Deutz TCD 2013 4V Industry Engine Workshop Manual – 2013 (P/N 0312 3132 en)

DEUTZ AG workshop manual for TCD 2013 4V Industry engines in L4 and L6 configurations, P/N 0312 3132 en, 2nd Edition (November 2006).

Searchable PDF with Job Card Bookmarks

Text search and navigation: Searchable PDF text and embedded bookmarks provide access to the technical data, individual Job Cards, and tool catalogs.

The ZIP contains one printable, English-language 356-page PDF. This total includes two preliminary pages—an outer-cover print-production page and a blank reverse—along with the manual’s title, publication, contents, section-divider, and other blank pages.

Engine Repair and Common Rail Job Cards

The following selected topics illustrate the manual’s coverage rather than reproduce its complete contents. Further procedures include crankcase-breather disassembly and crankshaft/camshaft impulse-transmitter replacement.

• Cylinder head and valve train: Compression testing, valve-clearance setting, cylinder-head removal, valve-control disassembly, valve inspection, valve-guide checks, and valve-lag measurement.

• Crankshaft, pistons, and liners: Crankshaft removal and inspection, sealing-ring replacement, piston and connecting-rod service, ring-groove inspection, cylinder-liner replacement, camshaft inspection, and gearcase procedures.

• DEUTZ Common Rail: Fuel supply pump, control block, high-pressure pumps in installation positions A and B, rail, injectors, pressure-limiting valve, rail-pressure sensor, and fuel-pressure sensor.

• Air, exhaust, and EGR: Turbocharger removal and installation, exhaust and charge-air lines, heating flange, flutter valve, EGR cooler, actuator, and shutoff valve.

• Lubrication and cooling: Heavy-duty oil-pan removal, oil cooler and housing, oil pressure switch, coolant pump, thermostat and housing, and temperature transmitter.

• Electrical components and accessories: Generator removal and installation on the operating and outlet sides, starter replacement, charge-air pressure/temperature sensor, torsional vibration damper, flywheel, and air conditioning compressor.

This manual is written for appropriately qualified technicians with the technical knowledge, workshop equipment, and special tools required for engine repair.

Job Card References and Workshop Preparation

The 63 indexed W-series Job Cards identify prerequisite work, standard and special tools, auxiliary materials, test and setting references, tightening references, safety notes, and illustrated repair procedures.

Alphabetical and numerical indexes are backed by a cross-reference matrix. These references help establish the related work and equipment needed before a major assembly is dismantled. Step-by-step instructions cover jobs such as cylinder-head removal, piston and connecting-rod installation, cylinder-liner replacement, and injector removal.

The separate operation manual is required for maintenance schedules, operating media, and the filling or bleeding procedures referenced by the Job Cards.

Internal Inspection and Assembly Details

Cylinder-head installation links piston-overhang measurement to head-gasket selection. Valve-control assembly distinguishes rocker-arm bracket orientation on engines with and without a brake module.

Crankshaft inspection includes journal hardness, diameter, runout, axial clearance, and thrust-ring selection. Piston inspection covers pin bores, skirt measuring points, piston rings, and ring grooves; liner procedures include bore measurement and overhang checks. Camshaft inspection is included, but repairing a damaged camshaft is not permitted.

A fractured connecting-rod cap must remain paired with its original rod and retain its orientation; incorrect assembly can make the rod unusable. Injector and crankshaft-seal procedures also identify damage risks at nozzle tips, sealing rings, O-ring grooves, and shaft sealing surfaces.

Common Rail Installation and Cleanliness

The two high-pressure-pump installation positions have separate procedures covering roller tappets, O-rings, fuel pipes, high-pressure lines, and connections. Rail and injector installation includes pipe-renewal requirements and component-specific tightening instructions.

The Common Rail cleanliness section addresses immediate capping of open ports and protection from dust, grinding, welding, and compressed-air cleaning around exposed fuel components.

The safety material covers residual fuel pressure and leak hazards, secure engine handling on the assembly block, electrical isolation, and recovery of coolant and oil. Refrigerant work must follow the vehicle or equipment manufacturer’s documentation.

Cooling, Lubrication, and Electrical Scope

Oil-pan and oil-cooler procedures include sealing-surface preparation, gasket or O-ring replacement, and tightening sequences. Cooling-system work addresses pump connections, both thermostats, their housing, and the temperature transmitter; filling instructions refer to the applicable operation or equipment documentation.

Electrical coverage concerns component removal and installation. Wiring diagrams, ECU fault-code routines, and electronic troubleshooting charts are outside this manual’s scope.

Factory Tables, Measuring Views, and Tools

Testing and setting tables cover cylinder-head dimensions, valve seats and guides, valve springs, crankshaft journals and bearings, connecting rods, piston pins, pistons and rings, camshaft bearings, crankcase bores, liner inspection, seal installation, and thermostat data.

The 112 tightening-table entries include torque and angle specifications, tightening sequences, fastener-renewal requirements, reuse limits, and assembly notes.

Visual references include separate L4/L6 valve-setting charts, cylinder-head tightening sequences, crankshaft-journal measuring diagrams, piston-pin-bore and piston-diameter schematics, and cylinder-liner measuring views. Photographs distinguish the two high-pressure-pump installation positions.

Tool references include compression tester 8005 with connector 100180, assembly block 6066, clamping bracket 6066/210, lifting device 6068, and high-pressure-line wrench 110500.

The illustrated catalogs also identify O-ring assembly case 110900, crankshaft-seal installers 142810 and 142820, and cylinder-liner removal and installation tools 150170/150171 and 150190/150191.

A Preview of Crankshaft and Compression Checks

For crankshaft inspection, the testing and setting data lists permissible axial clearance of 0.1–0.32 mm. The related Job Card covers dial-gauge measurement and thrust-ring selection.

Compression testing compares cylinders: a deviation greater than 15% calls for further investigation. The manual explains that cranking speed and installation altitude affect the measured pressure, preventing a universal absolute pressure limit.