Deutz B-FL 1011F Operation Manual

26 451

Operation Manual

B/F L 1011F B/FM 1011F

Safety guidelines / Accident prevention

● Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer’s 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 therefrom. 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.

● When the engine is running, there is a risk of injury through:

- turning/hot components

- engines with positive ignition

- ignition systems (high electrical voltage) You must avoid contact at all times!

● Unauthorized engine modifications will invalidate any liability claims against the manufacturer 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 guaranteed under such conditions.

● Do not change, convert or adjust the cooling air intake area to the blower. The manufacturer shall not be held responsible for any damage which results from such work.

● When carrying out maintenance/repair operations on the engine, the use of DEUTZ original parts is prescribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the warranty!

● Maintenance and cleaning of the engine should only be carried out when the engine is switched off and has cooled down. You must ensure that the electrical systems have been switched off and the ignition key has been removed. Accident prevention guidelines concerning electrical systems (e.g. VDE-0100/-0101/0104/-0105 Electrical protective measures against dangerous touch voltage) are to be observed. When cleaning with fluids, all electrical components are to be covered impermeably.

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). All rights reserved. Technical modifications required to improve our engines are reserved with regard to speci-

Operation Manual

B/F L 1011F B/FM 1011F

0297 9683 en

fication 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.

Foreword

Dear Customer,

Air / liquid-cooled DEUTZ engines are designed for a large number of applications. Consequently, a wide range of variants are 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 Manual are necessarily mounted to your engine. We have endeavored 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

Index

1 General

2 Engine Description

2.1 Model

2.1.1. Rating Plate

2.1.2 Rating Plate Location

2.1.3 Engine Serial Number

2.1.4 Cylinder Numbering

2.1.5 Fuel Delivery Lock

2.2 Engine Illustrations

2.2.1 Service Side FL 1011F

2.2.2 Exhaust Side FL 1011F

2.2.3 Service Side BFL 1011F

2.2.4 Exhaust Side BFL 1011F

2.2.5 Service Side FM 1011/ F

2.2.6 Exhaust Side FM 1011/ F

2.2.7 Service Side BFM 1011F

2.2.8 Exhaust Side BFM 1011F

2.3 Oil Circuit

2.3.1 Lube Oil Circuit

2.4 Fuel System Schematic

2.4.1 Fuel System

3 Engine Operation

3.1 Commissioning

3.1.1 Adding Engine Oil

3.1.2 Filling oil bath air filter with engine oil

3.1.3 Adding Fuel

3.1.4 Other Preparations

3.1.5 Additional Maintenance Work

3.2 Starting

3.2.1 Starting

3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

3.3.2 Coolant Temperature

3.4 Stopping

3.4.1 Mechanical Shutdown

3.4.2 Electrical Shutdown

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperature, High Altitude

4 Operating Media

4.1 Lube Oil

4.1.1 Quality Grade

4.1.2 Viscosity

4.2 Fuel Operating Media

4.2.1 Quality Grade

4.2.2 Winter-Grade Fuel

5 Routine Maintenance

5.1 Maintenance Schedule

5.2 Maintenance Chart

5.3 Maintenance Work Completed

6 Service and Maintenance

6.1 Lubrication System

6.1.1 Oil Change Intervals

6.1.2 Changing Engine Oil, Check Oil Level

6.1.3 Changing Oil Filter

6.2 Fuel System

6.2.1 Changing Fuel Filter

6.2.2 Clean Strainer of Fuel Filter

6.2.3 Change Fuel Leakage Line

6.3 Cooling System

6.3.1 Cleaning Intervals

6.4 Combustion Air Cleaner

6.4.1 Cleaning Intervals

6.4.2 Emptying Cyclone Type Precleaner

6.4.3 Cleaning Oil Bath Air Cleaner

6.4.4. Dry Type Air Cleaner

6.5 Belt Drives

6.5.1 Checking V-Belts

6.5.2 Tensioning V-Belts

6.5.3 Changing V-Belts

6.6 Adjustments

6.6.1 Checking / Adjusting Valve Clearances

6.7 Accessories

6.7.1 Battery

6.7.2 Three-Phase Alternator

6.7.3 Lifting Tackle

6.7.4 Ether Starting System

6.8.1 Engine Cleaning

7 Troubleshooting

7.1 Diagnostic chart

8 Engine Preservation

8.1 Preservation

8.1.1 Preserving Engine

8.1.2 Removing Engine Preservations

9 Technical Specification

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings

9.3 Tools

10 Service

26 451

General

DEUTZ Diesel Engines

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Beware of Running Engine

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

Care and Maintenance

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on 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.

Safety

This symbol is used for all safety warnings. Please follow them

and accident prevention regulations laid down by law must also be observed.

carefully. The attention of operating personnel should be drawn to these safety instructions. General safety

Service

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.

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.

Asbestos

DEUTZ original parts are asbestosfree.

2.1 Model

2.2 Engine Illustration

2.3 Lube Oil Circuit Schematic

2.4 Fuel System Schematic

Engine Description

2.1 Model

2.1.1 Rating Plate

The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.

26 332 2

2.1.2 Rating Plate Location

2 2

26 421 1 26 422 0

The rating plate C is attached to the valve cover.

2.1.3 Engine Serial Number

23045678

The engine serial number B is stamped on the crankcase D as well as the rating plate.

2.1 Model

Engine Description

2.1.4 Cylinder Numbering

1234

26 431 0

Cylinders are numbered consecutively, beginning at the flywheel end.

2.1.5 Fuel Delivery Lock

26 387 0

The manufacturer shall not be held liable for 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: torque balancer

2. with plastic protective cap on model: without torque balancer.

Adjustments to the regulator are to be carried out only by authorized DEUTZ SERVICE - specialists.

Engine Description 2.2 Engine Illustrations

2.2.1 Service Side FL 1011F

1 Oil filler neck (valve-gear cover) 2 Charge-air line / air-intake line 3 Fan with integrated generator 4 Narrow V-belt 5 Solenoid 6 Toothed belt cover 7 V-belt pulley on crankshaft 8 Oil sump

9 Cut-out handle 10 Speed control lever 11 Oil dipstick 12 Crankshaft housing 13 Oil fill point (on side of crankcase) 14 Fuel pump 15 Easy-change fuel filter 16 Connecting facility for oil heater 17 Lube oil easy-change filter 18 Removable coolant intake hood 19 Injection pumps 20 Date plate 21 Oil cooler

13 12 11 10 9 8

26 452 0

2.2 Engine Illustrations

Engine Description

2.2.2 Exhaust side FL 1011F

22 Date plate 23 Connection housing (SAE) 24 Flywheel with ring gear 25 Starter 26 Front cover 27 Crankcase 28 Cylinder head 29 Exhaust manifold pipe 30 Air-intake pipe

26444 0

Engine Description

2.2 Engine Illustrations

2.2.3 Service Side BFL 1011F

1 Oil filler neck (valve-gear housing cover) 2 Charge-air line / air-intake line 3 Fan with integrated generator 4 Narrow V-belt 5 Solenoid 6 Wheel-house cover 7 V-belt pulley on crankshaft 8 Oil sump

9 Cut-out handle 10 Speed control lever 11 Oil dipstick 12 Crankshaft housing 13 Oil fill point (on side of crankcase) 14 Fuel pump 15 Easy-change fuel filter 16 Connection facility for oil heater 17 Charge-air pressure full-load stop (LDA) 18 Lube oil easy-change filter 19 Removable coolant intake hood 20 Injection pumps 21 Oil cooler

13 12 11 10 9 8

26 443 0

Engine Description2.2 Engine Illustrations

2.2.4 Exhaust side BFL 1011F

22 Cylinder head 23 Exhaust manifold pipe 24 Flywheel with ring gear 25 Starter 26 Crankshaft housing 27 Inlet line to TC (Lube oil) 28 Return line from TC (Lube oil) 29 Induction pipe 30 Turbocharger (TC) 31 Intake manifold 32 Air-intake line

26448 0

Engine Description

2.2.5 Service Side FM 1011F

2.2 Engine Illustrations

1 Oil filler neck (valve-gear housing) 2 Charge-air line / air-intake line 3 Generator 4 Narrow V-belt 5 Solenoid 6 Wheel-house cover 7 V-belt pulley on crankshaft 8 Oil sump

9 Cut-out handle 10 Speed control lever 11 Oil dipstick 12 Crankshaft housing 13 Oil fill point (on side of crankcase) 14 Fuel pump 15 Easy-change fuel filter 16 Connecting facility for oil heater 17 Lube oil easy-change filter 18 Injection pumps 19 Connection for oil cooler 20 Leakage-fuel line 21 Injection valves

13 12 11 10 9 8

26 453 0

2.2 Engine Illustrations

2.2.6 Exhaust side FM 1011F

Engine Description

22 Cylinder head 23 Exhaust manifold line 24 Flywheel with ring gear 25 Starter 26 Front cover 27 Crankcase 28 Intake pipe

26 447 0

Engine Description

2.2 Engine Illustrations

2.2.7 Service Side BFM 1011F

1 Oil filler neck (valve-gear housing cover) 2 Charge-air line / air-intake line 3 Generator 4 Narrow V-belt 5 Solenoid 6 Wheel-house cover 7 V-belt on crankshaft 8 Oil sump

9 Cut-out handle 10 Speed control lever 11 Oil dipstick 12 Crankshaft housing 13 Oil fill point (on side of crankcase) 14 Fuel pump 15 Easy-change fuel filter 16 Connecting facility for oil heater 17 Charge-air pressure full-load stop (TC) 18 Lube oil easy-change 19 Injection pumps 20 Oil cooler connection 21 Injection valves

13 12 11 10 9 8

26 446 0

2.2 Engine Illustrations

Engine Description

2.2.8 Exhaust side BFM 1011F

26 448 0

Engine Description

2.3.1 Lube Oil Circuit Schematic

10 12

2.3 Oil Circuit

1 Oil sump 2 Intake manifold

118159

19 18

7 6

3 Oil pump 4 Main oil duct 5 Oil-cooled cylinder 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 the cam, con-rod and

crankshaft bearing 16 Injection jet for cooling the pistons 17 Oil return via crankcase to the oil sump 18 Lube oil intake to turbocharger 19 Turbocharger 20 Return from turbocharger to oil sump

1714

4321618

26 430 0

2.4 Fuel System

2.4.1 Fuel system schematic

Engine Description

1 Fuel line from tank to fuel pump 2 Fuel pump 3 Fuel line from fuel pump to easy-change

fuel filter 4 Easy-change fuel filter 5 Fuel line from filter to injection pump 6 Injection pumps 7 Fuel distributor line 8 Injection lines 9 Injection valves

10 Fuel leakage line 11 Fuel overflow pipe 12 Fuel return line to tank

432 5

26 437 0

3.1 Commissioning

3.2 Starting

3.3 Monitoring Systems

3.4 Stopping

3.5 Operating Conditions

Engine Operation

3.1 Commissioning

3.1.1 Adding Engine Oil

OIL

26 432 0

As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see 4.1.

3.1.1.1 Initial Engine Oil Fill-Up for B/FM1011F Series

● Fill oil into the oil sump up to the “max.” mark on

the engine dip stick (for oil top-up quantity see

9.1).

● Start the engine and allow to run at a low idling

speed for approx. 2 mins.

● Switch off the engine.

● Check the oil level, if necessary, top up oil to the

„max.“ mark.

3.1.1.2 Initial Engine Oil Fill-up for B/FM 1011F Series

● Fill oil into the oil sump up to the “min.” mark on

the engine dip stick.

● In addition, top up the oil quantity of the supply

hoses and of the external oil cooler (according to manufacturer’s details).

● Allow the engine to run warm until the thermostat

opens (at approx. 95

● Allow the engine to run for approx. 2 mins.

● Switch off the engine.

● Check the oil level, and if necessary, top up oil to

the „max.“ mark.

C).

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 dip stick when delivered. The level can then only be assessed after the engine has been run up.

3.1 Commissioning

Engine Operation

3.1.1.3 Initial Engine Oil Fill-Up for

B/FM 1011F Genset Engine

● Fill oil into the oil sump up to the “max.” mark on

the engine dip stick (for oil quantity see 9.1).

● Start up the engine and allow to run at a lower idling speed for approx. 2 mins.

● Switch off the engine.

● Check the oil level and fill up with oil up to the

upper „max.“ mark.

3.1.2 Filling Oil Bath Air Filter with Engine Oil

24 980 2 26 398 0

Fill oil cup 1 of the oil bath air cleaner with oil up to the arrow. For oil grade and viscosity, see 4.1.

3.1.3 Adding Fuel

FUEL

Use only commercial-grade diesel fuel. For fuel grade, see 4.2. Use summer or winter-grade fuel, depending on the ambient temperature.

Do not fill the precleaner dust collector (if fitted) with oil.

! !

Never fill the tank while the engine is running. Keep the filler cap area clean and do not spill fuel.

Engine Operation

3.1 Commissioning

3.1.4 Other Preparations

● Check battery and cable connections, see 6.7.1

● Transport hooks

Remove if fitted (see 6.7.3)

● Trial run After the engine has been prepared, let it run for about 10 minutes without load.

During and after trial run – Check the engine for leaks After the engine has been turned off – Check the oil level,

see 6.1.2 If necessary, top up oil, see 3.1.1

– Retension V-belts, see 6.5

● Breaking in During the break-in phase – about 200 operating hours – check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.

3.1.5 Additional Maintenance Work

When commissioning new and reconditioned engines, the following additional maintenance work must be carried out:

After 50-150 OH

● Change lube oil, see 6.1.2

● Change oil filter cartridge, see 6.1.3

● Change fuel filter cartridge, see 6.2.1

● Check V-belts and retension as necessary, see 6.5.

● Check the engine for leaks

● Check the engine mount and adjust as neces-

sary, see 9.2

After 500 OH

● Check the valve clearance and adjust as necessary, see 6.6.1.

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