Service Manual
Table Of Contents
- Frontpage
- Operation Manual
- This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for...
- This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for...
- This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for...
- This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for...
- Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the man...
- When the engine is running there is a danger of injury caused by:
- - rotating / hot parts
- - in engines with external ignition (high electrical voltage), avoid touching at all costs!
- Unauthorised modifications to the engine exclude manufacturer liability for resulting damages.
- Equally, manipulations to the injection and control system can affect the engine's performance and the exhaust characteristics. Compliance with legal environmental regulations will no longer be guaranteed in this case.
- Do not modify, obstruct the cooling air flow area to the fan, unhindered cooling air supply must be guaranteed.
- 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.
- Do not work on the fuel system when the engine is running -
- - Go to the workshop ilmmediately in case of leaks.
- - Make sure the engine is not started accidentally during repairs when working on the fuel system -
- This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for...
- This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for...
- Danger
- Caution
- Operation Manual TCD 2015
- Operation Manual TCD 2015
- Foreword
- Foreword
- Foreword
- Dear customer,
- Congratulations on your purchase of this DEUTZ engine. The DEUTZ air/liquid-cooled engines are developed for a broad spectrum of applications. A wide range of variants ensures that the respective requirements are met.
- The engine is equipped according to the installation case you have specified, i.e. not all the parts described in this instruction manual are installed in your engine.
- We have done our best to highlight the differences so that you can easily find the operating and maintenance instructions relevant to your engine.
- Please make sure that this instruction manual is available to everyone involved in the operation, maintenance and repair of the engine and that they have understood the contents.
- We will be glad to answer any inquiries you may have.
- Your
- Engine number
- Please enter the engine number here.
- Note
- Foreword
- Order number
- Foreword
- Operation Manual TCD 2015
- General
- General
- DEUTZ diesel engines
- Safety precautions when the engine is running
- Safety precautions when the engine is running
- Only carry out maintenance work or repairs with the engine switched off. Ensure that the engine cannot be started unintentionally - danger of accidents!
- Re-install any removed protective equipment upon completion of the work.
- Observe industrial safety regulations when operating the engine in enclosed spaces or underground.
- When working on the running engine, work clothing must be close fitting.
- Only re-fuel with the engine switched off.
- Maintenance and care
- Maintenance and care
- are decisive for whether the engine satisfactorily meets the set demands. Compliance with the prescribed maintenance times and the careful execution of maintenance and care work are therefore essential.
- Difficult operating conditions deviating from normal operation must be observed especially.
- Original DEUTZ parts
- DEUTZ Xchange components
- Asbestos
- Service
- Service
- We want to preserve the high performance of our engines and with it the confidence and satisfaction of our customers. Therefore we are represented by a network of service branches world-wide.
- The name DEUTZ stands not only for an engine which is the result of sophisticated development work, DEUTZ Parts catalogue also s...
- Contact one of our responsible service representatives in case of operation malfunctions and spare parts inquiries. Our trained specialist personnel ensures fast, professional repairs using original parts in the event of damage.
- The DEUTZ homepage with references to product responsibilities and services always gives you an up-to-date overview of the DEUTZ...
- DEUTZ AG
- Deutz-Mülheimer Str. 147-149
- D-51057 Köln
- Phone: 0049-221-822-0
- Fax: 0049-221-822-5304
- Telex: 8812-0 khd d
- http://www.deutz.com
- General
- Engine description
- Engine description
- Engine type
- Engine diagram
- Engine diagram
- 1. Crankcase venting
- 1. Crankcase venting
- 1. Crankcase venting
- 2. Connection to coolant heat exchanger
- 3. Charge air duct
- 4. Coolant pump
- 5. Connection from coolant heat exchanger
- 6. Vibration damper / V-belt pulley
- 7. Lubricating oil tray
- 8. Generator
- 9. Oil drain plug
- 10. Fuel supply pump
- 11. Connection from charge air cooler left
- 12. Connection to charge air cooler
- 13. Cylinder head cover
- 14. Transport bracket
- 15. Exhaust manifold
- 16. Connection from air filter
- 17. Turbocharger
- 18. Connection to exhaust silencer
- 1. Crankcase venting
- 1. Crankcase venting
- 1. Crankcase venting
- 1. Crankcase venting
- 1. Crankcase venting
- 2. Connection to coolant heat exchanger
- 3. Spark plug
- 4. Connection from the charge air cooler
- 5. Connection to charge air cooler
- 6. Connection from coolant heat exchanger
- 7. Lubrricating oil filter cartridge
- 8. Coolant pump
- 9. Connection of separate lubricating oil tank
- 10. Connection to separate lubricating oil tank
- 11. Vibration damper / V-belt pulley
- 12. Generator
- 13. Engine rating plate (company plate)
- 14. Exhaust manifold
- 15. Connection to the EMR3 system
- 16. Connection to the MVS system
- 17. Connection from air filter
- 18. Cylinder head cover
- 19. Connection to exhaust silencer
- 20. Turbocharger
- 21. Charge air suction pipe
- 22. Transport device
- 1. Crankcase venting
- 1. Crankcase venting
- Lubricating oil circuit (graphic with old legend)
- Lubricating oil circuit (graphic with old legend)
- 1. Lubricating oil tray
- 1. Lubricating oil tray
- 1. Lubricating oil tray
- 2. Lubricating oil suction intake pipe
- 3. Lubricating oil pump
- 4. Pressure relief valve
- 5. Lubricating oil cooler
- 6. Lubricating oil filter
- 7. Main oil lines
- 8. Crankshaft bearing
- 9. Big end bearing
- 10. Camshaft bearing
- 11. Oil supply to the individual injection pumps
- 12. Injection pump with injector
- 13. Camshaft lubrication
- 14. Line to injection nozzle
- 15. Injection nozzle with pressurestat for piston cooling
- 16. Tappet with pulse lubrication of the rocker arm
- 17. Tappet rod, oil supply for rocker arm lubrication
- 18. Rocker arm
- 19. Oil return bore in the cylinder head to the crankcase
- 20. Oil pressure sensor / oil pressure switch
- 21. Oil line to the turbocharger
- 22. Turbocharger
- 23. Oil line to the crankshaft and camshaft, compressor / hydraulic pump
- 24. Compressor (optional)
- 25. Hydraulic pump (optional)
- 26. Pressurestat (adjustable)
- 27. Return line from the compressor / hydraulic pump to the crankcase
- 28. Return line from the turbocharger
- 1. Lubricating oil tray
- 1. Lubricating oil tray
- Fuel circuit
- Fuel circuit
- 1. Fuel tank
- 1. Fuel tank
- 2. min. distance 500 mm
- 3. Fuel supply line from tank
- 4. Hand pump for venting
- 5. Fuel prefilter (example)
- 6. Fuel supply pump
- 7. Fuel double filter
- 8. Fuel supply line to the injection pumps
- 9. Injection pump
- 10. High pressure pipe
- 11. Injector
- 12. Fuel supply to the injection pumps
- 13. Fuel return from the injection pumps
- 14 Pressurestat
- 15 Fuel return to the fuel tank
- 1. Fuel tank
- Coolant circuit
- Coolant circuit
- 1. Coolant pump
- 1. Coolant pump
- 2. Lubricating oil cooler
- 3. Coolant duct
- 4. Cylinder pipe /head cooling (number/arrangement of cylinders depends on series)
- 5. Compressor (optional)
- 6. Gear oil cooler (optional)
- 7. Auxiliary cooler (optional)
- 8. Temperature sensor
- 9. Thermostat
- 10. Compensation tank
- 11. Filler neck
- 12. Heat exchanger
- 13. Cab heating (optional)
- 1. Coolant pump
- Electrics
- Electrics
- 1. Oil pressure sensor
- 1. Oil pressure sensor
- 2. Fuel temperature sensor
- 3. Charge air temperature-pressure sensor
- 4. Engine control unit
- 5. Coolant temperature sensor
- 6. Oil level sensor
- 7. Central plug
- 8. Impulse transmitter crankshaft
- 9. Impulse transmitter camshaft
- 10. Energy supply
- 11. Multifunction displays
- 12. Outputs (configurable)
- 13. Inputs (configurable) (PWM/digital/analogue)
- 14. Speed pedal
- 15. Hand accelerator (optional)
- 16. Switch functions
- 17. Detachable key switch Start/Stop
- 18. Diagnostic button
- 19. Fault lamp with blink code
- 20. Diagnostic interface/CAN-bus
- 1. Oil pressure sensor
- Operation
- Operation
- Ambient conditions
- High ambient temperatures, high altitude
- Initial commissioning
- Preparations for initial commissioning (maintenance schedule E 10)
- Preparations for initial commissioning (maintenance schedule E 10)
- Removing engine corrosion protection
- Removing engine corrosion protection
- Removing engine corrosion protection
- Remove any transport devices.
- Check the battery and cable connections and mount if necessary.
- Check the belt tension
- Have the engine monitor or warning system checked by authorised personnel.
- Check the engine mounting.
- Check that all hose unions and clips are fit properly.
- The following additional work must be carried out on generally overhauled engines:
- Check the fuel prefilter and main filter and change if necessary
- Removing engine corrosion protection
- Fill engine oil
- Filling fuel
- Trial run
- Start process
- Starting
- Starting
- Engine is controlled electronically, e.g. with electronic engine control EMR3.
- Engine is controlled electronically, e.g. with electronic engine control EMR3.
- Separate engine from driven devices by disconnecting if possible.
- Do not run up the engine immediately to high idling speed / full load operation from cold.
- If the starter is connected by a relay on the EMR3,
- - the maximum starting time is limited by the EMR3.
- - the pause between two start attempts is specified by the EMR3.
- - If the touch start function is programmed, a short start command with the ignition key in position 2 suffices, or a start button if available.
- - The start is then continued automatically by the EMR3.
- - For special applications, the EMR3 can be programmed by a data record so that the control unit also carries out automatic further start attempts if the engine does not start.
- Starting
- Operation monitoring
- Operation monitoring
- Operation monitoring by EMR3
- Operation monitoring by EMR3
- The EMR3 system operates the engine condition and itself.
- The EMR3 system operates the engine condition and itself.
- The EMR3 system operates the engine condition and itself.
- The states are indicated by the fault lamp.
- Lamp test:
- - The fault lamp lights for about 2 s after ignition (ignition lock stage 1).
- Steady light:
- - There is an error in the system or a variable of the engine (temperature, pressure, etc.) is in the warning range.
- Fast flashing:
- - Attention, the engine is in danger and must be switched off.
- - The control unit switches the engine off automatically depending on the application.
- - To cool down the engine before switching off, the control unit can command forced engine operation at low idling speed or automatic switch off.
- - There may be a start lock after stopping the engine.
- - Additional control lamps, e.g. for oil pressure or oil temperature may be switched on if necessary.
- - With the override button, the power reduction can be bypassed, the automatic shutdown delayed or a start prevention bypassed to avoid critical situations. This overriding of the engine protection function is logged in the control unit.
- - The start lock is released by switching off the system with the ignition key for about 30 s.
- The EMR3 system operates the engine condition and itself.
- Display instrument
- Possible displays:
- Stop process
- Operation
- Consumables
- Consumables
- Lubricating oil
- Lubricating oil
- General
- General
- Modern diesel engines place very high demands on the lubricating oil to be used. The specific engine performances which have inc...
- Lubricating oils always consist of a basic oil and an additive package. The most important tasks of a lubricating oil (e.g. wear...
- In principle, all engine oils can be mixed. However, mixing of engine oils should be avoided because the worst properties of the mixture are always dominant.
- The
- The
- Synthetic lubricating oils are used increasingly and have advantages. These oils have a better temperature and oxidation stability as well as a relatively...
- Biodegradable lubricating oils may be used in DEUTZ engines if they meet the requirements of this operating manual.
- Quality
- Lubricating oils are classified by DEUTZ according to their performance capability and quality class ((DQC: Deutz Quality Class)...
- Lubricating oils according to other comparable specifications can be used as long as they meet DEUTZ requirements. In regions in which none of these qualities is available, please contact your DEUTZ partner responsible.
- The following lubricating oils are specified for the engines described in this operating manual.
- Lubricating oil change intervals
- Lubricating oil change intervals
- The intervals
- The intervals
- The intervals
- - Oil quality
- - Sulphur content in the fuel
- - Type of engine application
- The lubricating oil change interval must be halved, if at least one of the following conditions apply:
- - Ambient temperatures permanently below -10 ˚C (14 ˚F) or oil temperature below 60 ˚C (84 ˚F).
- - Sulphur content in the diesel fuel of
- - Operation with bio-diesel fuel.
- If the oil change intervals for vehicle engines are to be carried out according to operating hours, the oil change intervals for built-in engines apply.
- If the oil change intervals are not reached within a year, the oil change should be carried out at least 1x yearly.
- The intervals
- Viscosity
- The ambient temperature at the installation site or area of application of the engine is decisive for the choice of the right vi...
- The viscosity is classified according to SAE. Multipurpose oils should be used basically. Single purpose oils can be used in closed, heated rooms at temperatures >5 ˚C.
- Depending on the ambient temperature we recommend the following common viscosity classes:
- Fuel
- Fuel
- Permissible fuels
- The following fuel specifications are permissible:
- Commercially available diesel fuels with a sulphur content below 0.5%. If the sulphur content is higher, the lubricating oil change intervals must be reduced
- If other fuels are used which do not meet the requirements of the operating manual, the warranty will be voided.
- The certification measurements to satisfy the legal emission limits are performed with the test fuels defined by law. These corr...
- Winter operation with diesel fuel
- At low ambient temperatures paraffin discharges can lead to blockages in the fuel system and cause operating faults. Use winter ...
- Generally, sufficient resistance to cold can also be achieved by adding a flow ameliorant. For questions regarding this please contact your DEUTZ partner.
- Fuel
- Coolant
- Coolant
- General
- Water quality
- Water quality
- The right water quality is important for conditioning the coolant. Clear, clean water within the following analysis values must always be used:
- Information about the water quality is available from local waterworks. A test case can be requested from your DEUTZ partner under the order for checking your water quality (order no. 1213 0382).
- The water must be conditioned in case of deviations in the analysis values.
- pH value too low: Add diluted caustic soda or potassium soda. Small test mixtures are recommended.
- pH value too low: Add diluted caustic soda or potassium soda. Small test mixtures are recommended.
- Total hardness too high: Mix with softened water (pH-neutral condensate or water softened by ion exchanger)
- Total hardness or carbon hardness too low: Mix with harder water (harder water is usually available in the form or drinking water)
- Chloride and or sulphates too high: Mix with softened water (pH neutral condensate or water softened by ion exchanger)
- pH value too low: Add diluted caustic soda or potassium soda. Small test mixtures are recommended.
- Cooling system corrosion protection agent
- Cooling system corrosion protection agent
- The conditioning of the coolant for liquid- cooled DEUTZ compact engines is done by mixing an antifreeze with corrosion protection inhibitors on an ethylene-glycol base with the water.
- This cooling system protection agent is free from nitrites, amines and phosphates and adapted to the materials in our engines. Order from your DEUTZ partner.
- If the DEUTZ cooling system protection agent is not available, please contact your DEUTZ partner.
- The cooling system must be monitored regularly. This includes checking the concentration of the cooling system protection agent, as well as inspecting the coolant level.
- The inspection of the concentration of cooling system protection agent can be carried out with standard testing devices (e.g. refractometers).
- For temperatures below -35 ˚C, please have a word with your responsible DEUTZ partner.
- The use of other cooling system protection agents (e.g. chemical corrosion protection agents) is possible in exceptional cases. Consult your DEUTZ partner.
- Maintenance
- Care and maintenance work
- Care and maintenance work
- Lubricating oil system
- Lubricating oil system
- Regulations for working on the lubricating oil system
- Regulations for working on the lubricating oil system
- Checking the lubricating oil level
- Pull out the oil dipstick and wipe off with a lint-free, clean cloth.
- Changing the lubricating oil
- Run the engine warm (oil temperature > 80 ˚C).
- Run the engine warm (oil temperature > 80 ˚C).
- Run the engine warm (oil temperature > 80 ˚C).
- Position the engine or vehicle so as to be level.
- Switch off the engine.
- Place a collecting receptacle underneath the oil drain plug.
- Unscrew the oil drain plug, drain oil.
- Fit a new sealing ring to the oil drain plug, insert and tighten it (tightening torque 100 Nm).
- Fill in oil.
- - Quality/viscosity data
- - Filling volume
- Check engine lubricating oil level (see previous chapter)
- Run the engine warm (oil temperature > 80 ˚C).
- Changing the lubricating oil filter cartridge
- Remove the clips if an anti-rotation lock is fitted.
- Remove the clips if an anti-rotation lock is fitted.
- Loosen and unscrew filter cartridge with tool
- Collect draining oil.
- Clean the sealing surface of the filter support with a lint-free, clean cloth.
- Oil the gasket of the new DEUTZ original filter cartridge lightly.
- Screw on the new filter cartridge by hand and tighten a further half a turn.
- If necessary, fix the clips of the anti-rotation lock.
- Fuel system
- Fuel system
- Regulations for working on the fuel system
- Additional regulations for DEUTZ pump line nozzle
- Changing the fuel filter cartridge
- Changing the fuel filter cartridge
- Remove the clips if an anti-rotation lock is fitted.
- Remove the clips if an anti-rotation lock is fitted.
- Loosen and unscrew filter cartridge with tool
- Collect fuel which runs out.
- Clean the sealing surface of the filter support with a lint-free, clean cloth.
- Oil the gasket of the new DEUTZ original filter cartridge lightly.
- Screw on the new filter cartridge by hand and tighten a further half a turn.
- If necessary, fix the clips of the anti-rotation lock.
- Vent the fuel system, see
- 1. Filter support
- Cleaning fuel prefilter/
- Cleaning fuel prefilter/
- Close fuel stopcock.
- Close fuel stopcock.
- Close fuel stopcock.
- Position fuel collecting receptacle beneath fuel prefilter.
- Loosen the drain plg 5 and drain fuel/water.
- Unscrew the filter cartridge 2 and the water collecting receptacle 3 in anti-clockwise direction and remove. Empty emulsion in the water collecting receptacle and clean the receptacle.
- Screw the filter cartridge 2 and the water collecting receptacle 3 together. Wet the sealing surfaces of the filter cartridge and the water collecting receptacle with fuel.
- Mount in clockwise direction.
- Open the fuel stopcock and vent the system.
- Check tightness after starting the engine.
- Close fuel stopcock.
- Changing the fuel prefilter cartridge
- Shut off the fuel supply to the engine (with high lying tank).
- Shut off the fuel supply to the engine (with high lying tank).
- Shut off the fuel supply to the engine (with high lying tank).
- Place a collecting receptacle underneath the prefilter.
- Pull out the plug of the optional water level sensor (4).
- Open the water drain cock (5) and drain liquid.
- Unscrew the filter cartridge (2) together with the water collecting receptacle (3).
- Unscrew water collecting vessel (3) from the filter cartridge (2).
- Clean the water collecting receptacle (3) and all the available sealing surfaces with a brush and clean diesel fuel.
- Oil the gaskets of the new DEUTZ original filter cartridge (2) lightly or wet with diesel fuel.
- Screw water collecting receptacle (3) to the filter cartridge (2).
- Screw new filter cartridge (2) to the filter support (tightening torque: 17-18 Nm).
- Connect the water level sensor (A).
- Open the fuel supply to the engine.
- Vent the fuel system
- Shut off the fuel supply to the engine (with high lying tank).
- Venting the fuel prefilter
- Loosen the vent screw 7 slightly.
- Cleaning / purging and possibly changing the fuel prefilter
- Cleaning (purging) - draining water:
- Cleaning (purging) - draining water:
- Cleaning (purging) - draining water:
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Close the fuel stopcock or supply (if available).
- Open the vent screw 1 on the cover 2.
- Position fuel collecting receptacle beneath fuel prefilter.
- Empty water and dirt from the bowl 6 by opening the drain cock (press in lightly without using force and turn) and close the drain cock again afterwards.
- Close the vent screw 1 on the cover 2.
- Vent the fuel system see
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Changing the filter element 5:
- Change at least once a year or when necessary (drop in performance even after purging).
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Close the fuel stopcock or supply (if available).
- Loosen the cover screws 3 diagonally.
- Remove cover 2.
- Remove spring cassette 4.
- Remove filter insert 5 on the clip.
- Insert new filter insert 5.
- Place the spring cassette 4 on the element.
- Check the cover gasket for correct fit in the cover 2 and for damage (change if necessary).
- Tighten the cover 2 with the screws 3 diagonally (tightening torque 6 Nm).
- Check the cover 2 for correct fit and tightness.
- Vent the fuel system see
- Shut off the engine or switch over to the other filter if a lubricating oil filter is fitted.
- Cooling system
- Cooling system
- Regulations for working on the cooling system
- Regulations for working on the cooling system
- Checking the coolant level in an external cooler
- Fill in new coolant and vent the system according to the cooling system manufacturer’s specifications.
- Checking the coolant additive concentration
- Open the cooling system cap carefully.
- The appropriate test device can be obtained from your DEUTZ partner under the order number 1824.
- Emptying the cooling system
- Open the cooling system cap carefully.
- Open the cooling system cap carefully.
- Open the cooling system cap carefully.
- Place a collecting receptacle underneath the screw plug (arrow). This is also available on the opposite side.
- Unscrew the screw plug and sealing ring, drain the coolant.
- Fit new sealing ring to screw plug, turn in and tighten it (tightening torque 38 Nm).
- Check for tightness.
- Open the cooling system cap carefully.
- Filling the cooling system
- Open the cooling system cap 1 carefully.
- Open the cooling system cap 1 carefully.
- Open the cooling system cap 1 carefully.
- Fill up with coolant to the MAX mark on the compensation tank and close cooling system cap 1.
- Switch on heating, if available, and set to maximum so that the heating circuit is filled and vented.
- Warm up the engine to operating temperature (opening temp. of the thermostat).
- Switch off the engine.
- Check the coolant level on the cool engine and fill up to the MAX mark of the compensation tank if necessary.
- Open the cooling system cap 1 carefully.
- Engine cleaning
- Engine cleaning
- Cleaning work
- Cleaning work
- General
- Cleaning with compressed air
- Cleaning with cold cleaner
- Cleaning with a high pressure cleaner
- Intake system
- Intake system
- Regulations for working on the intake system
- Regulations for working on the intake system
- Maintenance indicators for dry air filter
- The dry air filter is maintained according to a maintenance indicator or service gauge.
- The dry air filter is maintained according to a maintenance indicator or service gauge.
- The dry air filter is maintained according to a maintenance indicator or service gauge.
- Maintenance is necessary when:
- - when the engine is running, the yellow warning light of the
- - the red field (1) of the
- After completion of the maintenance work push the reset button on the service gauge. The service gauge is ready for operation again.
- The dry air filter is maintained according to a maintenance indicator or service gauge.
- Dry air filter
- Maintaining the dry air filter
- Maintaining the dry air filter
- Maintain the filter element (3) according to the interval in the maintenance schedule (see chap. 5.1).
- Maintain the filter element (3) according to the interval in the maintenance schedule (see chap. 5.1).
- Maintain the filter element (3) according to the interval in the maintenance schedule (see chap. 5.1).
- Lift up the clamping yoke (1).
- Remove the filter hood (2) and pull out the filter element (3).
- Filter element (3):
- - blow out with dry compressed air (max. 5 bar) from the inside to the outside if soiling is only slight,
- - renew if heavily soiled.
- Maintain the filter element (3) according to the interval in the maintenance schedule (see chap. 5.1).
- Renewing the safety cartridge of the dry air filter
- Belt drives
- Belt drives
- Checking the belt drive
- Check the whole belt drive visually for damage.
- Checking the belt tension
- Lower indicator arm (1) into the measuring device.
- Lower indicator arm (1) into the measuring device.
- Lower indicator arm (1) into the measuring device.
- Place guide (3) between two belt pulleys on the V-belt (2). The stop should be at the side.
- Press the button (4) at right angles to the V- belt (2) evenly until you hear or feel the spring snap in.
- Lift the measuring device carefully without altering the position of the indicator arm (1).
- Read the measured value at the point of intersection (arrow), scale (5) and indicator arm (1). Setting values see
- If necessary, re-tighten and repeat measurement.
- Lower indicator arm (1) into the measuring device.
- Tools
- Tightening the belt
- Loosen screws 2.
- Changing belts
- Adjustments
- Adjustments
- Setting the valve clearance
- Before valve clearance setting: Let the engine cool down for at least 30 minutes. Oil temperature below 80 ˚C.
- Before valve clearance setting: Let the engine cool down for at least 30 minutes. Oil temperature below 80 ˚C.
- Before valve clearance setting: Let the engine cool down for at least 30 minutes. Oil temperature below 80 ˚C.
- Set crankshaft according to setting schematic,
- Loosen screws 1.
- Remove valve cowling 2 with gasket 3
- Mount the turn-over gear on the flywheel with fastening screws.
- Turn over the crankshaft until you reach valve overlap.
- Before valve clearance setting: Let the engine cool down for at least 30 minutes. Oil temperature below 80 ˚C.
- Loosen lock nut (1).
- Loosen lock nut (1).
- Loosen lock nut (1).
- Mount rotation angle disc (4) and socket wrench insert on the valve clearance setting screw (2).
- Fix the magnet of the rotation angle disc (4).
- Turn the rotation angle disc (4) clockwise to the stop (rocker arm without clearance) and set the scale to zero.
- Turn the rotation angle disc (4) anticlockwise until reaching the specified rotation angle value.
- Hold the rotation angle disc (4) to stop it twisting.
- Tighten the lock nut 1 (tightening torque 20 Nm ).
- Then set the second valve on the rocker arm as described above.
- Repeat the setting procedure on every cylinder.
- Remount the valve cowling with a new gasket in reverse order.
- Replace the screws (tightening torque 22 Nm).
- Loosen lock nut (1).
- The valve clearance can also be set using a feeler gauge. Gauges with 0.25 mm or 0.09 inches must be used for the inlet valve.
- Setting schematic for the valve clearance
- Adjustments
- Electrical system
- Electrical system
- Regulations for working on the electrical system
- Regulations for working on the electrical system
- Battery
- Checking the voltage
- Checking the voltage
- Check the battery voltage with a conventional voltmeter. The voltage indicates the charging state. It should be between 12 and 14.4 [V] Volt per battery.
- Checking acid density
- Removing the battery
- Charging the battery
- Installing the battery
- Installing the battery
- Insert new or charged battery and attach the fastenings.
- Insert new or charged battery and attach the fastenings.
- Insert new or charged battery and attach the fastenings.
- Clean the terminals and battery poles with fine grained sandpaper.
- Connect the plus pole first and then the minus pole. Otherwise there is a danger of short-circuiting. Make sure the terminals have a good contact. Tighten the clamping screws by hand.
- Grease the assembled terminals with an acid-free, acid-resistant grease.
- Insert new or charged battery and attach the fastenings.
- Faults
- Faults
- Fault table
- Engine management
- Engine management
- Use of the Diagnosis button
- Use of the Diagnosis button
- With the diagnosis button the fault at hand can be read out as a blink code. The diagnosis button and the fault lamp are located...
- Table of fault blink codes Diagnosis button
- The possible blink codes, their meaning and measures for correcting faults can be found in the table on the following page. The ...
- Transport and storing
- Transport and storing
- Engine transport
- Engine transport
- Preservation
- General
- interior corrosion protection
- interior corrosion protection
- Interior corrosion protection is always provided by wetting of the walls with the implemented corrosion protection agent in a co...
- Fuel system
- Lubricating oil system
- Air compressor
- Cooling system
- Cooling system
- Depending on the series the engines are equipped with cooling air, cooling oil or cooling fluid system (cooling water with cooli...
- If not, the coolant must be drained and, to ensure the formation of a covering layer on the inside surfaces of the cooling system, a corrosion protection run performed with a mixture of:
- If not, the coolant must be drained and, to ensure the formation of a covering layer on the inside surfaces of the cooling system, a corrosion protection run performed with a mixture of:
- If not, the coolant must be drained and, to ensure the formation of a covering layer on the inside surfaces of the cooling system, a corrosion protection run performed with a mixture of:
- - 95% treated water
- - 5% corrosion protection agent
- The duration of the corrosion protection run and the concentration of the corrosion protection agent are specified by the manufacturer of the corrosion protection agent.
- Then drain the coolant.
- If not, the coolant must be drained and, to ensure the formation of a covering layer on the inside surfaces of the cooling system, a corrosion protection run performed with a mixture of:
- Air intake pipes
- Air intake pipes
- After the corrosion protection run, remove the cylinder cover and deinstall injectors. The respective piston must be set to LDC.
- The accessible part of the cylinder liner should be coated with corrosion protection oil with a spray lance through the opening.
- Exterior corrosion protection
- Exterior corrosion protection
- The engine must be cleaned thoroughly with a cleaning agent before exterior corrosion protection. Any signs of corrosion and damage to the paintwork must be removed.
- Cooling air system in air-cooled engines
- Bare exterior surfaces and parts
- Rubber parts
- Belt drives
- Engine openings
- Storage and packaging
- Removal of corrosion protection
- Removal of corrosion protection
- The corrosion protection must be removed from the corrosion protected engine before starting. The packaging must be removed as well as all covers from the sealed openings. Any signs of corrosion and damage to paintwork must be removed.
- Fuel system
- Coolant system
- Coolant system
- If the implemented corrosion protection agent is compatible with the intended coolant system protection agent, this can be filled directly into the coolant system as specified.
- If the implemented corrosion protection agent is compatible with the intended coolant system protection agent, this can be filled directly into the coolant system as specified.
- If the implemented corrosion protection agent is compatible with the intended coolant system protection agent, this can be filled directly into the coolant system as specified.
- If it is uncertain whether the implemented corrosion protection agent is compatible with the coolant system protection agent, the cooling system should be purged with fresh water for about 15 minutes before filling.
- If the implemented corrosion protection agent is compatible with the intended coolant system protection agent, this can be filled directly into the coolant system as specified.
- Removal of exterior corrosion protection
- Technical data
Faults
7.1 Fault table
44
7
Faults Causes Measures
Engine doesn't start up, or
starts up with difficulty
Not disconnected (if possible) Check clutch
Starting limit temperature not reached
15
Wrong SAE viscosity class of the engine oil Change the lubricating oil
(
23
)
Fuel quality does not comply with instruction manual Change the fuel
(
24
)
Air in fuel system Venting the fuel system
(
32
)
Battery defective or not charged Check battery
(
42
)
Cable connections to the starter loose or oxidised Check cable connections
Starter defective or pinion doesn't mesh Check starter
Engine doesn't start up and dia-
gnosis light is blinking
Engine electronics prevent start
Check error according to error code, clear error if
necessary
Engines starts up, but runs irre-
gularly or misfires
Fuel quality does not comply with instruction manual Change the fuel
(
24
)
High pressure pipe leaking Check high pressure pipe
Injector defective Check injector/change if necessary
Speed changes are possible
and diagnostic lamp lights up
Engine electronics has detected a system error and activates an equivalent
speed
Check error according to error code, clear error if
necessary
Engine gets too hot. Tempera-
ture warning system is activa-
ted
Oil level too low Fill up lubricating oil
(
29
)
Oil level too high Check oil level and drain if necessary
(
29
)
Air filter soiled / turbocharger defective Check /change if necessary
Air filter maintenance switch / display defective Check /change if necessary
Fan defective / V-belt torn or loose Check fan/V-belt/change if necessary
Heat short-circuit in the cooling system Check the cooling system
Resistance in cooling system is too high / flow volume too low Check the cooling system
Engine lacks power
Oil level too high Check lubricating oil level
(
29
)
Fuel quality does not comply with instruction manual Change the fuel
(
24
)
Air filter soiled / turbocharger defective Check /change if necessary
Air filter maintenance indicator / service gauge defective Check /change if necessary
Charge air pipe leaking Check charge air pipe
High pressure pipe leaking Check high pressure pipe
Fuel injector defective Check fuel injector
Engine lacks power and dia-
gnosis lamp lights up
Engine electronics reduce power
Check error according to error code, clear error if
necessary
T 7-1: Fault table