Deutz TBD 616 OEM, TBD 616 V-12, TBD 616 V-8, TBD 616 V-16 Operating Instructions Manual

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Operating Instructions

TBD 616 OEM

Operating Instructions

TBD 616 OEM

Operating Instructions

TBD 616 OEM

0299 8561 en

Engine Number:

Please enter your engine number here. This will help us to serve you better in questions of repairs, spare parts and after-sales service generally.

We reserve the right to make technical alterations to the drawings and particulars in this documentation package, if this should become necessary to improve the engines. Reprints and duplication of any kind, either in whole or in part, require our written permission.

TBD 616 OEM

This documentation is intended for the following engine

● Engine type:

● Application:

● System name:

● Rating: kW

● Speed: min

-1

● Commissioning on:

Please enter the relevant data. This will make it easier for us to help you in questions involving repairs, spare parts and after-sales service in general.

This documentation package is to be presented to the Service Partner responsible every time a service job is carried out.

Imprint: DEUTZ AG Service Information Systems Deutz-Mülheimer-Straße 147–149 D-51063 Cologne Tel.: (02 21) 8 22-0 Fax: (02 21) 8 22-53 58 http://www.deutz.de

Printed in Germany All rights reseved (1) 0304 ©

Ordering No 0299 8561 en

Chapter 0- Page 4 300200039-en-00.fm © 0304

Introduction

Medium-sized and large engines

0Introduction

instructions carefully. You will avoid accidents, retain the manufacturer’s warranty, and will be able to use a fully functional and operational engine.

● This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely by the user.

● The term “intended use” shall also include compliance with the operating, maintenance and repair conditions specified by the manufacturer. The engine may be used, maintained and repaired only by persons who are familiar with the work concerned and who have been properly informed of the risks involved.

● Make sure that these operating instructions are available to everyone involved in operating, maintaining, and repairing the engine, and that they have all understood the contents.

● Non-compliance with these operating instructions may result in engine malfunctions and even damage or injury to persons; the manufacturer will accept no liability in such cases.

● Proper maintenance and repair work depends on the availability of all requisite equipment, tools and special implements, all of which must be in perfect condition.

● Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled properly.

● The relevant accident prevention regulations and other generally recognized rules relating to safety engineering and health and safety at work must all be complied with.

● Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are used.

● Engine repairs must correspond to the intended use. In the event of modification work, only parts approved by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will preclude any liability of the manufacturer for resultant damage.

Please read all ...● Please read all the information contained in this manual, and follow the

Introduction

Medium-sized and large engines

Careful when the engine is running!

Carry out maintenance or repair jobs only when the engine is at a standstill. If you remove any protective features, fit them back in position after completing your work. Always wear tight-fitting clothing if you are working on the engine while it is running.

Safety

You will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safety instructions to your operating staff as well. In addition, comply with the statutory general safety and accident prevention regulations applying in your country.

Instruction

You will find this symbol next to instructions of a general nature. Follow these instructions carefully.

Asbestos

The seals and gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair jobs.

Chapter 0 - Page 6 300200002-en-00.fm © 0303

Introduction

Medium-sized and large engines

The engines of the DEUTZ brand have been developed for a broad spectrum of applications. A comprehensive range of differe nt variant s ensures that special requirements can be met for the individual case involved.

Your engine has been equipped to suit your own particular installation, and accordingly not all of the devices and components described in these operating instructions will actually be fitted to your engine.

We have endeavoured to present th e diff erences involved as clearly as possible, to make it easier for you to find the operating an d maintenance instructions you need for your own particular engine.

Please read this manual before you start up your engine, and follow the operating and maintenance instructions meticulously.

If you have any questions, just get in touch with us, and we will be pleased to answer them for you.

Yours sincerely, DEUTZ AG

ForwordDear customer,

The in-depth know-how thus acquired, in conjunction with high standards of quality, is your guarantee for engines manufactured for long lifetime , hig h re liability and low fuel consumption. And of course, stringent criteria of environment-friendliness are met as well.

requirements involved. Compliance with the specified maintenance intervals and meticulous performance of care and maintenance work are therefore absolutely essential. Special attention must be paid to any more critical operating conditions deviating from the norm.

our responsible service agencies. Our trained and qualified staff will ensure fast, professional rectification of any damage, using original parts.

Original parts from DEUTZ AG have always been manufactured to the very latest state-of-the-art.

You will find details of our after-sales service at the end of these operating instructions.

DEUTZ enginesare the culmination of long years filled with research and development work.

Care and maintenanceare crucial factors in ensuring that your engine satisfactorily meets the

DEUTZ ServiceIn the event of malfunctions, or if you need spare p ar ts, please contact one of

Introduction

Medium-sized and large engines

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Chapter 0 - Page 8 300200002-en-00.fm © 0303

TBD 616 Marine

Contents 0Introduction

Please read all ..................................................................................................... 0-5

Careful when the engine is running!..................................................................... 0-6

Forword................................................................................................................. 0-7

DEUTZ engines.................................................................................................... 0-7

Care and maintenance...................................................................................... 0-7

DEUTZ Service.................................................................................................. 0-7

1User Guide

General................................................................................................................. 1-1

Regulations........................................................................................................... 1-1

Safety Regulations / Rules for Accident Prevention .......................................... 1-1

Rules for disposal.............................................................................................. 1-2

Operating Instructions and Workshop Manual...................................................... 1-2

Job cards .............................................................................................................. 1-4

Spares .................................................................................................................. 1-6

2 Description

Type and designations.......................................................................................... 2-1

Type designation ............................................................................................... 2-1

Rating plate........................................................................................................ 2-1

Position on the engine.................................................................................... 2-1

Figure rating plate........................................................................................... 2-2

Designation of the engine sides, cylinder and direction of rotation.................... 2-3

Direction of rotation......................................................................................... 2-3

Engine figures.................................................................................................... 2-4

Left side.......................................................................................................... 2-4

Right side........................................................................................................ 2-5

Drive side........................................................................................................ 2-6

Structure and function........................................................................................... 2-7

Crankcase.......................................................................................................... 2-7

Crankcase bleeding (Racor)........................................................................... 2-8

Crank drive and valve drive............................................................................. 2-10

Wheel drive...................................................................................................... 2-12

Mass compensation shaft (V8 engines only)................................................ 2-13

Cylinder head................................................................................................... 2-14

Structure....................................................................................................... 2-14

Valve control................................................................................................. 2-15

Charging.......................................................................................................... 2-16

Schematic diagram of the charge air circuit (with liquid-cooled charge air cooler)

2-18

Schematic diagram of the charge air circuit (air / air charge air cooler)....... 2-19

Exhaust gas system......................................................................................... 2-20

Exhaust system with the DEUTZ PEARL® System...................................... 2-20

Surge charging............................................................................................. 2-20

Fuel system ..................................................................................................... 2-21

Contents

Emissions ..................................................................................................... 2-21

Injection .............................................. ... ... .................................................... 2-21

Fuel pipe system................ ... .... ... ... ................................................................. 2-22

Fuelpipe system V8 engine................ ... ... .................................................... 2-22

Fuel pipe system V12 engine ............................................. ... ... .... ................ 2-23

Fuel pipe system V 16 engine ............................................ ... ... .... ... ... ... ....... 2-24

Speed regulation .............................................................................................. 2-25

Electronic speed governing systems............................................................ 2-25

Lube oil system.................. ... ....................................... ... .... ... ... ... .... ... ............. 2-31

Cooling system ............ ... ... ... .... ... .................................................................... 2-31

Schematic representation of the dual-circu it coo ling ............................. ... .... 2-34

Starter............................................. ... .... ... ....................................................... 2-36

Electronic engine controller EMR2 ..................................... ... ... ....................... 2-37

Use and structure ..... ... ................................................................................. 2-37

Function.......... ... ... .... ... ... .............................................................................. 2-38

System functions ................................................ ... ... ... .... ... .......................... 2-39

Configuration and parameterization............................. ................................. 2-41

Diagnostic possibilities........................ .......................................................... 2-41

TBD 616 Marine

3 Operation

Work prior to commissioning................................................................................. 3-1

General.............................................................................................................. 3-1

Operating media................................................................................................ 3-2

Coolant ........................................................................................................... 3-2

Coolant level................................................................................................... 3-3

Fuel................................................................................................................. 3-3

Lubricant......................................................................................................... 3-5

Monitoring.......................................................................................................... 3-6

Starter system.................................................................................................... 3-6

Room ventilation................................................................................................ 3-6

Commissioning ..................................................................................................... 3-7

Starting the engine............................................................................................. 3-7

Monitoring operation.......................................................................................... 3-7

Shutting down.................................................................................................... 3-7

4 Expendables

General remarks................................................................................................... 4-1

Warranty............................................................................................................ 4-1

Product selection............................................................................................... 4-1

Mixability............................................................................................................ 4-1

Fuel....................................................................................................................... 4-1

Engine lube oil ...................................................................................................... 4-1

Engine coolant...................................................................................................... 4-1

Auxiliary materials................................................................................................. 4-3

Sealants and securing agents ........................................................................... 4-3

Gluing agents..................................................................................................... 4-5

Lubricants.......................................................................................................... 4-5

Other auxiliary materials.................................................................................... 4-6

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TBD 616 Marine

5 Maintenance

Continuous supervision ........................................................................................ 5-1

Maintenance schedule.......................................................................................... 5-1

General.............................................................................................................. 5-1

Selection and structure...................................................................................... 5-1

Deutz maintenance and service schedule......................................................... 5-2

Specific maintenance schedule performance group A1 ....................................... 5-3

Operating hour-independent maintenance work................................................ 5-4

Definition of activities in the maintenance schedule.......................................... 5-5

Operating hour-dependent maintenance work .................................................. 5-5

Overview of operating hour-independent maintenance work (copy form)......... 5-8

Overview of operating hour-dependent maintenance work (copy form)............ 5-9

Specific maintenance schedule performance group A2 ..................................... 5-13

Operating hour-independent maintenance work.............................................. 5-14

Definition of activities in the maintenance schedule........................................ 5-15

Operating hour-dependent maintenance work ................................................ 5-15

Overview of operating hour-independent maintenance work (copy form)....... 5-18

Overview of operating hour-dependent maintenance work (copy form).......... 5-19

Specific maintenance schedule performance group B ....................................... 5-21

Operating hour-independent maintenance work.............................................. 5-22

Definition of activities in the maintenance schedule........................................ 5-23

Operating hour-dependent maintenance work ................................................ 5-23

Overview of operating hour-independent maintenance work (copy form)....... 5-26

Overview of operating hour-dependent maintenance work (copy form).......... 5-27

Specific maintenance schedule performance group C....................................... 5-29

Operating hour-independent maintenance work.............................................. 5-30

Definition of activities in the maintenance schedule........................................ 5-31

Operating hour-dependent maintenance work ................................................ 5-31

Overview of operating hour-independent maintenance work (copy form)....... 5-34

Overview of operating hour-dependent maintenance work (copy form).......... 5-35

Tools for maintenance work up to E40............................................................... 5-37

Standard tool kits............................................................................................. 5-37

Small tool kit ................................................................................................. 5-37

Large tool kit................................................................................................. 5-38

Tool kit supplement I..................................................................................... 5-39

Tool kit supplement II.................................................................................... 5-39

Turning device.............................................................................................. 5-40

V-belt tension measuring instrument............................................................ 5-41

Tools for maintenance work from E50.................................................................. 5-1

Contents

6 Troubleshooting

Fault table............................................................................................................. 6-1

7Conservation

Conservation......................................................................................................... 7-1

8 Technical particulars

General engine data............................................................................................. 8-1

Contents

TBD 616 Marine

Basic data.......................................................................................................... 8-1

Control data....................................................................................................... 8-1

Ignition sequence............................................................................................... 8-1

Dimensions........................................................................................................ 8-2

Weights.............................................................................................................. 8-2

Operating data...................................................................................................... 8-3

Filling volumes................................................................................................... 8-3

Temperatures .................................................................................................... 8-3

Pressures........................................................................................................... 8-3

Emission data.................................................................................................... 8-3

Start of pumping ................................................................................................ 8-3

Tightening specifications for maintenance work up to E40................................... 8-5

Tightening specifications for maintenance work from E50.................................... 8-1

9Job Cards

Explanation of symbols......................................................................................... 9-1

Overviews............................................................................................................. 9-2

Arranged alphabetically..................................................................................... 9-2

Arranged by Job Card Numbers........................................................................ 9-3

10 Other instructions Index Service

We move your world.................................... ... ... ......................................... Service-1

DEUTZ AG - at your service........ ... ... .... ... ... ... ... .... ... ............................... Service-1

Sales & Service Index.................. ... .......................................... ... ............ Service-1

DEPIC.......................... ... ... ... .......................................... .... ..................... Service-1

Seminar program .... .... ... ... ... .......................................... .... ..................... Service-1

Contents - Page 4 300200038-en-00IVZ.fm © 0103

User Guide

Engines and systems

1 User Guide

and the workshop manual must be performed on schedule and in full. The maintenance and service personnel must have the necessary technical

knowledge to perform the work. Safety and protection devices which may have to be removed during maintenance and service work must be replaced afterwards.

The rules for the prevention of accidents and the safety regulations must be observed at all times during maintenance and service work.

Please also observe the special safety regulations for the various service groups which are listed in detail as job cards in the job cards chapter (cf. also chapter 1 Safety Regulations / Rules for Accident Prevention).

The maintenance and service intervals are listed in the maintenance and service schedules. These also provide information about the work to be performed.

The job cards provide technical hints for performing the work.

GeneralThe maintenance and service work prescribed in the operating instructions

Detailed safety instructions have been compiled for various service groups in the form of job cards, these precede the job cards of the respective service groups.

The legally prescribed rules for accident prevention (available from the appropriate associations or technical publishers) must be observed. These depend on the installation site, the mode of operation and the operating and auxiliary media being used.

Special safety measures depende nt on the respective work are spec ified and highlighted in the work description.

It generally applies among other things:

● for personnel:

- Only instructed personnel may operate or maintain the engine.

Unauthorised persons may not enter the engine room.

- Wear tight fitting clothing and ear protectors in the engine room

when engines are running.

- Only employ qualified personnel for repairs or service work.

● for the engine room:

- Ensure adequate fresh air and ventilation (do not cover ventila-

tion shafts).

- Provide first aid kits and suitable fire extinguishers. Check the fil-

ling and proper functioning regularly.

- Only store inflammable materials in the engine room which are

necessary for operating the system.

- Smoking and naked lights are prohibited in the engine room.

Regulations

Safety Regulations / Rules for Accident Prevention

User Guide

Engines and systems

● for operation and maintenance of the engine:

- Only start the engine when all safety devices have been fitted and

the turning gear has been removed. Make sure there is no-one in the danger zone.

- Only perform cleaning, maintenance and repair work when the

engine is switched off and secured against starting up.

Rules for disposal The work described in the operating instructions and workshop manual

necessitates the renewal of parts and expendables among other things. These renewed parts / e xpendables m ust be prope rly stored, tr ansp orted and disposed of. The owner is responsible for this.

Disposal includes recycling and disposal of parts / expendables whereby recycling has priority .

The details of disposal and its supervision are governed by regional, national and international laws and decrees which the plant owner is responsible for observing.

Operating Instructions and Workshop Manual

The service documentation is divided in to the operating instructions an d the workshop manual for a user-oriented organisation of the information content.

The Operating Instructions contain a general description as well as instructions for the necessary maintenance and service work which can be performed by a trained operator.

It contains the following chapters:

0 Introduction

Contents 1 User guide 2 Description (description of the engine and components) 3 Operation (operating the engine)

Expendables (operating media specifications and auxiliary materi-

als) 5 Maintenance 6 Troubleshooting 7 Conservation (conservation of the engine) 8 Technical particulars 9 Job cards (in order of job card numbers)

10 Sundry other instructions (if not in the appendix or separate folders)

Index

Service

Chapter 1 - Page 2 300200004-en-01.fm © 0303

User Guide

Engines and systems

The Workshop Manual assumes knowledge of the content of the operating instructions, this applies especially to the safety regulations. Minor repairs and emergency measures on components are described which require a greater effort and appropriately qualified personnel.

It contains the chapters:

0 Introduction

Contents 1User guide 2-4 See operating instructions 5 Tools for service 6-7 See operating instructions 8 Technical particulars 9 Job cards (in order of job card numbers) 10 Sundry other instructions (if not in the appendix or separate folders)

Service

User Guide

Engines and systems

Job cards

The Job cards are divided into Job cards of the operating instructions, e.g. B 1-1-1 and job cards of the workshop manual, e.g. W 4-5-1.

● Please see Figure 1-1 for explanations of the numbering.

● The structure of the job card is shown in Figure 1-2.

Type of documentation

• The letter at the front signifies the type of documentation involved.

 B = Operating Instructions

W = Workshop Manual

Maintenance Group (the same for all engines)

 0 General remarks

1 Cylinder head 2 Drive mechanism 3 Crankcase 4 Engine control 5 Governor 6 Exhaust gas system / Charging 7 Fuel system

/ cross-category jobs

8 Lube oil system

9 Coolant system 10 Compressed air system 11 Monitoring system 12 Other components 13 Electrical system

Subsystem (component)

• The subsystems are distinguished by maintenance groups.

• Generally valid:  0 Cross-subsystem or Safety Regulations

1 System parameters or general checks

B 3-3-3

Figure 1-1 Numbering of the job cards

Serial Number

• Counting per subsystem (component)

• Various jobs per subsystem (component)

• Version differences

Chapter 1 - Page 4 300200004-en-01.fm © 0303

User Guide

Engines and systems

3 4

111213

Figure 1-2 Numbering of the job cards

When making inquiries about the job card please always state the engine type or the system 2, the number of the job card 3, the page number 11, the date of issue 13 or alternatively the identification number of the job card.

DEUTZ Service, publisher of the service documen-

tation

8Figures

' 80300-5

2 Engine type or system 9 General notes 3 Number of the job card 10 Work sequence 4 Title of the job card 11 Page number 5 Tools, aids, spares and references 12 Identification number of the job card 6 Safety instructions 13 Date of issue of the job card 7 Sub-headings

User Guide

Engines and systems

Spares Spares are available from DEUTZ Service. You will find a list of spares in the

spare parts list of the engine or the system. You will find further information in

Chapter Service, at the end of the operating instructions.

Chapter 1 - Page 6 300200004-en-01.fm © 0303

Description

TBD 616 OEM

2 Description

The engines in this series are water-cooled four-stroke diesel engines which can be used for various powertrains.

See also rating plate (Figure 2-2, item 1)

Turbocharger T Charge air cooler B Diesel engine D Series 616 V-engine V

TBD616V_

Type and designations

Type designation

No. of cylinders 8, 12 or 16

tionally.

Rating plate Position on the engineThe rating plate is fixed to the engine. The engine number is punched addi-

Figure 2-1 Position of the rating plate and the engine number on the engine (example)

Description

Figure rating plate

TBD 616 OEM

Figure 2-2 Figure rating plate

1 Engine type designation 2 Year of manufacture 3 Engine number

Performance code according to DIN ISO 3046 Part 7

4, 5, 6

A * or ** is specified after the performance code if the available performance is restricted to a certain time according to special manufacturer specifications, see 13, 14.

7, 8, 9 Numeric value of the performance in kW

10, 11, 12 Engine speed in rpm

13, 14 Time limiting of the available performance in hours (h)

15 Height above sea level (conditions at installation site) 16 Air pressure p

Charge air coolant temperature t

tion site) 18 Relative humidity F 19 Air temperature t

in mbar (conditions at installation site)

in °C (conditions at installa-

in % (conditions at installation site)

in °C (conditions at installation site)

20, 21, 22 Numeric value of an auxiliary device in kW (F, G, H)

Chapter 2 - Page 2 300200040-en-00.fm © 0103

Description

TBD 616 OEM

Designation of the engine sides, cylinder and direction of rotation

The four sides of the engine normally carry the following designations in practice (see Figure 2-3): The designation used in this operating manual is highlighted respectively in bold print and corresponds with

DIN ISO 1204.

1 3

Figure 2-3 Designation of the engine sides and cylinders

Engine sides

1 Drive side Flywheel, clutch side 2 Left side Cylinder side A 3 Free side End, damper, flui d pump, clutch opposite side 4 Right side Cylinder side B

Cylinder numbering

... counted and labelled from the drive side.

Direction of rotation

Looking towards the drive side in anticlockwise direction ”left-han d rotation”

Description

Engine figures Left side

TBD 616 OEM

Figure 2-4 Engine, left side

1 Charge air cooler 7 Oil pan 2 Suction air intake filter 8 Rotary current alternator 3 Crankcase bleed valve 9 Coolant pump of the charge air cooler 4 Exhaust gas turbocharger cylinder side A 10 Rotary vibration damper 5 Heat insulation cladding PEARL exhaust pipe 11 Coolant pump engine cooling circuit 6 Starter 12 Holder for attaching the engine (second holder

on the diagonally opposite side)

Chapter 2 - Page 4 300200040-en-00.fm © 0103

Description

Right side

TBD 616 OEM

Figure 2-5 Engine, right side

1 Lube oil nozzle 5 Lube oil filter 2 Fuel filter 6 Fuel hand pump 3 Lube oil cooler 7 Heat insulation cladding PEARL exhaust pipe 4 Oil dipstick 8 Exhaust gas turbocharger cylinder side B

Description

Drive side

TBD 616 OEM

Figure 2-6 Engine, drive side

1 Flywheel 2 Flywheel housing 3 Holder for attaching the engine (second holder on the diagonally opposite side)

Chapter 2 - Page 6 300200040-en-00.fm © 0103

Description

TBD 616 OEM

Structure and function

Crankcase

The crankcase is made from a special alloyed casting. Torsional strength, breaking strength and casting tightness which enable low weight and compactness distinguish this manufacturing method. The side walls of the crankcase are pulled down below the center of the crankshaft and therefore guarantee additional torsional strength. The cylinder angle of 60° enables a narrow design which is demanded in ma ny applica tions.

Figure 2-7 Crankcase

Description

TBD 616 OEM

Crankcase bleeding (Racor)

Fumes are produced in the crankcase during engine operation. To protect the environment these fumes are not allowed to escape into the atmosphere but are fed into a closed crankcase bleeding system. In this crankcase bleeding system the filter performs important functions.

The fumes flowing into the filter first pass the pressure control valve which is mounted centrally in the top part of the filter system. After passing the filter element the purified residual gases are fed to the suction line between the suction air intake filter and the turbocharger.

The pressure regulator consists of a diaphragm valve loaded both sides. It controls the crankcase pressure while at the same time vacuum pressures from the suction intake system settle at an upper limit. Pulsating pressure peaks are limited as a result.

An optical indicator signals it is time to change the filter element. The exchangeable and recyclable filter element consists of a micro glass fibre structure with a filter effect up

to 0.3 µm. This can be changed without tools due to quick-change catches. The filtered oil particles collect in the sump of the filter casing and are fed back into the oil circuit by a return line.

A floor valve prevents gas getting in through the return line. The oil returns on exceeding the pressure difference between the filter and crankcase or at engine standstill.

Figure 2-8 Crankcase bleed valve

1 Optical indicator for due change of filter element 2 Quick-release catches 3 Filter top with integrated pressure regulator 4 Powder-coated metal housing 5 Filter element 6 Round sealing ring 7 Round sealing ring 8 Floor insert

Chapter 2 - Page 8 300200040-en-00.fm © 0103

Description

TBD 616 OEM

This crankcase bleeding system achieves that:

● the engine room and system are not contaminated by oil fumes,

● the smell in the immediate vicinity is reduced,

● environmental pollution is reduced,

● charge air cooler, turbocharger and inlet valves are better protected against soiling.

Figure 2-9 Schematic of the crankcase bleeding system

1 Sucked in air 2 Suction air intake filter 3 Turbocharger 4 Exhaust gas 5 Charge air cooler 6Engine 7 Line for fumes to the filter system 8 Line for filtered fumes into the suction line 9 Filter

10 Return to the oil pan

Description

TBD 616 OEM

Crank drive and valve drive

The crank drive comprises crankshaft, con rod, piston, rotary vibration damper and the flywheel. The drop-forged crankshaft 1 is hung in multilayer bearings in the crankcase 7. Every bearing cover is

secured by four studs. Multilayer be arings offer greater lubrication security and emergency running properties. The shaft and crank journals and the contact surfaces of the axial bearings are inductively hardened. The counterweights 9 screwed to the crank webs serve to dissipate the internal mass effect and relieve the crankshaft bearing. The rotary vibration damper and the flywheel ensure smooth running of the engine with their structure calculated exactly for every application.

The double T-shank con rods 2 are divided at an angle. This allows removal of the piston with con rod up through the cylinder liner 3. The con rods run on the crankshaft in sputter bearings. A liner is pressed into the upper con rod eye in which the piston bolt 4 is mounted on a floating bearing.

The pistons 6 are cast from a lightweight metal. The piston rings 5 (trapeze ring, minute ring and a narrow land drain oil control ring) are in cast steel beams. The pistons are supplied with cooling lube oil through a spray nozzle 8. The lube oil flows through the cooling channels of the piston base where it emits heat.

The cylinder liners 3 are made by a spin casting technique. Special emphasis is placed on honing in the further processing. The cross grind ing an gle cr eated d uring hon ing is asy m metr ical is res pon se to th e dema nd for low oil consumption and optimum run-in times . Th e cylin d er liner s to uc h th e cra n kca se and ar e gu id ed in a collar at the top and bottom.

The use of wet cylinder liners enables fast and low cost exch an ge of a cylin de r un it.

Chapter 2 - Page 10 300200040-en-00.fm © 0103

Description

TBD 616 OEM

Figure 2-10Crank and valve drive

1 Crankshaft 6 Piston 2 Con rod 7 Crankcase 3 Cylinder liner 8 Oil injection nozzle 4 Piston bolt 9 Counterweights of the cranksha ft 5Piston rings

Description

TBD 616 OEM

Wheel drive

The wheel drive serves for engine control and driving of sub-components.

Engine control unit

The toothed wheel 6 on the crankshaft drives the toothed wheel 3 on the camshaft.

Sub-components

The toothed wheel 3 on the camshaft drives the injection pump via toothed wheel 1. If hydraulic pumps are attached to the engine, toothed wheel 2 or 10, these are driven by toothed wheel 1.

The lube oil pump 7 is driven by toothed wheel 6 on the crankshaft. If a compressor is installed on the engine, toothed wheel 4, it is driven by the intermediate wheel 5, driven by

toothed wheel 6 on the crank sh aft. The coolant pump, toothed wheel 9, is driven by the intermediate wheel 8, driven by toothed wheel 6 on the

crankshaft.

Figure 2-11 Wheel drive on the free side

Gear wheels:

1 Injection pump 6 Crankshaft 2 Hydraulic pump 7 Lube oil pump 3 Camshaft 8 Intermediate wheel 4 Compressor 9 Coolant pump 5 Intermediate wheel 10 Hydraulic pump

Chapter 2 - Page 12 300200040-en-00.fm © 0103

Description

TBD 616 OEM

Mass compensation shaft (V8 engine s on ly )

Because of the number of cylinders, a mass compensation shaft must run as well in order to be able to achieve low-vibration running of the engine. The mass compensation shaft is driven by a separate wheel drive on the drive side.

Figure 2-12Wheel drive of the mass compensation shaft on the drive side

1 Crankshaft 2 Mass compensation shaft 3 Intermediate wheel

Description

TBD 616 OEM

Cylinder head Structure

The cylinder heads are made of a special alloyed casting like the crankcase. One single cylinder head is installed per cylinder. The single cylinder head can be changed very quickly thanks to its excellent accessibility and optimized design.

The channel guide is based on the cross current principle. The cylinder heads are supplied with charge air from the V-chamber via the charge air pipe. The two inlet channels 2 and 3 have different manifolds in the cylinder heads. They are divided into a filling channel 2 and a twist channel 3. The shape of these ensures a change air flow into the combustion cham ber which considerably improves the mix formation. The outlet channels 1 end on the respective outside of the engine in the exhaust system in which the exhaust gas energy is not lost but recycled.

Figure 2-13 Flow through the cylinder head into the combustion chamber

Chapter 2 - Page 14 300200040-en-00.fm © 0103

Description

TBD 616 OEM

Valve control

The cylinder heads are multi-valve heads, i.e. two inlet valves per cylinder provide for optimum filling and two outlet valves for fast exhaust gas discharge. The high heat-proof valves are fit in the pressed-in and thus easily replaceable valve seat rings. The valves are controlled by a proven valve bridge technique. The valve bridge control operates with very low wear and is extremely maintenance-friendly.

Figure 2-14Valve control

1 Camshaft 5 Toggle lever block 2 Pilz tappet 6 Valve bridges 3 Tappet rods 7 Outlet valves 4 Rocker arm 8 Inlet valves

Description

TBD 616 OEM

Charging

The engine is equipped with a bi-turbocharger and optionally with a liquid-cooled charge air cooler. The biturbocharger system shares one row of cylinders each. Therefore one exhaust turbocharger is installed per row of cylinders. The advantage of being equipped with the bi-tur bo is in the response beha vior for one thing. A small exhaust turbocharger builds up the necessary charge air pressure in a short time. On the one hand the whole engine output is available, on the other hand the typical black smoke is virtually eliminated.

Figure 2-15 Suction intake / charge air path (liquid-cooled charge air cooler)

1 Charge air cooler 5 Exhaust gas turbine of the turbocharger 2 Air filter 6 Heat insulation cladding 3 Air suction intake pipe 7 Exhaust pipe (DEUTZ PEARL 4 Turbocharger compressor 8 Charge air line

Charge air heated by the turbocharger Cool intake air and charge air cooled by the charge air cooler Hot exhaust gases

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System)

Description

TBD 616 OEM

Figure 2-16Suction intake / charge air path (air / air charge air cooling)

1 Charge air housing 5 Exhaust gas turbine of the turbocharger 2 Air filter 6 Heat insulation cladding 3 Air suction intake pipe 7 Exhaust pipe (DEUTZ PEARL 4 Turbocharger compressor 8 Charge air line

Charge air heated by the turbocharger Cool intake air and charge air cooled by the charge air cooler Hot exhaust gases

System)

Description

TBD 616 OEM

Schematic diagram of the charge air circuit (with liquid-cooled charge air cooler)

13 12 11 10

' 84204-0

Figure 2-17 Charge air circuit (with liquid-cooled charge air cooler)

1 Exhaust gas turbine of the turbocharger cylinder side A 2 Compressor turbine of the turbocharger cylinder side A 3 Suction intake air cylinder side A 4 Charge air pipe cylinder side A 5 DEUTZ PEARL 6 Charge air pipe cylinder side A 7 Cylinder heads cylinder side A 8 Charge air cooler 9 Cylinder heads cylinder side B

10 Charge air pipe cylinder side B

11 DEUTZ PEARL 12 Charge air pipe cylinder side B 13 Suction intake air cylinder side B 14 Compressor turbine of the turbocharger cylinder side B 15 Exhaust gas turbine of the turbocharger cylinder side B 16 Exhaust gas discharge cylinder side B 17 Exhaust gas discharge cylinder side A

exhaust pipe cylinder side A

exhaust pipe cylinder side B

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Description

TBD 616 OEM

Schematic diagram of the charge air circuit (air / air ch a r ge air co ol er)

12 11 10 9

Figure 2-18Charge air circuit (air / air charge air cooling)

10 DEUTZ PEARL

11 Charge air pipe cylinder side B 12 Suction intake air cylinder side B 13 Compressor turbine of the turbocharger cylinder side B 14 Exhaust gas turbine of the turbocharger cylinder side B 15 Exhaust gas discharge cylinder side B 16 Exhaust gas discharge cylinder side A

exhaust pipe cylinder side A

exhaust pipe cylinder side B

' 84243-0

Description

TBD 616 OEM

Exhaust gas system Exhaust system with the DEUTZ PEARL® System

The 12 and 16-cylinder engines are equipped with the DEUTZ PEARL DEUTZ PEARL joining of the exhaust pipe elements. This generates a backup in the two turbochargers resulting in a higher turbocharger performance.

The PEARL exhaust pipe elements 1 are connected to compensators 2. They take care of not only the simple connection between the PEARL exhaust pipe elements but also compensate the he at stresses which occur during the warm-up phase, operation and after shutting down the engine.

The PEARL exhaust gas elements are surrounded by a heatproof housing.

system allows a more effective utilization of the exhaust gas energy by special shaping and

system patented by DEUTZ. The

Figure 2-19 DEUTZ PEARL® System

Surge charging

The V8 engine is equipped with a surge charging exhaust gas system. The gases enter the exhaust pipe according to the order of ignition. The resulting p ressure waves are comb ined so that a surge charging t akes place on the turbocharger.

Figure 2-20 Surge charging

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Description

TBD 616 OEM

Fuel system Emissions

Bi-Turbo system with charge a ir cooling, cro ss curre nt cylinder heads with twist channels, pistons, multi-hole injection nozzles in connection with the high-pressure injection system, DEUTZ PEARL nents which contribute to the progressive emission behavior of the engine are adapted to each other with absolute accuracy. All the limit value specifications are complied with as a result.

Injection

The engines are equipped with a high-pressure injection system. The eight a nd twelve- cylinder eng ine operates with one, the sixteen cylinder engine with two high-pressure series injection pumps which are installed in the combustion chamber protected by the cylinder banks. The injection pump drive consists of a maintenance free laminar clutch. The connection between the two series injection pumps of the sixteen cylinder engine is guaranteed by a proven arched denture clutch.

The injection valves operate with mult i-hole injection nozzles. Eight injection holes arranged on two levels guarantee optimum fuel distribution and mix formation.

System, all compo-

Figure 2-21Spray behavior of the multi-hole nozzle

Description

TBD 616 OEM

Fuel pipe system Fuelpipe system V8 engine

The layout of the fuel pipes is shown in the following figures.

Figure 2-22 Fuel pipes V8 engine

1 Leak fuel pipe 4 Fuel hand pump 2 Solenoid valve engine shutdown 5 Series injection pump 3 Fuel pump 6 Fuel filter

Fuel pipe, supply to series injection pump Fuel pipe, return from series injection pump

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Description

Fuel pipe system V12 engine

TBD 616 OEM

Figure 2-23Fuel pipes V12 engine

1 Leak fuel pipe 4 Fuel hand pump 2 Solenoid valve engine shutdown 5 Series injection pump 3 Fuel pump 6 Fuel filter

Fuel pipe, supply to series injection pump Fuel pipe, return from series injection pump

Description

Fuel pipe system V 16 engine

TBD 616 OEM

Figure 2-24 Fuel pipes V16 engine

1 Leak fuel pipe 4 Fuel hand pump 2 Solenoid valve engine shutdown 5 Series injection pump 3 Fuel pump 6 Fuel filter

Fuel pipe of fuel hand pump Fuel pipe, supply to series injection pump Fuel pipe, return from series injection pump

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Description

TBD 616 OEM

engine by adjusting the injection pump control rod, in such a wa y that the performance required from the engine is obtained whilst maintaining a pre-set constant or variable speed.

Two electronic governing systems are available for the engines of the TBD 616 OEM series:

- Heinzmann actuator StG 2040-DP with EMR2 (digital)

- GAC (analog)

The following applies for speed governing systems:

● The speed governing systems are set according to the requirements and application of the engine.

● Settings, blockings and seals of the speed govering systems may not be changed or removed. In the event of manipulations to the governing systems, the warranty and guarantee are voided.

● If new settings become necessary due to repairs or changes in the application conditions, these may only be done by authorized personnel.

Speed regulationThe task of speed governing systems is to influence the fuel supply to the

In their basic design the electronic speed governing systems consist of the following components:

- Magnetic frequency pick-up

- Control device, analog or digital

- Actuator

- Set-point transmitter

The magnetic frequency pick-up records the actual value of the speed on the ring gear of the flywheel and passes it on to the control device. In the control device, which can be an analog or digital design, the actual value is compared to the setpoint. In the case of deviations the control device sends the command to the actuator to adjust the injection pum p control bar. The actuator sends a return signal of the control bar position to the control device.

Electronic speed governing systems

Description

TBD 616 OEM

Actuators Heinzmann actuator

On the internal shaft of the actuator is a multi-pole permanent magnet. Opposite the permanent magnet is a coil body on which is mounted a working coil. If the working coil conducts, torque occurs in one direction, the reversal of the current provides torque in the opposite direction.

The lever attached to the internal shaft is connected to the injection pump control rod with the help of a special connection system. By this means the rotary motion of the internal shaft is transferred directly as a linear movement to the control rod.

The setting of the control output shaft is detected using a non-contact method by a return system mounted firmly on the shaft and then passed to the control device.

On reaching the stop, current limitation is implemented after approx. 2 0 seconds, which reduces the actuator current to such an extent that no damage is suffered by the actuator.

Emergency stop is possible with an additional stop lever.

Figure 2-25 Actuator, Heinzmann StG 2040-DP

1 Injection pump 5 Working coil 2 Adapter plate 6 Stop lever 3 Return system 7 Control rod motion (adjustable) 4 Connection to injection pump control rod

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Description

TBD 616 OEM

GAC actuator

The GAC actuator is used to measure the fuel injection volume The difference between the nom inal and actual speed is converted into a voltage signal for the electric positioning magnets in the actuator which sets the control bar of the injection pump by the control device. In this way the fuel volume is const antly increased or reduced depending on the load requirement at constant speed. The actuator is mounted directly on the injection pump.

The actuator operates linearly, the feedback of the control bar position takes place without contact. Emergency stop is possible with an additional stop lever.

Figure 2-26GAC actuator

1 Injection pump 6 Connector plug, in GAC (digital) 2 Stop lever 7 Fastening strip 3 Connecting linkage 8 Upper chamber, in lube oil circuit 4 Connector plug, in GAC (digital) 9 Injection pump control rod 5 Electromagnetic chamber (encapsulated) 10 Connecting plate

Description

TBD 616 OEM

Frequency pick-up

The magnetic frequency pick-up is installed on the drive side. It produces electrica l pulses proportional to the speed of the ring gear on the flywheel, by sampling the teeth of the ring gear, which move past the frequency pick-up, and transmits these pulses to the control device.

The number of installed frequency pick-ups de pends on the speed governing system used.

Figure 2-27 Frequency pick-up (installation example for EMR2)

1 Frequency pick-up 2 Starter ring gear on flywheel

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Description

TBD 616 OEM

Setpoint potentiometer

The setting of the setpoint speed can be implemented by a setp oint potentiom eter, current or voltage signals or adjusted fixed values.

Control devices

The control device monitors the various input signals, e.g. the actual value of the speed, the current setting of the set-point transmitter and the setting of the actuator. In the case of deviations from the setpoint, the control device sends the command to the actuator to adjust the injection pump con trol bar and thus ada pt the available fuel volume.

According to the control system used, various control devices are available:

- Electronic engine controller DEUTZ EMR2

- Control device for GAC speed governing system (analog)

Electronic engine controller EMR2

The electronic engine controller EMR2 is equippe d with an ef ficient mi croproce ssor and an internal co ntroller program. Changes to the settings are made by a PC/laptop with a special conne cting cable and the ap propriate software and may only be performed by authorized personnel.

Further information about the electronic engine controller EMR2 can be found in the section ”Electronic engine controller EMR2”.

Control device for GAC speed governing system (analog)

This speed governing system is an electronic analog governor, it is set with the potentiometers and switches on the control device.

Description

TBD 616 OEM

Figure 2-28 Control device GAC (analog)

Item: Name: Function:

1 OVERSPEED Indicator LED for overspeed 2 C1 LEAD CIRCUIT Switch for additional damping

C2 SOFTCOUPLING Switch for resonance vibration suppression 3 RESET Overspeed reset button 4 TEST Overspeed test button, reduces the switching point by 10 % 5 OVERSPEED Setting of overspeed 6 STABILITY Setting the strength 7 GAIN Setting the sensitivity 8 SPEED Setting the rated speed 9 - Bridge or capacitor for improving stability

10 IDLE Setting the low idling speed

11 DROOP Setting the P factor 12 STARTING FUEL Setting the fuel starting volume 13 SPEED RAMPING Setting the start ramp to minimize the smoke development

Settings on the control unit may only be made by authorized personnel.

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Description

TBD 616 OEM

Lube oil system

The lube oil reduces friction of the components which rub against each other and dissipates heat from the rubbing positions and the piston. A film of lube oil on the cylinder surfaces supports the sealing effect of the piston rings. The lube oil also suspends contamination and transports it to the the lube oil filter.

The lube oil pump sucks the lube oil from the oil panand feeds it through the lube oil cooler and the lube oil filter into the lubrication circuit of the engine.

The lube oil pressure in the engine circuit is set by a lube oil pressure regulating valve. The bypass valve is installed in the lube oil cooler to avoid the flow of lube oil being interrupted in a cold start. The overpressure valve opens when the lube oil pressure is sufficiently high and allows the surplus lube oil to flow back into the oil pan.

Cooling system

The chemical energy in the fuel is converted into heat energy during combustion. The engin e can only partly convert this into mechanical energy. The remaining heat is dissipated mainly with the exhaust gas and the coolant.

The engine operates with a dual-circuit cooling, i.e. a high temperature circuit and a low temperature circuit. The combustion chamber walls are cooled by the high temperature circuit. The coolant is fed through the

coolant chambers between the crankcase and the cylinder liners. From there the coolant is fed through bores in the crankcase to the cylinder heads. Channels in the cylinder heads feed the coolant to the floor of the cylinder head and the valve seats. The coolant emerges from the cylinder heads and is fed into the coolant manifold to the thermostats integrated in the charge air line.

The charge air cooler is cooled by the low temperature circuit. Depending on the version as air/water or air/ air cooling. In the air/water version a second coolant pump drives another cooling circuit which cools the charge air in the charge air cooler. In the air/air charge air cooling, the charge air cooling system precedes.

Description

TBD 616 OEM

Figure 2-29 Cooling system (air / water charge air cooling)

1 Discharge of hot coolant to the cooler 7 Temperature sensor 2 Thermostat housing 8 Suction intake of cooled coolant to the charge

air cooler

3 Coolant pump and inlet of the coolant in cylin-

der side ”B” 4 Suction intake of cooled coolant to the engine 10 Charge air cooler 5 Inlet of coolant to cylinder side ”A” 11 Discharge of hot coolant after charge air cooler 6 Coolant overflow of cylinder heads

Coolant circuit for cooling the cylinders and cylinder heads Coolant circuit of the air/water charge air co oler

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9 Coolant pump (cooling circuit charge air cooler)

Description

TBD 616 OEM

Figure 2-30Cooling system (air/air)

1 Discharge of hot coolant to the cooler 5 Inlet of coolant to cylinder side ”A” 2 Thermostat housing 6 Coolant overflow of cylinder heads 3 Coolant pump and inle t of th e co ola nt in cylin -

der side ”B”

4 Suction intake of cooled coolant to the engine

Coolant circuit for cooling the cylinders and cylinder heads

7 Temperature sensor

Description

TBD 616 OEM

Schematic representation of the dual-circuit cooling

5 14 13

12 10 9

Figure 2-31 Cooling system schematic (air / water)

The dual-circuit cooling system is shown in the air/water version in the figure. In the air/air version the items 6, 10 and 11 are omitted. The charge air cooler then precedes in the air/air version.

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Description

TBD 616 OEM

1 Turbocharger 2 Exhaust pipe 3 Charge air line 4 Pipe from the coolant pump to the engine 5 Thermostat 6 Charge air cooler (air/water) 7 Coolant pump (low temperature circuit) 8 Engine interface 9 Pipes to the cooler (engine c oolin g)

10 Pipes from the cooler (charge air cooling)

11 Pipes to the cooler (charge air cooling) 12 Pipes from the cooler (engine cooling) 13 Coolant pump (high temperature circuit) 14 Short-circuit line 15 Lube oil cooler 16 Pipe from lube oil cooler to the engine

Labeling of coolant:

cold warm cold and warm mixed warm and warm/cold mixed line not filled

Description

TBD 616 OEM

Starter The engine is started by an electric or pneumatic starter depending on the

version. The starter 1 has the job of accelerating the engine crankshaft to ignition

speed. On reaching this speed the compression temperature in the cylinders has heated up to ignition temperature of the injected fuel.

Figure 2-32 Electrical starter

Figure 2-33 Pneumatic starter

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Description

TBD 616 OEM

Electronic engine controller EMR2 Use and structure

The electronic engine controller EMR2 serves for speed governing of DEUTZ diesel engines. The EMR2 basically consists of sensors, the contr ol device and the a ctuator. The installation on the engine

side and the system side are connected to the EMR2 control device by separate cable harnesses.

Engine side installations

Figure 2-34EMR2, engine side installations (example: TBD 616 V12)

1 Engine 6 Sensor lube oil level 2 Cable harness engine – EMR2 control device 7 Sensor coolant temperature 3 Actuator and connection for cable harness 8 Frequency pick-up 4 Stop magnet 9 Sensor lube oil pressur e 5 Sensor charge air temperature 10 Sensor crankcase pressure and safety cut-out

(Noris)

Description

TBD 616 OEM

System side installations

- EMR2 control device

- Power supply

- Speed potentiometer (setpoint generator)

- Diagnostic interface / CAN bus

- Fault lamp

- Diagnostic button

- Warning lamps for overspeed, lube oil pressure, lube oil level, coolant temperature

- Switch for P factor, speed

- Engine stop

Figure 2-35 EMR2 control device

1EMR2 control device Mconnection for engine side cable harness Fconnection for system side cable harness

Function

The sensors mounted on the engine supply the control device electronics with all the relevant data. According to the information about the momentary condition of the engine and the presets (setpoint genera-

tor for speed, etc.) the EMR2 drives the actuator which adjusts the injection pump control rod and thus adapts the fuel volume according to the power requir ement. The actua tor sends a return signal of the injection pump control rod position to the control device.

The EMR2 is equipped with safety devices and measures in hardware and software to ensure emergency operation functions.

The ignition switch cuts off the powe r to the EMR2 to sh ut down the engine. A suf ficient ly strong spring in th e actuator pulls the injection pump control bar to the zero position in th e powerless st ate. Additionally and independently of this the fuel supply is interrupted by shutoff magnets.

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Description

TBD 616 OEM

System functions

The EMR2 offers a wide range of function s which can be activated by an application-related configuration and allocation of the inputs and outputs. It enables a signal exchange both between the engine and EMR2 (via the engine side plug) and between the system and EMR2 (via the system side plug).

The functions of the EMR2 refer to the speed governor, volume restr iction (fuel injection) , monitoring, system and device functions and communication and diagnostic interfaces.

Sensor inputs:

● control bar path

● speed

● coolant temperature

● (charge air pressure)

● (oil pressure)

● (2. speed)

● (coolant level)

● (charge air temperature)

● (fuel temperature)

● (tachometer signal)

EMR2

(atmospheric pressure)

micro-

processor

memory for

operating

software

Setpoint preset

● Key operated switch

● Setpoint transmitter

● (via CAN bus)

● (voltage 0 - 5 V)

switch for functions

Interfaces

● ISO 9141

● CAN bus, SAE J1939

actuator functions

● actuator

● (stop magnet)

The functions in brackets are optional.

Figure 2-36System functions, overview

memory for

● Parameter

● Characteristic

ffield

● Fault

power supply

Display functions/

outputs

● Fault lamp

● (warning signals)

● (multifunction

displays)

Description

TBD 616 OEM

Selected system functions are described briefly below.

Speed governing system

Different versions of the speed governor are possible depending on the application, e.g. all speed governor, fixed speed governor.

It is possible to protect the engine against overspeed with the EMR2.

Setpoint preset

The setpoint preset can be made for example by a setpoint potentiometer, a voltage signal or via an interface.

P-factor

A constant or speed-dependent P factor can be set depending on the application. In addition, switching between two P factors or between constant and speed-dependent P factor can be provided for.

Engine start/stop

As soon as the control device detects the start speed, the injection pump control bar is released for starting. The power to the EMR2 must be cut off with the key operated switch to shut down the engine. The actuator then pulls the injection pump cont rol bar to the stop po sition. Additionally and independently of this, the fuel supply is interrupted by shutoff magnets.

The engine may also be shut down b y an error in th e EMR2, e.g. ex ceeding or dr opping below fixed measured value limits.

Displays/outputs (monitoring function)

Different signals can be displayed and output through the control device outputs, e.g. fault lamp, speed, warning signals for coolant temperature, lube oil pressure, lube oil level.

The fault lamp must be mounted by the customer in a well visible place on the system. It serves for a rough estimation of an error that has occurred, see also section ”Diagnostic possibilities”.

Interfaces

The EMR2 is equipped with different interfaces for diagnostics, programming and configuration as well as the measured value and data exchange.

Error messages, measured values and other par ameters can b e displaye d via the diagn ostic interface with a PC connected via an interface and the diagnostic software SERDIA, see also section ”Diagnostic possibilities”.

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Description

TBD 616 OEM

Configuration and parameterization

The EMR2 is programmed and configured for every engine, i.e. the EMR2 gets an engine-specific data record.

A PC with the SERDIA diagnostic software is connected to the diagnostic interface via an interface for programming. Access to the various parameters is protected by access rights divided into four levels and can only be gained by authorized personnel with the relevant authorization level.

Diagnostic possibilities Self-diagnosis

The EMR2 has numerous prot ection fun ctions for the engine. The scope depends on the available measuring points and sensors. Depending on the severity of the detected fault the engine may be able to continue running with restrictions whereby the fault lamp lights steadily or the engine is shut down whereupon the lamp starts flashing.

Self-diagnosis is started by switching on the key operated switch. There is no active fault if the fault lamp goes out after 2 s. When the fault lamp flashes after 2 s, there is at least one serious fault, the eng ine ca nnot be started. If the fault lamp lights steadily, there is at least one fault, the engine may possibly be operable with restrictions in emergency mode.

If other warning lamps are configured, e.g. oil pressure, coolant temperature, these are switched on with the key operated switch as well for the duration of the self-diagnosis (2 s).

Fault messages are recorded and saved in the EMR2 control device and displayed by the fault lamp. The fault lamp goes out as soon as the fault is eliminated. If the EMR2 has switched over to emergency operation, the engine has to be shut down briefly with the key operated switch to switch off the fault lamp.

Eliminated or no longer current faults remain stored in the control device and can be read out or deleted with the SERDIA diagnostic software.

Diagnosis with key and fault code

With a diagnosis key and the fault lamp, faults can be read out as flashing codes, it is also possible to clea r the fault memory 1, see also work card B 11-6-1, Reading out the fault memory 1 of the EMR2.

Description

TBD 616 OEM

Diagnosis with SERDIA

The SERDIA software program offers the following options:

- Monitoring measured values with the engine running

- Changing parameters with the engine at a standstill

- Read out and evaluate all the fault messages stored in the control device (fault memory 2) and delete fault message of eliminated or non-current faults

- Activate function test, outputs and actuator with engine at a standstill

- Show assignment of inputs and outputs

- Show measured values graphically

Handling SERDIA is described in a separate operating manual.

Figure 2-37 Diagnosis with SERDIA (illustrated Installation in the DEUTZ Training Center in Mannheim)

1 PC / Notebook with SERDIA diagnostic software 2 Interface 3 Diagnostic interface

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Operation

TBD 616 OEM

3 Operation

and for overhauled, serviced and maintained engines. Furthermore, the commissioning report must be observed.

The work and inspections described below are necessary for trouble-free operation and prevention of accidents. The perfect functioning of the drive mechanism and speed control is necessary above all for trouble-free operation.

● Clean the lines and tanks for fuel, coolant and lube oil before filling. All lines, screw fittings and connecting elements must be checked for a tight fit, perfect condition and leaks and repaired if necessary.

● Check the alignment of the engine and proper anchoring to the foundation.

● Clean the engine and remove objects which have been placed on the engine. Fit all protective coverings to the engine.

Work prior to commissioning

GeneralWork prior to commissioning applies both for commissioning new engines

Loose objects (especially on moving part s such as flywheels) can lead to serious damage or accidents.

● Check the electrical wiring for perfect condition and laying, correct if necessary.

● Check the easy action of the control and shut-down mechanism as well as the function of monitoring, shut-down and remote control devices and repair if necessary.

Operation

TBD 616 OEM

Operating media

Observe the necessary quality of the operating media mentioned below according to operating media specifications Chapter 4, Expendables.

Coolant New engines and engines overhauled at DEUTZ are run with a special cool-

ant on the test stand. This is drained off afterwards which means that the engines are delivered dry.

● The operator must clean the coolant lines before commissioning for the first time.

● Open engine bleeding screw (arrow)

● Open the valves in the coolant lines if available

Fig. 1 Engine bleeding screw thermostat housing

● Fill up the engine’s cooling system with prepared coolant through the filling nozzle on the cooler until the coolant emerges from the engine bleed valve without bubbles. Seal the engine bleed screw (arrow) with a new sealing ring.

● The filled cooling system does not bleed automatically depending on the structure of the external cooling system. It may be necessary to remove the highest coolant hose until the coolant emerges without bubbles. Collect the emerging coolant.

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Operation

TBD 616 OEM

on the system structrue.

● Lines, connecting elements and engine must be checked for leaks after filling and repaired if necessary.

● Make a test run, see job card B 0-1-4, Test run.

● Check the coolant after shutting off the engine and refill if necessary.

The cooling system is under pressure, danger of scalding!

Ensure cleanliness! Do not spill fuel!

Only fill up with fuel with an approved filling device with the engine switched off!

Coolant level● Check the coolant level in the cooler. The test marks may vary depending

Fuel

● Fill the supply tank and daily supply tank with fuel.

Bleed the fuel system and check for leaks:

● Loosen the bleeding screw 4.

Figure 3-1 Bleeding screw of the injection pump

Operation

TBD 616 OEM

● Operate the hand pump 1 until fuel emerges free of air bubbles.

Figure 3-2 Hand pump fuel system (installation site is access-dependent)

● Tighten the bleeding screw whilst continuing pumping.

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Operation

TBD 616 OEM

● Fill the engine with lube oil up to the top dipstick mark through the lube oil nozzle (arrow).

LubricantThe engines are delivered without lube oil filling.

Figure 3-3 Lube oil nozzle (depending on the installation position of the engine, the lube oil

Figure 3-4 Oil level dipstick

nozzle is on the side with the better access)

Operation

TBD 616 OEM

● Switch on pre-lubrication (if installed).

- Pre-lubricate for at least 10 minutes after changing the lube oil.

- Pre-lubricate for at least 10 minutes after an engine standstill of > 3 hours.

- Pre-lubricate for at least 2 minutes after an engine standstill of < 3 hours.

● Check the lube oil level again, fill up to the top mark if necessary.

Monitoring ● Check the power supply to the engine monitoring system (battery).

● Switch on engine monitoring system

Starter system Compressed air starter system

● Fill starter air tank with star ter air compre ssor or carbon dioxide (CO pressurised vessel to 30 bar and drain water.

) from

Filling the starter air tank with oxygen or combustible gases such as hydrogen is mortally dangerous due to the risk of explosion.

Electric starter system

● Check the power supply to the monitor (battery).

● Check the connecting cable for correct polarity, tight fit and good contact.

Room ventilation ● Switch on the room ventilation to evacuate radiation heat and oil vapour.

The room ventilation also has the job of supplying the engine with combustion air if this sucks in from the system room.

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Operation

TBD 616 OEM

There is a danger of fire, backfiring or explosion due to igniting of unburned fuel in the exhaust system which could cause damage.

Therefore the following notes must be observed.

There may be a danger of backfiring, fire or explosion:

● in the case of voluminous and long, horizontally laid exhaust systems;

● after setting and adjustment work on the fuel system with idling periods in

rapid succession and cold exhaust pipes;

● after three mis-fires;

● in the case of insufficiently bled fuel lines.

chapter 3 Commissioning.

● Open the coolant and fuel taps. Switch on the pump if available.

● Remove the turning gear (if attached).

● Switch on engine monitoring system

● Set low engine speed.

● Start engine on the engine monitoring system.

● Slowly increase the speed and load a fter building up the lube oil pressure .

Commissioning

Starting the engine● After longer pauses in operation (cold engine) perform work according to

Do not warm up engines in idling speed without load.

monitoring system are within the specified parameters.

Let the engine run for about another 5 minutes at increased idle speed without gears before shutting down to avoid heat building up at cylinder liners and cylinder heads as well as coking on the exhaust turbocharger.

● Shut down engine on the engine monitoring system.

● Let the coolant pump assembly run for a few minutes more after shutting

down.

● If the engine is shut down f or longer, close the coolant and fuel taps and the starter air tap if available.

Monitoring operationDuring engine operation, check whether the data displayed by the engine

Shutting down● Avoid shutting down from full load.

Operation

TBD 616 OEM

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Expendables

Diesel Engines

4 Expendables

expendables used conform to requirements, no warranty will be accepted by the engine’s manufacturer for trouble-free operation. This also applies for inadequate care and maintenance of the engines and the expend ables.

and the wide variety of qualities involved, plus continual improvements as well, it is impossible for us to check all suitable products and name them, and accordingly we cannot accept any responsibility for these products.

The supply of the expendables concerned bears sole responsibility for globally consistent quality of the products named here, and in the case of products not named additionally for compliance with the specified requirements for the expendables and their operational reliability. This shall also apply in the event that the producer concerned improves the products named here.

The expendables named here (reference products) are only a selection from certain producers and their products. Other expendables not listed here may also be used, provided they conform to the requirements involved, i.e. are at least equivalent in terms of all criteria. The expendables named in this specification shall be used as reference products for purposes of comparison. The expendables suppliers involved can supply the requisite information, and should also confirm the suitability of their products correspondingly.

General remarks

WarrantyIf unsuitable expendables are used, or if it cannot be documented that the

Product selectionDue to the large number of products available nationally and internationally

other, different coolant additives with each other, may lead to malfunctions. In every such case, before any mixing is performed, permission must be

obtained from the suppliers of the products involved, who shall then bear the responsibility for any such mixing. This shall also apply to putting any further additives in the expendables.

MixabilityMixing different expendable types together, .e.g. different lube oils with each

Fuelsee Technical Circular TR 0199-99-2089. Engine lube oilsee Technical Circular TR 0199-99-2090. Engine coolantsee Technical Circular TR 0199-99-2091.

Expendables

Diesel Engines

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Chapter 4 - Page 2 300200007-en-00.fm © 0303

Expendables

Medium-sized and large engines

Auxiliary materials

Sealants and securing agents

- Observe storage stability, if any, given on the package!

- Upon transport, storage and disposing of the above-mentioned items, observe Chapter 1, Regulati-

ons, of the operating manual, if no according information is given on the package.

Material designation

DEUTZ DW 43 Sealant Solvent-free, caoutchouc-based flexibly

DEUTZ DW 47 Sealant LV 0161 9672

DEUTZ DW 48 Sealant LV 0161 9572

Type Standards and

specifications

FV 0160 9610

Characteristics Application examples

Sealing of small joints hardening, rapid skin formation, temperature range 30°C to 100°C

Silicon caoutchouc, viscously flexible, easily detachable, temperature range max. 180°C, oil max. 150°C

Silicon caoutchouc, viscously flexible, strong adhesion, temperature range –65°C to 265°C

Sealing of rough and une-

ven surfaces

Sealing of rough and une-

ven surfaces

DEUTZ DW 49 Sealant LV 0161 9571

FV 0160 9607

DEUTZ DW 50 Sealant Liquid, hardening artificial resin, compati-

DEUTZ DW 51 Sealant LV 0161 9573 Physically dry artificial resin, permanently

DEUTZ DW 55 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 56 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 57 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 59 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

Mixed polymeride of vinyl- and acryl compositions, strong adhesion permanently elastic, temperature range –40°C to 130°C

ble with gaskets, temperature range –40°C to 180°C

elastic and vibration-free, temperature range –30°C to 150°C

substance hardening upon metal contact when excluding oxygen, high strength, fluid, temperature range –55°C to 150°C

substance hardening upon metal contact when excluding oxygen, high strength, thick-flowing, temperature range –55°C to 150°C

substance hardening upon metal contact when excluding oxygen, low strength, liquid, temperature range –55°C to 150°C

substance hardening upon metal contact when excluding oxygen, high strength, medium viscous, temperature range –55°C to 150°C

Sealing of core hole plugs

Sealing of housings

Sealing of surfaces

Securing and sealing of

threads up to M12;

joints up to max. gap width

of 0.15 mm

Securing and sealing of

threads up to R2"

Securing and sealing of

threads up to M12;

Securing and sealing of

threads up to M20;

joints up to max. gap width

of max. 0.15 mm

DEUTZ DW 60 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

substance hardening upon metal contact when excluding oxygen, medium strength, liquid, temperature range –55°C to 150°C

DEUTZ DW 61 Activator FV 0160 9605 Accelerates and permits the complete hard-

ening of anaerobic substances with passive materials

Securing and sealing of

threads up to M56 or R2"

Only for passive materials

Expendables

Medium-sized and large engines

Material designation

DEUTZ DW 62 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 63 Sealant FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 64 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 65 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 66 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

DEUTZ DW 67 Sealant FV 0160 0040 Anaerobic solvent-free single-component

Type Standards and

specifications

Characteristics Application examples

upon metal contact when excluding oxygen, high strength, medium-viscous, thixotrope, temperature range –55°C to 175°C

upon metal contact when excluding oxygen, low strength thick-flowing, thixotrope, temperature range –55°C to 150°C

upon metal contact when excluding oxygen, high strength, medium-viscous, temperature range –55°C to 150°C

upon metal contact when excluding oxygen, high strength, thick-flowing, temperature range –55°C to 150°C

upon metal contact when excluding oxygen, low strength thick-flowing, temperature range –55°C to 150°C

upon metal contact when excluding oxygen, high strength, thick-flowing, thixotrope, temperature range –55°C to 150°C

Joints up to a gap width of max. 0.12 mm

Sealing of surfaces up to a gap with of max. 0.10 mm

Securing and sealing of threads up to M80 or R3"

Joints up to a gap width of max. 0.25 mm

Securing and sealing of threads up to R3"

Sealing of surfaces up to a gap width of max. 0.50 mm

DEUTZ DW 68 Sealant FV 0160 0039 Anaerobic solvent-free single-component

upon metal contact when excluding oxygen, low strength thick-flowing, thixotrope, temperature range –55°C to 150°C

DEUTZ DW 69 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

upon metal contact when excluding oxygen, low strength liquid temperature range – 55°C to 150°C

DEUTZ DW 70 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

upon metal contact when excluding oxygen, medium strength liquid temperature range – 55°C to 150°C

DEUTZ DW 71 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

upon metal contact when excluding oxygen, high strength, medium viscous, temperature range –55°C to 175°C

DEUTZ DW 72 Securing agent FV 0160 9605 Anaerobic solvent-free single-component

substance hardening upon metal contact when excluding oxygen, medium strength, medium viscous, temperature range –55°C to 150°C

Tab. 1 Sealants and securing agents

Sealing of surfaces up to a gap width of max. 0.50 mm, securing and sealing of threads R2"

Securing and sealing of threads up to M36

Securing and sealing of threads up to M12

Securing and sealing of threads up to M20; joints up to a gap width of max. 0.15 mm

Securing and sealing of threads up to M36

Chapter 4 - Page 4 300200008-en-00.fm © 0103

Expendables

Medium-sized and large engines

Gluing agents

Material designation

DEUTZ KL 1 Gluing agent LV 0161 9633

DEUTZ KL 2 Hardening agent LV 0161 9633

Tab. 2 Gluing agents

Lubricants

Material designation

DEUTZ S1 FV 0160 9537 -180°C to 1400°C Avoids burning in of screw connections in exhaust gas pipes

Type Standards and

specifications

FV 0160 9608

Standards and specifications

Temperaturrange

Characteristics Application examples

Two-component, epoxy-resin based, water, oil- and diesel fuel resistant, admiss. application temperature max. 150°C

Mixing ratio 1:1, gluing agent DEUTZ KL 1 and hardener DEUTZ KL 2

Application examples

Combines steel, alumin-

ium, brass and plastic mate-

rials such as plexiglass,

polyethylene and similar,

gluing them together or

among them

DEUTZ S2 LV 0161 9734

FV 0160 9506

DEUTZ S3 LV 0161 9733

FV 0160 9505

DEUTZ S4 LV 0161 9735 -40°C to 450°C Preferably used for pre-treating components with a high application tem-

DEUTZ S5 LV 0161 9738 -30°C to 130°C For the long-term lubrication of antifriction- and slide bearings with

DEUTZ S6 LV 0161 9741 -20°C to 180°C For the long-term lubrication of antifriction- and slide bearings with

Grease DIN 51825-

KP 2 N-30

Tab. 3 Lubricants

-25°C to 450°C Spray for reducing friction and wear for surfaces difficult to access Generates an emergency lubrication and avoids sliding back.

-35°C to 450°C Spray for reducing friction and wear. Generates an emergency lubrication and avoids sliding back.

perature. After the evaporation of the carrier oil (at 200°C), an effectively lubricating solid film remains. Compatible with natural rubber and plastic materials.

medium bearing pressures and higher temperatures. Water-resistant, good emergency lubrication.

medium bearing pressures and higher temperatures. Water-resistant, good emergency lubrication

-30°C to 140°C Consistent grease for lubricating antifriction bearings, slide bearings and sliding surfaces. For example, for filling the spiral-toothed coupling TBD 234/616.

Expendables

Medium-sized and large engines

Other auxiliary materials

Below you will find a reference list for the used auxiliary materials with which the best results have been achieved. Equivalent products can also be used; in this case, the supplier must assure the suitability of the product for the application.

- When using the products indicated below, the following references of the manufacturer must absolutely be observed:

• Safety references

• Personal protection equipment

• Use as directed

• Disposal as directed

Chapter 4 - Page 6 300200008-en-00.fm © 0103

Expendables

Medium-sized and large engines

Product group Application Product name Supplier

Detergent for engine components P3 cold cleaner (liquid) Messrs. Henkel KGAA

40191 Düsseldorf

Vecom B 24 B (liquid) Messrs. Vecom GmbH

21107 Hamburg

Carbon remover or Ameroid ACC-9 (liquid) Messrs. Drew Ameroid

Deutschland GmbH 21107 Hamburg

for engine cooling system P3 T 288 (powder)

P3 Standard (powder) Vecom BA-S (powder)

Vecom BA-30 (liquid) SAF-Acid (powder)

HDE-777 (liquid)

Messrs. KGAA 40191 Düsseldorf

Messrs. Vecom GmbH 21107 Hamburg

Messrs. Drew Ameroid Deutschland GmbH 21107 Hamburg

for intercooler (water side) and raw water circuit

for intercooler (air side)

for tank plants Vecom B 24 B (liquid)

P3 - T1166 P3 - croni (neutraliser)

SAF-Acidonly calcium solutizer) Concentration: 5 % Temperature: 55 °C - 75 °C

Porodox Concentration: 2 % - 10 % Temperatuer: 20 °C - 60 °C Treatment time: max. 16 hours

ACC 9 Messrs. Drew Ameroid

Vecom B 85 Messrs. Vecom GmbH

P3T-5308 Messrs. Henkel KGAA

Vecom B 14 (liquid) Tank cleaner Nr. 4 (liquid) Messrs. Drew Ameroid

Messrs. Henkel KGAA 40191 Düsseldorf

Messrs. Drew Ameroid Deutschland GmbH 21107 Hamburg

Messrs. Collardi GmbH 50825 Köln

Deutschland GmbH 21107 Hamburg

21107 Hamburg

40191 Düsseldorf Messrs. Vecom GmbH

21107 Hamburg

Deutschland GmbH 21107 Hamburg

for lube oil filters Ameroid ACC-9 (liquid) Messrs. Drew Ameroid

Deutschland GmbH 21107 Hamburg

P3 RST, P3 SAXIN (powder) Messrs. Henkel KGAA

40191 Düsseldorf

Filterclean Messrs. Vecom GmbH

21107 Hamburg

Expendables

Medium-sized and large engines

Product group Application Product name Supplier

Detergent (continued)

Water treatment agent

Tab. 4 Other auxiliary materials

for air filters Soda solution 1%ig

for de-preservation Eskapon S 255 Messrs. Haug-Chemie

Hardness determination for cooling water

Cooling water hardening Vecom CN (powder) Messrs. Vecom GmbH

Cooling water softening Trisodiumphosphate

Burning kerosene Mixture of: 6,5 % trilene (german: Trichlor-Äthylen) 9,5 % Teepol (Messrs. Shell) 4,0 % Cyclohexanon 80,0 % fresh water

Aquamerk Art. Nr. 11129 DEUTZ ordering-no. 1215 8292

(german:Trinatriumphosphat) (powder)

GmbH 74889 Sinsheim

Messrs. E. Merck KGAA 64293 Darmstadt

21107 Hamburg Messrs. Benckiser GmbH

67001 Ludwigshafen

Chapter 4 - Page 8 300200008-en-00.fm © 0103

Maintenance

TBD 616 OEM

5 Maintenance

Please bear in mind that the following maintenance schedule is a Recommended maintenance schedule.

Deviations from this maintenance schedule may be necessary under certain operating conditions. For example, frequent starting, long operating times on zero load, extremely frequent load changes, frequent overloading can lead to increased wear and accordingly to shorter maintenance intervals. The maintenance schedule must then be adapted to the operating con ditions in consultation with your DEUTZ SERVICE partner.

Generally the on-site operating conditions are already taken into account in the planning phase. Ask your DEUTZ SERVICE partner when in doubt.

The normal care of your engine comprise s a daily visual in spection b y technically skilled persons. The appropriate activities are listed in work card B 0-1-

Continuous supervision

Maintenance schedule

condition and thus the operational reliability of the engine and the ap propriate maintenance intervals. The maintenance work procedures are described in the specified job cards.

● The intervals prescribed in the maintenance schedule are maximum values and assume that installation, purpose and operating conditions comply with DEUTZ specifications. It must be ensured that all operating media such as fuel, lube oil and coolant have the prescribed quality. You will find information about this in Chapter 4, Expendables.

● This maintenance schedule only applie s for th e engine itself and the parts attached to the engine. System part s must be serviced at the intervals and according to the instructions specified by the manufacturer. You will find the appropriate information in the respective enclosed manufacturer documents (marked ”MD” in the maintenance schedule).

● The work described must be performed by technically skilled persons or authorised specialists. The competencies are listed in Table 1, Deutz maintenance and service schedules.

group to which the engine is assigned according to the performance abbreviation and maximum speed.

● Every maintenance schedule for a performance group consists of:

- Overview of the Deutz maintenance and service schedules and their

intervals

- Overview of the operating hour-independent maintenance measures

- Overview of the operating hour-dependent maintenance measures

- Poss. overview of the operating hour-dependent maintenance meas-

ures which are outside the intervals of the Deutz maintenance and service schedules

- Copying forms for verification

GeneralThe maintenance schedule lists the measures for maintaining the nominal

Selection and structureAn appropriate maintenance schedule applies depending on the performance

Maintenance

TBD 616 OEM

Deutz maintenance and service schedule

The operating hour-dependent maintenance work is divided into Deutz maintenance and service schedules. All the work listed must be performed carefully according to the maintenance schedule determined specifically for the engine.

Deutz maintenance and service schedules Executed by

E10 due once respectively after commissioning and E60 and E70 E20 Daily check E30 Periodic maintenance (small scope) E40 Periodic maintenance (medium scope) E50 Periodic maintenance (extended scope)

E70 Complete overhaul

Tab. 1 Deutz maintenance and service schedule

Technically skilled persons

Authorised specialistsE60 Intermediate over haul

Please note that Deutz maintenance and service schedules may be added or omitted depending on the performance code and maximum speed.

● Plan the due Deutz maintenance and service schedules in good time according to the number of hours your engine has been in operation.

● Arrange the probable appointment with your responsible DEUTZ SERVICE partner in good time. Notify your DEUTZ Service partner of any irregularities of your engine (see operating check log) when you arrange the appointment.

● Sign a service contract with DEUTZ SERVICE if necessary. All the due maintenance work including repairs if agreed is then planned and expertly performed by DEUTZ SERVICE according to the contract. Your responsible DEUTZ SERVICE partner will be glad to give you the details.

Chapter 5 - Page 2 300200043-en-00.fm © 0103

Maintenance

TBD 616 OEM

Specific maintenance schedule performance group A1

This engine has been built exclusively for the application specified in the scope of supply - as described by the equipment manufacturer - and is to be used only for the intended purpose. Depending on its intended purpose the engine is identified by a performance code according to DIN ISO 3046-7 which is punched into the rating plate. The rating plate is described in detail in Chapter 2, Rating plate.

This maintenance schedule is valid for the following performance code and maximum speed embossed on the rating plate:

ICXN, ICN (continuous operation, speed max. 1,800 min IN (variable operation, speed max. 1,500 min ICFN (unrestricted continuous operation, speed max. 1,800 min

Type of application: Electricity generator units, depending on design as double-frequency systems, water pumps, compressors.

E10

Routine

Mainte-

nance

E20

Visual

inspection

E23

Mainte-

nance

work

E25

Mainte-

nance

work

-1

)

Mainte-

nance (small

scope)

E30

-1

);

E40

Mainte-

nance

(medium

scope)

-1

)

(extended

E50

Mainte-

nance

scope)

E60

Intermedi-

ate

overhaul

E70

Complete

overhaul

Performance group A1

once in special

cases

Tab. 2 Deutz maintenance and service schedules in performance group A1

daily after every

250 Oh

after every

500 Oh

after every

1,500 Oh

after every

3,000 Oh

after every

6,000 Oh

after every 12,000 Oh

after every 24,000 Oh

Maintenance

Operating hour-independent maintenance work

Description WC

as required

monthly

after every 6 months

after every year

after every 2 years

Performance group A1

Renew the suction air intake filter; when maintenance indicator is ”RED”

Maintain crankcase bleed valve; when maintenance indicator is ”RED”

Trial run; after maintenance measures

Run in engine; after maintenance work such as changing bearings, piston, cylinder liner

TBD 616 OEM

B 6-3-6

B 3-1-9

B 0-1-4

W 0-1-3

x Clean the engine B 0-3-6

x Trial run x Maintain the battery

Check percentage of corrosion protection agent o r antifre eze in the coolant

Lube oil change (engine without centrifugal lube oil filter)

Lube oil change (engine with centrifugal lube oil filter)

x Maintain the centrifugal lube oil filter

x Renew the coolant

1) To be executed by maintenance officer

2) To be performed by authorized experts

3) To be performed when the engine has not been operated on standby for longer than one month. The engine must be preserved during long periods out of action, e.g. over the Winter, see chapter 7, Preservation.

4) To be performed when the engine has been in operation for less than 250 Oh within one year.

5) To be performed when the engine has been in operation for less than 500 Oh within one year.

6) Observe the operating media specifications in chapter 4, Operating Media.

Tab. 3 Operating hour-independent maintenance work

B 0-1-4 B 13-4-1

B 9-1-1

B 8-1-2

B 8-13-1 B 9-1-2

Chapter 5 - Page 4 300200043-en-00.fm © 0103

Maintenance

TBD 616 OEM

Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts. Drain water Drain condensed water, for example. Renew Renew parts, function groups and liquids. Finishing

work Check

Clean Visual inspec-

tion Overhaul Check function groups, rework or renew parts.

Maintain Change Change lube oil, for example.

Tab. 4 Definition of activities

Material removal within the permitted tolerances to reinstate a nominal condition. Check according to criteria in the work card. If not all criteria are fulfilled the cause must be

found and the nominal condition reinstated. Cleaning by hand or machine (automatic), renewal of cleaning part s (e.g. air filters) may be

necessary. Visual inspection according to criteria in the job card. If not all criteria are fulfilled the cause

must be found and the nominal condition reinstated.

Maintain according to job card. Check function, reworking or renewal of parts may be necessary.

Performance group A1

Operating hour-dependent maintenance work

On reaching the operating hours sp ecifie d in the fo llow ing ma intena nce sc hed ule th e activit ies pr escrib ed in the description must be performed. Always use the job card referred to in the maintenance schedule.

E10 E20 E23 E25 E30 E40 E50 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,500 Oh

after every 3,000 Oh

after every 6,000 Oh

after every 12,000 Oh

after every 24,000 Oh

x Visual inspection of the system B 0-1-5

x xxx x x x Maintain the battery B 13-4-1

x x

x xxx x x x Maintain the centrifugal lube oil filter x xxxxxx

xxxxxx

Lube oil change (engine without centrifugal lube oil filter)

Lube oil change (engine with centrifugal lube oil filter)

1) 2)

xxx x x x Renew lube oil filter cartridge B 8-10-4

B 8-13-1 B 8-1-2

B 8-1-2

xxx x x x Renew fuel filter cartridge B 7-10-4 x x x x x x Maintain the double fuel filter B 7-10-1 x x x x x x Check engine shutdown B 11-0-1 x x xxx Maintain crankcase bleed valve, made by Racor

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

B 3-1-9

Table 4Note activity definition

Maintenance

TBD 616 OEM

E10 E20 E23 E25 E30 E40 E50 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,50 0 Oh

after every 3,00 0 Oh

after every 6,00 0 Oh

after every 12,000 Oh

after every 24,000 Oh

x x x Check V-belts B 12-2-1

x x x Renew V-belt B 12-2-1

Performance group A1

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

xx Check and set inlet and outlet valve clearance B 1-1-1 x x x x Check the injection valves B 7-7-3 xx Visually inspect arched denture clutch

x Check the coolant pump B 9-7-11 x Check the coolant pump, circuit 2 B 9-7-12

x x x Renew the coolant pump W 9-7-8 x x x Renew the coolant pump, circuit 2 W 9-7-9

x x Renew arched denture clutch

x x x Check compression W 0-2-6

x x Overhaul or renew cylinder heads W 1-4-2 x Clean the exhaust gas turbocharger ME x Check exhaust gas turbocharger bearing clearance ME

x x Overhaul the exhaust gas turbocharger ME x Check the charge air cooler W 6-4-5

x x Clean the charge air cooler W 6-4-3

x Check cylinder liners W 0-2-7

x Renew the cylinder liners W 3-3-3

x Chec k injection pump drive W 7-4-12

x Overhaul or renew injection pump drive W 7-4-7

x Check pistons (piston bolt, piston rings) W 2-9-3

x Renew pistons (piston bolt, piston rings) W 2-9-3 x x Water-cooled exhaust pipe, check liquid chambers x x Check solid insulation

x x Renew fabric mat insulation of the turbocharger x x Clean the lube oil cooler W 8-8-2 x x Renew the oil pressure control valve W 8-11-3 x x Renew the bypass valve W 8-11-5

Renew hose pipes, vibration dampers and flexible lines

B 7-4-16

W 7-4-6

W 6-1-3 W 6-1-4 W 6-6-3

W 0-3-4

Table 4Note activity definition

Maintenance

TBD 616 OEM

E10 E20 E23 E25 E30 E40 E50 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,50 0 Oh

after every 3,00 0 Oh

after every 6,00 0 Oh

after every 12,000 Oh

after every 24,000 Oh

x x Renew injection lines W 7-3-3 x x Renew check valve in the leak fuel system W 7-3-5 x x Renew con-rod bearing W 2-1-4 x x Check con-rod geometry W 2-3-5 x x Overhaul injection pump ME x x Overhaul dynamo ME

x Check coolant chambers W 9-0-3 x Renew rotary vibration dampers W 12-1-4 x Renew rocker arms, valve bridges W 1-2-2 x Check elastic suspension ME x Check elastic coupling ME x Renew main bearing W 2-7-2 x Renew crankcase bleed valve W 3-1-10 x Check crankshaft W 2-1-7 x Renew camshaft and valve lifter W 4-1-4 x Renew camshaft bearing W 4-1-1 x Renew camshaft axial bearing W 3-1-4 x Renew mass compensation shaft bearing x Check stop rods W 4-2-1

Check intermediate gear wheels and bearing bush of

the coolant pump x Check lube oil pump W 8-4-5 x Renew cooler cap x Renew crankshaft sealing ring (drive side) W 2-2-2 x Renew crankshaft sealing ring (free side) W 2-2-4 x Overhaul starter ME x Check solenoid valve(s) ME x Electric sensors, solenoids ME

Other connected parts ME

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

W 2-8-1

W 9-7-5

Performance group A1

Table 4Note activity definition

Maintenance

TBD 616 OEM

Overview of operating hour-independent maintenance work (copy form)

Date Activity Signature

Performance group A1

Tab. 5 Overview of operating hour-independent maintenance work performance group A1

Maintenance

TBD 616 OEM

Overview of operating hour-dependent maintenance work (copy form)

hours

1,000 1,250 1,500 1,750 2,000 2,250 2,500 2,750 3,000 3,250 3,500 3,750 4,000 4,250 4,500 4,750 5,000 5,250 11 5,500 5,750 6,000 6,250 6,500 6,750 7,000 7,250 7,500 7,750 8,000 8,250 8,500 8,750 9,000 9,250 9,500 9,750

Deutz maintenance and service schedule

E10 E23 E25 E30 E40 E50 E60 E70

250 500 750

Date Signature

Performance group A1

Maintenance

TBD 616 OEM

hours

10,000 14 10,250 10,500 10,750 11,000 11,250 11,500 11,750 12,000 12,050

Performance group A1

12,250 12,500 12,750 13,000 13,250 13,500 13,750 14,000 14,250 14,500 14,750 15,000 15,250 31 15,500 15,750 16,000 16,250 16,500 16,750 17,000 17,250 17,500 17,750 18,000 18,250 18,500 18,750 19,000 19,250 19,500 19,750

Deutz maintenance and service schedule

E10 E23 E25 E30 E40 E50 E60 E70

Date Signature

Maintenance

hours

20,000 27 20,250 20,500 20,750 21,000 21,250 21,500 21,750 22,000 22,250 22,500 22,750 23,000 23,250 23,500 23,750 24,000

Deutz maintenance and service schedule

E10 E23 E25 E30 E40 E50 E60 E70

TBD 616 OEM

Date Signature

Performance group A1

Number of Deutz maintenance and service schedules up to and including complete overhaul

Total 2483284211

Tab. 6 Overview of operating hour-dependent maintenance work performance group A1

Maintenance

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Performance group A1

TBD 616 OEM

Maintenance

TBD 616 OEM

Specific maintenance schedule performance group A2

This maintenance schedule is valid for the following performance code and maximum speed embossed on the rating plate:

)

E40

Mainte-

nance

scope)

-1

)

(extended

after every

6,000 Oh

E50

Mainte-

nance

scope)

E60

Intermedi-

ate

overhaul

after every

9,000 Oh

E70

Complete

overhaul

after every 18,000 Oh

ICFN (unrestricted continuous operation, speed max. 2,100 min IFN (limited continuous operation, speed max. 2,100 min

Type of application: Electricity generator units, water pumps, compressors, fire extinguisher pumps.

E10

Routine

Mainte-

nance

once in special

case

E20

Visual

inspection

daily after every

E23

Mainte-

nance

work

250 Oh

E25

Mainte-

nance

work

after every

500 Oh

E30

Mainte-

nance (small

scope)

after every

1,500 Oh

-1

(medium

after every

3,000 Oh

Performance group A2

Tab. 7 Deutz maintenance and service schedules in performance group A2

Maintenance

Operating hour-independent maintenance work

Description WC

as required

monthly

after every 6 months

after every year

after every 2 years

Performance group A2

Renew the suction air intake filter; when maintenance indicator is ”RED”

Maintain crankcase bleed valve; when maintenance indicator is ”RED”

Trial run; after maintenance measures

Run in engine; after maintenance work such as changing bearings, piston, cylinder liner

TBD 616 OEM

B 6-3-6

B 3-1-9

B 0-1-4

W 0-1-3

x Clean the engine B 0-3-6

x Trial run x Maintain the battery

Check percentage of corrosion protection agent o r antifre eze in the coolant

Lube oil change (engine without centrifugal lube oil filter)

Lube oil change (engine with centrifugal lube oil filter)

x Maintain the centrifugal lube oil filter

x Renew the coolant

1) To be executed by maintenance officer

2) To be performed by authorized experts

4) To be performed when the engine has been in operation for less than 250 Oh within one year.

5) To be performed when the engine has been in operation for less than 500 Oh within one year.

6) Observe the operating media specifications in chapter 4, Operating Media.

Tab. 8 Operating hour-independent maintenance work

B 0-1-4 B 13-4-1

B 9-1-1

B 8-1-2

B 8-13-1 B 9-1-2

Maintenance

TBD 616 OEM

Definition of activities in the maintenance schedule

work Check

Clean Visual inspec-

tion Overhaul Check function groups, rework or renew parts.

Maintain Change Change lube oil, for example.

Tab. 9 Definition of activities

Material removal within the permitted tolerances to reinstate a nominal condition. Check according to criteria in the work card. If not all criteria are fulfilled the cause must be

found and the nominal condition reinstated. Cleaning by hand or machine (automatic), renewal of cleaning part s (e.g. air filters) may be

necessary. Visual inspection according to criteria in the job card. If not all criteria are fulfilled the cause

must be found and the nominal condition reinstated.

Maintain according to job card. Check function, reworking or renewal of parts may be necessary.

Performance group A2

Operating hour-dependent maintenance work

E10 E20 E23 E25 E30 E40 E50 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,500 Oh

after every 3,000 Oh

after every 6,000 Oh

after every 9,000 Oh

after every 18,000 Oh

x Visual inspection of the system B 0-1-5

x xxx x x x Maintain the battery B 13-4-1

x x

x xxx x x x Maintain the centrifugal lube oil filter x xxxxxx

xxxxxx

Lube oil change (engine without centrifugal lube oil filter)

Lube oil change (engine with centrifugal lube oil filter)

1) 2)

xxx x x x Renew lube oil filter cartridge B 8-10-4

B 8-13-1 B 8-1-2

B 8-1-2

xxx x x x Renew fuel filter cartridge B 7-10-4 x x x x x x Maintain the double fuel filter B 7-10-1 x x x x x x Check engine shutdown B 11-0-1 x x xxx Maintain crankcase bleed valve, made by Racor

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

B 3-1-9

Table 4Note activity definition

Maintenance

TBD 616 OEM

E10 E20 E23 E25 E30 E40 E50 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,50 0 Oh

after every 3,00 0 Oh

after every 6,00 0 Oh

after every 9,00 0 Oh

after every 18,000 Oh

x x x Check V-belts B 12-2-1

x x x Renew V-belt B 12-2-1

Performance group A2

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

x xx Check and set inlet and outlet valve clearance B 1-1-1 x x x x x Check the injection valves B 7-7-3

xx Visually inspect arched denture clutch

x Check the coolant pump B 9-7-11 x Check the coolant pump, circuit 2 B 9-7-12

x x x Renew the coolant pump W 9-7-8 x x x Renew the coolant pump, circuit 2 W 9-7-9

x x Renew arched denture clutch

x x x Check compression W 0-2-6

x x Overhaul or renew cylinder heads W 1-4-2 x Clean the exhaust gas turbocharger ME x Check exhaust gas turbocharger bearing clearance ME

x x Overhaul the exhaust gas turbocharger ME x Check the charge air cooler W 6-4-5

x x Clean the charge air cooler W 6-4-3

x Check cylinder liners W 0-2-7

x Renew the cylinder liners W 3-3-3

x Chec k injection pump drive W 7-4-12

x Overhaul or renew injection pump drive W 7-4-7

x Check pistons (piston bolt, piston rings) W 2-9-3

x Renew pistons (piston bolt, piston rings) W 2-9-3 x x Water-cooled exhaust pipe, check liquid chambers x x Check solid insulation

x x Renew fabric mat insulation of the turbocharger x x Clean the lube oil cooler W 8-8-2 x x Renew the oil pressure control valve W 8-11-3 x x Renew the bypass valve W 8-11-5

Renew hose pipes, vibration dampers and flexible lines

B 7-4-16

W 7-4-6

W 6-1-3 W 6-1-4 W 6-6-3

W 0-3-4

Table 4Note activity definition

Maintenance

TBD 616 OEM

E10 E20 E23 E25 E30 E40 E50 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,50 0 Oh

after every 3,00 0 Oh

after every 6,00 0 Oh

after every 9,00 0 Oh

after every 18,000 Oh

x x Renew injection lines W 7-3-3 x x Renew check valve in the leak fuel system W 7-3-5 x x Renew con-rod bearing W 2-5-1 x x Check con-rod geometry W 2-3-5 x x Overhaul injection pump ME x x Overhaul dynamo ME

x Check coolant chambers W 9-0-3 x Renew rotary vibration dampers W 12-1-4 x Renew rocker arms, valve bridges W 1-2-2 x Check elastic suspension ME x Check elastic coupling ME x Renew main bearing W 2-7-2 x Renew crankcase bleed valve W 3-1-10 x Check crankshaft W 2-1-7 x Renew camshaft and valve lifter W 4-5-1 x Renew camshaft bearing W 4-1-1 x Renew camshaft axial bearing W 3-8-1 x Renew mass compensation shaft bearing x Check stop rods W 4-2-1

Check intermediate gear wheels and bearing bush of

Other connected parts ME

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

W 2-8-1

W 9-7-5

Performance group A2

Table 4Note activity definition

Maintenance

TBD 616 OEM

Overview of operating hour-independent maintenance work (copy form)

Date Activity Signature

Performance group A2

Tab. 10 Overview of operating hour-independent maintenance work performance group A2

Maintenance

TBD 616 OEM

Overview of operating hour-dependent maintenance work (copy form)

hours

Deutz maintenance and service schedule

E10 E23 E25 E30 E40 E50 E60 E70

250 500 750

Date Signature

Performance group A2

Maintenance

TBD 616 OEM

hours

9,750 20 10,000 10,250 10,500 10,750 11,000 11,250 11,500 11,750 12,000

Performance group A2

12,250 25 12,500 12,750 13,000 13,250 13,500 13,750 14,000 14,250 14,500 14,750 15,000 15,250 31 15,500 15,750 16,000 16,250 16,500 16,750 17,000 17,250 17,500 17,750 18,000

Deutz maintenance and service schedule

E10 E23 E25 E30 E40 E50 E60 E70

Date Signature

Number of Deutz maintenance and service schedules up to and including complete overhaul

Total 236246 2 2 1 1

Tab. 11 Overview of operating hour-dependent maintenance work performance group A2

Maintenance

TBD 616 OEM

Specific maintenance schedule performance group B

This maintenance schedule is valid for the following performance code and maximum speed embossed on the rating plate:

IFN (max. 1,500 min IN (variable operation, max. 1,800 min

Type of application: Electricity generator units, depending on design as double-frequency systems.

E10 Routine Mainte-

nance

once in special

cases

-1

);

E20

Visual

inspection

daily after every

E23

Mainte-

nance work

250 Oh

-1

)

E25

Mainte-

nance work

after every

500 Oh

E30

Mainte-

nance (small

scope)

after every

1,500 Oh

E40

Mainte-

nance

(medium

scope)

after every

3,000 Oh

E60

Intermedi-

ate

overhaul

after every

6,000 Oh

E70

Complete

overhaul

after every 12,000 Oh

Performance group B

Tab. 12 Deutz maintenance and service schedules in performance group B

Maintenance

Operating hour-independent maintenance work

Description WC

as required

monthly

after every 6 months

after every year

after every 2 years

Performance group B

Renew the suction air intake filter; when maintenance indicator is ”RED”

Maintain crankcase bleed valve; when maintenance indicator is ”RED”

Trial run; after maintenance measures

Run in engine; after maintenance work such as changing bearings, piston, cylinder liner

TBD 616 OEM

B 6-3-6

B 3-1-9

B 0-1-4

W 0-1-3

x Clean the engine B 0-3-6

x Trial run x Maintain the battery

Check percentage of corrosion protection agent o r antifre eze in the coolant

Lube oil change (engine without centrifugal lube oil filter)

Lube oil change (engine with centrifugal lube oil filter)

x Maintain the centrifugal lube oil filter

x Renew the coolant

1) To be executed by maintenance officer

2) To be performed by authorized experts

4) To be performed when the engine has been in operation for less than 250 Oh within one year.

5) To be performed when the engine has been in operation for less than 500 Oh within one year.

6) Observe the operating media specifications in chapter 4, Operating Media.

Tab. 13 Operating hour-independent maintenance work

B 0-1-4 B 13-4-1

B 9-1-1

B 8-1-2

B 8-13-1 B 9-1-2

Maintenance

TBD 616 OEM

Definition of activities in the maintenance schedule

work Check

Clean Visual inspec-

tion Overhaul Check function groups, rework or renew parts.

Maintain Change Change lube oil, for example.

Tab. 14 Definition of activities

Material removal within the permitted tolerances to reinstate a nominal condition. Check according to criteria in the work card. If not all criteria are fulfilled the cause must be

found and the nominal condition reinstated. Cleaning by hand or machine (automatic), renewal of cleaning part s (e.g. air filters) may be

necessary. Visual inspection according to criteria in the job card. If not all criteria are fulfilled the cause

must be found and the nominal condition reinstated.

Maintain according to job card. Check function, reworking or renewal of parts may be necessary.

Performance group B

Operating hour-dependent maintenance work

E10 E20 E23 E25 E30 E40 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,500 Oh

after every 3,000 Oh

after every 6,000 Oh

after every 12,000 Oh

x Visual inspection of the system B 0-1-5

x xxx x x Maintain the battery B 13-4-1

x x

x xxx x x Maintain the centrifugal lube oil filter x xxxxx

xxxxx

Lube oil change (engine without centrifugal lube oil filter)

Lube oil change (engine with centrifugal lube oil filter)

1) 2)

xxx x x Renew lube oil filter cartridge B 8-10-4

B 8-13-1 B 8-1-2

B 8-1-2

xxx x x Renew fuel filter cartridge B 7-10-4 x x x x x Maintain the double fuel filter B 7-10-1 x x x x x Check engine shutdown B 11-0-1 x x xx Maintain crankcase bleed valve, made by Racor

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

B 3-1-9

Table 4Note activity definition

Maintenance

TBD 616 OEM

E10 E20 E23 E25 E30 E40 E60 E70 Description WC

1x after 50 Oh

every 24 hours (daily)

after every 250 Oh

after every 500 Oh

after every 1,50 0 Oh

after every 3,00 0 Oh

after every 6,00 0 Oh

after every 12,000 Oh

x x x Check V-belts B 12-2-1

x x Renew V-belt B 12-2-1

Performance group B

1) Observe the operating media specifications in chapter 4, Operating Media .

2) Change annually if the operating hours are not reached.

3) The crankcase bleed valve must also be maintained when the maintenance indicator is ”RED”.

4) V16 engines only

5) V8 engines only

6) Clean annually if the operating hours are not reached. MD: Manufacturer Documents

x x Check and set inlet and ou tle t valv e cle ar an ce B 1-1-1 x x x x Check the injection valves B 7-7-3

x Visually inspect arched denture clutch

x Check the coolant pump B 9-7-11 x Check the coolant pump, circuit 2 B 9-7-12

x x Renew the coolant pump W 9-7-8 x x Renew the coolant pump, circuit 2 W 9-7-9 x x Renew arched denture clutch

x x Check compression W 0-2-6 x x Overhaul or renew cylinder heads W 1-4-2

Clean the exhaust gas turbocharger ME Check exhaust gas turbocharger bearing clearance ME

x x Overhaul the exhaust gas turbocharger ME

Check the charge air cooler W 6-4-5 x x Clean the charge air cooler W 6-4-3 x Check cylinder liners W 0-2-7

x Renew the cylinder liners W 3-3-3

x Check injection pump drive W 7-4-12

x Overhaul or renew injection pump drive W 7-4-7

x Check pistons (piston bolt, piston rings) W 2-9-3

x Renew pistons (piston bolt, piston rings) W 2-9-3 x x Water-cooled exhaust pipe, check liquid chambers x x Check solid insulation x x Renew fabric mat insulation of the turbocharger

x x Clean the lube oil cooler W 8-8-2 x x Renew the oil pressure control valve W 8-11-3 x x Renew the bypass valve W 8-11-5 x x Renew hose pipes, vibration dampers and flexible lines W 0-3-4 x x Renew injection lines W 7-3-3

B 7-4-16

W 7-4-6

W 6-1-3 W 6-1-4 W 6-6-3

Table 4Note activity definition

Deutz TBD 616 OEM, TBD 616 V-12, TBD 616 V-8, TBD 616 V-16 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operating Instructions

TBD 616 OEM

0299 8561 en

0Introduction

Please read all ...● Please read all the information contained in this manual, and follow the

ForwordDear customer,

DEUTZ enginesare the culmination of long years filled with research and development work.

Care and maintenanceare crucial factors in ensuring that your engine satisfactorily meets the

DEUTZ ServiceIn the event of malfunctions, or if you need spare p ar ts, please contact one of

Contents

1 User Guide

GeneralThe maintenance and service work prescribed in the operating instructions

Regulations

Rules for disposal The work described in the operating instructions and workshop manual

Job cards

Spares Spares are available from DEUTZ Service. You will find a list of spares in the

2 Description

Type designation

Figure rating plate

Designation of the engine sides, cylinder and direction of rotation

Direction of rotation

Right side

Drive side

Structure and function

Crankcase

Crankcase bleeding (Racor)

Crank drive and valve drive

Wheel drive

Mass compensation shaft (V8 engine s on ly )

Valve control

Charging

Schematic diagram of the charge air circuit (with liquid-cooled charge air cooler)

Schematic diagram of the charge air circuit (air / air ch a r ge air co ol er)

Surge charging

Injection

Fuel pipe system V12 engine

Fuel pipe system V 16 engine

Speed regulationThe task of speed governing systems is to influence the fuel supply to the

Lube oil system

Cooling system

Schematic representation of the dual-circuit cooling

Starter The engine is started by an electric or pneumatic starter depending on the

Function

System functions

Configuration and parameterization

3 Operation

GeneralWork prior to commissioning applies both for commissioning new engines

Operating media

Coolant New engines and engines overhauled at DEUTZ are run with a special cool-

Coolant level● Check the coolant level in the cooler. The test marks may vary depending

Fuel

LubricantThe engines are delivered without lube oil filling.

Monitoring ● Check the power supply to the engine monitoring system (battery).

Starter system Compressed air starter system

Room ventilation ● Switch on the room ventilation to evacuate radiation heat and oil vapour.

Commissioning

Starting the engine● After longer pauses in operation (cold engine) perform work according to

Monitoring operationDuring engine operation, check whether the data displayed by the engine

Shutting down● Avoid shutting down from full load.

4 Expendables

General remarks

WarrantyIf unsuitable expendables are used, or if it cannot be documented that the

Product selectionDue to the large number of products available nationally and internationally

MixabilityMixing different expendable types together, .e.g. different lube oils with each

Fuelsee Technical Circular TR 0199-99-2089. Engine lube oilsee Technical Circular TR 0199-99-2090. Engine coolantsee Technical Circular TR 0199-99-2091.

Auxiliary materials

Sealants and securing agents

Gluing agents

Lubricants

Other auxiliary materials

5 Maintenance

GeneralThe maintenance schedule lists the measures for maintaining the nominal

Selection and structureAn appropriate maintenance schedule applies depending on the performance

Deutz maintenance and service schedule

Specific maintenance schedule performance group A1

Operating hour-independent maintenance work