Deutz TD 2011 w, D 2011 w, TCD 2011 w Workshop Manual

Workshop Manual

0312 4176 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.

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TD 2011 w, TCD 2011 w

The engine company.

DEUTZ AG Sales & Service Information Systems Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-Mail: info@deutz.com

Regarding copyright questions and licensing agreements

please contact : TE-FI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: sonntag.j@deutz.com

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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

4 Technical dat a

4.1 Testing and setting data

4.2 Tightening specifications

5 Job card overview

5.1 Sorted alphabetically

5.2 Sorted numerically

6Job cards 7Commercial tools 8 Special tools

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DEUTZ enginesTable of contents

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DEUTZ engines Foreword

1 Foreword

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DEUTZ enginesForeword

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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 th is 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, 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.

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 in jury 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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DEUTZ enginesForeword

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DEUTZ engines General

2 General

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DEUTZ enginesGeneral

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DEUTZ engines General

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 cond itio 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.

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DEUTZ enginesGeneral

3

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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 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

3.2.1 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

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 th e 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. Gr ea 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 sys tem open.

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

tools, brakes or performance test benche 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 a nd tools in the vehicle hall

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 chro me plated.

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 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 must ob serve on his own responsibility.

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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.

The operation manual contains a general description 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: 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

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 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

Triebwerk

W 02-04-01

6

16

12

4

6

1 2 3

8

10

11

575

9

13

14

15

8

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

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D 2011 w Technical data TD 2011 w, TCD 2011 w Testing and setting data

4 Technical data

4.1 Testing and setting data

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D 2011 wTechnical data

TD 2011 w, TCD 2011 wTesting and setting data

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ID no. Name Additional information Value D 2011 w / TD 2011 w / TCD 2011 w

P00 04 Engine weight according to DIN 70020-A approx. 268 kg P00 51 Compression pressure

25 - 30 bar

(2500 - 3000 kPa) P00 71 Ignition sequence 1-3-4-2 P01 61 Valve clearance (inlet) 0.3 mm P01 62 Valve clearance (outlet) 0.5 mm

P01 72 Rocker arm, bore, diameter (outlet)

18 mm P01 73 Rocker arm, bore, diameter (inlet)

18 mm P01 74 Rocker arm pin, diameter

17,97 mm P02 75 Piston overhang

Identification, cylinder head gasket = 1 recess

0.325 - 0.604 mm

P02 76 Piston overhang

Identification, cylinder head gasket = 2 recesses

0.605 - 0.704 mm

P02 77 Piston overhang

Identification, cylinder head gasket = 3 recesses

0.705 - 0.804 mm

P08 74 Thermostat, compression spring, length 45.7 mm P09 11 Thermostat, start of opening 86 - 90 °C P09 13 Thermostat, stroke distance at least 9 mm

P12 11 V-belt tension, individual V-belts AVX 10 First assembly

450 N P12 21 V-belt tension, individual V-belts AVX 10

Check after 15 minutes running under load

300 N

D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head

P02 75 Piston overhang

Identification, cylinder head gasket = 1 recess

9.820 - 10.140 mm

P02 76 Piston overhang

Identification, cylinder head gasket = 2 recesses

10.141 - 10.239 mm

P02 77 Piston overhang

Identification, cylinder head gasket = 3 recesses

10.240 - 10.310 mm

+0.27

+0.01

−0.01

+50

−50

+20

−20

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D 2011 w Technical data TD 2011 w, TCD 2011 w Tightening specifications

4.2 Tightening specifications

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TD 2011 w, TCD 2011 wTightening specifications

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ID no. Name Screw type Notes / Remark Value D 2011 w / TD 2011 w / TCD 2011 w

A00 001 Clampin g bracke t on cran kc ase 90 Nm A00 002

Clamping bracket on adapter for assembly block

90 Nm

A00 003

Mounting foot/engine mounting on crankcase

M14x55-12.9 M14x100-12.9

200 Nm

A01 001 Cylinder head on crankcase

Stage 1: Cylinder head screws can be used a maximum of 3x with written documentation. Otherwise use new cylinder head screws. Observe tightening sequence.

30 Nm

A01 001 Cylinder head on crankcase Stage 2 80 Nm A01 001 Cylinder head on crankcase Stage 3 160 Nm A01 001 Cylinder head on crankcase Stage 4 90° A01 002 Rocker arm bracket on cylinder head 21 Nm A01 003 Locking nut, va lve adju ste r 20 Nm

A01 004

Cylinder head cover on cylinder head

8.5 Nm

A03 060

Crankcase bleeding on front cover / on cylinder head cover / on cylinder head

8.5 Nm

A05 041

Lifting magnet (engine shutdown) on front cover

8.5 Nm

A05 065

Lifting magnet (start amount r elease) on front cover

10 Nm

A06 001 Exhaust pipe at cylinder head

Torx screw, coated

Use new screws. 55 Nm A07 001 Fuel injector on cylinder head 21 Nm A07 003

Injection line on fuel injector / injection pump

M12x1.5 25 Nm

A07 015 Fuel supply line to injection pump Hollow screw Replace sealing rings 29 Nm A07 024 Fuel supply pump on crankcase 21 Nm A07 061 Fuel return line on injection pump Hollow screw Replace sealing rings 29 Nm

A08 003 Oil filter console on crankcase

Torx M8x50-8.8 Torx M8x90-8.8

21 Nm

A08 048

Control line to oil filter console / crankcase

Hollow screw M10x1

18 Nm

A08 051

Lubricating oil cooler on oil filter console

M6x16-10.9 13 Nm

A08 072

Thermostat on crankcase, locking screw,

90 Nm

A08 091 Oil pressure switch on crankcase M10x1 13 Nm A09 001 Thermostat housing to crankcase M8x100-10.9 34 Nm

A09 002

Outlet nozzles on thermostat housing

M8x30-10.9 22 Nm

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D 2011 w Technical data TD 2011 w, TCD 2011 w Tightening specifications

A09 010 Coolant pump on thermostat housing

M8x35-10.9 M8x100-10.9

20 Nm A09 020 Pipe clip on holder M6x16 21 Nm A09 031

Temperature transmitter on thermostat housing

25 Nm A09 042 Ventilator on flange hub M8x40-10.9 30 Nm A09 045 Air bearing on console M10x110-12.9

Stage 1: Use new screw.

30 Nm A09 045 Air bearing on console M10x110-12.9 Stage 2: 120° A12 001 Flywheel on cra nk s haft

Stage 1: Use new screws

30 Nm A12 001 Flywheel on crankshaft Stage 2: 60°

A12 001 Flywheel on crankshaft Stage 3: 30° A12 031

V belt pulley/flange hub on output flange

M10x30-8.8 43 Nm

A12 041

V-belt tensioning pulley (holder) on front cover

45 Nm

A12 051

Hydraulic pump on hydraulic pump console

57 Nm

A12 052

Tensioning pulley on hydrau lic pum p console

21 Nm

A12 056

Protective hood on hydraulic pump console

8.5 Nm

A13 001 Starter on crankcase 43.5 Nm A13 009 Shield on crankcase M6x14-8.8 8.5 Nm

A13 012 Generator on console

M8x70-10.9 M8x75-10.9

34 Nm A13 015 Clamping bracket on generator M8x30-8.8 22 Nm

A13 016 Clamping bracket on console M8x35-8.8 22 Nm A13 031

Glow plug in charge air line / intake pipe

60 Nm A13 032 Heating plug on cylinder head 21 Nm

A13 034 Cable conn ec tio n to glo w plu g 4 Nm A13 081

Charging current cable to generator B+

6.5 Nm

A13 082 Cable G1.D+ to generator M5 3.5 Nm

D2011w

A06 030

Air suction intake pipe on cylinder head

Torx screw, coated

Use new screws. 21 Nm

A06 057

Pipe to exhaust gas return valve/ cylinder head (cooling - intake)

Hollow screw M12x1.5

29 Nm

A06 062

Exhaust return pipe to exhaust return valve

M8x65-10.9 20 Nm

A06 063

Exhaust gas collection pipe to exhaust gas return valve

20 Nm

A06 071

Pipe to crankcase (exhaust gas return - cooling - return)

Hollow screw M8x1

12 Nm

A06 072

Pipe to exhaust gas return valve (exhaust gas return - cooling -

return)

Hollow screw M12x1.5

29 Nm

ID no. Name Screw type Notes / Remark Value

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D 2011 wTechnical data

TD 2011 w, TCD 2011 wTightening specifications

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A06 073

Exhaust gas collection pipe (exhaust gas return) on cylinder head

Torx M10x25-10.9 Torx M10x30-10.9 Torx M10x45-10.9

Use new screws. 55 Nm

A06 074

Exhaust gas return pipe to cylinder head (exhaust gas return)

8.5 Nm

A06 075

Safety cover on sensor housing (exhaust gas return)

Locking screw Torx-Plus 30IPR

8Nm

A07 087 Fuel filter console to crankcase 21 Nm

TD2011w / TCD2011w

A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm A06 020 Turbocharger on exhaust pipe M8 21 Nm

A06 030 Charge air pipe on cylinder head

Torx screw, coated

Use new screws. 21 Nm A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm A07 096

Cap on charge air-dependent full load stop

8Nm

A08 042

Lubricating oil pipe on turbocharger /

crankcase

Hollow screw Replace sealing rings 29 Nm

A08 044

Oil return line, hex spuds to turbocharger

M16x1.5 Use new sealing ring 40 Nm

A08 049 Holder oil return line on crankcase

Torx, M6x14-8.8

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.

ID no. Name Screw type Notes / Remark Value

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D 2011 w TD 2011 w, TCD 2011 w Job card overview

5 Job card overview

5.1 Sorted alphabetically

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D 2011 wJob card overview

TD 2011w, TCD 2011 wSorted alphabetically

5

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D 2011 w Job card overview TD 2011w, TCD 2011 w Sorted alphabetically

Activity Job card Maintenance group

Checking piston overhang W 01-04-09 Cylinder head Checking the compression pressure W 00-02-06 General Checking the thermostat (in the removed state) W 09-08-01 Cooling system Disassembling, assembling and checking the rocker

arm and rocker arm bracket

W 01-02-06 Cylinder head

Installing and removing charge air pressure-dependent full load stop

W 07-10-08 Fuel system

Mounting engine on assembly block and demounting

W 00-05-01 General

Removing and install the charge air line W 06-02-03 Exhaust system/Charging Removing and installing cylinder head W 01-04-04 Cylinder head Removing and installing fuel pipes W 07-10-06 Fuel system Removing and installing temperature transmitter W 09-12-01 Cooling system Removing and installing the control line W 08-16-01 Lube oil system Removing and installing the coolant pump W 09-07-08 Cooling system Removing and installing the crankcase bleeding W 03-01-11 Crankcase Removing and installing the exhaust gas collection

pipe (Exhaust gas recirculation)

W 06-09-08 Exhaust system/Charging

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

ve

W 06-09-06 Exhaust system/Charging

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 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 intake manifold W 06-07-03

Exhaust system/Charging

Removing

and installing the lifting magnet (charge

air pressure-dependent full load stop)

W 07-10-08 Fuel system

Removing and installing the lifting magnet (Engine shutdown)

W 11-00-03 Monitoring system

Removing and installing the lifting magnet (Start amount release)

W 07-02-07 Fuel system

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

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D 2011 wJob card overview

TD 2011w, TCD 2011 wSorted alphabetically

Removing and installing the oil filter console W 08-11-07 Lube oil system Removing and installing the oil pressure switch W 08-11-08 Lube oil system Removing and installing the rocker arm and rocker

arm bracket

W 01-02-02 Cylinder head

Removing and installing the starter W 13-03-02 Electrical system Removing and installing the thermostat W 09-08-02 Cooling system Removing and installing the thermostat (Lubricating

oil cooler)

W 08-11-12 Lube oil system

Removing and installing the thermostat housing W 09-08-04 Cooling system 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 V-belts, check V-belt tension W 12-02-01 Other components Renewing the injection lines W 07-03-01 Fuel system Setting valve clearance W 01-01-01 Cylinder head

Activity Job card Maintenance group

5

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5.2 Sorted numerically

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Job card Activity Maintenance group

W 00-02-06 Checking the compression pressure General

W 00-05-01

Mounting engine on assembly block and demounting

General

W 01-01-01 Setting valve clearance Cylinder head

W 01-02-02

Removing and installing the rocker arm and rocker arm bracket

Cylinder head

W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm bracket

Cylinder head

W 01-04-04 Removing and installing cylinder head Cylinder head W 01-04-09 Checking piston overhang Cylinder head W 03-01-11 Removing and installing the crankcase bleeding Crankcase W 06-01-05 Removing and installing the exhaust line 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 valve

Exhaust system/Charging

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 pipe (Exhaust gas recirculation)

Exhaust system/Charging

W 07-02-07

Removing and installing the lifting magnet (Start amount release)

Fuel system

W 07-03-01 Renewing the injection lines Fuel system W 07-07-01 Removing and installing the fuel injectors Fuel system W 07-10-06 Removing and installing fuel pipes Fuel system

W 07-10-08

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

Fuel system

W 07-10-08

Installing and removing charge air pressure-dependent full load stop

Fuel system

W 07-10-08 Removing and installing the fuel filter console Fuel system W 07-11-01 Removing and installing the fuel supply pump Fuel system W 08-08-02 Removing and installing the lubricating oil cooler Lube oil system 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 08-11-12

Removing and installing the thermostat (Lubricating oil cooler)

Lu

be oil system

W 08-16-01 Removing and installing the control line Lube oil system W 09-07-08 Removing and installing the coolant pump Cooling system

5

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W 09-08-01 Checking the thermostat (in the removed state) Cooling system W 09-08-02 Removing and installing the thermostat Cooling system W 09-08-04 Removing and installing the thermostat housing Cooling system W 09-12-01 Removing and installing temperature transmitter Cooling system

W 11-00-03

Removing and installing the lifting magnet (Engine shutdown)

Monitoring system

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 hy draulic pump Other components W 13-02-03 Removing and installing the generator Electrical system W 13-03-02 Removing and installing the starter Electrical system W 13-06-01 Removing and installing the heating plugs Elec tric al system W 13-06-02 Removing and installing the glow plug Electrical system

Job card Activity Maintenance group

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D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06

Checking the compression pressure

Commercial available 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“.

Checking the compression pressure

z Set valve clearance.

 W 01-01-01

z Removing fuel injectors.

 W 07-07-01

z Mount sealing ring (1).

z Insert connector (2).

Use sealing ring (1) for fuel injector.

2

1

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z Mount clamping shoe (1). z Tighten screw (2).

 21 Nm

2

1

z Connect adapter (1) to connector.

1

z Mount the compression tester on the adapter. z Turn over engine with starter.

 25-30bar (2500-3000kPa)

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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.

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.

z Remove the compression pressure tester.

z Remove the compression pressure tester and

adapter (1).

1

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z Unscrew screw (1).

1

z Remove connector (1). z Remove sealing ring. z Install fuel injectors.

 W 07-07-01

1

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Technical Data

Testing and setting data

Tightening specifications

ID no. Name Additional information Value

P00 51 Compression pressure

25 - 30 bar (2500 - 3000 kPa)

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.

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D 2011 w General TD 2011w, TCD 2011 w W 00-05-01

Mounting engine on assembly block and demounting

Commercial available tools: – Lifting gear – Suspension ropes – Eyelet bolts

Special tools:

– Assembly block. . . . . . . . . . . . . . . . 6067

– Supporting bracket . . . . . . . . . .6067/114

– Clamping bracket . . . . . . . . . . .6067/115

– 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.

Mounting engine on assembly block

z Remove starter.

 W 13-03-02

z Screw in eyelet bolts (1).

1

z Hang engine on workshop crane.

 approx. 268 kg

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z Unscrew screws (1). z Remove all mounting feet.

– TD 2011 w, TCD 2011 w

z Unscrew screw (2). z Remove holder (3). z Remove oil return pipe (4).

2

4

1

3

z Mount clamping holder (1). z Tighten screws (2).

 90 Nm

2

1

z Align engine on engine block. z Mount retainer plate (1). z Tighten screws (2) and lock nuts.

 90 Nm

2

1

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D 2011 w General TD 2011w, TCD 2011 w W 00-05-01

z Unhook the engine from the workshop crane. z Unscrew eyelet bolts (1).

1

Demounting engine from assembly block

z Screw in eyelet bolts (1). z Hang engine on workshop crane.

 approx. 268 kg

1

z Loosen lock nuts. z Unscrew screws (2). z Remove retainer plate (1).

2

1

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z Unscrew screws (2). z Remove clamping bracket (1).

Danger!

Lower engine with workshop crane.

2

1

– TD 2011 w, TCD 2011 w

z Insert new O-ring (1). z Lightly oil new O-ring (1).

1

– TD 2011 w, TCD 2011 w

z Mount oil return pipe (1).

z Mount holder (2). z Tighten screw (3).

 8.5 Nm

– D 2011 w, TD 2011 w, TCD 2011 w

z Install all mounting feet. z Tighten screws (4).

 200 Nm

Attention!

Install tension-free.

3

1

4

2

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D 2011 w General TD 2011w, TCD 2011 w W 00-05-01

z Unhook the engine from the workshop crane. z Unscrew eyelet bolts (1). z Install starter.

 W 13-03-02

Danger!

Put the engine down on a secure surface.

1

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Technical Data

Testing and setting data

Tightening specifications

ID no. Name Additional information Value

P00 04 Engine weight according to DIN 70020-A approx. 268 kg

ID no. Name Screw type Notes / Remark Value

A00 001 Clampin g bracke t on cran kc ase 90 Nm A00 002

Clamping bracket on adapter for assembly block

90 Nm

A00 003

Mounting foot/engine mounting on crankcase

M14x55-12.9 M14x100-12.9

200 Nm

TD 2011 w, TCD 2011 w

A08 049 Holder oil return line on crankcase

Torx, M6x14-8.8

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.

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01

Setting valve clearance

Commercial available tools: – Feeler gauges

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.

z Unscrew all screws (1). z Remove cylinder head cowling (2). z Remove gasket.

2

1

Setting engine to valve overlap

z Turn crankshaft in the direction of the eng ine (arrow). z Turn over crankshaft until the valve overlap is

achieved on cylinder 1.

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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.

IN

EX

z Select feeler gauge. z 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

z Loosen lock nut (1). z Hold adjusting screw (2). z Set valve clearance.

–Inlet

 0.3 mm

–Outlet

 0.5 mm

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

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

2

1

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

1

z Hold adjusting screw (2). z Tighten lock nut (1).

 20 Nm

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

2

1

z Check the valve clearance again with feeler gauge.

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Valve clearance setting schematic

z Turn over crankshaft until the valve overlap is

achieved on cylinder 1.

z Set black marked valves.

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

Crankshaft position 2

z Turn the crankshaft one turn (360°). z Set black marked valves.

z Clean sealing surfaces. z Mount new gasket.

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

1

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z Mount cylinder head cover. z Oil the screws lightly. z Tighten all screws (1) alternately.

 8.5 Nm

1

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Technical Data

Testing and setting data

Tightening specifications

ID no. Name Additional information Value

P00 71 Ignition sequence 1-3-4-2 P01 61 Valve clearance (inlet) 0.3 mm P01 62 Valve clearance (outlet) 0.5 mm

ID no. Name Screw type Notes / Remark Value

A01 003 Locking nut, va lve adju ste r 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.

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D 2011 w Cylinder head TD 2011w, TCD 2011 w W 01-02-02

Removing and installing the rocker arm and rocker arm bracket

Commercial available tools:

– Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 01-01-01

Removing the rocker arm and rocker arm bracket

z Unscrew all screws (1). z Remove cylinder head cowling (2). z Remove gasket.

2

1

z Unscrew screws (1).

z Remove rocker arm bracket (2) .

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

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

Note order of cylinders.

1

2

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z Remove push rods (1).

z Visually inspect the components.

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

11

Installing the rocker arm and rocker arm bracket

z 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.

11

z Loosen lock nut (1). z Unscrew setting screws (2). z Mount rocker arm bracket (3). z 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.

3

4

2

1

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D 2011 w Cylinder head TD 2011w, TCD 2011 w W 01-02-02

z Lightly oil screws (1). z Tighten screws .

 21 Nm

z Set valve clearance.

 W 01-01-01

Attention!

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

1

z Clean sealing surfaces. z Mount new gasket.

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

1

z Mount cylinder head cover. z Oil the screws lightly. z Tighten all screws (1) alternately.

 8.5 Nm

1

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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.

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm bracket

Commercial available tools: – Internal measuring device – Micrometer gauge – Locking ring pliers

Special tools:

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

– W 01-02-02

Disassembling the rocker arm bracket

z Remove rocker arm and rocker arm bracket.

 W 01-02-02

z Remove locking ring (1).

1

z Remove rocker arm.

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

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z Hold adjusting screw (2). z Loosen lock nut (1). z Unscrew adjusting screw (2).

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

1

2

z Visually inspect the components. z Check oil channels (arrows) for free passage.

z Screw in setting screw (1). z Screw in locking nut (2).

1

2

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06

Checking the rocker arm

z Prepare internal measuring device:

– Mount probe bolt for the appropriate measuring

range in the internal measuring device.

– Mount dial gauge with approx. 1 mm pre-tension in

the internal measuring device. – Set micrometer gauge to 18 mm. – Balance the internal measuring device between

the test surfaces of the micrometer gauge and set

the dial gauge at the reversal point of the pointer to

"0".

z Insert internal measuring device. z Measure rocker arm bore.

–Outlet

 18 mm

–Inlet

 18 mm

When the wear limit is reached the rocker arm must be renewed.

+0.27

Checking the rocker arm pin

z Measure diameter with micrometer gauge.

 17,97 mm

When the wear limit is reached the rocker arm bracket must be replaced.

+0.01

−0.01

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Assembling the rocker arm bracket

z Lightly oil the rocker arm pin. z Push rocker arm (1) onto rocker arm pin.

1

z Insert new locking rings (1).

z Install rocker arm and rocker arm bracket.

 W 01-02-02

Ensure that the installation location is free from faults.

1

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06

Technical Data

Testing and setting data

ID no. Name Additional information Value

P01 72 Rocker arm, bore, diameter (outlet)

18 mm

P01 73 Rocker arm, bore, diameter (inlet)

18 mm

P01 74 Rocker arm pin, diameter

17,97 mm

+0.27

+0.01

−0.01

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04

Removing and installing cylinder head

Commercial available tools: – Socket wrench insert Torx

E18 . . . . . . . . . . . . . . . . . . . . . . . . . 8116

– Dog wrench. . . . . . . . . . . . . . . . . . . 8018

– Rotation angle disc . . . . . . . . . . . . . 8190

Special tools:

– Plugs/caps . . . . . . . . . . . . . . . . . 170160

– W 01-02-02 – W 01-04-09

– W 06-02-03 . . . . . . . . . . . .TD 2011 w,

TCD 2011 w

– W 06-07-03 . . . . . . . . . . . .D 2011 w

– W 06-09-08 . . . . . . . . . . . .TD 2011 w,

TCD 2011 w – W 09-08-04

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“.

Removing the cylinder head

z Unscrew screws (1).

1

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z Unscrew lock nuts (1) with dog wrench. z Remove thermostat housing.

 W 09-08-04

– D 2011 w

z Remove the air intake pipe.

 W 06-07-03

– TD 2011 w, TCD 2011 w

z Remove the charge air pipe.

 W 06-02-03

z Remove exhaust gas collection pipe.

 W 06-09-08

1

z Remove rocker arm and rocker arm bracket.

 W 01-02-02

z Remove push rods (1).

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

Note order of cylinders.

1

z Unscrew all screws (1) with the socket wrench insert. z Remove cylinder head. z Remove gasket. z Visually inspect the components.

1

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04

Installing the cylinder head

z Check piston overhang.

 W 01-04-09

Measure the piston overhang on all pistons.

Select cylinder head gasket according to the largest piston projection measured.

z Select cylinder head gasket according to the largest

piston projection measured. – 1 recess

 0.325 - 0.604 mm

– 2 recesses

 0.605 - 0.704 mm

– 3 recesses

 0.705 - 0.804 mm

Example:Piston overhang = 0.7 mm, corresponds to cylinder head gasket with 2 recesses (arrow).

– Recess cylinder head

z Select cylinder head gasket according to the largest

piston projection measured. – 1 recess

 9.820 - 10.140 mm

– 2 recesses

 10.141 - 10.239 mm

– 3 recesses

 10.240 - 10.310 mm

z Remove the measuring device and holders.

Example:Piston overhang = 10.150 mm, corresponds to cylinder head gasket with 2 recesses (arrow).

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z Clean sealing surfaces.

The sealing surfaces for the cylinder head gasket must be clean and free of oil.

Make sure the clamping bushings (1) are in place.

1

z Fit a new cylinder head gasket.

Label OBEN / TOP facing the cylinder head.

1

z Fit cylinder head. z Oil the cylinder head screws slightly.

z Fasten all screws (1).

Attention!

Screws can be reused a maximum 3 times with written documentation.

1

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04

z Tighten cylinder head screws with socket wrench in-

sert according to the tightening sequence. – Stage 1:

 30 Nm

– Stage 2:

 80 Nm

– Stage 3:

 160 Nm

– Stage 4:

 90°

10

3 1

8

6 4

2

5

7

9

z Insert stop rods (1). z Install rocker arm and rocker arm bracket.

 W 01-02-02

– D 2011 w

z Install the air intake pipe.

 W 06-07-03

– TD 2011 w, TCD 2011 w

z Install the charge air pipe.

 W 06-02-03

1

z Install exhaust gas collection pipe.

 W 06-09-08

z Install thermostat housing.

 W 09-08-04

z Mount new injection lines (1). z Tighten union nuts (2) with claw span ne r .

 25 Nm

2

1

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z Position clamping claws (1).

z Tighten screws (2).

 21 Nm

Attention!

Install tension-free.

2

1

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04

Technical Data

Testing and setting data

Tightening specifications

ID no. Name Additional information Value

P02 75 Piston overhang

Identification, cylinder head gasket = 1 recess

0.325 - 0.604 mm

P02 76 Piston overhang

Identification, cylinder head gasket = 2 recesses

0.605 - 0.704 mm

P02 77 Piston overhang

Identification, cylinder head gasket = 3 recesses

0.705 - 0.804 mm

Recess cylinder head

P02 75 Piston overhang

Identification, cylinder head gasket = 1 recess

9.820 - 10.140 mm

P02 76 Piston overhang

Identification, cylinder head gasket = 2 recesses

10.141 - 10.239 mm

P02 77 Piston overhang

Identification, cylinder head gasket = 3 recesses

10.240 - 10.310 mm

ID no. Name Screw type Notes / Remark Value

A01 001 Cylinder head on crankcase

Stage 1: Cylinder head screws can be used a maximum of 3x with written documentation. Otherwise use new cylinder head screws. Observe tightening sequence.

30 Nm

A01 001 Cylinder head on crankcase Stage 2 80 Nm A01 001 Cylinder head on crankcase Stage 3 160 Nm A01 001 Cylinder head on crankcase Stag e 4 90°

A07 003

Injection line on fuel injector / injection pump

M12x1.5 25 Nm

A09 020 Pipe clip on holder M6x16 21 Nm

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

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09

Checking piston overhang

8190

Commercial available tools Special tools:

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

– Digital dial gauge . . . . . . . . . . . . 100410

– Measuring device . . . . . . . . . . . . 100750

– Holder . . . . . . . . . . . . . . . . . . . . . 150180

– W 01-04-04

Checking piston overhang

z Remove cylinder head.

 W 01-04-04

z Turn the crankshaft until the respective piston is just

in front of the top dead centre (arrow).

z Insert dial gauge 100400 in measuring beam. z Place spacing washers (1) on the sealing surface of

the crankcase.

z Place measuring beam (2) on the spacing washers. z Apply stylus of the dial gauge to the crankcase seal-

ing surface with pre-tension ( ar ro w) .

z Adjust dial gauge to "0".

2

1

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– Recess cylinder head

z Insert dial gauge 100410 in measuring beam. z Place holders (1) on the sealing surface of the crank-

case.

z Place measuring beam (2) on the holders. z Apply stylus of the dial gauge to the crankcase seal-

ing surface with pre-tension ( ar ro w) .

z Adjust dial gauge to "0".

2

11

z Measure at the points (1) and (2) on the piston.

Schematic representation

2

1

z Move the measuring beam. z Apply the stylus to the piston base (arrow) under pre-

tension.

z Continue turning the crankshaft evenly until the re-

versal point of the pointer on the dial gauge is reached.

The stylus may not be positioned on the labelling of the piston. Note greatest measured value.

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09

– Recess cylinder head

z Move the measuring beam. z Apply the stylus to the piston base (arrow) under pre-

tension.

z Continue turning the crankshaft evenly until the re-

versal point of the pointer on the dial gauge is reached.

The stylus may not be positioned on the labelling of the piston. Note greatest measured value.

z Select cylinder head gasket according to the largest

piston projection measured. – 1 recess

 0.325 - 0.604 mm

– 2 recesses

 0.605 - 0.704 mm

– 3 recesses

 0.705 - 0.804 mm

z Remove the measuring device and spacer discs. z Install cylinder head.

Example:Piston overhang = 0.7 mm, corresponds to cylinder head gasket with 2 recesses (arrow).

 W 01-04-04

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D 2011 wCylinder head

TD 2011 w, TCD 2011 wW 01-04-09

– Recess cylinder head

z Select cylinder head gasket according to the largest

piston projection measured. – 1 recess

 9.820 - 10.140 mm

– 2 recesses

 10.141 - 10.239 mm

– 3 recesses

 10.240 - 10.310 mm

z Remove the measuring device and holders. z Install cylinder head.

Example:Piston overhang = 10.150 mm, corresponds to cylinder head gasket with 2 recesses (arrow).

 W 01-04-04

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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09

Technical Data

Testing and setting data

ID no. Name Additional information Value

P02 75 Piston overhang

Identification, cylinder head gasket = 1 recess

0.325 - 0.604 mm

P02 76 Piston overhang

Identification, cylinder head gasket = 2 recesses

0.605 - 0.704 mm

P02 77 Piston overhang

Identification, cylinder head gasket = 3 recesses

0.705 - 0.804 mm

D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head

P02 75 Piston overhang

Identification, cylinder head gasket = 1 recess

9.820 - 10.140 mm

P02 76 Piston overhang

Identification, cylinder head gasket = 2 recesses

10.141 - 10.239 mm

P02 77 Piston overhang

Identification, cylinder head gasket = 3 recesses

10.240 - 10.310 mm

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

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D 2011 wCylinder head

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D 2011 w Crankcase TD 2011 w, TCD 2011 w W 03-01-11

Removing and installing the crankcase bleeding

Commercial available tools Special tools:

– Disassembly tool. . . . . . . . . . . . . 110901

Removing the crankcase bleeding

z Unscrew screw (1). z Remove crankcase bleeding (2).

1

2

z Remove the O-ring (1) with the disassembly tool. z Visually inspect the components.

1

2/4

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D 2011 wCrankcase

TD 2011 w, TCD 2011 wW 03-01-11

Install crankcase bleeding

z Clean sealing surfaces. z Insert new O-ring (1).

1

z Mount crankcase vent (2).

z Tighten screw (1).

 8.5 Nm

Ensure that the installation location is free from faults.

The crankcase bleeding must fit evenly.

1

2

3/4

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D 2011 w Crankcase TD 2011 w, TCD 2011 w W 03-01-11

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A03 060

Crankcase bleeding on front cover / on 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.

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D 2011 wCrankcase

TD 2011 w, TCD 2011 wW 03-01-11

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D 2011 w Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-01-05

Removing and installing the exhaust line

Commercial available tools:

– Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 06-06-04

Removing exhaust line

– TD 2011 w, TCD 2011 w

z Remove turbocharger.

 W 06-06-04

z Unscrew all screws (1). z Remove exhaust line (2).

1

12

1

z Remove gaskets (1).

1

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D 2011 wExhaust system/Charging

TD 2011 w, TCD 2011 wW 06-01-05

z Unscrew studs (1). z Visually inspect the components.

1

Installing exhaust line

z Clean sealing surfaces. z Turn on new pin bolts (1). z Tighten pin bolts (1).

 12 Nm

1

2

z Clean sealing surfaces. z Mount exhaust line (1). z Mount new gaskets.

z Turn in new screws (2). z Tighten new screws (2).

 55 Nm

– TD 2011 w, TCD 2011 w

z Install the turbocharger.

 W 06-06-04

Note installation position.

2

21

2

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D 2011 w Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-01-05

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A06 001 Exhaust pipe at cylinder head

Torx screw, coated

Use new screws. 55 Nm

A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 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

6

D 2011 wExhaust system/Charging

TD 2011 w, TCD 2011 wW 06-01-05

1/4

6

Exhaust system/Charging

TD 2011 w, TCD 2011 w W 06-02-03

Removing and install the charge air line

Commercial available tools:

– Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 06-06-04 – W 06-01-05

Remove charge air line

z Remove turbocharger.

 W 06-06-04

z Remove the exhaust pipe.

 W 06-01-05

z Unscrew all screws (1). z Remove charge air pipe (2). z Remove seals.

1

2

1

z Clean sealing surfaces.

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Exhaust system/Charging

TD 2011 w, TCD 2011 wW 06-02-03

Install charge air line

z Mount charge air line (1). z Mount new gaskets. z Tighten screws (2) alternately working from the cen-

tre to the outside.

 21 Nm

z Install the exhaust pipe.

 W 06-01-05

z Install the turbocharger.

 W 06-06-04

2

1

2

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6

Exhaust system/Charging

TD 2011 w, TCD 2011 w W 06-02-03

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A06 030 Charge air pipe on cylinder head

Torx screw, coated

Use new screws. 21 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

6

Exhaust system/Charging

TD 2011 w, TCD 2011 wW 06-02-03

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6

Exhaust system/Charging

TD 2011 w, TCD 2011 w W 06-06-04

Removing and installing the turbocharger

Commercial available tools:

– Clamping tongs. . . . . . . . . . . . . . . . 9088

– Spring band pliers. . . . . . . . . . . . . . 9090

– Lubricating oil – Fitting compound

DEUTZ S1

Attention!

Do not remove the stoppers/caps until immediately before assembly.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Removing turbocharger

z Unscrew screw (1). z Remove the holder (2). z Remove oil return pipe (3). z Unscrew hollow screw (4). z Remove sealing rings.

1

3

4

2

z Loosen hose clip (1) with clamping tongs. z Pull off hose clip (1) in the direction of the arrow.

1

2/8

6

Exhaust system/Charging

TD 2011 w, TCD 2011 wW 06-06-04

z Loosen spring band clip (1) with spring band pliers. z Remove reducer (2).

1

2

z Unscrew hollow screw (1). z Remove lubricating oil pipe (2). z Remove sealing rings. z Press in stoppers.

1

2

z Loosen spring band clip (1) with spring band pliers. z Pull off spring band clip (1) in the direction of the ar-

row.

1

3/8

6

Exhaust system/Charging

TD 2011 w, TCD 2011 w W 06-06-04

z Unscrew nuts (1).

1

z Remove turbocharger in the direction of the arrow. z Remove gasket (1).

1

z Remove the O-ring (1) with the disassembly tool. z Unscrew screw-in nipple (2). z Remove sealing ring (3).

1

2

3

4/8

6

Exhaust system/Charging

TD 2011 w, TCD 2011 wW 06-06-04

z Unscrew studs (1). z Check components for visible signs of wear.

1

Installing the turbocharger

z Mount sealing ring (1). z Tighten screw-in nipple (2).

 40 Nm

z Insert new O-ring (3).

3

2

1

z Clean sealing surfaces. z Coat pin bolts with mounting compound. z Screw in studs (1). z Tighten all pin bolts (1).

 12 Nm

1

5/8

6

Exhaust system/Charging

TD 2011 w, TCD 2011 w W 06-06-04

z Mount gasket (1). z Plug in the tubing connection (2). z Insert turbocharger in the direction of the arrow.

1

2

z Mount turbocharger (1). z Turn on new nuts (2). z Tighten nuts (2).

 21 Nm

2

1

2

z Position the spring band clip (1) with the spring band

pliers.

z Pull out stoppers. z Fill in clean lubricating oil (arrow).

1

6/8

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Exhaust system/Charging

TD 2011 w, TCD 2011 wW 06-06-04

z Mount lubrication oil line (1). z Mount sealing rings (2). z Screw on hollow screw (3).

3

2

1

z Insert new O-ring (1). z Lightly oil new O-ring (1).

1

z Mount oil return pipe (1). z Mount holder (2). z Tighten screw (3).

 8.5 Nm

z Mount new sealing rings (4). z Tighten hollow screw (5).

Attention!

Install tension-free.

3

1

5

4

2

7/8

6

Exhaust system/Charging

TD 2011 w, TCD 2011 w W 06-06-04

z Tighten hollow screw (1).

 29 Nm

Attention!

Install tension-free.

1

z Mount the reducer (1).

z Position spring band clip (2) with spring band pliers.

Attention!

Install tension-free.

2

1

z Position hose clip (1) with clamping tongs.

1

8/8

6

Exhaust system/Charging

TD 2011 w, TCD 2011 wW 06-06-04

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm A06 020 Turbocharger on exhaust pipe M8 21 Nm

A08 042

Lubricating oil pipe on turbocharger /

crankcase

Hollow screw Replace sealing rings 29 Nm

A08 044

Oil return line, hex spuds to turbocharger

M16x1.5 Use new sealing ring 40 Nm

A08 049 Holder oil return line on crankcase

Torx, M6x14-8.8

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.

1/4

6

Exhaust system/Charging

D 2011 w W 06-07-03

Removing and installing the intake manifold

Commercial available tools:

– Torx tool set . . . . . . . . . . . . . . . . . . 8189

– W 06-01-05

Removing the intake manifold

z Remove the exhaust pipe.

 W 06-01-05

z Unscrew all screws (1). z Remove intake manifold (2). z Remove seals.

1

11

2

z Clean sealing surfaces.

2/4

6

Exhaust system/Charging

D 2011 wW 06-07-03

Installing the intake manifold

z Mount new gaskets. z Mount intake manifold (1). z Tighten new screws (2) alternately working from the

centre to the outside.

 21 Nm

z Install the exhaust pipe.

 W 06-01-05

2

22

1

Deutz TD 2011 w, D 2011 w, TCD 2011 w Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual