Workshop Manual
TCD 2013 4V - Industry
0312 3132
Hinweis für Druckerei
Farbe: weiß
Papier: Ikonofix 250 g/Qm
en
Workshop Manual
TCD 2013 4V - Industry
Workshop Manual
TCD 2013 4V
Industry
0312 3132 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
Deutz-Mülheimer-Straße 147-149
51063 Köln
Germany
Tel.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5358
Web: http://www.deutz.com
Printed in Germany
All rights reserved
2nd Edition, 11/2006
Order No. 0312 3132 en
TCD 2013 4V
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 alphabetically
5.2 Sorted numerically
5.3 Job card references
6Job cards
7Commercial tools
8 Special tools
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Table of contents
TCD 2013 4V
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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, maintena nce 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
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DEUTZ engines
2 General
General
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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 co nditio ns,
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
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General
DEUTZ engines
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3 User notes
User notes
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User notes
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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 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
"6.2 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.
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User 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
3
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.
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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 instal la tion 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.
3
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
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User 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.
3
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 remed ies
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
– W.... Workshop 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
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User notes
3.4.2 Structure of a job card
1 2 3
16
15
14
13
12
11
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
10
Triebwerk
W 02-04-01
9
3.5 Explanation of symbols
Danger!
of death or to health. Must be observed!
4
575
6
6
8
8
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, environ mental 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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User notes
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