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).

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