Deutz BF4M 2012 Operation Manual Download Page 78

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Technical Specification

9.1 Engine Specifications and Settings

Model

-----------

----------- BF4M 2012

BF4M 2012

BF4M 2012 ------------------------

------------------------

------------------------ BF4M 2012 C

BF4M 2012 C

BF4M 2012 C ---------------------- BF6M 2012 C

BF6M 2012 C

BF6M 2012 C -------

Number of cylinders

------------------ 4 --------------------------------------- 4 ---------------------------------------- 6 ---------------

Cylinder arrangement

----------------------------------------------------- vertical in line -------------------------------------------------

Bore

[mm] ---------------------------------------------------------- ø 101 -------------------------------------------------------

Stroke

[mm] ----------------------------------------------------------- 126 --------------------------------------------------------

Total displacement

[cm

] ---------------- 4.04 ----------------------------------- 4.04 ----------------------------------- 6.06 -------------

Compression ratio

[

]. ------------------------------------------------------------ 19 ---------------------------------------------------------

Working cycle

-------------------------------------------------- Four-stroke diesel ----------------------------------------------

Combustion system

---------------------------------- with turbocharging and direct fuel injection ------------------------------

Charge air cooling

--------------- without --------------------------------- with ------------------------------------ with -------------

Direction of rotation

-------------------------------------------------- counter-clockwise -----------------------------------------------

Weight 2012/ C including cooling system
to DIN 70020-A [approx.kg]

------------------------------------------------- Refer to head-office ---------------------------------------------

Engine output

[kW] ------------------ 75 ------------------------------------ 103 ------------------------------------ 155 -------------

Max. speed

[1/rpm] ---------------------------------------------------------- 2500 -------------------------------------------------------

Valve clearance with cold engine (PTs)

[mm] ----------------------------------------- Inlet 0.3

+ 0.1

/ exhaust 0.5

+ 0.1

. --------------------------------------

Valve clearance with cold engine standard [mm] ------------------------------------ Adjustment with special tool, see 6.6.1 ---------------------------------
Injector opening pressure

[bar] ----------------------------------------------------------- 250 --------------------------------------------------------

Start of feed

[

CS BTOC] -------------------------------------------------------------

. ---------------------------------------------------------

Firing order of the engine

-------------- 1-3-4-2 ------------------------------- 1-3-4-2 ----------------------------- 1-5-3-6-2-4 --------

V-belt tension:

-------------------------------------------- Pre-tension / re-tension 2)

----------------------------------------------------------------------

Alternator / fan

[N] ----------------------------------------------------- 450 / 300

. --------------------------------------------------

Fuel pump - coolant pump

[N] ----------------------------------------------------- 450 / 300

. --------------------------------------------------

Compressor

[N] ----------------------------------------------------- 550 / 450

. --------------------------------------------------

Ribbed V-belt tension spring-loaded tension roller [N] ----------------------------------------------------- 900 / 600

. --------------------------------------------------

Engine output, speed, start of delivery are stamped on engine rating plate, etc., see also 2.1.

Re-tension 15 minutes after the engine has been operated under load.

Summary of Contents for BF4M 2012

Page 1: ... to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliation between Ingersoll Rand Company and Doosan Company or the products of either Revised 10 12 ...

Page 2: ...h electrical voltage You must avoid contact at all times Unauthorized engine modifications will in validateanyliabilityclaimsagainstthemanu facturer for resultant damage Manipulations of the injection and regulating system may also influence the performance of the engine and its emissions Adherence to legislation on pollution cannot be guaran teed under such conditions Do not change convert or adj...

Page 3: ... 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 be reproduced in any form or by any means without our written approval Operation Manual Operation Manual Operation Manual Operation Manual Operation Manual 2012 2012 2012...

Page 4: ...uipped for the installation concerned which means that not allofthecomponentsdescribedinthisOpera 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 opera...

Page 5: ...t Replace if Necessary 6 2 3 Bleed Fuel System with Fuel Pre filter 6 2 4 Bleed Fuel System without Fuel Pre filter 6 3 Cooling System 6 3 1 Cleaning Intervals 6 3 2 Clean Cooling System 6 3 3 Drain Cooling System 6 3 4 Fill Bleed Cooling System 6 4 Combustion Air Filter 6 4 1 Cleaning Intervals 6 4 2 Emptying Cyclone Type Precleaner 6 4 3 Clean Oil Bath Air Filter 6 4 4 Dry Type Air Cleaner 6 5 B...

Page 6: ...ransportation Shackles 7 7 7 7 7 Faults Causes and Remedies Faults Causes and Remedies Faults Causes and Remedies Faults Causes and Remedies Faults Causes and Remedies 7 1 Fault Table 8 8 8 8 8 Engine Preservation Engine Preservation Engine Preservation Engine Preservation Engine Preservation 8 1 Preservation 9 9 9 9 9 Technical Specification Technical Specification Technical Specification Technic...

Page 7: ...n it Recommended service intervals must be observed and service and maintenance work carried out conscientiously Special care should be taken under abnormally demanding operating conditions Asbestos DEUTZ original parts are asbestos free Safety This symbol is used for all safety warnings Please follow them carefully Theattentionofoperating personnelshouldbedrawntothese safety instructions General ...

Page 8: ...1 ...

Page 9: ...2 2 Engine Illustrations 2 2 Engine Illustrations 2 2 Engine Illustrations 2 3 Lube Oil Circuit Schematic 2 3 Lube Oil Circuit Schematic 2 3 Lube Oil Circuit Schematic 2 3 Lube Oil Circuit Schematic 2 3 Lube Oil Circuit Schematic 2 4 Fuel System 2 4 Fuel System 2 4 Fuel System 2 4 Fuel System 2 4 Fuel System 2 5 Coolant System 2 5 Coolant System 2 5 Coolant System 2 5 Coolant System 2 5 Coolant Sy...

Page 10: ...The model and engine serial number must be given when ordering parts 2 1 2 2 1 2 2 1 2 2 1 2 2 1 2 Position of the Rating Plate Position of the Rating Plate Position of the Rating Plate Position of the Rating Plate Position of the Rating Plate The rating plate C C C C C is attached to the crankcase 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 Engine Serial Number Engine Serial Number Engine Serial Number Engine ...

Page 11: ...Description Engine Description Engine Description Engine Description 2 1 4 2 1 4 2 1 4 2 1 4 2 1 4 Cylinder Enumeration Cylinder Enumeration Cylinder Enumeration Cylinder Enumeration Cylinder Enumeration Cylinders are numbered consecutively be ginning at the flywheel 1 2 4 3 31 813 0 ...

Page 12: ...de 2012 Ribbed V belt drive Ribbed V belt drive Ribbed V belt drive Ribbed V belt drive 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 Compresso...

Page 13: ... 2 2 2 2 2 2 2 Starter Side 2012 Starter Side 2012 Starter Side 2012 Starter Side 2012 Starter Side 2012 Ribbed V belt drive Ribbed V belt drive Ribbed V belt drive Ribbed V belt drive Ribbed V belt drive 18 Turbocharger 19 Engine suspension 20 Speed regulator 21 Flywheel 22 SAE housing 23 Starter 24 Exhaust manifold 25 Coolant inlet 26 Heater flange not shown 27 Thermostat housing coolant outlet ...

Page 14: ...2 2 3 2 2 3 Operating Side 2012 Operating Side 2012 Operating Side 2012 Operating Side 2012 Operating Side 2012 1 Turbocharger 2 Heater flange 3 Fan 4 Alternator 5 V belt pulley on crankshaft 6 Coolant pump 7 Fuel pump 8 Oil filler 9 Oil filter housing with engine oil cooler 10 Oil filter housing with oil filter cartridge 11 Oil dipstick 12 Fuel filter 13 Tractive electromagnet 14 Oil filler neck ...

Page 15: ...scription Engine Description Engine Description 2 2 4 2 2 4 2 2 4 2 2 4 2 2 4 Starter Side 2012 Starter Side 2012 Starter Side 2012 Starter Side 2012 Starter Side 2012 15 Engine suspension 16 Speed regulator 17 Flywheel 18 SAE housing 19 Oil pan 20 Starter 21 Feet 22 Alternator 23 Coolant inlet 24 Exhaust manifold 25 Coolant outlet 31 485 0 16 17 22 21 23 24 25 15 18 19 20 ...

Page 16: ...nger bypass valve 4 2 Shut off valve 4 3 Lube oil replacement filter 4 4 Oil pressure sensor 5 Main oil pipe 6 Crankshaft bearing 7 Con rod bearing 8 Camshaft bearing 9 Line to spray nozzle 10 Spray nozzle for piston cooling 11 Valve lifter with rocker arm impulse lubrica tion 12 Stop rod oil supply for rocker arm lubrication 13 Rocker arm 14 Return line to oil pan 15 Oil line to turbocharger 16 T...

Page 17: ... Fuel System Plan Fuel System Plan Fuel System Plan Fuel System Plan 1 Fuel tank 2 Line to fuel pump 3 Fuel pump 4 Line to fuel filter 5 Fuel filter 6 Line to the injection pumps 7 Injection pump 8 Line to injection valve 9 Injection valve 10 Banjoboltwithpressuremaintenancevalve 11 Return line to fuel filter housing from pressure maintenance valve with cup filter installation only 12 Return line ...

Page 18: ...mple With cup filter Example With cup filter Example With cup filter Example With cup filter Example With cup filter 1 Thermostat housing 2 Outlet neck cover 3 Coolant pump 4 Lube oil cooler 5 Cylinder cooling 6 Cylinder head cooling 7 Line from engine to heat exchanger 8 Heat exchanger 9 Line from heat exchanger to thermostat 10 Ventilation line to the compensation tank 11 Compensation tank 12 Co...

Page 19: ...3 2 3 2 3 2 Starting Starting Starting Starting Starting 3 3 3 3 3 3 3 3 3 3 Monitoring Operation Monitoring Operation Monitoring Operation Monitoring Operation Monitoring Operation 3 4 3 4 3 4 3 4 3 4 Shutting off Shutting off Shutting off Shutting off Shutting off 3 5 3 5 3 5 3 5 3 5 Operating Conditions Operating Conditions Operating Conditions Operating Conditions Operating Conditions ...

Page 20: ...gine Oil Pour in Engine Oil Pour in Engine Oil 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 Oil Bath Air Filter with Oil Bath Air Filter with Oil Bath Air Filter with Oil Bath Air Filter with Oil Bath Air Filter with Engine Oil Engine Oil Engine Oil Engine Oil Engine Oil Engine Operation Engine Operation Engine Operation Engine Operation Engine Operation 3 1 Commissioning 3 1 Commissioning 3 1 Commissioning 3 1 ...

Page 21: ...ial run During and after the trial run During and after the trial run During and after the trial run During and after the trial run Check the engine for leaks After the engine has been turned off After the engine has been turned off After the engine has been turned off After the engine has been turned off After the engine has been turned off Check oil level and top up if necessary see 6 1 2 Retens...

Page 22: ...rter substance e g injection with start pilot Risk of accident Caution If the speed regulator has been Caution If the speed regulator has been Caution If the speed regulator has been Caution If the speed regulator has been Caution If the speed regulator has been removed the engine must not be started removed the engine must not be started removed the engine must not be started removed the engine m...

Page 23: ...e against spring pressure Position 2 no function Position 3 start Release key as soon as engine fires The pilot lights will go out with cold start assistance with cold start assistance with cold start assistance with cold start assistance with cold start assistance Heater flange Heater flange Heater flange Heater flange Heater flange 3 2 Starting 3 2 Starting 3 2 Starting 3 2 Starting 3 2 Starting...

Page 24: ...aininthegreensector over the entire operating range The pointer of the oil pressure gauge must display the minimum oil pressure see 9 1 Oil Pressure Indicator Oil Pressure Indicator Oil Pressure Indicator Oil Pressure Indicator Oil Pressure Indicator Oil Pressure Gauge Oil Pressure Gauge Oil Pressure Gauge Oil Pressure Gauge Oil Pressure Gauge 3 3 1 3 3 1 3 3 1 3 3 1 3 3 1 Engine Oil Pressure Engi...

Page 25: ...off and establish the cause from the Fault Table see 7 1 3 3 2 3 3 2 3 3 2 3 3 2 3 3 2 Coolant temperature Coolant temperature Coolant temperature Coolant temperature Coolant temperature 3 3 Monitoring Operation 3 3 Monitoring Operation 3 3 Monitoring Operation 3 3 Monitoring Operation 3 3 Monitoring Operation Engine Operation Engine Operation Engine Operation Engine Operation Engine Operation 26 ...

Page 26: ...offlever2untiltheenginecomes to a stop The charge pilot light and the oil pressure pilot light illuminate when the en gine stops Turn key counterclockwise to position 0 and remove The pilot lights will go out Turn key counterclockwise to position 0 and remove The pilot lights will go out 3 4 1 Mechanical Stopping 3 4 1 Mechanical Stopping 3 4 1 Mechanical Stopping 3 4 1 Mechanical Stopping 3 4 1 M...

Page 27: ...ecessary smear the ring gear on the fly wheel via the pinion bore from time to time with cold resistant grease e g Bosch grease FT 1 V 31 Cold Start Assistance Theheaterflangeisautomaticallyinitialisedat temperatures 25 C Battery Efficient cold starting necessitates that the battery is well charged see 6 7 1 The starting limit temperatures can be low ered by 4 5 C by heating the bat teryuptoabout2...

Page 28: ...of this the engine s maximum output the quality of the exhaust gas the temperature level and in extreme cases starting behaviour are impeded In the event of non stationary operation use up to altitudes of 1000 m and tempera tures of 30 C is permissible If the engine is to operate under unfavour able conditions at higher altitudes or tem peratures it will be necessary to reduce the injected fuel qu...

Page 29: ...ating Media Operating Media Operating Media Operating Media 4 1 Lube Oil 4 1 Lube Oil 4 1 Lube Oil 4 1 Lube Oil 4 1 Lube Oil 4 2 Fuel 4 2 Fuel 4 2 Fuel 4 2 Fuel 4 2 Fuel 4 3 Coolant 4 3 Coolant 4 3 Coolant 4 3 Coolant 4 3 Coolant ...

Page 30: ...ity diagram as a guide Should the temperature fall temporarily below the limits of the SAE grade selected cold starting may be affected but the engine will not be damaged In order to keep wear to a minimum do not exceedapplicationlimitsforextendedperiods of time Synthetic lube oils feature an improved temperature and oxidation stability Only with preheating 30 298 1 LubeoilsaredifferentiatedbyDeut...

Page 31: ...pe of lube oil SAE class SAE class SAE class SAE class SAE class Availability Availability Availability Availability Availability DEUTZ DEUTZ DEUTZ DEUTZ DEUTZ TXL 10W40 FE TXL 10W40 FE TXL 10W40 FE TXL 10W40 FE TXL 10W40 FE 10W 40 10W 40 10W 40 10W 40 10W 40 AGIP Agip Sigma Ultra TFE 10W 40 worldwide AGIP Autol Valve Ultra FE 10W 40 Germany ARAL GmbH Aral MegaTurboral 10W 40 worldwide ARAL GmbH A...

Page 32: ...e available within good time by filling stations prior to the start of the winter season Kerosene must be added at temperatures below 20 C The relevant percentages are given in the adjacent diagram Special diesel fuels may be used in arctic climatic zones up to 44 C If summer grade diesel fuel must be used at temperaturesbelow0 C upto60 kerosene can be added see diagram In most cases adequate resi...

Page 33: ... 1 In addition to checking the coolant level this also involves checking the concentrationofthecoolingsystemprotectant The cooling system protectant concentration can be checked with commercially available testers example gefo glycomat 4 3 2 4 3 2 4 3 2 4 3 2 4 3 2 Coolant Treatment Coolant Treatment Coolant Treatment Coolant Treatment Coolant Treatment 4 3 3 4 3 3 4 3 3 4 3 3 4 3 3 Cooling System...

Page 34: ...protection protection protection protection in in in in in C C C C C For coolant content of your engine see Operation Manual Chapter 9 1 Note Grey sector only after consulting head office Cooling system protectant Cooling system protectant Cooling system protectant Cooling system protectant Cooling system protectant content of coolant system content of coolant system content of coolant system cont...

Page 35: ...ance Chart 5 2 Maintenance Chart 5 2 Maintenance Chart 5 2 Maintenance Chart 5 2 Maintenance Chart 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed Routine Maintenance Routine Maintenance Routine Maintenance Routine Maintenance Routine Maintenance ...

Page 36: ...ngines every 10 hours of operation or daily Operating hours OP every Years 250 500 1000 1500 12000 1 2 Top lube oil up if necessary 6 1 2 3 3 4 Lube oil oil change intervals depending on engine use see TR 0199 99 3002 6 1 1 6 1 2 Oil filter cartridge at each lube oil change 6 1 3 Fuel filter cartridge 6 2 1 Flexible fuel leak oil lines replace completely Injection valve Fuel pre cleaner filter ele...

Page 37: ...Section Operation check adjust clean replace Industrial engines The specified engine maintenance values are permissible recommended maximums Depending on usage reduced maintenance intervals may be necessary comply with the unit manufacturer s operating instructions Maintenance must only be carried out by authorised service personnel prior to or during 1st trial run check 2x daily during the breaki...

Page 38: ...plier for a fresh supply of labels Routine work should be carried out according to the schedule in 5 1 Routine Maintenance Routine Maintenance Routine Maintenance Routine Maintenance Routine Maintenance 5 2 Maintenance Chart 5 2 Maintenance Chart 5 2 Maintenance Chart 5 2 Maintenance Chart 5 2 Maintenance Chart 0297 9901 1 2012 1000 1500 10 10 AIR a OIL max in 500 O IL FUEL h Std 125 2000 ex 10 WA...

Page 39: ... The maintenance chart shown on this page is supplied as a self adhesive label with each engine It should be affixed where it can be seen clearly on the engine or driven equipment Check that this is the case If necessary ask your engine or equipment supplier for a fresh supply of labels Routine work should be carried out according to the schedule in 5 1 max min min 0297 9902 0 2012 9912EN_K05 1 P6...

Page 40: ...Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed Op hours Date Date Signature stamp Op hours Signature stamp 5 2003 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 50 150 125 375 625 875 1125 1375 1625 1875 2115 2375 2625 following commissioning of new and overhauled engines Duly completed maintenance jobs can be recorded and signed off in the above chart ...

Page 41: ... 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed Date Op hours Signature stamp Op hours Date Signature stamp 5 2003 2875 3125 3375 3625 3875 4125 4375 4625 4875 5125 5375 5625 Duly completed maintenance jobs can be recorded and signed off in the above chart 3000 3250 3500 3750 4000 4250 4500 4750 5000 5250 5500 5750 ...

Page 42: ... 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed Op hours Date Date Signature stamp Op hours Signature stamp 5 2003 5875 6125 6375 6625 6875 7125 7375 7625 7825 8125 8375 8625 6000 6250 6500 6750 7000 7250 7500 7750 8000 8250 8500 8750 Duly completed maintenance jobs can be recorded and signed off in the above chart ...

Page 43: ...intenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed Date Op hours Signature stamp Op hours Date Signature stamp 5 2003 8875 9125 9375 9625 9875 10125 10375 10625 10825 11125 11375 11625 9000 9250 9500 9750 10000 10250 10500 10750 11000 11250 11500 11750 Duly completed maintenance jobs can be recorded and signed off in the above chart ...

Page 44: ...Routine Maintenance Routine Maintenance 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed 5 3 Maintenance Work Completed Op hours Date Date Signature stamp Op hours Signature stamp 5 2003 ...

Page 45: ...g System 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 5 Belt Drives 6 5 Belt Drives 6 5 Belt Drives 6 5 Belt Drives 6 5 Belt Drives 6 6 Adjustments 6 6 Adjustments 6 6 Adjustments 6 6 Adjustments 6 6 Adjustments 6 7 Accessories 6 7 Accessories 6 7 Accessories 6 7 Accessories 6 7 Accessories Service and Maintenan...

Page 46: ...ht 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 Change the oil with the engine off but still warm lube oi...

Page 47: ...ls in op hours Lube oil change intervals in op hours Lube oil change intervals in op hours Lube oil change intervals in op hours series series series series series Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use Oil use normal normal normal normal normal high high high high high normal normal normal normal normal high high high high h...

Page 48: ... except for 15 000 20 000 busses BF4M2012C 95 kW from Euro II 20 000 BF6M2012C 143 kW from Euro II at cylinder 20 000 bore 101 mm with or 98 mm with MV system 135 kW from Euro II at cylinder bore 98 mm 20 000 with mechanical injection system Local 40 40 40 40 40 2012 2012 2012 2012 2012 Euro I 15 000 20 000 30 000 traffic Euro II and Euro III except for 20 000 30 000 BF4M2012C 95 kW from Euro II 3...

Page 49: ...l warm Ensure that the engine or vehicle is in a level position Lube oil temperature approx 80 C Switch off the engine Place oil tray under the engine Unscrew oil drain screw Drain oil Screw oil drain screw in with new seal ring and tighten Tightening torque see 9 2 Pour in lube oil For grade viscosity see 4 1 For quantity see 9 1 Check oil level see 6 1 2 1 Ensure that the engine or vehicle is in...

Page 50: ...en the lube oil filter cartridge with another half turn If locking piston is available Positiontensioningclampsandtightenwith tensioning screws Check oil level see 6 1 2 Check oil pressure see 3 3 1 Check lube oil filter cartridge seal for leaks With attached locking piston Undo tensioning screws and remove tensioning clamps downwards Undo the lube oil filter cartridge using a commercial tool and ...

Page 51: ...nd unscrew in an anticlockwise direction emties itself the system automatically drain valve Carefully loosen paper filter cartridge 3 upwards from the guide 4 Catch any escaping oil Replace paper filter cartridge 3 Clean any dirt from the sealing surface of the filter carrier and lube oil filter cover 1 and fromb the guide 4 Replace and lightly oil the rubber gasket 2 Carefully insert new paper fi...

Page 52: ... the fuel shut off valve Undo fuel filter cartridge with commercial tool and spin off Catch any escaping fuel Clean any dirt from the filter carrier sealing surface Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter car tridge Manually screw in the new cartridge until the gasket is flush Tighten the fuel filter cartridge with a final half turn Open fuel shutoff valv...

Page 53: ... Replace paper filter cartridge 3 Clean any dirt from the sealing surface of the filter carrier and fuel oil filter cover 1 and fromb the guide 4 Replace and lightly oil the rubber gasket 2 Carefully insert new paper filter cartridge 3 into guide 4 Tighten fuel oil filter cover 1 in a clockwise direction 25 Nm Start engine Check fuel oil filter attachment for leaks 6 2 Fuel System 6 2 Fuel System ...

Page 54: ...1 on the cover 2 again Bleed the fuel pipe according to instructions see 6 2 5 opposite Changing the filter element 5 Changing the filter element 5 Changing the filter element 5 Changing the filter element 5 Changing the filter element 5 Change at least once a year or as required drop in performance also after purging Turn off the engine or switch to other filter in case of changeover filter Close...

Page 55: ...tem Bleed Fuel System Bleed Fuel System Bleed Fuel System Bleed Fuel System with Fuel Pre filter with Fuel Pre filter with Fuel Pre filter with Fuel Pre filter with Fuel Pre filter Place fuel collection container beneath the fuel pre filter Bleed In the event of re commissioning following maintenance work or if the tank has been run empty the fuel system must be bled Bring engine regulator into st...

Page 56: ...the machine Because applications vary cleaning intervals have to be determined from case to case The cleaning intervals given in the table below can be used as a guide Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance 6 3 Cooling System 6 3 Cooling System 6 3 Cooling System 6 3 Cooling System 6 3 Cooling System 6 3 1 6 3 1 6 3 1...

Page 57: ...e MAX mark or filling limit if fitted system heater valve must be open Connect vent hose item 6 tighten screw plug item 4 Close radiator cap item 7 Start engine and warm up until thermostat opens Switch off the engine Check coolant level when engine is cold and top up if necessary Close radiator cap item 1 Position a collecting pan beneath screw plug 1 Remove screw plug 1 at crankcase Drain coolan...

Page 58: ...he air and the size of the air filter used If a high level of dust is anticipated a cyclone type pre cleaner can be fitted in front of the combustion air filter Cleaning intervals must therefore be determined from case to case If dry type air filters are used cleaning should only be carried out according to the service indicator or service switch Filter servicing is needed when Service indicator t...

Page 59: ... for the oil to drain from filter housing 1 Loosen snap clips 2 and remove oil cup 3 with filter element 4 if necessary loosen filter element with the aid of a screwdriver at the separating point Do not damage rubber gasket 5 Remove dirty oil and sludge Clean oil cup Clean filter element 4 in diesel fuel and allow to drip dry thoroughly Undo wing nut 1 and remove cover 2 Remove collector bowl 3 fr...

Page 60: ...nut 5 and remove cartridge 4 Insert new cartridge re install hex nut and tighten Install cartridge 3 replace hood 2 and do up clip fasteners 1 Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 4 Combustion Air Filter 6 4 Combustion Air Filter Undo cl...

Page 61: ...use a tension gauge see 9 3 Place indicator arm 1 into gauge Position guide 3 on V belt 2 midway between the pulleys with flange 3 on bottom of gauge against the edge of belt Push slowly on the black pad 4 at right angles to V belt 2 until the spring is heard or felt to trigger Carefully raise the gauge without chang ing the position of indicator arm 1 Read off the value where the indicator arm 1 ...

Page 62: ...ts Replace V belts Ribbed V belts Ribbed V belts Ribbed V belts Ribbed V belts Ribbed V belts Loosen screws 1 and 2 Press fuel pump 3 in direction of arrow Remove V belt and position new belt Press fuel pump counter to direction of arrow until the correct V belt tension has been achieved Tighten screws 1 and 2 again Press tension roller in direction of arrow until the ribbed V belt is free First r...

Page 63: ... of arrow by turning screw 3 until correct V belt tension is achieved Retighten screws 1 2 and 4 Loosen fuel pump V belt see 6 5 3 Loosen screws 1 2 and 4 Adjust screw 3 until V belt can be removed Position new belt Adjust screw 3 until the correct V belt tension has been achieved Retighten screws 1 2 and 4 Tension fuel pump V belt see 6 5 4 6 5 6 6 5 6 6 5 6 6 5 6 6 5 6 Replace V belts Replace V ...

Page 64: ...intenance Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance 6 5 Belt Drives 6 5 Belt Drives 6 5 Belt Drives 6 5 Belt Drives 6 5 Belt Drives Wear limit of the wedge ribV belt as follows examine Distance between the nose of the flexibiliti clamping arm and the notice of the firm tension adjuster housing examine If a a a a a is smaller than 3 mm then the ...

Page 65: ...6 6 2003 6 6 Adjustments 6 6 Adjustments 6 6 Adjustments 6 6 Adjustments 6 6 Adjustments Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance Service and Maintenance ...

Page 66: ...and valve 3 with feeler gauge 6 there should be only slight resistance when feeler blade is inserted For permissible valve clearance see 9 1 Adjust valve clearance if necessary Release locknut 4 Use screwdriver 7 to turn setscrew 5 so that the correct valve clearance 1 is attained after locknut 4 has been tigh tened Check and adjust valve clearance on all cylinders Reinstall cylinder head cover wi...

Page 67: ...Position 2 Crankshaft Position 2 Crankshaft Position 2 Crankshaft Position 2 Turn crankshaft one full revolution 360 Adjust valve clearance according to schematic marked in black marked in black marked in black marked in black marked in black 6 6 1 1 Valve Clearance Adjustment 6 6 1 1 Valve Clearance Adjustment 6 6 1 1 Valve Clearance Adjustment 6 6 1 1 Valve Clearance Adjustment 6 6 1 1 Valve Cle...

Page 68: ...ke good contact Tighten clamp bolts hand tight 6 7 1 2 Check Electrolyte Level 6 7 1 2 Check Electrolyte Level 6 7 1 2 Check Electrolyte Level 6 7 1 2 Check Electrolyte Level 6 7 1 2 Check Electrolyte Level 6 7 1 3 6 7 1 3 6 7 1 3 6 7 1 3 6 7 1 3Check Electrolyte Density Check Electrolyte Density Check Electrolyte Density Check Electrolyte Density Check Electrolyte Density Measuretheelectrolyteden...

Page 69: ...nce Tropical 1 23 1 12 1 08 Normal 32 24 16 Tropical 27 16 11 in kg l in Bé Baumé scale Charge status Normal 1 28 1 20 1 12 well charged semi charged re charge discharged immediately charge Electrolyte density Electrolyte density Electrolyte density Electrolyte density Electrolyte density Thegasesemittedbythebattery are explosive Keep sparks and naked flames away from the battery Donotallowbattery...

Page 70: ...ct jet of water steam Allow the engine to run warm so that the remaining water evaporates The habit of touching a lead against the frame to check whether it is live must under nocircumstancesbeusedwiththree phase electrical systems In case of electric welding connect the ground terminal on the welder directly to the piece being welded Service and Maintenance Service and Maintenance Service and Mai...

Page 71: ...lts Causes and Remedies Faults Causes and Remedies Faults Causes and Remedies Faults Causes and Remedies Faults Causes and Remedies 7 1 7 1 7 1 7 1 7 1 Fault Table Fault Table Fault Table Fault Table Fault Table ...

Page 72: ...ing fault table can be found on the opposite page If the cause of a fault cannot be determined oryouareunabletoremedyafault yourself then please contact your DEUTZ Service representative Before starting make sure that nobody is stand ingintheimmediatevicinityoftheengineordriven machine In the event of repair work Caution Caution Caution Caution Caution If the speed regulator has been removed the e...

Page 73: ...r loose V belt fuel pump in belt drive Cooling air temperature rise heating short circuits Battery defective or discharged P P P A S P E P E P W P P P W P R P R P R P W P P Engine Operation Combustion air Cooling system Electrics Section Section Section Section Section Engine does not start or is difficult to start Starting speed is not achieved on starting Check P P P P P Engine starts but runs i...

Page 74: ... oil SAE class or quality Fuel quality not as per operation manual Coolant deficiency P P E P P R P P W P W P R W W W P W P A Electrics Engine Operating media Faults Faults Faults Faults Faults Measures Measures Measures Measures Measures Engine does not start or is difficult to start Starting speed is not achieved on starting Check P P P P P Engine starts but runs irregularly or fails Adjust E E ...

Page 75: ...8 8 8 8 8 2003 8 1 Preservation 8 1 Preservation 8 1 Preservation 8 1 Preservation 8 1 Preservation Engine Preservation Engine Preservation Engine Preservation Engine Preservation Engine Preservation ...

Page 76: ...orrosion oil Drain fuel tank Make up a mixture of 90 diesel fuel and 10 anti corrosion oil and refill fuel tank Allow the engine to run for approx 10 mins Switch off the engine Manuallyturntheengineoverseveraltimes When turning over with starter set shutoff lever to stop position Remove V belts and store in wrapped con dition Spray grooves on V belt pulleys 2 with anti corrosion spray Drain anti c...

Page 77: ...d Settings 9 1 Engine Specifications and Settings 9 2 Torque Wrench Settings 9 2 Torque Wrench Settings 9 2 Torque Wrench Settings 9 2 Torque Wrench Settings 9 2 Torque Wrench Settings 9 3 Tools 9 3 Tools 9 3 Tools 9 3 Tools 9 3 Tools Technical Specification Technical Specification Technical Specification Technical Specification Technical Specification ...

Page 78: ... diesel Combustion system with turbocharging and direct fuel injection Charge air cooling without with with Direction of rotation counter clockwise Weight 2012 C including cooling system to DIN 70020 A approx kg Refer to head office Engine output kW 75 103 155 Max speed 1 rpm 2500 Valve clearance with cold engine PTs mm Inlet 0 3 0 1 exhaust 0 5 0 1 Valve clearance with cold engine standard mm Adj...

Page 79: ...ant pre heating 4 Coolant pump Feed pressure in bar 9 Feed quantity in m3 h 9 Power consumption in kW 9 Lubrication Pressure lubrication Oil temperature in oil pan C 125 Min oil pressure when warm 120 C and SAE oil 15 W 40 and low idle bar 0 8 Oil plate filling quantity without filter approx ltr 8 5 3 8 5 3 12 5 3 Oil plate filling quantity with filter approx ltr 10 3 10 3 14 0 3 3 Approx values m...

Page 80: ...ghtening Torques Installation location Pre tension Nm Re tension Nm Total Comments 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage 4 Stage Nm Cylinder head screw 8 5 Rocker arm adjustment screw 21 Foot on flywheel side 187 M16x40 8 8 8 A 4 C Foot on fan side 30 45 187 M16x40 8 8 8 A 4 C Intake manifold 8 5 Exhaust manifold 21 Oil drain screw 50 Injection valve attachment 16 Torx Injection line att...

Page 81: ...ch 14 05 80 D 42826 Remscheid D 42826 Remscheid D 42826 Remscheid D 42826 Remscheid D 42826 Remscheid The V belt tension gauge can be obtained under order number 8115 8120 8115 8120 8115 8120 8115 8120 8115 8120 from WILBÄR WILBÄR WILBÄR WILBÄR WILBÄR Postfach 14 05 80 Postfach 14 05 80 Postfach 14 05 80 Postfach 14 05 80 Postfach 14 05 80 D 42826 Remscheid D 42826 Remscheid D 42826 Remscheid D 42...

Page 82: ...9 2003 ...

Page 83: ... reproductive harm Warning in the Manual 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 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 h...

Page 84: ...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 ...

Page 85: ...he 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 to enhance your motor s performance This index Sales Service offers you an overview oftheDEUTZpartnersinyourvicinity includingthe products for which they are responsible and the rangeofservicesprovided Buteven...

Page 86: ...technik Motoren Deutz Mülheimer Str 147 149 D 51063 Köln Tel 49 0 2 21 8 22 0 Fax 49 0 2 21 8 22 53 58 Internet www deutz de E mail info deutz de Printed in Germany All rights reserved 3 Edition 03 03 Order No 0297 9912 en We move your world ...

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Summary of Contents for BF4M 2012

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Deutz BF4M 2012, Operation Manual, Page: 78 / 86

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Summary of Contents for BF4M 2012

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