OBJ_DOKU-19557-001.fm

Notes

2 © 2009 gine, the use of DEUTZ original parts is pre- scribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the war- ranty! Maintenance/cleaning work on the engine may only be carried out when the engine is not run- ning 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 dan- gerous contact voltages) must be observed. Cover all electrical components tightly when cleaning with liquids.

z Do not work on the fuel system while the engine is running - Danger to life! Wait for the pressure to drop after the engine has come to a standstill (in engines with DEUTZ Common Rail about 5 minutes, otherwise 1 minute) because the system is under high pressure - Danger to life! During the first trial run do not stand in the dan- ger area of the engine. Danger due to high pressure in case of leaks - Danger to life! In case of leaks immediately contact work- shop. When working on the fuel system, make sure that the engine is not started inadvertently during repairs - Danger to life!

z This engine is defined exclusively for purpose according to the scope of delivery and built by the equipment manufacturer (use for the intend- ed purpose). Any other use above and beyond this will be considered as misuse. The manufac- turer will not accept any liability for damages re- sulting from this. The user bears the sole risk. z Use for the intended purpose also includes ob- servance of the operating, maintenance and re- pair conditions specified by the manufacturer. The engine should only be operated, serviced and repaired by personnel trained in its use and the hazards involved.

The pertinent rules for the prevention of acci- dents and other generally recognised safety and industrial medicine rules must be observed. z When the engine is running there is a danger of injury caused by: rotating and hot components on motors with external ignition (high electri- cal voltage). Contact must be avoided! z Unauthorised engine modifications will invalidate any liability claims against the manufacturer for resultant damage. z Equally, manipulations to the injection and con- trol system can affect the engine's performance and the exhaust characteristics. Adherence to legislation on pollution can no longer be guaran- teed under such conditions.

z Do not change the cooling air feed area to the blower of fan. An unobstructed cooling air supply must be guaranteed. The manufacturer will accept no liability for dam- age resulting from this. z When carrying out maintenance work on the en- Notes Notes

Page 2

Foreword

Foreword © 2009 3 Please enter the engine serial number here. This will simplify the handling of customer service, repair and spare parts queries. We reserve the right to make technical changes to the descriptions and data in this operating manual in the interest of further development of the engines. This document may only be reprinted and repro- duced, even in part, with our express permission. Engine serial number Notes Congratulations on the purchase of your DEUTZ en- gine. DEUTZ air/liquid-cooled engines are developed for a 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 installation situation, i.e. not all the components de- scribed in the operating manual are installed in your engine. We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions applicable to your engine more quickly and easily. Please make sure that this operating manual is 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. Dear customer, DEUTZ AG Sincerely,

Page 3

Contents

4 © 2009 Belt drives . . . . . . . . . . . . . . . . . . 53 Setting work . . . . . . . . . . . . . . . . . 56 Electrical system . . . . . . . . . . . . . . . 59 7 Faults. . . . . . . . . . . . . . . . . . . . . 61 Transport . . . . . . . . . . . . . . . . . . . 69 Tools . . . . . . . . . . . . . . . . . . . . . 76 Aspiration system. . . . . . . . . . . . . . . 51 Fault table . . . . . . . . . . . . . . . . . . 61 Engine management . . . . . . . . . . . . . 66 8 Transport and storage . . . . . . . . . . . 69 Engine corrosion protection . . . . . . . . . 70 9 Technical data . . . . . . . . . . . . . . . . 72 Engine and setting data . . . . . . . . . . . 72 Notes . . . . . . . . . . . . . . . .

. . . . . . . 2 Foreword. . . . . . . . . . . . . . . . . . . . . 3 1 General. . . . . . . . . . . . . . . . . . . . 5 2 Engine description . . . . . . . . . . . . . 7 Model . . . . . . . . . . . . . . . . . . . . . 7 Engine illustrations . . . . . . . . . . . . . . 9 Lubricating oil diagram . . . . . . . . . . . . 17 Fuel diagram . . . . . . . . . . . . . . . . . 18 Coolant diagram . . . . . . . . . . . . . . . 19 Exhaust gas return . . . . . . . . . . . . . . 21 Electrics/Electronics . . . . . . . . . . . . . 22 3 Operation . . . . . . . . . . . . . . . . . . 24 Ambient conditions . . . . . . . . . . . . . . 24 Initial start-up . . . . . . . . . . . . . . . . . 25 Start procedure . . . . .

. . . . . . . . . . . 27 Operation monitoring . . . . . . . . . . . . . 29 Stop procedure . . . . . . . . . . . . . . . . 31 4 Operating media. . . . . . . . . . . . . . . 32 Lubricating oil. . . . . . . . . . . . . . . . . 32 Fuel . . . . . . . . . . . . . . . . . . . . . . 34 Coolant . . . . . . . . . . . . . . . . . . . . 35 5 Maintenance . . . . . . . . . . . . . . . . . 36 Maintenance schedule . . . . . . . . . . . . 36 6 Servicing and maintenance works . . . . . 39 Lubricating oil system. . . . . . . . . . . . . 39 Fuel system. . . . . . . . . . . . . . . . . . 42 Cooling system . . . . . . . . . . . . . . . . 48 Engine cleaning. . . . . . . . . . . . . . . . 50 Contents

Page 4

General

1 DEUTZ diesel engines General ity with notes on product responsibilities and servic- es. Or you can use another fast, convenient way via the Internet under www.deutzshop.de. The DEUTZ P@rts Online parts catalogue gives you a direct con- tact to your nearest local service partner. California Proposition 65 Warning Diesel engines and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. © 2009 5 Fax: +49 (0) 221-822-3525 Phone: +49 (0) 221-822-0 E-Mail:

info@deutz.com www.deutz.com Masthead DEUTZ AG OttostraЯe 1 51149 Kцln Germany velopments for improving the engines are also intro- duced in the original DEUTZ parts of course. Only the use of original DEUTZ parts manufactured ac- cording to the state-of-the-art can guarantee perfect functioning and high reliability. DEUTZ replacement parts are a low-cost alternative. Of course, the quality standards here are just as high as for new parts. DEUTZ replacement parts are equal to the original DEUTZ parts in function and re- liability. The gaskets used in this engine contain no asbestos. Please use the appropriate original DEUTZ parts for maintenance and repair work.

The DEUTZ name does not merely stand for engines that are the products of extensive development work, DEUTZ also stands for complete service pack- ages that ensure optimum operation of our engines, and for customer services operations that you can count on. We want to preserve the high performance of our en- gines, and with it the confidence and satisfaction of our customers. We are therefore represented world- wide by a network of service branches. Please contact your DEUTZ-partner in case of mal- functions and sare parts inquiries. Our specially trained personnel will ensure fast, professional re- pairs using original DEUTZ spare parts in case of damage.

The DEUTZ home page gives you a continuously up- to-date overview of the service partners in your vicin- DEUTZ Xchange components Asbestos Service DEUTZ diesel engines are the product of years of re- search and development. Profound know-how com- bined with high quality requirements are the guarantee for the production of engines with a long life, high reliability levels and low fuel consumption. Obviously the high requirements for the protection of the environment are also met. Maintenance work or repairs may only be performed on the shut-down engine. Make sure that the engine cannot be started inadvertently - Danger of acci- dent! After repair work:

Check that all guards have been replaced and that all tools have been removed from the engine. Observe industrial safety regulations when running the engine in an enclosed space or underground. When working on the running engine, work clothing must be close fitting. Service and maintenance are also decisive for whether the engine satisfactorily meets the set de- mands. Recommended service intervals must there- fore be observed and service and maintenance work must be carried out conscientiously. Special care should be taken under abnormally de- manding operating conditions. Original DEUTZ parts are subject to the same strict quality demands as the DEUTZ engines.

Further de- Safety precautions when the engine is running Never fill the fuel tank while the engine is running. Service and Maintenance Original DEUTZ parts

Page 5