Deutz TCD 2013 User Manual

Name: Deutz TCD 2013
Brand: Deutz
SKU: 3855397
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Instruction Manual

TCD 2012 L04/06 4V TCD 2013 L04/06 4V

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

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

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

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

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

-rotating / hot components

-engines with extraneous ignition

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

zThemanufacturerwillnotbeliablefordamages resulting from unauthorised modification to the engine.

Equally,manipulationstotheinjectionandcontrol system can affect the engine’s performance and the exhaust characteristics. Compliance with environmental regulations will no longer be guaranteed in this case.

zDo not alter, obstruct or block the area of the cool air supply to the fan.

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

zOnly DEUTZ original parts may be used when carrying out maintenance/repair work on the engine. These have been designed especially for your engine and ensure a trouble-free operation.

Failure to observe this will lead to voiding of the warranty!

zMaintenance/cleaning work on the engine may only be carried out when the engine is not running and has cooled down.

When doing this, make sure that the electrical system is switched off (remove ignition key). The specifications for accident prevention with electrical systems (e.g. VDE-0100/-0101/ -0104/-0105 Electrical protective measures against dangerous touch voltages) must be observed.

Cover all electrical components tightly when cleaning with liquids.

zDo not work on the fuel system while the engine is running - Danger to life.

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

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

-In case of leaks immediately contact the workshop.

-When working on the fuel system

ensure that the engine is not unintentionally started during repairs. Danger to life.

Enginenumber:

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

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

Instruction Manual

TCD 2012 L04/06 4V TCD 2013 L04/06 4V

0312 2443 en

Foreword

Dear customer,

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

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

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

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

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

Your

DEUTZAG

1.General

2.Engine description

2.1Engine type

2.1.1Companyplate

2.1.2Location of company plate

2.1.3Enginenumber

2.1.4Cylindernumbering

2.2.1Operation side

TDC 2012 L04 4V

2.2Engine diagrams

2.2.2Starter side

TDC 2012 L04 4V

2.2.3Operation side TDC 2012 L06 4V

2.2.4Starter side

TDC 2012 L06 4V

2.2.5Operation side TDC 2013 L06 4V

2.2.6Starter side

TDC 2013 L06 4V

2.2.7Operation side Agri Power

2.2.8Starter side

Agri Power

2.2Engine diagrams

2.3.1Lube oil diagram

TCD 2013 L06 4V (example)

2.4Fuel circuit

2.4.1Fueldiagram

2.5Coolant circuit

2.5.1Coolantdiagram

2.5.2Exhaust gas recirculation diagram

2.6Electrics

2.6.1Electrical cable connections for monitoring

3.Operation

3.1Initialcommisioning

3.1.1Fillingengineoil

3.1.2Fillingfuel

3.1.3Filling / bleeding cooling system

3.1.4Other preparations

3.2Starting

3.2.1Electrical starting

3.3Operation monitoring

3.3.1Engine oil pressure

3.3.2Coolant temperature

3.3.3Coolantlevel

3.3.4Lube oil level

3.4Shutting down

3.4.1Electrical shutdown

3.5Operating conditions

3.5.1Winter operation

3.5.2High ambient temperature, highaltitude

4.Operatingsubstances

4.1Lube oil

4.1.1Quality

4.1.2Viscosity

4.2Fuel

4.2.1Quality

4.2.2Winter fuel

4.3Coolant

4.3.1Water quality for coolant

4.3.2Coolant preparation

4.3.3Cooling system preservative

5. Maintenance

5.1Maintenance schedule

5.2Maintenance diagram

5.3Maintenance work carried out

6.Care and maintenance

work

6.1Lubrication system

6.1.1Oil change intervals

6.1.2Checking oil level, changing engine oil

6.1.3Changing oil filter insert

6.1.4Cleaning / changing oil filter (cup) fehlt

6.2Fuel system

6.2.1Changing fuel filter

6.2.2Cleaning / changing fuel filter (cup)

6.2.3Changing/bleedingfuelpre-filter,filter insert

6.3Cooling system

6.3.1Cleaning intervals

6.3.2Cleaning cooling system

6.3.3Emptying / filling / bleeding cooling isystem

6.4Combustion air filter

6.4.1Cleaning intervals

6.4.2Emptying cyclone pre-separator

6.4.3Dry air filter

6.5Belt drive

6.5.1Checking V-rib belt

6.5.2Changing V-rib belt

6.5.3Checking wear limit of v-rib belt fehlt

6.6Setting work

6.6.1Checking valve clearance, setting if necessary

6.6.2Checking control piston clearance at

	engine brake, setting if necessary
6.7	Add-on parts	© 2005
6.7.1	Battery
6.7.2	Three-phase current generator
6.7.3	Transportation suspension

Contents

7.Faults, causes and remedies

7.1Faulttable

7.2Enginemanagement

7.2.1Engine protection function of the electronic engine controller EMR3

7.2.2Using the diagnosis button

7.2.3Table of fault blink codes

8.Engine corrosion protection

8.1Corrosion protection

9.Technical data

9.1Engine and setting data

9.2Screw tightening torques

9.3Tools

10. Service

General

DEUTZengines	Maintenance and care	Service	1

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

Take care when the engine is running

Only carry out maintenance work or repairs with the engine switched off. Ensure that the engine cannot be started unintentionally - danger of accidents!

Re-install any removed protective equipment upon completion of the work.

Observe industrial safety regulations when operating the engine in enclosed spaces or underground.

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

Only re-fuel with the engine switched off.

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

Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast, professional repairs using original parts in the event of damage.

The Technical Circulars listed in this operating manual are obtainable from your DEUTZ partner.

Please turn to the end of this manual for further service information.

Danger

Warning

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

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

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

Engine description

2.1Engine type

2.2Engine diagrams

2.3Lube oil circuit

2.4Fuel circuit

2.5Coolant circuit

2.6Electrics

Engine description

2.1 Engine type

2		2.1.1 Company plate	2.1.2 Location of company plate

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

The company plate C is fixed on the crankcase.

Or company plate C is fixed on the cylinder head cover.

Or both plates are attached.

2.1 Engine type

Engine description

2.1.3 Engine number	2.1.4 Cylinder numbering	2

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

The cylinders are counted consecutively, starting from the flywheel.

Engine description

2.2 Engine diagrams

2	2.2.1	Operation side
2		TCD2013L044V
			1	Cylinder head cover
			2	Transportation eyelets
			3	Heating flange
			4	Cabin heater connection
			5	Intake elbow to charge air cooler
			6	Connection to air filter
			7	Coolant outlet adapter
			8	Deflection pulley
			9	Belt pulley on crankshaft
			10	Tension pulley
			11	Oil tray
			12	Oil drain screw
			13	Coolant inlet adapter
			14	Generator
			15	Oil cooler
			16	Exchangeable lube oil filter
			17	Engine control unit
			18	Exchangeable fuel filter
			19Railwithpressurereducingvalveandpressure
				sensor
			20	Crankcase ventilation (open system)
			21	Oil filler neck
	© 2005	© 38 980	1
		© 38 980	1

2.2 Engine diagrams

Engine description

2.2.6	Starter side
	TCD2013L044V
	© 38 981	1

22Charge air temperature line to transmitter

23Exhaust manifold

24Compressor (optional)

25SAE housing

26Starter cover

27Oil return line from turbocharger

28Inlet combustion air turbocharger

29Turbocharger exhaust gas outlet

30Screening plate (thermal protection)

Engine description

2.2 Engine diagrams

2	2.2.3	Operation side
2		TCD2013L064V
			1	Cylinder head cover
			2	Transportation eyelets
			3	Heating flange
			4	Cabin heater connection
			5	Intake elbow from charge air cooler
			6	Thermostat housing (coolant outlet)
			7	Spring-loaded tension pulley
			8	Compressor (optional)
			9	Belt pulley for fan attachment
			10	Tension pulley (s)
			11	Deflection pulley
			12	Oil tray
			13	Belt pulley coolant pump
			14	Oil drain screw
			15	Coolant inlet adapter
			16	Generator
			17	Oil cooler
			18	Hydraulic pump or compressor installation
				(optional)
			19	Exchangeable lube oil filter
			20	Engine control unit with fuel cooling
			21	Exchangeable fuel filter
			22Railwithpressurereducingvalveandpressure
				sensor
			23	Crankcase ventilation (open system)
	© 2005	© 38 982	0
		© 38 982	0

2.2 Engine diagrams

Engine description

2.2.4	Starter side
	TDC 2013 L06 4V
	© 38 983	0

24Pressureandtemperaturetransmitter,chargeair

25Oil filler neck

26Exhaust manifold

27Compressor (optional)

28SAE housing

29Starter cover

30Oil return line from turbocharger

31Exhaust turbocharger

32Screening plate (thermal protection).

Engine description

2.2 Engine diagrams

2
	2.2.5	Operation side Agri Power
		TCD2012 L044V

	1	Exhaust turbocharger
	2	EGR exhaust gas recirculation
	3	Intake elbow from charge air cooler
	4	Coolant return from cooler
	5	Coolantpump
	6	Fuel supply pump
	7	Spring-loaded tension pulley
	8	V-rib belt
	9	Belt pulley for drive
	10	Coolant inlet adapter from cooler
	11	Mounting foot (engine suspension)
	12	Oil tray
	13	Oil drain screw
	14	Fuel filter
	15	Lube oil filter
	16	Fuel connection from tank
	17	Lube oil cooler
	18	Fuel pre-filter
	19	Generator
	20	Central connector
	21	ECU ElectronicControl Unit
	22	High-pressure pump
	23	Crankcase ventilation
	24	Rail with pressure reducing valve
	25	Charge air sensor
	26	Cylinder head cover
©2005	0
© 43 895	0

2.2 Engine diagrams

Engine description

2.2.6 Operation side Agri Power	2
TCD2012L044V

27 EGR exhaustgasRecirculation

Throttle lever for exhaustgasrecirculation 28 Transportation eyelets

29SAE housing

30Starter with cover

31Lube oil filler neck

32Lube oil return from turbocharger

33Oil pressure pipe to turbocharger

34Exhaust manifold

35Cooling line to exhaust gas recirculation system

36Exhaust manifold

Engine description

2.2 Engine diagrams

2	2.2.7	Operation side
2		TCD 2013 L06 4V Agri Power

©2005	0
© 43 826

1 Exhaust turbocharger

2Coolant return from heater

3Coolant outlet to cooler

4Intake elbow from charge air cooler

5Generator

6Coolantpump

7Spring-loaded tension pulley

8Deflection pulley

9Front power takeoff

10Oil tray

11Coolant inlet adapter from cooler

12Lube oil filter

13Fuel filter

14Compressor (optional)

15SAE housing

16Lube oil cooler

17Crankcase ventilation socket

18Coolant outlet adapter to heater

19Engine suspension

20Cylinder head cover

2.2 Engine diagrams

Engine description

2.2.8 Starter side	2
TCD 2013 L06 4V Agri Power

21 EGR exhaustgasrecirculation system

22 Throttle lever for exhaustgasrecirculation

23Cooling line to exhaust gas recirculation system

24Fuel inlet to engine

25Fuel outlet to fuel container

26Starter

27Lube oil filler neck

28Compressor

29V-rib belt

30Fan bearing /coolant pump

31Thermostat housing coolant outlet to cooler

32Ventilation line to cooler

33Charge air supply to charge air cooler

34Coolant return from EGR

Engine description

2.3 Lube oil circuit

2	2.3.1	Lube oil diagram
2		TCD 2013 L06 4V (example)

	1	Oil tray
	2	Intakepipe
	3	Lube oil pump
		3.1 Safety valve
	4	Lube oil cooler
		4.1 Reverse lock valve
		4.2 By-pass valve
		4.3 By-pass valve
		4.4 Control valve
	5	Exchangeable lube oil filter
	6	Mainoilpipe
		6a Engine brake lubrication
	A Exhaustgasrecirculation (EGR) lubrication
	7	Crankshaft bearing
	8	Con rod bearing
	9	Camshaft bearing
	10	Line to injection nozzle
	11	Injection nozzle for piston cooling
	12	Tappet with rocker arm pulse lubrication
	13	Stop rod, oil supply for rocker arm
		lubrication
	14	Rocker arm
	15	Return line to oil tray
	16	Oil line to exhaust turbocharger
	17	Exhaust turbocharger
	18	Oil line to compressor or hydraulic pump
	19	Compressor or hydraulic pump
	20	Return line from compressor
	21	Return line from cylinder head
	22	Exhaust turbocharger return to crankcase
©2005	3
© 39 012	3

2.4 Fuel circuit

Engine description

2.4.1 Fuel diagram		2
2.4.1 Fuel diagram

1Fuel container

2Line to fuel pump

3Fuelpump

4Line to fuel filter

5Fuel cooling for engine control unit (without cooler, upper right in diagram)

6Fuel filter

7Line to injection pumps

8Fuel to control unit

9Tappet rollers on camshaft

10DCRRail

11Injection line to injection valve

12Injectors

13Fuelleakoilline

14Return line to container

A Keep distance as large as possible

Engine description

2.5 Coolant circuit

Engine description

1Coolant inlet to engine

2Coolantpump

3Thermostat housing

4Lube oil cooler (plate cooling)

5Cylinder head cooling and EGR cooling

6Coolant supply to engine brake

7Engine brake cooling

8Return line to thermostat

9Heat exchanger (customer)

10Fan (customer)

11Compensation tank (customer)

12Heating connection

13Compensation tank return line to heater connection

14Thermostat compensation tank return

15Engine ventilation to compensation tank 16 Return line from engine heat exchanger

Engine description

2.5 Coolant circuit

2	2.6.1	Exhaust gas recirculation
2		diagram

1Coolant inlet to engine

2Coolantpump

3Thermostat housing

4Lube oil cooler (plate cooling)

5Cylinder head cooling and EGR cooling

6Coolant supply to engine brake

7Engine brake cooling

8Return line to thermostat

9Heat exchanger (customer)

10Fan (customer)

11Compensation tank (customer)

12Heating connection

13Compensation tank return line to heater connection

14Thermostat compensation tank return

15Engine ventilation to compensation tank 16 Return line from engine heat exchanger

2.6 Electrics

Engine description

2.6.1 Electrical cable connections	2
for monitoring (example)

1 Fuel pressure

2 Shutdown magnet (solenoid valve) example

3 Charge air pressure/temperature sensor

4Coolant temperature

5Cold start aid

6Rail pressure (fuel pressure)

8 Oil temperature transmitter engine pre-heating heating

7 Oil pressure transmitter

9Oil level transmitter

10Oil pressure sensor

11Injectors engine brake (optional)

12E.M.SII

13Pick-up on SAE housing

14Speed sensor

15Energy supply

16Multifunction displays

17Outputs (configurable)

18Inputs (configurable) (PWM/digital/analogue)

19Accelerator pedal

20Hand throttle (optional)

21Switch functions

22Key switch Start/stop

23Diagnosis button

24Fault light with blink code

25Diagnosis interface/ CAN-Bus

Operation

3.1Initial commissioning

3.2Starting

3.3Operation monitoring

3.4Shutting down

3.5Operating conditions

	Operation			3.1 Initial commissioning

3		3.1.1 Filling engine oil	3.1.2 Filling fuel	3.1.3 Filling / bleeding cooling
3				system

The engines are generally supplied without oil filling.

Fill engine with lube oil through the oil filler (1) on the cylinder head cover. Alternatively, you can fill on the wheel box (2) or on the side of the crankcase.

For oil filling amount see 9.1.

For quality and viscosity of oil see 4.1.

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

Only use clean, standard, branded diesel fuel. For fuel quality see 4.2.

Depending on the outdoor temperature, use either summer or winter diesel fuel.

Only re-fuel when the engine is not running!

Pay attention to cleanliness!

Do not spill any fuel!

zConnect the coolant outlet 2 and coolant inlet 1 to the cooling system. Connect the lead line fromthecompensationtanktothewaterpump or to coolant inlet pipe 1.

zConnect vent lines from the engine and if necessaryfromthecoolertothecompensation tank.

zFill the cooling system through the compensation tank

zClose the compensation tank with the valve.

zStart the engine and warm up until the thermostat opens (line 2 heats up).

zRun engine run with open thermostat for 2 –3 minutes.

3.1 Initial commissioning		Operation

3.1.4	Otherpreparations		3
			3

zCheck the coolant level in the compensation tank and top up the coolant if necessary.

zRepeat the process with engine start if necessary.

zCheck battery and cable connections, see 6.7.1.

zTrial run

- After preparations carry out a short

trial run of approx. 10 min. Do not fully load the engine.

During and after the trial run

- Check engine for tightness.

With engine not running

-Check oil level, re-fill oil if necessary, see 6.1.2.

-Re-tighten V-belts, see 6.5.

zRunning-in

It is recommended to check the oil level twice a day during the running-in phase.

After the running-in phase, checking once a day is sufficient.

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

Operation

3.2 Starting

3	3.2.1	Electricalstarting
		Before starting make sure that

		there is nobody in the engine/
		work machine danger area.
		After repairs: Check that all
		protective	equipment is
	mounted and all tools have been removed
	from the engine.
	When starting with heating plugs/heating
	flange, do not use additional start aids (e.g.
	injection with start pilot)! Danger of accidents!
	z Engine is electronically controlled by
	Example: EMR3 (electronic engine control)
	- engine is programmed and supplied with
	the	necessary function	configurations.
	z As far as possible separate engine from
	driven devices by disconnecting.
	z Engine connector plug must be connected
	by the customer (e.g in driver’s cab/
	device) to at least:
	- Supply voltage
	- Torque output
	- Speed output.
	z Warm up the engine for approx. 30 seconds
	at a low idling speed.
	z Do not run up the engine immediately to
	high idling speed / full load operation from
	cold.
	If the starter is connected by a relay on the
	EMR3,
	- the maximum starting time is limited by
2005	the EMR3.
	- the pause between two start attempts
	is given by the EMR3.
©

without cold start aid

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

Thestartisthencontinuedautomaticallybythe EMR3.

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

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

zInsert key

-Step 0 = no operating voltage.

zTurn key to the right

-Step 1 = operating voltage,

-Warning lights light up.

zTurn the key further to the right against the spring load.

-Step 2 = start

zRelease key as soon as the engine starts up.

-Warning lights go out.

Start the engine for a maximum of 20 seconds uninterrupted. If the engine does not start up, wait for one minute and then repeat the starting process. If the engine does not start up after two starting processes, determine the cause as per fault table (see 7.1).

Iftheenginedoesnotstartandthediagnosticlamp flashes, the EMR3 system has activated the start lock to protect the engine.

The start lock is released by switching off the systemwiththeignitionkeyforabout30seconds.

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