Manitou TD 3.6 L4 ST5, TDC 3.6 L4 ST5 Engine Repair Manual 647848EN

Description

• Model List:
  • TD 3.6 L4 ST5 Engine. TDC 3.6 L4 ST5 Engine

• 1. MR_647848 EN
• 1.1. Special Tools
• 2. TD_TCD3.6 Stage V
• 2.1. Workshop Manual
• 2.2. Table of contents
• 2.3. General
• 2.4. Safety information / User information
• 2.5. Special tools
• 2.6. Job cards
• 2.6.1. Crankcase/Front cover
• 2.6.1.1. W 010001 Check crankcase pressure
• 2.6.1.2. W 010201 Replacing the crankshaft sealing ring (Flywheel side)
• 2.6.1.3. W 010301 Removing and installing the gasket housing
• 2.6.1.4. W 010705 Removing and installing the transfer line
• 2.6.1.5. W 019001 Sealing parts (Crankcase)
• 2.6.1.6. W 019063 Oil pressure control valve (gate valve)
• 2.6.2. Oil pan
• 2.6.2.1. W 020101 Removing and installing the lubricating oil pan
• 2.6.2.2. W 029001 Sealing parts
• 2.6.3. Crankshaft/Torsional vibration damper/
• 2.6.3.1. W 050101 Removing and installing the Vbelt pulley / Vribbed pulley
• 2.6.3.2. W 050301 Removing and installing the flywheel
• 2.6.3.3. W 050701 Removing and installing the sensor wheel
• 2.6.3.4. W 059013 Vbelt pulley
• 2.6.4. Cylinder head
• 2.6.4.1. W 080001 Checking the compression pressure (when injectors are removed)
• 2.6.4.2. W 080101 Removing and installing the cylinder head cover
• 2.6.5. Gear case/Gear drive
• 2.6.5.1. W 090101 Replacing the crankshaft sealing ring (opposite side to flywheel)
• 2.6.5.2. W 091701 Removing and installing the control valve
• 2.6.6. Lubricating oil cooler/Lubricating oil filter
• 2.6.6.1. W 150201 Removing and installing the lubricating oil cooler
• 2.6.6.2. W 159038 Lubricating oil filter installation (Crankcase)
• 2.6.7. Lubricating oil pipe
• 2.6.7.1. W 160101 Removing and installing the oil suction pipe
• 2.6.7.2. W 160401 Removing and installing the lubricating oil line (Exhaust turbocharger)
• 2.6.7.3. W 160501 Removing and installing the lubricating oil return line (upper partial section) (Exhaust turbocharger)
• 2.6.7.4. W 160502 Removing and installing the lubricating oil return line (lower partial section) (Exhaust turbocharger)
• 2.6.8. Injection pump/High pressure pump
• 2.6.8.1. W 170104 Removing and installing the highpressure pump
• 2.6.9. Fuel injector/Injector
• 2.6.9.1. W 190101 Removing and installing the injector
• 2.6.10. Fuel filter/Fuel pump
• 2.6.10.1. W 209016 Fuel prefilter
• 2.6.10.2. W 209017 Fuel filter
• 2.6.10.3. W 209020 Pressure sensor installation (Fuel pressure)
• 2.6.10.4. W 209040 Level sensor (Fuel prefilter)
• 2.6.10.5. W 209047 Fuel supply pump (electric)
• 2.6.11. Fuel pipes
• 2.6.11.1. W 210401 Removing and installing the rail
• 2.6.11.2. W 210403 Removing and installing the pressure relief valve (Rail)
• 2.6.11.3. W 210405 Removing and installing the rail pressure sensor
• 2.6.11.4. W 210505 Removing and installing the fuel line (injector, rail, highpressure pump)
• 2.6.12. Air filter/Suction pipe/Charge air line
• 2.6.12.1. W 220101 Removing and installing the charge air line
• 2.6.12.2. W 221301 Removing and installing pressure/temperature sensor (Charge air)
• 2.6.12.3. W 229089 Throttle valve
• 2.6.13. Coolant pump
• 2.6.13.1. W 370301 Removing and installing the coolant pump
• 2.6.13.2. W 379013 Vbelt pulley (Fastening parts, coolant pump)
• 2.6.14. Coolant pipes/Thermostat housing
• 2.6.14.1. W 380101 Removing and installing the thermostat
• 2.6.14.2. W 380102 Checking the thermostat (when removed)
• 2.6.14.3. W 389032 Coolant line (Cooler coolant pump)
• 2.6.14.4. W 389032 Hose line (Thermostat housing crankcase)
• 2.6.15. Exhaust pipe/Exhaust gas recirculation
• 2.6.15.1. W 410501 Removing and installing the flutter valve
• 2.6.15.2. W 410502 Removing and installing the cooler
• 2.6.15.3. W 410503 Removing and installing the actuator
• 2.6.15.4. W 419002 Locking screw (Coolant pipe, cooler thermostat housing)
• 2.6.15.5. W 419020 Pressure sensor / Line (Exhaust gas back pressure)
• 2.6.15.6. W 419021 Compensator installation (Exhaust line)
• 2.6.15.7. W 419032 Coolant line (Cooler Crankcase)
• 2.6.16. Exhaust gas turbocharger
• 2.6.16.1. W 430101 Removing and installing the exhaust gas turbocharger
• 2.6.17. Generator/Starter
• 2.6.17.1. W 440201 Removing and installing the generator (Clamping latch)
• 2.6.17.2. W 440206 Removing and installing the console (Generator)
• 2.6.17.3. W 440301 Removing and installing the starter
• 2.6.17.4. W 449007 Cover cap (Generator)
• 2.6.17.5. W 449042 Generator
• 2.6.18. Electric
• 2.6.18.1. W 489010 Holder (glow plugs relay) (on charge air line)
• 2.6.18.2. W 489020 Relay, holder (heating plugs)
• 2.6.18.3. W 489088 Protective caps (Connection line, relay starter)
• 2.6.19. Tools/Special tools
• 2.6.19.1. W 490103 Check cooling system for leaks
• 2.6.19.2. W 490201 Removing and installing turning gear/locking device
• 2.6.20. Measuring instruments
• 2.6.20.1. W 519020 Pressure sensor installation (Lubricating oil pressure)
• 2.6.20.2. W 519020 Speed sensor (Camshaft)
• 2.6.20.3. W 519020 Speed sensor (Crankshaft)
• 2.6.21. Connection housing
• 2.6.21.1. W 520101 Installing and removing the connection housing