operation manual d 909 l1 - vmtec.eu · operation manual d 909 l1 0312 0858 gb engine serial number...

Operation Manual

D 909 L1

● Please read and observe the informationgiven in this Operation Manual. This willenable you to avoid accidents, preserve themanufacturer's warranty and maintain theengine in peak operating condition.

● This engine has been built in accordancewith the application, which was specified inthe scope of supply. The application wasdefined by the manufacturer (use inaccordance with intended purpose). Any useexceeding that scope is considered to becontrary to the intended purpose. Themanufacturer will not assume responsibilityfor any damage resulting therefrom. The risksinvolved are to be borne solely by the user.

● Use in accordance with the intended purposealso implies compliance with the conditionslaid down by the manufacturer for operation,maintenance and servicing. The engineshould only be operated, serviced and repairedby personnel trained in its use and the hazardsinvolved.

● The relevant accident prevention guidelinesand other generally accepted safety andindustrial hygiene regulations must beobserved.

● When the engine is running there is a risk ofinjury from the following components:- Rotating/hot parts- Engines with spark ignition- Ignitions systems (high electrical voltage)Avoid contact with these components.

● Unauthorised engine modifications willinvalidate any liability claims against themanufacturer for resultant damage.Likewise manipulations of the injection andregulating system may also influence theperformance of the engine, and its emissions.Adherence to legislation on pollution cannotbe guaranteed under such conditions.

● Do not change, convert or adjust the coolingair intake area to the blower.The manufacturer accepts no liability for anydamage resulting from failure to comply withthese instructions.

● When carrying out maintenance/repairoperations on the engine, the use of DEUTZoriginal parts is prescribed. These are speciallydesigned for your engine and guaranteeperfect operation.Non-compliance results in the expiry of thewarranty.

● Maintenance and cleaning of the engineshould only be done when the engine isswitched off and cold.Check first that the electrical systems areswitched off, remove the ignition key.Observe the accident prevention regulationsfor electrical installations (for example VDE-0100/-0101/-0104/-0105 "Electrical protec-tive measures for safety against hazardoustouch voltages").

When cleaning with fluids, all electricalcomponents must be covered tightly.

Safety Measures: Rules for Accident Prevention

Operation Manual

D 909 L1

0312 0858 gb

Engine SerialNumber

Please enter the engine serial number here.This number should be quoted when inquiringabout Customer Service, Repairs or SpareParts (see Section 2.1).

Technical modifications required to improveour engines are reserved with regard tospecification data and other technicalinformation contained in this Operation Manual.No parts of this Manual may be reproduced inany form or by any means without our writtenapproval.

Foreword

Dear Customer,

Air / liquid-cooled DEUTZ engines are designedfor a wide range of applications. Consequently,a wide range of variants are offered to meetthe requirements of specific cases.

Your engine is appropriately equipped for theinstallation concerned, as specified by you,which means that not all of the componentsdescribed in this Operation Manual arenecessarily fitted to your engine.

We have endeavoured to highlight anydifferences so that you will be able to locate theoperating and maintenance instructionsapplicable to your engine more quickly andeasily.

Please read this Manual before starting yourengine, and always observe the operating andmaintenance instructions.

If you have any queries, please contact us,we'll be happy to advise you.

Sincerely,

DEUTZ AG

Table of Contents

1 General information

2 Description of the Engine2.1 Model2.1.1 Rating Plate2.1.2 Position of the Rating Plate2.1.3 Engine Serial Number2.1.4 Direct Injection System of the D 909 L12.2 Engine Illustrations2.2.1 Service Side2.2.2 Oil Dipstick and Oil Drain Side2.3 Lube Oil Circuit Schematic2.3.1 Lube Oil Circuit Schematic2.4 Fuel System2.4.1 Fuel System2.5 Engine Cooling System2.5.1 Cooling System

3 Operation3.1 Commissioning3.1.1 Adding Engine Oil3.1.2 Checking the Oil Level3.1.3 Adding Fuel3.1.4 Adjusting the Throttle3.1.5 Other Preparations3.1.6 Additional Maintenance Work3.2 Starting3.2.1 Starting with the Crank3.2.2 Electric Start3.3 Monitoring Systems3.3.1 Engine Oil Pressure3.3.2 Engine Temperature3.4 Shutdown3.4.1 Mechanical Shut-Off3.4.2 Electrical Shutdown

3.5 Operating Conditions3.5.1 Winter Operation3.5.2 High Ambient Temperatures, High

Altitudes

4 Operating Media4.1 Lube Oil4.1.1 Quality Grade4.1.2 Viscosity4.2 Fuel4.2.1 Quality Grade4.2.2 Winter Grade Fuel

5 Maintenance5.1 Maintenance Schedule5.2 Maintenance Diagrams5.3 Maintenance Work Completed

6 Service and Maintenance6.1 Lubrication System6.1.1 Oil Change Intervals6.1.2 Checking the Oil Level/Engine Oil

Change6.1.3 Oil Filter Change6.2 Fuel System6.2.1 Fuel filter change6.3 Cooling System6.3.1 Cleaning Intervals6.4 Combustion Air Filter6.4.1 Standard Air Filter6.4.2 Dry Type Air Cleaner6.5 Adjustments6.5.1 Check Valve Clearance, adjust if

necessary6.6 Accessories6.6.1 Battery

6.6.2 Magnet plate6.6.3 Transportation Shackles6.7 Engine Cleaning6.7.1 Engine Cleaning6.8 Additional Maintenance Work6.8.1 Sheathed Glow Plug

7 Troubleshooting7.1 Fault Table

8 Engine Preservation8.1 Preservation8.1.1 Engine Preservation8.1.2 Recommissioning After the

Engine Has Been Idle

9 Technical Specification9.1 Engine Specifications and Settings9.2 Torque Wrench Settings

10 Service

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General information

DEUTZ diesel engines

are the product of many years of researchand development. The resulting know-how,coupled with stringent quality standards,guarantee their long service life, high reliabilityand low fuel consumption.It goes without saying that the higheststandards for environmental protection aremet.

Service and Maintenance

will ensure that the engine continues to meetyour requirements. Recommended serviceintervals must be observed and maintenancework carried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.

Service

Please contact one of our authorised servicerepresentatives in the event of breakdownsor for spare parts inquiries. Our trainedspecialists will carry out repairs quickly andprofessionally, using only genuine spareparts.Genuine spare parts from DEUTZ AG arealways manufactured to the highest technicalstandards. A table of service contact numbersis given at the end of this Operation Manual.

Safety precautions when theengine is running

Shut the engine down before carrying outmaintenance or repair work. Ensure that theengine cannot be accidentally started,accidents may otherwise occur.When the work is complete, be sure to refit anypanels and guards that have been removed.Never fill the fuel tank while the engine isrunning.Observe industrial safety regulations whenrunning the engine in an enclosed space orunderground.

Safety

This symbol is used for all safetyinstructions. Follow theseinstructions particularly care-fully.The attention of operatingpersonnel should be drawn tothese safety instructions.

In addition to these instructions, the respec-tive general safety and accident preventionregulations must be observed.

The seals and gaskets used inthis engine are asbestos-free.

Asbestos

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Description of the Engine

2.1 Model2.2 Engine Illustrations2.3 Lube Oil Circuit Schematic2.4 Fuel System2.5 Engine Cooling System

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Description of the Engine 2.1 Model

2.1.1 Rating Plate

The model A, the engine serial number B andthe performance data of the engine arestamped on the rating plate.The model and engine serial number must begiven when ordering parts.

2.1.2 Position of the RatingPlate

Rating plate C is located on the engine block.

2.1.3 Engine Serial Number

The engine number D is stamped on theengine block and on the rating plate.

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2.1.4 Direct Injection System ofthe D 909 L1

Engines with direct injection are used inapplications where high power outputs arerequired.

2.1 Model Description of the Engine

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Description of the Engine 2.2 Engine Illustrations

2.2.1 Service Side

1 Fuel filler neck2 Cylinder head cover3 Oil filler neck4 Decompression lever5 Camshaft6 Throttle lever7 Cover (option: location for attaching

hydraulic pump)8 Lube oil filter9 Starter10 Injection pump11 Battery charge regulator12 Fuel tank

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2.2.2 Oil Dipstick and Oil DrainSide

2.2 Engine Illustrations Description of the Engine

13 Cover / dry type air cleaner14 Oil drain plug15 Oil dipstick16 Exhaust muffler

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Description of the Engine 2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Circuit Schematic

1 Intake manifold2 Oil pump3 Oil filter4 Safety valve5 Crankshaft6 Camshaft7 Valve tappet8 Push-rod guide9 Rocker arm10 Piston11 Valves

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2.4 Fuel System Description of the Engine

2.4.1 Fuel System

1 Fuel tank (14.5 litres)2 Fuel filter3 Line to the injection pump4 Injection pump5 Injection line6 Injection nozzle7 Automatic discharge line8 Fuel return line

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Description of the Engine 2.5 Engine Cooling System

2.5.1 Cooling System

1 Fan wheel2 Cooling air inlet3 Cooling air outlet

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Operation

3.1 Commissioning3.2 Starting3.3 Monitoring Systems3.4 Shutdown3.5 Operating Conditions

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Operation 3.1 Commissioning

3.1.1 Adding Engine Oil

The engines are normally delivered withoutoil.Pour lube oil into the oil filler neck (arrow).For oil grade and viscosity, see Chapter 4.1.

3.1.2 Checking the Oil Level

Check the oil level with the dipstick (withengine on horizontal surface).

3.1.3 Adding Fuel

The engines are delivered without fuel.Fill up the fuel tank by pouring fuel into the fillerneck (arrow).Use only commercially-available diesel fuels.For fuel grade, see Chapter 4.2. Use summeror winter-grade diesel fuel, depending on theambient temperature.

Always switch off the enginebefore re-fuelling!Ensure cleanliness!Do not spill fuel!

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3.1 Commissioning Operation

3.1.4 Adjusting the Throttle

Throttle lever fine setting

Move lever 1 into operating position.

Increase/reduce engine speed by turning theknurled nut 2.The maximum number of rotations is limited bythe stop.

Turn to the left = reduce engine speed.Turn to the right = increase engine speed.

Vehicle throttle lever

Move lever 1 into idle position.

To increase the number of revolutions turnthe lever in the direction of the arrow.The maximum number of rotations is limited bythe stop.

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Operation 3.1 Commissioning

3.1.5 Other Preparations

Check battery and cable connections, see6.6.1.1

Transport hooksRemove them if fitted (see 6.6.3).

Trial runAfter carrying out these preparationsexecute a brief trial run for 10 minutes. Donot load engine during this period.

During and after trial run- Check the engine for leaks.

After the engine has been turned off- Check oil level, see 6.1.2.

If necessary, top up oil, see 3.1.1.

Breaking inDuring the break-in phase - about 200operating hours - check the oil level twicea day. After the break-in phase, a checkonce a day is sufficient.

3.1.6 Additional MaintenanceWork

When commissioning new and reconditionedengines, the following additional maintenancework must be carried out:

Change lube oil, see 6.1.2.

Change oil filter, see 6.1.3.

Check the valve clearance and adjust ifnecessary, see 6.5.1.

Check the engine for leaks.

Check engine suspension and retighten ifnecessary.

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3.2 Starting Operation

3.2.1 Starting with the Crank

Before starting, make sure thatnobody is standing in theimmediate vicinity of the engineor driven machine.After repair work:

Check to see if all safety devices andguards have been re-attached and that alltools have been removed from the engine.

When starting with the sheathed glowplug, do not use any other starting aid (e.g.injection with start pilot). Risk of accident!

If possible, de-couple the engine from theequipment being driven - this will make iteasier to start.

Watch out for the restoring moment of thecrank if the crank has not been removedafter starting the engine. Risk of accident!

To repeat the starting process wait until theengine is at a complete standstill.Move the decompression lever 1 to position "A".

Slowly crank the engine a few turns - theinjection nozzle will spray continuously atthis point.With force, turn the crank as quickly aspossible, then move lever 1 to position "B"and turn again until it fires.Remove the crank immediately after theengine fires.

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Operation 3.2 Starting

3.2.2 Electric Start

Before starting, make sure thatnobody is standing in theimmediate vicinity of the engineor driven machine.After repair work:

Check to see if all safety devices and guardshave been re-attached and that all tools havebeen removed from the engine.When starting with sheathed glow plug, donot use any other starting aid (e.g. injectionwith start pilot). Risk of accident!

Do not operate the starter for more than 20seconds continuously. If the engine does notstart, wait one minute and repeat the startprocess.If the engine does not catch after two attempts,then refer to the Fault Table (see 7.1).

Where possible, disengage the clutch toseparate the engine from any driven parts.Move speed control lever 1 into operatingposition (arrow).

Insert ignition key.- Position 0 = operating voltage offTurn key clockwise.- Position 1 = operating voltage on- The pilot lamps light up.Turn key clockwise against springpressure.- Position 2 = StartRelease key as soon as engine fires.- The pilot lamps will go out.After starting, another attempt can only bemade after resetting to position 0 (stop).

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Without Starting Aid for ColdStart

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3.2 Starting Operation

With cold start assistance/sheathed glow plugDURATERM

Insert the ignition key.- Position 0 = operating voltage offTurn key clockwise.- Position 1 = operating voltage on- The pilot lamps light up.At temperatures below 0° C, keep the keyin this position for 4-5 seconds. Plug pre-heating times.Turn key clockwise against springpressure.- Position 2 = Start

At temperatures above 0° C, the key canbe moved from position 1 to position 2immediately. The pre-glow process willthen not take place.Release key as soon as engine fires.After starting, another attempt can only bemade after resetting to position 0 (stop).

The operating voltage must not be present formore than 8 seconds (position 1), otherwisethe relay may burn out.

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Operation 3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

Oil pressure lamp

The oil pressure pilot light comes on withoperating voltage on and engine off.The oil pressure pilot light should go outwhen the engine is running.

Oil pressure indicator

The pointer must remain in the green sectorover the entire operating range.

Oil pressure gauge

The pointer of the oil pressure gauge mustdisplay the minimum oil pressure (see 9.1).

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3.3 Monitoring Systems Operation

3.3.2 Engine Temperature

Engine temperature gauge

The pointer of the temperature gauge mustalways remain in the green sector. If thepointer moves into the red sector, theengine is overheating. Turn off the engineand establish the cause from the FaultTable (see 7.1).

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Operation 3.4 Shutdown

3.4.1 Mechanical Shut-Off

Move shut-off lever 1 in the direction of thearrow until the engine comes to a stop.After the engine has stopped, the chargeand oil pressure pilot lamps will light up.Turn the start key anticlockwise (position0) and remove. The pilot lamps will go out.

3.4.2 Electrical Shutdown

Ignition Key

Turn the key anticlockwise (position 0) andremove. The pilot lamps will go out.

If possible, do not suddenly switch the engineoff when at full load.

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3.5 Operating Conditions Operation

3.5.1 Winter OperationLube oil viscosity

- Select the oil viscosity (SAE grade) according to ambient temperature before starting engine, see 4.1.2.- If the engine is being operated at temperatures below -10º C, the oil will need to be changed more frequently, see 6.1.1.Diesel fuel- At temperatures below 0º C, use a winter fuel, see 4.2.2.Additional maintenance work- Once a week, remove the oil sludge that has been deposited in the fuel tank. (To do this, slacken the screw plug and drain off the sludge.)- If required, select an engine oil grade that is suitable for the ambient temperature.- At temperatures below -20° C, the starter may occasionally have to be removed and the ring gear on the flywheel lubricated with cold-resistant grease through the assembly hole of the starter. (for example Bosch grease FT 1 V 31).Cold start aidsAt temperatures below zero degrees, apre-heating plug may have to be used forstarting, see 3.2.2. This not only reducesthe temperature limit for starting but alsomakes it easier to start at temperatures atwhich starting aids are not normallyrequired.Battery

- For successful cold-starting, it is essential that the battery charge is good, see 6.6.1.- If the battery is warmed to around +20º C

(remove battery and store in a temperature- controlled location), the starting temperature limit is reduced by 4-5º C.

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3.5.2 High AmbientTemperatures, High Altitudes

At high altitudes or when the ambienttemperature rises, air density decreases.As a result of this, the engine's maximumoutput, the quality of the exhaust gas, thetemperature level and, in extreme cases,starting behaviour, are impeded. In non-steady state operating conditions, the enginecan be operated at altitudes of up to 1,000 mand at temperatures of up to 30º C. In lessfavourable operating conditions (higheraltitudes and higher temperatures), thequantity of fuel injected must be reducedand the engine power output falls as aresult.

If you have any doubts about engineoperation under these or similar conditions,ask your engine or equipment supplierwhether the required reduction in fuelquantity has been achieved by adjustingthe injection pump accordingly in theinterests of reliability, service life andexhaust gas quality (smoke). Alternatively,contact DEUTZ SERVICE.

Operation 3.5 Operating Conditions

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Operating Media

4.1 Lube Oil4.2 Fuel

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Operating Media 4.1 Lube Oil

4.1.1 Quality Grade

Lube oils are differentiated according to theirperformance and quality class. In commonuse are specifications named after the API(American Petroleum Institute) and ACEA(European Engine Oil Sequences).

Approved API oils:

Minimum: CF/CF-4

Approved ACEA oils:

Minimum: E2-96

4.1.2 Viscosity

As the viscosity of the lube oil is dependenton temperature, the choice of viscosity class(SAE grade) should be governed by theambient temperature prevailing at the engineoperating site. To maintain optimum operatingconditions, the user can use the viscositytable on this page as a guide.Should the temperature fall temporarily belowthe lower limit, cold starting behaviour willchange but the engine will not be damaged.If the temperature rises above the upper limit,avoid operating the engine under theseconditions for long periods of time, to preventexcessive engine wear.If multigrade oils are used, there is no need tochange the oil according to the season.Multigrade oils, particularly partially or fullysynthetic oils, whose viscosity does notfluctuate with temperature, reduce fuelconsumption.

*Oil change intervals, see 6.1.1 Oil fills, see 9.1

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Legend:

I Summer diesel

II Winter diesel

A Ambient temperature

B % of kerosene mixed with the fuel

4.2 Fuel Operating Media

4.2.1 Quality Grade

Use commercially available diesel fuels withless than 0.5 % sulphur content. If the sulphurcontent is higher, oil change intervals shouldbe reduced, see 6.1.1.

The following fuel specifications / standardsare approved:

● DIN EN 590

● BS 2869: A1 and A2(in the case of A2, note the sulphurcontent)

● ASTM D 975-88; 1-D and 2-D

● NATO code: F-54 and F-75.

Exhaust emission values which may becalculated in the course of type approvaltests always refer to the reference fuelprescribed by the authorities for the typeapproval test.

4.2.2 Winter Grade Fuel

At very low ambient temperatures, the fuelsystem may become blocked as a result ofparaffin decomposition; this may causeoperating faults. At ambient temperaturesbelow 0º C, use winter grade diesel (down to-15º C); normally this fuel will be on sale atfilling stations before the start of winter.Sometimes diesel fuel with additives("superdiesel") may be available; this can beused down to temperatures of -20° C.

● At temperatures below -15° C or -20° C, thefuel must be mixed with kerosene. Therelevant percentages are given in theadjacent diagram.

● Special diesel fuels may be used in arcticclimatic zones down to -44° C.

If summer-grade diesel fuel has to be used attemperatures below 0° C, up to 60% kerosenecan be added (see adjacent diagram).

In most cases, adequate resistance to coldcan also be obtained by adding a flow improver(additive). Please ask your DEUTZ partner.

0 10 20 30 40 50 60 %

0

- 5

- 10

- 15

- 20

- 25

- 30

+32

+23

+14

+ 5

- 4

- 13

- 22

BA

°F °C26441 1

I

II

Do not mix the fuels until theyare in the fuel tank. Fill with theappropriate amount of kerose-ne first, then add the diesel fuel.

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Maintenance

5.1 Maintenance Schedule5.2 Maintenance Diagrams5.3 Maintenance Work Completed

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Maintenance 5.1 Maintenance Schedule

Operating Hours (OP)1

every every

10 OPor

daily 125 250 500 1000 2000 3000 5000

check

clean

change

Activity

s e eSection

Oil level in engine 6.1.2

Engine leaks

Dry type air cleaner 3) 4) 6.3/6.4

Battery and cable connections 6.6.1

Cooling system (depending on how the engine has been used) 3) 6) 6.3.1

Engine oil (depending on how the engine has been used) 5) 6.1.1/6.1.2

Oil filter element 6.1.3

Fuel filter 6.2.1

Valve clearance (adjust if necessary) 6.5.1

Engine suspension (tighten if required) 9.2

Glow plug 6.8.1

Injection valve

The engine maintenance intervals stated are maximum values. In individual cases, shorter maintenance intervals may be required. Follow the manufacturer's instructions.

1)Maximum permissible reference value2)Commissioning new and reconditioned

engines3)Clean if required, see Chapter 6.4.4)Replace if required. Wait until the

maintenance display appears, if fitted.

5) Oil change intervals, see Chapter 6.1.1.6)Clean cooling system/fins.

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5.2 Maintenance Diagrams Maintenance

The self-adhesive maintenance diagramshown on this page is supplied with eachengine. It should be affixed to the engine ormachine where it can be seen clearly.

Check to see if this instruction has beenfollowed!

If necessary, request a replacementmaintenance diagram from the engine ormachine supplier.

Regular maintenance should be done inaccordance with the maintenance schedule(see 5.1).

Stop the engine before carryingout maintenance work.

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Op. hours Date Signature / stamp Date Op. hours Signature / stamp

–

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

50-150*

125

375

625

875

1125

1375

1625

1875

2115

2375

2625

Maintenance 5.3 Maintenance Work Completed

Duly completed maintenance jobs can be recorded and signed off in the maintenance chart.* Commissioning new and fully reconditioned engines.

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3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

Op. hours Date Signature / stamp Op. hours Date Signature / stamp

Duly completed maintenance jobs can be recorded and signed off in the maintenance chart.

5.3 Maintenance Work Completed Maintenance

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6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

5875

6125

6375

6625

6875

7125

7375

7625

7875

8125

8375

8625

Maintenance 5.3 Maintenance Work Completed

Op. hours Date Signature / stamp Op. hours Date Signature / stamp

Duly completed maintenance jobs can be recorded and signed off in the maintenance chart.

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6.1 Lubrication System6.2 Fuel System6.3 Cooling System6.4 Combustion Air Filter6.5 Adjustments6.6 Accessories6.7 Engine Cleaning6.8 Additional Maintenance Work

Trabajos de limpieza y mantenimiento

40 40 40

6

Service and Maintenance©

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Normal load, for example:

Road vehicles, cranes, construction machinery, ships, generatingsets, rotary pumps, etc.

Higher than normal load, for example:

Combine harvesters, emergency pumps, underground miningunits, road sweepers forwinter maintenance service,emergency generators, etc.

Vehicle engines

6.1 Lubrication System

6.1.1 Oil Change Intervals

The oil change intervals are dependent onthe engine application and the quality of thelube oil.

If the engine runs fewer hours during theyear than stated in the table, the oil shouldbe changed at least once a year.

The following conditions apply for the datagiven in the table:- For diesel fuel: Sulphur content max.0.5% by weight- Continuous ambient temperature of -10º C(+14º F).

If the fuels used have a sulphur content > 0.5% to 1%, or if the ambient temperatureis continually lower than -10º C (+14º F),the oil change intervals should be halved.

If the fuels used have a sulphur content ofmore than 1%, consult the servicecompany responsible for you.

Change the oil with the engine off but stillwarm (lube oil temperature 80 °C).

Built-in engines

Lube oil quality API specification

ACEA specification

Lube oil quality API specification

ACEA specification

Service group Annual usage kmAverage driving

speed approx. km/h

Oil change intervals in

operating hours

Naturally-aspirated engines

CF / CF-4

E2-96

500

250

Oil change intervals in

operating hours

Naturally-aspirated engines

CF / CF-4

E2-96

I > 30,000 20 10,000

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6.1.2 Checking the Oil Level/Engine Oil Change

Position the engine or vehicle on horizontalground.- Engine warm:Switch off engine, wait for 5 minutes andcheck the oil level.- Engine cold:Check oil level.

Proceed as follows:Remove the oil dipstick.Wipe the dipstick with a non-fibrous, cleancloth.Insert it to the stop and remove again.Check the oil level and fill up with oil up tothe upper "MAX " mark.- Even if the oil is just above the "MIN" mark, the oil must be topped up.

The level must not fall below the "MIN" mark.

6.1.2.1Checking the Oil Level

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6.1.2.2 Engine Oil Change

Allow the engine to run warm.Position the engine or vehicle on horizontalground.- Lube oil temperature approx. 80° C.Switch off the engine.

Place oil tray under the engine.Unscrew the oil drain screw.Drain the oil.Screw the oil drain screw back in.

Top up with lube oil.- For grade / viscosity, see 4.1.- For quantity, see 9.1.Check the oil level, see 6.1.2.1.

Caution when draining hot oil: Riskof scalding! Do not let the used oilrun into the soil; collect it in acontainer!

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6.1.3 Oil Filter Change

Undo the lubricant filter element using acommercial tool; unscrew and remove it.

Catch any escaping oil.

If necessary, clean the sealing surface ofthe filter housing.

Lightly oil the rubber gasket of the new lubeoil filter element.

Manually screw in the new filter elementuntil the gasket is flush.

Tighten the fuel filter insert with a final half-turn.

Check the oil level, see 6.1.2.

Check the oil pressure, see 3.3.1.

Check the oil filter element for leaks.

Caution is required in the case ofhot oil: Risk of scalding!


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6.2 Fuel System

6.2.1 Fuel filter change

Place a suitable container under the filterand catch any escaping fuel.Close the fuel feed line (using any aid).Slacken the clips 1 and the two ends of thefilter line, remove the filter and insert a newfilter.

When installing the new fuel filter, note thedirection of flow (arrow).After a short functional test, check the filterand lines for leaks.If the fuel is heavily contaminated, the filterchange interval must be shortened to 250hours.

Do not work with any nakedflames and do not smoke whenworking on the fuel system.

The fuel system does not need to be bled.

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6.3 Cooling System

6.3.1 Cleaning Intervals

The amount of contamination in the coolingsystem depends on the engine application.

Oil and fuel residues on the engine increasethe risk of contamination. If the ambient aircontains a lot of dust, pay special attentionto leaks.

There is a high risk of contamination in thefollowing conditions:- Construction site applications because of the high dust content in the air.- Harvesting applications, because of the large amount of cereal husks and straw around the machine.

Because working conditions vary, suitablecleaning intervals must be specified foreach individual case. The cleaning intervalslisted in the adjacent table should only beused as a guide.

Inspection and cleaning

intervalsGuidelines

Operating hours (OH)

Type of engine operation

2000 Ships, generating sets in enclosed areas, pumps

1000 Vehicles on paved roads

500 Tractors, fork-lift trucks, mobile generating sets

250 Vehicles on construction sites and unpaved roads, construction

machines, compressors and underground mining units

125 Agricultural machines, tractors in harvesting applications

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6.4 Combustion Air Filter

6.4.1 Standard Air Filter

The maintenance indicator (sticker on theengine) gives the general cleaning intervalsfor the standard air filter. However, thefilter element must always be replacedafter 250 operating hours, regardless ofthis. Proceed as follows:

Slacken screw 1 and remove, together withthe cover 2.Carefully pull out the filter element 3.Clean the filter element 3.Blow compressed-air through the filterelement, from the inside out (max. 5 bar,shake and tap out in difficult cases only).Insert the filter element 3, fit the cover 2 andtighten with the screw 1.Gaskets on the filter element can becomedamaged through regular removal andreplacement. Check the filter element fordamage to the filter paper (use backlight)and for leaks.Replace if necessary.

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6.4 Combustion Air Filter

6.4.2 Dry Type Air Cleaner

Dust Discharge Valve

Empty the dust discharge valve 1 bypressing together lips of discharge slot asindicated by arrows.Clean discharge slot from time to time.Remove any caked dirt by pressing togetherthe upper section of the valve.

Filter elements

Undo the clip fastener 1.Remove the filter cover 2 and pull out thefilter element 3.Clean the filter element, replace after oneyear at the latest.Clean the filter element 3.Blow through from the inside out withcompressed-air (max. 5 bar, shake and tapout in difficult cases only, or rinse accordingto the manufacturer's instructions, withoutdamaging the element).

Gaskets on the filter element 3 can becomedamaged through regular removal andreplacement. Check the filter element 3 fordamage to the filter paper (use backlight)and for leaks. Replace any damaged partsas required.Insert the filter element 3 and attach thefilter cover 2 with the clip fastener 1.

Under no circumstances rinsethe filter element 3 with petrol orhot liquids!

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6.5 Adjustments

6.5.1 Check Valve Clearance,adjust if necessary

Remove the cylinder head cover.Position of the crankshaftTurn the crankshaft until both valves incylinder 1 overlap (i.e., the exhaust valveis not yet closed and the inlet valve isbeginning to open). Adjust the valveclearance.Before adjusting the valve clearance allowthe engine to cool for at least 30 minutes,the oil temperature must be below 80º C.Check the valve clearance 1 between rockerarm / tappet contact face 2 and valve stem3 with the feeler gauge 6 (there should beslight resistance when feeler blade isinserted). For permissible valve clearance,see 9.1.

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If necessary, adjust the valve clearance;proceed as follows:- Release locknut 4.- Use screwdriver 7 to turn setscrew 5 sothat the correct valve clearance is attainedafter locknut 4 has been tightened.Check and adjust valve clearance on allremaining cylinders.Re-fit the cylinder head cover with a newgasket.

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6.6 Accessories

6.6.1 Battery6.6.1.1Checking Battery and Cable

Connectors

Keep the battery clean and dry.Undo dirty clamps.Clean terminal posts (+ and -) and clampsof the battery, and grease with acid-resistant grease.When re-installing the clamps, ensure thatthere is contact between the connections.Tighten the clamp bolts hand-tight.

6.6.1.2Checking Electrolyte Level

Remove the seal caps 1.If testers 2 are present: The electrolytelevel should reach base of these.If the testers 2 are not present: Theelectrolyte level should be 10-15 mm abovethe top of the plates.If necessary, top up with distilled water.Screw the sealing caps 1 back in.

6.6.1.3 Checking Electrolyte Density

Measure the electrolyte density of indivi-dual cells with a commercial hydrometer.

Hydrometer reading (see table on followingpage) indicates battery's state of charge.During measurement, the temperature ofthe electrolyte should preferably be +20° C.

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in [kg/l] in [º Bé (degrees Baumé)*] Charge condition

Normal Tropical Normal Tropical

1.28 1.23 32 27 sufficiently charged

1.20 1.12 24 16 semi-charged, recharge

1.12 1.08 16 11 discharged, charge immediately

* Measurement of electrolyte density in ° Bé (degrees Baumé) is out of date and rarely used today.

The gases emitted by the batteryare explosive! Keep sparks andnaked flames away from thebattery! Do not allow batteryacid to come into contact with

skin or clothing! Wear protective goggles! Donot rest tools on the battery!

6.6 Accessories

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6.6 Accessories

6.6.2 Magnet plate

Notes on the alternating current system:

Never disconnect the cables betweenbattery, alternator and regulator while theengine is running.If, however, it is necessary to start andoperate the engine without the battery,disconnect the regulator from the alternatorbefore starting.Do not mix up or interchange the batteryclamps.If the charge pilot lamp is faulty, replace itimmediately.When washing the engine, cover the coolingair inlets, the regulator and the alternator.In case of electric welding, connect theground terminal on the welder directly tothe piece being welded.

6.6.3 Transportation Shackles

Always use proper lifting tackle whentransporting the engine.

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Use only the correct liftingtackle.

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6.7 Engine Cleaning

6.7.1 Engine Cleaning

Using compressed air

Switch off the engine and wait until it is cold.Remove the fuel tank, the fuel lines and coolingair hoses and seal off the feed line.Cover the cooling air inlets and the electricalconnections and components (for examplethe starter motor, regulator).Blow air through the engine, paying particularattention to the cooling fins of the cylinder andcylinder head. Before reinstalling, clean thehoses, the fuel tank and the lines. Clean any dirtfrom the engine room/compartment.

Using cold-cleaning compound

Switch off the engine and wait until it is cold.Remove the fuel tank, the fuel lines and coolingair hoses and seal off the feed line.Cover the cooling air inlets and the electricalconnections and components (for examplethe starter motor, regulator).Spray the engine with a commerciallyavailable cold cleaner and allow it to reactfor around 10 minutes.Clean the engine with a powerful water jet, ifnecessary repeat the process.Before reinstalling, clean the hoses, the fueltank and the lines.Allow the engine to run warm so that theremaining water evaporates.

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Using high pressure device

Switch off the engine and wait until it is cold.Remove the fuel tank, the fuel lines and coolingair hoses and seal off the feed line.Cover the cooling air inlets and the electricalconnections and components (for examplethe starter motor, regulator).Clean the engine with a steam jet (max. 60bar, steam temperature max. 90º C).Before reinstalling, clean the hoses, the fueltank and the lines.Allow the engine to run warm so that theremaining water evaporates.

Clean the engine only when theengine is switched off.

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6.8 Additional Maintenance Work

6.8.1 Sheathed Glow Plug

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Move the speed control lever 1 to the STOPposition.Insert the ignition key.- Position 0 = operating voltage off Turn key clockwise.- Position 1 = operating voltage on The pilot lamps light up. Check to see if the sheathed glow plug is operating properly.

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Faults ActionsEngine does not start or is difficult to start Check C

Engine starts, but runs irregularly or fails Adjust AEngine becomes too hot, temperature warning system is activated Replace R

Engine output is deficient Clean ClEngine oil pressure is non-existent or excessively low Fill F

Engine oil consumption excessive Reduce RdEngine smokes - blue

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Cause Chapter

Troubleshooting 7.1 Fault Table

(Poss.) clutch is not disengaged /fuel filter contaminated Operation C/RTemperature lower than the minimum start temperature CFuel contains water or tank is empty C/FFuel pump faulty CInjection quantity too high RdFuel feed begins too early/valves blocked C/AFuel feed begins too late C/AInjection nozzle or injection pump valve blocked CInjection nozzle faulty C/RInjection nozzle seal faulty C/RLeak in injection lines C/AFuel temperature too high RInjection pump toothed rack sluggish CInjection pump incorrectly adjusted CEngine running predominantly at low load COil level too high Lubrication C/ROil level too low C/ClLube oil too viscous R

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Cause ChapterOil pressure control valve blocked Lubrication ClOil pump faulty C/ROil filter contaminated or faulty ClAir or dirt in oil intake pipe C/ROil pressure gauge or pressure display faulty C/RPre-heating plugs or electronic control system faulty Electrical CBattery faulty or flat system C/RCable connection in starter current relay loose or corroded C/RStarter motor faulty or pinion does not engage C/RAir filter dirty Maintenance CIdle speed too high C/ARun-in not completed CInjection pump toothed rack in Off position (electromagnet faulty) CEngine positioned at excessive angle C/AIncorrect valve clearance / valve wear C/ACooling fins dirty ClCooling air warm CCooling air guide vanes loose C

7.1 Fault Table Troubleshooting

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Counterpressure at exhaust too high Maintenance RdCompression too low CEngine load too high CEngine speed control lever incorrectly adjusted Adjustments C/ARegulator spring broken or unhooked CIdle speed too low C/AWear on cylinder and/or piston rings or piston rings are sticking C/RSpeed regulator linkage sluggish C/AValve guide worn C/RConnecting rod big-end and/or small-end bearings faulty CCylinder head leaking (retaining bolts loose) AUnsuitable SAE grade or lube oil quality Service RIncorrect fuel grade C/R

Troubleshooting 7.1 Fault Table





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Engine Preservation 8.1 Preservation

8.1 Preservation

If the engine is to remain idle for an extendedperiod of time, appropriate protectivemeasures have to be taken to prevent rust.The protective measures described here willprotect the engine for a maximum downtimeof 6 months. Before re-commissioning theengine, the preservative residues will haveto be removed.

● Anti-corrosion oils to specification:- MIL-L-212608- L 9150-037/2- NATO Code C 640 / 642

● Recommended cleaning products whenrecommissioning the engine after beingidle:Petroleum benzine (hazardous materialsclass A3)

8.1.1 Engine Preservation

● Clean the engine with a high-pressurecleaner (if necessary using a cold cleaner).

● Allow the engine to warm up and thenswitch it off.

● Drain the engine oil (see Chapter 6.1.2) andfill with anti-corrosion oil.

● Empty the fuel tank.● Make up a mixture of 90 % diesel fuel and

10 % anti-corrosion oil, and refill fuel tank.● Allow the engine to run for approx. 10 mins.● Switch off the engine.● Turn engine over manually several times to

preserve cylinders and combustionchambers.

● When turning over with a starter, set theshut-off lever to the "stop" position.

● The inlets and outlets can be sealed offwith plugs.

● Drain the corrosion protection oil.

8.1.2 Recommissioning After theEngine Has Been Idle

● Fill the fuel tank.

● Remove the plugs from the inlets and outlets.

● Commission the engine.

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Model D 909 L1Cylinder 1Cylinder diameter ( mm ) 95Stroke ( mm ) 100Displacement, total ( cm ) 709Compression ratio ( ε ) 18Mode of operation diesel engine, 4-strokeCombustion method Naturally-aspirated engine with direct injectionDirection of rotation to left (seen from flywheel)Weight incl. cooling system, in acc. with DIN 70020-Awithout: Starter, alternator, fuel, oil approx. ( Kg ) 106Engine power ( kW ) 1)Number of revolutions ( rev/min ) 1)Lubrication Pressure lubricationOil, in acc. with SAE grade 15W40Oil temperature in housing max. ( ºC ) 125Minimum oil pressure on warm engine (120º C)at idle / at rated speed ( bar ) >1Quantity of oil with first oil change approx. ( litres ) 2.3Valve clearance with engine cold ( mm ) 0.2Opening pressure of injector nozzles ( bar ) 220+5Start of injection (º CA BTDC) 25

1) For power output and engine speed, see rating plate (see 2.1).

Technical Specification 9.1 Engine Specifications and Settings

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Location Initial tightening Subsequent tightening Total Notes

Stage 1 Stage 2 Stage 3 Stage 4

Cylinder head cover - - - - - 15+5 M8

Rocker arm setscrew - - - - - 20+5 M8

Fastening bolt, crankshaft counterweights - - - - - 60+5 M 10

Con-rod bolt - - - - - 30+5 M8x1

Starter motor nut - - - - - 200+10 M24x1.5

Steering wheel fastening bolt - - - - - 90+5 M12x1.5

Injection nozzle mountings - - - - - 15+5 M8

9.2 Torque Wrench Settings Technical Specification

10It's good to know it's a DEUTZ.

DEUTZ has long been one of the leading enginemanufacturers. As an independent manufacturer,we offer - worldwide - a comprehensive range ofdiesel and petrol engines, (ranging in power outputfrom 4 to 7,400 kW. Our products are tailor-made tomeet our customers' requirements.

Over 1,400,000 DEUTZ engines are in reliableoperation in various parts of the world. We want tomaintain the high performance levels of our enginesand thereby the trust and satisfaction of ourcustomers; as a result we have a worldwide networkof service branches who will meet the needs of ourcustomers, wherever they are.

So the name DEUTZ does not merely mean enginesthat are the products of extensive developmentwork, DEUTZ also stands for complete servicepackages that ensure optimum operation of ourengines, and for customer services operations youcan count on.

This Register Sales & Service offers you anoverview of the DEUTZ service branches in yourvicinity, including the products for which they areresponsible and the range of services provided. Andeven if a specific product is not on the list, you canrest assured that your DEUTZ branch will be happyto give you advice and practical assistance at anytime.

The Register is regularly updated. The latest editioncan be obtained from your DEUTZ branch.

DEUTZ AGAlways at your service.

0312 0806Order no.:

0312 0807Order no.: (CD-ROM)

DEUTZ AGDeutz-Mülheimer Str. 147-149D-51057 Köln

Phone: 0049-221-822-0Fax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Available from your local dealer or from:

es

Service

i t

DEUTZ MOTOR España, S.A.Avda. de los Artesanos, 50, 1ª PlantaE-28760 TRES CANTOS (MADRID)SPAINPhone: +34-91 807 45 00Fax: +34-91 807 45 02

DEUTZ AGService-TechnikInstandhaltungstechnik Motoren(Engine servicing)Deutz-Mühlheimer Str. 147-149D-51057 KölnPhone: 02 21-8 22-0Fax: 02 21-8 22-53 58http://www.deutz.de

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