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Operation Manual
TCD 7.8 L6
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Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
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.
Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. Do not work on the fuel system while the engine
When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to 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
pressure - Danger to life!
Unauthorised engine modifications will invalidate
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. When working on the fuel system, make sure
Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
When carrying out maintenance work on the en-
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Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Components of the exhaust aftertreatment system
installation situation, i.e. not all the components de- Please enter the serial numbers of the exhaust after-
scribed in the operating manual are installed in your treatment components.
engine.
We have endeavoured to highlight any differences Diesel oxidation catalytic converter
so that you will be able to locate the operating and
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail- Diesel particle filter
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be SCR module
happy to advise you.
Sincerely,
DEUTZ AG
Notes
We reserve the right to make technical changes to
the descriptions and data in this operating manual in
the interest of further development of the engines.
This document may only be reprinted and repro-
duced, even in part, with our express permission.
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Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel system. . . . . . . . . . . . . . . . . . 46
Foreword. . . . . . . . . . . . . . . . . . . . . 3 SCR. . . . . . . . . . . . . . . . . . . . . . 51
1 General. . . . . . . . . . . . . . . . . . . . 5 Cooling system . . . . . . . . . . . . . . . . 52
2 Engine description . . . . . . . . . . . . . 7 Engine cleaning. . . . . . . . . . . . . . . . 54
Model . . . . . . . . . . . . . . . . . . . . . 7 Aspiration system. . . . . . . . . . . . . . . 55
Engine illustrations . . . . . . . . . . . . . . 10 Belt drives . . . . . . . . . . . . . . . . . . 57
Lubricating oil diagram . . . . . . . . . . . . 14 Adjustment work . . . . . . . . . . . . . . . 58
Fuel diagram . . . . . . . . . . . . . . . . . 15 Electrical system . . . . . . . . . . . . . . . 60
Coolant diagram . . . . . . . . . . . . . . . 16 7 Faults. . . . . . . . . . . . . . . . . . . . . 62
Exhaust gas return . . . . . . . . . . . . . . 18 Fault table . . . . . . . . . . . . . . . . . . 62
Exhaust gas aftertreatment . . . . . . . . . . 19 Engine management . . . . . . . . . . . . . 67
Electrics/Electronics . . . . . . . . . . . . . 21 8 Transport and storage . . . . . . . . . . . 69
3 Operation . . . . . . . . . . . . . . . . . . 23 Transport . . . . . . . . . . . . . . . . . . . 69
Ambient conditions . . . . . . . . . . . . . . 23 Engine corrosion protection . . . . . . . . . 70
Initial start-up . . . . . . . . . . . . . . . . . 24 9 Technical data . . . . . . . . . . . . . . . . 72
Start procedure . . . . . . . . . . . . . . . . 27 Engine and setting data . . . . . . . . . . . 72
Operation monitoring . . . . . . . . . . . . . 29 Tools . . . . . . . . . . . . . . . . . . . . . 74
Regeneration . . . . . . . . . . . . . . . . . 33
Stop procedure . . . . . . . . . . . . . . . . 34
4 Operating Media . . . . . . . . . . . . . . . 35
Lubricating oil . . . . . . . . . . . . . . . . . 35
Fuel . . . . . . . . . . . . . . . . . . . . . . 37
Coolant . . . . . . . . . . . . . . . . . . . . 38
SCR reduction agent . . . . . . . . . . . . . 39
5 Maintenance . . . . . . . . . . . . . . . . . 40
Maintenance schedule . . . . . . . . . . . . 40
6 Servicing and maintenance work . . . . . 43
Lubricating oil system. . . . . . . . . . . . . 43
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General
DEUTZ diesel engines
DEUTZ diesel engines and the appropriate exhaust
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
aftertreatment components are the result of years of
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
research and development. The detailed know-how
functioning and high reliability. tact to your nearest local service partner.
gained by this in connection with the high quality de-
mands are the guarantee for production of engines DEUTZ Xchange components California
with a long life, high reliability and low fuel consump- Proposition 65 Warning
tion. Naturally the high demands for protection of the DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high Diesel engines and some of its constituents are
environment are also met. known to the State of California to cause cancer,
as for new parts. DEUTZ replacement parts are
Safety precautions when the engine is running equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
liability. Masthead
Maintenance work or repairs may only be performed
on the shut-down engine. Make sure that the engine Asbestos DEUTZ AG
cannot be started inadvertently - Danger of accident!
The gaskets used in this engine contain no asbestos. Ottostrae 1
After repair work: Check that all guards have been Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from 51149 Kln
maintenance and repair work.
the engine. Germany
Observe industrial safety regulations when running Service Phone: +49 (0) 221-822-0
the engine in an enclosed space or underground. We want to preserve the high performance of our en- Fax: +49 (0) 221-822-3525
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
E-Mail: info@deutz.com
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
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General
1 Danger
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7.8 They are only certified by the responsible DEUTZ AG MADE IN GERMANY
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2 C
D
xxxxxxx
C
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left
2
1 2
right
1
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2 TCD 7.8 L6
Agricultural engine
11 View from right (example)
1 Coolant outlet
2 Tension pulley
10 3 Coolant inlet
4 V-rib belt
5 Lubricating oil drain plug
6 Lube oil replacement filter
1 7 Lubricating oil dipstick
9 8 Exchangeable fuel filter
9 Rail
10 Crankcase breather
2 11 Lubricating oil filling
8
3
7
4
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2 TCD 7.8 L6
Industrial engine with regeneration burner
11 View from right (example)
1 Coolant outlet
2 V-rib belt
10 3 Tension pulley
4 Coolant inlet
5 Lubricating oil drain plug
6 Lubricating oil dipstick
7 Lube oil cooler
9 8 Lube oil replacement filter
9 Rail
1 10 Crankcase breather
11 Lubricating oil filling
8
3
6
5
4
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8 7 3 2 1
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1 2 3 5 4
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2 6 7 8 9 10
x3 x2 x1 x2
T
x2
1 2 3 4 5 6
x3 x1
5 4 3 2 1 12 11
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11
10 9
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1 2 3 4 5 11
Electronic engine control
2
Engine side
1 Fuel transducer
12 2 Rail pressure sensor
3 Coolant temperature transmitter
6 4 Charge air pressure transmitter, charge air tem-
13 perature transmitter
5 Engine control unit
6 Central plug (for engine control)
14 7 Speed transmitter via crankshaft
8 Speed transmitter via camshaft
9 Lubricating oil pressure transmitter
15 10 Lubricating oil level transmitter (optional)
Equipment side
16
11 Power supply (battery)
12 Multifunction displays
17 13 Signal outputs, e.g. for lamps, torque (PWM),
speed, engine operation, etc.
14 Inputs (e.g. override button)
18 15 Accelerator
16 Hand throttle
17 Optional function selector switch, e.g. for P de-
19 gree, type of controls, maximum curve, fixed
speeds, etc.
18 Detachable key switch Start/Stop
20 19 Diagnosis button
20 Error lamp
21 Diagnostic interface/CAN bus
7 8 9 10 21
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AdBlue 3 2
Start the engine and run up until the thermostat
opens (line (2) heats up). 3
Engine operation with open thermostat 2 - 3 min-
utes.
Diesel Exhaust Fluid 1 Check the coolant level and top up coolant if nec-
essary.
Danger of scalding from hot coolant!
Cooling system under pressure! Only open
the cap when cool!
Observe safety regulations and national
specifications when handling cooling me-
dia.
If required, repeat procedure with engine start.
Fill up coolant to the MAX mark on the compen-
Filling with AdBlue Filling the coolant system sation tank and close the cooling system cap.
Switch on any available heating and set to the
Exhaust aftertreatment systems The coolant must have a prescribed con- highest level so that the heating circuit is filled
centration of cooling system corrosion pro- and vented.
SCR Selective Catalytic Reduction
tection agent! Observe the filling volume of the cooling system
Never operate the engine without coolant, (72).
Only re-fuel when the engine is not running. even for a short time!
Only fill with AdBlue!
Other media (e.g. diesel), even in the
smallest amounts, can cause destruction of Order coolant corrosion protection agent
the system. from your DEUTZ partner.
If you have filled with e.g. diesel and this
has got into the system, the complete Connect coolant outlet (2) and coolant inlet (1) to
AdBlue injection system must be re- the cooling system. Connect the feed line of the
placed! compensation tank to the coolant pump or to the
If the filled medium (e.g. diesel) has not coolant inlet line (3).
reached the lines and supply pump/meter- Connect ventilation line from the engine and, if
ing module, an emptying and thorough necessary, from the cooler to the compensation
cleaning of the AdBlue tank will be ade- tank.
quate. Fill cooling system via the compensation tank.
Ensure cleanliness. Close compensation tank with valve.
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3 Trial run
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Lubricating oil temperature Lubricating oil temperature too high Switch off engine
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or Switch off engine
lamp while the engine is running, the lubricating oil pres-
sure is too low
Lube oil level If the pilot lamp lights up after starting the engine or Fill up lube oil
while the engine is running, the lubricating oil level is
too low
Coolant level If the control lamp lights up after the engine starts or Shut down the engine, allow to cool and top up cool-
while the engine is running, the coolant level is too ant
low
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
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DPF function lamp Flashing Regeneration of the diesel particle filter is started
Continuous light Diesel particle filter is regenerated
Rapid flashing Regeneration of the diesel particle filter cannot be completed
Engine warning lamp Continuous light An interruption in the regeneration is shown in combination with the
Flashing DPF function lamp.
The engine performance is reduced when the lamp lights continu-
ously.
The engine is stopped when the lamp flashes.
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3
Operation monitoring of the diesel particle filter
Faults in the exhaust aftertreatment system
Filling level of the AdBlue tank
Battery voltage
Accelerator position
Fuel consumption
Operating hours
Error messages are displayed in clear text and
acoustically; the error memory of the control unit can
be read out.
For a detailed description, refer to the operating in-
structions enclosed with the DEUTZ Electronic Dis-
play.
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Regeneration Operation
Regeneration of the diesel particle filter The control unit registers the engine shutdown as a
fault. 3
Temperatures of approx. 600 C occur on
Manual mode
the exhaust pipe during regeneration.
These are independent of the actual engine Regeneration is necessary when the filter charging
performance, even in engine idling. has reached 100 % of the nominal charging.
Danger of burns!
The regeneration lamp starts flashing.
Automatic mode The operator must enable regeneration with the en-
able button.
The DPF system is operated without any operator in-
tervention in the automatic mode. Regeneration starts immediately after the enable.
Regeneration is necessary when the filter charging The regeneration lamp lights continuously during re-
has reached 100 % of the nominal charging. generation.
The regeneration lamp starts flashing. The regeneration lasts 25 minutes on average.
The regeneration begins after a delayed start. The regeneration lamp goes out when regeneration
The regeneration lamp lights continuously during re- has been successfully completed.
generation. If an active regeneration has to be interrupted, the
The regeneration lasts 25 minutes on average. operator can press the button to stop regeneration.
The regeneration request is still active because re-
The regeneration lamp goes out when regeneration
generation has not taken place.
has been successfully completed.
The regeneration lamp starts flashing.
If the regeneration has to be prevented or interrupted
after it has already been started (e.g. machine is in a The regeneration start must be re-enabled by the op-
hall), the operator must press the generation preven- erator.
tion switch. Regeneration starts immediately after the enable.
The regeneration request is still active because re- The regeneration lamp lights continuously during re-
generation has not taken place. generation.
The regeneration lamp starts flashing. If the button is not pressed for a long time when re-
No regeneration is possible as long as the regenera- generation is requested, the filter continues to be
tion prevention switch is actuated. charged.
If the regeneration switch is actuated continuously, The engine warning lamp lights, then the perform-
the filter is still charged. ance is reduced and the engine is finally shut down.
The engine warning lamp lights, then the perform- The control unit registers the engine shutdown as a
ance is reduced and the engine is finally shut down. fault.
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3
A
Shutting off
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SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
Container Order number:
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
below -40 C, the lubricating oil must be pre-heated 15
20 litre container 0101 7976 (e.g. by storing the vehicle or the machine in a hall).
209 litre barrel 0101 7977 The viscosity is classified according to SAE. Multi- 10
purpose lubricating oils should be used basically.
DEUTZ lubricating oils DQC IV synthetic Single-purpose lubricating oils can also be used in 5
DQC IV - 5W30-UHP enclosed, heated spaces at temperatures >5 C.
0
Not for DPF
The prescribed lubricating oil quality must
Container Order number: -5
be observed when selecting the viscosity
20 litre container 0101 7849 class! -10
209 litre barrel 0101 7850 Depending on the ambient temperature we recom-
-15
mend the following common viscosity classes:
Lubricating oil change intervals
-20
The intervals depend on:
lubricating oil quality -25
sulphur content in the fuel
type of application of engine -30
The lubricating oil change interval must be -35
halved if at least one of the following conditions
applies: -40
Constant ambient temperature below -10 C
(14 F) or lube oil temperature below 60 C
(84 F).
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ASTM D 975 Grade 1-D S15 For engines with DCR DEUTZ common
ASTM D 975 Grade 2-D S15 rail injection, the mixing of petroleum and
adding of extra low additives is not permis-
Sulphur <15 mg/kg sible.
Light heating oils At low ambient temperatures paraffin discharges can
EN 590 lead to blockages in the fuel system and cause oper-
ating faults. Below 0 C ambient temperature use
Sulphur <10 mg/kg winter diesel (down to -20 C) (filling stations provide
If other fuels are used which do not meet the require- this in good time before the cold season starts).
ments of the operating manual, the warranty will be Special diesel fuels can be used for arctic cli-
voided. mates to -44 C.
The certification measurements for compliance with
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AdBlue is a highly-pure, acqueous, 32.5 % urea The AdBlue tank may only be filled with AdBlue.
solution which is used as an NOX reduction agent for Filling with other media can lead to destruction of the
SCR exhaust aftertreatment in vehicles with diesel system.
engines. In this case the metering pump must be replaced.
The product is designated as AdBlue or AUS 32 AdBlue should not remain in the tank for longer
(AUS: Aqueous Urea Solution) and corresponds to than 4 months.
the ISO 22241-1 NOx reduction agent AUS 32.
This must be documented.
The length of time that AdBlue can be kept without
losing quality depends on the conditions of its stor- Empty and clean the AdBlue tank when decommis-
age. sioning.
It crystallises at -11 C and at over +35 C a hydrol- Please contact your DEUTZ partner
ysis reaction is initiated, i.e. it begins to slowly re-
http://www.deutz.com
lease ammonia and carbon dioxide.
E-Mail: info@deutz.com
Direct sunlight on exposed storage containers must
always be avoided.
Barrels must not be stored for longer than one year!
Ensure that the materials and storage containers
used are resistant to AdBlue.
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Observations
1) The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (35).
2) Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
3) The display of the operating hours should be ensured by the device manufacturer. The engine operating hours are recorded by the control unit. Enquiry via the CAN
bus and display in a display or creation/display via electromechanical counter.
4) Initial setting of the valve clearance after 500 oh must be performed on the engines in this operating manual.
General overhaul
5)
The best time for a general overhaul depends to a great extent on the load, application and ambient conditions and the care and maintenance of the engine during the
operating time.
Your DEUTZ partner will advise you on determining the best time for a general overhaul.
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
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E55 Extended maintenance III Authorised specialists 4.500 3)
E60 Intermediate overhaul 6.000
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5 Stage
E50
Activity
Settings
Measure
Valve clearance
Page
58
Check V-rib belt and tensioning pulley 57
Filter element of the diesel particle filter DPF
Replace if necessary
Spark plug of the DPF burner
Replace if necessary
E55 Replace Filter element of the diesel particle filter DPF
Spark plug of the DPF burner
E60 Replace Injector
Crankcase breather valve
V-rib belt and tensioning pulley 57
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
annually Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Replace Fuel pre-filter 50
Every 2 Replace Dry air filter 56
years V-belt, V-rib belt and tensioning pulley 57
Coolant 38 52
Check Crankcase breather valve
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.
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Change lubricating oil filter Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
Remove clamps when twist protection mounted Fasten clamps of the twist protection (optional).
(optional).
Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
Collect draining lubricating oil
Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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1
6
1
1
6
2 5
5 5
4
3 4 3
Replace lubricating oil filter cartridge Collect draining lubricating oil Replace gasket and oil lightly.
Bend the filter cartridge in the collecting contain- Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. Screw the cover clockwise (25 Nm).
tion! Clean components. Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
Switch off the engine.
Loosen cover by turning 2-3 times and wait for 30
seconds.
Unscrew cover with filter cartridge anti-clock-
wise.
Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
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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.
Observe the safety regulations and nation-
al specifications for handling fuels.
Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep away
into the ground.
After all work on the fuel system, the sys-
tem should be vented, a trial run performed
and the tightness checked.
It will be necessary to vent the fuel system
when commissioning for the first time, after
maintenance work or if the tank has been
run dry.
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Change the fuel filter cartridge Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 10-12 Nm
Fasten clamps of the twist protection (optional).
Remove clamps when twist protection mounted
(optional). Vent the fuel system.
Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
Catch any escaping fuel.
Clean the sealing surface of the filter support
with a lint-free, clean cloth.
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6 1
1
1
6
2 5
5 5
4
3 4 3
Replace fuel filter cartridge Catch any escaping fuel. Replace gasket and oil lightly.
Bend the filter cartridge in the collecting contain- Press new filter cartridge into bracket and place
The filter cartridge should never be pre- er slightly to the side until the cartridge comes them carefully into the guide.
filled. There is a danger of dirt contamina- out of the bracket. Screw the cover clockwise (25 Nm).
tion! Clean components. Start engine.
1 Cover
2 Sealing ring
3 Housing
4 Guide
5 Filter insert
6 Bracket
Switch off the engine.
Loosen cover by turning 2-3 times and wait for 30
seconds.
Unscrew cover with filter cartridge anti-clock-
wise.
Loosen the filter cartridge carefully out of the
guide in the housing and upwards.
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1 2 3
Change the filter cartridge of the AdBlue supply Pull out filter insert and compensation body.
pump Insert new filter insert with compensation body.
In engines with exhaust aftertreatment system Se- Mount cover.
lective Catalytic Reduction
Tightening torque 22.5 2.5 Nm
Protective gloves are to be worn when Electrical connection
working with Selective Catalytic Reduction
Connect cable connections.
(SCR) components.
Ensure cleanliness. Start
1 Cover
2 Compensation body
3 Filter insert
Switch off the engine.
Electrical connection
Disconnect cable connections.
Place suitable collecting containers underneath.
Remove cover.
Socket wrench insert 27 mm
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Only carry out cleaning work on the engine Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam temper-
Remove the engine cover and cooling air ature 90 C, distance at least 1m).
cover if available and remount after clean- Warm up the engine so that the water residues
ing. evaporate.
Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.
The following causes of soiling make it necessary to
clean the engine:
High dust content in the air.
Chaff and chopped straw in the area of the en-
gine.
Coolant leaks
Lubricating oil leakage
Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
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6
1
2
1
4
1
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter Emptying the cyclone precleaner
The dry air filter is maintained according to a 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!
Maintenance is necessary when: Remove any caked dust by pressing together the
the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. Clean the discharge slit. Loosen wing nut (1) and lift off housing cover (2).
the red field (1) of the maintenance indicator Remove the dust container (3) from the base (4)
is fully visible. and empty it. Clean the container using a brush
After carrying out maintenance work, reset the and clean diesel fuel. Then dry.
signal by pressing the button on the mainte- 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.
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6 Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. Check the battery voltage with a standard volt-
Allow engine to warm up. meter. The voltage gives information about the
Touching a lead against the frame to check charge status.
whether it is live must not, under any cir-
cumstances, be carried out.
Battery Charge status (Volt) Check acid density
For electrical welding work, the ground ter-
minal of the welding gear must be clamped 12 Volt 12-14,4 Unscrew caps.
directly to the part being welded. 24 Volt 24-28,4 Measure the electrolyte density of individual cells
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
connect the cables between battery, gener- Check acid level
reading indicates batterys state of charge. The
ator and regulator while the engine is Unscrew caps. acid temperature when measuring should be 20
running. C if possible.
Note the manufacturers specifications concern-
Battery ing the liquid level. Check the acid level before recharging.
The liquid should normally be 10-15 mm above Screw in caps.
Electronically stored data could be lost if the top edge of the plate or reach up to any avail-
able control device. Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. Only use distilled water to top up the battery. Normal Tropical
Make sure the battery is fitted correctly and Screw in caps. 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
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7 Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lube oil cooler defective Check/replace
Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Incorrect valve clearance Check valve clearance and set if necessary
Injector defective Change
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Exhaust gas backpressure too high Check
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7 Faults
Engine producing white smoke
Causes
Below starting limit temperature
Measures
Check
Cold starting device Check/replace
Incorrect valve clearance Check valve clearance and set if necessary
Fuel quality does not comply with operating manual Change the fuel
Injector defective Change
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air pressure-dependent full load stop defective Check
Incorrect valve clearance Check valve clearance and set if necessary
Charge air line leaking Check charge air line
Injector defective Change
Error in the SCR system AdBlue tank empty/display full Check tank sensor
SCR not working Check plug connection of the lines at the
pump and injector
SCR not working (cold) Lines frozen, clean lines
Implausible sensor signal Check NOx sensor
No regeneration in the diesel particle Power supply of the air compressor interrupted Check fuse and supply line, replace lock
filter Air compressor defective Check air compressor, replace lock
Air filter blocked Clean/Replace air filter, check air compres-
sor, if necessary replace lock
Fuel supply interrupted Check lines, check metering unit
Implausible sensor signal Check exhaust backpressure sensor, check
differential pressure sensor in the particle
filter, check pressure sensors in the meter-
ing unit
Swirl plate sooted up Clean, determine reason for the sooting
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7 Diagnosis button
The diagnosis button allows the errors currently
saved in the error memory of the electronic engine
control to be visualised in the form of a flash code.
The flash codes permit:
Errors that may occur can be classified.
Clear display of the error as visual signal.
The blink codes can only be interpreted by a
DEUTZ partner.
0,8 s
0,4 s
0,4 s
0,4 s
0,8 s
0,4 s
2s 2s
Use of the diagnostic key
The flash code displays all errors in the error memo-
ry, this means active as well as passive ones.
The control unit must be switched off to start the en-
1 2 8
quiry (ignition off). Then the diagnosis button should Display system error by flash code
be pressed for approx. 1s during the start (ignition
on). Example:
Then the next error (i.e. the following one in the error Flash code 1-2-8
memory) can be displayed by pressing the diagnos- 1 x short flash
tic key again. If the last error was displayed, the first
2 x long flash
error is displayed again on pressing the diagnostic
key again. 8 x short flash
After the display of the error flash code, the error This flash code indicates a break or short circuit in
lamp goes out for five seconds. the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
the illustration.
The blink codes can only be interpreted by a
DEUTZ partner.
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1 8
1
2
2
Suspension equipment
Danger to life!
The engine may tip over or fall down if sus-
The transport devices mounted on this en- pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com- The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. The fastening attachment can slip, the engine
swings backwards and forwards (1).
Always use proper suspension equipment when
transporting the engine. Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
After transportation and before commissioning of
engine: remove attachment eyes (2).
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8 General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
Cooling air system, see the Exterior corrosion
protection section.
tection: The corrosion protection run can be performed In engines of the oil-cooled series the circulating
once to protect the different systems: lubricating oil serves simultaneously for cooling.
Interior corrosion protection The cooling chambers are protected automati-
Exterior corrosion protection Fuel system cally against corrosion with the lube oil system.
If a coolant with corrosion protection properties is
Your DEUTZ partner has the right corro- Close the fuel/tank/supply line to the en- poured into liquid-cooled engines, no further ac-
sion protection agent for your needs. gine so that the system is protected against tion is necessary after draining.
dirt and dust. Protect the electronics
If not, the coolant must be drained and, to ensure
The following measures for corrosion protection after against moisture and corrosion.
the formation of a covering layer on the inside
taking the engine out of operation meet the require- surfaces of the cooling system, a corrosion pro-
Fill the fuel tank with a mixture of:
ments for 12 months corrosion protection. tection run performed with a mixture of:
90 % distilled fuel
The following corrosion protection work may only be 10 % corrosion protection oil. 95 % treated water
carried out by persons familiar with it and instructed 5 % corrosion protection agent
Perform a corrosion protection run with no load
in the potential dangers. The duration of the corrosion protection run and
for at least 5 minutes.
If these measures are deviated from by exposing the the concentration of the corrosion protection
corrosion-protected engines or parts to unfavourable Lubricating oil system agent are specified by the manufacturer of the
conditions (installation outdoors or storage in damp, corrosion protection agent.
Drain lubricating oil from warm engine.
badly aired places) or damage to the corrosion pro- Then drain the coolant.
Thoroughly clean lube oil tray, cylinder head with
tection layer, a shorter corrosion protection duration
rocker arms, valves, valve springs with diesel Air intake pipes
is to be expected.
fuel or cleaning agent.
The engine corrosion protection should be checked Fill the engine with corrosion protection oil up to After the corrosion protection run, remove the
about every 3 months by opening the covers. If cor- the MAX mark and perform a corrosion protec- cylinder head cover and deinstall injectors. The
rosion is detected, the corrosion protection should tion run for at least 5 minutes so that all the com- respective piston must be set to LT.
be renewed. ponents of the lubricating oil system are wetted The accessible part of the cylinder liner should
At the end of the corrosion protection work the crank or wet all accessible parts with corrosion protec- be coated with corrosion protection oil with a
drive may no longer be turned so that the corrosion tion oil and pump corrosion protection oil through spray lance through the opening.
protection agent in the bearings, bearing liners and the engine with a separate pump until all bear- Spray corrosion protection lubricating oil into the
cylinder liners is not scraped off. ings and bearing liners are wetted. suction intake pipe.
Before operating a corrosion protected engine, the Cooling system Exterior corrosion protection
corrosion protection must be removed.
Depending on the series the engines are The engine must be cleaned thoroughly with a
Interior corrosion protection equipped with cooling air, cooling oil or cooling cleaning agent before exterior corrosion protec-
fluid system (cooling water with cooling system tion. Any signs of corrosion and damage to the
Interior corrosion protection is always provided
protection agent). paintwork must be removed.
by wetting of the walls with the implemented cor-
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9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Please contact your DEUTZ partner
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SCR/DPF SCR
DEUTZ Oil Rodon 10W40 DEUTZ Oel TLX-10W40FE DEUTZ Cooling System
low SAPS (DQC III-10 LA) (DQC III-10) Conditioner
5L - 5L 0101 6335 5L 0101 1490
20 L 0101 7976 20 L 0101 6336 20 L 0101 6416
209 L 0101 7977 209 L 0101 6337 210 L 1221 1500
DEUTZ AG
Information Systems Sales & Service
Ottostrae 1
51149 Kln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
04/2011
All rights reserved
Order number:
0312 3790 en
The engine company. Original operating instructions