Deutz D 2011 L03 i, D 2011 L02 i, TD 2011 L04 w, D 2011 L04 i, D 2011 L03 o Operation Manual

...
5 (2)
Operation Manual
D/TD/TCD 2011
OBJ_DOKU-15294-001.fm Seite 1 Donnerstag, 28. Februar 2008 9:58 09
Notes
2 © 2008
Notes
z
z
Use for the intended purpose also includes ob­servance of the operating, maintenance and re­pair conditions specified by the manufacturer. The engine should only be operated, serviced and repaired by personnel trained in its use and the hazards involved.
The pertinent rules for the prevention of acci­dents and other generally recognised safety and industrial medicine rules must be observed.
z
When the engine is running there is a danger of injury caused by:
– rotating and hot components – on motors with external ignition (high electri-
cal voltage). Contact must be avoided!
z
Unauthorised engine modifications will invalidate any liability claims against the manufacturer for resultant damage.
z
Equally, manipulations to the injection and con­trol system can affect the engine's performance and the exhaust characteristics. Adherence to legislation on pollution can no longer be guaran­teed under such conditions.
z
Do not change the cooling air feed area to the blower of fan. An unobstructed cooling air supply must be guaranteed.
The manufacturer will accept no liability for dam­age resulting from this.
z
When carrying out maintenance work on the en-
gine, the use of DEUTZ original parts is pre­scribed. These are specially designed for your engine and guarantee perfect operation.
Non-compliance results in the expiry of the war­ranty! Maintenance/cleaning work on the engine may only be carried out when the engine is not run­ning and has cooled down.
When doing this, make sure that the electrical system is switched off (remove ignition key).
The specifications for accident prevention with electrical systems (e.g. VDE-0100/-0101/-0104/­0105 Electrical protective measures against dan­gerous contact voltages) must be observed. Cover all electrical components tightly when cleaning with liquids.
z
Do not work on the fuel system while the engine is running -
Danger to life!
Wait for the pressure to drop after the engine has come to a standstill (in engines with DEUTZ Common Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure
- Danger to life!
During the first trial run do not stand in the dan­ger area of the engine.
Danger due to high pressure in case of leaks -
Danger to life!
– In case of leaks immediately contact work-
shop.
– When working on the fuel system, make sure
that the engine is not started inadvertently during repairs -
Danger to life!
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Foreword
© 2008 3
Dear customer,
Congratulations on the purchase of your DEUTZ en­gine.
DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. Consequently, a wide range of variants is offered to meet the require­ments of specific cases.
The engine is equipped accordingly for the particular installation situation, i.e. not all the components de­scribed in the operating manual are installed in your engine.
We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions applicable to your engine more quickly and easily.
Please make sure that this operating manual is avail­able to everyone involved in the operation, mainte­nance and repair of the engine and that they have understood the contents.
If you have any queries, please contact us, we'll be happy to advise you.
Sincerely, DEUTZ AG
Engine serial number
Please enter the engine serial number here. This will simplify the handling of customer service, repair and spare parts queries.
Notes
We reserve the right to make technical changes to the descriptions and data in this operating manual in the interest of further development of the engines.
This document may only be reprinted and repro­duced, even in part, with our express permission.
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Contents
4 © 2008
Notes . . . . . . . . . . . . . . . . . . . . . . . 2
Foreword. . . . . . . . . . . . . . . . . . . . . 3
1 General. . . . . . . . . . . . . . . . . . . . 5
2 Engine description . . . . . . . . . . . . . 7
Type . . . . . . . . . . . . . . . . . . . . . 7
Engine illustrations . . . . . . . . . . . . . . 9
Lubricating oil schematic . . . . . . . . . . . 13
Fuel schematic . . . . . . . . . . . . . . . . 18
Coolant schematic . . . . . . . . . . . . . . 19
Exhaust gas recirculation . . . . . . . . . . . 21
Electrics/Electronics . . . . . . . . . . . . . 23
3 Operation . . . . . . . . . . . . . . . . . . 24
Ambient conditions . . . . . . . . . . . . . . 24
Initial commissioning . . . . . . . . . . . . . 25
Start procedure . . . . . . . . . . . . . . . . 27
Operation monitoring . . . . . . . . . . . . . 28
Stop procedure . . . . . . . . . . . . . . . . 30
4 Operating media. . . . . . . . . . . . . . . 31
Lubricating oil . . . . . . . . . . . . . . . . . 31
Fuel . . . . . . . . . . . . . . . . . . . . . . 33
Coolant . . . . . . . . . . . . . . . . . . . . 34
5 Maintenance . . . . . . . . . . . . . . . . . 35
Maintenance schedule . . . . . . . . . . . . 35
6 Care and maintenance work . . . . . . . . 38
Lubricating oil system. . . . . . . . . . . . . 38
Fuel system. . . . . . . . . . . . . . . . . . 40
Cooling system . . . . . . . . . . . . . . . . 44
Engine cleaning. . . . . . . . . . . . . . . . 46
Suction system . . . . . . . . . . . . . . . . 47
Belt drives . . . . . . . . . . . . . . . . . . 49
Setting work . . . . . . . . . . . . . . . . . 51
Electrical system . . . . . . . . . . . . . . . 53
7 Faults. . . . . . . . . . . . . . . . . . . . . 55
Fault table . . . . . . . . . . . . . . . . . . 55
Engine management . . . . . . . . . . . . . 60
8 Transport and storage . . . . . . . . . . . 62
Transport . . . . . . . . . . . . . . . . . . . 62
Protecting the engine against corrosion . . . 63
9 Technical data . . . . . . . . . . . . . . . . 65
Engine and setting data . . . . . . . . . . . 65
Tools . . . . . . . . . . . . . . . . . . . . . 70
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General
© 2008 5
1
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re­search and development. Profound know-how com­bined with high quality requirements are the guarantee for the production of engines with a long life, high reliability levels and low fuel consumption. Obviously the high requirements for the protection of the environment are also met.
Safety precautions when the engine is running
Maintenance work or repairs may only be performed on the shut-down engine. Make sure that the engine cannot be started inadvertently -
Danger of acci-
dent!
After repair work: Check that all guards have been replaced and that all tools have been removed from the engine.
Observe industrial safety regulations when running the engine in an enclosed space or underground.
When working on the running engine, work clothing must be close fitting.
Never fill the fuel tank while the engine is running.
Service and Maintenance
Service and maintenance are also decisive for whether the engine satisfactorily meets the set de­mands. Recommended service intervals must there­fore be observed and service and maintenance work must be carried out conscientiously.
Special care should be taken under abnormally de­manding operating conditions.
Original DEUTZ parts
Original DEUTZ parts are subject to the same strict quality demands as the DEUTZ engines. Further de-
velopments for improving the engines are also intro­duced in the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured ac­cording to the state-of-the-art can guarantee perfect functioning and high reliability.
DEUTZ Xchange components
DEUTZ replacement parts are a low-cost alternative. Of course, the quality standards here are just as high as for new parts. DEUTZ replacement parts are equal to the original DEUTZ parts in function and re­liability.
Asbestos
The gaskets used in this engine contain no asbestos. Please use the appropriate original DEUTZ parts for maintenance and repair work.
Service
We want to preserve the high performance of our en­gines, and with it the confidence and satisfaction of our customers. We are therefore represented world­wide by a network of service branches.
The DEUTZ name does not merely stand for engines that are the products of extensive development work, DEUTZ also stands for complete service pack­ages that ensure optimum operation of our engines, and for customer services operations that you can count on.
Please contact your DEUTZ-partner in case of mal­functions and sare parts inquiries. Our specially trained personnel will ensure fast, professional re­pairs using original DEUTZ spare parts in case of damage.
The DEUTZ home page gives you a continuously up­to-date overview of the service partners in your vicin-
ity with notes on product responsibilities and servic­es. Or you can use another fast, convenient way via the Internet under www.deutzshop.de. The DEUTZ P@rts Online parts catalogue gives you a direct con­tact to your nearest local service partner.
Masthead
DEUTZ AG Ottostraße 1 51149 Köln Germany Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-5850 www.deutz.com E-Mail: info@deutz.com
California Proposition 65 Warning
Diesel engines and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
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General
6 © 2008
1
Danger
Caution
Notes
This symbol is used for all safety instruc­tions which, if not observed, present a di­rect danger to life and limb for the person involved. Observe these carefully. The at­tention of operating personnel should be drawn to these safety instructions. Further­more, the legislation for "general regula­tions for safety and the prevention of accidents" must be observed.
This symbol indicates a danger to the part and engine. The relevant instructions must be observed, failure to do so can lead to de­struction of the part and the engine.
This symbol accompanies notes of a gen­eral kind.
OBJ_DOKU-15294-001.fm Seite 6 Donnerstag, 28. Februar 2008 9:58 09
Type Engine description
© 2008 7
2
Engine type designation
This manual covers the following engine types
D 2011 L02 i D 2011 L02 o D 2011 L04 w D 2011 L03 i D 2011 L03 o TD 2011 L04 w D 2011 L04 i D 2011 L04 o TCD 2011 L04 w
TD 2011 L04 i TD 2011 L04 o
TCD
T Exhaust gas turbocharger C Charge air cooler DDiesel
2011
2011 Series
L02/L03/L04
L in series 02 No. of cylinders 03 No. of cylinders 04 No. of cylinders
i/o/w
i oil-cooled (integrated cooler) o oil-cooled w water-cooled
Rating plate
The type (A), engine number (B) and performance data are stamped on the rating plate.
The engine type and number must be stated when purchasing spare parts.
DEUTZ AG
DEUTZ AG
MADE IN GERMANY
MADE IN GERMANY
Mot.-Typ
Mot.-Nr.
R
B
A
Location of the rating plate
The rating plate (C) is fixed to the cylinder head cov­er or the crankcase.
C
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Engine description Type
8 © 2008
2
Engine serial number
The engine number (D) is stamped onto the crank­case (arrow) and onto the rating plate.
XXXXXXX
D
Cylinder numbering
Cylinder arrangement The cylinders are counted consecutively starting
from flywheel (1).
Direction of rotation
Looking onto the flywheel. rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
1
left
right
Volume blocking
Unauthorised settings on the regulator will exclude the manufacturer from all liability for resulting dam­age. The blocking screws are adequately protected against this:
z
With locking varnish in version: torque adjust­ment
z
With protective plastic capsule in version: with­out torque adjustment.
OBJ_DOKU-15294-001.fm Seite 8 Donnerstag, 28. Februar 2008 9:58 09
Engine illustrations Engine description
© 2008 9
2
?
?
?
?
?
?
1
2
3
4
5
6
16
15
17
18
14
13
12
11
10
9
8
7
D 2011 L03 i
View from right (example) 1 Cooling fan (with integrated generator)
2 Tension pulley 3 Toothed belt cover 4 V-belt (fan) 5 Stop lever 6 Speed adjusting lever 7 Lubricating oil drain plug 8 Lubricating oil sump 9 Lubricating oil dipstick 10 Connection possibility for cab heating 11 Exchangeable fuel filter 12 Lube oil replacement filter 13 Fuel supply pump with integrated screen filter 14 Lubricating oil filling 15 Removable air guidance cowling (access to fuel
injectors) 16 Lube oil cooler 17 Cylinder head cover 18 Air intake pipe
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Engine description Engine illustrations
10 © 2008
2
1
2
5
4
3
D 2011 L03 i
View from left (example) 1 Fuel return to fuel tank
2 Flywheel 3Starter 4 Exhaust manifold line 5 Air intake pipe
OBJ_DOKU-15294-001.fm Seite 10 Donnerstag, 28. Februar 2008 9:58 09
Engine illustrations Engine description
© 2008 11
2
2
1
3
4
20
19
21
18
17
16
15
14
13
12
11
10
7
8
6
5
9
TCD 2011 L04 w
View from right (example) 1 Crankcase breather
2 Coolant outlet to the cooler 3 Coolant pump 4 Generator 5 V-belts 6 Toothed belt cover 7 Lubricating oil filling 8 Lubricating oil sump 9 Lubricating oil pump 10 Lubricating oil drain plug 11 Speed adjusting lever 12 Lubricating oil dipstick 13 Fuel supply pump with integrated screen filter 14 Exchangeable fuel filter 15 Lube oil replacement filter 16 Stop lever 17 Lube oil cooler 18 Coolant inlet 19 Injection pump 20 Coolant return to thermostat 21 Cylinder head cover
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Engine description Engine illustrations
12 © 2008
2
6
7
8
5
4
3
1
2
TCD 2011 L04 w
View from left (example) 1 Fuel return to fuel tank
2 Connections charge air cooler 3 Flywheel 4Starter 5 Coolant inlet 6 Turbocharger 7 Exhaust manifold line 8 Charge air line
OBJ_DOKU-15294-001.fm Seite 12 Donnerstag, 28. Februar 2008 9:58 09
Lubricating oil schematic Engine description
© 2008 13
2
3bar
7bar
T
oil
< 63°C
T
oil
>
63°C
T
oil
<
95°C
T
oil
> 95°C
1,7 bar
1bar
0,3 bar
9
8
15
12
13
14
10
1
3
2
16
11
6
7
4
5
TD 2011 L04 i
(example) 1 Lubricating oil sump
2 Lubricating oil pump 3 Pressure limiting valve 4 Cylinder (lubricating oil-cooled)
The lubricating oil is used first to cool the engine. 5 Cylinder head 6 Lubricating oil return from the cylinders 7 Lubricating oil collection pipe to the thermostat 8 Thermostat
(engine cold) lubricating oil flow directly to the lu-
bricating oil filter
(engine warm) lubricating oil flow through the lu-
bricating oil cooler 9 Lube oil cooler 10 Lubricating oil filter 11 Main lube oil channel 12 Turbocharger 13 Pressure holding valve 14 Connection possibility for cab heating
The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
by authorised qualified personnel. 15 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil. 16 Hydraulic tappets
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Engine description Lubricating oil schematic
14 © 2008
2
12/2004
3bar
1,7 bar
1bar
0,3 bar
bar
T
oil
<63°C
T
oil
>63°C
T
oil
<95°C
T
oil
> 95°C
7
1
15
11
8
5
4
12
14
9
6
10
16
2
3
7
17
13
D 2011 L04 i
Exhaust gas recirculation (example) 1 Lubricating oil sump
2 Lubricating oil pump 3 Pressure limiting valve 4 Cylinder (lubricating oil-cooled)
The lubricating oil is used first to cool the engine. 5 Cylinder head 6 Cooling valve housing (exhaust gas recircula-
tion) 7 Lubricating oil return from the cylinders 8 Rocker arm 9 Lubricating oil collection pipe to the thermostat 10 Thermostat
(engine cold) lubricating oil flow directly to the lu-
bricating oil filter
(engine warm) lubricating oil flow through the lu-
bricating oil cooler 11 Lube oil cooler 12 Lubricating oil filter 13 Main lube oil channel 14 Pressure holding valve 15 Connection possibility for cab heating
The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
by authorised qualified personnel. 16 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
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Lubricating oil schematic Engine description
© 2008 15
2
17 Hydraulic tappets
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Engine description Lubricating oil schematic
16 © 2008
2
3bar
T
oil
>63°C
T
oil
<63°C
7bar
10
12
4
6
13
1
9
8
5
11
7
3
2
TD 2011 L04 w
(example) 1 Lubricating oil sump
2 Lubricating oil pump 3 Pressure limiting valve 4 Lube oil cooler 5 Lubricating oil filter 6 Main lube oil channel 7 Lubricating oil pipe to the turbocharger 8 Turbocharger 9 Lubricating oil return line from the exhaust turbo-
charger 10 Rocker arm 11 Pressure holding valve 12 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil. 13 Hydraulic tappets
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Lubricating oil schematic Engine description
© 2008 17
2
3bar
7bar
Toil
>63°C
Toil
<63°C
4
6
11
8
10
1
5
9
3
2
7
D 2011 w
Exhaust gas recirculation (example) 1 Lubricating oil sump
2 Lubricating oil pump 3 Pressure limiting valve 4 Lube oil cooler 5 Lubricating oil filter 6 Cooling valve housing (exhaust gas recircula-
tion) 7 Main lube oil channel 8 Rocker arm 9 Pressure holding valve 10 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil. 11 Hydraulic tappets
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Engine description Fuel schematic
18 © 2008
2
1
2
5
7
8
9
11
10
6
34
12
Fuel schematic (example)
1 Fuel line from tank to fuel pump 2 Fuel supply pump with integrated screen filter 3 Fuel pipe from the supply pump to the fuel
change filter 4 Exchangeable fuel filter 5 Fuel pipe from the filter to the fuel injector 6 Fuel pipe to fuel injector 7 Injection pump 8 Injection line to injection valve 9 Injection valve 10 Return collection pipe 11 Fuel return to fuel tank 12 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
OBJ_DOKU-15294-001.fm Seite 18 Donnerstag, 28. Februar 2008 9:58 09
Coolant schematic Engine description
© 2008 19
2
1
7
10
6
4
3
9
8
5
2
OBJ_DOKU-15294-001.fm Seite 19 Donnerstag, 28. Februar 2008 9:58 09
Engine description Coolant schematic
20 © 2008
2
Coolant schematic (example)
D/TD/TCD 2011
w
1 Cooler 2 Coolant inlet 3 Coolant pump 4 Coolant supply for engine cooling 5 Cylinder pipe/head cooling 6 Coolant return to thermostat 7 Thermostat
(engine cold) coolant directly for engine cooling (engine warm) coolant flow through the cooler
8 Coolant partial flow to the lubricating oil cooler 9 Lube oil cooler 10 Coolant return to thermostat
OBJ_DOKU-15294-001.fm Seite 20 Donnerstag, 28. Februar 2008 9:58 09
Exhaust gas recirculation Engine description
© 2008 21
2
3
2
4
7
8
6
3
5
1
External exhaust gas recirculation
D 2011 L04 i D 2011 L04 o D 2011 L04 w (example) 1 Exhaust gas partial flow
(not connected) 2 Exhaust gas partial flow
(connected) 3 Valve housing 4 Actuator
(electrically actuated) 5 Distributor pipe 6 Electrical connection 7Switch
The switch is connected internally with the con-
trol linkage. The voltage to the actuator is inter-
rupted at load peaks. 8 Fuel filter console
The switch housing is designed to be safe from ma­nipulation.
Only have work performed on the components by authorised qualified personnel.
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Engine description Exhaust gas recirculation
22 © 2008
2
[
m
m
]
[°]
1
1
2
3
Internal exhaust gas recirculation
Engines with turbocharger TD/TCD 2011 1 Additional cams for exhaust gas recirculation
Inlet valve opens briefly during the outlet cycle
and emits an exhaust gas partial flow to the suc-
tion system.
This partial volume is sucked back in in the next
suction cycle. 2Outlet valve 3 Inlet valve
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Electrics/Electronics Engine description
© 2008 23
2
Information about the engine electronics
This engine can be equipped optionally with an elec­tronic DEUTZ control unit.
The equipping of the respective system depends on the desired scope of function and the planned type of engine application.
The resultant wiring with pin assignment can be seen in the appropriate wiring diagram.
The installation regulations of the DEUTZ AG must also be taken into account.
Precautions
The connections of the control units are only dust and water proof when the mating plugs are plugged (protection class IP69K)! The control units must be protected against spray water and moisture until plugging in the mating plugs! Reverse polarity can lead to failure of the control unit. To avoid damaging the control units, all the connections on the control unit must be dis­connected before electric welding work. Interventions in the electrical system con­trary to the DEUTZ regulations or by un­qualified personnel can permamently damage the engine electronics and have serious consequences which are not cov­ered by the manufacturer's guarantee.
Installation instructions
The control units are calibrated to the respective en­gine and identified by the engine number. Every en­gine may only be operated with the appropriate control unit.
Setpoint transmitters (pedal value transmitters) nec­essary for vehicle operation must be connected to the vehicle side cable harness and calibrated with the DEUTZ diagnostic program SERDIA (SERvice DIAgnosis). Wiring and cable assignment of the ve­hicle side cable harness must be taken from the con­nection diagram of the DEUTZ installation consulting.
It is strictly prohibited: a) to make changes or connections to the wiring of the electrical control devices and the data transmission cable (CAN lines). b) to switch control units. Diagnostic and maintenance work may only be carried out by authorised personnel using equipment approved by DEUTZ.
Supply voltage
DEUTZ diesel engines must be operated with a 12 V or 24 V supply. An adequate charging condition of the battery must be ensured. Interruption of the pow­er supply when the engine is running can lead to damage to the electrics/electronics. Failure of the supply voltage leads to engine standstill.
Voltages above 32 Volt will destroy the control unit.
Diagnostics
DEUTZ control units are equipped with self-diagno­sis. Active and passive error entries are saved in the error memory. Active errors are displayed by error lamp/diagnostic lamp (
60). The active errors can
be called by blink codes or by the DEUTZ diagnostic program SERDIA. Passive errors must be deleted by SERDIA.
z
with error lamp (optional).
z
via diagnostic socket (SERDIA).
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