DEUTZ TCD 4.1 L4 (Tier 4f) FENDT 500 Vario 54 435 436 437 438 DEUTZ Workshop Service Manual PDF

• DEUTZ engines are the result of years of research and development. The detailed know-how gained by this in connection with the high quality demands are the guarantee for production of engines with a long life, high reliability and low fuel consumption. Naturally the high demands for protection of the environment are also met.

• Maintenance and care are the prerequisite for the engine satisfying the demands placed on it. Compliance with the specified maintenance times and careful execution of maintenance and care work are therefore absolutely necessary. In particular, attention must be paid to more difficult operating conditions that deviate from normal operation.

• Please contact one of our assigned service agents in case of malfunctions and spare parts inquiries. Our specially trained personnel will ensure fast, professional repairs using original DEUTZ spare parts in case of damage. Original replacement parts from DEUTZAG are always manufactured in accordance with the state-of-the-art.

• Please read and take note of the information in this documentation. This will prevent accidents, preserve the manufacturer’s guarantee and maintain a functional and operational engine.

• This engine is defined exclusively for purpose according to the scope of delivery and built by the equipment manufacturer (use for the intended purpose). Any other use above and beyond this will be considered as misuse. The manufacturer will not accept any liability for damages resulting from this. The user bears the sole risk.

   • Proper intended use also includes compliance with the operating, maintenance and servicing conditions specified by the manufacturer. The engine may only be used, maintained and serviced by persons who are familiar with it and are aware of the hazards.

• Ensure the documentation is available to the relevant persons during operation, maintenance and servicing and that the contents are understood.

• Failure to observe this documentation may lead to malfunctioning and engine damage, as well as injuries to persons, for which the manufacturer bears no liability.

• A prerequisite for proper maintenance and servicing is the availability of all required equipment, standard and special tools in the industry and that they are in proper working order.

• Engine parts such as springs, clamps, elastic fasteners, etc. can pose an increased hazard if not used properly.

• Compliance with the relevant accident prevention regulations and other generally recognized safety and occupational medicine rules is required. General

• The highest level of economic efficiency, reliability and a long service life can only be ensured if DEUTZ original parts are used.

• The servicing of the engine must comply with the proper use. Only parts approved for the respective use may be used for retrofitting. Unauthorised modifications to the engine will exclude the manufacturer from all liability for resulting damage. The guarantee will be void in the event of noncompliance!

• The engines from DEUTZ were developed for a wide spectrum of applications. A comprehensive range of variants ensures that the respective special requirements are fulfilled.

• The engine is equipped accordingly for the particular installation situation, i.e. not all the components and parts described in the documentation are installed in your engine.

• We made every effort to clearly highlight the differences so you can easily find the relevant operating, maintenance and repair instructions for your engine.

Workshop
Manual
General
Safety information I User information
Special
tools
Job
cards
01 Crankcase/Front
cover
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) 48
W 01-05-02 Checking the cylinder
W 01-08-01 Removing and installing the piston cooling nozzles
W 01-09-01 Removing and installing mass balancing
shafts 56
W 01-09-02 Checking mass compensation
shafts 60
W 01-11-01 Removing and installing the camshaft bearing (camshaft removed}
W 01-11-02 Checking the camshaft bearings
W 01-12-01 Removing and installing crankshaft bearing
covers 72
W 01-90-01 Sealing
parts
02 Oil pan

W 02-01-01 Removing and installing the lubricating oil pan (metal sheet lubricating oil
pan) 76
W 02-90-24 Oil filler neck (Lubricating oil pan, start
page) 82
05 Crankshaft/Torsional vibration damper/
83
W 05-02-01 Removing and installing the torsional vibration damper
83
W 05-03-01 Removing and installing the flywheel (Fastening parts)
86
W 05-03-03 Replacing the starter ring on the
flywheel 90
W 05-04-01 Removing and installing the mass compensation gear
93
W 05-05-01 Removing and installing the crankshaft
101
W 05-05-02 Checking the crankshaft

103
W 05-05-03 Checking axial clearance of the crankshaft
107
W 05-06-01 Removing and installing crankshaft bearings
110
W 05-06-02 Checking the crankshaft bearing
113
W 05-07-01 Removing and installing the sensor wheel
115
06 Connecting rod

117
W 06-01-01 Removing and installing the con
rod 117
W 06-01-02 Checking the
con-rod
124
07
Piston
131
W 07-01-01 Removing and installing the piston
131
W 07-01-02 Checking the piston

133
W 07-02-01 Removing and installing piston rings
137
W 07-02-02 Checking piston rings

139
08 Cylinder head

141
W 08-00-01 Checking the compression pressure
141
W 08-01-01 Removing and installing the cylinder head cover
145
W 08-03-01 Removing and installing the cylinder head (Fastening parts)
148
W 08-04-01 Removing and installing the valves
152

W 08-04-02 Checking the valves, valve guide, valve spring, valve lag

W 08-05-02 Replacing the injector
sleeve
W 08-90-14 Engine suspension (Cylinder head)

09 Gear case/Gear drive

W 09-01-01 Replacing the crankshaft sealing ring (Flywheel
side)
W 09-02-01 Removing and installing the gear
case
W 09-90-01 Sealing parts (Gear case
cover)
10
Camshaft

W 10-02-01 Removing and installing the camshaft

W 10-02-02 Checking the camshaft

11 Control parts

W 11-01-01 Checking and setting valve clearance (4
cylinders)
W 11-02-01 Removing and installing the valve
control
W 11-02-02 Dismantling and assembling the valve
control
W 11-03-01 Removing and installing control units

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)

W 15-90-12 Add-on parts (Lubricating oil cooler housing)

W 15-90-32 Coolant line (Lubricating oil cooler housing – Crankcase)

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 17-01-03 Dismantling and assembling the control
block
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 20-90-17 Fuel
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 21-90-30 Fuel lines (Fuel supply pump, fuel filter, control block, rail, cylinder head)

22 Air filter/Suction pipe/Charge air line

W 22-01-01 Removing and installing the charge air line

W 22-90-20 Pressure sensor (Mixing pipe)

37 Coolant pump

W 37-03-01 Removing and installing the coolant pump (Fastening parts)
W 37-05-01 Removing and installing the adapter (Coolant pump – thermostat housing)
W 37-90-13 V-ribbed pulley

38 Coolant pipes/Thermostat
housing

W 38-01-02 Checking the thermostat (when removed)

W 38-02-01 Removing and installing the thermostat housing (Fastening
parts)
W 38-90-01 Sealing parts (Thermostat
housing)
W 38-90-32 Venting line (Thermostat housing –
cooler)
39 Cooling fan/Fan

W 39-03-01 Removing and installing the fan bearing (Fastening parts)

W 39-03-03 Dismantling and assembling the fan
bearing
W 39-90-76 Belt tensioner (Belt drive)

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 41-05-13 Removing and installing the bracket (cooler – exhaust gas
recirculation)
W 41-06-01 Removing and installing the temperature sensor

W 41-06-02 Removing and installing the pressure sensor (Venturi tube)

W 41-90-01 Threaded socket (Exhaust line)

W 41-90-32 Line (Exhaust pipe – mixing pipe)

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-ribbed pulley (with clamping cone)

W 44-90-05 Fastening parts
(Starter)

W 44-90-08 Shield plate (Starter)

48
Electric

W 48-02-01 Removing and installing the engine speed sensor (crankshaft) (Fastening parts)
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 48-90-05 Fastening parts (Cable harness)

W 48-90-05 Fastening parts (Relay –
generator)
W 48-90-05 Fastening parts (Speed sensor
crankshaft)
W 48-90-19 Temperature
sensor

49 Tools/Special tools

W 49-02-02 Installing and removing the turning gear (Torsional vibration damper)

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 63-01-01 Removing and installing the heating flange

W 63-01-02 Disassembling and assembling the heating
flange
W 63-06-01 Removing and installing the mixing pipe

W 63-07-01 Removing and installing the throttle valve

71 Exhaust gas
treatment

W 71-05-01 Disassembling and assembling the particle
filter
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 71-90-47 Supply pump SCR (Selective Catalytic Reduction)

75
Heater

W 75-90-72 Heat connection (Lubricating oil cooler
housing)
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)

48
Electric

T 48-10-01 Pressure sensor/ temperature sensor Technical data

T 48-10-02 Pressure sensor Technical data

T 48-10-05 Pressure sensor Technical data

T 48-10-11 Pressure sensor Technical data

T 48-10-19 Pressure sensor Technical data

T 48-20-02 Temperature sensor Technical data

T 48-20-03 Temperature sensor Technical data

T 48-30-05 Speed sensor Technical data

T 48-50-06 NOx sensor Technical data

91 Connection
diagrams

S 91-20-00 Gerateseitige Verkabelung / Equipment harness

S 91-10-00 Motor Kabelbaum / Engine harness

S 91-10-00 Motor Kabelbaum / Engine harness