Deutz TCD 2012-2013 Service Manual

Operation Manual

TCD 2012 L04/06 V2 TCD 2013 L04/06 V2

z Read and observe the information in this

instruction manual. You will avoid accidents, retain the manufacturer’s warranty and have a fully functional, ready to use engine at your disposal.

z This engine is exclusively for the purpose

according to the scope of delivery - defined and built by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user will bear the sole risk in this case.

z Use for the intended purpose also includes

observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with it and instructed in the dangers.

z The pertinent rules for the prevention of

accidents and other generally recognised safety and industrial medicine rules must be observed.

z When the engine is running there is a danger

of injury caused by:

- rotating / hot components

- engines with extraneous ignition

- ignition systems (high electrical voltage) Contact must be avoided!

z The manufacturer will not be liable for damages

resulting from unauthorised modification to the engine. Equally, manipulations to the injection and control system can affect the engine’s performance and the exhaust characteristics. Compliance with environmental regulations will no longer be guaranteed in this case.

z Do not alter, obstruct or block the area of the

cool air supply to the fan. The manufacturer will accept no liability for damages resulting from this.

z Only DEUTZ original parts may be used when

carrying out maintenance/repair work on the engine. These have been designed especially for your engine and ensure a trouble-free operation. Failure to observe this will lead to voiding of the warranty!

z Maintenance/cleaning work on the engine

may only be carried out when the engine is not running and has cooled down. When doing this, make sure that the electrical system is switched off (remove ignition key). The specifications for accident prevention with electrical systems (e.g. VDE-0100/-0101/

-0104/-0105 Electrical protective measures against dangerous touch voltages) must be observed. Cover all electrical components tightly when cleaning with liquids.

z Do not work on the fuel system while the

engine is running - Danger to life. Wait (1 minute) for the engine to come to a standstill (pressure release), as system is under high pressure: there is a - Danger to

life.

During the first trial run do not stand in the danger area of the engine (danger due to high pressure of leaks) - Danger to life.

- In case of leaks immediately contact the workshop.

- When working on the fuel system ensure that the engine is not unintentionally started during repairs - Danger to life.

Engine number:

Operation Manual

TCD 2012 L04/06 V2

TCD 2013 L04/06 V2

312 1890 en

Please enter the engine number here. This will simplify the handling of customer service, repair and spare parts queries (see Section 2.1).

Illustrations and data in this instruction manual are subject to technical changes in the course of improvements to the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

Foreword

Dear customer,

The liquid-cooled engines made by DEUTZ are developed for a wide variety of applications. An extensive range of variants ensures that the respective special requirements are met.

Your engine is equipped according to the installation, i.e. not all the parts and components described in this instruction manual are installed on your engine.

We have done our best to clearly identify the differences, so that you can easily find the operating, maintenance and repair instructions relevant to your engine.

Please read these instructions before you start your engine and observe the operating and maintenance instructions.

We are at your service for any questions you may have in this matter.

Your

DEUTZ AG

1. General

2. Engine description

2.1 Engine type

2.1.1 Company plate

2.1.2 Location of company plate

2.1.3 Engine number

2.1.4 Cylinder numbering

2.2 Engine diagrams

2.2.1 Operation side TCD 2012 L04 2V

2.2.2 Starter side TCD 2012 L04 2V

2.2.3 Operation side TCD 2012 L06 2V

2.2.4 Starter side TCD 2012 L06 2V

2.2.5 Operation side TCD 2013 L04 2V

2.2.6 Starter side TCD 2013 L04 2V

2.2.7 Operation side TCD 2013 L06 2V

2.2.8 Starter side TCD 2013 L06 2V

2.3 Lube oil circuit

2.3.1 Lube oil diagram (example)

2.4 Fuel circuit

2.4.1 Fuel diagram

2.5 Coolant circuit

2.5.1 Coolant diagram (example)

2.6 Electrics

2.6.1 Electrical cable connections for monitoring

3. Operation

3.1 Initial commissioning

3.1.1 Filling engine oil

3.1.2 Filling fuel

3.1.3 Filling / bleeding cooling system

3.1.4 Other preparations

3.2 Starting

3.2.1 Electrical starting

3.3 Operation monitoring

3.3.1 Engine oil pressure

3.3.2 Coolant temperature

3.3.3 Coolant level

3.4 Shutting down

3.4.1 Electrical shutdown

3.5 Operating conditions

3.5.1 Winter operation

3.5.2 High ambient temperature, high altitude

4. Operating substances

4.1 Lube oil

4.1.1 Quality

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality

4.2.2 Winter fuel

4.3 Coolant

4.3.1 General

4.3.2 Coolant preparation

5. Maintenance

5.1 Maintenance schedule

5.2 Maintenance diagram

5.3 Maintenance work carried out

6. Care and maintenance work

6.1 Lubrication system

6.1.1 Oil change intervals

6.1.2 Checking oil level, changing engine oil

6.1.3 Changing oil filter

6.1.4 Cleaning / changing oil filter (cup)

6.2 Fuel system

6.2.1 Changing fuel filter

6.2.3 Fuel pre-filter, changing / bleeding

filter insert

6.3 Cooling system

6.3.1 Cleaning intervals

6.3.2 Cleaning cooling system

6.3.3 Emptying cooling system

6.3.4 Filling / bleeding cooling system

6.4 Combustion air filter

6.4.1 Cleaning intervals

6.4.2 Emptying cyclone pre-separator

6.4.3 Cleaning oil bath air filter

6.4.4 Dry air filter

6.5 Belt drive

6.5.1 Checking V-belt

6.5.2 Changing V-rib belt

6.5.3 Checking wear limit of V-rib belt

6.6 Setting work

6.6.1 Checking valve clearance,

setting if necessary

6.6.2 Setting control piston clearance

in exhaust gas recirculation (EGR)

6.6.3 Diagram for setting valve / control piston clearance

Contents

6.7 Add-on parts

6.7.1 Battery

6.7.2 Three-phase current generator

6.7.3 Transportation suspension

7. Faults, causes and remedies

7.1 Fault table

7.2 Engine management

7.2.1 Engine protection function of the electronic engine controller EMR3

7.2.2 Using the diagnosis button

7.2.3 Table of fault blink codes

8. Engine corrosion protection

8.1 Corrosion protection

9. Technical data

9.1 Engine and setting data

9.2 Screw tightening torques

9.3 Tools

10. Service

General

DEUTZ Diesel Engines

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Beware of Running Engine

Care and Maintenance

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Safety

Service

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with stateof-the-art technology. The Technical Circulars listed in the instruction manual are obtainable from your DEUTZ partner. Please turn to the end of this manual for further service information.

Asbestos

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents! When working on the running engine, work clothing must be close fitting. Observe industrial safety regulations when running the engine in an enclosed space or underground. When the work is complete, be sure to refit any panels and guards that may have been removed.Never fill the fuel tank while the engine is running.

This symbol is used for all safety warnings which, if not observed, present a direct danger to life and limb for the

person involved. Please follow them carefully. The attention of operating personnel should be drawn to these safety instructions. General safety and accident prevention regulations laid down by law must also be observed.

DEUTZ original parts are asbestos-free.

2.1 Engine type

2.2 Engine diagrams

2.3 Lube oil circuit

2.4 Fuel circuit

2.5 Coolant circuit

2.6 Electrics

Engine description

2.1 Engine type

2.1.1 Company plate

The engine type A, engine number B and the power data are stamped on the company plate. The engine type and number must be stated when purchasing spare parts.

2.1.2 Location of company plate

The company plate C is fixed to the cylinder head cover or the crankcase.

2.1 Engine type

Engine description

2.1.3 Engine number

The engine number is stamped on the crankcase (arrow) and on the company plate.

2.1.4 Cylinder numbering

The cylinders are counted consecutively, starting from the flywheel.

Engine description

2.2 Engine diagrams

2.2.1 Operation side TCD 2012 L04 2V

1 Oil filler 2 Combustion air inlet 3 Cover 4Fan 5 Generator 6 Fuel pump 7 Tension pulley with torsion spring 8 Oil cooler 9 Exchangeable fuel filter 10 Exchangeable lube oil filter 11 Oil tray 12 Hydraulic pump or compressor mounting

possibility 13 Flywheel 14 Crankcase bleeding valve 15 Transport eyes 16 Charge air pipe 17 Fuel control unit

2.2 Engine diagrams

Engine description

2.2.2 Starter side TCD 2012 L04 2V

18 Exhaust manifold 19 Turbocharger 20 Oil filler (optional) 21 Engine mounting 22 Oil return line from turbocharger 23 Relay (starter) 24 V-rib belt 25 Coolant inlet 26 Coolant outlet 27 Coolant pump 28 Connection cabin heater or

compensation line

Engine description

2.2.3 Operation side TCD 2012 L06 2V

2.2 Engine diagrams

1 Oil filler 2 Combustion air inlet 3 Transport eyes 4 Generator 5 Fan hub 6 Fuel pump 7 V-rib belt drive on crankshaft 8 V-rib belt 9 Tension pulley with torsion spring 10 Coolant pump 11 Exchangeable lube oil filter (1x optional) 12 Oil drain screw 13 Oil dipstick 14 Lube oil cooler 15 Exchangeable fuel filter 16 Hydraulic pump or compressor installation

(optional) 17 Oil filler (optional) 18 Plug to control unit 19 Crankcase bleeding valve 20 High-pressure pump (2) 21 Rail 22 Injector

2.2 Engine diagrams

Engine description

2.2.4 Starter side TCD 2012 L06 2V

23 Crankcase bleeding valve 24 Charge air pipe 25 Solenoid valve for exhaust gas recirculation 26 SAE housing 27 Oil tray 28 Starter cover 29 Oil return line from turbocharger 30 Exhaust turbocharger 31 Charge air connection to charge air cooler 32 Coolant inlet 33 Coolant outlet 34 Exhaust manifold 35 Cylinder head cover

Engine description

2.2 Engine diagrams

2.2.5 Operation side TCD 2013 L04 2V

1 Combustion air inlet

(heating flange installation facility, optional)

2 Connection cabin heater or compensation

line 3 Fan (drive coolant pump) 4 Generator 5 Belt pulley on crankshaft 6 V-belt 7 Fuel pump drive 8 Exchangeable fuel filter 9 Exchangeable lube oil filter 10 Oil cooler 11 Drive facility (e.g. hydraulic pump,

optional) 12 Oil return line crankcase bleeding 13 Plug to control unit 14 Fuel control unit

(Electronic Control Unit) 15 High-pressure pump 16 Crankcase bleeding valve 17 Injector 18 Oil filler

2.2 Engine diagrams

Engine description

2.2.6 Starter side TCD 2013 L04 2V

19 Oil filler (optional) 20 SAE housing 21 Engine mounting 22 Oil drain screw 23 Oil tray 24 Starter 25 Lube oil return from turbocharger 26 Turbocharger 27 Coolant inlet 28 Charge air connection to cooler 29 Coolant outlet 30 Exhaust manifold 31 Charge air pipe 32 Transport eyes

Engine description

2.2 Engine diagrams

2.2.7 Operation side TCD 2013 L06 2V

1 Combustion air inlet 2 Oil filler 3 Transport eyes 4 Generator 5 Coolant pump 6 Exchangeable lube oil filter 7 Exchangeable fuel filter 8 Oil tray 9 Oil dipstick 10 Oil drain screw 11 Oil return line crankcase bleeding 12 Engine mounting 13 SAE housing 14 Plug to control unit 15 High-pressure pump 16 Rail 17 Crankcase bleeding valve 18 Injector

2.2 Engine diagrams

Engine description

2.2.8 Starter side TCD 2013 L06 2V

19 Turbocharger 20 Exhaust manifold 21 Starter 22 Lube oil line to turbocharger 23 Coolant drain screw 24 Coolant inlet 25 V-rib belt 26 Fan 27 Tension pulley with torsion spring 28 Connection compensation line 29 Ventilation line to compensation tank 30 Coolant outlet from engine to cooler

Engine description

2.3 Lube oil circuit

2.3.1 Lube oil diagram (example)

1 Oil tray 2 Intake pipe 3 Lube oil pump

3.1 Safety valve

4 Lube oil cooler

4.1 Return shutoff valve (only in 2012)

4.2 By-pass valve

4.3 By-pass valve oil filter

4.4 Pressure control valve 5 Exchangeable lube oil filter 6 Main oil pipe

6a Internal exhaust gas recirculation 7 Crankshaft bearing 8 Con rod bearing 9 Camshaft bearing 10 Line to injection nozzle 11 Injection nozzle for piston cooling 12 Tappet with rocker arm pulse lubrication 13 Stop rod, oil supply for rocker arm

lubrication 14 Rocker arm 15 Return line to oil tray 16 Lube oil line toexhaust turbocharger 17 Exhaust turbocharger 18 Return line from compressor 2x 19 Compressor or hydraulic pump 20 Oil line to compressor or hydraulic

pump 21 Return line from exhaust turbocharger

2.4 Fuel circuit

Engine description

2.4.1 Fuel diagram

1 Fuel container 2 Fuel pre-filter with pre-pressure pump

possibility for filling the low pressure area

(to be provided by the customer) 3 Line to fuel pump 4 Fuel pump 5 Fuel filter 6 Fuel supply line to fuel control unit 7 Rail 8 High-pressure pump 9 Fuel line to injector 10 Injectors 11 Control block FCU (Fuel Control Unit) 12 Fuel return at the cylinder head 13 Fuel return line to the tank 14 Fuel lines from the control block to the high -

pressure pumps and to the rail

A min. distance 500 mm

Engine description

2.5.1 Coolant diagram (example)

2.5 Coolant circuit

1 Coolant outlet at the cooler 2 Thermostat 3 Coolant feed line to pump 4 Coolant pump 5 Lube oil cooler 6 Cylinder cooling 7 Cylinder head cooling 8 Coolant inlet to heating

9 Heating 10 Coolant to thermostat 11 Heating connection 12 Compensation line 13 Ventilation line to compensation tank 14 Coolant outlet to cooler 15 Compensation tank 16 Compensation line to heat exchanger

Engine description

2.6 Electrics

2.6.1 Electrical cable connections

for monitoring

1 Solenoid valve EGR (optional) 2 Coolant temperature 3 Charge air pressure/temperature

transmitter

4 Connection facility example:

Control unit not mounted on the engine 5 Engine control unit 6 Speed governor via crankshaft 7 Rail pressure, on side of rail 8 Oil level transmitter (optional) 9 Oil pressure transmitter 10 Fuel pressure 11 Speed governor via camshaft 12 Central plug (for engine control) 13 Power supply (battery) 14 Multifunction displays 15 Outputs (configurable, e.g. for lamps,

torque (PWM), speed, engine running

signal, etc.) 16 Inputs (configurable)

(PWM/digital/analogue) 17 Accelerator pedal 18 Hand throttle (optional) 19 Switch functions (optional, e.g. for P factor,

controller type, roof curves, fixed

speeds, (etc. also multistage

switches)) 20 Key switch

Start/stop 21 Diagnosis button 22 Fault light with blink code 23 Diagnosis interface / CAN-Bus

2.6 Electrics

Other application-side components (depending on the application)

z Water trap fuel filter, see chap. 6.2.3 z Override key, see chap. 3.3.1 (for temporary bypassing of the engine protection

functions)

z Coolant level transmitter z Separate engine stop switch z Fan control z Switch for brake contact, engine brake, clutch z Drive speed sensor, drive speed control unit

(+ - keys, for speed increase reduction)

z Cold start aid control lamp, see chap. 3.2.1

If there is a serious fault, e.g. the heating flange draws current although the control unit does not control it, this lamp flashes. The power supply to the heating flange must then be disconnected separately (overheating protection heating flange).

Engine description

3.1 Initial commissioning

3.2 Starting

3.3 Operation monitoring

3.4 Shutting down

3.5 Operating conditions

Operation

3.1 Initial commissioning

3.1.1 Filling engine oil

The engines are generally supplied without oil filling. Fill engine with lube oil through the oil filler (1) on the cylinder head cover. Alternatively, you can fill on the wheel box (2) or on the side of the crankcase. For oil filling amount see 9.1. For quality and viscosity of oil see 4.1.

3.1.2 Filling fuel

Only use clean, standard, branded diesel fuel. For fuel quality see 4.2. Depending on the outdoor temperature, use either summer or winter diesel fuel.

Bled the fuel low pressure system after filling, see 6.2.3. Additional venting of the fuel system by a 5 minute trial run in idle or low load is absolutely essential.

Oil may not be filled into the dust collecting tank of the preseparator, if this is present.

Only re-fuel when the engine is not running!

Pay attention to cleanliness!

Do not spill any fuel!

3.1 Initial commissioning

Operation

3.1.3 Filling / bleeding cooling system

z Connect connection coolant outlet 1 and coolant

inlet 2 to the cooling system. Connect the lead line from the compensation tank to the water pump or to the coolant inlet pipe 2.

z Connect the bleed lines from the engine and

poss. from the cooler to the compensation tank.

z Fill the cooling system through the

compensation tank.

z Close the compensation tank with the valve. z Start the engine and run warm until the

thermostat opens (line 1 heats up).

z Engine run with open thermostat 2 - 3 minutes.

z Check the coolant level in the compensation

tank and top up the coolant if necessary.

z Repeat the process with engine start if

necessary.

Never operate the engine without coolant (not even briefly).

3.1.4 Other preparations

z Check battery and cable connections, see

6.7.1.

z Trial run

- After preparations carry out a short trial run of approx. 10 min.

Do not fully load the engine.

During and after the trial run

- Check engine for tightness.

With engine not running

- Check oil level, re-fill oil if necessary, see

6.1.2

- Check V-belt, re-tighten if necessary, see

6.5.

z Running-in

Check the oil level twice a day during the running-in phase. After the running-in phase, checking once a day is sufficient.

Operation

3.2.1 Electrical starting

3.2 Starting

without cold start aid

Before starting make sure that there is nobody in the engine/ work machine danger area. After repairs: Check that all

protective equipment is mounted and all tools have been removed from the engine. When starting with heating plugs/heating flange, do not use additional start aids (e.g. injection with start pilot)! Danger of accidents! z Engine is electronically controlled by

Example: EMR3 (electronic engine control)

- engine is programmed and supplied with the necessary function configurations.

z As far as possible separate engine from

driven devices by disconnecting.

z Engine connector plug must be connected

by the customer (e.g in driver’s cab/ device) to at least:

- Supply voltage

- Torque output

- Speed output.

z Warm up the engine for approx. 30 seconds

at a low idling speed.

z Do not run up the engine immediately to

high idling speed / full load operation from

cold. If the starter is connected by a relay on the EMR3,

- the maximum starting time is limited by

the EMR3.

- the pause between two start attempts

is given by the EMR3.

- If the touch start function is programmed, a short start command with the ignition key suffices in position 2 or, if available, by a start button. The start is then continued automatically by the EMR3.

- For special applications, the EMR3 can be programmed by data record so that the control unit performs other automatic start attempts if the engine fails to start.

z Insert key

- Step 0 = no operating voltage.

z Turn key to the right

- Step 1 = operating voltage,

- Warning lights light up.

z Turn the key further to the right against the

spring load.

- Step 2 = start

z Release key as soon as the engine starts up.

- Warning lights go out.

Start the engine for a maximum of 20 seconds uninterrupted. If the engine does not start up, wait for one minute and then repeat the starting process. If the engine does not start up after two starting processes, determine the cause as per fault table (see 7.1). If the engine does not start and the diagnostic lamp flashes, the EMR3 system has activated the start lock to protect the engine. The start lock is released by switching off the system with the ignition key for about 30 seconds.

3.2 Starting

Operation

with cold start aid

Heating plug/heating flange

z Insert key.

- Step 0 = no operating voltage.

z Turn key to the right.

- Step 1 = operating voltage,

- Warning lights 1+2+3 light up.

- Pre-heat until heating indicator goes out. If the pre-heating indicator flashes, there is an error, e.g. pre-heating relay sticking which can fully discharge the battery at standstill.

- Engine is ready for operation.

z Turn the key further to the right against the

spring load to

- Step 2 = start

z Release key as soon as the engine starts up.

- Warning lights go out.

Caution: Engine must start within 30 seconds, if not, repeat the starting process.

Operation

3.3 Operation monitoring

The EMR3 system monitors the engine condition and itself. The states are indicated by the diagnostic lamp. Lamp test: z The diagnostic lamp lights for about 2s after

ignition (ignition lock stage 1). Steady light: z There is an error in the system or a variable of

the engine (temperature, pressure, etc.) is in

the warning area. Depending on the error, the

performance of the engine may be reduced by

the EMR3 to protect the engine so that it is not

in danger. Fast flashing:

z Attention, the engine is in danger and

must be switched off. z Depending on the application, the

control unit switches the engine off

automatically.

z The control unit may also specify an idle speed

to cool the engine before shutting down. z There may be a start lock after stopping the

engine. z Additional control lamps e.g. for oil pressure or

oil temperature may be on. z The override key can bypass the reduction in

performance to avoid critical situations, as

well as delay the automatic shutdown or

bypass a start lock. This overwriting of the

engine protection functions is logged in the

control unit. z The start lock is released by switching off the

system with the ignition key for about 30

seconds.

3.3.1 Engine oil pressure Oil pressure light

z The oil pressure light comes on for about 2s

after switching on the system.

z The oil pressure light must be off when the

engine is running.

Oil pressure gauge

z Oil pressure gauge shows the lube oil pressure

(minimum lube oil pressure, see chap. 9.1).

3.3 Operation monitoring

Operation

3.3.2 Coolant temperature

z The needle of the temperature display should

always be in the green area, and only as an exception in the yellow/green area. If the needle rises into the orange area the engine is getting too hot. Switch off the engine and determine the cause as per fault table (see 7.1).

3.3.3 Coolant level

minmin

z Light on coolant level display comes on (contact

is via float switch/ level probe if coolant level is below minimum): Switch off the engine and determine the cause as per fault table (see 7.1).

z Function check of coolant level:

- Coolant level OK: Light goes out

Operation

3.4.1 Electrical shutdown

3.4 Shutting down

z Turn the key to the left (to step 0) and

remove. Warning lights go out. Note: The control unit remains active for about another 40 seconds to save the system data (lag) and then switches itself off.

Avoid shutting down from full load operation if possible (coking/ blockage of the remaining oil in the

turbocharger bearing housing). Lube oil is no longer supplied to the turbocharger! Run the engine after relieving the load for about one minute at low idling speed.

3.5 Operating conditions

3.5.1 Winter operation

Operation

z Lube oil viscosity

- Select the viscosity (SAE class) according to the ambient temperature before starting the engine, see 4.1.2.

- Observe shorter oil change times when operating below -10 °C, see 6.1.1.

z Diesel fuel

- Below 0 °C use winter fuel, see 4.2.2.

z Coolant

- Mixing ratio anti-freeze / water for lowest temperature (max. - 35 °C), see 4.3.1.

z Additional maintenance work

- Check the fuel container weekly for contaminations, clean if necessary.

- If necessary, adjust the oil filling of the oil bath air filter (as engine oil) according to the outside temperature.

z Cold start aids

- When there is a frost, start with heating plugs if necessary (see 3.2.1). This does not only lower the starting limit temperature, but also simplifies starting at temperatures which do not actually require a starting aid.

z Battery

- A well-charged battery is a prerequisite for a good cold start, see 6.7.1.

- Heating the battery to approx. 20 °C (dismantle and store in a warm room) lowers the starting limit temperature by 4-5 °C.

Operation

3.5.2 High ambient temperature, high altitude

z When the altitude or ambient temperature

increases, the air density decreases. This impairs the maximum engine performance, exhaust quality, temperature level and, in extreme cases, the starting performance. For transient operation, usage up to 1500 m altitude and a temperature of 30 °C is permissible, for stationary operation 1000 m altitude and a temperature of 40 °C is permissible. When using the engine under adverse conditions (high altitude or high temperature) the amount of fuel power injected is reduced and the amount of fuel injected and with it the engine power.

z In case of doubt regarding engine usage,

please ask your engine or device supplier whether necessary fuel stop reduction has been carried out in the interest of operational safety, service life and exhaust quality (smoke!), or contact your service representative.

3.5 Operating conditions

4.1 Lube oil

4.2 Fuel

4.3 Coolant

Operating substances

Operating substances 4.1 Lube oil

General

Modern diesel engines place very high demands on the lube oil to be used. The specific engine performances which have increased constantly over the last few years lead to an increased thermal load on the oil and also the oil is more exposed to contamination due to reduced oil comsumption and longer oil change intervals. For this reason it is necessary to observe the requirements and recommendations described in this instruction manual in order not to shorten the life of the engine.

Lube oils always consist of a basic oil and an additive package. The most important tasks of a lube oil (e.g. wear protection, corrosion protection, neutralization of acids from combustion products, prevention of coke and soot deposits on engine parts) are assumed by the additives. The properties of the basic oil are also decisive for the quality of the product, e.g. with regard to thermal load.

Mixing of engine oils should be avoided because the worst properties of the mixture are always dominant. Basically all engine oils are mixable so that a complete lube oil change from one oil type to another is unproblematical under the aspect of mixability.

Thelube oil quality has a considerable influence on the life, performance and thus also on the costeffectiveness of the engine. It basically applies that: the better the lube oil quality, the better these properties.

The lube oil viscosity describes the flow behavior of the lube oil dependent on the temperature. The lube oil viscosity has no influence and effect on the lube oil quality.

Synthetic lube oils are used increasingly and have advantages. These oils have a better temperature and oxidation stability as well as a relatively low cold viscosity. Since some processes relevant to the definition of the lube oil change intervals are not essentially dependent on the lube oil quality (such as the entry of soot and other contaminations), the lube oil change interval when using synthetic lube oils may not be increased in relation to the specifications of the lube oil change intervals section 6.1.1.

Biodegradable lube oils may be used in DEUTZ engines if they meet the requirements of this operating manual.

4.1 Lube oil Operating substances

4.1.1 Quality

Lube oils are classified by DEUTZ according to their performance and quality class (DQC : Deutz QualityClass). It basically applies that the lube oils are more efficient or higher quality with ascending quality class (DQC I, II, III, IV). The annex (- 02, - 05) specifies in what year the classification was created. Lube oils according to other, comparable specifications can be used as long as they meet the DEUTZ requirements. In regions in which none of these qualities is available, please contact the DEUTZ Service responsible.

The following lube oils are prescribed for the engines of this operating manual:

TCD 2012 / 2013 2V

with open crankcase bleeding:

DQC II - 05 DQC III - 05

DEUTZ lube oil quality classes DQC I - 02 DQC II - 05 DQC III - 05 DQC IV - 05 ACEA classification E2 - 96 E3 -96 / E4 - 99 / Table

(Association des Constructeurs E5 - 02 E6 - 04 T 4-1-4 Européen d’Automobiles) or according

E7 - 04 to table

T 4-1-3

or API classification CF / CF - 4 CG - 4 / - -

(American Petroleum Institute) CH-4 / CI-4

or worldwide classification - DHD - 1 - -

The best results are achieved with DEUTZ lube oils. These can be ordered from DEUTZ Service with the order

number.

DEUTZ lube oil DQC II - 05 DQC III - 05 quality classes

Lube oil type DEUTZ Öl TLS - 15W-40 D DEUTZ Öl TLX - 10W-40 FE

DQC IV - 05

Container Order no. Container Order no.

5 liter 0101 6331 5 liter 0101 6335

20 liter 0101 6332 20 liter 0101 6336

209 liter 0101 6333 209 liter 0101 6337

Tank store 0101 6334 Tank store 0101 6338

Operating substances 4.1 Lube oil

DEUTZ lube oil quality level DQC III-05

Manufacturer Lube oil type SAE class Availability DEUTZ DEUTZ oil TLX-10W40FE 10W-40 Europe

ADDINOL ADDINOL Super Truck MD 1048 10W-40 Europe, Asia

ADDINOL Ultra Truck MD 0538 5W-30 Europe, Asia

AGIP Agip Sigma Ultra TFE 10W-40 worldwide

Autol Valve Ultra FE 10W-40 Germany

ARAL Aral MegaTurboral 10W-40 worldwide

Aral SuperTurboral 5W-30 worldwide AVIA TURBOSYNTH HT-E 10W-40 Germany BAYWA BayWa Super Truck 1040 MC 10W-40 Southern Germany

BayWa Turbo 4000 10W-40 Southern Germany BP OIL International BP Vanellus E7 Plus 10W-40 Europe

BP Vanellus E7 Supreme 10W-40 Europe

BP Vanellus C8 Ultima 5W-30 Europe

Bucher AG MOTOREX FARMER 10W-40 Europe

Castrol Castrol Enduron Plus 5W-40 Europe, America, Australia, South Africa

Castrol Enduron 10W-40 Europe, America, Australia, South Africa

Castrol Elexion 5W-30 USA CEPSA EUROTRANS SHPD 10W-40 Spain, Portugal CHEVRON Chevron Delo 400 Synthetic 5W-40 North Amerika ESSO Essolube XTS 501 10W-40 Europe FUCHS EUROPE Fuchs Titan Cargo MC 10W-40 worldwide

Fuchs Titan Unic Plus MC 10W-40 worldwide MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, Africa

Mobil Delvac 1 5W-40 worldwide

Mobil Delvac XHP Extra 10W-40 Europe, SE Asia

OMV AG OMV super Truck 5W-30 Europe

OMC truck FE plus 10W-40 Europe

Ravensberger Ravenol Performance Truck 10W-40 Germany

Lube oil refinery

Salzbergen Wintershall TFG 10W-40 Europe varies Texaco Ursa Super TDX 10W-40 Europe

Ursa Premium FE 5W-3 0 Europe

TOTAL TOTAL RUBIA TIR 8600 10W-40 worldwide

T 4-1-3 Release list for DEUTZ lube oil quality class DQC III - 05

EXPERTY 10W-40 worldwide

4.1 Lube oil Operating substances

DEUTZ lube oil quality level DQC IV-05

Manufacturer Lube oil type SAE class Availability

FUCHS EUROPE Fuchs Titan Cargo SL 5W-30 worldwide

SHELL International Shell Rimula Ultra 5W-30 Europe, code country-specific, varies

Shell Rimula Ultra 10W-40 Europe, code country-specific, varies

T 4-1-4 Release list for DEUTZ lube oil quality class DQC IV - 05

Operating substances 4.1 Lube oil

4.1.2 Quality

The ambient temperature at the installation site or area of application of the engine is decisive for the choice of the right viscosity class. Too high a viscosity can lead to starting difficulties, too low a viscosity can endanger the lubrication effect and cause high lube oil consumption. At ambient temperatures below 40°C the lube oil must be pre-heated (e.g. by storing the vehicle or machine in a shed). The viscosity is classified according to SAE. Multipurpose oils should be used basically. Single purpose oils can also be used in closed, heated rooms at temperatures >5 °C. The specified lube oil qualities must also be single purpose oils of course.

Depending on the ambient temperature we recommend the following common viscosity classes:

only with engine pre-heating

30 298 1

4.2 Fuel Operating substances

4.2.1 Quality

The following fuel specifications are permitted:

z Diesel fuels according to DIN EN 590 z US diesel fuel according to ASTM D 975

Grade-No 1-D and 2-D

z Japanese diesel fuel JIS K 2204 Grade 1

Fuel and Grade 2 Fuel with lubricating properties according to diesel fuel EN 590 (HFFR max. 460 micrometer according to EN ISO 12156)

Use commercially available diesel fuels with a sulfur content below 0.5%. If the sulfur content is higher, the lube oil change intervals must be reduced (see 6.1.1).

If other fuels are used which do not meet the requirements of this instruction manual, the warranty will be voided.

The certification measurements to satisfy the legal emission limits are performed with the test fuels defined by law. These correspond to the diesel fuels according to EN 590 and ASTM D 975 described in this operating manual. No emission values are guaranteed with the other fuels

described in this instruction manual.

4.2.2 Winter fuel

For the engines TCD 2012/2013 2V and TCD 2012/2013 4V which are operated with fuel according to ASTM D 975 1-D/ 2-D, adding paraffin is not permissible.

At low ambient temperatures paraffin discharges can lead to blockages in the fuel system and cause operating faults. Use winter fuel at outside temperatures below 0 °C (to

-20 °C) (generally offered by petrol stations in good time before the cold season begins).

z Paraffin should be added at temperatures

below -20 °C. The mixing ratios required are as per the diagram on the right.

z Special diesel fuels can be used for arctic

climates to -44 °C.

If it is necessary to use summer diesel fuel under 0 °C, paraffin can also be added up to 30 % as per the diagram on the right.

Generally, sufficient resistance to cold can also be achieved by adding a flow ameliorant. For questions regarding this please contact your DEUTZ partner.

Diagram key:

I Summer diesel fuel

I I Winter diesel fuel

A Outside temperature

B Paraffin mixing proportion

Only carry out mixing in the tank! First pour in the necessary amount of paraffin, then the diesel fuel. Addition of normal and super petrol is not permitted.

Operating substances 4.3 Coolant

4.3.1 General

In liquid-cooled engines, the coolant must be conditioned and monitored otherwise the engine may incur damage due to:

z corrosion, z cavitation, z freezing.

The correct water quality is important for conditioning the coolant. Basically, clear, clean water within the following analysis values must be used:

Analysis values min. max.

ph value at 20 °C 6.5 8.5

Chloride ion content[mg/dm3] - 100

Sulfate ion content[mg/dm3] - 100

The water must be treated if it deviates from the analysis values.

z pH value too low:

Addition of diluted caustic soda or caustic potash solution. Small sample mixtures are advisable.

z Total hardness too high:

Mix with softened water

z Total hardness or carbon hardness too low:

Mix with harder water

z Chloride and / or sulfate too high:

Mix with softened water

Softened water is a distilled water, pH neutral

condensate or water treated with ion exchangers.

Total hardness *1[°dGH] 3 12

carbonate hardness proportion of total

hardness min 3 dGH. Water quality data are obtainable from the local waterworks. A test case can be requested from DEUTZ Service (order no. 1213 0382) for checking your water quality.

Harder water is available in most cases in the

form of drinking water (city water).

4.3 Coolant Operating substances

4.3.2 Coolant preparation

The coolant for liquid-cooled DEUTZ compact engines is conditioned by mixing an antifreeze with ethylene-glycol-based corrosion protection inhibitors into the water.

The best results are achieved with DEUTZ cooling system preservatives:

Container Order no. 5 liter container 0101 1490

20 liter container 0101 6416 210 liter container 1221 1500

This cooling system is free from nitrite, amine, phosphate and adapted to the materials in our engines. Order from your DEUTZ Service

f the DEUTZ cooling system preservative is not available, a coolant according to T 4-1-5 can be used. Coolants of product group A or B respectively can be mixed. Coolants of product group A may not be mixed with coolants of product group B.

The cooling system must be monitored regularly, see 5.1. This includes checking the concentration of the cooling system preservative, as well as inspecting the coolant level. The inspection of the concentration of cooling system preservative can be carried out with standard testing devices (e.g. refractometer).

Cooling system W ater Cold protection preservative percentage up to percentage

min. 35 % 65% -22 °C

40 % 60% -28 °C

max. 45 % 55% -35 °C

At temperatures below -35°C, please consult your responsible DEUTZ Service.

It is possible to use other cooling system preservatives (e.g. chemical corrosion preservatives) in exceptional cases. Consult

DEUTZ Service.

The mixing of nitrite based cooling system preservatives with aminebased agents forms nitrosamines which are hazardous to the health!

Cooling system preservatives must be disposed of in an environmentally friendly manner.

5.1 Maintenance schedule

5.2 Maintenance diagram

5.3 Maintenance work carried out

Maintenance

Maintenance 5.1 Maintenance schedule

check= z set= clean=L renew= 

⇓ check 2x daily before or during the 1st trial run, during the running-in phase or

when commissioning new and overhauled engines

⇓ every 10 oh or daily

in operating hours (oh) every year(s)

E10 E20 E30 E40 E45 E50 E60 E70

500 1,000 1,500 3,000 6,000 12,000 1 2

 



 z zz 

zzz zz  zz L

zz   zzz

zz zz zz

z z



z



Activity

Lube oil level, if necessary re-fill 6.1.2

Lube oil (oil change intervals depending on engine application and oil quality), see TR 0199-99-3002

Oil filter cartridge 6.1.3 Fuel filter cartridge 6.2.1 Electronic injector check via EMR3

Fuel filter insert1) (fuel pre-filter) 4.2 Coolant (additive concentration) 4.3.1/2/3 Coolant level – Intake air filter Charge air cooler (drain lube oil/condensation) Check function of heating plug / heating flange Battery and cable connections 6.7.1 Engine monitoring, warning system Valve clearance / contol piston clearance (exhaust gas return) 6.6.1 V-belt (re-tighten if necessary) 6.5.1 V-rib belt/tension pulley (renew when wear limit reached) 6.5.1 Crankcase pressure bleed valve Engine tightness (visual inspection for leaks) – Engine mounting (renew in case of damage) 9.2 Fastenings, hose connections / clamps

General overhaul

(if available, maintenance as per maintenance display)

Industrial engines

The engine maintenance times given are maximum permissible job times. Depending on the usage circumstances, shorter maintenance times may be necessary. Observe the instruction manual of the equipment manufacturer.

# Maintenance only to be carried out by authorised service personnel

Section

6.1.1/ 6.1.2

6.4.3 /6.4.4

3.3

–

#, 5.1.1

The maintenance interval must be halved for contaminated fuel or poor quality fuel.

If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.

5.1 Maintenance schedule Maintenance

check= z set=  clean= L renew= 

max. permissible job times in operating hours (oh) every

check 2x daily before or during the 1st trial run, during the running-in phase or

⇓

when commissioning new and overhauled engines

⇓ every 10 oh or daily

in operating hours (oh) every year(s)

E10 E30 E40 E70

500 5,000 12,000 1 2

z



z L z L





Lube oil Injector Charge air cooler (drain lube oil/condensation) Charge air cooler inlet surface (clean if necessary) # Crankcase bleeding valve Exhaust turbocharger compressor outlet -

Activity

(oil change intervals depending on engine application and oil quality), see TR 0199-99-3002

Enhancements or modifications

for engines with EPA acceptance

The engine maintenance times given are maximum permissible job times. Depending on the usage circumstances, shorter maintenance times may be necessary. Observe the instruction manual of the

equipment manufacturer.

# Maintenance only to be carried out by authorised service personnel

Section

6.1.1/ 6.1.2

# #

5.1 Maintenance schedule Maintenance

5.1.1 Standard maintenance schedule

Intervals Deutz maintenance Activity Execution by:

at/ after

50 oh E 10 after commissioning and E 50-E 70 authorised specialists

10 oh or daily E 20 daily inspection round the user / authorised specialists

500 oh E 30 inspection authorised specialists 100 0 oh E 40 intermediate overhaul authorised specialists 150 0 oh E 45 extended intermediate overhaul authorised specialists

3 000 oh E 50 partial overhaul authorised specialists 5 000 oh (EPA) E 60 extended partial overhaul authorised specialists 6 000 oh E 60 extended partial overhaul authorised specialists

12 000 oh

and service schedules

E 70 general overhaul authorised specialists

*) approximate value, depends on the type of engine application and/or regular engine maintenance. Please contact your responsible DEUTZ Service partner.

Maintenance 5.2 Maintenance diagram

The maintenance diagram shown on this page is supplied with every engine in selfadhesive form. It should be stuck onto a well visible location on the engine or equipment.

Check that this is the case!

If not, request a replacement from your engine or equipment supplier!

The maintenance schedule is decisive for standard maintenance, see 5.1.

All maintenance work should only be carried out when the engine is not running.

5.3 Maintenance work carried out Maintenance

Op. hrs.

50-150

125

375

625

875

1125

1375

1625

1875

Date

Signature / stamp Op. hrs. Date

250

500

750

1000

1250

1500

1750

2000

Signature / stamp

2115

2375

* after commissioning new and overhauled engines The maintenance work carried out methodically can be recorded in the table and confirmed.

2250

2500

2750

Maintenance 5.3 Maintenance work carried out

Op. hrs.

2875

3125

3375

3625

3875

4125

4375

4625

4875

Date Signature / stamp

Op. hrs. Signature / stamp

3000

3250

3500

3750

4000

4250

4500

4750

5000

Date

5125

5375

5625

The maintenance work carried out methodically can be recorded in the table and confirmed.

5250

5500

5750

5.3 Maintenance work carried out Maintenance

Op. hrs.

5875

6125

6375

6625

6875

7125

7375

7625

7825

Date

Signature / stamp Op. hrs. Date

6000

6250

6500

6750

7000

7250

7500

7750

8000

Signature / stamp

8125

8375

8625

The maintenance work carried out methodically can be recorded in the table and confirmed.

8250

8500

8750

Maintenance 5.3 Maintenance work carried out

Op. hrs.

8875

9125

9375

9625

9875

10125

10375

10625

10875

Date Signature / stamp

Op. hrs. Signature / stamp

9000

9250

9500

9750

10000

10250

10500

10750

11000

Date

11125

11375

11625

The maintenance work carried out methodically can be recorded in the table and confirmed.

11250

11500

11750

Care and maintenance work

6.1Lubrication system

6.2Fuel system

6.3Cooling system

6.4Combustion air filter

6.5Belt drive

6.6Setting work

6.7Add-on parts

Care and maintenance work 6.1 Lubrication system

6.1.1 Oil change intervals

z The oil change times depend on the engine

application and the quality of the lube oil.

z If the oil change times are not reached

within a year, the oil change should be carried out at least 1x yearly.

z The following conditions apply for the table

– Sulphur content max. 0.5 % of weight for diesel fuel. – Constant ambient temperature -10 °C (+14 °F)

z For fuels

– with sulphur content > 0.5 to 1%

– Constant ambient temperatures < -10 °C (+14 °F)

z For fuels with a sulphur content higher

than 1% ask your responsible service representative.

z If the lube oil change intervals are planned

in terms of operating hours, the lube oil change intervals for installed engines

6.1.1.1 apply.

Carry out oil changes on warm engine when the engine is not running (lube oil temperature < 80 °C).

6.1 Lubrication system Care and maintenance work

6.1.1.1 Lube oil change intervals for installed engines

Lube oil quality

Deutz lube oil quality class DQC I-02 DQC II-05 DQC III-05 DQC iV-05

ACEA specification E2-96 E3-96/E5-02/E07-04 E4-99/E6-04 E4-99/E6-04

see chap 6.1.1.3 only fully synthetic

API specification CF/CF-4 CG-4/CH-4/ CI-4 - -

worldwide specification - DHD-1 - -

special DEUTZ release list - - see chap 4.1.2.1 -

Standard lubricant code designation EO... EO...C - -

for building machines and building vehicles EO...A, EO...B

Engine Engine version Lube oil change intervals in oh

series

TCD 2012 Crankcase ventilation: L04/06 2V open - 500 500 500

TCD 2013 Crankcase ventilation: L04/06 2V open - 500 500 500

Care and maintenance work 6.1 Lubrication system

6.1.2 Checking oil level, changing engine oil

6.1.2.1 Checking oil level

z Position the engine or vehicle so as to be level.

– Engine warm:

Switch off the engine, wait for 5 minutes and check the oil level.

– Engine cold:

Check oil level.

z Extract oil dipstick. z Wipe with a fibre-free, clean cloth. z Insert until it stops and extract again. z Check oil level and re-fill to "MAX" if necessary.

– If the oil level lies just above the "MIN"

line marking, re-filling is necessary.

The oil level may not fall short of the "MIN“ line marking.

6.1.2.2Changing engine oil

z Warm up the engine. z Position the engine or vehicle so as to be level.

– Lube oil temperature approx. 80 °C.

z Switch off engine. z Position oil drip cup under the engine. z Unscrew oil drain screw.

z Drain off oil. z Screw in oil drain screw with new sealing ring

and tighten. (For tightening torque see 9.2).

z Fill lube oil

– For quality / viscosity data see 4.1. – For filling quantities, see 9.1

z Check oil level, see 6.1.2.1

Caution when draining hot oil: danger of scalding! Collect the used oil, do not allow to seep into floor! Dispose of according to instructions!

6.1 Lubrication system Care and maintenance work

6.1.3 Changing oil filter

z When anti-rotation lock is installed:

Loosen clamping screws and remove tightening clamps from below.

z Loosen lube oil filter cartridge with standard

tool and unscrew.

z Collect any oil which may run out.

z Clean the sealing surface of the filter support

for any dirt there may be.

z Lightly oil the rubber seal of the new lube oil

cartridge.

z Screw on the cartridge by hand until the seal

makes contact.

z Tighten the lube oil filter cartridge with a three-

quarter turn (about 10 Nm).

z Check the seal of the lube oil cartridge for

tightness.

z Check oil level, see 6.1.2.

Careful with hot oil: danger of scalding!

Care and maintenance work 6.1 Lubrication system

6.1.4 Cleaning / changing oil filter (cup)

z Switch off engine. z Loosen lube oil filter cover 1 with two or three

turns and wait for 30 seconds.

z Unscrew lube oil filter cover 1 with paper filter

cartridge 5 in anti-clockwise direction.

z Carefully loosen paper filter cartridge 5 from

the guide 4, which is inserted in the housing 3, from above.

z Collect any lube oil which may run out. z Crease the paper filter cartridge 5 in the

collection vessel slightly at the side until the cartridge is released from the clip 6.

z Clean the sealing surface of the filter support

and the lube oil filter cover 1 as well as the guide 4 of any dirt there may be

z Change the round sealing ring 2 and lightly oil. z Press new paper filter cartridge 5 into the clip

6 and insert carefully in the guide 4 together.

z Screw the lube oil filter cover 1 tight in clockwise

direction (25 Nm).

z Start the engine. z Check lube oil filter assembly for leaks. z Check engine oil level and top up if necessary.

Careful with hot oil: Danger of scalding Dispose of used oil in an environmentally friendly way.

6.1 Lubrication system Care and maintenance work

Care and maintenance work 6.2 Fuel system

Regulations for working on the fuel system

Engine must be switched off! Smoking and naked lights prohibited! No injection/high pressure pipes

may ever be disconnected when the engine is running. Caution when handling hot fuel!

Pay attention to absolute cleanliness when refueling and working on the fuel system! Clean the vicinity of the components concerned carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national regulations for handling fuels. Dispose of leaked fuel and filter elements according to regulations. Do not allow fuel to seep into the ground. After working on the fuel system, bleed it, conduct a test run and check for leaks.

Additional venting of the fuel system by a 5 minute trial run in idle or low load is absolutely essential.

Additional regulations for DEUTZ Common Rail Systems

Danger to life! Never work on the fuel system with the engine running. The system is under high pressure!

Do not stand near to a leak in the high pressure system because fuel jet can cause severe injury! After switching off the engine, wait 30 seconds before working on the fuel system. In the event of leaks in the fuel system contact your DEUTZ Service immediately!

Cleanliness hints and measures for handling DEUTZ Common Rail Systems

Pay attention to extreme cleanliness due to the high-precision technology! The fuel system must be tight and closed. Inspect visually for leaks/damage in the system. Clean the engine and engine compartment thoroughly and dry before starting work. Cover engine compartment areas from which dirt could be loosened with fresh, clean foil. Work on the fuel system may only be carried out in an absolutely clean environment. Air contamination such as dirt, dust, moisture etc. must be avoided.

6.2 Fuel system Care and maintenance work

6.2.1 Changing fuel filter

zClose fuel stopcock. zLoosen fuel filter cartridge with standard tool

and unscrew.

zCollect any fuel which may run out. zClean the sealing surface of the filter support

for any dirt there may be.

zLightly oil the rubber seal of the filter support.

zLightly oil the fuel filter cartridge or wet with

diesel fuel.

zScrew on the cartridge by hand until the seal

makes contact.

zTighten the fuel filter cartridge with a three-

quarter turn (10 Nm).

zOpen fuel stopcock. zCheck for tightness.

No open fire when working on the fuel system! Do not smoke! Pay attention to cleanliness as the fuel system (rail) is very sensitive!!!

Venting of the fuel system is necessary, see chapter 6.2.3.

Care and maintenance work 6.2 Fuel system

6.2.2 Cleaning / changing fuel filter (cup)

z Switch off engine. z Loosen fuel filter cover 1 with two or three

turns and wait for 30 seconds.

z Unscrew fuel filter cover 1 with paper filter

cartridge 5 in anti-clockwise direction.

z Carefully loosen paper filter cartridge 5 from

the guide 4, which is inserted in the housing 3, from above.

z Collect any fuel which may run out. z Slightly bend paper filter cartridge 5 sideways

in the collecting vessel until the cartridge is loosened from clamp 6.

z Clean the sealing surface of the filter support

and the fuel filter cover 1 as well as the guide 4 of any dirt there may be.

z Change the round sealing ring 2 and lightly oil. z Press new paper filter cartridge 5 into the clip

6 and insert carefully in the guide 4 together.

z Tighten the fuel filter cover 1 in clockwise

direction (25 Nm).

z Start the engine. z Check fuel filter attachment for tightness.

Only work on the fuel system when the engine is switched off. Wait at least 30 seconds. No open fire! Do not smoke! Dispose of used fuel in an environmentally friendly manner. Venting of the fuel system is necessary, see chapter 6.2.3.

6.2 Fuel system Care and maintenance work

6.2.3 Fuel pre-filter, changing / bleeding filter insert

Filter change:

z Close fuel stopcock (for high tanks). z Position fuel collecting vessel beneath fuel

pre-filter.

z Loosen drain cock (7) and drain water + fuel

completely.

z Unscrew filter cartridge (5) together with

water collecting vessel (8) in anti-clockwise direction and remove.

z Loosen water collecting vessel (8) from old

filter cartridge (5) in anti-clockwise direction and remove.

z Empty remaining fuel into the fuel collecting

vessel and clean water collecting vessel (8).

z Screw water collecting vessel (8) onto the

new filter cartridge (5) in clockwise direction.

z Clean any dirt from the sealing surface of the

new filter cartridge (5) and the reverse side of the filter head

z Wet the sealing surfaces of the filter cartridge

(5) slightly with fuel and screw back onto the filter head in clockwise direction (17-18 Nm).

z Open the fuel stopcock and bleed the system

(see "Bleeding fuel system").

z Dispose of collected fuel and old filter cartridge

(5) properly.

Bleeding fuel system:

z Unlock the bayonet plug of the fuel hand

pump (3) by pressing and turning anti-clockwise at the same time. The pump plunger is now pushed out through the spring.



Turn the shutdown lever of the ther-





mostat valve (4) by approx. 45° in clockwise direction until it is felt to engage.

z Pump until a very strong resistance is felt and

pumping becomes very slow.

z Now carry on pumping a few more times (the

return pipe must be filled).

z Start the engine and run for about 5 minutes in

idle or low load. Check the pre-filter for leaks.

z Perform some more pumping movements.

(The return line must be filled).

z Turn the shutdown lever of the thermostat

valve (4) by approx. 45° in anti-clockwise direction until it is felt to engage.

z Lock the bayonet plug of the fuel hand pump

(3) by pressing and turning clockwise at the same time.

1 Fuel supply to pump 2 Fuel return from control block FCU

Fuel Control Unit)

(

3 Fuel hand pump with bayonet

plug for locking and unlocking 4 Thermostat valve with shutdown lever 5 Filter cartridge 6 Connection facility for electrical

water level sensor 7 Drain cock 8 Water collecting vessel (bowl) 9 Fuel inlet from fuel tank

10 Fuel return to fuel tank

A Connection for electr. warning lamp / siren

Only work on the fuel system when the engine is switched off. No open fire! Do not smoke! Dispose of used fuel in an environmentally friendly manner.

Care and maintenance work 6.3 Cooling system

6.3.1 Cleaning intervals

z The cooling system soiling depends on thetype

of engine application.

z The risk of soiling is increased by oil and fuel

residues on the engine. Therefore pay particular attention to tightness when operating under high dust exposure.

z Increased soiling occurs, for example, during:

- Building site application from high dust content of air.

- Harvesting application from high proportion of chaff and chopped straw, for example, in the area of the work machine.

z Due to the various application conditions, the

cleaning intervals must be defined according to each case. Therefore, the cleaning intervals given in the table below can be used as guidelines.

Checking or cleaning intervals

Guideline oh

2000 Ships, electronic units in

1000 Vehicles on paved roads 500 Tractors, fork lift trucks, drivable

250 Vehicles on building sites and

125 Agricultural machinery, tractors

Engine application

enclosed spaces, pumps

electronic units

unpaved roads, building machines, compressors, mining equipment.

with harvesting application.

6.3.2 Cleaning cooling system

Cleaning with compressed air

z Blast out the engine with compressed air. Do

not damage any components.

z Rinse out the loosened dirt with a water jet.

Cleaning with cold cleaner

z Spray the engine with standard cold cleaner

and leave to work for approx. 10 minutes.

z Spray the engine clean with an acute water jet

(do not spray the water jet directly at sensitive engine parts, e.g. generator, cabling, electronic components, fan drive).

6.3 Cooling system Care and maintenance work

Cleaning with steam or hot water

z Remove oil and greasy residues with a gentle

jet setting (do not spray directly on sensitive engine parts, e.g. generator, wiring, electricalcomponents, fan drive).

z Warm up the engine so that the water residues

evaporate.

External cooling

z For external coolers: Cleaning as per

specifications of the cooling system manufacturer.

Injection pressure: maximum 100 bar and at a distance of 1 meter!

Care and maintenance work 6.3 Cooling system

6.3.3 Emptying cooling system

z Open cooler cover. z Position collecting dish underneath locking

screw 1.

z Remove locking screw 1 on the crankcase. z Drain off coolant. z Re-tighten locking screw 1. z If locking screw 1 is not accessible, the cooling

system can be emptied on the engine oil cooler (coolant channel).

Caution when draining hot coolant: danger of scalding! Collect coolant when draining off. Dispose of according to

instructions!

6.3.4 Filling / bleeding cooling system

z Open cooler cover. z Loosen locking screw item 1 (chap.6.3.3). z Pour in coolant until the maximum mark or

the filling limit (system heating valve must be open, if present).

z Tighten locking screw item 1(chap.6.3.3). z Close cooler cover. z Start engine and warm up until the thermostat

opens.

z Switch off engine. z Check the coolant level with the engine cold

and re-fill if necessary.

z Close cooler cover.

z The cooling system (if constructed under

consideration of our installation guidelines) is bled automatically after filling.

Never operate the engine without coolant (not even briefly).

Care and maintenance work 6.4 Combustion air filter

6.4.1 Cleaning intervals

z The soiling of the combustion air filter de-

pends on the dust content of the air and the selected filter size. If a high dust exposure is to be expected, a cyclone separator can be connected to the combustion air filter.

z The cleaning intervals cannot be generally

defined. They must be defined depending on each case.

z If dry air filters are used, cleaning should

only be carried out according to the maintenance display or maintenance switch.

z Filter maintenance is required when on the:

- Maintenance display

the red service field 1 is fully visible when the engine is not running.

- Maintenance switch

the yellow warning light lights up when the engine is running.

z After completion of the maintenance work

push the reset button on the maintenance display. The maintenance display is ready for operation again.

Care and maintenance work 6.4 Combustion air filter

6.4.2 Emptying cyclone preseparator

z Loosen wing nut 1 and lift housing cover 2. z Remove the dust container 3 from the base of

the cyclone 4 and empty. Clean foliage, straw and the like from the cylone base.

z Place the dust container 3 on the base 4 and

tighten the housing cover 2 with wing nut 1.

6.4.3 Cleaning oil bath air filter

z Turn off the engine and wait approx. 10 min

until the oil has run out of the filter housing 1.

z Loosen quick fasteners 2 and remove oil pan

3 with filter insert 4, if possible loosen filter insert on the dividing point with the aid of a screwdriver. Do not damage rubber seal 5!

z Remove soiled oil and sludge, clean oil pan. z Clean filter insert 4 in diesel fuel and allow to

drip dry thoroughly.

z In the event of heavy soiling, clean filter hou-

sing 1.

z Visually inspect rubber seals 5 and 6 and

renew if necessary.

z Fill up the oil pan with engine oil up to the oil level

mark (arrow) (for viscosity see 4.1.2).

z Place the oil pan with the filter insert on the filter

housing and close the plugs.

Never fill the dust container with oil, replace damaged containers!

Never clean the filter in petrol! Dispose of used oil according to instructions!

6.4 Combustion air filter Care and maintenance work

6.4.4 Dry air filter Dust discharge valve

z Empty the dust discharge valve 1 by squee-

zing the discharge slot in the direction of the arrow.

z Clean the discharge slot occasionally. z Remove any stuck on dust residues by squee-

zing the upper area of the valve.

Filter cartridge

z Open clamping bracket 1. z Remove filter hood 2 and pull out filter cartridge 3. z Clean filter cartridge, renew after a year at the

latest.

z Clean filter cartridge 3.

- Blast out from the inside out with dry compressed air (max. 5 bar), or

- beat out (only in extreme cases). Do not damage the cartridge, or

- wash according to manufacturer’s specifications.

z Check filter cartridge for damage to the filter

paper (shine light through) and damage to the seal. Exchange if necessary.

z Renew the safety cartridge 4 after 5 filter

maintenances, after 2 years at the latest (never clean!). To d o thi s:

- Loosen the hexagonal nut 5 and pull out the cartridge 4.

- Insert new cartridge, re-mount hexagonal nut and tighten.

z Insert filter cartridge 3, close hood 2 and

secure clamping bracket 1.

Never clean filter cartridge with petrol or hot liquids!

Care and maintenance work 6.5 Belt drive

6.5.1 Checking V-belt 2013 example

z Visual inspection of entire length of V-belt for

damages.

z Renew damaged V-belts. z Check the belt tension of new V-belts after 15

minutes running time.

z To check the V-belt tension

- Use a tension measuring device (see 9.3).

- Lower indicator arm 1 into the measuring device.

- Lay the guide 3 between two belt pulleys on the V-belt 2. The stop should lie sideways.

- Press the button 4 at right angles to the V-belt 2 steadily, until the spring is heard or felt to unlock.

- Carefully lift the measuring device, without altering the position of the indicator arm 1.

- Read off the measured values on the in tersection (arrow), scale 5 and the indicator arm 1. For setting values see 9.1.

- If necessary, re-tighten and repeat measurement.

Only test / tighten / change V-belts when the engine is not running. If necessary, re-mount V-rib belt guard.

6.5 Belt drive Care and maintenance work

6.5.2 Changing V-rib belt

z Push tension roller 1 with ratchet 3 in direction

of arrow until locking pin 4 can be fixed in the mounting hole. V-rib belt 2 is now tension-free.

z First pull the V-rib belt 2 from the smallest roller or

from the tension roller.

z Fit new V-rib belt 2. z Hold ratchet 3 in the opposite direction to the

arrow and remove pin 4.

z Loosen the tension pulley in the opposite

direction to the arrow until the V-rib belt is tight, at the same time checking that the V-rib belt is positioned correctly in its guides.

6.5.3 Checking wear limit

of V-rib belt

z The wear limit of the V-rib belt is checked as

follows:

z Check the distance between the projection

of the moving tension arm and the contact with the fixed tensioner housing.

z If the distance "a" is less than 3 mm, the V-rib belt

should be changed.

Only test / tighten / change when the engine is not running.If neces-

sary, re-mount V-belt guard.

Care and maintenance work 6.6 Setting work

6.6.1 Checking valve clearance, setting if necessary

z Before setting the valve clearance allow the

engine to cool down for at least 30 minutes: Oil temperature below 80 °C.

z Place the turning gear (see chap. 9.3) over the

fastening screws of the belt pulleys.

z Turn over engine until the valve overlap is

achieved, cylinder no. 1. The cylinders to be set are specified in the setting schematic, see chap. 6.6.3.

Special tools for valve setting see chap. 9.3

z Loosen lock nut 1 z Place rotation angle disc and socket wrench

insert 4 on the valve clearance setting screw 2.

z Fix magnet 5 to the rotation angle disc 3. z Turn the rotation angle disc 3 clockwise to the

stop (rocker arm without clearance) and set scale to zero.

z Turn the rotation angle disc anti-clockwise until

you reach the specified rotation angle size:

Engine 2012

IN = inlet valve 75° EX = outlet valve 120°

Engine 2013

IN = inlet valve 90° EX = outlet valve 150°

z Hold rotation angle disc 3 tight against

twisting.

z Tighten the lock nut 1. z Perform the setting on every cylinder (see

chap. 6.6.3).

6.6 Setting work Care and maintenance work

Valve clearance setting inlet valve in exhaust gas return line (EGR):

z Loosen lock nut 6. z Place rotation angle disc 3 with crow's foot

wrench 8 on valve clearance setting screw 7 on the inlet valve.

z Fix magnet 5 to the rotation angle disc 3. z Turn the rotation angle disc 3 clockwise to the

stop (rocker arm without clearance) and set scale to zero.

z Turn the rotation angle disc anti-clockwise until

you reach the specified rotation angle size.

Engine 2012

IN = inlet valve 75°

Engine 2013

IN = inlet valve 90°

z Hold rotation angle disc 3 tight against twisting. z Tighten the lock nut 6. z Perform the setting on every inlet valve (see

chap. 6.6.3)

Care and maintenance work 6.6 Setting work

6.6.2 Setting control piston clearance in exhaust gas recirculation (EGR)

z After setting the valve clearance, the control

piston clearance should be set as follows:

z Place the turning device over the fastening

screws of the belt pulley.

z Turn engine until reaching the valve overlap,

cylinder no. 1 The cylinders to be set are specified in the setting diagram, see chap.

6.6.3

z Loosen lock nut 1. z Place the rotation angle disc and socket wrench

insert on the setting screw 2

z Fix the magnet of the rotation angle disc. z Turn the rotation angle disc clockwise to the

stop (control piston without clearance) and set scale to zero.

z Turn the rotation angle disc counter-clockwise

until you reach the specified rotation angle. Control piston x : 144°

z Tighten the lock nut 1. z Perform the setting on every control piston

(see chap. 6.6.3)

Special tools for valve setting see chap. 9.3

6.6 Setting work Care and maintenance work

6.6.3 Diagram for setting valve / control piston clearance

Engine TCD 2012/2013 L04 2V

Ignition sequence: 1–3–4–2

Valves Cylinder overlap 1 3 4 2

set to 4 2 1 3

Valve operlap: Outlet valve not yet closed, inlet valve starts opening.

At fully open outlet valve, the inlet valve opens briefly by about 2 mm. This is not the valve overlap.

Engine TCD 2012/2013 L06 2V

Ignition sequence: 1–5–3–6–2–4

Valves Cylinder overlap 1 5 3 6 2 4

set to 6 2 4 1 5 3

Valve operlap: Outlet valve not yet closed, inlet valve starts opening.

At fully open outlet valve, the inlet valve opens briefly by about 2 mm. This is not the valve overlap.

Care and maintenance work 6.7 Add-on parts

6.7.1 Battery

6.7.1.1 Checking battery and cable connections

z Keep the battery clean and dry.

z Loosen soiled connection terminals.

z Clean the battery poles (+ and -) and terminals,

and grease with an acid-free and acid-resistant grease.

z Ensure that the terminal connections contact

well when assembling. Tighten the clamping screws by hand.

6.7.1.2 Checking the acid level

z Remove sealing caps 1.

z If checking inserts 2 are available:

The liquid level should reach to their bottom.

z Without checking inserts:

The liquid level should reach 10-15 mm above the upper edge of the plate.

z If necessary, re-fill with distilled water.

z Screw sealing caps back on.

6.7.1.3 Checking acid density

z Measure the acid density of individual cells

with a standard acid testing device.

The measured values (see table overleaf) indicate the charge status of the battery. The acid temperature when measuring should be 20 °C if possible.

6.7 Add-on parts Care and maintenance work

Acid density

in [kg/ l]

Charge level

Normal

1.28

1.20

1.12

Tropics

1.23

1.12

1.08

The gases released by the battery are explosive! Avoid sparks and open fire in the vicinity of the battery! Do not allow acid to get on skin or clothes! Wear protective glasses! Do not place any tools on the battery!

discharged, charge immediately

well charged

half charged, re-charge

Care and maintenance work 6.7 Add-on parts

6.7.2 Three-phase current generator

Notes on three-phase current system: z Do not interrupt the connections between the

battery, generator and governor when the engine is running.

z If, however, an engine must be started and

operated without battery, the connection governor / generator is to be separated before starting.

z Do not swap battery connections.

z Replace defective charging warning light im-

mediately.

z When cleaning engine: Do not spray water/

steam jet directly at generator! Warm up the engine so that the water residues evaporate.

z Under no circumstances may the voltage of a

three-phase current system be tested by tapping against the earth cable.

z When carrying out electrical welding work,

clamp the earth terminal of the welding device directly to the part to be clamped.

6.7.3 Transportation suspension

z Only use the correct suspension equipment

for engine transportation. Suspension equipment must be adjustable for the engine centre of gravity.

z Fastening devices cannot be fixed safely over

the centre of gravity.

z Fastening devices can slip, engine capsizes. z Short fastening devices cause bending mo-

ments in the suspension. This can damage the suspension.

z Disconnect battery and three-phase current

generator.

z Remove the control unit.

Only use correct suspension equipment!

Engine can fall. Danger to life!

Faults, causes and remedies

7.1 Fault table

7.2 Engine management

Faults, causes and remedies

z Faults are often caused by incorrect operation

or maintenance of the engine.

z For every fault, check whether or not all

operating and maintenance specifications have been observed.

z A corresponding fault table can be found

overleaf.

z If you cannot recognise the cause of a fault

or cannot remedy a fault yourself, please contact your DEUTZ Service.

Before starting make sure that there is nobody in the engine/ work machine danger area. For repairs: Caution: Separate battery connection!

7.1 Fault table

Faults Action

Faults, causes and remedies

Engine doesn't start up, or starts up with difficulty

Engine doesn't start up and diagnosis light is blinking Check C

Engines starts up, but runs irregularly or misfires Set S

Engine gets too hot. Temperature warning system is activated Change Ch

Engine lacks power

Engine lacks power and diagnosis light is lit up Clean Cl

Engine doesn't work on all cylinders Fill up F

Engine has no, or too little, oil pressure Lower L

Engine has too high oil consumption Engine electronics E*

Engine smoulders - blue * Identify fault by

- white monitoring the blink

- black code or fault memory

Cause

z zz zz

zz zz zz

zzz

zz z zz z zz z z

z zzz z

Not disconnected (if possible) Starting limit temperature not reached Engine shutdown lever is still in stop position (shutdown magnet defective) Oil level too low Oil level too high Engine is tilted too far Set throttle to halfway (only with mech. regulators) Air filter soiled / exhaust turbocharger defective Air filter maintenance switch / display defective Charge air line leaking Cool water pump defective (V-rib belt torn or loose) Charge air cooler soiled Coolant heat exchanger soiled V-belt/V-rib belt torn or loose (fuel pump in belt drive) Cool air heating / heat short circuit Battery defective or not charged

Section

Operation

Combustion air

Cooling system

Electrics

C C C

L C / S C / S

C / Ch

C C / Cl C / Cl C / W

Faults, causes and remedies

Faults Action

Engine doesn't start up, or starts up with difficulty Check C

Engine doesn't start up and diagnosis light is blinking Set S

Engines starts up, but runs irregularly or misfires Change Ch

Engine gets too hot. Temperature warning system is activated Clean Cl

Engine lacks power Fill up F

Engine lacks power and diagnosis light is lit up Lower L

Speed changes are possible + diagnostic light is lit up Engine electronics E*

Engine has no, or too little, oil pressure * Identify fault by monitoring the

Engine has too high oil consumption blink code or fault memory

Engine has too high oil consumption

Engine smoulders - blue

- white

- black

Cause Section

7.1 Fault table

z z zzz zz zzz z

z zz zzzz z zz zzz z zzz z

z zzz zzz z

Starter, circuit cable connections loose or oxidised Starter defective or pinion doesn't mesh Valve clearance incorrect Injection line leaking Ventilation line blocked (coolant heat exchanger) Heating plug defective Injector defective Air in fuel system Fuel filter / fuel pre-cleaner soiled Oil filter defective Incorrect SAE class or quality of engine lube oil Fuel quality does not comply with instruction manual Lack of cooling water Engine electronics prevent start Engine electronics reduce power Engine electronics has detected a system error and activates an equivalent speed

Electrics

Engine

Operating

substance

Electronics

C C

C / Cl

C C / Ch C / Ch

C/ Cl/

Ch Ch

C / Ch

C / Cl

C / E C / E

7.2 Engine management

Faults, causes and remedies

7.2.1 Engine protection function of the electronic engine controller EMR3

Depending on the design of the monitoring functions, the EMR3 can protect the engine against damage in certain fault situations by monitoring compliance with the important limit values during operation and checking the correct functioning of the system components. Depending on the severity of a detected fault, the engine may continue running with restrictions, whereby the fault lamp lights steadily or the fault lamp indicates a serious system fault by flashing. In this case,

the engine must be switched off as soon as it is safe to do so.

Depending on the engine configuration, the flashing fault lamp can have the following meaning:

z Request to the operator to shut down

Caution: Failure to heed this will lead to

loss of warranty!

z Autom. shutdown of the engine after a brief

warning time, poss. connected with a start prevention.

z To cool the engine, forced operation at low

idling speed, poss. with automatic shutdown.

z Start prevention. (see also chap. 3.3)

When the fault is corrected the light goes out. For some faults it is necessary to switch off the ignition, wait for 30 s and then switch the ignition back on.

7.2.2 Using the diagnosis button

With the diagnosis button (1) the fault at hand can be read out as a blink code. The diagnosis button (1) and the fault light (2) can be found on the vehicle driving stand. Faults are indicated by a blinking or continuous illumination of the fault light (2). More precise information regarding all existing faults can be read out in the form of a blink code, only when the engine is not running, in the following manner: After actuating the diagnosis button (1) for at least one second, the fault light (2) goes out and the first fault is, after releasing the key displayed as a blink code. Analyse the blink code as per the table on the following page. After the fault blink code has been displayed the fault light (2) goes out for five seconds. Then the next existing fault (i.e. the following one in the fault memory) can be shown by actuating the diagnosis button (1) again. If the last existing fault has been shown, by actuating the diagnosis button (1) once more the first fault will be shown again.

7.2.3 Table of fault blink codes

The possible blink codes, their meaning and measures for correcting faults can be found in the table on the following page. The blink code values in the first column indicate the number of preliminary short blink signals (illuminated duration approx. 0.4 s), the number of subsequent long blink signals (illuminated duration approx. 0.8 s) as well as the number of concluding short blink signals. The code 2-1-4 for the fault "overspeed" is made up of two short, one long and four short blink signals, for example. If a fault cannot be corrected by the measures given in the table please contact your service representative responsible.

Faults, causes and remedies

7.2 Engine management

Blinkcode Function / Component Error

Short Long Short

0.4s 0.8s 0.4s

1 2 3 Output to coolant temperature light Signal faulty, Overtemperature control unit 1 2 6 Hand accelerator Signal faulty / implausible 1 2 8 Suction air temperature sensor Signal faulty 1 3 3 Gear oil temperature sensor Signal faulty 1 3 4 Monitoring rail pressure Signal implausible, pressure / pressure deviation outside the permissible range 1 3 5 Output to oil pressure warning lamp Signal faulty, overtemperature control unit

Output to valve Signal faulty, overtemperature control unit

of the fuel measuring unit 1 3 6 Monitoring air filter Air pressure behind filter too low 1 3 7 Output to actuators Short circuit to battery 1 3 8 Output to actuators Short circuit to ground 1 4 2 Output to engine operating lamp Signal faulty, overtemperature control unit 1 4 3 Multi-step switch 1 / 2 / 3 Signal faulty / implausible 1 4 4 Oil temperature sensor Signal faulty / implausible

Monitoring the oil temperature Temperature outside the nominal range 1 4 5 Monitoring override switch Signal implausible 1 4 6 Rail pressure limiting valve Valve open / pressure surge necessary / do not open after pressure surge 1 4 7 Rail pressure sensor Signal faulty, pressure deviation outside the permissible range

7.2 Engine management

Faults, causes and remedies

Blinkcode Function / Component Error

Short Long Short

0.4s 0.8s 0.4s

2 1 2 Monitoring camshaft/crankshaft No camshaft signal, no crankshaft signal 2 1 3 Monitoring camshaft/crankshaft Deviation between the camshaft and crankshaft signal 2 1 4 Engine protection: Overspeed/override status implausible 2 1 6 Fuel low pressure sensor Signal faulty

Monitoring fuel low pressure Fuel low pressure outside the nominal range 2 1 9 Output to adjuster exhaust valve engine brake Signal faulty, overtemperature control unit 2 2 2 Input accelerator 1 (PWM) PWM signal faulty 2 2 3 Charge air pressure sensor Signal faulty

Monitoring charge air pressure Charge air pressure outside the nominal range 2 2 4 Oil pressure sensor Signal faulty / implausible 2 2 5 Coolant temperature sensor Signal faulty / implausible in comparison with the oil temperature, CAN signal invalid 2 2 6 Input accelerator 1 (analog) Signal faulty / implausible 2 2 7 Fuel temperature sensor Signal faulty

2 2 8 Water level sensor in the fuel filter Signal faulty

Monitoring fuel filter water level Max. water level exceeded

Faults, causes and remedies

7.2 Engine management

Blinkcode Function / Component Error

Short Long Short

0.4s 0.8s 0.4s

2 3 1 Monitoring oil pressure Pressure outside the nominal range 2 3 2 Monitoring coolant temperature Temperature above the nominal range 2 3 3 Monitoring suction intake air temperature Temperature above the nominal range 2 3 5 Monitoring coolant state Level below the nominal range 2 3 7 Monitoring fuel temperature Temperature outside the nominal range 2 3 8 Output to the fan adjuster 1 / 2 Signal faulty, overtemperature control unit

Monitoring fan speed Speed outside the nominal range 2 4 1 Monitoring combustion Misfiring detected in one or more cylinders 2 6 1 Monitoring output to actuators Relay does not open or opens too late, short-circuit to ground 2 6 3 Output to cold start aid Signal faulty, relay defective, jammed or connected incorrectly, short-circuit 2 7 1 CAN-Bus Timeout of one or more send messages, bus inactive 2 8 2 Sensor supply voltage 1 / 2 / 3 Voltage outside the nominal range 2 9 2 Atmospheric pressure sensor Signal faulty / implausible

7.2 Engine management

Faults, causes and remedies

Blinkcode Function / Component Error

Short Long Short

0.4s 0.8s 0.4s

3 1 4 Hydraulic oil temperature sensor Signal faulty

Monitoring hydraulic oil temperature Temperature outside the nominal range 3 1 8 Monitoring battery Voltage outside the nominal range 3 2 8 Output to cold start aid indicator lamp Signal faulty, overtemperature control unit 4 1 4 Output to external EGR actuator Signal faulty 4 1 5 Output to external EGR actuator Signal faulty, overtemperature control unit 4 1 6 Output to external EGR actuator Signal faulty 4 1 7 Oil wear meter Critical time reached

Faults, causes and remedies

Blink code Function / Component Error

Short Long Short

0,4s 0,8s 0,4s

5 1 2 Output to start relay Signal faulty, overtemperature control unit 5 1 3 Output to error lamp Signal faulty, overtemperature control unit 5 1 4 Monitoring terminal 15 No signal detected 5 1 5 Monitoring terminal 50 Permanent signal detected 5 2 1 Speed measurement Implausible drive speed 5 2 8 Output to internal engine brake Signal faulty

All other blink codes: Please contact your service partner Behavior in case of error signal faulty / implausible: Perform function test on the parts concerned; check wiring and plugs for short-circuits, breaks, corrosion.

7.2 Engine management

Engine corrosion protection

8.1 Corrosion protection

Engine corrosion protection 8.1Corrosion protection

8.1 Corrosion protection

If the engine should be shut down for a long period of time, corrosion protection will be necessary in order to prevent rust formation. The measures described here apply for a shutdown period of up to approx. 6 months. Before the engine is commissioned again the corrosion protection should be removed.

z Corrosion protection oils according to

specification:

- MIL-L 21260B

- TL 9150-037/2

- Nato Code C 640 / 642

z Recommended cleaning agent for removal of

corrosion protection:

- Petroleum benzine (hazard class A3)

Protecting engine from corrosion:

z Clean engine (possibly with cold cleaner). z Warm up the engine and switch off. z Drain off engine oil, see chapter 6.1.2 and pour

in corrosion protection oil.

z Drain off coolant, see 6.3.3. z Pour in corrosion protection agent, see above. z Drain fuel from container (tank). z Make fuel mixture from 90 % diesel fuel and 10 %

corrosion protection oil and fill up tank.

z Leave the engine running for approx. 10

minutes.

z Switch off engine z Turn over the engine manually several times.

When turning over with a starter position the shutdown lever in the Stop position.

z Remove V-belt 4, pack up and store.

z Spray the V-belt pulley 5 with corrosion

protection agent.

z Seal intake openings 1 and exhaust openings 3. z Lightly apply corrosion protection agent to the

coolant nozzle 2 and seal.

z Drain off corrosion protection agent.

Note: Fuel tank/supply line to the engine

should also be sealed, so that the sensitive rail system is protected against dirt and dust. Protect the electronics from moisture/ corrosion.

Removing engine corrosion protection:

z Remove corrosion protection agent from

grooves of V-belt pulley 5.

z Assemble V-rib belt 4 or V-belt, see 6.5.2. z Remove plugs from intake opening 1, exhaust

opening 3 and coolant inlet/outlet 2.

z Pour in coolant see 6.3.3 z Connect fuel tank / supply line to the engine. Pay

attention to cleanliness here.

z Start up the engine.

9.1 Engine and setting data

9.2 Screw tightening torques

9.3 Tools

Technical data

Technical data 9.1 Engine and setting data

Engine type ----------------------------- TDC 2012 L04 2V ----------------- TDC 2012 L06 2V ---------------------------

Number of cylinders ---------------------------------------- 4 --------------------------------------- 6--------------------------------------Cyl. arrangement ----------------------------------------------------------- In-line --------------------------------------------------------Bore [mm] ------------------------------------------------------------ 101 ---------------------------------------------------------Stroke [mm] ------------------------------------------------------------ 126 ---------------------------------------------------------Total displacement [cm Compression ratio [ε] ------------------------------------------------------------- 18 ----------------------------------------------------------- Working principle / combustion procedure -------------------- Four stroke diesel with charging and direct injection ---------------------------------Charge air cooler --------------------------------- without/with ------------------------------ with -----------------------------------Charge air cooler temperature outlet at rated power [°C] ------------------------------------------------------------- 50 -----------------------------------------------------------

Direction of rotation ----------------------------------------------------- rotation to left ---------------------------------------------------Injection system

Deutz Common Rail (DCR) --------------------------------- DCR + PLD ------------------------------ DCR -----------------------------------Pump Line Nozzle (PLD)

Weight TDC 2012 without cooling system according to DIN 70020-A [approx.kg] --------------------------------------- 410 ------------------------------------ 530 ------------------------------------Engine performance according to ISO 3046 [kW] -------------------------------------------------------------

Max. nominal speed [1/min] ----------------------------------------------------------- 2400 --------------------------------------------------------Valve clearance inlet/ exhaust, see 6.6.1 [mm] ----------------------------------------- 0.3/0.5 Setting with special tool Ignition pressure [bar] ------------------------------------------------------------ 160 ---------------------------------------------------------Start of pumping [°KW before TDC] ------------------------------------------------------------Engine ignition sequence ------------------------------------ 1-3-4-2 ---------------------------- 1-5-3-6-2-4 ------------------------------V-belt tension ------------------------------------------------ pre-tighten/re-tighten ----------------------------------------------Generator [N] ----------------------------------------------------- 650 / 400 Fuel pump - coolant pump [N] ------------------------------------------------------ 650 / 400 V-rib belt tension: ------------------------------------------- Spring-loaded tension pulley ------------------------------------------

] -------------------------------------- 4038 ---------------------------------- 6067 ------------------------------------

). -----------------------------------------------------------

+0.1/

angle degree 75/120 ----------------------------------------

). -----------------------------------------------------------

± 50

. ----------------------------------------------------

± 50

. ----------------------------------------------------

Engine power, speed and start of pumping, among other things, are stamped on the engine company plate, see also 2.1.

The V-rib belt has a spring-loaded tension pulley which tightens automatically and is not re-tightened: see ch. 6.5.2

9.1 Engine and setting data Technical data

Engine type ----------------------------- TDC 2012 L04 2V -----------------TDC 2012 L06 2V ---------------------------

Cooling ----------------------------------------- Liquid-cooled / cooling system protection --------------------------Coolant quantity (only engine content without cooler)[approx.ltr.] --------------------------------------- 5.6 ------------------------------------- 7.3 -------------------------------------

Permissible continuous coolant temperature engine outlet [°C ] --------------------------------------------------------------

max.110 ------------------------------------------------------Temperature difference between Coolant inlet/outlet [°C] ----------------------------------------------------------- 4 to 8 --------------------------------------------------------Start of thermostat opening at [°C] ------------------------------------------------------------- 86 ----------------------------------------------------------Thermostat fully open at [°C] ------------------------------------------------------------ 102 ---------------------------------------------------------Coolant pre-heating -------------------------------------------------------------(4. ------------------------------------------------------------

Lubrication ----------------------------------------------- Forced feed lubrication --------------------------------------------Oil SAE ------------------------------------------------------ see chap. 4 ---------------------------------------------------Maximum oil temperature in oil tray [°C] ------------------------------------------------------------ 125 ---------------------------------------------------------Minimum oil pressure in warm state (114 °C) and low idling [bar] ------------------------------------------------------------ 0,8 ----------------------------------------------------------Initial oil filling quantity without filter max. [approx.ltr.] -------------------------------------- 15 min. [approx.ltr.] -------------------------------------12.5 Initial oil filling quantity with filter max. [approx.ltr.] ------------------------------------- 15.5 min. [approx.ltr.] -------------------------------------- 13

. ---------------------------------- 26 3). ------------------------------------

. -------------------------------- 23.53). -----------------------------------

. -------------------------------- 26.53). -----------------------------------

. ----------------------------------- 24 3). ------------------------------------

Approximate values can vary depending on version. The upper oil measurement marking is always decisive.

Only necessary for winter operation, see 3.5.1.

--------------------

Technical data 9.1 Engine and setting data

Engine type ----------------------------- TDC 2013 L04 2V ----------------- TDC 2013 L06 2V ---------------------------

Number of cylinders ---------------------------------------- 4 --------------------------------------- 6--------------------------------------Cyl. arrangement ----------------------------------------------------------- In-line --------------------------------------------------------Bore [mm] ------------------------------------------------------------ 108 ---------------------------------------------------------Stroke [mm] ------------------------------------------------------------ 130 ---------------------------------------------------------Total displacement [cm Compression ratio [ε] ------------------------------------------------------------- 18 ----------------------------------------------------------- Working principle / combustion procedure -------------------- Four stroke diesel with charging and direct injection ---------------------------------Charge air cooler ----------- without/with ------------------------------------------------------------------- without/with --------Charge air cooler temperature outlet at rated power [°C] ------------------------------------------------------------- 50 -----------------------------------------------------------

Direction of rotation ----------------------------------------------------- rotation to left ---------------------------------------------------Injection system

Deutz Common Rail (DCR) [bar] ---------------------------------- DCR+PLD ------------------------------- DCR ------------------------------------ Pump Line Nozzle (PLD)

Weight TDC 2013 without cooling system according to DIN 70020-A [approx.kg] --------------------------------------- 450 ------------------------------------ 590 ------------------------------------Engine performance according to ISO 3046 [kW] ------------------------------------------------------------Max. nominal speed [1/min] ----------------------------------------------------------- 2300 --------------------------------------------------------Valve clearance inlet / exhaust, see 6.6.1 [mm] ----------------------------------------- 0.4/0.6 Setting with special tool Ignition pressure [bar] ------------------------------------------------------------ 160 ---------------------------------------------------------Start of pumping [°KW before TDC] ------------------------------------------------------------Engine ignition sequence ------------------------------------ 1-3-4-2 ---------------------------- 1-5-3-6-2-4 ------------------------------V-belt tension: Generator [N] ----------------------------------------------------- 550 / 300 Fuel pump - coolant pump [N] ------------------------------------------------------ 550 / 300 Compressor [N] ------------------------------------------------------ 650 / 400 V-rib belt tension: ------------------------------------------- Spring-loaded tension pulley ------------------------------------------

] -------------------------------------- 4761 ---------------------------------- 7142 ------------------------------------

). -----------------------------------------------------------

+0.1/

/ angle degree 90/150 ---------------------------------------

). -----------------------------------------------------------

± 50

. ----------------------------------------------------

± 50

. ----------------------------------------------------

± 50

. ----------------------------------------------------

Engine power, speed and start of pumping, among other things, are stamped on the engine company plate, see also 2.1.

The V-rib belt has a spring-loaded tension pulley which tightens automatically and is not re-tightened: see ch. 6.5.2

9.1 Engine and setting data Technical data

Engine type ----------------------------- TDC 2013 L04 2V ----------------- TDC 2013 L06 2V ---------------------------

Cooling ----------------------------------------- Liquid-cooled / cooling system protection --------------------------Coolant quantity (only engine content without cooler)[approx.ltr.] --------------------------------------- 7.2 ------------------------------------- 9.8 -------------------------------------

Permissible continuous coolant temperature engine outlet [°C] --------------------------------------------------------------

max.105 ------------------------------------------------------Temperature difference between Coolant inlet/outlet [°C] ----------------------------------------------------------- 4 to 8 --------------------------------------------------------Start of thermostat opening at [°C] ------------------------------------------------------------- 86 ----------------------------------------------------------Thermostat fully open at [°C] ------------------------------------------------------------ 102 ---------------------------------------------------------Coolant pre-heating -------------------------------------------------------------

. ------------------------------------------------------------

Initial oil filling quantity without filter max. [approx.ltr.] -------------------------------------- 15 min. [approx.ltr.] -------------------------------------12.5 Initial oil filling quantity with filter max. [approx.ltr.] ------------------------------------- 15.5 min. [approx.ltr.] -------------------------------------- 13

. ---------------------------------- 26 3). ------------------------------------

. -------------------------------- 23.53). -----------------------------------

. -------------------------------- 26.53). -----------------------------------

. ----------------------------------- 24 3). ------------------------------------

Approximate values can vary depending on version. The upper oil measurement marking is always decisive.

Only necessary for winter operation, see 3.5.1.

Technical data 9.2 Screw tightening torques

Installation Pre-tightening Re-tightening Total Comments

[Nm] 1st step 2nd step 3rd step 4th step

Cylinder head cover – – – – – 9 ± 1 Nm M6 Lock nut Valves – – – – – 20 ± 2 Nm Nut with inner square Front face mounting foot – – – – – 280 Nm M16 x 85 –10.9

– – – – – 280 Nm M16 x 40 –10.9 Oil drain screw aluminium tray – – – – – 55 Nm M 18x 1.5 with Cu ring Oil drain screw sheet metal oil tray

– – – – – 55 Nm M 18x 1.5 with Cu ring

9.3 Tools Technical data

Ordering tools

The special tools listed in this chapter must be ordered from:

FA.WILBÄR Postfach 14 05 80 D-42826 Remscheid http://www.deutz-tools.com

TORX V-belt tension measuring

device

25899 0

Order No. 8189

For engines of series 2012/2013, the TORX screw system BN. 8189, amongst others, is used. This system was introduced due to its many advantages:

Order No. 8115

Measuring device for checking the prescribed V-belt tensions

z Excellent screw accessibility. z High transfer of force when loosening and

tightening.

z Slipping or broken wrenches and the risk

of injury associated with this is practically impossible.

Technical data 9.3 Tools

Rotation angle disc

Order No. 8190

Rotation angle disc for setting the valve/ control piston clearance.

Socket wrench insert

Order No. 8193 (5 mm) valve clearance Order No. 8194 (4 mm) control piston

clearance. Wrench inserts for rotation angle disc.

Crow's foot wrench

Order No. 8199

Crow's foot wrench for rotation angle disc 8190 in connection with commercially available square bar extension.

9.3 Tools Technical data

Turning gear

Order No. 100 330

For turning over the engine (as add-on on the torsional vibration damper).

Deutz TCD 2012-2013 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operation Manual

Foreword

Contents

General

Engine description

Operation

Operating substances

Maintenance

Care and maintenance work

Faults, causes and remedies

Engine corrosion protection

Technical data