Page 1
5.1 Maintenance schedule
cardiagn.com
5.2 Maintenance diagram
5.3 Maintenance work carried out
Maintenance
5
© 2005
Page 2
Maintenance 5.1 Maintenance schedule
cardiagn.com
5
check= z set= clean=L renew=
⇓ check 2x daily before or during the 1st trial run, during the running-in phase or
when commissioning new and overhauled engines.
⇓ every 10 oh or daily
in operating hours (oh) every year(s)
E10 E20 E30 E40 E45 E50 E60 E70
500 1,000 1,5003,0006 ,00 0 12,000 1 2
zz
z
z
zz
zzz
zz
zz L
zz
zz
zz
zz
zz
1)
L
z
L
z
z
z
Activity
Lube oil level, if necessary re-fill 6.1.2
Lube oil (oil change intervals depending on engine application and oil quality), see TR 0199-99-3002
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Electronic injector check via EMR3
Fuel filter insert1) (fuel pre-filter) 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant level –
Intake air filter
Charge air cooler (drain lube oil/condensation)
EGR(option)* Check non-return valve (option)
EGR(option) Check cap and adjustment mechanism for clearance, renew if necessary .
CoolerEGR (option)
Check function of heating flange
Battery and cable connections 6.7.1
Engine monitoring, warning system 3.3
Valve clearance 6.6.1
V-belt/tension pulley (renew when wear limit reached) 6.5.1/6.5.3
Crankcase pressure bleed valve (option)
Engine tightness (visual inspection for leaks). –
Engine mounting (renew in case of damage) 9.2
Fastenings, hose connections / clamps –
General overhaul
(if available, maintenance as per maintenance display)
Industrial engines
The engine maintenance times given are maximum permissible job
times. Depending on the usage circumstances, shorter maintenance
times may be necessary. Observe the instruction manual of the
equipment manufacturer.
# Maintenance only to be carried out by authorised service personnel
Section
6.1.1/ 6.1.2
#
6.4.3 /6.4.4
#
#
#
EGR* exhaust gas recirculation (system); If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.
1)
The intervals can be reduced, depending on the degree of soiling of the fuel used.
© 2005
Page 3
5.1 Maintenance schedule Maintenance
cardiagn.com
check= z set= clean= L renew=
max. permissible job times in operating hours (oh) every
check 2x daily before or during the 1st trial run, during the running-in phase or
⇓
when commissioning new and overhauled engines.
⇓
every 10 oh or daily
in operating hours (oh) every
E10 E30 E40 E70
500 6.000 12.000 1 2
z L
z L
L
Charge air cooler (drain lube oil/condensation)
Charge air cooler inlet surface (clean if necessary) #
Crankcase pressure bleed valve (option)
Activity
Enhancements or modifications for engines with
EPA acceptance
The engine maintenance times given are maximum
permissible job times. Depending on the usage
circumstances, shorter maintenance times may be
necessary. Observe the instruction manual of the
equipment manufacturer. # Maintenance only to be
carried out by authorised service personnel
Section
#
#
5
© 2005
Page 4
Maintenance 5.1 Maintenance schedule
cardiagn.com
5
check= z set= clean= L renew=
⇓ check 2x daily before or during the 1st trial run, during the running in phase or when commissioning new and overhauled engines.
⇓ every 200 km or daily
OPERATIONAL PERFORMANCE IN (km)year(s)
E10 E20 E30 E4 0 E4 5 E5 0 E60 E70
5,000
1 0.000
2 0.000
3 0.000
120..000
240.000
1
zz
z
z
zz
zz z
zz
zz L
zz
zz
zz
zz
zz
EGR* Exhaust gas recirculation (system); If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.
1)
The intervals can be reduced, depending on the degree of soiling of the fuel used.
1)
L
z
L
z
z
z
2
General overhaul
Service Yearly op. Average
group performance
km
I <30 000 20
II >30 to 100 000 40
II I >100 000 60
Activity
Lube oil level, if necessary re-fill 6.1.2
Lube oil (oil change intervals depending on engine application and oil quality), see TR 0199-99-3002
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Electronic injector check via EMR3
Fuel filter insert1) (fuel pre-filter) 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant level –
Intake air filter
Charge air cooler (drain lube oil/condensation)
EGR(option)* Check non-return valve (option)
EGR(option) Check cap and adjustment mechanism for clearance, renew if necessary .
CoolerEGR (option)
Check function of heating flange
Battery and cable connections 6.7.1
Engine monitoring, warning system & 3.3
Valve clearance 6.6.1
V-belt/tension pulley (renew when wear limit reached) 6.5.1/6.5.3
Crankcase pressure bleed valve (option)
Engine tightness (visual inspection for leaks). –
Engine mounting (renew in case of damage) 9.2
Fastenings, hose connections / clamps –
(if available, maintenance as per maintenance display)
Drive
speed
approx.km/h
Service group I <30 000km 20
The engine maintenance times given are maximum permissible
job times. Depending on the usage circumstances, shorter
maintenance times may be necessary. Observe the instruction
manual of the equipment manufacturer.
to be carried out by authorised service personnel
Vehicle engines
approx.km/h
#
Maintenance only
Section
6.1.1/ 6.1.2
#
6.4.3 /6.4.4
#
#
#
Page 5
5.1 Maintenance schedule Maintenance
cardiagn.com
check= zset= clean= L renew=
⇓ check 2x daily before or during the 1st trial run, during the runningin phase or when commissioning new and overhauled engines.
⇓ every 200 km or daily
OPERATIONAL PERFORMANCE IN (km)year(s)
E10 E20 E30 E40 E40 E50 E60 E70
20,000
40, 000
50, 000
240,000
480,000
1
zz
z
z
zz
zz z
zz
zz L
zz
zz
zz
zz
zz
1)
L
z
L
z
z
z
Activity
2
Lube oil level, if necessary re-fill 6.1.2
L
ube oil (oil change intervals depending on engine application and oil quality), see TR 0199-99-3002
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Electronic injector check via EMR3
Fuel filter insert1) (fuel pre-filter) 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant level –
Intake air filter
Charge air cooler (drain lube oil/condensation)
EGR(option)* Check non-return valve (option)
EGR(option) Check cap and adjustment mechanism for clearance, renew if necessary .
CoolerEGR (option)
Check function of heating flange
Battery and cable connections 6.7.1
Engine monitoring, warning system & 3.3
Valve clearance 6.6.1
V-belt/tension pulley (renew when wear limit reached) 6.5.1/6.5.3
Crankcase pressure bleed valve (option)
Engine tightness (visual inspection for leaks). –
Engine mounting (renew in case of damage) 9.2
Fastenings, hose connections / clamps –
General overhaul
Service Yearly op. Average
group performance
km
I <30 000 20
II >30 to 100 000 40
II I >100 000 60
(if available, maintenance as per maintenance display)
Drive
speed
approx.km/h
Vehicle engines
Service group Il 100 000km 40approx.km/h
The engine maintenance times given are maximum permissible
job times. Depending on the usage circumstances, shorter
maintenance times may be necessary. Observe the instruction
manual of the equipment manufacturer. # Maintenance only to be
carried out by authorised service personnel
Section
6.1.1/ 6.1.2
#
6.4.3 /6.4.4
#
#
#
5
EGR* Exhaust gas recirculation (system); If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.
1)
The intervals can be reduced, depending on the degree of soiling of the fuel used.
Page 6
Maintenance
cardiagn.com
5.1 Maintenance schedule
5
check= zset= clean= L renew=
check 2x daily before or during the 1st trial run, during the running-in phase
⇓
or when commissioning new and overhauled engines
⇓ every 200 km or daily
OPERATIONAL PERFORMANCE IN (km) every
Service group III year(s)
E10 E20 E30 E40 E45 E50 E60 E70
30.000
60.000
zz
z
zz
zz z
zz
zz L
zz
zz
zz
zz
zz
EGR* Exhaust gas recirculation (system); If the warning system (light/siren) is activated, the fuel pre-filter must be emptied immediately.
1)
The intervals can be reduced, depending on the degree of soiling of the fuel used.
© 2005
1)
z
z
z
90.000
120.000
360.000
1000. 000
1
z
L
z
L
Activity
2
Lube oil level, if necessary re-fill 6.1.2
L
ube oil (oil change intervals depending on engine application and oil quality), see TR 0199-99-3002
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Electronic injector check via EMR3
Fuel filter insert1) (fuel pre-filter) 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant level –
Intake air filter
Charge air cooler (drain lube oil/condensation)
EGR(option)* Check non-return valve (option)
EGR(option) Check cap and adjustment mechanism for clearance, renew if necessary .
CoolerEGR (option)
Check function of heating flange
Battery and cable connections 6.7.1
Engine monitoring, warning system & 3.3
Valve clearance 6.6.1
V-belt/tension pulley (renew when wear limit reached) 6.5.1
Crankcase pressure bleed valve (option)
Engine tightness (visual inspection for leaks). –
Engine mounting (renew in case of damage) 9. 2
Fastenings, hose connections / clamps –
General overhaul
ServiceYearly op. Average
group performance
km
I <30 000 20
II >30 to 100 000 40
II I >100 000 60
(if available, maintenance as per maintenance display)
Drive
speed
approx.km/h
V ehicle engines
Service group Ill >100 000 km 60approx.km/h
The engine maintenance times given are maximum
permissible job times. Depending on the usage circumstances,
shorter maintenance times may be necessary. Observe the
instruction manual of the equipment manufacturer.
# Maintenance only to be carried out by authorised service personnel
Section
6.1.1/ 6.1.2
#
6.4.3/6.4.4
#
#
#
Page 7
Maintenance 5.1 Maintenance schedule
cardiagn.com
5.1.1 Standard maintenance schedule
Intervals Deutz maintenance and Activity Execution by:
at/after service schedules
50 oh E 10 after commissioning and E 50-E 70 authorised specialists
daily E 20 daily inspection round the user / authorised specialists
500 oh E 30 inspection authorised specialists
1000 oh E 40 intermediate overhaul authorised specialists
1500 oh E 45 extended intermediate overhaul authorised specialists
3 000 oh E 60 partial overhaul authorised specialists
6000 oh E 60 partial overhaul authorised specialists
10 000 oh (2012) E 70 overhaul authorised specialists
13 000 oh (2013) E 70 overhaul authorised specialists
5
*) approximate value, depends on the type of engine application and/or regular engine maintenance.
Please contact your responsible DEUTZ Service partner.
© 2005
Page 8
5
cardiagn.com
5.2 Maintenance diagram Maintenance
The maintenance diagram shown on this
page is supplied with every engine in selfadhesive form. It should be stuck onto a well
visible location on the engine or equipment.
Check that this is the case!
If not, request a replacement from your engine
or equipment supplier!
The maintenance schedule is decisive for
standard maintenance, see 5.1.
All maintenance work should
only be carried out when the
engine is not running.
© 2005
Page 9
5.3 Maintenance work carried out Maintenance
cardiagn.com
Op. hrs.
50-150
125
375
625
875
1125
1375
1625
1875
*
Date
Signature / stamp Op. hrs. D at e
250
500
750
1000
1250
1500
1750
2000
Signature / stamp
5
2115
2375
* after commissioning new and overhauled engines
The maintenance work carried out methodically can be recorded in the table and confirmed.
2250
2500
2750
© 2005
Page 10
Maintenance 5.3 Maintenance work carried out
cardiagn.com
5
Op. hrs.
2875
3125
3375
3625
3875
4125
4375
4625
4875
Da te Signature / stamp
Op. hrs. Signature / stamp
3000
3250
3500
3750
4000
4250
4500
4750
5000
Date
5125
5375
5625
The maintenance work carried out methodically can be recorded in the table and confirmed.
© 2005
5250
5500
5750
Page 11
5.3 Maintenance work carried out Maintenance
cardiagn.com
Op. hrs.
5875
6125
6375
6625
6875
7125
7375
7625
7825
Date
Signature / stamp Op. hrs. D at e
6000
6250
6500
6750
7000
7250
7500
7750
8000
Signature / stamp
5
8125
8375
8625
The maintenance work carried out methodically can be recorded in the table and confirmed.
8250
8500
8750
© 2005
Page 12
Maintenance 5.3 Maintenance work carried out
cardiagn.com
5
Op. hrs.
8875
9125
9375
9625
9875
10125
10375
10625
10875
Da te Signature / stamp
Op. hrs. Signature / stamp
9000
9250
9500
9750
10000
10250
10500
10750
10000
Date
10125
10375
10625
The maintenance work carried out methodically can be recorded in the table and confirmed.
© 2005
10250
10500
10750
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