Deutz BF4M (2012) Operation Manual

Page 1

Operation Manual

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is his torical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand C

ompany and Doosan

Company or the products of

ith

er.

Revised (10-12)

2012

C 2000

1 Gerade BA 2012 9912en

Page 2

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

Page 3

Operation ManualOperation Manual

Operation Manual

Operation ManualOperation Manual

20122012

2012

20122012

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).

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.

02970297

0297

02970297

9912 en9912 en

9912 en

9912 en9912 en

Page 4

ForewordForeword

Foreword

ForewordForeword

Dear Customer,Dear Customer,

Dear Customer,

Dear Customer,Dear Customer,

Liquid-cooled DEUTZ engines are designed for a large number of applications. Consequently, a wide range of variants are offered to meet the requirements of specific cases.

Your engine is appropriately equipped for the installation concerned, which means that not all of the components described in this Operation Manual are necessarily mounted to your engine.

We have endeavored to highlight any differences so that you will be able to locate the operating and maintenance instructions relevant to your engine quickly and easily.

Please read this Manual before starting your engine, and always observe the operating and maintenance instructions. We are available to help with any additional inquiries

Sincerely,

DEUTZ AG

Page 5

IndexIndex

Index

IndexIndex

1.1.

GeneralGeneral

General

1.1.

GeneralGeneral

2.2.

Engine DescriptionEngine Description

Engine Description

2.2.

Engine DescriptionEngine Description

2.1 Model

2.1.1 Rating Plate

2.1.2 Position of the Rating Plate

2.1.3 Engine Serial Number

2.1.4 Cylinder Enumeration

2.2 Engine Illustrations

2.2.1 Operating Side 2012 Ribbed V-belt Drive

2.2.2 Starter Side 2012 Ribbed V-belt Drive

2.2.3 Operating Side 2012

2.2.4 Starter Side 2012

2.3 Lube Oil Circuit Schematic

2.3.1 Lube Oil Plan

2.4 Fuel System

2.4.1 Fuel System Plan

2.5 Coolant System

2.5.1 Coolant Plan 2012

3.3.

Engine OperationEngine Operation

Engine Operation

3.3.

Engine OperationEngine Operation

3.1 Commissioning

3.1.1 Pour in Engine Oil

3.1.2 Filling Oil Bath Air Filter with Engine Oil

3.1.3 Pour in Fuel

3.1.4 Fill / Bleed Cooling System

3.1.5 Other Preparations

3.2 Starting

3.2.1 Electric Starting

3.3 Monitoring Operation

3.3.1 Engine Oil Pressure

3.3.2 Coolant Temperature

3.4 Shutting off

3.4.1 Mech. Stopping

3.4.2 Electr. Stopping

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperature, High Altitude

4.4.

Operating MediaOperating Media

Operating Media

4.4.

Operating MediaOperating Media

4.1 Lube Oil

4.1.1 Quality

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality

4.2.2 Winter Fuel

4.3 Coolant

4.3.1 Water Quality for Coolant

4.3.2 Coolant Treatment

4.3.3 Cooling System Protectants

5.5.

Routine MaintenanceRoutine Maintenance

Routine Maintenance

5.5.

Routine MaintenanceRoutine Maintenance

5.1 Maintenance Plan

5.2 Maintenance Diagram

5.3 Maintenance Work Completed

6.6.

Service and MaintenanceService and Maintenance

Service and Maintenance

6.6.

Service and MaintenanceService and Maintenance

6.1 Lubrication System

6.1.1 Oil Change Intervals

6.1.2 Check Oil Level, Change Engine Oil

6.1.3 Replace Oil Filter

6.1.4 Clean/Replace Oil Filter (Cup)

6.2 Fuel System

6.2.1 Replace Fuel Filter

6.2.2 Fuel Pre-filter, Clean Filter Element / Replace if Necessary

6.2.3 Bleed Fuel System

with Fuel Pre-filter

6.2.4 Bleed Fuel System

without Fuel Pre-filter

6.3 Cooling System

6.3.1 Cleaning Intervals

6.3.2 Clean Cooling System

6.3.3 Drain Cooling System

6.3.4 Fill / Bleed Cooling System

6.4 Combustion Air Filter

6.4.1 Cleaning Intervals

6.4.2 Emptying Cyclone Type Precleaner

6.4.3 Clean Oil Bath Air Filter

6.4.4 Dry Type Air Cleaner

6.5 Belt Drives

6.5.1 Check V-belts

– 2012 Standard – 2012 with Ribbed V-belt

Page 6

IndexIndex

Index

IndexIndex

6.5.2 Tension V-belts Coolant / Fuel Pump

6.5.3 Replace V-belts Coolant / Fuel Pump

6.5.4 Replace V-belts Ribbed V-belts

6.5.5 Tension Alternator V-belts

6.5.6 Replace Alternator V-belts

6.5.7 Wedge rib V-belts wear limit examine

6.6 Adjustments

6.6.1 Check Valve Clearance (Adjust if Neces sary)

6.6.1.1 Valve Clearance Adjustment Plan

6.7 Accessories

6.7.1 Battery

6.7.2 Rotary Current Alternator

6.7.3 Transportation Shackles

7.7.

Faults, Causes and RemediesFaults, Causes and Remedies

Faults, Causes and Remedies

7.7.

Faults, Causes and RemediesFaults, Causes and Remedies

7.1 Fault Table

8.8.

Engine PreservationEngine Preservation

Engine Preservation

8.8.

Engine PreservationEngine Preservation

8.1 Preservation

9.9.

Technical SpecificationTechnical Specification

Technical Specification

9.9.

Technical SpecificationTechnical Specification

9.1 Engine Specifications and Settings

9.2 Screw Tightening Torques

9.3 Tools

10.10.

ServiceService

10.

Service

10.10.

ServiceService

Page 7

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.

DEUTZ original parts are asbestosfree.

Page 8

Page 9

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

2.1 Model2.1 Model

2.1 Model

2.1 Model2.1 Model

2.2 Engine Illustrations2.2 Engine Illustrations

2.2 Engine Illustrations

2.2 Engine Illustrations2.2 Engine Illustrations

2.3 Lube Oil Circuit Schematic2.3 Lube Oil Circuit Schematic

2.3 Lube Oil Circuit Schematic

2.3 Lube Oil Circuit Schematic2.3 Lube Oil Circuit Schematic

2.4 Fuel System2.4 Fuel System

2.4 Fuel System

2.4 Fuel System2.4 Fuel System

2.5 Coolant System2.5 Coolant System

2.5 Coolant System

2.5 Coolant System2.5 Coolant System

Page 10

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

2.1.12.1.1

Rating PlateRating Plate

2.1.1

Rating Plate

2.1.12.1.1

Rating PlateRating Plate

2.1.22.1.2

Position of the Rating PlatePosition of the Rating Plate

2.1.2

Position of the Rating Plate

2.1.22.1.2

Position of the Rating PlatePosition of the Rating Plate

2.1.32.1.3

Engine Serial NumberEngine Serial Number

2.1.3

Engine Serial Number

2.1.32.1.3

Engine Serial NumberEngine Serial Number

2.1 Model2.1 Model

2.1 Model

2.1 Model2.1 Model

The model the performance data are stamped on the rating plate.The model and engine serial number must be given when ordering parts.

A, the engine serial number

B and

The rating plate

C is attached to the crankcase.

The engine serial number is stamped on the crankcase (

arrowarrow

arrow) as well as the rating plate.

arrowarrow

Page 11

2.1 Model2.1 Model

2.1 Model

2.1 Model2.1 Model

2.1.42.1.4

Cylinder EnumerationCylinder Enumeration

2.1.4

Cylinder Enumeration

2.1.42.1.4

Cylinder EnumerationCylinder Enumeration

1 2 43

Cylinders are numbered consecutively, beginning at the flywheel.

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

Page 12

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

2.2.12.2.1

Operating Side 2012Operating Side 2012

2.2.1

Operating Side 2012

2.2.12.2.1

Operating Side 2012Operating Side 2012 Ribbed V-belt driveRibbed V-belt drive

Ribbed V-belt drive

Ribbed V-belt driveRibbed V-belt drive

1 2 3

2.2 Engine Illustration2.2 Engine Illustration

2.2 Engine Illustration

2.2 Engine Illustration2.2 Engine Illustration

1 Alternator 2 Oil filler 3 Coolant connection compensation line 4 Fan pulley 5 Fuel pump 6 Coolant pump

7 Ribbed V-belt pulley on crankshaft 8Tension roller

9 Feet 10 Oil pan 11 Oil filler neck 12 Oil filter housing with engine oil cooler 13 Oil dipstick 14 Optional attachment of:

Compressor or hydraulic pump 15 Fuel filter cartridge 16 Oil filter cartridge 17 Tractive electromagnet

89101112

Page 13

2.2 Engine Illustration2.2 Engine Illustration

2.2 Engine Illustration

2.2 Engine Illustration2.2 Engine Illustration

2.2.22.2.2

Starter Side 2012Starter Side 2012

2.2.2

Starter Side 2012

2.2.22.2.2

Starter Side 2012Starter Side 2012 Ribbed V-belt driveRibbed V-belt drive

Ribbed V-belt drive

Ribbed V-belt driveRibbed V-belt drive

18 19

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

18 Turbocharger 19 Engine suspension 20 Speed regulator 21 Flywheel 22 SAE housing 23 Starter 24 Exhaust manifold 25 Coolant inlet 26 Heater flange not shown 27 Thermostat housing coolant outlet

2223

Page 14

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

2.2.32.2.3

Operating Side 2012Operating Side 2012

2.2.3

Operating Side 2012

2.2.32.2.3

Operating Side 2012Operating Side 2012

2.2 Engine Illustration2.2 Engine Illustration

2.2 Engine Illustration

2.2 Engine Illustration2.2 Engine Illustration

1Turbocharger 2 Heater flange

114

3 Fan 4 Alternator 5V-belt pulley on crankshaft 6 Coolant pump 7 Fuel pump 8 Oil filler

9 Oil filter housing with engine oil cooler 10 Oil filter housing with oil filter cartridge 11 Oil dipstick 12 Fuel filter 13 Tractive electromagnet 14 Oil filler neck

5678

Page 15

2.2 Engine Illustration2.2 Engine Illustration

2.2 Engine Illustration

2.2 Engine Illustration2.2 Engine Illustration

2.2.42.2.4

Starter Side 2012Starter Side 2012

2.2.4

Starter Side 2012

2.2.42.2.4

Starter Side 2012Starter Side 2012

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

15 Engine suspension 16 Speed regulator 17 Flywheel 18 SAE housing 19 Oil pan 20 Starter 21 Feet 22 Alternator 23 Coolant inlet 24 Exhaust manifold 25 Coolant outlet

181920

Page 16

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

2.3.12.3.1

Lube Oil PlanLube Oil Plan

2.3.1

Lube Oil Plan

2.3.12.3.1

Lube Oil PlanLube Oil Plan

2.3 Lube Oil Circuit Schematic2.3 Lube Oil Circuit Schematic

2.3 Lube Oil Circuit Schematic

2.3 Lube Oil Circuit Schematic2.3 Lube Oil Circuit Schematic

1 Oil pan

2 Intake line

3 Lube oil pump

4 Lube oil cooler

4.1 Heat exchanger bypass valve

4.2 Shut-off valve

4.3 Lube oil replacement filter

4.4 Oil pressure sensor 5 Main oil pipe 6 Crankshaft bearing 7 Con-rod bearing 8 Camshaft bearing 9 Line to spray nozzle

10 Spray nozzle for piston cooling 11 Valve lifter with rocker arm impulse lubrica-

tion 12 Stop rod, oil supply for rocker arm lubrication 13 Rocker arm 14 Return line to oil pan 15 Oil line to turbocharger 16 Turbocharger 17 Oil line to compressor or hydraulic pump 18 Compressor 19 Hydraulic pump 20 Return line from compressor or hydraulic

pump 21 Line to the differential (2x) 22 Balancer shafts 23 Turbocharger return to crankcase

Page 17

2.4 Fuel System2.4 Fuel System

2.4 Fuel System

2.4 Fuel System2.4 Fuel System

2.4.12.4.1

Fuel System PlanFuel System Plan

2.4.1

Fuel System Plan

2.4.12.4.1

Fuel System PlanFuel System Plan

98 7

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

1 Fuel tank 2 Line to fuel pump 3 Fuel pump 4 Line to fuel filter 5 Fuel filter 6 Line to the injection pumps 7 Injection pump 8 Line to injection valve

9 Injection valve 10 Banjo bolt with pressure maintenance valve 11 Return line to fuel filter housing from

pressure maintenance valve

(with cup filter installation only) 12 Return line to fuel tank 13 Maintain maximum possible distance

2 4 3 6

Page 18

Engine DescriptionEngine Description

Engine Description

Engine DescriptionEngine Description

2.5.12.5.1

Coolant block diagram 2012Coolant block diagram 2012

2.5.1

Coolant block diagram 2012

2.5.12.5.1

Coolant block diagram 2012Coolant block diagram 2012 Example: With cup filterExample: With cup filter

Example: With cup filter

Example: With cup filterExample: With cup filter

2.5 Coolant System2.5 Coolant System

2.5 Coolant System

2.5 Coolant System2.5 Coolant System

1. Thermostat housing

2. Outlet neck cover

3. Coolant pump

4. Lube oil cooler

5. Cylinder cooling

6. Cylinder head cooling

7. Line from engine to heat exchanger

8. Heat exchanger

9. Line from heat exchanger to thermostat

10. Ventilation line to the compensation tank

11. Compensation tank

12. Coolant compensation line

13. Coolant return from heater

14. Coolant supply to heating at V-belts

15. Coolant supply to heating at ribbed V-belts

Page 19

3.13.1

CommissioningCommissioning

3.1

Commissioning

3.13.1

CommissioningCommissioning

3.23.2

StartingStarting

3.2

Starting

3.23.2

StartingStarting

3.33.3

Monitoring OperationMonitoring Operation

3.3

Monitoring Operation

3.33.3

Monitoring OperationMonitoring Operation

3.43.4

Shutting offShutting off

3.4

Shutting off

3.43.4

Shutting offShutting off

3.53.5

Operating ConditionsOperating Conditions

3.5

Operating Conditions

3.53.5

Operating ConditionsOperating Conditions

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

Page 20

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

3.1.13.1.1

Pour in Engine OilPour in Engine Oil

3.1.1

Pour in Engine Oil

3.1.13.1.1

Pour in Engine OilPour in Engine Oil

OIL

Oil Bath Air Filter withOil Bath Air Filter with

3.1.23.1.2

3.1.2

Oil Bath Air Filter with

3.1.23.1.2

Oil Bath Air Filter withOil Bath Air Filter with Engine OilEngine Oil

Engine Oil

Engine OilEngine Oil

FUEL

3.1 Commissioning3.1 Commissioning

3.1 Commissioning

3.1 Commissioning3.1 Commissioning

As a rule, engines are delivered without oil. Pour lube oil into the oil filler neck (arrow). Oil capacity, see 9.1. For oil grade and viscosity, see 4.1.

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

Never fill the fuel tank while the engine is running. Ensure cleanliness! Do not spill fuel!

Page 21

3.1 Commissioning3.1 Commissioning

3.1 Commissioning

3.1 Commissioning3.1 Commissioning

3.1.33.1.3

Fill / Bleed Cooling SystemFill / Bleed Cooling System

3.1.3

Fill / Bleed Cooling System

3.1.33.1.3

Fill / Bleed Cooling SystemFill / Bleed Cooling System

3.1.43.1.4

Other PreparationsOther Preparations

3.1.4

Other Preparations

3.1.43.1.4

Other PreparationsOther Preparations

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

● 2012: In accordance with the radiator suppli-

er’s specifications

● Unit engine: In accordance with the radiator

supplier’s specifications

● Check battery and cable connections, see

6.7.1.

Trial runTrial run

●

Trial run

Trial runTrial run

- After the engine has been prepared, carry out a brief trial run for approx. 10 minutes, without load if possible.

During and after the trial runDuring and after the trial run

During and after the trial run

During and after the trial runDuring and after the trial run

- Check the engine for leaks.

After the engine has been turned offAfter the engine has been turned off

After the engine has been turned off

After the engine has been turned offAfter the engine has been turned off

- Check oil level and top up if necessary,

see 6.1.2.

- Retension V-belts, see 6.5.

Breaking inBreaking in

●

Breaking in

Breaking inBreaking in During the break-in phase - about 200 operating hours - check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.

In the event of commissioning enginesIn the event of commissioning engines

●

In the event of commissioning engines

In the event of commissioning enginesIn the event of commissioning engines which have been preservedwhich have been preserved

which have been preserved

which have been preservedwhich have been preserved Carry out removal of preservation in accordance with Chapter 8.1.

Page 22

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

3.2.13.2.1

Electric StartingElectric Starting

3.2.1

Electric Starting

3.2.13.2.1

Electric StartingElectric Starting

Before starting, make sure that nobody is standing in the im-

been replaced and that all tools have been removed from the engine. When starting with glow plugs, do not use any other starter substance (e.g. injection with start pilot). Risk of accident! Caution: If the speed regulator has beenCaution: If the speed regulator has been

Caution: If the speed regulator has been

Caution: If the speed regulator has beenCaution: If the speed regulator has been removed, the engine must not be startedremoved, the engine must not be started

removed, the engine must not be started

removed, the engine must not be startedremoved, the engine must not be started under any circumstances.under any circumstances.

under any circumstances.

under any circumstances.under any circumstances. Disconnect the battery!Disconnect the battery!

Disconnect the battery!

Disconnect the battery!Disconnect the battery!

mediate vicinity of the engine or driven machine. After repair work: Check that all guards have

3.2 Starting3.2 Starting

3.2 Starting

3.2 Starting3.2 Starting

without cold start assistancewithout cold start assistance

without cold start assistance

without cold start assistancewithout cold start assistance

Do not actuate the starter for more than 20 seconds. If the engine does not catch, wait for one minute then try again. If the engine does not catch after two attempts, refer to the Fault Table (see 7.1).

● Disengage the clutch to separate the en-

gine from any driven parts.

● Bring speed adjustment lever 1 into at least

the middle speed position in the direction of the arrow.

● Move cut-out handle 2 into operating posi-

tion counter to the direction of the arrow.

● Insert key

- Position 0 = no operating voltage.

● Turn key clockwise

- Position 1 = operating voltage

- Pilot lights 1 and 2 illuminate.

● Push key in and turn further clockwise

against spring pressure.

- Position 2 = no function

- Position 3 = start

● Release key as soon as engine fires

- The pilot lights will go out.

Page 23

3.2 Starting3.2 Starting

3.2 Starting

3.2 Starting3.2 Starting

with cold start assistancewith cold start assistance

with cold start assistance

with cold start assistancewith cold start assistance Heater flangeHeater flange

Heater flange

Heater flangeHeater flange

● Insert key

- Position 0 = no operating voltage.

● Turn key clockwise

- Position 1 = operating voltage.

- Pilot lights illuminate, pre-glowing until glow indicator is extinguished.

● Push key in and turn further clockwise

against spring pressure.

- Position 2 = no function

- Position 3 = start

● Release key as soon as engine fires.

Page 24

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

3.3.13.3.1

Engine Oil PressureEngine Oil Pressure

3.3.1

Engine Oil Pressure

3.3.13.3.1

Engine Oil PressureEngine Oil Pressure

Oil pressure lampOil pressure lamp

Oil pressure lamp

Oil pressure lampOil pressure lamp

Oil Pressure IndicatorOil Pressure Indicator

Oil Pressure Indicator

Oil Pressure IndicatorOil Pressure Indicator

3.3 Monitoring Operation3.3 Monitoring Operation

3.3 Monitoring Operation

3.3 Monitoring Operation3.3 Monitoring Operation

Oil Pressure GaugeOil Pressure Gauge

Oil Pressure Gauge

Oil Pressure GaugeOil Pressure Gauge

● The oil pressure pilot light comes on with

operating voltage on and engine off.

● The oil pressure pilot light must be extin-

guished when the engine is running.

● The pointer must remain in the green sector

over the entire operating range.

● The pointer of the oil pressure gauge must

display the minimum oil pressure (see 9.1)

Page 25

3.3 Monitoring Operation3.3 Monitoring Operation

3.3 Monitoring Operation

3.3 Monitoring Operation3.3 Monitoring Operation

3.3.23.3.2

Coolant temperatureCoolant temperature

3.3.2

Coolant temperature

3.3.23.3.2

Coolant temperatureCoolant temperature

● The engine temperature gauge pointer

should always remain in the green sector. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn off and establish the cause from the Fault Table (see 7.1).

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

Page 26

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

3.4.1 Mechanical Stopping3.4.1 Mechanical Stopping

3.4.1 Mechanical Stopping

3.4.1 Mechanical Stopping3.4.1 Mechanical Stopping

3.4.23.4.2

Electrical StoppingElectrical Stopping

3.4.2

Electrical Stopping

3.4.23.4.2

Electrical StoppingElectrical Stopping

3.4 Shutting Off3.4 Shutting Off

3.4 Shutting Off

3.4 Shutting Off3.4 Shutting Off

● Move speed adjustment lever 1 to low idle.

● Move shut-off lever 2 until the engine comes

to a stop. The charge pilot light and the oil pressure pilot light illuminate when the engine stops.

● Turn key counterclockwise (to position 0)

and remove. The pilot lights will go out.

If possible, do not switch off the engine when under full load. Subsequently allow the engine to idle for approx. 2 mins.

● Turn key counterclockwise (to position 0)

and remove. The pilot lights will go out.

Page 27

3.5 Operating Conditions3.5 Operating Conditions

3.5 Operating Conditions

3.5 Operating Conditions3.5 Operating Conditions

3.5.13.5.1

Winter OperationWinter Operation

3.5.1

Winter Operation

3.5.13.5.1

Winter OperationWinter Operation

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

● Lube Oil Viscosity

- Select the oil viscosity (SAE grade) according to the ambient temperature before starting the engine, see 4.1.2.

- Increase oil change frequency when operat-

ing below -10 °C, see 6.1.1.

● Diesel Fuel

- Use winter-grade diesel fuel for operation

below 0 °C, see 4.2.2.

● Coolant

- Mixture ratio of anti-freeze / water for mini-

mum temperature (max. -35 °C),

see 4.3.1.

● Additional Maintenance Work

- Drain the sludge from the fuel tank once a

week (undo the sludge drain screw).

- If necessary, adjust oilbath filter oil level,

like the engine oil, to the ambient temperture.

- 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 cold-resistant grease. (e.g. Bosch grease FT 1 V 31).

● Cold Start Assistance

- The heater flange is automatically initialised at

temperatures < -25 °C.

● Battery

-Efficient cold starting necessitates that the battery is well-charged, see 6.7.1.

-The starting limit temperatures can be low-

ered 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).

Page 28

Engine OperationEngine Operation

Engine Operation

Engine OperationEngine Operation

3.5.23.5.2

High Ambient TemperatureHigh Ambient Temperature

3.5.2

High Ambient Temperature

3.5.23.5.2

High Ambient TemperatureHigh Ambient Temperature High AltitudeHigh Altitude

High Altitude

High AltitudeHigh Altitude

● Air density decreases as altitude or ambi-

ent temperature increase. As a result of this, the engine’s maximum output, the quality of the exhaust gas, the temperature level and, in extreme cases, starting behaviour, are impeded. In the event of non-stationary operation, use up to altitudes of 1000 m and tempera-

tures of 30 °C is permissible.

If the engine is to operate under unfavourable conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and thus, engine power.

C F

0 32

3.5 Operating Conditions3.5 Operating Conditions

3.5 Operating Conditions

3.5 Operating Conditions3.5 Operating Conditions

● If you have any doubts about engine opera-

tion 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 your service representative.

Page 29

4.1 Lube Oil4.1 Lube Oil

4.1 Lube Oil

4.1 Lube Oil4.1 Lube Oil

4.2 Fuel4.2 Fuel

4.2 Fuel

4.2 Fuel4.2 Fuel

4.3 Coolant4.3 Coolant

4.3 Coolant

4.3 Coolant4.3 Coolant

Operating MediaOperating Media

Operating Media

Operating MediaOperating Media

Page 30

Operating MediaOperating Media

Operating Media

Operating MediaOperating Media

4.1.14.1.1

Quality GradeQuality Grade

4.1.1

Quality Grade

4.1.14.1.1

Quality GradeQuality Grade

4.1.24.1.2

4.1.2

4.1.24.1.2

ViscosityViscosity

Viscosity

ViscosityViscosity

4.1 Lube Oil4.1 Lube Oil

4.1 Lube Oil

4.1 Lube Oil4.1 Lube Oil

Lube oils are differentiated by to their performance and quality class. Oils of other, comparable specifications can be used.

Approved oils:Approved oils:

Approved oils:

Approved oils:Approved oils:

DeutzDeutz

Deutz DQC I DQC II DQC III

DeutzDeutz

ACEAACEA

ACEA E2-96 E3/96/E5-02 E4-99

ACEAACEA

APIAPI

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

APIAPI

DHDDHD

DHD - DHD-1 -

DHDDHD

The precise assignment of the admissible oil qualities to the engines is indicated in chapter 6.1.1. If in doubt, contact your service representative.

Deutz Deutz

Deutz according

Deutz Deutz

Generally, multi-grade oils shall be used. In

closed heated rooms at temperatures >5°C,

also single-grade oils can be used.

As the viscosity of 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 the 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.

Synthetic lube oils feature an improved temperature and oxidation stability.

Only with preheating

30 298 1

Page 31

4.1 Lube Oil 4.1 Lube Oil

4.1 Lube Oil

4.1 Lube Oil 4.1 Lube Oil

4.1.2.14.1.2.1

Specific lube oilSpecific lube oil

4.1.2.1

Specific lube oil

4.1.2.14.1.2.1

Specific lube oilSpecific lube oil definitionsdefinitions

definitions

definitionsdefinitions

Turbocharged engines with uprated power and engines with high loading The oils listed in enclosure 1 are to be used for the following engines and applications: COM/EPA II version and increased output BF4M 2012/C > 95 kW BF6M 2012/C > 143 kW (bore 101 + 98-MVS) BF6M 2012/C > 135 kW (bore 98 mech. FIE)

 all engines in CHP plants  all engines in gensets operating in parallel with

the mains/with each other  engines in combines with: These are high-grade oils according to ACEA or API. In addition most of these oils are partly synthetic, some even fully synthetic (5W-40) and thus achieve the thermal stability required for the relevant application and are distinguished by a low tendency to cause deposits in the turbocharger and in the charge air pipes with closed-circuit crankcase breather

Operating Media Operating Media

Operating Media

Operating Media Operating Media

Lube oils for engines with uprated power and engines with high loadingLube oils for engines with uprated power and engines with high loading

Lube oils for engines with uprated power and engines with high loading

Lube oils for engines with uprated power and engines with high loadingLube oils for engines with uprated power and engines with high loading

ProducerProducer

Producer

ProducerProducer DEUTZDEUTZ

DEUTZ

DEUTZDEUTZ

AGIP Agip Sigma Ultra TFE 10W-40 worldwide AGIP Autol Valve Ultra FE 10W-40 Germany ARAL GmbH Aral MegaTurboral 10W-40 worldwide ARAL GmbH Aral SuperTurboral 5W-30 worldwide BAYWA BayWa Super Truck 1040 MC 10W-40 South Gemany BAYWA BayWa Turbo 4000 10W-40 South Gemany Castrol GmbH Castrol SYNTRUCK 5W-40 Europe, North America, Brazil

Castrol GmbH Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil

CHEVRON Chevron Delo 400 Synthtic 5W-40 North America ESSO Essolube XTS 501 10W-40 Europe FINA FINA KAPPA FIRST 5W-30 Europe FINA FINA KAPPA ULTRA 10W-40 Europe FUCHS DEA DEA Cronos Synth 5W-40 Germany, Europe FUCHS DEA DEA Cronos Premium LD 10W-40 Germany, Europe FUCHS DEA Fuchs Titan Cargo MC 10W-40 worldwide FUCHS DEA Deutz Oel TLL 10W-40 MB 10W-40 Germany FUCHS DEA DEA Cronos Premium FX 10W-40 Europe FUCHS DEA Fuchs Titan Unic Plus MC 10W-40 worldwide MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, Africa MOBIL OIL Mobil Delvac 1 5W-40 worldwide MOBIL OIL Mobil Delvac XHP Extra 10W-40 Europe, SE Asia BP OIL International BP Vanellus HT Extra 10W-40 Europe Shell International Shell Myrina TX / 5W-30 Europe, different

Shell International Shell Myrina TX / 10W-40 Europe, different

TOTAL TOTAL RUBIA TIR 86000 10W-40 worldwide Schmierölraffinerie Wintershall TFG 10W-40 Europe Salzbergen GmbH The table will be extended as and when required.

Type of lube oilType of lube oil

Type of lube oil

Type of lube oilType of lube oil TXL-10W40 FETXL-10W40 FE

TXL-10W40 FE

TXL-10W40 FETXL-10W40 FE

Shell Rimula Ultra description in some countries

SAE classSAE class

SAE class

SAE classSAE class

10W-4010W-40

10W-40

10W-4010W-40

AvailabilityAvailability

Availability

AvailabilityAvailability

Argentina, Australia, South Africa

Page 32

Operating MediaOperating Media

Operating Media

Operating MediaOperating Media

4.2.14.2.1

QualityQuality

4.2.1

Quality

4.2.14.2.1

QualityQuality

4.2.24.2.2

4.2.2

4.2.24.2.2

Winter FuelWinter Fuel

Winter Fuel

Winter FuelWinter Fuel

4.2 Fuel4.2 Fuel

4.2 Fuel

4.2 Fuel4.2 Fuel

Use commercially available diesel fuel with less than 0.5 % sulphur content. If the sulphur content is higher, 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

Exhaust emission values which may be determined in the case of 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. Use winter-grade diesel fuel (up to

-20 °C) for operation below 0 °C. This is made

available within good time by filling stations prior to the start of the winter season.

 Kerosene must be added at temperatures

below -20 °C. The relevant percentages

are given in the adjacent diagram.

 Special diesel fuels may be used in arctic

climatic zones up to -44 °C.

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 ask your DEUTZ partner.

Diesel fuels must never be mixed with gasoline (Normal and Super grades)!

+32

+23

- 5

+14

- 10

+ 5

- 15

- 20

- 4

- 25

- 13

- 22

- 30

°F

°C

Legend:

I Summer-grade diesel fuel

II Winter-grade diesel fuel

A Ambient temperature

B Percentage of kerosen added

0102030405060 %

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

Page 33

4.3 Coolant 4.3 Coolant

4.3 Coolant

4.3 Coolant 4.3 Coolant

4.3.14.3.1

Quality of Water forQuality of Water for

4.3.1

Quality of Water for

4.3.14.3.1

Quality of Water forQuality of Water for

CoolantCoolant

Coolant

CoolantCoolant

4.3.24.3.2

Coolant TreatmentCoolant Treatment

4.3.2

Coolant Treatment

4.3.24.3.2

Coolant TreatmentCoolant Treatment

Operating MediaOperating Media

Operating Media

Operating MediaOperating Media

4.3.34.3.3

Cooling SystemCooling System

4.3.3

Cooling System

4.3.34.3.3

Cooling SystemCooling System

ProtectantsProtectants

Protectants

ProtectantsProtectants

The values listed below must not be exceeded. In order to examine the quality of your water, a test case can be ordered from DEUTZ under Order No. 12130382.

Water quality min. max. pH value at 20 °C 6.5 8.5

Chloride ion content [mg / dm3]

Sulphate ion content [mg / dm3] Total hardness [°dGH] 3 20

- 100

In the case of liquid-cooled engines, special attention must be paid to the treatment and control of the coolant, as the engine may otherwise become damaged as a result of corrosion, cavitation and freezing. The treatment of the coolant is carried out by adding a cooling system protectant to the cooling water. The cooling system must be continuously monitored, see 5.1. In addition to checking the coolant level, this also involves checking the concentration of the cooling system protectant. The cooling system protectant concentration can be checked with commercially available testers (example: gefo glycomat ®).

If nitrite-based cooling system protectants are mixed with

amine-based agents, dangerous nitrosamines are formed.

DEUTZ cooling system protectant must be purchased in drums under Order No. 01011490 (5 litres) or 1221 1500 (210 litres). These are nitrite, amine and phosphate-free, and provide effective protection against corrosion, cavitation and freezing. If the above mentioned cooling system protectant is unavailable, the following products may be used in exceptional cases.

Manufacturer Product designation

AVIA AVIA Antifreeze Extra ARAL Antifreeze Extra BASF Glysantin G 48

DEA DEA Radiator Antifreeze

SHELL SHELLGlycoShell

The cooling system protectant in the coolant should not fall below or exceed the following concentration:

Cooling system protectant Water

max. 45 Vol.% 55% min. 35 Vol.% 65%

Filling volume, see chart over page in combination with specifications in Chapter 9.1. The use of other cooling system protectants, e.g. chemical anti-corrosion agents, is possible in exceptional cases. Consult DEUTZ Service.

Cooling system protectants must be disposed of in an environmen-

tally-friendly manner.

Page 34

Operating Media Operating Media

Operating Media

Operating Media Operating Media

4.3 Coolant4.3 Coolant

4.3 Coolant

4.3 Coolant4.3 Coolant

CoolingCooling

Cooling

CoolingCooling

systemsystem

system

systemsystem

protectionprotection

protection

protectionprotection

inin

35 –22 6,3 7,0 7,7 8,75 9,5 10,5 11,2 12,3

40 –28 7,2 8,0 8,8 10 10,8 12 12,8 14

45 –35 8,1 9,0 9,9 11,3 12,2 13,5 14,4 15,8

50 –45 9,0 10 11 12,5 13,5 15 16 17,5

*) For coolant content of your engine, see Operation Manual Chapter 9.1.

Note: Grey sector only after consulting head office

FrostFrost

Frost

FrostFrost

protectionprotection

protection

protectionprotection

[ [

[

[ [

Cooling system protection Cooling system protection

Cooling system protection

Cooling system protection Cooling system protection

content of coolant systemcontent of coolant system

content of coolant system

content of coolant systemcontent of coolant system

inin

C]C]

18 20 22 25 27 30 32 35

Cooling system protectantCooling system protectant

Cooling system protectant

Cooling system protectantCooling system protectant

[Litres][Litres]

[Litres]

[Litres][Litres]

*) *)

Page 35

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

5.1 Maintenance Schedule5.1 Maintenance Schedule

5.1 Maintenance Schedule

5.1 Maintenance Schedule5.1 Maintenance Schedule

5.2 Maintenance Chart5.2 Maintenance Chart

5.2 Maintenance Chart

5.2 Maintenance Chart5.2 Maintenance Chart

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

5.3 Maintenance Work Completed

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

Page 36

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

5.1 Maintenance Schedule5.1 Maintenance Schedule

5.1 Maintenance Schedule

5.1 Maintenance Schedule5.1 Maintenance Schedule

check= ● adjust= ❍ clean= ▲ replace= ■

⇓

prior to or during 1st trial run, check 2x daily during the breaking in phase or

when commissioning new and overhauled engines

⇓

every 10 hours of operation or daily

Operating hours (OP) every

Years

250 500 1000

●●

■

●▲■

●● ■

●●

●● ■

●●▲

●●

●●■

* When the warning system responds (lamp/horn), the fuel pre-filter must be emptied immediately

1500 12000

■

●■

●

❍

■

Operation

Top lube oil up if necessary 6.1.2/3.3.4 Lube oil (oil change intervals depending on engine use), see TR 0199-99-3002 6.1.1/ 6.1.2 Oil filter cartridge (at each lube oil change) 6.1.3 Fuel filter cartridge 6.2.1 Flexible fuel leak oil lines (replace completely) Injection valve Fuel pre-cleaner/ filter element (cleaning or replace if necessary) 4.2/ 5.2 Coolant (additive concentration) 4.3.1/ 2/ 3 Coolant pump Coolant level – Intake air cleaner (If available, maintain according to maintenance indicator) 6.4.3 /6.4.4 Intercooler (drain lube oil/condensation) Battery and cable connectors 6.7.1 Engine monitoring system, warning system 3.3 Valve clearance 6.6.1 V-belts (retension or replace if necessary) 6.5.1

Industrial engines

The specified engine maintenance values are permissible recommended maximums. Depending on usage, reduced maintenance intervals may be necessary, comply with the unit manufacturer’s operating instructions. # Maintenance must only be carried out by authorised service personnel

Section

Page 37

5.1 Maintenance Schedule5.1 Maintenance Schedule

5.1 Maintenance Schedule

5.1 Maintenance Schedule5.1 Maintenance Schedule

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

check= ● adjust= ❍ clean= ▲ replace= ■

prior to or during 1st trial run, check 2x daily during the breaking in phase or when commissioning new and overhauled engines

every 10 hours of operation or daily

In hours of operation (HO) every

Years

250 500 1000

●●

Page 2 of 2Page 2 of 2

Page 2 of 2

Page 2 of 2Page 2 of 2

check= ● adjust= ❍ clean= ▲ replace= ■

Max. permissible reference times in operating hours (HO) every

prior to or during 1st trial run, check 2x daily during the breaking in phase or when commissioning new and overhauled engines

every 10 hours of operation or daily

In hours of operation (HO) every

250 500 1000

1500 12000

■

3000 6000

■

Years

12000

Operation

Check engine for leaks (visual inspection) – Engine suspension (replace if damaged) 9.2 Fastenings, hose connections / clamps Basic overhaul

Operation

Injection valve

Industrial engines

Additions and modifications

for engines with EPA approval

The specified engine maintenance values arepermissible recommended maximums. Depending on usage, reduced maintenance intervals may be necessary, comply with the unit manufacturer’s operating instructions.

# Maintenance must only be carried out by authorised service personnel

Section

– #

Section

Page 38

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

The maintenance chart shown on this page is

supplied as a self-adhesive label with each

engine. It should be affixed where it 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.

5.2 Maintenance Chart5.2 Maintenance Chart

5.2 Maintenance Chart

5.2 Maintenance Chart5.2 Maintenance Chart

1252000

in.

ex.

FUEL

1500

1000

Std.

500

OIL

WATER

OIL

max.

2012

0297 9901

Stop the engine before carrying out any maintenance work.

Page 39

5.2 Maintenance Chart5.2 Maintenance Chart

5.2 Maintenance Chart

5.2 Maintenance Chart5.2 Maintenance Chart

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

The maintenance chart shown on this page is supplied as a self-adhesive label with each engine. It should be affixed where it 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.

ax.

2012

0297 9902 0

9912EN_K05-1.P65 17.02.2003, 12:05 Uhr37

Page 40

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

5.3 Maintenance Work Completed

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

Op. hours

50-150

125

375

625

875

1125

1375

1625

1875

2115

2375

2625

* following commissioning of new and overhauled engines.

Duly completed maintenance jobs can be recorded and signed off in the above chart.

Date Signature/stamp

Op. hours Signature/stamp

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

Date

Page 41

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

5.3 Maintenance Work Completed

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

Op. hours

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

Date

Signature/stamp Op. hours Date

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

Signature/stamp

Duly completed maintenance jobs can be recorded and signed off in the above chart.

Page 42

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

5.3 Maintenance Work Completed

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

Op. hours

5875

6125

6375

6625

6875

7125

7375

7625

7825

8125

8375

8625

Duly completed maintenance jobs can be recorded and signed off in the above chart.

Date Signature/stamp

Op. hours Signature/stamp

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

Date

Page 43

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

5.3 Maintenance Work Completed

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

Op. hours

8875

9125

9375

9625

9875

10125

10375

10625

10825

11125

11375

11625

Duly completed maintenance jobs can be recorded and signed off in the above chart.

Date

Signature/stamp Op. hours Date

9000

9250

9500

9750

10000

10250

10500

10750

11000

11250

11500

11750

Signature/stamp

Page 44

Routine MaintenanceRoutine Maintenance

Routine Maintenance

Routine MaintenanceRoutine Maintenance

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

5.3 Maintenance Work Completed

5.3 Maintenance Work Completed5.3 Maintenance Work Completed

Op. hours

Date Signature/stamp

Op. hours Signature/stamp

Date

Page 45

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.1 Lubrication System6.1 Lubrication System

6.1 Lubrication System

6.1 Lubrication System6.1 Lubrication System

6.2 Fuel System6.2 Fuel System

6.2 Fuel System

6.2 Fuel System6.2 Fuel System

6.3 Cooling System6.3 Cooling System

6.3 Cooling System

6.3 Cooling System6.3 Cooling System

6.4 Combustion Air Filter6.4 Combustion Air Filter

6.4 Combustion Air Filter

6.4 Combustion Air Filter6.4 Combustion Air Filter

6.5 Belt Drives6.5 Belt Drives

6.5 Belt Drives

6.5 Belt Drives6.5 Belt Drives

6.6 Adjustments6.6 Adjustments

6.6 Adjustments

6.6 Adjustments6.6 Adjustments

6.7 Accessories6.7 Accessories

6.7 Accessories

6.7 Accessories6.7 Accessories

Page 46

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: sulfur content max. 0.5

% by weight.

– Continuous ambient temperatures down

to -10 °C / +14°F

● For fuels – with sulfur content is > 0.5 to 1 % or – continuous ambient temperature below

-10 °C/+14°F or – with bio-diesel fuels in accordance with

DIN 51606-FAME the intervals between oil changes should be halved.

● In the case of fuels containing more than

1 % sulfur, contact your service repre- sentative.

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

● If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table

6.1.1.1. equipment engines.

ENGLISCH • Kapitel 6 • Seite 52

9682en_K06.p65 30.07.2003, 10:1352

Page 47

6.1 Lubrication System6.1 Lubrication System

6.1 Lubrication System

6.1 Lubrication System6.1 Lubrication System

6.1.1.2 Lube oil change intervals for industrial and marine engines6.1.1.2 Lube oil change intervals for industrial and marine engines

6.1.1.2 Lube oil change intervals for industrial and marine engines

6.1.1.2 Lube oil change intervals for industrial and marine engines6.1.1.2 Lube oil change intervals for industrial and marine engines

Deutz lube oil quality classDeutz lube oil quality class

Deutz lube oil quality class

Deutz lube oil quality classDeutz lube oil quality class

ACEA-specficationACEA-specfication

ACEA-specfication E2-96 E3-96/E5-02 E4-99

ACEA-specficationACEA-specfication

API-specificationAPI-specification

API-specification CF/CF-4 CG-4/CH-4 -

API-specificationAPI-specification

Worldwide specificationWorldwide specification

Worldwide specification

Worldwide specificationWorldwide specification

special DEUTZ release listspecial DEUTZ release list

special DEUTZ release list

special DEUTZ release listspecial DEUTZ release list

Standard lube oil code for buildingStandard lube oil code for building

Standard lube oil code for building

Standard lube oil code for buildingStandard lube oil code for building

equipment and nonraod vehiclesequipment and nonraod vehicles

equipment and nonraod vehicles

equipment and nonraod vehiclesequipment and nonraod vehicles

EO...A, EO...B

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

DQC IDQC I

DQC I

DQC IDQC I

- DHD-1 -

EO... EO...C -

Lube oil gradeLube oil grade

Lube oil grade

Lube oil gradeLube oil grade

DQC IIDQC II

DQC II

DQC IIDQC II

DQC IIIDQC III

DQC III

DQC IIIDQC III

Enclosure 1

EngineEngine

Engine

EngineEngine

seriesseries

series

seriesseries

20122012

2012

20122012

Engine versionEngine version

Engine version

Engine versionEngine version

All engines except for:

BF4M2012C P > 95 kW - - 500

BF6M2012C P > 143 kW,

at cylinder bore 101 mm or 98 mm with MV system

BF6M2012C P > 135 kW,

at cylinder bore 98 mm with mech. injection system

Other engines from nonroad stage II

eng. in harv. machines, block-typethermal power stat., gensets

from nonroad stage II

Lube oil change intervals in op. hoursLube oil change intervals in op. hours

Lube oil change intervals in op. hours

Lube oil change intervals in op. hoursLube oil change intervals in op. hours

Oil useOil use

Oil use

Oil useOil use

normalnormal

normal

normalnormal

highhigh

high

highhigh

250 500 500

--500

- 500 500

--500

*Gensets as referred to here are units operating in parallel with the mains / with each other.

Emergency power units are dealt with in TR 0199-99-1126.

Oil useOil use

Oil use

Oil useOil use

normalnormal

normal

normalnormal

highhigh

high

highhigh

Oil useOil use

Oil use

Oil useOil use

normalnormal

normal

normalnormal

highhigh

high

highhigh

Page 48

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.1.1.2 Oil change intervals for vehicle engines6.1.1.2 Oil change intervals for vehicle engines

6.1.1.2 Oil change intervals for vehicle engines

6.1.1.2 Oil change intervals for vehicle engines6.1.1.2 Oil change intervals for vehicle engines

Deutz lube oil quality classDeutz lube oil quality class

Deutz lube oil quality class

Deutz lube oil quality classDeutz lube oil quality class

ACEA specification

API specification

worldwide specification

special DEUTZ release

ApplicationApplication

Application

ApplicationApplication Site

vehicles/ busses

Local traffic

Long distance traffic

If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4.1. for “Oil use under normal duty” will apply.

Engine versionEngine version

Engine version

Engine versionEngine version

2525

20122012

2012 Euro I 10 000 15 000 20 000

2525

20122012

BF4M2012C > 95 kW BF6M2012C > 143 kW

4040

20122012

2012 Euro I 15 000 20 000 30 000

4040

20122012

BF4M2012C > 95 kW BF6M2012C > 143 kW

6060

20122012

2012 Euro I 20 000 30 000 40 000

6060

20122012

Average speed in km/h approx. ]

BF6M2012C > 143 kW

Euro II and Euro III,

bore 101 mm with or 98 mm with MV system > 135 kW from Euro II

with mechanical injection system

Euro II and Euro III,

bore 101 mm with or 98 mm with MV system > 135 kW from Euro II bore 98 mm with mechanical injection system

Euro II and Euro III,

bore 101 mm with or 98 mm with MV system > 135 kW from Euro II bore 98 mm with mechanical injection system

6.1 Lubrication System6.1 Lubrication System

6.1 Lubrication System

6.1 Lubrication System6.1 Lubrication System

Schmieröl-QualitätSchmieröl-Qualität

Schmieröl-Qualität

Schmieröl-QualitätSchmieröl-Qualität

DQC IDQC I

DQC I

DQC IDQC I

E2-96 E3-96/E5-02 E4-99

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

- DHD-1 -

Lube oil change intervals in kmLube oil change intervals in km

Lube oil change intervals in km

Lube oil change intervals in kmLube oil change intervals in km

from from

from

except for:

Euro II - - 20 000

Euro II

Euro II - - 30 000

Euro II

at cylinder

at cylinder bore 98 mm

except for:

at cylinder

except for:

at cylinder

- 15 000 20 000

--20 000

- 20 000 30 000

--30 000

- 30 000 40 000

--40 000

DQC IIDQC II

DQC II

DQC IIDQC II

DQC IIIDQC III

DQC III

DQC IIIDQC III

Enclosure 1

Page 49

6.1 Lubrication System6.1 Lubrication System

6.1 Lubrication System

6.1 Lubrication System6.1 Lubrication System

6.1.26.1.2

Check Oil Level / ChangeCheck Oil Level / Change

6.1.2

Check Oil Level / Change

6.1.26.1.2

Check Oil Level / ChangeCheck Oil Level / Change Engine OilEngine Oil

Engine Oil

Engine OilEngine Oil

6.1.2.16.1.2.1

Check Oil LevelCheck Oil Level

6.1.2.1

Check Oil Level

6.1.2.16.1.2.1

Check Oil LevelCheck Oil Level

6.1.2.26.1.2.2

Engine Oil Change Engine Oil Change

6.1.2.2

Engine Oil Change

6.1.2.26.1.2.2

Engine Oil Change Engine Oil Change

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

 Ensure that the engine or vehicle is in a level

position.

 Engine warm:

Shut engine off, wait for 5 minutes and check oil level.

 Engine cold:

Check oil level.

 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 level must not fall below the “MIN” mark.

 Run engine until warm.  Ensure that the engine or vehicle is in a level

position.

- Lube oil temperature approx. 80 °C.

 Switch off the engine.

 Place oil tray under the engine.  Unscrew oil drain screw.  Drain oil.  Screw oil drain screw in with new seal ring

and tighten. (Tightening torque see 9.2).

 Pour in lube oil.

- For grade / viscosity, see 4.1

- For quantity, see 9.1.

 Check oil level, see 6.1.2.1.

Caution when draining hot oil: Risk of scalding! Do not let used oil run into the soil but

collect it in a container! Dispose of this in accordance with environmental regulations!

Page 50

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.1.36.1.3

Replace Oil FilterReplace Oil Filter

6.1.3

Replace Oil Filter

6.1.36.1.3

Replace Oil FilterReplace Oil Filter

6.1 Lubrication System6.1 Lubrication System

6.1 Lubrication System

6.1 Lubrication System6.1 Lubrication System

● With attached locking piston:

Undo tensioning screws and remove tensioning clamps downwards.

● Undo the lube oil filter cartridge using a

commercial tool and spin off.

● Catch any escaping oil.

Caution is required in the case of hot oil:Risk of scalding!

● Clean any dirt from the filter carrier sealing

surface.

● Lightly oil the rubber gasket of the new lube

oil filter cartridge.

● Manually screw in the new cartridge until

the gasket is flush.

● Tighten the lube oil filter cartridge with

another half-turn.

● If locking piston is available:

Position tensioning clamps and tighten with tensioning screws.

● Check oil level, see 6.1.2.

● Check oil pressure, see 3.3.1.

● Check lube oil filter cartridge seal for leaks.

Page 51

6.1 Lubrication System6.1 Lubrication System

6.1 Lubrication System

6.1 Lubrication System6.1 Lubrication System

6.1.46.1.4

Clean / ReplaceClean / Replace

6.1.4

Clean / Replace

6.1.46.1.4

Clean / ReplaceClean / Replace Oil Filter (Cup)Oil Filter (Cup)

Oil Filter (Cup)

Oil Filter (Cup)Oil Filter (Cup)

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

● Switch off the engine.

● Loosen lube oil filter cover 1 and unscrew

in an anticlockwise direction, emties itself the system automatically (drain valve).

● Carefully loosen paper filter cartridge 3

upwards from the guide 4.

● Catch any escaping oil.

● Replace paper filter cartridge 3.

● Clean any dirt from the sealing surface of

the filter carrier and lube oil filter cover 1 and fromb the guide 4.

Caution is required in the case of hot oil: Risk of scalding!

● Replace and lightly oil the rubber gasket 2.

● Carefully insert new paper filter cartridge 3

into guide 4.

● Tighten lube oil filter cover 1 in a clockwise

direction (25 Nm).

● Start engine.

● Check oil level, see 6.1.2.

● Check oil pressure, see 3.3.1.

● Check lube oil filter attachment for leaks.

Page 52

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.2.16.2.1

Replace Fuel FilterReplace Fuel Filter

6.2.1

Replace Fuel Filter

6.2.16.2.1

Replace Fuel FilterReplace Fuel Filter

6.2 Fuel System6.2 Fuel System

6.2 Fuel System

6.2 Fuel System6.2 Fuel System

 Close the fuel shut-off valve.

 Undo fuel filter cartridge with commercial

tool and spin off.

 Catch any escaping fuel.

 Clean any dirt from the filter carrier sealing

surface.

The fuel system does not need to be bled.

 Apply light film of oil or diesel fuel to the

rubber gasket of the new fuel filter cartridge.

 Manually screw in the new cartridge until

the gasket is flush.

 Tighten the fuel filter cartridge with a final

half-turn.

 Open fuel shutoff valve.

 Check for leaks.

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

Page 53

6.2 Fuel System6.2 Fuel System

6.2 Fuel System

6.2 Fuel System6.2 Fuel System

6.1.46.1.4

Clean / ReplaceClean / Replace

6.1.4

Clean / Replace

6.1.46.1.4

Clean / ReplaceClean / Replace Fuel Oil Filter (Cup)Fuel Oil Filter (Cup)

Fuel Oil Filter (Cup)

Fuel Oil Filter (Cup)Fuel Oil Filter (Cup)

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

● Switch off the engine.

● Loosen fuel oil filter cover 1 and unscrew in

an anticlockwise direction, emties itself the system automatically (drain valve).

● Carefully loosen paper filter cartridge 3

upwards from the guide 4.

● Catch any escaping oil.

● Replace paper filter cartridge 3.

● Clean any dirt from the sealing surface of

the filter carrier and fuel oil filter cover 1 and fromb the guide 4.

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

● Replace and lightly oil the rubber gasket 2.

● Carefully insert new paper filter cartridge 3

into guide 4.

● Tighten fuel oil filter cover 1 in a clockwise

direction (25 Nm).

● Start engine.

● Check fuel oil filter attachment for leaks.

Page 54

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.2.36.2.3

Clean / purge or change fuelClean / purge or change fuel

6.2.3

Clean / purge or change fuel

6.2.36.2.3

Clean / purge or change fuelClean / purge or change fuel pre-filterpre-filter

pre-filter

pre-filterpre-filter

Clean (purge) - remove water:Clean (purge) - remove water:

Clean (purge) - remove water:

Clean (purge) - remove water:Clean (purge) - remove water:

● Turn off engine or, in the case of a change-

over filter, switch over to the other filter.

● Close the fuel stopcock or supply. (if available)

● Open the bleed screw 1 on the cover 2

● Place the fuel collector underneath the fuel

pre-filter.

● Empty water and dirt from the bowl 6 by

opening (press in and turn slightly without using force) the drain cock 8 and close the drain cock 8 again

● Close the bleed screw 1 on the cover 2 again

● Bleed the fuel pipe according to instructions,

see 6.2.5 opposite

Changing the filter element 5:Changing the filter element 5:

Changing the filter element 5:

Changing the filter element 5:Changing the filter element 5: Change at least once a year or as required (drop

in performance also after purging)

● Turn off the engine or switch to other filter in

case of changeover filter

● Close the fuel stopcock or supply (if available)

● Loosen the cover screws 3 diagonally

● Remove the cover 2

● Remove the spring cassette 4

● Remove the filter element 5 from the bracket

● Insert new filter element 5

● Place spring cassette 4 on the element

● Check that the cover seal is fit properly in the

cover 2 and check for damage (change if necessary)

● Tighten the cover 2 with the screws 3

diagonally (torque 6 Nm)

● Check the cover 2 for proper fit and leaks

● Bleed the fuel system, see 6.2.4.

The connection of a warning system

(lamp/horn) via contacts 7 is specified. Immediate maintenance is necessary when the warning system is triggered.

Naked flames are prohibited when working on the fuel system! Do not smoke! Dispose of old fuel in an environmentally friendly way!

6.2 Fuel System6.2 Fuel System

6.2 Fuel System

6.2 Fuel System6.2 Fuel System

Page 55

6.2 Fuel System6.2 Fuel System

6.2 Fuel System

6.2 Fuel System6.2 Fuel System

6.2.46.2.4

Bleed Fuel SystemBleed Fuel System

6.2.4

Bleed Fuel System

6.2.46.2.4

Bleed Fuel SystemBleed Fuel System with Fuel Pre-filterwith Fuel Pre-filter

with Fuel Pre-filter

with Fuel Pre-filterwith Fuel Pre-filter

 Place fuel collection container beneath the

fuel pre-filter.

Bleed:

 In the event of re-commissioning, following

maintenance work or if the tank has been run empty, the fuel system must be bled.

 Bring engine regulator into stop position.  Position fuel collection container beneath

filter housing 8 / pressure maintenance valve 9.

 Open fuel shut-off valve, pressure

maintenance valve 9, bleeder screw 1.

 Turn engine over with starter (max. 20 sec.)

until bubble-free fuel escapes from bleeder screw 1 and pressure maintenance valve

 Firmly tighten bleeder screw 1 and pressure

maintenance valve 9.

 Bring engine regulator into start position

and start.

 Check for leaks after starting the engine.

Keep naked flames away when working on the fuel system. Do not smoke! Dispose of used fuel in an environmentally-friendly manner!

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.2.56.2.5

Bleed Fuel SystemBleed Fuel System

6.2.5

Bleed Fuel System

6.2.56.2.5

Bleed Fuel SystemBleed Fuel System without Fuel Pre-filterwithout Fuel Pre-filter

without Fuel Pre-filter

without Fuel Pre-filterwithout Fuel Pre-filter

● Bring engine regulator into stop position.

● Open fuel shut-off valve.

● Loosen pressure maintenance valve 9.

Collect any escaping fuel and dispose of this in an environmentally-friendly manner.

● Turn engine over with starter (max. 20 sec.)

until bubble-free fuel escapes from pressure maintenance valve 9.

● Tighten pressure maintenance valve 9.

● Bring engine regulator into start position

and start.

● Check for leaks after starting the engine.

Keep naked flames away when working on the fuel system. Do not smoke! Dispose of used fuel in an environmentally-friendly manner!

Page 56

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.3.16.3.1

Cleaning IntervalsCleaning Intervals

6.3.1

Cleaning Intervals

6.3.16.3.1

Cleaning IntervalsCleaning Intervals

6.3 Cooling System6.3 Cooling System

6.3 Cooling System

6.3 Cooling System6.3 Cooling System

6.3.26.3.2

Clean Cooling SystemClean Cooling System

6.3.2

Clean Cooling System

6.3.26.3.2

Clean Cooling SystemClean Cooling System

● The amount of contamination in the cooling

system depends on the engine application.

● Oil and fuel residues on the engine increase

the risk of contamination. Therefore pay special attention to leaks if the engine is used in dusty environments.

● Serious contamination occurs, for example:

- on construction sites where there is a high level of air-borne dust.

- in harvesting applications where there are high concentrations of chaff and chopped straw in

● Because applications vary, cleaning

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

the vicinity of the machine.

Checking or cleaning intervals

Engine application

Guideline values OH

2000 Ships, electrical modules in

1000 Vehicles on paved roads

500 Tractors, fork-lift trucks,

250

125 Agricultural machines, tractors

enclosed areas, pumps.

drivable electric units.

Vehicles on construction sites

and unpaved roads, construc-

tion machines, compressors,

underground mining units.

harvesting applications.

● External cooling system: Clean according

to cooling system manufacturer’s specifications.

Page 57

6.3 Cooling System6.3 Cooling System

6.3 Cooling System

6.3 Cooling System6.3 Cooling System

6.3.36.3.3

Drain Cooling SystemDrain Cooling System

6.3.3

Drain Cooling System

6.3.36.3.3

Drain Cooling SystemDrain Cooling System

6.3.46.3.4

Fill / Bleed Cooling SystemFill / Bleed Cooling System

6.3.4

Fill / Bleed Cooling System

6.3.46.3.4

Fill / Bleed Cooling SystemFill / Bleed Cooling System 20122012

2012

20122012

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

● Position a collecting pan beneath screw

plug 1.

● Remove screw plug 1 at crankcase.

● Drain coolant.

● Tighten screw plug 1 again.

● If screw plug 1 is not accessible,

drainage can be carried out at the engine radiator (coolant channel). Fill / bleed cooling system see Chapter 6.3.4

Caution when draining hot coolant: Risk of scalding! Collect coolant on draining. Dispose of this in accordance with environmental regulations!

ax.

in.

2012

● Open radiator cap item 1.

● Loosen vent hose item 2.

● Fill coolant item 1b in up to the “MAX” mark or

filling limit (if fitted, system heater valve must be open).

● Connect vent hose, item 6, + tighten screw

plug item 4.

● Close radiator cap item 7.

● Start engine and warm up until thermostat

opens.

● Switch off the engine.

● Check coolant level when engine is cold, and

top up if necessary.

● Close radiator cap item 1.

0297 9902 0

Bleed

● External cooling system: According to cooling

system manufacturer’s specifications.

Page 58

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.4.16.4.1

Cleaning IntervalsCleaning Intervals

6.4.1

Cleaning Intervals

6.4.16.4.1

Cleaning IntervalsCleaning Intervals

 The amount of dirt in the combustion air

filter depends on the amount of dust in the air and the size of the air filter used. If a high level of dust is anticipated, a cyclone-type pre-cleaner can be fitted in front of the combustion air filter.

● Cleaning intervals must therefore be

determined from case to case.

● If dry type air filters are used, cleaning

should only be carried out according to the service indicator or service switch.

● Filter 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 en gine is running.

● After carrying out service work, press the

reset button on the service indicator. The service indicator is now ready for operation again.

6.4 Combustion Air Filter6.4 Combustion Air Filter

6.4 Combustion Air Filter

6.4 Combustion Air Filter6.4 Combustion Air Filter

Page 59

6.4 Combustion Air Filter6.4 Combustion Air Filter

6.4 Combustion Air Filter

6.4 Combustion Air Filter6.4 Combustion Air Filter

6.4.26.4.2

Emtying Cyclone TypeEmtying Cyclone Type

6.4.2

Emtying Cyclone Type

6.4.26.4.2

Emtying Cyclone TypeEmtying Cyclone Type PrecleanerPrecleaner

Precleaner

PrecleanerPrecleaner

6.4.36.4.3

Clean Oil Bath Air FilterClean Oil Bath Air Filter

6.4.3

Clean Oil Bath Air Filter

6.4.36.4.3

Clean Oil Bath Air FilterClean Oil Bath Air Filter

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

● 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.

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

● Turn engine off and wait about 10 minutes

for the oil to drain from filter housing 1.

● Loosen snap clips 2 and remove oil cup 3

with filter element 4; if necessary, loosen filter element with the aid of a screwdriver at the separating point. Do not damage rubber gasket 5!

● Remove dirty oil and sludge. Clean oil cup.

● Clean filter element 4 in diesel fuel and

allow to drip-dry thoroughly.

● 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 clean filter with gasoline. Dispose of old oil in accordance with environmental regulations!

Page 60

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.4.46.4.4

Dry Type Air FilterDry Type Air Filter

6.4.4

Dry Type Air Filter

6.4.46.4.4

Dry Type Air FilterDry Type Air Filter Dust Discharge ValveDust Discharge Valve

Dust Discharge Valve

Dust Discharge ValveDust Discharge Valve

Filter CartridgeFilter Cartridge

Filter Cartridge

Filter CartridgeFilter Cartridge

6.4 Combustion Air Filter6.4 Combustion Air Filter

6.4 Combustion Air Filter

6.4 Combustion Air Filter6.4 Combustion Air Filter

● 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.

- Using dry compressed air (max. 5 bar), blow out from inside outwards,

- Tap out (in emergencies only). Do not damage the cartridge, or

- Wash out according to manufacturer’s specifications.

● Check paper filter (light showing through)

and gaskets for damage. Replace if necessary.

● After five filter 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.

- Insert new cartridge, re-install hex nut and tighten.

● Install cartridge 3, replace hood 2 and do

up clip fasteners 1.

Never clean filter cartridge with gasoline or hot fluids!

Page 61

6.5 Belt Drives6.5 Belt Drives

6.5 Belt Drives

6.5 Belt Drives6.5 Belt Drives

6.5.16.5.1

Check V-beltsCheck V-belts

6.5.1

Check V-belts

6.5.16.5.1

Check V-beltsCheck V-belts 2012 Standard2012 Standard

2012 Standard

2012 Standard2012 Standard

2012 with Ribbed V-belt2012 with Ribbed V-belt

2012 with Ribbed V-belt

2012 with Ribbed V-belt2012 with Ribbed V-belt

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

● Visually 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 guide 3 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 V-belt 2 until the spring is heard or felt to trigger.

- Carefully raise the gauge without changing the position of indicator arm 1.

- Read off the value where the indicator arm 1 intersects scale 5 (arrow) and read indicator arm 1 off. For settings, see 9.1.

- If necessary, retension belt and measure again.

Check, tension and change Vbelts only with the engine off. If necessary, reinstall V-belt

Page 62

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.5.26.5.2

Tension V-beltsTension V-belts

6.5.2

Tension V-belts

6.5.26.5.2

Tension V-beltsTension V-belts Coolant / Fuel PumpCoolant / Fuel Pump

Coolant / Fuel Pump

Coolant / Fuel PumpCoolant / Fuel Pump

6.5.36.5.3

Replace V-beltsReplace V-belts

6.5.3

Replace V-belts

6.5.36.5.3

Replace V-beltsReplace V-belts Coolant / Fuel PumpCoolant / Fuel Pump

Coolant / Fuel Pump

Coolant / Fuel PumpCoolant / Fuel Pump

6.5.46.5.4

Replace V-beltsReplace V-belts

6.5.4

Replace V-belts

6.5.46.5.4

Replace V-beltsReplace V-belts Ribbed V-beltsRibbed V-belts

Ribbed V-belts

Ribbed V-beltsRibbed V-belts

6.5 Belt Drives6.5 Belt Drives

6.5 Belt Drives

6.5 Belt Drives6.5 Belt Drives

● Loosen screws 1 and 2.

● Press fuel pump 3 in direction of arrow until

the correct V-belt tension has been achieved.

● Tighten screws 1 and 2 again.

Check, tension and change Vbelts only with the engine off. If necessary, reinstall V-belt guard.

● Loosen screws 1 and 2.

● Press fuel pump 3 in direction of arrow.

● Remove V-belt and position new belt.

● Press fuel pump counter to direction of

arrow until the correct V-belt tension has been achieved.

● Tighten screws 1 and 2 again.

● Press tension roller in direction of arrow

until the ribbed V-belt is free.

● First remove ribbed V-belt from the small-

est roller.

● Position new ribbed V-belt.

● Press tension roller counter to direction of

arrow until the ribbed V-belt is tensioned.

Check whether ribbed V-belt is positioned correctly in its guide.

Page 63

6.5 Belt Drives6.5 Belt Drives

6.5 Belt Drives

6.5 Belt Drives6.5 Belt Drives

6.5.56.5.5

Tension V-beltsTension V-belts

6.5.5

Tension V-belts

6.5.56.5.5

Tension V-beltsTension V-belts AlternatorAlternator

Alternator

AlternatorAlternator

6.5.66.5.6

Replace V-beltsReplace V-belts

6.5.6

Replace V-belts

6.5.66.5.6

Replace V-beltsReplace V-belts AlternatorAlternator

Alternator

AlternatorAlternator

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

4 3

 Loosen screws 1, 2 and 4. l Adjust alternator 5 in direction of arrow by

turning screw 3 until correct V-belt tension is achieved.

 Retighten screws 1, 2 and 4.

Check, tension and change Vbelts only with the engine off. If necessary, reinstall V-belt guard.

4 3

 Loosen fuel pump V-belt, see 6.5.3  Loosen screws 1, 2 and 4.  Adjust screw 3 until V-belt can be removed.  Position new belt.  Adjust screw 3 until the correct V-belt

tension has been achieved.

 Retighten screws 1, 2 and 4.  Tension fuel pump V-belt, see 6.5.4.

Page 64

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.5.76.5.7

Wedge rib V-belts wear limitWedge rib V-belts wear limit

6.5.7

Wedge rib V-belts wear limit

6.5.76.5.7

Wedge rib V-belts wear limitWedge rib V-belts wear limit examine.examine.

examine.

examine.examine.

● Wear limit of the wedge ribV- belt as follows

examine:

● Distance between the nose of the flexibiliti

clamping arm and the notice of the firm tension adjuster housing examine.

6.5 Belt Drives6.5 Belt Drives

6.5 Belt Drives

6.5 Belt Drives6.5 Belt Drives

„a“„a“

● If

„a“ is smaller than 3 mm, then the wedge

„a“„a“

rib V- belt is to be exchanged

Page 65

6.6 Adjustments6.6 Adjustments

6.6 Adjustments

6.6 Adjustments6.6 Adjustments

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

Page 66

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.6.16.6.1

Check Valve Clearance,Check Valve Clearance,

6.6.1

Check Valve Clearance,

6.6.16.6.1

Check Valve Clearance,Check Valve Clearance, Adjust if NecessaryAdjust if Necessary

Adjust if Necessary

Adjust if NecessaryAdjust if Necessary

6.6 Adjustments 6.6 Adjustments

6.6 Adjustments

6.6 Adjustments 6.6 Adjustments

 Loosen ventilation valve and swing to the

side.

 Remove the cylinder head cover.  Position crankshaft as per schematic, see

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 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1.

 Adjust valve clearance if necessary:

- Release locknut 4.

- Use screwdriver 7 to turn setscrew 5 so that the correct valve c attained after locknut 4 has been tightened.

 Check and adjust valve clearance on all

cylinders.

 Reinstall cylinder head cover (with new

gasket if necessary).

 Swing ventilation valve into position and

fasten.

learance 1 is

Page 67

6.6 Adjustments6.6 Adjustments

6.6 Adjustments

6.6 Adjustments6.6 Adjustments

6.6.1.1 Valve Clearance Adjustment6.6.1.1 Valve Clearance Adjustment

6.6.1.1 Valve Clearance Adjustment

6.6.1.1 Valve Clearance Adjustment6.6.1.1 Valve Clearance Adjustment Schematic Schematic

Schematic

Schematic Schematic

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance



Crankshaft Position 1:Crankshaft Position 1:



Crankshaft Position 1:



Crankshaft Position 1:Crankshaft Position 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust valve clearance according to schematic in black)in black)

in black). Mark respective rocker arm with

in black)in black) chalk to show that adjustment has been carried out.



Crankshaft Position 2:Crankshaft Position 2:



Crankshaft Position 2:



Crankshaft Position 2:Crankshaft Position 2:

Turn crankshaft one full revolution (360°).

Adjust valve clearance according to schematic

(marked in black).(marked in black).

(marked in black).

(marked in black).(marked in black).

(marked(marked

(marked

(marked(marked

Page 68

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.7.16.7.1

Battery Battery

6.7.1

Battery

6.7.16.7.1

Battery Battery

6.7.1.1 Check Battery and6.7.1.1 Check Battery and

6.7.1.1 Check Battery and

6.7.1.1 Check Battery and6.7.1.1 Check Battery and Cable ConnectionsCable Connections

Cable Connections

Cable ConnectionsCable Connections

6.7.1.2 Check Electrolyte Level6.7.1.2 Check Electrolyte Level

6.7.1.2 Check Electrolyte Level

6.7.1.2 Check Electrolyte Level6.7.1.2 Check Electrolyte Level

6.7 Accessories6.7 Accessories

6.7 Accessories

6.7 Accessories6.7 Accessories

6.7.1.36.7.1.3

Check Electrolyte DensityCheck Electrolyte Density

6.7.1.3

Check Electrolyte Density

6.7.1.36.7.1.3

Check Electrolyte DensityCheck 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 acid-resistant grease.

 When reassembling, ensure that clamps

make good contact. Tighten clamp bolts hand-tight.

24232 3

 Remove sealing caps 1.

 If testers 2 are present:

Electrolyte level should reach the base of these.

 Without testers:

The electrolyte level should be 10-15 mm above the top of the plates.

 If necessary, top up with distilled water.

 Screw sealing caps back in.

 Measure the electrolyte density of individual

cells with a commercial hydrometer. The hydrometer reading (see table on following page) indicates the battery’s state of charge. During measurement, the temperature of the electrolyte should pref-

erably be 20 °C.

Page 69

6.7 Accessories6.7 Accessories

6.7 Accessories

6.7 Accessories6.7 Accessories

in [kg/ l]

Normal

1.28

Tropical

1.23

Electrolyte densityElectrolyte density

Electrolyte density

Electrolyte densityElectrolyte density

in [°Bé (Baumé scale)*]

Normal

Tropical

Charge status

well charged

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

1.20

1.12

* Measurement of electrolyte density in ° Bé

(Baumé scale) is out of date and rarely used today.

into contact with skin or clothing! Wear protective goggles! Do not rest tools on the battery!

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

semi-charged, re-charge

discharged, immediately charge

Page 70

Service and MaintenanceService and Maintenance

Service and Maintenance

Service and MaintenanceService and Maintenance

6.7.26.7.2

Rotary Current AlternatorRotary Current Alternator

6.7.2

Rotary Current Alternator

6.7.26.7.2

Rotary Current AlternatorRotary Current Alternator

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 charge pilot lamp bulb

immediately.

6.7.36.7.3

Transportation ShacklesTransportation Shackles

6.7.3

Transportation Shackles

6.7.36.7.3

Transportation ShacklesTransportation Shackles

6.7 Accessories6.7 Accessories

6.7 Accessories

6.7 Accessories6.7 Accessories

 When cleaning the engine: Do not spray

the alternator with a direct jet of water/ steam! Allow the engine to run warm so that the remaining water evaporates.

 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.

● Only use proper lifting gear when

transporting the engine.

Use only the correct lifting gear !

Page 71

7.17.1

Fault TableFault Table

7.1

Fault Table

7.17.1

Fault TableFault Table

Faults, Causes and RemediesFaults, Causes and Remedies

Faults, Causes and Remedies

Faults, Causes and RemediesFaults, Causes and Remedies

Page 72

Faults, Causes and RemediesFaults, Causes and Remedies

Faults, Causes and Remedies

Faults, Causes and RemediesFaults, Causes and Remedies

● Faults can frequently be attributed to the fact

that the engine has been incorrectly operated or not serviced.

● Each time a fault occurs, check whether all

operating and servicing regulations have been complied with.

● A corresponding fault table can be found

on the opposite page.

● If the cause of a fault cannot be

determined, or you are unable to remedy a fault yourself, then please contact your DEUTZ Service representative.

Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. In the event of repair work:

Caution:Caution:

Caution: If the speed regulator

Caution:Caution: has been removed, the engine must not be started under any circumstances. Disconnect the battery!Disconnect the battery!

Disconnect the battery!

Disconnect the battery!Disconnect the battery!

Page 73

7.1 Fault Table7.1 Fault Table

7.1 Fault Table

7.1 Fault Table7.1 Fault Table

Faults, Causes and RemediesFaults, Causes and Remedies

Faults, Causes and Remedies

Faults, Causes and RemediesFaults, Causes and Remedies

FaultsFaults

Faults

FaultsFaults Engine does not start or is difficult to start (Starting speed is not achieved on starting) Check

Engine starts, but runs irregularly or fails Adjust

Engine becomes excessively hot. Temperature warning system responds Replace

Engine output is deficient Clean

Engine does not run on all cylinders Top up

Engine oil pressure is non-existant or excessively low Bleed

Engine oil consumption excessive

Engine smokes - blue

- white

- black CauseCause

Cause

CauseCause

●

●●

●● ●●

●●●

●

●● ●

●●

●● ●

●

●●

●

●●

●

●●

●

*CPD = Charge pressure-dependent full-load stop Table 1 of 2

●

Not declutched (where possible) Below starting limit temperature Engine shut-off lever still in stop position (shutoff magnet defective) Oil level too low Oil level too high Excessive inclination of engine Adjust throttle to half actuation travel Air cleaner clogged / turbocharger defective Air cleaner service switch / indicator defective CPD* defective (connection line leaks) Charge air line leaking Coolant pump defective Intercooler soiled Coolant heat exchanger soiled Cooling fan defective, torn or loose V-belt (fuel pump in belt drive) Cooling air temperature rise / heating short circuits Battery defective or discharged

MeasuresMeasures

Measures

MeasuresMeasures

SectionSection

Section

SectionSection

Engine Operation

Combustion air

Cooling system

Electrics

PP EE

EE WW

WW RR

RR AA

AA LL

P / W

P / E P / E

P / R P / R P / R

P P P A S

P P

Page 74

Faults, Causes and RemediesFaults, Causes and Remedies

Faults, Causes and Remedies

Faults, Causes and RemediesFaults, Causes and Remedies

7.1 Fault Table7.1 Fault Table

7.1 Fault Table

7.1 Fault Table7.1 Fault Table

FaultsFaults

Faults

FaultsFaults

Engine does not start or is difficult to start (Starting speed is not achieved on starting) Check

Engine starts, but runs irregularly or fails Adjust

Engine becomes excessively hot. Temperature warning system responds Replace

Engine output is deficient Clean

Engine does not run on all cylinders Top up

Engine oil pressure is non-existant or excessively low Reduce

Engine oil consumption excessive

Engine smokes - blue

- white

- black CauseCause

Cause

CauseCause

●

●● ● ●●

●● ●●

●

●●

● ●●●● ●●

●● ●●

●

●●●

●● ● ●

●

Cable connections, starter, electrical circuit loose or oxidised Starter defective or pinion does not engage Incorrect valve clearance Injection line leaks Ventilation line blocked (coolant heat exchanger) Sheathed glow plugs defective Injection valve defective Air in the fuel system Fuel filter / fuel pre-cleaner soiled Oil filter defective Incorrect engine lube oil SAE class or quality Fuel quality not as per operation manual Coolant deficiency

MeasuresMeasures

Measures

MeasuresMeasures

SectionSection

Section

SectionSection

Electrics

Engine

Operating media

PP EE

EE WW

WW RR

RR AA

AA SS

P P E P

P / R

P P / W P / W

P / R / W

W W

P / W

P / A

Table 2 of 2

Page 75

8.1 Preservation8.1 Preservation

8.1 Preservation

8.1 Preservation8.1 Preservation

Engine PreservationEngine Preservation

Engine Preservation

Engine PreservationEngine Preservation

Page 76

Engine PreservationEngine Preservation

Engine Preservation

Engine PreservationEngine Preservation

8.1 Preservation8.1 Preservation

8.1 Preservation

8.1 Preservation8.1 Preservation

8.18.1

8.1

8.18.1

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent the formation of corrosion. The preservative measures described here will protect the engine for up to approx. 6 months. The procedure will have to be reversed before the engine is recommissioned.

 Anti-corrosion oils to specification:

 Recommended cleaning agent to remove

PreservationPreservation

Preservation

PreservationPreservation

- MIL-L 21260B

- TL 9150-037/2

- Nato Code C 640 / 642

pre servatives:

Petroleum benzine (hazardous materials class

A3)

Preserve engine:Preserve engine:

Preserve engine:

Preserve engine:Preserve engine:  Clean engine (poss. with cold cleaner).

Radiator cleaning, see 6.3.2.

 Run engine until warm, then turn off.  Drain engine oil, see 6.1.2, and fill with anti-

corrosion oil.

 Drain coolant, see 6.3.3.  Top up anti-corrosion agent, see specifica-

tions.

 Clean oil bath air filter if necessary, see

6.4.3, and top up anti-corrosion oil.

 Drain fuel tank.  Make up a mixture of 90 % diesel fuel and

10 % anti-corrosion oil, and refill fuel tank.

 Allow the engine to run for approx. 10 mins.  Switch off the engine.  Manually turn the engine over several times.

When turning over with starter, set shutoff lever to stop position.

 Remove V-belts and store in wrapped con-

dition.

 Spray grooves on V-belt pulleys 2 with anti-

corrosion spray.

 Drain anti-corrosion agent, see 6.3.3.

 Lightly preserve coolant filler neck and seal

with cap.

 Seal intake ports and exhaust ports.

Remove engine preservation:Remove engine preservation:

Remove engine preservation:

Remove engine preservation:Remove engine preservation:  Remove anti-corrosion agent from

grooves in V-belt pulleys 2.

 Install V-belts. Retension after brief

operation if necessary, see 6.5.

 Remove covers from intake port 3 and

exhaust port 4.

 Disconnect coolant inlet and outlet neck

covers, remove protection and connect to cooling system.

 Top up coolant, see 6.3.4.

System must be bled.

 Commission engine

Page 77

Technical SpecificationTechnical Specification

Technical Specification

Technical SpecificationTechnical Specification

9.1 Engine Specifications and Settings9.1 Engine Specifications and Settings

9.1 Engine Specifications and Settings

9.1 Engine Specifications and Settings9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings9.2 Torque Wrench Settings

9.2 Torque Wrench Settings

9.2 Torque Wrench Settings9.2 Torque Wrench Settings

9.3 Tools9.3 Tools

9.3 Tools

9.3 Tools9.3 Tools

Page 78

Technical SpecificationTechnical Specification

Technical Specification

Technical SpecificationTechnical Specification

9.1 Engine Specifications and Settings9.1 Engine Specifications and Settings

9.1 Engine Specifications and Settings

9.1 Engine Specifications and Settings9.1 Engine Specifications and Settings

ModelModel

Model

ModelModel

Number of cylinders ------------------ 4 --------------------------------------- 4 ---------------------------------------- 6 --------------Cylinder arrangement ----------------------------------------------------- vertical in line ------------------------------------------------Bore [mm] ---------------------------------------------------------- ø 101 ------------------------------------------------------Stroke [mm] ----------------------------------------------------------- 126 --------------------------------------------------------

Total displacement [cm3] ---------------- 4.04 ----------------------------------- 4.04 ----------------------------------- 6.06 ------------Compression ratio [ε]. ------------------------------------------------------------ 19 --------------------------------------------------------- Working cycle -------------------------------------------------- Four-stroke diesel ---------------------------------------------Combustion system ---------------------------------- with turbocharging and direct fuel injection -----------------------------Charge air cooling --------------- without --------------------------------- with ------------------------------------ with ------------Direction of rotation -------------------------------------------------- counter-clockwise----------------------------------------------Weight 2012/ C including cooling system to DIN 70020-A [approx.kg] ------------------------------------------------- Refer to head-office ---------------------------------------------

Engine output [kW] ------------------ 75 ------------------------------------ 103 ------------------------------------ 155 ------------Max. speed [1/rpm] ---------------------------------------------------------- 2500 ------------------------------------------------------Valve clearance with cold engine (PTs) [mm] ----------------------------------------- Inlet 0.3 Valve clearance with cold engine standard [mm] ------------------------------------ Adjustment with special tool, see 6.6.1 --------------------------------Injector opening pressure [bar] ----------------------------------------------------------- 250 -------------------------------------------------------Start of feed [°CS BTOC] -------------------------------------------------------------1). --------------------------------------------------------Firing order of the engine -------------- 1-3-4-2 ------------------------------- 1-3-4-2 ----------------------------- 1-5-3-6-2-4 -------V-belt tension: -------------------------------------------- Pre-tension / re-tension 2) ---------------------------------------------------------------------- Alternator / fan [N] ----------------------------------------------------- 450 / 300 Fuel pump - coolant pump [N] ----------------------------------------------------- 450 / 300 Compressor [N] ----------------------------------------------------- 550 / 450 Ribbed V-belt tension spring-loaded tension roller

----------------------

-----------

----------------------

[N] ----------------------------------------------------- 900 / 600

BF4M 2012BF4M 2012

BF4M 2012

BF4M 2012BF4M 2012

------------------------------------------------

------------------------

------------------------------------------------

BF4M 2012 CBF4M 2012 C

BF4M 2012 C ----------------------

BF4M 2012 CBF4M 2012 C

+ 0.1

/ exhaust 0.5

BF6M 2012 CBF6M 2012 C

BF6M 2012 C -------

BF6M 2012 CBF6M 2012 C

+ 0.1

.--------------------------------------

± 50

. --------------------------------------------------

± 50

. --------------------------------------------------

± 50

. --------------------------------------------------

± 50

. --------------------------------------------------

Engine output, speed, start of delivery are stamped on engine rating plate, etc., see also 2.1.

Re-tension 15 minutes after the engine has been operated under load.

Page 79

9.1 Engine Specifications and Settings9.1 Engine Specifications and Settings

9.1 Engine Specifications and Settings

9.1 Engine Specifications and Settings9.1 Engine Specifications and Settings

Technical Specification Technical Specification

Technical Specification

Technical Specification Technical Specification

ModelModel

Model

ModelModel ling ----------------------------------- Liquid-cooled / cooling system protection ------------------------------Coolant volume 2012/ C [ca.ltr.] ----------------- 5,6 ------------------------------------- 5,6 ------------------------------------ 7,3 -------------Perm. constant coolant temperature Engine exhaust, output group I [°C] ------------------------------------------------------ max.110 Engine exhaust, output group II-IV [°C] ------------------------------------------------------ max. 105 Thermostat opening commencement at [°C] ------------------------------------------------------------ Thermostat fully open from [°C] ---------------------------------------------------------- 83 Coolant pre-heating -----------------------------------------------------------Coolant pump Feed pressure in [bar] -----------------------------------------------------------Feed quantity in [m3 /h] -----------------------------------------------------------Power consumption in [kW] ------------------------------------------------------------

Lubrication -------------------------------------------------Pressure lubrication --------------------------------------------Oil temperature in oil pan [°C] ----------------------------------------------------------- 125 -------------------------------------------------------- Min. oil pressure when warm (120 °C and SAE oil 15 W 40 ) and low idle

Oil plate filling quantity without filter [approx.ltr.] --------------- 8.5 Oil plate filling quantity with filter [approx.ltr.] ---------------- 10

Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.

Only necessary in winter operation, see 3.5.1.

Engine content without radiator only. Content of external cooling system depending on cooling system version.

Other output groups have different values, consultation with head office is required.

In the case of external cooling systems with outlet regulation, the thermostat begins to open at 87 °C

In the case of external cooling systems with outlet regulation, the thermostat is fully open at 102 °C

Consultation with head office is required (differ depending on engine version)

----------------------

-----------

----------------------

[bar] ------------------------------------------------------------ 0,8 --------------------------------------------------------

BF4M 2012BF4M 2012

BF4M 2012

BF4M 2012BF4M 2012

------------------------------------------------

------------------------

------------------------------------------------

. -------------------------------- 8.5

. ---------------------------------- 10 3). --------------------------------- 14.0 3). -----------

BF4M 2012 CBF4M 2012 C

BF4M 2012 C

BF4M 2012 CBF4M 2012 C

--------------------------------------------

----------------------

--------------------------------------------

. ---------------------------------------------------

. --------------------------------------------------

. ---------------------------------------------------------

. -------------------------------------------------------

. ---------------------------------------------------------

. --------------------------------------------------------. --------------------------------------------------------. ---------------------------------------------------------

. ------------------------------- 12.5

BF6M 2012 CBF6M 2012 C

BF6M 2012 C -------

BF6M 2012 CBF6M 2012 C

. -----------

Page 80

Technical SpecificationTechnical Specification

Technical Specification

Technical SpecificationTechnical Specification

9.2 Screw Tightening Torques9.2 Screw Tightening Torques

9.2 Screw Tightening Torques

9.2 Screw Tightening Torques9.2 Screw Tightening Torques

Installation location

Cylinder head screw 8.5

Rocker arm adjustment screw 21

Foot on flywheel side 187 M16x40 8.

Foot on fan side 30 45 187 M16x40 8.

Intake manifold 8.5

Exhaust manifold 21

Oil drain screw 50

Injection valve attachment 16 Torx

Injection line attachment 30 M14x1.5

Oil pan (cast) 29

Oil pan (sheet metal) 21

Pre-tension [Nm] Re-tension [Nm]

1. Stage 2. Stage 3. Stage 1. Stage 2. Stage 3. Stage 4. Stage

Total [Nm]

Comments

8.8 A 4 C

Page 81

9.3 Tools9.3 Tools

9.3 Tools

9.3 Tools9.3 Tools

Technical SpecificationTechnical Specification

Technical Specification

Technical SpecificationTechnical Specification

TORXTORX

TORX

TORXTORX

25899 0

A TORX wrench set is used with engines in the 2012 series. This system was chosen because of the many advantages it offers:

● Outstanding accessibility to bolts.

● High load transfer when loosening and

tightening.

● Almost impossible for socket to slide off

or break, thereby practically ruling out the risk of injury.

TORX toolsTORX tools

TORX tools can be ordered from:

TORX toolsTORX tools

WILBÄRWILBÄR

WILBÄR

WILBÄRWILBÄR Postfach 14 05 80Postfach 14 05 80

Postfach 14 05 80

Postfach 14 05 80Postfach 14 05 80 D-42826 RemscheidD-42826 Remscheid

D-42826 Remscheid

D-42826 RemscheidD-42826 Remscheid

V-belt tension gaugeV-belt tension gauge

V-belt tension gauge

V-belt tension gaugeV-belt tension gauge

26002 0

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

WILBÄRWILBÄR

WILBÄR

WILBÄRWILBÄR Postfach 14 05 80Postfach 14 05 80

Postfach 14 05 80

Postfach 14 05 80Postfach 14 05 80 D-42826 RemscheidD-42826 Remscheid

D-42826 Remscheid

D-42826 RemscheidD-42826 Remscheid

8115 + 8120 8115 + 8120

8115 + 8120

8115 + 8120 8115 + 8120

from:

Page 82

Page 83

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.

Page 84

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.

Page 85

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

Page 86

DEUTZ AG

Service-Technik

Instandhaltungstechnik Motoren

Deutz-Mülheimer Str. 147-149

D-51063 Köln

Tel.: ++49 (0) 2 21- 8 22 - 0

Fax: ++49 (0) 2 21-8 22 -53 58

Internet: www.deutz.de

E-mail: info@deutz.de

Printed in Germany

Order No.: 0297 9912 en

We move your world