Operating Instructions

TCG 2015
Operating Instructions

TCG 2015
 Operating Instructions

TCG 2015

0299 8924 en

Engine Number:

Please enter your engine number here. This will help us to serve
you better in questions of repairs, spare parts and after-sales ser-
vice generally.

We reserve the right to make technical alterations to the drawings

and particulars in this documentation package, if this should
become necessary to improve the engines. Reprints and duplica-
tion of any kind, either in whole or in part, require our written per-
mission.
 TCG 2015

This documentation is intended for the following engine

● Engine type:

● Application:

● System name:

● Rating: kW

● Speed: min-1

● Commissioning on:

Please enter the relevant data. This will make it easier for us to help you in questions involving
repairs, spare parts and after-sales service in general.
This documentation package is to be presented to the Service Partner responsible every time a ser-
vice job is carried out.

Imprint:
DEUTZ AG
Service Information Systems
Deutz-Mülheimer-Straße 147–149
D-51063 Cologne
Tel.: (02 21) 8 22-0
Fax: (02 21) 8 22-53 58
http://www.deutz.de

Printed in Germany
All rights reseved
(1) 0304 ©

Ordering No 0299 8924 en

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 Introduction
TCG 2015 0

0 Introduction

● Please read all the information contained in this manual, and follow the Please read all ...
instructions carefully. You will avoid accidents, retain the manufacturer’s
warranty, and will be able to use a fully functional and operational engine.
● This engine has been built solely for the purpose appropriate to the scope
of delivery concerned, as defined by the equipment manufacturer
(intended use). Any other use shall be construed as not intended. The
manufacturer shall not be liable for any damage resulting therefrom; all
risks involved shall be borne solely by the user.
● The term “intended use” shall also include compliance with the operating,
maintenance and repair conditions specified by the manufacturer. The
engine may be used, maintained and repaired only by persons who are
familiar with the work concerned and who have been properly informed of
the risks involved.
● Make sure that these operating instructions are available to everyone
involved in operating, maintaining, and repairing the engine, and that they
have all understood the contents.
● Non-compliance with these operating instructions may result in engine
malfunctions and even damage or injury to persons; the manufacturer will
accept no liability in such cases.
● Proper maintenance and repair work depends on the availability of all req-
uisite equipment, tools and special implements, all of which must be in
perfect condition.
● Engine parts like springs, brackets, elastic holding rings, etc., involve
increased risk of injury if not handled properly.
● The relevant accident prevention regulations and other generally recog-
nized rules relating to safety engineering and health and safety at work
must all be complied with.
● Maximized cost-efficiency, reliability and long lifetime are assured only if
original parts from DEUTZ AG are used.
● Engine repairs must correspond to the intended use. In the event of modi-
fication work, only parts approved by the manufacturer for the purpose
concerned may be used. Unauthorized changes to the engine will pre-
clude any liability of the manufacturer for resultant damage.

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Careful when the en- Carry out maintenance or repair jobs only when the engine is at a standstill. If
gine is running! you remove any protective features, fit them back in position after completing
your work. Always wear tight-fitting clothing if you are working on the engine
while it is running.

Safety
You will find this symbol next to all safety instructions. Follow these
meticulously. Pass on all safety instructions to your operating staff
as well. In addition, comply with the statutory general safety and
accident prevention regulations applying in your country.

Instruction
You will find this symbol next to instructions of a general nature.
Follow these instructions carefully.

Asbestos
The seals and gaskets used in this engine are asbestos-free. Please
use the appropriate spare parts for maintenance and repair jobs.

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 Introduction
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Dear customer, Forword

The engines of the DEUTZ brand have been developed for a broad spectrum
of applications. A comprehensive range of different variants ensures that spe-
cial requirements can be met for the individual case involved.
Your engine has been equipped to suit your own particular installation, and
accordingly not all of the devices and components described in these operat-
ing instructions will actually be fitted to your engine.
We have endeavoured to present the differences involved as clearly as possi-
ble, to make it easier for you to find the operating and maintenance instruc-
tions you need for your own particular engine.
Please read this manual before you start up your engine, and follow the oper-
ating and maintenance instructions meticulously.
If you have any questions, just get in touch with us, and we will be pleased to
answer them for you.

Yours sincerely,
DEUTZ AG

are the culmination of long years filled with research and development work. DEUTZ engines
The in-depth know-how thus acquired, in conjunction with high standards of
quality, is your guarantee for engines manufactured for long lifetime, high reli-
ability and low fuel consumption. And of course, stringent criteria of environ-
ment-friendliness are met as well.

are crucial factors in ensuring that your engine satisfactorily meets the Care and maintenance
requirements involved. Compliance with the specified maintenance intervals
and meticulous performance of care and maintenance work are therefore
absolutely essential. Special attention must be paid to any more critical oper-
ating conditions deviating from the norm.

In the event of malfunctions, or if you need spare parts, please contact one of DEUTZ Service
our responsible service agencies. Our trained and qualified staff will ensure
fast, professional rectification of any damage, using original parts.
Original parts from DEUTZ AG have always been manufactured to the very
latest state-of-the-art.
You will find details of our after-sales service at the end of these operating
instructions.

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 Contents
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Contents

0 Introduction
Please read all ... .................................................................................................. 0-5
Careful when the engine is running! ..................................................................... 0-6
Forword................................................................................................................. 0-7
DEUTZ engines .................................................................................................... 0-7
Care and maintenance ...................................................................................... 0-7
DEUTZ Service.................................................................................................. 0-7

1 User Guide
General ................................................................................................................. 1-1
Regulations ........................................................................................................... 1-1
Safety Regulations / Rules for Accident Prevention .......................................... 1-1
Rules for disposal .............................................................................................. 1-2
Operating Instructions and Workshop Manual...................................................... 1-2
Job cards .............................................................................................................. 1-4
Spares .................................................................................................................. 1-6

2 Description
Type and designations.......................................................................................... 2-1
Type designation ............................................................................................... 2-1
Rating plate........................................................................................................ 2-1
Position on the engine .................................................................................... 2-1
Figure, rating plate.......................................................................................... 2-3
Designation of the engine sides, cylinder and direction of rotation.................... 2-4
Engine and unit figures ......................................................................................... 2-5
Construction and function ................................................................................... 2-10
Cylinder head................................................................................................... 2-10
Driving gear ..................................................................................................... 2-11
Crankcase........................................................................................................ 2-11
Engine control and wheel drive........................................................................ 2-12
Speed control................................................................................................... 2-13
Functional principle....................................................................................... 2-13
Actuator ........................................................................................................... 2-14
Charging .......................................................................................................... 2-16
Charging schematic ...................................................................................... 2-16
Gas system...................................................................................................... 2-17
Gas regulator line ......................................................................................... 2-17
Gas filter ....................................................................................................... 2-20
Gas pressure regulator with solenoid valve.................................................. 2-20
Control valve with solenoid valve.................................................................. 2-21
Gas pressure monitor ................................................................................... 2-21
Automatic shutoff process ........................................................................ 2-22
Instructions for installation ............................................................................ 2-22
Gas / air carburettor, mixture formation ........................................................ 2-23
Lube oil system................................................................................................ 2-24
Lube oil cooler and lube oil filter ................................................................... 2-26

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Lube oil level switch...................................................................................... 2-27

Cooling system ................................................................................................ 2-28
Electrical system .............................................................................................. 2-29
Ignition .......................................................................................................... 2-29
Electrical starter ............................................................................................ 2-31

3 Operation
Work prior to first commissioningand after every inspection................................. 3-1
General .............................................................................................................. 3-1
Filling up coolant................................................................................................ 3-1
Filling up lube oil ................................................................................................ 3-1
Pre-lubrication.................................................................................................... 3-1
Gas supply......................................................................................................... 3-2
Note for all heat transformers ............................................................................ 3-2
Exhaust gas side ............................................................................................... 3-2
Note for oxidation catalyst ................................................................................. 3-2
Commissioning / Starting ...................................................................................... 3-3
Starting .............................................................................................................. 3-3
Warming up ....................................................................................................... 3-3
Room ventilation ................................................................................................ 3-3
Lube oil system .................................................................................................. 3-3
Monitoring operation ............................................................................................. 3-4
System monitoring ............................................................................................. 3-4
Engine Peripheral Systems ............................................................................... 3-4
Coolant circuit .................................................................................................... 3-4
Batteries............................................................................................................. 3-4

4 Expendables
General ................................................................................................................. 4-1
Guarantee.......................................................................................................... 4-1
Product selection ............................................................................................... 4-1
Mixability ............................................................................................................ 4-1
Combustion gases ................................................................................................ 4-1
Lube oil ................................................................................................................. 4-1
Engine coolant ...................................................................................................... 4-1
Auxiliary materials................................................................................................. 4-3
Sealants and securing agents ........................................................................... 4-3
Gluing agents..................................................................................................... 4-5
Lubricants .......................................................................................................... 4-5
Other auxiliary materials .................................................................................... 4-6

5 Maintenance
Continuous supervision......................................................................................... 5-1
Maintenance schedule .......................................................................................... 5-1
General .............................................................................................................. 5-1
Deutz maintenance and service schedules ....................................................... 5-2
Gas groups ........................................................................................................ 5-3
Silicon content ................................................................................................... 5-3
Specific scheduled maintenance plan................................................................... 5-4
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Scheduled maintenance plan 1 ......................................................................... 5-7

Maintenance work independent of operating hours........................................ 5-7
Definition of activities in the maintenance schedule ....................................... 5-8
Maintenance work depending on operating hours.......................................... 5-8
Maintenance work dependent on operating hours outside the DEUTZ
maintenance and service schedules............................................................. 5-10
Table for maintenance work independent of operating hours....................... 5-11
Table for maintenance work dependent on operating hours ........................ 5-12
Scheduled maintenance plan 2 ....................................................................... 5-15
Maintenance work independent of operating hours...................................... 5-15
Definition of activities in the maintenance schedule ..................................... 5-16
Maintenance work depending on operating hours........................................ 5-16
Maintenance work dependent on operating hours outside the DEUTZ
maintenance and service schedules............................................................. 5-18
Table for maintenance work independent of operating hours....................... 5-19
Table for maintenance work dependent on operating hours ........................ 5-20
Scheduled maintenance plan 3 ....................................................................... 5-23
Maintenance work independent of operating hours...................................... 5-23
Definition of activities in the maintenance schedule ..................................... 5-24
Maintenance work depending on operating hours........................................ 5-24
Maintenance work dependent on operating hours outside the DEUTZ
maintenance and service schedules............................................................. 5-26
Table for maintenance work independent of operating hours....................... 5-27
Table for maintenance work dependent on operating hours ........................ 5-28
Scheduled maintenance plan 4 ....................................................................... 5-31
Maintenance work independent of operating hours...................................... 5-31
Definition of activities in the maintenance schedule ..................................... 5-32
Maintenance work depending on operating hours........................................ 5-32
Maintenance work dependent on operating hours outside the DEUTZ
maintenance and service schedules............................................................. 5-34
Table for maintenance work independent of operating hours....................... 5-35
Table for maintenance work dependent on operating hours ........................ 5-36
Operating check log ............................................................................................ 5-39

6 Troubleshooting
Table of faults with instructions on their elimination ............................................. 6-1

7 Conservation
Conservation......................................................................................................... 7-1

8 Technical particulars
General engine data ............................................................................................. 8-1
Basic data .......................................................................................................... 8-1
Control data ....................................................................................................... 8-1
Dimensions ........................................................................................................ 8-2
Weights.............................................................................................................. 8-2
Operating data ...................................................................................................... 8-3
Filling levels ....................................................................................................... 8-3
Temperatures .................................................................................................... 8-3

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Pressures........................................................................................................... 8-3
Emission data .................................................................................................... 8-3
Engine, peripheral data......................................................................................... 8-4
Starter system.................................................................................................... 8-4
Speed controller................................................................................................. 8-4
RI flow diagrams ................................................................................................ 8-5
Legend............................................................................................................ 8-8
Tightening specifications....................................................................................... 8-9
Scheduled maintenance work up to E40 ........................................................... 8-9

9 Job Cards
Explanation of symbols ......................................................................................... 9-1
Overviews ............................................................................................................. 9-2
Arranged alphabetically ..................................................................................... 9-2
Arranged by Job Card Numbers ........................................................................ 9-3

10 Sundry other instructions

Index

Service
We move your world ................................................................................... Service-1
DEUTZ AG - at your service. ................................................................... Service-1
Sales & Service Index.............................................................................. Service-1
DEPIC...................................................................................................... Service-1
Seminar program .................................................................................... Service-1

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 User Guide
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1 User Guide

The maintenance and service work prescribed in the operating instructions General
and the workshop manual must be performed on schedule and in full.
The maintenance and service personnel must have the necessary technical
knowledge to perform the work. Safety and protection devices which may
have to be removed during maintenance and service work must be replaced
afterwards.

The rules for the prevention of accidents and the safety regulations
must be observed at all times during maintenance and service work.
Please also observe the special safety regulations for the various ser-
vice groups which are listed in detail as job cards in the job cards chap-
ter (cf. also chapter 1 Safety Regulations / Rules for Accident
Prevention).

The maintenance and service intervals are listed in the maintenance and
service schedules. These also provide information about the work to be per-
formed.
The job cards provide technical hints for performing the work.

Regulations

Detailed safety instructions have been compiled for various service Safety Regulations /
groups in the form of job cards, these precede the job cards of the Rules for Accident Pre-
respective service groups. vention
The legally prescribed rules for accident prevention (available from the
appropriate associations or technical publishers) must be observed.
These depend on the installation site, the mode of operation and the
operating and auxiliary media being used.
Special safety measures dependent on the respective work are speci-
fied and highlighted in the work description.
It generally applies among other things:
● for personnel:
- Only instructed personnel may operate or maintain the engine.
Unauthorised persons may not enter the engine room.
- Wear tight fitting clothing and ear protectors in the engine room
when engines are running.
- Only employ qualified personnel for repairs or service work.
● for the engine room:
- Ensure adequate fresh air and ventilation (do not cover ventila-
tion shafts).
- Provide first aid kits and suitable fire extinguishers. Check the fil-
ling and proper functioning regularly.
- Only store inflammable materials in the engine room which are
necessary for operating the system.
- Smoking and naked lights are prohibited in the engine room.

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● for operation and maintenance of the engine:

- Only start the engine when all safety devices have been fitted and
the turning gear has been removed. Make sure there is no-one in
the danger zone.
- Only perform cleaning, maintenance and repair work when the
engine is switched off and secured against starting up.

Rules for disposal The work described in the operating instructions and workshop manual
necessitates the renewal of parts and expendables among other things.
These renewed parts / expendables must be properly stored, transported and
disposed of. The owner is responsible for this.
Disposal includes recycling and disposal of parts / expendables whereby
recycling has priority.
The details of disposal and its supervision are governed by regional, national
and international laws and decrees which the plant owner is responsible for
observing.

Operating Instruc- The service documentation is divided into the operating instructions and the
tions and Workshop workshop manual for a user-oriented organisation of the information content.
Manual The Operating Instructions contain a general description as well as instruc-
tions for the necessary maintenance and service work which can be per-
formed by a trained operator.
It contains the following chapters:
0 Introduction
Contents
1 User guide
2 Description (description of the engine and components)
3 Operation (operating the engine)
Expendables (operating media specifications and auxiliary materi-
4
als)
5 Maintenance
6 Troubleshooting
7 Conservation (conservation of the engine)
8 Technical particulars
9 Job cards (in order of job card numbers)
10 Sundry other instructions (if not in the appendix or separate folders)
Index
Service

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 User Guide
TCG 2015 1

The Workshop Manual assumes knowledge of the content of the operating

instructions, this applies especially to the safety regulations. Minor repairs
and emergency measures on components are described which require a
greater effort and appropriately qualified personnel.
It contains the chapters:
0 Introduction
Contents
1 User guide
2-4 See operating instructions
5 Tools for service
6-7 See operating instructions
8 Technical particulars
9 Job cards (in order of job card numbers)
10 Sundry other instructions (if not in the appendix or separate folders)
Service

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Job cards
The Job cards are divided into Job cards of the operating instructions, e.g. B 1-1-1 and job cards of the
workshop manual, e.g. W 4-5-1.
● Please see Figure 1-1 for explanations of the numbering.
● The structure of the job card is shown in Figure 1-2.

Type of documentation
• The letter at the front signifies the type of documentation involved.

B = Operating Instructions
W = Workshop Manual

Maintenance Group (the same for all engines)

0 General remarks / cross-category jobs 8 Lube oil system
1 Cylinder head 9 Coolant system
2 Drive mechanism 10 Compressed air system
3 Crankcase 11 Monitoring system
4 Engine control 12 Other components
5 Governor 13 Electrical system
6 Exhaust gas system / Charging
7 Fuel system

Subsystem (component)
• The subsystems are distinguished by maintenance groups.
• Generally valid:

0 Cross-subsystem or Safety Regulations
1 System parameters or general checks

Serial Number
• Counting per subsystem (component)
• Various jobs per subsystem (component)
• Version differences

B 3-3-3 © 80301-3

Figure 1-1 Numbering of the job cards

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 User Guide
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1 2

10

13 12 11
' 80300-5

Figure 1-2 Numbering of the job cards

When making inquiries about the job card please always state the engine
type or the system 2, the number of the job card 3, the page number 11, the
date of issue 13 or alternatively the identification number of the job card.

DEUTZ Service, publisher of the service documen-

1 8 Figures
tation
2 Engine type or system 9 General notes
3 Number of the job card 10 Work sequence
4 Title of the job card 11 Page number
5 Tools, aids, spares and references 12 Identification number of the job card
6 Safety instructions 13 Date of issue of the job card
7 Sub-headings

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Spares Spares are available from DEUTZ Service. You will find a list of spares in the
spare parts list of the engine or the system. You will find further information in
Chapter Service, at the end of the operating instructions.

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 Description
TCG 2015 2

2 Description

The engines of the TCG 2015 series are water-cooled four-stroke, high-per- Type and designa-
formance Otto gas engines which can be used in a wide range of drive appli- tions
cations with easy usability of the coolant and exhaust heat in force-heat
coupling processes. A special low exhaust emission combustion process has
been developed for environmental protection.

Type designation

See also rating plate (Fig-

T C G 2015 V _
ure 2-3, item 1)

Turbocharger T

Mixture charge cooling C

Gas engine G

Series 2015

V-engine V

No. of cylinders 6 or 8

Rating plate
The rating plate is attached to the B3 or B4 cylinder. Position on the engine

Figure 2-1 Position of the rating plate on the engine

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The engine number 2 is also punched into the cylinder block behind the oil
cooler.

Figure 2-2 Position of the engine number

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Figure, rating plate

Figure 2-3 Figure, rating plate

1 Engine type designation

2 Engine code
3 Engine number
4 Numerical output value in kW (G= overall output; controlled cooling fan not active)
5 ISO standard specification (controlled cooling fan not active)
6 Output type (controlled cooling fan not active)
7 Engine speed in rpm (controlled cooling fan not active)
8 Numerical output value in kW (S= system output; controlled cooling fan active)
9 ISO standard specification (controlled cooling fan active)
10 Output type (controlled cooling fan active)
11 Engine speed in rpm (controlled cooling fan active)
12 Ignition point
13 Numerical output value in kW (G= overall output reduced according to H 0712)
14 Numerical output value in kW (S= system output reduced according to H 0712)
15 Open e.g. for customer ID number, delivery ID, year of manufacture etc.
16 Air temperature
17 Height above sea level in m
18 Number of ECE control and poster value where applicable
19 Number of ECE control and poster value where applicable
20 Methane number; MN > 70
21 Note on acceptance with 3 options: a) NOx=500 ; b) NOx=250 ; c) NOx= --
22 COM approval number (according to EC Official Journal C 328 dated 7.12.95)
E EC member state codes

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Designation of the engine sides, cylinder and direction of rotation

The four sides of the engine normally carry the following designations in practice (see Figure 2-4):
The designation used in this operating manual is highlighted respectively in bold print and corresponds with
DIN ISO 1204.

A1 A2 A3 A4

1 3

B1 B2 B3 B4

4
Figure 2-4 Designation of the engine sides and cylinders

Engine sides

1 Drive side Flywheel, clutch side

2 Left side Cylinder side A
3 Free side End, damper, fluid pump, opposite to clutch side
4 Right side Cylinder side B

Direction of rotation:
Looking towards the drive side: In anticlockwise direction ”left-hand rotation”

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Engine and unit figures

Illustration, TCG 2015 V6

Figure 2-5 Compact unit, B-side

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Figure 2-6 Compact unit, A-side

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Figure 2-7 Compact unit, end, damper, fluid pump, opposite to clutch side

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Illustration, TCG 2015 V8

Figure 2-8 Gen-Set-engine, end side

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Figure 2-9 Gen-Set-engine, end side

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Construction and
function

Cylinder head The cylinders are fitted with a single cylinder head each. The multiple valve
cylinder heads are equipped with two inlet and two outlet valves, each of
which is controlled by a camshaft, tappet, tappet rod and rocker arm. The cyl-
inder heads are liquid-cooled and integrated into the engine cooling system.

Figure 2-10 Cylinder head

1 Stop rods
2 Rocker arm bearing blocks
3 Adjusting screws (inlet valve)
4 Spark plug bore
5 Adjusting screws (outlet valve)
6 Rocker arm, outlet
7 Rocker arm, inlet

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The machined crankshaft with bolted on counterweights is suspended in the Driving gear
crankcase. The bearing covers are held vertically by two studs and are fas-
tened horizontally by two additional screws for cross bracing. The engine has
cast lightweight metal pistons and double T-shank con-rods. The lube oil sup-
ply to the main bearing and con-rod bearing is provided by a lube oil pump
which sucks the lube oil from the oil pan.

The crankcase is sphero-cast with suspended crankshaft bearings and wet Crankcase
cylinder liners.

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Engine control and wheel

drive

© 84507-0

Figure 2-11 Wheel drive (drive side)

1 Crankshaft toothed wheel

2 Camshaft drive

2 1

© 84508-0

Figure 2-12 Wheel drive (free side)

1 Crankshaft toothed wheel

2 Lube oil pump drive

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Speed control
The speed controller controls the speed and the performance of the engine Functional principle
by adjusting the throttle valve position. The speed is controlled electronically
by the DEUTZ TEM system.
In electronic speed control-mode the actual speed is measured with a mag-
netic pulse sensor (pickup), transferred to the DEUTZ TEM system and com-
pared with the reference speed. In the case of deviations the throttle valve
position is adjusted by the actuator controlled by the DEUTZ TEM system.

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Actuator The actuator is connected to the throttle valve by a regulating lever and con-
necting linkage.
A DC motor transfers the torque to the controller output shaft via intermediate
gearing.
The setting of the controller output shaft is scanned by the return probe with-
out contact and passed on to the DEUTZ TEM system.
On reaching the stop, current limitation is implemented after approx.
20 seconds, which reduces the actuator current to such an extent that no
damage is suffered by the actuator.
The actuator is distinguished by:
- high adjustment forces acting in both directions
- low power consumption
- Insensitivity at slow voltage change in the power supply, sudden
changes lead to controller faults

Figure 2-13 Actuator, Heinzmann

1 Working coil
2 Output shaft
3 Permanent magnet
4 Probe
5 Return cams
6 Return spring

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Figure 2-14 Actuator on the engine

1 Position of the actuator

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Charging
The turbocharger sucks in air and gas through a Venturi gas mixer under atmospheric conditions (mixture
charging) The compressed gas-air mixture is cooled down in a mixture cooler. The engine achieves a higher
performance with simultaneous reduction of the pollutant emissions due to the mixture charging.
Charging schematic

1 2 3 4 5 6 7

15

14

13

9 10 11 12
' 80977-3

Figure 2-15 Charging schematic

1 Intake air 9 Mixture cooler

2 Air filter 10 Cooled mixture
3 Filtered air 11 Inlet valve
4 Gas / air carburettor 12 Outlet valve
5 Gas 13 To the exhaust gas turbine
6 Mixture to the compressor 14 Exhaust gas turbine
7 Compressor 15 To the silencer
8 From the compressor

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Gas system
Gas regulator line
Construction and function (⇒ DIN EN 676; DIN 33831, part 2)
The control and safety systems incorporated in the gas regulator line ensure that the gas engine can be
operated safely and reliably. The gas pressure regulator adapts the mains side gas pressure to the require-
ments of the gas engine.

Incorrect assembly, adjustment, modification, operation or mai-

ntenance can result in injury to persons and/or damage to equip-
ment.
Fitting, wiring, adjustments and servicing by authorized specia-
list personnel only.
Read all instructions before assembly and use.
The equipment must be installed in accordance with valid regula-
tions.
Local regulations of electric and gas supply companies must be
observed.

Figure, gas regulator lines

Figure 2-16 Gas regulator line – gas group 1

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Figure 2-17 Gas regulator line – gas group 2 (with flame flashover protection)

Figure 2-18 Gas regulator line (overview of variants)

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Components - all DVGW tested!

1 Shutoff device (ballcock)

Manual shutoff of the gas supply for repair work within the gas regulator line and when the unit is shut
down.
2 Gas filter
3 Gas pressure monitor (electric pulse generator)
Automatic monitoring of the minimum admissible gas pressure upstream of the gas pressure regula-
tor
4 Manometer with pushbutton tap 0…100 mbar
5 Gas pressure regulator with solenoid valve
The pressure regulator reduces the gas pressure at the inlet to the gas regulator line. There is no gas
pressure on the engine. A diaphragm allows gas to pass through the gas line when there is a vacuum
in the mixer.
6 Manometer with pushbutton tap -10…+15 mbar
7 Control valve with solenoid valve
8 Flange
9 Flame flashover protection with temperature gauge (gas-group 2 only)
10 Gas pressure monitor (electric pulse generator)
Automatic monitoring of the minimum admissible gas pressure downstream of the gas pressure regu-
lator.
11 Gas pressure sensor (electric pulse generator)
Automatic monitoring of the minimum admissible gas pressure upstream of the gas pressure regula-
tor.

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Description
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Gas filter To protect units downstream against contamination by impurities in the gas.

Figure 2-19 Gas filter

Gas pressure regulator Once the solenoid valve opens, the gas outlet pressure is kept constant by
with solenoid valve the gas pressure regulator depending on the air control pressure.

Figure 2-20 Gas pressure regulator with solenoid valve

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 Description
TCG 2015 2

Solenoid valve with spring-loaded valve head for control of flow rate. The size Control valve with sole-
of the gap is controlled by the cam position. This controls the quantity of gas noid valve
required for the mixture.

Figure 2-21 Control valve with solenoid valve

Diaphragm pressure monitor with microswitch, switch range 0.5-500 mbar. Gas pressure monitor

Figure 2-22 Gas pressure monitor

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Description
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Automatic shutoff pro- To purge the engine when shutting off, the gas supply line is already closed
cess before the ignition is interrupted. This process is part of the automatic proc-
ess by the DEUTZ TEM system.
Assembly and testing
G 600 (DVGW-TRGI), G 490 and G 495 installation regulations apply for the
intake up to the customer’s on site shutoff device.
The components of the gas regulator line are tested by the manufacturer for
strength and leaks. The fully assembled plant must be subjected to a final
leak test at the installation site with air or inert gas with 1.2 times the maxi-
mum permissible operating pressure (set output pressure at the regulator)
but at least 150 mbar.
- The pressure in the input chamber (mains side) must always be equal
to or greater than the pressure in the outlet chamber (motor side).
- Pressure build-up always before the input side, pressure release
always before the output side (change pressure slowly!).
- The gas regulator line may only be attached horizontally.
- The gas regulator line must be protected against careless damage,
especially when mounted low.
- No vibrations may be transmitted from the engine to the gas pipe.
- The ballcock and pushbutton tap must be operable by hand.
(max. mounting height 2,100 mm!)
- The pressure gauges must be easy to read.
Instructions for installation
Depending on the gas type, the engine requires the appropriate gas control
line. Nonferrous metals (brass) may not be used for gas-carrying parts when
using aggressive gases. The gas control line must be installed in the same
room as the gas engine. This ensures that the gas control line is subjected to
the same air pressure conditions as the engine. Exhaust gas lines must be
directed into atmosphere with sufficient cross-section. Pressure regulators,
monitoring devices and pipes must be installed without bracings. Pressure
regulators and monitoring devices are always to be fitted according to the
manufacturer's instructions. The direction of flow must be followed. The gas
control line must be installed as close to the engine as possible. The distance
between the gas control line outlet and the gas mixer inlet must be max. 3 m
in length and with max. three 90° curves. Flame flashovers can occur with
fuel gas mixtures whose components may also contain oxygen. The gas con-
trol lines contain endurance burning flame flashover protection devices with
temperature monitoring to prevent flashovers in the gas-carrying line. For
this, a distance of maximum 40 times the pipe diameter of the gas line is per-
mitted between the engine and gas control line.

Example: Pipe diameter = 100 cm

40x100cm = 4000 cm
max. permissible distance = 4 m

For larger distances, an endurance burning detonation arrester must be pro-

vided instead of the flame flashover protection.

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 Description
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Gas / air carburettor, mixture formation

The gas and air are blended to form a combustible mixture in the carburettor immediately upstream of the
turbocharger, Figure 2-23.
The carburettor is in the form of a Venturi tube, i.e. a pipe with a converging section to channel flow which
gradually diverges again. The design means that the flow has only a minimum pressure drop and therefore
only minimum filling losses in the cylinders. The highest flow rate occurs at the most constricted section. The
gas is mixed with the core flow radially from outside at this location via an annular gap using the resulting
vacuum. This mixing mode has the advantage that the volume ratio of gas to air remains almost constant
even in the case of great fluctuations in the sucked mixture and deviates only slightly from the so-called
lambda window in which the safe and cost-effective operating range of the engine is contained.
The adjustable gas gap is used to set the gas-air mixture in the gas control line. The mixture volume is regu-
lated by means of the throttle valve.

Figure 2-23 Fixed gap mixer (illustration 8 cylinder engine)

1 Gas
2 Air
3 Gas - air mixture

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Description
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Lube oil system

The lube oil reduces friction of the components which rub against each other and dissipates heat from the
rubbing positions, the piston head and the turbocharger. A film of lube oil on the cylinder surfaces reduces
the gliding friction of the piston and piston rings. The lube oil also captures impurities within a suspension
and transports them to the lube oil filter.
The lube oil pump sucks the lube oil from the oil tray, feeds it through the lube oil cooler and the lube oil filter
into the lubrication circuit of the engine.
The lube oil pressure in the engine circuit is set by a lube oil pressure regulating valve. The bypass valve is
installed to avoid the flow of lube oil being interrupted when the lube oil filter is dirty. If the lube oil pressure
gets so high that the lube oil pump is at risk, the safety valve opens and allows the excess lube oil to flow
back into the oil tray.

Figure 2-24 Lube oil plan

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 Description
TCG 2015 2

1 Oil pan
2 Intake line
3 Lube oil pump
4 Pressure control valve
5 Lube oil cooler
6 Lube oil replacement filter
7 Main oil bore
8 Crankshaft bearing (base bearing)
9 Con-rod bearing
10 Camshaft bearing
11 Line to spray nozzle
12 Injection jet with pressure retention valve for piston cooling
13 Valve lifter with rocker arm impulse lubrication
14 Stop rod, oil supply for rocker arm lubrication
15 Rocker arm
16 Oil return bore in the cylinder head to the crankcase
17 Oil pressure sensor / oil pressure switch
18 Oil line to turbocharger
19 Turbocharger
20 Pressure retention valve (adjustable)
21 Return line from the ALT to the crankcase

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Description
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Lube oil cooler and lube

oil filter

Figure 2-25 Lube oil cooler

1 Lube oil cooler

Figure 2-26 Lube oil filter

1 Filter block 2 Filter cartridge

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 Description
TCG 2015 2

Lube oil level switch

Figure 2-27 Position of lube oil level switch

The TCG 2015 has a lube oil level switch in the oil pan.
When the oil falls below a minimum level the engine is switched off to prevent
it becoming damaged.

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Cooling system There are two cooling system variants available for the TCG 2015.
- Unit with integrated or external coolant pump.
Since a coolant pump case 1 is fitted in both versions, they cannot be distin-
guished visually.
The units have one cooling circuit for the whole engine. The coolant tempera-
ture is monitored automatically. The engine is switched off by the DEUTZ
TEM system at temperatures above the set maximum temperature.
The lube oil and the cylinder cooling systems are integrated into the coolant
circuit.
The external cooling measures for the coolant are designed so that the cool-
ant temperature remains constant after leaving the engine. The inlet tempera-
ture varies according to the engine load and is monitored by the DEUTZ TEM
system.

Figure 2-28 Coolant pump case

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 Description
TCG 2015 2

Electrical system
The engine is equipped with a PM1 microprocessor-controlled ignition sys- Ignition
tem which is supplied by the DEUTZ TEM system with a voltage of 24 V.
A toothed gear on the flywheel is scanned by an electronic sensor and ena-
bles the exact crank angle time to be determined. The selection of the right
process phase for the ignition spark in the four-stroke technique is made by
an additional sensor on the camshaft. The electronic control device sends
medium voltage pulses to the ignition coils assigned to every cylinder. From
there a high voltage cable leads to each spark plug. An extremely fast voltage
rise guarantees a powerful and short ignition spark with a gentle effect on the
spark plug electrodes.
Settings on the ignition device are made exclusively by DEUTZ service per-
sonnel, these are for example adjustment of the ignition time to adapt to the
gas quality or select two different ignition times in two-gas operation.
For work on the ignition system such as changing parts, e.g. spark plugs,
ignition cables and ignition coils, the ignition needs no longer be switched off
because the DEUTZ TEM system has switched it off safely when is at stand-
still.

Figure 2-29 Ignition system control unit

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Description
TCG 2015

Figure 2-30 Ignition coils

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 Description
TCG 2015 2

The engine is equipped with an electric starter. The starter accelerates the Electrical starter
engine crankshaft to ignition speed.
An electric motor drives the starter pinion to the crown gear of the flywheel via
an axially movable laminar coupling and thus drives the crankshaft. The lami-
nar coupling only transmits the full starter-torque after the starter pinion has
engaged in to avoid damaging the teeth edges. When the engine starts, the
laminar coupling is released by the steep thread and the starter pinion disen-
gaged.

Figure 2-31 Electrical starter

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Description
TCG 2015

1 2 3 4 5

' 80672-1

7 6

Figure 2-32 Electrical starter (section)

1 Starter pinion
2 Drive shaft to the pinion
3 Clutch housing
4 Steep thread sleeve of the clutch
5 Single track bar
6 Steep thread
7 Coupling lamellas

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 Operation
TCG 2015 3

3 Operation

Work prior to first

commissioningand
after every inspec-
tion

The following should be carried out before commissioning, after the engine General
has been out of operation for a long period and after maintenance and repair
work:
● Check all lines and connections for leaks of the following media:
- gas
- lube oil
- coolant
- suction intake air
- exhaust gas
● Check linkage of the speed controller for easy action. Check operation of
monitoring, shut-off and remote control systems.
● Check the control cable and the sensor with the DEUTZ TEM system self-
test.

The coolant is filled through the filling nozzle according to operating materials Filling up coolant
specification with supplements. The coolant chambers are bled by a bleeding
line with the coolant pump running. Then check the coolant level again and
add coolant if necessary.

The lube oil level is monitored during operation by the DEUTZ TEM system. Filling up lube oil
The approximate lube oil level can be checked with the oil dipstick (TBG 620,
TCG 2020, TCG 2032) or can be seen in the sight glass (TBG 616,
TCG 2016). When filling up with lube oil, this should be done in connection
with the DEUTZ TEM system.
Too low a lube oil state leads to non-release or switching off of the engine via
monitoring of the lube oil level and the lube oil pressure.
Initial filling in the TCG 2032
Fill the engine with the following lube oil quantities when filling for the first
time:

TCG 2032 V12: 1,450 litres

TCG 2032 V16: 1,800 litres

The engine is lubricated by the electric lubrication pump for constant standby Pre-lubrication
at regular intervals. Pre-lubrication must have taken place before the engine
has started.

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Gas supply

The room ventilation system must be switched on before any

work is carried out of the gas line.
Smoking an use of open flames are strictly prohibited.
Explosion hazard!

Clean the whole line leading to the engine internally (incl. desulphurising sys-
tem, gas compressor, cooler, gas pressure regulator and shut-off systems).
All parts of the line must be dry, clean and free of welding beads, scales and
other dirt particles. The joints should be checked for leaks using soapy water,
by applying , for example, nitrogen at overpressure .

Note for all heat trans- Before the insulation is closed, all the screws on pipe and connecting flanges
formers in the exhaust gas system must be tightened. This measure is necessary
because of ”settling” of the seals.
It is essential to tighten them once more after approx. 100 operating hours or
after 14 days.
Failure to do so will result in the manufacturer disclaiming responsibility for
leaking seals and escaping exhaust gases.
When filling the water side, bleed constantly (failure to bleed air sufficiently
leads to gas accumulations which could damage the boiler).
Particular attention must be paid to contamination of the cheating water.
Sludge and corrosion products from older heating water circuits and rolling
and welding residue can accumulate and for cause overheating, voltage
peaks and material breakage for example due to local insulation effects.
The heating water side must therefore be checked after the first 10 hours and
after a further 100 hours and, if necessary, be cleaned to remove sludge.
Sludge drains and filters make this job easier.

Exhaust gas side The exhaust gas parts resulting from engine combustion can deposit residue
on the smoke pipes.
Although this tendency is only very slight in three-way catalysts, coating on
the walls at the transmission surfaces cannot be ruled out over long operating
periods. This coating can be removed mechanically or wet chemically.

Note for oxidation cata- In systems with an oxidation catalyst the catalyst no longer needs to be
lyst removed for commissioning.

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 Operation
TCG 2015 3

Commissioning /
Starting

The values for the suction intake air temperature must be observed, see Starting
Chapter 8, Technical particulars.
The following functions are performed automatically by the system manage-
ment DEUTZ TEM system when starting.

1. Set the gas cross section at the mixer to start position for the gas type
concerned.
2. Check the readiness for starting on all module components
3. Switch on the starter
4. Purge air and exhaust gas system
5. Switch on the ignition
6. Open the gas valve —> engine runs up
7. Switch off the starter when the speed is fast enough and track out
8. Engine accelerates up to rated speed and is ready for synchronisation

The engines can be kept constantly at standby temperature by a separate Warming up

coolant heating (resistance heating or heating by pump operation) even at
standstill.
After starting, the engines generally run up quickly to operating temperature,
i.e. the set heating lead temperature, independently of the temperature state
of the heating system by return increase of the heating water flow. The drop
in temperature is reduced with the automatic load connection.

In the case of engines installed in enclosed spaces, a check must be carried Room ventilation
out after start-up as to whether the automatic inlet and outlet air shutters have
opened and the fans have started up.
Inadequate engine room ventilation results in excessive room temperatures
and a corresponding reduction in output by the engine and generator protec-
tion systems in the DEUTZ TEM system.

The lube oil pressure is monitored and recorded in the DEUTZ TEM system Lube oil system
and normally does not need to be checked by the operator any more.
Regular checking of the lube oil level and the lube oil supply in the day tank is
very important. It should be checked during the inspections with the engine at
a standstill. In continuous operation check every 24 hours. In case of low lube
oil level the engine is switched off automatically and must be unlocked manu-
ally on the switching system after filling up lube oil.

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Operation
TCG 2015

Monitoring opera-
tion

System monitoring All important system parameters of the engine, the generator and the con-
nected heat utilisation system are constantly monitored by the DEUTZ TEM
system.
The operating values of the systems must be checked against the recordings
made by the DEUTZ TEM system at regular operating intervals (daily in the
case of continuous operation). A log is best kept by continuously saving all
data to a central PC.
In case of irregularities, defects and faults must be documented by printing
out the last 24 h on the system PC printer and recorded in the operating log
and the causes of the fault eliminated.

Engine Peripheral Sys- The temperatures, pressures and other relevant states are monitored auto-
tems matically, the operating values saved continuously in the module control of
the DEUTZ TEM system. Once the set maximum values are reached, a warn-
ing is first issued and then, if exceeded again, the engine is shut off (fault indi-
cation).

Coolant circuit

Filling up coolant while the engine is running is prohibited!

Small quantities may be topped up after the engine has been switched off.
When filling frequently, make sure that the anti-corrosive content is observed.

Batteries If the engine has an electric starter, the appropriate batteries and the charger
must be checked weekly. The voltage given off by the backup battery of the
DEUTZ TEM system is monitored automatically. This serves for backing up
data in the event of a power failure.

Please note:
The operating manual for the DEUTZ TEM system is available as a sepa-
rate documentation and must be ordered separately.

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 Expendables
TCG 2015 4

4 Expendables

General

If unsuitable expendables are used or if no proof can be brought that the used Guarantee
expendables meet the requirements, the engine manufacturer cannot guar-
antee trouble-free operation. This also applies for defective maintenance of
the engines and the expendables.
The most important expendables for gas engine systems are listed in the
enclosed expendables specifications. The values specified therein are bind-
ing unless specified otherwise in the engine or system-specific contracts.

Due to the large number of products in national and international quality and Product selection
availability and as a result of the constant further development, it is not possi-
ble for us to test all suitable products and to name them, we therefore cannot
accept any responsibility for these products.
The supplier of the operating materials is solely responsible for the world-
wide consistent quality of the products listed here and for products not listed
here additionally for meeting the listed requirements for expendables and
their operational safety. This also applies for the event that the manufacturer
develops the listed products further.
The expendables (reference products) listed here are just a selection of a few
manufacturers and their products. Other expendables not listed here can be
used if they meet the necessary requirements, i.e. are at least equal in all cri-
teria. The expendables named in this specification are to be used as refer-
ence products for comparison. The respective expendables suppliers can
provide information about this and should confirm the suitability accordingly.

The mixing of different expendables types, e.g. different lube oils, with each Mixability
other, different coolants with each other and similar can lead to faults.
In any case the product supplier’s consent must be obtained before mixing
and he must take over the responsibility. This also applies for other additives
to the expendables.

see Technical Circular TR 0199-99-3017. Combustion gases

see Technical Circular TR 0199-99-2105. Lube oil

see Technical Circular TR 0199-99-1115. Engine coolant

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 Expendables
TCG 2015 4

Auxiliary materials

Sealants and securing agents

- Observe storage stability, if any, given on the package!
- Upon transport, storage and disposing of the above-mentioned items, observe Chapter 1, Regulati-
ons, of the operating manual, if no according information is given on the package.

Material designa- Type Standards and Characteristics Application examples

tion specifications

DEUTZ DW 43 Sealant Solvent-free, caoutchouc-based flexibly Sealing of small joints

hardening, rapid skin formation, tempera-
ture range 30°C to 100°C

DEUTZ DW 47 Sealant LV 0161 9672 Silicon caoutchouc, viscously flexible, eas- Sealing of rough and une-
FV 0160 9610 ily detachable, temperature range max. ven surfaces
180°C, oil max. 150°C

DEUTZ DW 48 Sealant LV 0161 9572 Silicon caoutchouc, viscously flexible, Sealing of rough and une-
FV 0160 9610 strong adhesion, temperature range –65°C ven surfaces
to 265°C

DEUTZ DW 49 Sealant LV 0161 9571 Mixed polymeride of vinyl- and acryl com- Sealing of core hole plugs
FV 0160 9607 positions, strong adhesion permanently
elastic, temperature range –40°C to 130°C

DEUTZ DW 50 Sealant Liquid, hardening artificial resin, compati- Sealing of housings

ble with gaskets, temperature range –40°C
to 180°C

DEUTZ DW 51 Sealant LV 0161 9573 Physically dry artificial resin, permanently Sealing of surfaces
elastic and vibration-free, temperature
range –30°C to 150°C

DEUTZ DW 55 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to M12;
when excluding oxygen, high strength, fluid, joints up to max. gap width
temperature range –55°C to 150°C of 0.15 mm

DEUTZ DW 56 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to R2"
when excluding oxygen, high strength,
thick-flowing, temperature range –55°C to
150°C

DEUTZ DW 57 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to M12;
when excluding oxygen, low strength, liq-
uid, temperature range –55°C to 150°C

DEUTZ DW 59 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to M20;
when excluding oxygen, high strength, joints up to max. gap width
medium viscous, temperature range –55°C of max. 0.15 mm
to 150°C

DEUTZ DW 60 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to M56 or R2"
when excluding oxygen, medium strength,
liquid, temperature range –55°C to 150°C

DEUTZ DW 61 Activator FV 0160 9605 Accelerates and permits the complete hard- Only for passive materials
ening of anaerobic substances with passive
materials

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Expendables
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Material designa- Type Standards and Characteristics Application examples

tion specifications

DEUTZ DW 62 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Joints up to a gap width of
upon metal contact when excluding oxygen, max. 0.12 mm
high strength, medium-viscous, thixotrope,
temperature range –55°C to 175°C

DEUTZ DW 63 Sealant FV 0160 9605 Anaerobic solvent-free single-component Sealing of surfaces up to a

upon metal contact when excluding oxygen, gap with of max. 0.10 mm
low strength thick-flowing, thixotrope, tem-
perature range –55°C to 150°C

DEUTZ DW 64 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
upon metal contact when excluding oxygen, threads up to M80 or R3"
high strength, medium-viscous, tempera-
ture range –55°C to 150°C

DEUTZ DW 65 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Joints up to a gap width of
upon metal contact when excluding oxygen, max. 0.25 mm
high strength, thick-flowing, temperature
range –55°C to 150°C

DEUTZ DW 66 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
upon metal contact when excluding oxygen, threads up to R3"
low strength thick-flowing, temperature
range –55°C to 150°C

DEUTZ DW 67 Sealant FV 0160 0040 Anaerobic solvent-free single-component Sealing of surfaces up to a

upon metal contact when excluding oxygen, gap width of max. 0.50 mm
high strength, thick-flowing, thixotrope, tem-
perature range –55°C to 150°C

DEUTZ DW 68 Sealant FV 0160 0039 Anaerobic solvent-free single-component Sealing of surfaces up to a

upon metal contact when excluding oxygen, gap width of max. 0.50 mm,
low strength thick-flowing, thixotrope, tem- securing and sealing of
perature range –55°C to 150°C threads R2"

DEUTZ DW 69 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
upon metal contact when excluding oxygen, threads up to M36
low strength liquid temperature range –
55°C to 150°C

DEUTZ DW 70 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
upon metal contact when excluding oxygen, threads up to M12
medium strength liquid temperature range –
55°C to 150°C

DEUTZ DW 71 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
upon metal contact when excluding oxygen, threads up to M20;
high strength, medium viscous, tempera- joints up to a gap width of
ture range –55°C to 175°C max. 0.15 mm

DEUTZ DW 72 Securing agent FV 0160 9605 Anaerobic solvent-free single-component Securing and sealing of
substance hardening upon metal contact threads up to M36
when excluding oxygen, medium strength,
medium viscous, temperature range –55°C
to 150°C

Tab. 1 Sealants and securing agents

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 Expendables
TCG 2015 4

Gluing agents

Material designa- Type Standards and Characteristics Application examples

tion specifications

DEUTZ KL 1 Gluing agent LV 0161 9633 Two-component, epoxy-resin based, water- Combines steel, alumin-
FV 0160 9608 , oil- and diesel fuel resistant, admiss. appli- ium, brass and plastic mate-
cation temperature max. 150°C rials such as plexiglass,
DEUTZ KL 2 Hardening agent LV 0161 9633
polyethylene and similar,
FV 0160 9608
Mixing ratio 1:1, gluing them together or
gluing agent DEUTZ KL 1 and hardener among them
DEUTZ KL 2

Tab. 2 Gluing agents

Lubricants

Material designa- Standards and Temperatur- Application examples

tion specifications range

DEUTZ S1 FV 0160 9537 -180°C to 1400°C Avoids burning in of screw connections in exhaust gas pipes

DEUTZ S2 LV 0161 9734 -25°C to 450°C Spray for reducing friction and wear for surfaces difficult to access Gener-
FV 0160 9506 ates an emergency lubrication and avoids sliding back.

DEUTZ S3 LV 0161 9733 -35°C to 450°C Spray for reducing friction and wear. Generates an emergency lubrication
FV 0160 9505 and avoids sliding back.

DEUTZ S4 LV 0161 9735 -40°C to 450°C Preferably used for pre-treating components with a high application tem-
perature. After the evaporation of the carrier oil (at 200°C), an effectively
lubricating solid film remains. Compatible with natural rubber and plastic
materials.

DEUTZ S5 LV 0161 9738 -30°C to 130°C For the long-term lubrication of antifriction- and slide bearings with
medium bearing pressures and higher temperatures. Water-resistant,
good emergency lubrication.

DEUTZ S6 LV 0161 9741 -20°C to 180°C For the long-term lubrication of antifriction- and slide bearings with
medium bearing pressures and higher temperatures. Water-resistant,
good emergency lubrication

Grease DIN 51825- -30°C to 140°C Consistent grease for lubricating antifriction bearings, slide bearings and
KP 2 N-30 sliding surfaces. For example, for filling the spiral-toothed coupling TBD
234/616.

Tab. 3 Lubricants

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Expendables
TCG 2015

Other auxiliary materials

Below you will find a reference list for the used auxiliary materials with which the best results have been
achieved. Equivalent products can also be used; in this case, the supplier must assure the suitability of the
product for the application.
- When using the products indicated below, the following references of the manufacturer must abso-
lutely be observed:
• Safety references
• Personal protection equipment
• Use as directed
• Disposal as directed

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 Expendables
TCG 2015 4

Product group Application Product name Supplier

Detergent for engine components P3 cold cleaner (liquid) Messrs. Henkel KGAA
40191 Düsseldorf

Vecom B 24 B (liquid) Messrs. Vecom GmbH

21107 Hamburg

Carbon remover or Ameroid ACC-9 (liquid) Messrs. Drew Ameroid

Deutschland GmbH
21107 Hamburg

for engine cooling system P3 T 288 (powder) Messrs. KGAA

P3 Standard (powder) 40191 Düsseldorf

Vecom BA-S (powder) Messrs. Vecom GmbH

Vecom BA-30 (liquid) 21107 Hamburg

SAF-Acid (powder) Messrs. Drew Ameroid

HDE-777 (liquid) Deutschland GmbH
21107 Hamburg

for intercooler (water side) and raw P3 - T1166 Messrs. Henkel KGAA
water circuit P3 - croni 40191 Düsseldorf
(neutraliser)

SAF-Acidonly calcium solutizer) Messrs. Drew Ameroid

Concentration: 5 % Deutschland GmbH
Temperature: 55 °C - 75 °C 21107 Hamburg

Porodox Messrs. Fischer Chemie

Concentration: 2 % - 10 % GmbH & Co. KG
Temperatuer: 20 °C - 60 °C 65201 Wiesbaden
Treatment time: max. 16 hours

for intercooler ACC 9 Messrs. Drew Ameroid

(air side) Deutschland GmbH
21107 Hamburg

Vecom B 85 Messrs. Vecom GmbH

21107 Hamburg

P3T-5308 Messrs. Henkel KGAA

40191 Düsseldorf

for tank plants Vecom B 24 B (liquid) Messrs. Vecom GmbH

Vecom B 14 (liquid) 21107 Hamburg

Tank cleaner Nr. 4 (liquid) Messrs. Drew Ameroid

Deutschland GmbH
21107 Hamburg

for lube oil filters Ameroid ACC-9 (liquid) Messrs. Drew Ameroid
Deutschland GmbH
21107 Hamburg

P3 RST, P3 SAXIN (powder) Messrs. Henkel KGAA

40191 Düsseldorf

Filterclean Messrs. Vecom GmbH

21107 Hamburg

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Expendables
TCG 2015

Product group Application Product name Supplier

Detergent for air filters Soda solution 1%ig

(continued) Burning kerosene
Mixture of:
6,5 % trilene (german: Trichlor-Äthylen)
9,5 % Teepol (Messrs. Shell)
4,0 % Cyclohexanon
80,0 % fresh water

for de-preservation Eskapon S 255 Messrs. Haug-Chemie

GmbH
74889 Sinsheim

Water treatment Hardness determination for cooling Aquamerk Art. Nr. 11129 Messrs. E. Merck KGAA
agent water DEUTZ ordering-no. 1215 8292 64293 Darmstadt

Cooling water hardening Vecom CN (powder) Messrs. Vecom GmbH

21107 Hamburg

Cooling water softening Trisodiumphosphate Messrs. Benckiser GmbH

(german:Trinatriumphosphat) (powder) 67001 Ludwigshafen

Tab. 4 Other auxiliary materials

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 Maintenance
TCG 2015 5

5 Maintenance

Please bear in mind that the following maintenance schedules are Schedu-
led Maintenance Plans.
It is not possible to make a permanent definition of the maintenance intervals
for all applications due to the numerous different relationships between ambi-
ent conditions, operating mode and quality of fuels.
It may be necessary to shorten the specified maintenance intervals under
harsher operating conditions. The scheduled maintenance plan must then be
revised in total. Generally the on-site operating conditions are already defined
in the planning phase.
Critical operation conditions are for example:
- Contamination of the combustion gases by ingredients which promote
wear, e.g. silicon, sulphur, chlorine, ...
- Frequent cold starts
- Increased dust contamination of the suction intake air
Ask your responsible DEUTZ SERVICE partner when in doubt.

The normal care of your engine comprises a daily visual inspection by techni- Continuous supervi-
cally skilled persons. The appropriate activities are listed in Job Card B 0-1-5. sion

Maintenance sched-
ule

The maintenance schedule lists the measures for maintaining the nominal General
condition and thus the operational reliability of the engine and the appropriate
maintenance intervals. The maintenance work procedures are described in
the specified Job Cards.
● The intervals prescribed in the maintenance schedule are maximum val-
ues and assume that installation, purpose and operating conditions com-
ply with DEUTZ specifications. It must be ensured that all operating media
such as combustion gas, lube oil and coolant have the prescribed quality.
You will find information about this in Chapter 4, Expendables.

In particular it must be ensured that the gas quality meets the minimum
requirements in accordance with TR 0199 - 99 - 3017 to avoid malfunctions
and/or premature wear of the engine

● This maintenance schedule only applies for the engine itself and the parts
attached to the engine. System parts must be serviced at the intervals and
according to the instructions specified by the manufacturer. You will find
the appropriate information in the respective enclosed manufacturer
documents (marked ”MD” in the maintenance schedule).
● The work described must be performed by technically skilled persons or
authorised specialists. The competencies are listed in Table 1 , Deutz
maintenance and service schedules.

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Maintenance
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Deutz maintenance and service schedules

Maintenance work dependent on operating hours is classified according to Deutz maintenance and service
schedules. All the work listed must be performed carefully according to the maintenance schedule deter-
mined specifically for the engine.

Deutz maintenance and service schedules Executed by

due respectively once after commissioning
E10
as well as E50, E60 and E70
E20 daily check technically skilled persons
E30 periodic maintenance (small scope)
E40 periodic maintenance (medium scope)
E50 periodic maintenance (extended scope)
E60 intermediate overhaul authorised specialists
E70 complete overhaul
Tab. 1 Deutz maintenance and service schedules

Please note that Deutz maintenance and service schedules may be added or
omitted depending on the speed and gas group.

● Make sure to observe the due dates for Deutz maintenance and service schedules according to the
number of hours your engine has been in operation.
● Arrange the necessary appointment with your responsible DEUTZ SERVICE partner in good time. Notify
your DEUTZ Service partner of any irregularities of your engine (see operating check log) when you
arrange the appointment.
● Sign a service contract with DEUTZ SERVICE if necessary. All the due maintenance work, including
repairs if agreed, is then planned and expertly performed by DEUTZ SERVICE according to the contract.
Your responsible DEUTZ SERVICE partner will be glad to give you the details.

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 Maintenance
TCG 2015 5

Gas groups
The scheduled maintenance also depends on the quality of the combustion gases.
The combustion gases are divided into two groups according to their wear properties for which different
scheduled maintenance plans apply, see also chapter 4, Technical Memo 0199 - 99 - 3017.

Use the scheduled maintenance plan corresponding to the type of gas used
in the system as a basis for the maintenance work.

Gas group 1 Gas group 2 (bio-gases)

natural gas sewage gas
pit gas methane gas
liquid gas
wood gas
- propane, butane, LNG (liquid natural gas)
petroleum gas other bio-gases
gases with a hydrogen content H > 30 vol%, e.g.
2

coke oven gas

Tab. 2 Gas groups

Please note for gas group 2:

The worst determined gas quality is essentially binding for defining the main-
tenance intervals. Please consult your responsible DEUTZ SERVICE partner.

Silicon content

When using combustion gases with a silicon content > 10 mg/mn3 CH4, the
maintenance intervals must be shortened in any case due to the heavily abra-
sive effect of silicon (TBO = Time between overhaul).
TBO

100 %

© 83908-1
0 10 mg/mn3 CH4 Silizium

Figure 5-1 Dependence silicon content - TBO

To guarantee the necessary life cycles, the silicon content of critical gases (gas-group 2, bio-gases) must be
determined regularly at least 3x a year in the course of extensive gas analyses and the maintenance inter-
vals may have to be shortened accordingly.

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Maintenance
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Specific scheduled maintenance plan

This engine has been built exclusively for the application specified in the scope of supply - as described by
the equipment manufacturer - and is to be used only for the intended purpose. Depending on its intended
purpose the engine is identified by a performance code according to DIN ISO 3046-7 which is punched into
the rating plate. The rating plate is described in detail in Chapter 2, Description.

Scheduled maintenance plan 1, see Page 7

Valid for:
- TCG 2015 V6 and TCG 2015 V8 with n = 1,500 rpm (50 Hz applications)
when using combustion gases of gas group 1
Performance abbreviation: ICN
Type of application: Current generators
E10 E20 E25 E30 E40 E50 E60 E70
Routine Inspection Inter-medi- Routine Routine Routine Inter-medi- Complete
Main- ate Main- Main- Main- Main- ate overhaul
tenance tenance tenance tenance tenance overhaul
(small (medium (extended
scope) scope) scope)
once in spe- daily after every after every after every after every after every after every
cial cases 750 Oh 1,500 Oh 3,000 Oh 12,000 Oh 24,000 Oh 48,000 Oh

Tab. 3 Specific DEUTZ maintenance and service schedules in scheduled maintenance plan 1

Scheduled maintenance plan 2, see Page 15

Valid for:
- TCG 2015 V6 and TCG 2015 V8 with n = 1,500 rpm (50 Hz applications)
when using combustion gases of gas group 2
Performance abbreviation: ICN
Type of application: Current generators
E10 E20 E25 E30 E40 E50 E60 E70
Routine Inspection Inter-medi- Routine Routine Routine Inter-medi- Complete
Main- ate Main- Main- Main- Main- ate overhaul
tenance enance tenance tenance tenance overhaul
(small (medium (extended
scope) scope) scope)
once in spe- daily after every after every after every after every after every after every
cial cases 500 Oh 1,000 Oh 2,000 Oh 10,000 Oh 20,000 Oh 40,000 Oh

Tab. 4 Specific DEUTZ maintenance and service schedules in scheduled maintenance plan 2

Chapter 5 - Page 4 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Scheduled maintenance plan 3, see Page 23

Valid for:
- TCG 2015 V6 and TCG 2015 V8 with n = 1,800 rpm (60 Hz applications)
when using combustion gases of gas group 1
Performance abbreviation: ICN
Type of application: Current generators
E10 E20 E25 E30 E40 E50 E60 E70
Routine Inspection Inter-medi- Routine Routine Routine Inter-medi- Complete
Main- ate Main- Main- Main- Main- ate overhaul
tenance tenance tenance tenance tenance overhaul
(small (medium (extended
scope) scope) scope)
once in spe- daily after every after every after every after every after every after every
cial cases 500 Oh 1,000 Oh 2,000 Oh 10,000 Oh 20,000 Oh 40,000 Oh

Tab. 5 Specific DEUTZ maintenance and service schedules in scheduled maintenance plan 3

Scheduled maintenance plan 4, see Page 31

Valid for:
- TCG 2015 V6 and TCG 2015 V8 with n = 1,800 rpm (60 Hz applications)
when using combustion gases of gas group 2
Performance abbreviation: ICN
Type of application: Current generators
E10 E20 E25 E30 E40 E50 E60 E70
Routine Inspection Inter-medi- Routine Routine Routine Inter-medi- Complete
Main- ate Main- Main- Main- Main- ate overhaul
tenance tenance tenance tenance tenance overhaul
(small (medium (extended
scope) scope) scope)
once in spe- daily after every after every after every after every after every after every
cial cases 500 Oh 1,000 Oh 2,000 Oh 10,000 Oh 20,000 Oh 40,000 Oh

Tab. 6 Specific DEUTZ maintenance and service schedules in scheduled maintenance plan 4

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 Maintenance
TCG 2015 5

Scheduled maintenance plan 1

Scheduled maintenance plan 1

This maintenance schedule applies for TCG 2015 V6 and TCG 2015 V8 with n = 1,500 rpm (50 Hz applica-
tions) when using combustion gases of gas group 1.
Maintenance work independent of operating hours
after every 12 months

Description JC
after every 6 months

after every 2 years

as required

monthly

Trial run
x -
after maintenance work 1)
Run in engine;
x after maintenance work such as changing bearings, W 0-1-3
piston, cylinder liner 2)
x Clean the engine B 0-3-6
3)
x Trial run -
3)
x Maintain the battery B 13-4-1
Check percentage of corrosion protection agent or
x B 9-1-1
antifreeze in the coolant 4)
x x Inspect pressure drop in gas filter MD
x Renew gas filter cartridge B 7-21-1
x Gas pressure sensor, check set gas pressure MD
x Check gas pressure regulator MD
x Check shutoff valves of the gas control line MD
x Check the entire gas control line for leaks MD
5)
x Lube oil change B 8-1-2
x Renew lube oil filter cartridge 6) B 8-10-4
4)
x Renew the coolant -
1) To be performed by maintenance officers
2) To be performed by authorized experts
3) This activity must be performed when the engine has not been operated on standby for longer than one month. The engine
must be preserved during long periods out of action, e.g. over the winter, see chapter 7, Preservation.
4) Observe the operating media specifications in chapter 4, Operating Media.
5) To be performed when the engine has been in operation for less than 2,000 Oh within one year.
6) To be performed when the engine has been in operation for less than 3,000 Oh within one year.

Tab. 7 Maintenance work independent of operating hours

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Maintenance
TCG 2015

Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts.
Drain water Drain condensed water for example.
Renew Renew parts, function groups and liquids.
Finishing Material removal within the permitted tolerances to reinstate a nominal condition, using
work oversize parts if necessary.
Check according to criteria in the job card. If not all criteria are fulfilled, the cause must be
Check
found and the nominal condition reinstated.
Clean Cleaning by hand or machine (automatic), renewal of cleaning parts may be necessary.
Visual inspec- Visual inspection according to criteria in the job card. If not all criteria are fulfilled, the
tion cause must be found and the nominal condition reinstated.
Overhaul Check function groups, rework or renew parts.
Maintain according to job card. Check function, reworking or renewal of parts may be nec-
Maintain
essary.
Change Change lube oil for example.
Tab. 8 Definition of activities

Maintenance work depending on operating hours

On reaching the operating hours specified in the following maintenance schedule, the activities prescribed in
the description must be performed. Always use the Job Card referred to in the maintenance schedule.

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 12,000 Oh

after every 24,000 Oh

after every 48,000 Oh

after every 1,500 Oh

after every 3,000 Oh

after every 750 Oh
1x after 50 Oh

x x x x x x x Visual inspection of the system B 0-1-5

x x x x x x Test and function run TEM
x x x Check valve clearance B 1-1-1
Check spark plugs (chamber plug), renew if neces-
x x x x x x B 13-5-4
sary
x x x x x Check starter battery B 13-4-1
x x x x x Check easy action of the speed controller TEM
2) 3)
x x x x x Renew lube oil filter cartridge B 8-10-4
x x x x Renew air filter cartridges, clean air filter casing B 6-3-6
x x x Renew crankcase bleed valve -
x x x Check ignition time -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 8 Note activity definition
The job card is binding for the activity

Chapter 5 - Page 8 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

Scheduled maintenance plan 1

after every 24 hrs (daily)

after every 12,000 Oh

after every 24,000 Oh

after every 48,000 Oh

after every 1,500 Oh

after every 3,000 Oh

after every 750 Oh
1x after 50 Oh

x x x Auxiliary aggregate test using the TEM System -

x x x Check the engine fastening -
x x x Check the starter pinion and crown gear -
x x Check the cylinder heads -
x Renew or overhaul cylinder heads -
x x Clean combustion chambers, check cylinder liners -
x Renew the cylinder liners -
x x Renew rubber compensators -
Check hose pipes, vibration dampers and flexible
x x -
lines
x x Check fittings and regulators -
x x Check, clean mixture cooler -
x x Check crankshaft axial clearance -
x x Check camshaft axial clearance -
x Check valve tappet -
x Renew valve tappet -
x Check con rod liners -
x Check con rod bearings -
x Renew con-rod bearing -
x Check piston -
x Renew piston -
x Check piston bolt -
x Renew piston rings -
x x Check camshaft -
x Renew camshaft bearing -
x x Renew main bearing -
x Renew con rods -
x Renew crankshaft sealing rings (drive side) -
x Renew crankshaft sealing rings (free side) -
x Check, clean wheel drive and control -
x Renew or overhaul lube oil pump -
x Renew or overhaul pressure limiting valve -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 8 Note activity definition
The job card is binding for the activity

© 0304 300201254-en-00.fm Chapter 5 - Page 9

Maintenance
TCG 2015

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 12,000 Oh

after every 24,000 Oh

after every 48,000 Oh

after every 1,500 Oh

after every 3,000 Oh

after every 750 Oh
1x after 50 Oh

x Renew rubber rotary vibration dampers -

4)
Check, clean exhaust gas turbocharger MD
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 8 Note activity definition
The job card is binding for the activity

Tab. 9 Maintenance work depending on operating hours

Maintenance work dependent on operating hours outside the DEUTZ maintenance and service sched-
ules

Interval Description JC

1x after 300 Oh Lube oil analysis according to TR 0199 - 99 - 2105 1) 2) B 8-1-1

1) Initial analysis after 300 Oh
2) Intervals for lube oil analysis and change according to agreement between operator and lab based on the limit values of the
initial analysis, see also Technical Memo TR 0199-99-2105.

Tab. 10 Maintenance work outside the DEUTZ maintenance and service schedules

We recommend you to record the proper execution of the work in the

enclosed maintenance tables.

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 Maintenance
TCG 2015 5

Table for maintenance work independent of operating hours

Scheduled maintenance plan 1

Date Activity Signature

Tab. 11 Table for maintenance work independent of operating hours (copy form)

© 0304 300201254-en-00.fm Chapter 5 - Page 11

Maintenance
TCG 2015

Table for maintenance work dependent on operating hours

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E25 E30 E40 E50 E60 E70
50 1
750 1
1,500 1
2,250 2
3,000 1
3,750 3
4,500 2
5,250 4
6,000 2
6,750 5
7,500 3
8,250 6
9,000 3
9,750 7
10,500 4
11,250 8
12,000 1
12,050 2
12,750 9
13,500 5
14,250 10
15,000 4
15,750 11
16,500 6
17,250 12
18,000 5
18,750 13
19,500 7
20,250 14
21,000 6
21,750 15
22,500 8
23,250 16
24,000 1
24,050 3
24,750 17
25,500 9
26,250 18
27,000 7

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 Maintenance
TCG 2015 5

after
Deutz maintenance and service

Scheduled maintenance plan 1

every Date Signature
schedule
OH
E10 E25 E30 E40 E50 E60 E70
27,750 19
28,500 10
29,250 20
30,000 8
30,750 21
31,500 11
32,250 22
33,000 9
33,750 23
34,500 12
35,250 24
36,000 2
36,050 4
36,750 25
37,500 13
38,250 26
39,000 10
39,750 27
40,500 14
41,250 28
42,000 11
42,750 29
43,500 15
44,250 30
45,000 12
45,750 31
46,500 16
47,250 32
48,000 1

Number of Deutz maintenance and service schedules up to and including

complete overhaul
Total 4 32 16 12 2 1 1

Tab. 12 Table for maintenance work dependent on operating hours (copy form)

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Maintenance
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 Maintenance
TCG 2015 5

Scheduled maintenance plan 2

Scheduled maintenance plan 2

This maintenance schedule applies for TCG 2015 V6 and TCG 2015 V8 with n = 1,500 rpm (50 Hz applica-
tions) when using combustion gases of gas group 2.
Maintenance work independent of operating hours
after every 12 months
Description JC
after every 4 months

after every 6 months

after every 2 years

as required

monthly

Trial run
x -
after maintenance work 1)
Run in engine;
x after maintenance work such as changing bearings, W 0-1-3
piston, cylinder liner 2)
x Clean the engine B 0-3-6
3)
x Trial run -
3)
x Maintain the battery B 13-4-1
x Gas analysis 4) -
Check percentage of corrosion protection agent or
x B 9-1-1
antifreeze in the coolant 5)
x x Inspect pressure drop in gas filter MD
x Renew gas filter cartridge B 7-21-1
x Gas pressure sensor, check set gas pressure MD
x Check gas pressure regulator MD
x Check shutoff valves of the gas control line MD
x Check the entire gas control line for leaks MD
x Lube oil change 6) B 8-1-2
7)
x Renew lube oil filter cartridge B 8-10-4
5)
x Renew the coolant -
1) To be performed by maintenance officers
2) To be performed by authorized experts
3) This activity must be performed when the engine has not been operated on standby for longer than one month. The engine
must be preserved during long periods out of action, e.g. over the winter, see chapter 7, Preservation.
4) The worst determined gas quality is essentially binding for defining the maintenance intervals. Please consult your responsi-
ble DEUTZ SERVICE partner.
5) Observe the operating media specifications in chapter 4, Operating Media.
6) To be performed when the engine has been in operation for less than 2,000 Oh within one year.
7) To be performed when the engine has been in operation for less than 3,000 Oh within one year.

Tab. 13 Maintenance work independent of operating hours

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Maintenance
TCG 2015

Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts.
Drain water Drain condensed water for example.
Renew Renew parts, function groups and liquids.
Finishing Material removal within the permitted tolerances to reinstate a nominal condition, using
work oversize parts if necessary.
Check according to criteria in the job card. If not all criteria are fulfilled, the cause must be
Check
found and the nominal condition reinstated.
Clean Cleaning by hand or machine (automatic), renewal of cleaning parts may be necessary.
Visual inspec- Visual inspection according to criteria in the job card. If not all criteria are fulfilled, the
tion cause must be found and the nominal condition reinstated.
Overhaul Check function groups, rework or renew parts.
Maintain according to job card. Checking of functions; reworking or renewal of parts may
Maintain
be necessary.
Change Change lube oil for example.
Tab. 14 Definition of activities

Maintenance work depending on operating hours

On reaching the operating hours specified in the following maintenance schedule, the activities prescribed in
the description must be performed. Always use the Job Card referred to in the maintenance schedule.

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x x x x x x x Visual inspection of the system B 0-1-5

x x x x x x Test and function run TEM
x x x Check valve clearance B 1-1-1
Check spark plugs (chamber plug), renew if neces-
x x x x x x B 13-5-4
sary
x x x x x Check starter battery B 13-4-1
x x x x x Check easy action of the speed controller TEM
2) 3)
x x x x x Renew lube oil filter cartridge B 8-10-4
x x x x Renew air filter cartridges, clean air filter casing B 6-3-6
x x x Renew crankcase bleed valve -
x x x Check ignition time -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 14 Note activity definition
The job card is binding for the activity

Chapter 5 - Page 16 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

Scheduled maintenance plan 2

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x x x Auxiliary aggregate test using the TEM System -

x x x Check the engine fastening -
x x x Check the starter pinion and crown gear -
x x Check the cylinder heads -
x Renew or overhaul cylinder heads -
x x Clean combustion chambers, check cylinder liners -
x Renew the cylinder liners -
x x Renew rubber compensators -
Check hose pipes, vibration dampers and flexible
x x -
lines
x x Check fittings and regulators -
x x Check, clean mixture cooler -
x x Check crankshaft axial clearance -
x x Check camshaft axial clearance -
x Check valve tappet -
x Renew valve tappet -
x Check con rod liners -
x Check con rod bearings -
x Renew con-rod bearing -
x Check piston -
x Renew piston -
x Check piston bolt -
x Renew piston rings -
x x Check camshaft -
x Renew camshaft bearing -
x x Renew main bearing -
x Renew con rods -
x Renew crankshaft sealing rings (drive side) -
x Renew crankshaft sealing rings (free side) -
x Check, clean wheel drive and control -
x Renew or overhaul lube oil pump -
x Renew or overhaul pressure limiting valve -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 14 Note activity definition
The job card is binding for the activity

© 0304 300201254-en-00.fm Chapter 5 - Page 17

Maintenance
TCG 2015

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x Renew rubber rotary vibration dampers -

4)
Check, clean exhaust gas turbocharger MD
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 14 Note activity definition
The job card is binding for the activity

Tab. 15 Maintenance work depending on operating hours

Maintenance work dependent on operating hours outside the DEUTZ maintenance and service sched-
ules

Interval Description JC

1x after 100 Oh Lube oil analysis according to TR 0199 - 99 - 2105 1) 2) B 8-1-1

1) Initial analysis after 100 Oh
2) Intervals for lube oil analysis and change according to agreement between operator and lab based on the limit values of the
initial analysis, see also Technical Memo TR 0199-99-2105.

Tab. 16 Maintenance work outside the DEUTZ maintenance and service schedules

We recommend you to record the proper execution of the work in the

enclosed maintenance tables.

Chapter 5 - Page 18 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Table for maintenance work independent of operating hours

Scheduled maintenance plan 2

Date Activity Signature

Tab. 17 Table for maintenance work independent of operating hours (copy form)

© 0304 300201254-en-00.fm Chapter 5 - Page 19

Maintenance
TCG 2015

Table for maintenance work dependent on operating hours

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
50 1
500 1
1,000 1
1,500 2
2,000 1
2,500 3
3,000 2
3,500 4
4,000 2
4,500 5
5,000 3
5,500 6
6,000 3
6,500 7
7,000 4
7,500 8
8,000 4
8,500 9
9,000 5
9,500 10
10,000 1
10,050 2
10,500 11
11,000 6
11,500 12
12,000 5
12,500 13
13,000 7
13,500 14
14,000 6
14,500 15
15,000 8
15,500 16
16,000 7
16,500 17
17,000 9
17,500 18
18,000 8
18,500 19

Chapter 5 - Page 20 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

after
Deutz maintenance and service

Scheduled maintenance plan 2

every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
19,000 10
19,500 20
20,000 1
20,050 3
20,500 21
21,000 11
21,500 22
22,000 9
22,500 23
23,000 12
23,500 24
24,000 10
24,500 25
25,000 13
25,500 26
26,000 11
26,500 27
27,000 14
27,500 28
28,000 12
28,500 29
29,000 15
29,500 30
30,000 2
30,050 4
30,500 31
31,000 16
31,500 32
32,000 13
32,500 33
33,000 17
33,500 34
34,000 14
34,500 35
35,000 18
35,500 36
36,000 15
36,500 37
37,000 19
37,500 38

© 0304 300201254-en-00.fm Chapter 5 - Page 21

Maintenance
TCG 2015

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
38,000 16
38,500 39
39,000 20
39,500 40
40,000 1

Number of Deutz maintenance and service schedules up to and including

complete overhaul
Total 4 40 20 16 2 1 1

Tab. 18 Table for maintenance work dependent on operating hours (copy form)

Chapter 5 - Page 22 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Scheduled maintenance plan 3

Scheduled maintenance plan 3

This maintenance schedule applies for TCG 2015 V6 and TCG 2015 V8 with n = 1,800 rpm (60 Hz applica-
tions) when using combustion gases of gas group 1.
Maintenance work independent of operating hours
after every 12 months

Description JC
after every 6 months

after every 2 years

as required

monthly

Trial run
x -
after maintenance work 1)
Run in engine;
x after maintenance work such as changing bearings, W 0-1-3
piston, cylinder liner 2)
x Clean the engine B 0-3-6
3)
x Trial run -
3)
x Maintain the battery B 13-4-1
Check percentage of corrosion protection agent or
x B 9-1-1
antifreeze in the coolant 4)
x x Inspect pressure drop in gas filter MD
x Renew gas filter cartridge B 7-21-1
x Gas pressure sensor, check set gas pressure MD
x Check gas pressure regulator MD
x Check shutoff valves of the gas control line MD
x Check the entire gas control line for leaks MD
5)
x Lube oil change B 8-1-2
x Renew lube oil filter cartridge 5) B 8-10-4
4)
x Renew the coolant -
1) To be performed by maintenance officers
2) To be performed by authorized experts
3) This activity must be performed when the engine has not been operated on standby for longer than one month. The engine
must be preserved during long periods out of action, e.g. over the winter, see chapter 7, Preservation.
4) Observe the operating media specifications in chapter 4, Operating Media.
5) To be performed when the engine has been in operation for less than 2,000 Oh within one year.

Tab. 19 Maintenance work independent of operating hours

© 0304 300201254-en-00.fm Chapter 5 - Page 23

Maintenance
TCG 2015

Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts.
Drain water Drain condensed water for example.
Renew Renew parts, function groups and liquids.
Finishing Material removal within the permitted tolerances to reinstate a nominal condition, using
work oversize parts if necessary.
Check according to criteria in the job card. If not all criteria are fulfilled, the cause must be
Check
found and the nominal condition reinstated.
Clean Cleaning by hand or machine (automatic), renewal of cleaning parts may be necessary.
Visual inspec- Visual inspection according to criteria in the job card. If not all criteria are fulfilled, the
tion cause must be found and the nominal condition reinstated.
Overhaul Check function groups, rework or renew parts.
Maintain according to job card. Checking of functions; reworking or renewal of parts may
Maintain
be necessary.
Change Change lube oil for example.
Tab. 20 Definition of activities

Maintenance work depending on operating hours

On reaching the operating hours specified in the following maintenance schedule, the activities prescribed in
the description must be performed. Always use the Job Card referred to in the maintenance schedule.

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x x x x x x x Visual inspection of the system B 0-1-5

x x x x x x Test and function run TEM
x x x Check valve clearance B 1-1-1
Check spark plugs (chamber plug), renew if neces-
x x x x x x B 13-5-4
sary
x x x x x Check starter battery B 13-4-1
x x x x x Check easy action of the speed controller TEM
2) 3)
x x x x x Renew lube oil filter cartridge B 8-10-4
x x x x Renew air filter cartridges, clean air filter casing B 6-3-6
x x x Renew crankcase bleed valve -
x x x Check ignition time -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 20 Note activity definition
The job card is binding for the activity

Chapter 5 - Page 24 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

Scheduled maintenance plan 3

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x x x Auxiliary aggregate test using the TEM System -

x x x Check the engine fastening -
x x x Check the starter pinion and crown gear -
x x Check the cylinder heads -
x Renew or overhaul cylinder heads -
x x Clean combustion chambers, check cylinder liners -
x Renew the cylinder liners -
x x Renew rubber compensators -
Check hose pipes, vibration dampers and flexible
x x -
lines
x x Check fittings and regulators -
x x Check, clean mixture cooler -
x x Check crankshaft axial clearance -
x x Check camshaft axial clearance -
x Check valve tappet -
x Renew valve tappet -
x Check con rod liners -
x Check con rod bearings -
x Renew con-rod bearing -
x Check piston -
x Renew piston -
x Check piston bolt -
x Renew piston rings -
x x Check camshaft -
x Renew camshaft bearing -
x x Renew main bearing -
x Renew con rods -
x Renew crankshaft sealing rings (drive side) -
x Renew crankshaft sealing rings (free side) -
x Check, clean wheel drive and control -
x Renew or overhaul lube oil pump -
x Renew or overhaul pressure limiting valve -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 20 Note activity definition
The job card is binding for the activity

© 0304 300201254-en-00.fm Chapter 5 - Page 25

Maintenance
TCG 2015

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x Renew rubber rotary vibration dampers -

4)
Check, clean exhaust gas turbocharger MD
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 20 Note activity definition
The job card is binding for the activity

Tab. 21 Maintenance work depending on operating hours

Maintenance work dependent on operating hours outside the DEUTZ maintenance and service sched-
ules

Interval Description JC

1x after 300 Oh Lube oil analysis according to TR 0199 - 99 - 2105 1) 2) B 8-1-1

1) Initial analysis after 300 Oh
2) Intervals for lube oil analysis and change according to agreement between operator and lab based on the limit values of the
initial analysis, see also Technical Memo TR 0199-99-2105.

Tab. 22 Maintenance work outside the DEUTZ maintenance and service schedules

We recommend you to record the proper execution of the work in the

enclosed maintenance tables.

Chapter 5 - Page 26 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Table for maintenance work independent of operating hours

Scheduled maintenance plan 3

Date Activity Signature

Tab. 23 Table for maintenance work independent of operating hours (copy form)

© 0304 300201254-en-00.fm Chapter 5 - Page 27

Maintenance
TCG 2015

Table for maintenance work dependent on operating hours

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
50 1
500 1
1,000 1
1,500 2
2,000 1
2,500 3
3,000 2
3,500 4
4,000 2
4,500 5
5,000 3
5,500 6
6,000 3
6,500 7
7,000 4
7,500 8
8,000 4
8,500 9
9,000 5
9,500 10
10,000 1
10,050 2
10,500 11
11,000 6
11,500 12
12,000 5
12,500 13
13,000 7
13,500 14
14,000 6
14,500 15
15,000 8
15,500 16
16,000 7
16,500 17
17,000 9
17,500 18
18,000 8
18,500 19

Chapter 5 - Page 28 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

after
Deutz maintenance and service

Scheduled maintenance plan 3

every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
19,000 10
19,500 20
20,000 1
20,050 3
20,500 21
21,000 11
21,500 22
22,000 9
22,500 23
23,000 12
23,500 24
24,000 10
24,500 25
25,000 13
25,500 26
26,000 11
26,500 27
27,000 14
27,500 28
28,000 12
28,500 29
29,000 15
29,500 30
30,000 2
30,050 4
30,500 31
31,000 16
31,500 32
32,000 13
32,500 33
33,000 17
33,500 34
34,000 14
34,500 35
35,000 18
35,500 36
36,000 15
36,500 37
37,000 19
37,500 38

© 0304 300201254-en-00.fm Chapter 5 - Page 29

Maintenance
TCG 2015

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
38,000 16
38,500 39
39,000 20
39,500 40
40,000 1

Number of Deutz maintenance and service schedules up to and including

complete overhaul
Total 4 40 20 16 2 1 1

Tab. 24 Table for maintenance work dependent on operating hours (copy form)

Chapter 5 - Page 30 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Scheduled maintenance plan 4

Scheduled maintenance plan 4

This maintenance schedule applies for TCG 2015 V6 and TCG 2015 V8 with n = 1,800 rpm (60 Hz applica-
tions) when using combustion gases of gas group 2.
Maintenance work independent of operating hours
after every 12 months
Description JC
after every 4 months

after every 6 months

after every 2 years

as required

monthly

Trial run
x -
after maintenance work 1)
Run in engine;
x after maintenance work such as changing bearings, W 0-1-3
piston, cylinder liner 2)
x Clean the engine B 0-3-6
3)
x Trial run -
3)
x Maintain the battery B 13-4-1
x Gas analysis 4) -
Check percentage of corrosion protection agent or
x B 9-1-1
antifreeze in the coolant 5)
x x Inspect pressure drop in gas filter MD
x Renew gas filter cartridge B 7-21-1
x Gas pressure sensor, check set gas pressure MD
x Check gas pressure regulator MD
x Check shutoff valves of the gas control line MD
x Check the entire gas control line for leaks MD
x Lube oil change 6) B 8-1-2
6)
x Renew lube oil filter cartridge B 8-10-4
5)
x Renew the coolant -
1) To be performed by maintenance officers
2) To be performed by authorized experts
3) This activity must be performed when the engine has not been operated on standby for longer than one month. The engine
must be preserved during long periods out of action, e.g. over the winter, see chapter 7, Preservation.
4) The worst determined gas quality is essentially binding for defining the maintenance intervals. Please consult your responsi-
ble DEUTZ SERVICE partner.
5) Observe the operating media specifications in chapter 4, Operating Media.
6) To be performed when the engine has been in operation for less than 2,000 Oh within one year.

Tab. 25 Maintenance work independent of operating hours

© 0304 300201254-en-00.fm Chapter 5 - Page 31

Maintenance
TCG 2015

Definition of activities in the maintenance schedule

Adjust Adjust torques, dimensions, pressures etc.; extra work may be necessary to renew parts.
Drain water Drain condensed water for example.
Renew Renew parts, function groups and liquids.
Finishing Material removal within the permitted tolerances to reinstate a nominal condition, using
work oversize parts if necessary.
Check according to criteria in the job card. If not all criteria are fulfilled, the cause must be
Check
found and the nominal condition reinstated.
Clean Cleaning by hand or machine (automatic), renewal of cleaning parts may be necessary.
Visual inspec- Visual inspection according to criteria in the job card. If not all criteria are fulfilled, the
tion cause must be found and the nominal condition reinstated.
Overhaul Check function groups, rework or renew parts.
Maintain according to job card. Checking of functions; reworking or renewal of parts may
Maintain
be necessary.
Change Change lube oil for example.
Tab. 26 Definition of activities

Maintenance work depending on operating hours

On reaching the operating hours specified in the following maintenance schedule, the activities prescribed in
the description must be performed. Always use the Job Card referred to in the maintenance schedule.

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x x x x x x x Visual inspection of the system B 0-1-5

x x x x x x Test and function run TEM
x x x Check valve clearance B 1-1-1
Check spark plugs (chamber plug), renew if neces-
x x x x x x B 13-5-4
sary
x x x x x Check starter battery B 13-4-1
x x x x x Check easy action of the speed controller TEM
2) 3)
x x x x x Renew lube oil filter cartridge B 8-10-4
x x x x Renew air filter cartridges, clean air filter casing B 6-3-6
x x x Renew crankcase bleed valve -
x x x Check ignition time -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 26 Note activity definition
The job card is binding for the activity

Chapter 5 - Page 32 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

Scheduled maintenance plan 4

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x x x Auxiliary aggregate test using the TEM System -

x x x Check the engine fastening -
x x x Check the starter pinion and crown gear -
x x Check the cylinder heads -
x Renew or overhaul cylinder heads -
x x Clean combustion chambers, check cylinder liners -
x Renew the cylinder liners -
x x Renew rubber compensators -
Check hose pipes, vibration dampers and flexible
x x -
lines
x x Check fittings and regulators -
x x Check, clean mixture cooler -
x x Check crankshaft axial clearance -
x x Check camshaft axial clearance -
x Check valve tappet -
x Renew valve tappet -
x Check con rod liners -
x Check con rod bearings -
x Renew con-rod bearing -
x Check piston -
x Renew piston -
x Check piston bolt -
x Renew piston rings -
x x Check camshaft -
x Renew camshaft bearing -
x x Renew main bearing -
x Renew con rods -
x Renew crankshaft sealing rings (drive side) -
x Renew crankshaft sealing rings (free side) -
x Check, clean wheel drive and control -
x Renew or overhaul lube oil pump -
x Renew or overhaul pressure limiting valve -
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 26 Note activity definition
The job card is binding for the activity

© 0304 300201254-en-00.fm Chapter 5 - Page 33

Maintenance
TCG 2015

E10 E20 E25 E30 E40 E50 E60 E70 Description JC

after every 24 hrs (daily)

after every 10,000 Oh

after every 20,000 Oh

after every 40,000 Oh

after every 1,000 Oh

after every 2,000 Oh

after every 500 Oh
1x after 50 Oh

x Renew rubber rotary vibration dampers -

4)
Check, clean exhaust gas turbocharger MD
1) For engines with this equipment
2) Only 50 Oh, as per E50 to E70
3) For other lube oil filter changes, see TR 0199 - 99 - 2105
4) Maintenance intervals, see manufacturer documentation
MD: Manufacturer Documents
Table 26 Note activity definition
The job card is binding for the activity

Tab. 27 Maintenance work depending on operating hours

Maintenance work dependent on operating hours outside the DEUTZ maintenance and service sched-
ules

Interval Description JC

1x after 100 Oh Lube oil analysis according to TR 0199 - 99 - 2105 1) 2) B 8-1-1

1) Initial analysis after 100 Oh
2) Intervals for lube oil analysis and change according to agreement between operator and lab based on the limit values of the
initial analysis, see also Technical Memo TR 0199-99-2105.

Tab. 28 Maintenance work outside the DEUTZ maintenance and service schedules

We recommend you to record the proper execution of the work in the

enclosed maintenance tables.

Chapter 5 - Page 34 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Table for maintenance work independent of operating hours

Scheduled maintenance plan 4

Date Activity Signature

Tab. 29 Table for maintenance work independent of operating hours (copy form)

© 0304 300201254-en-00.fm Chapter 5 - Page 35

Maintenance
TCG 2015

Table for maintenance work dependent on operating hours

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
50 1
500 1
1,000 1
1,500 2
2,000 1
2,500 3
3,000 2
3,500 4
4,000 2
4,500 5
5,000 3
5,500 6
6,000 3
6,500 7
7,000 4
7,500 8
8,000 4
8,500 9
9,000 5
9,500 10
10,000 1
10,050 2
10,500 11
11,000 6
11,500 12
12,000 5
12,500 13
13,000 7
13,500 14
14,000 6
14,500 15
15,000 8
15,500 16
16,000 7
16,500 17
17,000 9
17,500 18
18,000 8
18,500 19

Chapter 5 - Page 36 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

after
Deutz maintenance and service

Scheduled maintenance plan 4

every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
19,000 10
19,500 20
20,000 1
20,050 3
20,500 21
21,000 11
21,500 22
22,000 9
22,500 23
23,000 12
23,500 24
24,000 10
24,500 25
25,000 13
25,500 26
26,000 11
26,500 27
27,000 14
27,500 28
28,000 12
28,500 29
29,000 15
29,500 30
30,000 2
30,050 4
30,500 31
31,000 16
31,500 32
32,000 13
32,500 33
33,000 17
33,500 34
34,000 14
34,500 35
35,000 18
35,500 36
36,000 15
36,500 37
37,000 19
37,500 38

© 0304 300201254-en-00.fm Chapter 5 - Page 37

Maintenance
TCG 2015

after
Deutz maintenance and service
every Date Signature
schedule
OH
E10 E20 E30 E40 E50 E60 E70
38,000 16
38,500 39
39,000 20
39,500 40
40,000 1

Number of Deutz maintenance and service schedules up to and including

complete overhaul
Total 4 40 20 16 2 1 1

Tab. 30 Table for maintenance work dependent on operating hours (copy form)

Chapter 5 - Page 38 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Keep an operating check log! A copy form is provided on the next page. Operating check log
Please not down all irregularities (warnings, faults) and maintenance work in
this log. This means you always have a good idea when maintenance work is
due, and you can document all irregularities for our service personnel. If you
have connected a printer to your TEM system, print out a copy of the meas-
ured values in the event of warnings or faults.

Further operation of the engine in the case of a warning or restarting

after a fault without eliminating the cause can lead to total engine
failure.

© 0304 300201254-en-00.fm Chapter 5 - Page 39

Maintenance
TCG 2015

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Chapter 5 - Page 40 300201254-en-00.fm © 0304

 Maintenance
TCG 2015 5

Operating inspection log

Never acknowledge an alarm/malfunction message until you

have found out the cause.
Follow the advice given in the operating instructions.

System: Engine type: Page:

Date Module Event Signature /
Time Operating hours Measure Printer doc. no.

Tab. 1 Operating inspection log (form for copying)

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Maintenance
TCG 2015

This page intentionally left blank.

Chapter 5 - Page 42 300201267-en-00.fm © 0603

 Troubleshooting
TCG 2015 6

6 Troubleshooting

This section helps operating personnel to locate and eliminate faults in the Table of faults with
engine. Maintenance and repair of the units and elimination of minor faults instructions on their
require detailed knowledge of the function and of individual parts. elimination
All engine, unit, sensor and external faults are displayed by the DEUTZ TEM
system and sometimes indicate the cause. The following fault explanations
may be additionally useful. Potential engine operating faults are listed along
with their possible causes.
Please note that some of the work requires highly qualified personnel with
appropriate training and knowledge. Please contact your DEUTZ Service
operation if in doubt.

© 0304 300201268-en-00.fm Chapter 6 - Page 1

Troubleshooting
TCG 2015

Fault table

Fault (Please note: TEM fault messages generally cause the engine to shut down!)
Engine fails to start
Engine does not reach the specified output or speed
Engine fires irregularly (see combustion chamber temperature curve in the TEM)
Engine ”knocks” and runs intermittently
Engine stops suddenly or is switched off by TEM after a fault
Engine gets too hot or TEM indicates “lack of coolant”
Lube oil pressure too low / TEM ”Lube oil pressure too low” or ”Lube oil level too low”
Coolant in lube oil
Lube oil in coolant
Gas in coolant

TEM message Possible causes

STARTER SYSTEM
z Engine fails to start Batteries empty or defective
z Engine fails to start Starter defective
ELECTRICS
z Power supply unit terminal box failure
IGNITION
z Engine fails to start Ignition system defective
z Ignition failed (cable broken)
z z Ignition control unit defective
z Ignition cable defective
z z Ignition coils defective
z Electrode spacing at spark plug too big
z Spark plugs dirty / defective
Pickup (camshaft or control shaft) gap too great / or
z z z near limit
GAS-AIR-EXHAUST GAS
z Gas pressure Gas stop valves closed
z Gas pressure Gas stop valves not fully open
z Gas supply interrupted
z Gas mixer stop Gas-air mixture defective (too lean / too rich)
z Gas pressure too little gas
z Maintenance indicator on the air filter
z z Gas pipe not bled
z Gas pressure regulator jams
z Gas mixer stop lean Gas pressure too high
Exhaust gas backpressure too high Exhaust gas pipes constricted by dirt
z *
* optional, if installed

Chapter 6 - Page 2 300201268-en-00.fm © 0304

 Troubleshooting
TCG 2015 6

Remedy

Recharge or replace batteries

Replace starter

Damaged pipes / Replace pipe connections

Check the ignition system

Check the ignition system
Replace the ignition control unit
Check / replace the ignition cable
Check / replace the ignition coils
Check / replace spark plug
Clean / replace spark plugs
Check / adjust spacing

Open gas stop valves

Check gas stop valves / gas filter
Check gas pipes
Check regulation of the gas mixer
Check gas pressure
Check / replace air filter
Bleed gas line
Check the gas pressure controller (gas flow pressure)
Check, correct gas pressure at the gas pressure regulator
Clean the exhaust gas pipes (exhaust gas heat exchanger)

© 0304 300201268-en-00.fm Chapter 6 - Page 3

Troubleshooting
TCG 2015

Fault (Please note: TEM fault messages generally cause the engine to shut down!)
Engine fails to start
Engine does not reach the specified output or speed
Engine fires irregularly (see combustion chamber temperature curve in the TEM)
Engine ”knocks” and runs intermittently
Engine stops suddenly or is switched off by TEM after a fault
Engine gets too hot or TEM indicates “lack of coolant”
Lube oil pressure too low / TEM ”Lube oil pressure too low” or ”Lube oil level too low”
Coolant in lube oil
Lube oil in coolant
Gas in coolant

TEM message Possible causes

SPEED CONTROL
z Overspeed Speed controller defective
COOLANT
z z Low cooling water Too little cooling water
z z Fault cooling water pump Coolant pump: Pump shaft broken, bearing defective
Cooling channels in the engine sludged or blocked by
z z Overtemperature cooling water scale
z z Low cooling water Coolant pump losing too much water
z Three-way valve secondary heating circuit defective
z Heat transmission primary to secondary poor
LUBE OIL
z Lube oil filter soiled Lube oil filter soiled
Lube oil level too low / overtemper- Lube oil level too low
z z ature lube oil
z Lube oil pressure too low Manifold to lube oil pump soiled
z Lube oil pressure too low Lube oil pump heavily worn
z Lube oil pressure too low Safety valve on the lube oil pump leaking
z Lube oil cooler leaking
z Lube oil pressure gauge defective
z Regulating valve defective
GENERAL /OTHER
z no clearance between rocker arm and valve face
z Inlet and outlet valves leaking
Bearing clearance of the crankshaft and con-rod bear-
z ings too great (wear)
Oil carbon residue on spark plugs, pistons or outlet
z valve
z Cylinder liner seal in crankcase leaking

Chapter 6 - Page 4 300201268-en-00.fm © 0304

 Troubleshooting
TCG 2015 6

Remedy

Check the regulator and have repaired immediately

Refill coolant, find and eliminate the cause of the coolant loss
Check / replace the coolant pump
Clean the coolant system

Check / replace axial sealing rings of the coolant pump

Check / replace the three-way valve of the secondary heating circuit
Clean sludged elements of the heat transformer

Renew filter
Fill up lube oil

Clean manifold
Check / replace lube oil pump
Check / replace safety valve
Check / replace lube oil cooler
Check / replace if necessary
Check / replace regulating valve

Set valve clearance

Check, grind if necessary
Check bearing clearances, change bearings if necessary

check and clean (cf. TEM: combustion chamber temperature history)

Remove cylinder liner, insert new rubber rings, analyse lube oil sample

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 Conservation
TCG 2015 7

7 Conservation

see Technical Circular TR 0199-99-2116. Conservation

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 Technical particulars
TCG 2015 8

8 Technical particulars

General engine data

Basic data

TCG 2015
Type designation
V6 V8
Four-stroke
Lean mixture combustion
Work procedure
Mixture turbocharging
Mixture cooling
Cylinder arrangement V-engine, 90° V-angle
No. of cylinders 6 8
Bore mm 132 132
Stroke mm 145 145
Capacity per cylinder dm3 1.98 1.98
3
Total displacement dm 11.90 15.87
Compression ratio 12 : 1 12 : 1
DEUTZ TEM system, electronic controller with servo
Speed governing system
motor on mixture throttle valve
Power regulation DEUTZ TEM system
Gas mixture regulation DEUTZ TEM system on control valve
Screw in spark plugs Standard spark plugs
Electrode gap mm 0.35

Control data

V6 V8
Valve clearance with cold engine
Inlet mm 0.3 +0,1 0.3+0,1
Outlet mm 0.6 +0,1 0.6 +0,1

Ignition
sequence
V6 A1 B3 A3 B2 A2 B1
V8 A1 B4 A4 B1 B3 A3 B2 A2

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Dimensions

Engine V6 V8
Length mm 1.090 1.280
Width mm 1.120 1.120
Height mm 1.610 1.610

Weights

Weight 1)
Name
V6 V8
Shipping weight, engine kg 900 1.150
Shipping weight, unit kg 2.180 2.675
Cylinder head, complete kg 17.3 17.3
Cylinder liner kg 7.3 7.3
Piston, complete kg 4.1 4.1
Con-rod, complete kg 3.6 3.6
Camshaft kg 13.2 17.5
Flywheel kg 60 60
Connection housing kg 57.6 57.6
Assembly carrier kg 17.7 17.7
Vibration damper kg 14.2 6.4
Mix cooler kg 45 45
Lube oil pump, assembled kg 5.5 5.5
Oil cooler kg 6.8 8.7
Starter (electr.) kg 22.1 22.1
1) all data are approximate values

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 Technical particulars
TCG 2015 8

Operating data

Filling levels

V6 V8
3
Total lube oil content in engine dm 60 70
3
Coolant content of engine dm 34 46

Temperatures

V6 V8
Coolant temperature, engine
Inlet / outlet (max.) °C 80 / 88 80 / 88
for glycol (max.) °C 80 / 88 80 / 88
Intake air temperature
Minimum °C 5 5
Design project-related

Pressures

V6 V8
Gas pressure fluctuations
in % of the set value
at fluctuation frequency 1 /h
Exhaust gas backpressure from/to mbar - / 50 - / 50

Emission data

V6 V8
Noise
Airborne noise 1 m away from the
dB (A)
engine
Exhaust gas, un-silenced dB (A)

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Engine, peripheral data

Starter system

V6 V8
Electrical starter with 24 V DC (direct
current)
Power consumption kW 5.4 5.4
Starter battery 12 V, necessary bat-
Ah 2 x 143 2 x 143
tery capacity

Speed controller

Designation actuator StG 2040.25

Angle of rotation on the controller
° 86
output shaft
Max. torque on the regulator output
Nm (approx.) 6.5
shaft (stop direction)
Stop torque in the current limiting Nm (approx.) 3.2
Throughput time 0-100 % without
ms (approx.) 50
load
Current consumption of the complete
controller
in the steady state A (approx.) 1
at load change A (approx.) 3-4
max. current A (approx.) 4.5
limited current A (approx.) 2.5
Storage temperature °C -55 to +110
Ambient temperature in operation °C -25 to +90
Ambient temperature, custom ver-
°C -40 to +90
sion
Humidity % up to 100
Degree of protection
Housing IP 65
Connections IP 00 / IP 65
Weight kg (approx.) 3.9

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 Technical particulars
TCG 2015 8

RI flow diagrams

Figure 8-1 Compact unit (TCG2015V6-V8)

Item 30 Compact unit ASD Exhaust gas silencer

AWT Exhaust gas heat exchanger
1) in the case of biogas DV Throttle armature
3) depending on emission limits KAT Catalyst
KWT Cooling water heat exchanger
Exhaust gas measurement point
G1/2(T+P) + G2
Heating/cooling water measurement point
G1/2 with immersion sleeve

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Figure 8-2 BHKW (TCG2015V6-V8)

Item 1 Unit ASD Exhaust gas silencer

Item 2 Gas regulator line (*) AWT Exhaust gas heat exchanger
Item 4 Heat recovery (*) DV Throttle armature
Items 1-9 Unit compartment FU Frequency converter
(*) Local pipe work KAT Catalyst
Exhaust gas measurement point KWZT Cooling water heat exchanger
G1/2(T+P) + G2
Heating/cooling water measurement point 1) in the case of biogas
G1/2 with immersion sleeve 3) depending on emission limits

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 Technical particulars
TCG 2015 8

Figure 8-3 Electrical current module (TCG2015V6-V8)

Item 1 Unit ASD Exhaust gas silencer

Item 2 Gas regulator line (*) DV Throttle armature
Item 5 Engine cooling system (*) FU Frequency converter
Item 9 Exhaust gas system (*) KAT Catalyst
Items 1-9 Unit compartment TK Table cooler
(*) Local pipe work
Exhaust gas measurement point
G1/2(T+P) + G2 1) in the case of biogas
Heating/cooling water measurement point 3) depending on emission limits
G1/2 with immersion sleeve

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Legend

Shutoff valve

Ballcock

Three-way valve

Throttle valve

Check valve

Air/gas filter

Liquid filter

Safety valve

Safety corner valve

Compensator

Extension vessel

Engine drive

Electromagnetic drive

Circulation pump

Diaphragm drive

Turbocharger

Local display

Alternator

Chimney

Catalyst

Gas-Otto engine

Silencer

Pre-heater

Bleed valve

Gas / air carburettor

Heat exchanger

Table cooler

Flame flashover protection

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 Technical particulars
TCG 2015 8

Tightening specifications

Scheduled maintenance work up to E40

Code Screw connection Type and dimension Strength Tightening value Important notes
no.

Cylinder head cover on M8 x 30 10.9 22 Nm

cylinder head hood
M8 x 30 10.9
Cylinder head hood on
cylinder head M8 x 70 10.9 22 Nm
M8 x 80 10.9
Spark plug Spark plug, M14 x 1.25 35 Nm
Lock nut of the setting
screw on the rocker arm Hexagon nut M10 x 1 20 Nm

Apply a coating of oil to

Lube oil filter cartridge 27 Nm the sealing surface,
tighten fingertight
Engine drain screw M3 x 1.5 120 Nm
Screw plug for lube oil
M14 x 1.5 34 Nm
sampling outlet
Cover for gas filter
cartridge M6 8 Nm tighten crosswise

Coolant drain screw M16 x 1.5 38 Nm

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 Job Cards
TCG 2015 9

9 Job Cards

You will find there are various symbols used on the Job Cards, in order to Explanation of sym-
designate information not relating directly to the actual work sequence invol- bols
ved.

Tools
- The tools normally required are listed against this symbol.

Equipment
- Things like pressure gauges, lube oil and hydraulic oil

Spare parts
- Seals, locking parts, etc.

Cross-references
- Documents, reports or Job Cards to which reference is made in the Job
Card concerned.

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Overviews

Arranged alphabetically

Jobs Job Card

Changing lube oil B 8-1-2

Checking and adjusting inlet and outlet valve clearance B 1-1-1
Checking corrosion protection agent or antifreeze in coolant B 9-1-1
Checking easy action of the speed controller B 5-4-2
Checking the gas pressure in the gas regulator line B 7-20-1
Cleaning the engine B 0-3-6
Cleaning the gas filter / renewing the filter cartridge B 7-21-1
Maintaining the battery B 13-4-1
Renewing lube oil filter cartridge B 8-10-4
Replacing airfilter cartridge B 6-3-6
Safety regulations for handling components made of elastomers containing fluoride (e.g. Viton) B 0-0-3
Spark plugs, spark plug cables, checking, cleaning the spark plug shaft B 13-5-4
Specifications for cutting, grinding, soldering and welding work B 0-0-4
Taking lube oil samples B 8-1-1
Visual inspection of the system B 0-1-5

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 Job Cards
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Arranged by Job Card Numbers

Job Card Jobs

B 0-0-3 Safety regulations for handling components made of elastomers containing fluoride (e.g. Viton)
B 0-0-4 Specifications for cutting, grinding, soldering and welding work
B 0-1-5 Visual inspection of the system
B 0-3-6 Cleaning the engine
B 1-1-1 Checking and adjusting inlet and outlet valve clearance
B 5-4-2 Checking easy action of the speed controller
B 6-3-6 Replacing airfilter cartridge
B 7-20-1 Checking the gas pressure in the gas regulator line
B 7-21-1 Cleaning the gas filter / renewing the filter cartridge
B 8-1-1 Taking lube oil samples
B 8-1-2 Changing lube oil
B 8-10-4 Renewing lube oil filter cartridge
B 9-1-1 Checking corrosion protection agent or antifreeze in coolant
B 13-4-1 Maintaining the battery
B 13-5-4 Spark plugs, spark plug cables, checking, cleaning the spark plug shaft

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 TCG 2015 B 0-0-3

B 0-0-3
Safety regulations for handling components made of elastomers
containing fluoride (e.g. Viton)

Crass references
- Chapter 1, Rules for disposal

Gaskets, round sealing rings and moulded parts are manufactured partly from
elastomers containing fluoride (FPM) to withstand high thermal stress.
At unscheduled temperatures above 315 °C (caused for example by an
engine fire) the material decomposes and forms caustic acids. The residue is
tacky and black in appearance.

Touching the residue with your hands, even after cooling down, may be dam-
aging to health.

Proceed as follows if high temperatures have caused damage to gaskets or

round sealing rings:
● Check all gaskets which have suffered from the heat visually.
● Wear gloves (neoprene).
● Remove all residue material and dispose of it, see also Chapter 1, Rules
for disposal.
● Destroy clothing which has been contaminated by residue of the gaskets.

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 TCG 2015 B 0-0-4

B 0-0-4
Specifications for cutting, grinding, soldering and welding work

Cross references
- Accident prevention regulations

The contractor of cutting, grinding, soldering and welding work must alert the
persons enlisted to do the work to the dangers and ensure that the points
listed below are observed and executed.
Persons entrusted with cutting, grinding, soldering and welding work must be
familiar with and observe the valid regulations and specifications, especially
the rules for accident prevention of the respective national legislations.
The following points must be observed additionally to the specified regula-
tions and specifications.

Electrics / electron-
ics

The following points apply for welding work and work where electrical and
electronic components may be at risk (e.g. due to high temperatures or elec-
trical short-circuits).

● Disconnect the battery ground and remove and stow away the battery
safely if necessary.
● Pull out the plugs of electrical and electronic components (e.g. TEM
switch cabinet, MKS junction box, EMR 2-control unit, ignition system,
sensors).
● Sensitive parts in the immediate vicinity of the welding point (e.g. control
units, ignition system, sensors, cables) must be removed after unplugging.
● Always connect the ground terminal of the welding gear in the immediate
vicinity of the welding point to avoid vagrant currents. Pay attention to per-
fect ground connection. The paint may have to be removed in this area.

Failure to do so can lead to serious damage to the engine electronics.

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Sparks / danger of ● Keep all inflammable materials away from the danger area.
fire ● Remove inflammable objects (e.g. cables, compensators) or cover with
non-conductive, non-flammable material.
● Cover sensitive surfaces (e.g. air filter) with non-conductive and non-flam-
mable material.
● Seal openings in the engine.
● Seal off and cover openings to other work areas.
● Keep a sufficient number of fire extinguishers close by.

Danger of explosion ● Shut off gas pipes and fuel pipes.

● Work which could lead to a strong development of heat on gas or fuel
pipes and vessels may only be carried out when these have been com-
pletely emptied and bled or flushed.

Health hazard ● Air well, suck off fumes and dust particles.
● Cordon off the working area during arc welding to protect bystanders
against the harmful effects of optical radiation.

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 TCG 2015 B 0-1-5

B 0-1-5
Visual inspection of the system

Tools
- Standard tools

Cross references
- B 7-20-1, Checking the gas pressure in the gas regulator line
- B 13-4-1, Maintaining the battery

● Check display data on the switching system Dailycheck

- Power
- Current
- Operating hours
- Start counter
● Inspection of the system:
- Supply and return coolant temperature
- Exhaust gas backpressure
- Air filter underpressure
● Check the whole engine for leaks
● Check lube oil circuit
- Lube oil level and lube oil pressure
- External lube oil tightness
● Check coolant circuits:
- Tightness of hose clips, pipe unions, flanges and compensators
- Marks on plug shafts
- Coolant pressure
- Tighten flange connections and hose clips is necessary
● Check gas pressure of the gas control line
see Job Card B 7-20-1, Checking the gas pressure in the gas regulator
line
● Check the temperatures
- Coolant inlet in engine
- Coolant outlet from engine
- Suction intake air temperature
- Lube oil temperature
- Exhaust temperature after every cylinder

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● Check the maintenance instrument and pressure gauge

● Check the lambda valve position of the throttle valve setting
● Check load and cos phi
● Check the signal lamps
● Check noise and smooth running
● Check and log operating values and liquid levels (with TEM)

Once a week addi- ● Check the battery (if available),

tionally see Job Card B 13-4-1, Maintaining the battery
● Check water drain for leaks.
● Check regulating linkage of the throttle valve for easy action and auto-
matic return.
● Check exhaust gas system for leaks, by:

Danger of burst!

- Checking exhaust manifold, turbocharger, silencer and adapters for

tight fit and leaks.
- Tightening clamps.
- In systems with exhaust heat exchangers, check these for water-tight-
ness.
- Check the turbocharger, see manufacturer’s operating manual.

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 TCG 2015 B 0-3-6

B 0-3-6
Cleaning the engine

Auxiliary equipment
- Cleaning agents
- Compressed air
- Stoppers
- Covers

Cross references
- Chapter 4, Auxiliary materials

Carry out this work only when the engine has been shut down.

Wear protective goggles and gloves.

Care for sufficient ventilation!
Exhaust vapours,do not inhale!

● Switch off the engine and wait for it to cool down. See Chapter 4, Auxiliary Preparation
materials for selection of cleaning agents.
● Disconnect the battery.
● Remove protective covers.
● Remove heat shields from the exhaust pipes.
● Cover the air filter water-tight. If the air filters are removed, seal the inlets
water-tight.
● Cover electric components such as three-phase current generators and
starter.

If the engine is partly disassembled, seal open channels and lines.

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Cleaning

When working with high-pressure cleaning systems, sensitive parts such as

filters, rubber bushes, sealing rings and cables could be damaged. These
should therefore never be cleaned with high-pressure cleaning systems.
Joints and bearings which are coated with a lubricant or filled with grease
should not be cleaned with high-pressure cleaning systems.

● Blow out all places which are difficult to access with compressed air.

Cleaning with cold ● Spray engine with cold cleaner. Exposure time according to manufacturer
cleaner instructions.
● Clean protective covers and heat shields separately.
● Spray or wash down engine with a powerful water jet.
● Repeat procedure if necessary.

Dry the exhaust pipe heat shields before replacing. Otherwise there is a
danger of fires being causes by gas build-up and deflagration inside the
housing.

Finishing work ● Blow out spaces where water has accumulated with compressed air.
● Remove the covers from the sensitive batteries.
● Dry the exhaust pipe heat shields and remove.
● Fit protective covers after cleaning separately.
● Install filters if they were removed.
● Connect the battery.

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 TCG 2015 B 1-1-1

B 1-1-1
Checking and adjusting inlet and outlet valve clearance

Tools
- Standard tools
- Feeler gauges
- Engine turning gear

Spares
- gaskets if required

Inlet and outlet valves will only form a seal when closed if a specific clearance
is set in the valve drive between the camshaft and the valve shaft. Valves
which do not form a seal when closed can cause the valve seat and the valve
head to burn. On the other hand too much clearance causes considerable
wear. Exact setting and observation of the valve clearance therefore prolongs
the life and increases the operational reliability of the engine.

Checking valve
clearance

Only check and set the valve clearance when the engine is cold.
Follow the correct test and setting sequence.

● Unplug spark plug connector 1.

● Remove cylinder head cover 2.

Figure 1 Cylinder head cover

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B 1-1-1 TCG 2015

Example: TCG 2015 V8

● Turn the engine in the direction of rotation until the valves overlap on the
cylinder B3. Cylinder A 1 is in the upper dead point (ignition UDP).

EX IN
2 2

1 1

3 3

Figure 2 Components in the valve drive

● Check the valve clearance of cylinder A1 with a feeler gauge. The feeler
gauge must slip between valve 3 and rocker arm 2 with minimal resist-
ance.

V6 V8
Valve clearance ”1” when engine is
cold
Inlet valve mm 0.3 +0,1 0.3 +0,1
Outlet valve mm 0.6 +0,1 0.6 +0,1

The valve clearance must be reset if deviations occur.

A large valve clearance is due to wear in the valve drive. Depending on the
difference between the actual value and the reference value, the valve clear-
ance curve of the respective cylinder must be monitored and the cause inves-
tigated immediately.
The actual values must be noted in the ”Table of actual valve clearance val-
ues” table. A copy of the table is enclosed.

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 TCG 2015 B 1-1-1

Set valve clearance

IN 6
IN
7
EX
EX

4 5

Figure 3 Set valve clearance

● Loosen locknut 4 with ring spanner.

● Set the setting screw 5 with a screwdriver 6 until correct valve clearance is
reached, it should be possible to manipulate the feeler gauge 7 while
detecting resistance.
● Tighten lock nut 4, tightening torque 20 Nm.
● Check the valve clearance again.
● Check the gasket of the cylinder head cover and renew if necessary.
● Fit the cylinder head cover and tighten the screws, tightening torque
22 Nm. Make sure the gasket fits properly.
● Plug in spark plug connector.

Overlap valves in turn according to the ignition sequence. Test and setting se-
TCG 2015 V6 quence

Start with cylinder B2.

Ignition dead point A1 B3 A3 B2 A2 B1

Overlap B2 A2 B1 A1 B3 A3

TCG 2015 V8
Start with cylinder B3.

Ignition dead point A1 B4 A4 B1 B3 A3 B2 A2

Overlap B3 A3 B2 A2 A1 B4 A4 B1

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Table of actual valve clearance values

Cylinder A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
Valve
I C I C I C I C I C I C I C I C I C I C
OH Date

Tab. 1 Table of actual valve clearance values for series A cylinders

Cylinder B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
Valve
I C I C I C I C I C I C I C I C I C I C
OH Date

Tab. 2 Table of actual valve clearance values for series B cylinders

The total adjustment time can be determined by the actual value data. This can enable predictions to be
made about the previous wear in the valve drive.

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B 6-3-6
Replacing airfilter cartridge

Tools
- Standard tools

Auxiliary material
- Cleaning cloth
- Cleaning agent
- Compressed air

Spares
- Air filter cartridge

Carry out this work only when the engine has been shut down.

● Empty dust discharge valve 1 by pressing apart lips of discharge slot as Cleaning dust dis-
indicated by arrows. charge valve
● Clean discharge slot from time to time.
● Remove any caked dirt by pressing together the upper section of the
valve.

Figure 1

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Replacement of air
filter cartridge

Figure 2 Air filter housing

● Loosen wing nut 2 and remove the cover 3 from the air filter housing.

Figure 3 Air filter cartridge

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 TCG 2015 B 6-3-6

● Unscrew fastening nut 4 and remove air filter cartridge 5.

The air filter cartridge may be cleaned only in exceptional circumstances:

- blow dry compressed air (max. 5 bar) along the folded length and then
blow out from the inside (wear safety glasses) or
- tap it (only in emergency - take care not to damage the air filter in the
process) or
- wash out as directed by manufacturer.

Never clean filter cartridge with gasoline or hot fluids.

● Clean dust and dirt from the air filter housing with clean cloths.
● Insert a new air filter cartridge 5 and tighten the fastening nut 4.
● Place the cover 3 on the air filter housing and tighten the wing nuts 2.

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 TCG 2015 B 7-20-1

B 7-20-1
Checking the gas pressure in the gas regulator line

References
- B 7-21-1, Renewing the gas filter cartridge

The gas pressure in the gas regulator line can be read from the pressure
gauge. This is supplied by the pre-pressure regulator line and depends on the
gas type and quality.

● Press button 1 and read the gas pressure. Checking the gas
● If the gas pressure is not within the permissible values, the gas filter must pressure in the gas
be cleaned or the filter cartridge renewed. regulator line
See job card B 7-21-1, Renewing the gas filter cartridge.

Figure 1 Pressure gauge (gas regulator line)

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 TCG 2015 B 7-21-1

B 7-21-1 Renewin

Tools
- Standard tools

Spares
- Gasket
- Filter cartridge

References
- B 7-20-1, Checking the gas pressure in the gas regulator line

The ventilation system should be switched on before carrying out any

work on the gas line.
Smoking and the use of naked flames is prohibited.
Caution, explosion hazard!

The gas filter must be cleaned or the filter cartridge renewed when the gas
pressure in the gas regulator line has dropped below the required level.
This gas pressure can be read off a pressure gauge, see job card B 7-20-1,
Checking the gas pressure in the gas regulator line.

● Close the ballcock (arrow) to shut off the gas intake. Remove filter car-
● Loosen nuts 1 and remove the cover 2 from the air filter housing. tridge

Figure 1 Gas regulator line

● Remove filter cartridge 3 from cover 4.

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Clean or renew filter ● Clean cover and gas filter housing.

cartridge. ● Renew filter cartridge.
● Fit new filter cartridge to cover.

Note the position of the filter cartridge on the cover (arrows).

Figure 2 Filter cartridge and cover of the gas filter housing

Fit filter cartridge ● Renew seal 5.

● Place cover with filter cartridge 6 into gas filter housing

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 TCG 2015 B 7-21-1

● Screw on nuts and tighten crosswise, torque 8 Nm.

Figure 3 Cover with filter cartridge

Note the position of the filter cartridge on the gas filter housing (arrows).

● Open ballcock to restore gas supply.

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 TCG 2015 B 8-1-1

B 8-1-1
Taking lube oil samples

Tools
- Container for waste oil

Auxiliary material
- Lube oil according to operating media specifications, Chapter 4, Expen-
dables

When draining off hot lube oil:

Risk of scalding!

Trouble-free operation and resistance to undue wear depend to a great

extent on the lube oil condition. Checking the lube oil is therefore one of the
most important maintenance jobs.
An analysis should be carried out by the lube oil manufacturer because a
detailed examination is only possible in the laboratory. If no other possibilities
are available, DEUTZ will carry out the analysis at reimbursement of
expenses.

The lube oil sample must be taken with the engine running. Taking the lube oil
● Incorporate the coupling union into the oil circulation system at the appro- sample
priate point 1.

Figure 1 Lube oil sampling point

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● Start engine.
● Push in coupling union 2 with hose 3 until it engages in coupling union 4 .

Lube oil will start to flow out as soon as the coupling union has engaged.

Figure 2 Lube oil tapping valve

● Remove volume of lube oil required for analysis.

● Release and pull out coupling union 2 to stop the lube oil flow.
● Necessary details:
1. Lube oil brand and type
2. Operating hours counter reading,
3. Lube oil consumption since last sample.
The lube oil must be renewed if the result of the analysis is negative.

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 TCG 2015 B 8-1-2

B 8-1-2
Changing lube oil

Auxiliary material
- Lube oil according to operating material specification

References
- B 8-10-4, Renewing lube oil filter cartridge
- Chapter 4, Expendables
- Chapter 8, Technical particulars
- Technical memo TR0199-99-2105

Carry out this work only when the engine has been shut down.

When draining off hot lube oil:

Risk of scalding!

Collect the used oil,do not allow it to seep into the soil.
Dispose of in accordance with the relevant regulations.

Change the lube oil when the engine is hot.

(Lube oil temperature approx. 80°C).

● Place an oil tray below. Drain lube oil

● Unscrew drain screw 1 and drain lube oil.

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Figure 1 Lube oil drain screw

Pour in lube oil ● Replace gasket.

● Screw in drain screw 1 and tighten, torque 120 Nm.

Figure 2 Oil filler cap

● Unscrew oil filler cap.

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 TCG 2015 B 8-1-2

● Pour in lube oil

- Quality and viscosity data, see TR 0199-99-2105
- For capacities, see Chapter 8, Technical particulars.
● Tighten oil filler cap.

● Pull out the dipstick 3 and wipe with a clean, lint-free cloth. Check the lube oil
level
● Insert dipstick as far as the stop.
● Pull out dipstick and check the lube oil level,
refill to “MAX“ where necessary.

The level must not fall below the "MIN" mark.

Figure 3 Oil dipstick

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 TCG 2015 B 8-10-4

B 8-10-4
Renewing lube oil filter cartridge

Tools
- Strip key

Auxiliary material
- Container for spent oil
- Lube oil according to operating media specifications, Chapter 4, Expen-
dables

Spares
- Lube oil filter cartridge

Carry out this work only when the engine has been shut down.

When draining off hot lube oil:

Risk of scalding!

Collect the used oil,do not allow it to seep into the soil.
Dispose of in accordance with the relevant regulations.

● Loosen the lube oil filter cartridge 2 with standard commercial strip key Renew lube oil filter
and unscrew from filter block 1. cartridge

Figure 1 Lube oil filter cartridge

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B 8-10-4 TCG 2015

● Collect drained lube oil.

● Clean the seal surface of the filter block.
● Wet the gasket of the new filter cartridge slightly with lube oil.
● Fit filter cartridge to filter block and tighten, torque 27 Nm.

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 TCG 2015 B 9-1-1

B 9-1-1
Checking corrosion protection agent or antifreeze in coolant

Tools
- Test case order no. 12158292

Cross references
- Chapter 4, Expendables

Corrosion protection agent is added to the coolant to protect the coolant

areas from corrosion. However, this protection is only given when a certain
minimum content of corrosion protection agent is not exceeded. If there is
more corrosion protection agent than necessary in the coolant, the cooling
effect is reduced.
If an antifreeze is added to the coolant, this should also have corrosion pro-
tection properties. A corrosion protection agent does not need to be added in
this case. The antifreeze percentage must be dosed accordingly for the
above mentioned reasons.
If the cooling system needs refilling, the percentage of antifreeze or corrosion
protection agent in the coolant must be measured. Then the coolant should
be corrected according to the following description.

● Remove the coolant sample from the cooler, compensation tank or drain- Check the corrosion
ing tap. protection agent and
● Check the percentage additive with the measuring instrument. antifreeze percent-
● Setpoint according to Chapter 4, Expendables. age

Percentage additive too low: Correct the corro-

sion protection
total filling quantity × ( nominal value - measured value )
quantity of additiv required additionally = ------------------------------------------------------------------------------------------------------------------------------------------------- agent and antifreeze
100
percentage

To refill, drain coolant, mix well with the amount of additive to be refilled and
then pour in the mixture again.

Percentage additive too high:

Drain the amount of coolant and fill up with pure water (quality according to
Chapter 4, Expendables).

nominal value
coolant to be drained = ⎛ 1 – --------------------------------------------⎞ × total filling quantity
⎝ measured value ⎠

● Bleed the cooling system.

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 TCG 2015 B 13-4-1

B 13-4-1
Maintaining the battery

Tools
- Standard tools
- Acid tester order no. 12157944

Equipment
- Distilled water
- Acid protection grease
- Cloths

Carry out this work only when the engine has been shut down.

The gases emitted by the battery are explosive.

● Avoid sparks and open flames in the vicinity of the battery.
● Do not allow any acid to get on your skin or clothing.
● Wear protective goggles.
● Do not place any tools on the battery.

● Keep battery clean and dry. Check battery and

● Undo dirty clamps. cable connectors
● Clean terminal posts (+ and -) and clamps of battery, and grease with
acid-free and acid-resistant grease.
● When reassembling, ensure that clamps make good contact. Tighten
clamp bolts hand-tight.

Figure 1 Battery poles

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B 13-4-1 TCG 2015

Check acid level ● Remove sealing caps 1.

● If testers 2 are present:
Electrolyte level should reach the base of these.
● Without testers:
Electrolyte level should reach 10 - 15 mm above top edge of plate.
● If necessary, top up with distilled water.
● Screw sealing caps back in.

© 24232-5

Figure 2 Battery sealing caps

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 TCG 2015 B 13-4-1

● Measure the electrolyte density of individual cells with a commercial Check acid density
hydrometer.

Figure 3 Check acid density

Hydrometer reading (see table below) indicates battery's state of charge.

During measurement, temperature of electrolyte should preferably be 20 °C.

.
Acid density
in [kg/l] Charge status
Normal Tropical
1.28 1.23 well charged
1.20 1.12 semi-charged, re-charge
1.12 1.08 discharged, charge immediately

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 TCG 2015 B 13-5-4

B 13-5-4
Spark plugs, spark plug cables, checking, cleaning the spark plug shaft

Tools
- Standard tools
- Spark plug wrench
- Cleaning brush
- Multimeter
- Feeler gauge 0.35 mm

Auxiliary material
- Compressed air
- Protective glasses

Spares
- Spark plugs

Carry out this work only when the engine has been shut down.

When working on the high-voltage ignition system:

life-threatening risk!

Spark plug connector 1 and ignition cable 2 are a single unit and cannot be
separated.

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B 13-5-4 TCG 2015

Figure 1 Spark plug cable, dismantled.

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 TCG 2015 B 13-5-4

● Pull off spark plug connector 1 from the spark plug. Removing and in-
stalling spark plugs

Figure 2 Spark plug cable, installed

● Unscrew spark plug with spark plug wrench and remove.

● Clean spark plug with cleaning brush.
● Check spark plug.
Check electrode gap with feeler gauge, reference value: 0.35 mm.

Replace the spark plug if the reference value is exceeded.

If replacing spark plug, check the new spark plug for condition and damage.

● Insert spark plug and tighten, torque 35 Nm.

● Attach spark plug connector 1.

● Pull spark plug connector 1 off the spark plug and the ignition coil. Check spark plug ca-
● Measure the spec. resistance using a multimeter, reference value ble
max. 7 kΩ.

Replace the ignition cable if the reference value is exceeded.

● Attach spark plug connector 1 to the spark plug and the ignition coil.

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Clean the spark plug ● Pull spark plug connector 1 off the spark plug.
shaft. ● Check the spark plug shaft for dirt.
- If oil has penetrated: reseal cylinder head hood.
● Blow out spark plug shaft with compressed air.

Particles of dirt can cause injury when cleaning with compressed air.
Wear safety glasses and tight fitting clothing.

● Plug in spark plug connector 1.

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 Sundry other instructions
TCG 2015 10

10 Sundry other instructions

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TCG 2015

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 Index
TCG 2015

Index

A
Antifreeze percentage B 9-1-1
Auxiliary materials 4-3

B
Basic data 8-1

C
Changing lube oil B 8-1-2
Lube oil system B 8-1-2
Charging
Schematic 2-16
Check and clean spark plug shaft B 13-5-4
Check spark plug cable B 13-5-4
Checking and setting valve clearance B 1-1-1
Checking the gas pressure of the gas regulator line B 7-20-1
Combustion gas silicon content 5-3
Combustion gases 4-1
Commissioning / Starting
Filling up coolant 3-1
Filling up lube oil 3-1
Lube oil system 3-3
Pre-lubrication 3-1
Preparation work 3-1
Room ventilation 3-3
Starting 3-3
Warming up 3-3
Conservation 7-1
Control data 8-1
Cooling system 2-28
Antifreeze percentage B 9-1-1
Corrosion protection agent percentage B 9-1-1
Filling up coolant 3-1
Corrosion protection agent percentage B 9-1-1
Crankcase 2-11
Cylinder head 2-10

D
Description of the engine 2-1
DEUTZ maintenance and service schedules 5-2
Dimensions of the unit 8-2
Driving gear 2-11

E
Electrical system 2-29

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Index
TCG 2015

Starter 2-31
Emission data 8-3
Engine 2-29, 2-31
Charging
Schematic 2-16
Checking and setting valve clearance B 1-1-1
Cleaning B 0-3-6
Crankcase 2-11
Cylinder head 2-10
Daily inspections B 0-1-5
Driving gear 2-11
Electrical system
Ignition system 2-29
Engine control 2-12
Figures 2-5
Rating plate 2-1
Speed control 2-13
Starting 3-3
Type and designations 2-1
Type designation 2-1
Engine control 2-12
Engine coolant 4-1
Engine, peripheral data 8-4
Expendables 4-1
Auxiliary materials 4-3
Combustion gases 4-1
Engine coolant 4-1
Gluing agents 4-5
Guarantee 4-1
Lube oil 4-1
Lubricants 4-5
Mixability 4-1
Other auxiliary materials 4-6
Product selection 4-1
Sealants and securing agents 4-3

F
Filling volumes 8-3
Forword 0-7

G
Gas / air carburettor 2-23
Gas controlled system
Checking the gas pressure B 7-20-1
Gas groups 5-3
Gas regulator line 2-17
Gas regulator line components 2-19
Gas system 2-17
Gluing agents 4-5

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 Index
TCG 2015

I
Ignition system
Electrical system
Ignition system 2-29

J
Job cards
Structure 1-4

L
Lube oil 4-1
Filling up 3-1
Lube oil cooler 2-26
Lube oil filter 2-26
Lube oil level switch 2-27
Lube oil system 2-24
Lube oil cooler 2-26
Lube oil filter 2-26
Lube oil level switch 2-27
Renew lube oil filter cartridge B 8-10-4
Taking samples
Taking lube oil samples B 8-1-1
Lubricants 4-5

M
Maintaining the battery B 13-4-1
Maintenance 5-3, 5-4
Definition of activities 5-8, 5-16, 5-24, 5-32
DEUTZ maintenance and service schedules 5-2
Silicon content in the combustion gas 5-3
Mixture formation 2-23
Monitoring operation 3-4

O
Operating check log 5-39
Operating data 8-3
Operating Instructions 1-2
Overview 5-4

P
Pre-lubrication 3-1
Pressures 8-3

R
Renew lube oil filter cartridge B 8-10-4
RI flow diagrams 8-5

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TCG 2015

Routine Maintenance 5-1

Rules for disposal 1-2

S
Safety regulations
Careful when the engine is running! 0-6
Cutting, grinding, soldering and welding work B 0-0-4
Handling components made of elastomers containing fluoride (e.g. Viton) B 0-0-3
Rules for accident prevention 1-1
Scheduled maintenance plans 5-4
Sealants and securing agents 4-3
Silicon content in combustion gas 5-3
Spares 1-6
Spark plugs
Removing and installing B 13-5-4
Speed control 2-13
Speed controller 8-4
Starter
Electric starter 2-31
Starting 3-3
Sundry other instructions 10-1

T
Technical data
Basic data 8-1
Control data 8-1
Dimensions 8-2
Emission data 8-3
Filling volumes 8-3
Pressures 8-3
RI flow diagrams 8-5
Speed controller 8-4
Temperatures 8-3
Tightening specifications 8-9
Weights 8-2
Temperatures 8-3
Tightening specification 8-9
Troubleshooting 6-1

U
User Guide 1-1

V
Visual inspection of the system B 0-1-5
Viton, safety regulations B 0-0-3

W
Weights of components 8-2
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TCG 2015

Workshop Manual 1-2

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Index
TCG 2015

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 Service
TCG 2015

Service

We move your world

DEUTZ has always stood for excellence in engine construction, pioneering many developments in the indus-
try. As an independent engine manufacturer we offer a full range of diesel and gas engines in the perform-
ance range from 4 to 7,400 kW. Our products are tailor-made to meet our customers’ requirements.
More than 1.4 million DEUTZ engines are in service worldwide. We are determined to preserve the high
standard of performance and dependability of our engines, thus keeping our customers satisfied at all times.
For this reason we are represented worldwide through a network of highly competent service partners who
will meet the needs of our customers, wherever they are.
This is why DEUTZ is not only the name for engines which pack a lot of inventiveness. DEUTZ also means
reliable service and comprehensive support to enhance your engine’s performance.

DEUTZ AG - at your service.

Sales & Service Index

This Sales & Service Index offers you an overview of the DEUTZ
partners in your vicinity, including the products for which they are
responsible and the range of services provided. But even when
no direct product responsibility is mentioned, your DEUTZ part-
ner will be happy to help you with expert advice. The Index is
constantly updated. Please ask your DEUTZ service partner for
the latest edition.
Order no.: 0312 0806 (Printed version)
Order no.: 0312 0807 (CD-ROM)

DEPIC
The DEutz Parts Identification for Customers (DEPIC) offers you
spare parts identification individually adapted to your systems.
DEPIC enables you to generate an order list almost automati-
cally and to make your spare parts procurement more efficient.
Order no.: on request (CD-ROM)

Seminar program
Degree of availability, reliability and service life of equipment and
drive assemblies are determined to a great extent by profes-
sional operation and service by qualified and experienced opera-
tors and service technicians.
The DEUTZ AG offers service-related seminars for DEUTZ prod-
ucts to customers and operators staff for this.
Apart from the seminars which are held in our Training Centers in
Cologne and Mannheim it is also possible to hold special semi-
nars in the Training Centers or at another location requested by
the customer by agreement.
Information about the seminar program will be distributed in a
mailing.
Please ask your DEUTZ Service representative.

© 0103 300201283-en-00.fm Chapter Service - Page 1