Operation Manual 2013-08-12 Locked

OBJ_DOKU-37427-001.fm Seite 1 Dienstag, 6.
August 2013 8:47 08
Operation Manual
D 2.9 L4
TD 2.9 L4
TCD 2.9 L4
OBJ_DOKU-37427-001.fm Seite 2 Dienstag, 6. August 2013 8:47 08
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
● This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
Non-compliance results in the expiry of the war-
the equipment manufacturer (use for the intend-
ranty!
ed purpose). Any other use above and beyond
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.
● 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. ● Do not work on the fuel system while the engine
● When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to be relieved once the en-
– rotating and hot components gine has shut down (for engines with common
– on motors with external ignition (high electri- rail, approx. 5 minutes, otherwise 1 minute) as
cal voltage). Contact must be avoided! the system is under high pressure - Danger to
life!
● Unauthorised engine modifications will invalidate
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.
● 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
● 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.
● When carrying out maintenance work on the en-
2 © 2013
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 Components of the exhaust aftertreatment system
installation situation, i.e. not all the components de- Please enter the serial numbers of the exhaust after-
scribed in the operating manual are installed in your treatment components.
engine.
We have endeavoured to highlight any differences Diesel oxidation catalytic converter
so that you will be able to locate the operating and
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail- Diesel particle filter
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 Notes
happy to advise you.
We reserve the right to make technical changes to
Sincerely, the descriptions and data in this operating manual in
DEUTZ AG the interest of further development of the engines.
This document may only be reprinted and repro-
duced, even in part, with our express permission.
© 2013 3
Table of contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel system. . . . . . . . . . . . . . . . . . 47
Foreword . . . . . . . . . . . . . . . . . . . . . 3 Cooling system . . . . . . . . . . . . . . . . 50
1 General . . . . . . . . . . . . . . . . . . . . 5 Engine cleaning. . . . . . . . . . . . . . . . 52
2 Engine description . . . . . . . . . . . . . . 7 Suction system . . . . . . . . . . . . . . . . 53
Model . . . . . . . . . . . . . . . . . . . . . 7 Belt drives . . . . . . . . . . . . . . . . . . 55
Engine illustrations . . . . . . . . . . . . . . 10 Electrical system . . . . . . . . . . . . . . . 57
Lubricating oil diagram . . . . . . . . . . . . 16 7 Faults . . . . . . . . . . . . . . . . . . . . .59
Fuel diagram . . . . . . . . . . . . . . . . . 17 Fault table . . . . . . . . . . . . . . . . . . 59
Coolant diagram . . . . . . . . . . . . . . . 18 Engine management . . . . . . . . . . . . . 63
Exhaust gas recirculation . . . . . . . . . . . 19 8 Transport and storage . . . . . . . . . . . .65
Exhaust gas aftertreatment . . . . . . . . . . 20 Transport . . . . . . . . . . . . . . . . . . . 65
Electrics/Electronics . . . . . . . . . . . . . 22 Engine corrosion protection . . . . . . . . . 66
3 Operation . . . . . . . . . . . . . . . . . . . 24 9 Technical data . . . . . . . . . . . . . . . .68
Ambient conditions . . . . . . . . . . . . . . 24 Engine and setting data . . . . . . . . . . . 68
Initial commissioning . . . . . . . . . . . . . 25 Tools . . . . . . . . . . . . . . . . . . . . . 70
Starting process . . . . . . . . . . . . . . . 27
Operation monitoring . . . . . . . . . . . . . 28
Exhaust gas aftertreatment system. . . . . . 32
Passive regeneration . . . . . . . . . . . . . 33
Stopping process . . . . . . . . . . . . . . . 36
4 Operating media . . . . . . . . . . . . . . . 37
Lubricating oil . . . . . . . . . . . . . . . . . 37
Fuel . . . . . . . . . . . . . . . . . . . . . . 39
Coolant . . . . . . . . . . . . . . . . . . . . 40
5 Maintenance . . . . . . . . . . . . . . . . . 42
Maintenance schedule . . . . . . . . . . . . 42
6 Servicing and maintenance work . . . . . . . 45
Lubricating oil system. . . . . . . . . . . . . 45
4 © 2013
General
DEUTZ diesel engines
DEUTZ diesel engines and the appropriate exhaust
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
aftertreatment components are the result of years of cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
research and development. The detailed know-how functioning and high reliability. tact to your nearest local service partner.
gained by this in connection with the high quality de-
mands are the guarantee for production of engines DEUTZ Xchange components
with a long life, high reliability and low fuel consump- California
tion. Naturally the high demands for protection of the DEUTZ replacement parts are a low-cost alternative. Proposition 65 Warning
environment are also met. Of course, the quality standards here are just as high Diesel engines and some of its constituents are
as for new parts. DEUTZ replacement parts are known to the State of California to cause cancer,
Safety precautions when the engine is running equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
liability.
Maintenance work or repairs may only be performed Masthead
on the shut-down engine. Make sure that the engine Asbestos
cannot be started inadvertently - Danger of accident! DEUTZ AG
The gaskets used in this engine contain no asbestos. Ottostraße 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 maintenance and repair work. 51149 Köln
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
must be close fitting. our customers. We are therefore represented world- E-Mail: info@deutz.com
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-
© 2013 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 © 2013
Model Engine description

Engine type designation
The engines of these operating instructions fulfill
the following exhaust emissions regulations
2
This manual covers the following engine types
D 2.9 <37 kW A B
D 2.9 L4
With exhaust aftertreatment system
TD 2.9 L4
USA EPA Tier 4 final
TCD 2.9 L4
EU Stage IIIA Mot.-Typ Mot.-Nr.
TCD D 2.9 <37 kW

Without exhaust aftertreatment system
T Exhaust gas turbocharger
USA EPA Tier 4i
C Charge air cooler R
EU Stage IIIA
D Diesel
DEUTZ AG MADE IN GERMANY
TD/TCD 2.9 <56 kW

With exhaust aftertreatment system
2.9
USA EPA Tier 4 final
2.9 Displacement in litres Rating plate
EU Stage IIIB
TD 2.9 <56 kW The type (A), engine number (B) and performance
L4 data are stamped on the rating plate.
Without exhaust aftertreatment system
L in series The engine type and number must be stated when
USA EPA Tier 4i
4 No. of cylinders purchasing spare parts.
EU Stage IIIA
Emissions legislation
The exact certification is printed on the engine rating
The engine and the corresponding EAT plate.
system (Exhaust After Treatment) are
The engines of this operating manual may
adapted to each other and linked by an ap-
only be used with a functioning exhaust af-
propriate electronic controller.
tertreatment system.
They are only certified by the responsible
(if included in the DEUTZ scope of supply)
authorities and comply with the permissible
exhaust limits in this combination.
Operation of the engine with other EAT
systems is not allowed.
© 2013 7
Engine description Model
2
1
C
D
XXXXXX
Location of the rating plate Engine serial number Serial numbers of the exhaust aftertreatment com-
ponents
The rating plate (C) is fixed to the cylinder head cov- The engine number (D) is stamped onto the crank-
er or the crankcase. case (arrow) and onto the rating plate.
1 Rating plate of the diesel oxidation catalytic
converter
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates.
8 © 2013
Model Engine description
left
2
2 1
right
1
Serial numbers of the exhaust aftertreatment com- Cylinder numbering

ponents
Cylinder arrangement
1 Rating plate of the diesel oxidation catalytic The cylinders are counted consecutively starting
converter from flywheel (1).
2 Rating plate of the diesel particle filter Direction of rotation
Looking onto the flywheel.
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates. rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
© 2013 9
Engine description Engine illustrations
2 D 2.9 L4
Industrial engine
1 View from right (example)
1 Crankcase breather
2 Coolant outlet
3 Coolant supply flow to the cab heating
2 4 Tension pulley
10 5 V-rib belt
6 Lubricating oil drain plug
7 Lube oil replacement filter
8 Lubricating oil dipstick
9 3 9 Coolant inlet
10 Coolant return flow from the cab heating
8 4
5
7
10 © 2013
Engine illustrations Engine description

D 2.9 L4
Industrial engine
2
View from left (example)
1 Combustion air inlet
3 2 Exhaust outlet
3 Lubricating oil filling
1
© 2013 11
2 TD 2.9 L4
Industrial engine
View from right (example)
1 1 Crankcase breather
2 Coolant outlet
11 3 Coolant supply flow to the cab heating
2 4 Tension pulley
5 V-rib belt
10 8 Lubricating oil dipstick
3 9 Coolant inlet
10 Coolant return flow from the cab heating
9 11 Exhaust outlet
8 4
5
7
12 © 2013

TD 2.9 L4
Industrial engine
2
1 Combustion air inlet
2 2 Lubricating oil filling
© 2013 13
2 TCD 2.9 L4
Agricultural technology
View from right (example)
10 1 1 Crankcase breather
2 Coolant outlet
3 Coolant supply flow to the cab heating
9 2 4 Tension pulley
5 V-rib belt
7 Coolant inlet
8 8 Coolant return flow from the cab heating
3 9 Combustion air inlet
10 Exhaust outlet
7
14 © 2013

TCD 2.9 L4
Agricultural technology
2
2 Lubricating oil dipstick
© 2013 15
Engine description Lubricating oil diagram
2 Lubricating oil system

(example)
15 14 13 12 11 1 Lubricating oil sump
2 Lubricating oil pump
3 Overpressure valve
8 4 Lube oil cooler
5 Bypass valve
6 Pressure control valve
7 Lubricating oil filter
5 4 8 Main lube oil channel
9 Camshaft bearing
10 Crankshaft bearing
11 Piston cooling nozzle
12 Rocker arm
13 Hydraulic tappets
14 Turbocharger
15 Hydraulic pump
Optional
10 9 7 6 3 2 1
16 © 2013
Fuel diagram Engine description

Fuel schematic (example)
1 Fuel tank
2
12 8 9 10 2 Fuel pre-filter
3 Fuel pump
(electrically powered)
4 Exchangeable fuel filter
5 Fuel transducer
6 High-pressure pump
with
– Control block FCU (Fuel Control Unit)
7 7 Rail
8 Injector
9 Check valve
10 Return line
11 Fuel return to fuel tank
12 Engine control unit
1 2 3 4 5 6 11
© 2013 17
Engine description Coolant diagram
2 Coolant schematic (example)

1 Coolant pump
6 7 8 9
2 Coolant supply for engine cooling
3 Lube oil cooler
4 Cylinder pipe/head cooling
5 Exhaust return cooler
6 Connection possibility for cab heating
7 Temperature transmitter
8 Thermostat
9 Compensation tank
10 Cooler
x1 x2
T
x1
1 2 3 4
x2
5 4 3 2 1 10
18 © 2013
Exhaust gas recirculation Engine description

External exhaust gas recirculation
1 Exhaust gas partial flow
2
5 6 (uncooled)
2 Actuator
(electrically actuated)
3 Exhaust return cooler
4 Flatter valve
5 Exhaust gas partial flow
(cooled)
6 Mixing pipe
7 7 Coolant return
8 Coolant line to the EGR cooler
4 3 2 1 8
© 2013 19
Engine description Exhaust gas aftertreatment
2 Exhaust aftertreatment system

Diesel oxidation catalytic converter
1 1 Decoupling line
2 Diesel oxidation catalytic converter
3 Exhaust outlet
20 © 2013
Exhaust gas aftertreatment Engine description

Exhaust aftertreatment system
Diesel particle filter
2
1 2 1 Throttle valve
3 2 Decoupling line
4 Diesel particle filter
5 Exhaust outlet
© 2013 21
Engine description Electrics/Electronics
2 5
Electronic engine control
10 Engine side
1 2 3 4
1 Coolant temperature transmitter
11 2 Charge air pressure transmitter, charge air tem-
perature transmitter
3 Charge air pressure transmitter
12 TD 2.9 L4
4 Rail pressure sensor
5 Engine control unit
13 6 Speed transmitter via crankshaft
7 Lubricating oil pressure transmitter
8 Speed transmitter via camshaft
14
(on the opposite side)
9 Central plug (for engine control)
15 Equipment side
10 Power supply (battery)
16 11 Signal outputs, e.g. for lamps, speed, engine op-
eration, etc.
12 Inputs (e.g. override button)
17 13 Accelerator
14 Hand throttle
15 Optional function selector switch, e.g. for P de-
18 gree, type of controls, maximum curve, fixed
speeds, etc.
16 Detachable key switch Start/Stop
6 7 8 9 19 17 Diagnosis button
18 Error lamp
19 Diagnostic interface/CAN bus
22 © 2013
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
Diagnostics
DEUTZ control units are equipped with self-diagnos-
2
wiring of the electrical control devices and tics. Active and passive error entries are saved in the
The equipping of the respective system depends on the data transmission cable (CAN lines).
the desired scope of function and the planned type of error memory. Active errors are displayed on error
b) to switch control units. lamps/diagnostics lamps (63).
engine application. Otherwise guarantee rights will be lost!
The resultant wiring with pin assignment can be seen Diagnostic and maintenance work may A diagnosis can be made with:
in the appropriate wiring diagram. only be carried out by authorised personnel ● Error lamp (flash code)
The installation regulations of the DEUTZ AG must using equipment approved by DEUTZ. ● CAN bus
also be taken into account. ● DEUTZ electronics display
Installation instructions
● Diagnostic socket (SERIDA)
Precautions The control units are calibrated to the respective en-
gine and identified by the engine number. Every en- Equipment-side wiring
The connections of the control units are gine may only be operated with the appropriate The DEUTZ AG installation regulations should be
only dust and water proof when the mating control unit. adhered to. In particular, the plug contact must be
plugs are plugged (protection class IP69K)!
Setpoint transmitters (pedal value transmitters) nec- crimped with the appropriate standard tools. If it is
The control units must be protected against necessary to do so, plugged-in contacts may only be
essary for vehicle operation must be connected to
spray water and moisture until plugging in removed from the plug housing with the proper tools.
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.
To avoid damaging the control units, all the hicle side cable harness must be taken from the con-
connections on the control unit must be dis- nection diagram of the DEUTZ installation
connected before electric welding work. consulting.
Interventions in the electrical system con- Supply voltage
trary to the DEUTZ regulations or by un-
qualified personnel can permamently 12 Volt
damage the engine electronics and have 24 Volt
serious consequences which are not cov-
It should be ensured that the battery is sufficiently
ered by the manufacturer's guarantee.
charged. If the supply voltage is interrupted while the
engine is running, this can lead to damage to the
electrics/electronics. If the supply voltage fails, the
engine shuts down.
Voltages above 32 Volt will destroy the control unit.
© 2013 23
Operation Ambient conditions
3 Cold start aid

● The engines in these operating instructions are
equipped with glow plugs.(27)
Coolant
● Observe the mixing ratio anti-freeze/cooling wa-
0 °C ter. (40)
High ambient temperatures, high altitude
This engine is equipped with an electric

control unit.
Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
ically, controlled by the electronic control
unit.
Low ambient temperatures
● Application at high altitude
Lubricating oil ● Application at high ambient temperatures
● Select the lubricating oil viscosity according to
the ambient temperature. Reason: Air density decreases as altitude or ambient
● If cold starting occurs frequently cut the lube oil temperature increase. This reduces the amount of
changing interval by half. oxygen in the engine intake air and the fuel-air mix-
ture would be too rich if the injected amount of fuel
Fuel were not reduced.
● Use winter fuel below 0 °C (39). ● The results would be:
– black smoke in the exhaust
Battery
– high engine temperature
● A good charging condition of the battery (57) – reduction in engine performance
is the prerequisite for starting the engine. – possible impairment of starting behaviour
● Heating up the battery to approx. 20°C improves Consult your equipment supplier or DEUTZ partner if
the starting behaviour of the engine. (Remove you have any other questions.
and store the battery in a warm room).
24 © 2013
Initial commissioning Operation

Preparations for initial commissioning
(Maintenance schedule E 10)
3
● Remove engine corrosion protection
● Remove any transport devices.
● Check the battery and cable connections and
mount if necessary.
● Check belt tension (55).
● Have the engine monitor or warning system
checked by authorised personnel.
● Check the engine mounting.
● Check that all hose unions and clips fit properly.
The following additional work must be carried out on
generally overhauled engines:
● Check the fuel pre-filter and main filter and Fill with engine lube oil Pour in fuel
change if necessary.
● Check the intake air cleaner (if available, main- Low lubricating oil level and overfilling lead Never fill the fuel tank while the engine is
tain according to maintenance indicator). to engine damage. running.
● Drain lubricating oil and condensation water from Ensure cleanliness.
the charge air cooler. Do not spill fuel.
● Fill with engine lube oil. The engines are generally supplied without Additional venting of the fuel system by a 5
● Fill the coolant system (68). lubricating oil filling. minute trial run at idle speed or on low load
Select lubricating oil quality and viscosity is absolutely essential.
before filling.
Order DEUTZ lubricating oils from your ● Fuel low-pressure system must be vented before
DEUTZ partner initial start-up after filling with the electric fuel
supply pump. 49
● Fill the engine with lubricating oil via the lubricat-
ing oil filler neck. Only use clean commercially available brand diesel
● Observe the lubricating oil filling level (68). fuel. Observe fuel quality (39).
Use summer or winter-grade fuel, depending on the
ambient temperature.
© 2013 25
Operation Initial commissioning
3 1 3 2
● Start the engine and run up until the thermostat
opens (line (2) heats up).
Trial run
● Engine operation with open thermostat 2 - 3 min- Additional venting of the fuel system by a 5
utes. minute trial run at idle speed or on low load
● Check the coolant level and top up coolant if nec- is absolutely essential.
essary.
Carry out a brief trial run up to operating temperature
Danger of scalding from hot coolant! (approx. 90 °C) after preparations.
Cooling system under pressure! Only open Do not load the engine if possible.
the cap when cool!
Observe safety regulations and national ● Work with the engine not running:
specifications when handling cooling me- – Check engine for tightness.
dia. – Check lubricating oil level, if necessary top
up.
● If required, repeat procedure with engine start. – Check the coolant level and top up coolant if
● Fill up coolant to the MAX mark on the compen- necessary.
Filling the coolant system sation tank and close the cooling system cap. ● Work during the trial run:
● Switch on any available heating and set to the – Check engine for tightness.
The coolant must have a prescribed con- highest level so that the heating circuit is filled
centration of cooling system corrosion pro- and vented.
tection agent! ● Observe the filling volume of the cooling system
Never operate the engine without coolant, (68).
even for a short time!
Order coolant corrosion protection agent

from your DEUTZ partner.
● Connect coolant outlet (2) and coolant inlet (1) to

the cooling system. Connect the feed line of the
compensation tank to the coolant pump or to the
coolant inlet line (3).
● Connect ventilation line from the engine and, if
necessary, from the cooler to the compensation
tank.
● Fill cooling system via the compensation tank.
● Close compensation tank with valve.
26 © 2013
Starting process Operation

Starting control via a relay:
3
Before starting, make sure that nobody is
standing in the immediate vicinity of the en-
P 0 ● the maximum start duration is limited.
● the pause between two start attempts is speci-
fied.
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
1 – the start is then continued automatically
● starting while the engine is running is prevented.
been removed from the engine.
When starting with the flame glow plug/ If the touch start function is programmed, a short
glow plug/heating flange system do not use
any other starting aid (e.g. injection with
2 start command with the ignition key in position 2 or a
start button, if available, suffices.
start pilot). Risk of accident!
If the engine fails to fire and the error lamp

lights, the electronic engine control has ac-
tivated the start lock to protect the engine.
The start lock is released by switching off with cold starting device
the system with the ignition key for about 30 ● Insert key.
seconds. – Position 0 = no operating voltage.
Do not actuate the starter for more than
20 seconds. If the engine does not start up, ● Turn key to the right.
wait for one minute and then repeat the – Position 1 = operating voltage.
starting process. – Engine is ready for operation.
If the engine does not start up after two at- ● Below the temperature specified in the electronic
tempts, determine the cause as per fault ta- engine control, the pre-heating phase begins
ble (59). with turning on the ignition.
Do not run up the engine immediately to ● The electronic engine control controls and acti-
high idling speed / full load operation from vates the current feed to the glow plugs via the
cold. engine coolant temperatures.
● Push the key in and turn further clockwise
Disconnect the engine by uncoupling de- against spring pressure.
vices to be driven where possible. – Level 2 = start.
● release the key as soon as the engine starts up.
– The pilot lamps will go out.
If the starter is controlled by the electronic engine
© 2013 27
Operation Operation monitoring
3 Electronic engine control

The statuses are displayed by the error lamp.
necessary.
– 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
● 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. – optionally the power reduction can be by-
● The lamp does not light passed, the automatic switch-off delayed or
– After the lamp test an extinguished lamp indi- a start lock bypassed with the override key
cates an error-free and trouble-free operat- on the instrument panel to avoid critical situ-
ing state within the scope of the control ations. This brief deactivation of the engine
possibility. protection functions is logged in the control
unit. Display instrument
● Continuous light The engine protection functions are released in
– Error in the system. co-operation with the equipment manufacturer Possible displays:
– Operation continued with restrictions. and the DEUTZ installation consulting and may ● Colour scale
– The engine must be checked by a DEUTZ be designed individually. It is therefore absolute- – Display of operating state by coloured areas:
partner. ly essential to observe the operating instructions – green = normal operating state
– If a lamp lights steadily a monitored measur- of the equipment manufacturer.
– red = critical operatng state
ing variable (e.g. coolant temperature, lubri-
Take suitable action.
cating oil pressure) has left the permissible
value range. ● 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 (68).
● 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 with power reduction to
cool the engine, with automatic shutdown if
28 © 2013
Operation monitoring Operation

Instruments and symbols
3
Instruments/symbols Designation Possible display: Measure
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 pilot Lubricating oil pressure below minimum Switch off engine
lamp
Lube oil level Lubricating oil level too low Fill up lube oil
Coolant level Coolant level too low Shut down the engine, allow to cool and top up cool-
ant
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
Horn With acoustic signal See fault table (59).
© 2013 29
Operation Operation monitoring
3 Instruments/symbols Designation Possible display: Measure

Ash lamp Continuous light The ash lamp indicates that the loading of the diesel particle
filter with ash has reached a critical level and the device can
no longer regenerate.33
DPF function lamp Continuous light Initiate standstill regeneration 33

flashes (0.5 Hz)
flashes (2 Hz)
Engine warning lamp Continuous light Initiate standstill regeneration 33

Flashing
30 © 2013
Operation monitoring Operation

●
●
Operation monitoring of the diesel particle filter
Faults in the exhaust aftertreatment system 3
● Battery voltage
● Accelerator position
● Fuel consumption
● 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 driver´s position of working ma-
chines.
The following data may be displayed if they are sent
by the control unit.
● Engine speed
● Engine torque (current)
● Coolant temperature
● Suction intake air temperature
● Exhaust gas temperature
● Lubricating oil pressure
● Coolant pressure
● Charge air pressure
● Fuel pressure
● Status of the regeneration of the diesel particle
filter
© 2013 31
Operation Exhaust gas aftertreatment system

The diesel oxidation catalytic converter has a cata-
lytic surface which is used to convert the pollutants
in the exhaust gas into harmless substances. Here,
carbon monoxides and unburned hydrocarbons are
made to react with oxygen and converted into carbon
dioxide and water. In addition, the nitrogen monox-
ides are converted to nitrogen dioxides.
Temperatures > 250 °C are necessary for a high de-
gree of efficiency.
The combustion of diesel fuel results in soot, which
is separated in the diesel particle filter. This must be
regenerated as the contamination with soot increas-
es. That means that the soot in the diesel particle fil-
ter is burned.
The regeneration is based on a continuous regener-
ation process, which is activated as soon as the ex-
haust temperature of 250 °C is exceeded at the inlet
of the exhaust gas aftertreatment system. The filter
contamination with soot is monitored continuously by
the engine control unit.
Regeneration
The passive particle filter system burns the soot in
the filter with the nitrogen oxides in the exhaust
which are oxidised in the DOC beforehand. This
process runs continuously once the exhaust temper-
ature has exceeded 250°C. The passive particle fil-
ter system does not contain a burner. A prerequisite
for the passive continuous regeneration is having a
sufficient ratio of nitrogen oxides to soot in the raw
exhaust gas of the engine.
32 © 2013
Passive regeneration Operation

Normal operation
Under normal operating conditions (exhaust temper-
Standstill regeneration ● Warm up the engine; the coolant temperature
must reach at least 75°C. 3
Temperatures of approx. 600 °C occur on ● Operate the engine in idling.
ature > 250 °C), the filter contamination with soot re-
the exhaust pipe during regeneration. ● The engine control unit now requires a signal in-
mains in a permissible range and no actions are
A special engine operating state becomes dicating that the unit is safely parked (stationary
necessary.
active during standstill regeneration and signal).
The regeneration lamp is off. the machine is not allowed to be used dur- This occurs,depending on the application, for ex-
ing the active standstill regeneration. ample by:
Support mode
Danger of burns! – Activating the parking brake.
If the operating conditions of the engine do not per- – Engaging a specified gear position in the
mit any passive regeneration, the contamination of If the support mode does not attain an adequate re-
duction of the soot contamination, the filter will con- gearbox.
the diesel particle filter with soot will increase.
tinue to become contaminated with soot and a ● Operating the release button.
A throttle valve controlled via the engine control unit standstill regeneration will be necessary. Position depends on application, see device
is located in the combustion air inlet. This is used to manual.
increase the exhaust gas temperature for regenera- This is displayed by a flashing regeneration lamp.
tion of the diesel particle filter, if this is not reached The standstill regeneration must be initiated manual- The regeneration lamp lights up continuously.
during normal operation. ly by the operator. Once the standstill regeneration has been released,
This can be the case if: We recommend carrying out a necessary standstill the engine automatically increases the speed level.
● The engine only has short operating times. regeneration as quickly as possible, as otherwise the Using the device during standstill regeneration is
diesel particle filter will continue to become contami- prohibited.
● The engine workload is not high.
nated with soot.
The regeneration lasts 30 minutes on average.
This process is automatically activated by the engine If the standstill regeneration is not carried out, the
control unit, the operator does not need to perform engine control unit will activate the specified engine The standstill regeneration can be interrupted at any
any actions. protection functions, depending on the contamina- time by pressing the regeneration button again or by
tion of the diesel particle filter. removing the regeneration release.
The regeneration lamp is off.
Every standstill regeneration slightly dilutes the en- Using the device during standstill regeneration also
During this operating state, an acoustic gine oil with fuel. The oil quality is therefore moni- leads to it being interrupted.
change occurs to the running of the engine. tored. The request to change the oil must therefore The request for standstill regeneration remains until
be obeyed. it is completed without interruption.
Implementation of the standstill regeneration Certain engine faults lead to excessive carbon emis-
sion which cannot be seen due to the diesel particle
The engine must be brought into a "safe state" for filter.
the regeneration: In such cases, the diesel particle filter can be loaded
● Shut down the engine on an open terrain at a very quickly, among other things, to a level which no
safe distance to flammable objects. longer allows a standstill regeneration by the opera-
© 2013 33
Operation Passive regeneration
3 tor.
Very short intervals between two standstill regenera-
tions (<10h) can be an indication of such a defect.
Please contact the DEUTZ service.
The regeneration lamp goes out when regeneration
has been successfully completed.
If the standstill regeneration request is not observed
and the DPF is overloaded to an impermissible level,
then the filter can only be regenerated via the
DEUTZ service.
Replacing the diesel particle filter
It may be necessary to replace the diesel particle fil-
ter after a high filter running time as non-combustible
residues accumulate in the filter - so-called ash.
If the ash loading goes beyond a certain level, this
will be indicated by the ash lamp.
The diesel particle filter needs to be replaced.
The machine can operate normally until the replace-
ment is carried out by the service.
The time interval between two regeneration requests
is shortened in proportion to the run time.
Please contact your DEUTZ partner
The contaminated diesel particle filter can be re-
turned and replaced with a clean one in the DEUTZ
exchange programme.
34 © 2013
Passive regeneration Operation

Display of the regeneration control
The display and monitoring of the exhaust aftertreatment system can be executed either with pilot lights or with a CAN interface and a corresponding display, depending
3
on the engine version.
Instruments/symbols Power reduction Regeneration
Regeneration lamp Engine warning lamp Ash lamp

off off off Normal operation
off off off Support mode
flashes (0.5 Hz) off off Standstill regeneration
Release by the operator
flashes (2 Hz) Continuous light off -30 % Standstill regeneration
Release by the operator
flashes (2 Hz) Flashing off -30 % Standstill regeneration
+ Engine speed limitation to 1200 rpm Release only by the DEUTZ partner
flashes (2 Hz) Flashing Continuous light -30 % No regeneration possible
Ash load 100 % + Engine speed limitation to 1200 rpm
© 2013 35
Operation Stopping process
3 Lag time
P 0 The control unit remains active for about

another 40 seconds to save the system
data (lag) and then switches off automati-
1 cally.
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.
● Move the key to position 0.
P = gear position: park
0 = gear position: switch off engine
1 = gear position: Ignition on
2 = gear position: start engine
36 © 2013
Lubricating oil Operating media

General
Modern diesel engines place very high demands on
bricating oil flows, depending on the temperature.
The lubricating oil viscosity only has a small influ-
http://www.deutz.com
de \SERVICE \Betriebsstoffe und Addi-
4
ence and effect on the quality of the oil.
the lubricating oil to be used. The specific engine tive\Deutz Quality Class\DQC-Freigabeliste
performances which have increased constantly over Synthetic lubricating oils are used increasingly and
offer advantages. These lubricating oils have better en \SERVICE \Operating Liquids and Addi-
the last few years lead to an increased thermal load tives\Deutz Quality Class\DQC Release List
on the lubricating oil. The lubricating oil is also more temperature and oxidation stability as well as rela-
exposed to contamination due to reduced oil com- tively low cold vicosity. Since some processes which The choice of luricating oil essentially depends on
sumption and longer oil change intervals. For this are relevant for determining the lubricating oil the exhaust aftertreatment system.
reason it is necessary to observe the requirements change times are largely dependent on the oil quality
(e.g. the infiltration of soot and other contamination), The following lubricating oils are permissible for the
and recommendations described in this operating
the oil change time for synthetic lubricating oils may engines in this operating manual:
manual in order not to shorten the life of the engine.
not be increased in relation to the specifications on
Lubricating oils always consist of a base oil and an Permissible quality class
lubricating oil change intervals.
additive package. The most important tasks of a lu- DEUTZ Others
bricating oil (e.g. wear protection, corrosion protec- Biodegradable lubricating oils may be used in
tion, neutralisation of acids from combustion DEUTZ engines if they meet the requirements of this Engines with exhaust aftertreatment system
products, prevention of coke and soot deposits on operating manual. DQC III LA * Please contact your DEUTZ part-
the engine parts) are assumed by the additives. The DQC IV LA * ner
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 Engines without exhaust aftertreatment system
load capacity. to their performance and quality class (DQC: DEUTZ DQC II Please contact your DEUTZ part-
In principle, all engine oils of the same specification Quality Class). Essentially, the following applies: the DQC III ner
can be mixed. However, mixing of engine oils should higher the quality class (DQC I, II, III, IV), the more
effective/the better quality the lubricating oil is. DQC III LA *
be avoided because the worst properties of the mix-
ture are always dominant. The DQC quality classes are still to be extended by DQC IV
The lubricating oils approved by DEUTZ have been the DQC-LA quality classes which include the mod- DQC IV LA *
thoroughly tested for all engine applications. The ac- ern, low-ash lubricating oils (LA = Low Ash). * Sulphur content in the fuel < 15 mg/kg
tive ingredients they contain are compatible with Lubricating oils according to other comparable spec-
each other. Therefore, the use of additives for lubri- ifications can be used as long as they meet DEUTZ For low-ash engine oils released according to the
cating oils is not permitted in DEUTZ engines. requirements. In regions in which none of these DQC system an appropriate reference is made in the
qualities are available, please contact your responsi- oil release list.
The lubricating oil quality has a considerable influ-
ence on the life, performance and thus also on the ble DEUTZ partner.
costs-effectiveness of the engine. It basically applies or see www.deutz.com
that: The better the lubricating oil quality, the better
these properties.
The lubricating oil viscosity describes the way the lu-
© 2013 37
Operating media Lubricating oil
4 DEUTZ lubricating oils DQC II

TLS - 15W40 D
– lubricating oil quality
– sulphur content in the fuel °C
– type of application of engine
Not for engines with exhaust gas aftertreatment 45
– Number of standstill regenerations
Container Order number: ● The lubricating oil change interval must be 40
5 litre container 0101 6331 halved if at least one of the following conditions
20 litre canister 0101 6332 applies: 35
209 litre barrel 0101 6333 – Constant ambient temperature below -10 °C
(14 °F) or lube oil temperature below 60 °C
30
(84 °F). 25
DEUTZ lubricating oils DQC III – Sulphur content in diesel fuel of >0.5 weight
TLX - 10W40 FE
%. 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
Not for engines with exhaust gas aftertreatment ● If the lubricating oil change intervals are not
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
Container Order number: reached within a year, the oil should be changed 15
at least once a year.
5 litre container 0101 6335 10
20 litre canister 0101 6336 Viscosity
5
209 litre barrel 0101 6337 The ambient temperature at the installation site or in
the application area of the engine is decisive for 0
DEUTZ lubricating oils DQC III LA low-ash choosing the right viscosity class. Too high a viscos-
DEUTZ Oil Rodon 10W40 Low SAPS ity can lead to starting difficulties, too low a viscosity -5
can endanger the lubrication effect and cause a high
Container Order number:
lubricating oil consumption. At ambient temperatures -10
20 litre canister 0101 7976 below -40 °C, the lubricating oil must be pre-heated
209 litre barrel 0101 7977 (e.g. by storing the vehicle or the machine in a hall). -15
The viscosity is classified according to SAE. Multi- -20
DEUTZ lubricating oils DQC IV synthetic purpose lubricating oils should be used basically.
DQC IV - 5W30-UHP Single-purpose lubricating oils can also be used in -25
Not for engines with exhaust gas aftertreatment enclosed, heated spaces at temperatures >5 ° C.
-30
Container Order number: The prescribed lubricating oil quality must
20 litre canister 0101 7849 be observed when selecting the viscosity -35
class!
209 litre barrel 0101 7850 -40
Depending on the ambient temperature we recom-
Lubricating oil change intervals
mend the following common viscosity classes:
● The intervals depend on:
38 © 2013
Fuel Operating media

Permissible fuels
In order to satisfy the exhaust gas legislation, diesel
– in EN 590 quality
Sulphur <2,000 mg/kg
Winter operation with diesel fuel
Special demands are placed on the cold behaviour
4
engines that are equipped with an exhaust aftertreat- (temperature limit value of the filtrability) for winter
ment system may only be operated with a sulphur- – ASTM D 975 Grade 1-D S15 Quality operation. Suitable fuels are available at filling sta-
free diesel fuel. – ASTM D 975 Grade 2-D S15 Quality tions in winter.
The operational reliability and durability of the indi- Sulphur <2,000 mg/kg For engines with common rail injection, the
vidual exhaust aftertreatment technologies cannot
● Light heating oils mixing of petroleum and adding of extra low
be assured upon failure to comply.
additives is not permissible.
– in EN 590 quality
Exhaust aftertreatment systems At low ambient temperatures paraffin discharges can
Sulphur <2,000 mg/kg
DOC Diesel oxidation catalytic converter lead to blockages in the fuel system and cause oper-
DOC / DPF Diesel oxidation catalytic converter If other fuels are used which do not meet the require- ating faults. Below 0 °C ambient temperature use
Diesel particle filter ments of the operating manual, the warranty will be winter diesel (down to -20 °C) (filling stations provide
voided. this in good time before the cold season starts).
The following fuel specifications / standards are ap- The certification measurements for compliance with ● Special diesel fuels can be used for arctic cli-
proved: mates to -44 °C.
the legal emission values are made with the test fu-
● Diesel fuels els specified in the laws. These correspond to the
– EN 590 diesel fuels in accordance with EN 590 and
ASTM D 975 described in the operation manual. No
Sulphur <10 mg/kg emission values are guaranteed with the other fuels
– ASTM D 975 Grade 1-D S15 described in this operation manual.
– ASTM D 975 Grade 2-D S15 The respective fuels prescribed by law must be used
to comply with the national emission regulations
Sulphur <15 mg/kg (e.g. sulphur content).
● Light heating oils Please contact your DEUTZ partner
– in EN 590 quality or see www.deutz.com
Sulphur <10 mg/kg http://www.deutz.com
de \SERVICE\Betriebsstoffe und Additive\Kraft-
Exhaust aftertreatment systems
stoffe
without
en \SERVICE\Operating Liquids and Addi-
The following fuel specifications / standards are ap- tives\Fuels
proved:
● Diesel fuels
© 2013 39
Operating media Coolant
4 General ● pH value too low:

Addition of diluted sodium or potassium lye.
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, Small trial mixtures are advisable. Please contact your DEUTZ partner if the DEUTZ
even for a short time! ● Total hardness too high: cooling system corrosion protection agent is not
Mixing with softened water (pH neutralized con- available.
In liquid-cooled engines, the coolant must be condi- densate or water softened by ion exchanger). or see www.deutz.com
tioned and monitored, otherwise the engine could be ● Chlorides and/or sulphates too high:
damaged by: Mixing with softened water (pH neutralized con- http://www.deutz.com
● corrosion densate or water softened by ion exchanger). de \SERVICE\Betriebsstoffe und
● cavitation Cooling system corrosion protection agent Additive\Kühlsystemschutz
● freezing en \SERVICE\Operating Liquids and Addi-
● overheating Health damaging nitrous amines form tives\Cooling System Conditioner
when nitrite-based cooling system corro-
Water quality
sion protection agents are mixed with
The right water quality is important for conditioning amine-based agents!
the coolant. Clear, clean water within the following
analysis values should always be used: Cooling system corrosion protection agents
must be disposed of in an environmentally
Analysis values min max ASTM friendly way.
ph value 6,5 8,5 D 1293 Observe the notes on the safety data
Chlorine (Cl) [mg/l] - 100 D 512 sheet.
D 4327 The conditioning of the coolant for liquid-cooled
Sulphate (SO4) [mg/l] - 100 D 516 DEUTZ compact engines is performed by mixing an
Total hardness [mmol/l] 3,56 D 1126 anti-freeze with corrosion protection inhibitors based
(CaCO3) [mg/l] 356 on ethylene glycol into the water.
[°dGH] 20,0 - DEUTZ cooling system corrosion protection agent
[°e] 25,0 Container Order number:
[°fH] 35,6 5 litre container 0101 1490
Specifications of the water quality are made by the 20 litre canister 0101 6416
local water board. 210 litre barrel 1221 1500
The water must be conditioned if it deviates from the
This cooling system corrosion protection agent is
analysis values.
free from nitrite, amine and phosphate and is adapt-
40 © 2013
Coolant Operating media

The cooling system must be monitored regularly.
This also includes checking the coolant system cor- 4
rosion protection agent concentration in addition to
checking the coolant level.
The cooling system corrosion protection agent con-
centration can be checked with conventional test in-
struments (e.g. refractometer).
Cooling system Water percent- Cold pro-

corrosion protec- age tection up
tion agent percent- to
age
min. 35 % 65 % -22 °C
40 % 60 % -28 ℃
45 % 55 % -35 °C
max. 50 % 50 % -41 °C
At temperatures below -41 °C, please contact your
responsible DEUTZ partner.
It is possible to use other cooling system corrosion
protection agents (e.g. chemical corrosion protection
agents) in exceptional cases. Consult your DEUTZ
partner.
© 2013 41
Maintenance Maintenance schedule
5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
Standard maintenance schedule

D/TD/TCD 2.9 L4
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 500 1) 2) 3)
E40 Extended maintenance I 1.000 3)
E50 Extended maintenance II Authorised specialists 3.000 3)
E70 General overhaul 6.000 3) 4)
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (37).
2)
Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
3)
The display of the operating hours should be ensured by the device manufacturer. The engine operating hours are recorded by the control unit. Enquiry via the CAN
bus and display in a display or creation/display via electromechanical counter.
General overhaul
4)
The best time for a general overhaul depends to a great extent on the load, application and ambient conditions and the care and maintenance of the engine during the
operating time.
Your DEUTZ partner will advise you on determining the best time for a general overhaul.
42 © 2013
Maintenance schedule Maintenance

Maintenance measures
5
Stage Activity Measure Page
E10 The measures are listed in chapter 3. 25
E20 Check Lubricating oil level (if necessary top up) 45
Coolant level (top up if necessary) 26
Engine tightness (visual inspection for leaks)
Exhaust system including exhaust aftertreatment components for leaks 32
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 54
Emptying of the water tank in the fuel pre-filter 49
E30 Check V-belts 56
Coolant (additive concentration) 50
Intake air pipes for damage
Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 37/45
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Fuel filter cartridge 48
for filter size 0.6 L
Lubricating oil filter/insert (every time the lubricating oil is changed) 46
E40 Check Charge air cooler entry area (drain lube oil/condensate)
Battery and cable connectors 57
Cold starting device
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
V-rib belt and tensioning pulley 55
Replace Fuel filter cartridge 48
for filter size 0.9 L
Filter insert for the fuel pre-filter. If the warning system responds (lamp/horn), the water trap bowl must be emptied 49
immediately.
Dry air filter 54
V-belts 56
© 2013 43
Maintenance Maintenance schedule
5 Stage
E50
Activity
Replace
Measure
V-rib belt and tensioning pulley
Page
55
annually Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Replace Fuel pre-filter 49
Every 2 Replace Dry air filter 54
years Coolant 40 50
Status Change Diesel particle filter, the required exchange is displayed by the ash lamp or via an electronic display, depending on
dependent the engine version (see DEUTZ exchange programme 33).
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 3897 (D/TD/TCD 2.9 L4)
44 © 2013
Lubricating oil system Servicing and maintenance work

Regulations for working on the lubricating oil system
OIL ?
● Extract the lubricating oil dipstick and read off the
oil level. 6
Do not work when the engine is running! ● The oil level must always be between the MIN
Smoking and naked lights prohibited! and MAX marks! Top up to the MAX mark if nec-
Be careful of hot lubricating oil. Danger of essary.
scalding! OIL Changing the lubricating oil
+80°C
Pay attention to utmost cleanliness when +176°F ● Warm up the engine (lubricating oil temperature
working on the lubricating oil system. Clean > 80 °C).
the area around the components con- ● Ensure that the engine or vehicle is in a level po-
cerned carefully. Blow damp parts dry with sition.
compressed air.
Observe the safety regulations and nation-
al specifications for handling lube oils.
! ● Switch off the engine.
● Place a collecting receptacle underneath the
lube oil drain screw.
Dispose of leaking lubricating oil and filter
● Unscrew the lube oil drain screw, drain oil.
elements properly. Do not allow used oil to
Checking the lubricating oil level ● Turn in and tighten lubricating oil drain plug fitted
seep away into the ground.
with new sealing ring.
Perform a trial run after all work. Pay atten-
tion to tightness and lubricating oil pressure Low lubricating oil level and overfilling lead
Tightening torque 55 Nm
and then check the engine oil level. to engine damage.
The lubricating oil level may only be ● Pour in lube oil.
checked with the engine in a horizontal po- – Quality/viscosity data (37).
sition and switched off. – Filling volume (68).
If the engine is warm, switch off the engine
● Warm up the engine (lubricating oil temperature
and check the lubricating oil level after 5
> 80 °C).
minutes. If the engine is cold you can check
it immediately. ● Ensure that the engine or vehicle is in a level po-
sition.
● Check lubricating oil level, if necessary top up.
Be careful of hot lubricating oil. Danger of
scalding!
Do not pull out the dipstick while the engine
is running. Danger of injury!
● Pull out the lubricating oil dipstick and wipe off
with a lint-free, clean cloth.
● Insert the lubricating oil dipstick as far as it will
go.
© 2013 45
Servicing and maintenance work Lubricating oil system
Change lubricating oil filter ● Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- ● Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
● Remove clamps when twist protection mounted ● Fasten clamps of the twist protection (optional).
(optional).
● Loosen and unscrew filter with tool (order no.:
0189 9142)
● Collect draining lubricating oil
● Clean the sealing surface of the filter support
46 © 2013
Fuel system Servicing and maintenance work

Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
6
Engine must be switched off! work.
Smoking and naked lights prohibited! Areas of the engine compartment from
No injection/high pressure pipes may be which dirt could be loosened must be cov-
disconnected while the engine is running. ered with a fresh, clean foil.
Caution when handling hot fuel! Work on the fuel system may only be car-
Pay attention to utmost cleanliness when ried out in an absolutely clean environment.
refuelling and working on the fuel system. Contamination of the air such as dirt, dust,
Clean the respective affected parts careful- moisture etc. must be avoided.
ly. Blow damp areas dry with compressed
air.
Observe the safety regulations and nation-
al specifications for handling fuels.
Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep away
into the ground.
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.
Additional venting of the fuel system by a 5

minute trial run at idle speed or on low load
is absolutely essential.
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Make a visual inspection for leaks/damage
in the system.
© 2013 47
Servicing and maintenance work Fuel system
Change the fuel filter cartridge ● Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- ● Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 10-12 Nm
● Fasten clamps of the twist protection (optional).
● Remove clamps when twist protection mounted
(optional). ● Vent the fuel system.
● Loosen and unscrew filter with tool (order no.:
0189 9142)
● Catch any escaping fuel.
● Clean the sealing surface of the filter support
48 © 2013
Fuel system Servicing and maintenance work

– Connect cable connections.
Change the fuel pre-filter insert
seconds in order to vent the fuel system and build up
the required fuel pressure. 6
6 1 Wait until the electric fuel supply pump is disconnect-
● Switch off the engine. ed from the control unit.
● Shut off the fuel supply to the engine (with high- ● Ignition "OFF"
level tank).
● Place suitable collecting containers underneath. Repeat the process at least 2 times until the fuel sys-
5 2 ● Electrical connection tem is vented.
– Disconnect cable connections.
● Loosen drain plug and drain liquid.
● Disassemble filter insert.
4 3 ● Clean any dirt off the sealing surfaces of the new
filter cartridge and opposite side of filter head.
● Wet the sealing surfaces of the filter cartridge
Change/vent fuel pre-filter slightly with fuel and screw back on to the filter
head, clockwise (17-18 Nm).
1 Fuel supply flow to the pump ● Mount drain plug.
2 Venting screw
3 Electrical connection for water level sensor Tightening torque 1.6 ±0.3 Nm
4 Drain plug ● Electrical connection
5 Filter insert – Connect cable connections.
6 Fuel inlet from the fuel tank
● Open the fuel shutoff tap and vent the system,
Empty water tank see venting the fuel system.
● Switch off the engine. Vent the fuel system
● Place suitable collecting containers underneath.
● Electrical connection The fuel system is vented via the electric fuel supply
pump.
– Disconnect cable connections.
In order to ensure that no error messages are gener-
● Loosen drain plug. ated, no attempt should be made to start the system
● Drain fluid until pure diesel fuel runs out. up whilst venting.
● Mount drain plug. This process is carried out as follows:
Tightening torque 1.6 ±0.3 Nm ● Ignition "ON"
● Electrical connection The electronic fuel supply pump switches on for 20
© 2013 49
Servicing and maintenance work Cooling system
6 Specifications when working on the cooling system
Danger of scalding from hot coolant!

Cooling system under pressure! Only open
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.
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do 1
not allow them to seep into the ground.
Order coolant corrosion protection agent
from your DEUTZ partner. Check coolant additive concentration Emptying the cooling system
Never operate the engine without coolant, ● Open the cooling system cap (1) carefully. ● Open cooler locking cap carefully.
even for a short time!
● Check the coolant aditive concentration in the ● Place suitable collecting containers underneath.
Checking the coolant level with an external cooler cooler/compensation tank (2) with a convention- ● Remove the locking screw (1) in the crankcase.
al antifreeze measuring device (1) (e.g. hydrom- ● Drain coolant.
● Fill in new coolant and vent the system according eter, refractormeter).
to the specifications of the cooling system manu- ● Insert screw again with sealant.
● Necessary coolant additive concentration Cool- ● Close cooler locking cap.
facturer. ant mixing ratio (40).
● Open the cooling system cap (1) carefully.
● The coolant level must always be between the The corresponding test device can be ordered from
MIN and MAX marks of the compensation tank! your DEUTZ partner under the order no.: 0293
Fill up to the MAX mark if necessary. 7499.
50 © 2013
Cooling system Servicing and maintenance work

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

Cooling system under pressure! Only open
the cap when cool!
● Open the cooling system cap (1) carefully.
● Loosen the cooler venting screw if necessary.
● Fill coolant up to the max. mark or filling limit.
● Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
● Close cooler locking cap.
● Run engine up to operating temperature (open-
ing temperature of the thermostat).
● Switch off the engine.
● Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
tion tank if necessary.
© 2013 51
Servicing and maintenance work Engine cleaning
6 Cleaning work Cleaning with cold cleaner

● 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).
Cover electrical/electronic parts and con- ● Spray the engine clean with a high pressure wa-
ter jet.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do ● Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
Only carry out cleaning work on the engine ● Clean the engine with a steam jet (maximum
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- ● Warm up the engine so that the water residues
ing. evaporate.
● 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:
● High dust content in the air.
● Chaff and chopped straw in the area of the en-
gine.
● Coolant leaks
● Lubricating oil leakage
● Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
● Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
52 © 2013
Suction system Servicing and maintenance work

Regulations for working on the intake system
1 5 2
Renewing the safety cartridge of the dry air filter
6
Do not work when the engine is running! Never clean the safety cartridge (4).
● Renew safety cartridge (4) according to the inter-

Pay attention to utmost cleanliness when
val in the maintenance schedule
working on the intake system, close intake
● To do this:
openings if necessary.
Dispose of old filter elements properly. – Unscrew hexagon nut (5), pull out safety car-
tridge (4).
4 3 – Insert new safety cartridge, screw on hexag-
onal nut.
● Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
Maintaining the dry air filter
Do not clean the filter element (3) with pet-

rol or hot liquids!
Renew damaged filter elements.
● Maintain the filter element (3) according to the in-
terval in the maintenance schedule
● Lift up the clamping yoke (1).
● Remove the filter hood (2) and pull out the filter
element (3).
● Filter element (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.
© 2013 53
Servicing and maintenance work Suction system
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter
● The dry air filter is maintained according to a ● Empty the dust discharge valve (1) by pressing
maintenance switch or maintenance indicator. together the discharge slit.
● Maintenance is necessary when: ● Remove any caked dust by pressing together the
– the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. ● Clean the discharge slit.
– the red field (1) of the maintenance indicator
is fully visible.
● After carrying out maintenance work, reset the
signal by pressing the button on the mainte-
nance indicator. The maintenance indicator is
now ready for operation again.
54 © 2013
Belt drives Servicing and maintenance work

Checking the belt drive
1 6
Only carry out work on the belt drive with
the engine at a standstill!
After repair work: Check that all guards
have been replaced and that all tools have
been removed from the engine.
2
● Check the whole belt drive visually for damage.
● Renew damaged parts.
● Remount protective devices if necessary.
● Pay attention to correct fit of new belts, check the
tension after running for 15 minutes. 3
Replace V-rib belt

1 Tension pulley
2 Retaining pin
3 Assembly bore
● Press tensioning roller with socket wrench in the
direction of the arrow until a retaining pin can be
fixed in the assembly bore. The V-ribbed belt is
now tension free.
● First pull the V-ribbed belt off the smallest roller
or off the tensioning roller.
● Mount new V-ribbed belt.
● Retain tensioning pulley using the pin wrench
and remove the holding pin.
● Tension V-ribbed belt using the tensioning roller
and socket wrench. Check whether the V-ribbed
belt is correctly in its guide.
© 2013 55
Servicing and maintenance work Belt drives
6
1 3
1
1
2
B A
5 4 3 2
Checking the belt tension Change the belt

● Lower indicator arm (1) into the measuring de- 1 Screw
vice. 2 Screw
● Place guide (3) between two belt pulleys on the 3 Screw
V-belt (2). The stop have to be at the side.
● Press the button (4) at right angles to the V-belt ● Remove screw and lock nut.
(2) evenly until you hear or feel the spring snap ● Move the generator in direction (B) until the V-
in. belt is slack.
● Lift the measuring device carefully without alter- ● Remove belt and fit new one.
ing the position of the indicator arm (1). ● Move the generator in direction (A) until the V-
● Read the measured value at the point of inter- belt has attained the correct tension.
section (arrow), scale (5) and indicator arm (1). ● Checking the belt tension (68).
● If necessary, re-tension belt and measure again. ● Tighten screw and lock nut again.
Tools Tightening Screw 1 60 Nm

torque Screw 2 30 Nm
The belt tension measurement device (order no.:
0189 9062) can be ordered from your DEUTZ part- Screw 3 M8 30 Nm
ner. Screw 3 M10 60 Nm
56 © 2013
Electrical system Servicing and maintenance work

Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
6
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. ● 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)
For electrical welding work, the ground ter- Check acid density
minal of the welding gear must be clamped 12 Volt 12-14,4 ● Unscrew caps.
directly to the part being welded. 24 Volt 24-28,4 ● Measure the electrolyte density of individual cells
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
connect the cables between battery, gener- Check acid level
reading indicates battery’s state of charge. The
ator and regulator while the engine is ● Unscrew caps. acid temperature when measuring should be 20
running. °C if possible.
● Note the manufacturer’s specifications concern-
Battery ing the liquid level. ● Check the acid level before recharging.
The liquid should normally be 10-15 mm above ● Screw in caps.
Electronically stored data could be lost if the top edge of the plate or reach up to any avail-
able control device. Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. ● Only use distilled water to top up the battery. Normal Tropical
Make sure the battery is fitted correctly and ● Screw in caps. 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
© 2013 57
Servicing and maintenance work Electrical system
6 Removing the battery

● Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
of short-circuit!
● Remove the fastenings and take out the battery.
Charging the battery
● Unscrew caps.
● Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
● Screw in caps.
Installing the battery
● Insert new or charged battery and attach the fas-
tenings.
● Clean the terminals and battery poles with fine
emery paper.
● 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.
● Grease the assembled terminals with an acid-
free, acid-resistant grease.
58 © 2013
Fault table Faults

Faults and remedies
7
Faults Causes Measures
Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Fuel tank empty Tanks
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
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 Check error according to error code and
lamp flashes eliminate error if necessary
Engine starts, but runs irregularly or Exhaust gas backpressure too high Check
fails Compression pressure too low Check compression pressure
Air in fuel system Vent
Fuel filter contaminated Clean
Injector defective Change
© 2013 59
Faults Fault table
7 Faults Causes Measures

Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
Engine becomes excessively hot. Vent line blocked Clean
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
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension
Charge air line leaking Check charge air line
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
Exhaust gas backpressure too high Check
60 © 2013
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
Resistance in cooling system is too high / flow volume too low Check the cooling system
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
© 2013 61
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
62 © 2013
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 with power reduction to
1 safely possible. cool the engine, with automatic shutdown if
Error lamp necessary.
– 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.
● 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. – optionally the power reduction can be by-
passed, the automatic switch-off delayed or
– Check the error lamp if there is no reaction
a start lock bypassed with the override key
after switching on the ignition.
Engine protection function of the electronic engine on the instrument panel to avoid critical situ-
● The lamp does not light
control ations. This brief deactivation of the engine
– After the lamp test an extinguished lamp indi- protection functions is logged in the control
cates an error-free and trouble-free operat- unit.
1 Diagnosis button ing state within the scope of the control Please contact your DEUTZ-partner in case of
2 Error lamp possibility. malfunctions and sare parts inquiries. Our spe-
3 Electronic engine control (EMR) ● Continuous light cially trained personnel will ensure fast, profes-
Error in system. sional repairs using original DEUTZ spare parts
The error lamp goes out when all the errors in case of damage.
– 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 ● Flashing
the correct function of the system components. Serious error in system.
© 2013 63
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:
● Errors that may occur can be classified.
● Clear display of the error as visual signal.
– The blink codes can only be interpreted by a
DEUTZ partner.
0,8 s
0,4 s
0,4 s
0,4 s
0,8 s
0,4 s
2s 2s
Use of the diagnostic key
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.
● The blink codes can only be interpreted by a
DEUTZ partner.
64 © 2013
Transport Transport and storage
1 8
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- ● The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. ● The fastening attachment can slip, the engine
swings backwards and forwards (1).
● Always use proper suspension equipment when
transporting the engine. ● Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
● The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
● After transportation and before commissioning of
engine: remove attachment eyes (2).
© 2013 65
Transport and storage Engine corrosion protection
8 General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
● Cooling air system, see the Exterior corrosion
protection section.
● The corrosion protection run can be performed ● In engines of the oil-cooled series the circulating
tection:
once to protect the different systems: lubricating oil serves simultaneously for cooling.
● Interior corrosion protection The cooling chambers are protected automati-
● Exterior corrosion protection Fuel system cally against corrosion with the lube oil system.
Your DEUTZ partner has the right corro- ● If a coolant with corrosion protection properties is
Close the fuel/tank/supply line to the en- poured into liquid-cooled engines, no further ac-
sion protection agent for your needs. gine so that the system is protected against tion is necessary after draining.
dirt and dust. Protect the electronics ● If not, the coolant must be drained and, to ensure
The following measures for corrosion protection after against moisture and corrosion.
the formation of a covering layer on the inside
taking the engine out of operation meet the require- surfaces of the cooling system, a corrosion pro-
● Fill the fuel tank with a mixture of:
ments for 12 months corrosion protection. tection run performed with a mixture of:
– 90 % distilled fuel
The following corrosion protection work may only be – 10 % corrosion protection oil. – 95 % treated water
carried out by persons familiar with it and instructed – 5 % corrosion protection agent
● Perform a corrosion protection run with no load
in the potential dangers. ● The duration of the corrosion protection run and
for at least 5 minutes.
If these measures are deviated from by exposing the the concentration of the corrosion protection
corrosion-protected engines or parts to unfavourable Lubricating oil system agent are specified by the manufacturer of the
conditions (installation outdoors or storage in damp, corrosion protection agent.
● Drain lubricating oil from warm engine.
badly aired places) or damage to the corrosion pro- ● Then drain the coolant.
● Thoroughly clean lube oil tray, cylinder head with
tection layer, a shorter corrosion protection duration
rocker arms, valves, valve springs with diesel Air intake pipes
is to be expected.
fuel or cleaning agent.
The engine corrosion protection should be checked ● Fill the engine with corrosion protection oil up to ● After the corrosion protection run, remove the
about every 3 months by opening the covers. If cor- the MAX mark and perform a corrosion protec- cylinder head cover and deinstall injectors. The
rosion is detected, the corrosion protection should tion run for at least 5 minutes so that all the com- respective piston must be set to LT.
be renewed. ponents of the lubricating oil system are wetted ● The accessible part of the cylinder liner should
At the end of the corrosion protection work the crank or wet all accessible parts with corrosion protec- be coated with corrosion protection oil with a
drive may no longer be turned so that the corrosion tion oil and pump corrosion protection oil through spray lance through the opening.
protection agent in the bearings, bearing liners and the engine with a separate pump until all bear- ● Spray corrosion protection lubricating oil into the
cylinder liners is not scraped off. ings and bearing liners are wetted. suction intake pipe.
Before operating a corrosion protected engine, the Cooling system Exterior corrosion protection
corrosion protection must be removed.
● Depending on the series the engines are ● The engine must be cleaned thoroughly with a
Interior corrosion protection equipped with cooling air, cooling oil or cooling cleaning agent before exterior corrosion protec-
fluid system (cooling water with cooling system tion. Any signs of corrosion and damage to the
● Interior corrosion protection is always provided
protection agent). paintwork must be removed.
by wetting of the walls with the implemented cor-
66 © 2013
Engine corrosion protection Transport and storage

Bare exterior surfaces and parts
● Coat or spray all bare exterior parts and surfaces
Removal of corrosion protection
● The corrosion protection must be removed from
tilled fuel or a suitable cleaning agent.
● Wash out grooves of V-belt pulleys if necessary. 8
(e.g. flywheel, flange faces) with corrosion pro- the corrosion protected engine before starting. ● Mount V-belts or V-rib belts as specified.
tection agent. ● The packaging and all covers over the closed ● Fill with coolant.
openings must be removed. Corrosion protection agent / cleaning agent
Rubber parts
● Any corrosion deposits and paint damage should
● Rubber parts (e.g. muffs) which are not painted be remedied. Please ask your DEUTZ partner for reference prod-
over must be rubbed down with talcum powder. ucts for the corrosion protection agents/cleaning
Fuel system agents to be used which meet DEUTZ requirements.
Belt drive
If there is a mixture of diesel fuel/corrosion pro- or see www.deutz.com
● Remove V-belts and V-rib belts and store tection oil in the fuel tank, drain it.
packed. ● Connect fuel/tank/supply line to the engine. Pay http://www.deutz.com
● Spray V-belt pulleys and tension rollers with cor- attention to cleanliness. de \SERVICE \Betriebsstoffe und Addi-
rosion protection agent. ● Fill the fuel tank and fuel system with the proper tive\Motorkonservierung
fuel. en \SERVICE\Operating Liquids and Addi-
Engine openings
tives\Engine Corrosion Protection
Lubricating oil system
● All engine openings must be fitted with air-tight,
water-tight covers to delay the vapourisation ● Unscrew the lube oil drain screw, drain oil.
process of the corrosion protection agents. ● Fill the engine with lubricating oil via the lubricat-
● With installed air compressor, the suction and ing oil filler neck.
pressure connection must be sealed by a cap.
● Air should be excluded to avoid ventilation of the Coolant system
engine (chimney effect) for the suction from an ● If the implemented corrosion protection agent is
air supply pipe. compatible with the intended cooling system pro-
tection agent, this can be filled directly into the
Storage and packaging
coolant system as specified.
● After being protected against corrosion, the en- ● If it is uncertain whether the implemented corro-
gine must be stored in a dry, ventilated hall and sion protection agent is compatible with the cool-
suitably covered. ing system protection agent, the cooling system
● The cover must be placed loosely over the en- should be purged with fresh water for about 15
gine so that the air can circulate around it to pre- minutes before filling.
vent condensation from forming. Use a desiccant
if necessary. Removal of exterior corrosion protection
● All areas and components coated with corrosion
protection agent must be washed off with dis-
© 2013 67
Technical data Engine and setting data
9 General technical data
Engine type Dimension D 2.9 L4 TD 2.9 L4 TCD 2.9 L4

Working principle Four-stroke diesel engine
Charging Suction motor Exhaust gas turbo- Turbocharger with
charger charge air cooling
Type of cooling water-cooled
Cylinder arrangement in series
No. of cylinders 4
Bore/stroke [mm] 92/110
Total displacement [cm3] 2925
Combustion process Direct injection
Injection system Common Rail
Exhaust gas recirculation externally cooled
Exhaust gas aftertreatment Diesel oxidation catalytic converter
and/or
or
without
Valves per cylinder 2
Firing order of the engine 1-3-4-2
Direction of rotation looking onto the flywheel
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [min-1] see engine rating plate
Coolant volume (only engine content without cooler / hoses and pipes) ≈ [l] 3,5/3,5
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 8
Start of thermostat opening [°C] 86 - 90
Thermostat fully open [°C] 99 - 102
68 © 2013
Engine and setting data Technical data

Engine type
Lubricating oil change volume (with filter)
Dimension
≈ [l]
D 2.9 L4 TD 2.9 L4
8
TCD 2.9 L4
9
Lube oil temperature in the lube oil tray, maximum [°C] 125
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 140/1,4
Permissible maximum combustion air temperature after charge air cooler [°C] 50
V-belt tension Pre-tensioning/Re-tensioning
V-belts AVX (width: 13 mm) [N] 650±50/400±50
V-rib belt tensioning Automatic tensioning spring-loaded clamping roller
Weight without cooling system according to DIN 70020-A ≈ [kg] 265 280
*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.
© 2013 69
Technical data Tools
9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Please contact your DEUTZ partner
Torx tool V-belt tension measuring instrument

Order number: Order number:
0189 9092 0189 9062
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:
● Excellent accessibility
● High force transmission when loosening and
tightening
● Slipping or breaking of the key and risk of injury
are practically excluded.
70 © 2013
Tools Technical data

9
Special wrench for loosening exchangeable filters Refractometer

Order number: Order number:
0189 9142 0293 7499
For loosening changeable filters. The following operating media can be evaluated with
this test device:
● Coolant
● Battery acid
● AdBlue®
© 2013 71
DEUTZ Operating Fluids
DEUTZ Oil Rodon 10W40 DEUTZ Oel TLX-10W40FE DEUTZ Cooling System
low SAPS (DQC III-10 LA) (DQC III-10) Conditioner
5L - 5L 0101 6335 5L 0101 1490
20 L 0101 7976 20 L 0101 6336 20 L 0101 6416
209 L 0101 7977 209 L 0101 6337 210 L 1221 1500
DEUTZ Oel DQC4-5W30-UHP

(DQC IV-10)
5L -
20 L 0101 7849
209 L 0101 7850
DEUTZ AG
Information Systems Sales & Service
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
© 07/2013
All rights reserved
Order number:
0312 4628 en
The engine company. Original operating instructions

Operation Manual 2013-08-12 Locked

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OBJ_DOKU-37427-001.fm Seite 1 Dienstag, 6.

August 2013 8:47 08

This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

Model Engine description

TCD D 2.9 <37 kW

TD/TCD 2.9 <56 kW

Engine description Model

Model Engine description

Serial numbers of the exhaust aftertreatment com- Cylinder numbering

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Lubricating oil diagram

2 Lubricating oil system

Fuel diagram Engine description

Engine description Coolant diagram

2 Coolant schematic (example)

Exhaust gas recirculation Engine description

Engine description Exhaust gas aftertreatment

2 Exhaust aftertreatment system

Exhaust gas aftertreatment Engine description

Engine description Electrics/Electronics

Electrics/Electronics Engine description

Operation Ambient conditions

3 Cold start aid

This engine is equipped with an electric

Initial commissioning Operation

Operation Initial commissioning

Order coolant corrosion protection agent

● Connect coolant outlet (2) and coolant inlet (1) to

Starting process Operation

If the engine fails to fire and the error lamp

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 (59).

Operation Operation monitoring

3 Instruments/symbols Designation Possible display: Measure

DPF function lamp Continuous light Initiate standstill regeneration 33

Engine warning lamp Continuous light Initiate standstill regeneration 33

Operation monitoring Operation

DEUTZ Electronic Display

Operation Exhaust gas aftertreatment system

3 Diesel oxidation catalytic converter

Passive regeneration Operation

Operation Passive regeneration

Passive regeneration Operation

Instruments/symbols Power reduction Regeneration

Regeneration lamp Engine warning lamp Ash lamp

Operation Stopping process

P 0 The control unit remains active for about

Avoid switching off from full load (coking/

Lubricating oil Operating media

Operating media Lubricating oil

4 DEUTZ lubricating oils DQC II

Fuel Operating media

Operating media Coolant

4 General ● pH value too low:

Horn With acoustic signal See fault table (59).

DPF function lamp Continuous light Initiate standstill regeneration 33

Engine warning lamp Continuous light Initiate standstill regeneration 33