Professional Documents
Culture Documents
Deutz Workshop Manual TCD 2015
Deutz Workshop Manual TCD 2015
competence level 3
TCD 2015
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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.
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
4.2 Tightening specifications
6 Job cards
7 Commercial tools
8 Special tools
1 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
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
z Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
z Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
z Engine parts such as springs, clamps, elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
z The pertinent rules for the prevention of acci-
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
2 General
3 User notes
3.2 Specifications
3.1 General
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. 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.
– Only deploy trained personnel to do repairs
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-
pressure - danger of death.
nance work.
– Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
– Ensure adequate ventilation (do not cover air
shafts).
– Provide first aid kit and suitable fire extinguish-
ers. Check the filling and readiness for opera-
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.
– 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
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
this room.
– Smoking is strictly prohibited when working on
the fuel system. z Regular cleaning of the workshop area is manda-
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
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 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
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
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.
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-
able bags or - if available - in the packaging of the
new parts.
z Always use the original packaging of the new part
to send back the removed components.
Notes and measures for the vehicle workshop
area
z For work such as removal and installation on de-
fective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
z The workshop floor is sealed or tiled.
z No welding gear, grinders, general machine
tools, brakes or performance test benches may
be operated in this room.
z Regular cleaning of the workshop area is 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
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
12
man or machine.
8
Tool
Conventional and special tools required
for the work.
Auxiliary materials
11 10 9 Working materials required in addition to
the tools for performing the work
1. DEUTZ AG, (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.
4. Job card number or topic For example: Job card W 04-05-05
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.
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
4 Technical data
4.1 Testing and setting data
© 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)
TCD 2015
3/28
P00 03 about all data (Railway)
Height of engine with connection housing
TCD 2015
V08 837 mm
(Railway)
TCD 2015 V06 approx. 1020-1200 kg
TCD 2015 V08 1244 kg
P00 04 Engine weight according to DIN 70020-A without operating media TCD 2015
V06 920 kg
(Railway)
TCD 2015
V08 1160 kg
(Railway)
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
ID no. Name Information Series Value Unit
© 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
(32-34) (bar)
P00 70 Spark gap TCD 2015 V06 120 °
Testing and setting data
4/28
Standard +0.0
P01 01 Valve seat insert, bore (inlet) TCD 2015 47.500 0 mm
fit H6
+0.0
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
+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
+0.0
P01 06 Valve guide, bore in cylinder head 1. oversize level 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
8145-001
ID no. Name Information Series Value Unit
© 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 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
P01 24 Valve seat insert, outside diameter (outlet) 1. oversize level TCD 2015 44.300 +0.06 mm
Valve
+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
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
+0.
P01 35 Valve edge thickness, valve head (inlet) Standard TCD 2015 1.9 -0.2 mm
+0.
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.
P01 38 Valve head diameter (outlet) Standard TCD 2015 42.0 -0.2 mm
Valve seat
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
cylinder head sealing surface)
8145-001
Technical data
Testing and setting data
4
4
ID no. Name Information Series Value Unit
© 06/2006
Standard
(from the center of the valve head to the TCD 2015 2.4 mm
cylinder head sealing surface)
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 clearance
+1
with rotation angle disc 90 °
P01 61 Valve clearance (inlet) with cold engine TCD 2015 +0.
0.25 0 mm
with feeler gauge
+1
with rotation angle disc 108 °
6/28
P01 62 Valve clearance (outlet) with cold engine TCD 2015 +0.
0.30 0 mm
with feeler gauge
Valve overlap according to adjustment
P01 63 Valve clearance setting TCD 2015 T01 63 -
schematic
Rocker arm/bracket
+0.02
P01 72 Rocker arm, bore, diameter (outlet) TCD 2015 28 0 mm
+0.02
P01 73 Rocker arm, bore, diameter (inlet) 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
ID no. Name Information Series Value Unit
© 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
TCD 2015
Main journal
-0.01
P02 03 Main journal, diameter Standard TCD 2015 108 -0.03 mm
Undersize stage
P02 04 Main journal, diameter TCD 2015 0.25 each mm
3 stages
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
Fit journal
+0.06
P02 11 Fit bearing, width Standard TCD 2015 38 mm
+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
Lifting journal
-0.01
P02 22 Lifting journal, diameter TCD 2015 91 -0.03 mm
Undersize stage
P02 23 Lifting journal, diameter TCD 2015 0.25 each mm
3 stages
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
Testing and setting data
4
4
ID no. Name Information Series Value Unit
© 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
P02 36 Thrust ring half, thickness TCD 2015 3.485 mm
(upper and lower half)
2. oversize stage=0.125 mm +0.05
Technical data
8/28
and small end bush
P02 46 Assembly temperature of the small end bush cooled in coolant to TCD 2015 approx. -40 °C
P02 47 Assembly temperature of the connecting rod heated up in hot-air oven to TCD 2015 max. 220 °C
Big end bearing
installed
+0.05
P02 52 Big end bearing shells, inside diameter identification (n) / top TCD 2015 91.048 0 mm
lining spattered
Undersize stage
P02 54 Big end bearing TCD 2015 0.25 each mm
3 stages
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
ID no. Name Information Series Value Unit
© 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
TCD 2015
9/28
on the piston head)
P02 75 Piston projection 1.4 = 1 hole (cylinder head gasket) TCD 2015 -0.05 to 0.10 mm
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
+0.0
P02 78 Piston pin, bore TCD 2015 52 +0.00 mm
Piston rings
Standard 0.35 - 0.45 mm
8145-001
Technical data
Testing and setting data
4
4
ID no. Name Information Series Value Unit
© 06/2006
Standard 0.4 - 0.7 mm
P02 87 Axial clearance, 1st piston ring Wear limit TCD 2015 zoidal groove wear -
gauge
P02 88 Axial clearance, 2nd piston ring Wear limit TCD 2015 0.25 mm
P02 89 Axial clearance, 3rd piston ring Wear limit TCD 2015 0.15 mm
Testing and setting data
Crankcase
Camshaft bearing
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
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
P03 14 Camshaft bearing liner, inside diameter Wear limit TCD 2015 70.100 mm
+0.03
P03 23 Tappet bores, diameter TCD 2015 25.000 0 mm
P03 24 Tappet bores, diameter Wear limit TCD 2015 25.050 mm
+0.2
Installation depth of the crankshaft sealing ring First assembly 0.5 -0.2 mm
P03 25 TCD 2015 +0.2
(rear cover) Repairs 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
8145-001
ID no. Name Information Series Value Unit
© 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 Standard TCD 2015 70 -0.07 mm
TCD 2015
11/28
Tooth edge clearance of the idler gear - idler gear
P04 44 TCD 2015 0.04 - 0.3 mm
to camshaft gear wheel
Speed governing system
Clearance between speed governor (crankshaft) +0.
P05 91 TCD 2015 1.0 mm
and flywheel
Clearance between speed governor (camshaft)
P05 92 TCD 2015 0.3 - 0.9 mm
and camshaft gear wheel
Fuel system
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
Testing and setting data
4
4
ID no. Name Information Series Value Unit
© 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
Cooling system
Coloured marking black
P09 11 Thermostat, start opening (A-bank) TCD 2015 79 °C
venting notch top
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
12/28
Other components
Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device
500 N
rator, 120 Ampere) 8115
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
Tension of the single V-belt (generator, 120 Am- Check after 15 minutes running under +5
350 -50 N
pere) load
P12 21 TCD 2015
Tension of the single V-belt (generator, 55 Ampe- Check after 15 minutes running under +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
T00 81
Cylinder and side view
engine TCD 2015 V08 A4
A3
A2
A1 B4
B3
B2
B1
© 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
T01 63
Setting valve clearance
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
T13 054
Connection plan of the injection pumps
engine TCD 2015 V06
Item Component Cylinder assignment
1 Y15.1 A1
2 Y15.5 A2
3 Y15.3 A3
1 2 3
4 Y15.6 B1
5 Y15.4 B2
6 Y15.2 B3
4 5 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
© 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
TCD 2015
17/28
Oil lightly
A01 002 Rocker arm bracket on cylinder head TCD 2015 61 Nm
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
oil lightly
A01 005 Cylinder head cover on cylinder head hood M8x30 TCD 2015 22 Nm
hexagonal socket
+30°
A02 001 Counterweight on crankshaft oil lightly TCD 2015 50 Nm +60°
+60°
Screws can be used a
max. 3 times, otherwise re- +60°
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-
ID no. Name Screw type Notes / Remarks Series clamping
© 06/2006
ping value
value
Screws can be used a
max. 3 times, otherwise re- +30°
A02 011 Main bearing cover, horizontal screws TCD 2015 80 Nm
new every time they are loo- +30°
sened.
Technical data
18/28
oil lightly TCD 2015 120 Nm
A03 031 Oil drain plug on lubricating oil pan TCD 2015
120 Nm
(Railway)
TCD 2015
A03 034 Half-flange on connecting flange M8x30-10.9 30 Nm
(Railway)
TCD 2015
A03 035 Connecting flange on lubricating oil pan M10x20-10.9 30 Nm
(Railway)
A03 051 Valve housing (pressurestat) on crankcase 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
8145-001
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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°
TCD 2015
19/28
DEUTZ DW 59 +90°
Central screw for camshaft gear wheel on cams-
A04 001 oil lightly TCD 2015 50 Nm +150°
haft
Insert with locking agent
A04 002 Stop cover (camshaft) on crankcase TCD 2015 22 Nm
DEUTZ DW 72
A04 003 Camshaft gear wheel on idler gear oil lightly TCD 2015 30 Nm
A04 004 Gear wheel on camshaft for injection pumps TCD 2015 30 Nm +30°
Fastening screw for diverter
A04 005 Plug of injection pump camshaft on crankcase 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
Tightening specifications
4
4
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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
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
A06 010 Insert with fitting compound TCD 2015
Exhaust manifold to exhaust line 35 Nm
DEUTZ S1 (Railway)
TCD 2015 35 Nm
Insert with fitting compound
A06 020 Exhaust turbocharger to exhaust manifold TCD 2015
Nut DEUTZ S1 10 Nm 35 Nm
(Railway)
Hose clip
housing position of the hose
A06 021 Intake elbow to exhaust turbocharger TCD 2015 5 Nm
clip top
TCD 2015
8145-001
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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 20 Nm
TCD 2015
(Railway)
Joint plate on connecting pipe TCD 2015 57 Nm
A06 034 TCD 2015
Holder on exhaust manifold 20 Nm
(Railway)
A06 038 Screw plug on charge air pipe TCD 2015 34 Nm
Nut 20 Nm
A06 046 Connecting elbow to charge air pipe TCD 2015
Stud 4.5 Nm
21/28
TCD 2015 20 Nm
A06 056 Connecting pipe to holder TCD 2015
20 Nm
(Railway)
A06 058 Retaining plate on genset support TCD 2015 20 Nm
without leak oil
A07 001 Fuel injector on cylinder head Union screw Insert with fitting compound TCD 2015 70 Nm
DEUTZ S1
Nozzle cap
A07 002 Injection nozzle on fuel injector 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
Tightening specifications
4
4
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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 TCD 2015 22 Nm
Bearing housing (fuel supply pump) to genset
A07 024 TCD 2015 42 Nm
support
Tightening specifications
A07 034 Fuel line on fuel supply pump Hollow screw TCD 2015 max.35 Nm
Pipe clamp/holder
Fuel pipe fastening oil thread and head contact TCD 2015 8.5 Nm
A07 044 surface.
TCD 2015
Fuel pipe fastening Pipe clamp 8.5 Nm
(Railway)
22/28
TCD 2015
A07 057 Adapter (flame glow plug) on charge air pipe M45x1.5 SW50 50 Nm
(Railway)
TCD 2015
A07 058 Ground cable on lock nut (flame glow plug) 7.5 Nm
(Railway)
A07 059 Flame glow plug to connecting pipe Lock nut TCD 2015 25 Nm
TCD 2015 42 Nm
Connector (fuel pressure holding valve) to fuel
A07 066 Union nut TCD 2015
pipe 42 Nm
(Railway)
TCD 2015 39 Nm
TCD 2015
8145-001
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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
TCD 2015
23/28
A08 015 Oil suction intake pipe on oil pump TCD 2015
M8x20 22 Nm
(Railway)
TCD 2015 22 Nm
Holder oil suction pipe on retaining plate (main
M8x25 TCD 2015
bearing cover) 22 Nm
(Railway)
A08 016
TCD 2015 22 Nm
Holder on oil suction pipe TCD 2015
M8x16 22 Nm
(Railway)
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
Tightening specifications
4
4
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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 Pipe clamp 20 Nm
(Railway)
A08 050 Oil cooler housing cover on genset support TCD 2015 20 Nm
Tightening specifications
24/28
se
A08 091 Oil pressure pick-up on oil cooler housing M14 x 1.5 TCD 2015 20 Nm
Thermostat housing on crankcase 20 Nm
A09 001 Holder of pipe clamp (fuel TCD 2015
Holder on thermostat housing 20 Nm
pipe)
A09 002 Outlet branch on thermostat housing TCD 2015 20 Nm
A09 010 Coolant pump on genset support 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
8145-001
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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
A12 058 M10x110 oil lightly TCD 2015 30 Nm +120°
pump drive)
TCD 2015
25/28
TCD 2015 39 Nm
A12 082 Oil pressure pipe Union nut TCD 2015
45 Nm
(Railway)
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)
Hollow screw Breather pipe on oil cooler
A12 092 Hollow screw pipe union with ring piece TCD 2015 39 Nm
M14x1.5 cover
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
Tightening specifications
4
4
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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
+60°
M12x22
A13 006 Heat shield (starter) on crankcase TCD 2015 70 Nm
M12x28
Tightening specifications
26/28
TCD 2015 max. 5 Nm
A13 035 Cable to flame glow plug Nut M5 TCD 2015
5 Nm
(Railway)
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
Pressure sensor/temperature transmitter on con-
A13 046 TCD 2015 9 Nm
necting pipe
TCD 2015 1.0 Nm
A13 054 Cable to injection pump TCD 2015
TCD 2015
5 Nm
(Railway)
8145-001
Post-
Pre-clam-
ID no. Name Screw type Notes / Remarks Series clamping
© 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
TCD 2015
27/28
8145-001
Technical data
Tightening specifications
4
Technical data
Tightening specifications TCD 2015
5
5 Job card overview
5.1 Sorted alphabetically
5
5.2 Sorted numerically
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
W 01-02-02 Cylinder head
arm bracket
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
W 01-04-04 Removing and installing the cylinder head Cylinder head
W 01-04-09 Checking piston overhang Cylinder head
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
W 01-06-03 Checking the valve guide Cylinder head
W 01-07-08 Checking the valve lag Cylinder head
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
removed)
Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
installed)
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
W 02-02-04 Drive system
to flywheel)
W 02-03-01 Checking the con rod Drive system
W 02-04-01 Removing and installing the crankshaft Drive system
W 02-09-03 Removing and installing the piston and con rod Drive system
W 02-09-07 Checking the piston Drive system
W 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 02-15-01 Removing and installing the piston cooling nozzle Drive system
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
5
5.3 Job card references
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
Job card Activity and additional job cards necessary for its execution
Setting valve clearance
W 01-01-01
W 04-06-03
Removing and installing the rocker arm and rocker arm bracket
W 01-02-02 W 07-03-01 W 07-03-01
W 01-01-01 W 04-06-03
(A-bank) (B-bank)
Disassembling, assembling and checking the rocker arm and rocker arm bracket
W 01-02-06
W 01-02-02
Removing and installing the cylinder head
W 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
W 07-07-01
(B-bank)
Grinding the cylinder head sealing surface
I 01-04-08
W 01-05-01
Checking piston overhang
W 01-04-09
W 01-04-04 W 04-06-03
Removing and installing the valves
W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
Checking the valve guide
W 01-06-03
W 01-05-01
Renewing valve guide (oversize, pressed version)
I 01-06-04
W 01-05-01 W 01-06-03
Checking the valve lag
W 01-07-08
W 01-04-04
Replacing valve seat insert (oversize)
I 01-07-09
W 01-05-01 W 01-07-08
02 Drive system
Job card Activity and additional job cards necessary for its execution
Checking axial backlash of crankshaft (crankshaft removed)
W 02-01-04
W 02-04-01
Checking axial backlash of crankshaft (crankshaft installed)
W 02-01-04
W 03-08-01 W 03-09-01
Checking the crankshaft
W 02-01-07
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)
W 02-02-04
03 Crankcase
Job card Activity and additional job cards necessary for its execution
Removing and installing crankcase breather (oil separator)
W 03-01-11
03 Crankcase (continuation)
Job card Activity and additional job cards necessary for its execution
Checking the overhang of the cylinder liner
W 03-03-08
W 01-04-04
Removing and installing genset support
W 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
Removing and installing the connection housing
W 03-09-04
W 05-07-01 W 06-01-07 W 12-06-01 W 13-03-02
Repairing the collar rest of the cylinder liner
I 03-10-05
W 03-03-02
Removing and installing, testing camshaft bearing
W 03-11-01
W 04-05-05
04 Engine control
Job card Activity and additional job cards necessary for its execution
Removing and installing tappets, checking tappet bores
W 04-02-02
W 04-05-05
Removing and installing the gearcase cover
W 04-04-09
W 06-06-04
Removing and installing gear case cover
(Railway)
W 04-04-09
W 07-13-01
(Railway)
Removing and installing the camshaft
W 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)
05 Speed governing
Job card Activity and additional job cards necessary for its execution
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
07 Fuel system
Job card Activity and additional job cards necessary for its execution
Removing and installing flame glow plug
W 07-01-02
W 07-01-04
Removing and installing flame glow plug (Railway)
W 07-01-02 W 07-01-04
(Railway)
Removing and installing fuel shut-off valve (flame glow plugs)
W 07-01-03
Removing and installing fuel shut-off valve (flame glow plugs) (Railway)
W 07-01-03
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
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
(cylinder A2-B3)
Removing and installing the fuel injectors
W 07-07-01 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
W 07-07-01 W 07-07-05
Checking and setting fuel injectors
W 07-07-05
W 07-07-01 W 07-07-02
Removing and installing temperature transmitter
W 07-09-01 W 06-07-03
(B-bank)
Removing and installing fuel pipes
W 07-10-06 W 06-07-03 W 06-07-03
(A-bank) (B-bank)
Removing and installing fuel pipes
W 07-10-06 (Railway)
09 Cooling system
Job card Activity and additional job cards necessary for its execution
Removing and installing coolant pump
W 09-07-08
12 Other components
Job card Activity and additional job cards necessary for its execution
Removing and installing torsional vibration damper
5 W 12-01-04
13 Electrical system
Job card Activity and additional job cards necessary for its execution
Removing and installing the cable harness
W 13-01-02
W 06-02-03
Removing and installing the generator (V-belt drive)
W 13-02-03
6 Job cards
6
© 40640-0
© 40643-0
6
© 40641-0
© 40642-0
6
© 40641-0
© 40643-0
© 40640-0
© 40644-1
1 1
© 40645-0
6
© 40652-0
2 2
1 1
2 2
© 40646-1
1
1
© 40651-0
2
6
© 40649-0
© 40653-0
© 40649-0
2 2
6
© 40991-0
2 2
1 1
2 2
© 40646-1
© 40652-0
6
© 40645-0
© 40644-1
1 1
© 40627-0
© 40463-1
6
© 40629-0
IN IN
EX EX
© 40630-0
© 40631-0
P01 61
P01 62
6
© 40632_1
© 40633-0
© 40638_1
6
© 40802-0
© 40803-0
1 1
© 40804-0
Removing and installing the rocker arm and rocker arm bracket
Commercial available tools: – W 01-01-01
– Feeler gauges – W 04-06-03
– W 07-03-01 . . . . . . . . . . . . (A-bank)
– Locking agent – W 07-03-01 . . . . . . . . . . . . (B-bank)
DEUTZ DW 59
W 07-03-01
z Unscrew screws (1).
z Remove cylinder head cowling (2).
z Remove gasket.
1
© 42215-1
© 42217-1
6
© 42219-1
© 34824-2
© 42219-1
6
© 40490-0
© 45805-0
1 1
© 45806-0
6
© 42221-1
© 42222-1
3
© 42216-1
z Tighten screws .
A01 004
z Installing high pressure pipes (A-bank)
W 07-03-01
z Installing high pressure pipes (B-bank)
W 07-03-01
z Remove turning gear.
W 04-06-03
6
© 42223-1
Disassembling, assembling and checking the rocker arm and rocker arm
bracket
Commercial available tools: – W 01-02-02
– Internal measuring device
– Micrometer gauge
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 170120
© 34824-2
© 34768-2
6
© 34825-2
3
2
© 36749-1
© 34827-3
6
© 34828_3
© 34829_3
© 34830-2
2
6
© 36750-1
© 34832_3
© 34833_3
6
© 34834-2
© 36751-1
2 3
© 45385_1
6
© 34837_3
© 39757-1
© 39758-1
6
© 39759-1
© 39760-1
© 39761-1
6
© 39758-1
z Install valves.
W 01-05-01
© 39744-1
© 40578-0
© 42234-1
1
6
© 42235-1
© 45811_0
© 45811_1
6
© 45812_1
© 34976-2
© 40582-0
© 45424-0
© 45763-0
6
© 45766-0
© 37242-0
© 45767-0
P02 75
P02 76
P02 77
z Remove measuring instrument.
6
© 45767-2
© 45424-0
© 42227-1
© 42337-1
6
© 42336-1
© 42335-1
© 35856-2
6
© 42334-1
z Push new valve stem seal onto valve guide over the
assembly sleeve with assembly tool (1).
z Remove assembly sleeve.
© 42332-1
© 42331-1
6
© 42330-1
© 42329-1
© 42182-1
© 42183-1
6
© 42184-1
© 40713-0
© 40714-0
6
© 40715-0
© 40639-0
P01 15
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.
© 39737-1
6
© 39749-1
© 36630-1
6
© 39751-1
z Align bore unit and mandrin guide (1) with the hous-
ing bore.
The housing bores can have different dia-
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-
ble resistance.
1
© 39752-1
© 39753-1
6
© 39750-1
© 39750-1
© 39751-1
6
© 39754-1
© 36636-1
© 39755-1
6
© 39756-1
z Install valves.
W 01-05-01
© 39744-1
© 40650_1
© 42228-1
2
6
© 40650_1
© 40639-0
6
© 39739-1
© 39740-1
© 39741-1
6
© 39742-1
© 36640-1
© 39743-1
6
© 36641-1
© 36620-1
© 39745-1
6
© 39746-1
© 36624-1
© 39747-1
6
© 39748-1
© 36623-1
© 36643-1
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
© 39744-1
z Install valves.
W 01-05-01
z Check valve stand back.
W 01-07-08
© 40639-0
– Micrometer gauge
– Internal measuring device
© 40485-0
© 35825-2
6
© 42324-1
P02 34
With deviating axial backlash:
Set axial backlash by changing the thrust
ring halves. © 40600-0
z Install crankshaft.
W 02-04-01
© 40485-0
© 40479-0
© 40589-0
6
© 40588-0
© 40593-0
© 40594-0
6
© 40595-0
6
© 40596-0
© 40489-0
© 40598-0
6
© 40597-0
© 40599-0
© 40491-0
6
© 40492-0
© 45417-0
© 40479-0
z Remove crankshaft.
W 02-04-01
z Place crankshaft on prism.
© 40485-0
© 40585-0
6
© 40586-0
1
z Mount gear wheel (1).
© 40587-0
1 1
© 40584-0
6
© 34754-2
© 44445-0
© 43515-1
6
© 36424-2
© 42327-1
© 42326-1
6
© 42325-1
© 35825-2
© 42324-1
z Install crankshaft.
W 02-04-01
6
© 40485-0
– Self-tapping screw
– Washer
© 40656-0
© 42091-2
6
© 36764-1
© 40657-0
© 36756-2
6
© 36755-1
© 36757-1
© 36758-1
6 2
© 36759-1
© 36760-1
© 36761-1
6
© 40960-0
– Self-tapping screw
– Washer
© 40659-0
© 40660-0
6
© 40661-0
© 40662-0
© 40663-0
6
© 37153-2
© 37211-1
© 37208-1
6
© 35203-2
© 35204-2
© 35205-2
1
6
© 35206-2
© 35201-3
1
z Tighten all screws (1) alternately.
A12 030
© 40659-0
© 40592-0
© 34768-2
6
© 37239-1
© 34770-2
© 35908-2
© 34771-2
z Tighten screws .
A02 020
© 34772-2
6
© 36094-1
© 37239-1
© 34775-2
6
© 36768-1
© 36769-1
© 34771-2
z Tighten screws .
A02 020
6
© 34778-2
© 36094-1
© 37239-1
6
© 34775-2
© 36424-2
© 45399-0
z Remove screws.
z Remove the con rod bearing cover.
z Remove con rod bearing shells.
© 34778-2
© 35880-2
6
© 35881-2
© 40592-0
© 40404-0
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
z Align the top part (1) of the assembly tool and remov-
al gauge (2).
The top part of the assembly tool and the
removal gauge are level with the angled
surfaces (arrows) of the big end bearing.
© 40401-0
z Screw the top part (1) and bottom part (2) of the as-
sembly tool together.
© 40402-0
6
© 36284-2
© 36285-2
© 40405-0
2
6
© 40406-0
© 36288-3
2
3
© 40407-0
6
© 36290-3
© 40968-1
© 39730-2
Removing crankshaft
z Removing fuel injectors.
W 07-07-01
z Remove genset support.
W 03-08-01
z Remove rear cover.
W 03-09-01
© 40479-0
© 40470-0
6
© 40471-0
© 42140-1
© 40480-0
6
© 40496-0
© 40481-0
Attention!
Do not jam the con rods when turning the
crankshaft.
Do not damage the big end bearing shells.
z Turn the crankshaft with the turning gear evenly.
The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1
© 40482-0
6 1
© 40483-1
1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A
© 42144-1
© 40484-0
6
© 42145-1
© 37041-1
z Check crankshaft.
W 02-01-07
z Check axial backlash of crankshaft (crankshaft re-
moved).
W 02-01-04
© 40485-0
6
© 37042-1
© 37043-1
© 37044-1
6
© 36769-1
© 40488-0
© 37045-1
6
© 40470-0
© 42180-1
© 40489-0
1 - 2724 A
2 - 2724 A
3 - 2724 A
4 - 2724 A
Identifications legible from the flywheel
side.
2 2 2
6
© 42146-2
1
© 42147-1
© 42148-1
6
© 40491-0
© 40492-0
© 37204-1
6
© 42151-1
© 40493-0
© 37055-1
6
© 37056-1
1 1
© 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
1
6
© 42153-1
© 42154-1
© 40471-0
6
© 40470-0
© 40494-0
© 40495-0
© 40873-0
© 40591-0
6
© 42375-1
© 40821-0
© 42376-1
6
© 40592-0
© 42377-1
© 42378-1
1
6
© 40967-0
© 42379-1
Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black 2
anodised rear side (arrow) in the connec-
ting rod.
The anti-rotation lock (1) must lock in
groove (2).
z Insert bearing shell in the con rod.
© 36768-1
6
© 36769-1
© 42380-1
© 36771-1
6
© 36772-1
2
2
© 40964-1
© 42381-1
6
© 42382-1
© 42383-1
© 40591-0
6
© 40873-0
© 42229-1
© 34768-2
6
© 37239-1
© 36484-2
© 37244-1
P02 71
P02 72
P02 73
6
© 40969-0
© 40592-0
© 42323-1
z Clean piston.
z Clean piston ring grooves.
z Visually inspect the components.
© 42322-1
6
© 33866-2
© 33867-2
© 33868-2
6
© 42321-1
© 42320-1
© 42319-1
6
© 42318-1
© 42317-1
© 40592-0
Special tools:
– Tester . . . . . . . . . . . . . . . . . . . . . 102560
– Dipstick . . . . . . . . . . . . . . . . . . . . 102565
© 42353-1
© 42354-1
6
© 40787-0
1
2
© 42356-2
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
6
© 42358-1
© 40992-0
© 40664-0
4
2 3
© 45807-0
6
© 40667-0
© 40668-0
© 40669-0
6
© 45401-0
© 40671-0
© 40670-0
6 2
© 40672-0
© 45807-0
© 45808-0
6
© 40667-0
© 40664-0
© 45423-0
© 36094-1
4
6
© 37238-1
© 40677-0
© 42394-1
6
© 42395-1
– Fitting compound
DEUTZ AP1908
© 40826-0
© 51521-1
6
© 36782-1
© 42230-1
© 40677-0
6
© 42231-1
© 42231-1
© 42392-1
6
© 39911-0
z Coat the cylinder liner in the "X" area with fitting com-
pound.
Make sure that the liner surface and the
crankcase are absolutely clean before
installing the cylinder liner.
© 34932-1
© 39918-0
6
© 42232-1
© 42233-1
© 40583-0
© 45424-0
© 45762-0
6
© 45761-0
© 45424-0
© 40519-0
2 3
© 40520-1
6
© 40521-0
1
3
© 45803_0
© 40531-0
6
© 40532-0
© 40533-0
© 40534-0
6
© 40535-0
© 40536-0
2
1
© 40538-0
6
© 40539-0
© 40540-0
1
2
© 40541-0
6
© 40542-0
© 40543-0
© 40544-0
1 1
6
© 40545-0
© 40546-0
© 40547-0
6
© 40548-0
1
2
© 40541-0
© 40540-0
z Mount holder.
z Fasten all screws (1).
TIghten screws only after mounting the
connecting pipe.
6
© 40539-0
2
1
© 40538-0
© 40551-0
6
© 40549-0
© 40536-0
© 40536-0
6
© 40550-0
z Fix the cable strand with cable tie (1) without tension.
© 40534-0
z Fix the cable strand with cable tie (1) without tension.
© 40533-0
z Fix the cable strand with cable tie (1) without tension.
z Install crankshaft sealing ring (opposite side to fly-
wheel)
W 02-02-04
6
© 40532-0
© 40531-0
1
3
© 45803_0
6
© 40521-0
2 3
© 40520-1
A12 093
z Tighten nut (2).
1
A07 044
© 40565-0
6
© 40555-0
© 40519-0
© 40556-0
3 1
© 40557-0
6
© 40558-0
2
© 45371_1
© 40559-0
3 1
1
6
© 40560_1
© 40561-0
2
2
© 40562_1
1
1
6
© 40563-0
1 1
2 2
© 40564-0
1
1
© 40563-0
2
2
6
© 40562_1
© 40523-0
© 40524-0
6
© 40525-0
3 1
1
© 40560_1
© 40559-0
z Position O-rings.
z Mount adapter (2).
z Tighten nut (1).
A08 002
2
6
© 45371_1
© 40526-0
© 40527-0
6
© 40528-0
© 34738-2
3 1
© 40557-0
6
© 40648-0
© 40529-0
© 40530-0
6
© 40537-0
W 08-04-07
z Unscrew all screws (1).
z Remove rear cover 2.
2
z Remove gasket.
© 40684-0
© 37207-1
6
© 40685-0
© 40686-0
© 40687-0
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
z Tighten screws alternately.
A03 010
2
6
© 40688_1
© 40689-0
© 40655-0
© 40690-0
© 40691-0
6 3
© 40692-0
© 40693-0
© 45394-0
6
© 40899-0
© 42087-1
© 40695-0
z Fasten screws.
1
Insert screws with locking agent.
Note different screw lengths.
M12 x 35 mm (1)
M12 x 90 mm (2). 2
6
© 40694-0
© 40696-0
z Fasten screws.
Insert screws with locking agent.
Note different screw lengths.
M12 x 200 mm (1)
M12 x 175 mm (arrows).
1
z Tighten screws (1) alternately.
A03 088
© 40693-0
6
© 40697-0
© 45409-0
© 40692-0
6
© 40698-0
© 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
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.
© 39914-0
1
© 39902-0
6
© 39908-0
© 39904-0
© 39906-0
Check
z Move the bracket on the griding/surface plate.
B
Spotting side “B“ facing downwards.
6
© 39916-0
© 39906-1
© 39913-0
Grinding
z Move the bracket on the griding/surface plate.
A
Grinding side “A“ faces down.
6
© 39904-0
© 39907-0
© 39906-0
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
Regrinding
z Move the bracket on the griding/surface plate.
A
Grinding side “A“ faces down.
© 39904-0
© 39907-0
6
© 39906-0
© 39914-0
Assembly
z Insert new O-rings (1).
z Coat the O-rings with fitting compound. 1
© 39917-0
6
© 39911-0
© 39918-0
© 42126-1
© 34768-2
6
© 37239-1
© 42127-1
© 34711-2
1 6
© 34712-1
© 34713-2
© 34714-2
6
© 34716-2
© 45415-1
© 37179-1
6
© 34718-2
© 34720-2
© 40900-0
6
© 37180-1
© 37181-1
© 34723-2
6
© 34714-2
© 40901-0
Removing tappets.
z Remove camshaft.
W 04-05-05
z Remove tappets.
Lay out components in the order in which
they should be installed.
Note order of cylinders.
© 37198-1
© 40699-0
6
© 35825-2
© 34707-4
Installing tappets
z Oil all tappets lightly.
z Insert all tappets.
Note the assignment of the tappets.
© 37199-1
© 40700-0
1
2
© 40701-0
6
© 40702-0
© 40703-0
© 40704-0
6
© 40705-0
© 40706-0
© 40707-0
6
© 40708-0
© 40705-0
© 40704-0
6
© 40703-0
© 40702-0
1
2
© 40701-0
6
© 40700-0
© 42108-1
© 45777-0
6
© 45775-0
1
2
© 45776-0
© 42416-2
6
© 40707-0
© 42416-2
1
2
© 45776-0
6
© 45775-0
© 45778-1
© 45779-1
6
© 42108-1
– Packing compound
DEUTZ DW 48
– Locking agent
DEUTZ DW 72 6
© 40409-0
2
z Unscrew hollow screw (1).
z Place fuel hose (2) to one side.
z Remove sealing rings.
© 40458-0
6
© 40410-0
© 40411-1
© 40412-0
6
© 40413-0
1 2
© 40414-0
© 40415-0
6
© 40416-0
© 40417-0
© 40418-0
6
© 40419-0
© 40420-0
© 40421-0
6
© 40422-0
© 40423-0
© 40424-0
6
© 40425-0
© 40426-0
© 40427-0
1
6
© 40428-0
© 40429-0
© 40430-0
z Check camshaft.
W 04-05-06
6
© 36812-1
© 37079-1
© 40431-0
6
© 40429-0
© 40432-0
© 40433-0
6
© 40434-0
P04 37
© 40425-0
6 1
© 40435-0
© 40438-0
© 40437-0
6
© 40423-0
© 40422-0
1
© 40435-0
1
6
© 40436-0
© 40439-0
© 40420-0
6
© 40419-0
© 40440-0
© 40441-0
6
© 40442-0
© 40443-0
© 40444-0
6
© 42289-1
4
6
© 40445-1
© 40446-0
6 1
© 40447-0
Attention!
Make sure no parts fall into the crankcase!
© 40448-0
© 40449-0
6
© 40450-0
z Install crankshaft.
W 02-04-01
Do not install the turbocharger.
© 40503-0
© 40464-0
6
© 40989-0
© 40512-0
© 40513-0
6
© 40514-0
© 40515-0
© 40460-0
6
© 40459-0
2
z Mount gear case cover (1). 2
z Mount holder (2).
1
z Tighten all screws (3) alternately.
A04 020
© 40516-0
© 40456-0
6
© 40455-0
© 40517-0
© 40453-0
6
© 40458-0
© 40518-0
© 36812-1
© 36424-2
6
© 42128-1
© 40601-0
© 40602-1
6
© 40603-0
© 40604-0
© 40605-1
6
© 40601-0
© 40497-0
© 40458-0
6
© 40453-0
© 40517-0
© 40455-0
6
© 40456-0
© 40457-0
© 40459-0
3
2
1
6
© 40460-0
W 04-06-03
© 40417-0
© 40464-0
6
© 40465-0
1
2
© 40466-0
Attention!
Make sure no parts fall into the crankcase!
1 1
© 40590-0
6
© 40467-0
W 02-02-02
z Unscrew screw (1).
© 40419-0
© 40420-0
1
6
© 40421-0
© 40422-0
© 40423-0
6
© 40424-0
© 40468-0
© 40469-1
6
© 40470-0
© 40471-0
© 40472-0
6
© 40473-0
© 40474-0
© 45381-0
6
© 40475-0
© 40476-0
© 40993-0
6
© 40994-0
© 40995-0
Attention!
Do not damage the camshaft and camshaft
bearing!
z Move the injection pump camshaft over the opposite
side to the flywheel.
Use a suitable tool.
© 40996-0
6
© 40475-0
© 40997-0
© 40994-0
6
© 40993-0
4
6
© 40445-1
© 40431-0
6
© 40474-0
© 40473-0
© 40477-0
6
© 40473-0
© 40474-0
© 40478-0
P04 37
© 40468-0
1
© 40435-0
1
6
© 40438-0
© 40437-0
© 40423-0
6
© 40422-0
1
© 40435-0
© 40436-0
1
6
© 40439-0
© 40420-0
© 40419-0
6
© 40440-0
© 40441-0
© 40442-0
6
© 40443-0
© 40444-0
© 40474-0
6
© 40471-0
© 40470-0
© 40446-0
6 1
© 40447-0
© 40498-0
© 40449-0
6
© 40450-0
© 40690-0
Attention!
Make sure no parts fall into the crankcase!
© 40464-0
6
© 40503-0
© 40464-0
© 40989-0
6
© 40512-0
© 40513-0
© 40514-0
6
© 40515-0
© 40460-0
© 40459-0
2
z Mount gear case cover (1). 2
z Mount holder (2).
1
z Tighten all screws (3) alternately.
A04 020
6
© 40516-0
© 40456-0
© 40455-0
2
6
© 40517-0
© 40453-0
© 40458-0
6
© 40518-0
– Locking agent
DEUTZ DW 59
2
1
© 40461-0
1 2
© 40462-0
6
© 40463-0
© 40463-0
© 40461-0
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
– Fitting compound
DEUTZ AP1908
© 40710-0
© 40932-0
6
© 40711-0
© 45879-1
© 45900-0
6
© 45897-0
© 45898-0
6
Dimension (y) = 24.49 mm - 24.00 mm
Result: Dimension (y) = 0.49 mm
© 45878-1
6
© 45882-0
© 40711-0
© 40932-0
W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.
6
© 40710-0
© 40700-0
© 40717-0
6
© 40718-0
© 40719-0
© 40720-0
6
© 00000-0
© 45901-0
© 45897-0
6
© 45898-0
© 45882-0
6
© 45878-2
© 00000-0
© 40720-0
6
© 40719-0
© 40718-0
© 40717-0
6
© 40716-0
– Fitting compound
DEUTZ S1
© 40722-0
© 40723-0
6 2
© 45810-0
© 40725-0
© 40726-0
6
© 45374-0
© 45810-0
© 40986-0
6
© 40722-0
– Fitting compound
DEUTZ S1
© 40727-0
© 45809-0
1
6
© 40730-0
© 40729-0
© 45375-0
6
© 45809-0
© 40985-0
– Fitting compound
DEUTZ S1
© 40733-0
1
z Insert sealing ring.
Note installation position.
The cone (arrow) faces the exhaust pipe.
3
© 36795-1
3
2
6
© 36796-1
© 37216-1
© 40736-0
– Fitting compound
DEUTZ S1
© 40734-0
3
© 36799-1
6 2 3
© 36800-1
© 37218-1
© 40735-0
© 40731-0
© 40732-0
6
© 40732-0
© 40451-0
– Fitting compound
DEUTZ S1
2
© 42079-1
© 42081-2
6
© 42081-2
2
© 42079-1
– Fitting compound
DEUTZ S1
© 42080-1
© 42082-2
6 1
© 42082-2
© 42080-1
– Fitting compound
DEUTZ AP1908
© 40764-0
© 40765-1
6
© 45403-0
© 45403-0
© 40767-0
6
© 40768-1
© 40769-0
© 40737-0
© 40738-0
6
© 40739-0
© 40740-0
© 40741-0
1
1
6
© 40742-0
© 40743-0
© 40744-0
6
© 40745-0
© 40746-0
© 40747-0
6
© 40748-0
© 40747-0
© 40746-0
6
© 40745-0
© 40744-0
© 40743-0
1
1
6
© 40742-0
© 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
6
© 40751-0
© 40752-0
1
© 40950-0
z Mount washer.
z Tighten nut (1).
2
A13 035
6
© 40739-0
© 40738-0
© 40737-0
© 45926-0
© 45907-0
6
© 42025-2
1
1
© 42185-2
© 42192-2
6
© 42186-1
© 42418-1
© 42419-1
6
© 42501-1
1
1
© 45850-0
© 45851-1
6
© 42421-1
z Mount washers.
z Mount holder (1).
z Screw on nuts.
1
1
© 45850-0
1
1
© 45852-1
6
© 42501-1
1
1
© 45852-1
© 42419-1
Attention!
Lay the cables free from chafing and ten-
sion.
z Tighten screw (1).
A13 090
6
© 42418-1
© 42186-1
© 45909-0
Attention!
Note assignment and polarity of the electri-
cal connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Connect plus cable (R3.2) to flame glow plug (2).
z Mount washers. 1
z Screw on nuts.
6
© 45928-0
1
1
© 42185-2
© 45907-0
1
6
© 42423-1
© 45926-0
Special tools:
– Special wrench . . . . . . . . . . . . . . 170100
Collect leaking operating substances in
– Fitting compound suitable vessels and dispose of according
DEUTZ S1 to regulations.
Removing turbocharger
z Remove the charge air pipe.
W 06-02-03
© 40753-0
© 40754-0
6
© 40755-0
© 40756-0
© 40757-0
6
© 40758-0
© 40759-0
© 40760-0
6
© 40761-0
© 40762-0
© 40761-0
6
© 40760-0
© 40759-0
© 40758-0
1
z Insert pipe.
6
© 40757-0
© 45402-0
© 45373-0
6
© 40763-0
© 40753-0
Removing turbocharger
z Unscrew screw (1).
z Loosen pipe clip (2).
2 1
© 42048-1
© 42049-1
6
© 42050-1
2
© 42051-2
© 42052-2
6
© 42053-1
© 42054-1
© 42054-1
6
© 42053-1
© 42052-3
2
© 42051-2
6
© 42050-1
© 42049-1
2 1
© 42048-1
Removing turbocharger
z Unscrew union nuts (1).
z Remove lubricating oil pipe (2).
1
© 42056-1
© 42057-1
6
© 42059-2
1
© 42058-2
© 42055-1
6
© 42054-1
© 42054-1
© 42055-1
6
1
© 42058-2
© 42059-2
© 42057-1
1 6
© 42056-1
© 40552-0
© 40553-0
1 2
6
© 40554-0
2 1
© 40566-0
1 2
© 40567-0
6
© 40568-0
© 40574-0
© 40575-0
6
© 40576-0
© 40553-0
1 1
1 1
© 40577-0
6
© 40554-0
© 40552-0
© 40552-0
© 40569-0
6
© 40570-0
© 40571-0
1
z Turn in all screws (1) a few turns.
Screw length:
M8 x 65 mm
© 40572-0
6
© 40569-0
1
1
1
1
© 40573-0
© 40552-0
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-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
© 40770-0
2 1
6
© 40771-0
© 40772-0
© 45404-0
6
© 40773-0
© 40774-0
z Mount washer.
z Tighten nut (1).
A13 035
© 40775-0
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-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
© 45907-0
6
© 42025-2
1
1
© 42185-2
© 42192-2
2
3
6
© 42187-1
© 42188-1
© 42191-2
6
© 42188-1
© 42191-2
© 42187-2
6
© 45911-0
© 45927-0
Attention!
Note assignment and polarity of the electri-
cal connections!
z Connect plus cable (R3.1) to flame glow plug (1).
z Connect plus cable (R3.2) to flame glow plug (2).
1
© 45928-0
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
© 45907-0
© 40951-0
3
6
© 40776-0
© 40778-0
© 40779-0
A07 068
6
© 40779-0
© 40780-0
© 40781-0
6
© 40782-0
© 45406-0
© 40783-0
6
© 45407-0
Attention!
Install fuel pipes tension free!
© 40784-0
© 40951-0
© 42020-2
6
© 42021-1
© 42022-1
1
2
© 42023-1
6
© 45913-0
1 2
© 45912-0
1
© 42024-1
6
© 42023-2
© 45909-0
© 42023-2
1
6
© 42022-1
© 42021-1
© 42020-2
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing. 6
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
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
© 40785-0
1
1
6
© 45378-0
© 45376-0
© 45377-0
6
© 45376-0
1
1
© 45378-0
© 40785-0
6
© 40952-0
© 40789-0
© 45379-0
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. 6
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
© 42025-1
1
1
6
© 42026-1
1 2
© 42028-1
© 42029-1
6
© 42029-1
1 2
© 42028-1
1
1
© 42026-1
Attention!
Install fuel pipe tension free.
6
© 42027-1
Attention!
Install fuel pipe tension free.
© 42030-1
© 42025-1
1 1
© 40627-0
6
© 40792-0
© 40793-0
© 40796-0
6
© 40793-0
© 40634-0
© 40800-0
6
© 40801-0
© 40792-0
© 40802-0
6
© 40803-0
1 1
© 40804-0
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing. 6
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
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Injection pipes may not be bent.
1
1
© 40791-0
6
© 40794-0
© 40795-0
© 40796-0
6
© 40795-0
© 40634-0
© 40797-0
6
© 40798-0
© 40794-0
© 40635-0
6
© 40636-0
1
1
© 40637-0
© 40552-0
1
6
© 40808-0
© 40520-0
© 40521-0
6
© 40522-0
© 40809-0
© 45386-0
6
© 40810-0
© 40807-0
© 45387-0
6
© 40812-0
© 45390-1
1
© 40813-0
6
© 45388-0
© 45391-0
© 40807-0
6
© 42163-1
© 42164-1
© 42165-2
6
© 40954-0
© 40953-0
© 40809-0
6
© 40522-0
© 40521-0
© 40520-0
A12 093
z Tighten nut (2).
1
A07 044
6
© 40565-0
© 40555-0
© 40808-0
© 40554-0
6
© 45384-0
© 40805-0
© 40806-0
6
© 40807-0
© 40811-0
© 40812-0
6
© 42159-2
© 42160-1
1
© 45389-0
6
© 40814-0
© 40807-0
© 42163-1
6
© 42164-1
© 42165-2
© 45382-0
6
© 45383-0
© 45384-0
1 2
© 40554-0
6
© 40956-0
© 40495-0
6
© 40465-0
1
2
© 40466-0
© 40501-0
6
© 40458-0
© 42163-1
© 42164-1
6
© 40499-0
© 40500-0
© 40502-0
6
© 40503-0
© 40504-0
© 40517-0
6
© 40506-0
© 40456-0
1 2
© 40507-0
6
© 40459-0
3
2
© 40460-0
© 40508-0
6
© 40464-0
© 40501-0
© 40502-0
6
© 40509-0
© 40510-0
© 40511-0
6
© 40464-0
© 40989-0
© 40512-0
6
© 40513-0
© 40514-0
© 40515-0
1
6
© 40460-0
© 40459-0
© 40516-0
6
© 40456-0
© 40455-0
© 40517-0
6
© 40453-0
© 40458-0
© 40518-0
© 40957-0
6
© 40643-0
© 40815-0
© 40958-0
6
© 40816-0
© 43303-0
© 45419-0
6
© 45420-0
© 40607-1
© 45414-0
6
© 40818-0
z Coat the nozzle holder shaft in the (X) area with fit-
ting compound.
z Coat the lay-on surface of the sealing ring (arrow)
with fitting compound.
z Mount new sealing ring (1) on fuel injector. X
1
© 40819-0
© 40820-0
6
© 40643-0
© 40957-0
© 36271-2
© 36269-2
6
© 33904-2
© 33904-2
© 33905-2
6
© 36274-2
© 33907-2
© 33908-2
6
© 33909-2
© 33910-2
© 33911-2
6
© 33912-2
© 45414-0
6
© 36271-2
© 35889-2
© 36293-2
6
© 36293-2
Checking tightness
z Blow the injection nozzle and nozzle holder dry with
air.
z Press the hand lever of the tester down slowly until
about 20 bar below the previously read opening
pressure are reached.
© 36293-2
© 36294-2
6
© 36295-2
© 36296-2
© 36296-2
6
© 36271-2
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-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
© 40822-0
6
© 40823-0
© 40824-0
© 40825-0
6
© 40824-0
© 40823-0
© 40822-0
© 40606-0
6
© 45384-0
© 40608-0
© 40609-0
6
© 40610-0
1 1
© 40611-0
© 40612-0
6
© 40613-0
2 3
© 40623-0
© 40614-0
6
© 40615-0
© 40616-0
© 40617-0
6
© 40618-0
© 40619-0
© 40620-0
6
© 40621-0
Note assignment!
The lug (1) must lock in groove (2).
2 1
© 42115-1
© 40619-0
6
© 40618-0
© 40617-0
© 40622-0
6
© 40616-0
© 40615-0
© 40614-0
6
© 40623-0
A12 093
z Tighten nut (2). 1
A07 044
2
© 40625-0
© 40624-0
6
© 40613-0
z Mount washers.
z Tighten nuts (1).
A13 037
z Tighten nuts (2).
A13 038
© 40612-0
1 1
© 40611-0
6
© 40610-0
© 40609-0
© 40608-0
6
© 45384-0
© 40495-0
z Remove cables.
© 42107-2
6
© 42108-1
© 45854-0
© 42110-1
6
© 42112-1
© 45856-1
© 40620-0
1 1
1 1
6
© 42114-2
Note assignment!
The lug (1) must lock in groove (2).
2 1
© 42115-1
© 45856-1
6
© 42112-1
© 42111-1
1
2
© 45910-2
1
6
© 45854-0
© 42108-1
z Tighten screws .
A13 054
© 45858-0
2
1
© 40827-0
6
© 40828-0
© 40829-0
© 40830-0
6
© 40961-0
© 42286-2
© 40831-0
6
© 40832-0
A08 014
z Tighten hollow screw (1).
A08 013
2
© 40829-0
© 40828-0
2
1
6
© 40827-0
© 40519-0
6
© 40520-0
© 40521-0
© 40522-0
6
© 40948-0
© 40949-0
© 45848-0
6
© 40947-0
© 40949-0
© 40949-0
6
© 40948-1
© 40522-0
© 40521-0
6
© 40520-0
A12 093
z Tighten nut (2).
1
A07 044
© 40565-0
© 40555-0
6
© 40519-0
2
1
© 45925-1
1
6
© 45915-1
© 45916-0
3 1
© 45917-0
6
© 45769-0
© 40947-0
© 45770-0
6
© 45918-0
z Insert connector.
z Screw on lock nut (1).
© 45919-0
© 45920-0
6
© 45921-1
© 45922-1
2
1
© 45925-1
6
© 45924-0
Attention!
Lay the hose pipe free from chafing and 1
tension.
z Tighten hollow screw (2). X
A12 090
1
2
© 45910-0
© 40833-0
2
© 40834-0
6 2
© 40834-0
© 40833-0
© 40835-0
6
© 40962-0
© 45859-0
© 42171-1
6
© 42171-1
© 42170-1
© 42170-1
© 40836-0
© 40836-0
6
© 40837-0
© 40838-0
© 40839-0
1
6
© 40840-0
© 40841-0
© 40842-0
6
© 40843-0
© 40844-0
© 40845-0
6
© 40846-0
© 40839-0
28 25
30 29
27 26
23 19 15 11 7 3 2 6 10 14 18 22
© 45421-1
6
© 40838-0
© 40837-0
© 40848-0
© 42439-1
© 45860-0
6
© 45867-0
2
1
© 42441-1
© 42442-1
6
© 45861-0
© 45868-0
© 45862-0
6
© 45863-0
© 45862-0
© 42445-1
6
© 45864-0
© 43451-0
© 45869-0
6
© 45865-0
© 42447-1
28 25
30 29
27 26
23 19 15 11 7 3 2 6 10 14 18 22
© 45421-1
6
© 37110-1
© 42448-1
© 37112-1
6 2
© 45870-0
© 45871-0
© 45872-0
1 6
© 42442-1
© 40849-0
© 40519-0
1
2
6
© 40850-0
© 40851-0
© 40852-0
1
1
6
© 40853-0
© 40854-0
1 1
© 40855-0
6
© 40856-0
2 2
© 40857-0
1 1
© 40855-0
3 6
© 40858-0
© 40854-0
1
1
© 40853-0
6
© 40852-0
© 40851-0
1
2
© 40850-0
6
© 40519-0
1
z Tighten nut (2).
3
A07 044 2
z Tighten screw (3).
A07 044
© 40859-0
© 40849-0
© 40860-0
© 40861-0
6
© 40862-0
© 40861-0
© 40860-0
Removing pressurestat
z Removing the crankcase breather.
W 03-01-11
z Remove charge air pipe (B-bank).
W 06-07-03
© 40863-0
© 40608-0
6
© 40609-0
© 40864-0
© 40613-0
6
© 40972-0
© 40973-0
© 40865-0
6
© 40866-0
1
X
© 40867-0
© 40868-0
6
© 42460-1
Installing pressurestat
Overhang dimension (X) for basic setting
of adjusting bolt.
If the same oil pressure is to be set again,
the overhang dimension (X) noted before
removal must be reset.
P08 63
© 35022-2
© 40868-0
6
© 40869-0
© 40865-0
© 40973-0
6
© 40972-0
© 40990-0
© 40613-0
6
© 40864-0
© 40609-0
© 40608-0
6
© 40848-0
– Fitting compound
DEUTZ AP1908
© 40870_1
© 45393-0
6
© 40871-0
© 40872-0
z Remove screws.
z Remove the O-ring (1) with the disassembly tool.
z Remove the O-ring (2) with the disassembly tool.
© 36828_1
6
© 40874-0
© 36828_1
© 40876-0
6
© 40877-0
Attention!
Do not damage the gasket.
Do not move gasket.
1
2
© 40875-0
© 40878-0
6
© 40879-0
© 40870_1
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
z Remove thermostats.
W 09-08-02
z Measure beginning of stroke, dimension (a).
z Note measured value, dimension (a).
© 34679-3
6
© 34679-2
z Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Dimension (b) - dimension (a)
Result: = stroke
z Compare result with setpoint value.
P09 13
z Install thermostats.
W 09-08-02
© 34679-1
Removing thermostats
z Remove thermostat housing.
W 09-08-04 2
© 40880_1
© 40881-0
6
© 40882-0
Installing thermostats
z Select thermostats.
1
z Coat the sealing rings with fitting compound.
z Fit new sealing rings (1).
Note different opening
temperatures (arrows) of the thermostats.
P09 11
P09 12
© 40883-0
© 40884_2
6
© 40880_1
© 40885-0
© 40886-0
6
© 40887-0
© 40888-0
© 40889-0
6
© 40890-0
© 40891-0
© 40892-0
6
© 40893-0
© 40892-0
z Fasten screws.
Note different screw lengths.
M8 x 90 mm (1)
M8 x 65 mm (2)
2 1 2
© 40894-0
6
© 40890-0
2 1 2
© 40894-0
© 40889-0
6
© 40888-0
© 45406-0
© 40888-0
6
© 40887-0
© 40886-0
© 40956-0
© 40895-0
© 40896-0
6
© 44084-0
© 40896-0
© 40895-0
© 40965-0
© 40897-0
6
© 40898-0
© 40897-0
© 40965-0
Removing flywheel
z Unscrew all screws (1).
Block flywheel with suitable tool.
1
z Remove thrust washer (2).
2
© 40902_1
© 34985-2
6
© 40903-0
Install flywheel
z Position friction disc.
Make sure the clamping bushing (1) is in
place.
z Mount flywheel.
Make sure the clamping bushing and loca-
1
ting hole are in line.
© 40966-0
© 40658_1
Danger!
Danger of injury, do not touch hot parts!
© 40904-0
© 34764-2
6
© 34765-2
© 40905-0
© 40906-0
z Install flywheel.
W 12-06-01
6
© 40907-0
Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901
Collect leaking operating substances in
– Fitting compound suitable vessels and dispose of according
DEUTZ AP1908 to regulations.
– Locking agent
DEUTZ DW 59
© 40908-0
1
2
© 40909-0
6
© 40910-0
© 42200-2
© 42200-2
6
© 40913-0
© 40914-0
© 45409-0
6
© 40915-0
© 45395-0
© 40908-0
Attention!
Note assignment and polarity of the electri-
cal connections!
© 40916-0
© 40917-0
6
© 40534-0
© 40918-0
© 40919-0
6
© 40920-0
© 40921-0
© 40922-0
6
© 40923-0
© 40924-0
© 40925-0
6
© 40926-0
1 1 1
© 40927-0
© 40928-0
6
© 40929-0
© 40930-0
© 40931-0
6
© 40933-0
© 40934-0
© 40935-0
6
© 40936-0
© 40943-0
© 40532-0
6
© 40937-0
© 40938-0
© 40939-0
z Unlock central plug (1) (arrow) and pull off from hold-
er.
6
© 40940-0
© 40941-0
© 40942-0
z Push the central plug onto the holder until it snaps in.
z Tighten screw (1).
A12 095
6
© 40939-0
z Tighten screws .
A13 090
Screw length:
M8 x 20 mm (1) 2
M8 x 16 mm (2)
© 40987-0
© 40937-0
6
© 40532-0
© 40943-0
© 40936-0
6
© 40935-0
© 40934-0
© 40933-0
6
© 40935-0
© 40931-0
z Mount washer.
z Tighten nut (1).
A13 035
© 40930-0
6
© 40929-0
z Plug cables.
Attention!
Note assignment and polarity of the electri- 1
cal connections!
z Mount washers.
z Tighten nuts (1).
A13 037
2
z Tighten nuts (2).
A13 038
© 40928-0
1 1 1
© 40927-0
6
© 40926-0
© 40925-0
© 40924-0
6
© 40923-0
© 40922-0
© 40921-0
z Mount washer.
z Tighten nut (1).
2
A13 035
6
© 40920-0
© 40919-0
© 40918-0
6
© 40534-0
z Connect cables.
z Connect the battery's negative terminal.
© 40917-0
© 40956-0
3
© 45411-0
© 40975-0
6
© 40976-0
© 45412-0
© 40978-1
2 6
© 40979-0
© 40980-0
© 40988-1
6
© 45396-0
© 40978-0
2 1
© 40977-1
6
© 39582_2
© 40981-0
© 40982-0
6
© 45413-0
© 40983-0
© 40984-0
3 6
© 45411-0
– Fitting compound
DEUTZ AP1908
© 40917-0
© 40944-1
6
© 40945-0
© 42096-1
z Insert starter.
z Tighten nuts (1).
A13 001
© 40944-1
z Connect cables.
z Connect the battery's negative terminal.
6
© 40917-0
– Fitting compound
DEUTZ AP1908
© 40919-0
© 40946-0
6
© 42002-2
© 40946-0
© 40919-0
7 Standard tools
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
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 35410-2
7
8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles
© 35411-2
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
© 39426-1
8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.
© 37503-1
7
8016
Socket wrench insert
SW 17, reinforced
Unscrew and tighten flywheel screws.
© 37504-1
8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.
© 37506-1
8024
Assembly pliers
e. g. removing valve stem seals
© 37509-4
7
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 35416-3
8198
Pricker
Removing rotary shaft lip seal
© 43206-3
8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
© 42528-1
7
8191
Socket wrench insert
with slotted screwdriver insert (8x1.6)
(e. g. setting valve clearance)
© 43060-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
© 43197-0
9017
Assembly lever
e. g. removing and installing valves
© 37511-1
8 Special tools
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
6066
Assembly block
Engine clamping, double-sidedmaximum load capacity
at middle centre of gravity approx. 1200 kg
© 35451-2
6066/151
Clamping bracket 8
(in conjunction with assembly block 6066)
Engine clamping, double-sided
© 37601-1
100130
Connector
(in conjunction with compression pressure tester 8005)
© 37602-1
100300
Turning gear
with mechanical TDC transmitter and degree scale for
start of pumping check
Turn crankshaft,
block engine
© 37603-1
100350
8 Turning gear
Turn crankshaft on the V-belt pulley.
© 37604-1
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
© 37605-1
100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
© 43205-0
100850
Measuring instrument with measuring plate 8
Checking piston overhang
© 37606-1
101830
Dial gauge adapter
Measuring installation depth for impulse transmitter
© 45906-0
102560
Tester
Basic device with two dipsticks
Check radiation position of the piston cooling nozzle
(old version)
© 37608-1
102565
8 Dipstick
(in connection with tester 102560)
Check radiation position of the piston cooling nozzle
(new version)
© 37628-1
103240
Dial gauge holder
with stylus extension (diameter 5/95 mm)
Checking plunger lift of injection pumps
© 43927-3
110030
Puller
(in connection with sliding hammer 150800)
Removing fuel injector
© 35433-2
110110
Holder 8
SW11,
Clamp fuel injector in the vice
© 35434-2
110130
Slotted nut wrench
Unscrew and tighten union screw on the fuel injector.
© 37610-1
110500
Special wrench
Size 17
Removing and installing injection pipes
© 35436-1
110510
8 Special wrench
Removing and installing charge air pipe
© 43928-3
110700
Socket wrench insert
Size 27
long
Removing and installing oil pressure transmitter
© 42341-2
110901
Disassembly tool
Removing O-ring
© 45950-1
120660
Puller 8
(in connection with sliding hammer 150800)
Removing jammed fuel injector sealing ring
© 45421-0
120900
Support bracket
pivoting
Clamping cylinder head
© 35438-2
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
© 35439-2
121410
8 Assembly tool
Assembling valve stem gasket
© 37614-1
121420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
© 43210-0
130300
Universal piston ring pliers
Removing and installing the piston rings
© 35441-2
130400
Trapezoidal groove wear gauge 8
Testing piston ring groove
© 36461-1
130650
Piston ring compressor
Removing and installing the piston rings
© 35443-2
131200
Base plate
(in connection with assembly tool kit 131210)
Pressing small end bush out and in
© 37616-1
131210
8 Assembly tool kit
(in connection with base plate 131200)
Pressing small end bush out and in
© 37617-1
142640
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 37618-1
142650
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 37619-1
143830
Assembly tool 8
Removing and installing camshaft bearing
© 37621-1
144150
Counter support
Blocking camshaft gear wheel
© 37622-1
150030
Tool kit
Repairing the collar rest of the cylinder liner
© 40221-0
150120
8 Assembly device
Installing cylinder liner
© 37624-1
150130
Puller
Removing cylinder liner
© 37625-1
150800
Slide hammer
Removing fuel injector
© 35449-2
170050
Special wrench 8
Unscrewing the filter cartridges
© 37629-1
170100
Special wrench
Removing and installing lubricating oil pipe turbocharg-
er
© 37626-1
170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in
© 37627-1
170160
8 Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0