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1. 5 1 Service Plan Service Deutz maintenance andseniceschedue E check adjust Oclean 4 replace m Expansions or modifications for engines with fl prior to or during 1st trial run check 2x daily during the breaking in phase or EPA acceptance when commissioning new and overhauled engines The specified engine maintenance intervals are permissible fl every 10 operating hours or daily recommended maximums Depending on usage reduced maintenance intervals may be necessary comply with the unit in operating hours OH every manufacturer s operating instructions Maintenance must only be carried out by authorise Operation service personnel me SI Timing belt change intervals Engine application Engine application operating parameters Guideline values in OH Example Example 6000 or max 5 years Generating sets 1500 1800 rpm pump units low speed moderate ambient temperature low speed platform lifts refrigeration units etc low dust exposure 5000 or max 5 years compressors rollers forklift trucks welding units wheel loaders medium to high variable speed hig ambient small dumpers ski steer loaders etc temperature moderate dust exposure 3000 or max 5 years agricultural machinery ski steer loaders wheel loaders drilling highspeed impactloads extremeambienttemperature equipment trench cutting machines joint cutters bulldozers etc
2. Refer to head office tt Tes A0 ds Pie men denenes Dre M0 5 EE D 1 en 13 52 m Ionen 11 5 en 142 2 1 Engine power speed start of delivery are stamped on engine rating plate see also 2 1 2 Approx values can vary depending on sump and or cooler design external cooling system Upper oil dipstick mark is always authoritative 3 Values for engines without engine oil heating 2004 Tecnical Specification Installation location Pre tension Nm 1st stage 2nd stage 3rd stage 1st stage 9 2 Torque Wrench Settings Re tension Nm 3rd stage Ath stage Cylinder head cover Cylinder head cover Rocker arm adjustment screw Intake manifold Foot Rigid suspension Foot Elastic suspension Air intake pipe Exhaust manifold Oil drain plug 55 Oil pan sheet metal 21 Oil pan cast 31 Injection line attachment 30 Injection valve attachment 21 TORX Lube oil filter cartridge 27 on engine or separate Threaded pipe union 4 9 3 Tools Technical Specification TORX V belt tension gauge 26002 0 A TORX BN 8189 screw set is used with engines in The V belt tension gauge can be obtained under the 1011 series order number 8115 from This system was chosen because of the many advantages it offers FA WILBAR Postfach 14 05 80 Outstanding accessibility to bolts D 42826 Remscheid High load transfer when loosening and tighten
3. Bee Sng SAE 15W W 40 SAE 20W 50 en SAE 10W 30 SAE 10W 40 SAE 0W 30 SAE OW 40 SAE 5W 30 SAE 5W 40 Only with preheating 30 298 4 2 Fuel 4 2 1 Quality Use commercially available diesel fuel with less than 0 5 sulphur content Ifthe sulfur content is higher than 0 5 oil change intervals should be reduced see 6 1 1 The following fuel specifications standards are approved refer to TR 0199 3002 TR 0199 99 3005 supplies details to the fuel specifications The following fuel specifica tions are certified see for this TR 0199 99 3002 TR is to be referred more over the DEUTZ service organisacion Diesel fuel DIN EN 590 BS 2869 A1 and A2 with A2 take note of the sulfur content ASTM D 975 88 1 D and 2 D NATO Code F 54and F 75 ISO 8217 DMX ISO 8217 DMA Light heating oil according to DIN 51603 ASTM D 396 1 and 2 BS 2869 Class D Jet fuel F34 F35 F44 kerosene F54 equivalent to diesel fuel according to DIN EN 590 XF 63 equivalent to F34 F35 with addi tives Bio diesel fuel according to DIN 51606 FAME Exhaust emission values which may be deter mined in the cause of type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test 4 2 2 Winter Grade Fuel Waxing may occur at low temperatures clogging the fuel system a
4. 3 3 Monitoring Operation Engine Operation 3 3 2 Engine Temperature Engine Temperature Gauge e Engine temperature gauge pointer should re main in green sector most of time It should rarely enter yellow green sector Ifpointerenters orange sector engine is overheating Turn off and establish cause from Fault Table see 7 1 2004 2004 Engine Operation 3 4 1 Mechanical Shut Off 3 4 2 Electric Shut Off Ignition Key OJ26 424 p Move speed adjustment lever 1 to low idle Turn key anticlockwise to position 0 and re Move shut off lever 2 until engine comes to a move Pilot lights will go out stop Charge pilot light and oil pressure pilot light will come on when engine stops Turn key anticlockwise to position 0 and re move Pilot lights will go out If possible do not suddenly switch off engine when under full load 3 4 Shutting Off 3 5 Operating Conditions 3 5 1 Winter Operation Lube Oil Viscosity Select oil viscosity SAE grade according to ambient temperature before starting engine see 4 1 2 Increase oil change frequency when operating below 10 C see 6 1 1 Diesel Fuel Use winter grade diesel fuel for operation be low 0 C see 4 2 2 Additional Maintenance Work Drain sludge from fuel tank once a week undo sludge drain screw If necessary allow oil in oil bath air cleaner and engine oil to settle at ambient temperature Belo
5. Operation Manual N 201 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 e 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 forthe 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 pur pose also implies compliance with the con ditions laid down by the manufacturer for operation maintenance and servicing The engine should only be operated by person nel trained in its use and the hazards involved Therelevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be ob served When the engine is running there is a risk of injury through turning hot components engines with positive ignition ignition systems high electrical voltage You must avoid contact at all times Unauthorized engine modifications will in validate any liability claims against the manu facturer for resultant damage Manipulatio
6. 6 7 2 Rotary Current Alternator 6 7 3 Transportation Shackles Notes on the three phase system Never disconnect cables between battery alter nator and regulator while engine is running If however it is necessary to start and operate engine without battery disconnectregulatorfrom alternator before starting Be sure not to confuse battery terminals Replace defective charge pilot lamp bulb imme diately When washing engine cover up alternator and regulator Touching lead against frame to check whether it is live must not under any circumstances be carried out with three phase electrical systems In case of electric welding connect ground ter minal on welder directly to piece being welded Always use proper lifting tackle 1 when trans porting engine After transportation and before commissioning of engine remove attachment eyes 2 Use only correct lifting gear Service and Maintenance 6 8 Engine Cleaning 6 8 1 Engine Cleaning Preperation Switch off engine Remove engine covers and cooling air hood Replace them after cleaning and before test run e Cover electrical electronic components and connections e g alternator starter governor solenoid Using compressed air e Blow air through engine taking particular care not to damage cooler and cooling fins begin to blow through air from exhaust side Remove dirt which has blown into interior space Using cold cleanin
7. cool down for at least 30 minutes Oil tempera ture should be below 80 C e Check valve clearance 1 between rocker arm tappet contact face 2 and valve stem 3 with feeler gauge 6 there should be only slight resistance when feeler blade is inserted For permissible valve clearance see 9 1 Adjust valve clearance if necessary Release locknut 4 Use Allan key 7 to turn setscrew 5 so that correct clearance is attained after locknut 4 has been tightened Check and adjust valve clearance on all cylin ders Reinstall cylinder head cover with new gasket if necessary Service and Maintenance 6 6 Adjustments 6 6 1 1 Valve Clearance Adjust ments Schematic e Crankshaft Position 1 Turn crankshaft until both valves in cylinder 1 overlap exhaust valve about to close inlet valve aboutto open Adjust clearance of valves marked in black on schematic Mark respective rocker arm with chalk to show that adjustment has been carried out Crankshaft Position 2 Turn crankshaft one full revolution 360 Adjust clearance of valves marked in black on schematic lo 25 894 6 7 Accessories 6 7 1 Battery 6 7 1 1 Check Battery and Cable Connectors e Keep battery clean and dry Undo dirty clamps Clean terminal posts and and clamps of battery and grease wit
8. 2 4 Fuel System Schematic Engine Description 2 4 1 Fuel System oono eA Fuel line from tank to fuel pump Fuel pump Fuel line from fuel pump to easy change fuel filter Easy change fuel filter Fuel line from filter to injection pump Injection pump Fuel distributor line Injection line Injection valves Fuel overflow pipe Fuel return line to tank The installation of a fuel pre filter hand pump between the fuel tank and the engine is prescribed to protect the engines against dirt in the fuel 2004 00c Engine Operation 3 1 Commissioning 3 2 Starting 3 3 Monitoring Operation 3 4 Shutting Off 2004 2004 Engine Operation 3 1 1 Adding Engine Oil OIL SE SL Q u Al Til ie As a rule engines are delivered without oil Pour lube oil into the oil filler neck arrow For oil grade and viscosity see 4 1 ur OJ 26 432 0 3 1 1 1 Initial Engine Oil Fill Up for B FL 2011 Fill oil into oil pan up to Max mark on engine dipstick for oil quantity see 9 1 e Start engine and allow to run at low idling speed for approx 2 mins Switch off engine Check oil level if necessary top up oil to Max mark 3 1 Commissioning 3 1 1 2 Initial Engine Oil Fill Up B FM 2011 Fill oil into oil pan up to Min mark on engine dipstick eln addition top up oil quantity of supply hoses and of external oil coo
9. and Maintenance 0 25 881 0 Manually screw in new cartridge until gasketis flush Tighten lube oil filter cartridge with another half turn Check oil level see 6 1 2 Check oil pressure see 3 3 1 Check lube oil filter cartridge seal for leaks C 2004 C 2004 Service and Maintenance 6 1 4 Clean Replace Oil Filter Cup e Switch off engine Loosen lube oil filter cover 1 and unscrew in anticlockwise direction e Carefullyloosen paperfilter cartridge 3 upwards from guide 4 e Catch any escaping oil e Replace paper filter cartridge 3 e Clean any dirt from sealing surface of filter carrier and lube oil filter cover 1 and from guide 4 Caution is required in case of hot oil Risk of scalding e Replace and lightly oil rubber gasket 2 e Carefully insert new paper filter cartridge 3 into guide 4 e Tighten lube oil filter cover 1 in clockwise direction 25 Nm e Start engine e Check oil level see 6 1 2 e Check oil pressure see 3 3 1 e Check lube oil filter attachment for leaks 6 1 Lubrication System 6 2 Fuel System 6 2 1 Replace Fuel Filter Close fuel shut off valve Undo fuel filter cartridge with commercial tool and spin off Catch any escaping fuel Clean any dirt from filter carrier sealing surface Apply light film of oil or diesel fuel to rubber gasket of new fuel filter cartridge Keep naked fla
10. 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 Safety This symbolis 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 asbestos free Service Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries Our trained specialists will carry out repairs quickly and professionally using only genuine spare parts Original parts from DEUTZ AG are always produced in accordance with state of the art technology Please turn to the end of this manual for further service information California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Engine Description 2 1 Model 2 2 Engine Illustrations 2 3 Lube Oil Circuit Schematic 2 4 Fuel System Schematic 2004 2 2 1 1 Rating Plate 2 1 2 Position ofthe Rating Plate 2 1 3 Engine Serial Number 2004 Engine Description 2 1 Mo
11. high dust exposure 2004 2004 Service 5 2 1 Scheduled Maintenance Plan 5 2 Scheduled Maintenance Plan Intervals Deutz maintenance Operation Carried out by at after and service schedule 50 OH E10 After commissioning and E 45 E 60 Authorised specialists Daily E20 Daily check Operator 250 OH E25 Inspection Authorised specialists 500 OH E30 Extended inspection Authorised specialists 1000 OH E40 Interim overhaul Authorised specialists 3000 OH E45 Extended interim overhaul Authorised specialists 6000 OH E60 Partial overhaul Authorised specialists 5 3 Maintenance Chart Service The maintenance chartshown here issupplied as a self adhesive label with each engine It should be affixed where it can be seen clearly on the engine or driven equipment 0 012 in 0 5 mm 0 020 in 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 u 0297 9935 LL Stop the engine before carrying out any maintenance work 2004 Service 5 4 Maintenance Work Completed Op hours Date Signature stamp Op hours Date Signature stamp 50 150 125 250 375 500 625 750 875 1000 1125 1250 1375 1500 1625 1750 1875 2000 2115 2250 2375 2500 2625 2750 Fol
12. reliability service life and exhaust gas quality smoke Otherwise contact DEUTZ SERVICE 3 5 Operating Conditions Operating Media 4 1 Lube Oil 4 2 Fuel 2004 2004 Operating Media 4 1 1 Quality Grade Lube oils are differentiated by Deutz according to their performance and quality class Oils of other comparable specifications can be used Approved oils Deutz DQC DOC II DOC III ACEA E2 96 E3 96 E5 02 E4 99 API CF CF 4 CH 4 CG 4 DHD DHD 1 The precise assignment of the admissible oil qualities to the engines is indicated in chapter 6 1 1 If in doubt contact your service representative 4 1 2 Viscosity Generally multi grade oils shall be used In closed heated rooms at temperatures gt 5 C also single grade oils can be used As the viscosity of lube oil is dependent on temperature the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide Should the temperature fall temporarily below the limits of the SAE grade selected cold starting may be affected but the engine will not be damaged In order to keep wear to a minimum do not exceed application limits for extended periods of time Synthetic lube oils feature an improved tempera ture and oxidation stability 4 1 Lube Oil
13. should be below 80 C Injector opening pressure vehicle unit Start of feed Firing order of engine mm mm em e approx kg kW hp rpm C bar bar bar I approx I mm bar crankshaft BTDC V belt tension pretension retension after engine has been running under load for 15 mins N Technical Specification Four stroke diesel with turbocharging and direct fuel injection On left when looking at flywheel ee 20 W 20 nen 130 a a aiaa ee ae Denn TAEA ee Ste ue han ne Pre APM ne DD ee ts Cu LM ie ER D PE Dee te on es dl ph ne De nen A Dei HERNE GER ALLIED eine 8 105 2 Engine power speed start of delivery are stamped on engine rating plate see also 2 1 2 Approx values can vary depending on sump and or cooler design external cooling system Upper oil dipstick mark is always authoritative 3 Values for engines without engine oil heating 2004 2004 Technical Specification Model Number of cylinders Cylinder arrangement Bore mm Stroke mm Total displacement em Compression ratio Working cycle Combustion system Direction of rotation Weight without cooling system without starter with alternator approx approx kg Engine output KW hp Speed pm Lubrication SAE oil Maximum oil temperature in oil pan PC Min oil pressu
14. Type Precleaner Dry Type Air Cleaner Belt Drives Check V belt Tensioning Alternator Belts Changing Alternator Belts Adjustments Check Valve Clearance adjust if necessary zA Valve Clearance Adjustment Schematic Accessories Battery Rotary Current Alternator Transportation Shackles Engine Cleaning Engine Cleaning 2004 Contents 7 Faults Causes and Remedies 7 1 Fault Table 8 Engine Preservation 8 1 Preservation 8 1 1 Preserving Engine 8 1 2 Removing Engine Preservatives 9 Technical Specification 9 1 Engine Specifications and Settings 9 2 Torque Wrench Settings 9 3 Tools 10 Service r002 2004 General DEUTZ Diesel Engines are the product of many years of research and development The resulting know how coupled with stringent quality standards guarantee their long servicelife highreliability and low fuel consumption It goes without saying that DEUTZ Diesel Engines meet the highest standards for en vironmental protection Beware of Running Engine Shut the engine down before carrying out maintenance or repair work Ensure that the engine cannot be accidentally started Risk of accidents When the work is complete be sure to refit any panels and guards that may have been removed Never fill the fuel tank while the engine is running Observe industrial safety regulations when running the engine in an enclosed space or underground Care and Maintenance Sound care
15. UTZ The engine company DEUTZ AG Service Information Systems Deutz M lheimer Str 147 149 D 51063 K ln Phone 49 0 2 21 8 22 0 Fax 49 0 2 21 8 22 53 58 Internet www deutz de eMail info deutz de Printed in Germany All rights reserved 7th Edition 01 2006 Order No 0297 9929 en 09 06
16. ating sets Vehicles on construction sites and unpaved roads construc tion machines compressors underground mining units Agricultural machines tractors in harvesting applications 6 4 Combustion Air Filter 6 4 1 Cleaning Intervals Amount of dirt in air cleaner depends on amount of dust in air and size of air cleaner used If high level of dust is anticipated cyclone type precleaner can be fitted to air cleaner e Cleaning intervals will have to be determined from case to case If dry type air filters are used cleaning should only be carried out according to service indicator or service switch e Air cleaner servicing is needed when Service indicator red signal 1 is fully visible when engine is off Service switch yellow pilot light comes on when engine is running pressing button on service indicator Service indicator is now ready for operation again Service and Maintenance 6 4 2 Emptying Cyclone Type Precleaner 25 88610 Undo wing nut 1 and remove cover 2 Remove collector bowl 3 from lower section 4 and empty Clean leaves straw and other foreign matter from lower section of pre cleaner Reposition collector bowl 3 onto lower section 4 fasten cover 2 in place by tightening wing nut 1 Never fill collector bow with oil Replace collector bowl if damaged Service and Maintenance 6 4 3 Dry Type Air Cleaner Discharge Valve 25 888 1 e Empty du
17. contained in this Operation Ma nual No parts of this Manual may be reproduced in any form or by any means without our written approval Operation manual 2011 0297 9929 en DEUTZ 2004 Foreword Dear Customer Liquid cooled Deutz engines are designed for a large number of applications Consequently a wide range of variants is offered to meet the requirements of specific cases Your engine is appropriately equipped for the installation concerned which means that not all of the components described in this Ope ration Manual are necessarily fitted to your engine We have endeavoured to highlight any differences so that you will be able to locate the operating and maintenance instructions relevant to your engine quickly and easily Please read this Manual before starting your engine and always observe the operating and maintenance instructions We are available to help with any additional inquiries Sincerely DEUTZAG 1 2 2 1 2 1 1 2 1 2 2 1 3 2 1 4 2 1 5 2 2 2 2 1 2 2 2 2 2 3 2 2 4 2 2 5 2 2 6 2 2 7 2 2 8 2 3 2 3 1 2 4 2 4 1 2 5 2 5 1 General Engine Description Model Rating Plate Position of the Rating Plate Engine Serial Number Cylinder Numbering Fuel Delivery Lock Engine Illustrations Operation Side Example FL 2011 Exhaust Side Example FL 2011 Operation Side Example BF4L 2011 Exhaust Side Example BF4L 2011 Operation Side Example FM 2011 Exhau
18. del The model A the engine serial number B and The rating plate C is attached to the valve The engine serial number B is stamped on the performance data are stamped on the cover the crankcase D as well as the rating plate rating plate The model and engine serial number must be given when ordering parts 2 1 Model Engine Description 2 1 4 Cylinder Numbering 2 1 5 FuelDelivery Lock T os 4 G2 D ca A 1 8 d J 0 A l i Yallig IIL iig s A N j A LA d TE EST gl T 1114 3 Ye JE 26 43110 Cylinders are numbered consecutively The manufacturer shall not be held liable for beginning at the flywheel damages resulting from adjustments made to the regulator by the operator The lock screws are protected in order to prevent this 1 with locking paint on model with torque balancer 2 with plastic protective cap on model without torque balancer Adjustments to the regulator are to be carried out only by authorised DEUTZ SERVICE specialists 2004 2004 Engine Description 2 2 1 Operation Side FL 2011 O O1 BR D i oo oo Pom_ o _ anu 17 18 19 20 21 2 2 Engine Illustration Oil filler neck valve gear housing cover Charge air line air intake line Fan with integrated generator Narrow V belt Tractive electromagnet Wheel house cover V belt pulley on crankshaft Oil pan Shut off
19. dustrial engines Section fi prior to or during 1st trial run check 2x daily during the breaking in phase or The specified engine maintenance intervals are when commissioning new and overhauled engines permissible recommended maximums Depending on usage reduced maintenance intervals may be necessary comply with the unit manufacturer s i ting h OH operating instructions E20 E25 E30 E40 Eo E Maintenance mustonly be carried outby authorise 500 1000 3000 5000 6000 Operation service personnel Top lube oil up if necessary 6 1 2 3 1 4 FL 2011 lube oil see TC 0199 99 3002 6 1 1 6 1 2 BFL 2011 lube oil see TC 0199 99 3002 6 1 1 6 1 2 Oil bath lube oil quality see TC 0199 99 3002 Dry type filter Oil filter cartridge FL 2011 Oil filter cartridge BFL 2011 Fuel filter cartridge Change fuel pump strainer if necessary Flexible fuel leakage lines see TC 0138 21 9300 Injection valve Fuel pre cleaner halve if the fuel quality is poor Intake air cleaner if available maintain according to maintenance indicator Battery and cable connectors Engine monitoring system warning system replace if necessary Valve clearance V belt Crankcase pressure vent valve Timing belt extreme duty see adjacent table Timing belt heavy duty see adjacent table Timing belt light duty see adjacent table Check engine for leaks visual inspection Engine mount replace if damaged fl every 10 operating hours or daily
20. e engine from any driven parts Move speed control lever 1 into idle position Move shut off handle 2 into operating position 3 2 Starting Without cold start assistance 25 746 2 Insert key Position 0 no operating voltage Turn key clockwise Position 1 operating voltage Pilot lights come on Push key in and turn further clockwise against spring pressure Position 2 no function Position 3 start Release key as soon as engine fires Pilot lights go out 3 2 Starting With cold start assistance Glow plug Insert key Position 0 no operating voltage e Turn key clockwise Position 1 operating voltage Pilot lights come on Push key in and turn further clockwise against spring pressure Position 2 preheat hold for approx 1 minute Preheat lamp comes on Position 3 start Release key as soon as engine fires Pilot lights go out Engine Operation 2004 2004 Engine Operation 3 3 1 Engine Oil Pressure Oil Pressure Pilot Light 25 75211 e Oil pressure pilot light comes on with operating voltage on and engine off Oil pressure pilot light should go out when engine is running 3 3 Monitoring Operation Oil Pressure Indicator Oil Pressure Gauge OELORUCK OIL PRESSURE PRESSION D HUILE 25 753 O 25 75410 Pointer must remain in green sector over entire Pointer must indicate minimum oil pressure Operating range see 9 1
21. een turned off Check oil level see 6 1 2 Top up with oil if necessary see 3 1 1 Retension V belt see 6 5 3 1 3 1 4 Additional Maintenance Work When commissioning new and reconditioned en gines the following additional maintenance work must be carried out Change lube oil see 6 1 1 6 1 2 e Change oil filter cartridge see 6 1 3 Change fuel filter cartridge see 6 2 1 Check V belts and retension as necessary see 6 5 Check engine for leaks Check engine mounts retighten if necessary see 9 2 Check valve clearance adjust if necessary see 5 1 6 6 1 Commissioning 70072 2004 Engine Operation 3 2 1 Electric starting Before starting make sure that no body is standing in the immediate vicinity of the engine or driven ma chine After repair work Check that all guards have been replaced and that all tools have been removed from the engine When starting with glow plugs do notuse any other starter substance e g injection with start pilot Risk of accident Caution If the speed regulator has been re moved the engine must not be tested under any circumstances Disconnect the battery Do not actuate the starter for more than 20 sec onds If the engine does not catch wait a minute then try again If the engine does not catch after two attempts refer to the Fault Table see 7 1 e Where possible disengage clutch to separat
22. ent or excessively low Reduce Rd Engine oil consumption excessive Engine smokes blue white black Cause Section e Not declutched where possible Engine Operation Ch e e Below starting limit temperature Ch e e Oil level too low T oo ee Oil level too high Ch ee Excessive inclination of engine Rd e e Incorrect lube oil SAE class or guality Operating media Rp ee e e Fuel guality not as per operating manual Rp e Air cleaner clogged turbocharger defective Combustion air Ch Rp oo e Air cleaner service switch indicator defective Ch Rp e CPD defective Ch e e Charge air line leaking Ch e Oil cooler panels clogged Ch CI e Cooling fan defective split or loose V belt Cooling system Ch Rp e Cooling air temperature rise heating short circuit Ch e Resistance in cooling system too great through flow guantity too small Ch e Battery defective or discharged Electrics Ch T CPD Charge pressure dependent full load stop Faults Causes and Remedies 7 1 Fault Table Faults Measures Engine does not start or is difficult to start Check Ch Engine starts but runs irregularly or fails Adjust A Engine becomes excessively hot Temperature warning system responds Replace Rp Engine output is deficient Clean CI Engine does not run on all cylinders Top up T Engine oil pressure is non existent or excessively low Reduce Rd Engine oil consumpti
23. er of cylinders Cylinder arrangement Bore mm Stroke mm Total displacement em Compression ratio Working cycle Combustion system Direction of rotation Weight without cooling system without starter with alternator approx kg Engine output kW hp Speed rpm Lubrication SAE oil Maximum oil temperature in oil pan C Min oil pressure in warm condition oil temperature 110 C at 900 rpm low idling speed bar 1800 rpm bar max 2800 rpm bar Engine with Thermostat Oil change quantity without extemal cooler see 3 1 1 2 without filter approx Nm Oil change quantity without external cooler see 3 1 1 2 filter replacement standard 0 5 litre approx I Genset Engine without Thermostat Oil change quantity including extemal cooler see 3 1 1 3 without filter approx Oil change quantity including cooler see 3 1 1 3 filter replacement standard 0 5 litre approx I Valve clearance with cold engine Engine cooling time at least 30 min oil temperature should be below 80 C mm Start of feed crankshaft BTDC Injector opening pressure vehicle unit bar Firing order of engine V belt tension pretension retension after engine has been running under load for 15 mins N Technical Specification a 4 stroke diesel engine Turbocharging and direct injection Lamm On left when looking at flywheel
24. fill fuel tank Allow engine to run for approx 10 mins e Switch off engine Turn engine over manually several times to pre serve cylinders and combustion chamber Remove V belts and store in wrapped condition Spray grooves on V belt pulleys with anti corro sion spray Close intake ports and exhaust ports 8 1 Preservation 8 1 2 Removing Engine Preservatives Remove anti corrosion agent from grooves in V belt pulleys Install V belt retension after brief operation if necessary see 6 5 Remove covers from intake port and exhaust port Commission engine see also 5 1 note 2 Technical Specification 9 1 Engine Specifications and Settings 9 2 Torque Wrench Settings 9 3 Tools 2004 Technical Specification 9 1 Engine Specifications and Settings Model Numberofcylinders Cylinder arrangement Bore mm Stroke mm Total displacement cm Compression ratio Working cycle mrereemmnnmnnnennnnnnmnnnnnn 4 stroke diesel engine Combustionsystem Naturally aspirated engine with direct injection Birecti n fretation gt A fe On left when looking at flywheel Weight incl integral cooling system to DIN 70020 A without starter with alternator approx kg Engine output kW hp Speed rpm Lubrication SAE oil Maximum oil temperature in oil pan C Min oil pressure in warm condition oil temperature 110 C at 900 rpm low idling
25. for leaks valves strainer one unit Disconnect rubber hose 1 from fuel tank Clean fuel strainer 2 with diesel fuel Disconnect rubber hoses 4 3 and 1 from Replace if necessary unions 2 and dispose of in an environ Place seal 3 in position mentally friendly manner Connect new rubber hoses 4 3 and 1 to unions 2 Connect rubber hoses 3 to injection valves Connect rubber hose 1 to fuel tank Open fuel shut off valve Keep naked flames away when Check for leaks after start up working on the fuel system Do not smoke C 2004 Service and Maintenance 6 3 1 Cleaning Intervals Amount of contamination in cooling system depends on engine application Oil and fuel residues on engine increase risk of contamination Therefore pay special attention to leaks if engine is used in dusty environments Serious contamination can occur for example on construction sites where there is a high level of air borne dust inharvesting applications where there are high concentrations of chaff and chopped straw in vicinity of machine Because applications vary cleaning intervals have to be determined from case to case Clean ing intervals given in table on right can be used as a guide Checking or cleaning intervals Guideline values OH 6 3 Cooling System Engine application Ships generating sets in enclosed areas pumps Vehicles on paved roads Tractors fork lift trucks mobile gener
26. fuel filter 13 Connecting facility for oil heater 14 Lube oil replacement filter 15 Injection pump s 16 Oil cooler connection 17 Injection valve s oo J O O1 R D Q 5 fA Y Q e LES a GES 7 2004 2 2 Engine Illustration Engine Description 2 2 8 Exhaust Side BFM2011 18 Crankcase ventilation optional 19 Cylinder head cover 20 Exhaust manifold 21 SAE housing 22 Starter 23 Crankcase 24 Turbocharger 25 Generator with cover 26 Charge air line 27 Oil filler neck 2004 2004 Engine Description 2 3 1 Lube Oil Circuit Schematic oOoNODUPWDN 2 3 Oil Circuit Oil pan Oil intake pipe Oil pump Main oil duct Oil cooled cylinders Cylinder head cooling neck Oil duct for rocker arm lubrication Rocker arm Oil manifold for the thermostat Intake to external engine oil cooler Return from external engine oil cooler Thermostathousing with slidethermostat Oil duct to oil filter Oil filter Oil duct to cam con rod and crankshaft bearings Spray nozzle for piston cooling Oil return via crankcase to oil pan Lube oil intake to turbocharger Turbocharger Return from turbocharger to oil pan Oil filter console with integrated switching valve for the control of the hydraulic tappets arrow A engine is cold around an early adjustment of the beginning of delivery to reach the pistons in the pump tappet with oil become ge feed engine is warm
27. g compound Spray engine with commercial cold cleaning compound and allow to react for approx 10 mins Spray clean engine with strong water jet repeat if necessary Allow engine to run warm so that remaining water evaporates Using high pressure device Clean engine with steam jet max spray pres sure of 60 bar max steam temperature of 90 C Allow engine to run warm so that remaining water evaporates Clean the engine only when the en gine is switched off Faults Causes and Remedies 7 1 Fault Table Faults Causes and Remedies 7 1 Fault Table Faults are often caused by engine not being properly operated or maintained Each time fault occurs check whether all operat ing and servicing regulations have been com plied with Corresponding fault table can be found on adja cent page e If you cannot ascertain cause of a fault or cannot rectify fault please contact DEUTZ SERVICE 7 1 Fault Table Faults Causes and Remedies Faults Measures 7 Engine does not start or is difficult to start Check Ch Engine starts but runs irregularly or fails Adjust A Engine becomes excessively hot Temperature warning system responds Replace Rp Engine output is deficient Clean CI Engine does not run on all cylinders Top up T Engine oil pressure is non exist
28. gine Oil 6 1 2 1Check Oil Level i max lt F MIN 25 7290 Switch engine off before checking oil level Ensure that engine or vehicle is level Remove oil dipstick e Wipe dipstick with non fibrous clean cloth Insert it to stop and remove again Check oil level and if necessary top up to MAX mark If oil level is only just above MIN mark more oil must be added The level must not fall below the MIN mark 6 1 2 2 Change Engine Oil Allow engine to warm up Ensure that engine or vehicle is level Lube oil temperature approx 80 C Switch off engine 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 6 1 Lubrication System 26 023 0 Place oil tray under engine Unscrew oil drain plug Drain oil Fit oil drain plug with new seal ring and tighten firmly for torque see 9 2 Pour in lube oil For grade viscosity see 4 1 For quantity see 9 1 Check oil level see 6 1 2 1 6 1 Lubrication System 6 1 3 Changing Oil Filter Undo lube oil filter cartridge using commercial tool and spin off Catch any escaping oil Clean any dirtfrom filter carrier sealing surface e Lightly oil rubber gasket of new lube oil filter cartridge Caution is required in case of hot oil Risk of scalding Service
29. h acid free and acid resistant grease When reassembling ensure that clamps make good contact Tighten clamp bolts hand tight Service and Maintenance 6 7 1 2 Check Electrolyte Level ET D PE N T ll CEFAN Remove sealing caps 1 e If testers 2 are present Electrolyte level should reach base of these Without testers Electrolyte level should be 10 15 mm above top of plates e If necessary top up with distilled water Screw sealing caps back in 6 7 1 3 Check Electrolyte Density 25 896 0 Measure electrolyte density of individual cells with commercial hydrometer Hydrometer reading see table on following page indicates battery s state of charge During measurement temperature of electrolyte should preferably be 20 C Service and Maintenance Electrolyte density in kg in B Baum scale Charge status Normal Normal Tropical 1 28 32 27 well charged 1 20 24 16 semi charged re charge 1 12 16 11 discharged immediately charge Measurement of electrolyte density in B Baum scale is out of date and rarely used today Wear protective goggles Do not rest tools on the battery The gases emitted by the battery are explosive Keep sparks and na ked flames away from the battery Do not allow battery acid to come into contact with skin or clothing 6 7 Accessories 6 7 Accessories Service and Maintenance
30. ine 24 Flywheel with ring gear 25 Starter 26 Crankcase 27 Lube oil feed line to turbocharger 28 Lube oil return line from turbocharger 29 Induction pipe 30 Turbocharger TC 31 Intake manifold 32 Charge air line NNN fh lt 1 5 N twy Jr UT 2004 2004 Engine Description 2 2 5 Operation Side FM 2011 2 2 Engine Illustration oo J O O1 AON Oil filler neck valve gear housing cover Charge air line air intake line Alternator Narrow V belt Tractive electromagnet Timing belt cover V belt pulley on crankshaft Oil pan Shut off lever Speed control lever Oil dipstick Oil drain plug Oil fill point on side of crankcase Fuel pump Easy change fuel filter Connecting facility for oil heater Lube oil replacement filter Injection pump s Oil cooler connection Injection valve s fuel to run line fuel back run line 2 2 Engine Illustration Engine Description 2 2 6 Exhaust Side FM2011 21 Cylinder head 22 Exhaust manifold 23 Flywheel with ring gear 24 Starter 25 Starter guard optional 26 Crankcase 27 Air intake pipe 2004 Engine Description 2 2 Engine Illustration 2 2 7 Operation Side BFM 2011 Air intake pipe Fan wheel V belt pulley on crankshaft Narrow V belt Tractive electromagnet Timing belt cover Shut off lever Speed control lever Oil fill point on side of crankcase 10 Oil dipstick 11 Fuel pump 12 Easy change
31. ing Almost impossible for socket to slide off or break thereby practically ruling out risk of in jury TORX tools can be ordered from FA WILBAR Postfach 14 05 80 D 42826 Remscheid 2004 Notice For many years DEUTZ has stood for pioneering development in engine construction As an inde pendent engine manufacturer we offer a complete palette of diesel and gas engines worldwide Our products are perfecily tailored to meet the requirements of our customers More than 1 4 million DEUTZ engines reliably perform their service all over the world We want to preserve the operational readiness of our engines and with it the satisfaction of our customers Therefore we are represented worldwide by a network of competent partners the concentration of whom corresponds to the regional distribution of our engines Thus DEUTZ is not just a name for innovative engines Butalso fora complete service package for every aspect of engines anda service that you can rely on You can find a complete overview of DEUTZ partners in your area their product compe tencies and their services on the DEUTZ website see below Also if there is no direct product competency specified your DEUTZ partner will be able to help you further with professional advice Your DEUTZ AG Deutz M lheimer Str 147 149 D 51063 Cologne Telephone 0049 221 822 0 Fax 0049 221 822 3523 Telex 8812 0 khd d http www deutz de Service DE
32. ler according to manufacturer s specifications Allow engine to run warm until thermostat opens at approx 95 C Allow engine to run for approx 2 mins e Switch off engine Check oil level and if necessary top up oil to Max mark If the person operating the engine does not run up the engine until the thermostat opens the oil level may lie above the Max mark on the engine dipstick when delivered The level can then only be assessed after the engine has been run up 3 1 Commissioning 3 1 1 3 Initial Engine Oil Fill Up B FM 2011 Genset Engine Fill oil into oil pan up to Max mark on engine dipstick for oil quantity see 9 1 Start engine and allow to run at low idling speed for approx 2 mins Switch off engine Check oil level and fill up with oil up to upper Max mark 3 1 2 Adding Fuel CRU Use only commercial grade diesel fuel For fuel grade see 4 2 Use summer or winter grade fuel depending on the ambient temperature Never fill the tank while the engine is running Ensure cleanliness Do not spill fuel Engine Operation 2004 2004 Engine Operation 3 1 3 Other Preparations e Check battery and cable connectors see 6 7 1 Transport hooks Remove if fitted see 6 7 3 e Trial run After engine has been prepared let it run for about 10 minutes without being loaded During and after trial run Check engine for leaks After engine has b
33. lever Speed control lever Oil dipstick Oil drain plug Crankcase Oil fill point on side of crankcase Fuel pump Easy change fuel filter Connecting facility for oil heater Lube oil replacement filter Removable coolant intake hood Injection pumps Oil cooler 2 2 Engine Illustration Engine Description 2 2 2 Exhaust Side FL 2011 22 Date plate 23 Optional attachment of an SAE housing 24 Flywheel with ring gear 25 Starter 26 Front cover 27 Crankcase 28 Exhaust manifold 29 Air intake pipe EN r 4 Ti gt La S PPLE En LI A gt Sg k A i 2 WUE SS SSI le Gee iS Y DA j ENS 7 D ay 2004 2004 Engine Description 2 2 Engine Illustration 2 2 3 Operation Side Example BF4L 2011 1 Oil filler neck valve gear housing cover 2 Charge air line air intake line 3 Fan with integrated generator 4 Narrow V belt 5 Tractive electromagnet 6 Wheel house cover 7 V belt pulley on crankshaft 8 Oil pan 9 Shut off lever 10 Speed control lever 11 Oil dipstick 12 Crankcase 13 Oil fill point on side of crankcase 14 Fuel pump 15 Easy change fuel filter 16 Connecting facility for oil heater 17 Charge pressure dependent full load stop CPD 18 Lube oil replacement filter 19 Removable coolant intake hood 20 Injection pumps 21 Oil cooler 2 2 Engine Illustration Engine Description 2 2 4 Exhaust Side Example BFAL 2011 22 Cylinder head 23 Exhaust manifold l
34. lowing commissioning of new and overhauled engines Duly completed maintenance jobs can be recorded and signed off in the above chart 5 4 Maintenance Work Completed Service Op hours Date Signature stamp Op hours Date Signature stamp 2875 3000 3125 3250 3375 3500 3625 3750 3875 4000 4125 4250 4375 4500 4625 4750 4875 5000 5125 5250 5375 5500 5625 5750 Duly completed maintenance jobs can be recorded and signed off in the above chart Service 5 4 Maintenance Work Completed Op hours Date Signature stamp Op hours Date Signature stamp 5875 6000 6125 6250 6375 6500 6625 6750 6875 7000 7125 7250 7375 7500 7625 7750 7825 8000 8125 8250 8375 8500 8625 8750 Duly completed maintenance jobs can be recorded and signed off in the above chart 5 4 Maintenance Work Completed Service Op hours Date Signature stamp Op hours Date Signature stamp Service and Maintenance 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 6 8 Engine Cleaning C 2004 C 2004 Service and Maintenance 6 1 1 Oil Change Intervals e Oil change intervals are dependent on engine application and quality of lube oil e If engine runs fewer h
35. mes away when working on the fuel system Do not smoke Service and Maintenance 25 881 0 Manually screw in new cartridge until gasket is flush Tighten fuel filter cartridge with final half turn Open fuel shut off valve Check for leaks C 2004 C 2004 Service and Maintenance 6 2 2 Clean Replace Fuel Filter Cup Switch off engine Loosen fuel oil filter cover 1 and unscrew in anticlockwise direction Carefully loosen paper filter cartridge 3 upwards from guide 4 Catch any escaping fuel Replace paper filter cartridge 3 Clean any dirt from sealing surface of filter carrier and fuel filter cover 1 and from guide 4 Keep naked flames away when working on the fuel system Do not smoke Replace and lightly oil rubber gasket 2 e Carefully insert new paper filter cartridge 3 into guide 4 Tighten fuel filter cover 1 in clockwise direction 25 Nm e Start engine Check fuel filter attachment for leaks 6 2 Fuel System 6 2 Fuel System Service and Maintenance 6 2 3 Clean Strainer of Fuel Filter 6 2 4 Change Fuel Leakage Line il Close fuel shut off valve Mount fuel strainer cover 2 Close fuel shut off valve Loosen and unscrew hexagonal nut 1 Tighten hexagonal screw 1 Disconnect rubber hoses 3 from injection Remove fuel strainer cover 2 cover and Check
36. nd reducing engine efficiency If the ambient temperature is less than 0 C winter grade fuel suitable down to 15 C should be used This fuel is usually available from filling stations well in advance of the cold months Diesel fuel containing additives Super diesel is often on sale as well for use down to 20 C At temperatures below 15 C to 20 C kerosene should be added to the diesel fuel The relevant percentages are given in the adjacent diagram If summer grade diesel fuel must be used at temperatures below 0 C up to 60 kero sene can be added see diagram In most cases adequate resistance to cold can also be obtained by adding a flow improver additive Please inquire at DEUTZ SERVICE Operating Media 32 0 l 23 5 14 10 5 15 4 20 13 25 B Il 22 30 0 10 20 30 40 50 60 L 1 4 CEAN Summer grade diesel fuel Winter grade diesel fuel Ambient temperature B Percentage of kerosene added Diesel fuels must never be mixed with petrol Normal and Super grades Mix in tank only Fill with the appropriate amount of kerosene first then add the diesel fuel 2004 7002 Service 5 1 Service Plan 5 2 Scheduled Maintenance Plan 5 3 Maintenance Chart 5 4 Maintenance Work Completed 2004 Service 5 1 Service Plan Deutz maintenance and service schedule E check 6 _adjust O clean A replace WE In
37. ns of the injection and regulating system may also influence the performance ofthe engine and its emissions Adherence to legislation on pollution cannot be guaran teed under such conditions Donotchange convert or adjust the cooling air intake area to the blower The manufacturer shall not be held respon sible for any damage which results from such work When carrying out maintenance repair op erations 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 thatthe electrical systems have been switched off and the ignition key has been removed Accident prevention guidelines concerning electrical systems e g VDE 0100 0101 0104 0105 Electrical protective measures against dangerous touch voltage are to be observed When cleaning with fluids all electrical components are to be covered impermeably Engine Serial Number Please enter the engine serial number here This number should be quoted when inquiring about Customer Service Repairs or Spare Parts see Section 2 1 Technical modifications required to improve our engines are reserved with regard to specification data and other technical information
38. on excessive Engine smokes blue white black Cause Section e Electric cable connections to starter electrical system loose or oxidised Electrics Ch e Starter defective or pinion does not engage Ch e Solenoid defective release switch Ch e e e Incorrect valve clearance Engine A e e Injection line leaks Ch e Injection valve defective Ch Rp Engine Preservation 8 1 Preservation Engine Preservation If the engine is to remain idle for an extended period of time itis necessary to take protective measures to preventrusting The preservative measures described here will protect the engine for up to 6 months The procedure will have to be reversed before the engine is recommissioned Anti corrosion oils to specification MIL L 21260B TL 9150 037 2 Nato Code C 640 642 Anti corrosion media for exterior protection only to specification Nato Code C 632 Recommended cleaning agent to remove pre servatives Petroleum benzine hazardous materials class A3 8 1 1 Preserving Engine Clean engine using high pressure equipment or with cold cleansing agent in emergency Run engine until warm then turn off Drain engine oil see 6 1 2 and fill with anti corrosion oil e If necessary clean oil bath cleaner see 6 4 3 and fill with anti corrosion oil Drain fuel tank Make up a mixture of 90 diesel fuel and 10 anti corrosion oil and re
39. ours during year than stated in table oil should be changed at least once a year e Table refers to following conditions sulphur content max 0 5 by weight for diesel fuel continuous ambient temperature to 10 C 14 F e If sulphur content is gt 0 5 to 1 or continuous ambient temperature below 10 C 14 F intervals between oil changes should be halved In case of fuels containing more than 1 sulphur contact your service representative Change oil with engine off but still warm lube oil temperature approx 80 C e Gensets as referred to here are units operating in parallel with the mains with each other Emergency power units are dealt with in TC 0199 99 1126 6 1 Lubrication System 6 1 Lubrication System 6 1 1 1 Equipment Engines Service and Maintenance Lube oil grade Deutz lube oil quality class DQC DOC II DOC III ACEA specfication E2 96 E3 96 E5 02 E4 99 API specfication CF CF 4 CG 4 CH 4 Worldwide specification DHD 1 special DEUTZ release list see chap 4 1 2 1 Standard lube oil code for building EO EO C equipment and nonraod vehicles EO A EO B Engine Engine version Lube oil change intervals in op hours series Oil use Oil use Oil use normal high normal high normal high 1011 2011 Naturalli aspirated engines Turbocharged engines 500 C 2004 C 2004 Service and Maintenance 6 1 2 Check Oil Level Change En
40. re in warm condition oil temperature 110 C at 900 rpm lowidling speed bar 1800 rpm bar max 2800 rpm bar Engine with Thermostat Oil change quantity without external cooler see 3 1 1 2 without filter approx i Oil change quantity without external cooler see 3 1 1 2 filter replacement standard 0 5 litre approx l Genset Engine without Thermostat Oil change quantity including external cooler see 3 1 1 3 without filter approx Oil change quantity including cooler see 3 1 1 3 filter replacement standard 0 5 litre approx I Valve clearance with cold engine Engine cooling time at least 30 min oil temperature should be below 80 C mm Start of feed crankshaft BTDC Injector opening pressure vehicle unit bar Firing order of engine V belt tension pretension retension after engine has been running under load for 15 mins N 4 stroke diesel engine Naturally aspirated engine with direct injection On left when looking at flywheel Refer to head office 9 1 Engine Specifications and Settings 1 Engine power speed start of delivery are stamped on engine rating plate see also 2 1 2 Approx values can vary depending on sump and or cooler design external cooling system Upper oil dipstick mark is always authoritative 3 Values for engines without engine oil heating 9 1 Engine Specifications and Settings Model Numb
41. speed bar 1800 rom bar max 2800 rom bar Oil change quantity oil pan approx I f a Oil change quantity with filter standard 0 51 approx I 65 Dat ee pa 1 10 5 2 Valve clearance with cold engine Engine cooling time at least 30 min oil temperature should be below 80 C mm Start of feed crankshaft BTDC Injector opening pressure vehicle unit bar Firing order of engine V belt tension pretension retension after engine has been running under load for 15 mins IN Engine power speed start of delivery are stamped on engine rating plate see also 2 1 2 Approx values can vary depending on sump and or cooler design external cooling system Upper oil dipstick mark is always authoritative 9 Values for engines without engine oil heating re AN 9 1 Engine Specifications and Settings Model Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle Combustion system Direction of rotation Weight without cooling system Weight without starter with alternator as per DIN 70020 A approx Engine output Speed Lubrication SAE oil Maximum oil temperature in oil pan at 900 rpm low idling speed 1800 rpm max 2800 rpm Oil change quantity oil pan without cooling system ca Oil change quantity with filter Standard 0 5 I Valve clearance with cold engine Engine cooling time at least 30 min oil temperature
42. st Side Example FM 2011 Operation Side Example BFM 2011 Exhaust Side Example BFM 2011 Oil Circuit Lube Oil Circuit Schematic Fuel System Schematic Fuel System Coolant System Coolant Plan 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 2 3 2 1 3 3 3 3 1 3 3 2 3 4 3 4 1 3 4 2 3 5 3 5 1 3 3 2 4 4 1 4 1 1 4 1 2 4 2 4 2 1 4 2 2 5 5 1 5 2 5 3 5 4 Engine Operation Commissioning Adding Engine Oil Adding Fuel Other Preperations Additional Maintenance Work Starting Electric Starting Monitoring Operation Engine Oil Pressure Engine Temperature Shutting Off Mechanical Shut Off Electric Shut Off Operating Conditions Winter Operation High Ambient Temperature High Altitude Operating Media Lube Oil Quality Viscosity Fuel Quality Winter Grade Fuel Service Service Plan Scheduled Maintenance Plan Maintenance Chart Maintenance Work Completed Contents 6 Service and Maintenance 6 1 6 1 1 6 1 2 6 1 3 6 1 4 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 3 6 3 1 6 4 6 4 1 6 4 2 6 4 3 6 5 6 5 1 6 5 2 6 5 3 6 6 6 6 1 6 6 1 6 7 6 7 1 6 7 2 6 7 3 6 8 6 8 1 Lubrication System Oil Change Intervals Check Oil Level Change Engine Oil Changing Oil Filter Clean Replace Oil Filter Cup Fuel System Replace Fuel Filter Clean Replace Fuel Filter Cup Clean Stainer of Fuel Filter Change Fuel Leakage Line Cooling System Cleaning Intervals Combustion Air Filter Cleaning Intervals Emptying Cyclone
43. st discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows e Clean discharge slot from time to time Remove any caked dirt by pressing together upper section of valve Filter Cartridges Undo clip fasteners 1 Take off hood 2 and remove cartridge 3 Clean cartridge replace at least once a year Clean cartridge 3 Using dry compressed air max 5 bar blow out from inside to outside or in difficult cases tap out taking care not to damage cartridge or wash according to manufacturer s instructions Gaskets on filter cartridge can become damaged through regular removal and replacement Check paper filter light showing through and gaskets for damage Replace if necessary 6 4 Combustion Air Filter After five cleaner services or after two years at latest replace safety cartridge 4 never clean To do so Undo hex nut 5 and remove cartridge 4 Install new cartridge fit and tighten hex nut Install cartridge 3 replace hood 2 and do up clip fasteners 1 Never clean filter cartridge with pet rol or hot fluids 6 5 Belt Drives 6 5 1 Check V belt SEIEN e Visually inspect entire V belt for damage Replace damaged V belts After installing new belts run engine for 15 minutes then check belt tension To check tension of V belt use tension gauge see 9 3 Place indicator arm 1 into gauge Position guide 3 on V belt 2 midway between pulleys with
44. stop against edge of belt Push slowly on black pad 4 at right angles to V belt 2 until spring is heard or felt to trigger Service and Maintenance Carefully remove gauge without altering posi tion of indicator arm 1 Read off value where black indicator arm 1 intersects scale 5 arrow For settings see 9 1 If necessary retension belt and measure again Check tension and change belts only with engine off Refit belt guard if provided After installing new belts run engine for 15 min utes then check belt tension Service and Maintenance 6 5 2 Tensioning Alternator Belts e Slacken off bolts 1 2 and 3 Adjust alternator 4 in direction of arrow by turning bolt3 until correct belttension is achieved Retighten bolts 1 2 and 3 Check tension and change belts only with engine off Refit belt guard if provided 6 5 3 Changing Alternator Belts Oy D KO Slacken off bolts 1 2 and 3 Adjust alternator 4 in direction of arrow by turning bolt 3 Remove and replace belt Adjust alternator 4 against direction of arrow by turning bolt 3 until correct belt tension is achieved Retighten bolts 1 2 and 3 6 5 Belt Drives 6 6 Adjustments 6 6 1 Check Valve Clearance adjust if necessary Service and Maintenance Remove cylinder head cover Position crankshaft as per schematic see 6 6 1 1 Before adjusting valve clearance allow engine to
45. w 20 C after removing starter if neces Sary Smear ring gear on flywheel via pinion bore from time to time with cold resistant grease e g Bosch grease FT 1 V 31 e Cold Start Assistance At temperatures near or below freezing point use glow plugs if necessary see 3 2 1 This not only lowers starting limit temperature but provides easier starting at temperatures normally not requiring a starting aid Battery Efficient cold starting requires that battery is well charged see 6 7 1 Starting limit temperatures can be lowered by 4 5 C by heating battery up to about 20 C To do so remove battery and store in warm place Engine Operation 26 248 p 2004 2004 Engine Operation 3 5 2 High Ambient Temperature High Altitude e Air density decreases as altitude or ambient temperature increases As a result of this the engine s maximum output quality of exhaust gas temperature level and in extreme cases starting behaviour are impaired Engine can be used at altitudes up to 1000 m and temperatures up to 30 C for mobile operations If the engine is to operate under more severe conditions at higher altitudes or temperatures it will be nec essary to reduce the injected fuel quantity and thus engine power e If you have any doubts about engine operation under these or similar conditions ask your en gine or equipment supplier whether the engine has been derated in the interests of

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