Deutz D2008, D2009 Service Manual

Workshop Manual

D 2008/2009

3422 0312 en

Workshop Manual

D 2008/2009

Note for printers Color: white

Paper: Ikonofix 250 g/m2

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.

	DEUTZ AG
	Service Information Systems
	Ottostraße 1
	51149 Köln
	Deutschland
	Tel.: [phone]
	Fax: [phone]
	Web: http://www.deutz.com
	Printed in Germany
	All rights reserved
The engine company.	1st Edition, 02/2006
	Order No. 0312 3422 en

D 2008/2009

Table of contents

1Foreword

2General

3User notes

3.1General

3.2Specifications

3.2.1Safety regulations and rules for the prevention of accidents

3.2.2Disposal regulations

3.3Operating manual and workshop manual

3.4Job cards

3.5Explanation of symbols

4Technical data

4.1Testing and setting data

4.2Tightening specifications

5Job card overview

5.1Sorted numerically

6Job cards

7Commercial tools

8Special tools

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Table of contents

D 2008/2009

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DEUTZ engines

Foreword

1

1 Foreword

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Foreword

DEUTZ engines

1

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DEUTZ engines

Foreword

zRead and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.

zThis engine is built exclusively for purpose according 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.

zUse 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 this and are aware of the risks involved.

zMake sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents.

zFailure 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.

zPrerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and their perfect condition.

zEngine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury when handled incorrectly.

zThe pertinent rules for the prevention of accidents and other generally recognised health and safety regulations must be observed.

zMaximum economy, reliability and long life is only guaranteed when using DEUTZ original parts.

z Repair of the engine must correspond to its use	1
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!

zThe 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.

zThe engine is equipped according to the installation case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily.

zWe have done our best to highlight the differences 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

1

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DEUTZ engines

General

2

2 General

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General

DEUTZ engines

2

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DEUTZ engines

DEUTZ engines are the product of years of research 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

2

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General

DEUTZ engines

2

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User notes

3

3 User notes

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User notes

3

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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

3.2.1Accident 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 3 mode and the operating and auxiliary materials be-

ing 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:

zfor the personnel:

–Only briefed personnel may operate or maintain 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 engine 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.

zfor the engine room:

–Ensure adequate ventilation (do not cover air shafts).

–Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly.

–Only store inflammable materials in the machine room if they are essential for operation of the system.

–Smoking and naked flames are prohibited in the machine room.

zfor 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-

3 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.

3.3Operation 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:

zW 02-04-01: Documentation type

–WWorkshop manual

–I...... Repair instructions

zW 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

zW 02-04-01: Component grouping

zW 02-04-01: Consecutive number

3.4.2 Structure of a job card

1

2

3

Triebwerk
W 02-04-01	4	3

5

16

6

15

6 7

14

8

13

12	8

11

10

9

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

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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 conver-
	sion of the turbocharger can lead to serious
	injury.
3	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

Technical data

4

4 Technical data

4.1Testing and setting data

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Technical data
Testing and setting data	D 2008/2009

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001-5987

ID no.		Name	Information	Series			Value	Unit
General engine data
P00 01		Length of engine		D 2008	L3		538	mm
					L4		627	mm
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	L3		155	kg
					L4		189	kg
P00 10		Working procedure		D 2008			four-stroke diesel	-
							naturally aspirated
P00 20		Combustion system		D 2008			engine with indirect	-
							injection
P00 30		Total volume		D 2008	L3		1170	cm3
					L4		1560	cm3
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	L3		1-2-3	-
					L4		1-3-4-2	-
Power train
P02 34		Permissible axial backlash of crankshaft		D 2008			0,13 - 0,56	mm
P02 71		Piston, diameter, standard		D 2008			74 01	mm

2008/2009 D

setting and Testing	Technical
data	data

4

									4
©
		ID no.	Name	Information	Series			Value			Unit
02/2006
		P02 75	Piston projection		D 2008			0,65 - 0,9			mm
		P02 78	Piston pin bore		D 2008			25 0,0030,008			mm
		P02 79	Piston height		D 2008			66,15			mm
		P02 95	Position of the piston ring joints		D 2008			120			°
								(offset to each other)
		Control system
		P04 35	Camshaft, axial backlash	Nominal	D 2008			0,07 - 0,29			mm
		Fuel system
		P07 31	Start of pumping (static)	Part number: 0411 4267,	D 2008	L3		110			°
				at 1,500 rpm (fixed speed)
		P07 31	Start of pumping (static)	Part number: 0411 4267,	D 2008	L3		110			°
				at 1,800 rpm (fixed speed)
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		P07 31	Start of pumping (static)	Part number: 0411 4267,	D 2008	L3		not available			°
				at 3,000 rpm (variable speed)
		P07 31	Start of pumping (static)	Part number: 0411 4276,	D 2008	L4		110			°
				at 1500 rpm (fixed speed)
		P07 31	Start of pumping (static)	Part number: 0411 4276,	D 2008	L4		110,5			°
				at 1,800 rpm (fixed speed)
		P07 31	Start of pumping (static)	Part number: 0411 4276,	D 2008	L4		not available			°
				at 300 rpm (variable speed)
		P07 52	Nozzle opening pressure fuel injector		D 2008			150 - 158			bar
		Cooling system
		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
001-5987		P12 11	Tension of the V-belt	First assembly	D 2008			450			N

setting and Testing	data Technical
data

2008/2009 D

D 2008/2009

Unit

N

Value	2020
	300

Series	D 2008
Information	Check after 15 minutes running under load

Name	Tension of the V-belt
ID no.	P12 21

Technical data Testing and setting data

4

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02/2006 ©
		ID no.	Name	Information	Series			Value			Unit
		General engine data
		P00 01	Length of engine		D 2009	L3		597			mm
						L4		680			mm
		P00 01	Length of engine		TD 2009	L4		696			mm
		P00 02	Width of engine		D 2009	L3		490			mm
					TD 2009	L4		518			mm
					D 2009	L3		612			mm
		P00 03	Height of engine		D 2009	L4		612			mm
					TD 2009	L4		633			mm
		P00 04	Engine weight according to DIN 70020-A approx.		D 2009	L3		180			kg
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						L4		205			kg
		P00 10	Working procedure		D/TD 2009			four-stroke diesel			-
		P00 20	Combustion system		D/TD 2009			Direct injection			-
		P00 30	Total volume		D 2009	L3		1718			cm3
					D/TD 2009	L4		2289			cm3
		P00 31	Bore		D/TD 2009			90			mm
		P00 32	Stroke		D/TD 2009			90			mm
		P00 40	Compression ratio		D 2009			19,6 : 1			-
					TD 2009			18 : 1			-
		P00 50	Direction of rotation	looking onto the flywheel	D/TD 2009			left			-
		P00 71	Ignition sequence		D 2009	L3		1-2-3			-
					D/TD 2009	L4		1-3-4-2			-
001-5987
		P00 60	Max. declared speed		D/TD 2009			3000			[rpm]

setting and Testing	data Technical
data

2008/2009 D

02/2006 ©

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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 0,50,5	mm
P02 75		Piston projection		D/TD 2009			0,70 - 1,0	mm
P02 78		Piston pin bore		D/TD 2009			28 0,0300,008	mm
P02 79		Piston height		D/TD 2009			71,65	mm
P02 95		Position of the piston ring joints		D/TD 2009			120 (offset to each	°
							other)
Control system
P04 35		Camshaft, axial backlash	Nominal	D/TD 2009			0,07 - 0,29	mm
Fuel system
P07 31		Start of pumping (static)	Part number: 0411 2478,	D 2009	L3		90	°
			at 1500 rpm (fixed speed)
P07 31		Start of pumping (static)	Part number: 0411 2476,	D 2009	L3		90	°
			at 1,800 rpm (fixed speed)
P07 31		Start of pumping (static)	Part number: 0411 4099,	D 2009	L3		89	°
			at 3,000 rpm (variable speed)
P07 31		Start of pumping (static)	Part number: 0411 4088,	D 2009	L4		105	°
			at 1,500 rpm (fixed speed)
P07 31		Start of pumping (static)	Part number: 0411 4085,	D 2009	L4		105	°
			at 1,800 rpm (fixed speed)
P07 31		Start of pumping (static)	Part number: 0411 4421,	D 2009	L4		100	°
			at 3000 rpm (fixed speed)
P07 31		Start of pumping (static)	Part number: 0411 2192,	D 2009	L4		102,5	°
			at 3,000 rpm (variable speed)

2008/2009 D

setting and Testing	Technical
data	data

4

								4
©
	ID no.	Name	Information	Series			Value			Unit
02/2006
	P07 31	Start of pumping (static)	Part number: 0411 4102,	TD 2009	L4		103,5			°
			at 1500 rpm (fixed speed)
	P07 31	Start of pumping (static)	Part number: 0411 4104,	TD 2009	L4		not available			°
			at 1,800 rpm (fixed speed)
	P07 31	Start of pumping (static)	Part number: 0411 4074,	TD 2009	L4		102,5			°
			at 3,000 rpm (variable speed)
	P07 52	Nozzle opening pressure fuel injector		D/TD 2009			250 - 258			bar
	Cooling system
	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
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	P12 21	Tension of the V-belt	Check after 15 minutes running under	D/TD 2009			300 2020			N
			load

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setting and Testing	data Technical
data

2008/2009 D

	Technical data
D 2008/2009	Tightening specifications

4

4.2Tightening specifications

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Technical data
Tightening specifications	D 2008/2009

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©
02/2006		ID no.	Name	Screw type	Notes / Remarks	Series			Pre-clam-	Post-clam-
									ping value	ping value
		A00 003	Engine mounting on crankcase	M10 x 1.5		D/TD 2008/			41 Nm
						2009
						D/TD 2008/				35 Nm
		A01 001	Cylinder head on crankcase	M12 x 1.75	Use new screws				35 Nm	60°
						2009
										60°
		A01 002	Rocker arm bracket on cylinder head	M8 x 1.25		D/TD 2008/			27 Nm
						2009
		A01 004	Cylinder head cover on cylinder head	M8 x 1.25		D/TD 2008/			27 Nm
						2009
		A01 092	Lifting log on cylinder head	M8 x 1.25		D/TD 2008/			41 Nm
						2009
		A02 010	Main bearing housing on crankcase	M8 x 1.25		D/TD 2008/			15 Nm	27 Nm
						2009
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		A02 012	Main bearing housing on crankcase	M10 x 1.5	Locking screw	D/TD 2008/			41 Nm
						2009
		A02 013	Main bearing housing (assembly)	M8 x 1.25	Hexagon socket	D/TD 2008/			21 Nm
						2009
		A02 020	Big end bearing cap on connecting rod	M8 x 1.0		D/TD 2008/			35 Nm
						2009
		A03 020	Gear case cover on crankcase	M8 x 1.25		D/TD 2008/			27 Nm
						2009
		A03 030	Lubricating oil pan on crankcase	M8 x 1.25		D/TD 2008/			32 Nm
						2009
		A03 031	Drain plug on lubricating oil pan	M14 x 1.5		D/TD 2008/			39 Nm
						2009
		A03 080	Connection housing to crankcase	M14 x 1.5		D/TD 2008/			81 Nm
						2009
001-5987

2008/2009 D

data Technical

specifications Tightening

4