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TCD 2012 L04/06 4V TCD 2013 L04/06 4V: Instruction Manual
TCD 2012 L04/06 4V TCD 2013 L04/06 4V: Instruction Manual
TCD 2012 L04/06 4V TCD 2013 L04/06 4V: Instruction Manual
© 2005
0312 2443 en
Engine number:
© 2005
require our written permission.
Dear customer,
Your
DEUTZ AG
© 2005
© 2005
2.5.2 Exhaust gas recirculation diagram 5.1 Maintenance schedule 6.7.1 Battery
2.6 Electrics 5.2 Maintenance diagram 6.7.2 Three-phase current generator
2.6.1 Electrical cable connections for 5.3 Maintenance work carried out 6.7.3 Transportation suspension
monitoring
9. Technical data
9.1 Engine and setting data
9.2 Screw tightening torques
9.3 Tools
10. Service
© 2005
are the product of years of research and are decisive for whether the engine Please consult one of our service
development. The profound know-how satisfactorily meets the demands put on it. representatives responsible for operating
gained in connection with high quality Compliance with the prescribed maintenance faults and spare parts questions. Our trained
requirements is the guarantee for times and the careful execution of specialist personnel ensures fast,
manufacturing of engines with a long life, maintenance and care work are therefore professional repairs using original parts in
high reliability and low fuel consumption. essential. Difficult operating conditions the event of damage.
Naturally the high requirements for protection deviating from normal operation must be The Technical Circulars listed in this operating
of the environment are also met. observed especially. manual are obtainable from your DEUTZ
partner.
Please turn to the end of this manual for
further service information.
Only carry out maintenance work or repairs This symbol is used for all safety Danger for component/engine.
with the engine switched off. Ensure that the instructions which, if not Failure to comply can lead to
engine cannot be started unintentionally - observed, present a direct destruction of the component/
danger of accidents! danger to life and limb for the engine. Must be observed.
Re-install any removed protective equipment person involved. Observe these
upon completion of the work. carefully. Also pass on the
Observe industrial safety regulations when safety instructions to your operating
operating the engine in enclosed spaces or personnel. Furthermore, the legislation for
underground. „general regulations for safety and the
© 2005
When working on the running engine, work prevention of accidents“ must be observed.
clothing must be close fitting.
Only re-fuel with the engine switched off.
2
2.1 Engine type
2.2 Engine diagrams
2.3 Lube oil circuit
2.4 Fuel circuit
2.5 Coolant circuit
2.6 Electrics
© 2005
The engine type A, engine numberB and the The company plate C is fixed on the crankcase. Or company plate C is fixed on the cylinder head
power data are stamped on the company plate. cover.
The engine type and number must be stated Or both plates are attached.
when purchasing spare parts.
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© 38 988 0 © 38989 0
The engine number is stamped on the crankcase The cylinders are counted consecutively, starting
(arrow) and on the company plate. from the flywheel.
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© 38 980 1
© 38 981 1 © 2005
© 38 982 0
© 38 983 0 © 2005
1 Exhaust turbocharger
2 EGR exhaust gas recirculation
3 Intake elbow from charge air cooler
4 Coolant return from cooler
5 Coolant pump
6 Fuel supply pump
7 Spring-loaded tension pulley
8 V-rib belt
9 Belt pulley for drive
10 Coolant inlet adapter from cooler
11 Mounting foot (engine suspension)
12 Oil tray
13 Oil drain screw
14 Fuel filter
15 Lube oil filter
16 Fuel connection from tank
17 Lube oil cooler
18 Fuel pre-filter
19 Generator
20 Central connector
21 ECU ElectronicControl Unit
22 High-pressure pump
23 Crankcase ventilation
24 Rail with pressure reducing valve
25 Charge air sensor
26 Cylinder head cover
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© 43 895 0
© 43 896 0 © 2005
1 Exhaust turbocharger
2 Coolant return from heater
3 Coolant outlet to cooler
4 Intake elbow from charge air cooler
5 Generator
6 Coolant pump
7 Spring-loaded tension pulley
8 Deflection pulley
9 Front power takeoff
10 Oil tray
11 Coolant inlet adapter from cooler
12 Lube oil filter
13 Fuel filter
14 Compressor (optional)
15 SAE housing
16 Lube oil cooler
17 Crankcase ventilation socket
18 Coolant outlet adapter to heater
19 Engine suspension
20 Cylinder head cover
© 2005
© 43 826 0
© 43 827 0 © 2005
1 Oil tray
2 Intake pipe
3 Lube oil pump
3.1 Safety valve
4 Lube oil cooler
4.1 Reverse lock valve
4.2 By-pass valve
4.3 By-pass valve
4.4 Control valve
5 Exchangeable lube oil filter
6 Main oil pipe
6a Engine brake lubrication
A Exhaustgasrecirculation (EGR) lubrication
7 Crankshaft bearing
8 Con rod bearing
9 Camshaft bearing
10 Line to injection nozzle
11 Injection nozzle for piston cooling
12 Tappet with rocker arm pulse lubrication
13 Stop rod, oil supply for rocker arm
lubrication
14 Rocker arm
15 Return line to oil tray
16 Oil line to exhaust turbocharger
17 Exhaust turbocharger
18 Oil line to compressor or hydraulic pump
19 Compressor or hydraulic pump
20 Return line from compressor
21 Return line from cylinder head
22 Exhaust turbocharger return to crankcase
© 2005
© 39 012 3
© 38 991 0
1 Fuel container
2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
5 Fuel cooling for engine control unit
(without cooler, upper right in diagram)
6 Fuel filter
7 Line to injection pumps
8 Fuel to control unit
9 Tappet rollers on camshaft
10 DCRRail
11 Injection line to injection valve
12 Injectors
13 Fuel leak oil line
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14 Return line to container
A Keep distance as large as possible © 38 992 2
2
© 2005
© 39 982 3
2
1 Coolant inlet to engine
2 Coolant pump
3 Thermostat housing
4 Lube oil cooler (plate cooling)
5 Cylinder head cooling and EGR cooling
6 Coolant supply to engine brake
7 Engine brake cooling
8 Return line to thermostat
9 Heat exchanger (customer)
10 Fan (customer)
11 Compensation tank (customer)
12 Heating connection
13 Compensation tank return line
to heater connection
14 Thermostat compensation tank return
15 Engine ventilation to compensation tank
16 Return line from engine heat exchanger
© 2005
© 39 010 0 © 2005
© 2005
3.1.1 Filling engine oil 3.1.2 Filling fuel 3.1.3 Filling / bleeding cooling
3 system
The engines are generally supplied without Only use clean, standard, branded diesel fuel. z Connect the coolant outlet 2 and coolant inlet
oil filling. For fuel quality see 4.2. 1 to the cooling system. Connect the lead line
Fill engine with lube oil through the oil filler (1) Depending on the outdoor temperature, use from the compensation tank to the water pump
on the cylinder head cover. Alternatively, you either summer or winter diesel fuel. or to coolant inlet pipe 1.
can fill on the wheel box (2) or on the side of z Connect vent lines from the engine and if
the crankcase. necessary from the cooler to the compensation
For oil filling amount see 9.1. tank.
For quality and viscosity of oil see 4.1.
z Fill the cooling system through the
compensation tank
z Close the compensation tank with the valve.
z Start the engine and warm up until the
Oil may not be filled into the Only re-fuel when the engine is thermostat opens (line 2 heats up).
dust collecting tank of the not running! z Run engine run with open thermostat for
© 2005
© 2005
a 1 minute pause. If the engine has not started system with the ignition key for about 30 seconds.
is given by the EMR3. after two attempts, find the cause in the fault
table (see 7.1).
© 26 411 0
z Insert key.
- Step 0 = no operating voltage.
z Turn key to the right.
- Step 1 = operating voltage,
- Warning lights 1+2+3 light up.
- Pre-heat until heating indicator goes out. If the
pre-heating indicator flashes, there is an
error, e.g. pre-heating relay sticking which
can fully discharge the battery at standstill.
- Engine is ready for operation.
z Turn the key further to the right against the
spring load to
- Step 2 = start Caution: Engine must start within 30 seconds,
© 2005
z Release key as soon as the engine starts up. if not, repeat the starting process.
- Warning lights go out.
The EMR3 system monitors the engine condition 3.3.1 Engine oil pressure
3 and itself.
The states are indicated by the diagnostic
lamp. Oil pressure light Oil pressure gauge
Lamp test:
z The diagnostic lamp lights for about 2s after
ignition (ignition lock stage 1).
Steady light:
z There is an error in the system or a variable of
the engine (temperature, pressure, etc.) is in
the warning area. Depending on the error, the
performance of the engine may be reduced by
the EMR3 to protect the engine so that it is not
in danger.
Fast flashing:
z Attention, the engine is in danger and
must be switched off.
z Depending on the application, the
control unit switches the engine off
automatically.
z The control unit may also specify an idle speed
to cool the engine before shutting down. © 25 752 1 © 25 754 0
z There may be a start lock after stopping the z Needle of oil pressure measuring instrument
engine. must show the minimum oil pressure (see 9.1).
z Additional control lamps e.g. for oil pressure or z The oil pressure light comes on for about 2s
oil temperature may be on. after switching on the system.
z The override key can bypass the reduction in z The oil pressure light must be off when the
performance to avoid critical situations, as engine is running.
well as delay the automatic shutdown or
bypass a start lock. This overwriting of the
engine protection functions is logged in the
control unit.
z The start lock is released by switching off the
system with the ignition key for about 30
seconds.
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3.3.2 Coolant temperature 3.3.3 Coolant level 3.3.4 Lube oil level
3
© 26 246 0 © 26 291 1
min © 26 278 1
z The needle of the temperature display should z Light on coolant level display comes on (contact z Light on lube oil level display comes on (contact
always be in the green area, and only as an is via float switch/ level probe if coolant level is via float switch / level proble if lube oil level
exception in the yellow/green area. If the is at minimum): is at minimum):
needle rises into the orange area the engine is Switch off the engine and determine the cause Switch off the engine and determine the cause
getting too hot. Switch off the engine and as per fault table (see 7.1). as per fault table (see 7.1).
determine the cause as per fault table (see z Function check of coolant level: z Function check of lube oil level :
7.1). Key in step 1 or 2 Key in step 1 or 2
(Float switch or level probe) (Float switch or level probe)
Warning light comes on for approx. 2 seconds Warning light comes on for approx. 2 seconds
- Coolant level OK: - Lube oil level OK :
Light goes out Light extinguished.
- Coolant level not OK: - Lube oil level not OK :
Light comes on again. Light comes on again.
© 2005
P 0
– +
1
1
2 2
© 26 411 0
housing).
Lube oil is no longer supplied to the
turbocharger!
Run the engine after relieving the load for about
one minute at low idling speed.
© 2005
© 2005
Lube oils are classified by DEUTZ into quality Since lube oil changes its viscosity (viscidity)
classes according to their performance depending on temperature, the ambient
capability. Oils according to other comparable temperature of the location of engine operation
specifications can be used. is decisive for the selection of viscosity class
(SAE class). Refer to the oil viscosity diagram
on the right to achieve optimal operating
performance.
Permissible oils: Falling below the temperature limits
occasionally can impair the cold start ability,
but will not lead to engine damages. In order
Deutz DQC I-02 DQC II-05 DQCIII *+DQCIV# to minimise wear, the operating limits should
not be exceeded over a long period of time.
ACEA E2-96 E3-96/E5-02/ E4-99/ Oil changes determined by the time of year
E7-04 E6-04 can be avoided by using multi-viscosity oils.
Multi-viscosity oils, in particular smooth running
API CF/CF-4 CH-4/CG-4 - oils, also have the effect of reducing fuel
DHD - DHD-1 - consumption.
DQCIII-05 * Annex 1
DQC IV-05 # only fully synthetic
The exact assignment of permissible oil quality
and oil change intervals to the engines is
listed in chapter 6.1.1.
In case of doubt, please ask your service
representative.
© 2005
EXPERTY MX 1012 Scandinavia, Austria
FINA KAPPA FIRST 5W-30 Europe
FINA KAPPA ULTRA 10W-40 Europe
This table will be extended if necessary.
4.2.1 Quality
4 4.2.2 Winter fuel
Use standard diesel fuels with a sulphur content At low ambient temperatures paraffin
of less than 0.5 %. If the sulphur content is higher, discharges can lead to blockages in the fuel
the oil change intervals must be reduced (see system and cause operating faults. Use winter
6.1.1). fuel at outside temperatures below 0 °C (to
-20 °C) (generally offered by petrol stations
The following fuel specifications are in good time before the cold season begins).
permitted:
z Diesel fuels z Paraffin should be added at temperatures
- DIN EN 590 below -20 °C. The mixing ratios required
z JIS K 2204 grade 1 and 2 * are as per the diagram on the right.
z ASTM D 975-88; 1-D and 2-D *
* as long as the lubrication properties z Special diesel fuels can be used for arctic
correspond to diesel fuel EN 590 (positive climates to -44 °C.
test results are necessary)
(see TR 0199-99-3005) Íf it is necessary to use summer diesel fuel
If other fuels are used which do not meet the under 0 °C, paraffin can also be added by up
© 43 923 0
requirements of the technical circular, the to 30% as per the diagram on the right.
warranty will be voided.
Technical circular is obtainable from the DEUTZ Diagram key:
Service Organisation.
I Summer diesel fuel
The certification measurements for the
observance of legal emission limits are carried For the engines TCD 2013 4V II Winter diesel fuel
out with the test fuels defined by legislation. and fuel according to ASTM D
975 1-D/2-D, adding paraffin A Outside temperature
These correspond to the diesel fuels
described in section 1 in accordance with EN is not permissible. B Paraffin mixing proportion
590 and ASTM D 975. Emission values cannot
be guaranteed with the other fuels described
in this circular. Generally, sufficient resistance to cold can
also be achieved by adding a flow ameliorant.
For questions regarding this please contact Only carry out mixing in the tank!
your DEUTZ partner. First pour in the necessary
© 2005
4.3.1 Water quality for coolant 4.3.2 Coolant preparation 4.3.3 Cooling system preservative
4
The following values may not be exceeded or Particular attention should be paid to preparing Using the cooling system preservative, order
fallen short of. and inspecting the coolant in liquid-cooled no. 01011490/ 01016416/12211500 (nitrite,
A test case can be requested from DEUTZ engines, as otherwise corrosion, cavitation amine and phosphate free, available in 5/ 20/
Service under the order no. 1213 0382 for and freezing damages can occur on the 210 litre containers), provides effective
checking your water quality. engine. protection against corrosion, cavitation and
Preparation of the coolant involves mixing a freezing.
cooling system preservative to the cooling The cooling system preservative in the coolant
Analysis values min. max. water. must not fall below or exceed the following
ph value at 20 °C 6.5 8.5 The cooling system must be monitored concentrations:
regularly, see 5.1. This includes checking the Cooling system Water Cold protection
Chloride ion content[mg/dm3] - 100 concentration of the cooling system preservative proportion to
preservative, as well as inspecting the coolant proportion
Sulphate ion content[mg/dm3] - 100
level.
The inspection of the concentration of cooling min. 35 % 65% -22 °C
Total hardness [°dGH] 3 20
system preservative can be carried out with 40 % 60% -28 °C
* Carbonate hardness proportion of total standard testing devices. (Example: gefo
glycomat R ). max. 45 % 55% -35 °C
hardness min 3 dGH
For filling amounts see the table overleaf in
combination with the information in chapter
9.1.
The use of other cooling system
preservatives, e.g. chemical corrosion
preservatives, is possible in exceptional
cases, consult DEUTZ Service.
.Contact your local waterworks for information Mixing cooling system Cooling system preservatives
regarding the water quality. preservatives of a nitrite must be disposed of in an
© 2005
base with substances of an environmentally friendly manner.
amine basis forms harmful
nitrosamines.
© 2005
1)
The intervals can be reduced, depending on the degree of soiling of the fuel used.
© 2005
20.000
30.000
120.000
240.000
5,000
480,000
20,000
40,000
50,000
60.000
90.000
120.000
360.000
1000.000
EGR* Exhaust gas recirculation (system); If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.
1)
The intervals can be reduced, depending on the degree of soiling of the fuel used.
*) approximate value, depends on the type of engine application and/or regular engine maintenance.
Please contact your responsible DEUTZ Service partner.
© 2005
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2750
* after commissioning new and overhauled engines
The maintenance work carried out methodically can be recorded in the table and confirmed.
© 2005
5 Op. hrs. Date Signature / stamp Op. hrs. Date Signature / stamp
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
The maintenance work carried out methodically can be recorded in the table and confirmed.
© 2005
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
The maintenance work carried out methodically can be recorded in the table and confirmed.
© 2005
5 Op. hrs. Date Signature / stamp Op. hrs. Date Signature / stamp
8875 9000
9125 9250
9375 9500
9625 9750
9875 10000
10125 10250
10375 10500
10625 10750
10875 10000
10125 10250
10375 10500
10625 10750
The maintenance work carried out methodically can be recorded in the table and confirmed.
© 2005
6
6.1Lubrication system
6.2Fuel system
6.3Cooling system
6.4Combustion air filter
6.5Belt drive
6.6Setting work
6.7Add-on parts
© 2005
z The oil change times depend on the engine z If the lube oil change intervals are planned
application and the quality of the lube oil. in terms of operating hours, the lube oil
change intervals for installed engines
z If the oil change times are not reached 6.1.1.1 apply.
within a year, the oil change should be
carried out at least 1x yearly.
z For fuels
– with sulphur content > 0.5 to 1%
or
– Constant ambient temperatures < -10 °C
(+14 °F)
or
– with bio-diesel fuels according to DIN
51606- FAME the oil change times
should be halved.
© 2005
z Position the engine or vehicle so as to be level. z Warm up engine. z Position oil drip cup under the engine.
z – Engine warm: z Position the engine or vehicle so as to be level. z Unscrew oil drain screw.
Switch off the engine, wait for 5 minutes and – Lube oil temperature approx. 80 °C. z Drain off oil.
check oil level. z Switch off engine. z Screw in oil drain screw with new sealing ring
z – Engine cold: and tighten. (For tightening torque
Check oil level. see 9.2).
z Extract oil dipstick. z Pour in lube oil.
z Wipe with a fibre-free, clean cloth. – For quality / viscosity data see 4.1.
z Insert until it stops and extract again. – For filling quantities, see 9.1.
z Check oil level and re-fill to „MAX“ if necessary. z Check oil level, see 6.1.2.1.
– If the oil level lies just above the „MIN“-
line marking, re-filling is necessary. Caution when draining
hot oil: danger of scalding!
Collect the used oil, do not allow to
© 2005
seep into floor!
The oil level may not fall short of the „MIN“ line Dispose of according to instructions!
marking.
z When anti-rotation lock is installed: z Clean the sealing surface of the filter sup- z Tighten lube oil filter cartridge three quarters
Loosen clamping screws and remove tighte- port for any possible dirt. of a turn (approx. 10 Nm).
ning clamps from below.
z Lightly oil the rubber seal of the new lube z If there is an anti-rotation lock:
z Loosen lube oil filter cartridge with stan- oil cartridge. Position the tightening clamps and tighten
dard tool and unscrew. with clamping screws.
z Screw on the cartridge by hand until the
z Collect any oil which may run out. seal makes contact. z Check oil level, see 6.1.2.
Careful with hot oil: z Check the seal of the lube oil filter cartridge
danger of scalding! for tightness.
© 2005
© 30 0 74 1 © 43 937 0 © 300 74 0
z Switch off engine. z Collect any lube oil which may run out. z Change the round sealing ring 2 and lightly oil.
z Loosen lube oil filter cover 1 with two or three z Crease the paper filter cartridge 5 in the z Press new paper filter cartridge 5 into the clip
turns and wait for 30 seconds. collection vessel slightly at the side until the 6 and insert carefully in the guide 4 together.
z Unscrew lube oil filter cover 1 with paper filter cartridge is released from the clip 6. z Screw the lube oil filter cover 1 tight in clock-
cartridge 5 in anti-clockwise direction. z Clean the sealing surface of the filter support wise direction (25 Nm).
z Carefully loosen paper filter cartridge 5 from and the lube oil filter cover 1 as well as the guide z Start the engine.
the guide 4, which is inserted in the housing 3, 4 of any dirt there may be z Check lube oil filter assembly for leaks.
from above. z Check engine oil level and top up if necessary.
© 2005
Dispose of used oil in an
environmentally friendly way.
z Close fuel stopcock. z Screw on the cartridge by hand until the seal
z Loosen fuel filter cartridge with standard tool makes contact.
and unscrew.
z Collect any fuel which may run out. z Tighten the fuel filter cartridge with one more
z Clean the sealing surface of the filter support half turn.
for any dirt there may be.
z Lightly oil the rubber seal of the new DEUTZ z Open fuel stopcock.
original fuel filter cartridge or wet with diesel
fuel. z Check for tightness.
© 300 74 0
z Switch off engine z Change the rubber seal 2 and lightly oil.
z Loosen fuel filter cover 1 and unscrew in anti- z Carefully place new paper filter cartridge 3 in
clockwise direction. the guide 4.
z Carefully loosen paper filter cartridge 3 from z Tighten the fuel filter cover 1 in clockwise
the guide 4 from above. direction (25 Nm).
z Collect any fuel which may run out. z Start engine.
z Change paper filter cartridge 3. z Check fuel filter attachment for tightness.
z Clean the sealing surface of the filter support
and the fuel filter cover 1 as well as the guide4
of any dirt there may be.
© 2005
No open fire! Do not smoke!
Dispose of used fuel in an
environmentally friendly
manner.
z Clean any dirt from the sealing surface of the 1 Fuel supply to pump
new filter cartridge (5) and the reverse side 2 Fuel return from control block FCU
of the filter head (Fuel Control Unit)
z Wet the sealing surfaces of the filter cartridge 3 Fuel hand pump with bayonet plug for
(5) slightly with fuel and screw back onto the locking and unlocking
filter head in clockwise direction (17-18 Nm) 4 Thermostat valve with shutdown lever
z Open the fuel stopcock and bleed the system 5 Filter cartridge
(see „Bleeding fuel system“). 6 Connection facility for electrical
z Dispose of collected fuel and old filter cartridge water level sensor
(5) properly. 7 Drain cock
8 Water collecting vessel (bowl)
Bleeding fuel system: 9 Fuel inlet from fuel tank
z Unlock the bayonet plug of the fuel hand 10 Fuel return to fuel tank
pump (3) by pressing and turning
anti-clockwise at the same time. The pump
plunger is now pushed out through the spring.
© 43 848 1 Turn the shutdown lever of the ther-
Filter change: mostat valve (4) by approx. 45° in
z Close fuel stopcock (for high tanks). clockwise direction until it is felt to
z Position fuel collecting vessel beneath fuel pre-filter. engage.
z Loosen drain cock (7) and drain water + fuel z Pump until a very strong resistance is felt and
completely. pumping becomes very slow.
z Unscrew filter cartridge (5) together with z Now pump a few more times.
water collecting vessel (8) in anti-clockwise (The return line must be filled).
direction and remove. z Turn the shutdown lever of the thermostat
z Loosen water collecting vessel (8) from old valve (4) by approx. 45° in anti-clockwise
filter cartridge (5) in anti-clockwise direction direction until it is felt to engage.
and remove. z Lock the bayonet plug of the fuel hand pump
z Empty remaining fuel into the fuel collecting (3) by pressing and turning clockwise at the Only work on the fuel system
vessel and clean water collectingvessel (8). same time. when the engine is switched off.
z Screw water collecting vessel (8) onto the No open fire! Do not smoke!
new filter cartridge (5) in clockwise direction. Dispose of used fuel in an
© 2005
© 2005
machines, compressors, mining
equipment.
125 Agricultural machinery, tractors
with harvesting application.
© 2005
danger of scalding! Collect coolant
when draining off.
© 39 851 0
Dispose of according to
instructions!
© 25 886 0
© 2005
Never fill the dust container with oil, replace
damaged containers!
© 25 888 2 © 25 889 1
z Empty the dust discharge valve 1 by squeezing z Open clamping bracket 1. z Renew the safety cartridge 4 after 5 filter
the discharge slot in the direction of the arrow. z Remove filter hood 2 and pull out filter cartridge 3. maintenances, after 2 years at the latest
z Clean filter cartridge, renew after a year at the latest. (never clean!).
z Clean the discharge slot occasionally. z Clean filter cartridge 3. To do this:
- Blast out from the inside out with dry - Loosen the hexagonal nut 5 and pull out
z Remove any stuck on dust residues by compressed air (max. 5 bar), or the cartridge 4.
squeezing the upper area of the valve. - beat out (only in extreme cases). Do not - Insert new cartridge, re-mount hexagonal
damage the cartridge, or nut and tighten.
- Wash according to manufacturer’s z Insert filter cartridge 3, close hood 2 and
specifications. secure clamping bracket 1.
z Check filter cartridge for damage to the filter
paper (shine light through) and check seals.
Exchange if necessary.
Never clean filter cartridge with
© 2005
z Push tension pulley in the direction of the arrow z Push tension pulley in the direction of the arrow z The wear limit of the V-rib belt is checked as
until V-rib belt is free. until V-rib belt is free. follows:
z First remove the V-rib belt from the smallest z First remove the V-rib belt from the smallest pulley. z Check the distance between the projection
pulley. z Put on new V-rib belt of the moving tension arm and the contact
z Put on new V-rib belt z Loosen tension pulley in the opposite direction with the fixed tensioner housing.
z Loosen tension pulley in the opposite direction of the arrow until the V-rib belt is taut Whilst z If „a“ is less than 3 mm the V-rib belt should be
of the arrow until the V-rib belt is taut doing this, check that the V-rib belt is changed.
Whilst doing this, check that the V-rib belt is positioned correctly in your guide.
positioned correctly in your guide.
Only check/tighten/change V-
belts when the engine is not
running. If necessary, re-mount
V-belt guard.
© 2005
© 38 995 0 © 38 996 0
6.6.1.1, the table on the right. 3. Work step 4. Set cylinder to overlap, set cylinder 1.
4. Work step 2. Set cylinder to overlap, set cylinder 3.
© 38 997 0 © 2005
© 43 935 0 © 43 936 0
z After the valve clearance has been set. z Set control piston clearance if necessary, by: z Perform test and setting work on every
- Control unit for engine brake is already - Loosening the lock nut 2. cylinder.
mounted. - Mount the control piston clearance X on z Replace cylinder head cover (if necessary
z Set the clearance on the control unit as follows. setting screw 1 (see 6.6.1) with setting device with new gasket).
z Turn engine until reaching the valve overlap in EX and set as follows: z Swing the bleed valve into position and
is reached, cylinder no. 1 Fix the magnet fasten.
z Set control piston clearance on every exhaust Turn the setting device without clearance
valve. until the control piston contacts with the valve IN = Inlet valve
z Proceed as for valve clearance. bridge, set scale to „0“. EX = Exhaust valve
Then turn back angle degree 432° (by
Note hand or torque wrench): 1 Setting screw
Valve overlap means: 2 Lock nut
Exhaust valve is not yet closed. Inlet valve begins EX = exhaust valve 432° for M8 thread 3 Solenoid valve (electronic control)
to open, see valve setting diagram. (corresponds to 1.5 mm clearance) 4 Control board
© 2005
© 2005
z Keep the battery clean and dry. z Remove sealing cap 1. z Measure the acid density of individual cells
with a standard acid testing device.
z Loosen soiled connection terminals. z If checking inserts 2 are available:
The liquid level should reach to their bottom. The measured values (see table overleaf)
z Clean the battery poles (+ and -) and terminals, indicate the charge status of the battery. The
and grease with an acid-free and acid-resistant z Without checking inserts: acid temperature when measuring should be
grease. The liquid level should reach 10-15 mm above 20 °C if possible.
the upper edge of the plate.
z Ensure that the terminal connections contact
well when assembling. Tighten the clamping z If necessary, re-fill with distilled water.
screws by hand.
z Screw sealing cap back on.
© 2005
6
Acid density
in [kg/ l] in [°Bé (Baumé degree)*] Charge level
© 2005
skin or clothes!
Wear protective glasses!
Do not place any tools on the
battery!
equipment!
7
7.1 Fault table
7.2 Engine management
© 2005
7
z Faults are often caused by incorrect operation
or maintenance of the engine.
© 2005
z Battery defective or not charged Electrics C
7 Faults
Engine doesn't start up, or starts up with difficulty Check
Action
C
Engine doesn't start up and diagnosis light is blinking Set S
Engines starts up, but runs irregularly or misfires Change Ch
Engine gets too hot. Temperature warning system is activated Clean Cl
Engine lacks power Fill up F
Engine lacks power and diagnosis light is lit up Lower L
Speed changes are possible + diagnostic light is lit up Engine electronics E*
Engine has no, or too little, oil pressure * Identify fault by monitoring the
Engine has too high oil consumption blink code or fault memory
Engine has too high oil consumption
Engine smoulders - blue
- white
- black
Cause Section
z Starter, circuit cable connections loose or oxidised Electrics
z Starter defective or pinion doesn't mesh
z z z z z Valve clearance incorrect Engine
z z z z Injection line leaking
z Ventilation line blocked (coolant heat exchanger)
z z Heating plug defective
z z z z z z z Injector defective
z z z z Air in fuel system
z z z z Fuel filter / fuel pre-cleaner soiled
z Oil filter defective
z z z Incorrect SAE class or quality of engine lube oil Operating
z z z z Fuel quality does not comply with instruction manual substance
z Lack of cooling water
z Engine electronics prevent start Electronics
z Engine electronics reduce power
© 2005
z Engine electronics has detected a system error and activates an equivalent speed
7.2.1 Engine protection function of 7.2.2 Using the diagnosis button 7.2.3 Table of fault blink codes
the electronic engine 7
controller EMR3
Depending on the design of the monitoring With the diagnosis button (1) the fault at hand
functions, the EMR3 can protect the engine from can be read out as a blink code. The diagnosis
damage in certain fault situations by monitoring
compliance with important limit values during button (1) and the fault light (2) can be found
operation and checking the correct functioning of on the vehicle driving stand.
the system components. Depending on the Faults are indicated by a blinking or continuous
severity of a detected fault, the engine may
continue running with restrictions, whereby the illumination of the fault light (2). More precise
fault lamp lights steadily or the fault lamp indicates information regarding all existing faults can be
a serious system fault by flashing. In this case read out in the form of a blink code, only when
the engine must be switched off as soon
the engine is not running, in the following
as it is safe to do so!
Depending on the engine configuration, the manner: After actuating the diagnosis button
flashing fault lamp can have the following meaning: (1) for at least one second, the fault light (2)
goes out and the first fault is, after releasing
z Request to the operator to shut down
Caution: Failure to heed this will lead to the key displayed as a blink code. Analyse the © 43 929 0
loss of warranty! blink code as per the table on the following
page. After the fault blink code has been The possible blink codes, their meaning and
z Autom. switching off of the engine after a short
pre-warning time, possibly in connection with displayed the fault light (2) goes out for five measures for correcting faults can be found in
a start lock seconds. the table on the following page. The blink code
Then the next existing fault (i.e. the following values in the first column indicate the number of
z To cool down the engine before switching off, one in the fault memory) can be shown by preliminary short blink signals (illuminated duration
forced engine operation at low idling speed, approx. 0.4 s), the number of subsequent long
automatic switch-off if necessary actuating the diagnosis button (1) again. If the
blink signals (illuminated duration approx. 0.8 s)
last existing fault has been shown, by as well as the number of concluding short blink
z Start lock (see also chap. 3.3) actuating the diagnosis button (1) once more signals. The code 2-1-4 for the fault "overspeed"
the first fault will be shown again. is made up of two short, one long and four short
When the fault is corrected the light
goes out. For some faults it is blink signals, for example. If a fault cannot be
necessary to switch off the ignition, corrected by the measures given in the table
© 2005
wait for 30 s and then switch the please contact your service representative
ignition back on. responsible.
7 Blinkcode
Short Long Short
Function / Component Error
© 2005
When turning over with a starter position the against dirt and dust.
shutdown lever in the Stop position.
z Remove V-belt 4, pack up and store.
9
9.1 Engine and setting data
9.2 Screw tightening torques
9.3 Tools
© 2005
Engine type ----------------------------- TDC 2012 L04 V4 ---------------- TDC 2012 L06 V4 ---------------------------
9
Number of cylinders ---------------------------------------- 4 --------------------------------------- 6 ---------------------------------------
Cyl. arrangement ----------------------------------------------------------- In-line ---------------------------------------------------------
Bore [mm] ------------------------------------------------------------ 101 ----------------------------------------------------------
Stroke [mm] ------------------------------------------------------------ 126 ----------------------------------------------------------
Total displacement [cm3] -------------------------------------- 4038 ---------------------------------- 6057 ------------------------------------
Compression ratio [H] ------------------------------------------------------------- 18 -----------------------------------------------------------
Working principle / combustion procedure -------------------- Four stroke diesel with charging and direct injection ----------------------------------
Charge air cooler -------------------------------------- with ----------------------------------- with ------------------------------------
Charge air cooler temperature outlet
at rated power [°C] ------------------------------------------------------------- 50 -----------------------------------------------------------
1)
Engine power, speed and start of pumping, among other things, are stamped on the engine company plate, see also 2.1.
© 2005
3)
Approximate values can vary depending on version The upper oil dipstick marking is always decisive.
4)
Only necessary for winter operation, see 3.5.1.
© 2005
Engine type ----------------------------- TDC 2013 L04 V4 ---------------- TDC 2013 L06 V4 ---------------------------
9
Number of cylinders ---------------------------------------- 4 --------------------------------------- 6 ---------------------------------------
Cyl. arrangement ----------------------------------------------------------- In-line ---------------------------------------------------------
Bore [mm] ------------------------------------------------------------ 108 ----------------------------------------------------------
Stroke [mm] ------------------------------------------------------------ 130 ----------------------------------------------------------
Total displacement [cm3] -------------------------------------- 4761 ---------------------------------- 7142 ------------------------------------
Compression ratio [H] ------------------------------------------------------------- 18 -----------------------------------------------------------
Working principle / combustion procedure -------------------- Four stroke diesel with charging and direct injection ----------------------------------
Charge air cooler (optional) ------------------------------------ without ------------------------------- without ----------------------------------
Charge air cooler temperature outlet
at rated power/ (at max. power) [°C] ---------------------------------------------------- 42/ (max. 50°C) --------------------------------------------------
Oil cooler plate cooling share:: ------------------------------------------- Spring-loaded tension pulley ------------------------------------------
1)
Engine power, speed and start of pumping, among other things, are stamped on the engine company plate, see also 2.1.
Permissible continuous coolant temperature engine outlet [°C] --------------------------------------------------------- max.110 -------------------------------------------------------
Temperature difference between
Coolant inlet/outlet [°C] ----------------------------------------------------------- 4 to 8 ---------------------------------------------------------
Start of thermostat opening at ( Bus ) [°C] ---------------------------------------------------------- 83(75) --------------------------------------------------------
Thermostat fully open at [°C] ------------------------------------------------------------ 110 ----------------------------------------------------------
Coolant pre-heating ------------------------------------------------------------- (4. ------------------------------------------------------------
3
Cooling water pump amount [dm / min] ------------------------------------------------------------ 295 ----------------------------------------------------------
Delivery pressure in [kPa/bar] ------------------------------------------------------- 120000/1.2 -----------------------------------------------------
© 2005
3)
Approximate values can vary depending on version The upper oil dipstick marking is always decisive.
4)
Only necessary for winter operation, see 3.5.1.
9
Installation Pre-tightening Re-tightening Total Comments
[Nm] 1st step 2nd step 3rd step 4th step
Valve mechanism cover – – – – – 11 ± 1 Nm M6
Rocker arm setting screw – – – – – 20 ± 2 Nm Nut with inner square
Front face mounting foot – – – – – 260 Nm M16 x 85 –10.9
– – – – – 260 Nm M16 x 40 –10.9
Oil drain screw aluminium tray – – – – – 55 Nm M 18x 1.5 with Cu ring
Oil drain screw sheet metal oil tray – – – – – 55 Nm M 18x 1.5 with Cu ring
© 2005
25899 0 30 060 1
For engines of series 2012/2013, the TORX Special tool part no. 8190 can be obtained
screw system BN. 8189, amongst others, is from:
used.
This system was introduced due to its many WILBÄR
advantages: Postfach 14 05 80
D-42826 Remscheid
z Excellent screw accessibility.
z High transfer of force when loosening and
tightening.
z Slipping or broken wrenches and the risk
of injury associated with this is practically
impossible.
© 2005
TORX tools can be obtained from:
WILBÄR
Postfach 14 05 80
D-42826 Remscheid
Order No. 8190 Order No. 8193 (5 mm) valve clearance Order No. 8199
Rotation angle disc for setting the valve/ Order No. 8194 (4 mm) control piston Crow's foot wrench for rotation angle disc
control piston clearance. clearance. Wrench inserts for rotation angle 8190 in connection with commercially
disc. available square bar extension.
© 2005
© 35 423 1 © 43 186 0
© 2005
Service
10
For many years DEUTZ has stood for pioneering Thus, DEUTZ is not just a name for innovative D-51063 Cologne
development in engine construction. As an inde- engines. But also for a complete service package Telephone: 0049-221-822-0
pendent manufacturer we offer a complete for every aspect of engines, and a service that Fax: 0049-221-822-3523
palette of diesel and gas engines worldwide. Our you can rely on.
Telex: 8812-0 khd d
products are perfectly tailored to meet the
requirements of our customers. You can find an overview of DEUTZ partners in http://www.deutz.com
your area, their product competencies and their Email: info@deutz.de
More than 1.4 million DEUTZ engines reliably services on the DEUTZ website (see following
perform their service all over the world. We want addresses).
to preserve the operational readiness of our Also if there is no direct product competency
engines and with it the satisfaction of our specified, your DEUTZ partner will be able to help
customers. Therefore we are represented you further with professional advice.
worldwide by a network of competent partners, Your DEUTZ AG
the concentration of whom corresponds to the Deutz-Mülheimer Str. 147-149
regional distribution of our engines.
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All rights reserved
1st Edition, © 01/06
the engine company Order No.: 0312 2443