Workshop Manual 132

Workshop Manual
TCG 2016
0299 8938 EN, 10/2008
Engine number:
Please enter the engine serial number here. This will simplify the handling of customer service, repair and
spare parts queries.
Technical modifications required to improve our engines are reserved with regard to specification data and
other technical information contained in this documentation. No parts of this document may be reproduced
in any form or by any means without our written approval.
This is a translation of the German original. In case of argument the German original version is
binding.
Workshop Manual
This documentation is intended for the following engine
 Engine type:
 Type of application:
 System name:
 Power: kW
 Speed: rpm
 Commissioned on:
Please enter data. This will make it a lot easier for us to process after-sales support, repair work and spare
parts orders.
The documentation should be presented to the responsible service partner for every service assignment.
Hinweis
Changes in this document only concern our current layout. The content corresponds to
the date of issue 02/2008.
Imprint:
MWM GmbH
Service Documentation
Carl-Benz-Strasse 1
D-68167 Mannheim
Phone: +49 (0) 6 21 3 84-0
Fax: +49 (0) 6 21 3 84-88 41
www.mwm.net
Printed in Germany
All rights reserved
Date of issue:
© MWM GmbH 10/2008
Order number:
0299 8938
OBJ_DOKU-25768-001.fm /2 © MWM GmbH 10/2008

TCG 2016
Introduction
0
Introduction
Please read and keep in mind...
 Read and keep to the information in this documentation. You will avoid accidents, re-
tain the manufacturer’s warranty and have a fully functional, ready-to-use engine at
your disposal.
 This engine is built exclusively for the purpose intended according to the scope of de-
livery as 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 will bear the sole risk in this case.
 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 it and instructed in the dan-
gers.
 Make sure that this documentation is available to everyone involved in the operation,
maintenance and repair and that they have understood the contents.
 Non-compliance with this documentation package may lead to malfunctions and dam-
age to your engine, or even injury to persons, for which the manufacturer will not accept
any liability.
 A prerequisite for proper maintenance and repair is the availability of all necessary
equipment, hand tools and special tools. All equipment and tools must be in perfect
working condition.
 Engine parts such as springs, clamps, elastic retaining rings etc. constitute an in-
creased risk of injury when not used properly.
 The relevant rules for the prevention of accidents and other generally recognised safe-
ty and industrial medicine rules must be followed.
 Maximum cost-effectiveness, reliability and long life is only guaranteed when MWM
GmbH original parts are used.
 Repair of the engine must comply with use for the intended purpose. Only parts re-
leased for the purpose by the manufacturer may be used for conversion work. Unau-
thorised modifications to the engine exclude manufacturer liability for resulting
damages.
OBJ_DOKU-25769-001.fm 3 © MWM GmbH 0106

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Introduction
Take care when the engine is running

Carry out maintenance or repair work only when the engine is at a standstill. If you remove
any protective features, fit them back in place on completion of the work concerned. When
working on the running engine, work clothing must be close-fitting.
Safety
You will find this symbol next to all safety instructions. Follow these meticulously. The at-
tention of operating personnel should be drawn to these safety instructions. In addition,
general statutory safety and accident prevention regulations applying in your country must
be complied with.
Note
You will find this symbol next to instructions of a general nature.

Follow these meticulously.
Asbestos
Gaskets used in this engine are asbestos-free. Please use appropriate spare parts for
maintenance and repair work.

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Introduction
0
Foreword
Dear Customer,
MWM engines are designed for a large number of applications. A wide range of variants
ensures that the special requirements of each customer are met.
Your engine is appropriately equipped for your requirements, which means that not all of
the components described in this manual are necessarily fitted to your engine.
We have endeavoured to highlight any differences so that you will be able to locate the op-
erating and maintenance instructions relevant to your engine quickly and easily.
Please read this documentation before starting your engine, and always follow the operat-
ing and maintenance instructions.
We are at your service for any questions you may have.
Your
MWM Service
The engines of MWM GmbH

MWM GmbH engines are the product of many years of research and development. The
profound know-how gained in connection with high-quality requirements is our guarantee
for the manufacture of engines with a long life, high reliability and low fuel consumption.
Naturally the high requirements for environmental protection are also met.
Maintenance and care

Good service and maintenance will ensure that the engine continues to satisfy your require-
ments. Recommended service intervals must be observed and maintenance work carried
out conscientiously. If the engine becomes difficult to operate, or if operating conditions de-
viate from normal, it is particularly important to take steps to find out the cause.
MWM Service
Please consult one of our service representatives responsible for operating faults and ques-
tions on spare parts. Our trained specialist personnel ensures fast, professional repairs us-
ing original parts in the event of damage.
Original parts from MWM are always manufactured according to the latest standards in
technology.
Information about our service can be found at the end of this manual.

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Introduction

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Content
Content
0 Introduction
Please read and keep in mind... ......................................................................................................... 3
Take care when the engine is running ................................................................................................ 4
Foreword............................................................................................................................................. 5
The engines of MWM GmbH .............................................................................................................. 5
Maintenance and care ..................................................................................................................... 5
MWM Service .................................................................................................................................. 5
1 User notes
General ............................................................................................................................................. 13
Regulations ....................................................................................................................................... 13
Safety Regulations / Rules for Accident Prevention ...................................................................... 13
Rules for disposal .......................................................................................................................... 14
Competence classes ........................................................................................................................ 15
Operating manual and workshop manual ......................................................................................... 17
Operating Manual .......................................................................................................................... 17
Workshop Manual.......................................................................................................................... 18
Job cards .......................................................................................................................................... 19
Spare parts ....................................................................................................................................... 20
2 Description
Design and designations .................................................................................................................. 23
Type designation ........................................................................................................................... 23
Rating plate.................................................................................................................................... 23
Location on engine ..................................................................................................................... 23
Figure rating plate....................................................................................................................... 24
Designation of sides of engine, cylinder numbering and direction of engine rotation ....................... 25
Figures of engine and units .............................................................................................................. 26
Power unit...................................................................................................................................... 26
Design and function .......................................................................................................................... 30
Crankcase...................................................................................................................................... 30
Crank drive and valve drive ........................................................................................................... 31
Control system............................................................................................................................... 33
Cylinder head................................................................................................................................. 33
Design and function .................................................................................................................... 33
Valve control ............................................................................................................................... 33
Channel guide............................................................................................................................. 35
Exhaust system / Charging............................................................................................................ 36
Speed governing............................................................................................................................ 37
Actuator ...................................................................................................................................... 37
Gas unit ......................................................................................................................................... 38
Gas control system ..................................................................................................................... 38
Automatic switch off process ...................................................................................................... 38
Fitting and testing ....................................................................................................................... 39
Notes on fitting............................................................................................................................ 39
Gas-air mixer, formation of mixture ............................................................................................ 40
OBJ_BUCH-1160-001IVZ.fm 7 © MWM GmbH TCG 2016

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Content
Lubricating oil system .................................................................................................................... 42

Lube oil level switch....................................................................................................................... 44
Crankcase bleed valve .................................................................................................................. 45
Racor model ............................................................................................................................... 45
Model UPF 55............................................................................................................................. 47
Cooling system .............................................................................................................................. 47
Electrical system............................................................................................................................ 48
Electrical system......................................................................................................................... 48
Spark plug................................................................................................................................... 49
Electric starter............................................................................................................................. 50
Electrical components.................................................................................................................... 51
3 Operation
Work before commissioning for the first time and after every service .............................................. 57
General .......................................................................................................................................... 57
Filling up coolant............................................................................................................................ 57
Filling lubrication oil ....................................................................................................................... 57
Pre-lubrication................................................................................................................................ 58
Gas supply..................................................................................................................................... 58
Note for all heat exchangers.......................................................................................................... 58
Exhaust gas side ........................................................................................................................... 58
Commissioning / starting .................................................................................................................. 59
Start the engine. ............................................................................................................................ 59
Warming up ................................................................................................................................... 59
Ventilation of rooms ....................................................................................................................... 59
Lubricating oil system .................................................................................................................... 59
Operation monitoring ........................................................................................................................ 60
Inspections immediately after commissioning ............................................................................... 60
Unit monitoring............................................................................................................................... 60
Engine peripheral systems ............................................................................................................ 60
Reverse power............................................................................................................................... 60
Coolant circuit ................................................................................................................................ 61
Batteries......................................................................................................................................... 61
Shutting down ................................................................................................................................... 61
4 Operating and auxiliary materials

General ............................................................................................................................................. 65
Product selection ........................................................................................................................... 65
Mixability ........................................................................................................................................ 65
Guarantee...................................................................................................................................... 65
Operating media ............................................................................................................................... 66
Fuel gas ......................................................................................................................................... 66
Lube oil .......................................................................................................................................... 66
Engine coolant ............................................................................................................................... 66
Auxiliary materials............................................................................................................................. 67
Packing compound ........................................................................................................................ 67
Locking agent ................................................................................................................................ 68
Activator......................................................................................................................................... 70
Adhesive ........................................................................................................................................ 70

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Hardener........................................................................................................................................ 70
Lubricant ........................................................................................................................................ 71
Commercially available products ................................................................................................... 72
Conservation agents...................................................................................................................... 72
Cleaning agents............................................................................................................................. 73
Water treatment agents ................................................................................................................. 74
5 Maintenance
Maintenance schedule as separate documentation ......................................................................... 77
Tools for competence class 1 ........................................................................................................... 79
Address of order ............................................................................................................................ 79
Tools sorted according to order numbers ...................................................................................... 79
Tools for competence class 3 ........................................................................................................... 87
Tools sorted according to order numbers ...................................................................................... 87
6 Troubleshooting
Explanation of tabular representation ............................................................................................... 95
Fault table ......................................................................................................................................... 95
Troubleshooting remedies ................................................................................................................ 96
7 Preservation
Technical Circular TR 0199-99-2116 .............................................................................................. 107
8 Technical data
Test and setting values ................................................................................................................... 111
Tightening specifications ................................................................................................................ 117
Nominal and wear dimensions........................................................................................................ 123
9 Job cards
Explanation of symbols ................................................................................................................... 149
Job card list..................................................................................................................................... 150
Service

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User notes
1

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User notes

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User notes
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User notes
General
The maintenance and service work prescribed in the operating manual and the workshop
manual must be performed on schedule and in full.
The maintenance and repair personnel must have the necessary technical knowledge to
perform the work. Safety and protection devices which may have to be removed during
maintenance and repair work must be replaced afterwards.
The rules for the prevention of accidents and the safety regulations must be ob-
served at all times during maintenance and service work.
Please also observe the special safety regulations for the various service groups
which are listed in detail as job cards in the Job Cards chapter (cf. also chapter 1
Safety Regulations / Rules for Accident Prevention).
See the maintenance schedules for the maintenance intervals. These also provide informa-
tion about the work to be performed.
The job cards provide technical hints for performing the work.
Regulations
Safety Regulations / Rules for Accident Prevention

Detailed safety instructions have been compiled for various service groups in the
form of job cards, these precede the job cards of the respective service groups.
The legally prescribed rules for accident prevention (available from the appropriate
associations or technical publishers) must be observed. These will depend on the lo-
cation, the operating mode and the supplies and expendables used.
Special safety measures dependent on the respective work are specified and high-
lighted in the work description.
It generally applies among other things:
 for personnel:
- Only instructed personnel may operate or maintain the engine. Unauthor-
ized persons must not enter the engine room.
- Wear tight fitting clothing and ear protectors in the engine room when en-
gines are running.
- Only employ qualified personnel for repairs or service work.
 for the engine room:

- Make sure it is properly ventilated (do not cover the ventilation shafts).
- Provide a first aid kit and suitable fire extinguishers. Check filling and oper-
ational readiness at regular intervals.
- Only store inflammable materials in the engine room which are necessary
for operating the system.
- Smoking and naked lights are prohibited in the engine room.

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User notes
 for operation and maintenance of the engine:

- Only start the engine when all safety devices have been fitted and the turn-
ing gear has been removed. Make sure there is no-one in the danger zone.
- Only perform cleaning, maintenance and repair work when the engine is
switched off and secured against starting up.
Rules for disposal

The work described in the operation manual and workshop manual necessitate the renewal
of parts and operating media among other things. These renewed parts / operating media
must be properly stored, transported and disposed of. The owner is responsible for this.
Disposal includes recycling and disposal of parts / operating media whereby recycling has
priority.
The details of disposal and its supervision are governed by regional, national and interna-
tional laws and decrees which the plant owner is responsible for observing.

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1
Competence classes
The competence classes 1 to 3, see also SIT 07010, have been introduced to be able to
supply all contract partners with the appropriate information.
These are closely related to the respective partner contract and a number of conditions
such as:
 Training
 Spare parts stores
 Workshop equipment etc.
The following competence classes, hereinafter referred to as CC, are defined:
CC 1 Technical skilled qualified personnel

Maintenance stages 20, 30, 40
Work Operation and maintenance
Documents B job cards
- Regular maintenance according to the maintenance schedules in the operating
manuals
- Visual inspections, cleaning work
- Testing and replacing maintenance parts and operating media
- Minor repairs with conventional tools
- Test run and function test
CC 2 Authorised qualified personnel

Maintenance stages (10), 45, 50, 55
Work Inspection
Test and adjustment work
Repair work
Documents W job cards
- Testing the actual condition of the engine and engine components
- Error analysis
- Comparison of nominal / actual condition and determining of the resulting repair
measures
- Repair work on the engine periphery
- Components, including cylinder head, disassembly and assembly / replacement
- Testing of the parts and components for reusability and repair / replacement without
re-machining mechanically
- Adjustment work resulting from the repair

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User notes
CC 3 Authorised qualified personnel

Maintenance stages 60, 70
Work Intermediate overhaul
Major overhaul
Extensive diagnosis, test and adjustment work on the whole engine
Mechanical rework on engine parts (without removal of material)
Documents W job cards
- Extensive engine diagnosis
- Complete disassembly, examination, repair and reassembly of the engine
- Engine adjustment
- Function and performance test on the test bench or in the drive system
- Extensive, know-how intensive maintenance work on the drive assembly, parts and
components including mechanical rework (without removal of material) according
to maintenance documents

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1
Operating manual and workshop manual

To structure the information to suit the user, the service documentation is divided into op-
erating manual and workshop manual.
Operating Manual
The Operating Manual contains a general description of the engine as well as instructions
for the necessary maintenance measures and so on. The maintenance measures de-
scribed in the Operation Manual can be performed by technically skilled personnel.
The chapters of the operating manual are as follows:
0 Introduction
Contents
1 User notes
2 Description (description of the engine and components)
3 Operation (operating the engine)
4 Operating media (operating media, auxiliary materials and operating media specifi-
cations under Technical Bulletin)
5 Maintenance (maintenance schedules and special tools up to maintenance stages

E40)
6 Troubleshooting
7 Preservation (Technical Bulletin)
8 Technical data (technical data on the engine, tightening specifications and test and
setting values up to maintenance stages E40)
9 Job cards (job card list, job cards for maintenance work up to maintenance stages
E40)
10 Miscellaneous (this is an optional chapter only enclosed if needed, containing sup-

plementary documentation)
Service
General safety regulations

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User notes
Workshop Manual
The workshop manual contains all the same chapters as the operating manual, with the ad-
dition of the instructions required for maintenance work from MWM maintenance stages
E40 onwards. The maintenance measures from maintenance stages E40 onwards, as de-
scribed in the workshop manual, may only be performed by authorised personnel.
The chapters of the workshop manual are as follows:
0 Introduction
Contents
1 User notes
2 Description (description of the engine and components)
3 Operation (operating the engine)
4 Operating media (operating media, auxiliary materials and operating media specifi-
cations under Technical Bulletin)
5 Maintenance (maintenance schedules, special tools as required by all maintenance

stages)
6 Troubleshooting
7 Preservation (Technical Bulletin)
8 Technical data (technical data of the engine, tightening specifications and test and
setting values as required by all maintenance stages)
9 Job cards (job card list, job cards for maintenance work from all maintenance
stages)
10 Miscellaneous (this is an optional chapter only enclosed if needed, containing sup-

plementary documentation)
Service
General safety regulations

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1
Job cards
All job cards have a job card number which is associated with a defined work procedure.
An overview of the numbering system follows: The structure of the job card is shown in the
illustration on the next page.
Differentiation of the job cards

The first letter stands for the competence required to perform the maintenance work.
B Operating manual: to be carried out by technically skilled personnel only
W Workshop manual: to be carried out by authorised personnel only
I Repair: to be carried out by authorised Service Centres only.
Maintenance group
0 General
1 Cylinder head
2 Drive system
3 Crankcase
4 Engine control
5 Speed governing
6 Exhaust system / Charging
7 Fuel system
8 Lube oil system
9 Coolant system
10 Compressed air system
11 Monitoring system
12 Other components
13 Electrical system
Subssystem (component)
The subsystem differs depending on the maintenance group.
Consecutive number
- Counting per subsystem (component)

- Different activities in the subsystem (component)
- Version differences
T 1-1 Numbering of job cards

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User notes
A 1-1 Structure of the job cards
For inquiries about job cards please always give the engine type or system 1, the number
of the job card 2 and the date of issue 7.
1 Engine type or system

2 Number of the job card
3 Title of the job card
4 Tools, aids, spare parts and references
5 Safety instructions
6 General notes
7 Date of issue of the job card
Spare parts
Spares are available from Service. You will find a list of spares in the spare parts list of the
engine or the system. You will find further information in the Service chapter at the end of
the Operation Manual or Workshop Manual.

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Description
2
1 2 3 4

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Description

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Description
2
Description
Design and designations

The engines in this series are water-cooled four-stroke, high-performance Otto gas engines
which can be used in a wide range of drive applications with easy usability of the coolant
and exhaust heat in force-heat coupling processes. A special low exhaust emission com-
bustion process has been developed for environmental protection.
Type designation
See also the rating plate
T C G 2016 V -
Turbocharger
Mixture charge cooling
Gas engine
Series
V-engine
Number of cylinders
Rating plate
Location on engine
The rating plate is fixed to the engine. In addition the engine number is embossed.
A 2-1

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Description
Figure rating plate
A 2-2
1 Engine design designation

2 Year of manufacture
3 Engine number
4, 5, 6 Performance code according to DIN ISO 3046 Part 7 and code for the type
of gas.
Performance code
n = Natural gas
s = Sewage gas
l = Landfill gas
m = Marsh gas
p = Propane
A * or ** in front of the performance code indicates the relevant NOx emis-
sion, see 13,14.
7, 8, 9 Numerical value of output in kW
10, 11, 12 Engine speed at rpm
13, 14 NOx emission in mg
15 Height above sea level equates to sea level (conditions at installation site)
16 Air pressure px in mbar (conditions at installation site)
17 Charge air coolant temperature tcx in °C (conditions at installation site)
18 Relative humidity Φx in % (conditions at installation site)
19 Mixture coolant temperature tcx in °C (conditions at installation site)
20 Numerical value of output of lube oil pump in kW (F)

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2
Designation of sides of engine, cylinder numbering and direction of engine rotation

The designations in this operating manual comply with DIN ISO 1204.
A 2-3
Engine sides:
1 Drive side Flywheel, driving end
2 Left side Cylinder side A
3 Free side Front side, free end
4 Right side Cylinder side B
Cylinder designation:
Each individual cylinder is designated with a combination of a letter and a number.
Seen from the drive side counting on the left side starts with cylinder A1 and on the right
side with cylinder B1.
Engine rotational direction:
Seen from the drive side the engine turns in an anti-clockwise direction.

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Description
Figures of engine and units
Power unit
A 2-4
A 2-5

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2
Component overview
A 2-6
1 Generator
2 Flywheel / clutch
3 Ignition system
4 Engine
5 Mixture cooler
6 Turbocharger
7 Prelubrication pump
8 Base frame
9 Engine mounting

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Description
A 2-7
1 Air intake filter

2 Gas-air mixer
3 Starter
4 Crankcase breather
Racor model
5 Lube oil sump
6 Lube oil level switch
7 Torsional vibration damper

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Description
2
A 2-8
1 Coolant outlet (low temperature circuit)

2 Coolant inlet (low temperature circuit)
3 Coolant outlet (high temperature circuit)
4 Coolant inlet (high temperature circuit)

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Description
Design and function
Crankcase
The crankcase is made of a specially alloyed casting. This manufacturing method is distin-
guished by torsional strength, breaking strain and casting tightness which enables a low
weight and compactness. The side walls of the crankcase come down to below the centre
of the crankshaft and so ensure additional resistance to torsion.
The cylinder angle of 60° enables a narrow design as is required in many applications.
A 2-9

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Description
2
Crank drive and valve drive

The crank drive includes the crankshaft, con rod, piston, torsional vibration damper and fly-
wheel.
The drop-forged crankshaft 1 is hung in replaceable sliding bearings in the crankcase 7.
Every bearing cover is secured by four screws. A special bearing coating provides a greater
lubrication security and emergency running property. The shaft and crank journals and the
contact surfaces of the axial bearings are inductively hardened. The counterweights 9
screwed to the crank webs serve to dissipate the internal mass effect and relieve the crank-
shaft bearing. The torsional vibration damper and the flywheel guarantee smooth running
of the engine with a structure calculated exactly for every application.
The double T-shank con rods 2 are divided at an angle at the large con rod eye. This allows
the pistons with con rod to be removed upwards through the cylinder liner 3. The con rods
run on the crankshaft in sputter bearings. A liner is pressed into the top con rod eye in which
the piston bolt 4 is mounted on floating bearings.
The pistons 6 are cast from lightweight metals. The piston rings 5 are made up of trapeze
ring, minute ring and a roof chamfer ring. The upper piston ring sits in a cast steel beam.
The pistons are supplied with cooling lube oil by an injection nozzle 8. The lubricating oil
flows through the cooling channels of the piston base where it radiates heat.
The cylinder liners 3 are made by a centrifugal casting technique. Special attention is paid
to the honing in the further processing. The cross grinding angle generated in honing is
asymmetrical in response to the demand to achieve as low an oil consumption as possible
and optimum run-in times. The cylinder liners rest on the crankcase and are guided in a fit-
ting collar at the top and bottom.
By using wet cylinder liners it is possible to replace the cylinder unit quickly and cheaply.

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Description
A 2-10
1 Crankshaft
2 Con-rod
3 Cylinder liner
4 Piston bolt
5 Piston rings
6 Piston
7 Crankcase
8 Piston cooling nozzle
9 Counterweights of the crankshaft

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Description
2
Control system
The crankcase toothed wheel 2 drives the camshaft toothed wheel 1 and the lubricating oil
pump toothed wheel 3.
A 2-11
1 Camshaft drive
2 Spur toothed wheel (crankshaft)
3 Lubricating oil pump drive
Cylinder head
Design and function

The cylinder heads are made from a special alloyed casting like the crankcase. One single
cylinder head is installed per cylinder. Thanks to the excellent access and optimized design,
the single cylinder head can be replaced in a very short time.
The cylinder heads are liquid-cooled and integrated into the engine cooling system.
The sealing between the valve drive and the inlet and outlet channel is achieved by high
heat-resistant O-rings.
Valve control
The cylinder heads are multi-valve heads, i.e. each cylinder has two inlet valves for opti-
mum filling and two outlet valves for fast expulsion of exhaust gases. The high-temperature
resistant valves sit in the pressed in and so easily exchangeable valve seat inserts. The
valves are controlled with a proven valve bridge technology. The valve bridge control is par-
ticularly wear-resistant and is very maintenance-friendly.

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Description
A 2-12
1 Camshaft
2 Pilz tappet
3 Pushrods
4 Rocker arm
5 Rocker arm bracket
6 Valve bridges
7 Outlet valves
8 Inlet valves

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Description
2
Channel guide
The channel guide is based on the cross current principle. The cylinder heads are supplied
with the combusion gas through the charge mixture pipe from the one side. The two inlet
channels 2 and 3 have different manifolds in the cylinder heads. They are divided into a fill-
ing channel 2 and a twist channel 3. These ensure, by their shape, a combustion gas flow
into the combustion chamber which greatly improves the filing. The outlet channels 1 end
in the exhaust system in which the exhaust gas energy is not lost but recycled.
A 2-13

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Description
Exhaust system / Charging

The engine is fitted with a turbocharger and a liquid cooled mixture cooler. The charging of
the mixture achieves a higher level of output while at the same time reducing the pollutant
emissions.
Schematic diagram of the exhaust turbocharging
A 2-14
1 Intake air
2 Air filter
3 Filtered air
4 Gas-air mixer
5 Gas
6 Mixture to the compressor
7 Centrifugal impeller
8 From the compressor to the mixture cooler
9 Mixture cooler
10 Cooled mixture
11 Inlet valve
12 Exhaust valve
13 To the exhaust turbine
14 Turbine wheel
15 To the silencer
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Description
2
Speed governing
The speed governing has the task of controlling the engine speed by adjusting the throttle
valve position.
This control is carried out electronically through the TEM system. With an electronic speed
governing the actual speed is picked up using a flywheel sensor. This sensor signal is sent
to the TEM system and compared with the set rated speed. Speed fluctuations are control-
led by the TEM system and the actuator.
The actuator is connected to the throttle valve and is therefore able to adjust it.
Actuator
The actuators are distinguished by:
- high adjustment forces acting in both directions

- low power consumption
- Insensitivity at slow voltage change in the power supply, sudden changes lead to con-
troller faults.
A 2-15

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Description
Gas unit
Gas control system

Set up and function
The gas control system's control and safety units ensure danger-free and safe gas supply
to the engine. The gas pressure regulator matches the gas pressure on the network side to
the gas engine's needs.
Incorrect fitting, adjustment, alteration, operation or maintenance can cause injury

or damage to property.
Fitting, adjusting and maintenance only by authorised personnel.
Read instructions before fitting and using.
The units must be fitted in accordance with the applicable regulations.
The electricity and gas supply companies' local regulations must be observed.
Example gas control system
A 2-16
1 Shut-off system (ball valve)

2 Pressure gauge
3 Gas filter
4 Pressure switch
5 Safety cut-off valve, magnetic
6 Only for gas group 2 - flame penetration safety system
7 Gas pressure controller
Automatic switch off process

So as to purge the engine when switching off, the gas supply is closed off before the ingni-
tion is interrupted. This method is part of the automatic process by the TEM system.

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Description
2
Fitting and testing

For installation G 600 (DVGW-TRGI), G 490 and G 495 apply to the supply up to the cut-
off system to be fitted on the building side.
The components of the gas control system are tested by the manufacturer for strength and
seal. The completely fitted unit must undergo a final seal test with air or inert gas at 1.2
times the maximum permissible operating pressure (set outlet pressure at the controller),
but at least 150 mbar.
- The inlet pressure (network side) must always be the same as or greater than the outlet
pressure (engine side).
- Always create pressure build-up from the inlet side, reduce pressure always upstream
of the outlet side (adjust pressure slowly!).
- The gas control system may only be fitted horizontally.
- The gas control system must be protected from careless damage, especially when fit-
ted in a low position.
- No vibration may pass from the engine to the gas line.
- The operating elements must be easily accessible and easy to read.
Notes on fitting
Depending on the type of gas, the engine requires the right kind of gas control system.
If aggressive gases are used, nonferrous metal (brass) may not be used for parts carrying
gas.
The gas control system must be positioned in the same room as the gas engine. This en-
sures that the gas control system is subject to the same air pressures as the engine.
Blow-off lines must be led into the open air with adequate diameter.
Pressure control and control units and pipes must be fitted without tension. Pressure control
and control units must always be fitted in accordance with the manufacturer's instructions.
The direction of flow must be observed.
The gas control system must be fitted as close to the engine as possible. The distance be-
tween the gas control system outlet and the gas mixer inlet must not exceed 3 m and be
designed with max. three 90° bends.
Flame flashovers can occur with fuel gas mixtures whose components may also contain ox-
ygen. The gas control systems contain endurance burning flame flashover protection de-
vices with temperature monitoring to prevent flashovers in the gas-carrying line. Here a
maximum distance between the engine and the gas control system of 40x the gas line's di-
ameter is permissible. If the distance is greater, permanently fire-proof detonation protec-
tion must be fitted instead of the flame flashover protection.
Example: Line diameter = 10 cm

40 x 10 cm = 400 cm
max. permissible distance = 4m

TCG 2016
Description
Gas-air mixer, formation of mixture

The mixing of gas and air to a combustible mixture takes place immediately upstream of the
turbocharger, in the so-called mixer.
The mixer is a venturi pipe, i.e. flow-beneficial narrowing of the pipe which widens up again
gradually. The design causes only very slight loss of pressure to the flow and thus minimal
reduction of filling into the cylinders. At the narrowest point the flow is at its highest speed.
The underpressure created over a ring-shaped gap makes the gas mix into the main flow
radially from outside. This way of mixing has the advantage that the ratio of gas and air re-
mains almost constant even if the mixture sucked through changes considerably, and only
leaves the so-called lambda window, in which the engine operates safely and economically,
for short periods.
The adjustable gas gap serves to adjust the gas-air mixture.
The mixture volume is regulated by means of the throttle valve or rotary disk valve.
A 2-17
1 Gas inlet
2 Air inlet
3 Gas-air mixture outlet
4 Connection linkage to the stepper motor
5 Gas gap

TCG 2016
Description
2
Fitting position
A 2-18
1 Step motor
2 Gas-air mixer

TCG 2016
Description
Lubricating oil system

Component overview
A 2-19
1 Crankcase breather
Racor model
3 Lubricating oil collection vessel for crankcase breather
4 Lube oil sump
5 Lube oil filter
for turbocharger
7 Lubricating oil line
to the turbocharger
The lube oil reduces the friction of the components which rub against each other and feeds
heat away from the rubbing positions, the piston head and the turbocharger. A film of lube
oil on the running surfaces of the cylinders reduces the sliding friction of the pistons and
piston rings. Furthermore, the lube oil keeps impurities in suspension and carries them to
the lube oil filter.
The lube oil pump sucks the lube oil from the lube oil sump, feeds it through the lube oil
cooler and the lube oil filter into the engine's lube oil circuit.
The lube oil pressure in the engine circuit is set by a lube oil control valve. The bypass valve
is fitted so as to avoid the flow of lube oil being interrupted when the lube oil filter is dirty. If
the lube oil pressure is so high that the lube oil pump is at risk, the overpressure valve
opens and allows the excess lube oil carried flow back into the lube oil sump.

TCG 2016
Description
2
A 2-20
1 Lube oil filter

for engine circuit
2 Lube oil filter
for turbocharger

TCG 2016
Description
Lube oil level switch

The engine is fitted with a lube oil level switch. It passes various information about the level
of lube oil in the engine to the TEM system.
The lube oil is thus topped up automatically by the TEM system. If there is still too little lube
oil, the TEM system switches off the engine.
Likewise the lube oil level switch changes the lube oil automatically in conjunction with the
TEM system. The lube oil level switch reports the various lube oil levels to the TEM system.
A 2-21
1 Venting pipe
2 Cable set plug
3 Connecting pipe to the lubricating oil pan
4 Lubricating oil pan

TCG 2016
Description
2
Crankcase bleed valve
Racor model
Fumes are produced in the crankcase during engine operation. To protect the environment
these fumes are not allowed to escape into the atmosphere but are fed into a closed crank-
case breather. In this crankcase breather the filter performs important functions.
The fumes flowing into the filter first pass the pressure control valve which is mounted cen-
trally in the top part of the filter system. After passing the filter element the purified residual
gases are fed to the suction line between the suction air intake filter and the turbocharger.
The pressure regulator consists of a diaphragm valve loaded both sides. It controls the
crankcase pressure while at the same time vacuum pressures from the suction intake sys-
tem settle at an upper limit. Pulsating pressure peaks are limited as a result.
An optical indicator signals it is time to change the filter element.
The exchangeable and recyclable filter element consists of a micro-glass fibre structure
with a very great separating behaviour. This can be changed using quick release catches
without tools. The separated lubricating oil particles collect in the sump of the filter housing
and are fed back into the lubricating oil circuit via a return line.
A floor valve prevents gas getting in through the return line. The lubricating oil returns on
exceeding the pressure difference between the filter and crankcase or at engine standstill.
A 2-22
1 Optical display for imminent change of the filter element

2 Quick-release catches
3 Filter top part with intergrated pressure regulator
4 Powder-coated metal housing
5 Filter element
6 O-ring
7 O-ring
8 Floor insert

TCG 2016
Description
This crankcase breather achieves that:
 the engine room and system are not contaminated by lubricating oil fumes,
 the smell in the immediate vicinity is reduced,
 the environmental pollution is reduced,
 mixer or charge air cooler, turbocharger and inlet valves are better protected against
soiling.
A 2-23
1 Sucked in air
2 Suction air intake filter
3 Turbocharger
4 Exhaust gas
5 Mixer or charge air cooler
6 Engine
7 Line for fumes to the filter system
8 Line for filtered fumes into the suction line
9 Filter of the crankcase breather
10 Lubricating oil return to the lubricating oil tray

TCG 2016
Description
2
Model UPF 55
The crankcase breather UPF 55 has been developed for separating oily air.
The oil mist sucked in from the crankcase is fed from the inside to the outside through two
filter stages. The fine oil particles are separated in the filter stages.
A 2-24
1 Venting inlet from the engine (flow direction)

2 Measuring connections
3 Venting outlet
4 Outer filter insert
5 Inner filter insert
6 Process stage 1
7 Process stage 2
Cooling system
During combustion the chemical energy in the gas is converted into heat energy. Only some
of this can be converted into mechanical energy in the engine. The remaining residual heat
is mainly led away with the exhaust gas and the coolant.
The engine has a two-circuit cooling. The lubricating oil cooler, mixer cooler and cylinder
cooler are integrated in the engine circuit.
The low-temperature mixture cooler is cooled through a separate cooling circuit. That way
the mixture temperature could be lowered and the engine output increased.
The temperature of the coolant is controlled and monitored automatically. If the tempera-
tures exceed the maximum set values the engine is turned off by the TEM system.

TCG 2016
Description
Electrical system
Electrical system
The engine is fitted with a microprocessor controlled ignition system which is supplied with
24V power by the TEM system.
A gear rim fitted on the flywheel is scanned by an electronic sensor and enables the precise
crank angle time to be established. The selection of the correct process phase for the igni-
tion spark in the four stroke process is carried out by an additional sensor on the camshaft.
The electronic control unit sends medium voltage pulses to the ignition coils allocated to
each cylinder. From there a high voltage cable leads to the spark plugs. An extremely fast
increase in voltage ensures a powerful and short ignition spark which has a gentle effect on
the spark plug electrodes.
Adjustments to the ignition unit can only be made by your service partner; these include, for
example, adjusting the ignition time for matching to the gas quality with dual gas operation.
For work on the ignition system such as changing parts, e.g. spark plugs, ignition cables
and ignition coils, the ignition need not be switched off because the TEM system switches
off safely anyway when the ignition is at standstill.
A 2-25

TCG 2016
Description
2
Spark plug
The spark plug is designed as a prechamber spark plug. The ignition spark is created within
prechamber 1, the rays of flame pass through the holes 2 to the end face of the prechamber
into the combustion chamber.
The advantages of this design are the improved more even spread of the flame front across
the entire combustion chamber and lower wear and consequent longer service life of the
spark plug.
A 2-26
A 2-27

TCG 2016
Description
Electric starter
The engine is equipped with an electric starter.
The starter has the task of accelerating the engine crankshaft up to ignition speed.
An electric motor drives the starter pinion into the flywheel crown gear by an axially adjust-
able multiple disk clutch, thus driving the crankshaft. The multiple disk clutch does not
transmit the full starter torque until the starter pinion has tracked in, to avoid damage to the
edges of the teeth. When the engine starts, the multiple disk clutch is released by the steep
thread and the starter pinion tracks out.
A 2-28

TCG 2016
Description
2
Electrical components
A 2-29
1 Mixture temperature sensor in front of turbocharger

in the TEM system parameter intake air
2 Coolant temperature sensor (low temperature circuit inlet)
3 Ignition coil
One ignition coil per cylinder
4 Flywheel pulse sensor - location depending on model
5 Starter relay
6 Starter
7 Knocking sensor
One sensor for every two cylinders
9 Coolant temperature sensor (engine outlet)
10 Camshaft pulse sensor
11 Crankcase pressure sensor
12 Stepper motor gas-air mixer

TCG 2016
Description
A 2-30
1 Multi-function rail cylinder row B

2 Charging mixture temperature sensor after mixture cooler
in the TEM system parameter receiver
3 Combustion chamber temperature sensor
One sensor per cylinder
4 Coolant temperature sensor (high temperature circuit inlet)
6 Lube oil temperature sensor
7 Lube oil pressure sensor

TCG 2016
Description
2
A 2-31
1 Multi-function rail cylinder row B

2 Ignition coil
One ignition coil per cylinder
3 Ignition control unit
4 Actuator
5 Multi-function rail cylinder bank A

TCG 2016
Description

TCG 2016
Operation
3

TCG 2016
Operation

TCG 2016
Operation
3
Operation
Work before commissioning for the first time and after every service
General
Before commissioning for the first time, after the engine has been standing still for a long
time and after servicing and maintenance work the following tasks must be carried out:
 Check all leads and connections for the following media:

- Gas
- Lube oil
- Coolant
- Intake air
- Exhaust gas
 Check the speed transmitter for smooth action.
 Check the function of the monitoring, shut-off and remote control devices.
 Check that the electric wiring is in perfect condition.
 Check control cables and sensors usint the TEM system self-test facility.
Filling up coolant
Close the coolant drain cocks on the engine and the cooling devices.
The coolant is filled through a filler connection.
For specifications of the quality to be used see chapter 4, Operating media or Technical Cir-
cular
The coolant chambers are vented by a venting pipe with the coolant pump running.
Then check the coolant level again and top up the coolant if necessary.
Filling lubrication oil

Fill in lubricating oil through the pre-lubrication pump.
For specifications of the quality to be used see chapter 4, Operating media or Technical Cir-
cular
The lubrication oil level is monitored during oepration by the TEM system. The approximate
lubrication oil level can be checked with a dipstick or inspection glass. After topping up lu-
brication oil this must be done in conjunction with the TEM system.
If the lubrication oil level is too low thee monitoring system switches to non-release of the
starting process or to stopping the engine.

TCG 2016
Operation
Pre-lubrication
An electric pre-lubrication pump is fitted onto the engine.
Before the engine is started the TEM system switches on the pre-lubrication pump. The pre-
lubrication process runs for a fixed length of time. Only when the pre-lubrication process
has been completed is it possible to start the engine.
On engines which are on stand-by the engine is lubricated by the electric pre-lubrication
pump at regular intervals. Pre-lubrication must be completed before the engine is started.
Gas supply
Danger of explosion !
Before carrying out any work on the gas line, the room ventilation must be turned on.
Smoking and naked lights are prohibited.
The entire line leading to the engine (if appropriate, also the desulphurizer, gas compres-
sor, cooler, gas pressure controller and shut-off devices) must be cleaned from the inside
before commissioning. All parts of the line must be dry, clean and free of welding beads,
scale and other dirt particles.
The seals of the connections must be checked by spraying on soap suds or a leakage seek-
ing spray.
Note for all heat exchangers

When filling the water side of heat exchangers they must be permanently vented (if they are
not properly vented gas bubbles can be formed which cause damage to the boilers).
Particular care must be taken to avoid dirt in the heating water. Mud and corrosion products
from older boilers and residue from roller and welding can ge deposited and cause over-
heating, voltage spikes and material breaks because of the local isolation effect.
For this reason the heating water side must be checked and if necessary cleaned after the
first 10 hours and every additional 100 hours. Mud extraction nozzles and filters make this
task easier.
Exhaust gas side

Before closing the isolation all bolts on the pipe and container flanges of the exhaust system
must be tightened. This measure is neccessary because of the settling behaviour of tghe
seals.
It is essential that the tightening process is repeated after about 100 operating hours or af-
ter 14 Days.
If this is not carried out no guarantee can be made for leaky seals or escaping ehaust gas-
es.

TCG 2016
Operation
3
Commissioning / starting
Before every commissioning / starting of the engine
- Check the coolant level, correct if necessary.

- Check the lubricating oil level, correct if necessary.
Start the engine.

The intake air temperature levels must be adhered to - see Chapter 8, Technical Data
The following functions are carried out automatically in sequence by the TEM system unit
management system when starting:
1 Run mixer to the starting position for the type of gass concerned
2 Check readiness of all module components for starting
3 Switch on starter (engine runs, air and exhaust system is purged)
4 Switch on ignition
5 Open gas valve (engine starts)
6 Turn off starter when adequate speed is adequate and disconnect
7 Engine speed is increased to set speed
8 Unit is ready for synchronisation
Warming up
The engines can be kept at operating temperature, even when standing, by using separate
coolant heating (resistance heating or heating with pump operation).
After starting the engines usually reach operating temperature quickly by return increase of
the warm water flow, independently of the temperature in the heating system. In most cases
the working temperature is the same as the set heating flow temperature.
Ventilation of rooms
When engines are fitted in closed rooms, a check must be made after they have started that
the automatic room ventilation is working properely and that the fans re running.
Inadequate engine room ventilation leads to high room temperatures and to a correspond-
ing loss of performance due to the engine and generator protection in the TEM system.
Lubricating oil system

The lubrication oil pressure is monitored and recorded in the TEM system and normally
does not have to be checked any more by the operator.
Checking the lubrication oil level and the lubrication oil supply in the day tank regularly is
very important. It should be checked when the engine is standing still, during regular
checks, or when running constantly, every 24 hours. If there is not enough lubrication oil is
switched off automatically and has to be unlocked manually at the switchboard after the lu-
brication oil has been filled up.
The pre-lubrication process takes about 20 minutes. It is not possible to start the engine
before then.

TCG 2016
Operation
Operation monitoring
Inspections immediately after commissioning

Check engine for smooth running and noise.
Check the entire engine for leaks.
For further information about the visual inspection of the system - see job card B 0-1-5.
Unit monitoring
All important parameters of the engine, the generator and the connected heat utilization unit
are constantly monitored by the TEM system.
The unit's operating data must be checked using the printouts from the TEM system at reg-
ular operating hour intervals (daily when running continuously).
If there is a warning or a fault in the unit, these must be recorded before resetting. This pro-
vides the oppurtinity to print out the appropriate history or the operating daybook from the
TEM system.
Danger of destruction !
Never reset warning/fault reports before the cause has been ascertained.
Continuing to operate the engine when there is a warning or restarting after a fault
without eliminating the cause can lead to damage and total loss of the engine.
If the engine is restarted without fixing the cause of the warning or fault, the manu-
facturer's guarantee becomes invalid.
Engine peripheral systems

The temperatures, pressures and other relevant conditions are monitored automatically,
the operating data is stored continuously in the TEM system's module control.
When the set limit values are reached, a warning is first given out. If the limit value is passed
again the TEM system stops the engine.
Reverse power
If the unit is switched off by the TEM system while it is running parallel to the network and
it does not open the generator circuit breaker because of a fault, the unit goes into reverse
power. By switching off in the TEM system the solenoid valves are closed and the ignition
is turned off. No further combustion takes place.
Depending on the type of control the generator section switch is automatically cut off from
the power network. If this does not happen, the power fed in causes the generator to run as
a electric motor and it continues to run at the set speed.
If the Emergency Stop switch is operated in this situation, all electric pumps stop. The me-
chanical friction in the engine will continue to generate heat, but it will not be dissipated
through the cooling system. This can lead to the engine overheating and being written off.
If it gose into reverse flow the generator circuit breaker must be switched off or the
network section track must be disconnected from the power.

TCG 2016
Operation
3
Coolant circuit
The coolant must not be topped up while the engine is runnning!
Topping up must only be carried out when the engine has been stopped and with small
quantities. When topping up frequently, ensure that the correct content of corrosion protec-
tion and/or anti-freeze is adhered to.
Batteries
If the engine has an electric starter motor, its batteries and the chargers must be checked
weekly.
Please observe:
The TEM system operating instructions are a separate document and must be re-
quested separately.
Shutting down
If the engine is shut down for a longer period of time, the work steps listed below must be
performed.
Shutting down the engine for up to 3 months:
- Close the shut-off valve of the gas control line.

- Close the shut-off valves before and after the cooling devices.
- Switch on the pre-heating devices for the coolant, if available, in case of risk of frost.
If the pre-heating device is not switched on, anti-freeze must be added to the coolant.
If this is not possible, the cooling system must be emptied - see job card B 9-0-4.
- During engine standstill, turn over the engine at least two turns of the crankshaft once
a week. Pre-lubricate the engine first.
Shutting down the engine for 3 months or longer:
- Close the shut-off valve of the gas control line.

- Close the shut-off valves before and after the cooling devices.
- Drain the cooling system - see job card B 9-0-4.
- Drain lubricating oil from the engine, mounted parts, pipes and fittings.
- Fill the engine with corrosion protection agent - see chapter 7 Corrosion protection.

TCG 2016
Operation

TCG 2016
Operating and auxiliary materials

4
GAS

TCG 2016

TCG 2016

4
General
Activities described in the operating and workshop manuals necessitate the use of operat-
ing and auxiliary materials.
All operating and auxiliary materials must be stored, transported and disposed of properly.
The owner is responsible for this.
Disposal includes recycling and disposal of operating and auxiliary materials whereby re-
cycling has priority.
Details of disposal and their monitoring are governed by regional, national and international
laws and directives which the system operator must observe on his own responsibility.
It is essential that notes from the supplier on the packaging or in the form of enclosed leaf-
lets be observed.
These include, for example:
- Safety instructions
- Personal protection equipment
- Proper use
- Proper disposal
- Best before date
- Storage / transport
Product selection
Due to the large number of products in national and international quality and availability and
as a result of the constant further development, it is not possible for us to test all suitable
products and to name them, we therefore cannot accept any responsibility for these prod-
ucts.
The supplier of the operating materials is solely responsible for the world-wide consistent
quality of the products listed here and for products not listed here additionally for meeting
the listed requirements for operating media and their operational safety. This also applies
for the event that the manufacturer develops the listed products further.
The operating media (reference products) listed here are just a selection of a few manufac-
turers and their products. Other operating media not listed here may be used if they meet
the specified requirements. That means these operating media must be at least equal or
better in all criteria. The operating media named in this specification are to be used as ref-
erence products for comparison. The respective operating media suppliers can provide in-
formation about this and should confirm the suitability accordingly.
Mixability
Mixing different expendable types together, e.g. different lube oils with each other, different
coolant additives with each other, may lead to malfunctions.
In any case the product supplier’s consent must be obtained before mixing and he must
take over the responsibility. This also applies for other additives to the operating media.
Guarantee
If unsuitable operating media are used or if it is not possible to produce evidence that the
operating media used are suitable for the requirements, no guarantee of faultless operation
is accepted by the manufacturer of the engine. This also applies to inadequate mainte-
nance of the engines and the operating media.

TCG 2016
The most important operating media are shown in the accompanying operating media reg-
ulations. The data given in them are binding unless the engine or unit-specific contracts
state otherwise.
Operating media
Fuel gas
see technical circular TR 0199-99-3017.
Lube oil
Engine coolant

TCG 2016

4
Auxiliary materials
Packing compound
DW 43
Solvent free, rubber-based soft-elastic hardening, fast skin formation.
Temperature range 30 °C to 100 °C
For sealing narrow joints
DW 47
Silicone rubber, tenacious elastic, easily dissolvable.
Temperature range max. 180 °C, lube oil max 150 °C
For sealing of rough and uneven surfaces
DW 48
Silicone rubber, tenacious elastic, high adhesion strength.
Temperature range -65 °C to 265 °C
For sealing of rough and uneven surfaces
DW 49
Mixed polymerisate of vinyl and acrylic compounds, high adhesion strength and perma-
nent elasticity.
For sealing core hole plugs
DW 50
Liquid, hardening artificial resin, compatible with flat gaskets.
For sealing housings
DW 51
Physically dry artificial resin, permanently elastic and vibration free.
For sealing surfaces
DW 63
Anaerobic solvent-free single-component substance hardening upon metal contact when
excluding oxygen, low strength, high viscosity, thixothropic.
For sealing surfaces up to a max. gap width of 0.10 mm

TCG 2016
DW 67
For sealing surfaces up to a max. gap width of 0.50 mm
DW 68
For sealing surfaces up to a max. gap width of 0.50 mm, locking and sealing threads up
to R2"
Locking agent
DW 55
excluding oxygen, high strength, low viscosity.
Locking and sealing threads up to M12, joints up to a max. gap width of 0.15 mm
DW 56
excluding oxygen, high strength, high viscosity.
Locking and sealing threads up to R2"
DW 57
excluding oxygen, low strength, low viscosity.
Locking and sealing threads up to M12
DW 59
excluding oxygen, high strength, medium viscosity.
DW 60
excluding oxygen, medium strength, low viscosity.
Locking and sealing threads up to M56 or R2"

TCG 2016

4
DW 62
Joints up to a maximum gap width of 0.12 mm
DW 64
Locking and sealing threads up to M80 or R3"
DW 65
excluding oxygen, high strength, high viscosity.
Joints up to a maximum gap width of 0.25 mm
DW 66
excluding oxygen, low strength, high viscosity.
Locking and sealing threads up to R3"
DW 69
excluding oxygen, low strength, low viscosity.
DW 70
DW 71

TCG 2016
DW 72
Activator
DW 61
Accelerates and enables full hardening of anaerobic substances in passive materials
Adhesive
KL 1
Two-part epoxy resin based, water, lube oil and diesel fuel resistant. Mixing ratio 1:1, ad-
hesive KL 1 and hardener KL 2
Temperature range max. 150 °C
Sticks steel, aluminium, brass and plastics such as plexiglass, polyethylene etc. with
themselves and with each other
Hardener
KL 2
Two-part epoxy resin based, water, lube oil and diesel fuel resistant. Mixing ratio 1:1, ad-
hesive KL 1 and hardener KL 2
Temperature range max. 150 °C
Sticks steel, aluminium, brass and plastics such as plexiglass, polyethylene etc. with
themselves and with each other

TCG 2016

4
Lubricant
S1
Prevents burning of screw connections in exhaust pipes
S2
Spray medium, prevents friction and wear on poorly accessible sliding surfaces. Provides
an emergency lubrication and prevents jolting.
S3
Spray medium, prevents friction and wear. Provides an emergency lubrication and pre-
vents jolting.
S4
Preferably for pre-treating components with a high operational temperature. After evapo-
ration of the carrier oil (at 200 °C) a more effective lubricant solid film is left behind. Com-
patible with natural rubber and plastics.
S5
For long-term lubrication of rolling and plain bearings with high bearing pressures. Water-
resistant, good emergency lubrication.
S6
For long-term lubrication of roller and plain bearings with medium bearing pressures and
higher temperatures. Water-resistant, good emergency lubrication.
Grease
Consistent grease for lubricating rolling bearings, plain bearings and sliding surfaces. For
example, for filling the tooth coupling between the injection pumps.

TCG 2016
Commercially available products

Below is a reference list of auxiliary media used with which best results have been
achieved. Equivalent products can be used whereby the supplier must guarantee the suit-
ability of the product for the application.
Conservation agents
Manufacturer: BP Hamburg
SAE30W-30, BP- Run-in conservation oil for conserving the lube oil system and 15%
MEK 30 part distilled fuel for fuel systems
Manufacturer: Kuhbier Chemie GmbH, 58566 Kierspe

Puriton 3956 For corrosion protection of the coolant system
Manufacturer: Reicon Chemie, 04103 Leipzig

ODACON Z For corrosion protection of the coolant system
Manufacturer: Deutsche Castrol, 76829 Landau

Gerserol Super For protecting bare exterior surfaces and parts (wax-like)
Manufacturer: Fuchs Europe, 68169 Mannheim

Renolit MP2 Protective grease for control linkages and joints
Manufacturer: Silbermann GmbH & Co. KG, 86456 Gablingen

Talcum fine, white For rubber parts

TCG 2016

4
Cleaning agents
Manufacturer: Henkel KGAA, 40191 Düsseldorf

P3 Standard For enging cooling system, powder
P3 Cold cleaner For engine parts, liquid
P3 - croni Neutralising agent for raw water circuit and charge air cooler, water
side
P3T - 288 For enging cooling system, powder
P3T - 1166 Neutralising agent for raw water circuit and charge air cooler, water
side
P3T - 5308 For charge air cooler, air side
Manufacturer: Vecom GmbH, 21107 Hamburg

Vecom B 14 For tank systems, liquid
Vecom B 24 B For engine parts and tank systems, liquid
Vecom B 85 For charge air cooler, air side
Vecom BA-S For enging cooling system, powder
Vecom BA-30 For enging cooling system, liquid
Manufacturer: Drew Ameroid Deutschland GmbH, 21107 Hamburg

ACC 9 For charge air cooler, air side
SAF-Acid Limescale remover for engine cooling system, raw water circuit and
charge air cooler, water side, liquid, concentration 5%, temperature
range 55 °C to 75 °C
HDE-777 For enging cooling system, liquid
Carbon remover For engine parts, liquid
Tank cleaner No. 4 For tank systems, liquid
Ameroid ACC-9 For engine parts, liquid
Manufacturer: Collardi GmbH, 50825 Köln

Porodox For raw water circuit and charge air cooler, water side, treatment time
max. 16 hours, concentration 2% to 10%, temperature range 20 °C to
60 °C
Manufacturer: Haug-Chemie GmbH, 74889 Sinsheim

Eskapon S 255 For removal of conservation agent
Manufacturer: Fuchs Europe, 68169 Mannheim

Reponal B150 Thinners and removers of wax-like conservation agents

TCG 2016
Water treatment agents
Manufacturer: E. Merck KGAA, 64293 Darmstadt

Aquamerk Art. No. Hardness determiner for cooling water, order no. 1215 8292
11129
Manufacturer: Vecom GmbH, 21107 Hamburg

Vecom CN Coolant hardener, powder
Manufacturer: Benckiser GmbH, 67001 Ludwigshafen

Trisodium phos- Coolant softener, powder
phate

TCG 2016
Maintenance
5
E20
E30
E40
E50
E60
E70

TCG 2016
Maintenance

TCG 2016
Maintenance
5
Maintenance
Maintenance schedule as separate documentation

To ensure the operating reliability of the engine and the components fitted to the engine,
the maintenance measures must b e carried out according to the maintenance schedule or
the manufacturer documentation.
The maintenance schedule adapted to the engine is enclosed or available as a separate
documentation.
When operating the engine without observing the maintenance measures listed in
the maintenance schedule, the engine could be damaged or destroyed.
The manufacturer will not be liable if the engine is operated without performing the
prescribed maintenance work.

TCG 2016
Maintenance

TCG 2016
Tools
5
Tools for competence class 1
Address of order
You can buy the tools through your service partner.
Tools sorted according to order numbers
Name Figure
1 Description / Use (The illustrations are examples)
2 Module
3 Order number / Order from ...
Torque wrench
1 Measuring range 0-210 Nm (0-21 kpm)
2 00 General
3 1203 0350 / Service partner

TCG 2016
Tools
Name Figure
2 Module
Test case for lubricating oil and coolant

1 Equipment and aids for the lubricating oil and coolant
properties tests
2 00 General
consisting of: 1213 0403 Case (without contents)

For coolant test
1213 0395 Test rods for pH value
1213 0396 Test material for total hardness
1213 0397 Test material for carbonate hardness

1213 0398 Test material for chloride content
1213 0399 Test rod for sulphate content
For lubricating oil test
1213 0384 Complete set, consisting of:

1213 0385 Instrument for testing water content
1213 0386 Measuring cylinder
1213 0387 Suction measuring instrument
1213 0388 Float vessels (test water content)
1213 0389 Spare gasket
1213 0390 Tweezers
1213 0391 Pipette
1213 0393 Test tube A (check water content)
1213 0394 Test tube B (check water content)
1213 0400 Glass rods for drip sample

1213 0401 Filter paper for drip sample
1213 0402 Instrument for viscosity comparison

TCG 2016
Tools
5
Name Figure
2 Module
Tool kit
1 Standard set
2 00 General
consisting of: 1215 8074 Tool case

0115 4248 Open-end spanner 8 x 10
0112 4755 Ring spanner 13 x 17
0115 4367 Set of feeler gauges 0.05 - 1.0 x 100
0110 3964 Socket 10 x 12.5
0110 3965 Socket 13 x 12.5
0110 3966 Socket 14 x 12.5
0110 3967 Socket 17 x 12.5
0110 3968 Socket 19 x 12.5
0110 2416 Socket 22 x 12.5
0115 2905 T-handle A 12.5
0110 2415 Extension B 12.5 x 250
0115 4232 Universal joint C 12.5
0110 3385 Screwdriver A 0.8 x 4.0
0110 4281 Screwdriver A 1 x 5.5

TCG 2016
Tools
Name Figure
2 Module
Tool kit
1 Standard set (small)
2 00 General

0115 1243 Socket wrench 13 x 12.5
0115 2880 Socket wrench 15 x 12.5
0115 1245 Socket wrench 17 x 12.5
0115 1246 Socket wrench 19 x 12.5
0710 9772 Socket wrench 22 x 12.5
0710 9773 Socket wrench 24 x 12.5
0115 2882 Socket wrench 27 x 12.5
0115 2906 T-handle A 12.5
0110 4327 Extension B 12.5 x 125
0110 3385 Screwdriver A 0.8 x 4.0
1215 8173 Set of feeler gauges 0.2 - 0.45
1215 8115 Square spanner SW 3.25

TCG 2016
Tools
5
Name Figure
2 Module
Tool kit
1 Standard set (large)
2 00 General

0115 1243 Socket wrench 13 x 12.5
0115 2880 Socket wrench 15 x 12.5
0115 1245 Socket wrench 17 x 12.5
0115 1246 Socket wrench 19 x 12.5
0710 9772 Socket wrench 22 x 12.5
0710 9773 Socket wrench 24 x 12.5
0115 2882 Socket wrench 27 x 12.5
0115 2905 T-handle A 12.5
0110 4327 Extension B 12.5 x 125
0110 2415 Extension B 12.5 x 250
0115 4232 Universal joint C 12.5
1203 0362 Ratchet head (square)
1215 8146 Tubular handle
1215 8139 Torque wrench 0-210 Nm
1215 8148 Extension lever for 1215 8139 (0-420 Nm)
0110 3385 Screwdriver A 0.8 x 4.0
0115 4367 Set of feeler gauges 0.05 - 1.0 x 100
1215 8115 Square spanner SW 3.25

TCG 2016
Tools
Name Figure
2 Module
Strobe light
1 For checking the ignition time
2 13 Electrics
Acid tester
1 For checking the battery fluid density
2 13 Electrics
Lubricating oil filter key

1 For loosening the lubricating oil filter cartridge
2 08 Lubricating oil system

TCG 2016
Tools
5
Name Figure
2 Module
Depth gauge
1 For measuring the valve wear
2 01 Cylinder head
Turning gear
1 Standard set
2 00 General
consisting of: 1227 6679 Bolts

1227 6680 Guide
1221 2624 Compression spring
1221 2379 Pinion
0115 4439 Washer
0111 2416 Hexagon head screw
1227 6700 Screw fitting
0100 9670 Locking agent
Spark plug spanner

1 For removing and installing the spark plugs with inte-
grated ignition cable
2 13 Electrics

TCG 2016
Tools

TCG 2016
Tools
5
Tools for competence class 3
Tools sorted according to order numbers
Name Figure
2 Module
Dial gauge
1 For measuring stand and plate
2 01 Cylinder head
Piston ring pliers (diameter 150 mm)

1 For removing and installing the piston rings in the pis-
tons
2 02 Driving gear
Measuring tripod
1 For clamping and fixing the dial gauge
2 00 General
Assembly pliers for piston assembly

1 For clamping the piston rings when inserting the pistons
in the cylinder liner
2 02 Cylinder head

TCG 2016
Tools
Name Figure
2 Module
Press-out pin for valve stem guide

1 For pressing out the inlet and outlet valve stem guide
2 01 Cylinder head
Press-in pin for valve stem guide

1 For pressing in the inlet and outlet valve stem guide
2 01 Cylinder head
Lifting device for valve tappet

1 For lifting the valve tappet when removing the camshaft
2 04 Engine control
Guide pin for cylinder head

1 For positioning the cylinder head
2 01 Cylinder head

TCG 2016
Tools
5
Name Figure
2 Module
Measuring tap for charging mixture pressure measure-

ment
1 For installation in the charging mixture pipe for pressure
measurement
2 06 Exhaust system / Charging
The measuring taps can remain installed in the charging mixture pipe after the measurement.
Disassembly tool for cylinder liners

1 For removing the cylinder liners from the crankcase
2 03 Crankcase
Disassembly and assembly lever for valve spring

1 For clamping the valve springs when removing and in-
stalling the valves
2 01 Cylinder head
Disassembly and assembly tool for camshaft bearing

1 For removing and installing the camshaft bearing in the
crankcase
2 04 Engine control

TCG 2016
Tools
Name Figure
2 Module
Disassembly and assembly pin for camshaft

1 For removing and installing the camshaft
2 04 Engine control
Press-in pin for valve seat insert

1 For pressing in the inlet valve seat insert
2 01 Cylinder head
Press-in pin for valve seat insert

1 For pressing in the outlet valve seat insert
2 01 Cylinder head
Disassembly and assembly device for crankshaft seal-

ing ring
1 For removing and installing the crankshaft sealing ring
on the free side
2 02 Driving gear

TCG 2016
Tools
5
Name Figure
2 Module
Disassembly and assembly device for crankshaft seal-

ing ring
1 For removing and installing the crankshaft sealing ring
on the drive side
2 02 Driving gear
Inspection device for piston cooling nozzle

1 For testing the alignment of the piston cooling nozzle
2 02 Driving gear
Disassembly and assembly device for spark plug sleeve

1 For removing and installing the spark plug sleeve
2 01 Cylinder head
Cleaning tool for spark plug sleeve

1 For cleaning the sealing surface of the spark plug sleeve
2 01 Cylinder head

TCG 2016
Tools

TCG 2016
Troubleshooting
6
STOP

TCG 2016
Troubleshooting

TCG 2016
Troubleshooting
6
Troubleshooting
The following table is a list of faults which may occur during engine operation and their pos-
sible causes. It does not claim to be a full list.
The causes of the faults are listed in ascending order of effort required to localise them.
The tables listed below contain measures which may help to eliminate the fault. If the fault
persists even after carrying out the measures, please contact your Service Partner.
Never reset warning/fault reports before the cause has been ascertained.
Continuing to operate the engine when there is a warning or restarting after a fault
without eliminating the cause can lead to damage and total loss of the engine.
If the engine is restarted without fixing the cause of the warning or fault, the manu-
facturer's guarantee becomes invalid.
Explanation of tabular representation
Fault type
TEM message
Plain text entry
Possible cause of the fault
Troubleshooting
Fault table
Fault
Engine fails to start
Engine does not reach the prescribed performance or speed
Engine fires irregularly
Engine bangs and runs irregularly
Engine stops suddenly or is switched off by TEM after a fault
Engine gets too hot or TEM message lack of coolant
Lack of lubricating oil pressure or TEM message lubricating oil pressure too low or lubri-
cating oil level too low
Coolant in lubricating oil
Lubricating oil in coolant

TCG 2016
Troubleshooting
Troubleshooting remedies
Engine fails to start
TEM message
Engine does not start
Discharged or defective battery
Check battery, recharge / renew if necessary
Starter defective
Check the starter, renew if necessary
Power supply to the terminal box unit interrupted
Check the cable harness, repair / renew if necessary
Ignition system defective
Check the ignition system
Gas shutoff fittings closed
Open gas shutoff fittings
Gas pipe not bled
Bleed gas line

TCG 2016
Troubleshooting
6
Engine does not reach the prescribed performance or speed
TEM message
none
No valve clearance
Set the valve clearance
TEM message
Gas pressure
Gas shutoff fittings not fully open
Fully open the gas shut-off fittings / check gas filter and renew if necessary
Too little gas
Check gas pressure
Suction air intake filter blocked
Check the suction air intake filter, renew if necessary
TEM message
Gas mixer stop
Gas-air mixture defective (too lean / too rich)
Check regulation of the gas mixer

TCG 2016
Troubleshooting
Engine fires irregularly
TEM message
Engine misfires
Note: The smooth run detector of the TEM system can be used to diagnose the
misfiring
Ignition control unit defective
Check the ignition control unit, renew if necessary
Ignition coils defective
Check the ignition coils, renew if necessary
Electrode spacing at spark plug too big
Check the spark plug, reset / renew if necessary
Spark plugs defective
Check the spark plugs, renew if necessary
Frequency sensor (camshaft or flywheel) has too big a spacing / or are in

range of limit
Check the setting, adjust if necessary

TCG 2016
Troubleshooting
6
Engine bangs and runs irregularly
TEM message
none
Inlet and outlet valves leaking
Check inlet or outlet valves
Oil carbon residue on pistons or outlet valves
Check parts, clean if necessary
TEM message
Engine does not start
Ignition cable defective
Check the ignition cable, renew if necessary
Ignition coil defective
Check the ignition coil, renew if necessary

range of limit
Gas pipe not bled
Bleed gas line

TCG 2016
Troubleshooting
Engine stops suddenly or is switched off by TEM after a fault
TEM message
none
Ignition failed (cable broken)
Check the cable harness, repair / renew if necessary
Ignition control unit defective
Check the ignition control unit, renew if necessary

range of limit
Gas supply interrupted
Check the gas pipe
Gas pressure regulator sticks
Check the gas pressure regulator, repair or renew if necessary
TEM message
Gas mixer stop lean
Gas pressure too high
Check gas pressure on the gas pressure regulator and correct it if necessary
TEM message
Overspeed
Speed governor defective
Ask an authorised expert to check the speed governor and have it repaired
if necessary

TCG 2016
Troubleshooting
6
TEM message
Fault cooling water pump
Coolant pump defective (pump shaft broken, bearing defective)
Check the coolant pump, repair and renew if necessary
TEM message
Overtemperature cooling water
Coolant system sludged or blocked by scale
Clean the coolant system
TEM message
Low cooling water
Too little coolant
Check coolant level and correct if necessary, eliminate cause of the coolant
loss
Coolant leaks from the coolant pump
Check axial sealing rings of the coolant pump and renew if necessary
TEM message
Lubricating oil level too low / overtemperature lubricating oil
Lube oil level too low
Check the lube oil level and refill if necessary

TCG 2016
Troubleshooting
Engine gets too hot or TEM message lack of coolant
TEM message
none
Three-way valve secondary heating circuit defective
Check the three-way valve secondary heating circuit, renew if necessary
Heat transmission (from primary circuit to secondary circuit) defective
Clean sludged elements of the heat transformer
TEM message
Fault cooling water pump
Coolant pump defective (pump shaft broken, bearing defective)
Check the coolant pump, repair and renew if necessary
TEM message
Overtemperature cooling water
Coolant system sludged or blocked by scale
Clean the coolant system
TEM message
Low cooling water
Too little coolant
Check coolant level and correct if necessary, eliminate cause of the coolant
loss
Coolant leaks from the coolant pump
Check axial sealing rings of the coolant pump and renew if necessary

TCG 2016
Troubleshooting
6
Lack of lubricating oil pressure or TEM message lubricating oil pressure too low or
lubricating oil level too low
TEM message
none
Lube oil pressure gauge defective
Check the lube oil pressure gauge, renew if necessary
Regulating valve defective
Check the regulating valve, have it repaired or renew if necessary
Bearing clearance of the crankshaft or con-rod bearings too great (wear)
Check bearing clearances, renew components if necessary
TEM message
Lube oil filter dirty
Lube oil filter dirty
Replace lubricating oil filter
TEM message
Lubricating oil level too low / overtemperature lubricating oil
Lube oil level too low
Check the lube oil level and refill if necessary

TCG 2016
Troubleshooting
TEM message
Lube oil pressure too low
Manifold to lube oil pump soiled
Check and clean the manifold
Lube oil pump heavily worn
Check the lube oil pump, repair and renew if necessary
Safety valve on the lube oil pump leaking
Check the safety valve, repair and renew if necessary
Coolant in lube oil
TEM message
none
Cylinder liner seal in crankcase leaking
Remove the cylinder liner and seal it again, analyse the lubricating oil sam-
ple
Lube oil in coolant
TEM message
none
Lube oil cooler leaking
Check the lube oil cooler, renew if necessary

TCG 2016
Corrosion protection
7

TCG 2016

TCG 2016
7
Preservation
Technical Circular TR 0199-99-2116

TCG 2016

TCG 2016
Technical data
8

TCG 2016
Technical data

TCG 2016
Technical data
8
Technical data
Test and setting values
General
Work procedure
Otto four-stroke engine with four-valve technology
Mixture charging
Turbo charging with mixture cooling
Liquid-cooled mixture cooler
Cylinder arrangement
V-engine with 60o cylinder angle
No. of cylinders
12 and 16
Speed governing
TEM system
Actuator
Heinzmann StG 10 - 01
Type of combustion gas

Gases of gas group 1 and gas group 2
Bore
132 mm
Stroke
160 mm

TCG 2016
Technical data
Capacity per cylinder

2.19 dm3
Engine swept volume

V12 engine 26.3 dm3
V16 engine 35.0 dm3
Compression ratio
12 : 1
Ignition sequence
V12 engine A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
V16 engine A1 B3 A3 B7 A7 B5 A5 B8 A8 B6 A6 B2 A2 B4 A4 B1
Dimensions
V12 unit Length 3,520 mm
Width 1,450 mm
Height 2,200 mm
V16 unit Length 4,000 mm
Width 1,450 mm
Height 2,200 mm
Weights *
V12 engine Engine 2,380 kg
Power unit 5,100 kg
V16 engine Engine 2,880 kg
Power unit 6280 kg
Cylinder head complete 20 kg
Cylinder liner 8 kg
Piston complete 4 kg
Con-rod complete 4 kg
Camshaft V12 engine 33 kg
V16 engine 46 kg
Crankshaft V12 engine 190 kg
V16 engine 230 kg
Lubricating oil pan V12 engine 43 kg
V16 engine 55 kg
Flywheel 175 kg
Flywheel housing 80 kg
Front cover 57 kg
Vibration damper V12 engine 30 kg
V16 engine 40 kg
Mixture cooler 85 kg

TCG 2016
Technical data
8
Lubricating oil pump 9 kg

Lubricating oil cooler V12 engine 33 kg
V16 engine 44 kg
Starter V12 engine 19 kg
V16 engine 33 kg
* All data are approximate values
Coolant content (total)

V12 engine 40 dm3
V16 engine 53 dm3
Coolant temperatures
Inlet / outlet 84 / 90 °C
Suction intake air temperature

min. 20 °C
Design Project-related
Cylinder head
Control times (at valve clearance)

Inlet opens before TDC 18°
Inlet closes after BDC 34°
Outlet opens before TDC 65°
Outlet closes after BDC 14° 30’
Control times (at 1 mm valve clearance)

Outlet opens before TDC 58° 30’ (58,5°)
Outlet closes after BDC 6° 30’ (6,5°)
Valve bridge
0.05 mm
Valve clearance
Inlet 0.3 mm
Outlet 0.8 mm

TCG 2016
Technical data
Crankcase
Differential pressure UPF 55 (at full load)

Complete filter max. 200 mmWS
(max. 20 mbar)
1. stage (inner filter insert) max. 80 mmWS
(max. 8 mbar)
2. stage (outer filter insert) max. 120 mmWS
(max. 12 mbar)
Separating quality UPF 55 (measured at full load with Dust Trak TM Model 8520)
after 1st stage (inner filter insert) max. 20 mg/m3
after 2nd stage (outer filter insert) max. 5 mg/m3
Speed controller
Set Altronic frequency generator for camshaft.

Turn engine until pulse screw is visible.
Turn in frequency generator to stop.
Unscrew 0.75 - 1 turn (270°-360°)
Set the camshaft sensor (Jaquet)

Turn the engine until the pulse screw is visible
Turn in the frequency sensor to the stop
Unscrew 1 - 1.25 rotation (360°-450°)
Set the flywheel sensor (Jaquet)

Turn in the frequency sensor up to the system
Unscrew 1 rotation (360°)
Continue unscrewing until the marking is in running direction

TCG 2016
Technical data
8
Actuator Heinzmann Stg 10 - 01

Control output shaft Angle of rotation 36 °
max. torque 10 Nm
Holding torque 5 Nm
Throughput time 80 ms
Power consumption Steady state 1A
Load change 3-4 A
max. current 4.5 A
limited current 2.5 A
Storage temperature -55 to +110
Ambient temperature Standard -25 to +90
Special version -40 to +90
Air humidity up to 100 %
Type of protection Housing IP 44
Weight 4.5 kg
Setting dimension jointed heads (measured from centre hole to centre hole)
Setting dimension X 215 mm
Load mixture pressure - symchronisation of cylinder rows A and B

Differential pressure max. 30 mbar
Fuel system / gas system
Gas pressure in the gas control system*

20 to 100 mbar
* may deviate from set point depending on unit and type of gas
Coupling piece on the step motor of the gas-air mixer

Setting dimension 69.0 - 69.5 mm
Lube oil system
Lubricating oil content

V12 engine 100 dm3
V16 engine 135 dm3

TCG 2016
Technical data
Electrical system
Ignition point according to TEM system parameter 11301
Starter
Supply voltage 24 V
Power consumption V12 engine 5.4 kW
V16 engine 9 kW
Battery
Voltage 12 V
Capacity V12 engine 2 x 143 Ah
V16 engine 4 x 143 Ah
Battery acid density

Charge status Normal Tropical
well charged 1.28 kg/l 1.23 kg/l
semi-charged (re-charge) 1.20 kg/l 1.12 kg/l
discharged (recharge, renew if neces- 1.12 kg/l 1.08 kg/l
sary)

TCG 2016
Technical data
8
Tightening specifications
General
Nuts / bolts, standard values complying with H 0385-1, screw connection class II *
8.8 10.9 12.9
M4 2.5 3.5 4.5 Nm
M5 5.0 7.5 8.5 Nm
M6 8.5 13 15 Nm
M8 20 30 36 Nm
M10 42 60 70 Nm
M12 70 110 120 Nm
M14 110 170 200 Nm
M16 180 260 300 Nm
M18 260 360 420 Nm
M20 360 500 600 Nm
M22 480 700 800 Nm
M24 600 850 1000 Nm
M27 900 1300 1500 Nm
M30 1200 1700 2000 Nm
Caution !
* Use only if no component-specific torque values are specified.
Vibration dampers on pipes

according to manufacturer's specifications
Cylinder head
Lock nut of the valve bridge

M10x1 33 Nm
Lock nut for valve adjuster

M10x1 33 Nm
Rocker arm bracket on cylinder head

M10x75 - 12.9 85 Nm
M12x110 - 12.9 145 Nm

TCG 2016
Technical data
Cylinder head on the crankcase*

M18 - 10.9 20 Nm
+ 100 Nm
+ 200 Nm
+ 400 Nm
*Wet thread and screw head rest with lubricating oil. Mark screws with oil-resistant paint after tightening.
Cylinder head cover on cylinder head*

M8x85 - 12.9 30 Nm
*Renew CU sealing rings
Protective tube for spark plug on cylinder head

105 Nm
Drive gear
Screw connections in base frame

according to the manufacturer's specifications
Engine claw to crankcase

M14x45 / 100 / 140 - 12.9 200 Nm
Engine suspension to crankcase

M16x90 - 10.9 220 Nm
Counterweight on crankshaft*
M16x80 - 10.9 270 Nm
Crankshaft intermediate flange (free side) on crankshaft flange

M8x40 - 10.9 20 Nm
Crankshaft flange (free side) on crankshaft*

M16x1.5x80 - 12.9** 390 Nm
Retightening angle + 60°
M27x2x95 - 10.9 1620 Nm
M30x2x100 - 10.9 2350 Nm
**Renew screws
Caution !
Screw must be drip-free so that no lubricating oil can get into the flange separating joint
when screwing in.

TCG 2016
Technical data
8
Main bearing cover on crankcase*

M18x165 - 12.9 210 Nm
Big end bearing cover on connecting rod*

M16x1.5 - 12.9 90 Nm
Retightening angle +60°
Piston cooling nozzle on crankcase

M8x45/120 - 8.8 25 Nm
Crankcase
Clamping clip UPF filter M8x60 hand tight
Sealing cover
M8x20 - 10.9 25 Nm
Lubricating oil pan on crankcase*

M8x55 - 10.9 25 Nm
M8x130 - 8.8 25 Nm
*Tighten screws with 25 Nm after trial run
Flywheel housing on crankcase

M8x50 / 85 - 12.9 45 Nm
M12x55 / 60 / 85 - 12.9 145 Nm
M12x125 - 10.9 120 Nm
Engine control
Gearcase cover on crankcase

M10 - 10.9 82 Nm
M8 - 10.9 42 Nm
Camshaft wheel on camshaft*

M10x25 - 10.9 70 Nm
* with screw locking agent Loctite 0100 4100
Camshaft axial guide on crankcase

M8x20 - 10.9 35 Nm

TCG 2016
Technical data
Exhaust system / Charging
Exhaust pipe on cylinder head

M10x115 / 130 - 10.9* 55 Nm
M10x137 - 10.9 75 Nm
* with S1 packing compound
Clamp on exhaust pipe (Pearl)

M6 10 Nm
Holder on exhaust manifold

M10x25 - 10.9 70 Nm
Turbocharger to exhaust manifold

M16 100 Nm
Turbocharger to console
M16x190 - 10.9 100 Nm
Charge mixture pipe to cylinder head

M10x75 / 80 / 100 - 8.8 55 Nm
Lube oil system
Lubricating oil cooler on crankcase

M10x210 - 10.9 50 Nm
Lubricating oil filter head on lubricating oil cooler

M8x20 / 30 - 10.9 25 Nm
Lubricating oil filter on lubricating oil filter head

27 Nm

TCG 2016
Technical data
8
Cooling system
Coolant pipes (union nut)

Pipe diameter 6 mm
35 Nm
Pipe diameter 8 mm
45 Nm
Pipe diameter 10 mm
60 Nm
Pipe diameter 12 mm
75 Nm
Coolant pipes (hollow screws)
M10 x 1 18 Nm
M12 x 1.5 29 Nm
M14 x 1.5 39 Nm
M16 x 1.5 49 Nm
Other components
Torsional vibration damper on crankshaft*

Surface treated oil-blackened M16x100 - 10.9 310 Nm
Surface treated ZnAl-A M16x100 - 10.9 250 Nm
Compensator on flange
DN 40 / 50 15 Nm
DN 65 / 80 / 100 / 125 20 Nm
DN 150 25 Nm
Flywheel on crankshaft*
M16x1.5x80 390 Nm
Coupling on flywheel
according to system documentation

TCG 2016
Technical data
Electrical system
Generator on coupling
Generator on base frame

Spark plug on cylinder head

50 Nm

TCG 2016
Technical data
8
Nominal and wear dimensions
Cylinder head
Rocker arm block / rocker arm shaft
Position 1
Outer diameter of the rocker arm shaft

Rated dimension 24.959 - 24.98 mm
without position
Rocker arm bearing clearance

radial Rated dimension 0.02 - 0.062 mm
Wear limit 0.10 mm
axial Rated dimension 0.30 - 0.65 mm
Position 1
Inside diameter of the inlet rocker arm

Rated dimension 25,000 - 25.021 mm
Position 2
Inside diameter of the outlet rocker arm


TCG 2016
Technical data
Guide pin valve bridge
Position 1
Installation dimension of guide bolt for valve bridge


TCG 2016
Technical data
8
Cylinder head
Position 1
Bore diameter for valve stem guide

Standard 15.010 - 15.021 mm
1st oversize 15.110 - 15.121 mm
2nd oversize 15.210 - 15.221 mm
Position 2
Bore diameter for valve seat ring

Inlet Rated dimension 48,000 - 48.016 mm
Outlet Rated dimension 45,000 - 45.016 mm
Position 3
Bore depth for valve seat ring

Position 4
Height of the cylinder head


TCG 2016
Technical data
Valve
Position 1
Diameter of the valve shaft

Inlet Rated dimension 8.952 - 8.970 mm
Outlet Rated dimension 8.952 - 8.970 mm
Position 2
Thickness of the valve edge

Inlet Rated dimension 2.5 mm
Outlet Rated dimension 2.1 mm
Position 3
Diameter of the valve head

without position
Valve lag dimension*

* Measured from the bottom edge of the valve head to the cylinder head sealing surface

TCG 2016
Technical data
8
Valve spring
Position 1
Length of the valve spring (large spring)

untensioned Rated dimension 49.0 mm
Length of the valve spring (small spring)


TCG 2016
Technical data
Valve guide
Position 1
Outside diameter of the valve stem guide (removed)

Standard 15.032 - 15.047 mm
1st oversize 15.132 - 15.147 mm
2nd oversize 15.232 - 15.247 mm
Position 2
Inside diameter of the valve stem guide (installed)

Position 3
Length of valve stem guide

Position 4
Installation dimension of the valve stem guide

13.4 - 13.6 mm

TCG 2016
Technical data
8
Valve seat ring
Position 1
Outer diameter of the valve seat ring

Position 2
Valve seat angle

Inlet Rated dimension 30°
Outlet Rated dimension 30°

TCG 2016
Technical data
Drive gear
Con rod
Position 1
Big end bearing bore

Diameter Rated dimension 98,000 - 98.022 mm
Position 2
Con rod liner bore

Diameter Rated dimension 53.985 - 54.004 mm
Con rod
Parallelism of the big end bearing bore to the con rod liner
Measuring direction 1 to A
Rated dimension 0.02 mm

TCG 2016
Technical data
8
Crankshaft
Position 1
Diameter of the main bearing pin

Position 2
Width of the fit bearing pin (1st bearing drive side)

Position 3
Width of the main bearing pin (1st bearing free side)

Position 4
Width of the other main bearing pins

Position 5
Width of the lifting journal

Position 6
Diameter of the lifting journal

without position
Crankshaft bearing clearance


TCG 2016
Technical data
Crankshaft
Runout accuracies main bearing pin
Pos. to AB V 12 V 16
1 0 0
2 0,055 0,04
3 0,09 0,07
4 0,1 0,09
5 0,09 0,1
6 0,055 0,09
7 0 0,07
8 0,04
9 0
Run-out deviation of adjacent main bearing pins (also in zig-zag knocking)

maximum 0.04 mm

TCG 2016
Technical data
8
Crankshaft
Position 1
Parallelism of the main bearing pins

to A and B Rated dimension 0.01 mm
Straightness of the main bearing pins*

to 10 mm length of the reference area Rated dimension 0.01 mm
to the whole length of the reference area Rated dimension 0.01 mm
* The data for straightness according to DIN ISO 1101.
Position 2
Parallelism of the lifting journal

to A, B, C and 1 Rated dimension 0.01 mm
Straightness of the lifting journal*

to 10 mm length of the reference area Rated dimension 0.01 mm
to the whole length of the reference area Rated dimension 0.01 mm
* The data for straightness according to DIN ISO 1101.
without position
Roundness of the main bearing pin and lifting journal*

*The roundness must be tested according to test specification 0162 0022, except in the area of the lubricating
oil bores.

TCG 2016
Technical data
Con rod bearing shell
Position 1
Internal diameter of the big end bearing shell

Position 2
Width of the big end bearing shell

Position 3
Splay of the big end bearing shell

without position
Big end bearing clearance (theoretical)


TCG 2016
Technical data
8
Main bearing shell
Position 1
Inside diameter of the main bearing shell

Position 2
Width of the main bearing shell

Position 3
Splay of the main bearing shell

without position
Main bearing clearance (theoretical)


TCG 2016
Technical data
Thrust bearing shell
Position 1
Inside diameter of the thrust bearing shell

Position 2
Width of the fit bearing shell

Position 3
Splay of the thrust bearing shell

without position
Thrust bearing clearance (theoretical)


TCG 2016
Technical data
8
Piston
Position 1
Piston height
Position 2
Piston pin bore

without position
Piston ring groove height

1. Piston ring groove Rated dimension no specification
2. Piston ring groove Rated dimension 3.06 - 3.08 mm

TCG 2016
Technical data
Piston rings
Position 1
surge clearance
1. piston ring Rated dimension 0.35 - 0.50 mm
Position 2
Twist angle of the piston ring gaps

120°
without position
Piston ring thickness

1. piston ring Rated dimension Trapeze ring

TCG 2016
Technical data
8
Piston bolt
Position 1
Piston bolt length

Rated dimension 79.7 - 80 mm
Position 2
Piston bolt diameter


TCG 2016
Technical data
Crankcase
Cylinder liner
Position 1
Outside diameter of the cylinder liner

top Rated dimension 159.99 - 160.09 mm
Position 2
Inside diameter of the cylinder liner

Position 3
Height of the cylinder liner

Position 4
Height of the collar of the cylinder liner


TCG 2016
Technical data
8
Bearing bores in the crankcase
without position
Bore diameter for valve tappet

Wear limit 20.230 mm

TCG 2016
Technical data
Engine control
Camshaft bearing liner
Position 1
Inside diameter of the camshaft bearing shell

pressed in Rated dimension 55 - 55.030 mm
Position 2
Width of the camshaft bearing shell (1st bearing free side)

Width of the camshaft bearing shell (other bearings)


TCG 2016
Technical data
8
Valve tappet
Position 1
Outer diameter of the valve tappet

Position 2
Height of the valve tappet

Position 3
Outer diameter of the valve tappet head

Position 4
Height of the valve tappet head


TCG 2016
Technical data
Wheel drive
Position 1
Camshaft wheel
80 teeth
Position 2
Crankshaft wheel (drive camshaft)

40 teeth
Position 3
Crankshaft wheel (drive lubricating oil pump)

V12 engine 54 teeth
V16 engine 57 teeth
Position 4
Lubricating oil pump wheel

V12 engine 45 teeth
V16 engine 41 teeth
Position 5
Tooth edge clearance between
gear 1 and gear 2
Camshaft wheel and crankshaft wheel 0.13 - 0.21 mm
Toothed wheel 3 and toothed wheel 4
Crankshaft wheel and lubricating oil pump 0.15 - 0.25 mm

wheel

TCG 2016
Technical data
8
Camshaft
Position 1
Camshaft bearing pin diameter

without position
Camshaft cam stroke

8.20 - 8.28 mm
Camshaft bearing clearance

Run-out accuracy camshaft bearing
V 12 V 16
Position 1 0,04 0,04
Position 2 0,02 0,02

TCG 2016
Technical data
Other components
Connecting elements
DN40 DN50 DN65 DN80 DN100 DN125 DN150
without position
Nominal pressure 25 25 25 25 25 10 10 bar
Position 1
Outer pipe diameter 42 50 60 80 100 120 159 mm
Position 2
Internal diameter 34 43 63 75 95 120 145 mm
Position 3
Outer diameter sealing 73 85 104 117 136 165 190 mm

surface
Position 4
Hole circle diameter 84 96 116 126 148 176 202 mm
Position 5
Outer diameter flange 108 120 140 150 172 200 226 mm
Position 6
Total length 175 175 175 200 200 200 200 mm
Position 7
Length 125 125 125 150 150 150 150 mm
Position 8
Flange thickness 16 16 16 18 18 18 18 mm

TCG 2016
Job cards
9

TCG 2016
Job cards

TCG 2016
Job cards
9
Job cards
Explanation of symbols
Tools
- List of necessary tools and special tools.
Auxiliary material
- List of necessary sealing compounds, locking agents, adhesives, lubricants, cleaning
agents etc.
Spare parts
- List of maintenance and repair parts which must always or sometimes be renewed.
References
- List of chapters, job cards, logs etc. to which this job card makes reference.
You will find this symbol next to all safety instructions. Follow these meticulously. The at-
tention of operating personnel should be drawn to these safety instructions. In addition,
general statutory safety and accident prevention regulations applying in your country must
be complied with.
You will find this symbol next to instructions of a general nature.

Follow these meticulously.
Gaskets used in this engine are asbestos-free. Please use appropriate spare parts for
maintenance and repair work.

TCG 2016
Job cards
Job card list

The job cards are listed in two lists on the following pages.
- According to job card title

- According to job card number

TCG 2016
Job cards
9
Job cards
Auxiliaries test using TEM System (TEM Evolution with Touch Screen, BRT) B 0-1-6
Changing lube oil B 8-1-2
Checking and adjusting ignition timing W 13-5-3
Checking and adjusting inlet and outlet valve clearance B 1-1-1
Checking and cleaning coolant spaces W 9-0-2
Checking and measuring control times W 4-4-11
Checking bearing shells W 2-1-6
Checking camshaft W 4-5-6
Checking camshaft axial clearance W 4-1-4
Checking con rod geometry W 2-3-5
Checking crankcase W 2-1-7
Checking crankshaft axial clearance W 2-1-4
Checking cylinder liner W 3-3-1
Checking engine mounting W 3-7-1
Checking percentage of corrosion protection agent or antifreeze in coolant B 9-1-1
Checking piston W 2-9-7
Checking the crankcase pressure B 3-1-2
Checking the gas pressure in the gas regulator line B 7-20-1
Checking the speed governor linkage B 5-4-2
Checking valve lag (cylinder head fitted) B 1-7-10
Cleaning the engine B 0-3-6
Disassembling, assembling and testing the rocker arm and rocker arm bracket W 1-2-6
Empty and fill cooling system B 9-0-4
Endoscope examination of combustion chamber W 0-2-7
Installing, removing and actuating engine turning gear B 4-6-1
Lifting and setting down the engine W 0-5-1
Maintain crankcase breather (model Racor) B 3-1-9
Maintain crankcase breather (model UPF 55) B 3-1-9
Overhaul pressure limiting valve of the pre-lube pump B 8-4-11
Overhauling gas pressure regulator (model Donkin) W 7-20-6
Overhauling gas valve (model RMG) W 7-20-7
Overhauling gas-air mixer (V12 and V16 engines) W 7-22-3
Overhauling the cylinder head W 1-4-6
Regulations for cutting, grinding, soldering and welding work B 0-0-4
Removing and installing camshaft W 4-5-5
Removing and installing charge mixture pipe (V12 and V16 engine) W 6-2-7
OBJ_BUCH-1160-001EAL.fm 151 © MWM GmbH TCG 2016

TCG 2016
Job cards
Removing and installing compensator of exhaust pipe W 6-1-11

Removing and installing crankshaft W 2-4-1
Removing and installing crankshaft sealing ring (drive side) W 2-2-2
Removing and installing crankshaft sealing ring (free side) W 2-2-4
Removing and installing cylinder head W 1-4-4
Removing and installing cylinder liner W 3-3-2
Removing and installing exhaust gas turbocharger (V12 and V16 engine) W 6-6-4
Removing and installing exhaust pipe W 6-1-9
Removing and installing gear housing cover W 4-4-9
Removing and installing ignition control unit W 13-9-1
Removing and installing lube oil pressure sensor W 8-2-4
Removing and installing lube oil pump W 8-5-3
Removing and installing lube oil temperature sensor W 8-5-3
Removing and installing lube oil tray W 3-5-1
Removing and installing piston with con rod W 2-9-3
Removing and installing rocker arm and rocker arm block W 1-2-2
Removing and installing spark plugs, checking ignition cable B 13-5-4
Removing and installing the actuator W 5-5-3
Removing and installing the camshaft sensor (model Jaquet) W 5-7-3
Removing and installing the charge mixture manifold W 6-2-9
Removing and installing the coolant temperature sensor (engine inlet) W 9-12-3
Removing and installing the coolant temperature sensor (engine outlet) W 9-12-2
Removing and installing the crankshaft flange (drive side) W 2-2-9
Removing and installing the crankshaft flange (free side) W 2-2-10
Removing and installing the flywheel W 12-6-1
Removing and installing the flywheel housing W 3-6-1
Removing and installing the flywheel sensor (model Jaquet) W 5-7-5
Removing and installing the gas-air mixer W 7-22-1
Removing and installing the gear drive (free side) W 4-4-1
Removing and installing the jointed head for the speed transmitter linkage W 5-4-6
Removing and installing the lubricating oil level sensor W 8-2-1
Removing and installing the main bearing W 2-7-2
Removing and installing the starter (electric starter) W 13-3-2
Removing and installing the suction air intake filter housing W 6-3-8
Removing and installing torsional vibration dampers W 12-1-4
Removing and installing, cleaning mixture cooler (V12 and V16 engine) W 6-4-7
Removing, installing and checking hose pipes, vibration dampers and flexible pipes W 0-3-4

TCG 2016
Job cards
Removing, installing and checking piston cooling nozzle W 2-15-2

Removing, installing and checking piston rings W 2-10-1
Removing, installing and checking rubber compensators W 12-3-1
Removing, installing and checking valve tappet W 4-2-3
Removing, installing and cleaning the lube oil cooler W 8-8-2
Removing, installing and testing big end bearing W 2-5-3
Renewing gas filter insert B 7-21-1
Renewing lube oil filter cartridge B 8-10-4
Renewing the suction air intake filter B 6-3-6
Running-in instructions W 0-1-3
Safety regulations for drive unit work W 2-0-1
Safety regulations for handling components made of elastomers containing fluoride (e.g. B 0-0-3
Viton)
Servicing the battery B 13-4-1
Setting speed governor linkage W 5-4-7
Setting the stepper motor of the gas-air mixer W 7-20-2
Taking lube oil samples B 8-1-1
Tear inspection by diffusion liquid method W 0-3-2
Testing mixture cooler (endoscope) W 6-4-11
Use of liquid nitrogen W 0-3-1
Visual inspection of the system B 0-1-5

TCG 2016
Job cards
B 0-0-3 Safety regulations for handling components made of elastomers containing fluoride (e.g.
Viton)
B 0-0-4 Regulations for cutting, grinding, soldering and welding work
B 0-1-5 Visual inspection of the system
B 0-1-6 Auxiliaries test using TEM System (TEM Evolution with Touch Screen, BRT)
B 0-3-6 Cleaning the engine
B 1-1-1 Checking and adjusting inlet and outlet valve clearance
B 1-7-10 Checking valve lag (cylinder head fitted)
B 3-1-2 Checking the crankcase pressure
B 3-1-9 Maintain crankcase breather (model Racor)
B 3-1-9 Maintain crankcase breather (model UPF 55)
B 4-6-1 Installing, removing and actuating engine turning gear
B 5-4-2 Checking the speed governor linkage
B 6-3-6 Renewing the suction air intake filter
B 7-20-1 Checking the gas pressure in the gas regulator line
B 7-21-1 Renewing gas filter insert
B 8-1-1 Taking lube oil samples
B 8-1-2 Changing lube oil
B 8-4-11 Overhaul pressure limiting valve of the pre-lube pump
B 8-10-4 Renewing lube oil filter cartridge
B 9-0-4 Empty and fill cooling system
B 9-1-1 Checking percentage of corrosion protection agent or antifreeze in coolant
B 13-4-1 Servicing the battery
B 13-5-4 Removing and installing spark plugs, checking ignition cable
W 0-1-3 Running-in instructions
W 0-2-7 Endoscope examination of combustion chamber
W 0-3-1 Use of liquid nitrogen
W 0-3-2 Tear inspection by diffusion liquid method
W 0-3-4 Removing, installing and checking hose pipes, vibration dampers and flexible pipes
W 0-5-1 Lifting and setting down the engine
W 1-2-2 Removing and installing rocker arm and rocker arm block
W 1-2-6 Disassembling, assembling and testing the rocker arm and rocker arm bracket
W 1-4-4 Removing and installing cylinder head
W 1-4-6 Overhauling the cylinder head
W 2-0-1 Safety regulations for drive unit work
W 2-1-4 Checking crankshaft axial clearance
W 2-1-6 Checking bearing shells

TCG 2016
Job cards
W 2-1-7 Checking crankcase

W 2-2-2 Removing and installing crankshaft sealing ring (drive side)
W 2-2-4 Removing and installing crankshaft sealing ring (free side)
W 2-2-9 Removing and installing the crankshaft flange (drive side)
W 2-2-10 Removing and installing the crankshaft flange (free side)
W 2-3-5 Checking con rod geometry
W 2-4-1 Removing and installing crankshaft
W 2-5-3 Removing, installing and testing big end bearing
W 2-9-3 Removing and installing piston with con rod
W 2-7-2 Removing and installing the main bearing
W 2-9-7 Checking piston
W 2-10-1 Removing, installing and checking piston rings
W 2-15-2 Removing, installing and checking piston cooling nozzle
W 3-3-1 Checking cylinder liner
W 3-3-2 Removing and installing cylinder liner
W 3-5-1 Removing and installing lube oil tray
W 3-6-1 Removing and installing the flywheel housing
W 3-7-1 Checking engine mounting
W 4-1-4 Checking camshaft axial clearance
W 4-2-3 Removing, installing and checking valve tappet
W 4-4-1 Removing and installing the gear drive (free side)
W 4-4-9 Removing and installing gear housing cover
W 4-4-11 Checking and measuring control times
W 4-5-5 Removing and installing camshaft
W 4-5-6 Checking camshaft
W 5-5-3 Removing and installing the actuator
W 5-4-6 Removing and installing the jointed head for the speed transmitter linkage
W 5-4-7 Setting speed governor linkage
W 5-7-3 Removing and installing the camshaft sensor (model Jaquet)
W 5-7-5 Removing and installing the flywheel sensor (model Jaquet)
W 6-1-9 Removing and installing exhaust pipe
W 6-1-11 Removing and installing compensator of exhaust pipe
W 6-2-7 Removing and installing charge mixture pipe (V12 and V16 engine)
W 6-2-9 Removing and installing the charge mixture manifold
W 6-3-8 Removing and installing the suction air intake filter housing
W 6-4-7 Removing and installing, cleaning mixture cooler (V12 and V16 engine)
W 6-4-11 Testing mixture cooler (endoscope)

TCG 2016
Job cards
W 6-6-4 Removing and installing exhaust gas turbocharger (V12 and V16 engine)
W 7-20-2 Setting the stepper motor of the gas-air mixer
W 7-20-6 Overhauling gas pressure regulator (model Donkin)
W 7-20-7 Overhauling gas valve (model RMG)
W 7-22-1 Removing and installing the gas-air mixer
W 7-22-3 Overhauling gas-air mixer (V12 and V16 engines)
W 8-2-1 Removing and installing the lubricating oil level sensor
W 8-2-4 Removing and installing lube oil pressure sensor
W 8-5-3 Removing and installing lube oil temperature sensor
W 8-5-3 Removing and installing lube oil pump
W 8-8-2 Removing, installing and cleaning the lube oil cooler
W 9-0-2 Checking and cleaning coolant spaces
W 9-12-2 Removing and installing the coolant temperature sensor (engine outlet)
W 9-12-3 Removing and installing the coolant temperature sensor (engine inlet)
W 12-1-4 Removing and installing torsional vibration dampers
W 12-3-1 Removing, installing and checking rubber compensators
W 12-6-1 Removing and installing the flywheel
W 13-3-2 Removing and installing the starter (electric starter)
W 13-5-3 Checking and adjusting ignition timing
W 13-9-1 Removing and installing ignition control unit

TCG 2016
B 0-0-3
Safety regulations for handling components made of elastomers con-

taining fluoride (e.g. Viton)
References
- Chapter 1, Rules for disposal
General information
Seals, O-seals and shaped parts for high thermic loads are made in part of elastomers con-
taining fluoride (FPM).
If unplanned temperatures exceed 315°C (e.g. caused by engine fire) the material decom-
poses and forms caustic acids. The remains are sticky and have a black appearance.
If damage has occurred to seals or O-seals caused by high temperatures, proceed as fol-
lows:
 Check all seals visually which have been subjected to the effects of heat.
 Put on gloves (neoprene).
 Remove residual material and dispose of,
- see Chapter 1, disposal regulations.
 Destroy clothing that has come into contact with the remains of the seals.
Touching material remains with the human skin, even after they have cooled down,
can be harmful to health.

TCG 2016
B 0-0-3

TCG 2016
B 0-0-4
Regulations for cutting, grinding, soldering and welding work
References
- Accident prevention regulations
General information
The contractor of cutting, grinding, soldering and welding work must alert the persons en-
listed to do the work to the dangers and ensure that the points listed below are observed
and complied with.
Persons entrusted with cutting, grinding, soldering and welding work must be familiar with
and observe the valid regulations and specifications, especially the rules for accident pre-
vention of the respective national legislations.
The following points must be observed in addition to the specified regulations and specifi-
cations.
Electrics / electronics
The following points apply for work where electrical and electronic components may be at
risk due to heat or electrical short-circuiting.
 Disconnect the battery ground and remove and stow away the battery safely if neces-
sary.
 Pull out the cable set plugs of electrical and electronic components (e.g. switch cabi-
net, junction box, control unit, sensors).
 Remove electrical and electronic components in the immediate vicinity of the working
area.
 Always connect the ground terminal of the welding gear in the immediate vicinity of the
welding point to avoid vagrant currents. Make sure there is a perfect ground connec-
tion, remove varnish in the area of the ground terminal if necessary.
Failure to do so can lead to serious damage to the engine electronics.
Sparks / danger of fire
 Keep all inflammable materials away from the danger area.

 Inflammable objects (e.g. cables, compensators) must be covered with non-conduc-
tive, non-flammable material or must be removed.
 Sensitive surfaces (e.g. air filter) must be covered with non-conductive and non-flam-
mable material.
 Openings on the engine must be sealed or covered.
 Seal off and cover openings to other work areas.
 Keep a sufficient number of fire extinguishers close by.

TCG 2016
B 0-0-4
Danger of explosion
 Work which could lead to a strong development of heat on gas or fuel pipes and ves-
sels may only be carried out when these have been completely emptied and bled or
flushed.
 Shut off gas pipes and fuel pipes.
Health hazard
 Air well, draw off fumes and dust particles.

 Screen off the working area during arc welding to protect bystanders against the harm-
ful effects of optical radiation.

TCG 2016
B 0-1-5
Visual inspection of the system
Tools
- Commercially available tools
References
- B 5-4-2 Checking the speed governor linkage
- B 6-3-6 Renewing the suction air intake filter
- B 7-20-1 Checking the gas pressure in the gas regulator line
- B 7-21-1 Renewing gas filter insert
- B 13-4-1 Servicing the battery
General information
Danger of burning !
When working on hot engine.
Daily check
Engine monitoring
 Check display values and warning lamps in the switchboard.

- Observe engine monitoring operating manual.
 The operating values must be taken from the engine monitoring system and compared
with the values in the commissioning report.
- If the values are outside the range of tolerance the cause must be sought and re-
paired immediately.
Engine
 Check engine for smooth running and noise.

- If the engine is not running smoothly or if abnormal sounds can be heard the cause
must be found and repaired immediately.
Lube oil system
 Check the tightness of the lube oil circuit and all connected components.
- If leaks are discovered, find the causes and eliminate immediately.
Coolant system
 Check the tightness of the coolant circuits and all connected components.

TCG 2016
B 0-1-5
Intake air system
 Check maintenance display of intake air cleaner visually.

- If necessary the intake air cleaner must be replaced.
- Replace intake air cleaner - see job card B 6-3-6.
Gas system
 Check gas pressure in the gas control system - see job card B 7-20-1.
- If necessary the gas filter insert must be replaced.
- Replace gas filter insert - see job card B 7-21-1.
 Check the tightness of the gas system and all connected components.
Starter system
 if available - check battery - see job card B 13-4-1.

 Check the electrical component and connectors for corrosion and tight fit.
If the engine is out of operation, the following additional tests can be made.
Speed governor
 Check the easy action of the speed governor, see job card B 5-4-2.
Exhaust system
 Check the firm sit and tightness of the exhaust system and all connected components.
- If faults are discovered, they must be rectified immediately.

TCG 2016
B 0-1-6
Auxiliaries test using TEM System (TEM Evolution with Touch Screen,
BRT)
References
- TEM system operating manual
General information
Depending on the engine version and equipment, some of the following tests described
may not be carried out.
Only auxiliaries which are in the parameters and have been released are tested.
The test mode serves for checking individual auxiliaries for control by the TEM Evolution
control unit. The test can only be carried out with the engine standing still, manual operation
and without the emergency stop activated.
It is not possible to start the engine in test mode.
Individual auxiliaries (e.g. starter) can for safety reasons only be controlled with the button
keys. The auxiliary only stays switched on while the button remains pressed, it is not pos-
sible to turn it on and off.
Auxiliaries (e.g. gas mixer, emergency cooler) which are actuated by servo motors can be
checked as follows.
Cell 1 shows the auxiliary. Here positive adjustment can be made (e.g. rich, warmer) or neg-
ative (e.g. lean, cooler).
Cell 2 shows the currently calculated position of the auxiliary's servo motor.
Cell 3 shows the limit stops and the intermediate positions.
A1
A2

TCG 2016
B 0-1-6
Test results and measured values are shown as follows.
Red lightning Test result not OK.
Green hook Test result OK.
Blue plus sign Servo motor has reached plus stop (e.g. rich, warm)
Blue minus sign Servo motor has reached minus stop (e.g. lean, cold)
Blue double arrow Servo motor is moving or standing between the two limit stops.
Carrying out the tests
 Select Service 1 mask.

 Select auxiliaries 2 mask.
- Select appropriate sub-menu.
 Select test mode ON 3.
- All auxiliaries are automatically switched off.
A3

TCG 2016
B 0-1-6
Engine auxiliary test
A4
Ignition
 Switch on ignition.
- The ignition carries out a self-test and gives the result after about 10 seconds.
- Check wiring, supply voltage and communications

- Repeat test
 Switch off ignition.

TCG 2016
B 0-1-6
Starter
On engines with electric starters the mains starting device is actuated and so the function
is checked automatically.
While checking the starter the engine is turned as when starting the engine normally.
Therefore the engine's pre-lubrication pump and if appropriate the generator must
be switched on manually 3 minutes before the test.
When commissioning the engine's pre-lubrication pump must be switched on man-
ually 20 minutes before the test.
After changing the lube oil the automatic pre-lubrication is turned on automatically
by the TEM system. Here the engine's pre-lubrication pump is switched on for 20
minutes.
 Go to starter.
- Check function, speed and lube oil pressure.
Speed governor
 Switch on speed governor.

- The speed governor carries out a calibration process. For this it goes once from
0 % to 100 % and back.
- The throttle valve control voltage is shown in Volts.
 Change from the engine mask to the governor mask.
 Select test mode ON.
 Set the set position to 20%.
 Accept adjustment value.
 Read off display on actuator.
- The mechanical display on the actuator and the set nominal position must be iden-
tical.
 Also check set position at 50%, 75% and 90%.
 Select test mode OFF.
 Change from the governor mask to the engine mask.
 Turn off speed governor.

TCG 2016
B 0-1-6
Anti-knock control
 Switch on anti-knock control.

- The ignition carries out a self-test and gives the result after about 10 seconds.
- Check wiring, supply voltage and communications

- Repeat test
 Switch off anti-knock control.
Pre-lubrication pump
 Switch on pre-lubrication pump.

- Check direction of rotation.
- Lube oil pressure must rise.
 Switch off pre-lubrication pumps.
Gas mixer A
A5
 Switch on gas mixer A rich (cell 1).

- If the gas mixer is at the stop lean (cell 3 minus sign) after a few steps the stop
must move into the double arrow.
- The gas mixer must move a maximum of 4000 steps from the starting position to-
wards rich (Zelle 2). Here the mathematical leading sign in the starting position
must be observed. If the starting position is, for example, -400 steps, the maxi-
mum value must not exceed 3600 steps.
- Make sure that gas mixer really does move towards rich.
 Switch on gas mixer A lean (cell 1).
- The gas mixer goes back to the stop lean (cell 3 minus sign).
- Check the vision panel to make sure that gas mixer really does move towards
lean.
Gas mixer A starting position
 Go to gas mixer A starting position.

- The gas mixer moves to starting position (cell 2 - 0 steps).
- Reaching the starting position is displayed with a green hook.

TCG 2016
B 0-1-6
Gas mixer A stop position
 Switch on gas mixer A stop position.

- The gas mixer goes to the stop lean (cell 3 minus sign).
- A negative value must be shown in cell 2.
Auxiliary test gas
A6
Gas valve A1
 Go to gas valve A1.

- It is possible to feel and hear the solenoid valve switching.
Gas valve A2
 Go to gas valve A2.

In engines with two-gas operation, the gas valves B1 and B2 must be tested in the same
way as gas valves A1 and B1.

TCG 2016
B 0-1-6
Filling with lube oil
With this function the lube oil supply filler valves can be tested.
However. there is no report back in the mask.
Depending on the design of the unit different numbers of various valves may be fitted.
 Go to fill lube oil.

During the test the engine's lube oil circuit is filled with lube oil.
Auxiliary test cooling / heating circuit
A7
Motor cooling circuit pump
 Switch on motor cooling circuit pump (green hook is shown).

 If a green hook is shown in the next column, the system is OK.
Heating circuit pump
 Switch on heating circuit pump (green hook is shown).

Emergency cooling circuit pump
 Switch on emergency cooling circuit pump (green hook is shown).


TCG 2016
B 0-1-6
Mixture cooling circuit pump
 Switch on mixture cooling circuit pump (green hook is shown).

Pre-heating
Before testing the pre-heating, ensure that it is completely filled with coolant.
Danger of burning !
When testing the pre-heating, components can get hot.
 Switch on pre-heating.
- Check carefully whether the coolant lines warm up.
 Switch off pre-heating.
Heating water cooler / hotter
 Switch on hot water heater.

- The actuator moves to the hot stop.
- If the servo motor stands at the cold limit stop, after a few steps the display in the
stop cell should change to the double arrow.
- During this adjustment process the percentage should change accordingly.
 Switch on hot water to cooler.
- The servo motor moves back to the cold stop.
Emergency cooler hotter / cooler
 See hot water hotter / cooler.
Mixture cooler hotter / cooler
 See hot water hotter / cooler.

TCG 2016
B 0-1-6
Auxiliary test table cooler
A8
Depending on the system fitted, the fan speed can be actuated either variably or step by
step.
NK table cooler
 NK table cooler hotter/step 3

- The fan lowers the speed.
 NK table cooler cooler/step 4
- The fan increases the speed.
GK table cooler
 See NK table cooler

TCG 2016
B 0-1-6
Auxiliary test air/oil
A9
Room ventilation
 Control room ventilation and check function visually.
The auxiliary test hydrostatic pump A and B is only available with generators with lube oil
pressure pumps.
Hydrostatic pump A
 Actuate pump. Pump must run.
Hydrostatic pump B
 Actuate pump. Pump must run.

TCG 2016
B 0-1-6
Auxiliary test controller
A 10
In the controller mask two controllers which can be parameterised can be selected.
By actuating Output + the controller opens.
By actuating Output - the controller closes.
Release parameterisable controller 1
 Release parameterisable controller 1.

- Switch on controller 1.
 Parameterisable controller 1 output +.
- Controller 1 opens.
 Parameterisable controller 1 output -.
- Controller 1 closes.
Release paramterisable controller 2
 Release paramterisable controller 2.

- Switch on controller 2
 Parameterisable controller 2 output +.
- Controller 2 opens.
 Parameterisable controller 2 output -.
- Controller 2 closes.

TCG 2016
B 0-1-6

TCG 2016
B 0-3-6
Cleaning the engine
Auxiliary material
- Cleaning agents
- Plugs, covers
- Compressed air
References
- Chapter 4, Auxiliary materials
General information
Risk of injury !
Only carry out work when the engine is stopped.
Secure engine to prevent it starting.
Danger of poisoning !
Ensure adequate ventilation.
Suck off vapours, do not inhale.
Risk of injury !
Wear protective glasses and gloves.
Preparation
 Turn off engine and allow to cool down.

 Select cleaning agent, see Chapter 4, Auxiliary materials.
 Remove protective covers.
 Remove heat protection covers from exhaust lines.
 Seal engine openings (e.g. air inlet) or fit waterproof cover.
If the engine is partially dismantled, openings in housings must be sealed or have water-
proof covers fitted.

TCG 2016
B 0-3-6
Cleaning
The following must not be cleaned with pressure cleaning systems:
- Sensitive components (e.g. filters, sensors, rubber grommets, sealing rings, wires) as
these could be damaged.
- Joints and bearings which are covered with lubricant or filled with grease.
 Spray cleaning agent onto engine.

- Allow time to take effect as specified by the manufacturer.
 Spray off engine with powerful jet of water or wash off.
If the required level of cleanliness is not achieved, repeat process.

Dismantled protective covers and heat protection covers must be cleaned separately.
Reworking
It is essential that protective covers and heat protection covers are dried before fit-
ting.
Otherwise there is a danger of fire from the formation of gases or deflagration inside
the casing covers.
 Blow off accumulations of water with compressed air.

 Remove covers from electric and electronic components.
 Remove covers and seals from openings in the engine.
 Dry and fit exhaust line heat protection covers.

TCG 2016
B 1-1-1
Checking and adjusting inlet and outlet valve clearance
Tools
- Feeler gauge
- Spark plug key
- Torque wrench
Spare parts
- Sealing rings
- Shaped gasket for cylinder head cover, if necessary
References
- B 4-6-1 Installing, removing and actuating engine turning gear
Technical data
Valve bridge
0.05 mm
Valve clearance
Inlet 0.3 mm
Outlet 0.8 mm
Lock nut of the valve bridge

M10x1 33 Nm
Lock nut for valve adjuster

M10x1 33 Nm

M8x85 - 12.9 30 Nm

50 Nm
General information
Inlet and outlet valves will only form a seal when closed if the specified clearance is avail-
able in the valve drive between the camshaft and the valve shaft.
If the valve clearance is too small the valves are only closed briefly or not at all.
This results in a drop in performance for to the subsequent compression loss.
The valve seat and valve head may burn due to overheating. There is also a danger of an
TCG 2016
B 1-1-1
engine fire to to flashover in the exhaust or suction intake channel.

If the valve clearance is too great, the valves open later and close earlier.
Because the valves are only fully open briefly, the filling level of the engine drops. Drop in
performance is the result.
This also causes considerable wear in the valve control.
Exact setting and observation of the valve clearance prolongs the life and increases the op-
erational reliability of the engine.
A large valve clearance determined in the test is due to wear in the valve drive.
Depending on the difference between the actual value and the reference value, the valve
clearance curve of the respective cylinder must be monitored and the cause investigated
immediately.
The actual values must be noted in the “Valve clearance actual values table“. A copy of the
table is enclosed.
Test and setting sequence.

When setting the valves the inlet and outlet valve of the cylinder to be set must be com-
pletely closed, i.e. the valve drive must be on the base circle of the cam. This is guaranteed
when the cylinder firing 360° KW before the cylinder to be set is in valve overlap, i.e. the
outlet valve closes whilst the inlet valve opens.
The setting is made according to the order of ignition, starting with cylinder A1. Specified in
the figure below are the ignition order, ignition spacings in degrees of crankshaft and the
overlap cylinder assigned to every firing cylinder. For determining the correct position of the
cylinder to be set, the attached overlapping cylinder is monitored whilst turning slowly. It
must be turned until the valves just go into overlap. The whole overlap range of the overlap
cylinder is suitable for the valve setting of the firing cylinder.
The whole valve setting can be made with 2 revolutions of the crankshaft (Step 1 and Step
2).
Shown in the schematic engine figure below are the positions of the firing cylinders and the
overlapping cylinders for the first and second crankshaft revolution. The figure only shows
the position: the order is determined by the firing order.

TCG 2016
B 1-1-1
12 cylinder engine
Ignition TDC A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
Overlap A6 B2 A2 B4 A4 B1 A1 B5 A5 B3 A3 B6
T1
16 cylinder engine
Ignition TDC A1 B3 A3 B7 A7 B5 A5 B8 A8 B6 A6 B2 A2 B4 A4 B1
Overlap A8 B6 A6 B2 A2 B4 A4 B1 A1 B3 A3 B7 A7 B5 A5 B8
T2

TCG 2016
B 1-1-1
A1
 Pull ignition cable 1 from ignition coil 2.

 Check the spark plug shaft for dirt.
 Blow out spark plug shaft with compressed air.
Dirt particles can cause injury when cleaning with compressed air.
Wear protective glasses and clothing.
 Remove spark plugs.

 Unscrew screws and remove cylinder head cover with gasket.
Only check and set the valve clearance compensation and valve clearance when the en-
gine is cold.
Follow the correct test and setting sequence.
 Install engine turning gear - see job card B 4-6-1.

 Turn the engine in rotation direction until cylinder A1 is in the ignition TDC range.

TCG 2016
B 1-1-1
Check valve bridge
A2
 Insert feeler gauges between valve stem and valve bridge (arrows) on both valves on
one valve bridge at the same time.
 Push rocker arm onto valve bridge with the finger.
- It must be possible to pull out the feeler gauges evenly without too much resist-
ance.
- If this is not the case, the valve bridge must be adjusted again.
Adjust valve bridge
A3
 Loosen nut 1.
 Insert feeler gauges between valve stem and valve bridge (arrows) on both valves on
one valve bridge at the same time.
 Push rocker arm onto valve bridge with the finger.

TCG 2016
B 1-1-1
 Adjust valve bridge with screw 2.

- It must be possible to pull out the feeler gauges evenly without too much resist-
ance.
 Tighten nut 1.
- Hold against screw 2.
 Check valve bridge again with feeler gauge.
- If there are any variations, adjust valve bridge again.
Checking valve clearance
A4
 Push feeler gauge between the valve bridge and the toggle lever (arrow).
- The feeler gauge must be insertable and removable with little resistance.
- The valve clearance must be set if not.

TCG 2016
B 1-1-1
Setting valve clearance
A5
 Loosen nut 1.
 Push feeler gauge between the valve and the rocker arm (arrow).
 Set the valve clearance with screw 2.
- The feeler gauge must be insertable and removable with little resistance.
 Tighten nut 1.
- Hold against screw 2.
 Check the valve clearance again with the feeler gauge.
- Reset the valve clearance in case of deviations.
 Turn engine in direction of rotation until next cyllinder is at TDC.
 Repeat the test and setting procedure until the valve clearance is set on all cylinders.
 Remove engine turning gear - see job card B 4-6-1.
 Fit cylinder head cover with gasket and tighten screws.
- Check the gasket of the cylinder head hood and renew if necessary.
 Install spark plugs with new sealing rings.
 Plug the ignition cable to the ignition coil.

TCG 2016
B 1-1-1
Table of actual values of valve clearance

The total adjustment time can be determined by the actual value data.
This can tell you something about the previous wear in the valve drive.
Legend for the tables on the following pages.
A6
1: inlet-side gas-air mixture

2: outlet-side exhaust gas
X: short channel
Y: long channel
The following table is applicable for all series and number of cylinders available till date.

TCG 2016
B 1-1-1
Enclosure: Engine type:

Name: Engine no.:
Remark:
Operating hours
Inlet X
Y
A1 Outlet X
Y
Inlet X
Y
A2 Outlet X
Y
Inlet X
Y
A3 Outlet X
Y
Inlet X
Y
A4 Outlet X
Y
Inlet X
Y
A5 Outlet X
Y
Inlet X
Y
A6 Outlet X
Y
Inlet X
Y
A7 Outlet X
Y
Inlet X
Y
A8 Outlet X
Y
Inlet X
Y
A9 Outlet X
Y
Inlet X
Y
A10 Outlet X
Y

TCG 2016
B 1-1-1

Name: Engine no.:
Remark:
Operating hours
Inlet X
Y
B1 Outlet X
Y
Inlet X
Y
B2 Outlet X
Y
Inlet X
Y
B3 Outlet X
Y
Inlet X
Y
B4 Outlet X
Y
Inlet X
Y
B5 Outlet X
Y
Inlet X
Y
B6 Outlet X
Y
Inlet X
Y
B7 Outlet X
Y
Inlet X
Y
B8 Outlet X
Y
Inlet X
Y
B9 Outlet X
Y
Inlet X
Y
B10 Outlet X
Y

TCG 2016
B 1-7-10
Checking valve lag (cylinder head fitted)
Tools
- Feeler gauge
- Spark plug key
- Torque wrench
Spare parts
- Sealing rings
- Shaped gasket for cylinder head cover, if necessary
References
- B 4-6-1 Installing, removing and actuating engine turning gear
Technical data

M8x85 - 12.9 30 Nm

50 Nm
General information
By measuring the valve lag regularly it is possible to ascertain the wear behaviour of the
valve cones and valve seats.
The actual value table must be filled in continuously and sent to the MS-K (Product Support)
department for evaluation of the valve drive.
The measurement must be taken after every valve clearance setting on all inlet and outlet
valves.
Care must be taken here to ensure that the valves are completely closed when measuring.
The measurements must be taken in order of ignition sequence, starting with cylinder A1 -
see job card B 1-1-1, test and setting order.
The actual values must be noted in the valve lag actual value table. The table is attached
as a copy form.

TCG 2016
B 1-7-10
Checking valve lag
A1

Dirt particles can cause injury when cleaning with compressed air.

 Unscrew screws and remove cylinder head cover with gasket.
 Install engine turning gear - see job card B 4-6-1.

TCG 2016
B 1-7-10
A2
The figure shows measuring at the inlet valves

Proceed in the same manner with the outlet valves.
Position numbers X and Y are to aid orientation and are repeated on the copy form.
Before taking measurements it is essential to ensure that the cylinder head cover
gasket is no longer lying on the cylinder head as otherwise the measured results
could be inaccurate.
 Check valve lag on both inlet and outlet valves.

- Measure with depth gauge from the top of the valve spring plate to the sealing sur-
face on the cylinder head cover.
Ensure that the depth gauge is not tilted on the valve spring plate.
 Turn engine in direction of rotation until next cyllinder is at TDC.

 Repeat the process until the valve lag is established on all cylinders.
 Remove engine turning gear - see job card B 4-6-1.
 Fit cylinder head cover with gasket and tighten screws.

TCG 2016
B 1-7-10
Valve lag actual value table

The total wear value can be determined by the actual value data.
This can tell you something about the previous wear in the valve drive.
Legend for the tables on the following pages.
A3
1: inlet-side gas-air mixture

2: outlet-side exhaust gas
X: short channel
Y: long channel
The following table is applicable for all series and number of cylinders available till date.

TCG 2016
B 1-7-10

Name: Engine no.:
Remark:
Operating hours
Inlet X
Y
A1 Outlet X
Y
Inlet X
Y
A2 Outlet X
Y
Inlet X
Y
A3 Outlet X
Y
Inlet X
Y
A4 Outlet X
Y
Inlet X
Y
A5 Outlet X
Y
Inlet X
Y
A6 Outlet X
Y
Inlet X
Y
A7 Outlet X
Y
Inlet X
Y
A8 Outlet X
Y
Inlet X
Y
A9 Outlet X
Y
Inlet X
Y
A10 Outlet X
Y

TCG 2016
B 1-7-10

Name: Engine no.:
Remark:
Operating hours
Inlet X
Y
B1 Outlet X
Y
Inlet X
Y
B2 Outlet X
Y
Inlet X
Y
B3 Outlet X
Y
Inlet X
Y
B4 Outlet X
Y
Inlet X
Y
B5 Outlet X
Y
Inlet X
Y
B6 Outlet X
Y
Inlet X
Y
B7 Outlet X
Y
Inlet X
Y
B8 Outlet X
Y
Inlet X
Y
B9 Outlet X
Y
Inlet X
Y
B10 Outlet X
Y

TCG 2016
B 3-1-2
Checking the crankcase pressure
References
- B 3-1-9 Maintain crankcase breather (model Racor)
- B 3-1-9 Maintain crankcase breather (model UPF 55)
General information
The pressure in the crankcase is checked by the TEM system while the engine is running.
If the specified nominal value is not reached, the crankcase breather must be serviced - see
job card B 3-1-9.

TCG 2016
B 3-1-2

TCG 2016
B 3-1-9
Maintain crankcase breather (model Racor)
Tools
Spare parts
- Filter element (with O-rings)
- Base insert, if required
General information
The crankcase breather must be maintained when
- the maintenance intervals have been reached.

- the red indicator button is fully visible in the maintenance indicator.
Cleaning the filter elements is not permissible.
Observe the disposal regulations !

Collect operating materials and dispose of properly according to the national regu-
lations.
Dismantle crankcase breather
A1
 Open caps 2.
 Carefully remove container 4 downwards.
- There may be lubricating oil in the container.
 Pull filter element 5 from upper section of filter 3.
 Remove base insert 6 from the container 4.

TCG 2016
B 3-1-9
If a base insert is not fitted, this must be retrofitted.
 Clean components, check and renew if necessary.
Assemble crankcase breather
A2
 If present - check lubricating oil outlet and non-return valve for free passage.
 Check the diaphragms of the non-return valve for damage.
 Check all parts of the crankcase breather (e.g. hoses, rubber parts of the connecting
and discharge lines) visually, renew if necessary.
 Insert new O-ring 7 in upper section of filter 3.
 Insert new filter element 5 with new O-ring 8 in filter top section 3.
 Install base insert 6 in container 4.
Note installation position.
 Wet the new filter element with lube oil.

 Position container 4.
 Close caps 2.

TCG 2016
B 3-1-9
Check drain hose.
A3
 Check the condition and laying of the flexible drain hose 9 and correct if necessary.
The drain hose must be laid without tension and free from chafing.
Make sure it is far enough away from hot parts.
Resetting the maintenance indicator
 Unscrew cap of maintenance indicator 1.

 Push in the red indicator button.
 Mount and tighten cap.
Instructions for putting (returning) the system into operation
Depending on the design, back absorption through the lubricating oil drainage pipe can be
prevented by a non-return valve, a siphon trap or a lubricating oil outlet that ends below the
lubricating oil level (submerged pipe).
Before operating for the first time, the siphon trap must be filled with lubricating oil.
Where there are separate collectors with submerged pipes, a check must be made to en-
sure that the pipe is actually below the lubricating oil level. If necessary, top up the lubricat-
ing oil in the collector until there is a sufficient amount.

TCG 2016
B 3-1-9

TCG 2016
B 3-1-9
Maintain crankcase breather (model UPF 55)
Tools
- Measuring instrument for separating quality, e.g. Dust Trak TM Model 8520
- Hose for water column
- Measuring instrument for blowby volume
Auxiliary material
- Acid-free grease
Spare parts
- Inner filter insert
- Outer filter insert
- Gaskets, if necessary
Technical data
Differential pressure UPF 55 (at full load)

Complete filter max. 200 mmWS
(max. 20 mbar)
1. stage (inner filter insert) max. 80 mmWS
(max. 8 mbar)
2. stage (outer filter insert) max. 120 mmWS
(max. 12 mbar)
Separating quality UPF 55 (measured at full load with Dust Trak TM Model 8520)
after 1st stage (inner filter insert) max. 20 mg/m3
after 2nd stage (outer filter insert) max. 5 mg/m3
Clamping clip UPF filter M8x60 hand tight
General information
The crankcase breather must be maintained when the maintenance intervals specified in
the maintenance schedule are reached.
The pressure regulator is set to a fixed value at the factory and cannot be adjusted. Chang-
es to the pressure regulator are not permissible.
Observe the regulations for disposal !

Collect operating materials and dispose of them properly in accordance with nation-
al regulations.

TCG 2016
B 3-1-9
Cleaning the filter elements is not permissible and can damage the engine.
Renewal of the filter elements must be documented in the certificate of execution according
to the maintenance schedule.
All the filter elements of the crankcase breather must be renewed if coolant penetrates the
lubricating oil system.
Remove filter cartridge
A1
 Unscrew nut 1.
 Unscrew screw 2.
Loosen screw 2 on the opposite side.
 Remove clamp.
A2
 Remove filter cover 3.

TCG 2016
B 3-1-9
A3
 Remove outer filter cartridge 4.
A4
 Remove inner filter cartridge 5.

TCG 2016
B 3-1-9
A5
 Check the rubber seal 6 for damage and renew if necessary.
Make sure the drain holes are not blocked.
Fit filter cartridge
A6
 Insert inner filter cartridge 5.

TCG 2016
B 3-1-9
A7
 Insert outer filter cartridge 4.
A8
 Wet rubber seal 6 with acid-free grease.
Make sure that the sealing rubber 6 fits correctly on the filter housing.
 Fit filter cover 3.

 Turn on nut 1.
- Centre filter cover.
 Tighten nut 1.
- until filter cover is lying on the rubber seal 6 and is centred.

TCG 2016
B 3-1-9
A9
 Install clamp 7.
Make sure that the clamp 7 is sitting correctly on the rubber seal 6 and the filter housing 3.
A 10
 Tighten screw 2.
Make sure the screws are tightened evenly.

TCG 2016
B 3-1-9
A 11
After tightening the clamp, check fit of nut 1, tighten hand tight if necessary.

TCG 2016
B 3-1-9
Check filter function
Visual inspection
 Remove filter cover.

 After the second filter stage the filter housing should be dry inside or only be slightly
wet with lubricating oil or condensation.
If there is lubricating oil or condensation in the filter housing, the connecting hose between
the pressure regulator and the engine must be removed and cleaned.
 Fit filter cover.
Measure the differential pressure
Use a water column as a measuring device.

The water column must be attached to two measuring taps, do not measure against the
atmosphere.
The measurement is made in full load operation if possible.
A 12
 Connect the measuring device to the measuring connections required for the measure-
ment.
 Measure the differential pressure
Position 1 - of complete filter
Position 2 - 1st stage (inner filter insert)
Position 3 - 2nd stage (outer filter insert)
The sum of the differential pressures of the first and second stage must correspond to the
differential pressure of the complete filter.
 Remove the measuring device.

TCG 2016
B 3-1-9
Measure the separating quality
A 13
A measuring instrument, e.g. Dust Trak TM Model 8520 is necessary for the measurement.
A 14
 Measuring point 1
- after 1st stage (inner filter insert)
 Measuring point 2
- after second stage (outer filter insert)
It is not possible to measure the separating quality with the Dust Trak TM in front of the
crankcase breather because the range of the measuring instrument is inadequate.

TCG 2016
B 3-1-9
Measure blowby volume
A measuring instrument with the following parameters is required for the measurement:
 Measuring range 0 to 1000 l/min

 Temperature range 20 to 100 °C

TCG 2016
B 3-1-9
Copy form for elimination of fault
Date
Name
Enclosure
Engine type
Engine serial number
Lubricating oil make
Filter housing type
Type of 1st filter stage
Type of 2nd filter stage
Operating hours
Total engine
1. Filter stage
2. Filter stage
Lubricating oil
Unit 1 2 3 4 5
Engine performance P (electric) kW
Load %
Crankcase pressure TEM display* mbar
Total differential pressure filter mmWS
Differential pressure 1st filter stage mmWS
(inner filter)
Differential pressure 2nd filter stage mmWS
(outer filter)
Blowby temperature in tank °C
Blowby volume l/min
Optional measurement if measuring instrument available

Separating quality after 1st filter mg/m3
stage (pre-filter)
Separating quality after 2nd filter mg/m3
stage (fine filter)
* In units with Huba-Control pressure switches, the crankcase pressure must be measured
with a water column.

TCG 2016
B 3-1-9

TCG 2016
B 4-6-1
Installing, removing and actuating engine turning gear
Tools
- Special tool according to chapter 5
- Engine turning gear
General information
Risk of injury !
Installing the engine turning gear.
A1
 Unscrew screws 1.
 Remove sealing plate 2 with gasket.

TCG 2016
B 4-6-1
A2
 Insert engine turning gear 3.

 Tighten screws 4.
The engine turning gear is spring loaded for safety reasons.

To turn the engine, press in the hexagon and turn.
Removing the engine turning gear.
 Remove engine turning gear 3.
 Check the gasket of the sealing plate and renew if necessary.
 Mount sealing plate 2 with gasket.

TCG 2016
B 5-4-2
Checking the speed governor linkage
Tools
Auxiliary material
General information
Risk of injury !
Checking the speed governor linkage
A1
 Push lever 1 to full load stop.
While pushing an even resistance must be felt.

When releasing, the actuator must return automatically to the zero position.
 Move connecting rods 2 in direction of arrow and check jointed heads for play.
If irregular resistance can still be felt, there is probably a defect in the actuator or the throttle
valve.
If the swivel heads do have any play, they can be replaced.
For this contact your service partner.

TCG 2016
B 5-4-2

TCG 2016
B 6-3-6
Renewing the suction air intake filter
Tools
Spare parts
- Intake air cleaner
General information
Risk of injury !
Renew the suction air intake filters when
- the underpressure limit value has been reached (observe maintenance display).
- there is any damage or leaks (e.g. holes caused by outside factors).
A temporary appearance of the display in the maintenance indicator during engine opera-
tion may have other causes apart from a soiled air filter.
Removing filter insert
A1
 Unscrew wing nut 1.

 Remove cover from the air filter housing.

TCG 2016
B 6-3-6
A2
 Unscrew nut 2.
 Remove suction air intake filter.
 Clean the inside of the air filter housing with a cloth.
Fitting filter insert
 Insert new suction air intake filter.

 Tighten nut 2.
 Mount cover on air filter housing.
 Tighten wing nut 1.

TCG 2016
B 7-20-1
Checking the gas pressure in the gas regulator line
References
- B 7-21-1 Renewing gas filter insert
Technical data
Gas pressure in the gas control system*

20 to 100 mbar
* may deviate from set point depending on unit and type of gas
General information
The correct gas pressure for the unit is to be found in the commissioning report.
The gas pressure applied to the gas control system is read from the pressure gauge. This
is supplied by the pre-pressure control system and depends on the type and quality of gas.
A pressure check can only be made when the engine is running.
Checking the gas pressure in the gas regulator line
A1
 Press confirmation button 1 and read off gas pressure.
If the specified level has not been reached, the gas filter insert must be renewed - see job
card B-7-21-1.

TCG 2016
B 7-20-1

TCG 2016
B 7-21-1
Renewing gas filter insert
Tools
Spare parts
- Gasket
- Filter insert
References
- B 7-20-1 Checking the gas pressure in the gas regulator line
General information
Remove gas filter insert
A1
 Disconnect gas supply by closing the ballcock (arrow).

 Remover cover from gas filter housing 2.

TCG 2016
B 7-21-1
A2
 Remove filter insert 3 from cover 4.

 Remove gasket 5.
 Clean cover and gas filter housing.
Fit gas filter insert
A3
 Replace seal 5.
 Mount new filter insert 3 on cover 4.
- Note installation position.

TCG 2016
B 7-21-1
A4
 Place cover with filter insert 6 in gas filter housing.
Note positioning of filter insert on the gas filter housing (arrow).
 Fasten screws and tighten crosswise.

 Restore gas supply by opening the ballcock.
 Check the cover and gas filter housing for leaks.
- To do this, spray the cover with leak search spray or soap suds and watch for for-
mation of bubbles.

TCG 2016
B 7-21-1

TCG 2016
B 8-1-1
Taking lube oil samples
Tools
- Lube oil sample container
General information
Trouble-free operation and wear behaviour depend to a large extent on the state of the lube
oil. Therefore checking the lube oil is one of the most important maintenance jobs.
An analysis by the lube oil manufacturer is necessary since a detailed examination can only
be carried out in a laboratory. If there is no alternative, MWM will carry out the analysis for
reimbursement of expenses.
The necessary data for lube oil analysis are:
- Brand and type of lube oil.

- Reading on the operating hours counter.
- Lube oil consumption since the last sample was taken.
If the analysis proves negative, the lube oil must be replaced.
The lube oil sample must be taken from the lube oil circuit with the engine running and at
operating temperature.
Risk of scalding !
When working with hot operating materials.
Lube oil tap
A1

TCG 2016
B 8-1-1
A2
 Start engine and bring up to operating temperature (lube oil temperature above 60°C).
 Push coupling piece 1 with hose pipe until it clicks in to lube oil removal valve.
Risk of scalding !
When the coupling piece has clicked in, hot lube oil immediately flows out under
pressure.
 Drain the required amount of lube oil into the lube oil sample container.
 Unlock lube oil removal valve 1 and pull off coupling piece 2 with hose pipe 3.

TCG 2016
B 8-1-2
Changing lube oil
Tools
Spare parts
- Lubricating oil according to running material specifications
References
- Chapter 4, Operating media
- B 8-10-4 Renewing lube oil filter cartridge
- Operating Instructions TEM System
- Technical Circular TR 0199-99-2105.
General information
The lube oil change is performed in connection with the TEM System.
The lube oil change should be performed on the warm engine.
Depending on the system version, there is an option for remote oil change which enables
control of two solenoid valves for automatic switching between the pre-lubrication and
pumping modes. Lube oil can then be changed via modem.
Risk of injury !
Risk of scalding !

lations.

TCG 2016
B 8-1-2
Pump off lube oil
A1
 Switch over the three-way valve 1 on the pre-lubrication pump so that the old oil can
be pumped off.
 In the TEM system
- Select menu item Service.
- Select menu item Oil change.
- Select menu item Pump out oil - (pumping out process starts and finishes after
the time programmed in the TEM).
If the lube oil tray is not empty after the programmed time (pre-lube pump stops), the pump-
ing out process must continue with menu item Pump out oil.
If the lube oil tray is empty before the programmed time (pre-lube pump is sucking air), the
pre-lube pump can be turned off under menu item Oil sump empty.
 Switch the three-way valve 1 on the pre-lubrication pump back to engine operation.
The lube oil filter cartridges should always be renewed when changing the lube oil - see job
card B 8-10-4.

TCG 2016
B 8-1-2
Pour in lube oil
 In the TEM system

- Select menu item Refill - (fresh oil starts to fill).
The filling process is controlled automatically by the TEM system.

When the filling level is reached the lube oil level switch ends the filling process automati-
cally.
 At the end of fresh oil filling

- Select menu item Pre-lubrication - (pre-lubrication process starts).
The pre-lubrication process takes about 20 minutes. It is not possible to start the engine
before then.

TCG 2016
B 8-1-2

TCG 2016
B 8-4-11
Overhaul pressure limiting valve of the pre-lube pump
Tools
- Torque wrench
- Depth gauge
Spare parts
- Sealing rings (DIN 7603-A 21x26-Cu)
- poss. control piston
- poss. compression spring
General information
Risk of injury !
Dirt particles may collect on the control piston of the pre-lube pump's pressure limiting
valve. The control piston is then no longer fully in contact with the piston seat and leaks.
Some of the pumped lube oil is taken off directly due to this leak. The lube oil pressure re-
quired for pre-lurication is then no longer achieved.

TCG 2016
B 8-4-11
Overhaul pressure limiting valve of the pre-lube pump
Dismantle the pressure limiting valve
A1
 Unscrew the cap nut.
A2
 Determine dimension X with caliper gauge and note for later installation.
- measured from the top of the setting screw to the lock nut.

TCG 2016
B 8-4-11
A3
 Loosen lock nut and unscrew setting screw.
A4
 Remove compression spring and control piston.

 Clean the seat on the control piston (arrows) and in the housing of the pressure control
valve.
Check components (compression spring, control piston) for wear, renew if necessary.
Assemble pressure limiting valve
 Insert control piston and compression spring.

 Renew sealing ring and screw in setting screw with lock nut.

TCG 2016
B 8-4-11
A5
 Turn in setting screw to dimension X.
The dimension X determined when removing must be retained otherwise the set lube oil
pressure will be changed.
A6
 Tighten the lock nut.
Hold at the setting screw.

After tightening the lock nut, check the dimension X again with the depth measuring appli-
ance, loosen the lock nut again if necessary and reset the dimension X.
 Renew sealing ring and tighten cap nut.

TCG 2016
B 8-10-4
Renewing lube oil filter cartridge
Tools
- Lubricating oil filter key
Auxiliary material
- Collecting tray for old oil
Spare parts
- Lubricating oil according to running material specifications
- Lube oil filter cartridges
References
- TEM system operating manual
Technical data
Lubricating oil filter on lubricating oil filter head

27 Nm
General information
Risk of injury !
Risk of scalding !

lations.

TCG 2016
B 8-10-4
Removing the lubricating oil filter cartridge
A1
 Place collection tray underneath.

 Loosen the lubricating oil filter cartridge with the lubricating oil filter wrench and un-
screw.
When unscrewing the lube oil cartridge fine plastic chips are produced when the catch is
released. These chips do not get into the lube oil system and pose no danger.
Install lube oil filter cartridge.
A2
 Clean the sealing surface.

 Wet the gasket of the new lubricating oil filter cartridge with lubricating oil.

TCG 2016
B 8-10-4
A3
 Mount and tighten lube oil filter cartridge.

 Check lube oil filter cartridge for leaks.
- build up oil pressure with pre-lube pump to do so.

TCG 2016
B 8-10-4

TCG 2016
B 9-0-4
Empty and fill cooling system
Tools
Auxiliary material
- Collecting tray for coolant
Spare parts
- Gaskets
References
- B 9-1-1 Checking percentage of corrosion protection agent or antifreeze in coolant
General information
For various work, e.g. on the cylinder head, crankcase, heat exchanger and pipes, the cool-
ant must be partially or totally drained.
If no antifreeze is added, the coolant must be drained totally from the engine and the attach-
ment parts when shutting down the engine for a longer time and in case of frost.
In order to empty the engine completely, coolant must be drained from various points in the
cooling system.
A collecting tray must be placed underneath the appropriate places.
Danger of burning !
When corrosion protection is not in its hardened state, it is a fire hazard.
Risk of injury !

lations.

TCG 2016
B 9-0-4
Emptying the cooling system
A1
A2
 Shut off the coolant pipes from and to the engine.

 Open the drain valves and drain the coolant.
- on crankcase 1.
 Open the drain plugs and drain the coolant.
- on the coolant housing of exhaust gas pipe 2.
- on the lubricating oil cooler 3.
- on the intercooler 4.

TCG 2016
B 9-0-4
A3
In the V16 engine the middle drain plugs 5 on the exhaust pipe must be opened.
 Close drain plugs and drain valves again after complete drainage.
- Use new gaskets and sealing rings.
Filling the cooling system
Use the required quality of coolant as described in chapter 4, Operating materials.

Use the right percentage of corrosion protection agent or antifreeze as set out in job card
B 9-1-1.
Variant up to engine number 2206652
 Fill the engine cooling system with the prepared coolant.

 Bleed coolant pipes at the highest point.
- Loosen vent plug screws.
- Leave the vent plug screws open until the coolant emerges without bubbles.
- Tighten vent plug screws.
 Open coolant pipe from and to the engine.
 After filling, check pipes, connecting elements and engine for tightness and renew de-
fective components if necessary.
 Check the coolant level again, top up if necessary.

TCG 2016
B 9-0-4
Variant from engine number 2206653
 Fill the engine cooling system with the prepared coolant.
A4
 Bleed coolant pipe on the A and B side.

- Loosen the vent plug screws 6.
- Tighten vent plug screws 6.
 Bleed coolant pipes at the highest point.
- Loosen vent plug screws.
- Tighten vent plug screws.
 Open coolant pipe from and to the engine.
 After filling, check pipes, connecting elements and engine for tightness and renew de-
fective components if necessary.
 Check the coolant level again, top up if necessary.

TCG 2016
B 9-1-1
Checking percentage of corrosion protection agent or antifreeze in

coolant
Tools
- Measuring instrument
Spare parts
- Anti-corrosion agent or antifreeze if necessary
References
General information
In order to protect coolant chambers from corrosion anti-corrosion is added to the coolant.
This protection only exists, though, if the content of anti-corrosion agent does not go below
a certain amount. If more anti-corrosion agent than is necessary is in the coolant, the cool-
ing effect is reduced.
If antifreeze is mixed into the coolant , this must also have anti-corrosive properties. In this
case, no anti-corrosion agent has to be added. For those reasons the antifreeze content
must be measured accordingly.
If the cooling system has to be topped up, the antifreeze or anti-corrosion agent content in
the coolant must be checked. Then the coolant must be corrected as described below.
Danger of burning !
When corrosion protection is not in its hardened state, it is a fire hazard.
Checking the percentage of corrosion protection agent or antifreeze
 Take a coolant sample from the radiator, expansion tank or drain tap.
 Check the additive content with the measuring instrument - see TR 0199-99-2091.

TCG 2016
B 9-1-1
Correct the corrosion protection agent and antifreeze content
If additive content is too low:
 Calculate additive content.

A = B x (C - D) / 100
A= Quantity of extra additive needed

B= Total filling quantity
C= Nominal value
D= Measured value
 Drain off enough coolant.
 Mix the quantity of additive to be topped up well with the drained coolant.
 Fill the mixture.
If the additive content is too high:
 Calculate additive content.

A = (1 - B / C) x D
A= Coolant to be drained
B= Nominal value
C= Measured value
D= Total filling quantity
 Drain off necessary coolant.

 Fill cooling system with pure water.
Observe water quality - see chapter 4, Operating media
 Bleed cooling system.

TCG 2016
B 13-4-1
Servicing the battery
Tools
- Acid tester
Auxiliary material
- Distilled water
- Acid protection grease
- Cloths
Technical data
Battery acid density

Charge status Normal Tropical
well charged 1.28 kg/l 1.23 kg/l
semi-charged (re-charge) 1.20 kg/l 1.12 kg/l
discharged (recharge, renew if neces- 1.12 kg/l 1.08 kg/l
sary)
General information
The gases emitted by the battery are explosive.
Avoid sparks and naked flames.
Danger of burns !
Do not allow battery acid to come into contact with skin or clothing.
Danger of short-circuit !
Do not rest tools on the battery.
Cover the battery poles.
Risk of injury !
Keep battery clean and dry.

TCG 2016
B 13-4-1
Check battery and cable connectors
A1
 Remove dirty clamps.

 Clean the battery poles and clamps.
 Plug on and tighten clamps.
 Grease clamps with acid-proof grease.
 When reassembling, ensure that clamps make good contact. Tighten clamp bolts
hand-tight.
Make sure the clamps have good contact.

TCG 2016
B 13-4-1
Check acid level
A2
 Unscrew and remove sealing caps 1.

 Visually check the acid level.
- without control inserts 2: liquid level 10 - 15 mm above top edge of plate.
- with control inserts 2: liquid level up to their floor.
Only use distilled water for refilling.
Check acid density
A3
 Measure the acid density with a commercially available acid tester.
During measurement, temperature should preferably be 20 °C.

TCG 2016
B 13-4-1
If the battery is recharged, all the stoppers must be removed before charging.
Check the acid level after charging and correct if necessary.
Correct the acid density
 if acid density too low:

A = B x (C - D) / (E - D)
A= Amount of acid to be refilled

B= Cell content
C= Nominal density
D= Acid density in the cell
E= Density of acid to be refilled
- Suck amount of acid to be refilled from the battery.

- Fill determined amount of battery acid into the battery.
 if acid density too high:

A = B x (C - D) / (C - 1)
A= Amount of water to be refilled

B= Cell content
C= Acid density in the cell
D= Nominal density
- Suck amount of water to be refilled from the battery.

- Fill determined amount of water into the battery.

TCG 2016
B 13-5-4
Removing and installing spark plugs, checking ignition cable
Tools
- Spark-plug wrench
- Torque wrench
Auxiliary material
- Compressed air
- Safety goggles
Spare parts
- Sealing rings for spark plugs
- Spark plugs if necessary
Technical data

50 Nm
General information
Spark plugs and ignition cables are one component and cannot be separated.
Risk of injury !
Danger of death !
When working on the high voltage ignition system.

TCG 2016
B 13-5-4
Removing the spark plug
A1

If coolant or lubricating oil gets into the spark plug protection tube, this must be removed
and resealed, please contact your Service Partner.
Particles of dirt can cause injury when cleaning with compressed air.
Wear safety glasses and close-fitting clothing.
 Remove spark plug.
Checking the ignition cable
 Visually inspect the ignition cable for damage and renew if necessary.
Installing the spark plug
If the spark plug is renewed, the new spark plug must be checked for damage.
If the removed spark plugs are re-fitted, the sealing ring must be replaced.
 Insert and tighten spark plug.


TCG 2016
W 0-1-3
Running-in instructions
References
General information
New engines are run in at the factory, so it is not necessary to run them in again.
After maintenance work on main or con rod bearings, pistons, piston rings and cylinder lin-
ers, or after their replacement, the engine will need to be run in again.
This must be carried out according to the run-in program. In conjunction with the MWM
maintenance and service schedule E10, the lube oil must be changed to the type specified
in chapter 4 of the operating manual.
The engine commissioning log should be used as a basis for the setting values.
If the commissioning log is no longer available, the test bench acceptance documents can
be used.
Do not operate the engine for longer than 15 minutes under 30% power (increased oil in
cylinder at low load).
If the run-in program is interrupted, the last load point should be run again.
The data should be monitored during running-in and noted at 100% load.
If work has been done on the gear train the TDC must be checked, and redefined if neces-
sary.

TCG 2016
W 0-1-3
Running-in program
 Install measuring points

- Mixed pressure after turbocharger (compressor side)
before throttle valve or rotary disk valve and in the charge mixture pipe
- Exhaust gas pressure after turbocharger (turbine side)
 Start engine.
 Check the ignition angle with a stroboscopic lamp. Correct if necessary.
 Set the mixture with the gas mixer or the zero-pressure regulator until the engine is
idling satisfactorily.
 Operate the engine for 10 minutes at 25% of the rated power.
 Then increase the power by 25% every 10 minutes until full load is reached.
 Operate the engine on full load for one hour.
 Set the characteristic by measuring pollutants.

TCG 2016
W 0-2-7
Endoscope examination of combustion chamber
Tools
- Endoscope
- Spark plug key
Spare parts
- Sealing rings for spark plugs
Technical data

50 Nm
General information
Using endoscopy, it is possible to inspect the state of wear of the combustion chamber (pis-
ton, cylinder liner, cylinder head, valves) without having to remove the cylinder head. The
wear limits can be better exploited and maintenance costs reduced as a result.
Observe the manufacturer specifications for handling the endoscope!
Evaluation of normal signs of wear and determination of the next endoscopy date can only
be carried out by trained personnel.
The endoscope image can also be projected inverted or upside down depending on the
view of the lens.

TCG 2016
W 0-2-7
Endoscope examination of combustion chamber
A1

 Turn engine until the piston of the cylinder to be inspected is in the lower dead centre.
 Connect endoscope, switch on and feed carefully through the spark plug bore.
In order to be able to test the outlet and inlet valves, the engine must be turned accordingly.
Make sure that the endoscope is not damaged during this process.
Light reflections can lead to diagnostic errors. Swivel and alternately tilt the endoscope dur-
ing the examination. Make sure that the glass fibre cable does not get damaged during this
process.
 In case of clear signs of damage (e.g. breakouts, notches, grooves), the cylinder head
or cylinder liner must be removed.
 Watch out for drip formation on the floor of the cylinder head.
- This may be an indication of leaks or tears in the cylinder head.
 Remove the endoscope carefully.
 Renew sealing rings.
 Install spark plugs.

TCG 2016
W 0-3-1
Use of liquid nitrogen
General information
Risk of injury !
Do not touch liquid nitrogen or supercooled parts.
When the components are placed in liquid nitrogen, drops of liquid may splash out.
Wear protective glasses, snugly-fitting clothing and gloves.
For occasional brief periods of work with liquid nitrogen place two concentric containers one
inside the other for the immersion bath and fill the gap with glass wool, cork dust or sand.
The liquid nitrogen is poured as needed from the containers in which it is delivered into the
immersion bath, into which the components are inserted if necessary.
At the beginning of the metal cooling, the liquid nitrogen "boils" strongly. The bubbling per-
sists until the metal parts reach the temperature of the liquid nitrogen (-196 °C). If the bbub-
bling stops, the parts are ready for installation.
Use a suitable tool for inserting the components into the container and removing them.
Liquid nitrogen consumption

Under normal conditions, the following amount is required for cooling 1 kg of metal from
+15 °C to -196 °C:
 0.60 l for steel

 0.66 l for cast iron
 0.45 l for bronze, copper, brass
 0.96 l for aluminium

TCG 2016
W 0-3-1

TCG 2016
W 0-3-2
Tear inspection by diffusion liquid method
Auxiliary material
- Cleaning agent (trichlorethylene)
- Diffusion liquid (red)
- Developer (white)
- Dry cloth
- Safety goggles
- Protective gloves
- Suction device
General information
When working with trichlorethylene.
Risk of injury !
Cleaning component
A1
 Remove grease from component with cleaning agent.

 Allow cleaning agent to work for 10 - 15 minutes.
 Rub down the surface to be tested thoroughly with a dry cloth.
- This removes all residue grease which might fill in and cover any tears.

TCG 2016
W 0-3-2
Apply diffusion liquid
A2
 Applying diffusion liquid

- This is done with a spray can, spray gun, brush or by immersing the component in
the diffusion liquid.
Observe exposure time according to the manufacturer's specifications.
A3
 Clean component with water.

- Wash off the diffusion liquid thoroughly from the surface until it only remains in the
tears.
 Rub the surface dry thoroughly with a cloth.
 Let the component dry.
Applying developer.
A4
 Apply developer thinly with a spray can or brush.

- Avoid applying twice to the same surface.
 Let the developer dry for 1 - 2 minutes.
The diffusion liquid is drawn out of the tear by the developer (acting as blotting paper) and
therefore becomes visible.

TCG 2016
W 0-3-2
Evaluation
 Very thin tears may only become visible after several hours.
 Red areas in the white developer layer appear in the areas of the tears and other sur-
face irregularities because of the diffusion liquid being drawn up.
 Red lines indicate tears.
 Red dots indicate recesses and porosity.
 A red dotted line occurs with:
- very fine tears
- metal fatigue
- an only partial rupture

TCG 2016
W 0-3-2

TCG 2016
W 0-3-4
Removing, installing and checking hose pipes, vibration dampers and

flexible pipes
Tools
Spare parts
- poss. hose pipes
- poss. vibration dampers
- poss. flexible pipes
Technical data

General information
Due to the wide variety of applications and variants, these instructions do not cover every
single version.
If leaks, tears, porosity or other damage are visible, the corresponding components must
be renewed.
Removing and installing hose pipe and flexible pipe
A1
 Visually inspect hose pipes and flexible pipes.

 Remove clips and fastening nuts.
 Remove components.
 Clean connection nozzles.
TCG 2016
W 0-3-4
 Insert and position new parts.

 Position and tighten clips or fastening nuts.
 Start engine and check components for leaks.
- Leaks must be eliminated.
Removing and installing vibration dampers
A2
 Visually inspect vibration dampers.

- Position 1.
 Unscrew nuts and screws.
 Clean contact surface.
 Insert and position new parts.
 Tighten nuts and screws.
 Start engine and visually inspect vibration dampers.

TCG 2016
W 0-5-1
Lifting and setting down the engine
Tools
Auxiliary material
- Lifting gear
General information
If the generator and engine have been separated, check the alignment of the gener-
ator to the engine and correct if necessary !
The engine must be moved, lifted and set down to be able to perform certain work steps.
This is the case for example during a general overhaul or work on the lubricating oil system.
Danger of death !
Note the breaking strains of the ropes and hoist unit.
Lifting and setting down the engine
 Drain lube oil.

 Drain the coolant.
 Disconnect the pipes from the engine to the system.
 Remove the exhaust pipe.
 Disconnect electric cables.
 Separate the generator from the engine.
A cross-member must be used between the central hook of the lifting crane and the
suspending ropes. The cross-member must guarantee that the suspending ropes are
tensioned vertically upwards !

TCG 2016
W 0-5-1
A1
 Fix suspending rope to engine transport eyes.
A2
 Remove the base frame screw connection.

 Lift engine with hoist unit.
 Lift engine and set down on appropriately high, sturdy and safe support.

TCG 2016
W 1-2-2
Removing and installing rocker arm and rocker arm block
Tools
- Feeler gauge
Spare parts
- Gasket cylinder head cover, if necessary
References
- B 1-1-1 Checking and adjusting inlet and outlet valve clearance
Technical data

M10x75 - 12.9 85 Nm
M12x110 - 12.9 145 Nm

M8x85 - 12.9 30 Nm

50 Nm
General information
To avoid tension through the valve springs, the respective cylinder should be in the ignition
TDC when removing and installing.
Visually inspect all parts.
If wear is detected, the components must be renewed.

TCG 2016
W 1-2-2
Removing rocker arm and rocker arm block
A1
 Unscrew screws (arrows).

 Remove cylinder head hood and gasket.
- Position 1.
A2
Loosen screws evenly to avoid tension on the rocker arm bracket.
 Remove rocker arm with rocker arm bracket.

- Position 2.

TCG 2016
W 1-2-2
A3
 Remove the stop rods and check for visible signs of wear.
- Position 3.
 Remove valve bridges.
- Position 4.
Lay out all the components in the order in which they should be installed.
Install rocker arm and rocker arm block
Note assignment and installation position of the components.
A4
 Insert valve bridges.

- Position 4.

TCG 2016
W 1-2-2
 Insert stop rods.

- Position 3.
A5
 Insert rocker arm bracket and rocker arm.

- Position 2.
A6
The ball heads must be seated in the ladles of the stop rods (arrows).

TCG 2016
W 1-2-2
A7
 Tighten screws (arrows).
Makes sure that the stop rods are not under stress due to valve overlap when fastening the
screws, turn over the engine if necessary.
 Mark the screws with oil-resistant paint after tightening.

 Checking and adjusting inlet and outlet valve clearance - see job card B 1-1-1.
A8

 Mount cylinder head cover with gasket.
- Position 1.
 Install spark plug.
- Renew sealing ring.

TCG 2016
W 1-2-2

TCG 2016
W 1-2-6
Disassembling, assembling and testing the rocker arm and rocker arm
bracket
Tools
- Internal measuring device
- Micrometer gauge
Spare parts
- Ball stud if nec.
- Rocker arm if nec.
- Rocker arm bracket if nec.
References
- W 1-2-2 Removing and installing rocker arm and rocker arm block
Technical data
Outer diameter of the rocker arm shaft

Rocker arm bearing clearance

Wear limit 0.10 mm
Inside diameter of the inlet rocker arm

Inside diameter of the outlet rocker arm


TCG 2016
W 1-2-6
Disassembling the rocker arm bracket
 Remove the rocker arm and the rocker arm block - see job card W 1-2-2.
A1
 Check running surface 1 and setting screws 2 for wear.

- Renew components if necessary.
A2
 Remove locking ring with Seeger ring pliers.

- On both sides.
 Remove washers.
 Remove rocker arm from the rocker arm shaft.

TCG 2016
W 1-2-6
A3
 Clean all components.

 Check lubricating oil channels for free passage.
 Check all components for wear.
- Measure rocker arm bore with internal measuring device.
- Measure the diameter of the rocker arm axis with a micrometer gauge.
If the wear limit is reached, the components must be renewed.
Assembling the rocker arm bracket
 Wet all components with lube oil.

 Push the rocker arm onto the rocker arm shaft.
- Note assignment.
The inlet and outlet rocker arms are different.
 Mount the washer.

 Install locking ring with Seeger ring pliers.
Make sure the locking ring fits correctly.
 Install the rocker arm and the rocker arm block - see job card W 1-2-2.

TCG 2016
W 1-2-6

TCG 2016
W 1-4-4
Removing and installing cylinder head
Tools
- Torque wrench
- Guide pins cylinder head
Auxiliary material
- Lube oil
Spare parts
- Gasket set cylinder head
- Protective tube for stop rod if nec.
- Gasket cylinder head hood, if necessary
References
- B 9-0-4 Empty and fill cooling system
- W 6-1-9 Removing and installing exhaust pipe
- W 6-2-7 Removing and installing charge mixture pipe (V12 and V16 engine)
Technical data
Cylinder head on the crankcase*

M18 - 10.9 20 Nm
+ 100 Nm
+ 200 Nm
+ 400 Nm

M10x75 - 12.9 85 Nm
M12x110 - 12.9 145 Nm

M8x85 - 12.9 30 Nm

TCG 2016
W 1-4-4
General information
When working on the cylinder head gasket it is necessary to drain the coolant either partly
or completely - see job card B 9-0-4.
If the coolant is not drained from the crankcase, a large amount of cooling water will remain
in the cylinder heads. This runs into the cylinder liner when the cylinder heads are removed.
For correct positioning, the cylinder head must be aligned with the flange face on the charge
mixture pipe.
Removing cylinder head
Lay out all components in the order of installation.
 Drain the cooling system - see job card B 9-0-4.

 Remove charge mixture pipe - see job card W 6-2-7.
 Remove exhaust pipe - see job card W 6-1-9.
 Disconnect cable set plug combustion chamber temperature sensor.
A1

 Remove cylinder head hood and gasket.
- Position 1.

TCG 2016
W 1-4-4
A2
Loosen screws evenly to avoid tension on the rocker arm bracket.
 Remove rocker arm with rocker arm bracket.

- Position 2.
A3
 Remove stop rods (arrows).

 Remove valve bridges.
- Position 3.

TCG 2016
W 1-4-4
A4
 Loosen cylinder head screws (arrow) diagonally.
Use reinforced key wrench.
 Unscrew and removed cylinder head screws.

 Remove cylinder head and gasket.
A5
 Remove protective tube of the stop rods from the crankcase.

- Position 4.
 Remove adapter nozzles from crankcase.
- Position 5.

TCG 2016
W 1-4-4
Mounting cylinder head
 Clean all sealing surfaces.

 Check all components and gaskets and renew if necessary.
A6
 Check seals of the protective tube, renew protective tube if necessary.

 Seal short side.
- Position 6.
 Seal long side.
- Position 7.
The protective pipe must be inserted with the long side 7 in the crankcase.
A7
 Check adapter nozzles, renew if necessary.

TCG 2016
W 1-4-4
 Adapter nozzles small diameter.

- Position 8.
 Adapter nozzles large diameter.
- Position 9.
The adapter nozzles must be inserted with the side of the large diameter 9 in the crankcase.
A8
 Wet seal of the adapter nozzles with lubricating oil.

 Insert adapter nozzles into crankcase.
- Position 5.
 Wet seal of the protective tube with lubricating oil.
 Insert protective tube of the stop rods in the crankcase.
- Position 4.

TCG 2016
W 1-4-4
A9
 Fit a new cylinder head gasket.

 Screw guide pins into crankcase.
A 10
 Place the cylinder head on the crankcase.

 Wet cylinder head screws with lubricating oil.
 Insert and tighten two cylinder head screws diagonally.
Do not tighten cylinder head screws yet.

The cylinder head screw must be aligned first.
 Unscrew guide pins.

 Insert and tighten the other cylinder head screws.
 Install charge mixture pipe - see job card W 6-2-7.
 Allign cylinder head with the flange face on the charge mixture pipe.

TCG 2016
W 1-4-4
 Tighten the cylinder head screws diagonally in steps.
Use reinforced key wrench.
A 11
 Insert stop rods (arrows).

 Insert valve bridges.
- Position 3.
A 12
 Insert rocker arm bracket and rocker arm.

- Position 2.

TCG 2016
W 1-4-4
A 13
The ball heads must be seated in the ladles of the stop rods (arrows).
A 14
Makes sure that the stop rods are not under stress due to valve overlap when fastening the
screws, turn over the engine if necessary.
 Mark the screws with oil-resistant paint after tightening.

 Checking and adjusting inlet and outlet valve clearance - see job card B 1-1-1.

TCG 2016
W 1-4-4
A 15

 Mount cylinder head cover with gasket.
- Position 1.
 Install spark plug.
- Renew sealing ring.
 Install exhaust pipe - see job card W 6-1-9.
 Connect cable set plug combustion chamber temperature sensor.
 Fill up cooling system - see job card B 9-0-4.

TCG 2016
W 1-4-6
Overhauling the cylinder head
Tools
- Welding gear
- Press
- Reamers 15.1 mm (1st oversize)
- Reamers 15.2 mm (2nd oversize)
- Plug limit gauge 9 H8
- Knocking hammer
- Drilling machine
- Thread cutter
- Press-out pin for valve stem guide
- Press-in device for valve stem guide
- Press-in pin for inlet and outlet valve seat ring
- Disassembly and assembly lever for valve spring
- Disaasembly and assembly wrench for spark plug protective tube
Auxiliary material
- Loctite 270
- Liquid nitrogen
Spare parts
- Sealing rings
- Inlet and outlet valve stem guides
- Inlet and outlet valve seat rings
- Inlet and outlet valves
- Spark plug protective tube
- poss. valve barring gears
- poss. valve springs
- poss. valve clamping cone
- poss. spring plate
References
- W 0-3-1 Use of liquid nitrogen
- W 1-4-4 Removing and installing cylinder head

TCG 2016
W 1-4-6
Technical data
Valve guide / valve seat ring
Outside diameter of the valve stem guide (removed)

Standard 15.032 - 15.047 mm
1st oversize 15.132 - 15.147 mm
2nd oversize 15.232 - 15.247 mm
Inside diameter of the valve stem guide (installed)

Installation dimension of the valve stem guide

13.4 - 13.6 mm
Cylinder head
Installation dimension of guide bolt for valve bridge

Bore diameter for valve stem guide

Standard 15.010 - 15.021 mm
1st oversize 15.110 - 15.121 mm
2nd oversize 15.210 - 15.221 mm
Valve
Diameter of the valve shaft

Valve spring
Length of the valve spring (large spring)

Length of the valve spring (small spring)

Protective tube for spark plug on cylinder head

105 Nm

TCG 2016
W 1-4-6
General information
The cylinder head is removed and cleaned.
New valves, valve seat rings and valve stem guides must always be installed when over-
hauling the cylinder head.
The installation procedure must take place rapidly due to the necessary temperature differ-
ence of the individual components. For this reason, we recommend that you read this job
card carefully and practise the necessary actions before installation.
Suitable cleaning agents can be found in chapter 4, Auxiliary materials.
All gaskets, sealing rings and circlips must be renewed.
Material is removed from the locating hole in the cylinder head wnen the valve stem guide
is pressed out.
When pressing in the new valve stem guide, this is sitting in the bore of the cylinder head
with too low a pressure. The inside diameter of the valve stem guide is greater in this state
which causes the engine to suck lubricating oil through the valve shaft into the combustion
chamber during operation which is then burnt.
Therefore the bore in the cylinder head must be reworked to the next oversize stage with a
reamer after pressing out the valve stem guide and the appropriate valve stem guide (over-
size 1 or 2) installed.
A1
Three different cylinder heads are used
- Variant A - exhaust pipe with gap charging (form-milled sealing surface)

- Variant B - exhaust pipe with gap charging (plane-milled sealing surface)
- Variant C - exhaust pipe PEARL with back-up charging
Risk of injury !
Do not touch liquid nitrogen or supercooled parts.
When the components are placed in liquid nitrogen, drops of liquid may splash out.
Wear protective glasses, snugly-fitting clothing and gloves.

TCG 2016
W 1-4-6
Dismantling the cylinder head
Removing inlet and outlet valves
Risk of injury !
The component is under spring pressure.
 Remove cylinder head - see job card W 1-4-4.
A2
 Install assembly lever for valve springs.

 Press down valve spring head with assembly lever 1 (arrow).
A3
 Remove valve clamping cone 2.

 Release the tension on the valve spring carefully.

TCG 2016
W 1-4-6
A4
 Remove spring head 3.

 Remove valve spring 4.
 Remove valve spring 5.
 Remove washer 6.
 Remove all the other valves accordingly.
 Remove assembly lever for valve springs.
 Turn cylinder head 180°.
 Pull valve out of valve guide.
Removing the spark plug protective tube
A5
 Disaasembly and assembly wrench for spark plug protective tube

- Unscrew screw (arrow).
- Remove washer.

TCG 2016
W 1-4-6
 Clamp the cylinder head in the vice.
A6
 Insert disaasembly and assembly wrench 7 into spark plug protective tube
A7
 Mount and tighten screw 8 with washer.

TCG 2016
W 1-4-6
A8
 Loosen protective tube 9.

 Unscrew screw 8 with washer.
 Unscrew protective tube 9 and remove.
Removing valve seat ring
 Unscrew valve head about 5 mm.

 Insert valve in cylinder head.
A9
When welding (arrow), do not weld the valve to the valve seat ring.
The weld serves only to rest the valve head when removing the valve seat ring.

TCG 2016
W 1-4-6
 Weld seam (arrow) to valve seat ring.

- Welding electrode diameter 2 mm
- Current strength maximum 130 Ampere
Do not set a higher current, or damage may occur to the cylinder head.

 Remove the valve seat ring from the cylinder head by hitting the valve stem.
Removing valve guide
A 10
 Place cylinder head under the press.

 Press the valve stem guide out of the cylinder head with the press-out pin.
Removing the guide bolts for valve bridges
The guide bolts must only be renewed if worn.
 Centre punch the guide bolt.

 Drill out the guide bolt.
 Cut the thread in the guide bolt.
 Turn the hammer into the thread.
 Knock the guide bolt out of the cylinder head.

TCG 2016
W 1-4-6
Checking cylinder head
The dismantled cylinder head must be checked completely for various criteria.
These include visual inspection, tear testing and leak testing.
 Clean and check all components.
A 11
 Prepare and adjust internal measuring instrument.

 Measure valve seat bore with internal measuring instrument.
Assembling the cylinder head
Installing guide bolts for valve bridges
A 12
 Cool guide bolts in liquid nitrogen.

- Use of liquid nitrogen - see job card W 0-3-1.

TCG 2016
W 1-4-6
 Dry guide bolts, i.e. without oil, then insert into the holding bore of the cylinder head.
Do not force it in.
 Press the guide bolt into the cylinder head.
Observe installation dimension X.
Installing the spark plug protective tube
A new protective tube must always be used.

Do not wet the protective tube with locking agent in the area of the thread.
A 13
 Renew sealing rings 10.

 Wet sealing rings 10 with acid-free grease.
 Wet seat surface on the protective tube (arrow) with locking agent.
 Clamp the cylinder head in the vice.

TCG 2016
W 1-4-6
A 14
 Insert the protective tube in the cylinder head.

 Insert disaasembly and assembly wrench 7 into spark plug protective tube
A 15
 Mount and tighten screw 8 with washer.

TCG 2016
W 1-4-6
A 16
 Tighten protective tube 9.

 Unscrew screw 8 with washer.
 Remove disassembly and assembly wrench.
Installing valve guide
 Widen the locating hole mechanically with a reamer to the appropriate oversize stage.
The reamer has a left-hand twist and must always be turned clockwise.
Never turn the reamer anticlockwise.
The cuttings resulting from removing the material can get stuck and damage the cuttings.
 Blow out housing bore with compressed air.
A 17

TCG 2016
W 1-4-6
 Check the diameter of the locating hole for the valve stem guide with an internal meas-
uring instrument.
 Remove sealing ring from the valve stem guide.
 Cool the appropriate valve guide in liquid nitrogen.
Note post-assembly position of the valve guide.

The stepped side must face towards the combustion chamber when pressing in.
The different press-in depth of the valve stem guides for the respective variant must be ob-
served.
A 18
 Insert valve guide dry, i.e. without oil, without force with the stepped end in the locating
hole of the press-in device 11.
Apply press to press-in pin.

Release pressure briefly and then fully press in the valve guide.

TCG 2016
W 1-4-6
A 19
 Check the prescribed installation dimension X.
A 20
 Check the inside diameter of the valve guide with a plug gauge.
The target area of the plug gauge must be able to move upwards and downwards in the
valve stem guide with light suction.

TCG 2016
W 1-4-6
Installing valve seat ring
 Place cylinder head under the press.
A 21
 Cool valve ring in liquid nitrogen.

A 22
 Insert valve seat ring in cylinder head.

 Press the valve seat ring into the cylinder head with the press-in pin.
Apply press to press-in pin.

Release pressure briefly and then fully press in the valve seat ring.
To guarantee a permanent firm seat in the cylinder head, the valve seat ring must be
pressed with a force of 12,000 N (1200 kp) for at least 15 seconds.

TCG 2016
W 1-4-6
Machine valve seat ring
A 23
Machine the valve seat ring on the valve seat lathe.

Observe the manufacturer's specifications.
A 24
 Insert valves.
 Mount vacuum pump.
 Make vacuum measurement.
- On the inlet side and the outlet side.

TCG 2016
W 1-4-6
Installing inlet and outlet valves
A 25
 Wet sealing ring 12 with acid-free grease.

 Insert sealing ring 12 in valve guide.
 Wet the valve stem and valve stem guide with lube oil.
 Insert valve in cylinder head.
Do not damage the sealing ring in the valve stem guide.
A 26
 Fit washer 6.
 Mount valve spring 5.
 Mount valve spring 4.
 Mount valve spring head 3.
TCG 2016
W 1-4-6
A 27
 Install assembly lever for valve springs.

 Press down the valve spring plate with assembly lever.
 Mount valve clamping cone 2.
Make sure the valve clamping cone fits properly.

Never release the valve spring head when the valve clamping cone 2 is not sitting
properly in the valve shaft.
 Relieve the tension on the assembly levers for valve springs carefully.
 Install all the other valves accordingly.
 Remove assembly lever for valve springs.
 After repair work, the repair date and a company identification must be marked in a
suitable place.
 Mount cylinder head - see job card W 1-4-4.

TCG 2016
W 2-0-1
Safety regulations for drive unit work
General information
Before starting work
 Stop the engine and secure against restarting.

 Danger of burns!
- If necessary, drain lube oil or coolant and collect for re-use.
- Do not perform other drive unit work until the engine is sufficiently cool.
- When working on the exhaust system, remember that components may still be hot
despite a long cooling time.
 Wear protective glasses and gloves!
- Heat guards may have sharp edges.
 Do not start work until enough time has been allowed for ventilation.
 Make sure that the environment in which the engine is opened is clean.
During work
 Make sure no dirt gets into the crankcase.

 Before turning the crankshaft, check that
- the turning gear is properly engaged.
- no persons are working in or on the engine.
- no tools obstruct turning of the crankshaft, as this could result in damage.
- the drive unit is not unbalanced by the removal of parts of the drive unit.
 Make sure the crankshaft cannot be turned unintentionally.

TCG 2016
W 2-0-1
After finishing work
 Check that all tools, cleaning cloths etc. have been removed from the crankcase.
 Turn over the engine with spark plugs removed before commissioning.
 Pour in lube oil.
 Top up coolant.

TCG 2016
W 2-1-4
Checking crankshaft axial clearance
Tools
- Micrometer gauge
- Mounting iron
- Dial gauge
Technical data
Crankshaft bearing clearance

General information
The axial clearance can be determined with the crankschaft installed.
If the axial clarance of the crankshaft is exceeded, the rear thrust bearing must be renewed.
Checking crankshaft axial clearance
Crankshaft installed
 Remove flywheel guard if present.

 Attach magnetic measuring stand and insert dial gauge.
 Using the mounting iron, press flywheel to stop in the direction of the drive side.
 Adjust dial gauge to 0.
 Using the mounting iron, press flywheel to stop in the direction of the free side.
 Read the dial gauge.
Repeat the measurement several times and compare the measured values.
 Remove magnetic measuring stand and dial gauge.

 Install flywheel guard if present.
Crankshaft removed
 All components must be inspected visually.

TCG 2016
W 2-1-4
A1

 Measure thrust bearing width - measured value a.
A2
 Measure thrust bearing width - measured value b.

 Determine axial clearance.
- by subtraction of measured value a and measured value b
Calculation example
measured value a 32,54 mm
measured value b - 32,32 mm
Axial clearance 0,22 mm

TCG 2016
W 2-1-6
Checking bearing shells
Tools
- Caliper gauge
References
- Service Information System (Global SIS)
Technical data
Splay of the main bearing shell

Splay of the thrust bearing shell

Splay of the big end bearing shell

General information
Run bearing shells exhibit different running profiles depending on the number of operating
hours and operating conditions. The basic differences can often only be detected by trained
personnel. If in doubt, we recommend that you contact your service partner for an evalua-
tion.
Further information can be found in the Global SIS in the SD - Special Documentation sec-
tion.

TCG 2016
W 2-1-6
Checking bearing spread
 All components are removed and cleaned.
A1
1 Bearing spread
2 Bearing shell outer diameter
 Measure bearing spread 1 with caliper gauge.
The bearing spread 1 is always greater than the bearing shell outer diameter 2.
Correction of the bearing shell is not permissible.
Renew the bearing shells if the measured dimensions deviate from the nominal dimen-
sions.

TCG 2016
W 2-1-7
Checking crankcase
Tools
- Micrometer gauge
- Dial gauge
- Magnetic measuring stand
- Prisms
Auxiliary material
- Cleaning agents
References
- W 2-4-1 Removing and installing crankshaft
- W 0-3-2 Tear inspection by diffusion liquid method
Technical data
Data on tightening specifications, dimensions, position and form tolerances can be found
in chapter 8, Technical Data.
The technical test specifications listed in the text 0162 0000

0162 0022
0162 0030
can be found in the appendix, Technical Test Specifications.
General information
In case of slight running marks at the bearing points, it is possible to have the crankshaft
polished at our service centres.
Regrinding of the bearing points is not permissible.
Realigning the crankshaft is not permissible.
If a nominal value of a component is not observed, the component must be renewed.

The counterweights of the crankshaft remain installed.

TCG 2016
W 2-1-7
Checking crankcase
Cleaning
 Remove crankshaft - see job card W 2-4-1.
A1
 Cleaning the crankshaft.

- Select cleaning agent, see Chapter 4, Auxiliary materials.
 Blow crankshaft dry with compressed air.
 Rub the bearing points dry thoroughly with rags.
Tear test
 Carry out tear test by magnetic test method according to test specification 0162 0000
or diffusion liquid method - see job card W 0-3-2.
 Check the running surfaces of the main bearing pin for marks.
 Check the running surfaces of the lifting journal for marks.
Checking roundness
The roundness of main bearing pin and lifting journal must be checked according to the
Technical Test Specification 0162 0022.

TCG 2016
W 2-1-7
Checking the bearing pin
Mounting
A2
 Mount the crankshaft fixed on the outer main bearing pins and additionally on at least
two inner main bearing pins with floating prisms.
 Max. difference in height of the bearing points 0.01 mm.

TCG 2016
W 2-1-7
Diameter of the bearing pins
Do not measure in the area of the lubricating oil bores.
1 2
b b
a a
© 85046-0
A3
 Measuring schematic of the main bearing pin diameter at points a and b in the levels 1
and 2.
1 2 3 4
b b b b
a a a a
© 85047-0
A4
 Measuring schematic of the lifting journal diameter at points a and b in the levels 1, 2,
3 and 4.

TCG 2016
W 2-1-7
A5
 Measure diameter with micrometer gauge.
Straightness of the bearing pins
A6
 Attach magnetic measuring stand and insert dial.

 Place the stylus on the bearing pin under pre-tension.
 Move the dial gauge (arrow).
 Check parallelism.
 Mount the dial gauge on all other bearing pins.
 Repeat procedure.

TCG 2016
W 2-1-7
Run-out of the bearing pins
A7
 Attach magnetic measuring stand and insert dial gauge.

 Place the stylus on the bearing pin under pre-tension.
 Turn the crankshaft.
 Check the runout.
 Mount the dial gauge on all remaining bearing pins.
Special feature of the lifting journal
A8
 Do not turn the crankshaft but make the measurement once at three o'clock and once
at zero hundred hours.
 Mount the dial gauge on all remaining bearing pins.

TCG 2016
W 2-1-7
Checking parallelism

The parallelism of the main and lifting journals with each other and the main and lifting jour-
nals in relation to each other must be checked!
Do NOT readjust the dial gauge for measurements!
A9
 Attach magnetic measuring stand and insert dial at the first main bearing pin.
 Apply stylus to the main bearing journal with pre-tension.
 Mount the dial gauge on all remaining main bearing pins (arrow).
A 10
 Turn the lifting journal respectively to the measuring position.

 Repeat the measurement with all lifting journals.

TCG 2016
W 2-1-7

TCG 2016
W 2-2-2
Removing and installing crankshaft sealing ring (drive side)
Tools
- Assembly tool for crankshaft sealing ring
Auxiliary material
- DW 75
Spare parts
- Crankshaft sealing ring
- Crankshaft flange if nec.
References
- W 2-2-9 Removing and installing the crankshaft flange (drive side)
- W 12-6-1 Removing and installing the flywheel
General information
In case of leaks on the crankshaft sealing ring, check whether the crankshaft flange has
formed a run-in groove.
If the crankshaft flange is too heavily worn, it must be renewed.
Removing and installing the crankshaft flange (drive side) - see job card W 2-2-9.

TCG 2016
W 2-2-2
Removing crankshaft sealing ring
 Remove flywheel - see job card W 12-6-1.

 Removing the crankshaft flange (drive side) - see job card W 2-2-9.
Do not damage the sealing surfaces.

Do not damage the crankshaft and flywheel housing.
A1
 Remove crankshaft sealing ring

- Position 1.
- Loosen crankshaft sealing ring in its seat using a mandrel.
- Drill a hole (min. 3-3.5 mm) carefully in the crankshaft sealing ring.
- Turn self-tapping screw into the hole.
- Remove crankshaft sealing ring with suitable tool, e.g. assembly lever for valve
springs.
 Check the running surface of the crankshaft flange.
- Renew crankshaft flange if necessary.
Installing crankshaft sealing ring
The crankshaft sealing ring must be installed evenly and without skew.

Wet the sealing lip of the crankshaft sealing ring with lube oil, never use grease.

TCG 2016
W 2-2-2
A2
 Mount the crankshaft sealing ring on the assembly tool (arrow).

 Wet the outside of the crankshaft sealing ring with locking agent.
A3
 Mount the assembly tool with the crankshaft sealing ring.

TCG 2016
W 2-2-2
A4
 Screw in screws (arrows) evenly.

- Assembly tool must be on the flywheel housing.
 Remove assembly tool completely.
 Installing the crankshaft flange (drive side) - see job card W 2-2-9.
 Install flywheel - see job card W 12-6-1.

TCG 2016
W 2-2-4
Removing and installing crankshaft sealing ring (free side)
Tools
- Assembly tool for crankshaft sealing ring
Auxiliary material
- DW 75
Spare parts
- Crankshaft sealing ring
References
- W 2-2-10 Removing and installing the crankshaft flange (free side)
- W 12-1-4 Removing and installing torsional vibration dampers
General information
In case of leaks on the crankshaft sealing ring, check whether the crankshaft flange has
formed a run-in groove.
If the crankshaft flange is too heavily worn, it must be renewed.
Removing and installing the crankshaft flange (free side) - see job card W 2-2-10.

TCG 2016
W 2-2-4
Removing crankshaft sealing ring
 Remove torsional vibration damper - see job card W 12-1-4.

 Removing the crankshaft flange (free side) - see job card W 2-2-10.

Do not damage the crankshaft and gearcase cover.
A1
 Remove crankshaft sealing ring

- Position 1.
 Loosen crankshaft sealing ring in its seat using a mandrel.
 Drill a hole (min. 3-3.5 mm) carefully in the crankshaft sealing ring.
 Turn self-tapping screw into the hole.
 Remove crankshaft sealing ring with suitable tool, e.g. assembly lever for valve
springs.
 Check the running surface of the crankshaft flange.
- Renew crankshaft flange if necessary.
Installing crankshaft sealing ring
The crankshaft sealing ring must be installed evenly and without skew.

 Wet the outside of the crankshaft sealing ring with locking agent.

TCG 2016
W 2-2-4
A2
 Mount the crankshaft sealing ring evenly on the gearcase cover.

- Position 1.
 Apply the assembly tool to the crankshaft sealing ring (arrow).
A3
 Install crankshaft sealing ring.

- With assembly tool.
 Tighten screws 2 evenly.
- Assembly tool must be on the gearcase cover.
 Remove assembly tool completely.
 Installing the crankshaft flange (free side) - see job card W 2-2-10.
 Install torsional vibration damper - see job card W 12-1-4.

TCG 2016
W 2-2-4

TCG 2016
W 2-2-9
Removing and installing the crankshaft flange (drive side)
Tools
Auxiliary material
- DW 62
Spare parts
- Crankshaft sealing ring if nec.
References
- W 2-2-2 Removing and installing crankshaft sealing ring (drive side)
General information
The crankshaft sealing ring must be renewed if it is leaking.
Removing and installing the crankshaft sealing ring (drive side) - see job card W 2-2-2.
Removing the crankshaft flange
A1

 Remove crankshaft flange.

TCG 2016
W 2-2-9
Installing the crankshaft flange
Clean and check the threaded bores in crankshaft.

The flange faces of the crankshaft and the crankshaft flange must be free from oil and
grease.
A2
 Insert the crankshaft flange.

- Pay attention to the position of the locking pin 1.

TCG 2016
W 2-2-10
Removing and installing the crankshaft flange (free side)
Tools
- Force multiplier
Auxiliary material
- DW 62
Spare parts
- Crankshaft sealing ring if nec.
References
- W 2-2-4 Removing and installing crankshaft sealing ring (free side)
Technical data
Crankshaft flange (free side) on crankshaft*

M16x1.5x80 - 12.9** 390 Nm
M27x2x95 - 10.9 1620 Nm
M30x2x100 - 10.9 2350 Nm
**Renew screws
Caution !
Screw must be drip-free so that no lubricating oil can get into the flange separating joint
when screwing in.
General information
The crankshaft sealing ring must be renewed if it is leaking.
Removing and installing the crankshaft sealing ring (free side) - see job card W 2-2-4.

TCG 2016
W 2-2-10
Removing the crankshaft flange
A1

 Remove connecting flange.
- Position 1.
A2
 Unscrew screws.
- Position 2.
 Unscrew centre screw.
- Position 3.
Use force multiplier.
 Remove crankshaft flange.

TCG 2016
W 2-2-10
Installing the crankshaft flange
Clean and check the threaded bores in the crankshaft 5.

The flange faces of the crankshaft 5 and the crankshaft flange 6 must be free from oil and
grease.
A3
 Insert the crankshaft flange.

- Pay attention to the position of the locking pin.

TCG 2016
W 2-2-10
A4
 Tighten screws.
- Position 2.
 Tighten the centre screw.
- Position 3.
Use force multiplier.
A5
 Insert connecting flange.

- Pay attention to the position of the locking pin 4.

TCG 2016
W 2-3-5
Checking con rod geometry
Tools
References
- W 2-1-6 Checking bearing shells
Technical data
Big end bearing bore

Diameter Rated dimension 98,000 - 98.022 mm
Con rod liner bore

Diameter Rated dimension 53.985 - 54.004 mm

M16x1.5 - 12.9 90 Nm
General information
See job card W 2-1-6 for measurement and evaluation of the bearing shells.
The con rod bearing shells are measured additionally in the appropriate con rod before as-
sembly.
If a nominal value of a component is not observed, the component must be renewed.

TCG 2016
W 2-3-5
Measuring the con rod
A1
 Overview of measuring points
Big-end bearing
A2
 Schematic for measuring the diameter at points a, b and c in levels 1 and 2.

TCG 2016
W 2-3-5
Con rod eye
A3
 Schematic for measuring the diameter at points a and b in levels 1 and 2.

TCG 2016
W 2-3-5

TCG 2016
W 2-4-1
Removing and installing crankshaft
Tools
- Lifting gear
- Angled wrench
References
- W 2-1-4 Checking crankshaft axial clearance
- W 2-1-7 Checking crankcase
- W 2-9-3 Removing and installing piston with con rod
- W 3-6-1 Removing and installing the flywheel housing
- W 4-4-9 Removing and installing gear housing cover
- W 8-5-3 Removing and installing lube oil pump
Technical data

M18x165 - 12.9 210 Nm

TCG 2016
W 2-4-1
General information
All gaskets and sealing rings must be renewed.
The order of disassembly and assesmbly of the main bearing screw connections must be
observed.
Always loosen the main bearing screw connections from the outside to the inside when re-
moving.
Always tighten the main bearing screw connections from the inside to the outside when in-
stalling.
Tightening order V12
A1
A2
Removing crankshaft
Sub-units and supply lines are disconnected from the engine.

The lubricating oil pan and vibration dampers are removed.
The engine is turned 180°.
 Remove the piston with con rod - see job card W 2-9-3.
 Removing the flywheel housing - see job card W 3-6-1.
 Remove gear housing cover - see job card W 4-4-9.
 Remove lube oil pump - see job card W 8-4-5.

TCG 2016
W 2-4-1
A3
 Check the main bearing cover identification for the installation.

- Apply the identification if necessary.
 Unscrew main bearing screws.
Observe order of disassembly.
A4
 Loosen the screw connections in the crankcase from the outside to the inside (position
1 to 4).

TCG 2016
W 2-4-1
A5
 Loosen the screw connections on the main bearing cover from the outside to the inside
(position 1 and 2).
 Remove main bearing cover.
- Loosen main bearing cover if necessary by hitting lightly with a plastic hammer.
Do not damage the components.

Lay out all the components according to the installation position, note the identification.
A6
 Hang the crankshaft on a suitable hoist.

 Remove crankshaft.

TCG 2016
W 2-4-1
A7
 Remove the main bearing shells from the main bearing covers.
 Remove main bearing shells from crankcase.
 Check bearing shells - see job card W 2-1-6.
 Check crankshaft - see job card W 2-1-7.
 Check axial clearance of the crankshaft - see job card W 2-1-4.

TCG 2016
W 2-4-1
Installing crankshaft
The rear of the bearing shells must be oil and grease free.
The drive side main bearing (bearing number 1) is the fit bearing.
A8
 Insert the main bearing shell with lubricating oil groove in the crankcase.
- Pay attention to positioning of the torsion lock and alignment of the lube oil bore.
A9
 Insert the main bearing shell without lubricating oil groove in the main bearing cover.
- Pay attention to positioning of the twist protection (arrow).

TCG 2016
W 2-4-1
A 10
 Wet the bearing journal and bearing shells with lubricating oil.
 Insert the crankshaft carefully in the crankcase.
Pay attention to the control times when inserting the crankshaft.
 Remove hoist unit.

 Insert fit bearing and main bearing cover.
- Note assignment and position.
 Insert and turn in main bearing screws.
Observe order of assembly.
A 11
 Tighten the screw connections on the main bearing cover from the inside to the outside
(position 1 and 2).
TCG 2016
W 2-4-1
A 12
 TIghten the screw connections in the crankcase from the inside to the outside (position
1 to 4).
 Turn over the crankshaft and check for easy action.
 Tighten screws with angled wrench.
 Install lube oil pump - see job card W 8-4-5.
 Install gear housing cover - see job card W 4-4-9.
 Installing the flywheel housing - see job card W 3-6-1.
 Install the piston with con rod - see job card W 2-9-3.

TCG 2016
W 2-5-3
Removing, installing and testing big end bearing
Tools
- Angled wrench
Spare parts
- Big end bearing screws (amount - as required)
- poss. big end bearing shells (set)
- Gasket lubricating oil pan
References
- W 3-5-1 Removing and installing lube oil tray
Technical data

M16x1.5 - 12.9 90 Nm
General information
It is possible to remove and install the big end bearing without having to remove the pistons
and the crankshaft.

TCG 2016
W 2-5-3
Removing the big end bearing
 Remove lube oil tray - see job card W 3-5-1.
A1
 Turn the crankshaft until the big end bearing screw of the respective cylinder are ac-
cessible.
 Remove con rod bearing cover.
- Position 1.
 Turn the crankshaft slowly until the con rod base is free from the big end bearing pin.
- Make sure that the con rod does not damage the big end bearing pin.
 Remove the big end bearing shells from the con-rod and the big end bearing cover.

TCG 2016
W 2-5-3
Installing the big end bearing
A2
 Insert con rod bearing shells in con rods and con rod bearing covers.
- Pay attention to positioning of the twist protection.
A3
The identification (magnifying glass) on the con-rod and the big end bearing cover must be
identical and opposite to each other when assembled.

TCG 2016
W 2-5-3
A4
 Turn the crank shaft until the con-rod can be positioned on the crank shaft.
 Mount big end bearing cover on con-rod.
- Position 1.
 Screw on screws (arrows).
Check whether the con-rod still moves on the crankshaft.

 Install lube oil tray - see job card W 3-5-1.

TCG 2016
W 2-9-3
Removing and installing piston with con rod
Tools
- Angled wrench
- Assembly tool for piston installation
Spare parts
- Big end bearing screws (amount - as required)
- poss. big end bearing shells (set)
- Gaskets
References
- W 2-15-2 Removing, installing and checking piston cooling nozzle
Technical data

M16x1.5 - 12.9 90 Nm
General information
Before removing the pistons the combustion residue must be removed from the cylinder lin-
ers.
Always check the alignment of the piston cooling nozzle before installing the piston - see
job card W 2-15-2.

TCG 2016
W 2-9-3
Removing piston with con rod

A1
 Turn the crankshaft until the big end bearing screw of the respective cylinder are ac-
cessible.
 Remove con rod bearing cover.
- Position 1.
 Press the con-rods carefully out of the lifting journals.

 Pull the piston with con -od out of the cylinder liner.
 Remove the big end bearing shells from the con-rod and the big end bearing cover.

TCG 2016
W 2-9-3
Installing piston with con rod
A2
 Insert con rod bearing shells in con rods and con rod bearing covers.
A3
 Arrange piston ring joints offset by about 120°.


TCG 2016
W 2-9-3
A4
Danger of destroying the engine !

Make sure that the recess in the piston is on the piston cooling nozzle side.
A5
Apply the assembly tool for piston installation so that the wide arear of the compres-
sor faces the crankcase.
 Secure piston rings with assembly tool.

TCG 2016
W 2-9-3
A6
Note the cylinder assignment of the pistons.

The arrow on the piston points to the camshaft (direction of combustion chamber).
 Insert the piston with con-rod up into the cylinder liner until the assembly tool touches.
- Make sure that the con rod does not damage the big end bearing pin.
 Push the piston into the cylinder liner.
- Do not damage the piston ring.
- Do not damage the piston cooling nozzle.
A7
The identification (magnifying glass) on the con-rod and the big end bearing cover must be
identical and opposite to each other when assembled.

TCG 2016
W 2-9-3
A8
 Turn the crank shaft until the con-rod can be positioned on the crank shaft.
 Mount big end bearing cover on con-rod.
- Position 1.
Check whether the con-rod still moves on the crankshaft.


TCG 2016
W 2-7-2
Removing and installing the main bearing
Tools
- Lifting gear
- Angled wrench
References
- W 2-1-4 Checking crankshaft axial clearance
- W 2-1-7 Checking crankcase
- W 8-5-3 Removing and installing lube oil pump
Technical data

M18x165 - 12.9 210 Nm

TCG 2016
W 2-7-2
General information
The order of disassembly and assesmbly of the main bearing screw connections must be
observed.
Always loosen the main bearing screw connections from the outside to the inside when re-
moving.
stalling.
A1
A2
Removing the main bearing
Sub-units and supply lines are disconnected from the engine.

The lubricating oil pan and vibration dampers are removed.
The engine is turned 180°.
 Remove lube oil pump - see job card W 8-4-5.

TCG 2016
W 2-7-2
A3
 Check the main bearing cover identification for the installation.

- Apply the identification if necessary.
Observe order of disassembly.
A4
 Loosen the screw connections in the crankcase from the outside to the inside (position
1 to 4).

TCG 2016
W 2-7-2
A5
 Loosen the screw connections on the main bearing cover from the outside to the inside
(position 1 and 2).
 Remove main bearing cover.
- Loosen main bearing cover if necessary by hitting lightly with a plastic hammer.
Do not damage the components.

A6
 Hang the crankshaft on a suitable hoist.

 Remove crankshaft.

TCG 2016
W 2-7-2
A7
 Remove the main bearing shells from the main bearing covers.
 Remove main bearing shells from crankcase.
 Check crankshaft - see job card W 2-1-7.

TCG 2016
W 2-7-2
Installing the main bearing
The drive side main bearing (bearing number 1) is the fit bearing.
stalling.
A8
 Insert the main bearing shell with lubricating oil groove in the crankcase.
- Pay attention to positioning of the torsion lock and alignment of the lube oil bore.
A9
 Insert the main bearing shell without lubricating oil groove in the main bearing cover.

TCG 2016
W 2-7-2
A 10
 Wet the bearing journal and bearing shells with lubricating oil.
 Insert the crankshaft carefully in the crankcase.
Pay attention to the control times when inserting the crankshaft.

 Insert fit bearing and main bearing cover.
- Note assignment and position.
 Insert and turn in main bearing screws.
Observe order of assembly.
A 11
 Tighten the screw connections on the main bearing cover from the inside to the outside
(position 1 and 2).
TCG 2016
W 2-7-2
A 12
 TIghten the screw connections in the crankcase from the inside to the outside (position
1 to 4).
 Install lube oil pump - see job card W 8-4-5.

TCG 2016
W 2-9-7
Checking piston
Tools
- Micrometer gauge
References
Technical data
Piston height
Piston pin bore

Piston ring groove height

1. Piston ring groove Rated dimension no specification
General information
All components are removed and cleaned.
The cylinder liner must be changed when the piston rings are changed.


TCG 2016
W 2-9-7
Checking piston
Removing piston from con rod
A1
 Remove locking ring.

 Push piston pin out of piston.
- place piece of wood underneath if necessary and drive out with light knocks of the
hammer.
 Remove con rod from piston.
Checking the piston bolt bore
A2
 Measuring schematic of the piston bolt bore at points a and b in the levels 1 and 2.
 Measure piston pin bore with internal measuring device.
TCG 2016
W 2-9-7
Checking piston pin
A3
 Measuring schematic of the piston bolt diameter at points a and b in the levels 1, 2 and
3.
 Measure piston bolt diameter with micrometer gauge.
The clearance of the piston pin in the piston is calculated from the dimensions piston pin
bore - piston pin diameter.
Mounting piston on con rod
A4
 Install circlip with circlip pliers on one side of the piston.

- Make sure the circlip fits properly.

TCG 2016
W 2-9-7
A5
 Insert con rod in piston.
Pay attention to the position of the recess for the piston cooling nozzle (arrow).
The recess for the piston cooling nozzle is on the side of the con-rod screw 1 next to the
bolt.
A6
 Push piston bolt into piston.

 Install locking ring with Seeger ring pliers.
- Make sure the circlip fits properly.

TCG 2016
W 2-10-1
Removing, installing and checking piston rings
Tools
- Piston ring pliers
Spare parts
- poss. piston ring set
References
Technical data
surge clearance
Twist angle of the piston ring gaps

120°
Piston ring thickness

1. piston ring Rated dimension Trapeze ring
General information
If a piston ring is worn or defective, the complete piston ring set must be renewed (do not
renew single piston rings).
The piston rings must always be renewed when the piston or the cylinder liner are renewed.
The piston rings may only be removed and installed with the listed piston ring pliers, other-
wise the piston rings may be overstretched.

TCG 2016
W 2-10-1
Removing piston rings
A1
 Remove piston rings with piston ring pliers.
Cleaning pistons
A2
 Clean pistons and piston ring grooves

- Select cleaning fluid - see operating manual chapter 4.
- Place piston in cleaning fluid (see manufacturer's instructions for exposure time).
The piston ring groove 1 has a steel support ring.

The piston ring grooves 2 and 3 are machined directly in the piston. Clean carefully here so
that no piston material is removed.

TCG 2016
W 2-10-1
Checking the piston ring joint clearance
A3
Do not check the piston ring gap clearance in wear range 5 other the wear of the cylinder
liner will be measured as well.
Insert piston rings in the wear-free area 6.
 Clean cylinder liner.
A4
 Insert piston ring in cylinder liner.

- Insert piston ring horizontally, do not jam.
 Check joint clearance with feeler gauge.

TCG 2016
W 2-10-1
Installing piston rings.
A5
 Fit hose springs together.

- Position 4.
 Insert hose spring 4 in piston ring 3.
- Move the joint 7 of the hose spring 180° to joint 8 of the piston ring.
A6
 Mount piston rings on piston with piston ring pliers.

- Starting with the lowest piston ring (assembly order 3 - 2 - 1).
The TOP identification must face the piston base.

TCG 2016
W 2-10-1
A7
 Align piston ring joints.

- Offset the joint of piston rings 1, 2 and 3 by 120° to each other.

TCG 2016
W 2-10-1

TCG 2016
W 2-15-2
Removing, installing and checking piston cooling nozzle
Tools
- Torque wrench
- Inspection device piston cooling nozzle
Spare parts
- Piston cooling nozzle if nec.
- Sealing ring
References
Technical data
Piston cooling nozzle on crankcase

M8x45/120 - 8.8 25 Nm
General information
Danger of destruction of the piston cooling nozzle!

If the piston cooling nozzle is not in order, it must be renewed. Rebending the piston
cooling nozzle is not permissible.
The piston cooling nozzle should be checked whenever the accessibility allows.
The alignment is important because piston cooling is not fully guaranteed if the lubricating
oil jet is incorrect and the engine may be destroyed as a result.

TCG 2016
W 2-15-2
Checking the piston cooling nozzle
A1

 Mount inspection device on cylinder liner.
- Position 1.
 Insert test rod through the hole in the inspection device.
- Position 2.

TCG 2016
W 2-15-2
A2
 Check alignment of the piston cooling nozzle.
The right jet position is guaranteed when the test rod can be pushed into the piston cooling
nozzle.
 Loosen the screw and align the piston cooling nozzle if necessary.
Pull out the test rod before tightening the piston cooling nozzle.

TCG 2016
W 2-15-2
Removing piston cooling nozzle
A3

 Unscrew screw (arrow).
 Remove piston cooling nozzle with sealing ring.
- Position 3.

TCG 2016
W 2-15-2
Installing the piston cooling nozzle

The piston cooling nozzles of cylinder side A and cylinder side B are different and may not
be switched over.
A4
 Piston cooling nozzle for cylinder side A

- Position 4.
 Piston cooling nozzle for cylinder side B
- Position 5
A5
 Insert piston cooling nozzle with sealing ring.

- Position 3.

TCG 2016
W 2-15-2
 Fasten screw (arrow).

 Align the jet position of the piston cooling nozzle with the inspection device and test
rod.
 Tighten screw (arrow).
After tightening the pressure relief valve, the alignment of the piston cooling nozzle must be
checked again.

TCG 2016
W 3-3-1
Checking cylinder liner
Tools
- Micrometer gauge
- Depth gauge
- Dial gauge
Auxiliary material
- Commercially available grinding paste
Spare parts
- Cylinder liner if necessary
- Sealing rings
Technical data
Outside diameter of the cylinder liner

top Rated dimension 159.99 - 160.09 mm
Inside diameter of the cylinder liner

Height of the cylinder liner

Height of the collar of the cylinder liner

General information

TCG 2016
W 3-3-1
Checking cylinder liner
a b
1
a b
2
a b
3
a b
4
© 37238-0
A1
 Measuring schematic of the cylinder liner at points a and b in the levels 1 - 4.

 Measure cyliner liner with internal measuring device.
- Balance internal measuring device at the given measuring points and read off the
measured values.
In case of damage or deviations in measurements, the cylinder liner must be renewed.
In case of re-usable cylinder liners
A2
 Visually inspect collar surfaces.

- In area X.

TCG 2016
W 3-3-1
A3
 Clean and visually inspect collar rest and sealing surface for cylinder liner.
In case of rust or suspicion of leaks in the cylinder liners in the area of the collar rest, this
can easily be repaired with new or re-usable cylinder liners.
A4
 Wet the collar contact surface of the cylinder liner with a normal grinding paste.
Insert the cylinder liners in the crankcase without sealing rings for correction grinding.
 Insert cylinder liner and turn until there is an even contact pattern.
 Remove the cylinder liner from the crankcase.
 Clean the cylinder liner and crankcase thoroughly.

TCG 2016
W 3-3-1
Measuring sheet for cylinder liners
Customer: Order no.:

Engine type: Engine no.:
Operating hours: Signature:
Date:
Rated dimension
132.0 to 132.025 mm
Measuring heights
a= 25 mm
b= 50 mm
c= 150 mm
d= 250 mm
a b c d
A1 X/Y
B1 X/Y
A2 X/Y
B2 X/Y
A3 X/Y
B3 X/Y
A4 X/Y
B4 X/Y
A5 X/Y
B5 X/Y
A6 X/Y
B6 X/Y
A7 X/Y
B7 X/Y
A8 X/Y
B8 X/Y
A9 X/Y
B9 X/Y
A10 X / Y
B10 X / Y

TCG 2016
W 3-3-2
Removing and installing cylinder liner
Tools
- Disassembly tool for cylinder liner
Auxiliary material
- AP 1908
Spare parts
- Sealing rings
References
- W 3-3-1 Checking cylinder liner
General information

TCG 2016
W 3-3-2
Removing cylinder liner

A1
 Mount extraction tool for cylinder liner

- Position tension plate so that the contact surfaces touch the bottom of the cylinder
liner.
- Place counterholder on the crankcase.
Turn the crankshaft so that the respective cylinder liner is accessible.

Pay attention to the piston cooling nozzle when working on the crankcase.
 Pull out the cylinder liner with the extraction tool.

TCG 2016
W 3-3-2
A2
 Remove the cylinder liner from the crankcase.

 Remove the sealing rings from the crankcase.
 Check cylinder liner - see job card W 3-3-1.
Installing the cylinder liner
The collar contact and the sealing surface for the cylinder liner must be checked before in-
stalling the cylinder liner.
 Wet the contact surfacer of the cylinder all round lightly with spotting paste.
 Insert cylinder liner without sealing rings in the crankcase.
The cylinder liner must be easily insertable and turnable by hand.
 Turn the cylinder liner half a turn.

 Pull the cylinder liner back out.
 Check the contact surface of the cylinder liner and the cylinder liner rest.
- There must be a uniform bearing face.
If there is no uniform bearing face, please contact your service partner.
 Remove spotting paste.

 Clean the cylinder liner and crankcase thoroughly.

TCG 2016
W 3-3-2
A3
 Wet the sealing rings with acid-free grease.

 Insert sealing rings in the crankcase.
A4
 Coat the lower section of the cylinder liner thinly on the outside with a mounting com-
pound.
 Insert cylinder liner in the crankcase.
When installing, make sure that the sealing rings are correctly positioned and not damaged.
 Press the cylinder liner in until it touches.


TCG 2016
W 3-5-1
Removing and installing lube oil tray
Tools
Auxiliary material
- DW 47
References
- B 8-1-2 Changing lube oil
- W 0-5-1 Lifting and setting down the engine
Technical data

M8x55 - 10.9 25 Nm
M8x130 - 8.8 25 Nm
General information
Depending on the version, it is possible to pump off the lubricating oil through the pre-lubri-
cation pump.
Risk of injury !

lations.
Risk of scalding !

TCG 2016
W 3-5-1
Removing lube oil tray
 Pump off lube oil - see job card B 8-1-2.

 Lift engine - see job card W 0-5-1.
A1
 Disconnect all lubricating oil lines (arrows) from the lubricating oil pan.
A2
Secure the lubricating oil pan against falling out by suitable means before loosening the
screws.
 Unscrew screws.
 Remove lube oil tray from crankcase.
 Remove gasket.

TCG 2016
W 3-5-1
Install lube oil tray
A3
 Stick lube oil tray gasket with lube grease to the lube oil tray.
- Do not grease the transitional joint of the individual gasket parts.
 Wet the transitional joint of the lube oil tray gasket with sealant.
- Joints must be sealed completely with sealant.
 Apply packing compound in the area of the front and rear cover.
 Mount lube oil tray on crankcase.
 Connect all lubricating oil lines to the lubricating oil pan.
 Set down engine - see job card W 0-5-1.
 Fill up lube oil - see job card B 8-1-2.

TCG 2016
W 3-5-1

TCG 2016
W 3-6-1
Removing and installing the flywheel housing
Tools
- Guide pins
Auxiliary material
- DW 47
References
- W 2-2-2 Removing and installing crankshaft sealing ring (drive side)
Technical data
Flywheel housing on crankcase

M8x50 / 85 - 12.9 45 Nm
M12x55 / 60 / 85 - 12.9 145 Nm
M12x125 - 10.9 120 Nm


TCG 2016
W 3-6-1
General information
To avoid damage when removing and installing the flywheel housing, two guide pins must
be made and screwed into two opposite holes.
The different screw length must be taken into account when assembling and installing.
 Pos.1 - 8x screw M12 x 60 - 12.9

 Pos.2 - 5x screw M8 x 85 - 12.9
 Pos.3 - 2x screw M12 x 125 - 10.9
 Pos.4 - 3x screw M12 x 85 - 12.9
 Pos.5 - 2x screw M8 x 50 - 12.9
 Pos.6 - 1x screw M12 x 55 - 12.9
A1

TCG 2016
W 3-6-1
Removing the flywheel housing

 Remove flywheel flange.
A2
 Unscrew two screws.

 Hang the flywheel housing on a suitable hoist.
 Unscrew screws.
 Remove the flywheel housing.
- Position 1.

TCG 2016
W 3-6-1
Installing the flywheel housing

 Clean the sealing surfaces.
A3
 Apply sealant.
- On the crankcase around the contact surface of the flywheel housing.
A4
 Renew crankshaft sealing ring if nec.

- Removing and installing the crankshaft sealing ring - see job card W 2-2-2.
 Mount the flywheel housing.
- Position 1.
 Screw in screws.

TCG 2016
W 3-6-1
Pay attention to different screw lengths.

 Tighten screws crosswise.
 Insert flywheel flange.

TCG 2016
W 3-6-1

TCG 2016
W 3-7-1
Checking engine mounting
Tools
Technical data
Screw connections in base frame

according to the manufacturer's specifications
Engine claw to crankcase

M14x45 / 100 / 140 - 12.9 200 Nm
Engine suspension to crankcase

M16x90 - 10.9 220 Nm
General information
Since the base frame can change due to the effect of heat and tension, the fastening screws
must be checked for loosening.
This is particularly necessary after the first few hours of operation.
Fule, lubricating oil, water and coolant may not come into contact with the elastic mount-
ings.

TCG 2016
W 3-7-1
Checking engine mounting
A1
 Check mating pieces in rigid mounting and enclosures in elastic mounting by knocking
(including those which are difficult to access due to pipes running above them).
A metallic ring indicates a firm connection.
 Retighten screws if necessary.

TCG 2016
W 4-1-4
Checking camshaft axial clearance
Tools
- Dial gauge
Auxiliary material
- DW 68
Spare parts
- Sealing rings
References
- W 4-5-5 Removing and installing camshaft
Technical data

General information

TCG 2016
W 4-1-4
Checking camshaft axial clearance
A1

- Position 1.
 Measure axial clearance.
- Pull forward camshaft on gear as far as possible.
- Adjust dial gauge to 0.
- Push back camshaft gear as far as possible.
- Read axial clearance on dial gauge.
If the axial clearance is out of tolerance, the camshaft axial guide must be renewed -see job
card W 4-5-5.
Then repeat the measurement.


TCG 2016
W 4-2-3
Removing, installing and checking valve tappet
Tools
- Lifting device for valve tappet
References
- W 4-5-5 Removing and installing camshaft
Technical data
Bore diameter for valve tappet

Wear limit 20.230 mm
Outer diameter of the valve tappet

General information
A lifting device is required for every valve tappet according to the number of cylinders.

TCG 2016
W 4-2-3
Removing valve tappets
 Remove pushrods.
A1
 Loosen knurled nut 1.
A2
 Insert lifting device 2 in cylinder head.

- Up to the stop in the valve tappet.

TCG 2016
W 4-2-3
A3
 Tighten knurled nut 1.

 Lift valve tappet to the stop with the lifting device.
 Fix the lifting device to the cylinder head with rubber ring 3.
 Lift and fix all other valve tappets accordingly.
 Remove camshaft - see job card W 4-5-5.
 Loosen knurled nut of the lifting device.
 Remove valve tappet.
 Remove lifting device.
Checking the valve tappet and valve tappet bore
A4
 Measure valve tappet diameter with a micrometer gauge.

TCG 2016
W 4-2-3
 Measure valve tappet bore with internal measuring device.
Installing valve tappet
A5

- Knurled nut must be loosened.
 Insert valve tappet.
A6

 Install camshaft - see job card W 4-5-5.
TCG 2016
W 4-2-3


TCG 2016
W 4-2-3

TCG 2016
W 4-4-1
Removing and installing the gear drive (free side)
Tools
- Angled wrench
- Dial gauge
References
- W 4-4-11 Checking and measuring control times
Technical data
Camshaft wheel on camshaft*

M10x25 - 10.9 70 Nm
* with screw locking agent Loctite 0100 4100
General information

TCG 2016
W 4-4-1
Overview gear train
A1
1 Camshaft wheel
2 Crankshaft wheel
3 Lubricating oil pump wheel
Removing the gear drive
A2

 Unscrew screws.
 Removing the camshaft wheel

TCG 2016
W 4-4-1
Installing the gear drive
 Clean and check all components.
A3
 Mount camshaft wheel on camshaft.
Make sure that the toothed wheel markings are in line when mounting the camshaft wheel.
Turn crankshaft if necessary.
A4

 Check and measured control times - see job card W 4-4-11.

TCG 2016
W 4-4-1
Check tooth edge clearance
A5

- Position 1.
 Check tooth edge clearance.
- Turn the camshaft wheel to one side if possible (arrow).
- Turn the camshaft wheel to the other side if possible (arrow).
- Read the tooth edge clearance from the dial.
If the tooth edge clearance is out of tolerance, the camshaft wheel must be renewed.
Then repeat the measurement.


TCG 2016
W 4-4-9
Removing and installing gear housing cover
Tools
- Guide pins
Auxiliary material
- DW 47
Spare parts
- Gaskets
- Sealing rings
References
- W 2-2-4 Removing and installing crankshaft sealing ring (free side)
- W 5-7-3 Removing and installing the camshaft sensor (model Jaquet)
- W 6-6-4 Removing and installing exhaust gas turbocharger (V12 and V16 engine)
Technical data
Gearcase cover on crankcase

M10 - 10.9 82 Nm
M8 - 10.9 42 Nm

M8x55 - 10.9 25 Nm
M8x130 - 8.8 25 Nm

TCG 2016
W 4-4-9
General information
To avoid damage when removing and installing the front cover, two guide pins must be
made and screwed into two opposite holes.
Risk of injury !

lations.
Removing gear housing cover

 Drain lube oil.
 Remove coolant connection flange.
 Remove turbocharger - see job card W 6-6-4.
A1
 Remove lubricating oil level sensor.

- Position 1.
 Remove lubricating oil filter with holder and pipes.
- Position 2.
 Removing the camshaft sensor - see job card W 5-7-3.
- Position 3.

TCG 2016
W 4-4-9
A2
 Unscrew screws.
- in the area of the gearcase cover.
A3
 Unscrew screw and turn in guide pins.

- Position 1.
 Hang gear housing cover on suitable hoist unit.
 Unscrew screws.

TCG 2016
W 4-4-9
A4
 Hang gear housing cover on suitable hoist unit.

 Remove gearcase cover.

 Removing the crankshaft sealing ring (free side) - see job card W 2-2-4.
Mounting gear housing cover
Only use approved cleaning agents - see chapter 4.

 All gaskets and sealing rings must be renewed.
If the gasket of the lubricating oil pan is damaged, remove the lubricating oil pan and renew
the seal.
Removing and installing the lubricating oil pan - see job card W 3-5-1.

TCG 2016
W 4-4-9
A5
 Apply sealant.
- Apply packing compound evenly to the sealing surface of the gear case cover.
- Apply sealant to the crankcase in the area of the lube oil tray.
A6
Make sure that the groove is not blocked by packing compound.
 Wet sealing ring with acid-free grease.

TCG 2016
W 4-4-9
A7
 Wet bearing shell (arrow) with acid-free grease.
A8

 Mount gear housing cover.

TCG 2016
W 4-4-9
A9
 Insert screws.

- Position 1.
 Screw in screws.
 Align gear housing cover.
- Align gear housing cover to the crankcase and lube oil tray.
 Tighten screws.
A 10
 Tighten screws.
 Install crankshaft sealing ring (free side) - see job card W 2-2-4.
TCG 2016
W 4-4-9
A 11
 Fit camshaft pick-up.

- Position 3.
 Set camshaft sensor.
- Removing and installing the camshaft sensor - see job card W 5-7-3.
 Install lubricating oil filter with holder and pipes.
- Position 2.
 Install lubricating oil level sensor.
- Position 1.
 Install turbocharger - see job card W 6-6-4.
 Install coolant connection flange.
 Top up coolant.

TCG 2016
W 4-4-11
Checking and measuring control times
Tools
- Tape measure
- Pocket calculator
References
- W 4-4-1 Removing and installing the gear drive (free side)
Technical data
Control times (at valve clearance)

Outlet opens before TDC 65°
Outlet closes after BDC 14° 30’
General information
The work procedure is described on a valve.
Proceed accordingly if the other valves are also to be tested.
Only mark B1 is available on the flywheel. If the control times on the rest of the cylinders
are to be checked, the appropriate positions must be determined and marked.

TCG 2016
W 4-4-11
Checking control times
Visually inspecting gear wheel marks
A1
1 Camshaft wheel
2 Crankshaft wheel
 Turn the engine.
- until the gear marks are one above the other.
 Check toothed wheel markings.
If the toothed wheel markings are not in line, the control times must be set.
Removing and installing the gear drive - see job card W 4-4-1.

TCG 2016
W 4-4-11
Measuring control times
 Calculate arc dimension for flywheel

L = d x Pi x °KW / 360°
L= Calculated arc dimension in mm

d= Flywheel diameter in mm
Pi = Circle number
°KW = Crankshaft angle in °KW
Calculation example
d= 600 mm
Pi = 3,14
°KW = 58,5°
L = d x Pi x °KW / 360
L = 600 mm x 3.14 x 58.5° / 360°
L = 306.15 mm
A2
1= Ignition marks on crankcase or flywheel

X= Marking direction for values before TDC
Y= Marking direction for values after TDC

TCG 2016
W 4-4-11
A3
 Turn the engine.

- until the appropriate cylinder is in ignition TDC.
The ignition marks 1 on the flywheel and the crankcase are in line.
 Remove cylinder head cover.

 Set inlet and outlet valve clearance - see job card B 1-1-1.
- to 1 mm valve clearance.
 Transfer calculated arc dimension to flywheel at position 2.
A4
 Turn engine in direction of rotation.

- until marking of arc dimension 2 is in line with the TDC marking on crankcase 3.

TCG 2016
W 4-4-11
In this position the rocker arm must just begin to press open the valve.
This is the case when the pushrod of the valve concerned can no longer be turned by hand.
Before starting engine

Set inlet and outlet valve clearance - see job card B 1-1-1.

TCG 2016
W 4-4-11

TCG 2016
W 4-5-5
Removing and installing camshaft
Tools
- Assembly tool for camshafts
- Lifting device for valve tappet
Auxiliary material
- Lube oil
Spare parts
- Gaskets
- Sealing rings
- Screws
References
- W 4-4-1 Removing and installing the gear drive (free side)
- W 4-4-11 Checking and measuring control times
Technical data
Camshaft axial guide on crankcase

M8x20 - 10.9 35 Nm

TCG 2016
W 4-5-5
General information
A lifting device is required for every valve tappet according to the number of cylinders.
A1
When applying the assembly tool, make sure that there is no offset between the assemby
tool and the camshaft.
If the assembly tool is mounted with an offset, it catches on the camshaft bearings when
pulling out of the camshaft.

TCG 2016
W 4-5-5
Removing camshaft

 Remove pushrods.
A2
 Loosen knurled nut 1.
A3

- Up to the stop in the valve tappet.

TCG 2016
W 4-5-5
A4

 Removing the gear drive - see job card W 4-4-1.
A5
 Unscrew the four screws of the camshaft axial guide.

- Turn the camshaft so that the screws of the camshaft axial guide are accessible
through the large hole in the camshaft flange.

TCG 2016
W 4-5-5
A6
 Remove the camshaft axial guide.
A7
 Mount the assembly tool on the camshaft.

- On the drive side.
 Tighten screw.
 Push the assembly tool into the crankcase.

TCG 2016
W 4-5-5
A8
 Pull the camshaft with assembly tool out of the crankshaft.

 Remove the assembly tool from the camshaft.
Installing camshaft

The camshaft is installed with the assembly tool first through the free side.
A9
 Mount the assembly tool on the camshaft.
When applying the assembly tool, make sure that there is no offset between the assemby
tool and the camshaft.

TCG 2016
W 4-5-5
A 10
 Push the camshaft with assembly tool into the crankshaft.
A 11
 Pull the camshaft with assembly tool out of the crankshaft.

- Until the camshaft is pushed into the crankshaft completely.
 Remove the assembly tool from the camshaft.

TCG 2016
W 4-5-5
A 12
Pay attention to the positioning of the camshaft axial guide.

The stepped side faces the camshaft wheel.
A 13
 Insert camshaft axial guide.

TCG 2016
W 4-5-5
A 14
 Tighten the four screws of the camshaft axial guide.

- Turn the camshaft so that the screws of the camshaft axial guide are accessible
through the large hole in the camshaft flange.
A 15

 Installing the gear drive - see job card W 4-4-1.
 Check and set control times - see job card W 4-4-11.

TCG 2016
W 4-5-5

TCG 2016
W 4-5-6
Checking camshaft
Tools
- Micrometer gauge
- Prisms
- Dial gauge
References
- W 0-3-2 Tear inspection by diffusion liquid method
Technical data
Camshaft bearing pin diameter

Camshaft cam stroke

8.20 - 8.28 mm

Run-out accuracy camshaft bearing

see chapter 8, Technical Data
General information

TCG 2016
W 4-5-6
Checking camshaft
Tear test
 Carry out tear test by magnetic test method according to test specification 0162 0000
or diffusion liquid method - see job card W 0-3-2.
 Check the running surfaces of the bearings and cams for marks.
Check diameter of camshaft bearing pin
A1
 Measuring schematic of the camshaft bearing pin diameter at points a and b in the lev-
els 1 and 2.
 Check diameter of camshaft bearing pin with micrometer gauge.

TCG 2016
W 4-5-6
Checking runout
A2
 Place camshaft on prism.

- On the last but one outer bearing pin (arrows).
A3

- Place the stylus on the bearing pin under pre-tension.
- Turn camshaft.
- Read the run-out value from the dial.
 Mount dial on next bearing pin.
 Repeat measurement until the run-out has been checked at all bearing points.

TCG 2016
W 4-5-6

TCG 2016
W 5-5-3
Removing and installing the actuator
Tools
General information
Danger of burning !
Risk of injury !
Removing actuator
A1
 Remove the cable set plug (arrow).

- From the actuator.

TCG 2016
W 5-5-3
A2
- Remove washers.
- Hold against screw piece 2.
- Remove washers.
A3

 Remove actuator.
- Position 1.

TCG 2016
W 5-5-3
Installing actuator
A4
 Insert actuator.
- Position 1.
 Insert and tighten screws (arrows).
A5
 Mount speed governor linkage.

- Insert washers.
- Insert washers.

TCG 2016
W 5-5-3
A6
 Install the cable set plug (arrow).

TCG 2016
W 5-4-6
Removing and installing the jointed head for the speed transmitter link-
age
Tools
Spare parts
- Jointed head
References
- W 5-4-7 Setting speed governor linkage
Technical data
General information
The speed transmitter linkage must be reset after removing the jointed head - see job card
W 5-4-7.
Danger of burning !
Risk of injury !

TCG 2016
W 5-4-6
Removing swivel head for speed governor linkage
A1
- Remove washers.
- Remove washers.
A2

- Remove washers.
- Hold at the nuts.
 Remove the speed transmitter linkage.

TCG 2016
W 5-4-6
A3
 Loosen lock nut (arrow).
Position 4 - right-hand thread

Position 5 - left-hand thread
 Unscrew the jointed head from the linkage.

 Clean components, check and renew if necessary.

TCG 2016
W 5-4-6
Installing swivel head for speed governor linkage
A4
 Turn on the jointed head.
Observe installation dimension X.
 Tighten the lock nut (arrow).
A5

 Mount washers.
 Insert screws.
 Turn on the nuts.

TCG 2016
W 5-4-6
A6

- Insert washers.
- Insert washers.
 Setting the speed transmitter linkage - see job card W 5-4-7.

TCG 2016
W 5-4-6

TCG 2016
W 5-4-7
Setting speed governor linkage
Tools
- Electronic measured value sensors, measuring range -1 to 5 bar, quality class 0.5
%
- Measuring connections for charging mixture pressure measurement
Technical data
Load mixture pressure - symchronisation of cylinder rows A and B

Differential pressure max. 30 mbar
General information
Visually inspect all parts. Replace the parts if heavy wear is detected.
Setting speed governor linkage
A1
The speed controller linkage has a right-hand thread 1 on one side and a left-hand thread
2 on the other side.

TCG 2016
W 5-4-7
A2
 Turn in joint heads to dimension X.

- according to technical data.
A3
 Mount linkage 3 with screw 4, locking washer 5 and washers 6 on screw piece 7.
Mount second linkage accordingly.

TCG 2016
W 5-4-7
A4
 Apply lever 8 to actuator.
The lever 8 must be parallel to the top edge of the actuator when the pointer on the actuator
is at zero percent filling.
A5
 Set lever throttle valve.

- V12 engine: Elongated hole X completely free.
- V16 engine: Setting dimension Y 30 mm.

TCG 2016
W 5-4-7
A6
 Close throttle valve.

- Throttle valve closed (position 9).
- Throttle valve fully open (position 10).
A7
 Apply lever 11 to throttle valve shaft.

TCG 2016
W 5-4-7
A8
 Mount linkage 12 with screw, lock washer and washers on lever 11.
 Tighten nut (arrow).
Mount second linkage accordingly.
A9
The throttle valves may not be fully closed at zero percent filling.
This prevents the throttle valves from seizing.

 Turn the connecting rod until the throttle valve is fully closed.
 Turn back the connecting rod 14 half a turn.
TCG 2016
W 5-4-7
Set second linkage accordingly.
A 10
 Unscrew stopper (arrows).

 Connect measuring instruments.
 Start engine.
 Run the engine on full load.
 Watch the pressure meters.
- The maximum permissible pressure difference between the A side and the B side
may not exceed the specified nominal value.
When setting, always adjust the cylinder side with the lower pressure by lengthening the
connecting rod.

TCG 2016
W 5-4-7
 Set differential pressure.

- Loosen lock nut (arrow).
- Turn the connecting rod 14 until the differential pressure is in the nominal range.
- Tighten the lock nut (arrow).
 Remove measuring instruments.
 Insert and tighten stoppers with new gaskets.

TCG 2016
W 5-4-7

TCG 2016
W 5-7-3
Removing and installing the camshaft sensor (model Jaquet)
Tools
Spare parts
- Camshaft sensor
References
- W 13-5-3 Checking and adjusting ignition timing
Technical data
Set the camshaft sensor (Jaquet)

Turn the engine until the pulse screw is visible
Turn in the frequency sensor to the stop
General information

Incorrectly set camshaft sensors can lead to serious damage to the engine.
If the gap between the camshaft sensor and the pulse screw is not set correctly, it affects
the pulse output to the electronic control unit.
The camshaft sensor is set in the factory and should not be removed unless absolutely nec-
essary.
A1

TCG 2016
W 5-7-3
Removing the camshaft sensor
A2
 Remove cable set plug.

 Unscrew the camshaft sensor.
Installing the camshaft sensor
The camshaft sensor must be set to the fixed defined gap for the correct function.
A3
 Turn motor until the pulse screw 1 is visible in the threaded hole of the camshaft sen-
sor.
 Turn in the camshaft sensor to the stop
 Unscrew the camshaft sensor by the values specified in the technical data.

TCG 2016
W 5-7-3
 Install cable set plug.

After installing the camshaft sensor, check the ignition and set if necessary - see job
card W 13-5-3.

TCG 2016
W 5-7-3

TCG 2016
W 5-7-5
Removing and installing the flywheel sensor (model Jaquet)
Tools
Spare parts
- Flywheel sensor
Technical data
Set the flywheel sensor (Jaquet)

Turn in the frequency sensor up to the system
Continue unscrewing until the marking is in running direction
General information
If the gap the between the flywheel sensor sensor and the ring gear is not set correctly, it
affects the pulse output to the electronic control unit.
If the flywheel sensor is soiled, it must be removed and cleaned.

TCG 2016
W 5-7-5
Removing the flywheel sensor
A1

 Unscrew the flywheel sensor.
Installing the flywheel sensor
The flywheel sensor must be set to the fixed defined gap for the correct function.
A2
The mark on the sensor must always face in the running direction of the flywheel.
 Turn in the flywheel sensor to the stop.

TCG 2016
W 5-7-5
 Unscrew the flywheel sensor by the values specified in the technical data.
 Unscrew the flywheel sensor further until the marking is pointing in the running direc-
tion (see figure).
Check the installation position again after tightening the lock nut.
Function test
The function of the flywheel sensor must be checked using the TEM system after installa-
tion.
A3
 Select Service 1 mask.

 Select auxiliary unit engine.
 Select starter.
 Go to starter.
A speed display must appear in field 2 after actuating the starter.

TCG 2016
W 5-7-5

TCG 2016
W 6-1-9
Removing and installing exhaust pipe
Tools
Auxiliary material
- Lubricant S1
Spare parts
- Gaskets for exhaust gas compensator
- Gasket exhaust pipe
- Clamps if necessary
Technical data
Exhaust pipe on cylinder head

M10x115 / 130 - 10.9* 55 Nm
M10x137 - 10.9 75 Nm
* with S1 packing compound

M6 10 Nm
General information
The exhaust gas compensator is different on the two outer sides. It therefore has a specified
installation position.
A1
Position A - The open side faces towards the free side

TCG 2016
W 6-1-9
Position B - The closed side faces towards the drive side

Danger of burning !
Removing the exhaust pipe
A2

 Remove exhaust pipe cladding.
- Position 1.
A3
 Loosen the clamps on the exhaust pipe and compensator.

- Unscrew screws.

TCG 2016
W 6-1-9
 Push clamp aside.
A4
 Press together compensator (arrow direction).

 Remove compensator with gaskets upwards.
- Position 2.
A5

- Remove spacer sleeves.
 Remove exhaust pipe.
- Position 3.
 Remove exhaust pipe gasket from cylinder head.

TCG 2016
W 6-1-9
Installing exhaust pipe

 Renew gaskets.
A6
 Mount exhaust pipe gasket on cylinder head.

 Insert exhaust pipe.
- Position 3.
 Turn in screws with spacing sleeves.
A7

 Insert compensator.
- Position 2.

TCG 2016
W 6-1-9
A8
Wet the clamp all round with lubricant (arrows) in the area of the contact surface.
A9
 Position clamp (arrow direction).


TCG 2016
W 6-1-9
A 10
 Mount exhaust pipe cladding.

- Position 1.

TCG 2016
W 6-1-11
Removing and installing compensator of exhaust pipe
Tools
Auxiliary material
- Lubricant S1
Spare parts
- Gaskets for exhaust gas compensator
- Clamps if necessary
Technical data

M6 10 Nm
General information
The exhaust gas compensator is different on the two outer sides. It therefore has a specified
installation position.
A1
Position A - The open side faces towards the free side

Position B - The closed side faces towards the drive side
Danger of burning !
TCG 2016
W 6-1-11
Removing compensator of exhaust pipe
A2

- Position 1.
A3
 Loosen the clamps on the exhaust pipe and compensator.

- Unscrew screws.

TCG 2016
W 6-1-11
A4

 Remove compensator with gaskets upwards.
- Position 2.
Installing compensator of exhaust pipe

 Renew all gaskets.
A5

- Position 2.

TCG 2016
W 6-1-11
A6
Wet the clamp all round with lubricant (arrows) in the area of the contact surface.
A7
 Position clamp (arrow direction).


TCG 2016
W 6-1-11
A8
 Mount exhaust pipe cladding.

- Position 1.

TCG 2016
W 6-1-11

TCG 2016
W 6-2-7
Removing and installing charge mixture pipe (V12 and V16 engine)
Tools
Spare parts
- Gaskets
References
- W 6-2-9 Removing and installing the charge mixture manifold
- W 6-4-7 Removing and installing, cleaning mixture cooler (V12 and V16 engine)
- W 6-6-4 Removing and installing exhaust gas turbocharger (V12 and V16 engine)
Technical data
Charge mixture pipe to cylinder head

M10x75 / 80 / 100 - 8.8 55 Nm
General information
Proceed accordingly if the work for one engine side described below is to be performed on
the opposite side of the engine too.
Risk of injury !
Danger of burning !

TCG 2016
W 6-2-7
Removing charge mixture pipe
A1
 Unscrew nuts 2.
 Remove clamp.
 Remove coolant pipe 3.
 Removing the charge mixture manifold - see job card W 6-2-9.
 Remove mixture cooler - see job card W 6-4-7.
 Remove turbocharger - see job card W 6-6-4.

TCG 2016
W 6-2-7
A2
 Remove venting pipes.
A3
Mark the position of the screws before removing the holder.
 Remove washers.
 Remove holder.

TCG 2016
W 6-2-7
A4
 Unscrew nuts 8.
 Remove washers.
 Remove holder.
A5
 Unscrew all screws 9.

 Remove charge mixture pipe.

TCG 2016
W 6-2-7
Installing charge mixture pipe
A6

 Renew gaskets.
 Mount charge mixture pipe.
 Tighten all screws 9.
A7
 Mount bracket.
 Mount washers.
 Tighten nuts 8.

TCG 2016
W 6-2-7
A8
 Mount bracket.
 Mount screws 7 with washers.
Move the holder to the position marked before removing.
A9
 Mount the venting pipes.

 Installing the charge mixture manifold - see job card W 6-2-9.
 Install mixture cooler - see job card W 6-4-7.
 Install turbocharger - see job card W 6-6-4.
TCG 2016
W 6-2-7
A 10
 Mount coolant pipe 3.

 Position clamp.
 Tighten nuts 2.

TCG 2016
W 6-2-7

TCG 2016
W 6-2-9
Removing and installing the charge mixture manifold
Tools
Auxiliary material
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
General information
Risk of injury !
Danger of burning !

TCG 2016
W 6-2-9
Removing the charge mixture manifold
Proceed accordingly if the work for one engine side described below is to be performed on
the opposite side of the engine too.
A1
 Unscrew screw (arrow) and remove with washers.

- Hold at the nut.
 Swing the speed governor linkage to the side.
A2
 Pull out the charge mixture manifold 2 from the flange.

TCG 2016
W 6-2-9
Installing the charge mixture manifold
A3

A4
 Insert the charge mixture manifold 2 in the flange.


TCG 2016
W 6-2-9
A5

 Mount washers.
- Hold at the nut.

TCG 2016
W 6-3-8
Removing and installing the suction air intake filter housing
Tools
General information
Danger of burning !
Risk of injury !
Removing suction air intake filter housing
A1
 Loosen clamps 1.
 Remove clamps (arrows) from suction air intake filter housing.
 Remove suction air intake filter housing.

TCG 2016
W 6-3-8
Installing suction air intake filter housing
A2
 Insert suction air intake filter housing.

 Mount clamps (arrows) on suction air intake filter housing.
 Tighten clamps 1.

TCG 2016
W 6-4-7
Removing and installing, cleaning mixture cooler (V12 and V16 engine)
Tools
- Lifting gear
- Round brush
- Ultrasonic cleaner if nec.
Auxiliary material
- Cleaning agents
- Cleaning bath
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
References
- W 6-3-8 Removing and installing the suction air intake filter housing
General information
The best cleaning results are achieved with an ultrasonic cleaning device. The instructions
and regulations of the manufacturers of the ultrasonic cleaning equipment must be ob-
served.

Dispose of cleaning agents properly according to national regulations.

TCG 2016
W 6-4-7
Removing mixture cooler
A1

 Removing the suction air intake filter housing - see job card W 6-3-8.
 Remove multifunction rail 1.
- On the A and B side.
A2
 Remove the suction air intake filter console.
- Position 3.

TCG 2016
W 6-4-7
A3
 Loosen nuts (arrows).

 Remove compensator.
- Position 4.
A4


TCG 2016
W 6-4-7
A5
A6
 Unscrew nuts (arrows).

 Remove washers.

TCG 2016
W 6-4-7
A7
 Hang mixture cooler on suitable hoist unit (arrow).

 Lift mixture cooler with hoist unit.

TCG 2016
W 6-4-7
Cleaning mixture cooler
A8
 Unscrew screws.
 Remove housing.
A9
 Unscrew screws.
 Remove housing.

TCG 2016
W 6-4-7
A 10
 Unscrew screws.
 Remove cover.
A 11
 Unscrew screws.
 Remove cover.
 Clean all covers.
 Clean mixture cooler.
Only use approved cleaning agents - see operating manual chapter 4.


TCG 2016
W 6-4-7
Risk of injury !
A 12
 Mixture cooler insert.

- Mixture side 22.
- Water side 23.
 Check mixture cooler insert and renew if necessary.
 Place the mixture cooler insert in the cleaning bath with cleaning fluid.
 Clean the lamellas 22 with a suitable brush.
 Clean the ducts 23 with a suitable brush.
 Remove mixture cooler insert from cleaning bath.
 Rinse mixture cooler insert with water.
 Dry mixture cooler insert with compressed air.
 Check mixture cooler insert again and renew if necessary.

Dispose of cleaning agents properly according to national regulations.

TCG 2016
W 6-4-7

A 13
 Mount cover.
 Tighten screws.
A 14
 Mount cover.
 Tighten screws.

TCG 2016
W 6-4-7
A 15
 Mount housing.
 Tighten screws.
A 16
 Mount housing.
 Tighten screws.

TCG 2016
W 6-4-7
Installing mixture cooler
A 17
 Hang mixture cooler on suitable hoist unit (arrow).

 Mount mixture cooler.
A 18
If the mixture cooler is not aligned, tension cracks may occur on the mmixture cooler
during operation.
 Check alignment of the mixture cooler.

- Check whether the mixture cooler is lying level on the 4 fastening points (arrows).
If not, the mixture cooler must be aligned.

The charge mixture lines must be loosened and aligned to the mixer cooler for this.

TCG 2016
W 6-4-7
A 19
 Mount washers.
 Turn on nuts (arrows).
- Turn on the nuts until the washers no longer move.
- Then loosen the nuts one turn.
A 20


TCG 2016
W 6-4-7
A 21
- Position 4.
 Position the clamps.
 Tighten nuts (arrows).
A 22


TCG 2016
W 6-4-7
A 23
 Install the suction air intake filter console.

- Position 3.
A 24
 Install the multifunction rail 1.

 Installing the suction air intake filter housing - see job card W 6-3-8.

TCG 2016
W 6-4-11
Testing mixture cooler (endoscope)
Tools
- Endoscope
Spare parts
- Sealing rings
General information
By endoscopy, it is possible to inspect the state of soiling of the mixture cooler without hav-
ing to remove the mixture cooler first. The degree of soiling can be better determined and
maintenance costs reduced as a result.
Observe the manufacturer specifications for handling the endoscope!
The endoscopy pictures can usually only be evaluated by trained specialists.
The endoscope image can also be projected inverted or upside down depending on the
view of the lens.

TCG 2016
W 6-4-11
Testing mixture cooler (endoscope)
A1
 Unscrew stopper (arrows).

 Connect endoscope, switch on and feed carefully through the threaded bore.
Make sure that the endoscope is not damaged.

Light reflections can lead to diagnostic errors. Swivel and alternately tilt the endoscope dur-
ing the examination. Make sure that the glass fibre cable does not get damaged during this
process.
 Determine and evaluate the degree of soiling.

 Remove the endoscope carefully.
 Tighten the stopper.

TCG 2016
W 6-6-4
Removing and installing exhaust gas turbocharger (V12 and V16 en-
gine)
Tools
- Lifting gear
Auxiliary material
- Assembly paste
- Acid-free grease
Spare parts
- Gaskets
- Sealing rings
Technical data
Turbocharger to exhaust manifold

M16 100 Nm
Turbocharger to console
M16x190 - 10.9 100 Nm
General information
The turbocharger housing must be aligned additionally when the turbocharger is renewed.
See end of the job card - Renewing the turbocharger.
Danger of burning !
Risk of injury !

TCG 2016
W 6-6-4
Remove turbocharger
 Remove the lubricating oil line and the return line from the turbocharger.
A1
 Disconnect cable set plug stepper motor control TEM system (white cable).
- Position 1.
 Disconnect cable set plug sensor end stop (black cable).
- Position 2.
A2
- Hold at the nuts.

TCG 2016
W 6-6-4
A3
 Unscrew nuts 4.
 Remove washers.
A4
 Remove clamps 5.
 Remove retaining clamp 6.
 Remove suction intake pipe 7.
 Remove suction intake manifold (arrow) with gas mixer.

TCG 2016
W 6-6-4
A5
 Loosen nuts (arrows).

- Position 8.
A6

- Position 9.
 Remove exhaust compensator.
- From exhaust manifold 10.

TCG 2016
W 6-6-4
A7
 Hang turborcharger on suitable hoist unit (arrow).
A8
 Unscrew nuts 11.

- Hold at the nut.

TCG 2016
W 6-6-4
A9

 Lift turbocharger with hoist unit.
Installing turbocharger
A 10

 Coat stud bolts 12 with mounting compound.
 Wet the sealing rings (arrows) with acid-free grease.

TCG 2016
W 6-6-4
A 11
 Mount turbocharger with hoist unit.
Do not damage stud bolts 14.
A 12

TCG 2016
W 6-6-4
A 13
 Tighten nuts 11.

- Hold at the nut.
A 14
 Install exhaust compensator.

- On exhaust manifold 10.
 Install exhaust pipe cladding.
- Position 9.

TCG 2016
W 6-6-4
A 15
- Position 8.
 Position the clamps.
A 16
 Install suction intake manifold (arrow) with gas mixer.

 Insert suction intake pipe 7.
 Install retaining clamp 6.
 Install clamps 5.

TCG 2016
W 6-6-4
A 17
 Turn on nuts 4 with washers.

 Tighten nuts 4.
A 18
- Hold at the nuts.

TCG 2016
W 6-6-4
A 19
 Connect cable set plug stepper motor control TEM system (white cable).
- Position 1.
 Connect cable set plug sensor end stop (black cable).
- Position 2.
 Install lubricating oil line and the return line to the turbocharger.
Renew turbocharger
A 20
 Hang turborcharger on suitable hoist unit (arrow).

 Loosen all screws 15.

TCG 2016
W 6-6-4
A 21
 Mount turbocharger with hoist unit.
Do not damage stud bolts 14.

Turn turbocharger housing until the connecting flange can be mounted without tension.
A 22

 Loosen all screws 17.
Turn turbocharger housing until the connecting flange can be mounted without tension.


TCG 2016
W 6-6-4
A 23
A 24
The flange socket must be removed from the old turbocharger and reused if in perfect con-
dition.

 Mount flange socket 18.

TCG 2016
W 6-6-4

TCG 2016
W 7-20-2
Setting the stepper motor of the gas-air mixer
Tools
Technical data
Coupling piece on the step motor of the gas-air mixer

Setting dimension 69.0 - 69.5 mm
General information
The sensor for the -lean stop- is integrated in the new stepper motor. This changes the pro-
cedure for the basic setting of the lean stop.
The stepper motor must be removed from the charge air line for the correct setting.
The setting can only be made in the test mode of the TEM system.
The stepper motor may not be opened or dismantled, otherwise the guarantee and
warranty rights will become null and void.

TCG 2016
W 7-20-2
Setting the stepper motor of the gas-air mixer
A1
- Position 1.
- Position 2.
A2
 Unscrew the locking screw from the charge air line.

- Position 3.
 Loosen grub screw (arrow) of the connecting rod.
- Turn the coupling if necessary so that the grub screw is accessible.

TCG 2016
W 7-20-2
A3
 Unscrew screws.
- Position 4.
 Remove the stepper motor from the charge air pipe.
- Position 5
A4
 Unscrew the coupling from the threaded spindle.

 Turn the threaded spindle clockwise until the stepper motor is at the mechanical end
stop.

TCG 2016
W 7-20-2
A5
 Make a mark on the threaded spindle to help you later.

 Turn the threaded spindle four complete turns anticlockwise.
 Connect cable set plug for sensor end stop (black cable).
 Connect cable set plug for stepper motor control (white cable).
A6
 Select gas mixer to -start position- in the TEM system.

- Position 6.
- The stepper motor moves in -rich- direction.
 Then select the gas mixer to -stop position- in the TEM system
- Position 7.
- The stepper motor moves in -lean- direction until the stop position is reached.
- Position 1.

TCG 2016
W 7-20-2
A7
 Turn the threaded spindle 3/4 of a turn (270°) in clockwise direction.

 Connect cable set plug for stepper motor control (white cable).
A8
 Turn in the coupling to the stop on the threaded spindle.

- Position 8.
 Unscrew coupling by eleven turns.
- Position 8.
- Observe reference dimension X.

TCG 2016
W 7-20-2
A9
The coupling may only be unscrewed further for positioning.

Never turn the coupling back.
 Positioning the coupling for installation.

- The grub screw is at right angles to the cable connections.
A 10
 Gas mixer open.

- Position 9.
 Gas mixer closed.
- Position 10.
 Press the adjusting rod into the mixing line until the gas mixer is completely closed.
- The Venturi is on the housing.
- The gas mixer is in the mechanical end stop.

TCG 2016
W 7-20-2
 Insert the stepper motor in the charge air pipe.
Make sure that the coupling sits correctly in the adjustment rod.
 Tighten the screws of the stepper motor.

 Tighten the grub screw of the connection rod.
 Tighten the locking screw of the charge air pipe.
A 11
 Select gas mixer to -rich- in the TEM system.

- Position 11.
- The stepper motor moves in -rich- direction.
 Then select test mode -Off- in the TEM system
- Position 12.
- The stepper motor moves in -lean- direction until the stop position is reached.
- The step display 13 indicates the start position as a -minus value-.

TCG 2016
W 7-20-2

TCG 2016
W 7-20-6
Overhauling gas pressure regulator (model Donkin)
Tools
- Torque wrench
Spare parts
- Set of gaskets
General information
Component overview
A1
Risk of injury !
Diaphragms must be held when removing and installing otherwise they will be de-
stroyed.

TCG 2016
W 7-20-6
Dismantling the gas pressure regulator
A2
 Unscrew all screws 1 from the housing flange.

- Hold at the nuts.
A3
 Remove bottom of housing.

TCG 2016
W 7-20-6
Dismantling the gas pressure regulator top part
A4
 Remove cover.
- Use a suitable tool.
Do not unscrew the nut without holding otherwise the diaphragms will turn too and
be destroyed.
A5
 Unscrew nut 2.
- Hold with open-end wrench on threaded bolt (magnifying glass).

TCG 2016
W 7-20-6
A6
Unscrew the screw 5 last because this fixes the upper diaphragm plate.
If screw 5 is unscrewed beforehand, the upper diaphragm plate can be turned. The upper
diaphragm may be destroyed.
Do not unscrew the guide pin without holding otherwise the diaphragms will turn too
and be destroyed.
A7
 Unscrew the guide pin 6.

- Hold with open-end wrench on threaded bolt 3.

TCG 2016
W 7-20-6
A8
- Guide pin 6 with plastic reinforcement 7
- Gasket 8
- Upper diaphragm 9
- Valve body 10
 Check components and repair or renew if necessary.
Dismantling the gas pressure regulator bottom part
A9
 Unscrew screws.
 Remove bottom part 11 of diaphragm housing 12.

TCG 2016
W 7-20-6
A 10
 Remove spring 13.

 Remove discs 14.
A 11
 Unscrew cover 15.

 Renew sealing ring.
 Check components and repair or renew if necessary.

TCG 2016
W 7-20-6
Assembling gas pressure regulator
Assembling gas pressure regulator bottom part
A 12
 Mount cover 15.
A 13
 Insert discs 14.

 Insert spring 13.

TCG 2016
W 7-20-6
A 14
 Renew gasket.
 Install bottom part 11 of diaphragm housing 12.
 Tighten screws.
Assembling gas pressure regulator top part
Do not tighten the guide pin without holding otherwise the diaphragms will turn too
and be destroyed.
A 15
 Insert component.
- Valve body 10
- Upper diaphragm 9
- Gasket 8

TCG 2016
W 7-20-6
- Guide pin 6 with plastic reinforcement 7

 Tighten guide pin 6.
A 16
 Align the diaphragm plate on the hole circle.

Do not tighten the nut without holding otherwise the diaphragms will turn too and be
destroyed.
A 17
 Insert component.
 Tighten nut 2.
TCG 2016
W 7-20-6
A 18
 Mount cover.
- Use a suitable tool.
A 19
 Mount bottom of housing.

TCG 2016
W 7-20-6
A 20

- Hold at the nuts.

TCG 2016
W 7-20-6

TCG 2016
W 7-20-7
Overhauling gas valve (model RMG)
Tools
- Torque wrench
Spare parts
- Set of gaskets
General information
Risk of injury !

TCG 2016
W 7-20-7
Dismantling gas valve
 Cut off the gas supply by closing the ballcock on the gas regulator line.
A1
 Remove cover 2.
A2
 Remove the connecting cable 3.

 Pull the cable set out of the housing in the direction of the arrow.
 Unscrew nut 4.

TCG 2016
W 7-20-7
A3
 Remove the housing from the magnetic coil from the top.
A4

 Remove valve body 5.

TCG 2016
W 7-20-7
A5
 Remove valve 6 from housing from above.
A6
 Remove both sealing bands 7 from the valve.

TCG 2016
W 7-20-7
A7
 Press together the spring and spring plate 8.

 Remove lock 9.
 Press out bolt in direction of arrow.
 Remove valve plate 10 from valve body.
A8

 Check all components for wear.

TCG 2016
W 7-20-7
Assemble gas valve
A9
 Remove sealing ring from housing.

 Renew gasket.
A 10
 Mount spring and spring plate 8 on valve.

 Press together the spring and spring plate 8.
 Mount valve plate 10.
- Pay attention to positioning of the bore.
 Insert bolt in direction of arrow.
 Fit lock 9.

TCG 2016
W 7-20-7
A 11
 Insert valve 6 in housing.
A 12
 Install valve body 5.


TCG 2016
W 7-20-7
A 13
 Renew sealing ring 11.

 Mount housing of the magnetic coil.
A 14
 Turn on and tighten nut 4.

 Insert cable set in housing.
- Lay cable set free from chafing and strain.
 Install the connecting cable 3.

TCG 2016
W 7-20-7
A 15
 Fit cover 2 and tighten screws 1.

 Open ballcock to restore gas supply.

TCG 2016
W 7-20-7

TCG 2016
W 7-22-1
Removing and installing the gas-air mixer
Tools
Auxiliary material
- Unimolly 220
References
- W 7-20-2 Setting the stepper motor of the gas-air mixer
General information
If the stepper motor is removed from the charge air pipe, it must be set before installation.
You will find the appropriate information for this in job card W 7-20-2.
Removing the gas-air mixer
 Cut off the gas supply by closing the ballcock on the gas regulator line.
 Remove connecting flange 1.
- Remove gasket.
A1
 Remove clamps 2.
 Remove retaining clamp 3.
 Remove suction intake pipe 4.

TCG 2016
W 7-22-1
A2
- Position 5.
- Position 6.
A3
 Unscrew nuts 8.
 Remove gas-air mixer with mixture pipe.

TCG 2016
W 7-22-1
A4
 Unscrew the locking screw from the mixture pipe.

- Position 9.
 Loosen grub screw (arrow) of the connecting rod.
- Turn the coupling if necessary so that the grub screw is accessible.
A5
 Unscrew screws.
- Position 10.
 Remove the stepper motor from the mixture pipe.

TCG 2016
W 7-22-1
A6
 Unscrew nuts.
- Position 11.
 Pull apart gas-air mixer and mixture pipe.
- Remove gasket.
Do not bend or damage the drive shaft when removing the gas-air mixer.

TCG 2016
W 7-22-1
Installing the gas-air mixer
If the stepper motor has been removed from the mixture pipe, it must be reset as described
in job card W 7-20-2.
Therefore the mixture pipe can be installed without the stepper motor.
A7
When installing the gas-air mixer, make sure that the drive shaft is positioned correctly in
the guides (arrows) in the mixture pipe.
Wet the thread of the drive shaft with Unimolly.
A8
 Renew gasket.
 Push together gas-air mixer and mixture pipe.
 Tighten nuts 11.

TCG 2016
W 7-22-1
A9
 Insert gas-air mixer with mixture pipe.

 Tighten nuts 8.
A 10
 Insert suction intake pipe 4.

 Install retaining clamp 3.
 Install clamps 2.
 Install connecting flange 1.
- Renew gasket.
 Setting the stepper motor of the gas-air mixer - see job card W 7-20-2.
 Open ballcock to restore gas supply.

TCG 2016
W 7-22-3
Overhauling gas-air mixer (V12 and V16 engines)
Tools
Auxiliary material
- Unimolly 220
- Loctite 270
References
- W 7-20-2 Setting the stepper motor of the gas-air mixer
- W 7-22-1 Removing and installing the gas-air mixer
General information
Dismantling gas-air mixer (V12 and V16 engines)
 Removing the gas-air mixer - see job card W 7-22-1.
A1

TCG 2016
W 7-22-3
A2
 Remove housing guide pin with sealing ring.
A3
 Unscrew the guide pin.

TCG 2016
W 7-22-3
A4
 Remove Venturi insert from housing.

- The Venturi insert and the drive shaft are one part.
A5
 Check Teflon tapes (arrows), renew if necessary.

TCG 2016
W 7-22-3
A6
 Check drive shaft.

 Check Venturi insert.
- Check running surface of the Teflon belts, clean if necessary.
- Check the thread for the guide pin for wear.
The thread inserts on the Venturi insert may not be retapped.

TCG 2016
W 7-22-3
Assembling gas-air mixer
Do not damage the Teflon belts !
Do not turn the Venturi insert when inserting.
A7
 Insert Venturi insert carefully.
Pay attention to the thread for the guide pin.
A8
 Wet the thread on the guide pin with screw locking agent.
 Insert and tighten the guide pin.

TCG 2016
W 7-22-3
Make sure that the chamfer is aligned horizontally otherwise the housing cannot be mount-
ed.
A9
 Install housing guide pin with sealing ring.
A 10

 Check smooth action of Venturi insert.
- Move the Venturi insert backwards and forwards.
 Installing the gas-air mixer - see job card W 7-22-1.
 Setting the stepper motor of the gas-air mixer - see job card W 7-20-2.

TCG 2016
W 8-2-1
Removing and installing the lubricating oil level sensor
Tools
Auxiliary material
Spare parts
- Level sensor
- Sealing ring
References
General information
The pre-lubrication pump must be out of operation during the operating process. The en-
gine must be shut down for this. The pre-lubrication pump continues running for a fixed time
programmed in the TEM system. The emergency stop must be pressed at the end of the
lag time. This switches off the intereval lubrication and guarantees that the pre-lubrication
pump is out of operation during the operating process.
When opening the lubricating oil line between the lubricating oil pan and the lubricating oil
level sensor, there is a risk that the lubricating oil pan will run empty. The lubricating oil must
be drained first or the lubricating oil line sealed tightly.
Risk of injury !
Risk of scalding !

lations.

TCG 2016
W 8-2-1
Removing and installing the lubricating oil level sensor
A1

- Position 1.
 Remove the lubricating oil lines.
- Unscrew union nuts (arrows).
 Remove lubricating oil level sensor.
- Position 2.
 Install lubricating oil level sensor.
- Position 2.
 Install the lubricating oil lines.
- Tighten union nuts (arrows).
- Position 1.

TCG 2016
W 8-2-4
Removing and installing lube oil pressure sensor
Tools
Auxiliary material
Spare parts
- Pressure sensor
- Sealing ring
General information
Risk of injury !
Risk of scalding !

lations.

TCG 2016
W 8-2-4
Removing and installing lube oil pressure sensor
A1

 Unscrew lubricating oil pressure sensor (arrow).
 Tighten lubricating oil pressure sensor (arrow).

TCG 2016
W 8-5-3
Removing and installing lube oil temperature sensor
Tools
Auxiliary material
Spare parts
- Temperature sensor
- Sealing ring
General information
Risk of injury !
Risk of scalding !

lations.

TCG 2016
W 8-5-3
Removing and installing lube oil temperature sensor
A1

 Unscrew lubricating oil temperature sensor (arrow).
 Tighten lubricating oil temperature sensor (arrow).

TCG 2016
W 8-5-3
Removing and installing lube oil pump
Tools
- Dial gauge
Auxiliary material
References
Technical data
Crankshaft wheel and lubricating oil pump 0.15 - 0.25 mm

wheel
General information

TCG 2016
W 8-5-3
Removing lube oil pump

A1

 Remove the lubricating oil suction intake pipe with gasket.
- Position 1.
A2

 Remove the lubricating oil pump.
- Position 2.

TCG 2016
W 8-5-3
Cleaning components
Risk of injury !

 Blow out components with compressed air.
Install lube oil pump
A3
 Renew all gaskets.

 Insert lubricating oil pump.
- Position 2.

TCG 2016
W 8-5-3
A4

- Position 3.
- Turn lubricating oil pump wheel to the right and the left (arrow).
A5
 Set tooth edge clearance.

- To the left or right (arrows) by knocking the lubricating oil pump housing lightly with
a plastic hammer.
 Repeat test and setting until the nominal value is set.
 Tighten screws.

TCG 2016
W 8-5-3
A6
 Insert the lubricating oil suction intake pipe with gasket.

- Position 1.

TCG 2016
W 8-5-3

TCG 2016
W 8-8-2
Removing, installing and cleaning the lube oil cooler
Tools
Auxiliary material
- Cleaning fluid
- DW 47
Spare parts
- Set of gaskets
References
Technical data
Lubricating oil cooler on crankcase

M10x210 - 10.9 50 Nm
Lubricating oil filter head on lubricating oil cooler

M8x20 / 30 - 10.9 25 Nm
General information
Risk of scalding !

lations.
Risk of injury !

TCG 2016
W 8-8-2
Removing lube oil cooler
A1

 Unscrew cap (arrow).
A2

 Drain lube oil.

TCG 2016
W 8-8-2
A3
 Remove the lubricating oil filter console.

- Position 1.
A4
 Remove the lubricating oil line.

- Unscrew union nut (arrow).
- Unscrew screws 2.
- Remove gasket.

TCG 2016
W 8-8-2
A5
 Remove the lubricating oil cooler housing.
A6
 Remove the lubricating oil cooler cover with lubricating oil cooler.

TCG 2016
W 8-8-2
A7
 Remove lube oil cooler cover.

TCG 2016
W 8-8-2
Cleaning lube oil cooler insert
Only use approved cleaning agents - see operating manual chapter 4.

Check lube oil fine filter for leaks.
A8
 Seal connections for lube oil with stoppers.

 Mix cleaning fluid according to manufacturer specifications.
 Place the lubricating oil cooler insert 6 in a cleaning bath with cleaning fluid.
 Soften dirt with a cleaning solution.
- The soaking time depends on the degree of soiling.
 Spray off the lubricating oil cooler insert 6 with a powerful water jet.
 Unscrew plug.
 Fill and rinse the lubricating oil cooler insert 6 with fuel.
 Dry components with compressed air.

TCG 2016
W 8-8-2
Mounting lube oil cooler
Clean all sealing surfaces.

A9
 Mount the lubricating oil cooler on the lubricating oil cooler cover.
A 10
 Apply packing compound to the sealing surface of the lubricating oil cooler cover.
 Insert lube oil cooler cover.
 Turn on screws 4 and tighten diagonally.

TCG 2016
W 8-8-2
A 11
 Apply packing compound to the sealing surface of the lubricating oil cooler housing.
 Mount the lubricating oil cooler housing.
 Turn on screws 3 and tighten diagonally.
A 12
 Install the lubricating oil line.

- Tighten union nut (arrow).
- Mount gasket.
- Tighten screws 2.
Install lubricating oil line without tension.

TCG 2016
W 8-8-2
A 13
 Install the lubricating oil filter console.

- Position 1.

TCG 2016
W 8-8-2

TCG 2016
W 9-0-2
Checking and cleaning coolant spaces
Tools
Auxiliary material
- Cleaning agents
References
General information
Dirt in the cooling water (e.g. lime) and corrosion form deposits on the walls of the coolant
spaces; these must be removed.
This applies especially when leakage has led to a loss of coolant, so that the coolant spaces
required continuous topping up.
Risk of scalding !

lations.
Cleaning the coolant chambers

 Mix a cleaning solution according to the manufacturer's specifications.
 Fill the cleaning solution into the engine.
 Switch on the coolant pump (via the TEM system).
 Allow the cleaning solution to take effect according to the manufacturer's specifica-
tions.
 Drain the cleaning solution.
 Fill in clean water (according to TR 0199 - 99 - 2091).
 Switch on the coolant pump (via the TEM system).
 Drain water and repeat the procedure.
 Fill with new coolant mixture.
 Bleed cooling system.

TCG 2016
W 9-0-2

TCG 2016
W 9-12-2
Removing and installing the coolant temperature sensor (engine outlet)
Tools
Auxiliary material
Spare parts
- Sealing ring
General information
Risk of injury !
Risk of scalding !

lations.

TCG 2016
W 9-12-2
Removing and installing the coolant temperature sensor (engine outlet)
A1

 Unscrew coolant temperature sensor (arrow).
 Tighten coolant temperature sensor (arrow).

TCG 2016
W 9-12-3
Removing and installing the coolant temperature sensor (engine inlet)
Tools
Auxiliary material
Spare parts
- Sealing ring
General information
Risk of injury !
Risk of scalding !

lations.

TCG 2016
W 9-12-3
Removing and installing the coolant temperature sensor (high temperature circuit
inlet)
A1

 Unscrew coolant temperature sensor (arrow).
 Tighten coolant temperature sensor (arrow).

TCG 2016
W 12-1-4
Removing and installing torsional vibration dampers
Tools
- Angled wrench
Technical data
Torsional vibration damper on crankshaft*

Surface treated oil-blackened M16x100 - 10.9 310 Nm
Surface treated ZnAl-A M16x100 - 10.9 250 Nm
General information
Risk of injury!
Install torsional vibration damper.
A1
 Remove protective cover for torsional vibration dampers (arrow).

TCG 2016
W 12-1-4
A2
 Unscrew screws.
- Position 1.
A3
 Remove washer.
- Position 2.
 Pull off first torsional vibration damper 3 from connecting flange 6.
 Remove intermediate ring.
- Position 4.
 Pull off second torsional vibration damper 5 from connecting flange 6.

TCG 2016
W 12-1-4
Mounting torsional vibration damper.
A4
Make sure that the clamping pin is in the crankshaft.
 Mount the torsional vibration damper 5 on the connecting flange 6.

 Insert intermediate ring.
- Position 4.
 Mount the torsional vibration damper 3 on the connecting flange 6.
 Insert washer.
- Position 2.
A5

- Position 1.

TCG 2016
W 12-1-4
A6
 Install protective cover for torsional vibration dampers (arrow).

TCG 2016
W 12-3-1
Removing, installing and checking rubber compensators
Tools
Technical data
DN 40 / 50 15 Nm
DN 65 / 80 / 100 / 125 20 Nm
DN 150 25 Nm

General information
Check the compensators for damage, e.g. from transport, before installation.
Keep both the inside and outside of the rubber bellows free from foreign bodies, e.g. dirt or
insulating material. Check this before and after assembly.
Do not damage the rubber bellows, do not allow rough vibrations or knocks, do not throw.
Do not attach chains or ropes to the rubber bellows part.
The sealing surfaces of the flanges must be level and clean.
Torsional stress (twisting) during assembly and later during operation must be avoided at
all costs.
Compensators must not be mechanically stressed.
Further pipelines must be secured properly.
Protect the rubber bellows when welding: cover with non-conductive material.
Do not paint the rubber bellows, and do not attach insulation.
Do not exceed the permissible test pressure.
Risk of injury !
Risk of scalding !

TCG 2016
W 12-3-1

lations.
Removing rubber compensators
A1
To avoid damage to the rubber bellows from tools, the wrench must be held on the bellows
side and turned on the side of the opposite flange.
 Drain coolant or lube oil.

 Unscrew screws.
 Remove earthing cable.
 Loosen self-locking nuts on compensator diagonally.
 Unscrew screws.
 Dispose of compensators properly.
Installing rubber compensators

 Insert compensator and fix flange with screws and nuts.
- Renew all self-locking nuts.
- Attach earthing cable to a screw connection.
The flange faces of the compensators serve as seals.

Do not use any other sealing materials.

 Fill up coolant or lube oil.

TCG 2016
W 12-6-1
Removing and installing the flywheel
Tools
- Guide pins for flywheel positioning
Auxiliary material
- Lifting gear
Spare parts
- Screws flywheel on crankshaft
Technical data
Flywheel on crankshaft*
M16x1.5x80 390 Nm


TCG 2016
W 12-6-1
Remove flywheel
A1

- Hold at the nuts.
 Remove flywheel guard.
- Position 1.
 Block flywheel.
 Remove coupling.
Determine installation position and position of the generator.
 Unscrew screws of the generator.
Risk of injury !
Do not push the generator back too far otherwise it might tip from the base frame.
The generator must be secured in its end position, e.g. with straps.
The connecting cables may not be kinked or strained.
The connecting cables should be disconnected if this is not possible.
 Push back the generator on the base frame.

 Remove coupling.

TCG 2016
W 12-6-1
A2
 Loosen screws (arrows).

 Unscrew two screws and screw in the guide pins.
 Unscrew the rest of the screws.
 Pull flywheel off crankshaft.
 Remove flywheel with suitable hoist unit.
Installing flywheel
The flange faces of the flywheel and the crankshaft must be free from oil and grease.
Make sure that the clamping pin is in the crankshaft.
The screws must be renewed for every assembly.
 Turn in the guide pins.

 Mount the flywheel on the crankshaft with a suitable hoist.
Make sure that the clamping pin in the crankshaft is in line with the hole in the flywheel.
 Block flywheel.
 Wet screws with lube oil.

TCG 2016
W 12-6-1
A3
 Screw in and tighten screws.

 Insert and tighten the rest of the screws.
 Remove hoist from flywheel.
 Insert coupling.
Note installation position.
 Move the generator on the base frame.

 Align generator.

TCG 2016
W 12-6-1
A4
 Mount flywheel guard.

- Position 1.
- Hold at the nuts.

TCG 2016
W 12-6-1

TCG 2016
W 13-3-2
Removing and installing the starter (electric starter)
Tools
General information
Risk of injury !
The unit must be out of operation during the work process. The engine must be shutdown
and locked by the TEM system for this. This guarantees that the unit cannot be started with-
out authorisation while work is in progress.
Removing starter
A1
 Disconnect the battery.

 Remove cable set.
Terminal Designation
31 Battery minus (-)
50 Starter control
30 Battery plus (+)

TCG 2016
W 13-3-2
A2
 Unscrew nuts (arrows).

 Pull out starter.
Installing starter
A3
 Insert starter.

TCG 2016
W 13-3-2
A4
 Install cable set.
Terminal Designation
31 Battery minus (-)
50 Starter control
30 Battery plus (+)
 Connect the battery.

TCG 2016
W 13-3-2

TCG 2016
W 13-5-3
Checking and adjusting ignition timing
Tools
- Strobe light
Technical data
Ignition point according to TEM system parameter 11301
General information
The ignition time can only be adjusted or corrected by Service.
The ignition time is set by changing the camshaft offset.
The camshaft offset can only be adjusted with the engine switched off.
The adjustment of the stroboscope lamp must be switched off to test and set the ignition
time.
The input voltage of the stroboscope lamp must be observed (12 Volt).
Danger of death !

TCG 2016
W 13-5-3
Checking ignition time
A1
 Read standard ignition angle from TEM system.

 Connect the stroboscope lamp.
- High voltage clamp at ignition cable B1.
- Power supply of stroboscope lamp.
A2

- From flywheel housing.

TCG 2016
W 13-5-3
A3
 Start engine.
 Strobe ignition time on flywheel.
 Read ignition angle.
Setting ignition timing
A4
 Switch off the engine.

 Calculate new camshaft offset.
New camshaft offset = camshaft offset + (actual value - nominal value)
New camshaft offset = Calculated camshaft offset in °CA

Camshaft offset = From TEM system in °CA
Actual value = Value measured on the flywheel in °CA
Nominal value = Standard ignition angle according to TEM system in °CA

TCG 2016
W 13-5-3
Calculation example
Example 1
Camshaft offset = 102,0°
Actual value = 27°
Nominal value = 25°
New camshaft offset = 102.0° + (27° - 25°)
New camshaft offset = 104.0°
Example 2
Camshaft offset = 102,0°
Actual value = 23°
Nominal value = 25°
New camshaft offset = 102.0° + (23° - 25°)
New camshaft offset = 100.0°
 Enter new camshaft offset.
- Position 3.
A5
 Check ignition time again, repeat setting if necessary.

TCG 2016
W 13-5-3
A6
 Disconnect stroboscope lamp.

 Tighten the locking screw (arrow).

TCG 2016
W 13-5-3

TCG 2016
W 13-9-1
Removing and installing ignition control unit
Tools
General information
Risk of injury !
Danger of death !
Switch off the power supply to the unit.
Removing the ignition control unit
A1
 Remove all cable set plugs from ignition control unit.

- Remove ground cable.
 Remove ignition control unit.

TCG 2016
W 13-9-1
Installing the ignition control unit
A2
 Insert ignition control unit.

- Install ground cable.
 Install all cable set plugs in ignition control unit.

TCG 2016
Service
Service
DEPIC
The DEutz Parts Identification for Customers (DE-
PIC) offers you spare parts identification individually
adapted to your systems. DEPIC enables you to
generate an order list almost automatically, making
ordering your spare parts more efficient. Order no.:
on request (CD-ROM)
Tutorial programs
The degree of availability, reliability and service life
of equipment and drive assemblies are determined
to a great extent by professional operation and serv-
ice by qualified and experienced operators and
service technicians. The MWM GmbH also offers
service-related seminars for MWM GmbH products
to the staff of customers and operators. Apart from
the standard seminars, held in our Training Centre
in Mannheim, it is also possible to arrange special
seminars, either in the Training Centre or at another
location requested by the customer. Information
about the seminar program will be distributed in a
circular. Please ask your MWM Service representa-
tive.

TCG 2016
Service

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Workshop Manual

0299 8938 EN, 10/2008

This documentation is intended for the following engine

OBJ_DOKU-25768-001.fm /2 © MWM GmbH 10/2008

Please read and keep in mind...

OBJ_DOKU-25769-001.fm 3 © MWM GmbH 0106

Take care when the engine is running

You will find this symbol next to instructions of a general nature.

OBJ_DOKU-25769-001.fm 4 © MWM GmbH 0106

The engines of MWM GmbH

Maintenance and care

OBJ_DOKU-25769-001.fm 5 © MWM GmbH 0106

OBJ_DOKU-25769-001.fm 6 © MWM GmbH 0106

OBJ_BUCH-1160-001IVZ.fm 7 © MWM GmbH TCG 2016

Lubricating oil system .................................................................................................................... 42

4 Operating and auxiliary materials

OBJ_BUCH-1160-001IVZ.fm 8 © MWM GmbH TCG 2016

OBJ_BUCH-1160-001IVZ.fm 9 © MWM GmbH TCG 2016

OBJ_BUCH-1160-001IVZ.fm 10 © MWM GmbH TCG 2016

OBJ_DOKU-25770-001.fm 11 © MWM GmbH 0507

OBJ_DOKU-25770-001.fm 12 © MWM GmbH 0507

Safety Regulations / Rules for Accident Prevention

 for the engine room:

OBJ_DOKU-25770-001.fm 13 © MWM GmbH 0507

 for operation and maintenance of the engine:

Rules for disposal

OBJ_DOKU-25770-001.fm 14 © MWM GmbH 0507

CC 1 Technical skilled qualified personnel

CC 2 Authorised qualified personnel

OBJ_DOKU-25770-001.fm 15 © MWM GmbH 0507

CC 3 Authorised qualified personnel

OBJ_DOKU-25770-001.fm 16 © MWM GmbH 0507

Operating manual and workshop manual

2 Description (description of the engine and components)

3 Operation (operating the engine)

5 Maintenance (maintenance schedules and special tools up to maintenance stages

7 Preservation (Technical Bulletin)

10 Miscellaneous (this is an optional chapter only enclosed if needed, containing sup-

General safety regulations

OBJ_DOKU-25770-001.fm 17 © MWM GmbH 0507

2 Description (description of the engine and components)

3 Operation (operating the engine)

5 Maintenance (maintenance schedules, special tools as required by all maintenance

7 Preservation (Technical Bulletin)

10 Miscellaneous (this is an optional chapter only enclosed if needed, containing sup-

General safety regulations

OBJ_DOKU-25770-001.fm 18 © MWM GmbH 0507

Differentiation of the job cards

- Counting per subsystem (component)

T 1-1 Numbering of job cards

OBJ_DOKU-25770-001.fm 19 © MWM GmbH 0507

A 1-1 Structure of the job cards

1 Engine type or system

OBJ_DOKU-25770-001.fm 20 © MWM GmbH 0507

OBJ_DOKU-25771-001.fm 21 © MWM GmbH 0507

OBJ_DOKU-25771-001.fm 22 © MWM GmbH 0507

Design and designations

See also the rating plate

Mixture charge cooling

OBJ_DOKU-25771-001.fm 23 © MWM GmbH 0507

Figure rating plate

1 Engine design designation

OBJ_DOKU-25771-001.fm 24 © MWM GmbH 0507

Designation of sides of engine, cylinder numbering and direction of engine rotation