26 451
Operation Manual
B/F L 1011F
B/FM 1011F
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.
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).
All rights reserved. Technical modifications required to
improve our engines are reserved with regard to speci-
Operation Manual
B/F L 1011F
B/FM 1011F
0297 9683 en
fication 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.
1
Foreword
Dear Customer,
Air / liquid-cooled DEUTZ engines are designed for a
large number of applications. Consequently, a wide
range of variants are offered to meet the requirements of specific cases.
Your engine is appropriately equipped for the installation concerned, which means that not all of the
components described in this Operation Manual are
necessarily mounted to your engine.
We have 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
Index
1 General
2 Engine Description
2.1 Model
2.1.1. Rating Plate
2.1.2 Rating Plate Location
2.1.3 Engine Serial Number
2.1.4 Cylinder Numbering
2.1.5 Fuel Delivery Lock
2.2 Engine Illustrations
2.2.1 Service Side FL 1011F
2.2.2 Exhaust Side FL 1011F
2.2.3 Service Side BFL 1011F
2.2.4 Exhaust Side BFL 1011F
2.2.5 Service Side FM 1011/ F
2.2.6 Exhaust Side FM 1011/ F
2.2.7 Service Side BFM 1011F
2.2.8 Exhaust Side BFM 1011F
2.3 Oil Circuit
2.3.1 Lube Oil Circuit
2.4 Fuel System Schematic
2.4.1 Fuel System
3 Engine Operation
3.1 Commissioning
3.1.1 Adding Engine Oil
3.1.2 Filling oil bath air filter with engine oil
3.1.3 Adding Fuel
3.1.4 Other Preparations
3.1.5 Additional Maintenance Work
3.2 Starting
3.2.1 Starting
3.3 Monitoring Systems
3.3.1 Engine Oil Pressure
3.3.2 Coolant Temperature
3.4 Stopping
3.4.1 Mechanical Shutdown
3.4.2 Electrical Shutdown
3.5 Operating Conditions
3.5.1 Winter Operation
3.5.2 High Ambient Temperature,
High Altitude
4 Operating Media
4.1 Lube Oil
4.1.1 Quality Grade
4.1.2 Viscosity
4.2 Fuel Operating Media
4.2.1 Quality Grade
4.2.2 Winter-Grade Fuel
5 Routine Maintenance
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Work Completed
6 Service and Maintenance
6.1 Lubrication System
6.1.1 Oil Change Intervals
6.1.2 Changing Engine Oil, Check Oil Level
6.1.3 Changing Oil Filter
6.2 Fuel System
6.2.1 Changing Fuel Filter
6.2.2 Clean Strainer of Fuel Filter
6.2.3 Change Fuel Leakage Line
6.3 Cooling System
6.3.1 Cleaning Intervals
6.4 Combustion Air Cleaner
6.4.1 Cleaning Intervals
6.4.2 Emptying Cyclone Type Precleaner
6.4.3 Cleaning Oil Bath Air Cleaner
6.4.4. Dry Type Air Cleaner
6.5 Belt Drives
6.5.1 Checking V-Belts
6.5.2 Tensioning V-Belts
6.5.3 Changing V-Belts
6.6 Adjustments
6.6.1 Checking / Adjusting Valve Clearances
6.7 Accessories
6.7.1 Battery
6.7.2 Three-Phase Alternator
6.7.3 Lifting Tackle
6.7.4 Ether Starting System
6.8.1 Engine Cleaning
7 Troubleshooting
7.1 Diagnostic chart
8 Engine Preservation
8.1 Preservation
8.1.1 Preserving Engine
8.1.2 Removing Engine Preservations
9 Technical Specification
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
10 Service
1
1
26 451
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
!
and accident prevention regulations laid down by
law must also be observed.
carefully. The attention of operating
personnel should be drawn to these
safety instructions. General safety
Service
1
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.
Asbestos
DEUTZ original parts are asbestosfree.
1
2.1 Model
2.2 Engine Illustration
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
Engine Description
2
Engine Description
2.1 Model
2
2.1.1 Rating Plate
A
The model A, the engine serial number B and the
performance data are stamped on the rating plate.
The model and engine serial number must be given
when ordering parts.
B
26 332 2
2.1.2 Rating Plate Location
C
5
3
1
*
2 2
0
0
0
*
26 421 1 26 422 0
The rating plate C is attached to the valve cover.
2.1.3 Engine Serial Number
23045678
D
The engine serial number B is stamped on the
crankcase D as well as the rating plate.
2.1 Model
Engine Description
2.1.4 Cylinder Numbering
1234
26 431 0
Cylinders are numbered consecutively, beginning
at the flywheel end.
2.1.5 Fuel Delivery Lock
2
26 387 0
The manufacturer shall not be held liable for damages resulting from adjustments made to the regulator by the operator.
The lock screws are protected in order to prevent
this:
1. with locking paint on model:
torque balancer
2. with plastic protective cap on model:
without torque balancer.
!
Adjustments to the regulator are to
be carried out only by authorized
DEUTZ SERVICE - specialists.
Engine Description 2.2 Engine Illustrations
2
2.2.1 Service Side
FL 1011F
21
20
19
18
17
16
1
2
3
4
5
6
1 Oil filler neck (valve-gear cover)
2 Charge-air line / air-intake line
3 Fan with integrated generator
4 Narrow V-belt
5 Solenoid
6 Toothed belt cover
7 V-belt pulley on crankshaft
8 Oil sump
9 Cut-out handle
10 Speed control lever
11 Oil dipstick
12 Crankshaft housing
13 Oil fill point (on side of crankcase)
14 Fuel pump
15 Easy-change fuel filter
16 Connecting facility for oil heater
17 Lube oil easy-change filter
18 Removable coolant intake hood
19 Injection pumps
20 Date plate
21 Oil cooler
15
14
13 12 11 10 9 8
7
26 452 0
2.2 Engine Illustrations
Engine Description
2.2.2 Exhaust side
FL 1011F
30
29
28
27
22
23
2
22 Date plate
23 Connection housing (SAE)
24 Flywheel with ring gear
25 Starter
26 Front cover
27 Crankcase
28 Cylinder head
29 Exhaust manifold pipe
30 Air-intake pipe
26
25
24
26444 0
Engine Description
2.2 Engine Illustrations
2
2.2.3 Service Side
BFL 1011F
21
20
19
18
17
16
1
2
3
4
5
6
1 Oil filler neck (valve-gear housing cover)
2 Charge-air line / air-intake line
3 Fan with integrated generator
4 Narrow V-belt
5 Solenoid
6 Wheel-house cover
7 V-belt pulley on crankshaft
8 Oil sump
9 Cut-out handle
10 Speed control lever
11 Oil dipstick
12 Crankshaft housing
13 Oil fill point (on side of crankcase)
14 Fuel pump
15 Easy-change fuel filter
16 Connection facility for oil heater
17 Charge-air pressure full-load stop (LDA)
18 Lube oil easy-change filter
19 Removable coolant intake hood
20 Injection pumps
21 Oil cooler
15
14
13 12 11 10 9 8
7
26 443 0
Engine Description2.2 Engine Illustrations
2.2.4 Exhaust side
BFL 1011F
32
31
30
29
28
22
23
2
22 Cylinder head
23 Exhaust manifold pipe
24 Flywheel with ring gear
25 Starter
26 Crankshaft housing
27 Inlet line to TC (Lube oil)
28 Return line from TC (Lube oil)
29 Induction pipe
30 Turbocharger (TC)
31 Intake manifold
32 Air-intake line
27
26
25
24
26448 0
2
Engine Description
2.2.5 Service Side
FM 1011F
21
20
19
18
17
16
1
2
3
4
5
6
2.2 Engine Illustrations
1 Oil filler neck (valve-gear housing)
2 Charge-air line / air-intake line
3 Generator
4 Narrow V-belt
5 Solenoid
6 Wheel-house cover
7 V-belt pulley on crankshaft
8 Oil sump
9 Cut-out handle
10 Speed control lever
11 Oil dipstick
12 Crankshaft housing
13 Oil fill point (on side of crankcase)
14 Fuel pump
15 Easy-change fuel filter
16 Connecting facility for oil heater
17 Lube oil easy-change filter
18 Injection pumps
19 Connection for oil cooler
20 Leakage-fuel line
21 Injection valves
15
14
13 12 11 10 9 8
7
26 453 0
2.2 Engine Illustrations
2.2.6 Exhaust side
FM 1011F
28
Engine Description
2
22 Cylinder head
23 Exhaust manifold line
24 Flywheel with ring gear
25 Starter
26 Front cover
27 Crankcase
28 Intake pipe
22
27
26
25
23
24
26 447 0
Engine Description
2.2 Engine Illustrations
2
2.2.7 Service Side
BFM 1011F
21
20
19
18
17
16
1
2
3
4
5
6
1 Oil filler neck (valve-gear housing cover)
2 Charge-air line / air-intake line
3 Generator
4 Narrow V-belt
5 Solenoid
6 Wheel-house cover
7 V-belt on crankshaft
8 Oil sump
9 Cut-out handle
10 Speed control lever
11 Oil dipstick
12 Crankshaft housing
13 Oil fill point (on side of crankcase)
14 Fuel pump
15 Easy-change fuel filter
16 Connecting facility for oil heater
17 Charge-air pressure full-load stop (TC)
18 Lube oil easy-change
19 Injection pumps
20 Oil cooler connection
21 Injection valves
15
14
13 12 11 10 9 8
7
26 446 0
2.2 Engine Illustrations
Engine Description
2.2.8 Exhaust side
BFM 1011F
32
31
30
29
28
22
23
2
22 Cylinder head
23 Exhaust manifold pipe
24 Flywheel with ring gear
25 Starter
26 Crankshaft housing
27 Inlet line to TC (Lube oil)
28 Return line from TC (Lube oil)
29 Induction pipe
30 Turbocharger (TC)
31 Intake manifold
32 Air-intake line
27
26
25
24
26 448 0
2
Engine Description
2.3.1 Lube Oil Circuit Schematic
10
12
13
2.3 Oil Circuit
1 Oil sump
2 Intake manifold
118159
19
18
7
6
5
20
3 Oil pump
4 Main oil duct
5 Oil-cooled cylinder
6 Cylinder head cooling neck
7 Oil duct for rocker arm lubrication
8 Rocker arm
9 Oil manifold for the thermostat
10 Intake to external engine oil cooler
11 Return from external engine oil cooler
12 Thermostat housing with slide thermostat
13 Oil duct to oil filter
14 Oil filter
15 Oil duct to the cam, con-rod and
crankshaft bearing
16 Injection jet for cooling the pistons
17 Oil return via crankcase to the oil sump
18 Lube oil intake to turbocharger
19 Turbocharger
20 Return from turbocharger to oil sump
1
1714
4321618
26 430 0
2.4 Fuel System
2.4.1 Fuel system schematic
10
12
11
9
8
7
6
Engine Description
2
1 Fuel line from tank to fuel pump
2 Fuel pump
3 Fuel line from fuel pump to easy-change
fuel filter
4 Easy-change fuel filter
5 Fuel line from filter to injection pump
6 Injection pumps
7 Fuel distributor line
8 Injection lines
9 Injection valves
10 Fuel leakage line
11 Fuel overflow pipe
12 Fuel return line to tank
1
432 5
26 437 0
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 Operating Conditions
Engine Operation
3
Engine Operation
3.1 Commissioning
3
3.1.1 Adding Engine Oil
OIL
26 432 0
As a rule, engines are delivered empty of oil.
Pour lube oil into the oil filler neck (arrow).
For oil grade and viscosity, see 4.1.
3.1.1.1 Initial Engine Oil Fill-Up
for B/FM1011F Series
● Fill oil into the oil sump up to the “max.” mark on
the engine dip stick (for oil top-up quantity see
9.1).
● Start the engine and allow to run at a low idling
speed for approx. 2 mins.
● Switch off the engine.
● Check the oil level, if necessary, top up oil to the
„max.“ mark.
3.1.1.2 Initial Engine Oil Fill-up
for B/FM 1011F Series
● Fill oil into the oil sump up to the “min.” mark on
the engine dip stick.
● In addition, top up the oil quantity of the supply
hoses and of the external oil cooler (according to
manufacturer’s details).
● Allow the engine to run warm until the thermostat
opens (at approx. 95
● Allow the engine to run for approx. 2 mins.
● Switch off the engine.
● Check the oil level, and if necessary, top up oil to
the „max.“ mark.
o
C).
If the person operating the engine does not run up
the engine until the thermostat opens, the oil level
may lie above the „max“. mark on the engine dip
stick when delivered. The level can then only be
assessed after the engine has been run up.
3.1 Commissioning
Engine Operation
3.1.1.3 Initial Engine Oil Fill-Up for
B/FM 1011F Genset Engine
● Fill oil into the oil sump up to the “max.” mark on
the engine dip stick (for oil quantity see 9.1).
● Start up the engine and allow to run at a lower
idling speed for approx. 2 mins.
● Switch off the engine.
● Check the oil level and fill up with oil up to the
upper „max.“ mark.
3.1.2 Filling Oil Bath Air Filter with
Engine Oil
24 980 2 26 398 0
Fill oil cup 1 of the oil bath air cleaner with oil up to
the arrow.
For oil grade and viscosity, see 4.1.
3.1.3 Adding Fuel
3
FUEL
Use only commercial-grade diesel fuel. For fuel
grade, see 4.2. Use summer or winter-grade fuel,
depending on the ambient temperature.
Do not fill the precleaner dust collector (if fitted) with oil.
! !
Never fill the tank while the engine
is running. Keep the filler cap area
clean and do not spill fuel.
Engine Operation
3.1 Commissioning
3
3.1.4 Other Preparations
● Check battery and cable connections, see 6.7.1
● Transport hooks
Remove if fitted (see 6.7.3)
● Trial run
After the engine has been prepared, let it run
for about 10 minutes without load.
During and after trial run
– Check the engine for leaks
After the engine has been turned off
– Check the oil level,
see 6.1.2
If necessary, top up oil,
see 3.1.1
– Retension V-belts, see 6.5
● Breaking in
During the break-in phase – about 200 operating hours – check the oil level twice a day. After
the engine is broken in, checking once a day
will be sufficient.
3.1.5 Additional Maintenance Work
When commissioning new and reconditioned engines, the following additional maintenance work
must be carried out:
After 50-150 OH
● Change lube oil,
see 6.1.2
● Change oil filter cartridge,
see 6.1.3
● Change fuel filter cartridge,
see 6.2.1
● Check V-belts and retension as necessary,
see 6.5.
● Check the engine for leaks
● Check the engine mount and adjust as neces-
sary, see 9.2
After 500 OH
● Check the valve clearance and adjust as necessary, see 6.6.1.
3
Engine Operation
3.2 Starting
3
3.2.1 Electric Starting
Before starting, make sure that nobody is standing in the immediate
vicinity of the engine or driven ma-
!
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).
Caution: If the speed regulator has been removed, the engine must not be tested under any
circumstances:
Disconnect the battery.
Do not actuate the starter for more than 20 seconds. If the engine does not catch, wait a minute
then try again.
If the engine does not catch after two attempts,
refer to the Diagnosis Chart (see 7.1).
chine.
After repair work:
Check that all guards have been
2
1
26 423 0 25 746 2
● Where possible, disengage the clutch to separate the engine from any driven parts.
● Move speed control lever 1 into idle position.
● Move cut-out handle 2 into operating position.
Starting without Cold-Start Aid
● Insert key.
– Position 0 = no operating voltage
● Turn key clockwise
– Position 1 = operating voltage
– Pilot lights come on
● Push the key in and turn it further clockwise
against spring pressure
– Position 2 = no function
– Position 3 = start
● Release key as soon as engine fires
– Pilot lights go out
3.2 Starting
Engine Operation
with Cold-Start Aid
– Glow Plug
25 746 2 25 746 2 25 963 0
● Insert key.
– Position 0 = no operating voltage
● Turn key clockwise
– Position 1 = operating voltage
– Pilot lights come on
● Push key in and turn further clockwise against
spring pressure
– Position 2 = Preheat, hold for approx.
1 minute.
– Preheat lamp comes on
– Position 3 = Start
● Release key as soon as engine fires
– Pilot lights go out
with Cold-Start Aid
– Ether Starting System
● Insert key
– Position 0 = no operating voltage
● Turn key clockwise
– Position 1 = operating voltage
– Pilot lights come on
● Push key in and turn further clockwise against
spring pressure
– Position 2 = no function
– Position 3 = start
● Release key as soon as engine fires
– Pilot lights go out
● Starting fluid is injected automatically in switch
position A, as long as the starter is operated.
● To assist acceleration at lower temperatures
and to avoid white fumes, briefly hold the
arctic switch in switch position H.
The switch must not be moved to
position H when the engine is
!
switched off and the ignition is
switched on.
3
3
Engine Operation
3.3.1 Engine Oil Pressure
Oil Pressure Pilot Light
Oil Pressure Indicator
3.3 Monitoring Systems
Oil Pressure Gauge
25 752 1 25 754 025 753 0
● The oil pressure pilot light comes on with oper-
ating voltage on and engine off.
● The oil pressure pilot light should go out when
the engine is running.
● The pointer must remain in the green sector over
the entire range.
● The pointer must indicate the minimum oil
pressure (see 9.1).
3.3 Monitoring Systems Engine Operation
3.3.2 Coolant Temperature
Engine Temperature Gauge
24 985 0
● The engine temperature gauge pointer should
remain in the green sector most of the time. It
should rarely enter the yellow-green sector. If the
pointer enters the orange sector, the engine is
overheating. Turn off and establish the cause
from the Diagnosis Chart (see 7.1).
3
Engine Operation
3.4 Stopping
3
3.4.1 Mechanical Shutdown
2
1
26 424 0
● Move speed control lever 1 to low idle.
● Operate shutdown lever 2 until the engine comes
to a stop. The charge pilot light and the oil
pressure pilot light will come on when the engine
stops.
● Turn key counterclockwise (to position 0) and
remove. The pilot lights will go out.
3.4.2 Electrical Shutdown
(Ignition Key)
25 746 2
● Turn key counterclockwise (to position 0) and
remove. The pilot lights will go out.
If possible, do not suddenly switch off the engine
when under full load.
3.5.1 Winter Operation
Engine Operation3.5 Operating Conditions
3
● Lube Oil Viscosity
– Select the oil viscosity (SAE grade) accord-
ing to the ambient temperature when the
engine is started, see 4.1.2.
– Increase oil change frequency when oper-
ating below -10 °C, see 6.1.1.
● Diesel Fuel
– Use winter-grade diesel fuel for operation
below 0 °C, see 4.2.2.
● Additional Maintenance Work
– Drain the sludge from the fuel tank once a
week. (Unscrew the sludge drain plug)
– If necessary, allow the oil in the oil bath air
cleaner and the engine oil to settle at the
ambient temperature.
– Below -20 °C, after removing the starter if
necessary, smear the ring gear on the fly
wheel via the pinion bore from time to time
with cold-resistant grease.
(e.g. Bosch grease FT 1 V 31).
● Cold-Start Aid
– At temperatures near or below freezing
point, use glow plugs if necessary, see
3.2.1.
This not only lowers the starting limit temperature, but provides easier starting at
temperatures normally not requiring a starting aid.
● Battery
– Efficient cold starting requires a healthy
battery, see 6.7.1.
– The starting limit temperatures can be 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).
26 248 0
Engine Operation
3.5 Operating Conditions
3
3.5.2 High Ambient Temperatures,
High Altitude
● As the altitude and ambient temperature rise, the
density of air tends to decrease, which affects
the maximum power output of the engine, the
exhaust gas quality and, in extreme cases, the
starting behavior. Under transient conditions,
the engine can be used at altitudes up to 1000 m
and temperatures up to 30 °C. If the engine is to
operate under more severe conditions (at higher
altitudes or temperatures), it will be necessary to
reduce the injected fuel quantity and thus, engine power.
● If you have any doubts about engine operation
under these or similar conditions, ask your engine or equipment supplier whether the engine
has been derated in the interests of reliability,
service life and exhaust gas quality (smoke).
Otherwise contact DEUTZ SERVICE.
C F
0 32
25 901 1
4.1 Lube Oil
4.2 Fuel
4.3 Coolant
Operating Media
4
© 2002
Operating Media 4.1 Lube Oil
4
4.1.1 Quality Grade 4.1.2 Viscosi ty
Lube oils are differentiated by Deutz
according to their performance and quality
class. Oils of other, comparable specifications
can be used.
Approved oils:
Deutz DQC I DQC II DQC III
ACEA E2-96 E3/96/E5-02 E4-99
API CF/CF-4 CH-4/CG-4 DHD - DHD-1 -
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.
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.
© 2002
Only with preheating
30 298 1
Operating Media 4.2 Fuel
4
4.2.1 Quality Grade
Use commercially available diesel fuel with
less than 0.5% sulphur content. If the sulfur
content is higher than 0.5%, oil change
intervals should be reduced (see 6.1.1).
The following fuel specifications/standards
are approved:
(refer to TR 0199-3002)
● Diesel fuel
- DIN EN 590
- BS 2869: A1 and A2
(with A2, take note of the sulfur content!)
- ASTM D 975-88; 1-D and 2-D
- NATO Code F-54and F-75
- ISO 8217 DMX
- ISO 8217 DMA
● Light heating oil
according to DIN 51603
ASTM D 396; 1 and 2
BS 2869 Class D
● Jet fuel
- F34/F35/F44 (kerosene)
- F54 (equivalent to diesel fuel according to
DIN EN 590)
- XF 63 (equivalent to F34+F35 with addi tives)
4.2.2 Winter-Grade Fuel
Waxing may occur at low temperatures,
clogging the fuel system and reducing engine
efficiency. If the ambient temperature is less
than 0 °C, winter-grade fuel (suitable down
to -20 °C) should be used. This fuel is usually
available from filling stations well in advance
of the cold months.
● At temperatures below -20°C/, kerosene
should be added to the diesel fuel. The
relevant percentages are given in the diagram at the right
● Special diesel fuels can be used for climatic
zones down 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 contact your Deutzpartner .
Legend:
I Summer diesel fuel
II Winter diesel fuel
A Outside temperature
Percentage of kerosene to be added
B
● Bio diesel fuel
- according to DIN 51606- FAME
Exhaust emission values which may be
determined in the cause of type approval tests
always refer to the reference fuel prescribed
by the authorities for the type approval test.
© 2002
Diesel fuels must never be
mixed with petrol (normal and
super grade petrol)!
Mix in tank only. Fill with the
appropriate amount of kerosene
first, then add the diesel fuel.
Routine Maintenance
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Work Completed
5
Routine Maintenance
5.1 Maintenance Schedule
5
Operating Hours (OP) every 1)
once
after
2)
50-150
●
●●
●●
● ●
●
●●
every
10 OH
or daily
●
●
●
● ● ● ● ●
125
250
●
500
7)
7)
2)
750
●
●
●
●
●
1000
6)
6)
2000
●
check
clean
change
3000
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Section
Operation
Oil level in engine / separate container
9)
6.1.2/3.1.4
Engine leaks
Oil bath- and dry type air cleaners
3) 4) 5)
6.4
Battery and cable connectors 6.7.1
4) 6)
3)
4) 6)
6.3.1
6.1.1
6.1.3
Cooling system (depending on engine use
Engine oil (depending on engine use)
Oil filter cartridge (depending on oil change interval)
Fuel filter cartridge 6.2.1
Valve clearance (adjust if necessary) 6.6.1
Engine mounts (retighten if necessary) 9.2
V-belts (retension if necessary) 6.5
Toothed belts
8) 10)
Injection valves
Fuel pump / strainer
Fuel leakage line (change defective lines)
5)
11)
6.2.2
6.2.3
see
The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please
observe the operating instructions of the equipment manufacturer.
1) recommended maximum
2) once when commissioning new and reconditioned engines
3) clean if needed
4) Oil quality API-CF-4, CG-4, CH-4 or ACEA-E1-3/96 and E4-98
5) change if required
6) for oil change intervals, naturally aspirated engines, see
Section 6.1.1
7) for oil change intervals, turbocharged engines, see Section 6.1.1
8) without toothed belt ventilation renew after 3000 running hours, after 5 years at the
latest if running hours are not reached: in both cases together with idler pulley
with toothed belt ventilation renew after 4500 running hours, after 5 years at the latest
if running hours are not reached: in both cases together with idler pulley
9) during run-in period, check 2 x daily
10) retensioning of toothed belts is not permitted
11) Change at the latest after 2 years .
5.2 Maintenance Chart
Routine Maintenance
5
The maintenance chart shown here is supplied as a selfadhesive 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.
0,3 mm
in.
ex.
AIR
a
in.
OIL
FUEL
1000
10
BFL
500
FL
1000
1000
ex.
0.012 in.
0,5 mm
0.020 in.
B/FL 1011F
BFL
FL
h
Std.
125-
2000
BFL
500
FL
1000
1000
10
OIL
OIL
max.
!
Stop the engine before carrying out
any maintenance work.
0297 7790
0
5
Routine Maintenance
The maintenance chart shown here is supplied as a selfadhesive 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.
ex.
AIR
in.
a
1000
10
in.
ex.
0,3 mm
0.012 in.
0,5 mm
0.020 in.
5.2 Maintenance Chart
h
Std.
125-
2000
OIL
!
Stop the engine before carrying out
any maintenance work.
BFM
500
OIL
FM
1000
FUEL
1000
B/FM 1011/F
0297 7781
0
10
OIL
max.
BFM
125
250
500
1000
FM
500
1000
5.3 Completed Maintenance Jobs Routine Maintenance
Hours
50-150
125
375
625
875
1125
1375
1625
1875
Date
Signaure / Stamp Hours Date Signaure / Stamp
5
*
-
250
500
750
1000
1250
1500
1750
2000
2115
2375
2625
* Commissioning new and overhauled engines
The maintenance jobs duly completed can be recorded in the above table.
2250
2500
2750
Routine Maintenance 5.3 Completed Maintenance Jobs
5
Hours.
2875
3125
3375
3625
3875
4125
4375
4625
4875
Date
Signaure / Stamp Hours
3000
3250
3500
3750
4000
4250
4500
4750
5000
Date
Signaure / Stamp
5125
5375
5625
The maintenance jobs duly completed can be recorded in the above table.
5250
5500
5750
5.3 Completed Maintenance Jobs Routine Maintenance
Hours
5875
6125
6375
6625
6875
7125
7375
7625
7825
Date
Signaure / Stamp Hours Date Signaure / Stamp
5
6000
6250
6500
6750
7000
7250
7500
7750
8000
8125
8375
8625
The maintenance jobs duly completed can be recorded in the above table.
8250
8500
8750
5
Service and Maintenance
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air System
6.5 Belt Drives
6.6 Adjustments
6.7 AccessoriesService and Maintenance
6
Service and Maintenance
6.1 Lubrication System
6
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).
● If the sulfur content is > 0.5 to 1% or the
continuous ambient temperature below -10 °C
(+14 °F), the intervals between oil changes should
be halved.
Installed engines
Lube oil quality
Normal oil usage, e.g.:
Road vehicles, cranes, construction machinery, ships,
electrical units, pumps, rail-run vehicles
Heavy-duty oil usage, e.g.:
Combine harvesters, emergency pumps, underground
equipment, sweeping machines, winter operation
equipment, emergency power generating units
API classification
CCMC classification
Vehicle engines
API classification
Lube oil quality
Service
group
CCMC classification
Annual
kilometrage
km
average
speed approx.
km/h
Lube oil intervals in OH Lube oil intervals in OH
Naturally aspirated engines Turbocharged engines
CC 1) CD/CE 1)
D4 D5 2) (SHPD) 3) D4 D5 2) (SHPD) 3)
250 500 250 500
125 250 125 250
CD/CE/CF-4
—
Lube oil intervals in km Lube oil intervals in km
Turbocharged enginesNaturally aspirated engines
CC 1) CD/CE 1) CD/CE/CF-4
D4 D5 2) (SHPD) 3) D4 D5 2) (SHPD) 3)
—
● In the case of fuels containing more than 1% sulfur, contact your service representative.
I
II
III 60 15 000 30 000 15 000 30 000
to 30 000
more than 30 000
to 100 000
more than 100 000
20 5 000 10 000 5 000 10 000
40 10 000 20 000 10 000 20 000
Change the oil with the engine off but still warm (lube oil temperature approx. 80 °C).
1)
Lube oils having both a C- and an S classification (e.g. CD / SE) can be used. Oils with only a C classification
(e.g. CE) generally perform very well in diesel engines and are to be preferred.
2)
D5 grade oil with sulfate ash content > 1.8% by mass.
3)
SHPD lube oils can be used.
These are the equivalent of D5 grade.
6.1 Lubrication System
6.1.2 Checking Oil Level / Changing
Engine Oil
6.1.2.1
Checking Oil Level
Service and Maintenance
6
6.1.2.2 Changing the Engine Oil
25729 0
● Check the oil level with the engine switched off.
● Ensure that the engine or vehicle is in a level
position.
● Remove the oil dipstick.
● Wipe the dipstick with a non-fibrous,clean cloth
● Insert it to the stop and remove again.
● Check the oil level, and if necessary, top up to
the "MAX" mark. If the oil level is only just above
the "MIN" mark, more oil must be added.
The oil level must not drop below the "MIN" mark
26022 0
● Allow the engine to warm up.
● Ensure that the engine or vehicle is on a level
position.
- Lube oil temperature approx. 80 °C.
● Turn the engine off.
! Be careful when draining hot oil danger of scalds!
!
Do not let used oil run into the soil
but catch it in a container ready for
proper disposal!
26023 0
● Place oil tray under the engine.
● Unscrew drain plug.
● Drain oil.
● Fit oil drain plug with the new gasket and tighten
firmly (for torque see 9.2).
● Pour in lube oil
- For grade / viscosity, see 4.1.
- For quantity see 9.1.
● Check the oil level, see 6.1.2.1
6
Service and Maintenance
6.1.3 Changing Oil Filter
6.1 Lubrication System
● Undo the filter cartridge using a commercial tool
and spin off.
● Catch any dripping oil.
Beware of burns from hot oil.
!
25881 0
● Clean any dirt from the filter carrier rim.
● Lightly oil the rubber gasket of the new oil filter
cartridge.
● Screw in the new cartridge finger tight against
the gasket.
25882 025880 0
● Tighten the oil filter cartridge with another halfturn.
● Check oil level, see 6.1.2.
● Check oil pressure, see 3.3.1.
● Check cartridge seal for leaks.
6.2 Fuel System
6.2.1 Changing Fuel Filter
Service and Maintenance
6
25880 0
● Close fuel stopcock.
● Undo fuel filter cartridge with commercial tool
and spin off.
● Catch any fuel.
Keep naked flames away when working on the fuel system. Do not
!
25881 0
smoke.
● Clean any dirt from the filter cartridge with a final
half-turn.
● Apply light film of oil or diesel fuel to the rubber
gasket of the new fuel filter cartridge.
● Screw in the new cartridge finger tight against
25882 0
the gasket.
● Tighten the fuel filter cartridge with a final halfturn.
● Open fuel stopcock.
● Check for leaks.
The fuel system does not need to be bled.
Service and Maintenance
6.2 Fuel System
6
6.2.2 Fuel Pump
Cleaning the Strainer
2
3
1
26 436 0
● Close the fuel shut-off valve.
● Loosen and unscrew the hexagonal nut 1.
● Remove the fuel strainer cover 2 (cover and
strainer, one unit)
● Clean the fuel strainer with diesel fuel. Replace if
necessary.
● Place seals 3 in position.
Keep naked flames away when working on the fuel system.
!
Do not smoke!
● Mount the fuel strainer cover 2.
● Tighten the hexagonal screw 1.
● Check for leaks.
6.2.3 Change Fuel Leakage Line
4213
30 015 0
● Close the fuel shutoff valve.
● Disconnect rubber hoses 3 from the injection
valves.
● Disconnect rubber hose 1 from fuel tank.
● Disconnect rubber hoses 4, 3 and 1 from unions
2 and dispose of in an environmentally friendly
manner.
● Connect new rubber hoses 4, 3 and 1 to unions
2.
● Connect rubber hoses 3 to injection valves.
● Connect rubber hose 1 to fuel tank.
● Open fuel shutoff valve.
● Check for leaks after start-up.
6.3 Cooling System
Service and Maintenance
6.3.1 Cleaning Intervals
● The amount of contamination in the cooling
system depends on the engine application.
● Spilled oil or fuel on the engine increases the risk
of contamination. Be especially careful if the
engine is used in dusty environments.
● Serious contamination can occur, for example:
– on construction sites where there is a high
level of air-borne dust.
– in harvesting application where there are
high concentrations of chaff and chopped
straw in the vicinity of the machine.
● Because applications vary, cleaning intervals
have to be determined from case to case. The
cleaning intervals given in the table on the right
can be used as a guide.
● Clean the engine as described in 6.8.1.
Inspection and cleaning
intervals
Recommended
OH
2000 Ships, Electrical units in enclosed areas, pumps
1000 Vehicles on reinforced highways
500 Tractors, fork-lift trucks, mobile electrical units
250
125 Agricultural machinery, tractors used for harvesting purposes
6
Engine application
Vehicles on construction sites and on roads with loose surfaces,
construction machinery, compressors, mining equipment
6
Service and Maintenance
6.4.1 Cleaning Intervals
● The amount of dirt in the air cleaner depends on
the amount of dust in the air and the size of the
air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to
the air cleaner.
● Cleaning intervals will have to be determined
from case to case.
● Air cleaner servicing is needed when:
– Service indicator
the red signal 1 is fully visible when the
engine is off.
– Service switch
the yellow pilot light comes on when the
engine is running.
● After carrying out service work, reset the signal
by pressing the button on the service indicator.
6.4 Combustion Air Filter
25 885 1
6.4 Combustion Air Filter
Service and Maintenance
6.4.2 Emptying Cyclone Type
Precleaner
25 886 0 25 887 1
● Undo wing nut 1 and remove cover 2.
● Remove collector bowl 3 from lower section 4
and empty. Clean leaves, straw and other foreign
matter from lower section of precleaner.
● Reposition collector bowl 3 onto lower section 4,
fasten cover 2 in place by tightening wing nut 1.
6.4.3 Cleaning Oil Bath Air Cleaner
● Turn engine off and wait about 10 minutes for the
oil to drain from filter housing 1.
● Release snap clips 2 and remove oil cup 3
together with filter element 4. If necessary prise
element out with a screwdriver, taking care not to
damage the rubber gasket 5.
● Remove dirty oil and sludge. Clean oil cup.
● Clean filter element 4 in diesel fuel and allow to
drip-dry.
6
● Clean filter housing 1 if very dirty.
● Inspect and replace rubber gasket 5 and 6 if
necessary.
● Fill oil cup with engine oil up to the mark (arrow)
(for viscosity, see 4.1.2).
● Refit oil cup and element to filter housing and
secure with snap clips.
Never fill collector bowl with oil. Replace collector
bowl if damaged.
!
Never clean air cleaner with gasoline. Dispose of cold oil in accordance with environmental regulations!
Service and Maintenance
6.4 Combustion Air Cleaner
6
6.4.4 Dry Type Air Cleaner
Dust Discharge Valve Filter Cartridge
25 888 1 25 889 0
● Empty dust discharge valve 1 by pressing apart
lips of discharge slot as indicated by arrows.
● Clean discharge slot from time to time.
● Remove any caked dirt by pressing together the
upper section of the valve.
● Undo clip fasteners 1.
● Take off hood 2 and remove cartridge 3.
● Clean cartridge (replace at least once a year)
● Clean cartridge 3.
Blow out from inside out with dry compressed
air (max. 5 bar), (or in difficult cases, tap out,
taking care not to damage the cartridge, or wash
according to manufacturer’s instructions).
● Through regular removal and replacement, the
gaskets on the filter cartridge can become damaged. Check paper filter (light showing through)
and gaskets for damage. Replace if necessary.
● After five cleaner services or after two years at
the latest, replace safety cartridge 4 (never clean).
To do so:
– Undo hex. nut 5 and remove cartridge 4.
– Install new cartridge, insert and tighten hex
nut.
● Install cartridge 3, replace hood 2 and do up clip
fasteners 1.
Never clean filter cartridge with
gasoline or hot fluids.
!
6.5 Belt Drives
Service and Maintenance
6.5.1 Checking V-Belts
26 427 0 26 261 0
● Inspect entire V-belt for damage.
● Replace damaged V-belts.
● After installing new belts, run engine for 15
minutes, then check belt tension.
● To check the tension of the V-belt, use a tension
gauge (see 9.3).
– Place indicator arm 1 into gauge.
– Position gauge on V-belt 2, midway be-
tween the pulleys, with flange 3 on bottom
of gauge against the edge of belt.
– Push slowly on the black pad 4 at right
angles to belt 2 until the spring is heard or
felt to trigger.
– Carefully remove the gauge without alter-
ing the position of the indicator arm 1.
– Read off the value where the black indicator
arm 1 intersects scale 5 (arrow). For settings, see 9.1.
– If necessary, retension belt and measure
again.
Check tension and change belts only
with the engine off. Refit belt guard,
!
if provided. When new V-belts are fitted, check the belt tension
6
after ca. 15 minutes running time.
Service and Maintenance
6.5 Belt Drives
6
6.5.2 Tensioning Alternator Belts
4
2
1
3
26 425 0
● Slacken off bolts 1, 2 and 3.
● Adjust alternator 4 in direction of arrow by
turning bolt 3 until correct belt tension is achieved.
● Retighten bolts 1, 2 and 3.
6.5.3 Changing Alternator Belts
4
1
2
3
26 426 0
● Slacken off bolts 1, 2 and 3.
● Adjust alternator 4 in direction of arrow by
turning bolt 3.
● Remove and replace belt.
● Adjust alternator 4 against the direction of the
arrow by turning bolt 3, until correct belt tension
is achieved.
● Retighten bolts 1, 2 and 3.
!
Check, tension and change belts
only with the engine off. Refit belt
guard, if provided.
Service and Maintenance
6
Service and Maintenance
6.6 Adjustments
6
6.6.1 Checking / Adjusting Valve
Clearances
19 691 2 25 893 0
● Remove the cylinder head cover.
● Position crankshaft as per schematic 6.6.1.1.
● Before adjusting valve clearance, allow engine to
cool down for at least 30 minutes. The oil temperature should be below 80 °C.
● Check valve clearance 1 between rocker arm /
tappet contact face 2 and valve stem 3 with feeler
gauge 6 (there should be only slight resistance
when feeler blade is inserted).
For permissible valve clearance, see 9.1.
● Adjust valve clearance if necessary:
– Release locknut 4.
– Use allen key 7 to turn setscrew 5 so that
the correct clearance is attained after locknut
4 has been tightened.
● Check and adjust valve clearance on all remaining cylinders.
● Replace cylinder head cover (use new gasket if
needed).
6.6 Adjustments
Service and Maintenance
6.6.1.1 Valve Clearance Adjustments
Schematic
1
2
6
● Crankshaft Position 1:
Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance of valves marked
in black on schematic. Mark respective rocker
1 2341 2 1 23
234112 123
arm with chalk to show that adjustment has been
done.
● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in black on
schematic.
25 894 4
Service and Maintenance
6.7 Accessories
6
6.7.1 Battery
Connectors
25 895 0 24 232 3 25 896 0
● Keep battery clean and dry.
● Undo dirty clamps.
● Clean terminal posts (+ and -) and clamps of the
battery, and grease with acid-free and acidresistant grease.
● When reassembling, ensure that clamps make
good contact. Do up clamp bolts finger tight.
6.7.1.2 Checking Electrolyte Level6.7.1.1 Checking Battery and Cable
● Remove caps 1.
● If testers 2 are used, the electrolyte should come
up to their base.
● If testers are not used, the electrolyte level should
be 10-15 mm above the top of the plates.
● If necessary, top up with distilled water.
● Replace caps.
6.7.1.3 Checking Electrolyte
Density
● Measure the electrolyte density of individual
cells with a commercial hydrometer.
The hydrometer reading (see table on following
page) indicates the state of charge.
During measurement, the temperature of the
electrolyte should preferably be 20 °C.
6.7 Accessories
Electrolyte density
in kg/l in ° Bé (Baumégrad)*
State of Charge
Normal Tropics Normal Tropics
1.28 1.23 32 27 Fully charged
1.20 1.12 24 16 Half charged, recharge
1.12 1.08 16 11 Discharged, recharge immediately
Service and Maintenance
6
* Measurement of electrolyte density in ° Bé
(Baumé-grad) is out of date and rarely used
today.
The gases emitted by the battery
are explosive! Keep sparks and na-
!
Wear protective goggles. Do not rest tools on the
battery.
ked flames away from the battery.
Do not allow battery acid to come
into contact with skin or clothing.
Service and Maintenance
6.7 Accessories
6
6.7.2 Three-Phase 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 bulb of the charge pilot lamp
immediately.
● When washing the engine, cover up the alternator and regulator.
● The habit of touching a lead against the frame to
check whether it is live must under no circumstances be used with three-phase electrical systems.
● In case of electric welding, connect the ground
terminal on the welder directly to the piece being
welded.
6.7.3 Lifting Tackle
2
● Always use proper lifting tackle 1 when transporting the engine.
● After transportation and before commissioning
of the engine:
Remove attachment eyes 2.
1
26 434 0 26 435 0
!
Use only the correct lifting tackle.
6.7 Accessories
Service and Maintenance
6.7.4 Ether Starting System
6.7.4.1 Changing the Fluid Container
25 965 0 25 956 0
● Before removing the container, clean the container support and the top of the solenoid valve.
● Loosen the bracket 1.
● Unscrew the fluid container 2.
● Empty or replace the depressurized fluid con-
tainer.
6
● Place the container 1 on the solenoid valve 2 and
tighten by hand.
● When mounting, ensure that gasket 3 is seated
correctly.
● Pull in the brackets.
● Check for leaks.
Before commissioning, leave the
fluid container of the ether starting
!
tainer is not damaged. Prevent foreign substances
from entering the container. The fluid container
must not be stored at temperatures above 50 °C.
system in position for 15 minutes.
Check for leaks. The starting fluid is
inflammable. Ensure that the con-
6
Service and Maintenance
6.8.1 Engine Cleaning
Preparation
● Switch off the engine.
● Remove engine covers and cooling air hood.
Replace them after cleaning and before the test
run.
● Cover electrical / electronic components / connections (eg. generator, starter, governor, solenoid).
Using compressed air
● Blow air through the engine, taking particular
care not to damage the cooler and cooling fins
(begin to blow through air from the exhaust
side).
Remove the dirt which has blown into the inte-
rior space.
Using cold-cleaning compound
● Spray the engine with the commercial coldcleaning compound and allow to react for approx.
10 mins.
● Spray clean the engine with a strong water jet,
repeat if necessary.
● Allow the engine to run up so that the remaining
water evaporates.
6.8 Engine Cleaning
Using high pressure device
● Clean the engine with a steam jet (max. spray
pressure
of 60 bar, max. steam temperature of 90ºC).
● Allow the engine to run up so that the remaining
water evaporates.
Clean the engine only when the
engine is switched off.
!
7.1 Diagnosis Chart
Faults, Causes and Remedies
7
7
Faults, Causes and Remedies
● Faults are often caused by maloperation of the engine
or failure to service the engine.
● In the event of a fault, always check whether the
operating and servicing regulations have been adhered to.
● A corresponding fault table can be found on the
adjacent page.
● If you cannot ascertain the cause of a fault or cannot
rectify the fault, please contact DEUTZ SERVICE.
7.1 Diagnosis Chart
7.1 Diagnosis Chart
Fault Remedy
Engine fails or is difficult to start Check P
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes – blue
– white
– black
Cause
●
●●
●●
●● ●●
●●●
●●
●● ● ●
●● ●
●● ●
●●
●
●
●
●
●
Not declutched (where possible)
Below starting limit temperature
Oil level too low
Oil level too high
Excessive inclination of engine
Incorrect lube oil SAE class or quality
Fuel quality not as per operating manual
Air cleaner clogged / turbocharger defective
Air cleaner service switch / indicator defective
LDA* defective
●
Charge air line leaking
Oil cooler panels clogged
Cooling fan defective, split or loose V-belt
Cooling air temperature rise / heating short circuit
Resistance in cooling system too great / through-flow quantity too small
Battery defective or discharged
Faults, Causes and Remedies
Section
Operation
Operating
media
Combustion air
Cooling system
Electrics
7
P
P
A
P
S
W
W
P / W
P / W
P
P
P / R
P / W
P
P
P / A
* LDA = Aneroid device
7
Faults, Causes and Remedies
Fault Remedy
Engine fails or is difficult to start Check P
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes – blue
– white
– black
Cause
●
●
●
●● ● ●●
●●●
●●●●● ●●
Electric cable connections to starter electrical system loose or oxidized
Starter defect or pinion does not engage
Solenoid defective (release switch)
Incorrect valve clearance
Leaking injection line
Injection valve defective
7.1 Diagnosis Chart
Section
Electrics
Engine
P
P
P
E
P
P / W
8.1 Preservation
Engine Preservation
8
Engine Preservation
8.1 Preservation
8
If the engine is to remain idle for an extended period
of time, it is necessary to take protective measures to
prevent rusting. The preservative measures described
here will protect the engine for up to 6 month
The procedure will have to be reversed before the
engine is recommissioned.
● Anti-corrosion oils to specification:
MIL-L-21260B
TL 9150-037/2
Nato Code C 640 / 642
● Anti-corrosion media for exterior protection only
to specification:
Nato Code C 632
● Recommended cleaning agent to remove preservatives:
Petroleum benzine
(hazardous materials class A3)
s.
8.1.1 Preserving Engine
● Clean engine using high-pressure equipment
(or with cold-cleansing agent in emergency).
● Run engine until warm, then turn off.
● Drain engine oil (see 6.1.2) and fill with anti-
corrosion oil.
● If necessary, clean oil bath cleaner (see 6.4.3)
and fill with anti-corrosion oil.
● Drain fuel tank.
● Make up a mixture of 90% diesel fuel and 10%
anti-corrosion oil, and refill fuel tank.
● Allow engine to run for approx. 10 mins.
● Switch off engine.
● Turn engine over manually several times to pre-
serve cylinders and combustion chamber.
● Remove V-belts and store in wrapped condition.
● Spray grooves on V-belt pulleys with anti-corro-
sion spray.
● Close intake ports and exhaust ports.
8.1.2 Removing Engine
Preservatives
● Remove anti-corrosion agent from grooves in
V-belt pulleys.
● Install V-belt, retension after brief operation if
necessary, see 6.5.
● Remove covers from intake port and exhaust
port.
● Commission engine, see also 5.1, note 2.
Technical Specifications
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
9
Technical Specifications 9.1 Engine Specifications and Settings
9
Model
Numbers of cylinders
Cylinder arrangement
Bore [mm]
Stroke [mm]
Total displacement [cm
Compression ratio [
Working cycle
Combustion system
Direction of rotation
ε]
3
]
—— F2L 1011F —— F3L 1011F ————— F4L 1011F — F4L 1011FL* ——
——— 2 —————— 3 ————————— 4 ————— 4 ————
————————————— vertical in line ——————————————
———————————————— 91 ————————————————
——— 105 ———— 105 ———————— 105 ————— 112 ————
——— 1366 ———— 2049 ——————— 2732 ——— 2912 ———
——————————————— 18,5 ————————————————
———————————— 4-stroke diesel engine ————————————
——————————— naturally aspirated engine with direct injection ————
————————————— counter clockwise —————————————
Weight incl. integrated cooling system as per DIN 70020-A
(without starter, with alternator) ca.[kg]
Engine power [kW (PS)]
Speed [1/min]
Lubrication
SAE oil
Max. oil temperature in oil sump [°C]
——— 167 ———— 208 ———————— 249 ————— 250 ————
————————————————
————————————————
———————————— pressure lubrication —————————————
—————————————— 20 W 20 ———————————————
——————————————— 130 ————————————————
Min. oil pressure in warm condition, oil temperature 110 °C
at: 900/min (low idling speed) [bar]
1800 /min [bar]
max. 3300 /min, *max. 3000 /min [bar]
Oil change quantity (oil sump) ca. [ltr.]
Oil change quantity with filter (Standard 0.5 ltr.) ca. [ltr.]
Valve clearance with cold engine [mm]
(Engine cooling time at least 30 Min.: Oil temperature below 80°C)
Start of delivery [
[mm]
°crank angle b TDC
Injector opening pressure: vehicle/genset engine [bar]
Firing order of the engine
V-Belt tension:
(after the engine has been running under load for 15 mins):
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative.
3)
Values for engines without engine oil heating.
Pretension / Retension
[N]
——————————————— 1,4
——————————————— 2,2
——————————————— 3
——— 6
——— 6,5
2)
————
2)
—————
5,5
6
2)
2)
——————————————— inlet 0.3 ———————————————
—————————————— exhaust 0.5 ——————————————
————————————————
]
—————————————— 210 / 250
——— 1 - 2 ——— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 — 1 - 3 - 4 - 2 ——
————————————— 450 / 350 ±20 ——————————————
1)
———————————————————
1)
———————————————————
3)
——————————————————
3)
——————————————————
3)
——————————————————
—————————
————————
1)
———————————————————
+8
————————————————
10
10,5
2)
—————
2)
———
10
10,5
2)
————
2)
———
Technical Specifications
9.1 Engine Specifications and Settings
Model
Number of cylinders
Cylinder arrangement
Bore [mm]
Stroke [mm]
ε]
3
]
Total displacement [cm
Compression ratio [
Working cycle / Combustion system
Direction of rotation
Weight without cooling system [kg]
Weight without starter, with alternator as per DIN 70020-A ca. [kg]
Engine power [kW (PS)]
Speed [1/min]
Lubrication
SAE oil
Max. oil temperature in the oil sump [°C]
at: 900/min (low idling speed) [bar]
1800 /min [bar]
max. 3000 /min [bar]
Oil change quantity (oil sump without cooling system) ca. [ltr.]
Oil change quantity with filter (Standard 0.5 ltr.) ca. [ltr.]
Valve clearance with cold engine
(Engine cooling time at least 30 mins.: oil temperature below 80°C) [mm]
Injector opening pressure: vehicle/genset engine [bar]
Start of delivery [°crank angle b TDC]
Firing order of the engine
V-Belt tension:
Pretension / Retension (after the engine has been running under load for 15 mins):[N]
——— BF3L 1011F/L ———————— BF4L 1011F/FT ——
————— 3 ———————————— 4 ——————
—————————— vertical in line———————————
———————————— 91 —————————————
———— 105/112 ——————————— 105 —————
———— 2184 ——————————— 2732 —————
———————————— 17 —————————————
——— 4-stroke diesel with turbocharging and direct injection ——
————————— counter clockwise ——————————
————————— Refer to head-office —————————
————— 233 ———————————— 256 —————
1)
————————————
——————————————————————
———————————————
1)
———————————————
————————— pressure lubrication —————————
——————————— 20 W 20 ————————————
———————————— 130 ————————————
3)
——————————— 1,4
——————————— 2,2
———————————— 3
————— 7,5 ———————————— 10
————— 8 ——————————— 10,5
0,1
——————— inlet 0,3
+
—————————— 210 / 250
——————————————1)———————————————
——————————————
3)
——————————————
3)
——————————————
2)
2)
0,1
/ exhaust 0,5
+ 8
+
————————
————————————
——————
——————
———— 1 - 2 - 3 —————————— 1-3-4-2 —————
—————————— 450 / 350 ±20 ——————————
9
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Ca. value can vary depending on oil sump and or coolor design (external cooling system). The upper oil dipstick marking should always be taken as authoritative.
3)
Values for engines without engine oil heating.
Technical Specifications
Model
9 9
Number of cylinders
Cylinder arrangement
Bore [mm]
Stroke [mm]
Total displacement [cm3]
Compression ratio [e]
Working cycle
Combustion system
Direction of rotation
Weight without cooling system
(without starter, with generator) ca. [kg]
Engine power [kW (PS)]
Speed [1/min]
Lubrication
SAE oil
Maximum oil temperature in the oil sump [°C]
Minimum oil pressure in warm condition, oil temperature 110 °C,
at: 900/min (low idling speed) [bar]
1800 /min [bar]
max. 3000 /min [bar]
Engine with Thermostat
Oil change quantity without external cooler (see 3.1.1.2)/ without filter approx.
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement
(Standard 0.5 litre) approx.
Genset engine without Thermostat:
Oil change quantity including cooler (see 3.1.1.3)/ without filter approx.
Oil change quantity including cooler (see 3.1.1.3) + filter replacement [ltr.]
(Standard 0.5 litre) approx.
Valve clearance at cold engine
(Engine cooling time at least 30 mins.: oil temperature below 80°C) [mm]
Start delivery [°crank angle b TDC]
Injector opening pressure: vehicle/genset engine [bar]
Firing order of the engine
V-Belt tension: Pretension / Retension(after the engine has been running under load for 15 mins):[N]
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Ca. value can vary depending on oil sump and or coolor design (external cooling system).T
3)
Values for engines without engine oil heating.
[ltr.]
[ltr.]
[ltr.]
——— F3M 1011F ———————— F4M 1011F ——
————— 3 ———————————— 4 ————
—————————— vertical in line ————————
———————————— 91 ———————————
————— 112 ———————————— 112 ———
———— 2184 ——————————— 2912 ———
———————————— 18,5 —————
———————— 4-stroke diesel engine ———————
————— naturally aspirated engine with direct injection
————————— counter clockwise ————————
———————— Rückfrage Stammhaus ———————
————— 200 ———————————— 242 ———
———————————— 1) ———————————
————————————
———————— Druckumlaufschmierung ——————
——————————— 20 W 20 ——————————
———————————— 130 ——————————
——————————— 1,4 3) ——————————
——————————— 2,2 3)——————————
———————————— 3 3)——————————
———— 5,5 2)——————————— 10 2)———
————— 6 2)——————————— 10,5 2)———
———— 8,5 2)——————————— 13 2)———
————— 9 2)——————————— 13,5 2)———
—————————————
—————————————
—————— inlet 0,3
————————————
—————————— 210 / 250+8—————————
———— 1 - 2 - 3 ————————— 1 - 3 - 4 - 2 ——
+
1)
0,1
/ exhaust 0,5
1)
———————————
+
0,1
————
———————————
—————— 450 / 350 ±20 ————————
/ ———
he upper oil dipstick marking should always be taken as authoritative.
Technical Specifications
9.1 Engine Specifications and Settings
Model
Number of cylinders
Cylinder arrangement
Bore [mm]
Stroke [mm]
Total displacement [cm
Compression ratio [
Working cycle
Combustion system
Direction of rotation
Weight without cooling system
(without starter, with generator) ca. [kg]
Engine power [kW (PS)]
Speed [1/min]
Lubrication
SAE oil
Maximum oil temperature in the oil sump [°C]
Minimum oil pressure in warm condition, oil temperature 110 °C,
at: 900/min (low idling speed) [bar]
1800 /min [bar]
max. 2800 /min [bar]
3
ε]
]
——— BF3M 1011 F ———————— BF4M 1011 F ———
————— 3 ———————————— 4 ——
—————————— vertical, in line ——————————
———————————— 91 —————————————
———————————— 112 ————————————
———— 2184 ——————————— 2912 —————
———————————— 17 —————————————
—————————— 4-stroke diesel ——————————
—————— turbocharging and direct injection ———————
————————— counter clockwise ——————————
————————— Refer to head-office —————————
————— 226 ———————————— 249 —————
———————————— 1) —————————————
———————————— 1) —————————————
————————— pressure lubrication —————————
——————————— 20 W 20 ————————————
———————————— 130 ————————————
———————————— 1,4
———————————— 2,2
———————————— 3
3)
————————————————————
3)
————————————————————
3)
—————————————————————
Engine with Thermostat
Oil change quantity without external cooler (see 3.1.1.2)/ without filter approx. [ltr.]
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement [ltr.]
(Standard 0.5 litre) approx.
————— 7,5 ———————————— 10
————— 8 ——————————— 10,5
2)
—————————
2)
————————
Genset engine without Thermostat:
2)
Oil change quantity including cooler (see 3.1.1.3)/ without filter approx. [ltr.]
Oil change quantity including cooler (see 3.1.1.3) + filter replacement [ltr.]
(Standard 0.5 litre) approx.
Valve clearance at cold engine
(Engine cooling time at least 30 mins.: oil temperature below 80°C) [mm]
Start delivery [°crank angle b TDC]
Injector opening pressure: vehicle/genset engine [bar]
Firing order of the engine
V-Belt tension:
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Ca. value can vary depending on oil sump and or coolor design (external cooling system).The upper oil dipstick marking should always be taken as authoritative.
3)
Values for engines without engine oil heating.
Pretension / Retension (after the engine has been running under load for 15 mins):[N]
————— 11 ——————————— 13,5
————— 11,5 ——————————— 14
——————— inlet 0,3
+0,1
/ exhaust 0,5
+0,1
————————
———————————— 1) —————————————
+8
—————————— 210 / 250
———————————
———— 1-2-3 —————————— 1-3-4-2 —————
—————————— 400 / 300 ±20 ——————————
————————
2)
—————————
9
Technical Specifications
9.2 Torque Wrench Settings
9
Preload [Nm] Torquing Load [Nm]
Location
Rocker cover 8,5
Rocker arm set screw 21
Air intake manifold 8,5
Exhaust manifold 22
Oil drain plug 55
Injector mounting 21 TORX
Injector line mounting 30
1st
Stage
2nd
Stage
3rd
Stage
1st
Stage
2nd
Stage
3rd
Stage
4th
Stage
Total [Nm] Remarks
21
40
22
Oil pan (cast iron) 31
Oil pan (sheet metal) 21
9.3 Tools
Technical Specifications
TORX
25899 0 26002 0
A TORX wrench set (order number 8189) is used
with engines in the 1011 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.
V-belt Tension Gauge
9
The V-belt tension gauge can be obtained under
order number 91 107 from:
COMPANY WILBÄR
Postfach 14 05 80
D-42826 Remscheid
TORX tools can be ordered from:
COMPANY WILBÄR
Postfach 14 05 80
D-42826 Remscheid
Notes
en
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.
or
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.
C
ALIFORNIA
P
ROPOSITION
65 I
NFORMATION
Notes
en
TOC
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
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.)
1.
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.
Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
2.
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
ALIFORNIA CUSTOMERS AND
C
FOR USE IN
ALIFORNIA.
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.
9
Notes
Service
en
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
10
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
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