MANITOU TCD 3.6 L4 Repair manual

647461EN (07/11/2013)

ENGINE TCD 3.6 L4

Repair manual

MANITOU BF B.P 10249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com

2

647461EN

DATE OF ISSUE OBSERVATION

07 / 11 / 2013

- 1st ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.

Thi

te

c

te

ro

t p

h

g

ri

py

o

c

s

i

nt

e

m

u

c

do

s

u

ib

tr

s

Di

allowed without our prior agreement

ti

on

i

ei

n

th

e

ri

r p

nt

ed

o

r e

d.

le

Workshop Manual

competence level 2

TD 3.6 L4

TCD 3.6 L4

ot

n

s

i

rm

fo

c

i

on

tr

.

c

0312 3965 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.

-

Regarding copyright questions and licensing agreements please contact :

The engine company.

VE-FL, Mr. Lippke

Phone: +49 (0) 221 822-2599 E-mail: lippke.d@deutz.com

DEUTZ AG Information Systems Sales & Ser vice Ottostraße 1 D-51149 Köln (Cologne) Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-mail: info@deutz.com

-

DEUTZ engines Foreword

1 Foreword

1

1/4

DEUTZ enginesForeword

1

2/4

DEUTZ engines Foreword

● 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

-

1

3/4

DEUTZ enginesForeword

1

4/4

DEUTZ engines General

2 General

2

1/4

DEUTZ enginesGeneral

2

2/4

DEUTZ engines General

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. 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.

-

2

-

3/4

DEUTZ enginesGeneral

2

4/4

DEUTZ engines Safety information / User information

OBJ_DOKU-31078-001.fm

3 Safety information / User information

3

1/8

DEUTZ enginesSafety information / User information

OBJ_DOKU-31078-001.fm

3

2/8

DEUTZ engines Safety information / User information

OBJ_DOKU-31078-001.fm

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, illustra tions and parts due to further developments.

The valid documentations published by DEUTZ AG (for example Technical Circulars, Service Bulletins, etc.) must be observed.

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 regula tions

-

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:

– The common rail systems used work with op

erating pressures up to approximately 2000 bar. In the case of poten tial faults, the pressure can even rise to signif icantly higher values before the pressure reducing valve opens.

– After shutting down the engine, wait at least

30 seconds before performing work on the fuel system. Depending on the version of common rail sys tem, the fuel pressure in the common rail sys tem will still not have dissipated after 30 seconds. The fuel pressure can permanently be several 100 bar.

-

3

-

3/8

OBJ_DOKU-31078-001.fm

DEUTZ enginesSafety information / User information

The fuel pressure here does not drop until the fuel system is opened and the fuel can es cape.

– Only start the engine when all the protective

devices have been fitted. Make sure no-one is standing in the danger area.

3

– Cleaning, maintenance and repair work may

only be performed with the engine at a stand still and secured against starting.

– Fuel lines, injection lines or fuel high-pressure

lines must never be disconnected when the engine is running.

– Danger of injury !

The fuel jet can deeply penetrate the skin.

– Do not come close to the leakage area in the

fuel high-pressure system with any body parts (for example hand).

– Always carry out an exact visual inspection of

all high-pressure carrying components before tests on the running engine. Wear suitable protective clothing (for example goggles, gloves) for this. Leakages entail potential haz ard sources for the workshop personnel.

– Even if no leakages can be discerned in the

fuel high-pressure system, the workshop per sonnel should avoid the direct hazard zone or wear protective clothing (for example goggles, gloves) during tests when the engine is run ning and during the first test run.

– Always stay out of range of a fuel jet, as it

could cause severe injury.

– Fuel lines, injection lines and high-pressure

lines must not be deformed.

– Damaged fuel lines, injection lines and high-

pressure lines must be replaced.

– 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.

– Loosen screw connections slowly and not

abruptly

– Open screw connections on the fuel system

with extreme caution.

– After all work on the fuel system, it must be

bleeded - see the operation manual, chapter "6 Fuel system“.

-

3.2.2 Cleanliness instructions and measures for working with common rail systems

The common rail systems used in DEUTZ engines comprise high-precision components subjected to extreme loads. In view of the high-precision technol ogy, ensure utmost cleanliness when working on the fuel system.

-

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 chromeplated.

Notes and measures to be observed during work on the fuel system or with the fuel system open.

● Only work in clean overalls.

-

4/8

DEUTZ engines Safety information / User information

OBJ_DOKU-31078-001.fm

● 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 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 per formed at a suitably equipped workbench.

● 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 chromeplated.

3

-

3.2.3 Additional information and measures for

-

● Basically all the same regulations and instruc

-

● Utmost cleanliness must be observed for all

DPF (Diesel Particle Filter)

● The filter regeneration must be deactivated or, in

-

● The duration of a full filter regeneration is 25 min

-

● No foreign bodies may get into the exhaust line or

-

● Tensions and deformations of the shape of the V-

● V-belt clips and seals may not be reused (this

-

Ignition system

● Caution! Dangerous high voltage.

● The ignition system must not be operated without

● Store the components in a dry and clean area.

● It is not permitted to: store the components tem

-

● Components may only be stored and transported

the handling of exhaust aftertreatment systems

-

tions up to and including chapter 3.2.2 must also be observed for work on exhaust aftertreatment systems!

work.

systems with a filter regeneration prompt, not ac tivated before performing service work.

utes on average. High exhaust temperatures oc cur in the exhaust system/on the end exhaust pipe independently of the actual load state of the engine (i.e. also during engine idling).

the combustion chamber. If this happens, the en gine must be "run free" without diesel particle filter.

belt clip must be avoided. The DPF module may only be transported using the transport sleeves.

also applies as soon as the screw connection has been loosened once).

The ignition system operates with ignition voltag es up to 10000 Volts.

a secondary load.

porarily or stack them without their transport packaging.

in the specified packaging.

-

5/8

OBJ_DOKU-31078-001.fm

DEUTZ enginesSafety information / User information

● Only remove new parts from the original packag ing just before installation.

● Incorrectly operated or damaged components or parts that have been dropped must not be in stalled.

● Do not subject the components to any hard im

3

pacts or any other use of force.

● Faulty earthing, cable and plug connections can lead to malfunctions. Electronic components can be destroyed.

● Dirt and moisture on the primary and high voltage connections can cause malfunctions (leakage current, misfiring, high voltage sparks).

● Check the protective caps of the ignition lines for discolouration, deformation and cracks before each usage.

SCR (Selective Catalytic Reduction)

● AdBlue® is a caustic medium which causes heavy corrosion damage when it comes into con tact with electronic components or similar.

● Leaks on the AdBlue® pipes, the tank, the supply module and the feeding unit must be fixed imme diately to avoid leakage of AdBlue®.

● Make sure the room is well ventilated.

● Contact with the skin should be avoided. Wear la tex gloves if possible.

● Wash hands thoroughly before taking breaks and at the end of shifts.

● If the substance comes into contact with eyes, rinse thoroughly with water.

● If swallowed, rinse out mouth with a lot of water, drink plenty of water and seek medical advice.

● If discomfort or illness continues, seek medical advice.

● Product can pose danger of slipping if spilled. It is essential to remove spilled liquid. In so doing, ensure that the liquid does not enter the sewage system or ground/surface water. This means that the contamination should be physically removed and disposed of in suitable containers. Minimal amounts of remaining liquid may be rinsed away with a lot of water.

● The so-called lag time is application-dependent and may be up to 2 minutes in engines with an SCR system because the SCR pipes have to be pumped empty in this time.

-

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.

-

3.2.4 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.

-

6/8

DEUTZ engines Safety information / User information

OBJ_DOKU-31078-001.fm

3.3 Operation manual and workshop man ual

In order to structure the information layout in a userfriendly way, the service documentation is divided into operating instructions and job cards (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 use of job cards (workshop manual) presuppos es knowledge of the operating instructions content, this applying in particular for the service specifica tions. Repairs to the engine and components are described in the job cards (workshop manual), for the implementation of which more effort and corre spondingly qualified experts are required.

-

3.4 Job cards

The job cards are differentiated into "W" and "I" job cards. The "W" job card documents the standard repairs to the engine and/or its components. The necessary tools and special tools are also indicated in the "W" job card. The "I" job card also documents corresponding workflows for repairing the engine and/or its compo nents. Special prerequisites must be fulfilled by the workshops for implementation of these workflows. For example, special tools and machine tools must be available.

3

-

3.4.1 Numbering of job cards

The job card numbering uses the format W 08-03-

01. The individual parts of this format are explained below:

● W 08-03-01: Documentation type

– W.... Workshop manual

– I ...... Repair manual

-

●W 08-03-01: Module

according to module list

●W 08-03-01: Component group

● W 08-03-01: Consecutive number

7/8

OBJ_DOKU-31078-001.fm

6

17

13

4

5

7

1 2 3

9

11

12

6

8

10

14

15

16

9

DEUTZ enginesSafety information / User information

3.4.2 Structure of a job card

3.5 Explanation of symbols

Danger! of death or to health. Must be observed! For example: The incorrect use or conver

-

sion of the turbocharger can lead to serious injury.

3

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)

1. DEUTZ AG,

publisher of service documentation

2. Number of associated spare parts list sheet

(ETL)

3. Assembly - Designation

4. Numbering of the job cards

5. DEUTZ internal creation number

6. Title of job card

7. References / Notes

8. Chapter

9. Graphic or photo

10.DEUTZ internal designation

11.Page number

12.Date of issue of job card

13.Note

14.Danger / Important

15.Parts list / Workflow

16.Auxiliary materials

17.Conventional tools, special tools

References to important documents

Reference within the workflow or to assemblies in which further documents or job cards are provided.

Test and setting data The necessary values are indicated here with link to a table within the job card.

Tightening specifications The necessary values are indicated here with link to a table within the job card.

8/8

5 Job card overview

5.1 Sorted alphabetically

Job card overview

Sorted alphabetically

OBJ_DOKU-31079-001.fm

5

1/12

Job card overview Sorted alphabetically

OBJ_DOKU-31079-001.fm

5

2/12

Job card overview

Sorted alphabetically

OBJ_DOKU-31079-001.fm

Activity Job card Module

Charge air line W 22-90-55 Charge air line

Charge air manifold W 22-90-54 Charge air line

Checking the thermostat (in the removed state) W 38-01-02 Thermostat housing

Closing parts W 02-90-01 Lubricating oil sump

Compensator structure (Exhaust line) W 41-90-21 Exhaust pipe Connection (Crankcase housing, exhaust gas circu-

lation, coolant line)

Connection housing W 52-90-53 Connection housing

Console W 71-90-51 Exhaust gas treatment

Drive components W 37-90-06 Coolant pump

Engine mounting W 46-90-15 Engine mounting

Exhaust manifold (exhaust turbocharger) W 43-90-36 Exhaust gas turbocharger

Fuel filter W 20-90-17 Fuel filter

Fuel line W 20-90-30 Fuel pipes

Fuel pre-filter W 20-90-16 Fuel filter

Generator W 44-90-42 Parts to generator

W 41-90-04 Exhaust gas recirculation

5

Holder W 09-90-09 Gearcase

Impulse transmitter (camshaft) W 51-90-20 Measuring instruments

Intake nozzle (exhaust turbocharger) W 22-90-35 Air intake pipe

Intermediate gear W 09-90-50 Gearcase

Line W 38-90-32 Coolant pipes

Line W 01-90-32 Crankcase breather

Line W 38-90-32 Coolant pipes

Line (Thermostat housing, exhaust gas circulation, coolant line)

Lubricant oil filter console W 15-90-38 Lubricating oil filter

Oil filling W 02-90-24 Lubricating oil sump

Oil measuring device W 01-90-23 Oil measuring device

Pressure fan

W 41-90-32 Exhaust gas recirculation

W 39-90-52 Fa

n

3/12

Job card overview Sorted alphabetically

OBJ_DOKU-31079-001.fm

Activity Job card Module Pressure transmitter / temperature pressure trans-

mitter (charge air)

Removing and install the charge air line W 22-01-01 Charge air line

Removing and installing charge air manifold W 22-04-01 Charge air line

Removing and installing hydraulic pump drive W 83-02-01 Hydraulic pump drive

Removing and installing the belt tensioner (V-rib belt, level 1)

5

Removing and installing the connection housing W 52-01-01 Connection housing

Removing and installing the console (V-rib belt, level

1)

Removing and installing the cylinder head cover W 08-01-01 Cylinder head cover

Removing and installing the exhaust line W 41-01-01 Exhaust pipe

W 22-90-20 Charge air line

W 44-01-01 Add-on parts

W 44-02-06 Add-on parts

Removing and installing the flywheel (Fastening parts)

Removing and installing the fuel line (injector, rail, high-pressure pump)

Removing and installing the gasket housing W 01-03-01 Crankcase

Removing and installing the generator (Clamping latch)

Removing and installing the generator (Fastening parts)

Removing and installing the glow plugs W 63-02-01 Start aid

Removing and installing the high-pressure pump W 17-01-04 High-pressure pump

Removing and installing the injector W 19-01-01 Injector

Removing and installing the lubricating oil cooler Removing and installing the lubricating oil line (ex-

haust turbocharger) Removing and installing the lubricating oil line (ex-

haust turbocharger)

Removing and installing the lubricating oil pan W 02-01-01 Lubricating oil sump

W 05-03-01 Flywheel

W 21-05-05 Fuel pipes

W 44-02-01 Generator

ting oil cooler

W 15-02-01 Lu

W 16-04-01 Lubricating oil pipe

brica

Removing and installing the lubricating oil return line (exhaust turbocharger)

Removing and installing the oil suction pipe W 16-01-01 Oil suction pipe

W 16-05-01 Lubricating oil pipe

4/12

Job card overview

Sorted alphabetically

OBJ_DOKU-31079-001.fm

Activity Job card Module

Removing and installing the rail W 21-04-01 Fuel pipes

Removing and installing the starter W 44-03-01 Starter

Removing and installing the thermostat W 38-01-01 Thermostat housing

Removing and installing the transfer line W 01-07-05 Crankcase

Removing and installing the turbocharger W 43-01-01 Exhaust gas turbocharger

Renewing the crankshaft sealing ring (flywheel side) W 01-02-01 Crankcase

Supply pump (Fuel) W 20-90-47 Fuel supply pump

V-rib belt pulley W 37-90-13 Coolant pump

5

5/12

Job card overview Sorted alphabetically

OBJ_DOKU-31079-001.fm

5

6/12

5.2 Sorted numerically

Job card overview

Sorted numerically

OBJ_DOKU-31079-001.fm

5

7/12

Job card overview Sorted numerically

OBJ_DOKU-31079-001.fm

5

8/12

Job card overview

Sorted numerically

OBJ_DOKU-31079-001.fm

Job card Activity Module

W 01-02-01 Renewing the crankshaft sealing ring (flywheel side) Crankcase

W 01-03-01 Removing and installing the gasket housing Crankcase

W 01-07-05 Removing and installing the transfer line Crankcase

W 01-90-23 Oil measuring device Oil measuring device

W 01-90-32 Line Crankcase breather

W 02-01-01 Removing and installing the lubricating oil pan Lubricating oil sump

W 02-90-01 Closing parts Lubricating oil sump

W 02-90-24 Oil filling Lubricating oil sump

W 05-03-01

W 08-01-01 Removing and installing the cylinder head cover Cylinder head cover

W 09-90-09 Holder Gearcase

W 09-90-50 Intermediate gear Gearcase

W 15-02-01 Removing and installing the lubricating oil cooler Lubricating oil cooler

W 15-90-38 Lubricant oil filter console Lubricating oil filter

W 16-01-01 Removing and installing the oil suction pipe Oil suction pipe

W 16-04-01

W 16-05-01

Removing and installing the flywheel (Fastening parts)

Removing and installing the lubricating oil line (exhaust turbocharger)

Removing and installing the lubricating oil return line (exhaust turbocharger)

Flywheel

Lubricating oil pipe

5

W 17-01-04 Removing and installing the high-pressure pump High-pressure pump

W 19-01-01 Removing and installing the injector Injector

W 20-90-16 Fuel pre-filter Fuel filter

W 20-90-17 Fuel filter Fuel filter

W 20-90-30 Fuel line Fuel pipes

W 20-90-47 Supply pump (Fuel) Fuel supply pump

W 21-04-01 Removing and installing the rail Fuel pipes

W 21-05-05

W 22-01-01 Removing and install the charge air line Charge air line

W 22-04-01 Removing and installing charge air manifold Charge air line

W 22-90-20

90-35 Intake nozzle (exhaust turbocharger) Air intake pipe

2-

W 2

Removing and installing the fuel line (injector, rail, high-pressure pump)

Pressure transmitter / temperature pressure transmitter (charge air)

9/12

Fuel pipes

Charge air line

Job card overview Sorted numerically

OBJ_DOKU-31079-001.fm

Job card Activity Module

W 22-90-54 Charge air manifold Charge air line

W 22-90-55 Charge air line Charge air line

W 37-90-06 Drive components Coolant pump

W 37-90-13 V-rib belt pulley Coolant pump

W 38-01-01 Removing and installing the thermostat Thermostat housing

W 38-01-02 Checking the thermostat (in the removed state) Thermostat housing

5

W 38-90-32 Line Coolant pipes

W 39-90-52 Pressure fan Fan

W 41-01-01 Removing and installing the exhaust line Exhaust pipe

W 41-90-04

W 41-90-21 Compensator structure (Exhaust line) Exhaust pipe

W 41-90-32

W 43-01-01 Removing and installing the turbocharger Exhaust gas turbocharger

W 43-90-36 Exhaust manifold (exhaust turbocharger) Exhaust gas turbocharger

W 44-01-01

W 44-02-01

W 44-02-06

Connection (Crankcase housing, exhaust gas circulation, coolant line)

Line (Thermostat housing, exhaust gas circulation, coolant line)

Removing and installing the belt tensioner (V-rib belt, level 1)

Removing and installing the generator (Fastening parts)

Removing and installing the generator (Clamping latch)

Removing and installing the console (V-rib belt, level

1)

Exhaust gas recirculation

Add-on parts

Generator

Add-on parts

W 44-03-01 Removing and installing the starter Starter

W 44-90-42 Generator Parts to generator

W 46-90-15 Engine mounting Engine mounting

10/12

Job card overview

Sorted numerically

OBJ_DOKU-31079-001.fm

Job card Activity Module

W 51-90-20 Impulse transmitter (camshaft) Measuring instruments

W 52-01-01 Removing and installing the connection housing Connection housing

W 52-90-53 Connection housing Connection housing

W 63-02-01 Removing and installing the glow plugs Start aid

W 71-90-51 Console Exhaust gas treatment

W 83-02-01 Removing and installing hydraulic pump drive Hydraulic pump drive

5

11/12

Job card overview Sorted numerically

OBJ_DOKU-31079-001.fm

5

12/12

DEUTZ engines Job cards

OBJ_DOKU-31080-001.fm

6 Job cards

6

1/2

DEUTZ enginesJob cards

OBJ_DOKU-31080-001.fm

6

2/2

Renewing the crankshaft sealing ring

(flywheel side)

Standard tools

Special tools: – Pricker 01899103 – Assembly lever 01899110 – Assembly tool 02992214

– Self-tapping screw – Washer

Crankcase

W 01-02-01

OBJ_DOKU-31081-001.fm

6

Removing the crankshaft sealing ring

1 Gasket housing 2 Shaft sealing ring 3 Hexagon head screw 188 Packing compound

● Remove flywheel.



Module 05

● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention!

Do not damage the gasket housing and crankshaft!

1/4

Crankcase

W 01-02-01

OBJ_DOKU-31081-001.fm

● Screw in a self-tapping screw (1) with washer.

6

● Pull out the crankshaft sealing ring with assembly le ver.

Ensure that the crankshaft does not get damaged.

● Visually inspect the crankshaft sealing ring running surface.

Installing the crankshaft sealing ring

● Mount guide sleeve (1).

● Tighten screws (2).

The bores in the guide sleeve must match the threaded holes in the crankshaft flange.

-

2/4

Crankcase

W 01-02-01

OBJ_DOKU-31081-001.fm

● Place the crankshaft sealing ring carefully on the pe ripheral surface.

Do not oil waxed crankshaft sealing rings.

The sealing lip faces the crankcase.

● Mount assembly sleeve (1).

● Press on the crankshaft sealing ring to the stop.

● Plug in the bearing (2).

● Screw on nut (3).

-

6

● Tighten nut to the stop of the assembly sleeve (1).

The installation depth is determined by the assembly tool.

● Remove assembly tool.

● Install flywheel.



Module 05

3/4

Crankcase W 01-02-01

OBJ_DOKU-31081-001.fm

6

4/4

Removing and installing the gasket housing

Standard tools: – Splint driver

– Packing compound

DEUTZ DW 67

Crankcase

W 01-03-01

OBJ_DOKU-31082-001.fm

6

Removing the gasket housing

1 Gasket housing 2 Shaft sealing ring 3 Hexagon head screw 188 Packing compound

● Remove flywheel.



Module 05

● Remove connection housing.



Module 52

● Remove lubricating oil pan.



Module 02

● Unscrew all screws (1).

● Remove gasket housing (2).

1/4

Crankcase

W 01-03-01

OBJ_DOKU-31082-001.fm

● Knock out crankshaft sealing ring (1).

Attention!

Do not damage the sealing surfaces.

● Visually inspect the components.

6

Installing the gasket housing

● Clean sealing surfaces.

● Apply sealing compound (1) evenly on the sealing surface.

Sealing cord strength approx. 0.5 -

0.6 mm.

● Mount gasket housing.

● Tighten screws (1).

2/4

The sealing face (arrows) must be flush

with the oil pan sealing face.

Crankcase

W 01-03-01

OBJ_DOKU-31082-001.fm

6

● Tighten the screws according to the tightening se quence.

 20 Nm

● Renew crankshaft sealing ring (flywheel side).



Module 01

● Install lubricating oil pan.



Module 02

● Install connection housing.



Module 52

● Install flywheel.



Module 05

-

3/4

Crankcase W 01-03-01

OBJ_DOKU-31082-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A01 095 Gasket housing on crankcase

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Observe tightening sequence

20 Nm

6

4/4

Removing and installing the transfer line

Crankcase

W 01-07-05

OBJ_DOKU-31083-001.fm

8190

Standard tools

– Packing compound

DEUTZ DW 73

Removing the transfer line

1 Transfer line 2 Torx screw 3 Screw plug 35 Nm 291 Packing compound

6

● Remove lubricating oil pan.



Module 02

● Unscrew screws (1).

● Remove transfer line (2).

● Visually inspect the component.

1/4

Crankcase

W 01-07-05

OBJ_DOKU-31083-001.fm

Installing the transfer line

● Clean sealing surfaces.

Attention!

No packing compound must get into the oil channel (1)!

6

● Apply sealing compound (1) evenly on the sealing surface.

● Clean sealing surfaces.

● Mount transfer line (1).

● Tighten screws (2).

 20 Nm

● Install lubricating oil pan.



Module 02

2/4

W 01-07-05

OBJ_DOKU-31083-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value A01 016 Transfer line on crankcase 20 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Crankcase

6

3/4

Crankcase W 01-07-05

OBJ_DOKU-31083-001.fm

6

4/4

Oil measuring device

Standard tools

Oil measuring device

W 01-90-23

OBJ_DOKU-31084-001.fm

6

1 Oil dipstick 2Ball 3 Stopper 4 Guide tube 5O-ring

Use new round sealing ring.

1/2

Oil measuring device W 01-90-23

OBJ_DOKU-31084-001.fm

6

2/2

Line

Crankcase breather

W 01-90-32

OBJ_DOKU-31085-001.fm

Standard tools

6

1 Pipe clip 2Pipe 3 Spring band clip 4 Rubber sleeve 5 Intake nozzle 6 Spring band clip 7 Hexagon head screw 8 Nm

1/2

Crankcase breather W 01-90-32

OBJ_DOKU-31085-001.fm

6

2/2

Removing and installing the lubricating oil pan

Lubricating oil sump

W 02-01-01

OBJ_DOKU-31086-001.fm

Standard tools

Special tools: – Separating tool 02992301

– Packing compound

DEUTZ DW 73

Removing the lubricating oil pan

1 Lubricating oil pan 2Nut 3 Torx screw 244 Packing compound

Attention!

Make sure that no gasket residue falls into the crankcase. Seal all openings.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Emptying and filling the engine with opera ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

-

6

● Drain lubricating oil, c ollect and di spose of according to regulations.

● Unscrew all screws (arrow).

● Remove lube oil tray (1).

1/6

Lubricating oil sump

W 02-01-01

OBJ_DOKU-31086-001.fm

● Drive in separating tool (1) to the stop (2).

Attention!

The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces.

6

● Drive in second separating tool (1) to the stop (2).

Attention!

The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces.

● Lever out lubricating oil pan.

● Remove lubricating oil pan.

2/6

Installing the lubricating oil pan

● Scrape off sealing compound with separating tool.

Attention!

Wear protective glasses.

● Clean the sealing surface on the crankcase with a wire brush.

The sealing surfaces must be dry and free from grease and dirt.

Lubricating oil sump

W 02-01-01

OBJ_DOKU-31086-001.fm

6

Attention!

Wear protective glasses.

● Clean the sealing surface on the lubricating oil pan with a wire brush.

The sealing surfaces must be dry and free from grease and dirt.

● To align the lubricating oil pan, screw four pin bolts (1) diagonally opposed into the crankcase.

3/6

Lubricating oil sump

W 02-01-01

OBJ_DOKU-31086-001.fm

● Clean sealing surfaces.

The sealing surfaces must be dry and free from grease and dirt.

● Apply packing compound to the joints (arrows).

6

● Apply packing compound evenly to the sealing sur face.

● Align the lubricating oil pan in the appropriate instal lation position with the pin bolts.

● Mount lubricating oil pan.

Attention!

Do not move the lubricating oil pan any more. Observe the drying time for the packing compound.

-

● Unscrew the pin bolts.

● Fasten all screws (1).

4/6

Lubricating oil sump

W 02-01-01

OBJ_DOKU-31086-001.fm

● Tighten the screws according to the tightening se quence.

 20 Nm

● Fill in lubricating oil according to operating manual.

-

6

5/6

Lubricating oil sump W 02-01-01

OBJ_DOKU-31086-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A02 030 Lubricating oil pan on crankcase

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Observe tightening sequence!

20 Nm

6

6/6

Closing parts

Lubricating oil sump

W 02-90-01

OBJ_DOKU-31087-001.fm

Standard tools

1 Screw plug 55 Nm 2 Sealing ring

Use a new sealing ring.

Collect draining lubricating oil and dispose of properly.

6

1/2

Lubricating oil sump W 02-90-01

OBJ_DOKU-31087-001.fm

6

2/2

Oil filling

Standard tools

Lubricating oil sump

W 02-90-24

OBJ_DOKU-31088-001.fm

6

1 Oil filler pipe 2 Hexagon head screw 30 Nm 3 Filler lock 4Seal 5 Screw plug 95 Nm

Use a new gasket.

1/2

Lubricating oil sump W 02-90-24

OBJ_DOKU-31088-001.fm

6

2/2

Removing and installing the flywheel

(Fastening parts)

Standard tools

Special tools: – Guide pin (self-const

ructed) – Auxiliary screws M10x120 – Rotation angle disc 01899093

-

Flywheel

W 05-03-01

OBJ_DOKU-31089-001.fm

6

Removing the flywheel

1 Flywheel 2 Ring gear 3Screw 4 Bearing bush

● Hold the crankshaft at the central screw.

● Screw in auxiliary screws (1).

● Unscrew screws (2).

● Remove flywheel using auxiliary screws.

● Visually inspect the components.

1/4

Flywheel

W 05-03-01

OBJ_DOKU-31089-001.fm

Installing the flywheel

● Insert self-made guide pin (arrow).

The bores in the flywheel must match the threaded bores in the crankshaft flange.

● Mount flywheel using auxiliary screws.

6

Attention!

Renew screws every time they are loo sened.

● Tighten screws alternately.

– Stage 1:

 30 Nm

● Tighten screws with rotation angle disc.

– Stage 2:

 60°

– Stage 3:

 30°

● Remove guide pin.

● Unscrew auxiliary screws.

-

2/4

OBJ_DOKU-31089-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A05 001 Flywheel on crankshaft

A05 001 Flywheel on crankshaft Stage 2: 60° A05 001 Flywheel on crankshaft Stage 3: 30°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Stage 1: Use new screws

30 Nm

Flywheel

W 05-03-01

6

3/4

Flywheel W 05-03-01

OBJ_DOKU-31089-001.fm

6

4/4

Removing and installing the cylinder head cover

Standard tools

Cylinder head cover

W 08-01-01

OBJ_DOKU-31090-001.fm

6

Removing cylinder head

1 Cylinder head cowling 2Seal 3Screw 4 Filler lock 5 Plug piece

● Removing the crankcase breather.



Module 01

● Unscrew screws (1).

● Remove cylinder head cowling (2).

1/4

Cylinder head cover

W 08-01-01

OBJ_DOKU-31090-001.fm

● Remove gasket (1).

6

Installing cylinder head cover.

● Mount new gasket (1).

● Mount cylinder head cover (1).

2/4

Cylinder head cover

W 08-01-01

OBJ_DOKU-31090-001.fm

● Tighten the screws according to the tightening se quence.

 8.5 Nm

● Install crankcase breather.



Module 01

-

6

3/4

Cylinder head cover W 08-01-01

OBJ_DOKU-31090-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value A08 004 Cylinder head cover on cylinder head 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

4/4

Holder

OBJ_DOKU-31091-001.fm

Standard tools – Safety information / User

information

Attention!

Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling.

Gearcase

W 09-90-09

-

6

1 Holder 2 Impulse transmitter 3 Hexagon head screw 8.5 Nm 4 Hexagon head screw 5 Nm

Position 2:

Use new round sealing ring.

1/2

Gearcase W 09-90-09

OBJ_DOKU-31091-001.fm

6

2/2

Intermediate gear

Standard tools

Gearcase

W 09-90-50

OBJ_DOKU-31092-001.fm

6

1 Intermediate gear 2Shaft 3 Hexagon head screw 30 Nm

1/2

Gearcase W 09-90-50

OBJ_DOKU-31092-001.fm

6

2/2

Removing and installing the lubricating oil cooler

Lubricating oil cooler

W 15-02-01

OBJ_DOKU-31093-001.fm

Standard tools

Removing the lubricating oil cooler

1 Lubricating oil cooler 2Seal 3 Hexagon head screw

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate operating manual should be observed for emptying and filling the engine.

6

● Unscrew all screws (1).

● Remove lubricating oil cooler (2).

● Remove gasket (3).

Collect draining lubricating oil and dispose of properly.

● Visually inspect the components.

1/4

Lubricating oil cooler

W 15-02-01

OBJ_DOKU-31093-001.fm

Installing the lubricating oil cooler

● Visually inspect the components.

● Clean sealing surfaces.

● Turn in screws (arrows).

M8x20-10.9

● Fasten new seal (1) on lubricant oil cooler housing with screws.

6

● Mount lubricating oil cooler (1).

● Tighten screws (2).

● Tighten all screws (2) alternately.

 30 Nm

2/4

Lubricating oil cooler

W 15-02-01

OBJ_DOKU-31093-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value A15 051 Oil cooler housing on crankcase 30 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

3/4

Lubricating oil cooler W 15-02-01

OBJ_DOKU-31093-001.fm

6

4/4

Lubricant oil filter console

Lubricating oil filter

W 15-90-38

OBJ_DOKU-31094-001.fm

8190

Standard tools

1 Interchangeable filter 12 Nm 2 Threaded bush 3 Cover 4O-ring 5 Hexagon head screw 30 Nm

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instruc tions for emptying and filling the engine.

-

6

Use new round sealing ring.

1/2

Lubricating oil filter W 15-90-38

OBJ_DOKU-31094-001.fm

6

2/2

Removing and installing the oil suction pipe

Oil suction pipe

W 16-01-01

OBJ_DOKU-31095-001.fm

8190

Standard tools

– Packing compound

DEUTZ DW 73

Removing the oil suction pipe

1 Oil suction pipe 2 Torx screw 291 Packing compound

6

● Remove lubricating oil pan.



Module 02

● Unscrew screws (1).

● Remove oil suction pipe (2).

● Visually inspect the component.

1/4

Oil suction pipe

W 16-01-01

OBJ_DOKU-31095-001.fm

Installing the oil suction pipe

● Clean sealing surface.

● Apply sealing compound (1) evenly on the sealing surface.

6

● Clean sealing surface.

● Install oil suction pipe (1).

● Tighten screws (2).

 22 Nm

● Install lubricating oil pan.



Module 02

2/4

Oil suction pipe

W 16-01-01

OBJ_DOKU-31095-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value A16 015 Oil suction pipe on crankcase M8x25-10.9 22 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

3/4

Oil suction pipe W 16-01-01

OBJ_DOKU-31095-001.fm

6

4/4

Removing and installing the lubricating oil line

(exhaust turbocharger)

Standard tools Collect leaking operating substances in

Lubricating oil pipe

W 16-04-01

OBJ_DOKU-31096-001.fm

suitable vessels and dispose of according to regulations.

Observe the appropriate operating instruc tions for emptying and filling the engine.

-

6

Removing the lubricating oil line

1 Lubricating oil line 2 Hollow screw 3 Sealing ring

● Unscrew hollow screw (1).

● Remove sealing rings (2).

1/4

Lubricating oil pipe

W 16-04-01

OBJ_DOKU-31096-001.fm

● Unscrew hollow screw (1).

● Remove sealing rings (2).

● Remove lubricating oil pipe (3).

6

Installing the lubricating oil line

● Clean sealing surfaces.

● Mount lubrication oil line (1).

● Mount sealing rings (2).

● Screw on hollow screw (3).

● Clean sealing surfaces.

● Mount lubrication oil line (1).

● Mount sealing rings (2).

● Tighten hollow screw (3).

 18 Nm

Attention!

Install tension-free.

2/4

● Tighten hollow screw (1).

 18 Nm

Attention!

Install tension-free.

Lubricating oil pipe

W 16-04-01

OBJ_DOKU-31096-001.fm

6

3/4

Lubricating oil pipe W 16-04-01

OBJ_DOKU-31096-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A43 047

A43 048 Lubricating oil line on crankcase Hollow screw Use new sealing rings 18 Nm

Lubricating oil pipe on exhaust tur bocharger

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

-

Hollow screw Use new sealing rings 18 Nm

6

4/4

Removing and installing the lubricating oil line

(exhaust turbocharger)

Standard tools Collect leaking operating substances in

Lubricating oil pipe

W 16-04-01

OBJ_DOKU-31097-001.fm

suitable vessels and dispose of according to regulations.

Observe the appropriate operating instruc tions for emptying and filling the engine.

-

6

Removing the lubricating oil line

1 Lubricating oil line 2 Hollow screw 3 Sealing ring

● Unscrew hollow screw (1).

● Remove sealing rings (2).

1/4

Lubricating oil pipe

W 16-04-01

OBJ_DOKU-31097-001.fm

● Unscrew hollow screw (1).

● Remove sealing rings (2).

● Remove lubricating oil pipe (3).

6

Installing the lubricating oil line

● Clean sealing surfaces.

● Mount lubrication oil line (1).

● Mount sealing rings (2).

● Screw on hollow screw (3).

● Clean sealing surfaces.

● Mount lubrication oil line (1).

● Mount sealing rings (2).

● Tighten hollow screw (3).

 18 Nm

Attention!

Install tension-free.

2/4

● Tighten hollow screw (1).

 18 Nm

Attention!

Install tension-free.

Lubricating oil pipe

W 16-04-01

OBJ_DOKU-31097-001.fm

6

3/4

Lubricating oil pipe W 16-04-01

OBJ_DOKU-31097-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A43 047

A43 048 Lubricating oil line on crankcase Hollow screw Use new sealing rings 18 Nm

Lubricating oil pipe on exhaust tur bocharger

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

-

Hollow screw Use new sealing rings 18 Nm

6

4/4

Removing and installing the lubricating oil return line

(exhaust turbocharger)

Lubricating oil pipe

W 16-05-01

OBJ_DOKU-31098-001.fm

Standard tools

Special tools: – Disassembly tool 02992127

– Fitting compound

DEUTZ AP1908

Removing the oil return line

1 Fastening flange 2O-ring 3 Oil return line 4O-ring 5 Hexagon head screw 6 Hexagon head screw 7Seal

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instruc tions for emptying and filling the engine.

-

6

● Unscrew screws (1).

● Remove gasket (2).

1/6

Lubricating oil pipe

Lubricating oil pipe W 16-05-01

W 16-05-01

OBJ_DOKU-31098-001.fm

● Unscrew screw (1).

● Pull out oil return line (2) in direction of arrow.

6

● Remove flange (1) in direction of arrow.

● Remove round sealing ring (2) with disassembly tool.

● Visually inspect the component.

● Remove the O-ring (1) with the disassembly tool.

● Visually inspect the component.

2/6

Mounting the oil return line

● Clean sealing surfaces.

● Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound.

● Insert new O-ring (1).

Lubricating oil pipe

W 16-05-01

OBJ_DOKU-31098-001.fm

6

● Clean sealing surfaces.

● Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound.

● Insert new O-ring (1).

● Insert flange (2) in direction of arrow.

● Clean sealing surfaces.

● Mount oil return pipe (1).

● Insert oil return line (1) in direction of arrow.

● Fasten screw (2).

3/6

Lubricating oil pipe

Lubricating oil pipe W 16-05-01

W 16-05-01

OBJ_DOKU-31098-001.fm

● Clean sealing surfaces.

● Mount gasket (1).

● Mount oil return pipe (2).

● Tighten screws (3).

 8.5 Nm

6

● Tighten screw (1).

 8.5 Nm

Attention!

Install tension-free.

4/6

Lubricating oil pipe

W 16-05-01

OBJ_DOKU-31098-001.fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A43 044

A43 046 Oil return line on crankcase 8.5 Nm

Oil return line on exhaust turbochar ger

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

-

8.5 Nm

6

5/6

Lubricating oil pipe

Lubricating oil pipe W 16-05-01

W 16-05-01

OBJ_DOKU-31098-001.fm

6

6/6

Removing and installing the lubricating oil return line

(exhaust turbocharger)

Lubricating oil pipe

W 16-05-01

OBJ_DOKU-31099-001.fm

Standard tools

Special tools: – Disassembly tool 02992127

– Fitting compound

DEUTZ AP1908

Removing the oil return line

1 Fastening flange 2O-ring 3 Oil return line 4O-ring 5 Hexagon head screw 6 Hexagon head screw 7Seal

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instruc tions for emptying and filling the engine.

-

6

● Unscrew screws (1).

● Remove gasket (2).

1/6

Lubricating oil pipe

Lubricating oil pipe W 16-05-01

W 16-05-01

OBJ_DOKU-31099-001.fm

● Unscrew screw (1).

● Pull out oil return line (2) in direction of arrow.

6

● Remove flange (1) in direction of arrow.

● Remove round sealing ring (2) with disassembly tool.

● Visually inspect the component.

● Remove the O-ring (1) with the disassembly tool.

● Visually inspect the component.

2/6

Mounting the oil return line

● Clean sealing surfaces.

● Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound.

● Insert new O-ring (1).

Lubricating oil pipe

W 16-05-01

OBJ_DOKU-31099-001.fm

6

● Clean sealing surfaces.

● Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound.

● Insert new O-ring (1).

● Insert flange (2) in direction of arrow.

● Clean sealing surfaces.

● Mount oil return pipe (1).

● Insert oil return line (1) in direction of arrow.

● Fasten screw (2).

3/6

Lubricating oil pipe

Lubricating oil pipe W 16-05-01

W 16-05-01

OBJ_DOKU-31099-001.fm

● Clean sealing surfaces.

● Mount gasket (1).

● Mount oil return pipe (2).

● Tighten screws (3).

 8.5 Nm

6

● Tighten screw (1).

 8.5 Nm

Attention!

Install tension-free.

4/6

MANITOU TCD 3.6 L4 Repair manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Workshop Manual

1 Foreword

2 General

3 Safety information / User information

5 Job card overview

5.1 Sorted alphabetically

5.2 Sorted numerically

6 Job cards

Removing and installing the gasket housing

Removing and installing the transfer line

Oil measuring device

Line

Removing and installing the lubricating oil pan

Closing parts

Oil filling

Removing and installing the cylinder head cover

Holder

Intermediate gear

Removing and installing the lubricating oil cooler

Lubricant oil filter console

Removing and installing the oil suction pipe