Deutz 2011 Operation Manual

Operation Manual

2011

C 2000

Safety guidelines / Accident prevention

● Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer’s warranty and maintain the engine in peak operating condition.

● This engine has been built exclusively for the application specified in the scope of supply, as described by the equipment manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose. The manufacturer will not assume responsibility for any damage resulting therefrom. The risks involved are to be borne solely by the user.

● Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation, maintenance and servicing. The engine should only be operated by personnel trained in its use and the hazards involved.

● The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed.

● When the engine is running, there is a risk of injury through:

- turning/hot components

- engines with positive ignition

- ignition systems (high electrical voltage) You must avoid contact at all times!

● Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage. Manipulations of the injection and regulating system may also influence the performance of the engine, and its emissions. Adherence to legislation on pollution cannot be guaranteed under such conditions.

● Do not change, convert or adjust the cooling air intake area to the blower. The manufacturer shall not be held responsible for any damage which results from such work.

● When carrying out maintenance/repair operations on the engine, the use of DEUTZ original parts is prescribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the warranty!

● Maintenance and cleaning of the engine should only be carried out when the engine is switched off and has cooled down. You must ensure that the electrical systems have been switched off and the ignition key has been removed. Accident prevention guidelines concerning electrical systems (e.g. VDE-0100/-0101/0104/-0105 Electrical protective measures against dangerous touch voltage) are to be observed. When cleaning with fluids, all electrical components are to be covered impermeably.

Engine Serial Number:

Operation manual

2011

0297 9929 en

Please enter the engine serial number here. This number should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see Section 2.1).

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

C 2000

Foreword

Dear Customer,

Liquid-cooled Deutz engines are designed for a large number of applications. Consequently, a wide range of variants is offered to meet the requirements of specific cases.

Your engine is appropriately equipped for the installation concerned, which means that not all of the components described in this Operation Manual are necessarily fitted to your engine.

We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions relevant to your engine quickly and easily.

Please read this Manual before starting your engine, and always observe the operating and maintenance instructions.

We are available to help with any additional inquiries

Sincerely,

DEUTZ AG

1. General

2. Engine Description

2.1 Model

2.1.1 Rating Plate

2.1.2 Position of the Rating Plate

2.1.3 Engine Serial Number

2.1.4 Cylinder Numbering

2.1.5 Fuel Delivery Lock

2.2 Engine Illustrations

2.2.1 Operation Side: Example FL 2011

2.2.2 Exhaust Side: Example FL 2011

2.2.3 Operation Side: Example BF4L 2011

2.2.4 Exhaust Side: Example BF4L 2011

2.2.5 Operation Side: Example FM 2011

2.2.6 Exhaust Side: Example FM 2011

2.2.7 Operation Side: Example BFM 2011

2.2.8 Exhaust Side: Example BFM 2011

2.3 Oil Circuit

2.3.1 Lube Oil Circuit Schematic

2.4 Fuel System Schematic

2.4.1 Fuel System

2.5 Coolant System

2.5.1 Coolant Plan

3. Engine Operation

3.1 Commissioning

3.1.1 Adding Engine Oil

3.1.2 Adding Fuel

3.1.3 Other Preperations

3.1.4 Additional Maintenance Work

3.2 Starting

3.2.1 Electric Starting

3.3 Monitoring Operation

3.3.1 Engine Oil Pressure

3.3.2 Engine Temperature

3.4 Shutting Off

3.4.1 Mechanical Shut-Off

3.4.2 Electric Shut-Off

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperature, High Altitude

4. Operating Media

4.1 Lube Oil

4.1.1 Quality

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality

4.2.2 Winter-Grade Fuel

5. Service

5.1 Service Plan

5.2 Scheduled Maintenance Plan

5.3 Maintenance Chart

5.4 Maintenance Work Completed

6. Service and Maintenance

6.1 Lubrication System

6.1.1 Oil Change Intervals

6.1.2 Check Oil Level, Change Engine Oil

6.1.3 Changing Oil Filter

6.1.4 Clean/Replace Oil Filter (Cup)

6.2 Fuel System

6.2.1 Replace Fuel Filter

6.2.2 Clean/Replace Fuel Filter (Cup)

6.2.3 Clean Stainer of Fuel Filter

6.2.4 Change Fuel Leakage Line

6.3 Cooling System

6.3.1 Cleaning Intervals

6.4 Combustion Air Filter

6.4.1 Cleaning Intervals

6.4.2 Emptying Cyclone-Type Precleaner

6.4.3 Dry Type Air Cleaner

6.5 Belt Drives

6.5.1 Check V-belt

6.5.2 Tensioning Alternator Belts

6.5.3 Changing Alternator Belts

6.6 Adjustments

6.6.1 Check Valve Clearance, adjust if necessary

6.6.1.1 Valve Clearance Adjustment Schematic

6.7 Accessories

6.7.1 Battery

6.7.2 Rotary Current Alternator

6.7.3 Transportation Shackles

6.8 Engine Cleaning

6.8.1 Engine Cleaning

Contents

7. Faults, Causes and Remedies

7.1 Fault Table

8. Engine Preservation

8.1 Preservation

8.1.1 Preserving Engine

8.1.2 Removing Engine Preservatives

9. Technical Specification

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

9.3 Tools

10. Service

C 2000

General

DEUTZ Diesel Engines

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Beware of Running Engine

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

Care and Maintenance

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Safety

This symbol is used for all safety warnings. Please follow them

and accident prevention regulations laid down by law must also be observed.

carefully. The attention of operating personnel should be drawn to these safety instructions. General safety

Service

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.

California

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Asbestos

DEUTZ original parts are asbestosfree.

Engine Description

2.1 Model

2.2 Engine Illustrations

2.3 Lube Oil Circuit Schematic

2.4 Fuel System Schematic

C 2001

Engine Description 2.1 Model

2.1.1 Rating Plate

The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.

2.1.2 Position of the Rating Plate

The rating plate C is attached to the valve cover.

2.1.3 Engine Serial Number

The engine serial number B is stamped on the crankcase D as well as the rating plate.

C 2001

2.1 Model Engine Description

2.1.4 Cylinder Numbering

1234

Cylinders are numbered consecutively, beginning at the flywheel.

2.1.5 Fuel Delivery Lock

The manufacturer shall not be held liable for damages resulting from adjustments made to the regulator by the operator. The lock screws are protected in order to prevent this:

1. with locking paint on model: with torque balancer

2. with plastic protective cap on model: without torque balancer.

Adjustments to the regulator are to be carried out only by authorised DEUTZ SERVICE specialists

C 2001

Engine Description 2.2 Engine Illustration

2.2.1 Operation Side FL 2011

1 Oil filler neck (valve-gear housing cover) 2 Charge-air line / air-intake line 3 Fan with integrated generator 4 Narrow V-belt 5 Tractive electromagnet 6 Wheel-house cover 7 V-belt pulley on crankshaft 8 Oil pan 9 Shut-off lever 10 Speed control lever 11 Oil dipstick 12 Oil drain plug 13 Crankcase 14 Oil fill point (on side of crankcase) 15 Fuel pump 16 Easy-change fuel filter 17 Connecting facility for oil heater 18 Lube oil replacement filter 19 Removable coolant intake hood 20 Injection pumps 21 Oil cooler

C 2001

9 81214 13 11 10

2.2 Engine Illustration Engine Description

2.2.2 Exhaust Side FL 2011

22 Date plate 23 Optional attachment of an SAE housing 24 Flywheel with ring gear 25 Starter 26 Front cover 27 Crankcase 28 Exhaust manifold

29 Air intake pipe

C 2001

Engine Description 2.2 Engine Illustration

2.2.3 Operation Side Example: BF4L 2011

1 Oil filler neck (valve-gear housing cover)

21 1 2

2 Charge-air line / air-intake line 3 Fan with integrated generator 4 Narrow V-belt 5 Tractive electromagnet 6 Wheel-house cover 7 V-belt pulley on crankshaft 8 Oil pan 9 Shut-off lever 10 Speed control lever 11 Oil dipstick 12 Crankcase 13 Oil fill point (on side of crankcase) 14 Fuel pump 15 Easy-change fuel filter 16 Connecting facility for oil heater 17 Charge-pressure-dependent full-load stop

(CPD) 18 Lube oil replacement filter 19 Removable coolant intake hood 20 Injection pumps 21 Oil cooler

C 2001

9 810111213

2.2 Engine Illustration Engine Description

2.2.4 Exhaust Side Example: BF4L 2011

22 Cylinder head 23 Exhaust manifold line

24 Flywheel with ring gear 25 Starter 26 Crankcase 27 Lube oil feed line to turbocharger 28 Lube oil return line from turbocharger 29 Induction pipe 30 Turbocharger (TC) 31 Intake manifold 32 Charge-air line

C 2001

Engine Description 2.2 Engine Illustration

2.2.5 Operation Side FM 201 1

1 Oil filler neck (valve-gear housing cover) 2 Charge-air line / air-intake line 3 Alternator 4 Narrow V -belt 5 Tractive electromagnet 6 Timing belt cover 7 V-belt pulley on crankshaft 8 Oil pan 9 Shut-off lever 10 Speed control lever 11 Oil dipstick 12 Oil drain plug 13 Oil fill point (on side of crankcase) __ Crankcase 14 Fuel pump 15 Easy-change fuel filter 16 Connecting facility for oil heater 17 Lube oil replacement filter 18 Injection pump(s) 19 Oil cooler connection 20 Injection valve (s)

C 2001

xx fuel to run line YY fuel back run line

2.2 Engine Illustration Engine Description

2.2.6 Exhaust Side FM 2011

21 Cylinder head 22 Exhaust manifold 23 Flywheel with ring gear 24 Starter 25 Starter guard (optional) 26 Crankcase 27 Air intake pipe

C 2001

Engine Description 2.2 Engine Illustration

2.2.7 Operation Side BFM 201 1

1 Air-intake pipe 2 Fan wheel 3 V-belt pulley on crankshaft 4 Narrow V -belt 5 Tractive electromagnet 6 Timing belt cover 7 Shut-off lever 8 Speed control lever 9 Oil fill point (on side of crankcase) 10 Oil dipstick 11 Fuel pump 12 Easy-change fuel filter 13 Connecting facility for oil heater 14 Lube oil replacement filter 15 Injection pump(s) 16 Oil cooler connection 17 Injection valve(s)

C 2001

2.2 Engine Illustration Engine Description

2.2.8 Exhaust Side BFM 2011

18 Cylinder head cover 19 Exhaust manifold 20 SAE housing 21 Starter 22 Crankcase 23 Oil pistick 24 Turbocharger 25 Generator with cover 26 Charge-air line 27 Oil filler neck

Engine Description 2.3 Oil Circuit

2.3.1 Lube Oil Circuit Schematic

1 Oil pan 2 Oil-intake pipe 3 Oil pump 4 Main oil duct 5 Oil-cooled cylinders 6 Cylinder head cooling neck 7 Oil duct for rocker arm lubrication

8 Rocker arm 9 Oil manifold for the thermostat 10 Intake to external engine oil cooler 11 Return from external engine oil cooler 12 Thermostat housing with slide thermostat 13 Oil duct to oil filter 14 Oil filter 15 Oil duct to cam, con-rod and crankshaft

bearings 16 Spray nozzle for piston cooling 17 Oil return via crankcase to oil pan 18 Lube oil intake to turbocharger 19 Turbocharger 20 Return from turbocharger to oil pan

Oil filter console with integrated switching valve for the control of the hydraulic tappets (arrow)

A engine is cold (around an early adjustment

of the beginning of delivery to reach,

the pistons in the pump tappet with oil

become ge feed) B engine is warm

9929en

2.4 Fuel System Schematic Engine Description

2.4.1 Fuel System

1 Fuel line from tank to fuel pump 2 Fuel pump 3 Fuel line from fuel pump to easy-change fuel

filter 4 Easy-change fuel filter 5 Fuel line from filter to injection pump 6 Injection pump 7 Fuel injection line 8 Injection valves 9 Fuel overflow line

x Fuel overflow pipe y Fuel return line to tank

The installation of a fuel prefilter/hand pump between the fuel tank and the engine is prescribed to protect the engines against dirt in the fuel.

C 2001

3.1 Commissioning

3.2 Starting

3.3 Monitoring Operation

3.4 Shutting Off

3.5 Operating Conditions

Engine Operation

Engine Operation 3.1 Commissioning

3.1.1 Adding Engine Oil

OIL

As a rule, engines are delivered without oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see 4.1.

3.1.1.1 Initial Engine Oil Fill-Up for B/FL 2011

● Fill oil into oil pan up to "Max." mark on engine

dipstick (for oil quantity see 9.1).

● Start engine and allow to run at low idling speed

for approx. 2 mins.

● Switch off engine.

● Check oil level, if necessary, top up oil to "Max."

mark.

3.1.1.2 Initial Engine Oil Fill-Up B/FM 2011

● Fill oil into oil pan up to "Min." mark on engine

dipstick.

● In addition, top up oil quantity of supply hoses

and of external oil cooler (according to manufacturer’s specifications).

● Allow engine to run warm until thermostat opens

(at approx. 95°C).

● Allow engine to run for approx. 2 mins.

● Switch off engine.

● Check oil level, and if necessary, top up oil to

"Max." mark.

If the person operating the engine does not run up the engine until the thermostat opens, the oil level may lie above the "Max." mark on the engine dipstick when delivered. The level can then only be assessed after the engine has been run up.

3.1 Commissioning Engine Operation

3.1.1.3 Initial Engine Oil Fill-Up B/FM 2011 Genset Engine

● Fill oil into oil pan up to "Max." mark on engine

dipstick (for oil quantity see 9.1).

● Start engine and allow to run at low idling speed

for approx. 2 mins.

● Switch off engine.

● Check oil level and fill up with oil up to upper

"Max." mark.

3.1.2 Adding Fuel

FUEL

Use only commercial-grade diesel fuel. For fuel grade, see 4.2. Use summer or winter-grade fuel, depending on the ambient temperature.

Never fill the tank while the engine is running. Ensure cleanliness!

Do not spill fuel!

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