Deutz TCD 2012 L06, TD 2012 L04 Operation Manual

Download

Page 1

Operation Manual

TD/TCD 2012 L04/06 2V/m

Betriebsanleitung

TCD 2012 L04/L06 2V

TCD 2013 L04/06 2V/m

TCD 2013 L04/L06 2V

Page 2

Notes

This engine is defined exclusively for purpose according to the scope of delivery and built by the equipment manufacturer (use for the intended purpose). Any other use above and beyond this will be considered as misuse. The manufacturer will not accept any liability for damages resulting from this. The user bears the sole risk.

Use for the intended purpose also includes observance of the operating, maintenance and repair conditions specified by the manufacturer. The engine should only be operated, serviced and repaired by personnel trained in its use and the hazards involved.

The pertinent rules for the prevention of accidents and other generally recognised safety and industrial medicine rules must be observed.

When the engine is running there is a danger of injury caused by:

– rotating and hot components – on motors with external ignition (high electri-

cal voltage). Contact must be avoided!

Unauthorised engine modifications will invalidate any liability claims against the manufacturer for resultant damage.

Equally, manipulations to the injection and control system can affect the engine's performance and the exhaust characteristics. Adherence to legislation on pollution can no longer be guaranteed under such conditions.

Do not change the cooling air feed area to the blower of fan. An unobstructed cooling air supply must be guaranteed.

The manufacturer will accept no liability for damage resulting from this.

When carrying out maintenance work on the en-

gine, the use of DEUTZ original parts is prescribed. These are specially designed for your engine and guarantee perfect operation.

Non-compliance results in the expiry of the warranty! 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 contact voltages) must be observed. Cover all electrical components tightly when cleaning with liquids.

Do not work on the fuel system while the engine is running -

Wait for the pressure to drop after the engine has come to a standstill (in engines with DEUTZ Common Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure During the first trial run do not stand in the danger area of the engine.

Danger due to high pressure in case of leaks -

Danger to life!

– In case of leaks immediately contact work-

– When working on the fuel system, make sure

Danger to life!

- Danger to life!

shop.

that the engine is not started inadvertently during repairs -

Danger to life!

Page 3

Foreword

Dear customer,

Congratulations on the purchase of your DEUTZ engine.

DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. Consequently, a wide range of variants is offered to meet the requirements of specific cases.

The engine is equipped accordingly for the particular installation situation, i.e. not all the components described in the operating manual are installed in your engine.

We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions applicable to your engine more quickly and easily.

Please make sure that this operating manual is available to everyone involved in the operation, maintenance and repair of the engine and that they have understood the contents.

If you have any queries, please contact us, we'll be happy to advise you.

Sincerely, DEUTZ AG

Engine serial number

Please enter the engine serial number here. This will simplify the handling of customer service, repair and spare parts queries.

Notes

We reserve the right to make technical changes to the descriptions and data in this operating manual in the interest of further development of the engines.

This document may only be reprinted and reproduced, even in part, with our express permission.

Page 4

Notes . . . . . . . . . . . . . . . . . . . . . . . 2

Foreword. . . . . . . . . . . . . . . . . . . . . 3

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

2 Engine description . . . . . . . . . . . . . 7

Model . . . . . . . . . . . . . . . . . . . . . 7

Engine illustrations . . . . . . . . . . . . . . 9

Lubricating oil diagram . . . . . . . . . . . . 17

Fuel diagram . . . . . . . . . . . . . . . . . 18

Coolant diagram . . . . . . . . . . . . . . . 19

Exhaust gas return . . . . . . . . . . . . . . 21

Electrics/Electronics . . . . . . . . . . . . . 22

3 Operation . . . . . . . . . . . . . . . . . . 24

Ambient conditions . . . . . . . . . . . . . . 24

Initial start-up . . . . . . . . . . . . . . . . . 25

Start procedure . . . . . . . . . . . . . . . . 27

Operation monitoring . . . . . . . . . . . . . 29

Stop procedure . . . . . . . . . . . . . . . . 31

4 Operating media. . . . . . . . . . . . . . . 32

Lubricating oil . . . . . . . . . . . . . . . . . 32

Fuel . . . . . . . . . . . . . . . . . . . . . . 34

Coolant . . . . . . . . . . . . . . . . . . . . 35

5 Maintenance . . . . . . . . . . . . . . . . . 36

Maintenance schedule . . . . . . . . . . . . 36

6 Servicing and maintenance works . . . . . 39

Lubricating oil system. . . . . . . . . . . . . 39

Fuel system. . . . . . . . . . . . . . . . . . 42

Cooling system . . . . . . . . . . . . . . . . 48

Engine cleaning. . . . . . . . . . . . . . . . 50

Aspiration system. . . . . . . . . . . . . . . 51

Belt drives . . . . . . . . . . . . . . . . . . 53

Setting work . . . . . . . . . . . . . . . . . 56

Electrical system . . . . . . . . . . . . . . . 59

7 Faults. . . . . . . . . . . . . . . . . . . . . 61

Fault table . . . . . . . . . . . . . . . . . . 61

Engine management . . . . . . . . . . . . . 66

8 Transport and storage . . . . . . . . . . . 69

Transport . . . . . . . . . . . . . . . . . . . 69

Engine corrosion protection . . . . . . . . . 70

9 Technical data . . . . . . . . . . . . . . . . 72

Engine and setting data . . . . . . . . . . . 72

Tools . . . . . . . . . . . . . . . . . . . . . 76

Page 5

General

DEUTZ diesel engines

DEUTZ diesel engines are the product of years of research and development. Profound know-how combined with high quality requirements are the guarantee for the production of engines with a long life, high reliability levels and low fuel consumption. Obviously the high requirements for the protection of the environment are also met.

Safety precautions when the engine is running

Maintenance work or repairs may only be performed on the shut-down engine. Make sure that the engine cannot be started inadvertently -

dent!

After repair work: Check that all guards have been replaced and that all tools have been removed from the engine.

Observe industrial safety regulations when running the engine in an enclosed space or underground.

When working on the running engine, work clothing must be close fitting.

Never fill the fuel tank while the engine is running.

Service and Maintenance

Service and maintenance are also decisive for whether the engine satisfactorily meets the set demands. Recommended service intervals must therefore be observed and service and maintenance work must be carried out conscientiously.

Special care should be taken under abnormally demanding operating conditions.

Original DEUTZ parts

Original DEUTZ parts are subject to the same strict quality demands as the DEUTZ engines. Further de-

Danger of acci-

velopments for improving the engines are also introduced in the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured according to the state-of-the-art can guarantee perfect functioning and high reliability.

DEUTZ Xchange components

DEUTZ replacement parts are a low-cost alternative. Of course, the quality standards here are just as high as for new parts. DEUTZ replacement parts are equal to the original DEUTZ parts in function and reliability.

Asbestos

The gaskets used in this engine contain no asbestos. Please use the appropriate original DEUTZ parts for maintenance and repair work.

Service

We want to preserve the high performance of our engines, and with it the confidence and satisfaction of our customers. We are therefore represented worldwide by a network of service branches.

The DEUTZ name does not merely stand for engines that are the products of extensive development work, DEUTZ also stands for complete service packages that ensure optimum operation of our engines, and for customer services operations that you can count on.

Please contact your DEUTZ-partner in case of malfunctions and sare parts inquiries. Our specially trained personnel will ensure fast, professional repairs using original DEUTZ spare parts in case of damage.

The DEUTZ home page gives you a continuously upto-date overview of the service partners in your vicin-

ity with notes on product responsibilities and services. Or you can use another fast, convenient way via the Internet under www.deutzshop.de. The DEUTZ P@rts Online parts catalogue gives you a direct contact to your nearest local service partner.

California Proposition 65 Warning

Diesel engines and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

Masthead

DEUTZ AG Ottostraße 1 51149 Köln Germany Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 E-Mail: info@deutz.com www.deutz.com

Page 6

General

Danger

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. The attention of operating personnel should be drawn to these safety instructions. Furthermore, the legislation for "general regulations for safety and the prevention of accidents" must be observed.

Caution

This symbol indicates a danger to the part and engine. The relevant instructions must be observed, failure to do so can lead to destruction of the part and the engine.

Notes

This symbol accompanies notes of a general kind.

Page 7

Model Engine description

DEUTZ AGDEUTZ AG

MADE IN GERMANYMADE IN GERMANY

Mot.-Typ

Mot.-Nr.

Engine type designation

This manual covers the following engine types TD 2012 L04 2V m TCD 2012 L04 2V TCD 2013 L04 2V TCD 2012 L06 2V TCD 2013 L06 2V TCD 2012 L04 2V m TCD 2013 L04 2V m

TCD

T Exhaust gas turbocharger C Charge air cooler DDiesel

2012/2013

2012 Series 2013 Series

L04/L06

L in series 04 No. of cylinders 06 No. of cylinders

2V Number of valves

m Mechanical injection system

Pump-pipe-nozzle

Emissions legislation

The engines of these operating instructions fulfill the following exhaust emissions regulations

USA EPA Tier III EU Stage IIIA

Rating plate

The type (A), engine number (B) and performance data are stamped on the rating plate.

The engine type and number must be stated when purchasing spare parts.

Page 8

left

right

Engine description Model

xxxxxxx

Location of the rating plate

The rating plate (C) is fixed to the cylinder head cover or the crankcase.

Engine serial number

The engine number (D) is stamped onto the crankcase (arrow) and onto the rating plate.

Cylinder numbering

Cylinder arrangement The cylinders are counted consecutively starting

from flywheel (1).

Direction of rotation

Looking onto the flywheel. rotating to the left: counter-clockwise.

Engine sides

Looking onto the flywheel.

Page 9

Engine illustrations Engine description

TCD 2012 L04 2Vm

View from right (example) 1 Crankcase breather

2 Lubricating oil filling 3 Injection pump 4 Lubricating oil dipstick 5 Lube oil cooler 6 Lube oil replacement filter

7 Lubricating oil drain plug 8 Exchangeable fuel filter 9 V-belts 10 Generator

876

Page 10

Engine description Engine illustrations

TCD 2012 L04 2Vm

View from left (example) 1 Combustion air inlet

2 Coolant outlet

3 Coolant inlet 4 Connections charge air cooler 5 Exhaust outlet 6Starter

Page 11

Engine illustrations Engine description

TCD 2012 L04 2V

View from right (example) 1 Crankcase breather

2 Lubricating oil filling 3Rail 4 Lubricating oil dipstick 5 Lube oil cooler 6 Lube oil replacement filter

7 Lubricating oil drain plug 8 Exchangeable fuel filter 9 V-belts 10 Generator

876

Page 12

Engine description Engine illustrations

TCD 2012 L04 2V

View from left (example) 1 Combustion air inlet

2 Coolant outlet 3 Coolant inlet 4 Connections charge air cooler

5 Exhaust outlet 6Starter

Page 13

Engine illustrations Engine description

TCD 2013 L06 2V

View from right (example) 1 Crankcase breather

2 Lubricating oil filling

3Rail 4 Lube oil cooler 5 Lube oil replacement filter 6 Lubricating oil dipstick 7 Exchangeable fuel filter 8 Lubricating oil drain plug 9 Generator

Page 14

Engine description Engine illustrations

TCD 2013 L06 2V

View from left (example)

1 Exhaust outlet 2 Combustion air inlet 3 Coolant outlet 4 Coolant inlet 5 Connections charge air cooler 6Starter 7 Lubricating oil drain plug

Page 15

Engine illustrations Engine description

TCD 2012 L06 2V

PowerPack The complete solution of engine and cooling system

offered by DEUTZ is called PowerPack View from right (example)

1 Coolant inlet 2 Compensation tank 3 Charge air cooler 4 Cooler 5 Lubricating oil drain plug 6 Lube oil replacement filter 7 Lube oil cooler 8 Lubricating oil dipstick 9 Lubricating oil filling 10 Rail 11 Crankcase breather

Page 16

Engine description Engine illustrations

TCD 2012 L06 2V

PowerPack The complete solution of engine and cooling system

offered by DEUTZ is called PowerPack View from left (example) 1 Generator

2 Connections charge air cooler 3 Coolant outlet 4 Coolant inlet 5 Combustion air inlet 6 Turbocharger 7 Exhaust outlet

Page 17

Lubricating oil diagram Engine description

15 14

13 12

Lubricating oil system

(example) 1 Lubricating oil sump

2 Lubricating oil pump 3 Pressure limiting valve

TD/TCD 2013 4 Lube oil cooler 5 Check valve

TD/TCD 2012 6 Bypass valve

7 Bypass valve 8 Pressure control valve 9 Lubricating oil filter 10 Main lube oil channel 11 Piston cooling nozzle 12 Rocker arm 13 Internally switched exhaust gas return

TCD 2012/2013L06 14 Turbocharger 15 Air compressor

983 2

Page 18

Engine description Fuel diagram

Fuel schematic (example)

1 Fuel tank 2 Fuel pre-filter 3 Fuel pump 4 Exchangeable fuel filter 5 Fuel supply line to the control block FCU (Fuel

Control Unit) 6 Control block FCU (Fuel Control Unit) 7 High-pressure pump 8Rail 9 Injector 10 Fuel return to fuel tank

Page 19

Coolant diagram Engine description

1110 14139128

Page 20

Engine description Coolant diagram

Coolant schematic (example)

1 Cooler 2 Coolant inlet 3 Coolant pump 4 Coolant partial flow to the lubricating oil cooler 5 Lube oil cooler 6 Coolant supply for engine cooling 7 Cylinder pipe/head cooling 8 Connection possibility for cab heating 9 Heat exchanger 10 Return line 11 Coolant return to thermostat 12 Coolant outlet 13 Compensation line 14 Venting pipe

Page 21

Exhaust gas return Engine description

Internal exhaust gas recirculation

1 Additional cams for exhaust gas recirculation

TD/TCD 2012/2013L04

Inlet valve opens briefly during the outlet cycle

and emits an exhaust gas partial flow to the suc-

tion system.

This partial volume is sucked back in in the next

suction cycle.

TCD 2012/2013L06

The outlet valve opens briefly in the intake

] m m

[

stroke. 2Outlet valve 3 Inlet valve

[°]

Page 22

Engine description Electrics/Electronics

Electronic engine control

321 5

Engine side

1 Fuel transducer 2 Coolant temperature transmitter 3 Charge air pressure transmitter, charge air tem-

perature transmitter

TCD 2012/2013 L06 4 Charge air pressure transmitter, charge air tem-

perature transmitter

TCD 2012/2013 L04 5 Engine control unit 6 Central plug (for engine control) 7 Speed transmitter via crankshaft 8 Rail pressure sensor 9 Lubricating oil level transmitter (optional) 10 Lubricating oil pressure transmitter 11 Fuel transducer 12 Speed transmitter via camshaft

Equipment side

13 Power supply (battery) 14 Multifunction displays 15 Signal outputs, e.g. for lamps, torque (PWM),

speed, engine operation, etc. 16 Inputs (e.g. override button) 17 Accelerator 18 Hand throttle 19 Optional function selector switch, e.g. for P de-

gree, type of controls, maximum curve etc. 20 Detachable key switch Start/Stop 21 Diagnosis button 22 Error lamp 23 Diagnostic interface/CAN bus

Page 23

Electrics/Electronics Engine description

Information about the engine electronics

This engine is equipped with an electric control unit. The equipping of the respective system depends on

the desired scope of function and the planned type of engine application.

The resultant wiring with pin assignment can be seen in the appropriate wiring diagram.

The installation regulations of the DEUTZ AG must also be taken into account.

Precautions

The connections of the control units are only dust and water proof when the mating plugs are plugged (protection class IP69K)! The control units must be protected against spray water and moisture until plugging in the mating plugs! Reverse polarity can lead to failure of the control unit. To avoid damaging the control units, all the connections on the control unit must be disconnected before electric welding work. Interventions in the electrical system contrary to the DEUTZ regulations or by unqualified personnel can permamently damage the engine electronics and have serious consequences which are not covered by the manufacturer's guarantee.

It is strictly prohibited: a) to make changes or connections to the wiring of the electrical control devices and the data transmission cable (CAN lines). b) to switch control units. Otherwise guarantee rights will be lost! Diagnostic and maintenance work may only be carried out by authorised personnel using equipment approved by DEUTZ.

Installation instructions

The control units are calibrated to the respective engine and identified by the engine number. Every engine may only be operated with the appropriate control unit.

Setpoint transmitters (pedal value transmitters) necessary for vehicle operation must be connected to the vehicle side cable harness and calibrated with the DEUTZ diagnostic program SERDIA (SERvice DIAgnosis). Wiring and cable assignment of the vehicle side cable harness must be taken from the connection diagram of the DEUTZ installation consulting.

Supply voltage

12 Volt 24 Volt It should be ensured that the battery is sufficiently

charged. If the supply voltage is interrupted while the engine is running, this can lead to damage to the electrics/electronics. If the supply voltage fails, the engine shuts down.

Voltages above 32 Volt will destroy the control unit.

Diagnostics

DEUTZ control units are equipped with self-diagnostics. Active and passive error entries are saved in the error memory. Active errors are displayed on error lamps/diagnostics lamps (

A diagnosis can be made with:

Error lamp (flash code)

CAN bus

DEUTZ electronics display

Diagnostic socket (SERIDA)

Equipment-side wiring

The DEUTZ AG installation regulations should be adhered to. In particular, the plug contact must be crimped with the appropriate standard tools. If it is necessary to do so, plugged-in contacts may only be removed from the plug housing with the proper tools.



66).

Page 24

Operation Ambient conditions

0 °C

Low ambient temperatures Lubricating oil

Select the lubricating oil viscosity according to the ambient temperature.

If cold starting occurs frequently cut the lube oil changing interval by half.

Fuel

Use winter fuel below 0 °C (34).

Battery

A good charging condition of the battery (59) is the prerequisite for starting the engine.

Heating up the battery to approx. 20°C improves the starting behaviour of the engine. (Remove and store the battery in a warm room).

Cold start aid

Depending on the type of engine, glow plugs, heating plugs, heating flange, flame glow system can be used as cold starting aids.(

Coolant

Observe the mixing ratio anti-freeze/cooling wa-



35)

ter. (

High ambient temperatures, high altitude

This engine is equipped with an electric control unit. Under the operating conditions listed below, the amount of fuel is reduced automatically, controlled by the electronic control unit.

Under the following application and operating conditions, the amount of fuel must be reduced.

above 1000 m altitude

above 30 °C ambient temperature

Reason: Air density decreases as altitude or ambient temperature increase. This reduces the amount of oxygen in the engine intake air and the fuel-air mixture would be too rich if the injected amount of fuel were not reduced.

The results would be: – black smoke in the exhaust – high engine temperature – reduction in engine performance – possible impairment of starting behaviour

Consult your equipment supplier or DEUTZ partner if you have any other questions.



27)

Page 25

Initial start-up Operation

Preparations for initial commissioning

(Maintenance schedule E 10)

Remove engine corrosion protection

Remove any transport devices.

Check the battery and cable connections and mount if necessary.

Check belt tension (53).

Have the engine monitor or warning system checked by authorised personnel.

Check the engine mounting.

Check that all hose unions and clips fit properly.

The following additional work must be carried out on generally overhauled engines:

Check the fuel pre-filter and main filter and change if necessary.

Check the intake air cleaner (if available, maintain according to maintenance indicator).

Drain lubricating oil and condensation water from the charge air cooler.

Fill with engine lube oil.

Fill the coolant system (72).

Fill with engine lube oil

Low lubricating oil level and overfilling lead to engine damage.

The engines are generally supplied without lubricating oil filling. Select lubricating oil quality and viscosity before filling. Order DEUTZ lubricating oils from your DEUTZ partner

Fill the engine with lubricating oil via the lubricating oil filler neck.

Observe the lubricating oil filling level (72).

Pour in fuel

Never fill the fuel tank while the engine is running. Ensure cleanliness. Do not spill fuel. Additional venting of the fuel system by a 5 minute trial run at idle speed or on low load is absolutely essential.

The fuel low pressure system must be vented be-

fore the first start-up after filling with the manualy

supply pump.

Only use clean commercially available brand diesel fuel. Observe fuel quality (

Use summer or winter-grade fuel, depending on the ambient temperature.



34).

Page 26

Operation Initial start-up

Filling the coolant system

The coolant must have a prescribed concentration of cooling system corrosion protection agent! Never operate the engine without coolant, even for a short time!

Order coolant corrosion protection agent from your DEUTZ partner.

Connect coolant outlet (2) and coolant inlet (1) to the cooling system. Connect the feed line of the compensation tank to the coolant pump or to the coolant inlet line (3).

Connect ventilation line from the engine and, if necessary, from the cooler to the compensation tank.

Fill cooling system via the compensation tank.

Close compensation tank with valve.

Start the engine and run up until the thermostat

opens (line (2) heats up).

Engine operation with open thermostat 2 - 3 minutes.

Check the coolant level and top up coolant if necessary.

Danger of scalding from hot coolant! Cooling system under pressure! Only open the cap when cool! Observe safety regulations and national specifications when handling cooling media.

If required, repeat procedure with engine start.

Fill up coolant to the MAX mark on the compensation tank and close the cooling system cap.

Switch on any available heating and set to the highest level so that the heating circuit is filled and vented.

Observe the filling volume of the cooling system



72).

(

Trial run

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

Carry out a brief trial run up to operating temperature (approx. 90 °C) after preparations.

Do not load the engine if possible.

Work with the engine not running:

– Check engine for tightness.

– Check lubricating oil level, if necessary top

up.

– Check the coolant level and top up coolant if

necessary.

Work during the trial run:

– Check engine for tightness.

Page 27

Start procedure Operation

Starting

Before starting, make sure that nobody is standing in the immediate vicinity of the engine or work machine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with the flame glow plug/ glow plug/heating flange system do not use any other starting aid (e.g. injection with start pilot). Risk of accident!

If the engine fails to fire and the error lamp lights, the electronic engine control 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. Do not actuate the starter for more than 20 seconds. 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 attempts, determine the cause as per fault ta-



61).

ble ( Do not run up the engine immediately to high idling speed / full load operation from cold.

Disconnect the engine by uncoupling devices to be driven where possible.

Without cold start aid

Insert key.

Turn key to the right. – Position 1 = operating voltage. – Pilot lamps (1) and (2) light up.

Push the key in and turn further clockwise against spring pressure. – Level 2 = no function.

– Level 3 = start.

release the key as soon as the engine starts up. – The pilot lamps will go out.

with cold starting device

Insert key.

– Position 0 = no operating voltage.

Turn key to the right.

– Position 1 = operating voltage.

– Pilot lamps (A), (B) and (C) light up.

stage 2 = pre-heating

– Preheat until the glow display goes out; an

error has occurred if the preheating indicator flashes; e.g. the preheating relay is stuck, which can discharge the battery completely when at a standstill.

– Engine is ready for operation.

Push the key in and turn further clockwise

against spring pressure.

– Level 3 = start.

release the key as soon as the engine starts up.

– The pilot lamps will go out.

Page 28

Operation Start procedure

If the starter is controlled by the electronic engine control via a relay:

the maximum start duration is limited.

the pause between two start attempts is specified. – the start is then continued automatically

starting while the engine is running is prevented.

If the touch start function is programmed, a short start command with the ignition key in position 2 or a start button, if available, suffices.

Page 29

Operation monitoring Operation

Electronic engine control

The statuses are displayed by the error lamp. The system monitors the condition of the engine and

itself.

Function test – Ignition on, error lamp lights up for approx. 2

seconds and then goes out.

– Check the error lamp if there is no reaction

after switching on the ignition.

The lamp does not light – After the lamp test an extinguished lamp indi-

cates an error-free and trouble-free operating state within the scope of the control possibility.

Continuous light – Error in the system. – Operation continued with restrictions. – The engine must be checked by a DEUTZ

partner.

– If a lamp lights steadily a monitored measur-

ing variable (e.g. coolant temperature, lubricating oil pressure) has left the permissible

value range. Depending on the fault, the engine power may be reduced by the electronic engine control to protect the engine.

Flashing – Serious error in the system. – Switch off prompt for the operator. Attention:

Failure to do so will lead to loss of guaran-

tee! – The engine has reached switch-off condition. – Engine forced to run at low idle speed to cool

the engine, with automatic shutdown if nec-

essary.

– The switch-off process has been accom-

plished. – There may be a start lock after engine stop. – The start lock is deactivated by turning off the

system with the ignition key for approx. 30s. – Additional control lamps, e.g. for lubricating

oil pressure or lubricating oil temperature,

are switched on if necessary. – The power reduction can be bypassed, the

automatic switch-off delayed or a start lock

bypassed with the override key on the instru-

ment panel to avoid critical situations. This

brief deactivation of the engine protection

functions is logged in the control unit. The engine protection functions are released in

co-operation with the equipment manufacturer and the DEUTZ installation consulting and may be designed individually. It is therefore absolutely essential to observe the operating instructions of the equipment manufacturer.

Display instrument

Possible displays:

Colour scale – Display of operating state by coloured areas: – green = normal operating state – red = critical operatng state

Take suitable action.

Measured value scale – Actual value can be read off directly. The

nominal value should be taken from the Technical Data (



72).

Page 30

Operation Operation monitoring

Instruments and symbols

Instruments/symbols Designation Possible display: Measure

Lubricating oil pressure display

Coolant temperature Coolant temperature too high Switch off engine

Lubricating oil temperature Lubricating oil temperature too high Switch off engine

Lubricating oil pressure pilot lamp

Lube oil level If the pilot lamp lights up after starting the engine or

Coolant level If the control lamp lights up after the engine starts or

Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals

Lubricating oil pressure in the red area Switch off engine

If the pilot lamp lights up after starting the engine or while the engine is running, the lubricating oil pressure is too low

while the engine is running, the lubricating oil level is too low

while the engine is running, the coolant level is too low

Switch off engine

Fill up lube oil

Shut down the engine, allow to cool and top up coolant



Horn With acoustic signal See fault table (

61).

Page 31

Stop procedure Operation

Shutting off

Avoid switching off from full load (coking/ blockage of the remaining lubricating oil in the turbocharger bearing housing). The lubricating oil supply of the turbocharger is then no longer guaranteed! This shortens the life of the turbocharger. Run the engine in low idling speed for approximately one minute after relieving the load. The control unit remains active for about another 40 seconds to save the system data (lag) and then switches off automatically.

Run engine up to idling speed.

Move the key to position 0. Control lamps A+B+C go out.

Page 32

Operating media Lubricating oil

General

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

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

In principle, all engine oils of the same specification can be mixed. However, mixing of engine oils should be avoided because the worst properties of the mixture are always dominant.

The lubricating oils approved by DEUTZ have been thoroughly tested for all engine applications. The active ingredients they contain are compatible with each other. Therefore, the use of additives for lubricating oils is not permitted in DEUTZ engines.

lubricating oil quality

The ence on the life, performance and thus also on the costs-effectiveness of the engine. It basically applies that: The better the lubricating oil quality, the better these properties.

lubricating oil viscosity

The

has a considerable influ-

describes the way the

lubricating oil flows, depending on the temperature. The lubricating oil viscosity only has a small influence and effect on the quality of the oil.

Synthetic lubricating oils

and offer advantages. These lubricating oils have better temperature and oxidation stability as well as relatively low cold vicosity. Since some processes which are relevant for determining the lubricating oil change times are largely dependent on the oil quality (e.g. the infiltration of soot and other contamination), the oil change time for synthetic lubricating oils may not be increased in relation to the specifications on lubricating oil change intervals.

Biodegradable lubricating oils

DEUTZ engines if they meet the requirements of this operating manual.

Quality

Lubricating oils are classified by DEUTZ according to their performance and quality class (DQC: DEUTZ Quality Class). Essentially, the following applies: the higher the quality class (DQC I, II, III, IV), the more effective/the better quality the lubricating oil is.

Lubricating oils according to other comparable specifications can be used as long as they meet DEUTZ requirements. In regions in which none of these qualities are available, please contact your responsible DEUTZ partner.

or see www.deutz.com

http://www.deutz.com

en \SERVICE \Betriebsstoffe und Diag-

eutz Quality Class\

nose\

beliste

are used increasingly

may be used in

DQC-Freiga-

http://www.deutz.com

en \SERVICE \Operating Media and Diagno-

eutz Quality Class\

sis\

Minimum quality class DEUTZ Others

DQC II ACEA E3-96; E4-07; E5-02; E7-04

The lubricating oils may only be used in conjunction with an open crankcase breather.

The following lubricating oils are recommended for the engines in this operating manual:

Recommended quality class DEUTZ Others

DQC III Please contact your DEUTZ partner DQC IV

DEUTZ lubricating oils DQC III TLX - 10W40 FE

Container Order number:

5 litre container 0101 6335 20 litre container 0101 6336 209 litre barrel 0101 6337

DEUTZ lubricating oils DQC IV synthetic DQC IV - 5W30-UHP

Container Order number:

20 litre container 0101 7849 209 litre barrel 0101 7850

API CH-4/CG-4; CI-4,CI-4, CJ-4; DHD-1

DQC Release List

Page 33

Lubricating oil Operating media

-5

-10

-15

-20

-25

-30

-35

-40

°C

SAE 10W-40

SAE 20W-50

SAE 5W-30

SAE 0W-40

SAE 0W-30

SAE 15W-40

SAE 5W-40

SAE 10W-30

Lubricating oil change intervals

The intervals depend on: – lubricating oil quality – sulphur content in the fuel – type of application of engine

The lubricating oil change interval must be halved if at least one of the following conditions applies:

– Constant ambient temperature below -10 °C

(14 °F) or lube oil temperature below 60 °C (84 °F).

– Sulphur content in diesel fuel of >0.5 weight

% .

– operation with bio-diesel fuel

If the lubricating oil change intervals are not reached within a year, the oil should be changed at least once a year.

Viscosity

The ambient temperature at the installation site or in the application area of the engine is decisive for choosing the right viscosity class. Too high a viscosity can lead to starting difficulties, too low a viscosity can endanger the lubrication effect and cause a high lubricating oil consumption. At ambient temperatures below -40 °C, the lubricating oil must be pre-heated (e.g. by storing the vehicle or the machine in a hall).

The viscosity is classified according to SAE. Multipurpose lubricating oils should be used basically. Single-purpose lubricating oils can also be used in enclosed, heated spaces at temperatures >5 ° C.

The prescribed lubricating oil quality must be observed when selecting the viscosity class!

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

Page 34

Operating media Fuel

Permissible fuels

The following fuel specifications / standards are approved:

Diesel fuels – EN 590 –NATO F-54 – ASTM D 975 1-D – ASTM D 975 2-D – JIS K2204 Grade 1 – JIS K2204 Grade 2

Jet fuels –NATO F34 –NATO F35 Only for mechanical injection system Pump-pipe-nozzle

Biodiesel fuel – EN 14214

Use commercially available fuels with a sulphur content below 0.5 %. The lubricating oil change intervals must be halved at a higher sulphur content.

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

The certification measurements for compliance with the legal emission values are made with the test fuels specified in the laws. These correspond to the diesel fuels in accordance with EN 590 and ASTM D 975 described in the operation manual. No emission values are guaranteed with the other fuels described in this operation manual.

The respective fuels prescribed by law must be used to comply with the national emission regulations (e.g. sulphur content).

Please contact your DEUTZ partner

http://www.deutz.com

en \SERVICE\Betriebsstoffe und Diag-

en \SERVICE\Oils, Lubricants, Diagnosis\

Winter operation with diesel fuel

At low ambient temperatures paraffin discharges can lead to blockages in the fuel system and cause operating faults. Below 0 °C ambient temperature use winter diesel (down to -20 °C) (filling stations provide this in good time before the cold season starts).

If it is necessary to use Summer diesel fuel below 0 °C, up to 30 % petroleum can be added according to the diagram opposite.

Usually a sufficient cold resistance can be achieved by adding a flow improver. Ask your DEUTZ partner.

Kraftstoffe

nose\

Fuel

Only carry out mixing in the tank. Fill with the appropriate amount of paraffin first, then add the diesel fuel. Normal and high grade fuels may not be mixed.

Below -20 °C paraffin should be added. The relevant percentages are given in the adjacent diagram.

Special diesel fuels can be used for arctic climates to -44 °C.

I Summer-grade diesel fuel II Winter-grade diesel fuel A Outdoor temperature B Percentage of paraffin to be added

Page 35

Coolant Operating media

General

Never operate the engine without coolant, even for a short time!

In liquid-cooled engines, the coolant must be conditioned and monitored, otherwise the engine could be damaged by:

corrosion

cavitation

freezing

overheating

Water quality

The right water quality is important for conditioning the coolant. Clear, clean water within the following analysis values should always be used:

Analysis values min max ASTM

ph value 6,5 8,5 D 1293 Chlorine (Cl) [mg/l] - 100 D 512

Sulphate (SO Total hardness

(CaCO

Specifications of the water quality are made by the local water board.

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

pH value too low:

Addition of diluted sodium or potassium lye. Small trial mixtures are advisable.

) [mg/l] - 100 D 516

)

[mmol/l]

0,54543,56

[mg/l]

[°dGH] 3,0 20,0 -

D 4327

D 1126

356

Total hardness too high:

Mixing with softened water (pH neutralized condensate or water softened by ion exchanger).

Total hardness or carbonate hardness too low:

Mixing with harder water (harder water is usually available in the form of drinking water).

Chlorides and/or sulphates too high:

Mixing with softened water (pH neutralized condensate or water softened by ion exchanger).

Cooling system corrosion protection agent

Health damaging nitrous amines form when nitrite-based cooling system corrosion protection agents are mixed with amine-based agents!

Cooling system corrosion protection agents must be disposed of in an environmentally friendly way.

The conditioning of the coolant for liquid-cooled DEUTZ compact engines is performed by mixing an anti-freeze with corrosion protection inhibitors based on ethylene glycol into the water.

DEUTZ cooling system corrosion protection agent

Container Order number:

5 litre container 0101 1490 20 litre container 0116 4160 210 litre barrel 1221 1500

This cooling system corrosion protection agent is free from nitrite, amine and phosphate and is adapt-

ed to the materials in our engines. Order from your DEUTZ partner.

Please contact your DEUTZ partner if the DEUTZ cooling system corrosion protection agent is not available.

or see www.deutz.com

http://www.deutz.com

en \SERVICE\Betriebsstoffe und Diag-

en \SERVICE\Oils, Lubricants, Diagnosis\

The cooling system must be monitored regularly. This also includes checking the coolant system corrosion protection agent concentration in addition to checking the coolant level.

The cooling system corrosion protection agent concentration can be checked with conventional test instruments (e.g. refractometer).

Cooling system corrosion protection agent percentage

At temperatures below -35 °C, please contact your responsible DEUTZ partner.

It is possible to use other cooling system corrosion protection agents (e.g. chemical corrosion protection agents) in exceptional cases. Consult your DEUTZ partner.

Kühlsystemschutz

nose\

ing System Conditioner

Water percentage

min. 35 % 65 % -22 °C

40 % 60 % -28 °C

max. 45 % 55 % -35 °C

Cool-

Cold protection up to

Page 36

Maintenance Maintenance schedule

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals

Standard maintenance schedule TD/TCD 2012/2013 L04/L06 2V

Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)

E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation E30 Maintenance Qualified personnel 500 E40 Extended maintenance I 1000 E45 Interim stage 2000 E50 Extended maintenance II Authorised specialists 3.000

EPA-certified engines

The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.

Deviations from the standard maintenacne schedule for engines subject to EPA certification

Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)

E60 Intermediate overhaul Authorised specialists 6.000

Observations

The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (32).

For engines TD/TCD 2012 L04 2V with mechanical injection system, which are predominantly operated at a high load and a high speed, the lubricating oil change interval is reduced to 250 h.

Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.

1) 2) 3)

Page 37

Maintenance schedule Maintenance

Maintenance measures

Stage Activity Measure Page

E10 The measures are listed in chapter 3. E20 Check Lubricating oil level (if necessary top up)

Coolant level (top up if necessary) Engine tightness (visual inspection for leaks) Suction air filter/dry air filter (maintain in accordance with maintenance indicator)

E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application

type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.

Lubricating oil filter/insert (every time the lubricating oil is changed) Check Coolant (additive concentration) Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary)

E40 Check Charge air cooler entry area (drain lube oil/condensate)

Crankcase breather valve

Check valve in the fuel return line (for mechanical injection system)

Cold starting device

Battery and cable connectors

V-belts (retension or renew if necessary)

Cold starting device

Engine mounting (tighten, replace if damaged when necessary)

Fastenings, hose unions / clips (renew if damaged) Replace Fuel filter cartridge

Fuel pre-filter with water trap (renew the filter insert if necessary). If the warning system responds (lamp/horn), the

water trap bowl must be emptied immediately.

Suction air filter/dry air filter (maintain in accordance with maintenance indicator)

E45 Settings Valve clearance

Control piston clearance of exhaust return (optional)

E50 Replace V-belt, V-rib belt and tensioning pulley



32/39



25 39 26

40 48 45

59 53

43 45

52 56 58 53

Page 38

Maintenance Maintenance schedule

Stage Activity Measure Page

E60 Replace Injection valve

Crankcase breather valve

V-belt, V-rib belt and tensioning pulley Clean Charge air cooler entry area (drain lube oil/condensate)

Turbocharger compressor outlet

annually Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel

Replace Fuel pre-filter

Every 2 years

Maintenance work outside the DEUTZ maintenance and service schedules

*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.

Maintenance profile

A self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment.

Order number: 0312 3712 (TD/TCD 2012 2V) / 0312 3713 (TCD 2013 2V)

Replace Dry air filter

V-belt, V-rib belt and tensioning pulley

Coolant Check Crankcase breather valve



35

45 52 53

Page 39

Lubricating oil system Servicing and maintenance works

Regulations for working on the lubricating oil system

Do not work when the engine is running! Smoking and naked lights prohibited! Be careful of hot lubricating oil. Danger of scalding!

Pay attention to utmost cleanliness when working on the lubricating oil system. Clean the area around the components concerned carefully. Blow damp parts dry with compressed air. Observe the safety regulations and national specifications for handling lube oils. Dispose of leaking lubricating oil and filter elements properly. Do not allow used oil to seep away into the ground. Perform a trial run after all work. Pay attention to tightness and lubricating oil pressure and then check the engine oil level. In case of fuels containing more than 1% sulphur, contact your corresponding DEUTZ partner.

OIL ?

Checking the lubricating oil level

Low lubricating oil level and overfilling lead to engine damage. The lubricating oil level may only be checked with the engine in a horizontal position and switched off. If the engine is warm, switch off the engine and check the lubricating oil level after 5 minutes. If the engine is cold you can check it immediately.

Be careful of hot lubricating oil. Danger of scalding! Do not pull out the dipstick while the engine is running. Danger of injury!

Pull out the lubricating oil dipstick and wipe off with a lint-free, clean cloth.

Insert the lubricating oil dipstick as far as it will go.

OIL

+80°C +176°F

Extract the lubricating oil dipstick and read off the oil level.

The oil level must always be between the MIN and MAX marks! Top up to the MAX mark if necessary.

Changing the lubricating oil

Warm up the engine (lubricating oil temperature >80°C).

Ensure that the engine or vehicle is in a level position.

Switch off the engine.

Place a collecting receptacle underneath the lube oil drain screw.

Unscrew the lube oil drain screw, drain oil.

Fit a new sealing ring to the lube oil drain screw, insert and tighten. (tightening torque 100 Nm).

Pour in lube oil.



– Quality/viscosity data ( – Filling volume (

Warm up the engine (lubricating oil temperature >80°C).

Ensure that the engine or vehicle is in a level position.

Check lubricating oil level, if necessary top up.

33).



72).

Page 40

Servicing and maintenance works Lubricating oil system

Change lubricating oil filter

The filter cartridge should never be prefilled. There is a danger of dirt contamination!

Remove clamps when twist protection mounted (optional).

Loosen and unscrew filter cartridge with tool

der number: 170050)

Collect draining lubricating oil

Clean the sealing surface of the filter support with a lint-free, clean cloth.

(or-

Oil the gasket of the new DEUTZ original filter cartridge lightly.

Screw on new filter by hand until the gasket is touching and tighten with a torque of:

15-17 Nm

Fasten clamps of the twist protection (optional).

Page 41

Lubricating oil system Servicing and maintenance works

Replace lubricating oil filter cartridge

The filter cartridge should never be prefilled. There is a danger of dirt contamination!

1 Cover 2 Sealing ring 3 Housing 4 Guide 5 Filter insert 6Bracket

Switch off the engine.

Loosen cover by turning 2-3 times and wait for 30 seconds.

Unscrew cover with filter cartridge anti-clockwise.

Loosen the filter cartridge carefully out of the guide in the housing and upwards.

Collect draining lubricating oil

Bend the filter cartridge in the collecting container slightly to the side until the cartridge comes out of the bracket.

Clean components.

Replace gasket and oil lightly.

Press new filter cartridge into bracket and place them carefully into the guide.

Screw the cover clockwise (25 Nm).

Start engine.

Page 42

Servicing and maintenance works Fuel system

Specifications when working on the fuel system

Engine must be switched off! Smoking and naked lights prohibited! No injection/high pressure pipes may be disconnected while the engine is running. Caution when handling hot fuel! Pay attention to utmost cleanliness when refuelling and working on the fuel system. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Dispose of leaking fuel and filter elements properly. Do not allow fuel to seep away into the ground. After all work on the fuel system, the system should be vented, a trial run performed and the tightness checked. It will be necessary to vent the fuel system when commissioning for the first time, after maintenance work or if the tank has been run dry.

Additional venting of the fuel system by a 5 minute trial run at idle speed or on low load is absolutely essential. Pay attention to utmost cleanliness due to the high production accuracy of the system! The fuel system must be tight and closed. Make a visual inspection for leaks/damage in the system.

Clean and dry the engine and engine compartment thoroughly before beginning work. Areas of the engine compartment from which dirt could be loosened must be covered with a fresh, clean foil. Work on the fuel system may only be carried out in an absolutely clean environment. Contamination of the air such as dirt, dust, moisture etc. must be avoided.

Page 43

Fuel system Servicing and maintenance works

Change the fuel filter cartridge

The filter cartridge should never be prefilled. There is a danger of dirt contamination!

Remove clamps when twist protection mounted (optional).

Loosen and unscrew filter cartridge with tool

der number: 170050)

Catch any escaping fuel.

Clean the sealing surface of the filter support with a lint-free, clean cloth.

(or-

Oil the gasket of the new DEUTZ original filter cartridge lightly.

Screw on new filter by hand until the gasket is touching and tighten with a torque of:

10-12 Nm

Fasten clamps of the twist protection (optional).

Vent the fuel system.

Page 44

Servicing and maintenance works Fuel system

Replace fuel filter cartridge

The filter cartridge should never be prefilled. There is a danger of dirt contamination!

1 Cover 2 Sealing ring 3 Housing 4 Guide 5 Filter insert 6Bracket

Switch off the engine.

Loosen cover by turning 2-3 times and wait for 30 seconds.

Unscrew cover with filter cartridge anti-clockwise.

Loosen the filter cartridge carefully out of the guide in the housing and upwards.

Catch any escaping fuel.

Bend the filter cartridge in the collecting container slightly to the side until the cartridge comes out of the bracket.

Clean components.

Replace gasket and oil lightly.

Press new filter cartridge into bracket and place them carefully into the guide.

Screw the cover clockwise (25 Nm).

Start engine.

Page 45

Fuel system Servicing and maintenance works

Clean/change/vent the fuel pre-filter

1 Fuel pre-filter holder 2 Fuel filter insert 3 Water collection vessel 4 Water drain tap 5 Fuel pump 6 Sealing surface 7 Venting screw

Shut off the fuel supply to the engine (with highlevel tank).

Place a vessel under the drain plug.

Open the drain cock and drain liquid.

Unscrew the filter insert (2) together with the water collection vessel (3).

Empty emulsion in the water collection vessel (3) and clean the vessel.

Mount the filter insert (2) and water collection vessel (3). Wet the sealing surfaces (6) of the filter insert (2) and the water collection vessel (3)

with fuel.

Assembly in clockwise direction.

Open the fuel shutoff tap and vent the system, see venting the fuel system.

Start engine.

Check for leaks after starting the engine.

Change the fuel pre-filter insert

Shut off the fuel supply to the engine (with highlevel tank).

Place a vessel under the drain plug.

Open the drain cock and drain liquid.

Unscrew the filter insert (2) together with the water collection vessel (3).

Unscrew the water collection vessel (3) from the filter insert (2). – The special tool can be ordered under part

Clean the water collection vessel (3) and all the existing sealing surfaces (6) with a brush and diesel fuel.

Oil the gaskets and sealing surfaces (6) of the new DEUTZ original filter insert (2) lightly or wet with diesel fuel.

Screw the water collection vessel (3) to the filter insert (2).

Screw a new filter insert (2) with water collection vessel (3) onto the filter carrier 1) (tightening torque 17-18 Nm)

Open the fuel supply to the engine.

Vent the fuel system.

Vent the fuel pre-filter.

Loosen vent screws slightly.

Operate the pump until fuel emerges without

number

8192 (

76).

bubbles.

Catch any escaping fuel.

Tighten vent screw.

Vent the fuel system

Bring engine control to stop position.

Position fuel collecting vessel below the constant-pressure valve in the crankcase/filter housing.

Open constant-pressure valve in the crankcase/ fuel stopcock in the filter housing.

Turn over the engine with starter (max. 20 Sec.) until bubble-free fuel emerges at the constantpressure valve in the crankcase/filter housing.

Screw in ventilation screws (tightening torque 25-5 Nm) and constant-pressure valve.

Bring engine control to the start position and start.

Check for leaks after starting the engine.

Page 46

Servicing and maintenance works Fuel system

Clean/change/vent the fuel pre-filter

1 Venting screw 2 Cover 3Screw 4 Spring cassette 5 Filter insert 6 Water collection vessel 7 Electrical connection 8 Water drain tap

A warning system (lamp/horn) should be installed via the electric connections. If the warning system is triggered, immediate maintenance is required.

Cleaning/purging, draining of water

Switch off the engine or switch over to the other filter in case of switchable filter.

Shut off the fuel supply to the engine (with high-

level tank).

Place suitable collecting containers underneath.

Loosen vent screws slightly.

Open the drain cock and drain liquid. – To open, the drain cock must be pressed

lightly and turned.

Close the drain cock.

Tighten vent screw.

Vent the fuel system.

Change the fuel pre-filter insert

Change after maintenance interval, loss of power, or annually.

Switch off the engine or switch over to the other filter in case of switchable filter.

Shut off the fuel supply to the engine (with highlevel tank).

Loosen screws diagonally.

Remove cover.

Remove spring cassette.

Change filter cartridge

Place spring cassette on the filter cartridge.

Check the cover gasket for correct fit and damage (change if necessary).

Tighten cover with screws diagonally (tightening torque 6Nm).

Check for leaks after starting the engine.

Vent the fuel system.

Vent the fuel system

Shut down engine

Position fuel collecting vessel below the constant-pressure valve in the crankcase/filter housing.

Open constant-pressure valve in the crankcase/ fuel stopcock in the filter housing.

Start engine. – Turn over the engine with starter (max.

20 Sec.) until bubble-free fuel emerges at the constant-pressure valve in the crankcase/filter housing.

Shut down engine – Screw in ventilation screws (tightening

torque 25-5 Nm) and constant-pressure valve.

Start engine. – Bring engine control to the start position and

start.

– Check for leaks after starting the engine.

Page 47

Fuel system Servicing and maintenance works

Clean/change/vent the fuel pre-filter

eutz Common Rail (

1 Fuel supply flow to the pump 2 Fuel return flow from the control block FCU (Fuel

Control Unit) 3 Fuel pump 4 Thermostat valve with stop lever (optional) 5 Filter insert 6 Electrical connection for water level sensor 7 Water drain tap 8 Water collection vessel 9 Fuel inlet from the fuel tank 10 Fuel return to fuel tank 11 Connection for electrical warning lamp/horn

Change the fuel pre-filter insert

Shut off the fuel supply to the engine (with high-

level tank).

Place suitable collecting containers underneath.

DCR

)

Open the drain cock and drain liquid.

Unscrew the filter cartridge together with the water collection vessel in anticlockwise direction and remove.

Loosen the water collection vessel from the old filter cartridge by turning anti-clockwise and remove.

– The special tool can be ordered under part

Empty any fuel remaining in the fuel collection vessel and clean the water collection vessel.

Screw the water collection vessel clockwise onto the new filter cartridge.

Clean any dirt off the sealing surfaces of the new filter cartridge and opposite side of filter head.

Wet the sealing surfaces of the filter cartridge slightly with fuel and screw back on to the filter head, clockwise (17-18 Nm).

Open the fuel shutoff tap and vent the system, see venting the fuel system.

Vent the fuel system

Unlock the bayonet connection of the fuel supply pump by pressing upwards and simultaneously turning anticlockwise. The pump pistons are now pressed out through the spring.

Keep pumping until a very strong resistance can be felt and the pumping only progresses very slowly.

Now continue pumping several times. (The return line must be filled).

Lock the bayonet connection of the fuel supply pump by pressing upwards and simultaneously turning clockwise.

Start the engine and operate approx. 5 minutes

number

8192 (

76).

in idling mode or at low load. Check the pre-filter for leaks while doing this.

Page 48

Servicing and maintenance works Cooling system

Specifications when working on the cooling system

Danger of scalding from hot coolant! Cooling system under pressure! Only open the cap when cool! The coolant must have a prescribed concentration of cooling system corrosion protection agent! Observe safety regulations and national specifications when handling cooling media. Observe the manufacturer's specifications for an external cooler. Dispose of leaking liquids properly and do not allow them to seep into the ground. Order coolant corrosion protection agent from your DEUTZ partner. Never operate the engine without coolant, even for a short time!

Checking the coolant level with an external cooler

Fill in new coolant and vent the system according

to the specifications of the cooling system manu-

facturer.

Open the cooling system cap (1) carefully.

The coolant level must always be between the

MIN and MAX marks of the compensation tank!

Fill up to the MAX mark if necessary.

Check coolant additive concentration

Open the cooling system cap (1) carefully.

Check the coolant aditive concentration in the cooler/compensation tank (2) with a conventional antifreeze measuring device (1) (e.g. hydrometer, refractormeter).

Necessary coolant additive concentration Coolant mixing ratio (

You can order the appropriate test instrument from your DEUTZ partner under order number 1824.



35).

Emptying the cooling system

Open cooler locking cap carefully.

Place suitable collecting containers underneath.

Remove the locking screw (1) in the crankcase.

Drain coolant.

If the locking screw is not accessible, the drainage can be carried out at the engine oil cooler (coolant duct).

Insert screw again with sealant.

Close cooler locking cap.

Page 49

Cooling system Servicing and maintenance works

Fill and ventilate cooling system

Danger of scalding from hot coolant! Cooling system under pressure! Only open the cap when cool!

Open the cooling system cap (1) carefully.

Loosen the cooler venting screw if necessary.

Fill coolant up to the max. mark or filling limit.

Switch on any available heating and set to the

highest level so that the heating circuit is filled

and vented.

Close cooler locking cap.

Run engine up to operating temperature (open-

ing temperature of the thermostat).

Switch off the engine.

Check coolant level in cooled engine and top up

to the MAX mark or filling level on the compensa-

tion tank if necessary.

Page 50

Servicing and maintenance works Engine cleaning

Cleaning work

For all cleaning work, make sure that no parts are damaged (e.g. bent cooler mesh). Cover electrical/electronic parts and connections to clean the engine (e.g. control units, generator, solenoid valves etc.). Do not aim the water/steam jet directly at them. Allow engine to warm up.

Only carry out cleaning work on the engine when it is not running! Remove the engine cover and cooling air cover if available and remount after cleaning.

General

The following causes of soiling make it necessary to clean the engine:

High dust content in the air.

Chaff and chopped straw in the area of the en-

gine.

Coolant leaks

Lubricating oil leakage

Fuel leaks

Because of the different application conditions, cleaning depends on the degree of dirt contamination.

Cleaning with compressed air

Blow dirt off or out. Always blow out the cooler

and cooling fins from the exhaust air side to the

fresh air side.

Cleaning with cold cleaner

Spray the engine with cold cleaner and leave it for about 10 minutes to take effect.

Spray the engine clean with a high pressure water jet.

Warm up the engine so that the water residues evaporate.

Cleaning with a high pressure cleaner

Clean the engine with a steam jet (maximum spray pressure 60 bar, maximum steam temperature 90 °C, distance at least 1m).

Warm up the engine so that the water residues evaporate.

Always clean the cooler and cooling fins from the exhaust air side to the fresh air side.

Page 51

Aspiration system Servicing and maintenance works

Regulations for working on the intake system

Do not work when the engine is running!

Pay attention to utmost cleanliness when working on the intake system, close intake openings if necessary. Dispose of old filter elements properly.

4 3

Maintaining the dry air filter

Do not clean the filter element (3) with petrol or hot liquids! Renew damaged filter elements.

Maintain the filter element (3) according to the interval in the maintenance schedule

Lift up the clamping yoke (1).

Remove the filter hood (2) and pull out the filter element (3).

Filter element (3): – blow out with dry compressed air (max. 5

bar) from the inside to the outside if soiling is only slight,

– renew if heavily soiled.

Renewing the safety cartridge of the dry air filter

Never clean the safety cartridge (4).

Renew safety cartridge (4) according to the interval in the maintenance schedule

To do this: – Unscrew hexagon nut (5), pull out safety car-

tridge (4).

– Insert new safety cartridge, screw on hexag-

onal nut.

Insert filter element (3), mount hood (2) and fix with clamping yoke (1).

Page 52

Servicing and maintenance works Aspiration system

Maintenance indicators for dry air filter

The dry air filter is maintained according to a

maintenance switch or maintenance indicator.

Maintenance is necessary when:

– the yellow warning light of the

– the red field (1) of the

After carrying out maintenance work, reset the

signal by pressing the button on the mainte-

nance indicator. The maintenance indicator is

now ready for operation again.

lights up when the engine is running.

switch

is fully visible.

tor

maintenance

maintenance indica-

Clean the dust discharge valve of the dry air filter

Empty the dust discharge valve (1) by pressing together the discharge slit.

Remove any caked dust by pressing together the upper section of the valve.

Clean the discharge slit.

Emptying the cyclone precleaner

Never fill the dust container (3) with lubricating oil!

Loosen wing nut (1) and lift off housing cover (2).

Remove the dust container (3) from the base (4) and empty it. Clean the container using a brush and clean diesel fuel. Then dry.

Place the dust container (3) on the base (4) and tighten the housing cover (2) with wing nut (1).

Page 53

Belt drives Servicing and maintenance works

Checking the belt drive

Only carry out work on the belt drive with the engine at a standstill! Always change both belts in sets in case of wear on the double belts or damage to one V-belt. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine.

Check the whole belt drive visually for damage.

Renew damaged parts.

Remount protective devices if necessary.

Pay attention to correct fit of new belts, check the

tension after running for 15 minutes.

Checking the belt tension

Lower indicator arm (1) into the measuring device.

Place guide (3) between two belt pulleys on the V-belt (2). The stop have to be at the side.

Press the button (4) at right angles to the V-belt (2) evenly until you hear or feel the spring snap in.

Lift the measuring device carefully without altering the position of the indicator arm (1).

Read the measured value at the point of intersection (arrow), scale (5) and indicator arm (1).

If necessary, re-tension belt and measure again.

Tools

Belt tension measuring device

can be obtained from your DEUTZ partner.

8115)

(order number:

Change generator V-belts

1 Setting screw 2 Lock nut 3Screw 4 V-belts

Remove screw and lock nut.

Move the generator over the setting screw in direction (B) until the V-belt is slack.

Remove belt and fit new one.

Move the generator over the setting screw in direction (A) until the V-belt has attained the correct tension.

Tighten screw and lock nut again.

Page 54

Servicing and maintenance works Belt drives

Change the belt

Remove generator V-belts.

Loosen screws (1) and (2) and (3).

Move the tensioning pulley (3) in the direction of

the arrow (B).

Remove belt and fit new one.

Plug socket wrench insert of the torque wrench

ino the opening (4) of the tensioning pulley (3).

Move the tensioning pulley (3) with the torque

wrench in the direction of the arrow (A) until the

correct belt tension is reached.

Retighten the screws (1) and (2).

Checking the belt tension (53).

Mount generator V-belts.

Page 55

Belt drives Servicing and maintenance works

Replace V-rib belt

Press tensioning pulley (1) with pin wrench (3) in

the direction of the arrow until a holding pin

Ø 6 mm (4) can be fixed in the assembly bore.

The V-rib belt (2) is now free of tension.

First remove the V-rib belt (2) from the smallest

pulley or from the tensioning pulley.

Mount V-rib belt (2).

Retain tensioning pulley using the pin wrench

and remove the holding pin.

Re-tension using the tensioning pulley and pin

wrench (3). Check whether the V-rib belt is cor-

rectly in its guide.

Check belt length

Measure the gap between the journal of the movable tensioning arm and the stop of the fixed housing.

If gap "a" is less than 3 mm, the belt must be replaced.

Page 56

Servicing and maintenance works Setting work

Check valve clearance, adjust if necessary



Let the engine cool down for at least 30 minutes

before setting the valve clearance: Lubricating oil

temperature below 80 °C.



Release screws.



Remove the cylinder head hood.



Remove gasket.



Place turning gear over fastening screws of the

belt pulleys.



Turn the crankcase until reaching valve overlap.

Outlet valve is not yet closed, inlet valve begins to open.

The cylinders to be set can be seen in the setting schematic.

TD/TCD2012/2013L04 2V

Valve overlap Settings

TCD2012/2013L06 2V

Valve overlap Settings

Set valve clearance (inner exhaust recirculation)

1 Lock nut 2 Setting screw 3 Rotary angle disc 4 Insert 5 Magnet



Fit the rotary angle disc with socket wrench inset on the setting screw.



Fix magnet of the rotation angle disc.



Turn rotation angle disc clockwise to the stop (rocker arm without clearance) and set scale to zero.



Turn rotation angle disc anticlockwise until reaching the specified rotation angle:

Valve clearance

TD/TCD 2012

Inlet valve 75°

Outlet valve 120°

+ 10°

Valve clearance

TD/TCD 2013



Secure the rotation angle disc against twisting.



Turn rotation angle disc clockwise to the stop (rocker arm without clearance) and set scale to zero.



Tighten locking nut.

Tightening torque 20 Nm



Then set the second valve on the rocker arm as described above.



Perform the setting procedure on every cylinder.



Remount the cylinder head cover with a new gasket in the reverse order of disassembly.



Tighten screws.

Tightening torque 22 Nm

Inlet valve 90°

Outlet valve 150°

+10°

Page 57

Setting work Servicing and maintenance works

Set valve clearance (with internal exhaust gas recirculation EGR connected)

1 Lock nut 2 Setting screw 3 Rotary angle disc 4Insert 5 Magnet

The same setting regulation applies for the outlet valves as for engines without exhaust gas recirculation.

Set inlet valve

Fit the rotary angle disc with socket wrench inset

on the setting screw.

Fix magnet of the rotation angle disc.

Turn rotation angle disc clockwise to the stop

(rocker arm without clearance) and set scale to

zero.

Turn rotation angle disc anticlockwise until

reaching the specified rotation angle:

Valve clearance TD/TCD 2012

Valve clearance TD/TCD 2013

Secure the rotation angle disc against twisting.

Turn rotation angle disc clockwise to the stop (rocker arm without clearance) and set scale to zero.

Tighten locking nut.

Tightening torque 20 Nm

Then set the second valve on the rocker arm as described above.

Perform the setting procedure on every cylinder.

Remount the cylinder head cover with a new gasket in the reverse order of disassembly.

Tighten screws.

Inlet valve 75°

Outlet valve 120°

Inlet valve 90°

Outlet valve 150°

+ 10°

Tightening torque 22 Nm

Page 58

Servicing and maintenance works Setting work

Set control piston clearance (with internal exhaust gas recirculation EGR connected)

1 Lock nut 2 Setting screw

After setting the valve clearance, the control piston clearance should be set as follows:

Turn the crankcase until reaching valve overlap

of the first cylinder.

Outlet valve is not yet closed, inlet valve begins

to open.

The cylinders to be set can be seen in the setting

schematic.

Loosen lock nut.

Fit the rotary angle disc with socket wrench inset on the setting screw.

Fix magnet of the rotation angle disc.

Turn rotation angle disc clockwise to the stop (control piston without clearance) and set scale to zero.

Turn rotation angle disc anticlockwise until reaching the specified rotation angle:

Control piston clearance 144°

Tighten locking nut.

Perform the setting procedure on every control piston.

Page 59

Electrical system Servicing and maintenance works

Regulations for working on the electrical system

Do not touch the voltage conducting parts, faulty warning lamps should be immediately replaced.

Pay attention to correct polarity of the connections. Cover electrical/electronic parts and connections to clean the engine (e.g. control units, generator, solenoid valves etc.). Do not aim the water/steam jet directly at them. Allow engine to warm up. Touching a lead against the frame to check whether it is live must not, under any circumstances, be carried out. For electrical welding work, the ground terminal of the welding gear must be clamped directly to the part being welded. Three-phase current generator: Never disconnect the cables between battery, generator and regulator while the engine is running.

Battery

Electronically stored data could be lost if the battery is disconnected. Keep battery clean and dry. Make sure the battery is fitted correctly and securely. Dispose of old batteries in an environmentally friendly way.

Danger of explosion! The gases emitted by the battery are explosive! Fire, sparks, smoking and naked lights are prohibited! Danger of acid burns! Wear protective gloves and glasses! Avoid contact with skin and clothing! Danger of short circuit! Do not rest tools on the battery!

Checking the voltage

Check the battery voltage with a standard voltmeter. The voltage gives information about the charge status.

Battery Charge status (Volt)

12 Volt 12-14,4 24 Volt 24-28,4

Check acid level

Unscrew caps.

Note the manufacturer’s specifications concerning the liquid level. The liquid should normally be 10-15 mm above the top edge of the plate or reach up to any available control device.

Only use distilled water to top up the battery.

Screw in caps.

Check acid density

Unscrew caps.

Measure the electrolyte density of individual cells with a commercial hydrometer. Hydrometer reading indicates battery’s state of charge. The acid temperature when measuring should be 20 °C if possible.

Check the acid level before recharging.

Screw in caps.

Acid density [kg/ l] Charge Normal Tropical

1,28 1,23 good none 1,20 1,12 half charge 1,12 1,08 empty charge

status

Measure

Page 60

Servicing and maintenance works Electrical system

Removing the battery

Always disconnect the minus pole first when re-

moving the battery. Otherwise there is a danger

of short-circuit!

Remove the fastenings and take out the battery.

Charging the battery

Unscrew caps.

Charge the battery with a conventional battery

charger. Observe the manufacturer specifica-

tions!

Screw in caps.

Installing the battery

Insert new or charged battery and attach the fas-

tenings.

Clean the terminals and battery poles with fine

emery paper.

Connect the plus pole first and then the minus

pole. Otherwise there is a danger of short-circuit!

Make sure the terminals have good contact.

Tighten clamp bolts hand-tight.

Grease the assembled terminals with an acid-

free, acid-resistant grease.

Page 61

Fault table Faults

Faults and remedies

Faults Causes Measures

Engine does not start or is difficult to start

Engine does not start and diagnostic lamp flashes

Not disconnected (if possible) Check coupling Fuel tank empty Vent fuel system Fuel suction pipe blocked Check Below starting limit temperature Check Cold starting device Check/replace Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil Fuel quality does not comply with operating manual Change the fuel Battery defective or discharged Check battery Cable connection to starter loose or oxidized Check cable connections Starter defective or pinion does not engage Check starter Engine stop lever still in stop position

Mechanical injection system Stop magnet defective (release circuit) Check/replace Incorrect valve clearance Check valve clearance and set if necessary Air filter clogged / turbocharger defective Check/replace Air in fuel system Vent fuel system Compression pressure too low Check compression pressure Exhaust gas backpressure too high Check Injection line leaks Check injection line Engine electronics prevents starting Check error according to error code and

Check/replace

eliminate error if necessary

Page 62

Faults Fault table

Faults Causes Measures

Engine starts, but runs irregularly or fails

Speed changes are possible and diagnostic lamp lights up

Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose Incorrect valve clearance Check valve clearance and set if necessary Compression pressure too low Check compression pressure Cold starting device Check/replace Glow plugs defective Change Air in fuel system Vent Fuel filter contaminated Clean Fuel quality does not comply with operating manual Change the fuel Injector defective Change Injection line leaks Check injection line Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and

eliminate error if necessary

Page 63

Fault table Faults

Faults Causes Measures

Engine becomes excessively hot. Temperature warning system activates

Vent line blocked Clean Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil Lube oil cooler defective Check/replace Lube oil filter contaminated on the air or lube oil side Change Lube oil level too high Check lube oil level, if necessary drain off. Lubricating oil level too low Fill up lube oil Incorrect valve clearance Check valve clearance and set if necessary Injector defective Change Coolant heat exchanger soiled Clean Defective cooling water pump (torn or loose V-belt) Check whether torn or loose Low coolant Fill up Resistance in cooling system is too high / flow volume too low Check the cooling system Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension Charge air line leaking Check charge air line Charge air cooler soiled Check/clean Air filter clogged / turbocharger defective Check/replace Air filter maintenance switch / maintenance indicator defective Check/replace Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary

Page 64

Faults Fault table

Faults Causes Measures

Engine output is deficient Lube oil level too high Check lube oil level, if necessary drain off.

Lubricating oil cooler fins soiled Clean Engine stop lever still in stop position

Mechanical injection system Fuel suction temperature too high Check the system Fuel quality does not comply with operating manual Change the fuel Air filter clogged / turbocharger defective Check/replace Air filter maintenance switch / maintenance indicator defective Check/replace Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary Charge air line leaking Check charge air line Charge air cooler soiled Clean Resistance in cooling system is too high / flow volume too low Check the cooling system Injection line leaks Check injection line Injector defective Change

Engine performs poorly and diagnostic lamp lights

Engine does not run on all cylinders Injection line leaks Check injection line

Engine lubricating oil pressure is nonexistant or excessively low

Engine lubricating oil consumption excessive

Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor

Engine electronics reduce performance Please contact your DEUTZ partner

Injector defective Change Charge air line leaking Check charge air line Lube oil level too high Check lube oil level, if necessary drain off. Lubricating oil level too low Fill up lube oil Excessive inclination of engine Check engine mounting / reduce inclination Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil Lube oil level too high Check lube oil level, if necessary drain off. Excessive inclination of engine Check engine mounting / reduce inclination Crankcase breather Check/replace

Check/replace

Page 65

Fault table Faults

Faults Causes Measures

Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.

Excessive inclination of engine Check engine mounting / reduce inclination

Engine producing white smoke Below starting limit temperature Check

Cold starting device Check/replace Incorrect valve clearance Check valve clearance and set if necessary Fuel quality does not comply with operating manual Change the fuel Injector defective Change

Engine producing black smoke Air filter clogged / turbocharger defective Check/replace

Air filter maintenance switch / maintenance indicator defective Check/replace Charge air pressure-dependent full load stop defective Check Incorrect valve clearance Check valve clearance and set if necessary Charge air line leaking Check charge air line Injector defective Change

Page 66

Faults Engine management

Engine protection function of the electronic engine control

1 Diagnosis button 2 Error lamp 3 Electronic engine control (EMR)

The error lamp goes out when all the errors have been eliminated. For some errors, it is necessary to switch off the ignition, wait 30 s and only then switch back on the ignition. The appropriate monitoring functions are switched off when a sensor fails. Only the sensor failure is documented in the error memory.

Depending on the design of the monitoring functions, the electronic engine control can protect the engine in certain problematical situations by monitoring important limit values during operation and checking the correct function of the system components.

Depending on the seriousness of a recognised fault, the engine can continue to operate with limitations, during which the error lamp lights up continuously or indicates a serious system error by flashing. In this case, the engine should be switched off as soon as safely possible.

Error lamp

The error lamp is located in the vehicle drive stand. The error lamp can release the following signals:

Function test – Ignition on, error lamp lights up for approx. 2

seconds and then goes out.

– Check the error lamp if there is no reaction

after switching on the ignition.

The lamp does not light – After the lamp test an extinguished lamp indi-

cates an error-free and trouble-free operating state within the scope of the control possibility.

Continuous light Error in system. – Operation continued with restrictions. – The engine must be checked by a DEUTZ

partner.

– If a lamp lights steadily a monitored measur-

ing variable (e.g. coolant temperature, lubricating oil pressure) has left the permissible value range. Depending on the fault, the engine power may be reduced by the electronic engine control to protect the engine.

Flashing Serious error in system.

– Switch off prompt for the operator. Attention:

Failure to do so will lead to loss of guaran-

tee! – The engine has reached switch-off condition. – Engine forced to run at low idle speed to cool

the engine, with automatic shutdown if nec-

essary. – The switch-off process has been accom-

plished. – There may be a start lock after engine stop. – The start lock is deactivated by turning off the

system with the ignition key for approx. 30s. – The power reduction can be bypassed, the

automatic switch-off delayed or a start lock

bypassed with the override key on the instru-

ment panel to avoid critical situations. This

brief deactivation of the engine protection

functions is logged in the control unit. Please contact your DEUTZ-partner in case of

malfunctions and sare parts inquiries. Our specially trained personnel will ensure fast, professional repairs using original DEUTZ spare parts in case of damage.

Page 67

Engine management Faults

0,4 s

0,8 s

0,4 s

2 s

0,4 s

Diagnosis button

The diagnosis button allows the errors currently saved in the error memory of the electronic engine control to be visualised in the form of a flash code. The flash codes permit:

Errors that may occur can be classified.

Clear display of the error as visual signal. – The blink codes can only be interpreted by a

DEUTZ partner.

Use of the diagnostic key

The flash code displays all errors in the error memory, this means active as well as passive ones.

The control unit must be switched off to start the enquiry (ignition off). Then the diagnosis button should be pressed for approx. 1s during the start (ignition on).

Then the next error (i.e. the following one in the error memory) can be displayed by pressing the diagnostic key again. If the last error was displayed, the first error is displayed again on pressing the diagnostic key again.

After the display of the error flash code, the error lamp goes out for five seconds.

Display system error by flash code

Example: Flash code 1-2-8 1 x short flash 2 x long flash 8 x short flash This flash code indicates a break or short circuit in

the wiring of the charge air temperature sensor. The temporal sequence of the flash signals is shown in the illustration.

The blink codes can only be interpreted by a DEUTZ partner.

Page 68

Faults Engine management

Gear oil pressure

Battery voltage

Accelerator position

Fuel consumption

Operating hours

Error messages are displayed in clear text and acoustically; the error memory of the control unit can be read out.

For a detailed description, refer to the operating instructions enclosed with the DEUTZ Electronic Display.

DEUTZ Electronic Display

In order to show measured values and error messages of the EMR control unit, a CAN display is optionally available, which can be integrated into the dashboard of the driver´s position of working machines.

All data sent from the EMR control unit through CAN can be displayed.

Engine speed

Engine torque (current)

Lubricating oil temperature

Coolant temperature

Suction intake air temperature

Exhaust gas temperature

Gear oil temperature

Lubricating oil pressure

Coolant pressure

Charge air pressure

Fuel pressure

Page 69

Transport Transport and storage

Suspension equipment

The transport devices mounted on this engine are adapted to the engine weight. If the engine is transported with add-on components, the transport devices must be designed accordingly.

Always use proper suspension equipment when transporting the engine.

The suspension device (1) must be adjustable for the engine's centre of gravity.

After transportation and before commissioning of engine: remove attachment eyes (2).

Danger to life! The engine may tip over or fall down if suspended incorrectly!

The fastening attachment cannot be fixed securely above the centre of gravity (1).

The fastening attachment can slip, the engine swings backwards and forwards (1).

Too short a fastening attachment causes bending torques in the transport device (2) and can damage it.

Page 70

Transport and storage Engine corrosion protection

General

Engines contain the following types of corrosion protection:

Interior corrosion protection

Exterior corrosion protection

Your DEUTZ partner has the right corrosion protection agent for your needs.

The following measures for corrosion protection

ter taking the engine out of operation

quirements for 12 months corrosion protection. The following corrosion protection work may only be

carried out by persons familiar with it and instructed in the potential dangers.

If these measures are deviated from by exposing the corrosion-protected engines or parts to unfavourable conditions (installation outdoors or storage in damp, badly aired places) or damage to the corrosion protection layer, a shorter corrosion protection duration is to be expected.

The engine corrosion protection should be checked about every 3 months by opening the covers. If corrosion is detected, the corrosion protection should be renewed.

At the end of the corrosion protection work the crank drive may no longer be turned so that the corrosion protection agent in the bearings, bearing liners and cylinder liners is not scraped off.

Before operating a corrosion protected engine, the corrosion protection must be removed.

Interior corrosion protection

Interior corrosion protection is always provided

af-

meet the re-

by wetting of the walls with the implemented corrosion protection agent in a corrosion protection run of the engine.

The corrosion protection run can be performed once to protect the different systems:

Fuel system

Close the fuel/tank/supply line to the engine so that the system is protected against dirt and dust. Protect the electronics against moisture and corrosion.

Fill the fuel tank with a mixture of: – 90 % distilled fuel – 10 % corrosion protection oil.

Perform a corrosion protection run with no load for at least 5 minutes.

Lubricating oil system

Drain lubricating oil from warm engine.

Thoroughly clean lube oil tray, cylinder head with rocker arms, valves, valve springs with diesel fuel or cleaning agent.

Fill the engine with corrosion protection oil up to the MAX mark and perform a corrosion protection run for at least 5 minutes so that all the components of the lubricating oil system are wetted or wet all accessible parts with corrosion protection oil and pump corrosion protection oil through the engine with a separate pump until all bearings and bearing liners are wetted.

Cooling system

Depending on the series the engines are equipped with cooling air, cooling oil or cooling fluid system (cooling water with cooling system

protection agent).

Cooling air system, see the Exterior corrosion protection section.

In engines of the oil-cooled series the circulating lubricating oil serves simultaneously for cooling. The cooling chambers are protected automatically against corrosion with the lube oil system.

If a coolant with corrosion protection properties is poured into liquid-cooled engines, no further action is necessary after draining.

If not, the coolant must be drained and, to ensure the formation of a covering layer on the inside surfaces of the cooling system, a corrosion protection run performed with a mixture of: – 95 % treated water

– 5 % corrosion protection agent

The duration of the corrosion protection run and the concentration of the corrosion protection agent are specified by the manufacturer of the corrosion protection agent.

Then drain the coolant.

Air intake pipes

After the corrosion protection run, remove the cylinder head cover and deinstall injectors. The respective piston must be set to LT.

The accessible part of the cylinder liner should be coated with corrosion protection oil with a spray lance through the opening.

Spray corrosion protection lubricating oil into the suction intake pipe.

Exterior corrosion protection

The engine must be cleaned thoroughly with a cleaning agent before exterior corrosion protection. Any signs of corrosion and damage to the

Page 71

Engine corrosion protection Transport and storage

paintwork must be removed.

Bare exterior surfaces and parts

Coat or spray all bare exterior parts and surfaces (e.g. flywheel, flange faces) with corrosion protection agent.

Rubber parts

Rubber parts (e.g. muffs) which are not painted over must be rubbed down with talcum powder.

Belt drive

Remove V-belts and V-rib belts and store packed.

Spray V-belt pulleys and tension rollers with corrosion protection agent.

Engine openings

All engine openings must be fitted with air-tight, water-tight covers to delay the vapourisation process of the corrosion protection agents.

With installed air compressor, the suction and pressure connection must be sealed by a cap.

Air should be excluded to avoid ventilation of the engine (chimney effect) for the suction from an air supply pipe.

Storage and packaging

After being protected against corrosion, the engine must be stored in a dry, ventilated hall and suitably covered.

The cover must be placed loosely over the engine so that the air can circulate around it to prevent condensation from forming. Use a desiccant if necessary.

Removal of corrosion protection

The corrosion protection must be removed from the corrosion protected engine before starting.

The packaging and all covers over the closed openings must be removed.

Any corrosion deposits and paint damage should be remedied.

Fuel system

If there is a mixture of diesel fuel/corrosion protection oil in the fuel tank, drain it.

Connect fuel/tank/supply line to the engine. Pay attention to cleanliness.

Fill the fuel tank and fuel system with the proper fuel.

Lubricating oil system

Unscrew the lube oil drain screw, drain oil.

Fill the engine with lubricating oil via the lubricating oil filler neck.

Coolant system

If the implemented corrosion protection agent is compatible with the intended cooling system protection agent, this can be filled directly into the coolant system as specified.

If it is uncertain whether the implemented corrosion protection agent is compatible with the cooling system protection agent, the cooling system should be purged with fresh water for about 15 minutes before filling.

Removal of exterior corrosion protection

All areas and components coated with corrosion protection agent must be washed off with dis-

tilled fuel or a suitable cleaning agent.

Wash out grooves of V-belt pulleys if necessary.

Mount V-belts or V-rib belts as specified.

Fill with coolant.

Corrosion protection agent / cleaning agent

Please ask your DEUTZ partner for reference products for the corrosion protection agents/cleaning agents to be used which meet DEUTZ requirements.

or see www.deutz.com

http://www.deutz.com

en \SERVICE \Betriebsstoffe und Diag-

en \SERVICE\Oils, Lubricants, Diagno-

Motorkonservierung

nose\

Engine Corrosion Protection

sis\

Page 72

Technical data Engine and setting data

General technical data

Engine type Dimension TD 2012 L04 2Vm TCD 2012 L04 2Vm TCD 2012 L04 2V TCD 2012 L06 2V

Working principle Four-stroke diesel engine Charging Exhaust gas turbo-

Type of cooling water-cooled Cylinder arrangement in series No. of cylinders 46 Bore/stroke [mm] 101/126 Total displacement [cm Combustion process Direct injection Injection system Mechanical injection system Exhaust gas recirculation internal Valves per cylinder 2 Valve clearance: Inlet/outlet [mm] Setting with rotary angle disc [°] Firing order of the engine 1-3-4-2 1-5-3-6-2-4 Direction of rotation looking onto the flywheel left Engine power rating according to ISO 3046 [kW] see engine rating plate Speed (nominal revolutions) [rpm] see engine rating plate Injection timing [°BTDC] see engine rating plate Coolant volume (only engine content without cooler /

hoses and pipes) Coolant volume DEUTZ PowerPack cooler Permissible continuous coolant temperature [°C] max. 110 Temperature difference between coolant inlet/outlet [°C] 4 - 8 Start of thermostat opening [°C] 86 Thermostat fully open [°C] 102

] 4038 6067

≈

[l] 5,6 7,3

≈

[l] 18,5 22,7

charger

Turbocharger with charge air cooling

eutz Common Rail (

+10°

/120°

+10°

75°

DCR

)

Page 73

Engine and setting data Technical data

Engine type Dimension TD 2012 L04 2Vm TCD 2012 L04 2Vm TCD 2012 L04 2V TCD 2012 L06 2V

Lubricating oil change volume (with filter) Lube oil temperature in the lube oil tray, maximum [°C] 125 Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 80/0,8 Permissible maximum combustion air temperature after

charge air cooler V-belt tension Pre-tensioning/Re-tensioning V-belts AVX 11 (width: 11 mm) [N] 650±50/400±50 V-rib belt tensioning Automatic tensioning spring-loaded clamping roller Weight without cooling system according to DIN 70020-A *specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants

and/or special inclined versions, the lubricating oil volume may vary.

≈

[l] 15,5* 26,5*

[°C] 50

≈

[kg] 380 400 400 510

The lubricating oil dipstick mark is always decisive.

Page 74

Technical data Engine and setting data

Engine type Dimension TCD 2013 L04 2Vm TCD 2013 L04 2V TCD 2013 L06 2V

Working principle Four-stroke diesel engine Charging Turbocharger with charge air cooling Type of cooling water-cooled Cylinder arrangement in series No. of cylinders 46 Bore/stroke [mm] 108/130 Total displacement [cm Combustion process Direct injection Injection system Mechanical injection system Exhaust gas recirculation internal Valves per cylinder 2 Valve clearance: Inlet/outlet [mm] Setting with rotary angle disc [°] 90° Firing order of the engine 1-3-4-2 1-5-3-6-2-4 Direction of rotation looking onto the flywheel left Engine power rating according to ISO 3046 [kW] see engine rating plate Speed (nominal revolutions) [rpm] see engine rating plate Injection timing [°BTDC] see engine rating plate Coolant volume (only engine content without cooler /

hoses and pipes) Coolant volume DEUTZ PowerPack cooler Permissible continuous coolant temperature [°C] max. 105 Temperature difference between coolant inlet/outlet [°C] 4 - 8 Start of thermostat opening [°C] 86 Thermostat fully open [°C] 102 Lubricating oil change volume (with filter) Lube oil temperature in the lube oil tray, maximum [°C] 125

] 4761 7142

eutz Common Rail (

+10°

/150°

≈

[l] 7,2 9,8

≈

[l] 22,7 24,9

≈

[l] 15,5* 26,5*

DCR

)

Page 75

Engine and setting data Technical data

Engine type Dimension TCD 2013 L04 2Vm TCD 2013 L04 2V TCD 2013 L06 2V

Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 80/0,8 Permissible maximum combustion air temperature after

and/or special inclined versions, the lubricating oil volume may vary.

[°C] 50

≈

[kg] 500 610

The lubricating oil dipstick mark is always decisive.

Page 76

Technical data Tools

Tool ordering

The special tools described in this chapter can be or dered from:

Please contact your DEUTZ partner

Torx tool

Order number:

8189

The Torx screw system is used in engines in this se ries among other things. This system was introduced for a number of reasons:

● Excellent accessibility

● High force transmission when loosening and tightening

● Slipping or breaking of the key and risk of injury are practically excluded.

V-belt tension measuring instrument

Order number:

8115

Measuring instrument for checking the specified Vbelt tensions.

Page 77

Tools Technical data

Special tools for removing the water collection vessel.

Order number: 8192 On Racor filters, only loosen the water collection

vessel with a special tool.

Special wrench for loosening exchangeable filters

Order number: 170050 For loosening changeable filters.

Rotaqtion angle disc

Order number: 8190 Rotation angle disc for setting the valve and control

piston clearance

Page 78

Technical data Tools

Pin wrench insert

Order number: 8193 8194 Pin wrench inserts for rotation angle disc

Crow foot wrench

Order number: 8190 Crow foot wrench for rotation angle disc in connec-

tion with conventional square bar extension.

Turning gear

Order number: 100 330 For turning over the engine as an attachment for the

torsional vibration damper

Page 79

DEUTZ Oil

DEUTZ Oil DQC II-05

ACEA E5-02 / E3-96 / B3-04 API CG-4

TLS-15W40D (DQC II-05) 5 L 0101 6331 20 L 0101 6332 209 L 0101 6333

DEUTZ Oil DQC III-05

ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 API CI-4 / SL GLOBAL DHD-1

TLX-10W40FE (DQC III-05) 5 L 0101 6335 20 L 0101 6336 209 L 0101 6337

DEUTZ Oil DQC IV-05 (Synthetic)

ACEA E7-04 / E5-02 / E4-99

DEUTZ Oel DQC IV-5W30 (DQC

IV-05) 5 L - 20 L 0101 7849 209 L 0101 7850

Page 80

DEUTZ AG Information Systems Sales & Service Ottostraße 1 51149 Köln Germany Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 E-Mail: info@deutz.com www.deutz.com

0312 3761 en

The engine company.

Original operating instructions

Deutz TCD 2012 L06, TD 2012 L04 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Notes

Foreword

Contents

General

Model Engine description

Engine illustrations Engine description

Lubricating oil diagram Engine description

Engine description Fuel diagram

Coolant diagram Engine description

Exhaust gas return Engine description

Engine description Electrics/Electronics

Operation Ambient conditions

Initial start-up Operation

Start procedure Operation

Operation monitoring Operation

Stop procedure Operation

Operating media Lubricating oil

Fuel

Coolant Operating media

Maintenance Maintenance schedule

Lubricating oil system Servicing and maintenance works

Servicing and maintenance works Fuel system

Servicing and maintenance works Cooling system

Servicing and maintenance works Engine cleaning

Aspiration system Servicing and maintenance works

Belt drives Servicing and maintenance works

Servicing and maintenance works Setting work

Electrical system Servicing and maintenance works

Fault table Faults

Faults Engine management

Transport Transport and storage

Transport and storage Engine corrosion protection

Technical data Engine and setting data

Technical data Tools