DEUTZ Diesel Engine BF4/6M2012 Operation Manual

DEUTZ Diesel Engine
BF4/6M2012
Operation Manual
V A.0
EU STANDARD GENMAN QUALITY JA1000-56D-31 EN V A.0
Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the
manufacturers warranty and maintain the engine in peak operating condition.
This engine has been built exclusively for the application specified in the scope of supply, as described by the equipment
manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the
intended purpose. The manufacturer will not assume responsibility for any damage resulting there from. The risks involved are to be
borne solely by the user.
Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation,
maintenance and servicing. The engine should only be operated by personnel trained in its use and the hazards involved.
The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed.
Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage. This operation is
not valid for all DEUTZ engines. Please read this Manual before starting your engine, and always observe the operating and
maintenance instructions. We are available to help with any additional enquiries.
Sincerely, your genuine partnership
DEUTZ (DALIAN) ENGINE CO., LTD.
EU STANDARD GENMAN QUALITY
WORLD POWER FORTUNE ENGINE
1 WORLD POWER FORTUNE ENGINE

DEUTZ Diesel Engine

BF4/6M2012
Operation Manual

Contents
1 General 4 Operating Media 9 EDC16 Electronic Control

2 Engine Illustrations 4. 1 Lube Oil System
2. 1 Operation Side 4. 2 Fuel 9.1 System Overview
2. 2 Starter Side 4. 3 Coolant 9.2 Electronic-Controlled System
2. 3 Lube Oil System 5 Routine Maintenance Function
2. 4 Fuel System Schematic 6 Service and Maintenance 9.3 Interfaces
2. 5 Cooling System Schematic 6. 1 Lubrication System 9.4 Diagnosis
3 Engine Operation 6. 2 Fuel System 9.5 Rpair
3. 1 Adding Engine Oil 6. 3 Cooling System 9.6 Installation
3. 2 Filling Oil Bath Air Filter 6. 4 Combustion Air Cleaner 9.7 Technical data
3. 3 Adding Fuel 6. 5 Belt Drives 9.8 Engine Electronic Control
3. 4 Preparation for First Start 6. 6 Adjustments System for external wiring
3. 5 Starting 6. 7 Accessories diagram
3. 6 Monitoring Operation 7 Faults, Causes and Remedies 10 Technical Specification
3. 7 Winter Operation 8 Engine Preservation

1 General

2 Engine Illustrations
2.1 Operation Side 2.2 Starter Side
1 Oil filler 6 Fuel pump 11 Dipstick 16 Cylinder head 21 Coolant outlet joints 26 Exhaust manifold
2 Alternator 7 Front engine mount 12 Air compressor 17 Lube oil cooler 22 Coolant Inlet joints 27 SAE housing
3 Cooling fan 8 Lube oil filter 13 Steering pump 18 Heater intake joints 23 Coolant supply joints 28 Rear engine mount
4 Vibration damper 9 Fuel filter 14 EUP 19 Exhaust Turbocharger 24 Heating flange 29 Starter
5 Belt pulley 10 Sump 15 High pressure pipe 20 Crankcase 25 Air intake Manifold 30 Heater outlet joints

2.3 Lube Oil System

2.3.1 Pressed lube System (P0 is the opening pressure for
valves indicated)
1 Sump
2 Oil radiator by-pass valve (Pressure-relief valve)
3 Oil filter by-pass valve
4 Oil suction pipe
5 Oil pump
6 Turbocharger
7 Main oil gallery pressure limit valve (Back leak valve)

2.3.2 Lube Oil Circuit Schematic
1 Oil pan 12 Pushrod (designed for lube oil

2 Oil suction line supply of rocker arms)
3 Lube oil pump 13 Rocker arm
4 Lube oil cooler 14 Return line to oil pan
4.1 Pressure-relief valve 15 Oil line to exhaust turbocharger
4.2 Back leak valve 16 Exhaust Turbocharger
4.3 Lube oil filter 17 Oil line to compressor or hydraulic
4.4 Oil pressure sensor pump
5 Main oil gallery 18 Compressor
6 Crankshaft bearing 19 Hydraulic pump
7 Con-rod bearing 20 Return line from compressor or
8 Camshaft bearing hydraulic pump
9 Spray nozzle line 21 Line to the differential (2)
10 Spray nozzle for piston cooling 22 Balancer shafts
11 Tappet control bore for pulse 23 Turbocharger return to crankcase
lubrication of rocker arms

2.4 Fuel System schematic
1 Fuel tank
2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
5 Fuel filter
6 Line to the injection pump
7 Injection pump
8 Line to injection valve
9 Injection valve
10 Banjo bolt with pressure maintenance valve
11 Return line to fuel tank
12 Maintain maximum possible distance

2.5 Cooling System schematic

3 Engine Operation
3.2 Filling Oil Bath Air Cleaner 3.3 Adding Fuel
3.1 Adding Engine Oil
As a rule, engines are delivered without

oil. Pour lube oil into the oil filler neck
(arrow).
Oil capacity, see 10.
For oil grade and viscosity, see 4.1.

3.4 Preparation for First Start
3.4.1 Filling/Venting the Cooling System 3.4.2 Other preparations
Unscrew filling cap, unscrew vent Checking Battery and Cable Connectors
plugs. Trial run
Add coolant up to filling-up limit After the engine has been prepared, let it run for about 10 minutes without
mark. load.
Pay attention to the coolant outlet, During and after trial run
screw it if spilling. Check the engine for leaks.
Screw filling cap. After the engine has been turned off
Start engine and warm up until Check the oil level and top up if necessary.
thermostat opens (the coolant line Tighten the V-belt.
from fan unit to thermostat warming Breaking-in
obviously). During the break-in phase about 200 operating hours check the oil level
Switch off engine. twice a day.
For the first running, check coolant After the engine is broken in, checking once a day will be sufficient.
level and top up as required.

3.5 Starting
For MVS engines

z Disengage the clutch to
separate the engine from the
driven equipment
z Be sure that the cable
connectors for ECU have
been connected properly


3.6 Monitoring Operation

3.6.1 Engine Oil Pressure

3.6.2 Coolant Temperature

3.7 Winter Operation

4 Operating Media
4.1 Lube Oil

4.2 Fuel

4.3 Coolant


5 Routine Maintenance
Maintenance Schedule
1)
In operating hours(OH), every Check
The first 50 Every 10 Clean
operating operating 125 250 500 1000 1500 2000 Replace
hours
2) hours or Operation
daily
2 )10 )
Lube oil level, top up as necessary
Leakage
3) 4 )
Oil bath air cleaner
Battery and cable connections
3)8 )
Coolant system
Lube oil(oil changing interval acc. to
5)
engine application)
Oil filter cartridge
Fuel filter cartridge
Fuel pre- filter(change filter element if
necessary)
Fuel system
Valve Clearance(set if necessary, earlier
if noises occur)
Engine mounts
1) V-belt(retighten or replace as necessary)


1)
In operating hours(OH), every Check
The first 50 Every 10 Clean
operating operating 125 250 500 1000 1500 2000 Replace
hours
2) hours or Operation
daily
Engine monitoring, warning system
Fix parts
4) 4)
Preheater
7) 6)
Coolant
Coolant(additive concentration)

9) Coolant liquid level
Fixing, hose connections/clamp,air
intake connections
1) The max. permissible interval 2) New or reconditioned engines 3) Cleaning if necessary
4) Change if necessary 5) Oil quality and turbocharged engine oil quality
6) Check the antifreeze or anti-corrosion additive concentration every 500 hours
7) Or change every two years 8) System cleaning
9) Not necessary if integral cooling system with level gauge 10) During the break-in phase check it twice a day
The maintenance intervals are the max. permissible recommended intervals. Depending on the application, shorter
maintenance intervals may be necessary. Please refer to manufacturers regulations.

6 Service and Maintenance

6.1 Lubrication System
6.1.1 Oil Change intervals
z Oil change for the first time is 40 hours or 2,000 km Lube oil quality class Turbocharged engine
z The oil change intervals are dependent on the engine API-specification CF-4CG-4CH-4CI-4
ACEA-specification E2-96E3-96E4-99
application and the quality of the lube oil
z If the engine runs fewer hours during the year than
Oil change Service Average Operating Running
stated in the table, the oil should be changed at least
intervals Level speed hours in km
once a year approx.
z The table refers to the following conditions [km/h]
For diesel fuel: sulfur content max. 0.5% by weight Engine for 200
stable
Continuous ambient temperatures down to -10 equipments
/+14F Engine for 1 25 5000
z With sulfur content is >0.5% to 1% or continuous vehicles 2 40 10000
3 60 15000
temperature below -10 /+14 F, the intervals
between oil changes should be halved. Operating in bad environment, dirty lube oil, lube oil quality
z In the case of fuels containing more than 1% sulfur, does not meet the specification, the intervals between oil
contact your service representative. changes should be halved.
NoticeChange the oil with the engine off but still warm If the engine user does not replace lube oil according to
(lube oil temperature approx. 80 ) intervals set by manufacturer, warranty will not be
guaranteed!



6.2 Fuel System







6.3 Cooling System


6.4 Combustion Air Cleaner



6.5 Belt Drives

6.5.2 Tensioning / Changing
Coolant / Fuel Pump Belt
Slacken off bolts 1 and 2.
Tensioning
Insert proper square wrench in square
and pull the Fuel Pump 3 in direction of
arrow until correct belt tension is
achieved.
Changing
Insert proper square wrench in square
and loosen the Fuel Pump 3 in opposite
direction of arrow. Tension new belt as
described above.
Tighten bolts 1 and 2.

6.5.3 Tensioning / Changing
Alternator Belt
Tensioning
z Slacken off bolts 1 , 2, 3 and nut 4.
z Move Alternator 6 and tighten bolt
5 until correct belt tension is
achieved.
z Re-tighten bolts 123 and nut 4.
Changing
z Slacken off bolts 1, 2, 3 and nut 4.
z Loosen bolt 5 and move Alternator
6 until belt is exposed.
z Remove and replace belt, tension
(See above).
z Re-tighten bolts 123 and nut 4.

6.6 Adjustments
6.6.1 Checking / Adjusting Valve Clearances
z Slacken off breather valve and swing it to one side.

z Remove rocker cover.
z Position crankshaft as per schematic 6.6.2.
z Before adjusting valve clearance, allow engine to cool down for at least 30 minutes. The oil temperature should be
below 80C/176C.
z Check valve clearance between rocker arm / tappet contact face 2 and valve stem 3 feeler gauge 6 (there should be
only slight resistance when feeler blade is inserted).
For those which could not be checked by feeler gauge, check the angles with a special dial.
For permissible valve clearance,
INLET valve clearance: 0.30.05mm (7510) EXHAUST valve clearance: 0.50.05mm (12010)
z Adjust valve clearance if necessary:
Release locknut 4.
Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened.
z Check and adjust valve clearance on all remaining cylinders.
z Reinstall rocker cover (use new gasket if necessary).
z Swing breather valve back into position and secure.

6.6.2 Valve clearance adjustment Schematic

6.7 Accessories
6.7.1 Three-phase Generator 6.7.2 Lifting Frame

7 Faults, Causes and Remedies
z If engine problems occur, they frequently have their cause in improper operation or engine maintenance.
z If problems do occur, always check first that the operating and maintenance instructions have been followed.
z A diagnosis chart is given below.
z If you cannot identify the cause of the problem or are unable to rectify it yourself, please contact DDE customer
service.

Faults Table


8 Engine Preservation

9 EDC16 Electronic Control System

Foreword
The following is a brief description for customers who are using
electronic-controlled engines DEUTZ 2012 with solenoid valve
system(EDC16).
9.1 System Overview
The Solenoid Valve System (EDC16) is a fully-electronic diesel
fuel injection system with no mechanical connection to the
machine operator (no control rod). In contrast to conventional
mechanical injection systems, the use of the EDC16 means
that feed duration (injection quantity) and feed commencement
(injection start) are both freely controllable, thus ensuring
proper compliance with current emission regulations(Europe
).
The EDC16 is essentially divided into two elements:
_ Injection pump with high pressure tube and injector
_ Electronic system with sensors, switches and wiring loom

9.2 Electronic-Controlled System Function
9.2.1 Engine Functions
Start up
The start control remains active until the start release turning speed is exceeded. Only then can the machine operator take control
of running the engine. The start release turning speed is determined in relation to the coolant temperature.
Low idling speed
Once the turning speed of the motor reaches idling speed, the idling governor takes control of the motor turning speed. The idling
governor is purely a PID controller which always maintains the idling speed constant.
The idling speed can be increased in line with the coolant temperature, i.e. the idling speed is faster with a cold engine than when
the engine is hot. Furthermore, if a defective value is received from the pedal, the idling speed is increased to make available at
least a minimum level of operability.
Types of governor
z Min-Max Governor
z Variable-Speed Governor
Torque limitation
The maximum engine torque can be limited by various means.
z Exhaust smoke control
The maximum torque is also limited in line with the air intake pressure and air intake temperature, which is a measure the air intake
quantity, in order to avoid engine exhaust smoke.
z Engine protection
Whenever the coolant temperature rises in excess, the maximum possible torque is reduced in line with the coolant temperature in
order to prevent the engine overheating.

z Emergency Torque-limiting
In the event of a serious diagnostic fault occurring, the maximum torque can be reduced in order to oblige the machine operator to
repair the fault. The following faults can cause this to happen:
_ defective pedal master unit
_ defective speed transmitter
_ defective intake pressure sensor
_ defective solenoid valve output stage
Feed start adjustment
The function of feed start adjustment is to ensure compliance with current emission regulations while at the same time maintaining
low fuel consumption; for both better cold-starting and lower noise emissions.
Fuel temperature compensation
As the fuel temperature increases, motor performance drops. This is due to the fact that the thickness of the fuel decreases and, as
the fuel loses viscosity, there is an increase in leakage losses in the injection pumps. Fuel temperature compensation evens out this
effect by measuring the fuel temperature and making a corresponding control adjustment to compensate.
Cylinder equalization
The function of cylinder equalization is to compensate for the manufacturing tolerances of the injection pumps and the resulting
injection quantity.
Help with cold weather starting
Cold weather starting is not active if
_ a separate glow duration unit is used,
_ a separate flame primer system is used,
_ a separate air inlet heating system is used.

9.2.2 Engine protection functions
Reduction in performance
Performance reduction becomes active as soon as the engine finds itself in a critical state. The reduction is proportional to the
corresponding value either in excess of or below a given value. The following situations, either singly or in combination, can lead to
a reduction in performance:
_ Coolant temperature too high
_ Oil pressure too low (Option)
_ Reduction instruction via CAN interface
Engine cut-off
In exceptional circumstances, the engine can be shut off if the user desires and/or engine starting can be prevented from the
beginning. This can be caused by the following situations:
_ Coolant temperature too high
_ Oil pressure too low
_ Shut-off instruction via CAN interface
_ Start-prevention instruction via CAN interface
9.2.3 Vehicle functions
Engine exhaust braking
When receiving the engine exhaust brake switching signal, according to the engine speed (not too low), exhaust braking will
activated and the fuel injection stops simultaneously.
Maximum speed control
Maximum speed control allows the maximum permitted vehicle speed to be limited. The maximum speed value is pre-programmed
value.

Cruise control
A cruise control operating unit enables the cruise control device to be activated and deactivated.
9.3 Interfaces
9.3.1 ISO interfaces
The ISO interface is an ISO 9141-standard (K Line) serial data interface, which permits the exchange of data withthe control unit.
The ISO interface possesses the following functions:
_ Exchange of diagnosis data.
_ Programming of the control system (reading and programming of parameters).
_ Carrying out of engine test function.
_ Reading of measured and/or calculated values.
9.3.2 CAN interface
The CAN Interface is an SAE J1939-standard fast serial data bus, which enables data exchange to take place among various
control units. The CAN interface possesses the following functions:
_ Exchange of diagnosis data (error messages, delete stored error list)
_ Reading of measured and/or calculated values
_ Injection suppression
_ Operate the engine brake
_ Performance reduction
_ Entry of a desired default quantity or performance characteristic (In place of pedal master unit)
9.3.3 Turning speed interface
The purpose of the turning speed interface is to transmit a turning speed signal for a turning speed meter or a drive
transmission control unit, thus avoiding the need to fit an additional turning speed sensor. The turning speed signal is a digital signal,

whose impulse count can be adjusted.
9.4 Diagnosis
Diagnosis via fault-warning lamp
When there is a failure, the indicator light flashes, directing the operator to take the engine to service station to get it maintained.
The fault-warning lamp is directly connected to the electronic system. The lamp lights up as soon as a fault occurs, and indicate the
operator to get the engine to service station to be repaired.
9.5 Repair
Certain components can only be replaced (no repairs possible) and are individually available. As the control unit must be
programmed with an engine-specific programming statement, the following details are required:
_ Engine number
_ Complete part number.
Please contact your customer service.
Caution:
To avoid damaging the control units, always remove plug connections from control unit before carrying out any electrical welding
work!
Be sure power has been shutdown, when unplugging the connections of control unit ECU.
9.6 Installation
9.6.1 Environment
1 The permissible temperature to assure an ECU of normal working is -40 to +85 .
2 ECU must have good ventilation.
3 ECU suspension direction must avoid damaging the cable conjunctions of plug connections.

4 In order to conduct plug connections freely, there should be sufficient area at the plug connections side of ECU (about 1xECU
wide)
9.6.2 Operation Voltage
1 Rated voltage is 24V
2 Continuous operating voltage is 20 ~ 32V
3 The main Relay turn-on voltage is greater than 12.2V
4 The peak current consumption under 24V is 20A
5 For a 6-cylinder engine, Max power consumption under 24V is about 24W.
9.6.3 Harness length
1 The longest cable length between battery and ECU (power line) is 7m.
2 The longest cable length from ECU to Indicator panel (signal lights) and basic operating facility (switches) is 5m.
3 The longest cable length between ECU and EUP (solenoid valve fuel pump) is 5.5m. When the ambient temperature is 25
degrees, the cable resistance should be less than 100m.
4 The longest cable length between control unit ECU and ISO9141 Diagnosis connection plugs is10m.
5 Negative pole (cable connecting engine chassis) must be linked directly to battery cathode.
Caution:
Sensors and final control elements should never be individually connected to or between external power sources for test or
inspection purposes. They should only ever be connected via the ECU, as they may otherwise be irreparably damaged!
In spite of the pole reversal protection in the control units, incorrect pole connection should be avoided.
Reversed pole connection may damage the control unit!
The control unit plug sockets are only dustproof and watertight if the plug is inserted! Control units must be protected from being
splashed with water until the plugs are inserted!

9.7 Technical data
9.7.1 Sensors
z Temperature sensor, coolant
Pins: A58signalA41Groundengine Plug
Measuring range: -40~128
z Temperature sensor, fuel
Pin: A52signalA39Groundengine Plug
Measuring range: -40~128
z Temperature pressure sensor, inlet air
Pin: Power Supply A14+, A40(signal), A23(-), A53(temperature)
Measuring range: 0.5~4bar
Output Signal: 0.5~4.5V
z Turning speed sensor, camshaft
Pin: A10(signal ), A50(-), A20(screen)
Measuring range: 50~4000rpm
z Turning speed sensor, crankshaft
Pin: A27(signal ), A12(-), A07(screen)
Measuring range: 50~4000 rpm
z Pressure sensor, lubricant
Pin: A13(+), A51(-), A56(signal)
Measuring range: 0~10bar
Output Signal: 0.5~4.5V

z Position sensor, pedal
Pin: K08-K30-K22+K46+K09signal 1K31signal 2
Output Signal 1: 0.75~3.84V
Output Signal 2: 0.375~1.92V

9.8 Engine Electronic Control System for external wiring diagram

10 Technical specification
Item BF4M2012 BF6M2012
Number of cylinders 4 6
Cylinder arrangement Vertical in line
Working cycle/Combustion system 4-stroke diesel with turbo charging and direct injection
Direction of rotation(Facing the Counterclockwise
flywheel side)
Cylinder form No cylinder liner (parent)
Injection Pump EUP
Injector opening pressure [bar] 215 ~ 235bar
Boremm 101
strokemm 126
Firing order of engine 1-3-4-2 1-5-3-6-2-4
Total displacementL 4.04 6.06
Compression ratio 18.4
Rated PowerkW See engine nameplate
Rated speed(rpm) 2500
Weight [kg approx.] 450 560
Perm. constant coolant temperature, max.105
engine outlet [C]
Thermostat initial opening at [C] 83
Thermostat full open temperature [C] 95
Lubrication forced-feed lubrication
Oil temperature in oil sump [C] max. 125
Oil capacity (first fill-up) without filter 9L 17.5L
[litres approx.]

Oil capacity (first fill-up) with filter 11L 19.5L
[litres approx.]
V-belt tension: Pre-tension / re-tension(15 minutes after the engine has
been operated under load)
Alternator [N] 450 / 300 50
Fuel pump - coolant pump [N] 450 / 300 50

April 2009
Address: Zhengong Street 20th, Shahekou District, Dalian China

Telephone switchboard86-0411-83631588
Free Service Hotline8008909899
Customer Service Center0411-83649988
Postcode116021
http://www.deutzdalian.com
E-mail:fwk@deutzdalian.com

DEUTZ Diesel Engine BF4/6M2012 Operation Manual

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Sincerely, your genuine partnership

DEUTZ (DALIAN) ENGINE CO., LTD.

EU STANDARD GENMAN QUALITY

WORLD POWER FORTUNE ENGINE

1 WORLD POWER FORTUNE ENGINE

DEUTZ Diesel Engine

2 WORLD POWER FORTUNE ENGINE

1 General 4 Operating Media 9 EDC16 Electronic Control

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2.3 Lube Oil System

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2.3.2 Lube Oil Circuit Schematic

1 Oil pan 12 Pushrod (designed for lube oil

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As a rule, engines are delivered without

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For MVS engines

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3.6 Monitoring Operation

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3.6.2 Coolant Temperature

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3.7 Winter Operation

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6 Service and Maintenance

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Slacken off bolts 1 and 2.

Tighten bolts 1 and 2.

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z Slacken off breather valve and swing it to one side.

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6.6.2 Valve clearance adjustment Schematic

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