Professional Documents
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D 909 L1
Safety Measures: Rules for Accident Prevention
● Please read and observe the information ● Unauthorised engine modifications will
given in this Operation Manual. This will invalidate any liability claims against the
enable you to avoid accidents, preserve the manufacturer for resultant damage.
manufacturer's warranty and maintain the Likewise manipulations of the injection and
engine in peak operating condition. regulating system may also influence the
performance of the engine, and its emissions.
● This engine has been built in accordance Adherence to legislation on pollution cannot
with the application, which was specified in be guaranteed under such conditions.
the scope of supply. The application was
defined by the manufacturer (use in ● Do not change, convert or adjust the cooling
accordance with intended purpose). Any use air intake area to the blower.
exceeding that scope is considered to be The manufacturer accepts no liability for any
contrary to the intended purpose. The damage resulting from failure to comply with
manufacturer will not assume responsibility these instructions.
for any damage resulting therefrom. The risks
involved are to be borne solely by the user. ● When carrying out maintenance/repair
operations on the engine, the use of DEUTZ
● Use in accordance with the intended purpose original parts is prescribed. These are specially
also implies compliance with the conditions designed for your engine and guarantee
laid down by the manufacturer for operation, perfect operation.
maintenance and servicing. The engine Non-compliance results in the expiry of the
should only be operated, serviced and repaired warranty.
by personnel trained in its use and the hazards
involved. ● Maintenance and cleaning of the engine
should only be done when the engine is
● The relevant accident prevention guidelines switched off and cold.
and other generally accepted safety and Check first that the electrical systems are
industrial hygiene regulations must be switched off, remove the ignition key.
observed. Observe the accident prevention regulations
for electrical installations (for example VDE-
● When the engine is running there is a risk of 0100/-0101/-0104/-0105 "Electrical protec-
injury from the following components: tive measures for safety against hazardous
- Rotating/hot parts touch voltages").
- Engines with spark ignition
- Ignitions systems (high electrical voltage) When cleaning with fluids, all electrical
Avoid contact with these components. components must be covered tightly.
Operation Manual
D 909 L1
0312 0858 gb
Engine Serial
Number
Dear Customer,
Sincerely,
DEUTZ AG
Table of Contents
Shut the engine down before carrying out This symbol is used for all safety The seals and gaskets used in
maintenance or repair work. Ensure that the instructions. Follow these this engine are asbestos-free.
engine cannot be accidentally started, instructions particularly care-
fully.
accidents may otherwise occur.
The attention of operating
When the work is complete, be sure to refit any personnel should be drawn to
panels and guards that have been removed. these safety instructions.
Never fill the fuel tank while the engine is In addition to these instructions, the respec-
running. tive general safety and accident prevention
Observe industrial safety regulations when regulations must be observed.
running the engine in an enclosed space or
© 2003
underground.
Description of the Engine
2
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System
2.5 Engine Cooling System
© 2003
Description of the Engine 2.1 Model
2.1.1 Rating Plate 2.1.2 Position of the Rating 2.1.3 Engine Serial Number
2 Plate
The model A, the engine serial number B and Rating plate C is located on the engine block. The engine number D is stamped on the
the performance data of the engine are engine block and on the rating plate.
stamped on the rating plate.
The model and engine serial number must be
given when ordering parts.
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2.1 Model Description of the Engine
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Description of the Engine 2.2 Engine Illustrations
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2.2 Engine Illustrations Description of the Engine
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Description of the Engine 2.3 Lube Oil Circuit Schematic
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2.4 Fuel System Description of the Engine
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Description of the Engine 2.5 Engine Cooling System
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Operation
3
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Shutdown
3.5 Operating Conditions
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Operation 3.1 Commissioning
3.1.1 Adding Engine Oil 3.1.2 Checking the Oil Level 3.1.3 Adding Fuel
3
The engines are normally delivered without Check the oil level with the dipstick (with The engines are delivered without fuel.
oil. engine on horizontal surface). Fill up the fuel tank by pouring fuel into the filler
Pour lube oil into the oil filler neck (arrow). neck (arrow).
For oil grade and viscosity, see Chapter 4.1. Use only commercially-available diesel fuels.
For fuel grade, see Chapter 4.2. Use summer
or winter-grade diesel fuel, depending on the
ambient temperature.
before re-fuelling!
Ensure cleanliness!
Do not spill fuel!
3.1 Commissioning Operation
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Move lever 1 into operating position. Move lever 1 into idle position.
Increase/reduce engine speed by turning the To increase the number of revolutions turn
knurled nut 2. the lever in the direction of the arrow.
The maximum number of rotations is limited by The maximum number of rotations is limited by
the stop. the stop.
Turn to the left = reduce engine speed.
Turn to the right = increase engine speed.
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Operation 3.1 Commissioning
z Check battery and cable connections, see When commissioning new and reconditioned
6.6.1.1 engines, the following additional maintenance
work must be carried out:
z Transport hooks
Remove them if fitted (see 6.6.3). z Change lube oil, see 6.1.2.
During and after trial run z Check the engine for leaks.
- Check the engine for leaks.
z Check engine suspension and retighten if
After the engine has been turned off necessary.
- Check oil level, see 6.1.2.
If necessary, top up oil, see 3.1.1.
z Breaking in
During the break-in phase - about 200
operating hours - check the oil level twice
a day. After the break-in phase, a check
once a day is sufficient.
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3.2 Starting Operation
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Operation 3.2 Starting
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the relay may burn out.
Operation 3.3 Monitoring Systems
z The oil pressure pilot light comes on with z The pointer must remain in the green sector z 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).
z The oil pressure pilot light should go out
when the engine is running.
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3.3 Monitoring Systems Operation
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Operation 3.4 Shutdown
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z Move shut-off lever 1 in the direction of the z Turn the key anticlockwise (position 0) and
arrow until the engine comes to a stop. remove. The pilot lamps will go out.
z After the engine has stopped, the charge
and oil pressure pilot lamps will light up.
z Turn the start key anticlockwise (position
0) and remove. The pilot lamps will go out.
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z Battery
Operation 3.5 Operating Conditions
4
4.1 Lube Oil
4.2 Fuel
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Operating Media 4.1 Lube Oil
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Oil fills, see 9.1
4.2 Fuel Operating Media
● NATO code: F-54 and F-75. ● Special diesel fuels may be used in arctic A
26441 1
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are in the fuel tank. Fill with the
appropriate amount of kerose-
ne first, then add the diesel fuel.
Maintenance
5
5.1 Maintenance Schedule
5.2 Maintenance Diagrams
5.3 Maintenance Work Completed
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Maintenance 5.1 Maintenance Schedule
z z Engine leaks
z z z z Cooling system (depending on how the engine has been used) 3) 6) 6.3.1
z z z z z Engine oil (depending on how the engine has been used) 5) 6.1.1/6.1.2
z z 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 value 5) Oil change intervals, see Chapter 6.1.1.
2) Commissioning new and reconditioned 6) Clean cooling system/fins.
engines
3) Clean if required, see Chapter 6.4.
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Maintenance 5.3 Maintenance Work Completed
5 Op. hours Date Signature / stamp Date Op. hours Signature / stamp
50-150* –
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
Duly completed maintenance jobs can be recorded and signed off in the maintenance chart.
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Op. hours Date Signature / stamp Op. hours Date Signature / stamp 5
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 maintenance chart.
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Maintenance 5.3 Maintenance Work Completed
5 Op. hours Date Signature / stamp Op. hours Date Signature / stamp
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7875 8000
8125 8250
8375 8500
8625 8750
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Duly completed maintenance jobs can be recorded and signed off in the maintenance chart.
Trabajos de limpieza y mantenimiento
Service and Maintenance
6
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air Filter
6.5 Adjustments
6.6 Accessories
6.7 Engine Cleaning
6.8 Additional Maintenance Work
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Service and Maintenance 6.1 Lubrication System
Average driving
Service group Annual usage km
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Change the oil with the engine off but still speed approx. km/h
warm (lube oil temperature 80 °C).
I > 30,000 20 10,000
6.1 Lubrication System Service and Maintenance
z Position the engine or vehicle on horizontal z Allow the engine to run warm. z Place oil tray under the engine.
ground. z Position the engine or vehicle on horizontal z Unscrew the oil drain screw.
- Engine warm: ground. z Drain the oil.
Switch off engine, wait for 5 minutes and - Lube oil temperature approx. 80° C. z Screw the oil drain screw back in.
check the oil level. z Switch off the engine.
- Engine cold: z Top up with lube oil.
Check oil level. - For grade / viscosity, see 4.1.
Proceed as follows: - For quantity, see 9.1.
z Remove the oil dipstick. z Check the oil level, see 6.1.2.1.
z Wipe the dipstick with a non-fibrous, clean
cloth.
z Insert it to the stop and remove again.
z Check the oil level and fill up with oil up to Caution when draining hot oil: Risk
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the upper "MAX " mark. of scalding! Do not let the used oil
- Even if the oil is just above the "MIN" mark, run into the soil; collect it in a
the oil must be topped up. container!
z Undo the lubricant filter element using a z If necessary, clean the sealing surface of z Tighten the fuel filter insert with a final half-
commercial tool; unscrew and remove it. the filter housing. turn.
z Catch any escaping oil. z Lightly oil the rubber gasket of the new lube z Check the oil level, see 6.1.2.
oil filter element.
z Check the oil pressure, see 3.3.1.
z Manually screw in the new filter element
until the gasket is flush. z Check the oil filter element for leaks.
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z Place a suitable container under the filter z When installing the new fuel filter, note the
and catch any escaping fuel. direction of flow (arrow).
z Close the fuel feed line (using any aid). z After a short functional test, check the filter
z Slacken the clips 1 and the two ends of the and lines for leaks.
filter line, remove the filter and insert a new z If the fuel is heavily contaminated, the filter
filter. change interval must be shortened to 250
hours.
Do not work with any naked The fuel system does not need to be bled.
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flames and do not smoke when
working on the fuel system.
Service and Maintenance 6.3 Cooling System
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Service and Maintenance 6.4 Combustion Air Filter
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z Empty the dust discharge valve 1 by z Undo the clip fastener 1. z Gaskets on the filter element 3 can become
pressing together lips of discharge slot as z Remove the filter cover 2 and pull out the damaged through regular removal and
indicated by arrows. filter element 3. replacement. Check the filter element 3 for
z Clean discharge slot from time to time. z Clean the filter element, replace after one damage to the filter paper (use backlight)
z Remove any caked dirt by pressing together year at the latest. and for leaks. Replace any damaged parts
the upper section of the valve. z Clean the filter element 3. as required.
Blow through from the inside out with z Insert the filter element 3 and attach the
compressed-air (max. 5 bar, shake and tap filter cover 2 with the clip fastener 1.
out in difficult cases only, or rinse according
to the manufacturer's instructions, without
damaging the element).
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z Remove the cylinder head cover. z If necessary, adjust the valve clearance;
z Position of the crankshaft proceed as follows:
Turn the crankshaft until both valves in - Release locknut 4.
cylinder 1 overlap (i.e., the exhaust valve - Use screwdriver 7 to turn setscrew 5 so
is not yet closed and the inlet valve is that the correct valve clearance is attained
beginning to open). Adjust the valve after locknut 4 has been tightened.
clearance. z Check and adjust valve clearance on all
z Before adjusting the valve clearance allow remaining cylinders.
the engine to cool for at least 30 minutes, z Re-fit the cylinder head cover with a new
the oil temperature must be below 80º C. gasket.
z Check the valve clearance 1 between rocker
arm / tappet contact face 2 and valve stem
3 with the feeler gauge 6 (there should be
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slight resistance when feeler blade is
inserted). For permissible valve clearance,
see 9.1.
Service and Maintenance 6.6 Accessories
6.6.1 Battery
6 6.6.1.1Checking Battery and Cable 6.6.1.2Checking Electrolyte Level 6.6.1.3 Checking Electrolyte Density
Connectors
z Keep the battery clean and dry. z Remove the seal caps 1. z Measure the electrolyte density of indivi-
z Undo dirty clamps. z If testers 2 are present: The electrolyte dual cells with a commercial hydrometer.
z Clean terminal posts (+ and -) and clamps level should reach base of these.
of the battery, and grease with acid- z If the testers 2 are not present: The Hydrometer reading (see table on following
resistant grease. electrolyte level should be 10-15 mm above page) indicates battery's state of charge.
z When re-installing the clamps, ensure that the top of the plates. During measurement, the temperature of
there is contact between the connections. z If necessary, top up with distilled water. the electrolyte should preferably be +20° C.
Tighten the clamp bolts hand-tight. z Screw the sealing caps 1 back in.
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6.6 Accessories Service and Maintenance
* Measurement of electrolyte density in ° Bé (degrees Baumé) is out of date and rarely used today.
© 2003
skin or clothing! Wear protective goggles! Do
not rest tools on the battery!
Service and Maintenance 6.6 Accessories
tackle.
6.7 Engine Cleaning Service and Maintenance
z Switch off the engine and wait until it is cold. z Switch off the engine and wait until it is cold. z Switch off the engine and wait until it is cold.
z Remove the fuel tank, the fuel lines and cooling z Remove the fuel tank, the fuel lines and cooling z Remove the fuel tank, the fuel lines and cooling
air hoses and seal off the feed line. air hoses and seal off the feed line. air hoses and seal off the feed line.
z Cover the cooling air inlets and the electrical z Cover the cooling air inlets and the electrical z Cover the cooling air inlets and the electrical
connections and components (for example connections and components (for example connections and components (for example
the starter motor, regulator). the starter motor, regulator). the starter motor, regulator).
z Blow air through the engine, paying particular z Spray the engine with a commercially z Clean the engine with a steam jet (max. 60
attention to the cooling fins of the cylinder and available cold cleaner and allow it to react bar, steam temperature max. 90º C).
cylinder head. Before reinstalling, clean the for around 10 minutes. z Before reinstalling, clean the hoses, the fuel
hoses, the fuel tank and the lines. Clean any dirt z Clean the engine with a powerful water jet, if tank and the lines.
from the engine room/compartment. necessary repeat the process. z Allow the engine to run warm so that the
z Before reinstalling, clean the hoses, the fuel remaining water evaporates.
tank and the lines.
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Clean the engine only when the Allow the engine to run warm so that the
engine is switched off. remaining water evaporates.
Service and Maintenance 6.8 Additional Maintenance Work
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Troubleshooting 7.1 Fault Table
7 Faults Actions
Engine does not start or is difficult to start Check C
Engine starts, but runs irregularly or fails Adjust A
Engine becomes too hot, temperature warning system is activated Replace R
Engine output is deficient Clean Cl
Engine oil pressure is non-existent or excessively low Fill F
Engine oil consumption excessive Reduce Rd
Engine smokes - blue
- white
- black
Cause Chapter
● ● ● (Poss.) clutch is not disengaged /fuel filter contaminated Operation C/R
● ● Temperature lower than the minimum start temperature C
● ● Fuel contains water or tank is empty C/F
● ● ● ● ● ● Fuel pump faulty C
● ● Injection quantity too high Rd
● ● Fuel feed begins too early/valves blocked C/A
● ● Fuel feed begins too late C/A
● ● ● ● Injection nozzle or injection pump valve blocked C
● ● ● ● ● ● Injection nozzle faulty C/R
● ● ● ● ● Injection nozzle seal faulty C/R
● ● ● Leak in injection lines C/A
● ● Fuel temperature too high R
● ● Injection pump toothed rack sluggish C
● ● ● ● Injection pump incorrectly adjusted C
● ● Engine running predominantly at low load C
● ● ● ● Oil level too high Lubrication C/R
● ● Oil level too low C/Cl
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Faults Actions 7
Engine does not start or is difficult to start Check C
Engine starts, but runs irregularly or fails Adjust A
Engine becomes too hot, temperature warning system is activated Replace R
Engine output is deficient Clean Cl
Engine oil pressure is non-existent or excessively low Fill F
Engine oil consumption excessive Reduce Rd
Engine smokes - blue
- white
- black
Cause Chapter
● ● ● ● Oil pressure control valve blocked Lubrication Cl
● ● ● Oil pump faulty C/R
● ● Oil filter contaminated or faulty Cl
● ● Air or dirt in oil intake pipe C/R
● ● ● Oil pressure gauge or pressure display faulty C/R
● ● ● Pre-heating plugs or electronic control system faulty Electrical C
● Battery faulty or flat system C/R
● Cable connection in starter current relay loose or corroded C/R
● Starter motor faulty or pinion does not engage C/R
● ● ● ● ● ● Air filter dirty Maintenance C
● ● Idle speed too high C/A
● Run-in not completed C
● Injection pump toothed rack in Off position (electromagnet faulty) C
● ● ● Engine positioned at excessive angle C/A
● ● ● ● ● ● Incorrect valve clearance / valve wear C/A
● Cooling fins dirty Cl
● Cooling air warm C
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● Cooling air guide vanes loose C
Troubleshooting 7.1 Fault Table
7 Faults Actions
Engine does not start or is difficult to start Check C
Engine starts, but runs irregularly or fails Adjust A
Engine becomes too hot, temperature warning system is activated Replace R
Engine output is deficient Clean Cl
Engine oil pressure is non-existent or excessively low Fill F
Engine oil consumption excessive Reduce Rd
Engine smokes - blue
- white
- black
Cause Chapter
● ● ● Counterpressure at exhaust too high Maintenance Rd
● ● ● ● ● Compression too low C
● ● ● Engine load too high C
● ● Engine speed control lever incorrectly adjusted Adjustments C/A
● ● Regulator spring broken or unhooked C
● ● ● Idle speed too low C/A
● ● ● ● ● ● ● Wear on cylinder and/or piston rings or piston rings are sticking C/R
● ● Speed regulator linkage sluggish C/A
● ● Valve guide worn C/R
● Connecting rod big-end and/or small-end bearings faulty C
● ● Cylinder head leaking (retaining bolts loose) A
● ● ● Unsuitable SAE grade or lube oil quality Service R
● ● ● ● Incorrect fuel grade C/R
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Engine Preservation
8
8.1 Preservation
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Engine Preservation 8.1 Preservation
8.1 Preservation
8 8.1.1 Engine Preservation 8.1.2 Recommissioning After the
Engine Has Been Idle
If the engine is to remain idle for an extended ● Clean the engine with a high-pressure ● Fill the fuel tank.
period of time, appropriate protective cleaner (if necessary using a cold cleaner).
measures have to be taken to prevent rust. ● Allow the engine to warm up and then ● Remove the plugs from the inlets and outlets.
The protective measures described here will switch it off.
protect the engine for a maximum downtime ● Drain the engine oil (see Chapter 6.1.2) and ● Commission the engine.
of 6 months. Before re-commissioning the fill with anti-corrosion oil.
engine, the preservative residues will have ● Empty the fuel tank.
to be removed. ● Make up a mixture of 90 % diesel fuel and
10 % anti-corrosion oil, and refill fuel tank.
● Anti-corrosion oils to specification: ● Allow the engine to run for approx. 10 mins.
- MIL-L-212608 ● Switch off the engine.
- L 9150-037/2 ● Turn engine over manually several times to
- NATO Code C 640 / 642 preserve cylinders and combustion
chambers.
● When turning over with a starter, set the
● Recommended cleaning products when shut-off lever to the "stop" position.
recommissioning the engine after being ● The inlets and outlets can be sealed off
idle: with plugs.
Petroleum benzine (hazardous materials ● Drain the corrosion protection oil.
class A3)
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Technical Specification
© 2003
Technical Specification 9.1 Engine Specifications and Settings
Model D 909 L1
9 Cylinder 1
Cylinder diameter ( mm ) 95
Stroke ( mm ) 100
Displacement, total ( cm ) 709
Compression ratio (ε) 18
Mode of operation diesel engine, 4-stroke
Combustion method Naturally-aspirated engine with direct injection
Direction of rotation to left (seen from flywheel)
Weight incl. cooling system, in acc. with DIN 70020-A
without: Starter, alternator, fuel, oil approx. ( Kg ) 106
Engine power ( kW ) 1)
Number of revolutions ( rev/min ) 1)
Lubrication Pressure lubrication
Oil, in acc. with SAE grade 15W40
Oil temperature in housing max. ( ºC ) 125
Minimum oil pressure on warm engine (120º C)
at idle / at rated speed ( bar ) >1
Quantity of oil with first oil change approx. ( litres ) 2.3
Valve clearance with engine cold ( mm ) 0.2
Opening pressure of injector nozzles ( bar ) 220+5
Start of injection (º CA BTDC) 25
1) For power output and engine speed, see rating plate (see 2.1).
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9.2 Torque Wrench Settings Technical Specification
© 2003
Service
Printed in Spain
All rights reserved
1. Issue 03/03
Order no. 0312 0858 en