Deutz Operation Manual 2011

Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2
Suction system .
Foreword. . . . . . . . . . . . . . . . . . . . 3
Belt drives .
General. . . . . . . . . . . . . . . . . . . . 5
Setting work
2 Engine description . . . . . . . . . . . . . 7
Type . . . .
Electrical system . . .
. . . . . . . 47
. .. 49
.... 51
. . 53
.... 13
7 Faults. . . . . . . . . . . . . . . . . . . . 55
Fault table
. 55
Engine management
... 60
Fuel schematic .
.18
8 Transport and storage . . . . . . . . . . 62
Coolant schematic .
Exhaust gas recirculation.
.19
. 21
Electrics/Electronics
. 23
Engine illustrations. .
lubricating oil schematic
3 Operation . . . . . . . . . .
. . . . . . . . .. 62
Transport. . . .
Protecting the engine against corrosion.
. 24
Engine and setting data . . . . .
Ambient conditions. .
. 24
Tools.
Initial commissioning .
. 25
Start procedure. .
Operation monitoring.
Stop procedure. .
. 63
9 Technical data . . . . . . . . . . . . . . . . 65
.f,
. . 65
.70
. 27
.28
.30
4 Operating media. . . . . . . . . . . . . . . 31
Lubricating oil.
Fuel. . . .
Coolant. . . .
. 31
. .. 33
. .34
5 Maintenance................. 35
Maintenance schedule .
.35
6 Care and maintenance work . . . . . . . . 38
lubricating oil system.

Fuel system.
Cooling system ..
Engine cleaning.
. . . . . . . 38
.40
. ... 44
. .. 46
2008
General
II Iii\.I
Danger
This symbol is used for all safety iostruc

lions which, if not observed, present a di
red danger to life and limb for the person
involved. Observe these carefully. The at
tention of operating personnel should be
drawn to these safety instructions. Further
more, the legislation for "general.regula
tions for safety and the prtlVention of
accidents" must be observed.
Caution
I.W This symbol indicates a danger to the part
I!<2'J and engine. The relevant instructions must

~ be observed, failure to do so can lead to de
struction of the part and the engine.
Notes
~
This symbol accompanies notes of a gen
l~ eral kind.
200
Engine description
Type
Engine type designation
This manual covers the following engine types
~2011L02i
D 2011 L03 i
D 2011 L04 i
~1L04i
Teo
T
- I
D2011 L020
D2011 L030
D2011L04w
TO 2011 L04 w
D2011 L04 0 TCD 2011 L04 w

TO 2011 L04 0
Exhaust gas turbocharger
Charge air cooler
Diesel
Rating plate
The type (A), engine number (8) and performance
data are stamped on the rating plate.
L02IL031L04
The rating plate (C) is fixed to the cylinder head cov

er or the crankcase,
The engine type and number must be stated when

purchasing spare parts.
in series
No. of cylinders
--
ilolw
oil-cooled (integrated cooler)
0
w
water-cooled
2008
oil-cooled
I-
Engine description
Typ
Volume blocking
Engine serial number

The engine number (0) is stamped onto the crank
case (arrow) and onto the rating plate.
Cylinder arrangement
The cylinders are counted consecutively starting
from flywheel (1 ).
Direction of rotation
Looking onto the flywheel.
rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
Unauthorised settings on the regulator will exciud

the manufacturer from all liability for resulting dan
age. The blocking screws are adequately protect~
against this:
With locking varnish in version: torque adjust
ment
With protective plastic capsule in version: witt
out torque adjustment.
201
Engine illustrations
Engine description
02011 L03 i
View from right (example)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cooling fan (with integrated generator)

Tension pulley
Toothed belt cover
V-belt (fan)
Stop lever
Speed adjusting lever
Lubricating oil drain plug
Lubricating oil sump
Lubricating oil dipstick
Connection possibility for cab heating
Exchangeable fuel filter
Lube oil replacement filter
Fuel supply pump with integrated screen fi~er
Lubricating oil filling
Removable air guidance cowling (access to fuel
injectors)
16 Lube oil cooler
17 Cylinder head cover
18 Air intake pipe
2008
Engine description
D2011 L03i
View from left (example)

1 Fuel retum to fuel tank
2 Flywheel
3 Starter
4 Exhaust manifold line
5 Air intake pipe
10
2008
Engine description
Teo 2011 L04 w

View from right (example)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
200B
Crankcase breather
Coolant outlet to the cooler
Coolant pump
Generator
V-belts
Toothed belt cover
Lubricating oil filling
Lubricating oil pump
Lubricating oil drain plug
Speed adjusting lever
Lubricating oil dipstick
Fuel supply pump with integrated screen filter
Exchangeable fuel filter
Lube oil replacement filter
Stop lever
Lube oil cooler
Coolantinlet
Injection pump
Coolant return to thermostat
Cylinder head cover
11
Engine description
Teo 2011 L04 w
View from left (example)

1 Fuel retum to fuel tank
2 Connections charge air cooler

3 Flywheel
4
",[
5
6
7
8
Starter
Coolant inlet
Turbocharger
Exhaust manifold line
Charge air line
'''', 'O"''ii:";:,
12
2008
,
'ations
Lubricating oil schematic
Engine description
TO 2011104 i
'hlill
IT;,,> 9S'C I ~
.r&.l<.. 0,
95"~j
U!.'~
EJ!!&hp.,1
cr.. . > 63'C1 a:::s:;."..
I@
;>2008
2008
(example)
1 Lubrica1ing oil sump
2 Lubricating oil pump
3 Pressure limiting valve
4 Cylinder (lubricating oil-cooled)
The lubricating oil is used first to cool the engine.
5 Cylinder head
6 Lubricating oil return from the cylinders
7 Lubricating oil collection pipe to the thermostat
8 Thermostat
(engine cold) lubricating oil flow directly to the lu
bricating oil filter
(engine warm) lubricating oil flow through the lu
bricating oil oooler
9 Lube oil cooler
10 Lubricating oil filter
11 Main lube oil channel
12 Turbocharger
13 Pressure holding valve
14 Connection possibility for cab heating
The standard pressure holding valve must be re
placed by acombination for this. Retrofitting only
by authorised qualified personnel.
15 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap
pet
When the engine is cold, lubricating
oil is fed to the hydraulic tappet
To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
16 Hydraulic tappets
13
Engine description
Lubricating oil schemaU

02011 L04 i
iI;~:!~~?i
:::=i-j-:+
tt;;~[~:g
__.!JJ1+
-II'"
Exhaust gas recirculation

(example)
1
2
3
4
. = : : : .. :
'j'
"
,1>;f
'
",.
If
14
'I
".
",
' "
"'~
'I'
'I'
1/1~'\'.ll. ,11",t;1
'!'
"V,

Lubricating oil pump
Pressure limiting valve
Cylinder (lubricating oil-cooled)
The lubricating oil is used first to cool the engin
5 Cylinder head
6 Cooling valve housing (exhaust gas recircula
tion)
7 Lubricating oil return from the cylinders
8 Rocker arm
9 Lubricating oil collection pipe to the thermostat
10 Thermostat
(engine cold) lubricating oil flow directly to the II
bricating oil
warm) lubricating oil flow through the
g oil cooler
11 Lube oil cooler
13 Main lube all channel
15 Connection possibility for cab heating
The standard pressure holding valve must be n
placed by acombination for this_ Retrofitting ani
by authorised qualified personnel.
switching valve for controlling the hydraulic ta~
I.
When the engine is cold, lubricatin
is fed to the hydraulic tappet.
To achieve early adjustment of the fuel injectio
200
Engine description

TO 2011 L04 w
~-~/';1J
~ !i
"rJ .
16
\I
(example)
1 Lubricating oil sump
4 Lube oil cooler
7 Lubricating oil pipe to the turbocharger
8 Turbocharger
9 Lubricating oil retum line from the exhaust turbo
charger
10 Rocker ann
12 Lubricating oil filter console with intAnr::ltP.<1
switching valve for controlling the
t.
When
is fed to the
To achieve
in a cold start,
fuel injectors are supplied
2008
Engine description
02011
@
Toil<63~C
Toil> 63"C
~~'"'rr
I
.
I
.,
.~
lifi\
1
,3~~

(example)
1 Lubricating oil sump
4 Lube oil cooler
6 Cooling valve housing (exhaust gas recirculation)
8 Rockerarm
pet.
When the engine is cold. lubricating
oil is fed to the hydraulic tappet
I~ ~..
~,
'0~'
2008
17
..
,
Engine description
Fuel schematic
Fuel schematic (example)
1 Fuel line from tank to fuel pump
2 Fuel supply pump with integrated screen filter
3 Fuel pipe from the supply pump to the fuel
change filter
4 Exchangeable fuel filter
5 Fuel pipe from the filter to the fuel injector
6 Fuel pipe to fuel injector
7 Injection pump
8 Injection line to injection valve
9 Injection valve
10 Return collection pipe
11 Fuel return to fuel tank
pet.
When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
18
2008
atic
Engine description
Coolant schematic
11ter
,etlon
the
Jil.
008
2008
19
.f
Engine description
Coolant schemati
Coolant schematic (example)

DfTDrrCD 2011 w
1
2
3
4
5
6
7
Cooler
Coolant inlet
Coolant pump
Coolant supply for engine cooling
Cylinder pipe/head cooling
Cooiant return to thermostat
Thermostat
(engine cold) coolant directly for engine cooling
(engine warm) coolant flow through the cooler
8 Coolant partial flow to the lubricating oil cooler

9 Lube oil cooler
10 Coolant return to thermostat
20
200
rill.'
tic
108
J'"I""UJ---:;~"'''''''"'
Engine description
External exhaust gas recirculation

D 2011 L04 i D 2011 L04 0 D 2011 L04 w
(example)
1 Exhaust gas partial flow
(not connected)
2 Exhaust gas partial flow
(connected)
3 Valve housing
4 Actuator
(electrically actuated)
5 Distributor pipe
6 Electrical connecUon
7 Switch
The switch is connected internally with the con
trollinkage, The voltage to the actuator is inter
rupted at load peaks,
8 Fuel filter console
The switch housing is designed to be safe from ma
nipulation,
have work performed on the components by
qualified personnel.
2008
21
"
"'-;
Engine description
,to , , , ,
~,~----,--
""0;;;
:eOI
,Wi. jEtJ!i#.ttiii bUM"",.
JtsiSliliM"

Internal exhaust gas recirculation
Engines with turbocharger
TDfTCD2011
Additional cams for exhaust gas recirculation
Inlet valve opens briefiy during the outlet cyde
and emits an exhaust gas partial flow to the suc
tion system.
This partial volume is sucked back in in the next
suction cycle.
2 Outlet valve
3 Inlet valve
f------~-.
22
2008
""'lii."IIiV;."i:;,.;,~~ts:rt(gtt;\ttrttm,rW'W
Engine description
Electrics/E lectron ics

Information about the engine electronics
This enQine can be equipped ootionallv with an elec
control unit.
of the respective system depends on
scope of function and the planned type of
engine application.
The resultant wiring with pin assignment can be seen
in the appropriate wiring diagram.
The installation regulations of the DEUTZ AG must
3150 be taken into account
Precautions
The connections of the control units are
only dust and water proof when the mating
plugs are plugged (protection class IP69K)!
The control units must be protected against
spray water and moisture until plugging in
the mating plugs!
Reverse polarity can lead to failure of the
control unit.
To avoid damaging the control units, all the
connections on the control unit must be dis
connected before electric welding work.
Interventions in the electrical system conto the DEUTZ regulations or by un
personnel can pennamently
the engine electronics and have
serious consequences which are not cov
ered by the manufacturers guarantee.
2008
[If\]
!
It is strictly prohibited:
a) to make changes or connections to the
wiring of the electrical control devices and
the data transmission cable (CAN
b) to switch control units.
Diagnostic and maintenance work may
only be carried out by authorised personnel
using equipment approved by DEUTZ.
Installation instructions
The control units are calibrated to the respective en
and identified by the engine number. Every en
may only be operated with the appropriate
control unit
Setpoint transmitters (pedal value transmitters) nec
essary for vehicle operation must be connected to
the vehicle side cable harness apd calibrated with
the DEUTZ diagnostic program SERDIA (SERvice
DIAgnosis). Wiring and cable assignment of the ve
hicle side cable hamess must be taken from the con
nection diagram of the DEUTZ installation
consulting.
Supply voltage
DEUTZ diesel engines must be operated with a 12 V
or 24 V supply. An adequate charging condition of
the battery must be ensured. Interruption of the pow
er supply when the engine is running can lead to
damage to the electricslelectronics. Failure of the
supply voltage leads to engine standstill.
Voltages above 32 Volt will destroy the control unit.
Diagnostics
DEUTZ control units are equipped with self-diagno
sis. Active and passive error entries are saved in the
error memory. Active errors are displayed by error
lamp/diagnostic lamp (~60). The active errors can
be called by blink codes or by the DEUTZ diagnostic
program SERDIA. Passive errors must be deleted by
SERDIA.
with error lamp (optional).
via diagnostic socket (SERDIA).
23
Operation
Ambient conditions
-.
*
'.. . . . .' 1//'
Ill\,
OC
Cold start aid

Depending on the type of engine, glow plugs,
heating plugs, heating flange, flame glow system
can be used as cold starting aids,("3:27)
Coolant
DfTDfTCD 2011 w
Observe the mixing ratio anti-freeze/cooling wa
ter. (!~34)
High ambient temperatures, high altitude
- This engine can be equipped
~ with an electronic DEUTZ control unit.
Under the operating conditions listed be

low, the amount of fuel is reduced automat
ically, controlled by the electronic control
unit.
~
Low ambient temperatures
Lubricating oil
Select the lubricating oil viscosity according to
the ambient temperature,
If cold starting occurs frequently cut the lube oil
changing interval by half.
Fuel
Use winter fuel below 0 'C (I'li 33),
Battery
A good charging condition of the battery (l'El53)
is the prerequisite for starting the engine,
Heatino up the battery to approx, 20C improves
behaviour of the engine, (Remove
battery in a warm room),
24
application and
tions, the amount ot fuel must be
condi
above 1000 m altitude

above 30 C ambient temperature
Reason: Air density decreases as altrtude or ambient
temperature increase, This reduces the amount of
oxygen in the engine intake air and the fuel-air mix
ture would be too rich if the injected amount of fuel
were not reduced,
The results would be:
- black smoke in the exhaust
- high engine temperature
reduction in engine performance
- possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
you have any other questions,
2008
ns
)08
Operation
Initial commissioning
Preparations for initial commissioning
(Maintenance schedule E 10)
Remove engine corrosion protection
Remove any transport devices,
Check the battery and cable connections and
mount if necessary,
Check belt tension ([;[149),
Have the engine monitor or waming system
checked by authorised personnel,
Check the engine mounting,
Check that all hose unions and clips fit properly,
OIL
FUEL
The following additional work must be carried

out on generally overhauled engines:
Check the luel pre-filter and main filter and
change if necessary,
Check the intake air cleaner (il available, main
tain according to maintenance indicator),
Drain lubricating oil and condensation waterlrom
the charge air cooler.
Fill with engine lube oil.
DfTDITCD 2011 w
Fill the coolant system (1'l165),
Pour in fuel
I. tt ILow IUb,ricating oil level and overfilling lead

I! ~ to engine damage,
The engines are generally supplied without
lubricating oil filling.
Select lubricating oil quality and viscosity
before filling.
Order DEUTZ lubricating oils from your
DEUTZ partner
Fill the engine with lubricating oil via the lubricat
ing oil filler neck,
Observe the lubricating oil filling level (l"~65),
2008
I! tt IOnly
re-fuel when the engine is not running.
Ensure cleanliness,
~
Do not spill fuel.

Additional venting of the fuel system by a 5
minute trial run at idle speed or on low load
is absolutely essential.
The fuel low pressure system must be vented be

fore the first start-up after filling with the manualy
supply pump,
Only use clean commercially available brand diesel

fuel. Observe fuel quality (("! 33),
Use summer or winter-grade fuel, depending on the
ambient temperature,
25
''''>iIl.""
po,.
ail
Operation
Initial commission
Close compensation tank with valve.
Start the engine and run up until the thermostat
opens (line (2) heats up).
Engine operation with open thermostat 2 - 3 min
utes.
Check the coolant level and top up coolant if nec
essary.
t'1! \l
orrorrco 2011 w
I! (.J'~:I T.he
coolant must have a prescribed coo
centraUon of coofing system oorrosion pro
tection agent!
Never operate the engine without coolant,
even for a short time!
Danger of scalding from hot coolant!

Cooling system under pressure! Only open
the cap when cool!
Observe safety regulatlons and national
specifications when handling cooling me
dia.
If required, repeat procedure with engine start.

Fill up coolant to the MAX mark on the compen
sation tank and close the cooling system cap.
Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
Observe the filling volume of the cooling system
Trial run
I! (.J'
~ I Additional venting of the fuel system b
minute trial run at idle speed or on low
Carry out a brief trial run up to operating tempe,

(approx. 90 'C) after preparations.
Do not load the engine if possible.
Work with the engine not running:
- Check engine for tightness.
- Check lubricating oil level, if necessa[\
up.
- Check the coolant level and top up coe
necessary.
Work during the trial run:
Check engine for tightness.
(~65).
Order coolant corrosion protection agent

~ from your DeUTZ partner.
Connect coolant outlet (2) and coolant inlet (1 Jto
the cooling system. Connect the feed line of the
compensation tank to the coolant pump or to the
coolant inlet line (3).
Connect ventilation line from the engine and, if
necessary, from the cooler to the compensation
tank.
Fill cooling system via the compensation tank.
26
(!;
Operation
Start procedur~
Starting
.& ii
_J
i!
Before starting, make sure thaI nobody is

standing in the immediate vicinity of the en
gine or work machine.
After repair work: Check that all guards
have been replaced and thaI aliloois have
been removed from the engine.
When starting with the flame glow plug/
glow plug/heating flange syslem do nol use
any other starting aid (e.g. injection with
start pilot). Risk of accident!
If the engine fails to fire and the error lamp
lights, the EMR2 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.
00 not actuate the starter for more than
20 seconds. Ifthe engine does not start up,
wait for one minute and then repeat the
starting process.
If the engine does not start up after two at
tempts, determine the cause as per fault ta
ble (~55).
00 not run up the engine immediately to
high idling speed I full load operation from
cold.
Disconnect the engine by uncoupling de
vices to be driven where possible.
E=316~
25745-0
Without cold start aid
Glow plugs with cold start aid
Insert key.
Tum key to the right.
- Position 1 =operating voltage.
Pilot lamps (1) and (2) light up.
Push the key in and turn further clockwise

against spring pressure.
- Level 2 =no function
- Level 3 start.
release the key as soon as the engine starts up.

- The pilot lamps will go out.
Insert key.
Position 0 no operating voltage.
Turn key to the right.

Position 1 = operating voltage.
- Pilot lamps (A), (8) and (C) light up.
- Preheat until the glow display goes out; an
error has occurred if the preheating indicator
flashes; e.g. the preheating relay is stuck,
which can discharge the battery completely
when at a standstill.
- Engine is ready for operation.
Push the key in and turn further clockwise
against spring pressure.
- Level 2 = start.
release the key as soon as the engine starts up.

- The pilot lamps will go out
(t..
2008
27
Operation
Operation monitoring
Operation monitoring by EMR2

Optional
The EMR2 system monitors the
well as the engine electronics and
the driver/operator with the error lamp:
Function test
- Ignition on, error lamp lights up for approx. 2
seconds and then goes out.
The lamp does not light
- After the lamp test an extinguished lamp indi
cates an error-free and trouble-free
Ing state within the scope of the
possibility.
Steady light
- If a lamp lights steadily a monitored measur
ing variable (e.g. coolant temperature, lubri
cating oil pressure) has left the permissible
value range.
Flashing
- Serious error in the system.
Display instrument
Possible displays:
Colour scali
- Display of operating state by coloured areas:
green = normal operating state
- red = critical operatng state
Take suitable action.
Measured value scale

Actual value can be read off directly. The
nominal value should be taken from the
Technical Data (1"165).
.,
'!
28
2008
Operation
Operation monitoring
Instruments and symbols
[ Instruments/symbols
IDesignation
Lubricating oil pressure display
Lubricating oil pressure display
[91
2008
Possible display:
Lubricating oil pressure below minimum
ILubricating 011 pressure in the red area
DfTDfTCD 2011 w
Coolant temperature
Coolant temperature too high
Lubricating oil pressure pilot

lamp
If the pilot lamp lights up after starting the engilleor

while the engine is runr1ing, the lubricating oil pres
sure is too low
Lube oil level
If the pilot lamp lights

while the engine is
too low
DfTDfTCD 2011
Coolant level
Measure
Switch off engine
Switch off engine
Switch off engine
ISwitch off engine
after starting the engine or IFill up lube oil

the lubricating oil level is
If the control lamp lights up after the engine starts or

while the engine is running, the coolant level is too
low
IShut
down the engine, allow to cool and top up
ant
Operating hours counter
Indicates the previous operating time of the engine
IObserve the maintenance intervals
Horn
With acoustic signal
ISee fault table ([;!j 55).
29
Operation
Stop proce~ure
Electrical shutdown (optional)
0{f_hl
Move the key to position O.

Control lamps A+B+C go out.
A :: charge pilot light
B :: lube oil pressure pilot light
C pilot light for pre-heating system
P :: gear position: park
o gear position: switch off engine
1 :: gear position: pre-heat engine
2 :: gear position: start engine
Shutting off
tt I Avoid switching off from full load (coking/

,.! c..r
blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap
prOximately one minute after rerleving the
load.
The control unit remains active for about
another 40 seconds to save the system
data (lag) and then switches off automati
cally.
30
2008
ure
General
Modern diesel engines place very high demands on
the lubricating oil to be used. The specific engine
performances which have increased constantly over
the last few years lead to an increased thermal load
on the lubricating oil. The lubricating oil is also more
exposed to contamination due to reduced oil com
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements
and recommendations described in this operating
manual in order not to shorten the life of the engine.
perature and oxidation stability as well as a relatively

low cold viscosity. Since some processes relevant to
the definition of the lube oil change intervals are not
essentially dependent on the lube oil quality (such as
the incorporation of soot and other contaminations),
the lube oil change interval when using synthetic
lube oils may not be increased in relation to the spec
ifications of the lube oil change intervals.
the engines in this operating manual:
Biodegradable lubricating oils may be used in

DEUTZ engines if they meet the requirements ofthis
operating manual.
~CIV-05
Lubricating oils always consist of a base oil and an

additive package. The most important tasks of a lu
bricating oil (e.g. wear protection, corrosion protec
tion, neutralisation of acids from combustion
products, prevention of coke and soot deposits on
the engine parts) are assumed by the additives. The
properties of the base oil are also decisive for the
quality of the product, e.g. with regard to thermal
load capacity.
Quality
In prinCiple, all engine oils of the same specification

can be mixed. However, mixing of engine oils should
be avoided because the worst properties of the mix
ture are always dominant.
Lubricating oils according to other comparable spec

ifications can be used as long as they meet DEUTZ
requirements. In regions in which none of these
qualities are available, please contact your responsi
ble DEUTZ partner.
The lubricating oil quality has a considerable influ

ence on the life, performance and thus also on the
cosls-effectiveness of the engine. It basically applies
that: The better the lubricating oil quality, the better
Ihese properties.
The lubricating oil viscosity describes the flow be
haviour of the lubricating oil depending on the tem
perature The lubricating oil viscosity has no
inftuence and effect on the lubricating oil quality.
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem
)08
Operating media
Lubricating oil
2008
Lubricating oils are classified by DEUTZ according

to their efficiency and quality class (DOC: DEUTZ
Quality Class). It basically applies that: with increas
ing quality class (DQC I, II, III, IV) the lubricating oils
are more efficient and higher quality. The appended
quality class designation (- 02/- 05) indicates in
which year the classifij;8tion was made.
or see www.deutz.com SERVICE Operating

Media and Diagnosis Deutz Quality Class
DQC Release List (current edition)
Minimum quality class
DEUTZ
Others
IDQC 1__02 \ACEA E2-96; API CF/CF4
If the engine is operated with these lubricating oils,
the lub licating oil change interval must be halved.
Recommended quality class

DEUTZ
DQCII-05
Others
ACEA E3-96/E5-02;
API CH-4/CG4; DHD-1
---
DOC 111-05 ACEA E4-99/E6-04

Please
DEUTZ partner
-_ contact
__ __your
_ - - - - - _
_
.........
..............
.........
DEUTZ lubricating oils DQC II"()S

TlS15W40D
Container
Order number:
5 litre container
01016331
20 litre container
0101 6332
209 litre barrel
0101 6333
............
---~
DEUTZ lubricating oils DQC III"()S

TLX 10W40 FE
Container
Order number:
5 litre container
01016335
20 litre container
0101 6336
209 litre barrel
0101 6337
_ -.J
DEUTZ lubricating oils DQC IV"()S synthetic Container

20 litre container
01017849
209 litre barrel
01017850
Order number:
Lubricating oil change intervals

The intervals depend on:
- lubricating oil quality
The following lubricating oils are recommended for
31
Operating media
sulphur content in the fuel
- type of application of engine
The lubricating oil change interval must be

halved if at least one of the following conditions
applies:
- Constant ambient temperature below -10 'c
(14 'F) or lube oil temperature below 60 'C
(84 'F).
- Sulphur content in the diesel fuel of 0.5-1 %.
In case of fuels containing more than 1% sUl
phur, contact your corresponding DEUTZ
partner.
operation with bio-diesel fuel
If the lubricating oil change intervals are not
reached within ayear, the oil should be changed
at least once a year.
Lubricating oil
Viscosity
The ambient temperature at the installation site or in

the application area of the engine is decisive for
choosing the right viscosity class. Too high a viscos
ity can lead to starting difficutties, too Iowa viscosity
can endanger the lubrication effectand cause ahigh
lubricating oil consumption. Atambienttemperatures
below -40 'c, the lubricating oil must be pre-heated
(e.g. by storing the vehicle or the machine in a haU).
The viscosity is classified according to SAE. Multi
purpose lubricating oils should be used basically.
Single-purpose lubricating oils can also be used in
enclosed, healed spaces at temperatures >5 ' C.
Depending on the ambient temperature we recom
mend the following common viscosity classes:
C
45
L>.
40
35
30
25
2f .
o
15 .~
0010
..,
.. ~.
III
10 .~~~~
If)
The prescribed lubricating oil quality must

be observed when selecting the viscosfty
clas~
If)
If)
If)
..,.0
0
....
..,.
~ ..
'9
a; . ~
N
... ~
If)
If)
..
~
If)
-5
-10
-15
-20
-25
-30
-35
-40
32
2008
:ng oil
Permissible fuels
Winter operation with diesel fuel
The following fuel specifications I standards are ap

proved:
Diesel fuels
EN 590
ASTM D9751-D
ASTM D 975 2-D
NATO F-54
JIS K2204 Grade 1
JIS K2204 Grade 2
Use commerciall v
tent below 0,5 %,
must be halved at a higher
If other fuels are used which do not meet the
men!s of the operating manual. the warranty will be
voided,
certification measurements for compliance with
the legal emission values are made with the test fu
,cified in the laws, These correspond to the
fuels in accordance with EN 590 and
ASTM D 975 described in the operation manual, No
emission values are guaranteed with the other fuels
described in this operation manual.
2008
Operating media
Fuel
2008
+32
[ tt 1Only carry out mixing in the tanK. Fill with
+23
-5
..
+14
10
! c:-r
the appropriate amount of paraffin first.
then add the diesel fuel, Normal and high
grade fuels may not be mixed.
+ 5 15
- 4 - 20
this in good time before the cold season starts),

Below -20C paraffin should be added, The rel
evant percentages are given in the adjacent dia
gram,
Special diesel fuels can be used for arctic cli
mates to -44 :C,
13
25
10
20
30%
B-
If it is necessary to use Summer diesel fuel below
oDC, up to 30 % petroleum can be added according

to the diagram opposite,
A Outdoor temperature
B Percentage of paraffin to be added
sufficient cold resistance can be achieved

a flow improver, Ask your DEUTZ partner,
33
"
""
Operating media
General
A]
I!
even for ashort time!
DfTDfTCD 2011 w
In liquid-cooled engines, the coolant must be condi
tioned and monitored, otherwise the engine could be
damaged by:
corrosion
cavitation
freezing
The right water quality is important for conditioning
the coolant. Clear, clean water within the following
analysis values should always be used:
min
6,5
ph value
~"
Sulphate (S04)
Total hardness
(CaC0 3l
[mgll]
-
[mgll]
[mmolll] 0,53
[mgll]
53
['dGH] 3,0
max ASTM
8,5 D 1293
100 D 512
D4327
100 D 516
2,1 D 1126
213
12,0
-
Specifications of the water quality are made by Ihe

local water board.
The water must be conditioned if il deviates from the
analysis values.
pH value too low:

Addition of diluted sodium or potassium lye.
Smallirial mixtures are advisable
34
Total hardness too high:

Mixing with softened water (pH neutralized con
densate or waler softened by ion exchanger).
Total hardness or carbonate hardness too
low:
Mixing with harder water (harder water is usually
available in the form of drinking water).
Chlorides and/or sulphate! too high:

Mixing with softened water (pH neutralized con
densate or water softened by ion exchanger).
Cooling system corrosion protection agent
Water quality
~b""(CI)
Co
[&.~ Health damaging nitrous amines fonn

! I when nitrite-based cooling system corro
sion protection agents are mixed with
amine-based agents!
I~I must
Cooling system corrosion protection agents
be disposed of "in an environmentally
,
friendly way.
The conditioning of the coolant for liquid-cooled

DEUTZ compact engines is performed by mixing an
anti-freeze with corrosion protection inhibitors based
on ethylene glycol into the water.
DEUTZ cooling system corrosion protection
agent
Container
Order number:
5 litre container
01011490
Tolilre container
01164160
210 litre barrel
12211500
ed to the materials in our engines. Order Ir

DEUTZ partner.
Please contact your DEUTZ partner if the I
cooling system corrosion protection agent
available.
The cooling system must be monitored reg
This also includes checking the coolant sy~
rosion protection agent concentration in ad
checking the coolant level.
The cooling system corrosion protection a
centration can be checked with convention.
slruments (e.g. refractometer).
Cooling sys- Water percent Coldpr
tem corrosion age
tion up
protection
agent percent
age
min. 35 %
65%
-2t
60%
40%
-31
max. 45 %
55%
L __
At temperatures below -35 C, please cont

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

free from nitrite, amine and phosphate and is adapt
&',IItI.~i~i!'!lMl"i"'(CJcc,,, ,'~
Maintenance
lnt
Mainte~ance schedule
Jur
Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
;Standard maintenance schedule

D/TDrrCD 2011
To be carried out by
Maintenance interval every ....... operating hours (oh)
Authorised specialists
cor
1 to
When commissioning new or overhauled engines
Operator
1x daily or every 10 operating hours in continuous operation

D: 1.000 1)
- - + - - - - - - - - - - - - - - 1 1 Qualified personnel
TOrrCD: 500
1000
3.000 2) / 5.000 3) /6.000 4
~on
3t in-
",
Authorised specialists
EPA-certified engines
~he
EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to

Stage
IActivity
ITo be carried out by
'e60
IIntermediate overhaul
IAuthorised specialists
~A
certification
IMaintenance interval every ....... operating hours (oh)

3.000
Observations
/Our
sion
ction
UTZ
008
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here ([llJ31).
Toothed belt change intervals recommended
values in op. h
Engine application example:
3,000 or max. 5 years
Agricultural machinery; skid steer loader; wheel loader; Ihigh speed; impact load; extreme ambient tempera
drilling machines; trench differs; joint cutters; excavators ture; high dust load
etc.
compressors; rollers; stackers; welding units; wheel

loaders small dumpers; skid steer loaders, etc.
medium to high variable speed; high ambient temper

ature medium dust load
Electrical units 1500/1800 rpm; pump units with low

speed; lifting platforms; cooling aggregates etc.
low speed; medium ambient temperature low dust

load
i.J 2008
35
~"'''Y'''''''''''''l'' "Yl"".",,~
Maintenance
Maintenance schedule
Maintenance measures
Activity
Stage
E10
E20
Check
I
E30
Replace
Check
E40
Check
Measure
The measures are listed in chapter 3.
Lubricating oil level (if necessary top up)
OtTOtTCO 2011 w
Coolant level (top up if necessary)
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator)
Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application
type can be created, for example, with the OEUTZ oil diagnosis. Ask your OEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed)
TOtTCO:
Single checking and setting of the valve clearance if necessary at the first lubricating oil change
Heating plugs
OtTOtTCO 2011 w
Coolant (additive concentration)

Battery and cable connectors
V-belts (retension or renew if necessary)

Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Valve clearance
By-pass lubricating oil filter
Fuel filter cartridge
Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary)

Suction air filter/dry air filter (maintain in accordance with maintenance indicator)
Toothed belt
Injection valve
Charge air cooler entry area (drain lube Oil/condensate)
Turbocharger compressor outlet
Settings
Replace
Clean
E50
Replace
E60
Replace
Clean
--
36
----_ _
..
..
Page
@25
1l1i38
:!l:26
iiil48
r"l31/~38
~39
1~51
llil44
J!!53
[M9
l;l]51
~42
[ID411~43
1MB
:~35
J _______
2008
dule
Main~enance
schedule
Maintenance
---
'age
25
L_ _ _ _
!Stage
I Every 2
!years
Measure
V-belts
Heating plugs
Activity
Replace
OffOffCD 2011 w
Coolant
38
26
Page
~49
~34Cij44
----
Maintenance work outside the OeUTZ maintenance and service schedules

'If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately
Maintenance profile
"~
self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment
Order number:
0312 3538
'C51
'42
41/243
c48
35
;) 2008
2008
37
Care and maintenance work

Regulations for working on the lubricating oil
system
The oil level must always be between the MIN

and MAX marks! Top up to the MAX mark if nee
essary.
!--1 Do not work when the engine is running!

IA\ I Smoking and naked lights prohibited!
Changing the lubricating oil
Be careful of hot lubricating oil. Danger of

scalding!
'J
Pay attention to utmost cieanUness when

~ working on the lubricating oil system. Clean
the area around the components con
cemed carefully. Blow damp parts dry with
compressed air.
Obselve the safety regulations and nation
al specifications for handling lube oils.
Dispose of leaking lubricating oil and filter
elements proper1y. Do not allow used oil to
seep away lnto the ground.
Perform a trial run after all work. Pay atten
tion to lightness and lubricating oil pressure
and then check the engine oil level.
In case of fuels containing more than 1%
sulphur, contact your corresponding
DEUTZ partner.
Lubricating oil system
Checking the lubricating 011 level
Low IUbnca,'ting oil level and overfilling lead
! C.t to engine damage.
I,
Ji\
I
The lubricating oil level may only be

check~ with the engine in a horizontal p0
sition and switched off,
If the engine is warm, switch off the engine
and check the lubricating oil level after 5
minutes, Ifthe engine is cold you can check
it immediately.
Warm up the engine (lubricating oil temperature

> 80 e),
Ensure that the engine or vehicle is in a level po
sition.
Switch off the engine.
Place a collecting receptacle underneath the
lube oil drain screw.
Unscrew the lube oil drain screw, drain oil.
Fit a new sealing ring to the lube oil drain screw,
insert and tighten. (tightening torque 100 Nm).
Pour in lube oil.
Quality/viscosity data.
- Filling volume
Warm up the engine (lubricating oil temperature

> 80C).
Ensure that the engine or vehicle is in a level po
sition.
Check lubricating oil level, if necessary top up.
Be careful of hot lubricating oil. Danger of

scaldingl
Pull out the lubricating oil dipstick and wipe off

with a lintfree, clean cloth.
Insert the lubricating oil dipstick as far as it will
go.
Extract the lubricating oil dipstick and read off the
oil level.
38
2008
Change lubricating
The filter cartridge should never be pre

filled. There is a danger of dirt contamina
tion!
Oil the gasket of the new DEUTZ original filter

cartridge lightly.
Screw on new filter by hand until the gasket is
place and then tighten with a torque of 15-17 Nm.
Fasten clamps of the twist proteclion (optional).
Remove clamps when twist protection mounted

and unscrew filter cartridge with tool (or

der number: 170050).
draining lubricating oil

the sealing surface of the filter support
wilr a lint-free. clean cloth.
2008
39

Specifications when working on the fuel system
IAI
Engine must be switched off!
IA\ I SNomoking
and naked lights prohibited!
injection/high pressure pipes may be
disconnected while the engine is running.
Caution when handling hot fuel!
Pay attention to utmost cleanliness when
refuelling and working on the fuel system.
Clean the respective affected parts careful
ly. Blow damp areas dry with compressed
air.
Observe the safety regulations and nation
al specifICations for handling fuels.
Dispose of leaking fuel and filter elements
proper1y. Do not allow fuel to seep away
into the ground.
After aU work on the fuel system, the sys
tem should be vented, atrial run performed
and the tightness checked.
It will be necessary to vent the fuel system
When commissioning for the first time, after
maintenance work or if the tank has been
run dry.
I~
Fuel system
tt
I
I Clean and dry the engine and engine com
~ partment thoroughly before beginning
work.
Areas of the engine compartment from
which dirt could be loosened must be cov
ered with a fresh, clean foil.
Work on the fuel system may only be car
ried out in an absolutely clean environment.
Contamination of the air such as dirt, dust,
moisture etc. must be avoided.
ttl Additional
venting of the fuel system by a 5
c.r
minute trial run at idle speed or on low load
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and ciosed.
Make a visual inspection for leaks/damage
in the system.
40
2008
Fuel system
Vent the fuel system
Pump in the direction of the arrow (3) until a

strong resistance is felt and pressure has built
up.
The return line (5) must be tilled.
Startthl'! AnninAJ>nd run in idle oron low load. Air
the return pipe 5) to the tank.
change

fuel shutoff tap (with high-level tank) (sup
Re'Lwe connection (4) to the fuel tilter.

:1 any escaping fuel.
screw (1)
ReG!ove fuel screen (screw (1), cover and fuell
scre"i1 form one unit).
T8:, the sealing ring (2) and clean it, renew
wh.' damaged.

cover-fuel screen with fuel, renew deon the condition.
sealing ring (2) in position.
the cover-fuel filter with screw (1).
connection (4) to the fuel tilter.

fuel shutoff tap supply (7), start engine and
Idle or on low
for leaks after starting the engine.
2008
41
Change the fuel filter cartridge
.
J
The filter cartridge should never be pre

~ filled. There is a danger of dirt contamina
tion!
Remove clamps when twist protection mounted

(optional).
Loosen and unscrew filter cartridge with tool (or
der number: 170050).
Catch any escaping fuel.
Clean the sealing surface of the filter support
with a lint-free, clean cloth.
42
Fuel sySl
Oil the gasket of the new DEUTZ original filter

cartridge lightly.
Screw on new filter by hand until the gasket is in
place and then tighten with atorque of 10-12 Nm.
Pasten clamps of the twist protection (optional).
Vent the fuel system.
08
Fuel sys~em
with fuel.
Assembly in clockwise direction.
Open the fuel shutoff tap and vent the system.
see venting the fuel system.
Start engine.
Check for leaks after starting the engine.
Change the fuel pre-filter insert
Clean/change/vent the fuel pre-filter
3
4
6
7
~:uel pre-filter holder

::llel filter insert
'!Vater collection vessel
<.Vater drain tap
llel pump
'Sealing surface
Jenting screw
Shut off the fuel supply to the engine (with high

tank).
~)Iace a vessel under the drain plug.
.-Jpen the drain tap (4) and drain off the liquid.
Jnscrew the filter insert (2) together with the wa
collection vessel (3).
':mpty emulsion in the water collection vessel (3)
.1nd clean the vessel.
rv10unt the filter insert (2) and water collection
jessel (3). Wet the sealing surfaces (6) ofthe fil
insert (?\ and the water collection vessel (3)
<~vel
2008
Shut off the fuel supply to the engine (with highlevel tank).
Place a vessel under the drain plug.
Open the drain tap (4) and drain off the liquid.
Unscrew the filter insert (2) together with the wa
ter collection vessel (3).
Unscrew the water collection vessel (3) from the
filter insert (2).
- The
Clean the water collection vessel (3) and all the

existing sealing surfaces (6) with a brush and
diesel fuel.
surfaces (6) of the
Oil the gaskets and
new DEUTZ original filter
(2) lightly or wet
with diesel fuel.
Screw the water collection vessel (3) to the filter
insert (2).
Screw a new filter insert (2) with water collection
vessel (3) onto the filter carrier 1) (tightening
torque 17-18 Nm)
Open the fuel supply to the engine.
Vent the fuel system.
bubbles.
Catch any escaping fuel.
Tighten the venting screw (7).
Vent the fuel system
Bring engine control to stop position.

Position fuel collecting vessel below the con
stant-pressure valve in the crankcaselfilter hous
ing.
Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
Turn over the engine with starter (max. 20 Sec.)
until bubble-free fuel emerges at the constant
pressure valve in the crankcaselfilter housing.
Screw in ventilation screws (tightening torque
25-5 Nrn) and constant-pressure valve
Bring engine control to the start position and
start.
Check for leaks after starting the engine.
Vent the fuel pre-filter.
Loosen the venting screw (7) slightly.

Operate the pump until fuel emerges without
43

Specifications when working on the cooling sys
tem
DITDITCD 2011 w
'A! 1j
\
Danger of scalding from hot coolant!

Cooling system under pressure! Only open
- - the cap when cool!
The coolant must have a prescribed con
centration of cooling system corrosion pro
tection agentl
Observe safety regulations and national
specifications when handling cooling me
dia.
Observe the manufacturer's specifications
for an extemal cooler.
Dispose of leaking liquids properly and do
not allow them to seep into the ground.
Order coolant corrosion protection agent
from your DEUTZ partner.
even for a short time!
Checking the coolant level with an external cool

er
DITDITCD 2011 w
Fill in new coolant and vent the system according
to the specifications of the cooling system manu
facturer.
Open the cooling system cap (1) carefully.
The coolant level must always be between the
MIN and MAX marks of the compensation tank!
Fill up to the MAX mark if necessary.
44
Cooling system
(~~
c\{?
.,.~,

;;---0
-?
/'
Check coolant additive concentration
Emptying the cooling system
DITDITCD 2011 w
DITDITCD 2011 w
Open the cooling system cap (1) carefully.

Check the coolant aditive concentration in the
cooler/compensation tank (2) with a convention
al antifreeze measuring device (1) (e.g. hydrom
eter, refractormeter).
Necessary coolant additive concentration Cool
ant mixing ratio (!'1J34).
Open cooler locking cap carefully.

Place a collection tray underneath the coolant
connection (1),
Drain coolant.
Reconnect and tighten the coolant connection
(1 ).
If the locking screw is not accessible, the drain
age can be carried out al the engine oil cooler
(coolant duct).
Close cooler locking cap.
You can order the appropriate test instrument from

your DEUTZ partner under order number 1824.
2008
:ooling system
lion tank if necessary.
II and ventilate cooling system
TDITCD2011 w
)pen 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.
1::lose the cooler venting screw.
'::Iose cooler locking cap.
Run engine up to operating temperature (open
I1g temperature of the thermostat).
Switch off the engine.
(~heck coolant level in cooled engine and top up
)the
45

Cleaning work
Cleaning with cold cleaner
' ~ I For all cleaning work, make sure that no

II
~ parts are damaged (e.g. bent cooler mesh).
Spray the engine with cold cleaner and leave it

for about 10 minutes to take effect.
Spray the engine clean with a high pressure wa
ter jet.
Warm up the engine so that the water residues
evaporate.
Cover electricaVelectronic parts and con

nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do
not aim the water/steam jet directly at them.
Allow engine to wann up.
A1 Only carry out cleaning work on the engine

ili I when it is not running!
rI
~ Remove the engine cover and cooling air
cover if available and remount after clean

ing.
General
Engine cleaning
Cleaning with a high pressure cleaner

Clean the engine with a steam jet (maximum
spray pressure 60 bar, maximum steam temper
ature 90 'C, distance at least 1m).
Warm up the engine so that the water residues
evaporate.
Always clean the cooler and cooling fins from the
exhaust air side to the fresh air side.
The following causes of soiling make it necessary to

clean the engine:
High dust content in the air.
Chaff and chopped straw in the area of the en
gine.
Coolant leaks
Lubricating oil leakage
Fuelleaks
Because of the different application conditions.
cleaning depends on the degree of dirt contamina
tion.
Cleaning with compressed air
Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
46
2008
suction system
Regulations for working on the intake system
Renewing the safety cartridge of the dry air filter
~ Do not work when the engine is
[!2:) I Never clean the safety cartridge (4).

Renew safety cartridge (4) according to the inter
val in the maintenance schedule
To do this:
Unscrew hexagon nut (5), pull out safety car
tridge (4).
~ Insert new safety cartridge, screw on hexag
onalnut.
Insert fiHer element (3), mount hood (2) and fix
with clamping yoke
Pay attention to utmost cleanliness when
working on the intake system, close intake
openings if necessary.
Dispose of old filter elements properly.
Maintaining the dry air
IA.I
I
Do not clean the filter element (3) with pet

ral or hot liquids!
Renew damaged filter elements.
Maintain the filter element (3) according to the in

terval 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):
~ blowout with dry compressed air (max. 5
from the inside to the outside if soiling is
slight,
~ renew if heavily soiled.
2008
47
Suction system
11
Maintenance indicators for dry air filter
The dry air filter is maintained

maintenance switch or maintenance
Maintenance is necessary when:
- the yellow warning light of the maintenance
switch lights up when the engine is running.
- the red field (1) of the maintenance indica
tor is fully visible.
After carrying out maintenance work, reset the
signal by pressing the button on the mainte
nance indicator. The maintenance indicator is
now ready for operation again.
48
Clean the dust discharge valve of the

Emntv the dust discharge valve (1) by pressing
the discharge slit.
Remove any caked dust by pressing together the
upper section of the valve.
Clean the discharge slit.
Emptying the cyclone precleaner
Ch4
I l':-1.1 Never fill the dust container (3) with lubri

! c;..r eating oil!
Loosen wing nut (1) and lift off housing cover (2).
Remove the dust container (3) from the base
and empty it. Clean the container using a
and clean diesel fuel. Then dry.
Place the dust container (3) on the base (4) and
tighten the housing cover (2) with wing nut (1).
2008
Belt drives
Checking the belt tension
wear on
V-belt.
After repair work: Check that all guards
have been repfaced and that all tools have
been removed from the engine.
:over (2).
base
a
and
) 2008
..

Check the whole belt drive visually for damage.

Renew damaged parts.
Remount protective devices if necessary.
Pay attention to correctfit of new belts, check the
tension after nunning for 15 minutes.
Lower indicator arm (1) into the measuring de
(3) between two belt pulleys on the

The'stop have to be at the side.
Press the button (4) at right angles to the V-belt
evenly until you hear or feel the spring snap
Lift the measuring device carefully without alter

ing the position ofthe indicator arm (1).
Read the measured value at the point of inter
section (arrow), scale (5) and indicator arm (1).
If necessary, re-tension belt and measure again.
Tools
Belt tension measuring device (order number:
8115) can be obtained from your DEUTZ partner.
2008
generator
Loosen the screw (1), (2) and (3) slightly.
Push the generator (4) outwards in the direction
of the arrow until you get the correct V-belt ten
sion.
Retighten the screw (1), (2) and (3).
Renew the V-belts

Loosen the screw (1), (2) and (3) slightly.
Swing the generator (4) in in the opposite direc
tion to the arrow.
Remove the V-belt (5) and fit a new V-belt.
Push the generator (4) outwards in the direction
of the arrow until you get the correct V-belt ten
sion.
Retighten the screw (1), (2) and (3).
49
Belt drives
Retighten the screws (1) and (2).

Checking the belt tension (["165).
Tighten belt
Loosen screws (1) and (2) and (3).
Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
Retighten the screws (1) and (2).
Checking the belt tension (r165).
Change the belt

Loosen screws (1) and (2) and (3).
Move the tensioning pulley (3) in the direction of
the arrow (8).
Remove belt and fit new one.
Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
50
2008
~It
drives
.Setting work

Valve clearance setting schematic
Engines with turbocharger
TDITCD2011
This engine is equipped with an internal ex
~ haust feedback system.

The inlet valve opens briefly in the out
stroke.
Do not confuse this with the valve over
lap!
:;heck valve clearance, adjust if necessary

Let the engine cool down for at least 30 minutes
before setting the valve clearance: Lubricating oil
temperature below 80 'C.
Remove the cylinder head hood.
Place turning gear over fastening screws of the
belt pulleys.
Turn the crankcase until reaching valve overlap.
Outlet valve is not yet closed, inlet valve be
gins to open.
The cylinders to be set can be seen in the
setting schematic.
Engage hexagon socket head wrench (7) and in

sert and loosen the lock nut (4).
Adjust the valve clearance setting screw (5) with
the hexagon socket head wrench (7) so that the
correct valve clerarance (1) is reached after
tightening the lock nut (4).
Perform the setting procedure on every cylinder.
Reinstall cylinder head cover, with new gasket
Valve overlap
Settings
Cylinders
Cylinders
1
3
4
2
1
Check the valve clearance (1) between the rock

er arm lugs (2) and the valve (3) with a feeler
gauge (6).
The feeler gauge (6) must slide in with little re
sistance.
For permissible valve clearance, see (~65)
Adjust valve clearance if necessary:
2008
.~
2008
51
Setting work
Valve clearance setting schematic

Suction motor
D 2011
Crankshaft position 1
Tum crankshaft until both vaalves overlap on the
cylinder.
Outlet valve is not yet closed, inlet valve begins
to open.
Setblack marked valves.
Mark the respective rocker arm with chalk to
check the setting you have made.
Crankshaft position 2
Turn the crankshaft one turn (360 0).
Setblack marked valves.
[t]lU
'
52
2008
19 work
Electrical system
Regulations for working on the electrical system
---I Do not touch the voltage conducting parts,
1,6! faulty warning lamps should be immediate

,-- j
Iy replaced,
Jverlap on the
Pay attention to correct polarity of the con
nections.
Cover electricaVelectronic parts and con
nections to dean the engine (e,g. control
units, generator, solenoid valves etc.), Do
not aim the water/steam jet directly al them.
Allow engine to warm up.
Touching a lead against the frame to check
whether it is live must not, under any cir
cumstances' be carried out.
For electrical welding work, the ground ter
minal of the welding gear must be clamped
directly to the part being welded,
Three-phase current generator: Never dis
connect the cables between battery, gener
ator and regulator while the engine is
running.
t valve begins
ith chalk to
IJ,
Battery
Electronically stored data could be lost if
the battery is disconnected.
Keep battery dean and dry.
Make sure the battery is fitted correcUy and
securely.
Dispose of old batteries in an environmen
tally friendly way.
[J1\
I Danger of explosion! The gases emitted by
! I the battery are explosive!
- Fire, sparks, smoking and naked lights are

prohibited!
Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
and clothing!
Danger of short circuit! Do not rest tools on
the battery!
Checking the voltage

Check the battery voltage with a conventional
voltmeter. The voltage indicates the charging
state. It should be between 12 and 14.4 Volt de
pending per battery.
Check acid level
Check acid density
Unscre'l" caps.
Note the manufacturer's specifications concern
ing the liquid level.
The liquid should normally be 10-15 mm above
the top edge of the plate or reach up to any avail
able control device.
Only use distilled water to top up the battery.

Screw in caps,
Unscrew caps.
Measure the electrolyte density of individual cells
with a commercial hydrometer. Hydrometer
reading indicates battery's state of charge. The
acid temperature when measuring should be 20
C if possible.
Check the acid levaI before recharging.
Screw in caps.
Acid density [kg/I]
Nonnal
Tropical
r-------:-:-:-- 1---:-
1,23
1,28
1,20
1,12
1.12
1,08
Charge
status
Measure
-
good
half
empty
none
charge
charge
I
I
Removing the battery

Always disconnect the minus pole first when re
moving the battery. Otherwise there is a danger
2008
2008
53
Electrical SystE
of short-circuit!
Remove the fastenings and take out the battery,
Charging the battery
with a conventional battery
manufacturer specifica
Screw in caps,
InstaIIing the battery
Insert new or oharged battery and attaoh the fas

tenings,
Clean the terminals and battery poles with fine
emery paper.
Connect the plus pole first and then the minus
pole, Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact,
Tighten clamp bolts hand-tight
Grease the assembled terminals with an acid

free, acid-resistant grease,
54
2(
Faults
Fault table
Faults and remedies
does not start or is difficultto
does not start and d agnostic

flashes
--
2Q08
Causes
Not disconnected (if possible)
Below starting limit temperature
Wrong SAE viscosity class of the engine lubricating oil
Fuel quality does not comply with operating manual
Battery defective or discharged
Cable connection to starter loose or oxidized
Starter defective or pinion does not engage
Stop magnet defective (release circuit)
Engine stop lever still in stop position
Incorrect valve clearance
Injection valve defective
Air filter clogged f turbocharger defective
Air in fuel system
Compression pressure too low
Exhaust gas backpressure too high
Injection line leaks
Engine electronics prevents starting
Measures
!Check coupling
Check
Change the lubricating oil
Change the fuel
Check battery
Check cable connections
---Check starter
Check lifting magnet
-Check/replace
--Check/replace
Check valve clearance and set if necessary
Check fuel injector f change if necessary
Check/replace
Vent fuel system
Check compression pressure
Check
Check injection line
Check error according to error code and
eliminate error if necessary
--------~
-------~
--
-----
55
Faults
Fault tabh
Faults
Engine starts, but runs irregularly or
fails
Causes
BeIW-rib belt (fuel pump in belt drive)
Compression pressure too low
Glow plugs defective
Air in fuel system
Fuel filter contaminated
Speed changes are possible and diag Engine electronics has detected a system error and activates an equivalent speed
nostic
lamp_lights
up -.
_._._ ___
__
_
- --.-.- -.
_._._ _
_ __
...
..
._._..
..
._._...
..
- - - -..
..
..
-.~
... .. - - . - . - ..
.. --.-.
..
..
..
- -
- -
..
.. _._.
Measures
Check whether torn or loose
Check valve clearance and set if necessaf'!
Check compression pressure
Change
Vent
Clean
Change the fuel
Check fuel injector I change if necessary
'l,
56
"
2
I
_i""'&$kJ.4';;;M*iW~Jl~~~!~~i~'n.,
Faults
Fault table
Faults
. - - - _..
Engine becomes excessively
femperature warning system acti
vates
Causes
Vent line blocked

Wrong SAE viscosity class of the engine lubricating oil
Lubricating oil cooler fins soiled
Lube oil filter contaminated on the air or lube oil side
Lube oil level too high
Lubricating oil level too low
starter defective or pinion does not engage
----

Coolant heat exchanger soiled
Defective cooling water pump (torn or loose V-belt)
Low coolant
._.
Resistance in cooling system is too high / flow volume too low

Cooling fan or exhaust thermostat defective, V-belt torn or loose
Heat short-circuit in the cooling air guidance
----
Charge air line leaking

Charge air cooler soiled
Measures
Clean
..-
-
Clean
Change
Check lube oil level, if necessary drain off.
Fill up lube oil
._._
._-_._
Check starter
Check lifting magnet
Clean
Check whether torn or loose
Fill up
Check the cooling system
Check/replace/tension
Check charge air line
---
Check/clean
Check/replace
Check/replace
Check fanN-belt, change if necessary
._.
._
._.
Air filter clogged / turbocharger defective

Air filter maintenance switch / maintenance indicator defective
Fan defectiveN-rib belt torn or loose
2008
57
_1
Faults
Fault table
Faults
Engine output is deficient
causes
Measures
CheckiUbe oil level, if
drain off.
Lubricating oil level too low
Fill up lube oil
Lubricating oil cooler fins soiled
IClean
Engine stop lever still in stop position
IStop magnet defective (release circuit)
I
Change the fuel
~~~--------------~.
Air filter clogged I turbocharger defective
Check/replace
I
I Air filter maintenance switch f maintenance indicator defective
Check/replace
Fan defectiveN-rib belt torn or loose
ICheck fanN-belt, change if necessary
Check
air line
~~--------~----------------------------------~
Charge air cooler soiled
Clean
Heat short-circuit in the cooling air guidance
Resistance in cooling system is too high I flow volume too low
ICheck the cooling system
---------1
Check fuel
-----'---
Engine performs poorly and diagnos- Engine electronics reduce performance
tic lamp lights
Engine does not run on all cylinders IInjection line leaks
Check lube oil level, if
drain off.
,Air filter dogged f turbocharger defective
Check/replace
Air filter maintenance switch f maintenance indicator defective
Check/replace
Change the fuel
Engine lubricating oil pressure is non- Lubricating oil level too low
Fill up lube oil
.e.Xistant or excessively low
i Excessive inclination of engine
Check engine mounting I reduce inclination
'I
58
Wrong SAE viscosity dass of the engine lubricating oil
2008
'2008
=,~\l;~\I:"h'"
~~~1P'~,'l',I'~Y~'
Faul~
,,:'"
"I"",i"
",'1,.' '.
Faults
table
Faults
Engine.'""""""u"lj oil consumption
:excessive
Lubricating oil in theexh~ust system
Engine producing blue smoke
-----------
Engine producing white smoke
---------------
:Engine producing black smoke
Causes
Excessive inclination of engine
Engine operated continuously with too Iowa load (<( 2030%)
Excessive inclination of engine
Below starting limit temperature
Air filter clogged I turbocharger defective
Air filter maintenance switch I maintenance indicator defective
Charge air pressure-dependent fulllQad stop defective
Measures
Check load factor
Check
Change the fuel
Check/replace
Check/replace
Check
------------
@2008
59
Faults
Engine managem
Diagnostic key and error lamp
The diagnostic key (1) and the error lamp (2) are ac
commodated in the vehide drive stand. The blink
code release can be activated using the diagnostic
key (1).
The error lamp can release the following signals:
Function test
Ignition on, error lamp lights up for approx. 2
seconds and then goes out.
-
Optional
Depending on the design of the monitoring functions,
the EMR2 system (3) can protect the engine in cer
tain problematical situations by monitoring important
limit values during operation and checking the cor
rect function of the system components.
60
Check the error lamp if there is no reaction

after switching on the ignition.
The lamp does not light

- After the lamp test an extinguished lamp indi
cates an error-free and trouble-free operat
ing state within the scope of the control
possibility.
Switch off prompt for the operator. Attentic

Failure to do so will lead to loss of guaran
Automatic shutdown of the engine after a i
warning time, possibly in connection with <
lock.
Engine forced to run at low idle speed to co
engine, with automatic shutdown if necess
Start lock
Please contact your DEUTZ-partner in case o'

functions and sare parts inquiries. Our special
trained personnel will ensure fast, professiona
pairs using original DEUTZ spare parts in caS1
damage.
Steady light
- Error in the system.
- Operation continued with restrictions.
- The engine must be checked by a DEUTZ
partner.
Flashing
- Serious error in the system.
- The engine has reached switch-off condition.
The switch-off process has been accom
plished.
Blinkcode
- Errors that may occur can be dassified.
- The blink codes can only be interpreted by a
DEUTZ partner.
The flashing error lamp may have the follOwing
meaning depending on the engine configuration:
ent
Faults
Engine management
,n:
Gear oil pressure

Battery voltage
Accelerator position
Fuel consumption
tee!
,hart
l start
Error messages are displayed in clear text and

acoustically; the error memory of the control unit can
be read out.
For a detailed description, refer to the operating in
structions enclosed with the DEUTZ Electronic Dis
play.
to! the
;ary.
fmal
Ily
II re
e of
~ order to show measured values and error messag

;5 of the EMR control unit, a CAN display is option
lily available, which can be integrated into the
iashboard of the driver's position of working ma
:hines.
data sent from the EMR control unit through CAN
;an be displayed.
2008
Engine speed
Engine torque (current)
Lubricating oil temperature
Coolant temperature
Suction intake air temperature
Exhaust gas temperature
Gear oil temperature
Lubricating oil pressure
Coolant pressure
Charge air pressure
Fuel pressure
92008
61
Transport and storage
Transpol"i
~~
Suspension equipment
A'rNays use proper suspension equipment when

transporting the engine,
The suspension device (1) must be adjustable
for the engine's centre of gravity.
After transportation and before commissioning of
engine: remove attachment eyes (2).
62
rAl Danger to lifel
L61 The
engine may lip over or fall down if sus

pended incorrec:tly!
The fastening attachment cannot be fixed se

curely above the centre of gravity (1 ),
The fastening attachment can slip, the engine
swings backwards and forwards (1),
Too short a fastening attachment causes bend
ing torques in the transport device (2) and can
damage it.
'201
rt
008
Protec,ting the engine against corrosion

General
'engines contain the following types of corrosion pro
:ection:
Interior corrosion protection
Exterior corrosion protection
Your OEm partner has tile rig/lt corro

sioo proteciiM agent for Yfi;!r neeQs. ' .
(he following measures for corrosion protection af
'er taking the engine out of operation meet the re
luirements for 12 months corrosion protection.
he following corrosion protection work may only be
arried out by persons familiar with it and instructed
the potential dangers,
by wetting of the walls with the implemented cor

rosion protection agent in a corrosion protection
run of the engine.
The corrosion protection run can be performed
once to protect the different systems:
Cooling system
Fuel system
Close,"the,
k/supply line to the err.
~ gine so!hm the system is Pl'Qtectedagainst
dirt and dust. Proted the eIactrooics
against moisture and corrosion.
fueIIIao..
Fill the fuel tank with a mixture of:

- 90 % distilled fuel
- 10 % corrosion protection oil SAE 20W-20
Perform a corrosion protection run with no load
for at least 5 minutes.
Depending on the series the engines are

equipped with cooling air, cooling oil or cooling
fluid sYStem (cooling water with cooling system
agent),
see the Exterior corrosion
'he engine corrosion protection should be checked

,bout every 3 months by opening the covers, If cor
"sion is detected, the corrosion protection shouId
renewed.
!'It the end of the corrosion protection work the crank
'1rive may no longer be turned so that the corrosion
'rotection agent in the bearings, bearing liners and
'ylinder liners is not scraped off.
:3efore operating a corrosion protected engine, the
arrosion protection must be removed,
Drain lubricating oil from warm engine.

Thoroughly clean lube oil tray, cylinder head with
rocker arms, valves, valve springs with diesel
fuel or cleaning agent.
Fill the engine with corrosion protection oil SAE
20W-20 up to the MAX mark and perform a cor
rosion protection run for at least 5 minutes so
that all the components of the lubricating oil sys
tem are wetted or wet all accessible parts with
corrosion protection oil and pump corrosion pro
tection oil through the engine with a separate
pump until all bearings and bearing liners are
wetted.
'nlerior corrosion protection
Air compressor
Interior corrosion protection is always provided
~ 2008
suction system after shutting down the engine

until it emerges visibly from the pressure nozzle.
DfTDfTCD 2011 w
If acoolant with corrosion protection properties is
poured into liquid-cooled engines, no further ac
tion is necessary after draining,
If not, the coolant must be drained and, to ensure
the formation of a covering layer on the inside
surfaces of the cooling system, a corrosion pro
tection run performed with a mixture of:
95 % treated water
- 5 % corrosion protection agent
The duration of the corrosion protection run and
the concentration of the corrosion protection
agent are specified by the manufacturer of the
corrosion protection agent.
Then drain the coolant.
If a compressor is installed, a corrosion protec

tion agent must be sprayed into the compressor
63

Air intake pipes
After the corrosion protection run, remove the
cylinder head cover and deinstall injectors. The
respective piston must be set to LT.
The accessible part of the cylinder liner should
be coated with corrosion protection oil with a
spray lance through the opening.
Spray corrosion protection oil SAE 20W-20 into
the suction air intake line.
Exterior corrosion protection
The engine must be deaned thoroughly with a
deaning agent before exterior corrosion protec
tion. Any signs of corrosion and damage to the
paintwork must be removed.
Cooling air system in air-cooled engines
The air guidance compartment of the engines is
unpainted and must be sprayed with acorrosion
protection agent.
Bare exterior surfaces and parts
Coat or spray all bare exterior parts and surfaces
(e.g. flywheel, flange faces) with corrosion pro
tection agent.
Rubber parts
Rubber parts (e.g. muffs) which are not painted
over must be rubbed down wah talcum powder.
Belt drive
Remove V-belts and V-rib belts and store
packed.
Spray V-belt pulleys and tension rollers with cor
rosion protection agent.
64
Protecting the engine against corrosion
Toothed beits for engine control may not be re

moved.
Engine openings
All engine openings must be fitted with air-tight,
water-tight covers to delay the vapourisation
process of the corrosion protection agents.
With installed air compressor, the suction and
pressure connection must be sealed by a cap.
Air should be exduded to avoid ventilation of the
engine (chimney effect) for the suction from an
air supply pipe.
Storage and packaging
After being protected against corrosion, the en
gine must be stored ina dry, ventilated hall and
suitably covered.
The cover must be placed loosely over the en
gine so that the air can circulate around it to pre
vent oondensation from forming. Use a desiccant
if necessary.
Removal of corrosion protection

The corrosion protection must be removed from
the corrosion protected engine before starting.
The packaging and all covers over the closed
openings must be removed.
Any corrosion deposits and paint damage should
be remedied.
fuel.
Unscrew the lube oil drain screw, drain oil.
Fill the engine with lubricating oil via the lubricat
ing oil filler neck.
Coolant system
DITDITCD 2011 w
If the implemented corrosion protection agent is
compatible with the intended cooling system pro
tection agent, this can be fliled directly into the
coolant system as specified.
If it is uncertain whether the implemented corro
sion protection agent is compatible with the cool
ing system protection agent, the cooling system
should be purged with fresh water for about 15
minutes before filling.
Removal of exterior corrosion protection
Ail areas and components coated with corrosion

protection agent must be washed off with dis
tilled fuel or asuitable cleaning agent.
Wash out grooves of V-belt pulleys if necessary.
Mount V-belts or V-rib belts as specified.
Fill with coolant.
Fuel system
If there is a mixture of diesel fuel/corrosion pro
tection oil in the fuel tank, drain it.
Connect fuel/tank/supply line to the engine. Pay
attention to cleanliness.
Fill the fuel tank and fuel system with the proper
2008
Technical data
Engine and setting data
General technical data
Dimension
nginetype
lorking principle
narging
02011 L021
02011 L031
02011 L04 i
Four-stroke diesel engine
Suction motor
--
TD2011 L04i
Exha~~irg~:Urbo-
pief cooling
ylinder 0" a, 'I1v' , 'v,

u. ofcylillders
oil-cooled (integrated cooler)
---
in series
2
orelstroke
[mm]
tal UI~fJl"":' I"''''

Jmbustion process
[cm3]
941112
1554
96/125
2331
3619
Direct injection
'lection system
<haust gas recirculation
Pump-pipe-nozzle
without
lives per cylinder
,Ive clearance: Inlet/outlet
I
I
without
external
1-2-3
0,3+0,1 I 0,5+ U1
[mm]
ring order of the engine
1-2
I
I
intemal
2
1-3-4-2
rection of rotation looking onto the flywheel
left
lglne power rating according to ISO 3046

Jeed (nominal revolutions)
lection timing
lbricating oil filling volume (without/with filter)
[kW]
see engine rating plate
[rpm]
[OBTDC]

lbe oil temperature in the lube oil tray, maximum
",[I]
[0C]
-lbricating oil pressure minimum (low Idle, engine
[kPalbar]
6/6,5'
5,5/6'
11,3111,8'
--
130
150/1,5
3frll)
belt tension
Pre-tensioning/Re-tensloning
belt AVX 10
eight without cooling system according to DIN
I020-A
--
2008
'".. rt'."4!:.t~''''''7-:rr~~~~<:re':''''fllj~:''''''''
45050/30020
[N]
175
'" [kg]
-
217
261
--
258
65
Technical data
Engine and setting
-----
Dimension
Engine type
Working principle
D 2011 L020
---
---
f-----
D2011 L03 0

-------
Suction motor
Charging
oil-cooled
in series
Type of cooling
No. of cylinders
[mm]
Bore/stroke
Total displacement
Combustion process
~ata
-- 1----
[cm 3]
-------
94/112
1554
-------
2331
Direct injection
Pump-pipe-nozzle
Injection system
-------
Valves per cylinder

Valve clearance: Inlet/outlet
Firing order of the engine
Direction of rotation looking onto the flywheel
Engine power rating according to ISO 3046
Speed (nominal revolutions)
c---- ------
Injection timing
Lubricating oil filling volume (without/with fitter)
Lube oil temperature in the lube oil tray. maximum
Lubricating oil pressure minimum (low idle, engine
warm)
V-belt tension
1------ ------
V-belt AVX 10
Weight without cooling system according to DIN 70020
A
-------
without
2
0,3+01 / 0,5+U,1
[mm]
1-2
-----
without
2
1-2-3
left
[kW]

[rpm]
['BTDC]
,,[I]
6/6,5'
['C]
5,5/6,0'
130
-----
~-----
66
[kPa/bar]
----
150/1.5
-----
Pre-tensioning/Re-tensioning
45050/30020
[~-
",[kg]
169
210
-------
2008
Technical data

'9ine type
'~king principle
larging
;8 of cooling
iinder arrangement
of cylinders
"e/stroke
tal displacement
'mbustion process
ection system
r= -
iE,haust gas recirculation
rIv. "Ves per cylinder
IV,ve clearance: Inlet/outlet
IF" ing order of the engine
IDrection of rotation looking onto the flywheel
IE 'gine power rating according to ISO 3046
~~'eed (nominal revolutions)
II,ection timing
illbricating oil filling volume (without/with filter)
Lube oil temperature in the lube oil tray, maximum
Jbricating oil pressure minimum (low idle, engine warm)
\ belt tension
beltAVX 10
I eight without cooling system according to DIN 70020-A
Dimension
TD2011 L040
Suction motor
oil-cooled
in series
4
4
[mm]
[cm3]
961125
3619
Direct injection
Pump-pipe-nozzle
external
2
I
I
['BTDC]
,,"[IJ
['C]
[N]
" [kg]
internal
2
1-3-4-2
left
10'/10,5
130
15011,5
Pre-tensioningIRe-tensioning
45050130020
[kPalbarJ
I
I
0,3+ 0,1,0,5+0 ,1
[rnrn]
[kW]
[rpm]
2008
02011 L040
253
255
67
Technical data
Engine type
Engine and settin.g dat

Dimension
Working principle
Charging
Type of cooling
No. of cylinders
Borelstroke
Total displacement
rCOmbustion process
Injection system
Valves per cylinder
Valve clearance: Inlet/outlet
Firing order of the engine
Direction of rotation looking onto the flywheel
Engine power rating according to ISO 3046
Speed (nominal revolutions)
Injection timing
Coolant volume (only engine content without cooler I
hoses and pipes)
Permissible continuous coolant temperature
Temperature difference between coolant inlet/outlet
Start of thermostat opening
Thermostat fully open
Lubricating oil filling volume (withoutlwith filter)
Lube oil temperature in the lube oil tray, meximum
68
D2011 L04w
1'02011 L04w
Suction motor
[. Turbocharger with charge ai

cooling
------------
external
I
I
[mmJ
[cnn3J
2
[mmJ
TeD 2011 L04 w
--------------------------------
water-cooled
in series
4
961125
3619
Direct injection
Pump-pipe-nozzle
internal
2
0,3+01 1O,S+O1
I
I
internal
2
-------------
,
[kW]
[rpm]
[OBTDC]
-------------
",[IJ
[0C]
------------
['C]
[0C]
['C]
",[I]
[0C]
1-3-4-2
left
2,9
max. 110
4-6
88
92
10,0*110,5*
130
------------
------------------
20(
Technical data

En ~ine type
LL,~ rieating oil pressure minimum (low idle, engine
W': m)
air temperature outlet al rated power
Ct
Dimension
[kPalbarj
02011 L04w
I
I
TO 2011 L04w
150/1,5
TeO 2011 L04 w
['C]
50
Pre-tensioning/Re-tensioning
"It tension
45050/30020
[N]
V ' eltAVX 10
266
268
WI: ght without cooling system according to DIN 70020

" [kg]
A
I
*s' eeified lubricating oil filling volumes apply for standard versions. In engines whieh deViate from the standard, for example different lubncating oil pans/dipstick variants
al 'Jr special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
------------------
.)
------------------
. 2008
69
Technical data
Tools
Tool ordering
The special tools described in this chapter can be or
dered from:
WILBAR - Wilhelm Backer GmbH & Co. KG
Taubenstrasse 5
42857 Remscheid
Gemnany
+49 (0) 2191 9339-0
Phone:
Fax:
+49 (0) 2191 9339-200
info@wilbaer.de
E-mail:
www.deutz-tools.com
'/.:'
It
Torx tool
V-belt tension measuring instrument
Order number:
8189
The Ton< screw system is used in engines in this se
ries among other things. This system was introduced
for a number of reasons:
Order number:
8115
instrument for checking the specified V
Excellent accessibility
Hioh force transmission when loosening and
Slipping or breaking of the key and risk of injury
are practically excluded.
70
20ot
Is
Special tools for removing the water collection

vessel.
v-
Technical data
Tools
Order number:
8192
On Racor filters, only loosen the water collection
vessel with a special tool.
2008
Special wrench
Order number:
170050
For loosening changeable filters.
71
DEUTZ Oil
)EUTZ Oil DQC 11-05

~EA
E502 ! E3-96 ! 8304
'ICG4
TLS-15W40D
(DQC ,-;-11--,-0-,--,5)'---=-:-=-:-.==-~_
-5 L
0101 6331
.~O L
0101 6332
209 L I
0101 6333
DEUTZ Oil DQC 111-05
DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E704! E502 ! E396! B4041 A304
ACEA E7-041 E5-02! E499
API CI-4! SL GLOBAL DHD1
TLX-10W40FE
DQC 111-05)
5L
0101 63~!;_....
20 L
0101 6336
209 L I
0101 6337
:DEUTZ Oel DQCIV=SW30

(DQC IV-05)
5L I
20 L I
0101 7849
,
~O~U
0101 7850
I
~
DEUTZAG
Service Information Systems

ottostraBe 1
D-51149 Koln
Phone:
+ 49 (0) 2 21-8 22-0
Fax:
+ 49 (0) 2 21-8 22-58 50
Internet: www.deutz.com
E-Mail:
DEUTZ
info@deutz.com
Printed in Germany
All rights reserved

1st Edition, 03/2008
The engine company.
Order number: 0312 3547 en

(0108)

Deutz Operation Manual 2011

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Deutz Operation Manual 2011

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Contents

8 Transport and storage . . . . . . . . . . 62

Protecting the engine against corrosion.

Engine and setting data . . . . .

6 Care and maintenance work . . . . . . . . 38

lubricating oil system.

This symbol is used for all safety iostruc

I.W This symbol indicates a danger to the part

I!<2'J and engine. The relevant instructions must

This symbol accompanies notes of a gen

D2011 L04 0 TCD 2011 L04 w

Exhaust gas turbocharger

Charge air cooler

The rating plate (C) is fixed to the cylinder head cov

The engine type and number must be stated when

oil-cooled (integrated cooler)

Engine serial number

rotating to the left: counter-clockwise.

Unauthorised settings on the regulator will exciud

Cooling fan (with integrated generator)

View from left (example)

Teo 2011 L04 w

View from left (example)

2 Connections charge air cooler

Lubricating oil schematic

cr.. . > 63'C1 a:::s:;."..

Lubricating oil schemaU

Exhaust gas recirculation

Lubricating oil sump

Lubricating oil schematic

Lubricating oil schematic

Exhaust gas recirculation

oil is fed to the hydraulic tappet.

To achieve early adjustment of the fuel injection

in a cold start, the hydraulic tappets under the

fuel injectors are supplied with lubricating oil.

Coolant schematic (example)

8 Coolant partial flow to the lubricating oil cooler

Exhaust gas recirculation

External exhaust gas recirculation

,Wi. jEtJ!i#.ttiii bUM"",.

Exhaust gas recirculation

Inlet valve opens briefiy during the outlet cyde

and emits an exhaust gas partial flow to the suc

This partial volume is sucked back in in the next

Electrics/E lectron ics

with error lamp (optional).

via diagnostic socket (SERDIA).

'.. . . . .' 1//'

Cold start aid

~ with an electronic DEUTZ control unit.

Under the operating conditions listed be

Use winter fuel below 0 'C (I'li 33),

above 1000 m altitude

The following additional work must be carried

I. tt ILow IUb,ricating oil level and overfilling lead

Do not spill fuel.

The fuel low pressure system must be vented be

Only use clean commercially available brand diesel

Danger of scalding from hot coolant!

If required, repeat procedure with engine start.

Carry out a brief trial run up to operating tempe,

Order coolant corrosion protection agent

Before starting, make sure thaI nobody is