Deutz Operator Manual TCD 2015 en

Operation Manual
TCD 2015
z This engine is built exclusively for

purpose according to the scope
of delivery - defined by the equipment manufacturer (use for the
intended purpose). Any use above and beyond this is considered improper use.
The manufacturer will not be liable for damages
resulting from this. The user bears the sole risk.
z Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with it and
instructed in the dangers.
The pertinent rules for the prevention of accidents and other generally recognised safety and
industrial medicine rules must be observed.
z When the engine is running there is a danger of
injury caused by:
rotating / hot parts
in engines with external ignition (high electrical voltage), avoid touching at all costs!
z Unauthorised modifications to the engine exclude manufacturer liability for resulting damages.
z Equally, manipulations to the injection and control system can affect the engine's performance
and the exhaust characteristics. Compliance
with legal environmental regulations will no longer be guaranteed in this case.
z Do not modify, obstruct the cooling air flow area
to the fan, unhindered cooling air supply must be
guaranteed.
The manufacturer will accept no liability for damages resulting from this.
z Only DEUTZ original parts may be used when
carrying out maintenance/repair work on the engine. These have been designed especially for
your engine and ensure a trouble-free operation.
Failure to observe this will void the warranty !
Maintenance/cleaning work on the engine may

only be carried out when the engine is not running and has cooled down.
When doing this, make sure that the electrical
systems are switched off (remove ilgnition key).
The specifications for accident prevention with
electrical systems (e.g. -VDE-0100/-0101/-0104/
-0105 Electrical measures against dangerous
touch voltages) must be observed.
Cover all electrical components tightly when
cleaning with liquids.
z Do not work on the fuel system when the engine
is running - Danger to life.
Wait for the pressure to drop after the engine comes to a standstill (in engines with DEUTZ Common Rail about 5 minutes, otherwise 1 minute)
because the system is under high pressure Danger to life.
During the first trial run do not stand in the danger area of the engine.
In case of leaks danger due to high pressure Danger to life.
Go to the workshop ilmmediately in case of
leaks.
Make sure the engine is not started accidentally during repairs when working on the fuel
system - Danger to life.
Danger
This symbol is used for all safety instructions which, if not observed, present a direct danger to life and limb for
the person involved. Observe these
carefully. Also pass on the safety instructions to your operating personnel.
Furthermore, the legislation for "general regulations for safety and the prevention of accidents" must be
observed.
Caution
This symbol indicates a danger to the
component / engine. The appropriate
instructions must be followed otherwise the component / engine may be destroyed.
Operation Manual TCD 2015

Foreword
Engine number
Order number
Dear customer,
Please enter the engine number here.(6)

This will simplify the handling of customer service, repair and spare parts queries.
0312 3412 en
Congratulations on your purchase of this

DEUTZ engine. The DEUTZ air/liquid-cooled
engines are developed for a broad spectrum of
applications. A wide range of variants ensures
that the respective requirements are met.
The engine is equipped according to the installation case you have specified, i.e. not all the
parts described in this instruction manual are
installed in your engine.
We have done our best to highlight the differences so that you can easily find the operating
and maintenance instructions relevant to your
engine.
Note
Illustrations and data in this instruction manual
are subject to technical changes in the course
of further development of the engine.
Reprinting and reproduction of any kind, even
in part, require our express permission.
Please make sure that this instruction manual

is available to everyone involved in the operation, maintenance and repair of the engine and
that they have understood the contents.
We will be glad to answer any inquiries you
may have.
Your
DEUTZ AG.
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Engine description . . . . . . . . . . . . . . . . 6
2.1 Engine type. . . . . . . . . . . . . . . . . . . . . . 6
2.2 Engine diagram . . . . . . . . . . . . . . . . . . 7
2.3 Lubricating oil circuit . . . . . . . . . . . . . . 11
2.4 Fuel circuit . . . . . . . . . . . . . . . . . . . . . 12
2.5 Coolant circuit. . . . . . . . . . . . . . . . . . . 13
2.6 Electrics . . . . . . . . . . . . . . . . . . . . . . . 14
3 Operation . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Ambient conditions . . . . . . . . . . . . . . . 15
3.2 Initial commissioning . . . . . . . . . . . . . 16
3.3 Start process . . . . . . . . . . . . . . . . . . . 18
3.4 Operation monitoring . . . . . . . . . . . . . 19
3.5 Stop process. . . . . . . . . . . . . . . . . . . . 21
4 Consumables . . . . . . . . . . . . . . . . . . . . 22
4.1 Lubricating oil . . . . . . . . . . . . . . . . . . . 22
4.2 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . 25
5 Maintenance. . . . . . . . . . . . . . . . . . . . . 27
5.1 Maintenance schedule . . . . . . . . . . . . 27
6 Care and maintenance work. . . . . . . . 29
6.1 Lubricating oil system . . . . . . . . . . . . 29
6.2 Fuel system . . . . . . . . . . . . . . . . . . . . 31
6.3 Cooling system . . . . . . . . . . . . . . . . . . 34
6.4 Engine cleaning . . . . . . . . . . . . . . . . . 36
6.5 Intake system . . . . . . . . . . . . . . . . . . . 37
6.6 Belt drives. . . . . . . . . . . . . . . . . . . . . . 39
4
6.7 Adjustments . . . . . . . . . . . . . . . . . . . . 40
6.8 Electrical system . . . . . . . . . . . . . . . . 42
7 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.1 Fault table . . . . . . . . . . . . . . . . . . . . . 44
7.2 Engine management . . . . . . . . . . . . . 46
8 Transport and storing . . . . . . . . . . . . 48
8.1 Engine transport . . . . . . . . . . . . . . . . 48
8.2 Preservation. . . . . . . . . . . . . . . . . . . . 49
9 Technical data. . . . . . . . . . . . . . . . . . . 51
9.1 Technical data . . . . . . . . . . . . . . . . . . 51
General
DEUTZ diesel engines
are the product of years of research and development. The profound expertise gained through this, in combination with high demands
on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability and low fuel consumption. Naturally the
high requirements for protection of the environment are also met.
Safety precautions when the engine is

running
Only carry out maintenance work or repairs
with the engine switched off. Ensure that the
engine cannot be started unintentionally - danger of accidents!
Re-install any removed protective equipment
upon completion of the work.
Observe industrial safety regulations when
operating the engine in enclosed spaces or underground.
When working on the running engine, work clothing must be close fitting.
Only re-fuel with the engine switched off.
Maintenance and care

are decisive for whether the engine satisfactorily meets the set demands. Compliance with
the prescribed maintenance times and the careful execution of maintenance and care work
are therefore essential.
Difficult operating conditions deviating from
normal operation must be observed especially.
Original DEUTZ parts

are subject to the same strict quality requirements as the DEUTZ engines. Further developments for the improvement of the engines
are also introduced for the original DEUTZ

parts of course. Only the use of original
DEUTZ parts manufactured according to the
latest state of knowledge will guarantee perfect
functioning and high reliability.
DEUTZ Xchange components

DEUTZ Xchange components are a low-cost
alternative. The same high quality standards
as for new parts apply here of course. DEUTZ
Xchange components are equivalent to the original DEUTZ parts in function and reliability.
Asbestos
Gaskets used in this engine are asbestos-free.
Please use the appropriate spare parts for
maintenance and repair work.
Service
The DEUTZ homepage with references to product responsibilities and services always gives
you an up-to-date overview of the DEUTZ partners in your area. Or use the fast, comfortable
route via the Internet under www.deutzshop.de. With the DEUTZ P@rts OnlinePartsCatalogue you have direct contact to the
nearest local DEUTZ Service Station.
DEUTZ AG
Deutz-Mlheimer Str. 147-149
D-51057 Kln
Phone: 0049-221-822-0
Fax: 0049-221-822-5304
Telex:8812-0 khd d
http://www.deutz.com
We want to preserve the high performance of

our engines and with it the confidence and satisfaction of our customers. Therefore we are
represented by a network of service branches
world-wide.
The name DEUTZ stands not only for an engine which is the result of sophisticated development work, DEUTZ Parts catalogue also
stands for a complete service package which
guarantees the optimum operation of our engines and for a customer service on which you
can rely.
Contact one of our responsible service representatives in case of operation malfunctions
and spare parts inquiries. Our trained specialist personnel ensures fast, professional repairs using original parts in the event of
damage.
5
Engine description
2.1 Engine type

D
2
Mot.-Typ
Code
KW(S)
kW(G)
Mot.-Nr.
1/min
XX
left
XX
XX
KW(G) red.
EP
<
KW(S) red.
kW(W)
DEUTZ AG
MADE IN GERMANY
right
1
Company plate
The type A, the engine number B and the performance data are stamped on the company
plate. The engine type and number must be
stated when purchasing spare parts.
Position of the company plate and

engine number
The company plate C and engine number D
are fixed or stamped on the crankcase.
General definitions
Cylinder arrangement, engine sides
and direction of rotation
Cylinder arrangement
The cylinders are counted consecutively, starting from the flywheel1.
Direction of rotation
Looking onto drive side
z left-hand rotation: counter-clockwise (see
example)
Engine sides
Looking at the power transmission side.
z left,
z right.
Engine description
2.2 Engine diagram
17
18
16
15
14
4
13
1. Crankcase venting
2. Connection to coolant heat exchanger
3. Charge air duct
4. Coolant pump
5. Connection from coolant heat exchanger
6. Vibration damper / V-belt pulley
7. Lubricating oil tray
8. Generator
9. Oil drain plug
10.Fuel supply pump
11.Connection from charge air cooler left
(optional: right)
12.Connection to charge air cooler
13.Cylinder head cover
14.Transport bracket
15.Exhaust manifold
16.Connection from air filter
17.Turbocharger
18.Connection to exhaust silencer
12
6
7
11
10
Example: TCD2015 V08 standard, industrial and vehicle engine, right side
Engine description
2.2 Engine diagram

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

20
21
22
19
18
1. Crankcase venting
2. Connection to coolant heat exchanger
3. Spark plug
4. Connection from the charge air cooler
5. Connection to charge air cooler
6. Connection from coolant heat exchanger
7. Lubrricating oil filter cartridge
8. Coolant pump
9. Connection of separate lubricating oil tank
10.Connection to separate lubricating oil tank
11.Vibration damper / V-belt pulley
12.Generator
13.Engine rating plate (company plate)
14.Exhaust manifold
15.Connection to the EMR3 system
16.Connection to the MVS system
17.Connection from air filter
18.Cylinder head cover
19.Connection to exhaust silencer
20.Turbocharger
21.Charge air suction pipe
22.Transport device
17
6
16
15
14
13
12
11
10
Example: TCD2015 V06 railway engine, right side
Engine description
29
30
2.2 Engine diagram

23.Auxiliary drive
24.Engine mounting
25.Gear connection (SAE)
26.Flywheel
27.Free auxiliary drive
28.Crankcase vent pipe
29.Lubricating oil cooler
30.Injection pump (plug-in pump)
31
23
24
25
26
28
Example: TCD2015 V06 railway engine, left side
10
27
2.3 Lubricating oil circuit
Engine description
1. Lubricating oil tray
2. Lubricating oil suction intake pipe
3. Lubricating oil pump
4. Pressure relief valve
5. Lubricating oil cooler
6. Lubricating oil filter
7. Main oil lines
8. Crankshaft bearing
9. Big end bearing
10.Camshaft bearing
11.Oil supply to the individual injection pumps
12.Injection pump with injector
13.Camshaft lubrication
14.Line to injection nozzle
15.Injection nozzle with pressurestat for piston cooling
16.Tappet with pulse lubrication of the rocker arm
17.Tappet rod, oil supply for rocker arm lubrication
18.Rocker arm
19.Oil return bore in the cylinder head to the crankcase
20.Oil pressure sensor / oil pressure switch
21.Oil line to the turbocharger
22.Turbocharger
23.Oil line to the crankshaft and camshaft, compressor / hydraulic pump
24.Compressor (optional)
25.Hydraulic pump (optional)
26.Pressurestat (adjustable)
27.Return line from the compressor / hydraulic pump
to the crankcase
28.Return line from the turbocharger
Example: Lubricating oil diagram
11
Engine description
2.4 Fuel circuit

1. Fuel tank
2. min. distance 500 mm
3. Fuel supply line from tank
4. Hand pump for venting
5. Fuel prefilter (example)
6. Fuel supply pump
7. Fuel double filter
8. Fuel supply line to the injection pumps
9. Injection pump
11.Injector
12.Fuel supply to the injection pumps
13.Fuel return from the injection pumps
14 Pressurestat
15 Fuel return to the fuel tank
Example: Fuel diagram
12
Engine description
2.5 Coolant circuit
x1
11
x2
x1 x2
10
12
1.
2.
3.
4.
Coolant pump
Lubricating oil cooler
Coolant duct
Cylinder pipe /head cooling (number/arrangement of cylinders depends on series)
5. Compressor (optional)
6. Gear oil cooler (optional)
7. Auxiliary cooler (optional)
8. Temperature sensor
9. Thermostat
10.Compensation tank
11.Filler neck
12.Heat exchanger
13.Cab heating (optional)
13
Example: Coolant diagram
13
Engine description
1
2.6 Electrics
3
10
11
12
9
13
14
15
16
8
17
18
19
5
20
Example: Electrics
14
1. Oil pressure sensor

2. Fuel temperature sensor
3. Charge air temperature-pressure sensor
4. Engine control unit
5. Coolant temperature sensor
6. Oil level sensor
7. Central plug
8. Impulse transmitter crankshaft
9. Impulse transmitter camshaft
10.Energy supply
11.Multifunction displays
12.Outputs (configurable)
13.Inputs (configurable) (PWM/digital/analogue)
14.Speed pedal
15.Hand accelerator (optional)
16.Switch functions
17.Detachable key switch Start/Stop
18.Diagnostic button
19.Fault lamp with blink code
20.Diagnostic interface/CAN-bus
Operation
3.1 Ambient conditions

Coolant
z Mixing ratio antifreeze/cooling water(26).
High ambient temperatures, high

altitude
Low ambient temperatures

Lubricating oil
z Select lubricating oil according to ambient
temperature(22) and consult DEUTZ partner if necessary.
z Halve the oil change times in case of frequent cold starts.
Fuel
z Below 0 C use winter fuel(24).
Battery
z A well-charged battery(42) is a prerequisite for starting the engine.
z Heating the battery to about 20 C improves
the starting behaviour of the engine. (Remove and store the battery in a warm room).
Under the following operating conditions, the amount of fuel is reduced automatically, controlled by the electronic
control unit.
Under the following application and operating
conditions, the amount of fuel must be reduced.
z above 1000 m altitude
z above 30 C ambient temperature
Reason: When the altitude or ambient temperature increases, the air density decreases.
This reduces the amount of oxygen in the engine intake air and the fuel-air mixture would
be too rich if the injected amount of fuel were
not reduced.
z The results would be:
black smoke in the exhaust
high engine temperature
reduction in engine performance
poss. impairment of the start behaviour
Consult your equipment supplier or DEUTZ
partner if you have any other questions.
Cold start aid

z Heating plugs, heating flange, spark plug
system can be used as cold start aids, for
example.(18).
15
Operation
3.2 Initial commissioning
Preparations for initial commissioning

(maintenance schedule E 10)
z Oil filling volume(51).

z Check lubricating oil level, if necessary re-fill
z Removing engine corrosion protection(49).

z Remove any transport devices.
z Check the battery and cable connections
and mount if necessary.(42).
z Check the belt tension(39).
z Have the engine monitor or warning system
checked by authorised personnel.
z Check the engine mounting.
z Check that all hose unions and clips are fit
properly.
The following additional work must be carried out on generally overhauled engines:
z Check the fuel prefilter and main filter and
change if necessary
z Check the intake air cleaner (if available,
maintain according to maintenance indicator).
z Drain lubricating oil and condensation from
the charge air cooler.
Filling fuel
Fill engine oil

Low oil and overfilling damage the engine.
The engines are generally supplied without lubricating oil filling.
Select engine oil quality and viscosity
before filling(22). Order DEUTZ lubricating oils from your DEUTZ partner(22).
z Fill engine with lubricating oil (29) via lubricating oil filler neck.
16
z The fuel low pressure system must be vented with the hand pump after filling before
starting for the 1st time(32).
Only re-fuel when the engine is not
running. Pay attention to cleanliness.
Do not spill any fuel.
Additional venting of the fuel system by
a 5 minute trial run at idle speed or low
load is absolutely necessary.
Only use clean, standard, branded diesel fuel.
Note the fuel quality(24). Insert the fuel prefilter if necessary. In case of doubt, please ask
your DEUTZ partner. Depending on the outdoor temperature, use either summer or winter
diesel fuel.
Filling the coolant system

The coolant must have a prescribed
cooling system corrosion protection(26) concentration.
Never operate the engine without coolant, not even briefly!
Order cooling system correction protection agent(26) from your DEUTZ
partner.
z Open the cooling system cap 1 carefully.
z Fill coolant up to the MAX mark on the compensation tank and close the cooling system
cap 1.
z Switch on any heater and set to maximum
so that the heating circuit is filled and vented.
z Observe the filling level in the cooling system(51).
3.2 Initial commissioning
Operation
Trial run
Venting of the fuel system by operating
for 5 minutes at idle speed or low load
is absolutely necessary.
After preparations, perform a short trial run up
to operating temperature (approx. 90 C). Do
not apply load to the engine if possible.
z Work with the engine not running:
Check engine for tightness.
Check oil level, re-fill oil if necessary(29).
Check coolant level and refill coolant if
necessary(34).
z Work during the trial run:
Check engine for tightness.
17
Operation
Starting
Before starting make sure that there is
nobody in the engine / work machine
danger area! After repairs: Check that
all protective equipment is mounted
and all tools have been removed from
the engine! When starting with heating
plug/spark plug/heating flange do not
use any additional starting devices
(e.g. injection with start pilot). Danger
of accidents!
If the engine does not start and the

fault lamp flashes, the EMR3 system
has activated the start lock to protect
the engine.
The start lock is released by switching
off the system with the ignition key for
about 30 s.
Separate the engine if possible by disengaging driven units.
Start the engine for a maximum of 20
seconds uninterrupted! If the engine
does not start up, wait for one minute
and then repeat the starting process.
If the engine does not start up after two
starting processes, determine the cause as per fault table (see 7.1).
Do not run up the engine immediately
to high idling speed / full load operation
from cold.
z Engine is controlled electronically, e.g. with
electronic engine control EMR3.
Engine is programmed and supplied with the
necessary function configurations.
z Separate engine from driven devices by disconnecting if possible.
18
3.3 Start process

z Do not run up the engine immediately to
high idling speed / full load operation from
cold.
z If the starter is connected by a relay on the
EMR3,
the maximum starting time is limited by
the EMR3.
the pause between two start attempts is
specified by the EMR3.
If the touch start function is programmed,
a short start command with the ignition
key in position 2 suffices, or a start button
if available.
The start is then continued automatically
by the EMR3.
For special applications, the EMR3 can
be programmed by a data record so that
the control unit also carries out automatic
further start attempts if the engine does
not start.
Operation
3.4 Operation monitoring

Operation monitoring by EMR3
z The EMR3 system operates the engine condition and itself.
z The states are indicated by the fault lamp.
z Lamp test:
The fault lamp lights for about 2 s after ignition (ignition lock stage 1).
z Steady light:
There is an error in the system or a variable of the engine (temperature, pressure, etc.) is in the warning range.
Depending on the fault, the engine performance can be reduced by the EMR3 to
protect the engine.
z Fast flashing:
Attention, the engine is in danger and
must be switched off.
The control unit switches the engine
off automatically depending on the application.
To cool down the engine before switching
off, the control unit can command forced
engine operation at low idling speed or
automatic switch off.
There may be a start lock after stopping
the engine.
Additional control lamps, e.g. for oil pressure or oil temperature may be switched
on if necessary.
With the override button, the power reduction can be bypassed, the automatic
shutdown delayed or a start prevention
bypassed to avoid critical situations. This
overriding of the engine protection function is logged in the control unit.
The start lock is released by switching off

the system with the ignition key for about
30 s.
Display instrument
Possible displays:
z Colour scale
Display of operating state by coloured
areas (green OK / red take suitable
action)
z Measured value scale
Actual value can be read off directly. The
nominal value should be taken from the
Technical Data.(51).
19
Operation
Instrument or
display
3.4 Operation monitoring
Designation
Possible displays
Lubricating oil
pressure display
Lubricating oil pressure below min. Please see chap. 9.1

Shut down the engine
for minimum oil pressure.
Lubricating oil
pressure display
Lubricating oil pressure in the red
Engine tempeEngine temperature too high

rature
123
20
Measures
Lubricating oil
pressure pilot
lamp
If the control lamp lights after starting the engine or while

the engine is running, the lubricating oil pressure is too low
Lubricating oil
level

Check oil level, re-fill oil if necessary
the engine is running, the lubricating oil level is too low
Coolant level

Shut down the engine, allow to cool and refill coolant
the engine is running, the coolant level is too low
Operating
hours counter
Indicates the previous operating time of the engine
Observe the maintenance intervals
Horn
With acoustic signal
see fault table chap. 7
Operation
3.5 Stop process

Shutting down
Avoid switching-off from full load operation (coking/blockage of the remaining oil in the turbocharger bearing
housing)
Lubricating oil is no longer supplied to
the turbocharger!
Run the engine after relieving the load
for about 1 minute at low idling speed.
The control unit remains active for
about another 40 seconds to save the
system data (lag) and then switches off
automatically.
Electrical shutdown (optional)

z Move the key to position 0. Pilot lamps
A+B+C go out.
21
Consumables
General
Modern diesel engines place very high demands on the lubricating oil to be used. The
specific engine performances which have increased constantly over the last few years lead
to an increased thermal load on the oil and also
the oil is more exposed to contamination due to
reduced oil comsumption and longer oil
change intervals. For this reason it is necessary to observe the requirements and recommendations described in this operating manual in
order not to shorten the life of the engine.
Lubricating oils always consist of a basic oil
and an additive package. The most important
tasks of a lubricating oil (e.g. wear protection,
corrosion protection, neutralisation of acids
from combustion products, prevention of coke
and soot deposits on engine parts) are assumed by the additives. The properties of the
basic oil are also decisive for the quality of the
product, e.g. with regard to thermal load capacity.
In principle, all engine oils can be mixed. However, mixing of engine oils should be avoided
because the worst properties of the mixture are
always dominant.
The lubricating oil quality has a considerable
influence on the life, performance and thus
also on the costs-effectiveness of the engine. It
basically applies that: The better the lubricating
oil quality, the better these properties.
The lubricating oil viscosity describes the
flow behaviour of the lubricating oil depending
on the temperature. The lubricating oil viscosity has no influence and effect on the lubricating
oil quality.
22
4.1 Lubricating oil

Synthetic lubricating oils are used increasingly and have advantages. These oils have a
better temperature and oxidation stability as
well as a relatively low cold viscosity. Since
some processes relevant to the definition of
the lubricating oil change intervals are not essentially dependent on the lubricating oil quality (such as the entry of soot and other
contaminations), the lubricating oil change interval when using synthetic lubricating oils may
not be increased in relation to the specifications of the (27).
Biodegradable lubricating oils may be used
in DEUTZ engines if they meet the requirements of this operating manual.
Quality
Lubricating oils are classified by DEUTZ according to their performance capability and quality
class ((DQC: Deutz Quality Class). It basically
applies that: with ascending quality class (DQC
I, II, III, IV), the lubricating oils are more efficient or higher quality. (The suffix (- 02 / - 05)
to the quality class designation indicates in
what year the classification was made.
Lubricating oils according to other comparable
specifications can be used as long as they
meet DEUTZ requirements. In regions in which
none of these qualities is available, please
contact your DEUTZ partner responsible.
The following lubricating oils are specified for
the engines described in this operating manual.
Recommended quality class

DEUTZ DQC
ACEA
DQC-III
E4-99 / E6-04
DQC-IV
E4-99 / E6-04
1)
API
1)
Please contact your DEUTZ partner
DEUTZ lubricating oils DQC III TLX - 10W40

FE
Container
Order no..
0101 6335
5 litre container
20 litre container
0101 6336
209 litre barrel
0101 6337
Tank store
0101 6338
Lubricating oil change intervals

z The intervals (27) depend on:
Oil quality
Sulphur content in the fuel
Type of engine application
z The lubricating oil change interval must be
halved, if at least one of the following conditions apply:
Ambient temperatures permanently below -10 C (14 F) or oil temperature below 60 C (84 F).
Sulphur content in the diesel fuel of
0.5 - 1 weight %.
Operation with bio-diesel fuel.
z If the oil change intervals for vehicle engines
are to be carried out according to operating
hours, the oil change intervals for built-in engines apply.
Consumables
4.1 Lubricating oil
50
45
40
35
30
25
SAE 20W-50
SAE 20W-50
SAE 15W-40
SAE 10W-40
10
SAE 10W-30
15
SAE 5W-40
20
SAE 5W-30
The ambient temperature at the installation site

or area of application of the engine is decisive
for the choice of the right viscosity class. Too
high a viscosity can lead to starting difficulties,
too low a viscosity can endanger the lubrication effect and cause high lubricating oil consumption. At ambient temperatures below -40
C the lubricating oil must be pre-heated (e.g.
by storing the vehicle or machine in a shed).
The viscosity is classified according to SAE.
Multipurpose oils should be used basically.
Single purpose oils can be used in closed, heated rooms at temperatures >5 C.
Depending on the ambient temperature we recommend the following common viscosity
classes:
60
55
SAE 0W-40
Viscosity
SAE 0W-30
z If the oil change intervals are not reached

within a year, the oil change should be carried out at least 1x yearly.
-5
-10
-15
-20
-25
-30
-35
-40
23
Consumables
Permissible fuels
The following fuel specifications are permissible:

z Diesel fuels according to DIN EN 590
z US diesel fuel according to ASTM D 975
Grade-No.1-D and 2-D
z Japanese diesel fuel JIS K 2204 Grade 1
Fuel and Grade 2 fuel, with lubricating properties according to diesel fuel EN 590 (HFFR max. 460 micrometer according to EN
ISO 12156)
Commercially available diesel fuels with a sulphur content below 0.5%. If the sulphur content
is higher, the lubricating oil change intervals
must be reduced(27)
If other fuels are used which do not meet the
requirements of the operating manual, the warranty will be voided.
The certification measurements to satisfy the
legal emission limits are performed with the
test fuels defined by law. These correspond to
the diesel fuels according to EN 590 and
ASTM D 975 described in this operating manual. No emission values are guaranteed with the
other fuels described in this operating manual.
Winter operation with diesel fuel

Only carry out mixing in the tank. Fill
with the appropriate amount of paraffin
first, then add the diesel fuel. Normal
and high grade fuels may not be mixed.
At low ambient temperatures paraffin discharges can lead to blockages in the fuel system
and cause operating faults. Use winter fuel at
outside temperatures below 0 C (to -20 C)
24
4.2 Fuel
(generally offered by petrol stations in good
time before the cold season begins).
z Paraffin must be added below -20 C. Necessary mixing ratios according to the diagram opposite.
z For Arctic climate zones up to - 44 C, special diesel fuels can be used.
If Summer diesel fuel has to be used below 0
C, up to 30% paraffin can be mixed according
to the diagram opposite.
Generally, sufficient resistance to cold can also
be achieved by adding a flow ameliorant. For
questions regarding this please contact your
DEUTZ partner.
I
II
A
B
Summer diesel fuel

Winter diesel fuel
Outdoor temperature
Paraffin mixing proportion
Consumables
4.3 Coolant
General
In liquid-cooled engines, the coolant must be
conditioned and monitored because otherwise
the engine could be damaged.
z Corrosion
z Cavitation
z Freezing
Water quality
The right water quality is important for conditioning the coolant. Clear, clean water within the
following analysis values must always be used:
Analysis values
min. max.
ph-value at 20 C
6,5
8,5
Chloride-ion content
[mg/dm]
100
Sulfate-ion content
[mg/dm]
100
[dGH]
12
Total hardness1)
1)
The water must be conditioned in case of deviations in the analysis values.

z pH value too low: Add diluted caustic soda
or potassium soda. Small test mixtures are
recommended.
z Total hardness too high: Mix with softened
water (pH-neutral condensate or water softened by ion exchanger)
z Total hardness or carbon hardness too
low: Mix with harder water (harder water is
usually available in the form or drinking water)
z Chloride and or sulphates too high: Mix
with softened water (pH neutral condensate
or water softened by ion exchanger)
Carbonate hardness proportion of the

total hardness min. 3 dGH
Information about the water quality is available

from local waterworks. A test case can be requested from your DEUTZ partner under the
order for checking your water quality (order no.
1213 0382).
25
Consumables
Cooling system corrosion protection
agent
When mixing coolant system corrosion
protection agents on a nitrite basis with
amine-based media, health hazardous
nitrosamines are formed!
Coolant system corrosion protection

agents must be disposed of in an environmentally friendly way.
The conditioning of the coolant for liquidcooled DEUTZ compact engines is done by mixing an antifreeze with corrosion protection inhibitors on an ethylene-glycol base with the
water.
DEUTZ cooling system corrosion protection
agent
Container
Order no.
5 litre container
0101 1490
20 litre container
1016 4160
210 litre barrel
1221 1500
This cooling system protection agent is free

from nitrites, amines and phosphates and adapted to the materials in our engines. Order
from your DEUTZ partner.
If the DEUTZ cooling system protection agent
is not available, please contact your DEUTZ
partner.
The cooling system must be monitored regularly. This includes checking the concentration
of the cooling system protection agent, as well
as inspecting the coolant level.
26
4.3 Coolant
The inspection of the concentration of cooling
system protection agent can be carried out
with standard testing devices (e.g. refractometers).
Cooling system
corrosion protection part
min. 35 %
40 %
max. 45 %
Water part
Cold protection
up to
65 %
60 %
55 %
-22 C
-28 C
-35 C
For temperatures below -35 C, please have a

word with your responsible DEUTZ partner.
The use of other cooling system protection
agents (e.g. chemical corrosion protection
agents) is possible in exceptional cases. Consult your DEUTZ partner.
Maintenance
5.1 Maintenance schedule

Standard maintenance schedule
TCD 2015
Stage Activity
E 10
E 20
E 30
E 40
E 50
E 60
E 70
Execution by
Initial commissioning inspection

Daily inspection
Maintenance
Extended maintenance
Extended maintenance II
Intermediate overhaul
Complete overhaul
Authorised
specialists
Customer
Authorised
specialists
Industrial engines (oh)

Standard and EPA certified engines
(Enviromental Protection Agency)
Vehicle engines (km)

Annual operational performance [km] average
speed [km/h]
>30,00030,000 km
> 100,000 km
100,000 km
approx. 25 km/h
approx. 60 km/h
approx. 40 km/h
During the running-in phase or initial start-up of new or overhauled engines. See(16)
1x daily or every 10 oh in continuous operation
500 oh
20,000 km
30,000 km
1,000 oh
40,000 km
60,000 km
4,000 oh (only in EPA)
160,000 km
240,000 km
6,000 oh
240,000 km
360,000 km
12.000 Bh
480.000 km
720.000 km
60,000 km
120,000 km
480,000 km
720,000 km
1.440.000 km
T 5-1: Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
A maintenance diagram, order no. 0312 0040, is supplied with every engine in the self-adhesive version. It should be stuck onto a well visible location
on the engine or equipment.
Stage
E 20
daily
check
check
E 30
renew
clean
Activity
Lubricating oil level (if necessary re-fill)
Coolant level
Engine tightness (visual inspection for leaks)
V-belts (if necessary, re-tighten or renew )
Lubricating oil
Oil filter cartridge (at each lubricating oil change)
Fuel precleaner / fuel prefilter (change filter insert if necessary)1)
Section
(29)
(34)
(39)
(27)
(30)
(32)
T 5-2: Maintenance points
27
Maintenance
Stage
renew
E 40
check
E 50
set
renew
E 60
renew
clean
at least
once a year renew
every 2
years
renew
5.1 Maintenance schedule

Activity
Fuel filter cartridge
Intake air cleaner (if available, maintain according to service gauge)
Coolant (additive concentration)
Charge air cooler (Drain lubricating oil/condensation)
Battery and cable connections
V-belts (if necessary, re-tighten or renew )
Crankcase pressure breather valve
Engine mounting (renew in case of damage)
Fastenings, hose unions / clips (renew if damaged)
Valve clearance (set if necessary)
Fuel injector (only with EPA)
Spark plugs
Coolant pump
Pressurestat on the injection pump/MVS
Crankcase breather valve
Charge air cooler (Drain lubricating oil/condensation)
Fuel precleaner / fuel prefilter (change filter insert if necessary)
Engine monitoring, warning system2)
Coolant
Belt
Crankcase breather filter (only with EPA)
T 5-2: Maintenance points, Fortsetzung

1)
2)
28
If the warning system (lamp/siren) responds, the fuel prefilter must be emptied immediately.
Maintenance only to be carried out by authorised service personnel
Section
(32)
(37)
(34)
(42)
(39)
(40)
(32)
(34)
(39)
Care and maintenance work
6.1 Lubricating oil system

Regulations for working on the
lubricating oil system
Do not work when the engine is running.
Smoking and naked lights prohibited!
Danger of scalding with hot lubricating
oil!
Pay attention to utmost cleanliness
when working on the lubricating oil system.
Carefully clean the area around the affected parts. Blow damp areas dry with
compressed air.
Observe the safety regulations and national specifications for handling oils.
Dispose of leaking lubricating oil and
filter elements properly. Do not allow
used oil to seep into floor.
Perform a trial run after all work. Pay
attention to tightness and oil pressure
and then check the engine oil level. For
fuels with a sulphur content higher
than 1% ask your responsible service
representative.
Checking the lubricating oil level

Low oil level or overfilling lead to engine damage!
The oil level may only be checked with
the engine in a horizontal position and
switched off.
If the engine is warm, switch off the engine and check the oil level after 5 minutes. If the engine is cold you can
check it ilmmediately.
Quality/viscosity data(23).
Filling volume(51).
z Check engine lubricating oil level (see previous chapter)
Careful with hot oil. Danger of scalding!

z Pull out the oil dipstick and wipe off with a
lint-free, clean cloth.
z Insert the oil dipstick as far as it goes.
z Pull out the oil dipstick and read off the oil level.
z The oil level must always be between the
MIN and MAX marks! Fill up to the MAX
mark if necessary.
Changing the lubricating oil

z Run the engine warm (oil temperature > 80
C).
z Position the engine or vehicle so as to be level.
z Switch off the engine.
z Place a collecting receptacle underneath
the oil drain plug.
z Unscrew the oil drain plug, drain oil.
z Fit a new sealing ring to the oil drain plug, insert and tighten it (tightening torque 100
Nm).
z Fill in oil.
29
Changing the lubricating oil filter

cartridge
The filter cartridge may never be prefilled. There is a danger of soiling
z Remove the clips if an anti-rotation lock is fitted.
z Loosen and unscrew filter cartridge with
tool(order no. 170050) .
z Collect draining oil.
z Clean the sealing surface of the filter support with a lint-free, clean cloth.
z Oil the gasket of the new DEUTZ original filter cartridge lightly.
z Screw on the new filter cartridge by hand
and tighten a further half a turn.
z If necessary, fix the clips of the anti-rotation
lock.
30
6.1 Lubricating oil system
6.2 Fuel system

Regulations for working on the fuel
system
when refuelling and working on the fuel
system. Carefully clean the area
around the affected parts. Blow damp
areas dry with compressed air. Observe the safety regulations and national
specifications for handling fuels. Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep into
floor. After all work on the fuel system,
the system should be vented, a trial
run performed and the tightness chekked.
Additional venting of the fuel system by
a 5 minute trial run at idle speed or on
low load is absolutely essential.
Additional regulations for DEUTZ

pump line nozzle
Mortal danger! Do not work on the fuel
system while the engine is running.
The system is under high pressure! Do
not get near to a leak in the high pressure system because the fuel jet can
cause severe injury! Wait 30 seconds
after switching off the engine before
working on the fuel system. In case of
leaks in the fuel system, contact your
DEUTZ partner immediately.
Because of the high production accuracy of the system, utmost cleanliness

must be observed. The fuel system
must be tight and closed. Make a visual inspection for leaks / damage to the
system. Clean and dry the engine and
the engine compartment thoroughly
before starting work. Cover parts of the
engine compartment from which dirt
could be loosened with a new, clean
foil. Work on the fuel system may only
be carried out in an absolutely clean
environment. Air contamination such
as dirt, dust, moisture etc. must be
avoided.
Changing the fuel filter cartridge

The filter cartridge may never be prefilled. There is a danger of soiling
z Remove the clips if an anti-rotation lock is fitted.
z Loosen and unscrew filter cartridge with
tool(order no. 170050) .
z Collect fuel which runs out.
z Clean the sealing surface of the filter support with a lint-free, clean cloth.
z Oil the gasket of the new DEUTZ original filter cartridge lightly.
z Screw on the new filter cartridge by hand
and tighten a further half a turn.
z If necessary, fix the clips of the anti-rotation
lock.
z Vent the fuel system, see(32).
31
1.
2.
3.
4.
5.
6.
7.
8.
A
Filter support
Filter cartridge
Water collecting receptacle (bowl)
Electrical connection
Drain plug
Fuel hand pump
Vent screw
Sealing surface
Connection possibility for electrical water level
sensor (optional)
Cleaning fuel prefilter/

z Close fuel stopcock.
z Position fuel collecting receptacle beneath
fuel prefilter.
z Loosen the drain plg 5 and drain fuel/water.
z Unscrew the filter cartridge 2 and the water
collecting receptacle 3 in anti-clockwise direction and remove. Empty emulsion in the
water collecting receptacle and clean the receptacle.
32
z Screw the filter cartridge 2 and the water collecting receptacle 3 together. Wet the
sealing surfaces of the filter cartridge and
the water collecting receptacle with fuel.
z Mount in clockwise direction.
z Open the fuel stopcock and vent the system.
z Check tightness after starting the engine.
Changing the fuel prefilter cartridge
z Shut off the fuel supply to the engine (with
high lying tank).
the prefilter.
z Pull out the plug of the optional water level
sensor (4).
z Open the water drain cock (5) and drain liquid.
z Unscrew the filter cartridge (2) together with
the water collecting receptacle (3).
z Unscrew water collecting vessel (3) from the
filter cartridge (2).
z Clean the water collecting receptacle (3)
and all the available sealing surfaces with a
brush and clean diesel fuel.
z Oil the gaskets of the new DEUTZ original
filter cartridge (2) lightly or wet with diesel fuel.
z Screw water collecting receptacle (3) to the
filter cartridge (2).
z Screw new filter cartridge (2) to the filter
support (tightening torque: 17-18 Nm).
z Connect the water level sensor (A).
z Open the fuel supply to the engine.
z Vent the fuel system
6.2 Fuel system

Venting the fuel prefilter
z Loosen the vent screw 7 slightly.
z Operate the pump until bubble-free fuel
flows out.
z Tighten vent screw 7
.
.
6.2 Fuel system
Cleaning / purging and possibly

changing the fuel prefilter
Connection of a warning system (lamp/
siren) to contacts 7 is prescribed. Immediate maintenance is necessary if
the warning system is triggered.
No naked lights when working on the
fuel system!
Do not smoke!
Dispose of used fuel in an environmentally friendly way!
Cleaning (purging) draining water:
z Shut off the engine or switch over to the
other filter if a lubricating oil filter is fitted.
z Close the fuel stopcock or supply (if available).
z Open the vent screw 1 on the cover 2.

z Position fuel collecting receptacle beneath
fuel prefilter.
z Empty water and dirt from the bowl 6 by opening the drain cock (press in lightly without
using force and turn) and close the drain
cock again afterwards.
z Close the vent screw 1 on the cover 2.
z Vent the fuel system see(32).
Changing the filter element 5:
Change at least once a year or when necessary (drop in performance even after purging).
z Shut off the engine or switch over to the
other filter if a lubricating oil filter is fitted.
z Close the fuel stopcock or supply (if available).
z Loosen the cover screws 3 diagonally.
z Remove cover 2.
z Remove spring cassette 4.
z Remove filter insert 5 on the clip.
z Insert new filter insert 5.
z Place the spring cassette 4 on the element.
z Check the cover gasket for correct fit in the
cover 2 and for damage (change if necessary).
z Tighten the cover 2 with the screws 3 diagonally (tightening torque 6 Nm).
z Check the cover 2 for correct fit and tightness.
z Vent the fuel system see(32).
33
6.3 Cooling system
Regulations for working on the cooling

system
Danger of scalding with hot coolant!
Cooling system is under pressure!
Only open the cap in the cooled state!
Coolant must have a prescribed cooling system corrosion protection(26)
concentration !
Observe the safety regulations and national specifications for handling cooling media. In case of an external
cooler, proceed according to the manufacturers specifications. Dispose of
leaking coolant properly and do not allow them to seep into the ground. Order cooling system corrosion
protection agents from your DEUTZ
partner.(26).
Checking the coolant level in an

external cooler
z Fill in new coolant and vent the system according to the cooling system manufacturers specifications.
z Open the cooling system cap 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.
34
1
C
Checking the coolant additive

concentration
z With a conventional antifreeze measuring
instrument1 (e.g. hydrometer, refractometer), check the coolant additive concentration in the cooler / compensation tank 2 .
z For necessary coolant additive concentration, see(26).
The appropriate test device can be obtained
from your DEUTZ partner under the order
number 1824.
Emptying the cooling system

the screw plug (arrow). This is also available
on the opposite side.
z Unscrew the screw plug and sealing ring,
drain the coolant.
z Fit new sealing ring to screw plug, turn in
and tighten it (tightening torque 38 Nm).
z Check for tightness.
6.3 Cooling system
Filling the cooling system
z Open the cooling system cap 1 carefully.

z Fill up with coolant to the MAX mark on the
compensation tank and close cooling system cap 1.
z Switch on heating, if available, and set to
maximum so that the heating circuit is filled
and vented.
z Warm up the engine to operating temperature (opening temp. of the thermostat).(51)).
z Switch off the engine.
z Check the coolant level on the cool engine
and fill up to the MAX mark of the compensation tank if necessary.
35

Cleaning work
For all cleaning work, make sure that
no parts are damaged (e.g. bent cooler
mesh).Cover electrical/electronic parts
and connections to clean the engine
(e.g. control units, generator, solenoid
valves etc.) Do not aim the water/
steam jet directly at them. Run the engine warm afterwards.
Only carry out cleaning work on the engine when it is not running! Remove
the engine cover and cooling air cover
if available and remount after cleaning.
General
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
engine.
z Coolant leakage
z Lubricating oil leakage
z Fuel leakage
Because of the different application conditions,
cleaning depends on the degree of soiling.
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.
Cleaning with cold cleaner
z Spray the engine with cold cleaner and leave it for about 10 minutes to take effect.
z Spray the engine clean with a high pressure
water jet.
36
z Warm up the engine so that the water residues evaporate.

Cleaning with a high pressure cleaner
z Clean the engine with a steam jet (maximum
spray pressure 60 bar, maximum steam
temperature 90 C, distance at least 1m)
z Warm up the engine so that the water residues evaporate.
z Clean external cooler according to the manufacturers specifications.
6.4 Engine cleaning
6.5 Intake system
Regulations for working on the intake

system
Do not work when the engine is running.
when working on the intake system,
close intake openings if necessary.Dispose of old filter elements properly.
Maintenance indicators for dry air filter
Dry air filter
z The dry air filter is maintained according to a

maintenance indicator or service gauge.
z Maintenance is necessary when:
when the engine is running, the yellow
warning light of themaintenance indicatorlights up.
the red field (1) of theservice gaugeis
completely visible.
z After completion of the maintenance work
push the reset button on the service gauge.
The service gauge is ready for operation
again.
Maintaining the dry air filter
Never clean filter element (3) with petrol or hot liquids!

Renew damaged filter elements.
z Maintain the filter element (3) according to
the interval in the maintenance schedule
(see chap. 5.1).
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.
37
6.5 Intake system
Renewing the safety cartridge of the dry air

filter
Never clean the safety cartridge (4).
z Renew the safety cartridge (4) at the interval
specified in the maintenance schedule (see
chap. 5.1).
z To do this:
Unscrew hexagon nut (5), pull out safety
cartridge (4).
Insert new safety cartridge, screw on hexagonal nut.
z Insert filter element (3), mount hood (2) and
fix with clamping yoke (1).
Cleaning the dust discharge valve of

the dry air filter
z Empty the dust discharge valve (1) by pressing together the discharge slit.
z Remove any stuck on dust residues by
squeezing the upper area of the valve.
z Clean the discharge slit.
38
Emptying the cyclone precleaner

Never fill the dust container (3) with
lubricating oil!
z Loosen wing nut (1) and lift housing cover
(2).
z Remove the dust container (3) from the
base (4) and empty it. Clean the container
with a brush and clean diesel fuel. Then dry.
z Place the dust container (3) on the base (4)
and tighten the housing cover (2) with wing
nut (1).
6.6 Belt drives
Checking the belt drive
Checking the belt tension
Tightening the belt
Only carry out work on the belt drive

when the engine is not running!
z Check the whole belt drive visually for damage.
z Renew damaged parts.
z Remount protective devices if necessary.
z Pay attention to correct fit of new belts,
check the tension after running for 15 minutes.
z Lower indicator arm (1) into the measuring

device.
z Place guide (3) between two belt pulleys on
the V-belt (2). The stop should be at the side.
z Press the button (4) at right angles to the Vbelt (2) evenly until you hear or feel the
spring snap in.
z Lift the measuring device carefully without
altering the position of the indicator arm (1).
z Read the measured value at the point of intersection (arrow), scale (5) and indicator
arm (1). Setting values see(51).
z If necessary, re-tighten and repeat measurement.
Tools
(The belt tension measuring device (order no.
8115) is obtainable from your DEUTZ partner.
z Loosen screws 2.
z Tighten screw 1 in clockwise direction until
the desired belt tension is achieved.
z Tighten screws 2.
Changing belts
z Loosen screws 2.
z Loosen screw 1.
z Tighten screw 1 in clockwise direction until
the desired belt tension is achieved.
z Remove belt and fit new one.
z Tighten screws 2.
39
6.7 Adjustments
EX
IN
2
2
4
1
1
Setting the valve clearance

z Before valve clearance setting: Let the engine cool down for at least 30 minutes. Oil
temperature below 80 C.
z Set crankshaft according to setting schematic,(41)
z Loosen screws 1.
z Remove valve cowling 2 with gasket 3
z Mount the turn-over gear on the flywheel
with fastening screws.
z Turn over the crankshaft until you reach valve overlap.1) Cylinder 1 bank A order(41)
1)
Exhaust valve is not yet closed, inlet valve begins

to open.
40
z Loosen lock nut (1).

z Mount rotation angle disc (4) and socket
wrench insert on the valve clearance setting
screw (2).
z Fix the magnet of the rotation angle disc (4).
z Turn the rotation angle disc (4) clockwise to
the stop (rocker arm without clearance) and
set the scale to zero.
z Turn the rotation angle disc (4) anticlockwise until reaching the specified rotation angle
value. IN = inlet valve 90 +10 EX = outlet
valve 108 +10
z Hold the rotation angle disc (4) to stop it
twisting.
z Tighten the lock nut 1 (tightening torque 20
Nm ).
z Then set the second valve on the rocker arm
as described above.
z Repeat the setting procedure on every cylinder.(51).
3
z Remount the valve cowling with a new gasket in reverse order.
z Replace the screws (tightening torque 22
Nm).
The valve clearance can also be set using a
feeler gauge. Gauges with 0.25 mm or 0.09 inches must be used for the inlet valve.
Gauges with 0.30mm or 0.12 inches must be
used for the exhaust valve.
Setting schematic for the valve

clearance
Valve overlap: Exhaust valve is not yet closed.
Inlet valve begins to open.
6.7 Adjustments
This engine is equipped with an internal exhaust gas return system.
6-cylinder: The exhaust valve opens
briefly in the intake stroke.
8-cylinder: The exhaust valve opens
briefly in the discharge stroke.
Do not confuse this with the valve
overlap!
Engine TCD 2015 - 6 cylinder
Valve overlap
A1
B3
A3
B2
A2
B1
set
B2
A2
B1
A1
B3
A3
Engine TCD 2015 -8 cylinder

Valve overlap
A1
B4
A4
B1
B3
A3
B2
A2
set
B3
A3
B2
A2
A1
B4
A4
B1
41

Regulations for working on the
electrical system
Do not touch live parts! Replace defective pilot lamps immediately!
Pay attention to correct polarity of the
connections.Cover electrical/electronic parts and connections before cleaning the engine (e.g. control units,
generator, solenoid valves etc.) Do not
aim the water/steam jet directly at
them. Run the engine warm afterwards
to evaporate moisture residues.Do not
check for voltage by tapping against
ground.For electrical welding work, the
ground terminal of the welding gear
must be clamped directly to the part
being welded.Three-phase current generator: Do not interrupt the connections between the battery, generator
and governor when the engine is running.
Battery
Electronically saved data could be lost
when the battery is disconnected.Keep
the battery clean and dry. Make sure
the battery is fit correctly and firmly.Dispose of old batteries in an environmentally friendly way.
42
6.8 Electrical system

Danger of explosion! The gases released by the battery are explosive! Fire, sparks, smoking and naked lights
are prohibited! Danger of acid burns!
Wear protective gloves and glasses!
Avoid contact with skin and clothing.Danger of short circuit! Do not
place any tools on the battery!
Checking the acid level

z Unscrew caps.
z Note the manufacturers specifications on
the liquid level. The liquid should normally
be 10-15mm above the top edge of the plates or reach up to any available control device.
z Only use distilled water to top up the battery.
z Screw in caps.
Checking the voltage
z Check the battery voltage with a conventional voltmeter. The voltage indicates the
charging state. It should be between 12 and
14.4 [V] Volt per battery.
Checking acid density
z Unscrew caps.
z Measure the acid density of individual cells
with a standard acid testing device. The
measured values indicate the charging state
6.8 Electrical system

of the battery (see T 6-7-1). The acid temperature when measuring should be 20 C if
possible.
z Check the acid level before recharging.
z Screw in caps.
Acid density [kg/ l]
Charging
state
Normal
1,28
1,20
Tropics
1,23
1,12
good
half
1,12
1,08
empty
Action
z Connect the plus pole first and then the minus pole. Otherwise there is a danger of
short-circuiting. Make sure the terminals
have a good contact. Tighten the clamping
screws by hand.
z Grease the assembled terminals with an
acid-free, acid-resistant grease.
charge
charge immediately
T 6-7-1 acid density
Removing the battery

z Always disconnect the minus pole first when
removing the battery. Otherwise there is a
danger of short-circuiting.
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 manufacturers instructions.
z Screw in caps.
Installing the battery
z Insert new or charged battery and attach the
fastenings.
z Clean the terminals and battery poles with
fine grained sandpaper.
43
Faults
Faults
Engine doesn't start up, or

starts up with difficulty
Engine doesn't start up and diagnosis light is blinking

Engines starts up, but runs irregularly or misfires
Speed changes are possible
and diagnostic lamp lights up
Engine gets too hot. Temperature warning system is activated
Engine lacks power
Engine lacks power and diagnosis lamp lights up

T 7-1: Fault table
44
7.1 Fault table

Causes
Not disconnected (if possible)
Starting limit temperature not reached
Wrong SAE viscosity class of the engine oil
Fuel quality does not comply with instruction manual
Air in fuel system
Battery defective or not charged
Cable connections to the starter loose or oxidised
Starter defective or pinion doesn't mesh
Measures
Check clutch
15
Change the lubricating oil (23)
Change the fuel (24)
Venting the fuel system (32)
Check battery (42)
Check cable connections
Check starter
Check error according to error code, clear error if
Engine electronics prevent start
necessary
High pressure pipe leaking
Check high pressure pipe
Injector defective
Check injector/change if necessary
Engine electronics has detected a system error and activates an equivalent Check error according to error code, clear error if
speed
necessary
Oil level too low
Fill up lubricating oil (29)
Oil level too high
Check oil level and drain if necessary (29)
Air filter soiled / turbocharger defective
Check /change if necessary
Air filter maintenance switch / display defective
Fan defective / V-belt torn or loose
Check fan/V-belt/change if necessary
Heat short-circuit in the cooling system
Check the cooling system
Resistance in cooling system is too high / flow volume too low
Check the cooling system
Oil level too high
Check lubricating oil level (29)
Air filter maintenance indicator / service gauge defective
Charge air pipe leaking
Check charge air pipe
High pressure pipe leaking
Check high pressure pipe
Fuel injector defective
Check fuel injector
Check error according to error code, clear error if
Engine electronics reduce power
necessary
7.1 Fault table

Faults
Causes
Engine doesn't work on all cy- High pressure pipe leaking
linders
Oil level too low
Engine has no, or too little, oil
Engine is tilted too far
pressure
Incorrect SAE class or quality of engine lubricating oil
Oil level too high
Engine has too high oil consumption
Oil level too high
Engine smoulders blue
Starting limit temperature not reached
Engine smoulders white
Air filter maintenance indicator / service gauge defective
Engine smoulders black
Charge air pipe leaking
Faults
Measures
Check fuel injector/change if necessary
Fill up lubricating oil
Check engine mounting / reduce inclination
Change the lubricating oil (22)
Check oil level and drain if necessary
Check oil level and drain if necessary (29)
15
Check charge air pipe
Check fuel injector/ change if necessary
T 7-1: Fault table
45
Faults
When the fault is corrected the light

goes out. For some faults it is necessary to switch off the ignition, wait for
30 s and then switch the ignition back
on.
Engine protection function of the electronic
engine control EMR3
Depending on the design of the monitoring
functions, the EMR3 can protect the engine
from damage in certain fault situations by monitoring compliance with important limit values
during operation and checking the correct
function of the system components. Depending on how serious a detected fault is, the engine may continue to operate with restrictions,
whereby the fault lamp indicates a serious system fault by blinking. In this case, the engine
must be switched off as soon as it is safe to do
so. Depending on the engine configuration, the
blinking fault lamp may have the following meaning.
z Request to the operator to shut down
z Caution Failure to do so will void the warranty!Automatic shutdown of the engine after a
short warning time, possibly connected with
a start prevention To cool down the engine,
forced engine operation at low ildling speed,
possibly with automatic shutdown.Start prevention. See also (18)
Use of the Diagnosis button

With the diagnosis button the fault at hand can
be read out as a blink code. The diagnosis button and the fault lamp are located in the vehicle
drive stand. The occurrence of errors is indicated by flashing or steady lighting of the fault
lamp. More precise information regarding all
46
7.2 Engine management

existing faults can be read out in the form of a
blink code, only when the engine is not running, in the following manner: After pressing
the diagnosis button for at least one second,
the fault light goes out and the first fault is output as a blink code after releasing the button.
Analyse the blink code as per the table on the
following page. After outputting the fault blink
code, the fault lamp goes out for five seconds.
Then the next fault (i.e. the following one in the
fault memory) can be displayed by pressing
the diagnosis button. If the last existing fault
has been shown, by actuating the diagnosis
button once more the first fault will be shown
again.
Table of fault blink codes Diagnosis

button
The possible blink codes, their meaning and
measures for correcting faults can be found in
the table on the following page. The blink code
values in the first column indicate the number
of preliminary short blink signals (illuminated
duration approx. 0.4 s), the number of subsequent long blink signals (illuminated duration
approx. 0.8 s) as well as the number of concluding short blink signals. The code 2-1-4 for the
fault overspeed is made up of two short, one
long and four short blink signals, for example.
If a fault cannot be corrected by the measures
given in the table please contact your service
representative responsible.
Faults
7.2 Engine management

short (0.4 s)
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
5
5
Blink code
long (0.8 s)
2
3
4
1
2
2
2
2
3
3
3
3
3
3
4
7
1
1
1
1
short (0.4 s)
6
6
4
6
2
3
6
8
1
2
3
5
7
8
1
1
4
8
4
5
Function / component
Fault
Hand accelerator
Monitoring air filter
Monitoring of oil temperature
Monitoring fuel low pressure
Input accelerator 1 (PWM)
Monitoring charge air pressure
Input accelerator 1 (analogue)
Monitoring fuel filter water level
Monitoring oil pressured
Monitoring coolant temperature
Monitoring intake air temperature
Monitoring coolant level
Monitoring fuel temperature
Monitoring fan speed
Monitoring combustion
CAN-Bus
Monitoring hydraulic oil temperature
Monitoring battery
Monitoring terminal 15
Monitoring terminal 50
Signal faulty / implausible

Air pressure after filter too low
Temperature outside the nominal range
Fuel low pressure outside the nominal range
PWM signal faulty
Charge air pressure outside the nominal range
Signal faulty / implausible
Max. water level exceeded
outside the nominal range
Temperature above the nominal range
Temperature above the nominal range
Level below the nominal range
Speed outside the nominal range
Misfire detected in one or more cylinders
Timeout of one or more transmission messages, bus inactive
Voltage outside the nominal range
No signal detected
Permanent signal detected
47
Transport and storing
8.1 Engine transport
1
2
Suspension equipment
z Only use the correct suspension equipment
for engine transportation. Suspension
equipment must be adjustable for the engine
centre of gravity.
48
The engine may tip or crash down if

suspended incorrectly.
8.2 Preservation
General
Engines contain the following kinds of corrosion protection
z interior corrosion protection
z Exterior corrosion protection
Your DEUTZ partner has the right corrosion protection agent for your needs.
The following corrosion protection work may
only be carried out by persons familiar with it
and instructed in the potential dangers. Due to
the following corrosion protection measuresafter shutting down the engine the requirements for 12 month protection are met. If these
measures are deviated from by exposing the
corrosion-protected engines or parts to unfavourable conditions (installation outdoors or
storage in damp, badly aired places) or damage to the corrosion protection layer, a shorter
corrosion protection duration is to be expected.
The engine corrosion protection should checked about every 3 months by opening the covers. If corrosion is detected, the corrosion
protection should be renewed. At the end of
the corrosion protection work the crank drive
may no longer be turned so that the corrosion
protection agent in the bearings, bearing liners
and cylinder liners is not scraped off.Before
operating a corrosion protected engine, the
corrosion protection must be removed.
interior corrosion protection

Interior corrosion protection is always provided
by wetting of the walls with the implemented
corrosion protection agent in a corrosion protection running of the engine. The corrosion
protection ( run can be performed once to pro-
tect the different systems.

Fuel system
z Fill the fuel tank with a mixture of:
90% distilled fuel
10% corrosion protection oil SAE 20W-20
z Perform a corrosion protection run with no
load for at least 5 minutes.
Lubricating oil system
z Drain lubricating oil from warm engine.
z Thoroughly clean oil tray, cylinder head with
rocker arms, valves, valve springs with diesel fuel or cleaning agent.
z Fill the engine with corrosion protection oil
SAE 20W-20 up to the MAX mark and perform a corrosion protection run for at least 5
minutes so that all the components of the lubricating oil system are wetted or all accessible parts are wetted with corrosion
protection oil and pump corrosion protection
oil through the engine with a separate pump
until all bearings and bearing liners are wetted.
Air compressor
With a mounted air compressor a corrosion
protection agent should be sprayed into the air
compressor intake system after switching off
the engine until the agent visibly emerges from
the adapter.
Cooling system
Depending on the series the engines are
equipped with cooling air, cooling oil or cooling
fluid system (cooling water with cooling system

protection agent).See the chapter Exterior corrosion protection for the cooling air system.In
engines of the oil-cooled series the circulating
lubricating oil serves simultaneously for cooling. The cooling chambers are protected automatically against corrosion with the lubricating
oil system.If a coolant with corrosion protection
properties is poured into liquid-cooled engines,
no further action is necessary after draining.
z If not, the coolant must be drained and, to
ensure the formation of a covering layer on
the inside surfaces of the cooling system, a
corrosion protection run performed with a
mixture of:
95% treated water
5% corrosion protection agent
z The duration of the corrosion protection run
and the concentration of the corrosion protection agent are specified by the manufacturer of the corrosion protection agent.
z Then drain the coolant.
Air intake pipes
After the corrosion protection run, remove the
cylinder cover and deinstall injectors. The respective piston must be set to LDC.
z The accessible part of the cylinder liner
should be coated with corrosion protection
oil with a spray lance through the opening.
z Spray corrosion protection oil SAE 20W-20
into air intake pipe.
Oil drips in lines are not permissible and
must be sucked off if necessary.
49

Exterior corrosion protection
The engine must be cleaned thoroughly with a
cleaning agent before exterior corrosion protection. Any signs of corrosion and damage to
the paintwork must be removed.
Cooling air system in air-cooled engines
The air duct space in V engines is unpainted
and must be sprayed with a corrosion protection agent.
Bare exterior surfaces and parts
Coat or spray all bare exterior parts and surfaces (e.g. flywheel, flange faces) with corrosion protection agent.
Rubber parts
Rubber parts (e.g. muffs) which are not painted
over must be rubbed down with talcum powder.
Belt drives
Remove V-belts and V-rib belts and store packed. Spray V-belt pulleys and tension pulleys
with corrosion protection agent. Toothed belts
to the engine control may not be removed.
Engine openings
All engine openings must be fitted with airtight, water-tight covers to delay the liquefication process of the corrosion protection agents.
With installed air compressor, the suction and
pressure connection must be sealed by a cap.
Air should be locked out to avoid ventilation of
the engine (chimney effect) for the suction from
an air supply pipe.
50
8.2 Preservation
Storage and packaging
After being protected against corrosion, the engine must be stored in a dry, ventilated hall and
suitably covered. The cover must be placed
loosely over the engine so that the air can circulate around it to prevent condensation from
forming. Use a dessicant if necessary.
Removal of corrosion protection

The corrosion protection must be removed
from the corrosion protected engine before
starting. The packaging must be removed as
well as all covers from the sealed openings.
Any signs of corrosion and damage to paintwork must be removed.
Fuel system
z If there is a mixture of diesel fuel/corrosion
protection oil in the fuel tank, drain it.
z Fill the fuel tank and fuel system with the
proper fuel.
Coolant system
z If the implemented corrosion protection
agent is compatible with the intended
coolant system protection agent, this can be
filled directly into the coolant system as specified.
z If it is uncertain whether the implemented
corrosion protection agent is compatible
with the coolant system protection agent,
the cooling system should be purged with
fresh water for about 15 minutes before filling.
Removal of exterior corrosion protection

z Wash all surfaces and components coated
with corrosion protection agent with distilled
fuel or a suitable cleaning agent.
z Wash out grooves of V-belts if necessary.
z Mount V-belts or V-rib belts as specified.
Technical data
9.1 Technical data

Technical data
Number of cylinders
Cyl. arrangement
Bore
Stroke
Engine swept volume
Compression ratio
Working principle
Combustion process
Valve arrangement
Direction of rotation
according to DIN 70020-A
Engine power
Speed (nominal speed)
Valve clearance in cold engine (see note below 6.1.1)
Pre-stroke
Engine ignition sequence
Ignition pressure max.
V-belt tension: Generator 55 Ampere
V-belt tension: Generator 120 Ampere
Cooling
Coolant quantity
Permissible continuous coolant temperature engine outlet
Temperature difference between coolant inlet/outlet
Thermostat opens from
Thermostat is fully open at
Lubrication
Min. oil pressure in warm condition (120 C) and at low idling speed /
nominal speed
TCD 2015
6
[mm]
[mm]
[cm3]
[e]
[approx. kg]
[kW]
[rpm]
[mm]
[mm]
V- 90 form
132
145
11906
15874
17,5
4 stroke
Direct injection / charged
hanging in cylinder head, 2 inlet / 2 outlet valves
counter-clockwise
1020
1244
350-5001)
240-3601)
1500-2100
Inlet 0.25 + 0.1 / outlet 0.3 + 0.1
1)
A1-B3-A3-B2-A2-B1
[kPa (bar)]
[N]
[N]
[approx. l]
[C]
[C]
[C]
[C]
[kPa (bar)]
TCD 2015
8
A1-B4-A4-B1-B3-A3-B2-A2
17500 (175)
Pre-tightening: 55050 / retightening: 300502)

600 / 350 50
Liquid cooled
17 + ext. Cooling system
21 + ext. Cooling system
max.103
max. 5
Version A 79 or version B 87
Version A 94 or version B 102
Forced feed lubrication
1 00 (1)
T 9-1: Technical data
51
Technical data
Oiler stone filling volume
Oiler stone filling volume (filter installed in engine)
Oiler stone filling volume (filter separate)
Fuel
Fuel supply pump
Perm. low pressure suction side
Injection system
Impulse transmitter
9.1 Technical data

[l]
[l]
[l]
[kPa (bar)]
TCD 2015
343)
383)
383)
24
Gear pump
50 to 100 (0.5 to 1) absolute
Pump line nozzle
Electronic control unit (EMR3)
T 9-1: Technical data

1)
Engine power, speed, pre-stroke are stamped on the engine company plate among other things
Retighten after running under load for 15 minutes.
3) Approximate values can vary depending on version The upper oil measurement marking is always decisive.
2)
52
TCD 2015
453)
483)
503)
DEUTZ AG
Service Information Systems
Deutz-Mlheimer Strae 147-149
D - 51063 Kln
Telefon: ++ 49 (0) 221 - 822 - 0
Telefax: ++ 49 (0) 221 - 822 - 5358
Internet: www.deutz.com
E-mail: [email protected]
The engine company.
Printed in Germany
All rights reserved
1st Edition, 01/2006
Order no. 0312 3412 en

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Operation Manual

z This engine is built exclusively for

Maintenance/cleaning work on the engine may

Operation Manual TCD 2015

Please enter the engine number here.(6)

Congratulations on your purchase of this

Please make sure that this instruction manual

Safety precautions when the engine is

Maintenance and care

Original DEUTZ parts

are also introduced for the original DEUTZ

DEUTZ Xchange components

We want to preserve the high performance of

2.1 Engine type

Position of the company plate and

2.2 Engine diagram

2.2 Engine diagram

2.2 Engine diagram

Example: TCD2015 V06 railway engine, right side

2.2 Engine diagram

2.3 Lubricating oil circuit

Example: Lubricating oil diagram

2.4 Fuel circuit

Example: Fuel diagram

2.5 Coolant circuit

Example: Coolant diagram

1. Oil pressure sensor

3.1 Ambient conditions

High ambient temperatures, high

Low ambient temperatures

Cold start aid

3.2 Initial commissioning

Preparations for initial commissioning

z Oil filling volume(51).

z Removing engine corrosion protection(49).

Fill engine oil

Filling the coolant system

3.2 Initial commissioning

If the engine does not start and the

3.3 Start process

3.4 Operation monitoring

The start lock is released by switching off

3.4 Operation monitoring

Lubricating oil pressure below min. Please see chap. 9.1

Lubricating oil pressure in the red

Engine tempeEngine temperature too high

Shut down the engine

Shut down the engine

If the control lamp lights after starting the engine or while

If the control lamp lights after starting the engine or while

If the control lamp lights after starting the engine or while

Indicates the previous operating time of the engine

Observe the maintenance intervals

With acoustic signal

see fault table chap. 7

3.5 Stop process

Electrical shutdown (optional)

4.1 Lubricating oil

Recommended quality class

Please contact your DEUTZ partner

Please enter the engine number here.(6)

z Oil filling volume(51).

z Removing engine corrosion protection(49).