Operation Manual 7.8 - 03124572

OBJ_DOKU-35791-001.fm Seite 1 Donnerstag, 28.
März 2013 11:03 11
Operation Manual
TCD 7.8 L6
OBJ_DOKU-35791-001.fm Seite 2 Donnerstag, 28. März 2013 11:03 11
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 drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
pressure - Danger to life!
● Unauthorised engine modifications will invalidate
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
● Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
● Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
● When carrying out maintenance work on the en-
2 © 2013
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.
© 2013 3
Table of Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Lubricating oil system. . . . . . . . . . . . . 47
Foreword . . . . . . . . . . . . . . . . . . . . . 3 Fuel system. . . . . . . . . . . . . . . . . . 50
1 General . . . . . . . . . . . . . . . . . . . . 5 SCR. . . . . . . . . . . . . . . . . . . . . . 54
2 Engine description . . . . . . . . . . . . . . 7 Cooling system . . . . . . . . . . . . . . . . 55
Model . . . . . . . . . . . . . . . . . . . . . 7 Engine cleaning. . . . . . . . . . . . . . . . 57
Engine illustrations . . . . . . . . . . . . . . 10 Suction system . . . . . . . . . . . . . . . . 58
Lubricating oil diagram . . . . . . . . . . . . 14 Belt drives . . . . . . . . . . . . . . . . . . 60
Fuel diagram . . . . . . . . . . . . . . . . . 15 Adjustment work . . . . . . . . . . . . . . . 61
Coolant diagram . . . . . . . . . . . . . . . 16 Electrical system . . . . . . . . . . . . . . . 63
Exhaust gas recirculation . . . . . . . . . . . 17 7 Faults . . . . . . . . . . . . . . . . . . . . .65
Exhaust gas aftertreatment . . . . . . . . . . 18 Fault table . . . . . . . . . . . . . . . . . . 65
Electrics/Electronics . . . . . . . . . . . . . 20 Engine management . . . . . . . . . . . . . 70
3 Operation . . . . . . . . . . . . . . . . . . . 22 8 Transport and storage . . . . . . . . . . . .72
Ambient conditions . . . . . . . . . . . . . . 22 Transport . . . . . . . . . . . . . . . . . . . 72
Initial commissioning . . . . . . . . . . . . . 23 Engine corrosion protection . . . . . . . . . 73
Starting process . . . . . . . . . . . . . . . 26 9 Technical data . . . . . . . . . . . . . . . .76
Operation monitoring . . . . . . . . . . . . . 28 Engine and setting data . . . . . . . . . . . 76
Exhaust gas aftertreatment system. . . . . . 32 Tools . . . . . . . . . . . . . . . . . . . . . 78
Active regeneration . . . . . . . . . . . . . . 36
Stopping process . . . . . . . . . . . . . . . 38
4 Operating media . . . . . . . . . . . . . . . 39
Lubricating oil . . . . . . . . . . . . . . . . . 39
Fuel . . . . . . . . . . . . . . . . . . . . . . 41
Coolant . . . . . . . . . . . . . . . . . . . . 42
SCR reduction agent . . . . . . . . . . . . . 43
5 Maintenance . . . . . . . . . . . . . . . . . 44
Maintenance schedule . . . . . . . . . . . . 44
6 Servicing and maintenance work . . . . . . . 47
4 © 2013
General
DEUTZ diesel engines
DEUTZ diesel engines and the appropriate exhaust
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
aftertreatment components are the result of years of cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
research and development. The detailed know-how functioning and high reliability. tact to your nearest local service partner.
gained by this in connection with the high quality de-
mands are the guarantee for production of engines DEUTZ Xchange components California
with a long life, high reliability and low fuel consump- Proposition 65 Warning
tion. Naturally the high demands for protection of the DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high Diesel engines and some of its constituents are
environment are also met. known to the State of California to cause cancer,
as for new parts. DEUTZ replacement parts are
Safety precautions when the engine is running equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
liability. Masthead
Maintenance work or repairs may only be performed
on the shut-down engine. Make sure that the engine Asbestos DEUTZ AG
cannot be started inadvertently - Danger of accident!
The gaskets used in this engine contain no asbestos. 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-
© 2013 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 © 2013
Model Engine description

Engine type designation Emissions legislation
2
This manual covers the following engine types The engines of these operating instructions fulfill
the following exhaust emissions regulations A B
TCD 7.8 L6
With exhaust aftertreatment system
TCD USA EPA Tier 4i
Mot.-Typ Mot.-Nr.
T Exhaust gas turbocharger EU Stage IIIB
C Charge air cooler Without exhaust aftertreatment system
D Diesel The exact certification is printed on the engine rat-
ing plate or can be found on a separate plate for R
7.8 the respective markets. DEUTZ AG MADE IN GERMANY
7.8 Displacement in litres

The engine and the corresponding EAT
system (Exhaust After Treatment) are
L6
adapted to each other and linked by an ap- Rating plate
L in series propriate electronic controller.
The type (A), engine number (B) and performance
6 No. of cylinders They are only certified by the responsible
data are stamped on the rating plate.
authorities and comply with the permissible
exhaust limits in this combination. The engine type and number must be stated when
Operation of the engine with other EAT purchasing spare parts.
systems is not allowed.
The engines of this operating manual may

only be used with a functioning exhaust af-
tertreatment system.
(if included in the DEUTZ scope of supply)
© 2013 7
Engine description Model
2 C
D
xxxxxxx
C
Location of the rating plate Engine serial number

The rating plate (C) is fixed to the cylinder head cov- The engine number (D) is stamped onto the crank-
er or the crankcase. case (arrow) and onto the rating plate.
8 © 2013
Model Engine description
1 1 2 left
2
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 SCR catalyst 1 Rating plate of the diesel oxidation catalytic The cylinders are counted consecutively starting
converter from flywheel (1).
The serial numbers of the exhaust aftertreatment
2 Rating plate of the diesel particle filter Direction of rotation
components are stamped on the rating plates.
Looking onto the flywheel.
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates. rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
© 2013 9
Engine description Engine illustrations
2 TCD 7.8 L6
Agricultural engine
11 View from right (example)
1 Coolant outlet
2 Tension pulley
10 3 Coolant inlet
4 V-rib belt
5 Lubricating oil drain plug
6 Lube oil replacement filter
1 7 Lubricating oil dipstick
9 8 Exchangeable fuel filter
9 Rail
10 Crankcase breather
2 11 Lubricating oil filling
8
3
7
4
10 © 2013
Engine illustrations Engine description

TCD 7.8 L6
Agricultural engine
2
View from left (example)
1 Combustion air inlet
1 2 Heating flange
3 Exhaust outlet
4 Starter
© 2013 11
Engine description Engine illustrations
2 TCD 7.8 L6
Industrial engine with regeneration burner
11 View from right (example)
1 Coolant outlet
2 V-rib belt
10 3 Tension pulley
4 Coolant inlet
5 Lubricating oil drain plug
6 Lubricating oil dipstick
7 Lube oil cooler
9 8 Lube oil replacement filter
9 Rail
1 10 Crankcase breather
11 Lubricating oil filling
8
3
6
5
4
12 © 2013
Engine illustrations Engine description

TCD 7.8 L6
Industrial engine with regeneration burner
2
1 View from left (example)
2 Heating flange
3 Burner
4 Flexible pipe
2 5 Exhaust outlet
6 Air compressor
© 2013 13
Engine description Lubricating oil diagram
2 Lubricating oil system

(example)
1 Lubricating oil sump
13 12 11 10 2 Lubricating oil pump
3 Overpressure valve
4 Lube oil cooler
5 Bypass valve
9
6 Bypass valve
7 Pressure control valve
8 Lubricating oil filter
6 5 3 4 9 Main lube oil channel
10 Piston cooling nozzle
11 Rocker arm
12 Turbocharger
13 Air compressor
Optional
8 7 2 1
14 © 2013
Fuel diagram Engine description

Fuel schematic (example)
1 Fuel tank
2
6 7 8 9 2 Fuel pre-filter
3 Fuel pump
4 Exchangeable fuel filter
5 Fuel supply line to the control block FCU (Fuel
Control Unit)
6 Control block FCU (Fuel Control Unit)
10 7 High-pressure pump
8 Rail
9 Injector
10 Return line
11 11 Fuel return to fuel tank
1 2 3 5 4
© 2013 15
Engine description Coolant diagram
2 Coolant schematic (example)

1 Coolant pump
6 7 8 9 10 2 Lube oil cooler
3 Coolant supply for engine cooling
4 Cylinder pipe/head cooling
5 Air compressor
Optional
6 Connection possibility for cab heating
7 Exhaust return cooler
8 Temperature transmitter
9 Thermostat
10 Compensation tank
x1 x2 11 Cooler
T
x2
1 2 3 4 5 6
x1
5 4 3 2 1 11
16 © 2013
Exhaust gas recirculation Engine description

External exhaust gas recirculation
1 Exhaust gas partial flow
2
13 14 1 2 3 (uncooled)
2 Feeder actuator cooling
3 Actuator
(electrically actuated)
4 Return actuator cooling
5 Coolant line to the EGR cooler
6 Exhaust return cooler
7 Flapper valve
8 Pressure sensor
9 Temperature transmitter
10 Exhaust gas partial flow
(cooled)
11 Coolant return
12 Mixing pipe
14 Throttle valve
12 11 10 9 8 7 6 5 4
© 2013 17
Engine description Exhaust gas aftertreatment
2 Selective Catalytic Reduction (SCR)

Example:
1 Engine control unit
8 7 6 2 AdBlue® line
3 AdBlue® supply pump
4 AdBlue® tank
5 Solenoid valve
6 Coolant line
5 to pre-heat the AdBlue® tank
7 Exhaust temperature sensor
8 NOX sensor
9 SCR catalytic converter
10 Dosing device
11 Coolant line
to cool the dosing device
4
10
3
11
1 2
18 © 2013
Exhaust gas aftertreatment Engine description

Diesel Particle Filter (DPF)
Example:
2
1 Burner
2 Air compressor
1 3 5 7 9 3 Fuel metering unit
4 Flexible pipe
5 Exhaust temperature sensor
6 Diesel oxidation catalytic converter
7 Differential pressure sensor
8 Diesel particle filter
9 NOX sensor
2 4 6 8
© 2013 19
Engine description Electrics/Electronics
2 1 2 3 4 5 11
Electronic engine control
Engine side
1 Fuel transducer
12 2 Rail pressure sensor
3 Coolant temperature transmitter
6 4 Charge air pressure transmitter, charge air tem-
13 perature transmitter
5 Engine control unit
6 Central plug (for engine control)
14 7 Speed transmitter via crankshaft
8 Speed transmitter via camshaft
9 Lubricating oil pressure transmitter
15 10 Lubricating oil level transmitter (optional)
Equipment side
16
11 Power supply (battery)
12 Multifunction displays
17 13 Signal outputs, e.g. for lamps, speed, engine op-
eration, etc.
14 Inputs (e.g. override button)
18 15 Accelerator
16 Hand throttle
17 Optional function selector switch, e.g. for P de-
19 gree, type of controls, maximum curve, fixed
speeds, etc.
18 Detachable key switch Start/Stop
20 19 Diagnosis button
20 Error lamp
21 Diagnostic interface/CAN bus
7 8 9 10 21
20 © 2013
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
The equipping of the respective system depends on wiring of the electrical control devices and tics. Active and passive error entries are saved in the
the desired scope of function and the planned type of the data transmission cable (CAN lines). error memory. Active errors are displayed on error
engine application. b) to switch control units. lamps/diagnostics lamps (70).
Otherwise guarantee rights will be lost! A diagnosis can be made with:
The resultant wiring with pin assignment can be seen Diagnostic and maintenance work may
in the appropriate wiring diagram. only be carried out by authorised personnel ● Error lamp (flash code)
The installation regulations of the DEUTZ AG must using equipment approved by DEUTZ. ● CAN bus
also be taken into account. ● DEUTZ electronics display
Installation instructions ● Diagnostic socket (SERIDA)
Precautions
The control units are calibrated to the respective en- Equipment-side wiring
gine and identified by the engine number. Every en-
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
spray water and moisture until plugging in essary for vehicle operation must be connected to
the vehicle side cable harness and calibrated with removed from the plug housing with the proper tools.
the mating plugs!
Reverse polarity can lead to failure of the the DEUTZ diagnostic program SERDIA (SERvice
control unit. DIAgnosis). Wiring and cable assignment of the ve-
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-
ered by the manufacturer's guarantee. It should be ensured that the battery is sufficiently
charged. If the supply voltage is interrupted while the
engine is running, this can lead to damage to the
electrics/electronics. If the supply voltage fails, the
engine shuts down.
Voltages above 32 Volt will destroy the control unit.
© 2013 21
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.(26)
Coolant
0 °C ● Observe the mixing ratio anti-freeze/cooling wa-
ter. (42)
High ambient temperatures, high altitude
This engine is equipped with an electric

control unit.
Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
ically, controlled by the electronic control
Low ambient temperatures unit.
Lubricating oil Under the following application and operating condi-
● Select the lubricating oil viscosity according to tions, the amount of fuel must be reduced.
the ambient temperature. ● above 1000 m altitude
● If cold starting occurs frequently cut the lube oil ● above 30 °C ambient temperature
changing interval by half.
Reason: Air density decreases as altitude or ambient
Fuel temperature increase. This reduces the amount of
● Use winter fuel below 0 °C (41). 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 (63) ● The results would be:
is the prerequisite for starting the engine. – black smoke in the exhaust
● Heating up the battery to approx. 20°C improves – high engine temperature
the starting behaviour of the engine. (Remove
– reduction in engine performance
and store the battery in a warm room).
– possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
you have any other questions.
22 © 2013
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 (60).
● 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 (76). 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 (76). fuel. Observe fuel quality (41).
Use summer or winter-grade fuel, depending on the
ambient temperature.
© 2013 23
Operation Initial commissioning
3 AdBlue® 3 2
● Start the engine and run up until the thermostat
opens (line (2) heats up).
● Engine operation with open thermostat 2 - 3 min-
utes.
Diesel Exhaust Fluid 1 ● Check the coolant level and top up coolant if nec-
essary.
Danger of scalding from hot coolant!
Cooling system under pressure! Only open
the cap when cool!
Observe safety regulations and national
specifications when handling cooling me-
dia.
● If required, repeat procedure with engine start.
● Fill up coolant to the MAX mark on the compen-
Filling with AdBlue® Filling the coolant system sation tank and close the cooling system cap.
● Switch on any available heating and set to the
Exhaust aftertreatment systems The coolant must have a prescribed con- highest level so that the heating circuit is filled
centration of cooling system corrosion pro- and vented.
SCR Selective Catalytic Reduction
tection agent! ● Observe the filling volume of the cooling system
Never operate the engine without coolant, (76).
Only re-fuel when the engine is not running.
even for a short time!
Only fill with AdBlue®!
Other media (e.g. diesel), even in the
smallest amounts, can cause destruction of Order coolant corrosion protection agent
the system and a not emmission compliant from your DEUTZ partner.
operation.
If you have filled with e.g. diesel and this ● Connect coolant outlet (2) and coolant inlet (1) to
has got into the system, the complete the cooling system. Connect the feed line of the
AdBlue® injection system must be re- compensation tank to the coolant pump or to the
placed! coolant inlet line (3).
If the filled medium (e.g. diesel) has not ● Connect ventilation line from the engine and, if
reached the lines and supply pump/meter- necessary, from the cooler to the compensation
ing module, an emptying and thorough tank.
cleaning of the AdBlue® tank will be ade- ● Fill cooling system via the compensation tank.
quate. ● Close compensation tank with valve.
Ensure cleanliness.
24 © 2013
Initial commissioning Operation

Trial run
3
Additional venting of the fuel system by a 5
minute trial run at idle speed or on low load
is absolutely essential.
Carry out a brief trial run up to operating temperature
(approx. 90 °C) after preparations.
Do not load the engine if possible.
● Work with the engine not running:
– Check engine for tightness.
– Check lubricating oil level, if necessary top
up.
– Check the coolant level and top up coolant if
necessary.
● Work during the trial run:
– Check engine for tightness.
Do not subject the covers to loads.
© 2013 25
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- – Pilot lamps (A), (B) and (C) light up.
tivated the start lock to protect the engine.
● stage 2 = pre-heating
The start lock is released by switching off
the system with the ignition key for about 30 – Preheat until the glow display goes out; an
seconds. error has occurred if the preheating indicator
Do not actuate the starter for more than flashes; e.g. the preheating relay is stuck,
20 seconds. If the engine does not start up, which can discharge the battery completely
wait for one minute and then repeat the when at a standstill.
starting process. – Engine is ready for operation.
If the engine does not start up after two at- ● Push the key in and turn further clockwise
tempts, determine the cause as per fault ta- against spring pressure.
ble (65). – Level 3 = start.
Do not run up the engine immediately to
high idling speed / full load operation from ● release the key as soon as the engine starts up.
cold. – The pilot lamps will go out.
26 © 2013
Starting process Operation

If the starter is controlled by the electronic engine
control via a relay: 3
● the maximum start duration is limited.
● the pause between two start attempts is speci-
fied.
– the start is then continued automatically
● starting while the engine is running is prevented.
If the touch start function is programmed, a short
start command with the ignition key in position 2 or a
start button, if available, suffices.
© 2013 27
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 turning off the
● Function test system with the ignition key for approx. 30s.
– Ignition on, error lamp lights up for approx. 2 – Additional control lamps, e.g. for lubricating
seconds and then goes out. oil pressure or lubricating oil temperature,
– Check the error lamp if there is no reaction are switched on if necessary.
after switching on the ignition. – optionally the power reduction can be by-
● The lamp does not light passed, the automatic switch-off delayed or
– After the lamp test an extinguished lamp indi- a start lock bypassed with the override key
cates an error-free and trouble-free operat- on the instrument panel to avoid critical situ-
ing state within the scope of the control ations. This brief deactivation of the engine
possibility. protection functions is logged in the control
unit. Display instrument
● Continuous light The engine protection functions are released in
– Error in the system. co-operation with the equipment manufacturer Possible displays:
– Operation continued with restrictions. and the DEUTZ installation consulting and may ● Colour scale
– The engine must be checked by a DEUTZ be designed individually. It is therefore absolute- – Display of operating state by coloured areas:
partner. ly essential to observe the operating instructions – green = normal operating state
– If a lamp lights steadily a monitored measur- of the equipment manufacturer.
– red = critical operatng state
ing variable (e.g. coolant temperature, lubri-
Take suitable action.
cating oil pressure) has left the permissible
value range. ● Measured value scale
Depending on the fault, the engine power may be – Actual value can be read off directly. The
reduced by the electronic engine control to pro- nominal value should be taken from the
tect the engine. Technical Data (76).
● 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
28 © 2013
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 (65).
© 2013 29
Operation Operation monitoring
3 Instruments/symbols Designation
SCR function lamp
Possible display:
Continuous light
Measure
Check AdBlue® filling level
flashes (0.5 Hz) Check SCR system 32
flashes (1 Hz)
flashes (2 Hz)
Engine warning lamp Continuous light In combination with rapid flashing of the SCR function lamp
the engine performance is reduced in two steps
32
Regeneration
DPF function lamp Continuous light See active regeneration 36

flashes (0.5 Hz)
flashes (2 Hz)
Engine warning lamp Continuous light See active regeneration 36

Flashing
Ash lamp Continuous light The ash lamp indicates that the loading of the diesel particle
filter with ash has reached a critical level and the device can
no longer regenerate.36
30 © 2013
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
© 2013 31
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
The urea solution AUS 32 is known in the an appropriate signal.
USA and North America by the name Die- An acoustic signal transmitter must be in-
sel Exhaust Fluid (DEF). stalled additionally if an SCR function lamp
or customer display is used.
The DEUTZ SCR system continuously reduces the
NOx emissions from the engine (NOx=nitric oxides). Power reduction
A reduction agent, AdBlue®, injected into the ex-
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.
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
depending on the type of fault.
The injected volume of AdBlue® is controlled by the
engine electronics. Power reduction
Warning strategy SCR system USA EPA
Stage 1 Torque reduction 20%
The display and monitoring of the exhaust
aftertreatment system can be executed ei- Stage 2 Torque reduction 20%
+ Engine speed limitation to
ther with pilot lights or with a CAN interface
1200 rpm
and a corresponding display, depending on
the engine version.
Please see the device manufacturer's oper- EU
ating manual. Stage 1 Torque reduction 25%
In order to comply with the regulations of the Europe- Stage 2 Torque reduction 50%
an Union (EU) and the Environmental Protection
Agency (EPA), the DEUTZ SCR system reacts with
a warning strategy to faulty operation of the exhaust
gas aftertreatment system.
Emission-relevant faults are:
● AdBlue® filling level
● Catalytic converter efficiency/Adblue® quality
● Manipulation
● System fault
32 © 2013
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
<15% Continuous light off SCR symbol None
Text message
<10% flashes (0.5 Hz) off SCR symbol None
Text message
<5% flashes (0.5 Hz) Continuous light SCR symbol Stage 1
Acoustic signal Text message After pre-warning time
Acoustic signal
<5% flashes (1 Hz) Continuous light SCR symbol Stage 2
Acoustic signal
0% flashes (2 Hz) Continuous light SCR symbol Stage 2
Acoustic signal Text message Without pre-warning time
Acoustic signal
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
too low Continuous light Continuous light SCR symbol Stage 2
Acoustic signal
© 2013 33
Operation Exhaust gas aftertreatment system
3 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
detected Continuous light Continuous light SCR symbol Stage 1
Acoustic signal
not remedied Continuous light Continuous light SCR symbol Stage 2
Acoustic signal
not remedied Continuous light Continuous light SCR symbol Stage 2
Acoustic signal Text message
Acoustic signal
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-
jection is impaired by a system fault.
System fault SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
detected Continuous light Continuous light SCR symbol Stage 2
Acoustic signal
34 © 2013
Exhaust gas aftertreatment system Operation

Diesel oxidation catalytic converter
The diesel oxidation catalytic converter has a cata-
3
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.
Regeneration
The active particle filter system burns the soot col-
lected in the filter if necessary with the remaining ox-
ygen from the engine exhaust. For this,
temperatures above 600°C are required, which are
actively generated by catalytic burning of a second-
ary injection volume in the DOC during regeneration.
To ensure the process works, the active particle filter
system is fitted with a burner.
© 2013 35
Operation Active regeneration
3 Regeneration of the diesel particle filter The engine warning lamp flashes, then the perform-
ance is reduced and, ultimately, the maximum en-
generation is requested, the filter continues to be
charged.
Temperatures of approx. 600 °C occur on gine speed is reduced. The engine warning lamp lights up continuously,
the exhaust pipe during regeneration. The control unit registers this action as a fault. then the performance is reduced.
These are independent of the actual engine
If the regeneration request is not observed and the The engine warning lamp flashes, then the perform-
performance, even in engine idling.
DPF is overloaded to an impermissible level, then ance is reduced and, ultimately, the maximum en-
Danger of burns!
the filter can only be regenerated via the DEUTZ gine speed is reduced.
Automatic mode service. The control unit registers this action as a fault.
The DPF system is operated without any operator in- Manual mode If the regeneration request is not observed and the
tervention in the automatic mode. DPF is overloaded to an impermissible level, then
Regeneration is necessary when the filter loading
Regeneration is necessary when the filter loading the filter can only be regenerated via the DEUTZ
has reached 100 % of the nominal soot loading.
has reached 100 % of the nominal soot loading. service.
The regeneration lamp starts flashing.
The regeneration lamp starts flashing. Replacing the diesel particle filter
The operator must enable regeneration with the en-
The regeneration begins after a delayed start. able button. It may be necessary to replace the diesel particle fil-
The regeneration lamp lights continuously during re- Regeneration starts immediately after the enable. ter after a high filter running time as non-combustible
generation. residues accumulate in the filter - so-called ash.
The regeneration lamp lights continuously during re-
The regeneration lasts 30 minutes on average. generation. If the ash loading goes beyond a certain level, this
will be indicated by the ash lamp.
The regeneration lamp goes out when regeneration The regeneration lasts 30 minutes on average.
has been successfully completed. The diesel particle filter needs to be replaced.
The regeneration lamp goes out when regeneration
If the regeneration has to be prevented or interrupted has been successfully completed. The machine can operate normally until the replace-
after it has already been started (e.g. machine is in a ment is carried out by the service.
hall), the operator must press the generation preven- If an active regeneration has to be interrupted, the
operator can press the button to stop regeneration. The time interval between two regeneration requests
tion switch. is shortened in proportion to the run time.
The regeneration request is still active because re- The regeneration request is still active because re-
generation has not taken place. Please contact your DEUTZ partner
generation has not taken place.
The regeneration lamp starts flashing. The contaminated diesel particle filter can be re-
The regeneration lamp starts flashing. turned and replaced with a clean one in the DEUTZ
The regeneration start must be re-enabled by the op- exchange programme.
No regeneration is possible as long as the regenera-
erator.
tion prevention switch is actuated.
Regeneration starts immediately after the enable.
If the regeneration switch is actuated continuously,
the filter is still charged. The regeneration lamp lights continuously during re-
generation.
The engine warning lamp lights up continuously,
then the performance is reduced. If the button is not pressed for a long time when re-
36 © 2013
Active 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 Regeneration
Regeneration lamp Engine warning lamp Ash lamp

off off off Normal operation
flashes (0.5 Hz) off off Automatic release
Release by the operator
flashes (2 Hz) off off Release by the operator
flashes (2 Hz) Continuous light off -30 % Release by the operator
flashes (2 Hz) Flashing off -30 % Release only by the DEUTZ partner
+ Engine speed limitation to 1200 rpm
flashes (2 Hz) Flashing Continuous light -30 % No regeneration possible
Ash load 100 % + Engine speed limitation to 1200 rpm
© 2013 37
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
38 © 2013
Lubricating oil Operating media

General
Modern diesel engines place very high demands on
bricating oil flows, depending on the temperature.
The lubricating oil viscosity only has a small influ-
http://www.deutz.com 4
ence and effect on the quality of the oil. de \SERVICE \Betriebsstoffe und Addi-
the lubricating oil to be used. The specific engine tive\Deutz Quality Class\DQC-Freigabeliste
performances which have increased constantly over Synthetic lubricating oils are used increasingly and
the last few years lead to an increased thermal load offer advantages. These lubricating oils have better en \SERVICE \Operating Liquids and Addi-
on the lubricating oil. The lubricating oil is also more temperature and oxidation stability as well as rela- tives\Deutz Quality Class\DQC Release List
exposed to contamination due to reduced oil com- tively low cold vicosity. Since some processes which
are relevant for determining the lubricating oil The choice of luricating oil essentially depends on
sumption and longer oil change intervals. For this the exhaust aftertreatment system.
reason it is necessary to observe the requirements change times are largely dependent on the oil quality
and recommendations described in this operating (e.g. the infiltration of soot and other contamination), The following lubricating oils are permissible for the
manual in order not to shorten the life of the engine. the oil change time for synthetic lubricating oils may engines in this operating manual:
not be increased in relation to the specifications on
Lubricating oils always consist of a base oil and an Permissible quality class
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 DEUTZ Others
tion, neutralisation of acids from combustion DEUTZ engines if they meet the requirements of this SCR Selective Catalytic Reduction
products, prevention of coke and soot deposits on operating manual.
DQC III Please contact your DEUTZ part-
the engine parts) are assumed by the additives. The ner
Quality DQC III LA
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 DQC IV
load capacity. to their performance and quality class (DQC: DEUTZ DQC IV LA
In principle, all engine oils of the same specification Quality Class). Essentially, the following applies: the
DPF Diesel Particle Filter
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. DQC III LA Please contact your DEUTZ part-
be avoided because the worst properties of the mix-
ture are always dominant. DQC IV LA ner
The DQC quality classes are still to be extended by
The lubricating oils approved by DEUTZ have been the DQC-LA quality classes which include the mod- Without exhaust aftertreatment system
thoroughly tested for all engine applications. The ac- ern, low-ash lubricating oils (LA = Low Ash).
DQC III Please contact your DEUTZ part-
tive ingredients they contain are compatible with Lubricating oils according to other comparable spec- ner
each other. Therefore, the use of additives for lubri- ifications can be used as long as they meet DEUTZ DQC IV
cating oils is not permitted in DEUTZ engines. requirements. In regions in which none of these For low-ash engine oils released according to the
The lubricating oil quality has a considerable influ- qualities are available, please contact your responsi- DQC system an appropriate reference is made in the
ence on the life, performance and thus also on the ble DEUTZ partner. oil release list.
costs-effectiveness of the engine. It basically applies
that: The better the lubricating oil quality, the better
these properties.
The lubricating oil viscosity describes the way the lu-
© 2013 39
Operating media Lubricating oil
4 DEUTZ lubricating oils DQC III

TLX - 10W40 FE
– Sulphur content in diesel fuel of >0.5 weight
%. °C
● If the lubricating oil change intervals are not
Not for DPF 45
reached within a year, the oil should be changed
Container Order number: at least once a year. 40
5 litre container 0101 6335 Viscosity
35
20 litre canister 0101 6336 The ambient temperature at the installation site or in
209 litre barrel 0101 6337 the application area of the engine is decisive for 30
choosing the right viscosity class. Too high a viscos-
ity can lead to starting difficulties, too low a viscosity 25
DEUTZ lubricating oils DQC III LA low-ash
DEUTZ Oil Rodon 10W40 Low SAPS can endanger the lubrication effect and cause a high
20
lubricating oil consumption. At ambient temperatures
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
Container Order number:
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
below -40 °C, the lubricating oil must be pre-heated 15
20 litre canister 0101 7976 (e.g. by storing the vehicle or the machine in a hall).
209 litre barrel 0101 7977 The viscosity is classified according to SAE. Multi- 10
purpose lubricating oils should be used basically.
DEUTZ lubricating oils DQC IV synthetic Single-purpose lubricating oils can also be used in 5
DQC IV - 5W30-UHP enclosed, heated spaces at temperatures >5 ° C.
0
Not for DPF
The prescribed lubricating oil quality must
Container Order number: -5
be observed when selecting the viscosity
20 litre canister 0101 7849 class! -10
209 litre barrel 0101 7850 Depending on the ambient temperature we recom-
-15
Lubricating oil change intervals mend the following common viscosity classes:
-20
● The intervals depend on:
– lubricating oil quality -25
– sulphur content in the fuel
– type of application of engine -30
● The lubricating oil change interval must be -35
halved if at least one of the following conditions
applies: -40
– Constant ambient temperature below -10 °C
(14 °F) or lube oil temperature below 60 °C
(84 °F).
40 © 2013
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.
Please contact your DEUTZ partner
Exhaust aftertreatment systems
http://www.deutz.com
SCR Selective Catalytic Reduction
de \SERVICE\Betriebsstoffe und Additive\Kraft-
DPF Diesel particle filter stoffe
DOC Diesel oxidation catalytic con- en \SERVICE\Operating Liquids and Addi-
verter tives\Fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
proved:
● Diesel fuels Special demands are placed on the cold behaviour
(temperature limit value of the filtrability) for winter
– EN 590
operation. Suitable fuels are available at filling sta-
Sulphur <10 mg/kg tions in winter.
– ASTM D 975 Grade 1-D S15 For engines with DCR® DEUTZ common
– ASTM D 975 Grade 2-D S15 rail injection, the mixing of petroleum and
adding of extra low additives is not permis-
Sulphur <15 mg/kg sible.
● Light heating oils At low ambient temperatures paraffin discharges can
– in EN 590 quality lead to blockages in the fuel system and cause oper-
ating faults. Below 0 °C ambient temperature use
Sulphur <10 mg/kg
winter diesel (down to -20 °C) (filling stations provide
If other fuels are used which do not meet the require- this in good time before the cold season starts).
ments of the operating manual, the warranty will be ● Special diesel fuels can be used for arctic cli-
voided. mates to -44 °C.
The certification measurements for compliance with
the legal emission values are made with the test fu-
© 2013 41
Operating media Coolant
4 General ● pH value too low:

Addition of diluted sodium or potassium lye.
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, Small trial mixtures are advisable. Please contact your DEUTZ partner if the DEUTZ
even for a short time! ● Total hardness too high: cooling system corrosion protection agent is not
Mixing with softened water (pH neutralized con- available.
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: http://www.deutz.com
damaged by: Mixing with softened water (pH neutralized con- de \SERVICE\Betriebsstoffe und
● corrosion densate or water softened by ion exchanger). Additive\Kühlsystemschutz
● cavitation Cooling system corrosion protection agent en \SERVICE\Operating Liquids and Addi-
● freezing tives\Cooling System Conditioner
● overheating Cooling system corrosion protection agents The cooling system must be monitored regularly.
must be disposed of in an environmentally This also includes checking the coolant system cor-
Water quality
friendly way. rosion protection agent concentration in addition to
The right water quality is important for conditioning Observe the notes on the safety data checking the coolant level.
the coolant. Clear, clean water within the following sheet.
The cooling system corrosion protection agent con-
analysis values should always be used:
centration can be checked with conventional test in-
Health damaging nitrous amines form struments (e.g. refractometer).
Analysis values min max ASTM when nitrite-based cooling system corro-
ph value 6,5 8,5 D 1293 sion protection agents are mixed with Cooling system Water percent- Cold pro-
Chlorine (Cl) [mg/l] - 100 D 512 amine-based agents! corrosion protec- age tection up
D 4327 tion agent percent- to
The conditioning of the coolant for liquid-cooled
age
Sulphate (SO4) [mg/l] - 100 D 516 DEUTZ compact engines is performed by mixing an
anti-freeze with corrosion protection inhibitors based min. 35 % 65 % -22 ℃
Total hardness [mmol/l] 3,56 D 1126
(CaCO3) [mg/l] 356 on ethylene glycol into the water. 40 % 60 % -28 ℃
[°dGH] 20,0 - DEUTZ cooling system corrosion protection agent 45 % 55 % -35 ℃
[°e] 25,0 Container Order number: max. 50 % 50 % -41 ℃
[°fH] 35,6 5 litre container 0101 1490 At temperatures below -41 °C, please contact your
20 litre canister 0101 6416 responsible DEUTZ partner.
Specifications of the water quality are made by the
local water board. 210 litre barrel 1221 1500 It is possible to use other cooling system corrosion
protection agents (e.g. chemical corrosion protection
The water must be conditioned if it deviates from the
This cooling system corrosion protection agent is agents) in exceptional cases. Consult your DEUTZ
analysis values.
free from nitrite, amine and phosphate and is adapt- partner.
42 © 2013
SCR reduction agent Operating media

AdBlue® (urea solution AUS 32) Ensure that the materials and storage containers
used are resistant to AdBlue®. 4
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.
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 corresponds to This must be documented.
the ISO 22241-1 NOx reduction agent AUS 32. 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.
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!
© 2013 43
Maintenance Maintenance schedule
5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
Standard maintenance schedule

TCD 7.8 L6
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E30 Maintenance Qualified personnel 500 1) 2)
E40 Extended maintenance I 1.000
E50 Extended maintenance II Authorised specialists 2.000
E55 Extended maintenance III 4.500
E60 Intermediate overhaul 6.000
E70 General overhaul 10.000 3)
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (39).
2)
Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
General overhaul
3)
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.
44 © 2013
OBJ_DOKU-35791-001.fm Seite 45 Mittwoch, 17. April 2013 1:13 13
Maintenance schedule Maintenance

Maintenance measures
5
Stage Activity Measure Page
E10 The measures are listed in chapter 3. 23
E20 Check Lubricating oil level (if necessary top up) 47
Coolant level (top up if necessary) 24
Engine tightness (visual inspection for leaks)
Exhaust system including exhaust aftertreatment components for leaks 18
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 58
Emptying of the water tank in the fuel pre-filter 53
E30 Check Coolant (additive concentration) 55
Intake air pipes for damage
Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 39/47
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 48
Filtercartridge of the AdBlue® supply pump 54
E40 Check Charge air cooler entry area (drain lube oil/condensate)
Battery and cable connectors 63
Cold starting device
V-rib belt and tensioning pulley 60
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Replace Fuel filter cartridge 51
Fuel pre-filter with water trap (renew the filter insert if necessary). If the warning system responds (lamp/horn), the 50
water trap bowl must be emptied immediately.
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 58
E50 Settings Valve clearance 61
Check Exhaust gas recirculation, adjustment rods clearance
© 2013 45
Maintenance Maintenance schedule
5 Stage
E55
Activity
Replace
Measure
Spark plug of the DPF burner
Page
V-rib belt and tensioning pulley 60

Flatter valve
E60 Replace Crankcase breather valve
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
annually Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Replace Fuel pre-filter 50
Fuel filter cartridge 51
Lubricating oil 39/47
Lubricating oil filter/insert (every time the lubricating oil is changed) 48
Every 2 years Replace Dry air filter 58
Coolant 42 55
Filtercartridge of the AdBlue® supply pump 54
Status dependent Replace Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 58
Diesel particle filter, the required replacement is displayed by the ash lamp or via an electronic display, depending on 36
the engine version.
Empty Fuel pre-filter with water trap. If the warning system is activated (lamp/horn), the water trap bowl must be emptied 53
immediately.
Maintenance profile
A self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment.
Order number: 0312 3794 (TCD 7.8 L6)
46 © 2013
Lubricating oil system Servicing and maintenance work

Regulations for working on the lubricating oil system
OIL ?
● Extract the lubricating oil dipstick and read off the
oil level. 6
Do not work when the engine is running! ● The oil level must always be between the MIN
Smoking and naked lights prohibited! and MAX marks! Top up to the MAX mark if nec-
Be careful of hot lubricating oil. Danger of essary.
scalding! OIL Changing the lubricating oil
+80°C
Pay attention to utmost cleanliness when +176°F ● Warm up the engine (lubricating oil temperature
working on the lubricating oil system. Clean > 80 °C).
the area around the components con- ● Ensure that the engine or vehicle is in a level po-
cerned carefully. Blow damp parts dry with sition.
compressed air.
Observe the safety regulations and nation-
al specifications for handling lube oils.
! ● Switch off the engine.
● Place a collecting receptacle underneath the
lube oil drain screw.
Dispose of leaking lubricating oil and filter
● Unscrew the lube oil drain screw, drain oil.
elements properly. Do not allow used oil to
Checking the lubricating oil level ● Screw in and tighten lubricating oil drain plug,
seep away into the ground.
which is equipped with a new sealing ring.
Perform a trial run after all work. Pay atten-
tion to tightness and lubricating oil pressure Low lubricating oil level and overfilling lead
Tightening torque 55 Nm
and then check the engine oil level. to engine damage.
The lubricating oil level may only be ● Pour in lube oil.
checked with the engine in a horizontal po- – Quality/viscosity data (39).
sition and switched off. – Filling volume (76).
If the engine is warm, switch off the engine
● Warm up the engine (lubricating oil temperature
and check the lubricating oil level after 5
> 80 °C).
minutes. If the engine is cold you can check
it immediately. ● Ensure that the engine or vehicle is in a level po-
sition.
● Check lubricating oil level, if necessary top up.
Be careful of hot lubricating oil. Danger of
scalding!
Do not pull out the dipstick while the engine
is running. Danger of injury!
● Pull out the lubricating oil dipstick and wipe off
with a lint-free, clean cloth.
● Insert the lubricating oil dipstick as far as it will
go.
© 2013 47
Servicing and maintenance work Lubricating oil system
Change lubricating oil filter ● Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- ● Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
● Remove clamps when twist protection mounted ● Fasten clamps of the twist protection (optional).
(optional).
● Loosen and unscrew filter with tool (order no.:
0189 9142)
● Collect draining lubricating oil
● Clean the sealing surface of the filter support
48 © 2013
Lubricating oil system Servicing and maintenance work
1
6
1
1
6
2 5
5 5
4
3 4 3
Replace lubricating oil filter cartridge ● Collect draining lubricating oil ● Replace gasket and oil lightly.
● Bend the filter cartridge in the collecting contain- ● Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. ● Screw the cover clockwise (25 Nm).
tion! ● Clean components. ● Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
● Switch off the engine.
● Loosen cover by turning 2-3 times and wait for 30
seconds.
● Unscrew cover with filter cartridge anti-clock-
wise.
● Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
© 2013 49
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.
50 © 2013
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
© 2013 51
Servicing and maintenance work Fuel system
6 1
1
1
6
2 5
5 5
4
3 4 3
Replace fuel filter cartridge ● Catch any escaping fuel. ● Replace gasket and oil lightly.
● Bend the filter cartridge in the collecting contain- ● Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. ● Screw the cover clockwise (25 Nm).
tion! ● Clean components. ● Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
● Loosen cover by turning 2-3 times and wait for 30
seconds.
● Unscrew cover with filter cartridge anti-clock-
wise.
● Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
52 © 2013
Fuel system Servicing and maintenance work

Tightening torque 1.6 ±0.3 Nm
screw.
● Tighten vent screw. 6
1 ● Electrical connection
– Connect cable connections.
7 ● Lock the bayonet connection of the fuel supply
Change the fuel pre-filter insert
2 pump by pressing upwards and simultaneously
● Switch off the engine. turning clockwise.
● Shut off the fuel supply to the engine (with high- ● Start the engine and operate approx. 5 minutes
6 level tank). in idling mode or at low load. Check the pre-filter
3 ● Place suitable collecting containers underneath. for leaks while doing this.
● Electrical connection
– Disconnect cable connections.
5 4
● Loosen drain plug and drain liquid.
● Disassemble filter insert.
Change/vent fuel pre-filter ● Clean any dirt off the sealing surfaces of the new
filter cartridge and opposite side of filter head.
Deutz Common Rail (DCR) ● Wet the sealing surfaces of the filter cartridge
1 Venting screw slightly with fuel and screw back on to the filter
2 Fuel supply flow to the pump head, clockwise (17-18 Nm).
3 Fuel pump ● Mount drain plug.
4 Electrical connection for water level sensor
5 Drain plug
6 Filter insert ● Electrical connection
7 Fuel inlet from the fuel tank – Connect cable connections.
Empty water tank ● Open the fuel shutoff tap and vent the system,
see venting the fuel system.
● Place suitable collecting containers underneath. Vent the fuel system
● Electrical connection ● Loosen vent screw.
– Disconnect cable connections. ● Unlock the bayonet connection of the fuel supply
● Loosen drain plug. pump by pressing upwards and simultaneously
● Drain fluid until pure diesel fuel runs out. turning anticlockwise. The pump pistons are now
pressed out through the spring.
● Mount drain plug.
● Pump until no more air escapes at the vent
© 2013 53
Servicing and maintenance work SCR
1 2 3
Change the filter cartridge of the AdBlue® supply ● Pull out filter insert and compensation body.
pump ● Insert new filter insert with compensation body.
In engines with exhaust aftertreatment system Se- ● Mount cover.
lective Catalytic Reduction
Protective gloves are to be worn when ● Electrical connection
working with Selective Catalytic Reduction
– Connect cable connections.
(SCR) components.
Ensure cleanliness. ● Start
1 Cover
2 Compensation body
3 Filter insert
● Electrical connection
– Disconnect cable connections.
● Place suitable collecting containers underneath.
● Remove cover.
Socket wrench insert 27 mm
54 © 2013
Cooling system Servicing and maintenance work

Specifications when working on the cooling system
6
the cap when cool!
The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!
Observe safety regulations and national
specifications when handling cooling me-
dia.
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do 1
not allow them to seep into the ground.
Order coolant corrosion protection agent
from your DEUTZ partner. Check coolant additive concentration Emptying the cooling system
Never operate the engine without coolant, ● Open the cooling system cap (1) carefully. ● Open cooler locking cap carefully.
even for a short time!
● Check the coolant aditive concentration in the ● Place suitable collecting containers underneath.
Checking the coolant level with an external cooler cooler/compensation tank (2) with a convention- ● Remove the locking screw (1) in the crankcase.
al antifreeze measuring device (1) (e.g. hydrom- ● Drain coolant.
● Fill in new coolant and vent the system according eter, refractormeter).
to the specifications of the cooling system manu- ● If the locking screw is not accessible, the drain-
● Necessary coolant additive concentration Cool- age can be carried out at the engine oil cooler
facturer. ant mixing ratio (42).
● Open the cooling system cap (1) carefully. (coolant duct).
● The coolant level must always be between the The corresponding test device can be ordered from ● Insert screw again with sealant.
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.
© 2013 55
Servicing and maintenance work Cooling system
Fill and ventilate cooling system

the cap when cool!
● Open the cooling system cap (1) carefully.
● Loosen the cooler venting screw if necessary.
● Fill coolant up to the max. mark or filling limit.
● Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
● Close cooler locking cap.
● Run engine up to operating temperature (open-
ing temperature of the thermostat).
● Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
tion tank if necessary.
56 © 2013
Engine cleaning Servicing and maintenance work

Cleaning work Cleaning with cold cleaner
● Spray the engine with cold cleaner and leave it
6
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.
© 2013 57
Servicing and maintenance work Suction system
6 Regulations for working on the intake system

1 5 2
Renewing the safety cartridge of the dry air filter
Do not work when the engine is running! Never clean the safety cartridge (4).
● Replace safety cartridge (4) together with the dry

Pay attention to utmost cleanliness when
air filter.
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.
58 © 2013
Suction system Servicing and maintenance work

6
Clean the dust discharge valve of the dry air filter

● Empty the dust discharge valve (1) by pressing
together the discharge slit.
● Remove any caked dust by pressing together the
upper section of the valve.
● Clean the discharge slit.
© 2013 59
Servicing and maintenance work Belt drives
6 Checking the belt drive
Only carry out work on the belt drive with

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

1 Tension pulley
2 Retaining pin
3 Assembly bore
● Press tensioning roller with socket wrench in the
direction of the arrow until a retaining pin can be
fixed in the assembly bore. The V-ribbed belt is
now tension free.
● First pull the V-ribbed belt off the smallest roller
or off the tensioning roller.
● Mount new V-ribbed belt.
● Retain tensioning pulley using the pin wrench
and remove the holding pin.
● Tension V-ribbed belt using the tensioning roller
and socket wrench. Check whether the V-ribbed
belt is correctly in its guide.
60 © 2013
Adjustment work Servicing and maintenance work

Check valve clearance, adjust if necessary
● Let the engine cool down for at least 30 minutes
EX IN
3 6
before setting the valve clearance: Lubricating oil
temperature below 80 °C.
● Disassemble electric line at the injectors.
● Remove the cylinder head hood.
● Place turning gear over fastening screws of the
belt pulleys.
2
● Turn the crankcase until reaching valve overlap. 4
Outlet valve is not yet closed, inlet valve begins to
open.
The cylinders to be set can be seen in the setting 1 5
schematic.
TCD 7.8 L6
Set valve clearance
Tightening torque 20 Nm
Valve overlap Settings 1 Lock nut
1 6 2 Setting screw ● Now adjust the two other valves at the rocker
3 Rotary angle disc arm, as described above.
5 2
4 Insert ● Perform the setting procedure on every cylinder.
3 4 ● Reassemble cylinder head cowling (if necessary,
5 Magnet
6 1 with new seal) in reverse order of disassembly.
2 5 ● Fit the rotary angle disc with socket wrench inset ● Tighten screws.
on the setting screw.
4 3 Tightening torque 9 Nm
● Fix magnet of the rotation angle disc.
● Turn rotation angle disc clockwise to the stop Tools
Valve clearance
(rocker arm without clearance) and set scale to
TCD 7.8 L6 IN Inlet valve 75° ± 10° zero. The rotary angle disc (order no.: 0189 9093) can be
ordered from your DEUTZ partner.
EX Outlet valve 105° ± 10° ● Turn rotation angle disc anticlockwise until
reaching the specified rotation angle:
● Secure the rotation angle disc against twisting.
● Tighten locking nut.
© 2013 61
Servicing and maintenance work Adjustment work
6 Valve clearance setting schematic

● Crankshaft position 1
Turn crankshaft until both vaalves overlap on the
cylinder.
Outlet valve is not yet closed, inlet valve begins
to open.
Set black marked valves.
Mark the respective rocker arm with chalk to
check the setting you have made.
● Crankshaft position 2
Turn the crankshaft one turn (360 °).
Set black marked valves.
62 © 2013
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
© 2013 63
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.
64 © 2013
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
Incorrect valve clearance Check valve clearance and set if necessary
Air filter clogged / turbocharger defective Check/replace
Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
© 2013 65
Faults Fault table
7 Faults
Engine starts, but runs irregularly or
Causes
Incorrect valve clearance
Measures
Check valve clearance and set if necessary
fails Compression pressure too low Check compression pressure
Air in fuel system Vent
Fuel filter contaminated Change
Injector defective Change
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
66 © 2013
Fault table Faults

Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
7
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lube oil cooler defective Check/replace
Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
© 2013 67
Faults Fault table
7 Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
Fuel suction temperature too high Check the system
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air cooler soiled Clean
Resistance in cooling system is too high / flow volume too low Check the cooling system
Engine performs poorly and diagnos- Engine electronics reduce performance Please contact your DEUTZ partner
tic lamp lights
Engine does not run on all cylinders Injection line leaks Check injection line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
68 © 2013
Fault table Faults

Faults
Engine producing white smoke
Causes
Below starting limit temperature
Measures
Check
7
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Error in the SCR system AdBlue® tank empty/display full Check tank sensor
SCR not working Check plug connection of the lines at the
pump and injector
SCR not working (cold) Lines frozen, clean lines
Implausible sensor signal Check NOx sensor
No regeneration in the diesel particle Power supply of the air compressor interrupted Check fuse and supply line, replace lock
filter Air compressor defective Check air compressor, replace lock
Air filter blocked Clean/Replace air filter, check air compres-
sor, if necessary replace lock
Fuel supply interrupted Check lines, check metering unit
Implausible sensor signal Check exhaust backpressure sensor, check
differential pressure sensor in the particle
filter, check pressure sensors in the meter-
ing unit
Swirl plate sooted up Clean, determine reason for the sooting
© 2013 69
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 turning off the
3 system with the ignition key for approx. 30s.
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out. – optionally the power reduction can be by-
passed, the automatic switch-off delayed or
– Check the error lamp if there is no reaction
a start lock bypassed with the override key
after switching on the ignition.
Engine protection function of the electronic engine on the instrument panel to avoid critical situ-
● The lamp does not light
control ations. This brief deactivation of the engine
– After the lamp test an extinguished lamp indi- protection functions is logged in the control
cates an error-free and trouble-free operat- unit.
1 Diagnosis button ing state within the scope of the control Please contact your DEUTZ-partner in case of
2 Error lamp possibility. malfunctions and sare parts inquiries. Our spe-
3 Electronic engine control (EMR) ● Continuous light cially trained personnel will ensure fast, profes-
Error in system. sional repairs using original DEUTZ spare parts
The error lamp goes out when all the errors in case of damage.
– Operation continued with restrictions.
have been eliminated. For some errors, it is
– The engine must be checked by a DEUTZ
necessary to switch off the ignition, wait 30
partner.
s and only then switch back on the ignition.
The appropriate monitoring functions are – If a lamp lights steadily a monitored measur-
switched off when a sensor fails. Only the ing variable (e.g. coolant temperature, lubri-
sensor failure is documented in the error cating oil pressure) has left the permissible
memory. value range.
Depending on the fault, the engine power
Depending on the design of the monitoring functions, may be reduced by the electronic engine
the electronic engine control can protect the engine control to protect the engine.
in certain problematical situations by monitoring im-
portant limit values during operation and checking ● Flashing
the correct function of the system components. Serious error in system.
70 © 2013
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 off to start the en-
1 2 8
quiry (ignition off). Then the diagnosis button should Display system error by flash code
be pressed for approx. 1s during the start (ignition
on). Example:
Then the next error (i.e. the following one in the error Flash code 1-2-8
memory) can be displayed by pressing the diagnos- 1 x short flash
tic key again. If the last error was displayed, the first
2 x long flash
error is displayed again on pressing the diagnostic
key again. 8 x short flash
After the display of the error flash code, the error This flash code indicates a break or short circuit in
lamp goes out for five seconds. the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
the illustration.
● The blink codes can only be interpreted by a
DEUTZ partner.
© 2013 71
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).
72 © 2013
Engine corrosion protection Transport and storage

General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
Cooling system
● Depending on the series the engines are
8
● The corrosion protection run can be performed
tection: equipped with cooling air, cooling oil or cooling
once to protect the different systems:
● Interior corrosion protection fluid system (cooling water with cooling system
● Exterior corrosion protection Fuel system protection agent).
● Cooling air system, see the Exterior corrosion
Your DEUTZ partner has the right corro- Close the fuel/tank/supply line to the en- protection section.
sion protection agent for your needs. gine so that the system is protected against ● In engines of the oil-cooled series the circulating
dirt and dust. Protect the electronics lubricating oil serves simultaneously for cooling.
The following measures for corrosion protection after against moisture and corrosion. The cooling chambers are protected automati-
taking the engine out of operation meet the require- cally against corrosion with the lube oil system.
● Fill the fuel tank with a mixture of: ● If a coolant with corrosion protection properties is
ments for 12 months corrosion protection.
– 90 % distilled fuel poured into liquid-cooled engines, no further ac-
The following corrosion protection work may only be – 10 % corrosion protection oil. tion is necessary after draining.
carried out by persons familiar with it and instructed
● Perform a corrosion protection run with no load ● If not, the coolant must be drained and, to ensure
in the potential dangers.
for at least 5 minutes. the formation of a covering layer on the inside
If these measures are deviated from by exposing the surfaces of the cooling system, a corrosion pro-
corrosion-protected engines or parts to unfavourable Lubricating oil system
tection run performed with a mixture of:
conditions (installation outdoors or storage in damp, ● Drain lubricating oil from warm engine. – 95 % treated water
badly aired places) or damage to the corrosion pro-
● Thoroughly clean lube oil tray, cylinder head with – 5 % corrosion protection agent
tection layer, a shorter corrosion protection duration
rocker arms, valves, valve springs with diesel ● The duration of the corrosion protection run and
is to be expected.
fuel or cleaning agent. the concentration of the corrosion protection
The engine corrosion protection should be checked ● Fill engine with TITAN EM 2020 DEUTZ (SAE agent are specified by the manufacturer of the
about every 3 months by opening the covers. If cor- 20W-20) preservation oil and carry out corrosion corrosion protection agent.
rosion is detected, the corrosion protection should protection run (together with corrosion protection ● Then drain the coolant.
be renewed. run for fuel system), warm up the engine to ap-
At the end of the corrosion protection work the crank prox. 60 °C, duration at least 5 minutes so that all
drive may no longer be turned so that the corrosion components of the lubricating oil system are wet,
protection agent in the bearings, bearing liners and
cylinder liners is not scraped off. or
Before operating a corrosion protected engine, the
corrosion protection must be removed. all accessible components are wet with preser-
vation oil and pump approx. 60 °C warm preser-
Interior corrosion protection vation oil through the engine with a separate
pump until all bearings and bearing liners are
● Interior corrosion protection is always provided wet.
by wetting of the walls with the implemented cor-
© 2013 73
Transport and storage Engine corrosion protection
8 Exhaust aftertreatment system

Selective Catalytic Reduction
not be remedied.
Air intake pipes
air supply pipe.
Storage and packaging
The SCR system can be taken out of operation for up ● Spray ANTICORIT VCI UNI O 40 corrosion pro- ● After being protected against corrosion, the en-
to 4 months after completely shutting down (includes tection oil or TITAN EM 2020 DEUTZ (SAE 20W- gine must be stored in a dry, ventilated hall and
all lag functions) and the following conditions: 20) preservation oil into the intake air pipe. suitably covered.
● The vehicle or engine should be stored in a cov- ● The cover must be placed loosely over the en-
ered place, e.g. garage or hall, for longer shut- Exterior corrosion protection gine so that the air can circulate around it to pre-
downs. ● The engine must be cleaned thoroughly with a vent condensation from forming. Use a desiccant
● AdBlue® fill tank completely. cleaning agent before exterior corrosion protec- if necessary.
Evaporation of water as part of the AdBlue® must tion. Any signs of corrosion and damage to the
Removal of corrosion protection
be avoided. paintwork must be removed.
● Do not disconnect electrical or hydraulic connec- ● The corrosion protection must be removed from
tions. Bare exterior surfaces and parts the corrosion protected engine before starting.
● Maximum storage time at -40 ℃ to 40 ℃ ● Coat or spray all bare exterior parts and surfaces ● The packaging and all covers over the closed
2 months. (e.g. flywheel, flange faces) with corrosion pro- openings must be removed.
● Maximum storage time at -40 ℃ to 25 ℃ tection agent. ● Any corrosion deposits and paint damage should
4 months. be remedied.
Rubber parts
If the shutdown time of 4 months mentioned above Fuel system
● Rubber parts (e.g. muffs) which are not painted
has been exceeded, proceed as follows:
over must be rubbed down with talcum powder. If there is a mixture of diesel fuel/corrosion pro-
● AdBlue® tection oil in the fuel tank, drain it.
– Empty the tank completely. Belt drive
● Connect fuel/tank/supply line to the engine. Pay
● Remove V-belts and V-rib belts and store attention to cleanliness.
– Fill the tank completely with new AdBlue®.
packed. ● Fill the fuel tank and fuel system with the proper
– Renew the filter insert of the supply pump.
● Spray V-belt pulleys and tension rollers with cor- fuel.
● Warm up the engine to operating temperature
rosion protection agent.
and load so that pressure builds up and AdBlue® Lubricating oil system
is injected. Engine openings
● Unscrew the lube oil drain screw, drain oil.
If a fault is detected: ● All engine openings must be fitted with air-tight, ● Fill the engine with lubricating oil via the lubricat-
● Shut down engine. water-tight covers to delay the vapourisation ing oil filler neck.
Wait for the end of the lag time of the EDC (Elec- process of the corrosion protection agents.
● With installed air compressor, the suction and Coolant system
tronic Diesel Control).
pressure connection must be sealed by a cap. ● If the implemented corrosion protection agent is
● Repeat the process several times if necessary.
● Air should be excluded to avoid ventilation of the compatible with the intended cooling system pro-
Please contact your DEUTZ partner if the fault can- engine (chimney effect) for the suction from an tection agent, this can be filled directly into the
74 © 2013
Engine corrosion protection Transport and storage

coolant system as specified.
● If it is uncertain whether the implemented corro- 8
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.
Corrosion protection agent / cleaning agent
Please ask your DEUTZ partner for reference prod-
ucts for the corrosion protection agents/cleaning
agents to be used which meet DEUTZ requirements.
or see www.deutz.com
de \SERVICE \Betriebsstoffe und Addi-
tive\Motorkonservierung
en \SERVICE\Operating Liquids and Addi-
tives\Engine Corrosion Protection
© 2013 75
Technical data Engine and setting data
9 General technical data
Engine type Dimension TCD 7.8 L6

Working principle Four-stroke diesel engine
Charging Turbocharger with charge air cooling
Type of cooling water-cooled
Cylinder arrangement in series
No. of cylinders 6
Bore/stroke [mm] 110/136
Total displacement [cm3] 7755
Combustion process Direct injection
Injection system Deutz Common Rail (DCR)
Exhaust gas recirculation without
or
external
Exhaust gas aftertreatment Selective Catalytic Reduction SCR
or
Diesel particle filter DPF
Valves per cylinder 4
Valve clearance: Inlet/outlet
Setting with rotary angle disc [°] 75°±10° / 105°±10°
Firing order of the engine 1-5-3-6-2-4
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [min-1] see engine rating plate
Coolant volume (only engine content without cooler / hoses and pipes)
Industrial engines/Agricultural technology ≈ [l] 14,8/10,8
Permissible continuous coolant temperature [°C] max. 105
Temperature difference between coolant inlet/outlet [°C] 4-8
76 © 2013
Engine and setting data Technical data

Engine type
Start of thermostat opening
Dimension
[°C]
TCD 7.8 L6
86
9
Thermostat fully open [°C] 102
Lubricating oil change volume (with filter) ≈ [l] 23
Lube oil temperature in the lube oil tray, maximum [°C] 125
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 80/0,8
Permissible maximum combustion air temperature after charge air cooler [°C] 50
V-rib belt tensioning Automatic tensioning spring-loaded clamping roller
Weight without cooling system according to DIN 70020-A ≈ [kg] 725
*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.
© 2013 77
Technical data Tools
9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Please contact your DEUTZ partner
Torx tool Special wrench for loosening exchangeable filters

Order number: Order number:
0189 9092 0189 9142
The Torx screw system is used in engines in this se- For loosening changeable filters.
ries among other things. This system was introduced
for a number of reasons:
● Excellent accessibility
● High force transmission when loosening and
tightening
● Slipping or breaking of the key and risk of injury
are practically excluded.
78 © 2013
Tools Technical data

9
Rotaqtion angle disc Pin wrench insert Turning gear

Order number: Order number: Order number:
0189 9093 0189 9096 0299 2033
For setting the valve clearance For setting the valve clearance For turning over the engine as an attachment for the
torsional vibration damper
© 2013 79
Technical data Tools
Refractometer
Order number:
0293 7499
The following operating media can be evaluated with
this test device:
● Coolant
● Battery acid
● AdBlue®
80 © 2013
DEUTZ Operating Fluids
SCR/DPF SCR
DEUTZ Oil Rodon 10W40 DEUTZ Oel TLX-10W40FE DEUTZ Cooling System
low SAPS (DQC III-10 LA) (DQC III-10) Conditioner
5L - 5L 0101 6335 5L 0101 1490
20 L 0101 7976 20 L 0101 6336 20 L 0101 6416
209 L 0101 7977 209 L 0101 6337 210 L 1221 1500
DEUTZ Oel DQC4-5W30-UHP

(DQC IV-10)
5L -
20 L 0101 7849
209 L 0101 7850
DEUTZ AG
Information Systems Sales & Service
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
© 03/2013
All rights reserved
Order number:
0312 4572 en
The engine company. Original operating instructions

Operation Manual 7.8 - 03124572

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OBJ_DOKU-35791-001.fm Seite 1 Donnerstag, 28.

März 2013 11:03 11

This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

Model Engine description

7.8 the respective markets. DEUTZ AG MADE IN GERMANY

7.8 Displacement in litres

The engines of this operating manual may

Engine description Model

Location of the rating plate Engine serial number

Model Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Lubricating oil diagram

2 Lubricating oil system

Fuel diagram Engine description

Engine description Coolant diagram

2 Coolant schematic (example)

Exhaust gas recirculation Engine description

Engine description Exhaust gas aftertreatment

2 Selective Catalytic Reduction (SCR)

Exhaust gas aftertreatment Engine description

Engine description Electrics/Electronics

Electrics/Electronics Engine description

Operation Ambient conditions

3 Cold start aid

This engine is equipped with an electric

Initial commissioning Operation

Operation Initial commissioning

Initial commissioning Operation

Operation Starting process

Starting process Operation

Operation Operation monitoring

3 Electronic engine control

Operation monitoring Operation

Coolant temperature Coolant temperature too high Switch off engine

Horn With acoustic signal See fault table (65).

Operation Operation monitoring

DPF function lamp Continuous light See active regeneration 36

Engine warning lamp Continuous light See active regeneration 36

Operation monitoring Operation

DEUTZ Electronic Display

Operation Exhaust gas aftertreatment system

3 Selective Catalytic Reduction (SCR) An acoustic signal must sound in case of a

Exhaust gas aftertreatment system Operation

Operation Exhaust gas aftertreatment system

Exhaust gas aftertreatment system Operation

Operation Active regeneration

Active regeneration Operation

Instruments/symbols Power reduction Regeneration

Regeneration lamp Engine warning lamp Ash lamp

Operation Stopping process

P 0 The control unit remains active for about

Avoid switching off from full load (coking/

Lubricating oil Operating media

Operating media Lubricating oil

4 DEUTZ lubricating oils DQC III

Fuel Operating media

Operating media Coolant

4 General ● pH value too low:

Horn With acoustic signal See fault table (65).

DPF function lamp Continuous light See active regeneration 36

Engine warning lamp Continuous light See active regeneration 36

V-rib belt and tensioning pulley 60