Deutz 912 User Manual [nl]

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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.

3 Gerade

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.

7 Gerade

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.

Engine Operation 3.2 Starting

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:

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

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

Check that all guards have been

24 627 2 25 746 2

Starting without Cold-Start Aid

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 Diagnosis Chart (see 7.1).

● Where possible, disengage the clutch to separa-

te the engine from any driven parts.

● Move speed control lever 1 into idle position.

● Insert key.

– Position 0 = no operating voltage

● Turn key clockwise

– Position 1 = operating voltage – Pilot lights come on.

● Push the key in and turn it 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 Aid/Flame Glow Plug FR 60 = 9.5 and 19 volts

25 746 2

● 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. – Glow plug indicator comes on. – Position 2 = Preheat for approx. 60 seconds (hold key in position)*. – Glow plug indicator goes out. – Position 3 = start

● Release key as soon as engine fires.

– Pilot lights go out.

* By afterignition in position 2 for up to approx. 3

mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.

with Cold-Start Aid/Flame Glow Plug FR 20/30 = 11 and 23 volts

25 746 2

● 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. – Glow plug indicator comes on. – Position 2 = Preheat for approx. 20 -30 seconds (hold key in position)*. – Glow plug indicator goes out – Position 3 = start

● Release key as soon as engine fires

– Pilot lights go out.

* By afterignition in position 2 for up to approx. 3

mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.

with heating pipe

25 746 2

● 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 for approx. 60 seconds (hold key in position)*. – Position 3 = start

● Release key as soon as engine fires

– Pilot lights go out.

* By afterignition in position 2 for up to approx. 3

mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.

Engine Operation 3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

Oil Pressure Pilot Light

Oil Pressure Indicator Oil Pressure Gauge

● The oil pressure pilot light comes on with

operating voltage on and engine off.

● The oil pressure pilot light should go out when

the engine is running.

9690en_K03 21.08.2000, 11:36 Uhr28

25 752 1

● The pointer must remain in the green sector over

the entire range.

25 754 025 753 0

● The pointer must indicate the minimum oil

pressure (see 9.1).

3.3 Monitoring Systems Engine Operation

3.3.2 Engine Temperature

Temperature Gauge

24 985 0

● The engine temperature gauge pointer should

remain in the green sector most of the time. 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 Diagnosis Chart (see 7.1).

3.3.3 Cooling Fan Drive

24 590 1

● If the V-belt rips, pressure pin 1 of the electrical

switch is actuated by the tension roller and an acoustic or light signal is given.

Switch off the engine immediately to prevent overheating.

9690en_K03 21.08.2000, 11:35 Uhr29

Engine Operation 3.4 Stopping

3.4.1 Mechanical Shutdown 3.4.2 Electrical Shutdown

Ignition Key

24 630 1

● Move speed control lever 1 to low idle.

● Operate shutdown lever 2 until the engine comes

to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops.

● Turn key anticlockwise (to position 0) and remove.

The pilot lights will go out.

25 746 2

● Turn key anticlockwise (to position 0) and remove.

The pilot lights will go out.

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

3.5 Operating Conditions Engine Operation

3.5.1 Winter Operation

● Lube Oil Viscosity

– Select the oil viscosity (SAE grade) according

to the ambient temperature when the engine is started, 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 below

0 °C, see 4.2.2

● Additional Maintenance Work

– Drain the sludge from the fuel tank once a

week. (Unscrew the sludge drain plug.)

– If necessary, allow the oil in the oil bath air

cleaner and the engine oil to settle at the ambient temperature.

– Below -20 °C, after removing the starter if

necessary, smear the ring gear on the fly wheel via the pinion bore from time to time with coldresistant grease (e.g. Bosch grease FT 1 V 31).

● Cold-Start Aid

– At temperatures near or below freezing point,

use glow plugs if necessary, see 3.2.1. This not only lowers the starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

● Battery

– Efficient cold starting requires a healthy battery,

see 6.7.1

– The starting limit temperatures can be lowered

by 4-5 °C by heating the battery up to about +20 °C. (To do so, remove the battery and store in a warm place.)

26 248 0

Engine Operation 3.5 Operating Conditions

3.5.2 High Ambient Temperatures,

High Altitude

● As the altitude and ambient temperature rise, the

density of air tends to decrease, which affects the maximum power output of the engine, the exhaust gas quality and, in extreme cases, the starting behaviour. Under transient conditions, the engine can be used at altitudes up to 1000 m and temperatures up to 30 °C. 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

33 Gerade33 Gerade

Operating Media

4.1.1 Quality grade 4.1.2 Viscosity

4.1 Lube Oil

Lube oils are differentiated according to their performance and quality class. In common use are specifications named after the API (American Petroleum Institute) and ACEA (European Engine Oil Sequences).

Approved API Oils:

At least: CD

Approved ACEA Oils:

At least: E1-96

Oil change intervals, see 6.1.1 Oil capacities, see 9.1

As the viscosity of the 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 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. Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. Multi-grade oils – particularly light-flowing oils – also reduce fuel consumption.

- 13

- 22

-31

- 40

° C

° F

+ 30

+ 20

+ 10

SAE 10W/40

SAE 15W/30

SAE 15W/40

+ 0

- 10

- 4

- 20

- 30

- 40

SAE 10W/30

SAE 5W/30 (Synthetic)

✳

SAE 40

SAE 30

SAE 20W/20

26021 0

✳ nur mit Motorvorwärmung

*only with engine oil preheating

*Seulement avec préchauffe du moteur

34 34 34

4.2 Fuel Operating Media

4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel

Use commercially available diesel fuel with less than 0.5 % sulphur content. If the sulphur content is higher than 0.5 % oil change intervals should be reduced, see 6.1.1

The following fuel specifications / standards are approved:

● DIN EN 590

● BS 2869: A1 and A2

(with A2, take note of the sulphur content!)

● ASTM D 975-88; 1-D and 2-D

● NATO Code F-54 and F-75

Any exhaust emission levels which may have been determined during type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test.

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 the 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.

● Below -20 °C, petroleum must be added. For the

required mixing ratios please refer to the adjacent diagram.

● For artic climate zones down to -44 °C special

diesel fuels can be used.

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 be obtained by adding a flow improver (additive). Please inquire at DEUTZ-PARTNER.

+32

+23

- 5

+14

- 10

+ 5

- 15

- 20

- 4

- 25

- 13

- 22

- 30

°F

°C

Legend:

I Summer diesel fuel

II Winter diesel fuel

A Ambient

B Proportion of Kerosene to be

0 10 20 30 40 50 60 %

26441 1

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

35 Gerade35 Gerade

36 36 36

Routine Maintenance

5.1 Maintenance Schedule

5.2 Maintenance Charts

5.3 Maintenance Work Completed

37 Gerade37 Gerade

Routine Maintenance 5.1 Maintenance Schedule

Once

every

after

10 OH

50-150

daily

●

●●●

● ●●●

●●

●●●

●●

●

●●

Operating hours (OP)

every

●

2000 3000 50001000500250125

●

check

clean

change

Operation

●

●●

●

Oil level in engine / separate container 6.1.2 Engine leaks Oil bath- and dry type air cleaners 3) 4) 6.3/6.4 Battery and cable connectors 6.7.1 Cooling system (depending on engine use) 3) 6) 6.3.1/6.3.2 Engine oil (depending on engine use) 5) 6.1.1/6.1.2

●

Oil filter cartridge 6.1.3

●

Fuel filter cartridge 6.2.1 Valve clearance (adjust if necessary) 6.6.1 Engine mounts (retighten if necessary) 9.2 V-belts (retension if necessary) 6.5 Warning system 6.5.5

●

Fuel precleaner 6.2.2 Mountings 6.8.1 Flame glow plugs 4) 6.8.3

●

Partial-flow oil filter 6.1.4 Sheathed element heater plugs

Injection valve

See

Section

The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please observe the operating instructions of the equipment manufacturer.

1) Recommended maximum

2) Commissioning new or reconditioned engines

3) Clean if needed, see Section 6.3

4) Change if necessary. If fitted, service after service indicator.

5) Oil change interval, see Section 6.1.1

6) Clean system / cooling fins.

38 38 38

(Wartung Tab 5.1 BA 912/913 de)

5.2 Maintenance Charts Routine Maintenance

The maintenance charts shown here are supplied as self-adhesive labels with each engine. They should be affixed where they 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.

in.

ex.

0297 7224

0,15 mm

a =

0.006 in

1000

1252000

1000

500 500

FL 912/913

O IL

OIL

max.

Std.

ca.

1000

in.

ex.

OIL

max.

BF 4/6L 913/C/T

0297 4070

500

125-

2000

500

15 mm

0.6 in.

a =

250

500

0,15 mm

0.006 in

OIL

1000 1000

FUEL

Std.

AIR

15 mm

ca.

0.6 in.

250

500

Bildverkleinerung 65% x 65 % max Raster 117 breite 118 mm höhe

39 Gerade39 Gerade

Routine Maintenance 5.3 Completed Maintenance Jobs

Hours

50-150*

125

375

625

875

1125

1375

1625

1875

2115

2375

2625

* Commissioning new and overhauled engines. The maintenance jobs duly completed can be recorded in the above table.

Date

Signature / Stamp

Date Signature / StampHours

–

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

40 40 40

5.3 Completed Maintenance Jobs Routine Maintenance

Hours

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

The maintenance jobs duly completed can be recorded in the above table.

Date

Signature / Stamp

Hours

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

Date

Signature / Stamp

41 Gerade41 Gerade

Routine Maintenance 5.3 Completed Maintenance Jobs

Hours

5875

6125

6375

6625

6875

7125

7375

7625

7875

8125

8375

8625

The maintenance jobs duly completed can be recorded in the above table.

Date

Signature / Stamp

Hours

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

Date

Signature / Stamp

42 42 42

Service and Maintenance

6.1 Lubrication System

6.2 Fuel System

6.3 Cooling System

6.4 Combustion Air System

6.5 Belt Drives

6.6 Adjustments

6.7 Accessories

6.8 Engine Cleaning

6.9 Additional Maintenance

9690en_K06_1 21.08.2000, 11:40 Uhr43

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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: sulphur content max. 0.5% by

weight.

– Continuous ambient temperatures down to

-10 °C (+14 °F).

● If the sulphur content is > 0.5 to 1% or the

continuous ambient temperature below -10 °C (+14 °F), the intervals between oil changes should be halved.

● In the case of fuels containing more than 1%

sulphur, contact your service representative.

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

Installed engines

Lube oil quality

Normal oil usage, e.g.:

Road vehicles, cranes, construction machinery, ships, electrical units, pumps, rail-run vehicles

Heavy-duty oil usage, e.g.:

Combine harvesters, emergency pumps, underground sweeping machines, winter operation equipment, emergency power generating units

Vehicle engines

Lube oil quality

Service group

III

API classification

ACEA classification

API classification

ACEA classification

Annual kilome

trage km

30 000 – 100 000

< 100 000

equipment,

average speed

approx km/h

Lube oil intervals in OH

Naturally aspirated engines

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

E1-E3/96+ E4-98 E1-E2/96

500 250 500

250

Lube oil intervals in km

Naturally aspirated engine

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

E1-E3/96+ E4-98 E1-E2/96

10 000 5 000 10 00020 > 30 000I

20 000

30 000

Turbocharged engines

CH-4/CG-4

E3-96+ E4-98

125 250

Turbocharged engine

CH-4/CG-4

E3-96+ E4-98

10 000

15 000

20 000

30 000

44 44 44

9690en_K06_1 21.08.2000, 11:40 Uhr44

6.1 Lubrication System Service and Maintenance

6.1.2 Checking Oil Level / Changing Engine Oil

6.1.2.1 Checking Oil Level 6.1.2.2 Engine Oil Change

● Ensure that the engine or vehicle is in a horizon-

tal position.

● – Warm engine:

Switch off engine, wait 5 minutes and check the öil level.

● – Cold engine:

Check oil level. To this end:

● Remove the oil dipstick.

● Wipe the dipstick with a non-fibrous, clean cloth.

● Insert it to the stop and remove again.

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

“MAX” mark. – If the oil level is only just above the “MIN” mark, more oil must be added.

The oil level must not fall below the “MIN” marking.

● Ensure that the engine or vehicle is on a level

surface.

● Allow the engine to warm up

– Lube oil temperature approx. 80°C.

● Switch off the engine.

26 022 0 25 729 0

● Place oil tray under the engine.

● Unscrew drain plug.

● Drain oil.

● Fit oil drain plug, with the new gasket and tighten

firmly (for torque, see 9.2).

● Fill with lube oil.

– For grade / viscosity, see 4.1 – For quantity, see 9.1

● Check oil level, see 6.1.2.1

Be careful when draining hot oil – danger of scalds! Do not let used oil run into the

soil but catch it in a container ready for proper disposal.

26 023 0

9690en_K06_1 21.08.2000, 11:41 Uhr45

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Service and Maintenance 6.1 Lubrication System

6.1.3 Changing Oil Filter

● Undo the filter cartridge using a commercial tool

and spin off.

● Catch any dripping oil.

Beware of burns from hot oil.

46 46 46

9690en_K06_1 21.08.2000, 11:41 Uhr46

25881 0

● Clean any dirt from the filter carrier rim.

● Lightly oil the rubber gasket of the new oil filter

cartridge.

● Screw in the new cartridge finger tight against

the gasket.

25882 025880 0

● Tighten the oil filter cartridge with another half-

turn.

● Check oil level, see 6.1.2

● Check oil pressure, see 3.3.1

● Check cartridge seal for leaks.

6.1 Lubrication System Service and Maintenance

6.1.4 Changing the Partial-Flow Oil

Filter Insert

24 511 1

● Unscrew oil drain plug 1 and drain off oil.

● Unscrew tension screw 2. Remove the cover.

● Unscrew the dirtied filter insert 3. Clean the filter

housing.

● Check and if necessary replace cover seal 4.

● Screw in oil drain plug 1 with new seal 5.

● Fit new filter insert.

● Screw on cover with sealing ring 6.

● Check for leaks and check the oil pressure during

a test run.

9690en_K06_1 21.08.2000, 11:41 Uhr47

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Service and Maintenance 6.2 Fuel System

6.2.1 Changing Fuel Filter

● Close fuel stopcock.

● Undo fuel filter cartridge with commercial tool

and spin off.

● Catch any fuel.

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

48 48 48

9690en_K06_1 21.08.2000, 11:41 Uhr48

25880 0

25881 0

● Clean any dirt from the filter cartridge with a final

half-turn.

● Apply light film of oil or diesel fuel to the rubber

gasket of the new fuel filter cartridge.

● Screw in the new cartridge finger tight against

the gasket.

25882 0

● Tighten the fuel filter cartridge with a final half-

turn.

● Open fuel stopcock.

● Check for leaks.

The fuel system does not need to be bled.

6.2 Fuel Filter Service and Maintenance

6.2.2 Fuel Precleaner

Cleaning the Fuel Filter “Bosch” model

19 725 2

● Close the fuel shut-off valve.

● Loosen tensioning nut 2.

● Swing wire clip 1 to the side.

● Remove filter cone 5 with strainer 4 and clean in

fuel.

● Use a new seal 3 for filter cone 5.

● Bleed the fuel system, see 3.1.4

● Check for leaks.

Cleaning the Fuel Filter “IMSA” model

26 047 1

● Close the fuel shut-off valve.

● Loosen hexagonal nut 1 and unscrew with sealing

ring 2.

● Remove cover 3.

● Remove fuel strainer 4.

● Clean the fuel strainer 4 in fuel. Replace if

necessary.

● Refit in the reverse order.

● Bleed fuel system, see 3.1.4

● Check for leaks.

No naked flames when working on the fuel system. No smoking!

9690en_K06_1 21.08.2000, 11:41 Uhr49

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Service and Maintenance 6.3 Cooling System

6.3.1 Cleaning Intervals

● The amount of contamination in the cooling

system depends on the engine application.

● Spilled oil or fuel on the engine increases the risk

of contamination. Be especially careful if the 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 application where there are high

concentrations of chaff and chopped straw in the vicinity of the machine.

● Because applications vary, cleaning intervals

have to be determined from case to case. The cleaning intervals given in the table on the right can be used as a guide.

Inspection and cleaning

intervals

Recommended

2000

1000

500

250

125

Engine application

Ships, Electrical units in enclosed areas, pumps

Vehicles on reinforced highways

Tractors, fork-lift trucks, mobile electrical units

Vehicles on construction sites and on roads with loose surfaces, constrution machinery, compressors, mining equipment

Agricultural machinery, tractors used for harvesting purposes

50 50 50

6.4 Combustion Air Filter Service and Maintenance

6.4.1 Cleaning Intervals

● The amount of dirt in the air cleaner depends on

the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner.

● Cleaning intervals will have to be determined

from case to case.

● If dry-type air cleaners are used, they should be

cleaned only in accordance with the service indicator or the service switch.

● Air cleaner servicing is needed when:

– Service indicator the red signal 1 is fully visible when the engine is off. – Service switch the yellow pilot light comes on when the engine is running.

● After carrying out service work, reset the signal

by pressing the button on the service indicator.

25 885 1

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6.4 Combustion Air Filter Service and Maintenance

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 precleaner.

● Reposition collector bowl 3 onto lower section 4,

fasten cover 2 in place by tightening wing nut 1.

6.4.3 Cleaning Oil Bath Air Cleaner

25 886 0 25 887 0

● Turn engine off and wait about 10 minutes for the

oil to drain from filter housing 1.

● Release snap clips 2 and remove oil cup 3

together with filter element 4. If necessary prise element out with a screwdriver, taking care not to damage the rubber gasket 5.

● Remove dirty oil and sludge. Clean oil cup.

● Clean filter element 4 in diesel fuel and allow to

drip-dry.

● Clean filter housing 1 if very dirty.

● Inspect and replace rubber gasket 5 and 6 if

necessary.

● Fill oil cup with engine oil up to the mark (arrow)

(for viscosity, see 4.1.2).

● Refit oil cup and element to filter housing and

secure with snap clips.

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

52 52 52

Never clean air cleaner with gasoline. Dispose of cold oil in accordance with environmental regulations!

6.4 Combustion Air Filter Service and Maintenance

6.4.4 Dry Type Air Cleaner

Dust Discharge Valve Filter Cartridges

25 888 1 25 889 0

● 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 the

upper section of the valve.

● Undo clip fasteners 1.

● Take off hood 2 and remove cartridge 3.

● Clean cartridge (replace at least once a year).

● Clean cartridge 3.

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

● Through regular removal and replacement, the

gaskets on the filter cartridge can become damaged. Check paper filter (light showing through) and gaskets for damage. Replace if necessary.

● After five cleaner services or after two years at

the latest, replace safety cartridge 4 (never clean). To do so: – Undo hex. nut 5 and remove cartridge 4. – Install new cartridge, insert and tighten hex.

nut.

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

fasteners 1.

Never clean filter cartridge with gasoline or hot fluids.

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Service and Maintenance 6.5 Belt Drives

6.5.1 Checking V-Belts 6.5.2 Changing the Fan V-Belt

● 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 the tension of the V-belt, use a tension

gauge (see 9.3). – Place indicator arm 1 into gauge. – Position gauge on V-belt 2, midway between

the pulleys, with flange 3 on bottom of gauge against the edge of belt.

– Push slowly on the black pad 4 at right angles

to belt 2 until the spring is heard or felt to trigger.

54 54 54

– Carefully remove the gauge without altering the position of the indicator arm 1. Read off the value where the 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 the engine off. Refit belt guard, if provided.

24 684 1

24 684 125 890 2

● To replace, press in tension roller 1 using a

commercial tool and remove the V-belts.

● Fit new V-belts.

When new V-belts are fitted, check the belt tension after ca. 15 minutes running time.

6.5 Belt Drives Service and Maintenance

6.5.3 Tensioning Alternator Belts 6.5.5 Checking Warning System6.5.4 Changing Alternator Belts

26 051 1

● Loosen bolts 1, 2 and 3.

● Press alternator 4 outwards in direction of arrow

A until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

● Remove fan V-belts as described under 6.5.2

● Loosen bolts 1, 2 and 3.

● Swing alternator 4 inwards in direction of arrow

● Remove V-belts and place on new belt.

● Swing alternator 4 outwards in direction of arrow

A until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

● Fit fan V-belts.

26 052 0

24 590 1

● If the V-belt rips, pressure pin 1 of the electrical

switch is actuated by the tension roller and an acoustic or light signal is given.

● Functional check by pressing in pin 1.

Only check/tension/replace V-belts when the engine is at a standstill. If necessary, replace V-belt cover.

Retighten new V-belts after 15 minutes running time.

Only carry out a check when the engine is at a standstill.

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Service and Maintenance 6.5 Belt Drives

6.5.6 Tensioning and Changing Air

Compressor V-Belts

● Unscrew hexagonal bolts 1.

● Remove outer half of belt pulley 2.

● If necessary replace the V-belts.

56 56 56

9690en_K06_2.pm6 21.08.2000, 12:02 Uhr56

24 598 1

24 599 1

● To tighten, remove one or more of the inner

intermediate discs 3. Place the removed discs on the removed half of the V-belt pulley 2.

● Retighten bolt 1. Whilst tightening, simulta-

neously rotate the engine to prevent the V-belt from being crushed.

When new V-belts are fitted, check the belt tension after ca. 15 minutes running time.

6.5 Belt Drives Service and Maintenance

6.5.7 Air Compressor Design with Double V-Belt

20 762 2

● Screw off hexagonal nut 1, remove V-belt pulley

half 2, V-belt 3 and intermediate disc packet 7.

● Remove intermediate disc 4, rear V-belt 3,

intermediate disc packet 6 and V-belt disc half 5.

● To tighten, remove one or more of the in-

termediate discs from packet 6 or 7. Place the removed discs in front of or behind V-belt pulley halves 2, so that the V-belt remains aligned. Always take the same number of discs from each packet.

● Fit in the reverse order. Whilst tightening nut 1,

the engine must be rotated to prevent the V-belts from being crushed.

If a V-belt is worn or damaged, both belts in the set must be replaced. The difference in the length of the new V-belts may not exceed 0.15%.

Only check or replace the V-belts when the engine is at a standstill. If necessary, replace the V-belt cover. When new Vbelts are fitted, check the belt tension after approx. 15 minutes running time.

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Service and Maintenance 6.6 Adjustments

6.6.1 Checking / Adjusting Valve

Clearances

19 691 2

● Remove the cylinder head cover.

● Position crankshaft as per schematic 6.6.1.1

● Before adjusting valve clearance, allow engine to

cool down for at least 30 minutes. The 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

Only inclined engines are fitted with an additional oil jet for lubrication of the bearing. Any adjustments must be carried out in an authorised specialist workshop.

58 58 58

26 053 1

● Adjust valve clearance if necessary:

– Release locknut 4. – Use screwdriver 7 to turn setscrew 5 so that

the correct clearance is attained after locknut 4 has been tightened.

● Check and adjust valve clearance on all remaining

cylinders.

● Replace cylinder head cover (use new gasket if

needed).

6.6 Adjustments Service and Maintenance

6.6.1.1 Valve Clearance

Adjustments 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 arm with chalk to show that adjustment has been done.

● Crankshaft Position 2:

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

26 055 1

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Service and Maintenance 6.7 Accessories

6.7.1 Battery

6.7.1.1 Checking Battery and Cable Connectors

25 895 0 24 232 3 25 896 0

6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Electrolyte Density

● Keep battery clean and dry.

● Undo dirty clamps.

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

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

● When reassembling, ensure that clamps make

good contact. Do up clamp bolts finger tight.

60 60 60

● Remove caps 1.

● If testers 2 are used, the electrolyte should come

up to their base.

● If testers are not used, the electrolyte level should

be 10-15 mm above the top of the plates.

● If necessary, top up with distilled water.

● Replace caps.

● Measure the electrolyte density of individual

cells with a commercial hydrometer.

The hydrometer reading (see table on following page) indicates the state of charge. During measurement, the temperature of the electrolyte should preferably be +20 °C.

6.7 Accessories Service and Maintenance

in [kg/ l] in[°Bé (Baumégrad)*]

Normal Tropics Normal Tropics

1,28

1,20

1,12

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

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

1,23

1,12

1,08

The gases emitted by the battery are explosive! Keep sparks and naked flames away from the battery. Do not allow battery acid to come into contact with skin or clothing.

State of Charge

Fully charged

Half charged, recharge

Discharged, recharge immediately

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Service and Maintenance 6.7 Accessories

6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

Notes on the three-phase system:

● Never disconnect the cables between battery,

alternator and regulator while the engine is

running.

● If, however, it is necessary to start and operate

the engine without the battery, disconnect the regulator from the alternator before starting.

● Be sure not to confuse the battery terminals.

● Replace defective bulb of the charge pilot lamp

immediately.

● When washing the engine, cover up the alternator

and regulator.

● The habit of touching a lead against the frame to

check whether it is live must under no circumstances be used with three-phase electrical systems.

● In case of electric welding, connect the ground

terminal on the welder directly to the piece being welded.

● Always use proper lifting tackle 1 when trans-

porting the engine.

● After transportation and before commissioning

of the engine: Remove transport eyes 2.

26 056 0 26 057 0

62 62 62

Use only the correct lifting tackle.

6.8 Engine Cleaning Service and Maintenance

6.8.1 Cleaning the Engine

With Compressed Air

● Switch off the engine.

● Remove engine covers, cooling-air hoods.

Replace following cleaning and before test run.

● Cover electrical / electronic components /

connections (e.g. alternator, starter, regulator, solenoid).

● Pass compressed air through the engine, being

careful with the cooler and cooling fins (start at the exhaust side) Remove dirt which has been blown into the inner compartment.

● Switch off the engine.

● Remove engine covers, cooling-air hoods.

Replace following cleaning and before test run.

● Cover electrical / electronic components /

connections (e.g. alternator, starter, regulator, solenoid).

● Spray engine with commercial cold-cleaning

compound and leave to work for approx. 10 minutes.

● Spray engine clean with water jet and if necessary

repeat procedure.

● Drive the engine warm so that remaining water

evaporates.

With High-Pressure EquipmentWith Cold-Cleaning Compound

26 050 026 048 0 26 049 0

● Switch off the engine.

● Remove engine covers, cooling-air hoods.

Replace following cleaning and before test run.

● Cover electrical / electronic components /

connections (e.g. alternator, starter, regulator, solenoid).

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

● Drive the engine warm so that remaining water evaporates.

The engine may only be cleaned when it is at a standstill.

63 Gerade63 Gerade

Service and Maintenance 6.9 Additional Maintenance

6.9.1 Checking the Mountings 6.9.2 Checking the Function of the

26 111 0

● Cylinder head cover 1

● Air-intake pipe 2

● Coupling sleeves

● Exhaust line 3

● Engine mounting 4

Heating Pipe

● When functioning correctly, the heating pipe

heats up via the integrated heating coil when starting with preheating. – 1 heating pipe – 2 air intake pipe

6.9.3 Checking the Function of the Flame Glowing System

26 113 0 24 717 1

● When functioning correctly, intake pipe 4 heats

up in the vicinity of flame glow plug 2 when starting with preheating.

64 64 64

6.9 Additional Maintenance Service and Maintenance

25 746 2 24 717 1 24 717 1

Test stage 1:

● Move speed adjustment lever and shut-off lever

to “stop” position.

● Insert key

– Position 0 = no operating voltage

● Turn key clockwise.

– Position 1 = operating voltage – Pilot lights come on.

● Press in key and turn further clockwise against

the spring pressure. – Position 2 = preheat, hold for approx. 1 minute. – Preheat lamp lights up.

● Otherwise flame glow plug defective or power

interrupted.

Test stage 2:

● Loosen pipe connection 1.

●

Rotate engine with starter, key on switch position 3.

● Fuel must be emitted at loosened pipe connection.

Otherwise have the system, solenoid 3, checked by a specialist.

Test stage 3:

● Loosen pipe connection 1.

● Remove flame glow plug 2.

●

Rotate engine with starter, key in switch position 3.

● Fuel must be emitted at flame glow plug 2,

replace plug 2 as necessary.

● Use sealant DEUTZ DW 47 when fitting flame

glow plug 2.

● Refit flame glow plug 2 on fuel line. Keep clear of rotating parts.

Collect any leaked fuel and dispose of in an environmentally friendly fashion.

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66 66 66

7.1 Diagnosis Chart

Faults, Causes and Remedies

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Faults, Causes and Remedies 7.1 Diagnosis Chart

Fault Remedy

Engine fails or is difficult to start Inspect I

Engine starts but runs unevenly or stalls Adjust A

Engine overheats. Temperature monitor gives warning Replace R

Engine gives poor performance Clean C

Engine not firing on all cylinders Top up T

Engine has little or no oil pressure Lower level L

Engine oil consumption excessive

Engine smokes – blue

– white – black

Cause Section

●

●●

●● ●●

●●●

●●

●●● ●●●

●● ●

●

●● ●

●●

●

●● ●

●●

●

Not declutched (where possible) Operation I Below starting limit temperature I Engine shut-off lever not in stop position (shut-off magnet defective) I Oil level too low T Oil level too high L Excessive inclination of engine I/A Engine predominantly operated at lower load I Air cleaner clogged / turbocharger defective Combustion air R Air cleaner service switch / indicator defective I/R LDA defective (leak in connecting line) only with charged engines I/R Exhaust counter pressure too high I Charge-air line leaking, only with charged engines I/A Charge-air line leaking, only with charged engines Cooling system I/C Charge air cooler clogged I/C Oil cooler air and/or oil side clogged I/C Cooling fan or exhaust thermostat defective, V-belts ripped or loose I/R Cooling air temperature rise / heating short circuit I Cooling air fins loose, cracked or missing I

68 68 68

7.1 Diagnosis Chart Faults, Causes and Remedies

Fault Remedy

Engine fails or is difficult to start Inspect I

Engine starts but runs unevenly or stalls Adjust A

Engine overheats. Temperature monitor gives warning Replace R

Engine gives poor performance Clean C

Engine not firing on all cylinders Top up T

Engine has little or no oil pressure Lower level L

Engine oil consumption excessive

Engine smokes – blue

– white – black

Cause Section

●

●●●●● ●●

●● ●●

●

●● ●

●●●●● ●●

●● ●●

●●

●●●

●● ●● ●●

●

Battery defective or discharged Electrics I Electric cable connections to starter electrical system loose or oxidised I Starter defective or pinion does not engage I Oil pressure switch/oil pressure gauge defective I/R Incorrect valve clearance Engine A Leaking injection line I/C Vent line clogged I/C Flame glow system/heating pipe defective I/R Injection valve defective I/R Air in fuel system P/R Fuel filter/fuel precleaner clogged I/C/R Oil filter defective R Incorrect SAE class or grade of engine lube oil R Compression pressure too low I Oil in combustion chamber I/C

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70 70 70

8.1 Preservation

Engine Preservation

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Engine Preservation 8.1 Preservation

8.1 Preservation

8.1.1 Preserving Engine 8.1.2 Removing Engine Preservatives

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rust formation. 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

● Recommended cleansing agent to remove

preservatives when recommissioning engine: – Petroleum benzine (hazardous materials class A3)

● Clean engine (with cold cleansing agent if

preferred) using high pressure equipment.

● 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 from tank.

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

anti-corrosion oil, and refill fuel tank.

● Run engine for about 10 minutes.

● Turn engine off.

● Turn engine over manually several times to

preserve the cylinders and combustion chamber. When rotating with starter, place shut-off lever in stop position.

● Remove V-belts and store dry in wrapped

condition.

● Spray grooves on V-belt pulleys with anti-

corrosion spray.

● Close off intake ports and exhaust ports.

●

Remove anti-corrosion agent from grooves in V-

belt pulleys.

● Install V-belts. Retension after brief operation if

necessary, see 6.5

● Remove plugs from intake port and exhaust

port.

● Set the engine in operation.

72 72 72

␣ Technical Specifications

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

9.3 Tools

73 Gerade73 Gerade

Technical Specifications

9.1 Engine Specifications and Settings

Model

Numbers of cylinders

F3L 912 F4L 912 F5L 912 F6L 912

34 56 Cylinder arrangement Bore [mm] Stroke [mm] Total displacement [cm3]

2827 3770 4712 5655

Compression ratio [ε]

Working cycle Combustion system Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) [ca. kg]

270

Engine power [kW (PS)] Speed [1/min]

Lubrication SAE oil Oil temperature in oil pan [°C] Min. oil pressure in warm condition (120 °C) at low idling speed / rated speed [bar] Oil change quantity without filter [ca. ltr.] Oil change quantity with filter [ca. ltr.]

9,0 9,5

Valve clearance with cold engine [mm] Opening pressure of the injection valve [bar] Start of delivery [°crank angle b TDC] Firing order

1–2–3 1–3–4–2 1–2–4–5–3 1–5–3–6–2–4

V-belt pressure: pretension / tighten Alternator fan [N] Compressor [N]

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

2) Tighten after 15 minutes, after the engine has been driven under load.

3) Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative.

4) Values for engines without engine oil heating.

5) Ca. value can vary depending on oil pan design.

vertical in line

100 120

4-stroke diesel induction engine

direct injection

counterclockwise

300

pressure lubrication

15W 40

125

12,0 12,5

0,4

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05

250 +8

preload / torquing load

450 / 300 ± 20 550 / 400 ± 20

380

13,5

14,0

410

14,5 15,5

74 74 74

9.1 Engine Specifications and Settings Technical Specifications

Model

Numbers of cylinders Cylinder arrangement

F3L 913 F4L 913 F6L 913

346

vertical in line Bore [mm] Stroke [mm] Total displacement [cm3]

3064 4086 6128

Compression ratio [ε]

Working cycle Combustion system Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) [ca. kg]

277

4-stroke diesel induction engine

direct injection

counterclockwise

Engine power [kW (PS)] Speed [1/min]

Lubrication

pressure lubrication

SAE oil Oil temperature in oil pan [°C] Min. oil pressure in warm condition (120 °C) at low idling speed / rated speed [bar] Oil change quantity without filter [ca. ltr.] Oil change quantity with filter [ca. ltr.]

Valve clearance with cold engine [mm]

8,0 9,5

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05

Opening pressure of the injection valve [bar] Start of delivery [°crank angle b TDC] Firing order

V-belt pressure: pretension / tighten Alternator fan [N] Compressor [N]

1–2–3 1–3–4–2 1–5–3–6–2–4

preload / torquing load

450 / 300 ± 20 550 / 400 ± 20

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

2) Tighten after 15 minutes, after the engine has been driven under load.

3) Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative.

4) Ca. value can vary depending on oil pan design.

102 125

320

15W 40

125

0,4

13,5

250 + 8

420

16,5 18,5

75 Gerade75 Gerade

Technical Specifications

9.1 Engine Specifications and Settings

Model 913/C/CT

Numbers of cylinders

F3L 913W F4L 912W F6L 912W

346 Cylinder arrangement Bore [mm] Stroke [mm] Total displacement [cm3]

3064 4086 6128

Compression ratio [ε]

Working cycle Combustion syst Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) [ca. kg]

270

Engine power [kW (PS)] Speed [1/min]

8,0 9,5

Valve clearance with cold engine [mm] Opening pressure of the injection valve [bar] Start of delivery [°crank angle b TDC] Firing order

1–2–3 1–3–4–2 1–5–3–6–2–4

V-belt pressure: pretension / tighten Alternator fan [N] Compressor [N]

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

2) Tighten after 15 minutes, after the engine has been driven under load.

3) Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative.

4) Ca. value can vary depending on oil pan design.

vertical in line

102 125

4-stroke diesel induction engine

direct injection

counterclockwise

300

pressure lubrication

15W 40

125

0,4

13,5

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05

120 + 10

preload / torquing load

450 / 300 ± 20 550 / 400 ± 20

410

16,5 18,5

76 76 76

9.1 Engine Specifications and Settings Technical Specifications

Model 913/C/CT

Numbers of cylinders Cylinder arrangement

BF4L 913 BF6L 913 BF6L 913 C

466

vertical in line Bore [mm] Stroke [mm] Total displacement [cm3] Compression ratio [ε]

Working cycle Combustion syst Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) [ca. kg]

4086 6128 6128

18 18 17

supercharged 4-stroke diesel induction engine

direct injection

counterclockwise

360 Engine power [kW (PS)] Speed [1/min]

Lubrication

pressure lubrication

Valve clearance with cold engine [mm]

9,5

11,5

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05

Opening pressure of the injection valve [bar] Start of delivery [°crank angle b TDC] Firing order

V-belt pressure: pretension / tighten Alternator fan [N] Compressor [N]

1–3–4–2 1–5–3–6–2–4 1–5–3–6–2–4

preload / torquing load

450 / 300 ± 20 550 / 400 ± 20

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

2) Tighten after 15 minutes, after the engine has been driven under load.

3) Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative.

4) Values for engines without engine oil heating.

5) Ca. value can vary depending on oil pan design.

102 125

485

15W 40

125

0,5 16,0 18,2

250 + 8

510

16,0 18,2

77 Gerade77 Gerade

Technical Specifications 9.1 Engine Specifications and Settings

Location Preload Torquing load Total Remarks

Alternator mounting 20 180° – – – 180° M10 x 180

Cylinder head cover – – – – – 12 ± 1,2 Nm – Rocker arm set screw – – – – – 22 ± 2 Nm – Support foot 30 15° 60° –– 75° M14 x 100

Air intake manifold – – – – – 22 ± 2 Nm – Exhaust manifold – – – – – 40 ± 4 Nm –

Oil drain plug – cast iron oil pan

Oil drain plug – sheet metal oil pan

Injection valve mounting – – – – – 25–30 Nm –

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

30 180° – – – 180° M14 x 230

30 45° 60° – – 105° M14 x 110 30 45° 60° – – 105° M14 x 125

– – – – – 150 ± 10 Nm M22 x 1,5 – – – – – 100 ± 10 Nm M30 x 1,5

78 78 78

9.1 Engine Specifications and Settings Technical Specifications

V-belt Tension Gauge

26002 0

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

COMPANY WILBÄR Postfach 14 05 80 D-42826 Remscheid

79 Gerade79 Gerade

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.

Notes

CALIFORNIA PROPOSITION 65 INFORMATION

TO CALIFORNIA CUSTOMERS AND

TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR

FOR USE IN CALIFORNIA.

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.

2. 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

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

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:

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

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 912 User Manual [nl]

Specifications and Main Features

Frequently Asked Questions

User Manual