DZ D 2011 PDF

OBJ_DOKU-15294-001.fm Seite 1 Donnerstag, 28.
Februar 2008 9:58 09
Operation Manual
D/TD/TCD 2011
OBJ_DOKU-15294-001.fm Seite 2 Donnerstag, 28. Februar 2008 9:58 09
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
z This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
z Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. z Do not work on the fuel system while the engine
z When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
z Unauthorised engine modifications will invalidate pressure - Danger to life!
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
z Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
z Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
z When carrying out maintenance work on the en-
2 © 2008
Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail-
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG
© 2008 3
Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Suction system . . . . . . . . . . . . . . . . 47
Foreword. . . . . . . . . . . . . . . . . . . . . 3 Belt drives . . . . . . . . . . . . . . . . . . 49
1 General. . . . . . . . . . . . . . . . . . . . 5 Setting work . . . . . . . . . . . . . . . . . 51
2 Engine description . . . . . . . . . . . . . 7 Electrical system . . . . . . . . . . . . . . . 53
Type . . . . . . . . . . . . . . . . . . . . . 7 7 Faults. . . . . . . . . . . . . . . . . . . . . 55
Engine illustrations . . . . . . . . . . . . . . 9 Fault table . . . . . . . . . . . . . . . . . . 55
Lubricating oil schematic . . . . . . . . . . . 13 Engine management . . . . . . . . . . . . . 60
Fuel schematic . . . . . . . . . . . . . . . . 18 8 Transport and storage . . . . . . . . . . . 62
Coolant schematic . . . . . . . . . . . . . . 19 Transport . . . . . . . . . . . . . . . . . . . 62
Exhaust gas recirculation . . . . . . . . . . . 21 Protecting the engine against corrosion . . . 63
Electrics/Electronics . . . . . . . . . . . . . 23 9 Technical data . . . . . . . . . . . . . . . . 65
3 Operation . . . . . . . . . . . . . . . . . . 24 Engine and setting data . . . . . . . . . . . 65
Ambient conditions . . . . . . . . . . . . . . 24 Tools . . . . . . . . . . . . . . . . . . . . . 70
Initial commissioning . . . . . . . . . . . . . 25
Start procedure . . . . . . . . . . . . . . . . 27
Operation monitoring . . . . . . . . . . . . . 28
Stop procedure . . . . . . . . . . . . . . . . 30
4 Operating media. . . . . . . . . . . . . . . 31
Lubricating oil . . . . . . . . . . . . . . . . . 31
Fuel . . . . . . . . . . . . . . . . . . . . . . 33
Coolant . . . . . . . . . . . . . . . . . . . . 34
5 Maintenance . . . . . . . . . . . . . . . . . 35
Maintenance schedule . . . . . . . . . . . . 35
6 Care and maintenance work . . . . . . . . 38
Lubricating oil system. . . . . . . . . . . . . 38
Fuel system. . . . . . . . . . . . . . . . . . 40
Cooling system . . . . . . . . . . . . . . . . 44
Engine cleaning. . . . . . . . . . . . . . . . 46
4 © 2008
General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the
functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components
Obviously the high requirements for the protection of
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high California
Safety precautions when the engine is running as for new parts. DEUTZ replacement parts are Proposition 65 Warning
equal to the original DEUTZ parts in function and re- Diesel engines and some of its constituents are
Maintenance work or repairs may only be performed liability. known to the State of California to cause cancer,
on the shut-down engine. Make sure that the engine birth defects and other reproductive harm.
cannot be started inadvertently - Danger of acci- Asbestos
dent! Masthead
The gaskets used in this engine contain no asbestos.
After repair work: Check that all guards have been DEUTZ AG
Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from maintenance and repair work. Ottostraße 1
the engine.
51149 Köln
Observe industrial safety regulations when running Service
Germany
the engine in an enclosed space or underground. We want to preserve the high performance of our en-
gines, and with it the confidence and satisfaction of Phone: +49 (0) 221-822-0
When working on the running engine, work clothing
must be close fitting. our customers. We are therefore represented world- Fax: +49 (0) 221-822-5850
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 E-Mail: info@deutz.com
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-
© 2008 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 © 2008
Type Engine description

Engine type designation
C
2
This manual covers the following engine types
A B
D 2011 L02 i D 2011 L02 o D 2011 L04 w
D 2011 L03 i D 2011 L03 o TD 2011 L04 w
D 2011 L04 i D 2011 L04 o TCD 2011 L04 w Mot.-Typ Mot.-Nr.
TD 2011 L04 i TD 2011 L04 o
TCD
T Exhaust gas turbocharger R
DEUTZ AG
C Charge air cooler MADE IN GERMANY
D Diesel
2011 Rating plate Location of the rating plate

2011 Series The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cov-
data are stamped on the rating plate. er or the crankcase.
L02/L03/L04 The engine type and number must be stated when
L in series purchasing spare parts.
02 No. of cylinders
03 No. of cylinders
04 No. of cylinders
i/o/w
i oil-cooled (integrated cooler)
o oil-cooled
w water-cooled
© 2008 7
Engine description Type
2 left
D
XXXXXXX
right
1
Engine serial number Cylinder numbering Volume blocking

The engine number (D) is stamped onto the crank- Cylinder arrangement Unauthorised settings on the regulator will exclude
case (arrow) and onto the rating plate. The cylinders are counted consecutively starting the manufacturer from all liability for resulting dam-
from flywheel (1). age. The blocking screws are adequately protected
against this:
Direction of rotation
z With locking varnish in version: torque adjust-
Looking onto the flywheel. ment
rotating to the left: counter-clockwise. z With protective plastic capsule in version: with-
Engine sides out torque adjustment.
Looking onto the flywheel.
8 © 2008
Engine illustrations Engine description

D 2011 L03 i
View from right (example)
2
18 1 Cooling fan (with integrated generator)
2 Tension pulley
3 Toothed belt cover
17 4 V-belt (fan)
5 Stop lever
16 6 Speed adjusting lever
7 Lubricating oil drain plug
15 8 Lubricating oil sump
9 Lubricating oil dipstick
14 10 Connection possibility for cab heating
11 Exchangeable fuel filter
?
1 12 Lube oil replacement filter
13 13 Fuel supply pump with integrated screen filter
14 Lubricating oil filling
12 ?
2 15 Removable air guidance cowling (access to fuel
injectors)
?
3 16 Lube oil cooler
11 17 Cylinder head cover
18 Air intake pipe
?
4
10
?
5
9
8 ?
6
© 2008 9
Engine description Engine illustrations
2 D 2011 L03 i
View from left (example)
1 Fuel return to fuel tank
2 Flywheel
3 Starter
4 Exhaust manifold line
5 Air intake pipe
4
1
10 © 2008
Engine illustrations Engine description
21 1
TCD 2011 L04 w
View from right (example)
2
1 Crankcase breather
20 2 2 Coolant outlet to the cooler
3 Coolant pump
19 4 Generator
5 V-belts
3 6 Toothed belt cover
18
7 Lubricating oil filling
8 Lubricating oil sump
9 Lubricating oil pump
17 10 Lubricating oil drain plug
11 Speed adjusting lever
16 12 Lubricating oil dipstick
13 Fuel supply pump with integrated screen filter
14 Exchangeable fuel filter
15 Lube oil replacement filter
16 Stop lever
15 17 Lube oil cooler
18 Coolant inlet
14 4 19 Injection pump
20 Coolant return to thermostat
13 21 Cylinder head cover
5
12 6
11
10 8 7
9
© 2008 11
Engine description Engine illustrations
2 TCD 2011 L04 w

View from left (example)
1 Fuel return to fuel tank
2 Connections charge air cooler
3 Flywheel
8 4 Starter
5 Coolant inlet
1 6 Turbocharger
7 7 Exhaust manifold line
8 Charge air line
4 3
12 © 2008
Lubricating oil schematic Engine description

TD 2011 L04 i
(example)
2
Toil > 95°C
9
Toil < 95°C 3 Pressure limiting valve
4 Cylinder (lubricating oil-cooled)
5 The lubricating oil is used first to cool the engine.
Toil < 63°C 5 Cylinder head
15 4 6 Lubricating oil return from the cylinders
7 Lubricating oil collection pipe to the thermostat
Toil > 63°C 8 Thermostat
(engine cold) lubricating oil flow directly to the lu-
bricating oil filter
14 7 6 11 16 (engine warm) lubricating oil flow through the lu-
bricating oil cooler
9 Lube oil cooler
2 10 Lubricating oil filter
11 Main lube oil channel
3 12 Turbocharger
13 Pressure holding valve
1 bar
14 Connection possibility for cab heating
10 7 bar The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
by authorised qualified personnel.
1,7 bar 3 bar 15 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
0,3 bar
13 12 To achieve early adjustment of the fuel injection
1 in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
16 Hydraulic tappets
© 2008 13
Engine description Lubricating oil schematic
2 10
D 2011 L04 i
Exhaust gas recirculation
(example)
Toil> 95°C
11 8
Toil < 95°C 3 Pressure limiting valve
4 Cylinder (lubricating oil-cooled)
5 The lubricating oil is used first to cool the engine.
5 Cylinder head
16
4 6 Cooling valve housing (exhaust gas recircula-
Toil < 63°C
tion)
7 Lubricating oil return from the cylinders
Toil > 63°C 8 Rocker arm
9 Lubricating oil collection pipe to the thermostat
9 7 17 13 10 Thermostat
(engine cold) lubricating oil flow directly to the lu-
2
15 bricating oil filter
(engine warm) lubricating oil flow through the lu-
3 bricating oil cooler
11 Lube oil cooler
12
1 bar
12 Lubricating oil filter
7 bar
1,7 bar
14 14 Pressure holding valve
3 bar 15 Connection possibility for cab heating
0,3 bar
The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
1 by authorised qualified personnel.
16 Lubricating oil filter console with integrated
Pö 12/2004 pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
14 © 2008

17 Hydraulic tappets
2
© 2008 15
Engine description Lubricating oil schematic
2 10
TD 2011 L04 w
(example)
1 Lubricating oil sump
12 3 Pressure limiting valve
4 Lube oil cooler
Toil < 63°C 5 Lubricating oil filter
7 Lubricating oil pipe to the turbocharger
Toil > 63°C
8 Turbocharger
4 6 13 9 Lubricating oil return line from the exhaust turbo-
charger
10 Rocker arm
11 Pressure holding valve
2 12 Lubricating oil filter console with integrated
5 pet. When the engine is cold, lubricating
3 oil is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injection
7 in a cold start, the hydraulic tappets under the
7 bar
11 13 Hydraulic tappets
8
3 bar
9 1
16 © 2008
2
© 2008 17
Lubricating oil Operating media

General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
the engines in this operating manual:
4
the definition of the lube oil change intervals are not Recommended quality class
the lubricating oil to be used. The specific engine
essentially dependent on the lube oil quality (such as DEUTZ Others
performances which have increased constantly over
the incorporation of soot and other contaminations),
the last few years lead to an increased thermal load DQC II - 05 ACEA E3-96/E5-02;
the lube oil change interval when using synthetic
on the lubricating oil. The lubricating oil is also more API CH-4/CG-4; DHD-1
lube oils may not be increased in relation to the spec-
exposed to contamination due to reduced oil com- DQC III - 05 ACEA E4-99/E6-04
ifications of the lube oil change intervals.
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in DQC IV - 05 Please contact your DEUTZ partner
and recommendations described in this operating DEUTZ engines if they meet the requirements of this
manual in order not to shorten the life of the engine. operating manual. DEUTZ lubricating oils DQC II-05
Lubricating oils always consist of a base oil and an TLS - 15W40 D
Quality
additive package. The most important tasks of a lu- Container Order number:
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according
to their efficiency and quality class (DQC: DEUTZ 5 litre container 0101 6331
tion, neutralisation of acids from combustion
products, prevention of coke and soot deposits on Quality Class). It basically applies that: with increas- 20 litre container 0101 6332
the engine parts) are assumed by the additives. The ing quality class (DQC I, II, III, IV) the lubricating oils 209 litre barrel 0101 6333
properties of the base oil are also decisive for the are more efficient and higher quality. The appended
quality of the product, e.g. with regard to thermal quality class designation (- 02 / - 05) indicates in
DEUTZ lubricating oils DQC III-05
load capacity. which year the classification was made.
TLX - 10W40 FE
In principle, all engine oils of the same specification Lubricating oils according to other comparable spec-
Container Order number:
can be mixed. However, mixing of engine oils should ifications can be used as long as they meet DEUTZ
requirements. In regions in which none of these 5 litre container 0101 6335
be avoided because the worst properties of the mix-
ture are always dominant. qualities are available, please contact your responsi- 20 litre container 0101 6336
ble DEUTZ partner.
The lubricating oil quality has a considerable influ- 209 litre barrel 0101 6337
ence on the life, performance and thus also on the or see www.deutz.com >> SERVICE >> Operating
costs-effectiveness of the engine. It basically applies Media and Diagnosis >> Deutz Quality Class >> DEUTZ lubricating oils DQC IV-05 synthetic
that: The better the lubricating oil quality, the better DQC Release List (current edition)
these properties.
Minimum quality class 20 litre container 0101 7849
The lubricating oil viscosity describes the flow be-
haviour of the lubricating oil depending on the tem- DEUTZ Others 209 litre barrel 0101 7850
perature. The lubricating oil viscosity has no DQC I - 02 ACEA E2-96; API CF/CF-4
Lubricating oil change intervals
influence and effect on the lubricating oil quality. If the engine is operated with these lubricating oils,
the lub ricating oil change interval must be halved. z The intervals depend on:
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem- – lubricating oil quality
The following lubricating oils are recommended for
© 2008 31
Operating media Lubricating oil
4 – sulphur content in the fuel

– type of application of engine
Viscosity
The ambient temperature at the installation site or in
°C
z The lubricating oil change interval must be the application area of the engine is decisive for 45
halved if at least one of the following conditions choosing the right viscosity class. Too high a viscos-
applies: ity can lead to starting difficulties, too low a viscosity 40
– Constant ambient temperature below -10 °C can endanger the lubrication effect and cause a high
(14 °F) or lube oil temperature below 60 °C lubricating oil consumption. At ambient temperatures 35
(84 °F). below -40 °C, the lubricating oil must be pre-heated
– Sulphur content in the diesel fuel of 0.5-1 %. (e.g. by storing the vehicle or the machine in a hall). 30
In case of fuels containing more than 1% sul- The viscosity is classified according to SAE. Multi- 25
phur, contact your corresponding DEUTZ purpose lubricating oils should be used basically.
partner. Single-purpose lubricating oils can also be used in 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
– operation with bio-diesel fuel enclosed, heated spaces at temperatures >5 ° C.
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
z If the lubricating oil change intervals are not Depending on the ambient temperature we recom-
15
reached within a year, the oil should be changed mend the following common viscosity classes:
at least once a year. 10
The prescribed lubricating oil quality must 5
be observed when selecting the viscosity
class! 0
-5
-10
-15
-20
-25
-30
-35
-40
32 © 2008
Fuel Operating media

Permissible fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
4
proved: Only carry out mixing in the tank. Fill with
the appropriate amount of paraffin first,
z Diesel fuels then add the diesel fuel. Normal and high
– EN 590 grade fuels may not be mixed.
– ASTM D 975 1-D
– ASTM D 975 2-D At low ambient temperatures paraffin discharges can
lead to blockages in the fuel system and cause oper-
– NATO F-54
ating faults. Below 0 °C ambient temperature use
– JIS K2204 Grade 1 winter diesel (down to -20 °C) (filling stations provide
– JIS K2204 Grade 2 this in good time before the cold season starts).
z Below -20 °C paraffin should be added. The rel-
Use commercially available fuels with a sulphur con-
evant percentages are given in the adjacent dia-
tent below 0.5 %. The lubricating oil change intervals
gram.
must be halved at a higher sulphur content.
z Special diesel fuels can be used for arctic cli-
If other fuels are used which do not meet the require- mates to -44 °C. I Summer-grade diesel fuel
ments of the operating manual, the warranty will be II Winter-grade diesel fuel
voided. If it is necessary to use Summer diesel fuel below
0 °C, up to 30 % petroleum can be added according A Outdoor temperature
The certification measurements for compliance with
to the diagram opposite. B Percentage of paraffin to be added
the legal emission values are made with the test fu-
els specified in the laws. These correspond to the Usually a sufficient cold resistance can be achieved
diesel fuels in accordance with EN 590 and by adding a flow improver. Ask your DEUTZ partner.
ASTM D 975 described in the operation manual. No
emission values are guaranteed with the other fuels
described in this operation manual.
© 2008 33
Operating media Coolant
4 General z Total hardness too high:

Mixing with softened water (pH neutralized con-
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, densate or water softened by ion exchanger). Please contact your DEUTZ partner if the DEUTZ
even for a short time! z Total hardness or carbonate hardness too cooling system corrosion protection agent is not
low: available.
D/TD/TCD 2011 w Mixing with harder water (harder water is usually The cooling system must be monitored regularly.
available in the form of drinking water). This also includes checking the coolant system cor-
In liquid-cooled engines, the coolant must be condi-
tioned and monitored, otherwise the engine could be z Chlorides and/or sulphates too high: rosion protection agent concentration in addition to
damaged by: Mixing with softened water (pH neutralized con- checking the coolant level.
densate or water softened by ion exchanger).
z corrosion The cooling system corrosion protection agent con-
z cavitation Cooling system corrosion protection agent centration can be checked with conventional test in-
z freezing struments (e.g. refractometer).
Health damaging nitrous amines form
Water quality Cooling sys- Water percent- Cold protec-
when nitrite-based cooling system corro-
tem corrosion age tion up to
The right water quality is important for conditioning sion protection agents are mixed with
protection
the coolant. Clear, clean water within the following amine-based agents!
agent percent-
analysis values should always be used: age
Cooling system corrosion protection agents
Analysis values min max ASTM must be disposed of in an environmentally min. 35 % 65 % -22 °C
ph value 6,5 8,5 D 1293 friendly way. 40 % 60 % -28 °C
Chlorine (Cl) [mg/l] - 100 D 512 The conditioning of the coolant for liquid-cooled max. 45 % 55 % -35 °C
D 4327 DEUTZ compact engines is performed by mixing an At temperatures below -35 °C, please contact your
Sulphate (SO4) [mg/l] - 100 D 516 anti-freeze with corrosion protection inhibitors based responsible DEUTZ partner.
on ethylene glycol into the water.
Total hardness [mmol/l] 0,53 2,1 D 1126 It is possible to use other cooling system corrosion
(CaCO3) [mg/l] 53 213 DEUTZ cooling system corrosion protection protection agents (e.g. chemical corrosion protection
[°dGH] 3,0 12,0 - agent agents) in exceptional cases. Consult your DEUTZ
partner.
Specifications of the water quality are made by the Container Order number:
local water board. 5 litre container 0101 1490
The water must be conditioned if it deviates from the 20 litre container 0116 4160
analysis values. 210 litre barrel 1221 1500
z pH value too low:
This cooling system corrosion protection agent is
Addition of diluted sodium or potassium lye.
free from nitrite, amine and phosphate and is adapt-
Small trial mixtures are advisable.
34 © 2008
Maintenance schedule Maintenance

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule
D/TD/TCD 2011
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 D: 1.000 1) / TD/TCD: 500 1)
E40 Extended maintenance I 1000
2)
E50 Extended maintenance II Authorised specialists 3.000 / 5.000 3) / 6.000 4)
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to EPA certification
E60 Intermediate overhaul Authorised specialists 3.000
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (31).
Toothed belt change intervals recommended Engine application example:
values in op. h
2)
3,000 or max. 5 years Agricultural machinery; skid steer loader; wheel loader; high speed; impact load; extreme ambient tempera-
drilling machines; trench differs; joint cutters; excavators ture; high dust load
etc.
3)
5,000 or max. 5 years compressors; rollers; stackers; welding units; wheel medium to high variable speed; high ambient temper-
loaders small dumpers; skid steer loaders, etc. ature medium dust load
4)
6,000 or max. 5 years Electrical units 1500/1800 rpm; pump units with low low speed; medium ambient temperature low dust
speed; lifting platforms; cooling aggregates etc. load
© 2008 35
Maintenance Maintenance schedule
5 Maintenance measures
Stage Activity Measure Page

E10 The measures are listed in chapter 3. 25
E20 Check Lubricating oil level (if necessary top up) 38
D/TD/TCD 2011 w 26
Coolant level (top up if necessary)
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 48
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 31/38
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 39
Check TD/TCD: 51
Single checking and setting of the valve clearance if necessary at the first lubricating oil change
E40 Check Heating plugs
D/TD/TCD 2011 w 44
Coolant (additive concentration)
Battery and cable connectors 53
V-belts (retension or renew if necessary) 49
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Settings Valve clearance 51
Replace By-pass lubricating oil filter
Fuel filter cartridge 42
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 41/43
E50 Replace Toothed belt 35
E60 Replace Injection valve
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
36 © 2008

Stage
Every 2
Activity
Replace
Measure
V-belts
Page
49
5
years Heating plugs
D/TD/TCD 2011 w 34 44
Coolant
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 3538
© 2008 37
Care and maintenance work Lubricating oil system
6 Regulations for working on the lubricating oil

system OIL ?
z The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
essary.
Do not work when the engine is running!
Smoking and naked lights prohibited! Changing the lubricating oil
Be careful of hot lubricating oil. Danger of
scalding!
OIL z Warm up the engine (lubricating oil temperature
> 80 °C).
+80°C
+176°F z Ensure that the engine or vehicle is in a level po-
Pay attention to utmost cleanliness when sition.
working on the lubricating oil system. Clean z Switch off the engine.
the area around the components con- z Place a collecting receptacle underneath the
cerned carefully. Blow damp parts dry with
compressed air.
Observe the safety regulations and nation-
! lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
al specifications for handling lube oils. z Fit a new sealing ring to the lube oil drain screw,
Dispose of leaking lubricating oil and filter insert and tighten. (tightening torque 100 Nm).
elements properly. Do not allow used oil to Checking the lubricating oil level z Pour in lube oil.
seep away into the ground. – Quality/viscosity data.
Perform a trial run after all work. Pay atten- Low lubricating oil level and overfilling lead – Filling volume (65).
tion to tightness and lubricating oil pressure to engine damage. z Warm up the engine (lubricating oil temperature
and then check the engine oil level. The lubricating oil level may only be > 80 °C).
In case of fuels containing more than 1% checked with the engine in a horizontal po- z Ensure that the engine or vehicle is in a level po-
sulphur, contact your corresponding sition and switched off. sition.
DEUTZ partner. If the engine is warm, switch off the engine z Check lubricating oil level, if necessary top up.
and check the lubricating oil level after 5
minutes. If the engine is cold you can check
it immediately.

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

with a lint-free, clean cloth.
z Insert the lubricating oil dipstick as far as it will
go.
z Extract the lubricating oil dipstick and read off the
oil level.
38 © 2008
Lubricating oil system Care and maintenance work

6
Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 15-17 Nm.
tion! z Fasten clamps of the twist protection (optional).
z Remove clamps when twist protection mounted
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
© 2008 39
Care and maintenance work Fuel system
6 Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
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.
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.
40 © 2008
Fuel system Care and maintenance work

Vent the fuel system
z Pump in the direction of the arrow (3) until a
6
5 strong resistance is felt and pressure has built
up.
z The return line (5) must be filled.
4 ?
6
z Start the engine and run in idle or on low load. Air
is pressed through the return pipe 5) to the tank.
3 ?7
1
Fuel supply pump, sieve filter cartridge clean/
change
z Close fuel shutoff tap (with high-level tank) (sup-
ply (7)).
z Remove connection (4) to the fuel filter.
z Catch any escaping fuel.
z Loosen screw (1).
z Remove fuel screen (screw (1), cover and fuell
screen form one unit).
z Take the sealing ring (2) and clean it, renew
when damaged.
z Clean cover-fuel screen with fuel, renew de-
pending on the condition.
z Put the sealing ring (2) in position.
z Mount the cover-fuel filter with screw (1).
z Reinstall connection (4) to the fuel filter.
z Open fuel shutoff tap supply (7), start engine and
run in idle or on low load.
z Check for leaks after starting the engine.
© 2008 41
Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
z Remove clamps when twist protection mounted z Vent the fuel system.
(optional).
42 © 2008

with fuel.
z Assembly in clockwise direction.
bubbles.
z Catch any escaping fuel. 6
7 z Open the fuel shutoff tap and vent the system, z Tighten the venting screw (7).
see venting the fuel system.
5 1 z Start engine.
z Check for leaks after starting the engine. z Bring engine control to stop position.
z Position fuel collecting vessel below the con-
6 2 Change the fuel pre-filter insert stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
4 3
level tank). z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
z Place a vessel under the drain plug.
z Open the drain tap (4) and drain off the liquid. z Turn over the engine with starter (max. 20 Sec.)
z Unscrew the filter insert (2) together with the wa- until bubble-free fuel emerges at the constant-
ter collection vessel (3). pressure valve in the crankcase/filter housing.
z Unscrew the water collection vessel (3) from the z Screw in ventilation screws (tightening torque
Clean/change/vent the fuel pre-filter filter insert (2). 25-5 Nm) and constant-pressure valve.
– The special tool can be ordered under part z Bring engine control to the start position and
1 Fuel pre-filter holder
number 8192 (70). start.
2 Fuel filter insert
3 Water collection vessel z Clean the water collection vessel (3) and all the
4 Water drain tap existing sealing surfaces (6) with a brush and
5 Fuel pump diesel fuel.
6 Sealing surface z Oil the gaskets and sealing surfaces (6) of the
7 Venting screw new DEUTZ original filter insert (2) lightly or wet
with diesel fuel.
z Shut off the fuel supply to the engine (with high- z Screw the water collection vessel (3) to the filter
level tank). insert (2).
z Place a vessel under the drain plug. z Screw a new filter insert (2) with water collection
z Open the drain tap (4) and drain off the liquid. vessel (3) onto the filter carrier 1) (tightening
z Unscrew the filter insert (2) together with the wa- torque 17-18 Nm)
ter collection vessel (3). z Open the fuel supply to the engine.
z Empty emulsion in the water collection vessel (3) z Vent the fuel system.
and clean the vessel.
z Mount the filter insert (2) and water collection Vent the fuel pre-filter.
vessel (3). Wet the sealing surfaces (6) of the fil- z Loosen the venting screw (7) slightly.
ter insert (2) and the water collection vessel (3) z Operate the pump until fuel emerges without
© 2008 43
Lubricating oil Operating media

General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
the engines in this operating manual:
4
the definition of the lube oil change intervals are not Recommended quality class
the lubricating oil to be used. The specific engine
essentially dependent on the lube oil quality (such as DEUTZ Others
performances which have increased constantly over
the incorporation of soot and other contaminations),
the last few years lead to an increased thermal load DQC II - 05 ACEA E3-96/E5-02;
the lube oil change interval when using synthetic
on the lubricating oil. The lubricating oil is also more API CH-4/CG-4; DHD-1
lube oils may not be increased in relation to the spec-
exposed to contamination due to reduced oil com- DQC III - 05 ACEA E4-99/E6-04
ifications of the lube oil change intervals.
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in DQC IV - 05 Please contact your DEUTZ partner
and recommendations described in this operating DEUTZ engines if they meet the requirements of this
manual in order not to shorten the life of the engine. operating manual. DEUTZ lubricating oils DQC II-05
Lubricating oils always consist of a base oil and an TLS - 15W40 D
Quality
additive package. The most important tasks of a lu- Container Order number:
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according
to their efficiency and quality class (DQC: DEUTZ 5 litre container 0101 6331
tion, neutralisation of acids from combustion
products, prevention of coke and soot deposits on Quality Class). It basically applies that: with increas- 20 litre container 0101 6332
the engine parts) are assumed by the additives. The ing quality class (DQC I, II, III, IV) the lubricating oils 209 litre barrel 0101 6333
properties of the base oil are also decisive for the are more efficient and higher quality. The appended
quality of the product, e.g. with regard to thermal quality class designation (- 02 / - 05) indicates in
DEUTZ lubricating oils DQC III-05
load capacity. which year the classification was made.
TLX - 10W40 FE
In principle, all engine oils of the same specification Lubricating oils according to other comparable spec-
can be mixed. However, mixing of engine oils should ifications can be used as long as they meet DEUTZ
requirements. In regions in which none of these 5 litre container 0101 6335
be avoided because the worst properties of the mix-
ture are always dominant. qualities are available, please contact your responsi- 20 litre container 0101 6336
ble DEUTZ partner.
The lubricating oil quality has a considerable influ- 209 litre barrel 0101 6337
ence on the life, performance and thus also on the or see www.deutz.com >> SERVICE >> Operating
costs-effectiveness of the engine. It basically applies Media and Diagnosis >> Deutz Quality Class >> DEUTZ lubricating oils DQC IV-05 synthetic
that: The better the lubricating oil quality, the better DQC Release List (current edition)
these properties.
Minimum quality class 20 litre container 0101 7849
The lubricating oil viscosity describes the flow be-
haviour of the lubricating oil depending on the tem- DEUTZ Others 209 litre barrel 0101 7850
perature. The lubricating oil viscosity has no DQC I - 02 ACEA E2-96; API CF/CF-4
Lubricating oil change intervals
influence and effect on the lubricating oil quality. If the engine is operated with these lubricating oils,
the lub ricating oil change interval must be halved. z The intervals depend on:
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem- – lubricating oil quality
The following lubricating oils are recommended for
© 2008 31
Operating media Lubricating oil
4 – sulphur content in the fuel

– type of application of engine
Viscosity
The ambient temperature at the installation site or in
°C
z The lubricating oil change interval must be the application area of the engine is decisive for 45
halved if at least one of the following conditions choosing the right viscosity class. Too high a viscos-
applies: ity can lead to starting difficulties, too low a viscosity 40
– Constant ambient temperature below -10 °C can endanger the lubrication effect and cause a high
(14 °F) or lube oil temperature below 60 °C lubricating oil consumption. At ambient temperatures 35
(84 °F). below -40 °C, the lubricating oil must be pre-heated
– Sulphur content in the diesel fuel of 0.5-1 %. (e.g. by storing the vehicle or the machine in a hall). 30
In case of fuels containing more than 1% sul- The viscosity is classified according to SAE. Multi- 25
phur, contact your corresponding DEUTZ purpose lubricating oils should be used basically.
partner. Single-purpose lubricating oils can also be used in 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
– operation with bio-diesel fuel enclosed, heated spaces at temperatures >5 ° C.
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
z If the lubricating oil change intervals are not Depending on the ambient temperature we recom-
15
reached within a year, the oil should be changed mend the following common viscosity classes:
at least once a year. 10
The prescribed lubricating oil quality must 5
be observed when selecting the viscosity
class! 0
-5
-10
-15
-20
-25
-30
-35
-40
32 © 2008
Fuel Operating media

Permissible fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
4
proved: Only carry out mixing in the tank. Fill with
the appropriate amount of paraffin first,
z Diesel fuels then add the diesel fuel. Normal and high
– EN 590 grade fuels may not be mixed.
– ASTM D 975 1-D
– ASTM D 975 2-D At low ambient temperatures paraffin discharges can
lead to blockages in the fuel system and cause oper-
– NATO F-54
ating faults. Below 0 °C ambient temperature use
– JIS K2204 Grade 1 winter diesel (down to -20 °C) (filling stations provide
– JIS K2204 Grade 2 this in good time before the cold season starts).
z Below -20 °C paraffin should be added. The rel-
Use commercially available fuels with a sulphur con-
evant percentages are given in the adjacent dia-
tent below 0.5 %. The lubricating oil change intervals
gram.
must be halved at a higher sulphur content.
z Special diesel fuels can be used for arctic cli-
If other fuels are used which do not meet the require- mates to -44 °C. I Summer-grade diesel fuel
ments of the operating manual, the warranty will be II Winter-grade diesel fuel
voided. If it is necessary to use Summer diesel fuel below
0 °C, up to 30 % petroleum can be added according A Outdoor temperature
The certification measurements for compliance with
to the diagram opposite. B Percentage of paraffin to be added
the legal emission values are made with the test fu-
els specified in the laws. These correspond to the Usually a sufficient cold resistance can be achieved
diesel fuels in accordance with EN 590 and by adding a flow improver. Ask your DEUTZ partner.
ASTM D 975 described in the operation manual. No
emission values are guaranteed with the other fuels
described in this operation manual.
© 2008 33
Operating media Coolant
4 General z Total hardness too high:

Mixing with softened water (pH neutralized con-
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, densate or water softened by ion exchanger). Please contact your DEUTZ partner if the DEUTZ
even for a short time! z Total hardness or carbonate hardness too cooling system corrosion protection agent is not
low: available.
D/TD/TCD 2011 w Mixing with harder water (harder water is usually The cooling system must be monitored regularly.
available in the form of drinking water). This also includes checking the coolant system cor-
In liquid-cooled engines, the coolant must be condi-
tioned and monitored, otherwise the engine could be z Chlorides and/or sulphates too high: rosion protection agent concentration in addition to
damaged by: Mixing with softened water (pH neutralized con- checking the coolant level.
densate or water softened by ion exchanger).
z corrosion The cooling system corrosion protection agent con-
z cavitation Cooling system corrosion protection agent centration can be checked with conventional test in-
z freezing struments (e.g. refractometer).
Health damaging nitrous amines form
Water quality Cooling sys- Water percent- Cold protec-
when nitrite-based cooling system corro-
tem corrosion age tion up to
The right water quality is important for conditioning sion protection agents are mixed with
protection
the coolant. Clear, clean water within the following amine-based agents!
agent percent-
analysis values should always be used: age
Cooling system corrosion protection agents
Analysis values min max ASTM must be disposed of in an environmentally min. 35 % 65 % -22 °C
ph value 6,5 8,5 D 1293 friendly way. 40 % 60 % -28 °C
Chlorine (Cl) [mg/l] - 100 D 512 The conditioning of the coolant for liquid-cooled max. 45 % 55 % -35 °C
D 4327 DEUTZ compact engines is performed by mixing an At temperatures below -35 °C, please contact your
Sulphate (SO4) [mg/l] - 100 D 516 anti-freeze with corrosion protection inhibitors based responsible DEUTZ partner.
on ethylene glycol into the water.
Total hardness [mmol/l] 0,53 2,1 D 1126 It is possible to use other cooling system corrosion
(CaCO3) [mg/l] 53 213 DEUTZ cooling system corrosion protection protection agents (e.g. chemical corrosion protection
[°dGH] 3,0 12,0 - agent agents) in exceptional cases. Consult your DEUTZ
partner.
Specifications of the water quality are made by the Container Order number:
local water board. 5 litre container 0101 1490
The water must be conditioned if it deviates from the 20 litre container 0116 4160
analysis values. 210 litre barrel 1221 1500
z pH value too low:
This cooling system corrosion protection agent is
Addition of diluted sodium or potassium lye.
free from nitrite, amine and phosphate and is adapt-
Small trial mixtures are advisable.
34 © 2008

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule
D/TD/TCD 2011
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 D: 1.000 1) / TD/TCD: 500 1)
E40 Extended maintenance I 1000
2)
E50 Extended maintenance II Authorised specialists 3.000 / 5.000 3) / 6.000 4)
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to EPA certification
E60 Intermediate overhaul Authorised specialists 3.000
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (31).
Toothed belt change intervals recommended Engine application example:
values in op. h
2)
3,000 or max. 5 years Agricultural machinery; skid steer loader; wheel loader; high speed; impact load; extreme ambient tempera-
drilling machines; trench differs; joint cutters; excavators ture; high dust load
etc.
3)
5,000 or max. 5 years compressors; rollers; stackers; welding units; wheel medium to high variable speed; high ambient temper-
loaders small dumpers; skid steer loaders, etc. ature medium dust load
4)
6,000 or max. 5 years Electrical units 1500/1800 rpm; pump units with low low speed; medium ambient temperature low dust
speed; lifting platforms; cooling aggregates etc. load
© 2008 35
Maintenance Maintenance schedule
5 Maintenance measures
Stage Activity Measure Page

E10 The measures are listed in chapter 3. 25
E20 Check Lubricating oil level (if necessary top up) 38
D/TD/TCD 2011 w 26
Coolant level (top up if necessary)
Engine tightness (visual inspection for leaks)
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 31/38
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 39
Check TD/TCD: 51
Single checking and setting of the valve clearance if necessary at the first lubricating oil change
E40 Check Heating plugs
D/TD/TCD 2011 w 44
Coolant (additive concentration)
Battery and cable connectors 53
V-belts (retension or renew if necessary) 49
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Settings Valve clearance 51
Replace By-pass lubricating oil filter
Fuel filter cartridge 42
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 41/43
E50 Replace Toothed belt 35
E60 Replace Injection valve
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
36 © 2008

Stage
Every 2
Activity
Replace
Measure
V-belts
Page
49
5
years Heating plugs
D/TD/TCD 2011 w 34 44
Coolant
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 3538
© 2008 37
Care and maintenance work Lubricating oil system
6 Regulations for working on the lubricating oil

system OIL ?
z The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
essary.
Do not work when the engine is running!
Smoking and naked lights prohibited! Changing the lubricating oil
scalding!
OIL z Warm up the engine (lubricating oil temperature
> 80 °C).
+80°C
+176°F z Ensure that the engine or vehicle is in a level po-
Pay attention to utmost cleanliness when sition.
working on the lubricating oil system. Clean z Switch off the engine.
the area around the components con- z Place a collecting receptacle underneath the
cerned carefully. Blow damp parts dry with
compressed air.
! lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
al specifications for handling lube oils. z Fit a new sealing ring to the lube oil drain screw,
Dispose of leaking lubricating oil and filter insert and tighten. (tightening torque 100 Nm).
elements properly. Do not allow used oil to Checking the lubricating oil level z Pour in lube oil.
seep away into the ground. – Quality/viscosity data.
Perform a trial run after all work. Pay atten- Low lubricating oil level and overfilling lead – Filling volume (65).
tion to tightness and lubricating oil pressure to engine damage. z Warm up the engine (lubricating oil temperature
and then check the engine oil level. The lubricating oil level may only be > 80 °C).
In case of fuels containing more than 1% checked with the engine in a horizontal po- z Ensure that the engine or vehicle is in a level po-
sulphur, contact your corresponding sition and switched off. sition.
DEUTZ partner. If the engine is warm, switch off the engine z Check lubricating oil level, if necessary top up.
and check the lubricating oil level after 5
minutes. If the engine is cold you can check
it immediately.

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

z Insert the lubricating oil dipstick as far as it will
go.
z Extract the lubricating oil dipstick and read off the
oil level.
38 © 2008
Lubricating oil system Care and maintenance work

6
Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
z Remove clamps when twist protection mounted
(optional).
z Collect draining lubricating oil
© 2008 39
6 Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
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.
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.
40 © 2008

z Pump in the direction of the arrow (3) until a
6
5 strong resistance is felt and pressure has built
up.
z The return line (5) must be filled.
4 ?
6
z Start the engine and run in idle or on low load. Air
is pressed through the return pipe 5) to the tank.
3 ?7
1
Fuel supply pump, sieve filter cartridge clean/
change
z Close fuel shutoff tap (with high-level tank) (sup-
ply (7)).
z Remove connection (4) to the fuel filter.
z Loosen screw (1).
z Remove fuel screen (screw (1), cover and fuell
screen form one unit).
z Take the sealing ring (2) and clean it, renew
when damaged.
z Clean cover-fuel screen with fuel, renew de-
pending on the condition.
z Put the sealing ring (2) in position.
z Mount the cover-fuel filter with screw (1).
z Reinstall connection (4) to the fuel filter.
z Open fuel shutoff tap supply (7), start engine and
run in idle or on low load.
© 2008 41
Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
z Remove clamps when twist protection mounted z Vent the fuel system.
(optional).
42 © 2008

with fuel.
z Assembly in clockwise direction.
bubbles.
z Catch any escaping fuel. 6
7 z Open the fuel shutoff tap and vent the system, z Tighten the venting screw (7).
see venting the fuel system.
5 1 z Start engine.
z Check for leaks after starting the engine. z Bring engine control to stop position.
z Position fuel collecting vessel below the con-
6 2 Change the fuel pre-filter insert stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
4 3
level tank). z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
z Place a vessel under the drain plug.
z Open the drain tap (4) and drain off the liquid. z Turn over the engine with starter (max. 20 Sec.)
z Unscrew the filter insert (2) together with the wa- until bubble-free fuel emerges at the constant-
ter collection vessel (3). pressure valve in the crankcase/filter housing.
z Unscrew the water collection vessel (3) from the z Screw in ventilation screws (tightening torque
Clean/change/vent the fuel pre-filter filter insert (2). 25-5 Nm) and constant-pressure valve.
– The special tool can be ordered under part z Bring engine control to the start position and
1 Fuel pre-filter holder
number 8192 (70). start.
2 Fuel filter insert
3 Water collection vessel z Clean the water collection vessel (3) and all the
4 Water drain tap existing sealing surfaces (6) with a brush and
5 Fuel pump diesel fuel.
6 Sealing surface z Oil the gaskets and sealing surfaces (6) of the
7 Venting screw new DEUTZ original filter insert (2) lightly or wet
with diesel fuel.
z Shut off the fuel supply to the engine (with high- z Screw the water collection vessel (3) to the filter
level tank). insert (2).
z Place a vessel under the drain plug. z Screw a new filter insert (2) with water collection
z Open the drain tap (4) and drain off the liquid. vessel (3) onto the filter carrier 1) (tightening
z Unscrew the filter insert (2) together with the wa- torque 17-18 Nm)
ter collection vessel (3). z Open the fuel supply to the engine.
z Empty emulsion in the water collection vessel (3) z Vent the fuel system.
and clean the vessel.
z Mount the filter insert (2) and water collection Vent the fuel pre-filter.
vessel (3). Wet the sealing surfaces (6) of the fil- z Loosen the venting screw (7) slightly.
ter insert (2) and the water collection vessel (3) z Operate the pump until fuel emerges without
© 2008 43
Care and maintenance work Cooling system
6 Specifications when working on the cooling sys-

tem
D/TD/TCD 2011 w
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- 1
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
not allow them to seep into the ground. Check coolant additive concentration Emptying the cooling system
Order coolant corrosion protection agent D/TD/TCD 2011 w D/TD/TCD 2011 w
from your DEUTZ partner.
z Open the cooling system cap (1) carefully. z Open cooler locking cap carefully.
Never operate the engine without coolant,
even for a short time! z Check the coolant aditive concentration in the z Place a collection tray underneath the coolant
cooler/compensation tank (2) with a convention- connection (1).
Checking the coolant level with an external cool- al antifreeze measuring device (1) (e.g. hydrom- z Drain coolant.
er eter, refractormeter). z Reconnect and tighten the coolant connection
D/TD/TCD 2011 w z Necessary coolant additive concentration Cool- (1).
ant mixing ratio (34). z If the locking screw is not accessible, the drain-
z Fill in new coolant and vent the system according
You can order the appropriate test instrument from age can be carried out at the engine oil cooler
to the specifications of the cooling system manu-
your DEUTZ partner under order number 1824. (coolant duct).
facturer.
z Close cooler locking cap.
z Open the cooling system cap (1) carefully.
z The coolant level must always be between the
MIN and MAX marks of the compensation tank!
Fill up to the MAX mark if necessary.
44 © 2008
Cooling system Care and maintenance work

tion tank if necessary.
6
Fill and ventilate cooling system
Danger of scalding from hot coolant!

Cooling system under pressure! Only open
the cap when cool!
D/TD/TCD 2011 w
z Open the cooling system cap (1) carefully.
z Loosen the cooler venting screw if necessary.
z Fill coolant up to the max. mark or filling limit.
z Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
z Close the cooler venting screw.
z Close cooler locking cap.
z Run engine up to operating temperature (open-
ing temperature of the thermostat).
z Switch off the engine.
z Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
© 2008 45
Care and maintenance work Engine cleaning
6 Cleaning work Cleaning with cold cleaner

z Spray the engine with cold cleaner and leave it
For all cleaning work, make sure that no for about 10 minutes to take effect.
parts are damaged (e.g. bent cooler mesh).
z Spray the engine clean with a high pressure wa-
Cover electrical/electronic parts and con-
ter jet.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do z Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
Only carry out cleaning work on the engine z Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam temper-
Remove the engine cover and cooling air ature 90 °C, distance at least 1m).
cover if available and remount after clean- z Warm up the engine so that the water residues
ing. evaporate.
z Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.
The following causes of soiling make it necessary to
clean the engine:
z High dust content in the air.
z Chaff and chopped straw in the area of the en-
gine.
z Coolant leaks
z Lubricating oil leakage
z Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
z Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
46 © 2008
Suction system Care 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).
z 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
openings if necessary. z To do this:
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.
z 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.
z Maintain the filter element (3) according to the in-
terval in the maintenance schedule
z Lift up the clamping yoke (1).
z Remove the filter hood (2) and pull out the filter
element (3).
z Filter element (3):
– blow out with dry compressed air (max. 5
bar) from the inside to the outside if soiling is
only slight,
– renew if heavily soiled.
© 2008 47
Care and maintenance work Suction system
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter Emptying the cyclone precleaner
z The dry air filter is maintained according to a z Empty the dust discharge valve (1) by pressing
Never fill the dust container (3) with lubri-
maintenance switch or maintenance indicator. together the discharge slit.
cating oil!
z Maintenance is necessary when: z 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. z Clean the discharge slit. z Loosen wing nut (1) and lift off housing cover (2).
– the red field (1) of the maintenance indica- z Remove the dust container (3) from the base (4)
tor is fully visible. and empty it. Clean the container using a brush
z After carrying out maintenance work, reset the and clean diesel fuel. Then dry.
signal by pressing the button on the mainte- z Place the dust container (3) on the base (4) and
nance indicator. The maintenance indicator is tighten the housing cover (2) with wing nut (1).
now ready for operation again.
48 © 2008
Belt drives Care and maintenance work
4
6
2
Checking the belt drive Checking the belt tension Tighten the generator V-belts
z Lower indicator arm (1) into the measuring de- z Loosen the screw (1), (2) and (3) slightly.
Only carry out work on the belt drive with
vice. z Push the generator (4) outwards in the direction
the engine at a standstill!
Always change both belts in sets in case of z Place guide (3) between two belt pulleys on the of the arrow until you get the correct V-belt ten-
wear on the double belts or damage to one V-belt (2). The stop have to be at the side. sion.
V-belt. z Press the button (4) at right angles to the V-belt z Retighten the screw (1), (2) and (3).
After repair work: Check that all guards (2) evenly until you hear or feel the spring snap
in. Renew the V-belts
have been replaced and that all tools have
been removed from the engine. z Lift the measuring device carefully without alter- z Loosen the screw (1), (2) and (3) slightly.
ing the position of the indicator arm (1). z Swing the generator (4) in in the opposite direc-
z Check the whole belt drive visually for damage. z Read the measured value at the point of inter- tion to the arrow.
z Renew damaged parts. section (arrow), scale (5) and indicator arm (1). z Remove the V-belt (5) and fit a new V-belt.
z Remount protective devices if necessary. z If necessary, re-tension belt and measure again. z Push the generator (4) outwards in the direction
z Pay attention to correct fit of new belts, check the of the arrow until you get the correct V-belt ten-
tension after running for 15 minutes. Tools
sion.
Belt tension measuring device (order number: z Retighten the screw (1), (2) and (3).
8115) can be obtained from your DEUTZ partner.
© 2008 49
OBJ_DOKU-15294-001.fm Seite 50 Freitag, 7. März 2008 11:47 11
Care and maintenance work Belt drives
6 z Retighten the screws (1) and (2).

z Checking the belt tension (65).
1 2
3 4
Tighten belt
z Loosen screws (1) and (2) and (3).
z Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
z Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
z Retighten the screws (1) and (2).
z Checking the belt tension (65).
Change the belt
z Loosen screws (1) and (2) and (3).
z Move the tensioning pulley (3) in the direction of
the arrow (B).
z Remove belt and fit new one.
z Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
z Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
50 © 2008
Setting work Care and maintenance work

Valve clearance setting schematic
Engines with turbocharger
6
TD/TCD 2011
This engine is equipped with an internal ex-

haust feedback system.
The inlet valve opens briefly in the out
stroke.
Do not confuse this with the valve over-
lap!
Valve overlap Settings

Cylinders Cylinders
1 4
Check valve clearance, adjust if necessary 3 2
z Let the engine cool down for at least 30 minutes z Engage hexagon socket head wrench (7) and in- 4 1
before setting the valve clearance: Lubricating oil sert and loosen the lock nut (4). 2 3
temperature below 80 °C. z Adjust the valve clearance setting screw (5) with
z Remove the cylinder head hood. the hexagon socket head wrench (7) so that the
z Place turning gear over fastening screws of the correct valve clerarance (1) is reached after
belt pulleys. tightening the lock nut (4).
z Turn the crankcase until reaching valve overlap. z Perform the setting procedure on every cylinder.
Outlet valve is not yet closed, inlet valve be- z Reinstall cylinder head cover, with new gasket.
gins to open.
The cylinders to be set can be seen in the
setting schematic.
z Check the valve clearance (1) between the rock-
er arm lugs (2) and the valve (3) with a feeler
gauge (6).
z The feeler gauge (6) must slide in with little re-
sistance.
z For permissible valve clearance, see (65)
z Adjust valve clearance if necessary:
© 2008 51
Care and maintenance work Setting work
6 Valve clearance setting schematic
1 Suction motor
D 2011
z Crankshaft position 1
Turn crankshaft until both vaalves overlap on the
1 2 1 2 3 1 2 3 4 cylinder.
Outlet valve is not yet closed, inlet valve begins
to open.
Setblack marked valves.
Mark the respective rocker arm with chalk to
check the setting you have made.
z Crankshaft position 2
Turn the crankshaft one turn (360 °).
Setblack marked valves.
2
1 2 1 2 3 1 2 3 4
52 © 2008
Electrical system Care 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. z Check the battery voltage with a conventional
Allow engine to warm up. voltmeter. The voltage indicates the charging
Touching a lead against the frame to check state. It should be between 12 and 14.4 Volt de-
whether it is live must not, under any cir- pending per battery.
cumstances, be carried out.
For electrical welding work, the ground ter- Check acid level Check acid density
minal of the welding gear must be clamped z Unscrew caps.
z Unscrew caps.
directly to the part being welded. z Measure the electrolyte density of individual cells
z Note the manufacturer’s specifications concern-
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
ing the liquid level.
connect the cables between battery, gener- reading indicates battery’s state of charge. The
ator and regulator while the engine is The liquid should normally be 10-15 mm above
the top edge of the plate or reach up to any avail- acid temperature when measuring should be 20
running. °C if possible.
able control device.
Battery z Only use distilled water to top up the battery. z Check the acid level before recharging.
z Screw in caps. z Screw in caps.
Electronically stored data could be lost if Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. Normal Tropical
Make sure the battery is fitted correctly and 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
Removing the battery
z Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
© 2008 53
Care and maintenance work Electrical system
6 of short-circuit!
z Remove the fastenings and take out the battery.
Charging the battery
z Unscrew caps.
z Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
z Screw in caps.
Installing the battery
z Insert new or charged battery and attach the fas-
tenings.
z Clean the terminals and battery poles with fine
emery paper.
z Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
z Grease the assembled terminals with an acid-
free, acid-resistant grease.
54 © 2008
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 Below starting limit temperature Check
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
Stop magnet defective (release circuit) Check lifting magnet
Engine stop lever still in stop position Check/replace
Stop magnet defective (release circuit) Check/replace
Incorrect valve clearance Check valve clearance and set if necessary
Injection valve defective Check fuel injector / change if necessary
Air filter clogged / turbocharger defective Check/replace
Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
© 2008 55
Faults Fault table
7 Faults
Engine starts, but runs irregularly or
Causes
Belt/V-rib belt (fuel pump in belt drive)
Measures
Check whether torn or loose
fails Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Glow plugs defective Change
Air in fuel system Vent
Fuel filter contaminated Clean
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
56 © 2008
OBJ_DOKU-15294-001.fm Seite 57 Donnerstag, 10. Juli 2008 8:48 08
Fault table Faults

Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
7
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lubricating oil cooler fins soiled Clean
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
Stop magnet defective (release circuit) Check lifting magnet
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
Heat short-circuit in the cooling air guidance Check the cooling system
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
© 2008 57
Faults Fault table
7 Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Lubricating oil cooler fins soiled Clean
Engine stop lever still in stop position Stop magnet defective (release circuit)
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air cooler soiled Clean
Heat short-circuit in the cooling air guidance Check the cooling system
Resistance in cooling system is too high / flow volume too low Check the cooling system
Injection valve defective Check fuel injector
Engine performs poorly and diagnos- Engine electronics reduce performance Check error according to error code and
tic lamp lights eliminate error if necessary
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
58 © 2008
Fault table Faults

Faults
Engine lubricating oil consumption
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
7
excessive Excessive inclination of engine Check engine mounting / reduce inclination
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
Engine producing white smoke Below starting limit temperature Check
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Charge air pressure-dependent full load stop defective Check
© 2008 59
Faults Engine management
7 Diagnostic key and error lamp

The diagnostic key (1) and the error lamp (2) are ac-
z Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guarantee!
commodated in the vehicle drive stand. The blink- z Automatic shutdown of the engine after a short
code release can be activated using the diagnostic warning time, possibly in connection with a start
key (1). lock.
1 z Engine forced to run at low idle speed to cool the
The error lamp can release the following signals: engine, with automatic shutdown if necessary.
z Function test z Start lock
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out. Please contact your DEUTZ-partner in case of mal-
2 functions and sare parts inquiries. Our specially
3 – Check the error lamp if there is no reaction trained personnel will ensure fast, professional re-
after switching on the ignition. pairs using original DEUTZ spare parts in case of
damage.
z The lamp does not light
– After the lamp test an extinguished lamp indi-
Engine protection function of the EMR2 system cates an error-free and trouble-free operat-
ing state within the scope of the control
Optional possibility.
Depending on the design of the monitoring functions,
the EMR2 system (3) can protect the engine in cer- z Steady light
tain problematical situations by monitoring important – Error in the system.
limit values during operation and checking the cor- – Operation continued with restrictions.
rect function of the system components. – The engine must be checked by a DEUTZ
partner.
z Flashing
– Serious error in the system.
– The engine has reached switch-off condition.
– The switch-off process has been accom-
plished.
z Blink code
– Errors that may occur can be classified.
– The blink codes can only be interpreted by a
DEUTZ partner.
The flashing error lamp may have the following
meaning depending on the engine configuration:
60 © 2008
Engine management Faults

z
z
Gear oil pressure
Battery voltage 7
z Accelerator position
z Fuel consumption
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.
All data sent from the EMR control unit through CAN
can be displayed.
z Engine speed
z Engine torque (current)
z Lubricating oil temperature
z Coolant temperature
z Suction intake air temperature
z Exhaust gas temperature
z Gear oil temperature
z Lubricating oil pressure
z Coolant pressure
z Charge air pressure
z Fuel pressure
© 2008 61
Transport and storage Transport
8
1
Suspension equipment
Danger to life!
z Always use proper suspension equipment when The engine may tip over or fall down if sus-
transporting the engine. pended incorrectly!
z The suspension device (1) must be adjustable
z The fastening attachment cannot be fixed se-
for the engine's centre of gravity.
curely above the centre of gravity (1).
z After transportation and before commissioning of
engine: remove attachment eyes (2). z The fastening attachment can slip, the engine
swings backwards and forwards (1).
z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
damage it.
62 © 2008
Protecting the engine against corrosion Transport and storage

General
Engines contain the following types of corrosion pro-
by wetting of the walls with the implemented cor-
rosion protection agent in a corrosion protection
suction system after shutting down the engine
until it emerges visibly from the pressure nozzle. 8
run of the engine.
tection: Cooling system
z The corrosion protection run can be performed
z Interior corrosion protection once to protect the different systems: z Depending on the series the engines are
z Exterior corrosion protection equipped with cooling air, cooling oil or cooling
Fuel system fluid system (cooling water with cooling system
Your DEUTZ partner has the right corro-
protection agent).
sion protection agent for your needs. Close the fuel/tank/supply line to the en-
z Cooling air system, see the Exterior corrosion
gine so that the system is protected against
protection section.
The following measures for corrosion protection af- dirt and dust. Protect the electronics
against moisture and corrosion. z In engines of the oil-cooled series the circulating
ter taking the engine out of operation meet the re- lubricating oil serves simultaneously for cooling.
quirements for 12 months corrosion protection. The cooling chambers are protected automati-
z Fill the fuel tank with a mixture of:
The following corrosion protection work may only be – 90 % distilled fuel cally against corrosion with the lube oil system.
carried out by persons familiar with it and instructed – 10 % corrosion protection oil SAE 20W-20
in the potential dangers. D/TD/TCD 2011 w
z Perform a corrosion protection run with no load
If these measures are deviated from by exposing the for at least 5 minutes. z If a coolant with corrosion protection properties is
corrosion-protected engines or parts to unfavourable poured into liquid-cooled engines, no further ac-
conditions (installation outdoors or storage in damp, Lubricating oil system tion is necessary after draining.
badly aired places) or damage to the corrosion pro- z Drain lubricating oil from warm engine. z If not, the coolant must be drained and, to ensure
tection layer, a shorter corrosion protection duration the formation of a covering layer on the inside
z Thoroughly clean lube oil tray, cylinder head with
is to be expected. surfaces of the cooling system, a corrosion pro-
rocker arms, valves, valve springs with diesel
The engine corrosion protection should be checked fuel or cleaning agent. tection run performed with a mixture of:
about every 3 months by opening the covers. If cor- z Fill the engine with corrosion protection oil SAE – 95 % treated water
rosion is detected, the corrosion protection should 20W-20 up to the MAX mark and perform a cor- – 5 % corrosion protection agent
be renewed. rosion protection run for at least 5 minutes so z The duration of the corrosion protection run and
At the end of the corrosion protection work the crank that all the components of the lubricating oil sys- the concentration of the corrosion protection
drive may no longer be turned so that the corrosion tem are wetted or wet all accessible parts with agent are specified by the manufacturer of the
protection agent in the bearings, bearing liners and corrosion protection oil and pump corrosion pro- corrosion protection agent.
cylinder liners is not scraped off. tection oil through the engine with a separate z Then drain the coolant.
Before operating a corrosion protected engine, the pump until all bearings and bearing liners are
corrosion protection must be removed. wetted.
Interior corrosion protection Air compressor
z Interior corrosion protection is always provided z If a compressor is installed, a corrosion protec-

tion agent must be sprayed into the compressor
© 2008 63
Transport and storage Protecting the engine against corrosion
8 Air intake pipes

z After the corrosion protection run, remove the
z Toothed belts for engine control may not be re-
moved.
fuel.
Lubricating oil system
cylinder head cover and deinstall injectors. The Engine openings
respective piston must be set to LT. z Unscrew the lube oil drain screw, drain oil.
z All engine openings must be fitted with air-tight, z Fill the engine with lubricating oil via the lubricat-
z The accessible part of the cylinder liner should
water-tight covers to delay the vapourisation ing oil filler neck.
be coated with corrosion protection oil with a
process of the corrosion protection agents.
spray lance through the opening. Coolant system
z With installed air compressor, the suction and
z Spray corrosion protection oil SAE 20W-20 into
pressure connection must be sealed by a cap. D/TD/TCD 2011 w
the suction air intake line.
z Air should be excluded to avoid ventilation of the z If the implemented corrosion protection agent is
Exterior corrosion protection engine (chimney effect) for the suction from an compatible with the intended cooling system pro-
air supply pipe. tection agent, this can be filled directly into the
z The engine must be cleaned thoroughly with a
cleaning agent before exterior corrosion protec- Storage and packaging coolant system as specified.
tion. Any signs of corrosion and damage to the z If it is uncertain whether the implemented corro-
paintwork must be removed. z After being protected against corrosion, the en- sion protection agent is compatible with the cool-
gine must be stored in a dry, ventilated hall and ing system protection agent, the cooling system
Cooling air system in air-cooled engines suitably covered. should be purged with fresh water for about 15
z The air guidance compartment of the engines is z The cover must be placed loosely over the en- minutes before filling.
unpainted and must be sprayed with a corrosion gine so that the air can circulate around it to pre-
vent condensation from forming. Use a desiccant Removal of exterior corrosion protection
protection agent.
if necessary. z All areas and components coated with corrosion
Bare exterior surfaces and parts protection agent must be washed off with dis-
Removal of corrosion protection
z Coat or spray all bare exterior parts and surfaces tilled fuel or a suitable cleaning agent.
z The corrosion protection must be removed from z Wash out grooves of V-belt pulleys if necessary.
(e.g. flywheel, flange faces) with corrosion pro-
the corrosion protected engine before starting.
tection agent. z Mount V-belts or V-rib belts as specified.
z The packaging and all covers over the closed z Fill with coolant.
Rubber parts openings must be removed.
z Any corrosion deposits and paint damage should
z Rubber parts (e.g. muffs) which are not painted
be remedied.
over must be rubbed down with talcum powder.
Fuel system
Belt drive
z Remove V-belts and V-rib belts and store If there is a mixture of diesel fuel/corrosion pro-
tection oil in the fuel tank, drain it.
packed.
z Spray V-belt pulleys and tension rollers with cor- z Connect fuel/tank/supply line to the engine. Pay
rosion protection agent. attention to cleanliness.
z Fill the fuel tank and fuel system with the proper
64 © 2008
Engine and setting data Technical data

General technical data
9
Engine type Dimension D 2011 L02 i D 2011 L03 i D 2011 L04 i TD 2011 L04 i
Working principle Four-stroke diesel engine
Charging Suction motor Exhaust gas turbo-
charger
Type of cooling oil-cooled (integrated cooler)
Cylinder arrangement in series
No. of cylinders 2 3 4 4
Bore/stroke [mm] 94/112 96/125
Total displacement [cm3] 1554 2331 3619
Combustion process Direct injection
Injection system Pump-pipe-nozzle
Exhaust gas recirculation without without external internal
Valves per cylinder 2 2 2 2
Valve clearance: Inlet/outlet [mm] 0,3+0,1 / 0,5+0,1
Firing order of the engine 1-2 1-2-3 1-3-4-2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Lubricating oil filling volume (without/with filter) ≈ [l] 6/6,5* 5,5/6* 11,3/11,8*
Lube oil temperature in the lube oil tray, maximum [°C] 130
Lubricating oil pressure minimum (low idle, engine [kPa/bar] 150/1,5
warm)
V-belt tension Pre-tensioning/Re-tensioning
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN ≈ [kg] 175 217 261 258
70020-A
© 2008 65
Technical data Engine and setting data
9 Engine type Dimension D 2011 L02 o D 2011 L03 o

Charging Suction motor
Type of cooling oil-cooled
No. of cylinders 2 3
Bore/stroke [mm] 94/112
Total displacement [cm3] 1554 2331
Exhaust gas recirculation without without
Valves per cylinder 2 2
Firing order of the engine 1-2 1-2-3
Lubricating oil filling volume (without/with filter) ≈ [l] 6/6,5* 5,5/6,0*
Lubricating oil pressure minimum (low idle, engine [kPa/bar] 150/1,5
warm)
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN 70020- ≈ [kg] 169 210
A
66 © 2008

Engine type Dimension D 2011 L04 o TD 2011 L04 o 9
Charging Suction motor Exhaust gas turbocharger
Type of cooling oil-cooled
No. of cylinders 4 4
Total displacement [cm3] 3619
Exhaust gas recirculation external internal
Valves per cylinder 2 2
Firing order of the engine 1-3-4-2
Lubricating oil filling volume (without/with filter) ≈ [l] 10*/10,5*
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 150/1,5
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN 70020-A ≈ [kg] 253 255
© 2008 67
Technical data Engine and setting data
9 Engine type Dimension D 2011 L04 w TD 2011 L04 w TCD 2011 L04 w
Charging Suction motor Exhaust gas turbocharger Turbocharger with charge air
cooling
Type of cooling water-cooled
No. of cylinders 4 4 4
Total displacement [cm3] 3619
Exhaust gas recirculation external internal internal
Valves per cylinder 2 2 2
Firing order of the engine 1-3-4-2
Coolant volume (only engine content without cooler / ≈ [l] 2,9
hoses and pipes)
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 4-6
Start of thermostat opening [°C] 88
Thermostat fully open [°C] 92
Lubricating oil filling volume (without/with filter) ≈ [l] 8,0*/8,5*
68 © 2009

Engine type
Lubricating oil pressure minimum (low idle, engine
Dimension
[kPa/bar]
D 2011 L04 w TD 2011 L04 w
150/1,5
TCD 2011 L04 w 9
warm)
Charge air temperature outlet at rated power [°C] 50
V-belt AVX 10 [N] 450±50/300±20
Weight without cooling system according to DIN 70020- ≈ [kg] 266 268
A
*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.
© 2008 69
Technical data Tools
9 Tool ordering
The special tools described in this chapter can be or-
dered from:
WILBÄR - Wilhelm Bäcker GmbH & Co. KG

Taubenstrasse 5
42857 Remscheid
Germany
Phone: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
www.deutz-tools.com
Torx tool V-belt tension measuring instrument
Order number: Order number:
8189 8115
The Torx screw system is used in engines in this se- Measuring instrument for checking the specified V-
ries among other things. This system was introduced belt tensions.
for a number of reasons:
z Excellent accessibility
z High force transmission when loosening and
tightening
z Slipping or breaking of the key and risk of injury
are practically excluded.
70 © 2008
Tools Technical data

9
Special tools for removing the water collection Special wrench

vessel.
Order number:
Order number:
170050
8192
For loosening changeable filters.
On Racor filters, only loosen the water collection
vessel with a special tool.
© 2008 71
DEUTZ Oil
DEUTZ Oil DQC II-05 DEUTZ Oil DQC III-05 DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E5-02 / E3-96 / B3-04 ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 ACEA E7-04 / E5-02 / E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1
TLS-15W40D TLX-10W40FE DEUTZ Oel DQC IV-5W30

(DQC II-05) (DQC III-05) (DQC IV-05)
5L 0101 6331 5L 0101 6335 5L -
20 L 0101 6332 20 L 0101 6336 20 L 0101 7849
209 L 0101 6333 209 L 0101 6337 209 L 0101 7850
DEUTZ AG
Supporthouse Information Systems
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
© 02/2008
All rights reserved
Order number:
The engine company. 0312 3547 en

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OBJ_DOKU-15294-001.fm Seite 1 Donnerstag, 28.

Februar 2008 9:58 09

This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

Type Engine description

2011 Rating plate Location of the rating plate

Engine description Type

Engine serial number Cylinder numbering Volume blocking

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

2 TCD 2011 L04 w

Lubricating oil schematic Engine description

Engine description Lubricating oil schematic

Lubricating oil schematic Engine description

Engine description Lubricating oil schematic

Lubricating oil Operating media

Operating media Lubricating oil

4 – sulphur content in the fuel

Fuel Operating media

Operating media Coolant

4 General z Total hardness too high:

Maintenance schedule Maintenance

Maintenance Maintenance schedule

Stage Activity Measure Page

Maintenance schedule Maintenance

Order number: 0312 3538

Care and maintenance work Lubricating oil system

6 Regulations for working on the lubricating oil

Be careful of hot lubricating oil. Danger of

z Pull out the lubricating oil dipstick and wipe off

Lubricating oil system Care and maintenance work

Care and maintenance work Fuel system

Additional venting of the fuel system by a 5

Fuel system Care and maintenance work

Care and maintenance work Fuel system

Fuel system Care and maintenance work

Lubricating oil Operating media

Operating media Lubricating oil

4 – sulphur content in the fuel

Fuel Operating media

Operating media Coolant

4 General z Total hardness too high:

Maintenance schedule Maintenance

Maintenance Maintenance schedule

Stage Activity Measure Page

Maintenance schedule Maintenance

Order number: 0312 3538

Care and maintenance work Lubricating oil system

6 Regulations for working on the lubricating oil

Be careful of hot lubricating oil. Danger of

z Pull out the lubricating oil dipstick and wipe off

Lubricating oil system Care and maintenance work

Care and maintenance work Fuel system

Additional venting of the fuel system by a 5

Fuel system Care and maintenance work

Care and maintenance work Fuel system

Fuel system Care and maintenance work

Care and maintenance work Cooling system

6 Specifications when working on the cooling sys-

Danger of scalding from hot coolant!