OBJ_DOKU-37211-001.fm Seite 1 Donnerstag, 20.

Juni 2013 12:50 12

Operation Manual
Betriebsanleitung
TCGL04/L06
TCD 2012 2015 V06
2V
TCGL04/L06
TCD 2013 2015 V08
2V
OBJ_DOKU-37211-001.fm Seite 2 Donnerstag, 20. Juni 2013 12:50 12

Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
● This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
Non-compliance results in the expiry of the war-
the equipment manufacturer (use for the intend-
ranty!
ed purpose). Any other use above and beyond
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
● Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. ● Do not work on the fuel system while the engine
● When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
pressure - Danger to life!
● Unauthorised engine modifications will invalidate
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
● Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
● Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
● When carrying out maintenance work on the en-

2 © 2013
OBJ_DOKU-37211-001.fm Seite 3 Donnerstag, 20. Juni 2013 12:50 12

Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
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.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG

© 2013 3
OBJ_DOKU-37211-001.fm Seite 4 Donnerstag, 20. Juni 2013 12:50 12

Table of contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Belt drives . . . . . . . . . . . . . . . . . . 37
Foreword . . . . . . . . . . . . . . . . . . . . . 3 Adjustment work . . . . . . . . . . . . . . . 38
1 General . . . . . . . . . . . . . . . . . . . . 5 Electrical system . . . . . . . . . . . . . . . 40
2 Engine description . . . . . . . . . . . . . . 7 7 Faults . . . . . . . . . . . . . . . . . . . . .42
Model . . . . . . . . . . . . . . . . . . . . . 7 Fault table . . . . . . . . . . . . . . . . . . 42
Engine illustrations . . . . . . . . . . . . . . 9 Engine management . . . . . . . . . . . . . 46
Lubricating oil diagram . . . . . . . . . . . . 11 8 Transport and storage . . . . . . . . . . . .47
Coolant diagram . . . . . . . . . . . . . . . 12 Transport . . . . . . . . . . . . . . . . . . . 47
Fuel diagram . . . . . . . . . . . . . . . . . 13 Engine corrosion protection . . . . . . . . . 48
3 Operation . . . . . . . . . . . . . . . . . . . 14 9 Technical data . . . . . . . . . . . . . . . .50
Ambient conditions . . . . . . . . . . . . . . 14 Engine and setting data . . . . . . . . . . . 50
Initial commissioning . . . . . . . . . . . . . 15 Tools . . . . . . . . . . . . . . . . . . . . . 51
Starting process . . . . . . . . . . . . . . . 18
Operation monitoring . . . . . . . . . . . . . 19
Stopping process . . . . . . . . . . . . . . . 21
4 Operating media . . . . . . . . . . . . . . . 22
Lubricating oil . . . . . . . . . . . . . . . . . 22
Combustion gas . . . . . . . . . . . . . . . 23
Coolant . . . . . . . . . . . . . . . . . . . . 24
5 Maintenance . . . . . . . . . . . . . . . . . 25
Maintenance schedule . . . . . . . . . . . . 25
6 Servicing and maintenance work . . . . . . . 28
Lubricating oil system. . . . . . . . . . . . . 28
Combustion gas system . . . . . . . . . . . 30
Cooling system . . . . . . . . . . . . . . . . 31
Engine cleaning. . . . . . . . . . . . . . . . 33
Suction system . . . . . . . . . . . . . . . . 34
Ignition system . . . . . . . . . . . . . . . . 36

4 © 2013
OBJ_DOKU-37211-001.fm Seite 5 Donnerstag, 20. Juni 2013 12:50 12

General
DEUTZ engines
DEUTZ engines and the appropriate exhaust after-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
treatment components are the result of years of re- cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
search and development. The detailed know-how functioning and high reliability. tact to your nearest local service partner.
gained by this in connection with the high quality de-
mands are the guarantee for production of engines DEUTZ Xchange components Masthead
with a long life, high reliability and low fuel consump-
tion. Naturally the high demands for protection of the DEUTZ replacement parts are a low-cost alternative. DEUTZ AG
environment are also met. Of course, the quality standards here are just as high Ottostraße 1
as for new parts. DEUTZ replacement parts are
Safety precautions when the engine is running equal to the original DEUTZ parts in function and re- 51149 Köln
liability. Germany
Maintenance work or repairs may only be performed
on the shut-down engine. Make sure that the engine Asbestos Phone: +49 (0) 221-822-0
cannot be started inadvertently - Danger of accident! Fax: +49 (0) 221-822-3525
The gaskets used in this engine contain no asbestos.
After repair work: Check that all guards have been Please use the appropriate original DEUTZ parts for E-Mail: [email protected]
replaced and that all tools have been removed from maintenance and repair work. www.deutz.com
the engine.
Observe industrial safety regulations when running Service
the engine in an enclosed space or underground. We want to preserve the high performance of our en-
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches.
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-

© 2013 5
 OBJ_DOKU-37211-001.fm Seite 6 Donnerstag, 20. Juni 2013 12:50 12

General
1 Danger

This symbol is used for all safety instruc-

tions which, if not observed, present a di-
rect danger to life and limb for the person
involved. Observe these carefully. The at-
tention of operating 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

This symbol indicates a danger to the part

and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.
Notes

This symbol accompanies notes of a gen-

eral kind.

6 © 2013
OBJ_DOKU-37211-001.fm Seite 7 Donnerstag, 20. Juni 2013 12:50 12

Model Engine description

Engine type designation
2
This manual covers the following engine types
A B
TCG 2015 V06 C
TCG 2015 V08
Mot.-Typ Mot.-Nr.
TCG

X
XX
XX
T Exhaust gas turbocharger

XX
XX
C Charge air cooler
G gas engine R

DEUTZ AG MADE IN GERMANY

2015
2015 Series
Rating plate Location of the rating plate
V06/08
The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cov-
V Cylinder arrangement data are stamped on the rating plate. er or the crankcase.
06 No. of cylinders The engine type and number must be stated when
08 No. of cylinders purchasing spare parts.

© 2013 7
 OBJ_DOKU-37211-001.fm Seite 8 Donnerstag, 20. Juni 2013 12:50 12

Engine description Model

2 left

X
XX
XX
XX
XX
right

Engine serial number Cylinder numbering

The engine number (D) is stamped onto the crank- Cylinder arrangement
case (arrow) and onto the rating plate. The cylinders are counted consecutively starting
from flywheel (1).
Direction of rotation
Looking onto the flywheel.
rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.

8 © 2013
OBJ_DOKU-37211-001.fm Seite 9 Donnerstag, 20. Juni 2013 12:50 12

Engine illustrations Engine description

TCG 2015 V08
View from right (example)
2
1 Combustion air inlet
2 Coolant outlet
3 Coolant pipe to the exhaust manifold
4 Coolant inlet
11 1 5 V-rib belt
6 Generator
7 Lubricating oil drain plug
8 Exhaust manifold line
10 (cooled)
2 9 Lubricating oil filling
10 Throttle valve
11 Exhaust outlet
9
3

6 5 4

© 2013 9
 OBJ_DOKU-37211-001.fm Seite 10 Donnerstag, 20. Juni 2013 12:50 12

Engine description Engine illustrations

2 TCG 2015 V08

View from left (example)
12 13
1 Gas mixer (gas inlet to the gas mixer from the
gas control system)
2 Turbocharger
11 1 3 Exhaust line
4 Starter
5 Turning gear installation position
6 Lubricating oil sump
2 7 Lubricating oil drain plug
10 8 Lubricating oil dipstick
9 Lube oil replacement filter
10 Cylinder head cover
3 11 Ignition coil

8
5

5
7
6

10 © 2013
OBJ_DOKU-37211-001.fm Seite 11 Donnerstag, 20. Juni 2013 12:50 12

Lubricating oil diagram Engine description

TCG 2015 V06 / TCG 2015 V08
(example)
2
9 8 7 6 1 Lubricating oil sump
2 Lubricating oil pump
3 Pressure limiting valve
4 Lube oil cooler
5 Lube oil replacement filter
6 Piston cooling nozzle
7 Rocker arm
4
8 Lubricating oil pressure monitor
9 Pressure holding valve
10 Turbocharger
11 Lubricating oil level transmitter in the lubricating
oil pan

10 11 1 5 3 2

© 2013 11
 OBJ_DOKU-37211-001.fm Seite 12 Donnerstag, 20. Juni 2013 12:50 12

Engine description Coolant diagram

2 Coolant schematic (example)

TCG 2015 V06 TCG 2015 V08
7 8 9 10
1 Coolant pump
2 Lube oil cooler
3 Coolant supply for engine cooling
4 Cylinder pipe/head cooling
5 Liquid-cooled turbocharger
6 Mixture cooler
7 Liquid-cooled exhaust manifold
8 Temperature transmitter
9 Thermostat with coolant level sensor
(engine cold) coolant directly for engine cooling
(engine warm) coolant flow through the cooler
10 Compensation tank
11 Cooler

T
1 2 3 4

5 6 7 8

6 5 4 3 2 1 11

12 © 2013
OBJ_DOKU-37211-001.fm Seite 13 Donnerstag, 20. Juni 2013 12:50 12

Fuel diagram Engine description

Fuel diagram (example)
TCG 2015 V06 TCG 2015 V08
2
2 3 4 5
1 Gas supply (symbolic)
2 Gas filter
3 Solenoid shut-off valve
4 Zero-pressure regulator
5 Gas volume controller

50 - 60 mBar

© 2013 13
 OBJ_DOKU-37211-001.fm Seite 14 Donnerstag, 20. Juni 2013 12:50 12

Operation Ambient conditions

3 Coolant
● Observe the mixing ratio anti-freeze/cooling wa-
ter. (  24 )
High ambient temperatures, high altitude

This engine is equipped with an electric

0 °C control unit.
Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
ically, controlled by the electronic control
unit.
Under the following application and operating condi-
tions, the amount of fuel must be reduced.
● above 1000 m altitude
Low ambient temperatures ● above 30 °C ambient temperature
Lubricating oil Reason: Air density decreases as altitude or ambient
● Select the lubricating oil viscosity according to temperature increase. This reduces the amount of
the ambient temperature. oxygen in the engine intake air and the fuel-air mix-
● If cold starting occurs frequently cut the lube oil ture would be too rich if the injected amount of fuel
changing interval by half. were not reduced.
Combustion gas ● The results would be:
– black smoke in the exhaust
● Combustion gas in accordance with EN 676
– high engine temperature
Battery – reduction in engine performance
● A good charging condition of the battery (  40 ) – possible impairment of starting behaviour
is the prerequisite for starting the engine. Consult your equipment supplier or DEUTZ partner if
● Heating up the battery to approx. 20°C improves you have any other questions.
the starting behaviour of the engine. (Remove
and store the battery in a warm room).

14 © 2013
OBJ_DOKU-37211-001.fm Seite 15 Donnerstag, 20. Juni 2013 12:50 12

Initial commissioning Operation

Preparations for initial commissioning
(Maintenance schedule E 10) 1
3
● Remove engine corrosion protection
● Remove any transport devices.
● Check the battery and cable connections and
mount if necessary.
● Check belt tension (  37 ).
● Have the engine monitor or warning system
checked by authorised personnel.
● Check the engine mounting.
● Check that all hose unions and clips fit properly.
The following additional work must be carried out on
generally overhauled engines:
● Check the intake air cleaner (if available, main- Fill with engine lube oil Connecting the gas control system to the engine
tain according to maintenance indicator).
● Drain lubricating oil and condensation water from Low lubricating oil level and overfilling lead Danger of explosion!
the charge air cooler. to engine damage. The room ventilation must be switched on
● Fill with engine lube oil. before working on the gas system.
● Fill the coolant system (  50 ). Naked flames/smoking is prohibited.
The engines are generally supplied without Ensure cleanliness.
lubricating oil filling. Check gas system for leaks.
Select lubricating oil quality and viscosity
before filling. ● Connection (1) must be connected gas-tight.
Order DEUTZ lubricating oils from your Check for leaks.
DEUTZ partner
● Fill the engine with lubricating oil via the lubricat-
ing oil filler neck.
● Observe the lubricating oil filling level (  50 ).

© 2013 15
 OBJ_DOKU-37211-001.fm Seite 16 Donnerstag, 20. Juni 2013 12:50 12

Operation Initial commissioning

3 2 3
● If required, repeat procedure with engine start.
● Fill up coolant to the MAX mark on the compen-
sation tank and close the cooling system cap.
● Observe the filling volume of the cooling system
(  50 ).
1

Filling the coolant system ● Connect coolant outlet (2) and coolant inlet (1) to
the cooling system. Connect the feed line of the
The coolant must have a prescribed con- compensation tank to the coolant pump or to the
centration of cooling system corrosion pro- coolant inlet line (2).
tection agent! ● Connect venting pipes from the engine (3) and, if
Never operate the engine without coolant, necessary, from the cooler to the compensation
even for a short time! tank.
● Fill cooling system via the compensation tank.
Order coolant corrosion protection agent ● Start the engine and run up until the thermostat
from your DEUTZ partner. opens (line (2) heats up).
● Engine operation with open thermostat 2 - 3 min-
utes.
● Check the coolant level and top up coolant if nec-
essary.
Danger of scalding from hot coolant!
Cooling system under pressure! Only open
the cap when cool!
Observe safety regulations and national
specifications when handling cooling me-
dia.

16 © 2013
OBJ_DOKU-37211-001.fm Seite 17 Donnerstag, 20. Juni 2013 12:50 12

Initial commissioning Operation

3
1

Venting the exhaust manifold

● Loosen the venting screw (1) on both exhaust
manifolds until coolant emerges without bubbles.
Trial run
Carry out a brief trial run up to operating temperature
(approx. 90 °C) after preparations.
Do not load the engine if possible.
● Work with the engine not running:
– Check engine for tightness.
– Check lubricating oil level, if necessary top
up.
– Check the coolant level and top up coolant if
necessary.
● Work during the trial run:
– Check engine for tightness.

© 2013 17
 OBJ_DOKU-37211-001.fm Seite 18 Donnerstag, 20. Juni 2013 12:50 12

Operation Starting process

3 Starting

Before starting, make sure that nobody is

standing in the immediate vicinity of the en-
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
been removed from the engine.
Only operate combustion engines in ade-
quately aired rooms and use exhaust ex-
traction if necessary. Make sure the room
has adequate ventilation before starting.

If the engine fails to fire and the error lamp

lights, the electronic engine control has ac-
tivated the start lock to protect the engine.
The start lock is released by switching off ● Insert key.
the system with the ignition key for about 30 – Off stage = no operating voltage.
seconds.
Do not actuate the starter for more than ● Turn key to the right.
20 seconds. If the engine does not start up, – Run stage = operating voltage.
wait for one minute and then repeat the
● Turn the key further to the right against the spring
starting process.
pressure.
If the engine does not start up after two at-
tempts, determine the cause as per fault ta- – Start stage = start
ble (  42 ). ● release the key as soon as the engine starts up.
Do not run up the engine immediately to – The pilot lamps will go out.
high idling speed / full load operation from
cold.

18 © 2013
OBJ_DOKU-37211-001.fm Seite 19 Donnerstag, 20. Juni 2013 12:50 12

Operation monitoring Operation

6
Error messages are displayed in clear text and
acoustically; the error memory of the control unit can 3
1 be read out.
For a detailed description, refer to the operating in-
5 structions enclosed with the DEUTZ Electronic Dis-
play.

2 4

Instrument Panel DEUTZ Electronic Display

1 DEUTZ Electronic Display The engine is equipped with a CAN display to show
2 Engine speed control measured values and error messages of the engine
3 Ignition lock control unit.
4 Error lamp The following data may be displayed if they are sent
5 Engine standstill display by the control unit.
6 Charging current indicator lamp ● Engine speed
● Engine torque (current)
● Coolant temperature
● Suction intake air temperature
● Exhaust gas temperature
● Lubricating oil pressure
● Lubricating oil level
● Coolant pressure
● Coolant level
● Charge air pressure
● Battery voltage
● Accelerator position
● Operating hours

© 2013 19
 OBJ_DOKU-37211-001.fm Seite 20 Donnerstag, 20. Juni 2013 12:50 12

Operation Operation monitoring

3 Instruments and symbols

Instruments/symbols Designation Possible display: Measure

Lubricating oil pressure display Lubricating oil pressure in the red area Switch off engine

Coolant temperature Coolant temperature too high Switch off engine

Lubricating oil temperature Lubricating oil temperature too high Switch off engine

Lubricating oil pressure pilot lamp Lubricating oil pressure below minimum Switch off engine

Lube oil level Lubricating oil level too low Fill up lube oil

Coolant level Coolant level too low Shut down the engine, allow to cool and top up coolant

Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123

Horn With acoustic signal See fault table (  42 ).

20 © 2013
OBJ_DOKU-37211-001.fm Seite 21 Donnerstag, 20. Juni 2013 12:50 12

Stopping process Operation

Lag time
3
The control unit remains active for about
another 40 seconds to save the system
data (lag) and then switches off automati-
cally.
For this reason, the power supply to the en-
gine must not be suddenly interrupted by
the breaker.

Shutting off

Avoid switching off from full load (coking/

blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-
bricating oil supply of the turbocharger is
then no 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.
● Turn key to the left.
– Off stage = engine stops.
– Indicator lamps light up
● Remove key from ignition lock.

© 2013 21
 OBJ_DOKU-37211-001.fm Seite 22 Donnerstag, 20. Juni 2013 12:50 12

Operating media Lubricating oil

4 General
Modern gas engines place very high demands on the
The lubricating oil viscosity describes the way the lu-
bricating oil flows, depending on the temperature.
(84 °F).
● If the lubricating oil change intervals are not
The lubricating oil viscosity only has a small influ-
lubricating oil used. The specific engine performanc- ence and effect on the quality of the oil. reached within a year, the oil should be changed
es increased constantly in recent years lead to in- at least once a year.
creased thermal stress of the lubricating oil. In Synthetic lubricating oils are used increasingly and
addition, the lubricating oil is subject to heavier con- offer advantages. These lubricating oils have better Lubricating oil change intervals according to analy-
tamination due to reduced lubricating oil consump- temperature and oxidation stability as well as rela- sis
tion volumes and increased lubricating oil change tively low cold vicosity.
The lubricating oil change intervals depend on the lu-
intervals. For this reason it is necessary to observe bricating oil quality, the quality of the fuel and the op-
Quality
the requirements and recommendations in this oper- erating conditions. Prolonging of the specified
ating manual in order not to reduce the life of the en- The further technical development of the DEUTZ gas lubricating oil change intervals beyond the standard
gine. engines towards high efficiencies with low emission values requires prior lubricating oil analysis for ap-
Lubricating oils always consist of a base oil and an demands special, adapted low-ash lubricating oils. proval by DEUTZ.
additive package. The most important tasks of a lu- For use in DEUTZ gas motors we have a list of rec-
bricating oil (e.g. wear protection, corrosion protec- ommended oils on: Viscosity
tion, neutralisation of acids from combustion www.deutz.com The viscosity is classified according to SAE. Lubri-
products, prevention of coke and soot deposits on or they can be taken from Technical Bulletin cating oils for single ranges can be used in closed,
the engine parts) are assumed by the additives. The heated rooms at temperatures > 5 ℃ .
properties of the base oil are also decisive for the TR 0199-99-01213
quality of the product, e.g. with regard to thermal . The prescribed lubricating oil quality must
load capacity. These oils are adapted to the requirements of gas be observed when selecting the viscosity
In principle, all engine oils of the same specification engines and have been proven in hard engine oper- class!
can be mixed. However, mixing of engine oils should ation.
be avoided because the worst properties of the mix-
ture are always dominant. Lubricating oil change intervals
The lubricating oils approved by DEUTZ have been ● The intervals depend on:
thoroughly tested for all engine applications. The ac- – Gas quality
tive ingredients they contain are compatible with – lubricating oil quality
each other. Therefore, the use of additives for lubri- – Ambient conditions
cating oils is not permitted in DEUTZ engines. – type of application of engine
The lubricating oil quality has a considerable influ- ● The lubricating oil change interval must be
ence on the life, performance and thus also on the halved if at least one of the following conditions
costs-effectiveness of the engine. It basically applies applies:
that: The better the lubricating oil quality, the better – Constant ambient temperature below -10 °C
these properties. (14 °F) or lube oil temperature below 60 °C

22 © 2013
OBJ_DOKU-37211-001.fm Seite 23 Donnerstag, 20. Juni 2013 12:50 12

Combustion gas Operating media

Combustion gas
The following are approved as combustion gases for
bustion gas analysis being approved in writing, all
guarantee rights will be voided. Failure of a combus- 4
tion gas to comply with the minimum properties or its
gas engine operation: contamination by unspecified ingredients will lead to
● Natural gas a reduction in the life of the engine and all compo-
nents affected. A gas analysis must always be sub-
Other gases (e.g. biogas, landfill gas, etc.) are not mitted to DEUTZ Service or the dealer at
approved for series use. Individual project inspection commissioning (not older than 2 weeks) and docu-
is carried out by DEUTZ AG. mented in the commissioning report. A gas analysis
Natural gas must be made after commissioning and compliance
with the requirements tested.
Natural gas is a combustible gas found in under-
ground deposits. It is often found together with min- All gas analysis reports must be supported
eral oil as it evolves in a similar way. Natural gas is a to DEUTZ Service or the dealer in case of
gas mixture whose composition varies considerably a guarantee claim.
depending on where it is found. Natural gases con-
sist mainly of methane but differ in their further The respective manufacturer documents must be
chemical composition. consulted for system parts such as catalytic convert-
ers and exhaust gas heat exchangers with regard to
Requirements for natural gas compositions the gas composition and exhaust temperature. Be-
cause of the different composition of the combustion
Component min. Typical max.
gases, not every engine in a series achieves the
Methane number (MN) 70 - 95 maximum possible power for the series with every
Methane (CH4) in vol.-% 80 91 98 approved combustion gas. Delivered engines may
Alkanes (ethane, propane, 0 5 18 only be operated with the combustion gas prescribed
according to the scope of delivery.
butane, pentane) in vol.-%
Intert gases (nitrogen and 0 4 15
carbon monoxide) in vol.-%

DEUTZ recommends compliance with the

requirements for natural gas in accordance
with TR 0199-99-01213.
General
If the combustion gas does not meet these require-
ments or the combustion gas contains by-products
which are not specified without the concrete com-

© 2013 23
 OBJ_DOKU-37211-001.fm Seite 24 Donnerstag, 20. Juni 2013 12:50 12

Operating media Coolant

4 General ● pH value too low:

Addition of diluted sodium or potassium lye.
ed to the materials in our engines. Order from your
DEUTZ partner.
Never operate the engine without coolant, Small trial mixtures are advisable. Please contact your DEUTZ partner if the DEUTZ
even for a short time! ● Total hardness too high: cooling system corrosion protection agent is not
Mixing with softened water (pH neutralized con- available.
In liquid-cooled engines, the coolant must be condi- densate or water softened by ion exchanger).
tioned and monitored, otherwise the engine could be ● Chlorides and/or sulphates too high: http://www.deutz.com
damaged by: Mixing with softened water (pH neutralized con- de \SERVICE\Betriebsstoffe und
● corrosion densate or water softened by ion exchanger). Additive\Kühlsystemschutz
● cavitation Cooling system corrosion protection agent en \SERVICE\Operating Liquids and Addi-
● freezing tives\Cooling System Conditioner
● overheating Health damaging nitrous amines form The cooling system must be monitored regularly.
when nitrite-based cooling system corro- This also includes checking the coolant system cor-
Water quality
sion protection agents are mixed with rosion protection agent concentration in addition to
The right water quality is important for conditioning amine-based agents! checking the coolant level.
the coolant. Clear, clean water within the following
The cooling system corrosion protection agent con-
analysis values should always be used: Cooling system corrosion protection agents centration can be checked with conventional test in-
must be disposed of in an environmentally struments (e.g. refractometer).
Analysis values min max ASTM friendly way.
ph value 6,5 8,5 D 1293 Observe the notes on the safety data Cooling system Water percent- Cold pro-
Chlorine (Cl) [mg/l] - 100 D 512 sheet. corrosion protec- age tection up
D 4327 tion agent percent- to
The conditioning of the coolant for liquid-cooled
age
Sulphate (SO4) [mg/l] - 100 D 516 DEUTZ compact engines is performed by mixing an
anti-freeze with corrosion protection inhibitors based min. 35 % 65 % -22 ℃
Total hardness [mmol/l] 3,56 D 1126
(CaCO3) [mg/l] 356 on ethylene glycol into the water. 40 % 60 % -28 ℃
[°dGH] 20,0 - DEUTZ cooling system corrosion protection agent 45 % 55 % -35 ℃
[°e] 25,0 Container Order number: max. 50 % 50 % -41 ℃
[°fH] 35,6 5 litre container 0101 1490 At temperatures below -41 °C, please contact your
20 litre canister 0101 6416 responsible DEUTZ partner.
Specifications of the water quality are made by the
local water board. 210 litre barrel 1221 1500 It is possible to use other cooling system corrosion
protection agents (e.g. chemical corrosion protection
The water must be conditioned if it deviates from the
This cooling system corrosion protection agent is agents) in exceptional cases. Consult your DEUTZ
analysis values.
free from nitrite, amine and phosphate and is adapt- partner.

24 © 2013
OBJ_DOKU-37211-001.fm Seite 25 Donnerstag, 20. Juni 2013 12:50 12

Maintenance schedule Maintenance

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule
TCG 2015 V06 / TCG 2015 V08
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
Applications with 1,800 1/min Applications with 1,500 1/min
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E25 Intermediate maintenance Qualified personnel 500 750
E30 Maintenance 1.0001) 15001)
E40 Extended maintenance I 2.000 3000
E50 Extended maintenance II Authorised specialists 10.000 12.000
E60 Intermediate overhaul 20.0002) 24.0002)
2)
E70 General overhaul 40.000 48.0002)

Observations
1)
The lubricating oil interval refers to the normal case and may vary according to the application and gas quality.
The oil analyses must be within the scope of the limit values according to TR 0199-99-01213 to achieve these intervals.  22

General overhaul
2)
The best time for a general overhaul depends to a great extent on the load, application and ambient conditions and the care and maintenance of the engine during the
operating time.
Your DEUTZ partner will advise you on determining the best time for a general overhaul.

© 2013 25
 OBJ_DOKU-37211-001.fm Seite 26 Donnerstag, 20. Juni 2013 12:50 12

Maintenance Maintenance schedule

5 Maintenance measures

Stage Activity Measure Page

E10 The measures are listed in chapter 3.  15
E20 Check Lubricating oil level (if necessary top up)  28
Coolant level (top up if necessary)  16
Check engine for leak tightness and damage (visual inspection)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator)  35
E25 Check Spark plugs, electrode spacing  36
E30 Check Battery and cable connectors  40
Valve clearance (set if necessary, earlier if there is any noise)  38
Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine appli-  22 /  28
cation type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed)  29
Spark plugs  36
E40 Check V-belts (retension or renew if necessary)  37
Fastenings, hose unions / clips (renew if damaged)
Crankcase breather valve
E50 Check Engine mounting (tighten, replace if damaged when necessary)
Check pipe turbocharger - throttle valve - gas mixer for leaks, re-tighten if necessary
Starter pinion and gear ring
Mixture cooler
Turbocharger
Clean Gas controlled system
Replace Suction air filter/dry air filter (maintain in accordance with maintenance indicator)  34
Renew or overhaul the cylinder head
every 4 months Check Gas analysis
every 6 months Check Coolant (additive concentration)  31

26 © 2013
OBJ_DOKU-37211-001.fm Seite 27 Donnerstag, 20. Juni 2013 12:50 12

Maintenance schedule Maintenance

Stage
annually
Activity
Check
Measure
Gas shut-off valve
Page
5
Check gas controlled system for leaks
Gas pressure regulator
Replace Gas filter  30
Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine appli-  22
cation type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed)  28
Every 2 years Replace V-belts  37
Coolant  24  31
Status dependent Replace Suction air filter/dry air filter (maintain in accordance with maintenance indicator)  35

© 2013 27
 OBJ_DOKU-37211-001.fm Seite 28 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Lubricating oil system

6 Regulations for working on the lubricating oil system

OIL ?
● Extract the lubricating oil dipstick and read off the
oil level.
Do not work when the engine is running! ● The oil level must always be between the MIN
Smoking and naked lights prohibited! and MAX marks! Top up to the MAX mark if nec-
Be careful of hot lubricating oil. Danger of essary.
scalding! OIL Lubricating oil sampling
+80°C
Pay attention to utmost cleanliness when +176°F ● The lubricating oil is sampled through the open-
working on the lubricating oil system. Clean ing of the lubricating oil dipstick.
the area around the components con-
cerned carefully. Blow damp parts dry with Changing the lubricating oil
compressed air.
Observe the safety regulations and nation-
al specifications for handling lube oils.
! ● Warm up the engine (lubricating oil temperature
> 80 °C).
● Ensure that the engine or vehicle is in a level po-
Dispose of leaking lubricating oil and filter sition.
elements properly. Do not allow used oil to
Checking the lubricating oil level ● Switch off the engine.
seep away into the ground.
● Place a collecting receptacle underneath the
Perform a trial run after all work. Pay atten-
Low lubricating oil level and overfilling lead lube oil drain screw.
tion to tightness and lubricating oil pressure
and then check the engine oil level. to engine damage. ● Unscrew the lube oil drain screw, drain oil.
The lubricating oil level may only be ● Turn in and tighten lubricating oil drain plug fitted
checked with the engine in a horizontal po- with new sealing ring.
sition and switched off.
If the engine is warm, switch off the engine Tightening torque 120 Nm
and check the lubricating oil level after 5 ● Pour in lube oil.
minutes. If the engine is cold you can check
– Quality/viscosity data (  22 ).
it immediately.
– Filling volume (  50 ).
● Warm up the engine (lubricating oil temperature
Be careful of hot lubricating oil. Danger of
> 80 °C).
scalding!
Do not pull out the dipstick while the engine ● Ensure that the engine or vehicle is in a level po-
is running. Danger of injury! sition.
● Check lubricating oil level, if necessary top up.
● Pull out the lubricating oil dipstick and wipe off
with a lint-free, clean cloth.
● Insert the lubricating oil dipstick as far as it will
go.

28 © 2013
OBJ_DOKU-37211-001.fm Seite 29 Donnerstag, 20. Juni 2013 12:50 12

Lubricating oil system Servicing and maintenance work

6

Change lubricating oil filter ● Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- ● Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
● Remove clamps when twist protection mounted ● Fasten clamps of the twist protection (optional).
(optional).
● Loosen 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.

© 2013 29
 OBJ_DOKU-37211-001.fm Seite 30 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Combustion gas system

6 2 3 4 5

6
1

Renew gas filter cartridge ● Remove the filter cartridge (3) from the lid (4). ● Insert the lid with filter cartridge (6) into the gas
● Clean the lid and gas filter housing. filter housing.
Danger of explosion! ● Renew gasket (5).
The room ventilation must be switched on ● Fit a new filter cartridge (3) into the lid (4). Make sure that the filter cartridge is posi-
before working on the gas system. tioned correctly in the gas filter housing (ar-
Naked flames/smoking is prohibited. rows).
Make sure that the filter cartridge is posi-
Ensure cleanliness.
tioned correctly in the lid (arrows).
Check gas system for leaks. ● Turn on nuts and tighten diagonally.
● Interrupt gas supply by closing the ball cock (ar- Tightening torque 8 Nm
row).
● Undo nuts (2) and remove the lid of the gas filter ● Restore the gas supply by opening the ball cock.
housing (1). ● Check the lid and gas filter housing for leaks.
– To do this, spray leak test spray or soapy wa-
ter onto the lid and watch for formation of
bubbles.

30 © 2013
OBJ_DOKU-37211-001.fm Seite 31 Donnerstag, 20. Juni 2013 12:50 12

Cooling system Servicing and maintenance work

Specifications when working on the cooling system
6
Danger of scalding from hot coolant!
Cooling system under pressure! Only open
the cap when cool!
The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!
Observe safety regulations and national
specifications when handling cooling me-
dia.
Observe the manufacturer's specifications 1
for an external cooler.
Dispose of leaking liquids properly and do
not allow them to seep into the ground.
Order coolant corrosion protection agent
from your DEUTZ partner. Check coolant additive concentration Emptying the cooling system
Never operate the engine without coolant, ● Open the cooling system cap (1) carefully. ● Open cooler locking cap carefully.
even for a short time!
● Check the coolant aditive concentration in the ● Place a collection tray underneath the coolant
Checking the coolant level with an external cooler cooler/compensation tank (2) with a convention- connection (1).
al antifreeze measuring device (1) (e.g. hydrom- ● Drain coolant.
● Fill in new coolant and vent the system according eter, refractormeter). ● Reconnect and tighten the coolant connection
to the specifications of the cooling system manu- ● Necessary coolant additive concentration Cool- (1).
facturer. ant mixing ratio (  24 ). ● If the locking screw is not accessible, the drain-
● Open the cooling system cap (1) carefully.
The corresponding test device can be ordered from age can be carried out at the engine oil cooler
● The coolant level must always be between the (coolant duct).
MIN and MAX marks of the compensation tank! your DEUTZ partner under the order no.: 0293
7499. ● Close cooler locking cap.
Fill up to the MAX mark if necessary.

© 2013 31
 OBJ_DOKU-37211-001.fm Seite 32 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Cooling system

Fill and ventilate cooling system

Danger of scalding from hot coolant!

Cooling system under pressure! Only open
the cap when cool!
● Open the cooling system cap (1) carefully.
● Loosen the cooler venting screw 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.
● Run engine up to operating temperature (open-
ing temperature of the thermostat).
● Switch off the engine.
● Check coolant level in cooled engine and top up
to the MAX mark or filling level on the compensa-
tion tank if necessary.

32 © 2013
OBJ_DOKU-37211-001.fm Seite 33 Donnerstag, 20. Juni 2013 12:50 12

Engine cleaning Servicing and maintenance work

Cleaning work ● Spray the engine clean with a high pressure wa-
ter jet. 6
For all cleaning work, make sure that no ● Warm up the engine so that the water residues
parts are damaged (e.g. bent cooler mesh). evaporate.
Cover electrical/electronic parts and con-
nections to clean the engine (e.g. control Cleaning with a high pressure cleaner
units, generator, solenoid valves etc.). Do ● Clean the engine with a steam jet (maximum
not aim the water/steam jet directly at them. spray pressure 60 bar, maximum steam temper-
Allow engine to warm up. ature 90 °C, distance at least 1m).
● Warm up the engine so that the water residues
Only carry out cleaning work on the engine evaporate.
when it is not running! ● Always clean the cooler and cooling fins from the
Remove the engine cover and cooling air exhaust air side to the fresh air side.
cover if available and remount after clean-
ing.
General
The following causes of soiling make it necessary to
clean the engine:
● High dust content in the air.
● Coolant leaks
● Lubricating oil leakage
● Fuel leaks
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 out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
Cleaning with cold cleaner
● Spray the engine with cold cleaner and leave it
for about 10 minutes to take effect.

© 2013 33
 OBJ_DOKU-37211-001.fm Seite 34 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Suction system

6 Regulations for working on the intake system

Do not work when the engine is running!

1
2
Pay attention to utmost cleanliness when
working on the intake system, close intake
openings if necessary.
Dispose of old filter elements properly.

Remove the intake air filter Installing the intake air filter
● Install new intake air filter.
Do not clean the filter element!
● Tighten nut (2).
Renew damaged filter elements.
● Place lid on the air filter housing.
● Tighten wing nut (1).
● Maintain the filter element according to the inter-
val in the maintenance schedule or according to
the maintenance indicator.
● Unscrew wing nut (1).
● Remove the lid of the air filter box.
● Unscrew nut (2).
● Removing the intake air filter
● Clean the inside of the air filter housing with rags.

34 © 2013
OBJ_DOKU-37211-001.fm Seite 35 Donnerstag, 20. Juni 2013 12:50 12

Suction system Servicing and maintenance work

6

Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter
● The dry air filter is maintained according to a ● Empty the dust discharge valve (1) by pressing
maintenance switch or maintenance indicator. together the discharge slit.
● Maintenance is necessary when: ● Remove any caked dust by pressing together the
– the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. ● Clean the discharge slit.
– the red field (1) of the maintenance indicator
is fully visible.
● After carrying out maintenance work, reset the
signal by pressing the button on the mainte-
nance indicator. The maintenance indicator is
now ready for operation again.

© 2013 35
 OBJ_DOKU-37211-001.fm Seite 36 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Ignition system

6 Tightening torque 35 Nm
● Plug spark plug (1) into spark plug holder.

Removing and installing the spark plugs Checking and setting spark plug

Mortal danger! When working on the high The spark plug must be renewed if the mid-
voltage ignition system. dle electrode is too heavily burned or very
Only carry out work with the engine heavily soiled.
switched off. Cleaning of the spark plug is not permissi-
Secure the engine against starting. ble.
The ground electrode may only be re-bent
● Pull the spark plug (1) out of the spark plug hold- twice.
er and remove.
● Check the spark plug for soiling. ● Check electrode spacing with a feeler gauge.
● Set electrode spacing to the nominal value by
– if oil has penetrated: reseal the cylinder head bending slightly.
cowling
● Blow out spark plug shaft with compressed air. Electrode spacing 0.35 mm
● Remove spark plugs
● Spark plugs must be checked for:
– damages
– electrode spacing
● Install spark plug

36 © 2013
OBJ_DOKU-37211-001.fm Seite 37 Donnerstag, 20. Juni 2013 12:50 12

Belt drives Servicing and maintenance work

6 2 6
1

3 1
4
5

5 4 3 2

Checking the belt drive Checking the belt tension Tighten the generator V-belts
● Lower indicator arm (1) into the measuring de- ● Loosen lock nut (3).
Only carry out work on the belt drive with vice. ● Loosen screws (1) and (2) and (3).
the engine at a standstill!
● Place guide (3) between two belt pulleys on the ● Tighten the generator V-belts.
Always change both belts in sets in case of
V-belt (2). The stop have to be at the side. This is done with a screw (6).
wear on the double belts or damage to one
V-belt. ● Press the button (4) at right angles to the V-belt ● Retighten the screws (1) and (2).
After repair work: Check that all guards (2) evenly until you hear or feel the spring snap ● Tighten the lock nut (3) again.
have been replaced and that all tools have in.
been removed from the engine. ● Lift the measuring device carefully without alter- Renew the V-belts
ing the position of the indicator arm (1).
● Check the whole belt drive visually for damage. ● Loosen lock nut (3).
● Read the measured value at the point of inter- ● Loosen screws (1) and (2) and (3).
● Renew damaged parts. section (arrow), scale (5) and indicator arm (1).
● Swing the generator (4) in in the opposite direc-
● Remount protective devices if necessary. ● If necessary, re-tension belt and measure again.
tion to the arrow.
● Pay attention to correct fit of new belts, check the
tension after running for 15 minutes. Tools ● Remove the V-belt (5) and fit a new V-belt.
● Tighten the generator V-belts.
The belt tension measurement device (order no.:
0189 9062) can be ordered from your DEUTZ part-
ner. Tightening torque Screw 1, 2 20 Nm
Locking nut 3 42 Nm

© 2013 37
 OBJ_DOKU-37211-001.fm Seite 38 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Adjustment work

6 2 1 2 1
1 2
EX IN

3 3

Check valve clearance, adjust if necessary Check valve clearance, adjust if necessary ● Then set the second valve on the rocker arm as
1 Screw 1 Lock nut described above.
2 Cylinder head cover 2 Valve clearance setting screw ● Perform the setting procedure on every cylinder.
3 Gasket 3 Valve clearance ● Remount the cylinder head cover with a new
gasket in the reverse order of disassembly.
● Let the engine cool down for at least 30 minutes ● Check the valve clearance (3) between the rock- ● Tighten screws.
before setting the valve clearance: Lubricating oil er arm and valve with a feeler gauge.
temperature below 80 °C. ● The feeler gauge must slide in with little resist- Tightening torque 22 Nm
● Release screws. ance.
● Remove the cylinder head hood.
● Remove gasket. Valve clearance IN Inlet valve 0.3 mm
● Fit the turning gear.  10 EX Outlet valve 0.6 mm
● Turn the crankcase until reaching valve overlap.
Outlet valve is not yet closed, inlet valve be- ● Adjust valve clearance if necessary:
gins to open. ● Loosen locking nut (1).
The cylinders to be set can be seen in the ● Regulate the valve clearance setting screw (2)
setting schematic. with the hexagon socket wrench so that the cor-
rect valve clearance (3) is achieved after tighten-
ing the lock nut (1).
Tightening torque 20 Nm

38 © 2013
OBJ_DOKU-37211-001.fm Seite 39 Donnerstag, 20. Juni 2013 12:50 12

Adjustment work Servicing and maintenance work

Valve clearance setting schematic
Valve overlap: Exhaust valve is not yet closed, inlet
6
valve begins to open.
TCG 2015 V06

Valve overlap Settings

A1 B2
B3 A2
A3 B1
B2 A1
A2 B3
B1 A3
TCG 2015 V08

Valve overlap Settings

A1 B3
B4 A3
A4 B2
B1 A2
B3 A1
A3 B4
B2 A4
A2 B1

© 2013 39
 OBJ_DOKU-37211-001.fm Seite 40 Donnerstag, 20. Juni 2013 12:50 12

Servicing and maintenance work Electrical system

6 Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. ● Check the battery voltage with a standard volt-
Allow engine to warm up. meter. The voltage gives information about the
Touching a lead against the frame to check charge status.
whether it is live must not, under any cir-
cumstances, be carried out. Battery Charge status (Volt)
For electrical welding work, the ground ter- Check acid density
minal of the welding gear must be clamped 24 Volt 24-28,4 ● Unscrew caps.
directly to the part being welded. Check acid level ● Measure the electrolyte density of individual cells
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
connect the cables between battery, gener- ● Unscrew caps. reading indicates battery’s state of charge. The
ator and regulator while the engine is ● Note the manufacturer’s specifications concern- acid temperature when measuring should be 20
running. ing the liquid level. °C if possible.
Battery The liquid should normally be 10-15 mm above ● Check the acid level before recharging.
the top edge of the plate or reach up to any avail- ● Screw in caps.
able control device.
Electronically stored data could be lost if Acid density [kg/ l] Charge Measure
● Only use distilled water to top up the battery.
the battery is disconnected. status
Keep battery clean and dry. ● Screw in caps. Normal Tropical
Make sure the battery is fitted correctly and 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge

40 © 2013
OBJ_DOKU-37211-001.fm Seite 41 Donnerstag, 20. Juni 2013 12:50 12

Electrical system Servicing and maintenance work

Removing the battery
● Always disconnect the minus pole first when re-
6
moving the battery. Otherwise there is a danger
of short-circuit!
● Remove the fastenings and take out the battery.
Charging the battery
● Unscrew caps.
● Charge the battery with a conventional battery
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 paper.
● Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
● Grease the assembled terminals with an acid-
free, acid-resistant grease.

© 2013 41
 OBJ_DOKU-37211-001.fm Seite 42 Donnerstag, 20. Juni 2013 12:50 12

Faults Fault table

7 Faults and remedies

Faults Causes Measures

Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Below starting limit temperature Check
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Incorrect valve clearance Check valve clearance and set if necessary
Air filter clogged / turbocharger defective Check/replace
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Ignition system defective Check
Gas shut-off fittings closed Open
Gas pipe not vented Flush
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
Engine starts, but runs irregularly or Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose
fails Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Ignition control unit defective Check
Ignition coils defective Check
Electrode spacing at spark plug too big Settings
Spark plugs defective Check/replace
Crankshaft or camshaft sensor spacing too great or at limit Settings

42 © 2013
OBJ_DOKU-37211-001.fm Seite 43 Donnerstag, 20. Juni 2013 12:50 12

Fault table Faults

Faults
Engine "bangs" and runs irregularly
Causes
Ignition cable defective
Measures
Check
7
Ignition coils defective Check
Spark plug defective Check
Crankshaft or camshaft sensor spacing too great or at limit Settings
Gas pipe not vented Flush
Valves leaking Check
Oil carbon residue on pistons or outlet valves Clean
Speed changes are possible and diag- Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
nostic lamp lights up eliminate error if necessary
Engine becomes excessively hot. Vent line blocked Clean
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lube oil cooler defective Check/replace
Lubricating oil filter soiled Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Incorrect valve clearance Check valve clearance and set if necessary
Coolant heat exchanger soiled Clean
Defective cooling water pump (torn or loose V-belt) Check whether torn or loose
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
V-belt torn or loose Check/replace/tension
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary

© 2013 43
 OBJ_DOKU-37211-001.fm Seite 44 Donnerstag, 20. Juni 2013 12:50 12

Faults Fault table

7 Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check 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 or loose Check fan/V-belt, change if necessary
Charge air line leaking Check charge air line
Charge air cooler soiled Clean
Resistance in cooling system is too high / flow volume too low Check the cooling system
Gas shut-off fittings not fully open Open
Too little gas Check gas pressure
Gas-air mixture faulty Check gas mixer
Engine performs poorly and diagnos- Engine electronics reduce performance Please contact your DEUTZ partner
tic lamp lights
Engine does not run on all cylinders Charge air line leaking Check charge air line
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Crankcase breather Check/replace
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
Engine producing white smoke Below starting limit temperature Check
Incorrect valve clearance Check valve clearance and set if necessary
Gas quality does not meet specifications in the operating manual Check

44 © 2013
OBJ_DOKU-37211-001.fm Seite 45 Donnerstag, 20. Juni 2013 12:50 12

Fault table Faults

Faults
Engine producing black smoke
Causes
Air filter clogged / turbocharger defective
Measures
Check/replace
7
Air filter maintenance switch / maintenance indicator defective Check/replace
Incorrect valve clearance Check valve clearance and set if necessary
Charge air line leaking Check charge air line

© 2013 45
 OBJ_DOKU-37211-001.fm Seite 46 Donnerstag, 20. Juni 2013 12:50 12

Faults Engine management

7 the engine can continue to operate with limitations,

during which the error lamp lights up continuously or
indicates a serious system error by flashing. In this
case, the engine should be switched off as soon as
1 safely possible.

Engine protection function of the electronic engine

control

1 Error lamp
2 Electronic engine control (EMR)

The error lamp goes out when all the errors

have been eliminated. For some errors, it is
necessary to switch off the ignition, wait 30
s and only then switch back on the ignition.
The appropriate monitoring functions are
switched off when a sensor fails. Only the
sensor failure is documented in the error
memory.
Depending on the design of the monitoring functions,
the electronic engine control can protect the engine
in certain problematical situations by monitoring im-
portant limit values during operation and checking
the correct function of the system components.
Depending on the seriousness of a recognised fault,

46 © 2013
OBJ_DOKU-37211-001.fm Seite 47 Donnerstag, 20. Juni 2013 12:50 12

Transport Transport and storage

1 8
1

2
2

Suspension equipment
Danger to life!
The engine may tip over or fall down if sus-
The transport devices mounted on this en- pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com- ● The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. ● The fastening attachment can slip, the engine
swings backwards and forwards (1).
● Always use proper suspension equipment when
transporting the engine. ● Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
● The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
● After transportation and before commissioning of
engine: remove attachment eyes (2).

© 2013 47
 OBJ_DOKU-37211-001.fm Seite 48 Donnerstag, 20. Juni 2013 12:50 12

Transport and storage Engine corrosion protection

8 General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
● If a coolant with corrosion protection properties is
poured into liquid-cooled engines, no further ac-
● The corrosion protection run can be performed tion is necessary after draining.
tection:
once to protect the different systems: ● If not, the coolant must be drained and, to ensure
● Interior corrosion protection the formation of a covering layer on the inside
● Exterior corrosion protection Lubricating oil system surfaces of the cooling system, a corrosion pro-
● Drain lubricating oil from warm engine. tection run performed with a mixture of:
Your DEUTZ partner has the right corro-
sion protection agent for your needs. ● Thoroughly clean lube oil tray, cylinder head with – 95 % treated water
rocker arms, valves, valve springs with diesel – 5 % corrosion protection agent
fuel or cleaning agent. ● The duration of the corrosion protection run and
The following measures for corrosion protection after the concentration of the corrosion protection
● Fill engine with TITAN EM 2020 DEUTZ (SAE
taking the engine out of operation meet the require- agent are specified by the manufacturer of the
20W-20) preservation oil and carry out corrosion
ments for 12 months corrosion protection. corrosion protection agent.
protection run (together with corrosion protection
The following corrosion protection work may only be run for fuel system), warm up the engine to ap- ● Then drain the coolant.
carried out by persons familiar with it and instructed prox. 60 °C, duration at least 5 minutes so that all
in the potential dangers. components of the lubricating oil system are wet,
If these measures are deviated from by exposing the
corrosion-protected engines or parts to unfavourable or
conditions (installation outdoors or storage in damp,
badly aired places) or damage to the corrosion pro- all accessible components are wet with preser-
tection layer, a shorter corrosion protection duration vation oil and pump approx. 60 °C warm preser-
is to be expected. vation oil through the engine with a separate
pump until all bearings and bearing liners are
The engine corrosion protection should be checked
wet.
about every 3 months by opening the covers. If cor-
rosion is detected, the corrosion protection should Cooling system
be renewed.
● Depending on the series the engines are
At the end of the corrosion protection work the crank equipped with cooling air, cooling oil or cooling
drive may no longer be turned so that the corrosion fluid system (cooling water with cooling system
protection agent in the bearings, bearing liners and protection agent).
cylinder liners is not scraped off.
● Cooling air system, see the Exterior corrosion
Before operating a corrosion protected engine, the protection section.
corrosion protection must be removed. ● In engines of the oil-cooled series the circulating
Interior corrosion protection lubricating oil serves simultaneously for cooling.
The cooling chambers are protected automati-
● Interior corrosion protection is always provided cally against corrosion with the lube oil system.
by wetting of the walls with the implemented cor-

48 © 2013
OBJ_DOKU-37211-001.fm Seite 49 Donnerstag, 20. Juni 2013 12:50 12

Engine corrosion protection Transport and storage

Air intake pipes
● Spray ANTICORIT VCI UNI O 40 corrosion pro-
Storage and packaging
● After being protected against corrosion, the en-
protection agent must be washed off with dis-
tilled fuel or a suitable cleaning agent. 8
● Wash out grooves of V-belt pulleys if necessary.
tection oil or TITAN EM 2020 DEUTZ (SAE 20W- gine must be stored in a dry, ventilated hall and
20) preservation oil into the intake air pipe. suitably covered. ● Mount V-belts or V-rib belts as specified.
● The cover must be placed loosely over the en- ● Fill with coolant.
Exterior corrosion protection gine so that the air can circulate around it to pre- Corrosion protection agent / cleaning agent
● The engine must be cleaned thoroughly with a vent condensation from forming. Use a desiccant
cleaning agent before exterior corrosion protec- if necessary. Please ask your DEUTZ partner for reference prod-
tion. Any signs of corrosion and damage to the ucts for the corrosion protection agents/cleaning
Removal of corrosion protection agents to be used which meet DEUTZ requirements.
paintwork must be removed.
● The corrosion protection must be removed from or see www.deutz.com
Bare exterior surfaces and parts the corrosion protected engine before starting.
● Coat or spray all bare exterior parts and surfaces ● The packaging and all covers over the closed http://www.deutz.com
(e.g. flywheel, flange faces) with corrosion pro- openings must be removed. de \SERVICE \Betriebsstoffe und Addi-
tection agent. ● Any corrosion deposits and paint damage should tive\Motorkonservierung
be remedied. en \SERVICE\Operating Liquids and Addi-
Rubber parts
Lubricating oil system tives\Engine Corrosion Protection
● Rubber parts (e.g. muffs) which are not painted
over must be rubbed down with talcum powder. ● Unscrew the lube oil drain screw, drain oil.
● Fill the engine with lubricating oil via the lubricat-
Belt drive
ing oil filler neck.
● Remove V-belts and V-rib belts and store
packed. Coolant system
● Spray V-belt pulleys and tension rollers with cor- ● If the implemented corrosion protection agent is
rosion protection agent. compatible with the intended cooling system pro-
tection agent, this can be filled directly into the
Engine openings coolant system as specified.
● All engine openings must be fitted with air-tight, ● If it is uncertain whether the implemented corro-
water-tight covers to delay the vapourisation sion protection agent is compatible with the cool-
process of the corrosion protection agents. ing system protection agent, the cooling system
● With installed air compressor, the suction and should be purged with fresh water for about 15
pressure connection must be sealed by a cap. minutes before filling.
● Air should be excluded to avoid ventilation of the Removal of exterior corrosion protection
engine (chimney effect) for the suction from an
air supply pipe. ● All areas and components coated with corrosion

© 2013 49
 OBJ_DOKU-37211-001.fm Seite 50 Donnerstag, 20. Juni 2013 12:50 12

Technical data Engine and setting data

9 General technical data

Engine type Dimension TCG 2015 V06 TCG 2015 V08

Working principle Otto four-stroke gas engine
Mixture charging Turbocharging with liquid-cooled mixture cooler
Type of cooling Liquid-cooled/cooling system protection
Cylinder arrangement in V form in 90° angle
No. of cylinders 6 8
Bore/stroke [mm] 132/145
Total displacement [cm3] 11906 15874
Valves per cylinder 4
Valve clearance: Inlet/outlet
Setting with rotary angle disc [mm] 0,3/ 0,6
Firing order of the engine A1-B3-A3-B2-A2-B1 A1-B4-A4-B1-B3-A3-B2-A2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [min-1] see engine rating plate
Coolant volume (only engine content without cooler / hoses and pipes) ≈ [l] 34 46
Permissible continuous coolant temperature [°C] max. 88
Temperature difference between coolant inlet/outlet [°C] max. 8
Lubricating oil change volume (with filter) ≈ [l] 60 70
Permissible minimum intake air temperature [°C] 5
Electrode spacing of the spark plug [mm] 0,35
V-belt tension Pre-tensioning/Re-tensioning
V-belts AVX 13 (width: 13 mm) [N] 450±50/275±50
Weight without cooling system according to DIN 70020-A ≈ [kg] 995 1290

50 © 2013
OBJ_DOKU-37211-001.fm Seite 51 Donnerstag, 20. Juni 2013 12:50 12

Tools Technical data

Tool ordering
The special tools described in this chapter can be or-
9
dered from:
Please contact your DEUTZ partner

V-belt tension measuring instrument Special wrench for loosening exchangeable filters
Order number: Order number:
0189 9062 0189 9142
Measuring instrument for checking the specified V- For loosening changeable filters.
belt tensions.

© 2013 51
 OBJ_DOKU-37211-001.fm Seite 52 Donnerstag, 20. Juni 2013 12:50 12

Technical data Tools

Pin wrench insert Turning gear Turning gear

Order number: Order number: Order number:
0189 9096 0299 2449 0299 2022
For setting the valve clearance For turning over the engine as an attachment for the For turning over or blocking the engine at the fly-
torsional vibration damper wheel

52 © 2013
OBJ_DOKU-37211-001.fm Seite 53 Donnerstag, 20. Juni 2013 12:50 12

Tools Technical data

9

Refractometer
Order number:
0293 7499
The following operating media can be evaluated with
this test device:
● Coolant
● Battery acid

© 2013 53
OBJ_DOKU-37211-001.fm Seite 54 Donnerstag, 20. Juni 2013 12:50 12
OBJ_DOKU-37211-001.fm Seite 55 Donnerstag, 20. Juni 2013 12:50 12

DEUTZOperating Fluids

DEUTZCooling System
Conditioner
5L 01011490
20L 01016416
210L 1221 1500
OBJ_DOKU-37211-001.fm Seite 56 Donnerstag, 20. Juni 2013 12:50 12

DEUTZ AG
Information Systems Sales & Service
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
E-Mail: [email protected]
www.deutz.com

Printed in Germany
© 06/2013
All rights reserved
Order number:
0312 3992 en
The engine company. Original operating instructions