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Operation Manual 2012

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Operation Manual 2012 Operation Manual 2012 ® DEUTZ • Please read and observe the information • Unauthorized engine modifications will in­ given in this Operation Manual. This will validate any Iia bility clai ms against the manu­ enable you to avoid accidents, preserve facturer for resultant damage. the manufacturer's warranty and maintain Manipulations ofthe injection and regulating the engine in peak operating condition. system may also influence the performance ofthe engine, and its emissions. Adherence • This engine has been built exclusively for to legislation on pollution cannot be guaran­ the application specified in the scope of teed under such conditions. supply, as described by the equipment manufacturer and is to be used only for the • Do not change, convert oradjust the cooling intended purpose. Any use exceeding that air intake area to the blower. scope is considered to be contrary to the The manufacturer shall not be held respon­ intended purpose. The manufacturer will sible for any damage which results from not assume responsibility for any damage such work. resulting therefrom. The risks involved are to be borne solely by the user. • When carrying out maintenance/repair op­ erations on the engine, the use of DEUTZ • Use in accordance with the intended pur­ original parts is prescribed. These are pose also implies compliance with the con­ specially designed for your engine and ditions laid down by the manufacturer for guarantee perfect operation. operation, maintenance and servicing. The Non-compliance results in the expiry of the engine should only be operated by person­ warranty! nel trained in its use and the hazards involved. • Maintenance and cleaning of the engine should only be carried out when the engine • The relevant accident prevention gUidelines is switched off and has cooled down. and other generally accepted safety and You must ensure that the electrical systems industrial hygiene regulations must be ob­ have been switched off and the ignition served. key has been removed. Accident prevention guidelines concerning • When the engine is running, there is a risk electrical systems (e.g. VDE-01 00/-01 01/ of injury through: -0104/-0105 Electrical protective measures - turning/hot components against dangerous touch voltage) are to be - engines with positive ignition observed. - ignition systems (high electrical voltage) When cleaning with fluids, all electrical You must avoid contact at all times! components are to be covered impermeably. Operation Manual 2012 02979912 en Engine Serial ITIIIIJJ 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 DEUTZ this Operation Manual. No parts of this Manual C") o may be reproduced in any form or by any means o N without our written approval. @ Foreword Dear Customer, Liquid-cooled DEUTZ engines are designed for a large number of applications. Conse­ quently, a wide range ofvariants are offered to meet the requirements of specific cases. Your engine is appropriately equipped for the installation concerned, which means that not all ofthe components described in this Opera­ tion Manual are necessarily mounted to your engine. We have endeavored to highlight any differ­ ences so that you will be able to locate the operating and maintenance instructions rel­ evant 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 1©\31493101 (\') o o N @ Index 1. General 3.2.1 Electric Starting 6.1.1 Oil Change Intervals 3.3 Monitoring Operation 6.1.2 Check Oil Level, Change Engine Oil 2. Engine Description 3.3.1 Engine Oil Pressure 6.1.3 Replace Oil Filter 3.3.2 Coolant Temperature 6.1.4 Clean/Replace Oil Filter (Cup) 2.1 Model 3.4 Shutting off 6.2 Fuel System 2.1.1 Rating Plate 3.4.1 Mech. Stopping 6.2.1 Replace Fuel Filter 2.1.2 Position of the Rating Plate 3.4.2 Electr. Stopping 6.2.2 Clean / Replce Fuel Oil Filter (Cup) 2.1.3 Engine Serial Number 3.5 Operating Conditions 2.1.4 Cylinder Enumeration 3.5.1 Winter Operation 6.2.3 Clean / purge or change fuel Fuel 2.2 Engine Illustrations 3.5.2 High Ambient Temperature, High Alt- pre-filter 2.2.1 Operating Side 2012 itude 6.2.4 Bleed Fuel System Ribbed V-belt Drive with Fuel Pre-filter 2.2.2 Starter Side 2012 4. Operating Media 6.2.5 Bleed Fuel System Ribbed V-belt Drive 4.1 Lube Oil without Fuel Pre-filter 2.2.3 Operating Side 2012 4.1.1 Quality 6.2.6 Clean/Replace Fuel Pre-Filter, Filter 2.2.4 Starter Side 2012 4.1.2 Viscosity Element 2.3 Lube Oil Circuit Schematic 4.2 Fuel 6.2.7 Clean/Replace/VentFuel Pre-Filter, 2.3.1 Lube Oil Plan 4.2.1 Quality Filter Element 2.4 Fuel System 4.2.2 Winter Fuel 6.3 Cooling System 2.4.1 Fuel System Plan 4.3 Coolant 6.3.1 Cleaning Intervals 2.5 Coolant System 4.3.1 Water Quality for Coolant 6.3.2 Clean Cooling System 2.5.1 Coolant Plan 2012 4.3.2 Coolant Treatment 6.3.3 Drain Cooling System 4.3.3 Cooling System Protectants 6.3.4 Fill / Bleed Cooling System 3. Engine Operation 6.4 Combustion Air Filter 3.1 Commissioning 5. Routine Maintenance 6.4.1 Cleaning Intervals 3.1.1 Pour in Engine Oil 6.4.2 Emptying Cyclone Type Precleaner 5.1 Maintenance Plan 3.1.2 Filling Oil Bath Air Filter with Engine 6.4.3 Clean Oil Bath Air Filter 5.2 Maintenance Diagram Oil 6.4.4 Dry Type Air Cleaner 5.3 Maintenance Work Completed 3.1.3 Pour in Fuel 6.5 Belt Drives 3.1.4 Fill / Bleed Cooling System 6.5.1 Check V-belts 3.1.5 Other Preparations 6. Service and Maintenance - 2012 Standard ('f) 3.2 Starting 6.1 Lubrication System 0 - 2012 with Ribbed V-belt 0 N @ Index 6.5.2 Tension V-belts 7. Faults, Causes and Remedies Coolant / Fuel Pump 7.1 Fault Table 6.5.3 Replace V-belts Coolant / Fuel Pump 8. Engine Preservation 6.5.4 Replace V-belts 8.1 Preservation Ribbed V-belts 6.5.5 Tensjon Alternator V-belts 9. Technical Specification 6.5.6 Replace Alternator V-belts 6.5.7 Wedge rib V-belts wear limit examine 6.6 Adjustments 9.1 Engine Specifications and Settings 6.6.1 CheckValve Clearance(AdjustifNeces- 9.2 Screw Tightening Torques sary) 9.3 Tools 6.6.1.1 Valve Clearance Adjustment Plan 6.7 Accessories 10. Service 6.7.1 Battery 6.7.2 Rotary Current Alternator 6.7.3 Transportation Shackles ('f) o o N @ General DEUTZ Diesel Engines Care and Maintenance Service I are the product ofmany years ofresearch and Sound care and maintenance practices will en­ Please contact one of our authorized service development. The resulting know-how, cou­ sure that the engine continues to meet the re­ representatives in the event of breakdowns or pled with stringent quality standards, guaran­ quirements placed on it. Recommended service for spare parts inquiries. Our trained special­ tee their long service life, high reliability and intervals must be observed and service and ists will carry out repairs quickly and profes­ low fuel consumption. maintenance work carried out conscientiously. sionally, using only genuine spare parts. It goes without saying that DEUTZ Diesel Special care should be taken under abnormally Original parts from DEUTZ AG are always Engines meet the highest standards for envi­ demanding operating conditions. produced in accordance with state-of-the-art ronmental protection. technology. Please turn to the end ofthis manual for further service information. Beware of Running Engine Safety Asbestos Shutthe engine down before carrying out mainte­ This symbol is used for all safety DEUTZ original parts are nance or repair work. Ensure that the engine warnings. Pleasefollowthem care- asbestosfree. cannot be accidentally started. Risk ofaccidents. ' .. fully. The attention of operating When the work is complete, be sure to refit any . • personnel should be drawn to panels and guards that may have been removed. & these safety instructions. General Neverfill the fuel tank while the engine is running. safety and accident prevention Observe industrial safety regulations when run­ regulations laid down by law must also be ob­ ning the engine in an enclosed space or under­ served. ground. ('f) o o N @ I ('I) o o N @ Engine Description 2.1 Model 2.2 Engine Illustrations 2.3 Lube Oil Circuit Schematic 2.4 Fuel System 2.5 Coolant System oM o N @ Engine Description 2.1 Model I 2.1.1 Rating Plate 2.1.2 Position of the Rating Plate 2.1.3 Engine Serial Number 1©12633213 The model A, the engine serial number Band The rating plate C is attached to the crankcase. The engine serial number is stamped on the the performance data are stamped on the crankcase (arrow) as well as the rating plate. rating plate.The model and engine serial number must be given when ordering parts. ('I') o o N @ 2.1 Model Engine Description 2.1.4 Cylinder Enumeration I Cylinders are numbered consecutively, be­ ginning at the flywheel. Mo o C\I @ Engine Description 2.2 Engine Illustration !II 2.2.1 Operating Side 2012 III Ribbed V-belt drive 1 Alternator 2 Oil filler 3 Coolant connection compensation line 4 Fan pulley 5 Fuel pump 6 Coolant pump 7 Ribbed V-belt pulley on crankshaft 8 Tension roller 9 Feet 10 Oil pan 11 Oil filler neck 12 Oil filter housing with engine oil cooler 13 Oil dipstick 14 Optional attachment of: Compressor or hydraulic pump 15 Fuel filter cartridge 16 Oil filter cartridge 17 Tractive electromagnet ('t') o o N @ 2.2 Engine Illustration Engine
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