Deutz 2008-2009 Service Manual

Operation Manual

2008 2009

zRead and observe the information in this

instruction manual. You will avoid accidents, retain the manufacturer’s warranty and have a fully functional, ready to use engine at your disposal.

z This engine is exclusively for the purpose

according to the scope of delivery - defined and built by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user will bear the sole risk in this case.

z The manufacturer will not be liable for

damages resulting from unauthorised modification of the engine. Equally, manipulations to the injection and control system can affect the engine’s performance and the exhaust characteristics. Compliance with environmental regulations will no longer be guaranteed in this case.

z Do not alter, obstruct or block the area of

the cool air supply to the fan. The manufacturer will accept no liability for damages resulting from this.

z Use for the intended purpose also includes

observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with it and instructed in the dangers.

z The pertinent rules for the prevention of

accidents and other generally recognised safety and industrial medicine rules must be observed.

z When the engine is running there is a danger

of injury caused by:

- rotating / hot components

- engines with extraneous ignition

- ignition systems (high electrical voltage) Contact must be avoided!

z Only DEUTZ original parts may be used

when carrying out maintenance/repair work on the engine. These have been designed especially for your engine and ensure a trouble-free operation. Failure to observe this will lead to voiding of the warranty!

z Maintenance/cleaning work on the engine

may only be carried out when the engine is not running and has cooled down. When doing this, make sure that the electrical system is switched off. Remove ignition key. The specifications for accident prevention with electrical systems (e.g. VDE-0100/0101/-0104/-0105 Electrical protective measures against dangerous touch voltages) must be observed. Cover all electrical components tightly when cleaning with liquids.

Engine number

Operation Manual

2008 2009

0312 1419 en

Please enter the engine number here. This will simplify the handling of customer service, repair and spare parts queries (see Section

2.1).

Illustrations and data in this instruction manual are subject to technical changes in the course of improvements to the engines. Reprinting and reproductions of any kind, even in part, require our written permission.

Foreword

Dear customer,

DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. A comprehensive range of variants on offer ensures that the respective special requirements are met.

The engine is equipped according to the installation case, i.e. not all the parts and components described in this instruction manual are installed in your engine.

We have done our best to clearly identify the differences, so that you can easily find the operating, maintenance and repair instructions appropriate to your engine.

Please read these instructions before you start your engine and observe the operating and maintenance instructions.

We are at your service for any questions you may have in this matter.

Your DEUTZ AG

1 General

2 Engine description

2.1 Engine type

2.1.1. Company plate

2.1.2 Location of company plate

2.1.3 Cylinder numbering

2.2 Engine illustrations

2.2.1 Operation side D 2008 L04

2.2.2 Exhaust side D 2008 L04

2.2.3 Operation side D 2009 L04

2.2.4 Exhaust side D 2009 L04

2.2.5 Operation side TD 2009 L04

2.2.6 Exhaust side TD 2009 L04

2.3 Fuel diagram

2.3.1 Fuel circuit

3 Operating

3.1 Initial commisioning

3.1.1 Engine oil filling

3.1.2 Filling oil bath air filter with engine oil

3.1.3 Coolant initial filling with cooler

3.1.4 Other preparations

3.1.5 Additional maintenance work

3.2 Starting

3.2.1 Starting

3.3 Operation monitoring

3.3.1 Engine oil pressure

3.3.2 Engine temperature

3.4 Switching off

3.4.1 Mechanical switching off

3.4.2 Electrical switching off

3.5 Operating conditions

3.5.1 Winter operation

3.5.2 High ambient temperature, high altitude

4 Operating substances

4.1 Lube oil

4.1.1 Quality

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality

4.2.2 Winter fuel

4.3 Coolant

4.3.1 Water quality for coolant

4.3.2 Coolant preparation

4.3.3 Cooling system preservative

5 Maintenance

5.1 Maintenance schedule

5.2 Standard maintenance schedule

5.3 Maintenance diagram

5.4 Maintenance work carried out

6 Care and maintenance work

6.1 Lubrication system

6.1.1 Oil change intervals

6.1.2 Checking oil level, changing engine oil

6.1.3 Changing oil filter

6.2 Fuel system

6.2.1 Changing fuel filter

6.2.2 Bleeding fuel system

6.2.3 Draining water from fuel system

6.2.4 Changing diaphragm pump

6.3 Cooling system

6.3.1 Cleaning intervals

6.4 Combustion air filter

6.4.1 Cleaning intervals

6.4.2 Emptying cyclone pre-separator

6.4.3. Dry air filter

6.5 Belt drive

6.5.1 Test V-belt

6.5.2 Tightening/changing V-belt

6.5.3 Changing generator V-belt

6.6 Add-on components

6.6.1 Battery

6.6.2 Three-phase current generator

6.6.3 Transportation suspension

6.7 Engine cleaning

6.7.1 Engine cleaning

7 Faults, causes and remedies

7.1 Fault table

8 Engine corrosion protection

8.1 Corrosion protection

8.1.1 Protecting engine from corrosion

8.1.2 Removing engine corrosion protection

9 Technical data

9.1 Engine and setting data

9.2 Screw tightening torques

10 Service

General

DEUTZ Diesel Engines

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Beware of Running Engine

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

Care and Maintenance

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Safety

This symbol is used for all safety warnings. Please follow them

and accident prevention regulations laid down by law must also be observed.

carefully. The attention of operating personnel should be drawn to these safety instructions. General safety

Service

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.

California

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Asbestos

DEUTZ original parts are asbestosfree.

2.1 Engine type

2.2 Engine illustrations

2.3 Fuel diagram

Engine description

2.1 Engine type

2.1.1 Company plate

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

2.1.2 Location of company plate

The company plate C is fixed to the valve covering hood.

2.1.3 Cylinder numbering

The cylinders are counted consecutively, starting from the flywheel.

2.1 Engine type

Engine description

2.2.1 Operation side Example: D 2008 L04

2.2 Engine illustration

1 Oil filler neck (valve cover) 2 Valve cover

3 Exhaust manifold

4 Fuel supply pump 5 Exchangeable fuel filter 6 Generator

7 Oil tray 8 Crankcase

9 Auxiliary drive possibility e.g. hydr. pump 10 Narrow V-belt 11 Exchangeable lube oil filter 12 V-belt pulley on crankshaft 13 Fan 14 Coolant pump, coolant inlet from cooler 15 Coolant outlet from engine to cooler

2.2 Engine illustration

2.2.2Exhaust side Example: D 2008 L04

Engine description

16 Injection line 17 Injection valve 18 Speed governor 19 Injection pump 20 Oil dipstick 21 Starter 22 Connection housing (SAE) 23 Flywheel with gear rim 24 Air intake pipe 25 Crankcase 26 Fuel return line 27 Charge air manifold from air filter

Engine description

2.2.3 Operation side Example: D 2009 L04

2.2 Engine illustration

1 Oil filler neck (valve cover) 2 Valve cover

3 Exhaust manifold

4 Fuel supply pump

5 Exchangeable fuel filter with water

separator

6 Generator

7 Oil tray

8 Crankcase

9 Auxiliary drive possibility e.g. hydr. pump 10 Narrow V-belt 11 Exchangeable lube oil filter 12 Crankshaft drive flange 13 Fan 14 Auxiliary drive possibility e.g. hydr. pump 15 Coolant pump, coolant inlet from cooler 16 Coolant outlet from engine to cooler

2.2 Engine illustration

2.2.4Exhaust side Example: D 2009 L04

Engine description

17 Injection line 18 Injection valve 19 Speed governor/injection pump 20 Injection line 21 Oil dipstick 22 Starter 23 Connection housing (SAE) 24 Flywheel with gear rim 25 Air intake pipe 26 Crankcase 27 Fuel return line 28 Charge air manifold from air filter

Engine description

2.2.5 Operation side TD 2009 L04

2.2 Engine illustration

1 Oil filler neck 2 Valve cover

3 Exhaust manifold

4 Charge air line from turbocharger to

charge air manifold

5 Turbocharger

6 Exchangeable fuel filter with water

separator 7 Generator 8 Oil tray 9 Crankcase

10 Gearcase 11 Narrow V-belt 12 Exchangeable lube oil filter 13 V-belt pulley on crankshaft 14 Fan 15 Coolant pump, coolant inlet from cooler 16 Coolant outlet from engine to cooler

2.2 Engine illustration

2.2.6Exhaust side TD 2009 L04

Engine description

17 Injection line 18 Injection valve 19 Speed governor 20 Injection pump 21 Oil dipstick 22 Starter 23 Connection housing (SAE) 24 Flywheel with gear rim 25 Fuel supply pump 26 Air intake pipe from air filter 27 Crankcase 28 Fuel return line 29 Charge air manifold

Engine description

2.3.1 Fuel circuit

2.3 Fuel diagram

1 Fuel feed pump (connection line from

customer fuel container) 2 Fuel line from feed pump to fuel filter 3 Exchangeable fuel filter

2.3 Fuel diagram

Engine description

4 Fuel line from filter to injection pump 5 Injection pump 6 Injection line to injection valve 7 Injection valve 8 Fuel return line to customer fuel container

3.1 Initial commissioning

3.2 Starting

3.3 Operation monitoring

3.4 Switching off

3.5 Operating conditions

Operation

Operation 3.1 Initial commissioning

3.1.1 Engine oil filling

The engines are generally supplied without oil filling. Fill the engine with lube oil via the oil filler neck (A). For quality and viscosity of oil see 4.1.

3.1.1.1 Initial engine oil filling

z Fill the oil tray with oil up to the marking

"Max" on the oil dipstick (for oil filling quantities see 9.1).

z Start the engine and run at a low idling

speed for approx. 2 minutes.

z Switch off the engine z Check the oil level. If necessary, fill with oil

up to upper "Max" line marking.

3.1.2 Filling oil bath air filter with engine oil

Fill the oil pan 1 of the oil bath air filter with engine oil up to the arrow marking. For quality and viscosity of oil see 4.1.

Do not pour oil into the dust collecting tank of the preseparator, if there is one

present.

3.1 Initial commissioning Operation

3.1.3 Initial coolant filling with cooler

z Fill honeycomb cooler with coolant up to

the marking " Max ".

z Also fill the supply hoses and the external

honeycomb cooler to coolant capacity (per manufacturer specifications).

z Allow the engine to warm up until the

thermostat has opened (at approx. 86-90 °C ).

z Leave the engine running for approx. 2

minutes.

z Switch off the engine z Check the oil level. If necessary, fill with

coolant up to upper " Max " line marking.

3.1.4 Fuel filling

FUE

Only use standard branded diesel fuel. For fuel quality see 4.2. Depending on the outside temperature, use either summer or winter diesel fuel.

If the engine is not warmed up following the initial filling, the oil level will be above

the "Max" marking on the oil dipstick. Therefore, it is only possible to assess the oil level after the warm up.

Only re-fuel when the engine is not running! Pay attention to cleanliness! Do not spill any fuel!

Operation 3.1 Initial commissioning

3.1.5 Other preparations

z Check battery and cable connections,

see 6.6.1.

z Transportation eyelets

If installed, remove, see 6.6.3

z Trial run

After preparations carry out a short trial run of approx. 10 min. Do not apply load to the engine in doing this. Work during and after the trial run

- Check engine for tightness.

z With engine not running

- Check oil level, see 6.1.2, if necessary

re-fill oil, see 3.1.1

- Check coolant level, see 3.1.3

- Re-tighten V-belts, see 6.5

z Running-in

It is recommended to check the oil level twice a day during the running-in phase (approx. 200 oh). After the running-in phase checking once a day is sufficient.

3.1.6 Additional maintenance work

The following additional maintenance work is to be carried out for the commissioning of new and overhauled engines:

After 50-150 oh

z Change lube oil,

see 6.1.2

z Change oil filter cartridge,

see 6.1.3

z Change fuel filter cartridge,

see 6.2.1

z Check V-belt tension, if necessary

re-tighten, see 6.5.

z Check engine for tightness (leakages).

z Check engine bearing, re-tighten if

necessary.

+ 54 hidden pages

Deutz 2008-2009 Service Manual

Operation Manual

Foreword

Contents

General

Engine description

Operation