Deutz TCD 2013 L04 4V, TCD 2013 L06 4V: TCD 2013 L06 4V Operation Manual

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Page 1

Operation Manual

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

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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 -

Danger to life!

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

- Danger to life!

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-

shop.

– When working on the fuel system, make sure

that the engine is not started inadvertently during repairs -

Danger to life!

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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.

Order number

0312 3536 en

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Contents

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

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

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

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

Type . . . . . . . . . . . . . . . . . . . . . 7

Engine illustration. . . . . . . . . . . . . . . 9

Lubricating oil schematic . . . . . . . . . . . 19

Fuel schem a t ic . . . . . . . . . . . . . . . . 20

Coolant schematic . . . . . . . . . . . . . . 21

Exhaust gas recirculation. . . . . . . . . . . 23

Electrics/Electronics . . . . . . . . . . . . . 24

3 Operation . . . . . . . . . . . . . . . . . . 26

Ambient conditions . . . . . . . . . . . . . . 26

Commissi o ning . . . . . . . . . . . . . . . . 27

Start procedure . . . . . . . . . . . . . . . . 29

Operation monitoring . . . . . . . . . . . . . 31

Stop procedure . . . . . . . . . . . . . . . . 33

4 Operating media. . . . . . . . . . . . . . . 34

Lubricating oil. . . . . . . . . . . . . . . . . 34

Fuels . . . . . . . . . . . . . . . . . . . . . 36

Coolant . . . . . . . . . . . . . . . . . . . . 37

5 Maintenance . . . . . . . . . . . . . . . . . 38

Maintenance schedule . . . . . . . . . . . . 38

6 Service and m a intenance. . . . . . . . . . 41

Lubricating oil system. . . . . . . . . . . . . 41

Fuel system. . . . . . . . . . . . . . . . . . 43

Cooling syst e m . . . . . . . . . . . . . . . . 47

Engine cle a n in g. . . . . . . . . . . . . . . . 49

Suction syst e m . . . . . . . . . . . . . . . . 50

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

Setting work . . . . . . . . . . . . . . . . . 55

Electrical syst e m . . . . . . . . . . . . . . . 60

7 Faults. . . . . . . . . . . . . . . . . . . . . 62

Fault table . . . . . . . . . . . . . . . . . . 62

Engine management . . . . . . . . . . . . . 65

8 Tra n s p o rt and storage . . . . . . . . . . . 67

Transport . . . . . . . . . . . . . . . . . . . 67

Protecting the engine against corrosion . . . 68

9 T e c h n ic al data . . . . . . . . . . . . . . . . 70

Engine and setting data . . . . . . . . . . . 70

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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 -

Danger of acci-

dent!

When the work is complete, be sure to refit any panels and guards that have been removed.

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-

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 spare 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 service 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.

Masthead

DEUTZ AG Ottostraße 1 51149 Cologne Telephone:+49 (221) 822-0 Fax: +49 (221) 822-5850 www.deutz.com E-mail: info@deutz.com

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.

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General

Danger

Caution

Notes

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.

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.

This symbol accompanies notes of a general kind.

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Type Engine description

Rating plate

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

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

DEUTZ AG

MADE IN GERMANY

Mot.-Typ

Mot.-Nr.

Location of the rating plate

The rating plate C is mounted on the cylinder head cover or crankcase.

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Engine description Type

Rating plate

Or the C rating plate is fixed sideways on the flywheel side

Engine serial number

The engine number 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 at the power transmission side. rotating to the left: counter-clockwise.

Engine sides

Looking at the power transmission side.

left

right

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Engine illustration Engine description

123

1213

1516

21 22

TCD 2013 L04 4V engine, view from right (example)

1 Cylinder head cover 2 Transport device 3 Heating flange 4 Cab heater connection 5 Combustion air inlet 6 Connection from air filter 7 Cumbustion air outlet to the charge air cooler 8 Coolant outlet 9 Deflection pulley 10 Belt pulley on crankshaft 11 Tension pulley 12 Lubricating oil sump 13 Lubricating oil drain plug 14 Coolant inlet 15 Generator 16 Lube oil cooler 17 Lubricating oil filter 18 Engine control unit 19 Fuel filter 20 Rail with pressure reducing valve and pressure

sensor 21 Crankcase ventilation (open system) 22 Lubricating oil filling

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Engine description Engine illustration

TCD 2013 L04 4V engine, view from left (example)

1 Charge air temperature/pressure transmitter 2 Exhaust manifold line 3 Fuel supply pump 4 Transport device 5 Gear connection (SAE housing) 6Starter cover 7 Lubricating oil return line from the exhaust turbo-

charger 8 Cumbustion air outlet to the charge air cooler 9 Exhaust gas outlet of the turbocharger 10 Shield (thermal protection)

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Engine illustration Engine description

TCD 2013 L06 4V engine, view from right (example)

1 Cylinder head cover 2 Transport device 3 Heating flange 4 Cab heater connection 5 Combustion air inlet 6 Coolant outlet 7 Tension pulley 8 Hydraulic pump or compressor mounting (op-

tional) 9 Belt pulley for fan attachment 10 Tensioning pulley (s) 11 Deflection pulley 12 Lubricating oil sump 13 Belt pulley for coolant pump 14 Lubricating oil drain plug 15 Coolant inlet 16 Generator 17 Lube oil cooler 18 Hydraulic pump or compressor installation (op-

tional) 19 Lubricating oil filter 20 Engine control unit with fuel cooling 21 Fuel filter 22 Rail with pressure reducing valve and pressure

sensor 23 Crankcase ventilation valve

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Engine description Engine illustration

TCD 2013 L06 4V engine, view from left (example)

1 Charge air temperature/pressure transmitter 2 Lubricating oil filling (option a l) 3 Exhaust manifold line 4 Fuel supply pump 5 Gear connection (SAE housing) 6Starter cover 7 Lubricating oil return line from the exhaust turbo-

charger 8 Turbocharger 9 Shield (thermal protection)

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Engine illustration Engine description

TCD 2012 L04 4V Agri Power engine, view from right (example)

1 Turbocharger 2 Exhaust gas recirculation system (EGR) 3 Combustion air inlet 4 Coolant outlet 5 Coolant pump 6 Fuel supply pump 7 Tension pulley 8 V-rib belt 9 Front power take-off 10 Coolant inlet 11 Engine mounting 12 Lubricating oil sump 13 Lubricating oil drain plug 14 Exchangeable fuel filter 15 Lube oil replacement filter 16 Fuel connection from tank 17 Lube oil cooler 18 Fuel pre-filter 19 Generator 20 central plug 21 Electronic Control Unit (ECU) 22 High-pressure pump 23 Crankcase ventilation valve 24 Deutz common rail with pressure reducing valve 25 Connection injectors 26 Cylinder head cover

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Engine description Engine illustration

TCD 2012 L04 4V Agri Power engine, view from left (example)

1 Throttle lever for exhaust gas recirculation

(EGR) 2 Transport device 3 Gear connection (SAE housing) 4Starter cover 5 Lubricating oil filling (option a l) 6 Lubricating oil return line from the exhaust turbo-

charger 7 Exhaust manifold line 8 EGR line to the cooler 9 Exhaust manifold 10 Cooling line for the exhaust gas recirculation

system 11 Lubricating oil pressure line to the turbocharger

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Engine illustration Engine description

TCD 2013 L06 4V Agri Power engine, view from right (example)

1 Turbocharger 2 Coolant supply flow to the cab heating 3 Coolant outlet 4 Combustion air inlet 5 Generator 6 Coolant pump 7 Tension pulley 8 Deflection pulley 9 Front power take-off 10 Lubricating oil sump 11 Coolant inlet 12 Lube oil replacement filter 13 Exchangeable fuel filter 14 Compressor (optional) 15 Gear connection (SAE housing) 16 Lube oil cooler 17 Crankcase ventilation valve 18 Deutz common rail with pressure reducing valve 19 Transport device 20 Cylinder head cover

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Engine description Engine illustration

12 13 14 15

TCD 2013 L06 4V Agri Power engine, view from left (example)

1 Exhaust gas recirculation system (EGR) 2 Throttle lever for exhaust gas recirculation 3 Cooling line for the exhaust gas recirculation

system 4 Fuel connection from tank 5 Fuel connection to the tank 6Starter 7 Lubricating oil filling (option a l) 8 Air conditioning compressor 9 V-rib belt 10 Coolant pump 11 Coolant outlet 12 Ventilation line to the cooler 13 Combustion air inlet 14 Exhaust gas recirculation from the EGR cooler 15 Cumbustion air outlet to the charge air cooler

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Engine illustration Engine description

TCD 2013 L06 4V Genset engine, view from right (example)

1 Cap of the compensation tank 2 Coolant supply from the thermostat to the heat

exchanger 3 Heat exchanger 4 Charge air cooler 5 Fan cover 6 Line from the heat exchanger to the coolant

pump 7 Ventilation line from the thermostat housing to

the compensation tank 8 Compensation tank

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Engine description Engine illustration

1 2

TCD 2013 L06 4V Genset engine, view from left (example)

1 Line between the compensation tank and the

coolant pump 2 Charge air line from charge air cooler 3 Charge air line from the turbocharger to the

charge air cooler 4 Coolant drain plug 5 Fan cowling

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Lubricating oil schematic Engine description

Lubricating oil schematic (example)

1 Lubricating oil sump 2 Lubricating oil suction intake pipe 3 Lubricating oil pump

3.1 Overpressure valve

4 Lube oil cooler

4.1 Return flow shutoff valve (only for 2012)

4.2 Bypass valve

4.3 Bypass valve for lubricating oil filter

4.4 Pressure control valve 5 Lube oil replacement filter 6 Main lubricating oil lines

6a Internal connected exhaust gas recirculation 7 Crankshaft bearing 8 Big-end bearing 9 Camshaft bearing 10 Line to injector nozzle 11 Piston cooling nozzle with pressure holding

valve 12 Tappet with impulse lubrication of the rocker arm 13 Tappet rod, lubricating oil feed to the rocker arm

lubrication 14 Rocker arm 15 Return line to the lubricating oil pan 16 Lubricating oil pipe to the turbocharger 17 Turbocharger 18 Return line from the compressor/hydraulic pump

to the crankcase 19 Air compressor or hydraulic pump 20 Lubricating oil line to the crankshaft and cam

shaft, compressor/hydraulic pump 21 Return line from the turbocharger

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Engine description Fuel schematic

Fuel schematic (example)

1 Fuel container

X= The fuel must be pre-filtered in the fuel line to

the fuel supply pump. 2 Line to the fuel supply pump 3 Fuel supply pump 4 Line to the fuel filter 5 Fuel cooling for the Engine Control Unit ECU

(without cooler, top-right in the image) 6 Fuel filter 7 Return line 8 FCU Control Unit 9 Tappet rollers on camshaft 10 DCR rail 11 Injection line to injection valve 12 Injector 13 Fuel oil leakage line 14 Fuel return to fuel tank

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Coolant schematic Engine description

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Engine description Coolant schematic

Coolant schematic (example)

1 Coolant inlet to engine 2 Coolant pump 3 Thermostat 4 Lube oil cooler 5 Cylinder pipe/head cooling 6 Coolant supply for EGR cooling, (



23)(optional)

7 Engine brake cooling (optional) 8 Return line to the thermostat (optional) 9 Heat exchanger (by customer) 10 Fan (by customer) 11 Compensation tank 12 Cab heater connection 13 Coolant supply flow to the cab heating 14 Engine outlet to the cooler 15 Engine ventilation to compensation tank 16 Compensation line from the compensation tank to the coolant pump 17 Cab heating (optional) 18 Cooler breather

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Exhaust gas recirculation Engine description

Exhaust gas recirculation (example)

1 EGR actuator plug 2 EGR actuator 3 Throttle valve (check valve) 4 Coolant line to the EGR cooler 5 EGR cooler 6 Flapper valve 7 Exhaust gas outlet from the cooler 8 Fresh air intake elbow 9 Coolant return line of the cooler

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Engine description Electrics/Electronics

Information about the engine electronics

This engine is equipped with an electronic DEUTZ 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.

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.

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. Diagnostic and maintenance work may only be carried out by authorised personnel using equipment approved by DEUTZ.

Supply voltage

DEUTZ diesel engines must be operated with a 12 V or 24 V supply. An adequate charging condition of the battery must be ensured. Interruption of the power supply when the engine is running can lead to damage to the electrics/electronics. Failure of the supply voltage leads to engine standstill.

Voltages above 32 Volt will destroy the control unit.

Diagnostics

DEUTZ control units are equipped with self-diagnosis. Active and passive error entries are saved in the error memory. Active errors are displayed by error lamp/diagnostic lamp (



65). The active errors can

be called by blink codes or by the DEUTZ diagnostic program SERDIA. Passive errors must be deleted by SERDIA.

with error lamp (optional).

via diagnostic socket (SERDIA).

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Electrics/Electronics Engine description

Electrical cable connections for monitoring (example)

1 Control unit example EMR3, E.M.S II 2 Fuel pressure 3 Charge air pressure/temperature transmitter 4 Coolant temperature 5 Cold start aid 6 Cable harness for rail pressure sensor 7 Lubricating oil level transmitter (optional) 8 Lubricating oil level transmitter in the lubricating

oil pan 9 Lubricating oil pressure sensor 10 Lubricating oil pressure transmitter 11 Control unit plug 12 Pick-up on SAE housing 13 Speed transmitter via camshaft

14 Power supply (battery) 15 Multifunction displays 16 Outputs (configurable, e.g. for lamps, torque

(PWM), speed, engine running signal, etc.) 17 Inputs (configurable) 18 Accelerator 19 Hand throttle (optional) 20 Switch functions (optional, e.g. for P-factor, reg-

ulator type, peak curves, fixed speeds etc. also

multi-step switches) 21 Detachable key switch Start/Stop 22 Diagnostic button 23 Error lamp with blink code 24 Diagnostic interface/CAN bus

Engine side

Equipment side

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Operation Ambient conditions

Low ambient temperatures Lubricating oil

Select lubricating oil according to ambient temperature

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

Fuel

Use winter fuel below 0 °C (36).

Battery

A good charging condition of the battery (60) 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).

0 °C

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.(



29)

Coolant

Mixing ratio anti-freeze/cooling water.

High ambient temperatures, high altitude

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.

Under the operating conditions listed below, the amount of fuel is reduced automatically, controlled by the electronic control unit.

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Commissioning 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).

Fill with engine lube oil.

Fill with engine lube oil

Fill the engine with lubricating oil via the lubricat-

ing oil filler neck.

Observe the lubricating o il filling leve l (70).

Check lubricating oil level, if necessary top up.

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 oil-bath air filter with lubricating oil

Fill lubricating oil pan (1) of the oil-bath filter with lubricating oil as far as the marking arrow.

No lubricating oil may be filled in the cyclone pre-separator that may be connected upstream.

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Operation Commissioning

Pour in fuel

The fuel low pressure system must be vented before the first start-up after filling with the man ualy supply pump.

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



36).

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

Only re-fuel when the engine is not 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.

Filling the coolant system

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 (2).

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.

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.

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 in the compensation tank and top up coolant if necessary.

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 (



70).

If required, repeat procedure with engine start.

Trial run

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 the lubricating oil level and top up lu-

bricating oil if necessary.

– Check the coolant level and top up coolant if

necessary.

Work during the trial run: – Check engine for tightness.

Venting of the fuel system by operating for 5 minutes on no load or with low load is absolutely essential.

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Start procedure Operation

Starting

Engine is controlled electronically, e.g. delivered with electronic engine control EMR3 and the necessary function configurations.

Separate engine from driven devices by disconnecting if possible.

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

If the starter is connected to the EMR3 by a relay,

the maximum starting time is limited by the EMR3.

– The pause between two start attempts is pre-

set by the EMR3. 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.

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 does not start properly when the heating flange is automatically actuated (starter does not receive current as a result of a fault in the equipment/customer electrical control system) the starting procedure must be abandoned (set the ignition switch to OFF, disconnect the power supply to the heating flange).

– The start is then continued automatically by

the EMR3.

– The EMR3 can be programmed for special

applications by data record so that the control unit can also carry out further start attempts automatically if the engine fails to start.

If the engine does not start and the error lamp blinks, the EMR3 system has activated the start lock to protect the engine. The start lock is released by switching off the system with the ignition key for about 30 seconds. Separate the engine if possible by disengaging driven units. 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 table (



62).

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

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Page 30

Operation Start procedure

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.

Glow plugs/heating flange with cold start aid

Insert key. – Position 0 = no operating voltage.

Turn key to the right. – Position 1 = operating voltage. – Pilot lamps (1), (2) and (3) light up. – 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 2 = start.

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

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Page 31

Operation monitoring Operation

Operation monitoring by EMR3

The EMR3 system monitors the engine condition and itself.

The statuses are displayed by the error lamp.

Lamp test: – The error lamp lights up for approx. 2 s after

switching on the ignition (ignition lock stage

Steady light: – There is a system error or an engine variable

(temperature, pressure etc.) is in the warning range.

The EMR3 can reduced the engine performance depending on the error to protect the engine.

Fast flashing: – Attention, the engine is in danger and must

be switched off.

– The control unit switches the engine off auto-

matically depending on the application.

– The control unit can preset a forced engine

operation with low idling speed to cool down the engine before switching off, automatic

switch-off if necessary. – There may be a start lock after engine stop. – The start lock is released by switching off the

system with the ignition key for about 30 sec-

onds. – 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 instrument panel to avoid critical situations. This brief deactivation of the engine protection functions is logged in the control unit.

Display instrument

Possible displays:

Colour scale – Display of the operating state by coloured ar-

ears (green = OK/red = take suitable action).

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

nominal value should be taken from the Technical Data (



72).

OBJ_DOKU-12638-001.fm Seite 31 Mittwoch, 22. August 2007 9:25 09

Page 32

Operation Operation monitoring

Instruments and symbols

Instruments/symbols Designation Possible display: Measure

Lubricating oil pressure display

Lubricating oil pressure below minimum Switch off engine

Lubricating oil pressure display

Lubricating oil pressure in the red area Switch off engine

Coolant temperature Coolant temperature too high Switch off engine

Lubricating oil pressure pilot lamp

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

Switch off engine

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

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

Check lubricating oil level / if necessary top up

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

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

Switch off the engine, allow to cool down and top up coolant

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

Horn With acoustic signal See fault table (



62).

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Page 33

Stop procedure Operation

Shutting off

Electrical shutdown (optional)

Move the key to position 0. Control lamps A+B+C go out. A = charge pilot light

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.

B = lube oil pressure pilot light C = pilot light for pre-heating system P = gear position: park 0 = gear position: switch off engine 1 = gear position: pre-heat engine 2 = gear position: start engine

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Page 34

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 oil quality

has a considerable influence 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.

The

lubricating oil viscosity

describes the flow behaviour of the lubricating oil depending on the temperature. The lubricating oil viscosity has no influence and effect on the lubricating oil quality.

Synthetic lubricating oils

are used increasingly

and have advantages. These oils have a better tem-

perature and oxidation stability as well as a r elatively low cold viscosity. Since some processes relevant to the definition of the lube oil change intervals are not essentially dependent on the lube oil quality (such as the incorporation of soot and other contaminations), the lube oil change interval when using synthetic lube oils may not be increased in relation to the specifications of the lube oil change intervals.

Biodegradable lubricating oils

may be used in DEUTZ engines if they meet the requirements of this operating manual.

Quality

Lubricating oils are classified by DEUTZ according to their efficiency and quality class (DQC: DEUTZ Quality Class). It basically applies that: with increasing quality class (DQC I, II, III, IV) the lubricating oils are more efficient and higher quality. The appended quality class designation (- 02 / - 05) indicates in which year the classification was made.

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.

The following lubricating oils are specified for the engines described in this operating manual.

With open crankcase breather: DQC II - 05 DQC III - 05 DQC IV - 05 With closed crankcase breather: DQC III - 05 DQC IV - 05

Recommended quality class DEUTZ ACEA API

DQC II - 05 E3-96 / E5-02 /

E7-04

CG-4 / CH4 / C I4

DQC III - 05 See TR 0199-99-3002

Please contact your DEUTZ partner

DQC IV - 05

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Page 35

Lubricating oil Operating media

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 the diesel fuel of 0.5 - 1

weight %.

DEUTZ lubricating oils DQC II-05 TLS - 15W40 D

Container Order number

5 litre container 0101 6331 20 litre container 0101 6332 209 litre barrel 0101 6333

DEUTZ lubrica ti ng oils DQC III-05 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-05 synthetic Container Order number

20 litre container 0101 7849 209 litre barrel 0101 7850

– operation with bio-diesel fuel

If the oil change intervals for vehicle engines are to be carried out according to operating hours, the oil change intervals for built-in engines apply.

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.

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

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

-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

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Page 36

Operating media Fuels

Permissible fuels

The following fuel specifications / standards are approved:

In engines with increased power rating and engines with high loads we recommend the use of DEUTZ TLX10W.40FE Europa.

Diesel fuels according to DIN EN 590 – Nato F-54 (equivalent to diesel fuel in ac-

cordance with DIN EN 590)

US diesel fuel according to ASTM D 975 GradeNo.1-D and 2-D

Japanese diesel fuel JIS K 2204 Grade 1 Fuel and Grade 2 Fuel with lubricating properties according to diesel fuel EN 590 (HFFR max. 460 micrometer according to EN ISO 12156)

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 to satisfy the legal emission limits are performed with the test fuels defined by law. These correspond to the diesel fuels according to EN 590 and ASTM D 975 described in this operating manual. No emission values are guaranteed with the other fuels described in this operating manual.

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 prov ide this in good time before the cold season starts).

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.

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

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

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.

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

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Page 37

Coolant Operating media

General

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

corrosion

cavitation

freezing

Water quality

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

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.

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

Analysis values min max

ph value at 20 °C 6,5 8,5 Chloride ion content [mg/dm

] - 100

Sulphate ion content [mg/dm

] - 100

Total hardness (carbonate hardness percentage of the total hardness min. 3 dGH)

[°dGH] 3.0 12.0

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

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.

This cooling system corrosion protection agent is

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.

DEUTZ cooling system corrosion protection agent

Container Order number

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

free from nitrite, amine and phosphate and is adapted 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.

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. refractom eter).

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.

Cooling system corrosion protection agent percentage

Water percentage

Cold protection up to

min. 35 % 65 % -22 °C

40 % 60 % -28 °C

max. 45 % 55 % -35 °C

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Page 38

Maintenance Maintenance schedule

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals

Maintenance measures

Changing the pre-filter cartridge depends on the degree of dirt contamination of the fuel being used. If other fuels are used which do not meet the requirements of the operating manual, the warranty will be voided.

A self-adhesive maintenance diagram is provided with every engine. This should be stuck to the engine or device in a prominent position. Order number: 0312 2452 (TCD 2012 4V) and 0312 2453 (TCD 2013 4V)

Standard maintenance schedule TD/TCD 2012/2013 L04/06 4V

Standard and EPA 1) certified engines

Stage Activity see To be carried

out by:

Industrial engines/vehicle engines (every ........oh/km)

E10 Initial commissioning (27) Authorised spe-

cialists

For measures to be taken during the run-in phase or commissioning of new or overhauled engines, see (



27)

E20 Daily inspection Customer 1x daily or every 10 operating hours in continuous operation E30 Maintenance

500 oh

/ 45,000 km 3) / 60,000 km 3) / 80,000 km

E40 Extended maintenance I 1,000 oh / 100,000 km E45 Interim stage 1,500 oh

/ 200,000 km

E50 Extended maintenance II Authorised spe-

cialists

3,000 oh / 400,000 km E60 Intermediate overhaul (only for EPA) 6,000 oh E70 General overhaul 12,000 oh

EPA (Environmental Protection Agency).

The oil load may be high depending on the application. Shorter maintenance intervals are necessary in this case, 250 oh (15,000 km).

Specification for lubricating oil change interval related to the lubricating oil quality DQC III and an average drive speed of: approx. 25 km/h (local traffic), approx. 40 km/ h (regional traffic), approx. 60 km/h (long distance traffic).

For TCD 2012 L04/06 4V and TCD 2013 L06 4V engines, the valve clearance must be set for the first time after 500 oh and then, after every 1500 oh.

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Page 39

Maintenance schedule Maintenance

Stage 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 Clean Fuel pre-cleaner and 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.



Check V-belt/V-rib belt (retighten if necessary, replace if damaged)



Coolant (additive concentration)



Coolant level (top up if necessary)



Replace Lubricating oil (lubricating oil change intervals depending upon the engine application). See TR 0199-99-3002 for an

optimum lubricating oil utilisation/change strategy. Ask your DEUTZ-partner for information.



Lubricating oil filter/insert (every time the lubricating oil is changed)



E40 Check Charge air cooler (drain lubricating oil and condensation)



Check glow plugs and heating flange for functioning.



Flame glow system (check for functioning) EGR compensator line (replace if damaged) Battery and cable connectors



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



Filter cartridge of the crank space ventilation valve Tighten engine mountings, if necessary (renew in case of damage) Fastenings, hose unions / clips (renew if damaged)

Replace Fuel filter insert (main filter)



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



Fuel pre-cleaner and 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.



OBJ_DOKU-12638-001.fm Seite 39 Montag, 17. September 2007 2:52 14

Page 40

Maintenance Maintenance schedule

E50 Check V-rib belt and tensioning pulley (replace if wear limit is fallen below)



EGR (optional) adjustment lever and valve; replace if necessary



Replace EGR (optional) adjusting bar

E60 Check Electronic injector test via EMR3 (only for DEUTZ Common Rail System)



Clean Charge air cooler inlet area/charge air cooler, lubricating oil/drain condensation (only with EPA).

Non-return valve of the exhaust gas recirculation system (optional). Cooler of the exhaust gas recirculation system.

Replace Fuel injector valve (only with EPA).

Flame glow plugs



Crankcase breather valve/incl. Filter (only with EPA)

annually Clean Charge air cooler inlet area (lubricating oil/drain condensation), (only with EPA)



Replace Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary)



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



Every 2 years

Check EGR (optional) adjustment lever and valve; replace if necessary Replace Coolant (additive concentration)



V-belt, V-rib belt and tensioning pulley



Filter insert of the crankcase breather valve (only with EPA)

Stage Measure Page

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Page 41

Lubricating oil system Service and maintenance

Specifications when working on the lubricating oil system

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

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.

Check lubricating oil level

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.

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

Low lubricating oil level or 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.

Be careful of hot lubricating oil. Danger of scalding!

OIL ?

OIL

+80°C +176°F

The lubricating oil level must always be between the MIN and MAX-1 marks. Fill up to the MAX-1 mark if necessary.

The lubricating oil dipstick shows an apparent overfilling owing to the recirculating oil (e.g. filter) when the engine is cold. The MAX-2 mark is used for this.

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 (



70).

Check engine lubricating oil level (see previous chapter).

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Page 42

Service and maintenance Lubricating oil system

Change lubricating oil filter

Remove the clips if an anti-rotation lock is fitted.

Loosen and unscrew the filter cartridge with the tool

(order no. 170050)

Collect draining lubricating oil

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

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

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

Screw on new filter by hand until the gasket is in place and then tighten with a torque of 15-17 Nm.

If necessary, fix the clips of the anti-rotation lock.

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Page 43

Fuel system Service and maintenance

Specifications when working on the fuel system

Engine must be switched off! Smoking and naked lights prohibited! The common rail system is under high pressure. Do not get near to a leak in the high pressure system because the fuel jet can cause severe injury. Wait 30 seconds after switching off the engine before working on the fuel system. No injection/high pressure pipes may be disconnected while the engine is running. In case of leaks in the fuel system, contact your DEUTZ partner immediately.

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

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.

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.

OBJ_DOKU-12638-001.fm Seite 43 Mittwoch, 22. August 2007 9:25 09

Page 44

Service and maintenance Fuel system

Change the fuel filter cartridge

Remove the clips if an anti-rotation lock is fitted.

Loosen and unscrew the filter cartridge with the tool

(order no. 170050)

Catch any escaping fuel.

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

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

Screw on new filter by hand until the gasket is in place and then tighten with a torque of 15-17 Nm.

If necessary, fix the clips of the anti-rotation lock.

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

Vent the fuel system.

OBJ_DOKU-12638-001.fm Seite 44 Mittwoch, 22. August 2007 9:25 09

Page 45

Fuel system Service and maintenance

Change the fuel filter cartridge

Switch off the engine.

Loosen lubricating oil filter cap (1) with 2 to 3 turns and wait 30 seconds.

Unscrew fuel filter cap (1) with paper filter cartridge (5) anticlockwise.

Carefully loosen paper filter cartridge (5) upwards from the guide (4) located in the housing (3).

Catch any escaping fuel.

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

Collect any fuel oil that escapes.

Bend the paper filter cartridge (5) in the collecting vessel slightly sideways until the cartridge comes off the clamp (6).

Clean any dirt from the sealing area of the filter media and fuel filter cap (1) as well as guide (4).

Replace round sealing ring (2) and grease lightly.

Press new paper filter cartridge (5) into the clamp (6) and carefully insert into the guide (4).

Screw in fuel filter cap (1) clockwise (25 Nm).

Start engine.

OBJ_DOKU-12638-001.fm Seite 45 Mittwoch, 22. August 2007 9:25 09

Page 46

Service and maintenance Fuel system

Clean/purge or change the fuel pre-filter

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

Control Unit)

3 Fuel manual pump with bayonet lock for locking

and unlocking 4 Thermostat valve with stop lever (optional) 5 Filter insert 6 Connection option for electrical water level sen-

sor 7 Water drain tap 8 Water collecting vessel (bowl) 9 Fuel inlet from the fuel tank 10 Fuel return to fuel tank 11 Connection for electrical warning lamp/horn

Filter replacement

Close fuel shutoff tap (with high-level tank).

Place fuel collection vessel underneath the fuel

pre-filter.

Release the water drain tap (7), drain the water and the fuel completely.

Unscrew the filter insert (5) with water collection vessel (8) in anticlockwise direction and remove. Close fuel shutoff tap (with high-level tank).

Loosen water collecting vessel (8) anticlockwise from the old filer cartridge (5) and remove.

– The special tool can be ordered under part

number

8192

(74).

Drain remaining fuel into the fuel collecting vessel and clean water collecting vessel (8).

Screw water collecting vessel (8) clockwise onto the new filter cartridge (5).

Clean any dirt from the sealing area of the new filter cartridge (5) and opposite side of the filter head.

Lightly moisten sealing areas of the filter cartridge (5) with fuel and screw onto the filter head again clockwise (17-18 Nm).

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

Properly dispose of the collected fuel and old filter cartridge (5).

Vent the fuel system

Unlock bayonet lock of the fuel manual pump (3) by pressing and turning anticlockwise at the same time. The pump piston is now pressed out by 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 bayonet lock of the fuel manual pump (3) by pressing and turning clockwise at the same time.

Start the engine and operate approx. 5 minutes in idling mode or at low load. Check the pre-filter for leaks while doing this.

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Page 47

Cooling system Service and maintenance

Specifications when working on the cooling system

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.

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)!

Check coolant additive concentration

Open the cooling system cap (1) carefully.

Check the coolant additive concentration in the cooler / compensation tank (2) with a conventional freeze protection measuring instrument (1) (e.g. hydrometer, refractometer).

Necessary coolant additive concentration Coolant mixing ratio (



37)

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

°C

Fill the cooling system

Open the cooling system cap (1) carefully.

Fill up coolant to the MAX mark on the compensation tank and close the cooling system cap (1).

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

Run engine up to operating temperature (opening temperature of the thermostat).



70).

Switch off the engine.

Check coolant level in cooled engine and top up to the MAX mark on the compensation tank if necessary.

OBJ_DOKU-12638-001.fm Seite 47 Mittwoch, 22. August 2007 9:25 09

Page 48

Service and maintenance Cooling system

Empty/fill and ventilate cooling system

Position the collecting dish underneath the locking screw (5) and the coolant supply (4).

Verschlussschraube (5) am Kurbelgehäuse entfernen und Schlauch an (4) abziehen.

Loosen the vent screw (2).

Drain coolant.

Re-tighten the locking screw (5) and the hose on (4) and the vent screw (2).

If the locking screw (3) is not accessible, the drainage can be carried out at the engine oil cooler (coolant duct).

Fill and ventilate cooling system.

Fill and ventilate cooling system

Open cooler locking cap.

Loosen the vent screw (2).

Fill with coolant as far as the m ax. marking or filling limit (heating valve of the system mus be opened, if necessary).

Tighten the vent screw (2) and the locking screw (5).

Close cooler locking cap.

Start the engine and warm up until the thermostat opens.

Switch off the engine.

Check coolant level when the engine is cold and refill if necessary.

Close and ventilate cooler locking cap (1).

The cooling system, which was installed in compliance with our installation guidelines, is automatically drained after filling.

OBJ_DOKU-12638-001.fm Seite 48 Mittwoch, 22. August 2007 9:25 09

Page 49

Engine cleaning Service and maintenance

Cleaning work

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.

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.

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).

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

Warm up the engine so that the water residues evaporate.

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Page 50

Service and maintenance Suction system

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.

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

maintenance

switch

lights up when the engine is running.

– the red field (1) of the

maintenance indica-

tor

is fully visible.

After carrying out maintenance work, reset the signal by pressing the button on the maintenance indicator. The maintenance indicator is now ready for operation again.

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Page 51

Suction system Service and maintenance

Renewing the safety cartridge of the dry air filter

Renew safety cartridge (4) according to the inter-

val 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).

Never clean the safety cartridge (4).

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

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.

Maintaining the dry air filter

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.

4 3

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Page 52

Service and maintenance Suction system

Emptying the cyclone precleaner

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).

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

Cleaning oil bath air filter

Shut down engine and wait about 10 minutes until the lubricating oil has collected in the lubricating oil pan (3).

Loosen the quick release clamps (2) and remove the lubricating oil pan (3) with filter insert (4).

Dispose of dirty lubricating oil.

Clean lubricating oil pan (3), filter cartridge (4) and filter housing (1) with a brush and clean diesel fuel.

Visually inspect the rubber gaskets (5), (6) and

Never clean the filter with petrol!

Dispose of the old lubricating oil in accordance with the regulations. Select the engine lubricating oil according to the requirements before filling the filter.

renew if damaged.

Fill the lubricating oil pan (3) of the oil bath air filter with engine oil up to the mark (arrow).

Mount the lubricating oil pan (3) with filter insert (4) on the filter housing (1) and close the quick release clamps (2).

Start engine and check for tightness.

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Page 53

Belt drives Service and maintenance

Checking the belt drive

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.

Only carry out work/function check on the belt drive when the engine is not running! Only check / change V-belts when the engine is not running! Refit the V-belt guard! Retension the new V-belts after 15 minutes running time. In the event of wear of the double belts or damage to one of the Vbelts always replace both belts as a pair. The difference in length of the new V-belts must not exceed 0.15 % one to the other.

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

(order number:

8115)

can be obtained from your DEUTZ partner.

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Page 54

Service and maintenance Belt drives

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

Check wear limit of the V-rib belt as follows.

Spacing between the nose of the moving tensioning arm and the limit stop of the fixed tensioning housing.

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

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Page 55

Setting work Service and maintenance

Set valve clearance for TCD 2013 L04/06 4V

Loosen breather valve and swing it to the side.

Remove the cylinder head hood.

Let the engine cool down for at least 30 minutes

before setting the valve clearance: Lubricating oil

temperature below 80 °C.

Place turning gear over fastening screws of the

belt pulleys.

Tool (74).

Turn the engine until reaching valve overlap, cyl-

inder no. 1.

The cylinders to be set can be seen in the setting

schematic.

Note: Crankshaft means:

Outlet valve

is not yet closed, inlet valve

begins to open.

Loosen rotation angle disc (3)

(order no.: 8190)

and place pin wrench insert

(order no.: 8193)

the valve clearance setting screw (2).

Loosen locking nut (1) with special tool

(order

no.: 8199)

Fix magnet of the rotation angle disc.

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

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

Secure the rotation angle disc (3) against twisting.

Tighten the locking nut (1) (torque 20 Nm).

Perform the setting procedure on every cylinder.

Mount gasket (new gasket if necessary).

Visually inspect screws and rubber elements, replace if necessary.

Mount cylinder head cover (with a new gasket if necessary) and tighten the screws according to

tightening specification: 9 Nm (74).

Swing breather valve into position and fasten.

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Page 56

Service and maintenance Setting work

Valve-clearance setting schematic

Crankshaft/camshaft control time assignment is ensured when re-assembling using the markings on the toothed wheels.

The crankshaft can be turned using different turning gears:

– On the dynamic damper with

order no.: 100 330

– On the toothed starter ring with

order no.: 100 360

Crankshaft position 1

Turn the crankshaft until both valves overlap on cylinder 1 (outlet valve not yet closed, inlet valve starts to open).

The rocker arms to be set have clearance in delivered/new state.

Setting of the valve clearance: – Loosen locking nuts on marked rocker arms

(see image).

– Tighten setting screw using the angle meth-

od IN = 75° EX = 105°

– Tighten locking nut with 20 Nm.

Crankshaft position 2

Turn the crankshaft one more time, i.e. by 360°, valve overlap on the cylinder 4 or 6 according to the type.

Now set the rocker arms marked in figure 2 as described above.

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Page 57

Setting work Service and maintenance

Set valve clearance for TCD 2012 L04/06 4V

Remove the cylinder head hood.

Let the engine cool down for at least 30 minutes

before setting the valve clearance: Lubricating oil

temperature below 80 °C.

Place turning gear over fastening screws of the

belt pulleys.

Tool (74).

Turn the engine until reaching valve overlap, cyl-

inder no. 1.

The cylinders to be set can be seen in the setting

schematic.

Note: Crankshaft means:

Outlet valve

is not yet closed, inlet valve

begins to open.

5 6

Set valve clearance on the corresponding cylinder using the valve clearance setting device

(Or-

der no.: 100340)

Loosen all locking nuts (3) of the rocker arm assembly to be set.

Turn the setting screws (1) back by one rotation anticlockwise.

Turn the setting screw (1) without clearance clockwise on the rocker arm to be set. This means, there must not be any clearance between the rocker arm and the valve (2) and no pressure may be applied to the valve.

Set pointer (6) on the knurled handle (5) of the measuring plate (4) to "0°"; do not twist the knurled handle (5) anymore.

Hold the measuring plate (4) exactly in this position and turn the setting screw (1) anticlockwise using the knurled handle (5) until the pointer (6) reaches the "in" or "ex" marking.

Hold the knurled handle (5) exactly in this position and tighten the locking nut (3) using the

4 5

torque wrench (7) according to the 20 Nm tightening specification.

Perform the setting procedure on every cylinder.

Mount gasket (new gasket if necessary).

Visually inspect screws and rubber elements, replace if necessary.

Mount cylinder head cover (with a new gasket if necessary) and tighten the screws according to tightening specification: 9 Nm (



74).

Swing breather valve into position and fasten.

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Page 58

Service and maintenance Setting work

Install turning gear

Unscrew threaded stopper (1) from stopper.

Turn in M8 screw (1) into stopper.

Pull out stopper using the screw.

Insert turning gear (1) and set valve clearance as described.

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Page 59

Setting work Service and maintenance

Check/set control piston clearance for the engine brake

after valve clearance has ben set.

– Control unit for the engine brake has already

been mounted.

Turn the engine until reaching valve overlap, cyl-

inder no. 1

Carry out control piston clearance for every out-

let valve.

Further procedure similar to that for the valve

clearance.

Note:

Valve overlap means:

Outlet valve is not yet closed, inlet valve begins

to open, see valve-setting schematic.

If necessary, set control piston clearance, for this:

Loosen locking nut (2).

Mount the control piston clearance X on the setting screw (1) in EX (



55) using the setting de-

vice and set as follows: – Fix magnet – Then, turn back at an angle of 432° (manual-

ly or using a torque wrench):

– Turn the setting device until the control pis-

ton reaches the valve bridge without clearance; set scale to "0".

= outlet valve at 432° for M8 thread (corre-

sponds to 1.5 mm clearance) – Tighten locking nut (2).

Check and adjust valve clearance on all remaining cylinders.

Reinstall cylinder head cover, with new gasket.

Swing breather valve into position and fasten. EX = outlet valve

1 Setting screw for valve clearance

2 Locking nut

3 Solenoid valve (electronic control)

4 Control board

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Page 60

Service and maintenance Electrical system

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 before cleaning the engine (e.g. control units, generator, solenoid valves etc.) Do not aim the water/steam jet directly at them. Run the engine warm afterwards to evaporate moisture residues. 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!

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.

Checking the voltage

Check the battery voltage with a conventional voltmeter. The voltage indicates the charging state. It should be between 12 and 14.4 Volt depending per battery.

Check acid density

Unscrew caps.

Measure the electrolyte density of individual cells with a commercial hydrometer. Hydrometer

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Page 61

Electrical system Service and maintenance

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.

Removing the battery

Always disconnect the minus pole first when removing 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 specifications!

Screw in caps.

Installing the battery

Insert new or charged battery and attach the fastenings.

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-

Acid density [kg/ l] Charge

status

Measure

Normal Tropical

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

free, acid-resistant grease.

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Faults Fault table

Faults and remedies

Faults Causes Measures

Engine does not start or is difficult to start

Not disconnected (if possible) Check coupling Below starting limit temperature Check Lubricating oil level too low Fill up lube oil Lube oil level too high Check lube oil level, if necessary drain off. Lube oil cooler defective Check Exhaust gas backpressure too high Check Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil Fuel quality does not comply with operating manual Change the fuel Air in fuel system Vent fuel system 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 does not start and diagnostic lamp flashes

Engine electronics prevents starting Check error according to error code and eliminate error if

necessary

Engine starts, but runs irregularly or fails

Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose Incorrect valve clearance Settings Injector defective Change Injection valve defective Change Glow plugs defective Change Air in fuel system Vent Fuel filter contaminated Clean Fuel quality does not comply with operating manual Change the fuel Injection line leaks Check injection line Injection valve defective Check fuel injector / change if necessary

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Fault table Faults

Speed changes are possible and diagnostic lamp lights up

Engine electronics has detected a system error and activates an equivalent speed

Check error according to error code and eliminate error if necessary

Engine becomes excessively hot. Temperature warning system activates

Ventilation line of the coolant system blocked Clean Injector defective Change Coolant heat exchanger soiled Clean Coolant pump defective (V-rib belt torn or loose) Check whether torn or loose Low coolant Fill up Charge air line leaking Check charge air line Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose Lube oil filter contaminated on the air or lube oil side Change Lubricating oil level too low Fill up lube oil Lube oil level too high Check lube oil level, if necessary drain off. 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 Heat short-circuit in the cooling system Check the cooling system Resistance in cooling system is too high / flow volume too low Check the cooling system

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

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 Charge air line leaking Check charge air line Charge air cooler soiled Clean Injection line leaks Check injection line Injector defective Change Injection valve defective Check fuel injector

Faults Causes Measures

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Page 64

Faults Fault table

Engine performs poorly and diagnostic lamp lights

Engine electronics reduce performance Check error according to error code and eliminate error if

necessary

Engine does not run on all cylinders

Injection line leaks Check injection line Injection valve defective Check fuel injector / change if necessary

Engine lubricating oil pressure is non-existant or excessively low

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

Engine lubricating oil consumption excessive

Lube oil level too high Check lube oil level, if necessary drain off. Excessive inclination of engine Check engine mounting / reduce inclination

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

Fuel quality does not comply with operating manual Change the fuel Injection valve defective Check fuel injector / change if necessary

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

Air filter maintenance switch / maintenance indicator defective Check/replace Charge air line leaking Check charge air line Injection valve defective Check fuel injector / change if necessary Injector defective Change

Faults Causes Measures

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Engine management Faults

Engine protection function of the EMR3 system

Depending on the design of the monitoring functions, the EMR3 can protect the engine from damage in certain error situations by monitoring important limit values during operation and checking the correct functioning of the system components.

Override switch (if configured)

The switch-off procedure for the engine is bypassed using the override switch. This can destroy the engine. The actuation of the override switch is stored in the control unit

Diagnostic key and error lamp

The diagnostic key (1) and the error lamp (2) are accommodated in the vehicle drive stand. The blinkcode release can be activated using the diagnostic key (1).

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.

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

partner.

Flashing – Serious error in the system. – The engine has reached switch-off condition. – The switch-off process has been accom-

plished.

Blink code – Errors that may occur can be classified. – The blink codes can only be interpreted by a

DEUTZ partner.

The flashing error lamp may have the following meaning depending on the engine configuration:

Switch off prompt for the operator. Attention: Failure to do so will lead to loss of guarantee!

Automatic shutdown of the engine after a short warning time, possibly in connection with a start lock.

Engine forced to run at low idle speed to cool the engine, with automatic shutdown if necessary.

Start lock

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Faults Engine management

DEUTZ Electronic Display

In order to show measured values and error messages of the EMR control unit, a CAN display

(TN 0440

6060)

is optionally available, which can be integrated into the dashboard of the driver´s position of working machines.

The display unit communicates with the control unit through a CAN BUS in accordance with SAE J1939 under consideration of the DEUTZ CAN specification.

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

Gear oil pressure

Battery voltage

Accelerator position

Fuel consumption

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.

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Page 67

Transport Transport and storage

Suspension equipment

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).

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.

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

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Page 68

Transport and storage Protecting the engine against corrosion

General

Engines contain the following types of corrosion protection:

Interior corrosion protection

Exterior corrosion protection

The following measures for corrosion protection

af-

ter taking the engine out of operation

meet the re-

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 by wetting of the walls with the implemented cor-

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

rosion 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

Fill the fuel tank with a mixture of: – 90 % distilled fuel – 10 % corrosion protection oil SAE 20W-20

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 SAE 20W-20 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.

Air compressor

If a compressor is installed, a corrosion protection agent must be sprayed into the compressor suction system after shutting down the engine until it emerges visibly from the pressure nozzle.

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 oil SAE 20W-20 into the suction air intake line.

Exterior corrosion protection

The engine must be cleaned thoroughly with a cleaning agent before exterior corrosion protec-

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Page 69

Protecting the engine against corrosion Transport and storage

tion. Any signs of corrosion and damage to the paintwork must be removed.

Cooling air system in air-cooled engines

The air guidance compartment of the engines is unpainted and must be sprayed with a corrosion protection agent.

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.

Toothed belts for engine control may not be removed.

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.

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

Also close the fuel/tank/supply line to the engine so that the sensitive rail system is protected against dirt and dust. Protect the electronics against moisture/corrosion (



77).

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 distilled 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.

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

Start the engine.

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Page 70

Technical data Engine and setting data

General technical data

Engine type TCD 2012 L04 4V TCD 2012 L06 4V

No. of cylinders 46 Cylinder arrangement upright in row Bore [mm] 101 Stroke [mm] 126 Total displacement [cm

] 4038 6057

Compression ratio

[ε]

18 Functional principle/combustion method Four-stroke diesel with charging and direct injection Charge air cooler with Charge air temperature outlet at rated power [°C] 50 Direction of rotation looking onto the flywheel left Injection system

eutz Common Rail (

DCR

) DCR Weight excluding cooling system to DIN 70020-A [approx. kg] 450 570 Engine power rating according to ISO 3046 [kW] Engine performance, speed and start of pumping, among other things, are

stamped on the engine rating plate.

Speed (nominal revolutions) [min

-1

] Valve clearance: inlet/outlet Setting with special tool [°] Value specified by special tool

100 340

Ignition pressure [kPa (bar)] 16000 (160) start of delivery [°CABTDC] Engine performance, speed and start of pumping, among other things, are

stamped on the engine rating plate. Firing order of the engine 1-3-4-2 1-5-3-6-2-4 V-belt tension Pre-tensioning/Re-tensioning

Generator [N] 650/400 ± 50 Fuel pump/Coolant pump [N] 650/400 ± 50

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Engine and setting data Technical data

V-rib belt tensioning The V-rib belt has an automatically tensioning spring-loaded tensioning pulley and is not re-tensioned.

Spring-loaded tensioning pulley

Cooling Liquid-cooled/cooling system protection

Coolant volume (engine content only without cooler) [approx. ltr.] 5,6 7,3 Permissible continuous coolant temperature [°C] max. 110 Temperature difference between coolant inlet/outlet [°C] 4-8 Start of thermostat opening [°C] 87 Thermostat fully open [°C] 102

Coolant preheating Only necessary in winter operation. Lubrication Pressure lubrication Lubricating oil SAE (



34)

Lube oil temperature in the lube oil tray, maximum [°C] 125 Lubricating oil pressure in warm state (114°C) and low idle, minimum [kPa (bar)] 80 (0,8) Lube oil first fill quantities

Specified lubricating oil filling volumes apply for the standard versions. The lubricating oil filling volume may vary in engines which deviate from the standard, e.g. different lubricating oil pan/lubricating oil dipstick variants and/or special inclined versions. The lubricating oil dipstick mark is always decisive.

Lube oil first fill quantity without filter, minimum / maximum [approx. ltr.] 12,5/15,0 23,5/26,0 Lube oil first fill quantity with filter, minimum / maximum [approx. ltr.] 13,0/15,5 24,0/26,5

Engine type TCD 2012 L04 4V TCD 2012 L06 4V

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Technical data Engine and setting data

General technical data

Engine type TCD 2013 L04 4V TCD 2013 L06 4V

No. of cylinders 46 Cylinder arrangement upright in row Bore [mm] 108 Stroke [mm] 130 Total displacement [cm

] 4761 7142

Compression ratio

[ε]

eutz Common Rail (

DCR

) DCR Weight excluding cooling system to DIN 70020-A [approx. kg] 530 620 Engine power rating according to ISO 3046 [kW] Engine performance, speed and start of pumping, among other things, are

stamped on the engine rating plate.

Speed (nominal revolutions) [min

-1

] Valve clearance: inlet/outlet Setting with special tool [°] Angular degree 75/105 Ignition pressure [kPa (bar)] 16000 (160) start of delivery [°CABTDC] Engine performance, speed and start of pumping, among other things, are

stamped on the engine rating plate. Firing order of the engine 1-3-4-2 1-5-3-6-2-4 V-belt tension Pre-tensioning/Re-tensioning

Generator [N] 650/400 ± 50 Fuel pump/Coolant pump [N] 650/400 ± 50

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Engine and setting data Technical data

V-rib belt tensioning The V-rib belt has an automatically tensioning spring-loaded tensioning pulley and is not re-tensioned.

Spring-loaded tensioning pulley

Cooling Liquid-cooled/cooling system protection

Coolant volume (engine content only without cooler) [approx. ltr.] 7,5 9,8 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

Coolant preheating Only necessary in winter operation. Lubrication Pressure lubrication Lube oil SAE (



34)

Lube oil temperature in the lube oil tray, maximum [°C] 125 Lubricating oil pressure in warm state (114°C) and low idle, minimum [kPa (bar)] 80 (0,8) Lube oil first fill quantities

Lube oil first fill quantity without filter, minimum / maximum [approx. ltr.] 12,5/15,0 23,5/26,0 Lube oil first fill quantity with filter, minimum / maximum [approx. ltr.] 13,0/15,5 24,0/26,5

Engine type TCD 2013 L04 4V TCD 2013 L06 4V

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Technical data Engine and setting data

Tool ordering

The special tools described in this chapter can be ordered from:

Fa. Wilbär Taubenstraße 5 D-42826 Remscheid Tel.: 0049 (0) 2191-9339-0 Fax: 0049 (0) 2191-9339-200 E-mail: info@wilbaer.de http://www.deutz-tools.com

Torx tool Order no.: 8189

The Torx screw system is used in engines in this series 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.

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Engine and setting data Technical data

Rotaqtion angle disc Order no.: 8189

Rotation angle disc for setting the valve and control piston clearance

Pin wrench insert Order no.: 8193 (5 mm) valve clearance

Order no.: 8194 (4 mm) control piston clearance

Pin wrench inserts for rotation angle disc

Crow foot wrench Order no.: 8199

Crow foot wrench for rotation angle disc 8190 in connection with conventional square bar extension.

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Technical data Engine and setting data

Valve clearance setting tool Order no.: 100 340

For setting the valve clearance for TCD 2012 4V.

Turning gear order no.: 100 330

For turning over the engine as an attachment for the torsional vibration damper

Turning gear order no.: 100 360

For turning over the engine on the toothed starter ring.

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Engine and setting data Technical data

Bowl key Order no.: 8192

Special tool for removing the water collection vessel in the fuel pre-filter (Racor type)

Closing plugs and caps Order no.: 170 160

A set of closing plugs and caps for sealing fuel lines.

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Page 78

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DEUTZ Oil DQC II-05

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

DEUTZ Oil DQC III-05

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

DEUTZ Oil DQC IV-05 (Synthetic)

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

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

TLX-10W40FE (DQC III-05) 5

L 0101 6335 20 L 0101 6336 209 L 0101 6337

DEUTZ Oel DQC IV-5W30 (DQC IV-05) 5 L

- 20 L 0101 7849 209 L 0101 7850

DEUTZ Oil

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The engine company.

DEUTZ AG

Service Information Systems

Ottostraße 1 D-51149 Cologne Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-5850 Internet: www.deutz.com E-mail: info@deutz.com

OBJ_DOKU-12638-001.fm Seite 80 Mittwoch, 22. August 2007 9:25 09

Deutz TCD 2013 L04 4V, TCD 2013 L06 4V: TCD 2013 L06 4V Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual