Deutz d2011l03 руководство по ремонту

●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.

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

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.

–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

–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.

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

3.3 Operation manual and workshop

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

3.4.2 Structure of a job card

5

16

6

15

6 7

14

8

13

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 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

No.

Kompression in bar

Compression value in bar

1

2

3

4

5

6

7

8

General

W 00-02-06

●Unscrew screw (1).

6

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

W 07-07-01

D 2011

TD 2011

© 47005-0

© 47001-0

Standard tools:

– Lifting gear

– Suspension ropes

– Eyelet bolts

– 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 6 standard equipment are not shown.

Standard tools:

– Feeler gauges

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

Attention!

In case of internal exhaust gas recircula— tion, 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 6 consideration the setting dimension.

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