Deutz Engine TCD 2015 Operation Manual

Operation Manual TCD 2015 ProCarManuals.com

This engine is built exclusively for purpose according to the scope of delivery - defined by the equip- ment manufacturer (use for the intended purpose). Any use abo- ve and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk. Use for the intended purpose also includes ob- servance of the operating, maintenance and re- pair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with it and instructed in the dangers. The pertinent rules for the prevention of acci- dents and other generally recognised safety and industrial medicine rules must be observed. When the engine is running there is a danger of injury caused by: – rotating / hot parts – in engines with external ignition (high electri- cal voltage), avoid touching at all costs! Unauthorised modifications to the engine exclu- de manufacturer liability for resulting damages. Equally, manipulations to the injection and cont- rol system can affect the engine's performance and the exhaust characteristics. Compliance with legal environmental regulations will no lon- ger be guaranteed in this case. Do not modify, obstruct the cooling air flow area to the fan, unhindered cooling air supply must be guaranteed. The manufacturer will accept no liability for da- mages resulting from this. Only DEUTZ original parts may be used when carrying out maintenance/repair work on the en- gine. These have been designed especially for your engine and ensure a trouble-free operation. Failure to observe this will void the warranty ! Maintenance/cleaning work on the engine may only be carried out when the engine is not run- ning and has cooled down. When doing this, make sure that the electrical systems are switched off (remove ilgnition key). The specifications for accident prevention with electrical systems (e.g. -VDE-0100/-0101/-0104/ -0105 Electrical measures against dangerous touch voltages) must be observed. Cover all electrical components tightly when cleaning with liquids. Do not work on the fuel system when the engine is running - Danger to life. Wait for the pressure to drop after the engine co- mes to a standstill (in engines with DEUTZ Com- mon Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure Dan- ger to life. During the first trial run do not stand in the dan- ger area of the engine. In case of leaks danger due to high pressure - Danger to life. – Go to the workshop ilmmediately in case of leaks. – Make sure the engine is not started acciden- tally during repairs when working on the fuel system - Danger to life. Danger This symbol is used for all safety in- structions which, if not observed, pre- sent a direct danger to life and limb for the person involved. Observe these carefully. Also pass on the safety in- structions to your operating personnel. Furthermore, the legislation for "gene- ral regulations for safety and the pre- vention of accidents" must be observed. Caution This symbol indicates a danger to the component / engine. The appropriate instructions must be followed otherwi- se the component / engine may be de- stroyed. ProCarManuals.com

Operation Manual TCD 2015 3 Foreword Dear customer, Congratulations on your purchase of this DEUTZ engine. The DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. A wide range of variants ensures that the respective requirements are met. The engine is equipped according to the instal- lation case you have specified, i.e. not all the parts described in this instruction manual are installed in your engine. We have done our best to highlight the diffe- rences so that you can easily find the operating and maintenance instructions relevant to your engine. Please make sure that this instruction manual is available to everyone involved in the opera- tion, maintenance and repair of the engine and that they have understood the contents. We will be glad to answer any inquiries you may have. Your DEUTZ AG. Engine number Please enter the engine number here.( 6) This will simplify the handling of customer ser- vice, repair and spare parts queries. Note Illustrations and data in this instruction manual are subject to technical changes in the course of further development of the engine. Reprinting and reproduction of any kind, even in part, require our express permission. Order number 0312 3412 en ProCarManuals.com

Contents 4 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Engine description . . . . . . . . . . . . . . . . 6 2.1 Engine type. . . . . . . . . . . . . . . . . . . . . . 6 2.2 Engine diagram . . . . . . . . . . . . . . . . . . 7 2.3 Lubricating oil circuit . . . . . . . . . . . . . . 11 2.4 Fuel circuit . . . . . . . . . . . . . . . . . . . . . 12 2.5 Coolant circuit . . . . . . . . . . . . . . . . . . . 13 2.6 Electrics . . . . . . . . . . . . . . . . . . . . . . . 14 3 Operation . . . . . . . . . . . . . . . . . . . . . . . 15 3.1 Ambient conditions . . . . . . . . . . . . . . . 15 3.2 Initial commissioning . . . . . . . . . . . . . 16 3.3 Start process . . . . . . . . . . . . . . . . . . . 18 3.4 Operation monitoring . . . . . . . . . . . . . 19 3.5 Stop process. . . . . . . . . . . . . . . . . . . . 21 4 Consumables . . . . . . . . . . . . . . . . . . . . 22 4.1 Lubricating oil . . . . . . . . . . . . . . . . . . . 22 4.2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . 25 5 Maintenance . . . . . . . . . . . . . . . . . . . . . 27 5.1 Maintenance schedule . . . . . . . . . . . . 27 6 Care and maintenance work . . . . . . . . 29 6.1 Lubricating oil system . . . . . . . . . . . . 29 6.2 Fuel system . . . . . . . . . . . . . . . . . . . . 31 6.3 Cooling system . . . . . . . . . . . . . . . . . . 34 6.4 Engine cleaning . . . . . . . . . . . . . . . . . 36 6.5 Intake system . . . . . . . . . . . . . . . . . . . 37 6.6 Belt drives . . . . . . . . . . . . . . . . . . . . . . 39 6.7 Adjustments . . . . . . . . . . . . . . . . . . . . 40 6.8 Electrical system . . . . . . . . . . . . . . . . 42 7 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.1 Fault table . . . . . . . . . . . . . . . . . . . . . 44 7.2 Engine management . . . . . . . . . . . . . 46 8 Transport and storing . . . . . . . . . . . . 48 8.1 Engine transport . . . . . . . . . . . . . . . . 48 8.2 Preservation. . . . . . . . . . . . . . . . . . . . 49 9 Technical data . . . . . . . . . . . . . . . . . . . 51 9.1 Technical data . . . . . . . . . . . . . . . . . . 51 ProCarManuals.com

1 General 5 DEUTZ diesel engines are the product of years of research and deve- lopment. The profound expertise gained th- rough this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high relia- bility and low fuel consumption. Naturally the high requirements for protection of the environ- ment are also met. Safety precautions when the engine is running Only carry out maintenance work or repairs with the engine switched off. Ensure that the engine cannot be started unintentionally - dan- ger of accidents! Re-install any removed protective equipment upon completion of the work. Observe industrial safety regulations when operating the engine in enclosed spaces or un- derground. When working on the running engine, work clo- thing must be close fitting. Only re-fuel with the engine switched off. Maintenance and care are decisive for whether the engine satisfacto- rily meets the set demands. Compliance with the prescribed maintenance times and the ca- reful execution of maintenance and care work are therefore essential. Difficult operating conditions deviating from normal operation must be observed especially. Original DEUTZ parts are subject to the same strict quality require- ments as the DEUTZ engines. Further deve- lopments for the improvement of the engines are also introduced for the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured according to the latest state of knowledge will guarantee perfect functioning and high reliability. DEUTZ Xchange components DEUTZ Xchange components are a low-cost alternative. The same high quality standards as for new parts apply here of course. DEUTZ Xchange components are equivalent to the ori- ginal DEUTZ parts in function and reliability. Asbestos Gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair work. Service We want to preserve the high performance of our engines and with it the confidence and sa- tisfaction of our customers. Therefore we are represented by a network of service branches world-wide. The name DEUTZ stands not only for an engi- ne which is the result of sophisticated develop- ment work, DEUTZ Parts catalogue also stands for a complete service package which guarantees the optimum operation of our engi- nes and for a customer service on which you can rely. Contact one of our responsible service repre- sentatives in case of operation malfunctions and spare parts inquiries. Our trained specia- list personnel ensures fast, professional re- pairs using original parts in the event of damage. The DEUTZ homepage with references to pro- duct responsibilities and services always gives you an up-to-date overview of the DEUTZ part- ners in your area. Or use the fast, comfortable route via the Internet under www.deutz- shop.de. With the DEUTZ P@rts OnlineParts- Catalogue you have direct contact to the nearest local DEUTZ Service Station. DEUTZ AG Deutz-Mülheimer Str. 147-149 D-51057 Köln Phone: 0049-221-822-0 Fax: 0049-221-822-5304 Telex:8812-0 khd d http://www.deutz.com ProCarManuals.com

Engine description 2.1 Engine type 6 2 Company plate The type A, the engine number B and the per- formance data are stamped on the company plate. The engine type and number must be stated when purchasing spare parts. Position of the company plate and engine number The company plate C and engine number D are fixed or stamped on the crankcase. General definitions Cylinder arrangement, engine sides and direction of rotation Cylinder arrangement The cylinders are counted consecutively, star- ting from the flywheel1. Direction of rotation Looking onto drive side left-hand rotation: counter-clockwise (see example) Engine sides Looking at the power transmission side. left, right. ProCarManuals.com

2 2.2 Engine diagram Engine description 7 Example: TCD2015 V08 standard, industrial and vehicle engine, right side 1. Crankcase venting 2. Connection to coolant heat exchanger 3. Charge air duct 4. Coolant pump 5. Connection from coolant heat exchanger 6. Vibration damper / V-belt pulley 7. Lubricating oil tray 8. Generator 9. Oil drain plug 10.Fuel supply pump 11.Connection from charge air cooler left (optional: right) 12.Connection to charge air cooler 13.Cylinder head cover 14.Transport bracket 15.Exhaust manifold 16.Connection from air filter 17.Turbocharger 18.Connection to exhaust silencer ProCarManuals.com

Engine description 2.2 Engine diagram 8 2 Example: TCD2015 V08 standard, industrial and vehicle engine, left side 19.Injection pump (plug-in pump) 20.Gear connection (SAE) 21.Flywheel 22.Starter 23.Lubrricating oil filter cartridge 24.High pressure pipe 25.Lubricating oil cooler ProCarManuals.com

2 2.2 Engine diagram Engine description 9 Example: TCD2015 V06 railway engine, right side 1. Crankcase venting 2. Connection to coolant heat exchanger 3. Spark plug 4. Connection from the charge air cooler 5. Connection to charge air cooler 6. Connection from coolant heat exchanger 7. Lubrricating oil filter cartridge 8. Coolant pump 9. Connection of separate lubricating oil tank 10.Connection to separate lubricating oil tank 11.Vibration damper / V-belt pulley 12.Generator 13.Engine rating plate (company plate) 14.Exhaust manifold 15.Connection to the EMR3 system 16.Connection to the MVS system 17.Connection from air filter 18.Cylinder head cover 19.Connection to exhaust silencer 20.Turbocharger 21.Charge air suction pipe 22.Transport device ProCarManuals.com

Engine description 2.2 Engine diagram 10 2 Example: TCD2015 V06 railway engine, left side 23.Auxiliary drive 24.Engine mounting 25.Gear connection (SAE) 26.Flywheel 27.Free auxiliary drive 28.Crankcase vent pipe 29.Lubricating oil cooler 30.Injection pump (plug-in pump) 31.High pressure pipe ProCarManuals.com