TCG 2020 TCG 2020: Operating Instructions

Operating Instructions
TCG 2020
TCG 2020
TCG 2020
0299 8868 en
Engine Number:
Please enter your engine number here. This will help us to serve
you better in questions of repairs, spare parts and after-sales ser-
vice generally.
We reserve the right to make technical alterations to the drawings

and particulars in this documentation package, if this should
become necessary to improve the engines. Reprints and duplica-
tion of any kind, either in whole or in part, require our written per-
mission.
TCG 2020
This documentation is intended for the following engine
● Engine type:
● Application:
● System name:
● Rating: kW
● Speed: min-1
● Commissioning on:
Please enter the relevant data. This will make it easier for us to help you in questions involving
repairs, spare parts and after-sales service in general.
This documentation package is to be presented to the Service Partner responsible every time a ser-
vice job is carried out.
Imprint:
DEUTZ AG
Service Information Systems
Deutz-Mülheimer-Straße 147–149
D-51063 Cologne
Tel.: (02 21) 8 22-0
Fax: (02 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reseved
(1) 0903 ©
Ordering No 0299 8868 en
Chapter 0- Page 4 300201012-en-00.fm © 0903

Introduction
Medium-sized and large engines 0
0 Introduction
● Please read all the information contained in this manual, and follow the Please read all ...
instructions carefully. You will avoid accidents, retain the manufacturer’s
warranty, and will be able to use a fully functional and operational engine.
● This engine has been built solely for the purpose appropriate to the scope
of delivery concerned, as defined by the equipment manufacturer
(intended use). Any other use shall be construed as not intended. The
manufacturer shall not be liable for any damage resulting therefrom; all
risks involved shall be borne solely by the user.
● The term “intended use” shall also include compliance with the operating,
maintenance and repair conditions specified by the manufacturer. The
engine may be used, maintained and repaired only by persons who are
familiar with the work concerned and who have been properly informed of
the risks involved.
● Make sure that these operating instructions are available to everyone
involved in operating, maintaining, and repairing the engine, and that they
have all understood the contents.
● Non-compliance with these operating instructions may result in engine
malfunctions and even damage or injury to persons; the manufacturer will
accept no liability in such cases.
● Proper maintenance and repair work depends on the availability of all req-
uisite equipment, tools and special implements, all of which must be in
perfect condition.
● Engine parts like springs, brackets, elastic holding rings, etc., involve
increased risk of injury if not handled properly.
● The relevant accident prevention regulations and other generally recog-
nized rules relating to safety engineering and health and safety at work
must all be complied with.
● Maximized cost-efficiency, reliability and long lifetime are assured only if
original parts from DEUTZ AG are used.
● Engine repairs must correspond to the intended use. In the event of modi-
fication work, only parts approved by the manufacturer for the purpose
concerned may be used. Unauthorized changes to the engine will pre-
clude any liability of the manufacturer for resultant damage.
© 0303 300200002-en-00.fm Chapter 0 - Page 5

Introduction
Medium-sized and large engines
Careful when the en- Carry out maintenance or repair jobs only when the engine is at a standstill. If
gine is running! you remove any protective features, fit them back in position after completing
your work. Always wear tight-fitting clothing if you are working on the engine
while it is running.
Safety
You will find this symbol next to all safety instructions. Follow these
meticulously. Pass on all safety instructions to your operating staff
as well. In addition, comply with the statutory general safety and
accident prevention regulations applying in your country.
Instruction
You will find this symbol next to instructions of a general nature.
Follow these instructions carefully.
Asbestos
The seals and gaskets used in this engine are asbestos-free. Please
use the appropriate spare parts for maintenance and repair jobs.
Chapter 0 - Page 6 300200002-en-00.fm © 0303

Introduction
Dear customer, Forword
The engines of the DEUTZ brand have been developed for a broad spectrum
of applications. A comprehensive range of different variants ensures that spe-
cial requirements can be met for the individual case involved.
Your engine has been equipped to suit your own particular installation, and
accordingly not all of the devices and components described in these operat-
ing instructions will actually be fitted to your engine.
We have endeavoured to present the differences involved as clearly as possi-
ble, to make it easier for you to find the operating and maintenance instruc-
tions you need for your own particular engine.
Please read this manual before you start up your engine, and follow the oper-
ating and maintenance instructions meticulously.
If you have any questions, just get in touch with us, and we will be pleased to
answer them for you.
Yours sincerely,
DEUTZ AG
are the culmination of long years filled with research and development work. DEUTZ engines
The in-depth know-how thus acquired, in conjunction with high standards of
quality, is your guarantee for engines manufactured for long lifetime, high reli-
ability and low fuel consumption. And of course, stringent criteria of environ-
ment-friendliness are met as well.
are crucial factors in ensuring that your engine satisfactorily meets the Care and maintenance
requirements involved. Compliance with the specified maintenance intervals
and meticulous performance of care and maintenance work are therefore
absolutely essential. Special attention must be paid to any more critical oper-
ating conditions deviating from the norm.
In the event of malfunctions, or if you need spare parts, please contact one of DEUTZ Service
our responsible service agencies. Our trained and qualified staff will ensure
fast, professional rectification of any damage, using original parts.
Original parts from DEUTZ AG have always been manufactured to the very
latest state-of-the-art.
You will find details of our after-sales service at the end of these operating
instructions.

Introduction
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Contents
TCG 2020
Contents
0 Introduction
Please read all ... .................................................................................................. 0-5
Careful when the engine is running! ..................................................................... 0-6
Forword................................................................................................................. 0-7
DEUTZ engines .................................................................................................... 0-7
Care and maintenance ...................................................................................... 0-7
DEUTZ Service.................................................................................................. 0-7
1 User Guide
General ................................................................................................................. 1-1
Regulations ........................................................................................................... 1-1
Safety Regulations / Rules for Accident Prevention .......................................... 1-1
Rules for disposal .............................................................................................. 1-2
Operating Instructions and Workshop Manual...................................................... 1-2
Job cards .............................................................................................................. 1-4
Spares .................................................................................................................. 1-6
2 Description
Type and designations.......................................................................................... 2-1
Type designation ............................................................................................... 2-1
Rating plate........................................................................................................ 2-2
Position on the engine .................................................................................... 2-2
Figure rating plate........................................................................................... 2-3
Designation of the engine sides, cylinder and direction of rotation.................... 2-4
Engine and aggregate figures............................................................................... 2-5
Aggregate (illustrated TCG 2020 V20) .............................................................. 2-5
Engine cross section.......................................................................................... 2-6
Engine (illustrated TCG 2020 V20 left-hand side) ............................................. 2-8
Engine (illustrated TCG 2020 V20 right-hand side) ........................................... 2-9
Engine (illustrated TCG 2020 V20 free side) ................................................... 2-10
Engine (illustrated TCG 2020 V20 top side) .................................................... 2-11
Structure and function......................................................................................... 2-12
Cylinder head................................................................................................... 2-12
Driving gear ..................................................................................................... 2-13
Crankcase........................................................................................................ 2-13
Engine control and wheel drive........................................................................ 2-14
Speed regulation.............................................................................................. 2-15
Functional principle....................................................................................... 2-15
Actuator ........................................................................................................ 2-15
Regulating linkage ........................................................................................ 2-18
Installation location ....................................................................................... 2-19
Charging .......................................................................................................... 2-20
Charging schematic ...................................................................................... 2-20
Turbocharger ................................................................................................ 2-21
Compressor bypass...................................................................................... 2-22
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Contents
TCG 2020
Gas system...................................................................................................... 2-24

Gas regulator line ......................................................................................... 2-24
Gas/air carburettor, mixture formation .......................................................... 2-28
Lube oil system ................................................................................................ 2-30
Lube oil level switch...................................................................................... 2-31
Crankcase bleed valve ................................................................................. 2-33
Cooling system ................................................................................................ 2-35
Compressed air system ................................................................................... 2-37
Compressed air starter ................................................................................. 2-37
Air regulator line............................................................................................ 2-38
Electrical system .............................................................................................. 2-39
Ignition .......................................................................................................... 2-39
Spark plug..................................................................................................... 2-40
Terminal assignment plans TEM Evolution .................................................. 2-41
Electrical starter ............................................................................................ 2-45
Electrical components................................................................................... 2-47
3 Operation
Work prior to first commissioningand after every inspection................................. 3-1
General .............................................................................................................. 3-1
Filling up coolant................................................................................................ 3-1
Filling up lube oil ................................................................................................ 3-1
Pre-lubrication.................................................................................................... 3-1
Gas supply......................................................................................................... 3-2
Note for all heat transformers ............................................................................ 3-2
Exhaust gas side ............................................................................................... 3-2
Note for oxidation catalyst ................................................................................. 3-2
Commissioning / Starting ...................................................................................... 3-3
Starting .............................................................................................................. 3-3
Warming up ....................................................................................................... 3-3
Room ventilation ................................................................................................ 3-3
Lube oil system .................................................................................................. 3-3
Monitoring operation ............................................................................................. 3-4
System monitoring ............................................................................................. 3-4
Engine Peripheral Systems ............................................................................... 3-4
Coolant circuit .................................................................................................... 3-4
Batteries............................................................................................................. 3-4
4 Expendables
General ................................................................................................................. 4-1
Guarantee.......................................................................................................... 4-1
Product selection ............................................................................................... 4-1
Mixability ............................................................................................................ 4-1
Combustion gases ................................................................................................ 4-1
Lube oil ................................................................................................................. 4-1
Engine coolant ...................................................................................................... 4-1
Contents - Page 2 300201011-en-00IVZ.fm © 0903

Contents
TCG 2020
Auxiliary materials................................................................................................. 4-3

Sealants and securing agents ........................................................................... 4-3
Gluing agents..................................................................................................... 4-5
Lubricants .......................................................................................................... 4-5
Other auxiliary materials .................................................................................... 4-6
5 Maintenance
Continuous supervision ........................................................................................ 5-1
Maintenance schedule .......................................................................................... 5-1
General .............................................................................................................. 5-1
Maintenance and service schedules.................................................................. 5-2
Gas groups ........................................................................................................ 5-3
Silicon content ................................................................................................... 5-3
Specific scheduled maintenance plan .................................................................. 5-4
Scheduled maintenance plan 1 ......................................................................... 5-5
Operating hours-independent maintenance work........................................... 5-5
Definition of activities in the maintenance schedule ....................................... 5-6
Operating hours-dependent maintenance work.............................................. 5-6
Operating hours-dependent maintenance work outside the maintenance and
service schedules ........................................................................................... 5-8
Table for operating hours-independent maintenance work ............................ 5-9
Table for operating hours-dependent maintenance work ............................. 5-10
Scheduled maintenance plan 2 ....................................................................... 5-11
Operating hours-independent maintenance work......................................... 5-11
Definition of activities in the maintenance schedule ..................................... 5-12
Operating hours-dependent maintenance work............................................ 5-12
Operating hours-dependent maintenance work outside the maintenance and
service schedules ......................................................................................... 5-14
Table for operating hours-independent maintenance work .......................... 5-15
Table for operating hours-dependent maintenance work ............................. 5-16
Tools ................................................................................................................... 5-17
Tools kits.......................................................................................................... 5-17
Operating check log ............................................................................................ 5-22
6 Troubleshooting
Fault table with remedy instructions ..................................................................... 6-1
7 Conservation
Conservation......................................................................................................... 7-1
8 Technical particulars
General engine data ............................................................................................. 8-1
Basic data .......................................................................................................... 8-1
Control data ....................................................................................................... 8-1
Dimensions ........................................................................................................ 8-2
Weights.............................................................................................................. 8-2
© 0903 300201011-en-00IVZ.fm Contents - Page 3

Contents
TCG 2020
Operating data ...................................................................................................... 8-3

Filling levels ....................................................................................................... 8-3
Temperatures .................................................................................................... 8-3
Pressures........................................................................................................... 8-3
Emission data .................................................................................................... 8-3
Engine peripheral data.......................................................................................... 8-4
Start system....................................................................................................... 8-4
Speed controller................................................................................................. 8-4
RI flow diagrams ................................................................................................ 8-5
CHP system (example)................................................................................... 8-5
System without heat utilisation (example) ...................................................... 8-6
Lube oil supply................................................................................................ 8-7
Legend............................................................................................................ 8-8
Tightening specifications....................................................................................... 8-9
Scheduled maintenance work up to E40 ........................................................... 8-9
9 Job Cards
Explanation of symbols ......................................................................................... 9-1
Overviews ............................................................................................................. 9-2
Arranged alphabetically ..................................................................................... 9-2
Arranged by Job Card Numbers ....................................................................... 9-3
10 Sundry other instructions
Index
Service
We move your world ................................................................................... Service-1
DEUTZ AG - at your service. ................................................................... Service-1
Sales & Service Index.............................................................................. Service-1
DEPIC...................................................................................................... Service-1
Seminar program .................................................................................... Service-1
Please note:
The operating manual for the DEUTZ TEM system is available as a sepa-
rate documentation and must be ordered separately.
Contents - Page 4 300201011-en-00IVZ.fm © 0903

User Guide
Engines and systems 1
1 User Guide
The maintenance and service work prescribed in the operating instructions General
and the workshop manual must be performed on schedule and in full.
The maintenance and service personnel must have the necessary technical
knowledge to perform the work. Safety and protection devices which may
have to be removed during maintenance and service work must be replaced
afterwards.
The rules for the prevention of accidents and the safety regulations
must be observed at all times during maintenance and service work.
Please also observe the special safety regulations for the various ser-
vice groups which are listed in detail as job cards in the job cards chap-
ter (cf. also chapter 1 Safety Regulations / Rules for Accident
Prevention).
The maintenance and service intervals are listed in the maintenance and
service schedules. These also provide information about the work to be per-
formed.
The job cards provide technical hints for performing the work.
Regulations
Detailed safety instructions have been compiled for various service Safety Regulations /
groups in the form of job cards, these precede the job cards of the Rules for Accident Pre-
respective service groups. vention
The legally prescribed rules for accident prevention (available from the
appropriate associations or technical publishers) must be observed.
These depend on the installation site, the mode of operation and the
operating and auxiliary media being used.
Special safety measures dependent on the respective work are speci-
fied and highlighted in the work description.
It generally applies among other things:
● for personnel:
- Only instructed personnel may operate or maintain the engine.
Unauthorised persons may not enter the engine room.
- Wear tight fitting clothing and ear protectors in the engine room
when engines are running.
- Only employ qualified personnel for repairs or service work.
● for the engine room:
- Ensure adequate fresh air and ventilation (do not cover ventila-
tion shafts).
- Provide first aid kits and suitable fire extinguishers. Check the fil-
ling and proper functioning regularly.
- Only store inflammable materials in the engine room which are
necessary for operating the system.
- Smoking and naked lights are prohibited in the engine room.

User Guide
Engines and systems
● for operation and maintenance of the engine:

- Only start the engine when all safety devices have been fitted and
the turning gear has been removed. Make sure there is no-one in
the danger zone.
- Only perform cleaning, maintenance and repair work when the
engine is switched off and secured against starting up.
Rules for disposal The work described in the operating instructions and workshop manual
necessitates the renewal of parts and expendables among other things.
These renewed parts / expendables must be properly stored, transported and
disposed of. The owner is responsible for this.
Disposal includes recycling and disposal of parts / expendables whereby
recycling has priority.
The details of disposal and its supervision are governed by regional, national
and international laws and decrees which the plant owner is responsible for
observing.
Operating Instruc- The service documentation is divided into the operating instructions and the
tions and Workshop workshop manual for a user-oriented organisation of the information content.
Manual The Operating Instructions contain a general description as well as instruc-
tions for the necessary maintenance and service work which can be per-
formed by a trained operator.
It contains the following chapters:
0 Introduction
Contents
1 User guide
2 Description (description of the engine and components)
3 Operation (operating the engine)
Expendables (operating media specifications and auxiliary materi-
4
als)
5 Maintenance
6 Troubleshooting
7 Conservation (conservation of the engine)
9 Job cards (in order of job card numbers)
10 Sundry other instructions (if not in the appendix or separate folders)
Index
Service

User Guide
The Workshop Manual assumes knowledge of the content of the operating

instructions, this applies especially to the safety regulations. Minor repairs
and emergency measures on components are described which require a
greater effort and appropriately qualified personnel.
It contains the chapters:
0 Introduction
Contents
1 User guide
2-4 See operating instructions
5 Tools for service
6-7 See operating instructions
9 Job cards (in order of job card numbers)
10 Sundry other instructions (if not in the appendix or separate folders)
Service

User Guide
Engines and systems
Job cards
The Job cards are divided into Job cards of the operating instructions, e.g. B 1-1-1 and job cards of the
workshop manual, e.g. W 4-5-1.
● Please see Figure 1-1 for explanations of the numbering.
● The structure of the job card is shown in Figure 1-2.
Type of documentation
• The letter at the front signifies the type of documentation involved.
B = Operating Instructions
W = Workshop Manual
Maintenance Group (the same for all engines)

0 General remarks / cross-category jobs 8 Lube oil system
1 Cylinder head 9 Coolant system
2 Drive mechanism 10 Compressed air system
3 Crankcase 11 Monitoring system
4 Engine control 12 Other components
5 Governor 13 Electrical system
6 Exhaust gas system / Charging
7 Fuel system
Subsystem (component)
• The subsystems are distinguished by maintenance groups.
• Generally valid:
0 Cross-subsystem or Safety Regulations
1 System parameters or general checks
Serial Number
• Counting per subsystem (component)
• Various jobs per subsystem (component)
• Version differences
B 3-3-3 © 80301-3
Figure 1-1 Numbering of the job cards

User Guide
1 2
10
13 12 11
' 80300-5
Figure 1-2 Numbering of the job cards
When making inquiries about the job card please always state the engine
type or the system 2, the number of the job card 3, the page number 11, the
date of issue 13 or alternatively the identification number of the job card.
DEUTZ Service, publisher of the service documen-

1 8 Figures
tation
2 Engine type or system 9 General notes
3 Number of the job card 10 Work sequence
4 Title of the job card 11 Page number
5 Tools, aids, spares and references 12 Identification number of the job card
6 Safety instructions 13 Date of issue of the job card
7 Sub-headings

User Guide
Engines and systems
Spares Spares are available from DEUTZ Service. You will find a list of spares in the
spare parts list of the engine or the system. You will find further information in
Chapter Service, at the end of the operating instructions.

Description
TCG 2020 2
2 Description
The engines of the TCG 2020 series are water-cooled four-stroke, high- Type and designa-
performance Otto gas engines which can be used in a wide range of drive tions
applications with easy usability of the coolent and exhaust heat in force-heat
coupling processes. A special low exhaust emission combustion process has
been developed for environmental protection.
Type designation
See also rating plate

T C G 2020 V _
(Figure 2-3, item 1)
Turbocharger T
Mixture charge cooling C
Gas engine G
Series 2020
V-engine V
No. of cylinders 12, 16 or 20

Description
TCG 2020
Rating plate
Position on the engine The rating plate 1 is fixed to the engine.
Figure 2-1 Position of the rating plate on the engine
The engine number 2 is punched additionally.
Figure 2-2 Position of the engine number on the engine

Description
TCG 2020 2
Figure rating plate
Figure 2-3 Figure rating plate
1 Engine type designation

2 Year
3 Engine number
4, 5, 6 Performance abbreviation according to DIN ISO 3046 Part 7
and abbreviation for the gas type1).
A * or ** in front of the performance abbreviation refers to the
corresponding NOx emission, see 13, 14.
7, 8, 9 Numeric value of the performance in kW
10, 11, 12 Engine speed in rpm
13, 14 NOx emission in mg
15 Height above sea level (conditions at installation site)
16 Air pressure px in mbar (conditions at installation site)
17 Charge air coolant temperature tcx in °C (conditions at installa-
tion site)
18 Relative humidity Φx in % (conditions at installation site)
19 Mixture coolant temperature tcx in °C (conditions at installation
site)
20 Numeric value of performance of the oil pump in kW (F)
1)
Abbreviation for gas type
n natural gas
s sewage gas
l methane gas
m pit gas
p propane gas

Description
TCG 2020
Designation of the engine sides, cylinder and direction of rotation

The four sides of the engine normally carry the following designations in practice (see Figure 2-4):
The designation used in this operating manual is highlighted respectively in bold print and corresponds with
DIN ISO 1204.
A1 A2 A3 A4
1 3
B1 B2 B3 B4
4
Figure 2-4 Designation of the engine sides and cylinders
Engine sides:
1 Drive side Flywheel, clutch side

2 Left side Cylinder side A
3 Free side End, damper, fluid pump, clutch opposite side
4 Right side Cylinder side B
Direction of rotation:
Looking towards the drive side: In anticlockwise direction ”left-hand rotation”

Description
TCG 2020 2
Engine and aggregate figures
Aggregate (illustrated TCG 2020 V20)
Figure 2-5 Aggregate

Description
TCG 2020
Engine cross section
Figure 2-6 Engine cross section
1 Touch protection ATL

2 Multifunction rail
3 Coolant pipe mixture cooler
Description
TCG 2020 2
4 Coolant pipe overflow

5 Touch protection exhaust pipe
6 Coolant pipe mixture cooler
7 Rocker arm block
8 Valve
9 Base, rigid fixing
10 Stop rod
11 Roller tappet
12 Camshaft
13 Cylinder liner
14 Piston cooling oil nozzle
15 Counterweight crankshaft
16 Flywheel
17 Main bearing cover
18 Lube oil pump
19 Lube oil suction air intake pipe
20 Oil pan
21 Safety valve (lube oil)
22 Motor claw
23 Oil cooler
24 Safety valve (lube oil)
25 Crankshaft
26 Connecting rod
27 Receiver pipe
28 Piston
29 Cylinder head
30 Mixture pipe
31 Exhaust pipe
32 Mixture cooler cap
33 Ignition cable
34 Ignition coil
35 Turbocharger (TC)
36 Exhaust manifold after TC

Description
TCG 2020
Engine (illustrated TCG 2020 V20 left-hand side)
Figure 2-7 Left-hand side
A4 Turbocharger (TC)
F5 Speed controller (cylinder row A)
H249 Coolant inlet (high temperature circuit)
H250 Coolant outlet (high temperature circuit)
H415 Gas/air carburettor
H701 Exhaust pipe after TC
L2 Mix cooler
L5 Air filter
S38 Crankcase bleed valve
U55 Coolant compensator
V16 Starter
V38 Engine mount

Description
TCG 2020 2
Engine (illustrated TCG 2020 V20 right-hand side)
Figure 2-8 Right-hand side
A6 Exhaust gas compensator

F5 Speed controller (cylinder row B)
S7 Lube oil cooler
S33 Lube oil filter
S72 Electrical pre-lube pump
V18 Alternator
V23 Base frame
V24 Elastic suspension

Description
TCG 2020
Engine (illustrated TCG 2020 V20 free side)
Figure 2-9 Free side
H223 Coolant inlet (low temperature circuit)

H224 Coolant outlet (low temperature circuit)
H249 Coolant inlet (high temperature circuit)
H250 Coolant outlet (high temperature circuit)
H613 Pressure line from pre-lube pump
S57 Lube oil level switch
S72 Electrical pre-lube pump
S78 Lube oil tapping valve
V13 Vibration damper

Description
TCG 2020 2
Engine (illustrated TCG 2020 V20 top side)
Figure 2-10 Top side
A4 Turbocharger (TC)
G40 Ignition system
H415 Gas/air carburettor
H701 Exhaust pipe after TC

Description
TCG 2020
Structure and function
Cylinder head
The cylinders are fitted with a single cylinder head each. The multiple valve cylinder heads are equipped with
two inlet and two outlet valves each which are controlled by a camshaft, tappet, tappet rod and valve
bridges.
Figure 2-11 Cylinder head
1 Toggle lever (inlet)

2 Toggle lever (outlet)
3 Stop rod
4 Valve bridge
5 Spark plug chamber
6 Valve
7 Valve spring
8 Valve head

Description
TCG 2020 2
The machined crankshaft with bolted on counterweights is suspended in the Driving gear
crankcase. The bearing covers are held vertically by two studs and are fas-
tened horizontally by two additional screws for cross bracing. The engine has
forged light metal pistons which are cooled by lube-oil injection nozzles and
double T-shank con-rods. The lube oil supply to the main bearing and con-rod
bearing is provided by a lube oil pump which sucks the lube oil from the oil
pan.
The crank case is sphero-cast with suspended crankshaft bearings and wet Crankcase
cylinder liners. Lateral drive gear assembly openings enable fast access to
the crank gear.

Description
TCG 2020
Engine control and wheel drive
Figure 2-12 Wheel drive
1 Toothed wheel crankshaft (59 teeth)

2 Intermediate wheel (59 teeth)
3 Intermediate wheel (33 teeth)
4 Camshaft toothed wheel, B-side (66 teeth)
5 Camshaft toothed wheel, A-side (66 teeth)
6 Intermediate wheel to the lube oil pump (52 teeth)
7 Toothed wheel lube oil pump drive (40 teeth)

Description
TCG 2020 2
Speed regulation
The speed control has the job controlling the speed and thus the performance Functional principle
of the engine by adjusting the throttle valve or rotary disk valve position. The
speed is controlled electronically by the DEUTZ TEM system.
In the electronic speed control the actual speed is measured with a magnetic
pulse sensor (pickup), transferred to the DEUTZ TEM system and compared
with the set nominal speed. In the case of deviations the throttle valve or
rotary disk valve position is adjusted by the actuator controlled by the DEUTZ
TEM system.
In the engines TCG 2020 V12 and V16 the actuator is connected to the throt-
tle valve by a regulating lever and a connecting rod.
The TCG 2020 V20 is equipped with two actuators the output shafts of which
act directly on the rotary disk valves.
The engines TCG 2020 V12 and V16 are equipped with the actuator StG 30 Actuator
(see Figure 2-13), on the TCG 2020 V20 two actuators StG 2080 are
mounted (see Figure 2-14).
The actuators are distinguished by:
- high adjustment forces acting in both directions
- low power consumption
- Insensitivity at slow voltage change in the power supply, sudden
changes lead to controller faults

Description
TCG 2020
TCG 2020 V12 and V16 with StG 30

A d.c. motor transfers the torque to the controller output shaft via intermediate
gearing.
The setting of the controller output shaft is scanned by the return probe with-
out contact and passed on to the DEUTZ TEM system.
On reaching the stop, current limitation is implemented after approx.
20 seconds, which reduces the actuator current to such an extent that no
damage is suffered by the actuator.
Figure 2-13 Actuator, Heinzmann StG 30
1 d.c. motor
2 Gearbox
3 Output shaft
4 Probe
5 Return cams

Description
TCG 2020 2
TCG 2020 V20 with StG 2080

On the shaft of the actuator is a multi-pole permanent magnet. Opposite the
permanent magnet is a coil body on which is mounted a working coil. If the
working coil conducts, torque occurs in one direction, the reversal of the cur-
rent provides torque in the opposite direction.
A return spring is attached to the controller output shaft the force of which is
normally sufficient to pull the actuator to the stop position in the event of a
power failure.
The setting of the controller output shaft is scanned by the return probe with-
out contact and passed on to the DEUTZ TEM system.
On reaching the stop, current limitation is implemented after approx.
20 seconds, which reduces the actuator current to such an extent that no
damage is suffered by the actuator.
Figure 2-14 Actuator, Heinzmann StG 2080
1 Working coil
2 Output shaft
3 Permanent magnet
4 Probe
5 Return cams
6 Return spring

Description
TCG 2020
Regulating linkage
The regulating linkage consists of the regulating lever and the connecting linkage and connects the actuator
to the throttle valve.
The length of the connecting linkage is set so that the throttle valve is fully open in full load setting of the con-
troller.
The linkage must be free of clearance and have an easy action.
If there is friction or mechanical play between the actuator and the throttle valve, optimum control is not pos-
sible.
Figure 2-15 Regulating linkage
1 Actuator
2 Control lever
3 Position 0 %
4 Adjusting angle
5 Full load setting
6 Position 100 %
7 Connecting linkage

Description
TCG 2020 2
Installation location
Figure 2-16 Actuator on the engine
1 Actuator on the engine (TCG 2020 V12 and V16 with StG 30)
Figure 2-17 Actuator on the engine (represented: left-hand side)
2 Actuator on the engine (TCG 2020 V20 with StG 2080)

Description
TCG 2020
Charging
The turbocharger sucks in air and gas through a Venturi gas mixer under atmospheric conditions (mixture
charging). The compressed gas-air mixture is cooled down in a mixture cooler. The engine achieves a higher
performance with simultaneous reduction of the pollutant emissions due to the mixture charging.
Charging schematic
1 2 3 4 5 6 7
15
14
13
9 10 11 12
' 80977-3
Figure 2-18 Charging schematic
1 Suction intake air 9 Mix cooler

2 Air filter 10 Cooled mixture
3 Filtered air 11 Inlet valve
4 Gas/air carburettor 12 Outlet valve
5 Gas 13 To the exhaust gas turbine
6 Mixture to the compressor 14 Exhaust gas turbine
7 Compressor 15 To the silencer
8 From the compressor

Description
TCG 2020 2
Turbocharger
1 2 3 4
15
5
14
6
13
12 11 10 9 8 © 83756-1
Figure 2-19 Turbocharger, section
1 Mixture outlet 9 Turbine housing

2 Bearing casing 10 Lube oil inlet
3 Shaft 11 Lube oil outlet
4 Exhaust gas outlet 12 Radial sliding bearing
5 Exhaust manifold 13 Mixture inlet
6 Turbine wheel 14 Compressor wheel
7 Radial sliding bearing 15 Compressor housing
8 Exhaust inlet

Description
TCG 2020
Compressor bypass When adapting the turbocharger, the combustion behaviour of the gas
(energy content, combustion speed etc.) must be taken into account. Meth-
ane or sewage gas may vary greatly in composition. This results in great
changes in the combustion behaviour. At decreasing heat value and high
inert gas content the combustion speed is reduced which leads to a higher
exhaust gas temperature. This in turn leads to a higher charging pressure at
the same performance and the compressor of the turbocharger starts ”pump-
ing”.
An adjustable compressor bypass on the turbocharger avoids another turbo-
charger specification being necessary depending on the gas composition.
Optimum adaptation to the existing gas quality is possible at any time without
conversions.
For two-gas operation, i.e. alternative operation with natural gas or methane/
sewage gas, the compressor bypass with solenoid valve is provided.
The turbocharger is optimised for natural gas operation (solenoid valve
closed). For operation with methane/sewage gas the bypass is released by
opening the solenoid valve. In addition there is a setting option for adapting to
the methane gas quality.
The bypass is set in commissioning and when required (e.g. very great varia-
tion in the gas quality at dumps) by DEUTZ service personnel.
Figure 2-20 Compressor bypass (sewage/methane gas)
1 Bypass pipe
2 Setting screw
3 Mixture pipe before turbocharger
4 Mixture pipe after turbocharger

Description
TCG 2020 2
Figure 2-21 Compressor bypass (two-gas operation)
1 Bypass pipe
2 Setting screw
3 Mixture pipe before turbocharger
4 Mixture pipe after turbocharger
5 Solenoid valve
closed: natural gas
open: sewage/methane gas

Description
TCG 2020
Gas system
Gas regulator line
Structure and function (⇒ DIN EN 676; DIN 33831, part 2)
The control and safety systems incorporated in the gas regulator line ensure that the gas engine can be
operated safely and reliably. The gas pressure regulator adapts the mains side gas pressure to the require-
ments of the gas engine.
Incorrect assembly, adjustment, modification, operation or mai-

ntenance can result in injury to persons and/or damage to equip-
ment.
Fitting, wiring, adjustments and servicing by authorized specia-
list personnel only.
Read all instructions before assembly and use.
The equipment must be installed in accordance with valid regula-
tions.
Local regulations of electric and gas supply companies must be
observed.
Figure gas regulator line
1 2 3 4 5 6 7 8 9 10 11
Figure 2-22 Gas regulator line (example)

Description
TCG 2020 2
Components - all DVGW tested!
1 Flange
2 Shutoff device (ballcock)
hand-operated shutoff of the gas supply for repair work within the gas regulator line and with the
aggregate shut down. When the whole gas regulator line is disconnected the closed ballcock stays on
the gas mains.
3 Pressure gauge with pushbutton tap
to check the gas pressure at the regulator line input
4 Gas filter (see Figure 2-23)
5 Gas pressure sensor (electric pulse generator)
Automatic monitoring of the minimum permissible gas pressure before the gas pressure regulating
device and automatic monitoring of the soiling of the gas filter cartridge (measuring connection is
behind the filter fabric).
6 Solenoid valves (see Figure 2-24)
with measuring connection in the input and output on both sides
7 Flame flashover protection (see Figure 2-25)
for methane, pit and sewage gas
8 Reducer
9 Gas pressure regulator (see Figure 2-26 )
The pressure regulator reduces the gas pressure at the input of the gas regulator line to the gas pres-
sure required in the engine.
10 Outlet pipe
11 Flange
Automatic shutoff process

To purge the engine when shutting off, the gas supply line is already closed before the ignition is interrupted.
This process is part of the automatic process by the DEUTZ TEM system.
Assembly and testing
For installation, G 600 (DVGW-TRGI), G 490 and G 495 apply for delivering up to the shutoff device to be
provided on site by the customer.
The components of the gas regulator line are tested by the manufacturer for strength and leaks. The fully
assembled plant must be subjected to a final leak test with air or inert gas with 1.2 times the maximum per-
missible operating pressure (set output pressure at the regulator) but at least 150 mbar.
- The pressure in the input chamber (mains side) must always be equal to or greater than the pressure
in the outlet chamber (engine side).
- Pressure build-up always before the input side, pressure release always before the output side
(change pressure slowly!).
- The gas regulator line may only be attached horizontally.
- The gas regulator line must be protected against careless damage, especially when mounted low.
- No vibrations may be transmitted from the engine to the gas pipe.
- The ballcock and pushbutton tap must be operable by hand.
(max. mounting height 2,100 mm!)
- The pressure gauges must be easy to read.

Description
TCG 2020
Gas filter, item 4
Figure 2-23 Gas filter
1 Filter mat
Solenoid valve, item 6
Figure 2-24 Solenoid valve
1 electr. connection
2 Magnetic plate
3 Solenoid
4 Magnetic core
5 Closing spring
6 Valve head
7 Valve seat
8 Valve housing

Description
TCG 2020 2
Flame flashover protection, item 7
Figure 2-25 Flame flashover protection
1 Resistance thermometer (PT 100)

2 Cage
3 Band protection (flame inhibitor)
Gas pressure regulator, item 9
Figure 2-26 Gas pressure regulator
1 Actuator housing
2 Valve head
3 Valve seat
4 Compensation diaphragm
5 Connection for measuring line with throttle valve
6 Measuring diaphragm
7 Connection for following setpoint
8 Weight
9 Setpoint spring
10 Setpoint adjuster

Description
TCG 2020
Gas/air carburettor, mixture formation

The gas and air are blended to form a combustible mixture in the carburettor immediately upstream of the
turbocharger (Figure 2-27).
The carburettor is in the form of a Venturi tube, i.e. a pipe with a converging section to channel flow which
gradually diverges again. The design means that the flow has only a minimum pressure drop and therefore
only minimum filling losses in the cylinders. The highest flow rate occurs at the most constricted section. The
gas is mixed with the core flow radially from outside at this location via an annular gap using the resulting
vacuum. This mixing mode has the advantage that the volume ratio of gas to air remains almost constant
even in the case of great fluctuations in the sucked mixture and deviates only slightly from the so-called
lambda window in which the safe and cost-effective operating range of the engine is contained.
Another gas regulating possibility, the adjustable gas gap, is provided in the gas line to set the air ratio and
for minor corrections. The mixture volume is regulated by means of the throttle valve or rotary disk valve.
Figure 2-27 Multi-gas mixer
1 Servomotor 6 Gas-air mixture

2 Coupling 7 Venturi nozzle
3 Adjustment spindle 8 Air line
4 Adjustable gas gap 9 Air from filter
5 Gas inlet

Description
TCG 2020 2
Figure 2-28 Servomotor
Figure 2-29 Proximity switch, lean mixture

Description
TCG 2020
Lube oil system

The lube oil system is controlled and monitored completely by the DEUTZ TEM system. The pre-lube pump
enables oil pressure build-up before starting the engine. A lube oil toothed wheel pump supplies the engine
with the necessary lube oil pressure which is controlled by a lube oil pressure regulating valve. The lube oil is
cleaned by the lube oil filter. A lube oil cooler which is integrated in the cooling circuit of the engine provides
a suitable lube oil temperature.
S7
S17
S8 S8
H613 A4
S18
S63
S72 S4
M S17 S17
H641
S3 H657
' 84338-0
Figure 2-30 Lube oil system (example: TCG 2020 V12 and V16)
Parts mounted on the engine: Pipe connections on the engine:

A4 Turbocharger H613 Used oil drain
S3 Oil pan H657 Fresh oil flow (pump)
S4 Engine’s own lube oil toothed H641 Fresh oil flow (high tank)
wheel pump
S7 Lube oil cooler
S8 Lube oil filter
S17 Overpressure valve, control valve
S18 Pressure regulating valve
S63 Lube oil distributor/main oil channel
S72 Pre-lube pump electric

Description
TCG 2020 2
Lube oil level switch
Figure 2-31 Switching points
1 Safety switching point

Overfilling - engine stop
2 Operating switching point
max. lube oil level, solenoid valve closes - lube oil supply interrupted
3 Operating switching point
min. lube oil level, solenoid valve opens - lube oil refilled
4 Safety switching point
Oil shortage -engine stop, the message ”Oil Min.” appears in the TEM
display
The engine can only be started after this message after a pre-lube
time of at least 20 minutes.

Description
TCG 2020
Figure 2-32 Lube oil level switch
1 Connecting line to the oil pan

2 Vent line
3 Connector
4 Oil pan

Description
TCG 2020 2
The crankcase bleed valve is equipped with an oil mist trap. The sucked in air Crankcase bleed valve
is spun and accelerated in the oil mist trap by a rotating drum so strongly that
the micro-fine oil mist particles form small droplets and are separated from
the air in the rotating filter drum by the sieving and inertia effect. The oil
gained in this way flows back into the oil pan through the drain.
Figure 2-33 Crankcase bleed valve
1 Intake line
2 Air return line to the air filter
3 Oil mist trap
4 Drain line

Description
TCG 2020
Figure 2-34 Oil mist trap, function diagram
1 Air outlet, the cleaned air is returned

2 rotating filter drum with turbo wheel
3 Induction pipe
4 Drain for trapped oil

Description
TCG 2020 2
The TCG 2020 has a two circuit cooling. The engine cooling circuit integrates: Cooling system
lube oil cooler, mixture cooler, cylinder cooler
The low temperature mixture cooler is cooled by a separate cooling circuit.
This allowed the mixture temperature to be reduced and the engine perform-
ance increased.
The coolant temperature is automatically controlled and monitored. The
engine is switched off by the DEUTZ TEM system at temperatures above the
set maximum temperature.

Description
TCG 2020
U2 M U2 M
H223 H224 H250 H249
S7
U6 U1 U1 U6
L2.1 L2.1
L2.2 L2.2
Figure 2-35 Cooling system (example: TCG 2020 V12 and V16)
Parts mounted on the engine: Pipe connections on the engine:

L2.1 Mixture cooler (HT circuit) H223 Coolant inlet
L2.2 Mixture cooler (LT circuit) Table cooler -> mixture cooler
S7 Lube oil cooler H224 Coolant outlet
U1 Cooling fluid collector pipe Mixture cooler -> table cooler
U2 Coolant pump H249 Coolant inlet
U6 Coolant distributor chamber in H250 Coolant outlet
the crankcase

Description
TCG 2020 2
Compressed air system

The engine TCG 2020 V20 is equipped with a compressed air starter or an Compressed air starter
electric starter depending on the version.
The compressed air starter generates a sufficiently high starter speed to the
ignition through the flywheel.
Triggered by the DEUTZ TEM system control air of 8 bar presses the starter
pinion into the flywheel crown gear, the operating air of 8 bar then rotates the
engine up to starting speed. When the engine has fired, the DEUTZ TEM sys-
tem tracks out the starter and blocks further starts when the machine is run-
ning.

Description
TCG 2020
Air regulator line
Figure 2-36 Compressed air starter with air regulator line
Figure 2-37 Compressed air starter with air regulator line
1 Compressed air starter

2 Pressure reducing starter valve
- Input pressure: max. 30 bar
- Back pressure: 1…10 bar
3 Solenoid valve 24V
4 Safety valve
- Pressure setting: 12 bar
5 Pressure gauge
- Scale: 0…16 bar
6 Dirt trap
7 High pressure hose (air supply)

Description
TCG 2020 2
Electrical system
Ignition
The engine is equipped with a microprocessor-controlled ignition system TEM-ZS2 or TEM-ZS3 which is
supplied by the DEUTZ TEM system with a voltage of 24 V.
A toothed gear on the flywheel is scanned by an electronic sensor and enables the exact crank angle time to
be determined. The selection of the right process phase for the ignition spark in the four-stroke technique is
made by an additional sensor on the camshaft. The electronic control device sends medium voltage pulses
to the ignition coils assigned to every cylinder. From there a high voltage cable leads to each spark plug. An
extremely fast voltage rise guarantees a powerful and short ignition spark with a gentle effect on the spark
plug electrodes.
Settings on the ignition device are made exclusively by DEUTZ service personnel, these are for example
adjustment of the ignition time to adapt to the gas quality or select two different ignition times in two-gas
operation.
For work on the ignition system such as changing parts, e.g. spark plugs, ignition cables and ignition coils,
the ignition need no longer be switched off because the DEUTZ TEM system has switched off safely when
the ignition is at standstill.
Figure 2-38 Ignition system

Description
TCG 2020
Spark plug The spark plug is designed as a pre-chamber spark plug. The ignition spark is
generated in the pre-chamber 1, the flames flash through the five holes 2 at
the end face of the pre-chamber into the combustion chamber.
The advantages of this design are the improved more even propagation of
the flame front over the whole combustion chamber as well as less electrode
wear and therefore longer life of the spark plug.
Figure 2-39 shows a section through pre-chamber 1, the normal appearance
is shown in Figure 2-40.
Figure 2-39 Pre-chamber spark plug, demonstration section
Figure 2-40 Pre-chamber spark plug

Description
TCG 2020 2
Terminal assignment plans TEM Evolution
Figure 2-41 Terminal assignment plan TEM Evolution (12 cylinders)

Description
TCG 2020

Description
TCG 2020 2
1 Direction of rotation of camshaft

Description
TCG 2020
2 Pickup index on the camshaft toothed wheel

3 Connector O
4 Connector M
5 Multi-function rail cylinder row B
6 Connector F 1x12 pin (12 cylinders)
Connector F 1x16 pin (16 cylinders)
Connector F 1x24 pin (20 cylinders)
7 Plug
8 Ignition system TEM-ZS2 / ZS3
9 Plug P1
10 Pickup on the flywheel
11 Direction of rotation of flywheel
12 Plug
13 Plug
14 Multi-function rail cylinder row A
15 Plug
16 Ground point on the crankcase
17 Ignition coils
18 TEM Evolution
19 Crown gear crankshaft
20 Camshaft
21 Earthing of the switching system
22 Spark plug

Description
TCG 2020 2
The engines TCG 2020 V12 and V16 are equipped with an electric starter, Electrical starter
the engine TCG 2020 V20 either with a compressed air starter or an electric
starter.
The starter has the job of accelerating the engine crankshaft to ignition
speed.
An electric motor drives the starter pinion to the crown gear of the flywheel via
an axially movable laminar coupling and thus drives the crankshaft. The lami-
nar coupling only transmits the full starter-torque after the starter pinion has
engaged in to avoid damaging the teeth edges. When the engine starts, the
laminar coupling is released by the steep thread and the starter pinion disen-
gaged.
Figure 2-44 Electrical starter

Description
TCG 2020
1 2 3 4 5
' 80672-1
7 6
Figure 2-45 Electrical starter (section)
1 Starter pinion
2 Drive shaft to the pinion
3 Clutch housing
4 Steep thread sleeve of the clutch
5 Single track bar
6 Steep thread
7 Coupling lamellas

Description
TCG 2020 2
Electrical components
Figure 2-46 Electrical components (example TCG 2020 V16)
1 Plug C 11 Camshaft pickup (319)

2 Coolant temperature sensor before mixture 12 Multi-function rail (cylinder row A)
cooler (202) 13 Inductive proximity switch (159)
3 Knocking sensor (241...246) 14 Sensor for aspirated air temperature 16 cylin-
4 Thermocouple (461...466) ders (159)
5 Starter (7.5.1) 15 Sensor for aspirated air temperature 12 cylin-
6 Starter relay VK1 ders (203)
7 Crankcase - overpressure (145) 16 Plug G
8 Lube oil level (234) 17 Plug N
9 Electric motor for pre-lube pump (2.5.1) The data in brackets refer to the terminal assignment
10 Lube oil pressure switch (196) plan.

Description
TCG 2020
Figure 2-47 Electrical components (example TCG 2020 V16)
1 Multi-function rail (cylinder row B) 10 Ignition system TEM-ZS2 / ZS3

2 Coolant temperature sensor engine outlet 11 Earthing rail
(206) 12 Plug F
3 Temperature sensor (201) 13 Plug E
4 Coolant temperature sensor engine inlet (207) 14 Plug H
15 Stepper motor (1.5.16)
5 Lube oil temperature sensor (208) 16 Actuator (STG 30)
6 Lube oil pressure transmitter before filter (196) 17 Ignition coil
7 Knocking sensor (251...256) The data in brackets refer to the terminal assignment
8 Thermocouple (471...476) plan.
9 Pickup on the flywheel (200)

Operation
Gas Engines 3
3 Operation
Work prior to first

commissioningand
after every inspec-
tion
The following should be carried out before commissioning, after the engine General
has been out of operation for a long period and after maintenance and repair
work:
● Check all lines and connections for leaks of the following media:
- gas
- lube oil
- coolant
- suction intake air
- exhaust gas
● Check linkage of the speed controller for easy action. Check operation of
monitoring, shut-off and remote control systems.
● Check the control cable and the sensor with the DEUTZ TEM system self-
test.
The coolant is filled through the filling nozzle according to operating materials Filling up coolant
specification with supplements. The coolant chambers are bled by a bleeding
line with the coolant pump running. Then check the coolant level again and
add coolant if necessary.
The lube oil level is monitored during operation by the DEUTZ TEM system. Filling up lube oil
The approximate lube oil level can be checked with the oil dipstick (TBG 620,
TCG 2020, TCG 2032) or can be seen in the sight glass (TBG 616,
TCG 2016). When filling up with lube oil, this should be done in connection
with the DEUTZ TEM system.
Too low a lube oil state leads to non-release or switching off of the engine via
monitoring of the lube oil level and the lube oil pressure.
Initial filling in the TCG 2032
Fill the engine with the following lube oil quantities when filling for the first
time:
TCG 2032 V12: 1,450 litres

TCG 2032 V16: 1,800 litres
The engine is lubricated by the electric lubrication pump for constant standby Pre-lubrication
at regular intervals. Pre-lubrication must have taken place before the engine
has started.

Operation
Gas Engines
Gas supply
The room ventilation system must be switched on before any

work is carried out of the gas line.
Smoking an use of open flames are strictly prohibited.
Explosion hazard!
Clean the whole line leading to the engine internally (incl. desulphurising sys-
tem, gas compressor, cooler, gas pressure regulator and shut-off systems).
All parts of the line must be dry, clean and free of welding beads, scales and
other dirt particles. The joints should be checked for leaks using soapy water,
by applying , for example, nitrogen at overpressure .
Note for all heat trans- Before the insulation is closed, all the screws on pipe and connecting flanges
formers in the exhaust gas system must be tightened. This measure is necessary
because of ”settling” of the seals.
It is essential to tighten them once more after approx. 100 operating hours or
after 14 days.
Failure to do so will result in the manufacturer disclaiming responsibility for
leaking seals and escaping exhaust gases.
When filling the water side, bleed constantly (failure to bleed air sufficiently
leads to gas accumulations which could damage the boiler).
Particular attention must be paid to contamination of the cheating water.
Sludge and corrosion products from older heating water circuits and rolling
and welding residue can accumulate and for cause overheating, voltage
peaks and material breakage for example due to local insulation effects.
The heating water side must therefore be checked after the first 10 hours and
after a further 100 hours and, if necessary, be cleaned to remove sludge.
Sludge drains and filters make this job easier.
Exhaust gas side The exhaust gas parts resulting from engine combustion can deposit residue
on the smoke pipes.
Although this tendency is only very slight in three-way catalysts, coating on
the walls at the transmission surfaces cannot be ruled out over long operating
periods. This coating can be removed mechanically or wet chemically.
Note for oxidation cata- In systems with an oxidation catalyst the catalyst no longer needs to be
lyst removed for commissioning.

Operation
Gas Engines 3
Commissioning /
Starting
The values for the suction intake air temperature must be observed, see Starting
chapter 8, Technical data.
The following functions are performed automatically by the system manage-
ment DEUTZ TEM system when starting.
1. Set the gas cross section at the mixer to start position for the gas type
concerned.
2. Check the readiness for starting on all module components
3. Switch on the starter
4. Purge air and exhaust gas system
5. Switch on the ignition
6. Open the gas valve —> engine runs up
7. Switch off the starter when the speed is fast enough and track out
8. Engine accelerates up to rated speed and is ready for synchronisation
The engines can be kept constantly at standby temperature by a separate Warming up

coolant heating (resistance heating or heating by pump operation) even at
standstill.
After starting, the engines generally run up quickly to operating temperature,
i.e. the set heating lead temperature, independently of the temperature state
of the heating system by return increase of the heating water flow. The drop
in temperature is reduced with the automatic load connection.
In the case of engines installed in enclosed spaces, a check must be carried Room ventilation
out after start-up as to whether the automatic inlet and outlet air shutters have
opened and the fans have started up.
Inadequate engine room ventilation results in excessive room temperatures
and a corresponding reduction in output by the engine and generator protec-
tion systems in the DEUTZ TEM system.
The lube oil pressure is monitored and recorded in the DEUTZ TEM system Lube oil system
and normally does not need to be checked by the operator any more.
Regular checking of the lube oil level and the lube oil supply in the day tank is
very important. It should be checked during the inspections with the engine at
a standstill. In continuous operation check every 24 hours. In case of low lube
oil level the engine is switched off automatically and must be unlocked manu-
ally on the switching system after filling up lube oil.

Operation
Gas Engines
Monitoring opera-
tion
System monitoring All important system parameters of the engine, the generator and the con-
nected heat utilisation system are constantly monitored by the DEUTZ TEM
system.
The operating values of the systems must be checked against the recordings
made by the DEUTZ TEM system at regular operating intervals (daily in the
case of continuous operation). A log is best kept by continuously saving all
data to a central PC.
In case of irregularities, defects and faults must be documented by printing
out the last 24 h on the system PC printer and recorded in the operating log
and the causes of the fault eliminated.
Engine Peripheral Sys- The temperatures, pressures and other relevant states are monitored auto-
tems matically, the operating values saved continuously in the module control of
the DEUTZ TEM system. Once the set maximum values are reached, a warn-
ing is first issued and then, if exceeded again, the engine is shut off (fault indi-
cation).
Coolant circuit
Filling up coolant while the engine is running is prohibited!
Small quantities may be topped up after the engine has been switched off.
When filling frequently, make sure that the anti-corrosive content is observed.
Batteries If the engine has an electric starter, the appropriate batteries and the charger
must be checked weekly. The voltage given off by the backup battery of the
DEUTZ TEM system is monitored automatically. This serves for backing up
data in the event of a power failure.
Please note:
The operating manual for the DEUTZ TEM system is available as a sepa-
rate documentation and must be ordered separately.

Expendables
Gas Engines 4
4 Expendables
General
If unsuitable expendables are used or if no proof can be brought that the used Guarantee
expendables meet the requirements, the engine manufacturer cannot guar-
antee trouble-free operation. This also applies for defective maintenance of
the engines and the expendables.
The most important expendables for gas engine systems are listed in the
enclosed expendables specifications. The values specified therein are bind-
ing unless specified otherwise in the engine or system-specific contracts.
Due to the large number of products in national and international quality and Product selection
availability and as a result of the constant further development, it is not possi-
ble for us to test all suitable products and to name them, we therefore cannot
accept any responsibility for these products.
The supplier of the operating materials is solely responsible for the world-
wide consistent quality of the products listed here and for products not listed
here additionally for meeting the listed requirements for expendables and
their operational safety. This also applies for the event that the manufacturer
develops the listed products further.
The expendables (reference products) listed here are just a selection of a few
manufacturers and their products. Other expendables not listed here can be
used if they meet the necessary requirements, i.e. are at least equal in all cri-
teria. The expendables named in this specification are to be used as refer-
ence products for comparison. The respective expendables suppliers can
provide information about this and should confirm the suitability accordingly.
The mixing of different expendables types, e.g. different lube oils, with each Mixability
other, different coolants with each other and similar can lead to faults.
In any case the product supplier’s consent must be obtained before mixing
and he must take over the responsibility. This also applies for other additives
to the expendables.
see Technical Circular TR 0199-99-3017. Combustion gases
see Technical Circular TR 0199-99-2105. Lube oil
see Technical Circular TR 0199-99-2091. Engine coolant

Expendables
Gas Engines

Expendables
Auxiliary materials
Sealants and securing agents

- Observe storage stability, if any, given on the package!
- Upon transport, storage and disposing of the above-mentioned items, observe Chapter 1, Regulati-
ons, of the operating manual, if no according information is given on the package.
Material designa- Type Standards and Characteristics Application examples

tion specifications
DEUTZ DW 43 Sealant Solvent-free, caoutchouc-based flexibly Sealing of small joints

hardening, rapid skin formation, tempera-
ture range 30°C to 100°C
DEUTZ DW 47 Sealant LV 0161 9672 Silicon caoutchouc, viscously flexible, eas- Sealing of rough and une-
FV 0160 9610 ily detachable, temperature range max. ven surfaces
180°C, oil max. 150°C
DEUTZ DW 48 Sealant LV 0161 9572 Silicon caoutchouc, viscously flexible, Sealing of rough and une-
FV 0160 9610 strong adhesion, temperature range –65°C ven surfaces
to 265°C
DEUTZ DW 49 Sealant LV 0161 9571 Mixed polymeride of vinyl- and acryl com- Sealing of core hole plugs
FV 0160 9607 positions, strong adhesion permanently
elastic, temperature range –40°C to 130°C
DEUTZ DW 50 Sealant Liquid, hardening artificial resin, compati- Sealing of housings

ble with gaskets, temperature range –40°C
to 180°C
DEUTZ DW 51 Sealant LV 0161 9573 Physically dry artificial resin, permanently Sealing of surfaces
elastic and vibration-free, temperature
range –30°C to 150°C
DEUTZ DW 55 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to M12;
when excluding oxygen, high strength, fluid, joints up to max. gap width
temperature range –55°C to 150°C of 0.15 mm
substance hardening upon metal contact threads up to R2"
when excluding oxygen, high strength,
thick-flowing, temperature range –55°C to
150°C
when excluding oxygen, low strength, liq-
uid, temperature range –55°C to 150°C
when excluding oxygen, high strength, joints up to max. gap width
medium viscous, temperature range –55°C of max. 0.15 mm
to 150°C
substance hardening upon metal contact threads up to M56 or R2"
when excluding oxygen, medium strength,
liquid, temperature range –55°C to 150°C
DEUTZ DW 61 Activator FV 0160 9605 Accelerates and permits the complete hard- Only for passive materials
ening of anaerobic substances with passive
materials

Expendables

tion specifications
DEUTZ DW 62 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Joints up to a gap width of
upon metal contact when excluding oxygen, max. 0.12 mm
high strength, medium-viscous, thixotrope,
temperature range –55°C to 175°C
DEUTZ DW 63 Sealant FV 0160 9605 Anaerobic solvent-free single-component Sealing of surfaces up to a

upon metal contact when excluding oxygen, gap with of max. 0.10 mm
low strength thick-flowing, thixotrope, tem-
perature range –55°C to 150°C
upon metal contact when excluding oxygen, threads up to M80 or R3"
high strength, medium-viscous, tempera-
ture range –55°C to 150°C
DEUTZ DW 65 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Joints up to a gap width of
upon metal contact when excluding oxygen, max. 0.25 mm
high strength, thick-flowing, temperature
upon metal contact when excluding oxygen, threads up to R3"
low strength thick-flowing, temperature

upon metal contact when excluding oxygen, gap width of max. 0.50 mm
high strength, thick-flowing, thixotrope, tem-
perature range –55°C to 150°C

upon metal contact when excluding oxygen, gap width of max. 0.50 mm,
low strength thick-flowing, thixotrope, tem- securing and sealing of
perature range –55°C to 150°C threads R2"
upon metal contact when excluding oxygen, threads up to M36
low strength liquid temperature range –
55°C to 150°C
upon metal contact when excluding oxygen, threads up to M12
medium strength liquid temperature range –
55°C to 150°C
upon metal contact when excluding oxygen, threads up to M20;
high strength, medium viscous, tempera- joints up to a gap width of
ture range –55°C to 175°C max. 0.15 mm
substance hardening upon metal contact threads up to M36
when excluding oxygen, medium strength,
medium viscous, temperature range –55°C
to 150°C
Tab. 1 Sealants and securing agents

Expendables
Gluing agents

tion specifications
DEUTZ KL 1 Gluing agent LV 0161 9633 Two-component, epoxy-resin based, water- Combines steel, alumin-
FV 0160 9608 , oil- and diesel fuel resistant, admiss. appli- ium, brass and plastic mate-
cation temperature max. 150°C rials such as plexiglass,
DEUTZ KL 2 Hardening agent LV 0161 9633
polyethylene and similar,
FV 0160 9608
Mixing ratio 1:1, gluing them together or
gluing agent DEUTZ KL 1 and hardener among them
DEUTZ KL 2
Tab. 2 Gluing agents
Lubricants
Material designa- Standards and Temperatur- Application examples

tion specifications range
DEUTZ S1 FV 0160 9537 -180°C to 1400°C Avoids burning in of screw connections in exhaust gas pipes
DEUTZ S2 LV 0161 9734 -25°C to 450°C Spray for reducing friction and wear for surfaces difficult to access Gener-
FV 0160 9506 ates an emergency lubrication and avoids sliding back.
DEUTZ S3 LV 0161 9733 -35°C to 450°C Spray for reducing friction and wear. Generates an emergency lubrication
FV 0160 9505 and avoids sliding back.
DEUTZ S4 LV 0161 9735 -40°C to 450°C Preferably used for pre-treating components with a high application tem-
perature. After the evaporation of the carrier oil (at 200°C), an effectively
lubricating solid film remains. Compatible with natural rubber and plastic
materials.
DEUTZ S5 LV 0161 9738 -30°C to 130°C For the long-term lubrication of antifriction- and slide bearings with
medium bearing pressures and higher temperatures. Water-resistant,
good emergency lubrication.
DEUTZ S6 LV 0161 9741 -20°C to 180°C For the long-term lubrication of antifriction- and slide bearings with
medium bearing pressures and higher temperatures. Water-resistant,
good emergency lubrication
Grease DIN 51825- -30°C to 140°C Consistent grease for lubricating antifriction bearings, slide bearings and
KP 2 N-30 sliding surfaces. For example, for filling the spiral-toothed coupling TBD
234/616.
Tab. 3 Lubricants

Expendables
Other auxiliary materials

Below you will find a reference list for the used auxiliary materials with which the best results have been
achieved. Equivalent products can also be used; in this case, the supplier must assure the suitability of the
product for the application.
- When using the products indicated below, the following references of the manufacturer must abso-
lutely be observed:
• Safety references
• Personal protection equipment
• Use as directed
• Disposal as directed

Expendables
Product group Application Product name Supplier
Detergent for engine components P3 cold cleaner (liquid) Messrs. Henkel KGAA
40191 Düsseldorf
Vecom B 24 B (liquid) Messrs. Vecom GmbH

21107 Hamburg
Carbon remover or Ameroid ACC-9 (liquid) Messrs. Drew Ameroid

Deutschland GmbH
21107 Hamburg
for engine cooling system P3 T 288 (powder) Messrs. KGAA

P3 Standard (powder) 40191 Düsseldorf
Vecom BA-S (powder) Messrs. Vecom GmbH

Vecom BA-30 (liquid) 21107 Hamburg
SAF-Acid (powder) Messrs. Drew Ameroid

HDE-777 (liquid) Deutschland GmbH
21107 Hamburg
for intercooler (water side) and raw P3 - T1166 Messrs. Henkel KGAA
water circuit P3 - croni 40191 Düsseldorf
(neutraliser)
SAF-Acidonly calcium solutizer) Messrs. Drew Ameroid

Concentration: 5 % Deutschland GmbH
Temperature: 55 °C - 75 °C 21107 Hamburg
Porodox Messrs. Collardi GmbH

Concentration: 2 % - 10 % 50825 Köln
Temperatuer: 20 °C - 60 °C
Treatment time: max. 16 hours
for intercooler ACC 9 Messrs. Drew Ameroid

(air side) Deutschland GmbH
21107 Hamburg
Vecom B 85 Messrs. Vecom GmbH

21107 Hamburg
P3T-5308 Messrs. Henkel KGAA

40191 Düsseldorf
for tank plants Vecom B 24 B (liquid) Messrs. Vecom GmbH

Vecom B 14 (liquid) 21107 Hamburg
Tank cleaner Nr. 4 (liquid) Messrs. Drew Ameroid

Deutschland GmbH
21107 Hamburg
for lube oil filters Ameroid ACC-9 (liquid) Messrs. Drew Ameroid
Deutschland GmbH
21107 Hamburg
P3 RST, P3 SAXIN (powder) Messrs. Henkel KGAA

40191 Düsseldorf
Filterclean Messrs. Vecom GmbH

21107 Hamburg

Expendables
Product group Application Product name Supplier
Detergent for air filters Soda solution 1%ig

(continued) Burning kerosene
Mixture of:
6,5 % trilene (german: Trichlor-Äthylen)
9,5 % Teepol (Messrs. Shell)
4,0 % Cyclohexanon
80,0 % fresh water
for de-preservation Eskapon S 255 Messrs. Haug-Chemie

GmbH
74889 Sinsheim
Water treatment Hardness determination for cooling Aquamerk Art. Nr. 11129 Messrs. E. Merck KGAA
agent water DEUTZ ordering-no. 1215 8292 64293 Darmstadt
Cooling water hardening Vecom CN (powder) Messrs. Vecom GmbH

21107 Hamburg
Cooling water softening Trisodiumphosphate Messrs. Benckiser GmbH

(german:Trinatriumphosphat) (powder) 67001 Ludwigshafen
Tab. 4 Other auxiliary materials

Maintenance
TCG 2020 5
5 Maintenance
Please bear in mind that the following maintenance schedules are Schedu-
led Maintenance Plans.
It is not possible to make a permanent definition of the maintenance intervals
for all applications due to the numerous different relationships between ambi-
ent conditions, operating mode and quality of fuels.
It may be necessary to shorten the specified maintenance intervals under
harsher operating conditions. The scheduled maintenance plan must then be
revised in total. Generally the on-site operating conditions are already defined
in the planning phase.
Critical operation conditions are for example:
- Contamination of the combustion gases by ingredients which promote
wear, e.g. silicon, sulphur, chlorine, ...
- Frequent cold starts
- Increased dust contamination of the suction intake air
Ask your responsible DEUTZ SERVICE partner when in doubt.
The normal care of your engine comprises a daily visual inspection by techni- Continuous supervi-
cally skilled persons. The appropriate activities are listed in Job Card B 0-1-5. sion
Maintenance sched-
ule
The maintenance schedule lists the measures for maintaining the nominal General
condition and thus the operational reliability of the engine and the appropriate
maintenance intervals. The maintenance work procedures are described in
the specified Job Cards.
● The intervals prescribed in the maintenance schedule are maximum val-
ues and assume that installation, purpose and operating conditions com-
ply with DEUTZ specifications. It must be ensured that all expendables
such as combustion gas, lube oil and coolant have the prescribed quality.
You will find information about this in Chapter 4, Expendables.
In particular it must be ensured that the gas quality meets the minimum
requirements in accordance with TR 0199 - 99 - 3017 to avoid malfunctions
and/or premature wear of the engine
● This maintenance schedule only applies for the engine itself and the parts
attached to the engine. System parts must be serviced at the intervals and
according to the instructions specified by the manufacturer. You will find
the appropriate information in the respective enclosed manufacturer
documents (marked ‘‘MD” in the maintenance schedule).
● The work described must be performed by technically skilled persons or
authorised specialists. The competencies are listed in Table 1, mainte-
nance and service schedules.

Maintenance
TCG 2020
Maintenance and service schedules

The operating hours-dependent maintenance work is divided into maintenance and service schedules. All
the work listed must be performed carefully according to the maintenance schedule determined specifically
for the engine.
Maintenance and service schedules Executed by

Due respectively once after commissioning
E10
as well as E50, E60 and E70
E20 Daily inspection Technically skilled persons
E30 Periodic maintenance (small scope)
E40 Periodic maintenance (medium scope)
E50 Periodic maintenance (extended scope)
E60 Intermediate overhaul Authorised specialists
E70 Complete overhaul
Tab. 1 Maintenance and service schedules
Please note that maintenance and service schedules may be added or omit-
ted depending on the speed and gas group.
● Plan the due maintenance and service schedules in good time according to the number of hours your
engine has been in operation.
● Arrange the probable appointment with your responsible DEUTZ SERVICE partner in good time. Notify
your DEUTZ Service partner of any irregularities of your engine (see operating check log) when you
arrange the appointment.
● Sign a service contract with DEUTZ SERVICE if necessary. All the due maintenance work including
repairs if agreed is then planned and expertly performed by DEUTZ SERVICE according to the contract.
Your responsible DEUTZ SERVICE partner will be glad to give you the details.

Maintenance
TCG 2020 5
Gas groups
The scheduled maintenance also depends on the quality of the combustion gases.
The combustion gases are divided into two groups according to their wear properties for which different
scheduled maintenance plans apply, see also chapter 4, Technical Circular 0199 - 99 - 3017.
Use the scheduled maintenance plan corresponding to the type of gas used
in the system as a basis for the maintenance work.
Gas group 1 Gas group 2 (bio-gases)

natural gas sewage gas
pit gas dump gas
liquid gas
wood gas
- propane, butane, LNG (liquid natural gas)
petroleum gas other bio-gases
gases with a hydrogen content H > 30 vol%, e.g.
2
coke oven gas

Tab. 2 Gas groups
Please note for gas group 2:

The worst determined gas quality is essentially binding for defining the main-
tenance intervals. Please consult your responsible DEUTZ SERVICE partner.
Silicon content
When using combustion gases with a silicon content > 10 mg/mn3 CH4 the
maintenance intervals must be shortened in any case due to the heavily abra-
sive effect of silicon (TBO = Time between overhaul).
TBO
100 %
© 83908-1
0 10 mg/mn3 CH4 Silizium
Figure 5-1 Dependence silicon content - TBO
To guarantee the necessary life cycles, the silicon content of critical gases (gas-group 2, biogases) must be
determined regularly at least 3x a year in the course of extensive gas analyses and the maintenance inter-
vals may have to be shortened accordingly.

Maintenance
TCG 2020
Specific scheduled maintenance plan

This engine has been built exclusively for the application specified in the scope of supply - as described by
the equipment manufacturer - and is to be used only for the intended purpose. Depending on its intended
purpose the engine is identified by a performance code according to DIN ISO 3046-7 which is punched into
the rating plate. The rating plate is described in detail in Chapter 2, Rating plate.
Scheduled maintenance plan 1, see Page 5

Valid for:
- TCG 2020 V12, TCG 2020 V16 and TCG 2020 V20 with n = 1,500 rpm (50 Hz applications)
when using combustion gases of gas group 1
Performance abbreviation: ICN
Type of application: Current generators
E10 E20 E30 E40 E50 E60 E70
Routine main- Inspection Periodic Periodic Periodic main- Intermediate Complete
tenance maintenance maintenance tenance overhaul overhaul
(small scope) (medium (extended
scope) scope)
each time each time each time each time each time
once in spe- daily
after after after after after
cial cases
2,000 Oh 4,000 Oh 16,000 Oh 32,000 Oh 64,000 Oh
Tab. 3 Specific maintenance and service schedules in scheduled maintenance plan 1
Scheduled maintenance plan 2, see Page 11

Valid for:
when using combustion gases of gas group 2
Performance abbreviation: ICN
Type of application: Current generators
E10 E20 E30 E40 E50 E60 E70
Routine main- Inspection Periodic Periodic Periodic Intermediate Complete
tenance maintenance maintenance maintenance overhaul overhaul
(small scope) (medium (extended
scope) scope)
each time each time each time each time each time
once in daily
after after after after after
special cases
2,000 Oh 4,000 Oh 16,000 Oh 32,000 Oh 64,000 Oh
Tab. 4 Specific maintenance and service schedules in scheduled maintenance plan 2

Maintenance
TCG 2020 5
Scheduled maintenance plan 1

This maintenance schedule applies for TCG 2020 V12, TCG 2020 V16 and TCG 2020 V20 with
n = 1,500 rpm (50 Hz applications) as well as with n = 1,200 rpm (60 Hz applications) when using combus-
tion gases of gas group 1.
Operating hours-independent maintenance work each time after 12 months
Description WC
each time after 3 months
each time after 2 years

as requried
monthly
Clean suction air intake filter;

x B 6-3-6
when maintenance indicator is‘‘RED”
Trial run
x -
after maintenance work 1)
Run in engine;
x after maintenance work such as changing bearings, W 0-1-3
piston, cylinder liner 2)
x Clean the engine B 0-3-6
3)
x Trial run -
3)
x Maintain the battery B 13-4-1
x Crankcase bleed valve visual inspection B 3-1-9
Check percentage of corrosion protection agent or
x B 9-1-1
antifreeze in the coolant 4)
x x Inspect pressure drop in gas filter MD
x Clean gas filter or renew filter cartridge B 7-21-1
x Gas pressure sensor, check set gas pressure MD
x Check gas pressure regulator MD
x Check shutoff valves of the gas control line MD
x Check the entire gas control line for leaks MD
x Lube oil change 5) B 8-1-2
6)
x Renew lube oil filter cartridges B 8-10-4
6)
x Maintain crankcase bleed valve B 3-1-9
x Renew the coolant 4) -
1) To be performed by maintenance officers
2) To be performed by authorised experts
3) This activity must be performed when the engine has not been operated on standby for longer than one month. The engine
must be preserved during long periods out of action, e.g. over the winter, see chapter 7, Preservation.
4) Observe the expendables specifications in chapter 4, Expendables.
5) To be performed when the engine has been in operation for less than 2,000 Oh within one year.
Tab. 5 Operating hours-independent maintenance work

Maintenance
TCG 2020
Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts.
Drain water Drain condensed water for example.
Renew Renew parts, function groups and liquids.
Material acceptance within the permitted tolerances to reinstate a nominal condition, using
Rework
overmeasure parts if necessary.
Check according to criteria in the Job Card. If not all criteria are fulfilled the cause must be
Check
found and the nominal condition reinstated.
Clean Cleaning by hand or machine (automatic), renewal of cleaning parts may be necessary.
Visual inspec- Visual inspection according to criteria in the Job Card. If not all criteria are fulfilled the
tion cause must be found and the nominal condition reinstated.
Overhaul Check function groups; rework or renew parts.
Maintain according to Job Card. Check function; reworking or renewal of parts may be nec-
Maintain
essary.
Change Change lube oil for example.
Tab. 6 Definition of activities
Operating hours-dependent maintenance work

On reaching the operating hours specified in the following maintenance schedule the activities prescribed in
the description must be performed. Always use the Job Card referred to in the maintenance schedule.
E10 E20 E30 E40 E50 E60 E70 Description WC

each time after 24 hours (daily)
each time after 16,000 Oh


1x after 50 Oh
x x x x x x x Visual inspection of the system B 0-1-5

x x x x x x Test and function run TEM
x x x Check valve clearance B 1-1-1
1)
x x x x x Check starter battery B 13-4-1
x x x x x Check easy action of the speed regulator B 5-4-2
x2) x x x x Renew lube oil filter cartridges 3) B 8-10-4
x x Maintain crankcase bleed valve B 3-1-9
x x Overhaul crankcase bleed valve B 3-1-9
Check spark plugs (chamber plug), renew if neces-
x x x x B 13-5-4
sary
⇒
1) For engines with this equipment
2) Only 50 Oh according to E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documents
MD: Manufacturer Documents
Table 6 Note activity definition
The Job Card is binding for the activity

Maintenance
TCG 2020 5



1x after 50 Oh
x x x x Renew air filter cartridges, clean air filter casing B 6-3-6

x x x x Check, clean gas mixer MD
x x x Check ignition time -
x x x Auxiliary aggregate test using the TEM System B 0-1-6
x x x Check the engine fastening W 3-7-1
x x x Check the starter pinion and crown gear W 12-6-4
x x x Clean the flame filter 1) -
x x Check the cylinder heads -
x Renew or overhaul cylinder heads W 1-4-4
x x Clean combustion chambers, check cylinder liners W 3-3-1
W 3-3-3
x Renew the cylinder liners
W 3-3-4
x x Renew rubber compensators W 12-3-1
Check hose pipes, vibration dampers and flexible
x x W 0-3-4
lines
x x Renew fittings and regulators -
x x Renew viscosity rotary vibration dampers 1) -
x x Check, clean mixture cooler W 6-4-8
x x Check crankshaft axial clearance W 2-1-4
x x Check camshaft axial clearance W 4-5-1
x Check valve tappet W 4-2-1
x Renew valve tappet W 4-2-1
x Check con rod liners W 2-3-3
W 2-5-1
x Check con rod bearing
W 2-5-2
W 2-5-1
x Renew con rod bearing
W 2-5-2
x Check piston -
x Renew piston W 2-9-3
⇒

Maintenance
TCG 2020



1x after 50 Oh
x Check piston bolt W 2-12-4

x Renew piston rings W 2-10-1
x x Check camshaft W 4-5-1
x Renew camshaft bearing W 4-1-1
x Renew con rods -
x Renew crankshaft sealing rings (drive side) W 2-2-2
x Renew crankshaft sealing rings (free side) 1) -
x Measure crankshaft -
x Check, clean wheel drive and control W 4-4-1
x Renew main bearing, axial bearing W 2-7-3
x Renew or overhaul lube oil pump W 8-4-5
x Renew or overhaul pressure limiting valve W 8-11-1
x Renew exhaust gas compensators -
1)
x Check function of compressed air starter -
4)
Check, clean exhaust gas turbocharger MD
Tab. 7 Operating hours-dependent maintenance work
Operating hours-dependent maintenance work outside the maintenance and service schedules
Interval Description WC
1x after 300 Oh Lube oil analysis according to TR 0199 - 99 - 2105 1) 2) B 8-1-1

1) Initial analysis after 300 Oh
2) Intervals for lube oil analysis and change according to agreement between operator and lab based on the limit values of the
initial analysis, see also Technical Circular TR 0199-99-2105.
Tab. 8 Maintenance work outside the maintenance and service schedules
We recommend you to attest the proper execution of work in the enclosed

maintenance tables.

Maintenance
TCG 2020 5
Table for operating hours-independent maintenance work

Date Activity Signature
Tab. 9 Table for operating hours-independent maintenance work (copy form)

Maintenance
TCG 2020
Table for operating hours-dependent maintenance work

Hours Maintenance and service schedule Date Signature

E10 E30 E40 E50 E60 E70
50 1
2,000 1
4,000 1
6,000 2
8,000 2
10,000 3
12,000 3
14,000 4
16,000 1
16,050 2
18,000 5
20,000 4
22,000 6
24,000 5
26,000 7
28,000 6
30,000 8
32,000 1
32,050 3
34,000 9
36,000 7
38,000 10
40,000 8
42,000 11
44,000 9
46,000 12
48,000 2
48,050 4
50,000 13
52,000 10
54.000 14
56,000 11
58,000 15
60,000 12
62,000 16
64,000 1
Number of maintenance and service schedules up to and including complete overhaul

Total 4 16 12 2 1 1
Tab. 10 Table for operating hours-dependent maintenance work (copy form)

Maintenance
TCG 2020 5

This maintenance schedule applies for TCG 2020 V12, TCG 2020 V16 and TCG 2020 V20 with
n = 1,500 rpm (50 Hz applications) as well as with n = 1,200 rpm (60 Hz applications) when using combus-
tion gases of gas group 2.
Operating hours-independent maintenance work
each time after 12 months Description WC

each time after 2 years

as requried
monthly
Clean suction air intake filter;

x B 6-3-6
when maintenance indicator is ‘‘RED”
Trial run
x -
after maintenance work 1)
Run in engine;
x after maintenance work such as changing bearings, W 0-1-3
piston, cylinder liner 2)
x Clean the engine B 0-3-6
3)
x Trial run -
3)
x Maintain the battery B 13-4-1
x Crankcase bleed valve visual inspection B 3-1-9
x Gas analysis 4) -
Check percentage of corrosion protection agent or
x B 9-1-1
antifreeze in the coolant 5)
x x Inspect pressure drop in gas filter MD
x Clean gas filter or renew filter cartridge B 7-21-1
x Gas pressure sensor, check set gas pressure MD
x Check gas pressure regulator MD
x Check shutoff valves of the gas control line MD
x Check the entire gas control line for leaks MD
6)
x Lube oil change B 8-1-2
7)
x Renew lube oil filter cartridges B 8-10-4
x Maintain crankcase bleed valve 7) B 3-1-9
5)
x Renew the coolant -
1) To be performed by maintenance officers
2) To be performed by authorised experts
3) This activity must be performed when the engine has not been operated on standby for longer than one month. The engine
must be preserved during long periods out of action, e.g. over the winter, see chapter 7, Preservation.
4) The worst determined gas quality is essentially binding for defining the maintenance intervals. Please consult your responsi-
ble DEUTZ SERVICE partner.
5) Observe the expendables specifications in chapter 4, Expendables.
Tab. 11 Operating hours-independent maintenance work

Maintenance
TCG 2020
Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts.
Drain water Drain condensed water for example.
Renew Renew parts, function groups and liquids.
Material acceptance within the permitted tolerances to reinstate a nominal condition, using
Rework
overmeasure parts if necessary.
Check according to criteria in the Job Card. If not all criteria are fulfilled the cause must be
Check
found and the nominal condition reinstated.
Clean Cleaning by hand or machine (automatic), renewal of cleaning parts may be necessary.
Visual inspec- Visual inspection according to criteria in the Job Card. If not all criteria are fulfilled the
tion cause must be found and the nominal condition reinstated.
Overhaul Check function groups; rework or renew parts.
Maintain according to Job Card. Check function; reworking or renewal of parts may be nec-
Maintain
essary.
Change Change lube oil for example.
Tab. 12 Definition of activities
Operating hours-dependent maintenance work

On reaching the operating hours specified in the following maintenance schedule the activities prescribed in
the description must be performed. Always use the Job Card referred to in the maintenance schedule.



1x after 50 Oh
x x x x x x x Visual inspection of the system B 0-1-5

x x x x x x Test and function run TEM
x x x Check valve clearance B 1-1-1
1)
x x x x x Check starter battery B 13-4-1
x x x x x Check easy action of the speed regulator B 5-4-2
x2) x x x x Renew lube oil filter cartridges 3) B 8-10-4
x x Maintain crankcase bleed valve B 3-1-9
x x Overhaul crankcase bleed valve B 3-1-9
Check spark plugs (chamber plug), renew if neces-
x x x x B 13-5-4
sary
⇒

Maintenance
TCG 2020 5



1x after 50 Oh
x x x x Renew air filter cartridges, clean air filter casing B 6-3-6

x x x x Check, clean gas mixer MD
x x x Check ignition time -
x x x Auxiliary aggregate test using the TEM System B 0-1-6
x x x Check the engine fastening W 3-7-1
x x x Check the starter pinion and crown gear W 12-6-4
x x x Clean the flame filter 1) -
x x Check the cylinder heads -
x Renew or overhaul cylinder heads W 1-4-4
x x Clean combustion chambers, check cylinder liners W 3-3-1
W 3-3-3
x Renew the cylinder liners
W 3-3-4
x x Renew rubber compensators W 12-3-1
Check hose pipes, vibration dampers and flexible
x x W 0-3-4
lines
x x Renew fittings and regulators -
x x Renew viscosity rotary vibration dampers 1) -
x x Check, clean mixture cooler W 6-4-8
x x Check crankshaft axial clearance W 2-1-4
x x Check camshaft axial clearance W 4-5-1
x Check valve tappet W 4-2-1
x Renew valve tappet W 4-2-1
x Check con rod liners W 2-3-3
W 2-5-1
x Check con rod bearing
W 2-5-2
W 2-5-1
x Renew con rod bearing
W 2-5-2
x Check piston -
x Renew piston W 2-9-3
⇒

Maintenance
TCG 2020



1x after 50 Oh
x Check piston bolt W 2-12-4

x Renew piston rings W 2-10-1
x x Check camshaft W 4-5-1
x Renew camshaft bearing W 4-1-1
x Renew con rods -
x Renew crankshaft sealing rings (drive side) W 2-2-2
x Renew crankshaft sealing rings (free side) 1) -
x Measure crankshaft -
x Check, clean wheel drive and control W 4-4-1
x Renew main bearing, axial bearing W 2-7-3
x Renew or overhaul lube oil pump W 8-4-5
x Renew or overhaul pressure limiting valve W 8-11-1
x Renew exhaust gas compensators -
1)
x Check function of compressed air starter -
4)
Check, clean exhaust gas turbocharger MD
Tab. 13 Operating hours-dependent maintenance work
Operating hours-dependent maintenance work outside the maintenance and service schedules
Interval Description WC
1x after 100 Oh Lube oil analysis according to TR 0199 - 99 - 2105 1) 2) B 8-1-1

1) Initial analysis after 100 Oh
2) Intervals for lube oil analysis and change according to agreement between operator and lab based on the limit values of the
initial analysis, see also Technical Circular TR 0199-99-2105.
Tab. 14 Maintenance work outside the maintenance and service schedules
We recommend you to attest the proper execution of work in the enclosed

maintenance tables.

Maintenance
TCG 2020 5
Table for operating hours-independent maintenance work

Date Activity Signature
Tab. 15 Table for operating hours-independent maintenance work (copy form)

Maintenance
TCG 2020
Table for operating hours-dependent maintenance work

Hours Maintenance and service schedule Date Signature

E10 E30 E40 E50 E60 E70
50 1
2,000 1
4,000 1
6,000 2
8,000 2
10,000 3
12,000 3
14,000 4
16,000 1
16,050 2
18,000 5
20,000 4
22,000 6
24,000 5
26,000 7
28,000 6
30,000 8
32,000 1
32,050 3
34,000 9
36,000 7
38,000 10
40,000 8
42,000 11
44,000 9
46,000 12
48,000 2
48,050 4
50,000 13
52,000 10
54,000 14
56,000 11
58,000 15
60,000 12
62,000 16
64,000 1
Number of maintenance and service schedules up to and including complete overhaul

Total 4 16 12 2 1 1
Tab. 16 Table for operating hours-dependent maintenance work (copy form)

Maintenance
TCG 2020 5
Tools
The following section contains data about tools necessary for maintenance work up to and including E40.
You can order these from your DEUTZ Service under the part numbers.
Tools kits
Containing Illustration
Tool kit
Order no. Description
12150000 Tool kit complete
12158074 1 Tool box empty
01154248 2 Double ended open wrench
8x10 DIN 3110
12x14 DIN 3110
13x17 DIN 3110
14x15 DIN 3110
19x22 DIN 3110
24x27 DIN 3110
30x32 DIN 3110
01124755 9 Ring spanner 13x17 DIN 838
01154367 12 Feeler gauge set
07109764 13 Key wrench attachment 10x12.5 DIN 3124
01152905 19 T-handle A 12.5 DIN 3122
01102415 20 Extension B 12.5x250 DIN 3123
01154232 21 Universal joint C 12.5 DIN 3123
01103385 22 Screwdriver A 0.8x4.0 DIN 5265
01104281 23 Screwdriver A 1x5.5 DIN 5265

Maintenance
TCG 2020
Tool kit
12030366 1 Tool box empty
12030375 2 Single ended open wrench 46
01151236 3 Double ended open wrench 36x41 DIN
3110
01151248 5 Key wrench attachment 24x20 DIN 3124
12030376 9 Extra deep key size 36
12030354 10 Slider
12030348 11 Extension
12030360 12 Extension
01151239 13 Adapter A 20x12.5 DIN 3123
12030350 14 Measuring instrument for torque
12030346 15 Extension for torque measuring instru-
ment
12030372 16 Rotary pin turning bar extension
12030362 17 Ratchet 1/2“
12030352 18 Ratchet 3/4“, square
⇒

Maintenance
TCG 2020 5
01151262 19 Right angle screwdriver 5 DIN 911
12030377 24 Pin wrench 3/16“
01151253 25 Pliers A 10 DIN 5254
01151254 26 Pliers A 19 DIN 5254
01152915 27 Pliers C 40 DIN 5254
12030369 28 Brush
12030364 29 Handle
12030358 30 Feeler gauge
12030368 31 Extraction device
12030373 32 Pin for loosening the retaining bolts
12030378 33 Ring spanner size 22
12030356 34 Extension for torque measuring instru-
ment
12030370 35 Extension for brushes for pipe cooler
12030371 36 Round brush Ø 10 mm
12030374 37 Round brush Ø 13.5 mm

Maintenance
TCG 2020
Tool kit
12189924 1 Key wrench 3/8“, No. 33
07037935 4 Ring-open end spanner B 16 DIN 3113
12158153 5 Strip key
12141829 6 Pliers, valve aligning ring
12141853 7 Key wrench, spark plug key with holding
rubber
12214053 8 Adapter 3/8“ / 1/2“
07006798 9 T-handle A 20 DIN 3122
01100128 10 Extension B 20x200 DIN 3123

Maintenance
TCG 2020 5
Tool kit
12301538 Key wrench for pre-chamber spark plug

Maintenance
TCG 2020
Operating check log Keep an operating check log! A copy form is provided on the next page.
Please note down all irregularities (warnings, faults) and maintenance work in
this log. This means you always have a good idea when maintenance work is
due and can document all irregularities for our service personnel. If you have
connected a printer to your TEM system, print out a copy of the measured
values in the event of warnings or faults.
Further operation of the engine in the case of a warning or restarting

after a fault without eliminating the cause can lead to total engine
failure.

Maintenance
Gas Engines 5
Operating inspection log
Never acknowledge an alarm/malfunction message until you

have found out the cause.
Follow the advice given in the operating instructions.
System: Engine type: Page:

Date Module Event Signature /
Time Operating hours Measure Printer doc. no.
Tab. 1 Operating inspection log (form for copying)

Maintenance
Gas Engines

Troubleshooting
Gas Engines 6
6 Troubleshooting
This section serves to help operating personnel find and eliminate faults in Fault table with rem-
the engine. Maintenance and repair of the aggregate and elimination of minor edy instructions
faults require detailed knowledge of the function and the individual parts.
All engine, aggregate, sensor and external faults are displayed by the DEUTZ
TEM system and partly indicate the cause. The following fault explanations
may be additionally useful. Faults in engine operation which could occur as
well as their possible causes are listed.
Please note that some of the work assumes a higher level of qualification of
personnel and appropriate training and knowledge. Please contact your
DEUTZ Service if in doubt.

Troubleshooting
Gas Engines
Fault table
Fault (Please note: Fault messages from the TEM lead to general shutting down of the engine!)
Engine fails to start
Engine does not reach the prescribed performance or speed
Engine fires irregularly (compare combustion chamber temperature curve in the TEM)
Engine ”bangs” and runs irregularly.
Engine stops suddenly or is switched off by TEM after a fault
Engine gets too hot or TEM message ”lack of coolant”
Lube oil pressure too low / TEM ”Lube oil pressure too low” or ”Lube oil level too low”
Coolant in lube oil
Lube oil in coolant
Gas in coolant
Combustion chamber temperature at individual cylinders too low
TEM message Possible causes
STARTER SYSTEM
● Engine fails to start Batteries or compressed air system empty or defective
● Engine fails to start Starter defective
ELECTRICS
● Power supply aggregate-terminal box interrupted
IGNITION
● Engine fails to start Ignition system defective
● Ignition failed (cable broken)
● ● ● Ignition control unit defective
● ● Ignition cable defective
● ● ● Ignition coils defective
● Electrode spacing at spark plug too big
● ● Spark plugs soiled / defective
Pickup (camshaft or control shaft) has too big a
● ● ●
spacing / or is in range of limit
GAS-AIR-EXHAUST GAS
● Gas pressure Gas shutoff fittings closed
● Gas pressure Gas shutoff fittings not fully open
● Gas supply interrupted
Regulator on the gas mixer sticks / does not go into
●
start position
● Gas mixer stop Gas-air mixture defective (too lean / too rich)
● Gas pressure too little gas
● Maintenance indicator on the air filter - 50 mbar
● ● Gas pipe not bled
● Gas pressure regulator sticks
● Gas mixer stop lean Gas pressure too high
Exhaust gas backpressure too
● Exhaust gas pipes constricted by dirt
high *
* optional, if installed

Troubleshooting
Gas Engines 6
Remedy
Recharge or replace batteries / fill up air bottles or service compressed air system
Replace starter
Damaged pipes / Replace pipe connections
Check the ignition system

Check the ignition system
Replace the ignition control unit
Check / replace the ignition cable (cf. TEM: combustion chamber temperature history)
Replace the ignition coils (cf. TEM: combustion chamber temperature history)
Adjust spark plug (cf. TEM: combustion chamber temperature history)
Clean / replace spark plugs (cf. TEM: combustion chamber temperature history)
Check / adjust spacing
Open gas shutoff fittings

Check gas shutoff fittings / gas filter
Check gas pipes
Check easy action / check function of the stepper motor card
Check regulation of the gas mixer

Check gas pressure
Replace air filter
Bleed gas line
Check the gas pressure controller (gas flow pressure)
Check, correct gas pressure on the gas pressure regulator
Clean the exhaust gas pipes (exhaust gas heat exchanger)

Troubleshooting
Gas Engines
Coolant in lube oil
Lube oil in coolant
Gas in coolant
SPEED CONTROL
● Overspeed Speed controller defective / set incorrectly
● Overspeed Regulating linkage sluggish
● Overspeed Regulating linkage set incorrectly
COOLANT
● ● Low cooling water Too little cooling water
● ● Fault cooling water pump Coolant pump Pump shaft broken, bearing defective
Cooling channels in the engine sludged or blocked by
● ● Overtemperature cooling water
scale
● ● Low cooling water Coolant pump losing too much water
● Three-way valve secondary heating circuit defective
● Heat transmission primary to secondary poor
LUBE OIL
● Lube oil filter soiled Lube oil filter soiled
Lube oil level too low / overtemper-
● ● Lube oil level too low
ature lube oil
● Lube oil pressure too low Manifold to lube oil pump soiled
● Lube oil pressure too low Lube oil pump heavily worn
● Lube oil pressure too low Safety valve on the lube oil pump leaking
● Lube oil cooler leaking
● Lube oil pressure gauge defective
● Regulating valve defective

Troubleshooting
Gas Engines 6
Remedy
Check the regulator and have repaired immediately

Loosen the regulating linkage action
Check setting of regulating linkage and correct
Refill coolant, find and eliminate the cause of the coolant loss
Check the coolant pump (e.g. by TEM) and repair
Clean the coolant system
Change axial sealing rings of the coolant pump

Change the three-way valve of the secondary heating circuit
Clean sludged elements of the heat transformer
Renew or clean filter
Fill up lube oil
Clean manifold
Renew lube oil pump
Repair safety valve
Change lube oil cooler
Check and change if necessary
Change regulating valve

Troubleshooting
Gas Engines
Coolant in lube oil
Lube oil in coolant
Gas in coolant
GENERAL / OTHER
● Inlet and outlet valves seized
● no clearance between toggle lever and valve face
● Irregularities in the drive gear
● Inlet and outlet valves leaking
Bearing clearance of the crankshaft and con-rod bear-
●
ings too great (wear)
Oil carbon residue on spark plugs, pistons or outlet
●
valve
● Cylinder liner seal in crankcase leaking
● Spark plug sleeve leaking

Troubleshooting
Gas Engines 6
Remedy
Free valves
Set valve clearance
Check drive gear
Check, grind if necessary
Check bearing clearances, change bearings if necessary
check and clean (cf. TEM: combustion chamber temperature history)
Remove cylinder liner, insert new rubber rings, analyse lube oil sample
Reseal spark plug sleeve

Troubleshooting
Gas Engines

Conservation
7 Conservation
see Technical Circular TR 0199-99-2116. Conservation

Conservation

Technical particulars
TCG 2020 8
General engine data
Basic data
TCG 2020
Type designation
V12 V16 V20
Four-stroke
Lean mixture combustion
Work procedure
Mixture turbocharging
Mixture cooling
Cylinder arrangement V-engine, 90° V-angle
No. of cylinders 12 16 20
Bore mm 170 170 170
Stroke mm 195 195 195
Capacity per cylinder dm3 4.426 4.426 4.426
3
Total displacement dm 53.1 70.8 88.5
Compression ratio 13.5 : 1 13.5 : 1 13.5 : 1
DEUTZ TEM system, electronic controller with servo
Speed governing system
motor on mixture throttle valve or rotary disk valve
Power regulation DEUTZ TEM system
DEUTZ TEM system on servo motor on the mixer
Gas mixture regulation among other things according to the combustion
chamber temperatures
Spark plugs Pre-chamber spark plugs
Control data
V12 V16 V20

Valve clearance with cold engine
Inlet mm 0.3 0.3 0.3
Outlet mm 0.7 0.7 0.7
Ignition
sequence
V12 A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6
V16 A1 B2 A6 B5 A8 B7 A3 A7 B6 A4 B8 A2 B3 A5 B1 B4
V20 A1 B7 A2 B5 A4 B3 A6 B1 A8 B2 A10 B4 A9 B6 A7 B8 A5 B10 A3 B9

TCG 2020
Dimensions
Aggregate V12 V16 V20

Length mm 4,700 5,700 6,300
Width mm 1,750 1,750 1,750
Height mm 2,500 2,500 2,550
Weights
Weight 1)
Name
V12 V16 V20
Empty weight engine kg 4,200 5,800 7,800
Empty weight aggregate kg 10,500 13,500 17,580
Cylinder head, complete kg 54 54 54
Cylinder liner kg 16 16 16
Piston, complete kg 10 10 10
Piston bolt kg 3 3 3
Con-rod, complete kg 15 15 15
Crankshaft with counterweights kg 511 2) 452 611
Main bearing cover kg 16 16 16
Camshaft kg 19 25 35
Oil pan kg 90 100 340
Flywheel kg 316 316 315
Vibration damper kg – – 42
Mixture cooler without cover kg 75 75 113
Lube oil pump, complete kg 37 42 42
1) all data are approximate values
2) Larger number of counterweights

TCG 2020 8
Operating data
Filling levels
V12 V16 V20

1)
Total lube oil content in engine dm3 630 865 1,080
3
Coolant content of engine dm 111 151 210
Coolant content mixture cooler dm3 28 28 52
1) incl. additional tank in the base frame
Temperatures
V12 V16 V20

Coolant temperature engine
Inlet / outlet (max.) °C 80 / 92 80 / 92 80 / 92
for glycol (max.) °C 80 / 92 80 / 92 80 / 92
Suction intake air temperature
Minimum °C 20 20 20
Design project-related
Pressures
V12 V16 V20

Gas pressure fluctuations
in % of the setting value < 10 < 10 < 10
at fluctuation frequency 1 /h < 10 < 10 < 10
Max. exhaust gas backpressure mbar 50 50 50
Emission data
V12 V16 V20

Noise
Airborne noise 1 m away from the
dB(A) 103 108 107
engine
Exhaust gas unsilenced dB(A) 119 120 124

TCG 2020
Engine peripheral data
Start system
V12 V16 V20

Electric starter with 24 V DC (direct
current)
Power consumption kW 9 15 15 or 18
Starter battery 12 V, necessary bat-
Ah 4 x 143 4 x 215 4 or 6 x 215
tery capacity
Compressed air starter
Air pressure min. bar – – 16
Air pressure max. bar – – 30
3
Contents of air bottle dm – – 2,000
Speed controller
Designation actuator StG 30 - 01 StG 2080 - 01

Angle of rotation on the controller
° 42 36
output shaft
Max. torque on the regulator output
Nm (approx.) 28 11
shaft (direction stop)
Stop torque in the current limiting Nm (approx.) 14 5.5
Throughput time 0-100 % without
ms (approx.) 170 60
load
Current consumption of the complete
controller
in the steady condition A (approx.) 1 1
at load change A (approx.) 3-4 3-4
max. current A (approx.) 4.5 4.5
limited current A (approx.) 2.5 2.5
Storage temperature °C -55 to +110 -55 to +110
Ambient temperature in operation °C -25 to +90 -25 to +90
Ambient temperature special version °C -40 to +90 -40 to +90
Humidity % up to 100 up to 100
IP 65
Degree of protection IP 44
IP 00 / IP 65
Weight kg 12.3 6.6

TCG 2020 8
RI flow diagrams
CHP system (example)
4
8
90˚C
4
GS+
880
G2 M
G1/2 TIC
(A+B) 291
TZA++ G1/2
276
TI TSA+
288 277
TISA+
287 LZA-
G1/2 280
KAT ASD
(A+B)
AWT
PZA+
279
PSA+ GS+ DV
G2 157 8010
G1/2 LSA- GS- G1/2
1
(A+B) 123 8011
2 PDSA-
PDZA-
281
126
TISA+ M KWT
203 DV PI
GS-
159 EVH
M 545˚C 92˚C 82˚C

TICA+
207
TSA+ TISA+
147 206
G1/2
GIS+
197
TI
TISA+- LICSA 290
461-68/471-78 234
PI
PISA+
145 70˚C
9
PSA-
124 SICSA+ TISA+
200 208
TISA+ PISA-
209-11 196 TK
2 PI
PI M
TC LSA-
SC 8680 8682
319 M
NK
TICSA+ M
201 GS+ 7
3 G1/2
890
M
Erdgas
TI
289
7
1a
40˚C
1 4
6
G1/2 G1/2
PDSA-
309
M 5 6
GS+
M
PI
TC
TK 8650
LSA- ' 83571-1

308
Figure 8-1 CHP system (example)
1a Natural gas 6 Return heating water

2 Air 7 Return rise
3 Gas-air mixture 8 Lead heating water
4 Exhaust gas 9 Emergency cooler (option)
5 Lube oil supply and drain 10 Exhaust gas bypass flap

TCG 2020
System without heat utilisation (example)
9 5
TK TC
8050
GS+
867
G2
M
G1/2 DV
(A+B)
DV
ASD M
TISA+ PI
287
PSA+
157
1
2 G2
G1/2 LSA+
(A+B) 123
TISA+ PDSA-
203 126
GS- EVH
159
M 545 C 89 C 79 C 5
TICA+
207
TISA+
206
GIS+
197
TISA+- LICSA
461-68/471-78 234
PISA+
145
PSA-
124 SICSA+ TISA+
200 208
TISA+ PISA-
209-11 196
2
PI
SC
319 M
TICSA+
201
3
Erdgas
1a
40 C
1
6
G1/2 G1/2
PDSA-
309
M
GS+
5
885
M
PI
TC
TK 8650
LSA-
308 ' 82982-1
Figure 8-2 System without heat utilisation (example)
1a Natural gas 4 Exhaust gas

2 Air 5 Lube oil supply and drain
3 Gas-air mixture 9 Emergency cooler (option)

TCG 2020 8
Lube oil supply
LICSA
234
PISA+
145
TISA+
208
PISA-
196
M 1 4
2 5
12
LS+ LSA+ LSA++

8530 9511 M 9520
LS- LA- LSA+
8531 9510 9521
3 1 2 ' 83572-1
Figure 8-3 Lube oil supply
1 Fresh oil tank 4 DEUTZ standard aggregate

2 Used oil tank 5 System on site
3 Day tank 6 Aggregate 2-n

TCG 2020
Legend
Shutoff valve
Ballcock
Three-way valve
Throttle valve
Check valve
Air/gas filter
Liquid filter
Safety valve
Safety corner valve
Compensator
Extension vessel
Engine drive
Electromagnetic drive
Circulation pump
Diaphragm drive
Turbocharger
Local display
Alternator
Chimney
Catalyst
Gas-Otto engine
Silencer
Pre-heater
Bleed valve
Gas/air carburettor
Heat exchanger
Table cooler
Flame protection

TCG 2020 8
Tightening specifications
Scheduled maintenance work up to E40
Code Screw connection Type and dimension Strength Tightening value Important notes
no.
01/6 Hatch cover on the crank- M8 x 20 8.8 25 Nm Only use gasket once
case
11/1 Lock nut of the setting Hexagon nut M10 x 1 41Cr4 40 Nm

screw on the valve bridge K+V
11/3 Lock nut of the setting Hexagon nut M12 x 1.5 22H 45 + 5 Nm
screw on the toggle lever
11/5 Spark plug Spark plug M18 x 1.5 52 Nm Use new sealing rings
48/1 Knocking sensor M8 x 30 8.8 20 ± 5 Nm

TCG 2020

Job Cards
TCG 2020 9
9 Job Cards
You will find there are various symbols used on the Job Cards, in order to Explanation of sym-
designate information not relating directly to the actual work sequence bols
involved.
Tools
- The tools normally required are listed against this symbol.
Equipment
- Things like pressure gauges, lube oil and hydraulic oil
Spare parts
- Seals, locking parts, etc.
Cross references
- Documents, reports or Job Cards to which reference is made in the Job
Card concerned.
© 0903 300201011-en-00EAL.fm Chapter 9 - Page 1

Job Cards
TCG 2020
Overviews
Arranged alphabetically
Jobs Job Card

Auxiliary aggregate test by means of TEM system (TEM Evolution) B 0-1-6
Checking and setting inlet and outlet valve clearance B 1-1-1
Checking corrosion protection agent or antifreeze in coolant B 9-1-1
Checking easy action of the speed controller B 5-4-2
Checking the gas pressure of the gas regulator line B 7-20-1
Cleaning the engine B 0-3-6
Cleaning the gas filter / renewing the filter cartridge B 7-21-1
Draining water from and filling the air bottle (starter air tank) B 10-7-1
Lube oil change B 8-1-2
Maintain crankcase bleed valve B 3-1-9
Maintaining the battery B 13-4-1
Renewing lube oil filter cartridge B 8-10-4
Renewing the suction air intake filter B 6-3-6
Safety regulations for handling components made of elastomers containing fluoride (e.g.
B 0-0-3
Viton)
Spark plugs, spark plug cables, checking, cleaning the spark plug shaft B 13-5-4
Specifications for cutting, grinding, soldering and welding work B 0-0-4
Taking lube oilsamples B 8-1-1
Visual inspection of the system B 0-1-5
Chapter 9 - Page 2 300201011-en-00EAL.fm © 0903

Job Cards
TCG 2020 9
Arranged by Job Card Numbers
Job Card Jobs

Safety regulations for handling components made of elastomers containing fluoride (e.g.
B 0-0-3
Viton)
B 0-0-4 Specifications for cutting, grinding, soldering and welding work
B 0-1-5 Visual inspection of the system
B 0-1-6 Auxiliary aggregate test by means of TEM system (TEM Evolution)
B 0-3-6 Cleaning the engine
B 1-1-1 Checking and setting inlet and outlet valve clearance
B 3-1-9 Maintain crankcase bleed valve
B 5-4-2 Checking easy action of the speed controller
B 6-3-6 Renewing the suction air intake filter
B 7-20-1 Checking the gas pressure of the gas regulator line
B 7-21-1 Cleaning the gas filter / renewing the filter cartridge
B 8-1-1 Taking lube oilsamples
B 8-1-2 Lube oil change
B 8-10-4 Renewing lube oil filter cartridge
B 9-1-1 Checking corrosion protection agent or antifreeze in coolant
B 10-7-1 Draining water from and filling the air bottle (starter air tank)
B 13-4-1 Maintaining the battery
B 13-5-4 Spark plugs, spark plug cables, checking, cleaning the spark plug shaft
© 0903 300201011-en-00EAL.fm Chapter 9 - Page 3

Job Cards
TCG 2020
Chapter 9 - Page 4 300201011-en-00EAL.fm © 0903

Medium-sized and large engines B 0-0-3
B 0-0-3
Safety regulations for handling components made of elastomers
containing fluoride (e.g. Viton)
Crass references
- Chapter 1, Rules for disposal
Gaskets, round sealing rings and moulded parts are manufactured partly from
elastomers containing fluoride (FPM) to withstand high thermal stress.
At unscheduled temperatures above 315 °C (caused for example by an
engine fire) the material decomposes and forms caustic acids. The residue is
tacky and black in appearance.
Touching the residue with your hands, even after cooling down, may be dam-
aging to health.
Proceed as follows if high temperatures have caused damage to gaskets or

round sealing rings:
● Check all gaskets which have suffered from the heat visually.
● Wear gloves (neoprene).
● Remove all residue material and dispose of it, see also Chapter 1, Rules
for disposal.
● Destroy clothing which has been contaminated by residue of the gaskets.
© 0303 300200014-en-00.fm Page 1

B 0-0-3 Medium-sized and large engines
Page 2 300200014-en-00.fm © 0303

B 0-0-4
Specifications for cutting, grinding, soldering and welding work
Cross references
- Accident prevention regulations
The contractor of cutting, grinding, soldering and welding work must alert the
persons enlisted to do the work to the dangers and ensure that the points
listed below are observed and executed.
Persons entrusted with cutting, grinding, soldering and welding work must be
familiar with and observe the valid regulations and specifications, especially
the rules for accident prevention of the respective national legislations.
The following points must be observed additionally to the specified regula-
tions and specifications.
Electrics / electron-
ics
The following points apply for welding work and work where electrical and
electronic components may be at risk (e.g. due to high temperatures or elec-
trical short-circuits).
● Disconnect the battery ground and remove and stow away the battery
safely if necessary.
● Pull out the plugs of electrical and electronic components (e.g. TEM
switch cabinet, MKS junction box, EMR 2-control unit, ignition system,
sensors).
● Sensitive parts in the immediate vicinity of the welding point (e.g. control
units, ignition system, sensors, cables) must be removed after unplugging.
● Always connect the ground terminal of the welding gear in the immediate
vicinity of the welding point to avoid vagrant currents. Pay attention to per-
fect ground connection. The paint may have to be removed in this area.
Failure to do so can lead to serious damage to the engine electronics.
© 0803 300201035-en-00.fm Page 1

Sparks / danger of ● Keep all inflammable materials away from the danger area.
fire ● Remove inflammable objects (e.g. cables, compensators) or cover with
non-conductive, non-flammable material.
● Cover sensitive surfaces (e.g. air filter) with non-conductive and non-flam-
mable material.
● Seal openings in the engine.
● Seal off and cover openings to other work areas.
● Keep a sufficient number of fire extinguishers close by.
Danger of explosion ● Shut off gas pipes and fuel pipes.

● Work which could lead to a strong development of heat on gas or fuel
pipes and vessels may only be carried out when these have been com-
pletely emptied and bled or flushed.
Health hazard ● Air well, suck off fumes and dust particles.
● Cordon off the working area during arc welding to protect bystanders
against the harmful effects of optical radiation.
Page 2 300201035-en-00.fm © 0803

Gas Engines B 0-1-5
B 0-1-5
Visual inspection of the system
Tools
- Standard tools
Cross references
- B 7-20-1, Checking the gas pressure of the gas regulator line
- B 10-7-1, Drain water from and fill air bottle (starter air tank)
or
B 13-4-1, service battery
● Check display data on the switching system Dailycheck

- Power
- Current
- Operating hours
- Start counter
● Inspection of the system:
- Supply and return coolant temperature
- Exhaust gas backpressure
- Air filter underpressure
● Check the whole engine for leaks
● Check lube oil circuit
- Lube oil level and lube oil pressure
- External lube oil tightness
- Turn the gap filter on the rotary handle approx. 1 1/2 turns clockwise (if
available)
● Check coolant circuits:
- Tightness of hose clips, pipe unions, flanges and compensators
- Marks on plug shafts
- Coolant pressure
- Tighten flange connections and hose clips is necessary
● Check gas pressure of the gas control line
see Job Card B 7-20-1, Checking the gas pressure of the gas regulator
line
● Check the temperatures
- Coolant inlet in engine
- Coolant outlet from engine
- Suction intake air temperature
- Lube oil temperature
- Exhaust temperature after every cylinder
© 0903 300201021-en-01.fm Page 1

B 0-1-5 Gas Engines
● Check the maintenance instrument and pressure gauge

● Check the lambda valve position of the throttle valve setting
● Check load and cos phi
● Check the signal lamps
● Check noise and smooth running
● Check and log operating values and liquid levels (with TEM)
● Drain water from air bottle (if available),
see Job Card B 10-7-1, Drain water from and fill air bottle (starter air tank)
Once a week addi- ● Check the battery (if available),

tionally see Job Card B 13-4-1, service battery
● Check water drain for leaks.
● Check regulating linkage of the throttle valve for easy action and auto-
matic return.
● Check exhaust gas system for leaks, by:
Danger of burst!
- Checking exhaust manifold, turbocharger, silencer and adapters for

tight fit and leaks.
- Tightening clamps.
- In systems with exhaust heat exchangers, check these for water-tight-
ness.
- Check the turbocharger, see manufacturer’s operating manual.
Page 2 300201021-en-01.fm © 0903

Gas Engines B 0-1-6
B 0-1-6
Auxiliary aggregate test by means of TEM system (TEM Evolution)
Cross references
- Operating Instructions DEUTZ TEM System
The auxiliary aggregate test is only possible when the fast stop on the TEM-
EVO switch cabinet and the fast stop without run-on are not actuated.
The auxiliary aggregate test can only be performed with the engine at stand-
still and the ”manual mode” setting in the DEUTZ TEM system.
Only auxiliary aggregates are offered for testing which have had their param-
eters released.
The number of auxiliary aggregates offered for testing depends on the engine
type and the equipment of the system.
If the individual auxiliary aggregates are not operated in touch mode they
must be switched off again after the test.
● Switch on test mode in the mask ”Auxiliary aggregate control 1” (Figure 1). Conducting the test
● Conduct auxiliary aggregate test as described below.
● Switch off test mode
If errors occur in the auxiliary aggregate tests (displayed by a red flash of

lightning) or there is great deviation from the specified values, please contact
the DEUTZ Service.
Figure 1 Mask ”Auxiliary aggregate control 1” (example)
© 0403 300201023-en-00.fm Page 1

B 0-1-6 Gas Engines
Ignition ● Select and switch on the ignition The ignition runs a self-test and must
confirm the status as OK with a green checkmark after approx. 10 s.
● Switch on the ignition.
Speed controller ● Select and switch on the speed controller.
The speed controller runs a calibration sequence. To do this it runs from 0 %

to 100 % and back.
● Check that 100 % are actually reached on the actuator.

● Switch off the speed controller, switch off the test mode.
● Go to the ”Speed controller” (Figure 2) mask.
Figure 2 ”Speed controller” mask (example)
● Check calibration voltage for 0 % and 100 %. The value for 0 % must be
greater than 1 V, that for 100 % less than 4 V.
● Switch on test mode and set several values for the nominal position one
after another in the Manual mode window (20 %, 50 %, 75 %, 90 % and
100 %).
● Read the actual position directly from the actuator and compare with the
feedback in the mask.
● Switch off test mode.
● Go to the ”Auxiliary aggregate control 1” mask (Figure 1) again for other
auxiliary aggregates.
Pre-lube pump ● Switch on pre-lube pump.
● Check the direction of rotation and watch the oil pressure

(approx. 1…3 bar).
● Switch off pre-lube pump.
Page 2 300201023-en-00.fm © 0403

Gas Engines B 0-1-6
Starter
Switch on the pre-lube pump before actuating the starter.
With compressed air starter:

Set the pre-pressure and throttle the starter before actuating the starter.
● Key the starter briefly, ignition is off.

● Check the function and speed, observe the oil pressure.
Pre-heater
Bleed the pre-heater before starting the test or open all slides.
● Switch on the pre-heater and check the function.

● Switch off the pre-heater.
● Switch on the engine cooling circuit pump, observe the pressure monitor. Pump engine cool-
ing circuit
Run the pump for at least 30 s due to delayed release of the fault message.
● Check in the mask whether the pressure monitor reports the differential
pressure to the TEM system.
● Switch off the engine cooling circuit pump.
● Switch on the heating circuit pump, check the direction of rotation, Heating circuit pump
observe the pressure monitor.
● Switch off the heating circuit pump.
● Switch on the mixture cooling circuit pump, check the direction of rotation, Mixture cooling cir-
observe the pressure monitor. cuit pump
If a mixture cooler-table cooler exists, the table cooler fan must be switched
on with the pump.
● Switch off the pump mixture cooling circuit, switch off the table cooler fan if
available.
© 0403 300201023-en-00.fm Page 3

B 0-1-6 Gas Engines
Emergency cooling ● Switch on the emergency cooling circuit pump, check the direction of rota-
circuit pump tion, observe the pressure monitor.
If an emergency cooler-table cooler exists, the table cooler fan must be

switched on with the pump.
● Switch off the emergency cooling circuit, switch off the table cooler fan if
available.
Crankcase fan
Only for TCG 2032.
● Switch on crankcase fan, check direction of rotation and function.

● Switch off crankcase fan.
Filling valves lube oil ● Key lube oil filling valves briefly, check function.
Lube oil bleed valve ● Key lube oil bleed valve briefly, check function.
Check gas mixer
The following work steps are identical for gas mixer A and gas mixer B (only
in the TCG 2032).
● Switch on the rich setting. If the gas mixer is at the lean stop (indicated by
a blue minus sign) the lean stop must disappear after about 50 steps, the
number of steps must increase to 2300.
● Check whether the gas mixer really does adjust in rich direction (inspec-
tion opening of the gas mixer on the coupling of the stepper motor).
● Switch off the rich setting.
● Switch on the lean setting. The number of steps must be reduced until the
lean stop is reached (position in counter in the mask: minus Start posi-
tion).
● Check whether the gas mixer really does adjust in lean direction and the
lean stop is reached (inspection opening of the gas mixer on the coupling
of the stepper motor).
● Switch off the lean setting.
● Switch on move to start position. The gas mixer must adjust the parame-
terised number of steps rich until it has reached the start position (position
0 steps).
● Switch on move to stop position. The gas mixer must adjust in lean direc-
tion until it has reached the lean stop.
● Switch on move to start position. The stepper motor card then calibrates
the momentary position to minus start position and then moves the param-
eterised number of steps to the start position.
Page 4 300201023-en-00.fm © 0403

Gas Engines B 0-1-6
Gas leak inspection
The procedure for gas leak inspection A and B is identical (two-gas opera-
tion).
● Switch on gas leak inspection. The condition is confirmed after about 10 to

30 s by display of a green checkmark.
If the confirmation appears immediately, the message is faulty because the

leak check takes a certain time. If there is no confirmation, a red flash of light-
ning appears.
Gas valves
The procedure for gas valves A and B is identical (two-gas operation).
● Key gas valve 1 and gas valve 2 in succession, watch the function.
Check gas pressure

regulator B
In two-gas operation.
● Switch on increase gas pressure B. If the gas pressure regulator is at

minus stop (displayed by a blue minus sign), the minus stop must disap-
pear after about 50 steps. The gas pressure regulator then increases the
gas pressure until it reaches the plus stop (lower limit switch) (indicated by
a blue plus sign).
● Check whether the gas pressure regulator is actually adjusted in direction
of higher pressure.
● Switch off increase gas pressure B.
● Switch on reduce gas pressure B. The number of steps must be reduced
until the minus stop is reached.
● Check whether the gas pressure regulator is actually adjusted in minus
direction and the minus stop (upper limit switch) is reached.
● Switch off reduce gas pressure B.
● Start pos. Switch on gas pressure regulator B. The gas pressure regulator
must adjust the parameterised number of steps plus until it has reached
the start position (position 0 steps).
● Stop pos. Switch on gas pressure regulator B. The gas pressure regulator
must adjust in minus direction until it has reached the minus stop.
● Start pos. Switch on gas pressure regulator B. The stepper motor card
then calibrates the momentary position to minus start position and then
moves the parameterised number of steps to the start position.
© 0403 300201023-en-00.fm Page 5

B 0-1-6 Gas Engines
Control valves
The procedure for testing the control valves cooling/heating water, emer-
gency cooler and mixture cooler is identical.
● Move control valves (set colder or hotter).

● Check the positioning direction and stops. The cold stop is reported with
plus (=open), the hot stop with minus (=closed).
Exhaust gas bypass ● Open exhaust gas bypass valve, check function.
valve
If there is a feedback, the stop must be reported back to the TEM system.
Filling cooling water

day tank
Only for TCG 2032.
● Switch on filling cooling water DT.

● Check whether the solenoid valve opens and closes.
● Switch off filling cooling water DT.
Leak test cooling wa-

ter day tank
Only for TCG 2032.
● Switch on leak test cooling water DT. A green checkmark must appear
after performing the leak test.
● Switch off leak test cooling water DT.
Anti-knock regula- ● Switch on anti-knock regulation. The condition must be confirmed OK by a

tion green checkmark.
● Switch off anti-knock regulation.
Mains starter ● Switch on mains starter.

● Check whether the mains starter switches on.
● Switch off the mains starter.
Page 6 300201023-en-00.fm © 0403

B 0-3-6
Cleaning the engine
Auxiliary equipment
- Cleaning agents
- Compressed air
- Stoppers
- Covers
Cross references
- Chapter 4, Auxiliary materials
Carry out this work only when the engine has been shut down.
Wear protective goggles and gloves.

Care for sufficient ventilation!
Exhaust vapours,do not inhale!
● Switch off the engine and wait for it to cool down. See Chapter 4, Auxiliary Preparation
materials for selection of cleaning agents.
● Disconnect the battery.
● Remove protective covers.
● Remove heat shields from the exhaust pipes.
● Cover the air filter water-tight. If the air filters are removed, seal the inlets
water-tight.
● Cover electric components such as three-phase current generators and
starter.
If the engine is partly disassembled, seal open channels and lines.
© 0303 300200017-en-00.fm Page 1

Cleaning
When working with high-pressure cleaning systems, sensitive parts such as

filters, rubber bushes, sealing rings and cables could be damaged. These
should therefore never be cleaned with high-pressure cleaning systems.
Joints and bearings which are coated with a lubricant or filled with grease
should not be cleaned with high-pressure cleaning systems.
● Blow out all places which are difficult to access with compressed air.
Cleaning with cold ● Spray engine with cold cleaner. Exposure time according to manufacturer
cleaner instructions.
● Clean protective covers and heat shields separately.
● Spray or wash down engine with a powerful water jet.
● Repeat procedure if necessary.
Dry the exhaust pipe heat shields before replacing. Otherwise there is a
danger of fires being causes by gas build-up and deflagration inside the
housing.
Finishing work ● Blow out spaces where water has accumulated with compressed air.
● Remove the covers from the sensitive batteries.
● Dry the exhaust pipe heat shields and remove.
● Fit protective covers after cleaning separately.
● Install filters if they were removed.
● Connect the battery.
Page 2 300200017-en-00.fm © 0303

TCG 2020 B 1-1-1
B 1-1-1
Checking and setting inlet and outlet valve clearance
Tools
- Standard tools
- Feeler gauges
- Spark plug wrench
Spare parts
- Sealing rings
Inlet and outlet valves can definitely only close tightly when a certain clear-
ance is set in the valve drive between the camshaft and the valve shaft.
Valves which do not close tight can lead to burning of the valve seat and the
valve head. On the other hand too much clearance causes considerable
wear. Exact setting and observation of the valve clearance therefore prolongs
the life and increases the operational reliability of the engine.
Check valve clear-

ance
Only check and set the valve clearance on a cold engine.

Observe Test and setting order
● Remove spark plugs.

● Remove cylinder head hoods.
Figure 1 Check valve clearance
© 1203 300201024-en-01.fm Page 1

B 1-1-1 TCG 2020
Example: TCG 2020 V12

● Turn the engine in the direction of rotation until the valves are overlapping on cylinder A6. Cylinder A1 is
in the upper dead point (ignition UD).
● Check the valve clearance of cylinder A1 with a feeler gauge. The feeler gauge must slip between the
toggle lever 4 and valve bridge 2 with low resistance.
V12 V16 V20

Valve clearance with cold engine
Inlet mm 0.3 0.3 0.3
Outlet mm 0.7 0.7 0.7
Tab. 1 Valve clearance, values
The valve clearance must be reset in case of deviations.

If a large valve clearance was determined this is due to wear in the valve drive. Depending on the difference
between the actual value and the nominal value, the valve clearance curve of the cylinder concerned must
be monitored and the cause examined immediately.
The actual values must be noted in the table ”Valve clearance actual values table”. A copy of the table is
enclosed.
Set valve clearance
Level valve bridges

● Lift the valve bridge 2 slightly and push a 0.05 mm thick feeler gauge under the side opposite the setting
screw 3.
● Adjust the setting screw 3 so that the feeler gauge can be pulled to and fro with little resistance.
The lock nut must be mounted so that the round collar is on the valve bridge, the hexagon must face
upwards.
● Tighten the lock nut slightly.
● Lift the valve bridge 2 slightly and push a 0.05 mm thick feeler gauge under the setting screw 3.
● Press down the opposite side, the feeler gauge must move back and forward easily.
- The clearance must be equal on both sides of the valve bridge, otherwise adjust the setting screw 3.
- When the valve bridge is levelled, the tolerances on the components may lead to the 0.05 mm thick
feeler gauge moving backward and forward too easily. In this case levelling must be done with a
0.10 mm feeler gauge.
- When set correctly the feeler gauge can be moved with equally low resistance on both sides of the
valve bridge.
● After levelling the valve bridges, tighten the lock nuts with torque 40 Nm.
Page 2 300201024-en-01.fm © 1203

TCG 2020 B 1-1-1
Setting the clearance at the toggle levers
The prescribed valve clearance at the setting screws of the toggle levers is
only set after both valve bridges have been levelled.
● To set the valve clearance, loosen the lock nut of setting screw 1 and turn the screw until the feeler gauge
with the thickness of the specified valve clearance (see Table 1) can be inserted between the toggle lever
4 and the valve bridge with low resistance.
● Tighten the lock nut, check the tightening torque 45 + 5 Nm and valve clearance again.
● Set the other valves in the same way.
● Fit the cylinder head hoods and tighten the screws. Make sure the gasket fits properly.
● Install spark plugs with new sealing rings, tightening torque 52 Nm.
Test and setting order

Bring valves to overlap one after another according to the ignition order.
TCG 2020 V12
Start with cylinder A6.
Ignition dead
A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6
point
Overlapping A6 B5 A2 B3 A4 B6 A1 B2 A5 B4 A3 B1
TCG 2020 V16

Start with cylinder B6.
Ignition dead
A1 B2 A6 B5 A8 B7 A3 A7 B6 A4 B8 A2 B3 A5 B1 B4
point
Overlapping B6 A4 B8 A2 B3 A5 B1 B4 A1 B2 A6 B5 A8 B7 A3 A7
TCG 2020 V20

Start with cylinder A10.
Ignition dead
A1 B7 A2 B5 A4 B3 A6 B1 A8 B2 A10 B4 A9 B6 A7 B8 A5 B10 A3 B9
point
Overlapping A10 B4 A9 B6 A7 B8 A5 B10 A3 B9 A1 B7 A2 B5 A4 B3 A6 B1 A8 B2
© 1203 300201024-en-01.fm Page 3

B 1-1-1 TCG 2020
Valve clearance actual values table
Cylinder A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Valve
I A I A I A I A I A I A I A I A I A I A
OH Date
Tab. 2 Valve clearance actual values table of cylinder series A
Cylinder B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
Valve
I A I A I A I A I A I A I A I A I A I A
OH Date
Tab. 3 Valve clearance actual values table of cylinder series B
The total adjustment time can be determined by the actual value data. This can tell you something about the
previous wear in the valve drive.
Page 4 300201024-en-01.fm © 1203

TCG 2020 B 3-1-9
B 3-1-9
Maintain crankcase bleed valve
Tools
- Standard tools
- Special tools available from
Fa. Umwelt Technik 99 AG, Sunnehof, CH-8493 Saland, Switzerland
Extraction tool, order no. 909-190201
Tightening tool, order no. 909-190200
- Vibration measuring instrument for imbalance check
Spare parts
- Disposable filter
- Basic filter
- Round blow out
- Cover gasket
- Engine gasket
The crankcase bleed valve is equipped with an oil mist trap. Maintenance Maintain crankcase
takes place according to the instructions in the maintenance schedule. bleed valve
Preparation
Disconnect the oil mist trap from the power supply before beginning
work. Only work with the drum at a standstill.
● Loosen the clamping ring 12.

● Remove the housing cover 11 and the gasket 10.
● Check the disposable filter 9 for soiling and renew if necessary. Visual inspection
● Check the round blow out 4 for soiling and renew if necessary.
● Check the gasket 10 for damage and renew if necessary.
● Mark the interface of the disposable filter 9 in the drum 6 (danger of imbal- Renew the disposable fil-
ance). ter
● Remove the disposable filter 9 and check the basic filter 8 for soiling.
In case of heavy contamination the basic filter must also be renewed, see
removing and installing oil mist trap.
● Insert new disposable filter, note marking (danger of imbalance!).
© 0903 300201117-en-00.fm Page 1

B 3-1-9 TCG 2020
Removing and installing

the oil mist trap
Individual parts of the oil mist trap must be renewed at the times specified in
the maintenance schedule or when heavily soiled. The oil mist trap has to be
removed to do this.
● Mark interfaces of the disposable filter 9 and basic filter 8 in the drum 6
and remove the filter.
● Remove fastening parts and turbo wheel 7.
● Pull the drum 6 from the engine shaft with the extraction device 19
(Figure 2).
● Loosen the four fastening screws 16 of the electric motor 1. Do not drop
the electric motor on the floor.
● Check the engine gasket 2 for damage and renew if necessary.
● Remove wire grille 5 and round blow out 4 from the housing 3.
● Renew round blow out.
From Deutz maintenance and service schedule E60 onwards the electric
motor 1 must be overhauled and the engine gasket renewed additionally.
● Mount the wire grille 5, round blow out 4, housing bottom and engine gas-
ket 2 on the electric motor 1 with the four fastening screws 16, see assem-
bly drawing (Figure 1).
● Insert new basic and disposable filter in drum 6 and pay attention to
marks.
● Check imbalance of drum.
After changing the basic filter, it is essential to check the imbalance of the
drum, see Imbalance check.
● Place the drum 6 carefully on the engine shaft and pull slowly to the
engine stop with the tightening tool 20 (Figure 2).
● Screw turbo wheel 7 in the engine shaft with fastening parts.
● Mount the housing cover 11 with a new gasket 10 on the housing and fas-
ten with clamping ring 12.
Page 2 300201117-en-00.fm © 0903

TCG 2020 B 3-1-9
Figure 1 Oil mist trap (individual parts)
1 Electric motor 10 Cover gasket

2 Engine gasket 11 Housing cover
3 Housing 12 Clamping ring
4 Round blow out 13 Fastening screw with discs for fastening the
5 Wire grille drum
6 Drum 14 Centring disc
7 Turbo wheel 15 Plate spring
8 Basic filter 16 Fastening screws with discs for electric motor
9 Disposable filter
© 0903 300201117-en-00.fm Page 3

B 3-1-9 TCG 2020
Figure 2 Extraction and tightening device
19 Extraction tool
20 Tightening tool
Imbalance check
A measuring instrument made by Schenk, Darmstadt is suitable for measur-

ing vibrations.
Limit values
corresponds to
Hz rpm Vibration speed
vibration amplitude
50 2,810 < 3.2 mm/s < 10 µm
60 3,360 < 4.0 mm/s < 10 µm
Rebalancing is necessary on reaching the following values!
50 2,810 > 7.0 mm/s > 22 µm
60 3,360 > 8.0 mm/s > 22 µm
Tab. 1 Limit values for imbalance check
Page 4 300201117-en-00.fm © 0903

TCG 2020 B 5-4-2
B 5-4-2
Checking easy action of the speed controller
Tools
- Standard tools
Equipment
- Lithium soap grease
TCG 2020 V12 and V16 Checking easy ac-

● Press in lever 1 in the direction of the arrow to the stop, they may be no tion of the speed
tangible resistance when pressing in. controller
● If the resistance is tangible, coat the joints 3 with lithium soap grease and
repeat the check.
● If the resistance is still tangible, the actuator 2 or the throttle valve is
defective. Please contact your DEUTZ Service if this is the case.
Figure 1 Speed controllers (TCG 2020 V12 and V16)
© 0903 300201025-en-00.fm Page 1

B 5-4-2 TCG 2020
TCG 2020 V20
The TCG 2020 V20 is equipped with two actuators the output shafts of which
act directly on the rotary disk valves.
● Turn output shafts 5 of the actuators 4 by hand to the stops, there may be
no tangible resistance.
● If there is a tangible resistance, the actuator or the rotary disk valve is
defective. Please contact your DEUTZ Service if this is the case.
Figure 2 Speed controllers (TCG 2020 V20)
Page 2 300201025-en-00.fm © 0903

TCG 2020 B 6-3-6
B 6-3-6
Renewing the suction air intake filter
Tools
- Standard tools
Equipment
- Cleaning agent
- Cleaning cloth
Spare parts
- Filter cartridges
Soiled filter cartridges are changed at the appropriate maintenance intervals

and not cleaned. In the case of excessive soiling of the cartridges (e.g. oper-
ation in a heavily dusty environment) the vacuum pressure in the suction air
intake line reaches a value at which the optical indicator on the air filter
responds before the maintenance deadline runs out. To obtain better ventila-
tion conditions it is necessary to change the cartridges immediately in this
case.
© 0603 300201027-en-00.fm Page 1

B 6-3-6 TCG 2020
Renewing the suc- ● Loosen wing nuts 1 and remove the cover from the air filter housing.
tion air intake filter,
V12 and V16
Figure 1 Air filter housing lock (TCG 2020 V12 / V16)
● Unscrew the air filter fastening screw 2 and remove the air filter.
Figure 2 Air filter fastening
● Cleaning the air filter housing.

● Insert and fasten the new air filter in the air filter housing.
● Place the cover on the air filter housing and tighten the wing nuts 1.
Page 2 300201027-en-00.fm © 0603

TCG 2020 B 6-3-6
● Loosen the snap locks 3 of the air filter cover. Renewing the suc-
● Lift up the air filter cover. tion air intake filter,
V20
Figure 3 Air filter (TCG 2020 V20)
● Cleaning the filter housing.

● Remove the soiled filter cartridges 5 from the air filter housing.
Make sure so dirt gets inside the housing.
© 0603 300201027-en-00.fm Page 3

B 6-3-6 TCG 2020
Figure 4 Air filter (TCG 2020 V20)
● Insert new filter cartridges 5 in the air filter housing under consideration of
the direction of flow.
● Push the filter cartridges together in the direction of the arrow (see
Figure 3) so that the air filter cover can be closed properly.
● Close the air filter cover 4 and close the snap locks 3.
● Renew the filter cartridges on the opposite side as well.
Page 4 300201027-en-00.fm © 0603

Gas Engines B 7-20-1
B 7-20-1
Checking the gas pressure of the gas regulator line
Cross references
- B 7-21-1, Cleaning the gas filter / renewing the filter cartridge
The gas pressure applied to the gas regulator line can be read from the pres-
sure gauge. This is supplied by the pre-pressure regulator line and depends
on the gas type and quality.
● Press the button 1 and read the gas pressure. Checking the gas
● If the gas pressure is not within the permissible values, the gas filter must pressure of the gas
be cleaned or the filter cartridge renewed. regulator line
See Job Card B 7-21-1, Cleaning the gas filter / renewing the filter cart-
ridge.
Figure 1 Pressure gauge (gas regulator line)
© 0603 300201028-en-00.fm Page 1

B 7-20-1 Gas Engines
Page 2 300201028-en-00.fm © 0603

Gas Engines B 7-21-1
B 7-21-1
Cleaning the gas filter / renewing the filter cartridge
Tools
- Standard tools
Equipment
- Weak alkaline solution
Spare parts
- Gasket
- Poss. filter cartridge
Cross references
- B 7-20-1, Checking the gas pressure of the gas regulator line
The ventilation system should be switched on before carrying out any

work on the gas line.
Smoking and the use of naked flames is prohibited.
Danger of explosion!
The gas filter must be cleaned or the filter cartridge renewed when the gas
pressure to be applied to the gas regulator line has dropped.
This gas pressure can be read on a pressure gauge, see Job Card B 7-20-1,
Checking the gas pressure of the gas regulator line.
● Cut off the gas supply by closing the ballcock on the gas regulator line. Cleaning the gas fil-
● Remove fastening screws 1 and remove the cap from the gas filter. ter
● Remove the filter cartridge.
● Clean the gas filter housing.
● Wash the filter cartridge in a weak alkaline solution and then let it dry.
or
● Renew the filter cartridge.
The filter cartridge must be totally try when it is installed.
● Insert the filter cartridge and replace the gas filter cap with a new gasket.
● Open the ballcock on the gas regulator line.
© 0603 300201029-en-00.fm Page 1

B 7-21-1 Gas Engines
Figure 1 Cap of the gas filter
Page 2 300201029-en-00.fm © 0603

Gas Engines B 8-1-1
B 8-1-1
Taking lube oilsamples
Tools
- Container for waste oil
Equipment
- Lube oil according to expendables specifications, chapter 4
When draining off hot lube oil:

Risk of scalding!
Trouble-free operation and good wear behaviour depend to a great extent on

the lube oil condition. Checking the lube oil is therefore one of the most
important maintenance jobs.
Analysis by the lube oil manufacturer is necessary because a detailed exami-
nation is only possible in the laboratory. If no other possibilities are available,
DEUTZ will do the analysis at reimbursement of expenses.
The lube oil sample must be taken with the engine running. The lube oil sam- Taking the lube oil
ple must be taken at the lube oil tapping valve 1. sample
The position of the lube oil tapping valve depends on the series, see Position
of the lube oil tapping valve (Figure 3 to Figure 5).
● The coupling union 2 with hose pipe 3 is pressed in in the direction of the
arrow according to Figure 2 until it snaps into the mating union 4.
The lube oil flows immediately after snapping in.
Figure 1 Lube oil tapping valve
© 0603 300201030-en-00.fm Page 1

B 8-1-1 Gas Engines
Figure 2 Coupling
About 1 litre of lube oil is required for testing.

● The union 2 must be pulled off again to interrupt the lube oil flow.
Necessary data are:
1. Lube oil mark and type,
2. Operating hours counter reading,
3. lube oil consumption since last taking a sample.
The lube oil must be renewed in the event of a negative analysis result.
Page 2 300201030-en-00.fm © 0603

Gas Engines B 8-1-1
TBG 616 and TCG 2016 Position of the lube

oil tapping valve
Figure 3 Lube oil tapping valve on the engine (TBG 616 and TCG 2016)
TBG 620 and TCG 2020
Figure 4 Lube oil tapping valve on the engine (TBG 620 and TCG 2020)
© 0603 300201030-en-00.fm Page 3

B 8-1-1 Gas Engines
TCG 2032
Figure 5 Lube oil tapping valve on the engine (TCG 2032)
Page 4 300201030-en-00.fm © 0603

TCG 2020 B 8-1-2
B 8-1-2
Lube oil change
Spare parts
- Lube oil according to expendables specifications
Cross references
- B 8-10-4, Renewing lube oil filter cartridge
- Chapter 4, Expendables
- Operating Instructions DEUTZ TEM System

Risk of scalding!
Collect the used oil,do not allow it to seep into the soil.
Dispose of in accordance with the relevant regulations.
The lube oil change is performed in connection with the DEUTZ TEM System.
The lube oil change should be performed on the warm engine.
Pump off lube oil
The oil pan of the engine and the oil tank in the base frame must be emptied
one after the other.
● To pump the lube oil out of the engine oil tray, set the three-way cocks 1
and 2 and the stop cocks 3 and 4 as shown in Figure 1.
© 0603 300201031-en-00.fm Page 1

B 8-1-2 TCG 2020
Figure 1 Cock settings ”empty oil pan”
● Start the lube oil change process in the TEM System in the menu of the
”Oil Change” mask with the ”Pump off oil” button.
● Open an inspection hole to check the oil has been pumped off completely.
● When the lube oil has been pumped off, press the ”Oil pan empty” button
to end the pump off process.
● To pump the lube oil out of the oil tank in the base frame, set the three-way
cocks 1 and 2 and the stop cocks 3 and 4 as shown in Figure 2.
Figure 2 Cock settings ”empty base frame”
● Start the lube oil change process in the TEM System in the menu of the
”Oil Change” mask with the ”Pump off oil” button.
● When the lube oil has been pumped off, press the ”Oil pan empty” button
to end the pump off process.
Page 2 300201031-en-00.fm © 0603

TCG 2020 B 8-1-2
● At the end of the pumping process, set the three-way cocks 1 and 2 and
the stop cocks 3 and 4 as shown in Figure 3.
Figure 3 Cock settings ”pre-lubricate”
● Renew lube oil filter cartridges, see Job Card B 8-10-4, Renewing lube oil
filter cartridge.
● Fit a new seal to the inspection hole cover, tightening torque 25 Nm.
Positions in Figure 1 to Figure 4.
1 Three-way cock, suction connection
2 Three-way cock, pressure connection
3 Stop cock, base frame
4 Stop cock, oil pan
5 Engine oil pan
6 Base frame
7 Pre-lube pump
8 Overflow
9 Lube oil level switch
A from oil pan
B from base frame
C from used oil tank
D to engine lube oil circuit
© 0603 300201031-en-00.fm Page 3

B 8-1-2 TCG 2020
Pour in lube oil ● Press the ”Refill” button.

Now lube oil is pumped into the oil tank in the base frame 6. When this oil
tank is full, the lube oil flows through overflow 8 into the oil pan 5 of the
engine. The filling volume is controlled by the lube oil level switch 9.
Figure 4 Pre-lube pump
● Switch on the pre-lube pump when the lube oil filling is complete. Make
sure that the three-way cocks 1 and 2 and the stop cocks 3 and 4 are set
as shown in Figure 3.
The pre-lube process lasts about 20 minutes, the engine cannot be started by
the TEM system before this.
Page 4 300201031-en-00.fm © 0603

TCG 2020 B 8-10-4
B 8-10-4
Renewing lube oil filter cartridge
Tools
- Strip key
Equipment
- Container for waste oil
- Lube oil according to expendables specifications, chapter 4
Spare parts
- Lube oil filter cartridges

Risk of scalding!
Collect the used oil,do not allow it to seep into the soil.
Dispose of in accordance with the relevant regulations.
The number of installed lube oil filter cartridges depends on the size of the
engine. The procedure for removing and installing the lube oil filter cartridges
described below applies for all of them.
Renew lube oil filter

cartridge
Figure 1 Lube oil filter cartridges
● Loosen and unscrew the lube oil filter cartridge 1 with commercially avail-
able strip key.
● Collect emerging lube oil.
© 0403 300201032-en-00.fm Page 1

B 8-10-4 TCG 2020
● Clean the seal surface of the filter carrier.

● Wet the gasket of the new filter cartridge slightly with lube oil.
● Turn in the filter cartridge by hand until the gasket is touching.
● Tighten the filter cartridge by another full turn by hand.
In the TCG 2020 V12 and V16 the lube oil filter cartridge 2 for the turbo-
charger must be renewed additionally.
Figure 2 Lube oil filter cartridge for turbocharger
● Loosen and unscrew the lube oil filter cartridge 2 for the turbocharger with
commercially available strip key.
● Clean the seal surface of the filter carrier. Wet the sealing ring of the new
lube oil filter with lube oil.
● Screw the filter cartridge hand tight to the filter carrier.
After renewing all the filter cartridges, actuate the pre-lube pump, build up
lube oil pressure and check the filter cartridges for leaks.
Page 2 300201032-en-00.fm © 0403

Gas Engines B 9-1-1
B 9-1-1
Checking corrosion protection agent or antifreeze in coolant
Tools
- Test case order no. 12158292
Cross references
- Chapter 4, Expendables
Corrosion protection agent is added to the coolant to protect the coolant

areas from corrosion. However, this protection is only given when a certain
minimum content of corrosion protection agent is not exceeded. If there is
more corrosion protection agent than necessary in the coolant, the cooling
effect is reduced.
If an antifreeze is added to the coolant, this should also have corrosion pro-
tection properties. A corrosion protection agent does not need to be added in
this case. The antifreeze percentage must be dosed accordingly for the
above mentioned reasons.
If the cooling system needs refilling, the percentage of antifreeze or corrosion
protection agent in the coolant must be measured. Then the coolant should
be corrected according to the following description.
● Remove the coolant sample from the cooler, compensation tank or drain- Check the corrosion
ing tap. protection agent and
● Check the percentage additive with the measuring instrument. antifreeze percent-
● Setpoint according to Chapter 4, Expendables. age
Percentage additive too low: Correct the corro-

sion protection
total filling quantity × ( nominal value - measured value ) agent and antifreeze
quantity of additiv required additionally = -------------------------------------------------------------------------------------------------------------------------------------------------
100
percentage
To refill, drain coolant, mix well with the amount of additive to be refilled and
then pour in the mixture again.
Percentage additive too high:

Drain the amount of coolant and fill up with pure water (quality according to
Chapter 4, Expendables).
coolant to be drained =  1 – -------------------------------------------- × total filling quantity

nominal value
 measured value 
● Bleed the cooling system.
© 0303 300201118-en-00.fm Page 1

B 9-1-1 Gas Engines
Page 2 300201118-en-00.fm © 0303

B 10-7-1
Draining water from and filling the air bottle (starter air tank)
Tools
- Standard tools
● Open the drain valve 1 slowly until water emerges. If no water emerges,
close the drain valve again.
Do not open the drain cock too far because water is displaced if the flow
speed is too great and only air escapes. A riser 2 is installed on vertically
erected air bottles. The air pressure in the air bottle presses the water through
out through the riser into the open.
If no water emerges for several maintenance periods, have the air bottle
checked.
● Fill up the air bottle to 30 bar every time before switching off the engine.
' 80122-1
Figure 1 Starter air bottle
© 0503 300201033-en-00.fm Page 1

Page 2 300201033-en-00.fm © 0503

B 13-4-1
Maintaining the battery
Tools
- Standard tools
- Acid tester order no. 12157944
Equipment
- Distilled water
- Acid protection grease
- Cloths
The gases emitted by the battery are explosive.

● Avoid sparks and open flames in the vicinity of the battery.
● Do not allow any acid to get on your skin or clothing.
● Wear protective goggles.
● Do not place any tools on the battery.
● Keep battery clean and dry. Check battery and

● Undo dirty clamps. cable connectors
● Clean terminal posts (+ and -) and clamps of battery, and grease with
acid-free and acid-resistant grease.
● When reassembling, ensure that clamps make good contact. Tighten
clamp bolts hand-tight.
Figure 1 Battery poles
© 0303 300200034-en-00.fm Page 1

Check acid level ● Remove sealing caps 1.

● If testers 2 are present:
Electrolyte level should reach the base of these.
● Without testers:
Electrolyte level should reach 10 - 15 mm above top edge of plate.
● If necessary, top up with distilled water.
● Screw sealing caps back in.
Figure 2 Battery sealing caps
Page 2 300200034-en-00.fm © 0303

● Measure the electrolyte density of individual cells with a commercial Check acid density
hydrometer.
Figure 3 Check acid density
Hydrometer reading (see table below) indicates battery's state of charge.

During measurement, temperature of electrolyte should preferably be 20 °C.
.
Acid density
in [kg/l] Charge status
Normal Tropical
1.28 1.23 well charged
1.20 1.12 semi-charged, re-charge
1.12 1.08 discharged, charge immediately
© 0303 300200034-en-00.fm Page 3

Page 4 300200034-en-00.fm © 0303

TCG 2020 B 13-5-4
B 13-5-4
Spark plugs, spark plug cables, checking, cleaning the spark plug shaft
Tools
- Standard tools
- Spark plug wrench
- Cleaning brush
- Multimeter
Equipment
- Compressed air
- Protective glasses
Spare parts
- Spark plugs
- Sealing rings
When working on the high-voltage ignition system:

life-threatening risk!
● Pull off spark plug cable 2 from ignition coil 1 and remove spark plug 3 Removing and in-
with the spark plug wrench. stalling spark plugs
Figure 1 Spark plug
● Clean the spark plug is necessary.

● Renew spark plugs according to the instructions in the maintenance
schedule.
© 0403 300201034-en-00.fm Page 1

B 13-5-4 TCG 2020
● Screw spark plugs with new sealing ring carefully into the spark plug
thread and tighten, torque 52 Nm.
● Plug spark plug cable 2 to ignition coil 1.
Check spark plugca- The spark plug cable is integrated in the spark plug.
ble ● Check the spark plug cable 2 for damage, the spark plug may have to be
renewed.
Check spark plug- ● Illuminate the spark plug shaft 4 and check whether oil and water emerge.
shaft Please contact your DEUTZ Service is water or oil seep out.
Clean the spark plug ● Blow out spark plug shaft 4 with compressed air.
shaft.
Wear protective glasses to avoid injury.
The spark plug shaft, the spark plug and the spark plug receptacle must be
dry.
Page 2 300201034-en-00.fm © 0403

Sundry other instructions
Gas Engines 10
10 Sundry other instructions

Sundry other instructions
Gas Engines

Index
TCG 2020
Index
A
Air regulator line 2-38
Antifreeze percentage B 9-1-1
Auxiliary aggregate test
With TEM Evolution B 0-1-6
Auxiliary materials 4-3
B
Basic data 8-1
C
Changing lube oil B 8-1-2
Lube oil system B 8-1-2
Charging
Compressor bypass 2-22
Schematic 2-20
Turbocharger 2-21
Check and clean spark plug shaft B 13-5-4
Check spark plug cable B 13-5-4
Checking and setting valve clearance B 1-1-1
Checking the gas pressure of the gas regulator line B 7-20-1
Combustion gas silicon content 5-3
Combustion gases 4-1
Commissioning / Starting
Filling up coolant 3-1
Filling up lube oil 3-1
Lube oil system 3-3
Pre-lubrication 3-1
Preparation work 3-1
Room ventilation 3-3
Starting 3-3
Warming up 3-3
Compressed air system 2-37
Air regulator line 2-38
Compressed air starter
Compressed air starter 2-37
Draining water from and filling the air bottle B 10-7-1
Conservation 7-1
Control data 8-1
Cooling system 2-35
Antifreeze percentage B 9-1-1
Corrosion protection agent percentage B 9-1-1
Filling up coolant 3-1
Cooling system schematic 2-36
Corrosion protection agent percentage B 9-1-1
© 0903 300201011-en-00MIX.fm Chapter Index - Page 1

Index
TCG 2020
Crankcase 2-13
Crankcase bleed valve 2-33
Cylinder head 2-12
D
Description of the engine 2-1
Dimensions of the aggregate 8-2
Draining water from and filling the air bottle B 10-7-1
Driving gear 2-13
E
Electrical system 2-39
Components 2-47
Ignition system 2-39
Spark plug 2-40
Starter 2-45
Emission data 8-3
Engine 2-39
Charging
Schematic 2-20
Turbocharger 2-21
Checking and setting valve clearance B 1-1-1
Cleaning B 0-3-6
Crankcase 2-13
Cylinder head 2-12
Daily inspections B 0-1-5
Driving gear 2-13
Electrical system
Components 2-47
Spark plug 2-40
Starter 2-45
Engine control 2-14
Figures 2-5
Rating plate 2-2
Speed control 2-15
Starting 3-3
Type and designations 2-1
Type designation 2-1
Wheel drive 2-14
Engine control 2-14
Engine coolant 4-1
Engine data 8-1
Engine peripheral data 8-4
Expendables 4-1
Auxiliary materials 4-3
Combustion gases 4-1
Engine coolant 4-1
Chapter Index - Page 2 300201011-en-00MIX.fm © 0903

Index
TCG 2020
Gluing agents 4-5

Guarantee 4-1
Lube oil 4-1
Lubricants 4-5
Mixability 4-1
Other auxiliary materials 4-6
Product selection 4-1
Sealants and securing agents 4-3
F
Filling volumes 8-3
Forword 0-7
G
Gas controlled system
Checking the gas pressure B 7-20-1
Gas filter
Cleaning B 7-21-1
Renewing the filter cartridge B 7-21-1
Gas groups 5-3
Gas regulator line 2-24
Gas regulator line components 2-25
Gas system 2-24
Gas-air carburettor 2-28
Gluing agents 4-5
I
Ignition sequence 8-1
J
Job cards
Structure 1-4
L
Lube oil 4-1
Filling up 3-1
Lube oil change B 8-1-2
Lube oil level switch 2-32
Lube oil system 2-30
Lube oil filter cartridge B 8-10-4
Lube oil level switch 2-32
Oil mist trap 2-33
Taking samples
Taking lube oil samples B 8-1-1
Lube oil system schematic 2-30
Lubricants 4-5

Index
TCG 2020
M
Maintain crankcase bleed valve
Maintain oil mist trap B 3-1-9
Maintaining the battery B 13-4-1
Maintenance 5-3, 5-4
Definition of activities 5-6, 5-12
Maintenance and service schedules 5-2
Silicon content in the combustion gas 5-3
Maintenance and service schedules 5-2
Mixture formation 2-28
Monitoring operation 3-4
O
Operating check log 5-22
Operating data 8-3
Operating Instructions 1-2
Overview 5-4
P
Pre-lubrication 3-1
Pressures 8-3
R
Renewing lube oil filter cartridge B 8-10-4
RI flow diagrams 8-5
Routine maintenance 5-1
Rules for disposal 1-2
S
Safety regulations
Careful when the engine is running! 0-6
Cutting, grinding, soldering and welding work B 0-0-4
Handling components made of elastomers containing fluoride (e.g. Viton) B 0-0-3
Rules for accident prevention 1-1
Scheduled maintenance plans 5-4
Sealants and securing agents 4-3
Silicon content in combustion gas 5-3
Spares 1-6
Spark plug 2-40
Removing and installing B 13-5-4
Speed controller
Checking easy action B 5-4-2
Speed regulation 2-15
Start system 8-4
Starter
Electric starter 2-45
Starting 3-3

Index
TCG 2020
Suction air intake filter

Renew B 6-3-6
Sundry other instructions 10-1
T
Technical particulars 8-1
Basic data 8-1
Control data 8-1
Dimensions 8-2
Emission data 8-3
Filling volumes 8-3
Pressures 8-3
RI flow diagrams 8-5
Speed controller 8-4
Start system 8-4
Temperatures 8-3
Tightening specification 8-9
Weights 8-2
Temperatures 8-3
Tightening specifications 8-9
Tools 5-17
Troubleshooting 6-1
Turbocharger 2-21
U
User Guide 1-1
V
Visual inspection of the system B 0-1-5
Viton, safety regulations B 0-0-3
W
Weights of components 8-2
Wheel drive 2-14
Workshop Manual 1-2

Index
TCG 2020

Service
Medium and large engines
Service
We move your world

DEUTZ has always stood for excellence in engine construction, pioneering many developments in the indus-
try. As an independent engine manufacturer we offer a full range of diesel and gas engines in the perform-
ance range from 4 to 7,400 kW. Our products are tailor-made to meet our customers’ requirements.
More than 1.4 million DEUTZ engines are in service worldwide. We are determined to preserve the high
standard of performance and dependability of our engines, thus keeping our customers satisfied at all times.
For this reason we are represented worldwide through a network of highly competent service partners who
will meet the needs of our customers, wherever they are.
This is why DEUTZ is not only the name for engines which pack a lot of inventiveness. DEUTZ also means
reliable service and comprehensive support to enhance your engine’s performance.
DEUTZ AG - at your service.
Sales & Service Index

This Sales & Service Index offers you an overview of the DEUTZ
partners in your vicinity, including the products for which they are
responsible and the range of services provided. But even when
no direct product responsibility is mentioned, your DEUTZ part-
ner will be happy to help you with expert advice. The Index is
constantly updated. Please ask your DEUTZ service partner for
the latest edition.
Order no.: 0312 0806 (Printed version)
Order no.: 0312 0807 (CD-ROM)
DEPIC
The DEutz Parts Identification for Customers (DEPIC) offers you
spare parts identification individually adapted to your systems.
DEPIC enables you to generate an order list almost automati-
cally and to make your spare parts procurement more efficient.
Order no.: on request (CD-ROM)
Seminar program
Degree of availability, reliability and service life of equipment and
drive assemblies are determined to a great extent by profes-
sional operation and service by qualified and experienced opera-
tors and service technicians.
The DEUTZ AG offers service-related seminars for DEUTZ prod-
ucts to customers and operators staff for this.
Apart from the seminars which are held in our Training Centers in
Cologne and Mannheim it is also possible to hold special semi-
nars in the Training Centers or at another location requested by
the customer by agreement.
Information about the seminar program will be distributed in a
mailing.
Please ask your DEUTZ Service representative.
© 0103 300200037-en-00.fm Chapter Service - Page 1

TCG 2020 TCG 2020: Operating Instructions

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Operating Instructions

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Ordering No 0299 8868 en

Chapter 0- Page 4 300201012-en-00.fm © 0903

© 0303 300200002-en-00.fm Chapter 0 - Page 5

Chapter 0 - Page 6 300200002-en-00.fm © 0303

Dear customer, Forword

© 0303 300200002-en-00.fm Chapter 0 - Page 7

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Chapter 0 - Page 8 300200002-en-00.fm © 0303

© 0903 300201011-en-00IVZ.fm Contents - Page 1

Gas system...................................................................................................... 2-24

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Auxiliary materials................................................................................................. 4-3

© 0903 300201011-en-00IVZ.fm Contents - Page 3

Operating data ...................................................................................................... 8-3

10 Sundry other instructions

Contents - Page 4 300201011-en-00IVZ.fm © 0903

© 0303 300200004-en-01.fm Chapter 1 - Page 1

● for operation and maintenance of the engine:

Chapter 1 - Page 2 300200004-en-01.fm © 0303

The Workshop Manual assumes knowledge of the content of the operating

© 0303 300200004-en-01.fm Chapter 1 - Page 3

Maintenance Group (the same for all engines)

Figure 1-1 Numbering of the job cards

Chapter 1 - Page 4 300200004-en-01.fm © 0303

Figure 1-2 Numbering of the job cards

DEUTZ Service, publisher of the service documen-

© 0303 300200004-en-01.fm Chapter 1 - Page 5

Chapter 1 - Page 6 300200004-en-01.fm © 0303

See also rating plate

Mixture charge cooling C

No. of cylinders 12, 16 or 20

© 0603 300201013-en-00.fm Chapter 2 - Page 1

Figure 2-1 Position of the rating plate on the engine

The engine number 2 is punched additionally.

Figure 2-2 Position of the engine number on the engine

Chapter 2 - Page 2 300201013-en-00.fm © 0603

Figure rating plate

Figure 2-3 Figure rating plate

1 Engine type designation

© 0603 300201013-en-00.fm Chapter 2 - Page 3

Designation of the engine sides, cylinder and direction of rotation

1 Drive side Flywheel, clutch side

Chapter 2 - Page 4 300201013-en-00.fm © 0603

Engine and aggregate figures

Aggregate (illustrated TCG 2020 V20)

Figure 2-5 Aggregate

© 0603 300201013-en-00.fm Chapter 2 - Page 5

Engine cross section

Figure 2-6 Engine cross section

1 Touch protection ATL

4 Coolant pipe overflow

© 0603 300201013-en-00.fm Chapter 2 - Page 7

Engine (illustrated TCG 2020 V20 left-hand side)

Figure 2-7 Left-hand side

Chapter 2 - Page 8 300201013-en-00.fm © 0603

Engine (illustrated TCG 2020 V20 right-hand side)

Figure 2-8 Right-hand side

A6 Exhaust gas compensator

© 0603 300201013-en-00.fm Chapter 2 - Page 9

Engine (illustrated TCG 2020 V20 free side)