Acrobat-Dokument OBJ_DOKU-16314-001.fm Seite 1 Donnerstag, 24.
OBJ_DOKU-16314-001.fm Seite 2 Donnerstag, 24. Juli 2008 11:18 11 Notes Notes z This engine is defined exclusively for purpose according to the scope of delivery and built by the equipment manufacturer (use for the intended purpose). Any other use above and beyond this will be considered as misuse. The manufacturer will not accept any liability for damages resulting from this. The user bears the sole risk.
OBJ_DOKU-16314-001.fm Seite 3 Donnerstag, 24. Juli 2008 11:18 11 Foreword Dear customer, Engine serial number Congratulations on the purchase of your DEUTZ engine. Please enter the engine serial number here. This will simplify the handling of customer service, repair and spare parts queries. DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. Consequently, a wide range of variants is offered to meet the requirements of specific cases.
OBJ_DOKU-16314-001.fm Seite 4 Donnerstag, 24. Juli 2008 11:18 11 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 . . . . . . .
OBJ_DOKU-16314-001.fm Seite 5 Donnerstag, 24. Juli 2008 11:18 11 General DEUTZ diesel engines DEUTZ diesel engines are the product of years of research and development. Profound know-how combined 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.
OBJ_DOKU-16314-001.fm Seite 6 Donnerstag, 24. Juli 2008 11:18 11 General 1 Danger This symbol is used for all safety instructions which, if not observed, present a direct danger to life and limb for the person involved. Observe these carefully. The attention of operating personnel should be drawn to these safety instructions. Furthermore, the legislation for "general regulations for safety and the prevention of accidents" must be observed. Caution This symbol indicates a danger to the part and engine.
OBJ_DOKU-16314-001.fm Seite 7 Donnerstag, 24. Juli 2008 11:18 11 Engine description Model 2 Engine type designation This manual covers the following engine types D 914 L06 B A TCD 914 L06 D 914 L05 D 914 L04 Mot.-Typ C Mot.-Nr. D 914 L03 TCD T Exhaust gas turbocharger C Charge air cooler D Diesel 914 Series 914 L03/L04/L05/L06 L in series 03 No. of cylinders 04 No. of cylinders 05 No. of cylinders 06 No.
OBJ_DOKU-16314-001.fm Seite 8 Donnerstag, 24. Juli 2008 11:18 11 Engine description 2 D Model left right 1 Engine serial number Cylinder numbering The engine number (D) is stamped onto the crankcase (arrow) and onto the rating plate. Cylinder arrangement 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.
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OBJ_DOKU-16314-001.fm Seite 16 Donnerstag, 24. Juli 2008 11:18 11 Engine description Exhaust return 2 External exhaust gas recirculation 7 D 914 L03 > 37 kW D 914 L04 D 914 L05 D 914 L06 TCD 914 L06 Optional (example) 5 1 6 1 Exhaust gas partial flow (not connected) 2 Valve housing 3 Actuator (electrically actuated) 4 Distributor pipe 5 Electrical connection 6 Switch The switch is connected internally with the control linkage. The voltage to the actuator is interrupted at load peaks.
OBJ_DOKU-16314-001.fm Seite 17 Donnerstag, 24. Juli 2008 11:18 11 Engine description Exhaust return 2 Internal exhaust gas recirculation (example) D 914 L03 < 37 kW TCD 914 L06 Optional 1 3 [mm] 2 1 Additional cams for exhaust gas recirculation Inlet valve opens briefly during the outlet cycle and emits an exhaust gas partial flow to the suction system. This partial volume is sucked back in in the next suction cycle.
OBJ_DOKU-16314-001.fm Seite 18 Donnerstag, 24. Juli 2008 11:18 11 Operation 3 Ambient conditions 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 below, the amount of fuel is reduced automatically, controlled by the electronic control unit.
OBJ_DOKU-16314-001.fm Seite 19 Donnerstag, 24. Juli 2008 11:18 11 Operation Initial start-up Preparations for initial commissioning (Maintenance schedule E 10) 3 ing oil filler neck. z Observe the lubricating oil filling level ( 58). 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.
OBJ_DOKU-16314-001.fm Seite 20 Donnerstag, 24. Juli 2008 11:18 11 Operation 3 Initial start-up Trial run Additional venting of the fuel system by a 5 minute trial run at idle speed or on low load is absolutely essential. 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.
OBJ_DOKU-16314-001.fm Seite 21 Donnerstag, 24. Juli 2008 11:18 11 Operation Start procedure 3 Starting Before starting, make sure that nobody is standing in the immediate vicinity of the engine or work machine. Disconnect the engine by uncoupling devices 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.
OBJ_DOKU-16314-001.fm Seite 22 Donnerstag, 24. Juli 2008 11:18 11 Operation 3 A Start procedure After starting, any exhaust gas turbidity in the runup phase can be reduced by holding the key at stage 2. (maximum 3 minutes) B C 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.
OBJ_DOKU-16314-001.fm Seite 23 Donnerstag, 24. Juli 2008 11:18 11 Operation Operation monitoring 3 Operation monitoring by EMR2 Optional 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.
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OBJ_DOKU-16314-001.fm Seite 25 Donnerstag, 24. Juli 2008 11:18 11 Operation Stop procedure 3 Shutting off Avoid switching off from full load (coking/ blockage of the remaining lubricating oil in the turbocharger bearing housing). The lubricating 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 approximately one minute after relieving the load.
OBJ_DOKU-16314-001.fm Seite 26 Donnerstag, 24. Juli 2008 11:18 11 Operating media 4 General Modern diesel engines place very high demands on the lubricating oil to be used. The specific engine performances which have increased constantly over the last few years lead to an increased thermal load on the lubricating oil. The lubricating oil is also more exposed to contamination due to reduced oil comsumption and longer oil change intervals.
OBJ_DOKU-16314-001.fm Seite 27 Donnerstag, 24. Juli 2008 11:18 11 Operating media Lubricating oil z The intervals depend on: – lubricating oil quality – sulphur content in the fuel – type of application of engine z The lubricating oil change interval must be halved if at least one of the following conditions applies: – Constant ambient temperature below -10 °C (14 °F) or lube oil temperature below 60 °C (84 °F). – Sulphur content in the diesel fuel of 0.5-1 %.
OBJ_DOKU-16314-001.fm Seite 28 Donnerstag, 24. Juli 2008 11:18 11 Operating media 4 Permissible fuels The following fuel specifications / standards are approved: z Diesel fuels – EN 590 – ASTM D 975 1-D – ASTM D 975 2-D – 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.
OBJ_DOKU-16314-001.fm Seite 29 Donnerstag, 24. Juli 2008 11:18 11 Operating media Fuel 4 Winter operation with diesel fuel 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 operating faults.
OBJ_DOKU-16314-001.fm Seite 30 Donnerstag, 24. Juli 2008 11:18 11 Maintenance 5 Maintenance schedule Assignment of the DEUTZ maintenance and service schedules to maintenance intervals Standard maintenance schedule D/TCD 914 Stage Activity To be carried out by E10 Initial commissioning Authorised specialists E20 Daily inspection Operator E30 Maintenance Qualified personnel E40 Extended maintenance I E50 Extended maintenance II 1) Maintenance interval every .......
OBJ_DOKU-16314-001.fm Seite 31 Donnerstag, 24. Juli 2008 11:18 11 Maintenance schedule Maintenance 5 Maintenance measures Stage Activity E10 E20 Check Measure Page The measures are listed in chapter 3.
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OBJ_DOKU-16314-001.fm Seite 33 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works Lubricating oil system Regulations for working on the lubricating oil system Do not work when the engine is running! Smoking and naked lights prohibited! Be careful of hot lubricating oil. Danger of scalding! Pay attention to utmost cleanliness when working on the lubricating oil system. Clean the area around the components concerned carefully. Blow damp parts dry with compressed air.
OBJ_DOKU-16314-001.fm Seite 34 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works Lubricating oil system 6 Change lubricating oil filter The filter cartridge should never be prefilled. There is a danger of dirt contamination! z Remove clamps when twist protection mounted (optional). z Loosen and unscrew filter cartridge with tool (order number: 170050). z Collect draining lubricating oil z Clean the sealing surface of the filter support with a lint-free, clean cloth.
OBJ_DOKU-16314-001.fm Seite 35 Donnerstag, 24. Juli 2008 11:18 11 Lubricating oil system 4 3 5 6 2 1 Servicing and maintenance works 6 z Mount cover. z Insert screws with new sealing rings. z Check for leaks after starting the engine. 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.
OBJ_DOKU-16314-001.fm Seite 36 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works 6 Specifications when working on the fuel system Engine must be switched off! Smoking and naked lights prohibited! No injection/high pressure pipes may be disconnected while the engine is running. Caution when handling hot fuel! Pay attention to utmost cleanliness when refuelling and working on the fuel system. Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
OBJ_DOKU-16314-001.fm Seite 37 Donnerstag, 24. Juli 2008 11:18 11 Fuel system Servicing and maintenance works 6 Change the fuel filter cartridge The filter cartridge should never be prefilled. There is a danger of dirt contamination! z Remove clamps when twist protection mounted (optional). z Loosen and unscrew filter cartridge with tool (order number: 170050). z Catch any escaping fuel. z Clean the sealing surface of the filter support with a lint-free, clean cloth.
OBJ_DOKU-16314-001.fm Seite 38 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works 6 Cleaning work For all cleaning work, make sure that no parts are damaged (e.g. bent cooler mesh). Cover electrical/electronic parts and connections to clean the engine (e.g. control units, generator, solenoid valves etc.). Do not aim the water/steam jet directly at them. Allow engine to warm up.
OBJ_DOKU-16314-001.fm Seite 39 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works Aspiration system 6 Regulations for working on the intake system 1 Do not work when the engine is running! 5 2 Pay attention to utmost cleanliness when 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 1 4 3 Never clean the safety cartridge (4).
OBJ_DOKU-16314-001.fm Seite 40 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works Aspiration system 6 Maintenance indicators for dry air filter z The dry air filter is maintained according to a maintenance switch or maintenance indicator. z Maintenance is necessary when: – the yellow warning light of the maintenance switch lights up when the engine is running. – the red field (1) of the maintenance indicator is fully visible.
OBJ_DOKU-16314-001.fm Seite 41 Donnerstag, 24. Juli 2008 11:18 11 Aspiration system Servicing and maintenance works 6 sel fuel. z Visually inspect the rubber gaskets (5), (6) and renew if damaged. z Fill the lubricating oil pan (3) of the oil bath air filter with engine oil up to the mark (arrow). z Mount the lubricating oil pan (3) with filter insert (4) on the filter housing (1) and close the quick release clamps (2). z Check for leaks after starting the engine.
OBJ_DOKU-16314-001.fm Seite 42 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works External exhaust return 6 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.
OBJ_DOKU-16314-001.fm Seite 43 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works Belt drives 6 Checking the belt drive Only carry out work on the belt drive with the engine at a standstill! Always change both belts in sets in case of wear on the double belts or damage to one V-belt. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. z z z z Check the whole belt drive visually for damage. Renew damaged parts.
OBJ_DOKU-16314-001.fm Seite 44 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works 6 Belt drives z Installing fan V-belt ( 58). z Checking the belt tension ( 43). 5 Tighten belt Generator z Loosen screws (1), (2) and (3) slightly. z Push the generator (4) outwards in the direction of the arrow until you get the correct V-belt tension. z Retighten the screw (1), (2) and (3).
OBJ_DOKU-16314-001.fm Seite 45 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works Belt drives 6 Tighten belt z z z z Loosen screw (1). Remove the outer half of the belt pulley (2). Remove belt and fit new one. Checking the belt tension ( 43). © 2008 Tighten belt Air compressor with double V-belt z In order to re-tension, remove one or more of the intermediate discs (3) on the inside. Place the removed discs on the removed belt pulley half (2) on the outside. z Re-tighten screw (1).
OBJ_DOKU-16314-001.fm Seite 46 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works 6 Setting work Valve clearance setting schematic Valve overlap: Exhaust valve is not yet closed, inlet valve begins to open.
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OBJ_DOKU-16314-001.fm Seite 48 Donnerstag, 24. Juli 2008 11:18 11 Servicing and maintenance works 6 Regulations for working on the electrical system Do not touch the voltage conducting parts, faulty warning lamps should be immediately replaced. Pay attention to correct polarity of the connections. Cover electrical/electronic parts and connections to clean the engine (e.g. control units, generator, solenoid valves etc.). Do not aim the water/steam jet directly at them. Allow engine to warm up.
OBJ_DOKU-16314-001.fm Seite 49 Donnerstag, 24. Juli 2008 11:18 11 Electrical system Servicing and maintenance works 6 Removing the battery z Always disconnect the minus pole first when removing 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 specifications! z Screw in caps.
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OBJ_DOKU-16314-001.fm Seite 51 Donnerstag, 24. Juli 2008 11:18 11 Faults Fault table Faults Causes Measures Engine starts, but runs irregularly or fails Incorrect valve clearance Check valve clearance and set if necessary Engine becomes excessively hot. Temperature warning system activates © 2008 Cold starting device Check/replace Lube oil level too high Check lube oil level, if necessary drain off.
OBJ_DOKU-16314-001.fm Seite 52 Donnerstag, 24. Juli 2008 11:18 11 Faults 7 Fault table Faults Causes Measures Engine output is deficient Lube oil level too high Check lube oil level, if necessary drain off.
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OBJ_DOKU-16314-001.fm Seite 55 Donnerstag, 24. Juli 2008 11:18 11 Transport and storage Transport 8 1 2 Suspension equipment The transport devices mounted on this engine are adapted to the engine weight. If the engine is transported with add-on components, the transport devices must be designed accordingly. z Always use proper suspension equipment when transporting the engine. z The suspension device (1) must be adjustable for the engine's centre of gravity.
OBJ_DOKU-16314-001.fm Seite 56 Donnerstag, 24. Juli 2008 11:18 11 Transport and storage 8 General Engines contain the following types of corrosion protection: z Interior corrosion protection z Exterior corrosion protection Your DEUTZ partner has the right corrosion protection agent for your needs. The following measures for corrosion protection after taking the engine out of operation meet the requirements for 12 months corrosion protection.
OBJ_DOKU-16314-001.fm Seite 57 Donnerstag, 24. Juli 2008 11:18 11 Transport and storage Engine corrosion protection Bare exterior surfaces and parts Removal of corrosion protection z Coat or spray all bare exterior parts and surfaces (e.g. flywheel, flange faces) with corrosion protection agent. z The corrosion protection must be removed from the corrosion protected engine before starting. z The packaging and all covers over the closed openings must be removed.
OBJ_DOKU-16314-001.fm Seite 58 Donnerstag, 24. Juli 2008 11:18 11 Technical data 9 Engine and setting data General technical data Engine type Dimension D 914 L03 D 914 L04 D 914 L05 D 914 L06 Working principle Charging Suction motor Type of cooling Four-stroke turbocharged diesel engine air-cooled Cylinder arrangement in series No.
OBJ_DOKU-16314-001.fm Seite 59 Donnerstag, 24. Juli 2008 11:18 11 Technical data Engine and setting 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 and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
OBJ_DOKU-16314-001.fm Seite 60 Donnerstag, 24. Juli 2008 11:18 11 Technical data 9 Tools Tool ordering The special tools described in this chapter can be ordered from: WILBÄR - Wilhelm Bäcker GmbH & Co. KG Taubenstrasse 5 42857 Remscheid Germany Phone: +49 (0) 2191 9339-0 Fax: +49 (0) 2191 9339-200 E-mail: info@wilbaer.de www.deutz-tools.com V-belt tension measuring instrument Order number: 8115 Measuring instrument for checking the specified Vbelt tensions.
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OBJ_DOKU-16314-001.fm Seite 64 Donnerstag, 24. Juli 2008 11:18 11 DEUTZ AG 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 © 07/2008 All rights reserved Order number: The engine company.
