Deutz D 2011 w Workshop Manual

Workshop Manual

0312 4176 en

This document is subject to changes which may become necessary in the course of further de-

velopment of the engines. Reprinting and reproductions of any kind, even in part, require our

written permission.

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D 2011 w

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: [email protected]

Printed in Germany

1st Edition, 12/2008

Order No. 0312 4176 en

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 data

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

1

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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 this is con-

sidered 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 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.

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 in-

jury to persons for which the manufacturer will

not accept any liability.

z Prerequisite for proper maintenance and repair is

the availability of all the necessary equipment,

conventional and special tools and their perfect

condition.

z Engine parts such as springs, clamps, elastic re-

taining rings etc. pose an increased risk of injury

when handled incorrectly.

z The pertinent rules for the prevention of acci-

dents and other generally recognised health and

safety regulations must be observed.

z Maximum economy, reliability and long life is only

guaranteed when using DEUTZ original parts.

z Repair of the engine must correspond to its use

for the intended purpose. Only parts released by

the manufacturer for the respective purpose may

be used for conversion work. Unauthorised mod-

ifications to the engine exclude manufacturer lia-

bility 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 var-

iants ensures that the respective special require-

ments 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, 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

1

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DEUTZ enginesForeword

2

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DEUTZ engines General

2 General

2

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DEUTZ enginesGeneral

2

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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 de-

mands 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. Compli-

ance with the prescribed maintenance times and the

careful execution of maintenance and care work are

therefore essential. Difficult operating conditions,

deviating from normal operation, must be 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.

2

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DEUTZ enginesGeneral

3

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DEUTZ engines User notes

3 User notes

3

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DEUTZ enginesUser notes

3

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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, illustra-

tions 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 protec-

tion 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 mainte-

nance 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 per-

formed are specified in the maintenance schedule

of the operation manual. The job cards contain tech-

nical documentation on the execution of mainte-

nance work.

3.2 Specifications

3.2.1 Accident prevention and safety regu-

lations

The legally prescribed rules for the prevention of ac-

cidents 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 be-

ing used.

Special protection measures are specified depend-

ing 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 op-

eration.

– 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 opera-

tion 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 stand-

still and secured against starting.

– Injection lines and high pressure pipes must

not be deformed.

3

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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 pro-

tective glasses) when performing tests on the

running engine and during the first trial run.

– Always stay out of range of a fuel jet, as it

could cause severe injury.

– Smoking is strictly prohibited when working on

the fuel system.

– Do not work near to sparks and flames.

– Never disconnect an injector when the engine

is running.

3.2.2 Cleanliness instructions and meas-

ures for handling the DEUTZ Com-

mon Rail System

The DEUTZ Common Rail system used in the

DEUTZ engines consists of high-precision compo-

nents which are exposed to extreme stress. Great

attention must be paid to cleanliness when working

on the fuel system due to the high precision technol-

ogy.

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 con-

nections 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 sys-

tem.

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 regu-

larly. 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 en-

gines, 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 chrome-

plated.

Notes and measures to be observed during work

on the fuel system or with the fuel system 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 sys-

tem.

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 chrome-

plated.

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 fi-

bres (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 stop-

pers/caps.

z The stoppers/caps may only be removed imme-

diately before installing.

z Store stoppers/caps free from dust and dirt in the

original packaging and dispose of after using

once.

z Only remove new parts from the original packag-

ing just before installation.

z Removed components must be kept in new, seal-

able bags or - if available - in the packaging of the

new parts.

z Always use the original packaging of the new part

to send back the removed components.

Notes and measures for the vehicle workshop

area

z For work such as removal and installation on de-

fective hydraulic components on the Common

Rail System it is recommended to partition off a

separate workshop area in the factory. This must

be separate from other areas in which 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 benches 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.

Notes and measures for workbench and 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 chrome-

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 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.

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.

3

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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 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 es-

pecially for the safety regulations. The workshop

manual describes repairs to the engine and compo-

nents for which more effort and appropriately quali-

fied 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 appro-

priate work procedures for repairing the engine and/

or its components. The workshop must satisfy spe-

cial 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

5

7

5

9

13

14

15

8

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.

Caution!

Danger to the component/engine. Non-

compliance 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 re-

ference is given to the Test and Setting Va-

lues 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 re-

ference is given to the Tightening Specifi-

cations table.

For example:

ID no. A01 001 = cylinder head screws

3

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DEUTZ enginesUser notes

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