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Deutz TCD 2012 Series - User Manual

Deutz TCD 2012 Series
169 pages
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Installation Manual
Series TD/TCD 2012
TD/TCD 2013
Directions for the installation of
Liquid-cooled high-speed
Diesel engines
Responsible for contents:
DEUTZ AG
Applikations-/ System solutions
Deutz-Mülheimer-Str.147/149
Tel.: (0221) 822 2559
Fax.: (0221) 822 3198
1
st
. Edition 05.2006
Order-No. 0399 1969 en

Table of Contents

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Summary

List of Modification

Engine Cooling System

Arrangement of cooling system

Explains the configuration and placement of cooling system components.

Circuit of engine coolant

Describes the flow path and operation of the engine's coolant circuit.

Layout of fan and cooler

Covers the arrangement and design considerations for fans and coolers.

Design of the compensation tank, compensation and venting lines, water level check

Details the compensation tank, lines, and water level monitoring system.

Heating system

Describes systems for heating driver cabs and passenger compartments using engine heat.

Pipings and fittings

Covers the selection, resistance, and layout of piping and fittings for the cooling system.

Fan arrangement

Explains fan mounting options and performance data.

Fan arrangements and mounting configurations

Details various methods for mounting fans to the engine.

Mounting of radiators

Provides guidelines for the proper installation and mounting of radiators.

Cooler; Fan connections

Explains how coolers and fans are connected using ducts, rings, and scoops.

Cooling air system

General

Provides fundamental rules for ensuring cooling system efficiency and capacity.

Arrangement of air intake and discharge ducts

Details how air intake and discharge ducts should be arranged for optimal cooling.

Connection of air intake and discharge ducts

Explains the flexible connections for air intake and discharge ducts.

Dimensioning of short air intake ducts

Offers guidance on calculating the dimensions for short air intake ducts.

Mounting of charge air coolers

Covers the installation and arrangement of charge air coolers.

Arrangement of auxiliary coolers

Discusses the placement of auxiliary coolers relative to the main radiator.

Minimum cross sections for air intake and discharge ducts

Provides formulas for calculating minimum cross-sections for air ducts.

Heating up of cooling air

Addresses the impact of cooling air temperature rise on system capacity.

Filtration of cooling air

Details methods for filtering cooling air, including screens and filter mats.

Combustion air system

General

Emphasizes the importance of air filtration and proper layout for engine longevity.

Intake vacuum pressure

Explains intake vacuum pressure and its impact on combustion efficiency.

Air cleaner systems

Describes different types of air cleaner systems and their applications.

Servicing

Provides instructions for servicing dry-type air cleaners.

Calculation data for combustion air volume flow rate

Outlines methods for calculating combustion air volume flow rate for cleaner sizing.

Combustion air pipings

Covers the design, materials, and layout of combustion air piping.

Heating up of combustion air

Discusses acceptable temperature limits for combustion air.

Combustion air noise

Addresses methods for reducing combustion air noise.

Crankcase breathing system

Explains the system for managing crankcase gases.

Charge air cooling system

Details the design data and pressure loss limits for the charge air cooling system.

Pre-loading of hydraulic oil tanks

Explains the process of pre-loading hydraulic oil tanks.

Exhaust gas system

General

Introduces the exhaust system and the need for silencers and resistance management.

Permissible resistance in the exhaust gas system

Specifies admissible exhaust back pressure values for different engine types and systems.

Measuring the exhaust gas back pressure

Describes methods and points for measuring exhaust gas back pressure.

Dimensioning of exhaust gas pipes and determination of the piping resistance

Provides guidance on sizing exhaust pipes and calculating their resistance.

Silencer and end pipe lengths

Covers the selection and length considerations for silencers and end pipes.

Flexible exhaust pipe joints

Details the use of flexible elements for absorbing engine movement and thermal expansion.

Exhaust brake (exhaust brake flap)

Explains the function and installation of the exhaust brake flap.

Nomographs for determining the exhaust gas pipe resistance

Offers graphical tools for calculating exhaust gas pipe resistance.

Water scrubbers

Describes the function and installation of water scrubbers for exhaust gas treatment.

Exhaust gas catalytic converters

Covers the installation and considerations for exhaust gas catalytic converters.

Exhaust gas heat exchangers

Discusses the use of heat exchangers for utilizing exhaust gas heat.

Exhaust gas end pipe;water penetration guard

Addresses the design of exhaust end pipes to prevent water entry.

Condensed water separator

Explains the necessity and placement of condensed water separators.

Heat insulation

Discusses heat insulation for exhaust gas manifolds and turbochargers.

Particulate traps

Details the function, installation, and maintenance of particulate traps.

SCR System (Selective Catalytic Reduction)

Covers the SCR system for NOx reduction in exhaust emissions.

Exhaust gas recirculation

Explains the different types of exhaust gas recirculation systems used.

Fuel system

General

Emphasizes the importance of adequate fuel supply for engine starting and performance.

Fuel conveyance (System Tank - Supply Pump - Tank)

Details permissible resistances and temperature limits in the fuel conveyance system.

Laying and dimensioning of the fuel pipes

Provides guidelines for routing and sizing fuel pipes, including material requirements.

Fuel heater, fuel cooler

Discusses the need for fuel heating or cooling to maintain optimal temperatures.

Fuel tanks

Covers fuel tank design, ventilation, and material considerations.

Fuel filtering; water trapping

Explains the main and pre-filtering systems, including water traps and filter types.

Representation of fuel connections with regard to air tightness

Illustrates correct and incorrect methods for ensuring air-tight fuel connections.

Connecting elements in the suction pipe

Shows examples of connecting elements for setting up a low-resistance suction pipe system.

Assembly instructions for working on the low pressure system

Provides instructions for installing and maintaining the fuel main filter.

Engine operation at low temperatures

Addresses special measures for fuel supply in extremely cold regions.

Lube oil system

External lube oil systems in the main flow

Details considerations for external lube oil systems, focusing on resistance and pipe sizing.

Lube oil micro-filter in bypass flow

Discusses the installation and requirements for lube oil micro-filters in bypass flow.

External oil tank

Explains the use and connection of external oil tanks for dry sump systems.

Changing the oil dipstick marks for inclined engine installations

Provides instructions for adjusting oil level marks for inclined engine installations.

ENGINE MOUNTING

General

Discusses general principles for engine mounting configurations, favoring flexible designs.

Flexible mounting

Details the requirements and benefits of using flexible engine mounting systems.

Rigid mounting

Explains the principles and considerations for implementing rigid engine mounting systems.

Bending moment on the SAE housing

Addresses the limitations on bending torque exerted on the SAE housing during engine mounting.

POWER TRANSMISSION

Clutches; couplings

Discusses the selection and design of clutches and couplings for power transmission.

Installation of cardan shafts

Provides pre-conditions for installing cardan shafts to avoid angular velocity transmission.

Power take-offs

Details various types of power take-off points available on the engine.

Installation references

Offers general references and considerations for installing drive systems and power take-offs.

COMPRESSOR

Place of installation

Specifies the typical location for compressor installation on the engine.

Compressor; sizes

Lists the available compressor types and their sizes.

Pipe connections; pipe design

Details requirements for air-tight pipe connections and the design of intake lines.

Pressure regulation

Explains different pressure regulating systems used with compressors.

Cooling;lubrication of the compressor

Describes how compressors are cooled and lubricated via engine systems.

Compressor design

Addresses the process of determining the correct compressor size based on air requirements.

Compressor power take-off for auxiliary steering pump

Details the option of a power take-off for auxiliary steering pumps.

COLD CLIMATE APPLICATIONS

Coolant preheating

Explains the use of heating rods and auxiliary heating systems for coolant preheating.

Radiator cover (winter cover)

Describes the use of radiator covers to maintain engine temperature in winter.

VIBRATION DAMPER

Cooling system

Addresses the cooling system requirements for the vibration damper.

SOUND INSULATION; SOUND ABSORPTION

General

Introduces noise sources and the importance of sound insulation measures.

Sound insulation

Details sound insulation techniques, enclosures, and ducting treatments.

Sound insulation and absorption materials

Lists examples of materials used for sound insulation and absorption.

Additional measures required for engine enclosures

Outlines additional measures for engine enclosures, focusing on heat dissipation.

Notes

Provides notes on detailed enclosure measures and contact for specific applications.

HEATING OF ENGINE COMPARTMENT

Radiation heat

Explains heat generated by engine components and auxiliary systems.

Air volume for ventilating the engine compartment

Covers the calculation of required air volume for engine compartment ventilation.

INSTALLATION SURVEY BY MEASUREMENT

Temperature test

Describes how to perform temperature tests under full engine load conditions.

Pressure measurements

Outlines the specific pressure measurements required during installation surveys.

Temperature limit values

Lists admissible permanent and brief temperature limits for various engine components.

Diagram of measuring points

Provides a diagram illustrating the locations for various measurement points.

ELECTRICS

Starter System and Battery

Details starter selection, battery capacities, switches, and battery installation.

Cable Dimensioning and Voltage Drop

Guides on calculating cable cross-sections, voltage drops, and current densities.

Generators and Regulators

Covers the selection, installation, and operation of generators and regulators.

Electronic engine equipment

Discusses the installation, handling, and monitoring of electronic engine control systems.

ACCESSIBILITY FOR SERVICING AND MAINTENANCE JOBS, START-UP PROCEDURE

General

Emphasizes the importance of easy access for maintenance and adherence to schedules.

Maintenance jobs requiring easy and convenient access

Lists maintenance tasks that require direct and simple access without complications.

Maintenance jobs not requiring easy access

Lists maintenance tasks that require removal of parts or plates for access.

Engine commissioning

Details the procedure for venting the fuel system and commissioning the engine.

ANNEX

Calculation formulae for internal combustion engines

Provides formulas for calculating engine performance parameters like volume flow rate and piston speed.

Formal connections concerning fans and coolant pumps

Outlines the physical laws governing the performance of fans and coolant pumps.

Checklist for inspection of starter motor system

Offers a checklist for inspecting the starter motor system, including cables and relays.

Engine coolant

References technical circulars related to engine coolant specifications.

Engine lube oil

References technical circulars regarding engine lubrication oil.

Fuel

References technical circulars related to fuel specifications.

Deutz TCD 2012 Series Specifications

General IconGeneral
ConfigurationInline
Number of cylinders4
Fuel TypeDiesel
AspirationTurbocharged
Cooling SystemLiquid
Emission StandardsEU Stage IIIA / EPA Tier 3
Engine TypeDiesel

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