Professional Documents
Culture Documents
Operation Manual
TCD 2012 L04/06 4V
TCD 2013 L04/06 4V
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Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
z This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
z Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. z Do not work on the fuel system while the engine
z When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
z Unauthorised engine modifications will invalidate pressure - Danger to life!
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
z Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
z Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
z When carrying out maintenance work on the en-
2 © 2007
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Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily. Order number
Please make sure that this operating manual is avail- 0312 3536 en
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG
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Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Suction system . . . . . . . . . . . . . . . . 50
Foreword. . . . . . . . . . . . . . . . . . . . . 3 Belt drives . . . . . . . . . . . . . . . . . . 53
1 General. . . . . . . . . . . . . . . . . . . . 5 Setting work . . . . . . . . . . . . . . . . . 55
2 Engine description . . . . . . . . . . . . . 7 Electrical system . . . . . . . . . . . . . . . 60
Type . . . . . . . . . . . . . . . . . . . . . 7 7 Faults. . . . . . . . . . . . . . . . . . . . . 62
Engine illustration. . . . . . . . . . . . . . . 9 Fault table . . . . . . . . . . . . . . . . . . 62
Lubricating oil schematic . . . . . . . . . . . 19 Engine management . . . . . . . . . . . . . 65
Fuel schematic . . . . . . . . . . . . . . . . 20 8 Transport and storage . . . . . . . . . . . 67
Coolant schematic . . . . . . . . . . . . . . 21 Transport . . . . . . . . . . . . . . . . . . . 67
Exhaust gas recirculation . . . . . . . . . . . 23 Protecting the engine against corrosion . . . 68
Electrics/Electronics . . . . . . . . . . . . . 24 9 Technical data . . . . . . . . . . . . . . . . 70
3 Operation . . . . . . . . . . . . . . . . . . 26 Engine and setting data . . . . . . . . . . . 70
Ambient conditions . . . . . . . . . . . . . . 26
Commissioning . . . . . . . . . . . . . . . . 27
Start procedure . . . . . . . . . . . . . . . . 29
Operation monitoring . . . . . . . . . . . . . 31
Stop procedure . . . . . . . . . . . . . . . . 33
4 Operating media. . . . . . . . . . . . . . . 34
Lubricating oil . . . . . . . . . . . . . . . . . 34
Fuels . . . . . . . . . . . . . . . . . . . . . 36
Coolant . . . . . . . . . . . . . . . . . . . . 37
5 Maintenance . . . . . . . . . . . . . . . . . 38
Maintenance schedule . . . . . . . . . . . . 38
6 Service and maintenance . . . . . . . . . . 41
Lubricating oil system. . . . . . . . . . . . . 41
Fuel system. . . . . . . . . . . . . . . . . . 43
Cooling system . . . . . . . . . . . . . . . . 47
Engine cleaning. . . . . . . . . . . . . . . . 49
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General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the
functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components
Obviously the high requirements for the protection of
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high California
Safety precautions when the engine is as for new parts. DEUTZ replacement parts are Proposition 65 Warning
running equal to the original DEUTZ parts in function and re- Diesel engines and some of its constituents are
liability. known to the State of California to cause cancer,
Maintenance work or repairs may only be performed birth defects and other reproductive harm.
on the shut-down engine. Make sure that the engine Asbestos
cannot be started inadvertently - Danger of acci- Masthead
dent! The gaskets used in this engine contain no asbestos.
Please use the appropriate spare parts for mainte- DEUTZ AG
When the work is complete, be sure to refit any pan-
nance and repair work. Ottostraße 1
els and guards that have been removed.
Service 51149 Cologne
Observe industrial safety regulations when running
the engine in an enclosed space or underground. Telephone:+49 (221) 822-0
We want to preserve the high performance of our en-
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of Fax: +49 (221) 822-5850
must be close fitting. our customers. We are therefore represented world- www.deutz.com
Never fill the fuel tank while the engine is running. wide by a network of service branches.
E-mail: info@deutz.com
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your service partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
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General
1 Danger
Caution
Notes
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Mot.-Typ Mot.-Nr.
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2 left
right
1
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10
11
16 15 14 13 12
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7 6 5
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26 © 2007
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Commissioning Operation
Preparations for initial commissioning
(Maintenance schedule E 10)
3
z Remove engine corrosion protection
z Remove any transport devices.
z Check the battery and cable connections and
mount if necessary.
z Check belt tension (53).
z Have the engine monitor or warning system
checked by authorised personnel.
z Check the engine mounting.
z Check that all hose unions and clips fit properly.
The following additional work must be carried
out on generally overhauled engines:
z Check the fuel pre-filter and main filter and
change if necessary. Fill with engine lube oil Fill oil-bath air filter with lubricating oil
z Check the intake air cleaner (if available, main-
tain according to maintenance indicator). Low lubricating oil level and overfilling lead No lubricating oil may be filled in the cy-
to engine damage. clone pre-separator that may be connected
z Fill with engine lube oil.
upstream.
The engines are generally supplied without z Fill lubricating oil pan (1) of the oil-bath filter with
lubricating oil filling. lubricating oil as far as the marking arrow.
Select lubricating oil quality and viscosity
before filling.
Order DEUTZ lubricating oils from your
DEUTZ partner
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Operation Commissioning
z Start the engine and run up until the thermostat
3 opens (line (2) heats up).
z Engine operation with open thermostat 2 - 3 min-
utes.
z Check the coolant level in the compensation tank
and top up coolant if necessary.
z If required, repeat procedure with engine start.
z Fill up coolant to the MAX mark on the compen-
sation tank and close the cooling system cap.
z Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
z Observe the filling volume of the cooling system
(70).
z If required, repeat procedure with engine start.
Pour in fuel Filling the coolant system Trial run
Only re-fuel when the engine is not running. The coolant must have a prescribed con- Venting of the fuel system by operating for
Ensure cleanliness. centration of cooling system corrosion pro- 5 minutes on no load or with low load is ab-
Do not spill fuel. tection agent. solutely essential.
Additional venting of the fuel system by a 5 Never operate the engine without coolant,
minute trial run at idle speed or on low load even for a short time! Carry out a brief trial run up to operating temperature
is absolutely essential. (approx. 90 °C) after preparations.
Order coolant corrosion protection agent Do not load the engine if possible.
z The fuel low pressure system must be vented be-
from your DEUTZ partner. z Work with the engine not running:
fore the first start-up after filling with the manualy
supply pump. – Check engine for tightness.
z Connect coolant outlet (2) and coolant inlet (1) to
– Check the lubricating oil level and top up lu-
Only use clean commercially available brand diesel the cooling system. Connect the feed line of the
bricating oil if necessary.
fuel. Observe fuel quality (36). compensation tank to the coolant pump or to the
coolant inlet line (2). – Check the coolant level and top up coolant if
Use summer or winter-grade fuel, depending on the necessary.
ambient temperature. z Connect ventilation line from the engine and, if
necessary, from the cooler to the compensation z Work during the trial run:
tank. – Check engine for tightness.
z Fill cooling system via the compensation tank.
z Close compensation tank with valve.
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© 25745-0
Without cold start aid Glow plugs/heating flange with cold start
aid
z Insert key.
z Turn key to the right. z Insert key.
– Position 1 = operating voltage. – Position 0 = no operating voltage.
– Pilot lamps (1) and (2) light up. z Turn key to the right.
z Push the key in and turn further clockwise – Position 1 = operating voltage.
against spring pressure.
– Pilot lamps (1), (2) and (3) light up.
– Level 2 = no function. – Preheat until the glow display goes out; an
– Level 3 = start. error has occurred if the preheating indicator
z release the key as soon as the engine starts up. flashes; e.g. the preheating relay is stuck,
– The pilot lamps will go out. which can discharge the battery completely
when at a standstill.
– Engine is ready for operation.
z Push the key in and turn further clockwise
against spring pressure.
– Level 2 = start.
z release the key as soon as the engine starts up.
– The pilot lamps will go out.
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Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or while Switch off engine
lamp the engine is running, the lubricating oil pressure is too
low
Lube oil level If the pilot lamp lights up after starting the engine or while Check lubricating oil level / if necessary top up
the engine is running, the lubricating oil level is too low
Coolant level If the control lamp lights up after the engine starts or Switch off the engine, allow to cool down and top up
while the engine is running, the coolant level is too low coolant
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
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Shutting off
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4 General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
Quality
Lubricating oils are classified by DEUTZ according
the definition of the lube oil change intervals are not
the lubricating oil to be used. The specific engine to their efficiency and quality class (DQC: DEUTZ
essentially dependent on the lube oil quality (such as
performances which have increased constantly over Quality Class). It basically applies that: with increas-
the incorporation of soot and other contaminations),
the last few years lead to an increased thermal load ing quality class (DQC I, II, III, IV) the lubricating oils
the lube oil change interval when using synthetic
on the lubricating oil. The lubricating oil is also more are more efficient and higher quality. The appended
lube oils may not be increased in relation to the spec-
exposed to contamination due to reduced oil com- quality class designation (- 02 / - 05) indicates in
ifications of the lube oil change intervals.
sumption and longer oil change intervals. For this which year the classification was made.
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in
Lubricating oils according to other comparable spec-
and recommendations described in this operating DEUTZ engines if they meet the requirements of this
ifications can be used as long as they meet DEUTZ
manual in order not to shorten the life of the engine. operating manual.
requirements. In regions in which none of these
Lubricating oils always consist of a base oil and an qualities are available, please contact your responsi-
additive package. The most important tasks of a lu- ble DEUTZ partner.
bricating oil (e.g. wear protection, corrosion protec- The following lubricating oils are specified for the en-
tion, neutralisation of acids from combustion gines described in this operating manual.
products, prevention of coke and soot deposits on
the engine parts) are assumed by the additives. The With open crankcase breather:
properties of the base oil are also decisive for the DQC II - 05
quality of the product, e.g. with regard to thermal DQC III - 05
load capacity.
DQC IV - 05
In principle, all engine oils of the same specification
can be mixed. However, mixing of engine oils should With closed crankcase breather:
be avoided because the worst properties of the mix- DQC III - 05
ture are always dominant. DQC IV - 05
The lubricating oil quality has a considerable influ-
ence on the life, performance and thus also on the Recommended quality class
costs-effectiveness of the engine. It basically applies DEUTZ ACEA API
that: The better the lubricating oil quality, the better
these properties. DQC II - 05 E3-96 / E5-02 / CG-4 / CH4 / C I-
E7-04 4
The lubricating oil viscosity describes the flow be-
haviour of the lubricating oil depending on the tem- DQC III - 05 See TR 0199-99-3002
perature. The lubricating oil viscosity has no DQC IV - 05 Please contact your DEUTZ partner
influence and effect on the lubricating oil quality.
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem-
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SAE 20W-50
ity can lead to starting difficulties, too low a viscosity
SAE 10W-30
SAE 10W-40
SAE 15W-40
5 litre container 0101 6335
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
can endanger the lubrication effect and cause a high
20 litre container 0101 6336 15
lubricating oil consumption. At ambient temperatures
209 litre barrel 0101 6337 below -40 °C, the lubricating oil must be pre-heated 10
(e.g. by storing the vehicle or the machine in a hall).
DEUTZ lubricating oils DQC IV-05 synthetic The viscosity is classified according to SAE. Multi- 5
Container Order number purpose lubricating oils should be used basically.
Single-purpose lubricating oils can also be used in 0
20 litre container 0101 7849
enclosed, heated spaces at temperatures >5 ° C.
209 litre barrel 0101 7850 -5
Depending on the ambient temperature we recom-
Lubricating oil change intervals mend the following common viscosity classes: -10
z The intervals depend on: The prescribed lubricating oil quality must -15
– lubricating oil quality be observed when selecting the viscosity
– sulphur content in the fuel class! -20
– type of application of engine
-25
z The lubricating oil change interval must be
halved if at least one of the following conditions -30
applies:
– Constant ambient temperature below -10 °C -35
(14 °F) or lube oil temperature below 60 °C
(84 °F). -40
– sulphur content in the diesel fuel of 0.5 - 1
weight %.
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4 Permissible fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
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1)
EPA (Environmental Protection Agency).
2)
The oil load may be high depending on the application. Shorter maintenance intervals are necessary in this case, 250 oh (15,000 km).
3)
Specification for lubricating oil change interval related to the lubricating oil quality DQC III and an average drive speed of: approx. 25 km/h (local traffic), approx. 40 km/
h (regional traffic), approx. 60 km/h (long distance traffic).
4)
For TCD 2012 L04/06 4V and TCD 2013 L06 4V engines, the valve clearance must be set for the first time after 500 oh and then, after every 1500 oh.
Maintenance measures
Changing the pre-filter cartridge depends on the degree of dirt contamination of the fuel being used. If other fuels are used which do not meet the requirements of the
operating manual, the warranty will be voided.
A self-adhesive maintenance diagram is provided with every engine. This should be stuck to the engine or device in a prominent position.
Order number: 0312 2452 (TCD 2012 4V) and 0312 2453 (TCD 2013 4V)
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5 Stage
E50 Check
Measure
V-rib belt and tensioning pulley (replace if wear limit is fallen below)
Page
54
EGR (optional) adjustment lever and valve; replace if necessary 23
Replace EGR (optional) adjusting bar
E60 Check Electronic injector test via EMR3 (only for DEUTZ Common Rail System) 24
Clean Charge air cooler inlet area/charge air cooler, lubricating oil/drain condensation (only with EPA).
Non-return valve of the exhaust gas recirculation system (optional).
Cooler of the exhaust gas recirculation system.
Replace Fuel injector valve (only with EPA).
Flame glow plugs 30
Crankcase breather valve/incl. Filter (only with EPA)
annually Clean Charge air cooler inlet area (lubricating oil/drain condensation), (only with EPA) 47
Replace Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 46
Engine monitor, warning system Maintenance only to be carried out by authorised service personnel 31
Every 2 Check EGR (optional) adjustment lever and valve; replace if necessary
years Replace Coolant (additive concentration) 47
V-belt, V-rib belt and tensioning pulley 54
Filter insert of the crankcase breather valve (only with EPA)
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Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 15-17 Nm.
tion! z If necessary, fix the clips of the anti-rotation lock.
z Remove the clips if an anti-rotation lock is fitted.
z Loosen and unscrew the filter cartridge with the
tool (order no. 170050) .
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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Change the fuel filter cartridge z Collect any fuel oil that escapes. z Replace round sealing ring (2) and grease light-
z Bend the paper filter cartridge (5) in the collecting ly.
The filter cartridge should never be pre- vessel slightly sideways until the cartridge z Press new paper filter cartridge (5) into the clamp
filled. There is a danger of dirt contamina- comes off the clamp (6). (6) and carefully insert into the guide (4).
tion! z Clean any dirt from the sealing area of the filter z Screw in fuel filter cap (1) clockwise (25 Nm).
media and fuel filter cap (1) as well as guide (4). z Start engine.
z Switch off the engine.
z Loosen lubricating oil filter cap (1) with 2 to 3
turns and wait 30 seconds.
z Unscrew fuel filter cap (1) with paper filter car-
tridge (5) anticlockwise.
z Carefully loosen paper filter cartridge (5) up-
wards from the guide (4) located in the housing
(3).
z Catch any escaping fuel.
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6 renew if damaged.
z Fill the lubricating oil pan (3) of the oil bath air fil-
ter with engine oil up to the mark (arrow).
z Mount the lubricating oil pan (3) with filter insert
(4) on the filter housing (1) and close the quick
release clamps (2).
z Start engine and check for tightness.
Never fill the dust container (3) with lubri- Never clean the filter with petrol!
cating oil!
z Loosen wing nut (1) and lift off housing cover (2).
Dispose of the old lubricating oil in accord-
z Remove the dust container (3) from the base (4)
ance with the regulations. Select the en-
and empty it. Clean the container using a brush
gine lubricating oil according to the
and clean diesel fuel. Then dry.
requirements before filling the filter.
z Place the dust container (3) on the base (4) and
tighten the housing cover (2) with wing nut (1). z Shut down engine and wait about 10 minutes un-
til the lubricating oil has collected in the lubricat-
ing oil pan (3).
z Loosen the quick release clamps (2) and remove
the lubricating oil pan (3) with filter insert (4).
z Dispose of dirty lubricating oil.
z Clean lubricating oil pan (3), filter cartridge (4)
and filter housing (1) with a brush and clean die-
sel fuel.
z Visually inspect the rubber gaskets (5), (6) and
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Set valve clearance for TCD 2013 L04/06 z Loosen rotation angle disc (3) (order no.: 8190) tightening specification: 9 Nm (74).
4V and place pin wrench insert (order no.: 8193) on z Swing breather valve into position and fasten.
the valve clearance setting screw (2).
z Loosen breather valve and swing it to the side.
z Remove the cylinder head hood. z Loosen locking nut (1) with special tool (order
no.: 8199).
z Let the engine cool down for at least 30 minutes
z Fix magnet of the rotation angle disc.
before setting the valve clearance: Lubricating oil
temperature below 80 °C. z Turn rotation angle disc clockwise to the stop
(rocker arm without clearance) and set the scale
z Place turning gear over fastening screws of the
to zero.
belt pulleys.
z Tool (74). z Turn rotation angle disc anticlockwise until
reaching the specified rotation angle:
z Turn the engine until reaching valve overlap, cyl-
z Secure the rotation angle disc (3) against twist-
inder no. 1.
ing.
The cylinders to be set can be seen in the setting
z Tighten the locking nut (1) (torque 20 Nm).
schematic.
z Note: Crankshaft means: z Perform the setting procedure on every cylinder.
z Mount gasket (new gasket if necessary).
z Outlet valve EX is not yet closed, inlet valve IN
begins to open. z Visually inspect screws and rubber elements, re-
place if necessary.
z Mount cylinder head cover (with a new gasket if
necessary) and tighten the screws according to
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5 6 4 5
torque wrench (7) according to the 20 Nm tight-
ening specification. 6
z Perform the setting procedure on every cylinder.
z Mount gasket (new gasket if necessary).
z Visually inspect screws and rubber elements, re-
place if necessary.
3 z Mount cylinder head cover (with a new gasket if
1 necessary) and tighten the screws according to
tightening specification: 9 Nm (74).
z Swing breather valve into position and fasten.
2 6 7
Set valve clearance for TCD 2012 L04/06 z Set valve clearance on the corresponding cylin-
4V der using the valve clearance setting device (Or-
der no.: 100340).
z Remove the cylinder head hood.
z Let the engine cool down for at least 30 minutes z Loosen all locking nuts (3) of the rocker arm as-
before setting the valve clearance: Lubricating oil sembly to be set.
temperature below 80 °C. z Turn the setting screws (1) back by one rotation
anticlockwise.
z Place turning gear over fastening screws of the
belt pulleys. z Turn the setting screw (1) without clearance
clockwise on the rocker arm to be set. This
z Tool (74).
means, there must not be any clearance be-
z Turn the engine until reaching valve overlap, cyl-
tween the rocker arm and the valve (2) and no
inder no. 1.
pressure may be applied to the valve.
The cylinders to be set can be seen in the setting
z Set pointer (6) on the knurled handle (5) of the
schematic.
measuring plate (4) to "0°"; do not twist the
z Note: Crankshaft means: knurled handle (5) anymore.
z Outlet valve EX is not yet closed, inlet valve IN z Hold the measuring plate (4) exactly in this posi-
begins to open. tion and turn the setting screw (1) anticlockwise
using the knurled handle (5) until the pointer (6)
reaches the "in" or "ex" marking.
z Hold the knurled handle (5) exactly in this posi-
tion and tighten the locking nut (3) using the
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1
1
Install turning gear
z Unscrew threaded stopper (1) from stopper. z Turn in M8 screw (1) into stopper. z Insert turning gear (1) and set valve clearance as
z Pull out stopper using the screw. described.
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2 Locking nut
4 Control board
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7 Faults
Engine performs poorly and
Causes
Engine electronics reduce performance
Measures
Check error according to error code and eliminate error if
diagnostic lamp lights necessary
Engine does not run on all cylin- Injection line leaks Check injection line
ders Injection valve defective Check fuel injector / change if necessary
Engine lubricating oil pressure Lubricating oil level too low Fill up lube oil
is non-existant or excessively Excessive inclination of engine Check engine mounting / reduce inclination
low
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consump- Lube oil level too high Check lube oil level, if necessary drain off.
tion excessive Excessive inclination of engine Check engine mounting / reduce inclination
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
Engine producing white smoke Below starting limit temperature Check
Fuel quality does not comply with operating manual Change the fuel
Injection valve defective Check fuel injector / change if necessary
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
Injection valve defective Check fuel injector / change if necessary
Injector defective Change
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Suspension equipment
Danger to life!
z Always use proper suspension equipment when The engine may tip over or fall down if sus-
transporting the engine. pended incorrectly!
z The suspension device (1) must be adjustable
for the engine's centre of gravity. z The fastening attachment cannot be fixed se-
curely above the centre of gravity (1).
z After transportation and before commissioning of
engine: remove attachment eyes (2). z The fastening attachment can slip, the engine
swings backwards and forwards (1).
z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
damage it.
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8 General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
fluid system (cooling water with cooling system
protection agent).
tection: z The corrosion protection run can be performed z Cooling air system, see the Exterior corrosion
once to protect the different systems: protection section.
z Interior corrosion protection z In engines of the oil-cooled series the circulating
z Exterior corrosion protection Fuel system lubricating oil serves simultaneously for cooling.
Your DEUTZ partner has the right corro- z Fill the fuel tank with a mixture of: The cooling chambers are protected automati-
– 90 % distilled fuel cally against corrosion with the lube oil system.
sion protection agent for your needs.
– 10 % corrosion protection oil SAE 20W-20 z If a coolant with corrosion protection properties is
z Perform a corrosion protection run with no load poured into liquid-cooled engines, no further ac-
The following measures for corrosion protection af-
for at least 5 minutes. tion is necessary after draining.
ter taking the engine out of operation meet the re-
quirements for 12 months corrosion protection. z If not, the coolant must be drained and, to ensure
Lubricating oil system the formation of a covering layer on the inside
The following corrosion protection work may only be surfaces of the cooling system, a corrosion pro-
carried out by persons familiar with it and instructed z Drain lubricating oil from warm engine.
tection run performed with a mixture of:
in the potential dangers. z Thoroughly clean lube oil tray, cylinder head with
– 95 % treated water
rocker arms, valves, valve springs with diesel
If these measures are deviated from by exposing the – 5 % corrosion protection agent
fuel or cleaning agent.
corrosion-protected engines or parts to unfavourable z The duration of the corrosion protection run and
conditions (installation outdoors or storage in damp, z Fill the engine with corrosion protection oil SAE
20W-20 up to the MAX mark and perform a cor- the concentration of the corrosion protection
badly aired places) or damage to the corrosion pro- agent are specified by the manufacturer of the
tection layer, a shorter corrosion protection duration rosion protection run for at least 5 minutes so
that all the components of the lubricating oil sys- corrosion protection agent.
is to be expected. z Then drain the coolant.
tem are wetted or wet all accessible parts with
The engine corrosion protection should be checked corrosion protection oil and pump corrosion pro-
about every 3 months by opening the covers. If cor- Air intake pipes
tection oil through the engine with a separate
rosion is detected, the corrosion protection should pump until all bearings and bearing liners are z After the corrosion protection run, remove the
be renewed. wetted. cylinder head cover and deinstall injectors. The
At the end of the corrosion protection work the crank respective piston must be set to LT.
drive may no longer be turned so that the corrosion Air compressor z The accessible part of the cylinder liner should
protection agent in the bearings, bearing liners and z If a compressor is installed, a corrosion protec- be coated with corrosion protection oil with a
cylinder liners is not scraped off. tion agent must be sprayed into the compressor spray lance through the opening.
Before operating a corrosion protected engine, the suction system after shutting down the engine z Spray corrosion protection oil SAE 20W-20 into
corrosion protection must be removed. until it emerges visibly from the pressure nozzle. the suction air intake line.
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9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Fa. Wilbär
Taubenstraße 5
D-42826 Remscheid
Tel.: 0049 (0) 2191-9339-0
Fax: 0049 (0) 2191-9339-200
E-mail: info@wilbaer.de
http://www.deutz-tools.com
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DEUTZ Oil
DEUTZ Oil DQC II-05 DEUTZ Oil DQC III-05 DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E5-02 / E3-96 / B3-04 ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 ACEA E7-04 / E5-02 / E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1
DEUTZ AG
Service Information Systems
Ottostraße 1
D-51149 Cologne
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-mail: info@deutz.com
Printed in Germany
All rights reserved
1st edition, © 08/2007
The engine company. Order no.: 0312 3536 en