Deutz F2M 2011 Operation Manual

22093 Umschlag 16.01.2006 8:16 Uhr Seite 1

Operation Manual

2011


!

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).

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.

Operation manual

2011

0297 9929 en

Foreword

Dear Customer,

Liquid-cooled Deutz engines are designed for a large number of applications.

Consequently, a wide range of variants is 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 fitted to your engine.

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

Please read this Manual before starting your engine, and always observe the operating and maintenance instructions.

We are available to help with any additional inquiries

Sincerely,

DEUTZ AG

1.

General

2.

Engine 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 Numbering

2.1.5

Fuel Delivery Lock

2.2

Engine Illustrations

2.2.1 Operation Side:

Example FL 2011

2.2.2

Exhaust Side:

Example FL 2011

2.2.3

Operation Side:

Example BF4L 2011

2.2.4

Exhaust Side:

Example BF4L 2011

2.2.5

Operation Side:

Example FM 2011

2.2.6

Exhaust Side:

Example FM 2011

2.2.7

Operation Side:

Example BFM 2011

2.2.8

Exhaust Side:

Example BFM 2011

2.3

Oil Circuit

2.3.1 Lube Oil Circuit Schematic

2.4

Fuel System Schematic

2.4.1 Fuel System

2.5

Coolant System

2.5.1

Coolant Plan

3.

Engine Operation

3.1

Commissioning

3.1.1

Adding Engine Oil

3.1.2

Adding Fuel

3.1.3

Other Preperations

3.1.4 Additional Maintenance Work

3.2

Starting

3.2.1

Electric Starting

3.3

Monitoring Operation

3.3.1

Engine Oil Pressure

3.3.2 Engine Temperature

3.4

Shutting Off

3.4.1

Mechanical Shut-Off

3.4.2

Electric Shut-Off

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

4.1.2

Viscosity

4.2

Fuel

4.2.1 Quality

4.2.2

Winter-Grade Fuel

5. Service

5.1

Service Plan

5.2

Scheduled Maintenance Plan

5.3

Maintenance Chart

5.4

Maintenance Work Completed

Contents

6. Service and Maintenance

6.1

Lubrication System

6.1.1

Oil Change Intervals

6.1.2

Check Oil Level, Change Engine Oil

6.1.3 Changing Oil Filter

6.1.4

Clean/Replace Oil Filter (Cup)

6.2

Fuel System

6.2.1

Replace Fuel Filter

6.2.2 Clean/Replace Fuel Filter (Cup)

6.2.3

Clean Stainer of Fuel Filter

6.2.4

Change Fuel Leakage Line

6.3

Cooling System

6.3.1 Cleaning Intervals

6.4

Combustion Air Filter


6.4.2

Emptying Cyclone-Type Precleaner

6.4.3

Dry Type Air Cleaner

6.5

Belt Drives

6.5.1

Check V-belt

6.5.2

Tensioning Alternator Belts

6.5.3

Changing Alternator Belts

6.6

Adjustments

6.6.1

Check Valve Clearance, adjust if necessary

Valve Clearance Adjustment 6.6.1.1

Schematic

6.7

Accessories

6.7.1

Battery

6.7.2

Rotary Current Alternator

6.7.3 Transportation Shackles

6.8

Engine Cleaning

6.8.1

Engine Cleaning

Contents

7. Faults, Causes and

Remedies

7.1

Fault Table

8. Engine Preservation

8.1

Preservation

8.1.1 Preserving Engine

8.1.2 Removing Engine Preservatives

9. Technical Specification

9.1

9.2

9.3

Engine Specifications and Settings

Torque Wrench Settings

Tools

10. Service

General

1

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.

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.

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.

Safety

!

This symbol is used for all safety warnings. Please follow them carefully. The attention of operating personnel should be drawn to these safety instructions. General safety and accident prevention regulations laid down by law must also be observed.

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-theart 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 asbestos-free.


2

2.1 Model

2.2 Engine Illustrations

2.3 Lube Oil Circuit Schematic

2.4 Fuel System Schematic


2

2.1.1 Rating Plate 2.1.2 Position of the Rating Plate

C

A

B

2.1 Model

2.1.3 Engine Serial Number

© 26 332 2

The model A, the engine serial number B and the performance data are stamped on the rating plate.

The model and engine serial number must be given when ordering parts.

© 31 864 0

The rating plate C is attached to the valve cover.

© 31 865 0

The engine serial number B is stamped on the crankcase D as well as the rating plate.

2.1 Model

2.1.4 Cylinder Numbering

1 2 3 4

2.1.5 Fuel Delivery Lock


2

© 26 431 0

Cylinders are numbered consecutively, beginning at the flywheel.

© 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: with torque balancer

2. with plastic protective cap on model: without torque balancer.

!

Adjustments to the regulator are to be carried out only by authorised DEUTZ SERVICE specialists


2

2.2.1 Operation Side

FL 2011

19

18

17

16

15

21

20

14 13

2.2 Engine Illustration

12 11 10 9

1

4

5

2

3

6

7

8

© 31 873 1

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 Tractive electromagnet

6 Wheel-house cover

7 V-belt pulley on crankshaft

8 Oil pan

9 Shut-off lever

10 Speed control lever

11 Oil dipstick

12 Oil drain plug

13 Crankcase

14 Oil fill point (on side of crankcase)

15 Fuel pump

16 Easy-change fuel filter

17 Connecting facility for oil heater

18 Lube oil replacement filter

19 Removable coolant intake hood

20 Injection pumps

21 Oil cooler


2.2.2 Exhaust Side

FL 2011

29

28

27

26

26

23

24

22


22 Date plate

23 Optional attachment of an SAE housing

24 Flywheel with ring gear

25 Starter

26 Front cover

27 Crankcase

28 Exhaust manifold

29 Air intake pipe

2

© 31 874 1


2


Example: BF4L 2011

© 31869 2




3 Fan with integrated generator

4 Narrow V-belt


6 Wheel-house cover


8 Oil pan

9 Shut-off lever


11 Oil dipstick

12 Crankcase


14 Fuel pump



17 Charge-pressure-dependent full-load stop

(CPD)


19 Removable coolant intake hood

20 Injection pumps

21 Oil cooler



Example: BF4L 2011

32

31

29

27

30

28

26

25


2

22

23

24

22 Cylinder head

23 Exhaust manifold line


25 Starter

26 Crankcase

27 Lube oil feed line to turbocharger

28 Lube oil return line from turbocharger

29 Induction pipe

30 Turbocharger (TC)

31 Intake manifold

32 Charge-air line

© 31 868 1


2


FM 2011

© 31 875 3




3 Alternator

4 Narrow V-belt


6 Timing belt cover


8 Oil pan

9 Shut-off lever


11 Oil dipstick

12 Oil drain plug


14 Fuel pump




18 Injection pump(s)

19 Oil cooler connection

20 Injection valve(s)

X fuel to run line

Y fuel back run line



FM 2011


2

21 Cylinder head

22 Exhaust manifold


24 Starter

25 Starter guard (optional)

26 Crankcase

27 Air intake pipe

© 31876 2


2


BFM 2011

© 31 861 3


1 Air-intake pipe

2 Fan wheel


4 Narrow V-belt


6 Timing belt cover

7 Shut-off lever



10 Oil dipstick

11 Fuel pump




15 Injection pump(s)

16 Oil cooler connection

17 Injection valve(s)



BFM 2011


2

18 Crankcase ventilation (optional)

19 Cylinder head cover

20 Exhaust manifold

21 SAE housing

22 Starter

23 Crankcase

24 Turbocharger

25 Generator with cover

26 Charge-air line

27 Oil filler neck

© 31 862 3


2

2.3.1 Lube Oil Circuit Schematic

2.3 Oil Circuit

© 31877 2

1 Oil pan

2 Oil-intake pipe

3 Oil pump

4 Main oil duct

5 Oil-cooled cylinders

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 cam, con-rod and crankshaft bearings

16 Spray nozzle for piston cooling

17 Oil return via crankcase to oil pan

18 Lube oil intake to turbocharger

19 Turbocharger

20 Return from turbocharger to oil pan

Oil filter console with integrated switching valve for the control of the hydraulic tappets

(arrow)

A engine is cold (around an early adjustment of the beginning of delivery to reach, the pistons in the pump tappet with oil become ge feed)

B engine is warm

2.4 Fuel System Schematic

2.4.1 Fuel System


1 Fuel line from tank to fuel pump

2 Fuel pump

3 Fuel line from fuel pump to easy-change fuel filter


5 Fuel line from filter to injection pump

6 Injection pump

7 Fuel distributor line

8 Injection line

9 Injection valves x Fuel overflow pipe y Fuel return line to tank

2

© 31 863 2

The installation of a fuel pre-filter/ hand pump between the fuel tank and the engine is prescribed to protect the engines against dirt in the fuel.

2

3.1 Commissioning

3.2 Starting

3.3 Monitoring Operation

3.4 Shutting Off


3

3

3


3.1.1 Adding Engine Oil

OIL


3.1.1.1

Initial Engine Oil Fill-Up for B/FL 2011

● Fill oil into oil pan up to "Max." mark on engine dipstick (for oil quantity see 9.1).

● Start engine and allow to run at low idling speed for approx. 2 mins.

● Switch off engine.

● Check oil level, if necessary, top up oil to "Max." mark.

3.1.1.2

Initial Engine Oil Fill-Up

B/FM 2011

● Fill oil into oil pan up to "Min." mark on engine dipstick.

● In addition, top up oil quantity of supply hoses and of external oil cooler (according to manufacturer’s specifications).

● Allow engine to run warm until thermostat opens

(at approx. 95°C).

● Allow engine to run for approx. 2 mins.


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

"Max." mark.

© 26 432 0

As a rule, engines are delivered without oil.

Pour lube oil into the oil filler neck (arrow).

For oil grade and viscosity, see 4.1.

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 dipstick when delivered. The level can then only be assessed after the engine has been run up.


3.1.1.3

Initial Engine Oil Fill-Up

B/FM 2011 Genset Engine

● Fill oil into oil pan up to "Max." mark on engine dipstick (for oil quantity see 9.1).

● Start engine and allow to run at low idling speed for approx. 2 mins.


● Check oil level and fill up with oil up to upper

"Max." mark.

3.1.2 Adding Fuel

FUEL


3

3

© 26 398 0

Use only commercial-grade diesel fuel. For fuel grade, see 4.2. Use summer or winter-grade fuel, depending on the ambient temperature.

!

Never fill the tank while the engine is running.

Ensure cleanliness!

Do not spill fuel!


3

3.1.3 Other Preparations 3.1.4 Additional Maintenance Work

● Check battery and cable connectors, see 6.7.1.

● Transport hooks

Remove if fitted (see 6.7.3)

● Trial run

After engine has been prepared, let it run for about 10 minutes without being loaded.

During and after trial run

- Check engine for leaks.

After engine has been turned off

- Check oil level, see 6.1.2.

Top up with oil, if necessary, see 3.1.1.

- Retension V-belt, see 6.5).

When commissioning new and reconditioned engines, the following additional maintenance work must be carried out:

● Change lube oil, see 6.1.1. + 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 engine for leaks

● Check engine mounts, retighten if necessary, see 9.2.

● Check valve clearance, adjust if necessary, see 5.1. + 6.6.1.


3

3


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 machine.

After repair work:

Check that all guards have 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 been removed, the engine must not be tested under any circumstances.

Disconnect the battery!

2

1

© 26 423 0

● Where possible, disengage clutch to separate engine from any driven parts.

● Move speed control lever 1 into idle position.

● Move shut-off handle 2 into operating position.

Without cold start assistance

© 25 746 2

● Insert key

- Position 0 = no operating voltage

● Turn key clockwise

- Position 1 = operating voltage

- Pilot lights come on

● Push key in and turn further clockwise against spring pressure.

- Position 2 = no function

- Position 3 = start

● Release key as soon as engine fires

- Pilot lights go out.

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 Fault Table (see 7.1).

3.2 Starting

With cold start assistance

- Glow plug

© 25 746 2

● Insert key

- Position 0 = no operating voltage

● Turn key clockwise

- Position 1 = operating voltage

- Pilot lights come on

● Push key in and turn further clockwise against spring pressure.

- Position 2 = preheat, hold for approx. 1 minute.

- Preheat lamp comes on

- Position 3 = start

● Release key as soon as engine fires

- Pilot lights go out


3

3


3

3.3.1 Engine Oil Pressure

Oil Pressure Pilot Light

Oil Pressure Indicator


Oil Pressure Gauge

© 25 752 1

● Oil pressure pilot light comes on with operating voltage on and engine off.

● Oil pressure pilot light should go out when engine is running.

© 25 753 0

● Pointer must remain in green sector over entire operating range.

© 25 754 0

● Pointer must indicate minimum oil pressure

(see 9.1).


3.3.2 Engine Temperature

Engine Temperature Gauge

© 24 985 0

● Engine temperature gauge pointer should remain in green sector most of time. It should rarely enter yellow-green sector. If pointer enters orange sector, engine is overheating. Turn off and establish cause from Fault Table (see 7.1).


3

3


3

3.4.1 Mechanical Shut-Off 3.4.2 Electric Shut-Off

(Ignition Key)

2

1

© 26 424 0

● Move speed adjustment lever 1 to low idle.

● Move shut-off lever 2 until engine comes to a stop.

Charge pilot light and oil pressure pilot light will come on when engine stops.

● Turn key anticlockwise (to position 0) and remove. Pilot lights will go out.

© 25 746 2

● Turn key anticlockwise (to position 0) and remove. Pilot lights will go out.

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

3.4 Shutting Off

3.5 Operating Conditions

3.5.1 Winter Operation

● Lube Oil Viscosity

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

- Increase oil change frequency when operating below -10°C, see 6.1.1.

● Diesel Fuel

- Use winter-grade diesel fuel for operation be low 0°C, see 4.2.2.

● Additional Maintenance Work

- Drain sludge from fuel tank once a week (undo sludge drain screw).

- If necessary, allow oil in oil bath air cleaner and engine oil to settle at ambient temperature.

- Below -20°C, after removing starter if neces sary, smear ring gear on flywheel via pinion bore from time to time with cold-resistant grease.

(e.g. Bosch grease FT 1 V 31).

● Cold Start Assistance

- At temperatures near or below freezing point, use glow plugs if necessary, see 3.2.1.

This not only lowers starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

● Battery

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

- Starting limit temperatures can be lowered by

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


© 26 248 0

3

3


3

3.5.2 High Ambient Temperature,

High Altitude

● Air density decreases as altitude or ambient temperature increases. As a result of this, the engine’s maximum output, quality of exhaust gas, temperature level and, in extreme cases, starting behaviour, are impaired. Engine can be used at altitudes up to 1000 m and temperatures up to 30°C for mobile operations. 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

3.5 Operating Conditions

4.1 Lube Oil

4.2 Fuel

Operating Media

4

4

Operating Media

4.1.1 Quality Grade

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

Approved oils:

D e u t z

A C E A

A P I

DQC I

E2-96

DQC II

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

DQC III

E3/96/E5-02 E4-99

-

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.

4.1.2 Viscosity

Generally, multi-grade oils shall be used. In closed heated rooms at temperatures >5°C, also singlegrade 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.

4.1 Lube Oil

Only with preheating 30 298 1

4.2 Fuel

4.2.1 Quality

Operating Media

4.2.2 Winter-Grade Fuel

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)

TR 0199-99-3005 supplies details to the fuel specifications. The following fuel specifications are certified: (see for this TR 0199-99-

3002) TR is to be referred more over the

DEUTZ service organisacion

● 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)

● 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.

Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0°C, wintergrade fuel (suitable down to -15°C) should be used.

(This fuel is usually available from filling stations well in advance of the cold months). Diesel fuel containing additives (Super diesel) is often on sale as well, for use down to -20°C.

At temperatures below -15°C to -20°C, kerosene should be added to the diesel fuel. The relevant percentages are given in the adjacent diagram.

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 also be obtained by adding a flow improver

(additive). Please inquire at DEUTZ SERVICE.

+32

+23

+14

- 10

+ 5

- 15

0

- 5

I

- 4 - 20

- 13 - 25

II

- 22 - 30

°F

°C

0 10 20 30 40 50 60 %

A

A

B

I

II

Legend:

Summer-grade diesel fuel

Winter-grade diesel fuel

Ambient temperature

Percentage of kerosene added

!

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

!

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

4

4

5.1 Service Plan

5.2 Scheduled Maintenance Plan

5.3 Maintenance Chart

5.4 Maintenance Work Completed

Service

5

Service


5

Deutz maintenance and service schedule = E check = adjust = clean =

▲

replace = fl prior to or during 1st trial run, check 2x daily during the breaking-in phase or when commissioning new and overhauled engines fl every 10 operating hours or daily in operating hours (OH) every

E10 E20 E25 E30 E40 E45 E60

500 1000 3000 5000 6000

▲

▲

Years

1 2

Industrial engines

The specified engine maintenance intervals 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 authorise service personnel

Section

Operation

Top lube oil up if necessary

FL 2011 lube oil, see TC 0199-99-3002

BFL 2011 lube oil, see TC 0199-99-3002

Oil bath (lube oil quality, see TC 0199-99-3002 / Dry type filter

Oil filter cartridge FL 2011

Oil filter cartridge BFL 2011

Fuel filter cartridge

6.1.2/3.1.4

6.1.1/ 6.1.2

6.1.1/ 6.1.2

6.4

6.1.3

6.1.3

Change fuel pump/strainer if necessary

Flexible fuel leakage lines, see TC 0138-21-9300

Injection valve

Fuel pre-cleaner (halve if the fuel quality is poor)

6.2.2

6.2.1/ 6.2.3

#

4.2

Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3 /6.4.4

Battery and cable connectors 6.7.1

Engine monitoring system, warning system (replace if necessary)

Valve clearance

V-belt

Crankcase pressure vent valve

Timing belt, extreme-duty, see adjacent table

Timing belt, heavy-duty, see adjacent table

Timing belt, light-duty, see adjacent table

Check engine for leaks (visual inspection)

Engine mount (replace if damaged)

#

–

#

#

9.2

3.3 #

6.6.1#

6.5.#

#


Service

Deutz maintenance and service schedule = E check = adjust = clean =

▲

replace = fl prior to or during 1st trial run, check 2x daily during the breaking-in phase or when commissioning new and overhauled engines fl every 10 operating hours or daily in operating hours (OH) every

E10 E20 E25 E30 E40 E45 E60

500 1000 3000 5000 6000

Years

1 2

Operation

Injection valve

Expansions or modifications for engines with

EPA acceptance

The specified engine maintenance intervals 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 authorise service personnel

Section

#

5

Timing belt change intervals

Guideline values in OH

6000 or max. 5 years



Engine application

Example:

Generating sets 1500/1800 rpm; pump units, low speed; platform lifts; refrigeration units etc.

Engine/ application/operating parameters

Example: low speed; moderate ambient temperature; low dust exposure compressors; rollers; forklift trucks; welding units; ambient small dumpers; ski-steer loaders etc.

wheel loaders;medium to high variable speed; high temperature moderate dust exposure agricultural machinery; ski-steer loaders; wheel loaders; drilling high speed; impact loads; extreme ambient temperature; equipment; trench-cutting machines; joint cutters; bulldozers etc.

high dust exposure

5

Service

5.2 Scheduled Maintenance Plan

5.2.1 Scheduled Maintenance Plan

Intervals at/after

50 OH

Daily

250 OH

500 OH

1000 OH

3000 OH

6 000 OH

Deutz maintenance

E 10

E 20

E 25

E 30

E 40

E 45

E 60

Operation and service schedule

Carried out by:

After commissioning and E 45-E 60 Authorised specialists

Daily check Operator

Inspection

Extended inspection

Interim overhaul

Extended interim overhaul

Partial overhaul

Authorised specialists





5.3 Maintenance Chart

The maintenance chart shown here 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.

Stop the engine before carrying out any maintenance work.

Service

5

Service


5 Op. hours

50-150*

125

Date Signature/stamp Op. hours

-

375

625

875

1125

1375

1625

1875

250

500

750

1000

1250

1500

1750

2000

2115

2375

2250

2500

2625

* Following commissioning of new and overhauled engines

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

2750

Date Signature/stamp


4375

4625

4875

5125

5375

5625

Op. hours

2875

3125

3375

3625

3875

4125



4500

4750

5000

5250

5500

5750

Op. hours

3000

3250

3500

3750

4000

4250

Date

Signature/stamp

Service

5

Service


5

7375

7625

7825

8125

8375

8625

Op. hours

5875

6125

6375

6625

6875

7125



Op. hours

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750



Op. hours Date Signature/stamp Op. hours Date

Signature/stamp

Service

5

5

Service

Op. hours



Op. hours Date Signature/stamp

6.1Lubrication System

6.2Fuel System

6.3Cooling system

6.4Combustion Air Filter

6.5Belt Drives

6.6Adjustments

6.7Accessories

6.8Engine Cleaning

Service and Maintenance

6


6

6.1.1 Oil Change Intervals

Oil change intervals are dependent on engine application and quality of lube oil.

If engine runs fewer hours during year than stated in table, oil should be changed at least once a year.

Table refers to following conditions:

- sulphur content max. 0.5% by weight for diesel fuel

- continuous ambient temperature to

-10°C (+14°F).

If sulphur content is > 0.5 to 1% or continuous ambient temperature below -10°C (+14°F), intervals between oil changes should be halved.

In case of fuels containing more than 1% sulphur, contact your service representative.

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

Emergency power units are dealt with in TC

0199-99-1126.

6.1 Lubrication System

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


6.1.1.1 Equipment Engines

Deutz lube oil quality class

ACEA-specfication

API-specfication

Worldwide specification special DEUTZ release list

Standard lube oil code for building equipment and nonraod vehicles

Engine series

Engine version

1011/2011

Naturalli aspirated engines

Turbocharged engines


DQC I

E2-96

CF/CF-4

-

-

Lube oil grade

DQC II

E3-96/E5-02

CG-4/CH-4

DHD-1

-

DQC III

E4-99

-

see chap. 4.1.2.1

EO..

EO...A, EO...B

.

EO...C

-

Lube oil change intervals in op. hours

Oil use normal high

1000

250

500

125

Oil use normal high

1000

500

500

250

Oil use normal high

1000

500

500

250

6


6

6.1.2 Check Oil Level /

Change Engine Oil

6.1.2.1Check Oil Level

6.1.2.2 Change Engine Oil


© 25 729 0

● Switch engine off before checking oil level.

● Ensure that engine or vehicle is level.

● Remove oil dipstick.

● Wipe dipstick with non-fibrous, clean cloth.

● Insert it to stop and remove again.

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

"MAX" mark.

- If oil level is only just above "MIN" mark, more oil must be added.

© 26 022 0

● Allow engine to warm up.

● Ensure that engine or vehicle is level.

- Lube oil temperature approx. 80°C.


The level must not fall below the "MIN" mark.

!

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!

© 26 023 0

● Place oil tray under engine.

● Unscrew oil drain plug.

● Drain oil.

● Fit oil drain plug with new seal ring and tighten firmly (for 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.


6.1.3 Changing Oil Filter


6

© 25 880 0

● Undo lube oil filter cartridge using commercial tool and spin off.

● Catch any escaping oil.

● Clean any dirt from filter carrier sealing surface.

● Lightly oil rubber gasket of new lube oil filter cartridge.

© 25 881 0

● Manually screw in new cartridge until gasket is flush.

● Tighten lube oil filter cartridge with another halfturn.

● Check oil level, see 6.1.2.

● Check oil pressure, see 3.3.1.

● Check lube oil filter cartridge seal for leaks.

!

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

© 25 882 0


6

6.1.4 Clean / Replace

Oil Filter (Cup)

1

2

3

4

© 30 074 0

Switch off engine.

Loosen lube oil filter cover 1 and unscrew in anticlockwise direction.

Carefully loosen paper filter cartridge 3 upwards from guide 4.

Catch any escaping oil.

Replace paper filter cartridge 3.

Clean any dirt from sealing surface of filter carrier and lube oil filter cover 1 and from guide

4.

!

Caution is required in case of hot oil:

Risk of scalding!

Replace and lightly oil rubber gasket 2.

Carefully insert new paper filter cartridge 3 into guide 4.

Tighten lube oil filter cover 1 in 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.


6.2 Fuel System

6.2.1 Replace Fuel Filter


6

© 25 880 0

● Close fuel shut-off valve.

● Undo fuel filter cartridge with commercial tool and spin off.

● Catch any escaping fuel.

● Clean any dirt from filter carrier sealing surface.

● Apply light film of oil or diesel fuel to rubber gasket of new fuel filter cartridge.

!

Keep naked flames away when working on the

fuel system. Do not smoke!

© 25 881 0

● Manually screw in new cartridge until gasket is flush.

● Tighten fuel filter cartridge with final halfturn.

● Open fuel shut-off valve.

● Check for leaks.

© 25 882 0


6

6.2.2 Clean / Replace

Fuel Filter (Cup)

1

2

3

4

!

© 30 074 0


● Loosen fuel oil filter cover 1 and unscrew in anticlockwise direction.

● Carefully loosen paper filter cartridge 3 upwards from guide 4.

● Catch any escaping fuel.

● Replace paper filter cartridge 3.

● Clean any dirt from sealing surface of filter carrier and fuel filter cover 1 and from guide 4.

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

● Replace and lightly oil rubber gasket 2.

● Carefully insert new paper filter cartridge

3 into guide 4.

● Tighten fuel filter cover 1 in clockwise direction (25 Nm).

● Start engine.

● Check fuel filter attachment for leaks.

6.2 Fuel System

6.2 Fuel System

6.2.3 Clean Strainer of Fuel Filter

2 3

1

© 26 436 0


● Loosen and unscrew hexagonal nut 1.

● Remove fuel strainer cover 2 (cover and strainer, one unit).

● Clean fuel strainer 2 with diesel fuel.

Replace if necessary.

● Place seal 3 in position.

● Mount fuel strainer cover 2.

● Tighten hexagonal screw 1.

● Check for leaks.

!

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


6.2.4 Change Fuel Leakage Line

6

© 31 867 1


● Disconnect rubber hoses 3 from 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 shut-off valve.

● Check for leaks after start-up.

Service and Maintenance

6


● Amount of contamination in cooling system depends on engine application.

● Oil and fuel residues on engine increase risk of contamination. Therefore pay special attention to leaks if 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 applications where there are high concentrations of chaff and chopped straw in vicinity of machine.

● Because applications vary, cleaning intervals have to be determined from case to case. Cleaning intervals given in table on right can be used as a guide.

Checking or cleaning intervals

Guideline values OH

2000

1000

500

250

125

6.3 Cooling System

Engine application

Ships, generating sets in enclosed areas, pumps.

Vehicles on paved roads

Tractors, fork-lift trucks, mobile generating sets

Vehicles on construction sites and unpaved roads, construction machines, compressors, underground mining units

Agricultural machines, tractors in harvesting applications

6.4 Combustion Air Filter


● Amount of dirt in air cleaner depends on amount of dust in air and size of air cleaner used. If high level of dust is anticipated, cyclone-type precleaner can be fitted to air cleaner.

● Cleaning intervals will have to be determined from case to case.

● If dry type air filters are used, cleaning should only be carried out according to service indicator or service switch.

● Air cleaner servicing is needed when:

- Service indicator red signal 1 is fully visible when engine is off.

- Service switch yellow pilot light comes on when engine is running.

● pressing button on service indicator. Service indicator is now ready for operation again.


6.4.2 Emptying Cyclone-Type

Precleaner

© 25 885 1 © 25 886 0

● 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 pre-cleaner.

● 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.

6


6

6.4.3 Dry Type Air Cleaner

Discharge Valve Filter Cartridges

6.4 Combustion Air Filter

© 25 888 1

● 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 upper section of valve.

© 25 889 0

● 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 to outside (or in difficult cases, tap out, taking care not to damage cartridge, or wash according to manufacturer’s instructions).

● Gaskets on filter cartridge can become damaged through regular removal and replacement. Check paper filter (light showing through) and gaskets for damage.

Replace if necessary.

● After five cleaner services or after two years at latest, replace safety cartridge 4 (never clean).

To do so:

- Undo hex nut 5 and remove cartridge 4.

- Install new cartridge, fit and tighten hex nut.

● Install cartridge 3, replace hood 2 and do up clip fasteners 1.

!

Never clean filter cartridge with petrol or hot fluids.

6.5 Belt Drives

6.5.1 Check V-belt


6

© 31 866 0

● 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 tension of V-belt, use tension gauge

(see 9.3).

-Place indicator arm 1 into gauge.

- Position guide 3 on V-belt 2, midway between pulleys, with stop against edge of belt.

- Push slowly on black pad 4 at right angles to Vbelt 2 until spring is heard or felt to trigger.

© 26 261 0

- Carefully remove gauge without altering position of indicator arm 1.

- Read off value where 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 engine off. Refit belt guard, if provided.

After installing new belts, run engine for 15 minutes, then check belt tension.

6


6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts

3

5

3

5

1

1

4

2

© 31 859 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.

4

2

© 31 860 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 direction of arrow by turning bolt 3, until correct belt tension is achieved.

● Retighten bolts 1, 2 and 3.

!

Check, tension and change belts only with engine off. Refit belt guard, if provided.

6.5 Belt Drives

6.6 Adjustments

6.6.1 Check Valve Clearance, adjust if necessary

© 19 691 2

● Remove 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. 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.

© 25 893 0

● Adjust valve clearance if necessary:

- Release locknut 4.

- Use Allan key 7 to turn setscrew 5 so that correct clearance is attained after locknut 4 has been tightened.

● Check and adjust valve clearance on all cylinders.

● Reinstall cylinder head cover, with new gasket if necessary.


6


6

6.6.1.1 Valve Clearance Adjust ments Schematic

1

1 2 1 2 3

6.6 Adjustments

1 2 3 4

● Crankshaft Position 1:

Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked

in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been carried out.

2

1 2 1 2 3 1 2 3 4

● Crankshaft Position 2:

Turn crankshaft one full revolution (360°).

Adjust clearance of valves marked in black on schematic.

© 25 894 4

6.7 Accessories

6.7.1

Battery

6.7.1.1 Check Battery and Cable

Connectors

6.7.1.2 Check Electrolyte Level


6.7.1.3 Check Electrolyte Density

6

© 25 895 0

● Keep battery clean and dry.

● Undo dirty clamps.

● Clean terminal posts (+ and -) and clamps of battery, and grease with acid-free and acidresistant grease.

● When reassembling, ensure that clamps make good contact. Tighten clamp bolts hand-tight.

© 24 232 3

● Remove sealing caps 1.

● If testers 2 are present:

Electrolyte level should reach base of these.

● Without testers:

Electrolyte level should be 10-15 mm above top of plates.

● If necessary, top up with distilled water.

● Screw sealing caps back in.

© 25 896 0

● Measure electrolyte density of individual cells with commercial hydrometer.

Hydrometer reading (see table on following page) indicates battery’s state of charge.

During measurement, temperature of electrolyte should preferably be +20°C.

6


in [°Bé (Baumé scale)*]

Normal

32

24

16

Electrolyte density

Normal

1.28

in [kg/ l]

1.20

1.12

*Measurement of electrolyte density in °Bé (Baumé

scale) is out of date and rarely used today.

Tropical

27

16

11

Charge status well charged semi-charged, re-charge discharged, immediately charge

!

The gases emitted by the battery are explosive! Keep sparks and naked flames away from the battery!

Do not allow battery acid to come into contact with skin or clothing!

Wear protective goggles!

Do not rest tools on the battery!

6.7 Accessories

6.7 Accessories

6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

Notes on the three-phase system:

● Never disconnect cables between battery, alternator and regulator while engine is running.

● If, however, it is necessary to start and operate engine without battery, disconnect regulator from alternator before starting.

● Be sure not to confuse battery terminals.

● Replace defective charge pilot lamp bulb immediately.

● When washing engine, cover up alternator and regulator.

● Touching lead against frame to check whether it is live must not, under any circumstances, be carried out with three-phase electrical systems.

● In case of electric welding, connect ground terminal on welder directly to piece being welded.

1

2

© 31 871 0

● Always use proper lifting tackle 1 when transporting engine.

● After transportation and before commissioning of engine: remove attachment eyes 2.


© 31 870 0

6

!

Use only correct lifting gear.


6

6.8.1 Engine Cleaning

Preperation


● Remove engine covers and cooling air hood.

Replace them after cleaning and before test run.

● Cover electrical / electronic components and connections (e.g. alternator, starter, governor, solenoid).

Using compressed air

● Blow air through engine, taking particular care not to damage cooler and cooling fins (begin to blow through air from exhaust side).

Remove dirt which has blown into interior space.

Using cold-cleaning compound

● Spray engine with commercial cold-cleaning compound and allow to react for approx. 10 mins.

● Spray-clean engine with strong water jet, repeat if necessary.

● Allow engine to run warm so that remaining water evaporates.

Using high-pressure device

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

● Allow engine to run warm so that remaining water evaporates.

!

Clean the engine only when the engine is switched off.

6.8 Engine Cleaning

7.1 Fault Table

Faults, Causes and Remedies

7


7

● Faults are often caused by engine not being properly operated or maintained.

● Each time fault occurs, check whether all operating and servicing regulations have been complied with.

● Corresponding fault table can be found on adjacent page.

● If you cannot ascertain cause of a fault or cannot rectify fault, please contact DEUTZ SERVICE.

7.1 Fault Table

7.1 Fault Table


●

●

Faults

Engine does not start or is difficult to start

Engine starts, but runs irregularly or fails

Engine becomes excessively hot. Temperature warning system responds

Engine output is deficient

Engine does not run on all cylinders

Engine oil pressure is non-existent or excessively low

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

CPD * 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

*CPD = Charge pressure-dependent full-load stop

Measures

Check

Adjust

Replace

Clean

Top up

Reduce

Ch

A

Rp

Cl

T

Rd

Section

Engine Operation

Operating media

Combustion air

Cooling system

Electrics

Rp

Rp

Ch / Rp

Ch / Rp

Ch

Ch

Ch / Cl

Ch / Rp

Ch

Ch

Ch / T

Ch

Ch

T

Ch

Rd

7

7


Faults

Engine does not start or is difficult to start

Engine starts, but runs irregularly or fails

Engine becomes excessively hot. Temperature warning system responds

Engine output is deficient

Engine does not run on all cylinders

Engine oil pressure is non-existent or excessively low

Engine oil consumption excessive

Engine smokes - blue

- white

- black

Cause

●

●

●

● ● ●

● ● ●

● ● ● ● ●

●

●

●

●

Electric cable connections to starter electrical system loose or oxidised

Starter defective or pinion does not engage

Solenoid defective (release switch)

Incorrect valve clearance

Injection line leaks

Injection valve defective

7.1 Fault Table

Measures

Check

Adjust

Replace

Clean

Top up

Reduce

Cl

T

Rd

Ch

A

Rp

Section

Electrics

Engine

Ch

Ch

Ch

A

Ch

Ch / Rp

8.1 Preservation

Engine Preservation

8

8

Engine Preservation

8.1 Preservation

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 months.

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)

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 anticorrosion 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.


● Turn engine over manually several times to preserve cylinders and combustion chamber.

● Remove V-belts and store in wrapped condition.

● Spray grooves on V-belt pulleys with anti-corrosion 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 Specification

9

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

9.3 Tools



9

9

Model

Number of cylinders

Cylinder arrangement

Bore

Stroke

Total displacement

Compression ratio

Working cycle

Combustion system

[mm]

[mm]

[cm

3

]

[

ε

]

------- F2L 2011 ---------------- F3L 2011 --------------- F4L 2011 -------

------------ 2 --------------------------- 3 -------------------------- 4 ------------

---------------------------------- vertical in line ----------------------------------

------------------------------------------ 94 -----------------------------------------

----------------------------------------- 112 ----------------------------------------

--------- 1554 ---------------------- 2331 --------------------- 3108 ---------

------------------------------------------ 19 -----------------------------------------

------------------------------ 4-stroke diesel engine -----------------------------

------------- Naturally aspirated engine with direct injection ---------------

-------------------------- On left when looking at flywheel -------------------

Direction of rotation

Weight incl. integral cooling system to DIN 70020-A

(without starter, with alternator)

Engine output

Speed

Lubrication approx. [kg]

[kW (hp)]

[rpm]

---------- 175 ------------------------ 217 ----------------------- 256 ----------

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

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

1)

1)

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

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

------------------------------- Pressure lubrication ------------------------------

-------------------------------------- 20 W 20 ------------------------------------SAE oil

Maximum oil temperature in oil pan [°C]

----------------------------------------- 130 ----------------------------------------

Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed)

1800 rpm max. 2800 rpm

Oil change quantity (oil pan) approx.

Oil change quantity with filter (standard 0.5 l)

Start of feed

Injector opening pressure: vehicle/unit

[bar]

[bar]

[bar]

[l] approx. (l)

[°crankshaft BTDC]

[bar]

---------------------------------------- 1,4 3)

---------------------------------------- 2,2 3)

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

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

------------------------------------------ 3 3)

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

----------- 6 2)

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

5.5

---------- 6.5 2)

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

6 2)

2)

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

10 2)

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

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

10.5 2)

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

Valve clearance with cold engine

(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm]

Firing order of engine

-------------------------- Inlet 0.3 +0.1

/ Exhaust 0.5 +0.1

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

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

1 --------------------------------------------------------------------------

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

210 +8

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

---------- 1 - 2 ---------------------- 1 - 2 - 3 ----------------- 1 - 3 - 4 - 2 ------

V-belt tension: pretension / retension (after engine has been running under load for 15 mins)[N] ----------------------------------- 450 / 350 ±20 ----------------------------------

1)

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

2)

3)

Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

Values for engines without engine oil heating.

76

9929en

9.1 Engine Specifications and Settings

Technical Specification

Model

Number of cylinders


Bore

Stroke

Total displacement

Compression ratio

Working cycle / Combustion system


Weight without cooling system

Weight without starter, with alternator as per DIN 70020-A approx.

Engine output

Speed

Lubrication

SAE oil

[mm]

[mm]

[cm

3

]

[

ε

] approx. [kg]

[kW (hp)]

[rpm]

Maximum oil temperature in oil pan at: 900 rpm (low idling speed)


Oil change quantity (oil pan without cooling system) ca.

Oil change quantity with filter (Standard 0.5 l)


[°C]

[bar]

[bar]

[bar]

[l] approx. (l)

(Engine cooling time at least 30 min.: oil temperature should be below 80°C).

[mm]

Injector opening pressure: vehicle/unit [bar]

Start of feed


[°crankshaft BTDC]

V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N]

------------------- BF3L 2011 ------------------------------ BF4L 2011 ------

-------------------------- 3 -------------------------------------------- 4 ------------

---------------------------------- vertical in line ----------------------------------

------------------------------------------ 94 -----------------------------------------

----------------------------------------- 112 ----------------------------------------

----------------------- 2331 -------------------------------------- 3108 ---------

----------------------------------------- 17.5 ----------------------------------------

------------- Four-stroke diesel with turbocharging and direct fuel injection


------------------------ 222 ---------------------------------------- 257 ----------

. -----------------------------------------1) ------------------------------------------

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

1)

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


-------------------------------------- 20 W 20 -------------------------------------

----------------------------------------- 130 ----------------------------------------

---------------------------------------- 1.4

3)

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

---------------------------------------- 2.2 3) . ---------------------------------------

----------------------------------------- 3

3)

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

------------------------ 7.5 ---------------------------------------- 10 2) . ---------

-------------------------- 8 ---------------------------------------- 10.5

2)

. --------

-------------------------- Inlet 0.3

+ 0.1 /

Exhaust 0.5

+ 0.1

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

--------------------------------------- 210 + 8 ---------------------------------------

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

1)

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

---------------------- 1 - 2 - 3 ------------------------------------ 1-3-4-2 --------

----------------------------------- 450 / 350 ±20 ----------------------------------

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

2) Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

3)

Values for engines without engine oil heating.

9



9

9

Model

Number of cylinders


Bore

Stroke

Total displacement

Compression ratio

Working cycle

Combustion system



(without starter, with alternator) approx.

Engine output

Speed

Lubrication

SAE oil

[mm]

[mm]

[cm

[

3 approx. [kg]

[kW (hp)]

[rpm]


Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar]


[bar]

[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)

[l] approx.[l]

Genset Engine without Thermostat:

Oil change quantity including external cooler (see 3.1.1.3)/without filter approx.

[l]

Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l]



Start of feed


[mm]

[°crankshaft BTDC]

[bar]



1)


ε

]

------ F2M 2011 ---------------- F3M 2011 --------------- F4M 2011 ------

------------ 2 --------------------------- 3 --------------------------- 4 ------------

---------------------------------- vertical in line ----------------------------------

------------------------------------------ 94 -----------------------------------------

----------------------------------------- 112 ----------------------------------------

--------- 1554 ---------------------- 2331 --------------------- 3108 ---------

------------------------------------------ 19 -----------------------------------------

------------------------------ 4-stroke diesel engine -----------------------------

-------------------------- Naturally aspirated engine with direct injection -


------------------------------- Refer to head-office ------------------------------

---------- 169 ------------------------ 210 ----------------------- 248 ----------

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

1) -------------------------------------------------------------------------

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

1) -------------------------------------------------------------------------


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

+0.1

/ Exhaust 0.5

+0.1

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

-----------------------------------------1) . ------------------------------------------

---------------------------------------- 210 +8 ---------------------------------------

----------- 1-2 ---------------------- 1 - 2 - 3 ----------------- 1 - 3 - 4 - 2 ------

----------------------------------- 450 / 350 ±20 ----------------------------------

2)

Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

3) Values for engines without engine oil heating.

9.1 Engine Specifications and Settings


Model

Number of cylinders


Bore

Stroke

Total displacement

Compression ratio

Working cycle

Combustion system



(without starter, with alternator) approx.

Engine output

Speed

Lubrication

SAE oil

[mm]

[mm]

[cm

[

ε

3

[kg]

[kW (hp)]

[rpm]

]

]


Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar]


[bar]

[bar]

Engine with Thermostat

Oil change quantity without external cooler (see 3.1.1.2) / without filter approx.

[l]

Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre)

[l] approx.

Genset Engine without Thermostat:

Oil change quantity including external cooler (see 3.1.1.3) / without filter approx.

[l]

Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l]

------------------- BF3M 2011 ------------------ BF4M 2011 -------------------

-------------------------- 3 ------------------------------- 4 -------------------------

------------------------------------ vertical in line -----------------------------------

------------------------------------------ 94 -----------------------------------------

----------------------------------------- 112 ----------------------------------------

----------------------- 2331 -------------------------- 3108 -----------------------

----------------------------------------- 17.5 ----------------------------------------

------------------------------ 4-stroke diesel engine ------------------------------

-------------------------- Turbocharging and direct injection --------------------

-------------------------- On left when looking at flywheel -----------------------

-------------------------------- Refer to head-office -------------------------------

------------------------ 215 --------------------------- 250 -----------------------

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

1)

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

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

1)

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

-------------------------------- Pressure lubrication -------------------------------

-------------------------------------- 20 W 20 --------------------------------------

----------------------------------------- 130 ----------------------------------------

----------------------------------------- 1.4

3)

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

----------------------------------------- 2.2 3) ----------------------------------------

------------------------------------------ 3

3)

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

------------------------ 7.5 ---------------------------- 10

-------------------------- 8 --------------------------- 10.5

2)

2)

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

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

------------------------- 11 --------------------------- 13.5

2)

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

------------------------ 11.5 --------------------------- 14 2) -----------------------



Start of feed


[mm]

[°crankshaft BTDC]

[bar]



-------------------------- Inlet 0.3

+0.1

/ Exhaust 0.5

+0.1

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

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

1)

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

+8 ---------------------------------------- 210 ---------------------------------------

----------------------- 1-2-3 ------------------------- 1-3-4-2 ---------------------

----------------------------------- 450 / 350 ±20 ----------------------------------

1)


2) Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.

3) Values for engines without engine oil heating.

9

Tecnical Specification

9

9

Installation location

Cylinder head cover

Cylinder head cover

Rocker arm adjustment screw

Intake manifold

Foot Rigid suspension

Foot Elastic suspension

Air intake pipe

Exhaust manifold

Oil drain plug

Oil pan (sheet metal)

Oil pan (cast)

Injection line attachment

Injection valve attachment

Lube oil filter cartridge

Threaded pipe union

9.2 Torque Wrench Settings

1st stage

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

2nd stage 3rd stage 1st stage 2nd stage 3rd stage 4th stage

Total

[Nm]

8.5

8.5

21

8.5

30 45

55

21

31

30

106

21

22

21

27

4

Comments

TORX on engine or separate

9.3 Tools


TORX V-belt tension gauge

9

25899 0

A TORX BN. 8189 screw set 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, thereby practically ruling out risk of injury.

TORX tools can be ordered from:

FA.WILBÄR

Postfach 14 05 80

D-42826 Remscheid

26002 0

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

FA.WILBÄR

Postfach 14 05 80

D-42826 Remscheid

Notice

22093 Umschlag 16.01.2006 8:16 Uhr Seite 3 de de

For many years DEUTZ has stood for pioneering development in engine construction. As an independent engine manufacturer we offer a complete palette of diesel and gas engines worldwide. Our products are perfectly tailored to

For many years DEUTZ has stood for pioneering

More than 1.4 million DEUTZ engines reliably perform their service all over the world. We want customers. Therefore we are represented worldwide by a network of competent partners, the concentration of whom corresponds to the regional distribution of our engines.

Thus, DEUTZ is not just a name for innovative engines. But also for a complete service package for every aspect of engines, and a service that you can rely on.

You can find a complete overview of DEUTZ partners in your area, their product competencies and their services on the DEUTZ website

(see below).

Also if there is no direct product competency specified, your DEUTZ partner will be able to help you further with professional advice.

Your DEUTZ AG

Also if there is no direct product competency specified, your DEUTZ partner will be able to help

Fax: 0049-221-822-3523

Telex: 8812-0 khd d http://www.deutz.de

Telephone: 0049-221-822-0

F

Service

Ser

10


The engine company.

DEUTZ AG

Service IInformation Systems

Deutz-Mülheimer Str. 147-149

D-51063 Köln

Phone: +49 (0) 2 21-8 22-0

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

Internet: www.deutz.de

eMail: [email protected]

Printed in Germany

All rights reserved

7th Edition, © 01/2006

Order No.: 0297 9929 en

(09.06)

Deutz F2M 2011 Operation Manual

Operation Manual

Safety guidelines / Accident prevention

Engine Serial

Number:

Operation manual

0297 9929 en

Dear Customer,

1.

General

2.

Engine Description

3.

Engine Operation

4.

Operating Media

5. Service

6. Service and Maintenance

7. Faults, Causes and

Remedies

8. Engine Preservation

9. Technical Specification

10. Service

DEUTZ Diesel Engines

Care and Maintenance

Beware of Running Engine

Safety

Asbestos

Service

California

2.1 Model

2.2 Engine Illustrations

2.3 Lube Oil Circuit Schematic

2.4 Fuel System Schematic

2.1.1 Rating Plate 2.1.2 Position of the Rating Plate

2.1 Model

2.1.3 Engine Serial Number

2.1 Model

2.1.4 Cylinder Numbering

2.1.5 Fuel Delivery Lock

2.2.1 Operation Side

FL 2011

2.2 Engine Illustration

2.2 Engine Illustration

2.2.2 Exhaust Side

FL 2011

2.2.3 Operation Side

Example: BF4L 2011

2.2 Engine Illustration

2.2 Engine Illustration

2.2.4 Exhaust Side

Example: BF4L 2011

2.2.5 Operation Side

FM 2011

2.2 Engine Illustration

2.2 Engine Illustration

2.2.6 Exhaust Side

FM 2011

2.2.7 Operation Side

BFM 2011

2.2 Engine Illustration

2.2 Engine Illustration

2.2.8 Exhaust Side

BFM 2011

2.3.1 Lube Oil Circuit Schematic

2.3 Oil Circuit

2.4 Fuel System Schematic

2.4.1 Fuel System

3.1 Commissioning

3.2 Starting

3.3 Monitoring Operation

3.4 Shutting Off

3.1.1 Adding Engine Oil

3.1 Commissioning

3.1.1.1

Initial Engine Oil Fill-Up for B/FL 2011

3.1.1.2

Initial Engine Oil Fill-Up

B/FM 2011

3.1 Commissioning