DEUTZ 914 O&M MANUAL.pdf
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User guide and maintenance manual D D E E U U T T Z Z E E n n g g i i n n e e 9 9 1 1 4 4 03120382 01/01/2002 33522910601_0_1
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DEUTZ 914 ENGINE OPERATION AND MAINTENANCE MANUAL
Transcript of DEUTZ 914 O&M MANUAL.pdf
User guide and maintenance manual
DDEEUUTTZZ
EEnnggiinnee
991144
03120382 01/01/2002
33522910601_0_1
Op
erat
ion
Man
ual
914
●P
leas
e re
ad a
nd o
bser
ve t
he i
nfor
mat
ion
give
n in
thi
s O
pera
tion
Man
ual.
Thi
s w
illen
able
you
to a
void
acc
iden
ts, p
rese
rve
the
man
ufac
ture
r’s w
arra
nty
and
mai
ntai
n th
een
gine
in p
eak
oper
atin
g co
nditi
on.
●T
his
engi
ne h
as b
een
built
exc
lusi
vely
for
the
appl
icat
ion
spec
ified
in
the
scop
e of
supp
ly, a
s de
scrib
ed b
y th
e eq
uipm
ent m
anu-
fact
urer
and
is
to b
e us
ed o
nly
for
the
inte
nded
pur
pose
. Any
use
exc
eedi
ng t
hat
scop
e is
con
side
red
to b
e co
ntra
ry t
o th
ein
tend
ed p
urpo
se.
The
man
ufac
ture
r w
illno
t as
sum
e re
spon
sibi
lity
for
any
dam
age
resu
lting
the
refr
om.
The
ris
ks i
nvol
ved
are
to b
e bo
rne
sole
ly b
y th
e us
er.
●U
se i
n ac
cord
ance
with
the
int
ende
d pu
r-po
se a
lso
impl
ies
com
plia
nce
with
the
con-
ditio
ns l
aid
dow
n by
the
man
ufac
ture
r fo
rop
erat
ion,
mai
nten
ance
and
ser
vici
ng.
The
engi
ne s
houl
d on
ly b
e op
erat
ed b
y pe
rson
-ne
l tr
aine
d in
its
use
and
the
haz
ards
in-
volv
ed.
●T
he re
leva
nt a
ccid
ent p
reve
ntio
n gu
idel
ines
and
othe
r ge
nera
lly a
ccep
ted
safe
ty a
ndin
dust
rial
hygi
ene
regu
latio
ns m
ust
be o
b-se
rve
d.
●W
hen
the
engi
ne is
runn
ing,
ther
e is
a ri
sk o
fin
jury
thr
ough
:-
turn
ing/
hot
com
pone
nts
- en
gine
s w
ith p
ositi
ve i
gniti
on-
igni
tion
syst
ems
(hig
h el
ectr
ical
vol
tage
) Y
ou m
ust
avoi
d co
ntac
t at
all
times
!
●U
naut
horiz
ed e
ngin
e m
odifi
catio
ns w
ill i
n-va
lidat
e an
y lia
bilit
y cl
aim
s ag
ains
t the
man
u-fa
ctur
er f
or r
esul
tant
dam
age.
Man
ipul
atio
ns o
f the
inje
ctio
n an
d re
gula
ting
syst
em m
ay a
lso
influ
ence
the
perf
orm
ance
of th
e en
gine
, and
its
emis
sion
s. A
dher
ence
to le
gisl
atio
n on
pol
lutio
n ca
nnot
be
guar
an-
teed
und
er s
uch
cond
ition
s.
●D
o no
t cha
nge,
con
vert
or a
djus
t the
coo
ling
air
inta
ke a
rea
to t
he b
low
er.
The
man
ufac
ture
r sh
all n
ot b
e he
ld r
espo
n-si
ble
for
any
dam
age
whi
ch r
esul
ts f
rom
such
wor
k.
●W
hen
carr
ying
out
mai
nten
ance
/rep
air
op-
erat
ions
on
the
engi
ne,
the
use
of D
EU
TZ
orig
inal
par
ts is
pre
scrib
ed. T
hese
are
spe
-ci
ally
des
igne
d fo
r yo
ur e
ngin
e an
d gu
aran
-te
e pe
rfec
t op
erat
ion.
Non
-com
plia
nce
resu
lts in
the
exp
iry o
f th
ew
arr
an
ty!
●M
aint
enan
ce a
nd c
lean
ing
of t
he e
ngin
esh
ould
onl
y be
car
ried
out w
hen
the
engi
neis
sw
itche
d of
f an
d ha
s co
oled
dow
n.Y
ou m
ust e
nsur
e th
at th
e el
ectr
ical
sys
tem
sha
ve b
een
switc
hed
off a
nd th
e ig
nitio
n ke
yha
s be
en r
emov
ed.
Acc
iden
t pr
even
tion
guid
elin
es c
once
rnin
gel
ectr
ical
sys
tem
s (e
.g.
VD
E-0
100/
-010
1/-
0104
/-01
05 E
lect
rical
pro
tect
ive
mea
sure
sag
ains
t dan
gero
us to
uch
volta
ge)
are
to b
eo
bse
rve
d.
Whe
n cl
eani
ng w
ith fl
uids
, all
elec
tric
al c
om-
pone
nts
are
to b
e co
vere
d im
perm
eabl
y.
Saf
ety
gu
idel
ines
/ A
ccid
ent p
reve
nti
on
Op
erat
ion
Man
ual
914
0312
038
2 en
Eng
ine
Ser
ial N
umbe
r
Tech
nica
l m
odifi
catio
ns r
equi
red
to i
mpr
ove
our e
ngin
es a
re re
serv
ed w
ith re
gard
to s
peci
-fic
atio
n da
ta a
nd o
ther
tec
hnic
al i
nfor
mat
ion
cont
aine
d in
this
Ope
ratio
n M
anua
l. N
o pa
rts
ofth
is M
anua
l may
be
repr
oduc
ed in
any
form
or
by a
ny m
eans
with
out
our
writ
ten
appr
oval
.
Ple
ase
ente
r th
e en
gine
ser
ial
num
ber
here
.T
his
num
ber
shou
ld b
e qu
oted
whe
n in
quiri
ngab
out
Cus
tom
er S
ervi
ce,
Rep
airs
or
Spa
reP
arts
(se
e S
ectio
n 2.
1).
Fo
rew
ord
Dea
r Cus
tom
er,
Air
/ liq
uid-
cool
ed D
eutz
eng
ines
are
des
igne
dfo
r a
larg
e nu
mbe
r of
app
licat
ions
. C
onse
-qu
ently
, a
wid
e ra
nge
of v
aria
nts
is o
ffere
d to
mee
t th
e re
quire
men
ts o
f sp
ecifi
c ca
ses.
Your
eng
ine
is a
ppro
pria
tely
equ
ippe
d fo
r th
ein
stal
latio
n co
ncer
ned,
whi
ch m
eans
tha
t no
tal
l of t
he c
ompo
nent
s de
scrib
ed in
this
Ope
ra-
tion
Man
ual a
re n
eces
saril
y m
ount
ed t
o yo
uren
gine
.
We
have
end
eavo
ured
to
high
light
any
diff
er-
ence
s so
that
you
will
be
able
to lo
cate
thes
esdi
ffere
nces
rel
evan
t to
you
r en
gine
.
Ple
ase
read
thi
s M
anua
l bef
ore
star
ting
your
engi
ne, a
nd a
lway
s ob
serv
e th
e op
erat
ing
and
mai
nten
ance
ins
truc
tions
.
We
are
avai
labl
e to
hel
p w
ith a
ny a
dditi
onal
inqu
iries
Sin
cere
ly,
DE
UT
Z A
G
Ind
ex
1G
en
era
l2
En
gin
e D
escr
ipti
on
2.1
Mo
de
l2.
1.1
Rat
ing
Pla
te2.
1.2
Pos
ition
of t
he R
atin
g P
late
2.1.
3E
ngin
e S
eria
l Num
ber
2.1.
4C
ylin
der n
umbe
ring
2.1.
5D
irect
inje
ctio
n2.
2E
ng
ine
Illu
stra
tio
ns
2.2.
1O
pera
tion
side
BF
3L 9
142.
2.2
Air
outle
t si
de B
F3L
914
2.2.
3O
pera
tion
side
F4L
914
2.2.
4A
ir ou
tlet
side
F4L
914
2.2.
5O
pera
tion
side
BF
6L 9
14In
terc
oole
r ov
er a
ir-in
take
line
2.2.
6A
ir ou
tlet s
ide
BF
6L 9
14 C
Inte
rcoo
ler
over
air-
inta
ke li
ne2.
2.7
Ope
ratio
n si
de B
F6L
914
CIn
terc
oole
r ov
er f
lyw
heel
2.2.
8A
ir ou
tlet
side
BF
6L 9
14In
terc
oole
r ov
er f
lyw
heel
2.3
Lu
be
Oil
Cir
cuit
Sch
emat
ic2.
3.1
Lube
Oil
Circ
uit S
chem
atic
2.4
Fu
el S
yste
m P
lan
2.4.
1F
uel S
yste
m2.
5E
ng
ine
coo
ling
2.5.
1A
mo
un
t o
f co
ol
air
re
gu
late
d
by
exha
ust
ther
mos
tat
2.5.
2A
mo
un
t o
f co
ol
air
re
gu
late
d
by
exha
ust t
herm
osta
t and
sol
enoi
d va
lve
3E
ng
ine
Op
erat
ion
3.1
Co
mm
iss
ion
ing
3.1.
1P
our i
n E
ngin
e O
il3.
1.2
Fill
ing
Oil B
ath
Air
Filt
er w
ith E
ngin
e O
il3.
1.3
Pou
r in
Fue
l3.
1.4
Ble
ed3.
1.5
Oth
er P
repa
ratio
ns3.
1.6
Add
ition
al m
aint
enan
ce w
ork
3.1.
7C
hang
e-ov
er s
witc
h fo
r oi
l he
ater
3.2
Sta
rtin
g3.
2.1
Sta
rtin
g3.
3M
on
ito
rin
g O
per
atio
n3.
3.1
Eng
ine
Oil
Pre
ssur
e3.
3.2
Eng
ine
tem
pera
ture
3.3.
3C
oolin
g fa
n dr
ive
3.4
Sh
utt
ing
off
3.4.
1M
echa
nica
l sh
ut-o
ff3.
4.2
Ele
ctric
al s
hut-
off
3.5
Op
erat
ing
Co
nd
itio
ns
3.5.
1W
inte
r O
pera
tion
3.5.
2H
igh
Am
bie
nt
Tem
pe
ratu
re,
Hig
hA
ltitu
de4
Op
erat
ing
Med
ia4.
1L
ub
e O
il4.
1.1
Qua
lity
4.1.
2V
isco
sity
4.2
Fu
el4.
2.1
Qua
lity
4.2.
2W
inte
r Fue
l5
Ro
uti
ne
Mai
nte
nan
ce5.
1M
ain
ten
ance
Pla
n5.
2M
ain
ten
ance
Dia
gra
m5.
3M
ain
ten
ance
Wo
rk C
om
ple
ted
6S
ervi
ce a
nd
Mai
nte
nan
ce6.
1L
ub
e o
il sy
stem
6.1.
1O
il ch
ange
inte
rval
s6.
1.2
Che
ck O
il Le
vel /
Cha
nge
Eng
ine
Oil
6.1.
3R
epla
ce O
il F
ilter
6.1.
4C
hang
e by
pass
-oil
filte
r us
e6.
2F
uel
Sys
tem
6.2.
1R
epla
ce f
uel f
ilter
6.2.
2P
recl
eani
ng f
uel/c
lean
fue
l fil
ter
6.3
Co
oli
ng
sys
tem
6.3.
1C
lean
ing
Inte
rval
s6.
4C
om
bu
stio
n A
ir F
ilter
6.4.
1C
lean
ing
Inte
rval
s6.
4.2
Em
ptyi
ng C
yclo
ne T
ype
Pre
clea
ner
6.4.
3C
lean
Oil
Bat
h A
ir F
ilter
6.4.
4D
ry T
ype
Air
Cle
aner
6.5
Bel
t D
rive
s6.
5.1
Che
ck V
-bel
ts6.
5.2
Cha
nge
fan
belt
6.5.
3Te
nsio
n al
tern
ator
bel
ts6.
5.4
Cha
nge
alte
rnat
or b
elts
6.5.
5C
heck
war
ning
sys
tem
6.5.
6Te
nsio
n/ch
ange
air
com
pres
sor
belts
6.5.
7A
ir co
mpr
esso
r mod
el w
ith d
ual b
elts
6.6
Ad
jus
tme
nts
6.6.
1C
heck
val
ve c
lear
ance
(adj
ust
if ne
cess
ary)
6.7
Ac
ce
ss
ori
es
6.7.
1B
atte
ry6.
7.2
Rot
ary
Cur
rent
Alte
rnat
or6.
7.3
Tra
nspo
rtat
ion
Sha
ckle
s6.
8E
ng
ine
clea
nin
g6.
8.1
Eng
ine
clea
ning
6.9
Ad
dit
ion
al M
ain
ten
ance
Wo
rk6.
9.1
Che
ck f
aste
ning
s6.
9.2
Che
ck f
unct
ioni
ng o
f gl
ow p
lugs
7F
ault
s, C
ause
s an
d R
emed
ies
7.1
Fau
lt T
able
8E
ng
ine
Pre
serv
atio
n8.
1P
res
erv
ati
on
8.1.
1P
rese
rve
engi
ne8.
1.2
Rem
ove
engi
ne p
rese
rvat
ion
9Te
chn
ical
Sp
ecif
icat
ion
9.1
En
gin
e S
pec
ific
atio
ns
and
Se
ttin
gs
9.2
Scr
ew T
igh
ten
ing
To
rqu
es9.
3T
oo
ls
10S
erv
ice
1DE
UTZ
Dies
el E
ngin
es
are
the
prod
uct
of m
any
year
s of
res
earc
h an
dde
velo
pmen
t. Th
e re
sulti
ng k
now
-how
, co
uple
dw
ith s
tring
ent
qual
ity s
tand
ards
, gu
aran
tee
thei
rlo
ng s
ervi
ce l
ife,
high
rel
iabi
lity
and
low
fue
lco
nsum
ptio
n.It
goes
with
out s
ayin
g th
at D
EUTZ
Die
sel E
ngin
esm
eet
the
high
est
stan
dard
s fo
r en
viro
nmen
tal
prot
ectio
n.
Serv
ice
Plea
se c
onta
ct o
ne o
f ou
r au
thor
ized
ser
vice
repr
esen
tativ
es in
the
even
t of b
reak
dow
ns o
r for
spar
e pa
rts in
quiri
es. O
ur t
rain
ed s
peci
alis
ts w
illca
rry
out r
epai
rs q
uick
ly a
nd p
rofe
ssio
nally
, usi
ngon
ly g
enui
ne s
pare
par
ts.
Orig
inal
par
ts fr
om D
EUTZ
AG
are a
lway
s pro
duce
din
acc
orda
nce
with
sta
te-o
f-the
-art
tech
nolo
gy.
Plea
se tu
rn to
the
end
of th
is m
anua
l for
furth
erse
rvic
e in
form
atio
n.
Gene
ral
!
Care
and
Mai
nten
ance
Soun
d ca
re a
nd m
aint
enan
ce p
ract
ices
will
ens
ure
that
the e
ngin
e con
tinue
s to
mee
t the
requ
irem
ents
plac
ed o
n it.
Rec
omm
ende
d se
rvic
e in
terv
als
mus
tbe
obs
erve
d an
d se
rvic
e an
d m
aint
enan
ce w
ork
carr
ied
out c
onsc
ient
ious
ly.Sp
ecia
l ca
re s
houl
d be
tak
en u
nder
abn
orm
ally
dem
andi
ng o
pera
ting
cond
ition
s.
Asbe
stos
DEUT
Z or
igin
al p
arts
are
asb
esto
s-fre
e.
Safe
ty
This
sym
bol i
s us
ed f
or a
ll sa
fety
war
ning
s. P
leas
e fo
llow
the
mca
refu
lly. T
he at
tent
ion
of o
pera
ting
pers
onne
l sho
uld
be d
raw
n to
thes
esa
fety
inst
ruct
ions
. Gen
eral
saf
ety
and
acci
dent
pre
vent
ion
regu
latio
ns la
id d
own
byla
w m
ust a
lso
be o
bser
ved.
Bew
are
of R
unni
ng E
ngin
e
Shut
the
engi
ne d
own
befo
re c
arry
ing
out m
aint
e-na
nce o
r rep
air w
ork.
Ens
ure t
hat t
he en
gine
cann
otbe
acc
iden
tally
sta
rted.
Ris
k of
acc
iden
ts.
Whe
n th
e w
ork
is c
ompl
ete,
be
sure
to
refit
any
pane
ls a
nd g
uard
s th
at m
ay h
ave
been
rem
oved
.Ne
ver f
ill th
e fu
el ta
nk w
hile
the
engi
ne is
runn
ing.
Obse
rve i
ndus
trial
safe
ty re
gula
tions
whe
n ru
nnin
gth
e en
gine
in a
n en
clos
ed s
pace
or u
nder
grou
nd.
Calif
orni
aPr
opos
ition
65
War
ning
Dies
el e
ngin
e ex
haus
t and
som
e of
its
cons
ti-tu
ents
are
kno
wn
to th
e St
ate
of C
alifo
rnia
toca
use
canc
er, b
irth
defe
cts,
and
oth
er re
pro-
duct
ive
harm
.
1
2 © 2001
En
gin
e D
escr
ipti
on
2.1
Mo
de
l2.
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The
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© 3
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1F
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35 2
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En
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per
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1 C
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mis
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Fill
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1 of
the
oil b
ath
air
clea
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oil
up t
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.F
or o
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ade
and
visc
osity
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e 4.
1.
Use
onl
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mm
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die
sel
fuel
. F
orfu
el g
rade
, se
e 4.
2. U
se s
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r w
inte
r-gr
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fuel
, dep
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3.1.
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3.1.
3P
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As
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out
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Pou
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be o
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to th
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l fill
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For
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see
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©
24 9
80
2
©
26
39
8
0
3 © 2001
3.1
Co
mm
issi
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En
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●P
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en v
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1, s
till p
umpi
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emov
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llect
ing
tank
and
dis
pose
of t
hefu
el in
an
envi
ronm
enta
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ly m
anne
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3.1.
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del
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●C
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able
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1
●T
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t run
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min
utes
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out
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.
Dur
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un–
Che
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.2If
nece
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e 3.
1.1
–R
eten
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e 6.
5.
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reak
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00 o
per-
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che
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ice
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y.A
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ngin
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in, c
heck
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ill b
e su
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3.1.
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En
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1 C
om
mis
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Afte
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k is
to
be c
arrie
d ou
t:
●C
hang
e lu
be o
il,se
e 6.
1.2
●C
hang
e oi
l filt
er c
artr
idge
,se
e 6.
1.3
●C
hang
e fu
el f
ilter
car
trid
ge,
see
6.2.
1
●lC
heck
V-b
elts
and
ret
ensi
on a
s ne
cess
ary,
see
6.5.
●C
heck
val
ve c
lear
ance
(ad
just
if
nece
s-sa
ry)
see
6.6.
1
●C
heck
the
engi
ne fo
r le
aks
●C
heck
eng
ine
mou
nts
(ret
ight
en i
f ne
ces-
sary
) se
e 9.
2.
3.1.
5O
ther
Pre
par
atio
ns
3.1.
7C
han
ge-
ove
r sw
itch
for
oil
hea
ter
Pos
ition
of
chan
ge-o
ver
switc
h fo
r oi
l fil
ter
cons
oles
with
an
oil
heat
er c
onne
cted
:P
os. 1
: ope
nP
os.
2: c
lose
d Fo
r e
ng
ine
s w
itho
ut
an
o
ilhe
ater
, th
e ch
ange
-ove
r sw
itch
shou
ldal
way
s be
fix
ed t
o P
os.
2: c
lose
d.
©
30 0
27
0
3 © 2001
3
© 2001
0312
038
2 en
Engi
ne O
pera
tion
3.2
Star
ting
3.2.
1El
ectr
ic S
tart
ing
Mak
e su
re th
at n
o-on
e is
stan
ding
in th
e da
nger
are
a of
the
engi
ne/
mac
hine
bef
ore
switc
hing
on.
Afte
r rep
airs
: C
heck
whe
ther
all
prot
ectio
n de
vices
are
mou
nted
and a
ll too
ls ha
ve be
en re
mov
ed fr
om th
e eng
ine.
Do
not
use
any
addi
tiona
l st
artin
g ai
ds (
e.g.
inje
ctio
n w
ith s
tart
pilo
t) w
hen
sta
rting
with
glo
w/
heat
ing
plug
s. D
ange
r of a
ccid
ents
! Atte
ntio
n :
The
engi
ne m
ay n
ever
be
star
ted
with
the
spee
dgo
vern
or r
emov
ed.
Disc
onne
ct th
e ba
ttery
term
inal
s! If
the
engi
nedo
es n
ot s
tart
prop
erly
with
aut
omat
ic st
artin
g of
the
heat
ing
flang
e (s
tarte
r do
es n
ot g
et a
nycu
rrent
due
to
mal
func
tion
in t
he e
quip
men
t/cu
stom
er s
ide
elec
trica
l con
trol),
the
star
t pro
ce-
dure
mus
t be
abo
rted
com
plet
ely
(set
igni
tion
switc
h to
OFF
, int
erru
pt p
ower
sup
ply
for t
hehe
atin
g fla
nge)
.Be
fore
rest
artin
g th
e en
gine
, the
faul
t mus
t be
elim
inat
ed to
avo
id a
ny o
verh
eatin
g da
mag
eto
the
heat
ing
flang
e/ch
arge
air
hose
s.
Do
not
actu
ate
the
star
ter
for
mor
e th
an 2
0se
cond
s. If
the
engi
ne d
oes
not c
atch
, wai
t am
inut
e th
en tr
y ag
ain.
If th
e en
gine
doe
s no
t ca
tch
afte
r tw
o at
-te
mpt
s, re
fer t
o th
e D
iagn
osis
Cha
rt (s
ee 7
.1).
with
out c
old
star
t ass
ista
nce
Whe
re p
ossi
ble,
dis
enga
ge t
he c
lutc
h to
sepa
rate
the
engi
ne fr
om a
ny d
riven
par
ts.
Mov
e sp
eed
cont
rol le
ver 1
into
idle
pos
ition
.M
ove
cut-o
ut h
andl
e 2
in d
irect
ion
of “I
” and
star
t.R
egar
ding
ele
ctric
sta
rting
with
a s
olen
oid,
the
cut-o
ut h
andl
e 2
is p
ulle
d in
dire
ctio
n “I”
and
held
whe
n cu
rren
t is
flo
win
g. T
hech
arge
pilo
t lig
ht a
nd th
e oi
l pre
ssur
e pi
lot
light
go
out.
Inse
rt ke
y–
Posi
tion
0 =
no o
pera
ting
volta
geTu
rn k
ey c
lock
wis
e–
Posi
tion
1 =
oper
atin
g vo
ltage
–Pi
lot li
ghts
illum
inat
ePu
sh k
ey i
n an
d tu
rn f
urth
er c
lock
wis
eag
ains
t sp
ring
pres
sure
.–
Posi
tion
2 =
no fu
nctio
n–
Posi
tion
3 =
star
tR
elea
se k
ey a
s so
on a
s en
gine
fire
s–
The
pilo
t lig
hts
will
go o
ut.
©
25 7
46
2©
35
588
0
Nam
enlo
s-1
02.0
2.20
06, 1
0:38
26
3 © 2001
wit
h c
old
sta
rt a
ssis
tan
ce/g
low
lam
ps
FR
60
= 9,
5 an
d 1
9 Vo
lt
●In
sert
key
–P
ositi
on 0
= n
o op
erat
ing
volta
ge●
Tur
n ke
y cl
ockw
ise
–P
ositi
on 1
= o
pera
ting
volta
ge–
Pilo
t lig
hts
illum
inat
e●
Pus
h ke
y in
and
tur
n fu
rthe
r cl
ockw
ise
agai
nst
sprin
g pr
essu
re–
Pre
heat
lam
p co
mes
on
–P
ositi
on 2
= p
rehe
at fo
r ap
prox
. 60
secs
.(h
oldi
ng k
ey*)
–P
rehe
at la
mp
extin
guis
hes
–P
ositi
on 3
= s
tart
●R
elea
se k
ey a
s so
on a
s en
gine
fire
sT
he p
ilot l
ight
s w
ill g
o ou
t.
3.2
Sta
rtin
gE
ng
ine
Op
erat
ion
wit
h c
old
sta
rt a
ssis
tan
ce/g
low
lam
ps
FR
20/
30 =
11
and
23
Volt
●In
sert
key
–P
ositi
on 0
= n
o op
erat
ing
volta
ge●
Tur
n ke
y cl
ockw
ise
–P
ositi
on 1
= o
pera
ting
volta
ge–
Pilo
t lig
hts
illum
inat
e●
Pus
h ke
y in
and
tur
n fu
rthe
r cl
ockw
ise
agai
nst
sprin
g pr
essu
re–
Pre
heat
lam
p co
mes
on.
–P
ositi
on 2
= p
rehe
at f
or a
ppro
x. 2
0-30
secs
., (
hold
ing
key*
)–
Pre
heat
lam
p ex
tingu
ishe
s–
Pos
ition
3 =
sta
rt●
Rel
ease
key
as
soon
as
engi
ne f
ires
The
pilo
t lig
hts
will
go
out
*F
uel p
artic
les
not
burn
t du
ring
initi
al c
om-
bust
ion
in t
he c
ylin
der
are
subj
ecte
d to
ase
con
d s
tag
e c
om
bu
stio
n p
roce
ss f
or
appr
ox. 3
min
utes
in o
rder
to le
t the
exh
aust
gase
s be
com
e m
ore
tran
spar
ent
in t
hest
art-
up p
hase
.
*F
uel p
artic
les
not
burn
t du
ring
initi
al c
om-
bust
ion
in t
he c
ylin
der
are
subj
ecte
d to
ase
con
d s
tag
e c
om
bu
stio
n p
roce
ss f
or
appr
ox. 3
min
utes
in o
rder
to le
t the
exh
aust
gase
s be
com
e m
ore
tran
spar
ent
in t
hest
art-
upph
ase.
©
25 7
46
2
©
25 7
46
2
3
© 2001E
ng
ine
Op
erat
ion
3.3
Mo
nit
ori
ng
Op
erat
ion
Oil
Pre
ssu
re In
dic
ato
rO
il P
ress
ure
Gau
ge
●T
he o
il pr
essu
re p
ilot
light
com
es o
n w
ithop
erat
ing
volta
ge o
n an
d en
gine
off.
●T
he o
il pr
essu
re p
ilot
light
sho
uld
go o
utw
hen
the
engi
ne is
run
ning
.
●T
he p
oint
er m
ust r
emai
n in
the
gree
n se
ctor
over
the
ent
ire o
pera
ting
rang
e.●
The
poi
nter
of t
he o
il pr
essu
re g
auge
mus
tdi
spla
y th
e m
inim
um o
il pr
essu
re (s
ee 9
.1).
3.3.
1E
ng
ine
Oil
Pre
ssu
re
Oil
pre
ssu
re p
ilot l
igh
ts
©
25 7
52
1©
25
753
0
©
25 7
54
0
3 © 2001
●T
he e
ngin
e te
mpe
ratu
re g
auge
poi
nter
shou
ld r
emai
n in
the
gre
en s
ecto
r m
ost
ofth
e tim
e. I
t sh
ould
rar
ely
ente
r th
e ye
llow
-gr
een
sect
or.
If th
e po
inte
r en
ters
the
or-
ange
sec
tor,
the
engi
ne is
ove
rhea
ting.
Tur
nof
f an
d es
tabl
ish
the
caus
e fr
om t
he F
ault
Tabl
e (s
ee 7
.1).
3.3.
2E
ng
ine
tem
per
atu
re
Eng
ine
Tem
pera
ture
Gau
ge
3.3
Mo
nit
ori
ng
Op
erat
ion
En
gin
e O
per
atio
n
●W
hen
the
V-b
elt i
s to
rn, t
he p
ress
ure
pin
1of
ele
ctric
al s
witc
h is
act
uate
d by
the
ten
-si
on ro
ller a
nd a
n au
dio
sign
al o
r a lig
ht s
igna
lis
em
itted
.S
witc
h of
f the
eng
ine
imm
edia
tely
to a
void
over
heat
ing.
3.3.
3C
oo
ling
fan
dri
ve
©
24 9
85
2©
24
590
2
3
© 2001
If po
ssib
le,
do n
ot s
udde
nly
switc
h of
f th
een
gine
whe
n un
der
full
load
.
●T
urn
key
coun
terc
lock
wis
e (t
o po
sitio
n 0)
and
rem
ove.
The
pilo
t lig
hts
will
go
out.
●M
ove
spee
d ad
just
men
t lev
er 1
to lo
w id
le.
●M
ove
shut
-off
leve
r 2
in th
e di
rect
ion
of “
0”un
til th
e en
gine
com
es to
a s
top.
The
cha
rge
pilo
t lig
ht a
nd th
e oi
l pre
ssur
e pi
lot l
ight
will
com
e on
whe
n th
e en
gine
sto
ps.
●T
urn
key
coun
terc
lock
wis
e (t
o po
sitio
n 0)
and
rem
ove.
The
pilo
t lig
hts
will
go
out.
●C
once
rnin
g el
ectr
ical
shu
t-of
f or
pow
erfa
ilure
, the
shu
t-of
f lev
er 2
is d
isab
led
by th
eso
leno
ids
until
the
engi
ne s
tops
. The
cha
rge
pilo
t lig
ht a
nd t
he o
il pr
essu
re p
ilot
light
illum
inat
e w
hen
the
engi
ne s
tops
.●
Tur
n ke
y co
unte
rclo
ckw
ise
(to
posi
tion
0)an
d re
mov
e. T
he p
ilot l
ight
s w
ill g
o ou
t.
En
gin
e O
per
atio
n3.
4 S
hu
ttin
g O
ff
3.4.
1M
ech
anic
al s
hu
t-o
ff3.
4.2
Ele
ctri
cal s
hu
t-o
ffIg
nit
ion
key
©
25
746
2
©
35 5
88
0
3 © 2001
3.5.
1W
inte
r O
per
atio
n
●Lu
be O
il V
isco
sity
–S
elec
t th
e oi
l vi
scos
ity (
SA
E g
rade
) ac
-co
rdin
g to
the
am
bien
t te
mpe
ratu
re w
hen
star
ting
the
engi
ne,
see
4.1.
2.–
Inc
reas
e oi
l ch
ange
fre
quen
cy w
hen
oper
atin
g be
low
-10
°C
, se
e 6.
1.1.
●D
iese
l Fue
l–
Use
win
ter-
grad
e di
esel
fuel
for o
pera
tion
belo
w 0
°C
, se
e 4.
2.2
●A
dditi
onal
Mai
nten
ance
Wor
k–
Dra
in th
e sl
udge
from
the
fuel
tank
onc
e a
wee
k. (
Uns
crew
the
slu
dge
drai
n pl
ug)
–If
nece
ssar
y, a
llow
the
oil i
n th
e oi
l bat
h ai
rcl
eane
r an
d th
e en
gine
oil
to s
ettle
at t
heam
bien
t tem
pera
ture
.–
Bel
ow -
20 °
C,
afte
r re
mov
ing
the
star
ter
if n
eces
sary
, sm
ear
the
ring
gear
on
the
fly w
heel
via
the
pini
on b
ore
from
tim
e to
time
with
col
d-re
sist
ant g
reas
e (e
.g. B
osch
FT
1 V
31
grea
se).
●C
old
Sta
rt A
ssis
tanc
eA
t te
mpe
ratu
res
near
or
belo
w f
reez
ing
poin
t, us
e sh
eath
ed g
low
plu
gs i
f ne
ces-
sary
, se
e 3.
2.1.
Thi
s no
t on
ly l
ower
s th
est
artin
g lim
it te
mpe
ratu
re, b
ut p
rovi
des
easi
erst
artin
g at
tem
pera
ture
s no
rmal
ly n
ot re
quir-
ing
a st
artin
g ai
d.
3.5
Op
erat
ing
Co
nd
itio
ns
En
gin
e O
per
atio
n
●B
atte
ry–
Effi
cien
t col
d st
artin
g re
quire
s th
e ba
ttery
to b
e w
ell-c
harg
ed,
see
6.7.
1.–
The
sta
rtin
g lim
it te
mpe
ratu
res
can
be lo
w-
ered
by
4-5
°C b
y he
atin
g th
e ba
ttery
up
toab
out +
20 °C
. (To
do
so, r
emov
e th
e ba
ttery
and
stor
e in
a w
arm
pla
ce).
©
26 2
48
2
3
© 2001
●A
ir de
nsity
dec
reas
es a
s al
titud
e or
am
bien
tte
mpe
ratu
re in
crea
se. A
s a
resu
lt of
this
, the
engi
ne’s
max
imum
out
put,
the
qual
ity o
f the
exha
ust g
as, t
he te
mpe
ratu
re le
vel a
nd, i
nex
trem
e ca
ses,
sta
rtin
g be
havi
our,
are
im-
pede
d. U
nder
tra
nsie
nt c
ondi
tions
, th
e en
-gi
ne c
an b
e us
ed a
t alti
tude
s up
to 1
000
man
d te
mpe
ratu
res
up to
30
°C. I
f the
eng
ine
is to
ope
rate
und
er m
ore
seve
re c
ondi
tions
(at
high
er a
ltitu
des
or t
empe
ratu
res)
, it
will
be n
eces
sary
to
redu
ce t
he i
njec
ted
fuel
quan
tity
and
thus
, en
gine
pow
er.
●If
you
have
any
dou
bts
abou
t eng
ine
oper
a-tio
n un
der
thes
e or
sim
ilar
cond
ition
s, a
skyo
ur e
ngin
e or
equ
ipm
ent s
uppl
ier w
heth
erth
e en
gine
has
bee
n de
rate
d in
the
inte
rest
sof
rel
iabi
lity,
ser
vice
life
and
exh
aust
gas
qual
ity (s
mok
e). O
ther
wis
e co
ntac
t DE
UT
ZS
ER
VIC
E.
En
gin
e O
per
atio
n3.
5 O
per
atin
g C
on
dit
ion
s
3.5.
2H
igh
Am
bie
nt
Tem
per
atu
re,
Hig
h A
ltit
ud
e
© 2
5 90
1
1
4 © 2001
Op
erat
ing
Med
ia
4.1
Lu
be
Oil
4.2
Fu
el
4
© 2001O
per
atin
g M
edia
4.1
Lu
be
Oil
Lube
oils
are
diff
eren
tiate
d ac
cord
ing
to th
eir
perf
orm
ance
and
qua
lity
clas
s. I
n co
mm
onus
e ar
e sp
ecifi
catio
ns n
amed
afte
r th
e A
PI
(Am
eric
an P
etro
leum
Ins
titut
e) a
nd A
CE
A(E
urop
ean
Eng
ine
Oil
Seq
uenc
es).
App
rove
dA
PI O
ils:
At
leas
t:C
F-4
App
rove
dA
CE
A O
ils:
At
leas
t:E
1-96
It is
rec
omm
ende
d to
ope
rate
the
eng
ines
with
Deu
tz O
il T
LX
10W
-40F
E E
uro
pe.
If
this
is n
ot a
vaila
ble,
use
the
appr
opria
te o
il as
desc
ribed
abo
ve.
* O
il ch
ange
inte
rval
s, s
ee 6
.1.1
O
il ca
paci
ties,
see
9.1
As
the
visc
osity
of
the
lube
oil
is d
epen
dent
on t
empe
ratu
re,
the
choi
ce o
f S
AE
gra
desh
ould
be
gove
rned
by
the
ambi
ent t
empe
ra-
ture
pre
vaili
ng a
t th
e en
gine
ope
ratin
g si
te.
Opt
imum
ope
ratin
g be
havi
our w
ill b
e at
tain
edif
you
take
the
acc
ompa
nyin
g oi
l vi
scos
itydi
agra
m a
s a
guid
e.S
houl
d th
e te
mpe
ratu
re f
all
tem
pora
rily
be-
low
the
lim
its o
f S
AE
gra
de s
elec
ted,
col
dst
artin
g m
ay b
e af
fect
ed b
ut t
he e
ngin
e w
illno
t be
dam
aged
. In
ord
er t
o ke
ep w
ear
to a
min
imum
, do
not e
xcee
d ap
plic
atio
n lim
its fo
rex
tend
ed p
erio
ds o
f tim
e.O
il ch
ange
s di
ctat
ed b
y th
e se
ason
s ca
n be
avoi
ded
by u
sing
mul
ti-gr
ade
lube
oils
. Mul
ti-gr
ade
oils
, par
ticul
arly
ligh
t-flo
win
g oi
ls, a
lso
redu
ce f
uel
cons
umpt
ion.
4.1.
1Q
ual
ity
4.1.
2V
isco
sity
©
30 2
98
0O
nly
with
eng
ine
preh
eatin
g
4 © 2001
4.1
Lu
be
Oil
Op
erat
ing
Med
ia
Tur
boch
arge
d en
gine
s w
ith i
ncre
ased
out
-pu
t an
d en
gine
s w
ith h
igh
capa
city
.F
or t
he f
ollo
win
g en
gine
s, o
r ap
plic
atio
ns:
●fo
r eng
ines
with
an
outp
ut >
141k
W th
e oi
lslis
ted
in th
e fo
llow
ing
tabl
e ar
e to
be
used
.
Firs
tly, t
hese
oils
are
of h
igh
qual
ity in
acc
ord-
ance
with
AC
EA
or A
PI.
Add
ition
ally
, the
se o
ilsar
e m
ainl
y pa
rtly
syn
thet
ic,
som
e ev
en f
ully
synt
hetic
(5W
-40)
and
thu
s ac
hiev
e th
erm
alst
abili
ty i
f re
quire
d fo
r th
e ap
plic
atio
n an
dse
dim
ents
are
les
s lik
ely
if th
e cr
ankc
ase
vent
ilatio
n is
clo
sed
in t
he t
urbo
char
ger
and
in th
e ai
r-in
take
line
s.
Em
issi
on o
ptim
ised
eng
ines
for
com
mer
cial
vehi
cles
fro
m E
UR
O I
I an
d m
obile
driv
enm
achi
nes
from
pos
ition
2,
corr
espo
ndin
g to
the
follo
win
g em
issi
on r
equi
rem
ents
:
a)f
rom
EU
RO
II, t
he 8
8/77
/EE
C a
nd 9
1/54
2/E
EC
gui
delin
es fo
r com
mer
cial
veh
icle
s in
Eur
ope,
b)f
rom
pos
ition
2, t
he 9
7/68
/EC
gui
delin
es fo
rm
obile
driv
en m
achi
nes
in E
urop
ec
)fro
m p
ositi
on 2
, th
e U
S n
on-r
oad
engi
nes
guid
elin
es,
only
the
fol
low
ing
oil
qual
ities
are
perm
itted
:-A
CE
A E
3-96
and
AC
EA
E4-
98 fo
r req
uire
- m
ents
a)
and
b)-A
PI C
G-4
and
AP
I CH
-4 fo
r th
e re
quire
- m
ents
c)
4.1.
2.1
Sp
ecif
ic l
ub
e o
ild
efin
itio
ns
Man
ufac
ture
rLu
be o
il ty
peSA
E C
lass
Ava
ilabi
lity
DE
UT
ZD
eutz
TLX
Oil
10W
-40F
EE
urop
eA
GIP
Agip
Sig
ma
Ultr
a TF
E10
W-4
0w
orld
wid
eA
GIP
Auto
l Val
ve U
ltra
FE10
W-4
0G
erm
any
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Gm
bHA
ral
Meg
aTur
bora
l10
W-4
0w
orld
wid
eAR
AL G
mbH
Ara
l S
uper
Turb
oral
5W-3
0w
orld
wid
eB
AY
WA
BayW
a Su
per
Truc
k 10
40 M
C10
W-4
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uth
Ger
man
yB
AY
WA
BayW
a Tu
rbo
4000
10W
-40
Sout
h G
erm
any
Cas
trol
Gm
bHC
astro
l S
YN
TRU
CK
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rope
, N
orth
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eric
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razi
l,Ar
gent
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Aus
tralia
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uth
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astro
l G
mbH
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trol
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NA
MA
X7,
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rope
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orth
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eric
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razi
l,Ar
gent
ina,
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tralia
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uth
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aC
HE
VR
ON
Che
vron
Del
o 40
0 Sy
ntht
ic5W
-40
Nor
th A
mer
ica
ES
SO
Esso
lube
XTS
501
10W
-40
Eur
ope
FIN
AFI
NA
KA
PP
A F
IRS
T5W
-30
Eur
ope
FIN
AFI
NA
KA
PP
A U
LTR
A10
W-4
0E
urop
eFU
CH
S D
EA
DEA
Cro
nos
Synt
h5W
-40
Ger
man
y, E
urop
eFU
CH
S D
EA
DEA
Cro
nos
Prem
ium
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10W
-40
Ger
man
y, E
urop
eFU
CH
S D
EA
Fuch
s Ti
tan
Car
go M
C10
W-4
0w
orld
wid
eFU
CH
S D
EA
DEA
Cro
nos
Prem
ium
FX
10W
-40
Eur
ope
FUC
HS
DE
AFu
chs
Tita
n U
nic
Plus
MC
10W
-40
wor
ldw
ide
MO
BIL
OIL
Mob
il D
elva
c 1
SHC
5W-4
0Eu
rope
, Sou
th E
ast A
sia,
Afri
caM
OBI
L O
ILM
obil
Del
vac
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-40
wor
ldw
ide
MO
BIL
OIL
Mob
il D
elva
c XH
P Ex
tra10
W-4
0Eu
rope
, Sou
th E
ast A
sia
BP O
IL I
nter
natio
nal
BP V
anel
lus
HT
Extra
10W
-40
Eur
ope
Shel
l In
tern
atio
nal
Shel
l Myr
ina
TX /
5W-3
0Eu
rope
, la
bel
Shel
l R
imul
a U
ltra
coun
try-s
peci
fic,
vario
usSh
ell
Inte
rnat
iona
lSh
ell M
yrin
a TX
/10
W-4
0Eu
rope
, la
bel
Shel
l R
imul
a U
ltra
coun
try s
peci
fic,
vario
usTO
TAL
TOTA
L R
UBI
A TI
R 8
6000
10W
-40
wor
ldw
ide
lube
oil
refin
ery
Win
ters
hall
TFG
10W
-40
Eur
ope
Sal
zber
gen
Gm
bHLu
be
oil
for
eng
ines
wit
h i
ncr
ease
d o
utp
ut
and
eng
ines
wit
h h
igh
ou
tpu
t
The
tab
le c
an b
e ex
tend
ed i
f re
quire
d.
4
© 2001
Use
com
mer
cial
ly a
vaila
ble
dies
el f
uel
with
less
than
0.5
% s
ulph
ur c
onte
nt. I
f the
sul
phur
cont
ent i
s hi
gher
, oil
chan
ge in
terv
als
shou
ldbe
red
uced
(se
e 6.
1.1)
.
The
fol
low
ing
fuel
spe
cific
atio
ns /
sta
ndar
dsar
e ap
prov
ed:
(als
o se
e T
R 0
199-
3002
)●
Die
sel
fuel
- DIN
EN
590
- B
S 2
869:
A1
and
A2
(w
ith A
2, ta
ke n
ote
of th
e su
lphu
r con
tent
)- A
ST
M D
975
-88;
1-D
and
2-D
- N
ATO
Cod
e F
-54
and
F-7
5- I
SO
821
7 D
MX
- IS
O 8
217
DM
A
●L
igh
t fu
el o
ilsin
acc
orda
nce
with
DIN
516
03A
ST
M D
396
; 1 a
nd 2
BS
286
9 C
lass
D
●Je
t fu
el-
F34
/F35
/F44
(K
eros
ene)
- F54
(cor
resp
onds
to d
iese
l fue
l in
acco
rd-
ance
with
DIN
EN
590
)-
XF
63
(cor
resp
onds
to
F34
+F
35 w
ithad
ditiv
es)
●B
io d
iese
l fu
el-
in a
ccor
danc
e w
ith D
IN 5
1606
- FA
ME
Exh
aust
em
issi
on v
alue
s w
hich
may
be
dete
rmin
ed in
the
cas
e of
typ
e ap
prov
alte
sts
alw
ays
refe
r to
the
ref
eren
ce f
uel
pres
crib
ed b
y th
e au
thor
ities
for
the
type
appr
oval
tes
t.
Wax
ing
may
occ
ur a
t lo
w t
empe
ratu
res,
clog
ging
the
fuel
sys
tem
and
redu
cing
eng
ine
effic
ienc
y. If
the
ambi
ent t
empe
ratu
re is
less
than
0 °
C,
win
ter-
grad
e fu
el (
suita
ble
dow
nto
-20
°C
) sh
ould
be
used
. (T
his
fuel
is
avai
labl
e fr
om t
he f
illin
g st
atio
ns w
ell
in a
d-va
nce
of t
he c
old
mon
ths)
.
●K
eros
ene
mus
t be
adde
d at
tem
pera
ture
sbe
low
-20
°C
. T
he r
elev
ant
perc
enta
ges
are
give
n in
the
adj
acen
t di
agra
m.
●S
peci
al d
iese
l fue
ls m
ay b
e us
ed in
arc
ticcl
imat
ic z
ones
up
to -
44 °
C.
If su
mm
er-g
rade
die
sel f
uel m
ust b
e us
ed a
tte
mpe
ratu
res
belo
w 0
°C
, up
to
60%
ker
o-se
ne c
an b
e ad
ded
(see
dia
gram
).
In m
ost
case
s, a
dequ
ate
resi
stan
ce t
o co
ldca
n be
obt
aine
d by
add
ing
a flo
w i
mpr
over
(add
itive
). P
leas
e as
k yo
ur D
EU
TZ
par
tner
.
Op
erat
ing
Med
ia4.
2 F
uel
Mix
in
tank
onl
y! F
ill w
ith t
heap
prop
riate
am
ount
of k
eros
ene
first
, th
en a
dd t
he d
iese
l fue
l.
4.2.
1Q
ual
ity
4.2.
2W
inte
r F
uel
dies
el fu
el s
houl
d ne
ver b
e m
ixed
with
pet
rol
(nor
mal
or
supe
rpe
trol
)
Lege
nd:
IS
umm
er-g
rade
die
sel fu
el
IIW
inte
r-gra
de d
iese
l fuel
AA
mbi
ent te
mpe
ratu
re
BP
erce
ntag
e of
kero
sene
add
ed
5 © 2001
Ro
uti
ne
Mai
nte
nan
ce
5.1
Mai
nte
nan
ce P
lan
5.2
Mai
nte
nan
ce S
ched
ule
s5.
3M
ain
ten
ance
Wo
rk C
om
ple
ted
5
© 2001
Ind
ust
rial
en
gin
esT
he s
peci
fied
engi
ne m
aint
enan
ce v
alue
s ar
epe
rmis
sibl
e re
com
men
ded
max
imum
s. D
e-pe
ndin
g on
usa
ge,
redu
ced
mai
nten
ance
in-
terv
als
may
be
nece
ssar
y, c
ompl
y w
ith th
e un
itm
anuf
actu
rer’s
ope
ratin
g in
stru
ctio
ns.
# M
aint
enan
ce m
ust o
nly
be c
arrie
d ou
t by
auth
oris
ed s
ervi
ce p
erso
nnel
Ro
uti
ne
Mai
nte
nan
ce5.
1 M
ain
ten
ance
Sch
edu
le
chec
k =
●ad
just
= ❍
clea
n =
◆re
plac
e =
■
prio
r to
or
durin
g 1s
t tr
ial
run,
che
ck 2
x da
ily d
urin
g th
e br
eaki
ng i
n ph
ase
or w
hen
com
mis
sion
ing
new
and
ove
rhau
led
engi
nes
ever
y 10
hou
rs o
f op
erat
ion
or d
aily
In h
ours
of
oper
atio
n (H
O)
ever
y
Op
erat
ion
Sec
tio
nTo
p up
lub
e oi
l if
nece
ssar
y (a
lso
with
sep
arat
e co
ntai
ner)
6.1
.2/3
.3.4
Lube
oil
(oil
chan
ge i
nter
vals
dep
endi
ng o
n en
gine
use
), s
ee T
R 0
199-
99-3
002
6.1
.1/6
.1.2
Oil
filte
r ca
rtrid
ge (
at e
ach
lube
oil
chan
ge)
Oil
bath
air
filte
r6
.3B
ypas
s –
oil
filte
r6
.1.4
Fue
l fil
ter
cart
ridge
#F
uel
pre-
clea
ner
4.2/
6.2
.2In
take
air
clea
ner/
dry
type
air
clea
ner
(If
avai
labl
e, m
aint
ain
acco
rdin
g to
ma
inte
na
nce
in
dic
ato
r)6.
4.3
/6.4
.4B
atte
ry a
nd c
able
con
nect
ors
6.7
.1E
ngin
e m
onito
ring
syst
em,
war
ning
sys
tem
3.3
#V
alve
cle
aran
ce (
set
if ne
cess
ary,
ear
lier
if no
ises
occ
ur)
6.6
.1#
V-b
elts
(re
tens
ion
or r
epla
ce i
f ne
cess
ary)
6.5
.1S
heat
hed
glow
lam
ps6
.9.3
Che
ck e
ngin
e fo
r le
aks
(vis
ual
insp
ectio
n)–
Eng
ine
susp
ensi
on (
repl
ace
if da
mag
ed)
9.2
Fas
teni
ngs,
hos
e co
nnec
tions
/ c
lam
ps6
.9.1
Bas
ic o
verh
aul
#
E10
E20
E30
E40
E50
E60
E70
125
250
500
1000
1200
0 1
2
●●
■■
■
■■
■
●
■
■ ◆
●◆
●
●
❍❍
● ■
● ■
●
● ●
■
year
s
5 © 2001
5.1
Mai
nte
nan
ce S
ched
ule
Ro
uti
ne
Mai
nte
nan
ce
Ad
dit
ion
s an
d m
od
ific
atio
ns
for
eng
ines
wit
h E
PA
ap
pro
val
The
spe
cifie
d en
gine
mai
nten
ance
val
ues
are
perm
issi
ble
reco
mm
ende
d m
axim
ums.
Dep
endi
ng o
n us
age,
red
uced
mai
nten
ance
inte
rval
s m
ay b
e ne
cess
ary,
com
ply
with
the
unit
man
ufac
ture
r’s o
pera
ting
inst
ruct
ions
.#
Mai
nten
ance
mus
t on
ly b
e ca
rrie
d ou
t by
aut
horis
ed
ser
vice
per
sonn
el
chec
k =
●ad
just
= ❍
clea
n =
◆re
plac
e =
■
max
. re
com
men
ded
stan
dard
tim
es i
n op
erat
ing
hour
s (H
O)
of a
llpr
ior
to o
r du
ring
1st
tria
l ru
n, c
heck
2x
daily
dur
ing
the
brea
king
in
phas
e or
whe
nco
mm
issi
onin
g ne
w a
nd o
verh
aule
d en
gine
s
ever
y 10
hou
rs o
f op
erat
ion
or d
aily
In h
ours
of
oper
atio
n (H
O)
ever
y
Op
erat
ion
Sec
tio
nIn
ject
ion
va
lve
#In
terc
oole
r (d
rain
lub
e oi
l/con
dens
atio
n)#
CP
D c
ompr
esso
r ou
tlet
#B
asic
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rhau
l of
em
issi
on r
elat
ed p
arts
#
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0E
20
E3
0E
40
E5
0E
60
E7
02
50
50
01
00
02
00
03
00
04
00
0
1
2
■ ◆ ◆
■
year
s
5
© 2001M
ain
ten
ance
5.2
Ro
uti
ne
mai
nte
nan
ce w
ork
pla
n
Inte
rval
sM
ain
ten
ance
Act
ivit
yP
lan
exe
cute
d b
y:C
om
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ts
with
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]E
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thor
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ff
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ilyE
20
daily
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25
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tion
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oris
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peci
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taff
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taff
12 0
00[O
H]
E 7
0m
ajor
rep
air
auth
oris
ed s
peci
alis
ed s
taff
5.2.
1 R
ou
tin
e m
ain
ten
ance
wo
rk p
lan
5 © 2001
5.2
Mai
nte
nan
ce C
har
tsR
ou
tin
e M
ain
ten
ance
The
mai
nten
ance
cha
rts
show
n on
this
pag
ear
e su
pplie
d as
sel
f-ad
hesi
ve l
abel
s w
ithea
ch e
ngin
e. T
hey
shou
ld b
e af
fixed
whe
reth
ey c
an b
e se
en c
lear
ly o
n th
e en
gine
or
driv
en e
quip
men
t.
Che
ck t
hat
this
is t
he c
ase.
If ne
cess
ary,
ask
you
r en
gine
or
equi
pmen
tsu
pplie
r fo
r a
fres
h su
pply
of
labe
ls!
Rou
tine
wor
k sh
ould
be
carr
ied
out
acco
rd-
ing
to t
he s
ched
ule
(see
cha
pter
5.1
).
Sto
p th
e en
gine
bef
ore
carr
ying
out
any
mai
nten
ance
wor
k.
0312
036
00
hS
td.
0,15
mm
0.00
6 in
a = 12
5-20
00
1000
FL 9
14
in.
a
ex.
FUEL
OIL
OIL
AIR
500
1000
500
250
500
250
10
1000
OIL
max
.10
ca.15
mm
0.6
in.
0132
035
90
10 250
250
500
500
500
1010
0010
00
in.
a
ex.
FUEL
OIL
max
.
OIL
OIL
AIR
hS
td.
0,15
mm
0.00
6 in
a =
BF
L 91
4/C
125-
2000
ca.15
mm
0.6
in.
5
© 2001R
ou
tin
e M
ain
ten
ance
5.3
Mai
nte
nan
ce W
ork
Co
mp
lete
d
–
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
50-1
50*
125
375
625
875
1125
1375
1625
1875
2115
2375
2625
* fo
llow
ing
com
mis
sion
ing
of n
ew a
nd o
verh
aule
d en
gine
s.
Dul
y co
mpl
eted
mai
nten
ance
jobs
can
be
reco
rded
and
sig
ned
off
in t
he a
bove
cha
rt.
Dat
eS
igna
ture
/sta
mp
Dat
eS
igna
ture
/sta
mp
Op.
hou
rsO
p. h
ours
5 © 2001
3
000
3250
3500
3750
4000
4250
4500
4750
5000
5250
5500
5750
2875
3125
3375
3625
3875
4125
4375
4625
4875
5125
5375
5625
D
uly
com
plet
ed m
aint
enan
ce jo
bs c
an b
e re
cord
ed a
nd s
igne
d of
f in
the
abo
ve c
hart
.
Dat
eS
igna
ture
/sta
mp
Dat
eS
igna
ture
/sta
mp
Op.
hou
rsO
p. h
ours
5.3
Mai
nte
nan
ce W
ork
Co
mp
lete
dR
ou
tin
e M
ain
ten
ance
5
© 2001R
ou
tin
e M
ain
ten
ance
5.3
Mai
nte
nan
ce W
ork
Co
mp
lete
d
6
000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
5875
6125
6375
6625
6875
7125
7375
7625
7875
8125
8375
8625
D
uly
com
plet
ed m
aint
enan
ce jo
bs c
an b
e re
cord
ed a
nd s
igne
d of
f in
the
abo
ve c
hart
.
Dat
eS
igna
ture
/sta
mp
Dat
eS
igna
ture
/sta
mp
Op.
hou
rsO
p. h
ours
5 © 2001
5.3
Mai
nte
nan
ce W
ork
Co
mp
lete
dR
ou
tin
e M
ain
ten
ance
6
Ser
vice
an
d M
ain
ten
ance
6.1
Lu
bri
cati
on
Sys
tem
6.2
Fu
el S
yste
m6.
3C
oo
ling
sys
tem
6.4
Co
mb
ust
ion
Air
Filt
er6.
5B
elt
Dri
ves
6.6
Ad
just
men
ts6.
7A
cces
sori
es6.
8E
ng
ine
clea
nin
g6.
9A
dd
itio
nal
Mai
nte
nan
ce W
ork
6
Veh
icle
en
gin
es
6.1.
1O
il ch
ang
e in
terv
als
●T
he o
il ch
ange
inte
rval
s ar
e de
pend
ent o
nth
e en
gine
app
licat
ion
and
the
qual
ity o
f the
lube
oil.
●If
the
engi
ne r
uns
few
er h
ours
dur
ing
the
year
than
sta
ted
in th
e ta
ble,
the
oil s
houl
dbe
cha
nged
at
leas
t o
nce
a y
ear.
●T
he ta
ble
refe
rs to
the
follo
win
g co
nditi
ons:
–F
or d
iese
l fue
l: su
lphu
r co
nten
t m
ax.
0.5%
by
wei
ght.
–C
ontin
uous
am
bien
t tem
pera
ture
s do
wn
to -
10 °
C (
+14
°F
).
●If
the
sulp
hur
cont
ent i
s >
0.5
to 1
% o
r th
eco
ntin
uous
am
bien
t te
mpe
ratu
re b
elow
the
oil c
hang
e in
terv
als
mus
t be
hal
ved.
●In
the
case
of f
uels
with
a s
ulph
ur c
onte
nthi
gher
tha
n 1%
, co
ntac
t yo
urS
ervi
cere
pres
enta
tive.
Cha
nge
the
oil
with
the
eng
ine
off
but
still
war
m (
lube
oil
tem
pera
ture
app
rox.
80
°C).
Ser
vice
an
d M
ain
ten
ance
En
gin
es fo
r in
stal
lati
on
Lu
be
oil
qu
alit
yA
PI s
pec
ific
atio
n
AC
EA
-sp
ezif
icat
ion
No
rmal
oil
req
uir
emen
t, e
.g.:
Roa
d ve
hicl
es,
cran
es,
cons
truc
tion
mac
hine
s,sh
ips
elec
tric
al m
odul
es,
pum
ps,
railw
ayve
hic
les.
Hig
h o
il re
qu
irem
ent,
e.g
.:
Com
bine
s, e
mer
genc
y pu
mps
, un
derg
roun
d m
inin
gun
its,
swee
ping
mac
hine
s, w
inte
r se
rvic
eve
hicl
es,
emer
genc
y po
wer
uni
ts.
Lu
be
oil
qu
alit
y
Serv
ice g
roup
Lu
be
oil
chan
ge
inte
rval
s in
HO
Nat
ura
lly
asp
irat
ede
ng
ine
s
CF
-4/C
H-4
/ CG
-4C
F-4
C
G-4
/ C
H-4
E1+
E2-
96E
1+E
2-96
E3-
96/E
4-98
500
250
500
CF
-4/C
H-4
/ CG
-4C
F-4
C
G-4
/ C
H-4
E1+
E2-
96E
1+E
2-96
E3-
96/E
4-98
10 0
005
000
10 0
00
20 0
0010
000
20 0
00
30 0
0015
000
30 0
00
250
125
250
med
ium
drivi
ng sp
eed
appr
ox. k
m/h
Year
’s ki
lom
etra
gekmA
PI s
pec
ific
atio
n
AC
EA
-sp
ezif
icat
ion
Lu
be
oil
chan
ge
inte
rval
s in
km
Turb
oc
ha
rge
d e
ng
ine
s
Nat
ura
lly
asp
irat
ede
ng
ine
sT
urb
oc
ha
rge
d e
ng
ine
s
I >
30
000
20
II30
.000
-10
0.00
040
III<
100
000
6
0
6
6.1
Lubr
icat
ion
Syst
emSe
rvic
e an
d M
aint
enan
ce
26
023
0 2
6 02
2 0
25
729
0
Be ca
refu
l whe
n dra
inin
g hot
oil -
dang
erof
sca
lds!
Do
not l
et u
sed
oil r
un in
toth
e so
il bu
t cat
ch it
in a
con
tain
er re
ady
for p
rope
r dis
posa
l.
6.1.
2Ch
ecki
ng O
il Le
vel /
Chan
ging
Engi
ne O
il6.
1.2.
1Ch
ecki
ng O
il Le
vel
6.1.
2.2
Chan
ging
Eng
ine
Oil
●Ru
n th
e en
gine
war
m●
Ensu
re th
at th
e en
gine
or
vehi
cle
is o
n a
leve
lsu
rfac
e–
Lube
oil
tem
pera
ture
app
rox.
80°
C.●
Switc
h of
f the
eng
ine.
●Pl
ace
an o
il tra
y be
neat
h th
e en
gine
●Un
scre
w d
rain
plu
g.●
Drai
n oi
l.●
Fit
oil d
rain
plu
g w
ith n
ew g
aske
t an
d tig
hten
firm
ly (f
or to
rque
, see
9.2
).●
Fill
with
lube
oil
– Fo
r gra
de/v
isco
sity
, see
4.1
.–
For q
uant
ity, s
ee 9
.1.
●Ch
eck
oil l
evel
, see
6.1
.2.1
●En
sure
that
the
engi
ne o
r ve
hicl
e is
on
a le
vel
surf
ace.
●–
War
m e
ngin
e●
Switc
h of
f eng
ine,
wai
t 5 m
inut
es a
nd c
heck
the
oil l
evel
●–
Cold
eng
ine
Chec
k th
e oi
l lev
el●
Rem
ove
the
dips
tick
●W
ipe
off w
ith a
non
-fibr
ous,
cle
an c
loth
.●
Inse
rt up
to th
e st
op a
nd p
ull o
ut a
gain
.●
Chec
k oi
l lev
el, i
f req
uire
d to
p up
to th
e“M
AX”
leve
l–
If th
e oi
l lev
el is
just
abo
ve th
e“M
IN”
mar
k,it
shou
ld b
e to
pped
up.
!Th
e oi
l lev
el m
ust n
ot d
rop
belo
w th
e “M
IN” m
ark.
6
Ser
vice
an
d M
ain
ten
ance
6.1
Lu
bri
cati
on
Sys
tem
6.1.
3R
epla
ce O
il F
ilter
●C
lean
any
dirt
from
the
filte
r car
rier s
ealin
gsu
rfa
ce.
●Li
ghtly
oil
the
rubb
er g
aske
t of t
he n
ew lu
beoi
l fil
ter
cart
ridge
.
●M
anua
lly s
crew
in t
he n
ew c
artr
idge
unt
ilth
e ga
sket
is
flush
.
●T
ight
en t
he l
ube
oil
filte
r ca
rtrid
ge w
ithan
othe
r ha
lf-tu
rn.
●C
heck
the
oil l
evel
, see
6.1
.2
●C
heck
oil
pres
sure
, se
e 3.
3.1.
●C
heck
lube
oil
filte
r car
trid
ge s
eal f
or le
aks.
●U
ndo
the
lube
oil
filte
r ca
rtrid
ge u
sing
aco
mm
erci
al t
ool a
nd s
pin
off.
●C
atch
any
esc
apin
g oi
l.
Cau
tion
is r
equi
red
in th
e ca
seof
hot
oil:
Ris
k of
sca
ldin
g!P
leas
e di
spos
e of
oil
in a
ne
nv
iro
nm
en
tall
y-f
rie
nd
lym
anne
r!
©
25 8
81
0©
25
880
0
©
25 8
82
0
6
6.1
Lu
bri
cati
on
Sys
tem
Ser
vice
an
d M
ain
ten
ance
en
6.1.
4C
han
ge
byp
ass-
oil
filt
erus
e
●R
emov
e oi
l dra
in s
crew
1 a
nd le
t the
oil
run
out.
●C
atch
any
esc
apin
g oi
l.●
Re
mo
ve t
en
sio
nin
g s
cre
w 2
. R
em
ove
cove
r.●
Rem
ove
soile
d fil
ter
3. C
lean
filte
r ca
sing
.●
Che
ck c
over
4 f
or l
eaks
, an
d re
plac
e if
ne
cess
ary
.●
Scr
ew i
n oi
l dr
ain
scre
w w
ith a
new
sea
lrin
g 5.
●In
sert
new
filt
er.
●S
crew
on
cove
r w
ith s
eal
ring
6.●
Dur
ing
tria
l, ob
serv
e oi
l pre
ssur
e an
d ch
eck
for
leak
s.
©
24 5
11
1
6
Ser
vice
an
d M
ain
ten
ance
6.2
Fu
el S
yste
m
●C
lose
the
fue
l sh
ut-o
ff va
lve.
●U
ndo
fuel
filt
er c
artr
idge
with
com
mer
cial
tool
and
spi
n of
f.
●C
atch
any
esc
apin
g fu
el.
6.2.
1R
epla
ce F
uel
Filt
er
●C
lean
any
dirt
from
the
filte
r car
rier s
ealin
gsu
rfa
ce.
●A
pply
lig
ht f
ilm o
f oi
l or
die
sel
fuel
to
the
rub
be
r g
ask
et
of
the
n
ew
fu
el
filt
er
cart
ridg
e.
●M
anua
lly s
crew
in t
he n
ew c
artr
idge
unt
ilth
e ga
sket
is
flush
.
●T
ight
en t
he f
uel f
ilter
car
trid
ge w
ith a
fin
alha
lf-tu
rn.
●O
pen
fuel
shu
toff
valv
e.
●C
heck
for
leak
s.
Kee
p na
ked
flam
es a
way
whe
nw
orki
ng o
n th
e fu
el s
yste
m. D
ono
t sm
oke!
Th
e fu
el s
yste
m d
oes
no
t n
eed
to
be
ble
d.
©
25 8
81
0©
25
880
0
©
25 8
82
0
6
6.2
Fu
el S
yste
mS
ervi
ce a
nd
Mai
nte
nan
ce
●C
lose
the
fue
l sh
ut-o
ff va
lve.
●S
crew
out
and
rem
ove
filte
r ca
p 4.
●C
atch
any
esc
apin
g fu
el.
●R
emov
e st
rain
er 3
and
cle
an w
ith f
uel.
●R
emov
e se
al r
ing
2.●
Cle
an f
ilter
cas
ing
1 w
ith f
uel.
●S
crew
on
filte
r ca
p 4
and
stra
iner
3 w
ithne
w s
eal
2.●
Ble
ed f
uel
syst
em (
see
3.1.
4).
●O
pen
fuel
shu
toff
valv
e.●
Che
ck f
or le
aks.
6.2.
2F
uel
pre
clea
nin
gC
lean
fu
el f
ilter
“Mo
torp
al”
mo
del
Kee
p na
ked
flam
es a
way
whe
nw
orki
ng o
n th
e fu
el s
yste
m.
Do
not s
mok
e!
©
35 2
13
0
6
© 2001S
ervi
ce a
nd
Mai
nte
nan
ce6.
3 C
oo
ling
Sys
tem
6.3.
1C
lean
ing
Inte
rval
s
●T
he a
mou
nt o
f con
tam
inat
ion
in th
e co
olin
gsy
stem
dep
ends
on
the
engi
ne a
pplic
atio
n.
●O
il an
d fu
el r
esid
ues
on t
he e
ngin
e in
-cr
ease
the
ris
k of
con
tam
inat
ion.
The
re-
fore
pay
spe
cial
atte
ntio
n to
lea
ks i
f th
een
gine
is u
sed
in d
usty
env
ironm
ents
.
●S
erio
us c
onta
min
atio
n ca
n oc
cur,
for
ex-
ampl
e:-
On
cons
truc
tion
site
s w
here
the
re i
s a
high
lev
el o
f ai
r-bo
rne
dust
.-
In h
arve
stin
g ap
plic
atio
n w
here
ther
e ar
ehi
gh c
once
ntra
tions
of
chaf
f and
cho
pped
stra
w i
n th
e vi
cini
ty o
f th
e m
achi
ne.
●B
ecau
se a
pplic
atio
ns v
ary,
cle
anin
g in
ter-
vals
hav
e to
be
dete
rmin
ed f
rom
cas
e to
case
. T
he c
lean
ing
inte
rval
s gi
ven
in t
heta
ble
on th
e rig
ht c
an b
e us
ed a
s a
guid
e.
2000
1000
500
250
125
Ch
ecki
ng
or
clea
nin
g i
nte
rval
sE
ng
ine
app
licat
ion
Sta
ndar
d va
lues
OH
Shi
ps,
elec
tric
al m
odul
es in
enc
lose
d ar
eas,
pum
ps
Veh
icle
s on
pav
ed r
oads
Tra
ctor
s, f
ork-
lift
truc
ks,
driv
able
ele
ctric
uni
ts.
Veh
icle
s on
con
stru
ctio
n si
tes
and
unpa
ved
road
s,
cons
truc
tion
mac
hine
s co
mpr
esso
rs,
unde
rgro
und
min
ing
units
Agr
icul
tura
l mac
hine
s, t
ract
ors
in h
arve
stin
g ap
plic
atio
n
6 © 2001
●T
he a
mou
nt o
f di
rt i
n th
e ai
r cl
eane
r de
-pe
nds
on th
e am
ount
of d
ust i
n th
e ai
r an
dth
e si
ze o
f th
e ai
r cl
eane
r us
ed.
If a
high
leve
l of d
ust i
s an
ticip
ated
, a c
yclo
ne-t
ype
prec
lean
er c
an b
e fit
ted
to th
e ai
r cl
eane
r.
●C
lean
ing
inte
rval
s w
ill h
ave
to b
e de
ter-
min
ed f
rom
cas
e to
cas
e.
●If
dry
type
air
filte
rs a
re u
sed,
cle
anin
gsh
ould
onl
y be
car
ried
out a
ccor
ding
to th
ese
rvic
e in
dica
tor
or s
ervi
ce s
witc
h.
●A
ir cl
eane
r se
rvic
ing
is n
eede
d w
hen
-S
ervi
ce i
nd
icat
or
the
red
sign
al 1
is f
ully
vis
ible
whe
n th
een
gine
is
off.
-S
ervi
ce s
wit
chth
e ye
llow
pilo
t lig
ht c
omes
on
whe
n th
een
gine
is r
unni
ng.
●A
fter
carr
ying
out
ser
vice
wor
k, r
eset
the
sign
al b
y pr
essi
ng th
e bu
tton
on th
e se
rv-
ice
indi
cato
r. T
he s
ervi
ce in
dica
tor
is n
owre
ady
for
oper
atio
n ag
ain.
6.4
Co
mb
ust
ion
Air
Filt
erS
ervi
ce a
nd
Mai
nte
nan
ce
6.4.
1C
lean
ing
Inte
rval
s
©
25 8
85
1
6
© 2001
Nev
er f
ill c
olle
ctor
bow
l w
ith o
il. R
epla
ceco
llect
or b
owl
if da
mag
ed.
●U
ndo
win
g nu
t 1
and
rem
ove
cove
r 2.
●R
emov
e co
llect
or b
owl 3
fro
m lo
wer
sec
-tio
n 4
and
empt
y. C
lean
leav
es, s
traw
and
othe
r fo
reig
n m
atte
r fr
om lo
wer
sec
tion
ofpr
e-cl
eane
r.●
Rep
ositi
on c
olle
ctor
bow
l 3
onto
low
erse
ctio
n 4,
fas
ten
cove
r 2
in p
lace
by
tight
enin
g w
ing
nut
1.
●T
urn
engi
ne o
ff an
d w
ait a
bout
10
min
utes
for
the
oil t
o dr
ain
from
filt
er h
ousi
ng 1
.●
Loos
en q
uick
fas
tene
rs 2
and
rem
ove
oil
cup
3 w
ith f
ilter
ele
men
t 4;
if
nece
ssar
y,lo
osen
filt
er e
lem
ent
with
the
aid
of
asc
rew
driv
er a
t the
sep
arat
ing
poin
t. D
o no
tda
mag
e ru
bber
gas
ket 5
!●
Rem
ove
dirt
y oi
l and
slu
dge.
Cle
an o
il cu
p.●
Cle
an f
ilter
ele
men
t 4
in d
iese
l fu
el a
ndal
low
to
drip
-dry
.
●C
lean
filt
er h
ousi
ng 1
if v
ery
dirt
y.●
Insp
ect a
nd re
plac
e ru
bber
gas
ket 5
and
6if
nece
ssar
y.●
Fill
oil
cup
with
eng
ine
oil
up t
o th
e m
ark
(arr
ow)
(for
vis
cosi
ty,
see
4.1.
2).
●R
efit
oil c
up a
nd e
lem
ent
to f
ilter
hou
sing
and
secu
re w
ith s
nap
clip
s.
Nev
er c
lean
filte
r with
gas
olin
e!D
ispo
se o
f old
oil
in a
ccor
danc
ew
ith e
nviro
nmen
tal r
egul
atio
ns!
Ser
vice
an
d M
ain
ten
ance
6.4
Co
mb
ust
ion
Air
Filt
er
6.4.
2E
mp
tyin
g C
yclo
ne
Typ
eP
recl
ean
er6.
4.3
Cle
an O
il B
ath
Air
Filt
er
©
25 8
87
0©
25
886
0
6 © 2001
●E
mpt
y du
st d
isch
arge
val
ve 1
by
pres
sing
apar
t lip
s of
dis
char
ge s
lot a
s in
dica
ted
bya
rro
ws.
●C
lean
dis
char
ge s
lot f
rom
tim
e to
tim
e.●
Rem
ove
any
cake
d di
rt b
y pr
essi
ng t
o-ge
ther
the
upp
er s
ectio
n of
the
val
ve.
●U
ndo
clip
fas
tene
rs 1
.●
Take
off
hood
2 a
nd r
emov
e ca
rtrid
ge 3
.●
Cle
an c
artr
idge
(re
plac
e at
lea
st o
nce
aye
ar)
.●
Cle
an c
artr
idge
3.
Blo
w o
ut u
sing
dry
com
pres
sed
air
(max
.5
bar)
, (or
in d
iffic
ult c
ases
, tap
out
, tak
ing
care
not
to d
amag
e th
e ca
rtrid
ge, o
r w
ash
acco
rdin
g to
man
ufac
ture
r’s in
stru
ctio
ns).
●T
hrou
gh re
gula
r rem
oval
and
repl
acem
ent,
the
gask
ets
on t
he f
ilter
car
trid
ge c
anbe
com
e da
mag
ed. C
heck
pap
er fi
lter (
light
show
ing
thro
ugh)
and
gas
kets
for
dam
-ag
e.R
epla
ce i
f ne
cess
ary.
Nev
er c
lean
filte
r car
trid
ge w
ithga
solin
e or
hot
flu
ids.
●A
fter
five
clea
ner
serv
ices
(or
afte
r tw
oye
ars
at t
he l
ates
t),
repl
ace
safe
ty c
ar-
trid
ge 4
(ne
ver
clea
n).
To d
o so
:-
Und
o he
x. n
ut 5
and
rem
ove
cart
ridge
4.
-In
stal
l ne
w c
artr
idge
, in
sert
and
tig
hten
hex
nut.
●In
stal
l car
trid
ge 3
, rep
lace
hoo
d 2
and
do u
pcl
ip f
aste
ners
1.
6.4
Co
mb
ust
ion
Air
Filt
erS
ervi
ce a
nd
Mai
nte
nan
ce
6.4.
4D
ry t
ype
air
clea
ner
Du
st d
isch
arg
e va
lvel
Filt
er C
artr
idg
e
©
25 8
88
1©
25
889
0
6
© 2001
Rea
d of
f th
e va
lue
whe
re t
he i
ndic
ator
arm
1 i
nter
sect
s sc
ale
5 (a
rrow
). F
orse
tting
s, s
ee 9
.1.
-If
nece
ssar
y, re
tens
ion
belt
and
mea
sure
agai
n.
Che
ck, t
ensi
on a
nd c
hang
e be
ltson
ly w
ith t
he e
ngin
e of
f. R
ein-
stal
l V
-bel
t gu
ard
●V
isua
lly in
spec
t en
tire
V-b
elt
for
dam
age.
●R
epla
ce d
amag
ed V
-bel
ts.
●A
fter i
nsta
lling
new
bel
ts, r
un e
ngin
e fo
r 15
min
utes
, th
en c
heck
bel
t te
nsio
n.●
To c
heck
the
ten
sion
of
the
V-b
elt,
use
ate
nsio
n ga
uge
(see
9.3
).-
Pla
ce in
dica
tor
arm
1 in
to g
auge
.-
Pos
ition
gui
de 3
on
V-b
elt
2, m
idw
aybe
twee
n th
e pu
lleys
, w
ith f
lang
e 3
onbo
ttom
of g
auge
aga
inst
the
edge
of b
elt.
-P
ush
slow
ly o
n th
e bl
ack
pad
4 at
rig
htan
gles
to V
-bel
t 2 u
ntil
the
sprin
g is
hea
rdor
fel
t to
trig
ger.
-C
aref
ully
rem
ove
the
gaug
e w
ithou
tal
terin
g th
e po
sitio
n of
the
indi
cato
r arm
1.
Ser
vice
an
d M
ain
ten
ance
6.5
Bel
t D
rive
s
●To
rep
lace
the
ten
sion
rol
ler
1, p
ress
in-
war
ds w
ith a
com
mer
cial
tool
and
rem
ove
the
V-b
elt.
●P
ositi
on n
ew r
ibbe
d V
-bel
t.
Ret
ensi
on V
-bel
t af
ter
it ha
s ra
n fo
r 15
min
-ut
es.
6.5.
1C
hec
k V
-bel
ts6.
5.2
Fan
V-b
elt
©
24 6
84
1©
35
203
0
©
35 2
09
0
6 © 2001
6.5
Bel
t D
rive
sS
ervi
ce a
nd
Mai
nte
nan
ce
●Lo
osen
bol
ts 1
, 2
and
3 sl
ight
ly.
●P
ress
alte
rnat
or 4
out
war
ds i
n di
rect
ion
of a
rrow
A u
ntil
corr
ect
belt
tens
ion
isac
hiev
ed.
●R
etig
hten
bol
ts 1
, 2 a
nd 3
.
Che
ck, t
ensi
on a
nd c
hang
e be
ltson
ly w
ith t
he e
ngin
e of
f. R
ein-
stal
l V
-bel
t gu
ard.
●R
emov
e fa
n be
lt, a
s sh
own
in 6
.5.2
.●
Sla
cken
off
bolts
1,
2 an
d 3.
●S
win
g al
tern
ator
inw
ards
in
the
dire
ctio
nof
arr
ow B
.●
Rem
ove
and
repl
ace
belt.
●S
win
g al
tern
ator
4 o
utw
ards
in
dire
ctio
nof
arr
ow A
unt
il co
rrec
t be
lt te
nsio
n is
achi
eved
.●
Ret
ight
en b
olts
1, 2
and
3.
●F
it fa
n be
lt.
Ret
ensi
on V
-bel
t af
ter
it ha
s ra
n fo
r 15
min
-ut
es.
●W
hen
the
V-b
elt i
s to
rn, t
he p
ress
ure
pin
1of
ele
ctri
cal
switc
h is
act
uate
d by
the
tens
ion
rolle
r and
an
audi
o si
gnal
or a
ligh
tsi
gnal
is e
mitt
ed.
●C
heck
the
fun
ctio
n by
pre
ssin
g pi
n 1.
Onl
y ch
eck
func
tion
whe
n th
een
gine
is o
ff!
6.5.
3A
lter
nat
or b
elts
6.5.
5C
hec
k w
arn
ing
sys
tem
6.5.
4C
han
ge
alte
rnat
or
bel
t
©
35 2
07
0©
35
208
0
©
35 2
02
0
6
© 2001
●U
nscr
ew h
ex s
crew
1.
●R
emov
e ou
ter
belt
pulle
y ha
lf 2.
●R
epla
ce V
-bel
t if
nece
ssar
y.
●In
ord
er to
ret
ensi
on, r
emov
e on
e or
mor
ein
ner w
ashe
rs 3
. Pla
ce th
e re
mov
ed w
ash-
ers
on t
he o
utsi
de o
n th
e re
mov
ed b
elt
pulle
y ha
lf 2.
●T
ight
en s
crew
1 a
gain
. W
hils
t tig
hten
ing,
turn
eng
ine
over
sim
ulta
neou
sly
in o
rder
topr
even
t cr
ushi
ng t
he V
-bel
t.
Ser
vice
an
d M
ain
ten
ance
6.5
Bel
t D
rive
s
Afte
r in
stal
ling
new
bel
ts,
run
engi
ne f
or 1
5m
inut
es,
then
che
ck b
elt
tens
ion.
6.5.
6Te
nsi
on
ing
or
chan
gin
g V
-bel
ts
©
24 5
98
1©
24
599
1
6 © 2001
●U
ndo
hex
nut 1
, rem
ove
V-b
elt p
ulle
y ha
lf2,
V-b
elt
3 an
d in
ner
was
her
kit
7.●
Rem
ove
inne
r w
ashe
rs 4
, pos
terio
r V
-bel
t3,
inne
r w
ashe
r ki
t 6
and
pulle
y ha
lf 5.
●To
ret
ensi
on,
rem
ove
one
or m
ore
inne
rw
ashe
rs fr
om k
its 6
and
7. P
lace
rem
oved
was
hers
in f
ront
of
or b
ehin
d pu
lley
half
2to
ens
ure
belt
alig
nmen
ts.
Alw
ays
rem
ove
only
the
sam
e nu
mbe
r of
was
hers
fro
mea
ch k
it.●
For
ins
talla
tion,
now
pro
ceed
in
the
re-
vers
e or
der.
Whi
lst t
ight
enin
g th
e nu
t 1, t
urn
engi
ne o
ver
sim
ulta
neou
sly
in o
rder
to
prev
ent
crus
hing
the
V-b
elt.
Che
ck a
nd c
hang
e be
lts o
nly
with
the
engi
neo
ff.
Rei
nsta
ll V-b
elt g
uard
, if n
eces
sary
. Ret
ensi
onV
-bel
t af
ter
it ha
s ra
n fo
r 15
min
utes
.
If on
e be
lt lo
cks
or i
s da
mag
ed,
alw
ays
repl
ace
both
bel
ts.
The
diff
eren
ce o
f le
ngth
betw
een
the
new
bel
ts m
ay n
ot e
xcee
d0.
15%
.
6.5.
7A
ir c
om
pre
sso
r m
od
el w
ith
du
al b
elts
6.5
Bel
t D
rive
sS
ervi
ce a
nd
Mai
nte
nan
ce
©
20 7
62
2
6
© 2001
●R
emov
e th
e cy
linde
r he
ad c
over
.●
Pos
ition
cra
nksh
aft
as p
er s
chem
atic
, se
e6.
6.1.
1.●
Bef
ore
adju
stin
g va
lve
clea
ranc
e, a
llow
engi
ne to
coo
l dow
n fo
r at l
east
30
min
utes
.T
he o
il te
mpe
ratu
re s
houl
d be
bel
ow 8
0 °C
.●
Che
ck v
alve
cle
aran
ce 1
bet
wee
n ro
cker
arm
/ ta
ppet
con
tact
face
2 a
nd v
alve
ste
m3
with
feel
er g
auge
6 (t
here
sho
uld
be o
nly
slig
ht r
esis
tanc
e w
hen
feel
er b
lade
is
in-
sert
ed
).F
or p
erm
issi
ble
valv
e cl
eara
nce,
see
9.1
.
For
hig
h ou
tput
set
tings
, th
e en
gine
s ar
efit
ted
with
an
addi
tiona
l oil
nozz
le t
o lu
bric
ate
bear
ings
. If
nece
ssar
y, r
eadj
ustm
ent
may
only
be
carr
ied
out i
n an
aut
horis
ed s
peci
alis
tw
ork
sho
p!
●A
djus
t va
lve
clea
ranc
e if
nece
ssar
y:-
Rel
ease
lock
nut 4
.-
Use
alle
n ke
y 7
to tu
rn s
etsc
rew
5 s
o th
atth
e co
rrec
t cl
eara
nce
is a
ttain
ed a
fter
lock
nut
4 ha
s be
en t
ight
ened
.●
Che
ck a
nd a
djus
t va
lve
clea
ranc
e on
all
cylin
ders
.●
Rei
nsta
ll cy
linde
r he
ad c
over
with
new
gask
et i
f ne
cess
ary.
Ser
vice
an
d M
ain
ten
ance
6.6
Ad
just
men
ts
6.6.
1C
hec
k va
lve
clea
ran
ce,
adju
st if
nec
essa
ry
©
19 6
91
2©
25
893
0
6 © 2001
6.6.
1.1
Sch
emat
ic fo
rV
alve
Cle
aran
ce A
dju
stm
ents
6.6
Ad
just
men
tsS
ervi
ce a
nd
Mai
nte
nan
ce
●C
ran
ksh
aft
Po
siti
on
2:
Tur
n cr
anks
haft
one
full
revo
lutio
n (3
60°)
.A
djus
t cl
eara
nce
of v
alve
s m
arke
d i
nb
lack
on
sche
mat
ic.
●C
ran
ksh
aft
Po
siti
on
1:
Tur
n cr
anks
haft
until
bot
h va
lves
in c
ylin
-de
r 1
over
lap
(exh
aust
val
ve a
bout
to
clos
e,
inle
t va
lve
abou
t to
ope
n).
Adj
ust
clea
ranc
e of
val
ves
mar
ked
in
bla
ck o
nsc
hem
atic
. M
ark
resp
ectiv
e ro
cker
arm
with
cha
lk t
o sh
ow t
hat
adju
stm
ent
has
been
car
ried
out.
©
26 0
55
1
6
© 2001S
ervi
ce a
nd
Mai
nte
nan
ce6.
7 A
cces
sori
es
6.7.
1.2
Ch
eck
Ele
ctro
lyte
Lev
el6.
7.1.
3C
hec
k el
ectr
oly
tede
nsity
●K
eep
batte
ry c
lean
and
dry
.●
Und
o di
rty
clam
ps.
●C
lean
term
inal
pos
ts (
+ a
nd -
) an
d cl
amps
of t
he b
atte
ry,
and
grea
se w
ith a
cid-
free
and
acid
-res
ista
nt g
reas
e.●
Whe
n re
asse
mbl
ing,
ens
ure
that
cla
mps
mak
e go
od c
onta
ct.
Tig
hten
cla
mp
bolts
hand
-tig
ht.
●R
emov
e se
alin
g ca
ps 1
.●
If te
ster
s 2
are
pres
ent:
Ele
ctro
lyte
lev
elsh
ould
rea
ch t
he b
ase
of t
hese
.●
With
out
test
ers:
The
ele
ctro
lyte
leve
l sho
uld
be 1
0-15
mm
abov
e th
e to
p of
the
pla
tes.
●If
nece
ssar
y, t
op u
p w
ith d
istil
led
wat
er.
●S
crew
sea
ling
caps
bac
k in
.
●M
easu
re t
he e
lect
roly
te d
ensi
ty o
f in
di-
vidu
al c
ells
with
a c
omm
erci
al h
ydro
met
er.
The
hyd
rom
eter
rea
ding
(se
e ta
ble
on fo
l-lo
win
g pa
ge)
indi
cate
s th
e ba
ttery
’s s
tate
of c
harg
e.D
urin
g m
easu
rem
ent,
the
tem
pera
ture
of
the
elec
trol
yte
shou
ld p
refe
rabl
y be
+20
°C
.
6.7.
1B
atte
ry6.
7.1.
1C
hec
kin
g b
atte
ry a
nd
cab
le c
on
nec
tors ©
25
895
0
©
24 2
32
3©
25
896
0
6 © 2001
6.7
Acc
esso
ries
Ser
vice
an
d M
ain
ten
ance
*M
easu
rem
ent o
f ele
ctro
lyte
den
sity
in °
Bé
(Bau
mé-
scal
e) i
s ou
t of
dat
e an
d ra
rely
used
tod
ay. The
gas
es e
mitt
ed b
y th
e ba
t-te
ry a
re e
xplo
sive
! Kee
p sp
arks
and
nake
d fla
mes
aw
ay f
rom
the
batte
ry! D
o no
t allo
w b
atte
ryac
id t
o co
me
into
con
tact
with
skin
or c
loth
ing!
Wea
r pro
tect
ive
gogg
les!
Do
not
rest
too
ls o
n th
e ba
ttery
!
in [k
g/ l]
in [°
Bé
(Bau
mé
scal
e)*]
Cha
rge
stat
us
Nor
mal
Tro
pica
lN
orm
alT
ropi
cal
1,28
1,23
3227
wel
l ch
arge
d
1,20
1,12
2416
sem
i-cha
rged
, re
-cha
rge
1,12
1,08
1611
disc
harg
ed,
imm
edia
tely
cha
rge
6
© 2001
Not
es o
n th
e th
ree-
phas
e sy
stem
:●
Nev
er d
isco
nnec
t th
e ca
bles
bet
wee
nba
ttery
, al
tern
ator
and
reg
ulat
or w
hile
the
engi
ne i
s ru
nn
ing
.●
If, h
owev
er,
it is
nec
essa
ry t
o st
art
and
oper
ate
the
engi
ne w
ithou
t th
e ba
ttery
,di
scon
nect
the
reg
ulat
or f
rom
the
alte
rna-
tor
befo
re s
tart
ing.
●B
e su
re n
ot t
o co
nfus
e th
e ba
ttery
ter
mi-
nals
.●
Rep
lace
def
ectiv
e ch
arge
pilo
t la
mp
bulb
imm
edia
tely
.●
Whe
n w
ashi
ng t
he e
ngin
e, c
over
up
the
alte
rnat
or a
nd r
egul
ator
.●
The
hab
it of
tou
chin
g a
lead
aga
inst
the
fram
e to
che
ck w
heth
er it
is li
ve m
ust u
nder
no c
ircum
stan
ces
be e
xerc
ised
with
thre
e-ph
ase
elec
tric
al s
yste
ms.
●In
cas
e of
ele
ctric
wel
ding
, co
nnec
t th
egr
ound
ter
min
al o
n th
e w
elde
r di
rect
ly t
oth
e pi
ece
bein
g w
elde
d.
Ser
vice
an
d M
ain
ten
ance
6.7
Acc
esso
ries
6.7.
2R
ota
ry C
urr
ent A
lter
nat
or
6.7.
3Tr
ansp
ort
atio
n S
hac
kles
●A
lway
s us
e pr
oper
lift
ing
tack
le 1
whe
ntr
ansp
ortin
g th
e en
gine
.●
Afte
r tr
ansp
orta
tion
and
befo
re c
omm
is-
sion
ing
of th
e en
gine
:Rem
ove
atta
chm
ent
eyes
2.
Use
onl
y th
e co
rrec
t lift
ing
gear
!
©
35 2
10
0©
35
211
0
6 © 2001
6.8.
En
gin
e C
lean
ing
Ser
vice
an
d M
ain
ten
ance
6.8.
1E
ng
ine
clea
nin
g
Usi
ng
co
mp
ress
ed a
ir
●S
witc
h of
f th
e en
gine
.●
Rem
ove
engi
ne c
over
s an
d co
olin
g ai
rho
od.
Rep
lace
the
m a
fter
clea
ning
and
befo
re t
he t
est
run.
●C
over
ele
ctric
al /
ele
ctro
nic
com
pone
nts
/co
nnec
tions
(e.
g. g
ener
ator
, st
arte
r, go
v-er
nor,
sole
noid
).●
Blo
w a
ir th
roug
h th
e en
gine
, tak
ing
part
icu-
lar
care
not
to
dam
age
the
cool
er a
ndco
olin
g fin
s (b
egin
to b
low
thro
ugh
air f
rom
the
exha
ust
side
).R
emov
e th
e di
rt w
hich
has
blo
wn
into
the
inte
rior
spac
e.
Usi
ng
co
ld-c
lean
ing
co
mp
ou
nd
●S
witc
h of
f th
e en
gine
.●
Rem
ove
engi
ne c
over
s an
d co
olin
g ai
rho
od.
Rep
lace
the
m a
fter
clea
ning
and
befo
re t
he t
est
run.
●C
over
ele
ctric
al /
ele
ctro
nic
com
pone
nts
/co
nnec
tions
(e.
g. g
ener
ator
, st
arte
r, g
ov-
erno
r, so
leno
id).
●S
pray
the
engi
ne w
ith th
e co
mm
erci
al c
old-
clea
ning
com
poun
d an
d al
low
to
reac
t fo
rap
prox
. 10
min
s.●
Spr
ay c
lean
the
engi
ne w
ith a
str
ong
wat
erje
t, re
peat
if
nece
ssar
y.●
Allo
w t
he e
ngin
e to
run
war
m s
o th
at t
here
mai
ning
wat
er e
vapo
rate
s.
Usi
ng
hig
h p
ress
ure
dev
ice
●S
witc
h of
f th
e en
gine
.●
Rem
ove
engi
ne c
over
s an
d co
olin
g ai
rho
od.
Rep
lace
the
m a
fter
clea
ning
and
befo
re t
he t
est
run.
●C
over
ele
ctric
al /
ele
ctro
nic
com
pone
nts
/co
nnec
tions
(e.
g. g
ener
ator
, st
arte
r, go
v-er
nor,
sole
noid
).●
Cle
an t
he e
ngin
e w
ith a
ste
am j
et (
max
.sp
ray
pres
sure
of
60 b
ar,
max
. st
eam
tem
pera
ture
of
90ºC
).●
Allo
w t
he e
ngin
e to
run
war
m s
o th
at t
here
mai
ning
wat
er e
vapo
rate
s.
Cle
an th
e en
gine
onl
y w
hen
the
engi
ne i
s sw
itche
d of
f!
©
35 2
06
0©
35
204
0
©
35 2
05
0
6
© 2001S
ervi
ce a
nd
Mai
nte
nan
ce6.
9 A
dd
itio
nal
Mai
nte
nan
ce W
ork
●C
ylin
der
head
cov
er 1
●A
ir in
take
man
ifold
2●
Con
nect
ion
sock
ets
●E
xhau
st li
ne 3
●E
ngin
e m
ount
s 4
●W
ith p
erfe
ct fu
nctio
n, th
e ai
r-in
take
pip
e 4
war
ms
up n
ear t
he g
low
lam
ps 2
from
pre
-g
low
ing
.
Test
ste
p 1
●P
lace
spe
ed c
ontr
ol le
ver
or s
hut-
off l
ever
in“s
top”
pos
ition
.●
Inse
rt k
ey-P
ositi
on 0
= n
o op
erat
ing
volta
ge●
Key
clo
ckw
ise
-Pos
ition
1 =
ope
ratin
g vo
ltage
-Pilo
t lig
hts
illum
inat
e●
Pus
h ke
y in
and
tur
n fu
rthe
r cl
ockw
ise
agai
nst
sprin
g pr
essu
re.
-Pos
ition
2 =
Pre
heat
, ho
ld f
or a
ppro
x. 1
min
ute.
-Pre
heat
lam
p co
mes
on
●O
ther
wis
e th
e gl
ow la
mps
are
def
ectiv
e or
the
tran
smis
sion
line
inte
rrup
ted.
6.9.
1C
hec
k fa
sten
ing
s6.
9.2
Ch
ecki
ng
the
fun
ctio
n o
f t
he
glo
w p
lug
s
©
26
111
0
©
24 7
17
1©
25
746
2
6 © 2001
6.9
Ad
dit
ion
al M
ain
ten
ance
Wo
rkS
ervi
ce a
nd
Mai
nte
nan
ce
Test
ste
p 2
●Lo
osen
scr
ew 1
.●
Tur
n en
gine
ove
r with
sta
rter
, key
in s
witc
h-in
g po
sitio
n 3.
●F
uel m
ust b
e pr
esen
t on
the
loos
ened
pip
eco
nnec
tion.
Oth
erw
ise,
the
sys
tem
and
sole
noid
val
ve s
houl
d be
che
cked
by
asp
ecia
list!
Test
ste
p 3
●Lo
osen
scr
ew 1
.●
Rem
ove
glow
lam
ps 2
●Tu
rn e
ngin
e ov
er w
ith s
tart
er, k
ey in
sw
itch-
ing
posi
tion
3.●
Fue
l mus
t be
pres
ent o
n th
e gl
ow la
mps
2,
or r
epla
ce g
low
lam
ps 2
if
nece
ssar
y.●
Whe
n fit
ting
glow
lam
ps 2
, use
DE
UT
Z D
W47
sea
lant
s.●
Rei
nsta
ll gl
ow la
mps
to
fuel
line
.
Kee
p aw
ay fr
om m
ovin
g pa
rts!
Col
lect
any
esc
apin
g fu
el a
nddi
spos
e of
thi
s in
an
envi
ron-
men
tally
-frie
ndly
man
ner.
©
24 7
17
1©
24
717
1
6
© 2001
7 © 2001
Fau
lts, C
ause
s an
d R
emed
ies
7.1
Fau
lt T
able
7 © 2001
Fau
lts, C
ause
s an
d R
emed
ies
7.1
Fau
lt T
able
● ●●
●●
●●
●●
●●
●●
●
●●
●●
●●
●●
●●
●
●
●●
●
●●
● ●●
●
●●
● ● ●
Cau
seS
ecti
on
Not
dec
lutc
hed
(whe
re p
ossi
ble)
En
gin
e O
per
atio
nP
Bel
ow s
tart
ing
limit
tem
pera
ture
P
Eng
ine
shut
-off
leve
r st
ill i
n st
op p
ositi
on (
shut
-off
mag
net
defe
ctiv
e)P
Oil
leve
l too
low
A
Oil
leve
l too
hig
hS
Exc
essi
ve i
nclin
atio
n of
eng
ine
P/E
Eng
ine
runs
mai
nly
with
low
load
P
Air
clea
ner
clog
ged
/ tu
rboc
harg
er d
efec
tive
Co
mb
ust
ion
air
W
Air
clea
ner
serv
ice
switc
h /
indi
cato
r de
fect
ive
P/W
CP
D d
efec
tive
(con
nect
ion
line
leak
s) o
nly
with
tur
boch
arge
d en
gine
sP
/W
Exh
aust
gas
bac
kpre
ssur
e to
o hi
ghP
Cha
rge
air
line
leak
ing,
onl
y w
ith s
uper
char
ged
engi
nes
P/E
Coo
ling
fins
soile
dC
oo
ling
sys
tem
P/R
Inte
rcoo
ler
soile
dP
/R
Oil
cool
er s
oile
d on
the
air
and/
or th
e oi
l sid
eP
/R
Coo
ling
fan
or e
xhau
st t
ensi
on d
efec
tive,
tor
n or
loos
e V
-bel
tP
/W
Coo
ling
air
tem
pera
ture
ris
e / h
eatin
g sh
ort c
ircui
tP
Coo
ling
air
guid
e lo
ose,
torn
or
mis
sing
P
Fau
lts
Mea
sure
s
Eng
ine
does
not
sta
rt o
r is
diff
icul
t to
sta
rtC
heck
P
Eng
ine
star
ts,
but
runs
irr
egul
arly
or
fails
Ad
just
E
Eng
ine
over
heat
s, t
empe
ratu
re w
arni
ng s
yste
m r
espo
nds
Rep
lace
W
Eng
ine
outp
ut i
s de
ficie
ntC
lean
R
Eng
ine
does
not
run
on
all c
ylin
ders
Top
upA
Eng
ine
oil p
ress
ure
is n
on-e
xist
ent
or e
xces
sive
ly lo
wR
educ
eS
Eng
ine
oil
cons
umpt
ion
exce
ssiv
e
Eng
ine
smok
es-
blue
- w
hite
- bl
ack
7 © 2001
● ● ●
●
●●
●●
●●
●
●●
●●
●
●●
●
●●
●●
●●
●
●●
●●
●●
●●
●●
●●
●
●●
●●
●●
●
7.1
Fau
lt T
able
Fau
lts, C
ause
s an
d R
emed
ies
Fau
lts
Mea
sure
s
Eng
ine
does
not
sta
rt o
r is
diff
icul
t to
sta
rtC
heck
P
Eng
ine
star
ts,
but
runs
irr
egul
arly
or
fails
Ad
just
E
Eng
ine
over
heat
s, t
empe
ratu
re w
arni
ng s
yste
m r
espo
nds
Rep
lace
W
Eng
ine
outp
ut i
s de
ficie
ntC
lean
R
Eng
ine
does
not
run
on
all c
ylin
ders
Top
upA
Eng
ine
oil p
ress
ure
is n
on-e
xist
ent
or e
xces
sive
ly lo
wR
educ
eS
Eng
ine
oil
cons
umpt
ion
exce
ssiv
e
Eng
ine
smok
es-
blue
- w
hite
- bl
ack
Cau
seS
ecti
on
Bat
tery
def
ectiv
e or
dis
char
ged
Ele
ctri
csP
Cab
le c
onne
ctio
ns,
star
ter,
ele
ctric
al c
ircui
t lo
ose
or o
xidi
sed
P
Sta
rter
def
ectiv
e or
pin
ion
does
not
eng
age
P
Oil
pres
sure
sw
itch
/ ga
uge
defe
ctiv
eP
/W
Inco
rrec
t va
lve
clea
ranc
eE
ng
ine
P/E
Inje
ctio
n lin
e le
aks
P/R
Ven
tilat
ion
line
bloc
ked
P/R
Glo
w p
lugs
P/W
Inje
ctio
n va
lve
defe
ctiv
eP
/W
Air
in t
he f
uel
syst
emP
/W
Fue
l filt
er /
fue
l pre
-cle
aner
soi
led
P/R
/W
Oil
filte
r de
fect
ive
W
Inco
rrec
t en
gine
lube
oil
SA
E c
lass
or
qual
ityW
Com
pres
sion
too
low
P
Oil
in c
ombu
stio
n ch
ambe
rP
/R
7 © 2001
8 © 2001
En
gin
e P
rese
rvat
ion
8.1
Pre
serv
atio
n
8
© 2001If th
e en
gine
is to
rem
ain
idle
for a
n ex
tend
edpe
riod
of ti
me,
it is
nec
essa
ry to
take
pro
tec-
tive
mea
sure
s to
pre
vent
the
for
mat
ion
ofco
rros
ion.
The
pre
serv
ativ
e m
easu
res
de-
scrib
ed h
ere
will
pro
tect
the
engi
ne fo
r up
toap
prox
. 6 m
onth
s. T
he p
roce
dure
will
hav
e to
be
re
vers
ed
b
efo
re
the
e
ng
ine
is
reco
mm
issi
oned
●A
nti-c
orro
sion
oils
to
spec
ifica
tion:
- M
IL-L
212
60B
- T
L 91
50-0
37/2
- N
ato
Cod
e C
640
/ 64
2
●R
ecom
men
ded
clea
ning
age
nt t
o re
mov
ep
rese
rva
tive
s:-
Pet
role
um b
enzi
ne (
haza
rdou
s m
ater
ials
clas
s A
3)
En
gin
e P
rese
rvat
ion
8.1
Pre
serv
atio
n
●R
emov
e an
ti-co
rros
ion
agen
t fro
m g
roov
esin
V-b
elt
pulle
ys.
●In
stal
l V
-bel
t, re
tens
ion
afte
r br
ief
oper
a-tio
n if
nece
ssar
y (s
ee 6
.5).
●R
emov
e co
vers
fro
m i
ntak
e po
rt a
nd e
x-ha
ust
port
s.
●C
omm
issi
on e
ngin
e.
8.1
Pre
serv
atio
n8.
1.1
Pre
serv
e en
gin
e8.
1.2
Rem
ove
en
gin
ep
rese
rvat
ion
●C
lean
eng
ine
(with
col
d cl
eans
ing
agen
t if
pref
erre
d) u
sing
hig
h pr
essu
re e
quip
men
t(s
ee 6
.8.1
).●
Run
eng
ine
until
war
m,
then
tur
n of
f.●
Dra
in e
ngin
e oi
l, (s
ee 6
.1.2
), a
nd f
ill w
ithan
ti-co
rros
ion
oil.
●If
nece
ssar
y, c
lean
oil
bath
cle
aner
(se
e6.
4.3)
, an
d fil
l w
ith a
nti-c
orro
sion
oil.
●D
rain
fuel
tank
.●
Mak
e up
a m
ixtu
re o
f 90
% d
iese
l fue
l and
10 %
ant
i-cor
rosi
on o
il, a
nd r
efill
fuel
tank
.●
Allo
w th
e en
gine
to ru
n fo
r app
rox.
10
min
s.●
Sw
itch
off
the
engi
ne.
●T
urn
engi
ne o
ver m
anua
lly s
ever
al ti
mes
topr
eser
ve t
he c
ylin
ders
and
com
bust
ion
cham
ber.
Whe
n tu
rnin
g ov
er w
ith s
tart
er,
set
shut
-of
f le
ver
to s
top
posi
tion.
●R
emov
e V
-bel
ts a
nd s
tore
wra
pped
, dr
yan
d re
cum
bent
.●
Spr
ay g
roov
es o
n V
-bel
t pu
lleys
with
ant
i-co
rros
ion
spra
y.●
Clo
se o
ff in
take
por
ts a
nd e
xhau
st p
orts
,po
ssib
ly w
ith p
lugs
.
9 © 2001
Tech
nic
al S
pec
ific
atio
n
9.1
En
gin
e S
pec
ific
atio
ns
and
Set
tin
gs
9.2
Scr
ew T
igh
ten
ing
To
rqu
es9.
3To
ols
9
© 2001Te
chn
ical
Sp
ecif
icat
ion
9.1
En
gin
e S
pec
ific
atio
ns
and
Set
tin
gs
Mo
del
Num
ber
of c
ylin
ders
Cyl
inde
r ar
rang
emen
tB
ore
[mm
]S
troke
[mm
]T
otal
di
spla
cem
ent
[cm
3 ]C
ompr
essi
on r
atio
[ε]
Wor
king
cyc
leC
ombu
stio
n sy
stem
Dire
ctio
n of
rot
atio
n se
en o
n fly
whe
elW
eigh
t in
clud
ing
cool
ing
syst
em t
o D
IN 7
0020
-Aw
ithou
t st
arte
r or
alte
rnat
or[a
ppro
x. k
g]E
ngin
e ou
tput
[kW
]S
pe
ed
[rpm
]Lu
bric
atio
nS
AE
oil
Oil
tem
pera
ture
in o
il pa
n[°
C]
Min
. oil
pres
sure
whe
n w
arm
(12
0 °C
)an
d lo
w id
le[b
ar]
ÖO
il pl
ate
fillin
g qu
antit
y w
ithou
t fil
ter
[app
rox.
litr
es]
Oil
plat
e fil
ling
quan
tity
with
filt
er[a
ppro
x. li
tres
]V
alve
cle
aran
ce w
ith c
old
engi
ne [m
m]
Inje
ctor
ope
ning
pre
ssur
e[b
ar]
Sta
rt o
f fe
ed[°
KW
of T
DC
]F
iring
ord
er o
f th
e en
gine
V-B
elt
tens
ion:
Alte
rnat
or f
an[N
]C
ompr
esso
r[N
]
F3L
914
F4L
914
F5L
914
F6L
914
34
56
vert
ical
in
line
10
21
32
32
36
43
14
53
93
64
72
20
4-st
roke
nat
ura
lly a
spir
ated
die
sel e
ng
ine
Dire
ct i
njec
tion
coun
ter-
cloc
kwis
e
270
5)30
05)
380
5)41
05)
1) 1)P
ress
ure
lubr
icat
ion
15W
40
13
5
0,4
4)
9,0
3)12
,03)
13,5
3)14
,53)
9,6
3)13
,03)
15,0
3)16
,03)
Inle
t 0,
15 +
0,0
5 / e
xhau
st0,
15 +
0,0
520
0 +
101)
1–
2–
31
–3
–4
–2
1–
2–
4–
5–
31
–5
–3
–6
–2
–4
Pre
-ten
sion
/ r
e-te
nsio
n 2)
450
/ 300
± 2
055
0 / 4
00 ±
20
1) E
ngin
e ou
tput
, sp
eed,
sta
rt o
f de
liver
y ar
e st
ampe
d on
eng
ine
ratin
g pl
ate,
etc
., (s
ee a
lso
2.1)
.2)
Re-
tens
ion
15 m
inut
es a
fter
the
engi
ne h
as b
een
oper
ated
und
er lo
ad.
3) A
ppro
x. v
alue
s m
ay v
ary
depe
ndin
g on
ver
sion
. T
he u
pper
oil
dips
tick
mar
k is
alw
ays
auth
orita
tive.
4) V
alue
s fo
r en
gine
s w
ithou
t en
gine
oil
heat
ing.
5) A
ppro
x. v
alue
s m
ay v
ary
depe
ndin
g on
ver
sion
.
9 © 2001
9.1
En
gin
e S
pec
ific
atio
ns
and
Set
tin
gs
Tech
nic
al S
pec
ific
atio
n
BF
3L 9
14B
F4L
914
BF
6L 9
14B
F6L
914
C3
46
6ve
rtic
al i
n lin
e1
02
13
23
23
64
31
46
47
26
47
21
84-
stro
ke t
urbo
char
ged
dies
el e
ngin
e D
irect
inj
ectio
nco
unte
r-cl
ockw
ise
320
5)36
05)
485
5)51
05)
1) 1)P
ress
ure
lubr
icat
ion
15W
40
13
5
0,5
4)
93)
123)
16,0
3)16
,03)
9,6
3)13
3)17
,53)
17,5
3)
Inle
t 0,1
5 +
0,05
/ ex
haus
t 0,1
5 +
0,05
200
+ 10
1)1
–2
–3
1–
3–
4–
21
–5
–3
–6
–2
–4
1–
5–
3–
6–
2–
4P
rete
nsio
n /
Ret
ensi
on 2)
400
/ 250
± 2
050
0 / 3
50 ±
20
914/
C/C
T M
od
elN
umbe
r of
cyl
inde
rsC
ylin
der
arra
ngem
ent
Bo
re[m
m]
Stro
ke[m
m]
Tot
al
disp
lace
men
t[c
m3 ]
Com
pres
sion
rat
io[ε
]W
orki
ng c
ycle
Com
bust
ion
syst
emD
irect
ion
of r
otat
ion
seen
on
flyw
heel
Wei
ght
incl
udin
g co
olin
g sy
stem
to
DIN
700
20-A
with
out
star
ter
or a
ltern
ator
[app
rox.
kg]
Eng
ine
outp
ut[k
W]
Sp
ee
d[r
pm]
Lubr
icat
ion
SA
E o
ilO
il te
mpe
ratu
re in
oil
pan
[°C
]M
in. o
il pr
essu
re w
hen
war
m (
120
°C)
and
low
idle
[bar
]O
il pl
ate
fillin
g qu
antit
y w
ithou
t fil
ter
[app
rox.
litr
es]
Oil
plat
e fil
ling
quan
tity
with
filt
er[a
ppro
x. li
tres
]V
alve
cle
aran
ce w
ith c
old
engi
ne [m
m]
Inje
ctor
ope
ning
pre
ssur
e[b
ar]
Sta
rt o
f fe
ed[°
KW
of T
DC
]F
iring
ord
er o
f th
e en
gine
V-B
elt
tens
ion:
Pre
tens
ion
/ R
eten
sion
Alte
rnat
or f
an[N
]C
ompr
esso
r[N
]
1) E
ngin
e ou
tput
, sp
eed,
sta
rt o
f de
liver
y ar
e st
ampe
d on
eng
ine
ratin
g pl
ate,
etc
., (s
ee a
lso
2.1)
.2)
Re-
tens
ion
15 m
inut
es a
fter
the
engi
ne h
as b
een
oper
ated
und
er lo
ad.
3) A
ppro
x. v
alue
s m
ay v
ary
depe
ndin
g on
ver
sion
. T
he u
pper
oil
dips
tick
mar
k is
alw
ays
auth
orita
tive.
4) V
alue
s fo
r en
gine
s w
ithou
t en
gine
oil
heat
ing.
5) A
ppro
x. v
alue
s m
ay v
ary
depe
ndin
g on
ver
sion
.
9
© 2001Te
chn
ical
Sp
ecif
icat
ion
9.2
Torq
ue
Wre
nch
Set
tin
gs
Inst
alla
tio
nP
rete
nsi
on
Re
ten
sio
nT
ota
lC
om
me
nts
[Nm
]1st
pos
ition
2nd p
ositi
on3rd
pos
ition
4th p
ositi
on
Sec
urin
g th
e al
tern
ator
20
18
0°
––
–1
80
°M
10 x
180
30
18
0°
––
–1
80
°M
14 x
230
Cyl
inde
r he
ad c
over
––
––
–12
± 1
,2 N
m–
Val
ve c
lear
ance
adj
ustin
g sc
rew
––
––
–22
± 2
Nm
–F
oo
t3
06
0°
15
°–
–7
5°
M14
x 1
00
30
60
°4
5°
––
10
5°
M14
x 1
10
30
60
°4
5°
––
10
5°
M14
x 1
25
Inta
ke
ma
nifo
ld–
––
––
21 ±
2 N
m–
Exh
au
st
ma
nifo
ld–
––
––
40 ±
4 N
m–
Oil
drai
n sc
rew
––
––
–15
0 ±
10
Nm
M30
x 1
,5O
il dr
ain
scre
w–
––
––
80 ±
10
Nm
M22
x 1
,5
Inje
ctio
n
valv
e
att
ach
me
nt
––
––
–25
–30
Nm
–
9 © 2001
9.3
Too
lsTe
chn
ical
Sp
ecif
icat
ion
V-b
elt
ten
sio
n g
aug
e
The
V-b
elt
tens
ion
gaug
e ca
n be
obt
aine
dun
der
orde
r nu
mbe
r 81
15 f
rom
:
WIL
BÄ
RP
ostfa
ch 1
4 05
80
D-4
2826
Rem
sche
id
©
26 0
02
0
10
Serv
ice
Know
ing
it’s
DEUT
Z
DEUT
Z ha
s al
way
s st
ood
for
exce
llenc
e in
mot
orco
nstru
ctio
n, p
ione
erin
g m
any
deve
lopm
ents
in
the
indu
stry
. As
an
inde
pend
ent
mot
or m
anu-
fact
urer
, w
e of
fer
—
wor
ldw
ide
—
a co
m-
preh
ensi
ve
rang
e of
di
esel
an
d ga
s m
otor
ssp
anni
ng fr
om 4
kW to
7,4
00kW
. Our
pro
duct
s ar
epe
rfect
ly ta
ilore
d to
mee
t our
cust
omer
s’ in
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dual
requ
irem
ents
.
Over
1.4
mill
ion
DEUT
Z m
otor
s do
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ir jo
bre
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y al
l ove
r th
e w
orld
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rmin
ed to
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erve
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h st
anda
rd o
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rform
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ndab
ility
of
our
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ors,
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s ke
epin
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rcu
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es. T
here
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esen
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ldw
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hrou
gh a
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ork o
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hly
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ervi
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artn
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ene
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ur c
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EUTZ
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e fo
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ack
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us. D
EUTZ
als
om
eans
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ervi
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mpr
ehen
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ort
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nhan
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otor
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erfo
rman
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inde
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ervi
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ffers
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artn
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ur vi
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en
