DEUTZ TCD WH 2015 03123514

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

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Distr

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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.


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.


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

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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


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



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


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


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


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



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


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


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


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


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



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


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



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

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pe o

n re

tain

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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

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ID n

o.

Nam

eS

crew

typ

eN

ote

s / R

emar

ksS

erie

sP

re-c

lam

-p

ing

val

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st-

clam

pin

gva

lue

06/2006 8145-00123/28

4


044

Oil

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ipe

to tu

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rank

case

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015

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m

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lway

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A08

045

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pres

sure

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gea

r ca

se c

over

Pip

e cl

amps

TC

D 2

015

8.5

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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

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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

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osen

ing.

Oil

light

lyT

CD

201

550

Nm

+30

+

60

+60

A12

030

Fla

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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

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val

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Po

st-

clam

pin

gva

lue

06/2006 8145-00124/28

4



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

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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

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10x1

10oi

l lig

htly

TC

D 2

015

30 N

m+1

20

A12

059

Fla

nge

hous

ing

on b

earin

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usin

g (h

ydra

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pu

mp

driv

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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


096

Bre

athe

r pi

pe o

n ho

lder

Pip

e cl

amp

TC

D 2

015

(Rai

lway

)30

Documents

DEUTZ TCD WH 2015 03123514