Deutx 914 Operation and Maintenance Manual Abby
Deutx 914 Operation and Maintenance Manual Abby
Deutx 914 Operation and Maintenance Manual Abby
manual
DEUTZ
Engine
914
03120382
33522910601_ 0_1
01/01/2002
Operation Manual
914
DEUTZ
Safety g u id elin es/A ccid en t prevention
914
0312 0382 en
Engine Serial Number
A
Please enter the engine serial number here.
This num ber should be quoted when inquiring
about Custom er Service, Repairs or Spare
Parts (see Section 2.1).
DEUTZ
Foreword
Dear Customer,
Sincerely,
DEUTZ AG
Index
are the product of many years of research and Sound care and maintenance practices w ill ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or fo r
w ith stringent quality standards, guarantee their placed on it. Recommended service intervals m ust spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance w ork carry out repairs quickly and professionally, using
consum ption. carried out conscientiously. only genuine spare parts.
It goes w ithout saying that DEUTZ Diesel Engines Special care should be taken under abnorm ally Original parts from DEUTZ AG are always produced
meet the highest standards fo r environm ental demanding operating conditions. in accordance w ith state-of-the-art technology.
protection. Please turn to the end of this manual fo r further
service inform ation.
Shut the engine down before carrying out mainte This sym bol is used fo r all safety
A
nance or repair work. Ensure that the engine cannot w a rn in g s . Please fo llo w them Diesel engine exhaust and some of its consti
be accidentally started. Risk of accidents. carefully. The attention of operating tuents are known to the State of California to
When the w o rk is complete, be sure to refit any personnel should be drawn to these cause cancer, birth defects, and other repro
panels and guards that may have been removed. safety instructions. General safety ductive harm.
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law m ust also be observed.
the engine in an enclosed space or underground.
Asbestos
2
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Plan
2.5 Engine cooling
Engine Description 2.1 Model
The model A, the engine serial number B and The rating plate C is attached to the crankcase. The engine serial number is stamped on the
the performance data are stamped on the Depending on the model, a second rating crankcase (arrow) as well as the rating
rating plate. plate may be affixed to the air duct hood. plate.
The model and engine serial number must be
given when ordering parts.
2.1 Model Engine Description
C ylin d e rs are num bered co n se cu tive ly, Engines with direct injection are used if high
beginning at the flywheel. output is required.
Engine Description 2.2 Engine Illustrations
1 Cooling fan
2 V-Belts (fan)
3 Optional attachment of hydraulic pumps
4 V-belt washer
5 Tension roller
6 Oil pan
7 Oil drain screw
8 Oil filler neck
9 Oil dipstick
10 Fuel change filter
11 Solenoid (shut-off magnet)
12 Lube oil filter
13 Full-stop depending on charge air pressure
14 Air duct hood
15 Cylinder head cover
2.2 Engine Illustrations Engine Description
16 Air-intake line
17 Shielding plate
18 Flywheel
19 Oil drain screw
20 Starter
21 Exhaust turbocharger manifold
© 34 576 (i
Engine Description 2.2 Engine Illustrations
1 Cooling fan
2 V-Belts (fan)
3 Optional attachment of hydraulic pumps
4 V-belt washer
5 Tension roller
6 Oil filler neck
7 Fuel pump
8 Fuel change filter
9 Injection pump
10 Oil dipstick
11 Shut-off magnet
12 SAE housing
13 Lube oil filter
14 Air duct hood
15 Cylinder head cove
© 34 597 (i
2.2 Engine Illustrations Engine Description
16 Date plate
17 Flywheel
18 Oil drain screw
19 Starter
20 Oil pan
21 Air-intake manifold
22 Crankcase ventilation
© 34 576 0
2.2 Engine Illustrations Engine Description
1 Cooling fan
2 V-Belts (fan)
3 V-belt pulley on crankshaft
4 Tension roller
5 Oil filler neck
6 Oil drain screw
7 Fuel pump with fuel precleaning
8 Fuel filter cartridge
9 Injection pump
10 Shut-off lifting magnet
11 Oil dipstick
12 LDA
13 Lube oil filter cartridge
14 Engine oil cooler
15 Air duct hood
16 Cylinder head cover
© 34577 0
2.2 Engine Illustrations Engine Description
17 Intercooler
18 Air-intake line
19 Exhaust manifold line
20 Date plate
21 Flywheel
22 Starter
23 Oil drain screw
24 Turbocharger
25 Air-intake manifold to exhaust turbocharger
26 Alternator
© 34 578 I)
Engine Description 2.2 Engine Illustrations
1 Cooling fan
2 V-Belts (fan)
3 V-belt pulley on crankshaft
4 Tension roller
5 Oil filler neck
6 Oil drain screw
7 Fuel pump with fuel precleaning
8 Fuel filter cartridge
9 Injection pump
10 Shut-off lifting magnet
11 Oil dipstick
12 LDA
13 Lube oil filter cartridge
14 Engine oil cooler
15 Air duct hood
16 Cylinder head cover
2001
©
2.2 Engine Illustrations Engine Description
17 Intercooler
18 Flywheel
19 Starter
20 Oil drain screw
21 Alternator
22 Exhaust connection supports
23 Exhaust manifold line
24 Air-intake manifold to exhaust turbocharger
Engine Description 2.3 Lube Oil Circuit Schematic
1 Oil pan
2 Intake manifold
3 Oil pump
4 Oil pressure regulating valve
5 Pressure oil line
6 Short-circuit line or alternative
7 Ribbed tube coil or alternative
8 Block oil cooler
9 Lube oil filter
10 Safety valve
11 Main oil channel
12 Crankshaft bearing
13 Con-rod bearing
14 Camshaft bearing
15 Tappet
16 Pushrod (hollow, for oil intake to lubricate
rocker arm)
17 Rocker arm bearings
18 Rocker arm lubrication
19 Pushrod protective tube
20 Throttle bore (to lubricate cogwheels)
21 Spray nozzle for piston cooling
22 Connection for oil pressure gauge
23 Oil pressure gauge
24 Injection pump connected to lube oil circuit
schematic
25 Connection option for oil heater **
** here the filter carrier must be exchanged.
Please contact DEUTZ Service when
changing-over.
© 34 581 0
2.3 Lube Oil Circuit Schematic Engine Description
1 Oil pan
7 6 21 17 16 2
3
Intake line
Oil pump
4 Oil pressure regulating valve
5 Pressure oil line
6 Connection line to oil cooler
7 Block oil cooler
8 Lube oil filter
9 Safety valve
10 Main oil channel
11 Crankshaft bearing
12 Con-rod bearing
13 Camshaft bearing
14 Tappet (with impulse lubrication of rocker
arm)
15 Pushrod (hollow, for oil intake to lubricate
rocker arm)
16 Rocker arm bearings
17 Rocker arm lubrication
18 Pushrod protective tube (oil return from the
cylinder head to crankcase)
19 Throttle bore (to lubricate cogwheels)
20 Spray nozzle for piston cooling
21 Oil line to lubricate turbocharger
22 Oil return line from exhaust turbocharger
to crankcase
23 Oil pressure gauge
24 Bypass lube oil fine filter
25 Connection option for oil heater **
26 Injection pump connected to lube oil circuit
schematic
** here the filter carrier must be exchanged.
Please contact DEUTZ Service when
changing-over.
|© |35 583 j)
Engine Description 2.4 Fuel System Schematic
1 Fuel tank
2 Fuel line from tank to fuel pump
3 Fuel pump
4 Fuel change filter
5 Injection pump
6 Injection line
7 Injection valve
8 Fuel overflow pipe
3.1 Commissioning
3.2 Starting
3.3 Monitoring Operation
3.4 Shutting off
3.5 Operating Conditions
Engine Operation 3.1 Commissioning
3.1.1 Pour in Engine Oil 3.1.2 Oil Bath Air Filter with 3.1.3 Pour in Fuel
Engine Oil
OIL
hB I© 135 201 lo
As a rule, engines are delivered without oil. Fill oil cup 1 of the oil bath air cleaner with oil Use only commercial-grade diesel fuel. For
Pour lube oil into the oil filler neck (arrow). up to the arrow. fuel grade, see 4.2. Use summer or winter-
For oil grade and viscosity, see 4.1. For oil grade and viscosity, see 4.1. gradefuel, depending on the ambienttempera-
ture.
Do
Do not
not fill the precleaner
fill the precleaner dust
dust Never fill the tank while the en-
A
collector (if— fitted) with oil. \ gine is running.
Ensure cleanliness!
Do not spill fuel!
Z-La
3.1 Commissioning Engine Operation
3.1.4 Bleed
Model:
“Motorpal” model
3.1.5 Other Preparations 3.1.6 Additional maintenance 3.1.7 Change-over switch for oil
work heater
• Checking battery and cable connectors After 50-150 operating hours, the following
see 6.7.1 maintenance work is to be carried out:
A
For e n g in e s w ith o u t an oil
heater, the change-over switch
f \ should always be fixed to Pos.
* \ 2: closed.
Engine Operation 3.2 Starting
2001
bustion in the cylinder are subjected to a
• Fuel particles not burnt during initial com second stage com bustion process for
bustion in the cylinder are subjected to a approx. 3 minutes in order to let the exhaust _
second stage com bustion process for gases become more transparent in the ^
approx. 3 minutes in order to let the exhaust start-up phase.
gases become more transparent in the
start-uD Dhase.
Engine Operation 3.3 Monitoring Operation
Oil pressure pilot lights Oil Pressure Indicator Oil Pressure Gauge
© 25 752 1
• The oil pressure pilot light comes on with • The pointer must remain in the green sector • The pointer of the oil pressure gauge must
operating voltage on and engine off. over the entire operating range. display the minimum oil pressure (see 9.1).
• The oil pressure pilot light should go out
when the engine is running.
3.3 Monitoring Operation Engine Operation
• The engine tem perature gauge pointer • When the V-belt is torn, the pressure pin 1
should remain in the green sector most of of electrical switch is actuated by the ten
the time. It should rarely enter the yellow- sion rollerand an audio signal oralightsignal
green sector. If the pointer enters the or is emitted.
ange sector, the engine is overheating. Turn Switch off the engine immediately to avoid
off and establish the cause from the Fault overheating.
Table (see 7.1).
Engine Operation 3.4 Shutting Off
• Move speed adjustment lever 1 to low idle. • Turn key counterclockwise (to position 0)
• Move shut-off lever 2 in the direction of “0” and remove. The pilot lights will go out.
until the engine comes to a stop. The charge
pilot light and the oil pressure pilot light will
come on when the engine stops.
• Turn key counterclockwise (to position 0)
and remove. The pilot lights will go out.
• Concerning electrical shut-off or power
failure, the shut-off lever 2 is disabled by the
solenoids until the engine stops. The charge
pilot light and the oil pressure pilot light
illuminate when the engine stops.
• Turn key counterclockwise (to position 0) If possible, do not suddenly switch off the
and remove. The pilot lights will go out. engine when under full load.
3.5 Operating Conditions Engine Operation
Lube oils are differentiated according to their As the viscosity of the lube oil is dependent 25
performance and quality class. In common on temperature, the choice of SAE grade
use are specifications named after the API should be governed by the ambient tem pera
(American Petroleum Institute) and ACEA ture prevailing at the engine operating site. ■TfV
(European Engine Oil Sequences). Optimum operating behaviourw ill be attained
if you take the accompanying oil viscosity
Approved API Oils: diagram as a guide. 1D
At least: CF-4 Should the temperature fall tem porarily be 1
low the limits of SAE grade selected, cold 10
Approved ACEA Oils: starting may be affected but the engine will 5■ s
At least: E1-96 not be damaged. In order to keep wear to a
5 s
minimum, do not exceed application limits for
It is recommended to operate the engines extended periods of time. u;
with Deutz Oil TLX10W -40FE Europe. If Oil changes dictated by the seasons can be
this is not available, use the appropriate oil as avoided by using multi-grade lube oils. Multi F■s" s*1
described above. grade oils, particularly light-flowing oils, also J
reduce fuel consumption. -5 a”
Ss ■
;
-10 h
:i \ i *
u J J
1I :I i
-15
'in 1 1r
“ 'IrZ
xlD
1i l r
-30
* Oil change intervals, see 6.1.1 f 1 Only with engine preheating
Oil capacities, see 9.1 |©| 30 29810
4.1 Lube Oil Operating Media
Use com mercially available diesel fuel with W axing may occur at low tem peratures, +32 0
less than 0.5 % sulphur content. If the sulphur clogging the fuel system and reducing engine
content is higher, oil change intervals should efficiency. If the ambient temperature is less +23 -5
be reduced (see 6.1.1). than 0 °C, winter-grade fuel (suitable down
to -20 °C) should be used. (This fuel is +14 - 10
The following fuel specifications / standards available from the filling stations well in ad
are approved: (also see TR 0199-3002) vance of the cold months). + 5 - 15
• Diesel fuel
-D IN EN 590 • Kerosene must be added at temperatures - 4 -20
- BS 2869: A1 and A2 below -20 °C. The relevant percentages
(with A2, take note of the sulphur content) are given in the adjacent diagram. -13 -25
- ASTM D 975-88; 1-D and 2-D • Special diesel fuels may be used in arctic
- NATO Code F-54 and F-75 climatic zones up to -44 °C. -22 - 30
-IS O 8217D M X
- ISO 8217 DMA If sum mer-grade diesel fuel must be used at f f 0 10 20 30 40 50 60%
temperatures below 0 °C, up to 60% kero °F °C B -------------►
A
diesel fuel should never be mixed
A
Exhaust emission values which may be
determined in the case of type approval with petrol (normal or super appropriate amount of kerosene
tests always refer to the reference fuel petrol) first, then add the diesel fuel.
prescribed by the authorities for the type
approval test.
Routine Maintenance
5
5.1 Maintenance Plan
5.2 Maintenance Schedules
5.3 Maintenance Work Completed
Routine Maintenance 5.1 Maintenance Schedule
0312 0360 [E
A
out any maintenance work.
2001
©
0132 0359 BD
Routine Maintenance 5.3 Maintenance Work Completed
50-150* —
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
* following commissioning of new and overhauled engines.
Duly completed maintenance jobs can be recorded and signed off in the above chart.
5.3 Maintenance Work Completed Routine Maintenance
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
Duly completed maintenance jobs can be recorded and signed off in the above chart.
Routine Maintenance 5.3 Maintenance Work Completed
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7875 8000
8125 8250
8375 8500
8625 8750
Duly completed m aintenance jobs can be recorded and signed off in the above chart.
5.3 Maintenance Work Completed Routine Maintenance
Service and Maintenance
• If the engine runs fewer hours during the N o rm al oil re q u ire m e n t, e.g.: 500 250 500
year than stated in the table, the oil should
be changed at least once a year.
Road vehicles, cranes, construction machines,
ships electrical m odules, pumps, railway
• The table refers to the following conditions: vehicles.
- F o r diesel fuel: sulphur content max.
0.5% by weight. High oil re q u ire m e n t, e.g.: 250 125 250
-C o n tin u o u s ambient temperatures down
to -10 °C (+14 °F).
Combines, em ergency pumps, underground mining
units, sweeping m achines, w inter service
• If the sulphur content is > 0.5 to 1% or the vehicles, em ergency pow er units.
continuous ambient temperature below
the oil change intervals must be halved.
Vehicle engines Lube oil change intervals in km
Naturally aspirated
• In the case of fuels with a sulphur content T u rb o c h a rg e d e n g in e s
engines
higher than 1 %, contact your Service
representative.
A P I s p e c ific a tio n CF-4/CH-4/ CG-4 CF-4 C G -4 /C H -4
Lub e oil q u a lity
A C E A -s p e zific a tio n E1+E2-96 E1+E2-96 E3-96/E4-98
Change the oil with the engine off but still 1 30.000 -100.000 40 20 000 10 000 20 000
warm (lube oil temperature approx. 80 °C).
III < 10 0 000 60 30 000 15 000 30 000
6.1 Lubrication System Service and Maintenance
6.1.2 Checking Oil Level /
Changing Engine Oil
6.1.2.1 Checking Oil Level 6.1.2.2 Changing Engine Oil
+ 80°C
+176°F
O IL 26 022 0
• Ensure that the engine or vehicle is on a level • Run the engine warm • Place an oil tray beneath the engine
surface. • Ensure that the engine or vehicle is on a level • Unscrew drain plug.
• - W a r m engine surface • Drain oil.
• Switch off engine, wait 5 minutes and check the - Lube oil tem perature approx. 80°C. • Fit oil drain plug with new gasket and tighten
oil level • Switch off the engine. firm ly (for torque, see 9.2).
• - C o l d engine • Fill w ith lube oil
Check the oil level - For grade/viscosity, see 4.1.
• Remove the dipstick - For quantity, see 9.1.
• Wipe off w ith a non-fibrous, clean cloth. • Check oil level, see 6.1.2.1
• Insert up to the stop and pull out again.
• Check oil level, if required top up to the
“M A X” level
- If the oil level is ju st above the “M IN ” mark,
it should be topped up. Be careful when draining hot oil - danger
The oil level m ust not drop below the “M IN ” mark. A of scalds! Do not let used oil run into
the soil but catch it in a container ready
fo r proper disposal.
Service and Maintenance 6.1 Lubrication System
r j
© 25 882 0
• Undo the lube oil filter cartridge using a • Clean any dirt from the filter carrier sealing • Tighten the lube oil filter cartridge with
commercial tool and spin off. surfa ce. another half-turn.
• Catch any escaping oil. • Lightly oil the rubber gasket of the new lube • Check the oil level, see 6.1.2
oil filter cartridge.
• Check oil pressure, see 3.3.1.
• Manually screw in the new cartridge until
the gasket is flush. • Check lube oil filter cartridge seal for leaks.
A
Caution is required in the case
i \ of hot oil: Risk of scalding!
\ Please dispose of oil in an
' e n v iro n m e n ta lly -frie n d ly
manner!
6.1 Lubrication System Service and Maintenanceen
© 25 880 0
• Close the fuel shut-off valve. • Clean any dirt from the filter carrier sealing • Tighten the fuel filter cartridge with a final
surface. half-turn.
• Undo fuel filter cartridge with commercial
tool and spin off. • Apply light film of oil or diesel fuel to the • Open fuel shutoff valve.
ru b b e r g a ske t of the new fuel filte r
• Catch any escaping fuel. cartridge. • Check for leaks.
A
Keep naked flames away when The fuel system does not need to be
■X working on the fuel system. Do bled.
X not smoke!
6.2 Fuel System Service and Maintenance
A
working on the fuel system. Do
not smoke!
Service and Maintenance 6.3 Cooling System
• Serious contamination can occur, for ex 2000 Ships, electrical modules in enclosed areas, pumps
ample:
- On construction sites where there is a 10 0 0 Vehicles on paved roads
high level of air-borne dust. 500 Tractors, fork-lift trucks, drivable electric units.
- In harvesting application where there are
high concentrations of chaff and chopped 250 Vehicles on construction sites and unpaved roads,
straw in the vicinity of the machine.
construction machines compressors, underground
• Because applications vary, cleaning inter mining units
vals have to be determined from case to
case. The cleaning intervals given in the 125 Agricultural machines, tractors in harvesting application
table on the right can be used as a guide.
6.4 Combustion Air Filter Service and Maintenance
6.4.2 Emptying Cyclone Type 6.4.3 Clean Oil Bath Air Filter
Precleaner
886 o
• Undo wing nut 1 and remove cover 2. • Turn engine off and wait about 1 0 minutes • Clean filter housing 1 if very dirty.
• Remove collector bowl 3 from lower sec for the oil to drain from filter housing 1 . • Inspect and replace rubber gasket 5 and 6
tion 4 and empty. Clean leaves, straw and • Loosen quick fasteners 2 and remove oil if necessary.
other foreign matter from lower section of cup 3 with filter element 4; if necessary, • Fill oil cup with engine oil up to the mark
pre-cleaner. loosen filter elem ent with the aid of a (arrow) (for viscosity, see 4.1.2).
• Reposition collector bowl 3 onto lower screwdriver at the separating point. Do not • Refit oil cup and element to filter housing
section 4, fasten cover 2 in place by damage rubber gasket 5! and secure with snap clips.
tightening wing nut 1 . • Remove dirty oil and sludge. Clean oil cup.
• Clean filter element 4 in diesel fuel and
allow to drip-dry.
A
2001
Never fill collector bowl with oil. Replace Never clean filter with gasoline!
collector bowl if damaged. *A Dispose of old oil in accordance
© V with environmental regulations!
6.4 Combustion Air Filter Service and Maintenance
V
I f 1
© © 25 888 1
• Empty dust discharge valve 1 by pressing • Undo clip fasteners 1. • After five cleaner services (or after two
apart lips of discharge slot as indicated by • Take off hood 2 and remove cartridge 3. years at the latest), replace safety car
a rro w s . • Clean cartridge (replace at least once a tridge 4 (never clean).
• Clean discharge slot from time to time. year). To do so:
• Remove any caked dirt by pressing to • Clean cartridge 3. - Undo hex. nut 5 and remove cartridge 4.
gether the upper section of the valve. Blow out using dry compressed air (max. - Install new cartridge, insert and tighten
5 bar), (or in difficult cases, tap out, taking hex nut.
care not to damage the cartridge, or wash • Install cartridge 3, replace hood 2 and do up
according to m anufacturer’s instructions). clip fasteners 1 .
• Through regular removal and replacement,
the gaskets on the filter cartridge can
become damaged. Check paperfilter (light
showing through) and gaskets for dam
2001
Never clean filter cartridge with
A
age.
Replace if necessary. gasoline or hot fluids.
Service and Maintenance 6.5 Belt Drives
ca.3-
7mm
ca.10-
15mm
© 35 209
• Visually inspect entire V-belt for damage. Read off the value where the indicator • To replace the tension roller 1, press in
• Replace damaged V-belts. arm 1 intersects scale 5 (arrow). For wards with a commercial tool and remove
• After installing new belts, run engine for 15 settings, see 9.1. the V-belt.
minutes, then check belt tension. - If necessary, retension belt and measure
• To check the tension of the V-belt, use a again. • Position new ribbed V-belt.
tension gauge (see 9.3).
- Place indicator arm 1 into gauge.
- Position guide 3 on V-belt 2, midway
between the pulleys, with flange 3 on
bottom of gauge against the edge of belt.
- Push slowly on the black pad 4 at right
angles to V-belt 2 until the spring is heard
or felt to trigger.
- Carefully remove the gauge without Check, tension and change belts Retension V-belt after it has ran for 15 m in
A
altering the position of the indicator arm 1 . only with the engine off. Rein utes.
stall V-belt guard
6.5 Belt Drives Service and Maintenance
6.5.3 Alternator belts 6.5.4 Change alternator belt 6.5.5 Check warning system
• Loosen bolts 1, 2 and 3 slightly. • Remove fan belt, as shown in 6.5.2. • W hen the V-belt is torn, the pressure pin 1
• Slacken off bolts 1, 2 and 3. of electrical switch is actuated by the
• Press alternator 4 outwards in direction • Swing alternator inwards in the direction tension roller and an audio signal or a light
of arrow A until correct belt tension is of arrow B. signal is emitted.
achieved. • Remove and replace belt. • Check the function by pressing pin 1.
• Swing alternator 4 outwards in direction
• Retighten bolts 1, 2 and 3. of arrow A until correct belt tension is
achieved.
• Retighten bolts 1, 2 and 3.
• Fit fan belt.
Check, tension and change belts Retension V-belt after it has ran for 15 min- Only check function when the
6.5.6 Tensioning
or changing V-belts
HH CM
/ CO
B CM
-10 CO
• Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in
black on schematic.
in
CO
CM
- (
2001
© 26 055 1
©
Service and Maintenance 6.7 Accessories
6.7.1 Battery
6.7.1.1 Checking battery and 6.7.1.2 Check Electrolyte Level 6.7.1.3 Check electrolyte
cable connectors density
• Keep battery clean and dry. • Remove sealing caps 1. • Measure the electrolyte density of indi
• Undo dirty clamps. • If testers 2 are present: Electrolyte level vidual cells with a commercial hydrometer.
• Clean terminal posts (+ and -) and clamps should reach the base of these.
of the battery, and grease with acid-free • W ithout testers: The hydrometer reading (see table on fol
and acid-resistant grease. The electrolyte level should be 10-15 mm lowing page) indicates the battery’s state
• When reassembling, ensure that clamps above the top of the plates. of charge.
make good contact. Tighten clamp bolts • If necessary, top up with distilled water. During measurement, the temperature of
hand-tight. • Screw sealing caps back in. the electrolyte should preferably be +20 °C.
6.7 Accessories Service and Maintenance
A
tery are explosive! Keep sparks
and naked flam es away from
the battery! Do not allow battery
acid to come into contact with
skin or clothing! W ear protective goggles! Do
not rest tools on the battery!
Service and Maintenance 6.7 Accessories
a -----
6 .8. Engine Cleaning Service and Maintenance
Using compressed air Using cold-cleaning compound Using high pressure device
W “ ~
7
© 35 206 0
• Switch off the engine. • Switch off the engine. • Switch off the engine.
• Remove engine covers and cooling air • Remove engine covers and cooling air • Remove engine covers and cooling air
hood. Replace them after cleaning and hood. Replace them after cleaning and hood. Replace them after cleaning and
before the test run. before the test run. before the test run.
• Cover electrical / electronic components / • Cover electrical / electronic components / • Cover electrical / electronic components /
connections (e.g. generator, starter, gov connections (e.g. generator, starter, gov connections (e.g. generator, starter, gov
ernor, solenoid). ernor, solenoid). ernor, solenoid).
• Blow air through the engine, taking particu • Spray the engine with the commercial cold- • Clean the engine with a steam jet (max.
lar care not to damage the cooler and cleaning compound and allow to react for spray pressure of 60 bar, max. steam
cooling fins (begin to blow through air from approx. 1 0 mins. temperature of 90-C).
the exhaust side). • Spray clean the engine with a strong water • Allow the engine to run warm so that the
Remove the dirt which has blown into the jet, repeat if necessary. remaining water evaporates.
interior space. • Allow the engine to run warm so that the
remaining water evaporates. Clean the engine only when the
engine is switched off!
Service and Maintenance 6.9 Additional Maintenance Work
— +
I?
© 25 746 2
• Cylinder head cover 1 • With perfect function, the air-intake pipe 4 Test step 1
• Air intake manifold 2 warms up near the glow lamps 2 from pre • Place speed control lever or shut-off lever
• Connection sockets glowing. in “stop” position.
• Exhaust line 3 • Insert key
• Engine mounts 4 -Position 0 = no operating voltage
• Key clockwise
-Position 1 = operating voltage
-Pilot lights illuminate
• Push key in and turn further clockwise
against spring pressure.
-Position 2 = Preheat, hold for approx. 1
minute.
-Preheat lamp comes on
• Otherwise the glow lamps are defective or
the transmission line interrupted.
6.9 Additional Maintenance Work Service and Maintenance
2001
Keep away from moving parts!
A
Collect any escaping fuel and
dispose of this in an environ- ©
m entally-friendly manner.
Faults, Causes and Remedies
Faults Measures
Engine does not start or is difficult to start Check P
Engine starts, but runs irregularly or fails Adjust E
Engine overheats, temperature warning system responds Replace W
Engine output is deficient Clean R
Engine does not run on all cylinders Top up A
Engine oil pressure is non-existent or excessively low Reduce S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
• Not declutched (where possible) Engine Operation P
• • Below starting limit temperature P
• • Engine shut-off lever still in stop position (shut-off magnet defective) P
• • Oil level too low A
• • • • Oil level too high S
• • • Excessive inclination of engine P/E
• • Engine runs mainly with low load P
• • • • • • Air cleaner clogged / turbocharger defective Combustion air W
• • • Air cleaner service switch / indicator defective P/W
• CPD defective (connection line leaks) only with turbocharged engines P/W
• • • Exhaust gas backpressure too high P
• • Charge air line leaking, only with supercharged engines P/E
• Cooling fins soiled Cooling system P/R
• • • Intercooler soiled P/R
• • Oil cooler soiled on the air and/or the oil side P/R
• Cooling fan or exhaust tension defective, torn or loose V-belt P/W
• Cooling air temperature rise / heating short circuit P
• Cooling air guide loose, torn or missing P
7.1 Fault Table Faults, Causes and Remedies
Faults Measures
Engine does not start or is difficult to start Check P
Engine starts, but runs irregularly or fails Adjust E
Engine overheats, temperature warning system responds Replace W
Engine output is deficient Clean R
Engine does not run on all cylinders Top up A
Engine oil pressure is non-existent or excessively low Reduce S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
• Battery defective or discharged Electrics P
• Cable connections, starter, electrical circuit loose or oxidised P
• Starter defective or pinion does not engage P
• Oil pressure switch / gauge defective P/W
• • Incorrect valve clearance Engine P/E
• • • • Injection line leaks P/R
• Ventilation line blocked P/R
• • • Glow plugs P/W
• • Injection valve defective P/W
• • • • Air in the fuel system P/W
• • • • Fuel filter / fuel pre-cleaner soiled P/R/W
• • Oil filter defective W
• • • Incorrect engine lube oil SAE class or quality W
• • • • • • Compression too low P
• Oil in combustion chamber P/R
Engine Preservation
8
8.1 Preservation
Engine Preservation 8.1 Preservation
8.1 Preservation
8.1.1 Preserve engine 8.1.2 Remove engine
preservation
If the engine is to remain idle for an extended • Clean engine (with cold cleansing agent if • Remove anti-corrosion agent from grooves
period of time, it is necessary to take protec preferred) using high pressure equipment in V-belt pulleys.
tive measures to prevent the formation of (see 6 .8 . 1 ).
corrosion. The preservative measures de • Run engine until warm, then turn off. • Install V-belt, retension after brief opera
scribed here will protect the engine for up to • Drain engine oil, (see 6.1.2), and fill with tion if necessary (see 6.5).
approx. 6 months. The procedure will have to anti-corrosion oil.
be r ev er se d be fo re the e n g in e is • If necessary, clean oil bath cleaner (see • Remove covers from intake port and ex
recommissioned 6.4.3), and fill with anti-corrosion oil. haust ports.
• Drain fuel tank.
• Anti-corrosion oils to specification: • Make up a mixture of 90 % diesel fuel and • Commission engine.
- MIL-L 21260B 1 0 % anti-corrosion oil, and refill fuel tank.
- TL 9150-037/2 • Allow the engine to run for approx. 10 mins.
- Nato Code C 640 / 642 • Switch off the engine.
• Turn engine over manually several times to
• Recommended cleaning agent to remove preserve the cylinders and combustion
preservatives: chamber.
- Petroleum benzine (hazardous materials W hen turning over with starter, set shut-
class A3) off lever to stop position.
• Remove V-belts and store wrapped, dry
and recumbent.
• Spray grooves on V-belt pulleys with anti
corrosion spray.
• Close off intake ports and exhaust ports,
possibly with plugs.
Technical Specification
9
9.1 Engine Specifications and Settings
9.2 Screw Tightening Torques
9.3 Tools
Technical Specification 9.1 Engine Specifications and Settings
WILBAR
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Service
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