Om D-TCD 914

Acrobat-Dokument
OBJ_DOKU-16314-001.fm Seite 1 Donnerstag, 24. Juli 2008 11:18 11
Operation Manual
D/TCD 914
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
z This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. 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 feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
z When carrying out maintenance work on the en-
2 © 2008
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.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail-
able to everyone involved in the operation, mainte-
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
© 2008 3
Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical system . . . . . . . . . . . . . . . 48
Foreword. . . . . . . . . . . . . . . . . . . . . 3 7 Faults. . . . . . . . . . . . . . . . . . . . . 50
1 General. . . . . . . . . . . . . . . . . . . . 5 Fault table . . . . . . . . . . . . . . . . . . 50
2 Engine description . . . . . . . . . . . . . 7 8 Transport and storage . . . . . . . . . . . 55
Model . . . . . . . . . . . . . . . . . . . . . 7 Transport . . . . . . . . . . . . . . . . . . . 55
Engine illustrations . . . . . . . . . . . . . . 9 Engine corrosion protection . . . . . . . . . 56
Schematic for lubricating oil . . . . . . . . . 13 9 Technical data . . . . . . . . . . . . . . . . 58
Schematic for fuel . . . . . . . . . . . . . . 15 Engine and setting data . . . . . . . . . . . 58
Exhaust return . . . . . . . . . . . . . . . . 16 Tools . . . . . . . . . . . . . . . . . . . . . 60
3 Operation . . . . . . . . . . . . . . . . . . 18
Ambient conditions . . . . . . . . . . . . . . 18
Initial start-up . . . . . . . . . . . . . . . . . 19
Start procedure . . . . . . . . . . . . . . . . 21
Operation monitoring . . . . . . . . . . . . . 23
Stop procedure . . . . . . . . . . . . . . . . 25
4 Operating media. . . . . . . . . . . . . . . 26
Lubricating oil . . . . . . . . . . . . . . . . . 26
Fuel . . . . . . . . . . . . . . . . . . . . . . 28
5 Maintenance . . . . . . . . . . . . . . . . . 30
Maintenance schedule . . . . . . . . . . . . 30
6 Servicing and maintenance works . . . . . 33
Lubricating oil system. . . . . . . . . . . . . 33
Fuel system. . . . . . . . . . . . . . . . . . 36
Engine cleaning. . . . . . . . . . . . . . . . 38
Aspiration system. . . . . . . . . . . . . . . 39
External exhaust return . . . . . . . . . . . . 42
Belt drives . . . . . . . . . . . . . . . . . . 43
Setting work . . . . . . . . . . . . . . . . . 46
4 © 2008
General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the
functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components California
Obviously the high requirements for the protection of Proposition 65 Warning
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high Diesel engines and some of its constituents are
Safety precautions when the engine is running as for new parts. DEUTZ replacement parts are known to the State of California to cause cancer,
equal to the original DEUTZ parts in function and re- birth defects and other reproductive harm.
Maintenance work or repairs may only be performed liability.
on the shut-down engine. Make sure that the engine Masthead
cannot be started inadvertently - Danger of acci- Asbestos DEUTZ AG
dent!
The gaskets used in this engine contain no asbestos. Ottostraße 1
After repair work: Check that all guards have been Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from 51149 Köln
maintenance and repair work.
the engine. Germany
Observe industrial safety regulations when running Service Phone: +49 (0) 221-822-0
the engine in an enclosed space or underground. We want to preserve the high performance of our en- Fax: +49 (0) 221-822-5850
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of
E-Mail: info@deutz.com
must be close fitting. our customers. We are therefore represented world-
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
© 2008 5
General
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 part

and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.
Notes
This symbol accompanies notes of a gen-

eral kind.
6 © 2008
Model Engine description

Engine type designation
2
This manual covers the following engine types
A B
D 914 L06 TCD 914 L06 C
D 914 L05
D 914 L04 Mot.-Typ Mot.-Nr.
D 914 L03
TCD
T Exhaust gas turbocharger R
DEUTZ AG
C Charge air cooler MADE IN GERMANY
D Diesel
914 Rating plate Location of the rating plate

914 Series The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cov-
data are stamped on the rating plate. er or the crankcase.
L03/L04/L05/L06 The engine type and number must be stated when
L in series purchasing spare parts.
03 No. of cylinders
04 No. of cylinders
05 No. of cylinders
06 No. of cylinders
© 2008 7
Engine description Model
2 left
D
right
1
Engine serial number Cylinder numbering
The engine number (D) is stamped onto the crank- Cylinder arrangement
case (arrow) and onto the rating plate.
The cylinders are counted consecutively starting
from flywheel (1).
Direction of rotation
Looking onto the flywheel.
rotating to the left: counter-clockwise.
Engine sides
Looking onto the flywheel.
8 © 2008
Engine illustrations Engine description

D 914 L06
View from right (example)
2
13
1 Cooling fan
2 V-belt (fan)
3 Tension pulley
12
4 Lubricating oil filling
5 Lubricating oil sump
6 Fuel supply pump with integrated screen filter
11 1
7 Stop magnet
8 Lubricating oil dipstick
9 Injection pump
10 10 Lube oil replacement filter
2
11 Exchangeable fuel filter
12 Air guide hood
13 Cylinder head cover
9
7
3
6 5 4
© 2008 9
Engine description Engine illustrations
2 D 914 L06
View from left (example)
1 Air intake pipe
2 Exhaust manifold line
3 Flywheel
4 Starter
10 © 2008
Engine illustrations Engine description

TCD 914 L06
View from right (example)
2
1 Turbocharger
2 Generator
3 Tension pulley
4 Cooling fan
5 Lubricating oil filling
7 Lubricating oil dipstick
8 Stop magnet
9 Injection pump
10 Lube oil replacement filter
11 Lube oil cooler
13 Air guide hood
14 Injection valve
15 Cylinder head cover
© 2008 11
Engine description Engine illustrations
2 TCD 914 L06

View from left (example)
1 Charge air cooler
2 Flywheel
3 Starter
5 Lubricating oil pipe to the turbocharger
6 Exhaust outlet
7 Turbocharger
8 Combustion air inlet
9 Exhaust manifold line
12 © 2008
Schematic for lubricating oil Engine description

D 914
(example)
2
2 Lubricating oil pump
3 Pressure holding valve
4 Lube oil cooler
5 Lubricating oil filter
6 Overpressure valve
7 Main lube oil channel
8 Rocker arm
9 Lubricating oil pressure indicator
10 Injection pump
11 Connection possibility for cab heating
Retrofitting by authorised specialists only
© 2008 13
Engine description Schematic for lubricating oil
2 TCD 914 L06

(example)
2 Lubricating oil pump
3 Pressure holding valve
4 Lube oil cooler
5 Lubricating oil filter
6 Overpressure valve
7 Main lube oil channel
8 Sub-stream lubricating oil filter
9 Rocker arm
10 Lubricating oil pressure indicator
11 Turbocharger
12 Injection pump
13 Connection possibility for cab heating
Retrofitting by authorised specialists only
14 © 2008
Schematic for fuel Engine description

Fuel schematic (example)
1 Fuel tank
2
2 Fuel line from tank to fuel pump
5 Injection pump
6 Injection line to injection valve
7 Injection valve
8 Fuel return to fuel tank
© 2008 15
Engine description Exhaust return
2 7
External exhaust gas recirculation
D 914 L03 > 37 kW
D 914 L04
D 914 L05
D 914 L06
TCD 914 L06 Optional

(example)
1 Exhaust gas partial flow
(not connected)
2 Valve housing
3 Actuator
(electrically actuated)
4 Distributor pipe
5 5 Electrical connection
6 Switch
The switch is connected internally with the con-
trol linkage. The voltage to the actuator is inter-
rupted at load peaks.
7 Injection pump
1 6
The switch housing is designed to be safe from ma-
nipulation.
Only have work performed on the components by
authorised qualified personnel.
4 2 3
16 © 2008
Exhaust return Engine description

Internal exhaust gas recirculation
(example)
2
D 914 L03 < 37 kW
TCD 914 L06 Optional
1 Additional cams for exhaust gas recirculation

Inlet valve opens briefly during the outlet cycle
and emits an exhaust gas partial flow to the suc-
tion system.
1 This partial volume is sucked back in in the next
suction cycle.
2 Outlet valve
3 Inlet valve
2 3
[mm]
[°]
© 2008 17
Operation Ambient conditions
3 Cold start aid

z Depending on the type of engine, glow plugs,
heating plugs, heating flange, flame glow system
can be used as cold starting aids.(21)
High ambient temperatures, high altitude
0 °C This engine can be equipped optionally

with an electronic DEUTZ control unit.
Under the operating conditions listed be-
low, the amount of fuel is reduced automat-
ically, controlled by the electronic control
unit.
Under the following application and operating condi-
tions, the amount of fuel must be reduced.
Low ambient temperatures z above 1000 m altitude
Lubricating oil z above 30 °C ambient temperature
z Select the lubricating oil viscosity according to Reason: Air density decreases as altitude or ambient
the ambient temperature. temperature increase. This reduces the amount of
z If cold starting occurs frequently cut the lube oil oxygen in the engine intake air and the fuel-air mix-
changing interval by half. ture would be too rich if the injected amount of fuel
were not reduced.
Fuel
z The results would be:
z Use winter fuel below 0 °C (28). – black smoke in the exhaust
Battery – high engine temperature
z A good charging condition of the battery (48) – reduction in engine performance
is the prerequisite for starting the engine. – possible impairment of starting behaviour
z Heating up the battery to approx. 20°C improves Consult your equipment supplier or DEUTZ partner if
the starting behaviour of the engine. (Remove you have any other questions.
and store the battery in a warm room).
18 © 2008
Initial start-up Operation

Preparations for initial commissioning
(Maintenance schedule E 10)
ing oil filler neck.
z Observe the lubricating oil filling level (58). 3
z Remove engine corrosion protection
z Remove any transport devices.
z Check the battery and cable connections and
mount if necessary.
z Check belt tension (43).
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 pre-filter and main filter and Pour in fuel
change if necessary.
z Check the intake air cleaner (if available, main- Only re-fuel when the engine is not running.
tain according to maintenance indicator). Ensure cleanliness.
z Drain lubricating oil and condensation water from Do not spill fuel.
the charge air cooler. Additional venting of the fuel system by a 5
z Fill with engine lube oil. minute trial run at idle speed or on low load
is absolutely essential.
Fill with engine lube oil
z The fuel low pressure system must be vented be-
Low lubricating oil level and overfilling lead fore the first start-up after filling with the manualy
to engine damage. supply pump.
Only use clean commercially available brand diesel
The engines are generally supplied without fuel. Observe fuel quality (28).
lubricating oil filling. Use summer or winter-grade fuel, depending on the
Select lubricating oil quality and viscosity ambient temperature.
before filling.
Order DEUTZ lubricating oils from your
DEUTZ partner
z Fill the engine with lubricating oil via the lubricat-
© 2008 19
Operation Initial start-up
3 Trial run
Additional venting of the fuel system by a 5

minute trial run at idle speed or on low load
Carry out a brief trial run up to operating temperature
(approx. 90 °C) after preparations.
Do not load the engine if possible.
z Work with the engine not running:
– Check engine for tightness.
– Check lubricating oil level, if necessary top
up.
z Work during the trial run:
– Check engine for tightness.
20 © 2008
Start procedure Operation

Starting
3
Before starting, make sure that nobody is
standing in the immediate vicinity of the en-
gine or work machine.
Disconnect the engine by uncoupling de-
vices to be driven where possible.
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!
Do not actuate the starter for more than
20 seconds. If the engine does not start up, © 25745-0
wait for one minute and then repeat the Starting Without cold start aid
starting process. z Move speed adjustment lever (1) to slow idle. z Insert key.
z Turn shutdown lever (2) to position "I" and start. z Turn key to the right.
If the engine does not start up after two at- z In electrical start with a lifting magnet the shutoff – Position 1 = operating voltage.
tempts, determine the cause as per fault ta- lever (2) is pulled in direction "I" and held when – Pilot lamps (1) and (2) light up.
ble (50). current is applied. The charging control lamp and
Do not run up the engine immediately to z Push the key in and turn further clockwise
lubricating oil pressure control lamp go out. against spring pressure.
high idling speed / full load operation from
cold. – Level 2 = no function.
– Level 3 = start.
Disconnect the engine by uncoupling de- z release the key as soon as the engine starts up.
vices to be driven where possible. – The pilot lamps will go out.
© 2008 21
Operation Start procedure
3 After starting, any exhaust gas turbidity in

the runup phase can be reduced by holding
A the key at stage 2. (maximum 3 minutes)
with cold starting device

z Insert key.
– Position 0 = no operating voltage.
z Turn key to the right.
– Position 1 = operating voltage.
– Pilot lamps (A), (B) and (C) light up.
z stage 2 = pre-heating
– Preheat until the glow display goes out; an
error has occurred if the preheating indicator
flashes; e.g. the preheating relay is stuck,
which can discharge the battery completely
when at a standstill.
– Engine is ready for operation.
z Push the key in and turn further clockwise
against spring pressure.
– Level 3 = start.
z release the key as soon as the engine starts up.
– The pilot lamps will go out.
22 © 2008
Operation monitoring Operation

Operation monitoring by EMR2
Optional
3
The EMR2 system monitors the engine condition as
well as the engine electronics and displays these to
the driver/operator with the error lamp:
z Function test
– Ignition on, error lamp lights up for approx. 2
seconds and then goes out.
z The lamp does not light
– After the lamp test an extinguished lamp indi-
cates an error-free and trouble-free operat-
ing state within the scope of the control
possibility.
z Steady light Display instrument V-belt monitoring
– If a lamp lights steadily a monitored measur-
ing variable (e.g. coolant temperature, lubri- Possible displays:
A warning device for tearing of the V-belt
cating oil pressure) has left the permissible z Colour scale must be provided by the customer/device
value range. – Display of operating state by coloured areas: manufacturer.
– green = normal operating state
z Flashing z In the event of V-belt tear the pressure pin (1) of
– red = critical operatng state
– Serious error in the system. the electrical switch is actuated by the tensioning
Take suitable action. roller and an acoustic signal or light signal is ini-
z Measured value scale tiated.
– Actual value can be read off directly. The z Stop the engine immediately to avoid overheat-
nominal value should be taken from the ing.
Technical Data (58).
© 2008 23
Operation Operation monitoring
3 Instruments and symbols
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
24 © 2008
Stop procedure Operation

Shutting off
3
Avoid switching off from full load (coking/
blockage of the remaining lubricating oil in A
the turbocharger bearing housing). The lu-
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap-
B
proximately one minute after relieving the
load.
The control unit remains active for about
another 40 seconds to save the system C
data (lag) and then switches off automati-
cally.
Electrical shutdown (optional) Shutting off

z Run engine up to idling speed. z Run engine up to idling speed.
z Move the key to position 0. z Move the key to position 0.
Control lamps A+B+C go out. Control lamps A+B+C go out.
A = charge pilot light z In case of electrical shutdown or power failure
B = lube oil pressure pilot light the shutoff lever (2) is switched off by the lifting
C = pilot light for pre-heating system magnet up to engine standstill. The charging
0 = gear position: switch off engine control lamp and lubricating oil pressure control
lamp light up.
© 2008 25
Operating media Lubricating oil
4 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
Recommended quality class
DEUTZ Others
the definition of the lube oil change intervals are not
the lubricating oil to be used. The specific engine
essentially dependent on the lube oil quality (such as DQC II - 05 ACEA E3-96; E4-07; E5-02; E7-04
performances which have increased constantly over
the incorporation of soot and other contaminations), API CH-4/CG-4; CI-4,CI-4, CJ-4;
the last few years lead to an increased thermal load
the lube oil change interval when using synthetic DHD-1
on the lubricating oil. The lubricating oil is also more
lube oils may not be increased in relation to the spec- DQC III - 05 Please contact your DEUTZ partner
exposed to contamination due to reduced oil com-
ifications of the lube oil change intervals. or see www.deutz.com
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in DQC IV - 05 \SERVICE \Operating Media and
and recommendations described in this operating DEUTZ engines if they meet the requirements of this Diagnosis\Deutz Quality Class\DQC
manual in order not to shorten the life of the engine. operating manual. Release List
Lubricating oils always consist of a base oil and an Quality
additive package. The most important tasks of a lu- DEUTZ lubricating oils DQC II-05
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according TLS - 15W40 D
tion, neutralisation of acids from combustion to their efficiency and quality class (DQC: DEUTZ Container Order number:
products, prevention of coke and soot deposits on Quality Class). It basically applies that: with increas-
ing quality class (DQC I, II, III, IV) the lubricating oils 5 litre container 0101 6331
the engine parts) are assumed by the additives. The
properties of the base oil are also decisive for the are more efficient and higher quality. The appended 20 litre container 0101 6332
quality of the product, e.g. with regard to thermal quality class designation (- 02 / - 05) indicates in 209 litre barrel 0101 6333
load capacity. which year the classification was made.
In principle, all engine oils of the same specification Lubricating oils according to other comparable spec- DEUTZ lubricating oils DQC III-05
can be mixed. However, mixing of engine oils should ifications can be used as long as they meet DEUTZ TLX - 10W40 FE
be avoided because the worst properties of the mix- requirements. In regions in which none of these
qualities are available, please contact your responsi- Container Order number:
ture are always dominant.
ble DEUTZ partner. 5 litre container 0101 6335
The lubricating oil quality has a considerable influ-
ence on the life, performance and thus also on the or see www.deutz.com 20 litre container 0101 6336
costs-effectiveness of the engine. It basically applies \SERVICE \Operating Media and Diagnosis\Deutz 209 litre barrel 0101 6337
that: The better the lubricating oil quality, the better Quality Class\DQC Release List
these properties. The following lubricating oils are recommended for
The lubricating oil viscosity describes the flow be- the engines in this operating manual:
haviour of the lubricating oil depending on the tem-
perature. 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 tem-
26 © 2008
Lubricating oil Operating media

DEUTZ lubricating oils DQC IV-05 synthetic
Viscosity
The ambient temperature at the installation site or in
°C 4
Container Order number:
the application area of the engine is decisive for 45
20 litre container 0101 7849 choosing the right viscosity class. Too high a viscos-
209 litre barrel 0101 7850 ity can lead to starting difficulties, too low a viscosity 40
can endanger the lubrication effect and cause a high
Lubricating oil change intervals lubricating oil consumption. At ambient temperatures 35
z The intervals depend on: below -40 °C, the lubricating oil must be pre-heated
(e.g. by storing the vehicle or the machine in a hall). 30
– lubricating oil quality
– sulphur content in the fuel The viscosity is classified according to SAE. Multi- 25
– type of application of engine purpose lubricating oils should be used basically.
z The lubricating oil change interval must be Single-purpose lubricating oils can also be used in 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
enclosed, heated spaces at temperatures >5 ° C.
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
halved if at least one of the following conditions
applies: Depending on the ambient temperature we recom-
15
– Constant ambient temperature below -10 °C mend the following common viscosity classes: 10
(14 °F) or lube oil temperature below 60 °C
(84 °F). The prescribed lubricating oil quality must 5
– Sulphur content in the diesel fuel of 0.5-1 %. be observed when selecting the viscosity
In case of fuels containing more than 1% sul- class! 0
phur, contact your corresponding DEUTZ
partner. -5
– operation with bio-diesel fuel -10
z If the lubricating oil change intervals are not
reached within a year, the oil should be changed -15
at least once a year.
-20
-25
-30
-35
-40
© 2008 27
Operating media Fuel
4 Permissible fuels
The following fuel specifications / standards are ap-
els specified in the laws. These correspond to the
diesel fuels in accordance with EN 590 and
ASTM D 975 described in the operation manual. No
proved:
emission values are guaranteed with the other fuels
z Diesel fuels described in this operation manual.
– EN 590 The respective fuels prescribed by law must be used
– ASTM D 975 1-D to comply with the national emission regulations
– ASTM D 975 2-D (e.g. sulphur content).
– BS 2869 A1
– BS 2869 A2
– NATO F-54
– NATO F-75
– JIS K2204 Grade 1
– JIS K2204 Grade 2
z Light heating oils
– DIN 51603
– ASTM D 396 Grade No. 1
– ASTM D 396 Grade No. 2
– BS 286 Class D
z Jet fuels
– NATO F34
– NATO F35
– NATO F44
– NATO F63
z Biodiesel fuel
– EN 14214
Use commercially available fuels with a sulphur con-
tent below 0.5 %. The lubricating oil change intervals
must be halved at a higher sulphur content.
If other fuels are used which do not meet the require-
ments of the operating manual, the warranty will be
voided.
The certification measurements for compliance with
the legal emission values are made with the test fu-
28 © 2008
Fuel Operating media

Winter operation with diesel fuel
4
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 oper-
ating 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 rel-
evant percentages are given in the adjacent dia-
gram.
z Special diesel fuels can be used for arctic cli-
mates to -44 °C. I Summer-grade diesel fuel
II Winter-grade diesel fuel
If it is necessary to use Summer diesel fuel below
0 °C, up to 30 % petroleum can be added according A Outdoor temperature
to the diagram opposite. B Percentage of paraffin to be added
Usually a sufficient cold resistance can be achieved
by adding a flow improver. Ask your DEUTZ partner.
© 2008 29
Maintenance Maintenance schedule
5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
Standard maintenance schedule

D/TCD 914
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E30 Maintenance Qualified personnel D 1000 1) / TCD 500 1)
E40 Extended maintenance I 1000
E50 Extended maintenance II Authorised specialists 1.500
1) The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (27).
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to EPA certification
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E60 Intermediate overhaul Authorised specialists 3.000
30 © 2008
Maintenance schedule Maintenance

Maintenance measures
5
Stage Activity Measure Page
E10 The measures are listed in chapter 3. 19
E20 Check Lubricating oil level (if necessary top up) 33
Lubricating oil bath air filter 40
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 39
V-belts (retension or renew if necessary) 43
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 27/33
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 27
Check Battery and cable connectors 48
Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
E40 Check Cold starting device 18
V-belts (retension or renew if necessary) 43
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Settings Valve clearance 46
Replace Sub-stream lubricating oil filter 35
Fuel filter cartridge 37
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 37
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 39
E50 Check Switching valve of exhaust return 16
Injection valve
E60 Replace Injection valve
© 2008 31
Maintenance Maintenance schedule
5 Stage Activity
Replace
Measure
Switching valve of exhaust return
Page
16
Clean Charge air cooler entry area (drain lube oil/condensate)
Turbocharger compressor outlet
Exhaust channels of exhaust return (cylinder head) 42
Every 2 Replace V-belts 43
years Cold starting device 18
Dry air filter 39
Maintenance work outside the DEUTZ maintenance and service schedules
*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.
Maintenance profile
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
32 © 2008
Lubricating oil system Servicing and maintenance works

Regulations for working on the lubricating oil
system OIL ?
z The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec- 6
essary.
Do not work when the engine is running!
Smoking and naked lights prohibited! Changing the lubricating oil
Be careful of hot lubricating oil. Danger of
scalding!
OIL z Warm up the engine (lubricating oil temperature
> 80 °C).
+80°C
+176°F z Ensure that the engine or vehicle is in a level po-
Pay attention to utmost cleanliness when sition.
working on the lubricating oil system. Clean z Switch off the engine.
the area around the components con- z Place a collecting receptacle underneath the
cerned carefully. Blow damp parts dry with
compressed air.
Observe the safety regulations and nation-
! lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
al specifications for handling lube oils. z Fit a new sealing ring to the lube oil drain screw,
Dispose of leaking lubricating oil and filter insert and tighten. (tightening torque 100 Nm).
elements properly. Do not allow used oil to Checking the lubricating oil level z Pour in lube oil.
seep away into the ground. – Quality/viscosity data (26).
Perform a trial run after all work. Pay atten- Low lubricating oil level and overfilling lead – Filling volume (58).
tion to tightness and lubricating oil pressure to engine damage. z Check lubricating oil level, if necessary top up.
and then check the engine oil level. The lubricating oil level may only be
In case of fuels containing more than 1% checked with the engine in a horizontal po-
sulphur, contact your corresponding sition and switched off.
DEUTZ partner. 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.
Be careful of hot lubricating 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.
© 2008 33
Servicing and maintenance works Lubricating oil system
Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is
filled. There is a danger of dirt contamina- touching and tighten with a torque of:
tion! 15-17 Nm
z Remove clamps when twist protection mounted z Fasten clamps of the twist protection (optional).
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
with a lint-free, clean cloth.
34 © 2008
Lubricating oil system Servicing and maintenance works
4 5 6
z Mount cover.
z Insert screws with new sealing rings. 6
z Check for leaks after starting the engine.
3 2 1
Sub-stream lubricating oil filter
Change filter cartridge
1 Lubricating oil drain plug

2 Sealing ring
3 Screw
4 Cover
5 Filter cartridge
6 Gasket
z Place a collecting receptacle underneath the
lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
z Loosen screw.
z Remove cover.
z Unscrew soiled filter cartridge.
z Clean components.
z Insert new filter cartridge.
z Mount gasket (new gasket if necessary).
© 2008 35
Servicing and maintenance works Fuel system
6 Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
Engine must be switched off! work.
Smoking and naked lights prohibited! Areas of the engine compartment from
No injection/high pressure pipes may be which dirt could be loosened must be cov-
disconnected while the engine is running. ered with a fresh, clean foil.
Caution when handling hot fuel! Work on the fuel system may only be car-
Pay attention to utmost cleanliness when ried out in an absolutely clean environment.
refuelling and working on the fuel system. Air contamination such as dirt, dust, mois-
Clean the respective affected parts careful- ture etc. must be avoided.
ly. Blow damp areas dry with compressed
air.
Observe the safety regulations and nation-
al specifications for handling fuels.
Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep away
into the ground.
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
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Make a visual inspection for leaks/damage
in the system.
36 © 2008
Fuel system Servicing and maintenance works

6
Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter Clean/change/vent the fuel pre-filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is Keep naked flames away when working on
filled. There is a danger of dirt contamina- touching and tighten with a torque of: the fuel system! Do not smoke!
tion! 10-12 Nm
z Remove clamps when twist protection mounted z Fasten clamps of the twist protection (optional). z Shut off the fuel supply to the engine (with high-
(optional). z Vent the fuel system. level tank).
z Loosen and unscrew filter cartridge with tool (or- z Remove the filter hood (2) and pull out the filter
der number: 170050). element (3).
z Catch any escaping fuel. z Maintain the filter element (3) according to the in-
z Clean the sealing surface of the filter support terval in the maintenance schedule
with a lint-free, clean cloth. z Catch any escaping fuel.
z Collect the sealing ring (1) and clean it, renew if
damaged.
z Clean filter housing (4) with fuel.
z Screw on filter housing (4) with filter cover (2)
and filter element (3).
z Open the fuel supply to the engine.
z Vent the fuel system.
© 2008 37
Servicing and maintenance works Engine cleaning
6 Cleaning work Cleaning with cold cleaner

z Spray the engine with cold cleaner and leave it
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
Only carry out cleaning work on the engine z Clean the engine with a steam jet (maximum
when it is not running! spray pressure 60 bar, maximum steam temper-
Remove the engine cover and cooling air ature 90 °C, distance at least 1m).
cover if available and remount after clean- z Warm up the engine so that the water residues
ing. evaporate.
z Always clean the cooler and cooling fins from the
General exhaust air side to the fresh air side.
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 leaks
z Lubricating oil leakage
z Fuel leaks
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.
38 © 2008
Aspiration system Servicing and maintenance works

Regulations for working on the intake system
1 5 2
6
Do not work when the engine is running!
Pay attention to utmost cleanliness when 1

working on the intake system, close intake
openings if necessary.
Dispose of old filter elements properly.
Renewing the safety cartridge of the dry air filter 4 3
Never clean the safety cartridge (4).
z Renew safety cartridge (4) according to the inter- Maintaining the dry air filter Clean the dust discharge valve of the dry air filter
val in the maintenance schedule z Empty the dust discharge valve (1) by pressing
z To do this: Do not clean the filter element (3) with pet-
together the discharge slit.
– Unscrew hexagon nut (5), pull out safety car- rol or hot liquids!
Renew damaged filter elements. z Remove any caked dust by pressing together the
tridge (4). upper section of the valve.
– Insert new safety cartridge, screw on hexag- z Maintain the filter element (3) according to the in- z Clean the discharge slit.
onal nut. terval in the maintenance schedule
z Insert filter element (3), mount hood (2) and fix z Lift up the clamping yoke (1).
with 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.
© 2008 39
Servicing and maintenance works Aspiration system
Maintenance indicators for dry air filter Emptying the cyclone precleaner Cleaning oil bath air filter
z The dry air filter is maintained according to a
Never fill the dust container (3) with lubri- Never clean the filter with petrol!
maintenance switch or maintenance indicator.
cating oil!
z Maintenance is necessary when:
– the yellow warning light of the maintenance
switch lights up when the engine is running. z Loosen wing nut (1) and lift off housing cover (2).
Dispose of the old lubricating oil in accord-
– the red field (1) of the maintenance indica- z Remove the dust container (3) from the base (4)
ance with the regulations. Select the en-
tor is fully visible. and empty it. Clean the container using a brush
gine lubricating oil according to the
and clean diesel fuel. Then dry.
z After carrying out maintenance work, reset the requirements before filling the filter.
signal by pressing the button on the mainte- z Place the dust container (3) on the base (4) and
nance indicator. The maintenance indicator is tighten the housing cover (2) with wing nut (1). z Shut down engine and wait about 10 minutes un-
now ready for operation again. 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 Collect draining lubricating oil
z Dispose of in an environmentally correct man-
ner.
z Clean lubricating oil pan (3), filter cartridge (4)
and filter housing (1) with a brush and clean die-
40 © 2008
Aspiration system Servicing and maintenance works

sel fuel.
z Visually inspect the rubber gaskets (5), (6) and 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).
© 2008 41
Servicing and maintenance works External exhaust return
Clean cylinder head exhaust apertures
Carry out the work only when cold. Danger

of burning!
z Remove air guide hood.

z Disassemble exhaust return system.
z Clean exhaust gas apertures on each cylinder
using a wire brush (order number: 8167)
(60).
z Suck off residue.
z Assemble exhaust gas return system.
z Tighten screws.
z Install air guide hood.
42 © 2008
Belt drives Servicing and maintenance works

6
Checking the belt drive Checking the belt tension Change the belt
z Lower indicator arm (1) into the measuring de- Fan
Only carry out work on the belt drive with
vice. z Press clamping roller (1) in with conventional tool
the engine at a standstill!
Always change both belts in sets in case of z Place guide (3) between two belt pulleys on the to change.
wear on the double belts or damage to one V-belt (2). The stop have to be at the side. z Remove belt and fit new one.
V-belt. z Press the button (4) at right angles to the V-belt z Checking the belt tension (43).
After repair work: Check that all guards (2) evenly until you hear or feel the spring snap
have been replaced and that all tools have in.
been removed from the engine. z Lift the measuring device carefully without alter-
ing the position of the indicator arm (1).
z Check the whole belt drive visually for damage. z Read the measured value at the point of inter-
z Renew damaged parts. section (arrow), scale (5) and indicator arm (1).
z Remount protective devices if necessary. z If necessary, re-tension belt and measure again.
z Pay attention to correct fit of new belts, check the
tension after running for 15 minutes. Tools
Belt tension measuring device (order number:
8115) can be obtained from your DEUTZ partner.
© 2008 43
Servicing and maintenance works Belt drives
6 z Installing fan V-belt (58).

z Checking the belt tension (43).
5
Tighten belt Function test pressure pin
Generator
A warning device for tearing of the V-belt
z Loosen screws (1), (2) and (3) slightly. must be provided by the customer/device
z Push the generator (4) outwards in the direction manufacturer.
of the arrow until you get the correct V-belt ten-
sion. z In the event of V-belt tear the pressure pin (1) of
z Retighten the screw (1), (2) and (3). the electrical switch is actuated by the tensioning
roller and an acoustic signal or light signal is ini-
Change the belt tiated.
z Check the function by pushing the pin (1) in.
Generator
z Removing fan V-belt (43)
z Loosen screws (1), (2) and (3) slightly.
z Swing the generator (4) in in the opposite direc-
tion to the arrow.
z Remove the V-belt (5) and fit a new V-belt.
z Push the generator (4) outwards in the direction
of the arrow until you get the correct V-belt ten-
sion.
z Retighten the screw (1), (2) and (3).
44 © 2008
Belt drives Servicing and maintenance works

6
Tighten belt Tighten belt Air compressor with double V-belt

z Loosen screw (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 Remove belt and fit new one. moved discs on the removed belt pulley half (2) z Remove intermediate disc (4), rear V-belt (3), in-
z Checking the belt tension (43). 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.
© 2008 45
Servicing and maintenance works Setting work
6 Valve clearance setting schematic

Valve overlap: Exhaust valve is not yet closed, inlet
valve begins to open.
D 914 L03
Valve overlap Turn crankshaft Settings

360°
1 One turn 1
2 One turn 2
3 One turn 3
D 914 L04
Valve overlap Settings

Check valve clearance, adjust if necessary 1 4
z Engage hexagon socket head wrench (7) and in- 2 3
z Let the engine cool down for at least 30 minutes
before setting the valve clearance: Lubricating oil sert and loosen the lock nut (4). 3 2
temperature below 80 °C. z Adjust the valve clearance setting screw (5) with 4 1
z Remove the cylinder head hood. the hexagon socket head wrench (7) so that the
z Place turning gear over fastening screws of the correct valve clerarance (1) is reached after D 914 L05
belt pulleys. tightening the lock nut (4).
z Perform the setting procedure on every cylinder. Valve overlap Turn crankshaft Settings
z Turn the crankcase until reaching valve overlap. 360°
Outlet valve is not yet closed, inlet valve be- z Reinstall cylinder head cover, with new gasket.
gins to open. 1 One turn 1
The cylinders to be set can be seen in the 2 One turn 2
setting schematic. 3 One turn 3
z Check the valve clearance (1) between the rock- 4 One turn 4
er arm lugs (2) and the valve (3) with a feeler 5 One turn 5
gauge (6).
z The feeler gauge (6) must slide in with little re-
sistance.
z For permissible valve clearance, see (58)
z Adjust valve clearance if necessary:
46 © 2008
Setting work Servicing and maintenance works

D 914 L06
6
Valve overlap Settings
1 6
5 2
3 4
6 1
2 5
4 3
TCD 914 L06
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
6 One turn 6
© 2008 47
Servicing and maintenance works Electrical system
6 Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. z Check the battery voltage with a conventional
Allow engine to warm up. voltmeter. The voltage indicates the charging
Touching a lead against the frame to check state. It should be between 12 and 14.4 Volt de-
whether it is live must not, under any cir- pending per battery.
cumstances, be carried out.
For electrical welding work, the ground ter- Check acid level Check acid density
minal of the welding gear must be clamped z Unscrew caps.
z Unscrew caps.
directly to the part being welded. z Measure the electrolyte density of individual cells
z Note the manufacturer’s specifications concern-
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
ing the liquid level.
connect the cables between battery, gener- reading indicates battery’s state of charge. The
ator and regulator while the engine is The liquid should normally be 10-15 mm above
the top edge of the plate or reach up to any avail- acid temperature when measuring should be 20
running. °C if possible.
able control device.
Battery z Only use distilled water to top up the battery. z Check the acid level before recharging.
z Screw in caps. z Screw in caps.
Electronically stored data could be lost if Acid density [kg/ l] Charge Measure
the battery is disconnected. status
Keep battery clean and dry. Normal Tropical
Make sure the battery is fitted correctly and 1,28 1,23 good none
securely. 1,20 1,12 half charge
Dispose of old batteries in an environmen-
tally friendly way. 1,12 1,08 empty charge
48 © 2008
Electrical system Servicing and maintenance works

Removing the battery
z Always disconnect the minus pole first when re-
6
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 conventional battery
charger. Observe the manufacturer specifica-
tions!
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-
free, acid-resistant grease.
© 2008 49
Faults Fault table
7 Faults and remedies
Faults Causes Measures

Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Engine stop lever still in stop position Check/replace
Below starting limit temperature Check
Fuel tank empty Vent fuel system
Fuel suction pipe blocked Check
Fuel quality does not comply with operating manual Change the fuel
Fuel filter contaminated Check/replace
Air in fuel system Vent fuel system
Cold starting device Check/replace
Injection line leaks Check injection line
Injection valve defective Check fuel injector / change if necessary
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Incorrect valve clearance Check valve clearance and set if necessary
Air filter clogged / turbocharger defective Check/replace
Compression pressure too low Check compression pressure
50 © 2008
Fault table Faults

Faults
Engine starts, but runs irregularly or
Causes
Incorrect valve clearance
Measures
Check valve clearance and set if necessary
7
fails Cold starting device Check/replace
Lube oil level too high Check lube oil level, if necessary drain off.
Compression pressure too low Check compression pressure
Air in fuel system Vent
Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Empty/clean/change
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
Charge air cooler soiled Check/clean
Engine becomes excessively hot. Injection valve defective Check/replace
Temperature warning system acti- Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
vates
Lubricating oil cooler fins soiled Clean
Lube oil cooler defective Check/replace
Lube oil filter contaminated on the air or lube oil side Change
Lubricating oil level too low Fill up lube oil
Lube oil filter contaminated on the air or lube oil side Check
Cooling fan or exhaust thermostat defective, V-belt torn or loose Check/replace/tension
Cooling air guide plates loose, cracked or missing Check
Resistance in cooling system is too high / flow volume too low Check the cooling system
Heat short-circuit in the cooling air guidance Check the cooling system
© 2008 51
Faults Fault table
7 Faults
Engine output is deficient
Causes
Lube oil level too high
Measures
Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Lubricating oil cooler fins soiled Clean
Engine stop lever still in stop position Stop magnet defective (release circuit)
Fuel suction temperature too high Check the system
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Charge air cooler soiled Clean
Heat short-circuit in the cooling air guidance Check the cooling system
Resistance in cooling system is too high / flow volume too low Check the cooling system
Injection valve defective Check fuel injector
Engine stop lever still in stop position Check/replace
Engine does not run on all cylinders Injection line leaks Check injection line
Incorrect valve clearance Settings
Compression pressure too low Check the system
Fuel filter/fuel pre-cleaner contaminated (lamp/siren faulty) Empty/clean/change
52 © 2008
Fault table Faults

Faults Causes
Engine lubricating oil pressure is non- Lubricating oil level too low
Measures
Fill up lube oil
7
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Lube oil cooler defective Check/replace
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
Engine producing white smoke Below starting limit temperature Check
Cold starting device Check/replace
© 2008 53
Faults Fault table
7 Faults
Engine producing black smoke
Causes
Air filter clogged / turbocharger defective
Measures
Check/replace
54 © 2008
Transport Transport and storage

8
1
Suspension equipment
Danger to life!
The engine may tip over or fall down if sus-
The transport devices mounted on this en-
pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com- z The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. z The fastening attachment can slip, the engine
z Always use proper suspension equipment when swings backwards and forwards (1).
transporting the engine. z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
z The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
z After transportation and before commissioning of
engine: remove attachment eyes (2).
© 2008 55
Transport and storage Engine corrosion protection
8 General
Engines contain the following types of corrosion pro-
by wetting of the walls with the implemented cor-
rosion protection agent in a corrosion protection
until it emerges visibly from the pressure nozzle.
Cooling system
run of the engine.
tection:
z The corrosion protection run can be performed z Depending on the series the engines are
z Interior corrosion protection once to protect the different systems: equipped with cooling air, cooling oil or cooling
z Exterior corrosion protection fluid system (cooling water with cooling system
Fuel system protection agent).
Your DEUTZ partner has the right corro-
sion protection agent for your needs. z Cooling air system, see the Exterior corrosion
Close the fuel/tank/supply line to the en-
protection section.
gine so that the system is protected against
dirt and dust. Protect the electronics z In engines of the oil-cooled series the circulating
The following measures for corrosion protection af- lubricating oil serves simultaneously for cooling.
ter taking the engine out of operation meet the re- against moisture and corrosion.
The cooling chambers are protected automati-
quirements for 12 months corrosion protection. cally against corrosion with the lube oil system.
z Fill the fuel tank with a mixture of:
The following corrosion protection work may only be – 90 % distilled fuel
carried out by persons familiar with it and instructed Air intake pipes
– 10 % corrosion protection oil.
in the potential dangers. z After the corrosion protection run, remove the
z Perform a corrosion protection run with no load
If these measures are deviated from by exposing the for at least 5 minutes. cylinder head cover and deinstall injectors. The
corrosion-protected engines or parts to unfavourable respective piston must be set to LT.
conditions (installation outdoors or storage in damp, Lubricating oil system z The accessible part of the cylinder liner should
badly aired places) or damage to the corrosion pro- z Drain lubricating oil from warm engine. be coated with corrosion protection oil with a
tection layer, a shorter corrosion protection duration spray lance through the opening.
z Thoroughly clean lube oil tray, cylinder head with
is to be expected. z Spray corrosion protection lubricating oil into the
rocker arms, valves, valve springs with diesel
The engine corrosion protection should be checked fuel or cleaning agent. suction intake pipe.
about every 3 months by opening the covers. If cor- z Fill the engine with corrosion protection oil up to Exterior corrosion protection
rosion is detected, the corrosion protection should the MAX mark and perform a corrosion protec-
be renewed. tion run for at least 5 minutes so that all the com- z The engine must be cleaned thoroughly with a
At the end of the corrosion protection work the crank ponents of the lubricating oil system are wetted cleaning agent before exterior corrosion protec-
drive may no longer be turned so that the corrosion or wet all accessible parts with corrosion protection. Any signs of corrosion and damage to the
protection agent in the bearings, bearing liners and tion oil and pump corrosion protection oil through paintwork must be removed.
cylinder liners is not scraped off. the engine with a separate pump until all bear-
Cooling air system in air-cooled engines
Before operating a corrosion protected engine, the ings and bearing liners are wetted.
corrosion protection must be removed. z The air guidance compartment of the engines is
Air compressor unpainted and must be sprayed with a corrosion
Interior corrosion protection z If a compressor is installed, a corrosion protec- protection agent.
z Interior corrosion protection is always provided tion agent must be sprayed into the compressor
suction system after shutting down the engine
56 © 2008
Engine corrosion protection Transport and storage

Bare exterior surfaces and parts
z Coat or spray all bare exterior parts and surfaces
Removal of corrosion protection
z The corrosion protection must be removed from
\SERVICE \Operating Media and Diagnosis
8
(e.g. flywheel, flange faces) with corrosion pro- the corrosion protected engine before starting.
tection agent. z The packaging and all covers over the closed
openings must be removed.
Rubber parts
z Any corrosion deposits and paint damage should
z Rubber parts (e.g. muffs) which are not painted be remedied.
over must be rubbed down with talcum powder.
Fuel system
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 Connect fuel/tank/supply line to the engine. Pay
z Spray V-belt pulleys and tension rollers with cor- attention to cleanliness.
rosion protection agent. z Fill the fuel tank and fuel system with the proper
fuel.
Engine openings
Lubricating oil system
z All engine openings must be fitted with air-tight,
water-tight covers to delay the vapourisation z Unscrew the lube oil drain screw, drain oil.
process of the corrosion protection agents. z Fill the engine with lubricating oil via the lubricat-
z With installed air compressor, the suction and ing oil filler neck.
pressure connection must be sealed by a cap.
z Air should be excluded to avoid ventilation of the Removal of exterior corrosion protection
engine (chimney effect) for the suction from an z All areas and components coated with corrosion
air supply pipe. protection agent must be washed off with dis-
Storage and packaging tilled fuel or a suitable cleaning agent.
z Wash out grooves of V-belt pulleys if necessary.
z After being protected against corrosion, the en- z Mount V-belts or V-rib belts as specified.
gine must be stored in a dry, ventilated hall and z Fill with coolant.
suitably covered.
z The cover must be placed loosely over the en- Corrosion protection agent / cleaning agent
gine so that the air can circulate around it to pre-
Please ask your DEUTZ partner for reference prod-
vent condensation from forming. Use a desiccant
ucts for the corrosion protection agents/cleaning
if necessary. agents to be used which meet DEUTZ requirements.
or see www.deutz.com
© 2008 57
Technical data Engine and setting data
9 General technical data
Engine type Dimension D 914 L03 D 914 L04 D 914 L05 D 914 L06 TCD 914 L06
Working principle Four-stroke diesel engine
Charging Suction motor Four-stroke turbocharged
diesel engine
Type of cooling air-cooled
Cylinder arrangement in series
No. of cylinders 3 4 5 6 6
Bore/stroke [mm] 102/132
Total displacement [cm3] 3236 4314 5393 6472 6472
Combustion process Direct injection
Injection system Row injection pump
Exhaust gas recirculation < 37 kW > 37 kW
internal external external external external internal external
Valves per cylinder 2
Valve clearance: Inlet/outlet [mm] 0,15+0,15 / 0,15+0,15
Firing order of the engine 1-2-3 1-3-4-2 1-2-4-5-3 1-5-3-6-2-4 1-5-3-6-2-4
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Lubricating oil change volume (with filter) ≈ [l] 11 * 14 * 15,5 * 18 * 19,5 *
Lube oil temperature in the lube oil tray, maximum [°C] 135
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 50/0,5
V-belt tension Pre-tensioning/Re-tensioning
V-belt AVX 10 [N] 450±50/300±50
Weight without cooling system according to DIN 70020-A ≈ [kg] 277 307 380 430 510
58 © 2008
Engine and setting data Technical data

Engine type Dimension D 914 L03 D 914 L04 D 914 L05 D 914 L06 TCD 914 L06
*specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants
9
and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
© 2008 59
OBJ_DOKU-16314-001.fm Seite 60 Freitag, 25. November 2011 10:17 10
Technical data Tools
9 Tool ordering
The special tools described in this chapter can be or-
dered from:
Please contact your DEUTZ partner
V-belt tension measuring instrument Special wrench for loosening exchangeable filters
Order number: Order number:
8115 170050
Measuring instrument for checking the specified V- For loosening changeable filters.
belt tensions.
60 © 2011
DEUTZ Oil
DEUTZ Oil DQC II-05 DEUTZ Oil DQC III-05 DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E5-02 / E3-96 / B3-04 ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 ACEA E7-04 / E5-02 / E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1
TLS-15W40D TLX-10W40FE DEUTZ Oel DQC IV-5W30

(DQC II-05) (DQC III-05) (DQC IV-05)
5L 0101 6331 5L 0101 6335 5L -
20 L 0101 6332 20 L 0101 6336 20 L 0101 7849
209 L 0101 6333 209 L 0101 6337 209 L 0101 7850
! WARNING: Breathing diesel engine exhaust exposes

you to chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated area

- If in an enclosed area, vent the exhaust to the outside
- Do not modify or tamper with the exhaust system
- Do not idle the engine except as necessary
DEUTZ AG
For more information go to www.P65warnings.ca.gov/diesel
Supporthouse Information Systems
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
E-Mail: info@deutz.com
www.deutz.com
Printed in Germany
© 05/2018
All rights reserved
Order number:
The engine company. 0312 4926 en

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OBJ_DOKU-16314-001.fm Seite 1 Donnerstag, 24. Juli 2008 11:18 11

This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

Model Engine description

914 Rating plate Location of the rating plate

Engine description Model

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

2 TCD 914 L06

Schematic for lubricating oil Engine description

Engine description Schematic for lubricating oil

2 TCD 914 L06

Schematic for fuel Engine description

Engine description Exhaust return

TCD 914 L06 Optional

Exhaust return Engine description

TCD 914 L06 Optional

1 Additional cams for exhaust gas recirculation

Operation Ambient conditions

3 Cold start aid

0 °C This engine can be equipped optionally

Initial start-up Operation

Operation Initial start-up

Additional venting of the fuel system by a 5

Start procedure Operation

Operation Start procedure

3 After starting, any exhaust gas turbidity in

with cold starting device

Operation monitoring Operation

Operation Operation monitoring

3 Instruments and symbols

Instruments/symbols Designation Possible display: Measure

Horn With acoustic signal See Fault Table

Stop procedure Operation

Electrical shutdown (optional) Shutting off

Operating media Lubricating oil

Lubricating oil Operating media

Operating media Fuel

Fuel Operating media

Maintenance Maintenance schedule

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

Standard maintenance schedule

Maintenance schedule Maintenance

Maintenance Maintenance schedule

Order number: 0312 3144

Lubricating oil system Servicing and maintenance works

Be careful of hot lubricating oil. Danger of

z Pull out the lubricating oil dipstick and wipe off

Servicing and maintenance works Lubricating oil system

Lubricating oil system Servicing and maintenance works

1 Lubricating oil drain plug

Servicing and maintenance works Fuel system

Additional venting of the fuel system by a 5

Fuel system Servicing and maintenance works

Servicing and maintenance works Engine cleaning

6 Cleaning work Cleaning with cold cleaner

Aspiration system Servicing and maintenance works

Pay attention to utmost cleanliness when 1

Servicing and maintenance works Aspiration system

6 z Installing fan V-belt (58).