Manitou TD 2.9 L4, TCD 2.9 L4 Engine Repair Manual 52734218EN

Description

• Model List:
  • TD 2.9 L4 Engine. TCD 2.9 L4 Engine

• 1. PDG_MR52734218EN
• 2. MR_MotDeutz_03125261TCD 2.9_EN
• 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 011701 Removing and installing the control valve
• 2.6.1.3. W 019001 Sealing parts (crankcase, oil filler neck)
• 2.6.1.4. W 019023 Oil measuring device
• 2.6.1.5. W 019032 Line (crankcase breather)
• 2.6.2. Oil pan
• 2.6.2.1. W 020101 Removing and installing the lubricating oil pan
• 2.6.3. Crankshaft/Torsional vibration damper/
• 2.6.3.1. W 050203 Removing and installing the drive flange
• 2.6.3.2. W 050301 Removing and installing the flywheel
• 2.6.3.3. W 059013 Vbelt pulley / Vrib belt pulley (Fastening parts)
• 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 (Flywheel side)
• 2.6.5.2. W 090203 Removing and installing the sealing cover
• 2.6.5.3. W 090301 Removing and fitting the front cover (Fastening parts)
• 2.6.5.4. W 090401 Replacing the crankshaft sealing ring (opposite side to flywheel)
• 2.6.5.5. W 099063 Oil pressure 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
• 2.6.7. Lubricating oil pipe
• 2.6.7.1. W 160101 Removing and installing the oil suction pipe
• 2.6.7.2. W 160501 Removing and installing the lubricating oil return line (upper 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)
• 2.6.11.5. W 219030 Fuel line (Quick coupling)
• 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 229035 Intake nozzle
• 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)
• 2.6.15. Exhaust pipe/Exhaust gas recirculation
• 2.6.15.1. W 410101 Removing and installing the exhaust pipe
• 2.6.15.2. W 410501 Removing and installing the flutter valve
• 2.6.15.3. W 410502 Removing and installing the cooler
• 2.6.15.4. W 410503 Removing and installing the actuator
• 2.6.15.5. W 410510 Removing and installing the Venturi tube
• 2.6.15.6. W 410512 Remove and install connection nozzles (Coolant pump exhaust gas recirculation)
• 2.6.15.7. W 410601 Removing and installing the temperature sensor (Exhaust gas recirculation)
• 2.6.15.8. W 410602 Removing and installing the pressure sensor (Exhaust gas recirculation)
• 2.6.15.9. W 419012 Addon parts (crankcase exhaust gas return)
• 2.6.15.10. W 419020 Pressure sensor installation (Exhaust gas back pressure)
• 2.6.15.11. W 419021 Line (Exhaust gas recirculation)
• 2.6.15.12. W 419036 Exhaust manifold (Exhaust gas recirculation)
• 2.6.16. Exhaust gas turbocharger
• 2.6.16.1. W 430101 Removing and installing the exhaust gas turbocharger
• 2.6.16.2. W 430401 Removing and installing the lubricating oil line (Exhaust turbocharger)
• 2.6.16.3. W 430501 Removing and installing the lubricating oil return line (upper partial section) (Exhaust turbocharger)
• 2.6.16.4. W 430502 Removing and installing the lubricating oil return line (lower partial section) (Exhaust turbocharger)
• 2.6.17. Generator/Starter
• 2.6.17.1. W 440101 Removing and installing the belt tensioner (Vribbed belt)
• 2.6.17.2. W 440201 Removing and installing the generator
• 2.6.17.3. W 449042 Generator
• 2.6.17.4. W 449051 Console (belt tensioner, deflection pulley)
• 2.6.17.5. W 449090 Starter
• 2.6.18. Electric
• 2.6.18.1. W 489019 Temperature sensor (Coolant)
• 2.6.18.2. W 489020 Pressure sensor installation (Fuel pressure / lubricating oil pressure)
• 2.6.18.3. W 489068 Cable harness (Fastening parts)
• 2.6.18.4. W 489068 Cable harness (Fastening parts)
• 2.6.18.5. W 489068 Cable harness (Fastening parts)
• 2.6.18.6. W 489068 Cable harness (Fastening parts)
• 2.6.18.7. W 489068 Cable harness (Fastening parts)
• 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 510201 Removing and installing the speed sensor (Crankshaft)
• 2.6.20.2. W 510203 Removing and installing the speed sensor (Camshaft)
• 2.6.20.3. W 510801 Removing and installing pressure/temperature sensor (Charge air)
• 2.6.20.4. W 510801 Removing and installing pressure/temperature sensor (Charge air)
• 2.6.20.5. W 510901 Removing and installing the temperature sensor (Charge air)
• 2.6.20.6. W 519020 Pressure sensor installation (Lubricating oil pressure)
• 2.6.20.7. W 519020 Temperature sensor (Coolant)
• 2.6.21. Start aid
• 2.6.21.1. W 639002 Locking screw (heating plugs)
• 2.6.22. Exhaust gas treatment
• 2.6.22.1. W 711001 Order of assembly (Installing catalyst) DOC (Diesel Oxidation Catalyst), SCR (Selective Catalytic Reduction)
• 2.6.22.2. W 719001 Sealing parts (diesel oxidation catalytic converter/diesel particle filter, SCR catalytic converter) (NOx sensor, temperature sensor, diesel particle filter differential pressure sensor)
• 2.6.22.3. W 719001 Sealing parts (diesel oxidation catalytic converter/diesel particle filter, SCR catalytic converter) (temperature sensor, differential pressure sensor of diesel particulate filter)
• 2.6.22.4. W 719002 Locking screw, diesel oxidation catalytic converter (Temperature sensor)
• 2.6.22.5. W 719009 Holder (Differential pressure sensor)
• 2.6.22.6. W 719009 Holder (Module size 5.66)
• 2.6.22.7. W 719020 Differential pressure sensor (diesel particle filter)
• 2.6.22.8. W 719020 Temperature sensor (before and after diesel oxidation catalyst)
• 2.6.22.9. W 719022 Vbelt clip