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DEUTZ TCD WH 2015
Citation preview
Workshop Manual
TCD 2015
0312 3514 en
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.
This d
ocum
ent is
copy
right
prote
cted.
Distr
ibutio
n in e
ither
edor
elect
ronic
form
is not
allow
ed w
ithou
t our
prior
agree
ment.
competence level 3
.
The engine company.
DEUTZ AGService Information SystemsOttostrae 1D-51149 Kln (Cologne)Phone.: +49 (0) 221-822-0Fax: +49 (0) 221-822-5850Internet: www.deutz.comE-Mail: [email protected]
Printed in GermanyAll rights reserved1st Edition, 06/2007Order No. 0312 3514 en
Regarding copyright questions and licensing agreements please contact : VS-DI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: [email protected]
Table of contentsTCD 20151 Foreword
2 General
3 User notes3.1 General3.2 Specifications3.2.1 Safety regulations and rules for the prevention of accidents3.2.2 Disposal regulations3.3 Operating manual and workshop manual3.4 Job cards3.5 Explanation of symbols
4 Technical data4.1 Testing and setting data4.2 Tightening specifications
5 Job card overview5.1 Sorted alphabetically5.2 Sorted numerically5.3 Job card references
6 Job cards
7 Commercial tools
8 Special tools 06/2006 8141-0011/2
TCD 2015Table of contents 06/2006 8141-0012/2
1
ForewordDEUTZ engines1 Foreword 05/2005 8142-0011/4
1
DEUTZ enginesForeword 05/2005 8142-0012/4
1
ForewordDEUTZ engines Read and observe the information in this docu-mentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.
This engine is built exclusively for purpose ac-cording to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is con-sidered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk.
Use for the intended purpose also includes ob-servance of the operating, maintenance and re-pair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with this and are aware of the risks involved.
Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents.
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.
Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and their perfect condition.
Engine parts such as springs, clamps, elastic re-taining rings etc. pose an increased risk of injury when handled incorrectly.
The pertinent rules for the prevention of acci-dents and other generally recognised health and safety regulations must be observed.
Maximum economy, reliability and long life is only guaranteed when using DEUTZ original parts.
Repair of the engine must correspond to its use for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorised mod-ifications to the engine exclude manufacturer lia-bility for resulting damages. Failure to observe this will void the warranty!
The engines made by DEUTZ are developed for a wide range of applications. A wide range of var-iants ensures that the respective special require-ments are met.
The engine is equipped according to the installa-tion case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily.
We have done our best to highlight the differenc-es so that you can easily find the operating, main-tenance and repair instructions relevant to your engine.
We are at your service for any questions you may have in this matter.
Your DEUTZ AG 05/2005 8142-0013/4
1
DEUTZ enginesForeword 05/2005 8142-0014/4
2
GeneralDEUTZ engines2 General 11/2005 8143-0011/4
2
DEUTZ enginesGeneral 11/2005 8143-0012/4
2
GeneralDEUTZ enginesDEUTZ 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 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 responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast and professional repairs using original DEUTZ spare parts in the event of damage.Original spare parts from DEUTZ AG are always manufactured according to the state of the art. 11/2005 8143-0013/4
2
DEUTZ enginesGeneral 11/2005 8143-0014/4
3
User notes3 User notes 12/2005 8144-0011/8
3
User notes 12/2005 8144-0012/8
3
User notes3.1 General
The documentation of the workshop manual has been created based on the engine available at the time of going to press.There may be deviations in the descriptions, illustra-tions and parts due to further developments.
The maintenance work described in the operation manual and in the workshop manual must be carried out on schedule and completely. The maintenance personnel must have the necessary technical knowledge to perform the work. Safety and protec-tion devices which are removed during maintenance work must be replaced again afterwards.
Caution!
The rules for the prevention of accidents and the safety regulations must be observed during mainte-nance work.
Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.
The maintenance intervals and the work to be per-formed are specified in the maintenance schedule of the operation manual. The job cards contain tech-nical documentation on the execution of mainte-nance work.
3.2 Specifications
3.2.1 Accident prevention and safety regu-lations
The legally prescribed rules for the prevention of ac-cidents must be observed. These are available from professional associations or from dealers. These are dependent on the application site, operating mode and the operating and auxiliary materials be-ing used.
Special protection measures are specified depend-ing on the work being carried out, and are identified in the job description.
Among other things it generally applies that:
for the personnel:
Only briefed personnel may operate or main-tain the engine. Unauthorised persons are prohibited access to the machine room.
Wear close-fitting clothing and ear protectors in the machine room when the engine is in op-eration.
Only deploy trained personnel to do repairs and maintenance work.
Do not work on the fuel system when the en-gine is running. The fuel system is under high pressure - danger of death.
Go to the workshop immediately in case of leaks in the fuel system.
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.
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 8144-0013/8
3
User notes Damaged injection lines and high-pressure pipes must be renewed.
Injection lines and high pressure fuel lines must never be connected when the engine is running.
Do not place hands near to a leak in the high pressure fuel system.
Also carefully check all high pressure compo-nents visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel.
Even if no leaks are discernible on the high pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as pro-tective glasses) when performing tests on the running engine and during the first trial run.
Always stay out of range of a fuel jet, as it could cause severe injury.
Smoking is strictly prohibited when working on the fuel system.
Do not work near to sparks and flames.
Never disconnect an injector when the engine is running.
3.2.2 Cleanliness instructions and meas-ures for handling the DEUTZ Com-mon Rail System
The DEUTZ Common Rail system used in the DEUTZ engines consists of high-precision compo-nents which are exposed to extreme stress. Great attention must be paid to cleanliness when working on the fuel system due to the high precision technol-ogy.
Notes and measures to be observed before starting work on the fuel system
The fuel system must be closed. Make a visual inspection for leaks / damage to the fuel system.
Clean the whole engine and engine room with the system closed before starting work on the fuel system.
The engine must be dry when you start working on the fuel system.
Blowing (dry) with compressed air is only permis-sible with the fuel system closed.
When using a steam jet, first cover up the control unit, the cable plugs, all other electrical plug con-nections and the generator. Also, the steam jet may not be pointed directly at them.
Electrical plug connections must be plugged when spraying.
Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel sys-tem.
Only work on the fuel system in a clean environ-ment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regu-larly. No brake or performance test benches may be kept or operated in the same room.
Air currents which kick up dust, such as those caused by brake repairs or the starting of en-gines, should be avoided.
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.
No general machine tools may be operated in this room.
Regular cleaning of the workshop area is manda-tory. Draughts, ventilation systems and heating fans should be minimised.
Areas of the engine room from which particles of dirt could be loosened (for example the bottom part of the tipped driver cab) must be covered with fresh clean film.
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.
Notes and measures to be observed during work on the fuel system or with the fuel system open.
Only work in clean overalls.
Only lint-free cleaning cloths may be used for work on the fuel system.
Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel sys-tem.
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.
Do not use used cleaning fluid or test fluid for cleaning.
Compressed air must not be used for cleaning on the open fuel system.
Work on removed components may only be per-formed at a suitably equipped workbench. 12/2005 8144-0014/8
3
User notes When removing and installing components, no materials which can leave behind particles or fi-bres (cardboard, wood, cloths) may be used.
Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.
Openings on the components and on the engine must be closed immediately with suitable stop-pers/caps.
The stoppers/caps may only be removed imme-diately before installing.
Store stoppers/caps free from dust and dirt in the original packaging and dispose of after using once.
Only remove new parts from the original packag-ing just before installation.
Removed components must be kept in new, seal-able bags or - if available - in the packaging of the new parts.
Always use the original packaging of the new part to send back the removed components.
Notes and measures for the vehicle workshop area
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.
The workshop floor is sealed or tiled.
No welding gear, grinders, general machine tools, brakes or performance test benches may be operated in this room.
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
A special workbench must be set up for work on removed components.
Clean the removal and installation tools regularly and keep them in a closed tool cabinet.
Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device.
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
operating materials among other things. The re-newed parts / operating materials must be stored, transported and disposed of according to regula-tions. The owner himself is responsible for this.
Disposal includes recycling and the scrapping of parts / operating materials, although recycling has priority.
Details of disposal and their monitoring are gov-erned by regional, national and international laws and directives which the system operator must ob-serve on his own responsibility. 12/2005 8144-0015/8
3
User notes3.3 Operation manual and workshop manual
To structure the information to suit the user, the service documentation is divided into operation manual and workshop manual.
The operation manual contains a general descrip-tion and instructions for all other maintenance work.
It contains the following chapters:
1. Contents, General
2. Engine description
3. Operation
4. Operating media
5. Maintenance
6. Care and maintenance work
7. Faults, causes and remedies
8. Engine conservation
9. Technical data
10.Service
The workshop manual assumes knowledge of the contents of the operation manual. This applies es-pecially for the safety regulations. The workshop manual describes repairs to the engine and compo-nents for which more effort and appropriately quali-fied technicians are required.
3.4 Job cards
The job cards are divided in the workshop manual into "W" and "I" job cards. The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card.The "I" job card additionally documents the appro-priate work procedures for repairing the engine and/or its components. The workshop must satisfy spe-cial conditions to perform these work procedures. Special tools and machine tools must be available, for example.
3.4.1 Numbering of job cards
The job card numbers follow the pattern W 02-04-01. The individual parts of this pattern are explained below:
W 02-04-01: Documentation type
W.... Workshop manual
I ...... Repair instructions
W 02-04-01: Maintenance group
00 ... General / interdisciplinary activities
01 ... Cylinder head
02 ... Drive system
03 ... Crankcase
04 ... Engine control system
05 ... Speed governing
06 ... Exhaust system / Charging
07 ... Fuel system
08 ... Lube oil system
09 ... Cooling system
10 ... Compressed air system
11 ... Monitoring system
12 ... Other components
13 ... Electrical system
W 02-04-01: Component grouping
W 02-04-01: Consecutive number 12/2005 8144-0016/8
3
User notes3.4.2 Structure of a job card
1. DEUTZ AG, publisher of service documentation
2. Engine type (e.g. TCD 2013 4V)
3. Maintenance group
4. Job card number or topic
5. Title of job card
6. Reference to other job cards
7. Chapter
8. Graphic or photo
9. DEUTZ internal creation number
10.Page number
11.Date of issue of job card
12.Note
13.Danger / Important
14.Work sequence
15.Special tools; auxiliary materials
16.Conventional tools
3.5 Explanation of symbols
Triebwerk
W 02-04-01
6
16
12
4
6
1 2 3
8
1011
5
7
5
9
13
14
15
8
Danger!of death or to health. Must be observed! For example: The incorrect use or con-version of the turbocharger can lead to serious injury.
Caution!Danger to the component/engine. Non-compliance can lead to destruction of the component/engine.Must be observed!
NoteGeneral notes on assembly, environmen-tal protection etc. No potential danger for man or machine.
ToolConventional and special tools required for the work.
Auxiliary materialsWorking materials required in addition to the tools for performing the work(e.g. greases, oils, adhesives, sealants)
Referencesto important documents or job cards for the work process. For example: Job card W 04-05-05
Referenceto a document or a job card within the work process.
Test and setting dataThe necessary values are specified here.If several values are necessary, a cross reference is given to the Test and Setting Values table. For example: ID no. P01 61 = valve clearance, inlet
Tightening specificationThe necessary values are specified here.If several values are necessary, a cross reference is given to the Tightening Spe-cifications table. For example: ID no. A01 001 = cylinder head screws 12/2005 8144-0017/8
3
User notes 12/2005 8144-0018/8
4
Technical dataTCD 20154 Technical data
4.1 Testing and setting data 06/2006 8145-0011/28
4
TCD 2015Technical dataTesting and setting data 06/2006 8145-0012/28
4
TCD 2015Technical data
Testing and setting data
ID
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06/2006 8145-0013/28
4
TCD 2015Technical dataTesting and setting dataP00
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06/2006 8145-0014/28
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TCD 2015Technical data
Testing and setting dataP01
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it(f
rom
the
cent
er o
f the
val
ve h
ead
to th
e cy
linde
r he
ad s
ealin
g su
rfac
e)T
CD
201
51.
20 -
1.6
0m
m
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
+0.
00 +
0.0
0 +0.
07+
0.06
+0.
07+
0.06 +0.
07+
0.06
+0.
07+
0.06
+0.
00-0
.00
+0.
00-0
.00
+0.
-0.2
+0.
-0.2 +0.
-0.2
+0.
-0.2 06/2006 8145-0015/28
4
TCD 2015Technical dataTesting and setting dataP01
46
Val
ve s
tand
bac
k di
men
sion
(ou
tlet)
Sta
ndar
d(f
rom
the
cent
er o
f the
val
ve h
ead
to th
e cy
linde
r he
ad s
ealin
g su
rfac
e)T
CD
201
52.
4m
m
Wea
r lim
it(f
rom
the
cent
er o
f the
val
ve h
ead
to th
e cy
linde
r he
ad s
ealin
g su
rfac
e)T
CD
201
51.
25 -
1.6
5m
m
Val
ve s
prin
g
P01
51
Val
ve s
prin
g le
ngth
unte
nsio
ned,
nor
mal
TC
D 2
015
58.7
mm
Val
ve s
prin
g w
ire d
iam
eter
4.25
Val
ve c
lear
ance
P01
61
Val
ve c
lear
ance
(in
let)
with
rot
atio
n an
gle
disc
TC
D 2
015
90
with
col
d en
gine
with
feel
er g
auge
0.25
m
m
P01
62
Val
ve c
lear
ance
(ou
tlet)
with
rot
atio
n an
gle
disc
TC
D 2
015
108
with
col
d en
gine
with
feel
er g
auge
0.30
m
m
P01
63
Val
ve c
lear
ance
set
ting
Val
ve o
verla
p ac
cord
ing
to a
djus
tmen
t sc
hem
atic
TC
D 2
015
T01
63
-
Roc
ker
arm
/bra
cket
P01
72
Roc
ker
arm
, bor
e, d
iam
eter
(ou
tlet)
TC
D 2
015
28
mm
P01
73
Roc
ker
arm
, bor
e, d
iam
eter
(in
let)
TC
D 2
015
28
mm
P01
74
Roc
ker
arm
sha
ft (d
iam
eter
)T
CD
201
528
m
m
P01
75
Axi
al c
lear
ance
of t
he to
ggle
leve
rsA
xial
bea
ring
clea
ranc
e w
ith c
old
engi
neT
CD
201
50.
2 -
0.4
mm
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
+1 +
0.0 +1 +0.
0
+0.
020 +
0.02
0 - 0.0
4-0
.06
06/2006 8145-0016/28
4
TCD 2015Technical data
Testing and setting dataP01
93
Rou
ghne
ss
Sur
face
for
cylin
der
head
gas
ket
TC
D 2
015
10R
z
20[R
max
]
Sur
face
for
cylin
der
head
cov
erT
CD
201
516
Rz
20[R
max
]
Mai
n ru
nnin
g ge
ar
Cra
nksh
aft
Mai
n jo
urna
l
P02
03
Mai
n jo
urna
l, di
amet
erS
tand
ard
TC
D 2
015
108
mm
P02
04
Mai
n jo
urna
l, di
amet
erU
nder
size
sta
ge3
stag
esT
CD
201
50.
25 e
ach
mm
P02
06
Mai
n jo
urna
l, un
roun
dnes
sW
ear
limit
TC
D 2
015
0.01
0m
m
P02
07
Mai
n jo
urna
l, ha
rdne
ssS
tand
ard
TC
D 2
015
50
HR
C
Fit
jour
nal
P02
11
Fit
bear
ing,
wid
thS
tand
ard
TC
D 2
015
38
mm
P02
12
Fit
bear
ing,
wid
thO
vers
ize
stag
eT
CD
201
538
.25
mm
P02
13
Fit
bear
ing,
wid
thLi
mit
valu
e fo
r ov
ersi
ze s
tage
TC
D 2
015
38.5
0 m
m
Lifti
ng jo
urna
l
P02
22
Lifti
ng jo
urna
l, di
amet
erT
CD
201
591
m
m
P02
23
Lifti
ng jo
urna
l, di
amet
erU
nder
size
sta
ge3
stag
esT
CD
201
50.
25 e
ach
mm
P02
25
Lifti
ng jo
urna
l, un
roun
dnes
sW
ear
limit
TC
D 2
015
0.01
0m
m
P02
26
Rad
ial r
un-o
ut, c
rank
shaf
tm
axim
um p
erm
issi
ble
devi
atio
nT
CD
201
50.
15m
m
Mai
n be
arin
g
P02
34
Axi
al c
lear
ance
of c
rank
shaf
tpe
rmis
sibl
e T
CD
201
50.
205
- 0.
392
mm
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
-0.0
1-0
.03
+6
0 +0.
06 +0.
06
+0.
06
-0.0
1-0
.03
06/2006 8145-0017/28
4
TCD 2015Technical dataTesting and setting dataP02
35
Thr
ust r
ing
half,
thic
knes
sS
tand
ard
(upp
er a
nd lo
wer
hal
f)T
CD
201
53.
36
mm
P02
36
Thr
ust r
ing
half,
thic
knes
s1.
ove
rsiz
e st
age=
0.12
5 m
m(u
pper
and
low
er h
alf)
TC
D 2
015
3.48
5 m
m
P02
37
Thr
ust r
ing
half,
thic
knes
s2.
ove
rsiz
e st
age=
0.12
5 m
m(u
pper
and
low
er h
alf)
TC
D 2
015
3.61
0 m
m
Con
nect
ing
rod
P02
41
Par
alle
lism
of t
he c
onne
ctin
g ro
dP
erm
issi
ble
devi
atio
n (a
)T
CD
201
5m
ax. 0
.06
mm
at a
dis
tanc
e of
(x)
10
0m
m
P02
42
Tap
er o
n pe
riphe
ry o
f the
con
nect
ing
rod
Per
mis
sibl
e de
viat
ion
(A)
to (
B)
TC
D 2
015
max
. 0.1
0m
m
at a
dis
tanc
e of
(x)
10
0m
m
P02
43
Sm
all e
nd b
ush,
insi
de d
iam
eter
inst
alle
d, u
nmac
hine
dT
CD
201
552
.040
m
m
P02
45
Sm
all e
nd b
ush
clea
ranc
e be
twee
n pi
ston
pin
an
d sm
all e
nd b
ush
TC
D 2
015
0.04
- 0
.063
mm
P02
46
Ass
embl
y te
mpe
ratu
re o
f the
sm
all e
nd b
ush
cool
ed in
coo
lant
toT
CD
201
5ap
prox
. -40
C
P02
47
Ass
embl
y te
mpe
ratu
re o
f the
con
nect
ing
rod
heat
ed u
p in
hot
-air
oven
toT
CD
201
5m
ax. 2
20C
Big
end
bea
ring
P02
52
Big
end
bea
ring
shel
ls, i
nsid
e di
amet
erin
stal
led
iden
tific
atio
n (n
) / t
oplin
ing
spat
tere
dT
CD
201
591
.048
m
m
P02
54
Big
end
bea
ring
Und
ersi
ze s
tage
3 st
ages
TC
D 2
015
0.25
eac
hm
m
P02
55
Big
end
bea
ring,
bor
e in
con
nect
ing
rod
afte
r sep
arat
ion
and
re-a
ssem
bly
of ro
d an
d co
ver
TC
D 2
015
95
mm
P02
56
The
oret
ical
cle
aran
ce b
etw
een
the
big
end
bea-
ring
/ lift
ing
jour
nal
TC
D 2
015
0.06
0 -
0.13
6m
m
P02
57
Big
end
bea
ring
clea
ranc
eW
ear
limit
TC
D 2
015
0.17
mm
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
+0.
05
+0.
05
+0.
05
+0.
00 +
0.05
0
+0.
03-0
.00
06/2006 8145-0018/28
4
TCD 2015Technical data
Testing and setting dataPis
ton
pin
P02
61
Pis
ton
pin,
dia
met
erT
CD
201
551
.992
- 5
2.00
0m
m
P02
62
Pis
ton
pin
clea
ranc
eW
ear
limit
TC
D 2
015
0.09
mm
Pis
ton
P02
71
Pis
ton,
dia
met
er
Mea
surin
g po
int 1
at h
eigh
t 22.
5 m
m(I
dent
ifica
tion
of th
e in
stal
latio
n po
sitio
n on
the
pist
on h
ead)
TC
D 2
015
132
mm
P02
72
Pis
ton,
dia
met
er
Mea
surin
g po
int 2
at h
eigh
t 87.
5 m
m(I
dent
ifica
tion
of th
e in
stal
latio
n po
sitio
n on
the
pist
on h
ead)
TC
D 2
015
132
mm
P02
73
Pis
ton,
dia
met
er
Mea
surin
g po
int 3
at h
eigh
t 122
.7 m
m(I
dent
ifica
tion
of th
e in
stal
latio
n po
sitio
n on
the
pist
on h
ead)
TC
D 2
015
132
mm
P02
75
Pis
ton
proj
ectio
n1.
4 =
1 ho
le (
cylin
der
head
gas
ket)
TC
D 2
015
-0.0
5 to
0.1
0m
m
P02
76
Pis
ton
proj
ectio
n1.
6 =
2 h
oles
(cy
linde
r he
ad g
aske
t)T
CD
201
50.
10 to
0.3
0m
m
P02
77
Pis
ton
proj
ectio
n1.
8 =
3 h
oles
(cy
linde
r he
ad g
aske
t)T
CD
201
50.
30 to
0.5
1m
m
P02
78
Pis
ton
pin,
bor
eT
CD
201
552
m
m
Pis
ton
rings
P02
84
Clo
sed
gap,
pis
ton
ring
1
Sta
ndar
d
TC
D 2
015
0.35
- 0
.45
mm
Wea
r lim
it(id
entif
icat
ion
TO
P in
dire
ctio
n of
pis
ton
head
)0.
9m
m
P02
85
Clo
sed
gap,
pis
ton
ring
2
Sta
ndar
d
TC
D 2
015
1.1
- 1.
3m
m
Wea
r lim
it(id
entif
icat
ion
TO
P in
dire
ctio
n of
pis
ton
head
)1.
4m
m
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
+0.
00-0
.00
+0.
00-0
.00
+0.
0-0
.01
+0.
0+
0.00 06/2006 8145-0019/28
4
TCD 2015Technical dataTesting and setting dataP02
86
Clo
sed
gap,
pis
ton
ring
3
Sta
ndar
d
TC
D 2
015
0.4
- 0.
7m
m
Wea
r lim
it(id
entif
icat
ion
TO
P in
dire
ctio
n of
pis
ton
head
)1.
2m
m
P02
87
Axi
al c
lear
ance
, 1st
pis
ton
ring
Wea
r lim
itT
CD
201
5M
easu
re w
ith tr
ape-
zoid
al g
roov
e w
ear
gaug
e-
P02
88
Axi
al c
lear
ance
, 2nd
pis
ton
ring
Wea
r lim
itT
CD
201
50.
25m
m
P02
89
Axi
al c
lear
ance
, 3rd
pis
ton
ring
Wea
r lim
itT
CD
201
50.
15m
m
Cra
nkca
se
Cam
shaf
t bea
ring
P03
11
Bor
e di
amet
er fo
r ca
msh
aft b
earin
g lin
er in
the
cran
kcas
e T
CD
201
575
.000
m
m
P03
12
Cam
shaf
t bea
ring
liner
, out
side
dia
met
erT
CD
201
575
.090
m
m
P03
13
Cam
shaf
t bea
ring
liner
, ins
ide
diam
eter
TC
D 2
015
69.9
90
mm
Cam
shaf
t bea
ring
liner
, wal
l thi
ckne
ss2.
0493
m
m
P03
14
Cam
shaf
t bea
ring
liner
, ins
ide
diam
eter
Wea
r lim
itT
CD
201
570
.100
mm
P03
23
Tap
pet b
ores
, dia
met
erT
CD
201
525
.000
m
m
P03
24
Tap
pet b
ores
, dia
met
erW
ear
limit
TC
D 2
015
25.0
50m
m
P03
25
Inst
alla
tion
dept
h of
the
cran
ksha
ft se
alin
g rin
g (r
ear
cove
r)
Firs
t ass
embl
yT
CD
201
50.
5 m
m
Rep
airs
3.5
mm
P03
26
Inst
alla
tion
dept
h of
the
cran
ksha
ft se
alin
g rin
g (g
ense
t sup
port
)
Firs
t ass
embl
yT
CD
201
53
mm
Rep
airs
7 m
m
Cyl
inde
r lin
ers
P03
31
Cyl
inde
r bo
reS
tand
ard
TC
D 2
015
132
mm
P03
35
Fitt
ing
dept
h fo
r cy
linde
r lin
erT
CD
201
59.
87
mm
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
+0.
030 +
0.03
0 +0.
050 +
0.0
0 +0.
030
+0.
2-0
.2+
0.2
-0.2
+0.
-0.5
+0.
-0.5 +
0.0
-0.0
+0.
0-0
.0 06/2006 8145-00110/28
4
TCD 2015Technical data
Testing and setting dataP03
36
Col
lar
heig
ht o
f cyl
inde
r lin
erT
CD
201
59.
02
mm
P03
37
Thi
ckne
ss o
f shi
m
Sta
ndar
dT
CD
201
51.
0 m
m
P03
39
Ove
rhan
g of
cyl
inde
r lin
erT
CD
201
50.
09m
m
Con
trol
sys
tem
Cam
shaf
t
P04
31
Cam
shaf
t bea
ring
pin
diam
eter
Sta
ndar
dT
CD
201
570
m
m
P04
35
Axi
al c
lear
ance
of t
he c
amsh
aft
TC
D 2
015
0.25
- 0
.75
mm
P04
37
Thi
ckne
ss o
f the
gas
ket f
or a
xial
cle
aran
ce s
et-
ting
TC
D 2
015
0.3
mm
P04
39
Ove
rhan
g of
the
para
llel p
in o
n th
e ca
msh
aft g
ear
whe
elT
CD
201
55.
000
mm
P04
43
Axi
al c
lear
ance
of t
he c
amsh
aft f
or in
ject
ion
pum
psT
CD
201
50.
2 -
0.45
mm
P04
44
Too
th e
dge
clea
ranc
e of
the
idle
r gea
r - id
ler g
ear
to c
amsh
aft g
ear
whe
elT
CD
201
50.
04 -
0.3
mm
Spe
ed g
over
ning
sys
tem
P05
91
Cle
aran
ce b
etw
een
spee
d go
vern
or (c
rank
shaf
t)
and
flyw
heel
TC
D 2
015
1.0
mm
P05
92
Cle
aran
ce b
etw
een
spee
d go
vern
or (
cam
shaf
t)
and
cam
shaf
t gea
r w
heel
TC
D 2
015
0.3
- 0.
9m
m
Fue
l sys
tem
P07
19
Plu
nger
lift
of th
e ca
msh
aft f
or in
ject
ion
pum
psse
e na
me
plat
eT
CD
201
54.
00m
m
P07
20
Too
th e
dge
clea
ranc
e be
twee
n ge
ar w
heel
of t
he
cam
shaf
t for
inje
ctio
n pu
mps
and
cam
shaf
t gea
r w
heel
TC
D 2
015
0.04
- 0
.3m
m
Inje
ctio
n va
lve
P07
52
Noz
zle
open
ing
pres
sure
of t
he fu
el in
ject
orT
CD
201
528
0 -
288
bar
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
0 -0.0
+0.
0-0
.0
- 0.0
6-0
.07
+0. 06/2006 8145-00111/28
4
TCD 2015Technical dataTesting and setting dataP07
91
Inst
alla
tion
dim
ensi
ons
of th
e fu
el s
hut-
off v
alve
dim
ensi
on X
TC
D 2
015
appr
ox. 2
5m
m
P07
92
Inst
alla
tion
angl
e of
the
fuel
pip
edi
men
sion
XT
CD
201
5ap
prox
. 30
Lubr
icat
ing
oil s
yste
m
Lube
oil
pres
sure
P08
63
Bas
ic s
ettin
g of
the
pres
sure
stat
whe
n us
ing
new
pa
rts
for
3.00
bar
TC
D 2
015
35
mm
for
3.50
bar
32
for
4.00
bar
29.1
Coo
ling
syst
em
P09
11
The
rmos
tat,
star
t ope
ning
(A
-ban
k)C
olou
red
mar
king
bla
ckve
ntin
g no
tch
top
TC
D 2
015
79C
P09
12
The
rmos
tat,
star
t ope
ning
(B
-ban
k)V
entin
g no
tch
top
TC
D 2
015
87C
P09
13
The
rmos
tat,
stro
ke d
ista
nce
TC
D 2
015
at le
ast 8
mm
Oth
er c
ompo
nent
s
P12
11
Ten
sion
of t
he s
ingl
e V
-bel
t (fir
st a
ssem
bly,
gen
e-ra
tor,
120
Am
pere
)w
ith V
-bel
t ten
sion
mea
surin
g de
vice
81
15T
CD
201
5
500
N
Ten
sion
of t
he s
ingl
e V
-bel
t (fir
st a
ssem
bly,
gen
e-ra
tor,
55
Am
pere
)w
ith V
-bel
t ten
sion
mea
surin
g de
vice
81
1555
0 N
P12
21
Ten
sion
of t
he s
ingl
e V
-bel
t (ge
nera
tor,
120
Am
-pe
re)
Che
ck a
fter
15 m
inut
es r
unni
ng u
nder
lo
adT
CD
201
5
350
N
Ten
sion
of t
he s
ingl
e V
-bel
t (ge
nera
tor,
55
Am
pe-
re)
Che
ck a
fter
15 m
inut
es r
unni
ng u
nder
lo
ad30
0 N
P13
66
Scr
ew-in
hei
ght o
f the
flam
e gl
ow p
lug
in c
onne
c-tin
g lin
edi
men
sion
XT
CD
201
560
m
m
ID n
o.
Nam
eIn
form
atio
nS
erie
sV
alu
eU
nit
+5
-50
+5
-50
+5
-50
0 -3 06/2006 8145-00112/28
06/2006 8145-00113/28
4
Technical dataTCD 2015 Testing and setting data
T00 81 Cylinder and side viewengine TCD 2015 V06
B1B2
B3A1
A2A3
45418-0
T00 81 Cylinder and side viewengine TCD 2015 V08
B1
B4
B2B3
A1
A4
A2A3
45885-0
T01 63 Setting valve clearanceengine TCD 2015 V06Ignition sequence: A1-B3-A3-B2-A2-B1
Valve overlap on cylinder Setting on cylinderA1 B2B3 A2A3 B1B2 A1A2 B3B1 A3
00000-0
08/2008 8145-00214/28
4
Technical dataTCD 2015Testing and setting data
T01 63 Setting valve clearanceengine TCD 2015 V08Ignition sequence: A1-B4-A4-B1-B3-A3-B2-A2
Valve overlap on cylinder Setting on cylinderA1 B3B4 A3A4 B2B1 A2B3 A1A3 B4B2 A4A2 B1
00000-0
T13 054Connection plan of the injection pumpsengine TCD 2015 V06
Item Component Cylinder assignment1 Y15.1 A12 Y15.5 A23 Y15.3 A34 Y15.6 B15 Y15.4 B26 Y15.2 B3
4 5 6
1 2 3
40971-0
T13 054Connection plan of the injection pumpsengine TCD 2015 V08
Item Component Cylinder assignmentY15.1 A1Y15.8 A2Y15.6 A3Y15.3 A4Y15.4 B1Y15.7 B2Y15.5 B3Y15.2 B4
00000-0
4
Technical dataTCD 20154.2 Tightening specifications 06/2006 8145-00115/28
4
TCD 2015Technical dataTightening specifications 06/2006 8145-00116/28
4
TCD 2015Technical data
Tightening specificationsID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
A00
001
Cla
mpi
ng b
rack
et o
n cr
ankc
ase
Mou
ntin
g fe
et/e
ngin
e m
oun-
ting
on c
rank
case
, ela
stic
TC
D 2
015
106
Nm
Mou
ntin
g fe
et/e
ngin
e m
oun-
ting
on c
rank
case
, rig
id
oil l
ight
lyT
CD
201
530
Nm
+45
A00
002
Cla
mpi
ng b
rack
et o
n ad
apte
r fo
r as
sem
bly
bloc
kT
CD
201
590
Nm
A00
003
Mou
ntin
g fe
et/e
ngin
e m
ount
ing
on c
rank
case
elas
ticT
CD
201
510
6 N
m
rigid
oil l
ight
lyT
CD
201
530
Nm
+45
A01
001
Cyl
inde
r he
ad o
n cr
ankc
ase
Scr
ew c
an b
e us
ed a
m
ax.3
times
, oth
erw
ise
re-
new
eve
ry ti
me
they
are
loo-
sene
d.O
il lig
htly
TC
D 2
015
50 N
m+
120
+12
0+
60
A01
002
Roc
ker
arm
bra
cket
on
cylin
der
head
TC
D 2
015
61 N
m
A01
003
Lock
nut
val
ve c
lear
ance
set
ting
scre
wT
CD
201
520
Nm
A01
004
Cyl
inde
r he
ad c
over
on
cylin
der
head
oil l
ight
lyT
CD
201
522
Nm
A01
005
Cyl
inde
r he
ad c
over
on
cylin
der
head
hoo
dM
8x30
oil l
ight
lyhe
xago
nal s
ocke
tT
CD
201
522
Nm
A02
001
Cou
nter
wei
ght o
n cr
anks
haft
oil l
ight
lyT
CD
201
550
Nm
+30
+
60
+60
A02
010
Mai
n be
arin
g co
ver,
ver
tical
scr
ews
Scr
ews
with
w
ashe
rs
Scr
ews
can
be u
sed
a m
ax.3
times
, oth
erw
ise
re-
new
eve
ry ti
me
they
are
loo-
sene
d.O
il lig
htly
TC
D 2
015
50 N
m+
60
+60
+
120 06/2006 8145-00117/28
4
TCD 2015Technical dataTightening specificationsA02
011
Mai
n be
arin
g co
ver,
hor
izon
tal s
crew
s
Scr
ews
can
be u
sed
a m
ax.3
times
, oth
erw
ise
re-
new
eve
ry ti
me
they
are
loo-
sene
d.
TC
D 2
015
80 N
m+
30
+30
A02
020
Big
end
bea
ring
cove
r on
con
nect
ing
rod
Ren
ew s
crew
s ev
ery
time
they
are
loos
ened
.T
CD
201
550
- 6
0 N
m+
60
+60
A03
010
Rea
r co
ver
on c
rank
case
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W59
TC
D 2
015
21 N
m
A03
020
Gen
set s
uppo
rt o
n cr
ankc
ase
M10
TC
D 2
015
55 N
m
A03
030
Lubr
icat
ing
oil p
an o
n cr
ankc
ase
Gas
ket s
teel
bea
ding
Obs
erve
tigh
teni
ng o
rder
TC
D 2
015
28 N
m
TC
D 2
015
(Rai
lway
)24
Nm
A03
031
Oil
drai
n pl
ug o
n lu
bric
atin
g oi
l pan
oil l
ight
lyT
CD
201
512
0 N
m
TC
D 2
015
(Rai
lway
)12
0 N
m
A03
034
Hal
f-fla
nge
on c
onne
ctin
g fla
nge
M8x
30-1
0.9
TC
D 2
015
(Rai
lway
)30
Nm
A03
035
Con
nect
ing
flang
e on
lubr
icat
ing
oil p
anM
10x2
0-10
.9T
CD
201
5 (R
ailw
ay)
30 N
m
A03
051
Val
ve h
ousi
ng (
pres
sure
stat
) on
cra
nkca
seoi
l lig
htly
TC
D 2
015
50 N
m21
0 N
m
A03
060
Cra
nkca
se b
reat
her
Pip
e cl
amp
TC
D 2
015
8 N
m
A03
064
Bre
athe
r pi
pe o
n in
take
elb
ow/o
il se
para
tor
Hos
e cl
ipT
CD
201
56.
5 N
m
A03
069
Bre
athe
r pi
pe (
hold
er)
on c
able
har
ness
rai
lT
CD
201
520
Nm
Pip
e (c
rank
case
bre
athe
r) o
n ca
ble
harn
ess
rail
TC
D 2
015
(Rai
lway
)20
Nm
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00118/28
4
TCD 2015Technical data
Tightening specificationsA03
070
Pip
e (c
rank
case
bre
athe
r)H
ose
clip
TC
D 2
015
(Rai
lway
)6.
5 N
m
A03
080
Con
nect
ion
hous
ing
on lu
bric
atin
g oi
l pan
TC
D 2
015
70 N
m
A03
081
Con
nect
ion
hous
ing
to c
rank
case
M12
x1.5
x35
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W59
TC
D 2
015
30 N
m+
30
+30
A03
082
Con
nect
ion
hous
ing
to c
rank
case
M12
x1.5
x90
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W59
TC
D 2
015
30 N
m+
60
+60
A03
085
Cov
er o
n co
nnec
tion
hous
ing
M8x
16In
sert
with
lock
ing
agen
t D
EU
TZ
DW
59T
CD
201
521
Nm
A03
088
Con
nect
ion
hous
ing
to c
rank
case
M12
x190
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W59
TC
D 2
015
30 N
m+
60
+60
+
60
A03
089
Con
nect
ion
hous
ing
to c
rank
case
M12
x175
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W59
TC
D 2
015
30 N
m+
60
+90
A04
001
Cen
tral
scr
ew fo
r ca
msh
aft g
ear
whe
el o
n ca
ms-
haft
oil l
ight
lyT
CD
201
550
Nm
+15
0
A04
002
Sto
p co
ver
(cam
shaf
t) o
n cr
ankc
ase
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W72
TC
D 2
015
22 N
m
A04
003
Cam
shaf
t gea
r w
heel
on
idle
r ge
aroi
l lig
htly
TC
D 2
015
30 N
m
A04
004
Gea
r w
heel
on
cam
shaf
t for
inje
ctio
n pu
mps
TC
D 2
015
30 N
m+
30
A04
005
Plu
g of
inje
ctio
n pu
mp
cam
shaf
t on
cran
kcas
eF
aste
ning
scr
ew fo
r di
vert
er
stop
per
TC
D 2
015
8.5
Nm
A04
011
Fas
teni
ng s
crew
for
idle
r ge
ar o
n ge
nset
sup
port
TC
D 2
015
80 N
m
A04
012
Scr
ew p
lug
for
bolt
idle
r ge
aroi
l lig
htly
TC
D 2
015
79 N
m
A04
013
Scr
ew fo
r bo
lt id
ler
gear
M12
x100
oil l
ight
lyT
CD
201
570
Nm
A04
015
Pad
thru
st b
earin
g on
cra
nkca
seoi
l lig
htly
TC
D 2
015
30 N
m
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00119/28
4
TCD 2015Technical dataTightening specificationsA04
020
Gea
r ca
se c
over
on
cran
kcas
e
TC
D 2
015
21 N
m
M8x
35M
8x45
TC
D 2
015
(Rai
lway
)21
Nm
A04
022
Cov
er (
stop
cov
er)
on c
rank
case
Inse
rt w
ith lo
ckin
g ag
ent
DE
UT
ZD
W72
TC
D 2
015
20 N
m
A05
011
Spe
ed g
over
nor
on c
onne
ctio
n ho
usin
g (c
rank
s-ha
ft)T
CD
201
58
Nm
A05
012
Spe
ed g
over
nor
on c
over
(ca
msh
aft)
TC
D 2
015
8 N
m
A06
001
Exh
aust
pip
e at
cyl
inde
r he
adIn
sert
with
fitti
ng c
ompo
und
DE
UT
ZS
1T
CD
201
560
Nm
A06
002
Exh
aust
pip
e on
exh
aust
man
ifold
Inse
rt w
ith fi
tting
com
poun
d D
EU
TZ
S1
TC
D 2
015
22 N
m
A06
003
Exh
aust
pip
e on
exh
aust
line
Nut
Inse
rt w
ith fi
tting
com
poun
d D
EU
TZ
S1
TC
D 2
015
18 N
m
A06
010
Exh
aust
man
ifold
to c
onne
ctio
n ho
usin
gT
CD
201
528
Nm
Exh
aust
man
ifold
to e
xhau
st li
neIn
sert
with
fitti
ng c
ompo
und
DE
UT
ZS
1T
CD
201
5 (R
ailw
ay)
35 N
m
A06
020
Exh
aust
turb
ocha
rger
to e
xhau
st m
anifo
ldIn
sert
with
fitti
ng c
ompo
und
DE
UT
ZS
1
TC
D 2
015
35 N
m
Nut
TC
D 2
015
(Rai
lway
)10
Nm
35 N
m
A06
021
Inta
ke e
lbow
to e
xhau
st tu
rboc
harg
er
Hos
e cl
ipho
usin
g po
sitio
n of
the
hose
cl
ip to
psc
rew
hea
d re
ar
TC
D 2
015
5 N
m
A06
024
Tub
ing
conn
ectio
n to
turb
ocha
rger
Hos
e cl
ipT
CD
201
5 (R
ailw
ay)
5 N
m
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00120/28
4
TCD 2015Technical data
Tightening specificationsA06
030
Cha
rge
air
pipe
to c
ylin
der
head
TC
D 2
015
20 N
m
Cha
rge
air
pipe
to a
ir in
take
pip
eM
10 x
85
M10
x 6
5T
CD
201
560
Nm
A06
033
Con
nect
ion
pipe
to a
ir in
take
pip
e
TC
D 2
015
20 N
m
Nut
TC
D 2
015
(Rai
lway
)20
Nm
A06
034
Join
t pla
te o
n co
nnec
ting
pipe
TC
D 2
015
57 N
m
Hol
der
on e
xhau
st m
anifo
ldT
CD
201
5 (R
ailw
ay)
20 N
m
A06
038
Scr
ew p
lug
on c
harg
e ai
r pi
peT
CD
201
534
Nm
A06
046
Con
nect
ing
elbo
w to
cha
rge
air
pipe
Nut
TC
D 2
015
20 N
m
Stu
d4.
5 N
m
A06
056
Con
nect
ing
pipe
to h
olde
r
TC
D 2
015
20 N
m
TC
D 2
015
(Rai
lway
)20
Nm
A06
058
Ret
aini
ng p
late
on
gens
et s
uppo
rtT
CD
201
520
Nm
A07
001
Fue
l inj
ecto
r on
cyl
inde
r he
adU
nion
scr
eww
ithou
t lea
k oi
lIn
sert
with
fitti
ng c
ompo
und
DE
UT
ZS
1T
CD
201
570
Nm
A07
002
Inje
ctio
n no
zzle
on
fuel
inje
ctor
Noz
zle
cap
nut
TC
D 2
015
40 -
50
Nm
A07
003
Inje
ctio
n lin
e on
fuel
inje
ctor
/inje
ctio
n pu
mp
Uni
on n
utT
CD
201
525
Nm
A07
006
Pip
e cl
amp
for
inje
ctio
n pi
peM
6x12
TC
D 2
015
10 N
m
A07
009
Inje
ctio
n pu
mp
hous
ing
on c
rank
case
oil l
ight
lyT
CD
201
560
Nm
A07
012
Inje
ctio
n pu
mp
on in
ject
ion
pum
p ho
usin
goi
l lig
htly
TC
D 2
015
60 N
m
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00121/28
4
TCD 2015Technical dataTightening specificationsA07
015
Fue
l pip
e to
inje
ctio
n pu
mp
hous
ing
TC
D 2
015
25 N
m
TC
D 2
015
(Rai
lway
)25
Nm
A07
018
Fue
l pip
e to
fuel
shu
t-of
f val
ve (
flam
e flo
w p
lugs
)U
nion
nut
TC
D 2
015
20 N
m
A07
023
Tem
pera
ture
tran
smitt
er o
n co
nnec
tor
TC
D 2
015
22 N
m
A07
024
Bea
ring
hous
ing
(fue
l sup
ply
pum
p) to
gen
set
supp
ort
TC
D 2
015
42 N
m
A07
034
Fue
l lin
e on
fuel
sup
ply
pum
pH
ollo
w s
crew
TC
D 2
015
max
.35
Nm
A07
044
Fue
l pip
e fa
sten
ing
Pip
e cl
amp/
hold
eroi
l thr
ead
and
head
con
tact
su
rfac
e.T
CD
201
58.
5 N
m
Fue
l pip
e fa
sten
ing
Pip
e cl
amp
TC
D 2
015
(Rai
lway
)8.
5 N
m
A07
057
Ada
pter
(fla
me
glow
plu
g) o
n ch
arge
air
pipe
M45
x1.5
SW
50T
CD
201
5 (R
ailw
ay)
50 N
m
A07
058
Gro
und
cabl
e on
lock
nut
(fla
me
glow
plu
g)T
CD
201
5 (R
ailw
ay)
7.5
Nm
A07
059
Fla
me
glow
plu
g to
con
nect
ing
pipe
Lock
nut
TC
D 2
015
25 N
m
A07
066
Con
nect
or (
fuel
pre
ssur
e ho
ldin
g va
lve)
to fu
el
pipe
Uni
on n
ut
TC
D 2
015
42 N
m
TC
D 2
015
(Rai
lway
)42
Nm
A07
067
Ove
rflo
w v
alve
on
conn
ecto
r
TC
D 2
015
39 N
m
TC
D 2
015
(Rai
lway
)39
Nm
A07
068
Scr
ew-in
nip
ple
on fu
el s
hut-
off v
alve
TC
D 2
015
18 N
m
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00122/28
4
TCD 2015Technical data
Tightening specificationsA07
069
Scr
ew-in
nip
ple
on o
verf
low
val
veM
16x1
.5T
CD
201
5 (R
ailw
ay)
42 N
m
A07
093
Fue
l shu
t-of
f val
ve (
flam
e gl
ow p
lug)
on
cran
kca-
se (
ther
mos
tat h
ousi
ng)
Pip
e cl
amp
TC
D 2
015
20 N
m
A08
002
Ada
pter
on
oil f
ilter
noz
zle
(gen
set s
uppo
rtT
CD
201
550
Nm
A08
010
Oil
pres
sure
pum
p on
gen
set s
uppo
rtO
il th
read
and
hea
d co
ntac
t su
rfac
e.T
CD
201
540
.5 N
m
A08
011
Plu
g on
oil
pum
pO
il th
read
and
hea
d co
ntac
t su
rfac
e.T
CD
201
521
Nm
A08
013
Lubr
icat
ing
oil p
ipe
to g
ense
t sup
port
Hol
low
scr
ewT
CD
201
518
Nm
A08
014
Lubr
icat
ing
oil p
ipe
to fu
el s
uppl
y pu
mp
Uni
on n
utT
CD
201
520
Nm
A08
015
Oil
suct
ion
inta
ke p
ipe
on o
il pu
mp
M8x
16T
CD
201
522
Nm
M8x
20T
CD
201
5 (R
ailw
ay)
22 N
m
A08
016
Hol
der
oil s
uctio
n pi
pe o
n re
tain
ing
plat
e (m
ain
bear
ing
cove
r)M
8x25
TC
D 2
015
22 N
m
TC
D 2
015
(Rai
lway
)22
Nm
Hol
der
on o
il su
ctio
n pi
pe
TC
D 2
015
22 N
m
M8x
16T
CD
201
5 (R
ailw
ay)
22 N
m
A08
035
Gui
de tu
be o
n sc
rew
-in n
ippl
e (lu
bric
atin
g oi
l pan
Uni
on n
utT
CD
201
530
Nm
A08
038
Scr
ew-in
nip
ple
(gui
de tu
be) o
n lu
bric
atin
g oi
l pan
TC
D 2
015
45 N
m
A08
040
Lubr
icat
ing
oil p
ipe
on e
xhau
st tu
rboc
harg
erU
nion
nut
M14
x 1
.5T
CD
201
539
Nm
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00123/28
4
TCD 2015Technical dataTightening specificationsA08
044
Oil
retu
rn p
ipe
to tu
rboc
harg
er/c
rank
case
TC
D 2
015
20 N
m
TC
D 2
015
(Rai
lway
)20
Nm
A08
045
Oil
pres
sure
pip
e on
gea
r ca
se c
over
Pip
e cl
amps
TC
D 2
015
8.5
Nm
Oil
pres
sure
pip
e on
gen
set s
uppo
rtP
ipe
clam
pT
CD
201
5 (R
ailw
ay)
20 N
m
A08
050
Oil
cool
er h
ousi
ng c
over
on
gens
et s
uppo
rtT
CD
201
520
Nm
A08
051
Oil
cool
er o
n ge
nset
sup
port
TC
D 2
015
20 N
m
A08
071
Scr
ew p
lug
on v
alve
hou
sing
(pr
essu
rest
at)
Hex
agon
soc
ket h
ead
TC
D 2
015
180
Nm
A08
079
Hol
der
(lubr
icat
ing
oil p
ipe)
on
gens
et s
uppo
rt/
gear
cas
e co
ver
TC
D 2
015
20 N
m
A08
081
Rel
ief v
alve
of p
isto
n co
olin
g no
zzle
on
cran
kca-
seT
CD
201
528
Nm
A08
091
Oil
pres
sure
pic
k-up
on
oil c
oole
r ho
usin
gM
14 x
1.5
TC
D 2
015
20 N
m
A09
001
The
rmos
tat h
ousi
ng o
n cr
ankc
ase
TC
D 2
015
20 N
m
Hol
der
on th
erm
osta
t hou
sing
Hol
der
of p
ipe
clam
p (f
uel
pipe
)20
Nm
A09
002
Out
let b
ranc
h on
ther
mos
tat h
ousi
ngT
CD
201
520
Nm
A09
010
Coo
lant
pum
p on
gen
set s
uppo
rtoi
l lig
htly
TC
D 2
015
21 N
m
A09
011
Inle
t ada
pter
on
cool
ant p
ump
oil l
ight
lyT
CD
201
520
Nm
A09
031
Tem
pera
ture
tran
smitt
er o
n th
erm
osta
t hou
sing
TC
D 2
015
22 n
m
A12
001
Fly
whe
el o
n cr
anks
haft
M16
x70
Ren
ew s
crew
s af
ter
ever
y lo
osen
ing.
Oil
light
lyT
CD
201
550
Nm
+30
+
60
+60
A12
030
Fla
nged
hub
(to
rsio
nal v
ibra
tion
dam
per)
on
cran
ksha
ftoi
l lig
htly
TC
D 2
015
30 N
m+
120
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00124/28
4
TCD 2015Technical data
Tightening specificationsA12
031
V-b
elt p
ulle
y/to
rsio
nal v
ibra
tion
dam
per
on fl
an-
ged
hub
oil l
ight
lyT
CD
201
530
Nm
A12
057
Bea
ring
hous
ing
(hyd
raul
ic p
ump
driv
e) o
n cr
ank-
case
M10
x55
oil l
ight
lyT
CD
201
530
Nm
+60
A12
058
Fla
nge
hous
ing
on b
earin
g ho
usin
g (h
ydra
ulic
pu
mp
driv
e)M
10x1
10oi
l lig
htly
TC
D 2
015
30 N
m+1
20
A12
059
Fla
nge
hous
ing
on b
earin
g ho
usin
g (h
ydra
ulic
pu
mp
driv
e)M
10x2
10oi
l lig
htly
TC
D 2
015
30 N
m+1
80
A12
071
Hol
der
on g
ear
case
cov
er
M8x
16-8
.8T
CD
201
518
Nm
TC
D 2
015
(Rai
lway
)20
Nm
Hea
t shi
eld
on h
olde
r (g
ear
case
cov
er)
M8x
16-1
0.9
TC
D 2
015
20 N
m
A12
080
Fue
l pip
e on
flam
e gl
ow p
lug
Uni
on n
utT
CD
201
520
Nm
A12
082
Oil
pres
sure
pip
eU
nion
nut
TC
D 2
015
39 N
m
TC
D 2
015
(Rai
lway
)45
Nm
A12
090
Fue
l hos
e to
con
nect
or (
over
flow
val
ve/fu
el s
hut-
off v
alve
)H
ollo
w s
crew
M10
x1
TC
D 2
015
13 N
m
Pip
e un
ion
with
rin
g pi
ece,
pi
pe 6
mm
TC
D 2
015
(Rai
lway
)18
Nm
A12
092
Hol
low
scr
ew p
ipe
unio
n w
ith r
ing
piec
eH
ollo
w s
crew
M14
x1.5
Bre
athe
r pi
pe o
n oi
l coo
ler
cove
rT
CD
201
539
Nm
A12
093
Hol
low
scr
ew p
ipe
unio
nM
16x1
.5F
ule
pipe
on
fuel
pre
ssur
e ho
ldin
g va
lve
TC
D 2
015
40 N
m
A12
095
Pip
e cl
amps
, fue
l pip
e to
con
nect
ing
pipe
M6
TC
D 2
015
8.5
Nm
Fue
l hos
e to
air
inta
ke p
ipe
Pip
e cl
amp
8.5
Nm
Clip
(ca
ble)
on
hold
er (
cent
ral p
lug)
M8
18 N
m
ID n
o.
Nam
eS
crew
typ
eN
ote
s / R
emar
ksS
erie
sP
re-c
lam
-p
ing
val
ue
Po
st-
clam
pin
gva
lue
06/2006 8145-00125/28
4
TCD 2015Technical dataTightening specificationsA12
096
Bre
athe
r pi
pe o
n ho
lder
Pip
e cl
amp
TC
D 2
015
(Rai
lway
)30