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Care and maintenance work

6
6.1Lubrication system
6.2Fuel system
6.3Cooling system
6.4Combustion air filter

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6.5Belt drive
6.6Setting work
6.7Add-on parts

© 2005
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Care and maintenance work 6.1Lubrication system

6.1.1 Oil change intervals

6
z The oil change times depend on the engine z If the lube oil change intervals are planned
application and the quality of the lube oil. in terms of operating hours, the lube oil
change intervals for installed engines
z If the oil change times are not reached 6.1.1.1 apply.
within a year, the oil change should be
carried out at least 1x yearly.

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z The following conditions apply for the table
– Sulphur content max. 0.5 % of weight for
diesel fuel.
– Constant ambient temperature ³ -10 °C
(+14 °F)

z For fuels
– with sulphur content > 0.5 to 1%
or
– Constant ambient temperatures < -10 °C
(+14 °F)
or
– with bio-diesel fuels according to DIN
51606- FAME the oil change times
should be halved.

z For fuels with a sulphur content higher

than 1% ask your responsible
service representative.
© 2005

Carry out oil changes on warm engine when the

engine is not running (lube oil temperature < 80 °C).
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6.1 Lubrication system Care and maintenance work

6.1.1.1 Lube oil change intervals for installed engines

Lube oil quality
6
Deutz lube oil quality class DQC I-02 DQC II-05 DQC III-05 DQC iV-05
ACEA specification E2-96 E3-96/E5-02/E07-04 E4-99/E6-04 E4-99/E6-04
see 6.1.1.3 only fully synthetic
API specification CF/CF-4 CG-4/CH-4/ CI-4 - -
worldwide specification - DHD-1 - -

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special DEUTZ release list - - see chap. 4.1.2.1 -
Standard lubricant code designation EO... EO...C - -
for building machines and building vehicles EO...A, EO...B
Engine Engine version Lube oil change intervals in oh
series
TCD All engines with:
2012 Crankcase ventilation:
L04/06 4V open - 500 500 500
closed - - 500 500

2013 Crankcase ventilation:

L04/06 4V open - 500 500 500
closed - - 500 500

© 2005
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Care and maintenance work 6.1 Lubrication system

6.1.1.2 Lube oil change intervals for vehicle engines

6 Lube oil quality
Deutz lube oil quality class DQC I-02 DQC II-05 DQC III-05 DQC iV-05
ACEA specification E2-96 E3-96/E5-02/E07-04 E4-99/E6-04 E4-99/E6-04
see 6.1.1.3 only fully
synthetic
API specification CF/CF-4 CG-4/CH-4/ CI-4 - -

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worldwide specification - DHD-1 - -
special DEUTZ release list - - see chap. 4.1.2.1 -
Application Engine version Crankcase
TCD 2012/2013 L04/ 06 4V ventilation Lube oil change intervals in km
Building site TCD 2012 4V open - 20 000 20 000 20 000
closed - - 20 000 20 000
vehicles / TCD 2013 L06 4V
city buses/ Coach bus closed - 30 000 50 000 50 000
average driving speed km/h

25 Inter city bus closed - 20 000 30 000 30 000

City busbus closed - 15 000 20 000 20 000
City TCD 2013 L04 4V closed - 25 000 45 000 45 000
transport TCD 2013 L06 4V closed - 30 000 50 000 50 000
TCD 2012 4V open - 30 000 30 000 30 000
closed - - 30 000 30 000
Local transport 40 TCD 2013 L04 4V closed - 40 000 60 000 60 000
TCD 2013 L06 4V closed - 50 000 75 000 75 000
TCD 2012 4V open - 40 000 40 000 40 000
Long distance 60 closed - - 40 000 40 000
© 2005

transport TCD 2013 L04 4V closed - 60 000 80 000 80 000

TCD 2013 L06 4V closed - 75 000 100 000 100 000
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6.1 Lubrication system Care and maintenance work

6.1.2 Checking oil level / changing 6.1.2.2 Changing engine oil
engine oil 6
6.1.2.1Checking oil level

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z Position the engine or vehicle so as to be level. z Warm up engine. z Position oil drip cup under the engine.
z – Engine warm: z Position the engine or vehicle so as to be level. z Unscrew oil drain screw.
Switch off the engine, wait for 5 minutes and – Lube oil temperature approx. 80 °C. z Drain off oil.
check oil level. z Switch off engine. z Screw in oil drain screw with new sealing ring
z – Engine cold: and tighten. (For tightening torque
Check oil level. see 9.2).
z Extract oil dipstick. z Pour in lube oil.
z Wipe with a fibre-free, clean cloth. – For quality / viscosity data see 4.1.
z Insert until it stops and extract again. – For filling quantities, see 9.1.
z Check oil level and re-fill to „MAX“ if necessary. z Check oil level, see 6.1.2.1.
– If the oil level lies just above the „MIN“-
line marking, re-filling is necessary. Caution when draining
hot oil: danger of scalding!

© 2005
Collect the used oil, do not allow to
seep into floor!
The oil level may not fall short of the „MIN“ line Dispose of according to instructions!
marking.
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Care and maintenance work 6.1 Lubrication system

6.1.3 Changing oil filter insert

6

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z When anti-rotation lock is installed: z Clean the sealing surface of the filter sup- z Tighten lube oil filter cartridge three quarters
Loosen clamping screws and remove tighte- port for any possible dirt. of a turn (approx. 10 Nm).
ning clamps from below.
z Lightly oil the rubber seal of the new lube z If there is an anti-rotation lock:
z Loosen lube oil filter cartridge with stan- oil cartridge. Position the tightening clamps and tighten
dard tool and unscrew. with clamping screws.
z Screw on the cartridge by hand until the
z Collect any oil which may run out. seal makes contact. z Check oil level, see 6.1.2.

z Check oil pressure, see 3.3.1.

Careful with hot oil: z Check the seal of the lube oil filter cartridge
danger of scalding! for tightness.
© 2005
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6.1 Lubrication system Care and maintenance work

6.1.4 Cleaning / changing oil filter
(cup) 6

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z Switch off engine. z Collect any lube oil which may run out. z Change the round sealing ring 2 and lightly oil.
z Loosen lube oil filter cover 1 with two or three z Crease the paper filter cartridge 5 in the z Press new paper filter cartridge 5 into the clip
turns and wait for 30 seconds. collection vessel slightly at the side until the 6 and insert carefully in the guide 4 together.
z Unscrew lube oil filter cover 1 with paper filter cartridge is released from the clip 6. z Screw the lube oil filter cover 1 tight in clock-
cartridge 5 in anti-clockwise direction. z Clean the sealing surface of the filter support wise direction (25 Nm).
z Carefully loosen paper filter cartridge 5 from and the lube oil filter cover 1 as well as the guide z Start the engine.
the guide 4, which is inserted in the housing 3, 4 of any dirt there may be z Check lube oil filter assembly for leaks.
from above. z Check engine oil level and top up if necessary.

Careful with hot oil:

Danger of scalding

© 2005
Dispose of used oil in an
environmentally friendly way.
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Care and maintenance work 6.2 Fuel system

6.2.1 Changing fuel filter

6

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z Close fuel stopcock. z Screw on the cartridge by hand until the seal
z Loosen fuel filter cartridge with standard tool makes contact.
and unscrew.
z Collect any fuel which may run out. z Tighten the fuel filter cartridge with one more
z Clean the sealing surface of the filter support half turn.
for any dirt there may be.
z Lightly oil the rubber seal of the new DEUTZ z Open fuel stopcock.
original fuel filter cartridge or wet with diesel
fuel. z Check for tightness.

Only work on the fuel system

when the engine is switched off. It is necessary to bleed the fuel
© 2005

Wait at least 30 seconds. No open system.

fire! Do not smoke!
Pay attention to cleanliness as the
fuel system (Rail) is very sensiti-
ve!!!
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6.2 Fuel system Care and maintenance work

6.2.2 Cleaning / changing fuel filter

(cup)
6

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z Switch off engine z Change the rubber seal 2 and lightly oil.
z Loosen fuel filter cover 1 and unscrew in anti- z Carefully place new paper filter cartridge 3 in
clockwise direction. the guide 4.
z Carefully loosen paper filter cartridge 3 from z Tighten the fuel filter cover 1 in clockwise
the guide 4 from above. direction (25 Nm).
z Collect any fuel which may run out. z Start engine.
z Change paper filter cartridge 3. z Check fuel filter attachment for tightness.
z Clean the sealing surface of the filter support
and the fuel filter cover 1 as well as the guide4
of any dirt there may be.

Only work on the fuel system

when the engine is switched off
(at least 30 seconds).

© 2005
No open fire! Do not smoke!
Dispose of used fuel in an
environmentally friendly
manner.
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Care and maintenance work 6.2 Fuel system

6.2.3 Changing / bleeding

6 fuel pre-filter, filter insert

z Clean any dirt from the sealing surface of the 1 Fuel supply to pump
new filter cartridge (5) and the reverse side 2 Fuel return from control block FCU
of the filter head (Fuel Control Unit)
z Wet the sealing surfaces of the filter cartridge 3 Fuel hand pump with bayonet plug for
(5) slightly with fuel and screw back onto the locking and unlocking
filter head in clockwise direction (17-18 Nm) 4 Thermostat valve with shutdown lever
z Open the fuel stopcock and bleed the system 5 Filter cartridge

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(see „Bleeding fuel system“). 6 Connection facility for electrical
z Dispose of collected fuel and old filter cartridge water level sensor
(5) properly. 7 Drain cock
8 Water collecting vessel (bowl)
Bleeding fuel system: 9 Fuel inlet from fuel tank
z Unlock the bayonet plug of the fuel hand 10 Fuel return to fuel tank
pump (3) by pressing and turning
anti-clockwise at the same time. The pump
plunger is now pushed out through the spring.
© 43 848 1  Turn the shutdown lever of the ther-
Filter change: mostat valve (4) by approx. 45° in
z Close fuel stopcock (for high tanks). clockwise direction until it is felt to
z Position fuel collecting vessel beneath fuel pre-filter. engage.
z Loosen drain cock (7) and drain water + fuel z Pump until a very strong resistance is felt and
completely. pumping becomes very slow.
z Unscrew filter cartridge (5) together with z Now pump a few more times.
water collecting vessel (8) in anti-clockwise (The return line must be filled).
direction and remove. z Turn the shutdown lever of the thermostat
z Loosen water collecting vessel (8) from old valve (4) by approx. 45° in anti-clockwise
filter cartridge (5) in anti-clockwise direction direction until it is felt to engage.
and remove. z Lock the bayonet plug of the fuel hand pump
z Empty remaining fuel into the fuel collecting (3) by pressing and turning clockwise at the Only work on the fuel system
vessel and clean water collectingvessel (8). same time. when the engine is switched off.
z Screw water collecting vessel (8) onto the No open fire! Do not smoke!
new filter cartridge (5) in clockwise direction. Dispose of used fuel in an
© 2005

environmentally friendly manner.

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6.3 Cooling system Care and maintenance work

6.3.1 Cleaning intervals

6
z The cooling system soiling depends on the
type of engine application.
z The risk of soiling is increased by oil and fuel
residues on the engine. Therefore pay particular
attention to tightness when operating under
high dust exposure.
z Increased soiling occurs, for example, during:

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- Building site application from high dust content
of air.
- Harvesting application from high proportion of
chaff and chopped straw, for example, in the
area of the work machine.
z Due to the various application conditions, the
cleaning intervals must be defined according
to each case. Therefore, the cleaning intervals
given in the table below can be used as
guidelines.

Checking or cleaning intervals

Guidelineoh Engine application
2000 Ships, electronic units in
enclosed spaces, pumps.
1000 Vehicles on paved
roads
500 Tractors, fork lift trucks, drivable
electronic units.
250 Vehicles on building sites and
unpaved roads, building

© 2005
machines, compressors, mining
equipment.
125 Agricultural machinery, tractors
with harvesting application.
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Care and maintenance work 6.3 Cooling system

6.3.2 Cleaning cooling system

6

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Cleaning with compressed air Cleaning with cold cleaner

- Blast out the engine wih compressed air. Do not - Spray the engine with standard cold cleaner
damage any components. and leave to work for approx. 10 minutes.
- Rinse out the loosened dirt with a water jet. - Spray the engine clean with an acute water jet
(do not spray the water jet directly at sensitive
engine parts, e.g. generator, cabling, electronic
components, fan drive).
© 2005
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6.3 Cooling system Care and maintenance work

6.3.3 Emptying / filling / bleeding

cooling system
6
Emptying cooling system:
z Position collecting dish underneath locking
screw 5 and coolant supply 4.
z Remove locking screw 5 on the crankcase
and pull off hose on 4.
z Loosen bleed screw 2.
z Drain off coolant.
z Re-tighten locking screw 5 and hose on 4 and

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bleed screw 2.
z If locking screw 3 is not accessible,
emptying may be carried out on the engine
oil cooler (coolant channel).
Filling / bleeding cooling system:
z Open cooler cover.
z Loosen bleed screw item 2.
z Pourincoolantuntilthemaximummarkorthefilling
limit (system heating valve must be open, if
present).
z Tighten bleed screw item 2 + locking screw
item 5.
zClose cooler cover.
zStart engine and warm up until the thermostat opens.
zSwitch off engine.
zCheck the coolant level with the engine cold and
re-fill if necessary.
zClose cooler cover item 1.
Bleeding
zThe cooling system, which was built according
to our installation guides, is bled automatically
after filling.

Caution when draining hot coolant:

© 2005
danger of scalding! Collect coolant
when draining off.
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Dispose of according to
instructions!
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Care and maintenance work 6.4Combustion air filter

6.4.1 Cleaning intervals

6
z The soiling of the combustion air filter
depends on the dust content of the air and
the selected filter size. If a high dust
exposure is to be expected, a cyclone
separator can be connected to the
combustion air filter.

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z The cleaning intervals cannot be generally
defined. They must be defined depending
on each case.

z If dry air filters are used, cleaning should only

be carried out according to the maintenance
display or maintenance switch.

z Filter maintenance is required when on the:

- Maintenance display © 25 885 1
the red service field 1 is fully
visible when the engine is not running.
- Maintenance switch
the yellow warning light comes on when
the engine is running.

z After completion of the maintenance work

push the reset button on the maintenance
display. The maintenance display is ready
for operation again.
© 2005
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6.4 Combustion air filter Care and maintenance work

6.4.2 Emptying cyclone pre-

separator
6

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z Loosen wing nut 1 and lift housing cover 2.

z Remove the dust container 3 from the base of
the cyclone 4 and empty. Clean foliage, straw
and the like from the cylone base.
z Place the dust container 3 on the base 4 and
tighten the housing cover 2 with wing nut 1.

© 2005
Never fill the dust container with oil, replace
damaged containers!
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Care and maintenance work 6.4 Combustion air filter

6.4.3 Dry air filter

6
Dust discharge valve Filter cartridge

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© 25 888 2 © 25 889 1

z Empty the dust discharge valve 1 by squeezing z Open clamping bracket 1. z Renew the safety cartridge 4 after 5 filter
the discharge slot in the direction of the arrow. z Remove filter hood 2 and pull out filter cartridge 3. maintenances, after 2 years at the latest
z Clean filter cartridge, renew after a year at the latest. (never clean!).
z Clean the discharge slot occasionally. z Clean filter cartridge 3. To do this:
- Blast out from the inside out with dry - Loosen the hexagonal nut 5 and pull out
z Remove any stuck on dust residues by compressed air (max. 5 bar), or the cartridge 4.
squeezing the upper area of the valve. - beat out (only in extreme cases). Do not - Insert new cartridge, re-mount hexagonal
damage the cartridge, or nut and tighten.
- Wash according to manufacturer’s z Insert filter cartridge 3, close hood 2 and
specifications. secure clamping bracket 1.
z Check filter cartridge for damage to the filter
paper (shine light through) and check seals.
Exchange if necessary.
Never clean filter cartridge with
© 2005

petrol or hot liquids!

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6.5 Belt drive Care and Maintenance work

6.5.1 Changing V-belt 6.5.2 Changing V-belt 6.5.3 Checking V-rib belt
V-rib belt V-rib belt wear limit
6

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z Push tension pulley in the direction of the arrow z Push tension pulley in the direction of the arrow z The wear limit of the V-rib belt is checked as
until V-rib belt is free. until V-rib belt is free. follows:
z First remove the V-rib belt from the smallest z First remove the V-rib belt from the smallest pulley. z Check the distance between the projection
pulley. z Put on new V-rib belt of the moving tension arm and the contact
z Put on new V-rib belt z Loosen tension pulley in the opposite direction with the fixed tensioner housing.
z Loosen tension pulley in the opposite direction of the arrow until the V-rib belt is taut Whilst z If „a“ is less than 3 mm the V-rib belt should be
of the arrow until the V-rib belt is taut doing this, check that the V-rib belt is changed.
Whilst doing this, check that the V-rib belt is positioned correctly in your guide.
positioned correctly in your guide.

Only check/tighten/change V-
belts when the engine is not
running. If necessary, re-mount
V-belt guard.

© 2005
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Care and maintenance work 6.6 Setting work

6.6.1 Checking valve clearance,

6 setting if necessary

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z Loosen bleed valve and swing aside. Setting instructions:

z Remove cylinder head cover. IN= inlet valve
z Before setting the valve clearance allow the EX = exhaust valve
engine to cool down for at least 30 minutes: Oil z Perform test and setting work on every cylinder.
temperature below 80 °C. z Re-mount cylinder head cover (if necessary
z Place the turning device over the fastening with new gasket).
screws of the belt pulley. z Swing the bleed valve into position and fasten
z Turn over engine until the valve overlap is
achieved, cylinder no. 1
z Crankshaft setting as per setting diagram, see
Example: BF4M 2013
6.6.1.1.
Note: Valve overlap means: Valve clearance setting
Exhaust valve is not yet closed. Inlet valve 1. Work step 1. Set cylinder to overlap, set cylinder 4.
2. Work step 3. Set cylinder to overlap, set cylinder 2.
© 2005

begins to open. For valve setting diagram see

6.6.1.1, the table on the right. 3. Work step 4. Set cylinder to overlap, set cylinder 1.
4. Work step 2. Set cylinder to overlap, set cylinder 3.
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6.6 Setting work Care and maintenance work

6.6.1.1 Valve clearance setting diagram

6
Setting the valves: (black identification)
z Perform valve clearance setting on appropria-
te cylinder with valve clearance setting device
part no. 8190.
Loosen all lock nuts 2 of the rocker arm
assembly to be set. Turn setting screw 1 back
with the valve clearance setting device one

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turn in anti-clockwise direction.
On the valve to be set, turn setting screw 1 in
clockwise direction so as to be free of clearan-
ce.
That means, there must not be any clearance
between the rocker arm and valve and no
pressure may be applied to the valve.
z Set needle of measuring plate to [i| , not
twisting the knurled handle any more.
z Hold the measuring plate exactly in this position
and turn the setting screw 1 in anti-clockwise
direction with the knurled handle until the
needle is on the „in“ or „ex“ marking.
z Holdtheknurledhandleexactlyinthispositionand
tighten lock nut 2 with a torque wrench (20 Nm).
z Üput on seal (poss. new seal).
z Visual inspection of screws and rubber ele-
ments, renew if necessary.
z Put on valve mechanism cover and tighten
screws according to tightening specification:
9 Nm (see 9.2).

© 2005
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Care and maintenance work 6.6 Setting work

6.6.2 Checking control piston

6 clearance at engine brake,
setting if necessary

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z After the valve clearance has been set. z Set control piston clearance if necessary, by: z Perform test and setting work on every
- Control unit for engine brake is already - Loosening the lock nut 2. cylinder.
mounted. - Mount the control piston clearance X on z Replace cylinder head cover (if necessary
z Set the clearance on the control unit as follows. setting screw 1 (see 6.6.1) with setting device with new gasket).
z Turn engine until reaching the valve overlap in EX and set as follows: z Swing the bleed valve into position and
is reached, cylinder no. 1 Fix the magnet fasten.
z Set control piston clearance on every exhaust Turn the setting device without clearance
valve. until the control piston contacts with the valve IN = Inlet valve
z Proceed as for valve clearance. bridge, set scale to „0“. EX = Exhaust valve
Then turn back angle degree 432° (by
Note hand or torque wrench): 1 Setting screw
Valve overlap means: 2 Lock nut
Exhaust valve is not yet closed. Inlet valve begins EX = exhaust valve 432° for M8 thread 3 Solenoid valve (electronic control)
to open, see valve setting diagram. (corresponds to 1.5 mm clearance) 4 Control board
© 2005

- Tighten lock nut 4.

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© 2005
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Care and maintenance work 6.7 Add-on parts

6.7.1.1Testing battery and cable 6.7.1.2 Checking the acid level

6 connections
6.7.1.3 Checking acid density

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z Keep the battery clean and dry. z Remove sealing cap 1. z Measure the acid density of individual cells
with a standard acid testing device.
z Loosen soiled connection terminals. z If checking inserts 2 are available:
The liquid level should reach to their bottom. The measured values (see table overleaf)
z Clean the battery poles (+ and -) and terminals, indicate the charge status of the battery. The
and grease with an acid-free and acid-resistant z Without checking inserts: acid temperature when measuring should be
grease. The liquid level should reach 10-15 mm above 20 °C if possible.
the upper edge of the plate.
z Ensure that the terminal connections contact
well when assembling. Tighten the clamping z If necessary, re-fill with distilled water.
screws by hand.
z Screw sealing cap back on.
© 2005
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6.7 Add-on parts Care and maintenance work

6
Acid density
in [kg/ l] in [°Bé (Baumé degree)*] Charge level

Normal Tropics Normal Tropics

well charged

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1,28 1,23 32 27

1,20 1,12 24 16 half charged, re-charge

1,12 1,08 16 11 discharged, charge immediately

* The data for acid density in °Bé

(Baumé degree) is out of date and rarely
still in use.

The gases released by the battery

are explosive! Avoid sparks and
open fire in the vicinity of the
battery! Do not allow acid to get on

© 2005
skin or clothes!
Wear protective glasses!
Do not place any tools on the
battery!
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Care and maintenance work 6.7 Add-on parts

6.7.2 Three-phase current

6 generator
6.7.3 Transportation suspension

Notes on three-phase current system:

z Do not interrupt the connections between the

battery, generator and governor when the
engine is running.

z If, however, an engine must be started and

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operated without battery, the connection
governor / generator is to be separated before
starting.

z Do not swap battery connections.

z Replace defective charging warning light

immediately.

z When cleaning engine: Do not spray water/ © 38 994 0 © 38 9943 0

steam jet directly at generator!
lWarm up the engine so that the water residues z Fastening devices cannot be fixed safely over
evaporate. z Only use the correct suspension equipment
for engine transportation. Suspension the centre of gravity.
equipment must be adjustable for the engine z Fastening devices can slip, engine capsizes.
z Under no circumstances may the voltage of a z Short fastening devices cause bending
three-phase current system be tested by centre of gravity.
moments in the suspension. This can damage
tapping against the earth cable. the suspension.
z When carrying out electrical welding work,
clamp the earth terminal of the welding device
directly to the part to be clamped.

Only use correct suspension Engine can fall.

© 2005

equipment! Danger to life!