Deutz bf6m2012c руководство по ремонту

Operation Manual
C 2000
2012
Revised (10-12)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
1 Gerade BA 2012 9912en
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!
00_GB.p65
2
● 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.
04.02.2002, 14:23
Operation Manual
2012
0297 9912 en
Engine Serial
Number:
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.
© 2003
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).
Foreword
Dear Customer,
Liquid-cooled DEUTZ engines are designed
for a large number of applications. Consequently, a wide range of variants are offered to
meet the requirements of specific cases.
Your engine is appropriately equipped for the
installation concerned, which means that not
all of the components described in this Operation Manual are necessarily mounted to your
engine.
We have endeavored to highlight any differences so that you will be able to locate the
operating and maintenance instructions relevant to your engine quickly and easily.
Please read this Manual before starting your
engine, and always observe the operating
and maintenance instructions.
We are available to help with any additional
inquiries
Sincerely,
DEUTZ AG
© 2003
© 31 493 0
Index
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 Enumeration
2.2 Engine Illustrations
2.2.1 Operating Side 2012
Ribbed V-belt Drive
2.2.2 Starter Side 2012
Ribbed V-belt Drive
2.2.3 Operating Side 2012
2.2.4 Starter Side 2012
2.3 Lube Oil Circuit Schematic
2.3.1 Lube Oil Plan
2.4 Fuel System
2.4.1 Fuel System Plan
2.5 Coolant System
2.5.1 Coolant Plan 2012
3.
Engine Operation
3.1 Commissioning
3.1.1 Pour in Engine Oil
3.1.2 Filling Oil Bath Air Filter with Engine
Oil
3.1.3 Pour in Fuel
3.1.4 Fill / Bleed Cooling System
3.1.5 Other Preparations
3.2
Starting
3.2.1 Electric Starting
3.3 Monitoring Operation
3.3.1 Engine Oil Pressure
3.3.2 Coolant Temperature
3.4 Shutting off
3.4.1 Mech. Stopping
3.4.2 Electr. Stopping
3.5 Operating Conditions
3.5.1 Winter Operation
3.5.2 High Ambient Temperature, High Altitude
4.
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 Fuel
4.3 Coolant
4.3.1 Water Quality for Coolant
4.3.2 Coolant Treatment
4.3.3 Cooling System Protectants
5.
5.1
5.2
5.3
6.
6.1
Routine Maintenance
Maintenance Plan
Maintenance Diagram
Maintenance Work Completed
6.1.1 Oil Change Intervals
6.1.2 Check Oil Level, Change Engine Oil
6.1.3 Replace Oil Filter
6.1.4 Clean/Replace Oil Filter (Cup)
6.2 Fuel System
6.2.1 Replace Fuel Filter
6.2.2 Fuel Pre-filter, Clean Filter Element /
Replace if Necessary
6.2.3 Bleed Fuel System
with Fuel Pre-filter
6.2.4 Bleed Fuel System
without Fuel Pre-filter
6.3 Cooling System
6.3.1 Cleaning Intervals
6.3.2 Clean Cooling System
6.3.3 Drain Cooling System
6.3.4 Fill / Bleed Cooling System
6.4 Combustion Air Filter
6.4.1 Cleaning Intervals
6.4.2 Emptying Cyclone Type Precleaner
6.4.3 Clean Oil Bath Air Filter
6.4.4 Dry Type Air Cleaner
6.5 Belt Drives
6.5.1 Check V-belts
– 2012 Standard
– 2012 with Ribbed V-belt
Service and Maintenance
Lubrication System
© 2003
1.
Index
Tension V-belts
Coolant / Fuel Pump
6.5.3 Replace V-belts
Coolant / Fuel Pump
6.5.4 Replace V-belts
Ribbed V-belts
6.5.5 Tension Alternator V-belts
6.5.6 Replace Alternator V-belts
6.5.7 Wedge rib V-belts wear limit examine
6.6 Adjustments
6.6.1
Check Valve Clearance (Adjust if Necessary)
6.6.1.1 Valve Clearance Adjustment Plan
6.7 Accessories
6.7.1
Battery
6.7.2
Rotary Current Alternator
6.7.3 Transportation Shackles
© 2003
6.5.2
7.
7.1
8.
8.1
9.
9.1
9.2
9.3
Faults, Causes and Remedies
Fault Table
Engine Preservation
Preservation
Technical Specification
Engine Specifications and Settings
Screw Tightening Torques
Tools
10. Service
General
DEUTZ Diesel Engines
Care and Maintenance
Service
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.
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.
Please contact one of our authorized service
representatives in the event of breakdowns or for
spare parts inquiries. Our trained specialists will
carry out repairs quickly and professionally, using
only genuine spare parts.
Original parts from DEUTZ AG are always produced
in accordance with state-of-the-art technology.
Please turn to the end of this manual for further
service information.
Beware of Running Engine
Safety
1
California
Proposition 65 Warning
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.
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
DEUTZ original parts are asbestosfree.
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
1
Engine Description
2
© 2003
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System
2.5 Coolant System
Engine Description
2.1.1 Rating Plate
2
A
2.1 Model
2.1.2 Position of the Rating Plate
2.1.3 Engine Serial Number
B
C
© 26 332 3
© 2003
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.
© 31 488 0
The rating plate C is attached to the crankcase.
© 31 823 0
The engine serial number is stamped on the
arrow
crankcase (arrow
arrow) as well as the rating plate.
Engine Description
2.1 Model
2.1.4 Cylinder Enumeration
1
2
3
2
4
© 31 813 0
© 2003
Cylinders are numbered consecutively, beginning at the flywheel.
Engine Description
2.2 Engine Illustration
2.2.1 Operating Side 2012
Ribbed V-belt drive
2
1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Alternator
Oil filler
Coolant connection compensation line
Fan pulley
Fuel pump
Coolant pump
Ribbed V-belt pulley on crankshaft
Tension roller
Feet
Oil pan
Oil filler neck
Oil filter housing with engine oil cooler
Oil dipstick
Optional attachment of:
Compressor or hydraulic pump
15 Fuel filter cartridge
16 Oil filter cartridge
17 Tractive electromagnet
3
17
4
© 2003
16
15
5
14
6
13
7
12
11
10
9
8
© 31 482 0
Engine Description
2.2 Engine Illustration
2.2.2 Starter Side 2012
Ribbed V-belt drive
2
18
18
19
20
21
22
23
24
25
26
27
19
27
26
Turbocharger
Engine suspension
Speed regulator
Flywheel
SAE housing
Starter
Exhaust manifold
Coolant inlet
Heater flange not shown
Thermostat housing coolant outlet
20
25
24
23
22
© 31 483 0
© 2003
21
Engine Description
2.2 Engine Illustration
2.2.3 Operating Side 2012
2
14
1
13
2
12
3
11
4
10
© 2003
9
8
7
6
5
© 31 484 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Turbocharger
Heater flange
Fan
Alternator
V-belt pulley on crankshaft
Coolant pump
Fuel pump
Oil filler
Oil filter housing with engine oil cooler
Oil filter housing with oil filter cartridge
Oil dipstick
Fuel filter
Tractive electromagnet
Oil filler neck
Engine Description
2.2 Engine Illustration
2.2.4 Starter Side 2012
2
15
16
17
18
19
20
21
22
23
24
25
15
25
24
Engine suspension
Speed regulator
Flywheel
SAE housing
Oil pan
Starter
Feet
Alternator
Coolant inlet
Exhaust manifold
Coolant outlet
16
23
22
21
20
19
18
© 31 485 0
© 2003
17
Engine Description
2
2.3 Lube Oil Circuit Schematic
2.3.1 Lube Oil Plan
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
© 2003
21
22
23
© 31 808 0
Oil pan
Intake line
Lube oil pump
Lube oil cooler
4.1 Heat exchanger bypass valve
4.2 Shut-off valve
4.3 Lube oil replacement filter
4.4 Oil pressure sensor
Main oil pipe
Crankshaft bearing
Con-rod bearing
Camshaft bearing
Line to spray nozzle
Spray nozzle for piston cooling
Valve lifter with rocker arm impulse lubrication
Stop rod, oil supply for rocker arm lubrication
Rocker arm
Return line to oil pan
Oil line to turbocharger
Turbocharger
Oil line to compressor or hydraulic pump
Compressor
Hydraulic pump
Return line from compressor or hydraulic
pump
Line to the differential (2x)
Balancer shafts
Turbocharger return to crankcase
Engine Description
2.4 Fuel System
2
2.4.1 Fuel System Plan
9
1
2
3
4
5
6
7
8
9
10
11
Fuel tank
Line to fuel pump
Fuel pump
Line to fuel filter
Fuel filter
Line to the injection pumps
Injection pump
Line to injection valve
Injection valve
Banjo bolt with pressure maintenance valve
Return line to fuel filter housing from
pressure maintenance valve
(with cup filter installation only)
12 Return line to fuel tank
13 Maintain maximum possible distance
7
10
5
11
12
13
1
2
4
3
6
© 31 809 1
© 2003
8
Engine Description
2.5 Coolant System
2.5.1 Coolant block diagram 2012
Example: With cup filter
2
12
13
10
11
6
8
5
7
1
2
9
15
© 2003
3
4
14
© 31 810 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Thermostat housing
Outlet neck cover
Coolant pump
Lube oil cooler
Cylinder cooling
Cylinder head cooling
Line from engine to heat exchanger
Heat exchanger
Line from heat exchanger to thermostat
Ventilation line to the compensation tank
Compensation tank
Coolant compensation line
Coolant return from heater
Coolant supply to heating at V-belts
Coolant supply to heating at ribbed
V-belts
Engine Operation
3
Commissioning
Starting
Monitoring Operation
Shutting off
Operating Conditions
© 2003
3.1
3.2
3.3
3.4
3.5
Engine Operation
3.1.1 Pour in Engine Oil
3
3.1 Commissioning
3.1.2 Oil Bath Air Filter with
Engine Oil
OIL
FUEL
© 26 398 0
© 31 491 0
© 2003
As a rule, engines are delivered without oil.
Pour lube oil into the oil filler neck (arrow).
Oil capacity, see 9.1.
For oil grade and viscosity, see 4.1.
Fill oil cup 1 of the oil bath air cleaner (if
installed) with oil up to the arrow.
For oil grade and viscosity, see 4.1.
!
Never fill the fuel tank while the
engine is running. Ensure cleanliness! Do not spill fuel!
Engine Operation
3.1 Commissioning
3.1.3 Fill / Bleed Cooling System
3.1.4 Other Preparations
● 2012: In accordance with the radiator supplier’s specifications
● Unit engine: In accordance with the radiator
supplier’s specifications
● Check battery and cable connections, see
6.7.1.
3
● Trial run
- After the engine has been prepared, carry out
a brief trial run for approx. 10 minutes, without
load if possible.
During and after the trial run
- Check the engine for leaks.
After the engine has been turned off
- Check oil level and top up if necessary,
see 6.1.2.
- Retension V-belts, see 6.5.
● Breaking in
During the break-in phase - about 200 operating hours - check the oil level twice a day.
After the engine is broken in, checking once a
day will be sufficient.
© 2003
● In the event of commissioning engines
which have been preserved
Carry out removal of preservation in accordance with Chapter 8.1.
Engine Operation
3.2 Starting
3.2.1 Electric Starting
3
without cold start assistance
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 started
under any circumstances.
Disconnect the battery!
!
2
1
© 2003
© 31 824 0
Do not actuate the starter for more than 20
seconds. If the engine does not catch, wait for one
minute then try again.
If the engine does not catch after two attempts,
refer to the Fault Table (see 7.1).
© 25 745 0
● Disengage the clutch to separate the engine from any driven parts.
● Insert key
- Position 0 = no operating voltage.
● Bring speed adjustment lever 1 into at least
the middle speed position in the direction of
the arrow.
● Turn key clockwise
- Position 1 = operating voltage
- Pilot lights 1 and 2 illuminate.
● Move cut-out handle 2 into operating position counter to the direction of the arrow.
● Push key in and turn further clockwise
against spring pressure.
- Position 2 = no function
- Position 3 = start
● Release key as soon as engine fires
- The pilot lights will go out.
3.2 Starting
3
with cold start assistance
Heater flange
© 25 746 2
● Insert key
- Position 0 = no operating voltage.
● Turn key clockwise
- Position 1 = operating voltage.
- Pilot lights illuminate, pre-glowing until
glow indicator is extinguished.
● Release key as soon as engine fires.
- The pilot lights will go out.
© 2003
● Push key in and turn further clockwise
against spring pressure.
- Position 2 = no function
- Position 3 = start
Engine Operation
3.3 Monitoring Operation
3.3.1 Engine Oil Pressure
3
Oil pressure lamp
© 25 752 1
● The oil pressure pilot light comes on with
operating voltage on and engine off.
● The oil pressure pilot light must be extinguished when the engine is running.
© 2003
Oil Pressure Gauge
Oil Pressure Indicator
© 25 753 0
● The pointer must remain in the green sector
over the entire operating range.
© 25 754 0
● The pointer of the oil pressure gauge must
display the minimum oil pressure (see 9.1)
3.3 Monitoring Operation
Engine Operation
3.3.2 Coolant temperature
3
© 26 246 0
© 2003
● The engine temperature gauge pointer
should always remain in the green sector. It
should rarely enter the yellow-green sector.
If the pointer enters the orange sector, the
engine is overheating.
Turn off and establish the cause from the
Fault Table (see 7.1).
Engine Operation
3.4.1 Mechanical Stopping
3
3.4 Shutting Off
3.4.2 Electrical Stopping
2
1
© 31 825 0
● Move speed adjustment lever 1 to low idle.
● Move shut-off lever 2 until the engine comes
to a stop. The charge pilot light and the oil
pressure pilot light illuminate when the engine stops.
© 2003
● Turn key counterclockwise (to position 0)
and remove. The pilot lights will go out.
If possible, do not switch off the engine when
under full load. Subsequently allow the engine to idle for approx. 2 mins.
© 25 746 2
● Turn key counterclockwise (to position 0)
and remove. The pilot lights will go out.
Engine Operation
3.5 Operating Conditions
3.5.1 Winter Operation
● Lube Oil Viscosity
- Select the oil viscosity (SAE grade) according
to the ambient temperature before starting
the engine, see 4.1.2.
- Increase oil change frequency when operating below -10 °C, see 6.1.1.
● Diesel Fuel
- Use winter-grade diesel fuel for operation
below 0 °C, see 4.2.2.
3
● Battery
- Efficient cold starting necessitates that
the battery is well-charged, see 6.7.1.
-The starting limit temperatures can be lowered
by 4-5 °C by heating the battery up to about 20 °C. (To do so, remove the
battery and store in a warm place).
● Coolant
- Mixture ratio of anti-freeze / water for minimum temperature (max. -35 °C),
see 4.3.1.
● Additional Maintenance Work
- Drain the sludge from the fuel tank once a
week (undo the sludge drain screw).
- If necessary, adjust oilbath filter oil level,
like the engine oil, to the ambient temperture.
- Below -20 °C, after removing the starter if
necessary, smear the ring gear on the flywheel via the pinion bore from time to time
with cold-resistant grease. (e.g. Bosch
grease FT 1 V 31).
© 26 248 0
© 2003
● Cold Start Assistance
- The heater flange is automatically initialised at
temperatures < -25 °C.
Engine Operation
3.5 Operating Conditions
3.5.2 High Ambient Temperature
High Altitude
3
● Air density decreases as altitude or ambient temperature increase.
As a result of this, the engine’s maximum
output, the quality of the exhaust gas, the
temperature level and, in extreme cases,
starting behaviour, are impeded.
In the event of non-stationary operation,
use up to altitudes of 1000 m and temperatures of 30 °C is permissible.
If the engine is to operate under unfavourable conditions (at higher altitudes or temperatures), it will be necessary to reduce
the injected fuel quantity and thus, engine
power.
© 2003
● 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
your service representative.
C
F
0
32
© 25 901 1
Operating Media
4
© 2003
4.1 Lube Oil
4.2 Fuel
4.3 Coolant
Operating Media
4
4.1 Lube Oil
4.1.1 Quality Grade
4.1.2 Viscosity
Lube oils are differentiated by Deutz according
to their performance and quality class. Oils of
other, comparable specifications can be used.
Generally, multi-grade oils shall be used. In
closed heated rooms at temperatures >5°C,
also single-grade oils can be used.
Approved oils:
Deutz
ACEA
DQC I
E2-96
DQC II
DQC III
E3/96/E5-02 E4-99
API
CF/CF-4
CH-4/CG-4
-
DHD
-
DHD-1
-
© 2003
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.
As the viscosity of lube oil is dependent on
temperature, the choice of SAE grade should
be governed by the ambient temperature
prevailing at the engine operating site.
Optimum operating behaviour will be attained
if you take the accompanying oil viscosity
diagram as a guide.
Should the temperature fall temporarily below
the limits of the SAE grade selected, cold
starting may be affected but the engine will
not be damaged.
In order to keep wear to a minimum, do not
exceed application limits for extended periods
of time.
Synthetic lube oils feature an improved
temperature and oxidation stability.
Only with preheating
30 298 1
Operating Media
4.1 Lube Oil
Turbocharged engines with uprated power and
engines with high loading
The oils listed in enclosure 1 are to be used
for the following engines and applications:
COM/EPA II version and increased output
BF4M 2012/C > 95 kW
BF6M 2012/C > 143 kW (bore 101 + 98-MVS)
BF6M 2012/C > 135 kW (bore 98 mech. FIE)
all engines in CHP plants
all engines in gensets operating in parallel with
the mains/with each other
engines in combines with:
These are high-grade oils according to ACEA or
API. In addition most of these oils are partly
synthetic, some even fully synthetic (5W-40) and
thus achieve the thermal stability required for the
relevant application and are distinguished by a
low tendency to cause deposits in the turbocharger
and in the charge air pipes with closed-circuit
crankcase breather
4
Lube oils for engines with uprated power and engines with high loading
SAE class Availability
Producer
Type of lube oil
DEUTZ
TXL-10W40 FE
10W-40
AGIP
AGIP
ARAL GmbH
ARAL GmbH
BAYWA
BAYWA
Castrol GmbH
Agip Sigma Ultra TFE
Autol Valve Ultra FE
Aral MegaTurboral
Aral SuperTurboral
BayWa Super Truck 1040 MC
BayWa Turbo 4000
Castrol SYNTRUCK
10W-40
10W-40
10W-40
5W-30
10W-40
10W-40
5W-40
Castrol GmbH
Castrol DYNAMAX
7,5W-40
CHEVRON
Chevron Delo 400 Synthtic
ESSO
Essolube XTS 501
FINA
FINA KAPPA FIRST
FINA
FINA KAPPA ULTRA
FUCHS DEA
DEA Cronos Synth
FUCHS DEA
DEA Cronos Premium LD
FUCHS DEA
Fuchs Titan Cargo MC
FUCHS DEA
Deutz Oel TLL 10W-40 MB
FUCHS DEA
DEA Cronos Premium FX
FUCHS DEA
Fuchs Titan Unic Plus MC
MOBIL OIL
Mobil Delvac 1 SHC
MOBIL OIL
Mobil Delvac 1
MOBIL OIL
Mobil Delvac XHP Extra
BP OIL International BP Vanellus HT Extra
Shell International Shell Myrina TX /
Shell Rimula Ultra
Shell International Shell Myrina TX /
Shell Rimula Ultra
TOTAL
TOTAL RUBIA TIR 86000
Schmierölraffinerie Wintershall TFG
Salzbergen GmbH
The table will be extended as and when required.
5W-40
10W-40
5W-30
10W-40
5W-40
10W-40
10W-40
10W-40
10W-40
10W-40
5W-40
5W-40
10W-40
10W-40
5W-30
10W-40
10W-40
10W-40
worldwide
Germany
worldwide
worldwide
South Gemany
South Gemany
Europe, North America, Brazil
Argentina, Australia, South Africa
Europe, North America, Brazil
Argentina, Australia, South Africa
North America
Europe
Europe
Europe
Germany, Europe
Germany, Europe
worldwide
Germany
Europe
worldwide
Europe, SE Asia, Africa
worldwide
Europe, SE Asia
Europe
Europe, different
description in some countries
Europe, different
description in some countries
worldwide
Europe
© 2003
4.1.2.1 Specific lube oil
definitions
Operating Media
4
4.2.1 Quality
4.2.2 Winter Fuel
Use commercially available diesel fuel with
less than 0.5 % sulphur content. If the sulphur
content is higher, oil change intervals should
be reduced (see 6.1.1).
Waxing may occur at low temperatures,
clogging the fuel system and reducing engine
efficiency. Use winter-grade diesel fuel (up to
-20 °C) for operation below 0 °C. This is made
available within good time by filling stations
prior to the start of the winter season.
The following fuel specifications / standards
are approved:
DIN EN 590
BS 2869: A1 and A2
(with A2, take note of the sulphur content!)
ASTM D 975-88; 1-D and 2-D
NATO Code F-54 and F-75
Exhaust emission values which may be
determined in the case of type approval tests
always refer to the reference fuel prescribed
by the authorities for the type approval test.
© 2003
4.2 Fuel
Kerosene must be added at temperatures
below -20 °C. The relevant percentages
are given in the adjacent diagram.
Special diesel fuels may be used in arctic
climatic zones up to -44 °C.
If summer-grade diesel fuel must be used at
temperatures below 0 °C, up to 60% kerosene
can be added (see diagram).
+32
0
+23
-5
+14
- 10
+ 5
- 15
I
- 4 - 20
- 13 - 25
II
- 22 - 30
°F
!
0
10
20
30
40
50
60 %
B
A
In most cases, adequate resistance to cold
can be obtained by adding a flow improver
(additive). Please ask your DEUTZ partner.
Diesel fuels must never be
mixed with gasoline
(Normal and Super grades)!
°C
© 26 441 1
Legend:
I
Summer-grade diesel fuel
II
Winter-grade diesel fuel
A
Ambient temperature
B
Percentage of kerosen added
!
Mix in tank only! Fill with the
appropriate amount of kerosene
first, then add the diesel fuel.
4.3 Coolant
Operating Media
4
4.3.1 Quality of Water for
Coolant
4.3.2 Coolant Treatment
4.3.3 Cooling System
Protectants
The values listed below must not be exceeded.
In order to examine the quality of your water, a test
case can be ordered from DEUTZ under Order
No. 12130382.
In the case of liquid-cooled engines, special
attention must be paid to the treatment and
control of the coolant, as the engine may
otherwise become damaged as a result of
corrosion, cavitation and freezing.
The treatment of the coolant is carried out by
adding a cooling system protectant to the
cooling water.
The cooling system must be continuously monitored, see 5.1. In addition to checking the
coolant level, this also involves checking the
concentration of the cooling system protectant.
The cooling system protectant concentration
can be checked with commercially available
testers (example: gefo glycomat ®).
DEUTZ cooling system protectant must be purchased in drums under Order No. 01011490 (5
litres) or 1221 1500 (210 litres). These are nitrite,
amine and phosphate-free, and provide effective
protection against corrosion, cavitation and freezing.
If the above mentioned cooling system protectant
is unavailable, the following products may be
used in exceptional cases.
Manufacturer
Product designation
min.
max.
6.5
8.5
3
Chloride ion content [mg / dm ]
-
100
Sulphate ion content [mg / dm3]
-
100
Total hardness [°dGH]
3
20
AVIA
ARAL
BASF
DEA
SHELL
AVIA Antifreeze Extra
Antifreeze Extra
Glysantin G 48
DEA Radiator Antifreeze
SHELLGlycoShell
The cooling system protectant in the coolant should
not fall below or exceed the following concentration:
Cooling system protectant
Water
max. 45 Vol.%
55%
min. 35 Vol.%
65%
Filling volume, see chart over page in combination with specifications in Chapter 9.1.
The use of other cooling system protectants, e.g.
chemical anti-corrosion agents, is possible in
exceptional cases. Consult DEUTZ Service.
!
If nitrite-based cooling system
protectants are mixed with
amine-based agents, dangerous nitrosamines are formed.
!
Cooling system protectants must
be disposed of in an environmentally-friendly manner.
© 2003
Water quality
pH value at 20 °C
Operating Media
4
4.3 Coolant
Cooling system protection
Cooling
system
protection
content of coolant system *)
[Litres]
Frost
protection
in
[ °C]
18
35
–22
6,3
7,0
7,7
8,75
9,5
40
–28
7,2
8,0
8,8
10
45
–35
8,1
9,0
9,9
50
–45
9,0
10
11
in
20
22
27
30
32
35
10,5
11,2
12,3
10,8
12
12,8
14
11,3
12,2
13,5
14,4
15,8
12,5
13,5
15
16
17,5
Cooling system protectant
*) For coolant content of your engine, see Operation Manual Chapter 9.1.
Note: Grey sector only after consulting head office
© 2003
25
Routine Maintenance
5
© 2003
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Work Completed
Routine Maintenance
5.1 Maintenance Schedule
check= ●
adjust= ❍
clean= ▲
replace= ■
⇓ prior to or during 1st trial run, check 2x daily during the breaking in phase or
when commissioning new and overhauled engines
5
⇓ every 10 hours of operation or daily
Operating hours (OP) every
Years
250
●
500 1000 1 5 0 0 12000
1
2
●
■
■
■
●
■
■
●
●
▲
■
●
■
■
●
●
●
●
●
●
■
●
●
●
●
●
▲
❍
■
Operation
Industrial engines
The specified engine maintenance values are
permissible recommended maximums.
Depending on usage, reduced maintenance
intervals may be necessary, comply with the
unit manufacturer’s operating instructions.
# Maintenance must only be carried out by
authorised service personnel
Top lube oil up if necessary
Lube oil (oil change intervals depending on engine use), see TR 0199-99-3002
Oil filter cartridge (at each lube oil change)
Fuel filter cartridge
Flexible fuel leak oil lines (replace completely)
Injection valve
Fuel pre-cleaner/ filter element (cleaning or replace if necessary)
Coolant (additive concentration)
Coolant pump
Coolant level
Intake air cleaner (If available, maintain according to maintenance indicator)
Intercooler (drain lube oil/condensation)
Battery and cable connectors
Engine monitoring system, warning system
Valve clearance
V-belts (retension or replace if necessary)
© 2003
* When the warning system responds (lamp/horn), the fuel pre-filter must be emptied immediately
Section
6.1.2/3.3.4
6.1.1/ 6.1.2
6.1.3
6.2.1
#
4.2/ 5.2
4.3.1/ 2/ 3
#
–
6.4.3 /6.4.4
6.7.1
3.3 #
6.6.1#
6.5.1
Routine Maintenance
5.1 Maintenance Schedule
check= ●
adjust= ❍
clean= ▲
replace= ■
prior to or during 1st trial run, check 2x daily during the breaking in phase or when
commissioning new and overhauled engines
every 10 hours of operation or daily
In hours of operation (HO) every
Years
250
●
●
●
500 1000 1500 12000
1
2
●
●
●
■
5
Industrial engines
The specified engine maintenance values
are permissible recommended maximums.
Depending on usage, reduced maintenance
intervals may be necessary, comply with the
unit manufacturer’s operating instructions.
# Maintenance must only be carried out by
authorised service personnel
Operation
Check engine for leaks (visual inspection)
Engine suspension (replace if damaged)
Fastenings, hose connections / clamps
Basic overhaul
Section
–
9.2
–
#
Page 2 of 2
prior to or during 1st trial run, check 2x daily during the breaking in
phase or when commissioning new and overhauled engines
every 10 hours of operation or daily
In hours of operation (HO) every
250
Years
500 1000 3000 6000 12000 1
■
2
Operation
Injection valve
Additions and modifications
for engines with EPA approval
The specified engine maintenance values arepermissible
recommended maximums. Depending on usage, reduced
maintenance intervals may be necessary, comply with the
unit manufacturer’s operating instructions.
# Maintenance must only be carried out by authorised
service personnel
Section
#
© 2003
check= ●
adjust= ❍
clean= ▲
replace= ■
Max. permissible reference times in operating hours (HO) every
Routine Maintenance
5.2 Maintenance Chart
Check that this is the case.
If necessary, ask your engine or equipment
supplier for a fresh supply of labels.
h
Std.
AIR
1252000
10
500
OIL
The maintenance chart shown on this page is
supplied as a self-adhesive label with each
engine. It should be affixed where it can be
seen clearly on the engine or driven
equipment.
5
a
in.
1500
ex.
Routine work should be carried out according
to the schedule in 5.1.
OIL
500
FU
EL
1000
10
10
ER
WAT
OIL
max.
© 2003
0297 9901 1
!
Stop the engine before carrying out any maintenance work.
2012
Routine Maintenance
5.2 Maintenance Chart
The maintenance chart shown on this page is supplied as a self-adhesive label with each engine. It should be affixed where it can be seen
clearly on the engine or driven equipment.
Check that this is the case.
If necessary, ask your engine or equipment supplier for a fresh supply of labels.
Routine work should be carried out according to the schedule in 5.1.
5
max
.
min.
© 2003
2012
0297 9902 0
min.
9912EN_K05-1.P65
37
17.02.2003, 12:05 Uhr
Routine Maintenance
5
Op. hours
50-150
Date
*
Signature/stamp
5.3 Maintenance Work Completed
Op. hours
-
125
250
375
500
625
750
875
1000
1125
1250
1375
1500
1625
1750
1875
2000
2115
2250
2375
2500
2625
2750
© 2003
* following commissioning of new and overhauled engines.
Duly completed maintenance jobs can be recorded and signed off in the above chart.
Date
Signature/stamp
Routine Maintenance
5.3 Maintenance Work Completed
Op. hours
Date
Signature/stamp
Op. hours
2875
3000
3125
3250
3375
3500
3625
3750
3875
4000
4125
4250
4375
4500
4625
4750
4875
5000
5125
5250
5375
5500
5625
5750
Date
5
Signature/stamp
© 2003
Duly completed maintenance jobs can be recorded and signed off in the above chart.
Routine Maintenance
5
Op. hours
Date
Signature/stamp
5.3 Maintenance Work Completed
Op. hours
5875
6000
6125
6250
6375
6500
6625
6750
6875
7000
7125
7250
7375
7500
7625
7750
7825
8000
8125
8250
8375
8500
8625
8750
© 2003
Duly completed maintenance jobs can be recorded and signed off in the above chart.
Date
Signature/stamp
Routine Maintenance
5.3 Maintenance Work Completed
Op. hours
Date
Signature/stamp
Op. hours
8875
9000
9125
9250
9375
9500
9625
9750
9875
10000
10125
10250
10375
10500
10625
10750
10825
11000
11125
11250
11375
11500
11625
11750
Date
5
Signature/stamp
© 2003
Duly completed maintenance jobs can be recorded and signed off in the above chart.
Routine Maintenance
5
© 2003
Op. hours
Date
Signature/stamp
5.3 Maintenance Work Completed
Op. hours
Date
Signature/stamp
Service and Maintenance
6
© 2003
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air Filter
6.5 Belt Drives
6.6 Adjustments
6.7 Accessories
Service and Maintenance
6
6.1 Lubrication System
6.1.1 Oil Change Intervals
● The oil change intervals are dependent on
the engine application and the quality of
the lube oil.
● If the engine runs fewer hours during the
year than stated in the table, the oil should
be changed at least once a year.
● If, for vehicle engines, lube oil change
intervals are determined by operating hours,
the lube oil change intervals indicated in table
6.1.1.1. equipment engines.
● The table refers to the following conditions:
– For diesel fuel: sulfur content max. 0.5
% by weight.
– Continuous ambient temperatures down
to -10 °C / +14°F
● For fuels
– with sulfur content is > 0.5 to 1 %
or
– continuous ambient temperature below
-10 °C/+14°F
or
– with bio-diesel fuels in accordance with
DIN 51606-FAME the intervals between
oil changes should be halved.
© 2002
● In the case of fuels containing more than
1 % sulfur, contact your service representative.
Change the oil with the engine off but still
warm (lube oil temperature approx. 80 °C).
ENGLISCH • Kapitel 6 • Seite 52
9682en_K06.p65
52
30.07.2003, 10:13
Service and Maintenance
6.1 Lubrication System
6
6.1.1.2 Lube oil change intervals for industrial and marine engines
Lube oil grade
ACEA-specfication
API-specification
Worldwide specification
special DEUTZ release list
Standard lube oil code for building
equipment and nonraod vehicles
Engine
Engine version
series
2012
DQC I
DQC II
DQC III
E2-96
CF/CF-4
E3-96/E5-02
CG-4/CH-4
E4-99
-
EO...
EO...A, EO...B
DHD-1
EO...C
Enclosure 1
-
Lube oil change intervals in op. hours
Oil use
normal high
All engines except for:
BF4M2012C P > 95 kW
BF6M2012C P > 143 kW, from nonroad stage II
at cylinder bore 101 mm or 98 mm with MV system
BF6M2012C P > 135 kW, from nonroad stage II
at cylinder bore 98 mm with mech. injection system
Other engines from nonroad stage II
eng. in harv. machines, block-typethermal power stat., gensets**
Oil use
normal high
250
-
500
-
500
500
500
-
-
500
-
500
-
500
500
*Gensets as referred to here are units operating in parallel with the mains / with each other.
Emergency power units are dealt with in TR 0199-99-1126.
Oil use
normal high
© 2003
Deutz lube oil quality class
Service and Maintenance
6.1 Lubrication System
6.1.1.2 Oil change intervals for vehicle engines
6
Schmieröl-Qualität
Deutz lube oil quality class
ACEA specification
API specification
worldwide specification
special DEUTZ release
© 2003
E2-96
CF/CF-4
-
DQC II
DQC III
E3-96/E5-02
E4-99
CG-4/CH-4
DHD-1
Enclosure 1
Engine version
Lube oil change intervals in km
25 2012
Euro I
10 000
15 000
20 000
Euro II and Euro III, except for:
15 000
20 000
BF4M2012C > 95 kW from Euro II
20 000
20 000
BF6M2012C > 143 kW from Euro II at cylinder
bore 101 mm with or 98 mm with MV system
> 135 kW from Euro II at cylinder bore 98 mm
20 000
with mechanical injection system
40 2012
Local
Euro I
15 000
20 000
30 000
traffic
Euro II and Euro III,except for:
20 000
30 000
BF4M2012C > 95 kW from Euro II
30 000
BF6M2012C > 143 kW from Euro II at cylinder
30 000
bore 101 mm with or 98 mm with MV system
> 135 kW from Euro II at cylinder
30 000
bore 98 mm with mechanical injection system
60 2012
Long
Euro I
20 000
30 000
40 000
distance
Euro II and Euro III, except for:
30 000
40 000
traffic
BF6M2012C > 143 kW from Euro II at cylinder
40 000
bore 101 mm with or 98 mm with MV system
> 135 kW from Euro II at cylinder
40 000
bore 98 mm with mechanical injection system
If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4.1. for “Oil
use under normal duty” will apply.
Average speed in km/h approx. ]
Application
Site
vehicles/
busses
DQC I
Service and Maintenance
6.1 Lubrication System
© 25 729 0
Ensure that the engine or vehicle is in a level
position.
Engine warm:
Shut engine off, wait for 5 minutes and check
oil level.
Engine cold:
Check oil level.
Remove the oil dipstick.
Wipe the dipstick with a non-fibrous, clean
cloth.
Insert it to the stop and remove again.
Check the oil level, and if necessary, top up to
the “MAX” mark.
- If the oil level is only just above the “MIN”
mark, more oil must be added.
The level must not fall below the “MIN” mark.
6
6.1.2.2 Engine Oil Change
© 26 022 0
Run engine until warm.
Ensure that the engine or vehicle is in a level
position.
- Lube oil temperature approx. 80 °C.
Switch off the engine.
© 26 023 0
Place oil tray under the engine.
Unscrew oil drain screw.
Drain oil.
Screw oil drain screw in with new seal ring
and tighten. (Tightening torque
see 9.2).
Pour in lube oil.
- For grade / viscosity, see 4.1
- For quantity, see 9.1.
Check oil level, see 6.1.2.1.
Caution when draining hot oil: Risk of
scalding!
Do not let used oil run into the soil but
collect it in a container!
Dispose of this in accordance with environmental
regulations!
© 2003
6.1.2 Check Oil Level / Change
Engine Oil
6.1.2.1
Check Oil Level
6.1.2.1Check
Service and Maintenance
6.1 Lubrication System
6.1.3 Replace Oil Filter
6
© 25 880 0
● With attached locking piston:
Undo tensioning screws and remove
tensioning clamps downwards.
● Undo the lube oil filter cartridge using a
commercial tool and spin off.
● Catch any escaping oil.
© 25 881 0
© 25 882 0
● Clean any dirt from the filter carrier sealing
surface.
● Tighten the lube oil filter cartridge with
another half-turn.
● Lightly oil the rubber gasket of the new lube
oil filter cartridge.
● If locking piston is available:
Position tensioning clamps and tighten with
tensioning screws.
● Manually screw in the new cartridge until
the gasket is flush.
● Check oil level, see 6.1.2.
● Check oil pressure, see 3.3.1.
© 2003
● Check lube oil filter cartridge seal for leaks.
Caution is required in the case of
hot oil: Risk of scalding!
6.1 Lubrication System
Service and Maintenance
6.1.4 Clean / Replace
Oil Filter (Cup)
6
1
2
3
4
© 30 074 0
Caution is required in the case
of hot oil:
Risk of scalding!
● Replace and lightly oil the rubber gasket 2.
● Carefully insert new paper filter cartridge 3
into guide 4.
● Tighten lube oil filter cover 1 in a clockwise
direction (25 Nm).
● Start engine.
● Check oil level, see 6.1.2.
● Check oil pressure, see 3.3.1.
● Check lube oil filter attachment for leaks.
© 2003
● Switch off the engine.
● Loosen lube oil filter cover 1 and unscrew
in an anticlockwise direction, emties itself
the system automatically (drain valve).
● Carefully loosen paper filter cartridge 3
upwards from the guide 4.
● Catch any escaping oil.
● Replace paper filter cartridge 3.
● Clean any dirt from the sealing surface of
the filter carrier and lube oil filter cover 1
and fromb the guide 4.
Service and Maintenance
6.2 Fuel System
6.2.1 Replace Fuel Filter
6
© 25 880 0
Close the fuel shut-off valve.
© 2003
Undo fuel filter cartridge with commercial
tool and spin off.
© 25 881 0
Apply light film of oil or diesel fuel to the
rubber gasket of the new fuel filter cartridge.
Catch any escaping fuel.
Manually screw in the new cartridge until
the gasket is flush.
Clean any dirt from the filter carrier sealing
surface.
Tighten the fuel filter cartridge with a final
half-turn.
© 25 882 0
Open fuel shutoff valve.
Check for leaks.
The fuel system does not need
to be bled.
Keep naked flames away when working on the
fuel system. Do not smoke!
Service and Maintenance
6.2 Fuel System
6.1.4 Clean / Replace
Fuel Oil Filter (Cup)
6
1
2
3
4
© 30 074 0
Keep naked flames away when
working on the fuel system. Do
not smoke!
● Replace and lightly oil the rubber gasket 2.
● Carefully insert new paper filter cartridge 3
into guide 4.
● Tighten fuel oil filter cover 1 in a clockwise
direction (25 Nm).
● Start engine.
● Check fuel oil filter attachment for leaks.
© 2003
● Switch off the engine.
● Loosen fuel oil filter cover 1 and unscrew in
an anticlockwise direction, emties itself the
system automatically (drain valve).
● Carefully loosen paper filter cartridge 3
upwards from the guide 4.
● Catch any escaping oil.
● Replace paper filter cartridge 3.
● Clean any dirt from the sealing surface of
the filter carrier and fuel oil filter cover 1 and
fromb the guide 4.
Service and Maintenance
6.2 Fuel System
6.2.3 Clean / purge or change fuel
pre-filter
6
© 2003
© 31 811 2
Clean (purge) - remove water:
● Turn off engine or, in the case of a changeover filter, switch over to the other filter.
● Close the fuel stopcock or supply. (if available)
● Open the bleed screw 1 on the cover 2
● Place the fuel collector underneath the fuel
pre-filter.
● Empty water and dirt from the bowl 6 by
opening (press in and turn slightly without
using force) the drain cock 8 and close the
drain cock 8 again
● Close the bleed screw 1 on the cover 2 again
● Bleed the fuel pipe according to instructions,
see 6.2.5 opposite
Changing the filter element 5:
Change at least once a year or as required (drop
in performance also after purging)
● Turn off the engine or switch to other filter in
case of changeover filter
● Close the fuel stopcock or supply (if available)
● Loosen the cover screws 3 diagonally
● Remove the cover 2
● Remove the spring cassette 4
● Remove the filter element 5 from the bracket
● Insert new filter element 5
● Place spring cassette 4 on the element
● Check that the cover seal is fit properly in the
cover 2 and check for damage (change if
necessary)
● Tighten the cover 2 with the screws 3
diagonally (torque 6 Nm)
● Check the cover 2 for proper fit and leaks
● Bleed the fuel system, see 6.2.4.
The connection of a warning system
(lamp/horn) via contacts 7 is specified.
Immediate maintenance is necessary when the
warning system is triggered.
Naked flames are prohibited when
working on the fuel system! Do
not smoke!
Dispose of old fuel in an environmentally friendly way!
Service and Maintenance
6.2 Fuel System
6.2.5 Bleed Fuel System
without Fuel Pre-filter
6.2.4 Bleed Fuel System
with Fuel Pre-filter
6
Place fuel collection container beneath the
fuel pre-filter.
Bleed:
Keep naked flames away when
working on the fuel system. Do
not smoke!
Dispose of used fuel in an environmentally-friendly manner!
9
9
© 31 812 0
© 31 812 0
● Bring engine regulator into stop position.
● Open fuel shut-off valve.
● Loosen pressure maintenance valve 9.
Collect any escaping fuel and dispose of
this in an environmentally-friendly manner.
● Turn engine over with starter (max. 20 sec.)
until bubble-free fuel escapes from pressure
maintenance valve 9.
● Tighten pressure maintenance valve 9.
● Bring engine regulator into start position
and start.
● Check for leaks after starting the engine.
Keep naked flames away when
working on the fuel system. Do
not smoke!
Dispose of used fuel in an environmentally-friendly manner!
© 2003
In the event of re-commissioning, following
maintenance work or if the tank has been
run empty, the fuel system must be bled.
Bring engine regulator into stop position.
Position fuel collection container beneath
filter housing 8 / pressure maintenance
valve 9.
Open fuel shut-off valve, pressure
maintenance valve 9, bleeder screw 1.
Turn engine over with starter (max. 20 sec.)
until bubble-free fuel escapes from bleeder
screw 1 and pressure maintenance valve
9.
Firmly tighten bleeder screw 1 and pressure
maintenance valve 9.
Bring engine regulator into start position
and start.
Check for leaks after starting the engine.
Service and Maintenance
6.3 Cooling System
6.3.1 Cleaning Intervals
6
● The amount of contamination in the cooling
system depends on the engine application.
● Oil and fuel residues on the engine increase
the risk of contamination. Therefore pay
special attention to leaks if the engine is
used in dusty environments.
● Serious contamination occurs, for example:
- on construction sites where there is a high
level of air-borne dust.
- in harvesting applications where there are
high concentrations of chaff and chopped
straw in
the vicinity of the machine.
● Because applications vary, cleaning
intervals have to be determined from case
to case. The cleaning intervals given in the
table below can be used as a guide.
6.3.2 Clean Cooling System
Checking or cleaning intervals
Engine application
Guideline
values OH
2000
1000
500
250
© 2003
125
Ships, electrical modules in
enclosed areas, pumps.
Vehicles on paved roads
Tractors, fork-lift trucks,
drivable electric units.
Vehicles on construction sites
and unpaved roads, construction machines, compressors,
underground mining units.
Agricultural machines, tractors
in harvesting applications.
● External cooling system: Clean according
to cooling system manufacturer’s specifications.
Service and Maintenance
6.3 Cooling System
6.3.3 Drain Cooling System
1
6.3.4 Fill / Bleed Cooling System
2012
6
max
.
min.
● Position a collecting pan beneath screw
plug 1.
● Remove screw plug 1 at
crankcase.
● Drain coolant.
● Tighten screw plug 1 again.
● If screw plug 1 is not accessible,
drainage can be carried out at the engine
radiator (coolant channel).
Fill / bleed cooling system see Chapter 6.3.4
Caution when draining hot coolant:
Risk of scalding! Collect coolant
on draining.
Dispose of this in accordance with
environmental regulations!
2012
● Open radiator cap item 1.
● Loosen vent hose item 2.
● Fill coolant item 1b in up to the “MAX” mark or
filling limit (if fitted, system heater valve must
be open).
● Connect vent hose, item 6, + tighten screw
plug item 4.
● Close radiator cap item 7.
● Start engine and warm up until thermostat
opens.
● Switch off the engine.
● Check coolant level when engine is cold, and
top up if necessary.
● Close radiator cap item 1.
Bleed
● External cooling system: According to cooling
system manufacturer’s specifications.
© 2003
© 31 816 0
0297 9902 0
min.
Service and Maintenance
6.4 Combustion Air Filter
6.4.1 Cleaning Intervals
6
The amount of dirt in the combustion air
filter depends on the amount of dust in the
air and the size of the air filter used. If a high
level of dust is anticipated, a cyclone-type
pre-cleaner can be fitted in front of the
combustion air filter.
● Cleaning intervals must therefore be
determined from case to case.
● If dry type air filters are used, cleaning
should only be carried out according to the
service indicator or service switch.
● Filter servicing is needed when:
- Service indicator
the red signal 1 is fully visible when the engine
is off.
- Service switch
the yellow pilot light comes on when the engine is running.
© 2003
● After carrying out service work, press the
reset button on the service indicator. The
service indicator is now ready for operation
again.
© 25 885 1
6.4.2 Emtying Cyclone Type
Precleaner
© 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
precleaner.
● Reposition collector bowl 3 onto lower
section 4, fasten cover 2 in place by tightening wing nut 1.
Never fill collector bowl with oil. Replace
collector bowl if damaged.
Service and Maintenance
6.4.3 Clean Oil Bath Air Filter
6
© 25 885 1
● Turn engine off and wait about 10 minutes
for the oil to drain from filter housing 1.
● Loosen snap clips 2 and remove oil cup 3
with filter element 4; if necessary, loosen
filter element with the aid of a screwdriver
at the separating point. Do not damage
rubber gasket 5!
● Remove dirty oil and sludge. Clean oil cup.
● Clean filter element 4 in diesel fuel and
allow to drip-dry thoroughly.
● Clean filter housing 1 if very dirty.
● Inspect and replace rubber gasket 5 and 6
if necessary.
● Fill oil cup with engine oil up to the mark
(arrow) (for viscosity, see 4.1.2).
● Refit oil cup and element to filter housing
and secure with snap clips.
Never clean filter with gasoline.
Dispose of old oil in accordance
with environmental regulations!
© 2003
6.4 Combustion Air Filter
Service and Maintenance
6.4.4 Dry Type Air Filter
Dust Discharge Valve
6
Filter Cartridge
© 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
the upper section of the valve.
© 2003
6.4 Combustion Air Filter
© 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 outwards,
or
- Tap out (in emergencies only). Do not
damage
the cartridge, or
- Wash out according to manufacturer’s
specifications.
● Check paper filter (light showing through)
and gaskets for damage. Replace if
necessary.
● After five filter services or after two years at
the latest, replace safety cartridge 4 (never
clean!).
To do so:
- Undo hex nut 5 and remove cartridge 4.
- Insert new cartridge, re-install hex nut and
tighten.
● Install cartridge 3, replace hood 2 and do
up clip fasteners 1.
Never clean filter cartridge with
gasoline or hot fluids!
Service and Maintenance
6.5 Belt Drives
6.5.1 Check V-belts
2012 Standard
6
2012 with Ribbed V-belt
● Visually inspect entire V-belt for damage.
● Replace damaged V-belts.
● After installing new belts, run engine for 15
minutes, then check belt tension.
● To check the tension of the V-belt, use a
tension gauge (see 9.3).
- Place indicator arm 1 into gauge.
- Position guide 3 on V-belt 2, midway
between
the pulleys, with flange 3 on
bottom of gauge against the edge of belt.
- Push slowly on the black pad 4 at right
angles to V-belt 2 until the spring is heard
or felt to trigger.
© 31 818 0
© 26 261 1
- Carefully raise the gauge without changing the position of indicator arm 1.
- Read off the value where the indicator arm
1 intersects scale 5 (arrow) and read
indicator arm 1 off. For settings, see 9.1.
- If necessary, retension belt and measure
again.
Check, tension and change Vbelts only with the engine off. If
necessary, reinstall V-belt
© 2003
© 31 817 0
Service and Maintenance
6.5.2 Tension V-belts
Coolant / Fuel Pump
6
6.5.3 Replace V-belts
Coolant / Fuel Pump
6.5.4 Replace V-belts
Ribbed V-belts
1
1
3
6.5 Belt Drives
2
3
2
2
1
© 31 819 0
© 2003
● Loosen screws 1 and 2.
● Press fuel pump 3 in direction of arrow until
the correct V-belt tension has been
achieved.
● Tighten screws 1 and 2 again.
Check, tension and change Vbelts only with the engine off. If
necessary, reinstall V-belt guard.
© 31 821 0
● Loosen screws 1 and 2.
● Press fuel pump 3 in direction of arrow.
● Remove V-belt and position new belt.
● Press fuel pump counter to direction of
arrow until the correct V-belt tension has
been achieved.
● Tighten screws 1 and 2 again.
© 31 814 0
● Press tension roller in direction of arrow
until the ribbed V-belt is free.
● First remove ribbed V-belt from the smallest roller.
● Position new ribbed V-belt.
● Press tension roller counter to direction of
arrow until the ribbed V-belt is tensioned.
Check whether ribbed V-belt is
positioned correctly in its guide.
Service and Maintenance
6.5 Belt Drives
6.5.5 Tension V-belts
Alternator
6.5.6 Replace V-belts
Alternator
5
5
3
1
4
© 31 822 0
© 31 820 0
Check, tension and change Vbelts only with the engine off. If
necessary, reinstall V-belt guard.
1
2
2
Loosen screws 1, 2 and 4.
l Adjust alternator 5 in direction of arrow by
turning screw 3 until correct V-belt tension
is achieved.
Retighten screws 1, 2 and 4.
3
Loosen fuel pump V-belt, see 6.5.3
Loosen screws 1, 2 and 4.
Adjust screw 3 until V-belt can be removed.
Position new belt.
Adjust screw 3 until the correct V-belt
tension has been achieved.
Retighten screws 1, 2 and 4.
Tension fuel pump V-belt, see 6.5.4.
© 2003
4
6
Service and Maintenance
6.5 Belt Drives
6.5.7 Wedge rib V-belts wear limit
examine.
6
a
© 31 879 0
© 2003
● Wear limit of the wedge ribV- belt as follows
examine:
● Distance between the nose of the flexibiliti
clamping arm and the notice of the firm
tension adjuster housing examine.
● If „ a “ is smaller than 3 mm, then the wedge
rib V- belt is to be exchanged
Service and Maintenance
6
© 2003
6.6 Adjustments
Service and Maintenance
6.6 Adjustments
6.6.1 Check Valve Clearance,
Adjust if Necessary
6
© 19 691 2
© 2003
Loosen ventilation valve and swing to the
side.
Remove the cylinder head cover.
Position crankshaft as per schematic, see
6.6.1.1.
Before adjusting valve clearance, allow
engine to cool down for at least 30 minutes.
The oil temperature should be below 80 °C.
Check valve clearance 1 between rocker
arm / tappet contact face 2 and valve 3 with
feeler gauge 6 (there should be only slight
resistance when feeler blade is inserted).
For permissible valve clearance, see 9.1.
© 26 262 1
Adjust valve clearance if necessary:
- Release locknut 4.
- Use screwdriver 7 to turn setscrew 5 so
that the
correct valve clearance 1 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).
Swing ventilation valve into position and
fasten.
6.6 Adjustments
Service and Maintenance
6.6.1.1 Valve Clearance Adjustment
Schematic
6
Crankshaft Position 1:
Turn crankshaft until both valves in cylinder
1 overlap (exhaust valve about to close,
inlet valve about to open). Adjust valve
clearance according to schematic (marked
in black)
black). Mark respective rocker arm with
chalk to show that adjustment has been
carried out.
© 26 263 2
© 2003
Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust valve clearance according to
schematic (marked in black).
Service and Maintenance
6.7.1 Battery
6.7.1.1 Check Battery and
Cable Connections
6
6.7.1.2 Check Electrolyte Level
© 25 895 0
24232 3
Keep battery clean and dry.
Remove sealing caps 1.
Undo dirty clamps.
If testers 2 are present:
Electrolyte level should reach the base of
these.
Clean terminal posts (+ and -) and clamps
of the battery, and grease with acid-free
and acid-resistant grease.
When reassembling, ensure that clamps
make good contact. Tighten clamp bolts
hand-tight.
© 2003
6.7 Accessories
Without testers:
The electrolyte level should be 10-15 mm
above the top of the plates.
If necessary, top up with distilled water.
Screw sealing caps back in.
6.7.1.3
Check Electrolyte Density
6.7.1.3Check
© 25 896 0
Measure the electrolyte density of individual
cells with a commercial hydrometer.
The hydrometer reading (see table on
following page) indicates the battery’s state
of charge. During measurement, the
temperature of the electrolyte should preferably be 20 °C.
Service and Maintenance
6.7 Accessories
6
Electrolyte density
in [kg/ l]
in [°Bé (Baumé scale)*]
Charge status
Normal
Tropical
Normal
Tropical
1.28
1.23
32
27
well charged
1.20
1.12
24
16
semi-charged, re-charge
1.12
1.08
16
11
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!
© 2003
* Measurement of electrolyte density in ° Bé
(Baumé scale) is out of date and rarely
used today.
Service and Maintenance
6.7.2 Rotary Current Alternator
6
6.7 Accessories
6.7.3 Transportation Shackles
Notes on the three-phase system:
Never disconnect the cables between
battery, alternator and regulator while the
engine is running.
If, however, it is necessary to start and
operate the engine without the battery,
disconnect the regulator from the alternator
before starting.
Be sure not to confuse the battery terminals.
Replace defective charge pilot lamp bulb
immediately.
When cleaning the engine: Do not spray
the alternator with a direct jet of water/
steam!
Allow the engine to run warm so that the
remaining water evaporates.
© 31 826 0
● Only use proper lifting gear when
transporting the engine.
The habit of touching a lead against the
frame to check whether it is live must under
no circumstances be used with three-phase
electrical systems.
© 2003
In case of electric welding, connect the
ground terminal on the welder directly to
the piece being welded.
Use only the correct lifting gear !
© 31 827 0
Faults, Causes and Remedies
7
© 2003
7.1 Fault Table
Faults, Causes and Remedies
7
● Faults can frequently be attributed to the fact
that the engine has been incorrectly operated
or not serviced.
● Each time a fault occurs, check whether all
operating and servicing regulations have been
complied with.
● A corresponding fault table can be found
on the opposite page.
© 2003
● If the cause of a fault cannot be
determined, or you are unable to remedy a fault
yourself, then please contact your
DEUTZ Service representative.
Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven
machine.
In the event of repair work:
Caution: If the speed regulator
has been removed, the engine
must not be started under any
circumstances.
Disconnect the battery!
!
Faults, Causes and Remedies
Faults
Engine does not start or is difficult to start (Starting speed is not achieved on starting)
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-existant or excessively low
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause
●
Not declutched (where possible)
●
●
Below starting limit temperature
●
●
Engine shut-off lever still in stop position (shutoff magnet defective)
●
●
Oil level too low
● ●
● ●
Oil level too high
● ● ●
Excessive inclination of engine
●
Adjust throttle to half actuation travel
● ●
● Air cleaner clogged / turbocharger defective
● ●
● Air cleaner service switch / indicator defective
●
● CPD* defective (connection line leaks)
● ●
● Charge air line leaking
●
Coolant pump defective
●
● Intercooler soiled
●
Coolant heat exchanger soiled
Cooling fan defective, torn or loose V-belt
● ● ● ● ●
(fuel pump in belt drive)
● ●
Cooling air temperature rise / heating short circuits
●
Battery defective or discharged
*CPD = Charge pressure-dependent full-load stop
Measures
Check
Adjust
Replace
Clean
Top up
Bleed
7
P
E
W
R
A
L
Section
Engine Operation
P
P
P
A
S
P/E
P/E
Combustion air P / W
P
P
P/W
Cooling system P / R
P/R
P/R
P/W
P
P
Table 1 of 2
Electrics
© 2003
7.1 Fault Table
Faults, Causes and Remedies
7
Faults
Engine does not start or is difficult to start (Starting speed is not achieved on starting)
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-existant or excessively low
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause
●
Cable connections, starter, electrical circuit loose or oxidised
●
Starter defective or pinion does not engage
● ●
●
● ● Incorrect valve clearance
● ●
● ●
Injection line leaks
●
Ventilation line blocked (coolant heat exchanger)
●
●
Sheathed glow plugs defective
● ● ● ● ●
● ● Injection valve defective
● ●
● ●
Air in the fuel system
● ●
● ●
Fuel filter / fuel pre-cleaner soiled
●
Oil filter defective
●
● ●
Incorrect engine lube oil SAE class or quality
● ●
●
●
Fuel quality not as per operation manual
●
Coolant deficiency
7.1 Fault Table
Measures
Check
Adjust
Replace
Clean
Top up
Reduce
P
E
W
R
A
S
Section
Electrics
P
P
Engine
E
P
P/R
P
P/W
P/W
P/R/W
W
Operating media
W
P/W
P/A
© 2003
Table 2 of 2
Engine Preservation
8
© 2003
8.1 Preservation
Engine Preservation
8.1
8
8.1 Preservation
Preservation
If the engine is to remain idle for an extended
period of time, it is necessary to take protective measures to prevent the formation of
corrosion. The preservative measures described here will protect the engine for up to
approx. 6 months. The procedure will have to
be reversed before the engine is
recommissioned.
Anti-corrosion oils to specification:
- MIL-L 21260B
- TL 9150-037/2
- Nato Code C 640 / 642
Recommended cleaning agent to remove
pre servatives:
- Petroleum benzine (hazardous materials class
A3)
Preserve engine:
Clean engine (poss. with cold cleaner).
Radiator cleaning, see 6.3.2.
Run engine until warm, then turn off.
Drain engine oil, see 6.1.2, and fill with anticorrosion oil.
Drain coolant, see 6.3.3.
Top up anti-corrosion agent, see specifications.
Clean oil bath air filter if necessary, see
6.4.3, and top up anti-corrosion oil.
Drain fuel tank.
Make up a mixture of 90 % diesel fuel and
10 % anti-corrosion oil, and refill fuel tank.
Allow the engine to run for approx. 10 mins.
Switch off the engine.
Manually turn the engine over several times.
When turning over with starter, set shutoff
lever to stop position.
Remove V-belts and store in wrapped condition.
Spray grooves on V-belt pulleys 2 with anticorrosion spray.
Drain anti-corrosion agent, see 6.3.3.
© 2003
Lightly preserve coolant filler neck and seal
with cap.
Seal intake ports and exhaust ports.
Remove engine preservation:
Remove anti-corrosion agent from
grooves in V-belt pulleys 2.
Install V-belts. Retension after brief
operation if necessary, see 6.5.
Remove covers from intake port 3 and
exhaust port 4.
Disconnect coolant inlet and outlet neck
covers, remove protection and connect to
cooling system.
Top up coolant, see 6.3.4.
System must be bled.
Commission engine
Technical Specification
9
© 2003
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
Technical Specification
Model
Number of cylinders
Cylinder arrangement
Bore
Stroke
9
9.1 Engine Specifications and Settings
----------- BF4M 2012 ------------------------ BF4M 2012 C ---------------------- BF6M 2012 C ------------------------ 4 --------------------------------------- 4 ---------------------------------------- 6 ------------------------------------------------------------------- vertical in line ------------------------------------------------[mm] ---------------------------------------------------------- ø 101 ------------------------------------------------------[mm] ----------------------------------------------------------- 126 --------------------------------------------------------
Total displacement
[cm3] ---------------- 4.04 ----------------------------------- 4.04 ----------------------------------- 6.06 ------------Compression ratio
[ε]. ------------------------------------------------------------ 19 --------------------------------------------------------Working cycle
-------------------------------------------------- Four-stroke diesel ---------------------------------------------Combustion system
---------------------------------- with turbocharging and direct fuel injection -----------------------------Charge air cooling
--------------- without --------------------------------- with ------------------------------------ with ------------Direction of rotation
-------------------------------------------------- counter-clockwise ----------------------------------------------Weight 2012/ C including cooling system
to DIN 70020-A [approx.kg]
------------------------------------------------- Refer to head-office --------------------------------------------Engine output
[kW]
Max. speed
[1/rpm]
Valve clearance with cold engine (PTs)
[mm]
Valve clearance with cold engine standard [mm]
Injector opening pressure
[bar]
Start of feed
[°CS BTOC]
Firing order of the engine
V-belt tension:
Alternator / fan
[N]
Fuel pump - coolant pump
[N]
Compressor
[N]
Ribbed V-belt tension spring-loaded tension roller [N]
© 2003
1)
2)
------------------ 75 ------------------------------------ 103 ------------------------------------ 155 ---------------------------------------------------------------------- 2500 ----------------------------------------------------------------------------------------------- Inlet 0.3 + 0.1 / exhaust 0.5 + 0.1. ------------------------------------------------------------------------- Adjustment with special tool, see 6.6.1 ------------------------------------------------------------------------------------------- 250 -------------------------------------------------------------------------------------------------------------------- 1). ---------------------------------------------------------------------- 1-3-4-2 ------------------------------- 1-3-4-2 ----------------------------- 1-5-3-6-2-4 --------------------------------------------------- Pre-tension / re-tension 2) -------------------------------------------------------------------------------------------------------------------------- 450 / 300 ± 50. ------------------------------------------------------------------------------------------------------ 450 / 300 ± 50. ------------------------------------------------------------------------------------------------------ 550 / 450 ± 50. ------------------------------------------------------------------------------------------------------ 900 / 600 ± 50. --------------------------------------------------
Engine output, speed, start of delivery are stamped on engine rating plate, etc., see also 2.1.
Re-tension 15 minutes after the engine has been operated under load.
9.1 Engine Specifications and Settings
Model
ling
Coolant volume
2012/ C
[ca.ltr.]
Perm. constant coolant temperature
Engine exhaust, output group I
[°C]
Engine exhaust, output group II-IV
[°C]
Thermostat opening commencement at
[°C]
Thermostat fully open from
[°C]
Coolant pre-heating
Coolant pump
Feed pressure in
[bar]
Feed quantity in
[m3 /h]
Power consumption in
[kW]
Lubrication
Oil temperature in oil pan
Min. oil pressure when warm
(120 °C and SAE oil 15 W 40 ) and low idle
Technical Specification
----------- BF4M 2012 ------------------------ BF4M 2012 C ---------------------- BF6M 2012 C ----------------------------------------- Liquid-cooled / cooling system protection -------------------------------
9
----------------- 5,6 ------------------------------------- 5,6 ------------------------------------ 7,3 ------------------------------------------------------------------- max.110 6) . -------------------------------------------------------------------------------------------------------- max. 105 6) . ------------------------------------------------------------------------------------------------------------- 7) . ------------------------------------------------------------------------------------------------------------------ 83 8) . ------------------------------------------------------------------------------------------------------------------ (4 . ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
9)
. --------------------------------------------------------. --------------------------------------------------------9)
. --------------------------------------------------------9)
------------------------------------------------- Pressure lubrication --------------------------------------------[°C] ----------------------------------------------------------- 125 -------------------------------------------------------[bar] ------------------------------------------------------------ 0,8 --------------------------------------------------------
Oil plate filling quantity without filter [approx.ltr.] --------------- 8.5 3) . -------------------------------- 8.5 3) . ------------------------------- 12.5 3) . ----------Oil plate filling quantity with filter
[approx.ltr.] ---------------- 10 3) . ---------------------------------- 10 3). --------------------------------- 14.0 3). ----------3)
Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.
Only necessary in winter operation, see 3.5.1.
5)
Engine content without radiator only. Content of external cooling system depending on cooling system version.
6)
Other output groups have different values, consultation with head office is required.
7)
In the case of external cooling systems with outlet regulation, the thermostat begins to open at 87 °C
8)
In the case of external cooling systems with outlet regulation, the thermostat is fully open at 102 °C
9)
Consultation with head office is required (differ depending on engine version)
© 2003
4)
Technical Specification
9.2 Screw Tightening Torques
9
Installation location
Pre-tension [Nm]
Re-tension [Nm]
1. Stage 2. Stage 3. Stage 1. Stage 2. Stage 3. Stage 4. Stage
Total
[Nm]
Cylinder head screw
8.5
Rocker arm adjustment screw
21
Foot on flywheel side
187
M16x40 8.
8.8 A 4 C
187
M16x40 8.
8.8 A 4 C
Foot on fan side
30
45
Intake manifold
8.5
Exhaust manifold
21
Oil drain screw
50
Injection valve attachment
16
Torx
Injection line attachment
30
M14x1.5
Oil pan (cast)
Oil pan (sheet metal)
© 2003
Comments
29
21
Technical Specification
9.3 Tools
TORX
V-belt tension gauge
26002 0
25899 0
A TORX wrench set is used with engines in
the 2012 series.
This system was chosen because of the many
advantages it offers:
● Outstanding accessibility to bolts.
● High load transfer when loosening and
tightening.
● Almost impossible for socket to slide off
or break, thereby practically ruling out the
risk of injury.
9
The V-belt tension gauge can be obtained
under order number 8115 + 8120 from:
WILBÄR
Postfach 14 05 80
D-42826 Remscheid
WILBÄR
Postfach 14 05 80
D-42826 Remscheid
© 2003
TORX tools can be ordered from:
© 2003
9
Notes
en
Warnings to Place on Equipment
Warning in the Manual
CALIFORNIA
CALIFORNIA
Proposition 65 Warning
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.
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
or
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Notes
CALIFORNIA PROPOSITION 65 INFORMATION
TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.
The warning must appear in one of the following locations:
●
●
●
●
●
Inside The front cover
Inside the back cover
Outside the front cover
Outside the back cover
As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
en
Service
en
Order-No.: 0312 0806
Knowing it’s DEUTZ
DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manufacturer, we offer — worldwide — a comprehensive range of diesel and gas motors
spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job
reliably all over the world. We are determined to
preserve the high standard of performance and
dependability of our motors, thus keeping our
customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors
which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support
to enhance your motor’s performance.
This index Sales & Service offers you an overview
of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the
range of services provided. But even when no direct
product responsibility is mentioned, your DEUTZ
partner will be happy to help you with expert advice.
The Index is constantly updated. Please ask your
DEUTZ service partner for the latest edition.
DEUTZ AG — at your service.
Order-No.: 0312 0807 (CD-ROM)
DEUTZ AG
Deutz-Mülheimer Str. 147-149
D-51057 Köln
Obtainable from the local service Partner reponsible
for you or from:
Phone: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
http://www.deutz.de
10
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
Deutz-Mülheimer Str. 147-149
D-51063 Köln
Tel.: ++49 (0) 2 21- 8 22 - 0
Fax: ++49 (0) 2 21- 8 22 - 53 58
Internet: www.deutz.de
E-mail:
[email protected]
Printed in Germany
All rights reserved
3. Edition, © 03/03
We move your world
Order No.: 0297 9912 en

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Deutz TCD 2012

Deutz TCD 2013

Deutz Engine TCD 2015 Service Manual

Deutz Engines

Modern technologies and materials, top quality, dependability, durability, and longevity are all features of Deutz diesel engines manufactured in Germany. German brand engines have high specific power and torque at the lightest possible weight for power plants with such specs. As a result, Deutz engines, which use the company’s unique innovations, can function well even in the most adverse circumstances and at a high maximum load for extended periods without diminishing motor resources or increasing overhaul time, therefore saving operational expenses.

After years of research at the company’s scientific and design bureaus, Deutz engineers developed motors that balance low operating costs and little impact on the environment. Because of their low fuel consumption, power plants from the German company Deutz are among the most cost effective in the world per kilowatt-hour produced, and they conform to the strictest standards for environmental protection. This means you may save money on gasoline and put Deutz generator installations close to where people live and work.

The Deutz 413 Series consists of V-shaped (V-Twin) diesel engines with 6, 8, 10, or 12 cylinders, a horizontal selection shaft, and valves in the upper location (OHV) for use in industrial and domestic applications. Focused on usage in sub-zero temperatures (down to -30 degrees Celsius), the 137 hp. (100 kW) to 322 hp. (236 kW) range of power and forced air conditioning;

Four-stroke, overhead-valve (OHV), horizontal power-shaft (HPS), and forced-air-cooled (FAC.) Deutz 912 Series diesel engines are designed for typical circumstances and may produce anywhere from 47 horsepower (34 kilowatts) to 111 horsepower (70 kW) (82 kW). The W models have a two-stage fuel combustion mechanism;

The Deutz 913 Series consists of 4-stroke, 3, 4, and 6-cylinder diesel engines with OHV, a horizontal power shaft, and forced air cooling, designed for use in typical circumstances and ranging in output from 59 horsepower (44 kilowatts) to 191 horsepower (141 kilowatts);

The Deutz 914 Series consists of four-stroke, three-, four-, five-, and six-cylinder diesel engines designed for professional and household appliances, featuring overhead valves, a horizontal power shaft, and forced air cooling, and optimized for normal conditions of operation between 59 horsepower (44 kilowatts) and 189 horsepower (141 kilowatts);

The Deutz 912/914 Genset Series includes 19 hp (14 kW) to 97.9 hp (4-stroke, 2, 3, 4, 6, 6-cylinder, OHV, horizontal air-cooled shaft, air-cooled) diesel engines for electro generators designed for usage in normal and harsh climatic situations (73 kW) manufactured with a mechanical or electronic (optional) fuel supply regulator;

The Deutz 1008 Series is a line of four-stroke, 2, 3, and 4-cylinder diesel engines designed for use in construction machinery, featuring overhead valves (OHV), a horizontal power shaft, liquid cooling, and an emphasis on operating in harsh environments, with outputs ranging from 17.7 horsepower (13 kilowatts) to 42 horsepower (31 kilowatts).

The Deutz 1011 Series is a line of 30-liter, 4-stroke, 2-, 3-, and 4-cylinder diesel engines used in construction machinery. These engines have overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for usage in harsh climates. (22 kW) up to (89.5 hp) (61 kW). Gas emission regulations that are in line with those of the European Union’s STEP II and the United States CFR 40, part 89, Tier II;

The Deutz 1013 Series consists of 4-stroke, 4- and 6-cylinder diesel engines with OHV, the horizontal power shaft, liquid cooling, and an output range of 154 hp (115 kW) to 313 hp (233 kW) for use in industrial and construction equipment in both mild and severe climates.

The Deutz 1015 Series consists of 6- and 8-cylinder V-shaped diesel engines with OHV, a horizontal power shaft, liquid cooling, and an output range of 407 hp (300 kW) to 598 hp (440 kW) that are designed for usage in typical climates.

The Deutz 1013/1015 Genset Series consists of four-stroke, six- and eight-cylinder diesel engines for electric generators, with overhead valves (OHV), a horizontal power shaft, liquid cooling, and an output ranging from 103 horsepower (77 kilowatts) to 571 horsepower (362 kilowatts) (426 kW) produced using both a mechanical regulator and electronic control (as an extra);

With power ranging from 31 horsepower (23 kilowatts) to 88 horsepower (65 kilowatts), the Deutz 2011 Series consists of 2, 3, 4, and 4-cylinder diesel engines for mobile medium-power mobile equipment with OHV, horizontal power shaft, air or liquid cooling, and an emphasis on operation in normal climatic conditions; the L models feature a heat exchanger.

The Deutz TCD 2011 Series is a line of air-cooled, OHV, horizontally-mounted, 2- and 3-cylinder diesel engines for medium-power mobile equipment ranging in output from 31 to 100 horsepower (23 to 74 kilowatts) (74.9 kW). Meet the gas emission requirements of European Union (EU) STEP III and United States (US) Tier 3;

The Deutz 2012 Series is a line of four- and six-cylinder diesel engines designed for medium-power mobile equipment. They feature overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for use in typical climates. Their output ranges from 101.8 horsepower (74.9 kilowatts) to 210 horsepower (155 kilowatts).

The Deutz TCD 2012 Series is a four-stroke and six-cylinder diesel engine line designed for medium-power mobile equipment. They feature overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for use in temperate climates.

The Deutz 2011/2012 Genset Series consists of four-stroke 2, 3, and 4-cylinder diesel engines for electric generators with overhead valves, horizontal power shafts, liquid or air cooling, and a primary focus on operation in both normal and difficult climatic conditions, with outputs ranging from 15.5 horsepower (11.4 kilowatts) to 101 horsepower (75 kilowatts);

The Deutz TCD2013 Series is a line of four- and six-cylinder diesel engines designed for use in mobile medium-power equipment. These engines feature overhead valves (OHV), a horizontal power shaft, liquid cooling, and are optimized for use in temperate climates. Their output ranges from 173 horsepower (129 kilowatts) to 325.9 horsepower (243 kW). Meet the requirements for gas emissions set out by the European Union’s STEP III A and the United States’ Tier 3;

The Deutz TCD2013 Genset Series consists of four- and six-cylinder diesel engines with an output ranging from 121 horsepower (90 kilowatts) to 314 horsepower (234 kilowatts) with an emphasis on normal climate operating.

The Deutz TCD 2015 Series consists of 6 and 8-cylinder, OHV, the horizontal power shaft, liquid-cooled, industrial diesel engines designed for usage in typical climates and capable of producing between 489 horsepower (360 kilowatts) and 670 horsepower (500 kilowatts);

The Deutz TCD 2.9-16 liter Series consists of 4, 6, and 8-cylinder diesel engines for mobile equipment; their engine volumes range from 2.9 to 16 liters; they feature overhead valves (OHV), a horizontal power shaft, water cooling, and are optimized for use in extreme climates; their outputs range from 50 horsepower (36.9 kW) to 697 horsepower (600 lb-ft) (520 kW).