Operation Manual

D/TCD 914

Notes
Notes z This engine has been constructed exclusively for the application specified in the scope of supply as described by the equipment manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose. The manufacturer will not assume responsibility for any damage resulting therefrom. The user will bear the sole risk in this case. z Use for the intended purpose also includes observance of the operating, maintenance and repair conditions specified by the manufacturer. The engine should only be operated, serviced and repaired by personnel trained in its use and the hazards involved. The pertinent rules for the prevention of accidents and other generally recognised safety and industrial medicine rules must be observed. z When the engine is running there is a danger of injury caused by: rotating and hot components on motors with external ignition (high electrical voltage). Contact must be avoided! z Unauthorised engine modifications will invalidate any liability claims against the manufacturer for resultant damage. z Equally, manipulations to the injection and control system can affect the engine's performance and the exhaust characteristics. Adherence to legislation on pollution can no longer be guaranteed under such conditions. z Do not change the cooling air inlet area to the fan. Unimpaired inlet of cooling air must be maintained. The manufacturer will accept no liability for damage resulting from this. z When carrying out maintenance work on the engine, the use of DEUTZ original parts is prescribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the warranty! Maintenance/cleaning work on the engine may only be carried out when the engine is not running and has cooled down. When doing this, make sure that the electrical system is switched off (remove ignition key). The specifications for accident prevention with electrical systems (e.g. VDE-0100/-0101/-0104/0105 Electrical protective measures against dangerous contact voltages) must be observed. Cover all electrical components tightly when cleaning with liquids. z Do not work on the fuel system while the engine is running - Danger to life! Wait for the pressure to drop after the engine has come to a standstill (in engines with DEUTZ Common Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure - Danger to life! During the first trial run do not stand in the danger area of the engine. Danger due to high pressure in case of leaks Danger to life! In case of leaks immediately contact workshop. When working on the fuel system, make sure that the engine is not started inadvertently during repairs - Danger to life!

2007

Foreword
Dear customer, Congratulations on the purchase of your DEUTZ engine. DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. Consequently, a wide range of variants is offered to meet the requirements of specific cases. Your engine is appropriately equipped for the installation concerned, as specified by you, which means that not all of the components described in this Operation Manual are necessarily fitted to your engine. We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions applicable to your engine more quickly and easily. Please make sure that this operating manual is available to everyone involved in the operation, maintenance and repair of the engine and that they have understood the contents. If you have any queries, please contact us, we'll be happy to advise you. Sincerely, DEUTZ AG Engine serial number Please enter the engine serial number here. This will simplify the handling of customer service, repair and spare parts queries.

Notes We reserve the right to make technical changes to the descriptions and data in this operating manual in the interest of further development of the engines. This document may only be reprinted and reproduced, even in part, with our express permission. Order number 0312 3448 en

2007

Contents
Notes......................................................... 2 Foreword .................................................. 3 1 General ................................................ 5 2 Engine description ............................. 7 Design .................................................. 7 Engine diagram .................................... 9 Lube oil circuit..................................... 13 Fuel circuit .......................................... 16 Exhaust gas recirculation ................... 17 3 Operation........................................... 18 Ambient conditions ............................. 18 Initial commissioning .......................... 19 Start process ...................................... 20 Operation monitoring .......................... 22 Stop procedure ................................... 24 4 Operating media ............................... 25 Lubricating oil ..................................... 25 Fuels................................................... 27 5 Maintenance...................................... 28 Maintenance schedule........................ 28 6 Service and maintenance ................ 31 Lubricating oil system ......................... 31 Fuel system ........................................ 33 Engine cleaning .................................. 35 Combustion air filter............................ 36 Exhaust gas recirculation ................... 39 Belt drive............................................. 40 Adjustment works ............................... 43 Electrical system................................. 45 7 Faults ................................................. 47 Fault table........................................... 47 8 Transport and storage ..................... 52 Transport ............................................ 52 Engine corrosion protection................ 53 9 Technical data................................... 55 Engine and setting data...................... 55

2007

General notes
DEUTZ diesel engines DEUTZ diesel engines are the product of years of research and development. Profound know-how combined with high quality requirements are the guarantee for the production of engines with a long life, high reliability levels and low fuel consumption. Obviously the high requirements for the protection of the environment are also met. Safety precautions when the engine is running Maintenance or repair work must only be carried out with the engine shut down. Ensure that the engine cannot be started unintentionally - Danger of accidents! When the work is complete, be sure to refit any panels and guards that have been removed. Observe industrial safety regulations when running the engine in an enclosed space or underground. When working on the running engine, work clothing must be close fitting. Never fill the fuel tank while the engine is running. Service and Maintenance Service and maintenance are also decisive for whether the engine satisfactorily meets the set demands. Recommended service intervals must therefore be observed and service and maintenance work must be carried out conscientiously. Special care should be taken under abnormally demanding operating conditions. Original DEUTZ parts Original DEUTZ parts are subject to the same strict quality requirements as the DEUTZ engines themselves. Further developments for improvement of the engines are, of course, also implemented in the original DEUTZ parts. Only the use of original DEUTZ parts, manufactured according to the latest state of knowledge, will guarantee perfect functioning and high levels of reliability. DEUTZ Xchange components DEUTZ Xchange components are a cost-effective alternative. The same high quality standards apply here as for new parts. DEUTZ Xchange components are equivalent to the original DEUTZ parts in function and reliability. Asbestos Gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair work. Service We want to preserve the high performance of our engines, and with it the confidence and satisfaction of our customers. We are therefore represented worldwide by a network of service branches. The DEUTZ name does not merely stand for engines that are the products of extensive development work, DEUTZ also stands for complete service packages that ensure optimum operation of our engines, and for customer services operations that you can count on. Please contact your service partner in the event of a fault or for spare parts. Our trained specialist personnel ensure fast, professional repairs using original DEUTZ parts in the event of damage. The DEUTZ homepage always gives you the latest overview of the DEUTZ partners in your vicinity with

General
references to product responsibilities and service offers. Or use another fast, comfortable route via the Internet at www.deutzshop.de. With the DEUTZ P@rts Online Parts Catalogue you have direct contact with the nearest local DEUTZ Service Station.

California Proposition 65 Warning Diesel engines and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. Masthead DEUTZ AG Ottostrae 1 51149 Cologne Telephone:+49 (221) 822-0 Fax: +49 (221) 822-5850 www.deutz.com

2007

General

General notes

Danger This symbol is used for all safety instructions which, if not observed, present a direct danger to life and limb for the person involved. Observe these carefully. The attention of operating personnel should be drawn to these safety instructions. Furthermore, the legislation for "general regulations for safety and the prevention of accidents" must be observed. Caution This symbol indicates a danger to the component / engine. The appropriate instructions must be followed, otherwise the component / engine may be destroyed. Notes This symbol accompanies notes of a general kind.

2007

Design

Engine description

2
A
Mot.-Typ Mot.-Nr.

DEUTZ AG

MADE IN GERMANY

Rating plate The engine type A, engine number B and the power data are stamped on the rating plate. The engine type and number must be stated when purchasing spare parts.

Location of the rating plate The rating plate is fixed to the crankcase (arrow) .

Engine serial number The engine number (arrow) is stamped on the crankcase and on the rating plate.

2007

Engine description

Design

left

right 1
Cylinder numbering Cylinder arrangement The cylinders are counted consecutively starting from flywheel (1). Direction of rotation Looking at the power transmission side. rotating to the left: counter-clockwise. Engine sides Looking at the power transmission side. Direct injection In direct injection, the fuel is injected via a multi-aperture injection nozzle which protrudes into the combustion chamber at the end of the second working cycle (compression stroke) and vapourised.

2007

Engine diagram
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Engine description
Engine D 914 L06, right (example) Cooling fan V-belt (fan) V-belt pulley on crankshaft Tension pulley Lubricating oil filling Lubricating oil sump Fuel pump with fuel cleaning Stop magnet Lubricating oil dipstick Injection pump Lube oil replacement filter Exchangeable fuel filter Air guide hood Cylinder head cover

2007

Engine description

Engine diagram
Engine D 914 L06, left (example) 1 2 3 4 5 6 7 Air intake pipe Exhaust manifold line Standing plate Flywheel or (gearbox connection SAE) Starter Connection for engine mounting Generator mounting (optional)

10

2007

Engine diagram
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Engine description
Engine TCD 914 L06, right (example) Turbocharger Generator V-belt pulley on crankshaft Tension pulley Cooling fan Lubricating oil filling Fuel pump with fuel cleaning Lubricating oil dipstick Stop magnet Injection pump Lube oil replacement filter Block oil cooler Exchangeable fuel filter Air guide hood Injection line Cylinder head cover

2007

11

Engine description

Engine diagram
Engine TCD 914 L06, left (example) 1 2 3 4 5 6 7 8 9 10 Charge air cooler Flywheel or (gearbox connection SAE) Starter Lubricating oil sump Lubricating oil pressure pipe to turbocharger Exhaust manifold Air intake pipe Exhaust manifold line Charge air line to charge air cooler Charge air line from charge air cooler

12

2007

Lube oil circuit

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Engine description
Lube oil schematic D 914 (example) Lubricating oil sump Intake line Lubricating oil pump Lubricating oil pressure regulating valve Compression oil line Lube oil cooler Lube oil replacement filter Safety valve Main oil channel Crankshaft bearing Big-end bearing Camshaft bearing Tappet Push rod (hollow for lube oil feed to rocker arm lubrication Setting screw for valve clearance Rocker arm Push rod protection tube (lube oil return from cylinder head to crankcase) Throttle port (for lubrication of the gears) Injection nozzle for piston cooling Connection for lube oil pressure gauge Lube oil pressure gauge Injection pump connected to the lube oil circuit Connection possibilities for heat exchanger*

* this requires the filter support to be changed. Please contact our service partner if you wish to change over

2007

13

Engine description

Lube oil circuit

Lube oil schematic TCD 914 (example) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Lubricating oil sump Intake line Lubricating oil pump Lubricating oil pressure regulating valve Lube oil pressure line Connection line to lube oil cooler Lube oil replacement filter Lube oil cooler Safety valve Main lube oil channel Crankshaft bearing lubrication Big end bearing lubrication Camshaft bearing lubrication Tappet Push rod (hollow for lube oil feed to rocker arm lubrication

14

2007

Lube oil circuit

Engine description
1 Rocker arm bearing 2 Push rod protection tube (lube oil return from cylinder head to crankcase) 3 Throttle port (for lubrication of the gears) 4 Injection nozzle for piston cooling 5 Lube oil line for lubrication of turbocharger 6 Lube oil return line from turbocharger 7 Lube oil pressure gauge 8 By-pass lube oil fine filter 9 Connection facility for lube oil heating* 10 Injection pump connected to the lube oil circuit * this requires the filter support to be changed.

2007

15

Engine description

Fuel circuit
Fuel circuit (example) 1 2 3 4 5 6 7 8 9 Fuel container Fuel line from tank to fuel pump Fuel pump Exchangeable fuel filter Injection pump Fuel line to injection valve Injection valve Fuel overflow pipe Minimum distance 500 mm

16

2007

Exhaust gas recirculation

Engine description
Exhaust gas recirculation (example) 1 Exhaust gas recirculation valve 2 Return line

2007

17

Operation

Ambient conditions
(  27). z If cold starting occurs frequently cut the lube oil changing interval by half. High ambient temperatures, high altitude

3
0 C

Under the following application and operating conditions, the amount of fuel must be reduced. z above 1000 m altitude z above 30 C ambient temperature Reason: Air density decreases as altitude or ambient temperature increase. This reduces the amount of oxygen in the engine intake air and the fuel-air mixture would be too rich if the injected amount of fuel were not reduced. z 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.

Low ambient temperatures Lubricating oil z Select lubricating oil according to ambient temperature z If cold starting occurs frequently cut the lube oil changing interval by half. Fuel z Below 0 C use winter fuel (  27). Battery z A well charged battery is a prerequisite for starting the engine (  45). z Heating the battery to about 20 C improves the starting behaviour of the engine. (Remove and store the battery in a warm room). Cold start aid z Glow plugs, heating flange, spark plug system can be used as cold start aids, for example

18

2007

Initial commissioning
Preparations for initial commissioning (Maintenance schedule E 10) z Remove engine corrosion protection z Remove any transport devices. z Check the battery and cable connections and mount if necessary. z Checking the belt tension (  40). z Have the engine monitor or warning system checked by authorised personnel. z Check the engine mounting. z Check that all hose unions and clips fit properly. The following additional work must be carried out on generally overhauled engines: z Check the fuel prefilter and main filter and change if necessary. z Check the intake air cleaner (if available, maintain according to maintenance indicator). z Drain lubricating oil and condensation water from the charge air cooler. z Fill with engine lube oil. Fill with engine lube oil. Low lubricating oil level and overfilling lead 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 z Fill the engine with lubricating oil via the lubricating oil filler neck. z Lube oil filling quantity. z Check lubricating oil level, if necessary top up. Pour in fuel z The fuel low pressure system must be vented with the hand pump after filling before starting for the 1st time. Only 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. Only use clean, standard, branded diesel fuel. Note the fuel quality (  27) Use summer or winter-grade fuel, depending on the ambient temperature. Trial run

Operation

Additional venting of the fuel system by a 5 minute trial run at idle speed or on low load is absolutely essential. After preparations, perform a short trial run up to operating temperature (approx. 90 C). If possible, avoid loading the engine. z Work with the engine not running: Check engine for tightness. Check lubricating oil level, if necessary top up (  31). z Work during the trial run: Check engine for tightness.

2007

19

Operation

Start process

Starting Before starting, make sure that nobody is standing in the immediate vicinity of the engine or work machine. Separate the engine if possible by disengaging driven units. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with the flame glow plug/ glow plug/heating flange system do not use any other starting aid (e.g. injection with start pilot). Risk of accident! Caution: If the speed regulator has been removed, the engine must not be started under any circumstances. Disconnect the battery! If the engine does not start properly when the heating flange is automatically actuated (starter does not receive current as a result of a fault in the equipment/customer electrical control system) the starting procedure must be abandoned (set the ignition switch to OFF, disconnect the power supply to the heating flange). Do not actuate the starter for more than 20 seconds. If the engine does not start up, wait for one minute and then repeat the starting process. If the engine does not start up after two attempts, determine the cause as per fault table (  47). Do not run up the engine immediately to high idling speed / full load operation from cold.

z Separate engine from driven devices by disconnecting if possible. z Move speed control lever (1) into idle position. z Turn shutdown lever (2) to position "I" and start. z When starting electrically with a lifting magnet, the shutdown lever (2) is pulled into position "I" and held there when power is applied. Charge pilot light and lube oil pressure pilot light go out.

Without cold start aid z Insert key Position 0 = no operating voltage. z Turn key clockwise. Position 1 = operating voltage. Pilot lamps light up. z Push the key in and turn further clockwise against spring pressure. Position 2 = without function. Position 3 = start. The pilot lamps will go out. * By afterburning to position 2 for about 3 minutes, if required, it is possible to further reduce the exhaust colouration in the run-up phase.

20

2007

Start process

Operation

* By afterburning to position 2 for about 3 minutes, if required, it is possible to further reduce the exhaust colouration in the runup phase. with cold start aid/flame glow plug FR 60 = 9,5 and 19 Volt z Insert key Position 0 = no operating voltage. z Turn key clockwise. Pre-heating lamp lights up Position 2 = approx. 60 seconds pre-heating (hold the key in position for this)* Pre-heating lamp goes out Position 3 = start. z Release key as soon as engine fires. The pilot lamps will go out.

* By afterburning to position 2 for about 3 minutes, if required, it is possible to further reduce the exhaust colouration in the runup phase. with cold start aid/flame glow plug FR 20/30 = 11 and 23 Volt z Insert key Position 0 = no operating voltage. Pilot lamps light up. z Push the key in and turn further clockwise against spring pressure. Pre-heating lamp lights up Position 2 = approx. 20-30 seconds preheating (hold the key in position for this)* Pre-heating lamp goes out Position 3 = start. z Release key as soon as engine fires. The pilot lamps will go out.

2007

21

Operation

Operation monitoring

Display instrument Possible displays: z Colour scale Display of operating state by coloured areas (green OK / red take suitable action). z Measured value scale Actual value can be read off directly. The nominal value should be taken from the Technical Data (  55).

Cooling fan drive z In the event of V-belt tear the pressure pin (1) of the electrical switch is actuated by the tensioning roller and an acoustic signal or light signal is initiated. z Stop the engine immediately to avoid overheating.

22

2007

Operation monitoring
Instruments and symbols Instruments / symbols Designation Lubricating oil pressure display Possible display: Lubricating oil pressure below minimum Measure Switch off engine

Operation

Lubricating oil pressure display

Lubricating oil pressure in the red area

Switch off engine

Lubricating oil temperature display

The temperature display should always be in the green area and only be in the yellow-green area under exceptional circumstances If the pointer enters the orange sector, the engine is overheating.

Turn off and establish the cause from the Fault Table

Lubricating oil pressure pilot lamp If the pilot lamp lights up after starting the engine or while the engine is running, the lubricating oil pressure is too low Lube oil level

Switch off engine

If the pilot lamp lights up after starting the engine or Check lubricating oil level / if necessary top up while the engine is running, the lubricating oil level is too low Indicates the previous operating time of the engine Observe the maintenance intervals

Operating hours counter

123

Horn

With acoustic signal

See Fault Table

2007

23

Operation

Stop procedure

Shutting off Avoid switching-off from full load operation (coking/blockage of the remaining lubricating oil in the turbocharger bearing housing). Lubricating oil is no longer supplied to the turbocharger! Run the engine after removing the load for about 1 minute at slow idling speed.

Mechanical switching-off z Move speed adjustment lever (1) to slow idle. z Move the adjustment lever (2) to position "0" until the engine stops. Charge pilot light and lube oil pressure pilot light light up after the engine stops. z Turn key counterclockwise (to position 0) and remove. The pilot lamps will go out. z When switching off electrically or in the event of a power failure the shutdown lever (2) is switched off by the lifting magnet until the engine stops. Charge pilot light and lube oil pressure pilot light light up after the engine stops. z Turn key counterclockwise (to position 0) and remove. The pilot lamps will go out.

Electrical shutdown (optional) z Move the key to position 0. Pilot 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 0 = gear position: switch off engine 1 = gear position: pre-heat engine 2 = gear position: start engine

24

2007

Lubricating oil
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 comsumption 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. Lubricating oils always consist of a base oil and an additive package. The most important tasks of a lubricating oil (e.g. wear protection, corrosion protection, 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. 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 mixture are always dominant. The lubricating oil quality has a considerable influence on the life, performance and thus also on the costs-effectiveness of the engine. It basically applies that: The better the lubricating oil quality, the better these properties. The lubricating oil viscosity describes the flow behaviour of the lubricating oil depending on the temperature. The lubricating oil viscosity has no influence and effect on the lubricating oil quality. Synthetic lubricating oils are used increasingly and have advantages. These oils have a better temperature 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 specifications of the lube oil change intervals. Biodegradable lubricating oils may be used in DEUTZ engines if they meet the requirements of this operating manual. Quality Lubricating oils are classified by DEUTZ according to their performance capability and quality class ((DQC: Deutz Quality Class). It basically applies that: with ascending quality class (DQC I, II, III, IV), the lubricating oils are more efficient or of higher quality. (The suffix (- 02 / - 05) to the quality class designation indicates in what year the classification was made. Lubricating oils according to other comparable specifications can be used as long as they meet DEUTZ requirements. In regions in which none of these qualities is available, please contact your DEUTZ partner responsible. The following lubricating oils are specified for the engines described in this operating manual.

Operating media
Minimum quality class DEUTZ DQC I - 02 ACEA E2-96 API CF/ CF4

If an engine under load is lubricated with a DQC !lubricating oil then the lubricating oil change inteval should be cut by half. Recommended quality class DEUTZ ACEA API DQC II - 05 E3-96 / E5-02 / CG-4 / CH4 / C I-4 E7-04 DQC III - 05 E4-99 / E6-04 DQC IV - 05 E4-99 / E6-04 Please contact your DEUTZ partner

DEUTZ lubricating oils DQC II-05 TSL - 15W40 D Container 5 litre container 20 litre container 209 litre barrel Order number 0101 6331 0101 6332 0101 6333

DEUTZ lubricating oils DQC III-05 TLX - 10W40 FE Container 5 litre container 20 litre container 209 litre barrel Order number 0101 6335 0101 6336 0101 6337

2007

25

Operating media

Lubricating oil
(e.g. by storing the vehicle or work machine indoors). The viscosity is classified according to SAE. Multipurpose lubricating oils should be used basically. Single-purpose lubricating oils can also be used in enclosed, heated spaces at temperatures >5 C. Depending on the ambient temperature we recommend the following common viscosity classes:

DEUTZ lubricating oils DQC IV-05 synthetic Container 20 litre container 209 litre barrel Order number 0101 7849 0101 7850

C 45 40 35 30 25
SAE 20W-50 SAE 10W-40 SAE 0W-30 SAE 0W-40 SAE 5W-30 SAE 15W-40 SAE 5W-40 SAE 10W-30

Lubricating oil change intervals z The intervals depend on: lubricating oil quality sulphur content in the fuel type of application of engine z 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 weight %. operation with bio-diesel fuel z If the oil change intervals for vehicle engines are to be carried out according to operating hours, the oil change intervals for built-in engines apply. z If the lubricating oil change intervals are not reached within a year, the oil should be changed at least once a year. Viscosity The ambient temperature at the installation site or area of application of the engine is decisive for the choice of the right viscosity class. Too high a viscosity can lead to starting difficulties, too low a viscosity can endanger the lubrication effect and cause high lubricating oil consumption. At ambient temperatures below -40 C the lubricating oil must be pre-heated

20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40

26

2007

Fuels
Permissible fuels The following fuel specifications / standards are approved: z In engines with increased power rating and engines with high loads we recommend the use of DEUTZ TLX10W.40FE Europa. z Diesel fuels according to DIN EN 590 Nato F-54 (equivalent to diesel fuel in accordance with DIN EN 590) z US diesel fuel according to ASTM D 975 GradeNo.1-D and 2-D z Japanese diesel fuel JIS K 2204 Grade 1 Fuel and Grade 2 Fuel with lubricating properties according to diesel fuel EN 590 (HFFR max. 460 micrometer according to EN ISO 12156) Use commercially available diesel fuel with less than 0.5 % sulphur content. If the sulphur content is higher, the lube oil change intervals must be reduced. If other fuels are used which do not meet the requirements of the operating manual, the warranty will be voided. The certification measurements to satisfy the legal emission limits are performed with the test fuels defined by law. These correspond to the diesel fuels according to EN 590 and ASTM D 975 described in this operating manual. No emission values are guaranteed with the other fuels described in this operating manual. Winter operation with diesel fuel Only carry out mixing in the tank. Fill with the appropriate amount of paraffin first, then add the diesel fuel. Normal and high grade fuels may not be mixed. At low ambient temperatures paraffin discharges can lead to blockages in the fuel system and cause operating faults. Below 0 C ambient temperature use winter diesel (down to -20 C) (filling stations provide this in good time before the cold season starts). z Below -20 C paraffin should be added. The relevant percentages are given in the adjacent diagram. z Special diesel fuels can be used for arctic climates to -44 C. If it is necessary to use summer diesel fuel below 0C, paraffin can also be added by up to 30 % as per the diagram on the right. Generally, sufficient resistance to cold can also be achieved by adding a flow improvement additive. Please ask your DEUTZ partner.

Operating media

Summer-grade diesel fuel

II Winter-grade diesel fuel A Outdoor temperature B Percentage of paraffin to be added

2007

27

Maintenance

Maintenance schedule

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals Standard maintenance schedule D/TCD 914 Stage Activity To be carried out by

Industrial engines (every.....Op.Hr.) Standard and EPA 3) certified engines (Environmental Protection Agency) During the running-in phase or initial start-up of new or overhauled engines. 1x daily or every 10 operating hours in continuous operation 250 oh 500 operating hours 1) 2) 1000 oh Authorised specialists only on EPA certified engines 1,500 operating hours only on EPA certified engines 3,000 operating hours 12,000 oh (only in EPA 4,000 operating hours)

E10 E20 E25 E30 E40 E50 E60 E70

Initial commissioning Daily inspection Extended checking Maintenance Extended maintenance I Extended maintenance II Intermediate overhaul General overhaul

Authorised specialists Customer

Maintenance work outside the DEUTZ maintenance and service schedules

1) 2) 3)

Depending upon the individual case, the demand on the lube oil can be high. Shorter maintenance intervals are required for this 250 operating hours. The values for lubricating oil change intervals apply both for normally aspirated and for turbocharged engines, if the turbocharged engine is running with at least DQC II - lubricating oils. If this is not the case, the lubricating oil change intervals must be reduced by half on turbocharged engines. EPA (Environmental Protection Agency).

Maintenance measures *If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately. Changing the pre-filter cartridge depends on the degree of dirt contamination of the fuel being used. If other fuels are used which do not meet the requirements of the operating manual, the warranty will be voided. A 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 3144

28

2007

Maintenance schedule
Stage E10 E20 Check Measure The measures are listed in chapter 3. Lubricating oil level (if necessary top up) Lubricating oil bath air filter Engine tightness (visual inspection for leaks) Suction air filter/dry air filter (maintain in accordance with maintenance indicator) E25 E30 Check Check Replace Settings E40 Check V-belts (retension or renew if necessary) Battery and cable connectors

Maintenance
Page  19  55  38  36  40  45  26  32  43

Engine monitor, warning system Maintenance only to be carried out by authorised service personnel Lubricating oil (lubricating oil change intervals depending upon the engine application). xxxxxxxx Lubricating oil filter cartridge (at each lube oil change) Valve clearance (turbocharged engine) Flame glow plugs Tighten engine mountings, if necessary (renew in case of damage) Fastenings, hose unions / clips (renew if damaged) Replace Clean Settings E50 E60 Check Clean Replace Clean 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) Valve clearance(normally aspirated engine) EGR valve, in the event of a fault in function, replace Injection valve From the exhaust recirculation casing, replace valve Injection valve Charge air cooler entry area (drain lube oil/condensate) Turbocharger compressor outlet Exhaust channels on the cylinder head and with exhaust recirculation unit removed  32  34  34  36  43

2007

29

Maintenance

Maintenance schedule
Measure Page  40

Stage Every 2 years Replace

V-belts Flame glow plugs

30

2007

Lubricating oil system

Regulations for working on the lubricating oil system Pay attention to utmost cleanliness when working on the lubricating oil system. Clean the respective affected parts carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling lube oils. Dispose of leaking lubricating oil and filter elements properly. Do not allow used oil to seep away into the ground. Perform a trial run after all work. Pay attention to tightness and lubricating oil pressure and then check the engine oil level. In case of fuels containing more than 1% sulphur, contact your service representative. Checking the lubricating oil level

Service and maintenance

Low lubricating oil level or overfilling lead to engine damage! The lubricating oil level may only be checked with the engine in a horizontal position and switched off. If the engine is warm, switch off the engine and check the lubricating oil level after 5 minutes. If the engine is cold you can check it immediately. Careful with hot lube oil. Danger of scalding! z Pull out the lubricating oil dipstick and wipe off with a lint-free, clean cloth. z Insert the lubricating oil dipstick as far as it will go. z Extract the lubricating oil dipstick and read off the oil level. z The oil level must always be between the MIN and MAX marks! Top up to the MAX mark if necessary. Changing the lubricating oil z Warm up the engine (lubricating oil temperature > 80 C). z Ensure that the engine or vehicle is in a level position. z Switch off the engine. z Place a collecting receptacle underneath the lube oil drain screw. z Unscrew the lube oil drain screw, drain oil. z Fit a new sealing ring to the lube oil drain screw, insert and tighten. (tightening torque 100 Nm). z Pour in lube oil. Quality/viscosity data. Filling volume (  55) z Check engine lubricating oil level (see previous chapter)

2007

31

Service and maintenance

Lubricating oil system

Changing the lubricating oil filter cartridge The filter cartridge should never be prefilled. There is a danger of dirt contamination! z Remove the clips if an anti-rotation lock is fitted. z Loosen and unscrew the filter cartridge with the tool (order no. 170050) . z Collect draining lubricating oil z Clean the sealing surface of the filter support with a lint-free, clean cloth.

z Oil the gasket of the new DEUTZ original filter cartridge lightly. z Screw on the new filter cartridge by hand until the gasket is flush and tighten a further half a turn. z If necessary, fix the clips of the anti-rotation lock.

Change the by-pass lubricating oil filter insert z Unscrew the lube oil drain screw (1) and allow the lube oil to drain out. z Catch any escaping lube oil. z Unscrew the clamping screw (2). Remove the cover. z Unscrew the contaminated filter insert (3). Clean the filter housing. z Check cover seal (4) and renew if necessary. z Reinsert the lube oil drain screw (1) with new seal ring (5). z Insert new filter insert. z Screw the cover and seal ring (6) back in position. z Check lubricating oil pressure and tightness during trial run.

32

2007

Fuel system
Regulations for working on the fuel system Engine must be switched off! Smoking and naked lights prohibited! No 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 carefully. Blow damp areas dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Dispose of leaking fuel and filter elements properly. Do not allow fuel to seep away into the ground. After all work on the fuel system, the system should be vented, a trial 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. Additional venting of the fuel system by a 5 minute trial run at idle speed or on low load is absolutely essential. Additional regulations

Service and maintenance

Danger! Do not work on the fuel system while the engine is running. Wait approx. 30 seconds after switching off the engine before working on the fuel system! The fuel system must be tight and closed. Make a visual inspection for leaks / damage to the system. Clean and dry the engine and the engine compartment thoroughly before starting work. Work on the fuel system may only be carried out in an absolutely clean environment. Air contamination such as dirt, dust, moisture etc. must be avoided.

2007

33

Service and maintenance

Fuel system

Change the fuel filter cartridge The filter cartridge should never be prefilled. There is a danger of dirt contamination! z Remove the clips if an anti-rotation lock is fitted. z Loosen and unscrew filter cartridge with tool (order number: 170050). z Collect draining lubricating oil z Dispose of in an environmentally correct manner. z Clean the sealing surface of the filter support with a lint-free, clean cloth.

z Oil the gasket of the new DEUTZ original filter cartridge lightly. z Screw on the new filter cartridge by hand until the gasket is flush and tighten a further half a turn. z If necessary, fix the clips of the anti-rotation lock.

Fuel pre-cleaning Keep naked flames away when working on the fuel system! Do not smoke! z z z z z z z Close the fuel shut-off valve. Unscrew the filter housing (4) and pull off. Catch any escaping fuel. Remove cleaning strainer (3) and clean with fuel. Pull off seal ring (2). Clean filter housing (1) with fuel. Screw filter housing (4) and cleaning strainer (3) with new seal ring (2) in position. z Bleeding fuel system. z Open fuel shutoff valve. z Check for leaks.

34

2007

Engine cleaning
Cleaning work For all cleaning work, make sure that no parts are damaged (e.g. bent cooler mesh). Cover electrical/electronic parts and connections 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 warm up. Only carry out cleaning work on the engine when it is not running! Remove the engine cover and cooling air cover if available and remount after cleaning. General The following causes of soiling make it necessary to clean the engine: z High dust content in the air. z Chaff and chopped straw in the area of the engine. z Coolant leakage z Lubricating oil leakage z Fuel leakage Because of the different application conditions, cleaning depends on the degree of dirt contamination. Cleaning with compressed air z Blow dirt off or out. Always blow out the cooler and cooling fins from the exhaust air side to the fresh air side. Cleaning with cold cleaner

Service and maintenance

z Spray the engine with cold cleaner and leave it for about 10 minutes to take effect. z Spray the engine clean with a high pressure water jet. z Warm up the engine so that the water residues evaporate. Cleaning with a high pressure cleaner z Clean the engine with a steam jet (maximum spray pressure 60 bar, maximum steam temperature 90 C, distance at least 1m). z Warm up the engine so that the water residues evaporate. z Clean external cooler according to the manufacturers specifications.

2007

35

Service and maintenance

Combustion air filter

Regulations for working on the intake system Do not work when the engine is running!

Pay attention to utmost cleanliness when working on the intake system, close intake openings if necessary. Dispose of old filter elements properly.

Maintenance indicators for dry air filter z The dry air filter is maintained according to a maintenance switch or maintenance indicator. z 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 indicator is fully visible. z After carrying out maintenance work, reset the signal by pressing the button on the maintenance indicator. The maintenance indicator is now ready for operation again.

36

2007

Combustion air filter

Renewing the safety cartridge of the dry air filter Never clean the safety cartridge (4). z Renew safety cartridge (4) according to the interval in the maintenance schedule z To do this: Unscrew hexagon nut (5), pull out safety cartridge (4). Insert new safety cartridge, screw on hexagonal nut. z Insert filter element (3), mount hood (2) and fix with clamping yoke (1).

Service and maintenance

1 5 2

Clean the dust discharge valve of the dry air filter z Empty the dust discharge valve (1) by pressing together the discharge slit. z Remove any caked dust by pressing together the upper section of the valve. z Clean the discharge slit.

Maintaining the dry air filter Never clean filter element (3) with petrol or hot liquids! Renew damaged filter elements. z Maintain the filter element (3) according to the interval in the maintenance schedule z Lift up the clamping yoke (1). z Remove the filter hood (2) and pull out the filter element (3). z Filter element (3): blow out with dry compressed air (max. 5 bar) from the inside to the outside if soiling is only slight, renew if heavily soiled.

2007

37

Service and maintenance

Combustion air filter

renew if damaged. z Fill the lubricating oil pan (3) of the oil bath air filter with engine oil up to the mark (arrow). z Mount the lubricating oil pan (3) with filter insert (4) on the filter housing (1) and close the quick release clamps (2). z Start engine and check for tightness.

Emptying the cyclone precleaner Never fill the dust container (3) with lubricating oil! z Loosen wing nut (1) and lift off housing cover (2). z Remove the dust container (3) from the base (4) and empty it. Clean the container using a brush and clean diesel fuel. Then dry. z Place the dust container (3) on the base (4) and tighten the housing cover (2) with wing nut (1).

Cleaning oil bath air filter Never clean the filter with petrol!

Dispose of the old lubricating oil in accordance with the regulations. Select the engine lubricating oil according to the requirements before filling the filter. z Shut down engine and wait about 10 minutes until the lubricating oil has collected in the lubricating oil pan (3). z Loosen the quick release clamps (2) and remove the lubricating oil pan (3) with filter insert (4). z Dispose of dirty lubricating oil. z Clean the lubricating oil pan (3), filter insert (4) and filter housing (1) using a brush and clean diesel fuel. z Visually inspect the rubber gaskets (5), (6) and

38

2007

Exhaust gas recirculation

Service and maintenance

Clean cylinder head exhaust apertures Carry out the work only when cold. Danger of burning! z z z z z z z z Remove air guide hood. Release screws. Remove exhaust gas recirculation unit. Clean exhaust gas apertures on each cylinder using a wire brush (order number: 8167) (  28). If possible remove the remnants by suction. Refit the exhaust gas recirculation unit. Tighten screws (tightening torque 42 Nm). Install air guide hood.

2007

39

Service and maintenance

Belt drive

Checking the belt drive Only carry out work/function check on the belt drive when the engine is not running! Only check / change V-belts when the engine is not running! Refit the V-belt guard! Retension the new V-belts after 15 minutes running time. In the event of wear of the double belts or damage to one of the Vbelts always replace both belts as a pair. The difference in length of the new V-belts must not exceed 0.15 % one to the other. z z z z Check the whole belt drive visually for damage. Renew damaged parts. Remount protective devices if necessary. Pay attention to correct fit of new belts, check the tension after running for 15 minutes.

Checking the belt tension z Lower indicator arm (1) into the measuring device. z Place guide (3) between two belt pulleys on the V-belt (2). The stop have to be at the side. z Press the button (4) at right angles to the V-belt (2) evenly until you hear or feel the spring snap in. z Lift the measuring device carefully without altering the position of the indicator arm (1). z Read the measured value at the point of intersection (arrow), scale (5) and indicator arm (1). z If necessary, re-tension belt and measure again. Tools Belt tension measuring device (order number: 8115) can be obtained from your DEUTZ partner.

Replacing the fan V-belt z In order to change the belt, push the tensioning roller (1) inwards with ordinary tooling and remove the V-belt. z Fit new V-belts.

40

2007

Belt drive

Service and maintenance

Tightening fan V-belt z Loose screws (1), (2) and (3). z Push the generator (4) outwards in the direction of the arrow A until the correct V-belt tension is achieved. z Retighten bolts (1), (2) and (3).

Changing fan V-belt z Remove fan V-belt. z Loose screws (1), (2) and (3). z Swing the generator (4) inwards in the direction of the arrow B. z Remove and replace V-belt by a new one. z Push the generator (4) outwards in the direction of the arrow A until the correct V-belt tension is achieved. z Retighten bolts (1), (2) and (3). z Fit fan V-belt.

Check the extension of the belt z In the event of V-belt tear the pressure pin (1) of the electrical switch is actuated by the tensioning roller and an acoustic signal or light signal is initiated. z Check the function by pushing the pin (1) in.

2007

41

Service and maintenance

Belt drive

Tensioning the air compressor V-belt z Unscrew the hex. head bolts (1). z Remove the outer half of the belt pulley (2). z Replace the V-belt if necessary.

Changing the air compressor V-belt z In order to re-tension, remove one or more of the intermediate discs (3) on the inside. Place the removed discs on the removed belt pulley half (2) on the outside. z Re-tighten screw (1). Turn the engine over whilst tightening to prevent trapping the V-belt.

Air compressor with double V-belt z Unscrew hex. nut (1), remove V-belt pulley half (2), V-belt (3) and intermediate pack of discs (7). z Remove intermediate disc (4), rear V-belt (3), intermediate pack of discs (6) and the V-belt disc half (5). z To re-tighten, remove one or more of the intermediate discs from the packs (6) and (7). Place the removed discs in front of, or behind, the Vbelt pulley halves (2) to ensure that the belt alignment is maintained. Always remove the same number of intermediate discs from each pack. z Installation in reverse order. Turn the engine over whilst tightening the nut (1) to prevent the Vbelt from being trapped.

42

2007

Adjustment works

Service and maintenance

Check valve clearance, adjust if necessary z Remove the cylinder head hood. z Set crankshaft according to setting schematic. z Before adjusting valve clearance, allow engine to cool down for at least 30 minutes. Lubricating oil temperature below 80 C. z Check valve clearance (1) between rocker arm / tappet contact face (2) and valve (3) with feeler gauge (6) (there should be only slight resistance when feeler gauge inserted). permissible valve clearance: (  55)

z Adjust valve clearance if necessary: Loosen the locknut (4). Use Allen key (7) to turn setscrew (5) so that correct clearance is attained after locknut (4) has been tightened. Check and adjust valve clearance on all remaining cylinders. Reinstall cylinder head cover, with new gasket.

2007

43

Service and maintenance

Adjustment works

Setting schematic for the valve clearance Valve overlap: Exhaust valve is not yet closed, inlet valve begins to open. D 914 L03 Valve overlap 1 2 3 D 914 L04 Valve overlap 1 2 3 4 D 914 L05 Valve overlap 1 2 3 4 5 Turn crankshaft 360 One turn One turn One turn One turn One turn Settings 1 2 3 4 5 Settings 4 3 2 1 Turn crankshaft 360 One turn One turn One turn Settings 1 2 3

D/TCD 914 L06 Valve overlap 1 5 3 6 2 4 Settings 6 2 4 1 5 3

44

2007

Electrical system
Regulations for working on the electrical system Do not touch the voltage conducting parts, faulty warning lamps should be immediately replaced. Pay attention to correct polarity of the connections. Cover electrical/electronic parts and connections before cleaning the engine (e.g. control units, generator, solenoid valves etc.) Do not aim the water/steam jet directly at them. Run the engine warm afterwards to evaporate moisture residues. Touching a lead against the frame to check whether it is live must not, under any circumstances, be carried out. For electrical welding work, the ground terminal of the welding gear must be clamped directly to the part being welded. Three-phase current generator: Never disconnect the cables between battery, generator and regulator while the engine is running. Electronically stored data could be lost if the battery is disconnected. Keep battery clean and dry. Make sure the battery is fitted correctly and securely. Dispose of old batteries in an environmentally friendly way.

Service and maintenance

Danger of explosion! The gases emitted by 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!

Check acid level z Unscrew caps. z Note the manufacturers specifications concerning the liquid level. The liquid should normally be 10-15 mm above the top edge of the plate or reach up to any available control device. z Only use distilled water to top up the battery. z Screw in caps. Checking the voltage z Check the battery voltage with a conventional voltmeter. The voltage indicates the charging state. It should be between 12 and 14.4 Volt depending per battery. Check acid density z Unscrew caps. z Measure the electrolyte density of individual cells with a commercial hydrometer. Hydrometer

2007

45

Service and maintenance

Electrical system

reading indicates batterys state of charge. The acid temperature when measuring should be 20 C if possible. z Check the acid level before recharging. z Screw in caps. Acid density [kg/ l] Normal 1,28 1,20 1,12 Tropical 1,23 1,12 1,08 Charge status good half empty Measure none charge charge

free, acid-resistant grease.

Removing the battery z Always disconnect the minus pole first when removing the battery. Otherwise there is a danger of short-circuit! z Remove the fastenings and take out the battery. Charging the battery z Unscrew caps. z Charge the battery with a normal commercially available battery charger. Observe the manufacturers instructions! z Screw in caps. Installing the battery z Insert new or charged battery and attach the fastenings. z Clean the terminals and battery poles with fine emery paper. z 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. z Grease the assembled terminals with an acid-

46

2007

Fault table
Faults and remedies Faults Causes Measures Check clutch Check/replace Clean/replace turbocharger Change the lubricating oil Settings Check injection line Check/replace Check/replace Change the fuel Vent fuel system Check the system Empty/clean/change Check Check cable connections Check/replace Change the fuel Empty/clean/change Settings Check/replace Vent fuel system Check injection line

Faults

7
Engine shut-off lever still in stop position (shutoff magnet defective) Air filter clogged / turbocharger defective Wrong SAE viscosity class of the engine lubricating oil Incorrect valve clearance Injection line leaks Flame glow unit Injection valve defective Fuel quality does not comply with operating manual Air in fuel system Compression pressure too low Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Battery defective or discharged Cable connection to starter loose or oxidized Starter defective or pinion does not engage

Engine does not start or is diffi- Not disconnected (if possible) cult to start Below starting limit temperature

Engine starts, but runs irregularly or fails

Fuel quality does not comply with operating manual Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Incorrect valve clearance Flame glow unit Air in fuel system Injection line leaks Injection valve defective Compression pressure too low

Check fuel injector / change if necessary Check the system

2007

47

Faults

Fault table
Causes Wrong SAE viscosity class of the engine lubricating oil Lube oil level too high Injection valve defective Air filter clogged / turbocharger defective Vent line blocked Air filter maintenance switch / maintenance indicator defective Exhaust gas backpressure too high Incorrect valve clearance Charge air cooler soiled Cooling fins dirty Cooling fan or exhaust thermostat defective, V-belt torn or loose Cooling air heating / heat short circuit Cooling diverting plates loose, cracked or missing Lube oil filter contaminated on the air or lube oil side Lube oil cooler defective Resistance in cooling system is too high / flow volume too low Measures Fill up lube oil Check lube oil level, if necessary drain off. Check fuel injector / change if necessary Check/replace Clean Check/replace Check Settings Check/clean Check/clean Check/replace/tension Check Check Check Check Check the cooling system

Faults Engine becomes excessively hot. Temperature warning system activates

48

2007

Fault table
Faults Engine output is deficient Causes Lube oil level too high Fuel quality does not comply with operating manual Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Incorrect valve clearance Air filter clogged / turbocharger defective Air filter maintenance switch / maintenance indicator defective Charge air line leaking Charge air cooler soiled Air in fuel system Compression pressure too low LDA defective (connecting line leaking) only when motor under load Exhaust gas backpressure too high Resistance in cooling system is too high / flow volume too low Injection line leaks Injection valve defective Engine shut-off lever still in stop position (shutoff magnet defective) Engine does not run on all cylin- Injection line leaks ders Incorrect valve clearance Compression pressure too low Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Air in fuel system Injection valve defective Measures

Faults
Check lube oil level, if necessary drain off. Change the fuel Empty/clean/change Settings Check/replace Check/replace Check charge air line Check/clean Check Check the system Check/replace Check Check the cooling system Check injection line Check fuel injector / change if necessary Check/replace Check fuel injector / change if necessary Settings Check the system Empty/clean/change Vent fuel system Check fuel injector / change if necessary

2007

49

Faults

Fault table
Causes Lubricating oil level too low Excessive inclination of engine Injection line leaks Injection valve defective Lube oil cooler defective Incorrect valve clearance Compression pressure too low Air in fuel system Wrong SAE viscosity class of the engine lubricating oil Measures Fill up lube oil Check engine mounting / reduce inclination Check injection line Check fuel injector / change if necessary Check Settings Check the system Vent fuel system Change the lubricating oil Check lube oil level, if necessary drain off. Check engine mounting / reduce inclination Check/replace Check Check lube oil level, if necessary drain off. Check/clean Check Check engine mounting / reduce inclination Check Check/replace Check Check lube oil level, if necessary drain off. Change the fuel Settings Check the system Check/replace Check fuel injector / change if necessary

Faults Engine lubricating oil pressure is non-existant or excessively low

Engine lubricating oil consump- Lube oil level too high tion excessive Excessive inclination of engine Air filter clogged / turbocharger defective Engine is used primarily at low load Engine producing blue smoke Lube oil level too high Lube oil in the combustion chamber Lube oil filter contaminated on the air or lube oil side Excessive inclination of engine Engine is used primarily at low load Air filter clogged / turbocharger defective Engine producing white smoke Below starting limit temperature Lube oil level too high Fuel quality does not comply with operating manual Incorrect valve clearance Compression pressure too low Flame glow unit Injection valve defective

50

2007

Fault table
Faults Causes Air filter maintenance switch / maintenance indicator defective Charge air line leaking Charge air cooler soiled Compression pressure too low Incorrect valve clearance Injection valve defective Measures Check/replace Check/replace Check charge air line Check/clean Check the system Settings

Faults

Engine producing black smoke Air filter clogged / turbocharger defective

Check fuel injector / change if necessary

2007

51

Transport and storage

Transport

8
2

Suspension equipment z Always use proper suspension equipment when transporting the engine. z Suspension equipment (1) must be adjustable for the engine centre of gravity. z After transportation and before commissioning of engine: remove attachment eyes (2).

Danger to life! The engine may tip over or fall down if suspended incorrectly! z Fastening devices cannot be fixed safely over the centre of gravity (1). z Fastening devices can slip, engine tips over (1). z Short fastening device causes bending moments in the suspension. This can damage the suspension. (2)

52

2007

Engine corrosion protection

General Engines contain the following kinds of corrosion protection z Interior corrosion protection z Exterior corrosion protection Your DEUTZ partner has the right corrosion protection agent for your needs. The following measures for corrosion protection after shutting down the engine meet the requirement for corrosion protection of 12 months. The following corrosion protection work may only be carried out by persons familiar with it and instructed in the potential dangers. If these measures are deviated from by exposing the corrosion-protected engines or parts to unfavourable conditions (installation outdoors or storage in damp, badly aired places) or damage to the corrosion protection layer, a shorter corrosion protection duration is to be expected. The engine corrosion protection should be checked about every 3 months by opening the covers. If corrosion is detected, the corrosion protection should be renewed. At the end of the corrosion protection work the crank drive may no longer be turned so that the corrosion protection agent in the bearings, bearing liners and cylinder liners is not scraped off. Before operating a corrosion protected engine, the corrosion protection must be removed. Interior corrosion protection z Interior corrosion protection is always provided by wetting of the walls with the implemented corrosion protection agent in a corrosion protection run of the engine. z The corrosion protection run can be performed once to protect the different systems: Fuel system z Fill the fuel tank with a mixture of: 90 % distilled fuel 10 % corrosion protection oil SAE 20W-20 z Perform a corrosion protection run with no load for at least 5 minutes. Lubricating oil system z Drain lubricating oil from warm engine. z Thoroughly clean lube oil tray, cylinder head with rocker arms, valves, valve springs with diesel fuel or cleaning agent. z Fill the engine with corrosion protection oil SAE 20W-20 up to the MAX mark and perform a corrosion protection run for at least 5 minutes so that all the components of the lubricating oil system are wetted or wet all accessible parts with corrosion protection oil and pump corrosion protection oil through the engine with a separate pump until all bearings and bearing liners are wetted. Air compressor z With a mounted air compressor a corrosion protection agent should be sprayed into the air compressor intake system after switching off the engine until the agent visibly emerges from the pressure socket. Cooling system z Depending on the series the engines are

Transport and storage

equipped with cooling air, cooling oil or cooling fluid system (cooling water with cooling system protection agent). Cooling air system, see section Exterior corrosion protection. In engines of the oil-cooled series the circulating lubricating oil serves simultaneously for cooling. The cooling chambers are protected automatically against corrosion with the lube oil system. If a coolant with corrosion protection properties is poured into liquid-cooled engines, no further action 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 protection 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.

z z

z z

Air intake pipes z After the corrosion protection run, remove the cylinder head cover and deinstall injectors. The respective piston must be set to LT. z The accessible part of the cylinder liner should be coated with corrosion protection oil with a spray lance through the opening. z Spray corrosion protection oil SAE 20W-20 into the suction air intake line. Exterior corrosion protection z The engine must be cleaned thoroughly with a

2007

53

Transport and storage

Engine corrosion protection

Storage and packaging z After being protected against corrosion, the engine must be stored in a dry, ventilated hall and suitably covered. z The cover must be placed loosely over the engine so that the air can circulate around it to prevent condensation from forming. Use a desiccant if necessary. Removal of corrosion protection z The corrosion protection must be removed from the corrosion protected engine before starting. z The packaging and all covers over the closed openings must be removed. z Any corrosion deposits and paint damage should be remedied. Fuel system If there is a mixture of diesel fuel/corrosion protection oil in the fuel tank, drain it. z Fill the fuel tank and fuel system with the proper fuel. Coolant system z If the implemented corrosion protection agent is compatible with the intended cooling system protection agent, this can be filled directly into the coolant system as specified. z If it is uncertain whether the implemented corrosion protection agent is compatible with the cooling system protection agent, the cooling system should be purged with fresh water for about 15 minutes before filling. Removal of exterior corrosion protection z Wash all surfaces and components coated with corrosion protection agent with distilled fuel or a suitable cleaning agent. z Wash out grooves of V-belt pulleys if necessary. z Mount V-belts or V-rib belts as specified. z Fill with coolant.

cleaning agent before exterior corrosion protection. Any signs of corrosion and damage to the paintwork must be removed. Cooling air system in air-cooled engines z The air duct space in engines is unpainted and must be sprayed with a corrosion protection agent. Bare exterior surfaces and parts z Coat or spray all bare exterior parts and surfaces (e.g. flywheel, flange faces) with corrosion protection agent. Rubber parts z Rubber parts (e.g. muffs) which are not painted over must be rubbed down with talcum powder. Belt drive z Remove V-belts and V-rib belts and store packed. z Spray V-belt pulleys and tension rollers with corrosion protection agent. z Toothed belts for engine control may not be removed. Engine openings z All engine openings must be fitted with air-tight, water-tight covers to delay the vapourisation process of the corrosion protection agents. z With installed air compressor, the suction and pressure connection must be sealed by a cap. z Air should be excluded to avoid ventilation of the engine (chimney effect) for the suction from an air supply pipe.

54

2007

Engine and setting data

General technical data Engine type Stroke Engine swept volume Compression ratio Working principle Combustion process Direction of rotation looking onto the flywheel Weight excluding cooling system to DIN 70020-A Engine power rating according to ISO 3046 Speed (nominal revolutions) Valve clearance inlet/outlet Start of pumping Firing order of the engine V-belt tension generator / fan 3) V-belt tension air compressor 3) Cooling Lubrication Lube oil SAE (  25) Lube oil temperature in the lube oil tray, maximum Lube oil pressure when hot (120C) and at slow idle speed, minimum Lube oil first fill quantities Lube oil first fill quantity without filter, minimum / maximum Lube oil first fill quantity with filter, minimum / maximum
1)

Technical data

9
D 914 L03 [mm] [cm3] [] 3236 4314 20 Four-stroke diesel normally-aspirated engine Direct injection counter-clockwise [approx. kg] [kW] [rpm] [mm] [KW before TDC] 1-2-3 [N] [N] 1 -3-4-2 Inlet: 0.15
+0,15 1)

D 914 L04 132

D 914 L05 5393

D 914 L06 6472

270 5)

300 5)
1) 1)

380 5)

410 5)

Outlet: 0.15+0,15

1- 2 - 4 - 5 - 3

1-5-3-6-2-4

Pre-tension 650 / re-tension 400 50 Pre-tension 650 / re-tension 400 50 Air-cooled Pressure lubrication 15W40

[C] [kPa] (bar)

135 50 (0,5) 4)
2)

[approx. l] [approx. l]

9.0/11.0 9.6/11.6

12.0/14.0 13.0/15.0

13.5/15.5 14.5/16.5

16.0/18.0 17.5/19.5

Engine power, speed and start of pumping, among other things, are stamped on the engine rating plate.

2007

55

Technical data

Engine and setting data

2) 3) 4) 5)

The quoted lube oil fill quantities apply to the standard versions. In case of engines which deviate from the standard (e.g. other lube oil trays/oil dipstick variants and/or special inclined position versions), the oil filling volume may vary. The oil dipstick mark is always decisive. Re-tension 15 minutes after the engine has been operated under load. Details of engines without engine lube oil heating. Approximate values can vary depending on lube oil tray version.

56

2007

Engine and setting data

General technical data Engine type No. of cylinders Cylinder arrangement Bore Stroke Engine swept volume Compression ratio Working principle Combustion process Direction of rotation looking onto the flywheel Weight excluding cooling system to DIN 70020-A Engine power rating according to ISO 3046 Speed (nominal revolutions) Valve clearance inlet/outlet Start of pumping Firing order of the engine V-belt tension generator / fan 3) V-belt tension air compressor 3) Cooling Lubrication Lube oil SAE (  25) Lube oil temperature in the lube oil tray, maximum Lube oil pressure when hot (120C) and at slow idle speed, minimum Lube oil first fill quantities Lube oil first fill quantity without filter, minimum / maximum Lube oil first fill quantity with filter, minimum / maximum [approx. l] [approx. l] [C] [kPa] (bar) [N] [N] [approx. kg] [kW] [rpm] [mm] [KW before TDC] Inlet: 0.15
+0,15 1)

Technical data

9
TCD 914 L06 6 standing in row [mm] [mm] [cm3] [] 102 132 6472 19 Four-stroke turbocharged diesel engine Direct injection counter-clockwise 410 5)
1) 1)

Outlet: 0.15+0,15 1-5-3-6-2-4

Pre-tension 650 / re-tension 400 50 Pre-tension 650 / re-tension 400 50 Air-cooled + integrated exhaust recirculation Pressure lubrication 15W40 135 50 (0,5) 4)
2)

16.0/18.0 17.5/19.5

2007

57

Technical data

Engine and setting data

Tool ordering The special tools described in this chapter can be ordered from: Wilbr Taubenstrasse 5 D-42857 Remscheid Tel.: 0049 (0) 2191-9339-0 Fax: 0049 (0) 2191-9339-200 Email: info@wilbaer.de http://www.deutz-tools.com

V-belt tension measuring instrument Order number: 8115 Measuring instrument for checking the specified Vbelt tensions.

Special wrench Order number: 170050 Tool for releasing the filter cartridges.

58

2007

DEUTZ AG Service Information Systems Ottostrae 1 D-51149 Kln Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com E-mail: info@deutz.com Printed in Germany All rights reserved 1st Edition, 01/2007 Order number: 0312 3448 en

The engine company.