Deutz TCD 7.8 OM

OBJ_DOKU-25980-001.fm Seite 1 Dienstag, 12.
April 2011 10:06 10
Operation Manual
TCD 7.8 L6
OBJ_DOKU-25980-001.fm Seite 2 Dienstag, 12. April 2011 10:06 10
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. Do not work on the fuel system while the engine
When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
rotating and hot components come to a standstill (in engines with DEUTZ
on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
pressure - Danger to life!
Unauthorised engine modifications will invalidate
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. When working on the fuel system, make sure
Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
When carrying out maintenance work on the en-
2 2011
Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
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 Components of the exhaust aftertreatment system
installation situation, i.e. not all the components de- Please enter the serial numbers of the exhaust after-
scribed in the operating manual are installed in your treatment components.
engine.
We have endeavoured to highlight any differences Diesel oxidation catalytic converter
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- Diesel particle filter
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 SCR module
happy to advise you.
Sincerely,
DEUTZ AG
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.
2011 3
Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel system. . . . . . . . . . . . . . . . . . 46
Foreword. . . . . . . . . . . . . . . . . . . . . 3 SCR. . . . . . . . . . . . . . . . . . . . . . 51
1 General. . . . . . . . . . . . . . . . . . . . 5 Cooling system . . . . . . . . . . . . . . . . 52
2 Engine description . . . . . . . . . . . . . 7 Engine cleaning. . . . . . . . . . . . . . . . 54
Model . . . . . . . . . . . . . . . . . . . . . 7 Aspiration system. . . . . . . . . . . . . . . 55
Engine illustrations . . . . . . . . . . . . . . 10 Belt drives . . . . . . . . . . . . . . . . . . 57
Lubricating oil diagram . . . . . . . . . . . . 14 Adjustment work . . . . . . . . . . . . . . . 58
Fuel diagram . . . . . . . . . . . . . . . . . 15 Electrical system . . . . . . . . . . . . . . . 60
Coolant diagram . . . . . . . . . . . . . . . 16 7 Faults. . . . . . . . . . . . . . . . . . . . . 62
Exhaust gas return . . . . . . . . . . . . . . 18 Fault table . . . . . . . . . . . . . . . . . . 62
Exhaust gas aftertreatment . . . . . . . . . . 19 Engine management . . . . . . . . . . . . . 67
Electrics/Electronics . . . . . . . . . . . . . 21 8 Transport and storage . . . . . . . . . . . 69
3 Operation . . . . . . . . . . . . . . . . . . 23 Transport . . . . . . . . . . . . . . . . . . . 69
Ambient conditions . . . . . . . . . . . . . . 23 Engine corrosion protection . . . . . . . . . 70
Initial start-up . . . . . . . . . . . . . . . . . 24 9 Technical data . . . . . . . . . . . . . . . . 72
Start procedure . . . . . . . . . . . . . . . . 27 Engine and setting data . . . . . . . . . . . 72
Operation monitoring . . . . . . . . . . . . . 29 Tools . . . . . . . . . . . . . . . . . . . . . 74
Regeneration . . . . . . . . . . . . . . . . . 33
Stop procedure . . . . . . . . . . . . . . . . 34
4 Operating Media . . . . . . . . . . . . . . . 35
Lubricating oil . . . . . . . . . . . . . . . . . 35
Fuel . . . . . . . . . . . . . . . . . . . . . . 37
Coolant . . . . . . . . . . . . . . . . . . . . 38
SCR reduction agent . . . . . . . . . . . . . 39
5 Maintenance . . . . . . . . . . . . . . . . . 40
Maintenance schedule . . . . . . . . . . . . 40
6 Servicing and maintenance work . . . . . 43
Lubricating oil system. . . . . . . . . . . . . 43
4 2011
General
DEUTZ diesel engines
DEUTZ diesel engines and the appropriate exhaust
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
aftertreatment components are the result of years of
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
research and development. The detailed know-how
functioning and high reliability. tact to your nearest local service partner.
gained by this in connection with the high quality de-
mands are the guarantee for production of engines DEUTZ Xchange components California
with a long life, high reliability and low fuel consump- Proposition 65 Warning
tion. Naturally the high demands for protection of the DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high Diesel engines and some of its constituents are
environment are also met. known to the State of California to cause cancer,
as for new parts. DEUTZ replacement parts are
Safety precautions when the engine is running equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
liability. Masthead
Maintenance work or repairs may only be performed
on the shut-down engine. Make sure that the engine Asbestos DEUTZ AG
cannot be started inadvertently - Danger of accident!
The gaskets used in this engine contain no asbestos. Ottostrae 1
After repair work: Check that all guards have been Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from 51149 Kln
maintenance and repair work.
the engine. Germany
Observe industrial safety regulations when running Service Phone: +49 (0) 221-822-0
the engine in an enclosed space or underground. We want to preserve the high performance of our en- Fax: +49 (0) 221-822-3525
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
E-Mail: info@deutz.com
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
2011 5
General
1 Danger
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.
Caution
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.
Notes
This symbol accompanies notes of a gen-

eral kind.
6 2011
Model Engine description

Engine type designation Emissions legislation
2
This manual covers the following engine types The engines of these operating instructions fulfill
the following exhaust emissions regulations A B
TCD 7.8 L6
USA EPA Tier 4i
TCD EU Stage IIIB
Mot.-Typ Mot.-Nr.
T Exhaust gas turbocharger
C Charge air cooler The engine and the corresponding EAT
system (Exhaust After Treatment) are
D Diesel adapted to each other and linked by an ap-
propriate electronic controller. R
7.8 They are only certified by the responsible DEUTZ AG MADE IN GERMANY
7.8 Displacement in litres authorities and comply with the permissible

exhaust limits in this combination.
Operation of the engine with other EAT
L6
systems is not allowed. Rating plate
L in series
The type (A), engine number (B) and performance
6 No. of cylinders The engines of this operating manual may data are stamped on the rating plate.
only be used with a functioning exhaust af-
tertreatment system. The engine type and number must be stated when
purchasing spare parts.
2011 7
Engine description Model
2 C
D
xxxxxxx
C
Location of the rating plate Engine serial number

The rating plate (C) is fixed to the cylinder head cov- The engine number (D) is stamped onto the crank-
er or the crankcase. case (arrow) and onto the rating plate.
8 2011
Model Engine description
left
2
1 2
right
1
EAT serial numbers Cylinder numbering

Cylinder arrangement
1 Rating plate of the diesel oxidation catalytic
converter The cylinders are counted consecutively starting
from flywheel (1).
2 Rating plate of the diesel particle filter
Direction of rotation
The serial numbers of the exhaust aftertreatment
Looking onto the flywheel.
components are stamped on the rating plates.
rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
2011 9
Engine description Engine illustrations
2 TCD 7.8 L6
Agricultural engine
11 View from right (example)
1 Coolant outlet
2 Tension pulley
10 3 Coolant inlet
4 V-rib belt
5 Lubricating oil drain plug
6 Lube oil replacement filter
1 7 Lubricating oil dipstick
9 8 Exchangeable fuel filter
9 Rail
10 Crankcase breather
2 11 Lubricating oil filling
8
3
7
4
10 2011
Engine illustrations Engine description

TCD 7.8 L6
Agricultural engine
2
View from left (example)
1 Combustion air inlet
1 2 Heating flange
3 Exhaust outlet
4 Starter
2011 11
Engine description Engine illustrations
2 TCD 7.8 L6
Industrial engine with regeneration burner
11 View from right (example)
1 Coolant outlet
2 V-rib belt
10 3 Tension pulley
4 Coolant inlet
5 Lubricating oil drain plug
6 Lubricating oil dipstick
7 Lube oil cooler
9 8 Lube oil replacement filter
9 Rail
1 10 Crankcase breather
11 Lubricating oil filling
8
3
6
5
4
12 2011
Engine illustrations Engine description

TCD 7.8 L6
Industrial engine with regeneration burner
2
1 View from left (example)
2 Heating flange
3 Burner
4 Flexible pipe
2 5 Exhaust outlet
6 Air compressor
2011 13
Engine description Lubricating oil diagram
2 Lubricating oil system

(example)
1 Lubricating oil sump
2 Lubricating oil pump
13 12 11 10 3 Overpressure valve
4 Lube oil cooler
5 Bypass valve
9 6 Bypass valve
7 Pressure control valve
8 Lubricating oil filter
9 Main lube oil channel
6 5 4 10 Piston cooling nozzle
11 Rocker arm
12 Turbocharger
13 Air compressor
Optional
8 7 3 2 1
14 2011
Fuel diagram Engine description

Fuel schematic (example)
1 Fuel tank
2
6 7 8 9 2 Fuel pre-filter
3 Fuel pump
4 Exchangeable fuel filter
5 Fuel supply line to the control block FCU (Fuel
Control Unit)
6 Control block FCU (Fuel Control Unit)
10 7 High-pressure pump
8 Rail
9 Injector
10 Return line
11 11 Fuel return to fuel tank
1 2 3 5 4
2011 15
Engine description Coolant diagram
2 6 7 8 9 10
x3 x2 x1 x2
T
x2
1 2 3 4 5 6
x3 x1
5 4 3 2 1 12 11
16 2011
Coolant diagram Engine description

Coolant schematic (example)
1 Coolant pump
2
2 Lube oil cooler
3 Coolant supply for engine cooling
4 Cylinder pipe/head cooling
5 Air compressor
Optional
6 Pre-heating of the AdBlue tank
Optional
7 Exhaust return cooler
8 Temperature transmitter
9 Thermostat
10 Compensation tank
11 Cooler
12 Connection possibility for cab heating
2011 17
Engine description Exhaust gas return
2 External exhaust gas recirculation

1 Exhaust gas partial flow
12 13 1 2 3 (uncooled)
2 Feeder actuator cooling
3 Actuator
(electrically actuated)
4 Return actuator cooling
5 Coolant line to the EGR cooler
6 Exhaust return cooler
7 Pressure sensor
8 Temperature transmitter
9 Exhaust gas partial flow
(cooled)
10 Coolant return
11 Mixing pipe
13 Throttle valve
11 10 9 8 7 6 5 4
18 2011
Exhaust gas aftertreatment Engine description

Selective Catalytic Reduction (SCR)
Example:
2
1 Engine (example)
2 Engine control unit
3 Vehicle control unit VECU (VehicleElectronic-
1 2 3 4 5 ControlUnit )
Optional
4 AdBlue supply pump
5 AdBlue tank
6 Temperature/Filling level sensor
7 Coolant valve
6 8 SCR catalytic converter
9 NOX sensor
10 Metering module
11 Exhaust temperature sensor
7
8
11
10 9
2011 19
Engine description Exhaust gas aftertreatment
2 Diesel Particle Filter (DPF)

Example:
1 Burner
2 Air compressor
1 4 5 6 7 8
3 Fuel metering unit
4 Flexible pipe
5 Exhaust line
6 Exhaust temperature sensor
7 Differential pressure sensor
8 NOX sensor
9 Diesel particle filter
2 3 9
20 2011
Electrics/Electronics Engine description
1 2 3 4 5 11
Electronic engine control
2
Engine side
1 Fuel transducer
12 2 Rail pressure sensor
3 Coolant temperature transmitter
6 4 Charge air pressure transmitter, charge air tem-
13 perature transmitter
5 Engine control unit
6 Central plug (for engine control)
14 7 Speed transmitter via crankshaft
8 Speed transmitter via camshaft
9 Lubricating oil pressure transmitter
15 10 Lubricating oil level transmitter (optional)
Equipment side
16
11 Power supply (battery)
12 Multifunction displays
17 13 Signal outputs, e.g. for lamps, torque (PWM),
speed, engine operation, etc.
14 Inputs (e.g. override button)
18 15 Accelerator
16 Hand throttle
17 Optional function selector switch, e.g. for P de-
19 gree, type of controls, maximum curve, fixed
speeds, etc.
18 Detachable key switch Start/Stop
20 19 Diagnosis button
20 Error lamp
21 Diagnostic interface/CAN bus
7 8 9 10 21
2011 21
Engine description Electrics/Electronics
2 Information about the engine electronics

This engine is equipped with an electric control unit.
It is strictly prohibited:
a) to make changes or connections to the
Diagnostics
DEUTZ control units are equipped with self-diagnos-
wiring of the electrical control devices and tics. Active and passive error entries are saved in the
The equipping of the respective system depends on
the data transmission cable (CAN lines). error memory. Active errors are displayed on error
the desired scope of function and the planned type of
b) to switch control units. lamps/diagnostics lamps (67).
engine application.
Otherwise guarantee rights will be lost!
The resultant wiring with pin assignment can be seen A diagnosis can be made with:
Diagnostic and maintenance work may
in the appropriate wiring diagram. only be carried out by authorised personnel Error lamp (flash code)
The installation regulations of the DEUTZ AG must using equipment approved by DEUTZ. CAN bus
also be taken into account. DEUTZ electronics display
Installation instructions
Diagnostic socket (SERIDA)
Precautions The control units are calibrated to the respective en-
gine and identified by the engine number. Every en- Equipment-side wiring
The connections of the control units are gine may only be operated with the appropriate The DEUTZ AG installation regulations should be
only dust and water proof when the mating control unit. adhered to. In particular, the plug contact must be
plugs are plugged (protection class IP69K)!
Setpoint transmitters (pedal value transmitters) nec- crimped with the appropriate standard tools. If it is
The control units must be protected against
essary for vehicle operation must be connected to necessary to do so, plugged-in contacts may only be
spray water and moisture until plugging in
the vehicle side cable harness and calibrated with removed from the plug housing with the proper tools.
the mating plugs!
the DEUTZ diagnostic program SERDIA (SERvice
Reverse polarity can lead to failure of the
DIAgnosis). Wiring and cable assignment of the ve-
control unit.
hicle side cable harness must be taken from the con-
To avoid damaging the control units, all the
nection diagram of the DEUTZ installation
connections on the control unit must be dis-
consulting.
connected before electric welding work.
Interventions in the electrical system con- Supply voltage
trary to the DEUTZ regulations or by un-
qualified personnel can permamently 12 Volt
damage the engine electronics and have 24 Volt
serious consequences which are not cov- It should be ensured that the battery is sufficiently
ered by the manufacturer's guarantee.
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.
22 2011
Ambient conditions Operation

Cold start aid
Depending on the type of engine, glow plugs,
3
heating plugs, heating flange, flame glow system
can be used as cold starting aids.(27)
Coolant
0 C Observe the mixing ratio anti-freeze/cooling wa-
ter. (38)
High ambient temperatures, high altitude
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
Low ambient temperatures unit.
Lubricating oil Under the following application and operating condi-
Select the lubricating oil viscosity according to tions, the amount of fuel must be reduced.
the ambient temperature. above 1000 m altitude
If cold starting occurs frequently cut the lube oil above 30 C ambient temperature
changing interval by half.
Reason: Air density decreases as altitude or ambient
Fuel temperature increase. This reduces the amount of
Use winter fuel below 0 C (37). oxygen in the engine intake air and the fuel-air mix-
ture would be too rich if the injected amount of fuel
Battery were not reduced.
A good charging condition of the battery (60) The results would be:
is the prerequisite for starting the engine. black smoke in the exhaust
Heating up the battery to approx. 20C improves high engine temperature
the starting behaviour of the engine. (Remove
reduction in engine performance
and store the battery in a warm room).
possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
you have any other questions.
2011 23
Operation Initial start-up
3 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 (57).
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 Pour in fuel
Fill with engine lube oil
change if necessary.
Check the intake air cleaner (if available, main- Never fill the fuel tank while the engine is
Low lubricating oil level and overfilling lead
tain according to maintenance indicator). running.
to engine damage.
Drain lubricating oil and condensation water from Ensure cleanliness.
the charge air cooler. Do not spill fuel.
Fill with engine lube oil. The engines are generally supplied without Additional venting of the fuel system by a 5
Fill the coolant system (72). lubricating oil filling. minute trial run at idle speed or on low load
Select lubricating oil quality and viscosity is absolutely essential.
before filling.
Order DEUTZ lubricating oils from your The fuel low pressure system must be vented be-
DEUTZ partner fore the first start-up after filling with the manualy
supply pump.
Fill the engine with lubricating oil via the lubricat-
ing oil filler neck. Only use clean commercially available brand diesel
Observe the lubricating oil filling level (72). fuel. Observe fuel quality (37).
Use summer or winter-grade fuel, depending on the
ambient temperature.
24 2011
Initial start-up Operation
AdBlue 3 2
Start the engine and run up until the thermostat
opens (line (2) heats up). 3
Engine operation with open thermostat 2 - 3 min-
utes.
Diesel Exhaust Fluid 1 Check the coolant level and top up coolant if nec-
essary.
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.
If required, repeat procedure with engine start.
Fill up coolant to the MAX mark on the compen-
Filling with AdBlue Filling the coolant system sation tank and close the cooling system cap.
Switch on any available heating and set to the
Exhaust aftertreatment systems The coolant must have a prescribed con- highest level so that the heating circuit is filled
centration of cooling system corrosion pro- and vented.
SCR Selective Catalytic Reduction
tection agent! Observe the filling volume of the cooling system
Never operate the engine without coolant, (72).
Only re-fuel when the engine is not running. even for a short time!
Only fill with AdBlue!
Other media (e.g. diesel), even in the
smallest amounts, can cause destruction of Order coolant corrosion protection agent
the system. from your DEUTZ partner.
If you have filled with e.g. diesel and this
has got into the system, the complete Connect coolant outlet (2) and coolant inlet (1) to
AdBlue injection system must be re- the cooling system. Connect the feed line of the
placed! compensation tank to the coolant pump or to the
If the filled medium (e.g. diesel) has not coolant inlet line (3).
reached the lines and supply pump/meter- Connect ventilation line from the engine and, if
ing module, an emptying and thorough necessary, from the cooler to the compensation
cleaning of the AdBlue tank will be ade- tank.
quate. Fill cooling system via the compensation tank.
Ensure cleanliness. Close compensation tank with valve.
2011 25
Operation Initial start-up
3 Trial run
Additional venting of the fuel system by a 5

minute trial run at idle speed or on low load
is absolutely essential.
Carry out a brief trial run up to operating temperature
(approx. 90 C) after preparations.
Do not load the engine if possible.
Work with the engine not running:
Check engine for tightness.
Check lubricating oil level, if necessary top
up.
Check the coolant level and top up coolant if
necessary.
Work during the trial run:
Check engine for tightness.
Do not subject the covers to loads.
26 2011
Start procedure Operation

Starting
Disconnect the engine by uncoupling de-
vices to be driven where possible.
3
Before starting, make sure that nobody is
standing in the immediate vicinity of the en- A
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
been removed from the engine. B
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 C
the heating flange is automatically actuated
(starter does not receive current as a result
of a fault in the equipment/customer electri-
cal control system) the starting procedure with cold starting device
must be abandoned (set the ignition switch Insert key.
to OFF, disconnect the power supply to the
Position 0 = no operating voltage.
heating flange).
Turn key to the right.
If the engine fails to fire and the error lamp Position 1 = operating voltage.
lights, the electronic engine control has ac- Pilot lamps (A), (B) and (C) light up.
tivated the start lock to protect the engine.
stage 2 = pre-heating
The start lock is released by switching off
the system with the ignition key for about 30 Preheat until the glow display goes out; an
seconds. error has occurred if the preheating indicator
Do not actuate the starter for more than flashes; e.g. the preheating relay is stuck,
20 seconds. If the engine does not start up, which can discharge the battery completely
wait for one minute and then repeat the when at a standstill.
starting process. Engine is ready for operation.
If the engine does not start up after two at- Push the key in and turn further clockwise
tempts, determine the cause as per fault ta- against spring pressure.
ble (62). Level 3 = start.
Do not run up the engine immediately to
high idling speed / full load operation from release the key as soon as the engine starts up.
cold. The pilot lamps will go out.
2011 27
Operation Start procedure
3 If the starter is controlled by the electronic engine

control via a relay:
the maximum start duration is limited.
the pause between two start attempts is speci-
fied.
the start is then continued automatically
starting while the engine is running is prevented.
If the touch start function is programmed, a short
start command with the ignition key in position 2 or a
start button, if available, suffices.
28 2011
Operation monitoring Operation

Electronic engine control
The statuses are displayed by the error lamp.
essary.
The switch-off process has been accom- 3
plished.
The system monitors the condition of the engine and There may be a start lock after engine stop.
itself.
The start lock is deactivated by turning off the
Function test system with the ignition key for approx. 30s.
Ignition on, error lamp lights up for approx. 2 Additional control lamps, e.g. for lubricating
seconds and then goes out. oil pressure or lubricating oil temperature,
Check the error lamp if there is no reaction are switched on if necessary.
after switching on the ignition. The power reduction can be bypassed, the
The lamp does not light automatic switch-off delayed or a start lock
After the lamp test an extinguished lamp indi- bypassed with the override key on the instru-
cates an error-free and trouble-free operat- ment panel to avoid critical situations. This
ing state within the scope of the control brief deactivation of the engine protection
possibility. functions is logged in the control unit.
The engine protection functions are released in Display instrument
Continuous light co-operation with the equipment manufacturer
Error in the system. and the DEUTZ installation consulting and may Possible displays:
Operation continued with restrictions. be designed individually. It is therefore absolute- Colour scale
The engine must be checked by a DEUTZ ly essential to observe the operating instructions Display of operating state by coloured areas:
partner. of the equipment manufacturer. green = normal operating state
If a lamp lights steadily a monitored measur- red = critical operatng state
ing variable (e.g. coolant temperature, lubri-
Take suitable action.
cating oil pressure) has left the permissible
value range. Measured value scale
Depending on the fault, the engine power may be Actual value can be read off directly. The
reduced by the electronic engine control to pro- nominal value should be taken from the
tect the engine. Technical Data (72).
Flashing
Serious error in the system.
Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guaran-
tee!
The engine has reached switch-off condition.
Engine forced to run at low idle speed to cool
the engine, with automatic shutdown if nec-
2011 29
Operation Operation monitoring
3 Instruments and symbols
Instruments/symbols Designation Possible display: Measure

Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play
Coolant temperature Coolant temperature too high Switch off engine
Lubricating oil temperature Lubricating oil temperature too high Switch off engine
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or Switch off engine
lamp while the engine is running, the lubricating oil pres-
sure is too low
Lube oil level If the pilot lamp lights up after starting the engine or Fill up lube oil
while the engine is running, the lubricating oil level is
too low
Coolant level If the control lamp lights up after the engine starts or Shut down the engine, allow to cool and top up cool-
while the engine is running, the coolant level is too ant
low
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
Horn With acoustic signal See fault table (62).
30 2011
Operation monitoring Operation

Instruments/symbols Designation Possible display: Measure 3
SCR function lamp Continuous light AdBlue/DEF filling level below 15 %
Flashing AdBlue/DEF filling level below 10 %
Rapid flashing AdBlue/DEF filling level below 5 %
Filling AdBlue/DEF
Engine warning lamp Flashing In combination with rapid flashing of the SCR function lamp the
Rapid flashing engine performance is reduced in two steps
Filling AdBlue/DEF
DPF function lamp Flashing Regeneration of the diesel particle filter is started
Continuous light Diesel particle filter is regenerated
Rapid flashing Regeneration of the diesel particle filter cannot be completed
Engine warning lamp Continuous light An interruption in the regeneration is shown in combination with the
Flashing DPF function lamp.
The engine performance is reduced when the lamp lights continu-
ously.
The engine is stopped when the lamp flashes.
2011 31
Operation Operation monitoring
3

Operation monitoring of the diesel particle filter
Faults in the exhaust aftertreatment system
Filling level of the AdBlue tank
Battery voltage
Accelerator position
Fuel consumption
Operating hours
Error messages are displayed in clear text and
acoustically; the error memory of the control unit can
be read out.
For a detailed description, refer to the operating in-
structions enclosed with the DEUTZ Electronic Dis-
play.
DEUTZ Electronic Display

In order to show measured values and error messag-
es of the EMR control unit, a CAN display is option-
ally available, which can be integrated into the
dashboard of the drivers position of working ma-
chines.
The following data may be displayed if they are sent
by the control unit.
Engine speed
Engine torque (current)
Coolant temperature
Suction intake air temperature
Exhaust gas temperature
Lubricating oil pressure
Coolant pressure
Charge air pressure
Fuel pressure
Status of the regeneration of the diesel particle
filter
32 2011
Regeneration Operation
Regeneration of the diesel particle filter The control unit registers the engine shutdown as a
fault. 3
Temperatures of approx. 600 C occur on
Manual mode
the exhaust pipe during regeneration.
These are independent of the actual engine Regeneration is necessary when the filter charging
performance, even in engine idling. has reached 100 % of the nominal charging.
Danger of burns!
The regeneration lamp starts flashing.
Automatic mode The operator must enable regeneration with the en-
able button.
The DPF system is operated without any operator in-
tervention in the automatic mode. Regeneration starts immediately after the enable.
Regeneration is necessary when the filter charging The regeneration lamp lights continuously during re-
has reached 100 % of the nominal charging. generation.
The regeneration lamp starts flashing. The regeneration lasts 25 minutes on average.
The regeneration begins after a delayed start. The regeneration lamp goes out when regeneration
The regeneration lamp lights continuously during re- has been successfully completed.
generation. If an active regeneration has to be interrupted, the
The regeneration lasts 25 minutes on average. operator can press the button to stop regeneration.
The regeneration request is still active because re-
The regeneration lamp goes out when regeneration
generation has not taken place.
has been successfully completed.
The regeneration lamp starts flashing.
If the regeneration has to be prevented or interrupted
after it has already been started (e.g. machine is in a The regeneration start must be re-enabled by the op-
hall), the operator must press the generation preven- erator.
tion switch. Regeneration starts immediately after the enable.
The regeneration request is still active because re- The regeneration lamp lights continuously during re-
generation has not taken place. generation.
The regeneration lamp starts flashing. If the button is not pressed for a long time when re-
No regeneration is possible as long as the regenera- generation is requested, the filter continues to be
tion prevention switch is actuated. charged.
If the regeneration switch is actuated continuously, The engine warning lamp lights, then the perform-
the filter is still charged. ance is reduced and the engine is finally shut down.
The engine warning lamp lights, then the perform- The control unit registers the engine shutdown as a
ance is reduced and the engine is finally shut down. fault.
2011 33
Operation Stop procedure
3
A
Shutting off
Avoid switching off from full load (coking/

blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-
bricating 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 ap-
proximately 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 automati-
cally.
Run engine up to idling speed.
Move the key to position 0.
Control lamps A+B+C go out.
34 2011
Lubricating oil Operating Media

General
Modern diesel engines place very high demands on
bricating oil flows, depending on the temperature.
The lubricating oil viscosity only has a small influ-
http://www.deutz.com
de \SERVICE \Betriebsstoffe und Addi-
4
ence and effect on the quality of the oil.
the lubricating oil to be used. The specific engine tive\Deutz Quality Class\DQC-Freigabeliste
performances which have increased constantly over Synthetic lubricating oils are used increasingly and
offer advantages. These lubricating oils have better en \SERVICE \Operating Liquids and Addi-
the last few years lead to an increased thermal load
temperature and oxidation stability as well as rela- tives\Deutz Quality Class\DQC Release List
on the lubricating oil. The lubricating oil is also more
exposed to contamination due to reduced oil com- tively low cold vicosity. Since some processes which The choice of luricating oil essentially depends on
sumption and longer oil change intervals. For this are relevant for determining the lubricating oil the exhaust aftertreatment system.
reason it is necessary to observe the requirements change times are largely dependent on the oil quality
(e.g. the infiltration of soot and other contamination), The following lubricating oils are permissible for the
and recommendations described in this operating
the oil change time for synthetic lubricating oils may engines in this operating manual:
manual in order not to shorten the life of the engine.
not be increased in relation to the specifications on
Lubricating oils always consist of a base oil and an lubricating oil change intervals. Permissible quality class
additive package. The most important tasks of a lu- DEUTZ Others
bricating oil (e.g. wear protection, corrosion protec- Biodegradable lubricating oils may be used in
tion, neutralisation of acids from combustion DEUTZ engines if they meet the requirements of this SCR
products, prevention of coke and soot deposits on operating manual. Selective Catalytic Reduction
the engine parts) are assumed by the additives. The DQC III Please contact your DEUTZ part-
Quality
properties of the base oil are also decisive for the DQC III LA ner
quality of the product, e.g. with regard to thermal Lubricating oils are classified by DEUTZ according
load capacity. to their performance and quality class (DQC: DEUTZ DQC IV
In principle, all engine oils of the same specification Quality Class). Essentially, the following applies: the DPF
can be mixed. However, mixing of engine oils should higher the quality class (DQC I, II, III, IV), the more Diesel Particle Filter
be avoided because the worst properties of the mix- effective/the better quality the lubricating oil is. DQC III LA Please contact your DEUTZ part-
ture are always dominant. The DQC quality classes are still to be extended by ner
The lubricating oils approved by DEUTZ have been the DQC-LA quality classes which include the mod-
ern, low-ash lubricating oils (LA = Low Ash). For low-ash engine oils released according to the
thoroughly tested for all engine applications. The ac- DQC system an appropriate reference is made in the
tive ingredients they contain are compatible with Lubricating oils according to other comparable spec- oil release list.
each other. Therefore, the use of additives for lubri- ifications can be used as long as they meet DEUTZ
cating oils is not permitted in DEUTZ engines. requirements. In regions in which none of these
The lubricating oil quality has a considerable influ- qualities are available, please contact your responsi-
ence on the life, performance and thus also on the ble DEUTZ partner.
costs-effectiveness of the engine. It basically applies or see www.deutz.com
that: The better the lubricating oil quality, the better
these properties.
The lubricating oil viscosity describes the way the lu-
2011 35
Operating Media Lubricating oil
4 DEUTZ lubricating oils DQC III

TLX - 10W40 FE
Sulphur content in diesel fuel of >0.5 weight
%. C
If the lubricating oil change intervals are not
Not for DPF 45
reached within a year, the oil should be changed
Container Order number: at least once a year. 40
5 litre container 0101 6335 Viscosity
35
20 litre container 0101 6336
The ambient temperature at the installation site or in
209 litre barrel 0101 6337 the application area of the engine is decisive for 30
choosing the right viscosity class. Too high a viscos-
DEUTZ lubricating oils DQCIII LA low-ash ity can lead to starting difficulties, too low a viscosity 25
DEUTZ Oil Rodon 10W40 Low SAPS can endanger the lubrication effect and cause a high
20
lubricating oil consumption. At ambient temperatures
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
Container Order number:
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
below -40 C, the lubricating oil must be pre-heated 15
20 litre container 0101 7976 (e.g. by storing the vehicle or the machine in a hall).
209 litre barrel 0101 7977 The viscosity is classified according to SAE. Multi- 10
purpose lubricating oils should be used basically.
DEUTZ lubricating oils DQC IV synthetic Single-purpose lubricating oils can also be used in 5
DQC IV - 5W30-UHP enclosed, heated spaces at temperatures >5 C.
0
Not for DPF
The prescribed lubricating oil quality must
Container Order number: -5
be observed when selecting the viscosity
20 litre container 0101 7849 class! -10
209 litre barrel 0101 7850 Depending on the ambient temperature we recom-
-15
mend the following common viscosity classes:
Lubricating oil change intervals
-20
The intervals depend on:
lubricating oil quality -25
sulphur content in the fuel
type of application of engine -30
The lubricating oil change interval must be -35
halved if at least one of the following conditions
applies: -40
Constant ambient temperature below -10 C
(14 F) or lube oil temperature below 60 C
(84 F).
36 2011
Fuel Operating Media

Permissible fuels
In order to satisfy the exhaust gas legislation, diesel
the legal emission values are made with the test fu-
els specified in the laws. These correspond to the 4
diesel fuels in accordance with EN 590 and
engines that are equipped with an exhaust aftertreat-
ASTM D 975 described in the operation manual. No
ment system may only be operated with a sulphur-
emission values are guaranteed with the other fuels
free diesel fuel.
described in this operation manual.
The operational reliability and durability of the indi-
The respective fuels prescribed by law must be used
vidual exhaust aftertreatment technologies cannot
to comply with the national emission regulations
be assured upon failure to comply.
(e.g. sulphur content).
Exhaust aftertreatment systems Please contact your DEUTZ partner
SCR Selective Catalytic Reduction
DPF Diesel particle filter
de \SERVICE\Betriebsstoffe und Additive\Kraft-
DOC Diesel oxidation catalytic con- stoffe
verter
en \SERVICE\Operating Liquids and Addi-
The following fuel specifications / standards are ap- tives\Fuels
proved:
Winter operation with diesel fuel
Diesel fuels
DIN 51628 Special demands are placed on the cold behaviour
(temperature limit value of the filtrability) for winter
EN 590
operation. Suitable fuels are available at filling sta-
Sulphur <10 mg/kg tions in winter.
ASTM D 975 Grade 1-D S15 For engines with DCR DEUTZ common
ASTM D 975 Grade 2-D S15 rail injection, the mixing of petroleum and
adding of extra low additives is not permis-
Sulphur <15 mg/kg sible.
Light heating oils At low ambient temperatures paraffin discharges can
EN 590 lead to blockages in the fuel system and cause oper-
ating faults. Below 0 C ambient temperature use
Sulphur <10 mg/kg winter diesel (down to -20 C) (filling stations provide
If other fuels are used which do not meet the require- this in good time before the cold season starts).
ments of the operating manual, the warranty will be Special diesel fuels can be used for arctic cli-
voided. mates to -44 C.
The certification measurements for compliance with
2011 37
Operating Media Coolant
4 General Total hardness too high:

Mixing with softened water (pH neutralized con-
Please contact your DEUTZ partner if the DEUTZ
cooling system corrosion protection agent is not
Never operate the engine without coolant, densate or water softened by ion exchanger). available.
even for a short time! Total hardness or carbonate hardness too low: or see www.deutz.com
Mixing with harder water (harder water is usually
In liquid-cooled engines, the coolant must be condi- available in the form of drinking water). http://www.deutz.com
tioned and monitored, otherwise the engine could be Chlorides and/or sulphates too high: de \SERVICE\Betriebsstoffe und
damaged by: Mixing with softened water (pH neutralized con- Additive\Khlsystemschutz
corrosion densate or water softened by ion exchanger). en \SERVICE\Operating Liquids and Addi-
cavitation Cooling system corrosion protection agent tives\Cooling System Conditioner
freezing
The cooling system must be monitored regularly.
overheating Health damaging nitrous amines form This also includes checking the coolant system cor-
when nitrite-based cooling system corro- rosion protection agent concentration in addition to
Water quality
sion protection agents are mixed with checking the coolant level.
The right water quality is important for conditioning amine-based agents!
The cooling system corrosion protection agent con-
the coolant. Clear, clean water within the following
centration can be checked with conventional test in-
analysis values should always be used: Cooling system corrosion protection agents struments (e.g. refractometer).
must be disposed of in an environmentally
Analysis values min max ASTM friendly way. Cooling system Water percent- Cold pro-
ph value 6,5 8,5 D 1293 corrosion protec- age tection up
The conditioning of the coolant for liquid-cooled
Chlorine (Cl) [mg/l] - 100 D 512 DEUTZ compact engines is performed by mixing an tion agent percent- to
D 4327 anti-freeze with corrosion protection inhibitors based age
Sulphate (SO4) [mg/l] - 100 D 516 on ethylene glycol into the water. min. 35 % 65 % -22
Total hardness [mmol/l] 0,54 3,56 D 1126 40 % 60 % -28
DEUTZ cooling system corrosion protection agent
(CaCO3) [mg/l] 54 356 max. 45 % 55 % -35
Container Order number:
[dGH] 3,0 20,0 -
5 litre container 0101 1490 At temperatures below -35 C, please contact your
Specifications of the water quality are made by the responsible DEUTZ partner.
20 litre container 0101 4616
local water board. It is possible to use other cooling system corrosion
210 litre barrel 1221 1500 protection agents (e.g. chemical corrosion protection
The water must be conditioned if it deviates from the
analysis values. This cooling system corrosion protection agent is agents) in exceptional cases. Consult your DEUTZ
free from nitrite, amine and phosphate and is adapt- partner.
pH value too low:
Addition of diluted sodium or potassium lye. ed to the materials in our engines. Order from your
Small trial mixtures are advisable. DEUTZ partner.
38 2011
SCR reduction agent Operating Media

AdBlue (urea solution AUS 32) AdBlue freezes below -11 C ambient tempera-
ture. 4
The urea solution AUS 32 is known in the It will be necessary to preheat the SCR system at
USA and North America by the name Die- ambient temperatures below -11 C.
sel Exhaust Fluid (DEF).
Protective gloves and goggles must be

worn when handling AdBlue.
Do not swallow.
Ensure sufficient ventilation.
Ensure cleanliness.
Residues of AdBlue must be disposed of
in an environmentally friendly manner.
Exhaust aftertreatment systems

SCR Selective Catalytic Reduction AdBlue tank
AdBlue is a highly-pure, acqueous, 32.5 % urea The AdBlue tank may only be filled with AdBlue.
solution which is used as an NOX reduction agent for Filling with other media can lead to destruction of the
SCR exhaust aftertreatment in vehicles with diesel system.
engines. In this case the metering pump must be replaced.
The product is designated as AdBlue or AUS 32 AdBlue should not remain in the tank for longer
(AUS: Aqueous Urea Solution) and corresponds to than 4 months.
the ISO 22241-1 NOx reduction agent AUS 32.
This must be documented.
The length of time that AdBlue can be kept without
losing quality depends on the conditions of its stor- Empty and clean the AdBlue tank when decommis-
age. sioning.
It crystallises at -11 C and at over +35 C a hydrol- Please contact your DEUTZ partner
ysis reaction is initiated, i.e. it begins to slowly re-
lease ammonia and carbon dioxide.
Direct sunlight on exposed storage containers must
always be avoided.
Barrels must not be stored for longer than one year!
Ensure that the materials and storage containers
used are resistant to AdBlue.
2011 39
Maintenance Maintenance schedule
5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
Standard maintenance schedule

TCD 7.8 L6
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E30 Maintenance Qualified personnel 500 1)2)4)
E40 Extended maintenance I 1.000 3)
E50 Extended maintenance II Authorised specialists 2.000 3)4)
E70 General overhaul 10.000 5)
Observations
1) The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (35).
2) Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
3) The display of the operating hours should be ensured by the device manufacturer. The engine operating hours are recorded by the control unit. Enquiry via the CAN
bus and display in a display or creation/display via electromechanical counter.
4) Initial setting of the valve clearance after 500 oh must be performed on the engines in this operating manual.
General overhaul
5)
The best time for a general overhaul depends to a great extent on the load, application and ambient conditions and the care and maintenance of the engine during the
operating time.
Your DEUTZ partner will advise you on determining the best time for a general overhaul.
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to EPA certification
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E55 Extended maintenance III Authorised specialists 4.500 3)
E60 Intermediate overhaul 6.000
40 2011
Maintenance schedule Maintenance

Maintenance measures
5
Stage Activity Measure Page
E10 The measures are listed in chapter 3. 24
E20 Check Lubricating oil level (if necessary top up) 43
Coolant level (top up if necessary) 25
Engine tightness (visual inspection for leaks)
Exhaust system including exhaust aftertreatment components for leaks 19
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 56
Emptying of the water tank in the fuel pre-filter 50
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 35/43
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 44
Filtercartridge of the AdBlue supply pump 51
In engines with exhaust aftertreatment system Selective Catalytic Reduction
Check Coolant (additive concentration) 52
Intake air pipes for damage
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 50
E40 Check Charge air cooler entry area (drain lube oil/condensate)
Crankcase breather valve
Battery and cable connectors 60
Cold starting device
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Replace Fuel filter cartridge 47
Fuel pre-filter with water trap (renew the filter insert if necessary). If the warning system responds (lamp/horn), the 50
water trap bowl must be emptied immediately.
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 56
2011 41
Maintenance Maintenance schedule
5 Stage
E50
Activity
Settings
Measure
Valve clearance
Page
58
Check V-rib belt and tensioning pulley 57
Filter element of the diesel particle filter DPF
Replace if necessary
Spark plug of the DPF burner
Replace if necessary
E55 Replace Filter element of the diesel particle filter DPF
Spark plug of the DPF burner
E60 Replace Injector
Crankcase breather valve
V-rib belt and tensioning pulley 57
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
annually Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Replace Fuel pre-filter 50
Every 2 Replace Dry air filter 56
years V-belt, V-rib belt and tensioning pulley 57
Coolant 38 52
Check Crankcase breather valve
Maintenance work outside the DEUTZ maintenance and service schedules
*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.
Maintenance profile
A self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment.
Order number: 0312 3794 (TCD 7.8 L6)
42 2011
Lubricating oil system Servicing and maintenance work

Regulations for working on the lubricating oil system
OIL ?
Extract the lubricating oil dipstick and read off the
oil level. 6
Do not work when the engine is running! The oil level must always be between the MIN
Smoking and naked lights prohibited! and MAX marks! Top up to the MAX mark if nec-
Be careful of hot lubricating oil. Danger of essary.
scalding! OIL Changing the lubricating oil
+80C
Pay attention to utmost cleanliness when +176F Warm up the engine (lubricating oil temperature
working on the lubricating oil system. Clean > 80 C).
the area around the components con- Ensure that the engine or vehicle is in a level po-
cerned carefully. Blow damp parts dry with sition.
compressed air.
Observe the safety regulations and nation-
al specifications for handling lube oils.
! Switch off the engine.
Place a collecting receptacle underneath the
lube oil drain screw.
Dispose of leaking lubricating oil and filter
Unscrew the lube oil drain screw, drain oil.
elements properly. Do not allow used oil to
seep away into the ground. Checking the lubricating oil level Fit a new sealing ring to the lube oil drain screw,
Perform a trial run after all work. Pay atten- insert and tighten. (tightening torque 100 Nm).
tion to tightness and lubricating oil pressure Low lubricating oil level and overfilling lead Pour in lube oil.
and then check the engine oil level. to engine damage. Quality/viscosity data (35).
The lubricating oil level may only be Filling volume (72).
checked with the engine in a horizontal po- Warm up the engine (lubricating oil temperature
sition and switched off. > 80 C).
If the engine is warm, switch off the engine Ensure that the engine or vehicle is in a level po-
and check the lubricating oil level after 5 sition.
minutes. If the engine is cold you can check
Check lubricating oil level, if necessary top up.
it immediately.
Be careful of hot lubricating oil. Danger of

scalding!
Do not pull out the dipstick while the engine
is running. Danger of injury!
Pull out the lubricating oil dipstick and wipe off
with a lint-free, clean cloth.
Insert the lubricating oil dipstick as far as it will
go.
2011 43
Servicing and maintenance work Lubricating oil system
Change lubricating oil filter Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
Remove clamps when twist protection mounted Fasten clamps of the twist protection (optional).
(optional).
Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
Collect draining lubricating oil
Clean the sealing surface of the filter support
44 2011
Lubricating oil system Servicing and maintenance work
1
6
1
1
6
2 5
5 5
4
3 4 3
Replace lubricating oil filter cartridge Collect draining lubricating oil Replace gasket and oil lightly.
Bend the filter cartridge in the collecting contain- Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. Screw the cover clockwise (25 Nm).
tion! Clean components. Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
Switch off the engine.
Loosen cover by turning 2-3 times and wait for 30
seconds.
Unscrew cover with filter cartridge anti-clock-
wise.
Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
2011 45
Servicing and maintenance work Fuel system
6 Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
Engine must be switched off! work.
Smoking and naked lights prohibited! Areas of the engine compartment from
No injection/high pressure pipes may be which dirt could be loosened must be cov-
disconnected while the engine is running. ered with a fresh, clean foil.
Caution when handling hot fuel! Work on the fuel system may only be car-
Pay attention to utmost cleanliness when ried out in an absolutely clean environment.
refuelling and working on the fuel system. Contamination of the air such as dirt, dust,
Clean the respective affected parts careful- moisture etc. must be avoided.
ly. Blow damp areas dry with compressed
air.
Observe the safety regulations and nation-
al 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 sys-
tem should be vented, a trial run performed
and the tightness checked.
It will be necessary to vent the fuel system
when commissioning for the first time, after
maintenance work or if the tank has been
run dry.
Additional venting of the fuel system by a 5

minute trial run at idle speed or on low load
is absolutely essential.
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Make a visual inspection for leaks/damage
in the system.
46 2011
Fuel system Servicing and maintenance work

6
Change the fuel filter cartridge Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 10-12 Nm
Fasten clamps of the twist protection (optional).
Remove clamps when twist protection mounted
(optional). Vent the fuel system.
Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
Catch any escaping fuel.
Clean the sealing surface of the filter support
2011 47
6 1
1
1
6
2 5
5 5
4
3 4 3
Replace fuel filter cartridge Catch any escaping fuel. Replace gasket and oil lightly.
Bend the filter cartridge in the collecting contain- Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. Screw the cover clockwise (25 Nm).
tion! Clean components. Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
Loosen cover by turning 2-3 times and wait for 30
seconds.
Unscrew cover with filter cartridge anti-clock-
wise.
Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
48 2011
Fuel system Servicing and maintenance work

1
Close the drain cock.
Change the fuel pre-filter insert
Now continue pumping several times. (The re-
turn line must be filled). 6
Lock the bayonet connection of the fuel supply
10 2 Shut off the fuel supply to the engine (with high- pump by pressing upwards and simultaneously
level tank). turning clockwise.
Place suitable collecting containers underneath. Start the engine and operate approx. 5 minutes
9 3 Open the drain cock and drain liquid. in idling mode or at low load. Check the pre-filter
Unscrew the filter cartridge together with the wa- for leaks while doing this.
8 4 ter collection vessel in anticlockwise direction
and remove.
Loosen the water collection vessel from the old
7 5 filter cartridge by turning anti-clockwise and re-
move.
11 6 The special tool can be ordered under part
number 8192 (74).
Clean/change/vent the fuel pre-filter
Empty any fuel remaining in the fuel collection
Deutz Common Rail (DCR) vessel and clean the water collection vessel.
1 Fuel supply flow to the pump Screw the water collection vessel clockwise onto
2 Fuel return flow from the control block FCU (Fuel the new filter cartridge.
Control Unit) Clean any dirt off the sealing surfaces of the new
3 Fuel pump filter cartridge and opposite side of filter head.
4 Thermostat valve with stop lever (optional) Wet the sealing surfaces of the filter cartridge
5 Filter insert slightly with fuel and screw back on to the filter
head, clockwise (17-18 Nm).
6 Electrical connection for water level sensor
Open the fuel shutoff tap and vent the system,
7 Water drain tap
see venting the fuel system.
8 Water collection vessel
9 Fuel inlet from the fuel tank Vent the fuel system
10 Fuel return to fuel tank Unlock the bayonet connection of the fuel supply
11 Connection for electrical warning lamp/horn pump by pressing upwards and simultaneously
Empty water tank turning anticlockwise. The pump pistons are now
pressed out through the spring.
Switch off the engine. Keep pumping until a very strong resistance can
Place suitable collecting containers underneath. be felt and the pumping only progresses very
Open the drain cock and drain liquid. slowly.
2011 49
6 Loosen drain plug.

Drain fluid until pure diesel fuel runs out.
turning anticlockwise. The pump pistons are now
pressed out through the spring.
9 1 Mount drain plug. Pump until no more air escapes at the vent
screw.
Tightening torque 1.6 0.3 Nm Tighten vent screw.
2
Electrical connection Tightening torque 6.5 1.3 Nm
8 Connect cable connections.
3 Lock the bayonet connection of the fuel supply
Change the fuel pre-filter insert pump by pressing upwards and simultaneously
7 Switch off the engine. turning clockwise.
4 Start the engine and operate approx. 5 minutes
Shut off the fuel supply to the engine (with high-
level tank). in idling mode or at low load. Check the pre-filter
6 5 for leaks while doing this.
Place suitable collecting containers underneath.
Electrical connection
Disconnect cable connections.
Clean/change/vent the fuel pre-filter
Loosen drain plug and drain liquid.
Deutz Common Rail (DCR)
Disassemble filter insert.
1 Venting screw Clean any dirt off the sealing surfaces of the new
2 Fuel supply flow to the pump filter cartridge and opposite side of filter head.
3 Fuel return flow from the control block FCU (Fuel Wet the sealing surfaces of the filter cartridge
Control Unit) slightly with fuel and screw back on to the filter
4 Fuel pump head, clockwise (17-18 Nm).
5 Electrical connection for water level sensor Mount drain plug.
6 Drain plug
Tightening torque 1.6 0.3 Nm
7 Filter insert
8 Fuel inlet from the fuel tank Electrical connection
9 Fuel return to fuel tank Connect cable connections.
Empty water tank Open the fuel shutoff tap and vent the system,
see venting the fuel system.
Place suitable collecting containers underneath. Vent the fuel system
Loosen vent screw.
Unlock the bayonet connection of the fuel supply
pump by pressing upwards and simultaneously
50 2011
SCR Servicing and maintenance work

6
1 2 3
Change the filter cartridge of the AdBlue supply Pull out filter insert and compensation body.
pump Insert new filter insert with compensation body.
In engines with exhaust aftertreatment system Se- Mount cover.
lective Catalytic Reduction
Tightening torque 22.5 2.5 Nm
Protective gloves are to be worn when Electrical connection
working with Selective Catalytic Reduction
Connect cable connections.
(SCR) components.
Ensure cleanliness. Start
1 Cover
2 Compensation body
3 Filter insert
Place suitable collecting containers underneath.
Remove cover.
Socket wrench insert 27 mm
2011 51
Servicing and maintenance work Cooling system
6 Specifications when working on the cooling system

the cap when cool!
The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!
Observe safety regulations and national
specifications when handling cooling me-
dia.
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do 1
not allow them to seep into the ground.
Order coolant corrosion protection agent
from your DEUTZ partner. Check coolant additive concentration Emptying the cooling system
Never operate the engine without coolant, Open the cooling system cap (1) carefully. Open cooler locking cap carefully.
even for a short time!
Check the coolant aditive concentration in the Place suitable collecting containers underneath.
Checking the coolant level with an external cooler cooler/compensation tank (2) with a convention- Remove the locking screw (1) in the crankcase.
al antifreeze measuring device (1) (e.g. hydrom- Drain coolant.
Fill in new coolant and vent the system according eter, refractormeter).
to the specifications of the cooling system manu- If the locking screw is not accessible, the drain-
Necessary coolant additive concentration Cool- age can be carried out at the engine oil cooler
facturer. ant mixing ratio (38).
Open the cooling system cap (1) carefully. (coolant duct).
The coolant level must always be between the You can order the appropriate test instrument from Insert screw again with sealant.
MIN and MAX marks of the compensation tank! your DEUTZ partner under order number 1824. Close cooler locking cap.
Fill up to the MAX mark if necessary.
52 2011
Cooling system Servicing and maintenance work

6
Fill and ventilate cooling system

the cap when cool!
Open the cooling system cap (1) carefully.
Loosen the cooler venting screw if necessary.
Fill coolant up to the max. mark or filling limit.
Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
Close cooler locking cap.
Run engine up to operating temperature (open-
ing temperature of the thermostat).
Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
tion tank if necessary.
2011 53
Servicing and maintenance work Engine cleaning
6 Cleaning work Cleaning with cold cleaner

Spray the engine with cold cleaner and leave it
For all cleaning work, make sure that no for about 10 minutes to take effect.
parts are damaged (e.g. bent cooler mesh).
Spray the engine clean with a high pressure wa-
Cover electrical/electronic parts and con-
ter jet.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
Only carry out cleaning work on the engine Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam temper-
Remove the engine cover and cooling air ature 90 C, distance at least 1m).
cover if available and remount after clean- Warm up the engine so that the water residues
ing. evaporate.
Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.
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 contamina-
tion.
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.
54 2011
Aspiration system Servicing and maintenance work

Regulations for working on the intake system
1 5 2
Renewing the safety cartridge of the dry air filter
6
Do not work when the engine is running! Never clean the safety cartridge (4).
Renew safety cartridge (4) according to the inter-

Pay attention to utmost cleanliness when
val in the maintenance schedule
working on the intake system, close intake
openings if necessary. To do this:
Dispose of old filter elements properly. Unscrew hexagon nut (5), pull out safety car-
tridge (4).
4 3 Insert new safety cartridge, screw on hexag-
onal nut.
Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
Maintaining the dry air filter
Do not clean the filter element (3) with pet-

rol or hot liquids!
Renew damaged filter elements.
Maintain the filter element (3) according to the in-
terval 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.
2011 55
Servicing and maintenance work Aspiration system
6
1
2
1
4
1
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter Emptying the cyclone precleaner
The dry air filter is maintained according to a Empty the dust discharge valve (1) by pressing
Never fill the dust container (3) with lubri-
maintenance switch or maintenance indicator. together the discharge slit.
cating oil!
Maintenance is necessary when: Remove any caked dust by pressing together the
the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. Clean the discharge slit. Loosen wing nut (1) and lift off housing cover (2).
the red field (1) of the maintenance indicator Remove the dust container (3) from the base (4)
is fully visible. and empty it. Clean the container using a brush
After carrying out maintenance work, reset the and clean diesel fuel. Then dry.
signal by pressing the button on the mainte- Place the dust container (3) on the base (4) and
nance indicator. The maintenance indicator is tighten the housing cover (2) with wing nut (1).
now ready for operation again.
56 2011
Belt drives Servicing and maintenance work

Checking the belt drive
6
Only carry out work on the belt drive with
the engine at a standstill!
After repair work: Check that all guards
have been replaced and that all tools have 1
been removed from the engine.
Check the whole belt drive visually for damage.
Renew damaged parts.
Remount protective devices if necessary. 2
Pay attention to correct fit of new belts, check the
tension after running for 15 minutes.
3
Replace V-rib belt

1 Tension pulley
2 Retaining pin
3 Assembly bore
Press tensioning roller with socket wrench in the
direction of the arrow until a retaining pin can be
fixed in the assembly bore. The V-ribbed belt is
now tension free.
First pull the V-ribbed belt off the smallest roller
or off the tensioning roller.
Mount new V-ribbed belt.
Retain tensioning pulley using the pin wrench
and remove the holding pin.
Tension V-ribbed belt using the tensioning roller
and socket wrench. Check whether the V-ribbed
belt is correctly in its guide.
2011 57
Servicing and maintenance work Adjustment work
6 Check valve clearance, adjust if necessary

Let the engine cool down for at least 30 minutes
EX IN
3
before setting the valve clearance: Lubricating oil
temperature below 80 C.
Disassemble electric line at the injectors.
Remove the cylinder head hood.
Place turning gear over fastening screws of the
belt pulleys.
2
Turn the crankcase until reaching valve overlap. 4
Outlet valve is not yet closed, inlet valve begins to
open.
The cylinders to be set can be seen in the setting 1 5
schematic.
TCD 7.8 L6
Set valve clearance Secure the rotation angle disc against twisting.
Valve overlap Settings 1 Lock nut Turn rotation angle disc clockwise to the stop
1 6 2 Setting screw (rocker arm without clearance) and set scale to
zero.
5 2 3 Rotary angle disc
Tighten locking nut.
3 4 4 Insert
5 Magnet Tightening torque 20 Nm
6 1
2 5 Now adjust the two other valves at the rocker
Valve clearance
arm, as described above.
4 3 TCD 7.8 L6 IN Inlet valve 75 10
Perform the setting procedure on every cylinder.
EX Outlet valve 105 10 Remount the cylinder head cover with a new
gasket in the reverse order of disassembly.
Fit the rotary angle disc with socket wrench inset
Tighten screws.
on the setting screw.
Fix magnet of the rotation angle disc. Tightening torque 22 Nm
Turn rotation angle disc clockwise to the stop
(rocker arm without clearance) and set scale to
zero.
Turn rotation angle disc anticlockwise until
reaching the specified rotation angle:
58 2011
Adjustment work Servicing and maintenance work

Valve clearance setting schematic
Crankshaft position 1
6
Turn crankshaft until both vaalves overlap on the
cylinder.
Outlet valve is not yet closed, inlet valve begins
to open.
Set black marked valves.
Mark the respective rocker arm with chalk to
check the setting you have made.
Crankshaft position 2
Turn the crankshaft one turn (360 ).
Set black marked valves.
2011 59
Servicing and maintenance work Electrical system
6 Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. Check the battery voltage with a standard volt-
Allow engine to warm up. meter. The voltage gives information about the
Touching a lead against the frame to check charge status.
whether it is live must not, under any cir-
cumstances, be carried out.
Battery Charge status (Volt) Check acid density
For electrical welding work, the ground ter-
minal of the welding gear must be clamped 12 Volt 12-14,4 Unscrew caps.
directly to the part being welded. 24 Volt 24-28,4 Measure the electrolyte density of individual cells
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
connect the cables between battery, gener- Check acid level
reading indicates batterys state of charge. The
ator and regulator while the engine is Unscrew caps. acid temperature when measuring should be 20
running. C if possible.
Note the manufacturers specifications concern-
Battery ing the liquid level. Check the acid level before recharging.
The liquid should normally be 10-15 mm above Screw in caps.
Electronically stored data could be lost if the top edge of the plate or reach up to any avail-
able control device. Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. Only use distilled water to top up the battery. Normal Tropical
Make sure the battery is fitted correctly and Screw in caps. 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
60 2011
Electrical system Servicing and maintenance work

Removing the battery
Always disconnect the minus pole first when re-
6
moving the battery. Otherwise there is a danger
of short-circuit!
Remove the fastenings and take out the battery.
Charging the battery
Unscrew caps.
Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
Screw in caps.
Installing the battery
Insert new or charged battery and attach the fas-
tenings.
Clean the terminals and battery poles with fine
emery paper.
Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
Grease the assembled terminals with an acid-
free, acid-resistant grease.
2011 61
Faults Fault table
7 Faults and remedies
Faults Causes Measures

Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Fuel tank empty Vent fuel system
Fuel suction pipe blocked Check
Below starting limit temperature Check
Cold starting device Check/replace
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Fuel quality does not comply with operating manual Change the fuel
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Incorrect valve clearance Check valve clearance and set if necessary
Air filter clogged / turbocharger defective Check/replace
Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
62 2011
Fault table Faults

Faults
Engine starts, but runs irregularly or
Causes
Belt/V-rib belt (fuel pump in belt drive)
Measures
Check whether torn or loose
7
fails Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Air in fuel system Vent
Fuel filter contaminated Clean
Injector defective Change
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
2011 63
Faults Fault table
7 Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lube oil cooler defective Check/replace
Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
64 2011
Fault table Faults

Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
7
Lubricating oil cooler fins soiled Clean
Fuel suction temperature too high Check the system
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air cooler soiled Clean
Resistance in cooling system is too high / flow volume too low Check the cooling system
Engine performs poorly and diagnos- Engine electronics reduce performance Please contact your DEUTZ partner
tic lamp lights
Engine does not run on all cylinders Injection line leaks Check injection line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low 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 Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
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
2011 65
Faults Fault table
7 Faults
Engine producing white smoke
Causes
Below starting limit temperature
Measures
Check
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Charge air pressure-dependent full load stop defective Check
Error in the SCR system AdBlue tank empty/display full Check tank sensor
SCR not working Check plug connection of the lines at the
pump and injector
SCR not working (cold) Lines frozen, clean lines
Implausible sensor signal Check NOx sensor
No regeneration in the diesel particle Power supply of the air compressor interrupted Check fuse and supply line, replace lock
filter Air compressor defective Check air compressor, replace lock
Air filter blocked Clean/Replace air filter, check air compres-
sor, if necessary replace lock
Fuel supply interrupted Check lines, check metering unit
Implausible sensor signal Check exhaust backpressure sensor, check
differential pressure sensor in the particle
filter, check pressure sensors in the meter-
ing unit
Swirl plate sooted up Clean, determine reason for the sooting
66 2011
Engine management Faults

Depending on the seriousness of a recognised fault,
the engine can continue to operate with limitations,
Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guaran- 7
during which the error lamp lights up continuously or tee!
indicates a serious system error by flashing. In this The engine has reached switch-off condition.
case, the engine should be switched off as soon as Engine forced to run at low idle speed to cool
1 safely possible. the engine, with automatic shutdown if nec-
essary.
Error lamp
The switch-off process has been accom-
The error lamp is located in the vehicle drive stand. plished.
2 The error lamp can release the following signals: There may be a start lock after engine stop.
Function test The start lock is deactivated by turning off the
3 system with the ignition key for approx. 30s.
Ignition on, error lamp lights up for approx. 2
seconds and then goes out. The power reduction can be bypassed, the
automatic switch-off delayed or a start lock
Check the error lamp if there is no reaction
bypassed with the override key on the instru-
after switching on the ignition.
Engine protection function of the electronic engine ment panel to avoid critical situations. This
The lamp does not light brief deactivation of the engine protection
control
After the lamp test an extinguished lamp indi- functions is logged in the control unit.
cates an error-free and trouble-free operat-
1 Diagnosis button Please contact your DEUTZ-partner in case of
ing state within the scope of the control
malfunctions and sare parts inquiries. Our spe-
2 Error lamp possibility.
cially trained personnel will ensure fast, profes-
3 Electronic engine control (EMR) Continuous light sional repairs using original DEUTZ spare parts
Error in system. in case of damage.
The error lamp goes out when all the errors Operation continued with restrictions.
have been eliminated. For some errors, it is
The engine must be checked by a DEUTZ
necessary to switch off the ignition, wait 30
partner.
s and only then switch back on the ignition.
The appropriate monitoring functions are If a lamp lights steadily a monitored measur-
switched off when a sensor fails. Only the ing variable (e.g. coolant temperature, lubri-
sensor failure is documented in the error cating oil pressure) has left the permissible
memory. value range.
Depending on the fault, the engine power
Depending on the design of the monitoring functions, may be reduced by the electronic engine
the electronic engine control can protect the engine control to protect the engine.
in certain problematical situations by monitoring im-
portant limit values during operation and checking Flashing
the correct function of the system components. Serious error in system.
2011 67
Faults Engine management
7 Diagnosis button
The diagnosis button allows the errors currently
saved in the error memory of the electronic engine
control to be visualised in the form of a flash code.
The flash codes permit:
Errors that may occur can be classified.
Clear display of the error as visual signal.
The blink codes can only be interpreted by a
DEUTZ partner.
0,8 s
0,4 s
0,4 s
0,4 s
0,8 s
0,4 s
2s 2s
Use of the diagnostic key
The flash code displays all errors in the error memo-
ry, this means active as well as passive ones.
The control unit must be switched off to start the en-
1 2 8
quiry (ignition off). Then the diagnosis button should Display system error by flash code
be pressed for approx. 1s during the start (ignition
on). Example:
Then the next error (i.e. the following one in the error Flash code 1-2-8
memory) can be displayed by pressing the diagnos- 1 x short flash
tic key again. If the last error was displayed, the first
2 x long flash
error is displayed again on pressing the diagnostic
key again. 8 x short flash
After the display of the error flash code, the error This flash code indicates a break or short circuit in
lamp goes out for five seconds. the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
the illustration.
The blink codes can only be interpreted by a
DEUTZ partner.
68 2011
Transport Transport and storage
1 8
1
2
2
Suspension equipment
Danger to life!
The engine may tip over or fall down if sus-
The transport devices mounted on this en- pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com- The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. The fastening attachment can slip, the engine
swings backwards and forwards (1).
Always use proper suspension equipment when
transporting the engine. Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
After transportation and before commissioning of
engine: remove attachment eyes (2).
2011 69
Transport and storage Engine corrosion protection
8 General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
Cooling air system, see the Exterior corrosion
protection section.
tection: The corrosion protection run can be performed In engines of the oil-cooled series the circulating
once to protect the different systems: lubricating oil serves simultaneously for cooling.
Interior corrosion protection The cooling chambers are protected automati-
Exterior corrosion protection Fuel system cally against corrosion with the lube oil system.
If a coolant with corrosion protection properties is
Your DEUTZ partner has the right corro- Close the fuel/tank/supply line to the en- poured into liquid-cooled engines, no further ac-
sion protection agent for your needs. gine so that the system is protected against tion is necessary after draining.
dirt and dust. Protect the electronics
If not, the coolant must be drained and, to ensure
The following measures for corrosion protection after against moisture and corrosion.
the formation of a covering layer on the inside
taking the engine out of operation meet the require- surfaces of the cooling system, a corrosion pro-
Fill the fuel tank with a mixture of:
ments for 12 months corrosion protection. tection run performed with a mixture of:
90 % distilled fuel
The following corrosion protection work may only be 10 % corrosion protection oil. 95 % treated water
carried out by persons familiar with it and instructed 5 % corrosion protection agent
Perform a corrosion protection run with no load
in the potential dangers. The duration of the corrosion protection run and
for at least 5 minutes.
If these measures are deviated from by exposing the the concentration of the corrosion protection
corrosion-protected engines or parts to unfavourable Lubricating oil system agent are specified by the manufacturer of the
conditions (installation outdoors or storage in damp, corrosion protection agent.
Drain lubricating oil from warm engine.
badly aired places) or damage to the corrosion pro- Then drain the coolant.
Thoroughly clean lube oil tray, cylinder head with
tection layer, a shorter corrosion protection duration
rocker arms, valves, valve springs with diesel Air intake pipes
is to be expected.
fuel or cleaning agent.
The engine corrosion protection should be checked Fill the engine with corrosion protection oil up to After the corrosion protection run, remove the
about every 3 months by opening the covers. If cor- the MAX mark and perform a corrosion protec- cylinder head cover and deinstall injectors. The
rosion is detected, the corrosion protection should tion run for at least 5 minutes so that all the com- respective piston must be set to LT.
be renewed. ponents of the lubricating oil system are wetted The accessible part of the cylinder liner should
At the end of the corrosion protection work the crank or wet all accessible parts with corrosion protec- be coated with corrosion protection oil with a
drive may no longer be turned so that the corrosion tion oil and pump corrosion protection oil through spray lance through the opening.
protection agent in the bearings, bearing liners and the engine with a separate pump until all bear- Spray corrosion protection lubricating oil into the
cylinder liners is not scraped off. ings and bearing liners are wetted. suction intake pipe.
Before operating a corrosion protected engine, the Cooling system Exterior corrosion protection
corrosion protection must be removed.
Depending on the series the engines are The engine must be cleaned thoroughly with a
Interior corrosion protection equipped with cooling air, cooling oil or cooling cleaning agent before exterior corrosion protec-
fluid system (cooling water with cooling system tion. Any signs of corrosion and damage to the
Interior corrosion protection is always provided
protection agent). paintwork must be removed.
by wetting of the walls with the implemented cor-
70 2011
Engine corrosion protection Transport and storage

Bare exterior surfaces and parts
Coat or spray all bare exterior parts and surfaces
Removal of corrosion protection
The corrosion protection must be removed from
tilled fuel or a suitable cleaning agent.
Wash out grooves of V-belt pulleys if necessary. 8
(e.g. flywheel, flange faces) with corrosion pro- the corrosion protected engine before starting. Mount V-belts or V-rib belts as specified.
tection agent. The packaging and all covers over the closed Fill with coolant.
openings must be removed. Corrosion protection agent / cleaning agent
Rubber parts
Any corrosion deposits and paint damage should
Rubber parts (e.g. muffs) which are not painted be remedied. Please ask your DEUTZ partner for reference prod-
over must be rubbed down with talcum powder. ucts for the corrosion protection agents/cleaning
Fuel system agents to be used which meet DEUTZ requirements.
Belt drive
If there is a mixture of diesel fuel/corrosion pro- or see www.deutz.com
Remove V-belts and V-rib belts and store tection oil in the fuel tank, drain it.
packed. Connect fuel/tank/supply line to the engine. Pay http://www.deutz.com
Spray V-belt pulleys and tension rollers with cor- attention to cleanliness. de \SERVICE \Betriebsstoffe und Addi-
rosion protection agent. Fill the fuel tank and fuel system with the proper tive\Motorkonservierung
fuel. en \SERVICE\Operating Liquids and Addi-
Engine openings
tives\Engine Corrosion Protection
All engine openings must be fitted with air-tight, Lubricating oil system
water-tight covers to delay the vapourisation Unscrew the lube oil drain screw, drain oil.
process of the corrosion protection agents. Fill the engine with lubricating oil via the lubricat-
With installed air compressor, the suction and ing oil filler neck.
pressure connection must be sealed by a cap.
Air should be excluded to avoid ventilation of the Coolant system
engine (chimney effect) for the suction from an If the implemented corrosion protection agent is
air supply pipe. compatible with the intended cooling system pro-
tection agent, this can be filled directly into the
Storage and packaging
coolant system as specified.
After being protected against corrosion, the en- If it is uncertain whether the implemented corro-
gine must be stored in a dry, ventilated hall and sion protection agent is compatible with the cool-
suitably covered. ing system protection agent, the cooling system
The cover must be placed loosely over the en- should be purged with fresh water for about 15
gine so that the air can circulate around it to pre- minutes before filling.
vent condensation from forming. Use a desiccant
if necessary. Removal of exterior corrosion protection
All areas and components coated with corrosion
protection agent must be washed off with dis-
2011 71
OBJ_DOKU-25980-001.fm Seite 72 Mittwoch, 13. April 2011 12:22 12
Technical data Engine and setting data
9 General technical data
Engine type Dimension TCD 7.8 L6

Working principle Four-stroke diesel engine
Charging Turbocharger with charge air cooling
Type of cooling water-cooled
Cylinder arrangement in series
No. of cylinders 6
Bore/stroke [mm] 110/136
Total displacement [cm3] 7755
Combustion process Direct injection
Injection system Deutz Common Rail (DCR)
Exhaust gas recirculation without
or
external
Exhaust gas aftertreatment Selective Catalytic Reduction SCR
or
Diesel particle filter DPF
Valves per cylinder 4
Setting with rotary angle disc [] 7510 / 10510
Firing order of the engine 1-5-3-6-2-4
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [min-1] see engine rating plate
Injection timing [BTDC] see engine rating plate
Coolant volume (only engine content without cooler / hoses and pipes)
Industrial engines/Agricultural technology [l] 14,8/10,8
Permissible continuous coolant temperature [C] max. 105
Temperature difference between coolant inlet/outlet [C] 4-8
72 2011
Engine and setting data Technical data

Engine type
Start of thermostat opening
Dimension
[C]
TCD 7.8 L6
86
9
Thermostat fully open [C] 102
Lubricating oil change volume (with filter) [l] 26,5*
Lube oil temperature in the lube oil tray, maximum [C] 125
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 80/0,8
Permissible maximum combustion air temperature after charge air cooler [C] 50
V-rib belt tensioning Automatic tensioning spring-loaded clamping roller
Weight without cooling system according to DIN 70020-A [kg] 705
*specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants
and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
2011 73
OBJ_DOKU-25980-001.fm Seite 74 Freitag, 25. November 2011 9:39 09
Technical data Tools
9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Please contact your DEUTZ partner
Special wrench for loosening exchangeable filters Rotaqtion angle disc

Order number: Order number:
170050 8190
For loosening changeable filters. For setting the valve clearance
74 2011
Tools Technical data

9
Pin wrench insert Turning gear Refractometer

Order number: Order number: Order number:
8193 100 500 0293 7499
For setting the valve clearance For turning over the engine as an attachment for the The following operating media can be evaluated with
torsional vibration damper this test device:
Coolant
Battery acid
AdBlue
The test device can be ordered via the relevant
DEUTZ partner.
2011 75
OBJ_DOKU-22665-001.fm Seite 79 Dienstag, 10. Juli 2012 12:10 12
DEUTZ Operating Fluids
SCR/DPF SCR
DEUTZ Oil Rodon 10W40 DEUTZ Oel TLX-10W40FE DEUTZ Cooling System
low SAPS (DQC III-10 LA) (DQC III-10) Conditioner
5L - 5L 0101 6335 5L 0101 1490
20 L 0101 7976 20 L 0101 6336 20 L 0101 6416
209 L 0101 7977 209 L 0101 6337 210 L 1221 1500
DEUTZ Oel DQC4-5W30-UHP

(DQC IV-10)
5L -
20 L 0101 7849
209 L 0101 7850
DEUTZ AG
Information Systems Sales & Service
Ottostrae 1
51149 Kln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
www.deutz.com
Printed in Germany
04/2011
All rights reserved
Order number:
0312 3790 en
The engine company. Original operating instructions

Deutz TCD 7.8 OM

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OBJ_DOKU-25980-001.fm Seite 1 Dienstag, 12.

April 2011 10:06 10

This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

Model Engine description

7.8 Displacement in litres authorities and comply with the permissible

Engine description Model

Location of the rating plate Engine serial number

Model Engine description

EAT serial numbers Cylinder numbering

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Lubricating oil diagram

2 Lubricating oil system

Fuel diagram Engine description

Engine description Coolant diagram

Coolant diagram Engine description

Engine description Exhaust gas return

2 External exhaust gas recirculation

Exhaust gas aftertreatment Engine description

Engine description Exhaust gas aftertreatment

2 Diesel Particle Filter (DPF)

Electrics/Electronics Engine description

Engine description Electrics/Electronics

2 Information about the engine electronics

Ambient conditions Operation

This engine is equipped with an electric

Operation Initial start-up

3 Preparations for initial commissioning

Initial start-up Operation

Operation Initial start-up

Additional venting of the fuel system by a 5

Start procedure Operation

Operation Start procedure

3 If the starter is controlled by the electronic engine

Operation monitoring Operation

Operation Operation monitoring

3 Instruments and symbols

Instruments/symbols Designation Possible display: Measure

Coolant temperature Coolant temperature too high Switch off engine

Horn With acoustic signal See fault table (62).

Operation monitoring Operation

Operation Operation monitoring

DEUTZ Electronic Display

Operation Stop procedure

Avoid switching off from full load (coking/

Lubricating oil Operating Media

Operating Media Lubricating oil

4 DEUTZ lubricating oils DQC III

Fuel Operating Media

Operating Media Coolant

4 General Total hardness too high:

SCR reduction agent Operating Media

Protective gloves and goggles must be

Exhaust aftertreatment systems

Maintenance Maintenance schedule

5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals

Standard maintenance schedule

Maintenance schedule Maintenance

Maintenance Maintenance schedule

Order number: 0312 3794 (TCD 7.8 L6)