Operation Manual

D 909 L1
 Safety Measures: Rules for Accident Prevention
● Please read and observe the information
given in this Operation Manual. This will
enable you to avoid accidents, preserve the
manufacturer's warranty and maintain the
engine in peak operating condition.
● This engine has been built in accordance
with the application, which was specified in
the scope of supply. The application was
defined by the manufacturer (use in
accordance with intended purpose). Any use
exceeding that scope is considered to be
contrary to the intended purpose. The
manufacturer will not assume responsibility
for any damage resulting therefrom. The risks
involved are to be borne solely by the user.
● Use in accordance with the intended purpose
also implies compliance with the conditions
laid down by the manufacturer for operation,
maintenance and servicing. The engine
should only be operated, serviced and repaired
by personnel trained in its use and the hazards
involved.
● The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be
observed.
● When the engine is running there is a risk of
injury from the following components:
- Rotating/hot parts
- Engines with spark ignition
- Ignitions systems (high electrical voltage)
Avoid contact with these components.
● Unauthorised engine modifications will
invalidate any liability claims against the
manufacturer for resultant damage.
Likewise manipulations of the injection and
regulating system may also influence the
performance of the engine, and its emissions.
Adherence to legislation on pollution cannot
be guaranteed under such conditions.
● Do not change, convert or adjust the cooling
air intake area to the blower.
The manufacturer accepts no liability for any
damage resulting from failure to comply with
these instructions.
● When carrying out maintenance/repair
operations on the engine, the use of DEUTZ
original parts is prescribed. These are specially
designed for your engine and guarantee
perfect operation.
Non-compliance results in the expiry of the
warranty.
● Maintenance and cleaning of the engine
should only be done when the engine is
switched off and cold.
Check first that the electrical systems are
switched off, remove the ignition key.
Observe the accident prevention regulations
for electrical installations (for example VDE-
0100/-0101/-0104/-0105 "Electrical protec-
tive measures for safety against hazardous
touch voltages").
When cleaning with fluids, all electrical
components must be covered tightly.
 Operation Manual
D 909 L1

0312 0858 gb
Engine Serial
Number

Please enter the engine serial number here.

This number should be quoted when inquiring
about Customer Service, Repairs or Spare
Parts (see Section 2.1).

Technical modifications required to improve

our engines are reserved with regard to
specification data and other technical
information contained in this Operation Manual.
No parts of this Manual may be reproduced in
any form or by any means without our written
approval.
Foreword

Dear Customer,

Air / liquid-cooled DEUTZ engines are designed

for a wide range of applications. Consequently,
a wide range of variants are offered to meet
the requirements of specific cases.

Your engine is appropriately equipped for the

installation concerned, as specified by you,
which means that not all of the components
described in this Operation Manual are
necessarily fitted to your engine.

We have endeavoured to highlight any

differences so that you will be able to locate the
operating and maintenance instructions
applicable to your engine more quickly and
easily.

Please read this Manual before starting your

engine, and always observe the operating and
maintenance 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 3.5 Operating Conditions 6.6.2 Magnet plate

3.5.1 Winter Operation 6.6.3 Transportation Shackles
2 Description of the Engine 3.5.2 High Ambient Temperatures, High 6.7 Engine Cleaning
2.1 Model Altitudes 6.7.1 Engine Cleaning
2.1.1 Rating Plate 6.8 Additional Maintenance Work
2.1.2 Position of the Rating Plate 4 Operating Media 6.8.1 Sheathed Glow Plug
2.1.3 Engine Serial Number 4.1 Lube Oil
2.1.4 Direct Injection System of the D 909 L1 4.1.1 Quality Grade 7 Troubleshooting
2.2 Engine Illustrations 4.1.2 Viscosity 7.1 Fault Table
2.2.1 Service Side 4.2 Fuel
2.2.2 Oil Dipstick and Oil Drain Side 4.2.1 Quality Grade 8 Engine Preservation
2.3 Lube Oil Circuit Schematic 4.2.2 Winter Grade Fuel 8.1 Preservation
2.3.1 Lube Oil Circuit Schematic 8.1.1 Engine Preservation
2.4 Fuel System 5 Maintenance 8.1.2 Recommissioning After the
2.4.1 Fuel System 5.1 Maintenance Schedule Engine Has Been Idle
2.5 Engine Cooling System 5.2 Maintenance Diagrams
2.5.1 Cooling System 5.3 Maintenance Work Completed 9 Technical Specification
9.1 Engine Specifications and Settings
3 Operation 6 Service and Maintenance 9.2 Torque Wrench Settings
3.1 Commissioning 6.1 Lubrication System
3.1.1 Adding Engine Oil 6.1.1 Oil Change Intervals 10 Service
3.1.2 Checking the Oil Level 6.1.2 Checking the Oil Level/Engine Oil
3.1.3 Adding Fuel Change
3.1.4 Adjusting the Throttle 6.1.3 Oil Filter Change
3.1.5 Other Preparations 6.2 Fuel System
3.1.6 Additional Maintenance Work 6.2.1 Fuel filter change
3.2 Starting 6.3 Cooling System
3.2.1 Starting with the Crank 6.3.1 Cleaning Intervals
3.2.2 Electric Start 6.4 Combustion Air Filter
3.3 Monitoring Systems 6.4.1 Standard Air Filter
3.3.1 Engine Oil Pressure 6.4.2 Dry Type Air Cleaner
3.3.2 Engine Temperature 6.5 Adjustments
3.4 Shutdown 6.5.1 Check Valve Clearance, adjust if
3.4.1 Mechanical Shut-Off necessary
3.4.2 Electrical Shutdown 6.6 Accessories
6.6.1 Battery
General information
DEUTZ diesel engines
are the product of many years of research
and development. The resulting know-how,
coupled with stringent quality standards,
guarantee their long service life, high reliability
and low fuel consumption.
It goes without saying that the highest
standards for environmental protection are
met.
Safety precautions when the
engine is running
Shut the engine down before carrying out
maintenance or repair work. Ensure that the
engine cannot be accidentally started,
accidents may otherwise occur.
When the work is complete, be sure to refit any
panels and guards that have been removed.
Never fill the fuel tank while the engine is
running.
Observe industrial safety regulations when
running the engine in an enclosed space or
underground.
Service and Maintenance
will ensure that the engine continues to meet
your requirements. Recommended service
intervals must be observed and maintenance
work carried out conscientiously.
Special care should be taken under abnormally
demanding operating conditions.
Safety
This symbol is used for all safety
instructions. Follow these
instructions particularly care-
fully.
The attention of operating
personnel should be drawn to
these safety instructions.
In addition to these instructions, the respec-
tive general safety and accident prevention
regulations must be observed.
Service
1
Please contact one of our authorised service
representatives in the event of breakdowns
or for spare parts inquiries. Our trained
specialists will carry out repairs quickly and
professionally, using only genuine spare
parts.
Genuine spare parts from DEUTZ AG are
always manufactured to the highest technical
standards. A table of service contact numbers
is given at the end of this Operation Manual.
Asbestos
The seals and gaskets used in
this engine are asbestos-free.
© 2003
 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

© 36 672 0 © 36 673 0 © 36 674 0

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.
© 2003
2.1 Model Description of the Engine

2.1.4 Direct Injection System of

the D 909 L1
2

© 36 687 0

Engines with direct injection are used in

applications where high power outputs are
required.

© 2003
 Description of the Engine 2.2 Engine Illustrations

2.2.1 Service Side

2
1 Fuel filler neck
2 Cylinder head cover
3 Oil filler neck
4 Decompression lever
5 Camshaft
6 Throttle lever
7 Cover (option: location for attaching
hydraulic pump)
8 Lube oil filter
9 Starter
10 Injection pump
11 Battery charge regulator
12 Fuel tank
© 2003

© 36 688 0
2.2 Engine Illustrations Description of the Engine

2.2.2 Oil Dipstick and Oil Drain

Side
2
13 Cover / dry type air cleaner
14 Oil drain plug
15 Oil dipstick
16 Exhaust muffler

© 2003
© 36 689 0
 Description of the Engine 2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Circuit Schematic

2
1 Intake manifold
2 Oil pump
3 Oil filter
4 Safety valve
5 Crankshaft
6 Camshaft
7 Valve tappet
8 Push-rod guide
9 Rocker arm
10 Piston
11 Valves
© 2003

© 36 692 0
2.4 Fuel System Description of the Engine

2.4.1 Fuel System

2
1 Fuel tank (14.5 litres)
2 Fuel filter
3 Line to the injection pump
4 Injection pump
5 Injection line
6 Injection nozzle
7 Automatic discharge line
8 Fuel return line

© 2003
© 36 693 0
 Description of the Engine 2.5 Engine Cooling System

2.5.1 Cooling System

2
1 Fan wheel
2 Cooling air inlet
3 Cooling air outlet
© 2003

© 36 695 0
 Operation

3
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Shutdown
3.5 Operating Conditions

© 2003
 Operation 3.1 Commissioning

3.1.1 Adding Engine Oil 3.1.2 Checking the Oil Level 3.1.3 Adding Fuel
3

© 36 696 0 © 36 697 0 © 36 698 0

The engines are normally delivered without
oil.
Pour lube oil into the oil filler neck (arrow).
For oil grade and viscosity, see Chapter 4.1.
Check the oil level with the dipstick (with
engine on horizontal surface).
The engines are delivered without fuel.
Fill up the fuel tank by pouring fuel into the filler
neck (arrow).
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.

Always switch off the engine

© 2003

before re-fuelling!
Ensure cleanliness!
Do not spill fuel!
3.1 Commissioning Operation

3.1.4 Adjusting the Throttle

3
Throttle lever fine setting Vehicle throttle lever

© 36 699 0 © 36 700 0

Move lever 1 into operating position. Move lever 1 into idle position.

Increase/reduce engine speed by turning the
knurled nut 2.
The maximum number of rotations is limited by
the stop.
Turn to the left = reduce engine speed.
Turn to the right = increase engine speed.
To increase the number of revolutions turn
the lever in the direction of the arrow.
The maximum number of rotations is limited by
the stop.

© 2003
 Operation 3.1 Commissioning

3.1.5 Other Preparations 3.1.6 Additional Maintenance

3 Work

z Check battery and cable connections, see
6.6.1.1
z Transport hooks
Remove them if fitted (see 6.6.3).
When commissioning new and reconditioned
engines, the following additional maintenance
work must be carried out:
z Change lube oil, see 6.1.2.

z Trial run z Change oil filter, see 6.1.3.

After carrying out these preparations
execute a brief trial run for 10 minutes. Do z Check the valve clearance and adjust if
not load engine during this period. necessary, see 6.5.1.

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.
© 2003
3.2 Starting Operation

3.2.1 Starting with the Crank

3
Before starting, make sure that
nobody is standing in the
immediate vicinity of the engine
or driven machine.
After repair work:
Check to see if all safety devices and
guards have been re-attached and that all
tools have been removed from the engine.

z When starting with the sheathed glow

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

z If possible, de-couple the engine from the

equipment being driven - this will make it
easier to start.
z Watch out for the restoring moment of the
crank if the crank has not been removed
after starting the engine. Risk of accident!
z To repeat the starting process wait until the
engine is at a complete standstill.
z Move the decompression lever 1 to position "A".
© 36 701 0
z Slowly crank the engine a few turns - the
injection nozzle will spray continuously at
this point.
z With force, turn the crank as quickly as
possible, then move lever 1 to position "B"
and turn again until it fires.
z Remove the crank immediately after the
engine fires.

© 2003
 Operation 3.2 Starting

3.2.2 Electric Start

3 Without Starting Aid for Cold
Start
Before starting, make sure that
nobody is standing in the
immediate vicinity of the engine
or driven machine.
After repair work:
Check to see if all safety devices and guards
have been re-attached and that all tools have
been removed from the engine.
When starting with sheathed glow plug, do
not use any other starting aid (e.g. injection
with start pilot). Risk of accident!

© 36 702 0 © 25 746 2

z Where possible, disengage the clutch to z Insert ignition key.

separate the engine from any driven parts. - Position 0 = operating voltage off
z Move speed control lever 1 into operating z Turn key clockwise.
position (arrow). - Position 1 = operating voltage on
- The pilot lamps light up.
z Turn key clockwise against spring
pressure.
- Position 2 = Start
Do not operate the starter for more than 20 z Release key as soon as engine fires.
seconds continuously. If the engine does not - The pilot lamps will go out.
start, wait one minute and repeat the start After starting, another attempt can only be
process. made after resetting to position 0 (stop).
If the engine does not catch after two attempts,
© 2003

then refer to the Fault Table (see 7.1).

3.2 Starting
With cold start assistance/
sheathed glow plug
DURATERM
© 25 746
z Insert the ignition key.
- Position 0 = operating voltage off
z Turn key clockwise.
- Position 1 = operating voltage on
- The pilot lamps light up.
z At temperatures below 0° C, keep the key
in this position for 4-5 seconds. Plug pre-
heating times.
z Turn key clockwise against spring
pressure.
- Position 2 = Start
Operation
3
2
z At temperatures above 0° C, the key can
be moved from position 1 to position 2
immediately. The pre-glow process will
then not take place.
z Release key as soon as engine fires.
z After starting, another attempt can only be
made after resetting to position 0 (stop).
The operating voltage must not be present for
more than 8 seconds (position 1), otherwise
© 2003
the relay may burn out.
 Operation 3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

3
Oil pressure lamp Oil pressure indicator Oil pressure gauge

© 25 752 1 © 25 753 0 © 25 754 0

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.
© 2003
3.3 Monitoring Systems Operation

3.3.2 Engine Temperature

3
Engine temperature gauge

© 24 985 2

z The pointer of the temperature gauge must

always remain in the green sector. If the
pointer moves into the red sector, the
engine is overheating. Turn off the engine
and establish the cause from the Fault
Table (see 7.1).

© 2003
 Operation 3.4 Shutdown

3.4.1 Mechanical Shut-Off 3.4.2 Electrical Shutdown

3
Ignition Key

© 36 703 0 © 25 746 2

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.

If possible, do not suddenly switch the engine

© 2003

off when at full load.

3.5 Operating Conditions Operation

3.5.1 Winter Operation

z Lube oil viscosity 3
- Select the oil viscosity (SAE grade) - For successful cold-starting, it is essential
according to ambient temperature before that the battery charge is good, see 6.6.1.
starting engine, see 4.1.2. - If the battery is warmed to around +20º C
- If the engine is being operated at (remove battery and store in a temperature-
temperatures below -10º C, the oil will controlled location), the starting temperature
need to be changed more frequently, see limit is reduced by 4-5º C.
6.1.1.
z Diesel fuel
- At temperatures below 0º C, use a winter
fuel, see 4.2.2.
z 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. © 26 248 0
- 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).
z Cold start aids
At temperatures below zero degrees, a
pre-heating plug may have to be used for
starting, see 3.2.2. This not only reduces
the temperature limit for starting but also
makes it easier to start at temperatures at
which starting aids are not normally
required.

© 2003
z Battery
 Operation 3.5 Operating Conditions

3.5.2 High Ambient

3 Temperatures, High Altitudes

z At high altitudes or when the ambient

temperature rises, air density decreases.
As a result of this, the engine's maximum
output, the quality of the exhaust gas, the
temperature level and, in extreme cases,
starting behaviour, are impeded. In non-
steady state operating conditions, the engine
can be operated at altitudes of up to 1,000 m
and at temperatures of up to 30º C. In less
favourable operating conditions (higher
altitudes and higher temperatures), the
quantity of fuel injected must be reduced
and the engine power output falls as a
result.

z If you have any doubts about engine

operation under these or similar conditions, © 25 901 1
ask your engine or equipment supplier
whether the required reduction in fuel
quantity has been achieved by adjusting
the injection pump accordingly in the
interests of reliability, service life and
exhaust gas quality (smoke). Alternatively,
contact DEUTZ SERVICE.
© 2003
 Operating Media

4
4.1 Lube Oil
4.2 Fuel

© 2003
 Operating Media 4.1 Lube Oil

4.1.1 Quality Grade 4.1.2 Viscosity

4
Lube oils are differentiated according to their
performance and quality class. In common
use 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
As the viscosity of the lube oil is dependent
on temperature, the choice of viscosity class
(SAE grade) should be governed by the
ambient temperature prevailing at the engine
operating site. To maintain optimum operating
conditions, the user can use the viscosity
table on this page as a guide.
Should the temperature fall temporarily below
the lower limit, cold starting behaviour will
change but the engine will not be damaged.
If the temperature rises above the upper limit,
avoid operating the engine under these
conditions for long periods of time, to prevent
excessive engine wear.
If multigrade oils are used, there is no need to
change the oil according to the season.
Multigrade oils, particularly partially or fully
synthetic oils, whose viscosity does not
fluctuate with temperature, reduce fuel
consumption.

*Oil change intervals, see 6.1.1

© 2003

© 30 298 1
Oil fills, see 9.1
4.2 Fuel Operating Media

4.2.1 Quality Grade 4.2.2 Winter Grade Fuel

4
Use commercially available diesel fuels with At very low ambient temperatures, the fuel +32 0
less than 0.5 % sulphur content. If the sulphur system may become blocked as a result of I
content is higher, oil change intervals should paraffin decomposition; this may cause +23 -5
be reduced, see 6.1.1. operating faults. At ambient temperatures
below 0º C, use winter grade diesel (down to +14 - 10
The following fuel specifications / standards -15º C); normally this fuel will be on sale at
are approved: filling stations before the start of winter. + 5 - 15
Sometimes diesel fuel with additives
● DIN EN 590 ("superdiesel") may be available; this can be
- 4 - 20
used down to temperatures of -20° C.
● BS 2869: A1 and A2 - 13 - 25
(in the case of A2, note the sulphur ● At temperatures below -15° C or -20° C, the
II
content) fuel must be mixed with kerosene. The - 22 - 30
relevant percentages are given in the
● ASTM D 975-88; 1-D and 2-D adjacent diagram. 0 10 20 30 40 50 60 %
°F °C B

● NATO code: F-54 and F-75. ● Special diesel fuels may be used in arctic A
26441 1

climatic zones down to -44° C.

Exhaust emission values which may be
calculated in the course of type approval
tests always refer to the reference fuel
prescribed by the authorities for the type
approval test.
Legend:
If summer-grade diesel fuel has to be used at
temperatures below 0° C, up to 60% kerosene
can be added (see adjacent diagram). I Summer diesel
II Winter diesel
In most cases, adequate resistance to cold
can also be obtained by adding a flow improver A Ambient temperature
(additive). Please ask your DEUTZ partner.
B % of kerosene mixed with the fuel

Do not mix the fuels until they

© 2003
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

© 2003
 Maintenance 5.1 Maintenance Schedule

Operating Hours (OP)1 check

5
every every clean see
Section
change
10 OP
or
Activity
daily 125 250 500 1000 2000 3000 5000
z z Oil level in engine 6.1.2

z z Engine leaks

z z Dry type air cleaner 3) 4) 6.3/6.4

z z Battery and cable connections 6.6.1

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 Oil filter element 6.1.3

z z Fuel filter 6.2.1

z z z Valve clearance (adjust if necessary) 6.5.1

z z Engine suspension (tighten if required) 9.2

z z Glow plug 6.8.1

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.
© 2003

4)Replace if required. Wait until the

maintenance display appears, if fitted.
5.2 Maintenance Diagrams Maintenance

The self-adhesive maintenance diagram 5

shown on this page is supplied with each
engine. It should be affixed to the engine or
machine where it can be seen clearly.

Check to see if this instruction has been

followed!

If necessary, request a replacement

maintenance diagram from the engine or
machine supplier.

Regular maintenance should be done in

accordance with the maintenance schedule
(see 5.1).

Stop the engine before carrying

out maintenance work.

© 2003
 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.
© 2003

* Commissioning new and fully reconditioned engines.

5.3 Maintenance Work Completed Maintenance

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.

© 2003
 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
© 2003

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

© 2003
 Service and Maintenance 6.1 Lubrication System

6.1.1 Oil Change Intervals

6 Built-in engines
Oil change intervals in
operating hours
Naturally-aspirated engines
z The oil change intervals are dependent on
Lube oil quality API specification CF / CF-4
the engine application and the quality of the
lube oil. ACEA specification E2-96
z If the engine runs fewer hours during the Normal load, for example:
year than stated in the table, the oil should
be changed at least once a year.
Road vehicles, cranes, construction machinery, ships, generating 500
z The following conditions apply for the data
given in the table: sets, rotary pumps, etc.
- For diesel fuel: Sulphur content max.
0.5% by weight
- Continuous ambient temperature of -10º C
(+14º F). Higher than normal load, for example: 250
z If the fuels used have a sulphur content
> 0.5% to 1%, or if the ambient temperature Combine harvesters, emergency pumps, underground mining
is continually lower than -10º C (+14º F), units, road sweepers forwinter maintenance service,
the oil change intervals should be halved. emergency generators, etc.

z If the fuels used have a sulphur content of

more than 1%, consult the service
company responsible for you. Oil change intervals in
Vehicle engines operating hours
Naturally-aspirated engines

Lube oil quality API specification CF / CF-4

ACEA specification E2-96

Average driving
Service group Annual usage km
© 2003

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

6.1.2 Checking the Oil Level/

Engine Oil Change
6
6.1.2.1Checking the Oil Level 6.1.2.2 Engine Oil Change

© 25 729 0 © 26 022 0 © 26 023 0

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

© 2003
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!

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

 Service and Maintenance
6.1.3 Oil Filter Change
6
© 36 704 0
z Undo the lubricant filter element using a
commercial tool; unscrew and remove it.
z Catch any escaping oil.
Caution is required in the case of
© 2003
hot oil: Risk of scalding!
© 36 705 0
z If necessary, clean the sealing surface of
the filter housing.
z Lightly oil the rubber gasket of the new lube
oil filter element.
z Manually screw in the new filter element
until the gasket is flush.
6.1 Lubrication System
© 36 706 0
z Tighten the fuel filter insert with a final half-
turn.
z Check the oil level, see 6.1.2.
z Check the oil pressure, see 3.3.1.
z Check the oil filter element for leaks.
6.2 Fuel System Service and Maintenance

6.2.1 Fuel filter change

6

© 36 707 0 © 36 708 0

z Place a suitable container under the filter
and catch any escaping fuel.
z Close the fuel feed line (using any aid).
z Slacken the clips 1 and the two ends of the
filter line, remove the filter and insert a new
filter.
z When installing the new fuel filter, note the
direction of flow (arrow).
z After a short functional test, check the filter
and lines for leaks.
z If the fuel is heavily contaminated, the filter
change interval must be shortened to 250
hours.

Do not work with any naked The fuel system does not need to be bled.

© 2003
flames and do not smoke when
working on the fuel system.
 Service and Maintenance 6.3 Cooling System

6.3.1 Cleaning Intervals

6
z The amount of contamination in the cooling
system depends on the engine application. Inspection and cleaning
intervals Type of engine operation
z Oil and fuel residues on the engine increase Guidelines
the risk of contamination. If the ambient air Operating hours (OH)
contains a lot of dust, pay special attention
to leaks. 2000 Ships, generating sets in enclosed areas, pumps
z There is a high risk of contamination in the 1000 Vehicles on paved roads
following conditions: 500 Tractors, fork-lift trucks, mobile generating sets
- Construction site applications because of
the high dust content in the air. 250 Vehicles on construction sites and unpaved roads, construction
- Harvesting applications, because of the machines, compressors and underground mining units
large amount of cereal husks and straw 125 Agricultural machines, tractors in harvesting applications
around the machine.

z Because working conditions vary, suitable

cleaning intervals must be specified for
each individual case. The cleaning intervals
listed in the adjacent table should only be
used as a guide.
© 2003
6.4 Combustion Air Filter Service and Maintenance

6.4.1 Standard Air Filter

6
z The maintenance indicator (sticker on the
engine) gives the general cleaning intervals
for the standard air filter. However, the
filter element must always be replaced
after 250 operating hours, regardless of
this. Proceed as follows:

z Slacken screw 1 and remove, together with

the cover 2.
z Carefully pull out the filter element 3.
z Clean the filter element 3.
Blow compressed-air through the filter
element, from the inside out (max. 5 bar,
shake and tap out in difficult cases only).
z Insert the filter element 3, fit the cover 2 and
tighten with the screw 1.
© 36 709 0
z Gaskets on the filter element can become
damaged through regular removal and
replacement. Check the filter element for
damage to the filter paper (use backlight)
and for leaks.
Replace if necessary.

© 2003
 Service and Maintenance
6.4.2 Dry Type Air Cleaner
6
Dust Discharge Valve
© 25 888 1
z Empty the dust discharge valve 1 by
pressing together lips of discharge slot as
indicated by arrows.
z Clean discharge slot from time to time.
z Remove any caked dirt by pressing together
the upper section of the valve.
© 2003
Filter elements
© 36 710 0
z Undo the clip fastener 1.
z Remove the filter cover 2 and pull out the
filter element 3.
z Clean the filter element, replace after one
year at the latest.
z Clean the filter element 3.
Blow through from the inside out with
compressed-air (max. 5 bar, shake and tap
out in difficult cases only, or rinse according
to the manufacturer's instructions, without
damaging the element).
6.4 Combustion Air Filter
z Gaskets on the filter element 3 can become
damaged through regular removal and
replacement. Check the filter element 3 for
damage to the filter paper (use backlight)
and for leaks. Replace any damaged parts
as required.
z Insert the filter element 3 and attach the
filter cover 2 with the clip fastener 1.
Under no circumstances rinse
the filter element 3 with petrol or
hot liquids!
6.5 Adjustments Service and Maintenance

6.5.1 Check Valve Clearance,

adjust if necessary
6

© 19 691 2 © 26 053 1

z Remove the cylinder head cover.
z Position of the crankshaft
Turn the crankshaft until both valves in
cylinder 1 overlap (i.e., the exhaust valve
is not yet closed and the inlet valve is
beginning to open). Adjust the valve
clearance.
z Before adjusting the valve clearance allow
the engine to cool for at least 30 minutes,
the oil temperature must be below 80º C.
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
z If necessary, adjust the valve clearance;
proceed as follows:
- Release locknut 4.
- Use screwdriver 7 to turn setscrew 5 so
that the correct valve clearance is attained
after locknut 4 has been tightened.
z Check and adjust valve clearance on all
remaining cylinders.
z Re-fit the cylinder head cover with a new
gasket.

© 2003
slight resistance when feeler blade is
inserted). For permissible valve clearance,
see 9.1.
 Service and Maintenance
6.6.1 Battery
6 6.6.1.1Checking Battery and Cable
Connectors
© 25 895 0
z Keep the battery clean and dry.
z Undo dirty clamps.
z Clean terminal posts (+ and -) and clamps
of the battery, and grease with acid-
resistant grease.
z When re-installing the clamps, ensure that
there is contact between the connections.
Tighten the clamp bolts hand-tight.
© 2003
6.6.1.2Checking Electrolyte Level
© 24 232 3
z Remove the seal caps 1.
z If testers 2 are present: The electrolyte
level should reach base of these.
z If the testers 2 are not present: The
electrolyte level should be 10-15 mm above
the top of the plates.
z If necessary, top up with distilled water.
z Screw the sealing caps 1 back in.
6.6 Accessories
6.6.1.3 Checking Electrolyte Density
© 25 896 0
z Measure the electrolyte density of indivi-
dual cells with a commercial hydrometer.
Hydrometer reading (see table on following
page) indicates battery's state of charge.
During measurement, the temperature of
the electrolyte should preferably be +20° C.
6.6 Accessories Service and Maintenance

in [kg/l] in [º Bé (degrees Baumé)*] Charge condition 6

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 battery

are explosive! Keep sparks and
naked flames away from the
battery! Do not allow battery
acid to come into contact with

© 2003
skin or clothing! Wear protective goggles! Do
not rest tools on the battery!
 Service and Maintenance 6.6 Accessories

6.6.2 Magnet plate 6.6.3 Transportation Shackles

6
Notes on the alternating current system:

z Never disconnect the cables between

battery, alternator and regulator while the
engine is running.
z If, however, it is necessary to start and
operate the engine without the battery,
disconnect the regulator from the alternator
before starting.
z Do not mix up or interchange the battery
clamps.
z If the charge pilot lamp is faulty, replace it
immediately.
z When washing the engine, cover the cooling
air inlets, the regulator and the alternator.
z In case of electric welding, connect the
© 36 711 0 © 36 712 0
ground terminal on the welder directly to
the piece being welded.
z Always use proper lifting tackle when
transporting the engine.

Use only the correct lifting

© 2003

tackle.
6.7 Engine Cleaning
6.7.1 Engine Cleaning
Using compressed air
© 36 713 0
z Switch off the engine and wait until it is cold.
z Remove the fuel tank, the fuel lines and cooling
air hoses and seal off the feed line.
z Cover the cooling air inlets and the electrical
connections and components (for example
the starter motor, regulator).
z Blow air through the engine, paying particular
attention to the cooling fins of the cylinder and
cylinder head. Before reinstalling, clean the
hoses, the fuel tank and the lines. Clean any dirt
from the engine room/compartment.
Clean the engine only when the
engine is switched off.
Service and Maintenance
Using cold-cleaning compound
© 36 714 0
z Switch off the engine and wait until it is cold.
z Remove the fuel tank, the fuel lines and cooling
air hoses and seal off the feed line.
z Cover the cooling air inlets and the electrical
connections and components (for example
the starter motor, regulator).
z Spray the engine with a commercially
available cold cleaner and allow it to react
for around 10 minutes.
z Clean the engine with a powerful water jet, if
necessary repeat the process.
z Before reinstalling, clean the hoses, the fuel
tank and the lines.
Allow the engine to run warm so that the
remaining water evaporates.
6
Using high pressure device
© 36 715 0
z Switch off the engine and wait until it is cold.
z Remove the fuel tank, the fuel lines and cooling
air hoses and seal off the feed line.
z Cover the cooling air inlets and the electrical
connections and components (for example
the starter motor, regulator).
z Clean the engine with a steam jet (max. 60
bar, steam temperature max. 90º C).
z Before reinstalling, clean the hoses, the fuel
tank and the lines.
z Allow the engine to run warm so that the
remaining water evaporates.
© 2003
 Service and Maintenance 6.8 Additional Maintenance Work

6.8.1 Sheathed Glow Plug

6

© 25 746 2 © 36 716 0

Move the speed control lever 1 to the STOP

position.
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.
© 2003
 Troubleshooting

7.1 Fault Table

© 2003
 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
© 2003

● ● Lube oil too viscous R

7.1 Fault Table Troubleshooting

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

© 2003
● 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
© 2003
 Engine Preservation

8
8.1 Preservation

© 2003
 Engine Preservation
8.1 Preservation
8 8.1.1 Engine Preservation
If the engine is to remain idle for an extended
period of time, appropriate protective
measures have to be taken to prevent rust.
The protective measures described here will
protect the engine for a maximum downtime
of 6 months. Before re-commissioning the
engine, the preservative residues will have
to be removed.
● Anti-corrosion oils to specification:
- MIL-L-212608
- L 9150-037/2
- NATO Code C 640 / 642
● Recommended cleaning products when
recommissioning the engine after being
idle:
Petroleum benzine (hazardous materials
class A3)
© 2003
8.1 Preservation
8.1.2 Recommissioning After the
Engine Has Been Idle
● Clean the engine with a high-pressure ● Fill the fuel tank.
cleaner (if necessary using a cold cleaner).
● Allow the engine to warm up and then ● Remove the plugs from the inlets and outlets.
switch it off.
● Drain the engine oil (see Chapter 6.1.2) and ● Commission the engine.
fill 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 combustion
chambers.
● When turning over with a starter, set the
shut-off lever to the "stop" position.
● The inlets and outlets can be sealed off
with plugs.
● Drain the corrosion protection oil.
 Technical Specification

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

© 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).
© 2003
9.2 Torque Wrench Settings Technical Specification

Location Initial tightening Subsequent tightening Total Notes

9
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

© 2003
 Service

It's good to know it's a DEUTZ. 0312 0806

Order no.:
10
es DEUTZ has long been one of the leading engine
manufacturers. As an independent manufacturer,
we offer - worldwide - a comprehensive range of
diesel and petrol engines, (ranging in power output
from 4 to 7,400 kW. Our products are tailor-made to
meet our customers' requirements.

Over 1,400,000 DEUTZ engines are in reliable

operation in various parts of the world. We want to
maintain the high performance levels of our engines
and thereby the trust and satisfaction of our
customers; as a result we have a worldwide network
of service branches who will meet the needs of our
customers, wherever they are.

So the name DEUTZ does not merely mean engines

that are the products of extensive development
work, DEUTZ also stands for complete service
packages that ensure optimum operation of our
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This Register Sales & Service offers you an 0312 0807

overview of the DEUTZ service branches in your Order no.: (CD-ROM)
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even if a specific product is not on the list, you can Available from your local dealer or from: DEUTZ AG
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Always at your service.
it

DEUTZ MOTOR España, S.A. DEUTZ AG

Avda. de los Artesanos, 50, 1ª Planta Service-Technik
E-28760 TRES CANTOS (MADRID) Instandhaltungstechnik Motoren
SPAIN (Engine servicing)
Phone: +34-91 807 45 00 Deutz-Mühlheimer Str. 147-149
Fax: +34-91 807 45 02 D-51057 Köln
Phone: 02 21-8 22-0
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