Deutz D 2011, TD 2011 Service Manual

Workshop Manual

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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

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DEUTZ enginesTable of contents

2/2

DEUTZ engines Foreword

1 Foreword

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DEUTZ enginesForeword

1

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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

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DEUTZ enginesForeword

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DEUTZ engines General

2 General

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DEUTZ enginesGeneral

2

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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.

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DEUTZ enginesGeneral

2

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DEUTZ engines User notes

3 User notes

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DEUTZ enginesUser notes

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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.

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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

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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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.

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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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.

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 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

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DEUTZ engines User notes

Triebwerk

W 02-04-01

6

16

12

4

6

1 2 3

8

10

11

575

9

13

14

15

8

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

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DEUTZ enginesUser notes

3

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D 2011 Job card overview TD 2011 Sorted alphabetically

5 Job card overview

5.1 Sorted alphabetically

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D 2011Job card overview

TD 2011Sorted alphabetically

5

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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

5

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

ve

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

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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

5

(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

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D 2011 Job card overview TD 2011 Sorted numerically

5.2 Sorted numerically

5

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D 2011Job card overview

TD 2011Sorted numerically

5

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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

5

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

a

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

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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

5

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

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rical system

DEUTZ engines Job cards

6 Job cards

6

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DEUTZ enginesJob cards

6

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D 2011 General

1

2

TD 2011 W 00-02-06

Checking the compression pressure

Standard tools: – Compression pressure

tester 8005

Special tools: – Connector 100120

– W 01-01-01 – W 07-07-01

Attention!

Pay attention to utmost cleanliness when working on the fuel system. Remove residue paint and particles of dirt before removing. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations. After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system“.

6

Checking the compression pressure

● Set valve clearance.

 W 01-01-01

● Removing fuel injectors.

 W 07-07-01

● Mount sealing ring (1).

Use sealing ring (1) for fuel injector.

● Insert connector (2).

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D 2011General

1

2

1

TD 2011W 00-02-06

● Mount clamping shoe (1).

● Tighten screw (2).

 21 Nm

6

● Connect adapter (1) to connector.

● Mount the compression tester on the adapter.

● Turn over engine with starter.

 25 - 30 bar (2500 - 3000 kPa)

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D 2011 General

No.

Kompression in bar Compression value in bar Pression en bar

Dat. _________

DBGM Made in Germany

M

OTOMETER

10 15 20 25 30 35 40

1 2 3 4 5 6 7 8

Zyl.

1

TD 2011 W 00-02-06

The measured compression pressure depends on the starting speed during the measuring process and the altitude of the engine installation site. Therefore, limit values cannot be determined exactly. The compression pressure measurement is only recommended as a reference measurement of all cylinders of an engine to each other. If more than 15% deviation has been determined, the cause should be determined by disassembling the cylinder unit concerned.

6

● Remove the compression pressure tester.

● Remove the compression pressure tester and adapter (1).

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D 2011General

1

TD 2011W 00-02-06

● Unscrew screw (1).

6

● Remove connector (1).

● Remove sealing ring.

● Install fuel injectors.

 W 07-07-01

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D 2011 General TD 2011 W 00-02-06

Technical Data

Testing and setting data

ID no. Name Additional information Value

P00 51 Compression pressure

Tightening specifications

ID no. Name Screw type Notes / Remark Value A07 001 Fuel injector on cylinder head 21 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

25 - 30 bar (2500 - 3000 kPa)

6

5/6

D 2011General

TD 2011W 00-02-06

6

6/6

D 2011 General

1

TD 2011 W 00-05-01

Mounting engine on assembly block and demounting

Standard tools: – Lifting gear – Suspension ropes – Eyelet bolts

Special tools: – Assembly block 6067 – Supporting bracket 6067/114 – Clamping bracket 6067/115

Mounting engine on assembly block

● Remove starter.

 W 13-03-02

● Screw in eyelet bolts (1).

– W 13-03-02

Danger!

When using hoists (workshop crane) the safety regulations for handling hoists must be observed. It is not permitted to stay under moving loads.

Different customer scopes are not taken into account in the repair sequence shown here, accessories which deviate from the standard equipment are not shown.

6

● Hang engine on workshop crane.

– D 2011 L02

 approx. 169 - 175 kg

– D 2011 L03

 approx. 210 -217 kg

– D 2011 L04

 approx. 253 - 261 kg

– TD 2011 L04

 approx. 255 - 258 kg

1/6

D 2011General

2

4

1

3

2

1

2

TD 2011W 00-05-01

● Unscrew screws (1).

● Remove all mounting feet.

– TD 2011

● Unscrew screw (2).

● Remove holder (3).

● Remove oil return pipe (4).

6

● Mount clamping holder (1).

● Tighten screws (2).

 90 Nm

● Align engine on engine block.

● Mount retainer plate (1).

● Tighten screws (2) and lock nuts.

 90 Nm

2/6

D 2011 General

1

2

TD 2011 W 00-05-01

● Unhook engine.

● Unscrew eyelet bolts (1).

6

Demounting engine from assembly block

● Screw in eyelet bolts (1).

● Hang engine on workshop crane.

– D 2011 L02

 approx. 169 - 175 kg

– D 2011 L03

 approx. 210 -217 kg

– D 2011 L04

 approx. 253 - 261 kg

– TD 2011 L04

 approx. 255 - 258 kg

● Loosen lock nuts.

● Unscrew screws (2).

● Remove retainer plate (1).

3/6

D 2011General

2

1

3

1

4

2

TD 2011W 00-05-01

Danger!

Lower engine with workshop crane.

● Unscrew screws (2).

● Remove clamping bracket (1).

6

– TD 2011

● Insert new O-ring (1).

● Lightly oil new O-ring (1).

– TD 2011

● Mount oil return pipe (1).

Attention!

Install tension-free.

● Mount holder (2).

● Tighten screw (3).

 8.5 Nm

– D 2011, TD 2011

● Install all mounting feet.

● Tighten screws (4).

 200 Nm

4/6

D 2011 General

1

TD 2011 W 00-05-01

Danger!

Put the engine down on a secure surface.

● Unhook the engine from the workshop crane.

● Unscrew eyelet bolts (1).

● Install starter.

 W 13-03-02

6

5/6

D 2011General

TD 2011W 00-05-01

Technical Data

Testing and setting data

ID no. Name Additional information Value D2011L02

P00 04 Engine weight according to DIN 70020-A

D2011L03

P00 04 Engine weight according to DIN 70020-A

D2011L04

P00 04 Engine weight according to DIN 70020-A

TD 2011 L04

6

P00 04 Engine weight according to DIN 70020-A

Tightening specifications

approx. 169 -

175 kg

approx. 210 217 kg

approx. 253 -

261 kg

approx. 255 -

258 kg

ID no. Name Screw type Notes / Remark Value A00 001 Clamping bracket on crankcase 90 Nm

A00 002

A00 003

TD 2011

A08 049 Holder oil return line on crankcase

Clamping bracket on adapter for assembly block

Mounting foot/engine mounting on crankcase

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

M14x55-12.9 M14x100-12.9

Torx, M6x14-8.8

90 Nm

200 Nm

8.5 Nm

6/6

D 2011 Cylinder head

2

1

TD 2011 W 01-01-01

Setting valve clearance

Standard tools: – Feeler gauges

● Unscrew all screws (1).

● Remove cylinder head cowling (2).

● Remove gasket.

Attention!

In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap.

Allow the engine to cool down for at least 30 minutes before setting the valve clearance. Engine oil temperature < 80 °C

The following work procedure describes the setting of the valve clearance on an inlet valve. The procedure is the same for the setting on an outlet valve, taking into consideration the setting dimension.

6

Setting engine to valve overlap

● Turn crankshaft in the direction of the engine (arrow).

● Turn over crankshaft until the valve overlap is achieved on cylinder 1.

1/6

D 2011Cylinder head

INEX EX IN

2

1

TD 2011W 01-01-01

Arrangement of the inlet and exhaust valves. IN = inlet valve EX = exhaust valve

Valve overlap means: The inlet valve starts opening,exhaust valve closes.

Attention!

In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an additional cam on the camshaft. This is not to be confused with the valve overlap.

6

● Select feeler gauge.

● Check the setting on the appropriate valve.

The feeler gauge must pass between the rocker arm's sliding surface and the valve without too much resistance.

Setting valve clearance

● Loosen lock nut (1).

● Hold adjusting screw (2).

● Set valve clearance.

If there is not enough valve clearance, unscrew setting screw (2).

If there is too much valve clearance, turn in setting screw (2).

–Inlet

 0.3 mm

–Outlet

 0.5 mm

2/6

D 2011 Cylinder head

1

2

1

TD 2011 W 01-01-01

● Check the valve clearance with feeler gauge (1).

6

● Hold adjusting screw (2).

● Tighten lock nut (1).

 20 Nm

Do not turn the setting screw when tightening the locking nut.

● Check the valve clearance again with feeler gauge.

3/6

Valve clearance setting schematic

1

– D 2011

According to the order given below, the setting of the valve clearance is possible in two turns of the crankshaft (each 360°).

Crankshaft position 1

● Turn over crankshaft until the valve overlap is achieved on cylinder 1.

● Set black marked valves.

D 2011Cylinder head

TD 2011W 01-01-01

6

Crankshaft position 2

● Turn the crankshaft one turn (360°).

● Set black marked valves.

– TD 2011

Valves Cylinders overlap 1 3 4 2 set to 4 2 1 3

Valve overlap: Outlet valve is not yet closed, inlet valve begins to open.

When the outlet valve is fully open, the inlet valve opens briefly approx. 2 mm. This is not the valve overlap!

● Clean sealing surfaces.

● Mount new gasket.

Note installation position: The bar (1) must face the front cover.

4/6

D 2011 Cylinder head

1

TD 2011 W 01-01-01

● Mount cylinder head cover.

● Oil the screws lightly.

● Tighten all screws (1) alternately.

 8.5 Nm

6

5/6

D 2011Cylinder head

TD 2011W 01-01-01

Technical Data

Testing and setting data

ID no. Name Additional information Value D2011L02 P00 71 Ignition sequence 1-2 D2011L03 P00 71 Ignition sequence 1-2-3 D2011L04 P00 71 Ignition sequence 1-3-4-2 D 2011, TD 2011 P01 61 Valve clearance (inlet) 0.3 mm P01 62 Valve clearance (outlet) 0.5 mm

6

Tightening specifications

ID no. Name Screw type Notes / Remark Value A01 003 Locking nut, valve adjuster 20 Nm A01 004 Cylinder head cover on cylinder head 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6/6

D 2011 Cylinder head

2

1

2

TD 2011 W 01-02-02

Removing and installing the rocker arm and rocker arm bracket

Standard tools: – Torx tool set 8189

Removing the rocker arm and rocker arm bracket

● Unscrew all screws (1).

● Remove cylinder head cowling (2).

● Remove gasket.

– W 01-01-01

6

● Unscrew screws (1).

Loosen screws evenly to avoid tension on the rocker arm brackets.

● Remove rocker arm bracket (2).

Lay out components in the order in which they should be installed.

Note order of cylinders.

1/4

D 2011Cylinder head

1

3

1

4

2

TD 2011W 01-02-02

● Remove push rods (1).

Lay out components in the order in which they should be installed.

● Visually inspect the components.

6

Installing the rocker arm and rocker arm bracket

● Insert stop rods (1).

Note the assignment of the stop rods.

The stop rod must be seated with the ball head in the ladle of the tappet.

● Loosen lock nut (1).

● Unscrew setting screws (2).

● Mount rocker arm bracket (3).

● Position rocker arm.

The ball heads (4) must be seated in the ladles of the stop rods.

The rocker arm (arrow) must sit on the valve stem.

2/4

D 2011 Cylinder head

1

TD 2011 W 01-02-02

● Lightly oil screws (1).

● Tighten screws .

 21 Nm

Attention!

Makes sure that the stop rods are not under stress due to valve overlap when fastening the screws.

● Set valve clearance.

 W 01-01-01

6

● Clean sealing surfaces.

● Mount new gasket.

Note installation position: The bar (1) must face the front cover.

● Mount cylinder head cover.

● Oil the screws lightly.

● Tighten all screws (1) alternately.

 8.5 Nm

3/4

D 2011Cylinder head

TD 2011W 01-02-02

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value A01 002 Rocker arm bracket on cylinder head 21 Nm A01 004 Cylinder head cover on cylinder head 8.5 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6

4/4

D 2011 Drive system

1

TD 2011 W 02-02-02

Renewing the crankshaft sealing ring (flywheel side)

Standard tools: – Pricker 8198 – Assembly lever 9017

Special tools: – Assembly tool 142680

– Self-tapping screw – Washer

Removing the crankshaft sealing ring

● Remove flywheel.

 W 12-06-01

● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention!

Do not damage the rear cover and crankshaft!

– W 12-06-01

6

● Screw in a self-tapping screw (1) with washer.

1/4

D 2011Drive system

2

1

TD 2011W 02-02-02

● Pull out the crankshaft sealing ring with assembly lever.

● Visually inspect the crankshaft sealing ring running surface.

6

Installing the crankshaft sealing ring

● Mount guide sleeve (1).

● Tighten screws (2).

The bores in the guide sleeve must match the threaded holes in the crankshaft flange.

● Place the crankshaft sealing ring carefully on the peripheral surface.

Do not oil waxed crankshaft sealing rings.

The sealing lip faces the crankcase.

2/4

D 2011 Drive system

2

1

3

1

TD 2011 W 02-02-02

● Mount assembly sleeve (1).

● Press on the crankshaft sealing ring to the stop.

● Plug in the bearing (2).

● Screw on nut (3).

6

● Tighten nut to the stop of the assembly sleeve (1).

The installation depth is determined by the assembly tool.

● Remove assembly tool.

● Install flywheel.

 W 12-06-01

3/4

D 2011Drive system

TD 2011W 02-02-02

6

4/4

D 2011 Drive system

1

TD 2011 W 02-02-04

Renewing the crankshaft sealing ring (opposite side to flywheel)

Standard tools: – Pricker 8198 – Assembly lever 9017

Special tools: – Assembly tool 142690

– Self-tapping screw – Washer

Removing the crankshaft sealing ring

● Remove toothed belt wheel.

 W 04-04-15

● Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

Attention!

Do not damage the front cover or crankshaft.

– W 04-04-15

6

● Screw in a self-tapping screw (1) with washer.

1/4

D 2011Drive system

TD 2011W 02-02-04

● Pull out the crankshaft sealing ring with assembly lever.

● Visually inspect the crankshaft sealing ring running surface.

6

● Visually inspect all running surfaces.

Installing the crankshaft sealing ring

● Place new crankshaft sealing ring on assembly tool.

Do not oil waxed crankshaft sealing rings.

The sealing lip faces the crankcase.

2/4

D 2011 Drive system

1

TD 2011 W 02-02-04

● Mount assembly tool (1).

● Tighten screw until it reaches the assembly tool (1).

The installation depth is determined by the assembly tool.

● Unscrew screw.

● Remove assembly tool.

● Install toothed belt wheel.

 W 04-04-15

6

3/4

D 2011Drive system

TD 2011W 02-02-04

6

4/4

D 2011 Crankcase

1

2

1

TD 2011 W 03-01-11

Removing and installing the crankcase bleeding

Standard tools

Special tools: – Disassembly tool 110901

6

Removing the crankcase bleeding

● Unscrew screw (1).

● Remove crankcase bleeding (2).

● Remove the O-ring (1) with the disassembly tool.

● Visually inspect the components.

1/6

D 2011Crankcase

1

2

1

2

TD 2011W 03-01-11

– TD 2011

● Unscrew screws (1).

● Remove gasket (2).

6

● Loosen hose clip (1) with clamping tongs.

● Pull off hose clip (1) in the direction of the arrow.

● Pull out the pipe (2) in the direction of the arrow.

● Clean sealing surfaces.

2/6

D 2011 Crankcase

2

1

2

1

TD 2011 W 03-01-11

Install crankcase bleeding

● Push on the pipe (1) in the direction of the arrow.

● Position the hose clip (2) with clamping tongs.

6

● Fix new gasket (1) to the crankcase with a little grease.

● Position pipe (1).

● Tighten screws (2).

 8.5 Nm

Attention!

Install tension-free.

3/6

D 2011Crankcase

1

2

TD 2011W 03-01-11

– D 2011, TD 2011

● Clean sealing surfaces.

● Insert new O-ring (1).

6

● Mount crankcase vent (2).

Ensure that the installation location is free from faults.

The crankcase bleeding must fit evenly.

● Tighten screw (1).

 8.5 Nm

4/6

D 2011 Crankcase TD 2011 W 03-01-11

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

Crankcase bleeding on front cover /

A03 060

TD 2011 L04

A03 062

on cylinder head cover / on cylinder head

Crankcase breather, pipe to cylinder head

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

M6x30-8.8 8.5 Nm

8.5 Nm

6

5/6

D 2011Crankcase

TD 2011W 03-01-11

6

6/6

D 2011 Crankcase

1

2

1

TD 2011 W 03-09-01

Removing and installing rear cover

Standard tools

– Packing compound

DEUTZ DW 67

Removing rear cover

● Remove connection housing.

 W 03-09-04

● Remove lubricating oil pan.

 W 08-04-07

– W 02-02-02 – W 03-09-04 – W 08-04-07

6

● Unscrew all screws (1).

● Remove rear cover 2.

● Knock out crankshaft sealing ring (1).

Attention!

Do not damage the sealing surfaces.

● Visually inspect the components.

1/4

D 2011Crankcase

1

2

3

4

5

6

7

8

TD 2011W 03-09-01

Installing rear cover

● Clean sealing surfaces.

● Apply packing compound evenly to the sealing surface.

Sealing cord strength approx. 0.5 -

0.6 mm.

6

● Mount rear cover.

● Oil the screws lightly.

● Fasten all screws (1).

● Align front cover flush with the oil tray sealing surface.

● Tighten the screws according to the tightening sequence.

 21 Nm

2/4

D 2011 Crankcase

TD 2011 W 03-09-01

● Renew crankshaft sealing ring (flywheel side).

 W 02-02-02

● Install lubricating oil pan.

 W 08-04-07

● Install connection housing.

 W 03-09-04

6

3/4

D 2011Crankcase

TD 2011W 03-09-01

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A03 010 Rear cover on crankcase

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Observe tightening sequence

21 Nm

6

4/4

D 2011 Crankcase

1

TD 2011 W 03-09-04

Removing and installing the connection housing

Standard tools – W 12-06-01

6

Removing the connection housing

● Remove flywheel.

 W 12-06-01

● Unscrew all screws (1).

● Remove connection housing.

● Visually inspect the components.

1/4

D 2011Crankcase

1

TD 2011W 03-09-04

Installing the connection housing

● Clean contact surfaces.

● Make sure the clamping bushings (arrows) are in place.

● Drive in clamping sleeves in the crankcase as far as they will go.

6

● Mount connection housing.

● Centre connection housing over the clamping bushings.

● Tighten all screws (1) alternately.

 Technical Data

2/4

● Install flywheel.

 W 12-06-01

D 2011 Crankcase TD 2011 W 03-09-04

6

3/4

D 2011Crankcase

TD 2011W 03-09-04

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

M12x20 M12x30

A03 081

A03 082 Connection housing to crankcase

6

A03 082

A03 082 Connection housing to crankcase

A03 082

Connection housing/connection ring to crankcase

M12x35 M12x55 M12x70 M12x75 M12x95

M8x10 M8x30 M8x50

M10x40 M10x30 M10x25

Cylinder head screws M10x40

M14x55 180 Nm

106 Nm

22 Nm

45 Nm

60 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

4/4

D 2011 Engine control

1

2

TD 2011 W 04-03-01

Renew camshaft sealing ring (opposite side to flywheel)

Standard tools: – Pricker 8198 – Assembly lever 9017

Special tools: – Assembly tool 142050 – Counter support 144130

– Self-tapping screw – Washer

Remove camshaft sealing ring

● Remove toothed belt wheel (1).

 W 04-04-15

– W 04-04-15

6

● Position holder.

● Unscrew screw (1).

● Remove toothed belt wheel (2).

1/4

D 2011Engine control

1

TD 2011W 04-03-01

Attention!

Do not damage front cover and camshaft!

● Make a hole of approx. 3mm in the camshaft sealing ring with a pricker.

6

● Screw in a self-tapping screw (1) with washer.

● Pull out camshaft sealing ring with assembly lever.

● Visually inspect the components.

2/4

D 2011 Engine control

1

2

1

TD 2011 W 04-03-01

● Visually inspect all running surfaces.

6

Install camshaft sealing ring

● Mount new camshaft sealing ring (1) on assembly tool (2).

Do not oil waxed crankshaft sealing rings.

The sealing lip faces the crankcase.

● Carefully insert camshaft sealing ring.

● Fasten screw (1).

3/4

D 2011Engine control

1

2

1

TD 2011W 04-03-01

● Tighten screw until it reaches the assembly tool (1).

The installation depth is determined by the assembly tool.

● Unscrew screw.

● Remove assembly tool.

6

All connecting surfaces must be clean and free of oil.

● Mount toothed belt wheel (2).

● Position holder.

● Turn in new screw (1).

● Install toothed belt wheel (1).

 W 04-04-15

4/4

D 2011 Engine control

1

TD 2011 W 04-04-11

Check control times

Standard tools

Special tools: – Ajustable bolt 100700

–Chalk

6

Check control times

● Unscrew locking screw (1).

● Remove sealing ring.

● Insert adjustable bolt (1).

1/6

D 2011Engine control

1

TD 2011W 04-04-11

● Press adjustable bolt in lightly in direction of arrow and hold.

● Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft.

6

● Knock in the adjustable bolt (1) to the stop.

● Unscrew locking screw (1).

● Remove sealing ring.

2/6

D 2011 Engine control

1

TD 2011 W 04-04-11

● Tension central screw in direction of arrow.

 40 Nm

● Carefully relax torque wrench.

Attention!

Do not twist crankshaft.

6

● Insert adjustable bolt (1).

● Screw in adjustable bolt (1).

Screw in adjustment bolts until they come into contact with the crankshaft

Attention!

Do not twist crankshaft.

● Apply help marking (arrow).

3/6

D 2011Engine control

X

1

TD 2011W 04-04-11

● The engine control times are set correctly if the adjusting bolt can still be screwed into the crankcase

0.75 to 2.25 revolutions as far as the system.

● If the screwing depth “X“ diverges from the specification, the toothed belt and clamping roller must be replaced.

6

● Unscrew adjustable bolt (1).

● Insert new sealing ring.

● Tighten screw plug (1).

 18 Nm

4/6

D 2011 Engine control

1

TD 2011 W 04-04-11

● Unscrew adjustable bolt (1).

6

● Insert new sealing ring.

● Tighten screw plug (1).

 18 Nm

5/6

D 2011Engine control

TD 2011W 04-04-11

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

Adapter for adjustable

A03 003 Locking screw on crankcase M10x1

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

bolt on camshaft lock/ crankshaft lock. Replace sealing ring.

18 Nm

6

6/6

D 2011 Engine control

1

TD 2011 W 04-04-12

Renew toothed belt and tensioning pulley

Standard tools: – Rotation angle disc 8190 – Special bit, 70 mm long 9120

Special tools: – Ajustable bolt 100700 – Counter support 144130

–Chalk

Remove toothed belt and tensioning pulley

● Remove V-belt pulley.

 W 12-01-04

● Remove toothed belt and tensioning pulley (hydraulic pump).

– W 12-01-04 – W 12-08-03

Attention!

Re-tensioning of toothed belts which have already been running is not permissible! The setting of engine control times should only be carried out with new toothed belts! The crankshaft may only be turned in the direction of the engine.

6

 W 12-08-03

● Unscrew screws (1).

● Remove cable tie (1).

1/12

D 2011Engine control

1

2

1

TD 2011W 04-04-12

● Unscrew screw (1) with special bit.

● Unscrew screws (2).

● Remove holder.

● Remove protective hood.

6

● Unscrew screws (1).

● Remove protective hood.

● Unscrew locking screw (1).

● Remove sealing ring.

2/12

D 2011 Engine control

1

TD 2011 W 04-04-12

● Insert adjustable bolt (1).

6

● Press adjustable bolt in lightly in direction of arrow and hold.

● Turn crankshaft slowly in direction of engine until the adjustable bolt engages with the bore of the camshaft.

● Knock in the adjustable bolt (1) to the stop.

3/12

D 2011Engine control

1

TD 2011W 04-04-12

● Unscrew locking screw (1).

● Remove sealing ring.

6

● Insert adjustable bolt (1).

● Knock in the adjustable bolt (1) to the stop.

4/12

D 2011 Engine control

1

2

3

1

2

TD 2011 W 04-04-12

● Turn crankshaft in the direction of the engine until it reaches the stop of the adjustable bolt.

6

● Unscrew screw (1).

● Remove tensioning pulley (2).

● Remove the toothed belt (3).

● Position counter support (2).

● Loosen screw (1).

Attention!

Do not turn camshaft.

5/12

D 2011Engine control

1

TD 2011W 04-04-12

Install toothed belt and tensioning pulley

● Fasten screw (1).

To guarantee the length adjustment of the toothed belt, the toothed belt wheel must still be able to be turned slightly.

6

● Turn crankshaft in the direction of the engine until it reaches the stop of the adjustable bolt.

● Mount new toothed belt (1).

6/12

D 2011 Engine control

1

2

1

TD 2011 W 04-04-12

● Mount new tensioning pulley (1).

● Position setting eccentric (arrow) at 6 o'clock.

● Fasten screw (2).

6

● Press tensioning pulley (1) against the toothed belt.

● Fasten screws.

● Align toothed belt.

Align toothed belt centrally on the toothed belt wheels.

7/12

D 2011Engine control

2

1

2

3

1

2

TD 2011W 04-04-12

● Align toothed belt.

● Press tensioning pulley (1) against the stop.

● Turn the toothed belt wheel by hand in the direction of the arrow.

The tension side (2) is tightened.

6

● Turn setting eccentric in the direction of arrow with hexagon socket.

● Bring markings (1) and bores into alignment.

● Tighten screw (2).

 21 Nm

● Press tensioning pulley (1) against the stop.

● Hold toothed belt wheel (2) with counter support.

● Tighten new screw (3).

– Stage 1:

 30 Nm

● Tighten new screw (3) with rotation angle disc.

– Stage 2:

 210°

8/12

D 2011 Engine control

1

2

TD 2011 W 04-04-12

Check toothed wheel tension

● Unscrew adjustable bolt to the camshaft and crankshaft lock.

● Bring help markings (1) on toothed wheel and opposite screw into line.

● Turn crankshaft two revolutions in the direction of the arrow (direction of engine) until the help markings are in line.

6

Markings (1) and bores must be in alignment.

If the markings are not aligned with each other, the toothed belt tension must be corrected.

Correct toothed belt tension

● Loosen screw (2).

● Turn setting eccentric in the direction of arrow with hexagon socket.

● Bring markings (1) and bores into alignment.

● Tighten screw (2).

 21 Nm

9/12

D 2011Engine control

1

2

TD 2011W 04-04-12

● Visually inspect the components.

6

● Mount protective hood.

Ensure that the installation location is free from faults.

● Tighten screws (1).

 7Nm

● Mount protective hood.

● Mount holder.

● Tighten screws (2).

 7Nm

● Tighten screw (1) with special bit.

 7Nm

10/12

● Fix cable tie (1).

1

D 2011 Engine control TD 2011 W 04-04-12

6

● Install toothed belt and tensioning pulley (hydraulic pump).

 W 12-08-03

● Insert V-belt tensioning pulley.

● Tighten screws (1).

● Install V-belt pulley.

 W 12-01-04

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TD 2011W 04-04-12

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A04 001 Toothed belt wheel on camshaft

A04 001 Toothed belt wheel on camshaft Stage 2: 210° A04 052 Tensioning pulley on front cover 21 Nm

A04 053

Protective hood (toothed wheel) on front cover

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Stage 1: Use new screw.

30 Nm

7Nm

6

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D 2011 Engine control

1

2

1

2

TD 2011 W 04-04-15

Removing and installing the toothed belt wheel

Standard tools: – Socket wrench insert,

spanner size 32 8036 – Force multiplier 8049 – Rotation angle disc 8190

Special tools: – Counter support 143420 – Counter support 144130

– Packing compound

DEUTZ DW 67

Remove toothed belt wheel

● Remove toothed belt and tensioning pulley.

 W 04-04-12

● Insert counter support 144130.

● Unscrew screw (1).

● Remove toothed belt wheel (2).

– W 04-04-12

6

● Insert counter support 143420.

● Insert fixing bolts (1) in the bores (2).

Attention!

Do not twist crankshaft.

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D 2011Engine control

1

2

1

TD 2011W 04-04-15

● Tighten screws (1).

Attention!

Do not twist crankshaft.

6

● Insert socket wrench insert and force multiplier (1).

● Snap in non-return device (2) in position CCW.

● Hold force multiplier.

● Loosen screw.

● Remove force multiplier and socket wrench insert.

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D 2011 Engine control

1

2

3

1

2

3

TD 2011 W 04-04-15

● Unscrew screws (1).

● Remove counter holder.

6

● Unscrew screw (1).

● Remove flange (2).

● Remove toothed belt wheel (3).

Install toothed belt wheel

● Mount toothed belt wheel (3).

● Mount flange (2).

All connecting surfaces must be clean and free of oil.

● Turn in new screw (1).

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1

2

1

TD 2011W 04-04-15

● Tighten screw.

– Stage 1:

 130 Nm

6

● Insert counter support 143420.

● Insert fixing bolts (1) in the bores (2).

Attention!

Do not twist crankshaft.

● Tighten screws (1).

Attention!

Do not twist crankshaft.

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Deutz D 2011, TD 2011 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Workshop Manual

1 Foreword

2 General

3 User notes

5 Job card overview

5.1 Sorted alphabetically

5.2 Sorted numerically

6 Job cards

Checking the compression pressure

Mounting engine on assembly block and demounting

Setting valve clearance

Removing and installing the rocker arm and rocker arm bracket

Renewing the crankshaft sealing ring (flywheel side)

Renewing the crankshaft sealing ring (opposite side to flywheel)

Removing and installing the crankcase bleeding

Removing and installing rear cover

Removing and installing the connection housing

Renew camshaft sealing ring (opposite side to flywheel)

Check control times

Renew toothed belt and tensioning pulley

Removing and installing the toothed belt wheel