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C2000

OperationM

anual

2011

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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!

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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.

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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

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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

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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

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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.

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2C2001

EngineDescription

2.1

Model

2.2

EngineIllustrations

2.3

Lube

OilCircuitSchematic

2.4

Fuel

System

Schematic

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C2001

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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.

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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

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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

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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

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C2001

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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


singcover)

2


e

3

Fanwithintegratedgenerator

4

NarrowV-belt

5


6

Wheel-housecover

7


8

Oilpan

9

Shut-offlever

10

Speedcontrollever

11

Oildipstick

12

Crankcase

13


case)

14

Fuelpump

15


16


ter

17

Charge-pressure-dependentfull-loadstop

(CPD)

18


19

Removablecoolantintakeho

od

20

Injectionpumps

21

Oilcooler

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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


25

Starter

26

Crankcase

27

Lubeoilfeedlinetoturb

ocharger

28

Lubeoilreturnlinefrom

turbocharger

29

Inductionpipe

30

Turbocharger(TC)

31

Intakemanifold

32

Charge-airline

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EngineDescription

2.2

EngineIllustration

2.2.5

O

perationSide

F

M2

011

1


singcover)

2


e

3

Alternator

4

NarrowV-belt

5


6

Timingbeltcover

7


8

Oilpan

9

Shut-offlever

10

Speedcontrollever

11

Oildipstick

12

Oildrainplug

13


case)

12

Crankcase

14

Fuelpump

15


16


ter

17


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

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2C2001

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0

2.2

EngineIllustration

EngineDescription

2.2.

6

ExhaustSide

FM

2011

22

23

24

28

27

26

25

22

Cylinderhead

23

Exhaustmanifold

24


25

Starter

26

Starterguard(optional)

27

Crankcase

28

Airintakepipe

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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


4

NarrowV-belt

5


6

Timingbeltcover

7

Shut-offlever

8

Speedcontrollever

9


case)

10

Oildipstick

11

Fuelpump

12


13


ter

14


15

Injectionpump(s)

16

Oilcoolerconnection

17

Injectionvalve(s)

18

Fuelleakageline

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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

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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

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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


5

Fuellinefromfiltertoinjectionpump

6

Injectionpump

7

Fueldistributorline

8

Injectionline

9

Injectionvalves

10

Fuelleakageline

11

Fueloverflowpipe

12

Fuelreturnlinetotank

Theinstallationofafuelpre-filter/

handpumpb

etweenthefueltank

andtheeng

ineisprescribedto

protecttheenginesagainstdirtin

thefuel.

!

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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

.

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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!

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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.

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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.

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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

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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

).

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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

).

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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.

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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).

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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.

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4C2000

Operatingmedia

4.1

Lube

Oil

4.2

Fuel

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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.

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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.

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C2001

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5

Service

5.1

ServicePlan

5.2

Sched

uledMaintenance

Plan

5.3

MaintenanceChart

5.4

MaintenanceWorkCom

pleted

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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

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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


500

OH

E30

Extendedinspection


1000

OH

E40

Interimo

verhaul


3000

OH

E50

Extendedinterimo

verhaul


6000

OH

E60

Partialoverhaul


12000OH

E70

Basicoverhaul


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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.

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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.

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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.

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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

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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

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Date

Date

Signature/stamp

Op.

hours

Signature/stamp

5

Service

5.4

MaintenanceWorkCo

mpleted

Op.

hour

s

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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

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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).

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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.

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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

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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

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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

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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

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C2001

3

1

2

2

4

3

1


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

!


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

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

!

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318710

1 2

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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

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7

Faults,

CausesandR

emedies

7.1

FaultT

able

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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

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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

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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

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EngineP

reservation

8.1

Preservation

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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

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9

TechnicalSpec

ification

9.1

Engin

eSpecificationsandSettings

9.2

Torqu

eWrenchSettings

9.3

Tools

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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

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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.

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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.

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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

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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

s08 deutz-2011a

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