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!

Engine Operation

3.1 Commissioning

3.1.3 Other Preparations

● Check battery and cable connectors, see 6.7.1.

● Transport hooks Remove if fitted (see 6.7.3)

● Trial run After engine has been prepared, let it run for about 10 minutes without being loaded.

During and after trial run

- Check engine for leaks. After engine has been turned off

- Check oil level,

see 6.1.2. Top up with oil, if necessary, see 3.1.1.

- Retension V-belt,

see 6.5).

3.1.4 Additional Maintenance Work

When commissioning new and reconditioned engines, the following additional maintenance work must be carried out:

● Change lube oil, see 6.1.1. + 6.1.2.

● Change oil filter cartridge, see 6.1.3.

● Change fuel filter cartridge, see 6.2.1.

● Check V-belts and retension as necessary, see 6.5.

● Check engine for leaks

● Check engine mounts, retighten if necessary,

see 9.2.

● Check valve clearance, adjust if necessary, see 5.1. + 6.6.1.

Engine Operation 3.2 Starting

3.2.1 Electric starting Without cold start assistance

Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven ma-

replaced and that all tools have been removed from the engine. When starting with glow plugs, do not use any other starter substance (e.g. injection with start pilot). Risk of accident!

Caution: If the speed regulator has been removed, the engine must not be tested under any circumstances.

chine. After repair work: Check that all guards have been

Disconnect the battery!

Do not actuate the starter for more than 20 seconds. If the engine does not catch, wait a minute then try again. If the engine does not catch after two attempts, refer to the Fault Table (see 7.1).

● Where possible, disengage clutch to separate engine from any driven parts.

● Move speed control lever 1 into idle position.

● Move shut-off handle 2 into operating position.

● Insert key

- Position 0 = no operating voltage

● Turn key clockwise

- Position 1 = operating voltage

- Pilot lights come on

● Push key in and turn further clockwise against spring pressure.

- Position 2 = no function

- Position 3 = start

● Release key as soon as engine fires

- Pilot lights go out.

3.2 Starting Engine Operation

With cold start assistance

- Glow plug

● Insert key

- Position 0 = no operating voltage

● Turn key clockwise

- Position 1 = operating voltage

- Pilot lights come on

● Push key in and turn further clockwise against spring pressure.

- Position 2 = preheat, hold for approx. 1 minute.

- Preheat lamp comes on

- Position 3 = start

● Release key as soon as engine fires

- Pilot lights go out

Engine Operation 3.3 Monitoring Operation

3.3.1 Engine Oil Pressure Oil Pressure Pilot Light

● Oil pressure pilot light comes on with operating

voltage on and engine off.

● Oil pressure pilot light should go out when

engine is running.

Oil Pressure Indicator

● Pointer must remain in green sector over entire operating range.

Oil Pressure Gauge

● Pointer must indicate minimum oil pressure (see 9.1).

3.3 Monitoring Operation Engine Operation

3.3.2 Engine Temperature Engine Temperature Gauge

● Engine temperature gauge pointer should re-

main in green sector most of time. It should rarely enter yellow-green sector. If pointer enters orange sector, engine is overheating. Turn off and establish cause from Fault Table (see 7.1).

Engine Operation 3.4 Shutting Off

3.4.1 Mechanical Shut-Off

● Move speed adjustment lever 1 to low idle.

● Move shut-off lever 2 until engine comes to a

stop. Charge pilot light and oil pressure pilot light will come on when engine stops.

● Turn key anticlockwise (to position 0) and remove. Pilot lights will go out.

3.4.2 Electric Shut-Off (Ignition Key)

● Turn key anticlockwise (to position 0) and re-

move. Pilot lights will go out.

If possible, do not suddenly switch off engine when under full load.

3.5 Operating Conditions Engine Operation

3.5.1 Winter Operation

● Lube Oil Viscosity

- Select oil viscosity (SAE grade) according to ambient temperature before starting engine, see 4.1.2.

- Increase oil change frequency when operating below -10°C, see 6.1.1.

● Diesel Fuel

- Use winter-grade diesel fuel for operation be low 0°C, see 4.2.2.

● Additional Maintenance Work

- Drain sludge from fuel tank once a week (undo sludge drain screw).

- If necessary, allow oil in oil bath air cleaner and engine oil to settle at ambient temperature.

- Below -20°C, after removing starter if neces sary, smear ring gear on flywheel via pinion bore from time to time with cold-resistant grease. (e.g. Bosch grease FT 1 V 31).

● Battery

- Efficient cold starting requires that battery is well-charged, see 6.7.1.

- Starting limit temperatures can be lowered by 4-5°C by heating battery up to about +20°C. (To do so, remove battery and store in warm place).

● Cold Start Assistance

- At temperatures near or below freezing point, use glow plugs if necessary, see 3.2.1. This not only lowers starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

Engine Operation 3.5 Operating Conditions

3.5.2 High Ambient Temperature, High Altitude

● Air density decreases as altitude or ambient

temperature increases. As a result of this, the engine’s maximum output, quality of exhaust gas, temperature level and, in extreme cases, starting behaviour, are impaired. Engine can be used at altitudes up to 1000 m and temperatures up to 30°C for mobile operations. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and thus engine power.

● If you have any doubts about engine operation

under these or similar conditions, ask your engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.

C F

0 32

25 901 1

4.1 Lube Oil

4.2 Fuel

Operating media

C 2000

Operating MediaOperating Media

Operating Media

Operating MediaOperating Media

4.1 Lube Oil4.1 Lube Oil

4.1 Lube Oil

4.1 Lube Oil4.1 Lube Oil

4.1.14.1.1

4.1.1

4.1.14.1.1

Lube oils are differentiated by to their performance and quality class. Oils of other, comparable specifications can be used.

DeutzDeutz

Deutz DQC I DQC II DQC III

DeutzDeutz

ACEAACEA

ACEA E2-96 E3/96/E5-02 E4-99

ACEAACEA

APIAPI

API CF/CF-4 CH-4/CG-4

APIAPI

DHDDHD

DHD - DHD-1 -

DHDDHD

The precise assignment of the admissible oil qualities to the engines is indicated in chapter 6.1.1. If in doubt, contact your service representative.

Quality GradeQuality Grade

Quality Grade

Quality GradeQuality Grade

Approved oils:Approved oils:

Approved oils:

Approved oils:Approved oils:

Deutz Deutz

Deutz according

Deutz Deutz

4.1.24.1.2

4.1.2

4.1.24.1.2

Generally, multi-grade oils shall be used. In closed heated rooms at temperatures >5°C, also single-grade oils can be used.

As the viscosity of lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site. Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of the SAE grade selected, cold starting may be affected but the engine will not be damaged. In order to keep wear to a minimum, do not exceed application limits for extended periods of time.

Synthetic lube oils feature an improved temperature and oxidation stability.

ViscosityViscosity

Viscosity

ViscosityViscosity

Only with preheating

30 298 1

4.2 Fuel Operating Media

4.2.1 Quality

Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher, oil change intervals should be reduced (see

6.1.1).

The following fuel specifications / standards are approved:

● DIN EN 590

● BS 2869

● ASTM D 975-96; 1-D and 2-D

● NATO Code F-54 / F-34 / F-44 and XF 63

Exhaust emission values which may be determined in the case of type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test.

4.2.2 Winter-Grade Fuel

Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0°C, wintergrade fuel (suitable down to -15°C) should be used. (This fuel is usually available from filling stations well in advance of the cold months). Diesel fuel containing additives (Super diesel) is often on sale as well, for use down to -20°C.

● At temperatures below -15°C to -20°C, kerosene should be added to the diesel fuel. The relevant percentages are given in the adjacent diagram.

If summer-grade diesel fuel must be used at temperatures below 0°C, up to 60% kerosene can be added (see diagram).

In most cases, adequate resistance to cold can also be obtained by adding a flow improver (additive). Please inquire at DEUTZ SERVICE.

+32

+23

+14

+ 5

- 4

- 13

- 22

°F

Legend:

- 5

- 10

- 15

- 20

- 25

- 30

0 10 20 30 40 50 60 %

°C

26441 1

I Summer-grade diesel fuel

II Winter-grade diesel fuel

A Ambient temperature

B Percentage of kerosene added

Diesel fuels must never be mixed with petrol (Normal and Super

! !

grades)!

Mix in tank only! Fill with the appropriate amount of kerosene first, then add the diesel fuel.

C 2000

C 2001

5.1 Service Plan

5.2 Scheduled Maintenance Plan

5.3 Maintenance Chart

5.4 Maintenance Work Completed

Service

Service 5.1 Service Plan

Deutz maintenance and service schedule = E check =zadjust = clean = V replace = 

•

prior to or during 1st trial run, check 2x daily during the breaking-in phase or

when commissioning new and overhauled engines

•

every 10 operating hours or daily

in operating hours (OH) every

E10 E20 E25 E30 E40 E45 E60 Y e ar s

500 1000



z V 



z



3000 5000 6000



z



z 



z

Operation

Top lube oil up if necessary 6.1.2/3.1.4

FL 2011 lube oil, see TC 0199-99-3002 6.1.1/ 6.1.2 BFL 2011 lube oil, see TC 0199-99-3002 6.1.1/ 6.1.2 Oil bath (lube oil quality, see TC 0199-99-3002 / Dry type filter 6.4 Oil filter cartridge FL 2011 6.1.3 Oil filter cartridge BFL 2011 6.1.3

Fuel filter cartridge

Change fuel pump/strainer if necessary Flexible fuel leakage lines, see TC 0138-21-9300 6.2.1/ 6.2.3 Injection valve Fuel pre-cleaner (halve if the fuel quality is poor) 4.2 Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3 /6.4.4 Battery and cable connectors 6.7.1 Engine monitoring system, warning system (replace if necessary) 3.3 Valve clearance 6.6.1 V-belt 6.5. Crankcase pressure vent valve Timing belt, extreme-duty, see adjacent table Timing belt, heavy-duty, see adjacent table Timing belt, light-duty, see adjacent table Check engine for leaks (visual inspection) – Engine mount (replace if damaged) 9.2

The specified engine maintenance intervals are permissible recommended maximums. Depending on usage, reduced maintenance intervals may be necessary (comply with the unit manufacturer’s operating instructions). #

Maintenance must only be carried out by authorise

service personnel

Industrial engines

Section

6.2.2

# # # # #

5.1 Service Plan Service

Deutz maintenance and service schedule = E check =zadjust = clean = V replace = 

•

prior to or during 1st trial run, check 2x daily during the breaking-in phase or

when commissioning new and overhauled engines

•

every 10 operating hours or daily

in operating hours (OH) every

E10 E20 E25 E30 E40 E45 E60 Y e ar s

500 1000

3000 5000 6000



Operation

Injection valve #

Expansions or modifications for engines with

EPA acceptance

Maintenance must only be carried out by authorise

service personnel

Section

Timing belt change intervals Engine application Engine/ application/operating parameters

Guideline values in OH Example: Example:

6000 or max. 5 years Generating sets 1500/1800 rpm; pump units, low speed; moderate ambient temperature;

low speed; platform lifts; refrigeration units etc. low dust exposure

5000 or max. 5 years compressors; rollers; forklift trucks; welding units;

ambient

3000 or max. 5 years agricultural machinery; ski-steer loaders; wheel loaders; drilling high speed; impact loads; extreme ambient temperature;

equipment; trench-cutting machines; joint cutters; bulldozers etc. high dust exposure

small dumpers; ski-steer loaders etc. temperature moderate dust exposure

wheel loaders;medium to high variable speed; high

Service 5.2 Scheduled Maintenance Plan

5.2.1 Scheduled Maintenance Plan

Intervals Deutz maintenance Operation Carried out by:

at/after and service schedule

50 OH E 10 After commissioning and E 45-E 60 Authorised specialists

Daily E 20 Dai ly c heck Op era tor

250 OH E 25 Inspection Authorised specialists

500 OH E 30 Extended inspection Author ised s pecialists

1000 OH E 40 Interim overhaul Authorised specialists

3000 OH E 45 Extended interim overhaul Authorised specialists

6 000 OH E 60 Partial overhaul Authorised specialists

5.3 Maintenance Chart Service

The maintenance chart shown here is supplied as a self-adhesive label with each engine. It should be affixed where it can be seen clearly on the engine or driven equipment.

Check that this is the case.

If necessary, ask your engine or equipment supplier for a fresh supply of labels.

Routine work should be carried out according to the schedule in 5.1.

Stop the engine before carrying out any maintenance work.

5.4 Maintenance Work Completed Service

50-150*

125

375

625

875

1125

1375

1625

1875

DateOp. hours Signature/stamp Op. hours Date

250

500

750

1000

1250

1500

1750

2000

Signature/stamp

2115

2375

2625

* Following commissioning of new and overhauled engines Duly completed maintenance jobs can be recorded and signed off in the above chart.

2250

2500

2750

Service

5.4 Maintenance Work Completed

Op. hours

2875

3125

3375

3625

3875

4125

4375

4625

4875

Date Signature/stamp

Op. hours Signature/stamp

3000

3250

3500

3750

4000

4250

4500

4750

5000

Date

5125

5375

5625

Duly completed maintenance jobs can be recorded and signed off in the above chart.

5250

5500

5750

5.4 Maintenance Work Completed Service

5875

6125

6375

6625

6875

7125

7375

7625

7825

DateOp. hours Signature/stamp Op. hours Date

6000

6250

6500

6750

7000

7250

7500

7750

8000

Signature/stamp

8125

8375

8625

Duly completed maintenance jobs can be recorded and signed off in the above chart.

8250

8500

8750

Service

5.4 Maintenance Work Completed

Op. hours

Date Signature/stamp

Op. hours Signature/stamp

Date

6.1 Lubrication System

6.2 Fuel System

6.3 Cooling system

6.4 Combustion Air Filter

6.5 Belt Drives

6.6 Adjustments

6.7 Accessories

6.8 Engine Cleaning

Service and Maintenance

C 2001

Service and Maintenance 6.1 Lubrication System

6.1.1 Oil Change Intervals

● The oil change intervals are dependent on the engine application and the quality of the lube oil.

● If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year.

● The table refers to the following conditions: – For diesel fuel: sulfur content max. 0.5

% by weight.

– Continuous ambient temperatures down

to -10 °C / +14°F

● For fuels – with sulfur content is > 0.5 to 1 % or – continuous ambient temperature below

-10 °C/+14°F or – with bio-diesel fuels in accordance with

DIN 51606-FAME the intervals between oil changes should be halved.

● If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table

6.1.1.1. equipment engines.

● In the case of fuels containing more than 1 % sulfur, contact your service repre- sentative.

Change the oil with the engine off but still warm (lube oil temperature approx. 80 °C).

6.1 Lubrication System Service and Mantennace

6.1.1.1 Lube oil change intervals for Installation engines

Lube oil grade

Deutz lube oil quality class

ACEA-specfication E2 - 9 6 E3- 9 6 / E 5- 0 2 E4 - 99 API-specification CF/CF-4 CG - 4/C H - 4 Worldwide specification special DEUTZ release list Standard lube oil code for building equipment and nonraod vehicles

DQC I DQC II DQC III

- DHD-1 -

- - Enclosure 4.1

EO... EO...C -

EO...A, EO...B

Engine Lube oil change intervals in op. hours

series Engine version Oil use Oil use Oil use

normal

1011F/ 2011 Naturalli aspirated engines 1000 500 1000 500 1000 500

Turbocharged engines

25 0 125 500 250 500 250

high

normal

high

normal high

*Gensets as referred to here are units operating in parallel with the mains / with each other.

Emergency power units are dealt with in TR 0199-99-1126

C 2001

6.1 Lubrication System Service and Maintenance

6.1.2 Check Oil Level / Change Engine Oil

6.1.2.1 Check Oil Level

6.1.2.2 Change Engine Oil

● Switch engine off before checking oil level.

● Ensure that engine or vehicle is level.

● Remove oil dipstick.

● Wipe dipstick with non-fibrous, clean cloth.

● Insert it to stop and remove again.

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

mark.

- If oil level is only just above "MIN" mark, more

oil must be added.

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

● Allow engine to warm up.

● Ensure that engine or vehicle is level.

- Lube oil temperature approx. 80°C.

● Switch off engine.

Caution when draining hot oil: Risk of scalding!

Do not let used oil run into the soil but collect it in a container! Dispose of this in accordance with environmental regulations!

● Place oil tray under engine.

● Unscrew oil drain plug.

● Drain oil.

● Fit oil drain plug with new seal ring and tighten

firmly (for torque, see 9.2)

● Pour in lube oil

- For grade / viscosity, see 4.1

- For quantity, see 9.1

● Check oil level, see 6.1.2.1.

C 2001

Service and Maintenance 6.1 Lubrication System

6.1.3 Changing Oil Filter

● Undo lube oil filter cartridge using commercial tool and spin off.

● Catch any escaping oil.

Caution is required in case of hot oil: Risk of scalding!

C 2001

● Clean any dirt from filter carrier sealing surface.

● Lightly oil rubber gasket of new lube oil filter

cartridge.

● Manually screw in new cartridge until gasket is flush.

● Tighten lube oil filter cartridge with another halfturn.

● Check oil level, see 6.1.2.

● Check oil pressure, see 3.3.1.

● Check lube oil filter cartridge seal for leaks.

6.1 Lubrication System Service and Maintenance

6.1.4 Clean / Replace Oil Filter (Cup)

● Switch off engine.

● Loosen lube oil filter cover 1 and unscrew in

anticlockwise direction.

● Carefully loosen paper filter cartridge 3 upwards

from guide 4.

● Catch any escaping oil.

● Replace paper filter cartridge 3.

● Cle

an any dirt from sealing surface of filter carrier

and lube oil filter cover 1 and from guide 4.

● Replace and lightly oil rubber gasket 2.

● Carefully insert new paper filter cartridge 3 into

guide 4.

● Tighten lube oil filter cover 1 in clockwise direction (25 Nm).

● Start engine.

● Check oil level, see 6.1.2.

● Check oil pressure, see 3.3.1.

● Check lube oil filter attachment for leaks.

Caution is required in case of hot oil: Risk of scalding!

C 2001

Service and Maintenance 6.2 Fuel System

6.2.1 Replace Fuel Filter

● Close fuel shut-off valve.

● Undo fuel filter cartridge with commercial tool

and spin off.

● Catch any escaping fuel.

Keep naked flames away when working on the fuel

C 2001

system. Do not smoke!

● Clean any dirt from filter carrier sealing surface.

● Apply light film of oil or diesel fuel to rubber

gasket of new fuel filter cartridge.

● Manually screw in new cartridge until gasket is flush.

● Tighten fuel filter cartridge with final half-turn.

● Open fuel shut-off valve.

● Check for leaks.

The fuel system does not need to be bled.

6.2 Fuel System Service and Maintenance

6.2.2 Clean / Replace Fuel Filter (Cup)

● Switch off engine.

● Loosen fuel oil filter cover 1 and unscrew in

anticlockwise direction.

● Carefully loosen paper filter cartridge 3 upwards

from guide 4.

● Catch any escaping fuel.

● Replace paper filter cartridge 3.

● Clean any dirt from sealing surface of filter

carrier and fuel filter cover 1 and from guide 4.

Keep naked flames away when working on the fuel system. Do not

smoke!

● Replace and lightly oil rubber gasket 2.

● Carefully insert new paper filter cartridge 3 into

guide 4.

● Tighten fuel filter cover 1 in clockwise direction (25 Nm).

● Start engine.

● Check fuel filter attachment for leaks.

C 2001

Service and Maintenance 6.2 Fuel System

6.2.3 Clean Strainer of Fuel Filter

● Close fuel shut-off valve.

● Loosen and unscrew hexagonal nut 1.

● Remove fuel strainer cover 2 (cover and strainer,

one unit).

● Clean fuel strainer 2 with diesel fuel. Replace if necessary.

● Place seal 3 in position.

● Mount fuel strainer cover 2.

● Tighten hexagonal screw 1.

● Check for leaks.

6.2.4 Change Fuel Leakage Line

● Close fuel shut-off valve.

● Disconnect rubber hoses 3 from injection valves.

● Disconnect rubber hose 1 from fuel tank.

● Disconnect rubber hoses 4, 3 and 1 from unions

2 and dispose of in an environmentally friendly manner.

● C

onnect new rubber hoses 4, 3 and 1 to unions 2

● Connect rubber hoses 3 to injection valves.

● Connect rubber hose 1 to fuel tank.

● Open fuel shut-off valve.

● Check for leaks after start-up.

C 2001

Keep naked flames away when working on the fuel system. Do not smoke!

6.3 Cooling System Service and Maintenance

6.3.1 Cleaning Intervals

● Amount of contamination in cooling system depends on engine application.

● Oil and fuel residues on engine increase risk of contamination. Therefore pay special attention to leaks if engine is used in dusty environments.

● Serious contamination can occur, for example:

- on construction sites where there is a high

level of air-borne dust.

- in harvesting applications where there are high

concentrations of chaff and chopped straw in vicinity of machine.

● Because applications vary, cleaning intervals have to be determined from case to case. Cleaning intervals given in table on right can be used as a guide.

Checking or cleaning intervals

Guideline values OH Engine application

2000 Ships, generating sets in enclosed areas, pumps.

1000 Vehicles on paved roads

500 Tractors, fork-lift trucks, mobile generating sets

250 Vehicles on construction sites and unpaved roads, construc-

tion machines, compressors, underground mining units

125 Agricultural machines, tractors in harvesting applications

Service and Maintenance 6.4 Combustion Air Filter

6.4.1 Cleaning Intervals

● Amount of dirt in air cleaner depends on amount of dust in air and size of air cleaner used. If high level of dust is anticipated, cyclone-type precleaner can be fitted to air cleaner.

● Cleaning intervals will have to be determined from case to case.

● If dry type air filters are used, cleaning should only be carried out according to service indicator or service switch.

● Air cleaner servicing is needed when:

- Service indicator

red signal 1 is fully visible when engine is off.

- Service switch

yellow pilot light comes on when engine is running.

● pressing button on service indicator. Service indicator is now ready for operation again.

6.4.2 Emptying Cyclone-Type Precleaner

● Undo wing nut 1 and remove cover 2.

● Remove collector bowl 3 from lower section 4

and empty. Clean leaves, straw and other foreign matter from lower section of pre-cleaner.

● Reposition collector bowl 3 onto lower section 4,

fasten cover 2 in place by tightening wing nut 1.

Never fill collector bowl with oil. Replace collector bowl if damaged.

6.4 Combustion Air Filter Service and Maintenance

6.4.3 Dry Type Air Cleaner Discharge Valve

Filter Cartridges

● Empty dust discharge valve 1 by pressing apart

lips of discharge slot as indicated by arrows.

● Clean discharge slot from time to time.

● Remove any caked dirt by pressing together

upper section of valve.

● Undo clip fasteners 1.

● Take off hood 2 and remove cartridge 3.

● Clean cartridge, replace at least once a year.

● Clean cartridge 3.

Using dry compressed air (max. 5 bar), blow out from inside to outside (or in difficult cases, tap out, taking care not to damage cartridge, or wash according to manufacturer’s instructions).

● Gaskets on filter cartridge can become damaged through regular removal and replacement. Check paper filter (light showing through) and gaskets for damage. Replace if necessary.

● After five cleaner services or after two years at latest, replace safety cartridge 4 (never clean). To do so:

- Undo hex nut 5 and remove cartridge 4.

- Install new cartridge, fit and tighten hex nut.

● Install cartridge 3, replace hood 2 and do up clip fasteners 1.

Never clean filter cartridge with petrol or hot fluids.

Service and Maintenance

6.5.1 Check V-belt

6.5 Belt Drives

● Visually inspect entire V-belt for damage.

● Replace damaged V-belts.

● After installing new belts, run engine for 15

minutes, then check belt tension.

● To check tension of V-belt, use tension gauge (see 9.3).

- Place indicator arm 1 into gauge.

- Position guide 3 on V-belt 2, midway between

pulleys, with stop against edge of belt.

- Push slowly on black pad 4 at right angles to V-

belt 2 until spring is heard or felt to trigger.

- Carefully remove gauge without altering position of indicator arm 1.

- Read off value where black indicator arm 1 intersects scale 5 (arrow). For settings, see

9.1.

- If necessary, retension belt and measure again.

Check, tension and change belts only with engine off. Refit belt guard,

if provided.

After installing new belts, run engine for 15 minutes, then check belt tension.

6.5 Belt Drives Service and Maintenance

6.5.2 Tensioning Alternator Belts

● Slacken off bolts 1, 2 and 3.

● Adjust alternator 4 in direction of arrow by

turning bolt 3 until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

6.5.3 Changing Alternator Belts

● Slacken off bolts 1, 2 and 3.

● Adjust alternator 4 in direction of arrow by

turning bolt 3.

● Remove and replace belt.

● Adjust alternator 4 against direction of arrow by

turning bolt 3, until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

Check, tension and change belts only with engine off. Refit belt guard, if provided.

Service and Maintenance 6.6 Adjustments

6.6.1 Check Valve Clearance, adjust if necessary

● Remove cylinder head cover.

● Position crankshaft as per schematic, see 6.6.1.1.

● Before adjusting valve clearance, allow engine to

cool down for at least 30 minutes. Oil temperature should be below 80°C.

● Check valve clearance 1 between rocker arm /

tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1.

● Adjust valve clearance if necessary:

- Release locknut 4.

- Use Allan key 7 to turn setscrew 5 so that correct clearance is attained after locknut 4 has been tightened.

● Check and adjust valve clearance on all cylinders.

● Reinstall cylinder head cover, with new gasket if necessary.

6.6 Adjustments Service and Maintenance

6.6.1.1 Valve Clearance Adjust ments Schematic

● Crankshaft Position 1:

Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked in black on schematic. Mark respective rocker

1 2341 2 1 23

234112 123

arm with chalk to show that adjustment has been carried out.

● Crankshaft Position 2:

Turn crankshaft one full revolution (360°). Adjust clearance of valves marked in black on schematic.

Service and Maintenance 6.7 Accessories

6.7.1 Battery

6.7.1.1 Check Battery and Cable Connectors

6.7.1.2 Check Electrolyte Level 6.7.1.3 Check Electrolyte Density

● Keep battery clean and dry.

● Undo dirty clamps.

● Clean terminal posts (+ and -) and clamps of

battery, and grease with acid-free and acidresistant grease.

● When reassembling, ensure that clamps make

good contact. Tighten clamp bolts hand-tight.

● Remove sealing caps 1.

● If testers 2 are present:

Electrolyte level should reach base of these.

● Without testers: Electrolyte level should be 10-15 mm above top of plates.

● If necessary, top up with distilled water.

● Screw sealing caps back in.

● Measure electrolyte density of individual cells with commercial hydrometer.

Hydrometer reading (see table on following page) indicates battery’s state of charge. During measurement, temperature of electrolyte should preferably be +20°C.

6.7 Accessories Service and Maintenance

Electrolyte density

in [kg/ l]

Normal

1.28

1.20

1.12

*Measurement of electrolyte density in °Bé (Baumé scale) is out of date and rarely used today.

Tropical

1.23

1.12

1.08

in [°Bé (Baumé scale)*]

Normal

Tropical

Charge status

well charged

semi-charged, re-charge

discharged, immediately charge

The gases emitted by the battery are explosive! Keep sparks and na-

Wear protective goggles! Do not rest tools on the battery!

ked flames away from the battery! Do not allow battery acid to come into contact with skin or clothing!

Service and Maintenance 6.7 Accessories

6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

Notes on the three-phase system:

● Never disconnect cables between battery, alternator and regulator while engine is running.

● If, however, it is necessary to start and operate engine without battery, disconnect regulator from alternator before starting.

● Be sure not to confuse battery terminals.

● Replace defective charge pilot lamp bulb imme-

diately.

● When washing engine, cover up alternator and regulator.

● Touching lead against frame to check whether it is live must not, under any circumstances, be carried out with three-phase electrical systems.

● In case of electric welding, connect ground terminal on welder directly to piece being welded.

● Always use proper lifting tackle 1 when transporting engine.

● After transportation and before commissioning of engine: remove attachment eyes 2.

Use only correct lifting gear.

6.8 Engine Cleaning Service and Maintenance

6.8.1 Engine Cleaning

Preperation

● Switch off engine.

● Remove engine covers and cooling air hood.

Replace them after cleaning and before test run.

● Cover electrical / electronic components and connections (e.g. alternator, starter, governor, solenoid).

Using compressed air

● Blow air through engine, taking particular care not to damage cooler and cooling fins (begin to blow through air from exhaust side). Remove dirt which has blown into interior space.

Using cold-cleaning compound

● Spray engine with commercial cold-cleaning compound and allow to react for approx. 10 mins.

● Spray-clean engine with strong water jet, repeat if necessary.

● Allow engine to run warm so that remaining water evaporates.

Using high-pressure device

● Clean engine with steam jet (max. spray pressure of 60 bar, max. steam temperature of 90ºC).

● Allow engine to run warm so that remaining water evaporates.

Clean the engine only when the engine is switched off.

7.1 Fault Table

Faults, Causes and Remedies

Faults, Causes and Remedies 7.1 Fault Table

● Faults are often caused by engine not being properly operated or maintained.

● Each time fault occurs, check whether all operating and servicing regulations have been complied with.

● Corresponding fault table can be found on adjacent page.

● If you cannot ascertain cause of a fault or cannot rectify fault, please contact DEUTZ SERVICE.

7.1 Fault Table Faults, Causes and Remedies

Faults Measures

Engine does not start or is difficult to start Check Ch

Engine starts, but runs irregularly or fails Adjust A

Engine becomes excessively hot. Temperature warning system responds Replace Rp

Engine output is deficient Clean Cl

Engine does not run on all cylinders Top up T

Engine oil pressure is non-existent or excessively low Reduce Rd

Engine oil consumption excessive

Engine smokes - blue

- white

- black

Cause

●

●●

●● ●●

●●●

●●

●● ● ●

●● ●

●●

●

Not declutched (where possible) Below starting limit temperature Oil level too low Oil level too high Excessive inclination of engine Incorrect lube oil SAE class or quality Fuel quality not as per operating manual Air cleaner clogged / turbocharger defective Air cleaner service switch / indicator defective CPD * defective

●

Charge air line leaking Oil cooler panels clogged Cooling fan defective, split or loose V-belt Cooling air temperature rise / heating short circuit Resistance in cooling system too great / through-flow quantity too small Battery defective or discharged

Section

Engine Operation

Operating media

Combustion air

Cooling system

Electrics

Ch Ch

T Ch Rd Rp Rp

Ch / Rp Ch / Rp

Ch Ch

Ch / Cl

Ch / Rp

Ch Ch

Ch / T

*CPD = Charge pressure-dependent full-load stop

Faults, Causes and Remedies 7.1 Fault Table

Faults Measures

Engine does not start or is difficult to start Check Ch

Engine starts, but runs irregularly or fails Adjust A

Engine becomes excessively hot. Temperature warning system responds Replace Rp

Engine output is deficient Clean Cl

Engine does not run on all cylinders Top up T

Engine oil pressure is non-existent or excessively low Reduce Rd

Engine oil consumption excessive

Engine smokes - blue

- white

- black

●

●● ● ●●

●●●

●●●●● ●●

Cause

Electric cable connections to starter electrical system loose or oxidised Starter defective or pinion does not engage Solenoid defective (release switch) Incorrect valve clearance Injection line leaks Injection valve defective

Section

Electrics

Engine

Ch Ch Ch

Ch / Rp

8.1 Preservation

Engine Preservation

8.1 Preservation

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rusting. The preservative measures described here will protect the engine for up to 6 month The procedure will have to be reversed before the engine is recommissioned.

● Anti-corrosion oils to specification: MIL-L-21260B TL 9150-037/2 Nato Code C 640 / 642

● Anti-corrosion media for exterior protection only to specification: Nato Code C 632

● Recommended cleaning agent to remove preservatives: Petroleum benzine (hazardous materials class A3)

8.1.1 Preserving Engine

● Clean engine using high-pressure equipment (or with cold-cleansing agent in emergency).

● Run engine until warm, then turn off.

● Drain engine oil (see 6.1.2) and fill with anti-

corrosion oil.

● If necessary, clean oil bath cleaner (see 6.4.3) and fill with anti-corrosion oil.

● Drain fuel tank.

● Make up a mixture of 90% diesel fuel and 10%

anti-corrosion oil, and refill fuel tank.

● Allow engine to run for approx. 10 mins.

● Switch off engine.

● Turn engine over manually several times to pre-

serve cylinders and combustion chamber.

● Remove V-belts and store in wrapped condition.

● Spray grooves on V-belt pulleys with anti-corro-

sion spray.

● Close intake ports and exhaust ports.

8.1.2 Removing Engine Preservatives

● Remove anti-corrosion agent from grooves in V-belt pulleys.

● Install V-belt, retension after brief operation if necessary, see 6.5.

● Remove covers from intake port and exhaust port.

● Commission engine, see also 5.1, note 2.

Technical Specification

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

9.3 Tools

Technical Specification 9.1 Engine Specifications and Settings

Model

Number of cylinders Cylinder arrangement Bore [mm] Stroke [mm] Total displacement [cm Compression ratio [ Working cycle Combustion system Direction of rotation Weight incl. integral cooling system to DIN 70020-A (without starter, with alternator) approx. [kg] Engine output [kW (hp)] Speed [rpm] Lubrication SAE oil Maximum oil temperature in oil pan [°C] Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar] 1800 rpm [bar] max. 2800 rpm [bar] Oil change quantity (oil pan) approx. [l] Oil change quantity with filter (standard 0.5 l) approx. (l) Valve clearance with cold engine (Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] Start of feed [°crankshaft BTDC] Injector opening pressure: vehicle/unit [bar] Firing order of engine

V-belt tension: pretension / retension (after engine has been running under load for 15 mins)[N]

ε]

———— F2L 2011 ————— F3L 2011 —————— F4L 2011 ————

————— 2 ————————— 3 ———————— 4 —————— ————————————— vertical in line —————————————— ———————————————— 94 ———————————————— ——————————————— 112 ————————————————

———— 1554 ——————— 2331 ———————— 3108 —————

]

———————————————— 19 ———————————————— ———————————— 4-stroke diesel engine ———————————— ——————— Naturally aspirated engine with direct injection ———————— —————————— On left when looking at flywheel ——————————

————— 175 ———————— 217 ———————— 256 ————— ———————————————— ————————————————

———————————————————

———————————— Pressure lubrication ————————————— —————————————— 20 W 20 ——————————————— ——————————————— 130 ————————————————

——————————————— 1.4 ——————————————— 2.2 ——————————————— 3 ————— 6 ———— 6.5

————————— 5.52)————————— 102)——————

————————— 62)———————— 10.52)——————

——————————— Inlet 0.3 ———————————————— ——————————————— 210

——————————————————

+0.1

/ Exhaust 0.5

———————————————————

——————————————————

+0.1

———————————

————— 1 - 2 ——————— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 ———— ————————————— 450 / 350 ±20 ——————————————

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.

Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

Values for engines without engine oil heating.

9.1 Engine Specifications and Settings Technical Specification

Model

Number of cylinders Cylinder arrangement Bore [mm] Stroke [mm] Total displacement [cm Compression ratio [

ε]

Working cycle / Combustion system Direction of rotation Weight without cooling system Weight without starter, with alternator as per DIN 70020-A approx. approx. [kg] Engine output [kW (hp)] Speed [rpm] Lubrication SAE oil Maximum oil temperature in oil pan [°C] at: 900 rpm (low idling speed) [bar] 1800 rpm [bar] max. 2800 rpm [bar] Oil change quantity (oil pan without cooling system) ca. [l] Oil change quantity with filter (Standard 0.5 l) approx. (l) Valve clearance with cold engine (Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] Injector opening pressure: vehicle/unit [bar] Start of feed [°crankshaft BTDC] Firing order of engine

V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N]

——— BF3L 2011 ————————— BF4L 2011 ————

————— 3 ———————————— 4 —————— —————————— vertical in line ——————————— ———————————— 94 ————————————— ———————————— 112 ————————————

]

———— 2331 ——————————— 3108 ————— ———————————— 17.5 ———————————— ———

Four-stroke diesel with turbocharging and direct fuel injection ——

—————— On left when looking at flywheel ———————

————— 222 ———————————— 257 —————

——————————————

————————————

—————————————

————————————— ————————— Pressure lubrication ————————— ——————————— 20 W 20 ———————————— ———————————— 130 ———————————— ———————————— 1.4 ———————————— 2.2 ———————————— 3 ————— 7.5 ———————————— 10 ————— 8 ——————————— 10.5

——————— Inlet 0.3

+ 0.1

——————————— 210

——————————————

Exhaust 0.5

+ 8

————————————

+ 0.1

———————

———————————

———— 1 - 2 - 3 —————————— 1-3-4-2 ————— —————————— 450 / 350 ±20 ——————————

——————

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.

Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

Values for engines without engine oil heating.

Technical Specification 9.1 Engine Specifications and Settings

Model

Number of cylinders Cylinder arrangement Bore [mm] Stroke [mm] Total displacement [cm Compression ratio [ Working cycle Combustion system Direction of rotation Weight without cooling system (without starter, with alternator) approx. approx. [kg] Engine output [kW (hp)] Speed [rpm] Lubrication SAE oil Maximum oil temperature in oil pan [°C] Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed)

[bar] 1800 rpm [bar] max. 2800 rpm [bar]

— F2M 2011 ————— F3M 2011 ———— F4M 2011 ——

——— 2 ———————— 3 ———————— 4 ———— —————————— vertical in line ——————————— ———————————— 94 ————————————— ———————————— 112 ————————————

—— 1554 ——————— 2331 —————— 3108 ———

]

———————————— 19 —————————————

ε]

———————— 4-stroke diesel engine ————————— —————

Naturally aspirated engine with direct injection —————

——————— On left when looking at flywheel —————— ————————— Refer to head-office ————————— —— 169 ——————— 210 —————— 248 ——— ———————————— ————————————

———————————————

————————— Pressure lubrication ————————— ——————————— 20 W 20 ———————————— ———————————— 130 ———————————— ———————————— 1.4 ———————————— 2.2

———————————— 3

——————————————

Engine with Thermostat

Oil change quantity without external cooler (see 3.1.1.2)/without filter approx. [l]

Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre) approx

—————— 5.5

. [l]

——————— 6

————————— 102)————————

————————— 10.52)————————

Genset Engine without Thermostat:

Oil change quantity including external cooler (see 3.1.1.3)/without filter approx. [l]

Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l]

—————— 8.5 ——————— 9

————————— 132)————————

————————— 13.52)————————

Valve clearance with cold engine (Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] Start of feed [°crankshaft BTDC] Injector opening pressure: vehicle/unit [bar] Firing order of engine

V-belt tension: pretension / retension (after engine has been running under load for 15 mins):[N]

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.

Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

Values for engines without engine oil heating.

——————— Inlet 0.3 ———————————— ——————————— 210 +8———————————— —— 1-2 —————— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 ——

—————————— 450 / 350 ±20 ——————————

+0.1

/ Exhaust 0.5

———————————————

+0.1

———————

9.1 Engine Specifications and Settings Technical Specification

Model

Number of cylinders Cylinder arrangement Bore [mm] Stroke [mm]

ε]

]

Total displacement [cm Compression ratio [ Working cycle Combustion system Direction of rotation Weight without cooling system (without starter, with alternator) approx. [kg] Engine output [kW (hp)] Speed [rpm] Lubrication SAE oil Maximum oil temperature in oil pan [°C]

Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar]

1800 rpm [bar] max. 2800 rpm [bar]

Engine with Thermostat

Oil change quantity without external cooler (see 3.1.1.2) / without filter approx. [l]

Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre) approx.

[l]

Genset Engine without Thermostat:

Oil change quantity including external cooler (see 3.1.1.3) / without filter approx. [l]

Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l]

V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N]

————— BF3M 2011 ————— BF4M 2011 ——————

——————— 3 ————————— 4 ———————— —————————— vertical in line ——————————— ———————————— 94 ————————————— ———————————— 112 ———————————— —————— 2331 ———————— 3108 ——————— ———————————— 17.5 ———————————— ———————— 4-stroke diesel engine ————————— ———————

Turbocharging and direct injection ————————

——————— On left when looking at flywheel —————— ————————— Refer to head-office ————————— —————— 215 ———————— 250 ——————— ———————————— ————————————

————————————

————————— Pressure lubrication ————————— ——————————— 20 W 20 ———————————— ———————————— 130 ————————————

———————————— 1.4 ———————————— 2.2 ———————————— 3

——————— 7.5 ———————— 10 ——————— 8 ———————— 10.5

——————— 11 ———————— 13.5 —————— 11.5 ———————— 14

——————— Inlet 0.3

+0.1

/ Exhaust 0.5 ———————————— ——————————— 210

————————————

—————————————

———————

+0.1

—————————————

————————————

———————

—————— 1-2-3 —————— 1-3-4-2 —————— ————————— 450 / 350 ±20 ———————————

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.

Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

Values for engines without engine oil heating.

Tecnical Specification

9.2 Torque Wrench Settings

Installation location Pre-tension [Nm] Re-tension [Nm] Total Comments

1st stage 2nd stage 3rd stage 1st stage 2nd stage 3rd stage 4th stage [Nm]

Cylinder head cover 8.5

Rocker arm adjustment screw 21

Intake manifold 8.5

Foot Rigid suspension 30 45

Foot Elastic suspension 106

Air intake pipe 21

Exhaust manifold 22

Oil drain plug 55

Oil pan (sheet metal) 21

Oil pan (cast) 31

Injection line attachment 30

Injection valve attachment 21 TORX

Lube oil filter cartridge 27 on engine or separate

Threaded pipe union 4

9.3 Tools Technical Specification

TORX V-belt tension gauge

25899 0 26002 0

A TORX BN. 8189 screw set is used with engines in the 1011 series. This system was chosen because of the many advantages it offers:

● Outstanding accessibility to bolts.

● High load transfer when loosening and tighten-

ing.

● Almost impossible for socket to slide off or break, thereby practically ruling out risk of injury.

TORX tools can be ordered from:

FA.WILBÄR Postfach 14 05 80 D-42826 Remscheid

The V-belt tension gauge can be obtained under order number 8115 from:

FA.WILBÄR Postfach 14 05 80 D-42826 Remscheid

Notice

Notes

Warnings to Place on Equipment

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.

Warning in the Manual

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.

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.

ALIFORNIA

ROPOSITION

65 I

NFORMATION

Notes

TOC

TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR

Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law, including certain chemicals in diesel engine exhaust.

Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court order containing these provisions is attached.)

On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after

January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display, you may usee that method of providing warning.

Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning

in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.

The warning must appear in one of the following locations:

●

Inside The front cover

●

Inside the back cover

●

Outside the front cover

●

Outside the back cover

●

As the first page of text

ALIFORNIA CUSTOMERS AND

FOR USE IN

ALIFORNIA.

Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.

Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California. Should you have any questions, please call Deutz Corporation Product Support Department.

Service

Knowing it’s DEUTZ

DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry. As an independent motor manufacturer, we offer — worldwide — a comprehensive range of diesel and gas motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers’ individual requirements.

Over 1.4 million DEUTZ motors do their job reliably all over the world. We are determined to preserve the high standard of performance and dependability of our motors, thus keeping our customers satisfied at all times. Therefore we are represented worldwide through a network of highly competent service partners who will meet the needs of our customers, wherever they are.

This is why DEUTZ is not only the name for motors which pack a lot of inventive genius. DEUTZ also means reliable service and comprehensive support to enhance your motor’s performance.

Order-No.: 0312 0806

Order-No.: 0312 0807 (CD-ROM)

This index Sales & Service offers you an overview of the DEUTZ partners in your vicinity, including the products for which they are responsible and the range of services provided. But even when no direct product responsibility is mentioned, your DEUTZ partner will be happy to help you with expert advice.

The Index is constantly updated. Please ask your DEUTZ service partner for the latest edition.

DEUTZ AG — at your service.

Obtainable from the local service Partner reponsible for you or from:

DEUTZ AG Deutz-Mülheimer Str. 147-149 D-51057 Köln

Phone: 0049-221-822-0 Telefax: 0049-221-822-5304 Telex: 8812-0 khd d http://www.deutz.de

Deutz 2011 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operation manual

Foreword

Contents

General

Engine Description

Engine Operation

Service

Service and Maintenance

Engine Preservation

Technical Specification 9.1 Engine Specifications and Settings

Service