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

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Instruction Manual

TCD 2012 L04/06 4V

TCD 2013 L04/06 4V

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!

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.

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

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

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

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.

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

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.

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.

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

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)

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

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).

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

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

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

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

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

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

Engine description

2.5 Coolant circuit

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

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

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

Operation

3.1 Initial commissioning

3.2 Starting

3.3 Operation monitoring

3.4 Shutting down

3.5 Operating conditions

Operation

3.1 Initial commissioning

3.1.3 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!

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).

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).

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