2015.book (EN)

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z This engine is built exclusively for purpose according to the scope of delivery - defined by the equip- ment manufacturer (use for the intended purpose). Any use abo- ve and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk. z Use for the intended purpose also includes ob- servance of the operating, maintenance and re- pair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with it and instructed in the dangers.

The pertinent rules for the prevention of acci- dents and other generally recognised safety and industrial medicine rules must be observed. z When the engine is running there is a danger of injury caused by: rotating / hot parts in engines with external ignition (high electri- cal voltage), avoid touching at all costs! z Unauthorised modifications to the engine exclu- de manufacturer liability for resulting damages. z Equally, manipulations to the injection and cont- rol system can affect the engine's performance and the exhaust characteristics. Compliance with legal environmental regulations will no lon- ger be guaranteed in this case.

z Do not modify, obstruct the cooling air flow area to the fan, unhindered cooling air supply must be guaranteed. The manufacturer will accept no liability for da- mages resulting from this. z Only DEUTZ original parts may be used when carrying out maintenance/repair work on the en- gine. These have been designed especially for your engine and ensure a trouble-free operation. Failure to observe this will void the warranty ! Maintenance/cleaning work on the engine may only be carried out when the engine is not run- ning and has cooled down. When doing this, make sure that the electrical systems are switched off (remove ilgnition key).

The specifications for accident prevention with electrical systems (e.g. -VDE-0100/-0101/-0104/ -0105 Electrical measures against dangerous touch voltages) must be observed. Cover all electrical components tightly when cleaning with liquids. z Do not work on the fuel system when the engine is running - Danger to life . Wait for the pressure to drop after the engine co- mes to a standstill (in engines with DEUTZ Com- mon Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure Dan- ger to life . During the first trial run do not stand in the dan- ger area of the engine. In case of leaks danger due to high pressure - Danger to life .

Go to the workshop ilmmediately in case of leaks. Make sure the engine is not started acciden- tally during repairs when working on the fuel system - Danger to life . Caution This symbol indicates a danger to the component / engine. The appropriate instructions must be followed otherwi- se the component / engine may be de- stroyed. Danger This symbol is used for all safety in- structions which, if not observed, pre- sent a direct danger to life and limb for the person involved. Observe these carefully. Also pass on the safety in- structions to your operating personnel. Furthermore, the legislation for "gene- ral regulations for safety and the pre- vention of accidents" must be observed.

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0312 3412 en

Operation Manual TCD 2015 Foreword Dear customer, Engine number Please enter the engine number here. ( 6 ) This will simplify the handling of customer ser- vice, repair and spare parts queries. Order number 0312 3412 en Congratulations on your purchase of this DEUTZ engine. The DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. A wide range of variants ensures that the respective requirements are met. Note The engine is equipped according to the instal- lation case you have specified, i.e. not all the parts described in this instruction manual are installed in your engine.

Illustrations and data in this instruction manual are subject to technical changes in the course of further development of the engine. Reprinting and reproduction of any kind, even in part, require our express permission. We have done our best to highlight the diffe- rences so that you can easily find the operating and maintenance instructions relevant to your engine. Please make sure that this instruction manual is available to everyone involved in the opera- tion, maintenance and repair of the engine and that they have understood the contents. We will be glad to answer any inquiries you may have. Your DEUTZ AG . 3

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<TABELLE>

Contents 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6.7 Adjustments. . . . . . . . . . . . . . . . . . . . 40 6.8 Electrical system . . . . . . . . . . . . . . . . 42 2 Engine description . . . . . . . . . . . . . . . . 6 2.1 Engine type. . . . . . . . . . . . . . . . . . . . . . 6 2.2 Engine diagram . . . . . . . . . . . . . . . . . . 7 2.3 Lubricating oil circuit. . . . . . . . . . . . . . 11 2.4 Fuel circuit . . . . . . . . . . . . . . . . . . . . . 12 2.5 Coolant circuit. . . . . . . . . . . . . . . . . . . 13 2.6 Electrics . . . . . . . . . . . . . . . . . . . . . . . 14 7 Faults . . . . . . . . . . . . .

. . . . . . . . . . . . . 44 7.1 Fault table . . . . . . . . . . . . . . . . . . . . . 44 7.2 Engine management . . . . . . . . . . . . . 46 8 Transport and storing . . . . . . . . . . . . 48 8.1 Engine transport . . . . . . . . . . . . . . . . 48 8.2 Preservation. . . . . . . . . . . . . . . . . . . . 49 3 Operation . . . . . . . . . . . . . . . . . . . . . . . 15 3.1 Ambient conditions . . . . . . . . . . . . . . . 15 3.2 Initial commissioning . . . . . . . . . . . . . 16 3.3 Start process . . . . . . . . . . . . . . . . . . . 18 3.4 Operation monitoring . . . . . . . . . . . . . 19 3.5 Stop process. . . . . . . . . . . . . . . . . . . . 21 9 Technical data. . . . . . . . . . . . . . . . .

. . 51 9.1 Technical data . . . . . . . . . . . . . . . . . . 51 4 Consumables. . . . . . . . . . . . . . . . . . . . 22 4.1 Lubricating oil . . . . . . . . . . . . . . . . . . . 22 4.2 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . 25 5 Maintenance. . . . . . . . . . . . . . . . . . . . . 27 5.1 Maintenance schedule . . . . . . . . . . . . 27 6 Care and maintenance work. . . . . . . . 29 6.1 Lubricating oil system . . . . . . . . . . . . 29 6.2 Fuel system . . . . . . . . . . . . . . . . . . . . 31 6.3 Cooling system. . . . . . . . . . . . . . . . . . 34 6.4 Engine cleaning . . . . . . . . . . . . . . . . .

36 6.5 Intake system . . . . . . . . . . . . . . . . . . . 37 6.6 Belt drives. . . . . . . . . . . . . . . . . . . . . . 39 4

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http://www.deutz.com

General DEUTZ diesel engines are the product of years of research and deve- lopment. The profound expertise gained th- rough this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high relia- bility and low fuel consumption. Naturally the high requirements for protection of the environ- ment are also met. are also introduced for the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured according to the latest state of knowledge will guarantee perfect functioning and high reliability.

The DEUTZ homepage with references to pro- duct responsibilities and services always gives you an up-to-date overview of the DEUTZ part- ners in your area. Or use the fast, comfortable route via the Internet under www.deutz- shop.de. With the DEUTZ P@rts OnlineParts- Catalogue you have direct contact to the nearest local DEUTZ Service Station. 1 DEUTZ Xchange components DEUTZ Xchange components are a low-cost alternative. The same high quality standards as for new parts apply here of course. DEUTZ Xchange components are equivalent to the ori- ginal DEUTZ parts in function and reliability.

Safety precautions when the engine is running Only carry out maintenance work or repairs with the engine switched off. Ensure that the engine cannot be started unintentionally - dan- ger of accidents! Re-install any removed protective equipment upon completion of the work. Observe industrial safety regulations when operating the engine in enclosed spaces or un- derground. When working on the running engine, work clo- thing must be close fitting. Only re-fuel with the engine switched off. DEUTZ AG Deutz-Mьlheimer Str. 147-149 D-51057 Kцln Asbestos Gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair work. Phone: 0049-221-822-0 Fax:

0049-221-822-5304 Telex:8812-0 khd d http://www.deutz.com Service We want to preserve the high performance of our engines and with it the confidence and sa- tisfaction of our customers. Therefore we are represented by a network of service branches world-wide. The name DEUTZ stands not only for an engi- ne which is the result of sophisticated develop- ment work, DEUTZ Parts catalogue also stands for a complete service package which guarantees the optimum operation of our engi- nes and for a customer service on which you can rely. Contact one of our responsible service repre- sentatives in case of operation malfunctions and spare parts inquiries.

Our trained specia- list personnel ensures fast, professional re- pairs using original parts in the event of damage. Maintenance and care are decisive for whether the engine satisfacto- rily meets the set demands. Compliance with the prescribed maintenance times and the ca- reful execution of maintenance and care work are therefore essential. Difficult operating conditions deviating from normal operation must be observed especially. Original DEUTZ parts are subject to the same strict quality require- ments as the DEUTZ engines. Further deve- lopments for the improvement of the engines 5

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