Deutz TCD 2015 User Manual

Workshop Manual

competence level 3

TCD 2015

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0312 3514 en

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This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

	Regarding copyright questions and licensing agreements
	please contact :
	VS-DI, Mr. Sonntag
	Tel.: + 49 (0) 221 822-3053
	EMail: [e-mail]
	DEUTZ AG
	Service Information Systems
	Ottostraße 1
	D-51149 Köln (Cologne)
	Phone.: [phone]
	Fax: [phone]
	Internet: www.deutz.com
	E-Mail: [e-mail]
	Printed in Germany
	All rights reserved
The engine company.	1st Edition, 06/2007
	Order No. 0312 3514 en

TCD 2015	Table of contents

1Foreword

2General

3User notes

3.1General

3.2Specifications

3.2.1Safety regulations and rules for the prevention of accidents

3.2.2Disposal regulations

3.3Operating manual and workshop manual

3.4Job cards

3.5Explanation of symbols

4Technical data

4.1Testing and setting data

4.2Tightening specifications

5Job card overview

5.1Sorted alphabetically

5.2Sorted numerically

5.3Job card references

6Job cards

7Commercial tools

8Special tools

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Table of contents	TCD 2015

© 06/2006	2/2	8141-001

DEUTZ engines	Foreword

1

1Foreword

© 05/2005	1/4	8142-001

Foreword	DEUTZ engines

1

© 05/2005	2/4	8142-001

DEUTZ engines	Foreword

Read and observe the information in this documentation. 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 according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk.

Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with 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 injury 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 retaining rings etc. pose an increased risk of injury when handled incorrectly.

The pertinent rules for the prevention of accidents 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	1
for the intended purpose. Only parts released by

the manufacturer for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability 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 variants ensures that the respective special requirements are met.

The engine is equipped according to the installation 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 differences so that you can easily find the operating, maintenance 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	3/4	8142-001

Foreword	DEUTZ engines

1

© 05/2005	4/4	8142-001

DEUTZ engines	General

2

2General

© 11/2005	1/4	8143-001

General	DEUTZ engines

2

© 11/2005	2/4	8143-001

DEUTZ engines

DEUTZ engines are the product of years of research and development. The profound expertise gained through this, in combination with high demands 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. Compliance 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 particularly 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.

General

2

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General	DEUTZ engines

2

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User notes

3

3User notes

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User notes

3

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User notes

3.1 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, illustrations 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 protection devices which are removed during maintenance work must be replaced again afterwards.

Caution!

3.2 Specifications

3.2.1Accident prevention and safety regulations

The legally prescribed rules for the prevention of accidents must be observed. These are available from professional associations or from dealers. These

are dependent on the application site, operating 3 mode and the operating and auxiliary materials be-

ing used.

Special protection measures are specified depending on the work being carried out, and are identified in the job description.

Among other things it generally applies that:

for the personnel:

The rules for the prevention of accidents and the safety regulations must be observed during maintenance 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 performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

–Only briefed personnel may operate or maintain 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 operation.

–Only deploy trained personnel to do repairs and maintenance work.

–Do not work on the fuel system when the engine 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 extinguishers. Check the filling and readiness for operation regularly.

– Only store inflammable materials in the machine 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 standstill and secured against starting.

– Injection lines and high pressure pipes must not be deformed.

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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

3pressure fuel system.

–Also carefully check all high pressure components 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 protective 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.

3.2.2Cleanliness instructions and measures for handling the DEUTZ Common Rail System

The DEUTZ Common Rail system used in the DEUTZ engines consists of high-precision components which are exposed to extreme stress. Great attention must be paid to cleanliness when working on the fuel system due to the high precision technology.

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 permissible with the fuel system closed.

When using a steam jet, first cover up the control unit, the cable plugs, all other electrical plug connections 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 system.

Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. 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 engines, should be avoided.

For work such as removal and installation on defective 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 mandatory. 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 before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

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 system.

Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

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 performed at a suitably equipped workbench.

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User notes

When removing and installing components, no materials which can leave behind particles or fibres (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 stoppers/caps.

The stoppers/caps may only be removed immediately 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 packaging just before installation.

Removed components must be kept in new, sealable 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 defective 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 mandatory. 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 before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

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.	3
	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.

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User notes

3.3 Operation manual and workshop

		manual
	To structure the information to suit the user, the
	service documentation is divided into operation
	manual and workshop manual.
3	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 especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified 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 appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special 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

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User notes

3.4.2 Structure of a job card

1

2

3

Triebwerk

W 02-04-01 4

5

16

6

3.5 Explanation of symbols

Danger!

of death or to health. Must be observed!

For example: The incorrect use or con- 3 version of the turbocharger can lead to

serious injury.

15

6 7

14

8

13

12	8

11

10

9

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

Caution!

Danger to the component/engine. Noncompliance can lead to destruction of the component/engine.

Must be observed!

Note

General notes on assembly, environmental protection etc. No potential danger for man or machine.

Tool

Conventional and special tools required for the work.

Auxiliary materials

Working materials required in addition to the tools for performing the work

(e.g. greases, oils, adhesives, sealants)

References

to important documents or job cards for the work process.

For example: Job card W 04-05-05

Reference

to a document or a job card within the work process.

Test and setting data

The 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 specification

The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table.

For example:

ID no. A01 001 = cylinder head screws

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User notes

3

© 12/2005	8/8	8144-001

TCD 2015	Technical data

4

4Technical data

4.1Testing and setting data

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Technical data
Testing and setting data	TCD 2015

4

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06/2006 ©

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001-8145

ID no.	Name	Information	Series			Value	Unit
General engine data
	Length of engine		TCD 2015		V06	1200	mm
			TCD 2015		V06	1107	mm
P00 01		about all data	(Railway)
	Length of engine with connection housing
			TCD 2015		V08	1454	mm
			(Railway)
	Width of engine		TCD 2015		V06	1200	mm
			TCD 2015		V06	1125	mm
P00 02		about all data	(Railway)
	Width of engine with connection housing
			TCD 2015		V08	1120	mm
			(Railway)
	Height of engine		TCD 2015		V06	1300	mm
			TCD 2015		V06	835	mm
P00 03		about all data	(Railway)
	Height of engine with connection housing
			TCD 2015		V08	837	mm
			(Railway)
			TCD 2015		V06	approx. 1020-1200	kg
			TCD 2015		V08	1244	kg
P00 04	Engine weight according to DIN 70020-A	without operating media	TCD 2015		V06	920	kg
			(Railway)
			TCD 2015		V08	1160	kg
			(Railway)
P00 10	Working principle		TCD 2015			4 stroke	-
P00 20	Combustion process		TCD 2015			Direct injection	-
P00 30	Total volume		TCD 2015		V06	11906	cm3
			TCD 2015		V08	15874	cm3
P00 31	Bore		TCD 2015			132	mm

2015 TCD

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data	data

4

4

©

ID no.

Name

Information

Series

Value

Unit

06/2006

P00 32

Stroke

TCD 2015

145

mm

TCD 2015

17.5:1

-

P00 40

Compression ratio

TCD 2015

16.5:1

-

(Railway)

P00 50

Direction of rotation

looking onto the flywheel

TCD 2015

counter-clockwise

-

P00 51

Compression pressure

TCD 2015

3200-3400

kPa

(32-34)

(bar)

P00 70

Spark gap

TCD 2015

V06

120

°

TCD 2015

V06

A1-B3-A3-B2-A2-B1

-

P00 71

Ignition sequence

TCD 2015

V08

A1-B4-A4-B1-B3-A3-

-

B2-A2

P00 81

Cylinder and side view

TCD 2015

T00 81

-

4/28

Cylinder head

P01 01

Valve seat insert, bore (inlet)

Standard

TCD 2015

47.500

+0.0

mm

fit H6

0

P01 02

Valve seat insert, bore (outlet)

Standard

TCD 2015

44.500

+0.0

mm

0

P01 03

Valve seat insert, bore (inlet)

1. oversize level

TCD 2015

47.800

+0.0

mm

0

P01 04

Valve seat insert, bore (outlet)

1. oversize level

TCD 2015

44.300

+0.0

mm

0

P01 05

Valve guide, bore in cylinder head

Standard

TCD 2015

15.000

+0.0

mm

0

P01 06

Valve guide, bore in cylinder head

1. oversize level

TCD 2015

15.100

+0.0

mm

0

P01 07

Valve guide, bore in cylinder head

2. oversize level

TCD 2015

15.200

+0.0

mm

0

P01 08

Cylinder head, height

Standard

TCD 2015

120

mm

P01 09

Cylinder head, height

Undersize

TCD 2015

119.70

mm

Valve guide

001-8145

P01 11

Valve guide, external diameter

Standard

TCD 2015

15.0

mm

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001-8145

ID no.	Name	Information	Series			Value					Unit
P01 12	Valve guide, external diameter	1. oversize level	TCD 2015			15.1					mm
P01 13	Valve guide, external diameter	2. oversize level	TCD 2015			15.2					mm
P01 14	Valve guide, inside diameter (inlet)	Standard	TCD 2015			8.030			+0.0		mm
									0
P01 15	Valve guide, inside diameter (outlet)	Standard	TCD 2015			8.030			+0.0		mm
									0
Valve seat insert
P01 21	Valve seat insert, outside diameter (inlet)	Standard	TCD 2015			47.5		+0.0			mm
								+0.0
P01 22	Valve seat insert, outside diameter (outlet)	Standard	TCD 2015			44.0		+0.0			mm
								+0.0
P01 23	Valve seat insert, outside diameter (inlet)	1. oversize level	TCD 2015			47.800				+0.0	mm
										+0.0
P01 24	Valve seat insert, outside diameter (outlet)	1. oversize level	TCD 2015			44.300				+0.0	mm
										+0.0
Valve
P01 31	Valve shaft diameter (inlet)	Standard	TCD 2015			7.97		+0.0			mm
								-0.00
P01 32	Valve shaft diameter (outlet)	Standard	TCD 2015			7.96		+0.0			mm
								-0.00
P01 33	Valve shaft clearance (inlet)	Wear limit	TCD 2015			0.12					mm
P01 34	Valve shaft clearance (outlet)	Wear limit	TCD 2015			0.14					mm
P01 35	Valve edge thickness, valve head (inlet)	Standard	TCD 2015			1.9	+0				mm
							-0.
P01 36	Valve edge thickness, valve head (outlet)	Standard	TCD 2015			1.5	+0				mm
							-0.
P01 37	Valve head diameter (inlet)	Standard	TCD 2015			46.0		+0			mm
								-0.
P01 38	Valve head diameter (outlet)	Standard	TCD 2015			42.0		+0			mm
								-0.
Valve seat
		Standard
		(from the center of the valve head to the	TCD 2015			2.5					mm
P01 45	Valve stand back dimension (inlet)	cylinder head sealing surface)
		Wear limit
		(from the center of the valve head to the	TCD 2015			1.20 - 1.60					mm
		cylinder head sealing surface)

2015 TCD

setting and Testing	Technical
data	data

4

4

©

ID no.

Name

Information

Series

Value

Unit

06/2006

Standard

(from the center of the valve head to the

TCD 2015

2.4

mm

P01 46

Valve stand back dimension (outlet)

cylinder head sealing surface)

Wear limit

(from the center of the valve head to the

TCD 2015

1.25 - 1.65

mm

cylinder head sealing surface)

Valve spring

P01 51

Valve spring length

untensioned, normal

TCD 2015

58.7

mm

Valve spring wire diameter

4.25

Valve clearance

with rotation angle disc

90 +1

°

P01 61

Valve clearance (inlet)

TCD 2015

with cold engine

+0

mm

with feeler gauge

0.25 0

6/28

with rotation angle disc

108 +1

°

P01 62

Valve clearance (outlet)

with cold engine

TCD 2015

+0

mm

with feeler gauge

0.30 0

P01 63

Valve clearance setting

Valve overlap according to adjustment

TCD 2015

T01 63

-

schematic

Rocker arm/bracket

P01 72

Rocker arm, bore, diameter (outlet)

TCD 2015

28

+0.0

mm

0

P01 73

Rocker arm, bore, diameter (inlet)

TCD 2015

28

+0.0

mm

0

P01 74

Rocker arm shaft (diameter)

TCD 2015

28

-0.0

mm

-0.06

P01 75

Axial clearance of the toggle levers

Axial bearing clearance with cold engine

TCD 2015

0.2 - 0.4

mm

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001-8145

ID no.		Name	Information	Series			Value	Unit
			Surface for cylinder head gasket	TCD 2015			10	Rz
P01 93		Roughness					20	[Rmax]
			Surface for cylinder head cover	TCD 2015			16	Rz
							20	[Rmax]
Main running gear
Crankshaft
Main journal
P02 03		Main journal, diameter	Standard	TCD 2015			-0.0	mm
							108 -0.03
P02 04		Main journal, diameter	Undersize stage	TCD 2015			0.25 each	mm
			3 stages
P02 06		Main journal, unroundness	Wear limit	TCD 2015			0.010	mm
P02 07		Main journal, hardness	Standard	TCD 2015			+	HRC
							50 0
Fit journal
P02 11		Fit bearing, width	Standard	TCD 2015			38 +0.0	mm
P02 12		Fit bearing, width	Oversize stage	TCD 2015			38.25 +0.0	mm
P02 13		Fit bearing, width	Limit value for oversize stage	TCD 2015			38.50 +0.0	mm
Lifting journal
P02 22		Lifting journal, diameter		TCD 2015			-0.0	mm
							91 -0.03
P02 23		Lifting journal, diameter	Undersize stage	TCD 2015			0.25 each	mm
			3 stages
P02 25		Lifting journal, unroundness	Wear limit	TCD 2015			0.010	mm
P02 26		Radial run-out, crankshaft	maximum permissible deviation	TCD 2015			0.15	mm
Main bearing
P02 34		Axial clearance of crankshaft	permissible	TCD 2015			0.205 - 0.392	mm

2015 TCD

setting and Testing	Technical
data	data

4

									4
©
		ID no.	Name	Information	Series			Value			Unit
06/2006
		P02 35	Thrust ring half, thickness	Standard	TCD 2015			3.36 +0.0			mm
				(upper and lower half)
		P02 36	Thrust ring half, thickness	1. oversize stage=0.125 mm	TCD 2015			3.485 +0.0			mm
				(upper and lower half)
		P02 37	Thrust ring half, thickness	2. oversize stage=0.125 mm	TCD 2015			3.610 +0.0			mm
				(upper and lower half)
		Connecting rod
		P02 41	Parallelism of the connecting rod	Permissible deviation (a)	TCD 2015			max. 0.06			mm
				at a distance of (x)				100			mm
		P02 42	Taper on periphery of the connecting rod	Permissible deviation (A) to (B)	TCD 2015			max. 0.10			mm
				at a distance of (x)				100			mm
		P02 43	Small end bush, inside diameter	installed, unmachined	TCD 2015			+0.0			mm
								52.040 0
8/28
		P02 45	Small end bush clearance between piston pin		TCD 2015			0.04 - 0.063			mm
			and small end bush
		P02 46	Assembly temperature of the small end bush	cooled in coolant to	TCD 2015			approx. -40			°C
		P02 47	Assembly temperature of the connecting rod	heated up in hot-air oven to	TCD 2015			max. 220			°C
		Big end bearing
				installed				+0.0
		P02 52	Big end bearing shells, inside diameter	identification (n) / top	TCD 2015						mm
								91.048 0
				lining spattered
		P02 54	Big end bearing	Undersize stage	TCD 2015			0.25 each			mm
				3 stages
		P02 55	Big end bearing, bore in connecting rod	after separation and re-assembly of rod	TCD 2015			+0.0			mm
				and cover				95 -0.00
		P02 56	Theoretical clearance between the big end bea-		TCD 2015			0.060 - 0.136			mm
			ring / lifting journal
001-8145		P02 57	Big end bearing clearance	Wear limit	TCD 2015			0.17			mm

setting and Testing	data Technical
data

2015 TCD

06/2006 ©

9/28

001-8145

ID no.	Name	Information	Series			Value		Unit
Piston pin
P02 61	Piston pin, diameter		TCD 2015			51.992 - 52.000		mm
P02 62	Piston pin clearance	Wear limit	TCD 2015			0.09		mm
Piston
		Measuring point 1
P02 71	Piston, diameter	at height 22.5 mm	TCD 2015			132	+0.0	mm
		(Identification of the installation position					-0.00
		on the piston head)
		Measuring point 2
P02 72	Piston, diameter	at height 87.5 mm	TCD 2015			132	+0.0	mm
		(Identification of the installation position					-0.00
		on the piston head)
		Measuring point 3
P02 73	Piston, diameter	at height 122.7 mm	TCD 2015			132	+0.0	mm
		(Identification of the installation position					-0.01
		on the piston head)
P02 75	Piston projection	1.4 = 1 hole (cylinder head gasket)	TCD 2015			-0.05 to 0.10		mm
P02 76	Piston projection	1.6 = 2 holes (cylinder head gasket)	TCD 2015			0.10 to 0.30		mm
P02 77	Piston projection	1.8 = 3 holes (cylinder head gasket)	TCD 2015			0.30 to 0.51		mm
P02 78	Piston pin, bore		TCD 2015			+0.0		mm
						52 +0.0
Piston rings
		Standard				0.35 - 0.45		mm
P02 84	Closed gap, piston ring 1	Wear limit	TCD 2015
		(identification TOP in direction of piston				0.9		mm
		head)
		Standard				1.1 - 1.3		mm
P02 85	Closed gap, piston ring 2	Wear limit	TCD 2015
		(identification TOP in direction of piston				1.4		mm
		head)

2015 TCD

setting and Testing	Technical
data	data

4

4

©

ID no.

Name

Information

Series

Value

Unit

06/2006

Standard

0.4 - 0.7

mm

P02 86

Closed gap, piston ring 3

Wear limit

TCD 2015

(identification TOP in direction of piston

1.2

mm

head)

Measure with trape-

P02 87

Axial clearance, 1st piston ring

Wear limit

TCD 2015

zoidal groove wear

-

gauge

P02 88

Axial clearance, 2nd piston ring

Wear limit

TCD 2015

0.25

mm

P02 89

Axial clearance, 3rd piston ring

Wear limit

TCD 2015

0.15

mm

Crankcase

Camshaft bearing

P03 11

Bore diameter for camshaft bearing liner in the

TCD 2015

75.000

+0.0

mm

crankcase

0

10/28

P03 12

Camshaft bearing liner, outside diameter

TCD 2015

75.090

+0.0

mm

0

Camshaft bearing liner, inside diameter

69.990

+0.0

mm

P03 13

TCD 2015

0

Camshaft bearing liner, wall thickness

2.0493

+0.0

mm

0

P03 14

Camshaft bearing liner, inside diameter

Wear limit

TCD 2015

70.100

mm

P03 23

Tappet bores, diameter

TCD 2015

25.000

+0.0

mm

0

P03 24

Tappet bores, diameter

Wear limit

TCD 2015

25.050

mm

Installation depth of the crankshaft sealing ring

First assembly

0.5

+0.

mm

P03 25

TCD 2015

-0.2

(rear cover)

Repairs

3.5

+0.

mm

-0.2

Installation depth of the crankshaft sealing ring

First assembly

3

+0

mm

P03 26

TCD 2015

-0.

(genset support)

Repairs

7

+0

mm

-0.

Cylinder liners

P03 31

Cylinder bore

Standard

TCD 2015

132

+0.

mm

-8145

-0.0

P03 35

Fitting depth for cylinder liner

TCD 2015

+0.

mm

9.87 -0.0

001

setting and Testing	data Technical
data

2015 TCD