Operation Manual
2012
®
DEUTZ
•Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer'swarranty 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 Iiability clai ms against the manufacturer for resultant damage.
Manipulations ofthe injection and regulating system may also influence the performance ofthe 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 syste ms have been switched off and the ignition key has been removed.
Accident prevention guidelines concerning electrical systems (e.g. VDE-01 00/-01 01/ -0104/-0105 Electrical protective measures against dangerous touch voltage) are to be observed.
When cleaning with fluids, all electrical components are to be covered impermea bly.
Engine Serial ITIIIIJJ
Number:
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.
Operation Manual
2012
02979912 en
®
DEUTZ
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Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed for a large number of applications. Consequently, a wide range of variants are 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 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
1©\31493101
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1.General
2.Engine Description
2.1Model
2.1.1Rating Plate
2.1.2Position of the Rating Plate
2.1.3Engine Serial Number
2.1.4Cylinder Enumeration
2.2Engine Illustrations
2.2.1Operating Side 2012 Ribbed V-belt Drive
2.2.2Starter Side 2012 Ribbed V-belt Drive
2.2.3Operating Side 2012
2.2.4Starter Side 2012
2.3Lube Oil Circuit Schematic
2.3.1Lube Oil Plan
2.4Fuel System
2.4.1Fuel System Plan
2.5Coolant System
2.5.1Coolant Plan 2012
3.Engine Operation
3.1Commissioning
3.1.1Pour in Engine Oil
3.1.2Filling Oil Bath Air Filter with Engine Oil
3.1.3Pour in Fuel
3.1.4Fill / Bleed Cooling System
3.1.5Other Preparations
3.2Starting
3.2.1Electric Starting
3.3Monitoring Operation
3.3.1Engine Oil Pressure
3.3.2Coolant Temperature
3.4Shutting off
3.4.1Mech. Stopping
3.4.2Electr. Stopping
3.5Operating Conditions
3.5.1Winter Operation
3.5.2High Ambient Temperature, High Altitude
4.Operating Media
4.1Lube Oil
4.1.1Quality
4.1.2Viscosity
4.2Fuel
4.2.1Quality
4.2.2Winter Fuel
4.3Coolant
4.3.1Water Quality for Coolant
4.3.2Coolant Treatment
4.3.3Cooling System Protectants
5.Routine Maintenance
5.1Maintenance Plan
5.2Maintenance Diagram
5.3Maintenance Work Completed
6.Service and Maintenance
6.1Lubrication System
Index
6.1.1Oil Change Intervals
6.1.2Check Oil Level, Change Engine Oil
6.1.3Replace Oil Filter
6.1.4Clean/Replace Oil Filter (Cup)
6.2Fuel System
6.2.1Replace Fuel Filter
6.2.2Clean / Replce Fuel Oil Filter (Cup)
6.2.3Clean / purge or change fuel Fuel pre-filter
6.2.4Bleed Fuel System with Fuel Pre-filter
6.2.5Bleed Fuel System without Fuel Pre-filter
6.2.6Clean/Replace Fuel Pre-Filter, Filter Element
6.2.7Clean/Replace/VentFuel Pre-Filter, Filter Element
6.3Cooling System
6.3.1 |
Cleaning Intervals |
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6.3.2 |
Clean Cooling System |
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6.3.3 |
Drain Cooling System |
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6.3.4 Fill / Bleed Cooling System |
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6.4 |
Combustion Air Filter |
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6.4.1 |
Cleaning Intervals |
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6.4.2 Emptying Cyclone Type Precleaner |
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6.4.3 Clean Oil Bath Air Filter |
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6.4.4 Dry Type Air Cleaner |
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6.5 |
Belt Drives |
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6.5.1 |
Check V-belts |
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Index
6.5.2Tension V-belts Coolant / Fuel Pump
6.5.3Replace V-belts Coolant / Fuel Pump
6.5.4Replace V-belts Ribbed V-belts
6.5.5Tensjon Alternator V-belts
6.5.6Replace Alternator V-belts
6.5.7Wedge rib V-belts wear limit examine
6.6Adjustments
6.6.1CheckValveClearance(Adjust ifNecessary)
6.6.1.1Valve Clearance Adjustment Plan
6.7Accessories
6.7.1Battery
6.7.2Rotary Current Alternator
6.7.3Transportation Shackles
7.Faults, Causes and Remedies
7.1Fault Table
8.Engine Preservation
8.1Preservation
9.Technical Specification
9.1Engine Specifications and Settings
9.2Screw Tightening Torques
9.3Tools
10.Service
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General
DEUTZ Diesel Engines |
Care and Maintenance |
Service |
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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.
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.
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.
Beware of Running Engine |
Safety |
Asbestos |
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.
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warnings. Pleasefollowthem care- |
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& these safety instructions. General safety and accident prevention
regulations laid down by law must also be observed.
DEUTZ original parts are asbestosfree.
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Engine Description
2.1Model
2.2Engine Illustrations
2.3Lube Oil Circuit Schematic
2.4Fuel System
2.5Coolant System
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Engine Description |
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2.1 Model |
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2.1.1 Rating Plate |
2.1.2 Position of the Rating Plate |
2.1.3 Engine Serial Number |
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The model A, the engine serial number Band the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.
The rating plate C is attached to the crankcase.
The engine serial number is stamped on the crankcase (arrow) as well as the rating plate.
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2.1 Model Engine Description
2.1.4 Cylinder Enumeration |
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Cylinders are numbered consecutively, beginning at the flywheel.
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Engine Description |
2.2 Engine Illustration |
!II III
2.2.1Operating Side 2012 Ribbed V-belt drive
1 Alternator
2 Oil filler
3 Coolant connection compensation line
4 Fan pulley
5 Fuel pump
6 Coolant pump
7 Ribbed V-belt pulley on crankshaft
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
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2.2 Engine Illustration |
Engine Description |
2.2.2Starter Side 2012 Ribbed V-belt drive
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 on crankshaft
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
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2.2 Engine Illustration |
Engine Description |
2.2.4 Starter Side 2012
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Engine suspension |
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Speed regulator |
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Flywheel |
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SAE housing |
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Oil pan |
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Starter |
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Feet |
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Alternator |
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Coolant inlet |
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Exhaust manifold |
25 |
Coolant outlet |
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Engine Description
2.3 Lube Oil Circuit Schematic
I 2.3.1 Lube Oil Plan
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4.2 |
4.3 |
4.1 |
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1Oil pan
2Intake line
3Lube oil pump
4Lube oil cooler
4.1Heat exchanger bypass valve
4.2Shut-off valve
4.3Lube oil replacement filter
4.4Oil pressure sensor
5Main oil pipe
6Crankshaft bearing
7Con-rod bearing
8Camshaft bearing
9Line to spray nozzle
10Spray nozzle for piston cooling
11Valve lifter with rocker arm impulse lubrication
12Stop rod, oil supply for rocker arm lubrication
13Rocker arm
14Return line to oil pan
15Oil line to turbocharger
16Turbocharger
17Oil line to compressor or hydraulic pump
18Compressor
19Hydraulic pump
20Return line from compressor or hydraulic pump
21Line to the differential (2x)
22Balancer shafts
23Turbocharger return to crankcase
2.4 Fuel System Engine Description
2.4.1 Fuel System Plan |
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Fuel tank |
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Line to fuel pump |
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Fuel pump |
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4 Line to fuel filter |
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Fuel filter |
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Line to the injection pumps |
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Injection pump |
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Line to injection valve |
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Injection valve |
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Banjo boltwith pressure maintenance valve |
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Return line to fuel filter housing from |
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pressure maintenance valve |
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(with cup filter installation only) |
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12 Return line to fuel tank |
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Maintain maximum possible distance |
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Engine Description |
2.5 Coolant System |
!II 2.5.1 Coolant block diagram 2012 iii Example: With cup filter
1. Thermostat housing
2. Outlet neck cover
3. Coolant pump
4. Lube oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Line from engine to heat 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
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Engine Operation
3.1Commissioning
3.2Starting
3.3Monitoring Operation
3.4Shutting off
3.5Operating Conditions
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Engine Operation |
3.1 Commissioning |
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3.1.2 |
Oil Bath Air Filter with |
II 3.1.1 Pour in Engine Oil
Engine Oil
FUEL
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.
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Fill oil cup 1 of the oil bath air cleaner (if installed) with oil up to the arrow.
For oil grade and viscosity, see 4.1.
~Never fill the fuel tank while the , engine is running. Ensure clean-
• liness! Do not spill fuel!
3.1 Commissioning |
Engine Operation |
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3.1.3 Filii Bleed Cooling System |
3.1.4 Other Preparations |
•2012: In accordance with the radiator supplier'sspecifications
•Unit engine: In accordance with the radiator supplier'sspecifications
•Check battery and cable connections, see 6.7.1 .
•Trial run
-Afterthe engine has been prepared, carry out
a brieftrial run for approx. 10 minutes, without load if possible.
During and after the trial run
- Check the engine for leaks.
After the engine has been turned off
-Check oil level and top up if necessary, see 6.1.2.
-Retension V-belts, see 6.5.
•Breaking in
During the break-in phase - about 200 operating hours - check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.
•In the event of commissioning engines which have been preserved
Carry out removal of preservation in accordance with Chapter 8.1.
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Engine Operation |
3.2 Starting |
II 3.2.1 Electric Starting
Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine.
After repair work:
Check that all guards have been 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 started under any circumstances.
Disconnect the batteryl
Do not actuate the starter for more than 20 seconds. Ifthe engine does not catch, waitforone
C") minute then try again.
oIf the engine does not catch after two attempts,
~refer to the Fault Table (see 7.1).
without cold start assistance
•Disengage the clutch to separate the engine from any driven parts.
•Bring speed adjustment lever 1 into at least the middle speed position in the direction of the arrow.
•Move cut-out handle 2 into operating position counter to the direction of the arrow.
•Insert key
-Position 0 = no operating voltage.
•Turn key clockwise
-Position 1 =operating voltage
-Pilot lights 1 and 2 illuminate.
•Push key in and turn further clockwise against spring pressure.
-Position 2 = no function
-Position 3 =start
•Release key as soon as engine fires
-The pilot lights will go out.
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3.2 Starting
with cold start assistance Heater flange
1©12574612
•Insert key
-Position 0 =no operating voltage.
•Turn key clockwise
-Position 1 =operating voltage.
-Pilot lights illuminate, pre-glowing until glow indicator is extinguished.
•Push key in and turn further clockwise against spring pressure.
-Position 2 =no function
-Position 3 =start
•Release key as soon as engine fires.
-The pilot lights will go out.
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Engine Operation |
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3.3 Monitoring Operation |
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3.3.1 Engine Oil Pressure |
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Oil pressure lamp |
Oil Pressure Indicator |
Oil Pressure Gauge |
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•The oil pressure pilot light comes on with operating voltage on and engine off.
•The oil pressure pilot light must be extinguished when the engine is running.
• The pointer must remain in the green sector |
• The pointer of the oil pressure gauge must |
over the entire operating range. |
display the minimum oil pressure (see 9.1) |
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3.3 Monitoring Operation |
Engine Operation |
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3.3.2 Coolant temperature |
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•The engine temperature gauge pointer should always remain in the green sector. It should rarely enter 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).
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Engine Operation |
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3.4 Shutting Off |
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II 3.4.1 Mechanical Stopping |
3.4.2 |
Electrical Stopping |
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•Move speed adjustment lever 1 to low idle.
•Move shut-off lever 2 until the engine comes 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.
•Turn key counterclockwise (to position 0) and remove. The pilot lights will go out.
8 If possible, do not switch off the engine when
~under full load. Subsequently allow the en-
@gine to idle for approx. 2 mins.
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