Deutz TCD 2012 L04/06 4V, TCD 2013 L04/06 4V Instruction Manual

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Page 1

Instruction Manual

TCD 2012 L04/06 4V

TCD 2013 L04/06 4V

Page 2

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 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.

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!

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Instruction Manual

TCD 2012 L04/06 4V

TCD 2013 L04/06 4V

0312 2443 en

Engine number:

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.

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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

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Contents

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

2.2.1 Operation side TDC 2012 L04 4V

2.2 Engine diagrams

2.2.2 Starter side TDC 2012 L04 4V

2.2.3 Operation side TDC 2012 L06 4V

2.2.4 Starter side TDC 2012 L06 4V

2.2.5 Operation side TDC 2013 L06 4V

2.2.6 Starter side TDC 2013 L06 4V

2.2.7 Operation side Agri Power

2.2.8 Starter side Agri Power

2.2 Engine diagrams

2.3.1 Lube oil diagram TCD 2013 L06 4V (example)

2.4 Fuel circuit

2.4.1 Fuel diagram

2.5 Coolant circuit

2.5.1 Coolant diagram

2.5.2 Exhaust gas recirculation diagram

2.6 Electrics

2.6.1 Electrical cable connections for monitoring

3. Operation

3.1 Initial commisioning

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

3.3.4 Lube oil 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 Water quality for coolant

4.3.2 Coolant preparation

4.3.3 Cooling system preservative

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 insert

6.1.4 Cleaning / changing oil filter (cup) fehlt

6.2 Fuel system

6.2.1 Changing fuel filter

6.2.2 Cleaning / changing fuel filter (cup)

6.2.3 Changing / bleeding fuel pre-filter, filter

insert

6.3 Cooling system

6.3.1 Cleaning intervals

6.3.2 Cleaning cooling system

6.3.3

Emptying / filling / bleeding cooling isystem

6.4 Combustion air filter

6.4.1 Cleaning intervals

6.4.2 Emptying cyclone pre-separator

6.4.3 Dry air filter

6.5 Belt drive

6.5.1 Checking V-rib belt

6.5.2 Changing V-rib belt

6.5.3 Checking wear limit of v-rib belt fehlt

6.6 Setting work

6.6.1 Checking valve clearance, setting if

necessary

6.6.2 Checking control piston clearance at

engine brake, setting if necessary

6.7 Add-on parts

6.7.1 Battery

6.7.2 Three-phase current generator

6.7.3 Transportation suspension

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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

Contents

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Page 8

General

DEUTZ engines Maintenance and care

This symbol is used for all safety instructions which, if not observed, present a direct danger to life and limb for the person involved. Observe these

carefully. Also pass on the safety instructions to your operating personnel. Furthermore, the legislation for „general regulations for safety and the prevention of accidents“ must be observed.

Service

Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast, professional repairs using original parts in the event of damage. The Technical Circulars listed in this operating manual are obtainable from your DEUTZ partner. Please turn to the end of this manual for further service information.

Take care when the engine is running

Only carry out maintenance work or repairs with the engine switched off. Ensure that the engine cannot be started unintentionally danger of accidents! Re-install any removed protective equipment upon completion of the work. Observe industrial safety regulations when operating the engine in enclosed spaces or underground. When working on the running engine, work clothing must be close fitting. Only re-fuel with the engine switched off.

are decisive for whether the engine satisfactorily meets the demands put on it. Compliance with the prescribed maintenance times and the careful execution of maintenance and care work are therefore essential. Difficult operating conditions deviating from normal operation must be observed especially.

Warning

Danger for component/engine. Failure to comply can lead to destruction of the component/ engine. Must be observed.

Danger

are the product of years of research and development. The profound know-how gained in connection with high quality requirements is the guarantee for manufacturing of engines with a long life, high reliability and low fuel consumption. Naturally the high requirements for protection of the environment are also met.

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Engine description

2.1 Engine type

2.2 Engine diagrams

2.3 Lube oil circuit

2.4 Fuel circuit

2.5 Coolant circuit

2.6 Electrics

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Engine description

2.1 Engine type

2.1.1 Company plate

The engine type A, engine numberB 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 on the crankcase.

Or company plate C is fixed on the cylinder head cover. Or both plates are attached.

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Engine description

2.1 Engine type

2.1.4 Cylinder numbering

The cylinders are counted consecutively, starting from the flywheel.

2.1.3 Engine number

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

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Engine description

2.2 Engine diagrams

2.2.1 Operation side TCD 2013 L04 4V

1 Cylinder head cover 2 Transportation eyelets 3 Heating flange 4 Cabin heater connection 5 Intake elbow to charge air cooler 6 Connection to air filter 7 Coolant outlet adapter 8 Deflection pulley 9 Belt pulley on crankshaft

10 Tension pulley

11 Oil tray 12 Oil drain screw 13 Coolant inlet adapter 14 Generator 15 Oil cooler 16 Exchangeable lube oil filter 17 Engine control unit 18 Exchangeable fuel filter

19 Rail with pressure reducing valve and pressure

sensor 20 Crankcase ventilation (open system) 21 Oil filler neck

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Engine description

2.2 Engine diagrams

2.2.6 Starter side TCD 2013 L04 4V

22 Charge air temperature line to transmitter 23 Exhaust manifold 24 Compressor (optional) 25 SAE housing 26 Starter cover 27 Oil return line from turbocharger 28 Inlet combustion air turbocharger 29 Turbocharger exhaust gas outlet 30 Screening plate (thermal protection)

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Engine description

2.2 Engine diagrams

1 Cylinder head cover 2 Transportation eyelets 3 Heating flange 4 Cabin heater connection 5 Intake elbow from charge air cooler 6 Thermostat housing (coolant outlet) 7 Spring-loaded tension pulley 8 Compressor (optional) 9 Belt pulley for fan attachment

10 Tension pulley (s)

11 Deflection pulley 12 Oil tray 13 Belt pulley coolant pump 14 Oil drain screw 15 Coolant inlet adapter 16 Generator 17 Oil cooler 18 Hydraulic pump or compressor installation

(optional) 19 Exchangeable lube oil filter 20 Engine control unit with fuel cooling 21 Exchangeable fuel filter

22 Rail with pressure reducing valve and pressure

sensor 23 Crankcase ventilation (open system)

2.2.3 Operation side TCD 2013 L06 4V

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Engine description

2.2 Engine diagrams

2.2.4 Starter side TDC 2013 L06 4V

2 4 P r e s s u r e a n d t e m p e r a t u r e t r a n s m i t t e r, c h a r g e a i r

25 Oil filler neck 26 Exhaust manifold 27 Compressor (optional) 28 SAE housing 29 Starter cover 30 Oil return line from turbocharger 31 Exhaust turbocharger 32 Screening plate (thermal protection).

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Engine description

2.2 Engine diagrams

2.2.5 Operation side Agri Power TCD 2012 L04 4V

1 Exhaust turbocharger 2 EGR exhaust gas recirculation 3 Intake elbow from charge air cooler 4 Coolant return from cooler 5 Coolant pump 6 Fuel supply pump 7 Spring-loaded tension pulley 8 V-rib belt 9 Belt pulley for drive

10 Coolant inlet adapter from cooler

11 Mounting foot (engine suspension) 12 Oil tray 13 Oil drain screw 14 Fuel filter 15 Lube oil filter 16 Fuel connection from tank 17 Lube oil cooler 18 Fuel pre-filter 19 Generator 20 Central connector 21 ECU ElectronicControl Unit 22 High-pressure pump 23 Crankcase ventilation 24 Rail with pressure reducing valve 25 Charge air sensor 26 Cylinder head cover

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Engine description

2.2 Engine diagrams

27 EGR exhaustgasRecirculation

Throttle lever for exhaustgasrecirculation 28 Transportation eyelets 29 SAE housing 30 Starter with cover 31 Lube oil filler neck 32 Lube oil return from turbocharger 33 Oil pressure pipe to turbocharger 34 Exhaust manifold 35 Cooling line to exhaust gas recirculation

system 36 Exhaust manifold

2.2.6 Operation side Agri Power TCD 2012 L04 4V

Page 18

Engine description

2.2 Engine diagrams

2.2.7 Operation side TCD 2013 L06 4V Agri Power

1 Exhaust turbocharger 2 Coolant return from heater 3 Coolant outlet to cooler 4 Intake elbow from charge air cooler 5 Generator 6 Coolant pump 7 Spring-loaded tension pulley 8 Deflection pulley 9 Front power takeoff

10 Oil tray

11 Coolant inlet adapter from cooler 12 Lube oil filter 13 Fuel filter 14 Compressor (optional) 15 SAE housing 16 Lube oil cooler 17 Crankcase ventilation socket 18 Coolant outlet adapter to heater 19 Engine suspension 20 Cylinder head cover

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Engine description

2.2 Engine diagrams

21 EGR exhaustgasrecirculation system 22 Throttle lever for exhaustgasrecirculation 23 Cooling line to exhaust gas recirculation

system 24 Fuel inlet to engine 25 Fuel outlet to fuel container 26 Starter 27 Lube oil filler neck 28 Compressor 29 V-rib belt 30 Fan bearing /coolant pump 31 Thermostat housing coolant outlet

to cooler 32 Ventilation line to cooler 33 Charge air supply to charge air cooler 34 Coolant return from EGR

2.2.8 Starter side TCD 2013 L06 4V Agri Power

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Engine description

2.3 Lube oil circuit

2.3.1 Lube oil diagram TCD 2013 L06 4V (example)

1 Oil tray 2 Intake pipe 3 Lube oil pump

3.1 Safety valve

4 Lube oil cooler

4.1 Reverse lock valve

4.2 By-pass valve

4.3 By-pass valve

4.4 Control valve 5 Exchangeable lube oil filter 6 Main oil pipe

6a Engine brake lubrication

A Exhaustgasrecirculation (EGR) lubrication

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 Oil line to exhaust turbocharger 17 Exhaust turbocharger

18 Oil line to compressor or hydraulic pump 19 Compressor or hydraulic pump 20 Return line from compressor 21 Return line from cylinder head 22 Exhaust turbocharger return to crankcase

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Engine description

2.4 Fuel circuit

2.4.1 Fuel diagram

1 Fuel container 2 Line to fuel pump 3 Fuel pump 4 Line to fuel filter 5 Fuel cooling for engine control unit

(without cooler, upper right in diagram) 6 Fuel filter 7 Line to injection pumps 8 Fuel to control unit 9 Tappet rollers on camshaft

10 DCR Rail

11 Injection line to injection valve 12 Injectors 13 Fuel leak oil line 14 Return line to container

A Keep distance as large as possible

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Engine description

2.5 Coolant circuit

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Engine description

2.5 Coolant circuit

1 Coolant inlet to engine 2 Coolant pump 3 Thermostat housing 4 Lube oil cooler (plate cooling) 5 Cylinder head cooling and EGR cooling 6 Coolant supply to engine brake 7 Engine brake cooling 8 Return line to thermostat 9 Heat exchanger (customer)

10 Fan (customer)

11 Compensation tank (customer) 12 Heating connection 13 Compensation tank return line

to heater connection 14 Thermostat compensation tank return 15 Engine ventilation to compensation tank

16 Return line from engine heat exchanger

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Engine description

2.5 Coolant circuit

10 Fan (customer)

11 Compensation tank (customer) 12 Heating connection 13 Compensation tank return line

to heater connection 14 Thermostat compensation tank return 15 Engine ventilation to compensation tank

16 Return line from engine heat exchanger

2.6.1 Exhaust gas recirculation diagram

Page 25

Engine description

2.6 Electrics

2.6.1 Electrical cable connections for monitoring (example)

1 Fuel pressure

2 Shutdown magnet (solenoid valve) example

3 Charge air pressure/temperature sensor 4 Coolant temperature 5 Cold start aid 6 Rail pressure (fuel pressure)

8 Oil temperature transmitter engine pre-heating

heating 7 Oil pressure transmitter 9 Oil level transmitter

10 Oil pressure sensor 11 Injectors engine brake (optional) 1 2 E.M.S II 13 Pick-up on SAE housing 14 Speed sensor 15 Energy supply 16 Multifunction displays 17 Outputs (configurable) 18 Inputs (configurable)

(PWM/digital/analogue)

19 Accelerator pedal 20 Hand throttle (optional) 21 Switch functions 22 Key switch

Start/stop

23 Diagnosis button 24 Fault light with blink code 25 Diagnosis interface/

CAN-Bus

Page 26

Operation

3.1 Initial commissioning

3.2 Starting

3.3 Operation monitoring

3.4 Shutting down

3.5 Operating conditions

Page 27

Operation

3.1 Initial commissioning

3.1.3 Filling / bleeding cooling system

z Connect the coolant outlet 2 and coolant inlet

1 to the cooling system. Connect the lead line from the compensation tank to the water pump or to coolant inlet pipe 1.

z Connect vent lines from the engine and if

necessary 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 warm up until the

thermostat opens (line 2 heats up).

z Run engine run with open thermostat for

2 –3 minutes.

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

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

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.

Only re-fuel when the engine is not running!

Pay attention to cleanliness!

Do not spill any fuel!

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Operation

3.1 Initial commissioning

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.

- Re-tighten V-belts, see 6.5.

z Running-in

It is recommended to check the oil level twice a day during the running-in phase. After the running-in phase, checking once a day is sufficient.

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).

Page 29

Operation

3.2 Starting

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.

3.2.1 Electrical 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.

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.

- 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.

Start uninterruptedly for max. 20 s. If the engine does not start, repeat the start procedure after a 1 minute pause. If the engine has not started after two attempts, find the cause in the fault table (see 7.1).

Page 30

Operation

3.3 Operation monitoring

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.

Page 31

Operation

3.3 Operation monitoring

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 Needle of oil pressure measuring instrument

must show the minimum oil pressure (see 9.1).

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.

Page 32

Operation

3.4 Shutting down

min

3.3.3 Coolant level

z Light on coolant level display comes on (contact

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

z Function check of coolant level:

Key in step 1 or 2 (Float switch or level probe) Warning light comes on for approx. 2 seconds

- Coolant level OK: Light goes out

- Coolant level not OK: Light comes on again.

3.3.4 Lube oil level

z Light on lube oil level display comes on (contact

is via float switch / level proble if lube oil level is at minimum): Switch off the engine and determine the cause as per fault table (see 7.1).

z Function check of lube oil level :

Key in step 1 or 2 (Float switch or level probe) Warning light comes on for approx. 2 seconds

- Lube oil level OK : Light extinguished.

- Lube oil level not OK : Light comes on again.

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).

Page 33

Operation

3.5 Operating conditions

+–

3.4.1 Electrical shutdown

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.

Page 34

Operation

3.5 Operating conditions

z Cold start aids

- When there is a frost, start with heating flange if if necessary (see 3.2.1). The heating flange not only lowers the starting limit temperature, but also simplifies starting at temperatures which don’t 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 temperatureby 4-5 °C.

3.5.1 Winter 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 contamination, clean if necessary.

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

Page 35

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 1000 m altitude and a temperature of 30°C is permissible.

z In case of doubt regarding engine usage, 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.

Page 36

Operating substances

4.1 Lube oil

4.2 Fuel

4.3 Coolant

Page 37

only with engine pre-heating

30 298 1

Operating substances 4.1 Lube oil

4.1.1 Quality

Lube oils are classified by DEUTZ into quality classes according to their performance capability. Oils according to other comparable specifications can be used.

Permissible oils:

Deutz DQC I-02 DQC II-05 DQC III *+DQC IV

ACEA E2-96 E3-96/E5-02/ E4- 99/

E7-04 E6-04

API CF/CF-4 CH-4/CG-4 DHD - DHD-1 -

DQC III-05 * Annex 1 DQC IV-05

only fully synthetic

The exact assignment of permissible oil quality and oil change intervals to the engines is listed in chapter 6.1.1. In case of doubt, please ask your service representative.

*For oil change intervals see 6.1.1 For oil filling amounts see 9.1

4.1.2 Viscosity

Since lube oil changes its viscosity (viscidity) depending on temperature, the ambient temperature of the location of engine operation is decisive for the selection of viscosity class (SAE class). Refer to the oil viscosity diagram on the right to achieve optimal operating performance. Falling below the temperature limits occasionally can impair the cold start ability, but will not lead to engine damages. In order to minimise wear, the operating limits should not be exceeded over a long period of time. Oil changes determined by the time of year can be avoided by using multi-viscosity oils. Multi-viscosity oils, in particular smooth running oils, also have the effect of reducing fuel consumption.

Page 38

4.1 Lube oil Operating substances

DEUTZ lube oil quality level DQC III Annex 1

Manufacturer Lube oil type SAE class Availability

DEUTZ DEUTZ ÖlTLX-10W40 FE 10W-40 Europe

ADDINOL ADDINOL SuperTruck MD 1048 10W-40 Europe, Asia ADDINOL Ultra TruckMD 0538 5W-30 Europe, Asia AGIP Agip SigmaUltra TFE 10W-40 worldwide Autol Valve UltraFE 10W-40 Germany ARAL Aral MegaTurboral 10W-40 worldwide Aral SuperTurboral 5W-30 worldwide AVIA TURBOSYNTHHT-E 10W-40 Germany BAYWA BayWa SuperTruck 1040 MC 10W-40 Southern Germany BayW a Turbo4000 10W-40 Southern Germany BP OIL International BP Vanellus E7 Plus 10W-40 Europe BP Vanellus E7Supreme 5W-40 Europe Castrol CastrolSYNTRUCK 5W-40 Europe, North America, Brazil, Argentina, Australia, South Africa Castrol Castrol DYNAMAX 7.5W-40 Europe, North America, Brazil, Argentina, Australia, South Africa CEPSA EUROTRANSSHPD 10W-40 Spain, Portugal CHEVRON Chevron Delo400 Synthtic 5W-40 North America DEA DEA CronosSynth 5W-30 Germany, Europe DEA Cronos PremiumLD 10W-40 Germany, Europe DEA Cronos PremiumLD 10W-40 Europe ESSO EssolubeXTS 501 10W-40 Europe FUCHS EUROPE Fuchs Titan Cargo MC 10W-40 worldwide Fuchs Titan UnicPlus MC 10W-40 worldwide MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, Africa Mobil De lva c 15W-40 worldwide Mobil Delvac XHP Extra 10W-40 Europe, SE Asia Lube oil refinery Wintershall TFG 10W-40 Europe, Salzbergen Shell International ShellMyrina TX / 5W-30 Europe, code

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

Texaco Ursa Super TDX 10W-40 10W-40 Europe

Ursa Premium FE 5W-30 5W-30 Europe

TOTALFINA ELF TOTAL RUBIA TIR 8600 10W-40 worldwide

ELF PERFORMANCE 10W-40 worldwide EXPERTY MX 1010 ELF PERFORMANCE 10W-40 Germany, Benelux, EXPERTY MX 1012 Scandinavia, Austria FINA KAPPA FIRST 5W-30 Europe FINA KAPPA ULTRA 10W-40 Europe

This table will be extended if necessary.

Page 39

Operating substances 4.2 Fuel

4.2.1 Quality

Use standard diesel fuels with a sulphur content of less than 0.5 %. If the sulphur content is higher, the oil change intervals must be reduced (see

6.1.1).

The following fuel specifications are permitted:

z Diesel fuels

- DIN EN 590

z JIS K 2204 grade 1 and 2 *

z ASTM D 975-88; 1-D and 2-D *

* as long as the lubrication properties

correspond to diesel fuel EN 590 (positive

test results are necessary) (see TR 0199-99-3005) If other fuels are used which do not meet the requirements of the technical circular, the warranty will be voided. Technical circular is obtainable from the DEUTZ Service Organisation.

The certification measurements for the observance of legal emission limits are carried out with the test fuels defined by legislation. These correspond to the diesel fuels described in section 1 in accordance with EN 590 and ASTM D 975. Emission values cannot be guaranteed with the other fuels described in this circular.

4.2.2 Winter fuel

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.

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

Only carry out mixing in the tank! First pour in the necessary amount of paraffin, then the diesel fuel.

Diagram key:

I Summer diesel fuel

I I Winter diesel fuel

A Outside temperature

B Paraffin mixing proportion

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

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

Page 40

4.3 Coolant Operating substances

Contact your local waterworks for information regarding the water quality.

4.3.2 Coolant preparation

Particular attention should be paid to preparing and inspecting the coolant in liquid-cooled engines, as otherwise corrosion, cavitation and freezing damages can occur on the engine. Preparation of the coolant involves mixing a cooling system preservative to the cooling water. 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. (Example: gefo glycomat R ).

Mixing cooling system preservatives of a nitrite

base with substances of an amine basis forms harmful

nitrosamines.

4.3.3 Cooling system preservative

Using the cooling system preservative, order no. 01011490/ 01016416/12211500 (nitrite, amine and phosphate free, available in 5/ 20/ 210 litre containers), provides effective protection against corrosion, cavitation and freezing. The cooling system preservative in the coolant must not fall below or exceed the following concentrations:

Cooling system Water Cold protection preservative proportion to proportion

min. 35 % 65% -22 °C

40 % 60% -28 °C

max. 45 % 55% -35 °C

For filling amounts see the table overleaf in combination with the information in chapter

9.1. The use of other cooling system preservatives, e.g. chemical corrosion preservatives, is possible in exceptional cases, consult DEUTZ Service.

Order the cooling system preservative from:

DEUTZ AG

4.3.1 Water quality for coolant

The following values may not be exceeded or fallen short of. A test case can be requested from DEUTZ Service under the order no. 1213 0382 for checking your water quality.

Analysis values min. max.

ph value at 20 °C 6.5 8.5 Chloride ion content[mg/dm3] - 100 Sulphate ion content[mg/dm3] - 100 Total hardness [°dGH] 3 20

* Carbonate hardness proportion of total hardness min 3 dGH

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

Page 41

Maintenance

5.1 Maintenance schedule

5.2 Maintenance diagram

5.3 Maintenance work carried out

Page 42

Activity

Maintenance 5.1 Maintenance schedule

check= z set= clean=L renew= 

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

⇓ 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

EGR* exhaust gas recirculation (system);  If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.

The intervals can be reduced, depending on the degree of soiling of the fuel used.

 



z

zz  zzz zz  zz L

z

z z



zz

z zz zz zz



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

6.1.1/ 6.1.2 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

(if available, maintenance as per maintenance display)

6.4.3 /6.4.4 Charge air cooler (drain lube oil/condensation)

EGR(option)* Check non-return valve (option) EGR (option) Check cap and adjustment mechanism for clearance, renew if necessary.

Cooler EGR(option) Check function of heating flange Battery and cable connections 6.7.1 Engine monitoring, warning system  3.3

Valve clearance 6.6.1 V-belt/tension pulley (renew when wear limit reached) 6.5.1/6.5.3 Crankcase pressure bleed valve (option)

Engine tightness (visual inspection for leaks). – Engine mounting (renew in case of damage) 9.2 Fastenings, hose connections / clamps – General overhaul

Page 43

Activity

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

E10 E30 E40 E70

500 6.000 12.000 1 2

Enhancements or modifications for engines with

EPA acceptance

carried out by authorised service personnel

Section

Charge air cooler (drain lube oil/condensation)

Charge air cooler inlet surface (clean if necessary) # Crankcase pressure bleed valve (option)

z L z L

L 

Page 44

Maintenance 5.1 Maintenance schedule

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

6.1.1/ 6.1.2 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

(if available, maintenance as per maintenance display)

6.4.3 /6.4.4 Charge air cooler (drain lube oil/condensation)

EGR(option)* Check non-return valve (option) EGR (option) Check cap and adjustment mechanism for clearance, renew if necessary.

Cooler EGR(option) Check function of heating flange Battery and cable connections 6.7.1 Engine monitoring, warning system & 3.3

Valve clearance 6.6.1 V-belt/tension pulley (renew when wear limit reached) 6.5.1/6.5.3 Crankcase pressure bleed valve (option)

Engine tightness (visual inspection for leaks). – Engine mounting (renew in case of damage) 9.2 Fastenings, hose connections / clamps –

General overhaul

Service Yearly op. Average

group performance

Drive

speed

approx.km/h

I <30 000 20

II >30 to 100 000 40 III >100 000 60

Vehicle engines

Service group I <30 000km 20

approx.km/h

Maintenance only

to be carried out by authorised service personnel

Section

EGR* Exhaust gas recirculation (system);  If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.

The intervals can be reduced, depending on the degree of soiling of the fuel used.

⇓ check 2x daily before or during the 1st trial run, during the running in phase or when commissioning new and overhauled engines.

⇓ every 200 km or daily OPERATIONAL PERFORMANCE IN (km) ye a r(s)

E10 E20 E30 E40 E45 E50 E60 E70

Activity

check= z set=  clean= L renew= 

5,000

10.000

20.000

30.000

120..000

240.0 0 0

 



z

zz  zz z zz  zz L

z

z z



zz

z zz zz zz



Page 45

5.1 Maintenance schedule Maintenance

Lube oil level, if necessary re-fill 6.1.2 L

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

6.1.1/ 6.1.2 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

(if available, maintenance as per maintenance display)

6.4.3 /6.4.4 Charge air cooler (drain lube oil/condensation)

EGR(option)* Check non-return valve (option) EGR (option) Check cap and adjustment mechanism for clearance, renew if necessary.

Cooler EGR(option) Check function of heating flange Battery and cable connections 6.7.1 Engine monitoring, warning system & 3.3

Valve clearance 6.6.1 V-belt/tension pulley (renew when wear limit reached) 6.5.1/6.5.3 Crankcase pressure bleed valve (option)

Engine tightness (visual inspection for leaks). – Engine mounting (renew in case of damage) 9.2 Fastenings, hose connections / clamps – General overhaul

check= zset=  clean= L renew= 

Vehicle engines

Service group Il 100 000km 40approx.km/h

Section

Activity

EGR* Exhaust gas recirculation (system);  If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.

The intervals can be reduced, depending on the degree of soiling of the fuel used.

20,000

40,000

50,000

240,000

480,000

⇓ check 2x daily before or during the 1st trial run, during the runningin phase or when commissioning new and overhauled engines.

⇓ every 200 km or daily

OPERATIONAL PERFORMANCE IN (km) ye a r(s)

E10 E20 E30 E40 E40 E50 E60 E70

Service Yearly op. Average

gro up performance

Drive

speed

approx.km/h

I <30 000 20

II >30 to 100 000 40 III >100 000 60

 



z

zz  zz z zz  zz L

z

z z



zz

z zz zz zz



Page 46

Maintenance

5.1 Maintenance schedule

check= zset=  clean= L renew= 

ServiceYearly op. Average gro up performance

Drive

speed

approx.km/h I <30 000 20 II >30 to 100 000 40

III >100 000 60

Vehicle engines

Service group Ill >100 000 km 60approx.km/h

# Maintenance only to be carried out by authorised service personnel

Section

30.000

60.000

90.000

120.000

360.000

1000.000

EGR* Exhaust gas recirculation (system);  If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.

The intervals can be reduced, depending on the degree of soiling of the fuel used.

Activity

⇓

check 2x daily before or during the 1st trial run, during the running-in phase or when commissioning new and overhauled engines

⇓ every 200 km or daily

OPERATIONAL PERFORMANCE IN (km) every

Service group III year(s)

E10 E20 E30 E40 E45 E50 E60 E70

 



z

zz  zz z zz  zz L

z

z z



zz

z zz zz zz



Lube oil level, if necessary re-fill 6.1.2 L

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

6.1.1/ 6.1.2 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

(if available, maintenance as per maintenance display)

6.4.3/6.4.4 Charge air cooler (drain lube oil/condensation)

EGR(option)* Check non-return valve (option) EGR (option) Check cap and adjustment mechanism for clearance, renew if necessary.

Cooler EGR(option) Check function of heating flange Battery and cable connections 6.7.1 Engine monitoring, warning system & 3.3

Valve clearance 6.6.1 V-belt/tension pulley (renew when wear limit reached) 6.5.1 Crankcase pressure bleed valve (option)

Engine tightness (visual inspection for leaks). – Engine mounting (renew in case of damage) 9.2 Fastenings, hose connections / clamps – General overhaul

Page 47

Maintenance 5.1 Maintenance schedule

5.1.1 Standard maintenance schedule

Intervals Deutz maintenance and Activity Execution by: at/after service schedules

50 oh E 10 after commissioning and E 50-E 70 autho rised specialists

daily E 20 daily inspection round the user / authorised specialists

500 o h E 30 inspection authorised specialists 1000 oh E 40 intermediate overhaul authorised specialists 1500 oh E 45 extended intermediate overhaul authorised specialists

3 000 oh E 60 partial overhaul authorised specialists

6000 oh E 60 partial overhaul authorised specialists

10 000 oh (2012) E 70 overhaul authorised specialists 13 000 oh (2013) E 70 overhaul authorised specialists

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

Page 48

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

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.

5.2 Maintenance diagram Maintenance

Page 49

Date

Op. hrs.

Signature / stamp Op. hrs. Date

Signature / stamp

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

50-150

125

375

625

875

1125

1375

1625

1875

2115

2375

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

5.3 Maintenance work carried out Maintenance

Page 50

Op. hrs.

Date

Date Signature / stamp

Op. hrs. Signature / stamp

Maintenance 5.3 Maintenance work carried out

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

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

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

Page 51

Date

Op. hrs.

Signature / stamp Op. hrs. Date

Signature / stamp

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

5875

6125

6375

6625

6875

7125

7375

7625

7825

8125

8375

8625

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

5.3 Maintenance work carried out Maintenance

Page 52

Op. hrs.

Date

Date Signature / stamp

Op. hrs. Signature / stamp

Maintenance 5.3 Maintenance work carried out

8875

9125

9375

9625

9875

10125

10375

10625

10875

10125

10375

10625

9000

9250

9500

9750

10000

10250

10500

10750

10000

10250

10500

10750

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

Page 53

Care and maintenance work

6.1 Lubrication system

6.2Fuel system

6.3Cooling system

6.4Combustion air filter

6.5 Belt drive

6.6Setting work

6.7Add-on parts

Page 54

Care and maintenance work 6.1Lubrication 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 ³ -10 °C

(+14 °F)

z For fuels

– with sulphur content > 0.5 to 1%

– Constant ambient temperatures < -10 °C

(+14 °F)

or – with bio-diesel fuels according to DIN 51606- FAME the oil change times should be halved.

z For fuels with a sulphur content higher

than 1% ask your responsible service representative.

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

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.

Page 55

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 specificat ion E2-96 E3-96/E5-02/E07-04 E4-99/E6-04 E4-99/E6-04

see 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 All engines with: 2012 Crankcase ventilation:

L04/06 4V open - 500 500 500

closed - - 500 500

2013 Crankcase ventilation: L04/06 4V open - 500 500 500

closed - - 500 500

Page 56

average driving speed km/h

Care and maintenance work 6.1 Lubrication system

6.1.1.2 Lube oil change intervals for vehicle engines

Lube oil quality

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

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

see 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 -

Application

Engine version Crankcase

TCD 2012/2013 L04/ 06 4V ventilation Lube oil change intervals in km

Building site

TCD

2012 4V open - 20 000 20 000 20 000

closed - - 20 000 20 000

vehicles /

TCD 2013 L06 4V

city buses/ Coach bus closed - 30 000 50 000 50 000

25 Inter city bus closed - 20 000 30 000 30 000

City busbus closed - 15 000 20 000 20 000 City TCD 2013 L04 4V closed - 25 000 45 000 45 000 transport TCD 2013 L06 4V closed - 30 000 50 000 50 000

TCD

2012 4V open - 30 000 30 000 30 000

closed - - 30 000 30 000

Local transport 4 0 TCD 2013 L04 4V closed - 40 000 60 000 60 000

TCD 2013 L06 4V closed - 50 000 75 000 75 000

TCD

2012 4V open - 40 000 40 000 40 000

Long distance

60 closed - - 40 000 40 000

transport

TCD 2013 L04 4V closed - 60 000 80 000 80 000

TCD 2013 L06 4V closed - 75 000 100 000 100 000

Page 57

6.1 Lubrication system Care and maintenance work

6.1.2 Checking oil level / changing engine oil

6.1.2.1Checking oil level

z Position the engine or vehicle so as to be level. z – Engine warm:

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

z – 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.

6.1.2.2 Changing engine oil

z Warm up 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 Pour in 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!

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

Page 58

Care and maintenance work 6.1 Lubrication system

6.1.3 Changing oil filter insert

z When anti-rotation lock is installed:

Loosen clamping screws and remove tightening clamps from below.

z Loosen lube oil filter cartridge with stan-

dard tool and unscrew.

z Collect any oil which may run out.

z Clean the sealing surface of the filter sup-

port for any possible dirt.

z Lightly oil the rubber seal of the new lube

oil cartridge.

z Screw on the cartridge by hand until the

seal makes contact.

Careful with hot oil: danger of scalding!

z Tighten lube oil filter cartridge three quarters

of a turn (approx. 10 Nm).

z If there is an anti-rotation lock:

Position the tightening clamps and tighten with clamping screws.

z Check oil level, see 6.1.2.

z Check oil pressure, see 3.3.1.

z Check the seal of the lube oil filter cartridge

for tightness.

Page 59

6.1 Lubrication system Care and maintenance work

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

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

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 clock-

wise 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.

Page 60

Care and maintenance work 6.2 Fuel system

6.2.1 Changing fuel filter

z Screw on the cartridge by hand until the seal

makes contact.

z Tighten the fuel filter cartridge with one more

half turn.

z Open fuel stopcock.

z Check 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! Pay attention to cleanliness as the fuel system (Rail) is very sensitive!!!

It is necessary to bleed the fuel system.

z Close fuel stopcock. z Loosen fuel filter cartridge with standard tool

and unscrew.

z Collect any fuel 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 DEUTZ

original fuel filter cartridge or wet with diesel fuel.

Page 61

6.2 Fuel system Care and maintenance work

Only work on the fuel system when the engine is switched off (at least 30 seconds). No open fire! Do not smoke! Dispose of used fuel in an environmentally friendly manner.

6.2.2 Cleaning / changing fuel filter

(cup)

z Change the rubber seal 2 and lightly oil. z Carefully place new paper filter cartridge 3 in

the guide 4.

z Tighten the fuel filter cover 1 in clockwise

direction (25 Nm).

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

z Switch off engine z Loosen fuel filter cover 1 and unscrew in anti-

clockwise direction.

z Carefully loosen paper filter cartridge 3 from

the guide 4 from above.

z Collect any fuel which may run out. z Change paper filter cartridge 3. z Clean the sealing surface of the filter support

and the fuel filter cover 1 as well as the guide4 of any dirt there may be.

Page 62

6.2.3 Changing / bleeding fuel pre-filter, filter insert

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 thermostat 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 pump a few more times.

(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.

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.

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

Care and maintenance work 6.2 Fuel system

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.

Page 63

6.3 Cooling system Care and maintenance work

6.3.1 Cleaning intervals

z The cooling system soiling depends on the

type 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

Engine application

2000 Ships, electronic units in

enclosed spaces, pumps.

1000 Vehicles on paved

roads

500 Tractors, fork lift trucks, drivable

electronic units.

250 Vehicles on building sites and

unpaved roads, building machines, compressors, mining equipment.

125 Agricultural machinery, tractors

with harvesting application.

Page 64

Care and maintenance work 6.3 Cooling system

6.3.2 Cleaning cooling system

Cleaning with compressed air

- Blast out the engine wih compressed air. Do not damage any components.

- Rinse out the loosened dirt with a water jet.

Cleaning with cold cleaner

- Spray the engine with standard cold cleaner and leave to work for approx. 10 minutes.

- 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).

Page 65

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

6.3.3 Emptying / filling / bleeding cooling system

Emptying cooling system:

z Position collecting dish underneath locking

screw 5 and coolant supply 4.

z Remove locking screw 5 on the crankcase

and pull off hose on 4.

z Loosen bleed screw 2. z Drain off coolant. z Re-tighten locking screw 5 and hose on 4 and

bleed screw 2.

z If locking screw 3 is not accessible,

emptying may be carried out on the engine oil cooler (coolant channel).

Filling / bleeding cooling system:

z Open cooler cover. z Loosen bleed screw item 2. z Pour in coolant until the maximum mark or the filling

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

z Tighten bleed screw item 2 + locking screw

item 5.

zClose cooler cover. zStart engine and warm up until the thermostat opens. zSwitch off engine. zCheck the coolant level with the engine cold and

re-fill if necessary.

zClose cooler cover item 1.

Bleeding

zThe cooling system, which was built according

to our installation guides, is bled automatically after filling.

6.3 Cooling system Care and maintenance work

Page 66

Care and maintenance work 6.4Combustion air filter

6.4.1 Cleaning intervals

z The soiling of the combustion air filter

depends 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 comes on 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.

Page 67

6.4 Combustion air filter Care and maintenance work

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.

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

Page 68

6.4.3 Dry air filter

Dust discharge valve

Filter cartridge

Care and maintenance work 6.4 Combustion air filter

z Empty the dust discharge valve 1 by squeezing

the discharge slot in the direction of the arrow.

z Clean the discharge slot occasionally.

z Remove any stuck on dust residues by

squeezing the upper area of the valve.

Never clean filter cartridge with petrol or hot liquids!

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 check seals. Exchange if necessary.

z Renew the safety cartridge 4 after 5 filter

maintenances, after 2 years at the latest (never clean!). To do t h is :

- 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.

Page 69

6.5.1 Changing V-belt V-rib belt

6.5.2 Changing V-belt V-rib belt

6.5 Belt drive Care and Maintenance work

z Push tension pulley in the direction of the arrow

until V-rib belt is free.

z First remove the V-rib belt from the smallest

pulley.

z Put on new V-rib belt z Loosen tension pulley in the opposite direction

of the arrow until the V-rib belt is taut Whilst doing this, check that the V-rib belt is positioned correctly in your guide.

z Push tension pulley in the direction of the arrow

until V-rib belt is free.

z First remove the V-rib belt from the smallest pulley. z Put on new V-rib belt z Loosen tension pulley in the opposite direction

of the arrow until the V-rib belt is taut Whilst doing this, check that the V-rib belt is positioned correctly in your guide.

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

6.5.3 Checking V-rib belt wear limit

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 „a“ is less than 3 mm the V-rib belt should be

changed.

Page 70

Care and maintenance work 6.6 Setting work

6.6.1 Checking valve clearance, setting if necessary

z Loosen bleed valve and swing aside. z Remove cylinder head cover. 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 device over the fastening

screws of the belt pulley.

z Turn over engine until the valve overlap is

achieved, cylinder no. 1

z Crankshaft setting as per setting diagram, see

6.6.1.1.

Note: Valve overlap means:

Exhaust valve is not yet closed. Inlet valve begins to open. For valve setting diagram see

6.6.1.1, the table on the right.

Setting instructions: IN= inlet valve EX = exhaust valve

z Perform test and setting work on every cylinder. z Re-mount cylinder head cover (if necessary

with new gasket).

z Swing the bleed valve into position and fasten

Example: BF4M 2013 Valve clearance setting

1. Work step 1. Set cylinder to overlap, set cylinder 4.

2. Work step 3. Set cylinder to overlap, set cylinder 2.

3. Work step 4. Set cylinder to overlap, set cylinder 1.

4. Work step 2. Set cylinder to overlap, set cylinder 3.

Page 71

6.6.1.1 Valve clearance setting diagram

Setting the valves: (black identification

)

z Perform valve clearance setting on appropria-

te cylinder with valve clearance setting device part no. 8190. Loosen all lock nuts 2 of the rocker arm assembly to be set. Turn setting screw 1 back with the valve clearance setting device one turn in anti-clockwise direction. On the valve to be set, turn setting screw 1 in clockwise direction so as to be free of clearance. That means, there must not be any clearance between the rocker arm and valve and no pressure may be applied to the valve.

z Set needle of measuring plate to [i| , not

twisting the knurled handle any more.

z Hold the measuring plate exactly in this position

and turn the setting screw 1 in anti-clockwise direction with the knurled handle until the needle is on the „in“ or „ex“ marking.

z Hold the knurled handle exactly in this position and

tighten lock nut 2 with a torque wrench (20 Nm).

z Üput on seal (poss. new seal). z Visual inspection of screws and rubber ele-

ments, renew if necessary.

z Put on valve mechanism cover and tighten

screws according to tightening specification: 9 Nm (see 9.2).

6.6 Setting work Care and maintenance work

Page 72

6.6.2 Checking control piston clearance at engine brake, setting if necessary

z After the valve clearance has been set.

- Control unit for engine brake is already mounted.

z Set the clearance on the control unit as follows. z Turn engine until reaching the valve overlap

is reached, cylinder no. 1

z Set control piston clearance on every exhaust

valve.

z Proceed as for valve clearance.

Note

Valve overlap means: Exhaust valve is not yet closed. Inlet valve begins to open, see valve setting diagram.

z Set control piston clearance if necessary, by:

- Loosening the lock nut 2.

- Mount the control piston clearance X on setting screw 1 (see 6.6.1) with setting device in EX and set as follows:

Fix the magnet Turn the setting device without clearance until the control piston contacts with the valve bridge, set scale to „0“. Then turn back angle degree 432° (by hand or torque wrench):

EX = exhaust valve 432° for M8 thread

(corresponds to 1.5 mm clearance)

- Tighten lock nut 4.

z Perform test and setting work on every

cylinder.

z Replace cylinder head cover (if necessary

with new gasket).

z Swing the bleed valve into position and

fasten.

IN = Inlet valve EX = Exhaust valve

1 Setting screw 2 Lock nut 3 Solenoid valve (electronic control) 4 Control board

Care and maintenance work 6.6 Setting work

Page 73

Page 74

Care and maintenance work 6.7 Add-on parts

6.7.1.1Testing 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 cap 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 cap 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.

Page 75

Tropics

1,23

1,12

1,08

Normal

Tropics

in [kg/ l]

in [°Bé (Baumé degree)*] Charge level

Normal

1,28

1,20

1,12

well charged

half charged, re-charge

discharged, charge immediately

6.7 Add-on parts Care and maintenance work

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!

Acid density

* The data for acid density in °Bé

(Baumé degree) is out of date and rarely still in use.

Page 76

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

immediately.

z When cleaning engine: Do not spray water/

steam jet directly at generator! lWarm 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.

Only use correct suspension equipment!

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

moments in the suspension. This can damage the suspension.

Engine can fall. Danger to life!

Page 77

Faults, causes and remedies

7.1 Fault table

7.2 Engine management

Page 78

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!

Page 79

Faults, causes and remedies

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

Engine doesn't start up and diagnosis light is blinking

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 smoulders - blue

- white

- black

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 (only with mech. regulators) Set throttle to halfway 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-rib belt torn or loose (fuel pump in belt drive) Cool air heating / heat short circuit Battery defective or not charged

Section

Faults Action

Operation

Combustion air

Cooling system

Electrics

C C C

L C / S C / S

C / Ch

C / Cl C / Cl C / W

7.1 Fault table

Cause

z zz zz

zz zz zz

zzz

zz z zz z zz z z

z zzz z

Page 80

Faults, causes and remedies

7.1 Fault table

Electrics

Engine

Operating

substance

Electronics

Faults Action

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

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

Page 81

Faults, causes and remedies

7.2 Engine management

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 from damage in certain fault situations by monitoring compliance with 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. switching off of the engine after a short

pre-warning time, possibly in connection with a start lock

z To cool down the engine before switching off,

forced engine operation at low idling speed, automatic switch-off if necessary

z Start lock (see also chap. 3.3)

7.2.2 Using the diagnosis button

7.2.3 Table of fault blink codes

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.

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.

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.

Page 82

Faults, causes and remedies

7.2 Engine management

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

Page 83

8.1 Corrosion protection

Engine corrosion protection

Page 84

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 preiod 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.

Engine corrosion protection 8.1 Corrosion protection

3 1

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.

Removing engine corrosion protection:

z Remove corrosion protection agent from

grooves of V-belt pulley 5.

z Assemble V-rib belt 4, 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

paying attention to cleanliness.

z Start up the engine.

Note: Fuel tank/supply line to the engine

should also be sealed, so that the sensitive Rail System is protected against dirt and dust.

Page 85

9.1 Engine and setting data

9.2 Screw tightening torques

9.3 Tools

Technical data

Page 86

Technical data 9.1 Engine and setting data

Engine type ----------------------------- TDC 2012 L04 V4 ---------------- TDC 2012 L06 V4 ---------------------------

Number of cylinders ---------------------------------------- 4 --------------------------------------- 6 --------------------------------------Cyl. arrangement -----------------------------------------------------------In-line --------------------------------------------------------Bore [mm] ------------------------------------------------------------ 101 ---------------------------------------------------------Stroke [mm] ------------------------------------------------------------ 126 ---------------------------------------------------------Total displacement [cm

] -------------------------------------- 4038 ---------------------------------- 6057 ------------------------------------

Compression ratio [H] ------------------------------------------------------------- 18 -----------------------------------------------------------

Working principle / combustion procedure -------------------- Four stroke diesel with charging and direct injection ---------------------------------Charge air cooler -------------------------------------- with ----------------------------------- with -----------------------------------Charge air cooler temperature outlet at rated power [°C] ------------------------------------------------------------- 50 -----------------------------------------------------------

Direction of rotation ----------------------------------------------------- rotation to left ---------------------------------------------------injection system Deutz Common Rail (DCR) [kPa/bar] ------------------------------------------------------ 140000/1400 ---------------------------------------------------Engine type EP18 --------------------------------------------------------- PF 45 K -------------------------------------------------------Weight TDC 2012 without cooling system according to DIN 70020-A [approx.kg] --------------------------------------- 450 ------------------------------------ 570 ------------------------------------Engine power [kW] -------------------------------------------------------------

). ----------------------------------------------------------Speed max. [rpm] ----------------------------------------------------------- 3000 --------------------------------------------------------Valve clearance inlet / exhaust, see 6.6.1 [mm] --------------------------------------- 0.4/0.5

± 0.05/

/ angle degree 160/195 -----------------------------------

Setting with special tool Ignition pressure [kPa/bar] ---------------------------------------------------- 1.6000.000/160 -------------------------------------------------Start of pumping [°KW before TDC] -------------------------------------------------------------

V-rib belt tension : ------------------------------------------- Spring-loaded tension pulley ------------------------------------------

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

Page 87

9.1 Engine and setting data Technical data

Engine type ----------------------------- TDC 2012 L04 V4 ---------------- TDC 2012 L06 V4 ---------------------------

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 Bus [°C] ---------------------------------------------------------- 86 (75) -------------------------------------------------------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 [kPa/bar] -------------------------------------------------------- 8,000/0.8 -----------------------------------------------------Initial oil filling quantity without filter max. [approx.ltr.] ------------------------------------- 8.5

. -------------------------------- 12.5 3). ----------------------------------

min. [approx.ltr.] --------------------------------------- 5

. ----------------------------------- 9.53). ------------------------------------

Initial oil filling quantity with filter max. [approx.ltr.] -------------------------------------- 10

. ----------------------------------- 14 3). ------------------------------------

min. [approx.ltr.] --------------------------------------- 7

. ------------------------------------11 3). ------------------------------------

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

Only necessary for winter operation, see 3.5.1.

Page 88

Technical data 9.1 Engine and setting data

Engine type ----------------------------- TDC 2013 L04 V4 ---------------- TDC 2013 L06 V4 ---------------------------

Number of cylinders ---------------------------------------- 4 --------------------------------------- 6 --------------------------------------Cyl. arrangement -----------------------------------------------------------In-line --------------------------------------------------------Bore [mm] ------------------------------------------------------------ 108 ---------------------------------------------------------Stroke [mm] ------------------------------------------------------------ 130 ---------------------------------------------------------Total displacement [cm

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

Compression ratio [H] ------------------------------------------------------------- 18 -----------------------------------------------------------

Working principle / combustion procedure -------------------- Four stroke diesel with charging and direct injection ---------------------------------Charge air cooler (optional) ------------------------------------ without ------------------------------- without ---------------------------------Charge air cooler temperature outlet at rated power/ (at max. power) [°C] ---------------------------------------------------- 42/ (max. 50°C) --------------------------------------------------

Weight TDC 2013 without cooling system according to DIN 70020-A [approx.kg] --------------------------------------- 530 ------------------------------------ 620 ------------------------------------Engine power [kW] -------------------------------------------------------------

). ----------------------------------------------------------Speed max. [rpm] ----------------------------------------------------------- 3220 --------------------------------------------------------Valve clearance inlet / exhaust, see 6.6.1 [mm] ----------------------------------------------------- 0.35/0.45

± 0,05

. --------------------------------------------------Setting with special tool Ignition pressure [kPa/bar] ------------------------------------------------------- 17500/175-----------------------------------------------------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

± 50

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

Fuel pump - coolant pump [N] ------------------------------------------------------ 550 / 300

± 50

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

Compressor [N] ------------------------------------------------------650 / 400

± 50

. ---------------------------------------------------V-rib belt tension Oil cooler plate cooling share:: ------------------------------------------- Spring-loaded tension pulley ------------------------------------------

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

Page 89

9.1 Engine and setting data Technical data

Engine type ----------------------------- TDC 2013 L04 V4 ---------------- TDC 2013 L06 V4 ---------------------------

Cooling ----------------------------------------- Liquid-cooled / cooling system protection --------------------------Coolant quantity (only engine content without cooler)[approx.ltr.] --------------------------------------- 5.0 ------------------------------------- 6.6 -------------------------------------

Permissible continuous coolant temperature engine outlet [°C] --------------------------------------------------------- max.110 ------------------------------------------------------Temperature difference between Coolant inlet/outlet [°C] ----------------------------------------------------------- 4 to 8 --------------------------------------------------------Start of thermostat opening at ( Bus ) [°C] ---------------------------------------------------------- 83(75) -------------------------------------------------------Thermostat fully open at [°C] ------------------------------------------------------------ 110 ---------------------------------------------------------Coolant pre-heating -------------------------------------------------------------(4. -----------------------------------------------------------Cooling water pump amount [dm

/ min] ------------------------------------------------------------ 295 ----------------------------------------------------------

Delivery pressure in [kPa/bar] ------------------------------------------------------- 120000/1.2 -----------------------------------------------------

Lubrication ----------------------------------------------- Forced feed lubrication --------------------------------------------Oil SAE -------------------------------------------------- 15 W 40 /15 W 30 ------------------------------------------------Maximum oil temperature in oil tray [°C] ------------------------------------------------------------ 125 ---------------------------------------------------------Minimum oil pressure in warm state (114 °C) and low idling [kPa/bar] ------------------------------------------------------- 150000/1,5 ----------------------------------------------------Initial oil filling quantity without filter max.[approx.ltr.] ------------------------------------ 10

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

min. [approx.ltr.] ------------------------------------- 6.5

. ---------------------------------- 19 3). ------------------------------------

Initial oil filling quantity with filter max.[approx.ltr.] ------------------------------------13.5

. -------------------------------- 27.53). -----------------------------------

min. [approx.ltr.] ------------------------------------- 9.5

. -------------------------------- 22.53). ----------------------------------Oil cooler plate cooling share: Water [Quant.] --------------------------------------- 10 ------------------------------------- 11 -------------------------------------Oil [Quant.] ---------------------------------------- 9 -------------------------------------- 10 --------------------------------------

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

Only necessary for winter operation, see 3.5.1.

Page 90

Technical Data 9.2 Screw tightening torques

Installation Pre-tightening Re -t ig htening T ota l Comme nt s

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

Valve mechanism cover – – – – – 11 ± 1 Nm M6 Rocker arm setting screw – – – – – 20 ± 2 Nm Nut with inner square Front face mounting foot – – – – – 260 Nm M16 x 85 –10.9

– – – – – 260 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

Page 91

TORX Valve clearance

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:

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.

TORX tools can be obtained from: WILBÄR

Postfach 14 05 80 D-42826 Remscheid

25899 0

9.3 Tools Technical data

30 060 1

Special tool part no. 8190 can be obtained from:

WILBÄR Postfach 14 05 80 D-42826 Remscheid

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Technical data 9.3 Tools

Socket wrench insert

Order No. 8199

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

Crow's foot wrench

Rotation angle disc

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

clearance. Wrench inserts for rotation angle disc.

Order No. 8190

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

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9.3 Tools Technical data

Order No. 100 330

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

Turning gear

Order No. 100 330

To turn over the engine on the SAE housing (Remove cap from SAE housing andmmount turning gear).

Turning gear for valve clerance setting

Page 94

Page 95

Service

For many years DEUTZ has stood for pioneering development in engine construction. As an independent manufacturer we offer a complete palette of diesel and gas engines worldwide. Our products are perfectly tailored to meet the requirements of our customers.

More than 1.4 million DEUTZ engines reliably perform their service all over the world. We want to preserve the operational readiness of our engines and with it the satisfaction of our customers. Therefore we are represented worldwide by a network of competent partners, the concentration of whom corresponds to the regional distribution of our engines.

Thus, DEUTZ is not just a name for innovative engines. But also for a complete service package for every aspect of engines, and a service that you can rely on.

You can find an overview of DEUTZ partners in your area, their product competencies and their services on the DEUTZ website (see following addresses). Also if there is no direct product competency specified, your DEUTZ partner will be able to help you further with professional advice. Your DEUTZ AG Deutz-Mülheimer Str. 147-149

D-51063 Cologne Telephone: 0049-221-822-0 Fax: 0049-221-822-3523 Telex: 8812-0 khd d http://www.deutz.com Email: info@deutz.de

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the engine company

DEUTZ AG Service-Information Systems

Deutz-Mülheimer Str. 147-149 D-51057 Köln Tel.: ++49 (0)2 21-8 22-0 Fax: ++49 (0)2 21-8 22-53 58 Internet: www.deutz.de