Deutz D2008, D2009 Service Manual

Workshop Manual D 2008/2009

0312 3422

Note for printers Color: white Paper: Ikonofix 250 g/m

Workshop Manual D 2008/2009

Workshop Manual

D 2008/2009

0312 3422 en

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

The engine company.

DEUTZ AG Service Information Systems

Ottostraße 1 51149 Köln

Deutschland Tel.: +49 (0) 221-822-0

Fax: +49 (0) 221-822-5850

Web: http://www.deutz.com

D 2008/2009

1 Foreword

2 General

3 User notes

3.1 General

3.2 Specifications

3.2.1 Safety regulations and rules for the prevention of accidents

3.2.2 Disposal regulations

3.3 Operating manual and workshop manual

3.4 Job cards

3.5 Explanation of symbols

4 Technical data

4.1 Testing and setting data

4.2 Tightening specifications

Table of contents

5 Job card overview

5.1 Sorted numerically

6Job cards

7Commercial tools

8 Special tools

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Table of contents

D 2008/2009

2/2

DEUTZ engines

1 Foreword

Foreword

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Foreword

DEUTZ engines

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DEUTZ engines

Foreword

z Read and observe the information in this docu-

mentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.

z This engine is built exclusively for purpose ac-

cording to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk.

z Use for the intended purpose also includes ob-

servance 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 this and are aware of the risks involved.

z Make sure that this documentation is available to

everyone involved in the operation, maintenance and repair and that they have understood the contents.

z Failure to observe this documentation may lead

to malfunctions and engine damage as well as injury to persons for which the manufacturer will not accept any liability.

z Prerequisite for proper maintenance and repair is

the availability of all the necessary equipment, conventional and special tools and their perfect condition.

z Engine parts such as springs, clamps, elastic re-

taining rings etc. pose an increased risk of injury when handled incorrectly.

z The pertinent rules for the prevention of acci-

dents and other generally recognised health and safety regulations must be observed.

z Maximum economy, reliability and long life is only

guaranteed when using DEUTZ original parts.

z Repair of the engine must correspond to its use

for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void the warranty!

z The engines made by DEUTZ are developed for

a wide range of applications. A wide range of variants ensures that the respective special requirements are met.

z The engine is equipped according to the installa-

tion case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily.

z We have done our best to highlight the differenc-

es so that you can easily find the operating, maintenance and repair instructions relevant to your engine.

We are at your service for any questions you may have in this matter.

Your DEUTZ AG

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Foreword

DEUTZ engines

4/4

DEUTZ engines

2 General

General

1/4

General

DEUTZ engines

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DEUTZ engines

DEUTZ engines are the product of years of re-

search and development. The profound expertise gained through this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high reliability and low fuel consumption. It goes without saying that the high environmental protection requirements are also met.

Maintenance and care are the only way the engine can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the careful execution of maintenance and care work are therefore essential. Difficult operating conditions, deviating from normal operation, must be particularly heeded.

Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast and professional repairs using original DEUTZ spare parts in the event of damage. Original spare parts from DEUTZ AG are always manufactured according to the state of the art.

General

3/4

General

DEUTZ engines

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3 User notes

User notes

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User notes

2/6

User notes

3.1 General

The documentation of the workshop manual has been created based on the engine available at the time of going to press. There may be deviations in the descriptions, illustrations and parts due to further developments.

The maintenance work described in the operation manual and in the workshop manual must be carried out on schedule and completely. The maintenance personnel must have the necessary technical knowledge to perform the work. Safety and protection devices which are removed during maintenance work must be replaced again afterwards.

Caution!

The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.

Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.

The maintenance intervals and the work to be performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

3.2 Specifications

3.2.1 Accident prevention and safety regulations

The legally prescribed rules for the prevention of accidents must be observed. These are available from professional associations or from dealers. These are dependent on the application site, operating mode and the operating and auxiliary materials being used.

Special protection measures are specified depending on the work being carried out, and are identified in the job description.

Among other things it generally applies that:

z for the personnel:

– Only briefed personnel may operate or main-

tain the engine. Unauthorised persons are prohibited access to the machine room.

– Wear close-fitting clothing and ear protectors

in the machine room when the engine is in operation.

– Only deploy trained personnel to do repairs

and maintenance work.

– Do not work on the fuel system when the en-

gine is running. The fuel system is under high pressure - danger of death.

– Go to the workshop immediately in case of

leaks in the fuel system.

z for the engine room:

– Ensure adequate ventilation (do not cover air

shafts).

– Provide first aid kit and suitable fire extinguish-

ers. Check the filling and readiness for operation regularly.

– Only store inflammable materials in the ma-

chine room if they are essential for operation of the system.

– Smoking and naked flames are prohibited in

the machine room.

z for operation, maintenance and repairs on the

engine:

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

bleeded - see the operation manual, chapter "6.2 Fuel system“.

– Only start the engine when all the protective

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

– Cleaning, maintenance and repair work may

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

– Injection lines and high pressure pipes must

not be deformed.

– Damaged injection lines and high-pressure

pipes must be renewed.

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User notes

– Injection lines and high pressure fuel lines

must never be connected when the engine is running.

– Do not place hands near to a leak in the high

pressure fuel system.

– Also carefully check all high pressure compo-

nents visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel.

– Even if no leaks are discernible on the high

pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as protective glasses) when performing tests on the running engine and during the first trial run.

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

could cause severe injury.

– Smoking is strictly prohibited when working on

the fuel system.

– Do not work near to sparks and flames.

3.2.2 Disposal regulations

The work described in the operation manual and workshop manual necessitates renewal of parts and operating materials among other things. The renewed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this.

Disposal includes recycling and the scrapping of parts / operating materials, although recycling 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.

3.3 Operation manual and workshop

manual

To structure the information to suit the user, the service documentation is divided into operation manual and workshop manual.

The operation manual contains a general description and instructions for all other maintenance work.

It contains the following chapters:

1. Contents, General

2. Engine description

3. Operation

4. Operating media

5. Maintenance

6. Care and maintenance work

7. Faults, causes and remedies

8. Engine conservation

9. Technical data

10.Service

The workshop manual assumes knowledge of the contents of the operation manual. This applies especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

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User notes

3.4 Job cards

The job cards are divided in the workshop manual into "W" and "I" job cards. The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card. The "I" job card additionally documents the appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special conditions to perform these work procedures. Special tools and machine tools must be available, for example.

3.4.1 Numbering of job cards

The job card numbers follow the pattern W 02-04-

01. The individual parts of this pattern are explained

below:

z W 02-04-01: Documentation type

– WWorkshop manual

– I...... Repair instructions

z W 02-04-01: Maintenance group

– 00... General / interdisciplinary activities

– 01... Cylinder head

– 02... Drive system

– 03... Crankcase

– 04... Engine control system

– 05... Speed governing

– 06... Exhaust system / Charging

– 07... Fuel system

– 08 ... Lube oil system

– 09... Cooling system

– 10... Compressed air system

– 11... Monitoring system

– 12... Other components

– 13... Electrical system

z W 02-04-01: Component grouping

z W 02-04-01: Consecutive number

3.4.2 Structure of a job card

1 2 3

1. DEUTZ AG,

publisher of service documentation

2. Engine type (e.g. TCD 2013 4V)

3. Maintenance group

4. Job card number or topic

5. Title of job card

6. Reference to other job cards

7. Chapter

8. Graphic or photo

9. DEUTZ internal creation number

10.Page number

11.Date of issue of job card

12.Note

13.Danger / Important

14.Work sequence

15.Special tools; auxiliary materials

16.Conventional tools

Triebwerk

W 02-04-01

575

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User notes

3.5 Explanation of symbols

Danger!

of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury.

Caution!

Danger to the component/engine. Noncompliance can lead to destruction of the component/engine. Must be observed!

Note

General notes on assembly, environmental protection etc. No potential danger for man or machine.

Tool

Conventional and special tools required for the work.

Auxiliary materials

Working materials required in addition to the tools for performing the work (e.g. greases, oils, adhesives, sealants)

References

to important documents or job cards for the work process. For example: Job card W 04-05-05

Reference

to a document or a job card within the work process.

Test and setting data

The necessary values are specified here. If several values are necessary, a cross reference is given to the Test and Setting Values table. For example: ID no. P01 61 = valve clearance, inlet

Tightening specification

The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table. For example: ID no. A01 001 = cylinder head screws

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D 2008/2009

4 Technical data

4.1 Testing and setting data

Technical data

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Technical data Testing and setting data

D 2008/2009

2/14

D 2008/2009

Technical data

Testing and setting data

L3 538 mm

L4 627 mm

 1

 0

naturally aspirated

engine with indirect

injection

L3 155 kg

L4 189 kg

L3 1170 cm

L4 1560 cm

L3 1-2-3 -

L4 1-3-4-2 -

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P00 30 Total volume D 2008

P00 31 Bore D 2008 76 mm

P00 32 Stroke D 2008 86 mm

P00 40 Compression ratio D 2008 23,5 : 1 -

P00 50 Direction of rotation looking onto the flywheel D 2008 left -

P00 60 Max. declared speed D 2008 3000 [rpm]

P00 61 Min. idling speed D 2008 900 [rpm]

P00 71 Ignition sequence D 2008

Power train

P02 34 Permissible axial backlash of crankshaft D 2008 0,13 - 0,56 mm

P02 71 Piston, diameter, standard D 2008 74 mm

ID no. Name Information Series Value Unit

General engine data

P00 01 Length of engine D 2008

P00 02 Width of engine D 2008 480 mm

P00 03 Height of engine D 2008 620 mm

P00 04 Engine weight according to DIN 70020-A approx. D 2008

P00 10 Working procedure D 2008 four-stroke diesel -

P00 20 Combustion system D 2008

Technical data Testing and setting data

D 2008/2009

 0,008

 0,003

120

(offset to each other)

D 2008 L3 110 °

D 2008 L3 not available °

D 2008 L4 110 °

D 2008 L4 110,5 °

D 2008 L4 not available °

Part number: 0411 4267,

at 1,500 rpm (fixed speed)

Part number: 0411 4267,

at 1,800 rpm (fixed speed)

Part number: 0411 4267,

at 3,000 rpm (variable speed)

Part number: 0411 4276,

at 1500 rpm (fixed speed)

Part number: 0411 4276,

at 1,800 rpm (fixed speed)

Part number: 0411 4276,

at 300 rpm (variable speed)

P02 75 Piston projection D 2008 0,65 - 0,9 mm

P02 78 Piston pin bore D 2008 25 mm

P02 79 Piston height D 2008 66,15 mm

P02 95 Position of the piston ring joints D 2008

Control system

P04 35 Camshaft, axial backlash Nominal D 2008 0,07 - 0,29 mm

Fuel system

ID no. Name Information Series Value Unit

P07 31 Start of pumping (static)

Cooling system

P07 52 Nozzle opening pressure fuel injector D 2008 150 - 158 bar

P09 11 Coolant thermostat start of opening D 2008 86 - 90 °C

P09 13 Coolant thermostat, stroke distance D 2008 at least 8 mm

Other components

P12 11 Tension of the V-belt First assembly D 2008 450 N

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Technical data

D 2008/2009

20

20

Testing and setting data

D 2008 300 N

Check after 15 minutes running under

load

P12 21 Tension of the V-belt

ID no. Name Information Series Value Unit

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Technical data Testing and setting data

D 2008/2009

L3 180 kg

L3 597 mm

L4 680 mm

L4 205 kg

D 2009 L3 490 mm

TD 2009 L4 518 mm

D 2009 L3 612 mm

D 2009 L4 612 mm

TD 2009 L4 633 mm

D 2009 L3 1718 cm

D/TD 2009 L4 2289 cm

D 2009 19,6 : 1 -

TD 2009 18 : 1 -

D 2009 L3 1-2-3 -

D/TD 2009 L4 1-3-4-2 -

P00 10 Working procedure D/TD 2009 four-stroke diesel -

P00 20 Combustion system D/TD 2009 Direct injection -

P00 01 Length of engine TD 2009 L4 696 mm

ID no. Name Information Series Value Unit

General engine data

P00 01 Length of engine D 2009

P00 02 Width of engine

P00 03 Height of engine

P00 04 Engine weight according to DIN 70020-A approx. D 2009

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P00 30 Total volume

P00 31 Bore D/TD 2009 90 mm

P00 32 Stroke D/TD 2009 90 mm

P00 40 Compression ratio

P00 50 Direction of rotation looking onto the flywheel D/TD 2009 left -

P00 71 Ignition sequence

P00 60 Max. declared speed D/TD 2009 3000 [rpm]

D 2008/2009

Technical data

Testing and setting data

0,5

0,5

0,008

0,030

120 (offset to each

other)

D 2009 L3 90 °

D 2009 L3 89 °

D 2009 L4 105 °

D 2009 L4 100 °

D 2009 L4 102,5 °

ID no. Name Information Series Value Unit

P00 61 Min. idling speed D/TD 2009 900 [rpm]

Power train

P02 34 Permissible axial backlash of crankshaft D/TD 2009 0,13 - 0,56 mm

P02 71 Piston, diameter, standard D/TD 2009 88 mm

P02 75 Piston projection D/TD 2009 0,70 - 1,0 mm

P02 78 Piston pin bore D/TD 2009 28 mm

P02 79 Piston height D/TD 2009 71,65 mm

P02 95 Position of the piston ring joints D/TD 2009

Control system

P04 35 Camshaft, axial backlash Nominal D/TD 2009 0,07 - 0,29 mm

Fuel system

Part number: 0411 2478,

at 1500 rpm (fixed speed)

Part number: 0411 2476,

at 1,800 rpm (fixed speed)

Part number: 0411 4099,

at 3,000 rpm (variable speed)

P07 31 Start of pumping (static)

Part number: 0411 4088,

at 1,500 rpm (fixed speed)

Part number: 0411 4085,

at 1,800 rpm (fixed speed)

Part number: 0411 4421,

at 3000 rpm (fixed speed)

P07 31 Start of pumping (static)

Part number: 0411 2192,

at 3,000 rpm (variable speed)

P07 31 Start of pumping (static)

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Technical data Testing and setting data

20

20

D 2008/2009

TD 2009 L4 103,5 °

Part number: 0411 4102,

TD 2009 L4 not available °

at 1500 rpm (fixed speed)

Part number: 0411 4104,

TD 2009 L4 102,5 °

at 1,800 rpm (fixed speed)

Part number: 0411 4074,

at 3,000 rpm (variable speed)

D/TD 2009 300 N

Check after 15 minutes running under

load

P07 31 Start of pumping (static)

ID no. Name Information Series Value Unit

P07 31 Start of pumping (static)

Cooling system

P07 52 Nozzle opening pressure fuel injector D/TD 2009 250 - 258 bar

P09 11 Coolant thermostat start of opening D/TD 2009 86 - 90 °C

P09 13 Coolant thermostat stroke distance D/TD 2009 at least 8 mm

Other components

P12 11 Tension of the V-belt First assembly D/TD 2009 450 N

P12 21 Tension of the V-belt

8/14

D 2008/2009

4.2 Tightening specifications

Technical data

Tightening specifications

9/14

Technical data Tightening specifications

D 2008/2009

10/14

Post-clam-

ping value

Pre-clam-

ping value

41 Nm

D/TD 2008/

2009

D 2008/2009

35 Nm

60°

35 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

41 Nm

D/TD 2008/

2009

D/TD 2008/

15 Nm 27 Nm

2009

41 Nm

D/TD 2008/

2009

21 Nm

D/TD 2008/

2009

Technical data

Tightening specifications

35 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

32 Nm

D/TD 2008/

2009

39 Nm

D/TD 2008/

2009

81 Nm

D/TD 2008/

2009

ID no. Name Screw type Notes / Remarks Series

A00 003 Engine mounting on crankcase M10 x 1.5

A01 001 Cylinder head on crankcase M12 x 1.75 Use new screws

A01 002 Rocker arm bracket on cylinder head M8 x 1.25

A01 004 Cylinder head cover on cylinder head M8 x 1.25

A01 092 Lifting log on cylinder head M8 x 1.25

A02 010 Main bearing housing on crankcase M8 x 1.25

11/14

A02 012 Main bearing housing on crankcase M10 x 1.5 Locking screw

A02 013 Main bearing housing (assembly) M8 x 1.25 Hexagon socket

A02 020 Big end bearing cap on connecting rod M8 x 1.0

A03 020 Gear case cover on crankcase M8 x 1.25

A03 030 Lubricating oil pan on crankcase M8 x 1.25

A03 031 Drain plug on lubricating oil pan M14 x 1.5

A03 080 Connection housing to crankcase M14 x 1.5

+ 121 hidden pages