TD 36 l4 PDF

OBJ_DOKU-44425-001.fm Seite 1 Donnerstag, 19.
Februar 2015 2:46 14
TD / TCD 3.6 L4
Operation Manual
EU Stage IV / US EPA Tier 4
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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
Non-compliance results in the expiry of the war-
the equipment manufacturer (use for the intend-
ranty!
ed purpose). Any other use above and beyond
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 be relieved once the en-
– rotating and hot components gine has shut down (for engines with common
– on motors with external ignition (high electri- rail, approx. 5 minutes, otherwise 1 minute) as
cal voltage). Contact must be avoided! 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 © 2014

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.
© 2014 3

Table of contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Lubricating oil system. . . . . . . . . . . . . 52
Foreword . . . . . . . . . . . . . . . . . . . . . 3 Fuel system. . . . . . . . . . . . . . . . . . 54
1 General . . . . . . . . . . . . . . . . . . . . 5 SCR. . . . . . . . . . . . . . . . . . . . . . 57
2 Engine description . . . . . . . . . . . . . . 7 Cooling system . . . . . . . . . . . . . . . . 58
Model . . . . . . . . . . . . . . . . . . . . . 7 Engine cleaning. . . . . . . . . . . . . . . . 60
Engine illustrations . . . . . . . . . . . . . . 10 Suction system . . . . . . . . . . . . . . . . 61
Lubricating oil diagram . . . . . . . . . . . . 16 Belt drives . . . . . . . . . . . . . . . . . . 63
Fuel diagram . . . . . . . . . . . . . . . . . 17 Electrical system . . . . . . . . . . . . . . . 65
Coolant diagram . . . . . . . . . . . . . . . 18 7 Faults . . . . . . . . . . . . . . . . . . . . .67
Exhaust gas recirculation . . . . . . . . . . . 19 Fault table . . . . . . . . . . . . . . . . . . 67
Exhaust gas aftertreatment . . . . . . . . . . 20 Engine management . . . . . . . . . . . . . 72
Electrics/Electronics . . . . . . . . . . . . . 22 8 Transport and storage . . . . . . . . . . . .74
3 Operation . . . . . . . . . . . . . . . . . . . 24 Transport . . . . . . . . . . . . . . . . . . . 74
Ambient conditions . . . . . . . . . . . . . . 24 Engine corrosion protection . . . . . . . . . 75
Initial commissioning . . . . . . . . . . . . . 25 9 Technical data . . . . . . . . . . . . . . . .79
Starting process . . . . . . . . . . . . . . . 28 Engine and setting data . . . . . . . . . . . 79
Operation monitoring . . . . . . . . . . . . . 30 Tools . . . . . . . . . . . . . . . . . . . . . 81
Exhaust gas aftertreatment system. . . . . . 34
Passive regeneration . . . . . . . . . . . . . 39
Stopping process . . . . . . . . . . . . . . . 42
4 Operating media . . . . . . . . . . . . . . . 43
Lubricating oil . . . . . . . . . . . . . . . . . 43
Fuel . . . . . . . . . . . . . . . . . . . . . . 45
Coolant . . . . . . . . . . . . . . . . . . . . 46
SCR reduction agent . . . . . . . . . . . . . 48
5 Maintenance . . . . . . . . . . . . . . . . . 49
Maintenance schedule . . . . . . . . . . . . 49
6 Servicing and maintenance work . . . . . . . 52
4 © 2014

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
information on product areas and services.
1
the use of original DEUTZ parts manufactured ac- California
aftertreatment components are the result of years of cording to the state-of-the-art can guarantee perfect Proposition 65 Warning
research and development. The detailed know-how functioning and high reliability. Diesel engines and some of its constituents are
gained by this in connection with the high quality de- known to the State of California to cause cancer,
mands are the guarantee for production of engines DEUTZ Xchange components birth defects and other reproductive harm.
with a long life, high reliability and low fuel consump-
tion. Naturally the high demands for protection of the DEUTZ replacement parts are a low-cost alternative. Masthead
environment are also met. Of course, the quality standards here are just as high
as for new parts. DEUTZ replacement parts are DEUTZ AG
Safety precautions when the engine is running equal to the original DEUTZ parts in function and re- Ottostraße 1
liability.
Maintenance work or repairs may only be performed 51149 Köln
on the shut-down engine. Make sure that the engine Asbestos Germany
cannot be started inadvertently - Danger of accident!
The gaskets used in this engine contain no asbestos. Phone: +49 (0) 221-822-0
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 Fax: +49 (0) 221-822-3525
maintenance and repair work.
the engine. E-Mail: info@deutz.com
Observe industrial safety regulations when running Service www.deutz.com
the engine in an enclosed space or underground. We want to preserve the high performance of our en-
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches.
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 homepage provides a continuously up-
quality demands as the DEUTZ engines. Further de- dated overview of the service partners near you, and
© 2014 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 © 2014

Model Engine description

Engine type designation USA
EU
EPA Tier 4 final
Stage IV
2
This manual covers the following engine types
TD 3.6 L4<56 kW A B
TD 3.6 L4
With exhaust aftertreatment system
TCD 3.6 L4
USA EPA Tier 4 final
Mot.-Typ
TCD EU Stage IV Mot.-Nr.
T Exhaust gas turbocharger

The engines of this operating manual may
C Charge air cooler only be used with a functioning exhaust af-
D Diesel tertreatment system. R
(if included in the DEUTZ scope of supply) DEUTZ AG MADE IN GERMANY
3.6
3.6 Displacement in litres
Rating plate
L4
The type (A), engine number (B) and performance
L in series data are stamped on the rating plate.
4 No. of cylinders The engine type and number must be stated when
Emissions legislation purchasing spare parts.
The engine and the corresponding EAT

system (Exhaust After Treatment) are
adapted to each other and linked by an ap-
propriate electronic controller.
They are only certified by the responsible
authorities and comply with the permissible
exhaust limits in this combination.
Operation of the engine with other EAT
systems is not allowed.
The engines of these operating instructions fulfill

the following exhaust emissions regulations
TCD 3.6 L4
With exhaust aftertreatment system
© 2014 7

Engine description Model
2 C
1
D
XXXXXXX
Location of the rating plate Engine serial number Serial numbers of the exhaust aftertreatment com-
ponents
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.
1 Rating plate of the diesel oxidation catalytic
converter
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates.
8 © 2014

Model Engine description
left
2
2 1 1
right
1
Serial numbers of the exhaust aftertreatment com- Serial numbers of the exhaust aftertreatment com- Cylinder numbering
ponents ponents
Cylinder arrangement
1 Rating plate of the diesel oxidation catalytic 1 Rating plate of the SCR catalyst The cylinders are counted consecutively starting
converter from flywheel (1).
2 Rating plate of the diesel particle filter Direction of rotation
components are stamped on the rating plates.
Looking onto the flywheel.
components are stamped on the rating plates. rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
© 2014 9

Engine description Engine illustrations
2 TD 3.6 L4
Industrial engine
View from right (example)
1 Lubricating oil filling
2 V-belts
3 Coolant inlet
4 Lubricating oil drain plug
5 Lube oil replacement filter
1 6 Lubricating oil dipstick
7 Coolant outlet
6 2
5 3
10 © 2014

Engine illustrations Engine description

TD 3.6 L4
Industrial engine
2
View from left (example)
1 Combustion air inlet
2 Crankcase breather
3 Exhaust outlet
Optional
1 5 Lube oil replacement filter
Optional
6 Diesel oxidation catalytic converter
6
3
© 2014 11

2 TCD 3.6 L4
Industrial engine
10 1 2 Throttle valve
3 Tension pulley
4 V-rib belt
5 Coolant inlet
9 Coolant outlet
9 10 Differential pressure flow meter
8 3
7 4
12 © 2014


TCD 3.6 L4
Industrial engine
2
View from left (example)
1 1 Combustion air inlet
2 Lube oil cooler
Optional
Optional
5 Generator
2
5
© 2014 13

2 TCD 3.6 L4
Agricultural technology
10 1 1 Exhaust outlet
3 V-rib belt
4 Tension pulley
5 Coolant inlet
2 7 Lubricating oil filling
9 9 Coolant outlet
10 Combustion air inlet
8 4
7 5
14 © 2014


TCD 3.6 L4
Agricultural technology
2
1 View from right (example)
© 2014 15

Engine description Lubricating oil diagram
2 Lubricating oil system

(example)
15 14 13 12 11 1 Lubricating oil sump
2 Lubricating oil pump
3 Overpressure valve
8 4 Lube oil cooler
5 Bypass valve
6 Pressure control valve
7 Lubricating oil filter
5 4 8 Main lube oil channel
9 Camshaft bearing
10 Crankshaft bearing
11 Piston cooling nozzle
12 Rocker arm
13 Hydraulic tappets
14 Turbocharger
15 Air compressor
Optional
10 9 7 6 3 2 1
16 © 2014

Fuel diagram Engine description

Fuel schematic (example)
1 Fuel tank
2
12 8 9 10 2 Fuel pre-filter
3 Fuel pump
(electrically powered)
4 Exchangeable fuel filter
5 Fuel transducer
6 High-pressure pump
with
– Control block FCU (Fuel Control Unit)
7 7 Rail
8 Injector
9 Check valve
10 Return line
11 Fuel return to fuel tank
12 Engine control unit
1 2 3 4 5 6 11
© 2014 17

Engine description Coolant diagram
2 Coolant schematic (example)

1 Coolant pump
6 7 8 9 10
2 Coolant supply for engine cooling
3 Cylinder pipe/head cooling
4 Lube oil cooler
5 Exhaust return cooler
6 Connection possibility for cab heating
7 Temperature transmitter
8 Thermostat
9 Cooler
10 Compensation tank
x1 x2
T
x1
1 2 3 4
x2
5 4 3 2 1
18 © 2014

Exhaust gas recirculation Engine description

External exhaust gas recirculation
1 Exhaust gas partial flow
2
(uncooled)
9 8 7 6 2 Actuator
(electrically actuated)
3 Coolant return
4 Exhaust return cooler
5 Coolant line to the EGR cooler
6 Differential pressure flow meter
7 Exhaust gas partial flow
(cooled)
8 Mixing pipe
9 Throttle valve
3 2 1 4 5
© 2014 19

Engine description Exhaust gas aftertreatment
2 Exhaust aftertreatment system

Example:
1 Decoupling line
9 8 7 2 Differential pressure sensor
3 Exhaust temperature sensor
6 5 Diesel particle filter
Optional
6 Differential pressure sensor
5 7 Exhaust outlet
8 Differential pressure flow meter
9 Throttle valve
4
20 © 2014

Exhaust gas aftertreatment Engine description

Exhaust aftertreatment system
Example:
2
11 12 13 1 Coolant line
to pre-heat the AdBlue® tank
10 2 AdBlue® tank
3 Solenoid valve
4 Engine control unit
9 5 AdBlue® supply pump
6 SCR catalytic converter
7 NOX sensor
8 Dosing device
9 Pressure sensor
8
10 Temperature transmitter
12 Coolant line
to cool the dosing device
13 AdBlue® line
7
1
5 4 3
© 2014 21

Engine description Electrics/Electronics
2 Electronic engine control

1 Throttle valve
1 2 3 4 2
5 2 Differential pressure flow meter
3 Rail pressure sensor
4 Coolant temperature transmitter
5 Actuator
6 Generator
7 Speed transmitter via camshaft
8 Speed transmitter via crankshaft
9 Fuel transducer
13 10 Lubricating oil pressure transmitter
(on the opposite side)
11 High-pressure pump
6 12 Central plug (for engine control)
13 Charge air pressure transmitter, charge air tem-
12 perature transmitter
7
11
10 8
22 © 2014

Electrics/Electronics Engine description

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-
2
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).
the desired scope of function and the planned type of error memory. Active errors are displayed on error
b) to switch control units. lamps/diagnostics lamps (72).
engine application. Otherwise guarantee rights will be lost!
The resultant wiring with pin assignment can be seen Diagnostic and maintenance work may A diagnosis can be made with:
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 necessary to do so, plugged-in contacts may only be
essary for vehicle operation must be connected to
spray water and moisture until plugging in removed from the plug housing with the proper tools.
the vehicle side cable harness and calibrated with
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.
To avoid damaging the control units, all the hicle side cable harness must be taken from the con-
connections on the control unit must be dis- nection diagram of the DEUTZ installation
connected before electric welding work. consulting.
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.
© 2014 23

Operation Ambient conditions
3 Cold start aid

● Depending on the type of engine, glow plugs,
heating plugs, heating flange, flame glow system
can be used as cold starting aids.(28)
Coolant
0 °C ● Observe the mixing ratio anti-freeze/cooling wa-
ter. (46)
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. ● Application at high altitude
● If cold starting occurs frequently cut the lube oil ● Application at high ambient temperatures
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 (45). 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 (65) ● The results would be:
is the prerequisite for starting the engine. – high engine temperature
● Heating up the battery to approx. 20°C improves – reduction in engine performance
the starting behaviour of the engine. (Remove
– possible impairment of starting behaviour
and store the battery in a warm room).
Consult your equipment supplier or DEUTZ partner if
you have any other questions.
24 © 2014

Initial commissioning Operation

Preparations for initial commissioning
(Maintenance schedule E 10)
3
● Remove engine corrosion protection
● Remove any transport devices.
● Check the battery and cable connections and
mount if necessary.
● Check belt tension (63).
● Have the engine monitor or warning system
checked by authorised personnel.
● Check the engine mounting.
● Check that all hose unions and clips fit properly.
The following additional work must be carried out on
generally overhauled engines:
● Check the fuel pre-filter and main filter and 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 (79). 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 (79). fuel. Observe fuel quality (45).
Use summer or winter-grade fuel, depending on the
ambient temperature.
© 2014 25

Operation Initial commissioning
3 Filling the coolant system Trial run
The coolant must have a prescribed con- Additional venting of the fuel system by a 5
R centration of cooling system corrosion pro- minute trial run at idle speed or on low load
tection agent! is absolutely essential.
Never operate the engine without coolant,
even for a short time! Carry out a brief trial run up to operating temperature
(approx. 90 °C) after preparations.
Order coolant corrosion protection agent Do not load the engine if possible.
from your DEUTZ partner. ● Work with the engine not running:
– Check engine for tightness.
– Check lubricating oil level, if necessary top
Danger of scalding from hot coolant! up.
Cooling system under pressure! Only open
– Check the coolant level and top up coolant if
the cap when cool!
necessary.
Observe safety regulations and national
Filling with AdBlue® specifications when handling cooling me- ● Work during the trial run:
dia. – Check engine for tightness.
Only re-fuel when the engine is not running.
Only fill with AdBlue®!
Other media (e.g. diesel), even in the
smallest amounts, can cause destruction of
the system and a not emmission compliant
operation.
If you have filled with e.g. diesel and this
has got into the system, the complete
AdBlue® injection system must be re-
placed!
If the filled medium (e.g. diesel) has not
reached the lines and supply pump/meter-
ing module, an emptying and thorough
cleaning of the AdBlue® tank will be ade-
quate.
Ensure cleanliness.
26 © 2014

Initial commissioning Operation

3
Do not subject the covers to loads.
© 2014 27

Operation Starting process
3 Starting
Disconnect the engine by uncoupling de-
Before starting, make sure that nobody is
standing in the immediate vicinity of the en-
vices to be driven where possible.
P 0
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
1
been removed from the engine.
When starting with the flame glow plug/
glow plug/heating flange system do not use
any other starting aid (e.g. injection with
2
start pilot). Risk of accident!
If the engine does not start properly when
the heating flange is automatically actuated
(starter does not receive current as a result
of a fault in the equipment/customer 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- – Engine is ready for operation.
tivated the start lock to protect the engine. ● Below the temperature specified in the electronic
The start lock is cancelled by switching off engine control, the pre-heating phase begins
the system with the ignition key for approx. with turning on the ignition.
2 min. ● The electronic engine control controls and acti-
Do not actuate the starter for more than vates the current feed to the glow plugs via the
20 seconds. If the engine does not start up, engine coolant temperatures.
wait for one minute and then repeat the
● Push the key in and turn further clockwise
starting process.
against spring pressure.
If the engine does not start up after two at-
tempts, determine the cause as per fault ta- – Level 2 = start.
ble (67). ● release the key as soon as the engine starts up.
Do not run up the engine immediately to – The pilot lamps will go out.
high idling speed / full load operation from
cold. If the starter is controlled by the electronic engine
28 © 2014

Starting process Operation

control via a relay:
● the maximum start duration is limited.
3
● 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.
© 2014 29

Operation Operation monitoring
3 Electronic engine control

The statuses are displayed by the error lamp.
necessary.
– The switch-off process has been accom-
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 switching off
● Function test the system with the ignition key for approx. 2
– Ignition on, error lamp lights up for approx. 2 min.
seconds and then goes out. – If necessary, additional indicator lamps are
– Check the error lamp if there is no reaction switched on, e.g. for lubricating oil pressure
after switching on the ignition. or the coolant temperature.
● The lamp does not light – optionally the power reduction can be by-
– After the lamp test an extinguished lamp indi- passed, the automatic switch-off delayed or
cates an error-free and trouble-free operat- a start lock bypassed with the override key
ing state within the scope of the control on the instrument panel to avoid critical situ-
possibility. ations. This brief deactivation of the engine
protection functions is logged in the control Display instrument
● Continuous light unit.
– Error in the system. The engine protection functions are released in Possible displays:
– Operation continued with restrictions. co-operation with the equipment manufacturer ● Colour scale
– The engine must be checked by a DEUTZ and the DEUTZ installation consulting and may – Display of operating state by coloured areas:
partner. be designed individually. It is therefore absolute- – green = normal operating state
– If a lamp lights steadily a monitored measur- ly essential to observe the operating instructions
– red = critical operatng state
ing variable (e.g. coolant temperature, lubri- of the equipment manufacturer.
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 (79).
● 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 with power reduction to
cool the engine, with automatic shutdown if
30 © 2014

Operation monitoring Operation

Instruments and symbols
3
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 Lubricating oil pressure below minimum Switch off engine
lamp
Lube oil level Lubricating oil level too low Fill up lube oil
Coolant level Coolant level too low Shut down the engine, allow to cool and top up cool-
ant
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
Horn With acoustic signal See fault table (67).
© 2014 31

Operation Operation monitoring
3 Instruments/symbols Designation Possible display: Measure

SCR function lamp Continuous light Check AdBlue® filling level
flashes (0.5 Hz) Check SCR system 34
flashes (1 Hz)
flashes (2 Hz)
Regeneration lamp Continuous light Initiate standstill regeneration 34
flashes (0.5 Hz)
flashes (3 Hz)
Ash lamp Continuous light The ash lamp indicates, that the loading of the diesel particle
filter with incombustible residues has reached a critical level
and must be replaced.39
Engine warning lamp Continuous light In combination with the SCR function lamp
Flashing Check AdBlue® filling level
Check SCR system 34
In combination with the DPF function lamp
Initiate standstill regeneration 39
32 © 2014

Operation monitoring Operation

●
●
Operation monitoring of the diesel particle filter
Faults in the exhaust aftertreatment system 3
● 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 driver´s 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
© 2014 33

Operation Exhaust gas aftertreatment system
3 Selective Catalytic Reduction (SCR) An acoustic signal must sound in case of a

fault. If a DEUTZ display is used, this has
Standstill regeneration
The urea solution AUS 32 is known in the an appropriate signal. Temperatures of approx. 600 °C occur on
USA and North America by the name Die- An acoustic signal transmitter must be in- the exhaust pipe during regeneration.
sel Exhaust Fluid (DEF). stalled additionally if an SCR function lamp A special engine operating state becomes
or customer display is used. active during standstill regeneration and
The DEUTZ SCR system continuously reduces the the machine is not allowed to be used dur-
NOx emissions from the engine (NOx=nitric oxides). Power reduction ing the active standstill regeneration.
A reduction agent, AdBlue®, injected into the ex- Danger of burns!
If a serious fault occurs or a fault is not remedied, the
haust system reacts in the SCR catalytic converter
system reacts by reducing the engine performance. The SCR system is monitored for possible formation
with the NOx emissions in the exhaust gas and re-
duces these to nitrogen (N2) and water (H2O). There is a one or two-stage performance reduction and build-up of crystals (crystalisation)
depending on the type of fault. As soon as crystalisation is detected, a standstill re-
The injected volume of AdBlue® is controlled by the
engine electronics. generation request is issed.
Power reduction
This is displayed by a flashing regeneration lamp.
Warning strategy SCR system Stage 1 Torque reduction
The standstill regeneration must be initiated by the
Stage 2 Torque reduction operator.
The display and monitoring of the exhaust + Engine speed limitation
aftertreatment system can be executed ei- It is recommended that standstill regeneration be un-
ther with pilot lights or with a CAN interface Bridging of the power reduction dertaken as soon as possible.
and a corresponding display, depending on If standstill regeneration is not undertaken, the en-
A separate emergency switch has been provided, in
the engine version. gine control unit will activate the specified engine
order to temporarily disable power reductions
Please see the device manufacturer's oper- protection functions.
caused by the EAT system.
ating manual.
This function is available for a limited period and is Every standstill regeneration slightly dilutes the en-
In order to comply with the regulations of the Europe- expected to enable the user to move the machine to gine oil with fuel. The number of standstill regenera-
an Union (EU) and the Environmental Protection a safe location. tions is therefore monitored..
Agency (EPA), the DEUTZ SCR system reacts with This function is available for engines with power re-
a warning strategy to faulty operation of the exhaust
duction levels 1 and 2, in accordance with EU legis-
gas aftertreatment system.
lation, and with power reduction level 1, in
Emission-relevant faults are: accordance with EPA legislation.
● AdBlue® filling level
● Catalytic converter efficiency/Adblue® quality
● Manipulation
● System fault
34 © 2014

Exhaust gas aftertreatment system Operation

AdBlue ® filling level
Warnings begin from an AdBlue® filling level below 15 %.
3
AdBlue® filling level SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
EU EPA
<15 Continuous light off SCR symbol None None
% Text message
<10 flashes (0.5 Hz) off SCR symbol None None
% Text message
<5% flashes (0.5 Hz) Continuous light SCR symbol None None
Acoustic signal Text message
Acoustic signal
<5% ≥ 10 min flashes (1 Hz) Continuous light SCR symbol Stage 1 None
Acoustic signal
<5% ≥ 15 min flashes (2 Hz) Flashing SCR symbol Stage 1 None
Acoustic signal
<5% ≥ 20 min flashes (2 Hz) Flashing SCR symbol Stage 2 Stage 2
Acoustic signal
© 2014 35

3 Catalytic converter efficiency/Adblue® quality

If the catalytic converter efficiency (conversion rate) is too low, warnings are sent to the SCR function lamp or optionally to the CAN display despite previous refuelling.
Warnings are also given due to use of the wrong reduction agent.
Catalytic converter effi- SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
ciency/Adblue® quality EU EPA
too low Continuous light Continuous light SCR symbol Stage 1 None
Acoustic signal Text message After pre-warning time
Acoustic signal
too low Continuous light Flashing SCR symbol Stage 2 Stage 2
not remedied Acoustic signal Text message After pre-warning time After pre-warning
Acoustic signal time
Manipulation
If the system detects a manipulated part or use of the wrong reduction agent, the performance is reduced. The performance is reduced in stages and depends on the motor
performance.
Manipulation SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
EU EPA
detected Continuous light Continuous light SCR symbol Stage 1 None
Acoustic signal Text message After pre-warning time
Acoustic signal
not remedied Continuous light Flashing SCR symbol Stage 2 Stage 2
Acoustic signal Text message After pre-warning time After pre-warning
Acoustic signal time
36 © 2014

Exhaust gas aftertreatment system Operation

System fault
System faults may be faults of individual SCR components such as the implausible value of a Nox or temperature sensor. The performance is reduced if the AdBlue® in-
3
jection is impaired by a system fault.
System fault SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
detected Continuous light Flashing SCR symbol None
Acoustic signal
detected ≥ 10min Continuous light Flashing SCR symbol Stage 2
Acoustic signal
Crystalisation
Crystalisation results when the engine's workload is too low, or its operating times are too short.
System fault Regeneration lamp Engine warning lamp DEUTZ CAN display Power reduction
detected flashes (0.5 Hz) off Text message None
Standstill regeneration Acoustic signal
required
detected flashes (0.5 Hz) Continuous light Text message Stage 1
required
detected flashes (3 Hz) Flashing Text message Stage 2
required
© 2014 37


The diesel oxidation catalytic converter has a cata-
lytic surface which is used to convert the pollutants
in the exhaust gas into harmless substances. Here,
carbon monoxides and unburned hydrocarbons are
made to react with oxygen and converted into carbon
dioxide and water. In addition, the nitrogen monox-
ides are converted to nitrogen dioxides.
Temperatures > 250 °C are necessary for a high de-
gree of efficiency.
Diesel particle filter
The combustion of diesel fuel results in soot, which
is separated in the diesel particle filter. This must be
regenerated as the contamination with soot increas-
es. That means that the soot in the diesel particle fil-
ter is burned.
The regeneration is based on a continuous regener-
ation process, which is activated as soon as the ex-
haust temperature of 250 °C is exceeded at the inlet
of the exhaust gas aftertreatment system. The filter
contamination with soot is monitored continuously by
the engine control unit.
Regeneration
The passive particle filter system burns the soot in
the filter with the nitrogen oxides in the exhaust
which are oxidised in the DOC beforehand. This
process runs continuously once the exhaust temper-
ature has exceeded 250°C. The passive particle fil-
ter system does not contain a burner. A prerequisite
for the passive continuous regeneration is having a
sufficient ratio of nitrogen oxides to soot in the raw
exhaust gas of the engine.
38 © 2014

Passive regeneration Operation

Normal operation
Under normal operating conditions (exhaust temper-
Power reduction
regeneration as quickly as possible, as otherwise the
diesel particle filter will continue to become contami- 3
Stage 1 Torque reduction nated with soot.
ature > 250 °C), the filter contamination with soot re-
mains in a permissible range and no actions are Stage 2 Torque reduction If the standstill regeneration is not carried out, the
necessary. + Engine speed limitation engine control unit will activate the specified engine
protection functions, depending on the contamina-
The regeneration lamp is off. Bridging of the power reduction tion of the diesel particle filter.
Support mode A separate emergency switch has been provided, in Every standstill regeneration slightly dilutes the en-
order to temporarily disable power reductions gine oil with fuel. The number of standstill regenera-
During this operating state, an acoustic caused by the EAT system. tions is therefore monitored..
change occurs to the running of the engine. This function is available for a limited period and is
Implementation of the standstill regeneration
expected to enable the user to move the machine to
If the operating conditions of the engine do not per- a safe location. The engine must be brought into a "safe state" for
mit any passive regeneration, the contamination of This function is available for engines with power re- the regeneration:
the diesel particle filter with soot will increase. duction levels 1 and 2, in accordance with EU legis- ● Shut down the engine on an open terrain at a
A throttle valve controlled via the engine control unit lation, and with power reduction level 1, in safe distance to flammable objects.
is located in the combustion air inlet. This is used to accordance with EPA legislation. ● Warm up the engine; the coolant temperature
increase the exhaust gas temperature for regenera- Standstill regeneration must reach at least 75°C.
tion of the diesel particle filter, if this is not reached ● Operate the engine in idling.
during normal operation. ● The engine control unit now requires a signal in-
Temperatures of approx. 600 °C occur on
This can be the case if: the exhaust pipe during regeneration. dicating that the unit is safely parked (stationary
A special engine operating state becomes signal).
● The engine only has short operating times.
active during standstill regeneration and This occurs,depending on the application, for ex-
● The engine workload is not high.
the machine is not allowed to be used dur- ample by:
This process is automatically activated by the engine ing the active standstill regeneration. – Activating the parking brake.
control unit, the operator does not need to perform Danger of burns! – Engaging a specified gear position in the
any actions. gearbox.
If the support mode does not attain an adequate re-
The regeneration lamp is off. ● Operating the release button.
duction of the soot contamination, the filter will con-
tinue to become contaminated with soot and a Position depends on application, see device
Power reduction manual.
standstill regeneration will be necessary.
If a serious fault occurs or a fault is not remedied, the The regeneration lamp lights up continuously.
This is displayed by a flashing regeneration lamp.
system reacts by reducing the engine performance.
The standstill regeneration must be initiated by the Once the standstill regeneration has been released,
There is a one or two-stage performance reduction the engine automatically increases the speed level.
operator.
depending on the type of fault.
We recommend carrying out a necessary standstill Using the device during standstill regeneration is
© 2014 39

Operation Passive regeneration
3 prohibited.
The regeneration lasts 35 to 40 minutes on average.
The machine can operate normally until the replace-
ment is carried out by the service.
The standstill regeneration can be interrupted at any The time interval between two regeneration requests
time by pressing the regeneration button again or by is shortened in proportion to the run time.
removing the regeneration release. Please contact your DEUTZ partner
Using the device during standstill regeneration also DEUTZ particle filters come with a catalysing coat-
leads to it being interrupted. ing, so require a special cleaning procedure to pre-
The request for standstill regeneration remains until vent damage to the coating. The DEUTZ filter
it is completed without interruption. replacement programme guarantees that the filter
medium is properly cleaned, and the medium fully
Certain engine faults lead to excessive carbon emis- functions and performs as if it were a new part!
sion which cannot be seen due to the diesel particle
filter.
In such cases, the diesel particle filter can be loaded
very quickly, among other things, to a level which no
longer allows a standstill regeneration by the opera-
tor.
Very short intervals between two standstill regenera-
tions (<10h) can be an indication of such a defect.
Please contact the DEUTZ service.
The regeneration lamp goes out when regeneration
has been successfully completed.
If the standstill regeneration request is not observed
and the DPF is overloaded to an impermissible level,
then the filter can only be regenerated via the
DEUTZ service.
Replacing the diesel particle filter
It may be necessary to replace the diesel particle fil-
ter after a high filter running time as non-combustible
residues accumulate in the filter - so-called ash.
If the ash loading goes beyond a certain level, this
will be indicated by the ash lamp.
The diesel particle filter needs to be replaced.
40 © 2014

Passive regeneration Operation

Display of the regeneration control
The display and monitoring of the exhaust aftertreatment system can be executed either with pilot lights or with a CAN interface and a corresponding display, depending
3
on the engine version.
Instruments/symbols Power reduction Remark
Regeneration lamp Engine warning lamp Ash lamp

off off off Normal operation
off off off Support mode
flashes (0.5 Hz) off off Standstill regeneration required
Approval by the operator required
flashes (0.5 Hz) Continuous light off Stage 1 Standstill regeneration required
Approval by the operator required
flashes (3 Hz) Flashing off Stage 2 Please contact your DEUTZ partner
Continuous light off off Standstill regeneration
off off Continuous light 100% ash load
Please contact your DEUTZ partner
off off Flashing 105% ash load
off Continuous light Flashing Stage 1 110% ash load
© 2014 41

Operation Stopping process
3 Lag time
P 0 The control unit remains active for about

another 40 seconds to save the system
data (lag) and then switches off automati-
1 cally.
For engines with an SCR system, this proc-
ess can take up to 2 minutes as the SCR
lines must be pumped until empty.
2 For this reason, the power supply to the en-
gine must not be suddenly interrupted by
the breaker.
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.
● Move the key to position 0.
P = gear position: park
0 = gear position: switch off engine
1 = gear position: Ignition on
2 = gear position: start engine
42 © 2014

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-
The following lubricating oils are permissible for the
engines in this operating manual: 4
ence and effect on the quality of the oil.
the lubricating oil to be used. The specific engine Permissible quality class
performances which have increased constantly over Synthetic lubricating oils are used increasingly and
the last few years lead to an increased thermal load offer advantages. These lubricating oils have better DQC III LA
on the lubricating oil. The lubricating oil is also more temperature and oxidation stability, as well as rela- DQC IV LA
exposed to contamination due to reduced oil com- tively low cold vicosity. Since some processes which
sumption and longer oil change intervals. For this are relevant for determining the lubricating oil For low-ash engine oils released according to the
reason it is necessary to observe the requirements change times are largely dependent on the oil quality DQC system an appropriate reference is made in the
and recommendations described in this operating (e.g. the infiltration of soot and other contamination), oil release list.
manual in order not to shorten the life of the engine. the oil change time for synthetic lubricating oils may
not be increased in relation to the specifications on DEUTZ lubricating oils DQC III LA low-ash
Lubricating oils always consist of a base oil and an DEUTZ Oil Rodon 10W40 Low SAPS
lubricating oil change intervals.
additive package. The most important tasks of a lu-
bricating oil (e.g. wear protection, corrosion protec- Biodegradable lubricating oils may be used in Container Order number:
tion, neutralisation of acids from combustion DEUTZ engines if they meet the requirements of this 20 litre canister 0101 7976
products, prevention of coke and soot deposits on operating manual.
209 litre barrel 0101 7977
the engine parts) are assumed by the additives. The
Quality Lubricating oil change intervals
properties of the base oil are also decisive for the
quality of the product, e.g. with regard to thermal Lubricating oils are classified by DEUTZ according
● The intervals depend on:
load capacity. to their performance and quality class (DQC: DEUTZ
– lubricating oil quality
In principle, all engine oils of the same specification Quality Class). Essentially, the following applies: the
higher the quality class (DQC I, II, III, IV), the more – sulphur content in the fuel
can be mixed. However, mixing of engine oils should
effective/the better quality the lubricating oil is. – type of application of engine
be avoided because the worst properties of the mix-
ture are always dominant. – Number of standstill regenerations
The DQC quality classes are still to be extended by
the DQC-LA quality classes which include the mod- ● The lubricating oil change interval must be
The lubricating oils approved by DEUTZ have been halved if at least one of the following conditions
thoroughly tested for all engine applications. The ac- ern, low-ash lubricating oils (LA = Low Ash).
applies:
tive ingredients they contain are compatible with or see www.deutz.com
– Constant ambient temperature below -10 °C
each other. Therefore, the use of additives for lubri-
(14 °F) or lube oil temperature below 60 °C
cating oils is not permitted in DEUTZ engines. http://www.deutz.com
(84 °F).
The lubricating oil quality has a considerable influ- de \SERVICE \Betriebsstoffe und Addi- – Sulphur content in diesel fuel of >0.5 weight
ence on the life, performance and thus also on the tive\Deutz Quality Class\DQC-Freigabeliste %.
costs-effectiveness of the engine. It basically applies en \SERVICE \Operating Liquids and Addi- ● If the lubricating oil change intervals are not
that: The better the lubricating oil quality, the better tives\Deutz Quality Class\DQC Release List reached within a year, the oil should be changed
these properties. at least once a year.
The choice of luricating oil essentially depends on
The lubricating oil viscosity describes the way the lu-
the exhaust aftertreatment system.
© 2014 43

Operating media Lubricating oil
4 Viscosity
The ambient temperature at the installation site or in °C
the application area of the engine is decisive for
choosing the right viscosity class. Too high a viscos- 45
ity can lead to starting difficulties, too low a viscosity
can endanger the lubrication effect and cause a high 40
lubricating oil consumption. At ambient temperatures
below -40 °C, the lubricating oil must be pre-heated 35
(e.g. by storing the vehicle or the machine in a hall).
The viscosity is classified according to SAE. Oils 30
suitable for multiple ranges must always be used.
25
The prescribed lubricating oil quality must
be observed when selecting the viscosity 20
SAE 15W-40
SAE 15W-30
SAE 10W-30
SAE 10W-40
class!
SAE 5W-30
SAE 5W-40
15
Depending on the ambient temperature we recom-
mend the following common viscosity classes:
10
5
0
-5
-10
-15
-20
-25
-30
44 © 2014

Fuel Operating media

Permissible fuels
In order to satisfy the exhaust gas legislation, diesel
els specified in the laws. These correspond to the
diesel fuels in accordance with EN 590 and 4
ASTM D 975 described in the operation manual. No
engines that are equipped with an exhaust aftertreat- emission values are guaranteed with the other fuels
ment system may only be operated with a sulphur- described in this operation manual.
free diesel fuel.
The respective fuels prescribed by law must be used
The operational reliability and durability of the indi- to comply with the national emission regulations
vidual exhaust aftertreatment technologies cannot (e.g. sulphur content).
be assured upon failure to comply.
Exhaust aftertreatment systems or see www.deutz.com
SCR Selective Catalytic Reduction
http://www.deutz.com
DOC Diesel oxidation catalytic con-
verter de \SERVICE\Betriebsstoffe und Additive\Kraft-
stoffe
DPF Diesel particle filter
en \SERVICE\Operating Liquids and Addi-
The following fuel specifications / standards are ap- tives\Fuels
proved:
Winter operation with diesel fuel
● Diesel fuels
– EN 590 Special demands are placed on the cold behaviour
(temperature limit value of the filtrability) for winter
Sulphur <10 mg/kg operation. Suitable fuels are available at filling sta-
tions in winter.
– ASTM D 975 Grade 1-D S15
– ASTM D 975 Grade 2-D S15 For engines with DCR® DEUTZ common
Sulphur <15 mg/kg rail injection, the mixing of petroleum and
adding of extra low additives is not permis-
● Light heating oils sible.
– in EN 590 quality
At low ambient temperatures paraffin discharges can
Sulphur <10 mg/kg lead to blockages in the fuel system and cause oper-
ating faults. Below 0 °C ambient temperature use
If other fuels are used which do not meet the require- winter diesel (down to -20 °C) (filling stations provide
ments of the operating manual, the warranty will be this in good time before the cold season starts).
voided.
● Special diesel fuels can be used for arctic cli-
The certification measurements for compliance with mates to -44 °C.
the legal emission values are made with the test fu-
© 2014 45

Operating media Coolant
4 General ● pH value too low:

Addition of diluted sodium or potassium lye.
DEUTZ cooling system corrosion protection agent
Specifications Observations
Never operate the engine without coolant, Small trial mixtures are advisable.
even for a short time! ● Total hardness too high: DQC CC-14 free of silicates on the basis of
Mixing with softened water (pH neutralized con- organic acids (OAT) and MEG
In liquid-cooled engines, the coolant must be condi- densate or water softened by ion exchanger).
tioned and monitored, otherwise the engine could be ● Chlorides and/or sulphates too high: DEUTZ cooling system corrosion protection agent
damaged by: Mixing with softened water (pH neutralized con- Container Order number:
● corrosion densate or water softened by ion exchanger). 5 litre container 0101 1490
● cavitation Cooling system corrosion protection agent 20 litre canister 0101 6416
● freezing
210 litre barrel 1221 1500
● overheating Health damaging nitrous amines form
when nitrite-based cooling system corro- The DEUTZ cooling system protection agent corre-
Water quality sponds to the quality class DEUTZ DQC CA-14
sion protection agents are mixed with
The right water quality is important for conditioning amine-based agents! This cooling system corrosion protection agent is
the coolant. Clear, clean water within the following free from nitrite, amine and phosphate and is adapt-
analysis values should always be used: Cooling system corrosion protection agents ed to the materials in our engines. Order from your
must be disposed of in an environmentally DEUTZ partner.
Analysis values min max ASTM friendly way. Please contact your DEUTZ partner if the DEUTZ
ph value 6,5 8,5 D 1293 Observe the notes on the safety data cooling system corrosion protection agent is not
Chlorine (Cl) [mg/l] - 100 D 512 sheet. available.
D 4327 The conditioning of the coolant for liquid-cooled or see www.deutz.com
Sulphate (SO4) [mg/l] - 100 D 516 DEUTZ compact engines is performed by mixing an
anti-freeze with corrosion protection inhibitors based http://www.deutz.com
Total hardness [mmol/l] 3,56 D 1126
(CaCO3) [mg/l] 356 on ethylene glycol into the water. de \SERVICE\Betriebsstoffe und
Products released are recorded according to the fol- Additive\Kühlsystemschutz
[°dGH] 20,0 -
lowing DEUTZ cooling system protection specifica- en \SERVICE\Operating Liquids and Addi-
[°e] 25,0 tions. tives\Cooling System Conditioner
[°fH] 35,6
DEUTZ cooling system corrosion protection agent
Specifications of the water quality are made by the
Specifications Observations
local water board.
DQC CA-14 siliceous on the basis of MEG
The water must be conditioned if it deviates from the
analysis values. DQC CB-14 free of silicates on the basis of
organic acids (OAT) and MEG
46 © 2014

Coolant Operating media

The cooling system must be monitored regularly.
This also includes checking the coolant system cor- 4
rosion protection agent concentration in addition to
checking the coolant level.
The cooling system corrosion protection agent con-
centration can be checked with conventional test in-
struments (e.g. refractometer).
Cooling system Water percent- Cold pro-

corrosion protec- age tection up
tion agent percent- to
age
min. 35 % 65 % -22 °C
40 % 60 % -28 °C
45 % 55 % -35 °C
max. 50 % 50 % -41 °C
At temperatures below -41 °C, please contact your
responsible DEUTZ partner.
It is possible to use other cooling system corrosion
protection agents (e.g. chemical corrosion protection
agents) in exceptional cases. Consult your DEUTZ
partner.
© 2014 47

Operating media SCR reduction agent
4 AdBlue® (urea solution AUS 32) Ensure that the materials and storage containers
used are resistant to AdBlue®.
The urea solution AUS 32 is known in the AdBlue® freezes below -11 °C ambient tempera-
USA and North America by the name Die- ture. R
sel Exhaust Fluid (DEF).
It will be necessary to preheat the SCR system at
ambient temperatures below -11 °C.
Protective gloves and goggles must be
worn when handling AdBlue®. AdBlue®
Do not swallow.
Ensure sufficient ventilation. Container Order number:
Ensure cleanliness. 10 litre canister 0101 7982
Residues of AdBlue® must be disposed of 210 litre barrel 0101 7983
in an environmentally friendly manner.
Observe the notes on the safety data
sheet.
AdBlue® tank
Exhaust aftertreatment systems
SCR Selective Catalytic Reduction The AdBlue® tank may only be filled with AdBlue®.
Filling with other media can lead to destruction of the
AdBlue® is a highly-pure, acqueous, 32.5 % urea system.
solution which is used as an NOX reduction agent for In this case the metering pump must be replaced.
SCR exhaust aftertreatment in vehicles with diesel
engines. AdBlue® should not remain in the tank for longer
than 4 months.
The product is designated as AdBlue® or AUS 32
(AUS: Aqueous Urea Solution) and must correspond This must be documented.
to the DIN 70070, ISO 22241-1 or ATSTM D 7821. Empty and clean the AdBlue® tank when decommis-
The length of time that AdBlue® can be kept without sioning.
losing quality depends on the conditions of its stor- Please contact your DEUTZ partner
age.
http://www.deutz.com
It crystallises at -11 °C and at over +35 °C a hydrol-
ysis reaction is initiated, i.e. it begins to slowly re- E-Mail: info@deutz.com
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!
48 © 2014

Maintenance schedule Maintenance

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule
TD/TCD 3.6 L4
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) 3)
E40 Extended maintenance I 1.000 3)
E50 Extended maintenance II Authorised specialists 3.000 3)
E70 General overhaul 6.000 3) 4)
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (43).
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.
General overhaul
4) 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.
© 2014 49

Maintenance Maintenance schedule
5 Maintenance measures
Stage Activity Measure Page

E10 The measures are listed in chapter 3. 25
E20 Check Lubricating oil level (if necessary top up) 52
Coolant level (top up if necessary) 26
Engine tightness (visual inspection for leaks)
Exhaust system including exhaust aftertreatment components for leaks 20
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 62
Emptying of the water tank in the fuel pre-filter 56
E30 Check V-belts 63
Coolant (additive concentration) 58
Replace Lubricating oil filter/insert (every time the lubricating oil is changed) 53
Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 43/52
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Filtercartridge of the AdBlue® supply pump 57
E40 Check Charge air cooler entry area (drain lube oil/condensate)
Battery and cable connectors 65
Cold starting device
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
V-rib belt and tensioning pulley 64
Replace Fuel filter cartridge 55
Filter insert for the fuel pre-filter. If the warning system responds (lamp/horn), the water trap bowl must be emptied 56
immediately.
Dry air filter 62
V-belts 63
E50 Replace V-rib belt and tensioning pulley 64
50 © 2014

Maintenance schedule Maintenance

Stage
annually
Activity
Check
Measure
Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Page
5
Replace Fuel filter cartridge 55
Fuel pre-filter 56
Lubricating oil 43
Lubricating oil filter/insert (every time the lubricating oil is changed) 53
Every 2 Replace Dry air filter 62
years V-belts 63
Coolant 46 58
Filtercartridge of the AdBlue® supply pump 57
Status Change Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 62
dependent Diesel particle filter, the required exchange is displayed by the ash lamp or via an electronic display, depending on 39
the engine version (see DEUTZ exchange programme 34).
Empty Fuel pre-filter with water trap. If the warning system is activated (lamp/horn), the water trap bowl must be emptied 56
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 3911 (TD/TCD 3.6 L4)
© 2014 51

Servicing and maintenance work Lubricating oil system
6 Regulations for working on the lubricating oil system

OIL ?
● The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
Do not work when the engine is running! essary.
Smoking and naked lights prohibited!
Be careful of hot lubricating oil. Danger of Changing the lubricating oil
scalding! OIL ● Warm up the engine (lubricating oil temperature
+80°C
> 80 °C).
Pay attention to utmost cleanliness when +176°F ● Ensure that the engine or vehicle is in a level po-
working on the lubricating oil system. Clean sition.
the area around the components con- ● Switch off the engine.
cerned carefully. Blow damp parts dry with ● Place a collecting receptacle underneath the
compressed air.
Observe the safety regulations and nation-
al specifications for handling lube oils.
! lube oil drain screw.
● Unscrew the lube oil drain screw, drain oil.
– In the case of agricultural technology en-
Dispose of leaking lubricating oil and filter
gines with a separate oil pan, both oil drain
elements properly. Do not allow used oil to plugs must be unscrewed.
seep away into the ground. Checking the lubricating oil level
Perform a trial run after all work. Pay atten- ● Turn in and tighten lubricating oil drain plug fitted
tion to tightness and lubricating oil pressure Low lubricating oil level and overfilling lead with new sealing ring.
and then check the engine oil level. to engine damage.
The lubricating oil level may only be Tightening torque 55 Nm
checked with the engine in a horizontal po-
sition and switched off. ● Pour in lube oil.
Only check lubricating oil level whilst warm, – Quality/viscosity data (43).
5 minutes after shutting down. – Filling volume (79).
● Warm up the engine (lubricating oil temperature
Be careful of hot lubricating oil. Danger of > 80 °C).
scalding! ● Ensure that the engine or vehicle is in a level po-
Do not pull out the dipstick while the engine sition.
is running. Danger of injury! ● Check lubricating oil level, if necessary top up.
● Pull out the lubricating oil dipstick and wipe off
with a lint-free, clean cloth.
● Insert the lubricating oil dipstick as far as it will
go.
● Extract the lubricating oil dipstick and read off the
oil level.
52 © 2014

Lubricating oil system Servicing and maintenance work

6
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! 10-12 Nm
● Remove clamps when twist protection mounted ● Fasten clamps of the twist protection (optional).
(optional).
● Loosen and unscrew filter with tool (order no.:
0189 9142)
● Collect draining lubricating oil
● Clean the sealing surface of the filter support
© 2014 53

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.
54 © 2014

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 with tool (order no.:
0189 9142)
● Catch any escaping fuel.
● Clean the sealing surface of the filter support
© 2014 55

Servicing and maintenance work Fuel system
6 – Connect cable connections.

Change the fuel pre-filter insert
seconds in order to vent the fuel system and build up
the required fuel pressure.
6 1 Wait until the electric fuel supply pump is disconnect-
● Switch off the engine. ed from the control unit.
● Shut off the fuel supply to the engine (with high- ● Ignition "OFF"
level tank).
● Place suitable collecting containers underneath. Repeat the process at least 2 times until the fuel sys-
5 2 ● Electrical connection tem is vented.
– Disconnect cable connections.
● Loosen drain plug and drain liquid.
● Disassemble filter insert.
4 3 ● Clean any dirt off the sealing surfaces of the new
filter cartridge and opposite side of filter head.
● Wet the sealing surfaces of the filter cartridge
Change/vent fuel pre-filter slightly with fuel and screw back on to the filter
head, clockwise (17-18 Nm).
1 Fuel supply flow to the pump ● Mount drain plug.
2 Venting screw
3 Electrical connection for water level sensor Tightening torque 1,6 ±0,3 Nm
4 Drain plug ● Electrical connection
5 Filter insert – Connect cable connections.
6 Fuel inlet from the fuel tank
● Open the fuel shutoff tap and vent the system,
Empty water tank see venting the fuel system.
● Switch off the engine. Vent the fuel system
● Place suitable collecting containers underneath.
● Electrical connection The fuel system is vented via the electric fuel supply
pump.
In order to ensure that no error messages are gener-
● Loosen drain plug. ated, no attempt should be made to start the system
● Drain fluid until pure diesel fuel runs out. up whilst venting.
● Mount drain plug. This process is carried out as follows:
Tightening torque 1,6 ±0,3 Nm ● Ignition "ON"
● Electrical connection The electronic fuel supply pump switches on for 20
56 © 2014

SCR Servicing and maintenance work

6
1 2 3
Change the filter cartridge of the AdBlue® supply ● Insert new filter insert with compensation body.
pump ● Mount cover.
Protective gloves are to be worn when Tightening torque 22,5 ±2,5 Nm
working with Selective Catalytic Reduction
(SCR) components. ● Electrical connection
Ensure cleanliness. – Connect cable connections.
1 Cover ● Start
2 Compensation body
3 Filter insert
● Switch off the engine.
● Electrical connection
● Place suitable collecting containers underneath.
● Remove cover.
Socket wrench insert 27 mm
● Pull out filter insert and compensation body.
© 2014 57

Servicing and maintenance work Cooling system
6 Specifications when working on the cooling system
Danger of scalding from hot coolant!

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. 1
Dispose of leaking liquids properly and do
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 (46). (coolant duct).
● Open the cooling system cap (1) carefully.
The corresponding test device can be ordered from ● Insert screw again with sealant.
● The coolant level must always be between the
MIN and MAX marks of the compensation tank! your DEUTZ partner under the order no.: 0293 ● Close cooler locking cap.
Fill up to the MAX mark if necessary. 7499.
58 © 2014

Cooling system Servicing and maintenance work

6
Fill and ventilate cooling system
Danger of scalding from hot coolant!

the cap when cool!
● Open the cooling system cap (1) carefully.
● Loosen the cooler venting screw if necessary.
● Fill coolant up to the max. mark or filling limit.
● Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
● Close cooler locking cap.
● Run engine up to operating temperature (open-
ing temperature of the thermostat).
● Switch off the engine.
● Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
tion tank if necessary.
© 2014 59

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).
Cover electrical/electronic parts and con- ● Spray the engine clean with a high pressure wa-
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.
60 © 2014

Suction 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
● To do this:
openings if necessary.
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.
© 2014 61

Servicing and maintenance work Suction system
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter
● The dry air filter is maintained according to a ● Empty the dust discharge valve (1) by pressing
maintenance switch or maintenance indicator. together the discharge slit.
● 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.
– the red field (1) of the maintenance indicator
is fully visible.
● After carrying out maintenance work, reset the
signal by pressing the button on the mainte-
nance indicator. The maintenance indicator is
now ready for operation again.
62 © 2014

Belt drives Servicing and maintenance work

Checking the belt drive
4
6
Only carry out work on the belt drive with
the engine at a standstill! 1 B A
After repair work: Check that all guards 3
have been replaced and that all tools have
been removed from the engine.
● Check the whole belt drive visually for damage.
● Renew damaged parts.
2
● Remount protective devices if necessary.
● Pay attention to correct fit of new belts, check the
tension after running for 15 minutes. 1
5 4 3 2
Checking the belt tension Renew the V-belts

● Lower indicator arm (1) into the measuring de- 1 Screw
vice. 2 Screw
● Place guide (3) between two belt pulleys on the 3 Screw
V-belt (2). The stop have to be at the side. 4 Setting screw
● Press the button (4) at right angles to the V-belt
(2) evenly until you hear or feel the spring snap ● Remove screw and lock nut.
in. ● Move the generator over the setting screw in di-
● Lift the measuring device carefully without alter- rection (B) until the V-belt is slack.
ing the position of the indicator arm (1). ● Remove belt and fit new one.
● Read the measured value at the point of inter- ● Move the generator over the setting screw in di-
section (arrow), scale (5) and indicator arm (1). rection (A) until the V-belt has attained the cor-
● If necessary, re-tension belt and measure again. rect tension.
● Checking the belt tension (79).
Tools ● Tighten screw and lock nut again.
The belt tension measurement device (order no.:
Tightening Screw 1 30 Nm
0189 9062) can be ordered from your DEUTZ part-
torque Screw 2 42 Nm
ner.
Screw 3 30 Nm
© 2014 63

Servicing and maintenance work Belt drives
6
1
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.
64 © 2014

Electrical system Servicing and maintenance work

Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
6
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)
For electrical welding work, the ground ter- Check acid density
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 battery’s 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 manufacturer’s 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
© 2014 65

Servicing and maintenance work Electrical system
6 Removing the battery

● Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
of short-circuit!
● Remove the fastenings and take out the battery.
Charging the battery
● Unscrew caps.
● Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
● Screw in caps.
Installing the battery
● Insert new or charged battery and attach the fas-
tenings.
● Clean the terminals and battery poles with fine
emery paper.
● Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
● Grease the assembled terminals with an acid-
free, acid-resistant grease.
66 © 2014

Fault table Faults

Faults and remedies
7
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
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
High-pressure pump defective Check/replace
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and elimi-
lamp flashes nate error if necessary
© 2014 67

Faults Fault table
7 Faults
Engine starts, but runs irregularly or
Causes
Belt/V-rib belt (fuel pump in belt drive)
Measures
Check whether torn or loose
fails Compression pressure too low Check compression pressure
Cold starting device Check/replace
Air in fuel system Vent
Fuel filter contaminated Change
Injector defective Change
Engine cable harness defective Check/replace
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent Check error according to error code and elimi-
nostic lamp lights up speed nate error if necessary
Engine becomes excessively hot. Vent line blocked Clean
Temperature warning system acti- Injector defective Change
vates
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
Fan / viscous coupling defective, V-belt torn or loose Check/replace/tension
Charge air cooler soiled Check/clean
Throttle valve defective Check/replace
Coolant temperature transmitter Check/replace
Coolant thermostat defective Check/replace
Coolant cover defective Check/replace
68 © 2014

Fault table Faults

Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
7
Throttle valve defective Check/replace
Exhaust gas recirculation, actuator defective Check/replace
Fuel suction temperature too high Check the system
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air line leaking Check charge air line
Charge air cooler soiled Clean
Exhaust gas backpressure too high Check/clean
Exhaust gas turbocharger defective Change
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
Compression pressure too low Check compression pressure
Engine cable harness defective Check/replace
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
Lubricating oil pressure sensor defective Check/replace
Lubricating oil control valve jammed Check/clean
Lubricating oil suction pipe blocked Check/clean
© 2014 69

Faults Fault table
7 Faults
Engine lubricating oil consumption
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
Valve shaft seals defective Check/replace
Piston rings worn Check/replace
Exhaust gas turbocharger defective 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
Crankcase breather Check/replace
Piston rings worn Check/replace
Engine producing white smoke Coolant in the exhaust gas Check
Condensation Warm up engine so that water residues evap-
orate
Engine producing black smoke Diesel particle filter defective Check/replace
70 © 2014

Fault table Faults

Faults
Error in the SCR system
Causes
AdBlue® tank empty/display full
Measures
Check tank sensor
7
SCR not working Check plug connections and lines at the sup-
ply pump and injector.
Check plugs and lines of supply pump, Nox
sensor and exhaust temperature sensor.
SCR not working (cold) Lines frozen, lines to be cleaned, heating to
be checked
AdBlue® Tank frozen, heating to be checked
Frequent standstill regenerations Air filter clogged / turbocharger defective Check/replace
Charge air line leaking Check charge air line
Differential pressure of flow meter defective Change
Nox sensor defective Change
Differential pressure sensor of diesel particulate filter is issuing an implausible Change
signal
Differential pressure line added Clean
© 2014 71

Faults Engine management
7 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-
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 with power reduction to
1 safely possible. cool the engine, with automatic shutdown if
Error lamp necessary.
– 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 switching off
3 the system with the ignition key for approx. 2
– Ignition on, error lamp lights up for approx. 2
min.
seconds and then goes out.
– optionally the power reduction can be by-
– Check the error lamp if there is no reaction
passed, the automatic switch-off delayed or
after switching on the ignition.
Engine protection function of the electronic engine a start lock bypassed with the override key
● The lamp does not light
control on the instrument panel to avoid critical situ-
– After the lamp test an extinguished lamp indi- ations. This brief deactivation of the engine
cates an error-free and trouble-free operat- protection functions is logged in the control
1 Diagnosis button ing state within the scope of the control unit.
2 Error lamp possibility. Please contact your DEUTZ-partner in case of
3 Electronic engine control (EMR) ● Continuous light malfunctions and sare parts inquiries. Our spe-
Error in system. cially trained personnel will ensure fast, profes-
When all errors are rectified, the error lamp sional repairs using original DEUTZ spare parts
– Operation continued with restrictions.
goes out. For some errors, it is possible to in case of damage.
– The engine must be checked by a DEUTZ
switch off the ignition, wait 2 minutes and
partner.
then switch the ignition back on again.
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.
72 © 2014

Engine management Faults

Diagnosis button
The diagnosis button allows the errors currently
7
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 on to start the en-
1 2 8
quiry (ignition on). Then the diagnosis button must Display system error by flash code
be pressed and held for approx. 1 s.
Example:
Then the next error (i.e. the following one in the error
memory) can be displayed by pressing the diagnos- Flash code 1-2-8
tic key again. If the last error was displayed, the first 1 x short flash
error is displayed again on pressing the diagnostic
2 x long flash
key again.
8 x short flash
After the display of the error flash code, the error
lamp goes out for five seconds. This flash code indicates a break or short circuit in
the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
the illustration.
● The blink codes can only be interpreted by a
DEUTZ partner.
© 2014 73

Transport and storage Transport
8 1
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).
74 © 2014

Engine corrosion protection Transport and storage

General
Engines contain the following types of corrosion pro-
Exhaust aftertreatment system
Selective Catalytic Reduction
not be remedied.
8
tection: The SCR system can be taken out of operation for up
● Interior corrosion protection to 4 months after completely shutting down (includes
● Exterior corrosion protection all lag functions) and the following conditions:
Your DEUTZ partner has the right corro- ● The vehicle or engine should be stored in a cov-
sion protection agent for your needs. ered place, e.g. garage or hall, for longer shut-
downs.
● AdBlue® fill tank completely.
The following measures for corrosion protection after Evaporation of water as part of the AdBlue® must
taking the engine out of operation meet the require- be avoided.
ments for 12 months corrosion protection.
● Do not disconnect electrical or hydraulic connec-
The following corrosion protection work may only be tions.
carried out by persons familiar with it and instructed ● Maximum storage time at -40 ℃ to 40 ℃
in the potential dangers. 2 months.
If these measures are deviated from by exposing the ● Maximum storage time at -40 ℃ to 25 ℃
corrosion-protected engines or parts to unfavourable 4 months.
conditions (installation outdoors or storage in damp,
badly aired places) or damage to the corrosion pro- If the shutdown time of 4 months mentioned above
tection layer, a shorter corrosion protection duration has been exceeded, proceed as follows:
is to be expected. ● AdBlue®
The engine corrosion protection should be checked – Empty the tank completely.
about every 3 months by opening the covers. If cor-
– Fill the tank completely with new AdBlue®.
rosion is detected, the corrosion protection should
be renewed. – Renew the filter insert of the supply pump.
● Warm up the engine to operating temperature
At the end of the corrosion protection work the crank and load so that pressure builds up and AdBlue®
drive may no longer be turned so that the corrosion is injected.
protection agent in the bearings, bearing liners and
cylinder liners is not scraped off. If a fault is detected:
Before operating a corrosion protected engine, the ● Shut down engine.
corrosion protection must be removed. Wait for the end of the lag time of the EDC (Elec-
tronic Diesel Control).
● Repeat the process several times if necessary.
Please contact your DEUTZ partner if the fault can-
© 2014 75

Transport and storage Engine corrosion protection
8 Corrosion protection of engines which have already

been in operation
all accessible components are wet with preser-
vation oil, and then, using a separate pump,
Intake air lines
● Spray corrosion protection oil or preservation oil
Internal corrosion protection pump warm preservation oil (at approx. 60 °C) into the intake air pipe.
through the engine until all bearings and bearing
The internal corrosion protection is always effected liners are wet.
by wetting the walls with the corrosion protection
agent by running the engine. The corrosion protec- Air compressor
tion run can be carried out once to protect the differ- ● If a compressor is installed, a corrosion protec-
ent systems. tion agent must be sprayed into the compressor
Fuel system suction system after shutting down the engine
until it emerges visibly from the pressure nozzle.
Close the fuel/tank/supply line to the en-
gine so that the system is protected against Cooling system
dirt and dust. Protect the electronics ● Depending on the series the engines are
against moisture and corrosion. equipped with cooling air, cooling oil or cooling
Standstill times of longer than 4 weeks fluid system (cooling water with cooling system
must always be avoided with biodiesel. protection agent).
● In liquid-cooled engines, the coolant must be
● Fill fuel tank with according to biodiesel-free fuel drained and the cooling system cleaned
EN590 or ASTM D975 grade 1-D S15
● In cooling system not contaminated by lubricat-
● Perform a corrosion protection run with no load
ing oil, fill with clean water, start engine and flush
for at least 5 minutes.
the cooling system.
Lubricating oil system ● Then carry out a corrosion protection run so that
a coating forms on the inside surfaces of the
● Drain lubricating oil from warm engine.
cooling system. With a mixture consisting of:
● Thoroughly clean lube oil tray, cylinder head with
– Treated water
rocker arms, valves, valve springs with diesel
fuel or cleaning agent. – Corrosion protection agent
● Fill engine with preservation oil and carry out cor- or
rosion protection run (together with corrosion – Treated water
protection run for fuel system), then warm up the – Corrosion protection agent with light anti-
engine to approx. 60 °C, duration at least 5 min- freeze
utes so that all components of the lubricating oil ● The duration of the corrosion protection run and
system are wet, the concentration of the corrosion protection
agent are specified by the manufacturer of the
or corrosion protection agent.
● Then drain the coolant.
76 © 2014

Engine corrosion protection Transport and storage

External corrosion protection
The engine must be cleaned thoroughly with clean-
Storage and packing
● After being protected against corrosion, the en-
Re-application of engine corrosion protection
If the max. protection duration of the corrosion pro-
8
ing agent before external corrosion protection. gine must be stored in a dry, ventilated hall and tection is reached or damaged corrosion protection
Bare outside surfaces and parts suitably covered. is detected and the engine is to stay in storage, new
● The cover must be placed loosely over the en- corrosion protection must be applied. The new corro-
● Coat or spray all bare exterior parts and surfaces
gine so that the air can circulate around it to pre- sion protection protects the engine or spare parts for
(e.g. flywheel, flange faces) with corrosion pro-
vent condensation from forming. Use a desiccant another 12 months.
tection agent.
if necessary.
The new corrosion protection is applied in the same
● Under extreme conditions, e.g. sea transport or way as for the initial corrosion protection with a cor-
military specifications, a long-term corrosion pro- rosion protection run. If a corrosion protection run is
tection oil should be used. not possible (engine is removed from the device or
system for example), certain special conditions must
Rubber parts
be observed for application of new corrosion protec-
● Rubber parts (e.g. muffs) which are not painted tion which we describe below.
over must be rubbed down with talcum powder.
Internal corrosion protection
Belt drives Fuel system
● Remove V-belts and V-rib belts and store ● DEUTZ recommends using diesel fuel contain-
packed. ing polycyclic aromatic hydrocarbons ≤ 8.0 %(m/
● Spray V-belt pulleys and tension rollers with cor- m), a lubricity of ≤ 400 micrometers in the HFRR
rosion protection agent. test (EN ISO 12156-1) and biodiesel (FAME) ≤
0.1 %(V/V).
Engine openings
Pump fuel with a separate pump or a fuel hand
● All engine openings must be fitted with air-tight, pump until the fuel system is full Then drain the
water-tight covers to delay the vapourisation fuel mixture.
process of the corrosion protection agents.
● With installed air compressor, the suction and Lubricating oil system
pressure connection must be sealed by a cap. ● Press warm preservation oil (at approx. 60 °C)
● Air should be excluded to avoid ventilation of the into the lubricating oil circuit with a separate
engine (chimney effect) for the suction from an pump, or with the prelubricating hand pump.
air supply pipe. Turn over the engine by hand or with the electric
turning gear so that all bearings and bearing lin-
ers are wet. The engine can also be turned over
with the starter without starting the engine.
● Remove the cylinder head cover and spray
valves, valve springs and rocker arms with pres-
© 2014 77

Transport and storage Engine corrosion protection
8 ervation oil.
Cooling system
Removal of corrosion protection
Removal of internal corrosion protection
Corrosion protection agent / cleaning agent
Please ask your DEUTZ partner for reference prod-
Fuel system ucts for the corrosion protection agents/cleaning
● The corrosion protection does not normally need
agents to be used which meet DEUTZ requirements.
to be renewed up to 24 months. If necessary, the ● Fill the fuel tank and fuel system with the proper
coolant system can be filled with a mixture of cor- fuel. or see www.deutz.com
rosion protection agents and circulated by an ex-
ternal pump, so that a new coating can form on Lubricating oil system http://www.deutz.com
the inside surfaces of the cooling system. ● Fill the engine with lubricating oil via the lubricat- de \SERVICE \Betriebsstoffe und Addi-
● The duration of the corrosion protection run and ing oil filler neck. tive\Motorkonservierung
the concentration of the corrosion protection en \SERVICE\Operating Liquids and Addi-
agent are specified by the manufacturer of the Cooling system
tives\Engine Corrosion Protection
corrosion protection agent. ● If the implemented corrosion protection agent is
● Then drain the coolant. compatible with the intended cooling system pro-
tection agent, this can be filled directly into the
coolant system as specified.
● If it is uncertain whether the implemented corro-
sion protection agent is compatible with the cool-
ing system protection agent, the cooling system
should be purged with fresh water for about 15
minutes before filling.
Removal of exterior corrosion protection
● All areas and components coated with corrosion
protection agent must be washed off with dis-
tilled fuel or a suitable cleaning agent.
● Wash out grooves of V-belt pulleys if necessary.
● Mount V-belts or V-rib belts as specified.
● Fill with coolant.
78 © 2014

Engine and setting data Technical data

General technical data
9
Engine type Dimension TD 3.6 L4 TCD 3.6 L4
Working principle Four-stroke diesel engine
Charging Exhaust gas turbocharger Turbocharger with charge air cool-
ing
Type of cooling water-cooled
Cylinder arrangement in series
No. of cylinders 4
Bore/stroke [mm] 98/120
Total displacement [cm3] 3621
Combustion process Direct injection
Injection system Common Rail
Exhaust gas recirculation externally cooled
Exhaust gas aftertreatment Diesel oxidation catalytic converter Diesel oxidation catalytic converter
and/or and/or
Diesel particle filter Diesel particle filter
and/or
Selective Catalytic Reduction
Valves per cylinder 2
Firing order of the engine 1-3-4-2
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
Coolant volume (only engine content without cooler / hoses and pipes)
Industrial engines/Agricultural technology ≈ [l] 4,6/4,6
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 8
Start of thermostat opening [°C] 86
© 2014 79

Technical data Engine and setting data
9 Engine type
Thermostat fully open
Dimension
[°C]
TD 3.6 L4
102
TCD 3.6 L4
Lubricating oil change volume (with filter) ≈ [l] 8*

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-belt tension Pre-tensioning/Re-tensioning
V-belts AVX (width: 13 mm) [N] 650±50/400±50
V-rib belt tensioning Automatic tensioning spring-loaded clamping roller
Weight without cooling system according to DIN 70020-A ≈ [kg] 350
*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.
80 © 2014

Tools Technical data

Tool ordering
The special tools described in this chapter can be or-
9
dered from:
Torx tool V-belt tension measuring instrument

Order number: Order number:
0189 9092 0189 9062
The Torx screw system is used in engines in this se- Measuring instrument for checking the specified V-
ries among other things. This system was introduced belt tensions.
for a number of reasons:
● Excellent accessibility
● High force transmission when loosening and
tightening
● Slipping or breaking of the key and risk of injury
are practically excluded.
© 2014 81

Technical data Tools
Special wrench for loosening exchangeable filters Refractometer

Order number: Order number:
0189 9142 0293 7499
For loosening changeable filters. The following operating media can be evaluated with
this test device:
● Coolant
● Battery acid
● AdBlue®
82 © 2014

DEUTZ Operating Fluids
DEUTZ Oil Rodon 10W40 DEUTZ Cooling System

low SAPS (DQC III-10 LA) Conditioner
5L - 5L 0101 1490
20 L 0101 7976 20L 0101 6416
209 L 0101 7977 210L 1221 1500

DEUTZ AG
Information Systems Sales & Service
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
© 06/2014
All rights reserved
Order number:
0312 4679 en
The engine company. Original operating instructions

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OBJ_DOKU-44425-001.fm Seite 1 Donnerstag, 19.

Februar 2015 2:46 14

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This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

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Model Engine description

T Exhaust gas turbocharger

(if included in the DEUTZ scope of supply) DEUTZ AG MADE IN GERMANY

The engine and the corresponding EAT

The engines of these operating instructions fulfill

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Engine description Model

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Model Engine description

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Engine description Engine illustrations

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Engine description Engine illustrations

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Engine illustrations Engine description

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Engine description Lubricating oil diagram

2 Lubricating oil system

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Fuel diagram Engine description

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Engine description Coolant diagram

2 Coolant schematic (example)

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Exhaust gas recirculation Engine description

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Engine description Exhaust gas aftertreatment

2 Exhaust aftertreatment system

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Exhaust gas aftertreatment Engine description

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Engine description Electrics/Electronics

2 Electronic engine control

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Operation Ambient conditions

3 Cold start aid

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Initial commissioning Operation

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Operation Initial commissioning

3 Filling the coolant system Trial run

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Initial commissioning Operation

Horn With acoustic signal See fault table (67).