Professional Documents
Culture Documents
TD/TCD 2012 L04/06 2V/m TCD 2013 L04/06 2V/m
TD/TCD 2012 L04/06 2V/m TCD 2013 L04/06 2V/m
Operation Manual
Betriebsanleitung
TD/TCD 2012L04/L06
TCD 2012 L04/062V2V/m
TCDTCD
2013 L04/06
2013 2V/m
L04/L06 2V
OBJ_DOKU-19557-001.fm Seite 2 Mittwoch, 15. April 2009 9:10 09
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
z This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
z 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. z Do not work on the fuel system while the engine
z When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
z Unauthorised engine modifications will invalidate pressure - Danger to life!
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.
z 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
z 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.
z When carrying out maintenance work on the en-
2 © 2009
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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 Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail-
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG
© 2009 3
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Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Aspiration system. . . . . . . . . . . . . . . 51
Foreword. . . . . . . . . . . . . . . . . . . . . 3 Belt drives . . . . . . . . . . . . . . . . . . 53
1 General. . . . . . . . . . . . . . . . . . . . 5 Setting work . . . . . . . . . . . . . . . . . 56
2 Engine description . . . . . . . . . . . . . 7 Electrical system . . . . . . . . . . . . . . . 59
Model . . . . . . . . . . . . . . . . . . . . . 7 7 Faults. . . . . . . . . . . . . . . . . . . . . 61
Engine illustrations . . . . . . . . . . . . . . 9 Fault table . . . . . . . . . . . . . . . . . . 61
Lubricating oil diagram . . . . . . . . . . . . 17 Engine management . . . . . . . . . . . . . 66
Fuel diagram . . . . . . . . . . . . . . . . . 18 8 Transport and storage . . . . . . . . . . . 69
Coolant diagram . . . . . . . . . . . . . . . 19 Transport . . . . . . . . . . . . . . . . . . . 69
Exhaust gas return . . . . . . . . . . . . . . 21 Engine corrosion protection . . . . . . . . . 70
Electrics/Electronics . . . . . . . . . . . . . 22 9 Technical data . . . . . . . . . . . . . . . . 72
3 Operation . . . . . . . . . . . . . . . . . . 24 Engine and setting data . . . . . . . . . . . 72
Ambient conditions . . . . . . . . . . . . . . 24 Tools . . . . . . . . . . . . . . . . . . . . . 76
Initial start-up . . . . . . . . . . . . . . . . . 25
Start procedure . . . . . . . . . . . . . . . . 27
Operation monitoring . . . . . . . . . . . . . 29
Stop procedure . . . . . . . . . . . . . . . . 31
4 Operating media. . . . . . . . . . . . . . . 32
Lubricating oil . . . . . . . . . . . . . . . . . 32
Fuel . . . . . . . . . . . . . . . . . . . . . . 34
Coolant . . . . . . . . . . . . . . . . . . . . 35
5 Maintenance . . . . . . . . . . . . . . . . . 36
Maintenance schedule . . . . . . . . . . . . 36
6 Servicing and maintenance works . . . . . 39
Lubricating oil system. . . . . . . . . . . . . 39
Fuel system. . . . . . . . . . . . . . . . . . 42
Cooling system . . . . . . . . . . . . . . . . 48
Engine cleaning. . . . . . . . . . . . . . . . 50
4 © 2009
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General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the
functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components California
Obviously the high requirements for the protection of Proposition 65 Warning
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high Diesel engines and some of its constituents are
Safety precautions when the engine is running as for new parts. DEUTZ replacement parts are known to the State of California to cause cancer,
equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
Maintenance work or repairs may only be performed liability.
on the shut-down engine. Make sure that the engine Masthead
cannot be started inadvertently - Danger of acci- Asbestos DEUTZ AG
dent!
The gaskets used in this engine contain no asbestos. Ottostraße 1
After repair work: Check that all guards have been Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from 51149 Köln
maintenance and repair work.
the engine. Germany
Observe industrial safety regulations when running Service Phone: +49 (0) 221-822-0
the engine in an enclosed space or underground. We want to preserve the high performance of our en- Fax: +49 (0) 221-822-3525
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
E-Mail: info@deutz.com
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
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General
1 Danger
6 © 2009
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TCD
T Exhaust gas turbocharger R
DEUTZ AG
C Charge air cooler MADE IN GERMANY
D Diesel
2V
2V Number of valves
m
m Mechanical injection system
Pump-pipe-nozzle
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2 left
D
xxxxxxx
right
1
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Fuel schematic (example)
1 Fuel tank
2 Fuel pre-filter
3 Fuel pump
4 Exchangeable fuel filter
5 Fuel supply line to the control block FCU (Fuel
Control Unit)
6 Control block FCU (Fuel Control Unit)
5 7 High-pressure pump
5 6 7 8 8 Rail
9 Injector
10 Fuel return to fuel tank
3
10
TCD 2013 3
1 2 4
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5 4 3 2 1
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20 © 2009
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2 3
[mm]
[°]
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2 1 2 3 4 5
Electronic engine control
13 Engine side
1 Fuel transducer
14 2 Coolant temperature transmitter
3 Charge air pressure transmitter, charge air tem-
perature transmitter
15 TCD 2012/2013 L06
4 Charge air pressure transmitter, charge air tem-
6 perature transmitter
16 TCD 2012/2013 L04
5 Engine control unit
6 Central plug (for engine control)
17 7 Speed transmitter via crankshaft
8 Rail pressure sensor
9 Lubricating oil level transmitter (optional)
18 10 Lubricating oil pressure transmitter
11 Fuel transducer
12 Speed transmitter via camshaft
19
Equipment side
12
20 13 Power supply (battery)
14 Multifunction displays
15 Signal outputs, e.g. for lamps, torque (PWM),
21 speed, engine operation, etc.
16 Inputs (e.g. override button)
17 Accelerator
22
18 Hand throttle
11 10 9 8 7 19 Optional function selector switch, e.g. for P de-
23 gree, type of controls, maximum curve etc.
20 Detachable key switch Start/Stop
21 Diagnosis button
22 Error lamp
23 Diagnostic interface/CAN bus
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3 3 2
z Start the engine and run up until the thermostat
opens (line (2) heats up).
Trial run
z Engine operation with open thermostat 2 - 3 min- Additional venting of the fuel system by a 5
utes. minute trial run at idle speed or on low load
1 z Check the coolant level and top up coolant if nec- is absolutely essential.
essary.
Carry out a brief trial run up to operating temperature
Danger of scalding from hot coolant! (approx. 90 °C) after preparations.
Cooling system under pressure! Only open Do not load the engine if possible.
the cap when cool!
Observe safety regulations and national z Work with the engine not running:
specifications when handling cooling me- – Check engine for tightness.
dia. – Check lubricating oil level, if necessary top
up.
z If required, repeat procedure with engine start. – Check the coolant level and top up coolant if
z Fill up coolant to the MAX mark on the compen- necessary.
Filling the coolant system sation tank and close the cooling system cap. z Work during the trial run:
z Switch on any available heating and set to the – Check engine for tightness.
The coolant must have a prescribed con- highest level so that the heating circuit is filled
centration of cooling system corrosion pro- and vented.
tection agent! z Observe the filling volume of the cooling system
Never operate the engine without coolant, (72).
even for a short time!
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Lubricating oil temperature Lubricating oil temperature too high Switch off engine
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or Switch off engine
lamp while the engine is running, the lubricating oil pres-
sure is too low
Lube oil level If the pilot lamp lights up after starting the engine or Fill up lube oil
while the engine is running, the lubricating oil level is
too low
Coolant level If the control lamp lights up after the engine starts or Shut down the engine, allow to cool and top up cool-
while the engine is running, the coolant level is too ant
low
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
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Shutting off
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4 General
Modern diesel engines place very high demands on
lubricating oil flows, depending on the temperature.
The lubricating oil viscosity only has a small influ-
http://www.deutz.com
en \SERVICE \Operating Media and Diagno-
ence and effect on the quality of the oil.
the lubricating oil to be used. The specific engine sis\Deutz Quality Class\DQC Release List
performances which have increased constantly over Synthetic lubricating oils are used increasingly
the last few years lead to an increased thermal load and offer advantages. These lubricating oils have
Minimum quality class
on the lubricating oil. The lubricating oil is also more better temperature and oxidation stability as well as
exposed to contamination due to reduced oil com- relatively low cold vicosity. Since some processes DEUTZ Others
sumption and longer oil change intervals. For this which are relevant for determining the lubricating oil DQC II ACEA E3-96; E4-07; E5-02; E7-04
reason it is necessary to observe the requirements change times are largely dependent on the oil quality API CH-4/CG-4; CI-4,CI-4, CJ-4;
and recommendations described in this operating (e.g. the infiltration of soot and other contamination), DHD-1
manual in order not to shorten the life of the engine. the oil change time for synthetic lubricating oils may
The lubricating oils may only be used in conjunc-
not be increased in relation to the specifications on
Lubricating oils always consist of a base oil and an tion with an open crankcase breather.
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 The following lubricating oils are recommended for
tion, neutralisation of acids from combustion DEUTZ engines if they meet the requirements of this the engines in this operating manual:
products, prevention of coke and soot deposits on operating manual.
the engine parts) are assumed by the additives. The Recommended quality class
Quality
properties of the base oil are also decisive for the DEUTZ Others
quality of the product, e.g. with regard to thermal Lubricating oils are classified by DEUTZ according DQC III Please contact your DEUTZ partner
load capacity. to their performance and quality class (DQC: DEUTZ
Quality Class). Essentially, the following applies: the DQC IV
In principle, all engine oils of the same specification
can be mixed. However, mixing of engine oils should higher the quality class (DQC I, II, III, IV), the more
effective/the better quality the lubricating oil is. DEUTZ lubricating oils DQC III
be avoided because the worst properties of the mix-
TLX - 10W40 FE
ture are always dominant. Lubricating oils according to other comparable spec-
ifications can be used as long as they meet DEUTZ Container Order number:
The lubricating oils approved by DEUTZ have been
thoroughly tested for all engine applications. The ac- requirements. In regions in which none of these 5 litre container 0101 6335
tive ingredients they contain are compatible with qualities are available, please contact your responsi-
20 litre container 0101 6336
each other. Therefore, the use of additives for lubri- ble DEUTZ partner.
209 litre barrel 0101 6337
cating oils is not permitted in DEUTZ engines. or see www.deutz.com
The lubricating oil quality has a considerable influ- DEUTZ lubricating oils DQC IV synthetic
ence on the life, performance and thus also on the http://www.deutz.com
DQC IV - 5W30-UHP
costs-effectiveness of the engine. It basically applies en \SERVICE \Betriebsstoffe und Diag-
that: The better the lubricating oil quality, the better nose\Deutz Quality Class\DQC-Freiga- Container Order number:
these properties. beliste 20 litre container 0101 7849
The lubricating oil viscosity describes the way the 209 litre barrel 0101 7850
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SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
%.
15
– operation with bio-diesel fuel
z If the lubricating oil change intervals are not 10
reached within a year, the oil should be changed
at least once a year. 5
Viscosity 0
The ambient temperature at the installation site or in
-5
the application area of the engine is decisive for
choosing the right viscosity class. Too high a viscos- -10
ity can lead to starting difficulties, too low a viscosity
can endanger the lubrication effect and cause a high -15
lubricating oil consumption. At ambient temperatures
below -40 °C, the lubricating oil must be pre-heated -20
(e.g. by storing the vehicle or the machine in a hall).
-25
The viscosity is classified according to SAE. Multi-
purpose lubricating oils should be used basically. -30
Single-purpose lubricating oils can also be used in
enclosed, heated spaces at temperatures >5 ° C. -35
The prescribed lubricating oil quality must -40
be observed when selecting the viscosity
class!
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4 Permissible fuels
The following fuel specifications / standards are ap-
Please contact your DEUTZ partner
http://www.deutz.com
proved:
en \SERVICE\Betriebsstoffe und Diag-
z Diesel fuels nose\Kraftstoffe
– EN 590
en \SERVICE\Oils, Lubricants, Diagnosis\Fuel
– NATO F-54
– ASTM D 975 1-D Winter operation with diesel fuel
– ASTM D 975 2-D
– JIS K2204 Grade 1 Only carry out mixing in the tank. Fill with
– JIS K2204 Grade 2 the appropriate amount of paraffin first,
z Jet fuels then add the diesel fuel. Normal and high
grade fuels may not be mixed.
– NATO F34
– NATO F35 At low ambient temperatures paraffin discharges can
Only for mechanical injection system lead to blockages in the fuel system and cause oper-
Pump-pipe-nozzle ating faults. Below 0 °C ambient temperature use I Summer-grade diesel fuel
z Biodiesel fuel winter diesel (down to -20 °C) (filling stations provide II Winter-grade diesel fuel
– EN 14214 this in good time before the cold season starts).
A Outdoor temperature
z Below -20 °C paraffin should be added. The rel-
Use commercially available fuels with a sulphur con- evant percentages are given in the adjacent dia- B Percentage of paraffin to be added
tent below 0.5 %. The lubricating oil change intervals gram.
must be halved at a higher sulphur content.
z Special diesel fuels can be used for arctic cli-
If other fuels are used which do not meet the require- mates to -44 °C.
ments of the operating manual, the warranty will be
voided. If it is necessary to use Summer diesel fuel below
0 °C, up to 30 % petroleum can be added according
The certification measurements for compliance with
to the diagram opposite.
the legal emission values are made with the test fu-
els specified in the laws. These correspond to the Usually a sufficient cold resistance can be achieved
diesel fuels in accordance with EN 590 and by adding a flow improver. Ask your DEUTZ partner.
ASTM D 975 described in the operation manual. No
emission values are guaranteed with the other fuels
described in this operation manual.
The respective fuels prescribed by law must be used
to comply with the national emission regulations
(e.g. sulphur content).
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Deviations from the standard maintenacne schedule for engines subject to EPA certification
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E60 Intermediate overhaul Authorised specialists 6.000
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (32).
2)
For engines TD/TCD 2012 L04 2V with mechanical injection system, which are predominantly operated at a high load and a high speed, the lubricating oil change
interval is reduced to 250 h.
3)
Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
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5 Stage
E60
Activity
Replace
Measure
Injection valve
Page
Order number: 0312 3712 (TD/TCD 2012 2V) / 0312 3713 (TCD 2013 2V)
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Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
z Remove clamps when twist protection mounted z Fasten clamps of the twist protection (optional).
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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2 5
5 5
4
3 4 3
Replace lubricating oil filter cartridge z Collect draining lubricating oil z Replace gasket and oil lightly.
z Bend the filter cartridge in the collecting contain- z Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. z Screw the cover clockwise (25 Nm).
tion! z Clean components. z Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
z Switch off the engine.
z Loosen cover by turning 2-3 times and wait for 30
seconds.
z Unscrew cover with filter cartridge anti-clock-
wise.
z Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
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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.
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Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z 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
z Remove clamps when twist protection mounted z Fasten clamps of the twist protection (optional).
(optional). z Vent the fuel system.
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Catch any escaping fuel.
z Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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6
1 1
1
6
2 5
5 5
4
3 4 3
Replace fuel filter cartridge z Catch any escaping fuel. z Replace gasket and oil lightly.
z Bend the filter cartridge in the collecting contain- z Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. z Screw the cover clockwise (25 Nm).
tion! z Clean components. z Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
z Switch off the engine.
z Loosen cover by turning 2-3 times and wait for 30
seconds.
z Unscrew cover with filter cartridge anti-clock-
wise.
z Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
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6 level tank).
z Place suitable collecting containers underneath.
z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
z Loosen vent screws slightly. z Start engine.
z Open the drain cock and drain liquid. – Turn over the engine with starter (max.
– To open, the drain cock must be pressed 20 Sec.) until bubble-free fuel emerges at the
lightly and turned. constant-pressure valve in the crankcase/fil-
ter housing.
z Close the drain cock.
z Tighten vent screw. z Shut down engine
z Vent the fuel system. – Screw in ventilation screws (tightening
torque 25-5 Nm) and constant-pressure
Change the fuel pre-filter insert valve.
Change after maintenance interval, loss of power, or z Start engine.
annually. – Bring engine control to the start position and
z Switch off the engine or switch over to the other start.
Clean/change/vent the fuel pre-filter filter in case of switchable filter. – Check for leaks after starting the engine.
z Shut off the fuel supply to the engine (with high-
1 Venting screw level tank).
2 Cover z Loosen screws diagonally.
3 Screw z Remove cover.
4 Spring cassette z Remove spring cassette.
5 Filter insert z Change filter cartridge
6 Water collection vessel z Place spring cassette on the filter cartridge.
7 Electrical connection z Check the cover gasket for correct fit and dam-
8 Water drain tap age (change if necessary).
z Tighten cover with screws diagonally (tightening
A warning system (lamp/horn) should be in- torque 6Nm).
stalled via the electric connections. If the z Check for leaks after starting the engine.
warning system is triggered, immediate z Vent the fuel system.
maintenance is required.
Vent the fuel system
Cleaning/purging, draining of water
z Shut down engine
z Switch off the engine or switch over to the other z Position fuel collecting vessel below the con-
filter in case of switchable filter. stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
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Only carry out cleaning work on the engine z 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- z Warm up the engine so that the water residues
ing. evaporate.
z 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:
z High dust content in the air.
z Chaff and chopped straw in the area of the en-
gine.
z Coolant leaks
z Lubricating oil leakage
z Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
z Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
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Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter Emptying the cyclone precleaner
z The dry air filter is maintained according to a z Empty the dust discharge valve (1) by pressing
Never fill the dust container (3) with lubri-
maintenance switch or maintenance indicator. together the discharge slit.
cating oil!
z Maintenance is necessary when: z 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. z Clean the discharge slit. z Loosen wing nut (1) and lift off housing cover (2).
– the red field (1) of the maintenance indica- z Remove the dust container (3) from the base (4)
tor is fully visible. and empty it. Clean the container using a brush
z After carrying out maintenance work, reset the and clean diesel fuel. Then dry.
signal by pressing the button on the mainte- z Place the dust container (3) on the base (4) and
nance indicator. The maintenance indicator is tighten the housing cover (2) with wing nut (1).
now ready for operation again.
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1
6
2 A
3 B
Checking the belt drive Checking the belt tension Change generator V-belts
z Lower indicator arm (1) into the measuring de- 1 Setting screw
Only carry out work on the belt drive with
vice. 2 Lock nut
the engine at a standstill!
Always change both belts in sets in case of z Place guide (3) between two belt pulleys on the 3 Screw
wear on the double belts or damage to one V-belt (2). The stop have to be at the side. 4 V-belts
V-belt. z Press the button (4) at right angles to the V-belt
(2) evenly until you hear or feel the spring snap z Remove screw and lock nut.
After repair work: Check that all guards
have been replaced and that all tools have in. z Move the generator over the setting screw in di-
been removed from the engine. z Lift the measuring device carefully without alter- rection (B) until the V-belt is slack.
ing the position of the indicator arm (1). z Remove belt and fit new one.
z Check the whole belt drive visually for damage. z Read the measured value at the point of inter- z Move the generator over the setting screw in di-
z Renew damaged parts. section (arrow), scale (5) and indicator arm (1). rection (A) until the V-belt has attained the cor-
z Remount protective devices if necessary. z If necessary, re-tension belt and measure again. rect tension.
z Pay attention to correct fit of new belts, check the z Tighten screw and lock nut again.
tension after running for 15 minutes. Tools
Belt tension measuring device (order number:
8115) can be obtained from your DEUTZ partner.
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6 1
4 2
B
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Valve overlap Settings Turn rotation angle disc clockwise to the stop Then set the second valve on the rocker arm as
(rocker arm without clearance) and set scale to described above.
1 6 zero. Perform the setting procedure on every cylinder.
5 2 Turn rotation angle disc anticlockwise until Remount the cylinder head cover with a new
3 4 reaching the specified rotation angle: gasket in the reverse order of disassembly.
6 1 Tighten screws.
Valve clearance IN Inlet valve 75° + 10°
2 5 Tightening torque 22 Nm
TD/TCD 2012 EX Outlet valve 120° + 10°
4 3
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EX IN
3
Tightening torque 22 Nm 6
2 5
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Set control piston clearance (with internal ex- z Loosen lock nut.
haust gas recirculation EGR connected) z Fit the rotary angle disc with socket wrench inset
1 Lock nut on the setting screw.
2 Setting screw z Fix magnet of the rotation angle disc.
z Turn rotation angle disc clockwise to the stop
After setting the valve clearance, the control piston (control piston without clearance) and set scale
clearance should be set as follows: to zero.
z Turn the crankcase until reaching valve overlap z Turn rotation angle disc anticlockwise until
of the first cylinder. reaching the specified rotation angle:
Outlet valve is not yet closed, inlet valve begins Control piston clearance 144°
to open.
The cylinders to be set can be seen in the setting z Tighten locking nut.
schematic. z Perform the setting procedure on every control
piston.
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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 Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Cold starting device Check/replace
Glow plugs defective Change
Air in fuel system Vent
Fuel filter contaminated Clean
Fuel quality does not comply with operating manual Change the fuel
Injector defective Change
Injection line leaks Check injection line
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
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7 Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
Lubricating oil cooler fins soiled Clean
Engine stop lever still in stop position Check/replace
Mechanical injection system
Fuel suction temperature too high Check the system
Fuel quality does not comply with operating manual Change the fuel
Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
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
Resistance in cooling system is too high / flow volume too low Check the cooling system
Injection line leaks Check injection line
Injector 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
Injector defective Change
Charge air line leaking Check charge air line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
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0,8 s
0,4 s
0,4 s
0,4 s
0,8 s
0,4 s
Use of the diagnostic key
The flash code displays all errors in the error memo-
ry, this means active as well as passive ones.
The control unit must be switched off to start the en- 1 2 8
quiry (ignition off). Then the diagnosis button should Display system error by flash code
be pressed for approx. 1s during the start (ignition
on). Example:
Then the next error (i.e. the following one in the error Flash code 1-2-8
memory) can be displayed by pressing the diagnos- 1 x short flash
tic key again. If the last error was displayed, the first
2 x long flash
error is displayed again on pressing the diagnostic
key again. 8 x short flash
After the display of the error flash code, the error This flash code indicates a break or short circuit in
lamp goes out for five seconds. the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
the illustration.
z The blink codes can only be interpreted by a
DEUTZ partner.
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7 z
z
Gear oil pressure
Battery voltage
z Accelerator position
z Fuel consumption
z 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.
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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- z The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. z The fastening attachment can slip, the engine
z Always use proper suspension equipment when swings backwards and forwards (1).
transporting the engine. z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
z The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
z After transportation and before commissioning of
engine: remove attachment eyes (2).
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8 General
Engines contain the following types of corrosion pro-
by wetting of the walls with the implemented cor-
rosion protection agent in a corrosion protection
protection agent).
z Cooling air system, see the Exterior corrosion
run of the engine. protection section.
tection:
z The corrosion protection run can be performed z In engines of the oil-cooled series the circulating
z Interior corrosion protection once to protect the different systems: lubricating oil serves simultaneously for cooling.
z Exterior corrosion protection The cooling chambers are protected automati-
Fuel system cally against corrosion with the lube oil system.
Your DEUTZ partner has the right corro-
sion protection agent for your needs. z If a coolant with corrosion protection properties is
Close the fuel/tank/supply line to the en-
poured into liquid-cooled engines, no further ac-
gine so that the system is protected against
tion is necessary after draining.
The following measures for corrosion protection af- dirt and dust. Protect the electronics
against moisture and corrosion. z If not, the coolant must be drained and, to ensure
ter taking the engine out of operation meet the re- the formation of a covering layer on the inside
quirements for 12 months corrosion protection. surfaces of the cooling system, a corrosion pro-
z Fill the fuel tank with a mixture of:
The following corrosion protection work may only be – 90 % distilled fuel tection run performed with a mixture of:
carried out by persons familiar with it and instructed – 10 % corrosion protection oil. – 95 % treated water
in the potential dangers. – 5 % corrosion protection agent
z Perform a corrosion protection run with no load
If these measures are deviated from by exposing the for at least 5 minutes. z The duration of the corrosion protection run and
corrosion-protected engines or parts to unfavourable the concentration of the corrosion protection
conditions (installation outdoors or storage in damp, Lubricating oil system agent are specified by the manufacturer of the
badly aired places) or damage to the corrosion pro- z Drain lubricating oil from warm engine. corrosion protection agent.
tection layer, a shorter corrosion protection duration z Then drain the coolant.
z Thoroughly clean lube oil tray, cylinder head with
is to be expected.
rocker arms, valves, valve springs with diesel Air intake pipes
The engine corrosion protection should be checked fuel or cleaning agent.
about every 3 months by opening the covers. If cor- z Fill the engine with corrosion protection oil up to z After the corrosion protection run, remove the
rosion is detected, the corrosion protection should the MAX mark and perform a corrosion protec- cylinder head cover and deinstall injectors. The
be renewed. tion run for at least 5 minutes so that all the com- respective piston must be set to LT.
At the end of the corrosion protection work the crank ponents of the lubricating oil system are wetted z The accessible part of the cylinder liner should
drive may no longer be turned so that the corrosion or wet all accessible parts with corrosion protec- be coated with corrosion protection oil with a
protection agent in the bearings, bearing liners and tion oil and pump corrosion protection oil through spray lance through the opening.
cylinder liners is not scraped off. the engine with a separate pump until all bear- z Spray corrosion protection lubricating oil into the
Before operating a corrosion protected engine, the ings and bearing liners are wetted. suction intake pipe.
corrosion protection must be removed. Cooling system Exterior corrosion protection
Interior corrosion protection z Depending on the series the engines are z The engine must be cleaned thoroughly with a
z Interior corrosion protection is always provided equipped with cooling air, cooling oil or cooling cleaning agent before exterior corrosion protec-
fluid system (cooling water with cooling system tion. Any signs of corrosion and damage to the
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Engine type Dimension TD 2012 L04 2Vm TCD 2012 L04 2Vm TCD 2012 L04 2V TCD 2012 L06 2V
Working principle Four-stroke diesel engine
Charging Exhaust gas turbo- Turbocharger with charge air cooling
charger
Type of cooling water-cooled
Cylinder arrangement in series
No. of cylinders 4 6
Bore/stroke [mm] 101/126
Total displacement [cm3] 4038 6067
Combustion process Direct injection
Injection system Mechanical injection system Deutz Common Rail (DCR)
Exhaust gas recirculation internal
Valves per cylinder 2
Valve clearance: Inlet/outlet [mm]
Setting with rotary angle disc [°] 75° +10°/120° +10°
Firing order of the engine 1-3-4-2 1-5-3-6-2-4
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Coolant volume (only engine content without cooler / ≈ [l] 5,6 7,3
hoses and pipes)
Coolant volume DEUTZ PowerPack cooler ≈ [l] 18,5 22,7
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 4-8
Start of thermostat opening [°C] 86
Thermostat fully open [°C] 102
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9 Engine type Dimension TCD 2013 L04 2Vm TCD 2013 L04 2V TCD 2013 L06 2V
Working principle Four-stroke diesel engine
Charging Turbocharger with charge air cooling
Type of cooling water-cooled
Cylinder arrangement in series
No. of cylinders 4 6
Bore/stroke [mm] 108/130
Total displacement [cm3] 4761 7142
Combustion process Direct injection
Injection system Mechanical injection system Deutz Common Rail (DCR)
Exhaust gas recirculation internal
Valves per cylinder 2
Valve clearance: Inlet/outlet [mm]
Setting with rotary angle disc [°] 90° +10°/150° +10°
Firing order of the engine 1-3-4-2 1-5-3-6-2-4
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Coolant volume (only engine content without cooler / ≈ [l] 7,2 9,8
hoses and pipes)
Coolant volume DEUTZ PowerPack cooler ≈ [l] 22,7 24,9
Permissible continuous coolant temperature [°C] max. 105
Temperature difference between coolant inlet/outlet [°C] 4-8
Start of thermostat opening [°C] 86
Thermostat fully open [°C] 102
Lubricating oil change volume (with filter) ≈ [l] 15,5* 26,5*
Lube oil temperature in the lube oil tray, maximum [°C] 125
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9 Tool ordering
The special tools described in this chapter can be or-
dered from:
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Special tools for removing the water collection Special wrench for loosening exchangeable fil- Rotaqtion angle disc
vessel. ters
Order number:
Order number: Order number:
8190
8192 170050
Rotation angle disc for setting the valve and control
On Racor filters, only loosen the water collection For loosening changeable filters. piston clearance
vessel with a special tool.
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DEUTZ Oil
DEUTZ Oil DQC II-05 DEUTZ Oil DQC III-05 DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E5-02 / E3-96 / B3-04 ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 ACEA E7-04 / E5-02 / E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1
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
© 04/2009
All rights reserved
Order number:
0312 3761 en
The engine company. Original operating instructions