Operation Manual

Operation Manual
2011
C 2000
Safety guidelines / Accident prevention
● Please read and observe the information

given in this Operation Manual. This will ● Unauthorized engine modifications will in-
enable you to avoid accidents, preserve the validate any liability claims against the manu-
manufacturer’s warranty and maintain the facturer for resultant damage.
engine in peak operating condition. Manipulations of the injection and regulating
system may also influence the performance
● This engine has been built exclusively for of the engine, and its emissions. Adherence
the application specified in the scope of to legislation on pollution cannot be guaran-
supply, as described by the equipment manu- teed under such conditions.
facturer and is to be used only for the
intended purpose. Any use exceeding that ● Do not change, convert or adjust the cooling
scope is considered to be contrary to the air intake area to the blower.
intended purpose. The manufacturer will The manufacturer shall not be held respon-
not assume responsibility for any damage sible for any damage which results from
resulting therefrom. The risks involved are such work.
to be borne solely by the user.
● When carrying out maintenance/repair op-
● Use in accordance with the intended pur- erations on the engine, the use of DEUTZ
pose also implies compliance with the con- original parts is prescribed. These are spe-
ditions laid down by the manufacturer for cially designed for your engine and guaran-
operation, maintenance and servicing. The tee perfect operation.
engine should only be operated by person- Non-compliance results in the expiry of the
nel trained in its use and the hazards in- warranty!
volved.
● Maintenance and cleaning of the engine
● The relevant accident prevention guidelines should only be carried out when the engine
and other generally accepted safety and is switched off and has cooled down.
industrial hygiene regulations must be ob- You must ensure that the electrical systems
served. have been switched off and the ignition key
has been removed.
● When the engine is running, there is a risk of Accident prevention guidelines concerning
injury through: electrical systems (e.g. VDE-0100/-0101/-
- turning/hot components 0104/-0105 Electrical protective measures
- engines with positive ignition against dangerous touch voltage) are to be
- ignition systems (high electrical voltage) observed.
You must avoid contact at all times! When cleaning with fluids, all electrical com-
ponents are to be covered impermeably.
Operation manual
2011
0297 9929 en
Engine Serial
Number:
Please enter the engine serial number here. This

number should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see
Section 2.1).
Technical modifications required to improve our

engines are reserved with regard to specification
data and other technical information contained in
this Operation Manual. No parts of this Manual may
C 2000
be reproduced in any form or by any means without
our written approval.
Foreword
Dear Customer,
Liquid-cooled Deutz engines are designed for a

large number of applications. Consequently, a wide
range of variants is offered to meet the requirements
of specific cases.
Your engine is appropriately equipped for the

installation concerned, which means that not all of
the components described in this Operation Manu-
al are necessarily fitted to your engine.
We have endeavoured to highlight any differences

so that you will be able to locate the operating and
maintenance instructions relevant to your engine
quickly and easily.
Please read this Manual before starting your engine,

and always observe the operating and maintenance
instructions.
We are available to help with any additional inquiries
Sincerely,
DEUTZ AG
Contents
1. General 3. Engine Operation 6. Service and Maintenance

3.1 Commissioning 6.1 Lubrication System
2. Engine Description 3.1.1 Adding Engine Oil 6.1.1 Oil Change Intervals
2.1 Model 3.1.2 Adding Fuel 6.1.2 Check Oil Level, Change Engine Oil
2.1.1 Rating Plate 3.1.3 Other Preperations 6.1.3 Changing Oil Filter
2.1.2 Position of the Rating Plate 3.1.4 Additional Maintenance Work 6.1.4 Clean/Replace Oil Filter (Cup)
2.1.3 Engine Serial Number 3.2 Starting 6.2 Fuel System
2.1.4 Cylinder Numbering 3.2.1 Electric Starting 6.2.1 Replace Fuel Filter
2.1.5 Fuel Delivery Lock 3.3 Monitoring Operation 6.2.2 Clean/Replace Fuel Filter (Cup)
2.2 Engine Illustrations 3.3.1 Engine Oil Pressure 6.2.3 Clean Stainer of Fuel Filter
2.2.1 Operation Side: 3.3.2 Engine Temperature 6.2.4 Change Fuel Leakage Line
Example FL 2011 3.4 Shutting Off 6.3 Cooling System
2.2.2 Exhaust Side: 3.4.1 Mechanical Shut-Off 6.3.1 Cleaning Intervals
Example FL 2011 3.4.2 Electric Shut-Off 6.4 Combustion Air Filter
2.2.3 Operation Side: 3.5 Operating Conditions 6.4.1 Cleaning Intervals
Example BF4L 2011 3.5.1 Winter Operation 6.4.2 Emptying Cyclone-Type Precleaner
2.2.4 Exhaust Side: 3.5.2 High Ambient Temperature, High Altitude 6.4.3 Dry Type Air Cleaner
Example BF4L 2011 6.5 Belt Drives
2.2.5 Operation Side: 4. Operating Media 6.5.1 Check V-belt
Example FM 2011 4.1 Lube Oil 6.5.2 Tensioning Alternator Belts
2.2.6 Exhaust Side: 4.1.1 Quality 6.5.3 Changing Alternator Belts
Example FM 2011 4.1.2 Viscosity 6.6 Adjustments
2.2.7 Operation Side: 4.2 Fuel 6.6.1 Check Valve Clearance, adjust if necessary
Example BFM 2011 4.2.1 Quality 6.6.1.1 Valve Clearance Adjustment Schematic
2.2.8 Exhaust Side: 4.2.2 Winter-Grade Fuel 6.7 Accessories
Example BFM 2011 6.7.1 Battery
2.3 Oil Circuit 5. Service 6.7.2 Rotary Current Alternator
2.3.1 Lube Oil Circuit Schematic 5.1 Service Plan 6.7.3 Transportation Shackles
2.4 Fuel System Schematic 5.2 Scheduled Maintenance Plan 6.8 Engine Cleaning
2.4.1 Fuel System 5.3 Maintenance Chart 6.8.1 Engine Cleaning
2.5 Coolant System 5.4 Maintenance Work Completed
2.5.1 Coolant Plan
Contents
7. Faults, Causes and Remedies

7.1 Fault Table
8. Engine Preservation
8.1 Preservation
8.1.1 Preserving Engine
8.1.2 Removing Engine Preservatives
9. Technical Specification
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
10. Service
C 2000
C 2000
General
DEUTZ Diesel Engines Care and Maintenance Service
1
are the product of many years of research and Sound care and maintenance practices will ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or for
with stringent quality standards, guarantee their placed on it. Recommended service intervals must spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance work carry out repairs quickly and professionally, using
consumption. carried out conscientiously. only genuine spare parts.
It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced
meet the highest standards for environmental demanding operating conditions. in accordance with state-of-the-art technology.
protection. Please turn to the end of this manual for further
service information.
Beware of Running Engine Safety

California
Proposition 65 Warning
Shut the engine down before carrying out mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
DEUTZ original parts are asbestos-

free.
1
Engine Description
2
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
C2001
Engine Description 2.1 Model
2.1.1 Rating Plate 2.1.2 Position of the Rating Plate 2.1.3 Engine Serial Number
2
C
A B
© 26 332 2 © 31 864 0 © 31 865 0
The model A, the engine serial number B and The rating plate C is attached to the valve The engine serial number B is stamped on
the performance data are stamped on the cover. the crankcase D as well as the rating plate.
rating plate.
The model and engine serial number must be given
when ordering parts.
C2001
2.1 Model Engine Description
2.1.4 Cylinder Numbering 2.1.5 Fuel Delivery Lock
2
1 2 3 4
© 26 431 0 © 26 387 0
Cylinders are numbered consecutively, The manufacturer shall not be held liable for
beginning at the flywheel. damages resulting from adjustments made
to the regulator by the operator.
The lock screws are protected in order to
prevent this:
1. with locking paint on model:
with torque balancer
2. with plastic protective cap on model:
without torque balancer.
Adjustments to the regulator

are to be carried out only by
C2001
authorised DEUTZ SERVICE
specialists
Engine Description 2.2 Engine Illustration
2.2.1 Operation Side

2 FL 2011
1 Oil filler neck (valve-gear housing cover)

2 Charge-air line / air-intake line
1 3 Fan with integrated generator
21 4 Narrow V-belt
5 Tractive electromagnet
2 6 Wheel-housecover
20 7 V-belt pulley on crankshaft
8 Oil pan
3 9 Shut-off lever
10 Speed control lever
11 Oil dipstick
19 4 12 Oil drain plug
13 Crankcase
14 Oil fill point (on side of crankcase)
5 15 Fuelpump
18 16 Easy-change fuel filter
17 Connecting facility for oil heater
18 Lube oil replacement filter
19 Removable coolant intake hood
17 20 Injection pumps
6 21 Oil cooler
16
7
15
C2001
14 13 12 11 10 9 8
© 31 873 1
2.2 Engine Illustration Engine Description
2.2.2 Exhaust Side
FL 2011 2
22 Date plate
23 Optional attachment of an SAE housing
24 Flywheel with ring gear
25 Starter
26 Front cover
27 Crankcase
28 Exhaust manifold
29 29 Air intake pipe
22
28
27
23
26 24
26
C2001
© 31 874 1

2 Example: BF4L 2011

21 1 2 3 Fan with integrated generator
4 Narrow V-belt
3 6 Wheel-housecover
7 V-belt pulley on crankshaft
8 Oil pan
20 9 Shut-off lever
11 Oil dipstick
19 12 Crankcase
4 14 Fuelpump
18 15 Easy-change fuel filter
17 Charge-pressure-dependent full-load stop
17 5 (CPD)
19 Removable coolant intake hood
20 Injection pumps
16 21 Oil cooler
6
15
14 7
C2001
13 12 11 10 9 8
© 31869 1
2.2.4 Exhaust Side
Example: BF4L 2011 2
22 Cylinder head
23 Exhaust manifold line
32 24 Flywheel with ring gear
25 Starter
26 Crankcase
27 Lube oil feed line to turbocharger
31 28 Lube oil return line from turbocharger
29 Induction pipe
22 30 Turbocharger (TC)
31 Intake manifold
29 32 Charge-air line
23
27
30 24
28
26
25
C2001
© 31 868 1

2 FM 2011

3 Alternator
4 Narrow V-belt
6 Timing belt cover
8 Oil pan
9 Shut-off lever
11 Oil dipstick
12 Oil drain plug
12 Crankcase
14 Fuelpump
15 Easy-change fuel filter
18 Injection pump(s)
19 Oil cooler connection
20 Fuel leakage line
21 Injection valve(s)
C2001
© 31 875 2
2.2.6 Exhaust Side
FM 2011 2
22 Cylinder head
23 Exhaust manifold
24 Flywheel with ring gear
25 Starter
26 Starter guard (optional)
27 Crankcase
28 Air intake pipe
C2001
© 31876 2

2 BFM 2011
1 Air-intake pipe
2 Fanwheel
4 Narrow V-belt
6 Timing belt cover
7 Shut-off lever
10 Oil dipstick
11 Fuelpump
15 Injection pump(s)
16 Oil cooler connection
17 Injection valve(s)
C2001
© 31 861 0
2.2.8 Exhaust Side
BFM 2011 2
19 Crankcase ventilation (optional)
20 Cylinder head cover
21 Exhaust manifold
22 SAEhousing
23 Starter
24 Crankcase
25 Turbocharger
26 Generator with cover
27 Charge-air line
28 Oil filler neck
C2001
© 31 862 0
Engine Description 2.3 Oil Circuit
2.3.1 Lube Oil Circuit Schematic

2
1 Oil pan
2 Oil-intake pipe
3 Oil pump
4 Main oil duct
5 Oil-cooled cylinders
6 Cylinder head cooling neck
7 Oil duct for rocker arm lubrication
8 Rocker arm
9 Oil manifold for the thermostat
10 Intake to external engine oil cooler
11 Return from external engine oil cooler
12 Thermostat housing with slide thermostat
13 Oil duct to oil filter
14 Oil filter
15 Oil duct to cam, con-rod and crankshaft
bearings
16 Spray nozzle for piston cooling
17 Oil return via crankcase to oil pan
18 Lube oil intake to turbocharger
19 Turbocharger
20 Return from turbocharger to oil pan
C2001
© 31877 2
2.4 Fuel System Schematic Engine Description
2.4.1 Fuel System
2
1 Fuel line from tank to fuel pump
2 Fuelpump
3 Fuel line from fuel pump to easy-change fuel
filter
5 Fuel line from filter to injection pump
6 Injection pump
7 Fuel distributor line
8 Injection line
9 Injection valves
11 Fuel overflow pipe
12 Fuel return line to tank
The installation of a fuel pre-

filter/hand pump between the
fuel tank and the engine is
C2001
prescribed to protect the
© 31 863 0
engines against dirt in the fuel.
2
C2001
Engine Operation
3
3.1 Commissioning
3.2 Starting
3.3 Monitoring Operation
3.4 Shutting Off
3.5 Operating Conditions
Engine Operation 3.1 Commissioning
3.1.1 Adding Engine Oil 3.1.1.2 Initial Engine Oil Fill-Up

3 3.1.1.1 Initial Engine Oil Fill-Up for
B/FL 2011 B/FM 2011
● Fill oil into oil pan up to "Max." mark on engine ● Fill oil into oil pan up to "Min." mark on engine
dipstick (for oil quantity see 9.1). dipstick.
OIL ● Start engine and allow to run at low idling speed ● In addition, top up oil quantity of supply hoses
for approx. 2 mins. and of external oil cooler (according to manufac-
● Switch off engine. turer’s specifications).
● Check oil level, if necessary, top up oil to "Max." ● Allow engine to run warm until thermostat opens
mark. (at approx. 95°C).
● Allow engine to run for approx. 2 mins.
● Switch off engine.
● Check oil level, and if necessary, top up oil to
"Max." mark.
© 26 432 0
As a rule, engines are delivered without oil.

Pour lube oil into the oil filler neck (arrow).
For oil grade and viscosity, see 4.1.
If the person operating the engine does not run up

the engine until the thermostat opens, the oil level
may lie above the "Max." mark on the engine
dipstick when delivered. The level can then only be
assessed after the engine has been run up.
3.1 Commissioning Engine Operation
3.1.2 Adding Fuel

3.1.1.3 Initial Engine Oil Fill-Up 3
B/FM 2011 Genset Engine
● Fill oil into oil pan up to "Max." mark on engine
dipstick (for oil quantity see 9.1).
● Start engine and allow to run at low idling speed
for approx. 2 mins.
FUEL
● Check oil level and fill up with oil up to upper
"Max." mark.
© 26 398 0
Use only commercial-grade diesel fuel. For fuel

grade, see 4.2. Use summer or winter-grade fuel,
depending on the ambient temperature.
Never fill the tank while the engine

is running.
! Ensure cleanliness!
Do not spill fuel!
Engine Operation 3.1 Commissioning
3.1.3 Other Preparations 3.1.4 Additional Maintenance Work

3
● Check battery and cable connectors, When commissioning new and reconditioned en-
see 6.7.1. gines, the following additional maintenance work
must be carried out:
● Transport hooks
Remove if fitted (see 6.7.3) ● Change lube oil,
see 6.1.1. + 6.1.2.
● Trial run
After engine has been prepared, let it run for ● Change oil filter cartridge,
about 10 minutes without being loaded. see 6.1.3.
During and after trial run ● Change fuel filter cartridge,

- Check engine for leaks. see 6.2.1.
After engine has been turned off
- Check oil level, ● Check V-belts and retension as necessary,
see 6.1.2. see 6.5.
Top up with oil, if necessary,
see 3.1.1. ● Check engine for leaks
- Retension V-belt,
see 6.5). ● Check engine mounts, retighten if necessary,
see 9.2.
● Check valve clearance, adjust if necessary,

see 5.1. + 6.6.1.
3
Engine Operation 3.2 Starting
3.2.1 Electric starting

3 Without cold start assistance
Before starting, make sure that no-

body is standing in the immediate
vicinity of the engine or driven ma- 2
! chine.
After repair work:
Check that all guards have been
replaced and that all tools have been removed from
the engine.
When starting with glow plugs, do not use any other
starter substance (e.g. injection with start pilot).
Risk of accident!
Caution: If the speed regulator has been re- 1
moved, the engine must not be tested under any
circumstances.
Disconnect the battery!
© 26 423 0 © 25 746 2
● Where possible, disengage clutch to separate ● Insert key

engine from any driven parts. - Position 0 = no operating voltage
● Move speed control lever 1 into idle position. ● Turn key clockwise
● Move shut-off handle 2 into operating position. - Position 1 = operating voltage
- Pilot lights come on
● Push key in and turn further clockwise against
spring pressure.
- Position 2 = no function
- Position 3 = start
● Release key as soon as engine fires
- Pilot lights go out.
Do not actuate the starter for more than 20 sec-
onds. If the engine does not catch, wait a minute
then try again.
If the engine does not catch after two attempts,
refer to the Fault Table (see 7.1).
3.2 Starting Engine Operation
With cold start assistance 3

- Glow plug
© 25 746 2
● Insert key
- Position 0 = no operating voltage
● Turn key clockwise
- Position 1 = operating voltage
- Pilot lights come on
● Push key in and turn further clockwise against
spring pressure.
- Position 2 = preheat, hold for approx. 1 minute.
- Preheat lamp comes on
- Position 3 = start
● Release key as soon as engine fires
- Pilot lights go out
Engine Operation 3.3 Monitoring Operation
3.3.1 Engine Oil Pressure

3 Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge
© 25 752 1 © 25 753 0 © 25 754 0
● Oil pressure pilot light comes on with operating ● Pointer must remain in green sector over entire ● Pointer must indicate minimum oil pressure
voltage on and engine off. operating range. (see 9.1).
● Oil pressure pilot light should go out when
engine is running.
3.3 Monitoring Operation Engine Operation
3.3.2 Engine Temperature

Engine Temperature Gauge
3
© 24 985 0
● Engine temperature gauge pointer should re-

main in green sector most of time. It should
rarely enter yellow-green sector. If pointer enters
orange sector, engine is overheating. Turn off
and establish cause from Fault Table (see 7.1).
Engine Operation 3.4 Shutting Off
3.4.1 Mechanical Shut-Off 3.4.2 Electric Shut-Off

3 (Ignition Key)
© 26 424 0 © 25 746 2
● Move speed adjustment lever 1 to low idle. ● Turn key anticlockwise (to position 0) and re-
● Move shut-off lever 2 until engine comes to a move. Pilot lights will go out.
stop.
Charge pilot light and oil pressure pilot light will
come on when engine stops.
● Turn key anticlockwise (to position 0) and re-
move. Pilot lights will go out.
If possible, do not suddenly switch off engine when

under full load.
3.5 Operating Conditions Engine Operation
3.5.1 Winter Operation

3
● Lube Oil Viscosity ● Battery
- Select oil viscosity (SAE grade) according to - Efficient cold starting requires that battery is
ambient temperature before starting engine, well-charged, see 6.7.1.
see 4.1.2. - Starting limit temperatures can be lowered by
- Increase oil change frequency when operating 4-5°C by heating battery up to about +20°C. (To
below -10°C, see 6.1.1. do so, remove battery and store in warm place).
● Diesel Fuel
- Use winter-grade diesel fuel for operation be
low 0°C, see 4.2.2.
● Additional Maintenance Work

- Drain sludge from fuel tank once a week (undo
sludge drain screw).
- If necessary, allow oil in oil bath air cleaner and
engine oil to settle at ambient temperature.
© 26 248 0
- Below -20°C, after removing starter if neces
sary, smear ring gear on flywheel via pinion
bore from time to time with cold-resistant
grease.
(e.g. Bosch grease FT 1 V 31).
● Cold Start Assistance

- At temperatures near or below freezing point,
use glow plugs if necessary, see 3.2.1.
This not only lowers starting limit temperature,
but provides easier starting at temperatures
normally not requiring a starting aid.
Engine Operation 3.5 Operating Conditions
3.5.2 High Ambient Temperature,

3 High Altitude
● Air density decreases as altitude or ambient
temperature increases. As a result of this, the
engine’s maximum output, quality of exhaust
gas, temperature level and, in extreme cases,
starting behaviour, are impaired. Engine can be C F
used at altitudes up to 1000 m and temperatures
up to 30°C for mobile operations. If the engine is
to operate under more severe conditions (at
higher altitudes or temperatures), it will be nec-
essary to reduce the injected fuel quantity and
thus engine power. 0 32
● If you have any doubts about engine operation
under these or similar conditions, ask your en-
gine or equipment supplier whether the engine
has been derated in the interests of reliability,
service life and exhaust gas quality (smoke).
Otherwise contact DEUTZ SERVICE. 25 901 1
Operating media
4.1 Lube Oil

4.2 Fuel
C 2000
Operating Media 4.1 Lube Oil
4.1.1 Quality Grade 4.1.2 Viscosity

4
Lube oils are differentiated by Deutz according Generally, multi-grade oils shall be used. In
to their performance and quality class. Oils of closed heated rooms at temperatures >5°C,
other, comparable specifications can be used. also single-grade oils can be used.
As the viscosity of lube oil is dependent on

temperature, the choice of SAE grade should
be governed by the ambient temperature
Approved oils: prevailing at the engine operating site.
Optimum operating behaviour will be attained
if you take the accompanying oil viscosity
Deutz DQC I DQC II DQC III diagram as a guide.
Should the temperature fall temporarily below
ACEA E2-96 E3/96/E5-02 E4-99 the limits of the SAE grade selected, cold
API CF/CF-4 CH-4/CG-4 - starting may be affected but the engine will
not be damaged.
DHD - DHD-1 - In order to keep wear to a minimum, do not
exceed application limits for extended periods
of time.
The precise assignment of the admissible
oil qualities to the engines is indicated in Synthetic lube oils feature an improved
chapter 6.1.1. temperature and oxidation stability.
If in doubt, contact your service represen-
tative.
© 2003
Only with preheating

30 298 1
4.2 Fuel Operating Media
4.2.1 Quality 4.2.2 Winter-Grade Fuel

4
Use commercially available diesel fuel with less Waxing may occur at low temperatures, clogging
+32 0
than 0.5% sulphur content. If the sulphur content is the fuel system and reducing engine efficiency. If I
higher, oil change intervals should be reduced (see the ambient temperature is less than 0°C, winter-
+23 -5
6.1.1). grade fuel (suitable down to -15°C) should be used.
(This fuel is usually available from filling stations
+14 - 10
The following fuel specifications / standards are well in advance of the cold months). Diesel fuel
approved: containing additives (Super diesel) is often on sale
+ 5 - 15
as well, for use down to -20°C.
● DIN EN 590
● At temperatures below -15°C to -20°C, kerosene - 4 - 20
● BS 2869 should be added to the diesel fuel. The relevant
percentages are given in the adjacent diagram. - 13 - 25
● ASTM D 975-96; 1-D and 2-D II
If summer-grade diesel fuel must be used at tem- - 22 - 30
● NATO Code F-54 / F-34 / F-44 and XF 63 peratures below 0°C, up to 60% kerosene can be 0 10 20 30 40 50 60 %
added (see diagram). °F °C B
Exhaust emission values which may be determined A
© 26 441
26441 11
in the case of type approval tests always refer to the In most cases, adequate resistance to cold can also
reference fuel prescribed by the authorities for the be obtained by adding a flow improver (additive).
type approval test. Please inquire at DEUTZ SERVICE. Legend:
I Summer-grade diesel fuel

II Winter-grade diesel fuel
A Ambient temperature
B Percentage of kerosene added
Diesel fuels must never be mixed Mix in tank only! Fill with the ap-
with petrol (Normal and Super propriate amount of kerosene first,
C 2000
! grades)!
! then add the diesel fuel.
4
C 2001
Service
5
5.1 Service Plan
5.2 Scheduled Maintenance Plan
5.3 Maintenance Chart
5.4 Maintenance Work Completed
Service 5.1 Service Plan
Deutz maintenance and service schedule = E check = z adjust = clean = V replace = Industrial engines Section
5 prior to or during 1st trial run, check 2x daily during the breaking-in phase or The specified engine maintenance intervals are
when commissioning new and overhauled engines permissible recommended maximums. Depending
on usage, reduced maintenance intervals may be
every 10 operating hours or daily necessary (comply with the unit manufacturer’s
in operating hours (OH) every operating instructions).
E10 E20 E25 E30 E40 E50 E60 E70 Years #Maintenance must only be carried out by authorise
500 1000 3000 5000 6000 12000 1 2 Operation service personnel
z z Top lube oil up if necessary 6.1.2/3.1.4
FL 2011 lube oil, see TC 0199-99-3002 6.1.1/ 6.1.2
BFL 2011 lube oil, see TC 0199-99-3002 6.1.1/ 6.1.2
z V Oil bath (lube oil quality, see TC 0199-99-3002 / Dry type filter 6.4
Oil filter cartridge FL 2011 6.1.3
Oil filter cartridge BFL 2011 6.1.3
Fuel filter cartridge
V Change fuel pump/strainer if necessary 6.2.2
z Flexible fuel leakage lines, see TC 0138-21-9300 6.2.1/ 6.2.3
z Injection valve #
z V Fuelpre-cleaner 4.2
z Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3 /6.4.4
z Battery and cable connectors 6.7.1
z z Engine monitoring system, warning system (replace if necessary) 3.3 #
Valveclearance 6.6.1#
V-belt 6.5.#
z Crankcase pressure vent valve #
Timing belt, extreme-duty, see adjacent table #
Timing belt, heavy-duty, see adjacent table #
Timing belt, light-duty, see adjacent table #
z Check engine for leaks (visual inspection) –
z Engine mount (replace if damaged) 9.2
Basic overhaul #
5.1 Service Plan Service
Timing belt change intervals Engine application Engine/ application/operating parameters

Guideline values in OH Example: Example:
5
6000 or max. 5 years Generating sets 1500/1800 rpm; pump units, low speed; moderate ambient temperature;
lowspeed;platformlifts;refrigerationunitsetc. lowdustexposure
5000ormax.5years compressors;rollers;forklifttrucks;weldingunits; wheelloaders;mediumtohighvariablespeed;highambient

small dumpers; ski-steer loaders etc. temperature moderate dust exposure
3000 or max. 5 years agricultural machinery; ski-steer loaders; wheel loaders; drillinghigh speed; impact loads; extreme ambient
temperature;
equipment; trench-cutting machines; joint cutters; bulldozers etc. high dust exposure
5 Service
5.2 Scheduled Maintenance Plan
5.2.1 Scheduled Maintenance Plan
Intervals Deutz maintenance Operation Carried out by:
at/after and service schedule
50 OH E10 After commissioning and E 50-E 70 Authorisedspecialists
Daily E20 Dailycheck Operator
250 OH E25 Inspection Authorisedspecialists
500 OH E30 Extendedinspection Authorisedspecialists
1000 OH E40 Interim overhaul Authorisedspecialists
3000 OH E50 Extendedinterimoverhaul Authorisedspecialists
6 000 OH E60 Partialoverhaul Authorisedspecialists
12000 OH E70 Basicoverhaul Authorisedspecialists
5.3 Maintenance Chart Service
5
The maintenance chart shown here is supplied as a in. 0,3mm
self-adhesive label with each engine. It should be 1 0.012in. 1 4 h /Bh
a
ex. 0,5mm
affixed where it can be seen clearly on the engine or 0.020in.
ex.
driven equipment. 2
in. 1000 125ñ2000
Check that this is the case.
3 BFM/BFL 4
If necessary, ask your engine or equipment supplier OIL
500
for a fresh supply of labels. 5
2 BFM/BFL FM/ FL
Routine work should be carried out according to the 500 1000
6
schedule in 5.1. B/FM2011 5
FM/ FL
OIL
1000
1 4 10 OIL
max.
3 2 6
1000
FU
EL 1000
6
2011 5 B/FL2011
02979935 0
Stop the engine before carrying out

any maintenance work.
5.4 Maintenance Work Completed Service
Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5
50-150* -
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
* Following commissioning of new and overhauled engines
Duly completed maintenance jobs can be recorded and signed off in the above chart.
Service 5.4 Maintenance Work Completed

5
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
5.4 Maintenance Work Completed Service

5
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
Service 5.4 Maintenance Work Completed

5
Service and Maintenance
6
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling system
6.4 Combustion Air Filter
6.5 Belt Drives
6.6 Adjustments
6.7 Accessories
6.8 Engine Cleaning
C 2001
Service and Maintenance 6.1 Lubrication System
6.1.1 Oil Change Intervals

6
● The oil change intervals are dependent on ● If, for vehicle engines, lube oil change
the engine application and the quality of intervals are determined by operating hours,
the lube oil. the lube oil change intervals indicated in table
6.1.1.1. equipment engines.
● If the engine runs fewer hours during the
year than stated in the table, the oil should
be changed at least once a year.
● The table refers to the following condi-

tions:
– For diesel fuel: sulfur content max. 0.5
% by weight.
– Continuous ambient temperatures down
to -10 °C / +14°F
● For fuels
– with sulfur content is > 0.5 to 1 %
or
– continuous ambient temperature below
-10 °C/+14°F
or
– with bio-diesel fuels in accordance with
DIN 51606-FAME the intervals between
oil changes should be halved.
● In the case of fuels containing more than

1 % sulfur, contact your service repre-
sentative.
© 2002
Change the oil with the engine off but still

warm (lube oil temperature approx. 80 °C).
6.1 Lubrication System Service and Mantennace
6.1.1.1 Lube oil change intervals for Installation engines
6
Lube oil grade
Deutz lube oil quality class DQC I DQC II DQC III
ACEA-specfication E2-96 E3-96/E5-02 E4-99
API-specification CF/CF-4 CG-4/CH-4 -
Worldwide specification - DHD-1 -
special DEUTZ release list - - Enclosure 4.1
Standard lube oil code for building EO... EO...C -
equipment and nonraod vehicles EO...A, EO...B
Engine Lube oil change intervals in op. hours

series Engine version Oil use Oil use Oil use
normal high normal high normal high
1011F/ 2011 Naturalli aspirated engines 1000 500 1000 500 1000 500
Turbocharged engines 250 125 500 250 500 250
*Gensets as referred to here are units operating in parallel with the mains / with each other.
Emergency power units are dealt with in TR 0199-99-1126
C 2001
6.1 Lubrication System Service and Maintenance
6.1.2 Check Oil Level /
Change Engine Oil 6
6.1.2.1 Check Oil Level 6.1.2.2 Change Engine Oil
© 25 729 0 © 26 022 0 © 26 023 0
● Switch engine off before checking oil level. ● Allow engine to warm up. ● Place oil tray under engine.
● Ensure that engine or vehicle is level. ● Ensure that engine or vehicle is level. ● Unscrew oil drain plug.
● Remove oil dipstick. - Lube oil temperature approx. 80°C. ● Drain oil.
● Wipe dipstick with non-fibrous, clean cloth. ● Switch off engine. ● Fit oil drain plug with new seal ring and tighten
● Insert it to stop and remove again. firmly (for torque, see 9.2)
● Check oil level, and if necessary, top up to "MAX" ● Pour in lube oil
mark. - For grade / viscosity, see 4.1
- If oil level is only just above "MIN" mark, more - For quantity, see 9.1
oil must be added. ● Check oil level, see 6.1.2.1.
Caution when draining hot oil: Risk

of scalding!
! Do not let used oil run into the soil
but collect it in a container!
C 2001
Dispose of this in accordance with
The level must not fall below the "MIN" mark. environmental regulations!
Service and Maintenance 6.1 Lubrication System
6.1.3 Changing Oil Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
● Undo lube oil filter cartridge using commercial ● Clean any dirt from filter carrier sealing surface. ● Tighten lube oil filter cartridge with another half-
tool and spin off. turn.
● Lightly oil rubber gasket of new lube oil filter
● Catch any escaping oil. cartridge. ● Check oil level, see 6.1.2.
● Manually screw in new cartridge until gasket is ● Check oil pressure, see 3.3.1.
flush.
● Check lube oil filter cartridge seal for leaks.
Caution is required in case of hot

oil: Risk of scalding!
C 2001
!
6.1 Lubrication System Service and Maintenance
6.1.4 Clean / Replace

Oil Filter (Cup) 6
4
© 30 074 0
● Switch off engine. ● Replace and lightly oil rubber gasket 2.

● Loosen lube oil filter cover 1 and unscrew in ● Carefully insert new paper filter cartridge 3 into
anticlockwise direction. guide 4.
● Carefully loosen paper filter cartridge 3 upwards ● Tighten lube oil filter cover 1 in clockwise direc-
from guide 4. tion (25 Nm).
● Catch any escaping oil. ● Start engine.
● Replace paper filter cartridge 3. ● Check oil level, see 6.1.2.
● Clean any dirt from sealing surface of filter carrier ● Check oil pressure, see 3.3.1.
and lube oil filter cover 1 and from guide 4. ● Check lube oil filter attachment for leaks.
Caution is required in case of hot

oil:
C 2001
! Risk of scalding!
Service and Maintenance 6.2 Fuel System
6.2.1 Replace Fuel Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
● Close fuel shut-off valve. ● Clean any dirt from filter carrier sealing surface. ● Tighten fuel filter cartridge with final half-turn.
● Undo fuel filter cartridge with commercial tool ● Apply light film of oil or diesel fuel to rubber ● Open fuel shut-off valve.
and spin off. gasket of new fuel filter cartridge.
● Check for leaks.
● Catch any escaping fuel. ● Manually screw in new cartridge until gasket is
flush.
Keep naked flames away

when working on the fuel
C 2001
! system. Do not smoke! The fuel system does not need to be bled.
6.2 Fuel System Service and Maintenance
6.2.2 Clean / Replace

Fuel Filter (Cup) 6
4
© 30 074 0
● Switch off engine. ● Replace and lightly oil rubber gasket 2.

● Loosen fuel oil filter cover 1 and unscrew in ● Carefully insert new paper filter cartridge 3 into
anticlockwise direction. guide 4.
● Carefully loosen paper filter cartridge 3 upwards ● Tighten fuel filter cover 1 in clockwise direction
from guide 4. (25 Nm).
● Catch any escaping fuel. ● Start engine.
● Replace paper filter cartridge 3. ● Check fuel filter attachment for leaks.
● Clean any dirt from sealing surface of filter
carrier and fuel filter cover 1 and from guide 4.
Keep naked flames away when work-

ing on the fuel system. Do not
!
C 2001
smoke!
Service and Maintenance 6.2 Fuel System
6.2.3 Clean Strainer of Fuel Filter 6.2.4 Change Fuel Leakage Line
6
4 2
2 3
3
1
1
© 26 436 0 © 31 867 0
● Close fuel shut-off valve. ● Mount fuel strainer cover 2. ● Close fuel shut-off valve.
● Loosen and unscrew hexagonal nut 1. ● Tighten hexagonal screw 1. ● Disconnect rubber hoses 3 from injection valves.
● Remove fuel strainer cover 2 (cover and strainer, ● Check for leaks. ● Disconnect rubber hose 1 from fuel tank.
one unit). ● Disconnect rubber hoses 4, 3 and 1 from unions
● Clean fuel strainer 2 with diesel fuel. Replace if 2 and dispose of in an environmentally friendly
necessary. manner.
● Place seal 3 in position. ● Connect new rubber hoses 4, 3 and 1 to unions 2.
● Connect rubber hoses 3 to injection valves.
● Connect rubber hose 1 to fuel tank.
● Open fuel shut-off valve.
● Check for leaks after start-up.
Keep naked flames away when work-

ing on the fuel system. Do not
C 2001
! smoke!
6.3 Cooling System Service and Maintenance
6.3.1 Cleaning Intervals

6
● Amount of contamination in cooling system
depends on engine application. Checking or cleaning intervals
Guideline values OH Engine application
● Oil and fuel residues on engine increase risk of
contamination. Therefore pay special attention 2000 Ships, generating sets in enclosed areas, pumps.
to leaks if engine is used in dusty environments.
● Serious contamination can occur, for example: 1000 Vehicles on paved roads
- on construction sites where there is a high
level of air-borne dust. 500 Tractors, fork-lift trucks, mobile generating sets
- in harvesting applications where there are high
concentrations of chaff and chopped straw in 250 Vehicles on construction sites and unpaved roads, construc-
vicinity of machine.
tion machines, compressors, underground mining units
● Because applications vary, cleaning intervals
have to be determined from case to case. Clean- 125 Agricultural machines, tractors in harvesting applications
ing intervals given in table on right can be used
as a guide.
Service and Maintenance 6.4 Combustion Air Filter
6.4.1 Cleaning Intervals 6.4.2 Emptying Cyclone-Type

6 Precleaner
● Amount of dirt in air cleaner depends on amount

of dust in air and size of air cleaner used. If high
level of dust is anticipated, cyclone-type
precleaner can be fitted to air cleaner.
● Cleaning intervals will have to be determined

from case to case.
● If dry type air filters are used, cleaning should

only be carried out according to service indicator
or service switch.
● Air cleaner servicing is needed when:

- Service indicator
red signal 1 is fully visible when engine is off.
- Service switch
© 25 885 1 © 25 886 0
yellow pilot light comes on when engine is
running.
● Undo wing nut 1 and remove cover 2.
● pressing button on service indicator. Service ● Remove collector bowl 3 from lower section 4
indicator is now ready for operation again. and empty. Clean leaves, straw and other foreign
matter from lower section of pre-cleaner.
● Reposition collector bowl 3 onto lower section 4,
fasten cover 2 in place by tightening wing nut 1.
Never fill collector bowl with oil. Replace collector

bowl if damaged.
6.4 Combustion Air Filter Service and Maintenance
6.4.3 Dry Type Air Cleaner

Discharge Valve Filter Cartridges 6
© 25 888 1 © 25 889 0
● Empty dust discharge valve 1 by pressing apart ● Undo clip fasteners 1. ● After five cleaner services or after two years at
lips of discharge slot as indicated by arrows. ● Take off hood 2 and remove cartridge 3. latest, replace safety cartridge 4 (never clean).
● Clean discharge slot from time to time. ● Clean cartridge, replace at least once a year. To do so:
● Remove any caked dirt by pressing together ● Clean cartridge 3. - Undo hex nut 5 and remove cartridge 4.
upper section of valve. Using dry compressed air (max. 5 bar), blow out - Install new cartridge, fit and tighten hex nut.
from inside to outside (or in difficult cases, tap ● Install cartridge 3, replace hood 2 and do up clip
out, taking care not to damage cartridge, or wash fasteners 1.
according to manufacturer’s instructions).
● Gaskets on filter cartridge can become damaged
through regular removal and replacement. Check
paper filter (light showing through) and gaskets
for damage.
Replace if necessary. Never clean filter cartridge with pet-
rol or hot fluids.
!
Service and Maintenance 6.5 Belt Drives
6.5.1 Check V-belt

6
© 31 866 0 © 26 261 0
● Visually inspect entire V-belt for damage. - Carefully remove gauge without altering posi-
● Replace damaged V-belts. tion of indicator arm 1.
● After installing new belts, run engine for 15 - Read off value where black indicator arm 1
minutes, then check belt tension. intersects scale 5 (arrow). For settings, see
● To check tension of V-belt, use tension gauge 9.1.
(see 9.3). - If necessary, retension belt and measure again.
- Place indicator arm 1 into gauge.
- Position guide 3 on V-belt 2, midway between
pulleys, with stop against edge of belt.
- Push slowly on black pad 4 at right angles to V-
belt 2 until spring is heard or felt to trigger.
Check, tension and change belts

only with engine off. Refit belt guard,
! if provided. After installing new belts, run engine for 15 min-
utes, then check belt tension.
6.5 Belt Drives Service and Maintenance
6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts

6
3 5 3 5
1 1
4 4
2 2
© 31 859 0 © 31 860 0
● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1, 2 and 3.

● Adjust alternator 4 in direction of arrow by
● Adjust alternator 4 in direction of arrow by turning bolt 3.
turning bolt 3 until correct belt tension is achieved. ● Remove and replace belt.
● Adjust alternator 4 against direction of arrow by
● Retighten bolts 1, 2 and 3. turning bolt 3, until correct belt tension is
achieved.
● Retighten bolts 1, 2 and 3.
Check, tension and change belts

only with engine off. Refit belt guard,
! if provided.
Service and Maintenance 6.6 Adjustments
6.6.1 Check Valve Clearance, adjust

6 if necessary
© 19 691 2 © 25 893 0
● Remove cylinder head cover. ● Adjust valve clearance if necessary:

● Position crankshaft as per schematic, see 6.6.1.1. - Release locknut 4.
● Before adjusting valve clearance, allow engine to - Use Allan key 7 to turn setscrew 5 so that
cool down for at least 30 minutes. Oil tempera- correct clearance is attained after locknut 4 has
ture should be below 80°C. been tightened.
● Check valve clearance 1 between rocker arm / ● Check and adjust valve clearance on all cylin-
tappet contact face 2 and valve stem 3 with feeler ders.
gauge 6 (there should be only slight resistance ● Reinstall cylinder head cover, with new gasket if
when feeler blade is inserted). necessary.
For permissible valve clearance, see 9.1.
6.6 Adjustments Service and Maintenance
6.6.1.1 Valve Clearance Adjust 6

ments Schematic
● Crankshaft Position 1:
1 Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance of valves marked
in black on schematic. Mark respective rocker
1 2 1 2 3 1 2 3 4 arm with chalk to show that adjustment has been
carried out.
2 ● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in black on
schematic.
1 2 1 2 3 1 2 3 4
© 25 894 4
Service and Maintenance 6.7 Accessories
6.7.1 Battery
6 6.7.1.1 Check Battery and Cable 6.7.1.2 Check Electrolyte Level 6.7.1.3 Check Electrolyte Density
Connectors
© 25 895 0 © 24 232 3 © 25 896 0
● Keep battery clean and dry. ● Remove sealing caps 1. ● Measure electrolyte density of individual cells
● Undo dirty clamps. ● If testers 2 are present: with commercial hydrometer.
● Clean terminal posts (+ and -) and clamps of Electrolyte level should reach base of these.
battery, and grease with acid-free and acid- ● Without testers: Hydrometer reading (see table on following page)
resistant grease. Electrolyte level should be 10-15 mm above top indicates battery’s state of charge.
● When reassembling, ensure that clamps make of plates. During measurement, temperature of electrolyte
good contact. Tighten clamp bolts hand-tight. ● If necessary, top up with distilled water. should preferably be +20°C.
● Screw sealing caps back in.
6.7 Accessories Service and Maintenance
Electrolyte density
in [kg/ l] in [°Bé (Baumé scale)*] Charge status
Normal Tropical Normal Tropical
1.28 1.23 32 27 well charged
1.20 1.12 24 16 semi-charged, re-charge
1.12 1.08 16 11 discharged, immediately charge
*Measurement of electrolyte density in °Bé (Baumé

scale) is out of date and rarely used today.
The gases emitted by the battery

are explosive! Keep sparks and na-
! ked flames away from the battery!
Do not allow battery acid to come
into contact with skin or clothing!
Wear protective goggles!
Do not rest tools on the battery!
Service and Maintenance 6.7 Accessories
6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles

6
Notes on the three-phase system:
● Never disconnect cables between battery, alter-
nator and regulator while engine is running.
● If, however, it is necessary to start and operate
engine without battery, disconnect regulator from
alternator before starting.
● Be sure not to confuse battery terminals. 1
● Replace defective charge pilot lamp bulb imme-
diately.
● When washing engine, cover up alternator and
regulator.
● Touching lead against frame to check whether it 2
is live must not, under any circumstances, be
carried out with three-phase electrical systems.
● In case of electric welding, connect ground ter-
minal on welder directly to piece being welded.
© 31 871 0 © 31 870 0
● Always use proper lifting tackle 1 when trans-

porting engine.
● After transportation and before commissioning
of engine: remove attachment eyes 2.
Use only correct lifting gear.
!
6.8 Engine Cleaning Service and Maintenance
6.8.1 Engine Cleaning

6
Preperation
● Remove engine covers and cooling air hood.
Replace them after cleaning and before test run.
● Cover electrical / electronic components and
connections (e.g. alternator, starter, governor,
solenoid).
Using compressed air
● Blow air through engine, taking particular care
not to damage cooler and cooling fins (begin to
blow through air from exhaust side).
Remove dirt which has blown into interior space.
Using cold-cleaning compound
● Spray engine with commercial cold-cleaning
compound and allow to react for approx. 10
mins.
● Spray-clean engine with strong water jet, repeat
if necessary.
● Allow engine to run warm so that remaining
water evaporates.
Using high-pressure device
● Clean engine with steam jet (max. spray pres-
sure of 60 bar, max. steam temperature of 90ºC).
● Allow engine to run warm so that remaining
water evaporates.
Clean the engine only when the en-

gine is switched off.
!
6
Faults, Causes and Remedies
7.1 Fault Table

Faults, Causes and Remedies 7.1 Fault Table
7
● Faults are often caused by engine not being
properly operated or maintained.
● Each time fault occurs, check whether all operat-

ing and servicing regulations have been com-
plied with.
● Corresponding fault table can be found on adja-

cent page.
● If you cannot ascertain cause of a fault or cannot

rectify fault, please contact DEUTZ SERVICE.
7.1 Fault Table Faults, Causes and Remedies
Faults Measures
Engine does not start or is difficult to start Check Ch 7
Engine starts, but runs irregularly or fails Adjust A
Engine becomes excessively hot. Temperature warning system responds Replace Rp
Engine output is deficient Clean Cl
Engine does not run on all cylinders Top up T
Engine oil pressure is non-existent or excessively low Reduce Rd
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Not declutched (where possible) Engine Operation Ch
● ● Below starting limit temperature Ch
● ● Oil level too low T
● ● ● ● Oil level too high Ch
● ● ● Excessive inclination of engine Rd
● ● Incorrect lube oil SAE class or quality Operating media Rp
● ● ● ● Fuel quality not as per operating manual Rp
● ● ● Air cleaner clogged / turbocharger defective Combustion air Ch / Rp
● ● ● Air cleaner service switch / indicator defective Ch / Rp
● CPD * defective Ch
● ● Charge air line leaking Ch
● Oil cooler panels clogged Ch / Cl
● Cooling fan defective, split or loose V-belt Cooling system Ch / Rp
● Cooling air temperature rise / heating short circuit Ch
● Resistance in cooling system too great / through-flow quantity too small Ch
● Battery defective or discharged Electrics Ch / T
*CPD = Charge pressure-dependent full-load stop
Faults, Causes and Remedies 7.1 Fault Table
Faults Measures
7 Engine does not start or is difficult to start Check Ch
Engine starts, but runs irregularly or fails Adjust A
Engine becomes excessively hot. Temperature warning system responds Replace Rp
Engine output is deficient Clean Cl
Engine does not run on all cylinders Top up T
Engine oil pressure is non-existent or excessively low Reduce Rd
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Electric cable connections to starter electrical system loose or oxidised Electrics Ch
● Starter defective or pinion does not engage Ch
● Solenoid defective (release switch) Ch
● ● ● ● ● Incorrect valve clearance Engine A
● ● ● Injection line leaks Ch
● ● ● ● ● ● ● Injection valve defective Ch / Rp
Engine Preservation
8
8.1 Preservation
Engine Preservation 8.1 Preservation
8.1.1 Preserving Engine 8.1.2 Removing Engine

8 Preservatives
If the engine is to remain idle for an extended period ● Clean engine using high-pressure equipment ● Remove anti-corrosion agent from grooves in
of time, it is necessary to take protective measures to (or with cold-cleansing agent in emergency). V-belt pulleys.
prevent rusting. The preservative measures described ● Run engine until warm, then turn off. ● Install V-belt, retension after brief operation if
here will protect the engine for up to 6 months. ● Drain engine oil (see 6.1.2) and fill with anti- necessary, see 6.5.
The procedure will have to be reversed before the corrosion oil. ● Remove covers from intake port and exhaust
engine is recommissioned. ● If necessary, clean oil bath cleaner (see 6.4.3) port.
● Anti-corrosion oils to specification: and fill with anti-corrosion oil. ● Commission engine, see also 5.1, note 2.
MIL-L-21260B ● Drain fuel tank.
TL 9150-037/2 ● Make up a mixture of 90% diesel fuel and 10%
Nato Code C 640 / 642 anti-corrosion oil, and refill fuel tank.
● Anti-corrosion media for exterior protection only ● Allow engine to run for approx. 10 mins.
to specification: ● Switch off engine.
Nato Code C 632 ● Turn engine over manually several times to pre-
● Recommended cleaning agent to remove preserve cylinders and combustion chamber.
servatives: ● Remove V-belts and store in wrapped condition.
Petroleum benzine ● Spray grooves on V-belt pulleys with anti-corro-
(hazardous materials class A3) sion spray.
● Close intake ports and exhaust ports.
Technical Specification
9
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
Technical Specification 9.1 Engine Specifications and Settings
Model
9 Number of cylinders
———— F2L 2011 ————— F3L 2011 —————— F4L 2011 ————
————— 2 ————————— 3 ———————— 4 ——————
Cylinder arrangement ————————————— vertical in line ——————————————
Bore [mm] ———————————————— 94 ————————————————
Stroke [mm] ——————————————— 112 ————————————————
Total displacement [cm3] ———— 1554 ——————— 2331 ———————— 3108 —————
Compression ratio [ε] ———————————————— 19 ————————————————
Working cycle ———————————— 4-stroke diesel engine ————————————
Combustion system ——————— Naturally aspirated engine with direct injection ————————
Direction of rotation —————————— On left when looking at flywheel ——————————
Weight incl. integral cooling system to DIN 70020-A
(without starter, with alternator) approx. [kg] ————— 175 ———————— 217 ———————— 256 —————
Engine output [kW (hp)] ———————————————— 1) ———————————————————
Speed [rpm] ———————————————— 1) ———————————————————
Lubrication ———————————— Pressure lubrication —————————————
SAE oil —————————————— 20 W 20 ———————————————
Maximum oil temperature in oil pan [°C] ——————————————— 130 ————————————————
Min. oil pressure in warm condition, oil temperature 110°C
at: 900 rpm (low idling speed) [bar] ——————————————— 1.4 3) ——————————————————
1800 rpm [bar] ——————————————— 2.2 3) ——————————————————
max. 2800 rpm [bar] ——————————————— 3 3) ——————————————————
Oil change quantity (oil pan) approx. [l] ————— 6 2) ————————— 5.5 2) ————————— 10 2) ——————
Oil change quantity with filter (standard 0.5 l) approx. (l) ———— 6.5 2) ————————— 6 2) ———————— 10.5 2) ——————
Valve clearance with cold engine
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————————— Inlet 0.3 +0.1 / Exhaust 0.5 +0.1 ———————————
Start of feed [°crankshaft BTDC] ———————————————— 1) ———————————————————
Injector opening pressure: vehicle/unit [bar] ——————————————— 210 +8 ——————————————————
Firing order of engine ————— 1 - 2 ——————— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 ————
V-belt tension: pretension / retension (after engine has been running under load for 15 mins)[N] ————————————— 450 / 350 ±20 ——————————————
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Approx. values can vary depending on sump and/or cooler design (external cooling system). Upper oil dipstick mark is always authoritative.
3)
Values for engines without engine oil heating.
9.1 Engine Specifications and Settings Technical Specification
Model
Number of cylinders
——— BF3L 2011 ————————— BF4L 2011 ————
————— 3 ———————————— 4 ——————
9
Cylinder arrangement —————————— vertical in line ———————————
Bore [mm] ———————————— 94 —————————————
Stroke [mm] ———————————— 112 ————————————
Total displacement [cm3] ———— 2331 ——————————— 3108 —————
Compression ratio [ε] ———————————— 17.5 ————————————
Working cycle / Combustion system ——— Four-stroke diesel with turbocharging and direct fuel injection ——
Direction of rotation —————— On left when looking at flywheel ———————
Weight without cooling system
Weight without starter, with alternator as per DIN 70020-A approx. approx. [kg] ————— 222 ———————————— 257 —————
Engine output [kW (hp)] —————————————— 1) —————————————
Speed [rpm] ———————————— 1) —————————————
Lubrication ————————— Pressure lubrication —————————
SAE oil ——————————— 20 W 20 ————————————
Maximum oil temperature in oil pan [°C] ———————————— 130 ————————————
at: 900 rpm (low idling speed) [bar] ———————————— 1.4 3) ——————————————
1800 rpm [bar] ———————————— 2.2 3) ——————————————
max. 2800 rpm [bar] ———————————— 3 3) ——————————————
Oil change quantity (oil pan without cooling system) ca. [l] ————— 7.5 ———————————— 10 2) ——————
Oil change quantity with filter (Standard 0.5 l) approx. (l) ————— 8 ——————————— 10.5 2) ——————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————— Inlet 0.3 + 0.1 / Exhaust 0.5 + 0.1 ———————
Injector opening pressure: vehicle/unit [bar] ——————————— 210 + 8 ———————————
Start of feed [°crankshaft BTDC] —————————————— 1)
————————————
Firing order of engine ———— 1 - 2 - 3 —————————— 1-3-4-2 —————
V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N] —————————— 450 / 350 ±20 ——————————
1)
2)
3)
Technical Specification 9.1 Engine Specifications and Settings
Model — F2M 2011 ————— F3M 2011 ———— F4M 2011 ——

9 Number of cylinders ——— 2 ———————— 3 ———————— 4 ————
Bore [mm] ———————————— 94 —————————————
Stroke [mm] ———————————— 112 ————————————
Total displacement [cm3] —— 1554 ——————— 2331 —————— 3108 ———
Compression ratio [ε] ———————————— 19 —————————————
Working cycle ———————— 4-stroke diesel engine —————————
Combustion system ————— Naturally aspirated engine with direct injection —————
Direction of rotation ——————— On left when looking at flywheel ——————
Weight without cooling system ————————— Refer to head-office —————————
(without starter, with alternator) approx. approx. [kg] —— 169 ——————— 210 —————— 248 ———
Engine output [kW (hp)] ———————————— 1) ———————————————
Speed [rpm] ———————————— 1) ———————————————
SAE oil ——————————— 20 W 20 ————————————
Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar] ———————————— 1.4 3) ——————————————
1800 rpm [bar] ———————————— 2.2 3) ——————————————
max. 2800 rpm [bar] ———————————— 3 3) ——————————————
Engine with Thermostat
Oil change quantity without external cooler (see 3.1.1.2)/without filter approx. [l] —————— 5.5 2) ————————— 10 2) ————————
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre) approx. [l] ——————— 6 2) ————————— 10.5 2) ————————
Genset Engine without Thermostat:
Oil change quantity including external cooler (see 3.1.1.3)/without filter approx. [l] —————— 8.5 2) ————————— 13 2) ————————
Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l] ——————— 9 2) ————————— 13.5 2) ————————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). [mm] ——————— Inlet 0.3 +0.1 / Exhaust 0.5 +0.1 ———————
Start of feed [°crankshaft BTDC] ———————————— 1) ———————————————
Injector opening pressure: vehicle/unit [bar] ——————————— 210 +8 ————————————
Firing order of engine —— 1-2 —————— 1 - 2 - 3 ————— 1 - 3 - 4 - 2 ——
V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N] —————————— 450 / 350 ±20 ——————————
1)
2)
3)
9.1 Engine Specifications and Settings Technical Specification
Model ————— BF3M 2011 ————— BF4M 2011 ——————
Number of cylinders ——————— 3 ————————— 4 ———————— 9
Bore [mm] ———————————— 94 —————————————
Stroke [mm] ———————————— 112 ————————————
Total displacement [cm3] —————— 2331 ———————— 3108 ———————
Compression ratio [ε] ———————————— 17.5 ————————————
Working cycle ———————— 4-stroke diesel engine —————————
Combustion system ——————— Turbocharging and direct injection ————————
Direction of rotation ——————— On left when looking at flywheel ——————
Weight without cooling system ————————— Refer to head-office —————————
(without starter, with alternator) approx. [kg] —————— 215 ———————— 250 ———————
Engine output [kW (hp)] ———————————— 1) ————————————
Speed [rpm] ———————————— 1) ————————————
SAE oil ——————————— 20 W 20 ————————————
Min. oil pressure in warm condition, oil temperature 110°C at: 900 rpm (low idling speed) [bar] ———————————— 1.4 3) ————————————
1800 rpm [bar] ———————————— 2.2 3) ————————————
max. 2800 rpm [bar] ———————————— 3 3) —————————————
Engine with Thermostat
Oil change quantity without external cooler (see 3.1.1.2) / without filter approx. [l] ——————— 7.5 ———————— 10 2) ———————
Oil change quantity without external cooler (see 3.1.1.2) + filter replacement (standard 0.5 litre) approx. [l] ——————— 8 ———————— 10.5 2) ———————
Genset Engine without Thermostat:
Oil change quantity including external cooler (see 3.1.1.3) / without filter approx. [l] ——————— 11 ———————— 13.5 2) ———————
Oil change quantity including cooler (see 3.1.1.3) + filter replacement (standard 0.5 litre) approx. [l] —————— 11.5 ———————— 14 2) ———————
(Engine cooling time at least 30 min.: oil temperature should be below 80°C). ——————— Inlet 0.3 +0.1 / Exhaust 0.5 +0.1 ———————
[mm]
Start of feed ———————————— 1) —————————————
[°crankshaft BTDC]
Injector opening pressure: vehicle/unit ——————————— 210 +8 ————————————
[bar]
Firing order of engine —————— 1-2-3 —————— 1-3-4-2 ——————
V-belt tension: pretension / retension (after engine has been running under load for 15 mins): [N] ————————— 450 / 350 ±20 ———————————
1)
2)
3)
Tecnical Specification 9.2 Torque Wrench Settings
9 Installation location Pre-tension [Nm] Re-tension [Nm] Total Comments
1st stage 2nd stage 3rd stage 1st stage 2nd stage 3rd stage 4th stage [Nm]
Cylinder head cover 8.5
Cylinder head cover 8.5
Rocker arm adjustment screw 21
Intake manifold 8.5
Foot Rigid suspension 30 45
Foot Elastic suspension 106
Air intake pipe 21
Exhaust manifold 22
Oil drain plug 55
Oil pan (sheet metal) 21
Oil pan (cast) 31
Injection line attachment 30
Injection valve attachment 21 TORX
Lube oil filter cartridge 27 on engine or separate
Threaded pipe union 4
9.3 Tools Technical Specification
TORX V-belt tension gauge

9
25899 0 26002 0
A TORX BN. 8189 screw set is used with engines in The V-belt tension gauge can be obtained under
the 1011 series. order number 8115 from:
This system was chosen because of the many
advantages it offers: FA.WILBÄR
Postfach 14 05 80
● Outstanding accessibility to bolts. D-42826 Remscheid
● High load transfer when loosening and tighten-
ing.
● Almost impossible for socket to slide off or
break, thereby practically ruling out risk of in-
jury.
TORX tools can be ordered from:
FA.WILBÄR
Postfach 14 05 80
D-42826 Remscheid
Notice
Notes
en Warnings to Place on Equipment Warning in the Manual
CALIFORNIA CALIFORNIA
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Diesel engine exhaust and some of its
constituents are known to the State of constituents are known to the State of
California to cause cancer, birth California to cause cancer, birth
defects, and other reproductive harm. defects, and other reproductive harm.
or
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Notes
CALIFORNIA PROPOSITION 65 INFORMATION en

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.
The warning must appear in one of the following locations:

● Inside The front cover
● Inside the back cover
● Outside the front cover
● Outside the back cover
● As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
Service
Knowing it’s DEUTZ Order-No.: 0312 0806 10

en DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manu-
facturer, we offer — worldwide — a com-
prehensive range of diesel and gas motors
spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job

reliably all over the world. We are determined to
preserve the high standard of performance and
dependability of our motors, thus keeping our
customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors

which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support Order-No.: 0312 0807 (CD-ROM)
to enhance your motor’s performance.
This index Sales & Service offers you an overview

of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the Obtainable from the local service Partner reponsible DEUTZ AG
range of services provided. But even when no direct for you or from: Deutz-Mülheimer Str. 147-149
product responsibility is mentioned, your DEUTZ D-51057 Köln
partner will be happy to help you with expert advice.
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. Telex: 8812-0 khd d
http://www.deutz.de
DEUTZ AG — at your service.

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Operation Manual

● Please read and observe the information

Please enter the engine serial number here. This

Technical modifications required to improve our

Liquid-cooled Deutz engines are designed for a

Your engine is appropriately equipped for the

We have endeavoured to highlight any differences

Please read this Manual before starting your engine,

We are available to help with any additional inquiries

1. General 3. Engine Operation 6. Service and Maintenance

7. Faults, Causes and Remedies

Beware of Running Engine Safety

DEUTZ original parts are asbestos-

© 26 332 2 © 31 864 0 © 31 865 0

Adjustments to the regulator

2.2.1 Operation Side

1 Oil filler neck (valve-gear housing cover)

2.2.3 Operation Side

1 Oil filler neck (valve-gear housing cover)

2.2.5 Operation Side

1 Oil filler neck (valve-gear housing cover)

2.2.7 Operation Side

2.3.1 Lube Oil Circuit Schematic

The installation of a fuel pre-

3.1.1 Adding Engine Oil 3.1.1.2 Initial Engine Oil Fill-Up

As a rule, engines are delivered without oil.

If the person operating the engine does not run up

3.1.2 Adding Fuel

Use only commercial-grade diesel fuel. For fuel

Never fill the tank while the engine

3.1.3 Other Preparations 3.1.4 Additional Maintenance Work

During and after trial run ● Change fuel filter cartridge,

● Check valve clearance, adjust if necessary,

3.2.1 Electric starting

Before starting, make sure that no-

● Where possible, disengage clutch to separate ● Insert key

With cold start assistance 3

3.3.1 Engine Oil Pressure

© 25 752 1 © 25 753 0 © 25 754 0

3.3.2 Engine Temperature

● Engine temperature gauge pointer should re-

3.4.1 Mechanical Shut-Off 3.4.2 Electric Shut-Off

If possible, do not suddenly switch off engine when

3.5.1 Winter Operation

● Additional Maintenance Work

● Cold Start Assistance

3.5.2 High Ambient Temperature,

4.1 Lube Oil

4.1.1 Quality Grade 4.1.2 Viscosity

As the viscosity of lube oil is dependent on

Only with preheating

4.2.1 Quality 4.2.2 Winter-Grade Fuel

I Summer-grade diesel fuel

Timing belt change intervals Engine application Engine/ application/operating parameters

5000ormax.5years compressors;rollers;forklifttrucks;weldingunits; wheelloaders;mediumtohighvariablespeed;highambient

Stop the engine before carrying out

Op. hours Date Signature/stamp Op. hours Date Signature/stamp

Op. hours Date Signature/stamp Op. hours Date Signature/stamp

Op. hours Date Signature/stamp Op. hours Date Signature/stamp