Deutz D 2011, TD 2011 Service Manual

Workshop Manual

competence level 2

D 2011

TD 2011

t

o

is

n

orm

.

f

ted

ic

c

n

prote

tro

o

lec .

yright

e

ment

e

r

d

e

p

int

re

g

s

co

r

a

t

r

p

ior

i

e

r

men

e

p

u

ith

our

n

n

ut

doc

i

This

ibut

io

o

with

D

r

wed

t

s

i

lo

al

0312 4232 en

.

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

Regarding copyright questions and licensing agreements please contact :

VE-FL,	Mr. Lippke
Tel.:	+ 49 (0) 221 822-2599
EMail:	[e-mail]

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

Printed in Germany All rights reserved 1st edition, 02/2011

Order No. 0312 4232 en

© 07/2007

DEUTZ engines

Table of contents

1Foreword

2General

3User notes

3.1General

3.2Specifications

3.3Operating manual and workshop manual

3.4Job cards

3.5Explanation of symbols

5Job card overview

5.1Sorted alphabetically

5.2Sorted numerically

6Job cards

7Commercial tools

8Special tools

© 01/2009	1/2	OBJ_DOKU-23449-001.fm

Table of contents

DEUTZ engines

© 01/2009	2/2	OBJ_DOKU-23449-001.fm

DEUTZ engines

Foreword

1

1Foreword

© 05/2005	1/4	OBJ_DOKU-23450-001.fm

Foreword

DEUTZ engines

1

© 05/2005	2/4	OBJ_DOKU-23450-001.fm

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 con- sidered 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 ob- servance of the operating, maintenance and re- pair 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.

●Makesure thatthisdocumentationis availableto everyoneinvolvedin theoperation,maintenance and repair and that they have understood the contents.

●Failure to observe this documentation may lead tomalfunctions and engine damageaswellasin- jury to persons for which the manufacturer will not accept any liability.

●Prerequisiteforpropermaintenanceandrepairis the availability of all the necessary equipment, conventional and special tools and their perfect condition.

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

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

●Maximumeconomy,reliabilityandlonglifeisonly guaranteed when using DEUTZ original parts.

● Repair of the engine must correspond to its use	1
for the intended purpose. Only parts released by

themanufacturerfortherespectivepurposemay be used for conversion work. Unauthorised mod- ifications to the engine exclude manufacturer lia- bility 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 var- iants ensures that the respective special require- ments are met.

●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.

●We have done our best to highlight the differenc- essothatyoucaneasilyfindtheoperating,main- tenance and repair instructions relevant to your engine.

We are at your service for any questions you may have in this matter.

Your DEUTZ AG

© 05/2005	3/4	OBJ_DOKU-23450-001.fm

Foreword

DEUTZ engines

1

© 05/2005	4/4	OBJ_DOKU-23450-001.fm

DEUTZ engines

General

2

2General

© 11/2005	1/4	OBJ_DOKU-23451-001.fm

General

DEUTZ engines

2

© 11/2005	2/4	OBJ_DOKU-23451-001.fm

DEUTZ engines

General

DEUTZenginesaretheproductofyearsofresearch 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 2 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. Compli- ancewiththeprescribedmaintenancetimesandthe carefulexecutionofmaintenanceandcareworkare therefore essential. Difficult operating conditions, deviating from normal operation, must be particular- ly 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.

© 11/2005	3/4	OBJ_DOKU-23451-001.fm

General

DEUTZ engines

2

© 11/2005	4/4	OBJ_DOKU-23451-001.fm

DEUTZ engines

User notes

3

3 User notes

© 01/2009

1/8

18610-001

User notes

DEUTZ engines

3

© 01/2009

2/8

18610-001

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 protection devices which are removed during maintenance work must be replaced again afterwards.

Caution!

The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.

Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.

The maintenance intervals and the work to be performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

3.2 Specifications

3.2.1Accident prevention and safety regulations

The legally prescribed rules for the prevention of accidents must be observed. These are available from

professional associations or from dealers. These 3 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:

zfor the personnel:

–Only briefed personnel may operate or maintain the engine. Unauthorised persons are prohibited access to the machine room.

–Wear close-fitting clothing and ear protectors in the machine room when the engine is in operation.

–Only deploy trained personnel to do repairs and maintenance work.

–Do not work on the fuel system when the engine is running. The fuel system is under high pressure - danger of death.

–Go to the workshop immediately in case of leaks in the fuel system.

zfor the engine room:

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

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

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

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

zfor operation, maintenance and repairs on the engine:

–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.

© 01/2009

3/8

18610-001

User notes

DEUTZ engines

–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 components 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.

3.2.2Cleanliness 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. Great 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

zThe fuel system must be closed. Make a visual inspection for leaks / damage to the fuel system.

zClean the whole engine and engine room with the system closed before starting work on the fuel system.

zThe engine must be dry when you start working on the fuel system.

zBlowing (dry) with compressed air is only permissible with the fuel system closed.

zWhen 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.

zElectrical plug connections must be plugged when spraying.

zRemove 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.

zOnly work on the fuel system in a clean environment (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.

zAir currents which kick up dust, such as those caused by brake repairs or the starting of engines, should be avoided.

zFor work such as removal and installation on defective 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.

zNo general machine tools may be operated in this room.

zRegular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised.

zAreas 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.

zWorking materials and tools must be cleaned before 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 system open.

zOnly work in clean overalls.

zOnly lint-free cleaning cloths may be used for work on the fuel system.

zRemove 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.

zWorking materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

zDo not use used cleaning fluid or test fluid for cleaning.

zCompressed air must not be used for cleaning on the open fuel system.

zWork on removed components may only be performed at a suitably equipped workbench.

© 01/2009

4/8

18610-001

DEUTZ engines

User notes

zWhen removing and installing components, no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

zRemoved parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.

zOpenings on the components and on the engine must be closed immediately with suitable stoppers/caps.

zThe stoppers/caps may only be removed immediately before installing.

zStore stoppers/caps free from dust and dirt in the original packaging and dispose of after using once.

zOnly remove new parts from the original packaging just before installation.

zRemoved components must be kept in new, sealable bags or - if available - in the packaging of the new parts.

zAlways use the original packaging of the new part to send back the removed components.

Notes and measures for the vehicle workshop area

zFor work such as removal and installation on defective 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.

zThe workshop floor is sealed or tiled.

zNo welding gear, grinders, general machine tools, brakes or performance test benches may be operated in this room.

zRegular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised.

Notes and measures for workbench and tools in the vehicle hall

zA special workbench must be set up for work on removed components.

zClean the removal and installation tools regularly and keep them in a closed tool cabinet.

zRemove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device.

zWorking materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

3.2.3 Disposal regulations

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

	operating materials among other things. The re-
	newed parts / operating materials must be stored,
	transported and disposed of according to regula-
	tions. The owner himself is responsible for this.
	Disposal includes recycling and the scrapping of
	parts / operating materials, although recycling has
	priority.	3
	Details of disposal and their monitoring are gov-
	erned by regional, national and international laws
	and directives which the system operator must ob-
	serve on his own responsibility.

© 01/2009

5/8

18610-001

User notes

DEUTZ engines

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 descrip-
	tion and instructions for all other maintenance work.
	It contains the following chapters:
	1.	Contents, General
	2.	Engine description
	3.	Operation
	4.	Operating media
	5.	Maintenance
	6.	Care and maintenance work
	7.	Faults, causes and remedies
	8.	Engine conservation
	9.	Technical data

10.Service

The workshop manual assumes knowledge of the contents of the operation manual. This applies especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

3.4 Job cards

The job cards are divided in the workshop manual into "W" and "I" job cards.

The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card.

The "I" job card additionally documents the appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special conditions to perform these work procedures. Special tools and machine tools must be available, for example.

3.4.1 Numbering of job cards

The job card numbers follow the pattern W 02-04- 01. The individual parts of this pattern are explained below:

zW 02-04-01: Documentation type

–WWorkshop manual

–I ...... Repair instructions

zW 02-04-01: Maintenance group

–00 ... General / interdisciplinary activities

–01 ... Cylinder head

–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

zW 02-04-01: Component grouping

zW 02-04-01: Consecutive number

© 01/2009

6/8

18610-001

DEUTZ engines

User notes

3.4.2 Structure of a job card

1

2

3

Triebwerk
W 02-04-01	4

5

16

6

15

6 7

14

8

13

12	8

11

10

9

1.DEUTZ AG,

publisher of service documentation

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

3.Maintenance group

4.Job card number or topic

5.Title of job card

6.Reference to other job cards

7.Chapter

8.Graphic or photo

9.DEUTZ internal creation number 10.Page number

11.Date of issue of job card 12.Note

13.Danger / Important 14.Work sequence

15.Special tools; auxiliary materials 16.Conventional tools

3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
injury.	3
Caution!

Danger to the component/engine. Noncompliance can lead to destruction of the component/engine.

Must be observed!

Note

General notes on assembly, environmental protection etc. No potential danger for man or machine.

Tool

Conventional and special tools required for the work.

Auxiliary materials

Working materials required in addition to the tools for performing the work

(e.g. greases, oils, adhesives, sealants)

References

to important documents or job cards for the work process.

For example: Job card W 04-05-05

Reference

to a document or a job card within the work process.

Test and setting data

The necessary values are specified here. If several values are necessary, a cross reference is given to the Test and Setting Values table.

For example:

ID no. P01 61 = valve clearance, inlet

Tightening specification

The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table.

For example:

ID no. A01 001 = cylinder head screws

© 01/2009

7/8

18610-001

User notes

DEUTZ engines

3

© 01/2009

8/8

18610-001

D 2011	Job card overview
TD 2011	Sorted alphabetically

5

5Job card overview

5.1Sorted alphabetically

© 01/2009	1/8	OBJ_DOKU-24383-001.fm

Job card overview	D 2011
Sorted alphabetically	TD 2011

5

© 01/2009	2/8	OBJ_DOKU-24383-001.fm

	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-		W 07-08-02	Fuel system
pendent full load stop
Mounting engine on assembly block and demoun-		W 00-05-01	General
					5
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		W 06-09-08	Exhaust system/Charging
pipe (Exhaust gas recirculation)
Removing and installing the exhaust gas return pipe		W 06-09-07	Exhaust system/Charging
Removing and installing the exhaust gas return val-		W 06-09-06	Exhaust system/Charging
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 filter console		W 07-10-08	Fuel system
Removing and installing the fuel injector pump		W 07-04-01	Fuel system
Removing and installing the fuel injectors		W 07-07-01	Fuel system
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

© 01/2009	3/8	OBJ_DOKU-24383-001.fm

			Job card overview		D 2011
			Sorted alphabetically		TD 2011
			Activity	Job card	Maintenance group
			Removing and installing the lifting magnet (charge	W 07-08-01	Fuel system
			air pressure-dependent full load stop)
			Removing and installing the lifting magnet (Engine	W 11-00-03	Monitoring system
			shutdown)
			Removing and installing the lifting magnet (Start	W 07-02-07	Fuel system
			amount release)
			Removing and installing the lubricating oil cooler	W 08-08-02	Lube oil system
			Removing and installing the lubricating oil pan	W 08-04-07	Lube oil system
	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	W 06-09-10	Exhaust system/Charging
			gas recirculation)
			Removing and installing the oil filter console	W 08-11-07	Lube oil system
			Removing and installing the oil pressure regulating	W 08-11-02	Lube oil system
			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	W 01-02-02	Cylinder head
			arm bracket
			Removing and installing the sensor (Exhaust gas	W 06-09-09	Exhaust system/Charging
			recirculation)
			Removing and installing the starter	W 13-03-02	Electrical system
			Removing and installing the starter	W 13-03-02	Electrical system
			Removing and installing the thermostat (Lubricating	W 08-11-12	Lube oil system
			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-	W 04-03-01	Engine control
			wheel)
			Renew toothed belt and tensioning pulley	W 04-04-12	Engine control
			Renewtoothedbeltandtensioningpulley(Hydraulic	W 12-08-03	Other components
			pump)
			Renew V-belts, check V-belt tension	W 12-02-01	Other components
			Renewing the crankshaft sealing ring (flywheel side)	W 02-02-02	Drive system
			Renewing the crankshaft sealing ring (opposite side	W 02-02-04	Drive system
			to flywheel)
			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

© 01/2009	4/8	OBJ_DOKU-24383-001.fm

D 2011	Job card overview
TD 2011	Sorted numerically

5

5.2Sorted numerically

© 01/2009	5/8	OBJ_DOKU-24383-001.fm

Job card overview	D 2011
Sorted numerically	TD 2011

5

© 01/2009	6/8	OBJ_DOKU-24383-001.fm

			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			Mounting engine on assembly block and demoun-	General
				ting
	W 01-01-01			Setting valve clearance	Cylinder head
	W 01-02-02			Removing and installing the rocker arm and rocker	Cylinder head
				arm bracket
	W 02-02-02			Renewing the crankshaft sealing ring (flywheel side)	Drive system
							5
	W 02-02-04			Renewing the crankshaft sealingring (opposite side	Drive system
				to flywheel)
	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			Renew camshaft sealing ring (opposite side to fly-	Engine control
				wheel)
	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
	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			Removing and installing the exhaust gas return val-	Exhaust system/Charging
				ve
	W 06-09-07			Removing and installing the exhaust gas return pipe	Exhaust system/Charging
	W 06-09-08			Removing and installing the exhaust gas collection	Exhaust system/Charging
				pipe (Exhaust gas recirculation)
	W 06-09-09			Removing and installing the sensor (Exhaust gas	Exhaust system/Charging
				recirculation)
	W 06-09-10			Removing and installing the magnet clip (Exhaust	Exhaust system/Charging
				gas recirculation)
	W 07-02-07			Removing and installing the lifting magnet (Start	Fuel system
				amount release)
	W 07-03-01			Renewing the injection lines	Fuel system
	W 07-04-01			Removing and installing the fuel injector pump	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

© 01/2009	7/8	OBJ_DOKU-24383-001.fm

		Job card overview		D 2011
		Sorted numerically		TD 2011
		Job card	Activity	Maintenance group
		W 07-08-01	Removing and installing the lifting magnet (charge	Fuel system
			air pressure-dependent full load stop)
		W 07-08-02	Installing and removing charge air pressure-de-	Fuel system
			pendent full load stop
		W 07-10-06	Removing and installing fuel pipes	Fuel system
		W 07-10-08	Removing and installing the fuel filter console	Fuel system
		W 07-10-08	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	Removing and installing the lubricating oil pan	Lube oil system
			(metal sheet lubricating oil pan)
		W 08-08-02	Removing and installing the lubricating oil cooler	Lube oil system
		W 08-11-02	Removing and installing the oil pressure regulating	Lube oil system
			valve
		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
		W 08-11-11	Removing and installing temperature transmitter	Lube oil system
		W 08-11-12	Removing and installing the thermostat (Lubricating	Lube oil system
			oil cooler)
		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	Removing and installing the lifting magnet (Engine	Monitoring system
			shutdown)
		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	Renewtoothedbeltandtensioningpulley(Hydraulic	Other components
			pump)
		W 13-02-03	Removing and installing the generator	Electrical system
		W 13-03-02	Removing and installing the starter	Electrical system
		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

© 01/2009	8/8	OBJ_DOKU-24383-001.fm

DEUTZ engines

Job cards

	6	Job cards
			6

© 11/2005	1/2	OBJ_DOKU-23455-001.fm

Job cards

DEUTZ engines

6

© 11/2005	2/2	OBJ_DOKU-23455-001.fm