B/FL/FM 2011: Operation Manual

OBJ_DOKU-15769-001.fm Seite 1 Montag, 5.
Mai 2008 3:02 15
Operation Manual
B/FL/FM 2011
OBJ_DOKU-15769-001.fm Seite 2 Montag, 5. Mai 2008 3:02 15
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
z This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
the equipment manufacturer (use for the intend- Non-compliance results in the expiry of the war-
ed purpose). Any other use above and beyond ranty!
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
z Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. z Do not work on the fuel system while the engine
z When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
z Unauthorised engine modifications will invalidate pressure - Danger to life!
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
z Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
z Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
z When carrying out maintenance work on the en-
2 © 2008
Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de- We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily.
Please make sure that this operating manual is avail-
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG
© 2008 3
Contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Fault table . . . . . . . . . . . . . . . . . . 47
Foreword. . . . . . . . . . . . . . . . . . . . . 3 8 Transport and storage . . . . . . . . . . . 50
1 General. . . . . . . . . . . . . . . . . . . . 5 Transport . . . . . . . . . . . . . . . . . . . 50
2 Engine description . . . . . . . . . . . . . 7 Engine corrosion protection . . . . . . . . . 51
Model . . . . . . . . . . . . . . . . . . . . . 7 9 Technical data . . . . . . . . . . . . . . . . 53
Engine illustrations . . . . . . . . . . . . . . 9 Engine and setting data . . . . . . . . . . . 53
Schematic for lubricating oil . . . . . . . . . 17 Tools . . . . . . . . . . . . . . . . . . . . . 55
Schematic for fuel . . . . . . . . . . . . . . 18
3 Operation . . . . . . . . . . . . . . . . . . 19
Ambient conditions . . . . . . . . . . . . . . 19
Initial start-up . . . . . . . . . . . . . . . . . 20
Start procedure . . . . . . . . . . . . . . . . 22
Operation monitoring . . . . . . . . . . . . . 23
Stop procedure . . . . . . . . . . . . . . . . 25
4 Operating media. . . . . . . . . . . . . . . 26
Lubricating oil . . . . . . . . . . . . . . . . . 26
Fuel . . . . . . . . . . . . . . . . . . . . . . 28
5 Maintenance . . . . . . . . . . . . . . . . . 29
Maintenance schedule . . . . . . . . . . . . 29
6 Servicing and maintenance works . . . . . 32
Lubricating oil system. . . . . . . . . . . . . 32
Fuel system. . . . . . . . . . . . . . . . . . 34
Engine cleaning. . . . . . . . . . . . . . . . 38
Aspiration system. . . . . . . . . . . . . . . 39
Belt drives . . . . . . . . . . . . . . . . . . 41
Setting work . . . . . . . . . . . . . . . . . 43
Electrical system . . . . . . . . . . . . . . . 45
7 Faults. . . . . . . . . . . . . . . . . . . . . 47
4 © 2008
OBJ_DOKU-15294-001.fm Seite 5 Donnerstag, 28. Februar 2008 9:58 09
General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the
functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components
Obviously the high requirements for the protection of
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
Of course, the quality standards here are just as high California
Safety precautions when the engine is running as for new parts. DEUTZ replacement parts are Proposition 65 Warning
equal to the original DEUTZ parts in function and re- Diesel engines and some of its constituents are
Maintenance work or repairs may only be performed liability. known to the State of California to cause cancer,
on the shut-down engine. Make sure that the engine birth defects and other reproductive harm.
cannot be started inadvertently - Danger of acci- Asbestos
dent! Masthead
The gaskets used in this engine contain no asbestos.
After repair work: Check that all guards have been DEUTZ AG
Please use the appropriate original DEUTZ parts for
replaced and that all tools have been removed from maintenance and repair work. Ottostraße 1
the engine.
51149 Köln
Observe industrial safety regulations when running Service
Germany
the engine in an enclosed space or underground. We want to preserve the high performance of our en-
gines, and with it the confidence and satisfaction of Phone: +49 (0) 221-822-0
When working on the running engine, work clothing
must be close fitting. our customers. We are therefore represented world- Fax: +49 (0) 221-822-5850
wide by a network of service branches. www.deutz.com
Never fill the fuel tank while the engine is running.
The DEUTZ name does not merely stand for engines E-Mail: [email protected]
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your DEUTZ-partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
© 2008 5
General
1 Danger
This symbol is used for all safety instruc-

tions which, if not observed, present a di-
rect danger to life and limb for the person
involved. Observe these carefully. The at-
tention of operating personnel should be
drawn to these safety instructions. Further-
more, the legislation for "general regula-
tions for safety and the prevention of
accidents" must be observed.
Caution
This symbol indicates a danger to the part

and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.
Notes
This symbol accompanies notes of a gen-

eral kind.
6 © 2008
OBJ_DOKU-15769-001.fm Seite 7 Donnerstag, 24. September 2009 4:01 16
Model Engine description

Engine type designation
C
2
This manual covers the following engine types
A B
F2L 2011 F2M 2011
F3L 2011 F3M 2011
F4L 2011 F4M 2011 Mot.-Typ Mot.-Nr.
BF3L 2011 BF3M 2011
BF4L 2011 BF4M 2011
BF4M 2011C
R
DEUTZ AG
F/BF MADE IN GERMANY
F Four-stroke diesel engine

B Exhaust gas turbocharger
Rating plate Location of the rating plate
2/3/4 The type (A), engine number (B) and performance The rating plate (C) is fixed to the cylinder head cov-
2 No. of cylinders data are stamped on the rating plate. er or the crankcase.
3 No. of cylinders The engine type and number must be stated when
4 No. of cylinders purchasing spare parts.
L/M
L oil-cooled (integrated cooler)
M oil-cooled
2011
2011 Series
C
C Charge air cooler
© 2009 7
Engine description Model
2 left
D
XXXXXXX
right
1
Engine serial number Cylinder numbering Volume blocking

The engine number (D) is stamped onto the crank- Cylinder arrangement Unauthorised settings on the regulator will exclude
case (arrow) and onto the rating plate. The cylinders are counted consecutively starting the manufacturer from all liability for resulting dam-
from flywheel (1). age. The blocking screws are adequately protected
against this:
Direction of rotation
z With locking varnish in version: torque adjust-
Looking onto the flywheel. ment
rotating to the left: counter-clockwise. z With protective plastic capsule in version: with-
Engine sides out torque adjustment.
Looking onto the flywheel.
8 © 2008
Engine illustrations Engine description

F3L 2011
View from right (example)
2
18 1 Cooling fan (with integrated generator)
2 Tension pulley
3 Toothed belt cover
17 4 V-belt (fan)
5 Stop lever
16 6 Speed adjusting lever
7 Lubricating oil drain plug
15 8 Lubricating oil sump
9 Lubricating oil dipstick
14 10 Connection possibility for cab heating
11 Exchangeable fuel filter
?
1 12 Lube oil replacement filter
13 13 Fuel supply pump with integrated screen filter
14 Lubricating oil filling
12 ?
2 15 Removable air guidance cowling (access to fuel
injectors)
?
3 16 Lube oil cooler
11 17 Cylinder head cover
18 Air intake pipe
?
4
10
?
5
9
8 ?
6
© 2008 9
Engine description Engine illustrations
2 F3L 2011
View from left (example)
1 Fuel return to fuel tank
2 Flywheel
3 Starter
4 Exhaust manifold line
5 Air intake pipe
4
1
10 © 2008

BF4L 2011
2
21 1 2
2 Charge air line
3 Cooling fan (with integrated generator)
3 4 V-belt (fan)
5 Stop magnet
20 7 Tension pulley
8 Lubricating oil sump
9 Stop lever
19 10 Speed adjusting lever
4 11 Lubricating oil dipstick
18 13 Lubricating oil filling
14 Fuel supply pump with integrated screen filter
5 15 Exchangeable fuel filter
17 16 Connection possibility for cab heating
17 Charging pressure-dependent full load stop
18 Lube oil replacement filter
16 19 Removable air guidance cowling (access to fuel
injectors)
6 20 Injection pump
15 21 Lube oil cooler
14 7
13 12 11 10 9 8
© 2008 11
2 BF4L 2011
1 Cylinder head
3 Flywheel
10 4 Starter
5 Crankcase
6 Lubricating oil return line from the exhaust turbo-
1 charger
9 7 Turbocharger
8 Lubricating oil pipe to the turbocharger
9 Air intake pipe
2
8 10 Charge air line
7 3
12 © 2008

F4M 2011
2
2 Air intake pipe
3 Generator
4 V-belts
5 Stop magnet
7 Lubricating oil sump
8 Stop lever
9 Speed adjusting lever
15 Connection possibility for cab heating
17 Injection pump
18 Return from external lubricating oil cooler
19 Supply to external lubricating oil cooler
20 Injection valve
© 2008 13
2 F4M 2011
1 Cylinder head
3 Flywheel
4 Starter
5 Air intake pipe
14 © 2008

BF4M 2011
2
1 Air intake pipe
2 Fan
3 V-belts
4 Stop magnet
6 Stop lever
7 Speed adjusting lever
14 Injection pump
15 Return from external lubricating oil cooler
16 Supply to external lubricating oil cooler
17 Injection valve
© 2008 15
2 BF4M 2011
1 Cylinder head cover
3 Flywheel
8 1 4 Starter
5 Lubricating oil return line from the exhaust turbo-
charger
6 Turbocharger
2 7 Generator
8 Charge air line
7
5
3
4
16 © 2008
Schematic for lubricating oil Engine description

FL/FM 2011
(example)
2
Toil > 95°C
9
8 1 Lubricating oil sump
2 Lubricating oil pump
Toil < 95°C 3 Pressure limiting valve
4 Cylinder (lubricating oil-cooled)
5 The lubricating oil is used first to cool the engine.
Toil < 63°C 5 Cylinder head
15 4 6 Lubricating oil return from the cylinders
7 Lubricating oil collection pipe to the thermostat
Toil > 63°C 8 Thermostat
(engine cold) lubricating oil flow directly to the lu-
bricating oil filter
14 7 6 11 16 (engine warm) lubricating oil flow through the lu-
bricating oil cooler
9 Lube oil cooler
2 10 Lubricating oil filter
11 Main lube oil channel
3 12 Turbocharger
13 Pressure holding valve
1 bar
10 7 bar The standard pressure holding valve must be re-
placed by a combination for this. Retrofitting only
by authorised qualified personnel.
1,7 bar 3 bar 15 Lubricating oil filter console with integrated
switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
oil is fed to the hydraulic tappet.
0,3 bar
13 12 To achieve early adjustment of the fuel injection
1 in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
16 Hydraulic tappets
© 2008 17
Engine description Schematic for fuel
2 Fuel schematic (example)

1 Fuel line from tank to fuel pump
9 2 Fuel supply pump with integrated screen filter
3 Fuel pipe from the supply pump to the fuel
change filter
5 Fuel pipe from the filter to the fuel injector
6 Fuel pipe to fuel injector
8 7 Injection pump
8 Injection line to injection valve
9 Injection valve
10 Return collection pipe
11 Fuel return to fuel tank
12 Lubricating oil filter console with integrated
11 switching valve for controlling the hydraulic tap-
pet. When the engine is cold, lubricating
7 oil is fed to the hydraulic tappet.
10 To achieve early adjustment of the fuel injection
in a cold start, the hydraulic tappets under the
fuel injectors are supplied with lubricating oil.
6
5
12
2
1
4 3
18 © 2008
Ambient conditions Operation

Cold start aid
z Depending on the type of engine, glow plugs,
3
heating plugs, heating flange, flame glow system
can be used as cold starting aids.(22)
High ambient temperatures, high altitude
0 °C Under the following application and operating condi-

tions, the amount of fuel must be reduced.
z above 1000 m altitude
z above 30 °C ambient temperature
Reason: Air density decreases as altitude or ambient
temperature increase. This reduces the amount of
oxygen in the engine intake air and the fuel-air mix-
ture would be too rich if the injected amount of fuel
Low ambient temperatures were not reduced.
z The results would be:
Lubricating oil
– black smoke in the exhaust
z Select the lubricating oil viscosity according to – high engine temperature
the ambient temperature.
– reduction in engine performance
z If cold starting occurs frequently cut the lube oil
– possible impairment of starting behaviour
changing interval by half.
Consult your equipment supplier or DEUTZ partner if
Fuel you have any other questions.
z Use winter fuel below 0 °C (28).
Battery
z A good charging condition of the battery (45)
is the prerequisite for starting the engine.
z Heating up the battery to approx. 20°C improves
the starting behaviour of the engine. (Remove
and store the battery in a warm room).
© 2008 19
Operation Initial start-up
3 Preparations for initial commissioning External cooler

(Maintenance schedule E 10)
z Remove engine corrosion protection
OIL B/FM 2011
z Fill lubricating oil up to maximum mark of the lu-
z Remove any transport devices. bricating oil dipstick.
z Check the battery and cable connections and z Filling volume (53).
mount if necessary. z Start engine and let it run for one minute.
z Check belt tension (41). z Switch off the engine.
z Have the engine monitor or warning system z Fill lubricating oil up to maximum mark of the lu-
checked by authorised personnel. bricating oil dipstick.
z Check the engine mounting.
z Check that all hose unions and clips fit properly. The first time the thermostat is opened the
lubricating oil volume in the lubricating oil
The following additional work must be carried pan is reduced by the volume of the exter-
out on generally overhauled engines: nal lubricating oil cooler.
z Check the fuel pre-filter and main filter and Fill with engine lube oil z Start the engine and warm up until the thermo-
change if necessary.
stat opens.
z Check the intake air cleaner (if available, main- Low lubricating oil level and overfilling lead z Engine operation with open thermostat 2 - 3 min-
tain according to maintenance indicator). to engine damage. utes.
z Fill with engine lube oil. z Switch off the engine.
The lubricating oil level must have dropped con-
The engines are generally supplied without siderably due to the filling of the external lubricat-
lubricating oil filling. ing oil cooler.
Select lubricating oil quality and viscosity
before filling.
bricating oil dipstick.
Order DEUTZ lubricating oils from your
DEUTZ partner
Integrated cooler
B/FL 2011
bricating oil dipstick.
z Filling volume (53).
The maximum mark on the lubricating oil dipstick is
always decisive.
20 © 2008
Initial start-up Operation

Trial run
3
Additional venting of the fuel system by a 5
minute trial run at idle speed or on low load
is absolutely essential.
Carry out a brief trial run up to operating temperature
(approx. 90 °C) after preparations.
Do not load the engine if possible.
z Work with the engine not running:
– Check engine for tightness.
– Check lubricating oil level, if necessary top
up.
z Work during the trial run:
– Check engine for tightness.
Pour in fuel
Only re-fuel when the engine is not running.

Ensure cleanliness.
Do not spill fuel.
z The fuel low pressure system must be vented be-
fore the first start-up after filling with the manualy
supply pump.
Only use clean commercially available brand diesel
fuel. Observe fuel quality (28).
Use summer or winter-grade fuel, depending on the
ambient temperature.
© 2008 21
Operation Start procedure
3 Starting
Before starting, make sure that nobody is

standing in the immediate vicinity of the en- A
gine or work machine.
After repair work: Check that all guards
have been replaced and that all tools have
been removed from the engine.
When starting with the flame glow plug/ B
glow plug/heating flange system do not use
any other starting aid (e.g. injection with
start pilot). Risk of accident!
C
Do not actuate the starter for more than
20 seconds. If the engine does not start up,
© 25745-0
wait for one minute and then repeat the
starting process. Without cold start aid Glow plugs with cold start aid
If the engine does not start up after two at- z Insert key. z Insert key.
tempts, determine the cause as per fault ta- z Turn key to the right. – Position 0 = no operating voltage.
ble (47). – Position 1 = operating voltage.
Do not run up the engine immediately to z Turn key to the right.
– Pilot lamps (1) and (2) light up.
high idling speed / full load operation from – Position 1 = operating voltage.
cold. z Push the key in and turn further clockwise
– Pilot lamps (A), (B) and (C) light up.
against spring pressure.
– Level 2 = no function. – Preheat until the glow display goes out; an
Disconnect the engine by uncoupling de- error has occurred if the preheating indicator
vices to be driven where possible. – Level 3 = start.
flashes; e.g. the preheating relay is stuck,
z release the key as soon as the engine starts up. which can discharge the battery completely
– The pilot lamps will go out. when at a standstill.
– Engine is ready for operation.
z Push the key in and turn further clockwise
against spring pressure.
– Level 2 = start.
z release the key as soon as the engine starts up.
– The pilot lamps will go out.
22 © 2008
Operation monitoring Operation

3
Display instrument
Possible displays:
z Colour scale
– Display of operating state by coloured areas:
– green = normal operating state
– red = critical operatng state
Take suitable action.
z Measured value scale
– Actual value can be read off directly. The
nominal value should be taken from the
Technical Data (53).
© 2008 23
Operation Operation monitoring
3 Instruments and symbols
Instruments/symbols Designation Possible display: Measure

Lubricating oil pressure dis- Lubricating oil pressure below minimum Switch off engine
play
Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play
Lubricating oil temperature Lubricating oil temperature too high Switch off engine
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or Switch off engine
lamp while the engine is running, the lubricating oil pres-
sure is too low
Lube oil level If the pilot lamp lights up after starting the engine or Fill up lube oil
while the engine is running, the lubricating oil level is
too low
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
123
Horn With acoustic signal See fault table (47).
24 © 2008
Stop procedure Operation

1 = gear position: pre-heat engine
2 = gear position: start engine 3
A
Shutting off
Avoid switching off from full load (coking/

blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap-
proximately one minute after relieving the
load.
Electrical shutdown (optional)
z Move the key to position 0.
Control lamps A+B+C go out.
A = charge pilot light
B = lube oil pressure pilot light
C = pilot light for pre-heating system
P = gear position: park
0 = gear position: switch off engine
© 2008 25
Operating media Lubricating oil
4 General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
The following lubricating oils are recommended for
the engines in this operating manual:
the definition of the lube oil change intervals are not
the lubricating oil to be used. The specific engine Recommended quality class
essentially dependent on the lube oil quality (such as
performances which have increased constantly over
the incorporation of soot and other contaminations), DEUTZ Others
the last few years lead to an increased thermal load
the lube oil change interval when using synthetic
on the lubricating oil. The lubricating oil is also more DQC II - 05 ACEA E3-96/E5-02;
lube oils may not be increased in relation to the spec-
exposed to contamination due to reduced oil com- API CH-4/CG-4; DHD-1
ifications of the lube oil change intervals.
sumption and longer oil change intervals. For this DQC III - 05 ACEA E4-99/E6-04
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in
and recommendations described in this operating DEUTZ engines if they meet the requirements of this DQC IV - 05 Please contact your DEUTZ partner
manual in order not to shorten the life of the engine. operating manual.
Lubricating oils always consist of a base oil and an DEUTZ lubricating oils DQC II-05
Quality
additive package. The most important tasks of a lu- TLS - 15W40 D
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according Container Order number:
tion, neutralisation of acids from combustion to their efficiency and quality class (DQC: DEUTZ
Quality Class). It basically applies that: with increas- 5 litre container 0101 6331
products, prevention of coke and soot deposits on
the engine parts) are assumed by the additives. The ing quality class (DQC I, II, III, IV) the lubricating oils 20 litre container 0101 6332
properties of the base oil are also decisive for the are more efficient and higher quality. The appended 209 litre barrel 0101 6333
quality of the product, e.g. with regard to thermal quality class designation (- 02 / - 05) indicates in
load capacity. which year the classification was made.
DEUTZ lubricating oils DQC III-05
In principle, all engine oils of the same specification Lubricating oils according to other comparable spec- TLX - 10W40 FE
can be mixed. However, mixing of engine oils should ifications can be used as long as they meet DEUTZ
Container Order number:
be avoided because the worst properties of the mix- requirements. In regions in which none of these
qualities are available, please contact your responsi- 5 litre container 0101 6335
ture are always dominant.
ble DEUTZ partner. 20 litre container 0101 6336
The lubricating oil quality has a considerable influ-
ence on the life, performance and thus also on the or see www.deutz.com >> SERVICE >> Operating 209 litre barrel 0101 6337
costs-effectiveness of the engine. It basically applies Media and Diagnosis >> Deutz Quality Class >>
that: The better the lubricating oil quality, the better DQC Release List (current edition) DEUTZ lubricating oils DQC IV-05 synthetic
these properties. Container Order number:
Minimum quality class
The lubricating oil viscosity describes the flow be- 20 litre container 0101 7849
haviour of the lubricating oil depending on the tem- DEUTZ Others
perature. The lubricating oil viscosity has no DQC I - 02 ACEA E2-96; API CF/CF-4 209 litre barrel 0101 7850
influence and effect on the lubricating oil quality. BFL 2011, BFM 2011: Lubricating oil change intervals
Synthetic lubricating oils are used increasingly If the engine is operated with these lubricating oils,
the lub ricating oil change interval must be halved. z The intervals depend on:
and have advantages. These oils have a better tem-
– lubricating oil quality
26 © 2008
Lubricating oil Operating media

– sulphur content in the fuel
– type of application of engine
Viscosity
The ambient temperature at the installation site or in
°C 4
z The lubricating oil change interval must be the application area of the engine is decisive for 45
halved if at least one of the following conditions choosing the right viscosity class. Too high a viscos-
applies: ity can lead to starting difficulties, too low a viscosity 40
– Constant ambient temperature below -10 °C can endanger the lubrication effect and cause a high
(14 °F) or lube oil temperature below 60 °C lubricating oil consumption. At ambient temperatures 35
(84 °F). below -40 °C, the lubricating oil must be pre-heated
– Sulphur content in the diesel fuel of 0.5-1 %. (e.g. by storing the vehicle or the machine in a hall). 30
In case of fuels containing more than 1% sul- The viscosity is classified according to SAE. Multi- 25
phur, contact your corresponding DEUTZ purpose lubricating oils should be used basically.
partner. Single-purpose lubricating oils can also be used in 20
SAE 20W-50
SAE 10W-30
SAE 10W-40
SAE 15W-40
– operation with bio-diesel fuel enclosed, heated spaces at temperatures >5 ° C.
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
z If the lubricating oil change intervals are not Depending on the ambient temperature we recom-
15
reached within a year, the oil should be changed mend the following common viscosity classes:
at least once a year. 10
The prescribed lubricating oil quality must 5
be observed when selecting the viscosity
class! 0
-5
-10
-15
-20
-25
-30
-35
-40
© 2008 27
Operating media Fuel
4 Permissible fuels
The following fuel specifications / standards are ap-
The certification measurements for compliance with
the legal emission values are made with the test fu-
els specified in the laws. These correspond to the
proved:
diesel fuels in accordance with EN 590 and
z Diesel fuels ASTM D 975 described in the operation manual. No
– EN 590 emission values are guaranteed with the other fuels
– ASTM D 975 1-D described in this operation manual.
– ASTM D 975 2-D
Winter operation with diesel fuel
– BS 2869 A1
– BS 2869 A2 Only carry out mixing in the tank. Fill with
– NATO F-54 the appropriate amount of paraffin first,
– NATO F-75 then add the diesel fuel. Normal and high
– JIS K2204 Grade 1 grade fuels may not be mixed.
– JIS K2204 Grade 2
At low ambient temperatures paraffin discharges can
– ISO 8217 DMX
lead to blockages in the fuel system and cause oper-
– ISO 8217 DMA I Summer-grade diesel fuel
ating faults. Below 0 °C ambient temperature use
z Light heating oils winter diesel (down to -20 °C) (filling stations provide II Winter-grade diesel fuel
– DIN 51603 this in good time before the cold season starts). A Outdoor temperature
– ASTM D 396 Grade No. 1 z Below -20 °C paraffin should be added. The rel- B Percentage of paraffin to be added
– ASTM D 396 Grade No. 2 evant percentages are given in the adjacent dia-
– BS 286 Class D gram.
z Jet fuels z Special diesel fuels can be used for arctic cli-
– NATO F34 mates to -44 °C.
– NATO F35
If it is necessary to use Summer diesel fuel below
– NATO F44 0 °C, up to 30 % petroleum can be added according
– NATO F63 to the diagram opposite.
z Biodiesel fuel
Usually a sufficient cold resistance can be achieved
– EN 14214 by adding a flow improver. Ask your DEUTZ partner.
Use commercially available fuels with a sulphur con-
tent below 0.5 %. The lubricating oil change intervals
must be halved at a higher sulphur content.
If other fuels are used which do not meet the require-
ments of the operating manual, the warranty will be
voided.
28 © 2008
Maintenance schedule Maintenance

Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
5
Standard maintenance schedule
FL/BFL/FM/BFM 2011
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E10 Initial commissioning Authorised specialists When commissioning new or overhauled engines
E20 Daily inspection Operator 1x daily or every 10 operating hours in continuous operation
E30 Maintenance Qualified personnel FL/FM: 1,000 1) / BFL/BFM: 500 1)
E40 Extended maintenance I 1000
2)
E50 Extended maintenance II Authorised specialists 3.000 / 5.000 3) / 6.000 4)
EPA-certified engines
The EPA (Environmental Protection Agency) is a US Government organisation for the protection of the environment and human health.
Deviations from the standard maintenacne schedule for engines subject to EPA certification
Stage Activity To be carried out by Maintenance interval every ....... operating hours (oh)
E60 Intermediate overhaul Authorised specialists 3.000
Observations
1)
The lubricating oil load may be high depending on the application. The lubricating oil change interval must be halved here (26).
Toothed belt change intervals recommended Engine application example:
values in op. h
2)
3,000 or max. 5 years Agricultural machinery; skid steer loader; wheel loader; high speed; impact load; extreme ambient tempera-
drilling machines; trench differs; joint cutters; excavators ture; high dust load
etc.
3)
5,000 or max. 5 years compressors; rollers; stackers; welding units; wheel medium to high variable speed; high ambient temper-
loaders small dumpers; skid steer loaders, etc. ature medium dust load
4)
6,000 or max. 5 years Electrical units 1500/1800 rpm; pump units with low low speed; medium ambient temperature low dust
speed; lifting platforms; cooling aggregates etc. load
© 2008 29
Maintenance Maintenance schedule
5 Maintenance measures
Stage Activity Measure Page

E10 The measures are listed in chapter 3. 20
E20 Check Lubricating oil level (if necessary top up) 32
Engine tightness (visual inspection for leaks)
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 40
E30 Replace Lubricating oil An lubricating oil application/change strategy adapted optimally to the individual engine application 26/32
type can be created, for example, with the DEUTZ oil diagnosis. Ask your DEUTZ partner.
Lubricating oil filter/insert (every time the lubricating oil is changed) 33
E40 Check Heating plugs
Battery and cable connectors 45
V-belts (retension or renew if necessary) 41
Engine mounting (tighten, replace if damaged when necessary)
Fastenings, hose unions / clips (renew if damaged)
Settings Valve clearance 43
Replace Fuel filter cartridge 36
Clean Fuel pre-cleaner / fuel pre-filter (change filter insert if necessary) 35/37
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 40
E50 Check Crankcase breather valve
Replace Toothed belt 29
Injection valve
E60 Replace Injection valve
Clean Turbocharger compressor outlet
Every 2 Check Engine monitor, warning system Maintenance only to be carried out by authorised service personnel
years Replace V-belts 41
Heating plugs
Dry air filter 40
30 © 2008
Maintenance schedule Maintenance

Maintenance work outside the DEUTZ maintenance and service schedules
*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.
5
Maintenance profile
A self-adhesive maintenance diagram is delivered with every engine. It should be stuck in a well visible location on the engine or equipment.
Order number: 0297 9935
© 2008 31
Servicing and maintenance works Lubricating oil system
6 Regulations for working on the lubricating oil

system OIL ?
z The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
essary.
Do not work when the engine is running!
Smoking and naked lights prohibited! Changing the lubricating oil
Be careful of hot lubricating oil. Danger of
scalding!
OIL z Warm up the engine (lubricating oil temperature
> 80 °C).
+80°C
+176°F z Ensure that the engine or vehicle is in a level po-
Pay attention to utmost cleanliness when sition.
working on the lubricating oil system. Clean z Switch off the engine.
the area around the components con- z Place a collecting receptacle underneath the
cerned carefully. Blow damp parts dry with
compressed air.
Observe the safety regulations and nation-
! lube oil drain screw.
z Unscrew the lube oil drain screw, drain oil.
al specifications for handling lube oils. z Fit a new sealing ring to the lube oil drain screw,
Dispose of leaking lubricating oil and filter insert and tighten. (tightening torque 100 Nm).
elements properly. Do not allow used oil to Checking the lubricating oil level z Fill lubricating oil up to maximum mark of the lu-
seep away into the ground. bricating oil dipstick.
Perform a trial run after all work. Pay atten- Low lubricating oil level and overfilling lead – Quality/viscosity data (26).
tion to tightness and lubricating oil pressure to engine damage.
The lubricating oil level may only be z Warm up the engine (lubricating oil temperature
and then check the engine oil level.
checked with the engine in a horizontal po- > 80 °C).
In case of fuels containing more than 1%
sulphur, contact your corresponding sition and switched off. z Ensure that the engine or vehicle is in a level po-
DEUTZ partner. If the engine is warm, switch off the engine sition.
and check the lubricating oil level after 5 z Check lubricating oil level, if necessary top up.
minutes. If the engine is cold you can check
it immediately.
Be careful of hot lubricating oil. Danger of

scalding!
z Pull out the lubricating oil dipstick and wipe off

with a lint-free, clean cloth.
z Insert the lubricating oil dipstick as far as it will
go.
z Extract the lubricating oil dipstick and read off the
oil level.
32 © 2008
Lubricating oil system Servicing and maintenance works

6
Change lubricating oil filter z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 15-17 Nm.
tion! z Fasten clamps of the twist protection (optional).
z Remove clamps when twist protection mounted
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Collect draining lubricating oil
z Clean the sealing surface of the filter support
© 2008 33
Servicing and maintenance works Fuel system
6 Specifications when working on the fuel system Clean and dry the engine and engine com-
partment thoroughly before beginning
Engine must be switched off! work.
Smoking and naked lights prohibited! Areas of the engine compartment from
No injection/high pressure pipes may be which dirt could be loosened must be cov-
disconnected while the engine is running. ered with a fresh, clean foil.
Caution when handling hot fuel! Work on the fuel system may only be car-
Pay attention to utmost cleanliness when ried out in an absolutely clean environment.
refuelling and working on the fuel system. Contamination of the air such as dirt, dust,
Clean the respective affected parts careful- moisture etc. must be avoided.
ly. Blow damp areas dry with compressed
air.
Observe the safety regulations and nation-
al specifications for handling fuels.
Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep away
into the ground.
After all work on the fuel system, the sys-
tem should be vented, a trial run performed
and the tightness checked.
It will be necessary to vent the fuel system
when commissioning for the first time, after
maintenance work or if the tank has been
run dry.

Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Make a visual inspection for leaks/damage
in the system.
34 © 2008
Fuel system Servicing and maintenance works

Vent the fuel system
z Pump in the direction of the arrow (3) until a
6
5 strong resistance is felt and pressure has built
up.
z The return line (5) must be filled.
4 ?
6
z Start the engine and run in idle or on low load. Air
is pressed through the return pipe 5) to the tank.
3 ?7
1
Fuel supply pump, sieve filter cartridge clean/
change
z Close fuel shutoff tap (with high-level tank) (sup-
ply (7)).
z Remove connection (4) to the fuel filter.
z Catch any escaping fuel.
z Loosen screw (1).
z Remove fuel screen (screw (1), cover and fuell
screen form one unit).
z Take the sealing ring (2) and clean it, renew
when damaged.
z Clean cover-fuel screen with fuel, renew de-
pending on the condition.
z Put the sealing ring (2) in position.
z Mount the cover-fuel filter with screw (1).
z Reinstall connection (4) to the fuel filter.
z Open fuel shutoff tap supply (7), start engine and
run in idle or on low load.
z Check for leaks after starting the engine.
© 2008 35
Servicing and maintenance works Fuel system
Change the fuel filter cartridge z Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- z Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 10-12 Nm.
tion! z Fasten clamps of the twist protection (optional).
z Remove clamps when twist protection mounted z Vent the fuel system.
(optional).
z Loosen and unscrew filter cartridge with tool (or-
der number: 170050).
z Catch any escaping fuel.
z Clean the sealing surface of the filter support
36 © 2008
Fuel system Servicing and maintenance works

with fuel.
z Assembly in clockwise direction.
bubbles.
z Catch any escaping fuel. 6
7 z Open the fuel shutoff tap and vent the system, z Tighten the venting screw (7).
see venting the fuel system.
Vent the fuel system
5 1 z Start engine.
z Check for leaks after starting the engine. z Bring engine control to stop position.
z Position fuel collecting vessel below the con-
6 2 Change the fuel pre-filter insert stant-pressure valve in the crankcase/filter hous-
z Shut off the fuel supply to the engine (with high- ing.
4 3
level tank). z Open constant-pressure valve in the crankcase/
fuel stopcock in the filter housing.
z Place a vessel under the drain plug.
z Open the drain tap (4) and drain off the liquid. z Turn over the engine with starter (max. 20 Sec.)
z Unscrew the filter insert (2) together with the wa- until bubble-free fuel emerges at the constant-
ter collection vessel (3). pressure valve in the crankcase/filter housing.
z Unscrew the water collection vessel (3) from the z Screw in ventilation screws (tightening torque
Clean/change/vent the fuel pre-filter filter insert (2). 25-5 Nm) and constant-pressure valve.
– The special tool can be ordered under part z Bring engine control to the start position and
1 Fuel pre-filter holder
number 8192 (55). start.
2 Fuel filter insert
z Check for leaks after starting the engine.
3 Water collection vessel z Clean the water collection vessel (3) and all the
4 Water drain tap existing sealing surfaces (6) with a brush and
5 Fuel pump diesel fuel.
6 Sealing surface z Oil the gaskets and sealing surfaces (6) of the
7 Venting screw new DEUTZ original filter insert (2) lightly or wet
with diesel fuel.
z Shut off the fuel supply to the engine (with high- z Screw the water collection vessel (3) to the filter
level tank). insert (2).
z Place a vessel under the drain plug. z Screw a new filter insert (2) with water collection
z Open the drain tap (4) and drain off the liquid. vessel (3) onto the filter carrier 1) (tightening
z Unscrew the filter insert (2) together with the wa- torque 17-18 Nm)
ter collection vessel (3). z Open the fuel supply to the engine.
z Empty emulsion in the water collection vessel (3) z Vent the fuel system.
and clean the vessel.
z Mount the filter insert (2) and water collection Vent the fuel pre-filter.
vessel (3). Wet the sealing surfaces (6) of the fil- z Loosen the venting screw (7) slightly.
ter insert (2) and the water collection vessel (3) z Operate the pump until fuel emerges without
© 2008 37
Servicing and maintenance works Engine cleaning
6 Cleaning work for about 10 minutes to take effect.

z Spray the engine clean with a high pressure wa-
For all cleaning work, make sure that no ter jet.
parts are damaged (e.g. bent cooler mesh). z Warm up the engine so that the water residues
Cover electrical/electronic parts and con- evaporate.
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Cleaning with a high pressure cleaner
not aim the water/steam jet directly at them. z Clean the engine with a steam jet (maximum
Allow engine to warm up. spray pressure 60 bar, maximum steam temper-
ature 90 °C, distance at least 1m).
Only carry out cleaning work on the engine z Warm up the engine so that the water residues
when it is not running! evaporate.
Remove the engine cover and cooling air z Always clean the cooler and cooling fins from the
cover if available and remount after clean- exhaust air side to the fresh air side.
ing.
General
The following causes of soiling make it necessary to
clean the engine:
z High dust content in the air.
z Chaff and chopped straw in the area of the en-
gine.
z Lubricating oil leakage
z Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
z Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
Cleaning with cold cleaner
z Spray the engine with cold cleaner and leave it
38 © 2008
Aspiration system Servicing and maintenance works

Regulations for working on the intake system
1 5 2
Renewing the safety cartridge of the dry air filter
6
Do not work when the engine is running! Never clean the safety cartridge (4).
z Renew safety cartridge (4) according to the inter-

Pay attention to utmost cleanliness when
val in the maintenance schedule
working on the intake system, close intake
openings if necessary. z To do this:
Dispose of old filter elements properly. – Unscrew hexagon nut (5), pull out safety car-
tridge (4).
4 3 – Insert new safety cartridge, screw on hexag-
onal nut.
z Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
Maintaining the dry air filter
Do not clean the filter element (3) with pet-

rol or hot liquids!
Renew damaged filter elements.
z Maintain the filter element (3) according to the in-
terval in the maintenance schedule
z Lift up the clamping yoke (1).
z Remove the filter hood (2) and pull out the filter
element (3).
z Filter element (3):
– blow out with dry compressed air (max. 5
bar) from the inside to the outside if soiling is
only slight,
– renew if heavily soiled.
© 2008 39
Servicing and maintenance works Aspiration system
Maintenance indicators for dry air filter Clean the dust discharge valve of the dry air filter Emptying the cyclone precleaner
z The dry air filter is maintained according to a z Empty the dust discharge valve (1) by pressing
Never fill the dust container (3) with lubri-
maintenance switch or maintenance indicator. together the discharge slit.
cating oil!
z Maintenance is necessary when: z Remove any caked dust by pressing together the
– the yellow warning light of the maintenance upper section of the valve.
switch lights up when the engine is running. z Clean the discharge slit. z Loosen wing nut (1) and lift off housing cover (2).
– the red field (1) of the maintenance indica- z Remove the dust container (3) from the base (4)
tor is fully visible. and empty it. Clean the container using a brush
z After carrying out maintenance work, reset the and clean diesel fuel. Then dry.
signal by pressing the button on the mainte- z Place the dust container (3) on the base (4) and
nance indicator. The maintenance indicator is tighten the housing cover (2) with wing nut (1).
now ready for operation again.
40 © 2008
Belt drives Servicing and maintenance works
4
6
2
Checking the belt drive Checking the belt tension Tighten the generator V-belts
z Lower indicator arm (1) into the measuring de- z Loosen the screw (1), (2) and (3) slightly.
Only carry out work on the belt drive with
vice. z Push the generator (4) outwards in the direction
the engine at a standstill!
Always change both belts in sets in case of z Place guide (3) between two belt pulleys on the of the arrow until you get the correct V-belt ten-
wear on the double belts or damage to one V-belt (2). The stop have to be at the side. sion.
V-belt. z Press the button (4) at right angles to the V-belt z Retighten the screw (1), (2) and (3).
After repair work: Check that all guards (2) evenly until you hear or feel the spring snap
in. Renew the V-belts
have been replaced and that all tools have
been removed from the engine. z Lift the measuring device carefully without alter- z Loosen the screw (1), (2) and (3) slightly.
ing the position of the indicator arm (1). z Swing the generator (4) in in the opposite direc-
z Check the whole belt drive visually for damage. z Read the measured value at the point of inter- tion to the arrow.
z Renew damaged parts. section (arrow), scale (5) and indicator arm (1). z Remove the V-belt (5) and fit a new V-belt.
z Remount protective devices if necessary. z If necessary, re-tension belt and measure again. z Push the generator (4) outwards in the direction
z Pay attention to correct fit of new belts, check the of the arrow until you get the correct V-belt ten-
tension after running for 15 minutes. Tools
sion.
Belt tension measuring device (order number: z Retighten the screw (1), (2) and (3).
8115) can be obtained from your DEUTZ partner.
© 2008 41
Servicing and maintenance works Belt drives
6 z Retighten the screws (1) and (2).

z Checking the belt tension (53).
1 2
3 4
Tighten belt
z Loosen screws (1) and (2) and (3).
z Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
z Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
z Retighten the screws (1) and (2).
z Checking the belt tension (53).
Change the belt
z Loosen screws (1) and (2) and (3).
z Move the tensioning pulley (3) in the direction of
the arrow (B).
z Remove belt and fit new one.
z Plug socket wrench insert of the torque wrench
ino the opening (4) of the tensioning pulley (3).
z Move the tensioning pulley (3) with the torque
wrench in the direction of the arrow (A) until the
correct belt tension is reached.
42 © 2008
Setting work Servicing and maintenance works

6
Check valve clearance, adjust if necessary

z Let the engine cool down for at least 30 minutes z Engage hexagon socket head wrench (7) and in-
before setting the valve clearance: Lubricating oil sert and loosen the lock nut (4).
temperature below 80 °C. z Adjust the valve clearance setting screw (5) with
z Remove the cylinder head hood. the hexagon socket head wrench (7) so that the
z Place turning gear over fastening screws of the correct valve clerarance (1) is reached after
belt pulleys. tightening the lock nut (4).
z Turn the crankcase until reaching valve overlap. z Perform the setting procedure on every cylinder.
Outlet valve is not yet closed, inlet valve be- z Reinstall cylinder head cover, with new gasket.
gins to open.
The cylinders to be set can be seen in the
setting schematic.
z Check the valve clearance (1) between the rock-
er arm lugs (2) and the valve (3) with a feeler
gauge (6).
z The feeler gauge (6) must slide in with little re-
sistance.
z For permissible valve clearance, see (53)
z Adjust valve clearance if necessary:
© 2008 43
Servicing and maintenance works Setting work
6 Valve clearance setting schematic
1 z Crankshaft position 1
Turn crankshaft until both vaalves overlap on the
cylinder.
Outlet valve is not yet closed, inlet valve begins
1 2 1 2 3 1 2 3 4 to open.
Setblack marked valves.
Mark the respective rocker arm with chalk to
check the setting you have made.
z Crankshaft position 2
Turn the crankshaft one turn (360 °).
Setblack marked valves.
2
1 2 1 2 3 1 2 3 4
44 © 2008
Electrical system Servicing and maintenance works

Regulations for working on the electrical system Danger of explosion! The gases emitted by
the battery are explosive!
6
Do not touch the voltage conducting parts, Fire, sparks, smoking and naked lights are
faulty warning lamps should be immediate- prohibited!
ly replaced. Danger of acid burns! Wear protective
gloves and glasses! Avoid contact with skin
Pay attention to correct polarity of the con- and clothing!
nections. Danger of short circuit! Do not rest tools on
Cover electrical/electronic parts and con- the battery!
nections to clean the engine (e.g. control
units, generator, solenoid valves etc.). Do Checking the voltage
not aim the water/steam jet directly at them. z Check the battery voltage with a conventional
Allow engine to warm up. voltmeter. The voltage indicates the charging
Touching a lead against the frame to check state. It should be between 12 and 14.4 Volt de-
whether it is live must not, under any cir- pending per battery.
cumstances, be carried out.
For electrical welding work, the ground ter- Check acid level Check acid density
minal of the welding gear must be clamped z Unscrew caps.
z Unscrew caps.
directly to the part being welded. z Measure the electrolyte density of individual cells
z Note the manufacturer’s specifications concern-
Three-phase current generator: Never dis- with a commercial hydrometer. Hydrometer
ing the liquid level.
connect the cables between battery, gener- reading indicates battery’s state of charge. The
ator and regulator while the engine is The liquid should normally be 10-15 mm above
the top edge of the plate or reach up to any avail- acid temperature when measuring should be 20
running. °C if possible.
able control device.
Battery z Only use distilled water to top up the battery. z Check the acid level before recharging.
z Screw in caps. z Screw in caps.
Keep battery clean and dry. Acid density [kg/ l] Charge Measure
Make sure the battery is fitted correctly and status
securely. Normal Tropical
Dispose of old batteries in an environmen- 1,28 1,23 good none
tally friendly way. 1,20 1,12 half charge
1,12 1,08 empty charge
© 2008 45
Servicing and maintenance works Electrical system
6 Removing the battery

z Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
of short-circuit!
z Remove the fastenings and take out the battery.
Charging the battery
z Unscrew caps.
z Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
z Screw in caps.
Installing the battery
z Insert new or charged battery and attach the fas-
tenings.
z Clean the terminals and battery poles with fine
emery paper.
z Connect the plus pole first and then the minus
pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
Tighten clamp bolts hand-tight.
z Grease the assembled terminals with an acid-
free, acid-resistant grease.
46 © 2008
Fault table Faults

Faults and remedies
7
Faults Causes Measures
Engine does not start or is difficult to Not disconnected (if possible) Check coupling
start Below starting limit temperature Check
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Fuel quality does not comply with operating manual Change the fuel
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Stop magnet defective (release circuit) Check lifting magnet
Engine stop lever still in stop position Check/replace
Stop magnet defective (release circuit) Check/replace
Incorrect valve clearance Check valve clearance and set if necessary
Injection valve defective Check fuel injector / change if necessary
Air filter clogged / turbocharger defective Check/replace
Air in fuel system Vent fuel system
Compression pressure too low Check compression pressure
Exhaust gas backpressure too high Check
Injection line leaks Check injection line
Engine starts, but runs irregularly or Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose
fails Incorrect valve clearance Check valve clearance and set if necessary
Compression pressure too low Check compression pressure
Glow plugs defective Change
Air in fuel system Vent
Fuel filter contaminated Clean
© 2008 47
Faults Fault table
7 Faults
Engine becomes excessively hot.
Causes
Vent line blocked
Measures
Clean
Temperature warning system acti- Fuel tank empty Vent fuel system
vates
Fuel suction pipe blocked Check
Lubricating oil cooler fins soiled Clean
Lube oil filter contaminated on the air or lube oil side Change
Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Heat short-circuit in the cooling air guidance Check the cooling system
Charge air line leaking Check charge air line
Air filter maintenance switch / maintenance indicator defective Check/replace
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Engine output is deficient Lube oil level too high Check lube oil level, if necessary drain off.
Lubricating oil level too low Fill up lube oil
Lubricating oil cooler fins soiled Clean
Engine stop lever still in stop position Stop magnet defective (release circuit)
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Heat short-circuit in the cooling air guidance Check the cooling system
Injection valve defective Check fuel injector
48 © 2008
Fault table Faults

Faults
Engine does not run on all cylinders
Causes
Injection line leaks
Measures
Check injection line
7
Lube oil level too high Check lube oil level, if necessary drain off.
Engine lubricating oil pressure is non- Lubricating oil level too low Fill up lube oil
existant or excessively low Excessive inclination of engine Check engine mounting / reduce inclination
Engine lubricating oil consumption Lube oil level too high Check lube oil level, if necessary drain off.
excessive Excessive inclination of engine Check engine mounting / reduce inclination
Lubricating oil in the exhaust system Engine operated continuously with too low a load (< 20-30%) Check load factor
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
Engine producing white smoke Below starting limit temperature Check
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Charge air pressure-dependent full load stop defective Check
© 2008 49
Transport and storage Transport
8
1
Suspension equipment
Danger to life!
The engine may tip over or fall down if sus-
The transport devices mounted on this en-
pended incorrectly!
gine are adapted to the engine weight. If
the engine is transported with add-on com- z The fastening attachment cannot be fixed se-
ponents, the transport devices must be de- curely above the centre of gravity (1).
signed accordingly. z The fastening attachment can slip, the engine
z Always use proper suspension equipment when swings backwards and forwards (1).
transporting the engine. z Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
z The suspension device (1) must be adjustable
damage it.
for the engine's centre of gravity.
z After transportation and before commissioning of
engine: remove attachment eyes (2).
50 © 2008
Engine corrosion protection Transport and storage

General
Engines contain the following types of corrosion pro-
by wetting of the walls with the implemented cor-
rosion protection agent in a corrosion protection
suction system after shutting down the engine
until it emerges visibly from the pressure nozzle. 8
run of the engine.
tection: Cooling system
z The corrosion protection run can be performed
z Interior corrosion protection once to protect the different systems: z Cooling air system, see the Exterior corrosion
z Exterior corrosion protection protection section.
Fuel system
Your DEUTZ partner has the right corro- z In engines of the oil-cooled series the circulating
sion protection agent for your needs. lubricating oil serves simultaneously for cooling.
Close the fuel/tank/supply line to the en-
The cooling chambers are protected automati-
gine so that the system is protected against
cally against corrosion with the lube oil system.
The following measures for corrosion protection af- dirt and dust. Protect the electronics
ter taking the engine out of operation meet the re- against moisture and corrosion. Air intake pipes
quirements for 12 months corrosion protection.
z Fill the fuel tank with a mixture of: z After the corrosion protection run, remove the
The following corrosion protection work may only be – 90 % distilled fuel cylinder head cover and deinstall injectors. The
carried out by persons familiar with it and instructed – 10 % corrosion protection oil SAE 20W-20 respective piston must be set to LT.
in the potential dangers. z The accessible part of the cylinder liner should
z Perform a corrosion protection run with no load
If these measures are deviated from by exposing the for at least 5 minutes. be coated with corrosion protection oil with a
corrosion-protected engines or parts to unfavourable spray lance through the opening.
conditions (installation outdoors or storage in damp, Lubricating oil system z Spray corrosion protection oil SAE 20W-20 into
badly aired places) or damage to the corrosion pro- z Drain lubricating oil from warm engine. the suction air intake line.
tection layer, a shorter corrosion protection duration
z Thoroughly clean lube oil tray, cylinder head with Exterior corrosion protection
is to be expected.
rocker arms, valves, valve springs with diesel
The engine corrosion protection should be checked fuel or cleaning agent. z The engine must be cleaned thoroughly with a
about every 3 months by opening the covers. If cor- z Fill the engine with corrosion protection oil SAE cleaning agent before exterior corrosion protec-
rosion is detected, the corrosion protection should 20W-20 up to the MAX mark and perform a cor- tion. Any signs of corrosion and damage to the
be renewed. rosion protection run for at least 5 minutes so paintwork must be removed.
At the end of the corrosion protection work the crank that all the components of the lubricating oil sys- Cooling air system in air-cooled engines
drive may no longer be turned so that the corrosion tem are wetted or wet all accessible parts with
protection agent in the bearings, bearing liners and corrosion protection oil and pump corrosion pro- z The air guidance compartment of the engines is
cylinder liners is not scraped off. tection oil through the engine with a separate unpainted and must be sprayed with a corrosion
pump until all bearings and bearing liners are protection agent.
Before operating a corrosion protected engine, the
corrosion protection must be removed. wetted.
Bare exterior surfaces and parts
Interior corrosion protection Air compressor
z Coat or spray all bare exterior parts and surfaces
z If a compressor is installed, a corrosion protec- (e.g. flywheel, flange faces) with corrosion pro-
z Interior corrosion protection is always provided
tion agent must be sprayed into the compressor tection agent.
© 2008 51
Transport and storage Engine corrosion protection
8 Rubber parts
z Rubber parts (e.g. muffs) which are not painted
openings must be removed.
z Any corrosion deposits and paint damage should
over must be rubbed down with talcum powder. be remedied.
Belt drive Fuel system

If there is a mixture of diesel fuel/corrosion pro-
z Remove V-belts and V-rib belts and store
tection oil in the fuel tank, drain it.
packed.
z Spray V-belt pulleys and tension rollers with cor- z Connect fuel/tank/supply line to the engine. Pay
rosion protection agent. attention to cleanliness.
z Fill the fuel tank and fuel system with the proper
z Toothed belts for engine control may not be re-
fuel.
moved.
Lubricating oil system
Engine openings
z All engine openings must be fitted with air-tight, z Unscrew the lube oil drain screw, drain oil.
water-tight covers to delay the vapourisation z Fill the engine with lubricating oil via the lubricat-
process of the corrosion protection agents. ing oil filler neck.
z With installed air compressor, the suction and Removal of exterior corrosion protection
pressure connection must be sealed by a cap.
z Air should be excluded to avoid ventilation of the z All areas and components coated with corrosion
engine (chimney effect) for the suction from an protection agent must be washed off with dis-
air supply pipe. tilled fuel or a suitable cleaning agent.
z Wash out grooves of V-belt pulleys if necessary.
Storage and packaging z Mount V-belts or V-rib belts as specified.
z After being protected against corrosion, the en-
gine must be stored in a dry, ventilated hall and
suitably covered.
z The cover must be placed loosely over the en-
gine so that the air can circulate around it to pre-
vent condensation from forming. Use a desiccant
if necessary.
Removal of corrosion protection
z The corrosion protection must be removed from
the corrosion protected engine before starting.
z The packaging and all covers over the closed
52 © 2008
Engine and setting data Technical data

General technical data
9
Engine type Dimension F2L 2011 F3L 2011 F4L 2011 BF3L 2011 BF4L 2011
Working principle Four-stroke diesel engine
Charging Suction motor Exhaust gas turbocharger
Type of cooling oil-cooled (integrated cooler)
Cylinder arrangement in series
No. of cylinders 2 3 4 3 4
Bore/stroke [mm] 94/112
Total displacement [cm3] 1554 2331 3108 2331 3108
Combustion process Direct injection
Injection system Pump-pipe-nozzle
Exhaust gas recirculation without
Valves per cylinder 2
Valve clearance: Inlet/outlet [mm] 0,3+0,1 / 0,5+0,1
Firing order of the engine 1-2 1-2-3 1-3-4-2 1-2-3 1-3-4-2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Lubricating oil change volume (with filter) ≈ [l] 6,5* 6,0* 10,5 8,0* 10,5*
Lube oil temperature in the lube oil tray, maximum [°C] 130
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 140/1,4
V-belt tension Pre-tensioning/Re-tensioning
V-belt AVX 10 [N] 450±50/300±50
Weight without cooling system according to DIN 70020-A ≈ [kg] 175 217 256 222 257
*specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants
and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
© 2008 53
Technical data Engine and setting data
9 Engine type Dimension F2M 2011 F3M 2011 F4M 2011 BF3M 2011 BF4M 2011
Working principle Four-stroke diesel engine
Charging Suction motor Exhaust gas turbocharger
Type of cooling oil-cooled
Cylinder arrangement in series
No. of cylinders 2 3 4 3 4
Bore/stroke [mm] 94/112
Total displacement [cm3] 1554 2331 3108 2331 3108
Combustion process Direct injection
Injection system Pump-pipe-nozzle
Exhaust gas recirculation without
Valves per cylinder 2
Valve clearance: Inlet/outlet [mm] 0,3+0,1 / 0,5+0,1
Firing order of the engine 1-2 1-2-3 1-3-4-2 1-2-3 1-3-4-2
Direction of rotation looking onto the flywheel left
Engine power rating according to ISO 3046 [kW] see engine rating plate
Speed (nominal revolutions) [rpm] see engine rating plate
Injection timing [°BTDC] see engine rating plate
Volume of initial charge lubricating oil (with filter and external cooler) ≈ [l] 9,5* 9,0* 13,5 11,0* 13,5*
Lubricating oil change volume (with filter) ≈ [l] 6,5* 6,0* 10,5 8,0* 10,5*
Lube oil temperature in the lube oil tray, maximum [°C] 130
Lubricating oil pressure minimum (low idle, engine warm) [kPa/bar] 140/1,4
V-belt tension Pre-tensioning/Re-tensioning
V-belt AVX 10 [N] 450±50/300±50
Weight without cooling system according to DIN 70020-A ≈ [kg] 169 210 248 215 250
*specified lubricating oil filling volumes apply for standard versions. In engines which deviate from the standard, for example different lubricating oil pans/dipstick variants
and/or special inclined versions, the lubricating oil volume may vary. The lubricating oil dipstick mark is always decisive.
54 © 2008
Tools Technical data

Tool ordering
The special tools described in this chapter can be or-
9
dered from:
WILBÄR - Wilhelm Bäcker GmbH & Co. KG

Taubenstrasse 5
42857 Remscheid
Germany
Phone: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: [email protected]
www.deutz-tools.com
Torx tool V-belt tension measuring instrument
Order number: Order number:
8189 8115
The Torx screw system is used in engines in this se- Measuring instrument for checking the specified V-
ries among other things. This system was introduced belt tensions.
for a number of reasons:
z Excellent accessibility
z High force transmission when loosening and
tightening
z Slipping or breaking of the key and risk of injury
are practically excluded.
© 2008 55
Technical data Tools
Special tools for removing the water collection Special wrench for loosening exchangeable fil-
vessel. ters
Order number: Order number:
8192 170050
On Racor filters, only loosen the water collection For loosening changeable filters.
vessel with a special tool.
56 © 2008
DEUTZ Oil
DEUTZ Oil DQC II-05 DEUTZ Oil DQC III-05 DEUTZ Oil DQC IV-05 (Synthetic)
ACEA E5-02 / E3-96 / B3-04 ACEA E7-04 / E5-02 / E3-96 / B4-04 / A3-04 ACEA E7-04 / E5-02 / E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1
TLS-15W40D TLX-10W40FE DEUTZ Oel DQC IV-5W30

(DQC II-05) (DQC III-05) (DQC IV-05)
5L 0101 6331 5L 0101 6335 5L -
20 L 0101 6332 20 L 0101 6336 20 L 0101 7849
209 L 0101 6333 209 L 0101 6337 209 L 0101 7850
DEUTZ AG
Supporthouse Information Systems
Ottostraße 1
51149 Köln
Germany
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
E-Mail: [email protected]
www.deutz.com
Printed in Germany
© 04/2008
All rights reserved
Order number:
The engine company. 0312 3606 en

B/FL/FM 2011: Operation Manual

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OBJ_DOKU-15769-001.fm Seite 1 Montag, 5.

Mai 2008 3:02 15

This symbol is used for all safety instruc-

This symbol indicates a danger to the part

This symbol accompanies notes of a gen-

Model Engine description

F Four-stroke diesel engine

Engine description Model

Engine serial number Cylinder numbering Volume blocking

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Engine illustrations Engine description

Engine description Engine illustrations

Schematic for lubricating oil Engine description

Engine description Schematic for fuel

2 Fuel schematic (example)

Ambient conditions Operation

0 °C Under the following application and operating condi-

Operation Initial start-up

3 Preparations for initial commissioning External cooler

Initial start-up Operation

Only re-fuel when the engine is not running.

Operation Start procedure

Before starting, make sure that nobody is

Operation monitoring Operation

Operation Operation monitoring

3 Instruments and symbols

Instruments/symbols Designation Possible display: Measure

Horn With acoustic signal See fault table (47).

Stop procedure Operation

Avoid switching off from full load (coking/

Operating media Lubricating oil

Lubricating oil Operating media

Operating media Fuel

Maintenance schedule Maintenance

Maintenance Maintenance schedule

Stage Activity Measure Page

Maintenance schedule Maintenance

Order number: 0297 9935

Servicing and maintenance works Lubricating oil system

6 Regulations for working on the lubricating oil

Be careful of hot lubricating oil. Danger of

z Pull out the lubricating oil dipstick and wipe off

Lubricating oil system Servicing and maintenance works

Servicing and maintenance works Fuel system

Additional venting of the fuel system by a 5

Fuel system Servicing and maintenance works

Servicing and maintenance works Fuel system

Fuel system Servicing and maintenance works

Servicing and maintenance works Engine cleaning

6 Cleaning work for about 10 minutes to take effect.

Aspiration system Servicing and maintenance works

z Renew safety cartridge (4) according to the inter-

Maintaining the dry air filter

Do not clean the filter element (3) with pet-

Horn With acoustic signal See fault table (47).