Deutz 0312 4004 2011 Service Manual

Workshop Manual

competence level 2

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 reproductions of 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: [e-mail]

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

Printed in Germany All rights reserved 1st edition, 11/2004 Order No. 0312 4004

© 11/2004

Contents

2011

1Foreword

2General

3User notes

3.1General

3.2Specifications

3.2.1Safety regulations and rules for the prevention of accidents

3.2.2Disposal regulations

3.3	Operating manual and workshop manual	1
3.4	Job cards
3.5	Explanation of symbols

4Technical data

4.1Test and adjustment data

4.2Tightening specifications

5Job card overview

5.1Alphabetical sorting

5.2Numeric sorting

5.3Job card references

6Job cards

7Commercial tools

8Special tools

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1 Foreword

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1 Foreword

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zRead 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.

zThis engine is built exclusively for the purpose according to the scope of delivery - defined 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.

zUse 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.

zMake sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents.

zFailure 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.	1

zPrerequisite 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.

zEngine parts such as springs, clamps, elastic retaining rings etc. constitute an increased risk of injury when not used properly.

zThe pertinent rules for the prevention of accidents and other generally recognized safety and industrial medicine rules must be observed.

zMaximum cost effectiveness, reliability and long life is only guaranteed when DEUTZ original parts are used.

zRepair 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!

zThe 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.

zThe engine is equipped according to the installation, i.e. not all the parts and components described in this documentation are installed in your engine.

zWe 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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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 normal operation must be observed especially.

DEUTZ AG

Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast, professional repairs using original parts in the event of damage.

Original parts of the DEUTZ AG are always produced according to the latest state of the art. 2 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 the 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 and 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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Notes

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3 User notes

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3.1General

The maintenance work prescribed in the operating manual and in the workshop manual must be performed on schedule and completely.

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

Caution!

!The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.

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

3.2Specifications

3.2.1Safety 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.

It generally applies among other things:

zfor 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 maintenance.

zfor 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.

zFor 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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3.2.2Disposal regulations

The work described in the operating manual and workshop manual necessitates renewal of parts and operating materials. The renewed parts / operating materials must be stored, transported and disposed of properly. 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 governed by regional, national and international laws and directives which the system operator must observe on his own responsibility.

3.3Operating 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:
3	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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3.4Job 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	07	Kraftstoffsystem
		01	Zylinderkopf	08	Schmierölsystem		3
		02	Triebwerk	09	Kühlflüssigkeitssystem
		03	Kurbelgehäuse	10	Druckluftsystem
		04	Motorsteuerung	11	Überwachungssystem
		05	Drehzahlregelung	12	Sonstige Bauteile
		06	Abgasanlage / Aufladung	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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Structure of a job card

1

2

3

Kurbelgehäuse	4
W 00-00-00
13
12
11	5
	6

3

10

6

9

7

8

© 39744 1

1.	DEUTZ, publisher of the	8.	DEUTZ-internal part number of job card and
	service documentation		technical order number
2.	Engine type (e. g. 914)	9.	Date of issue of the job card
3.	Maintenance group	10.	Work sequence
4.	Job card number	11.	Safety and general notes
5.	Reference to other job cards,	12.	Necessary tools, auxiliary materials and
	Specifications and similar		spare parts
6.	Explanatory graphics	13.	Title of the job card
7.	Page number

Note

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

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3.5Explanation of symbols

Caution!

!

Auxiliary material

For example: Lifting gear, adhesive

Tools

for example:100 400 - meter

	3
	Note
	For example: Cylinder head is dismantled.
	Always renew when assembling
	For example: Gaskets
	References
	For example: Job card no. W xx-yy-zz
01 61	See technical data (test and setting data)
	Line note, for example: ”01 61 – Valve clearance (inlet)”
01001	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

4

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4.1 Test and adjustment data	2011
Notes

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			2011	4.1 Test and adjustment data
00 00	Engine general
ID			Name	Remark	Value	Unit
No.
00 04	Engine weight according to			F2L engine	175
	DIN 70020-A
				F3L engine	217
				F4L engine	256
				F2M engine	169
				F3M engine	210
						kg
				F4M engine	248
								4
				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	left
				flywheel
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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4.1 Test and adjustment data

2011

ID

Name

Remark

Value

Unit

No.

00 71

Ignition sequence

2-cylinder

1 - 2

3-cylinder

1 - 2 - 3

4-cylinder

1 - 3 - 4 - 2

00 81

Cylinder arrangement

A

2-cylinder

A = Manifold side

B = Operating side

1

2

B

© 39617 0

4

Cylinder arrangement

A

3-cylinder

A = Manifold side

B = Operating side

1

2

3

B

© 39618 0

Cylinder arrangement

A

4-cylinder

A = Manifold side

B = Operating side

1

2

3

4

B

© 39619 0

01 00

Cylinder head

ID

Name

Additional information

Value

Unit

No.

01 60

Valve clearance

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		2011			4.1 Test and adjustment data
ID			Name		Additional information	Value	Unit
No.
01 61	Valve clearance (inlet)			•	after a cooling time of at
					least 0.5 h (oil	0.3 ±0.05
					temperature < 80 °C)
				• Test and setting values
					in inspections from a
					running time of		mm
					50 operating hours of
					the engine or life of the
					cylinder head gasket	(0.4 ±0.05)
					(see maintenance
					schedule)
				• Setting values when
					changing the cylinder
					head gasket				4
01 62	Valve clearance (outlet)			•	after a cooling time of at
					least 0.5 h (oil	0.5 ±0.05
					temperature < 80 °C)
				• Test and setting values
					in inspections from a
					running time of		mm
					50 operating hours of
					the engine or life of the
					cylinder head gasket	(0.6 ±0.05)
					(see maintenance
					schedule)
				• Setting values when
					changing the cylinder
					head gasket

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4.1 Test and adjustment data			2011
ID	Name	Additional information	Value		Unit
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

4

white = not adjustable

black = adjustable

Crankshaft setting 2

white = not adjustable

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

black = adjustable

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ID			Name	Additional information	Value	Unit
No.
01 70	toggle lever / toggle lever block
01 72	toggle lever bore for toggle lever axle				18 ±0.27	mm
	(outlet)
01 73	toggle lever bore for toggle lever axle				18 ±0.27	mm
	(inlet)
01 74	diameter of the toggle lever axle				17.97 ±0.01	mm
01 98	Length of the cylinder head screw			Standard	+ 0.8	mm
					150.000 - 0.8
02 00	Drive system							4
ID			Name	Additional information	Value	Unit
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
08 00 Lube oil system
ID			Name	Additional information	Value	Unit
No.
08 74	Length of the compression spring for the				116.7	mm
	lube oil thermostat

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			4.1 Test and adjustment data			2011
		09 00		Cooling system
			ID	Name	Additional information	Value			Unit
			No.
			09 91	Gap dimension between running wheel		min. = 0.2			mm
				and blower jacket inlet		max. = 0.8
		12 00		Other components
			ID	Name	Additional information	Value			Unit
			No.
			12 11	Tension of the single V-belt	First assembly	450 ±50			N
	4
			12 21	Tension of the single V-belt	Check after 15 min	300 ±20			N
					running under load

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Notes

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	4	Technical data
	4.2	Tightening specifications
			4

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