Operation Manual: OBJ - DOKU-18580-001.fm Seite 1 Mittwoch, 25. Februar 2009 11:46 11

OBJ_DOKU-18580-001.fm Seite 1 Mittwoch, 25.
Februar 2009 11:46 11
Operation Manual
TCD 2015
OBJ_DOKU-18580-001.fm Seite 2 Mittwoch, 25. Februar 2009 11:46 11
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 2009
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.
Please make sure that this operating manual is avail-
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
2009 3
Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Aspiration system. . . . . . . . . . . . . . . 43
Foreword. . . . . . . . . . . . . . . . . . . . . 3 Belt drives . . . . . . . . . . . . . . . . . . 45
1 General. . . . . . . . . . . . . . . . . . . . 5 Setting work . . . . . . . . . . . . . . . . . 46
2 Engine description . . . . . . . . . . . . . 7 Electrical system . . . . . . . . . . . . . . . 48
Model . . . . . . . . . . . . . . . . . . . . . 7 7 Faults. . . . . . . . . . . . . . . . . . . . . 50
Engine illustrations . . . . . . . . . . . . . . 9 Fault table . . . . . . . . . . . . . . . . . . 50
Lubricating oil diagram . . . . . . . . . . . . 13 Engine management . . . . . . . . . . . . . 55
Fuel diagram . . . . . . . . . . . . . . . . . 14 8 Transport and storage . . . . . . . . . . . 58
Coolant diagram . . . . . . . . . . . . . . . 15 Transport . . . . . . . . . . . . . . . . . . . 58
Exhaust return . . . . . . . . . . . . . . . . 16 Engine corrosion protection . . . . . . . . . 59
Electrics/Electronics . . . . . . . . . . . . . 18 9 Technical data . . . . . . . . . . . . . . . . 61
3 Operation . . . . . . . . . . . . . . . . . . 20 Engine and setting data . . . . . . . . . . . 61
Ambient conditions . . . . . . . . . . . . . . 20 Tools . . . . . . . . . . . . . . . . . . . . . 63
Initial start-up . . . . . . . . . . . . . . . . . 21
Start procedure . . . . . . . . . . . . . . . . 23
Operation monitoring . . . . . . . . . . . . . 24
Stop procedure . . . . . . . . . . . . . . . . 26
4 Operating media. . . . . . . . . . . . . . . 27
Lubricating oil . . . . . . . . . . . . . . . . . 27
Fuel . . . . . . . . . . . . . . . . . . . . . . 29
Coolant . . . . . . . . . . . . . . . . . . . . 30
5 Maintenance . . . . . . . . . . . . . . . . . 31
Maintenance schedule . . . . . . . . . . . . 31
6 Servicing and maintenance works . . . . . 34
Lubricating oil system. . . . . . . . . . . . . 34
Fuel system. . . . . . . . . . . . . . . . . . 36
Cooling system . . . . . . . . . . . . . . . . 40
Engine cleaning. . . . . . . . . . . . . . . . 42
4 2009
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 California
Obviously the high requirements for the protection of Proposition 65 Warning
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high Diesel engines and some of its constituents are
Safety precautions when the engine is running 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.
Maintenance work or repairs may only be performed liability.
on the shut-down engine. Make sure that the engine Masthead
cannot be started inadvertently - Danger of acci- Asbestos DEUTZ AG
dent!
The gaskets used in this engine contain no asbestos. Ottostrae 1
After repair work: Check that all guards have been Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from 51149 Kln
maintenance and repair work.
the engine. Germany
Observe industrial safety regulations when running Service Phone: +49 (0) 221-822-0
the engine in an enclosed space or underground. We want to preserve the high performance of our en- Fax: +49 (0) 221-822-3525
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
E-Mail: info@deutz.com
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
2009 5
General
1 Danger
This symbol is used for all safety instruc-

tions which, if not observed, present a di-
rect danger to life and limb for the person
involved. Observe these carefully. The at-
tention of operating personnel should be
drawn to these safety instructions. Further-
more, the legislation for "general regula-
tions for safety and the prevention of
accidents" must be observed.
Caution
This symbol indicates a danger to the part

and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.
Notes
This symbol accompanies notes of a gen-

eral kind.
6 2009
Model Engine description

Engine type designation
X
2
This manual covers the following engine types XX
XX
A B XX
TCD 2015 V06
TCD 2015 V08
Mot.-Typ Mot.-Nr.
TCD
C
T Exhaust gas turbocharger
C Charge air cooler
D Diesel R
DEUTZ AG MADE IN GERMANY
2015
2015 Series
Rating plate Location of the rating plate
V06/V08
The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cov-
V Cylinder arrangement data are stamped on the rating plate. er or the crankcase.
06 No. of cylinders The engine type and number must be stated when
08 No. of cylinders purchasing spare parts.
2009 7
Engine description Model
2 D XX
X
left
X
XXX
right
Engine serial number Cylinder numbering

The engine number (D) is stamped onto the crank- Cylinder arrangement
case (arrow) and onto the rating plate. The cylinders are counted consecutively starting
from flywheel (1).
Direction of rotation
Looking onto the flywheel.
rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
8 2009
Engine illustrations Engine description

TCD 2015 V08
View from right (example)
2
15 16 1 2 3 1 Crankcase breather
2 Coolant outlet to the cooler
14 3 Charge air line
4 Lube oil replacement filter
5 Coolant pump
6 Coolant inlet
7 V-belts
8 Lubricating oil sump
9 Generator
10 Lubricating oil drain plug
11 Fuel pump
12 Connections charge air cooler
4 13 Cylinder head cover
14 Combustion air inlet
15 Turbocharger
16 Exhaust outlet
5
13
6
12 11 10 9
2009 9
Engine description Engine illustrations
2 TCD 2015 V08

View from left (example)
1 Single injection pump
2 Flywheel
3 Starter
5 Injection line
1 6 Lube oil cooler
2
3
10 2009
Engine illustrations Engine description

TCD 2015 V06
Flat version
2
16 17 1 2 3 4 View from right (example)
1 Crankcase breather
2 Coolant outlet to the cooler
3 Flame glow system
5 Coolant inlet
15 6 Lube oil replacement filter
7 Coolant pump
8 Connections of separate lubricating oil tank
9 V-belts
10 Generator
11 Exhaust manifold line
12 Connections to engine control unit
13 Combustion air inlet
14 Cylinder head cover
15 Exhaust outlet
16 Turbocharger
17 Charge air line
14
13
5
6
12
7
11 10 9 8
2009 11
Engine description Engine illustrations
2 TCD 2015 V06

Flat version
4 5 6 View from left (example)
1 Ancillary drive
2 Fuel pump
3 Flywheel
4 Lube oil cooler
6 Injection line
12 2009
Lubricating oil diagram Engine description

TCD 2015
(example)
2
12 10 9 8 7
1 Lubricating oil sump
2 Lubricating oil pump
6 3 Pressure limiting valve
4 Lube oil cooler
6 Piston cooling nozzle
7 Rocker arm
9 Pressure holding valve
4 10 Lubricating oil pressure monitor
11 Turbocharger
12 Air compressor
Optional
13 Hydraulic pump
Optional
13 11 1 5 3 2
2009 13
Engine description Fuel diagram
2 Fuel schematic (example)

1 Fuel tank
2 Fuel line from tank to fuel pump
3 Fuel pump
14 13 11 10 9 4 Manual pump for venting
5 Fuel pre-filter
6 Fuel pump
7 Exchangeable fuel filter
8 Fuel pipe from the filter to the fuel injector
10 Injection line to injection valve
11 Injection valve
12 Return collection pipe
13 Pressure holding valve
14 Fuel return to fuel tank
15 15 Flame glow system
12 8
1 2 5 6
14 2009
Coolant diagram Engine description

Coolant schematic (example)
TCD 2015
2
6 7 8 9 10 11 12
1 Coolant pump
2 Lube oil cooler
3 Coolant supply for engine cooling
4 Cylinder pipe/head cooling
5 Air compressor
Optional
6 Gear oil cooler
Optional
x1 x2
7 Auxiliary cooler
Optional
T 8 Temperature transmitter
x1 x2
9 Thermostat
(engine cold) coolant directly for engine cooling
(engine warm) coolant flow through the cooler
10 Compensation tank
11 Filler neck
1 2 3 4 12
13
Cooler
Cab heater connection
Optional
5 4 3 2 1 13
2009 15
Engine description Exhaust return
2 External exhaust gas recirculation

(example)
1 Exhaust gas partial flow
9 12 (uncooled)
2 Compensator pipe
3 Shutoff valve
4 Adjustment rod
6 5 4 3
5 Actuator
(electrically actuated)
6 Electrical connection
11 7 Coolant inlet
8 Exhaust return cooler
9 Check valve
10 Exhaust gas partial flow
(cooled)
11 Coolant outlet
10 Only have work performed on the components by

authorised qualified personnel.
8 7
16 2009
Exhaust return Engine description

Internal exhaust gas recirculation
1 Additional cams for exhaust gas recirculation
2
Inlet valve opens briefly during the outlet cycle
and emits an exhaust gas partial flow to the suc-
tion system.
This partial volume is sucked back in in the next
suction cycle.
2 Outlet valve
3 Inlet valve
2 3
[mm]
[]
2009 17
Engine description Electrics/Electronics
2 1 2 3 4
Electronic engine control
10 Engine side
1 Lubricating oil pressure transmitter
11 2 Fuel temperature transmitter
3 Charge air pressure transmitter, charge air tem-
perature transmitter
12 4 Engine control unit
5 Coolant temperature transmitter
9 6 Lubricating oil level transmitter (optional)
13 7 Central plug (for engine control)
8 Speed transmitter via crankshaft
9 Speed transmitter via camshaft
14
Equipment side
10 Power supply (battery)
15 11 Multifunction displays
12 Signal outputs, e.g. for lamps, torque (PWM),
speed, engine operation, etc.
16 13 Inputs (e.g. override button)
14 Accelerator
8
17 15 Hand throttle
16 Optional function selector switch, e.g. for P de-
gree, type of controls, maximum curve, fixed
18 speeds, etc.
17 Detachable key switch Start/Stop
18 Diagnosis button
19 19 Error lamp
7 6 5 20 Diagnostic interface/CAN bus
20
18 2009
Electrics/Electronics Engine description

Information about the engine electronics
This engine is equipped with an electric control unit.
It is strictly prohibited:
a) to make changes or connections to the
tics. Active and passive error entries are saved in the
error memory. Active errors are displayed on error 2
wiring of the electrical control devices and lamps/diagnostics lamps (55).
The equipping of the respective system depends on
the data transmission cable (CAN lines). A diagnosis can be made with:
the desired scope of function and the planned type of
b) to switch control units. z Error lamp (flash code)
engine application.
Otherwise guarantee rights will be lost!
The resultant wiring with pin assignment can be seen z CAN bus
Diagnostic and maintenance work may
in the appropriate wiring diagram. z DEUTZ electronics display
only be carried out by authorised personnel
using equipment approved by DEUTZ. z Diagnostic socket (SERIDA)
The installation regulations of the DEUTZ AG must
also be taken into account. Equipment-side wiring
Installation instructions
Precautions The control units are calibrated to the respective en- The DEUTZ AG installation regulations should be
gine and identified by the engine number. Every en- adhered to. In particular, the plug contact must be
The connections of the control units are gine may only be operated with the appropriate crimped with the appropriate standard tools. If it is
only dust and water proof when the mating control unit. necessary to do so, plugged-in contacts may only be
plugs are plugged (protection class IP69K)! removed from the plug housing with the proper tools.
Setpoint transmitters (pedal value transmitters) nec-
The control units must be protected against
essary for vehicle operation must be connected to
spray water and moisture until plugging in
the vehicle side cable harness and calibrated with
the mating plugs!
the DEUTZ diagnostic program SERDIA (SERvice
Reverse polarity can lead to failure of the
DIAgnosis). Wiring and cable assignment of the ve-
control unit.
hicle side cable harness must be taken from the con-
To avoid damaging the control units, all the
nection diagram of the DEUTZ installation
connections on the control unit must be dis-
consulting.
connected before electric welding work.
Interventions in the electrical system con- Supply voltage
trary to the DEUTZ regulations or by un-
qualified personnel can permamently 24 Volt
damage the engine electronics and have It should be ensured that the battery is sufficiently
serious consequences which are not cov- charged. If the supply voltage is interrupted while the
ered by the manufacturer's guarantee. 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.
Diagnostics
DEUTZ control units are equipped with self-diagnos-
2009 19
Operation Ambient conditions
3 Cold start aid

z Depending on the type of engine, glow plugs,
heating plugs, heating flange, flame glow system
can be used as cold starting aids.(23)
Coolant
z Observe the mixing ratio anti-freeze/cooling wa-
0 C ter. (30)
High ambient temperatures, high altitude
This engine can be equipped optionally

with an electronic DEUTZ control unit.
Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
ically, controlled by the electronic control
Low ambient temperatures unit.
Lubricating oil Under the following application and operating condi-
z Select the lubricating oil viscosity according to tions, the amount of fuel must be reduced.
the ambient temperature. z above 1000 m altitude
z If cold starting occurs frequently cut the lube oil z above 30 C ambient temperature
changing interval by half.
Reason: Air density decreases as altitude or ambient
Fuel temperature increase. This reduces the amount of
z Use winter fuel below 0 C (29). oxygen in the engine intake air and the fuel-air mix-
ture would be too rich if the injected amount of fuel
Battery were not reduced.
z A good charging condition of the battery (48) z The results would be:
is the prerequisite for starting the engine. black smoke in the exhaust
z Heating up the battery to approx. 20C improves high engine temperature
the starting behaviour of the engine. (Remove
reduction in engine performance
and store the battery in a warm room).
possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
you have any other questions.
20 2009
Initial start-up Operation

Preparations for initial commissioning
(Maintenance schedule E 10)
Fill with engine lube oil
3
Low lubricating oil level and overfilling lead
z Remove engine corrosion protection to engine damage.
z Remove any transport devices.
z Check the battery and cable connections and
mount if necessary. The engines are generally supplied without
z Check belt tension (45). lubricating oil filling.
z Have the engine monitor or warning system Select lubricating oil quality and viscosity
checked by authorised personnel. before filling.
z Check the engine mounting. Order DEUTZ lubricating oils from your
DEUTZ partner
z Check that all hose unions and clips fit properly.
z Fill the engine with lubricating oil via the lubricat-
The following additional work must be carried
ing oil filler neck.
out on generally overhauled engines:
z Observe the lubricating oil filling level (61).
z Check the fuel pre-filter and main filter and Pour in fuel
change if necessary.
z Check the intake air cleaner (if available, main- Never fill the fuel tank while the engine is
tain according to maintenance indicator). running.
z Drain lubricating oil and condensation water from Ensure cleanliness.
the charge air cooler. Do not spill fuel.
z Fill with engine lube oil. Additional venting of the fuel system by a 5
minute trial run at idle speed or on low load
z Fill the coolant system (61).
is absolutely essential.
z The fuel low pressure system must be vented be-
fore the first start-up after filling with the manualy
supply pump.
Only use clean commercially available brand diesel
fuel. Observe fuel quality (29).
Use summer or winter-grade fuel, depending on the
ambient temperature.
2009 21
Operation Initial start-up
3 z Close compensation tank with valve.

z Connect ventilation line from the engine and, if
necessary, from the cooler to the compensation
tank.
z Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
z Start the engine and warm up until the thermo-
stat opens.
z Engine operation with open thermostat 2 - 3 min-
utes.
z Check the coolant level and top up coolant if nec-
essary.
z If required, repeat procedure with engine start.
z Fill up coolant to the MAX mark on the compen-
Filling the coolant system sation tank and close the cooling system cap.
z Observe the filling volume of the cooling system
Danger of scalding from hot coolant! (61).
Cooling system under pressure! Only open
Trial run
the cap when cool!
Observe safety regulations and national
specifications when handling cooling me- Additional venting of the fuel system by a 5
dia. minute trial run at idle speed or on low load
is absolutely essential.
The coolant must have a prescribed con- Carry out a brief trial run up to operating temperature
centration of cooling system corrosion pro- (approx. 90 C) after preparations.
tection agent! Do not load the engine if possible.
Never operate the engine without coolant,
even for a short time! z Work with the engine not running:
Check engine for tightness.
Order coolant corrosion protection agent Check lubricating oil level, if necessary top
from your DEUTZ partner. up.
Check the coolant level and top up coolant if
necessary.
z Open the cooling system cap (1) carefully.
z Work during the trial run:
z Fill cooling system via the compensation tank.
Check engine for tightness.
22 2009
Start procedure Operation

Starting If the starter is controlled by the electronic engine
control via a relay: 3
Before starting, make sure that nobody is z the maximum start duration is limited.
standing in the immediate vicinity of the en- A z the pause between two start attempts is speci-
gine or work machine. fied.
After repair work: Check that all guards the start is then continued automatically
have been replaced and that all tools have
been removed from the engine. z starting while the engine is running is prevented.
When starting with the flame glow plug/ B
glow plug/heating flange system do not use If the touch start function is programmed, a short
any other starting aid (e.g. injection with start command with the ignition key in position 2 or a
start pilot). Risk of accident! start button, if available, suffices.
C Electronic cold start assist
If the engine fails to fire and the error lamp
lights, the electronic engine control has ac- Flame glow unit
tivated the start lock to protect the engine. z The electronic engine control controls and acti-
The start lock is released by switching off with cold starting device
vates the current feed of the flame glow plugs
the system with the ignition key for about 30 z Insert key. and the fuel solenoid valve via the engine coolant
seconds. Position 0 = no operating voltage. temperature
Do not actuate the starter for more than z Below the temperature specified in the electronic
20 seconds. If the engine does not start up, z Turn key to the right. engine control, the pre-heating phase begins
wait for one minute and then repeat the Position 1 = operating voltage. with turning on the ignition.
starting process. Pilot lamps (A), (B) and (C) light up. z If the engine is started, the fuel solenoid valve
If the engine does not start up after two at- Pre-heating until glow display (C) lights up, opens and the fuel ignites on the hot glow plugs.
tempts, determine the cause as per fault ta- max. 30s. z The intake air is therefore pre-warmed in the cold
ble (50). Engine is ready for operation. run phase.
Do not run up the engine immediately to
z Push the key in and turn further clockwise
high idling speed / full load operation from
against spring pressure.
cold.
Level 2 = start.
Disconnect the engine by uncoupling de- z release the key as soon as the engine starts up.
vices to be driven where possible. The pilot lamps will go out.
2009 23
Operation Operation monitoring
3 Electronic engine control

The statuses are displayed by the error lamp.
essary.
The switch-off process has been accom-
plished.
The system monitors the condition of the engine and There may be a start lock after engine stop.
itself.
The start lock is deactivated by turning off the
z Function test system with the ignition key for approx. 30s.
Ignition on, error lamp lights up for approx. 2 Additional control lamps, e.g. for lubricating
seconds and then goes out. oil pressure or lubricating oil temperature,
Check the error lamp if there is no reaction are switched on if necessary.
after switching on the ignition. The power reduction can be bypassed, the
z The lamp does not light automatic switch-off delayed or a start lock
After the lamp test an extinguished lamp indi- bypassed with the override key on the instru-
cates an error-free and trouble-free operat- ment panel to avoid critical situations. This
ing state within the scope of the control brief deactivation of the engine protection
possibility. functions is logged in the control unit.
The engine protection functions are released in Display instrument
z Continuous light co-operation with the equipment manufacturer
Error in the system. and the DEUTZ installation consulting and may Possible displays:
Operation continued with restrictions. be designed individually. It is therefore absolute- z Colour scale
The engine must be checked by a DEUTZ ly essential to observe the operating instructions Display of operating state by coloured areas:
partner. of the equipment manufacturer. green = normal operating state
If a lamp lights steadily a monitored measur- red = critical operatng state
ing variable (e.g. coolant temperature, lubri-
Take suitable action.
cating oil pressure) has left the permissible
value range. z Measured value scale
Depending on the fault, the engine power may be Actual value can be read off directly. The
reduced by the electronic engine control to pro- nominal value should be taken from the
tect the engine. Technical Data (61).
z Flashing
Serious error in the system.
Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guaran-
tee!
The engine has reached switch-off condition.
Engine forced to run at low idle speed to cool
the engine, with automatic shutdown if nec-
24 2009
Operation monitoring Operation

3
Instruments/ Designation Possible display: Measure
symbols
Lubricating oil pressure dis- Lubricating oil pressure below minimum Switch off engine
play
Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play
Coolant temperature Coolant temperature too high Switch off engine
Lubricating oil temperature Lubricating oil temperature too high Switch off engine
Lubricating oil pressure If the pilot lamp lights up after starting the engine or while the Switch off engine
pilot lamp 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 the Fill up lube oil
engine is running, the lubricating oil level is too low
Coolant level If the control lamp lights up after the engine starts or while the Shut down the engine, allow to cool and top up cool-
engine is running, the coolant level is too low ant
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
Horn With acoustic signal See fault table (50).
2009 25
Operation Stop procedure
3 P = gear position: park

0 = gear position: switch off engine
1 = gear position: pre-heat engine
A 2 = gear position: start engine
Shutting off
Avoid switching off from full load (coking/

blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap-
proximately one minute after relieving the
load.
The control unit remains active for about
another 40 seconds to save the system
data (lag) and then switches off automati-
cally.
z Move the key to position 0.
Control lamps A+B+C go out.
A = charge pilot light
B = lube oil pressure pilot light
C = pilot light for pre-heating system
26 2009
Lubricating oil Operating media

General
Modern diesel engines place very high demands on
lubricating oil flows, depending on the temperature.
The lubricating oil viscosity only has a small influ-
http://www.deutz.com
en \SERVICE \Operating Media and Diagno-
4
ence and effect on the quality of the oil.
the lubricating oil to be used. The specific engine sis\Deutz Quality Class\DQC Release List
performances which have increased constantly over Synthetic lubricating oils are used increasingly
the last few years lead to an increased thermal load and offer advantages. These lubricating oils have The following lubricating oils are recommended for
on the lubricating oil. The lubricating oil is also more better temperature and oxidation stability as well as the engines in this operating manual:
exposed to contamination due to reduced oil com- relatively low cold vicosity. Since some processes
sumption and longer oil change intervals. For this which are relevant for determining the lubricating oil Minimum quality class
reason it is necessary to observe the requirements change times are largely dependent on the oil quality DEUTZ Others
and recommendations described in this operating (e.g. the infiltration of soot and other contamination),
DQC III Please contact your DEUTZ partner
manual in order not to shorten the life of the engine. the oil change time for synthetic lubricating oils may
DQC IV or see www.deutz.com
not be increased in relation to the specifications on
Lubricating oils always consist of a base oil and an
lubricating oil change intervals.
additive package. The most important tasks of a lu-
bricating oil (e.g. wear protection, corrosion protec- Biodegradable lubricating oils may be used in DEUTZ lubricating oils DQC III
tion, neutralisation of acids from combustion DEUTZ engines if they meet the requirements of this TLX - 10W40 FE
products, prevention of coke and soot deposits on operating manual. Container Order number:
the engine parts) are assumed by the additives. The 5 litre container 0101 6335
Quality
properties of the base oil are also decisive for the
quality of the product, e.g. with regard to thermal Lubricating oils are classified by DEUTZ according 20 litre container 0101 6336
load capacity. to their performance and quality class (DQC: DEUTZ 209 litre barrel 0101 6337
In principle, all engine oils of the same specification Quality Class). Essentially, the following applies: the
can be mixed. However, mixing of engine oils should higher the quality class (DQC I, II, III, IV), the more DEUTZ lubricating oils DQC IV synthetic
be avoided because the worst properties of the mix- effective/the better quality the lubricating oil is. DQC IV - 5W30-UHP
ture are always dominant. Lubricating oils according to other comparable spec- Container Order number:
The lubricating oils approved by DEUTZ have been ifications can be used as long as they meet DEUTZ
20 litre container 0101 7849
thoroughly tested for all engine applications. The ac- requirements. In regions in which none of these
qualities are available, please contact your responsi- 209 litre barrel 0101 7850
tive ingredients they contain are compatible with
each other. Therefore, the use of additives for lubri- ble DEUTZ partner.
cating oils is not permitted in DEUTZ engines. or see www.deutz.com
The lubricating oil quality has a considerable influ-
ence on the life, performance and thus also on the http://www.deutz.com
costs-effectiveness of the engine. It basically applies de \SERVICE \Betriebsstoffe und Diag-
that: The better the lubricating oil quality, the better nose\Deutz Quality Class\DQC-Freiga-
these properties. beliste
The lubricating oil viscosity describes the way the
2009 27
Operating media Lubricating oil
4 Engines with exhaust aftertreatment Viscosity

The ambient temperature at the installation site or in
C
Exhaust aftertreatment systems the application area of the engine is decisive for 45
SCR Selective Catalytic Reduction choosing the right viscosity class. Too high a viscos-
DPF Diesel particle filter ity can lead to starting difficulties, too low a viscosity 40
can endanger the lubrication effect and cause a high
If engines are operated with an exhaust aftertreat- lubricating oil consumption. At ambient temperatures 35
ment system, only low ash oils may be used. below -40 C, the lubricating oil must be pre-heated
(e.g. by storing the vehicle or the machine in a hall). 30
Please contact your DEUTZ partner
or see www.deutz.com The viscosity is classified according to SAE. Multi- 25
purpose lubricating oils should be used basically.
http://www.deutz.com Single-purpose lubricating oils can also be used in 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
enclosed, heated spaces at temperatures >5 C.
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
de \SERVICE \Betriebsstoffe und Diag- 15
nose\Deutz Quality Class\DQC-Freiga-
The prescribed lubricating oil quality must
beliste 10
be observed when selecting the viscosity
en \SERVICE \Operating Media and Diagno- class!
sis\Deutz Quality Class\DQC Release List 5
Depending on the ambient temperature we recom-
Lubricating oil change intervals mend the following common viscosity classes: 0
z The intervals depend on: -5
lubricating oil quality
sulphur content in the fuel -10
type of application of engine
-15
z The lubricating oil change interval must be
halved if at least one of the following conditions -20
applies:
Constant ambient temperature below -10 C -25
(14 F) or lube oil temperature below 60 C
(84 F). -30
Sulphur content in diesel fuel of >0.5 weight
%. -35
operation with bio-diesel fuel -40
z If the lubricating oil change intervals are not
reached within a year, the oil should be changed
at least once a year.
28 2009
Fuel Operating media

Permissible fuels
The following fuel specifications / standards are ap-
voided.
The certification measurements for compliance with
4
proved: the legal emission values are made with the test fu-
els specified in the laws. These correspond to the
z Diesel fuels
diesel fuels in accordance with EN 590 and
EN 590 ASTM D 975 described in the operation manual. No
DIN 51628 emission values are guaranteed with the other fuels
ASTM D 975 1-D described in this operation manual.
ASTM D 975 2-D The respective fuels prescribed by law must be used
z Light heating oils to comply with the national emission regulations
(e.g. sulphur content).
Please contact your DEUTZ partner
Winter operation with diesel fuel
http://www.deutz.com
de \SERVICE\Betriebsstoffe und Diag- Only carry out mixing in the tank. Fill with
nose\Kraftstoffe the appropriate amount of paraffin first, Usually a sufficient cold resistance can be achieved
en \SERVICE\Oils, Lubricants, Diagnosis\Fuel then add the diesel fuel. Normal and high by adding a flow improver. Ask your DEUTZ partner.
grade fuels may not be mixed.
z Jet fuels I Summer-grade diesel fuel
At low ambient temperatures paraffin discharges can
NATO F34 II Winter-grade diesel fuel
lead to blockages in the fuel system and cause oper-
NATO F35 ating faults. Below 0 C ambient temperature use A Outdoor temperature
NATO F44 winter diesel (down to -20 C) (filling stations provide B Percentage of paraffin to be added
NATO F63 this in good time before the cold season starts).
JP-5 z Below -20 C paraffin should be added. The rel-
Jet A evant percentages are given in the adjacent dia-
Jet A1 gram.
z Biodiesel fuel z Special diesel fuels can be used for arctic cli-
EN 14214 mates to -44 C.
ASTM D 6751-07a If it is necessary to use Summer diesel fuel below
maximum percentage 50% 0 C, up to 30 % petroleum can be added according
to the diagram opposite.
Fuels with more than 1 weight % sulphur content are
not permitted.
If other fuels are used which do not meet the require-
ments of the operating manual, the warranty will be
2009 29
Operating media Coolant
4 General z Total hardness too high:

Mixing with softened water (pH neutralized con-
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, densate or water softened by ion exchanger). Please contact your DEUTZ partner if the DEUTZ
even for a short time! z Total hardness or carbonate hardness too cooling system corrosion protection agent is not
low: available.
In liquid-cooled engines, the coolant must be condi- Mixing with harder water (harder water is usually or see www.deutz.com
tioned and monitored, otherwise the engine could be available in the form of drinking water).
damaged by: z Chlorides and/or sulphates too high: http://www.deutz.com
z corrosion Mixing with softened water (pH neutralized con- de \SERVICE\Betriebsstoffe und Diag-
z cavitation densate or water softened by ion exchanger). nose\Khlsystemschutz
z freezing Cooling system corrosion protection agent en \SERVICE\Oils, Lubricants, Diagnosis\Cool-
z overheating ing System Conditioner
Health damaging nitrous amines form
Water quality The cooling system must be monitored regularly.
when nitrite-based cooling system corro-
This also includes checking the coolant system cor-
The right water quality is important for conditioning sion protection agents are mixed with
rosion protection agent concentration in addition to
the coolant. Clear, clean water within the following amine-based agents!
checking the coolant level.
analysis values should always be used:
Cooling system corrosion protection agents The cooling system corrosion protection agent con-
Analysis values min max ASTM must be disposed of in an environmentally centration can be checked with conventional test in-
ph value 6,5 8,5 D 1293 friendly way. struments (e.g. refractometer).
Chlorine (Cl) [mg/l] - 100 D 512 The conditioning of the coolant for liquid-cooled Cooling system Water percent- Cold pro-
D 4327 DEUTZ compact engines is performed by mixing an corrosion protec- age tection up
Sulphate (SO4) [mg/l] - 100 D 516 anti-freeze with corrosion protection inhibitors based tion agent per- to
on ethylene glycol into the water. centage
Total hardness [mmol/l] 0,54 3,56 D 1126
(CaCO3) [mg/l] 54 356 min. 35 % 65 % -22 C
DEUTZ cooling system corrosion protection
[dGH] 3,0 20,0 - agent 40 % 60 % -28 C
Container Order number: max. 45 % 55 % -35 C
Specifications of the water quality are made by the
local water board. 5 litre container 0101 1490 At temperatures below -35 C, please contact your
The water must be conditioned if it deviates from the 20 litre container 0116 4160 responsible DEUTZ partner.
analysis values. It is possible to use other cooling system corrosion
210 litre barrel 1221 1500
z pH value too low: protection agents (e.g. chemical corrosion protection
Addition of diluted sodium or potassium lye. This cooling system corrosion protection agent is agents) in exceptional cases. Consult your DEUTZ
Small trial mixtures are advisable. free from nitrite, amine and phosphate and is adapt- partner.
30 2009
OBJ_DOKU-18580-001.fm Seite 31 Mittwoch, 3. Mrz 2010 11:57 11
Maintenance schedule Maintenance

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule Industrial engines Vehicle engines
TCD 2015 V06/V08
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E30 Maintenance Qualified personnel Local transport (~ 25 km/h ) 20,000 km 1)
500 1) Regional transport (~ 40 km/h) 30,000 km 1)
Long-distance transport (~ 60 km/h) 60,000 km 1)
E40 Extended maintenance I 1.000 2)
E50 Extended maintenance II Authorised specialists 3.000 2)
E55 Extended maintenance III 4.000 2)
E60 Intermediate overhaul 6.000 2)
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (27).
2)
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.
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
2010 31
Maintenance Maintenance schedule
5 Maintenance measures
Stage Activity Measure Page

E10 The measures are listed in chapter 3. 21
E20 Check Lubricating oil level (if necessary top up) 34
Coolant level (top up if necessary) 22
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 43
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 27/
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner. 34
Lubricating oil filter/insert (every time the lubricating oil is changed) 35
E40 Check Flame glow unit
Coolant (additive concentration) 40
Battery and cable connectors 48
V-belts (retension or renew if necessary) 45
Cold starting device
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
External exhaust return (optional), compensator pipes (replace in case of damage) 16
Settings Valve clearance (set if necessary, earlier if there is any noise) 46
Replace Fuel filter cartridge 37
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 38
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 43
E50 Check External exhaust return (optional), adjustment rod and shutoff valve (replace in case of damage) 16
E55 Replace Injection valve
EPA-certified engines Injection lines must be replaced after being removed for the third time
Replace Charging pressure control valve
TCD 2015 V08 440 kW
32 2010
Maintenance schedule Maintenance

Stage
E60
Activity
Replace
Measure
Injection valve
Page 5
Injection lines must be replaced after being removed for the third time
Coolant pump
Crankcase breather
Pressure holding valve behind the fuel injectors
External exhaust return (optional), adjustment rod, shutoff valve and check valve 16
(At least every 2 years)
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
annually Replace Lubricating oil filter/insert (every time the lubricating oil is changed) 35
Every 2 Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
years Replace V-belts 45
Flame glow unit 23
Coolant (additive concentration) 30 40
External exhaust return (optional), adjustment rod, shutoff valve and check valve 16
Maintenance work outside the DEUTZ maintenance and service schedules
*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.
Order number: 0312 0040
2010 33
Servicing and maintenance works Lubricating oil system
6 Regulations for working on the lubricating oil

system
OIL ?
z The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
essary.
Do not work when the engine is running!
Smoking and naked lights prohibited! Changing the lubricating oil
Be careful of hot lubricating oil. Danger of z Warm up the engine (lubricating oil temperature
scalding! OIL > 80 C).
+80C z Ensure that the engine or vehicle is in a level po-
+176F
Pay attention to utmost cleanliness when sition.
working on the lubricating oil system. Clean z Switch off the engine.
the area around the components con- z Place a collecting receptacle underneath the
cerned carefully. Blow damp parts dry with
compressed air.
Observe the safety regulations and nation-
! lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
z Fit a new sealing ring to the lube oil drain screw,
al specifications for handling lube oils.
Dispose of leaking lubricating oil and filter insert and tighten. (tightening torque 100 Nm).
elements properly. Do not allow used oil to Checking the lubricating oil level z Pour in lube oil.
seep away into the ground. Quality/viscosity data (27).
Perform a trial run after all work. Pay atten- Low lubricating oil level and overfilling lead Filling volume (61).
tion to tightness and lubricating oil pressure to engine damage. z Warm up the engine (lubricating oil temperature
and then check the engine oil level. The lubricating oil level may only be > 80 C).
In case of fuels containing more than 1% checked with the engine in a horizontal po- z Ensure that the engine or vehicle is in a level po-
sulphur, contact your corresponding sition and switched off. sition.
DEUTZ partner. If the engine is warm, switch off the engine z Check lubricating oil level, if necessary top up.
and check the lubricating oil level after 5
minutes. If the engine is cold you can check
it immediately.
Be careful of hot lubricating oil. Danger of

scalding!
z Pull out the lubricating oil dipstick and wipe off

with a lint-free, clean cloth.
z Insert the lubricating oil dipstick as far as it will
go.
z Extract the lubricating oil dipstick and read off the
oil level.
34 2009
Lubricating oil system Servicing and maintenance works

6
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
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
z Remove clamps when twist protection mounted z Fasten clamps of the twist protection (optional).
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
2009 35
Servicing and maintenance works Fuel system
6 Specifications when working on the fuel system Additional venting of the fuel system by a 5
minute trial run at idle speed or on low load
Engine must be switched off! is absolutely essential.
Keep naked flames away when working on Pay attention to utmost cleanliness due to
the fuel system! Do not smoke! the high production accuracy of the system!
No injection/high pressure pipes may be The fuel system must be tight and closed.
disconnected while the engine is running. Make a visual inspection for leaks/damage
Caution when handling hot fuel! in the system.
Pay attention to utmost cleanliness when Clean and dry the engine and engine com-
refuelling and working on the fuel system. partment thoroughly before beginning
Clean the respective affected parts careful- work.
ly. Blow damp areas dry with compressed Areas of the engine compartment from
air. which dirt could be loosened must be cov-
Observe the safety regulations and nation- ered with a fresh, clean foil.
al specifications for handling fuels. Work on the fuel system may only be car-
Dispose of leaking fuel and filter elements ried out in an absolutely clean environment.
properly. Do not allow fuel to seep away Contamination of the air such as dirt, dust,
into the ground. moisture etc. must be avoided.
After all work on the fuel system, the sys-
tem should be vented, a trial run performed
and the tightness checked.
It will be necessary to vent the fuel system
when commissioning for the first time, after
maintenance work or if the tank has been
run dry.
36 2009
Fuel system Servicing and maintenance works

6
Change the fuel filter cartridge 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
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 10-12 Nm
z Remove clamps when twist protection mounted z Fasten clamps of the twist protection (optional).
(optional). z Vent the fuel system.
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Catch any escaping fuel.
z Clean the sealing surface of the filter support
2009 37
Servicing and maintenance works Fuel system
6 with fuel.
z Assembly in clockwise direction.
bubbles.
z Catch any escaping fuel.
7 z Open the fuel shutoff tap and vent the system, z Tighten vent screw.
see venting the fuel system.
Vent the fuel system
5 1 z Start engine.
z Check for leaks after starting the engine. z Bring engine control to stop position.
z Position fuel collecting vessel below the con-
6 2 Change the fuel pre-filter insert stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
4 3
level tank). z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
z Place suitable collecting containers underneath.
z Open the drain cock and drain liquid. z Turn over the engine with starter (max. 20 Sec.)
z Unscrew the filter insert (2) together with the wa- until bubble-free fuel emerges at the constant-
ter collection vessel (3). pressure valve in the crankcase/filter housing.
z Unscrew the water collection vessel (3) from the z Screw in ventilation screws (tightening torque
Clean/change/vent the fuel pre-filter filter insert (2). 25-5 Nm) and constant-pressure valve.
The special tool can be ordered under part z Bring engine control to the start position and
1 Fuel pre-filter holder
number 8192 (63). start.
2 Filter insert
z Check for leaks after starting the engine.
3 Water collection vessel z Clean the water collection vessel (3) and all the
4 Water drain tap existing sealing surfaces (6) with a brush and
5 Fuel pump diesel fuel.
6 Sealing surface z Oil the gaskets and sealing surfaces (6) of the
7 Venting screw new DEUTZ original filter insert (2) lightly or wet
with diesel fuel.
z Shut off the fuel supply to the engine (with high- z Screw the water collection vessel (3) to the filter
level tank). insert (2).
z Place suitable collecting containers underneath. z Screw a new filter insert (2) with water collection
z Open the drain cock and drain liquid. vessel (3) onto the filter carrier 1) (tightening
z Unscrew the filter insert (2) together with the wa- torque 17-18 Nm)
ter collection vessel (3). z Open the fuel supply to the engine.
z Empty emulsion in the water collection vessel (3) z Vent the fuel system.
and clean the vessel.
z Mount the filter insert (2) and water collection Vent the fuel pre-filter.
vessel (3). Wet the sealing surfaces (6) of the fil- z Loosen vent screws slightly.
ter insert (2) and the water collection vessel (3) z Operate the pump until fuel emerges without
38 2009
Fuel system Servicing and maintenance works

level tank).
z Place suitable collecting containers underneath.
z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing. 6
z Loosen vent screws slightly. z Start engine.
z Open the drain cock and drain liquid. Turn over the engine with starter (max.
To open, the drain cock must be pressed 20 Sec.) until bubble-free fuel emerges at the
lightly and turned. constant-pressure valve in the crankcase/fil-
ter housing.
z Close the drain cock.
z Tighten vent screw. z Shut down engine
z Vent the fuel system. Screw in ventilation screws (tightening
torque 25-5 Nm) and constant-pressure
Change the fuel pre-filter insert valve.
Change after maintenance interval, loss of power, or z Start engine.
annually. Bring engine control to the start position and
z Switch off the engine or switch over to the other start.
Clean/change/vent the fuel pre-filter filter in case of switchable filter. Check for leaks after starting the engine.
z Shut off the fuel supply to the engine (with high-
1 Venting screw level tank).
2 Cover z Loosen screws diagonally.
3 Screw z Remove cover.
4 Spring cassette z Remove spring cassette.
5 Filter insert z Change filter cartridge
6 Water collection vessel z Place spring cassette on the filter cartridge.
7 Electrical connection z Check the cover gasket for correct fit and dam-
8 Water drain tap age (change if necessary).
z Tighten cover with screws diagonally (tightening
A warning system (lamp/horn) should be in- torque 6Nm).
stalled via the electric connections. If the z Check for leaks after starting the engine.
warning system is triggered, immediate z Vent the fuel system.
maintenance is required.
Vent the fuel system
Cleaning/purging, draining of water
z Shut down engine
z Switch off the engine or switch over to the other z Position fuel collecting vessel below the con-
filter in case of switchable filter. stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
2009 39
Servicing and maintenance works Cooling system
6 Specifications when working on the cooling sys-

tem
Danger of scalding from hot coolant!

the cap when cool!
The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!
Observe safety regulations and national
specifications when handling cooling me-
dia. 1
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do
not allow them to seep into the ground.
Order coolant corrosion protection agent Check coolant additive concentration Emptying the cooling system
from your DEUTZ partner.
z Open the cooling system cap (1) carefully. z Open cooler locking cap carefully.
Never operate the engine without coolant,
even for a short time! z Check the coolant aditive concentration in the z Place a collection tray underneath the coolant
cooler/compensation tank (2) with a convention- connection (1).
Checking the coolant level with an external cool- al antifreeze measuring device (1) (e.g. hydrom- z Drain coolant.
er eter, refractormeter). z Reconnect and tighten the coolant connection
z Fill in new coolant and vent the system according z Necessary coolant additive concentration Cool- (1).
to the specifications of the cooling system manu- ant mixing ratio (30). z If the locking screw is not accessible, the drain-
facturer. You can order the appropriate test instrument from age can be carried out at the engine oil cooler
z Open the cooling system cap (1) carefully. your DEUTZ partner under order number 1824. (coolant duct).
z The coolant level must always be between the z Close cooler locking cap.
MIN and MAX marks of the compensation tank!
Fill up to the MAX mark if necessary.
40 2009
Cooling system Servicing and maintenance works

6
Fill and ventilate cooling system
Danger of scalding from hot coolant!

the cap when cool!
z Open the cooling system cap (1) carefully.
z Loosen the cooler venting screw if necessary.
z Fill coolant up to the max. mark or filling limit.
z Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
z Close the cooler venting screw.
z Close cooler locking cap.
z Run engine up to operating temperature (open-
ing temperature of the thermostat).
z Switch off the engine.
z Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
tion tank if necessary.
2009 41
Servicing and maintenance works Engine cleaning
6 Cleaning work Cleaning with cold cleaner

z 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).
z Spray the engine clean with a high pressure wa-
Cover electrical/electronic parts and con-
ter jet.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do z Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
Only carry out cleaning work on the engine z Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam temper-
Remove the engine cover and cooling air ature 90 C, distance at least 1m).
cover if available and remount after clean- z Warm up the engine so that the water residues
ing. evaporate.
z Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.
The following causes of soiling make it necessary to
clean the engine:
z High dust content in the air.
z Chaff and chopped straw in the area of the en-
gine.
z Coolant leaks
z Lubricating oil leakage
z Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
z Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
42 2009
Aspiration system Servicing and maintenance works

nance indicator. The maintenance indicator is
now ready for operation again. 6
Regulations for working on the intake system Emptying the cyclone precleaner
Do not work when the engine is running! Never fill the dust container (3) with lubri-
cating oil!
z Loosen wing nut (1) and lift off housing cover (2).
Pay attention to utmost cleanliness when
z Remove the dust container (3) from the base (4)
working on the intake system, close intake
and empty it. Clean the container using a brush
openings if necessary.
and clean diesel fuel. Then dry.
Dispose of old filter elements properly.
z Place the dust container (3) on the base (4) and
Maintenance indicators for dry air filter tighten the housing cover (2) with wing nut (1).
z The dry air filter is maintained according to a
maintenance switch or maintenance indicator.
z Maintenance is necessary when:
the yellow warning light of the maintenance
switch lights up when the engine is running.
the red field (1) of the maintenance indica-
tor is fully visible.
z After carrying out maintenance work, reset the
signal by pressing the button on the mainte-
2009 43
Servicing and maintenance works Aspiration system
6 Maintaining the dry air filter

1 5 2
Do not clean the filter element (3) with pet-
rol or hot liquids!
Renew damaged filter elements.
1 z Maintain the filter element (3) according to the in-

terval in the maintenance schedule
z Lift up the clamping yoke (1).
z Remove the filter hood (2) and pull out the filter
element (3).
z Filter element (3): 4 3
blow out with dry compressed air (max. 5
bar) from the inside to the outside if soiling is
only slight,
renew if heavily soiled.
Clean the dust discharge valve of the dry air filter Renewing the safety cartridge of the dry air filter
z Empty the dust discharge valve (1) by pressing
Never clean the safety cartridge (4).
together the discharge slit.
z Remove any caked dust by pressing together the
upper section of the valve.
z Clean the discharge slit. z Renew safety cartridge (4) according to the inter-
val in the maintenance schedule
z To do this:
Unscrew hexagon nut (5), pull out safety car-
tridge (4).
Insert new safety cartridge, screw on hexag-
onal nut.
z Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
44 2009
Belt drives Servicing and maintenance works
1 2
6
3
4
Checking the belt drive Checking the belt tension Tighten the generator V-belts
z Lower indicator arm (1) into the measuring de- z Loosen lock nut (3).
Only carry out work on the belt drive with
vice. z Loosen screws (1) and (2) and (3).
the engine at a standstill!
Always change both belts in sets in case of z Place guide (3) between two belt pulleys on the z Push the generator (4) outwards in the direction
wear on the double belts or damage to one V-belt (2). The stop have to be at the side. of the arrow until you get the correct V-belt ten-
V-belt. z Press the button (4) at right angles to the V-belt sion.
After repair work: Check that all guards (2) evenly until you hear or feel the spring snap This is done with a screw (1).
have been replaced and that all tools have in. z Retighten the screws (1) and (2).
been removed from the engine. z Lift the measuring device carefully without alter- z Tighten the lock nut (3) again.
ing the position of the indicator arm (1).
z Check the whole belt drive visually for damage. z Read the measured value at the point of inter- Renew the V-belts
z Renew damaged parts. section (arrow), scale (5) and indicator arm (1). z Loosen screws (1) and (2) and (3).
z Remount protective devices if necessary. z If necessary, re-tension belt and measure again. z Swing the generator (4) in in the opposite direc-
z Pay attention to correct fit of new belts, check the tion to the arrow.
tension after running for 15 minutes. Tools
z Remove the V-belt (5) and fit a new V-belt.
Belt tension measuring device (order number: z Push the generator (4) outwards in the direction
8115) can be obtained from your DEUTZ partner. of the arrow until you get the correct V-belt ten-
sion.
z Tighten the generator V-belts.
2009 45
Servicing and maintenance works Setting work
6
4 2 1 2 1
3 1
5 3
2
EX IN
6 6
2
Check valve clearance, adjust if necessary Set valve clearance z Secure the rotation angle disc against twisting.
1 Screw 1 Lock nut z Turn rotation angle disc clockwise to the stop
2 Cylinder head cover 2 Valve clearance setting screw (rocker arm without clearance) and set scale to
zero.
3 Gasket 3 Insert
z Tighten locking nut.
4 Rotary angle disc
z Let the engine cool down for at least 30 minutes
before setting the valve clearance: Lubricating oil 5 Magnet Tightening torque 20 Nm
temperature below 80 C. 6 Valve clearance
z Then set the second valve on the rocker arm as
z Release screws. z Mount rotation angle disc on valve clearance set- described above.
z Remove the cylinder head hood. ting screw with pin wrench insert. z Perform the setting procedure on every cylinder.
z Remove gasket. z Fix magnet of the rotation angle disc. z Remount the cylinder head cover with a new
z Place turning gear over fastening screws of the z Turn rotation angle disc clockwise to the stop gasket in the reverse order of disassembly.
belt pulleys. (rocker arm without clearance) and set scale to z Tighten screws.
z Turn the crankcase until reaching valve overlap. zero.
Outlet valve is not yet closed, inlet valve be- z Turn rotation angle disc anticlockwise until Tightening torque 22 Nm
gins to open. reaching the specified rotation angle: The valve clearance can also be set with a feeler
The cylinders to be set can be seen in the gauge. Gauges with 0.25 or 0.09 in must be used for
setting schematic. Valve IN Inlet valve 90+10 the inlet valve. Gauges with 0.30 or 0.12 in must be
clearance EX Outlet valve 108+10 used for the outlet valve.
46 2009
Setting work Servicing and maintenance works

Valve clearance setting schematic
Valve overlap: Exhaust valve is not yet closed, inlet
TCD 2015 V08
6
Valve overlap Settings
valve begins to open.
A1 B3
This engine is equipped with an internal ex- B4 A3
haust feedback system. A4 B2
Do not confuse this with the valve overlap! B1 A2
6- Cylinders The outlet valve opens briefly in B3 A1
the intake stroke. A3 B4
8- Cylinders The inlet valve opens briefly in B2 A4
the out stroke. A2 B1
TCD 2015 V06
Valve overlap Settings

A1 B2
B3 A2
A3 B1
B2 A1
A2 B3
B1 A3
2009 47
Servicing and maintenance works Electrical system
6 Regulations for working on the electrical system Danger of explosion! The gases emitted by
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
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. z Check the battery voltage with a standard volt-
Allow engine to warm up. meter. The voltage gives information about the
Touching a lead against the frame to check charge status.
whether it is live must not, under any cir-
cumstances, be carried out.
Battery Charge status (Volt) Check acid density
For electrical welding work, the ground ter-
minal of the welding gear must be clamped 24 Volt 24-28,4 z Unscrew caps.
directly to the part being welded. z Measure the electrolyte density of individual cells
Check acid level
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
connect the cables between battery, gener- z Unscrew caps. reading indicates batterys state of charge. The
ator and regulator while the engine is z Note the manufacturers specifications concern- acid temperature when measuring should be 20
running. ing the liquid level. C if possible.
The liquid should normally be 10-15 mm above z Check the acid level before recharging.
Battery
the top edge of the plate or reach up to any avail- z Screw in caps.
able control device.
Electronically stored data could be lost if Acid density [kg/ l] Charge Measure
z Only use distilled water to top up the battery.
the battery is disconnected. status
Keep battery clean and dry. z Screw in caps. Normal Tropical
Make sure the battery is fitted correctly and 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
48 2009
Electrical system Servicing and maintenance works

Removing the battery
z Always disconnect the minus pole first when re-
6
moving the battery. Otherwise there is a danger
of short-circuit!
z Remove the fastenings and take out the battery.
Charging the battery
z Unscrew caps.
z Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
z Screw in caps.
Installing the battery
z Insert new or charged battery and attach the fas-
tenings.
z Clean the terminals and battery poles with fine
emery paper.
z Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
z Grease the assembled terminals with an acid-
free, acid-resistant grease.
2009 49
Faults Fault table
7 Faults and remedies
Faults Causes Measures

Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Fuel tank empty Vent fuel system
Fuel suction pipe blocked Check
Below starting limit temperature Check
Cold starting device Check/replace
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Fuel quality does not comply with operating manual Change the fuel
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Injection valve defective Check fuel injector / change if necessary
Air filter clogged / turbocharger defective Check/replace
Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine does not start and diagnostic Engine electronics prevents starting Please contact your DEUTZ partner
lamp flashes
50 2009
Fault table Faults

Faults
Engine starts, but runs irregularly or
Causes
Fuel quality does not comply with operating manual
Measures
Change the fuel
7
fails Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Starter defective or pinion does not engage Check starter
Cold starting device Check/replace
Flame glow unit Change
Air in fuel system Vent
Fuel filter contaminated Clean
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Please contact your DEUTZ partner
nostic lamp lights up
2009 51
Faults Fault table
7 Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lube oil cooler defective Check/replace
Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Incorrect valve clearance Check valve clearance and set if necessary
Coolant heat exchanger soiled Clean
Coolant pump broken Check
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Heat short-circuit in the cooling air guidance Check the cooling system
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
52 2009
Fault table Faults

Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
7
Fuel suction temperature too high Check the system
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air cooler soiled Clean
Heat short-circuit in the cooling air guidance Check the cooling system
Resistance in cooling system is too high / flow volume too low Check the cooling system
Injection valve defective Check fuel injector
Engine performs poorly and diagnos- Engine electronics reduce performance Please contact your DEUTZ partner
tic lamp lights
Engine does not run on all cylinders Injection line leaks Check injection line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
2009 53
Faults Fault table
7 Faults
Engine producing white smoke
Causes
Below starting limit temperature
Measures
Check
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
54 2009
Engine management Faults

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
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 at low idle speed to cool
1 safely possible. the engine, with automatic shutdown if nec-
essary.
Error lamp
The switch-off process has been accom-
The error lamp is located in the vehicle drive stand. plished.
2 The error lamp can release the following signals: There may be a start lock after engine stop.
z Function test The start lock is deactivated by turning off the
3 system with the ignition key for approx. 30s.
Ignition on, error lamp lights up for approx. 2
seconds and then goes out. The power reduction can be bypassed, the
automatic switch-off delayed or a start lock
Check the error lamp if there is no reaction
bypassed with the override key on the instru-
after switching on the ignition.
Engine protection function of the electronic en- ment panel to avoid critical situations. This
z The lamp does not light
gine control brief deactivation of the engine protection
After the lamp test an extinguished lamp indi- functions is logged in the control unit.
cates an error-free and trouble-free operat-
1 Diagnosis button Please contact your DEUTZ-partner in case of
ing state within the scope of the control
malfunctions and sare parts inquiries. Our spe-
2 Error lamp possibility.
cially trained personnel will ensure fast, profes-
3 Electronic engine control (EMR) z Continuous light sional repairs using original DEUTZ spare parts
Error in system. in case of damage.
The error lamp goes out when all the errors Operation continued with restrictions.
have been eliminated. For some errors, it is
The engine must be checked by a DEUTZ
necessary to switch off the ignition, wait 30
partner.
s and only then switch back on the ignition.
The appropriate monitoring functions are If a lamp lights steadily a monitored measur-
switched off when a sensor fails. Only the ing variable (e.g. coolant temperature, lubri-
sensor failure is documented in the error cating oil pressure) has left the permissible
memory. value range.
Depending on the fault, the engine power
Depending on the design of the monitoring functions, may be reduced by the electronic engine
the electronic engine control can protect the engine control to protect the engine.
in certain problematical situations by monitoring im-
portant limit values during operation and checking z Flashing
the correct function of the system components. Serious error in system.
2009 55
Faults Engine management
7 Diagnosis button
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:
z Errors that may occur can be classified.
z Clear display of the error as visual signal.
The blink codes can only be interpreted by a
DEUTZ partner.
2s 2s
0,8 s
0,4 s
0,4 s
0,4 s
0,8 s
0,4 s
Use of the diagnostic key
The flash code displays all errors in the error memo-
ry, this means active as well as passive ones.
The control unit must be switched off to start the en- 1 2 8
quiry (ignition off). Then the diagnosis button should Display system error by flash code
be pressed for approx. 1s during the start (ignition
on). Example:
Then the next error (i.e. the following one in the error Flash code 1-2-8
memory) can be displayed by pressing the diagnos- 1 x short flash
tic key again. If the last error was displayed, the first
2 x long flash
error is displayed again on pressing the diagnostic
key again. 8 x short flash
After the display of the error flash code, the error This flash code indicates a break or short circuit in
lamp goes out for five seconds. the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
the illustration.
z The blink codes can only be interpreted by a
DEUTZ partner.
56 2009
Engine management Faults

z
z
Gear oil pressure
Battery voltage 7
z Accelerator position
z Fuel consumption
z Operating hours
Error messages are displayed in clear text and
acoustically; the error memory of the control unit can
be read out.
For a detailed description, refer to the operating in-
structions enclosed with the DEUTZ Electronic Dis-
play.
DEUTZ Electronic Display
In order to show measured values and error messag-

es of the EMR control unit, a CAN display is option-
ally available, which can be integrated into the
dashboard of the drivers position of working ma-
chines.
All data sent from the EMR control unit through CAN
can be displayed.
z Engine speed
z Engine torque (current)
z Lubricating oil temperature
z Coolant temperature
z Suction intake air temperature
z Exhaust gas temperature
z Gear oil temperature
z Lubricating oil pressure
z Coolant pressure
z Charge air pressure
z Fuel pressure
2009 57
Transport and storage Transport
8 1
1
2
! 2
Suspension equipment
Danger to life!
The engine may tip over or fall down if sus-
The transport devices mounted on this en-
pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com- z The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. z The fastening attachment can slip, the engine
z Always use proper suspension equipment when swings backwards and forwards (1).
transporting the engine. z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
z The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
z After transportation and before commissioning of
engine: remove attachment eyes (2).
58 2009
Engine corrosion protection Transport and storage

General
Engines contain the following types of corrosion pro-
by wetting of the walls with the implemented cor-
rosion protection agent in a corrosion protection
until it emerges visibly from the pressure nozzle.
Cooling system
8
run of the engine.
tection:
z The corrosion protection run can be performed z Depending on the series the engines are
z Interior corrosion protection once to protect the different systems: equipped with cooling air, cooling oil or cooling
z Exterior corrosion protection fluid system (cooling water with cooling system
Fuel system protection agent).
Your DEUTZ partner has the right corro-
sion protection agent for your needs. z Cooling air system, see the Exterior corrosion
Close the fuel/tank/supply line to the en-
protection section.
gine so that the system is protected against
dirt and dust. Protect the electronics z In engines of the oil-cooled series the circulating
The following measures for corrosion protection af- lubricating oil serves simultaneously for cooling.
ter taking the engine out of operation meet the re- against moisture and corrosion.
The cooling chambers are protected automati-
quirements for 12 months corrosion protection. cally against corrosion with the lube oil system.
z Fill the fuel tank with a mixture of:
The following corrosion protection work may only be 90 % distilled fuel z If a coolant with corrosion protection properties is
carried out by persons familiar with it and instructed 10 % corrosion protection oil. poured into liquid-cooled engines, no further ac-
in the potential dangers. tion is necessary after draining.
z Perform a corrosion protection run with no load
If these measures are deviated from by exposing the for at least 5 minutes. z If not, the coolant must be drained and, to ensure
corrosion-protected engines or parts to unfavourable the formation of a covering layer on the inside
conditions (installation outdoors or storage in damp, Lubricating oil system surfaces of the cooling system, a corrosion pro-
badly aired places) or damage to the corrosion protection run performed with a mixture of:
z Drain lubricating oil from warm engine.
tection layer, a shorter corrosion protection duration 95 % treated water
z Thoroughly clean lube oil tray, cylinder head with
is to be expected. 5 % corrosion protection agent
rocker arms, valves, valve springs with diesel
The engine corrosion protection should be checked fuel or cleaning agent. z The duration of the corrosion protection run and
about every 3 months by opening the covers. If cor- z Fill the engine with corrosion protection oil up to the concentration of the corrosion protection
rosion is detected, the corrosion protection should the MAX mark and perform a corrosion protec- agent are specified by the manufacturer of the
be renewed. tion run for at least 5 minutes so that all the com- corrosion protection agent.
At the end of the corrosion protection work the crank ponents of the lubricating oil system are wetted z Then drain the coolant.
drive may no longer be turned so that the corrosion or wet all accessible parts with corrosion protec-
Air intake pipes
protection agent in the bearings, bearing liners and tion oil and pump corrosion protection oil through
cylinder liners is not scraped off. the engine with a separate pump until all bear- z After the corrosion protection run, remove the
Before operating a corrosion protected engine, the ings and bearing liners are wetted. cylinder head cover and deinstall injectors. The
corrosion protection must be removed. respective piston must be set to LT.
Air compressor
z The accessible part of the cylinder liner should
Interior corrosion protection z If a compressor is installed, a corrosion protec- be coated with corrosion protection oil with a
tion agent must be sprayed into the compressor spray lance through the opening.
z Interior corrosion protection is always provided
suction system after shutting down the engine z Spray corrosion protection lubricating oil into the
2009 59
Transport and storage Engine corrosion protection
8 suction intake pipe.

Exterior corrosion protection
suitably covered.
z The cover must be placed loosely over the en-
minutes before filling.
Removal of exterior corrosion protection
gine so that the air can circulate around it to pre-
z The engine must be cleaned thoroughly with a vent condensation from forming. Use a desiccant z All areas and components coated with corrosion
cleaning agent before exterior corrosion protec- if necessary. protection agent must be washed off with dis-
tion. Any signs of corrosion and damage to the tilled fuel or a suitable cleaning agent.
paintwork must be removed. Removal of corrosion protection
z Wash out grooves of V-belt pulleys if necessary.
z The corrosion protection must be removed from z Mount V-belts or V-rib belts as specified.
Bare exterior surfaces and parts
the corrosion protected engine before starting. z Fill with coolant.
z Coat or spray all bare exterior parts and surfaces z The packaging and all covers over the closed
(e.g. flywheel, flange faces) with corrosion pro- openings must be removed. Corrosion protection agent / cleaning agent
tection agent. z Any corrosion deposits and paint damage should Please ask your DEUTZ partner for reference prod-
be remedied. ucts for the corrosion protection agents/cleaning
Rubber parts
Fuel system agents to be used which meet DEUTZ requirements.
z Rubber parts (e.g. muffs) which are not painted
or see www.deutz.com
over must be rubbed down with talcum powder. If there is a mixture of diesel fuel/corrosion pro-
tection oil in the fuel tank, drain it. \SERVICE \Operating Media and Diagnosis
Belt drive
z Connect fuel/tank/supply line to the engine. Pay
z Remove V-belts and V-rib belts and store attention to cleanliness.
packed. z Fill the fuel tank and fuel system with the proper
z Spray V-belt pulleys and tension rollers with cor- fuel.
rosion protection agent.
Lubricating oil system
Engine openings
z Unscrew the lube oil drain screw, drain oil.
z All engine openings must be fitted with air-tight, z Fill the engine with lubricating oil via the lubricat-
water-tight covers to delay the vapourisation ing oil filler neck.
process of the corrosion protection agents.
z With installed air compressor, the suction and Coolant system
pressure connection must be sealed by a cap. z If the implemented corrosion protection agent is
z Air should be excluded to avoid ventilation of the compatible with the intended cooling system pro-
engine (chimney effect) for the suction from an tection agent, this can be filled directly into the
air supply pipe. coolant system as specified.
z If it is uncertain whether the implemented corro-
Storage and packaging
sion protection agent is compatible with the cool-
z After being protected against corrosion, the en- ing system protection agent, the cooling system
gine must be stored in a dry, ventilated hall and should be purged with fresh water for about 15
60 2009
Engine and setting data Technical data

General technical data
9
Engine type Dimension TCD 2015 V06 TCD 2015 V08
Working principle Four-stroke diesel engine
Charging Turbocharger with charge air cooling
Type of cooling water-cooled
Cylinder arrangement in V form in 90 angle
No. of cylinders 6 8
Bore/stroke [mm] 132/145
Total displacement [cm3] 11906 15874
Combustion process Direct injection
Injection system Pump-pipe-nozzle
Exhaust gas recirculation internal internal
Valves per cylinder 4
Valve clearance: Inlet/outlet [mm] 0,25+0,1 / 0,3+0,1
Setting with rotary angle disc [] Angle 90 +10/108 +10
Firing order of the engine A1-B3-A3-B2-A2-B1 A1-B4-A4-B1-B3-A3-B2-A2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [BTDC] see engine rating plate
Coolant volume (only engine content without cooler / hoses and pipes) [l] 17 21
Permissible continuous coolant temperature [C] max. 103
Temperature difference between coolant inlet/outlet [C] max. 5
Start of thermostat opening [C] 79/87
Thermostat fully open [C] 94/102
Lubricating oil change volume (with filter) [l] 38 48
Lube oil temperature in the lube oil tray, maximum [C] 120
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 100/1
2009 61
Technical data Engine and setting data
9 Engine type
Charge air temperature outlet at rated power
Dimension
[C]
TCD 2015 V06
50
TCD 2015 V08
V-belt tension Pre-tensioning/Re-tensioning

V-belts AVX (width: 13 mm) [N] 65050/40050
Weight without cooling system according to DIN 70020-A [kg] 1020 1245
*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.
62 2009
Tools Technical data

Tool ordering
The special tools described in this chapter can be or-
9
dered from:
WILBR - Wilhelm Bcker GmbH & Co. KG
Taubenstrasse 5
42857 Remscheid
Germany
Phone: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
www.deutz-tools.com
Torx tool V-belt tension measuring instrument

Order number: Order number:
8189 8115
The Torx screw system is used in engines in this se- Measuring instrument for checking the specified V-
ries among other things. This system was introduced belt tensions.
for a number of reasons:
z Excellent accessibility
z High force transmission when loosening and
tightening
z Slipping or breaking of the key and risk of injury
are practically excluded.
2009 63
Technical data Tools
Special tools for removing the water collection Special wrench for loosening exchangeable fil- Rotaqtion angle disc
vessel. ters
Order number:
Order number: Order number:
8190
8192 170050
Rotation angle disc for setting the valve and control
On Racor filters, only loosen the water collection For loosening changeable filters. piston clearance
vessel with a special tool.
64 2009
Tools Technical data

9
Pin wrench insert Crow foot wrench Turning gear

Order number: Order number: Order number:
8193 8190 100 350
Pin wrench inserts for rotation angle disc Crow foot wrench for rotation angle disc in connec- For turning over the engine as an attachment for the
tion with conventional square bar extension. torsional vibration damper
2009 65
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
TLS-15W40D TLX-10W40FE DEUTZ Oel DQC IV-5W30

(DQC II-05) (DQC III-05) (DQC IV-05)
5L 0101 6331 5L 0101 6335 5L -
20 L 0101 6332 20 L 0101 6336 20 L 0101 7849
209 L 0101 6333 209 L 0101 6337 209 L 0101 7850
DEUTZ AG
Information Systems Sales & Service
Ottostrae 1
51149 Kln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
02/2009
All rights reserved
Order number:
0312 3562 en
The engine company. Original operating instructions

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This symbol accompanies notes of a gen-

Model Engine description

DEUTZ AG MADE IN GERMANY

Engine description Model

Engine serial number Cylinder numbering

Engine illustrations Engine description

Engine description Engine illustrations

2 TCD 2015 V08

Engine illustrations Engine description

Engine description Engine illustrations

2 TCD 2015 V06

Lubricating oil diagram Engine description

Engine description Fuel diagram

2 Fuel schematic (example)

Coolant diagram Engine description

Engine description Exhaust return

2 External exhaust gas recirculation

10 Only have work performed on the components by

Exhaust return Engine description

Engine description Electrics/Electronics

Electrics/Electronics Engine description

Operation Ambient conditions

3 Cold start aid

This engine can be equipped optionally

Initial start-up Operation

Operation Initial start-up

3 z Close compensation tank with valve.

Start procedure Operation

Operation Operation monitoring

3 Electronic engine control

Operation monitoring Operation

Coolant temperature Coolant temperature too high Switch off engine

Horn With acoustic signal See fault table (50).

Operation Stop procedure

3 P = gear position: park

Avoid switching off from full load (coking/

Lubricating oil Operating media

Operating media Lubricating oil

4 Engines with exhaust aftertreatment Viscosity

Fuel Operating media

Operating media Coolant

4 General z Total hardness too high:

Maintenance schedule Maintenance

Maintenance Maintenance schedule

Stage Activity Measure Page

Maintenance schedule Maintenance

Order number: 0312 0040

Servicing and maintenance works Lubricating oil system

6 Regulations for working on the lubricating oil

Be careful of hot lubricating oil. Danger of

z Pull out the lubricating oil dipstick and wipe off

Lubricating oil system Servicing and maintenance works

Servicing and maintenance works Fuel system

Fuel system Servicing and maintenance works

Servicing and maintenance works Fuel system

Fuel system Servicing and maintenance works

Servicing and maintenance works Cooling system

6 Specifications when working on the cooling sys-

Danger of scalding from hot coolant!

Horn With acoustic signal See fault table (50).