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2011 Operation

Apr 03, 2018

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    Operation

    2011

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    G Please read and observe the informationgiven in this Operation Manual. This willenable you to avoid accidents, preserve themanufacturers warranty and maintain theengine in peak operating condition.

    G This engine has been built exclusively for

    the application specified in the scope ofsupply, as described by the equipment manu-facturer and is to be used only for theintended purpose. Any use exceeding thatscope is considered to be contrary to theintended purpose. The manufacturer willnot assume responsibility for any damageresulting therefrom. The risks involved areto be borne solely by the user.

    G Use in accordance with the intended pur-pose also implies compliance with the con-

    ditions laid down by the manufacturer foroperation, maintenance and servicing. Theengine should only be operated by person-nel trained in its use and the hazards in-volved.

    G The relevant accident prevention guidelinesand other generally accepted safety andindustrial hygiene regulations must be ob-served.

    G When the engine is running, there is a risk ofinjury through:- turning/hot components- engines with positive ignition

    G Unauthorized engivalidate any liabilityfacturer for resultaManipulations of thsystem may also inof the engine, and i

    to legislation on polteed under such c

    G Do not change, conair intake area to tThe manufacturer ssible for any damsuch work.

    GWhen carrying outerations on the enoriginal parts is pre

    cially designed for tee perfect operatiNon-compliance rewarranty!

    GMaintenance and should only be carris switched off andYou must ensure thhave been switchehas been removedAccident preventioelectrical systems 0104/-0105 Electriagainst dangerous

    Safety guidelines / Accident prevention

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    Operation ma

    2011

    0297 9929 en

    Engine SerialNumber:

    Please enter the engine serial number here. Thisnumber should be quoted when inquiring aboutCustomer Service, Repairs or Spare Parts (seeSection 2.1).

    T h i l difi ti i d t i

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    Foreword

    Dear Customer,

    Liquid-cooled Deutz engines are designed for a

    large number of applications. Consequently, a widerange of variants is offered to meet the requirementsof specific cases.

    Your engine is appropriately equipped for theinstallation concerned, which means that not all ofthe components described in this Operation Manu-al are necessarily fitted to your engine.

    We have endeavoured to highlight any differencesso that you will be able to locate the operating andmaintenance instructions relevant to your engine

    quickly and easily.

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

    We are available to help with any additional inquiries

    Sincerely,

    DEUTZ AG

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    1. General

    2. Engine Description2.1 Model

    2.1.1 Rating Plate

    2.1.2 Position of the Rating Plate2.1.3 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 S ide:

    Example FL 2011

    2.2.3 Operation Side:

    Example BF4L 2011

    2.2.4 Exhaust S ide:Example BF4L 2011

    2.2.5 Operation Side:

    Example FM 2011

    2.2.6 Exhaust S ide:

    Example FM 2011

    2.2.7 Operation Side:

    Example BFM 2011

    2.2.8 Exhaust S ide:

    Example BFM 2011

    2.3 Oil Circuit2.3.1 Lube Oil Circuit Schematic

    2 4 Fuel System Schematic

    3. Engine Operation3.1 Commissioning

    3.1.1 Adding Engine Oil

    3.1.2 Adding Fuel

    3.1.3 Other Preperations

    3.1.4 Additional Maintenance Work3.2 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 Media4.1 Lube Oil

    4.1.1 Quality

    4.1.2 Viscosity

    4.2 Fuel

    4.2.1 Quality

    4.2.2 Winter-Grade Fuel

    5. Service5.1 Service Plan5 2 Scheduled Maintenance Plan

    6. Service and 6.1 Lubrication Sys

    6.1.1 Oil Change In

    6.1.2 Check Oil Lev

    6.1.3 Changing Oil

    6.1.4 Clean/Replac6.2 Fuel System

    6.2.1 Replace Fuel

    6.2.2 Clean/Replace

    6.2.3 Clean Stainer

    6.2.4 Change Fuel

    6.3 Cooling System

    6.3.1 Cleaning Inte

    6.4 Combustion Ai

    6.4.1 Cleaning Inte

    6.4.2 Emptying Cyc

    6.4.3 Dry Type Air 6.5 Belt Drives

    6.5.1 Check V-belt

    6.5.2 Tensioning A

    6.5.3 Changing Alt

    6.6 Adjustments

    6.6.1 Check Valve C

    6.6.1.1 Valve Clearan

    6.7 Accessories

    6.7.1 Battery

    6.7.2 Rotary Curre6.7.3 Transportatio

    6 8 Engine Cleanin

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    Contents

    7. Faults, Causes and Remedies7.1 Fault Table

    8. Engine Preservation8.1 Preservation

    8.1.1 Preserving Engine8.1.2 Removing Engine Preservatives

    9. Technical Specification9.1 Engine Specifications and Settings

    9.2 Torque Wrench Settings

    9.3 Tools

    10. Service

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    DEUTZ Diesel Engines

    are the product of many years of research anddevelopment. The resulting know-how, coupled

    with stringent quality standards, guarantee theirlong service life, high reliability and low fuelconsumption.It goes without saying that DEUTZ Diesel Enginesmeet the highest standards for environmentalprotection.

    Service

    Please contact one orepresentatives in the

    spare parts inquiries. carry out repairs quickonly genuine spare paOriginal parts from DEUin accordance with staPlease turn to the endservice information.

    !

    Care and Maintenance

    Sound care and maintenance practices will ensurethat the engine continues to meet the requirements

    placed on it. Recommended service intervals mustbe observed and service and maintenance workcarried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.

    Asbestos

    Safety

    This symbol is used for all safetywarnings. Please follow themcarefully. The attention of operatingpersonnel should be drawn to thesesafety instructions. General safety

    and accident prevention regulations laid down bylaw must also be observed.

    Beware of Running Engine

    Shut the engine down before carrying out mainte-nance or repair work. Ensure that the engine cannotbe accidentally started. Risk of accidents.When the work is complete, be sure to refit anypanels and guards that may have been removed.Never fill the fuel tank while the engine is running.Observe industrial safety regulations when runningthe engine in an enclosed space or underground.

    CalPropositio

    Diesel engine exhaustuents are known to cause cancer, birth dductive harm.

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    1

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    Engine

    2.1 Model2.2 Engine Illustrations

    2.3 Lube Oil Circuit Schematic2.4 Fuel System Schematic

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    2

    C

    31 864 0 26 332 2

    A B

    Engine Description

    2.1.1 Rating Plate

    The model A, the engine serial number B and theperformance data are stamped on the rating plate.The model and engine serial number must be givenwhen ordering parts.

    2.1.2 Position of the Rating Plate

    The rating plate C is attached to the valve cover.

    2.1.3 Engine Serial

    The engine serial numbercrankcase D as well as the

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    1 2 3 4

    26 431 0 26 387 0

    2.1 Model Engine

    2.1.4 Cylinder Numbering

    Cylinders are numbered consecutively, beginningat the flywheel.

    2.1.5 Fuel Delivery Lock

    The manufacturer shall not be held liable for dam-ages resulting from adjustments made to the regu-lator by the operator.The lock screws are protected in order to preventthis:1. with locking paint on model:

    with torque balancer2. with plastic protective cap on model:

    without torque balancer.

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    2

    1

    2

    3

    4

    5

    7

    6

    16

    21

    20

    19

    18

    17

    Engine Description 2.2 Engine

    2.2.1 Operation SideFL 2011

    1 Oil filler neck (valve-ge2 Charge-air line / air-int3 Fan with integrated ge4 Narrow V-belt5 Tractive electromagnet6 Wheel-house cover7 V-belt pulley on cranks8 Oil pan9 Shut-off lever

    10 Speed control lever11 Oil dipstick12 Oil drain plug13 Crankcase14 Oil fill point (on side o15 Fuel pump16 Easy-change fuel filter17 Connecting facility for18 Lube oil replacement f19 Removable coolant int20 Injection pumps21 Oil cooler

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    2.2 Engine Illustration Engine

    2.2.2 Exhaust SideFL 2011

    22 Date plate23 Optional attachme

    24 Flywheel with ring25 Starter26 Front cover27 Crankcase28 Exhaust manifold29 Air intake pipe

    22

    24

    23

    29

    28

    27

    26

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    2

    3

    4

    6

    15

    20

    19

    18

    17

    16

    21 1 2

    5

    Engine Description 2.2 Engine

    2.2.3 Operation SideExample: BF4L 2011

    1 Oil filler neck (valve-ge2 Charge-air line / air-int3 Fan with integrated ge4 Narrow V-belt5 Tractive electromagnet6 Wheel-house cover7 V-belt pulley on cranks8 Oil pan9 Shut-off lever

    10 Speed control lever11 Oil dipstick12 Crankcase13 Oil fill point (on side o14 Fuel pump15 Easy-change fuel filter16 Connecting facility for17 Charge-pressure-depe

    (CPD)18 Lube oil replacement f19 Removable coolant int20 Injection pumps21 Oil cooler

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    22

    23

    24

    26

    28

    30

    27

    29

    31

    32

    2.2 Engine Illustration Engine

    2.2.4 Exhaust SideExample: BF4L 2011

    22 Cylinder head23 Exhaust manifold

    24 Flywheel with ring25 Starter26 Crankcase27 Lube oil feed line 28 Lube oil return lin29 Induction pipe30 Turbocharger (TC31 Intake manifold32 Charge-air line

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    2

    Engine Description 2.2 Engine

    2.2.5 Operation SideFM 2011

    1 Oil filler neck (valve-ge2 Charge-air line / air-int

    3 Alternator4 Narrow V-belt5 Tractive electromagnet6 Timing belt cover7 V-belt pulley on cranks8 Oil pan9 Shut-off lever10 Speed control lever11 Oil dipstick12 Oil drain plug13 Oil fill point (on side o

    12 Crankcase14 Fuel pump15 Easy-change fuel filter16 Connecting facility for17 Lube oil replacement f18 Injection pump(s)19 Oil cooler connection20 Fuel leakage line21 Injection valve(s)

    1

    2

    3

    4

    5

    7

    616

    15

    21

    20

    19

    18

    17

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    2.2 Engine Illustration Engine

    2.2.6 Exhaust SideFM 2011

    22

    23

    24

    28

    27

    22 Cylinder head23 Exhaust manifold

    24 Flywheel with ring25 Starter26 Starter guard (opt27 Crankcase28 Air intake pipe

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    2

    1

    2

    4

    3

    12

    11

    18

    17

    16

    15

    14

    13

    Engine Description 2.2 Engine

    2.2.7 Operation SideBFM 2011

    1 Air-intake pipe2 Fan wheel

    3 V-belt pulley on cranks4 Narrow V-belt5 Tractive electromagnet6 Timing belt cover7 Shut-off lever8 Speed control lever9 Oil fill point (on side o10 Oil dipstick11 Fuel pump12 Easy-change fuel filter13 Connecting facility for

    14 Lube oil replacement f15 Injection pump(s)16 Oil cooler connection17 Injection valve(s)18 Fuel leakage line

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    19

    28

    20

    21

    24

    22

    23

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    26

    25

    2.2 Engine Illustration Engine

    2.2.8 Exhaust SideBFM 2011

    19 Crankcase ventilat20 Cylinder head cov

    21 Exhaust manifold22 SAE housing23 Starter24 Crankcase25 Turbocharger26 Generator with co27 Charge-air line28 Oil filler neck

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    2

    Engine Description 2.

    2.3.1 Lube Oil Circuit Schematic

    1 Oil pan2 Oil-intake pipe

    3 Oil pump4 Main oil duct5 Oil-cooled cylinders6 Cylinder head cooling 7 Oil duct for rocker arm8 Rocker arm9 Oil manifold for the th

    10 Intake to external engi11 Return from external e12 Thermostat housing w13 Oil duct to oil filter14 Oil fi lter

    15 Oil duct to cam, con-roings16 Spray nozzle for piston17 Oil return via crankcas18 Lube oil intake to turb19 Turbocharger20 Return from turbocha

    5

    1

    118159

    10

    13

    12

    6

    7

    20

    7

    19

    18

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    8

    11 10 9

    5

    4

    12

    7

    2.4 Fuel System Schematic Engine

    2.4.1 Fuel System

    1 Fuel line from tan2 Fuel pump

    3 Fuel line from fuefilter

    4 Easy-change fuel 5 Fuel line from filte6 Injection pump7 Fuel distributor lin8 Injection line9 Injection valves

    10 Fuel leakage line11 Fuel overflow pipe12 Fuel return line to

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    2

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    Engin

    3.1 Commissioning

    3.2 Starting3.3 Monitoring Operation3.4 Shutting Off3.5 Operating Conditions

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    3

    OIL

    3.1.1.2 Initial EngB/FM 2011

    26 432 0

    Engine Operation 3.1 Co

    3.1.1 Adding Engine Oil

    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.

    G Fill oil into oil pan up to "Max." mark on enginedipstick (for oil quantity see 9.1).

    G Start engine and allow to run at low idling speedfor approx. 2 mins.

    G Switch off engine.

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

    G Fill oil into oil pan up todipstick.

    G In addition, top up oil quand of external oil cooler turers specifications).

    G Allow engine to run warm(at approx. 95C).

    G Allow engine to run for a

    G Switch off engine.

    G Check oil level, and if n

    "Max." mark.

    3.1.1.1 Initial Engine Oil Fill-Up forB/FL 2011

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    FUEL

    26 398 0

    3.1 Commissioning Engin

    3.1.1.3 Initial Engine Oil Fill-UpB/FM 2011 Genset Engine

    G Fill oil into oil pan up to "Max." mark on enginedipstick (for oil quantity see 9.1).

    G Start engine and allow to run at low idling speedfor approx. 2 mins.

    G Switch off engine.

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

    "Max." mark.

    3.1.2 Adding Fuel

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

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    3

    Engine Operation 3.1 Co

    3.1.3 Other Preparations

    G Check battery and cable connectors,see 6.7.1.

    G Transport hooksRemove if fitted (see 6.7.3)

    G Trial runAfter engine has been prepared, let it run forabout 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).

    3.1.4 Additional Maintenance Work

    When commissioning new and reconditioned en-gines, the following additional maintenance work

    must be carried out:

    G Change lube oil,see 6.1.1. + 6.1.2.

    G Change oil filter cartridge,see 6.1.3.

    G Change fuel filter cartridge,see 6.2.1.

    G Check V-belts and retension as necessary,see 6.5.

    G Check engine for leaks

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

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

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    3

    2

    1

    !

    26 423 0

    Engine Operation

    3.2.1 Electric starting

    Before starting, make sure that no-body is standing in the immediate

    vicinity of the engine or driven ma-chine.After repair work:Check that all guards have been

    replaced and that all tools have been removed fromthe engine.When starting with glow plugs, do not use any otherstarter substance (e.g. injection with start pilot).Risk of accident!Caution: If the speed regulator has been re-moved, the engine must not be tested under anycircumstances.

    Disconnect the battery!

    G Where possible, disengage clutch to separateengine from any driven parts.

    G Move speed control lever 1 into idle position.G Move shut-off handle 2 into operating position.

    Without cold start as

    G Insert key- Position 0 = no operati

    G Turn key clockwise- Position 1 = operating - Pilot lights come on

    G Push key in and turn furspring pressure.- Position 2 = no functio- Position 3 = start

    G Release key as soon as ePilot lights go out

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    25 746 2

    3.2 Starting Engin

    With cold start assistance- Glow plug

    G Insert key- Position 0 = no operating voltage

    G Turn key clockwise- Position 1 = operating voltage- Pilot lights come on

    G Push key in and turn further clockwise againstspring pressure.- Position 2 = preheat, hold for approx. 1 minute.- Preheat lamp comes on- Position 3 = start

    G Release key as soon as engine fires

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    3

    25 753 0 25 752 1

    Engine Operation 3.3 Monitori

    3.3.1 Engine Oil PressureOil Pressure Pilot Light

    G Oil pressure pilot light comes on with operatingvoltage on and engine off.

    G Oil pressure pilot light should go out whenengine is running.

    Oil Pressure Indicator

    G Pointer must remain in green sector over entireoperating range.

    Oil Pressure Gauge

    G Pointer must indicate m(see 9.1).

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    24 985 0

    3.3 Monitoring Operation Engin

    3.3.2 Engine TemperatureEngine Temperature Gauge

    G Engine temperature gauge pointer should re-main in green sector most of time. It shouldrarely enter yellow-green sector. If pointer entersorange sector, engine is overheating. Turn offand establish cause from Fault Table (see 7.1).

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    3

    2

    1

    26 424 0 25 746 2

    Engine Operation 3.4

    3.4.1 Mechanical Shut-Off

    G Move speed adjustment lever 1 to low idle.G Move shut-off lever 2 until engine comes to a

    stop.Charge pilot light and oil pressure pilot light willcome on when engine stops.

    G Turn key anticlockwise (to position 0) and re-move. Pilot lights will go out.

    3.4.2 Electric Shut-Off(Ignition Key)

    G Turn key anticlockwise (to position 0) and re-move. Pilot lights will go out.

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    3.5 Operating Conditions Engin

    3.5.1 Winter Operation

    G Lube Oil Viscosity- Select oil viscosity (SAE grade) according to

    ambient temperature before starting engine,see 4.1.2.

    - Increase oil change frequency when operatingbelow -10C, see 6.1.1.

    G Diesel Fuel- Use winter-grade diesel fuel for operation be

    low 0C, see 4.2.2.

    G 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 -20C, after removing starter if neces

    sary, smear ring gear on flywheel via pinionbore from time to time with cold-resistantgrease.(e.g. Bosch grease FT 1 V 31).

    G 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.

    G Battery- Efficient cold starting requires that battery is

    well-charged, see 6.7.1.- Starting limit temperatures can be lowered by

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

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    3

    C F

    0 32

    25 901 1

    Engine Operation 3.5 Operatin

    3.5.2 High Ambient Temperature,High Altitude

    G Air density decreases as altitude or ambienttemperature increases. As a result of this, theengines maximum output, quality of exhaustgas, temperature level and, in extreme cases,

    starting behaviour, are impaired. Engine can beused at altitudes up to 1000 m and temperaturesup to 30C for mobile operations. If the engine isto operate under more severe conditions (athigher altitudes or temperatures), it will be nec-essary to reduce the injected fuel quantity andthus engine power.

    G If you have any doubts about engine operationunder these or similar conditions, ask your en-gine or equipment supplier whether the enginehas been derated in the interests of reliability,service life and exhaust gas quality (smoke).Otherwise contact DEUTZ SERVICE.

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    Oper

    4.1 Lube Oil

    4.2 Fuel

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    4

    Operating Media 4.1

    4.1.1 Quality

    Lube oils are differentiated according to their per-formance and quality class. In common use arespecifications named after the API (American Pe-troleum Institute) and ACEA European Engine OilSequences.

    Approved API Oils:Minimum: CF-4

    Approved ACEA Oils:Minimum: E1-96

    4.1.2 Viscosity

    As the viscosity of the lube oil is dependent ontemperature, the choice of SAE grade should begoverned by the ambient temperature prevailing atthe engine operating site. Optimum operating be-haviour will be attained if you take the accompany-ing oil viscosity diagram as a guide.Should the temperature fall temporarily below thelimits of SAE grade selected, cold starting may beaffected but the engine will not be damaged. Inorder to keep wear to a minimum, do not exceedapplication limits for extended periods of time.Oil changes dictated by the seasons can be avoidedby using multi-grade lube oils. Multi-grade oils,particularly light-flowing oils, also reduce fuel con-sumption.

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    0 10

    0

    - 5

    - 10

    - 15

    - 20

    - 25

    - 30

    +32

    +23

    +14

    + 5

    - 4

    - 13

    - 22

    A

    F

    C

    II

    4.2 Fuel Opera

    4.2.1 Quality

    Use commercially available diesel fuel with lessthan 0.5% sulphur content. If the sulphur content ishigher, oil change intervals should be reduced (see6.1.1).

    The following fuel specifications / standards areapproved:

    G DIN EN 590

    G BS 2869

    G ASTM D 975-96; 1-D and 2-D

    G NATO Code F-54 / F-34 / F-44 and XF 63

    Exhaust emission values which may be determinedin the case of type approval tests always refer to thereference fuel prescribed by the authorities for thetype approval test.

    4.2.2 Winter-Grade Fuel

    Waxing may occur at low temperatures, cloggingthe fuel system and reducing engine efficiency. Ifthe ambient temperature is less than 0C, winter-grade fuel (suitable down to -15C) should be used.(This fuel is usually available from filling stationswell in advance of the cold months). Diesel fuelcontaining additives (Super diesel) is often on saleas well, for use down to -20C.

    G At temperatures below -15C to -20C, keroseneshould be added to the diesel fuel. The relevantpercentages are given in the adjacent diagram.

    If summer-grade diesel fuel must be used at tem-peratures below 0C, up to 60% kerosene can be

    added (see diagram).

    In most cases, adequate resistance to cold can alsobe obtained by adding a flow improver (additive).Please inquire at DEUTZ SERVICE. Legend:

    I Summer-g

    II Winter-g

    A Ambien

    B Percentage o

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    4

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    5.1 Service Plan5.2 Scheduled Maintenance Plan5.3 Maintenance Chart

    5.4 Maintenance Work Completed

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    5

    Operation

    Service 5

    Deutz maintenance and service schedule = E check = z adjust = clean =V replace =

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

    when commissioning new and overhauled engines

    every 10 operating hours or daily

    in operating hours (OH) everyE10 E20 E25 E30 E40 E50 E60 E70 Years

    500 1000 3000 5000 6000 12000 1 2

    z z

    z V

    V

    z

    z

    z V

    z

    z

    z z

    z

    Industrial engineThe specified engine maintenanpermissible recommended maximon usage, reduced maintenance necessary (comply with the unitoperating instructions).#Maintenance must only be carried

    service personnel

    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

    Oil filter cartridge FL 2011

    Oil filter cartridge BFL 2011

    Fuel filter cartridge

    Change fuel pump/strainer if necessary

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

    Injection valve

    Fuel pre-cleaner

    Intake air cleaner (if available, maintain according to mainten

    Battery and cable connectors

    Engine monitoring system, warning system (replace

    Valve clearance

    V-belt

    Crankcasepressureventvalve

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    5.1 Service Plan

    Timing belt change intervals Engine application Engine/ app

    Guideline values in OH Example:

    6000 or max. 5 years Generating sets 1500/1800 rpm; pump units, low speed; mod

    low speed; platform lifts; refrigeration units etc. low dust exposure

    5000 or max. 5 years compressors; rollers; forklift trucks; welding units; wheel loaders;med

    small dumpers; ski-steer loaders etc. temperature mo

    3000 or max. 5 years agricultural machinery; ski-steer loaders; wheel loaders; drillinghigh speed;

    temperature;

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    5

    equipment; trench-cutting machines; joint cutters; bulldozers etc. high

    Service

    5.2 Scheduled Maintenance Plan5.2.1 Scheduled Maintenance PlanIntervals Deutz maintenance Operation Carried out by:

    at/after and service schedule

    50 OH E 10 After commissioning and E 50-E 70 Authorised specialistsDaily E 20 Daily check Operator

    250 OH E 25 Inspection Authorised specialists

    500 OH E 30 Extended inspection Authorised specialists

    1000 OH E 40 Interim overhaul Authorised specialists

    3000 OH E 50 Extended interim overhaul Authorised specialists

    6 000 OH E 60 Partial overhaul Authorised specialists

    12 000 OH E 70 Basic overhaul Authorised specialists

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    5.3 Maintenance Chart

    The maintenance chart shown here is supplied as aself-adhesive label with each engine. It should beaffixed where it can be seen clearly on the engine ordriven equipment.

    Check that this is the case.

    If necessary, ask your engine or equipment supplierfor a fresh supply of labels.

    Routine work should be carried out according to theschedule in 5.1.

    0297 9935 0

    1000

    1000

    B/FM201

    2011

    FUEL

    OIL

    a

    ex.

    in.

    0,3mm0.012in.in.0,5mm0.020in.ex.

    1

    2

    3

    1

    3

    5

    6

    2

    B/FL20

    1

    2

    6

    3

    5

    BFM/BFL

    FM/FL

    1000

    500

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    DateOp. hours Signature/stamp Op. hours Date Signatu

    5.4 Maintenance Work Completed

    -

    250

    500

    750

    1000

    1250

    1500

    1750

    2000

    2250

    2500

    2750

    50-150*

    125

    375

    625

    875

    1125

    1375

    1625

    1875

    2115

    2375

    2625

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    DateDate Signature/stamp Op. hours Signature/sta5

    Service 5.4 Maintenance Wor

    Op. hours

    2875

    3125

    3375

    3625

    3875

    4125

    4375

    4625

    4875

    5125

    5375

    5625

    3000

    3250

    3500

    3750

    4000

    4250

    4500

    4750

    5000

    5250

    5500

    5750

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    DateOp. hours Signature/stamp Op. hours Date Signatu

    5.4 Maintenance Work Completed

    5875

    6125

    6375

    6625

    6875

    7125

    7375

    7625

    7825

    8125

    8375

    8625

    6000

    6250

    6500

    6750

    7000

    7250

    7500

    7750

    8000

    8250

    8500

    8750

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    DateDate Signature/stamp Op. hours Signature/sta5

    Service 5.4 Maintenance Wor

    Op. hours

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    Service and M

    6.1 Lubrication System6.2 Fuel System6.3 Cooling system6.4 Combustion Air Filter6.5 Belt Drives6.6 Adjustments6.7 Accessories6.8 Engine Cleaning

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    6

    E1-E3/96+ E4-98

    E1-E3/96+ E4-98

    CF-4/ CG-4 / CH-4

    CF-4/ CG-4 / CH-4

    Engines for installation

    Lube qualityAPI-specification

    ACEA-specification

    Normal duty oil, e.g.:

    road vehicles, cranes, construction machinery, ships,generating sets, pumps, rail vehicles.

    Heavy duty for oil, e.g.:

    combine harvesters, emergency pumps, undergroundmining units, sweeping machines, winter maintenance

    equipment, emergency generators.

    Lube oil quality

    Service group

    API specification

    ACEA specification

    Annual usage km Average driving

    speed approx. km/h

    Lube oil chan

    Naturally aspirated engin

    Lube oil chan

    Naturally aspirated enginVehicle engines

    1000

    500

    Service and Maintenance 6.1 Lubrica

    6.1.1 Oil Change Intervals

    G Oil change intervals are dependent on engineapplication and quality of lube oil.

    G If engine runs fewer hours during year thanstated in table, oil should be changed at leastonce a year.

    G Table refers to following conditions:- sulphur content max. 0.5% by weight for diesel

    fuel- continuous ambient temperature to-10C (+14F).

    G If sulphur content is > 0.5 to 1% or continuousambient temperature below -10C (+14F), in-

    tervals between oil changes should be halved.

    G In case of fuels containing more than 1% sul-phur, contact your service representative.

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    6.1.2 Check Oil Level /Change Engine Oil

    6.1.2.1 Check Oil Level 6.1.2.2 Change Engine Oil

    G Allow engine to warm up.G Ensure that engine or vehicle is level.

    - Lube oil temperature approx. 80C.G Switch off engine.

    G Switch engine off before checking oil level.G Ensure that engine or vehicle is level.G Remove oil dipstick.G Wipe dipstick with non-fibrous, clean cloth.G Insert it to stop and remove again.G 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.

    G Place oil tray under G Unscrew oil drain pG Drain oil.G Fit oil drain plug wit

    firmly (for torque, sG Pour in lube oil

    - For grade / viscos- For quantity, see 9

    G Check oil level, see

    6.1 Lubrication System Service and M

    25 729 0 26 022 0

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    6

    Service and Maintenance 6.1 Lubrica

    6.1.3 Changing Oil Filter

    G Clean any dirt from filter carrier sealing surface.

    G Lightly oil rubber gasket of new lube oil filtercartridge.

    G Manually screw in new cartridge until gasket isflush.

    G Undo lube oil filter cartridge using commercialtool and spin off.

    G Catch any escaping oil.

    G Tighten lube oil filter cartturn.

    G Check oil level, see 6.1.2

    G Check oil pressure, see 3

    G Check lube oil filter cartr

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    6.1 Lubrication System Service and M

    6.1.4 Clean / ReplaceOil Filter (Cup)

    G Switch off engine.G Loosen lube oil filter cover 1 and unscrew in

    anticlockwise direction.G Carefully loosen paper filter cartridge 3 upwards

    from guide 4.G Catch any escaping oil.G Replace paper filter cartridge 3.G Clean any dirt from sealing surface of filter carrier

    and lube oil filter cover 1 and from guide 4.

    G Replace and lightly oil rubber gasket 2.G Carefully insert new paper filter cartridge 3 into

    guide 4.G Tighten lube oil filter cover 1 in clockwise direc-

    tion (25 Nm).G Start engine.G Check oil level, see 6.1.2.G Check oil pressure, see 3.3.1.G Check lube oil filter attachment for leaks.

    2

    3

    4

    1

    30 074 0

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    6

    Service and Maintenance 6.2

    6.2.1 Replace Fuel Filter

    G Close fuel shut-off valve.

    G Undo fuel filter cartridge with commercial tooland spin off.

    G Catch any escaping fuel.

    G Clean any dirt from filter carrier sealing surface.

    G Apply light film of oil or diesel fuel to rubbergasket of new fuel filter cartridge.

    G Manually screw in new cartridge until gasket isflush.

    G Tighten fuel filter cartrid

    G Open fuel shut-off valve

    G Check for leaks.

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    6.2.2 Clean / ReplaceFuel Filter (Cup)

    G Switch off engine.G Loosen fuel oil filter cover 1 and unscrew in

    anticlockwise direction.G Carefully loosen paper filter cartridge 3 upwards

    from guide 4.G Catch any escaping fuel.G Replace paper filter cartridge 3.G Clean any dirt from sealing surface of filter

    carrier and fuel filter cover 1 and from guide 4.

    G Replace and lightly oil rubber gasket 2.G Carefully insert new paper filter cartridge 3 into

    guide 4.G Tighten fuel filter cover 1 in clockwise direction

    (25 Nm).G Start engine.G Check fuel filter attachment for leaks.

    2

    3

    4

    1

    30 074 0

    6.2 Fuel System Service and M

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    6

    3

    1

    2

    4

    1

    G Close fuel shut-off valve.G Loosen and unscrew hexagonal nut 1.G Remove fuel strainer cover 2 (cover and strainer,

    one unit).G Clean fuel strainer 2 with diesel fuel. Replace if

    necessary.G Place seal 3 in position.

    G Mount fuel strainer cover 2.G Tighten hexagonal screw 1.G Check for leaks.

    6.2.3 Clean Strainer of Fuel Filter

    Service and Maintenance 6.2

    G Close fuel shut-off valveG Disconnect rubber hosesG Disconnect rubber hoseG Disconnect rubber hoses

    2 and dispose of in an emanner.

    G Connect new rubber hoseG Connect rubber hoses 3G Connect rubber hose 1 tG

    Open fuel shut off valveG Check for leaks after sta

    6.2.4 Change Fuel L

    26 436 0

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    6.3 Cooling System Service and M

    6.3.1 Cleaning Intervals

    Checking or cleaning intervals

    Guideline values OH Engine applicat

    2000 Ships, generating sets in enclose

    1000 Vehicles on paved roads

    500 Tractors, fork-lift trucks, mobile g

    250 Vehicles on construction sites and

    tion machines, compressors, und

    125 Agricultural machines, tractors in

    G Amount of contamination in cooling systemdepends on engine application.

    GOil and fuel residues on engine increase risk ofcontamination. Therefore pay special attentionto leaks if engine is used in dusty environments.

    G 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 invicinity of machine.

    G Because applications vary, cleaning intervalshave to be determined from case to case. Clean-ing intervals given in table on right can be usedas a guide.

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    66.4.2 Emptying Cyc

    Precleaner

    G Undo wing nut 1 and remG Remove collector bowl

    and empty. Clean leaves,matter from lower sectio

    G Reposition collector bowfasten cover 2 in place by

    G Amount of dirt in air cleaner depends on amountof dust in air and size of air cleaner used. If highlevel of dust is anticipated, cyclone-type

    precleaner can be fitted to air cleaner.

    G Cleaning intervals will have to be determinedfrom case to case.

    G If dry type air filters are used, cleaning shouldonly be carried out according to service indicatoror service switch.

    G 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 isrunning.

    G pressing button on service indicator. Serviceindicator is now ready for operation again.

    6.4.1 Cleaning Intervals

    25 885 1

    Service and Maintenance 6.4 Combust

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    G Empty dust discharge valve 1 by pressing apartlips of discharge slot as indicated by arrows.

    G Clean discharge slot from time to time.G Remove any caked dirt by pressing together

    upper section of valve.

    G Undo clip fasteners 1.G Take off hood 2 and remove cartridge 3.G Clean cartridge, replace at least once a year.G Clean cartridge 3.

    Using dry compressed air (max. 5 bar), blow outfrom inside to outside (or in difficult cases, tapout, taking care not to damage cartridge, or washaccording to manufacturers instructions).

    G Gaskets on filter cartridge can become damaged

    through regular removal and replacement Checkfilt (li ht h i th h) d k t

    6.4.3 Dry Type Air CleanerDischarge Valve

    G After five cleaner selatest, replace safetyTo do so:- Undo hex nut 5 an- Install new cartrid

    G Install cartridge 3, refasteners 1.

    Filter Cartridges

    25 889 0 25 888 1

    6.4 Combustion Air Filter Service and M

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    6

    Service and Maintenance 6.

    6.5.1 Check V-belt

    - Carefully remove gauge without altering posi-tion of indicator arm 1.

    - Read off value where black indicator arm 1intersects scale 5 (arrow). For settings, see9.1.

    - If necessary, retension belt and measure again.

    G Visually inspect entire V-belt for damage.G Replace damaged V-belts.G After installing new belts, run engine for 15

    minutes, then check belt tension.G 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 V-

    belt 2 until spring is heard or felt to trigger

    26 261 0 31 866 0

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    6.5.2 Tensioning Alternator Belts

    G Slacken off bolts 1, 2 and 3.

    G Adjust alternator 4 in direction of arrow byturning bolt 3 until correct belt tension is achieved.

    G Retighten bolts 1, 2 and 3.

    6.5.3 Changing Alternator Belts

    G Slacken off bolts 1, 2 and 3.G Adjust alternator 4 in direction of arrow by

    turning bolt 3.G Remove and replace belt.G Adjust alternator 4 against direction of arrow by

    turning bolt 3, until correct belt tension isachieved.

    G Retighten bolts 1, 2 and 3.

    31 860 0 31 859 0

    6.5 Belt Drives Service and M

    53

    2

    1

    4

    53

    2

    1

    4

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    66.6.1 Check Valve Clearance, adjust

    if necessary

    G Remove cylinder head cover.G Position crankshaft as per schematic, see 6.6.1.1.G Before adjusting valve clearance, allow engine to

    cool down for at least 30 minutes. Oil tempera-ture should be below 80C.

    G Check valve clearance 1 between rocker arm /tappet contact face 2 and valve stem 3 with feelergauge 6 (there should be only slight resistancewhen feeler blade is inserted).For permissible valve clearance, see 9.1.

    G Adjust valve clearance if necessary:- Release locknut 4.- Use Allan key 7 to turn setscrew 5 so thatcorrect clearance is attained after locknut 4 hasbeen tightened.

    G Check and adjust valve clearance on all cylin-ders.

    G Reinstall cylinder head cover, with new gasket ifnecessary.

    Service and Maintenance 6.6

    19 691 2 25 893 0

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    2

    1

    1 2 3 41 2 1 2 3

    2 3 411 2 1 2 3

    6.6.1.1 Valve Clearance Adjustments Schematic

    6.6 Adjustments Service and M

    G Crankshaft PositionTurn crankshaft oneAdjust clearance of schematic.

    G Crankshaft PositionTurn crankshaft untoverlap (exhaust val

    about to open). Adjusin black on schemaarm with chalk to shocarried out.

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    66.7.1 Battery

    Service and Maintenance 6.7

    6.7.1.1 Check Battery and CableConnectors

    6.7.1.2 Check Electrolyte Level 6.7.1.3 Check Ele

    G Keep battery clean and dry.G Undo dirty clamps.G Clean terminal posts (+ and -) and clamps of

    battery, and grease with acid-free and acid-resistant grease.

    GWhen reassembling, ensure that clamps makegood contact. Tighten clamp bolts hand-tight.

    G Remove sealing caps 1.G If testers 2 are present:

    Electrolyte level should reach base of these.G Without testers:

    Electrolyte level should be 10-15 mm above topof plates.

    G If necessary, top up with distilled water.G Screw sealing caps back in.

    G Measure electrolyte denwith commercial hydrom

    Hydrometer reading (see indicates batterys state During measurement, temshould preferably be +20

    24 232 3 25 895 0

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    6.7 Accessories Service and M

    Tropical

    1.23

    1.12

    1.08

    Normal

    32

    24

    16

    Tropical

    27

    16

    11

    in [kg/ l] in [B (Baum scale)*] Charge status

    Normal

    1.28

    1.20

    1.12

    well charged

    semi-charged, re-charge

    discharged, immediately charge

    *Measurement of electrolyte density in B (Baumscale) is out of date and rarely used today.

    The gases emitted by the batteryl i ! K k d

    Electrolyte density

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    66.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

    Notes on the three-phase system:G Never disconnect cables between battery, alter-

    nator and regulator while engine is running.G If, however, it is necessary to start and operate

    engine without battery, disconnect regulator fromalternator before starting.

    G Be sure not to confuse battery terminals.G Replace defective charge pilot lamp bulb imme-

    diately.GWhen washing engine, cover up alternator and

    regulator.G Touching lead against frame to check whether it

    is live must not, under any circumstances, becarried out with three-phase electrical systems.

    G In case of electric welding, connect ground ter-minal on welder directly to piece being welded.

    G Always use proper lifting tackle 1 when trans-porting engine.

    G After transportation and before commissioningof engine: remove attachment eyes 2.

    Service and Maintenance 6.7

    31 871 0

    1

    2

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    6.8.1 Engine Cleaning

    PreperationG Switch off engine.G Remove engine covers and cooling air hood.

    Replace them after cleaning and before test run.G Cover electrical / electronic components and

    connections (e.g. alternator, starter, governor,solenoid).

    Using compressed airG Blow air through engine, taking particular care

    not to damage cooler and cooling fins (begin toblow through air from exhaust side).Remove dirt which has blown into interior space.

    Using cold-cleaning compoundG Spray engine with commercial cold-cleaning

    compound and allow to react for approx. 10

    mins.G Spray-clean engine with strong water jet, repeatif necessary.

    G Allow engine to run warm so that remainingwater evaporates.

    Using high-pressure deviceG Clean engine with steam jet (max. spray pres-

    sure of 60 bar, max. steam temperature of 90C).G Allow engine to run warm so that remaining

    water evaporates.

    6.8 Engine Cleaning Service and M

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    6

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    Faults, Causes an

    7.1 Fault Table

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    7

    G Faults are often caused by engine not beingproperly operated or maintained.

    G Each time fault occurs, check whether all operat-ing and servicing regulations have been com-plied with.

    G Corresponding fault table can be found on adja-cent page.

    G If you cannot ascertain cause of a fault or cannotrectify fault, please contact DEUTZ SERVICE.

    Faults, Causes and Remedies 7.

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    7.1 Fault Table Faults, Causes an

    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

    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 lowEngine oil consumption excessive

    Engine smokes - blue

    - white

    - black

    G

    G G

    G G

    G G G G

    G G G

    G G

    G G G G

    G G G

    G G G

    G

    G G

    G

    G

  • 7/28/2019 2011 Operation

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    7Engine does not start or is difficult to start Ch

    Engine starts, but runs irregularly or fails Ad

    Engine becomes excessively hot. Temperature warning system responds Re

    Engine output is deficient Cle

    Engine does not run on all cylinders To

    Engine oil pressure is non-existent or excessively low ReEngine oil consumption excessive

    Engine smokes - blue

    - white

    - black

    S Cause

    Faults Me

    Faults, Causes and Remedies 7.

    Electric cable connections to starter electrical system loose or oxidised

    Starter defective or pinion does not engage

    Solenoid defective (release switch)

    Incorrect valve clearanceInjection line leaks

    Injection valve defective

    G

    G

    G

    G G G G GG G G

    G G G G G G G

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    Engine Preserv

    8.1 Preservation

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    8

    Engine Preservation 8.1 Preserv

    If the engine is to remain idle for an extended periodof time, it is necessary to take protective measures toprevent rusting. The preservative measures describedhere will protect the engine for up to 6 months.The procedure will have to be reversed before theengine is recommissioned.G Anti-corrosion oils to specification:

    MIL-L-21260BTL 9150-037/2Nato Code C 640 / 642

    G Anti-corrosion media for exterior protection onlyto specification:Nato Code C 632

    G Recommended cleaning agent to remove pre-servatives:Petroleum benzine

    (hazardous materials class A3)

    8.1.2 Removing Engine

    Preservatives

    G Clean engine using high-pressure equipment(or with cold-cleansing agent in emergency).

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

    corrosion oil.G If necessary, clean oil bath cleaner (see 6.4.3)

    and fill with anti-corrosion oil.G Drain fuel tank.G Make up a mixture of 90% diesel fuel and 10%

    anti-corrosion oil, and refill fuel tank.G Allow engine to run for approx. 10 mins.G Switch off engine.G Turn engine over manually several times to pre-

    serve cylinders and combustion chamber.G Remove V-belts and store in wrapped condition.G Spray grooves on V-belt pulleys with anti-corro-

    sion spray.G Close intake ports and exhaust ports.

    G Remove anti-corrosion agent from groV-belt pulleys.

    G Install V-belt, retension after brief opnecessary, see 6.5.

    G Remove covers from intake port andport.

    G Commission engine, see also 5.1, not

    8.1.1 Preserving Engine

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    Technical Sp

    9.1 Engine Specifications and Settings9.2 Torque Wrench Settings

    9.3 Tools

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    9Model

    Number of cylinders

    Cylinder arrangement

    Bore [mm]

    Stroke [mm]

    Total displacement [cm3]

    Compression ratio []

    Working cycle

    Combustion system

    Direction of rotation

    Weight incl. integral cooling system to DIN 70020-A

    (without starter, with alternator) approx. [kg]

    Engine output [kW (hp)]

    Speed [rpm]

    Lubrication

    SAE oil

    Maximum oil temperature in oil pan [C]

    Min. oil pressure in warm condition, oil temperature 110C

    at: 900 rpm (low idling speed) [bar]

    1800 rpm [bar]

    max. 2800 rpm [bar]

    Oil change quantity (oil pan) approx. [l]

    Oil change quantity with filter (standard 0.5 l) approx. (l)

    Valve clearance with cold engine

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

    Start of feed [crankshaft BTDC]

    Injector opening pressure: vehicle/unit [bar]

    Technical Specification9.1 Engine Specifications

    F2L 2011 F3L 2011 2 3

    vertical in line

    94

    112

    1554 2331

    19

    4-stroke diesel engine

    Naturally aspirated engine with dir

    On left when looking at flyw

    175 217

    1)

    1)

    Pressure lubrication

    20 W 20

    130

    1.4 3)

    2.2 3)

    3 3)

    6 2) 5.5 2)

    6.5 2) 6 2)

    Inlet 0.3 +0.1 / Exhaust 0.5

    1)

    210 +8

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    Model

    Number of cylinders

    Cylinder arrangement

    Bore [mm]

    Stroke [mm]

    Total displacement [cm3]

    Compression ratio []Working cycle / Combustion system

    Direction of rotation

    Weight without cooling system

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

    Engine output [kW (hp)]

    Speed [rpm]

    Lubrication

    SAE oil

    Maximum oil temperature in oil pan [C]

    at: 900 rpm (low idling speed) [bar]

    1800 rpm [bar]

    max. 2800 rpm [bar]

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

    Oil change quantity with filter (Standard 0.5 l) approx. (l)

    Valve clearance with cold engine

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

    Injector opening pressure: vehicle/unit [bar]

    Start of feed [crankshaft BTDC]

    BF3L 2011

    3

    vertical in line

    94

    112

    2331

    17.5 Four-stroke diesel with turbocharging a

    On left when looking at fly

    222

    1)

    1)

    Pressure lubrication

    20 W 20

    130

    1.4 3)

    2.2 3)

    3 3)

    7.5

    8

    Inlet 0.3+ 0.1/Exhaust 0.5

    210+ 8

    1)

    9.1 Engine Specifications and Settings

    Technical Sp

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    9.1 Engine Specifications and Settings

    Technical SpModel

    Number of cylindersCylinder arrangementBore [mm]Stroke [mm]Total displacement [cm3]Compression ratio []

    Working cycleCombustion systemDirection of rotationWeight without cooling system(without starter, with alternator) approx. [kg]Engine output [kW (hp)]Speed [rpm]LubricationSAE oilMaximum oil temperature in oil pan [C]Min. oil pressure in warm condition, oil temperature 110C at: 900 rpm (low idling speed) [bar]

    1800 rpm [bar]max. 2800 rpm [bar]Engine with ThermostatOil 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) 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]Valve clearance with cold engine(Engine cooling time at least 30 min.: oil temperature should be below 80C). [mm]Start of feed [crankshaft BTDC]

    BF3M 2011 B 3

    vertical in line 94 112 2331 17.5 4-stroke diesel eng Turbocharging and direc On left when looking a Refer to head-offic 215 1) 1) Pressure lubricatio 20 W 20 130 1.4 3) 2.2 3) 3 3)

    7.5 8

    11 11.5

    Inlet 0.3 +0.1 / Exhaust 1) 210 +8

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    9

    Tecnical Specification 9.2 Torque Wre

    Installation location Pre-tension [Nm] Re-tension [Nm] Total C

    1st stage 2nd stage 3rd stage 1st stage 2nd stage 3rd stage 4th stage [Nm]

    Cylinder head cover 8.5

    Cylinder head cover 8.5

    Rocker arm adjustment screw 21

    Intake manifold 8.5

    Foot Rigid suspension 30 45

    Foot Elastic suspension 106

    Air intake pipe 21

    Exhaust manifold 22

    Oil drain plug 55

    Oil pan (sheet metal) 21

    Oil pan (cast) 31

    Injection line attachment 30

    Injection valve attachment 21 TO

    Lube oil filter cartridge 27 on

    Threaded pipe union 4

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    TORX V-belt tension gauge

    A TORX BN. 8189 screw set is used with engines inthe 1011 series.This system was chosen because of the manyadvantages it offers:

    G Outstanding accessibility to bolts.G High load transfer when loosening and tighten-

    ing.G Almost impossible for socket to slide off or

    break, thereby practically ruling out risk of in-

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

    FA.WILBRPostfach 14 05 80D-42826 Remscheid

    25899 0 26002 0

    9.3 Tools Technical Spe

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    Notice

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    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 Manu

    CALIFORNIA

    Proposition 65 Warni

    Diesel engine exhaust and som

    constituents are known to the

    California to cause cancer, bir

    defects, and other reproductiv

    or

    CALIFORNIA

    Proposition 65 Warning

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    CALIFORNIA PROPOSITION 65INFORMATION

    TO CALIFORNIA CUSTOMERS ANDTO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR

    FOR USE IN CALIFORNIA.

    Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicaincluding certain chemicals in diesel engine exhaust.

    Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approvedtwo methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diorder containing these provisions is attached.)

    1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or foJanuary 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment wheequipment. The warning must be secured to the equipment. If warnings or operating instructions are provided thyou may usee that method of providing warning.

    2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is eain 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:

    q Inside The front coverq Inside the back coverq Outside the front coverq Outside the back coverq As the first page of text

    10

    Service

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    10Knowing its DEUTZDEUTZ has always stood for excellence in motorconstruction, pioneering many developments inthe industry. As an independent motor manu-facturer, we offer worldwide a com-prehensive range of diesel and gas motorsspanning from 4kW to 7,400kW. Our products areperfectly tailored to meet our customers individualrequirements.

    Over 1.4 million DEUTZ motors do their jobreliably all over the world. We are determined topreserve the high standard of performance anddependability of our motors, thus keeping ourcustomers satisfied at all times. Therefore we arerepresented worldwide through a network of highly

    competent service partners who will meet theneeds of our customers, wherever they are.

    This is why DEUTZ is not only the name for motorswhich pack a lot of inventive genius. DEUTZ alsomeans reliable service and comprehensive supportto enhance your motors performance.

    This index Sales & Service offers you an overviewof the DEUTZ partners in your vicinity, including theproducts for which they are responsible and therange of services provided. But even when no directproduct responsibility is mentioned, your DEUTZ

    partner will be happy to help you with expert advice.The Index is constantly updated. Please ask yourDEUTZ service partner for the latest edition.

    DEUTZ AG at your service.

    Order-No.: 03120806

    Order-No.: 03120807(CD-ROM)

    DEUTZ AGDeutz-Mlheimer Str. 147-149D-51057 Kln

    Phone: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

    Obtainable from the local service Partner reponsiblefor you or from:

    en

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