This is the COMPLETE Service Repair Manual for the Deutz TCD 4.1 L4 Industry Diesel Engine (EU Stage V / US EPA Tier 4). It contains service, repair procedures, assembling, disassembling, wiring diagrams and everything you need to know.
The Service Manual contains detailed information, electrical and hydraulic diagrams, actual real photo illustrations and schemes, which give you complete step-by-step operations on repair, Diagnosing, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. YOU CAN DO THE REPAIRS YOURSELF AND SAVE MONEY $$$
Service Repair Manual Contains:
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General
Safety information / User information
Special tools
Job cards
01 Crankcase/Front cover
W 01-00-01 Check crankcase pressure
W 01-01-01 Removing and installing the crankcase ventilation.
W 01-02-01 Replacing the crankshaft sealing ring (opposite side to flywheel)
W 01-02-02 Mounting / dismounting shaft sleeve on the crankshaft (opposite side to flywheel)
W 01-03-01 Removing and fitting the front cover (Fastening parts)
W 01-90-01 Sealing parts (Crankcase)
W 01-90-09 Holder (crankcase breather)
W 01-90-09 Holder (oil measuring device, cylinder head)
W 01-90-32 Line (crankcase breather)
02 Oil pan
W 02-01-01 Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)
05 Crankshaft/Torsional vibration damper/
W 05-01-01 Removing and installing the V-ribbed pulley
W 05-03-01 Removing and installing the flywheel (Fastening parts)
W 05-07-01 Removing and installing the sensor wheel
08 Cylinder head
W 08-00-01 Checking the compression pressure
W 08-01-01 Removing and installing the cylinder head cover
W 08-05-03 Clean injector sleeve
W 08-90-14 Transport eye (Cylinder head)
09 Gear case/Gear drive
W 09-01-01 Replacing the crankshaft sealing ring (Flywheel side)
11 Control parts.
W 11-01-01 Checking and setting valve clearance (4 cylinders)
15 Lubricating oil cooler/Lubricating oil filter
W 15-02-01 Removing and installing the lubricating oil cooler
W 15-02-02 Removing and installing the lubricating oil cooler housing
W 15-90-01 Sealing parts (Lubricating oil cooler housing)
16 Lubricating oil pipe
W 16-01-01 Removing and installing the oil suction pipe
17 Injection pump/High pressure pump
W 17-01-01 Removing and installing the control block (Fastening parts)
W 17-01-04 Removing and installing the high-pressure pump (Fastening parts)
19 Fuel injector/Injector.
W 19-01-01 Removing and installing the injector (1600 bar injection system)
20 Fuel filter/Fuel pump
W 20-02-01 Removing and installing the fuel supply pump (Fastening parts)
W 20-90-01 Sealing parts (Fuel supply pump)
W 20-90-16 Fuel pre-filter
W 20-90-40 Level sensor (Fuel pre-filter)
21 Fuel pipes.
W 21-01-02 Removing and installing the fuel line (control block – high-pressure pumps)
W 21-04-01 Removing and installing the rail (1600 bar injection system)
W 21-04-03 Removing and installing the pressure relief valve (Rail)
W 21-04-05 Removing and installing the rail pressure sensor
W 21-05-04 Removing and installing the fuel line (Rail, cylinder head, control block)
W 21-90-71 Vibration damper (installation position) (High pressure lines)
22 Air filter/Suction pipe/Charge air line
W 22-01-01 Removing and installing the charge air line
W 22-90-01 Sealing parts (Mixing pipe, charge air)
W 22-90-35 Intake nozzle (Exhaust turbocharger)
37 Coolant pump
W 37-03-01 Removing and installing the coolant pump (V-rib belt, level 1)
W 37-90-06 Drive components (Coolant pump)
38 Coolant pipes/Thermostat housing
W 38-01-01 Removing and installing the thermostat
W 38-01-02 Checking the thermostat (when removed)
W 38-02-01 Removing and installing the thermostat housing (Fastening parts)
W 38-05-02 Removing and installing the breather pipe (Cooler – thermostat housing, exhaust gas recirculation)
W 38-90-01 Sealing parts (Coolant pump – thermostat housing)
W 38-90-04 Connection (Compensation tank)
W 38-90-32 Line (cylinder head – cooler, exhaust gas recirculation)
39 Cooling fan/Fan
W 39-01-01 Removing and installing the belt tensioner (V-rib belt, level 1)
W 39-90-05 Fastening parts (Fan bearing)
41 Exhaust pipe/Exhaust gas recirculation
W 41-01-01 Removing and installing the exhaust pipe
W 41-05-01 Removing and installing the flutter valve
W 41-05-02 Removing and installing the cooler
W 41-05-03 Removing and installing the actuator
W 41-05-10 Removing and installing the Venturi tube
W 41-06-01 Removing and installing the temperature sensor (Exhaust gas recirculation)
W 41-06-02 Removing and installing the pressure sensor (Exhaust gas recirculation)
W 41-90-12 Add-on parts (Cylinder head)
W 41-90-21 Exhaust hose (Venturi tube – mixer pipe)
W 41-90-32 Line (cylinder head – cooler, exhaust gas recirculation)
43 Exhaust gas turbocharger
W 43-01-01 Removing and installing the exhaust gas turbocharger
W 43-04-01 Removing and installing the lubricating oil line (Exhaust turbocharger)
W 43-05-01 Removing and installing the lubricating oil return line (upper partial section) (Exhaust turbocharger)
W 43-05-02 Removing and installing the lubricating oil return line (lower partial section) (Exhaust turbocharger)
44 Generator/Starter
W 44-02-01 Removing and installing the generator (V-rib belt, level 1)
W 44-02-03 Removing and installing the V-belt pulley / V-ribbed pulley
W 44-02-06 Removing and installing the console (V-rib belt, level 1)
W 44-02-06 Removing and installing the console (V-rib belt, level 1)
W 44-90-04 Connection (Starter)
W 44-90-08 Shield plate (Starter)
W 44-90-42 Generator
W 44-90-90 Starter (Fastening parts)
47 Engine mounting elastic
W 47-90-09 Holder (Stand foot, opposite side to flywheel)
48 Electric
W 48-02-01 Removing and installing the engine speed sensor (crankshaft)
W 48-02-03 Removing and installing the speed sensor (camshaft) (add-on parts)
W 48-03-01 Removing and installing pressure/temperature sensor (Charge air)
W 48-90-08 Shield plate (Pressure/temperature sensor charge air)
W 48-90-09 Holder (fastening parts) (Cable harness)
W 48-90-11 Holder (Cable harness)
W 48-90-20 Pressure sensor installation (Fuel pressure / lubricating oil pressure)
W 48-90-68 Cable harness (Fastening parts)
49 Tools/Special tools
W 49-01-03 Check cooling system for leaks
W 49-02-02 Installing and removing the turning gear (V-ribbed pulley)
52 Connection housing
W 52-01-01 Installing and removing the connection housing
W 52-90-07 Cover sheet (Connection housing)
63 Start aid
W 63-06-01 Removing and installing the mixing pipe
W 63-07-01 Removing and installing the throttle valve
W 63-08-01 Removing and installing the flange
71 Exhaust gas treatment
W 71-05-01 Dismantling and assembling the diesel particle filter (System 8.5″ axial and radial -removed)
W 71-05-04 Removing and installing the sensor (NOx)
W 71-06-02 Removing and installing the metering unit SCR (Selective Catalytic Reduction)
W 71-06-06 Flush the supply pump SCR (Selective Catalytic Reduction)
W 71-06-07 Flush/test metering unit SCR (Selective Catalytic Reduction)
W 71-06-08 Flush the line (supply pump – metering unit). SCR (Selective Catalytic Reduction)
W 71-90-01 Sealing parts (diesel oxidation catalytic converter/diesel particle filter, SCR catalytic
converter) (NOx sensor, temperature sensor, diesel particle filter differential pressure sensor)
W 71-90-02 Locking screw, SCR catalytic converter (NOx sensor)
W 71-90-02 Locking screw, diesel oxidation catalytic converter (Temperature sensor)
W 71-90-20 Differential pressure sensor (diesel particle filter)
W 71-90-20 Temperature sensor (Air intake temperature, Ambient air temperature)
W 71-90-20 Temperature sensor (before SCR catalytic converter)
W 71-90-20 Temperature sensor (before and after diesel oxidation catalyst)
W 71-90-22 V-belt clip (Exhaust pipe 3″)
W 71-90-22 V-belt clip (Exhaust turbocharger)
W 71-90-29 Solenoid valve SCR (Selective Catalytic Reduction)
W 71-90-48 Inlet module
W 71-90-49 Outlet module
83 Hydraulic pump/Hydraulic pump drive
W 83-90-01 Sealing parts (Auxiliary power take-off PTO-B)
W 83-90-01 Sealing parts (Crankcase, auxiliary power take-off PTO-A)
W 83-90-01 Sealing parts (Crankcase, auxiliary power take-off PTO-A)
W 83-90-01 Sealing parts (Gear case, auxiliary power take-off PTO-C)
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** Model Specification: Deutz TCD 4.1 L4 Industry Diesel Engine (EU Stage V / US EPA Tier 4)
** Language: English
** Total Pages: 313
** File Format: PDF
** Requirements: Adobe PDF Reader
** Compatible: All Versions of Windows & Mac, Linux OS, Iphone, Ipad, Android etc…
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