Deutz TD 3.6 L4, TCD 3.6 L4 Operation Manual

0 (0)

TD / TCD 3.6 L4

Operation Manual

EU Stage IV / US EPA Tier 4

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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 intend

ed purpose). Any other use above and beyond this will be considered as misuse. The manufac

turer will not accept any liability for damages re

sulting from this. The user bears the sole risk.

● Use for the intended purpose also includes ob

servance of the operating, maintenance and re

pair 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 acci

dents 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 con

trol system can affect the engine's performance and the exhaust characteristics. Adherence to legislation on pollution can no longer be guaran

teed 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 dam

age resulting from this.

● When carrying out maintenance work on the en

gine, the use of DEUTZ original parts is pre

scribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the war

ranty! Maintenance/cleaning work on the engine may

only be carried out when the engine is not run

ning 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 dan

gerous 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 be relieved once the en

gine has shut down (for engines with common rail, approx. 5 minutes, otherwise 1 minute) as the system is under high pressure - Danger to life! During the first trial run do not stand in the dan

ger 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 en

gine.

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

ments of specific cases.

The engine is equipped accordingly for the particular installation situation, i.e. not all the components de

scribed 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 avail

able to everyone involved in the operation, mainte

nance 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.

Components of the exhaust aftertreatment system

Please enter the serial numbers of the exhaust after

treatment components.

Diesel oxidation catalytic converter

Diesel particle filter

SCR module

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 repro

duced, even in part, with our express permission.

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Table of contents

Notes

. . . . . . . . . . . . . . . . . . . . . .

. 2

Foreword

. . . . . . . . . . . . . . . . . . . .

. 3

General

. . . . . . . . . . . . . . . . . . .

. 5

Engine description

. . . . . . . . . . . . .

. 7

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

Engine illustrations . . . . . . . . . . . . . . 10

Lubricating oil diagram . . . . . . . . . . . . 16

Fuel diagram . . . . . . . . . . . . . . . . . 17

Coolant diagram . . . . . . . . . . . . . . . 18

Exhaust gas recirculation . . . . . . . . . . . 19

Exhaust gas aftertreatment . . . . . . . . . . 20

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

Operation

. . . . . . . . . . . . . . . . . .

. 24

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

Initial commissioning . . . . . . . . . . . . . 25

Starting process . . . . . . . . . . . . . . . 28

Operation monitoring . . . . . . . . . . . . . 30

Exhaust gas aftertreatment system. . . . . . 34

Passive regeneration . . . . . . . . . . . . . 39

Stopping process . . . . . . . . . . . . . . . 42

Operating media

. . . . . . . . . . . . . .

. 43

Lubricating oil . . . . . . . . . . . . . . . . . 43

Fuel . . . . . . . . . . . . . . . . . . . . . . 45

Coolant . . . . . . . . . . . . . . . . . . . . 46

SCR reduction agent . . . . . . . . . . . . . 48

Maintenance

. . . . . . . . . . . . . . . .

. 49

Maintenance schedule . . . . . . . . . . . . 49

Servicing and maintenance work

. . . . . .

. 52

Lubricating oil system. . . . . . . . . . . . . 52

Fuel system. . . . . . . . . . . . . . . . . . 54

SCR. . . . . . . . . . . . . . . . . . . . . . 57

Cooling system . . . . . . . . . . . . . . . . 58

Engine cleaning. . . . . . . . . . . . . . . . 60

Suction system . . . . . . . . . . . . . . . . 61

Belt drives . . . . . . . . . . . . . . . . . . 63

Electrical system . . . . . . . . . . . . . . . 65

Faults

. . . . . . . . . . . . . . . . . . . .

.67

Fault table . . . . . . . . . . . . . . . . . . 67

Engine management . . . . . . . . . . . . . 72

Transport and storage

. . . . . . . . . . .

.74

Transport . . . . . . . . . . . . . . . . . . . 74

Engine corrosion protection . . . . . . . . . 75

Technical data

. . . . . . . . . . . . . . .

.79

Engine and setting data . . . . . . . . . . . 79

Tools . . . . . . . . . . . . . . . . . . . . . 81

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General

DEUTZ diesel engines

DEUTZ diesel engines and the appropriate exhaust aftertreatment components are the result of years of research and development. The detailed know-how gained by this in connection with the high quality de

mands are the guarantee for production of engines with a long life, high reliability and low fuel consump

tion. Naturally the high demands for 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 accident!

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

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

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

Never fill the fuel tank while the engine is running.

Service and Maintenance

Service and maintenance are also decisive for whether the engine satisfactorily meets the set de

mands. Recommended service intervals must there

fore be observed and service and maintenance work must be carried out conscientiously.

Special care should be taken under abnormally de

manding 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 intro

duced in the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured ac

cording 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 re

liability.

Asbestos

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

Service

We want to preserve the high performance of our en

gines, 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 pack

ages that ensure optimum operation of our engines, and for customer services operations that you can count on.

Please contact your DEUTZ-partner in case of mal

functions and sare parts inquiries. Our specially trained personnel will ensure fast, professional re

pairs using original DEUTZ spare parts in case of damage.

The DEUTZ homepage provides a continuously up

dated overview of the service partners near you, and

information on product areas and services.

Masthead

DEUTZ AG

Ottostraße 1

51149 Köln

Germany

Phone: +49 (0) 221-822-0

Fax: +49 (0) 221-822-3525 E-Mail: info@deutz.com

www.deutz.com

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 instruc

tions which, if not observed, present a di

rect danger to life and limb for the person involved. Observe these carefully. The at

tention of operating personnel should be drawn to these safety instructions. Further

more, the legislation for "general regula

tions 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 de

struction of the part and the engine.

This symbol accompanies notes of a gen

eral kind.

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Model Engine description

Engine type designation

Emissions legislation

This manual covers the following engine types

TD 3.6 L4

TCD 3.6 L4

TCD

T Exhaust gas turbocharger

C Charge air cooler

DDiesel

3.6

3.6 Displacement in litres

L in series

4 No. of cylinders

The engine and the corresponding EAT system (Exhaust After Treatment) are adapted to each other and linked by an ap

propriate electronic controller. They are only certified by the responsible authorities and comply with the permissible exhaust limits in this combination. Operation of the engine with other EAT systems is not allowed.

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

TCD 3.6 L4 With exhaust aftertreatment system

USA EPA Tier 4 final

EU Stage IV

TD 3.6 L4<56 kW With exhaust aftertreatment system

USA EPA Tier 4 final

EU Stage IV

The engines of this operating manual may only be used with a functioning exhaust af

tertreatment system. (if included in the DEUTZ scope of supply)

Rating plate

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

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

DEUTZ AGDEUTZ AG

MADE IN GERMANYMADE IN GERMANY

Mot.-Typ

Mot.-Nr.Mot.-Nr.

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Engine description Model

Location of the rating plate

The rating plate (C) is fixed to the cylinder head cov

er or the crankcase.

Engine serial number

The engine number (D) is stamped onto the crank

case (arrow) and onto the rating plate.

XXXXX

Serial numbers of the exhaust aftertreatment com

ponents

The serial numbers of the exhaust aftertreatment components are stamped on the rating plates.

1 Rating plate of the diesel oxidation catalytic

converter

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Model Engine description

Serial numbers of the exhaust aftertreatment com

ponents

The serial numbers of the exhaust aftertreatment components are stamped on the rating plates.

1 Rating plate of the diesel oxidation catalytic

converter

2 Rating plate of the diesel particle filter

2 1

Serial numbers of the exhaust aftertreatment com

ponents

The serial numbers of the exhaust aftertreatment components are stamped on the rating plates.

1 Rating plate of the SCR catalyst

Cylinder numbering

Cylinder arrangement The cylinders are counted consecutively starting

from flywheel (1).

Direction of rotation

Looking onto the flywheel.

rotating to the left: counter-clockwise.

Engine sides

Looking onto the flywheel.

left

right

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Engine description Engine illustrations

TD 3.6 L4

Industrial engine

View from right (example)

1 Lubricating oil filling 2 V-belts 3 Coolant inlet 4 Lubricating oil drain plug 5 Lube oil replacement filter 6 Lubricating oil dipstick 7 Coolant outlet

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Engine illustrations Engine description

TD 3.6 L4

Industrial engine

View from left (example)

1 Combustion air inlet 2 Crankcase breather 3 Exhaust outlet 4 Lubricating oil dipstick

Optional

5 Lube oil replacement filter

Optional

6 Diesel oxidation catalytic converter

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Engine description Engine illustrations

TCD 3.6 L4

Industrial engine

View from right (example)

1 Crankcase breather 2 Throttle valve 3 Tension pulley 4 V-rib belt 5 Coolant inlet 6 Lubricating oil drain plug 7 Lube oil replacement filter 8 Lubricating oil dipstick 9 Coolant outlet 10 Differential pressure flow meter

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Engine illustrations Engine description

TCD 3.6 L4

Industrial engine

View from left (example)

1 Combustion air inlet 2 Lube oil cooler 3 Lubricating oil dipstick

Optional

4 Lube oil replacement filter

Optional 5 Generator 6 Lubricating oil filling

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Engine description Engine illustrations

TCD 3.6 L4

Agricultural technology

View from right (example)

1 Exhaust outlet 2 Lubricating oil filling 3 V-rib belt 4 Tension pulley 5 Coolant inlet 6 Lubricating oil drain plug 7 Lubricating oil filling 8 Lube oil replacement filter 9 Coolant outlet 10 Combustion air inlet

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Engine illustrations Engine description

TCD 3.6 L4

Agricultural technology

View from right (example)

1 Crankcase breather 2 Lubricating oil drain plug

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Engine description Lubricating oil diagram

15 14

710 6932

Lubricating oil system

(example)

1 Lubricating oil sump 2 Lubricating oil pump 3 Overpressure valve 4 Lube oil cooler 5 Bypass valve 6 Pressure control valve 7 Lubricating oil filter 8 Main lube oil channel 9 Camshaft bearing 10 Crankshaft bearing 11 Piston cooling nozzle 12 Rocker arm 13 Hydraulic tappets 14 Turbocharger 15 Air compressor

Optional

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Fuel diagram Engine description

8910

61154312

Fuel schematic (example)

1 Fuel tank 2 Fuel pre-filter 3 Fuel pump

(electrically powered) 4 Exchangeable fuel filter 5 Fuel transducer 6 High-pressure pump

with

– Control block FCU (Fuel Control Unit)

7Rail 8 Injector 9 Check valve 10 Return line 11 Fuel return to fuel tank 12 Engine control unit

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Engine description Coolant diagram

610

987

123

Coolant schematic (example)

1 Coolant pump 2 Coolant supply for engine cooling 3 Cylinder pipe/head cooling 4 Lube oil cooler 5 Exhaust return cooler 6 Connection possibility for cab heating 7 Temperature transmitter 8 Thermostat 9 Cooler 10 Compensation tank

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Exhaust gas recirculation Engine description

External exhaust gas recirculation

1 Exhaust gas partial flow

(uncooled) 2 Actuator

(electrically actuated) 3 Coolant return 4 Exhaust return cooler 5 Coolant line to the EGR cooler 6 Differential pressure flow meter 7 Exhaust gas partial flow

(cooled) 8 Mixing pipe 9 Throttle valve

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Engine description Exhaust gas aftertreatment

Exhaust aftertreatment system

Example:

1 Decoupling line 2 Differential pressure sensor 3 Exhaust temperature sensor 4 Diesel oxidation catalytic converter 5 Diesel particle filter

Optional 6 Differential pressure sensor 7 Exhaust outlet 8 Differential pressure flow meter 9 Throttle valve

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Exhaust gas aftertreatment Engine description

435

Exhaust aftertreatment system

Example:

1 Coolant line

to pre-heat the AdBlue® tank 2AdBlue

tank 3 Solenoid valve 4 Engine control unit 5 AdBlue® supply pump 6 SCR catalytic converter 7NO

sensor 8 Dosing device 9 Pressure sensor 10 Temperature transmitter 11 Diesel oxidation catalytic converter 12 Coolant line

to cool the dosing device

13 AdBlue® line

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Engine description Electrics/Electronics

32 4 5

Electronic engine control

1 Throttle valve 2 Differential pressure flow meter 3 Rail pressure sensor 4 Coolant temperature transmitter 5 Actuator 6 Generator 7 Speed transmitter via camshaft 8 Speed transmitter via crankshaft 9 Fuel transducer 10 Lubricating oil pressure transmitter

(on the opposite side) 11 High-pressure pump 12 Central plug (for engine control) 13 Charge air pressure transmitter, charge air tem

perature transmitter

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Electrics/Electronics Engine description

Information about the engine electronics

This engine is equipped with an electric control unit.

The equipping of the respective system depends on the desired scope of function and the planned type of engine application.

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

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

Precautions

The connections of the control units are only dust and water proof when the mating plugs are plugged (protection class IP69K)! The control units must be protected against spray water and moisture until plugging in the mating plugs! Reverse polarity can lead to failure of the control unit. To avoid damaging the control units, all the connections on the control unit must be dis

connected before electric welding work. Interventions in the electrical system con

trary to the DEUTZ regulations or by un

qualified personnel can permamently damage the engine electronics and have serious consequences which are not cov

ered by the manufacturer's guarantee.

Installation instructions

The control units are calibrated to the respective en

gine and identified by the engine number. Every en

gine may only be operated with the appropriate control unit.

Setpoint transmitters (pedal value transmitters) nec

essary 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 ve

hicle side cable harness must be taken from the con

nection diagram of the DEUTZ installation consulting.

Supply voltage

12 Volt

24 Volt

It should be ensured that the battery is sufficiently charged. If the supply voltage is interrupted while the engine is running, this can lead to damage to the electrics/electronics. If the supply voltage fails, the engine shuts down.

Voltages above 32 Volt will destroy the control unit.

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

Diagnostics

DEUTZ control units are equipped with self-diagnos

tics. Active and passive error entries are saved in the error memory. Active errors are displayed on error lamps/diagnostics lamps (



72).

A diagnosis can be made with:

● Error lamp (flash code)

● CAN bus

● DEUTZ electronics display

● Diagnostic socket (SERIDA)

Equipment-side wiring

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

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Operation Ambient conditions

Low ambient temperatures

Lubricating oil

● Select the lubricating oil viscosity according to the ambient temperature.

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

Fuel

● Use winter fuel below 0 °C (



45).

Battery

● A good charging condition of the battery (



65)

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.(



28)

Coolant

● Observe the mixing ratio anti-freeze/cooling wa

ter. (46)

High ambient temperatures, high altitude

Under the following application and operating condi

tions, the amount of fuel must be reduced.

● Application at high altitude

● Application at high ambient temperatures

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 mix

ture would be too rich if the injected amount of fuel were not reduced.

● The results would be: – 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.

This engine is equipped with an electric control unit. Under the operating conditions listed be

low, the amount of fuel is reduced automat

ically, controlled by the electronic control unit.

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Initial 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 (



63).

● 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, main

tain according to maintenance indicator).

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

● Fill with engine lube oil.

● Fill the coolant system (



79).

Fill with engine lube oil

● Fill the engine with lubricating oil via the lubricat

ing oil filler neck.

● Observe the lubricating oil filling level (



79).

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

Pour in fuel

● The fuel low pressure system must be vented be

fore the first start-up after filling with the manualy supply pump.

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



45).

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

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

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Operation Initial commissioning

Filling with AdBlue®

Only re-fuel when the engine is not running. Only fill with AdBlue®! Other media (e.g. diesel), even in the smallest amounts, can cause destruction of the system and a not emmission compliant operation. If you have filled with e.g. diesel and this has got into the system, the complete AdBlue® injection system must be re

placed! If the filled medium (e.g. diesel) has not reached the lines and supply pump/meter

ing module, an emptying and thorough cleaning of the AdBlue® tank will be ade

quate. Ensure cleanliness.

Filling the coolant system

The coolant must have a prescribed con

centration of cooling system corrosion pro

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

Order coolant corrosion protection agent from your DEUTZ partner.

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

dia.

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 lubricating oil level, if necessary top

up.

– Check the coolant level and top up coolant if

necessary.

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

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

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