Deutz TD/TCD 2012 L04/06 2V/m, TCD 2013 L04/06 2V/m Engine Operators Manual

Operation Manual TCD 2012 L04/06 4V TCD 2013 L04/06 4V OBJ_DOKU-12638-001.fm Seite 1 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Notes 2 © 2007 Notes This engine is defined exclusively for purpose according to the scope of delivery and built by the equipment manufacturer (use for the intended purpose). Any other use above and beyond this will be considered as misuse. The manufacturer will not accept any liability 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 repair conditions specified by the manufacturer. The engine should only be operated, serviced and repaired by personnel trained in its use and the hazards involved. The pertinent rules for the prevention of accidents 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 and hot components – on motors with external ignition (high electrical voltage). Contact must be avoided! Unauthorised engine modifications will invalidate any liability claims against the manufacturer for resultant damage. Equally, manipulations to the injection and control system can affect the engine's performance and the exhaust characteristics. Adherence to legislation on pollution can no longer be guaranteed under such conditions. Do not change the cooling air feed area to the blower of fan. An unobstructed cooling air supply must be guaranteed. The manufacturer will accept no liability for damage resulting from this. When carrying out maintenance work on the engine, the use of DEUTZ original parts is pre- scribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the war- ranty! Maintenance/cleaning work on the engine may only be carried out when the engine is not running and has cooled down. When doing this, make sure that the electrical system is switched off (remove ignition key). The specifications for accident prevention with electrical systems (e.g. VDE-0100/-0101/-0104/- 0105 Electrical protective measures against dan- gerous contact voltages) must be observed. Cover all electrical components tightly when cleaning with liquids. Do not work on the fuel system while the engine is running - Danger to life! Wait for the pressure to drop after the engine has come to a standstill (in engines with DEUTZ Common Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure - Danger to life! During the first trial run do not stand in the danger area of the engine. Danger due to high pressure in case of leaks - Danger to life! – In case of leaks immediately contact work- shop. – When working on the fuel system, make sure that the engine is not started inadvertently during repairs - Danger to life! OBJ_DOKU-12638-001.fm Seite 2 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Foreword © 2007 3 Dear customer, Congratulations on the purchase of your DEUTZ engine. DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. Consequently, a wide range of variants is offered to meet the requirements of specific cases. The engine is equipped accordingly for the particular installation situation, i.e. not all the components de- scribed in the operating manual are installed in your engine. We have endeavoured to highlight any differences 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- able to everyone involved in the operation, maintenance and repair of the engine and that they have understood the contents. If you have any queries, please contact us, we'll be happy to advise you. Sincerely, DEUTZ AG Engine serial number Please enter the engine serial number here. This will simplify the handling of customer service, repair and spare parts queries. Notes We reserve the right to make technical changes to the descriptions and data in this operating manual in the interest of further development of the engines. This document may only be reprinted and repro- duced, even in part, with our express permission. Order number 0312 3536 en OBJ_DOKU-12638-001.fm Seite 3 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Contents 4 © 2007 Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Foreword. . . . . . . . . . . . . . . . . . . . . 3 1 General. . . . . . . . . . . . . . . . . . . . 5 2 Engine description . . . . . . . . . . . . . 7 Type . . . . . . . . . . . . . . . . . . . . . 7 Engine illustration. . . . . . . . . . . . . . . 9 Lubricating oil schematic . . . . . . . . . . .19 Fuel schematic . . . . . . . . . . . . . . . .20 Coolant schematic . . . . . . . . . . . . . .21 Exhaust gas recirculation . . . . . . . . . . .23 Electrics/Electronics . . . . . . . . . . . . .24 3 Operation . . . . . . . . . . . . . . . . . .26 Ambient conditions . . . . . . . . . . . . . .26 Commissioning . . . . . . . . . . . . . . . .27 Start procedure . . . . . . . . . . . . . . . .29 Operation monitoring . . . . . . . . . . . . .31 Stop procedure . . . . . . . . . . . . . . . .33 4 Operating media. . . . . . . . . . . . . . .34 Lubricating oil . . . . . . . . . . . . . . . . .34 Fuels . . . . . . . . . . . . . . . . . . . . .36 Coolant . . . . . . . . . . . . . . . . . . . .37 5 Maintenance . . . . . . . . . . . . . . . . .38 Maintenance schedule . . . . . . . . . . . .38 6 Service and maintenance . . . . . . . . . .41 Lubricating oil system. . . . . . . . . . . . .41 Fuel system. . . . . . . . . . . . . . . . . .43 Cooling system . . . . . . . . . . . . . . . .47 Engine cleaning. . . . . . . . . . . . . . . .49 Suction system . . . . . . . . . . . . . . . .50 Belt drives . . . . . . . . . . . . . . . . . .53 Setting work . . . . . . . . . . . . . . . . .55 Electrical system . . . . . . . . . . . . . . .60 7 Faults. . . . . . . . . . . . . . . . . . . . .62 Fault table . . . . . . . . . . . . . . . . . .62 Engine management . . . . . . . . . . . . .65 8 Transport and storage . . . . . . . . . . .67 Transport . . . . . . . . . . . . . . . . . . .67 Protecting the engine against corrosion . . .68 9 Technical data . . . . . . . . . . . . . . . .70 Engine and setting data . . . . . . . . . . .70 OBJ_DOKU-12638-001.fm Seite 4 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

General © 2007 5 1 DEUTZ diesel engines DEUTZ diesel engines are the product of years of re- search and development. Profound know-how com- bined with high quality requirements are the guarantee for the production of engines with a long life, high reliability levels and low fuel consumption. Obviously the high requirements for the protection of the environment are also met. Safety precautions when the engine is running Maintenance work or repairs may only be performed on the shut-down engine. Make sure that the engine cannot be started inadvertently - Danger of accident! When the work is complete, be sure to refit any pan- els and guards that have been removed. Observe industrial safety regulations when running the engine in an enclosed space or underground. When working on the running engine, work clothing must be close fitting. Never fill the fuel tank while the engine is running. Service and Maintenance Service and maintenance are also decisive for whether the engine satisfactorily meets the set demands. Recommended service intervals must therefore be observed and service and maintenance work must be carried out conscientiously. Special care should be taken under abnormally de- manding operating conditions. Original DEUTZ parts Original DEUTZ parts are subject to the same strict quality demands as the DEUTZ engines. Further de- velopments for improving the engines are also intro- duced in the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured according to the state-of-the-art can guarantee perfect functioning and high reliability. DEUTZ Xchange components DEUTZ replacement parts are a low-cost alternative. Of course, the quality standards here are just as high as for new parts. DEUTZ replacement parts are equal to the original DEUTZ parts in function and reliability. Asbestos The gaskets used in this engine contain no asbestos. 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 satisfaction of our customers. We are therefore represented world- wide by a network of service branches. The DEUTZ name does not merely stand for engines that are the products of extensive development work, DEUTZ also stands for complete service pack- ages that ensure optimum operation of our engines, and for customer services operations that you can count on. Please contact your service partner in case of mal- functions and sare parts inquiries. Our specially trained personnel will ensure fast, professional repairs using original DEUTZ spare parts in case of damage. The DEUTZ home page gives you a continuously up- to-date overview of the service partners in your vicin- ity with notes on product responsibilities and services. Or you can use another fast, convenient way via the Internet under www.deutzshop.de. The DEUTZ P@rts Online parts catalogue gives you a direct contact to your nearest local service partner. Masthead DEUTZ AG Ottostraße 1 51149 Cologne Telephone:+49 (221) 822-0 Fax: +49 (221) 822-5850 www.deutz.com E-mail: info@deutz.com California Proposition 65 Warning Diesel engines and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. OBJ_DOKU-12638-001.fm Seite 5 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

General 6 © 2007 1 Danger Caution Notes This symbol is used for all safety instructions which, if not observed, present a direct 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 regulations for safety and the prevention of accidents" must be observed. 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. This symbol accompanies notes of a general kind. OBJ_DOKU-12638-001.fm Seite 6 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Type Engine description © 2007 7 2 Rating plate The engine type A, engine number B and the power data are stamped on the rating plate. The engine type and number must be stated when purchasing spare parts. Location of the rating plate The rating plate C is mounted on the cylinder head cover or crankcase. OBJ_DOKU-12638-001.fm Seite 7 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Engine description Type 8 © 2007 2 Rating plate Or the C rating plate is fixed sideways on the flywheel side Engine serial number The engine number is stamped onto the crankcase (arrow) and onto the rating plate. Cylinder numbering Cylinder arrangement The cylinders are counted consecutively starting from flywheel (1). Direction of rotation Looking at the power transmission side. rotating to the left: counter-clockwise. Engine sides Looking at the power transmission side. OBJ_DOKU-12638-001.fm Seite 8 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Engine illustration Engine description © 2007 9 2 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 14 18 19 20 21 22 2 17 TCD 2013 L04 4V engine, view from right (example) 1 Cylinder head cover 2 Transport device 3 Heating flange 4 Cab heater connection 5 Combustion air inlet 6 Connection from air filter 7 Cumbustion air outlet to the charge air cooler 8 Coolant outlet 9 Deflection pulley 10 Belt pulley on crankshaft 11 Tension pulley 12 Lubricating oil sump 13 Lubricating oil drain plug 14 Coolant inlet 15 Generator 16 Lube oil cooler 17 Lubricating oil filter 18 Engine control unit 19 Fuel filter 20 Rail with pressure reducing valve and pressure sensor 21 Crankcase ventilation (open system) 22 Lubricating oil filling OBJ_DOKU-12638-001.fm Seite 9 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Engine description Engine illustration 10 © 2007 2 1 2 3 5 6 7 8 9 10 4 TCD 2013 L04 4V engine, view from left (example) 1 Charge air temperature/pressure transmitter 2 Exhaust manifold line 3 Fuel supply pump 4 Transport device 5 Gear connection (SAE housing) 6 Starter cover 7 Lubricating oil return line from the exhaust turbocharger 8 Cumbustion air outlet to the charge air cooler 9 Exhaust gas outlet of the turbocharger 10 Shield (thermal protection) OBJ_DOKU-12638-001.fm Seite 10 Mittwoch, 22. August 2007 9:25 09 Downloaded from www.Manualslib.com manuals search engine

Deutz TD/TCD 2012 L04/06 2V/m, TCD 2013 L04/06 2V/m Engine Operators Manual

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