Deutz TCD 2013 L04 4V Operation Manual Download Page 23 | Manualshive

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Exhaust gas recirculation

Engine description

© 2007

23

2

Exhaust gas recirculation (example)

1

EGR actuator plug

2

EGR actuator

3

Throttle valve (check valve)

4

Coolant line to the EGR cooler

5

EGR cooler

6

Flapper valve

7

Exhaust gas outlet from the cooler

8

Fresh air intake elbow

9

Coolant return line of the cooler

OBJ_DOKU-12638-001.fm Seite 23 Mittwoch, 22. August 2007 9:25 09

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Summary of Contents for TCD 2013 L04 4V

Page 1: ...Operation Manual TCD 2012 L04 06 4V TCD 2013 L04 06 4V OBJ_DOKU 12638 001 fm Seite 1 Mittwoch 22 August 2007 9 25 09...

Page 2: ...air feed area to the blower of fan An unobstructed cooling air supply must be guaranteed The manufacturer will accept no liability for dam age resulting from this z When carrying out maintenance work...

Page 3: ...more quickly and easily Please make sure that this operating manual is avail able to everyone involved in the operation mainte nance and repair of the engine and that they have understood the contents...

Page 4: ...edure 33 4 Operating media 34 Lubricating oil 34 Fuels 36 Coolant 37 5 Maintenance 38 Maintenance schedule 38 6 Service and maintenance 41 Lubricating oil system 41 Fuel system 43 Cooling system 47 En...

Page 5: ...high reliability DEUTZ Xchange components DEUTZ replacement parts area low cost alternative Of course the quality standards here are just as high as for new parts DEUTZ replacement parts are equal to...

Page 6: ...should be drawn to these safety instructions Further more the legislation for general regula tions for safety and the prevention of accidents must be observed This symbol indicates a danger to the pa...

Page 7: ...e rating plate The engine type and number must be stated when purchasing spare parts DEUTZ AG DEUTZ AG MADE IN GERMANY MADE IN GERMANY Mot Typ Mot Nr R B A Location of the rating plate The rating plat...

Page 8: ...nkcase arrow and onto the rating plate Cylinder numbering Cylinder arrangement The cylinders are counted consecutively starting from flywheel 1 Direction of rotation Looking at the power transmission...

Page 9: ...er 7 Cumbustion air outlet to the charge air cooler 8 Coolant outlet 9 Deflection pulley 10 Belt pulley on crankshaft 11 Tension pulley 12 Lubricating oil sump 13 Lubricating oil drain plug 14 Coolant...

Page 10: ...itter 2 Exhaust manifold line 3 Fuel supply pump 4 Transport device 5 Gear connection SAE housing 6 Starter cover 7 Lubricating oil return line from the exhaust turbo charger 8 Cumbustion air outlet t...

Page 11: ...pulley for fan attachment 10 Tensioning pulley s 11 Deflection pulley 12 Lubricating oil sump 13 Belt pulley for coolant pump 14 Lubricating oil drain plug 15 Coolant inlet 16 Generator 17 Lube oil co...

Page 12: ...temperature pressure transmitter 2 Lubricating oil filling optional 3 Exhaust manifold line 4 Fuel supply pump 5 Gear connection SAE housing 6 Starter cover 7 Lubricating oil return line from the exh...

Page 13: ...10 Coolant inlet 11 Engine mounting 12 Lubricating oil sump 13 Lubricating oil drain plug 14 Exchangeable fuel filter 15 Lube oil replacement filter 16 Fuel connection from tank 17 Lube oil cooler 18...

Page 14: ...t device 3 Gear connection SAE housing 4 Starter cover 5 Lubricating oil filling optional 6 Lubricating oil return line from the exhaust turbo charger 7 Exhaust manifold line 8 EGR line to the cooler...

Page 15: ...pump 7 Tension pulley 8 Deflection pulley 9 Front power take off 10 Lubricating oil sump 11 Coolant inlet 12 Lube oil replacement filter 13 Exchangeable fuel filter 14 Compressor optional 15 Gear conn...

Page 16: ...for the exhaust gas recirculation system 4 Fuel connection from tank 5 Fuel connection to the tank 6 Starter 7 Lubricating oil filling optional 8 Air conditioning compressor 9 V rib belt 10 Coolant p...

Page 17: ...tion tank 2 Coolant supply from the thermostat to the heat exchanger 3 Heat exchanger 4 Charge air cooler 5 Fan cover 6 Line from the heat exchanger to the coolant pump 7 Ventilation line from the the...

Page 18: ...e view from left example 1 Line between the compensation tank and the coolant pump 2 Charge air line from charge air cooler 3 Charge air line from the turbocharger to the charge air cooler 4 Coolant d...

Page 19: ...Crankshaft bearing 8 Big end bearing 9 Camshaft bearing 10 Line to injector nozzle 11 Piston cooling nozzle with pressure holding valve 12 Tappet with impulse lubrication of the rocker arm 13 Tappet r...

Page 20: ...ump 3 Fuel supply pump 4 Line to the fuel filter 5 Fuel cooling for the Engine Control Unit ECU without cooler top right in the image 6 Fuel filter 7 Return line 8 FCU Control Unit 9 Tappet rollers on...

Page 21: ...Coolant schematic Engine description 2007 21 2 OBJ_DOKU 12638 001 fm Seite 21 Mittwoch 22 August 2007 9 25 09...

Page 22: ...ing optional 8 Return line to the thermostat optional 9 Heat exchanger by customer 10 Fan by customer 11 Compensation tank 12 Cab heater connection 13 Coolant supply flow to the cab heating 14 Engine...

Page 23: ...1 EGR actuator plug 2 EGR actuator 3 Throttle valve check valve 4 Coolant line to the EGR cooler 5 EGR cooler 6 Flapper valve 7 Exhaust gas outlet from the cooler 8 Fresh air intake elbow 9 Coolant r...

Page 24: ...opriate control unit Setpoint transmitters pedal value transmitters nec essary for vehicle operation must be connected to the vehicle side cable harness and calibrated with the DEUTZ diagnostic progra...

Page 25: ...cating oil pressure transmitter 11 Control unit plug 12 Pick up on SAE housing 13 Speed transmitter via camshaft 14 Power supply battery 15 Multifunction displays 16 Outputs configurable e g for lamps...

Page 26: ...freeze cooling water High ambient temperatures high altitude Under the following application and operating condi tions the amount of fuel must be reduced z above 1000 m altitude z above 30 C ambient...

Page 27: ...in according to maintenance indicator z Fill with engine lube oil Fill with engine lube oil z Fill the engine with lubricating oil via the lubricat ing oil filler neck z Observe the lubricating oil fi...

Page 28: ...thout coolant even for a short time Order coolant corrosion protection agent from your DEUTZ partner z Start the engine and run up until the thermostat opens line 2 heats up z Engine operation with op...

Page 29: ...f the engine does not start properly when theheatingflange isautomatically actuated starter does not receive current as a result of a fault in the equipment customer electri cal control system the sta...

Page 30: ...aid z Insert key Position 0 no operating voltage z Turn key to the right Position 1 operating voltage Pilot lamps 1 2 and 3 light up Preheat until the glow display goes out an error has occurred if t...

Page 31: ...ool down the engine before switching off automatic switch off if necessary There may be a start lock after engine stop The start lock is released by switching off the system with the ignition key for...

Page 32: ...e engine is running the lubricating oil pressure is too low Switch off engine Lube oil level If the pilot lamp lights up after starting the engine or while the engine is running the lubricating oil le...

Page 33: ...longer guaranteed This shortens the life of the turbocharger Run the engine in low idling speed for ap proximately one minute after relieving the load The control unit remains active for about anothe...

Page 34: ...icating oil viscosity has no influence and effect on the lubricating oil quality Synthetic lubricating oils are used increasingly and have advantages These oils have a better tem perature and oxidatio...

Page 35: ...rs the oil change intervals for built in engines apply z If the lubricating oil change intervals are not reached within a year the oil should be changed at least once a year Viscosity The ambient temp...

Page 36: ...sel fuels according to EN 590 and ASTM D 975 described in this operating manual No emission values are guar anteed with the other fuels described in this operat ing manual Winter operation with diesel...

Page 37: ...Z compact engines is performed by mixing an anti freeze with corrosion protection inhibitors based on ethylene glycol into the water This cooling system corrosion protection agent is Health damaging n...

Page 38: ...missioning of new or overhauled engines see 27 E20 Daily inspection Customer 1x daily or every 10 operating hours in continuous operation E30 Maintenance 2 500 oh 3 45 000 km 3 60 000 km 3 80 000 km 3...

Page 39: ...isation change strategy Ask your DEUTZ partner for information 41 Lubricating oil filter insert every time the lubricating oil is changed 42 E40 Check Charge air cooler drain lubricating oil and conde...

Page 40: ...lation system Replace Fuel injector valve only with EPA Flame glow plugs 30 Crankcase breather valve incl Filter only with EPA annually Clean Charge air cooler inlet area lubricating oil drain condens...

Page 41: ...cating oil dipstick and readoff the oil level Low lubricating oil level or overfilling lead to engine damage The lubricating oil level may only be checked with the engine in a horizontal po sition and...

Page 42: ...ean the sealing surface of the filter support with a lint free clean cloth The filter cartridge should never be pre filled There is a danger of dirt contamina tion z Oil the gasket of the new DEUTZ or...

Page 43: ...y with compressed air Observe the safety regulations and nation al specifications for handling fuels Dispose of leaking fuel and filter elements properly Do not allow fuel to seep away into the ground...

Page 44: ...ace of the filter support with a lint free clean cloth z Oil the gasket of the new DEUTZ original filter cartridge lightly z Screw on new filter by hand until the gasket is in place and then tighten w...

Page 45: ...ridge should never be pre filled There is a danger of dirt contamina tion z Collect any fuel oil that escapes z Bendthepaperfilter cartridge 5 inthecollecting vessel slightly sideways until the cartri...

Page 46: ...t number 8192 74 z Drain remaining fuel into the fuel collecting ves sel and clean water collecting vessel 8 z Screw water collecting vessel 8 clockwise onto the new filter cartridge 5 z Clean any dir...

Page 47: ...ion protection agent from your DEUTZ partner Never operate the engine without coolant even for a short time Check coolant additive concentration z Open the cooling system cap 1 carefully z Check the c...

Page 48: ...entilate cooling system Fill and ventilate cooling system z Open cooler locking cap z Loosen the vent screw 2 z Fill with coolant as far as the max marking or fill ing limit heating valve of the syste...

Page 49: ...gine e g control units generator solenoid valves etc Do not aimthewater steamjet directly at them Allow engine to warm up Only carry out cleaning work on the engine when it is not running Remove the e...

Page 50: ...filter z The dry air filter is maintained according to a maintenance switch or maintenance indicator z Maintenance is necessary when the yellow warning light of the maintenance switch lights up when t...

Page 51: ...ged filter elements Clean the dust discharge valve of the dry air filter z Empty the dust discharge valve 1 by pressing together the discharge slit z Removeany cakeddust bypressingtogether the upper s...

Page 52: ...2 and remove the lubricating oil pan 3 with filter insert 4 z Dispose of dirty lubricating oil z Clean lubricating oil pan 3 filter cartridge 4 and filter housing 1 with a brush and clean die sel fue...

Page 53: ...ays replace both belts as a pair The difference in length of the new V belts must not exceed 0 15 one to the other Checking the belt tension z Lower indicator arm 1 into the measuring de vice z Place...

Page 54: ...ount V rib belt 2 z Retain tensioning pulley using the pin wrench and remove the holding pin z Re tension using the tensioning pulley and pin wrench 3 Check whether the V rib belt is cor rectly in its...

Page 55: ...ench insert order no 8193 on the valve clearance setting screw 2 z Loosen locking nut 1 with special tool order no 8199 z Fix magnet of the rotation angle disc z Turn rotation angle disc clockwise to...

Page 56: ...ft until both valves overlap on cylinder 1 outlet valve not yet closed inlet valve starts to open z The rocker arms to be set have clearance in de livered new state z Setting of the valve clearance Lo...

Page 57: ...ance clockwise on the rocker arm to be set This means there must not be any clearance be tween the rocker arm and the valve 2 and no pressure may be applied to the valve z Set pointer 6 on the knurled...

Page 58: ...turning gear z Unscrew threaded stopper 1 from stopper 1 z Turn in M8 screw 1 into stopper z Pull out stopper using the screw 1 z Insert turning gear 1 and set valve clearance as described 1 OBJ_DOKU...

Page 59: ...en locking nut 2 z Mount the control piston clearance X on the set ting screw 1 in EX 55 using the setting de vice and set as follows Fix magnet Then turn back at an angle of 432 manual ly or using a...

Page 60: ...if the battery is disconnected Keep battery clean and dry Make sure the battery is fitted correctly and securely Dispose of old batteries in an environmen tally friendly way Danger of explosion The ga...

Page 61: ...a conventional battery charger Observe the manufacturer specifica tions z Screw in caps Installing the battery z Insert new or charged battery and attach the fas tenings z Clean the terminals and batt...

Page 62: ...defective or discharged Check battery Cable connection to starter loose or oxidized Check cable connections Starter defective or pinion does not engage Check starter Engine does not start and diag no...

Page 63: ...lube oil level if necessary drain off Air filter clogged turbocharger defective Check replace Air filter maintenance switch maintenance indicator defective Check replace Fan defective V rib belt torn...

Page 64: ...Check lube oil level if necessary drain off Excessive inclination of engine Check engine mounting reduce inclination Engine producing blue smoke Lube oil level too high Check lube oil level if necessa...

Page 65: ...Ignition on error lamp lights up for approx 2 seconds and then goes out Check the error lamp if there is no reaction after switching on the ignition z Steady light Error in the system Operation conti...

Page 66: ...l unit through CAN can be displayed z Engine speed z Engine torque current z Lubricating oil temperature z Coolant temperature z Suction intake air temperature z Exhaust gas temperature z Gear oil tem...

Page 67: ...ioningof engine remove attachment eyes 2 1 2 z The fastening attachment cannot be fixed se curely above the centre of gravity 1 z The fastening attachment can slip the engine swings backwards and forw...

Page 68: ...the engine with corrosion protection oil SAE 20W 20 up to the MAX mark and perform a cor rosion protection run for at least 5 minutes so that all the components of the lubricating oil sys tem are wet...

Page 69: ...around it to pre ventcondensationfromforming Useadesiccant if necessary Removal of corrosion protection z The corrosion protection must be removed from the corrosion protected engine before starting z...

Page 70: ...ight excluding cooling system to DIN 70020 A approx kg 450 570 Engine power rating according to ISO 3046 kW Engine performance speed and start of pumping among other things are stamped on the engine r...

Page 71: ...cating oil SAE 34 Lube oil temperature in the lube oil tray maximum C 125 Lubricating oil pressure in warm state 114 C and low idle minimum kPa bar 80 0 8 Lube oil first fill quantities Specified lubr...

Page 72: ...CR DCR Weight excluding cooling system to DIN 70020 A approx kg 530 620 Engine power rating according to ISO 3046 kW Engine performance speed and start of pumping among other things are stamped on the...

Page 73: ...ube oil SAE 34 Lube oil temperature in the lube oil tray maximum C 125 Lubricating oil pressure in warm state 114 C and low idle minimum kPa bar 80 0 8 Lube oil first fill quantities Specified lubrica...

Page 74: ...der no 8189 The Torx screw system is used in engines in this se ries among other things This systemwas introduced for a number of reasons z Excellent accessibility z High force transmission when loose...

Page 75: ...clearance Pin wrench insert Order no 8193 5 mm valve clearance Order no 8194 4 mm control piston clearance Pin wrench inserts for rotation angle disc Crow foot wrench Order no 8199 Crow foot wrench f...

Page 76: ...tting the valve clearance for TCD 2012 4V Turning gear order no 100 330 For turning over the engine as an attachment for the torsional vibration damper Turning gear order no 100 360 For turning over t...

Page 77: ...rder no 8192 Special tool for removing the water collection vessel in the fuel pre filter Racor type Closing plugs and caps Order no 170 160 A set of closing plugs and caps for sealing fuel lines OBJ_...

Page 78: ...OBJ_DOKU 12638 001 fm Seite 78 Mittwoch 22 August 2007 9 25 09...

Page 79: ...1 DEUTZ Oil DQC IV 05 Synthetic ACEA E7 04 E5 02 E4 99 TLS 15W40D DQC II 05 5 L 0101 6331 20 L 0101 6332 209 L 0101 6333 TLX 10W40FE DQC III 05 5 L 0101 6335 20 L 0101 6336 209 L 0101 6337 DEUTZ Oel...

Page 80: ...tostra e 1 D 51149 Cologne Phone 49 0 221 822 0 Fax 49 0 221 822 5850 Internet www deutz com E mail info deutz com Printed in Germany All rights reserved 1st edition 08 2007 Order no 0312 3536 en OBJ_...

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