Deutz D 2011, TD 2011 Service Manual

Workshop Manual

competence level 2

D 2011

TD 2011

men

This doc

n e

wed with

yright prote

ut our

or a

ted

r e

lec e

tro

ment.

orm

0312 4232 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.

Regarding copyright questions and licensing agreements

please contact : VE-FL, Mr. Lippke Tel.: + 49 (0) 221 822-2599 EMail: lippke.d@deutz.com

Deutz AG Informations Systeme Vertrieb u. Service Ottostraße 1 D - 51149 Cologne Tel.: + 49 (0) 221-8 22-0 Fax: + 49 (0) 221-8 22-3525 http://www.deutz.com

DEUTZ engines Table of contents

1 Foreword

2 General

3 User notes

3.1 General

3.2 Specifications

3.3 Operating manual and workshop manual

3.4 Job cards

3.5 Explanation of symbols

5 Job card overview

5.1 Sorted alphabetically

5.2 Sorted numerically

6 Job cards

7 Commercial tools

8 Special tools

1/2

DEUTZ enginesTable of contents

2/2

DEUTZ engines Foreword

1 Foreword

1/4

DEUTZ enginesForeword

2/4

DEUTZ engines Foreword

● 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.

● 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.

● Use 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.

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

● 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.

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

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

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

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

● 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!

● 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.

● The 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.

● We 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

3/4

DEUTZ enginesForeword

4/4

DEUTZ engines General

2 General

1/4

DEUTZ enginesGeneral

2/4

DEUTZ engines General

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.

3/4

DEUTZ enginesGeneral

4/4

DEUTZ engines User notes

3 User notes

1/8

DEUTZ enginesUser notes

2/8

DEUTZ engines 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 pr otection devices which are removed during mainten ance 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: – Wait 30 seconds after switching off the engine

before working on the fuel sytem.

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

bleeded - see the operation manual, chapter "6 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.

3/8

DEUTZ enginesUser notes

– Damaged injection lines and high-pressure

pipes must be renewed.

– 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. – Never disconnect an injector when the engine

is running.

3.2.2 Cleanliness instructions and measures for handling the DEUTZ Common Rail System

The DEUTZ Common Rail system used in the DEUTZ engines consists of high-precision components which are exposed to extreme stress . Grea t attention must be paid to cleanliness when working on the fuel system due to the high precision technology.

Notes and measures to be observed before starting work on the fuel system

z The fuel system must be closed. Make a visual

inspection for leaks / damage to the fuel system.

z Clean the whole engine and engine room with the

system closed before starting work on the fuel system.

z The engine must be dry when you start working

on the fuel system.

z Blowing (dry) with compressed air is only permis-

sible with the fuel system closed.

z When using a steam jet, first cover up the control

unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet may not be pointed directly at them.

z Electrical plug connections must be plugged

when spraying.

z Remove loose parts (for example paint chips

from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

z Only work on the fuel system in a clean environ-

ment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may be kept or operated in the same room.

z Air currents which kick up dust, such as those

caused by brake repairs or the starting of engines, should be avoided.

z For work such as removal and installation on de-

fective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out.

z No general machine tools may be operated in

this room.

z Regular cleaning of the workshop area is manda-

tory. Draughts, ventilation systems and heating fans should be minimised.

z Areas of the engine room from which particles of

dirt could be loosened (for example the bottom part of the tipped driver cab) must be covered with fresh clean film.

z Working materials and tools must be cleaned be-

fore work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

Notes and measures to be observed during work on the fuel system or with the fuel s ystem ope n.

z Only work in clean overalls. z Only lint-free cleaning cloths may be used for

work on the fuel system.

z Remove loose parts (for example paint chips

from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

z Working materials and tools must be cleaned be-

fore work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

z Do not use used cleaning fluid or test fluid for

cleaning.

z Compressed air must not be used for cleaning on

the open fuel system.

z Work on removed components may only be per-

formed at a suitably equipped workbench.

4/8

DEUTZ engines User notes

z When removing and installing components, no

materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

z Removed parts may only be rubbed down with

clean, lint-free cloths. No dirt particles may be rubbed into the components.

z Openings on the components and on the engine

must be closed immediately with suitable stoppers/caps.

z The stoppers/caps may only be removed imme-

diately before installing.

z Store stoppers/caps free from dust and dirt in the

original packaging and dispose of after using once.

z Only remove new parts from the original packag-

ing just before installation.

z Removed components must be kept in new, seal-

able bags or - if available - in the packaging of the new parts.

z Always use the original packaging of the new part

to send back the removed components.

Notes and measures for the vehicle workshop area

z For work such as removal and installation on de-

fective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which gener al vehicle repairs such as brake repairs are carried out.

z The workshop floor is sealed or tiled. z No welding gear, grinders, general machine

tools, brakes or performance test benc he s ma y be operated in this room.

z Regular cleaning of the workshop area is manda-

tory. Draughts, ventilation systems and heating fans should be minimised.

Notes and measures for workbench and tools in the vehicle hall

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 mu st ob serve on his own responsibility.

z A special workbench must be set up for work on

removed components.

z Clean the removal and installation tools regularly

and keep them in a closed tool cabinet.

z Remove loose parts (for example paint chips

from assembly work) with an industrial vacuum cleaner or other suction device.

z Working materials and tools must be cleaned be-

fore work. Only use tools without damage to the chrome plating or tools which are not chr o me plated.

3.2.3 Disposal regulations

The work described in the operation manual and workshop manual necessitates renewal of parts and

5/8

DEUTZ enginesUser notes

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 wo rk.

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.

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 – 02Drive 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

6/8

DEUTZ engines User notes

Triebwerk

W 02-04-01

1 2 3

575

3.4.2 Structure of a job card

1. DEUTZ AG,

publisher of service documentation

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

3. Maintenance gr oup

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 crea tion 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

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

7/8

DEUTZ enginesUser notes

8/8

D 2011 Job card overview TD 2011 Sorted alphabetically

5 Job card overview

5.1 Sorted alphabetically

1/8

D 2011Job card overview

TD 2011Sorted alphabetically

2/8

D 2011 Job card overview TD 2011 Sorted alphabetically

Activity Job card Maintenance group

Calculating the thickness of shim W 07-06-03 Fuel system

Check start of injection W 07-06-01 Fuel system

Checking the compression pressure W 00-02-06 General

Dismantling and assembling the cooling blower W 09-11-02 Cooling system Installing and removing charge air pressure-de-

pendent full load stop Mounting engine on assembly block and demoun-

ting

Remove and install the cooling blower W 09-11-01 Cooling system

Removing and install the charge air line W 06-02-03 Exhaust system/Charging

Removing and installing air duct W 09-11-03 Cooling system

Removing and installing fuel pipes W 07-10-06 Fuel system

Removing and installing rear cover W 03-09-01 Crankcase

Removing and installing temperature transmitter W 08-11-11 Lube oil system

Removing and installing the air bearing W 09-13-02 Cooling system

Removing and installing the connection housing W 03-09-04 Crankcase

Removing and installing the control line W 08-16-01 Lube oil system

Removing and installing the crankcase bleeding W 03-01-11 Crankcase

Removing and installing the exhaust damper W 06-01-05 Exhaust system/Charging

Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation)

W 07-08-02 Fuel system

W 00-05-01 General

W 06-09-08 Exhaust system/Charging

Removing and installing the exhaust gas return pipe W 06-09-07 Exhaust system/Charging Removing and installing the exhaust gas return val-

Removing and installing the exhaust line W 06-01-05 Exhaust system/Charging

Removing and installing the flywheel W 12-06-01 Other components

Removing and installing the fuel filter console W 07-10-08 Fuel system

Removing and installing the fuel injector pump

Removing and installing the fuel injectors W 07-07-

Removing and installing the fuel supply pump W 07-11-01 Fuel system

Removing and installing the generator W 13-02-03 Electrical system

Removing and installing the glow plug W 13-06-02 Electrical system

Removing and installing the heating plugs W 13-06-01 Electrical system

Removing and installing the hydraulic pump W 12-08-02 Other components

Removing and installing the impulse transmitter W 05-07-01 Speed control

Removing and installing the intake manifold W 06-07-03 Exhaust system/Charging

W 06-09-06 Exhaust system/Charging

W 07-04-01 Fuel sys

01 Fuel system

tem

3/8

D 2011Job card overview

TD 2011Sorted alphabetically

Activity Job card Maintenance group

Removing and installing the lifting magnet (charge air pressure-dependent full load stop)

Removing and installing the lifting magnet (Engine shutdown)

Removing and installing the lifting magnet (Start amount release)

Removing and installing the lubricating oil cooler W 08-08-02 Lube oil system

Removing and installing the lubricating oil pan

(metal sheet lubricating oil pan)

Removing and installing the lubricating oil pump W 08-04-05 Lube oil system

Removing and installing the magnet clip (Exhaust gas recirculation)

Removing and installing the oil filter console W 08-11-07 Lube oil system

Removing and installing the oil pressure regulating valve

Removing and installing the oil pressure switch W 08-11-08 Lube oil system

Removing and installing the oil suction pipe W 08-04-06 Lube oil system

Removing and installing the rocker arm and rocker arm bracket

W 07-08-01 Fuel system

W 11-00-03 Monitoring system

W 07-02-07 Fuel system

W 08-04-07 Lube oil system

W 06-09-10 Exhaust system/Charging

W 08-11-02 Lube oil system

W 01-02-02 Cylinder head

Removing and installing the sensor (Exhaust gas recirculation)

Removing and installing the starter W 13-03-02 Electrical system

Removing and installing the thermostat (Lubricating oil cooler)

Removing and installing the toothed belt wheel W 04-04-15 Engine control

Removing and installing the turbocharger W 06-06-04 Exhaust system/Charging

Removing and installing the V-belt pulley W 12-01-04 Other components Renew camshaft sealing ring (opposite side to fly-

wheel)

Renew toothed belt and tensioning pulley W 04-04-12 Engine control

Renew toothed belt and tensioning pulley (Hydraulic pump)

Renew V-belts, check V-belt tension W 1

Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system

Renewing the crankshaft sealing ring (opposite side to flywheel)

W 06-09-09 Exhaust system/Charging

W 08-11-12 Lube oil system

W 04-03-01 Engine control

W 12-08-03 Other components

2-02-01 Other

W 02-02-04 Drive system

components

Renewing the injection lines W 07-03-01 Fuel system

Setting valve clearance W 01-01-01 Cylinder head

Steuerzeiten prüfen W 04-04-11 Engine control

4/8

D 2011 Job card overview TD 2011 Sorted numerically

5.2 Sorted numerically

5/8

D 2011Job card overview

TD 2011Sorted numerically

6/8

D 2011 Job card overview TD 2011 Sorted numerically

Job card Activity Maintenance group

W 00-02-06 Checking the compression pressure General

W 00-05-01

W 01-01-01 Setting valve clearance Cylinder head

W 01-02-02

W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system

W 02-02-04

W 03-01-11 Removing and installing the crankcase bleeding Crankcase

W 03-09-01 Removing and installing rear cover Crankcase

W 03-09-04 Removing and installing the connection housing Crankcase

W 04-03-01

W 04-04-11 Steuerzeiten prüfen Engine control

W 04-04-12 Renew toothed belt and tensioning pulley Engine control

W 04-04-15 Removing and installing the toothed belt wheel Engine control

W 05-07-01 Removing and installing the impulse transmitter Speed control

Mounting engine on assembly block and demounting

Removing and installing the rocker arm and rocker arm bracket

Renewing the crankshaft sealing ring (opposite side to flywheel)

Renew camshaft sealing ring (opposite side to flywheel)

General

Cylinder head

Drive system

Engine control

W 06-01-05 Removing and installing the exhaust line Exhaust system/Charging

W 06-01-05 Removing and installing the exhaust damper Exhaust system/Charging

W 06-02-03 Removing and install the charge air line Exhaust system/Charging

W 06-06-04 Removing and installing the turbocharger Exhaust system/Charging

W 06-07-03 Removing and installing the intake manifold Exhaust system/Charging

W 06-09-06

W 06-09-07 Removing and installing the exhaust gas return pipe Exhaust system/Charging

W 06-09-08

W 06-09-09

W 06-09-10

W 07-02-07

W 07-03-01 Renewing the injection lines Fuel system

W 07-04-01 Removing and installing the fuel injector pump Fuel system

Removing and installing the exhaust gas return valve

Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation)

Removing and installing the sensor (Exhaust gas recirculation)

Removing and installing the magnet clip (Exhaust gas recirculation)

Removing and installing the lifting magnet (Start

mount

release)

Exhaust system/Charging

Fuel system

W 07-06-01 Check start of injection Fuel system

W 07-06-03 Calculating the thickness of shim Fuel system

W 07-07-01 Removing and installing the fuel injectors Fuel system

7/8

D 2011Job card overview

TD 2011Sorted numerically

Job card Activity Maintenance group

W 07-08-01

W 07-08-02

W 07-10-06 Removing and installing fuel pipes Fuel system

W 07-10-08 Removing and installing the fuel filter console Fuel system

W 07-11-01 Removing and installing the fuel supply pump Fuel system

W 08-04-05 Removing and installing the lubricating oil pump Lube oil system

W 08-04-06 Removing and installing the oil suction pipe Lube oil system

W 08-04-07

W 08-08-02 Removing and installing the lubricating oil cooler Lube oil system

W 08-11-02

W 08-11-07 Removing and installing the oil filter console Lube oil system

W 08-11-08 Removing and installing the oil pressure switch Lube oil system

Removing and installing the lifting magnet (charge air pressure-dependent full load stop)

Installing and removing charge air pressure-dependent full load stop

Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)

Removing and installing the oil pressure regulating valve

Fuel system

Lube oil system

W 08-11-11 Removing and installing temperature transmitter Lube oil system

W 08-11-12

W 08-16-01 Removing and installing the control line Lube oil system

W 09-11-01 Remove and install the cooling blower Cooling system

W 09-11-02 Dismantling and assembling the cooling blower Cooling system

W 09-11-03 Removing and installing air duct Cooling system

W 09-13-02 Removing and installing the air bearing Cooling system

W 11-00-03

W 12-01-04 Removing and installing the V-belt pulley Other components

W 12-02-01 Renew V-belts, check V-belt tension Other components

W 12-06-01 Removing and installing the flywheel Other components

W 12-08-02 Removing and installing the hydraulic pump Other components

W 12-08-03

W 13-02-03 Removing and installing the generator Electrical system

Removing and installing the thermostat (Lubricating oil cooler)

Removing and installing the lifting magnet (Engine shutdown)

Renew toothed belt and tensioning pulley (Hydraulic pump)

Lube oil system

Monitoring system

Other components

Elect

W 13-03-02 Removing and installing the starter

W 13-03-02 Removing and installing the starter Electrical system

W 13-06-01 Removing and installing the heating plugs Electrical system

W 13-06-02 Removing and installing the glow plug Electrical system

8/8

rical system

DEUTZ engines Job cards

6 Job cards

1/2

DEUTZ enginesJob cards

2/2

+ 358 hidden pages