© Please read and observe the information given in this Operation Manuel. This will enable you to avoid ‘accidents, preserve the manufacturer's Warranty and maintain the engine in peak ‘operating condition © This engine has been built ‘exclusively for the application specified in the scope of supply, as described by the equipment manufacturer and is to be used only for the intended purpose. Any se exceeding that scope is considered to be contrary to the intended purpose. Not assume responsibility {or any damage resuting there from, The risks involved are to be borne solely by the user. @ Use in accordance with the intended purpose also implies compliance with the conditions laid ‘down by the manufacturer for operation, ‘maintenance and servicing. The only be operated by personn ‘and the hazards involved. @ The relevant accident prevention guidelines ‘and other generally accepted safety and industrial hygiene regulations must be observed. © When the engine is running, there is a risk of through: inglhot components ~ engines with positive ignition ignition systems (high You must avoid contact a sultant damage Manipulations of the injection and regulating system may also influence the performance of the engine, and its emissions, Adherence to legislation on poluton cannot be guaranteed under such conditions, © Donot change, convert or adjust the cool ait intake area tothe blower. The manufacturer Shall not be held responsible for any damage which results from such work JA1000-52D-4E © ‘When canying out mainienancelrepair ‘operations on the engine, the use of FAW Original pats is prescribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results inthe expiry ofthe warranty! © Maintenance and cleaning of the engine should only be carried out when the engine is Switched off and has cooled down, You must ensure that the electrical systems have been switched off and the ignition key has been removed. ‘Accident prevention guidelines conceming electrical systems (eg, VI -0104/-0105 Erectrical protective mea ch ‘Components are to be covered impermeably. twerr [enue] UoRHesadG enoidde uayUM sno NOW sua Aue Aq 40 wo Aue u! peonpoides oq ew jenuey sit) Jo syed on ‘jenuew uoqesedo sity Lu paure}uoo uoneuuoyur jeo1UYyDe} ZeyjO pue eVeP no @noudww! 0} pasinbes suoneoy|pow jeo1uyoe | (-Z uonoes 998) syed aueds 10 sireday ‘eojnsas sewio}sno ynoge Buyinbue ueym pejonb eq pinoys sequinu SIU “@Jy Jequunu jeues euIGue ey) JeqUe esealg uequinu jeues eujbuR ‘ae-d7s-0001 VEAS Dear Customer, Liquid-cooled Deutz engines are designed for a large number of applications. Consequently, a wide range of variants are offered to meet the requirements of specific, cases. Your engine is appropriately equipped for the installation concerned, which means that not all of the components described in this Operation Manual are necessarily mounted on your engine. We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions relevant to your engine quickly and easily. Please read this Manual before starting your engine, and always observe the operating and maintenance instructions. We are available to help with any additional enquiries Sincerely, FAW DDEW JA1000-52D-4E Foreworde01sag ‘OL S]0o) €°6 senbios Bulueyyb1, mesog z'g sBumeg Pue suoveoyoads oubug 16 Uoneoyroads jeojuyoe, -g Uonenieseig |g uonenisseig ou6ug “9 alge Lyne 1° Solpewiey pue sasneo ‘syneg -, Souosseooy 1:9 sjuswisnipy 9:9 senu eg $9 J9UEBI9 sy UONSNqUIOD $9 waIshg Buyoon eg weyshg jan z'9 we}skg Uoneougn] 19 SoUeUaIUIEW pue so1Alag “9 Plooey eoueuauEW Eg ueYD souRUa}UIEW z'¢ ainpeuog eoueuajurey 1-5 soueus}UEW eunnoY “¢ luej009 ¢'y fend zy 10 ©an7 Ly e1pew Buneedo y SuoNIpUco Buyesedg ge yo Bunnys pg Uoneiedg Buuojuoy e-e Gunes ze Buuorssiuu0y j-¢ uonesedg eubug “¢ SHeWAYOS WeIskg BulJooD gz ONEWAYOS Warskg jong Hz SHeWAYDS yNDUID 119 Bqny Ez Suonessny} eulbu3 z'2 lePOW LZ Uonduoseg aujBu3 *z Te10u99 +) sjuajuo5 ‘ar d7S-000IVE orots @& JA1000-52D-4E. 1 General DEUTZ Diesel Engines Care and Maintenance Service are the product of many years f research and Sound eareand mantenance practices wi sure a xclosad space or underground ‘Asbestes ex UTZ origial pats are asbestes-asenyuedo ot 0} paucege S19 ae uel LL sequiny yeu9s ouyuy 6°12 woyye907 ayeld Buney 2°12 ayeia Suey be? l9POW 1% uondiuoseg eulbug Zz ‘ar-dzs-0001VE ar ¥‘pus iy OU) 8 Gupequiny sepuyAg yt-z, ‘ar-dzS-0001VE49}009 j10 847 BL peoy spur Sh @o1A@p UMOP INYS PL adid eunssead yBIH EF sosseiduioo sty Z/ yousdig bb qunow eui6u3 Z dwnd jang 9 Jeduiep uonesqiA ¢ Aeiind wea ue} Buljoo9 & JoeWenY Z 49\N HO L E10} apis uonerado 127 suoyjeysnyy| eulbuy 77% ‘AP-AzS-“O00TVE @ ¥ev ELOL OPIS OHEIS ZZ ‘AP-zS-000TVEyp 96 LE Sb bh OL Eb Ze OL Es LE GL SL 12 Ze 0% oeurayos WNOUID 10.2407 £7 AP-A7S-000T VE oeron | oyewayos wayshs [end 9% ov ‘ay-azs-000rveonewayos wayskg Buyjood ¢°Z “AP-azS-O00IWE @& AgAS sas 20-46 3 Engine Operation 3.1 Commissioningio ourdug Guppy EE yong Guppy EVE raueayg ny Meg 10 Guys ZTE Ar OTS-O00TVE @ wrSao saction 6.3.6 (© Unit engine cwit section 63.8, radiator) 3.1.5 Other Preparations (© Check battery and cable connections, see 6.7.1 run io the angine has bean prepare for about 10 minutes without oad run AMter the engine has boon turned off Greek tea vel andtop un neeasary seo cea day. necking once a 8 as outined in section 8.1 JA1000-52D-4Est ym “WaqeD Jou seop aurbue aU m0 06 SwOH Old ~ Jo} RURIS eu alentoe Jou OG ue se U00s Se fe (ious yo uaqoeup aysoaio i) Luoqisoa Suyeredo o4 Z 18% UNODINYS GROW @ vonsoa peeds apps Jo uogoasip ui b s8Aa} jonu ‘fen bujedo OU 0 UORISOd wousdnbe vanuD & wd) fey yesuj@ — eupue ey ereedes pal) aDeDUESIO @ asuy20n 84m} ‘yo au z pue } SOL ‘bok DUNJBRAO = | UOHH Avajeq jaauuossig “pecoures seuroro6 poods woe eujbue eu) HES 1900N PIV wers-Plog wow Hanes ‘ar-dzs-0001VEAS Starting with Heater Plugs © insort key ~ Position 0 = no operating voltage (@ Turn kay clockwise. = Post (@ Push kay In and turn further clockwise against ‘ping pressure, = Position 2 = no function, = Position 3 start e key as soon as on (0 out. JA1000-52D-4Euum s ouue au aw yo o6 pinous 1110} euNSSe1d 0 BLL @ es) aunsseud cer Buqesedo augue eu J8R0 yo unsunw oq separ ALN Joued eu @ ses ves8 mu UA! HUN MO wl @ fceacal wr WoHd aRsseAd HO einssoig (0 on16ug 1°C°E uonjesedo BuvoyuOW ‘Br-azs-0001WE @ weAS 3.3.2 Coolant Temperatere 3.3.3 Coolant Level / Coolant Level Gauge ‘@ when the engines cold coolant love 1 should be above the KALT-COLD mark ‘he pointe ‘overheating. Turn it off cause from the Diagnosis C ereao op. wh coat up toe usparoége of Is not posse to cary aut a check at the ing, If required carry out 8 JA1000-52D-4E (© a level switch is fited, the engine fs shut jn automatically when the level fas below the MIN marking,6 yo Buynus +e ‘W-OtS-0001VE @' 7a @ JA1000-52D-4E 9.4.1. Engines with Mechanical 3.4.2 Engines with Electrical ‘Shatdown Shutdown‘Ar-0zS-0001WE iz ‘aneyd wien e Ul al0}s pue ‘veqeq au) @xowed ‘0S OP OL "9402+ INODE dn Alpes aut Buyeeu Ag 9.$-VAG pexoMo| fq ueo ainjeieduse) yu) uns @u1 ~ £9 08) Aenea Augyeoy @ seuinber Buprels bl00 Wer — ae © pre Sunsets fe Suyjnbes you Apewuou sesnyexedwe) ye Suryeys Jase sopitord ing “aamjexeduia, u HUES ayy Semo} Ayo. JOU SiMh 1 2'e #@s) Auessaont Smt 0)0 est wrod Burzeay ojed 20 seau Saunyesedua) WY ~ Spiy ves-D100 ‘afou uoruid eu wonouy esearb oy 20 pue sales al enous Os OP OL 114 wasog se yons aseei6 ‘qua eusy 0} el, Woy 1880 Bul Aq SANNYEACL ai Ae AL NS 1 (D8 saueats fe Wea 10 UN HL ‘ond usp al aouo Ue (eT aut Wo! og 82 be y2es (9,56 xe 5210 a4} UNS 0} 37 279 88S "9,0 "ORC uojerado 40} fen} 989 apesO-s81UMA asf) — ang yesaig. @ ¥°19 895 ‘0.01- Moje Out essco uaypt Aoupnbal} BOUELD 10 251 (ZL 720s) payers St auDue A veya eunjeszdlue) uoigule ay 0) Bums0.9e oped ays) AiSoDSM 0 PS ~ Ausoasi wonezedg 20m L°S"E suoypuos BuyesedQ $< evA: @& JA1000-52D-4E. 3.5.2 High Ambient Temperat High Altitude ibm 8 Nas Dean dara fe and exhaust gas quay (sole), Otherwise, cont ‘Sarvs representative. aelo ean7 Lb IPEW BuyesedQ ¥ ‘ar-dzs-0001VE @& weAS 41.1 Quality Grade Lube oils are di scorch dass. ated by Deutz "thee performance and qual ofoter camperelespectesbors ‘oan be used. “Approved oils acu 4-09) The ise assignment of the admissible Wegais pero Dats Fe ns jor ance mpm 41.2 Viscosity Goneraly, muli-grade ails shall be used. in dosed heated rooms at temperatures >5°C, ‘ako single grade ols can be used {As the viscosity of lube oi is dependent on temperature, the choice ‘of SAE grade shouldbe’ governed by the ambient temperature ‘provaling at the engine 9 ste Optimum operating behaviour wal be altained i you take the accompanying oil Yiscosty diagram as a guide. Temperature fall temporarily below te ims of he SAE pode seed Cold starting may be affected but the engne ‘wil not be damaged. In order to keep wear to a minimum, do not exceed application limits for” extended periods of time Sytc hbe i feature an_ improved tehporetur end ondaton tab JA1000-52D-4E‘Av-A7S-0001VE4.2.1 Quality Grade Use commercially available diesel fuel with less than 0.5% sulphur cont ‘content is higher than 0.5%, ol! change infervals should be reduced (see 6.1.1). ‘are approvi (refer to TR 0199-3002) 2869: At and AZ (with AZ take note ofthe sulfur content!) ASTM 0 975-86: 1-0 and 2D “NATO Code F-Shand F-75 's082i7 DMX ++ 1SO 8217 DMA @ Light he seria ASTM D 396; 1 and 2 BS 2869 Clase D @Jet fuel + F34/F35/F44 (kerosene) =F54 (equivalentto diesel fuel according to INEN's90) + YF 63 (equivalent to F34+F35 wih addi- tives) F @Blo diese! fuel + according to BIN 51606- FAME Guhauat emission values which may be : inthe cause of type approval tests ways refer to the reference fuel prescribod bby the authorities forthe type approval test 4.2.2 Winter-Grade Fuel Waxing may occur at low temperatures ag the uel system andreduany engine fiery. ithe ambient temperate i ess an 0% © At tomporatures below -20°C), kerosene should be added to the diesel fuel The relevant percentages are given in the dia 2 right (© Special diesel tuels can beusedforclimatic zones down to - 44°C. if summer-grade diesol fuel must be used at temperatures below 0°C, upto 60% kerosene can be added (see diagram) {n most cases, adequate resistance to cold can be obtained by adding a flow improver (additive). Please contact your Deutz partner. [SS Diesel fuels must never be mixed with petrol (normal and super grade petrol)! 26 JA1000-52D-4E [Tsai deat —| [| Winer case ner | [Asus ore —] [ [rin cnewe oor Mix in tank only. Fill with the apr osene fist, then add the diesel fuel,yueRjood ey ‘ap-azs-000TVE @ . VAS Preparation exceeded, ‘Attest kit (order number ‘obtained from DEUTZ Quality of the water available 4.3.1. Water Quality for Coolant The values given below must not be 13.0382) can be 122 to check the fein, [max ts [8s [= | 0 | Julfate ion content [mg/dm3}] — | 100 hardness ach] | 3 | 20 4.3.2. Coolant Preparation The coolant is prepar cooling system protective liquid with the by admixing a water, The cooling system must be monitored regularly (see 5.1). The water level and the ing system protective liquid concen- tration should both be check The cooling system protective _ liquid concentration can be checked with a ly available tester (e.g. gofo based cooling tive liquids aro ids, harmfulritrosamines are formed, JA1000-52D-4E 43.3 Cooling System Protective Liquid system protective agonts red under order number 108) or 1221 1500 (210 litres). These are nitite-, amine- and phosphate- free and provide effective protection products can be used in exceptional cases. Manufacturer] Product description Vi Ain inioe baa BASF Giysantin G 48 DEA DEA radiator antifreeze SHELL ‘SHELL GlycoShell For the quantity, see table Overpage and in section 9.4 er the cooling system protecve liquid from: DEUTZSewicg TY. Goolngsystemprotecivetiquics Inet be Gnposed of #1 accor: dance. with environmental regulations,Zaye prey o1ypeq Ta py ead ur sonny 105 ON 1-6 voreg 298 ‘euBue snok Ui WUeo09 Jo Anuenb JO4 (, oa oo ost sel oa Ob oor [= Sy os est vr seb ae eu 66 06 8 se sy Or Bz oz gor ooF 8 08 aL 82- OF e + et a sol lea S28 ae oL 4 2 se [sso] pinbyj eanoejoid we}sAs Buyjoop, fo.) [% 100) quae uoyejoid se ze of Ze st 2 oz 8 eanoejoid weysks [sien] Buyjoo9 Buyjooo (, Aivedeo waysks Buyjooa u0}09}01q Wa}sks BulooD arazS-0001VE ar aIc TPIS pouren peaowgne rewero Ie oa wa 0002 Ws pauea pomgne "Tea arspoUL pORUEDG 33 waoo08 as pauea pominine Treyaro erepeuoy, 083 ue oc0e YeIS peuregR pezLOWINE wompedsiy Pepuey ora 48.000), "HEIs pouren pezuoyANE ‘vompedsuj 063 4a 008. [7s paren pazuougne sojeredo ougna: spat ARO wa ‘ep EIS peurEy pazuOYINE (043 093053 Pur Buuossxu09 Jey 013 ugOS wonn2ex3, soueuowen eoueusyujew |euonIPPY 12'S eyo soueuaweW Z's uewep Sunweies pue qq — 7 shag a aia poamposb coun You Sutwomnuuns 6a seuj6ue |e3snput Samy ywHO-ebY e apa 3 Gar oOmRNIIET ‘Ap-A7S-000TVE @& aaa ¥JA1000-52D-4E to the schedule in 5.1 Sept engine befors : AN gaming out any maintenance9 < liz ©) teach engine. It should be affixes BFM 1012 BFM 1013eo JA1000-52D-4E_ fe label with each engine. It should be affixed where it can be seen clearly on ask your engine or equipment supper Work should be camed out aecording to thest "Gey anOge OU) U Pep10o8/ 6g LED DererdwoD AINp Sol eoUEUE UIE GUL ‘soujGue payneyseno pue mau SujworSsIWWOD . ost sege + | ose | suse oszz sha 0002 suet ost seat t 4 00st [sav aszh seth 0008 sia Oss S29 aos | sue 082 seh _ - ;0si-08 dag jamais [aaa] dug 7aTeUBS aaa | son piooay soueuazuleN £°S ‘Ar-AzS-0001VE @® rvJA1000-52D-4E Date Signaure 7 Starip Hours Dale Signaure /Stamp 3000 3250 3500 3750 4000 4250 4500 4750 5000 , 7 5250 5500 5750 sruintenance jobs duly completed can be recorded inthe above table‘Ge @nOge RH UL pepsOTE ag LO pererduico Ap sqo|soUEURTUIEL eA, 0s28 $298 00s8 seg 028 S18 0008 7 S282 osee See 00s2 GLEL ose Sele oe $189 oszg sag o0s9 | szea ose Stig 0009 SLES ueisyanabs [eg [son Garis anes aeg_[_snon ‘Ap-dzS-0001VE evJA1000-52D-4E Signaiie /Stamp Hous Signaure /Stamp 9000 9250 9500 9750 10000 10250 10500 10750 11000 11250 obs duly completed can be recorded in the above table6 wa}shs uojeougn] 1°9 aoueuauleW pue ed1A1aS 9 “AP-dzS-000TVE @ 7JA1000-52D-4E © for vehicle engines. lube od change intervals are deterrined by operating hours, the lube oll change intoras indicated n table 6.1.11. for “OF use under normal duty’ wal apply. OTe table refers tothe folowing cond- = Eo coal fk als between ‘hanges should be halved si a ean en 1% sulfur, contact your service repre oO ol the % eenta Chango the olf with the engine off but ail warm (lube ofl temperature approx. 80 °C),“SZ14-66-6610 21 u! WIM Heep ale sun Jomod AoueBieWg es NOIO02< a OJELOHNGIE vey eulou vey ul sn 10 eno enw sunoy ‘do uy sjeasojuy eBueYo j10 eqn] uojsien oui6ua] ousug TOV OF Tea PORNDT FUE NEUGTBS : 9°03 03 ‘upyng 10} p00 jo eqn puepuEIS Ley deysees ~ Wij eseeje) Z/N30 lepeds: | THE TORESIBETE SPMBTOM | FROPDD 7D Tereaped av] ora WSFA wa 200 ‘a-C7S-O00TVE Tae VION ‘s8e[0 Ayjenb yo eqn] aneg sourbug yuewdinby 4°19 evAS 6.1.1.2 BF6M1013-26 change intervals for vehicle engines Deutz lube oil quality clas ACEA-specification| API-specification| tion Lube oil change intervals it ite _ vehicles/Stadtbusse| busses Local traffic long distance© Loosen the lube oilfilter cap 1 and unscrew wise direction the paper fiter cartridge 3 out ‘Caution: hot oil! A Risk of scalding! JA1000-52D-4E @ Replace rubber seal 2 and apply a small amount of grease © Carefully insert the new paper filter cart guide 4. © Tighten lube offiter cover 1 inthe clockwise direction (25 Nm). @ Start the engine. © Check the off level, see 6.12. @ Check the ail pressure, seo 3.3.1 © Check lube oi iter fitting for leakswayshg jeny z'9 Garr ‘ardzs- ‘aP-d7S-0001VEA@S 6.21 Changing Fuel Filter © Close fuel stoponck (© Undo fue fiter cartridge with commercial toot and spin of © Catch any fuel Keop naked flames away when working onthe fuel systam. Do not smoke! (© Clean any dit from the fiter carrier rm. (© Apply lightfim of od or diesel fuel othe rubber ‘gasket of the new fuel iter carridge, @saew in the now \ Sera Reipenee™ “meee Soon JA1000-52D-4E © Check that the cartidge is seated correctly aganst the gasket and tighten with a final hralf-tum, (© Open fuel stopcock (© Check for leaks. The fuel system does not MN need to be bledJA1000-52D-4E [flees the fuel shutoff valve ffendo fuel filter cartridge with commercial rubber Pipe! and spin off fu Catch any escaping fuel OM ‘© Apply light fim of oil or diese! fuel to the gasket of the new original DEUTZ w cartridge until FW Clean any cit from te iter carer seaing surface ao The fuel system needs to be » M\ bled. fuel fher cantridge with a final alAS 6.2.3 Clean/Replace Fuel Pre-Fitter, Fitter Element © Clase fuel stopcock (© Place the fuel pan beneath the pretminary fuel fiter. @ Remove drain plug 4 and drain off fuel @ Unscrew clamping screw 1. romove Titer housing 5 vith iter insert 3, ing ring 6 and fiter insert 3 (change as necessary). =Push the fiter insert up to approx. 3.cm ‘over the edge of the housing onto the guide in the fier housing 5. oh rang inet an cepa es Sra Mee, flguering foraue 25 Nm). h tah arareame reenter Shane cose ‘© Check for leaks after the engine has been started, Replace: @ Replace defective fiter insert 3. JA1000-52D-4E, 6.24 Venting the Fuel System with Preliminary Fuel Fitter fuel pan beneath the preliminary in plug 4 and observe the ing urd When drain pug 4 engine has been commissioning, after rk or if the tank is run tye eioe es an oie carer tengo eee ee Keepnaked ames away when ‘working on the fuel system. Do not smoke! Dispose of waste fuel in an environmentally. friendly manner!AS JA1000-52D-4E 62.5 Clean/Replace Fuel Pre-Filter, 6.26 Vent Fuel System with Fuel Filter Element Pre-Filter Drain Water: CleaniReplace: ‘© Close the fuel shut-off valve, ‘© Place fuel collection container beneath the fuel pre-fi ‘© Loosen the drain screw 7+9 and drain fuel. © Tum the iterelementhousing 4 with gasket 3 and fi remove ‘© Clean any dir from the sealing face of the fier carter and fiter element housing 4 and sludge chamber 4 and fiter element (replace Hf necessary), @ Insert new round sealing rings 2+3+6, © Screw in fiter element housing 4 and fiter element (max. torque 25~* Ne) element 3 antidockwise and Bl cI Spe feed 3) 1ck for leaks after starting the engine. ight he ten the drain screw 749 fuel shut-off valve ‘@ Place fuel collection container beneath the @ Check Vent: @ In the eventofre-commissioning, following ‘maintenance work or if the tank has been for leaks after starting the engine. © Open fuel shut-off valve. p mainlonance vaive 9. vent scre ‘9 Vent system, turn over engi starter (max. 20 sec.) up to vent screw 10 and pressure retention valve 9 ‘@ Firmly ughten vent screw 10 (tightening torque 25°Nm) and pressuremaintenance valve 9. ‘© Bring engine regulator into start position and start ‘© Check for leaks after starting the engine. Keep naked flames away when working on te foe system, Do notsmoke! Dispose of wastefu environmental ‘manned!peunojied oq Ajuo ABU YONA, dex wip 049 ut osues Jere) jeryusyem 10} uonoauuoo jeOU12013 0} Ayigyssod uon2euUcd =y ‘we108 1UBA 919 UOIYBIL ® so6soun soragnd sie wo 994 jary jun duind oi) ejenoy ® ‘ANUBIS 2 M0108 WBA Oly L950 © U9, “AP-A7S-O001VE Ue ul jeny aysem jo esodsiq, {2yOuIs}0U 0g jseweY PExELON yo payoums euBve yy yum worshs fony ou vo ‘oubuo oxy Sues seyje weeks avy war pue S480 0} 924 & ‘nen yrs ony Udo ¢ den up pue z eBpuue> sony tum Squfmsg seoepne BeOS ‘ug yom ony im z SBD 2 @ soopis Bujees | sees sony) 0y) wod} up Aue UBeID © Z @Bpupes soyy ergoajep ereidey © seoeydons eubue ou Sues ye sy80| 10} Yo0uD © ‘wore og poor pue oxen yonus ony etn U8dO Tony Wu OBPULED Jy U3 16 £08) Lip pue 2 obpuned sy om maIDg © den Uap alp Ueop pue souLEIuc> uonoey}eo Jory oy) OW UorSWe AdL3 © ‘now pue esunyoopque ¢ deg up wn] © ‘9:01 UP es¥OpO;ENUE ¢ den wp pue 7 ebpuyes = v € z b a OWE, JUL TEMA, feng yuoneoedayuegyy 179 ov628 Clean / purge or change fuel pen the bleed screw 1 on the cover 2 1 the fuel collector underneath the fual sing force) the drain cock 8 and close the © Close the bleed sorew 1 on the cover 2 Changing the filter element 5: Change at least once a year or as required (drop in performance also after purgin @ Tum off the engine oF switch to oth in case of changeover fter the fuel stopcock or suppl the cover screws 3 dagmnaly ‘@ Remove the cover 2 @ Remove the spring cassette 4 © Remove theft elements ftom thebracket @ insert new fiter element 5 @ Place spring cassette 4 on the element © Check that the cover seal is ft properly in the cover 2 and check for damage (change if necessary) @ Tighten the cover 2 with the screws 3 diagonally torque 6 Nm) © Check the cover 2 for proper fit and leaks © Bleed the fuel sysiem, see 623. necessary when the warning system is triggered Naked flames are prohibited when working on the fuel system! Do not sm: Dispose of old fuelinan environ- mentally friendly way! 2 JA1000-52D-4E 62.9 Venting the Fuel System with Preliminary Fuel Filter @ During initial commissioning, maintenance work or if the tank bles 9 holding valve @ Tighten pressure © Set engine contro! start @ When the engine has started check for leaksBu'snoy so}ou! 4) oyu fe} 9 dures esoy ayy Ue aajeA Ldjoahu exp OF SROYS po} depp asoy 94 yeUg o3nsU5 920] 40} spay popes sey euBUE oy LOUK @ ue uonisod yes 0; J0H0 48400 de. '§ 409 que goad Buu oz0g duep esoy jun osoyo pue senen ‘ay Jo s9jddiu uonseuuos out 23504 yume (25%0:6 Bununows {MW opssul ayeougni) ¢ sesoy seqgry eprs, sedid ebeyeo| jony mau Bununoyy @ fem Apusiy-AyequaWUORAUe UE UL JO ‘asodsip puez a0aid uonauuoo ue ppue g | S0804 Joggni "9 sdulep sou aRUEWISIG @ 6 @Alen Bulppoy einssexd u9s007 @ ‘sanjeA vonzalut ay) wos, 9 sduuepp asoy pue ¢ sesoy Jeqq aA0Ui2y @ (6'deyo 805) 0209 NL» dues 9504 igim 9 sdue|o e504 aM deo Onen o eGeyeo] jon4 BuBueyd 1:79 em fypuou -Ayewvouuonue We uo ‘aysem jo asodsiq ‘@youis 7ou 00 Wa}eAs jong s4y U0 BuDpOM USym SOU) pOYeU plony ‘syeo] 20} xp9YD pavers Sey aubus 9 LOUM @ {We pur uogPod Wes 0 9foAIe0 BUR UO PS @ ‘ ONeR Oubppy oinesaxd dn woo] @ 6 2NeR BUD woy sedense sajggnd ie ou jory vedo @ Luorisod dois 0} s24031U09 auibus 19g @ eBeyeo? yond BuySueys 0179 ‘AP-AzS-000TVE evA: JA1000-52D-4E_ 6.3 Cooling System4eq 09} _xew “esnssaxd 9s} ‘sonp 42-61009 oy 2 UE) @ ‘eujbue wun ‘soprusu ssanpenuc oy snoqoy pony 61 ways BuyoDd UR Ue 1 @ ELOWRZLOL Seu0S 191em Suiuiewes Aue ejesodese 0} exrgesoduie, Buyesado jeuuou 0} dn our6uo out UM @ ‘doy GoneS WOH @ 40s apue6 © oreelb. pub a — no wears qm Buueetg (on uy ‘suouodueo owomso(9 “sa1ae> “ypjeseue6 Be ‘jel eye © YUM pep Siiscoducs oubueaayses A Uoaisod ud tel uoRlsod m2 uk Woop Keds If ~ ra eg mpi ve) po Aisuee po [DA “thos © qum 1o6umypxe eay otf Aad — WeBy BuIsUed|D PIED yun. senpt 2230 204, cu a P paueno| no Use = Bujooo omy oBewep 0} you jryeveD 2g oy ueKp “1 WOH I “woo yim Jebueyoxe (usu 20s) seBuey> <9 yeay oy) uo dey 2019s ay BROWIEY @ wayshg Buyjoop Buluee|a Z'¢'9 “Dopen 1aSSAIEY seuypeu jenynouby | Sz qwaudrbe Guukn punatiepun ‘spsseiduuo ‘weudinbe Loy Speor peed vO SSPREA, ‘sauund seoeds pesopue ur sesue6 ‘SUS ‘pnb e se posh 9q u, Uan6 sjearsiu Buluesp ou) “2529 OF ‘2582 Wiol} PaULUlayep oq 0 aneY SIeAID} Sur Buiueap "Alen suoyemydde esne29g @ euypeu og p Auon ag w mens paddoyp pue yey yo suoReR20U00 YBIy Sie mig alolyn uoneaxide Gupsenuey Ut — np 8Wod-se 40 fA9| YOY f 51 oie e104m SOUS UONoruISUOD UO — ‘aduexe oj -amp20 ued UoHeULWEILED -STOUES @ stuewuoute Asnp u pasn si aubu2 ou y pyre Apenadse 2g \LONeLAUENXO 1 YSU A Soseobur auto eg 0 or 0 1 POHES @ ‘uoneade eure aig uo spuadap warshs Bujoos aig Ul YONEURLIERDD Jo INOW OY) @ sreatequy BulueeId 19 ‘ar-dzs-0001VE evAi @& JA1000-52D-4E 6.3.3 Draining Cooling System 6.34 Filling / Venting Cooling System 1012/1013 1012/1013 ‘© Place container under drain plug 3. Fillivent the cooling system: see section © Unscrew cap 1. 634 © Unscrew drain plug 3 fly. (© Drain coolant. Sooler (coolant duct). © Screw in the sealing plug 3 up to the fst 9 Sitch off engine fotch and screw in the sealing plug onthe oil a} cooler (arrow), A © Check coolant level (see secton 33.3) and system. top-up as required, 19 3 (10 mm) up to the art up tthe max. mating of Cheater valve —i fied of the tat must Steerer aa omgtrn tn (@ Start engne and warm up untl thermostat| vorysod Gr Buyeos apes a 25019 © 1 Oem arbas ae dh aot pe joo si euBue aig, UayN jana} UBIO PUD & sub 10 ous @ su yepsousang wun dh uvem pue eubue YES @ seg woes a0, (Norgeed deo 1rpe! e509 © eps Buyooo on BunveNGutE ‘upd (fonp WEED) 6nxd Gupeas + 7 vowsod Bred 1u0n UEIYGLL @ 49900 JO. guBUe oun Ye PSUR Od me OLEpOIDE Ul SUISSAS BUIOOD FEWIAY IM @ (pany 3 ~ B Ubists 019 oxgS5a200 US! | Box! Bulees H @ ‘poy ueag anzy Key s5ye Ajeoewoine ‘oq jens weyshs atp jo aeA J0}29u) UM ‘webe | Bryd Guess UeIybt] @ pouon axe ‘soupprb vouye ro Hn 5 Bunge Lilo 3 & dD 102000 PPY @ 24 Jo 20 @ Gur orang ave Upiye‘Swiashs BUCO 1 @ eseoquen 219 way | Bnd Buyeos B7OUIoy @ ‘ Bngd Ougeas pun OURALOD © BOP} @ ao waa Fi 3zt0b Waa. aujBue puepuers aelol/azior ‘BeLoWazioL waasks Buyjooo ay Bunueneumiis gg WRIAS Guyjoop eu Buesg S'F9 ‘AF-zS-000VE =i5) a(© Loosen vert plug positon 2 and sealing plug (© Add coolant up to the maximum marking or file imi (heater valve of the system must be © Tighten vent plug postion 2 + seaing plug © Check coolant level when the engine is cold JA1000-52D-4E 63.7 Draining the Cooling System Unit Engine (4 Cylinders) urate ey have been Hed eben recon wl coon sored (© Wh exemalcoaing systoms m accordance @ Dran off casant wh he scheatan Gite manccems: — ¢ pant ean fine te radiator through (© Stan the engne and warm up unl the wth dear wee tharmostat opens. Tighten knured sro 2 Fingering te cong system seo secon 8381 Bd wep 2p 2500) @ ‘Sauews eq Aew yey sanpses yo fue yo weld @ ‘apes 3b ‘aia J pue euy uo | Bnd WEI 344 UEEODT @ 42}009 any-oBseyo oun Buri 69 ‘Ar-azs-0001VE 6s ‘soup jeas2s éinpenoxd oup yeodad ‘oH euj6ug Wun weysAS Buyjood eu Bunuenuyld 8E9 suoqeinBa jeueuuos -1ave 0} Bulpioace jo esodsip pue 14003 | PaUleIp 192]0 fspreas jo sobuep = \UeDcD oy Bululesp Loy njaxeo og £9 voIpos 00s swoysts Buyooo 8 Bu 7] Zoned BuNees UAL @ Sain 200 rk YBroxg sojerpes aig asuy “BubBop jo 5e2 Uy @ "U2 yp WEA) © (ssepuyAo 9) eujBue yun)Ay & JA1000-52D-4E 6.4 Combustion Air Cleaner, 6.4.1 Cleaning Intervals © The amount of dt inthe air leaner depends @ Air cleaner servicing is needed wher: ontheamountofdustintheatandtheszeot service Indicator the ar deaner used. If a high level of dust s onkcpated,'s Gekne-ype prodesnct can theo spa 1 uly viable ween to be fited to the air deaner = Service Switch ‘© Cleaning intervals will have to be determined the yellow pilot light comes on when the from case to case. engine is running, (© Ifa dey type air Geaner is used, clean when @ After carrying out service work, reset the inde bythe saree ndcabs or ah spel by pressing the buton on the service indicator. 0‘suonenba1 je -uyewuuonnue Yum 20uep10008 Ur fo plo 4o asodsiq “eujose6 ya Jaue9,9 41 UEP 1OAeN, ip deus yn eunoos pue uel} pue dro 0 Wee @ Bussnoy (ZL 7, 998 ‘Aysonsin 10}) 0 yew auf 0} dn po eurbue ian pue ¢ syeyse6 saqqns aoe ‘Ausp Aran |, Buisnoy ‘Lup-dup 0} pue jon} jaseIp ul p ewe Jey e pe dno po Uee)) abs pue yo Aup enowey @ g yeyseb veqgru ay aGewep 0} jou e129 Burye) “OAUMeHS & YAR {Mo JUsWeP ezVd ‘Kressaou jp 1eWaye Jey) yw 19460) ¢dno jo enous pue z sdip deus eseorey @ 1, Buisnoy s9jy Woy WeIP 0} YO OU) 205 ‘seynutli | JnOgE yom pue yo eUIBUE LN @ Joure|D atv WEE NO Buus EVO paBewep 4! (Moq 10) R00 22eideyy “WO YUM IMOG_ 40192109 I) JEAON 1 anu Bum Buusnubn fq aed u 2 19709 uaIse) 'y UONDeS FOMO} O10 ¢ PROq JOPAYoI UONSOdaY @ jeepeid 40 voyses samo] wou, Jeu UBIO} JEL ue mens ‘sanea] uea|5 Aidwo pue P UOT *928 Jem] WOW} £ WOK 20}28I100 SNOWY @ sono anowies pu | ynu BuIM Opn] @ sauee|eld adh] euopio Buixiduig Z779 ar dzs-000LVE ovseaug Hed G9 ay-dzS-O001VE @' ¥a Ae @S JA1000-52D-4E 651 CheckingV-Belts © irspect ene bet for damage © caret move the gauge wihoutaterng the postin of fe ator erm (© Replace damaged V-bots — Read of the va: Tum he gauge sideways eee to see the exact spot where the top of fe (© Aer insaling naw bets, un enghe fr 15 Hack indicator am 1 ritseds, scale 5 mites, en check bot iension (aro) For sting, see 91 — Fnwcessary, retasion bet and measure Uso a V.bokt tension gauge (see 93) to agen check bat enson — Place indicator arm 1 into gauge — Pesiton gauge on V-belt 2, midway between the puleys. wih flange 3 on bottom of gauge agains the edge of bet — Push slowly on the black pad 4 a ight angles to bet 2 untl the spring is heard or fl 10 trigger.zh syeg dung 1en4 uejoog Buuorsue| V5" AP-ATS-“O00TVE syoRORWOIY juey Buporsuel 7S'9 zo syaqsoreweny jue4 Bubuey) ¢S9 evAS 6.5.5 Changing Coolant / Fuel Pump Belts 1012 65.6 Tensioning Coolant / Fuol Pump Belts JA1000-52D-4E 65.7 Changing Coolant / Fuel Pump Bolts. 4012E (© Remove fan bet as described in 6.53 © Shcken off bts 1 and 2. (© Push fue punp 3 in direction of arrow (8). (© Remove and replace bet. (© Push fue pump in direction of arrow (A) unt cored bet torsion is chioved © Tighten bolts 1 and 2 (© Renstal fan bet are tension as deserbed in 652, © Siacken of bots 1 and 2 (© Push fuel purnp 3 in direction of arom. (© Tighten bits 1 and 2jeg soyeweyy Buibuey) 6°59 pg sowewoyy Bujwosuel 8's°9 AP AzS-“O00TVE @ aRie A, PE ) JA1000-52D-4E 65.10 Tensioning / 65.11 Tensioning Coolant / 6512 Changing Coolant / Changing Fan Belt Ful Pump belts Fuel Purp Betts 1013 © Tighten bots 1 ospuen6 409 1821 gum uo Skea ——— Z pur, SPaueL @ pxoupe soja pq joaunD yun MONE yo vopaup aysoddo Uy € ound fn} pny @ eq condos pue mcLIEY © ‘mau jo UORRRIP Ue ind fry Us @ Z PUB, $909 YOURS @ ZPHE | SEU @ paroupe suas pun moue yo uoES=Ip Z pe | Gog IPUBPEIS © eq eM ‘und any ys @ ‘syeg duing jen squepog BuiGuey) s1s9 ‘AP-dzS-000TVE pn we—OD Buluosuel yLS'9 BujGueyo/ Buyworsuey g)'S9 evAy S JA1000-52D-45 65.16 Tensioning iChanging Compressor Belt (© Remove ex bs 1 (© Toretnsionbet, move ore ormoreshirm 3a may be regured from nade re © Toke of cater at ey 2 reoved dam) cube on reve ek ou © Replace belt if n aa @Tun engine over while tightening bolts 1 to rovert bet berg prchek‘gs couelzap anjen argsstued 10) ops uayh EBSA! oypod ons! 009 SARA 24 4.9u4 19, og mona an preus armosunt oi Dia Peso} unop roc SUS fal p Rages Guamipe 2° © ote gg reuaips sad se yupen woased @ yono9 229901 SAOURY @ Ww ops ua cy Gums pu ANA OIG YO LOFOES @ syuewysn{py 9°9 ov Er AzS-O00IWE7.1.1 Checking Battery and Cable Connectors. JA1000-52D-4E 67.1.2Checking Electrolyte 67.1.3Checking Specific Level Gravity of Electrolyte © Clean ternal posts (+ and -) and camps of the battery, and grease wit acklfee and (@ Remove caps 1 @ Measure the spectic gravity of individual cals wih a commercial Fydrometer. (© teaters 2 are used, the electobte should ‘come up to her base, testers are not used, he elective level During measure be 10-15 mm above the bp of the electrolyte should bly be 20°C 68°F recessary, top up with dstiled water. (© Replace caps.AS JA1000-52D-4E_ ——_— Spe Gaeiy ah wearer Sad oaw 1 [Reva [Tone [ Rowe [Tepes wm [miles ayaa oe | | Ti degel, ane me foe[ore B s iby * Measurement of specitic gravity in °B6 is ‘ott of dato and rarely used today. ‘Thegaseseriiedbythebattery are explosive. Keep sparks and faked flames away from the battery, Do not alow battery acid to ‘come into contact with skin or clothing Wear protective goggles Do rot rest tools on the battery. 1”‘ap-dzs-000TWr ‘appe uy yoausoo ou {UO 887) eee ubue ayy Supode Lown ope, 6uyy dor) ‘can Stowy © appa, Bua £29 opiam Bug s000 ‘219.0 Apaup soppm o44 uo asus puna 3 rauuco “Suppam auoae JO OF 34 Y @ swore eae ceaytoang yun pom oq soCUeRUTEID {i sopun jr an 9 9 SOUR 2pLP ‘rues an puree peoye unpre OIE OU) @ “jem Ouureus fue oyecden> crarweauay Based eusoua dn a60 Sip ung ceuDye oy LO AfrRUp WES Phen desde preg UBL 944 BINED) @ Aen de, rope sBimp ain Jo arg ONES RP SomeR) @ ges) Aug op seryucD oF ONE 9 @ ouyer ‘jog sowaueye 04g wy 1.9! 29 PAL Stoo ‘Aner a rouge 9uBu0 ef SL “Sho ur pas 0 esau S11 NOROY |S @ ouary a ubuo ay) aay soya: pus yeni ASL Seq uaa So(Fe SA PORCIEP HAAN @ oye soniptoauy 94 UO SPH soyeweyy eseycoayl 729 evAS 7 Faults, Causes and Remedies 7.1 Fault Table (©: engine problems occur, they trequenty have i thelr cause in improper operation or engine mahtenance ‘©-1 problems do occur, always check frst that the operding and mahtznance structions have ben foowed, (© Addagnesis charts gven onthe facing page ‘© Ifyou cannot identity the cause of the problem are unable to rectly yourse contact DEUT2 Service Before sariing. make sure Tat miobody is standing In the Imme- diate vicinty of the engine or aren machine, Important: When carrying out repair work. never stat the engine wth speed governor removed, Disconsoe! bara. 6 JA1000-52D-4E_sopap porauy=¥OTe . 204 age a] sag FaERAp sae) aU 4 “Tommy ne jou asp anveacwal ae BULA ele [aa AT vt) As] 0 nS ULB eleletele wid Fup Ue Pa Ue wid aeueueg 1}009 We Ie Wid was BATON, znpajap und EO mid Tit SEND é Supe) anna VOT 4 TapSOD RIBAS OES FURST IN Tard [ EBOUSTANICS enoeany Age 00e9! We ABO aid Tans por os 161 on woo peed 7 aid ue 6 ORR aNSSeIG S. ou 01 F210 ele v ‘no( COL a e é Ga Tag) WTSI CO wn OHI AD . © J arierenvay nur cuues none | |e 2 ee TaatS500 3180) PRESTON e womnes ese wae a aig Sas aN aS Wo AUINSHO 10 BOS 3 BAA BOT ansaid YO.OU 10 Ml SPU SU v andoy app 4 uo Gu YOU oN ¥ veal ‘ewiojed 100d Son ou mesa ven So Toyuou ampseoua, eae BAA 3 sai us 10 Avenoun suru yoo seis au0U J a [ye 0, way S10 HeLa Tpauw u ‘Ar AzS-“O00TVEJA1000-52D-4E ble comedtons to Starter, elec cal eytem base Or oR a Coeatng medal Table 2012 7%cutua ums @ {ee9/¥8'9 088) WROD yoo Tex pue ¢ od are WOH A BAO © shaq yaa: uy sanoou8 wo) wabe vlsou09-Me ANCL @ (se9/ec 922s) ate asco we UO @ unjipuoapaddesusiospue] SRA: ARRCUPY @ uosocdosoj2runopmss's2Ue.Su TesaNeS APRAURLS 4080 AUBU U yp autuaun, @ saynus 9} 110980} auue UT @ ue ay ayes pu Yo uoisoneo we 0} pue Re} Sep “06 40 oa cn HEH @ ‘wey anjuRIG © younsouno we (er 962s) aveep ie uuoueRD Asse 6 2) wate UOISD.I00 UE UTA I @ (Seyee9 as) WOOD URI ® ue ya in PUR (9 #8) ‘yo wn ue (ey sso SELB snopes) syaveN wa|ORed — ‘uu bij unsslsode) Lay anes anouisi 0} abe SUrSUPa}9 papvaWUDdey @ ‘yar0r9 9 2pp0 OLY — ziee0-0816 11 - nosziz"11 oye goad 0 S10 UO: a) 9) autus au ainjaq pestenth oq ws aunpenoxd a, "suquou 9 0 oh io 2p SeuNSPal NEES woryearesaid 1°9 uoyeaesald 18 uonjenesaig aujbuy 8 ‘A-dzS-000TWE ovAy @ JA1000-52D-4E_ 9 Technical Specification | Hem “aMioi3, — BFEMI013 6 _| ‘Number of eylinders 4 | Cylinder arrangement = \ ‘Bore [mm] ‘Stroke {mm I 7 7 : ‘Compression ratio [©] _ 16 1 Total displacement [om3] 4764 ‘Working cycle/Combustion system _ [astroke diesel wih turbo charging Charge air cooler wi Direction of rotation ‘Weight [kg approx.) ‘Valve clearance with cold engine Imm Injector opening pressure [bar] Firing order of engine ‘V-belt tension \ Generator [N] Fuel pump - coolant pump (N] ‘quantity (tres approx.) Permissible continuous coolant temperature Engine outlet, with performance group I Ch |Tremoaat initial opening at [° C) | _| atl “Thermostat full open temperature ["_C) Lubrication Oil temperature in oil pan {” Cl T Min. oll pressure with engine warm (120° C ‘and SAE oil 15 W 40) and low idle speed Toil capacity (first fil-up) without fiter ites approx]Operation Manual 1013 A. veutz (DAL IAN) ENG INE CO.,LTD