Deutz 912 User Manual [nl]

26 472

Operation Manual

912

913

1 Gerade

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.

00_GB.p65 04.02.2002, 14:232

Engine Serial 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).

Operation Manual

912

913

0297 9690 en

All rights reserved. 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.

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Foreword

Dear Customer,

Air / 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 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

4 4

Index

1 General

2 Engine Description

2.1 Model

2.1.1 Rating Plate

2.1.2 Rating Plate Location

2.1.3 Engine Serial Number

2.1.4 Cylinder Numbering

2.1.5 Direct Injection

2.1.6 Two-stage Combustion

2.2 Engine Illustrations

2.2.1 Service Side F4L 912

2.2.2 Exhaust Side F4L 912

2.2.3 Service Side BF4L 913

2.2.4 Exhaust Side BF4L 913

2.3 Lube Oil Circuit

2.3.1 Lube Oil Circuit FL 912/913

2.4 Fuel System Schematic

2.4.1 Fuel Circuit

2.5 Engine Cooling

2.5.1 Regulation of Coolant Flow using the Exhaust Thermostat

2.5.2 Regulation of Coolant Flow using the Exhaust Thermostat and Solenoid

3 Engine Operation

3.1 Commissioning

3.1.1 Adding Engine Oil

3.1.2 Filling Oil Bath Air Cleaner

3.1.3 Adding Fuel

3.1.4 Ventilation

3.1.5 Other Preparations

3.1.6 Additional Maintenance Work

3.1.7 Selector Switch for Oil Heater

3.2 Starting

3.2.1 Electric Starting

3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

3.3.2 Engine Temperature

3.3.3 Cooling Fan Drive

3.4 Stopping

3.4.1 Mechanical Shutdown

3.4.2 Electrical Shutdown

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperatures, High Altitude

4 Operating Media

4.1 Lube Oil

4.1.1 Quality Grade

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality Grade

4.2.2 Winter-Grade Fuel

5 Routine Maintenance

5.1 Maintenance Schedule

5.2 Maintenance Chart

5.3 Maintenance Work Completed

6 Service and Maintenance

6.1 Lube Oil System

6.1.1 Oil Change Intervals

6.1.2 Checking Oil Level / Changing Oil Level

6.1.3 Changing Oil Filter

6.1.4 Changing the Partial-Flow Oil Filter Insert

6.2 Fuel System

6.2.1 Changing Fuel Filter

6.2.2 Fuel Precleaner Cleaning the Fuel Filter

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 Cleaning Oil Bath Air Cleaner

6.4.4 Dry Type Air Cleaner

6.5 Belt Drives

6.5.1 Checking V-Belts

6.5.2 Changing the Fan V-Belt

6.5.3 Tensioning Alternator Belts

6.5.4 Changing Alternator Belts

6.5.5 Checking Warning System

6.5.6 Tensioning and Changing Air Compressor V-Belts

6.5.7 Air Compressor Design with Double V-Belt

6.6 Adjustments

6.6.1 Checking / Adjusting Valve Clearance

6.7 Accessories

6.7.1 Battery

6.7.2 Three-Phase Alternator

6.7.3 Lifting Tackle

6.8 Cleaning the Engine

6.8.1 Cleaning the Engine

6.9 Additional Maintenance

6.9.1 Checking the Mountings

6.9.2 Checking the Function of the Heating Pipe

6.9.3 Checking the Function of the Flame Glowing System

7 Faults, Causes and Remedies

7.1 Diagnosis Chart

8 Engine Preservation

8.1 Preservation

8.1.1 Preserving Engine

8.1.2 Removing Engine Preservatives

9 Technical Specifications

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

9.3 Tools

10 Service

AZ-TD3/Vo 19.7.96 5

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6 6

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 carefully. The attention of operating

personnel should be drawn to these

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

safety instructions. General safety

Asbestos

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.

9690en_K01_neu 18.08.2000, 14:56 Uhr7

DEUTZ original parts are asbestosfree.

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8 8

9690en_K01_neu 18.08.2000, 14:56 Uhr8

2.1 Model

2.2 Engine Illustration

2.3 Lube Oil Circuit

2.4 Fuel System Schematic

2.5 Engine Cooling

Engine Description

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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.

25 611 2

2.1.2 Rating Plate Location 2.1.3 Engine Serial Number

24 587 1 24 552 1

The rating plate C is attached to the crankcase; depending on the design, a second rating plate may be attached to the air duct.

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

2.1 Model Engine Description

2.1.4 Cylinder Numbering

24 858 1

Cylinders are numbered consecutively, beginning at the flywheel end.

2.1.5 Direct Injection FL 912

21 878 3 26 045 0

Engines with direct injection are used where high performance is required.

2.1.6 Two-stage Combustion FL 912W

Engines with two-stage combustion are used where it is particularly important to keep exhaust emissions to an absolute minimum.

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Engine Description 2.2 Engine Illustrations

2.2.1 Service Side

F4L 912

1 Fan 2 V-belt (fan) 3 Injection pump 4 V-belt (alternator) 5 V-belt pulley 6 Tension roller 7 Oil fill point 8 Oil pan

9 Oil drain plug 10 Fuel pump 11 Oil dipstick 12 Lube oil filter 13 Easy-change fuel filter 14 Air duct cover 15 Cylinder-head cover

7891011

24 856 2

2.2 Engine Illustrations Engine Description

2.2.2 Exhaust Side F4L 912

16 Air-intake pipe 17 Exhaust manifold pipe 18 Screen 19 Alternator 20 Starter 21 Engine mounting 22 Crankcase 23 Crankcase ventilation

24 857 1

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Engine Description 2.2 Engine Illustrations

2.2.3 Service Side

BF4L 913

1 Fan

2 V-belt (fan) 3 V-belt (alternator) 4 V-belt pulley on crankshaft 5 Tension roller 6 Oil fill point 7 Oil drain plug 8 Fuel filter cartridge

9 Fuel pump with fuel precleaner 10 Injection pump 11 Oil dipstick 12 Lube oil filter cartridge 13 Air duct cover 14 Engine oil radiator cover

6578910

30016 0

2.2 Engine Illustrations Engine Description

2.2.4 Exhaust Side BF4L 913

15 Exhaust manifold line 16 Terminal housing 17 Starter 18 Crankcase ventilation 19 Oil pan 20 Alternator 21 Exhaust turbocharger 22 Air-intake pipe-exhaust turbocharger 23 Charge-air line

171819

30017 0

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Engine Description 2.3 Lube Oil Circuit

2.3.1 Lube Oil Circuit

FL 912 / 913

1 Oil pan

1718222378

19 16

2 Intake manifold 3 Oil pump 4 Oil pressure control valve 5 Pressure-oil line 6 Bypass line or selectively 7 Finned pipe spiral or selectively 8 Frame oil cooler

9 Lube oil filter 10 Safety valve 11 Main oil gallery 12 Crankshaft bearing 13 Con-rod bearing 14 Camshaft bearing 15 Tappets 16 Push rod (hollow, for oil feed to rocker arm

lubrication) 17 Rocker arm bearing 18 Metering plug ( 19 Protective sleeve for push rod 20 Throttle bore (for lubrication of the gear wheels) 21 Injection jet for cooling the pistons 22 Connection for oil pressure gauge 23 Oil pressure gauge 24 Injection pump connected to lube oil circuit

25 Connection point for oil heating**

r. arm lubrication

10 9 11 13 21 1 12 14 2 3

19 058 6

* only for inclined engines ** in this instance the filter holder must

be replaced. Please contact our service

representative for this alteration.

2.3 Lube Oil Circuit Engine Description

2.3.1 Lube Oil Circuit BF6L 913

23 25

8 9

1 Oil pan 2 Intake manifold

2167

1617

18 15

22 14

5 3

21112120102426 13

24 355 2

3 Oil pump 4 Oil pressure control valve 5 Pressure-oil line 6 Connecting line to oil cooler 7 Frame oil cooler 8 Lube oil filter

9 Safety valve 10 Main oil gallery 11 Crankshaft bearing 12 Con-rod bearing 13 Camshaft bearing 14

Tappets (with impulse lubrication of the rocker arm)

Push rod (hollow, for oil feed to r. arm lubrication) 16 Rocker arm bearing 17 Metering plug ( 18 Protective sleeve for push rod (oil return from

cylinder head to crankcase) 19 Throttle bore (for lubrication of the gear wheels) 20 Injection jet for cooling the pistons 21 Oil line for lub. of the exhaust turbocharger 22

Oil ret. line from exhaust turboc. to the crankcase 23 Oil pressure gauge 24 Partial-flow lube oil filter 25 Connection point for oil heating** 26 Injection pump connected to lube oil circuit

* only for inclined engines ** in this instance the filter holder must be

replaced. Please contact our service represen-

tative for this alteration.

r. arm lubrication

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Engine Description 2.4 Fuel System Schematic

2.4.1 Fuel Circuit

1 Fuel tank 2 Fuel line from tank to fuel pump 3 Fuel supply pump 4 Easy-change fuel filter 5 Injection pump 6 Injection lines 7 Injection valves 8 Oil leakage line

9 Fuel overflow pipe 10 Overflow valve 11 Fuel return line to tank

A Clearance: keep as far apart as possible

24 673 3

2.5 Engine Cooling Engine Description

2.5.1 Regulation of Coolant Flow using the Exhaust Thermostat

1 Pressure-oil line from engine to exhaust

thermostat 2 Air line to exhaust thermostat 3 Exhaust manifold pipe 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive 9 Oil return line to crankcase

10 Ventilation line 11 Adjusting pin with special seal

26 120 1

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Engine Description 2.5 Engine Cooling

2.5.2 Regulation of Coolant Flow using the Exhaust Thermostat and Solenoid

1 Pressure-oil line from engine to exhaust

10 Ventilation line 11 Adjusting pin with special gasket 12 Solenoid

26 121 0

3.1 Commissioning

3.2 Starting

3.3 Monitoring Systems

3.4 Stopping

3.5 Operating Conditions

Engine Operation

Engine Operation 3.1 Commissioning

3.1.1 Adding Engine Oil 3.1.2 Filling Oil Bath Air Cleaner 3.1.3 Adding Fuel

FUEL

24 675 1

As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see 4.1

24 980 2

Fill oil cup 1 of the oil bath air cleaner with engine oil up to the arrow. For oil grade and viscosity, see 4.1

Oil may not be filled into the dust collector of the precleaner, if this is fitted.

! !

26 398 0

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. Keep the filler cap area clean and do not spill fuel.

3.1 Commissioning Engine Operation

3.1.4 Ventilation Model: “Bosch” fuel pump

24 593 1 24 592 1

● Loosen overflow valve 1 at the lower (larger)

hexagon.

● Loosen hand pump 2 at the notched grip 3 by

unscrewing by several turns to the left.

● Actuate hand pump 2 until bubble-free fuel is

emitted at the loosened overflow valve 1.

● Tighten overflow valve 1, continuing to pump at

the same time.

● Tighten grip 3.

Ventilation Model: “IMSA” fuel pump

● Loosen overflow valve 1 at the lower (larger)

hexagon.

● Actuate preliminary pump lever 2 against the

spring pressure until bubble-free fuel is emitted at the loosened overflow valve 1.

● Tighten overflow valve 1, continuing to pump at

the same time.

Engine Operation 3.1 Commissioning

3.1.5 Other Preparations

● Check battery and cable connections, see 6.7.1

● Transport hooks

Remove if fitted (see 6.7.3).

● Trial run

After the engine has been prepared, let it run for about 10 minutes without load.

During and after trial run

– Check the engine for leaks.

After the engine has been turned off

– Check the oil level, see 6.1.2 If necessary, top up oil, see 3.1.1 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.

3.1.6 Additional Maintenance Work

The following maintenance should be carried out after 50-150 operating hours:

● Change lube oil,

see 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 valve clearance and adjust as necessary,

see 6.6.1

● Check the engine for leaks.

● Check the engine mount and adjust as necessary,

see 9.2

3.1.7 Selector Switch for Oil Heater

30 027 0

Position of selector switch for oil filter console with oil heater connection: Pos. 1: open

Pos. 2: closed

For engines without oil heating, the selector switch is always open Pos. 2: to lock closed.

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