Deutz TD 3.6 L4 User manual

TD / TCD 3.6 L4
Operation Manual
EU Stage IV / US EPA Tier 4
OBJ_DOKU-44425-001.fm Seite 1 Donnerstag, 19. Februar 2015 2:46 14

Notes
2© 2014
Notes
● This engine is defined exclusively for purpose
according to the scope of delivery and built by
the equipment manufacturer (use for the intend
-
ed purpose). Any other use above and beyond
this will be considered as misuse. The manufac
-
turer will not accept any liability for damages re -
sulting from this. The user bears the sole risk.
● Use for the intended purpose also includes ob
-
servance of the operating, maintenance and re -
pair conditions specified by the manufacturer.
The engine should only be operated, serviced
and repaired by personnel trained in its use and
the hazards involved.
The pertinent rules for the prevention of acci
-
dents and other generally recognised safety and
industrial medicine rules must be observed.
● When the engine is running there is a danger of
injury caused by:
– rotating and hot components
– on motors with external ignition (high electri
-
cal voltage). Contact must be avoided!
● Unauthorised engine modifications will invalidate
any liability claims against the manufacturer for
resultant damage.
● Equally, manipulations to the injection and con
-
trol system can affect the engine's performance
and the exhaust characteristics. Adherence to
legislation on pollution can no longer be guaran
-
teed under such conditions.
● Do not change the cooling 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.
● When carrying out maintenance work on the en
-
gine, the use of DEUTZ original parts is pre -
scribed. These are specially designed for your
engine and guarantee perfect operation.
Non-compliance results in the expiry of the war
-
ranty!
Maintenance/cleaning work on the engine may
only be carried out when the engine is not run
-
ning and has cooled down.
When doing this, make sure that the electrical
system is switched off (remove ignition key).
The specifications for accident prevention with
electrical systems (e.g. VDE-0100/-0101/-0104/-
0105 Electrical protective measures against dan
-
gerous contact voltages) must be observed.
Cover all electrical components tightly when
cleaning with liquids.
● Do not work on the fuel system while the engine
is running - Danger to life!
Wait for the pressure to be relieved once the en
-
gine has shut down (for engines with common
rail, approx. 5 minutes, otherwise 1 minute) as
the system is under high pressure - Danger to
life!
During the first trial run do not stand in the dan
-
ger area of the engine.
Danger due to high pressure in case of leaks -
Danger to life!
– In case of leaks immediately contact work
-
shop.
– When working on the fuel system, make sure
that the engine is not started inadvertently
during repairs - Danger to life!
OBJ_DOKU-44425-001.fm Seite 2 Montag, 7. Juli 2014 7:46 07

Foreword
© 2014 3
Dear customer,
Congratulations on the purchase of your DEUTZ en
-
gine.
DEUTZ air/liquid-cooled engines are developed for a
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
installation situation, i.e. not all the components de
-
scribed in the operating manual are installed in your
engine.
We have endeavoured to highlight any differences
so that you will be able to locate the operating and
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
Engine serial number
Please enter the engine serial number here. This will
simplify the handling of customer service, repair and
spare parts queries.
Components of the exhaust aftertreatment system
Please enter the serial numbers of the exhaust after
-
treatment components.
Diesel oxidation catalytic converter
Diesel particle filter
SCR module
Notes
We reserve the right to make technical changes to
the descriptions and data in this operating manual in
the interest of further development of the engines.
This document may only be reprinted and repro
-
duced, even in part, with our express permission.
OBJ_DOKU-44425-001.fm Seite 3 Montag, 7. Juli 2014 7:46 07

Table of contents
4© 2014
Notes . . . . . . . . . . . . . . . . . . . . . . . 2
Foreword
. . . . . . . . . . . . . . . . . . . . . 3
1General
. . . . . . . . . . . . . . . . . . . . 5
2Engine description
. . . . . . . . . . . . . . 7
Model . . . . . . . . . . . . . . . . . . . . . 7
Engine illustrations . . . . . . . . . . . . . . 10
Lubricating oil diagram . . . . . . . . . . . . 16
Fuel diagram . . . . . . . . . . . . . . . . . 17
Coolant diagram . . . . . . . . . . . . . . . 18
Exhaust gas recirculation . . . . . . . . . . . 19
Exhaust gas aftertreatment . . . . . . . . . . 20
Electrics/Electronics . . . . . . . . . . . . . 22
3Operation
. . . . . . . . . . . . . . . . . . . 24
Ambient conditions . . . . . . . . . . . . . . 24
Initial commissioning . . . . . . . . . . . . . 25
Starting process . . . . . . . . . . . . . . . 28
Operation monitoring . . . . . . . . . . . . . 30
Exhaust gas aftertreatment system. . . . . . 34
Passive regeneration . . . . . . . . . . . . . 39
Stopping process . . . . . . . . . . . . . . . 42
4Operating media
. . . . . . . . . . . . . . . 43
Lubricating oil . . . . . . . . . . . . . . . . . 43
Fuel . . . . . . . . . . . . . . . . . . . . . . 45
Coolant . . . . . . . . . . . . . . . . . . . . 46
SCR reduction agent . . . . . . . . . . . . . 48
5Maintenance
. . . . . . . . . . . . . . . . . 49
Maintenance schedule . . . . . . . . . . . . 49
6Servicing and maintenance work
. . . . . . . 52
Lubricating oil system. . . . . . . . . . . . . 52
Fuel system. . . . . . . . . . . . . . . . . . 54
SCR. . . . . . . . . . . . . . . . . . . . . . 57
Cooling system . . . . . . . . . . . . . . . . 58
Engine cleaning. . . . . . . . . . . . . . . . 60
Suction system . . . . . . . . . . . . . . . . 61
Belt drives . . . . . . . . . . . . . . . . . . 63
Electrical system . . . . . . . . . . . . . . . 65
7Faults
. . . . . . . . . . . . . . . . . . . . .67
Fault table . . . . . . . . . . . . . . . . . . 67
Engine management . . . . . . . . . . . . . 72
8Transport and storage
. . . . . . . . . . . .74
Transport . . . . . . . . . . . . . . . . . . . 74
Engine corrosion protection . . . . . . . . . 75
9Technical data
. . . . . . . . . . . . . . . .79
Engine and setting data . . . . . . . . . . . 79
Tools . . . . . . . . . . . . . . . . . . . . . 81
OBJ_DOKU-44425-001.fm Seite 4 Montag, 7. Juli 2014 7:46 07

General
© 2014 5
1
DEUTZ diesel engines
DEUTZ diesel engines and the appropriate exhaust
aftertreatment components are the result of years of
research and development. The detailed know-how
gained by this in connection with the high quality de
-
mands are the guarantee for production of engines
with a long life, high reliability and low fuel consump
-
tion. Naturally the high demands for protection of the
environment are also met.
Safety precautions when the engine is running
Maintenance work or repairs may only be performed
on the shut-down engine. Make sure that the engine
cannot be started inadvertently - Danger of accident!
After repair work: Check that all guards have been
replaced and that all tools have been removed from
the engine.
Observe industrial safety regulations when running
the engine in an enclosed space or underground.
When working on the running engine, work clothing
must be close fitting.
Never fill the fuel tank while the engine is running.
Service and Maintenance
Service and maintenance are also decisive for
whether the engine satisfactorily meets the set de
-
mands. Recommended service intervals must there -
fore be observed and service and maintenance work
must be carried out conscientiously.
Special care should be taken under abnormally de
-
manding operating conditions.
Original DEUTZ parts
Original DEUTZ parts are subject to the same strict
quality demands as the DEUTZ engines. Further de
-
velopments for improving the engines are also intro -
duced in the original DEUTZ parts of course. Only
the use of original DEUTZ parts manufactured ac
-
cording to the state-of-the-art can guarantee perfect
functioning and high reliability.
DEUTZ Xchange components
DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high
as for new parts. DEUTZ replacement parts are
equal to the original DEUTZ parts in function and re
-
liability.
Asbestos
The gaskets used in this engine contain no asbestos.
Please use the appropriate original DEUTZ parts for
maintenance and repair work.
Service
We want to preserve the high performance of our en
-
gines, and with it the confidence and satisfaction of
our customers. We are therefore represented world-
wide by a network of service branches.
The DEUTZ name does not merely stand for engines
that are the products of extensive development
work, DEUTZ also stands for complete service pack
-
ages that ensure optimum operation of our engines,
and for customer services operations that you can
count on.
Please contact your DEUTZ-partner in case of mal
-
functions and sare parts inquiries. Our specially
trained personnel will ensure fast, professional re
-
pairs using original DEUTZ spare parts in case of
damage.
The DEUTZ homepage provides a continuously up
-
dated overview of the service partners near you, and
information on product areas and services.
Masthead
DEUTZ AG
Ottostraße 1
51149 Köln
Germany
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
www.deutz.com
California
Proposition 65 Warning
Diesel engines and some of its constituents are
known to the State of California to cause cancer,
birth defects and other reproductive harm.
OBJ_DOKU-44425-001.fm Seite 5 Montag, 7. Juli 2014 7:46 07

General
6© 2014
1
Danger
Caution
Notes
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.
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.
This symbol accompanies notes of a gen -
eral kind.
OBJ_DOKU-44425-001.fm Seite 6 Montag, 7. Juli 2014 7:46 07

Model Engine description
© 2014 7
2
Engine type designation
Emissions legislation
This manual covers the following engine types
TD 3.6 L4
TCD 3.6 L4
TCD
T Exhaust gas turbocharger
C Charge air cooler
DDiesel
3.6
3.6 Displacement in litres
L4
L in series
4 No. of cylinders
The engine and the corresponding EAT
system (Exhaust After Treatment) are
adapted to each other and linked by an ap
-
propriate electronic controller.
They are only certified by the responsible
authorities and comply with the permissible
exhaust limits in this combination.
Operation of the engine with other EAT
systems is not allowed.
The engines of these operating instructions fulfill
the following exhaust emissions regulations
TCD 3.6 L4
With exhaust aftertreatment system
USA EPA Tier 4 final
EU Stage IV
TD 3.6 L4<56 kW
With exhaust aftertreatment system
USA EPA Tier 4 final
EU Stage IV
The engines of this operating manual may
only be used with a functioning exhaust af
-
tertreatment system.
(if included in the DEUTZ scope of supply)
Rating plate
The type (A), engine number (B) and performance
data are stamped on the rating plate.
The engine type and number must be stated when
purchasing spare parts.
DEUTZ AGDEUTZ AG
MADE IN GERMANYMADE IN GERMANY
Mot.-Typ Mot.-Nr.Mot.-Nr.
R
B
A
OBJ_DOKU-44425-001.fm Seite 7 Montag, 7. Juli 2014 7:46 07

Engine description Model
8© 2014
2
Location of the rating plate
The rating plate (C) is fixed to the cylinder head cov
-
er or the crankcase.
C
Engine serial number
The engine number (D) is stamped onto the crank
-
case (arrow) and onto the rating plate.
XX
XXXXX
D
Serial numbers of the exhaust aftertreatment com -
ponents
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates.
1 Rating plate of the diesel oxidation catalytic
converter
1
OBJ_DOKU-44425-001.fm Seite 8 Montag, 7. Juli 2014 7:46 07

Model Engine description
© 2014 9
2
Serial numbers of the exhaust aftertreatment com -
ponents
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates.
1 Rating plate of the diesel oxidation catalytic
converter
2 Rating plate of the diesel particle filter
2 1
Serial numbers of the exhaust aftertreatment com -
ponents
The serial numbers of the exhaust aftertreatment
components are stamped on the rating plates.
1 Rating plate of the SCR catalyst
1
Cylinder numbering
Cylinder arrangement
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.
1
left
right
OBJ_DOKU-44425-001.fm Seite 9 Montag, 7. Juli 2014 7:46 07

Engine description Engine illustrations
10 © 2014
2
3
1
2
6
5
4
7
TD 3.6 L4
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 Lubricating oil dipstick
7 Coolant outlet
OBJ_DOKU-44425-001.fm Seite 10 Montag, 7. Juli 2014 7:46 07

Engine illustrations Engine description
© 2014 11
2
2
4
3
5
1
6
TD 3.6 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 Diesel oxidation catalytic converter
OBJ_DOKU-44425-001.fm Seite 11 Montag, 7. Juli 2014 7:46 07

Engine description Engine illustrations
12 © 2014
2
5
2
3
1
4
8
7
10
6
9
TCD 3.6 L4
Industrial engine
View from right (example)
1 Crankcase breather
2 Throttle valve
3 Tension pulley
4 V-rib belt
5 Coolant inlet
6 Lubricating oil drain plug
7 Lube oil replacement filter
8 Lubricating oil dipstick
9 Coolant outlet
10 Differential pressure flow meter
OBJ_DOKU-44425-001.fm Seite 12 Montag, 7. Juli 2014 7:46 07

Engine illustrations Engine description
© 2014 13
2
5
3
2
1
4
6
TCD 3.6 L4
Industrial engine
View from left (example)
1 Combustion air inlet
2 Lube oil cooler
3 Lubricating oil dipstick
Optional
4 Lube oil replacement filter
Optional
5 Generator
6 Lubricating oil filling
OBJ_DOKU-44425-001.fm Seite 13 Montag, 7. Juli 2014 7:46 07

Engine description Engine illustrations
14 © 2014
2
5
2
3
1
4
8
7
10
6
9
TCD 3.6 L4
Agricultural technology
View from right (example)
1 Exhaust outlet
2 Lubricating oil filling
3 V-rib belt
4 Tension pulley
5 Coolant inlet
6 Lubricating oil drain plug
7 Lubricating oil filling
8 Lube oil replacement filter
9 Coolant outlet
10 Combustion air inlet
OBJ_DOKU-44425-001.fm Seite 14 Montag, 7. Juli 2014 7:46 07

Engine illustrations Engine description
© 2014 15
2
1
2
TCD 3.6 L4
Agricultural technology
View from right (example)
1 Crankcase breather
2 Lubricating oil drain plug
OBJ_DOKU-44425-001.fm Seite 15 Montag, 7. Juli 2014 7:46 07

Engine description Lubricating oil diagram
16 © 2014
2
1
4
5
12
13
15 14 11
8
710 6932
Lubricating oil system
(example)
1 Lubricating oil sump
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 Piston cooling nozzle
12 Rocker arm
13 Hydraulic tappets
14 Turbocharger
15 Air compressor
Optional
OBJ_DOKU-44425-001.fm Seite 16 Montag, 7. Juli 2014 7:46 07

Fuel diagram Engine description
© 2014 17
2
12
7
8910
61154312
Fuel schematic (example)
1 Fuel tank
2 Fuel pre-filter
3 Fuel pump
(electrically powered)
4 Exchangeable fuel filter
5 Fuel transducer
6 High-pressure pump
with
– Control block FCU (Fuel Control Unit)
7Rail
8 Injector
9 Check valve
10 Return line
11 Fuel return to fuel tank
12 Engine control unit
OBJ_DOKU-44425-001.fm Seite 17 Montag, 7. Juli 2014 7:46 07

Engine description Coolant diagram
18 © 2014
2
x1 x2
1234
T
x1
610
987
123
4
x2
5
Coolant schematic (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 for cab heating
7 Temperature transmitter
8 Thermostat
9 Cooler
10 Compensation tank
OBJ_DOKU-44425-001.fm Seite 18 Montag, 7. Juli 2014 7:46 07

Exhaust gas recirculation Engine description
© 2014 19
2
89 7
154
32
6
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 Differential pressure flow meter
7 Exhaust gas partial flow
(cooled)
8 Mixing pipe
9 Throttle valve
OBJ_DOKU-44425-001.fm Seite 19 Montag, 7. Juli 2014 7:46 07

Engine description Exhaust gas aftertreatment
20 © 2014
2
2
3
4
5
6
7
1
98
Exhaust aftertreatment system
Example:
1 Decoupling line
2 Differential pressure sensor
3 Exhaust temperature sensor
4 Diesel oxidation catalytic converter
5 Diesel particle filter
Optional
6 Differential pressure sensor
7 Exhaust outlet
8 Differential pressure flow meter
9 Throttle valve
OBJ_DOKU-44425-001.fm Seite 20 Montag, 7. Juli 2014 7:46 07