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Operation Manual |
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912 |
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913 |
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472 |
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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 |
2 |
04.02.2002, 14:23 |
Operation Manual
912
913
0297 9690 en
Engine
Serial Number
Please enter the engine serial number here. This number should be quoted when inquiring about CustomerService, RepairsorSpareParts(seeSection 2.1).
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
1
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
Index
1 |
General |
3.4 |
Stopping |
6.5 |
Belt Drives |
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3.4.1 |
Mechanical Shutdown |
6.5.1 |
Checking V-Belts |
2 |
Engine Description |
3.4.2 |
Electrical Shutdown |
6.5.2 |
Changing the Fan V-Belt |
2.1 |
Model |
3.5 |
Operating Conditions |
6.5.3 |
Tensioning Alternator Belts |
2.1.1 |
Rating Plate |
3.5.1 |
Winter Operation |
6.5.4 |
Changing Alternator Belts |
2.1.2 |
Rating Plate Location |
3.5.2 |
High Ambient Temperatures, High Altitude |
6.5.5 |
Checking Warning System |
2.1.3 |
Engine Serial Number |
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6.5.6 |
TensioningandChanging AirCompressor |
2.1.4 |
Cylinder Numbering |
4 |
Operating Media |
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V-Belts |
2.1.5 |
Direct Injection |
4.1 |
Lube Oil |
6.5.7 |
Air Compressor Design with Double |
2.1.6 |
Two-stage Combustion |
4.1.1 |
Quality Grade |
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V-Belt |
2.2 |
Engine Illustrations |
4.1.2 |
Viscosity |
6.6 |
Adjustments |
2.2.1 |
Service Side F4L 912 |
4.2 |
Fuel |
6.6.1 |
Checking / Adjusting Valve Clearance |
2.2.2 |
Exhaust Side F4L 912 |
4.2.1 |
Quality Grade |
6.7 |
Accessories |
2.2.3 |
Service Side BF4L 913 |
4.2.2 |
Winter-Grade Fuel |
6.7.1 |
Battery |
2.2.4 |
Exhaust Side BF4L 913 |
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6.7.2 |
Three-Phase Alternator |
2.3 |
Lube Oil Circuit |
5 |
Routine Maintenance |
6.7.3 |
Lifting Tackle |
2.3.1 |
Lube Oil Circuit FL 912/913 |
5.1 |
Maintenance Schedule |
6.8 |
Cleaning the Engine |
2.4 |
Fuel System Schematic |
5.2 |
Maintenance Chart |
6.8.1 |
Cleaning the Engine |
2.4.1 |
Fuel Circuit |
5.3 |
Maintenance Work Completed |
6.9 |
Additional Maintenance |
2.5 |
Engine Cooling |
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6.9.1 |
Checking the Mountings |
2.5.1 |
Regulation of Coolant Flow using the |
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6.9.2 |
Checking the Function of the |
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Exhaust Thermostat |
6 |
Service and Maintenance |
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Heating Pipe |
2.5.2 |
Regulation of Coolant Flow using the |
6.1 |
Lube Oil System |
6.9.3 |
Checking the Function of the Flame |
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Exhaust Thermostat and Solenoid |
6.1.1 |
Oil Change Intervals |
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Glowing System |
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6.1.2 |
Checking Oil Level / Changing Oil Level |
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3 |
Engine Operation |
6.1.3 |
Changing Oil Filter |
7 |
Faults, Causes and Remedies |
3.1 |
Commissioning |
6.1.4 |
Changing the Partial-Flow Oil Filter Insert |
7.1 |
Diagnosis Chart |
3.1.1 |
Adding Engine Oil |
6.2 |
Fuel System |
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3.1.2 |
Filling Oil Bath Air Cleaner |
6.2.1 |
Changing Fuel Filter |
8 |
Engine Preservation |
3.1.3 |
Adding Fuel |
6.2.2 |
Fuel Precleaner Cleaning the Fuel Filter |
8.1 |
Preservation |
3.1.4 |
Ventilation |
6.3 |
Cooling System |
8.1.1 |
Preserving Engine |
3.1.5 |
Other Preparations |
6.3.1 |
Cleaning Intervals |
8.1.2 |
Removing Engine Preservatives |
3.1.6 |
Additional Maintenance Work |
6.4 |
Combustion Air Filter |
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3.1.7 |
Selector Switch for Oil Heater |
6.4.1 |
Cleaning Intervals |
9 |
Technical Specifications |
3.2 |
Starting |
6.4.2 |
Emptying Cyclone Type Precleaner |
9.1 |
Engine Specifications and Settings |
3.2.1 |
Electric Starting |
6.4.3 |
Cleaning Oil Bath Air Cleaner |
9.2 |
Torque Wrench Settings |
3.3 |
Monitoring Systems |
6.4.4 |
Dry Type Air Cleaner |
9.3 |
Tools |
3.3.1Engine Oil Pressure
3.3.2 |
Engine Temperature |
10 |
Service |
3.3.3Cooling Fan Drive
AZ-TD3/Vo 19.7.96 5
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6
General
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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 |
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.
This symbol is used for all safety
!carefully. The attention of operating personnel should be drawn to these safety instructions. General safetywarnings. Please follow them
and accident prevention regulations laid down by law must also be observed.
Asbestos
DEUTZ original parts are asbestosfree.
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.
7 Gerade
9690en_K01_neu |
7 |
18.08.2000, 14:56 Uhr |
1
8
9690en_K01_neu |
8 |
18.08.2000, 14:56 Uhr |
Engine Description
2
2.1Model
2.2Engine Illustration
2.3Lube Oil Circuit
2.4Fuel System Schematic
2.5Engine Cooling
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9 Gerade |
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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 Rating Plate Location |
2.1.3 Engine Serial Number |
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25 611 2
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.
24 587 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.
24 552 1
The engine serial number D is stamped on the crankcase as well as the rating plate.
10
10
2.1 Model |
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Engine Description |
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2.1.4 Cylinder Numbering |
2.1.5 Direct Injection |
2.1.6 Two-stage Combustion |
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FL 912 |
FL 912W |
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24 858 1
Cylinders are numbered consecutively, beginning at the flywheel end.
21 878 |
3 |
Engines with direct injection are used where high performance is required.
Engines with two-stage combustion are used where it is particularly important to keep exhaust emissions to an absolute minimum.
11 |
11 Gerade |
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Engine Description |
2.2 Engine Illustrations |
2 |
2.2.1 |
Service Side |
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F4L 912 |
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Fan |
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V-belt (fan) |
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Injection pump |
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V-belt (alternator) |
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V-belt pulley |
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Tension roller |
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Oil fill point |
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Oil pan |
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Oil drain plug |
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Fuel pump |
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Oil dipstick |
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Lube oil filter |
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Easy-change fuel filter |
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Air duct cover |
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Cylinder-head cover |
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24 856 |
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2.2 Engine Illustrations |
Engine Description |
2.2.2 |
Exhaust Side |
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F4L 912 |
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24 857 |
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16Air-intake pipe
17Exhaust manifold pipe
18Screen
19Alternator
20Starter
21Engine mounting
22Crankcase
23Crankcase ventilation
13 |
13 Gerade |
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Engine Description |
2.2 Engine Illustrations |
2 |
2.2.3 |
Service Side |
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BF4L 913 |
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Fan |
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V-belt (fan) |
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V-belt (alternator) |
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V-belt pulley on crankshaft |
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Tension roller |
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Oil fill point |
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Oil drain plug |
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8 |
Fuel filter cartridge |
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Fuel pump with fuel precleaner |
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Injection pump |
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Oil dipstick |
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12 |
Lube oil filter cartridge |
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Air duct cover |
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Engine oil radiator cover |
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30016 |
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2.2 Engine Illustrations |
Engine Description |
2.2.4 |
Exhaust Side |
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BF4L 913 |
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30017 |
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15Exhaust manifold line
16Terminal housing
17Starter
18Crankcase ventilation
19Oil pan
20Alternator
21Exhaust turbocharger
22Air-intake pipe-exhaust turbocharger
23Charge-air line
15 |
15 Gerade |
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Engine Description |
2.3 Lube Oil Circuit |
2 |
2.3.1 |
Lube Oil Circuit |
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FL 912 / 913 |
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19 058 |
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1Oil pan
2Intake manifold
3Oil pump
4Oil pressure control valve
5Pressure-oil line
6Bypass line or selectively
7Finned pipe spiral or selectively
8Frame oil cooler
9Lube oil filter
10Safety valve
11Main oil gallery
12Crankshaft bearing
13Con-rod bearing
14Camshaft bearing
15Tappets
16Push rod (hollow, for oil feed to rocker arm lubrication)
17Rocker arm bearing
18Metering plug (r. arm lubrication)*
19Protective sleeve for push rod
20Throttle bore (for lubrication of the gear wheels)
21Injection jet for cooling the pistons
22Connection for oil pressure gauge
23Oil pressure gauge
24Injection pump connected to lube oil circuit
25Connection point for oil heating**
*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 |
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2.3.1 Lube Oil Circuit |
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BF6L 913 |
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24 355 |
2 |
1Oil pan
2Intake manifold
3Oil pump
4Oil pressure control valve
5Pressure-oil line
6Connecting line to oil cooler
7Frame oil cooler
8Lube oil filter
9Safety valve
10Main oil gallery
11Crankshaft bearing
12Con-rod bearing
13Camshaft bearing
14Tappets (with impulse lubrication of the rocker arm)
15Push rod (hollow, for oil feed to r. arm lubrication)
16Rocker arm bearing
17Metering plug (r. arm lubrication)*
18Protective sleeve for push rod (oil return from cylinder head to crankcase)
19Throttle bore (for lubrication of the gear wheels)
20Injection jet for cooling the pistons
21Oil line for lub. of the exhaust turbocharger
22Oilret.linefromexhaustturboc.tothecrankcase
23Oil pressure gauge
24Partial-flow lube oil filter
25Connection point for oil heating**
26Injection pump connected to lube oil circuit
*only for inclined engines
**in this instance the filter holder must be replaced. Please contact our service representative for this alteration.
17 |
17 Gerade |
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Engine Description |
2.4 Fuel System Schematic |
2.4.1 Fuel Circuit
2
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
18
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2.5 Engine Cooling |
Engine Description |
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2.5.1 Regulation of Coolant Flow using the Exhaust Thermostat |
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Pressure-oil line from engine to exhaust |
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thermostat |
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Air line to exhaust thermostat |
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Exhaust manifold pipe |
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Exhaust thermostat |
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Control line to hydraulic coupling |
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Hydraulic coupling |
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Cooling fan |
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Cooling fan drive |
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9 |
Oil return line to crankcase |
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Ventilation line |
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11 |
Adjusting pin with special seal |
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19 |
19 Gerade |
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Engine Description 2.5 Engine Cooling
2.5.2 Regulation of Coolant Flow using the Exhaust Thermostat and Solenoid
2
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 gasket
12 Solenoid
26 121 0
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Engine Operation
3
3.1Commissioning
3.2Starting
3.3Monitoring Systems
3.4Stopping
3.5Operating Conditions
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Engine Operation |
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3.1 Commissioning |
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3 |
3.1.1 Adding Engine Oil |
3.1.2 Filling Oil Bath Air Cleaner |
3.1.3 Adding Fuel |
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FUEL
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24 675 |
1 |
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24 980 |
2 |
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26 398 |
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As a rule, engines are delivered empty of oil. |
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Fill oil cup 1 of the oil bath air cleaner with engine |
Use only commercial-grade diesel fuel. For fuel |
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Pour lube oil into the oil filler neck (arrow). |
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oil up to the arrow. |
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grade, see 4.2. Use summer or winter-grade fuel, |
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For oil grade and viscosity, see 4.1 |
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For oil grade and viscosity, see 4.1 |
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depending on the ambient temperature. |
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Oil may not be filled into the dust |
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collector |
of the precleaner, if this is |
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fitted. |
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Never fill the tank while the engine |
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is running. Keep the filler cap area |
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clean and do not spill fuel. |
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3.1 Commissioning |
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Engine Operation |
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3.1.4 Ventilation |
Ventilation |
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3 |
Model: |
Model: |
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“Bosch” fuel pump |
“IMSA” fuel pump |
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24 593 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.
24 592 1
●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.
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Engine Operation |
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3.1 Commissioning |
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3 |
3.1.5 Other Preparations |
3.1.6 Additional Maintenance Work |
3.1.7 Selector Switch for Oil Heater |
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●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.
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
30 027 |
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Position of selector switch for oil filter console with oil heater connection:
Pos. 1: open Pos. 2: closed
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For engines without oil heating, the |
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selector switch is always open |
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Pos. 2: to lock closed. |
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3
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