6
© 45861-0
25 .IR
z Pull lubricating oil pan in direction of arrow.
z Remove gasket.
46 ft
9
01 So
12 ine
09 h
1
ac
M
© 45868-0
z Pull out plug elements (1).
© 45862-0
© 06/2006 3/10 8231-001

Lube oil system

6
© 45863-0
25 .IR
z Insert plug elements (1).
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 45862-0
Mount lube oil tray with gasket.

The sealing surfaces must be dry and free
z Apply packing compound to the joints (arrows).
© 42445-1
© 06/2006 4/10 8231-001

Lube oil system

The bright side of the gasket faces the
crankcase.
In case of metal bead seals, the beading
faces the crankcase. 1
6
© 45864-0
25 .IR
Mount lube oil tray with packing com-
pound.
46 ft
9
01 So
face and in the beading of the lube oil tray.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
12 ine
The position of the packing compound is

only partly illlustrated.
09 h
ac
M
© 43451-0
z Mount lubricating oil pan.

z Push on lubricating oil pan in direction of arrow.
Attention!
Do not move or damage O-rings.
© 45869-0
© 06/2006 5/10 8231-001

Lube oil system
z Align lubricating oil pan to crankcase.

Attention!
Do not move gasket/packing compound.
Do not move the gasket when mounting
the lubricating oil pan.
6
© 45865-0
25 .IR
z Mount holder (arrows).
z Position cable.
46 ft
9
01 So
12 ine
09 h
ac
M
© 42447-1

A03 030
See graphic for tightening sequence. 24 20 16 12 8 4 1 5 9 13 17 21
28 25
30 29
27 26
23 19 15 11 7 3 2 6 10 14 18 22
© 45421-1
© 06/2006 6/10 8231-001

Lube oil system

6
© 37110-1
25 .IR
z Mount connecting flange (2).
Attention!
46 ft
The labels “IN“ and “EX“ on the connecting EX IN
9
01 So
flange and the lubricating oil pan must
match.
12 ine
A03 035 1
09 h
1
ac
2
M
© 42448-1

© 37112-1
© 06/2006 7/10 8231-001

Lube oil system
z Mount half-flange (1).

z Mount washers.
z Insert flanged socket (3).
3
6 2
© 45870-0
25 .IR
z Mount washers.
46 ft
9
2
01 So
1
12 ine
2
09 h
ac
M
© 45871-0

z Mount washers.
3
z Insert flanged socket (2).
z Align both flanged sockets centrally. 2
A03 034
© 45872-0
© 06/2006 8/10 8231-001

Lube oil system
z Mount holder (2).

A13 098
1
z Fill engine oil according to operating instructions.
2
1 6
© 42442-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 9/10 8231-001

Lube oil system
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 10/10 8231-001

Lube oil system
TCD 2015 W 08-08-02
Removing and installing the oil cooler

– W 09-08-04

to regulations.
25 .IR
Removing the oil cooler
46 ft
9
W 06-07-03
01 So
W 09-08-04
12 ine
09 h
ac
M
© 40849-0

© 40519-0
© 06/2006 1/8 8232-001

Lube oil system
W 08-08-02 TCD 2015

1
2
6
© 40850-0
25 .IR
z Unscrew nut (1).
46 ft
9
01 So
1
12 ine
09 h
ac
2
M
© 40851-0


1
© 40852-0
© 06/2006 2/8 8232-001

Lube oil system
TCD 2015 W 08-08-02
1
1
6
© 40853-0
25 .IR
z Remove oil cooler cover (2).
z Remove gasket.
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40854-0

z Remove oil cooler (2).
z Remove O-rings.
1 1
© 40855-0
© 06/2006 3/8 8232-001

Lube oil system
W 08-08-02 TCD 2015
6
© 40856-0
25 .IR
Installing the oil cooler
46 ft
9
01 So
z Insert new O-rings (2). 1 1
12 ine
2
09 h
2
ac
M
© 40857-0
z Mount oil cooler (2).

z Align oil cooler.
A08 051
1 1
© 40855-0
© 06/2006 4/8 8232-001

Lube oil system
TCD 2015 W 08-08-02

z Mount new gasket.
z Mount oil cooler cover.
z Mount holder (1).
Screw length:
M8 x 35 mm

Screw length: 2 2
M8 x 65 mm
3 6
© 40858-0
25 .IR
z Align oil cooler cover (2).
The lay-on surfaces of the oil cooler cover
46 ft
and the genset support must contact the
9
01 So
holders.
Do not move gasket.
1
12 ine
A08 050
09 h
2
ac
M
© 40854-0

A06 058
1
1
© 40853-0
© 06/2006 5/8 8232-001

Lube oil system
W 08-08-02 TCD 2015

6
© 40852-0
25 .IR
z Mount holder (2).
z Screw on nut (1).
46 ft
9
01 So
1
12 ine
09 h
ac
2
M
© 40851-0
z Mount holder (2).

z Fasten screw (1).
1
2
© 40850-0
© 06/2006 6/8 8232-001

Lube oil system
TCD 2015 W 08-08-02
z Mount holder (2).

A07 044
6
© 40519-0
25 .IR
A12 093
46 ft
9
01 So
1
z Tighten nut (2).
12 ine
3
A07 044 2
A07 044
09 h
ac
M
© 40859-0

W 09-08-04
W 06-07-03
© 40849-0
© 06/2006 7/8 8232-001

Lube oil system
W 08-08-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8232-001

Lube oil system
TCD 2015 W 08-11-09
Removing and installing oil pressure pick-up

Commercial available tools Read out error memory of the motor con-
Special tools:
– Socket wrench insert . . . . . . . . . 110700
to regulations.
25 .IR
Removing oil pressure pick-up
z Pull out cable plug (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40860-0
z Unscrew oil pressure pick-up (1) with the socket

wrench insert.
© 40861-0
© 06/2006 1/2 8233-001

Lube oil system
W 08-11-09 TCD 2015
6
© 40862-0
25 .IR
Installing oil pressure pick-up
z Mount new gasket.
46 ft
9
z Insert oil pressure pick-up (1). 1
01 So
z Tighten oil pressure pick-up with socket wrench in-
sert.
A08 091
12 ine
09 h
ac
M
© 40861-0

1
© 40860-0
© 06/2006 2/2 8233-001

Lube oil system
TCD 2015 W 08-11-10
Removing and installing pressurestat

– Depth-measuring – W 06-07-03 . . . . . . . . . . . . (B-bank)
appliance
to regulations.
25 .IR
Removing pressurestat
46 ft
9
W 03-01-11
01 So
W 06-07-03
12 ine
09 h
ac
M
© 40863-0

© 40608-0
© 06/2006 1/10 8234-001

Lube oil system
W 08-11-10 TCD 2015
6
© 40609-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40864-0

© 40613-0
© 06/2006 2/10 8234-001

Lube oil system
TCD 2015 W 08-11-10
z Unscrew nuts (1).

6
© 40972-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40973-0

© 40865-0
© 06/2006 3/10 8234-001

Lube oil system
W 08-11-10 TCD 2015
z Unscrew valve housing (1).

Do not move the adjusting bolt (2).
1
6
© 40866-0
25 .IR
If the same oil pressure is to be set again,
the overhang of the adjusting bolt must be
measured before removing.
46 ft
9
01 So
z Measure overhang (X) from adjusting bolt (1) to
crankcase with the depth measuring appliance.
12 ine
1
X
09 h
ac
M
© 40867-0
z Unscrew adjusting bolt (1).

z Remove compression spring.
z Remove valve plunger.
1
© 40868-0
© 06/2006 4/10 8234-001

Lube oil system
TCD 2015 W 08-11-10

– Adjusting bolt (1).
– Compression spring (2)
– Valve plunger (3)
1 2 3
6
© 42460-1
25 .IR
Installing pressurestat
46 ft
Overhang dimension (X) for basic setting
of adjusting bolt.
9
01 So
If the same oil pressure is to be set again,
the overhang dimension (X) noted before
removal must be reset.
12 ine
P08 63
09 h
ac
M
© 35022-2
z Insert valve plunger.

z Insert compression spring.
z Screw in adjusting bolt (1).
P08 63 1
Note overhang dimension of the adjusting
bolt.
© 40868-0
© 06/2006 5/10 8234-001

Lube oil system
W 08-11-10 TCD 2015

z Oil the thread valve housing lightly.
z Tighten valve housing (1).
A03 051
Do not move the adjusting bolt (2).
6
© 40869-0
25 .IR
A08 071 46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40865-0

© 40973-0
© 06/2006 6/10 8234-001

Lube oil system
TCD 2015 W 08-11-10

z Mount holder (2).
z Tighten nuts (1).
A07 044
1
6
© 40972-0
25 .IR
A07 066
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40990-0
z Mount holder (2).

A07 044
© 40613-0
© 06/2006 7/10 8234-001

Lube oil system
W 08-11-10 TCD 2015
6
© 40864-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40609-0

© 40608-0
© 06/2006 8/10 8234-001

Lube oil system
TCD 2015 W 08-11-10

W 06-07-03
W 03-01-11
6
© 40848-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 9/10 8234-001

Lube oil system
W 08-11-10 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 10/10 8234-001

Cooling system
TCD 2015 W 09-07-08
Removing and installing the coolant pump

Special tools: to regulations.
– Disassembly tool. . . . . . . . . . . . . 110901
DEUTZ AP1908
25 .IR
Removing coolant pump
46 ft
9
z Removing screw-in nipple (2).
01 So
z Remove gasket.
2
12 ine
1
09 h
ac
M
© 40870_1
© 45393-0
© 06/2006 1/6 8235-001

Cooling system
W 09-07-08 TCD 2015
6
© 40871-0
25 .IR
Use three studs M8 to push the coolant
46 ft
pump off the genset support. 1 1
9
01 So
z Press off the coolant pump.
z Remove gasket.
12 ine
09 h
ac
1
M
© 40872-0
z Remove screws.
© 36828_1
© 06/2006 2/6 8235-001

Cooling system
TCD 2015 W 09-07-08
6
© 40874-0
25 .IR
Installing coolant pump
z Insert new O-rings.
46 ft
9
O-rings:
01 So
75 x 3 mm (1)
80 x 3 mm (2)
12 ine
z Coat the O-rings with fitting compound. 1

09 h
2
ac
M
© 36828_1

Check drainage holes (arrows) for free
passage.
© 40876-0
© 06/2006 3/6 8235-001

Cooling system
W 09-07-08 TCD 2015
z Screw in studs (1).

To fix the gasket and the coolant pump.
1 1
z Mount new gasket.
6
© 40877-0
25 .IR
z Insert coolant pump.
The gear wheel (1) must engage the toot-
46 ft
hing of the idler gear (2).
9
01 So
Attention!
Do not damage the gasket.
12 ine
Do not move gasket.
1
2
09 h
ac
M
© 40875-0

z Unscrew studs (2). 1
2 2
© 40878-0
© 06/2006 4/6 8235-001

Cooling system
TCD 2015 W 09-07-08

A09 010 1 1
6
© 40879-0
25 .IR
z Mount new gasket.
z Mount inlet adapter (2).
46 ft
9
01 So
A09 011 2
12 ine
1
09 h
ac
M
© 40870_1
© 06/2006 5/6 8235-001

Cooling system
W 09-07-08 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 6/6 8235-001

Cooling system
TCD 2015 W 09-08-01
Checking the thermostat when uninstalled

– Thermometer
Danger!
Risk of injury!
Hot water and hot thermostat.
25 .IR
Checking thermostat
z Remove thermostats.
46 ft
9
W 09-08-02
01 So
z Measure beginning of stroke, dimension (a).
12 ine
09 h
ac
M
© 34679-3
z Heat up the thermostat in the water bath.

z Determine beginning of opening.
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
Do not touch the thermostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1°C/min. Otherwise the begin-
ning of opening will be delayed accordin-
gly.
P09 11
P09 12
© 34680-2
© 06/2006 1/2 8236-001

Cooling system
W 09-08-01 TCD 2015
z Measure end of stroke, dimension (b).

6
© 34679-2
25 .IR
z Determine stroke.
Calculation example
Desired: Stroke
46 ft
9
01 So
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Dimension (b) - dimension (a)
12 ine
Result: = stroke
z Compare result with setpoint value.
P09 13
09 h
z Install thermostats.
ac
W 09-08-02
M
© 34679-1
© 06/2006 2/2 8236-001

Cooling system
TCD 2015 W 09-08-02
Removing and installing thermostats

– W 09-08-04
– Fitting compound Collect leaking operating substances in

DEUTZ AP1908 suitable vessels and dispose of according
to regulations.
25 .IR
Removing thermostats
46 ft
9
W 09-08-04 2
01 So
z Remove outlet nozzle (2). 1
12 ine
09 h
ac
M
© 40880_1
z Remove thermostats (1).
© 40881-0
© 06/2006 1/4 8237-001

Cooling system
W 09-08-02 TCD 2015

z Check thermostats.
W 09-08-01
6
© 40882-0
25 .IR
Installing thermostats
z Select thermostats.
46 ft 1
9
z Coat the sealing rings with fitting compound.
01 So
z Fit new sealing rings (1).
Note different opening
temperatures (arrows) of the thermostats.
12 ine
P09 11
P09 12
09 h
ac
M
© 40883-0

The markings (3) face upwards.
Note thermostat assignment.
z Insert thermostat (1). 3
1 2
P09 12
z Insert thermostat (2).
P09 11
© 40884_2
© 06/2006 2/4 8237-001

Cooling system
TCD 2015 W 09-08-02
z Mount outlet nozzle (2).

A09 002 2
W 09-08-04 1
6
© 40880_1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 3/4 8237-001

Cooling system
W 09-08-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8237-001

Cooling system
TCD 2015 W 09-08-04
Removing and installing the thermostat housing


to regulations.
25 .IR
Removing thermostat housing
46 ft
9
W 07-01-04
01 So
12 ine
09 h
ac
M
© 40885-0
© 40886-0
© 06/2006 1/8 8238-001

Cooling system
W 09-08-04 TCD 2015

z Place holder (2) to one side.
6
© 40887-0
25 .IR
z Remove spacing sleeve.
z Place pipe to one side.
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40888-0

© 40889-0
© 06/2006 2/8 8238-001

Cooling system
TCD 2015 W 09-08-04

2
6
© 40890-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40891-0
z Remove the thermostat housing (1).

z Remove gasket. 1
© 40892-0
© 06/2006 3/8 8238-001

Cooling system
W 09-08-04 TCD 2015
6
© 40893-0
25 .IR
Installing thermostat housing
46 ft 1
9
z Mount new gasket.
01 So
z Mount thermostat housing (1).
Do not move gasket.
12 ine
z Plug in the cable plug (2). 2

09 h
ac
M
© 40892-0
z Fasten screws.
M8 x 90 mm (1)
M8 x 65 mm (2)
2 1 2
© 40894-0
© 06/2006 4/8 8238-001

Cooling system
TCD 2015 W 09-08-04
z Mount holder (1).

z Fasten screw (2).
2
Screw length:
M8 x 140 mm.
TIghten screw only after mounting the fuel
pipes (flame glow plugs). 1
6
© 40890-0
25 .IR
A09 001
46 ft
9
01 So
A09 001
12 ine
1
09 h
ac
2 1 2
M
© 40894-0

A12 092
© 40889-0
© 06/2006 5/8 8238-001

Cooling system
W 09-08-04 TCD 2015
z Mount fuel pipe.

z Position spacing sleeve.
z Fasten screw (1).
6
© 40888-0
25 .IR
P07 91
46 ft X
9
01 So
12 ine
09 h
ac
M
© 45406-0

A07 093
© 40888-0
© 06/2006 6/8 8238-001

Cooling system
TCD 2015 W 09-08-04
z Mount holder (2).

A09 001
Screw length:
M8 x 150 mm
6
© 40887-0
25 .IR
A13 094
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40886-0

W 07-01-04
© 40956-0
© 06/2006 7/8 8238-001

Cooling system
W 09-08-04 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8238-001

Cooling system
TCD 2015 W 09-12-01

to regulations.
25 .IR
Removing temperaure transmitter
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40895-0
z Unscrew temperature transmitter (1).
© 40896-0
© 06/2006 1/2 8239-001

Cooling system
W 09-12-01 TCD 2015
6
© 44084-0
25 .IR
Installing temperature transmitter
46 ft
z Tighten temperature transmitter (1).
9
A09 031
01 So
12 ine
1
09 h
ac
M
© 40896-0

© 40895-0
© 06/2006 2/2 8239-001

Other components
TCD 2015 W 12-01-04
Removing and installing torsional vibration damper

25 .IR
Removing the torsional vibration damper
46 ft
9
z Remove V-belt pulley (2).
01 So
1
12 ine
09 h
ac
2
M
© 40965-0
z Pull off torsional vibration damper (1).

Danger!
1
Risk of injury!
© 40897-0
© 06/2006 1/2 8240-001

Other components
W 12-01-04 TCD 2015
6
© 40898-0
25 .IR
Installing the torsional vibration damper
46 ft
z Mount torsional vibration damper (1).
1
9
01 So
12 ine
09 h
ac
M
© 40897-0
z Mount V-belt pulley (2).

A12 031
1
© 40965-0
© 06/2006 2/2 8240-001

Other components
TCD 2015 W 12-06-01
Removing and installing flywheel

– Socket wrench insert . . . . . . . . . . . 8016 Do not turn the crankshaft without screws/
– Rotation angle disc . . . . . . . . . . . . . 8190 mandrin guide.
Special tools: The crankshaft gear wheel is positioned by
– Self-made mandrin guide screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.
25 .IR
Removing flywheel
46 ft
9
01 So
1
z Remove thrust washer (2).
12 ine
2
09 h
ac
M
© 40902_1
z Insert self-made mandrin guide.

z Remove flywheel.
z Remove friction disc.
Attention!
Do not turn the crankshaft without screws/
mandrin guide.
The crankshaft gear wheel is positioned by
screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.
© 34985-2
© 06/2006 1/2 8241-001

Other components
W 12-06-01 TCD 2015
6
© 40903-0
25 .IR
Install flywheel
z Position friction disc.
46 ft
9
Make sure the clamping bushing (1) is in
01 So
place.
z Mount flywheel.
12 ine
Make sure the clamping bushing and loca-

1
ting hole are in line.
09 h
ac
M
© 40966-0
z Insert thrust washer (2).

z Remove self-made mandrin guide.
Attention! 1
Renew screws every time they are loo-
sened. 2
z Tighten all screws (1) with the socket wrench insert.
A12 001
© 40658_1
© 06/2006 2/2 8241-001

Other components
TCD 2015 W 12-06-03
Renewing toothed starter ring on the flywheel

Danger!
Danger of injury, do not touch hot parts!
25 .IR
Removing toothed starter ring
z Remove flywheel.
46 ft
9
W 12-06-01
01 So
z Check marking.
The marking (arrow) is on the flywheel and
12 ine
exactly in the middle of the tooth notch of

the toothed starter ring.
09 h
ac
M
© 40904-0
z Remove toothed starter ring with suitable tool.
© 34764-2
© 06/2006 1/4 8242-001

Other components
W 12-06-03 TCD 2015
z Visually inspect joint (arrow) and contact surface.

z Clean flywheel.
The joint and contact surface must be free
6
© 34765-2
25 .IR
Install toothed starter ring
46 ft
z Check marking of new toothed starter ring.
9
The marking (arrow) is on the flywheel and
01 So
exactly in the middle of the tooth notch of
the toothed starter ring.
12 ine
09 h
ac
M
© 40905-0
z Heat up toothed starter ring to 220 °C.

z Place toothed starter ring on flywheel.
The markings on the flywheel and toothed
starter ring must match.
The toothed starter ring must lie evenly on
the joint of the flywheel.
© 40906-0
© 06/2006 2/4 8242-001

Other components
TCD 2015 W 12-06-03
z Install flywheel.
W 12-06-01
6
© 40907-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 3/4 8242-001

Other components
W 12-06-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8242-001

Other components
TCD 2015 W 12-08-04
Removing and installing hydraulic pump drive

Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901
– Fitting compound suitable vessels and dispose of according
DEUTZ AP1908 to regulations.
– Locking agent
DEUTZ DW 59
25 .IR
Removing hydraulic pump drive
46 ft 1
9
W 06-01-06
01 So
z Unscrew lock nuts (2).
12 ine
z Remove lubricating oil pipe (3). 3 2

09 h
ac
2
M
© 40908-0

z Remove flange housing (2).
1
2
© 40909-0
© 06/2006 1/4 8243-001

Other components
W 12-08-04 TCD 2015

z Remove hydraulic pump drive (2).
6
© 40910-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
1
M
© 42200-2
Installing hydraulic pump drive

z Coat the O-ring with fitting compound.
© 42200-2
© 06/2006 2/4 8243-001

Other components
TCD 2015 W 12-08-04
z Insert hydraulic pump drive.

The gear wheel (1) must engage the toot-
hing of the idler gear (2).
2
6
© 40913-0
25 .IR
A12 057 46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40914-0

z Coat lay-on surface (arrow) with locking agent.
© 45409-0
© 06/2006 3/4 8243-001

Other components
W 12-08-04 TCD 2015
z Mount flange housing (1).

Screw length:
M10 x 110 mm 2 1

Screw length:
M10 x 210 mm
6
© 40915-0
25 .IR
A12 058
46 ft
9
01 So
A12 059
1
12 ine
09 h
ac
2
M
© 45395-0

z Fasten screw (1).
z Tighten lock nut (2). 1
A12 082
A08 045 3 2
W 06-01-06
© 40908-0
© 06/2006 4/4 8243-001

Electrical system
TCD 2015 W 13-01-02
Removing and installing the cable harness

Attention!
cal connections!
25 .IR
Removing the cable harness
46 ft
9
W 06-02-03
01 So
12 ine
09 h
ac
M
© 40916-0
z Disconnect the battery's negative terminal.

z Disconnect cables.
© 40917-0
© 06/2006 1/20 8244-001

Electrical system
W 13-01-02 TCD 2015
6
© 40534-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40918-0
© 40919-0
© 06/2006 2/20 8244-001

Electrical system
TCD 2015 W 13-01-02
z Unscrew nut (1).

z Remove washer.
before removing.
1
6
© 40920-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40921-0
© 40922-0
© 06/2006 3/20 8244-001

Electrical system
W 13-01-02 TCD 2015

z Pull cables off all injection pumps.
before removing.
6
© 40923-0
25 .IR
46 ft
9
01 So
12 ine
2
09 h
ac
M
© 40924-0
© 40925-0
© 06/2006 4/20 8244-001

Electrical system
TCD 2015 W 13-01-02
6
© 40926-0
25 .IR
46 ft
9
01 So
1
12 ine
1 1
09 h
ac
M
© 40927-0
z Unscrew nuts (1).

z Unscrew the nuts (2).
z Remove washers. 1
z Remove cables.
before removing.
© 40928-0
© 06/2006 5/20 8244-001

Electrical system
W 13-01-02 TCD 2015
6
© 40929-0
25 .IR
before removing.
46 ft 1
9
z Unscrew nut (1).
01 So
2
z Remove washer.
12 ine
09 h
ac
M
© 40930-0
© 40931-0
© 06/2006 6/20 8244-001

Electrical system
TCD 2015 W 13-01-02
6
© 40933-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40934-0

z Remove fuel pipe.
© 40935-0
© 06/2006 7/20 8244-001

Electrical system
W 13-01-02 TCD 2015
z Pull out cable plug (1).
6
© 40936-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40943-0
© 40532-0
© 06/2006 8/20 8244-001

Electrical system
TCD 2015 W 13-01-02
6
© 40937-0
25 .IR
46 ft
9
01 So
12 ine
1
09 h
ac
M
© 40938-0
© 40939-0
© 06/2006 9/20 8244-001

Electrical system
W 13-01-02 TCD 2015
z Unlock central plug (1) (arrow) and pull off from hold-
er.
6
© 40940-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40941-0
Installing the cable harness

z Position the cable harness on the engine according-
ly.
z Lay the cable plugs to the individual components.
© 40942-0
© 06/2006 10/20 8244-001

Electrical system
TCD 2015 W 13-01-02
z Push the central plug onto the holder until it snaps in.
A12 095
6
© 40939-0
25 .IR
z Tighten screws .
A13 090
46 ft
9
Screw length:
01 So
M8 x 20 mm (1) 2
M8 x 16 mm (2)
12 ine
1
09 h
ac
M
© 40987-0
© 40937-0
© 06/2006 11/20 8244-001

Electrical system
W 13-01-02 TCD 2015
z Lay cable harness and fix with cable ties (1).
6
© 40532-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
2
ac
M
© 40943-0
© 40936-0
© 06/2006 12/20 8244-001

Electrical system
TCD 2015 W 13-01-02
z Mount fuel pipe.

z Position pipe clip.
z Fasten screw (1).
6
© 40935-0
25 .IR
A12 080
46 ft
9
Attention!
01 So
Install fuel pipe tension free. 1
12 ine
09 h
ac
M
© 40934-0

A12 080
© 40933-0
© 06/2006 13/20 8244-001

Electrical system
W 13-01-02 TCD 2015

A07 044
6
© 40935-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40931-0

Attention! 1
cal connections! 2
before removing.
z Mount washer.
z Tighten nut (1).
A13 035
© 40930-0
© 06/2006 14/20 8244-001

Electrical system
TCD 2015 W 13-01-02

A13 094
6
© 40929-0
25 .IR
z Plug cables.
Attention!
46 ft
Note assignment and polarity of the electri- 1
9
01 So
cal connections!

before removing.
12 ine
z Mount washers.
z Tighten nuts (1).
09 h
A13 037
2
ac
z Tighten nuts (2).

A13 038
M
© 40928-0
1 1 1
© 40927-0
© 06/2006 15/20 8244-001

Electrical system
W 13-01-02 TCD 2015
6
© 40926-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40925-0

© 40924-0
© 06/2006 16/20 8244-001

Electrical system
TCD 2015 W 13-01-02
z Plug cables to all injection pumps.

T13 054
Attention!
cal connections!

before removing.
1
A13 054
6
© 40923-0
25 .IR
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40922-0
© 40921-0
© 06/2006 17/20 8244-001

Electrical system
W 13-01-02 TCD 2015

Attention!
cal connections!

1
before removing.
z Mount washer.
z Tighten nut (1).
2
A13 035
6
© 40920-0
25 .IR
46 ft 1
9
01 So
12 ine
09 h
ac
M
© 40919-0
© 40918-0
© 06/2006 18/20 8244-001

Electrical system
TCD 2015 W 13-01-02
6
© 40534-0
25 .IR
z Connect cables.
z Connect the battery's negative terminal.
46 ft
9
01 So
12 ine
09 h
ac
M
© 40917-0

W 06-02-03
© 40956-0
© 06/2006 19/20 8244-001

Electrical system
W 13-01-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 20/20 8244-001

Electrical system
TCD 2015 W 13-02-03
Removing and installing the generator

(V-belt drive)
– V-belt tension measuring Only test / tighten / renew V-belts when the
device . . . . . . . . . . . . . . . . . . . . . . . 8115 engine is not running.
The V-belt tension of new V-belts must be

checked after they have been running for
15 minutes.
25 .IR
Removing the generator
46 ft
9
z Remove cable from generator.
01 So
Note assignment! 1
- (1) = terminal W
12 ine
- (2) = terminal D+
- (3) = terminal B+
2
09 h
ac
M
3
© 45411-0
© 40975-0
© 06/2006 1/8 8245-001

Electrical system
W 13-02-03 TCD 2015
z Loosen nut (1).
6
© 40976-0
25 .IR
z Loosen screw (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 45412-0
z Press generator in direction of arrow.

z Remove V-belt (1).
© 40978-1
© 06/2006 2/8 8245-001

Electrical system
TCD 2015 W 13-02-03

Hold nuts.
z Remove generator (2).
2 6
© 40979-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 40980-0
Installing the generator

z Mount generator.
z Insert screws.
Note different screw lengths: 1
M10 x 100 mm (1)
M10 x 120 mm (2)
z Fasten screws.
Hold nuts.
© 40988-1
© 06/2006 3/8 8245-001

Electrical system
W 13-02-03 TCD 2015

A13 015
Hold nuts.
6
© 45396-0
25 .IR
z Mount V-belt (1).
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40978-0
z Tighten V-belt (1) by turning the clamping screw (2).

A13 017
z Fasten screws (3). 3
2 1
© 40977-1
© 06/2006 4/8 8245-001

Electrical system
TCD 2015 W 13-02-03
Check V-belt tension with V-belt tension

measuring device
z Lower indicator arm (1) into V-belt tension measuring
device.
1
6
© 39582_2
25 .IR
z Mount V-belt tension measuring device on V-belt.
The V-belt must be between the
guides (arrow).
46 ft
9
01 So
12 ine
09 h
ac
M
© 40981-0
z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
© 40982-0
© 06/2006 5/8 8245-001

Electrical system
W 13-02-03 TCD 2015
z Read measured value at the intersection (arrow) of

the indicator arm and scale.
P12 11
P12 21
Note different units on the scale.
z If the nominal value is not reached, the tensioning

process must be repeated.
6
© 45413-0
25 .IR
A13 012
46 ft
9
01 So
1
12 ine
09 h
ac
M
© 40983-0
z Tighten nut (1).

A13 017
© 40984-0
© 06/2006 6/8 8245-001

Electrical system
TCD 2015 W 13-02-03
z Remove cable from generator.

Note assignment!
- (1) = terminal W
- (2) = terminal D+
1
- (3) = terminal B+
3 6
© 45411-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 7/8 8245-001

Electrical system
W 13-02-03 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8245-001

Electrical system
TCD 2015 W 13-03-02
Removing and installing the starter

DEUTZ AP1908
25 .IR
Removing the starter
46 ft
9
z Disconnect cables.
01 So
12 ine
09 h
ac
M
© 40917-0
z Unscrew nuts (1).

z Remove starter.
© 40944-1
© 06/2006 1/4 8246-001

Electrical system
W 13-03-02 TCD 2015
6
© 40945-0
25 .IR
Installing the starter
z Insert new O-ring (arrow).
46 ft
9
z Coat the O-ring with fitting compound.
01 So
12 ine
09 h
ac
M
© 42096-1
z Insert starter.
z Tighten nuts (1).
A13 001
© 40944-1
© 06/2006 2/4 8246-001

Electrical system
TCD 2015 W 13-03-02
z Connect cables.
6
© 40917-0
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 3/4 8246-001

Electrical system
W 13-03-02 TCD 2015
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 4/4 8246-001

Electrical system
TCD 2015 W 13-08-01
Removing and installing the pressure/temperature sensor

(charge air)
DEUTZ AP1908
25 .IR
Remove pressure/temperature sensor
46 ft 1
9
01 So
12 ine
09 h
ac
M
© 40919-0

z Remove pressure/temperature sensor
© 40946-0
© 06/2006 1/2 8247-001

Electrical system
W 13-08-01 TCD 2015
Installing the pressure/temperature sensor

z Lightly coat O-ring with fitting compound.
6
© 42002-2
25 .IR
z Insert pressure/temperature sensor.
A13 046 46 ft
9
01 So
12 ine
09 h
ac
1
M
© 40946-0

Delete error entry in the error memory of 1
© 40919-0
© 06/2006 2/2 8247-001

TCD 2015 Standard tools
7 Standard tools
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 1/8 8248-001

Standard tools TCD 2015
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bäcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/8 8248-001

8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 35410-2
25 .IR
8008
Nozzle tester
with spray mist collecting vessel
46 ft
9
Check injection nozzles
01 So
12 ine
09 h
ac
M
© 35411-2
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
© 39426-1
© 06/2006 3/8 8248-001

8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.
© 37503-1
25 .IR
8016
SW 17, reinforced
46 ft
9
Unscrew and tighten flywheel screws.
01 So
12 ine
09 h
ac
M
© 37504-1
8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.
© 37506-1
© 06/2006 4/8 8248-001

8024
Assembly pliers
e. g. removing valve stem seals
© 37509-4
25 .IR
8115
V-belt tension measuring device
150 to 600 N
46 ft
9
Check V-belt tension
01 So
12 ine
09 h
ac
M
© 35416-3
8198
Pricker
Removing rotary shaft lip seal
© 43206-3
© 06/2006 5/8 8248-001

8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
© 42528-1
25 .IR
8191
46 ft
with slotted screwdriver insert (8x1.6)
9
(e. g. setting valve clearance)
01 So
12 ine
09 h
ac
M
© 43060-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
© 43197-0
© 06/2006 6/8 8248-001

9017
Assembly lever
e. g. removing and installing valves
© 37511-1
25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 7/8 8248-001

25 .IR
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 8/8 8248-001

TCD 2015 Special tools
8 Special tools
25 .IR
8
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 1/16 8249-001

Special tools TCD 2015
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bäcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com
25 .IR
8
46 ft
9
01 So
12 ine
09 h
ac
M
© 06/2006 2/16 8249-001

6066
Assembly block
Engine clamping, double-sidedmaximum load capacity
at middle centre of gravity approx. 1200 kg
© 35451-2
25 .IR
6066/151
Clamping bracket 8
46 ft
(in conjunction with assembly block 6066)
9
Engine clamping, double-sided
01 So
12 ine
09 h
ac
M
© 37601-1
100130
Connector
(in conjunction with compression pressure tester 8005)
© 37602-1
© 06/2006 3/16 8249-001

100300
Turning gear
with mechanical TDC transmitter and degree scale for
start of pumping check
Turn crankshaft,
block engine
© 37603-1
25 .IR
100350
8 Turning gear
Turn crankshaft on the V-belt pulley.
46 ft
9
01 So
12 ine
09 h
ac
M
© 37604-1
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
© 37605-1
© 06/2006 4/16 8249-001

100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
© 43205-0
25 .IR
100850
Measuring instrument with measuring plate 8
46 ft
9
01 So
12 ine
09 h
ac
M
© 37606-1
101830
Dial gauge adapter
Measuring installation depth for impulse transmitter
© 45906-0
© 06/2006 5/16 8249-001

102560
Tester
Basic device with two dipsticks
Check radiation position of the piston cooling nozzle
(old version)
© 37608-1
25 .IR
102565
8 Dipstick
(in connection with tester 102560)
46 ft
9
Check radiation position of the piston cooling nozzle
01 So
(new version)
12 ine
09 h
ac
M
© 37628-1
103240
Dial gauge holder
with stylus extension (diameter 5/95 mm)
Checking plunger lift of injection pumps
© 43927-3
© 06/2006 6/16 8249-001

110030
Puller
(in connection with sliding hammer 150800)
© 35433-2
25 .IR
110110
Holder 8
SW11,
46 ft
9
Clamp fuel injector in the vice
01 So
12 ine
09 h
ac
M
© 35434-2
110130
Slotted nut wrench
Unscrew and tighten union screw on the fuel injector.
© 37610-1
© 06/2006 7/16 8249-001

110500
Special wrench
Size 17
Removing and installing injection pipes
© 35436-1
25 .IR
110510
8 Special wrench
46 ft
9
01 So
12 ine
09 h
ac
M
© 43928-3
110700
Size 27
long
Removing and installing oil pressure transmitter
© 42341-2
© 06/2006 8/16 8249-001

110901
Disassembly tool
Removing O-ring
© 45950-1
25 .IR
120660
Puller 8
46 ft
(in connection with sliding hammer 150800)
9
Removing jammed fuel injector sealing ring
01 So
12 ine
09 h
ac
M
© 45421-0
120900
Support bracket
pivoting
Clamping cylinder head
© 35438-2
© 06/2006 9/16 8249-001

120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
© 35439-2
25 .IR
121410
8 Assembly tool
Assembling valve stem gasket
46 ft
9
01 So
12 ine
09 h
ac
M
© 37614-1
121420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
© 43210-0
© 06/2006 10/16 8249-001

130300
Universal piston ring pliers
Removing and installing the piston rings
© 35441-2
25 .IR
130400
Trapezoidal groove wear gauge 8
Testing piston ring groove
46 ft
9
01 So
12 ine
09 h
ac
M
© 36461-1
130650
Piston ring compressor
Removing and installing the piston rings
© 35443-2
© 06/2006 11/16 8249-001

131200
Base plate
(in connection with assembly tool kit 131210)
Pressing small end bush out and in
© 37616-1
25 .IR
131210
8 Assembly tool kit
46 ft
(in connection with base plate 131200)
9
Pressing small end bush out and in
01 So
12 ine
09 h
ac
M
© 37617-1
142640
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 37618-1
© 06/2006 12/16 8249-001

142650
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 37619-1
25 .IR
143830
Assembly tool 8
46 ft
Removing and installing camshaft bearing
9
01 So
12 ine
09 h
ac
M
© 37621-1
144150
Counter support
Blocking camshaft gear wheel
© 37622-1
© 06/2006 13/16 8249-001

150030
Tool kit
© 40221-0
25 .IR
150120
8 Assembly device
Installing cylinder liner
46 ft
9
01 So
12 ine
09 h
ac
M
© 37624-1
150130
Puller
Removing cylinder liner
© 37625-1
© 06/2006 14/16 8249-001

150800
Slide hammer
© 35449-2
25 .IR
170050
Special wrench 8
Unscrewing the filter cartridges
46 ft
9
01 So
12 ine
09 h
ac
M
© 37629-1
170100
Special wrench
Removing and installing lubricating oil pipe turbocharg-
er
© 37626-1
© 06/2006 15/16 8249-001

170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in
© 37627-1
25 .IR
170160
8 Stoppers/caps
46 ft
1 set of differently-sized stoppers and caps
9
Sealing openings on the fuel system
01 So
12 ine
09 h
ac
M
© 43663-0
© 06/2006 16/16 8249-001

TCD 2015

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TCD 2015

Uploaded by

Copyright:

Available Formats

Workshop Manual

Downloaded from www.Manualslib.com manuals search engine

Regarding copyright questions and licensing agreements

Downloaded from www.Manualslib.com manuals search engine

5 Job card overview

© 06/2006 1/2 8141-001

Downloaded from www.Manualslib.com manuals search engine

© 06/2006 2/2 8141-001

Downloaded from www.Manualslib.com manuals search engine

© 05/2005 1/4 8142-001

Downloaded from www.Manualslib.com manuals search engine

© 05/2005 2/4 8142-001

Downloaded from www.Manualslib.com manuals search engine

the availability of all the necessary equipment,

z Engine parts such as springs, clamps, elastic re-

when handled incorrectly.

© 05/2005 3/4 8142-001

Downloaded from www.Manualslib.com manuals search engine

© 05/2005 4/4 8142-001

Downloaded from www.Manualslib.com manuals search engine

© 11/2005 1/4 8143-001

Downloaded from www.Manualslib.com manuals search engine

© 11/2005 2/4 8143-001

Downloaded from www.Manualslib.com manuals search engine

DEUTZ engines are the product of years of re-

Maintenance and care are the only way the engine

Please consult one of our service representatives

© 11/2005 3/4 8143-001

Downloaded from www.Manualslib.com manuals search engine

© 11/2005 4/4 8143-001

Downloaded from www.Manualslib.com manuals search engine

© 12/2005 1/8 8144-001

Downloaded from www.Manualslib.com manuals search engine

© 12/2005 2/8 8144-001

Downloaded from www.Manualslib.com manuals search engine

3.1 General 3.2 Specifications

The documentation of the workshop manual has

pressure - danger of death.

– Ensure adequate ventilation (do not cover air

© 12/2005 3/8 8144-001

Downloaded from www.Manualslib.com manuals search engine

z Working materials and tools must be cleaned be-

© 12/2005 4/8 8144-001

Downloaded from www.Manualslib.com manuals search engine

Rail System it is recommended to partition off a

vehicle repairs such as brake repairs are carried

z The workshop floor is sealed or tiled.

tools, brakes or performance test benches may

© 12/2005 5/8 8144-001

Downloaded from www.Manualslib.com manuals search engine

3.3 Operation manual and workshop 3.4 Job cards

fied technicians are required. – 03 ... Crankcase

– 06 ... Exhaust system / Charging

– 07 ... Fuel system

– 10 ... Compressed air system

© 12/2005 6/8 8144-001

Downloaded from www.Manualslib.com manuals search engine

3.4.2 Structure of a job card 3.5 Explanation of symbols

46 ft for the work.

(e.g. greases, oils, adhesives, sealants)

4. Job card number or topic For example: Job card W 04-05-05

5. Title of job card Reference

8. Graphic or photo Test and setting data