Upload
anonymous-iu95trpxn
View
237
Download
1
Embed Size (px)
Citation preview
7/24/2019 S08 DEUTZ-2011a
1/81
C2000
OperationM
anual
2011
7/24/2019 S08 DEUTZ-2011a
2/81
C2000
Pleasereadandobservetheinformationgivenin
thisOp
erationManual.Thiswillenabley
outo
avoid
accidents,preservethemanufacturers
warranty
and
maintain
the
enginein
peak
operatingcondition.
T
hisen
ginehasbeenbuiltexclusivelyforthe
applicationspecifiedinthescopeofsupply-as
describ
edbytheequipmentmanufacturer-and
istobe
usedonlyfortheintendedpurpose.
Any
useexceedingthatscopeisconsidered
tobe
contra
ry
to
the
intended
purpose.
The
manufa
cturerwillnotassumeresponsibilityfor
anyda
mageresultingtherefrom.
The
risks
involvedaretobebornesolelybytheuse
r.
U
sein
accordancewiththeintendedpu
rpose
alsoimpliescompliancewiththeconditionslaid
down
bythemanufacturerforoperation,
maintenanceandservicing.
Theengines
hould
onlybe
operatedbypersonneltrainedinitsuse
andthe
hazardsinvolved.
T
herele
vantaccidentpreventionguideline
sand
otherg
enerallyacceptedsafetyandindustrial
medicin
eregulationsmustbeobserved.
U
nauthorisedenginemodificationswillinvalidate
anyliab
ilityclaimsagainstthemanufacturerfor
resultantdamage.
Manipu
lationsoftheinjectionandregu
lating
system
mayalsoinfluencetheperformanceof
theengine,anditsemissions.
Adheren
ceto
legislationonpollutioncannotbeguara
nteed
unders
uchconditions.
D
onotchange,con
vertoradjustthecoolingair
intakeareatotheb
lower.
Themanufacturers
hallnotbeheldresponsible
foranydamagewh
ichresultsfromsuchwork.
W
hencarryingoutm
aintenance/repairoperations
ontheengine,theu
seofDEUTZoriginalpartsis
prescribed.
Thesearespeciallydesignedforyourengineand
guaranteeperfecto
peration.
Non-complianceresultsintheexpiryofthe
warranty!
7/24/2019 S08 DEUTZ-2011a
3/81
C2000
O
perationmanual
2
011
0
2979929en
EngineSerial
Number:
Pleaseentertheengineserialnumberhere.
This
numbershouldbequotedw
heninquiringabout
CustomerService,
Repairs
orSpareParts(see
Section2.1
).
Technicalmodificationsrequiredtoimproveour
enginesarereservedwithre
gardtospecification
dataandothertechnicalinfo
rmationcontainedin
thisOperationManual.NopartsofthisManualmay
bereproducedinanyformor
byanymeanswithout
ourwrittenapproval.
7/24/2019 S08 DEUTZ-2011a
4/81
Fore
word
DearCu
stomer,
Liquid-cooledDeutzenginesaredesigned
fora
largenumberofapplications.Consequently,awide
rangeofva
riantsisofferedtomeettherequirements
ofspecific
cases.
Yourengineisappropriatelyequippedfo
rthe
installationconcerned,whichmeansthatnotallof
thecompo
nentsdescribedinthisOperationM
anu-
alarenecessarilyfittedtoyourengine.
Wehavee
ndeavouredtohighlightanydiffer
ences
sothatyouwillbeabletolocatetheoperatin
gand
maintenan
ceinstructionsrelevanttoyoure
ngine
quicklyan
deasily.
PleasereadthisManualbeforestartingyourengine,
andalwaysobservetheoperatingandmaintenance
instructions.
Weareava
ilabletohelpwithanyadditionalinq
uiries
Sincerely,
DEUTZAG
7/24/2019 S08 DEUTZ-2011a
5/81
Contents
1.
General
2.
EngineDescription
2.1
Model
2.1.1
RatingPlate
2.1.2
PositionoftheRatingPlate
2.1.3
EngineSerialNumber
2.1.4
CylinderNumbering
2.1.5
FuelDeliveryLock
2.2
EngineIllustrations
2.2.1
OperationSide:
ExampleFL2011
2.2.2
ExhaustSide:
ExampleFL2011
2.2.3
OperationSide:
ExampleBF4L2011
2.2.4
ExhaustSide:
ExampleBF4L2011
2.2.5
OperationSide:
ExampleFM2011
2.2.6
ExhaustSide:
ExampleFM2011
2.2.7
OperationSide:
ExampleBFM2011
2.2.8
ExhaustSide:
ExampleBFM2011
2.3
OilCircuit
2.3.1
LubeOilCircuitSchematic
2.4
FuelSystemSchematic
2.4.1
FuelSystem
2.5
CoolantSystem
2.5.1
CoolantPlan
3.
EngineOperation
3.1
Commissioning
3.1.1
AddingEngineOil
3.1.2
AddingFuel
3.1.3
OtherPreperations
3.1.4
Addition
alMaintenanceWork
3.2
Starting
3.2.1
ElectricStarting
3.3
MonitoringOperation
3.3.1
EngineO
ilPressure
3.3.2
EngineT
emperature
3.4
ShuttingO
ff
3.4.1
MechanicalShut-Off
3.4.2
ElectricShut-Off
3.5
Operating
Conditions
3.5.1
WinterO
peration
3.5.2
HighAm
bientTemperature,H
ighAltitude
4.
OperatingMedia
4.1
LubeOil
4.1.1
Quality
4.1.2
Viscosity
4.2
Fuel
4.2.1
Quality
4.2.2
Winter-G
radeFuel
5.
Service
5.1
ServicePlan
5.2
Scheduled
MaintenancePlan
5.3
Maintenan
ceChart
5.4
Maintenan
ceWorkCompleted
6.
ServiceandMain
tenance
6.1
LubricationSystem
6.1.1
OilChangeIntervals
6.1.2
CheckOilLevel,ChangeEngineOil
6.1.3
ChangingOilFilter
6.1.4
Clean/ReplaceOilFilter(Cup)
6.2
FuelSystem
6.2.1
ReplaceFuelFilter
6.2.2
Clean/ReplaceFuelFilter(Cup)
6.2.3
CleanStainerofFue
lFilter
6.2.4
ChangeFuelLeakag
eLine
6.3
CoolingSystem
6.3.1
CleaningIntervals
6.4
CombustionAirFilter
6.4.1
CleaningIntervals
6.4.2
EmptyingCyclone-T
ypePrecleaner
6.4.3
DryTypeAirCleaner
6.5
BeltDrives
6.5.1
CheckV-belt
6.5.2
TensioningAlternatorBelts
6.5.3
ChangingAlternator
Belts
6.6
Adjustments
6.6.1
CheckValveClearance,a
djustifnecessary
6.6.1.1
ValveClearanceAdjustmentSchematic
6.7
Accessories
6.7.1
Battery
6.7.2
RotaryCurrentAlternator
6.7.3
TransportationShac
kles
6.8
EngineCleaning
6.8.1
EngineCleaning
7/24/2019 S08 DEUTZ-2011a
6/81
C2000
Cont
ents
7.
Faults,
CausesandRemedies
7.1
FaultTable
8.
EnginePreservation
8.1
P
reservation
8.1.1
P
reservingEngine
8.1.2
R
emovingEnginePreservatives
9.
TechnicalSpecification
9.1
E
ngineSpecificationsandSettings
9.2
T
orqueWrenchSettings
9.3
T
ools
10
.
Service
7/24/2019 S08 DEUTZ-2011a
7/81
C2000
7/24/2019 S08 DEUTZ-2011a
8/811
C2000
G
enera
l
DEUTZE
ng
ines
Serv
icean
dMaintenance
Thissy
mbolisusedinthecaseofall
safety
instructions.
Failuretocom-
plywiththeseinstructionsplaces
thehe
althandlifeoftheaffected
person
sinimmediatedanger.Please
follow
themcarefully.Theattention
ofoperatingpersonnelshouldbedrawntothese
safetyinstructions.G
eneralsafetyandaccident
preventionregulationslaiddownbylawmustalso
beobserved.
Serv
ice
Pleasecontactoneofourauthorisedservicerepre-
sentativesintheeventofbreakdo
wnsorforspare
partsinquiries.Ourtrainedspecialistswillcarryout
repairsquicklyandprofessionally,
usingonlygenu-
inespareparts.
Beware
ofRunn
ing
Eng
ine
Shutthee
nginedownbeforecarryingoutm
ainte-
nanceorrepairwork.Ensurethattheenginec
annot
beaccidentallystarted-accidentsmayothe
rwise
occur.
Whenthe
workiscomplete,
besuretorefitany
panelsandguardsthathavebeenremoved.
Observein
dustrialsafetyregulationswhenru
nning
theengine
inanenclosedspaceorunderground.
Workclothingmustbetight-fittingwhenworking
ontherun
ningengine.
Neverfillthefueltankwhiletheengineisrunning.
willensurethattheen
ginecontinuestomeetyour
requirements.Recomm
endedserviceintervalsmust
beobservedandma
intenanceworkcarriedout
conscientiously.
Spec
ialcareshouldbetakenun-
derabnormallydemandingoperatingconditions.
As
bestos
Sa
fety !
aretheproductofmanyyearsofresearchand
development.Theresultingknow-how,co
upled
withstringentqualitystandards,guarantee
their
longservicelife,
highreliabilityandlowfue
lcon-
sumption.
Itgoeswithoutsayingthatthehighest
standards
forenvironmentalprotectionarealso
met.
DEUTZenginecomponentsareas-
bestos-free.
7/24/2019 S08 DEUTZ-2011a
9/81
2C2001
EngineDescription
2.1
Model
2.2
EngineIllustrations
2.3
Lube
OilCircuitSchematic
2.4
Fuel
System
Schematic
7/24/2019 S08 DEUTZ-2011a
10/812
C2001
C
3
1864
0
26
332
2
A
B
31865
0
EngineDescription
2
.1Model
2.1.1
R
atingPlate
Themode
lA,theengineserialnumberBa
ndthe
performan
cedataarestampedontherating
plate.
Themodelandengineserialnumbermustbe
given
whenorderingparts.
2.1.2
Positiono
ftheRatingPlate
TheratingplateCi
sa
ttachedtothevalvecover.
2.1.3
EngineSerialNumber
TheengineserialnumberB
isstampedonthe
crankcaseDa
swellastherating
plate.
7/24/2019 S08 DEUTZ-2011a
11/81
2C2001
!
1
2
3
4
26431
0
263870
2.1
Model
EngineDescription
2.1.
4
CylinderNumbering
Cylindersarenumberedconsecutively,
beginning
atthe
flywheel.
2.1.5
FuelD
eliveryLock
Themanufacturershallnotbeheldliablefordam-
agesresultingfro
madjustmentsmadetotheregu-
latorbytheopera
tor.
Thelockscrewsareprotectedinordertoprevent
this:
1.withlockingpaintonmodel:
withtorqueba
lancer
2.withplasticprotectivecaponmodel:
withouttorque
balancer.
A
djustmentstotheregulatorareto
b
ecarriedoutonlybyauthorised
D
EUTZSERVICEspecialists
7/24/2019 S08 DEUTZ-2011a
12/812
C2001
318731
1 2 3 4 5 76
16
15
21
20
19
18
17
9
8
12
14
13
11
10
EngineDescription
2.2
EngineIllustration
2.2.1
O
perationSide
F
L2011
1
Oilfillerneck(valve-gearhou
singcover)
2
Charge-airline/air-intakelin
e
3
Fanwithintegratedgenerator
4
NarrowV-belt
5
Tractiveelectromagnet
6
Wheel-housecover
7
V-beltpulleyoncrankshaft
8
Oilpan
9
Shut-offlever
10
Speedcontrollever
11
Oildipstick
12
Oildrainplug
13
Crankcase
14
Oilfillpoint(onsideofcrank
case)
15
Fuelpump
16
Easy-changefuelfilter
17
Connectingfacilityforoilhea
ter
18
Lubeoilreplacementfilter
19
Removablecoolantintakeho
od
20
Injectionpumps
21
Oilcooler
7/24/2019 S08 DEUTZ-2011a
13/81
2C2001
318741
2.2EngineIllustratio
n
EngineDescription
2.2.
2
ExhaustSide
FL2011
22
Dateplate
23
Optionalattachmentofa
nSAEhousing
24
Flywheelwithringgear
25
Starter
26
Frontcover
27
Crankcase
28
Exhaustmanifold
29
Airintakepipe
22
24
23
29
28
27
26
26
7/24/2019 S08 DEUTZ-2011a
14/812
C2001
318691
3 4 76
15
14
20
19
18
17
16
21
1
2
9
8
10
11
12
13
5
EngineDescription
2.2
EngineIllustration
2.2.3
O
perationSide
E
xample:BF4L2011
1
Oilfillerneck(valve-gearhou
singcover)
2
Charge-airline/air-intakelin
e
3
Fanwithintegratedgenerator
4
NarrowV-belt
5
Tractiveelectromagnet
6
Wheel-housecover
7
V-beltpulleyoncrankshaft
8
Oilpan
9
Shut-offlever
10
Speedcontrollever
11
Oildipstick
12
Crankcase
13
Oilfillpoint(onsideofcrank
case)
14
Fuelpump
15
Easy-changefuelfilter
16
Connectingfacilityforoilhea
ter
17
Charge-pressure-dependentfull-loadstop
(CPD)
18
Lubeoilreplacementfilter
19
Removablecoolantintakeho
od
20
Injectionpumps
21
Oilcooler
7/24/2019 S08 DEUTZ-2011a
15/81
2C2001
3
1868
1
22
23
24
2
6
2
8
3
0
2
7
2
9
3
1
3
2
2
5
2.2
EngineIllustration
EngineDescription
2.2.
4
ExhaustSide
Example:BF4L2011
22
Cylinderhead
23
Exhaustmanifoldline
24
Flywheelwithringgear
25
Starter
26
Crankcase
27
Lubeoilfeedlinetoturb
ocharger
28
Lubeoilreturnlinefrom
turbocharger
29
Inductionpipe
30
Turbocharger(TC)
31
Intakemanifold
32
Charge-airline
7/24/2019 S08 DEUTZ-2011a
16/812
C2001
31875
0
EngineDescription
2.2
EngineIllustration
2.2.5
O
perationSide
F
M2
011
1
Oilfillerneck(valve-gearhou
singcover)
2
Charge-airline/air-intakelin
e
3
Alternator
4
NarrowV-belt
5
Tractiveelectromagnet
6
Timingbeltcover
7
V-beltpulleyoncrankshaft
8
Oilpan
9
Shut-offlever
10
Speedcontrollever
11
Oildipstick
12
Oildrainplug
13
Oilfillpoint(onsideofcrank
case)
12
Crankcase
14
Fuelpump
15
Easy-changefuelfilter
16
Connectingfacilityforoilhea
ter
17
Lubeoilreplacementfilter
18
Injectionpump(s)
19
Oilcoolerconnection
20
Fuelleakageline
21
Injectionvalve(s)
1 2 3 4 5 76
16 1521 20 19 18 17
9
8
14
13
12
1
1
10
7/24/2019 S08 DEUTZ-2011a
17/81
2C2001
31876
0
2.2
EngineIllustration
EngineDescription
2.2.
6
ExhaustSide
FM
2011
22
23
24
28
27
26
25
22
Cylinderhead
23
Exhaustmanifold
24
Flywheelwithringgear
25
Starter
26
Starterguard(optional)
27
Crankcase
28
Airintakepipe
7/24/2019 S08 DEUTZ-2011a
18/812
C2001
3
1
861
0
1 2 43
12 1118 17 16 15 14 13
7
6
5
10
9
8
EngineDescription
2.2
EngineIllustration
2.2.7
O
perationSide
B
FM
2011
1
Air-intakepipe
2
Fanwheel
3
V-beltpulleyoncrankshaft
4
NarrowV-belt
5
Tractiveelectromagnet
6
Timingbeltcover
7
Shut-offlever
8
Speedcontrollever
9
Oilfillpoint(onsideofcrank
case)
10
Oildipstick
11
Fuelpump
12
Easy-changefuelfilter
13
Connectingfacilityforoilhea
ter
14
Lubeoilreplacementfilter
15
Injectionpump(s)
16
Oilcoolerconnection
17
Injectionvalve(s)
18
Fuelleakageline
7/24/2019 S08 DEUTZ-2011a
19/81
2C2001
19
28
20
21
24
22
23
27
26
25
2.2
EngineIllustration
EngineDescription
2.2.
8
ExhaustSide
BFM
2011
19
Crankcaseventilation(optional)
20
Cylinderheadcover
21
Exhaustmanifold
22
SAEhousing
23
Starter
24
Crankcase
25
Turbocharger
26
Generatorwithcover
27
Charge-airline
28
Oilfillerneck
3
1
8620
7/24/2019 S08 DEUTZ-2011a
20/812
C2001
31877
0
EngineDescription
2.3
O
ilCircuit
2.3.1
L
ubeOilCircuitSchematic
1
Oilpan
2
Oil-intakepipe
3
Oilpump
4
Mainoilduct
5
Oil-cooledcylinders
6
Cylinderheadcoolingneck
7
Oilductforrockerarmlubric
ation
8
Rockerarm
9
Oilmanifoldforthethermostat
10
Intaketoexternalengineoilc
ooler
11
Returnfromexternalengineoilcooler
12
Thermostathousingwithslid
ethermostat
13
Oilducttooilfilter
14
Oilfilter
15
Oilducttocam,con-rodand
crankshaftbear
ings
16
Spraynozzleforpistoncooling
17
Oilreturnviacrankcasetooilpan
18
Lubeoilintaketoturbocharg
er
19
Turbocharger
20
Returnfromturbochargerto
oilpan
51
4
3
2
16
18
17
14
11
8
15
9
10 1312
67
20
71
9
1
8
7/24/2019 S08 DEUTZ-2011a
21/81
2C2001
8
11
10
9
5 412
7
2
3
6
1
318630
2.4
FuelSystem
Sche
matic
EngineDescription
2.4.
1
FuelSystem
1
Fuellinefromtanktofuelpump
2
Fuelpump
3
Fuellinefromfuelpump
toeasy-changefuel
filter
4
Easy-changefuelfilter
5
Fuellinefromfiltertoinjectionpump
6
Injectionpump
7
Fueldistributorline
8
Injectionline
9
Injectionvalves
10
Fuelleakageline
11
Fueloverflowpipe
12
Fuelreturnlinetotank
Theinstallationofafuelpre-filter/
handpumpb
etweenthefueltank
andtheeng
ineisprescribedto
protecttheenginesagainstdirtin
thefuel.
!
7/24/2019 S08 DEUTZ-2011a
22/812
C2001
7/24/2019 S08 DEUTZ-2011a
23/81
7/24/2019 S08 DEUTZ-2011a
24/813
OIL
3.1.1.2
InitialEngineO
ilFill-Up
B/FM
2011
26
432
0
EngineOperation
3.1
Commissioning
3.1.1
A
ddingEngineOil
Asaru
le,
eng
inesare
de
livere
dw
ithouto
il.
Pour
lube
oilintotheo
ilfillernec
k(arrow
).
Foro
ilgra
dean
dv
iscos
ity,see
4.1.
Fillo
ilintoo
ilpanu
pto"Max."
markoneng
ine
dipstic
k(foro
ilquantitysee
9.1
).
Starteng
inean
dall
owtorunat
low
idlingspee
d
forapprox
.2m
ins.
Sw
itc
ho
ffeng
ine.
Chec
ko
illeve
l,ifne
cessary
,topupo
ilto"Max."
mark
.
Fillo
ilintoo
ilpanupto"Min."
markoneng
ine
dipstic
k.
Ina
ddition
,topupo
ilquantity
ofsupp
lyhoses
an
do
fexterna
loilcoo
ler
(accor
dingtomanu
fac-
turersspec
ifications
).
Alloweng
inetorunwarmuntilt
hermostatopens
(atapprox
.95
C).
Alloweng
inetorun
forapprox
.2m
ins
.
Sw
itc
ho
ffeng
ine
.
Chec
ko
illeve
l,an
difnecessa
ry,
topupo
ilto
"Max."
mark
.
3.1.1.1
Initial
EngineOilFill-Upfor
B/FL2011
Ifthepersonoperatingtheeng
ine
doesnotrunup
theeng
ineunti
lthethermostatop
ens
,theo
illeve
l
may
liea
bovethe"Max."
mark
ontheeng
ine
dipstic
kw
hen
de
livere
d.
The
level
canthenon
lybe
assesse
da
ftertheeng
ine
has
bee
nrunup
.
7/24/2019 S08 DEUTZ-2011a
25/81
3
!
F
UEL
26398
0
3.1
Commissioning
EngineO
peration
3.1.
1.3
InitialEngineOilFil
l-Up
B/FM
2011GensetE
ngine
Filloilintooilpanupto"Max."mark
onengine
dip
stick(foroilquantitysee9.1
).
Startengineandallowtorunatlowid
lingspeed
for
approx.
2mins.
Sw
itchoffengine.
Ch
eckoillevelandfillupwithoiluptoupper
"M
ax."mark.
3.1.2
Adding
Fuel
Useonlycommercial-gradedieselfuel.Forfuel
grade,see4.2.U
sesummerorwinter-gradefuel,
dependingonthe
ambienttemperature.
Neverfillthetankwhiletheengine
is
running.
Ensurecleanliness!
Donotspillfuel!
7/24/2019 S08 DEUTZ-2011a
26/813
EngineOperation
3.1
Commissioning
3.1.3
O
therPreparations
Checkbatteryandcableconnectors,
see6.7
.1.
Transporthooks
Removeiffitted(see6.7.3
)
Trialrun
Afterenginehasbeenprepared,
letitrunfor
about1
0minuteswithoutbeingloaded.
During
andaftertrialrun
-Check
engineforleaks.
Afteren
ginehasbeenturnedoff
-Check
oillevel,
see6.1.2.
Topupwithoil,
ifnecessary,
see3.1.1.
-Reten
sionV-belt,
see6.5
).
3.1.4
AdditionalMaintenanceWork
Whencommissioning
newandreconditioneden-
gines,thefollowinga
dditionalmaintenancework
mustbecarriedout:
Changelubeoil,
see6.1.1.+6.1.2.
Changeoilfiltercartridge,
see6.1.3.
Changefuelfiltercartridge,
see6.2.1.
CheckV-beltsandretensionasnecessary,
see6.5.
Checkengineforle
aks
Checkenginemounts,retightenifnecessary,
see9.2.
Checkvalveclearance,adjustifnecessary,
see5.1.+6.6.1.
7/24/2019 S08 DEUTZ-2011a
27/81
3
7/24/2019 S08 DEUTZ-2011a
28/813
2 1
!
25746
2
26423
0
EngineOperation
3.2
Starting
3.2.1
E
lectricstarting
Beforestarting,makesureth
atno-
bodyisstandingintheimm
ediate
vicinityoftheengineordrive
nma-
chine.
Afterrepairwork:
Checkthatallguardshave
been
replaceda
ndthatalltoolshavebeenremovedfrom
theengine
.
Whenstar
tingwithglowplugs,donotuseany
other
startersubstance(e.g.
injectionwithstart
pilot).
Riskofac
cident!
Caution:
Ifthe
speed
regulatorhas
bee
n
re-
moved,th
eenginemustnotbetestedunderany
circumsta
nces.
Disconnectthebattery!
Donotac
tuatethestarterformorethan20sec-
onds.
Ifth
eenginedoesnotcatch,waitam
inute
thentryagain.
Iftheeng
inedoesnotcatchaftertwoatte
mpts,
refertoth
eFaultTable(see7.1
).
Wherepossible,d
isengageclutchtoseparate
enginefrom
anydr
ivenparts.
Movespeedcontro
llever1intoidleposition.
Moveshut-offhandle2intooperatingposition.
Withoutcoldstartassista
nce
Insertkey
-Position0=nooperatingvoltage
Turnkeyclockwise
-Position1=operatingvoltage
-Pilotlightscomeon
Pushkeyinandturnfurtherclockwiseagainst
springpressure.
-Position2=nofunction
-Position3=start
Releasekeyassoonasengine
fires
-Pilotlightsgoout.
7/24/2019 S08 DEUTZ-2011a
29/81
3
25746
2
3.2
Starting
EngineO
peration
With
coldstartassistance
-Glo
wplug
Ins
ertkey
-P
osition0=nooperatingvoltage
Turnkeyclockwise
-P
osition1=operatingvoltage
-P
ilotlightscomeon
Pu
shkeyinandturnfurtherclockwiseagainst
springpressure.
-P
osition2=preheat,holdforapprox
.1minute.
-P
reheatlampcomeson
-P
osition3=start
Re
leasekeyassoonasenginefires
-P
ilotlightsgoout
7/24/2019 S08 DEUTZ-2011a
30/813
25754
0
257530
25
752
1
EngineOperation
3.3
MonitoringO
peration
3.3.1
E
ngineOilPressure
O
ilPressurePilotLight
Oilpres
surepilotlightcomesonwithope
rating
voltage
onandengineoff.
Oilpre
ssurepilotlightshouldgoout
when
engine
isrunning.
OilPressureIndicator
Pointermustremainingreensectoroverentire
operatingrange.
OilPressureGauge
Pointermustindicateminimum
oilpressure
(see9.1
).
7/24/2019 S08 DEUTZ-2011a
31/81
3
24985
0
3.3
MonitoringOperation
EngineO
peration
3.3.
2
EngineTemperature
EngineTemperatureGauge
Enginetemperaturegaugepointershouldre-
ma
iningreensectormostoftime.
Itshould
rar
elyenteryellow-greensector.Ifpointerenters
orangesector,engineisoverheating.
Turnoff
andestablishcausefrom
FaultTable
(see7.1
).
7/24/2019 S08 DEUTZ-2011a
32/813
2 1
26424
0
25746
2
EngineOperation
3.4
ShuttingOff
3.4.1
M
echanicalShut-Off
Moves
peedadjustmentlever1tolowidle.
Moves
hut-offlever2untilenginecome
stoa
stop.
Charge
pilotlightandoilpressurepilotlig
htwill
comeo
nwhenenginestops.
Turnke
yanticlockwise(toposition0)andre-
move.Pilotlightswillgoout.
3.4.2
ElectricShut-Off
(IgnitionK
ey)
Turnkeyanticlockwise(toposition0)andre-
move.
Pilotlightsw
illgoout.
Ifpossible,
donotsuddenlyswitchoffenginewhen
underfullload.
7/24/2019 S08 DEUTZ-2011a
33/81
3
26248
0
3.5
OperatingConditio
ns
EngineO
peration
3.5.
1
WinterOperation
LubeOilViscosity
-S
electoilviscosity(SAEgrade)acc
ordingto
ambienttemperaturebeforestartingengine,
see4.1.2.
-In
creaseoilchangefrequencywhen
operating
below-10C,see6.1.1.
DieselFuel
-U
sewinter-gradedieselfuelforope
rationbe
lo
w0C,see4.2.2.
Ad
ditionalMaintenanceWork
-D
rainsludgefromfueltankonceaw
eek(undo
sludgedrainscrew).
-If
necessary,allowoilinoilbathairc
leanerand
engineoiltosettleatambienttemp
erature.
-B
elow-20C,afterremovingstarterifneces
sary,smearringgearonflywheelviapinion
borefrom
timetotimewithcold-re
sistant
grease.
(e.g.
BoschgreaseFT1V31).
Co
ldStartAssistance
-A
ttemperaturesnearorbelowfreezingpoint,
useglowplugsifnecessary,see3.2.1.
Thisnotonlylowersstartinglimittemperature,
butprovideseasierstartingattemp
eratures
normallynotrequiringastartingaid.
Battery
-Efficientcold
startingrequiresthatbatteryis
well-charged,see6.7.1.
-Startinglimit
temperaturescanbeloweredby
4-5Cbyheat
ingbatteryuptoabout+20C.(
To
doso,removebatteryandstoreinwarmplace).
7/24/2019 S08 DEUTZ-2011a
34/813
C
F
0
32 2
5901
1
EngineOperation
3.5
OperatingConditions
3.5.2
H
ighAmbientTemperature,
H
ighAltitude
Airden
sitydecreasesasaltitudeoram
bient
temperatureincreases.
Asaresultofthis,the
enginesmaximum
output,qualityofex
haust
gas,temperatureleveland,
inextremecases,
starting
behaviour,areimpaired.
Enginec
anbe
usedat
altitudesupto1000mandtemperatures
upto30Cformobileoperations.
Iftheengineis
tooperateundermoresevereconditions(at
higheraltitudesortemperatures),itwillbenec-
essary
toreducetheinjectedfuelquantityand
thusen
ginepower.
Ifyouh
aveanydoubtsaboutengineope
ration
undert
heseorsimilarconditions,askyouren-
gineor
equipmentsupplierwhetherthee
ngine
hasbeenderatedintheinterestsofreliability,
service
lifeandexhaustgasquality(sm
oke).
Otherw
isecontactDEUTZSERVICE.
7/24/2019 S08 DEUTZ-2011a
35/81
4C2000
Operatingmedia
4.1
Lube
Oil
4.2
Fuel
7/24/2019 S08 DEUTZ-2011a
36/814
C2001
*Oilchangeintervals,see6.1.1
Oilcapac
ities,see9.1
Onlywithengin
e
pre-heater
302981
Oper
atingMedia
4.1
LubeOil
4.1.1
Q
uality
Lubeoilsaredifferentiatedaccordingtotheirper-
formance
andqualityclass.
Incommonuseare
specificationsnamedaftertheAPI(America
nPe-
troleumIn
stitute)andACEAE
uropeanEngineOil
Sequences.
Approved
APIOils:
Minimum:
CF-4
Approved
ACEA
Oils:
Minimum:
E1-96
4.1.2
Viscosity
Astheviscosityofth
elubeoilisdependenton
temperature,thechoiceofSAEgradeshouldbe
governedbytheambienttemperatureprevailingat
theengineoperatingsite.
Optimum
operatingbe-
haviourwillbeattainedifyoutaketheaccompany-
ingoilviscositydiagramasaguide.
Shouldthetemperatu
refalltemporarilybelowthe
limitsofSAEgradese
lected,coldstartingmaybe
affectedbuttheenginewillnotbedamaged.
In
ordertokeepwearto
aminimum,
donotexceed
applicationlimitsforextendedperiodsoftime.
Oilchangesdictatedbytheseasonscanbeavoided
byusingmulti-grade
lubeoils.
Multi-gradeoils,
particularlylight-flowingoils,alsoreducefuelcon-
sumption.
7/24/2019 S08 DEUTZ-2011a
37/81
4C2000
0
10
20
30
40
50
60%
0-5
-10
-15
-20
-25
-30
+32
+23
+14
+
5
-
4
-13
-22
B
A
F
C
26441
1
I
I
I
!
!
26441
1
4.2
Fuel
Operatin
gMedia
4.2.
1
Quality
Usec
ommerciallyavailabledieselfuelwithless
than0
.5%s
ulphurcontent.Ifthesulphurcontentis
highe
r,oilchangeintervalsshouldbereduced(see
6.1.1
).
Thefollowingfuelspecifications/stan
dardsare
appro
ved:
DIN
EN590
BS
2869
AS
TMD975-96;1-Dand2-D
NA
TOCodeF-54/F-34/F-44andXF
63
Exhau
stemissionvalueswhichmaybed
etermined
inthe
caseoftypeapprovaltestsalwaysrefertothe
refere
ncefuelprescribedbytheauthoritiesforthe
typeapprovaltest.
4.2.2
Winter-GradeFuel
Waxingmayoccuratlowtemperatures,clogging
thefuelsystema
ndreducingengineefficiency.If
theambienttemp
eratureislessthan0C,winter-
gradefuel(suitabledownto-15C)shouldbeused.
(Thisfuelisusua
llyavailablefrom
fillingstations
wellinadvanceofthecoldmonths).Dieselfuel
containingadditiv
es(Superdiesel)isoftenonsale
aswell,
forusedownto-20C.
Attemperature
sbelow-15Cto-20C,kerosene
shouldbeaddedtothedieselfuel.Therelevant
percentagesaregivenintheadjacentdiagram.
Ifsummer-grade
dieselfuelmustbeusedattem-
peraturesbelow0C,upto60%k
erosenecanbe
added(seediagram).
Inmostcases,adequateresistancetocoldcanalso
beobtainedbyaddingaflowimprover(additive).
Pleaseinquireat
DEUTZSERVICE.
D
ieselfuelsmustneverbemixed
w
ithpetrol(NormalandSuper
g
rades)!
Legend:
I
Summer-graded
ieselfuel
II
Winter-gradedieselfuel
A
Ambienttemperature
B
Percentageofkero
seneadded
Mixintanko
nly!Fillwiththeap-
propriateamountofkerosenefirst,
thenaddthe
dieselfuel.
7/24/2019 S08 DEUTZ-2011a
38/814
C2001
7/24/2019 S08 DEUTZ-2011a
39/81
5
Service
5.1
ServicePlan
5.2
Sched
uledMaintenance
Plan
5.3
MaintenanceChart
5.4
MaintenanceWorkCom
pleted
7/24/2019 S08 DEUTZ-2011a
40/81
7/24/2019 S08 DEUTZ-2011a
41/81
5
O
peration
5.1ServicePlan
Service
Deutzm
aintenanceandserviceschedule
=E
check=
adjust=
clean=
replace=
priortoorduring1sttrialrun,
check2xd
ailyduringthebreaking-inphaseorwhen
com
missioningnew
andoverhauledeng
ine
every10operatinghoursordaily
inoperatinghours(OH
)every
E10
E20
E25
E30
E40
E50
E60
E70
Years
250
500
1000
3000
6000
1200
0
1
2
Page2
of2
Additionsandmodifications
forengineswithEPAapproval
Thespecifiedenginemaintenanceintervalsarepermissible
recommended
maximums.
Dependingonusage,
red
uced
maintenancein
tervalsmaybenecessary(complywiththe
unitmanufacturersoperatinginstructions).
#
Maintenanc
e
mustonlybe
carried
outbyautho
rised
servicepersonnel
Section
FL2011lubeoil,seeTC0199-99-3002
6.1.1
/6.1.2
BFL2
011lubeoil,seeTC0199-99-300
6.1.1
/6.1.2
Injectionvalve
#
Crank
casepressureventvalve
#
Timingbeltchangeintervals
Engineapplication
Engine/application/operatingparameters
G
uidelinevaluesinOH
Example:
Example:
6000ormax.5years
Generatingsets1500/1800rpm;pu
mpunits,
lowspeed;moderateambienttempe
rature;
lowspeed;platforml
ifts;refrigerationunitsetc.
lowdustexposure
5000ormax.5years
compressors;rollers;forklifttrucks
;weldingunits;
wheelloaders;mediumt
ohighvariablespeed;highambient
smalldumpers;ski-steerloaderset
c.
temperaturemoderatedustexposure
3000ormax.5years
agriculturalmachinery;ski-steerloaders;wheelloaders;drilling
highspeed;impactloads;extremea
mbienttemperature;
equipment;trench-cuttingmachine
s;jointcutters;bulldozersetc.
highdustexposure
7/24/2019 S08 DEUTZ-2011a
42/815
Service
5.2
Sch
eduledMaintenancePlan
5.2.1Sch
eduledMaintenancePlan
Intervals
Deutzmaintenance
Operation
Carriedoutby:
at/after
andserviceschedule
50
OH
E10
AftercommissioningandE50-
E70
Authorisedspecialists
Daily
E20
Dailycheck
Operator
250
OH
E25
Inspection
Authorisedspecialists
500
OH
E30
Extendedinspection
Authorisedspecialists
1000
OH
E40
Interimo
verhaul
Authorisedspecialists
3000
OH
E50
Extendedinterimo
verhaul
Authorisedspecialists
6000
OH
E60
Partialoverhaul
Authorisedspecialists
12000OH
E70
Basicoverhaul
Authorisedspecialists
7/24/2019 S08 DEUTZ-2011a
43/81
5
!
5.3
MaintenanceChar
t
Service
Themaintenancechartshownhereissuppliedasa
self-a
dh
esivelabelwitheachengine.
Itshouldbe
affixedwhereitcanbeseenclearlyontheengineor
drivene
quipment.
Checkt
hatthisisthecase.
Ifneces
sary,
askyourengineorequipmentsupplier
forafre
shsupplyoflabels.
Routine
workshouldbecarriedoutaccordingtothe
schedulein5.1. S
toptheenginebeforecarryingout
anymaintenancework.
7/24/2019 S08 DEUTZ-2011a
44/81
5
5.3
MaintenanceChart
Service
Thema
intenancechartshownhereissuppliedas
aself-a
dhesivelabelwitheachengine.
Its
houldbe
affixedwhereitcanbeseenclearlyonth
eengine
ordrive
nequipment.
Checkt
hatthisisthecase.
Ifneces
sary,
askyourengineorequipmentsupplier
forafreshsupplyoflabels.
Routine
workshouldbecarriedoutacco
rdingto
thesch
edulein5.1.
Stoptheenginebeforecarryingout
anymaintenancework.
7/24/2019 S08 DEUTZ-2011a
45/81
Date
Op.hours
Signature/stamp
Op.
hours
Date
Signature/stam
p
5
5.4
MaintenanceWork
Completed
Service
- 250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
50
-150*
125
375
625
875
1
125
1
375
1
625
1
875
2
115
2
375
2
625
*Followingcommissioningofnew
and
overhauledengines
Duly
completedmaintenancejobscan
berecordedandsignedoffinthe
abovechart.
7/24/2019 S08 DEUTZ-2011a
46/81
Date
Date
Signature/stamp
Op.
hours
Signature/stamp
5
Service
5.4
MaintenanceWorkCo
mpleted
Op.
hour
s
2875
3125
3375
3625
3875
4125
4375
4625
4875
5125
5375
5625
Dulycom
pletedmaintenancejobscanberecordedandsignedoffintheabovechart.
3000
3250
3500
3750
4000
4250
4500
4750
5000
5250
5500
5750
7/24/2019 S08 DEUTZ-2011a
47/81
Date
Op.hours
Signature/stamp
Op.
hours
Date
Signature/stam
p
5
5.4
MaintenanceWork
Completed
Service
Dulycompletedmaintenancejobscanberecordedandsignedoffintheabovechart.
58
75
61
25
63
75
66
25
68
75
71
25
73
75
76
25
78
25
81
25
83
75
86
25
6000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
7/24/2019 S08 DEUTZ-2011a
48/81
Date
Date
Signature/stamp
Op.
hours
Signature/stamp
5
Service
5.4
MaintenanceWorkCo
mpleted
Op.
hour
s
7/24/2019 S08 DEUTZ-2011a
49/81
6C2001
Se
rviceandMain
tenance
6.1
LubricationSystem
6.2
FuelSystem
6.3
Cooli
ngsystem
6.4
Comb
ustionAirFilter
6.5
BeltDrives
6.6
Adjus
tments
6.7
Accessories
6.8
Engin
eCleaning
7/24/2019 S08 DEUTZ-2011a
50/816
C2001
E1-
E3/96+
E4-
98
E1-
E3/96+
E4-
98
CF-4/CG-4
/CH-4
CF-4/CG-4
/CH-4
CF-4
CG-4
/CH-4
E1
-E2/96
E3-
96+
E4-
98
CF-4
CG-4
/CH-4
E1
-E2/96
E3-
96+
E4-
98
Enginesforinstallation
Lubequality
API-specification
ACEA-specification
Norm
aldutyoil
,e.g.:
roadvehicles,cranes
,constructionmachinery,ships,
generatingsets,pum
ps,railvehicles.
Heavydutyforoil,e.g.:
combineharvesters,
emergencypumps,underground
miningunits,sweepingmachines,wintermaintenance
equipment,emergencygenerators.
Lubeoilquality
Servicegroup
APIspecification
ACEAspecification
Annualusage
km
Averagedriving
speedapprox.
km
/h
LubeoilchangeintervalsinOH
Naturallyaspiratedengines
Tu
rbochargedengines
Lubeoilchangeintervalsinkm
Naturallyaspiratedengines
Tu
rbochargedengines
V
ehicleengines
1000
250
500
500
125
250
20000
5000
10000
20
100000
60
60000
1
5000
30000
ServiceandMainte
nance
6.1
Lubrication
System
6.1.1
OilChangeIntervals
Oilchangeintervalsaredependentonen
gine
applicationandqualityoflubeoil.
Ifenginerunsfewerhoursduringyear
than
statedin
table,oilshouldbechangedat
least
onceayear.
Tablereferstofollowingconditions:
-sulphur
contentmax.0.5%byweightford
iesel
fuel
-continu
ousambienttemperatureto
-10C(
+14F).
Ifsulphu
rcontentis>0.5to1%orcontinuous
ambient
temperaturebelow-10C(+14F),in-
tervalsb
etweenoilchangesshouldbehalved.
Incaseoffuelscontainingmorethan1%
sul-
phur,contactyourservicerepresentative
.
Changeoil
withengineoffbutstillwarm
(lub
eoil
temperatureapprox.80C).
7/24/2019 S08 DEUTZ-2011a
51/81
6C2001
6.1.2
CheckOilLevel/
ChangeEngineOil
6.1.2
.1
CheckOilLevel
6.1.2.2
ChangeEngineOil
Allowengineto
warmup.
Ensurethateng
ineorvehicleislevel.
-Lubeoiltemp
eratureapprox.80C.
Switchoffengine.
Switchengineoffbeforecheckingoil
level.
Ensurethatengineorvehicleislevel.
Rem
oveoildipstick.
Wip
edipstickwithnon-fibrous,clean
cloth.
Inse
rtittostopandremoveagain.
Checkoillevel,andifnecessary,topup
to"MAX"
mar
k.
-Ifo
illevelisonlyjustabove"MIN"mark,more
oil
mustbeadded.
Cau
tionwhendraininghotoil:Risk
ofs
calding!
Do
notletusedoilrunintothesoil
but
collectitinacontainer!
Disposeofthisinaccordancewith
environmentalregulations!
!
Placeoiltrayunderengine
.
Unscrewoildrainplug.
Drainoil.
Fitoildrainplugwithnew
sealringandtighten
firmly(fortorque,see9.2)
Pourinlubeoil
-Forgrade/viscosity,see
4.1
-Forquantity,see9.1
Checkoillevel,see6.1.2.1
.
6.1
LubricationSystem
Se
rviceandMain
tenance
257290
260220
260230
Thelev
elmustnotfallbelowthe"MIN"m
ark.
7/24/2019 S08 DEUTZ-2011a
52/816
C2001
Servi
ceandMainte
nance
6.1
LubricationSystem
6.1.3
ChangingOilFilter
Cleananydirtfromfiltercarriersealingsurface.
Lightlyoilrubberg
asketofnewlubeoilfilter
cartridge.
Manuallyscrewinn
ewcartridgeuntilgasketis
flush.
Undolubeoilfiltercartridgeusingcommercial
tooland
spinoff.
Catchan
yescapingoil.
Cautionisrequiredincaseo
fhot
oil:Riskofscalding!
Tightenlubeoilfiltercartridgew
ithanotherhalf-
turn.
Checkoillevel,see6.1.2.
Checkoilpressure,see3.3.1.
Checklubeoilfiltercartridgesealforleaks.
!
258
800
258820
258810
7/24/2019 S08 DEUTZ-2011a
53/81
6C2001
6.1
LubricationSyste
m
Ser
viceandMaintenance
6.1.4
Clean/Replace
OilFilter(Cup)
Cautionisrequiredinca
seofhot
oil:Riskofscalding!
Switchoffengine.
Loosenlubeoilfiltercover1andun
screw
in
anticlockwisedirection.
Carefullyloosenpaperfiltercartridge3
upwards
from
guide4.
Catc
hanyescapingoil.
Rep
lacepaperfiltercartridge3.
Cleananydirtfroms
ealingsurfaceoffiltercarrier
and
lubeoilfiltercover1andfromg
uide4.
Replaceandlig
htlyoilrubbergasket2.
Carefullyinsert
newpaperfiltercartridge3into
guide4.
Tightenlubeoil
filtercover1inclockwisedirec-
tion(25Nm).
Startengine.
Checkoillevel,
see6.1.2.
Checkoilpress
ure,see3.3.1.
Checklubeoilfilterattachmentforleaks.
!
2 3 41
30074
0
7/24/2019 S08 DEUTZ-2011a
54/816
C2001ServiceandMainten
ance
6.2
Fue
lSystem
6.2.1
ReplaceFuelFilter
Keepnakedflamesaway
whenworkingonthefuel
system.Donotsmoke!
Closefuelshut-offvalve.
Undofuelfiltercartridgewithcommercialtool
andspin
off.
Catchan
yescapingfuel.
Cleananydirtfromfiltercarriersealingsurface.
Applylightfilm
ofoilordieselfueltorubber
gasketofnewfuelfiltercartridge.
Manuallyscrewinn
ewcartridgeuntilgasketis
flush.
Tightenfuelfiltercartridgewith
finalhalf-turn.
Openfuelshut-offvalve.
Checkforleaks.
Thefuelsystemdoesnotneedto
bebled.
!
258
800
258820
258810
7/24/2019 S08 DEUTZ-2011a
55/81
6C2001
6.2.2
Clean/Replace
FuelFilter(Cup)
Keepnakedflamesawaywhenwork-
ingonthefuelsystem.Donot
smoke!
Switchoffengine.
Loosenfueloilfiltercover1andun
screw
in
anticlockwisedirection.
Care
fullyloosenpaperfiltercartridge3
upwards
from
guide4.
Catc
hanyescapingfuel.
Rep
lacepaperfiltercartridge3.
Clea
nanydirtfrom
sealingsurface
offilter
carr
ierandfuelfiltercover1andfrom
guide4.
Replaceandlig
htlyoilrubbergasket2.
Carefullyinsert
newpaperfiltercartridge3into
guide4.
Tightenfuelfiltercover1inclockwisedirection
(25Nm).
Startengine.
Checkfuelfilterattachmentforleaks.
2 3 41
30074
0
!
6.2
FuelSystem
Se
rviceandMain
tenance
7/24/2019 S08 DEUTZ-2011a
56/816
C2001
3
1
2
2
4
3
1
Closefuelshut-offvalve.
Loosenandunscrewhexagonalnut1.
Remove
fuelstrainercover2(coverandstrainer,
oneunit).
Cleanfuelstrainer2withdieselfuel.Replaceif
necessary.
Placeseal3inposition.
Mountfuelstrainer
cover2.
Tightenhexagonals
crew1.
Checkforleaks.
6.2.3
CleanStrainerofFuelFilter
Keepnakedflamesawaywhenw
ork-
ingonthefuelsystem.Do
not
smoke!
ServiceandMainten
ance
6.2
Fue
lSystem
!
Closefuelshut-offvalve.
Disconnectrubberhoses3from
injectionvalves.
Disconnectrubberhose1from
fueltank.
Disconnectrubberhoses4,3an
d1fromunions
2anddisposeofinanenvironm
entallyfriendly
manner.
Connectnewrubberhoses4,
3a
nd1tounions2.
Connectrubberhoses3toinjectionvalves.
Connectrubberhose1tofueltank.
Openfuelshut-offvalve.
Checkforleaksafterstart-up.
6.2.4
ChangeFuelLeaka
geLine
264
360
318670
7/24/2019 S08 DEUTZ-2011a
57/81
6
6.3
CoolingSystem
ServiceandMain
tenance
6.3.1
CleaningIntervals
Checkingorcle
aningintervals
Guideline
valuesOH
Engineapplication
20
00
Ships,
generatingsetsinenclosedareas
,pumps.
10
00
Vehiclesonpavedroads
500
Tractors,
fork-l
ifttrucks,
mobilegeneratingsets
250
Vehiclesonconstructionsitesandunpavedroads,
construc-
tionm
achines,
compressors,
undergrou
ndminingunits
125
Agricu
lturalmachines,
tractorsinharvestingapplications
Amountofcontaminationincoolingsystem
dependsonengineapplication.
Oilandfuelresiduesonengineincrea
seriskof
contamination.
Thereforepayspecial
attention
tole
aksifengineisusedindustyenvir
onments.
Seriouscontaminationcanoccur,for
example:
-on
constructionsiteswherethereis
ahigh
levelofair-bornedust.
-in
harvestingapplicationswherether
earehigh
co
ncentrationsofchaffandchoppedstrawin
vicinityofmachine.
Becauseapplicationsvary,
cleaning
intervals
havetobedeterminedfromcasetocase.
Clean-
ingintervalsgivenintableonrightcanbeused
asa
guide.
7/24/2019 S08 DEUTZ-2011a
58/816
6.4.2
EmptyingCyclone-Type
Precleaner
Neverfillcollectorbowlwithoil.R
eplacecollector
bowlifdamaged.
Undowingnut1andremovecover2.
Removecollectorbowl3from
lowersection4
andempty.C
leanleaves,s
trawa
ndotherforeign
matterfrom
lowersectionofpre-c
leaner.
Repositioncollectorbowl3onto
lowersection4,
fastencover2inplacebytighte
ningwingnut1.
25886
0
Amountofdirtinaircleanerdependsonam
ount
ofdustinairandsizeofaircleanerused.If
high
levelof
dustis
anticipated,
cyclone-type
preclean
ercanbefittedtoaircleaner.
Cleaning
intervalswillhavetobedeterm
ined
from
cas
etocase.
Ifdrytypeairfiltersareused,
cleaningsh
ould
onlybec
arriedoutaccordingtoserviceindicator
orservic
eswitch.
Airclean
erservicingisneededwhen:
-Serviceindicator
redsig
nal1isfullyvisiblewhenengineisoff.
-Serviceswitch
yellow
pilotlightcomesonwhenengine
is
running.
pressing
buttononserviceindicator.Se
rvice
indicatorisnowreadyforoperationagain.
6.4.1
CleaningIntervals
25885
1
Servi
ceandMainte
nance
6.4
CombustionAirFilter
7/24/2019 S08 DEUTZ-2011a
59/81
6
Emp
tydustdischargevalve1bypressingapart
lips
ofdischargeslotasindicatedbyarrows.
Clea
ndischargeslotfrom
timetotime.
Rem
oveanycakeddirtbypressing
together
uppersectionofvalve.
Undoclipfasteners1.
Takeoffhood2
andremovecartridge3.
Cleancartridge,
replaceatleastonceayear.
Cleancartridge
3.
Usingdrycomp
ressedair(max.
5bar),
blowout
from
insidetooutside(orindifficultcases,
tap
out,takingcare
nottodamagecartridge,o
rwash
accordingtom
anufacturersinstructions).
Gasketsonfiltercartridgecanbecomedamaged
throughregular
removalandreplacement.Check
paperfilter(ligh
tshowingthrough)andgaskets
fordamage.
Replaceifnece
ssary.
6.4.3
DryTypeAirCleaner
DischargeValve
Nevercleanfiltercartridgewithpet-
rolorhotfluid
s.
Afterfivecleanerservices
oraftertwoyearsat
latest,replacesafetycartridge4(neverclean).
Todoso:
-Undohexnut5andremovecartridge4.
-Installnewcartridge,
fitandtightenhexnut.
Installcartridge3,
replacehood2anddoupclip
fasteners1.
FilterCartridg
es
!
258890
258881
6.4
CombustionAirFil
ter
ServiceandMain
tenance
7/24/2019 S08 DEUTZ-2011a
60/816
Servi
ceandMainten
ance
6.5
Be
ltDrives
6.5.1
CheckV-belt
-Carefullyremovegaugewithoutalteringposi-
tionofindicatorarm1.
-Readoffvaluewh
ereblackindicatorarm1
intersectsscale5
(arrow).Forsettings,see
9.1.
-Ifnecessary,retensionbeltandmeasureagain.
Check,
tensionandchangebelts
onlywithengineoff.Refitbeltguard,
ifprovided.
Visually
inspectentireV-beltfordamage.
Replace
damagedV-belts.
Afterins
tallingnew
belts,runenginefo
r15
minutes,thencheckbelttension.
TochecktensionofV-belt,usetensiong
auge
(see9.3).
-Placeindicatorarm1intogauge.
-Positio
nguide3onV-belt2,midwaybetween
pulleys
,withstopagainstedgeofbelt.
-Pushs
lowlyonblackpad4atrightangles
toV-
belt2untilspringisheardorfelttotrigg
er.
Afterinstallingnewbelts,runenginefor15min-
utes,thencheckbelttension.
!
262610
318
660
7/24/2019 S08 DEUTZ-2011a
61/81
6
6.5.2
TensioningAlternatorBelts
Slac
kenoffbolts1,
2and3.
Adju
stalternator4indirectionofarrow
by
turn
ingbolt3untilcorrectbelttensionis
achieved.
Retightenbolts1,
2and3.
Check,tensionandchangebelts
onlywithengineoff.Refitb
eltguard,
ifprovided.
6.5.3
Changi
ngAlternatorBelts
Slackenoffbolts1,
2and3.
Adjustalternat
or4indirectionofarrow
by
turningbolt3.
Removeandre
placebelt.
Adjustalternato
r4againstdirectionofarrowby
turningbolt3
,untilcorrectbelttensionis
achieved.
Retightenbolts
1,
2and3.
!
318600
31859
0
6.5
BeltDrives
Se
rviceandMain
tenance
5
3
2
1 4
5
3
2
1 4
7/24/2019 S08 DEUTZ-2011a
62/816
6.6.1
CheckValveClearance,
adjust
if
necessary
Remove
cylinderheadcover.
Positioncrankshaftasperschematic,see6.6
.1.1.
Beforeadjustingvalveclearance,a
llowengineto
cooldow
nforatleast30minutes.
Oiltempera-
tureshouldbebelow80C.
Checkvalveclearance1betweenrockerarm
/
tappetco
ntactface2andvalvestem3withf
eeler
gauge6
(thereshouldbeonlyslightresistance
whenfeelerbladeisinserted).
Forperm
issiblevalveclearance,see9.1.
Adjustvalveclearan
ceifnecessary:
-Releaselocknut4.
-UseAllankey7toturnsetscrew
5sothat
correctclearanceis
attainedafterlocknut4has
beentightened.
Checkandadjustv
alveclearanceonallcylin-
ders.
Reinstallcylinderhe
adcover,withnewgasketif
necessary.
ServiceandMainten
ance
6.6
Adjustments
196
912
25893
0
7/24/2019 S08 DEUTZ-2011a
63/81
6
21
1
2
3
4
1
2
1
2
3
2
3
4
1
1
2
1
2
3
6.6.1
.1
ValveClearanceAdjust
mentsSchematic
6.6
Adjustments
Se
rviceandMain
tenance
CrankshaftPosition2:
Turncrankshaftonefullrevolution(360).
Adjustclearanceofvalves
markedinblackon
schematic.
CrankshaftPosition1:
Turncrankshaftuntilboth
valvesincylinder1
overlap(exhaustvalveabouttoclose,
inletvalve
abouttoopen).Adjustcleara
nceofvalvesmarked
inblackonschematic.
Ma
rkrespectiverocker
armwithchalktoshowthat
adjustmenthasbeen
carriedout.
258944
7/24/2019 S08 DEUTZ-2011a
64/816
6.7.1
Battery
Servi
ceandMainten
ance
6.7
Acc
essories
6.7.1.1
CheckBatteryandCable
Connectors
6.7.1.2
Check
ElectrolyteLevel
6.7.1.3
CheckElectroly
teDensity
Keepbatterycleananddry.
Undodirtyclamps.
Cleanterminalposts(+and-)andclampsof
battery,
andgreasewithacid-freeandacid-
resistantgrease.
Whenre
assembling,ensurethatclampsmake
goodcontact.Tightenclampboltshand-tight.
Removesealingcap
s1.
Iftesters2arepresent:
Electrolytelevelsho
uldreachbaseofthese.
Withouttesters:
Electrolytelevelsho
uldbe10-15mmabovetop
ofplates.
Ifnecessary,topup
withdistilledwater.
Screwsealingcaps
backin.
Measureelectrolytedensityof
individualcells
withcommercialhydrometer.
Hydrometerreading(seetableonfollowingpage)
indicatesbatterysstateofchar
ge.
Duringmeasurement,temperatureofelectrolyte
shouldpreferablybe+20C.
258960
242323
258
95
0
7/24/2019 S08 DEUTZ-2011a
65/81
6
6.7
Accessories
Se
rviceandMain
tenance
Tropical
1.2
3
1.1
2
1.0
8
Norm
al
32 24 16
Tropical
27
16
11
in[kg/l]
in[B(Baumscale)*]
Chargestatus
No
rmal
1
.28
1
.20
1
.12
wellcharged
se
mi-charged,re-charge
disch
arged,
immediatelycharge
*Meas
urementofelectrolytedensityinB
(Baum
scale)isoutofdateandrarelyusedtod
ay.
Thegasesemittedbyth
ebattery
areexplosive!Keepspark
sandna-
kedflamesawayfromthebattery!
Donotallowbatteryacid
tocome
intocontactwithskinorclothing!
Wearp
rotectivegoggles!
Donot
resttoolsonthebattery!
!
Electrolytedensity
7/24/2019 S08 DEUTZ-2011a
66/816
6.7.2
RotaryCurrentAlternator
6.7.3
Transporta
tionShackles
Useonlycorrectliftinggear.
Notesonth
ethree-phasesystem:
Neverdisconnectcablesbetweenbattery,alter-
natorandregulatorwhileengineisrunning.
If,
however,itisnecessarytostartandop
erate
enginew
ithoutbattery,d
isconnectregulator
from
alternato
rbeforestarting.
Besurenottoconfusebatteryterminals.
Replace
defectivechargepilotlampbulbim
me-
diately.
Whenwashingengine,coverupalternatorand
regulator.
Touchingleadagainstframetocheckwhetherit
islivem
ustnot,underanycircumstances,
be
carriedo
utwiththree-phaseelectricalsyst
ems.
Incaseo
felectricwelding,connectgroundter-
minalon
welderdirectlytopiecebeingwe
lded.
Alwaysuseproper
liftingtackle1whentrans-
portingengine.
Aftertransportation
andbeforecommissioning
ofengine:removea
ttachmenteyes2.
ServiceandMainten
ance
6.7
Acc
essories
!
318700
318710
1 2
7/24/2019 S08 DEUTZ-2011a
67/81
6
6.8.1
EngineCleaning
!
Preperation
Switchoffengine.
Rem
oveenginecoversandcooling
airhood.
Rep
lacethemaftercleaningandbeforetestrun.
Cov
erelectrical/electroniccompon
entsand
con
nections(e.g.alternator,starter,
governor,
sole
noid).
Using
compressedair
Blowairthroughengine,takingparticularcare
not
todamagecoolerandcoolingfins
(beginto
blowthroughairfromexhaustside).
Rem
ovedirtwhichhasblownintointer
iorspace.
Using
cold-c
leaningcompound
Sprayenginewithcommercialcold
-cleaning
com
poundandallow
toreactforapprox.
10
min
s.
Spray-cleanenginewithstrongwaterjet,repeat
ifnecessary.
Allo
w
enginetorunwarm
sothatremaining
waterevaporates.
Using
high-pressuredevice
Cleanenginewithsteam
jet(max.sp
raypres-
sureof60bar,max.steamtemperatureof90C).
Allo
w
enginetorunwarm
sothatremaining
waterevaporates.
Cleantheengineonlywhe
ntheen-
gineisswitchedoff.
6.8
EngineCleaning
ServiceandMaintenance
7/24/2019 S08 DEUTZ-2011a
68/816
7/24/2019 S08 DEUTZ-2011a
69/81
7
Faults,
CausesandR
emedies
7.1
FaultT
able
7/24/2019 S08 DEUTZ-2011a
70/817
Faultsareoften
caused
byenginenotb
eing
properly
operatedormaintained.
Eachtim
efaultoccurs,
checkwhetherallop
erat-
ingand
servicingregulationshavebeencom-
pliedwit
h.
Correspondingfaulttablecanbefoundon
adja-
centpag
e.
Ifyoucannotascertaincauseofafaultorca
nnot
rectifyfa
ult,
pleasecontactDEUTZSERVIC
E.
Fault
s,
CausesandRemedies
7.1
Fa
ultTable
7/24/2019 S08 DEUTZ-2011a
71/81
7
7.1
FaultTable
Faults
,CausesandR
emedies
Section
Cause
Notdeclutched(w
herepossible)
Below
startinglim
ittemperature
Oilleveltoolow
Oilleveltoohigh
Excessiveinclinationofengine
IncorrectlubeoilSAEclassorquality
Fuelqualitynotas
peroperatingmanual
Aircleanerclogge
d/turbochargerdefective
Aircleanerserviceswitch/indicatordefective
CPD*defective
Chargeairlinelea
king
Oilcoolerpanelsclogged
Coolingfandefective,
splitorlooseV-belt
Coolingairtempe
raturerise/heatingshortcircuit
Resistanceincoo
lingsystemt
oogreat/through-flow
quantitytoosmall
Batterydefectiveordischarged
Faults
Measures
Enginedoesnotstartorisdifficulttostart
Chec
k
Ch
Enginestarts,
butrunsirregularlyorfails
Adju
st
A
Enginebecomesexcessivelyhot.Temperaturewarningsystemr
esponds
Repl
ace
Rp
Engineoutputisdeficient
Clean
Cl
Enginedoesnot
runonallcylinders
Topup
T
Engineoilp
ressureisnon-existentorexcess
ivelylow
Redu
ce
Rd
Engin
eoilconsumptionexcessive
Enginesmokes-
blue
-white
-black
*CPD=
Chargepressure-dependentfull-loadstop
EngineOperation
Opera
tingmedia
Comb
ustionair
Coolingsystem
Electrics
Ch
ChTC
hRd
Rp
Rp
Ch/Rp
Ch/Rp
Ch
Ch
Ch/Cl
Ch/Rp
Ch
Ch
Ch/T
7/24/2019 S08 DEUTZ-2011a
72/817
Enginedo
esnotstartorisdifficulttostart
Check
Ch
Eng
inestarts,
butrunsirregularlyorfails
Adjust
A
Enginebecomesexcessivelyhot.Temperaturewarningsystemre
sponds
Replace
Rp
Engineoutputisdeficient
Clean
Cl
Enginedoesnotrunonallcylinders
Topup
T
Engineoilpress
ureisnon-existentorexcessively
low
Reduce
Rd
Engineoil
consumptionexcessive
Engin
esmokes-
blue
-white
-black
Section
Cause
Faults
Measures
Faults,
CausesandR
emedies
7.1
Fa
ultTable
Electriccableconnectionstostarterelectricalsystemloo
seoroxidised
Starterdefectiveorpin
iondoesnotengage
Solenoiddefective(releaseswitch)
Incorrectvalveclearan
ce
Injectionlineleaks
Injectionvalvedefectiv
e
Ch
Ch
ChAC
h
Ch/Rp
Electrics
Engine
7/24/2019 S08 DEUTZ-2011a
73/81
EngineP
reservation
8.1
Preservation
7/24/2019 S08 DEUTZ-2011a
74/81
Engine
Preservation
8.1
Preservation
Iftheengineistoremainidlefor
anextendedperiod
oftime,
itisnecessarytotakepro
tectivemeasuresto
preventrusting.T
hepreservativemeasuresdescribed
herewillprotecttheengineforu
pto6months.
Theprocedurewillhavetobereversedbeforethe
engineisrecommissioned.
Anti-corrosionoilstospecification:
MIL-L-2
1260B
TL9150-0
37/2
NatoCodeC640/642
Anti-corrosionmediaforexteriorprotectiononly
tospecification:
NatoCodeC632
Recommendedcleaningage
nttoremovepre-
servatives:
Petroleumb
enzine
(hazardousmaterialsclassA
3)
8.1.2
Removing
Engine
Preservatives
Cleanengineusinghigh-pressureequipme
nt
(orwith
cold-c
leansingagentinemergency).
Runengineuntilwarm,
thenturnoff.
Draine
ngineoil(see6.1.2
)andfillwith
anti-
corrosionoil.
Ifnecessary,
cleanoilbathcleaner(see6.4.3
)
andfill
withanti-corrosionoil.
Drainfu
eltank.
Makeupamixtureof90%
dieselfueland10%
anti-corrosionoil,
andrefillfueltank.
Allowenginetorunforapprox.
10mins.
Switch
offengine.
Turnen
gineovermanuallyseveraltimesto
pre-
servecylindersandcombustionchamber.
RemoveV-beltsandstoreinwrappedcondition.
Sprayg
roovesonV-beltpulleyswithanti-corro-
sionspray.
Closein
takeportsandexhaustports.
Removeanti-corrosionagentfromg
roovesin
V-beltpulleys.
InstallV-belt,
retensio
nafterbriefoperationif
necessary,
see6.5.
Removecoversfromi
ntakeportandexhaust
port.
Commissionengine,s
eealso5.1,
note2.
8.1.1
PreservingEngine
7/24/2019 S08 DEUTZ-2011a
75/81
9
TechnicalSpec
ification
9.1
Engin
eSpecificationsandSettings
9.2
Torqu
eWrenchSettings
9.3
Tools
7/24/2019 S08 DEUTZ-2011a
76/819
Model
Numberof
cylinders
Cylinderarrangement
Bore
[mm]
Stroke
[mm]
Totaldispla
cement
[cm
3]
Compressionratio
[]
Workingcy
cle
Combustionsystem
Directionofrotation
Weightincl.integralcoolingsystemtoDIN70020-A
(withoutstarter,withalternator)
approx.[kg]
Engineoutput
[kW
(hp)]
Speed
[rpm]
Lubrication
SAEoil
Maximumoiltemperatureinoilpan
[C]
Min.o
ilpre
ssureinwarmcondition,o
iltemperature110C
at:900rpm
(lowidlingspeed)
[bar]
1800rpm
[bar]
max.2
800rpm
[bar]
Oilchangequantity(oilpan)approx.
[l]
Oilchangequantitywithfilter(standard0.5l)
approx.(
l)
Valveclearancewithcoldengine
(Enginecoolingtimeatleast30min.:oiltemperatureshouldbebelow80C).
[mm]
Startoffeed
[crankshaftBTDC]
Injectoropeningpressure:vehicle/unit
[bar]
Firingorderofengine
V-belttensio
n:pretension/retension(afterengine
hasbeenrunningunderloadfor15mins)[N]
1)Enginepo
wer,speed,startofdeliveryarestampedonengineratingplate,seealso2.1.
2) Approx.v
aluescanvarydependingonsum
pand/orcoolerdesign(externalc
oolingsystem).Upperoildipstickmarkisalwaysauthoritative.
3) Valuesforengineswithoutengineoilheating.
TechnicalSpecification
9.1
EngineSpecificationsandSettings
F2L2011
F3L2011
F4L2011
2
3
4
verticalinline
94
112
1554
2331
3108
19
4-strokedieselengine
Naturallyaspiratedenginewithdirectinje
ction
Onleftwhenlookingatflywheel
175
217
256
1)
1)
Pressurelubrication
20W20
130
1.43)
2.23)
33)
62)
5.52)
102)
6.52)
62)
10.5
2)
Inlet0.3+0.1/
Exhaust0.5+0.1
1)
210+8
1-2
1-2-3
1-3-4-2
450/35020
7/24/2019 S08 DEUTZ-2011a
77/81
9
Model
Numberofcylinders
Cylinderarrangement
Bore
[mm]
Stroke
[mm]
Totald
isplacement
[cm3]
Compr
essionratio
[]
Workin
gcycle/Combustionsystem
Directionofrotation
Weightwithoutcoolingsystem
Weightwithoutstarter,withalternatoras
perDIN70020-Aapprox.
approx.[
kg]
Engine
output
[kW(hp)]
Speed
[rpm]
Lubrication
SAEoil
Maxim
umoiltemperatureinoilpan
[C]
at:900
rpm(lowidlingspeed)
[bar]
1800rpm
[bar]
max.2
800rpm
[bar]
Oilcha
ngequantity(oilpanwithoutcoolingsystem)ca.
[l]
Oilcha
ngequantitywithfilter(Standard0.5l)
approx.(
l)
Valvec
learancewithcoldengine
(Enginecoolingtimeatleast30min.:oil
temperatureshouldbebelow80
C).
[mm]
Injecto
ropeningpressure:vehicle/unit
[bar]
Startoffeed
[crankshaftBTDC]
Firingorderofengine
V-belttension:pretension/retension(afteren
ginehasbeenrunningunderloadfor15mins):[N]
BF3L2
011
BF4L2011
3
4
verticalinline
94
112
233
1
3
108
17.5
Four-strokedieselwithturbocharginganddirectfuelinjection
Onleftwhenlookingatflywheel
222
257
1)
1)
Pressurelubrication
20W20
130
1.43)
2.23)
33)
7.5
1
02)
8
10.52)
Inlet0.3+0.1/ Exhaust0.5+0.1
210+8
1)
1-2
-3
1-3-4-2
450/35020
9.1
EngineSpecificatio
nsandSettings
TechnicalSpec
ification
1)Engin
epower,speed,startofdeliveryarestampedonengineratingplate,seealso2.1.
2)A
pprox.valuescanvarydependingon
sumpand/orcoolerdesign(externalcoolingsystem).Upperoildipstickmarkisalwaysauthoritative.
3)V
aluesforengineswithoutengineoilh
eating.
7/24/2019 S08 DEUTZ-2011a
78/81
7/24/2019 S08 DEUTZ-2011a
79/81
9
9.1
EngineSpecificatio
nsandSettings
TechnicalSpec
ification
Model
Numberofcylinders
Cylinderarrangement
Bore
[mm]
Stroke
[mm]
Totald
isplacement
[cm3]
Compr
essionratio
[]
Workin
gcycle
Combu
stionsystem
Directionofrotation
Weightwithoutcoolingsystem
(withoutstarter,withalternator)approx.
[kg]
Engine
output
[kW(hp)]
Speed
[rpm]
Lubrication
SAEoil
Maxim
umoiltemperatureinoilpan
[C]
Min.oi
lpressureinwarmcondition,o
iltem
perature110Cat:900rpm(lowidlingspeed)[bar]
1800rpm
[bar]
max.2
800rpm
[bar]
Engine
withThermostat
Oilcha
ngequantitywithoutexternalcooler(see3.1.1.2)/withoutfilterapprox.
[l]
Oilchan
gequantitywithoutexternalcooler(see
3.1.1.2
)+filterreplacement(standard0
.5litre)approx.
[l]
GensetEnginewithoutThermostat:
Oilcha
ngequantityincludingexternalco
oler(see3.1.1.3)/withoutfilterapprox.
[l]
Oilchangequantityincludingcooler(see3.1.1.3
)+filterreplacement(standard0.5litre)approx.[
l]
Valvec
learancewithcoldengine
(Enginecoolingtimeatleast30min.:oil
temperatureshouldbebelow80
C).
[mm]
Startoffeed
[crankshaftBTDC]
Injecto
ropeningpressure:vehicle/unit
[bar]
Firingorderofengine
V-belttension:pretension/retension(after
enginehasbeenrunningunderload
for15mins):[N]
B
F3M2011
BF4M2
011
3
4
verticalinline
94
112
2331
3108
17.5
4-strokedieselengine
Turbocharginganddirectinjectio
n
Onleftwhenlookingatflywh
eel
Refertohead-office
215
250
1)
1)
Pressurelubrication
20W20
130
1.43)
2.23)
33)
7.5
102
)
8
10.5
2)
1113.5
2)
11.5
142
)
Inlet0.3+0.1/
Exhaust0.5+0.1
1)
210+8
1-2-3
1-3-4-2
450/35020
1)Engin
epower,speed,startofdeliveryarestampedonengineratingplate,seealso2.1.
2)A
pprox.valuescanvarydependingon
sumpand/orcoolerdesign(exter
nalcoolingsystem).Upperoildipstickmarkisalwaysauthoritative.
3)V
aluesforengineswithoutengineoilh
eating.
7/24/2019 S08 DEUTZ-2011a
80/819
TecnicalSpecification
9.2
TorqueWrench
Settings
Installationlocation
Pre-tension[Nm]
Re-tension[Nm]
Total
Comments
1ststage
2ndstage
3rdstage
1ststage
2ndstage
3rdstage
4thstage
[Nm]
Cylinderheadcover
8.5
Cylinderheadcover
8.5
Rockerarmadjustmentscrew
21
Intakemanifold
8.5
FootRigidsuspension
30
45
FootElas
ticsuspension
106
Airintake
pipe
21
Exhaustmanifold
22
Oildrainplug
55
Oilpan(sheetmetal)
21
Oilpan(cast)
31
Injection
lineattachment
30
Injection
valveattachment
21
TORX
Lubeoilfiltercartridge
27
onengine
orseparate
Threaded
pipeunion
4
7/24/2019 S08 DEUTZ-2011a
81/81
9
V-belttensiongauge
sedwithe
nginesin
auseofthemany
bolts.
seningandtighten-
kettoslideoffor
lingoutriskofin-
m:
TheV-belttensiongaugecanbeobtainedunder
ordernumber811
5from:
FA.W
ILBR
Postfach140580
D-4
2826Remscheid
25899
0
26002
0TechnicalSpecification