Page 1: ...Operation Manual TD 3 6 L4 TCD 3 6 L4 A DEUTZ...
Page 2: ...tzy when dents and other generally recognised safety and clean SJg with liqu ds industrial medicine rules must be observed D ot work on th fuel sy tem while tl l ngine When the engine is running there...
Page 3: ...ing manual isavail able to everyone involved inthe operation mainte nance and repair of the engine and that they have understood the contents If you have any queries please contact us we ll be happy t...
Page 4: ...monitoring 27 Exhaust gas aftertreatment system 31 Passive regeneration 32 Stopping process 35 4 Operating media 36 Lubricating oil 36 Fuel 39 Coolant 40 5 Maintenance 41 Maintenance schedule 41 6 Se...
Page 5: ...state of the art can guarantee perfect functioning and high reliability DEUTZ Xchange components DEUTZ replacementpartsare alow costalternative Ofcourse thequality standards here arejustas high as for...
Page 6: ...ng personnel 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 Caution J Sl This symbol ind...
Page 7: ...ms is not allowed The engines of these operating instructions fulfill the following exhaust emissions regulations TCD 3 6 56 kW With exhaust aftertreatment system USA EPATier4i EU stage IIIB TD3 6 56k...
Page 8: ...kcase Engine serial number The engine number D isstamped onto thecrank case arrow and onto the rating plate Model Serial numbers of the exhaust aftertreatmentcom ponents Rating plate of the diesel oxi...
Page 9: ...le filter The serial numbers of the exhaust aftertreatment componentsare stamped on the rating plates Cylinder numbering Cylinder arrangement The cylinders are counted consecutivelystarting from flywh...
Page 10: ...ngine illustrations TD3 6L4 Industrial engine View from right example 1 Lubricating oil filling 2 V belts 3 Coolant inlet 4 Lubricating oil drain plug 5 Lube oil replacement filter 6 Lubricatingoil di...
Page 11: ...ription TD3 6 L4 Industrial engine View from left example 1 Combustion air inlet 2 Crankcase breather 3 Exhaust outlet 4 Lubricating oil dipstick Optional 5 Lube oil replacement filter Optional 6 Dies...
Page 12: ...ns TCD3 6 L4 Industrial engine View from right example 1 Crankcase breather 2 Throttle valve 3 Tension pulley 4 V ribbelt 5 Coolant inlet 6 Lubricating oil drain plug 7 Lube oil replacement filter 8 L...
Page 13: ...L4 Industrial engine View from left example 1 Combustion airinlet 2 Exhaust outlet 3 Diesel particle filter 4 Diesel oxidation catalytic converter 5 Lubricating oil dipstick Optional 6 Lube oil replac...
Page 14: ...ltural technology View from right example 1 Exhaust outlet 2 Lubricating oil filling 3 V ribbelt 4 Tension pulley 5 Coolant inlet 6 Lubricating oil drainplug 7 Lubricating oil filling 8 Lube oil repla...
Page 15: ...Engine illustrations Engine description TCD3 6L4 Agricultural technology View from right example 1 Crankcase breather 2 Lubricating oil drain plug...
Page 16: ...mp 2 Lubricating oil pump 3 Overpressure valve 4 Lube oil cooler 5 Bypass valve 6 Pressure control valve 7 Lubricating oil filter 8 Main lube oil channel 9 Camshaft bearing 10 Crankshaft bearing 11 Pi...
Page 17: ...el pre filter 3 Fuel pump electrically pow 4 Exch ered 5 F angeable fuel filter 6 uel transducer High pressure pump With Control block FCU 7 Rail Fuel Control Unit 8 Injector 9 Check valve 10 Return l...
Page 18: ...ematic example 1 Coolant pump 2 Coolant supply for engine cooling 3 Cylinder pipe head cooling 4 Lube oil cooler 5 Exhaust return cooler 6 Connection possibility forcab heating 7 Temperature transmitt...
Page 19: ...External exhaust gas recirculation 1 Exhaust gas partial flow uncooled 2 Actuator electrically actuated 3 Coolant return 4 Exhaust return cooler 5 Coolant line to the EGR cooler 6 Exhaust gas partial...
Page 20: ...xhaust aftertreatment system Example 1 Decoupling line 2 Differential pressuresensor 3 Exhaust temperature sensor 4 Diesel oxidation catalytic converter 5 Diesel particlefiller Optional 6 Differential...
Page 21: ...a crankshaft 7 Fuel transducer 8 Lubricating oil pressure transmitter on the opposite side 9 Central plug for engine control Equipment side 10 Power supply battery 11 Signal outputs e g for lamps spee...
Page 22: ...arried out byauthorisedpersonnel using equipment approved by DEUTZ Installation instructions The control units are calibrated to the respective en gine and identified by the engine number Every en gin...
Page 23: ...tio anti freeze cooling wa ter IMO High ambient temperatures high altitude This engine is equipped with an electric control unit Under the operating conditions listed be low the amount offuel is reduc...
Page 24: ...system 67 Fill with engine lube oil I ISl Low lubricating oil level and overfilling lead L J to enginedamage d Theengines aregenerallysupplied without EJ lubricatingoil filling Select lubricating oil...
Page 25: ...tifnec essary rJ l Danger of scalding from hot coolant Coolingsystem underpressure Onlyopen the capwhencool Observe safety regulationsand national specifications when handling cooling me dia If requir...
Page 26: ...ately to high idling speed I full load operation from cold Q Disconnect the engine by uncoupling de EJ vices to be driven where possible with oold starting device Insert key Position0 no operating vol...
Page 27: ...e forced to run withpower reductionto cool the engine with automaticshutdown if necessary The switch off process has beenaccom plished There may be a start lock after engine stop The start lockisdeact...
Page 28: ...bricating oil temperature too high Switch off engine Lubricating oil pressure pilot Lubricating oil pressure below minimum Switch off engine lamp Lube oil level Lubricating oil level too low Fill up l...
Page 29: ...p indicates that the loading of the diesel particle filter with ash has reached a critical level and the device can no longer regenerate 32 DPF function lamp Continuous light Initiate standstill regen...
Page 30: ...ke air temperature Exhaust gas temperature Lubricating oil pressure Coolant pressure Charge air pressure Fuel pressure Status of the regeneration of the diesel particle filter Operation monitoring of...
Page 31: ...amination with soot increas es That means that the soot in the diesel particle fil ter is burned Theregeneration is based on a continuous regener ation process which is activated as soon as the ex hau...
Page 32: ...ter will continue to becomecontami nated with soot If thestandstill regeneration isnot carried out the engine control unit will activate the specified engine protection functions depending on the cont...
Page 33: ...lter It may be necessary to replace the diesel particle fil ter after ahigh filterrunning time as non combustible residues accumulate in the filter so called ash If the ash loading goes beyond acertai...
Page 34: ...n _ G J Regeneration lamp Engine warning lamp Ash lamp off off off Normal operation off off off Support mode fiashes 0 5 Hz off off Standstill regeneration Release by the operator fiashes 2 Hz Continu...
Page 35: ...d This shortens the life of the turbocharger Run the engine inlow idling speed for ap proximatelyone minute after relieving the load Move the key to position 0 P gearposition park 0 gearposition switc...
Page 36: ...e oil Syntheticlubricating oils are used increasingly and offer advantages These lubricating oils have better temperature and oxidation stability as well as rela tively lowcold vicosity Since some pro...
Page 37: ...e of thefollowing conditions applies Constant ambient temperature below 10 C 14 F or lube oil temperature below 60 C 84 F Sulphur content indiesel fuel of 0 5weight If the lubricating oil change inter...
Page 38: ...Operating media Lubricating oil II oc 45 40 35 30 25 20 0 15 0 0 0 0 0 0 0 0 l 0 0 l 0 0 l l N 10 UJ UJ UJ UJ UJ UJ UJ UJ 5 0 5 10 15 20 25 30 35 40...
Page 39: ...fuels in accordance with EN 590 and ASTM D975 described in theoperation manual No emission values are guaranteed with the other fuels described in this operationmanual The respective fuels prescribed...
Page 40: ...ronmentally friendly way Observe the notes on the safetydata sheet The conditioning of the coolant for liquid cooled OEUTZ compact enginesis performed by mixing an anti freezewith corrosion protection...
Page 41: ...eral overhaul 6 000 3 4 Observations 1 The lubricating oil load may be high depending on the application The lubricating oil change interval must be halved here 0036 2 Data for lubricating oil change...
Page 42: ...insert every time the lubricating oil is changed IM 5 Lubricating oil An lubricating oil application change strategy adapted optimally to the individual engine application 00 36 IM 4 type can be creat...
Page 43: ...by the ash lamp orvia an electronic display depending on dependent the engine version see DEUTZ exchange programme 1 132 Maintenance wot1 outside the DEUTZ maintenance and service schedules Ifthe wate...
Page 44: ...minutes after shutting down W Be careful of hot lubricating oil Danger of 9 scalding Do not pull out the dipstick while the engine is running Danger of injury Pull out the lubricating oil dipstick and...
Page 45: ...sen and unscrew filter with tool order no 0189 9142 Collect draining lubricating oil Clean the sealing surface of the filter support with a lint free clean cloth Servicing and maintenance work Oil the...
Page 46: ...be vented atrial run performed and the tightness checked It will be necessary to vent the fuel system when commissioning forthe first time after maintenance work or if the tank has been run dry 1 Addi...
Page 47: ...crew filter with tool order no 0189 9142 Catch any escaping fuel Clean the sealing surface of the filter support with a lint free clean cloth Servicing and maintenance work Oil the gasket of the new D...
Page 48: ...emble filter insert Clean any dirt offthe sealing surfaces of the new filter cartridge and opposite side of filter head Wet the sealing surfaces of the filter cartridge slightly with fuel and screw ba...
Page 49: ...ystem manu facturer Open the cooling system cap 1 carefully Thecoolant level must always be between the MIN and MAX marks of the compensation tank Fill up to the MAX mark if necessary Servicing and ma...
Page 50: ...rew if necessary Fill coolant up to the max mark or filling limit Switch on any available heating and set to the highest level so that the heating circuit is filled and vented Close cooler locking cap...
Page 51: ...ks Lubricatingoil leakage Fuelleaks Because of the different application conditions cleaning depends on the degree of dirt contamina tion Cleaning with compressed air Blow dirt off or out Always blow...
Page 52: ...ording to thein terval inthe maintenance schedule Lift up the clamping yoke 1 Remove the filter hood 2 and pull out the filter element 3 Filterelement 3 blow out with dry compressed air max 5 bar from...
Page 53: ...d field 1 of the maintenanceindicator is fully visible After carrying out maintenance work reset the signalby pressing the button on the mainte nance indicator The maintenance indicator is now ready f...
Page 54: ...eck the tension after running for 15 minutes Replace V rib belt 1 Tension pulley 2 Retaining pin 3 Assembly bore Press tensioning rollerwith socket wrench in the directionof the arrow until a retainin...
Page 55: ...cale 5 and indicator arm 1 If necessary re tension belt and measure again Tools The belt tension measurement device order no 0189 9062 can be ordered fromyour DEUTZ part ner Servicing and maintenance...
Page 56: ...in an environmen tally friendly way rA l Danger ofexplosion The gases emitted by l eJ the battery areexplosive Fire sparks smoking and naked lights are prohibited Danger of acid burns Wear protective...
Page 57: ...charger Observe the manufacturer specifica tions Screw in caps Installing the battery Insert new or charged battery and attach the fas tenings Clean the terminals and battery poles with fine emery pa...
Page 58: ...pinion does not engage Check starter Air filter clogged I turbocharger defective Check replace Air in fuel system Vent fuel system Compression pressure too low Check compression pressure Exhaust gas b...
Page 59: ...ube oil side Change Lube oil level too high Check lube oil level ifnecessary drain off Lubricating oil level too low Fill up lube oil Injector defective Change Coolant heat exchanger soiled Clean Defe...
Page 60: ...ic lamp lights Engine does not run on all cylinders Injection line leaks Check injection line Injector defective Change Charge air line leaking Check charge air line Lube oil level too high Check lube...
Page 61: ...icle filter is contaminated with soot and must be regenerated Initiate standstill regeneration 32 Regeneration lamp flashing quickly Diesel particle filter is contaminated with soot and must be regene...
Page 62: ...ight After the lamp test an extinguished lamp indi cates an error free and trouble free operat ing state within the scope of the control possibility Continuous light Error in system Operation continue...
Page 63: ...nition on Thenthe nexterror i e the followingonein theerror memory can be displayed bypressing the diagnos tic keyagain Ifthe last error was displayed thefirst error is displayed again on pressing the...
Page 64: ...he suspension device 1 must be adjustable for the engine scentre of gravity Aftertransportation and before commissioning of engine remove attachment eyes 2 rAJ Danger to life Theengine may tipoverorfa...
Page 65: ...at least 5 minutes Lubricating oil system Drain lubricating oil from warm engine Thoroughlyclean lube oil tray cylinderhead with rocker arms valves valve springs with diesel fuel or cleaning agent Fil...
Page 66: ...nt damage should be remedied Fuel system If there is a mixture of diesel fuel corrosion pro tection oil in the fuel tank drain it Connect fuel tank supply lineto the engine Pay attention to cleanlines...
Page 67: ...ally cooled Exhaust gas aftertreatment Diesel oxidation catalytic converter DOC and or Diesel particle filter DPF or without Valves per cylinder 2 Firing order of the engine 1 3 4 2 Direction of rotat...
Page 68: ...ooler C 50 V belt tension Pre tensioning Re tensioning V belts AVX width 13 mm N 650 50 400 50 V rib belt tensioning Automatic tensioning spring loaded clamping roller Weight without cooling system ac...
Page 69: ...engines inthis se ries among otherthings This systemwas introduced for a number of reasons Excellent accessibility High force transmission when loosening and tightening Slipping or breaking of the ke...
Page 70: ...ch for loosening exchangeable filters Order number 0189 9142 For loosening changeable filters Refractometer Order number 0293 7499 The following operating mediacan beevaluatedwith this test device Coo...
Page 71: ...W40FE DEUTZ Cooling System low SAPS DQC 111 10 LA DQC 111 10 Conditioner 5L 5L 0101 6335 5L 01011490 20 L 0101 7976 20 L 0101 6336 20 L 0101 6416 209 L 0101 7977 209 L 0101 6337 210 L 12211500 DEUTZ O...
Page 72: ...es Service OttostraBe 1 D 51149 Koln Germany Phone 49 o 2 21 8 22 o 49 o 2 21 8 22 35 25 info deutz com Fax E Mail Internet www deutz com Printed in Germany oS 2013 All rights reserved Order number 03...
