Deutz 2012 Operation Manual
Operation
2012
Manual
DEUTZ
®
• Please read and observe the information
given in this Operation Manual. This will
enable you
the manufacturer's warranty and maintain
the engine
• This engine has been built exclusively for
the application specified
supply, as described by the equipment
manufacturerand is to
intended purpose. Any use exceeding that
scope is considered to
intended purpose. The manufacturer will
not assume responsibility for any damage
resulting therefrom. The risks involved are
be
to
• Use in accordance with the intended purpose also implies compliance withtheconditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only
nel trained
involved.
• The relevant accidentpreventiongUidelines
and other generally accepted safety and
industrial hygiene regulations must
served.
• 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
to
avoid accidents, preserve
in
peak operating condition.
in
the scope
be
used only forthe
be
contrary to the
borne solelybythe user.
be
in
must avoid contact at all times!
operated by person-
its use and the hazards
be
ob-
• Unauthorized engine modifications will invalidateany
facturer for resultant damage.
Manipulationsofthe injectionand regulating
system mayalso influencethe performance
oftheengine, and its emissions.Adherence
of
to legislationon pollutioncannot
teed under such conditions.
Do
•
air intake area to the blower.
The manufacturershall not
sible for any damage which results from
such work.
• When carrying out maintenance/repair operations on the engine, the use
original parts is prescribed. These are
specially designed for your engine and
guarantee perfect operation.
Non-compliance results
warranty!
• Maintenance and cleaningofthe engine
should only
is switched
You must ensurethat theelectricalsystems
have been switched off and the ignition
key has been removed.
Accident prevention guidelinesconcerning
electrical systems (e.g. VDE-01 00/-01
-0104/-0105Electricalprotective measures
againstdangeroustouch voltage) are
observed.
When cleaning with fluids, all electrical
componentsareto
Iia
bilityclaimsagainstthe manu-
notchange, convert oradjust thecooling
in
be
carried out when the engine
off
and has cooled down.
be
covered impermea
be
guaran-
be
held respon-
of
DEUTZ
the expiryofthe
01/
to
bly.
be
Operation Manual
2012
02979912 en
Engine Serial
ITIIIIJJ
Number:
Please enterthe 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
this Operation Manual. No partsofthis Manual
may be reproduced
without our written approval.
in
any form or by any means
in
DEUTZ
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®
Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed
for a large number
quently, awide range
meet the requirements
Your engine is appropriately equipped for the
installation concerned, which means that not
of
the componentsdescribedinthis Opera-
all
tion Manual are necessarily mounted to your
engine.
We have endeavored 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
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of
applications. Conse-
of
variants areoffered to
of
specific cases.
1©\31493101
Index
General
1.
2. Engine Description
2.1
Model
2.1.1 Rating Plate
of
2.1.2 Position
2.1.3 Engine Serial Number
2.1.4 Cylinder Enumeration
2.2 Engine Illustrations
2.2.1
Operating Side 2012
Ribbed V-belt Drive
2.2.2 Starter Side 2012
Ribbed V-belt Drive
2.2.3 Operating Side 2012
2.2.4
Starter Side 2012
2.3 Lube Oil Circuit Schematic
2.3.1 Lube Oil Plan
2.4 Fuel System
2.4.1 Fuel System Plan
2.5 Coolant System
2.5.1
Coolant Plan 2012
3.
Engine Operation
3.1
Commissioning
3.1.1 Pour
3.1.2 Filling Oil Bath Air Filter with Engine
Oil
3.1.3 Pour
3.1.4 Fill / Bleed Cooling System
3.1.5 Other Preparations
3.2 Starting
the Rating Plate
in
Engine Oil
in
Fuel
3.2.1 Electric Starting 6.1.1
3.3 Monitoring Operation 6.1.2
3.3.1 Engine Oil Pressure 6.1.3
3.3.2 Coolant Temperature 6.1.4
3.4 Shutting off
3.4.1 Mech. Stopping
3.4.2 Electr. Stopping
Operating Conditions
3.5
3.5.1 Winter Operation 6.2.3
3.5.2 High AmbientTemperature, High Alt-
itude 6.2.4
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 Fuel
4.3
Coolant
4.3.1 Water Quality for Coolant
4.3.2 Coolant Treatment
4.3.3 Cooling System Protectants
5.
Routine Maintenance
5.1
Maintenance Plan
5.2
Maintenance Diagram
5.3
Maintenance Work Completed
6.
Service and Maintenance
6.1
Lubrication System
6.2 Fuel System
6.2.1 Replace Fuel Filter
6.2.2 Clean / Replce Fuel Oil Filter (Cup)
6.2.5 Bleed Fuel System
6.2.6
6.2.7 Clean/Replace/VentFuel Pre-Filter,
6.3
6.3.1
6.3.2
6.3.3 Drain Cooling System
6.3.4
6.4 Combustion Air Filter
6.4.1 Cleaning Intervals
6.4.2
6.4.3
6.4.4
6.5 Belt Drives
6.5.1 Check V-belts
Oil Change Intervals
Check Oil Level, Change Engine Oil
Replace Oil Filter
Clean/Replace Oil Filter (Cup)
Clean / purge or change fuel Fuel
pre-filter
Bleed Fuel System
with Fuel Pre-filter
without Fuel Pre-filter
Clean/Replace Fuel Pre-Filter, Filter
Element
Filter Element
Cooling System
Cleaning Intervals
Clean Cooling System
Fill / Bleed Cooling System
Emptying Cyclone Type Precleaner
Clean Oil Bath Air Filter
Dry Type Air Cleaner
- 2012 Standard
- 2012 with Ribbed V-belt
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Index
6.5.2 Tension V-belts
Coolant / Fuel Pump
6.5.3 Replace V-belts
Coolant / Fuel Pump
Replace V-belts
6.5.4
Ribbed V-belts
Tensjon Alternator V-belts
6.5.5
6.5.6 Replace Alternator V-belts
6.5.7 Wedge
Adjustments
6.6
6.6.1 Check
6.6.1.1 Valve Clearance Adjustment Plan
6.7
Accessories
6.7.1 Battery
6.7.2 Rotary CurrentAlternator
6.7.3
rib
V-belts wear limit examine
Valve
Clearance(AdjustifNeces-
sary)
Transportation Shackles
7.
Faults, Causes and Remedies
7.1
Fault Table
8.
Engine Preservation
8.1
Preservation
9.
Technical Specification
9.1
Engine Specifications and Settings
9.2 Screw Tightening Torques
9.3 Tools
10.
Service
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General
DEUTZ Diesel Engines
arethe productofmany
development. The resulting know-how, coupled with stringent qualitystandards, guarantee their long service life, high reliability and
low fuel consumption.
goes
without saying that
It
Engines
ronmental protection.
meet
the highest standards
yearsofresearch and
DEUTZ
for
Diesel
envi-
BewareofRunning Engine
Shuttheengine downbefore carryingout maintenance or repair work. Ensure that the engine
cannotbeaccidentally started. Riskofaccidents.
When the work
panelsand guardsthat mayhave beenremoved.
fill
Never
Observe industrial safety regulations when running the engine
ground.
is
complete, be sure to refit any
thefueltank whilethe engineisrunning.
in
an enclosed space or under-
Care and Maintenance
Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on
intervals must be observed and service and
maintenance work carried out conscientiously.
Special care should be taken under abnormally
demanding operating conditions.
it.
Recommended service
Safety
This symbolisused for
warnings. Pleasefollowthem care-
'
..
fully.
.
• personnel should be drawn to
&
regulations laid down by law must also be observed.
The attention of operating
these safetyinstructions. General
safety and accident prevention
all
safety
Service
Please contact oneofour authorized service
representatives
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
technology.
Pleaseturnto theend
service information.
in
the eventofbreakdowns
in
accordance with state-of-the-art
of
this manualforfurther
Asbestos
DEUTZ
asbestosfree.
original
parts
are
I
or
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Engine Description
2.1
Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System
2.5 Coolant System
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Engine
2.1.1
Rating Plate
Description
1©12633213
2.1.2
Positionofthe
Rating
Plate
2.1.3
Engine
2.1
Model
Serial Number
The modelA, the engineserial number
the performance data are stampedonthe
rating plate.The model and engine serial
number must
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be
given when ordering parts.
Band
The
rating
plateCis
attached to the crankcase.
The engine serial number is stamped on the
crankcase
(arrow)
as well as the rating plate.
2.1
Model
2.1.4 Cylinder Enumeration
Cylinders are numbered consecutively, beginning at the flywheel.
Engine
Description
I
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!II
Engine
2.2.1
Operating Side 2012
Description
III Ribbed V-belt drive
2.2
Engine
1 Alternator
2 Oil filler
3 Coolant connection compensation line
4 Fan pulley
5 Fuel pump
6 Coolant pump
7 Ribbed V-belt pulley
8 Tension roller
9 Feet
10
Oil pan
11
Oil filler neck
12
Oil filter housing with engine oil cooler
13
Oil dipstick
14
Optional attachment of:
Compressor or hydraulic pump
15
Fuel filter cartridge
16
Oil filter cartridge
17
Tractive electromagnet
Illustration
on
crankshaft
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2.2
Engine Illustration
2.2.2 Starter Side 2012
Ribbed V-belt drive
Engine Description
18
Turbocharger
19
Engine suspension
20
Speed regulator
21
Flywheel
22
SAE housing
23
Starter
24
Exhaust manifold
25 Coolant inlet
26
Heater flange not shown
27
Thermostat housing coolant outlet
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Engine
Description
2.2
Engine
Illustration
12.2.3
Operating Side 2012
1 Turbocharger
2 Heater flange
3
Fan
4 Alternator
5 V-belt pulley
6 Coolant pump
7 Fuel pump
8 Oil filler
9 Oil filter housing with engine oil cooler
10
Oil filter housing with oil filter cartridge
11
Oil dipstick
12
Fuel filter
13
Tractive electromagnet
14
Oil filler neck
on
crankshaft
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2.2
Engine
Illustration
2.2.4 Starter Side 2012
Engine
15
Engine suspension
16 Speed regulator
17 Flywheel
18 SAE housing
19
Oil
pan
20
Starter
21
Feet
22
Alternator
23
Coolant inlet
24
Exhaust manifold
25
Coolant outlet
Description
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Engine Description
2.3
Lube Oil Circuit Schematic
I
2.3.1
Lube Oil Plan
18 20 19 16 17 15
21
11
12
1 Oil pan
5
2 Intake line
3 Lube oil pump
4 Lube oil cooler
4.1
Heat exchanger bypass valve
4.2 Shut-off valve
4.3 Lube oil replacement filter
4.4 Oil pressure sensor
5 Main oil pipe
6 Crankshaft bearing
7 Con-rod bearing
8 Camshaft bearing
9 Line to spray nozzle
10 Spray nozzle for piston cooling
11
Valve lifter with rocker arm impulse lubrica-
tion
12 Stop rod, oil supply for rocker arm lubrication
13 Rocker arm
14 Return line to oil pan
15 Oil line to turbocharger
16 Turbocharger
17 Oil line to compressor or hydraulic pump
18 Compressor
19 Hydraulic pump
20 Return line from compressor or hydraulic
pump
21
Line to the differential (2x)
22 Balancer shafts
23 Turbocharger return to crankcase
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1
7 6
2 4.2 4.3
4.1
3
2.4
Fuel
2.4.1 Fuel System Plan
System
Engine
1 Fuel tank
2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
5 Fuel filter
6 Line to the injection pumps
7 Injection pump
8 Line to injection valve
9 Injection valve
10
Banjoboltwith pressure maintenancevalve
11
Return line to fuel filter housing from
pressure maintenance valve
(with cup filter installation only)
12
Return linetofuel tank
13
Maintain maximum possible distance
Description
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Engine
2.5.1
Coolant block diagram 2012
Description
iii Example: With cup filter
2.5
Coolant
1.
Thermostat housing
2.
Outlet neck cover
3.
Coolant pump
4.
Lube oil cooler
5.
Cylinder cooling
6.
Cylinder head cooling
7.
Line from enginetoheat exchanger
8.
Heat exchanger
9.
Line from heat exchanger to thermostat
10.
Ventilation line to the compensation tank
11.
Compensation tank
12.
Coolant compensation line
13.
Coolant return from heater
14.
Coolant supply to heating at V-belts
15.
Coolant supply to heating at ribbed
V-belts
System
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3.1
Commissioning
3.2
Starting
3.3
Monitoring Operation
3.4
Shutting
off
3.5 Operating Conditions
Engine Operation
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Engine
Operation
3.1
Commissioning
II
3.1.1
PourinEngine Oil
As a rule, engines are delivered without oil.
Pour lube oil into the oil filler neck (arrow).
Oil capacity, see 9.1.
For oil grade and viscosity, see 4.1.
3.1.2 Oil Bath Air Filter with
Engine Oil
FUEL
Fill oil cup 1ofthe oil bath air cleaner (if
installed) with oil up to the arrow.
For oil grade and viscosity, see 4.1.
Never
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, engine is running. Ensure clean-
•
~
fill the fuel tank while the
liness! Do not spill fuel!
3.1
Commissioning
Engine
Operation
3.1.3
Filii
Bleed Cooling System
•
2012:Inaccordance
er's specifications
• Unit
engine:Inaccordance
supplier's specifications
with
the
radiator suppli-
with
the
radiator
3.1.4 Other Preparations
•
Check
battery
and
cable
been
the
trial
leaks.
been
and
topupif
see
6.5.
phase
oil
level
preserved
8.1.
connections,
prepared,
run
turned
-about
twiceaday.
in,
checking
6.7.1
.
•
Trial
run
-After
the
abrief
loadifpossible.
During
-
Check
After
the
-
Check
see
6.1.2.
-
Retension
•
Breaking
During
ing
hours - check
After
the
day
willbesufficient.
•Inthe
which
Carry
out
ance
with
engine
has
trial
run
for
approx.10minutes,
and
after
the
engine for
engine
has
oil
level
V-belts,
in
the
break-in
the
engineisbroken
eventofcommissioning
have
been
removalofpreservationinaccordChapter
carry
without
off
necessary,
200
operat-
once
engines
see
out
a
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Engine
Operation
3.2
Starting
II
3.2.1
Electric Starting
Beforestarting,makesure that
,.
• or driven machine.
&
been replaced and that all tools have been
removed from the engine.
When starting with glowplugs, donotuse any
other starter substance (e.g. injection with
start pilot). Risk
Caution:Ifthe speed regulator has been
removed, the engine must not
under any circumstances.
Disconnect the batteryl
Do
not actuate the starter for more than
seconds. Ifthe enginedoes notcatch, waitforone
C") minute then try again.
o If the engine does not catch after two attempts,
~
refertothe Fault
@
nobody is standing
mediate vicinityofthe engine
After repair work:
Check that all guards have
of
accident!
Table
(see
7.1).
in
be
the im-
started
• Disengage the clutch to separate the engine from any driven parts.
• Bring speedadjustmentlever 1into atleast
the middlespeedposition
the arrow.
• Move cut-out handle 2 into operating position counter to the direction
20
in
the direction
of
the arrow.
without
• Insert key
• Turn key clockwise
of
• Push key
• Release key as soon as engine fires
cold
start assistance
- Position 0
- Position 1
- Pilot lights 1 and 2 illuminate.
against spring pressure.
- Position 2
- Position 3
- The pilot lights will go out.
= no operating voltage.
=operating voltage
in
and turn further clockwise
= no function
=start
3.2
Starting
with cold start assistance
Heater flange
1©12574612
• Insert key
- Position 0
• Turn key clockwise
- Position 1
- Pilot lights illuminate, pre-glowing until
glow indicator
• Push key
against spring pressure.
- Position 2
- Position 3
• Release key as soon as engine fires.
- The pilot lights will go out.
=no operating voltage.
=operating voltage.
is
extinguished.
in
and turn further clockwise
=no function
=start
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Engine Operation
3.3.1
Engine
Oil
Pressure
3.3
Monitoring Operation
II
Oil
pressure lamp
• The oil pressure pilot light comesonwith
operating voltage
• The oil pressure pilot light must
guished when the engine is running.
("f)
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on
and engine off.
1<91
be
25
752
11
extin-
Oil
Pressure
• The pointermust remaininthegreensector
over the entire operating range.
Indicator
Oil
Pressure
• The pointerofthe oil pressure gauge must
displaythe minimum oil pressure (see 9.1)
Gauge
3.3
Monitoring
Operation
3.3.2 Coolant temperature
• The engine temperature gauge pointer
should always remain
should rarelyenter the yellow-green sector.
If the pointer enters the orange sector, the
engine is overheating.
Turn off and establish the cause from the
Fault Table (see 7.1).
in
the green sector. It
Engine
Operation
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Engine
Operation
3.4
Shutting
Off
II3.4.1 Mechanical Stopping
• Move speed adjustment lever 1to lowidle.
• Moveshut-offlever2 untiltheenginecomes
to a stop. The charge pilot light and the oil
pressure pilot light illuminate when the engine stops.
• Turn key counterclockwise (to position 0)
and remove. The pilot lights will go out.
3.4.2 Electrical Stopping
• Turn key counterclockwise (to position
and remove. The pilot lights will go out.
0)
8 If possible, do not switch offthe engine when
~
under full load. Subsequently allow the en-
@ gine to idle for approx. 2 mins.
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