Deutz - TCD - 914 Op 03123448 - en PDF

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Operation Manual

D/TCD 914
Notes
Notes age resulting from this.
z This engine has been constructed exclusively for z When carrying out maintenance work on the en-
the application specified in the scope of supply - gine, the use of DEUTZ original parts is pre-
as described by the equipment manufacturer - scribed. These are specially designed for your
and is to be used only for the intended purpose. engine and guarantee perfect operation.
Any use exceeding that scope is considered to Non-compliance results in the expiry of the war-
be contrary to the intended purpose. The manu- ranty!
facturer will not assume responsibility for any Maintenance/cleaning work on the engine may
damage resulting therefrom. The user will bear only be carried out when the engine is not run-
the sole risk in this case. ning and has cooled down.
z Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. z Do not work on the fuel system while the engine
z When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
z Unauthorised engine modifications will invalidate pressure - Danger to life!
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
z Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
z Do not change the cooling air inlet area to the that the engine is not started inadvertently
fan. Unimpaired inlet of cooling air must be main- during repairs - Danger to life!
tained.
The manufacturer will accept no liability for dam-

2 © 2007
Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
Your engine is appropriately equipped for the instal-
Notes
lation concerned, as specified by you, which means
that not all of the components described in this Op- We reserve the right to make technical changes to
eration Manual are necessarily fitted to your engine. the descriptions and data in this operating manual in
We have endeavoured to highlight any differences the interest of further development of the engines.
so that you will be able to locate the operating and This document may only be reprinted and repro-
maintenance instructions applicable to your engine duced, even in part, with our express permission.
more quickly and easily.
Order number
Please make sure that this operating manual is avail-
able to everyone involved in the operation, mainte- 0312 3448 en
nance 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

© 2007 3
Contents
Notes......................................................... 2 9 Technical data................................... 55
Foreword .................................................. 3 Engine and setting data...................... 55
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

4 © 2007
General notes General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
selves. Further developments for improvement of
the engines are, of course, also implemented in the
references to product responsibilities and service of-
fers. Or use another fast, comfortable route via the 1
original DEUTZ parts. Only the use of original Internet at www.deutzshop.de. With the DEUTZ
search and development. Profound know-how com-
DEUTZ parts, manufactured according to the latest P@rts Online Parts Catalogue you have direct con-
bined with high quality requirements are the
state of knowledge, will guarantee perfect function- tact with the nearest local DEUTZ Service Station.
guarantee for the production of engines with a long
ing and high levels of reliability.
life, high reliability levels and low fuel consumption.
Obviously the high requirements for the protection of DEUTZ Xchange components
the environment are also met. California
DEUTZ Xchange components are a cost-effective
Safety precautions when the engine is alternative. The same high quality standards apply Proposition 65 Warning
running here as for new parts. DEUTZ Xchange components Diesel engines and some of its constituents are
are equivalent to the original DEUTZ parts in function known to the State of California to cause cancer,
Maintenance or repair work must only be carried out birth defects and other reproductive harm.
and reliability.
with the engine shut down. Ensure that the engine
cannot be started unintentionally - Danger of acci- Asbestos Masthead
dents!
Gaskets used in this engine are asbestos-free. DEUTZ AG
When the work is complete, be sure to refit any pan-
Please use the appropriate spare parts for mainte- Ottostraße 1
els and guards that have been removed.
nance and repair work. 51149 Cologne
Observe industrial safety regulations when running
the engine in an enclosed space or underground. Service Telephone:+49 (221) 822-0
When working on the running engine, work clothing We want to preserve the high performance of our en- Fax: +49 (221) 822-5850
must be close fitting. gines, and with it the confidence and satisfaction of www.deutz.com
Never fill the fuel tank while the engine is running. our customers. We are therefore represented world-
wide by a network of service branches.
Service and Maintenance The DEUTZ name does not merely stand for engines
Service and maintenance are also decisive for that are the products of extensive development
whether the engine satisfactorily meets the set de- work, DEUTZ also stands for complete service pack-
mands. Recommended service intervals must there- ages that ensure optimum operation of our engines,
fore be observed and service and maintenance work and for customer services operations that you can
must be carried out conscientiously. count on.
Special care should be taken under abnormally de- Please contact your service partner in the event of a
manding operating conditions. fault or for spare parts. Our trained specialist person-
nel ensure fast, professional repairs using original
Original DEUTZ parts DEUTZ parts in the event of damage.
Original DEUTZ parts are subject to the same strict The DEUTZ homepage always gives you the latest
quality requirements as the DEUTZ engines them- overview of the DEUTZ partners in your vicinity with

© 2007 5
General General notes

1 Danger

This symbol is used for all safety instruc-


tions which, if not observed, present a di-
rect 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 prevention of
accidents" must be observed.

Caution

This symbol indicates a danger to the com-


ponent / engine. The appropriate instruc-
tions must be followed, otherwise the
component / engine may be destroyed.

Notes

This symbol accompanies notes of a gen-


eral kind.

6 © 2007
Design Engine description
2
A B

Mot.-Typ Mot.-Nr.

DEUTZ AG MADE IN GERMANY

Rating plate Location of the rating plate Engine serial number


The engine type A, engine number B and the power The rating plate is fixed to the crankcase (arrow) . The engine number (arrow) is stamped on the
data are stamped on the rating plate. crankcase and on the rating plate.
The engine type and number must be stated when
purchasing spare parts.

© 2007 7
Engine description Design

2
left

right
1

Cylinder numbering Direct injection


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

8 © 2007
Engine diagram Engine description
Engine D 914 L06, right (example)
1 Cooling fan
2
2 V-belt (fan)
3 V-belt pulley on crankshaft
4 Tension pulley
5 Lubricating oil filling
6 Lubricating oil sump
7 Fuel pump with fuel cleaning
8 Stop magnet
9 Lubricating oil dipstick
10 Injection pump
11 Lube oil replacement filter
12 Exchangeable fuel filter
13 Air guide hood
14 Cylinder head cover

© 2007 9
Engine description Engine diagram

2 Engine D 914 L06, left (example)


1 Air intake pipe
2 Exhaust manifold line
3 Standing plate
4 Flywheel or (gearbox connection SAE)
5 Starter
6 Connection for engine mounting
7 Generator mounting (optional)

10 © 2007
Engine diagram Engine description
Engine TCD 914 L06, right (example)
1 Turbocharger
2
2 Generator
3 V-belt pulley on crankshaft
4 Tension pulley
5 Cooling fan
6 Lubricating oil filling
7 Fuel pump with fuel cleaning
8 Lubricating oil dipstick
9 Stop magnet
10 Injection pump
11 Lube oil replacement filter
12 Block oil cooler
13 Exchangeable fuel filter
14 Air guide hood
15 Injection line
16 Cylinder head cover

© 2007 11
Engine description Engine diagram

2 Engine TCD 914 L06, left (example)


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

12 © 2007
Lube oil circuit Engine description
Lube oil schematic D 914 (example)
1 Lubricating oil sump
2
2 Intake line
3 Lubricating oil pump
4 Lubricating oil pressure regulating valve
5 Compression oil line
6 Lube oil cooler
7 Lube oil replacement filter
8 Safety valve
9 Main oil channel
10 Crankshaft bearing
11 Big-end bearing
12 Camshaft bearing
13 Tappet
14 Push rod (hollow for lube oil feed to rocker arm
lubrication
15 Setting screw for valve clearance
16 Rocker arm
17 Push rod protection tube (lube oil return from cyl-
inder head to crankcase)
18 Throttle port (for lubrication of the gears)
19 Injection nozzle for piston cooling
20 Connection for lube oil pressure gauge
21 Lube oil pressure gauge
22 Injection pump connected to the lube oil circuit
23 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

2 Lube oil schematic TCD 914 (example)


1 Lubricating oil sump
2 Intake line
3 Lubricating oil pump
4 Lubricating oil pressure regulating valve
5 Lube oil pressure line
6 Connection line to lube oil cooler
7 Lube oil replacement filter
8 Lube oil cooler
9 Safety valve
10 Main lube oil channel
11 Crankshaft bearing lubrication
12 Big end bearing lubrication
13 Camshaft bearing lubrication
14 Tappet
15 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 cyl-
2
inder 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

2 Fuel circuit (example)


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

16 © 2007
Exhaust gas recirculation Engine description
Exhaust gas recirculation (example)
1 Exhaust gas recirculation valve
2
2 Return line

© 2007 17
Operation Ambient conditions

3 (27).
z If cold starting occurs frequently cut the lube oil
changing interval by half.
High ambient temperatures, high altitude

Under the following application and operat-


0 °C ing 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 mix-
ture would be too rich if the injected amount of fuel
Low ambient temperatures were not reduced.
Lubricating oil z The results would be:
z Select lubricating oil according to ambient tem- – black smoke in the exhaust
perature – high engine temperature
z If cold starting occurs frequently cut the lube oil – reduction in engine performance
changing interval by half. – possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
Fuel
you have any other questions.
z Below 0 °C use winter fuel (27).
Battery
z A well charged battery is a prerequisite for start-
ing 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 Operation
Preparations for initial commissioning
(Maintenance schedule E 10)
ing oil filler neck.
z Lube oil filling quantity.
Trial run
3
z Check lubricating oil level, if necessary top up. Additional venting of the fuel system by a 5
z Remove engine corrosion protection minute trial run at idle speed or on low load
z Remove any transport devices. Pour in fuel is absolutely essential.
z Check the battery and cable connections and z The fuel low pressure system must be vented
mount if necessary. After preparations, perform a short trial run up to op-
with the hand pump after filling before starting for erating temperature (approx. 90 °C). If possible,
z Checking the belt tension (40). the 1st time. avoid loading the engine.
z Have the engine monitor or warning system
checked by authorised personnel. z Work with the engine not running:
Only re-fuel when the engine is not running.
z Check the engine mounting. Ensure cleanliness. – Check engine for tightness.
z Check that all hose unions and clips fit properly. Do not spill fuel. – Check lubricating oil level, if necessary top
up (31).
The following additional work must be carried
out on generally overhauled engines: Additional venting of the fuel system by a 5 z Work during the trial run:
minute trial run at idle speed or on low load – Check engine for tightness.
z Check the fuel prefilter and main filter and
is absolutely essential.
change if necessary.
z Check the intake air cleaner (if available, main- Only use clean, standard, branded diesel fuel. Note
tain according to maintenance indicator). the fuel quality (27)
z Drain lubricating oil and condensation water from Use summer or winter-grade fuel, depending on the
the charge air cooler. ambient temperature.
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 lubricat-

© 2007 19
Operation Start process

3 Starting

Before starting, make sure that nobody is


standing in the immediate vicinity of the en-
gine or work machine.
Separate the engine if possible by disen-
gaging 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 re-
moved, the engine must not be started un-
der any circumstances. Disconnect the z Separate engine from driven devices by discon- Without cold start aid
battery! necting if possible.
If the engine does not start properly when z Insert key
z Move speed control lever (1) into idle position. – Position 0 = no operating voltage.
the heating flange is automatically actuated
(starter does not receive current as a result z Turn shutdown lever (2) to position "I" and start.
z When starting electrically with a lifting magnet, z Turn key clockwise.
of a fault in the equipment/customer electri-
the shutdown lever (2) is pulled into position "I" – Position 1 = operating voltage.
cal control system) the starting procedure
must be abandoned (set the ignition switch and held there when power is applied. Charge pi- – Pilot lamps light up.
to OFF, disconnect the power supply to the lot light and lube oil pressure pilot light go out. z Push the key in and turn further clockwise
heating flange). against spring pressure.
Do not actuate the starter for more than – Position 2 = without function.
20 seconds. If the engine does not start up, – Position 3 = start.
wait for one minute and then repeat the – The pilot lamps will go out.
starting process.
If the engine does not start up after two at- * By afterburning to position 2 for about 3 min-
tempts, determine the cause as per fault ta- utes, if required, it is possible to further reduce
ble (47). the exhaust colouration in the run-up phase.
Do not run up the engine immediately to
high idling speed / full load operation from
cold.

20 © 2007
Start process Operation
3

* By afterburning to position 2 for about 3 * By afterburning to position 2 for about 3


minutes, if required, it is possible to further minutes, if required, it is possible to further
reduce the exhaust colouration in the run- reduce the exhaust colouration in the run-
up phase. up phase.

with cold start aid/flame glow plug with cold start aid/flame glow plug
FR 60 = 9,5 and 19 Volt FR 20/30 = 11 and 23 Volt
z Insert key z Insert key
– Position 0 = no operating voltage. – Position 0 = no operating voltage.
– Pilot lamps light up.
z Turn key clockwise.
z Push the key in and turn further clockwise
– Pre-heating lamp lights up
against spring pressure.
– Position 2 = approx. 60 seconds pre-heating
– Pre-heating lamp lights up
(hold the key in position for this)*
– Position 2 = approx. 20-30 seconds pre-
– Pre-heating lamp goes out heating (hold the key in position for this)*
– Position 3 = start.
– Pre-heating lamp goes out
z Release key as soon as engine fires.
– Position 3 = start.
– The pilot lamps will go out. z Release key as soon as engine fires.
– The pilot lamps will go out.

© 2007 21
Operation Operation monitoring

Display instrument Cooling fan drive


Possible displays: z In the event of V-belt tear the pressure pin (1) of
z Colour scale the electrical switch is actuated by the tensioning
roller and an acoustic signal or light signal is ini-
– Display of operating state by coloured areas
tiated.
(green – OK / red – take suitable action).
z Stop the engine immediately to avoid overheat-
z Measured value scale ing.
– Actual value can be read off directly. The
nominal value should be taken from the
Technical Data (55).

22 © 2007
Operation monitoring Operation
Instruments and symbols
3
Instruments / symbols Designation Possible display: Measure
Lubricating oil pressure display Lubricating oil pressure below minimum Switch off engine

Lubricating oil pressure display Lubricating oil pressure in the red area Switch off engine

Lubricating oil temperature dis- The temperature display should always be in the Turn off and establish the cause from the Fault
play green area and only be in the yellow-green area Table
under exceptional circumstances
If the pointer enters the orange sector, the engine is
overheating.
Lubricating oil pressure pilot lamp If the pilot lamp lights up after starting the engine or Switch off engine
while the engine is running, the lubricating oil pres-
sure is too low

Lube oil level 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

Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123

Horn With acoustic signal See Fault Table

© 2007 23
Operation Stop procedure

3 Shutting off

Avoid switching-off from full load operation


(coking/blockage of the remaining lubricat- A
ing 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. B

Mechanical switching-off Electrical shutdown (optional)


z Move speed adjustment lever (1) to slow idle. z Move the key to position 0.
z Move the adjustment lever (2) to position "0" until Pilot lamps A+B+C go out.
the engine stops. Charge pilot light and lube oil A = charge pilot light
pressure pilot light light up after the engine stops. B = lube oil pressure pilot light
z Turn key counterclockwise (to position 0) and re- C = pilot light for pre-heating system
move. The pilot lamps will go out. P = gear position: park
z When switching off electrically or in the event of 0 = gear position: switch off engine
a power failure the shutdown lever (2) is
1 = gear position: pre-heat engine
switched off by the lifting magnet until the engine
stops. Charge pilot light and lube oil pressure pi- 2 = gear position: start engine
lot light light up after the engine stops.
z Turn key counterclockwise (to position 0) and re-
move. The pilot lamps will go out.

24 © 2007
Lubricating oil Operating media
General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
Minimum quality class 4
the definition of the lube oil change intervals are not DEUTZ ACEA API
the lubricating oil to be used. The specific engine
essentially dependent on the lube oil quality (such as DQC I - 02 E2-96 CF/ CF4
performances which have increased constantly over
the incorporation of soot and other contaminations),
the last few years lead to an increased thermal load
the lube oil change interval when using synthetic If an engine under load is lubricated with a DQC !-
on the lubricating oil. The lubricating oil is also more
lube oils may not be increased in relation to the spec- lubricating oil then the lubricating oil change inteval
exposed to contamination due to reduced oil com-
ifications of the lube oil change intervals. should be cut by half.
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in
Recommended quality class
and recommendations described in this operating DEUTZ engines if they meet the requirements of this
manual in order not to shorten the life of the engine. operating manual. DEUTZ ACEA API
Lubricating oils always consist of a base oil and an DQC II - 05 E3-96 / E5-02 / CG-4 / CH4 / C I-4
Quality
additive package. The most important tasks of a lu- E7-04
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according DQC III - 05 E4-99 / E6-04 Please contact
tion, neutralisation of acids from combustion to their performance capability and quality class your DEUTZ part-
((DQC: Deutz Quality Class). It basically applies DQC IV - 05 E4-99 / E6-04
products, prevention of coke and soot deposits on ner
the engine parts) are assumed by the additives. The that: with ascending quality class (DQC I, II, III, IV),
properties of the base oil are also decisive for the the lubricating oils are more efficient or of higher
quality. (The suffix (- 02 / - 05) to the quality class DEUTZ lubricating oils DQC II-05
quality of the product, e.g. with regard to thermal TSL - 15W40 D
load capacity. designation indicates in what year the classification
was made. Container Order number
In principle, all engine oils of the same specification
can be mixed. However, mixing of engine oils should Lubricating oils according to other comparable spec- 5 litre container 0101 6331
be avoided because the worst properties of the mix- ifications can be used as long as they meet DEUTZ 20 litre container 0101 6332
ture are always dominant. requirements. In regions in which none of these qual-
ities is available, please contact your DEUTZ partner 209 litre barrel 0101 6333
The lubricating oil quality has a considerable influ- responsible.
ence on the life, performance and thus also on the DEUTZ lubricating oils DQC III-05
costs-effectiveness of the engine. It basically applies The following lubricating oils are specified for the en-
gines described in this operating manual. TLX - 10W40 FE
that: The better the lubricating oil quality, the better
these properties. Container Order number
The lubricating oil viscosity describes the flow be- 5 litre container 0101 6335
haviour of the lubricating oil depending on the tem- 20 litre container 0101 6336
perature. The lubricating oil viscosity has no 209 litre barrel 0101 6337
influence and effect on the lubricating oil quality.
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem-

© 2007 25
Operating media Lubricating oil

4 DEUTZ lubricating oils DQC IV-05 synthetic


(e.g. by storing the vehicle or work machine indoors).
The viscosity is classified according to SAE. Multi- °C
Container Order number
purpose lubricating oils should be used basically.
20 litre container 0101 7849 45
Single-purpose lubricating oils can also be used in
209 litre barrel 0101 7850 enclosed, heated spaces at temperatures >5 ° C. 40
Depending on the ambient temperature we recom-
Lubricating oil change intervals mend the following common viscosity classes: 35
z The intervals depend on:
30
– lubricating oil quality
– sulphur content in the fuel 25
– type of application of engine
z The lubricating oil change interval must be 20

SAE 20W-50
SAE 10W-30

SAE 10W-40

SAE 15W-40
SAE 0W-30

SAE 0W-40

SAE 5W-30

SAE 5W-40
halved if at least one of the following conditions
applies: 15
– Constant ambient temperature below -10 °C 10
(14 °F) or lube oil temperature below 60 °C
(84 °F). 5
– sulphur content in the diesel fuel of 0.5 - 1
weight %. 0
– operation with bio-diesel fuel
-5
z If the oil change intervals for vehicle engines are
to be carried out according to operating hours, -10
the oil change intervals for built-in engines apply.
z If the lubricating oil change intervals are not -15
reached within a year, the oil should be changed
at least once a year. -20
Viscosity -25
The ambient temperature at the installation site or -30
area of application of the engine is decisive for the
choice of the right viscosity class. Too high a viscos- -35
ity can lead to starting difficulties, too low a viscosity
can endanger the lubrication effect and cause high -40
lubricating oil consumption. At ambient temperatures
below -40 °C the lubricating oil must be pre-heated

26 © 2007
Fuels Operating media
Permissible fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
4
proved: Only carry out mixing in the tank. Fill with
the appropriate amount of paraffin first,
z In engines with increased power rating and en- then add the diesel fuel. Normal and high
gines with high loads we recommend the use of grade fuels may not be mixed.
DEUTZ TLX10W.40FE Europa.
z Diesel fuels according to DIN EN 590 At low ambient temperatures paraffin discharges can
– Nato F-54 (equivalent to diesel fuel in ac- lead to blockages in the fuel system and cause oper-
cordance with DIN EN 590) ating faults. Below 0 °C ambient temperature use
winter diesel (down to -20 °C) (filling stations provide
z US diesel fuel according to ASTM D 975 Grade- this in good time before the cold season starts).
No.1-D and 2-D z Below -20 °C paraffin should be added. The rel-
z Japanese diesel fuel JIS K 2204 Grade 1 Fuel evant percentages are given in the adjacent dia-
and Grade 2 Fuel with lubricating properties ac- gram.
cording to diesel fuel EN 590 (HFFR max. 460
z Special diesel fuels can be used for arctic cli-
micrometer according to EN ISO 12156) I Summer-grade diesel fuel
mates to -44 °C.
Use commercially available diesel fuel with less than II Winter-grade diesel fuel
If it is necessary to use summer diesel fuel below
0.5 % sulphur content. If the sulphur content is high- A Outdoor temperature
0°C, paraffin can also be added by up to 30 % as per
er, the lube oil change intervals must be reduced.
the diagram on the right. B Percentage of paraffin to be added
If other fuels are used which do not meet the require-
Generally, sufficient resistance to cold can also be
ments of the operating manual, the warranty will be
achieved by adding a flow improvement additive.
voided.
Please ask your DEUTZ partner.
The certification measurements to satisfy the legal
emission limits are performed with the test fuels de-
fined 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 guar-
anteed with the other fuels described in this operat-
ing manual.

© 2007 27
Maintenance Maintenance schedule

5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals

Standard maintenance schedule


D/TCD 914 Industrial engines (every.....Op.Hr.)
Stage Activity To be carried out by
Standard and EPA 3) certified engines
(Environmental Protection Agency)
E10 Initial commissioning Authorised specialists During the running-in phase or initial start-up of new or overhauled engines.
E20 Daily inspection Customer 1x daily or every 10 operating hours in continuous operation
E25 Extended checking 250 oh
E30 Maintenance 500 operating hours 1) 2)
E40 Extended maintenance I 1000 oh
E50 Extended maintenance II Authorised specialists only on EPA certified engines 1,500 operating hours
E60 Intermediate overhaul only on EPA certified engines 3,000 operating hours
E70 General overhaul 12,000 oh (only in EPA 4,000 operating hours)
Maintenance work outside the DEUTZ maintenance and service schedules
1)
Depending upon the individual case, the demand on the lube oil can be high. Shorter maintenance intervals are required for this 250 operating hours.
2)
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.
3)
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 Maintenance
Stage Measure Page 5
E10 The measures are listed in chapter 3. 19
E20 Check Lubricating oil level (if necessary top up) 55
Lubricating oil bath air filter 38
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 36
E25 Check V-belts (retension or renew if necessary) 40
E30 Check Battery and cable connectors 45
Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
Replace Lubricating oil (lubricating oil change intervals depending upon the engine application). xxxxxxxx 26
Lubricating oil filter cartridge (at each lube oil change) 32
Settings Valve clearance (turbocharged engine) 43
E40 Check Flame glow plugs
Tighten engine mountings, if necessary (renew in case of damage)
Fastenings, hose unions / clips (renew if damaged)
Replace By-pass lubricating oil filter 32
Fuel filter cartridge 34
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 34
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 36
Settings Valve clearance(normally aspirated engine) 43
E50 Check EGR valve, in the event of a fault in function, replace
Clean Injection valve
E60 Replace From the exhaust recirculation casing, replace valve
Injection valve
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
Exhaust channels on the cylinder head and with exhaust recirculation unit removed

© 2007 29
Maintenance Maintenance schedule

5 Stage
Every 2 Replace
Measure
V-belts
Page
40
years Flame glow plugs

30 © 2007
Lubricating oil system Service and maintenance
z Pour in lube oil.
Regulations for working on the lubricat-
ing oil system
Checking the lubricating oil level
– Quality/viscosity data. 6
Low lubricating oil level or overfilling lead to – Filling volume (55)
Pay attention to utmost cleanliness when engine damage! z Check engine lubricating oil level (see previous
working on the lubricating oil system. Clean The lubricating oil level may only be chapter)
the respective affected parts carefully. checked with the engine in a horizontal po-
Blow damp areas dry with compressed air. sition and switched off.
Observe the safety regulations and nation- If the engine is warm, switch off the engine
al specifications for handling lube oils. and check the lubricating oil level after 5
Dispose of leaking lubricating oil and filter minutes. If the engine is cold you can check
elements properly. Do not allow used oil to it immediately.
seep away into the ground.
Perform a trial run after all work. Pay atten-
Careful with hot lube oil. Danger of scald-
tion to tightness and lubricating oil pressure
ing!
and then check the engine oil level.
In case of fuels containing more than 1%
sulphur, contact your service representa- z Pull out the lubricating oil dipstick and wipe off
tive. 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 nec-
essary.
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 po-
sition.
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).

© 2007 31
Service and maintenance Lubricating oil system

Changing the lubricating oil filter car- z Oil the gasket of the new DEUTZ original filter Change the by-pass lubricating oil filter
tridge cartridge lightly. insert
z Screw on the new filter cartridge by hand until the z Unscrew the lube oil drain screw (1) and allow
The filter cartridge should never be pre- gasket is flush and tighten a further half a turn. the lube oil to drain out.
filled. There is a danger of dirt contamina- z If necessary, fix the clips of the anti-rotation lock. z Catch any escaping lube oil.
tion!
z Unscrew the clamping screw (2). Remove the
z Remove the clips if an anti-rotation lock is fitted. cover.
z Loosen and unscrew the filter cartridge with the z Unscrew the contaminated filter insert (3). Clean
tool (order no. 170050) . the filter housing.
z Collect draining lubricating oil z Check cover seal (4) and renew if necessary.
z Clean the sealing surface of the filter support z Reinsert the lube oil drain screw (1) with new
with a lint-free, clean cloth. seal ring (5).
z Insert new filter insert.
z Screw the cover and seal ring (6) back in posi-
tion.
z Check lubricating oil pressure and tightness dur-
ing trial run.

32 © 2007
Fuel system Service and maintenance
Regulations for working on the fuel sys-
tem
Additional regulations
6
Danger! Do not work on the fuel system
Engine must be switched off! while the engine is running.
Smoking and naked lights prohibited! Wait approx. 30 seconds after switching off
No injection/high pressure pipes may be the engine before working on the fuel sys-
disconnected while the engine is running. tem!
Caution when handling hot fuel!
Pay attention to utmost cleanliness when
The fuel system must be tight and closed.
refuelling and working on the fuel system.
Make a visual inspection for leaks / dam-
Clean the respective affected parts careful-
age to the system.
ly. Blow damp areas dry with compressed
Clean and dry the engine and the engine
air.
compartment thoroughly before starting
Observe the safety regulations and nation-
work.
al specifications for handling fuels.
Work on the fuel system may only be car-
Dispose of leaking fuel and filter elements
ried out in an absolutely clean environment.
properly. Do not allow fuel to seep away
Air contamination such as dirt, dust, mois-
into the ground.
ture etc. must be avoided.
After all work on the fuel system, the sys-
tem 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.

© 2007 33
Service and maintenance Fuel system

Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter Fuel pre-cleaning
cartridge lightly.
The filter cartridge should never be pre- z Screw on the new filter cartridge by hand until the Keep naked flames away when working on
filled. There is a danger of dirt contamina- gasket is flush and tighten a further half a turn. the fuel system! Do not smoke!
tion! z If necessary, fix the clips of the anti-rotation lock.
z Close the fuel shut-off valve.
z Remove the clips if an anti-rotation lock is fitted.
z Unscrew the filter housing (4) and pull off.
z Loosen and unscrew filter cartridge with tool (or-
z Catch any escaping fuel.
der number: 170050).
z Remove cleaning strainer (3) and clean with fuel.
z Collect draining lubricating oil
z Pull off seal ring (2).
z Dispose of in an environmentally correct man-
ner. z Clean filter housing (1) with fuel.
z Clean the sealing surface of the filter support z Screw filter housing (4) and cleaning strainer (3)
with a lint-free, clean cloth. with new seal ring (2) in position.
z Bleeding fuel system.
z Open fuel shutoff valve.
z Check for leaks.

34 © 2007
Engine cleaning Service and maintenance
Cleaning work Cleaning with cold cleaner
z Spray the engine with cold cleaner and leave it
6
For all cleaning work, make sure that no for about 10 minutes to take effect.
parts are damaged (e.g. bent cooler mesh).
z Spray the engine clean with a high pressure wa-
Cover electrical/electronic parts and con-
ter jet.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do z Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
z Clean the engine with a steam jet (maximum
Only carry out cleaning work on the engine
spray pressure 60 bar, maximum steam temper-
when it is not running!
ature 90 °C, distance at least 1m).
Remove the engine cover and cooling air
cover if available and remount after clean- z Warm up the engine so that the water residues
ing. evaporate.
z Clean external cooler according to the manufac-
General turer’s specifications.
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 en-
gine.
z Coolant leakage
z Lubricating oil leakage
z Fuel leakage
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
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.

© 2007 35
Service and maintenance Combustion air filter

6 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 indica-
tor is fully visible.
z 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.

36 © 2007
Combustion air filter Service and maintenance
Renewing the safety cartridge of the dry
air filter
1 5 2
6
Never clean the safety cartridge (4).

z Renew safety cartridge (4) according to the inter- 1


val in the maintenance schedule
z To do this:
– Unscrew hexagon nut (5), pull out safety car-
tridge (4).
– Insert new safety cartridge, screw on hexag- 4 3
onal nut.
z Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
Clean the dust discharge valve of the dry Maintaining the dry air filter
air filter
z Empty the dust discharge valve (1) by pressing Never clean filter element (3) with petrol or
together the discharge slit. hot liquids!
z Remove any caked dust by pressing together the Renew damaged filter elements.
upper section of the valve. z Maintain the filter element (3) according to the in-
z Clean the discharge slit. terval 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

6 renew if damaged.
z Fill the lubricating oil pan (3) of the oil bath air fil-
ter 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 Cleaning oil bath air filter

Never fill the dust container (3) with lubri- Never clean the filter with petrol!
cating oil!

z Loosen wing nut (1) and lift off housing cover (2).
Dispose of the old lubricating oil in accord-
z Remove the dust container (3) from the base (4)
ance with the regulations. Select the en-
and empty it. Clean the container using a brush
gine lubricating oil according to the
and clean diesel fuel. Then dry.
requirements before filling the filter.
z Place the dust container (3) on the base (4) and
tighten the housing cover (2) with wing nut (1). z Shut down engine and wait about 10 minutes un-
til the lubricating oil has collected in the lubricat-
ing 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
6

Clean cylinder head exhaust apertures

Carry out the work only when cold. Danger


of burning!

z Remove air guide hood.


z Release screws.
z Remove exhaust gas recirculation unit.
z Clean exhaust gas apertures on each cylinder
using a wire brush (order number: 8167)
(28).
z If possible remove the remnants by suction.
z Refit the exhaust gas recirculation unit.
z Tighten screws (tightening torque 42 Nm).
z Install air guide hood.

© 2007 39
Service and maintenance Belt drive

Checking the belt drive Checking the belt tension Replacing the fan V-belt
z Lower indicator arm (1) into the measuring de- z In order to change the belt, push the tensioning
Only carry out work/function check on the vice. roller (1) inwards with ordinary tooling and re-
belt drive when the engine is not running!
z Place guide (3) between two belt pulleys on the move the V-belt.
Only check / change V-belts when the en-
V-belt (2). The stop have to be at the side. z Fit new V-belts.
gine is not running! Refit the V-belt guard!
Retension the new V-belts after 15 minutes z Press the button (4) at right angles to the V-belt
running time. In the event of wear of the (2) evenly until you hear or feel the spring snap
double belts or damage to one of the V- in.
belts always replace both belts as a pair. z Lift the measuring device carefully without alter-
The difference in length of the new V-belts ing the position of the indicator arm (1).
must not exceed 0.15 % one to the other. z Read the measured value at the point of inter-
section (arrow), scale (5) and indicator arm (1).
z Check the whole belt drive visually for damage. z If necessary, re-tension belt and measure again.
z Renew damaged parts.
z Remount protective devices if necessary. Tools
z Pay attention to correct fit of new belts, check the Belt tension measuring device (order number:
tension after running for 15 minutes. 8115) can be obtained from your DEUTZ partner.

40 © 2007
Belt drive Service and maintenance
6

Tightening fan V-belt Changing fan V-belt Check the extension of the belt
z Loose screws (1), (2) and (3). z Remove fan V-belt. z In the event of V-belt tear the pressure pin (1) of
z Push the generator (4) outwards in the direction z Loose screws (1), (2) and (3). the electrical switch is actuated by the tensioning
of the arrow A until the correct V-belt tension is z Swing the generator (4) inwards in the direction roller and an acoustic signal or light signal is ini-
achieved. of the arrow B. tiated.
z Retighten bolts (1), (2) and (3). z Remove and replace V-belt by a new one. z Check the function by pushing the pin (1) in.
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.

© 2007 41
Service and maintenance Belt drive

Tensioning the air compressor V-belt Changing the air compressor V-belt Air compressor with double V-belt
z Unscrew the hex. head bolts (1). z In order to re-tension, remove one or more of the z Unscrew hex. nut (1), remove V-belt pulley half
z Remove the outer half of the belt pulley (2). intermediate discs (3) on the inside. Place the re- (2), V-belt (3) and intermediate pack of discs (7).
z Replace the V-belt if necessary. moved discs on the removed belt pulley half (2) z Remove intermediate disc (4), rear V-belt (3), in-
on the outside. termediate pack of discs (6) and the V-belt disc
z Re-tighten screw (1). Turn the engine over whilst half (5).
tightening to prevent trapping the V-belt. z To re-tighten, remove one or more of the inter-
mediate discs from the packs (6) and (7). Place
the removed discs in front of, or behind, the V-
belt pulley halves (2) to ensure that the belt align-
ment 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 V-
belt from being trapped.

42 © 2007
Adjustment works Service and maintenance
6

Check valve clearance, adjust if neces- z Adjust valve clearance if necessary:


sary
– Loosen the locknut (4).
z Remove the cylinder head hood. – Use Allen key (7) to turn setscrew (5) so that
z Set crankshaft according to setting schematic. correct clearance is attained after locknut (4)
z Before adjusting valve clearance, allow engine to has been tightened.
cool down for at least 30 minutes. Lubricating oil – Check and adjust valve clearance on all re-
temperature below 80 °C. maining cylinders.
z Check valve clearance (1) between rocker arm / – Reinstall cylinder head cover, with new gas-
tappet contact face (2) and valve (3) with feeler ket.
gauge (6) (there should be only slight resistance
when feeler gauge inserted). permissible valve
clearance: (55)

© 2007 43
Service and maintenance Adjustment works

6 Setting schematic for the valve clearance


Valve overlap: Exhaust valve is not yet closed, inlet
D/TCD 914 L06

Valve overlap Settings


valve begins to open.
1 6
D 914 L03
5 2
Valve overlap Turn crankshaft Settings 3 4
360° 6 1
1 One turn 1 2 5
2 One turn 2 4 3
3 One turn 3
D 914 L04

Valve overlap Settings


1 4
2 3
3 2
4 1
D 914 L05

Valve overlap Turn crankshaft Settings


360°
1 One turn 1
2 One turn 2
3 One turn 3
4 One turn 4
5 One turn 5

44 © 2007
Electrical system Service and maintenance
Regulations for working on the electrical
system Danger of explosion! The gases emitted by
the battery are explosive!
6
Fire, sparks, smoking and naked lights are
Do not touch the voltage conducting parts,
prohibited!
faulty warning lamps should be immediate-
Danger of acid burns! Wear protective
ly replaced.
gloves and glasses! Avoid contact with skin
and clothing!
Pay attention to correct polarity of the con- Danger of short circuit! Do not rest tools on
nections. the battery!
Cover electrical/electronic parts and con-
nections 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 cir- Check acid level
cumstances, be carried out. z Unscrew caps.
For electrical welding work, the ground ter-
z Note the manufacturer’s specifications concern-
minal of the welding gear must be clamped
ing the liquid level.
directly to the part being welded.
Three-phase current generator: Never dis- The liquid should normally be 10-15 mm above
connect the cables between battery, gener- the top edge of the plate or reach up to any avail-
ator and regulator while the engine is able control device.
running. z Only use distilled water to top up the battery.
z Screw in caps.
Electronically stored data could be lost if Checking the voltage
the battery is disconnected.
Keep battery clean and dry. z Check the battery voltage with a conventional
Make sure the battery is fitted correctly and voltmeter. The voltage indicates the charging
securely. state. It should be between 12 and 14.4 Volt de-
Dispose of old batteries in an environmen- pending per battery.
tally friendly way. 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

6 reading indicates battery’s state of charge. The


acid temperature when measuring should be 20
free, acid-resistant grease.

°C if possible.
z Check the acid level before recharging.
z Screw in caps.
Acid density [kg/ l] Charge Measure
Normal Tropical status
1,28 1,23 good none
1,20 1,12 half charge
1,12 1,08 empty charge

Removing the battery


z Always disconnect the minus pole first when re-
moving 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 manufac-
turer’s instructions!
z Screw in caps.
Installing the battery
z Insert new or charged battery and attach the fas-
tenings.
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
Faults and remedies
7
Faults Causes Measures
Engine does not start or is diffi- Not disconnected (if possible) Check clutch
cult to start Below starting limit temperature
Engine shut-off lever still in stop position (shutoff magnet defective) Check/replace
Air filter clogged / turbocharger defective Clean/replace turbocharger
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Incorrect valve clearance Settings
Injection line leaks Check injection line
Flame glow unit Check/replace
Injection valve defective Check/replace
Fuel quality does not comply with operating manual Change the fuel
Air in fuel system Vent fuel system
Compression pressure too low Check the system
Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Empty/clean/change
Battery defective or discharged Check
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check/replace
Engine starts, but runs irregu- Fuel quality does not comply with operating manual Change the fuel
larly or fails Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Empty/clean/change
Incorrect valve clearance Settings
Flame glow unit Check/replace
Air in fuel system Vent fuel system
Injection line leaks Check injection line
Injection valve defective Check fuel injector / change if necessary
Compression pressure too low Check the system

© 2007 47
Faults Fault table

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

48 © 2007
Fault table Faults
Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
7
Fuel quality does not comply with operating manual Change the fuel
Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Empty/clean/change
Incorrect valve clearance Settings
Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Air in fuel system Check
Compression pressure too low Check the system
LDA defective (connecting line leaking) only when motor under load Check/replace
Exhaust gas backpressure too high Check
Resistance in cooling system is too high / flow volume too low Check the cooling system
Injection line leaks Check injection line
Injection valve defective Check fuel injector / change if necessary
Engine shut-off lever still in stop position (shutoff magnet defective) Check/replace
Engine does not run on all cylin- Injection line leaks Check fuel injector / change if necessary
ders Incorrect valve clearance Settings
Compression pressure too low Check the system
Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Empty/clean/change
Air in fuel system Vent fuel system
Injection valve defective Check fuel injector / change if necessary

© 2007 49
Faults Fault table

7 Faults
Engine lubricating oil pressure
Causes
Lubricating oil level too low
Measures
Fill up lube oil
is non-existant or excessively Excessive inclination of engine Check engine mounting / reduce inclination
low
Injection line leaks Check injection line
Injection valve defective Check fuel injector / change if necessary
Lube oil cooler defective Check
Incorrect valve clearance Settings
Compression pressure too low Check the system
Air in fuel system Vent fuel system
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consump- Lube oil level too high Check lube oil level, if necessary drain off.
tion excessive Excessive inclination of engine Check engine mounting / reduce inclination
Air filter clogged / turbocharger defective Check/replace
Engine is used primarily at low load Check
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Lube oil in the combustion chamber Check/clean
Lube oil filter contaminated on the air or lube oil side Check
Excessive inclination of engine Check engine mounting / reduce inclination
Engine is used primarily at low load Check
Air filter clogged / turbocharger defective Check/replace
Engine producing white smoke Below starting limit temperature Check
Lube oil level too high Check lube oil level, if necessary drain off.
Fuel quality does not comply with operating manual Change the fuel
Incorrect valve clearance Settings
Compression pressure too low Check the system
Flame glow unit Check/replace
Injection valve defective Check fuel injector / change if necessary

50 © 2007
Fault table Faults
Faults Causes
Engine producing black smoke Air filter clogged / turbocharger defective
Measures
Check/replace
7
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Compression pressure too low Check the system
Incorrect valve clearance Settings
Injection valve defective Check fuel injector / change if necessary

© 2007 51
Transport and storage Transport

8
1

Suspension equipment
Danger to life!
z Always use proper suspension equipment when The engine may tip over or fall down if sus-
transporting the engine. pended incorrectly!
z Suspension equipment (1) must be adjustable
for the engine centre of gravity. z Fastening devices cannot be fixed safely over
the centre of gravity (1).
z After transportation and before commissioning of
engine: remove attachment eyes (2). z Fastening devices can slip, engine tips over (1).
z Short fastening device causes bending moments
in the suspension. This can damage the suspen-
sion. (2)

52 © 2007
Engine corrosion protection Transport and storage
General
Engines contain the following kinds of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
equipped with cooling air, cooling oil or cooling
fluid system (cooling water with cooling system 8
tection z The corrosion protection run can be performed protection agent).
once to protect the different systems: z Cooling air system, see section Exterior corro-
z Interior corrosion protection sion protection.
z Exterior corrosion protection Fuel system z In engines of the oil-cooled series the circulating
Your DEUTZ partner has the right corro- z Fill the fuel tank with a mixture of: lubricating oil serves simultaneously for cooling.
– 90 % distilled fuel The cooling chambers are protected automati-
sion protection agent for your needs.
– 10 % corrosion protection oil SAE 20W-20 cally against corrosion with the lube oil system.
z Perform a corrosion protection run with no load z If a coolant with corrosion protection properties is
The following measures for corrosion protection af-
for at least 5 minutes. poured into liquid-cooled engines, no further ac-
ter shutting down the engine meet the require-
tion is necessary after draining.
ment for corrosion protection of 12 months.
Lubricating oil system z If not, the coolant must be drained and, to ensure
The following corrosion protection work may only be the formation of a covering layer on the inside
carried out by persons familiar with it and instructed z Drain lubricating oil from warm engine.
surfaces of the cooling system, a corrosion pro-
in the potential dangers. z Thoroughly clean lube oil tray, cylinder head with
tection run performed with a mixture of:
rocker arms, valves, valve springs with diesel
If these measures are deviated from by exposing the – 95 % treated water
fuel or cleaning agent.
corrosion-protected engines or parts to unfavourable – 5 % corrosion protection agent
conditions (installation outdoors or storage in damp, z Fill the engine with corrosion protection oil SAE
20W-20 up to the MAX mark and perform a cor- z The duration of the corrosion protection run and
badly aired places) or damage to the corrosion pro- the concentration of the corrosion protection
tection layer, a shorter corrosion protection duration rosion protection run for at least 5 minutes so
that all the components of the lubricating oil sys- agent are specified by the manufacturer of the
is to be expected. corrosion protection agent.
tem are wetted or wet all accessible parts with
The engine corrosion protection should be checked corrosion protection oil and pump corrosion pro- z Then drain the coolant.
about every 3 months by opening the covers. If cor- tection oil through the engine with a separate
rosion is detected, the corrosion protection should Air intake pipes
pump until all bearings and bearing liners are
be renewed. wetted. z After the corrosion protection run, remove the
At the end of the corrosion protection work the crank cylinder head cover and deinstall injectors. The
drive may no longer be turned so that the corrosion Air compressor respective piston must be set to LT.
protection agent in the bearings, bearing liners and z With a mounted air compressor a corrosion pro- z The accessible part of the cylinder liner should
cylinder liners is not scraped off. tection agent should be sprayed into the air com- be coated with corrosion protection oil with a
Before operating a corrosion protected engine, the pressor intake system after switching off the spray lance through the opening.
corrosion protection must be removed. engine until the agent visibly emerges from the z Spray corrosion protection oil SAE 20W-20 into
pressure socket. the suction air intake line.
Interior corrosion protection
Cooling system Exterior corrosion protection
z Interior corrosion protection is always provided
by wetting of the walls with the implemented cor- z Depending on the series the engines are z The engine must be cleaned thoroughly with a

© 2007 53
Transport and storage Engine corrosion protection

8 cleaning agent before exterior corrosion protec-


tion. Any signs of corrosion and damage to the
Storage and packaging
z After being protected against corrosion, the en-
Coolant system
z If the implemented corrosion protection agent is
paintwork must be removed.
gine must be stored in a dry, ventilated hall and compatible with the intended cooling system pro-
Cooling air system in air-cooled engines suitably covered. tection agent, this can be filled directly into the
z The cover must be placed loosely over the en- coolant system as specified.
z The air duct space in engines is unpainted and
gine so that the air can circulate around it to pre- z If it is uncertain whether the implemented corro-
must be sprayed with a corrosion protection
vent condensation from forming. Use a desiccant sion protection agent is compatible with the cool-
agent.
if necessary. ing system protection agent, the cooling system
Bare exterior surfaces and parts should be purged with fresh water for about 15
Removal of corrosion protection minutes before filling.
z Coat or spray all bare exterior parts and surfaces z The corrosion protection must be removed from
(e.g. flywheel, flange faces) with corrosion pro- Removal of exterior corrosion protection
the corrosion protected engine before starting.
tection agent. z Wash all surfaces and components coated with
z The packaging and all covers over the closed
Rubber parts openings must be removed. corrosion protection agent with distilled fuel or a
z Any corrosion deposits and paint damage should suitable cleaning agent.
z Rubber parts (e.g. muffs) which are not painted z Wash out grooves of V-belt pulleys if necessary.
be remedied.
over must be rubbed down with talcum powder.
z Mount V-belts or V-rib belts as specified.
Fuel system z Fill with coolant.
Belt drive
If there is a mixture of diesel fuel/corrosion pro-
z Remove V-belts and V-rib belts and store
tection oil in the fuel tank, drain it.
packed.
z Fill the fuel tank and fuel system with the proper
z Spray V-belt pulleys and tension rollers with cor-
fuel.
rosion protection agent.
z Toothed belts for engine control may not be re-
moved.
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 Technical data
General technical data
9
Engine type D 914 L03 D 914 L04 D 914 L05 D 914 L06
Stroke [mm] 132
Engine swept volume [cm3] 3236 4314 5393 6472
Compression ratio [ε] 20
Working principle Four-stroke diesel normally-aspirated engine
Combustion process Direct injection
Direction of rotation looking onto the flywheel counter-clockwise
Weight excluding cooling system to DIN 70020-A [approx. kg] 270 5) 300 5) 380 5) 410 5)
1)
Engine power rating according to ISO 3046 [kW]
1)
Speed (nominal revolutions) [rpm]
+0,15
Valve clearance inlet/outlet [mm] Inlet: 0.15 Outlet: 0.15+0,15
1)
Start of pumping [°KW before
TDC]
Firing order of the engine 1-2-3 1 -3-4-2 1- 2 - 4 - 5 - 3 1-5-3-6-2-4
V-belt tension generator / fan 3) [N] Pre-tension 650 / re-tension 400 ± 50
V-belt tension air compressor 3) [N] Pre-tension 650 / re-tension 400 ± 50
Cooling Air-cooled
Lubrication Pressure lubrication
Lube oil SAE (25) 15W40
Lube oil temperature in the lube oil tray, maximum [°C] 135
Lube oil pressure when hot (120°C) and at slow idle speed, [kPa] (bar) 50 (0,5) 4)
minimum
2)
Lube oil first fill quantities
Lube oil first fill quantity without filter, minimum / maximum [approx. l] 9.0/11.0 12.0/14.0 13.5/15.5 16.0/18.0
Lube oil first fill quantity with filter, minimum / maximum [approx. l] 9.6/11.6 13.0/15.0 14.5/16.5 17.5/19.5

1)
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

9 2) 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.
3) Re-tension 15 minutes after the engine has been operated under load.
4) Details of engines without engine lube oil heating.
5) Approximate values can vary depending on lube oil tray version.

56 © 2007
Engine and setting data Technical data
General technical data
9
Engine type TCD 914 L06
No. of cylinders 6
Cylinder arrangement standing in row
Bore [mm] 102
Stroke [mm] 132
Engine swept volume [cm3] 6472
Compression ratio [ε] 19
Working principle Four-stroke turbocharged diesel engine
Combustion process Direct injection
Direction of rotation looking onto the flywheel counter-clockwise
Weight excluding cooling system to DIN 70020-A [approx. kg] 410 5)
1)
Engine power rating according to ISO 3046 [kW]
1)
Speed (nominal revolutions) [rpm]
+0,15
Valve clearance inlet/outlet [mm] Inlet: 0.15 Outlet: 0.15+0,15
1)
Start of pumping [°KW before TDC]
Firing order of the engine 1-5-3-6-2-4
V-belt tension generator / fan 3) [N] Pre-tension 650 / re-tension 400 ± 50
V-belt tension air compressor 3) [N] Pre-tension 650 / re-tension 400 ± 50
Cooling Air-cooled + integrated exhaust recirculation
Lubrication Pressure lubrication
Lube oil SAE (25) 15W40
Lube oil temperature in the lube oil tray, maximum [°C] 135
Lube oil pressure when hot (120°C) and at slow idle speed, min- [kPa] (bar) 50 (0,5) 4)
imum
2)
Lube oil first fill quantities
Lube oil first fill quantity without filter, minimum / maximum [approx. l] 16.0/18.0
Lube oil first fill quantity with filter, minimum / maximum [approx. l] 17.5/19.5

© 2007 57
Technical data Engine and setting data

9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Wilbär
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 Special wrench


Order number: 8115 Order number: 170050
Measuring instrument for checking the specified V- Tool for releasing the filter cartridges.
belt tensions.

58 © 2007
DEUTZ AG
Service Information Systems

Ottostraße 1
D-51149 Köln
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
The engine company. Order number: 0312 3448 en

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