OBJ_DOKU-29003-001.fm Seite 1 Montag, 7.

November 2011 3:17 15

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Operation Manual

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TD 3.6 L4

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TCD 3.6 L4

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Notes
Notes
● This engine is defined exclusively for purpose
according to the scope of delivery and built by
the equipment manufacturer (use for the intend-
ed purpose). Any other use above and beyond
this will be considered as misuse. The manufac-
turer will not accept any liability for damages re-
sulting from this. The user bears the sole risk.
● Use for the intended purpose also includes ob-
servance of the operating, maintenance and re-
pair conditions specified by the manufacturer.
The engine should only be operated, serviced
and repaired by personnel trained in its use and
the hazards involved.
The pertinent rules for the prevention of acci-
dents and other generally recognised safety and
industrial medicine rules must be observed.
● When the engine is running there is a danger of
injury caused by:
– rotating and hot components
– on motors with external ignition (high electri-
cal voltage). Contact must be avoided!
● Unauthorised engine modifications will invalidate
any liability claims against the manufacturer for
resultant damage.
● Equally, manipulations to the injection and con-
trol system can affect the engine's performance
and the exhaust characteristics. Adherence to
legislation on pollution can no longer be guaran-
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teed under such conditions.
● Do not change the cooling air feed area to the
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blower of fan. An unobstructed cooling air supply
must be guaranteed.
The manufacturer will accept no liability for dam-
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age resulting from this.
● When carrying out maintenance work on the en-
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2 © 2011
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gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
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engine and guarantee perfect operation.
Non-compliance results in the expiry of the war-
ranty!
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Maintenance/cleaning work on the engine may
only be carried out when the engine is not run-
ning and has cooled down.
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When doing this, make sure that the electrical
system is switched off (remove ignition key).
The specifications for accident prevention with
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electrical systems (e.g. VDE-0100/-0101/-0104/-
0105 Electrical protective measures against dan-
gerous contact voltages) must be observed.
Cover all electrical components tightly when
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cleaning with liquids.
● Do not work on the fuel system while the engine
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is running - Danger to life!
Wait for the pressure to drop after the engine has
come to a standstill (in engines with DEUTZ
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Common Rail about 5 minutes, otherwise
1 minute) because the system is under high
pressure - Danger to life!
During the first trial run do not stand in the dan-
ger area of the engine.
ofDanger due to high pressure in case of leaks -
Danger to life!
– In case of leaks immediately contact work-
shop.
– When working on the fuel system, make sure
that the engine is not started inadvertently
during repairs - Danger to life!
OBJ_DOKU-29003-001.fm Seite 3 Montag, 7. November 2011 3:17 15

Foreword

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Dear customer, Engine serial number

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Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.

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broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.

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The engine is equipped accordingly for the particular Components of the exhaust aftertreatment system
installation situation, i.e. not all the components de- Please enter the serial numbers of the exhaust after-
scribed in the operating manual are installed in your treatment components.

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engine.
We have endeavoured to highlight any differences Diesel oxidation catalytic converter
so that you will be able to locate the operating and
maintenance instructions applicable to your engine

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more quickly and easily.
Please make sure that this operating manual is avail- Diesel particle filter

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able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.

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If you have any queries, please contact us, we'll be Notes
happy to advise you.
We reserve the right to make technical changes to
Sincerely, the descriptions and data in this operating manual in
DEUTZ AG the interest of further development of the engines.
of
This document may only be reprinted and repro-
duced, even in part, with our express permission.
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© 2011 3
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Contents

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Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Cooling system . . . . . . . . . . . . . . . . 46

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Foreword. . . . . . . . . . . . . . . . . . . . . 3 Engine cleaning. . . . . . . . . . . . . . . . 48
1 General. . . . . . . . . . . . . . . . . . . . 5 Suction system . . . . . . . . . . . . . . . . 49
2 Engine description . . . . . . . . . . . . . 7 Belt drives . . . . . . . . . . . . . . . . . . 51

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Model . . . . . . . . . . . . . . . . . . . . . 7 Electrical system . . . . . . . . . . . . . . . 53
Engine illustrations . . . . . . . . . . . . . . 10 7 Faults. . . . . . . . . . . . . . . . . . . . . 55

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Lubricating oil diagram . . . . . . . . . . . . 14 Fault table . . . . . . . . . . . . . . . . . . 55
Fuel diagram . . . . . . . . . . . . . . . . . 15 Engine management . . . . . . . . . . . . . 59
Coolant diagram . . . . . . . . . . . . . . . 16 8 Transport and storage . . . . . . . . . . . 61

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Exhaust gas return . . . . . . . . . . . . . . 17 Transport . . . . . . . . . . . . . . . . . . . 61
Exhaust gas aftertreatment . . . . . . . . . . 18 Engine corrosion protection . . . . . . . . . 62
Electrics/Electronics . . . . . . . . . . . . . 19 9 Technical data . . . . . . . . . . . . . . . . 64

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3 Operation . . . . . . . . . . . . . . . . . . 21 Engine and setting data . . . . . . . . . . . 64

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Ambient conditions . . . . . . . . . . . . . . 21 Tools . . . . . . . . . . . . . . . . . . . . . 66
Initial start-up . . . . . . . . . . . . . . . . . 22
Start procedure . . . . . . . . . . . . . . . . 24

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Operation monitoring . . . . . . . . . . . . . 25
Exhaust aftertreatment system . . . . . . . . 29
Stop procedure . . . . . . . . . . . . . . . . 32
4 Operating Media . . . . . . . . . . . . . . . 33 of
Lubricating oil . . . . . . . . . . . . . . . . . 33
Fuel . . . . . . . . . . . . . . . . . . . . . . 35
Coolant . . . . . . . . . . . . . . . . . . . . 36
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5 Maintenance . . . . . . . . . . . . . . . . . 38
Maintenance schedule . . . . . . . . . . . . 38
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6 Servicing and maintenance work . . . . . 41

Lubricating oil system. . . . . . . . . . . . . 41
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Fuel system. . . . . . . . . . . . . . . . . . 43
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4 © 2011
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DEUTZ diesel engines
DEUTZ diesel engines and the appropriate exhaust
aftertreatment components are the result of years of
research and development. The detailed know-how
gained by this in connection with the high quality de-
mands are the guarantee for production of engines
with a long life, high reliability and low fuel consump-
tion. Naturally the high demands for protection of the
environment are also met.
Safety precautions when the engine is running
Maintenance work or repairs may only be performed
on the shut-down engine. Make sure that the engine
cannot be started inadvertently - Danger of accident!
After repair work: Check that all guards have been
replaced and that all tools have been removed from
the engine.
Observe industrial safety regulations when running
the engine in an enclosed space or underground.
When working on the running engine, work clothing
must be close fitting.
Never fill the fuel tank while the engine is running.
Service and Maintenance
Service and maintenance are also decisive for
whether the engine satisfactorily meets the set de-
mands. Recommended service intervals must there-
fore be observed and service and maintenance work
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must be carried out conscientiously.
Special care should be taken under abnormally de-
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manding operating conditions.
Original DEUTZ parts
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Original DEUTZ parts are subject to the same strict
quality demands as the DEUTZ engines. Further de-
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© 2011
General
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velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
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the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
functioning and high reliability. tact to your nearest local service partner.
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DEUTZ Xchange components California
Proposition 65 Warning
DEUTZ replacement parts are a low-cost alternative.
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Diesel engines and some of its constituents are
Of course, the quality standards here are just as high
as for new parts. DEUTZ replacement parts are known to the State of California to cause cancer,
equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
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liability. Masthead
Asbestos DEUTZ AG
The gaskets used in this engine contain no asbestos. Ottostraße 1
ic
Please use the appropriate original DEUTZ parts for
51149 Köln
maintenance and repair work.
Germany
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Service Phone: +49 (0) 221-822-0
We want to preserve the high performance of our en- Fax: +49 (0) 221-822-3525
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gines, and with it the confidence and satisfaction of
E-Mail: info@deutz.com
our customers. We are therefore represented world-
wide by a network of service branches. www.deutz.com
The DEUTZ name does not merely stand for engines
that are the products of extensive development
of
work, DEUTZ also stands for complete service pack-
ages that ensure optimum operation of our engines,
and for customer services operations that you can
count on.
Please contact your DEUTZ-partner in case of mal-
functions and sare parts inquiries. Our specially
trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
damage.
The DEUTZ home page gives you a continuously up-
to-date overview of the service partners in your vicin-
5
 OBJ_DOKU-29003-001.fm Seite 6 Montag, 7. November 2011 3:17 15

General

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1 Danger

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This symbol is used for all safety instruc-
tions which, if not observed, present a di-
rect danger to life and limb for the person

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involved. Observe these carefully. The at-
tention of operating personnel should be
drawn to these safety instructions. Further-

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more, the legislation for "general regula-
tions for safety and the prevention of
accidents" must be observed.

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Caution

This symbol indicates a danger to the part

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and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.

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Notes

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This symbol accompanies notes of a gen-
eral kind.

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Model Engine description

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Engine type designation The engines of these operating instructions fulfill
2

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the following exhaust emissions regulations
This manual covers the following engine types
TCD 3.6 >56 kW A B
TD 3.6 L4 With exhaust aftertreatment system

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TCD 3.6 L4 USA EPA Tier 4i
EU Stage IIIB Mot.-Typ Mot.-Nr.
TCD

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TD/TCD 3.6 <56 kW
T Exhaust gas turbocharger With exhaust aftertreatment system
C Charge air cooler USA EPA Tier 4 final
D Diesel

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EU Stage IV
R

DEUTZ AG MADE IN GERMANY

TCD 3.6 >56 kW
3.6 Without exhaust aftertreatment system
3.6 Displacement in litres

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USA EPA Tier III
EU Stage IIIA Rating plate
L4

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TD/TCD 3.6 <56 kW The type (A), engine number (B) and performance
L in series data are stamped on the rating plate.
Without exhaust aftertreatment system
4 No. of cylinders The engine type and number must be stated when
USA EPA Tier 4i

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Emissions legislation purchasing spare parts.
EU Stage IIIB

The engine and the corresponding EAT The engines of this operating manual may
system (Exhaust After Treatment) are only be used with a functioning exhaust af-
adapted to each other and linked by an ap- of tertreatment system.
propriate electronic controller. (if included in the DEUTZ scope of supply)
They are only certified by the responsible
authorities and comply with the permissible
exhaust limits in this combination.
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Operation of the engine with other EAT
systems is not allowed.
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Engine description Model

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2

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C
1 2
D

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XXXXXXX

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Location of the rating plate Engine serial number Serial numbers of the exhaust aftertreatment com-
ponents

The rating plate (C) is fixed to the cylinder head cov-
er or the crankcase.
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The engine number (D) is stamped onto the crank-
case (arrow) and onto the rating plate.
1 Rating plate of the diesel oxidation catalytic
converter

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2 Rating plate of the diesel particle filter
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates.
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Model Engine description

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2

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left

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right
1

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Cylinder numbering

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Cylinder arrangement
The cylinders are counted consecutively starting
from flywheel (1).

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Direction of rotation
Looking onto the flywheel.
rotating to the left: counter-clockwise.
Engine sides of
Looking onto the flywheel.
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Engine description Engine illustrations

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2 TD 3.6 L4

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Industrial engine
View from right (example)
1 Lubricating oil filling

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2 V-belts
3 Coolant inlet

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4 Lubricating oil drain plug
5 Lube oil replacement filter
1 6 Lubricating oil dipstick
7 Coolant outlet

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7

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6 2

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5 3

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Engine illustrations Engine description

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TD 3.6 L4
2

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Industrial engine
View from left (example)
1 Combustion air inlet

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2 Crankcase breather
3 Exhaust outlet

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2 4 Lubricating oil dipstick
Optional
1 5 Lube oil replacement filter
Optional

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6 Diesel oxidation catalytic converter
6

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3

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Engine description Engine illustrations

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2 TCD 3.6 L4

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Industrial engine
View from right (example)
1 1 Crankcase breather

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2 Throttle valve
3 Tension pulley

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4 V-rib belt
5 Coolant inlet
6 Lubricating oil drain plug
2 7 Lube oil replacement filter

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8 Lubricating oil dipstick
9 9 Coolant outlet

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7 4

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Engine illustrations Engine description

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TCD 3.6 L4
2

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Industrial engine
1 View from left (example)
1 Combustion air inlet

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7 2 Exhaust outlet
3 Diesel particle filter

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2 4 Diesel oxidation catalytic converter
5 Lubricating oil dipstick
Optional
6 Lube oil replacement filter

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Optional
3 7 Lubricating oil filling

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Engine description Lubricating oil diagram

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2 Lubricating oil system

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(example)
15 14 13 12 11 1 Lubricating oil sump
2 Lubricating oil pump

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3 Overpressure valve
8 4 Lube oil cooler

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5 Bypass valve
6 Pressure control valve
7 Lubricating oil filter
5 4 8 Main lube oil channel

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9 Camshaft bearing
10 Crankshaft bearing
11 Piston cooling nozzle

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12 Rocker arm
13 Hydraulic tappets

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14 Turbocharger
15 Air compressor
Optional

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Fuel diagram Engine description

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Fuel schematic (example)
2

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1 Fuel tank
12 8 9 10 2 Fuel pre-filter
3 Fuel pump

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(electrically powered)
4 Exchangeable fuel filter
5 Fuel transducer

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6 High-pressure pump
with
– Control block FCU (Fuel Control Unit)

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7 7 Rail
8 Injector
9 Check valve

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10 Return line
11 Fuel return to fuel tank

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12 Engine control unit

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Engine description Coolant diagram

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2 Coolant schematic (example)

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6 7 8 9 10 1 Coolant pump
2 Lube oil cooler
3 Air compressor

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Optional
4 Coolant supply for engine cooling
5 Cylinder pipe/head cooling

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6 Exhaust return cooler
7 Temperature transmitter
8 Thermostat

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x1 x2 9 Cooler
10 Compensation tank
11 Connection possibility for cab heating

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x2

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Exhaust gas return Engine description

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External exhaust gas recirculation
2

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1 Exhaust gas partial flow
8 7 6 (uncooled)
2 Actuator

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(electrically actuated)
3 Coolant line to the EGR cooler
4 Exhaust return cooler

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5 Coolant return
6 Exhaust gas partial flow
(cooled)

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7 Mixing pipe
8 Throttle valve

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Engine description Exhaust gas aftertreatment

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2 Exhaust aftertreatment system

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Example:
8 7 1 Decoupling line
2 Differential pressure sensor

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3 Exhaust temperature sensor
6 4 Diesel oxidation catalytic converter

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5 Diesel particle filter
Optional
5 6 Differential pressure sensor
7 Exhaust outlet

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8 Throttle valve
4

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Electrics/Electronics Engine description

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Electronic engine control
2

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1 2 3 4 Engine side
1 Rail pressure sensor

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12/24 V 10 2 Charge air pressure transmitter, charge air tem-
perature transmitter
3 Coolant temperature transmitter

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11 4 Engine control unit
5 Speed transmitter via camshaft
6 Speed transmitter via crankshaft

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12 7 Fuel transducer
8 Lubricating oil pressure transmitter
(on the opposite side)
13 9 Central plug (for engine control)

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Equipment side

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14 10 Power supply (battery)
11 Signal outputs, e.g. for lamps, speed, engine op-

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15 eration, etc.
12 Inputs (e.g. override button)
13 Accelerator
16 14 Hand throttle
15 Optional function selector switch, e.g. for P de-
of gree, type of controls, maximum curve, fixed
17 speeds, etc.
16 Detachable key switch Start/Stop
17 Diagnosis button
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18 18 Error lamp
19 Diagnostic interface/CAN bus
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Engine description
2 Information about the engine electronics
This engine is equipped with an electric control unit.
The equipping of the respective system depends on
the desired scope of function and the planned type of
engine application.
The resultant wiring with pin assignment can be seen
in the appropriate wiring diagram.
The installation regulations of the DEUTZ AG must
also be taken into account.
Precautions
The connections of the control units are
only dust and water proof when the mating
plugs are plugged (protection class IP69K)!
The control units must be protected against
spray water and moisture until plugging in
the mating plugs!
Reverse polarity can lead to failure of the
control unit.
To avoid damaging the control units, all the
connections on the control unit must be dis-
connected before electric welding work.
Interventions in the electrical system con-
trary to the DEUTZ regulations or by un-
qualified personnel can permamently
damage the engine electronics and have
serious consequences which are not cov-
ered by the manufacturer's guarantee.
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Electrics/Electronics
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It is strictly prohibited: Diagnostics
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a) to make changes or connections to the DEUTZ control units are equipped with self-diagnos-
wiring of the electrical control devices and tics. Active and passive error entries are saved in the
the data transmission cable (CAN lines). error memory. Active errors are displayed on error
b) to switch control units. lamps/diagnostics lamps (59).
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Otherwise guarantee rights will be lost!
A diagnosis can be made with:
Diagnostic and maintenance work may
● Error lamp (flash code)
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only be carried out by authorised personnel
using equipment approved by DEUTZ. ● CAN bus
● DEUTZ electronics display
Installation instructions
● Diagnostic socket (SERIDA)
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The control units are calibrated to the respective en-
gine and identified by the engine number. Every en- Equipment-side wiring
gine may only be operated with the appropriate The DEUTZ AG installation regulations should be
control unit. adhered to. In particular, the plug contact must be
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Setpoint transmitters (pedal value transmitters) nec- crimped with the appropriate standard tools. If it is
essary for vehicle operation must be connected to necessary to do so, plugged-in contacts may only be
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the vehicle side cable harness and calibrated with removed from the plug housing with the proper tools.
the DEUTZ diagnostic program SERDIA (SERvice
DIAgnosis). Wiring and cable assignment of the ve-
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hicle side cable harness must be taken from the con-
nection diagram of the DEUTZ installation
consulting.
Supply voltage
of
12 Volt
24 Volt
It should be ensured that the battery is sufficiently
charged. If the supply voltage is interrupted while the
engine is running, this can lead to damage to the
electrics/electronics. If the supply voltage fails, the
engine shuts down.
Voltages above 32 Volt will destroy the control unit.
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Ambient conditions Operation

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Cold start aid
3

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● The engines in these operating instructions are
equipped with glow plugs.(24)
Coolant

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● Observe the mixing ratio anti-freeze/cooling wa-
0 °C ter. (36)

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High ambient temperatures, high altitude

This engine is equipped with an electric

control unit.

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Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
ically, controlled by the electronic control

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unit.
Low ambient temperatures
● Application at high altitude

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Lubricating oil ● Application at high ambient temperatures
● Select the lubricating oil viscosity according to
the ambient temperature. Reason: Air density decreases as altitude or ambient

● If cold starting occurs frequently cut the lube oil
changing interval by half.
Fuel
● Use winter fuel below 0 °C (35).
Battery
● A good charging condition of the battery (53)
is the prerequisite for starting the engine.
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● Heating up the battery to approx. 20°C improves
the starting behaviour of the engine. (Remove
and store the battery in a warm room).
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temperature increase. This reduces the amount of
oxygen in the engine intake air and the fuel-air mix-
ture would be too rich if the injected amount of fuel
were not reduced.
● The results would be:
of – black smoke in the exhaust
– high engine temperature
– reduction in engine performance
– possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
you have any other questions.

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Operation Initial start-up

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3 Preparations for initial commissioning

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(Maintenance schedule E 10)
● Remove engine corrosion protection
● Remove any transport devices.

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● Check the battery and cable connections and
mount if necessary.
● Check belt tension (51).

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● Have the engine monitor or warning system
checked by authorised personnel.
● Check the engine mounting.

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● Check that all hose unions and clips fit properly.
The following additional work must be carried out on
generally overhauled engines:

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● Check the fuel pre-filter and main filter and Fill with engine lube oil Pour in fuel
change if necessary.

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● Check the intake air cleaner (if available, main- Low lubricating oil level and overfilling lead Never fill the fuel tank while the engine is
tain according to maintenance indicator). to engine damage. running.
● Drain lubricating oil and condensation water from Ensure cleanliness.

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the charge air cooler. Do not spill fuel.
● Fill with engine lube oil. The engines are generally supplied without Additional venting of the fuel system by a 5
● Fill the coolant system (64). lubricating oil filling. minute trial run at idle speed or on low load
Select lubricating oil quality and viscosity is absolutely essential.
before filling.
of Order DEUTZ lubricating oils from your ● The fuel low pressure system must be vented be-
DEUTZ partner fore the first start-up after filling with the manualy
supply pump.
● Fill the engine with lubricating oil via the lubricat-
Only use clean commercially available brand diesel
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ing oil filler neck.
● Observe the lubricating oil filling level (64). fuel. Observe fuel quality (35).
Use summer or winter-grade fuel, depending on the
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ambient temperature.
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Initial start-up
3 ● Engine operation with open thermostat 2 - 3 min-
2 1
Filling the coolant system
The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!
Never operate the engine without coolant,
even for a short time!
Order coolant corrosion protection agent
from your DEUTZ partner.
● Connect coolant outlet (2) and coolant inlet (1) to
the cooling system. Connect the feed line of the
ty
compensation tank to the coolant pump or to the
coolant inlet line (3).
● Connect ventilation line from the engine and, if
er
necessary, from the cooler to the compensation
tank.
● Fill cooling system via the compensation tank.
op
● Close compensation tank with valve.
Pr
© 2011
Operation
s
● Start the engine and run up until the thermostat
opens (line (2) heats up).
Trial run
3
ne
Additional venting of the fuel system by a 5
utes. minute trial run at idle speed or on low load
● Check the coolant level and top up coolant if nec- is absolutely essential.
rli
essary.
Carry out a brief trial run up to operating temperature
Danger of scalding from hot coolant! (approx. 90 °C) after preparations.
Ai
Cooling system under pressure! Only open Do not load the engine if possible.
the cap when cool!
● Work with the engine not running:
Observe safety regulations and national
specifications when handling cooling me- – Check engine for tightness.
an
dia. – Check lubricating oil level, if necessary top
up.
● If required, repeat procedure with engine start. – Check the coolant level and top up coolant if
● Fill up coolant to the MAX mark on the compen- necessary.
ic
sation tank and close the cooling system cap. ● Work during the trial run:
● Switch on any available heating and set to the – Check engine for tightness.
er
highest level so that the heating circuit is filled
and vented.
● Observe the filling volume of the cooling system
Am
(36).
of
23
 OBJ_DOKU-29003-001.fm Seite 24 Montag, 7. November 2011 3:17 15
Operation
3 Starting
Before starting, make sure that nobody is
standing in the immediate vicinity of the en-
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
been removed from the engine.
When starting with the flame glow plug/
glow plug/heating flange system do not use
any other starting aid (e.g. injection with
start pilot). Risk of accident!
If the engine fails to fire and the error lamp
lights, the electronic engine control has ac-
tivated the start lock to protect the engine.
The start lock is released by switching off
the system with the ignition key for about 30
seconds.
Do not actuate the starter for more than
20 seconds. If the engine does not start up,
wait for one minute and then repeat the
starting process.
If the engine does not start up after two at-
tempts, determine the cause as per fault ta-
ble (55).
Do not run up the engine immediately to
high idling speed / full load operation from
cold.
ty
Disconnect the engine by uncoupling de-
vices to be driven where possible.
er
op
Pr
24
Start procedure
s
control via a relay:
ne
P 0 ● the maximum start duration is limited.
● the pause between two start attempts is speci-
fied.
1 – the start is then continued automatically
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● starting while the engine is running is prevented.
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If the touch start function is programmed, a short
2 start command with the ignition key in position 2 or a
start button, if available, suffices.
an
ic
with cold starting device
er
● Insert key.
– Position 0 = no operating voltage.
Am
● Turn key to the right.
– Position 1 = operating voltage.
– Engine is ready for operation.
● Below the temperature specified in the electronic
engine control, the pre-heating phase begins
ofwith turning on the ignition.
● The electronic engine control controls and acti-
vates the current feed to the glow plugs via the
engine coolant temperatures.
● Push the key in and turn further clockwise
against spring pressure.
– Level 2 = start.
● release the key as soon as the engine starts up.
– The pilot lamps will go out.
If the starter is controlled by the electronic engine
© 2011
OBJ_DOKU-29003-001.fm Seite 25 Montag, 7. November 2011 3:17 15
Operation monitoring
Electronic engine control
The statuses are displayed by the error lamp.
The system monitors the condition of the engine and
itself.
● Function test
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out.
– Check the error lamp if there is no reaction
after switching on the ignition.
● The lamp does not light
– After the lamp test an extinguished lamp indi-
cates an error-free and trouble-free operat-
ing state within the scope of the control
possibility.
● Continuous light
– Error in the system.
– Operation continued with restrictions.
– The engine must be checked by a DEUTZ
partner.
– If a lamp lights steadily a monitored measur-
ing variable (e.g. coolant temperature, lubri-
cating oil pressure) has left the permissible
value range.
Depending on the fault, the engine power may be
reduced by the electronic engine control to pro-
tect the engine.
● Flashing
ty
– Serious error in the system.
– Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guaran-
er
tee!
– The engine has reached switch-off condition.
op
– Engine forced to run with power reduction to
cool the engine, with automatic shutdown if
Pr
© 2011
Operation
s
necessary.
3
ne
– The switch-off process has been accom-
plished.
– There may be a start lock after engine stop.
– The start lock is deactivated by turning off the
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system with the ignition key for approx. 30s.
– Additional control lamps, e.g. for lubricating
Ai
oil pressure or lubricating oil temperature,
are switched on if necessary.
– optionally the power reduction can be by-
passed, the automatic switch-off delayed or
an
a start lock bypassed with the override key
on the instrument panel to avoid critical situ-
ations. This brief deactivation of the engine
protection functions is logged in the control
ic
unit. Display instrument
The engine protection functions are released in
er
co-operation with the equipment manufacturer Possible displays:
and the DEUTZ installation consulting and may ● Colour scale
be designed individually. It is therefore absolute- – Display of operating state by coloured areas:
Am
ly essential to observe the operating instructions – green = normal operating state
of the equipment manufacturer.
– red = critical operatng state
Take suitable action.
● Measured value scale
of – Actual value can be read off directly. The
nominal value should be taken from the
Technical Data (64).
25
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Operation Operation monitoring

s
3 Instruments and symbols

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Instruments/symbols Designation Possible display: Measure
Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play

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Ai
Coolant temperature Coolant temperature too high Switch off engine

an
Lubricating oil temperature Lubricating oil temperature too high Switch off engine

ic
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or Switch off engine
lamp while the engine is running, the lubricating oil pres-

er
sure is too low

Am
Lube oil level If the pilot lamp lights up after starting the engine or Fill up lube oil
while the engine is running, the lubricating oil level is
too low

Coolant level If the control lamp lights up after the engine starts or Shut down the engine, allow to cool and top up cool-
while the engine is running, the coolant level is too
of ant
low

Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
ty
123
er

Horn With acoustic signal See fault table (55).

op
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Operation monitoring Operation

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Instruments/symbols Designation Possible display: Measure 3

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DPF function lamp Flashing Initiate standstill regeneration 29
Standstill regeneration of the diesel particle filter is
necessary

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Engine warning lamp Continuous light Initiate standstill regeneration 29

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A necessary, but not yet released standstill regener-
ation is displayed in combination with the DPF func-
tion lamp

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 OBJ_DOKU-29003-001.fm Seite 28 Montag, 7. November 2011 3:17 15

Operation Operation monitoring

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3 ● Operation monitoring of the diesel particle filter

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● Faults in the exhaust aftertreatment system
● Battery voltage
● Accelerator position
● Fuel consumption

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● Operating hours
Error messages are displayed in clear text and

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acoustically; the error memory of the control unit can
be read out.
For a detailed description, refer to the operating in-

an
structions enclosed with the DEUTZ Electronic Dis-
play.

ic
DEUTZ Electronic Display

er
In order to show measured values and error messag-
es of the EMR control unit, a CAN display is option-
ally available, which can be integrated into the

Am
dashboard of the driver´s position of working ma-
chines.
The following data may be displayed if they are sent
by the control unit.
● Engine speed of
● Engine torque (current)
● Coolant temperature
● Suction intake air temperature
● Exhaust gas temperature
ty
● Lubricating oil pressure
● Coolant pressure
er

● Charge air pressure

● Fuel pressure
op

● Status of the regeneration of the diesel particle

filter
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28 © 2011
OBJ_DOKU-29003-001.fm Seite 29 Montag, 7. November 2011 3:17 15
Exhaust aftertreatment system
Diesel oxidation catalytic converter
The diesel oxidation catalytic converter has a cata-
lytic surface which is used to convert the pollutants
in the exhaust gas into harmless substances. Here
carbon monoxides and unburned hydrocarbons are
made to react with oxygen and converted into carbon
dioxide and water. In addition, the nitrogen monox-
ides are converted to nitrogen dioxides.
Temperatures > 250 °C are necessary for a high de-
gree of efficiency.
Diesel particle filter
The combustion of diesel fuel results in soot, which
is separated in the diesel particle filter. This must be
regenerated as the contamination with soot increas-
es. That means that the soot in the diesel particle fil-
ter is burned.
The regeneration is based on a continuous regener-
ation process, which is activated as soon as the ex-
haust temperature of 250 °C is exceeded at the inlet
of the exhaust aftertreatment system. The filter con-
tamination with soot is monitored continuously by the
engine control unit.
Normal operation
Under normal operating conditions (exhaust temper-
ature > 250 °C), the filter contamination with soot re-
mains in a permissible range and no actions are
necessary.
ty
The regeneration lamp is off.
er
Support mode
If the operating conditions of the engine do not per-
op
mit any passive regeneration, the contamination of
the diesel particle filter with soot will increase.
Pr
© 2011
A throttle valve controlled via the engine control unit
is located in the combustion air inlet. This is used to
increase the exhaust gas temperature for regenera-
tion of the diesel particle filter, if this is not reached
during normal operation.
This can be the case if:
● The engine only has short operating times.
● The engine workload is not high.
This process is automatically activated by the engine
control unit, the operator does not need to perform
an
any actions.
The regeneration lamp is off.
Standstill regeneration
ic
If the support mode does not attain an adequate re-
duction of the soot contamination, the filter will con-
er
tinue to become contaminated with soot and a
standstill regeneration will be necessary.
Am
Temperatures of approx. 600 °C occur on
the exhaust pipe during regeneration.
A special engine operating state becomes
active during standstill regeneration and
the machine is not allowed to be used dur-
of ing the active standstill regeneration.
Danger of burns!
This is displayed by a flashing regeneration lamp.
The standstill regeneration must be initiated manual-
ly by the operator.
We recommend carrying out a necessary standstill
regeneration as quickly as possible, as otherwise the
diesel particle filter will continue to become contami-
nated with soot.
If the standstill regeneration is not carried out, the
Operation
s
engine control unit will activate the specified engine
protection functions, depending on the contamina- 3
ne
tion of the diesel particle filter.
Implementation of the standstill regeneration
rli
The engine must be brought into a "safe state" for
the regeneration:
Ai
● Shut down the engine on an open terrain at a
safe distance to flammable objects.
● Operate the engine in idling.
● The engine control unit now requires a signal in-
dicating that the unit is safely parked (stationary
signal).
This occurs,depending on the application, for ex-
ample by:
– Activating the parking brake.
– Engaging a specified gear position in the
gearbox.
● Operating the release button.
Position depends on application, see device
manual.
The regeneration lamp lights continuously during re-
generation.
The regeneration lasts 30 minutes on average.
The regeneration lamp goes out when regeneration
has been successfully completed.
Instead of the standstill regeneration, the engine can
be operated with a higher load for a certain time. If
the regeneration conditions return to the normal op-
erating range during this, the warning will be reset by
the engine control unit.
Replacing the diesel particle filter
The ash lamp indicates that the diesel particle filter
29
 OBJ_DOKU-29003-001.fm Seite 30 Montag, 7. November 2011 3:17 15

Operation Exhaust aftertreatment system

s
3 has become permanently clogged and can no longer
be regenerated in the unit.

ne
The ash lamp lights up.
Please contact your DEUTZ partner

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The contaminated diesel particle filter can be re-
turned and replaced with a clean one in the DEUTZ
exchange programme.

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30 © 2011
OBJ_DOKU-29003-001.fm Seite 31 Montag, 7. November 2011 3:17 15

Exhaust aftertreatment system Operation

s
Display of the regeneration control
3

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The display and monitoring of the exhaust aftertreatment system can be executed either with pilot lights or with a CAN interface and a corresponding display, depending
on the engine version.

Instruments/symbols Power reduction Regeneration

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Ai
Regeneration lamp Engine warning lamp Ash lamp
off off off Normal operation

an
off off off Support mode
Flashing off off Standstill regeneration
Release by the operator

ic
Flashing quickly Continuous light off -30 % Standstill regeneration
Release by the operator

er
Flashing quickly Flashing off -30 % Standstill regeneration
+ Engine speed limitation to 1200 rpm Release only by the DEUTZ partner

Am
Flashing quickly Flashing Continuous light -30 % No regeneration possible
Ash load 100 % + Engine speed limitation to 1200 rpm

of
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© 2011 31
 OBJ_DOKU-29003-001.fm Seite 32 Montag, 7. November 2011 3:17 15

Operation Stop procedure

s
3 Lag time

ne
P 0 The control unit remains active for about
another 40 seconds to save the system
data (lag) and then switches off automati-
1

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cally.

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2

an
ic
Shutting off

er
Avoid switching off from full load (coking/
blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-

Am
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap-
proximately one minute after relieving the
load.
● Move the key to position 0.
of
P = gear position: park
ty
0 = gear position: switch off engine
1 = gear position: Ignition on
2 = gear position: start engine
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32 © 2011
OBJ_DOKU-29003-001.fm Seite 33 Donnerstag, 5. Januar 2012 8:59 08
Lubricating oil
General
Modern diesel engines place very high demands on
the lubricating oil to be used. The specific engine
performances which have increased constantly over
the last few years lead to an increased thermal load
on the lubricating oil. The lubricating oil is also more
exposed to contamination due to reduced oil com-
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements
and recommendations described in this operating
manual in order not to shorten the life of the engine.
Lubricating oils always consist of a base oil and an
additive package. The most important tasks of a lu-
bricating oil (e.g. wear protection, corrosion protec-
tion, neutralisation of acids from combustion
products, prevention of coke and soot deposits on
the engine parts) are assumed by the additives. The
properties of the base oil are also decisive for the
quality of the product, e.g. with regard to thermal
load capacity.
In principle, all engine oils of the same specification
can be mixed. However, mixing of engine oils should
be avoided because the worst properties of the mix-
ture are always dominant.
The lubricating oils approved by DEUTZ have been
thoroughly tested for all engine applications. The ac-
tive ingredients they contain are compatible with
each other. Therefore, the use of additives for lubri-
cating oils is not permitted in DEUTZ engines.
ty
The lubricating oil quality has a considerable influ-
ence on the life, performance and thus also on the
er
costs-effectiveness of the engine. It basically applies
that: The better the lubricating oil quality, the better
these properties.
op
The lubricating oil viscosity describes the way the lu-
Pr
© 2012
Operating Media
s
bricating oil flows, depending on the temperature.
The lubricating oil viscosity only has a small influ-
http://www.deutz.com
4
ne
de \SERVICE \Betriebsstoffe und Addi-
ence and effect on the quality of the oil.
tive\Deutz Quality Class\DQC-Freigabeliste
Synthetic lubricating oils are used increasingly and
offer advantages. These lubricating oils have better en \SERVICE \Operating Liquids and Addi-
rli
temperature and oxidation stability as well as rela- tives\Deutz Quality Class\DQC Release List
tively low cold vicosity. Since some processes which The choice of luricating oil essentially depends on
Ai
are relevant for determining the lubricating oil the exhaust aftertreatment system.
change times are largely dependent on the oil quality
(e.g. the infiltration of soot and other contamination), The following lubricating oils are permissible for the
the oil change time for synthetic lubricating oils may engines in this operating manual:
an
not be increased in relation to the specifications on
lubricating oil change intervals. Permissible quality class
DEUTZ Others
Biodegradable lubricating oils may be used in
DEUTZ engines if they meet the requirements of this Engines with exhaust aftertreatment system
ic
operating manual. DQC III LA Please contact your DEUTZ part-
ner
er
Quality DQC IV LA
Lubricating oils are classified by DEUTZ according Engines without exhaust aftertreatment system
to their performance and quality class (DQC: DEUTZ DQC III Please contact your DEUTZ part-
Am
Quality Class). Essentially, the following applies: the DQC III LA ner
higher the quality class (DQC I, II, III, IV), the more
effective/the better quality the lubricating oil is. DQC IV
The DQC quality classes are still to be extended by DQC IV LA
the DQC-LA quality classes which include the mod-
of For low-ash engine oils released according to the
ern, low-ash lubricating oils (LA = Low Ash). DQC system an appropriate reference is made in the
Lubricating oils according to other comparable spec- oil release list.
ifications can be used as long as they meet DEUTZ
requirements. In regions in which none of these
qualities are available, please contact your responsi-
ble DEUTZ partner.
or see www.deutz.com
33
 OBJ_DOKU-29003-001.fm Seite 34 Donnerstag, 5. Januar 2012 8:59 08

Operating Media Lubricating oil

s
4 DEUTZ lubricating oils DQC III ● If the lubricating oil change intervals are not
reached within a year, the oil should be changed °C

ne
TLX - 10W40 FE
at least once a year.
Not for DPF 45
Container Order number: Viscosity
40

rli
5 litre container 0101 6335 The ambient temperature at the installation site or in
the application area of the engine is decisive for 35
20 litre container 0101 6336
choosing the right viscosity class. Too high a viscos-

Ai
209 litre barrel 0101 6337 ity can lead to starting difficulties, too low a viscosity 30
can endanger the lubrication effect and cause a high
DEUTZ lubricating oils DQC III LA low-ash lubricating oil consumption. At ambient temperatures 25

an
DEUTZ Oil Rodon 10W40 Low SAPS below -40 °C, the lubricating oil must be pre-heated
(e.g. by storing the vehicle or the machine in a hall). 20

SAE 20W-50
SAE 10W-30

SAE 10W-40

SAE 15W-40
Container Order number:

SAE 0W-30

SAE 0W-40

SAE 5W-30

SAE 5W-40
20 litre container 0101 7976 The viscosity is classified according to SAE. Multi- 15
purpose lubricating oils should be used basically.

ic
209 litre barrel 0101 7977 Single-purpose lubricating oils can also be used in 10
enclosed, heated spaces at temperatures >5 ° C.

er
DEUTZ lubricating oils DQC IV synthetic 5
DQC IV - 5W30-UHP The prescribed lubricating oil quality must
be observed when selecting the viscosity 0
Not for DPF

Am
class!
Container Order number: -5
20 litre container 0101 7849 Depending on the ambient temperature we recom-
mend the following common viscosity classes: -10
209 litre barrel 0101 7850
-15
Lubricating oil change intervals of
● The intervals depend on:
-20
– lubricating oil quality -25
– sulphur content in the fuel
ty
– type of application of engine -30
● The lubricating oil change interval must be
er

halved if at least one of the following conditions -35

applies:
-40
– Constant ambient temperature below -10 °C
op

(14 °F) or lube oil temperature below 60 °C

(84 °F).
Pr

34 © 2012
OBJ_DOKU-29003-001.fm Seite 35 Donnerstag, 5. Januar 2012 8:59 08

Fuel Operating Media

s
Permissible fuels diesel fuels in accordance with EN 590 and
ASTM D 975 described in the operation manual. No 4

ne
In order to satisfy the exhaust gas legislation, diesel
emission values are guaranteed with the other fuels
engines that are equipped with an exhaust aftertreat-
described in this operation manual.
ment system may only be operated with a sulphur-
free diesel fuel. The respective fuels prescribed by law must be used

rli
to comply with the national emission regulations
The operational reliability and durability of the indi-
(e.g. sulphur content).
vidual exhaust aftertreatment technologies cannot

Ai
be assured upon failure to comply. Please contact your DEUTZ partner

Exhaust aftertreatment systems http://www.deutz.com

DPF Diesel particle filter de \SERVICE\Betriebsstoffe und Additive\Kraft-

an
stoffe
DOC Diesel oxidation catalytic con-
verter en \SERVICE\Operating Liquids and Addi-
tives\Fuels

ic
The following fuel specifications / standards are ap-
proved: Winter operation with diesel fuel

er
● Diesel fuels Special demands are placed on the cold behaviour
– EN 590 (temperature limit value of the filtrability) for winter
operation. Suitable fuels are available at filling sta-

Am
Sulphur <10 mg/kg tions in winter.
– ASTM D 975 Grade 1-D S15
For engines with DCR® DEUTZ common
– ASTM D 975 Grade 2-D S15 rail injection, the mixing of petroleum and
Sulphur <15 mg/kg adding of extra low additives is not permis-
of sible.
● Light heating oils
– in EN 590 quality At low ambient temperatures paraffin discharges can
lead to blockages in the fuel system and cause oper-
Sulphur <10 mg/kg ating faults. Below 0 °C ambient temperature use
ty
winter diesel (down to -20 °C) (filling stations provide
If other fuels are used which do not meet the require- this in good time before the cold season starts).
ments of the operating manual, the warranty will be
er

● Special diesel fuels can be used for arctic cli-

voided.
mates to -44 °C.
The certification measurements for compliance with
the legal emission values are made with the test fu-
op

els specified in the laws. These correspond to the

Pr

© 2012 35
 OBJ_DOKU-29003-001.fm Seite 36 Montag, 7. November 2011 3:17 15

Operating Media Coolant

s
4 General ● pH value too low: ed to the materials in our engines. Order from your
DEUTZ partner.

Never operate the engine without coolant,
even for a short time!
Addition of diluted sodium or potassium lye.
Small trial mixtures are advisable.
● Total hardness too high:
Mixing with softened water (pH neutralized con-
ne
Please contact your DEUTZ partner if the DEUTZ
cooling system corrosion protection agent is not
available.

rli
In liquid-cooled engines, the coolant must be condi- densate or water softened by ion exchanger). or see www.deutz.com
tioned and monitored, otherwise the engine could be ● Chlorides and/or sulphates too high:

Ai
damaged by: Mixing with softened water (pH neutralized con- http://www.deutz.com
● corrosion densate or water softened by ion exchanger). de \SERVICE\Betriebsstoffe und
● cavitation Cooling system corrosion protection agent Additive\Kühlsystemschutz
● freezing

an
en \SERVICE\Operating Liquids and Addi-
● overheating Health damaging nitrous amines form tives\Cooling System Conditioner
when nitrite-based cooling system corro-
Water quality The cooling system must be monitored regularly.
sion protection agents are mixed with

ic
amine-based agents! This also includes checking the coolant system cor-
The right water quality is important for conditioning
rosion protection agent concentration in addition to
the coolant. Clear, clean water within the following
checking the coolant level.

er
analysis values should always be used: Cooling system corrosion protection agents
must be disposed of in an environmentally The cooling system corrosion protection agent con-
Analysis values min max ASTM friendly way. centration can be checked with conventional test in-

Am
ph value 6,5 8,5 D 1293 Observe the notes on the safety data struments (e.g. refractometer).
Chlorine (Cl) [mg/l] - 100 D 512 sheet.
Cooling system Water percent- Cold pro-
D 4327 The conditioning of the coolant for liquid-cooled corrosion protec- age tection up
Sulphate (SO4) [mg/l] - 100 D 516 DEUTZ compact engines is performed by mixing an tion agent percent- to
anti-freeze with corrosion protection inhibitors based age
Total hardness [mmol/l] 3,56 D 1126 of
(CaCO3) [mg/l] 356 on ethylene glycol into the water. min. 35 % 65 % -22 °C
[°dGH] 20,0 - DEUTZ cooling system corrosion protection agent 40 % 60 % -28 °C
[°e] 25,0 Container Order number: 45 % 55 % -35 °C
ty
[°fH] 35,6 5 litre container 0101 1490 max. 50 % 50 % -41 °C
20 litre container 0101 4616 At temperatures below -41 °C, please contact your
er

Specifications of the water quality are made by the

local water board. 210 litre barrel 1221 1500 responsible DEUTZ partner.
The water must be conditioned if it deviates from the It is possible to use other cooling system corrosion
This cooling system corrosion protection agent is
op

analysis values. protection agents (e.g. chemical corrosion protection

free from nitrite, amine and phosphate and is adapt- agents) in exceptional cases. Consult your DEUTZ
Pr

36 © 2011
OBJ_DOKU-29003-001.fm Seite 37 Montag, 7. November 2011 3:17 15

Coolant Operating Media

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partner.
4

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© 2011 37
 OBJ_DOKU-29003-001.fm Seite 38 Montag, 7. November 2011 3:17 15

Maintenance Maintenance schedule

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

ne
Standard maintenance schedule
TD/TCD 3.6 L4
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)

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E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation

Ai
E30 Maintenance Qualified personnel 500 1) 2) 3)
E40 Extended maintenance I 1.000 3)
E50 Extended maintenance II Authorised specialists 3.000 3)

an
E70 General overhaul 5.000 3) 4)

Observations

ic
1) The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (33).
2)

er
Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
3) The display of the operating hours should be ensured by the device manufacturer. The engine operating hours are recorded by the control unit. Enquiry via the CAN
bus and display in a display or creation/display via electromechanical counter.

Am
General overhaul
4)
The best time for a general overhaul depends to a great extent on the load, application and ambient conditions and the care and maintenance of the engine during the
operating time.
Your DEUTZ partner will advise you on determining the best time for a general overhaul.
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Maintenance schedule Maintenance

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Maintenance measures
5

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Stage Activity Measure Page
E10 The measures are listed in chapter 3. 22

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E20 Check Lubricating oil level (if necessary top up) 41
Coolant level (top up if necessary) 23

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Engine tightness (visual inspection for leaks)
Exhaust system including exhaust aftertreatment components for leaks 18
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 50

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Emptying of the water tank in the fuel pre-filter 45
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 33/41
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.

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Lubricating oil filter/insert (every time the lubricating oil is changed) 42
Check Coolant (additive concentration) 46

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Intake air pipes for damage
V-belts 52

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Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 45
E40 Check Charge air cooler entry area (drain lube oil/condensate)
Battery and cable connectors 53
Cold starting device
Engine mounting (tighten, replace if damaged when necessary)
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Fastenings, hose unions / clips (renew if damaged)
V-rib belt and tensioning pulley 51
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Replace Fuel filter cartridge 44
Filter insert for the fuel pre-filter. If the warning system responds (lamp/horn), the water trap bowl must be emptied 45
immediately.
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Dry air filter 50

V-belts 52
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E50 Replace V-rib belt and tensioning pulley 51

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Maintenance Maintenance schedule

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5 Stage Activity Measure Page

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annually Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Replace Fuel pre-filter 45
Every 2 Replace Dry air filter 50

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years Coolant 36 46
Status Change Diesel particle filter, the required exchange is displayed by the ash lamp or via an electronic display, depending on

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dependent the engine version (see DEUTZ exchange programme 29).
Maintenance work outside the DEUTZ maintenance and service schedules

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*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.
Maintenance profile
A self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment.

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Order number: 0312 3911 (TD/TCD 3.6 L4)

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Lubricating oil system
Regulations for working on the lubricating oil system
Do not work when the engine is running!
Smoking and naked lights prohibited!
Be careful of hot lubricating oil. Danger of
scalding!
Pay attention to utmost cleanliness when
working on the lubricating oil system. Clean
the area around the components con-
cerned carefully. Blow damp parts dry with
compressed air.
Observe the safety regulations and nation-
al specifications for handling lube oils.
Dispose of leaking lubricating oil and filter
elements properly. Do not allow used oil to
seep away into the ground.
Perform a trial run after all work. Pay atten-
tion to tightness and lubricating oil pressure
and then check the engine oil level.
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© 2011
Servicing and maintenance work
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OIL ?
● Extract the lubricating oil dipstick and read off the
oil level. 6
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● The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
essary.
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OIL Changing the lubricating oil
+80°C
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+176°F ● Warm up the engine (lubricating oil temperature
> 80 °C).
● Ensure that the engine or vehicle is in a level po-
sition.
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! ● Switch off the engine.
● Place a collecting receptacle underneath the
lube oil drain screw.
● Unscrew the lube oil drain screw, drain oil.
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Checking the lubricating oil level ● Fit a new sealing ring to the lube oil drain screw,
insert and tighten. (tightening torque 55 Nm).
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Low lubricating oil level and overfilling lead ● Pour in lube oil.
to engine damage. – Quality/viscosity data (33).
The lubricating oil level may only be
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– Filling volume (64).
checked with the engine in a horizontal po- ● Warm up the engine (lubricating oil temperature
sition and switched off. > 80 °C).
If the engine is warm, switch off the engine ● Ensure that the engine or vehicle is in a level po-
and check the lubricating oil level after 5 sition.
minutes. If the engine is cold you can check
of ● Check lubricating oil level, if necessary top up.
it immediately.
Be careful of hot lubricating oil. Danger of
scalding!
Do not pull out the dipstick while the engine
is running. Danger of injury!
● Pull out the lubricating oil dipstick and wipe off
with a lint-free, clean cloth.
● Insert the lubricating oil dipstick as far as it will
go.
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Servicing and maintenance work Lubricating oil system

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6

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Change lubricating oil filter ● Oil the gasket of the new DEUTZ original filter
cartridge lightly.

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The filter cartridge should never be pre- ● Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion!

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15-17 Nm
● Remove clamps when twist protection mounted ● Fasten clamps of the twist protection (optional).
(optional).
● Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
● Collect draining lubricating oil of
● Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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Fuel system Servicing and maintenance work

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Specifications when working on the fuel system Clean and dry the engine and engine com-
6

Engine must be switched off!
Smoking and naked lights prohibited!
No injection/high pressure pipes may be
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partment thoroughly before beginning
work.
Areas of the engine compartment from
which dirt could be loosened must be cov-

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disconnected while the engine is running. ered with a fresh, clean foil.
Caution when handling hot fuel! Work on the fuel system may only be car-
Pay attention to utmost cleanliness when

refuelling and working on the fuel system.
Clean the respective affected parts careful-
ly. Blow damp areas dry with compressed
air.
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ried out in an absolutely clean environment.
Contamination of the air such as dirt, dust,
moisture etc. must be avoided.

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Observe the safety regulations and nation-
al specifications for handling fuels.
Dispose of leaking fuel and filter elements

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properly. Do not allow fuel to seep away
into the ground.
After all work on the fuel system, the sys-

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tem should be vented, a trial run performed
and the tightness checked.
It will be necessary to vent the fuel system

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when commissioning for the first time, after
maintenance work or if the tank has been
run dry.

Additional venting of the fuel system by a 5 of

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

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6

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Change the fuel filter cartridge ● Oil the gasket of the new DEUTZ original filter
cartridge lightly.

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The filter cartridge should never be pre- ● Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion!

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10-12 Nm
● Fasten clamps of the twist protection (optional).
● Remove clamps when twist protection mounted
(optional). ● Vent the fuel system.
● Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
● Catch any escaping fuel. of
● Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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Fuel system Servicing and maintenance work

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● Loosen drain plug. turning anticlockwise. The pump pistons are now
pressed out through the spring. 6

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● Drain fluid until pure diesel fuel runs out.
9 1 ● Mount drain plug. ● Pump until no more air escapes at the vent
screw.
Tightening torque 1.6 ± 0.3 Nm ● Tighten vent screw.

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2
● Electrical connection Tightening torque 6.5 ± 1.3 Nm
8 – Connect cable connections.

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3 ● Lock the bayonet connection of the fuel supply
Change the fuel pre-filter insert pump by pressing upwards and simultaneously
7 ● Switch off the engine. turning clockwise.
4
● Shut off the fuel supply to the engine (with high- ● Start the engine and operate approx. 5 minutes

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level tank). in idling mode or at low load. Check the pre-filter
6 5 ● Place suitable collecting containers underneath. for leaks while doing this.
● Electrical connection

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– Disconnect cable connections.
Clean/change/vent the fuel pre-filter
● Loosen drain plug and drain liquid.

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Deutz Common Rail (DCR)
● Disassemble filter insert.
1 Venting screw ● Clean any dirt off the sealing surfaces of the new
2 Fuel supply flow to the pump

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filter cartridge and opposite side of filter head.
3 Fuel return flow from the control block FCU (Fuel ● Wet the sealing surfaces of the filter cartridge
Control Unit) slightly with fuel and screw back on to the filter
4 Fuel pump head, clockwise (17-18 Nm).
5 Electrical connection for water level sensor ● Mount drain plug.
6 Drain plug of
Tightening torque 1.6 ± 0.3 Nm
7 Filter insert
8 Fuel inlet from the fuel tank ● Electrical connection
9 Fuel return to fuel tank – Connect cable connections.
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Empty water tank ● Open the fuel shutoff tap and vent the system,
see venting the fuel system.
● Switch off the engine.
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● Place suitable collecting containers underneath. Vent the fuel system

● Electrical connection
● Loosen vent screw.
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– Disconnect cable connections.

● Unlock the bayonet connection of the fuel supply
pump by pressing upwards and simultaneously
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Servicing and maintenance work Cooling system

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6 Specifications when working on the cooling system

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Danger of scalding from hot coolant!
Cooling system under pressure! Only open
the cap when cool!

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The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!

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Observe safety regulations and national
specifications when handling cooling me-
dia.
Observe the manufacturer's specifications

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for an external cooler. 1
Dispose of leaking liquids properly and do
not allow them to seep into the ground.

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Order coolant corrosion protection agent
from your DEUTZ partner. Check coolant additive concentration Emptying the cooling system
Never operate the engine without coolant,

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● Open the cooling system cap (1) carefully.
even for a short time!
● Check the coolant aditive concentration in the
Checking the coolant level with an external cooler cooler/compensation tank (2) with a convention-
● Open cooler locking cap carefully.
● Place suitable collecting containers underneath.
● Remove the locking screw (1) in the crankcase.

● Fill in new coolant and vent the system according
to the specifications of the cooling system manu-
facturer.
● Open the cooling system cap (1) carefully.
● The coolant level must always be between the
MIN and MAX marks of the compensation tank!
Fill up to the MAX mark if necessary.
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al antifreeze measuring device (1) (e.g. hydrom-
eter, refractormeter).
● Necessary coolant additive concentration Cool-
ant mixing ratio (36).
You can order the appropriate test instrument from
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your DEUTZ partner under order number 1824.
● Drain coolant.
● If the locking screw is not accessible, the drain-
age can be carried out at the engine oil cooler
(coolant duct).
● Insert screw again with sealant.
● Close cooler locking cap.

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Cooling system Servicing and maintenance work

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6

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Fill and ventilate cooling system

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Danger of scalding from hot coolant!
Cooling system under pressure! Only open
the cap when cool!

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

to the MAX mark or filling level on the compensa-
tion tank if necessary.
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Servicing and maintenance work Engine cleaning

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6 Cleaning work Cleaning with cold cleaner

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● Spray the engine with cold cleaner and leave it
For all cleaning work, make sure that no for about 10 minutes to take effect.
parts are damaged (e.g. bent cooler mesh).
● Spray the engine clean with a high pressure wa-
Cover electrical/electronic parts and con-
ter jet.

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nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do ● Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.

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Allow engine to warm up. Cleaning with a high pressure cleaner

Only carry out cleaning work on the engine ● Clean the engine with a steam jet (maximum
spray pressure 60 bar, maximum steam temper-

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when it is not running!
Remove the engine cover and cooling air ature 90 °C, distance at least 1m).
cover if available and remount after clean- ● Warm up the engine so that the water residues
ing. evaporate.

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● Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.

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The following causes of soiling make it necessary to
clean the engine:
● High dust content in the air.

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● Chaff and chopped straw in the area of the en-
gine.
● Coolant leaks
● Lubricating oil leakage
● Fuel leaks of
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
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Cleaning with compressed air
● Blow dirt off or out. Always blow out the cooler
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and cooling fins from the exhaust air side to the

fresh air side.
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Suction system Servicing and maintenance work

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Regulations for working on the intake system Renewing the safety cartridge of the dry air filter
6

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1 5 2
Do not work when the engine is running! Never clean the safety cartridge (4).

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● Renew safety cartridge (4) according to the inter-
Pay attention to utmost cleanliness when
val in the maintenance schedule
working on the intake system, close intake

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openings if necessary. ● To do this:
Dispose of old filter elements properly. – Unscrew hexagon nut (5), pull out safety car-
tridge (4).
4 3 – Insert new safety cartridge, screw on hexag-

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onal nut.
● Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).

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Maintaining the dry air filter

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Do not clean the filter element (3) with pet-
rol or hot liquids!
Renew damaged filter elements.

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● Maintain the filter element (3) according to the in-
terval in the maintenance schedule
● Lift up the clamping yoke (1).
● Remove the filter hood (2) and pull out the filter
of element (3).
● Filter element (3):
– blow out with dry compressed air (max. 5
bar) from the inside to the outside if soiling is
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only slight,
– renew if heavily soiled.
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Servicing and maintenance work Suction system

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6

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1

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1

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Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter

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● The dry air filter is maintained according to a ● Empty the dust discharge valve (1) by pressing
maintenance switch or maintenance indicator. together the discharge slit.
● Maintenance is necessary when: ● Remove any caked dust by pressing together the

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– the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. ● Clean the discharge slit.
– the red field (1) of the maintenance indicator
is fully visible.
● After carrying out maintenance work, reset the
signal by pressing the button on the mainte- of
nance indicator. The maintenance indicator is
now ready for operation again.
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Belt drives Servicing and maintenance work

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Checking the belt drive
6

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Only carry out work on the belt drive with 1
the engine at a standstill!
After repair work: Check that all guards

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have been replaced and that all tools have
been removed from the engine.

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● Check the whole belt drive visually for damage.
● Renew damaged parts. 2
● Remount protective devices if necessary.
● Pay attention to correct fit of new belts, check the

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tension after running for 15 minutes.
3

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Replace V-rib belt

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1 Tension pulley
2 Retaining pin
3 Assembly bore

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● Press tensioning roller with socket wrench in the
direction of the arrow until a retaining pin can be
fixed in the assembly bore. The V-ribbed belt is
now tension free.
● First pull the V-ribbed belt off the smallest roller
ofor off the tensioning roller.
● Mount new V-ribbed belt.
● Retain tensioning pulley using the pin wrench
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and remove the holding pin.
● Tension V-ribbed belt using the tensioning roller
and socket wrench. Check whether the V-ribbed
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belt is correctly in its guide.

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Servicing and maintenance work Belt drives

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6

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4
1 B A
3

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2

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1
5 4 3 2

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Checking the belt tension Change the belt

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● Lower indicator arm (1) into the measuring de- 1 Screw
vice. 2 Screw
● Place guide (3) between two belt pulleys on the 3 Screw

V-belt (2). The stop have to be at the side.
● Press the button (4) at right angles to the V-belt
(2) evenly until you hear or feel the spring snap
in.
● Lift the measuring device carefully without alter-
ing the position of the indicator arm (1).
● Read the measured value at the point of inter-
section (arrow), scale (5) and indicator arm (1).
● If necessary, re-tension belt and measure again.
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Tools
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4 Setting screw
● Remove screw and lock nut.
● Move the generator over the setting screw in di-
rection (B) until the V-belt is slack.
● Remove belt and fit new one.
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● Move the generator over the setting screw in di-
rection (A) until the V-belt has attained the cor-
rect tension.
● Checking the belt tension (51).
● Tighten screw and lock nut again.

Belt tension measuring device (order number: 8115)

Tightening torque 30 Nm
can be obtained from your DEUTZ partner.
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Electrical system Servicing and maintenance work

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Regulations for working on the electrical system Danger of explosion! The gases emitted by
6

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the battery are explosive!
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective

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gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!

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nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage

not aim the water/steam jet directly at them.
Allow engine to warm up.
Touching a lead against the frame to check
whether it is live must not, under any cir-
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● Check the battery voltage with a standard volt-
meter. The voltage gives information about the
charge status.

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cumstances, be carried out.
Battery Charge status (Volt) Check acid density
For electrical welding work, the ground ter-
12 Volt 12-14,4

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minal of the welding gear must be clamped ● Unscrew caps.
directly to the part being welded. 24 Volt 24-28,4 ● Measure the electrolyte density of individual cells
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
Check acid level

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connect the cables between battery, gener- reading indicates battery’s state of charge. The
ator and regulator while the engine is ● Unscrew caps. acid temperature when measuring should be 20
running. °C if possible.
● Note the manufacturer’s specifications concern-
Battery ing the liquid level. ● Check the acid level before recharging.
The liquid should normally be 10-15 mm above ● Screw in caps.
Electronically stored data could be lost if
ofthe top edge of the plate or reach up to any avail-
able control device. Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. ● Only use distilled water to top up the battery. Normal Tropical
Make sure the battery is fitted correctly and ● Screw in caps. 1,28 1,23 good none
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securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
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Servicing and maintenance work Electrical system

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6 Removing the battery

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● Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
of short-circuit!
● Remove the fastenings and take out the battery.

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Charging the battery

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● Unscrew caps.
● Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!

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● Screw in caps.
Installing the battery

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● Insert new or charged battery and attach the fas-
tenings.

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● Clean the terminals and battery poles with fine
emery paper.
● Connect the plus pole first and then the minus

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pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
● Grease the assembled terminals with an acid-
free, acid-resistant grease.
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Fault table Faults

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Faults and remedies
7

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Faults Causes Measures
Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start

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Fuel tank empty Tanks
Fuel suction pipe blocked Check

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Below starting limit temperature Check
Cold starting device Check/replace
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil

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Fuel quality does not comply with operating manual Change the fuel
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections

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Starter defective or pinion does not engage Check starter
Air filter clogged / turbocharger defective Check/replace

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Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure

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Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
Engine starts, but runs irregularly or Exhaust gas backpressure too high
of Check
fails Compression pressure too low Check compression pressure
Cold starting device Check/replace
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Air in fuel system Vent
Fuel filter contaminated Clean
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Fuel quality does not comply with operating manual Change the fuel
Injector defective Change
Injection line leaks Check injection line
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Faults Fault table

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7 Faults Causes Measures

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Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
Engine becomes excessively hot. Vent line blocked Clean

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Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lube oil cooler defective Check/replace

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Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil

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Injector defective Change
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose

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Low coolant Fill up

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Resistance in cooling system is too high / flow volume too low Check the cooling system
Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension
Charge air line leaking Check charge air line

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Charge air cooler soiled Check/clean
Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose
of Check fan/V-belt, change if necessary
Exhaust gas backpressure too high Check
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Fault table Faults

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Faults Causes Measures
7

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Engine output is deficient Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil cooler fins soiled Clean
Fuel suction temperature too high Check the system

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Fuel quality does not comply with operating manual Change the fuel
Air filter clogged / turbocharger defective Check/replace

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Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air line leaking Check charge air line

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Charge air cooler soiled Clean
Resistance in cooling system is too high / flow volume too low Check the cooling system

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Injection line leaks Check injection line
Injector defective Change

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Engine performs poorly and diagnos- Engine electronics reduce performance Please contact your DEUTZ partner
tic lamp lights
Engine does not run on all cylinders Injection line leaks Check injection line

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Injector defective Change
Charge air line leaking Check charge air line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low
of Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
ty
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
er

Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
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Excessive inclination of engine Check engine mounting / reduce inclination

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 OBJ_DOKU-29003-001.fm Seite 58 Montag, 7. November 2011 3:17 15

Faults Fault table

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7 Faults Causes Measures

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Engine producing white smoke Below starting limit temperature Check
Cold starting device Check/replace
Fuel quality does not comply with operating manual Change the fuel

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Injector defective Change
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace

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Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
Injector defective Change

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Regeneration lamp flashing Diesel particle filter is contaminated with soot and must be regenerated Initiate standstill regeneration 29
Regeneration lamp flashing quickly Diesel particle filter is contaminated with soot and must be regenerated Initiate standstill regeneration 29
Engine warning lamp lit Standstill regeneration has not been released

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Regeneration lamp flashing quickly Diesel particle filter is contaminated with soot and must be regenerated Release of the standstill regeneration by the
Engine warning lamp flashing Standstill regeneration has not been released DEUTZ partner

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Power reduction
Regeneration lamp flashing quickly Diesel particle filter is overloaded Replace diesel particle filter

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Engine warning lamp flashing
Ash lamp lit

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58 © 2011
OBJ_DOKU-29003-001.fm Seite 59 Montag, 7. November 2011 3:17 15
Engine management
1 safely possible.
2 The error lamp can release the following signals:
3 system with the ignition key for approx. 30s.
Engine protection function of the electronic engine
control
1 Diagnosis button
2 Error lamp
3 Electronic engine control (EMR)
The error lamp goes out when all the errors
have been eliminated. For some errors, it is
necessary to switch off the ignition, wait 30
s and only then switch back on the ignition.
The appropriate monitoring functions are
switched off when a sensor fails. Only the
ty
sensor failure is documented in the error
memory.
er
Depending on the design of the monitoring functions,
the electronic engine control can protect the engine
in certain problematical situations by monitoring im-
op
portant limit values during operation and checking
the correct function of the system components.
Pr
© 2011
Faults
s
Depending on the seriousness of a recognised fault,
the engine can continue to operate with limitations,
– Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guaran- 7
ne
during which the error lamp lights up continuously or tee!
indicates a serious system error by flashing. In this – The engine has reached switch-off condition.
case, the engine should be switched off as soon as – Engine forced to run with power reduction to
rli
cool the engine, with automatic shutdown if
necessary.
Error lamp
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– The switch-off process has been accom-
The error lamp is located in the vehicle drive stand. plished.
– There may be a start lock after engine stop.
● Function test – The start lock is deactivated by turning off the
an
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out. – optionally the power reduction can be by-
passed, the automatic switch-off delayed or
– Check the error lamp if there is no reaction
a start lock bypassed with the override key
ic
after switching on the ignition.
on the instrument panel to avoid critical situ-
● The lamp does not light ations. This brief deactivation of the engine
er
– After the lamp test an extinguished lamp indi- protection functions is logged in the control
cates an error-free and trouble-free operat- unit.
ing state within the scope of the control
Please contact your DEUTZ-partner in case of
Am
possibility.
malfunctions and sare parts inquiries. Our spe-
● Continuous light cially trained personnel will ensure fast, profes-
Error in system. sional repairs using original DEUTZ spare parts
in case of damage.
– Operation continued with restrictions.
– The engine must be checked by a DEUTZ
of partner.
– If a lamp lights steadily a monitored measur-
ing variable (e.g. coolant temperature, lubri-
cating oil pressure) has left the permissible
value range.
Depending on the fault, the engine power
may be reduced by the electronic engine
control to protect the engine.
● Flashing
Serious error in system.
59
 OBJ_DOKU-29003-001.fm Seite 60 Montag, 7. November 2011 3:17 15

Faults Engine management

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7 Diagnosis button

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The diagnosis button allows the errors currently
saved in the error memory of the electronic engine
control to be visualised in the form of a flash code.
The flash codes permit:

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● Errors that may occur can be classified.
● Clear display of the error as visual signal.

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– The blink codes can only be interpreted by a
DEUTZ partner.

0,8 s
0,4 s
0,4 s

0,4 s
0,8 s

0,4 s
2s 2s
Use of the diagnostic key

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The flash code displays all errors in the error memo-
ry, this means active as well as passive ones.
The control unit must be switched off to start the en-
1 2 8

ic
quiry (ignition off). Then the diagnosis button should Display system error by flash code
be pressed for approx. 1s during the start (ignition

er
on). Example:
Then the next error (i.e. the following one in the error Flash code 1-2-8
memory) can be displayed by pressing the diagnos-

Am
1 x short flash
tic key again. If the last error was displayed, the first
2 x long flash
error is displayed again on pressing the diagnostic
key again. 8 x short flash
After the display of the error flash code, the error This flash code indicates a break or short circuit in
lamp goes out for five seconds. the wiring of the charge air temperature sensor. The
of
temporal sequence of the flash signals is shown in
the illustration.
● The blink codes can only be interpreted by a
DEUTZ partner.
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60 © 2011
OBJ_DOKU-29003-001.fm Seite 61 Montag, 7. November 2011 3:17 15

Transport Transport and storage

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8

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1
1

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2

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2

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Suspension equipment
Danger to life!

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The engine may tip over or fall down if sus-
The transport devices mounted on this en- pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com-

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● The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. ● The fastening attachment can slip, the engine
swings backwards and forwards (1).
● Always use proper suspension equipment when
transporting the engine. ● Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
● The suspension device (1) must be adjustable ofdamage it.
for the engine's centre of gravity.
● After transportation and before commissioning of
engine: remove attachment eyes (2).
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© 2011 61
 OBJ_DOKU-29003-001.fm Seite 62 Montag, 7. November 2011 3:17 15
Transport and storage
8 General
Engines contain the following types of corrosion pro-
tection:
● Interior corrosion protection
● Exterior corrosion protection
Your DEUTZ partner has the right corro-
sion protection agent for your needs.
The following measures for corrosion protection after
taking the engine out of operation meet the require-
ments for 12 months corrosion protection.
The following corrosion protection work may only be
carried out by persons familiar with it and instructed
in the potential dangers.
If these measures are deviated from by exposing the
corrosion-protected engines or parts to unfavourable
conditions (installation outdoors or storage in damp,
badly aired places) or damage to the corrosion pro-
tection layer, a shorter corrosion protection duration
is to be expected.
The engine corrosion protection should be checked
about every 3 months by opening the covers. If cor-
rosion is detected, the corrosion protection should
be renewed.
At the end of the corrosion protection work the crank
drive may no longer be turned so that the corrosion
protection agent in the bearings, bearing liners and
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cylinder liners is not scraped off.
Before operating a corrosion protected engine, the
er
corrosion protection must be removed.
Interior corrosion protection
op
● Interior corrosion protection is always provided
by wetting of the walls with the implemented cor-
Pr
62
rosion protection agent in a corrosion protection
run of the engine.
● The corrosion protection run can be performed
once to protect the different systems:
Fuel system
Close the fuel/tank/supply line to the en-
gine so that the system is protected against
dirt and dust. Protect the electronics
against moisture and corrosion.
an
● Fill the fuel tank with a mixture of:
– 90 % distilled fuel
– 10 % corrosion protection oil.
ic
● Perform a corrosion protection run with no load
for at least 5 minutes.
er
Lubricating oil system
● Drain lubricating oil from warm engine.
Am
● Thoroughly clean lube oil tray, cylinder head with
rocker arms, valves, valve springs with diesel
fuel or cleaning agent.
● Fill the engine with corrosion protection oil up to
the MAX mark and perform a corrosion protec-
tion run for at least 5 minutes so that all the com-
ofponents of the lubricating oil system are wetted
or wet all accessible parts with corrosion protec-
tion oil and pump corrosion protection oil through
the engine with a separate pump until all bear-
ings and bearing liners are wetted.
Cooling system
● Depending on the series the engines are
equipped with cooling air, cooling oil or cooling
fluid system (cooling water with cooling system
protection agent).
Engine corrosion protection
s
● Cooling air system, see the Exterior corrosion
protection section.
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● In engines of the oil-cooled series the circulating
lubricating oil serves simultaneously for cooling.
The cooling chambers are protected automati-
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cally against corrosion with the lube oil system.
● If a coolant with corrosion protection properties is
poured into liquid-cooled engines, no further ac-
Ai
tion is necessary after draining.
● If not, the coolant must be drained and, to ensure
the formation of a covering layer on the inside
surfaces of the cooling system, a corrosion pro-
tection run performed with a mixture of:
– 95 % treated water
– 5 % corrosion protection agent
● The duration of the corrosion protection run and
the concentration of the corrosion protection
agent are specified by the manufacturer of the
corrosion protection agent.
● Then drain the coolant.
Air intake pipes
● After the corrosion protection run, remove the
cylinder head cover and deinstall injectors. The
respective piston must be set to LT.
● The accessible part of the cylinder liner should
be coated with corrosion protection oil with a
spray lance through the opening.
● Spray corrosion protection lubricating oil into the
suction intake pipe.
Exterior corrosion protection
● The engine must be cleaned thoroughly with a
cleaning agent before exterior corrosion protec-
tion. Any signs of corrosion and damage to the
paintwork must be removed.
© 2011
OBJ_DOKU-29003-001.fm Seite 63 Montag, 7. November 2011 3:17 15
Engine corrosion protection
Bare exterior surfaces and parts
● Coat or spray all bare exterior parts and surfaces
(e.g. flywheel, flange faces) with corrosion pro-
tection agent.
Rubber parts
● Rubber parts (e.g. muffs) which are not painted
over must be rubbed down with talcum powder.
Belt drive
● Remove V-belts and V-rib belts and store
packed.
● Spray V-belt pulleys and tension rollers with cor-
rosion protection agent.
Engine openings
● All engine openings must be fitted with air-tight,
water-tight covers to delay the vapourisation
process of the corrosion protection agents.
● With installed air compressor, the suction and
pressure connection must be sealed by a cap.
● Air should be excluded to avoid ventilation of the
engine (chimney effect) for the suction from an
air supply pipe.
Storage and packaging
● After being protected against corrosion, the en-
gine must be stored in a dry, ventilated hall and
ty
suitably covered.
● The cover must be placed loosely over the en-
gine so that the air can circulate around it to pre-
er
vent condensation from forming. Use a desiccant
if necessary.
op
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© 2011
Transport and storage
s
Removal of corrosion protection tilled fuel or a suitable cleaning agent.
8
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● The corrosion protection must be removed from ● Wash out grooves of V-belt pulleys if necessary.
the corrosion protected engine before starting. ● Mount V-belts or V-rib belts as specified.
● The packaging and all covers over the closed ● Fill with coolant.
openings must be removed.
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Corrosion protection agent / cleaning agent
● Any corrosion deposits and paint damage should
be remedied. Please ask your DEUTZ partner for reference prod-
Ai
ucts for the corrosion protection agents/cleaning
Fuel system agents to be used which meet DEUTZ requirements.
If there is a mixture of diesel fuel/corrosion pro- or see www.deutz.com
tection oil in the fuel tank, drain it.
an
● Connect fuel/tank/supply line to the engine. Pay http://www.deutz.com
attention to cleanliness. de \SERVICE \Betriebsstoffe und Addi-
● Fill the fuel tank and fuel system with the proper tive\Motorkonservierung
ic
fuel. en \SERVICE\Operating Liquids and Addi-
tives\Engine Corrosion Protection
Lubricating oil system
er
● Unscrew the lube oil drain screw, drain oil.
● Fill the engine with lubricating oil via the lubricat-
Am
ing oil filler neck.
Coolant system
● If the implemented corrosion protection agent is
compatible with the intended cooling system pro-
oftection agent, this can be filled directly into the
coolant system as specified.
● If it is uncertain whether the implemented corro-
sion protection agent is compatible with the cool-
ing system protection agent, the cooling system
should be purged with fresh water for about 15
minutes before filling.
Removal of exterior corrosion protection
● All areas and components coated with corrosion
protection agent must be washed off with dis-
63
 OBJ_DOKU-29003-001.fm Seite 64 Montag, 7. November 2011 3:17 15

Technical data Engine and setting data

s
9 General technical data

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Engine type Dimension TD 3.6 L4 TCD 3.6 L4
Working principle Four-stroke diesel engine

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Charging Exhaust gas turbocharger Turbocharger with charge air cool-
ing
Type of cooling water-cooled

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Cylinder arrangement in series
No. of cylinders 4
Bore/stroke [mm] 98/120

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Total displacement [cm3] 3621
Combustion process Direct injection

ic
Injection system Common Rail
Exhaust gas recirculation externally cooled

er
Exhaust gas aftertreatment Diesel oxidation catalytic converter DOC
and/or

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Diesel particle filter DPF
Valves per cylinder 2
Firing order of the engine 1-3-4-2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 of [kW] see engine rating plate
Speed (nominal revolutions) [min-1] see engine rating plate
Injection timing [°BTDC] see engine rating plate
ty
Coolant volume (only engine content without cooler / hoses and pipes)
Industrial engines/Agricultural technology  [l] 4,6/4,6
er

Permissible continuous coolant temperature [°C] max. 110

Temperature difference between coolant inlet/outlet [°C] 8
Start of thermostat opening [°C] 88
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Thermostat fully open [°C] 95

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64 © 2011
OBJ_DOKU-29003-001.fm Seite 65 Montag, 7. November 2011 3:17 15

Engine and setting data Technical data

s
Engine type Dimension TD 3.6 L4 TCD 3.6 L4
9

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Lubricating oil change volume (with filter)  [l] 8*
Lube oil temperature in the lube oil tray, maximum [°C] 125
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 80/0,8

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Permissible maximum combustion air temperature after charge air cooler [°C] 50
V-belt tension Pre-tensioning/Re-tensioning

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V-belts AVX (width: 13 mm) [N] 650±50/400±50
V-rib belt tensioning Automatic tensioning spring-loaded clamping roller
Weight without cooling system according to DIN 70020-A  [kg] 350

an
*specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants
and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.

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© 2011 65
 OBJ_DOKU-29003-001.fm Seite 66 Montag, 14. November 2011 9:43 09

Technical data Tools

s
9 Tool ordering

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The special tools described in this chapter can be or-
dered from:
Please contact your DEUTZ partner

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Ai
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Special wrench for loosening exchangeable filters Refractometer

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Order number: Order number:
170050 0293 7499

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For loosening changeable filters. The following operating media can be evaluated with
this test device:
● Coolant
● Battery acid
● AdBlue®
of The test device can be ordered via the relevant
DEUTZ partner.
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66 © 2011
OBJ_DOKU-34031-001.fm Seite 95 Montag, 26. November 2012 1:56 13

DEUTZ Operating Fluids

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Ai
an
ic
er
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DEUTZ Oil Rodon 10W40 DEUTZ Oel TLX-10W40FE DEUTZ Cooling System
low SAPS (DQC III-10 LA) (DQC III-10) Conditioner
5L
20 L
-
0101 7976
5L
20 L
of 0101 6335
0101 6336
5L
20 L
0101 1490
0101 6416
209 L 0101 7977 209 L 0101 6337 210 L 1221 1500
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DEUTZ Oel DQC4-5W30-UHP

er

(DQC IV-10)
5L -
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20 L 0101 7849
209 L 0101 7850
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OBJ_DOKU-29003-001.fm Seite 68 Montag, 7. November 2011 3:17 15

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Ai
DEUTZ AG

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Information Systems Sales & Service
Ottostraße 1

ic
51149 Köln
Germany

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Phone: +49 (0) 221-822-0

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Fax: +49 (0) 221-822-3525
E-Mail: info@deutz.com
www.deutz.com
of Printed in Germany
© 11/2011
All rights reserved
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Order number:
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0312 3907 en
The engine company. Original operating instructions
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