TD 3.6 L4. Parts Manual. Deutz Engine. Telescopic Handlers. Gehl RS6-34 (Tier IV) Manitou MT6034 T (Tier IV)

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1 TD 3.6 L4 Form No Revision A September 04 Deutz Engine Telescopic Handlers Gehl RS6-34 (Tier IV) Manitou MT6034 T (Tier IV) Parts Manual

Introduction Deutz TD 3.6 L4 The Table of Contents pages list the page locations of the various component groups on the engine. Manitou Americas, Inc.

When ordering service parts, specify the part number, full description, quantity required, and the engine model and serial number.

NOTE: The engine manufacturer occasionally makes changes to engine components; therefore, it is important to always provide the factory parts department with the model and serial number of the engine

2 Introduction Deutz TD 3.6 L4 The Table of Contents pages list the page locations of the various component groups on the engine. Manitou Americas, Inc. reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any unit previously delivered. When ordering service parts, specify the part number, full description, quantity required, and the engine model and serial number. Model and serial number for this engine are stamped on the engine identification plate located on the top of the valve cover. NOTE: The engine manufacturer occasionally makes changes to engine components; therefore, it is important to always provide the factory parts department with the model and serial number of the engine when ordering parts. This is especially important when the part number in this parts manual is listed as CFPD (Call Factory Parts Department) or TBD (To Be Determined). The following icons shown on various pages provide important information or identify where additional information can be found. Valve cover is shown on page 8. Identifies where additional information can be found. Informs user of specific parts details for ordering. 0 Nm NOTE: Fastens to valve cover. Identifies missing, hidden parts, or adds informational comments. Refer to page 0 for the installation sequence. Alerts and directs user to investigate more information. NOTE: Quantities are for one piston; the engine uses four pistons. Identifies the correct torque of the bolt, nut, fitting, or other hardware. When a value is not present, refer to the engine shop manual for correct torque values and procedures. Model Serial Number Engine Identification Plate (Located on top of the valve cover)

3 Deutz TD 3.6 L4 Table of Contents Component Locations Engine Block, Oil Pan, Plugs, and Gasket Set Oil Pickup Lines Oil Cooler, Oil Filter, and Oil Pressure Sensor Connecting Rod Piston Crankshaft, Pulley, and Sensor Camshaft, Lifters, Rocker Arms, and Sensor Cylinder Head and Valve Cover Flywheel Housing, Starter, and Starter Relay Flywheel and Starter Ring Oil Pump and Timing Gear Cover Fuel Injector Pressure Pump Fuel Rail and High-Pressure Fuel Lines Fuel Return Lines Fuel Injector Glow Plug Turbocharger Turbocharger Oil Lines Turbocharger Hose and Crankcase Breather Tube Turbocharger Exhaust Exhaust Manifold Group Diesel Oxidation Catalyst (DOC) Group Air Intake Manifold Air Intake Sensors Air Intake Tube Group EGR Valve and EGR Cooler Group Water Pump Group Thermostat Housing Group Alternator Group Fan Belt and Tensioner Engine Wire Harnesses Harness Connectors ECU (Electronic Control Unit) Numeric Index Subject Index Specifications PRINTED IN U.S.A /AP094

4 Component Locations Deutz TD 3.6 L4 Intake Manifold Pressure Sensor Page 33; item 5 Fuel Rail Pressure Sensor Page ; item 7 Coolant Temperature Sensor Page 40; item 7 EGR Control Valve Page 36; item Alternator Page 4; item Air Temperature Sensor Page 33; item Starter Page 4; item 8 Camshaft Speed Sensor Page ; item 0 Crankshaft Speed Sensor Page 0; item Fuel Injector Pressure Pump Page 0; item Volume Control Page 0; item Starter Relay (hidden from view) Page 5; item /AP094 PRINTED IN U.S.A.

5 Deutz TD 3.6 L4 Component Locations Coolant Temperature Sensor Page 40; item 7 Fuel Rail Pressure Sensor Page ; item 7 EGR Control Valve Page 36; item Volume Control Page 0; item Turbocharger Page 6; item Alternator Page 4; item Crankshaft Speed Sensor Page 0; item Camshaft Speed Sensor Page ; item 0 Oil Pressure Sensor Page 7; item 9 Oil Filter Page 7; item 4 PRINTED IN U.S.A /AP094

6 Engine Engine Block, Oil Pan, Plugs, and Gasket Set Deutz TD 3.6 L4 5 0 Nm 80 Nm Nm 0 Nm Nm Nm 4 95 Nm 0 Nm 44 0 Nm 4 Refer to Shop Manual Nm /AP094 4 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Engine Block, Oil Pan, Plugs, and Gasket Set Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500780 ENGINE BLOCK ASSEMBLY.

7 Deutz TD 3.6 L4 Engine Engine Block, Oil Pan, Plugs, and Gasket Set Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req ENGINE BLOCK ASSEMBLY..... (includes items 6-7) PISTON COOLING NOZZLE VALVE BEARING, THRUST Standard Oversize,53 mm 05 BEARING, MAIN Standard Undersize 84,75 mm Undersize 84,50 mm PLUG PLUG PLUG PLUG (M0-.0 mm) VALVE SEALING RING PLUG HOSE CONNECTOR SEALING RING PLUG (M-.5 mm) PLUG (M0-.0 mm) SEALING RING STUD PLUG (M4-.5 mm) COMPRESSION SPRING BUSHING ADAPTER BOLT, MAIN BEARING CAP ALIGNMENT BUSHING BY-PASS TBD CAM BEARING/BUSHING NSS MAIN BEARING CAP (included with item ) PLUG BOLT, TORX HEAD PLUG, OIL PAN DRAIN SEAL OIL PAN SEALANT BOLT REAR MAIN SEAL REAR MAIN SEAL HOUSING..... (includes item 4) SEALANT FILLER CAP OIL FILLER TUBE BOLT (torque 30Nm) GASKET DIPSTICK, ENGINE OIL LEVEL... (includes item #56) O-RING (included w/#57) GUIDE TUBE, DIPSTICK SAFETY LOCK AGENT GASKET SET, TD3.6 L4 ENGINE.. NOTE: At the time of publication of this parts manual, the engine OEM was unable to provide availability or pricing for the cam bushings/bearings (item 6). Please contact the Factory Parts Department for more information. 70 PRINTED IN U.S.A /AP094

Engine Oil Pickup Lines Deutz TD 3.6 L4 0 Nm 6 35 Nm 3 6 5 4 0 Nm 0 Nm Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500406 TRANSFER PIPE, OIL.

8 Engine Oil Pickup Lines Deutz TD 3.6 L4 0 Nm 6 35 Nm Nm 0 Nm Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req TRANSFER PIPE, OIL BOLT, TORX-HEAD PLUG OIL SUCTION PIPE BOLT, TORX-HEAD SEALANT /AP094 6 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Oil Cooler, Oil Filter, and Oil Pressure Sensor 9 0 Nm 4 3 5 40 Nm 3 30 Nm 8 6 7 Item Part Description Qty.

....................... 4 04 303 FILTER, ENGINE OIL........... 05 3336 THREADED ADAPTER.......... 06 500404 PLATE/COVER................ 07 500405 O-RING.

9 Deutz TD 3.6 L4 Engine Oil Cooler, Oil Filter, and Oil Pressure Sensor 9 0 Nm Nm 3 30 Nm Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req OIL COOLER GASKET, OIL COOLER BOLT FILTER, ENGINE OIL THREADED ADAPTER PLATE/COVER O-RING BOLT SENSOR, OIL PRESSURE (includes item 0) O-RING SEAL PRINTED IN U.S.A /AP094

Engine Connecting Rod Deutz TD 3.6 L4 5 4 Refer to Shop Manual 3 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 50035 CONNECTING ROD ASSEMBLY.

10 Engine Connecting Rod Deutz TD 3.6 L4 5 4 Refer to Shop Manual 3 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req CONNECTING ROD ASSEMBLY.. (includes items -4) BUSHING, WRIST PIN BOLT, CONNECTING ROD NSS CONNECTING ROD CAP (included with item ) 05 ROD BEARING Standard 68,0 mm st undersize 67,75 mm nd undersize 67,50 mm NOTE: Quantities are for one connecting rod; the engine uses four connecting rods /AP094 8 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Piston 4 3 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500357 PISTON ASSEMBLY............ (includes items -4 0 500358 SNAP RING, WRIST PIN.

11 Deutz TD 3.6 L4 Engine Piston 4 3 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req PISTON ASSEMBLY (includes items SNAP RING, WRIST PIN WRIST PIN PISTON RING SET (one piston)... NOTE: Quantities are for one piston; the engine uses four pistons. PRINTED IN U.S.A /AP094

Engine Crankshaft, Pulley, and Sensor Deutz TD 3.6 L4 3 8.

No. No. Req. 0 500344 GEAR, ENGINE SPEED......... 0 500345 BOLT........................ 3 03 500346 PIN, ALIGNMENT.

............. 07 500350 WASHER, FLAT............... 08 500343 CRANKSHAFT................ 500376 BRACKET, ENGINE SPEED.

12 Engine Crankshaft, Pulley, and Sensor Deutz TD 3.6 L Nm Nm Nm Refer to Shop Manual Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req GEAR, ENGINE SPEED BOLT PIN, ALIGNMENT PULLEY, CRANKSHAFT BOLT, CRANKSHAFT PULLEY PIN, ALIGNMENT WASHER, FLAT CRANKSHAFT BRACKET, ENGINE SPEED SENSOR, ENGINE SPEED BOLT ( 8,5 Nm) BOLT ( 5 Nm) O-RING /AP094 0 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Camshaft, Lifters, Rocker Arms, and Sensor 3 30 Nm 5 4 0 6 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 0535 VALVE LIFTER, HYDRAULIC.

13 Deutz TD 3.6 L4 Engine Camshaft, Lifters, Rocker Arms, and Sensor 3 30 Nm Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req VALVE LIFTER, HYDRAULIC PUSHROD, VALVE LIFTER BOLT ROCKER ARM ROCKER ARM BEARING CAMSHAFT SENSOR, ENGINE SPEED (includes item 3) 877 BOLT O-RING PRINTED IN U.S.A /AP094

33 3 80 Nm 4 5 Refer to Shop Manual 35 6 3 50 9 0

14 Engine Cylinder Head and Valve Cover 34 Deutz TD 3.6 L4 3 8,5 Nm The breather tube is shown on page Nm 4 5 Refer to Shop Manual /AP094 PRINTED IN U.S.A.

15 Deutz TD 3.6 L4 Engine Cylinder Head and Valve Cover Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req CYLINDER HEAD (includes items -4) VALVE SEAT, INTAKE VALVE SEAT, EXHAUST VALVE KEEPER VALVE SPRING CAP VALVE SEAL PLUG PLUG PLUG SEALING RING (x7 mm) PLUG (M-.5) VALVE SPRING INTAKE VALVE EXHAUST VALVE GASKET, CYLINDER HEAD BUSHING, ALIGNMENT CYLINDER HEAD BOLT VALVE COVER (includes items 3-34) GASKET, VALVE COVER BOLT CAP, OIL FILL PLUG SAFETY LOCK AGENT AR PRINTED IN U.S.A /AP094

16 Engine Flywheel Housing, Starter, and Starter Relay Deutz TD 3.6 L Nm 0 60 Nm Nm /AP094 4 PRINTED IN U.S.A.

17 Deutz TD 3.6 L4 Engine Flywheel Housing, Starter, and Starter Relay Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req FLYWHEEL HOUSING BOLT BOLT COVER PLATE BUSHING, ALIGNMENT SEALING RING SCREW PLUG TBD STARTER BOLT BOLT BOLT RELAY, STARTER BRACKET, STARTER RELAY PROTECTING CAP PROTECTING CAP HARNESS, STARTER RELAY.... NOTE: At the time of publication of this parts manual, the OEM for the starter was unable to provide availability or pricing. Please contact the Factory Parts Department for more information. PRINTED IN U.S.A /AP094

18 Engine Flywheel and Starter Ring Deutz TD 3.6 L4 3 Refer to Shop Manual /AP094 6 PRINTED IN U.S.A.

19 Deutz TD 3.6 L4 Item Part Description Qty. No. No. Req. Engine Flywheel and Starter Ring FLYWHEEL (includes item ) STARTER RING (included with item ) BOLT PRINTED IN U.S.A /AP094

20 Engine Oil Pump and Timing Gear Cover Deutz TD 3.6 L The idler gear fastens to the front of the engine block /AP094 8 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Oil Pump and Timing Gear Cover Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500785 COVER, TIMING GEAR......... 0 500385 VALVE PLUNGER.

........... 3 500395 OIL PUMP.................... (includes items -4) 500396 GEAR, OIL PUMP.............. 3 500397 ADAPTER TUBE............... 4 500398 O-RING...................... 4 7 500399 DOWEL BUSHING.

21 Deutz TD 3.6 L4 Engine Oil Pump and Timing Gear Cover Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req COVER, TIMING GEAR VALVE PLUNGER VALVE SPRING SPRING CAP ( 60 Nm) O-RING PIN, ALIGNMENT THREADED INSERT OIL PUMP (includes items -4) GEAR, OIL PUMP ADAPTER TUBE O-RING DOWEL BUSHING BOLT ( 8,5 Nm) GEAR, IDLER SHAFT BOLT ( 30 Nm) BOLT ( 30 Nm) BOLT ( 30 Nm) BOLT ( 30 Nm) PLUG ( 55 Nm) CONNECTOR, COOLANT PORT RETAINER, COOLANT CONN SEALING RING (8x0 mm) SEAL, CRANKSHAFT PROFILE WASHER SEALANT Nm 55 Nm 30 Nm 30 Nm 30 Nm 8,5 Nm 60 Nm PRINTED IN U.S.A /AP094

22 Engine Fuel Injector Pressure Pump Deutz TD 3.6 L Nm Nm /AP094 0 PRINTED IN U.S.A.

23 Deutz TD 3.6 L4 Engine Fuel Injector Pressure Pump Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req HIGH PRESSURE PUMP (includes items -7) VOLUME CONTROL VALVE (includes items 3-4) GASKET O-RING OVER-FLOW VALVE (includes items 6-7) O-RING O-RING O-RING SEAL SPACER/ADAPTER O-RING SEAL GEAR, FUEL INJ. PUMP DRIVE WASHER NUT, INJECTION PUMP PRINTED IN U.S.A /AP094

Engine Fuel Rail and High-Pressure Fuel Lines Deutz TD 3.6 L4 30 Nm 5 4 7 3 8 Fuel Injector 0 9 6 7 6 30 Nm NOTE: All fuel line nuts are torqued at 30 Nm. Item Part Description Qty.

24 Engine Fuel Rail and High-Pressure Fuel Lines Deutz TD 3.6 L4 30 Nm Fuel Injector Nm NOTE: All fuel line nuts are torqued at 30 Nm. Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req FUEL RAIL (includes item 7 and 8) FUEL LINE ASSEMBLY (includes items 9-) FUEL LINE ASSEMBLY (used with cylinders 3 and 4) FUEL LINE, HIGH-PRESSURE... (used with cylinders and ) BOLT, TORX-HEAD SPACER, FUEL RAIL RAIL PRESSURE SENSOR KIT... (includes item 8) O-RING NSS BOLT (included with item ) NSS PIPE CLAMP (included with item ) NSS NUT(included with item ) MULTI-PURPOSE GREASE.... AR /AP094 PRINTED IN U.S.A.

25 Deutz TD 3.6 L4 Engine Fuel Return Lines 3 Fuel Injector Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 a FUEL LINE ASSEMBLY (includes items 5-7) FUEL RETURN LINE HOSE RETAINER CLAMP, SPRING BAND HOSE ASSEMBLY PIPE CLAMP BOLT NUT STUD PRINTED IN U.S.A /AP094

Engine Fuel Injector Deutz TD 3.6 L4 5 4 30 Nm 6 3 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 5004 FUEL INJECTOR.

26 Engine Fuel Injector Deutz TD 3.6 L Nm 6 3 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req FUEL INJECTOR (includes items and 5) SEAL, FUEL INJECTOR CLAMP, FUEL INJECTOR BOLT, FUEL INJECTOR RETAINING CLIP O-RING NOTE: The engine uses four injectors; the quantities shown are for all four injectors /AP094 4 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Glow Plug 3,5 Nm Item Part Description Qty. No. No. Req. 0 500557 GLOW PLUG.................. 4 0 500558 CONNECTING RAIL.

27 Deutz TD 3.6 L4 Engine Glow Plug 3,5 Nm Item Part Description Qty. No. No. Req GLOW PLUG CONNECTING RAIL NOTE: The engine uses four glow plugs; the quantities shown are for all four. PRINTED IN U.S.A /AP094

Engine Turbocharger Deutz TD 3.6 L4 3 30 Nm Turbocharger rubber hose adapter is on page 6. Item Part Description Qty. No. No. Req.

28 Engine Turbocharger Deutz TD 3.6 L Nm Turbocharger rubber hose adapter is on page 6. Item Part Description Qty. No. No. Req TURBOCHARGER GASKET, TURBOCHARAGER BOLT /AP094 6 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Turbocharger Oil Lines 3 Turbocharger 7 6 3 8,5 Nm 3 8,5 Nm 5 4 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500798 OIL LINE, PRESSURE.

29 Deutz TD 3.6 L4 Engine Turbocharger Oil Lines 3 Turbocharger ,5 Nm 3 8,5 Nm 5 4 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req OIL LINE, PRESSURE (includes items -3) BOLT, HOLLOW SEALING RING FLANGE O-RING SEAL OIL LINE, RETURN (includes items 4) 4 87 O-RING BOLT BOLT GASKET, FLANGE PRINTED IN U.S.A /AP094

Engine Turbocharger Hose and Crankcase Breather Tube Deutz TD 3.6 L4 8,5 Nm 3 4 5 4 6 7 6 Turbocharger Valve Cover is shown on page. Item Part Description Qty. Item Part Description Qty. No. No. Req.

30 Engine Turbocharger Hose and Crankcase Breather Tube Deutz TD 3.6 L4 8,5 Nm Turbocharger Valve Cover is shown on page. Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req INTAKE ELBOW BOLT HOSE NIPPLE SPRING CLAMP HOSE SPRING CLAMP HOSE /AP094 8 PRINTED IN U.S.A.

31 Deutz TD 3.6 L4 Engine Turbocharger Exhaust Turbocharger 30 Nm Item Part Description Qty. No. No. Req CLAMP, T-BOLT NUT PRINTED IN U.S.A /AP094

No. No. Req. 0 50080 COMPENSATOR TUBE......... 0 500486 GASKET, COMPENSATOR TUBE. 03 500487 BOLT.

32 Engine Exhaust Manifold Group Deutz TD 3.6 L4 3 0 Nm 30 Nm Turbocharger Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req COMPENSATOR TUBE GASKET, COMPENSATOR TUBE BOLT EXHAUST MANIFOLD GASKET, EXHAUST MANIFOLD BOLT /AP PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Diesel Oxidation Catalyst (DOC) Group 4 3 6 8 7 5 6 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500574 CLAMP, EXHAUST.

33 Deutz TD 3.6 L4 Engine Diesel Oxidation Catalyst (DOC) Group Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req CLAMP, EXHAUST GASKET, EXHAUST OUTLET, DOC BRACKET, DOC INLET, DOC (includes items 6-8) LOCK, CAP GASKET CLAMP, DOC PRINTED IN U.S.A /AP094

Engine Air Intake Manifold Deutz TD 3.6 L4 Cylinder Head 30 Nm 4 3 Item Part Description Qty. No. No. Req. 0 500438 AIR INTAKE MANIFOLD.

34 Engine Air Intake Manifold Deutz TD 3.6 L4 Cylinder Head 30 Nm 4 3 Item Part Description Qty. No. No. Req AIR INTAKE MANIFOLD GASKET, AIR INTAKE MANIFOLD BOLT RETAINING PLATE /AP094 3 PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine Air Intake Sensors 50 Nm 5 Nm 4 5 0 8 Nm 8 9 7 6 Air Intake Manifold 30 Nm 3 Fastens to engine intake air pressure tube; item on page 34. Item Part Description Qty.

35 Deutz TD 3.6 L4 Engine Air Intake Sensors 50 Nm 5 Nm Nm Air Intake Manifold 30 Nm 3 Fastens to engine intake air pressure tube; item on page 34. Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req SENSOR, TEMPERATURE BOLT BOLT, TORX-HEAD BOLT SENSOR, PRESSURE PRESSURE SENSOR ASSEMBLY. (includes items 7-9) SEALING RING BOLT, HOLLOW HOSE FITTING O-RING (included w/ item ) SEALANT, SENSOR PRINTED IN U.S.A /AP094

36 Engine Air Intake Tube Group Deutz TD 3.6 L4 4 3 Nm 0 30 Nm Nm 3 Fastens to engine air intake pressure sensor; item 9 on page Air Intake Manifold /AP PRINTED IN U.S.A.

37 Deutz TD 3.6 L4 Engine Air Intake Tube Group Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req AIR INTAKE TUBE HOSE, RUBBER 90º CLAMP, SPRING CLAMP, SPRING CLAMP, SPRING GASKET, AIR INTAKE TUBE PIPE CLAMP BOLT HOSE, RUBBER BOLT AIR PRESSURE TUBE ASSY,.... (includes items and 3) 334 BOLT, HOLLOW SEALING RING PRINTED IN U.S.A /AP094

6 L4 5 0 Nm 80 Nm 8 Nm 3 9 5 0 4 8 9 7 4

38 Engine EGR Valve and EGR Cooler Group Deutz TD 3.6 L4 5 0 Nm 80 Nm 8 Nm Nm 8 0 Nm 4 0 Nm /AP PRINTED IN U.S.A.

39 Deutz TD 3.6 L4 Engine EGR Valve and EGR Cooler Group Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req COOLANT TUBE, EGR BOLT, TORX-HEAD BOLT PIPE CLAMP GASKET, EGR COOLANT TUBE HOSE, RUBBER CLAMP, SPRING SEALING RING x7mm PLUG (M-.5) EGR BRACKET ASSEMBLY BOLT EGR BRACKET BOLT BOLT O-RING SEAL HOSE CONNECTOR HOSE, EGR COOLER EGR COOLER (includes items 0-5) EGR CONTROL VALVE (includes items and ) NSS O-RING NSS O-RING SHUTTLE VALVE NSS END CAP (included with item 9).. 5 NSS BRACKET (included with item 9) HOSE CLAMP SPRING CLAMP PRINTED IN U.S.A /AP094

40 Engine Water Pump Group Deutz TD 3.6 L Nm 30 Nm Nm 35 Nm Nm 60 Nm 4 Nm 3 Bolts to the front of the engine /AP PRINTED IN U.S.A.

41 Deutz TD 3.6 L4 Engine Water Pump Group Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req WATER PUMP SEAL HOSE CONNECTOR PLUG PUG O-RING SEAL O-RING SEAL BOLT PULLEY, FAN BOLT BOLT BOLT SHIM/WASHER MANIFOLD, COOLANT NSS SILICON O-RING SEAL (included with item ) PRINTED IN U.S.A /AP094

9 30 Nm 3 9 9 8 4 3 Nm 5 Fastens to engine;

42 Engine Thermostat Housing Group Deutz TD 3.6 L4 Cylinder Head Nm 30 Nm Nm Nm Nm 5 Fastens to engine; refer to page 4, item /AP PRINTED IN U.S.A.

43 Deutz TD 3.6 L4 Engine Thermostat Housing Group Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req THERMOSTAT HOUSING ASY.... (includes items -4) THERMOSTAT O-RING SEAL PLUG GASKET, THERMOSTAT BOLT TEMPERATURE SENDER TUBE, COOLANT CLAMP, SPRING MANIFOLD, COOLANT HOSE, COOLANT BOLT BRACKET, SUPPORT PIPE CLAMP BOLT PRINTED IN U.S.A /AP094

44 Engine Alternator Group Deutz TD 3.6 L Nm Nm 4 Nm Fastens to timing gear cover; refer to page6. 30 Nm /AP094 4 PRINTED IN U.S.A.

45 Deutz TD 3.6 L4 Engine Alternator Group Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req ALTERNATOR (includes items -5) REGULATOR, ALTERNATOR FAN, ALTERNATOR NUT AND WASHERS PULLEY, ALTERNATOR BOLT MOUNT, ALTERNATOR BUSHING BOLT BOLT BOLT PIN, ALIGNMENT SEALANT PRINTED IN U.S.A /AP094

46 Engine Fan Belt and Tensioner Deutz TD 3.6 L4 3 4 Refer to Shop Manual /AP PRINTED IN U.S.A.

47 Deutz TD 3.6 L4 Item Part Description Qty. No. No. Req. Engine Fan Belt and Tensioner V-RIBBED BELT IDLER, BELT BOLT, SOCKET-HEAD BELT TENSIONER PRINTED IN U.S.A /AP094

48 Engine Engine Wire Harnesses Deutz TD 3.6 L NOTE: Wire harness shown is for illustrative purposes only; the wire harness and connectors may be different from those on the machine /AP PRINTED IN U.S.A.

49 Deutz TD 3.6 L4 Engine Engine Wire Harnesses Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req ENGINE WIRE HARNESS CONNECTOR, INTERFACE CONNECTOR, COOLANT TEMP CONNECTOR, INJECTORS CONNECTOR, RAIL PRES CONNECTOR, BOOST PRES CONNECTOR, EGR VALVE CONNECTOR, OIL PRES CLAMPING BAND CLAMPING BAND CLAMPING BAND CLAMPING BAND CLAMPING BAND BOLT SPACER PRINTED IN U.S.A /AP094

Engine Harness Connectors Deutz TD 3.6 L4 5 9 8 6 7 Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req. 0 500537 PLUG-IN CONNECTOR......... ( pins) 05 500540 ADAPTER.

50 Engine Harness Connectors Deutz TD 3.6 L Item Part Description Qty. Item Part Description Qty. No. No. Req. No. No. Req PLUG-IN CONNECTOR ( pins) ADAPTER PLUG-IN CONNECTOR PLUG-IN CONNECTOR PLUG-IN CONNECTOR PLUG-IN CONNECTOR /AP PRINTED IN U.S.A.

Deutz TD 3.6 L4 Engine ECU (Engine Control Unit) Item Part Description Qty. No. No. Req. 0 500456 ENGINE CONTROL UNIT (ECU).. NOTE: This is a special order item that requires programming.

51 Deutz TD 3.6 L4 Engine ECU (Engine Control Unit) Item Part Description Qty. No. No. Req ENGINE CONTROL UNIT (ECU).. NOTE: This is a special order item that requires programming. Please provide the engine model and serial number when placing the order for this part. Be aware that because of the programming requirements there will be a delay in obtaining this part. PRINTED IN U.S.A /AP094

52 Numerical Index Deutz TD 3.6 L4 Part Page Item No. No. No. Part Page Item No. No. No. Part Page Item No. No. No. Part Page Item No. No. No /AP PRINTED IN U.S.A.

53 Deutz TD 3.6 L4 Numerical Index Part Page Item No. No. No. Part Page Item No. No. No. Part Page Item No. No. No. Part Page Item No. No. No PRINTED IN U.S.A /AP094

54 Subject Index Deutz TD 3.6 L4 A Air Intake Manifold Air Intake Tube Air Pressure Tube Assembly Alternator B Belt Tensioner Belt, Serpentine Bracket, DOC Bracket, Engine Speed Bracket, Starter Relay By-Pass Plug C Camshaft Cap, Oil Fill Clamp, Doc Clamp, Exhaust Clamp, Fuel Injector Compensator Tube Compression Spring Connecting Rail Connecting Rod Assembly Connector , 47 Coolant Tube, EGR Cover Plate, Flywheel Housing Cover, Timing Gear Crankshaft Cylinder Head D Dipstick, Engine Oil Level E EGR Bracket EGR Control Valve EGR Cooler Engine Block Assembly Engine Control Unit (ECU) Engine Wire Harness Exhaust Manifold Exhaust Valve /AP094 5 PRINTED IN U.S.A.

55 Deutz TD 3.6 L4 Subject Index F Fan, Alternator Filler Cap, Engine Oil Filter, Engine Oil Flywheel Flywheel Housing Fuel Injector Fuel Line Assembly , 3 Fuel Rail Fuel Return Line G Gasket Set, Td3.6 L4 Engine Gasket, Air Intake Manifold Gasket, Air Intake Tube Gasket, Compensator Tube Gasket, Cylinder Head Gasket, EGR Coolant Tube Gasket, Exhaust Gasket, Exhaust Manifold Gasket, Flange Gasket, Oil Cooler Gasket, Thermostat Gasket, Turbocharager Gasket, Valve Cover Gear, Engine Speed Gear, Fuel Injection Pump Drive Gear, Idler Gear, Oil Pump Glow Plug Guide Tube, Dipstick H High Pressure Pump Hose, Coolant Hose, EGR Cooler Hose, Rubber , 37 I Idler, Belt Inlet, Doc Intake Elbow Intake Valve PRINTED IN U.S.A /AP094

56 Subject Index Deutz TD 3.6 L4 M Manifold, Coolant , 4 Mount, Alternator O Oil Cooler Oil Filler Tube Oil Line, Pressure Oil Line, Return Oil Pan Oil Pump Oil Suction Pipe Outlet, Doc Over-Flow Valve P Piston Assembly Piston Cooling Nozzle Pressure Sensor Assembly Pulley, Alternator Pulley, Crankshaft Pulley, Fan Pushrod, Valve Lifter R Rail Pressure Sensor Kit Rear Main Seal Regulator, Alternator Relay, Starter Rocker Arm S Seal, Crankshaft Seal, Fuel Injector Sensor, Engine Speed , Sensor, Oil Pressure Sensor, Pressure Sensor, Temperature Starter Starter Ring /AP PRINTED IN U.S.A.

57 Deutz TD 3.6 L4 Subject Index T Temperature Sender Thermostat Transfer Pipe, Oil Tube, Coolant Turbocharger V Valve Cover Valve Lifter, Hydraulic Volume Control Valve W Water Pump Wire Harness, Starter Relay Wrist Pin PRINTED IN U.S.A /AP094

58 Specifications Deutz TD 3.6 L4 Use these torque values when tightening hardware excluding: lock nuts, thread-forming, self-tapping, and metal screws unless otherwise specified. Grade 8.8 Grade 0.9 Grade.9 Metric Coarse-Pitch Thread All torque values are in Foot-Pounds and Newton Meters (Nm). DIN 9, DIN 93, DIN 933, etc... DIN M5 4. (5.5) 6 (8) 7 (0) 4 (5) 5 (7) M6 7 (0) 0 (4) 3 (7) 6.3 (8.5) 9 () M8 8 ( 5) 6 (35) 3 (4) 5 (0) (30) M0 33 (45) 48 (65) 59 (80) 30 (40) 44 (59) M 64 (87) 8 (0) 08 (47) 5 (69) 74 (00) M4 00 (35) 33 (80) 70 (30) 8 (0) 8 (60) M6 55 (0) 03 (75) 58 (350) 5 (70) 84 (50) M8 07 (80) 30 (40) 354 (480) 8 (45) 54 (345) M0 30 (40) 40 (570) 509 (690) 5 (340) 36 (490) M 406 (550) 575 (780) 686 (930) 339 (460) 487 (660) M4 54 (70) 738 (000) 878 (90) 435 (590) 60 (840) M7 767 (040) 09 (480) 305 (770) 64 (870) 9 (50) M (40) 48 (00) 770 (400) 885 (00) 54 (700) Metric Fine-Pitch Thread All torque values are in Foot-Pounds and Newton Meters (Nm). DIN 9, DIN 93, DIN 933, etc... DIN M8X.0 8 (5) 7 (37) 3 (43) 6 () 4 (3) M0X.0 37 (50) 55 (75) 65 (88) 3 (43) 48 (65) M0X.5 36 (49) 5 (7) 6 (83) 3 (4) 46 (6) MX.5 64 (87) 96 (30) (50) 55 (75) 8 (0) MX.5 6 (83) 9 (5) 07 (45) 53 (7) 77 (05) M4X.5 00 (35) 48 (00) 73 (35) 89 (0) 9 (75) M6X.5 55 (0) 9 (30) 66 (360) 33 (80) 95 (65) M8X.5 3 (35) 33 (450) 39 (530) 99 (70) 84 (385) M0X.5 35 (440) 465 (630) 538 (730) 77 (375) 39 (530) MX (590) 60 (840) 73 (980) 369 (500) 54 (70) M4X (740) 789 (070) 9 (50) 465 (630) 664 (900) M7X.0 8 (00) 43 (550) 38 (800) 679 (90) 959 (300) M30X.0 06 (500) 586 (50) 844 (500) 959 (300) 364 (850) /AP PRINTED IN U.S.A.

59 Deutz TD 3.6 L4 Specifications Use these torque values when tightening hardware excluding: lock nuts, thread-forming, self-tapping, and metal screws unless otherwise specified. NOTE: All torque values are in foot-pounds (lb.-ft.), except those marked with asterisks (*), which are in inch-pounds (lb.-in.). To convert lb.-ft. to Newton Meter (Nm) metric torque values, multiply the lb.-ft. value by.355, or for inch pounds, multiply the lb.-in. value by 0.3. Unified National Thread Grade Dry Oiled Grade 5 Dry Oiled Grade 8 Dry Oiled 8-3 9* 4* 30* * 4* 3* * 5* 3* 3* 43* 3* 0-4 7* * 43* 3* 60* 45* 0-3 3* 3* 49* 36* 68* 5* /4-0 66* 50* 9 75* 9 /4-8 76* 56* 0 86* 4 0 5/ /6/ / / / / / / / / / / / / / / * Value shown is in pound-force inch (lb.-in.) inch pounds. PRINTED IN U.S.A /AP094

PARTS MANUAL SUPPORTED BY HUSTLER TURF EQUIPMENT AND EXCEL INDUSTRIES, INC.

SHIBAURA DIESEL ENGINE MODEL: N843 and N843L PARTS MANUAL SUPPORTED BY HUSTLER TURF EQUIPMENT AND EXCEL INDUSTRIES, INC. Table of Contents Chapter 1 General Information....................................