D / TD / TCD 2.

9 L4

Operating manual
EU Stage IV & V / US EPA Tier 4
Notes
Notes ● As a general rule, only DEUTZ original parts may ● Wear suitable personal protective equipment (e.g.
be used when carrying out maintenance/repair ear protection, safety gloves, safety glasses,
● This engine is defined exclusively for purpose work on the engine. These have been designed protective clothing, safety helmet, safety shoes).
according to the scope of delivery and built by the especially for your engine and ensure fault-free
equipment manufacturer (use for the intended ● Only let the engine run when the bonnet / engine
operation. compartment is closed. Caution Risk of injury!
purpose). Any other use above and beyond this
will be considered as misuse. The manufacturer Maintenance/cleaning work on the engine may ● Do not approach a running engine if the bonnet /
will not accept any liability for damages resulting only be carried out when the engine is not running engine compartment is not closed. Attention
from this. The user bears the sole risk. and has cooled down. When performing such Risk of injury!
works, make sure that the electrical system is
● Use for the intended purpose also includes switched off (remove ignition key). ● It is generally not permitted to enter the engine
observance of the operating, maintenance and and/or engine and exhaust after-treatment parts.
repair instructions specified by the manufacturer. The rules for the prevention of accidents on Access is only permitted on specially designated
The engine may only be used, maintained and electrical systems (e.g. -VDE- and marked areas (treads). Attention Risk of
serviced by persons who are familiar with it and 0100/-0101/-0104/-0105 Electrical Protection injury! Risk of property damage!
are aware of the hazards. Measures against Dangerous Live Voltages) must ● Do not reach into the engine compartment (only
The relevant rules for the prevention of accidents be observed. permitted in case of service or maintenance using
and other generally recognised safety and Cover all electrical components tightly when suitable personal protective equipment and
occupational medicine rules must be observed. cleaning with liquids. trained personnel). Caution Risk of injury!
● Unauthorised modifications to the engine will ● The engine, engine parts and exhaust system can
Failure to observe the following safety be very hot — even after a long period of
exclude the manufacturer from all liability for instructions may result in damage to property,
resulting damage. downtime. Caution Risk of fire and injury!
environmental damage and serious injury to
● Equally, manipulations to the injection and control persons, including death! ● Regardless of the operating condition of the
system can affect the engine's performance and engine, the exhaust gas can be very hot and
the exhaust characteristics. In this case, ● Read the operating instructions before use. If you suddenly change its temperature. This applies in
compliance with environmental regulations will no have any trouble understanding these, please particular to regeneration mode. Caution Risk of
longer be guaranteed. contact DEUTZ Support [email protected] or your fire and injury!
local service partner. ● Engine parts and exhaust system may be sharp-
● Do not change the cooling air feed area to the
blower or fan. An unobstructed cooling air supply ● Make sure that the operating instructions are edged. Caution Risk of injury!
must be guaranteed. available to everyone who operates, maintains or ● Before working on the engine, take suitable
repairs the engine and that the contents have measures to ensure that the engine cannot be
The manufacturer will accept no liability for been understood.
damages resulting from this. started unintentionally. Caution Risk of injury!
● Before use, have a qualified person instruct you in ● Pay attention to unusual noises and switch off the
the operation of the device or the engine. engine in case of doubt! Risk of property
damage!

2 © 12/2018
 Notes
● In the event of smoke or fire in the engine ● Do not operate the engine unattended or without ● Observe noise protection and environmental
compartment, switch off the engine as quickly as monitoring. Caution Risk of injury! Risk of protection regulations (e.g. operation in drinking
possible. In the event of a fire, take yourself and property damage! water protection areas) Caution Risk of injury!
other persons to safety. Caution Risk of injury! ● Do not operate, maintain or repair the engine if Risk of environmental damage!
Risk of property damage! you are tired or unfocused. Caution Risk of ● Loud engine noise can severely impair voice
● Avoid open sources of fire and heat in the injury! Risk of property damage! communication and the perception of audible
immediate vicinity of the engine, exhaust after- ● Do not operate, maintain or repair the engine if warning signals. Caution Risk of injury! Risk of
treatment system and tank system. Caution Risk you are under the influence of medication, drugs property damage!
of injury! Risk of property damage! or alcohol, if you have any health restrictions or if ● Optical warning devices (e.g. display) may not be
● Only operate the engine in areas where there is a you are unable to do so. Caution Risk of injury! legible or only be legible to a limited extent under
risk of fire by observing special precautions. Note Risk of property damage! unfavourable environmental conditions. Caution
the risk assessment for working places. Caution ● Do not leave children or helpless persons Risk of property damage!
Risk of explosion, injury and fire! Risk of unattended near the engine. Caution Risk of ● Gas engines or engines with burners in the
property damage! injury! exhaust after-treatment system are equipped with
● The engine must not be operated in an explosive ● Do not swallow any engine fluids. Observe the a high-voltage ignition system. Observe the
atmosphere (according to ATEX Directive information in the safety data sheets. Caution corresponding warnings. Caution Risk of injury!
94/9/EC). Caution Risk of explosion, injury and Risk of injury! ● Electromagnetic fields emanating from the engine
fire! Risk of property damage! can influence the function of electrical and
● Do not swallow or drink any engine fluids, in
● If liquids, in particular oil, fuel and gases, are particular oil, fuel, hydraulic fluids, UREA electronic devices despite compliance with the
leaking, switch off the engine as quickly as ("AdBlue®") and coolant. Observe the information applicable directives on electromagnetic
possible. Do not smoke, use open light or fire. in the safety data sheets. Caution Risk of injury! compatibility (EMC). Caution Risk of property
Caution Risk of explosion, injury and fire! Risk damage!
of property damage! Risk of environmental ● Avoid inhaling exhaust, fuel, or oil vapours
(including gaseous fuels such as liquefied ● Persons with pacemakers should avoid the
damage! immediate vicinity of the engine. Caution Risk of
petroleum gas or natural gas). Caution Risk of
● Leaking liquids lead to an increased risk of poisoning and suffocation! injury!
slipping and falling. Caution Risk of injury! ● Only trained personnel may operate, maintain or
● Do not allow engine fluids to get into your eyes.
● Operate the engine only outdoors or with Avoid skin contact with the operating materials. service the engine. Access to the engine by
adequate ventilation (including shutting down the This applies in particular to oil, fuel, hydraulic unauthorised persons is prohibited. Caution Risk
device). Caution Note for LPG engines: LPG fluids, UREA ("AdBlue®") and coolant. Observe of injury! Risk of property damage!
(Liquefied Petroleum Gas) is heavier than air and the information in the safety data sheets. Caution ● Have the engine serviced regularly by authorised
can accumulate near the ground and in pits in Risk of injury! personnel in accordance with the manufacturer's
high concentrations! Caution Risk of explosion, instructions. Caution Risk of injury! Risk of
injury, poisoning and suffocation! property damage!

© 12/2018 3
Notes
● DEUTZ recommends the use of genuine DEUTZ
spare parts. Risk of property damage!
● When the intended engine service life is reached,
the engine must be subjected to a general
overhaul by authorised personnel or replaced.
Caution Risk of injury! Risk of property
damage!
● In addition to the safety instructions given in the
operating instructions, the safety instructions in
the technical bulletins (TR) must also be
observed.
● In addition to the safety instructions listed here,
special regulations of the vehicle manufacturer /
equipment manufacturer / machine manufacturer
or of the operator may apply.

4 © 12/2018
 Foreword
CALIFORNIA PROPOSITION 65 WARNING Please make sure that this operating manual is
available to everyone involved in the operation,
WARNING: Breathing diesel engine maintenance and repair of the engine and that they
exhaust exposes you to chemicals have understood the contents. Notes
known to the State of California to cause
cancer and birth defects or other If you have any queries, please contact us, we'll be Illustrations and data in this instruction manual are
reproductive harm. happy to advise you. subject to technical changes in the course of further
Always start and operate the engine in a Sincerely, development of the engine.
well-ventilated area.
If in an enclosed area, vent the exhaust to DEUTZ AG No parts of this document may be reproduced in any
the outside. form or by any means without our express approval.
Do not modify or tamper with the exhaust Engine number
DEUTZ engine registration
system.
Please enter the engine serial number here. This will
Do not idle the engine except as necessary.
simplify the handling of customer service, repair and
For more information go to
spare parts queries.
www.P65warnings.ca.gov/diesel

Dear customer,
Congratulations on the purchase of your DEUTZ
engine. Components of the exhaust aftertreatment
system
The liquid-cooled engines made by DEUTZ are
developed for a wide variety of applications. A Please enter the serial numbers of the exhaust
comprehensive range of variants ensures that the aftertreatment components.
respective special requirements are fulfilled.
Diesel oxidation catalytic converter
The engine is equipped accordingly for the particular
installation situation, i.e. not all the components
described in the operating manual are installed in DEUTZ AG aims to provide an excellent service
your engine. worldwide. In order to ensure this, information about
Diesel particle filter the locations of devices with DEUTZ engines is very
We have endeavoured to highlight any differences so helpful.
that you will be able to locate the operating and
maintenance instructions applicable to your engine
quickly and easily.
SCR catalytic converter

© 12/2018 5
Foreword
DUETZ engine registration is available for you at
www.deutz.com or using the code. You can enter
your DEUTZ engine data there directly so that your
engine can receive the best possible maintenance
from the global DEUTZ Service Network.

6 © 12/2018
 Table of contents
Notes ................................................ 2 Maintenance schedule ...................... 60
Foreword .......................................... 5 Service and maintenance work ........ 63
General ............................................. 8 Lubricating oil system ....................... 63
Engine description ............................ 10 Fuel system ...................................... 66
Model ................................................ 10 SCR (Selective Catalytic Reduction) 69
Engine illustration ............................. 14 Cooling system ................................. 70
Lubricating oil plan ............................ 22 Engine cleaning ................................ 72
Fuel system plan .............................. 23 Suction system ................................. 73
Coolant plan ..................................... 24 Belt drives ......................................... 75
Exhaust gas recirculation ................. 25 Electrical system ............................... 77
Exhaust gas aftertreatment .............. 27 Faults ................................................ 78
Electrics/Electronics ......................... 30 Fault table ......................................... 78
Operation .......................................... 32 Engine management ........................ 84
Ambient conditions ........................... 32 Transport and storage ...................... 86
Initial commissioning ........................ 34 Transport .......................................... 86
Start process .................................... 37 Engine corrosion protection .............. 87
Operation monitoring ........................ 38 Technical data .................................. 90
Exhaust gas aftertreatment system 42 Engine and setting data .................... 90
Regeneration Stage V / Tier 4 .......... 47 Tools ................................................. 92
Regeneration Stage IIIA, IIIB and
Tier 4i, 4 ............................................ 50
Stopping process .............................. 53
Operating media ............................... 54
Lubricating oil ................................... 54
Fuel ................................................... 56
Coolant ............................................. 57
SCR reduction agent ........................ 59
Maintenance ..................................... 60

© 12/2018 7
General
DEUTZ engines Original DEUTZ parts Please contact your DEUTZ partner in case of
malfunctions and spare parts inquiries. Our specially
DEUTZ engines and the appropriate exhaust Original DEUTZ parts are subject to the same strict trained personnel will ensure fast, professional
aftertreatment components are the result of years of quality demands as the DEUTZ engines. Of course, repairs using original DEUTZ spare parts in case of
research and development. The detailed know–how further developments for the improvement of the damage.
gained by this in connection with the high quality engines are also introduced in the original DEUTZ
demands are the guarantee for production of engines parts. Only the use of original DEUTZ parts The DEUTZ homepage provides a continuously
with a long life, high reliability and low fuel manufactured according to the state-of-the-art can updated overview of the service partners near you,
consumption. Naturally the high demands for guarantee perfect functioning and high reliability. and information on product areas and services.
protection of the environment are also met.
DEUTZ Xchange components Imprint
Safety precautions when the engine is running
DEUTZ replacement parts are a low-cost alternative. DEUTZ AG
Maintenance work or repairs may only be performed Of course, the quality standards here are just as high Ottostraße 1
on the shut-down engine. Make sure that the engine as for new parts. DEUTZ replacement parts are equal 51149 Cologne
cannot be started inadvertently — Danger of to the original DEUTZ parts in function and reliability. Germany
accident! Telephone:+49 (0) 221–822–0
Asbestos Fax:+49 (0) 221–822–3525
After repairs: Check that all protective equipment is E–mail:[email protected]
mounted and all tools have been removed from the The gaskets used in this engine contain no asbestos.
Please use the appropriate original DEUTZ parts for www.deutz.com
engine.
maintenance and repair work. Danger
Observe industrial safety regulations when running
the engine in an enclosed space or underground. Service
This symbol is used in all safety instructions
When working on the running engine, work clothing We want to preserve the high performance of our which, if not observed, present a direct
must be close fitting. engines and with it the confidence and satisfaction of danger to life and limb for the person
our customers. This is why we have a global network involved. Pay attention to it carefully.
Never fill the fuel tank while the engine is running. of service branches. Forward safety instructions to your operating
personnel as well. Furthermore, the
Service and maintenance The name DEUTZ means more than just engines legislation for "general regulations for safety
created as a result of sophisticated development and the prevention of accidents" must be
Service and maintenance are the prerequisite for the work, it also stands for a complete service package observed.
engine satisfying the demands placed on it. that guarantees the optimum operation of our
Compliance with the specified maintenance intervals engines as well as customer service that you can
and careful execution of service and maintenance count on.
work are therefore absolutely necessary.
Special care should be taken under abnormally
demanding operating conditions.

8 © 12/2018
 General
Caution

This symbol indicates a danger to the part

and engine. The relevant instructions must
be observed, failure to do so can lead to
destruction of the part and the engine.

Notes

You will find this symbol in all instructions of

the general type.

© 12/2018 9
Engine description Model
Engine type designation The engines of these operating instructions fulfill the (if include in the DEUTZ scope of supply)
following exhaust emissions regulations
This manual covers the following engine types
D 2.9 <37 kW
D 2.9 L4 With exhaust aftertreatment system
TD 2.9 L4 USA EPA Tier 4 final
EU Stage IIIA
TCD 2.9 L4 Stage V
TCD D 2.9 <37 kW
Without exhaust aftertreatment system
T Exhaust gas turbocharger
USA EPA Tier 4 I
C Charge air cooler
EU Stage IIIA
D Diesel
TD/TCD 2.9 <56 kW
2.9 With exhaust aftertreatment system
2.9 Displacement in litres USA EPA Tier 4 final
EU Stage IIIB
L4 Stage V
L in a row TD 2.9 <56 kW
Without exhaust aftertreatment system
4 Number of cylinders
USA EPA Tier 4 I
Emissions legislation EU Stage IIIA
TCD 2.9 >56 kW
The engine and the corresponding EAT
with exhaust aftertreatment system
system (Exhaust After Treatment) are
adapted to each other and linked by an USA EPA Tier 4 final
appropriate electronic controller. EU Stage IV
They are only certified by the responsible Stage V
authorities and comply with the permissible
exhaust limits in this combination. Operation The exact certification is printed on the engine rating
of the engine with other EAT systems is not plate.
allowed.
The engines of this operating manual may
only be used with a functioning exhaust
aftertreatment system.

10 © 12/2018
Model Engine description

Rating plate Position of the rating plate Engine number

The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cover The engine number (D) is attached to the crankcase
data are attached to the rating plate. or the crankcase. (arrow) and onto the rating plate.
The engine type and number must be stated when
purchasing spare parts.

© 12/2018 11
Engine description Model

Serial numbers of the exhaust aftertreatment Serial numbers of the exhaust aftertreatment Serial numbers of the exhaust aftertreatment
components components components
1 Rating plate of the diesel oxidation catalytic 1 Rating plate of the diesel oxidation catalytic 1 Rating plate of the SCR catalyst
converter converter
The serial numbers of the exhaust aftertreatment 2 Rating plate of the diesel particle filter The serial numbers of the exhaust aftertreatment
components are attached to the rating plates. components are attached to the rating plates.
The serial numbers of the exhaust aftertreatment
components are attached to the rating plates.

12 © 12/2018
Model Engine description

Cylinder numeration
I Left
II Right

Cylinder arrangement
The cylinders should be counted consecutively
starting from the flywheel (1).
Direction of rotation
Looking onto the flywheel.
Left-hand rotation: anti-clockwise
Engine sides
Looking onto the flywheel.

© 12/2018 13
Engine description Engine illustration
D 2.9 L4
Industrial engine
View from right (example)
1 Crankcase ventilation
2 Coolant outlet
3 Coolant supply flow to the cab heating
4 Coolant return flow from the cab heating
5 Tension pulley
6 V-rib belts
7 Coolant inlet
8 Exhaust outlet
9 Combustion air inlet

14 © 12/2018
Engine illustration Engine description
D 2.9 L4
Industrial engine
View from left (example)
1 Lubricating oil drain plug
2 Fuel filter
3 Lube oil spare filter
4 Lube oil filling

© 12/2018 15
Engine description Engine illustration
TD 2.9 L4
Industrial engine
View from right (example)
1 Crankcase ventilation
2 Coolant outlet
3 Coolant supply flow to the cab heating
4 Coolant return flow from the cab heating
5 Tension pulley
6 V-rib belts
7 Coolant inlet
8 Exhaust outlet

16 © 12/2018
Engine illustration Engine description
TD 2.9 L4
Industrial engine
View from left (example)
1 Lubricating oil drain plug
2 Fuel filter
3 Lube oil spare filter
4 Lube oil filling
5 Combustion air inlet

© 12/2018 17
Engine description Engine illustration
TCD 2.9 L4
Industrial engine
View from right (example)
1 Crankcase ventilation
2 Coolant outlet
3 Coolant supply flow to the cab heating
4 Coolant return flow from the cab heating
5 Tension pulley
6 V-rib belts
7 Coolant inlet
8 Charge air outlet
9 Exhaust outlet
10 Charge air inlet

18 © 12/2018
Engine illustration Engine description
TCD 2.9 L4
Industrial engine
View from left (example)
1 Lubricating oil drain plug
2 Fuel filter
3 Lube oil spare filter
4 Lube oil filling
5 Combustion air inlet

© 12/2018 19
Engine description Engine illustration
TCD 2.9 L4
Agricultural engineering
View from right (example)
1 Crankcase ventilation
2 Coolant outlet
3 Coolant supply flow to the cab heating
4 Coolant return flow from the cab heating
5 Tension pulley
6 V-rib belts
7 Lubricating oil drain plug
8 Coolant inlet
9 Charge air inlet
10 Charge air outlet
11 Exhaust outlet

20 © 12/2018
Engine illustration Engine description
TCD 2.9 L4
Agricultural engineering
View from left (example)
1 Lubricating oil drain plug
2 Combustion air inlet
3 Lube oil spare filter
4 Lube oil filling
5 Combustion air inlet

© 12/2018 21
Engine description Lubricating oil plan
Lubricating oil system
(example)
1 Lubricating oil pan
2 Lubricating oil pump
3 Pressure control valve
4 Lubricating oil cooler
5 Bypass valve
6 Pressure control valve
7 Lubricating oil filter
8 Main lube oil channel
9 Camshaft bearing
10 Crankshaft bearings
11 Piston cooling nozzle
12 Rocker arm
13 Hydraulic tappets
14 Exhaust gas turbocharger
15 Hydraulic pump
Optional

22 © 12/2018
Fuel system plan Engine description
Fuel schematic
(example)
1 Fuel tank
2 Fuel pre-filter
3 Fuel supply pump
(electric)
4 Fuel filter
5 Fuel transducer
6 Overflow valve
with control block FCU (Fuel Control Unit)
7 High-pressure storage vessel (rail)
8 Injector
9 Check valve
10 Return line
11 Fuel return to the fuel tank
12 Engine control unit

© 12/2018 23
Engine description Coolant plan
Coolant diagram
(example)
1 Coolant pump
2 Coolant supply for engine cooling
3 Lubricating oil cooler
4 Cylinder pipe/head cooling
5 Exhaust return cooler.
6 Connection possibility for cab heating
7 Temperature sensor
8 Thermostat
9 Compensation tank
10 Cooler

24 © 12/2018
Exhaust gas recirculation Engine description
Exhaust gas recirculation
Stage V / Tier 4
1 Exhaust partial flow
(uncooled)
2 Exhaust return cooler.
3 Flutter valve
4 Exhaust partial flow
(cooled)
5 Differential pressure flow meter
6 Mixing pipe
7 Coolant return
8 Actuator
(electric)
9 Coolant line of the cooler

© 12/2018 25
Engine description Exhaust gas recirculation
Exhaust gas recirculation
Stage IIIA, IIIB / Tier 4i, 4
1 Exhaust partial flow
(uncooled)
2 Actuator
(electric)
3 Exhaust return cooler.
4 Flutter valve
5 Exhaust partial flow
(cooled)
6 Mixing pipe
7 Coolant return
8 Coolant line to the cooler

26 © 12/2018
Exhaust gas aftertreatment Engine description
Exhaust gas aftertreatment system
Diesel oxidation catalytic converter
1 Decoupling line
2 Diesel oxidation catalytic converter
3 Exhaust outlet

© 12/2018 27
Engine description Exhaust gas aftertreatment
Exhaust gas aftertreatment system
Diesel particle filter
1 Throttle valve
2 Decoupling line
3 Diesel oxidation catalytic converter
4 Diesel particle filter
5 Exhaust outlet

28 © 12/2018
Exhaust gas aftertreatment Engine description
Exhaust gas aftertreatment system
SCR catalytic converter
1 Coolant line
for preheating the SCR tank
2 SCR tank
3 Solenoid valve
4 Engine control unit
5 SCR supply pump
6 SCR catalytic converter
7 NOx sensor
8 Metering unit
9 Pressure sensor
10 Temperature sensor
11 Diesel particle filter
12 Coolant line
for cooling the metering unit
13 SCR line

© 12/2018 29
Engine description Electrics/Electronics
Electronic engine control
1 Charge air pressure transmitter, charge air
temperature transmitter
2 Coolant temperature transmitter
3 Injector
4 Rail pressure sensor
5 Central connector (for engine control unit)
6 High-pressure pump
7 Speed sensor, crankshaft
8 Lubricating oil pressure transmitter
9 Alternator
10 Speed sensor, camshaft
11 Actuator of the exhaust gas return
12 Starter

30 © 12/2018
Electrics/Electronics Engine description
Information about the engine electronics Diagnostic and maintenance work may only Diagnostics
be carried out by authorised personnel using
This engine is equipped with an electric control unit. DEUTZ control units are equipped with self-
equipment approved by DEUTZ.
diagnostics. Active and passive error entries are
The equipping of the respective system depends on saved in the error memory. Active errors are
the desired scope of function and the planned type of Installation notes
displayed on error lamps/diagnostics lamps or a
engine application. display 84.
The control units are calibrated to the respective
The installation regulations of the DEUTZ AG must engine and identified by the engine number. Every
A diagnosis can be made with:
also be taken into account. engine may only be operated with the appropriate
control unit. ● Error lamp (flash code)
Precautions
Nominal value sensors (pedal position sensors) ● CAN bus
The connections of the control units are only required for vehicle operation must be connected to ● DEUTZ electronics display
dust and water proof when the mating plugs the cable harness on the vehicle side and calibrated
using the DEUTZ diagnostic program SERDIA ● Diagnostic socket (SERIDA)
are plugged (protection class IP69K)! The
control units must be protected against (SERvice DIAgnosis). Wiring and cable assignment Equipment-side wiring
spray water and moisture until plugging in of the vehicle side cable harness must be taken from
the mating plugs! the DEUTZ connection diagram. The DEUTZ AG installation regulations must be
Reverse polarity can lead to failure of the adhered to. In particular, the plug contact must be
Supply voltage crimped with the DEUTZ tools provided for this
control units.
To avoid damaging the control units, all the 12 Volt purpose. If it is necessary to do so, plugged-in
connections on the control unit must be contacts may only be removed from the plug housing
disconnected before electric welding work. 24 Volt with the proper tools.
Interventions in the electrical system
contrary to the DEUTZ regulations or by Sufficient charging of the battery must be ensured.
unqualified personnel can permamently Interruption of the power supply while the engine is
damage the engine electronics and have running can cause damage to the
serious consequences which are not electrics/electronics. Failure of the supply voltage
covered by the manufacturer's guarantee. leads to engine standstill.
It is strictly prohibited: Voltages above 32 Volt will destroy the control unit.
a) to make changes or add connections to
the wiring of the electrical control devices
and the data transmission cable (CAN lines).
b) to switch control units.
Warranty claims will otherwise be lost.

© 12/2018 31
Operation Ambient conditions
Use of engines in low load operation (engine does Coolant
not reach the operating temperature) over a long time
period under cold climatic conditions results in fuel ● Observe the mixing ratio of anti-freeze/cooling
waste, increased wear and potentially to engine water 57.
damage. These low temperature conditions result in The following possibilities can be considered by
incomplete combustion and therefore to a build-up of the device manufacturer or retrofitted by
deposits on components within the engine. In authorised specialist personnel:
addition, operating an engine with low exhaust
temperatures and low exhaust gas mass flow can ● Warming the cooling circuit and/or the oil circuit
cause premature faults such as engine or the when the engine is not running.
exhaust aftertreatment system failure. ● Maintaining the desired engine operation
The following measures can be taken by the temperature, particularly in low-load operation,
operator: requires:
– Superimposition of additional load through the
Lubricating oil application.
Low ambient temperature
● Select the lubricating oil viscosity according to the – Use of a device cooler hood or housing.
The operation of engines under cold or even Arctic ambient temperature. – Housing the oil pan and the underside of the
climatic conditions requires modifications to the ● Halve the oil change times in case of frequent engine in order to protect against cold air
engine during installation, engine operation and cold starts. through the engine fan.
maintenance. If these modifications are not taken into
account, this can have an impact on the engine Fuel – If possible, use of a temperature-dependent
starting properties, performance, reliability and the fan coupling.
● Use winter fuel below 0 °C 56.
operation of the corresponding exhaust ● Insulation of fuel lines, filters, pumps or even
aftertreatment system. Battery tanks.
● The battery must be well-charged before the ● Warming of the intake air through intake air
Operating an engine under cold or Arctic
engine is started 77. preheating or diverting the warm engine
climatic conditions without suitable
● Warming the battery to about 20°C improves the compartment air.
modifications can affect the warranty.
engine starting behaviour. (Remove and store the ● Warming the crankcase ventilation.
battery in a warm room). If you have any additional questions, please contact
Cold start aid your equipment supplier or DEUTZ partner.
● The engines in these operating instructions are
equipped with glow plugs 37.

32 © 12/2018
Ambient conditions Operation
High ambient temperature, high altitude

These engines are equipped with an electric

control unit.
Under the operating conditions listed below,
the amount of fuel is reduced automatically,
controlled by the electronic control unit.

● Application at high altitude

● Application at high ambient temperatures
Reason: Air density decreases as altitude or ambient
temperature increase. This also reduces the quantity
of oxygen in the engine intake air resulting in a
fuel/air mixture that is too fatty without any reduction
in the fuel injection rate.
● The results would be:
– black smoke in the exhaust
– high engine temperature
– reduced engine performance
– possible impairment of the starting behaviour
If you have any additional questions, please contact
your equipment supplier or DEUTZ partner.

© 12/2018 33
Operation Initial commissioning
Preparation for initial commissioning The engines are generally supplied without
lubricating oil filling.
(maintenance schedule E 10)
Select the engine lubricating oil quality and
● Remove corrosion protection from protected viscosity before filling.
engine. DEUTZ lubricating oils can be ordered from
your DEUTZ partner.
● Remove and existing transport devices.
● Check battery and cable connections and install if ● Fill the engine with lubricating oil via the oil filler
necessary. neck.
● Check the belt tension 75. ● Observe the lubricating oil filling level 90.
● Have the engine monitor or warning system
checked by authorised personnel.
● Check engine mounting.
● Check all hose connections and clips for correct
fit. Pour in fuel
The following actions must be performed Never fill the fuel tank while the engine is
additionally for generally overhauled engines: running.
Pay attention to cleanliness. Do not spill any
● Check the fuel pre-filter and main filter and
fuel.
change if necessary.
Additional venting of the fuel system by a 5-
● Check suction intake air filter (if available, minute trial run on no-load or low load is
maintain according to maintenance pointer). absolutely essential.
● Drain lubricating oil and condensation from the C- Only use clean commercially available brand
intercooler. diesel fuel. Observe fuel quality 56.
Use summer or winter-grade fuel depending
● Fill up with engine lubricating oil.
on the ambient temperature.
● Filling the coolant system 90.
● Fuel low-pressure system must be vented before
Fill up with engine lube oil. initial start-up after filling with the electric fuel
supply pump. 66.
Lack of lube oil or overfilling lead to engine
damage.

34 © 12/2018
Initial commissioning Operation
If the filled medium (e.g. diesel) has not ● Engine operation with open thermostat 2 - 3
reached the lines and supply pump/metering minutes.
module, emptying and thoroughly cleaning ● Check the coolant level and top up coolant if
the SCR tank is sufficient. necessary.
Pay attention to cleanliness.
Danger of scalding from hot coolant!
AdBlue® minimum refilling quantity Cooling system under pressure!
Only open the cap when cool! Observe
When fuelling with AdBlue®, the following minimum safety regulations and national specifications
refilling quantities must be adhered to. Filling below when handling cooling media.
the prescribed minimum refilling quantity is only
permissible if the tank does not have sufficient spare ● If required, repeat procedure with engine start.
tank volume at the time of filling.
● Fill up coolant to the MAX mark on the
Tank volume Minimum refilling compensation tank and close the cooling system
quantity cap.
Filling with AdBlue® ● Switch on any available heating and set to the
< 20 litres 5 litres or a full tank
≥ 20 litres 10 litres or a full tank highest level so that the heating circuit is filled
AdBlue® is known by different names
and vented.
depending on the region:
in the USA as DEF (Diesel Exhaust Fluid), in Filling the coolant system ● Observe the filling volume of the cooling system
Brazil as ARLA32. 90.
The technical designation is AUS32. The coolant must have a prescribed
AdBlue® is a registered trademark of the concentration of cooling system corrosion Trial run
Verband der Automobilindustrie e.V (VDA - protection agent!
Never operate the engine without coolant, Additional venting of the fuel system by a 5-
German Association of the Automotive
not even briefly! minute trial run on no-load or low load is
Industry).
absolutely essential.
Only re-fuel when the engine is not running. Order coolant corrosion protection agent
from your DEUTZ partner. Carry out a brief trial run up to operating temperature
Only fill with AdBlue®! (approx. 90 °C) after preparations.
Other media (e.g. diesel), even in the
smallest amounts, can cause destruction of ● Fill cooling system via the compensation tank. Do not load the engine if possible.
the system.
● Close compensation tank with valve. ● Work with the engine not running:
If you have filled with e.g. diesel and this has
got into the system, the complete SCR ● Start the engine and warm up until the thermostat – Check engine for tightness.
injection system must be replaced! opens.
– Check lubricating oil level, if necessary re-fill

© 12/2018 35
Operation Initial commissioning
– Check the coolant level and top up coolant if
necessary.
● Work during the trial run:
– Check engine for tightness.

36 © 12/2018
Start process Operation
Before starting make sure that there is ● the maximum start duration is limited.
nobody in the engine/work machine hazard ● the pause between two start attempts is specified.
zone.
– the start is then continued automatically
After repairs: Check that all protective
equipment is mounted and all tools have ● starting while the engine is running is prevented.
been removed from the engine. If the touch start function is programmed, a short start
When starting with glow plugs do not use command with the ignition key in position 2 or a start
any additional starting devices (e.g. injection button, if available, suffices.
with start pilot). Danger of accident!

If the engine fails to fire and the error lamp

lights, the electronic engine control has
activated the start lock to protect the engine.
The start lock is released by switching off
the system with the ignition key for about 30
seconds. with cold starting device
Start the engine for a maximum of 20
seconds uninterrupted. If the engine does ● Insert key.
not start up, wait for one minute and then – Step 0 = no operating voltage.
repeat the starting process. ● Turn key to the right.
If the engine does not start up after two
starting processes, determine the cause as – Step 1 = operating voltage.
per fault table. 78. – Engine is ready for operation.
Do not run the engine up to high idling
● The electronic engine control activates the current
speed/full load operation straight from cold.
feed to the glow plugs when the engine coolant
temperature falls below a certain temperature.
Disconnect the engine by uncoupling
devices to be driven where possible. ● Push in the key and turn further to the right
against the spring pressure.
– Level 2 = start.
● release the key as soon as the engine starts up.
– Pilot lamps go out.
If the starter is controlled by the electronic engine
control via a relay:

© 12/2018 37
Operation Operation monitoring
Electronic engine control – Engine forced to run at low power to cool the
engine, with automatic shutdown if necessary.
The system monitors the condition of the engine and
itself. – The switch-off process has been
accomplished.
● Function test – There may be a start lock after engine stop.
– Ignition on, error lamp lights up for approx. 2 – The start lock is deactivated by turning off the
seconds and then goes out. system with the ignition key for approx. 30
– Check the error lamp if there is no reaction seconds.
after switching on the ignition. – Additional control lamps, e.g. for lubricating oil
● Error light does not light up. pressure or lubricating oil temperature, are
– After the lamp test an extinguished lamp switched on if necessary.
indicates an error-free and trouble-free – In order to avoid critical situations the power
operating state within the scope of the control reduction can be bypassed, automatic switch-
possibilities. off delayed or a start lock bypassed using the
optional override key on the instrument panel. Display instrument
● Continuous light
This brief deactivation of the engine protection Possible displays:
– Error in system. functions is logged in the control unit.
– Operation continued with restrictions. The engine protection functions are released in ● Colour scale
– The engine must be checked by a DEUTZ cooperation with the equipment manufacturer and the – Display of operating state by coloured areas:
partner. DEUTZ installation consulting and may be designed – green = normal operating state
– If a lamp lights steadily a monitored measuring individually. This is why the operating manual of the
device manufacturer must be observed. – red = critical operating state
variable (e.g. coolant temperature, lubricating Take suitable action.
oil pressure) has left the permissible value
range. ● Measured value scale
Depending on the fault, the engine power may be – Actual value can be seen directly. The target
reduced by the electronic engine control to protect value must be taken from the technical data.
the engine. 90.

● Flashing
– Serious error in system.
– Switch off prompt for the operator. Attention:
Failure to do so will lead to loss of guarantee!
– The engine has reached switch-off condition.

38 © 12/2018
Operation monitoring Operation
Instruments and symbols

Instruments/symbols Designation Possible displays Measure

Lube oil pressure indicator Lubricating oil pressure in the red 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 control Lubricating oil below minimum Switch off engine
light

Lubricating oil level Lubricating oil pressure too low Shut down the engine, allow to cool and top up with
lubricating oil

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

Operating time counter Indicates the engine operating time passed Observe the maintenance intervals

© 12/2018 39
Operation Operation monitoring
Instruments/symbols Designation Possible displays Measure
Horn With acoustic signal See fault table 78

SCR function lamp Continuous light Check AdBlue® filling level

Flashing Check SCR system

Ash lamp Continuous light The ash lamp indicates, that loading of the diesel
particle filter with incombustible residues has reached a
critical level and must be replaced. 47

Regeneration lamp Continuous light Initiate standstill regeneration 47

Flashing

Engine warning lamp Continuous light Initiate standstill regeneration in combination with the
Flashing regeneration lamp 47

40 © 12/2018
Operation monitoring Operation
● Fuel pressure
● Status of the regeneration of the diesel particle
filter
● Operation monitoring of the diesel particle filter
● Faults in the exhaust aftertreatment system
● Filling level of the SCR tank
● Battery voltage
● Position of the accelerator pedal
● Fuel consumption
● Operating hours
Error messages are displayed in clear text and
acoustically; the error memory of the control unit can
DEUTZ Electronic Display be read out.

In order to show measured values and error For a detailed description, refer to the operating
messages of the EMR control unit, a CAN display is instructions enclosed with the DEUTZ Electronic
optionally available, which can be integrated into the Display.
dashboard of the driver´s position of working
machines.
The following data may be displayed if they are sent
by the control unit.
● Engine speed
● Engine torque (current)
● Coolant temperature
● Intake air temperature
● Exhaust gas temperature
● Lubricating oil pressure
● Coolant pressure
● Charge air pressure

© 12/2018 41
Operation Exhaust gas aftertreatment system
Selective Catalytic Reduction (SCR) An acoustic signal must sound in case of a Standstill regeneration
fault. If a DEUTZ display is used, this has an
The DEUTZ SCR system reduces the NOx emissions Temperatures of approx. 600 °C occur on
appropriate signal.
from the engine (NOx=nitric oxides). the exhaust pipe during regeneration.
An acoustic signal transmitter must be
A reduction agent, AdBlue®, injected into the exhaust installed additionally if an SCR function lamp A special engine operating state becomes
system reacts in the SCR catalytic converter with the or customer display is used. active during standstill regeneration and the
NOx emissions in the exhaust gas and reduces these machine is not allowed to be used during the
Power reduction active standstill regeneration.
to nitrogen (N 2) and water (H 2O).
Danger of burns!
If a serious fault occurs or a fault is not remedied, the
The injected volume of SCR is controlled by the system reacts by reducing the engine performance. The SCR system is monitored for possible formation
engine electronics. and build-up of crystals (crystallisation)
There is a one or two-stage performance reduction
Warning strategy SCR system depending on the type of fault. As soon as crystalisation is detected, a standstill
regeneration request is issed.
The display and monitoring of the exhaust Power reduction
aftertreatment system can be executed This is displayed by a flashing regeneration lamp.
either with pilot lights or with a CAN interface Stage 1 Torque reduction
and a corresponding display, depending on Stage 2 Torque reduction The standstill regeneration must be initiated by the
the engine version. + Engine speed limitation operator.
Please see the device manufacturer's
operating manual. Bridging of the power reduction It is recommended that standstill regeneration be
undertaken as soon as possible.
A separate emergency switch has been provided, in
In order to comply with the regulations of the If standstill regeneration is not undertaken, the
order to temporarily disable power reductions caused
European Union (EU) and the Environmental engine control unit will activate the specified engine
by the exhaust aftertreatment system.
Protection Agency (EPA), the DEUTZ SCR system protection functions.
reacts with a warning strategy to faulty operation of This function is available for a limited period and is
the exhaust gas aftertreatment system. expected to enable the user to move the machine to Every standstill regeneration slightly dilutes the
a safe location. engine oil with fuel. The number of standstill
Emission-relevant faults are: regenerations is therefore monitored.
This function is available for engines with power
● AdBlue® filling level
reduction levels 1 and 2, in accordance with EU
● Catalytic converter efficiency/Adblue® quality legislation, and with power reduction level 1, in
accordance with EPA legislation.
● Manipulation
● System fault

42 © 12/2018
Exhaust gas aftertreatment system Operation
AdBlue® filling level
Warnings begin from an AdBlue® filling level below 15 %.

AdBlue® filling level SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
< Continuous light OFF SCR symbol None
15% Text message
< flashes (0.5 Hz) OFF SCR symbol None
10% Text message
< 5% flashes (0.5 Hz) Continuous light SCR symbol None
Acoustic signal Text message
Acoustic signal
< 5% ≥ 10 min flashes (1 Hz) Continuous light SCR symbol Stage 1
Acoustic signal Text message
Acoustic signal
< 5% ≥ 15 min flashes (2 Hz) Flashing SCR symbol Stage 1
Acoustic signal Text message
Acoustic signal
< 5% ≥ 20 min flashes (2 Hz) Flashing SCR symbol Stage 2
Acoustic signal Text message
Acoustic signal

Catalytic converter efficiency/AdBlue® quality

If the catalytic converter efficiency (conversion rate) is too low, warnings are sent to the SCR function lamp or optionally to the CAN display despite previous refuelling.
Warnings are also given due to use of the wrong reduction agent.

Catalytic converter SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
efficiency/AdBlue®
quality
too low Continuous light Continuous light SCR symbol Stage 1
Acoustic signal Text message After pre-warning time
Acoustic signal
too low Continuous light Flashing SCR symbol Stage 2
not remedied Acoustic signal Text message After pre-warning time
Acoustic signal

© 12/2018 43
Operation Exhaust gas aftertreatment system
Manipulation
If the system detects a manipulated part or use of the wrong reduction agent, the performance is reduced. The performance is reduced in stages and depends on the motor
performance.

Manipulation SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
detected Continuous light Continuous light SCR symbol Stage 1
Acoustic signal Text message After pre-warning time
Acoustic signal
not remedied Continuous light Flashing SCR symbol Stage 2
Acoustic signal Text message After pre-warning time
Acoustic signal

System fault
System faults may be faults of individual SCR components such as an implausible NOx or temperature sensor value. The performance is reduced if the SCR injection is
impaired by a system fault.

System fault SCR function lamp Engine warning lamp DEUTZ CAN display Power reduction
detected Continuous light Flashing SCR symbol None
Acoustic signal Text message
Acoustic signal
detected ≥ 10min Continuous light Flashing SCR symbol Stage 2
Acoustic signal Text message
Acoustic signal

Crystalisation
Crystalisation results when the engine's workload is too low, or its operating times are too short.

System fault Regeneration lamp Engine warning lamp DEUTZ CAN display Power reduction
detected flashes (0.5 Hz) OFF Text message None
Standstill regeneration Acoustic signal
required
detected flashes (0.5 Hz) Continuous light Text message Stage 1
Standstill regeneration Acoustic signal
required

44 © 12/2018
Exhaust gas aftertreatment system Operation
System fault Regeneration lamp Engine warning lamp DEUTZ CAN display Power reduction
detected flashes (3 Hz) Flashing Text message Stage 2
Standstill regeneration Acoustic signal
required

© 12/2018 45
Operation Exhaust gas aftertreatment system
Diesel oxidation catalyst (DOC) Regeneration
The diesel oxidation catalytic converter has a The passive particle filter system burns the soot in
catalytic surface which is used to convert the the filter with the nitrogen oxide contained in the
pollutants in the exhaust gas into harmless exhaust, which is first oxidised in the DOC. This
substances. Here, carbon monoxides and unburned process takes place continuously as soon as the
hydrocarbons are made to react with oxygen and exhaust temperature exceeds 250 °C. The passive
converted into carbon dioxide and water. In addition, particle filter system does not contain a burner. A
the nitrogen monoxides are converted to nitrogen prerequisite for the passive continuous regeneration
dioxides. is having a sufficient ratio of nitrogen oxides to soot in
the raw exhaust gas of the engine.
Temperatures > 250 °C are necessary for a high
degree of efficiency. Regeneration differs depending on the variant of the
external exhaust gas recirculation and exhaust
Diesel particle filter (DPF) emissions stage. 25
The combustion of diesel fuel results in soot, which is
separated in the diesel particle filter. This must be
regenerated as the contamination with soot
increases. That means that the soot in the diesel
particle filter is burned.
The regeneration is based on a continuous
regeneration process, which is activated as soon as
the exhaust temperature of 250 °C is exceeded at
the inlet of the exhaust gas aftertreatment system.
The filter contamination with soot is monitored
continuously by the engine control unit.

46 © 12/2018
Regeneration Stage V / Tier 4 Operation
Normal operation There is a one or two-stage performance reduction This is displayed by a flashing regeneration lamp.
depending on the type of fault.
Under normal operating conditions (exhaust The standstill regeneration must be initiated by the
temperature > 250 °C), the filter contamination with Power reduction operator.
soot remains in a permissible range and no actions Stage 1 Torque reduction
are necessary. We recommend carrying out a necessary standstill
Stage 2 Torque reduction regeneration as quickly as possible, as otherwise the
The regeneration lamp is OFF. + Engine speed limitation diesel particle filter will continue to become
contaminated with soot.
Support mode Bridging of the power reduction
If the standstill regeneration is not carried out, the
During this operating state, an acoustic A separate emergency switch has been provided, in engine control unit will activate the specified engine
change occurs to the running of the engine. order to temporarily disable power reductions caused protection functions, depending on the contamination
by the exhaust aftertreatment system. of the diesel particle filter.
If the operating conditions of the engine do not permit This function is available for a limited period and is Every standstill regeneration slightly dilutes the
any passive regeneration, the contamination of the expected to enable the user to move the machine to lubricating oil with fuel. The number of standstill
diesel particle filter with soot will increase. a safe location. regenerations is therefore monitored.
A throttle valve controlled via the engine control unit This function is available for engines with power Implementation of the standstill regeneration
is located in the combustion air inlet. This is used to reduction levels 1 and 2, in accordance with EU
increase the exhaust gas temperature for legislation, and with power reduction level 1, in The engine must be brought into a "safe state" for the
regeneration of the diesel particle filter, if this is not accordance with EPA legislation. regeneration:
reached during normal operation.
Standstill regeneration ● Shut down the engine on an open terrain at a safe
This can be the case if: distance to flammable objects.
Temperatures of approx. 600 °C occur on ● Warm up the engine; the coolant temperature
● The engine only has short operating times. the exhaust pipe during regeneration. must reach at least 75 °C.
● The engine workload is not high. A special engine operating state becomes
active during standstill regeneration and the ● Operate the engine in idling.
This process is automatically activated by the engine
machine is not allowed to be used during the ● The engine control unit now requires a signal
control unit, the operator does not need to perform
active standstill regeneration. indicating that the unit is safely parked (stationary
any actions.
Danger of burns! signal).
The regeneration lamp is OFF. ● This occurs independently of the application, for
If the support mode does not attain an adequate example by:
Power reduction reduction of the soot contamination, the filter will
continue to become contaminated with soot and a – Activating the parking brake.
If a serious fault occurs or a fault is not remedied, the standstill regeneration will be necessary. – Engaging a specified gear position in the
system reacts by reducing the engine performance.
gearbox.

© 12/2018 47
Operation Regeneration Stage V / Tier 4
● Operating the release button. If the standstill regeneration request is not observed
Position depends on application, see device and the diesel particle filter is overloaded to an
manual. impermissible level, then the diesel particle filter can
The regeneration lamp lights up continuously. only be regenerated via DEUTZ service.

Once the standstill regeneration has been released, Replacing the diesel particle filter
the engine automatically increases the speed level. It may be necessary to replace the diesel particle
Using the device during standstill regeneration is filter after a high filter running time as non-
prohibited. combustible residues accumulate in the diesel
particle filter - so-called ash.
The regeneration lasts 35 to 40 minutes on average.
If the ash loading goes beyond a certain level, this
The standstill regeneration can be interrupted at any will be indicated by the ash lamp.
time by pressing the regeneration button again or by
removing the regeneration release. The diesel particle filter needs to be replaced.

Using the device during standstill regeneration also The machine can operate normally until the
leads to it being interrupted. replacement is carried out by the service.

The request for standstill regeneration remains until it The time interval between two regeneration requests
is completed without interruption. is shortened in proportion to the run time.

Certain engine faults lead to excessive carbon Please contact your DEUTZ partner.
emissions from the engine which cannot be seen due DEUTZ particle filters come with a catalysing coating,
to the diesel particle filter. so require a special cleaning procedure to prevent
In such cases, the diesel particle filter can be loaded damage to the coating. The DEUTZ filter replacement
very quickly, among other things, to a level which no programme guarantees that the filter medium is
longer allows a standstill regeneration by the properly cleaned, and the medium fully functions and
operator. performs as if it were a new part!

Very short intervals between two standstill

regenerations (<10 hours) can be an indication of
such a defect.
Please contact the DEUTZ service.
The regeneration lamp goes out when regeneration
has been successfully completed.

48 © 12/2018
Regeneration Stage V / Tier 4 Operation
Display of the regeneration control
The display and monitoring of the exhaust aftertreatment system can be executed either with pilot lights or with a CAN interface and a corresponding display, depending on the
engine version.

Instruments/symbols Power reduction Remark

Regeneration lamp Engine warning lamp Ash lamp

OFF OFF OFF Normal operation
OFF OFF OFF Support mode
flashes (0.5 Hz) OFF OFF Standstill regeneration required
Approval by the operator required
flashes (0.5 Hz) Continuous light OFF Stage 1 Standstill regeneration required
Approval by the operator required
flashes (3 Hz) Flashing OFF Stage 2 Please contact your DEUTZ partner
Continuous light OFF OFF Standstill regeneration
OFF OFF Continuous light 100% ash load
Please contact your DEUTZ partner
OFF OFF Flashing 105% ash load
Please contact your DEUTZ partner
OFF Continuous light Flashing Stage 1 110% ash load
Please contact your DEUTZ partner

© 12/2018 49
Operation Regeneration Stage IIIA, IIIB and Tier 4i, 4
Normal operation There is a one or two-stage performance reduction Every standstill regeneration slightly dilutes the
depending on the type of fault. engine oil with fuel. The number of standstill
Under normal operating conditions (exhaust regenerations is therefore monitored..
temperature > 250 °C), the filter contamination with Power reduction
soot remains in a permissible range and no actions Stage 1 Torque reduction Implementation of the standstill regeneration
are necessary.
Stage 2 Torque reduction The engine must be brought into a "safe state" for the
The regeneration lamp is OFF. + Engine speed limitation regeneration:
Support mode Standstill regeneration ● Shut down the engine on an open terrain at a safe
distance to flammable objects.
During this operating state, an acoustic Temperatures of approx. 600 °C occur on ● Warm up the engine; the coolant temperature
change occurs to the running of the engine. the exhaust pipe during regeneration. must reach at least 75 °C.
A special engine operating state becomes
active during standstill regeneration and the ● Operate the engine in idling.
If the operating conditions of the engine do not permit
machine is not allowed to be used during the ● The engine control unit now requires a signal
any passive regeneration, the contamination of the
active standstill regeneration. indicating that the unit is safely parked (stationary
diesel particle filter with soot will increase.
Danger of burns! signal).
A throttle valve controlled via the engine control unit ● This occurs independently of the application, for
is located in the combustion air inlet. This is used to If the support mode does not attain an adequate example by:
increase the exhaust gas temperature for reduction of the soot contamination, the filter will
continue to become contaminated with soot and a - Activating the parking brake.
regeneration of the diesel particle filter, if this is not
reached during normal operation. standstill regeneration will be necessary. - Engaging a specified gear position in the
gearbox.
This can be the case if: This is displayed by a flashing regeneration lamp.
● Operating the release button.
● The engine only has short operating times. The standstill regeneration must be initiated by the Position depends on application, see device
operator. manual.
● The engine workload is not high.
This process is automatically activated by the engine We recommend carrying out a necessary standstill The regeneration lamp lights up continuously.
control unit, the operator does not need to perform regeneration as quickly as possible, as otherwise the
any actions. diesel particle filter will continue to become Once the standstill regeneration has been released,
contaminated with soot. the engine automatically increases the speed level.
The regeneration lamp is OFF.
If the standstill regeneration is not carried out, the Using the device during standstill regeneration is
Power reduction engine control unit will activate the specified engine prohibited.
protection functions, depending on the contamination
If a serious fault occurs or a fault is not remedied, the of the diesel particle filter. The regeneration lasts 35 to 40 minutes on average.
system reacts by reducing the engine performance.

50 © 12/2018
Regeneration Stage IIIA, IIIB and Tier 4i, 4 Operation
The standstill regeneration can be interrupted at any If the ash loading goes beyond a certain level, this
time by pressing the regeneration button again or by will be indicated by the ash lamp.
removing the regeneration release.
The diesel particle filter needs to be replaced.
Using the device during standstill regeneration also
leads to it being interrupted. The machine can operate normally until the
replacement is carried out by the service.
The request for standstill regeneration remains until it
is completed without interruption. The time interval between two regeneration requests
is shortened in proportion to the run time.
Certain engine faults lead to excessive carbon
emission which cannot be seen due to the diesel Please contact your DEUTZ partner
particle filter. DEUTZ particle filters come with a catalysing coating,
In such cases, the diesel particle filter can be loaded so require a special cleaning procedure to prevent
very quickly, among other things, to a level which no damage to the coating. The DEUTZ filter replacement
longer allows a standstill regeneration by the programme guarantees that the filter medium is
operator. properly cleaned, and the medium fully functions and
performs as if it were a new part!
Very short intervals between two standstill
regenerations (<10h) can be an indication of such a
defect.
Please contact the DEUTZ service.
The regeneration lamp goes out when regeneration
has been successfully completed.
If the standstill regeneration request is not observed
and the diesel particle filter is overloaded to an
impermissible level, then the filter can only be
regenerated via the DEUTZ service.
Replacing the diesel particle filter
It may be necessary to replace the diesel particle
filter after a high filter running time as non-
combustible residues accumulate in the filter - so-
called ash.

© 12/2018 51
Operation Regeneration Stage IIIA, IIIB and Tier 4i, 4
Display of the regeneration control
The display and monitoring of the exhaust aftertreatment system can be executed either with pilot lights or with a CAN interface and a corresponding display, depending on the
engine version.

Instruments/symbols Power reduction Remark

Regeneration lamp Engine warning lamp Ash lamp

OFF OFF OFF Normal operation
OFF OFF OFF Support mode
flashes (0.5 Hz) OFF OFF Standstill regeneration required
Approval by the operator required
flashes (1 Hz) Continuous light OFF Stage 1 Standstill regeneration required
Approval by the operator required
flashes (1 Hz) Flashing OFF Stage 2 Please contact your DEUTZ partner
Continuous light OFF OFF Standstill regeneration
OFF OFF Continuous light 100% ash load
Please contact your DEUTZ partner
OFF OFF Flashing 105% ash load
Please contact your DEUTZ partner

52 © 12/2018
Stopping process Operation
Lag time

The control unit remains active for about

another 40 seconds to save the system data
(lag) and then switches off automatically.

Shutting down

Avoid switching off from full load

(coking/blockage of the remaining lubricating
oil in the turbocharger bearing housing). The
turbocharger's lube oil supply is no longer
ensured! This shortens the life of the
turbocharger.
Run the engine in low idling speed for
approximately one minute after relieving the
load.

● Move the key to position 0.

– P = gear position: park
– 0 = gear position: Shut down engine
– 1 = gear position: Ignition on
– 2 = gear position: Start engine

© 12/2018 53
Operating media Lubricating oil
General The lubricating oil quality has a considerable The following lubricating oils are permissible for the
influence on the life, efficiency and thus the economy engines in this operating manual:
Modern diesel engines place very high demands on of the engine. As a general principle, the better the
the lubricating oil used. The specific engine lubricating oil quality, the better these properties. Permissible quality class
performances increased constantly in recent years DEUTZ Other
lead to increased thermal stress of the lubricating oil. The lubricating oil viscosity describes the way the
In addition, the lubricating oil is subject to heavier lubricating oil flows, depending on the temperature. Engines with exhaust aftertreatment system
contamination due to reduced lubricating oil The lubricating oil viscosity only has a small influence DQC III LA * Please contact your DEUTZ
consumption volumes and increased lubricating oil and effect on the quality of the oil. DQC IV LA * partner or visit www.deutz.com
change intervals. For this reason it is necessary to Engines without exhaust aftertreatment system
observe the requirements and recommendations Synthetic lubricating oils are used increasingly and
described in this operating manual in order not to offer advantages. These lubricating oils have better DQC III Please contact your DEUTZ
shorten the life of the engine. temperature and oxidation stability, as well as DQC III LA * partner or visit www.deutz.com
relatively low cold viscosity. Since some processes
DQC IV
Lubricating oils always consist of a base lubricating which are relevant for determining the lubricating oil
oil and an additive package. The additives perform change times are largely dependent on the oil quality DQC IV LA *
the most important tasks of a lubricating oil (e.g. wear (e.g. the infiltration of soot and other contamination), * Sulphur content in the fuel
protection, corrosion protection, neutralisation of the oil change time for synthetic lubricating oils may < 15 mg/kg
acids from combustion products, prevention of coke not be increased in relation to the specifications on
and soot deposits on the engine components). The lubricating oil change intervals. For low-ash engine oils released according to the
properties of the base lubricating oil are also decisive DQC system, an appropriate reference is made in the
for the quality of the product, e.g. with regard to the Biodegradable lubricating oils may be used in oil release list.
thermal load. DEUTZ engines if they meet the requirements of this
operating manual. DEUTZ lubricating oils DQC II
In principle, all engine lubricating oils of the same TLS - 15W40 D
specification can be mixed. Mixtures of engine Quality
Not for engines with exhaust gas aftertreatment
lubricating oils should however be avoided because Lubricating oils are classified by DEUTZ according to Container Ordering number:
the worst properties of the mixture always dominate. their efficiency and quality class (DQC: DEUTZ 5 litre canister 0101 6331
The lubricating oils approved by DEUTZ AG have Quality Class). the higher the quality class (DQC I, II,
III, IV), the more effective/the better quality the 20 litre canister 0101 6332
been thoroughly tested for all engine applications.
The active ingredients they contain are compatible lubricating oil is. 209 litre barrel 0101 6333
with each other. Therefore, the use of additives for The DQC quality classes are still to be extended by
lubricating oils is not permitted in DEUTZ engines. the DQC-LA quality classes which include the
modern, low-ash lubricating oils (LA = Low Ash).
The choice of lubricating oil essentially depends on
the exhaust aftertreatment system.

54 © 12/2018
Lubricating oil Operating media
DEUTZ lubricating oils DQC III - Continuous ambient temperatures below -10
TLX - 10W40 FE °C (14 °F) or lubricating oil temperature below
Not for engines with exhaust gas aftertreatment 60 °C (140 °F).
Container Ordering number: - Sulphur content in the diesel fuel >0.5 mass
fraction.
5 litre canister 0101 6335
● If the prescribed lubricating oil change intervals
20 litre canister 0101 6336
are not reached within a year, the lubricating oil
209 litre barrel 0101 6337 must be changed at least once a year.
DEUTZ lubricating oils DQC IV, low ash Viscosity
DEUTZ Oil Rodon 10W40 Low SAPS
The ambient temperature at the installation site or in
Container Ordering number: the area of application of the engine is decisive for
20 litre canister 0101 7976 selecting the right viscosity class. Too high a
209 litre barrel 0101 7977 viscosity can lead to starting difficulties, too low a
viscosity can endanger the lubricating effect and
DEUTZ lubricating oils DQC IV synthetic result in high lubricating oil consumption. At ambient
DQC IV - 5W30-UHP temperatures below -40 °C, the lubricating oil must
Not for engines with exhaust gas aftertreatment be pre-heated (e.g. by storing the vehicle or the
machine in a hall).
Container Ordering number:
20 litre canister 0101 7849 The viscosity is classified according to SAE. Oils
209 litre barrel 0101 7850 suitable for multiple ranges must always be used.

Lubricating oil change intervals The prescribed lubricating oil quality must be
observed when selecting the viscosity class!
● The intervals depend on:
- Lubricating oil quality Depending on the ambient temperature we
- Sulphur content in the fuel recommend the following common viscosity classes.
- Engine application type
- Number of standstill regenerations
● The lubricating oil replacement interval must be
halved if at least one of the following conditions
applies:

© 12/2018 55
Operating media Fuel
Permissible fuels Exhaust gas after-treatment systems The respective fuels prescribed by law must be used
without to comply with the national emission regulations (e.g.
In order to satisfy the exhaust gas legislation, diesel sulphur content).
engines that are equipped with an exhaust
aftertreatment system may only be operated with a The following fuel specifications are approved: Please contact your DEUTZ partner or visit
sulphur-free diesel fuel. ● Diesel fuels www.deutz.com
The operational reliability and durability of the - EN 590 (B7) Winter operation with diesel fuel
individual exhaust aftertreatment technologies cannot sulphur <500 mg/kg
be assured upon failure to comply. Special demands are placed on the cold behaviour
- ASTM D 975 Grade 1-D S15 Quality (temperature limit value of the filtrability) for winter
Exhaust gas after-treatment systems - ASTM D 975 Grade 2-D S15 Quality operation. Suitable fuels are available at fuel stations
sulphur <500 mg/kg in winter.
SCR Selective catalytic reduction
DOC Diesel oxidation catalytic converter ● Biodiesel fuel mixtures
For engines with common rail injection, the
DPF Diesel particle filter - EN 16734 (B10) mixing of petroleum and adding of extra low
- EN 16709 (B20 / B30) additives is not permissible.
The following fuel specifications are approved:
- ASTM D 7467
At low ambient temperatures paraffin discharges can
● Diesel fuels ● Synthetic and paraffinic fuels lead to blockages in the fuel system and cause
- EN 590 (B7) - EN 15940 operating faults. Winter diesel fuel must be used at
sulphur <10 mg/kg ambient temperatures below 0 °C (up to -20 °C) (this
● Light heating oils
- ASTM D 975 Grade 1-D S15 is offered at fuel stations in good time before the start
- In EN 590 quality of winter).
- ASTM D 975 grade 2-D S15 sulphur <500 mg/kg
sulphur <15 mg/kg ● Special diesel fuels can be used for arctic
The warranty is excluded when using other fuels
● Biodiesel fuel mixtures climates up to -44 C.
which do not meet the requirements of this operation
- EN 16734 (B10) manual.
- EN 16709 (B20 / B30) The certification measurements for compliance with
- ASTM D 7467 the legal emission limit values are carried out with the
test fuels specified in the laws. These correspond to
● Synthetic and paraffinic fuels
the diesel fuels described in this operating manual
- EN 15940 according to EN 590 and ASTM D 975. With the
● Light heating oils other fuels described in this operating manual, no
emission values are guaranteed.
- In EN 590 quality
sulphur <10 mg/kg

56 © 12/2018
Coolant Operating media
General The water must be conditioned if it deviates from the DEUTZ cooling system corrosion protection
analysis values. agent
Never operate the engine without coolant,
● pH value too low: Specifications Remarks
not even briefly!
Add diluted caustic soda or potassium soda. It is DQC CA-14 siliceous on the basis of MEG
advisable to make small test mixtures. DQC CB-14 free of silicates on the basis of
In liquid-cooled engines, the coolant must be organic acids (OAT) and MEG
conditioned and monitored, otherwise the engine ● Total hardness too high:
could be damaged by: DQC CC-14 free of silicates on the basis of
Mixing with softened water (pH neutralized organic acids (OAT) and MEG
● corrosion condensate or water softened by ion exchanger).
● Cavitation DEUTZ cooling system corrosion protection
● Chlorides and/or sulphates too high: agent
● freezing Mixing with softened water (pH neutralized Container Ordering number:
● overheating condensate or water softened by ion exchanger).
5 litre canister 0101 7990
Water quality Cooling system protective agent 20 litre canister 0101 7991
The right water quality is important for conditioning 210 litre barrel 0101 7992
Health damaging nitrous amines form when
the coolant. Clear, clean water within the following nitrite-based cooling system corrosion The DEUTZ cooling system protection agent
analysis values should always be used: protection agents are mixed with amine- corresponds to quality class DEUTZ DQC CB-14.
based agents!
Analysis values min max ASTM This cooling system corrosion protection agent is free
ph value 6.5 8.5 D 1293 Cooling system corrosion protection agents from nitrite, amine and phosphate and is adapted to
Chlorine (Cl) [mg/l] - 100 D 512 must be disposed of in an environmentally the materials in our engines. Order from your DEUTZ
D 4327 friendly way. partner.
Sulphate (SO 4) [mg/l] - 100 D 516 Observe the notes on the safety data sheet.
If the DEUTZ cooling system corrosion protection
Total hardness [m- 3.56 D 1126 The coolant is conditioned for liquid-cooled DEUTZ agent is not available please contact your DEUTZ
(CaCO 3) mol/l] 356 engines by mixing an antifreeze with corrosion partner or visit www.deutz.com.
protection inhibitors on an ethylene-glycol base with The cooling system must be monitored regularly. This
[°dGH] 20.0 - the water. also includes checking the coolant system corrosion
[°e] 25.0 -
Products released are recorded according to the protection agent concentration in addition to checking
[°fH] 35.6 the coolant level.
following DEUTZ cooling system protection
Specifications of the water quality are made by the specifications. The control of the concentration of the cooling system
local water board. protection agent can be done using the DEUTZ
Refractometer (Order number: 0293 7499).

© 12/2018 57
Operating media Coolant
Cooling system Water Cold
corrosion percentage protection
protection agent up to
percentage
min. 35 % 65 % −22 °C
40 % 60 % −28 °C
45 % 55 % −35 °C
max. 50 % 50 % −41 °C

At temperatures below − 41 °C, please contact your

responsible DEUTZ partner.
It is possible to use other cooling system corrosion
protection agents (e.g. chemical corrosion protection
agents) in exceptional cases. Consult your DEUTZ
partner.

58 © 12/2018
SCR reduction agent Operating media
AdBlue® (SCR reducing agent) It crystallises at −11 °C and at over +35°C a
hydrolysis reaction is initiated, i.e. it begins to slowly
AdBlue® is known by different names release ammonia and carbon dioxide.
depending on the region:
in the USA as DEF (Diesel Exhaust Fluid), in Direct sunlight on exposed storage containers must
Brazil as ARLA32. always be avoided.
The technical designation is AUS32. Barrels must not be stored for longer than one year!
AdBlue® is a registered trademark of the
Verband der Automobilindustrie e.V (VDA - Ensure that the materials and storage containers
German Association of the Automotive used are resistant to AdBlue®.
Industry).
AdBlue® freezes below −11°C ambient temperature.
Protective gloves and goggles must be worn It is necessary to preheat the SCR system at ambient
when handling AdBlue®. temperatures below − 11 °C.
Do not swallow.
Ensure sufficient ventilation. DEUTZ offers its customers an additive reducing SCR tank
Pay attention to cleanliness. agent, DEUTZ® PowerBlue.
Residues of AdBlue® must be disposed of in The SCR tank may only be filled with AdBlue®. Filling
an environmentally friendly manner. The patented formula improves the injection pattern with other media can lead to destruction of the
Observe the notes on the safety data sheet. of the urea solution and prevents crystallisation and system.
potential blocking of the catalytic converter.
Exhaust gas after-treatment systems In this case the metering pump must be replaced.
Users with frequent applications in low load
SCR Selective catalytic reduction operation, with several starts and stops and at low AdBlue® should not remain in the tank for longer
external temperatures benefit in particular from the than 4 months.
AdBlue® is a highly-pure, aqueous, 32.5% urea additive reducing agent.
solution which is used as an NOx reduction agent for This must be documented.
SCR exhaust aftertreatment in vehicles with diesel DEUTZ® PowerBlue
engines. Empty and clean the SCR tank when
Container Ordering number: decommissioning.
The product is designated as AdBlue® or AUS 32 10 litre canister 0101 6546
(AUS: Aqueous Urea Solution) and must correspond Please contact your DEUTZ partner
208 litre barrel 0101 6547
to the DIN 70070, ISO 222411 or ATSTM D 7821. 1000 litre canister 0101 4648 or see www.deutz.com
The length of time that AdBlue® can be kept without
losing quality depends on the conditions of its
storage.

© 12/2018 59
Maintenance Maintenance schedule
Assignment of the DEUTZ maintenance and service schedules to the maintenance intervals

Routine maintenance work plan

D/TD/TCD 2.9 L4
Stage Activity To be performed by: Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised qualified personnel When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 oh in continuous operation
1) 2) 3) 4)
E30 Maintenance Qualified personnel 500
1) 2) 3) 4)
E40 Extended maintenance I 1,000
4)
E50 Extended maintenance II Authorised qualified personnel 3,000
4) 5)
E70 Major overhaul 5,000
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved. 54
2)
Specification for lubricating oil change interval, based on lubricating oil quality DQC III.
3)
For engines with a < 6.5 litre lube oil change volume with filter, the lubricating oil change interval must be shortened as follows:
2)
D 2.9 L4 750 h
2)
TD / TCD 2.9 L4 350 h
4)
The display of the operating hours should be ensured by the device manufacturer. The engine operating hours are recorded by the control unit. Enquiry via the CAN
bus and display in a display or creation/display via electromechanical counter.
5)
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.

60 © 12/2018
Maintenance schedule Maintenance
Maintenance measures

Stage Activity Measure

E10 The measures are described in the Operation chapter.
E20 Check Lubricating oil level (refill when necessary)
Coolant level (refill when necessary)
Check engine for tightness (visual check for leakage)
Exhaust system including exhaust aftertreatment components for leaks
Suction air filter/dry air filter (if available maintain according to maintenance pointer)
Emptying of the water tank in the fuel pre-filter
E30 Check Coolant (additive concentration) 70
Intake air pipes for damage 73
V-belts 75
Replace TD / TCD 2.9 L4:
Lube oil A lube oil application/change strategy adapted optimally to the individual engine application type can be created, for example,
with the DEUTZ oil diagnosis. Ask your DEUTZ partner. 63
TD / TCD 2.9 L4:
Lubricating oil filter/insert (every time the lubricating oil is changed) 63
Fuel filter
for filter size 0.6 L 66
E40 Check C-intercooler cooler inlet area (drain lube oil/condensation)
battery and cable connections 77
Cold starting device
Engine mounting (tighten if necessary, renew if damaged)
Fastenings, hose connections/clips (renew if damaged)
V-rib belt and tensioning pulley 75

© 12/2018 61
Maintenance Maintenance schedule
Stage Activity Measure
E40 Replace D 2.9 L4:
Lube oil A lube oil application/change strategy adapted optimally to the individual engine application type can be created, for example,
with the DEUTZ oil diagnosis. Ask your DEUTZ partner. 63
D 2.9 L4:
Lubricating oil filter/insert (every time the lubricating oil is changed) 63
Fuel filter
for filter size 0.9 L 66
Fuel pre-filter 66
Dry air filter 73
V-belts 75
SCR-feed pump filter cartridge 69
E50 Replace V-rib belt and tensioning pulley 75
annually Check Engine monitor, warning system To be maintained by authorised service personnel only!
Replace Fuel filter 66
Fuel pre-filter 66
Lubricating oil 63
Lubricating oil filter/insert (every time the lubricating oil is changed) 63
Every 2 Replace Dry air filter 73
years V-belts 75
Every 3 Replace SCR-feed pump filter cartridge 69
years
Every 4 Replace Coolant 70
years
Status Change Dry air filter (if available maintain according to maintenance pointer) 73
dependent Diesel particle filter, the required change is displayed by the ash lamp or via an electronic display, depending on the engine version
(see DEUTZ change programme)
Empty Fuel pre-filter with water trap. If the warning system is activated (lamp/horn), the water trap bowl must be emptied immediately. 66

Maintenance diagram
A self-adhesive maintenance diagram is provided with every engine. This should be stuck to the engine or device in a prominent position.
Ordering number: 0312 3897 (D/TD/TCD 2.9 L4)
62 © 12/2018
Lubricating oil system Service and maintenance work
Regulations for working on the lubricating oil ● The lubricating oil level must always be between
system MIN- and MAX-1 markings! If necessary, fill up to
MAX-marking.
Do not work on the running engine!
Smoking and naked lights are prohibited! Changing the lubricating oil
Be careful with hot lubricating oil. Danger of
scalding! 550 operating hours after the last standstill
regeneration, the control unit automatically
requests a new standstill regeneration to
Ensure the highest degree of cleanliness
reset the soot load of the diesel particulate
when working on the lubricating oil system.
filter or to refresh the SCR system. The
Carefully clean the area around the
counter is then reset automatically.
components concerned. Blow wet parts dry
It is therefore recommended to have a
with compressed air.
standstill regeneration done by an
Observe safety regulations and national
authorised DEUTZ partner each time before
regulations when working with lube oils!
changing the lubricating oil. This avoids any
Dispose of leaking lube oil and filter Checking the lubricating oil level. premature fuel ingress into the lubricating
elements according to regulations. Do not
oil.
allow used lube oil to seep into the ground. Lack of lube oil or overfilling lead to engine
Do a trial run after all work. Pay attention to damage. ● Run the engine warm (lubricating oil temperature
leakage and lube oil pressure and then The lubricating oil level may only be checked > 80 °C).
check the engine lube oil level. when the engine is horizontal and switched
● Position the engine or vehicle / device so as to be
off.
level.
Only check lubricating oil level whilst warm,
5 minutes after shutting down. ● Shut down engine
● Position a collecting vessel under the lubricating
Be careful with hot lubricating oil. Danger of oil drain plug .
scalding! ● Unscrew the lubricating oil drain plug, drain the
Do not pull out the dipstick while the engine lubricating oil.
is running. Danger of injury!
- In the case of agricultural technology engines
● Pull out the lubricating oil dipstick and wipe off with a separate oil pan, both oil drain plugs
with a lint-free, clean cloth. must be unscrewed.
● Insert the lubricating oil dipstick as far as it goes. ● Turn in and tighten lubricating oil drain plug fitted
with new sealing ring.
● Remove the lubricating oil dipstick and read the
lubricating oil level. Tightening torque:

© 12/2018 63
Service and maintenance work Lubricating oil system
55 Nm
● Fill in lubricating oil.
- Quality/viscosity information. 54
- Filling volume. 90
● Run the engine warm (lubricating oil temperature
> 80 °C).
● Position the engine or vehicle so as to be level.
● Check lubricating oil level, if necessary re-fill

Change lubricating oil filter ● Oil the seal of the new DEUTZ original spare filter
lightly.
Filter may never be pre-filled. Danger of ● Screw on new filter by hand until the gasket is
soiling! touching and tighten.
Tightening torque:
● Loosen and unscrew filter with tool (order no.:
0189 9142). 10 Nm - 12 Nm
● Collect escaping lube oil.
● Clean the sealing surface of the filter carrier with
a clean, lint-free cloth.

64 © 12/2018
Lubricating oil system Service and maintenance work

© 12/2018 65
Service and maintenance work Fuel system
Specifications when working on the fuel system Clean and dry the engine and engine
compartment thoroughly before beginning
Engine must be switched off! work.
Smoking and naked lights are prohibited! Areas of the engine compartment from
No injection/high pressure pipes may be which dirt could be loosened must be
disconnected while the engine is running. covered with a fresh, clean foil.
Careful with hot fuel. Work on the fuel system may only be carried
Ensure the highest degree of cleanliness out in an absolutely clean environment.
when refuelling and working on the fuel Contamination of the air such as dirt, dust,
system. moisture etc. must be avoided.
Carefully clean the area around the
components concerned. Blow wet parts dry
with compressed air.
Observe safety regulations and national
regulations when working with fuels.
Dispose of leaking fuel and filter elements
Replace fuel filter cartridge
properly. Do not allow fuel to seep into the
ground. Filter may never be pre-filled. Danger of
After all works on the fuel system, the soiling!
system should be vented, a trial run
performed and the tightness checked.
It is necessary to vent the fuel system when ● Remove clamps when twist protection mounted
recommissioning, following maintenance (optional).
work or if the tank has been completely Loosen and unscrew filter with tool (order no.:
emptied. 0189 9142).

Additional venting of the fuel system by a 5- ● Collect escaping fuel.

minute trial run on no-load or low load is ● Clean the sealing surface of the filter carrier with
absolutely essential. a clean, lint-free cloth.
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Make a visual inspection for leaks/damage
in the system.

66 © 12/2018
Fuel system Service and maintenance work

● Oil the seal of the new DEUTZ original spare filter Change/vent fuel pre-filter
lightly.
1 Fuel supply flow to the pump
● Screw on new filter by hand until the gasket is
touching and tighten. 2 Venting screw
Tightening torque: 3 Electrical connection for water level sensor
4 Drain plug
10 Nm - 12 Nm
5 Filter cartridge
● Vent the fuel system. 6 Fuel supply from the fuel tank.
Empty water tank
● Shut down engine
● Place suitable collecting containers underneath.
● Electrical connection
- Disconnect cable connections.
● Loosen drain plug.
● Drain fluid until pure diesel fuel runs out.
● Mount drain plug.

© 12/2018 67
Service and maintenance work Fuel system
Tightening torque: Vent the fuel system
1.6 Nm ± 0.3 Nm Failure to observe the venting process will
● Electrical connection result in damage to the high-pressure pump
of the injection system.
- Connect cable connections.
The fuel system is vented via the electric fuel supply
Change the fuel pre-filter insert pump.
● Shut down engine In order to ensure that no error messages are
● Shut off the fuel supply to the engine (with high generated, no attempt should be made to start the
lying tank). system up whilst venting.
● Place suitable collecting containers underneath. This process is carried out as follows:
● Electrical connection
● Ignition "ON"
- Disconnect cable connections.
The electronic fuel supply pump switches on for 20
● Loosen drain plug and drain liquid. seconds in order to vent the fuel system and build up
● Disassemble filter insert. the required fuel pressure.
● Clean any dirt off the sealing surfaces of the new Wait until the electric fuel supply pump is
filter cartridge and opposite side of filter head. disconnected from the control unit.
● Wet the sealing surfaces of the filter cartridge
slightly with fuel and screw back on to the filter ● Ignition "OFF"
head, clockwise. Repeat the process at least 4 times until the fuel
Tightening torque: system is vented.

17 Nm - 18 Nm
● Mount drain plug.
Tightening torque:
1.6 Nm ± 0.3 Nm
● Electrical connection
- Connect cable connections.
● Open the fuel shutoff tap and vent the system,
see venting the fuel system.

68 © 12/2018
SCR (Selective Catalytic Reduction) Service and maintenance work

Change the filter cartridge of the SCR supply ● Insert new filter insert with compensation body.
pump ● Mount cover.
1 Cover Tightening torque:
2 Compensation body 22.5 Nm ± 2.5 Nm
3 Filter cartridge
● Electrical connection
Protective gloves must be worn when – Connect cable connections.
working with components of the SCR ● Start the engine.
system.
Pay attention to cleanliness.

● Shut down engine

● Electrical connection
– Disconnect cable connections.
● Place suitable collecting containers underneath.
● Remove cover.
– Socket wrench insert 27 mm
● Pull out filter insert and compensation body.

© 12/2018 69
Service and maintenance work Cooling system
Specifications when working on the cooling
system

Danger of scalding from hot coolant!

Cooling system under pressure! Only open
the cap when cool!
The coolant must have a prescribed
concentration of cooling system corrosion
protection agent!
Observe safety regulations and national
specifications when handling cooling media.
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do
not allow them to seep into the ground.
Order coolant corrosion protection agent
Check coolant additive concentration Emptying the cooling system
from your DEUTZ partner.
Never operate the engine without coolant, ● Open the cooling system cap (1) carefully. ● Open cooler locking cap carefully.
not even briefly!
● Check the coolant additive concentration in the ● Place suitable collecting containers underneath.
Checking the coolant level with an external cooler cooler/compensation tank (2) with a conventional ● Remove the locking screw (1) in the crankcase.
antifreeze measuring device (1) (e.g. hydrometer,
● Fill in new coolant and vent the system according refractometer). ● Drain the coolant.
to the specifications of the cooling system ● Necessary coolant additive concentration Coolant ● Insert the locking screw (1) with a new sealing
manufacturer. mixing ratio. 57 ring.
● Open the cooling system cap (1) carefully. The corresponding test device can be ordered from Tightening torque:
● The coolant level must always be between the your DEUTZ partner under the order no.: 0293 7499. 26 Nm
MIN and MAX marks of the compensation tank!
● Close cooler locking cap.

70 © 12/2018
Cooling system Service and maintenance work

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 (opening
temperature of the thermostat).
● Shut down engine
● Check coolant level in the cooled engine and top
up to the MAX mark or filling level on the
compensation tank if necessary.

© 12/2018 71
Service and maintenance work Engine cleaning
Cleaning work Cleaning with cold cleaner

With all cleaning work it must be ensured ● Spray the engine with cold cleaner and leave it for
that components are not damaged (e.g. bent about 10 minutes to take effect.
cooler grille etc.). ● Spray the engine clean with a high pressure water
Cover electrical/electronic parts and jet.
connections to clean the engine (e.g. control ● Warm up the engine so that the water residues
units, generator, solenoid valves etc.). Do evaporate.
not aim water/steam jet directly at them. Run
the engine warm afterwards. Cleaning with a high pressure cleaner

Only carry out cleaning work on the engine ● Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam
Remove the engine cover and cooling air temperature 90 °C, distance at least 1 meter).
hood if applicable and replace after cleaning. ● Warm up the engine so that the water residues
The respective applicable environmental evaporate.
regulations must be observed. ● Always clean the cooler and cooling fins from the
exhaust air side to the fresh air side.
General
The following causes of contamination make cleaning
the engine necessary:
● High dust content in the air
● Chaff and chopped straw in the area of the engine
● Coolant leaks
● Lubricating oil leakage
● Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of soiling.
Cleaning with compressed air
● Blowing dirt off or out. Always blow the cooler and
cooling fins from the exhaust air side to the fresh
air side.

72 © 12/2018
Suction system Service and maintenance work
Regulations for working on the intake system Renewing the safety cartridge of the dry air filter

Do not work on the running engine! Never clean the safety cartridge (4).

Ensure the highest degree of cleanliness ● Renew the safety cartridge (4) at the interval
when working on the intake system, close specified in the maintenance schedule.
intake openings if necessary. ● To do this:
Dispose of old filter elements properly. – Unscrew hexagon nut (5), pull out safety
cartridge (4).
– Insert new safety cartridge, screw on
hexagonal nut.
● Insert filter element (3), mount filter hood (2) and
fix with clamping yoke (1).
Maintaining the dry air filter

Do not clean the filter element (3) with petrol

or hot liquids!
Renew damaged filter elements.

● Maintain the filter element (3) according to the

interval in the maintenance schedule.
● Lift up the clamping yoke (1).
● Remove the filter hood (2) and pull out the filter
element (3).
● Filter element (3):
– blow out with dry compressed air (max. 5 bar)
from the inside to the outside if soiling is only
slight,
– renew if heavily soiled.

© 12/2018 73
Service and maintenance work Suction system

Maintenance indicators for dry air filter Clean the dry air filter dust discharge valve.
● The dry air filter is maintained according to a ● Empty the dust discharge valve (1) by pressing
maintenance indicator or service gauge. together the discharge slit.
● Maintenance is necessary when: ● Remove any stuck on dust residues by squeezing
– the yellow indicator light of the maintenance the upper area of the valve.
switch illuminates when the engine is running. ● Clean the discharge slit.
– the red field (1) of the maintenance indicator
is fully visible.
● After completion of the maintenance work push
the reset button on the service gauge. The
service gauge is ready for operation again.

74 © 12/2018
Belt drives Service and maintenance work
Checking the belt drive

Only carry out work on the belt drive with the

engine at a standstill!
After repairs: Check that all protective
equipment is mounted and all tools have
been removed from the engine.

● Check the entire belt drive visually for damage.

● Renew damaged parts.
● Remount protective devices if necessary.
● Pay attention to correct fit of new belts, check the
tension after running for 15 minutes.

Replace V-rib belt Checking the V-belt tensioning

1 Tension pulley ● Lower indicator arm (1) into the measuring
2 Retaining pin device.
3 Assembly bore ● Place guide (3) between two belt pulleys on the
V-belt (2). The stop must be at the side.
● Press tensioning roller with socket wrench in the ● Press the button (4) at right angles to the V-belt
direction of the arrow until a retaining pin can be (2) evenly until you hear or feel the spring snap in.
fixed in the assembly bore. The V-ribbed belt is
● Lift the measuring device carefully without altering
now tension free.
the position of the indicator arm (1).
● First pull the V-ribbed belt off the smallest roller or ● Read the measured value at the point of
off the tensioning roller. intersection (arrow), scale (5) and indicator arm
● Mount new V-ribbed belt. (1).
● Retain tensioning pulley using the pin wrench and ● Retighten and repeat the measurement if
remove the holding pin. necessary.
● Tension V-ribbed belt using the tensioning roller Tool
and socket wrench. Check whether the V-ribbed
belt is correctly in its guide. The belt tension measuring device (order no.: 0189
9062) is available to order from your DEUTZ partner.

© 12/2018 75
Service and maintenance work Belt drives
Screw (3) M8 30 Nm
Screw (3) M10 42 Nm

Replace V-belt
1 Screw
2 Screw
3 Screw

● Loosen all screws and lock nuts.

● Move the generator in direction (B) until the V-belt
is slack.
● Remove belt and fit new one.
● Move the generator in direction (A) until the V-belt
has attained the correct tension.
● Checking V-belt tensioning. 90
● Tighten all screws and lock nuts again.
Tightening torque:
Screw (1) 42 Nm
Screw (2) 30 Nm

76 © 12/2018
Electrical system Service and maintenance work
Regulations regarding work on the electrical Fire, sparks, smoking and naked lights are
system prohibited!
Danger of acid burns! Wear protective
Do not touch live parts, replace faulty gloves and glasses! Avoid contact with skin
indicator lamps immediately. and clothing.
Danger of short circuit! Do not place tools on
top of the battery!
Pay attention to correct polarity of the
connections. Removing the battery
Cover electrical/electronic parts and
connections to clean the engine (e.g. control ● When clamping off the battery, always disconnect
units, generator, solenoid valves etc.). Do the negative pole first. Otherwise there is a risk of
not aim water/steam jet directly at them. Run a short circuit!
the engine warm afterwards. ● Remove the fastenings and take out the battery.
Under no circumstances may the voltage be
tested by tapping against the earth cable. Installing the battery
During electrical welding work, the earthing
terminal of the welding device must be ● Insert new or charged battery and attach the
directly clamped to the part to be welded. fastenings.
Three-phase current generator: Do not ● Clean the terminals and battery poles with fine-
interrupt the connection between the battery, grained sandpaper.
generator and controller while the engine is
● When connecting, connect the plus pole first and
running.
then the minus pole. Otherwise there is a risk of a
Battery short circuit!
● Make sure the terminals have a good contact.
When clamping off the battery, electronically Tighten the clamping screws by hand.
stored data may be lost. ● Grease the assembled terminals with an acid-
Keep the battery clean and dry. free, acid-resistant grease.
Make sure that the battery fits correctly and
tightly.
Dispose of old batteries in an
environmentally friendly way.

Danger of explosion! The gases released by

the battery are explosive!

© 12/2018 77
Faults Fault table
Faults and corrective measures

Faults Causes Measures

Engine does not start up or starts up Not disconnected (if possible) Check coupling
with difficulty Fuel tank empty Tanks
Fuel suction pipe blocked Check
Starting limit temperature not reached Check
Cold starting device Check/replace
Wrong SAE viscosity class of the engine lubricating oil Change lubricating oil
Fuel quality does not comply with operating manual Change the fuel
Battery defective or not charged Check battery
Cable connections to the starter loose or oxidised Check cable connections
Starter defective or pinion doesn't mesh Check starter
Air filter soiled/turbocharger defective Check/replace
Air in fuel system Vent the fuel system
Compression pressure too low Checking the compression pressure
Exhaust gas backpressure too high Check
High pressure pipe leaking Check/replace
High-pressure pump defective Check/replace
Engines starts up, but runs irregularly Exhaust gas backpressure too high Check
or misfires Compression pressure too low Checking the compression pressure
Cold starting device Check/replace
Air in fuel system Vent
Fuel filter contaminated Clean
Fuel quality does not comply with operating manual Change the fuel
Injector defective Change
High pressure pipe leaking Check/replace
Engine cable harness defective Check/replace

78 © 12/2018
Fault table Faults
Faults Causes Measures
Engine does not start and diagnostic Engine electronics prevents starting Check error according to error code and
lamp flashes eliminate error if necessary
Speed changes are possible and Engine electronics has detected a system error and activates an equivalent speed Check error according to error code and
diagnostic lamp lights up eliminate error if necessary
Engine shuts down unintentionally Engine brake flap closed Check control of engine brake flap
Please contact your DEUTZ partner
Power supply interrupted Please contact your DEUTZ partner
Leakage or low pressure in fuel low pressure circuit Visual inspection
Please contact your DEUTZ partner
Electronics malfunction read the error memory of the engine control
unit
Fuel supply not guaranteed Check fuel system pressure.
Charge pilot lamp lights up while Insufficient tension on V-belt or V-ribbed belt Check/replace/tension
engine is running V-belt or V-ribbed belt torn Replace
Cable connections loose or disconnected Fasten/replace
Generator, rectifier or regulator defective Please contact your DEUTZ partner
Test circuit open Please contact your DEUTZ partner
Engine gets too hot. Temperature Venting line to the coolant compensation tank blocked. Clean
warning system is activated Defective lubricating oil cooler Check/replace
Lubricating oil filter soiled on the air and/or lubricating oil side Change
Lubricating oil level too high Check lubricating oil level, if necessary drain
Lubricating oil pressure too low Fill up lubricating oil
Injector defective Change
Coolant heat exchanger soiled Clean
Coolant pump defective (V-belt or V-ribbed belt torn, loose) Check/replace/tension
Low coolant Fill up
Resistance in cooling system is too high / flow volume too low Check the cooling system
Fan / visco coupling defective, V-belt or V-ribbed belt torn, loose Check/change/tension
Fan speed too low (hydrostatic fan drive only) Check/replace

© 12/2018 79
Faults Fault table
Faults Causes Measures
Engine gets too hot. Temperature Charge air pipe leaking Check charge air line
warning system is activated
Charge air pipe soiled Check/clean
Air filter soiled/turbocharger defective Check/replace
Air filter maintenance indicator / service gauge defective Check/replace
Fan defective / V-belt or V-ribbed belt torn, loose Check/replace/tension
Exhaust gas backpressure too high Check
Throttle valve defective Check/replace
Coolant temperature transmitter defective Check/replace
Coolant thermostat defective Check/replace
Coolant cover defective Check/replace
Engine lacks power Lubricating oil level too high Check lubricating oil level, if necessary drain
Exhaust gas recirculation, actuator defective Check/replace
Fuel suction temperature too high Check system
Fuel quality does not comply with operating manual Change the fuel
Air filter soiled/turbocharger defective Check/replace
Air filter maintenance indicator / service gauge defective Check/replace
Fan defective / V-belt or V-ribbed belt torn, loose Check/replace/tension
Charge air pipe leaking Check charge air line
Charge air pipe soiled Clean
Valve clearance incorrectly adjusted Check/adjust
High pressure pipe leaking Check/replace
Injector defective Change
Throttle valve defective Check/replace
Exhaust gas recirculation, actuator defective Check/replace
Exhaust gas backpressure too high Check/clean
Exhaust gas turbocharger defective Change

80 © 12/2018
Fault table Faults
Faults Causes Measures
Engine performs poorly and Engine electronics reduce performance Please contact your DEUTZ partner
diagnostic lamp lights
Insufficient engine braking power Engine brake flap without function Check the engine brake flap for function and
damage
Please contact your DEUTZ partner
Engine doesn't work on all cylinders High pressure pipe leaking Check/replace
Injector defective Change
Compression pressure too low Checking the compression pressure
Engine cable harness defective Check/replace
Engine has no, or too little, Lubricating oil pressure too low Fill up lubricating oil
lubricating oil pressure Engine is tilted too far Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change lubricating oil
Lubricating oil pressure sensor defective Check/replace
Lubricating oil control valve jammed Check/clean
Lubricating oil suction pipe blocked Check/clean
Engine lubricating oil consumption Lubricating oil level too high Check lubricating oil level, if necessary drain
too high Engine is tilted too far Check engine mounting / reduce inclination
Crankcase ventilation defective Check/replace
Wrong SAE viscosity class of the engine lubricating oil Change lubricating oil
Valve shaft seals defective Check/replace
Piston rings worn Check/replace
Exhaust gas turbocharger defective Check/replace
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20% - 30%) Check load factor
Valve shaft seals defective Check/replace
Exhaust gas turbocharger defective Check/replace
Lubricating oil in the cooling system Lubricating oil cooler or lubricating oil cooler plate leaking. Please contact your DEUTZ partner
Coolant in lubricating oil Lubricating oil cooler or lubricating oil cooler plate leaking. Please contact your DEUTZ partner

© 12/2018 81
Faults Fault table
Faults Causes Measures
Engine emits blue smoke Lubricating oil level too high Check lubricating oil level, if necessary drain
Engine is tilted too far Check engine mounting / reduce inclination
Crankcase ventilation defective Check/replace
Wrong SAE viscosity class of the engine lubricating oil Change lubricating oil
Valve shaft seals defective Check/replace
Piston rings worn Check/replace
Exhaust gas turbocharger defective Check/replace
Engine emits white smoke Fuel quality does not comply with operating manual Change the fuel
Cold starting device defective Check/replace
Injector defective Change
Condensation Warm up the engine so that the water residues
evaporate.
Coolant in the exhaust gas Check
Engine emits black smoke Diesel particle filter defective Please contact your DEUTZ partner
Charge air pipe leaking Check/replace
Injection system defective Please contact your DEUTZ partner
Charge air pressure sensor defective Check/replace
Abnormal noises Leaks in suction intake pipes and exhaust pipes cause whistling noises Eliminate leak
Replace gasket if necessary
Fault in SCR system AdBlue® tank empty/display full Check tank sensor
SCR not working Check plug connections and lines at the supply
pump and injector
Check plugs and cables of supply pump and
sensors
SCR not working (cold) Lines frozen, clean lines, check heating
AdBlue® tank frozen, check heating
Frequent standstill regenerations Air filter soiled/turbocharger defective Check/replace
Charge air pipe leaking Check charge air line
Injector defective Change

82 © 12/2018
Fault table Faults
Faults Causes Measures
Frequent standstill regenerations Differential pressure of flow meter defective Change
NOx sensor defective Change
Differential pressure sensor of diesel particulate filter is issuing an implausible signal Change
Differential pressure line added Clean

© 12/2018 83
Faults Engine management
Depending on the design of the monitoring functions, – The engine must be checked by a DEUTZ
the electronic engine control can protect the engine in partner.
certain problematical situations by monitoring – If a lamp lights steadily a monitored measuring
important limit values during operation and checking variable (e.g. coolant temperature, lubricating
the correct function of the system components. oil pressure) has left the permissible value
Depending on the seriousness of a recognised fault, range.
the engine can continue to operate with limitations, – Depending on the fault, the engine power may
during which the diagnostics lamp lights up be reduced by the electronic engine control to
continuously or indicates a serious system error by protect the engine.
flashing. In this case, the engine should be switched ● Flashing
off as soon as safely possible.
Serious error in system.
Diagnostics lamp
– Switch off prompt for the operator. Attention:
The diagnostics lamp is located in the vehicle drive Failure to do so will lead to loss of guarantee!
Engine protection function of the electronic stand. – Engine forced to run at low power to cool the
engine control The diagnostics lamp can release the following engine, with automatic shutdown if necessary.
1 Diagnosis button signals: – The engine has reached switch-off condition.
2 Diagnostics lamp ● Function test – The switch-off process has been
accomplished.
3 Electronic engine control (EMR) – Ignition on, diagnostics lamp lights up for
approx. 2 seconds and then goes out. – There may be a start lock after engine stop.
When all errors are rectified, the diagnostics – Check the diagnostics lamp if there is no – The start lock is deactivated by turning off the
lamp goes out. For some errors, it is reaction after switching on the ignition. system with the ignition key for approx. 30
necessary to switch off the ignition, wait 30 seconds.
seconds and only then switch back on the ● The lamp does not light up
– In order to avoid critical situations the power
ignition. – After the lamp test an extinguished lamp reduction can be bypassed, automatic switch-
The appropriate monitoring functions are indicates an error-free and trouble-free off delayed or a start lock bypassed using the
switched off when a sensor fails. Only the operating state within the scope of the control optional emergency key on the instrument
sensor failure is documented in the error possibility. panel. This brief deactivation of the engine
memory. ● Continuous light protection functions is logged in the control
Error in system. unit.

– Operation continued with restrictions.

84 © 12/2018
Engine management Faults
● Please contact your service partner in case of
malfunctions and spare parts inquiries. Our
specially trained personnel will ensure fast,
professional repairs using original DEUTZ spare
parts in case of damage.
Diagnosis button
The diagnosis button allows the errors currently
saved in the error memory of the electronic engine
control to be visualised in the form of a flash code.
The flash codes permit:
● Errors that may occur can be classified.
● Clear display of the error as visual signal.
– The blink codes can only be interpreted by a
DEUTZ partner. Displaying system errors by blink code

Use of the diagnostic key Example:

The flash code displays all errors in the error 1 x short flash
memory, this means active as well as passive ones. 2 x long flash
The control unit must be switched off to start the 8 x short flash
enquiry (ignition off). Following this, the diagnosis
button should be pressed for approx. 1second during This flash code indicates a break or short circuit in
the start (ignition on). the wiring of the charge air temperature sensor. The
temporal sequence of the flash signals is shown in
The next error (i.e. the following one in the error the illustration.
memory) can then be displayed by pressing the
diagnostic key again. If the last existing fault has ● The blink codes can only be interpreted by a
been shown the first fault will be shown again by DEUTZ partner.
pressing the diagnosis button once more.
After the display of the error flash code, the
diagnostics lamp goes out for five seconds.

© 12/2018 85
Transport and storage Transport

Suspension equipment Mortal danger!

The engine may tip or crash down if
The transport devices mounted on this suspended incorrectly.
engine are adapted to the engine weight. If
the engine is transported with add-on ● The fastening attachment cannot be fixed
components, the transport devices must be securely above the centre of gravity (1).
designed accordingly.
● The fastening attachment can slip, the engine
● Only use the correct suspension equipment for swings backwards and forwards (1).
engine transportation. ● Too short a fastening attachment causes bending
● The suspension device (1) must be adjustable for torques in the transport device (2) and can
the engine's centre of gravity. damage it.
● Following transport/before commissioning the
engine: Remove the transport equipment (2).

86 © 12/2018
Engine corrosion protection Transport and storage
General Before operating a corrosion protected engine, the If a fault is detected:
corrosion protection must be removed.
Engines contain the following types of corrosion ● Shut down engine.
protection: Exhaust gas aftertreatment system ● Wait for the end of the lag time of the EDC
● Internal corrosion protection Selective Catalytic Reduction (SCR) (Electronic Diesel Control).
● External corrosion protection ● Repeat the process several times if necessary.
The SCR system can be taken out of operation for up
to 4 months after completely shutting down (includes Please contact your DEUTZ partner if the fault cannot
Your DEUTZ partner has the right corrosion be remedied.
all lag functions) and the following conditions:
protection agent for your needs.
● The engine or the vehicle / device should be Corrosion protection of engines which have
parked at a covered location, e.g. garage or hall, already been in operation
The following measures for corrosion protection after
taking the engine out of operation meet the if it has been shut down for a longer period of Internal corrosion protection
requirements for 12 months corrosion protection. time.
● Completely fill the SCR tank. The internal corrosion protection is always effected
The following corrosion protection work may only be by wetting the walls with the corrosion protection
● Evaporation of water as part of the AdBlue® must agent by running the engine. The corrosion protection
carried out by persons familiar with it and instructed
be avoided. run can be carried out once to protect the different
in the potential dangers.
● Do not disconnect electrical or hydraulic systems.
A shorter corrosion duration is to be expected in case connections.
of deviation from the measures by exposure of the Fuel system
● Maximum storage time at −40 °C to 40 ℃ 2
corrosion protected engines or parts to unfavourable
conditions (installation outdoors or storage in damp, months. ● Fill fuel tank with EN590 or ASTM D975 grade 1–
unventilated places) or damage to the corrosion D S15 biodiesel-free fuel
● Maximum storage time at −40 °C to 25 °C 4
protection coating. months. ● Perform a corrosion protection run with no load
for at least 5 minutes.
The engine corrosion protection must be checked If the shutdown time of 4 months mentioned above
about every 3 months by opening the covers. If has been exceeded, proceed as follows: Close the fuel/tank/supply line to the engine
corrosion is detected, the corrosion protection should so that the system is protected against dirt
be renewed. ● Completely empty the SCR tank.
and dust. Protect the electronics against
● Completely fill the SCR tank with new AdBlue®. moisture and corrosion.
After completion of the corrosion protection work, the Standstill times of longer than 4 weeks must
crank drive may no longer be turned in order to ● Replace the filter cartridge of the SCR supply
pump, if available. always be avoided with biodiesel.
prevent the corrosion protection agent from being
scraped off in the bearings, bearing liners and ● Warm up the engine to operating temperature and Lubricating oil system
cylinder liners. load so that pressure builds up and AdBlue® is
injected. ● Drain the lubricating oil from the engine at
operating temperature.

© 12/2018 87
Transport and storage Engine corrosion protection
● Fill the engine with preservation oil and perform a – Treated water Engine openings
corrosion protection run (together with corrosion – Corrosion protection agent with light antifreeze
protection run for the fuel system). For this, run ● All engine openings must be fitted with airtight,
the engine to reach a temperature of 60 °C, ● The duration of the corrosion protection run and watertight covers to delay the evaporation
duration of at least 5 minutes, so that all the concentration of the corrosion protection processes of the corrosion protection agent.
components of the lubricating oil system are wet, agent are specified by the manufacturer of the If an air compressor is installed, then the suction
or corrosion protection agent. and pressure connection must be sealed by a
wet all accessible components with preservation ● Then drain the coolant. cap.
oil and pump preservation oil at a temperature of Intake air lines
around 60 °C through the engine until all bearings Air should be locked out to avoid ventilation of the
and bearing liners are wet. ● Spray corrosion protection oil or preservation oil engine (chimney effect) for the suction from an air
into the intake air pipe. supply pipe.
● Clean the lubricating oil pan, cylinder head with
rocker arms, valves, valve springs thoroughly with External corrosion protection Storage and packing
diesel fuel or cleaning agent.
The engine must be cleaned thoroughly with cleaning ● After being protected against corrosion, the
Air compressor engine must be stored in a dry, ventilated hall and
agent before external corrosion protection.
● If an air compressor is installed, a corrosion suitably covered.
protection agent must be sprayed into the Bare external parts and surfaces The cover must lie loosely on the engine so that
compressor suction system after shutting down air can circulate around the engine to prevent
● Coat or spray all bare exterior parts and surfaces
the engine until it emerges visibly from the condensation from forming. Use desiccant if
(e.g. flywheel, flange faces) with corrosion
pressure nozzle. necessary.
protection agent.
Cooling system Re-application of engine corrosion protection
● Under extreme conditions, e.g. sea transport, a
● Depending on the series the engines are long-term corrosion protection oil should be used.
If the max. protection duration of the corrosion
equipped with a cooling air, cooling lubricating oil Rubber parts protection is reached or damaged corrosion
or coolant system (cooling water with cooling protection is detected and the engine is to stay in
system protection agent). ● Rubber parts (e.g. muffs) which are not painted
must be rubbed with talcum powder. storage, new corrosion protection must be applied.
● In liquid-cooled engines, the coolant must be The new corrosion protection protects the engine or
drained and the cooling system cleaned. Belt drives spare parts for another 12 months.
● Then carry out a corrosion protection run so that a ● Disassemble V-belts and V-rib belts and store
coating forms on the inside surfaces of the packed.
cooling system. With a mixture consisting of:
● Spray V-belt pulleys and tension pulleys with
– Treated water corrosion protection agent.
– Corrosion protection agent
or

88 © 12/2018
Engine corrosion protection Transport and storage
The new corrosion protection is applied in the same Cooling system Removal of corrosion protection from external
way as the initial corrosion protection with a corrosion parts
protection run. If a corrosion protection run is not ● The corrosion protection does not normally need
possible (engine is removed from the device or to be renewed up to 24 months. If necessary, the ● All areas and components coated with corrosion
system for example), certain special conditions must coolant system can be filled with a mixture of protection agent must be washed off with distilled
be observed for application of new corrosion corrosion protection agents and circulated by an fuel or a suitable cleaning agent.
protection which are described below: external pump, so that a new coating can form on ● Wash out grooves of V-belts if necessary.
the inside surfaces of the cooling system.
Internal corrosion protection ● Fit V-belts and V-rib belts according to
● The duration of the corrosion protection run and specifications.
Fuel system the concentration of the corrosion protection
agent are specified by the manufacturer of the ● Fill up the coolant.
● DEUTZ recommends using diesel fuel containing corrosion protection agent. Corrosion protection agent / cleaning agent
polycyclic aromatic hydrocarbons ≤ 8.0 %(m/m), ● Then drain the coolant.
a lubricity of ≤ 400 micrometres in the HFRR test Please ask your DEUTZ partner for reference
(EN ISO 12156-1) and biodiesel (FAME) ≤ 0.1 % Removal of corrosion protection products for the corrosion protection agents/cleaning
(V/V). agents to be used which meet DEUTZ requirements.
Removal of internal corrosion protection
Pump fuel with a separate pump or a fuel hand or see www.deutz.com
pump until the fuel system is full. Then drain the Fuel system
fuel mixture.
● Fill the fuel tank and fuel system with the proper
Lubricating oil system fuel.
● Press warm preservation oil at approx. 60°C into Lubricating oil system
the lubricating oil circuit with a separate pump, or ● Fill the engine with lubricating oil via the oil filler
with the prelubricating hand pump. Turn over the neck.
engine by hand or with the electric turning gear so
that all bearings and bearing liners are wet. The Cooling system
engine can also be turned over with the starter ● If the implemented corrosion protection agent is
without starting the engine. compatible with the intended coolant system
● Remove the cylinder head cover and spray protection agent, this can be filled directly into the
valves, valve springs and rocker arms with coolant system as specified.
preservation oil. ● If it is uncertain whether the implemented
corrosion protection agent is compatible with the
coolant system protection agent, the cooling
system should be purged with fresh water for
about 15 minutes before filling.

© 12/2018 89
Technical data Engine and setting data
General technical data

Engine type Dimension D 2.9 L4 TD 2.9 L4 TCD 2.9 L4

Working principle Four-stroke diesel engine
Charging Aspirated engine Exhaust gas turbocharger Turbocharger with charge
air cooler
Type of cooling water-cooled
Cylinder arrangement in a row
Number of cylinders 4
Bore/stroke [mm] 92/110
Engine swept volume [cm 3] 2925
Combustion method Direct injection
Injection system Common Rail
Exhaust gas recirculation Externally cooled
Exhaust aftertreatment Diesel oxidation catalytic converter
and/or
Diesel particle filter
or
without
Valves per cylinder 2
Ignition sequence of the engine 1-3-4-2
Direction of rotation looking onto the flywheel left
Engine power according to ISO 3046 [kW] See engine rating plate
Speed (nominal speed) [rpm] See engine rating plate
Coolant volume (only engine content without cooler / hoses and pipes) ~ [l] 3.5
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 8
Start of thermostat opening [°C] 86-90
Thermostat fully open [°C] 99-102

90 © 12/2018
Engine and setting data Technical data
Engine type Dimension D 2.9 L4 TD 2.9 L4 TCD 2.9 L4
Lube oil change volume (with filter) ~ [l] 8.9* / 9.4*
Industrial engines/Agricultural technology
Lube oil temperature in the lube oil pan, maximum [°C] 125
Lube oil pressure minimum (low idle speed, engine warm) [kPa/bar] 120/1.2
Permissible maximum combustion air temperature after charge air [°C] 50
cooler
V-belt tension Pre-tighten/retighten
V-belts AVX 13 (width: 13 mm) [N] 650±50 / 400±50
V-rib belt tensioning Automatic tensioning spring-loaded clamping roller
Weight without cooling system according to DIN 70020-A ~ [kg] 267 / - 288 / 339 280 / 339
Industrial engines/Agricultural technology
*specified lube oil filling volumes apply for standard versions. The lubricating oil filling volume may vary in engines which deviate from the standard, e.g. different lubricating
oil pan/lubricating oil dipstick variants and/or special inclined versions. The lubrication oil dipstick mark is always decisive

© 12/2018 91
Technical data Tools
Tool ordering
The special tools described in this chapter are
available to order from your DEUTZ partner.

Hexalobular tool kit V-belt tension meter

Ordering number: Ordering number:
0189 9092 0189 9062
Tool kit for loosening and tightening hexalobular Measuring device for testing the specified v-belt
screws. tension.

92 © 12/2018
Tools Technical data

Special wrench for loosening exchangeable Refractometer

filters
Ordering number:
Ordering number:
0293 7499
0189 9142
The following operating media can be evaluated with
For loosening interchangeable filters. this test device:
● Coolant
● Battery acid
● SCR reduction agent

© 12/2018 93
 ! WARNING: Breathing diesel engine exhaust exposes
you to chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.

- Always start and operate the engine in a well-ventilated area

- If in an enclosed area, vent the exhaust to the outside
- Do not modify or tamper with the exhaust system
- Do not idle the engine except as necessary

For more information go to www.P65warnings.ca.gov/diesel

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

Printed in Germany
All rights reserved.
0312 5151 en
© 12/2018
Original operating instructions