Deutz 0312 4004 2011 Service Manual

Workshop Manual

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2011

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0312 4004 en

Illustrations and data in this workshop manual are subject to technical change in the course of improvements to the engines. Reprinting and repr od uctions o f any kind, even in part, require our written permission.

Regarding copyright questions and licensing agreements

please contact : VS-DI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: sonntag.j@deutz.com

Deutz AG Service Information Systems Ottostraße 1 D - 51149 Cologne Tel.: + 49 (0) 221-8 22-0 Fax: + 49 (0) 221-8 22-58 50 http://www.deutz.com

2011

1 Foreword

2 General

3 User notes

3.1 General

3.2 Specifications

3.2.1 Safety regulations and rules for the prevention of accidents

3.2.2 Disposal regulations

3.3 Operating manual and workshop manual

3.4 Job cards

3.5 Explanation of symbols

Contents

4 Technical data

4.1 Test and adjustment data

4.2 Tightening specifications

5 Job card overview

5.1 Alphabetical sorting

5.2 Numeric sorting

5.3 Job card references

6Job cards

7Commercial tools

8 Special tools

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Contents

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Notes

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1 Foreword

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1 Foreword

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1 Foreword

2011

z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer’s

warranty and have a fully functional, ready to use engine at your disposal.

z This engine is built exclusively for the purpose according to the scope of delivery - d efined by the equipment

manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user will bear the sole risk in this case.

z Use for the intended purpose also includes observance of the operating, maintenance and repair

instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with it and instructed in the dangers.

z Make sure that this documentation is available to everyone involved in the operation, maintenanc e and

repair and that they have understood the contents.

z Failure to observe this documentation can lead to malfunctions and engine damage as well as

injury to persons for which the manufacturer will accept no liability.

z Prerequisite for the proper maintenance and repair is the availability of all necessary equipment,

commercial tools and special tools as well as their perfect working order.

z Engine parts such as springs, clamps, elastic retaining rings etc. constitute an increased risk of injury when

not used properly.

z The pertinent rules for the prevention of accid en ts a nd other generally recognized safety and industrial

medicine rules must be observed.

z Maximum cost effectiveness, reliability and long life is only guaranteed when DEUTZ original parts are

used.

z Repair of the engine must comply with use for the intended purpose. Only parts released by the

manufacturer for the respective purpose may be used for conversion work. Unauthorized modification to the engine exclude manufacturer liability for resulting damages. Failure to observe this will lead to voiding of the warranty!

z The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants

ensures that the respective special requirements are met.

z The engine is equipped according to the installation, i.e. not all the parts and components de scribed in this

documentation are installed in your engine.

z We have done our best to clearly identify the differences so that you can easily find the operating,

maintenance and repair instructions relevant to your engine.

We are at your service for any questions you may have in this matter.

Your DEUTZ AG

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2 General

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2 General

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Notes

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2 General

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DEUTZ engines

are the product of years of research and development. The profound know-how gained in connection with high quality requirements is the guarantee for manufacturing of engines with a long life, high reliability and low fuel consumption. Naturally the high requirements for protection of the environment are also met.

Maintenance and care

are decisive for whether the engine satisfactorily meets the set demands. Compliance with the prescribed maintenance times and the careful execution of maintenance and care are therefore essential. Difficult operating conditions deviation from norm al oper ation must be observed especially.

DEUTZ AG

Please consult one of our service representa tive s re sp on sib le fo r op erat i ng faul ts an d sp ar e pa rt s quest ion s . Our trained specialist personnel ensures fast, professional repairs using original par ts in the event of damage. Original parts of the DEUTZ AG are always produced according to the latest state of the art. Information about our service can be found at the end of this documentation.

Take care when the engine is running

Only perform maintenance work or repairs when the engine is at a standstill. Replace any removed protective devices upon completion of the work. When working on t he running engine, work clothing must be close fitting.

Safety

This symbol accompanies all safety notes. Observe these carefully. Also pass on the safety instructions to your operating personnel. The ”General safety regulations a nd rules for the prevention of accidents” of the legislator must be observed additionally.

Note

This symbol accompanies information of a general kind. Observe these carefully.

Asbestos

Gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair work.

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3User notes

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3 User notes

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3 User notes

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3.1 General

The maintenance work prescribed in the oper ating manual and in the wor kshop manual must be performed on schedule and completely.

The maintenance personnel must possess th e necessary technical knowledge to perform the work. Safety and protection devices which are removed during maintenance work must be replaced again afterwards.

Also observe the special safety regulations for the different maintenance groups which are listed in detail as job cards in the Job cards chapter (cf. also section 1.2).

See the maintenance schedules for the maintenance intervals. These also inform you of the work to be performed.

The job cards provide technical instructions for performing the work.

3.2 Specifications

3.2.1 Safety regulations and rules for the prevention of accidents

For various maintenance groups, detailed safety notes in the form of job cards have been compiled, these precede the job cards of the respective maintenance groups.

The legally prescribed rules for the prevention of accidents (available from professional associations or from dealers) must be observed. These are dependent on the installation site, operating mode and the operating and auxiliary materials being used.

Special protection measures depending on the respective work are specified and identified in the job description.

Caution!

The rules for the prevention of accidents and the safety re gu la tion s mu st be ob se rve d duri ng maintenance work.

It generally applies among other things: z for the personnel

- Only instructed personnel may operate or maintain the engine. Unauthorized persons may not enter the engine room.

- Wear close fitting clothing and ear protectors in the engine room when the engine is running.

- Only appoint qualified personnel to do repairs and maintena nce.

z for the engine room:

- Ensure adequate ventilation (do not cover air shafts)

- Install first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly.

- Only store inflammable materials in the engine room if these are necessary for operating the system.

- Smoking and naked lights are prohibited in the engine room.

z For operation and maintenance of the engine:

- Only start the engine when all protection devices are installed. Make sure that no-one is standing in the danger area.

- Only perform cleaning, maintenance and repair work when the engine has been shut down and secured against starting.

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3.2.2 Disposal regulations

The work described in the operating manual and workshop manual necessitates renewal of parts and oper ating materials. The renewed parts / operating materia ls must be stored, tran sported and disp osed of pr operly. The owner himself is responsible for this.

Disposal includes recycling and the scrapping of parts / operating materials whereby recycling has priority. Details of disposal and their monitoring are gove rned by regional, national and international laws and directives

which the system operator must observe on his own responsibility.

3.3 Operating manual and workshop manual

To structure the information to suit the user, the service documentation is divided into operating manual and workshop manual.

The operating manual contains a general description and instructions for all other maintenance work. It contains the following chapters:

1. General, Contents

2. Engine description

3. Operation

4. Operating materials

5. Maintenance

6. Care and maintenance work

7. Faults, causes and remedies

8. Engine corrosion protection

9. Technical data

10. Service

The workshop manual assumes knowledge of the contents of the operating manual, this applies especially for the safety regulations. Minor repairs and emergency measures on components are described the execution of which requires more effort and appropriately qualified personnel.

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3.4 Job cards

The job cards are divided into job cards of the workshop manual e. g. W 04-05-01 and the maintenance manual I 04-05-01.

Numbering of job cards

Dokumentationsart

• Der führende Buchstabe steht für die Art der Dokumentation. W = Werkstatthandbuch I = Instandsetzungsanleitung

Instandhaltungsgruppe (für alle Motoren gleich) 00 Allgemein / übergreifende Tätigkeiten

01 Zylinderkopf 02 Triebwerk 03 Kurbelgehäuse 04 Motorsteuerung 05 Drehzahlregelung 06 Abgasanlage / Aufladung

07 Kraftstoffsystem 08 Schmierölsystem 09 Kühlflüssigkeitssystem 10 Druckluftsystem 11 Überwachungssystem 12 Sonstige Bauteile 13 Elektrische Anlage

Teilsystem (Bauteil)

• Die Teilsysteme unterscheiden sich je Instandhaltungsgruppe.

• Allgemein gültig: 00 Teilsysteme-übergreifend bzw. Sicherheitsvorschriften (SV) 01 Systemparameter bzw. generelle Kontrollen

Fortlaufende Nummer

• Zählend je Teilsystem (Bauteil)

• Verschiedene Tätigkeiten je Teilsystem (Bauteil)

• Versions-Unterschiede

W 03-03-03

80301 3

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3 User notes

Structure of a job card

13 12

1 2 3

Kurbelgehäuse

W 00-00-00

2011

39744 1

1. DEUTZ, publisher of the

service documentation

2. Engine type (e. g. 914)

3. Maintenance group

4. Job card number

5. Reference to other job cards,

Specifications and similar

6. Explanatory graphics

7. Page number

Note

For inquiries about the job card please always state the engine type (2), the job car d number (4) , the page number (7), the date of issue (9) or alternatively the DEUTZ-internal part number (8).

8. DEUTZ-internal part number of job card and technical order number

9. Date of issue of the job card

10. Work sequence

11. Safety and general notes

12. Necessary tools, auxiliary materials and spare parts

13. Title of the job card

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3.5 Explanation of symbols

3 User notes

Auxiliary material

Caution!

For example: Lifting gear, adhesive

Tools

for example:100 400 - meter

Note

For example: Cylinder head is dismantled.

Always renew when assembling

For example: Gaskets

01 61

01001

References

For example: Job card no. W xx-yy-zz

See technical data (test and setting data)

Line note, for example: ”01 61 – Valve clearance (inlet)”

See technical data (tightening specifications)

Line note, for example: ”01001 – Cylinder head on crankcase”

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Notes

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4 Technical data

4.1 Test and adjustment data

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4 Technical data

4.1 Test and adjustment data Notes

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4 Technical data

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00 00 Engine general

No.

00 04 Engine weight according to

DIN 70020-A

Name Remark Value Unit

4.1 Test and adjustment data

F2L engine 175

F3L engine 217

F4L engine 256

F2M engine 169

F3M engine 210

F4M engine 248

BF3L engine 222

BF4L engine 257

BF3M engine 215

BF4M engine 250

00 10 Working principle four-stroke diesel

00 20 Combustion process Direct injection

00 31 Bore Diameter 94 mm

00 32 Stroke 112 mm

00 40 Compression ratio FL/M engines 19:1

BFL/M engines 17.5:1

00 50 Direction of rotation looking onto the

flywheel

left

00 51 Compression pressure FL/M engines 25 to 30 bar

BFL/M engines 22 to 27 bar

00 70 Ignition distance 2 and 4 cylinder 180 °

3-cylinder 120 °

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4 Technical data

4.1 Test and adjustment data

No.

00 71 Ignition sequence 2-cylinder 1 - 2

00 81 Cylinder arrangement

2-cylinder A = Manifold side B = Operating side

Name Remark Value Unit

3-cylinder 1 - 2 - 3

4-cylinder 1 - 3 - 4 - 2

Cylinder arrangement 3-cylinder A = Manifold side B = Operating side

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2011

Cylinder arrangement 4-cylinder A = Manifold side B = Operating side

01 00 Cylinder head

No.

01 60 Valve clearance

1234

Name Additional information Value Unit

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No.

01 61 Valve clearance (inlet) • after a cooling time of at

01 62 Valve clearance (outlet) • after a cooling time of at

Name Additional information Value Unit

least 0.5 h (oil temperature < 80 °C)

• Test and setting values in inspections from a running time of 50 operating hours of the engine or life of the cylinder head gasket (see maintenance schedule)

• Setting values when changing the cylinder head gasket

least 0.5 h (oil temperature < 80 °C)

4.1 Test and adjustment data

0.3

(0.4

0.5

±0.05

±0.05)

±0.05

• Test and setting values in inspections from a running time of 50 operating hours of the engine or life of the cylinder head gasket (see maintenance schedule)

• Setting values when changing the cylinder head gasket

(0.6

±0.05)

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4 Technical data

4.1 Test and adjustment data

No.

01 63 Valve clearance setting scheme

• Turn over engine up until reaching the valve overlap cyl. no. 1.

Note

According to the order below (see table) the valve clearance setting is possible with 2 crankshaft revolutions á 360°.

Crankshaft setting 1 Cyl. no. 1 = overlap

Name Additional information Value Unit

2011

white = not adjustable black = adjustable

Crankshaft setting 2

• Turn the crankshaft one rev on (360°).

white = not adjustable black = adjustable

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No.

01 70 toggle lever / toggle lever block

01 72 toggle lever bore for toggle lever axle

(outlet)

01 73 toggle lever bore for toggle lever axle

(inlet)

01 74 diameter of the toggle lever axle 17.97

01 98 Length of the cylinder head screw

Name Additional information Value Unit

Standard 150.000

4.1 Test and adjustment data

02 00 Drive system

±0.27

±0.01

+0.8

-0.8

No.

02 70 Piston

02 75 Piston overlap for cylinder head gasket 1 Notch 0.514 - 0.69 mm

02 76 Piston overlap for cylinder head gasket 2 Notches 0.691 - 0.76 mm

02 77 Piston overlap for cylinder head gasket 3 Notches 0.761 - 0.83 mm

Name Additional information Value Unit

08 00 Lube oil system

No.

08 74 Length of the compression spring for the

lube oil thermostat

Name Additional information Value Unit

116.7 mm

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4 Technical data

4.1 Test and adjustment data

09 00 Cooling system

No.

09 91 Gap dimension between running wheel

and blower jacket inlet

12 00 Other components

No.

12 11 Tension of the single V-belt First assembly 450

12 21 Tension of the single V-belt Check after 15 min

Name Additional information Value Unit

max. = 0.8

Name Additional information Value Unit

running under load

2011

min. = 0.2

±50

±20

300

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Notes

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4.1 Test and adjustment data

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4 Technical data

4.2 Tightening specifications

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