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.

Operation Manual

B/F L 1011F

B/FM 1011F

0297 9683 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).

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

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

1Dear 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	3.5	Operating Conditions	6.5.3	Changing V-Belts		1
2	Engine Description	3.5.1	Winter Operation	6.6	Adjustments
		3.5.2	High Ambient Temperature,	6.6.1	Checking / Adjusting Valve Clearances
2.1	Model		High Altitude	6.7	Accessories
2.1.1.	Rating Plate			6.7.1	Battery
2.1.2	Rating Plate Location	4	Operating Media	6.7.2	Three-Phase Alternator
2.1.3	Engine Serial Number			6.7.3	Lifting Tackle
		4.1	Lube Oil
2.1.4	Cylinder Numbering			6.7.4	Ether Starting System
		4.1.1	Quality Grade
2.1.5	Fuel Delivery Lock			6.8.1	Engine Cleaning
		4.1.2	Viscosity
2.2	Engine Illustrations
		4.2	Fuel Operating Media
2.2.1	Service Side FL 1011F
		4.2.1	Quality Grade	7	Troubleshooting
2.2.2	Exhaust Side FL 1011F
		4.2.2	Winter-Grade Fuel	7.1	Diagnostic chart
2.2.3	Service Side BFL 1011F
2.2.4	Exhaust Side BFL 1011F	5	Routine Maintenance	8	Engine Preservation
2.2.5	Service Side FM 1011/ F
2.2.6	Exhaust Side FM 1011/ F	5.1	Maintenance Schedule	8.1	Preservation
2.2.7	Service Side BFM 1011F	5.2	Maintenance Chart	8.1.1	Preserving Engine
2.2.8	Exhaust Side BFM 1011F	5.3	Maintenance Work Completed	8.1.2	Removing Engine Preservations

2.3Oil Circuit

2.3.1	Lube Oil Circuit	6	Service and Maintenance	9	Technical Specification
2.4	Fuel System Schematic	6.1	Lubrication System	9.1	Engine Specifications and Settings
2.4.1	Fuel System	6.1.1	Oil Change Intervals	9.2	Torque Wrench Settings
		6.1.2	Changing Engine Oil, Check Oil Level	9.3	Tools
3	Engine Operation	6.1.3	Changing Oil Filter
3.1	Commissioning	6.2	Fuel System	10	Service
3.1.1	Adding Engine Oil	6.2.1	Changing Fuel Filter
3.1.2	Filling oil bath air filter with engine oil	6.2.2	Clean Strainer of Fuel Filter
3.1.3	Adding Fuel	6.2.3	Change Fuel Leakage Line
3.1.4	Other Preparations	6.3	Cooling System
3.1.5	Additional Maintenance Work	6.3.1	Cleaning Intervals
3.2	Starting	6.4	Combustion Air Cleaner
3.2.1	Starting	6.4.1	Cleaning Intervals
3.3	Monitoring Systems	6.4.2	Emptying Cyclone Type Precleaner
3.3.1	Engine Oil Pressure	6.4.3	Cleaning Oil Bath Air Cleaner
3.3.2	Coolant Temperature	6.4.4.	Dry Type Air Cleaner
3.4	Stopping	6.5	Belt Drives
3.4.1	Mechanical Shutdown	6.5.1	Checking V-Belts
3.4.2	Electrical Shutdown	6.5.2	Tensioning V-Belts

1

26 451

General

DEUTZ Diesel Engines	Care and Maintenance	Service		1

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.

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.

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.

Beware of Running Engine

Safety

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.

This symbol is used for all safety warnings. Please follow them ! carefully. The attention of operating personnel should be drawn to these safety instructions. General safety

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

Asbestos

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.

DEUTZ original parts are asbestosfree.

1

Engine Description

2

2.1Model

2.2Engine Illustration

2.3Lube Oil Circuit Schematic

2.4Fuel System Schematic

Engine Description

2.1 Model

2		2.1.1 Rating Plate	2.1.2 Rating Plate Location	2.1.3 Engine Serial Number

A B

26 332 2

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.

C
*	00022135	*
		26 421	1

The rating plate C is attached to the valve cover.

23045678
D
26 422	0

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	2.1.5 Fuel Delivery Lock		2

1	2	3	4
			26 431	0

Cylinders are numbered consecutively, beginning at the flywheel end.

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

!DEUTZ SERVICE - specialists.be carried out only by authorized

Engine Description

2.2 Engine Illustrations

22.2.1 Service Side FL 1011F

21						1
20						2
19						3
18						4
17						5
16						6
15						7
14
13	12	11	10	9	8	26 452	0

1 Oil filler neck (valve-gear cover) 2 Charge-air line / air-intake line 3 Fan with integrated generator

4Narrow V-belt

5Solenoid

6Toothed belt cover

7 V-belt pulley on crankshaft

8Oil sump

9Cut-out handle

10Speed control lever

11Oil dipstick

12Crankshaft housing

13Oil fill point (on side of crankcase)

14Fuel pump

15Easy-change fuel filter

16Connecting facility for oil heater

17Lube oil easy-change filter

18Removable coolant intake hood

19Injection pumps

20Date plate

21Oil cooler

2.2 Engine Illustrations

Engine Description

	2.2.2 Exhaust side		2
	FL 1011F

			22	Date plate
			23	Connection housing (SAE)
			24	Flywheel with ring gear
30	22		25	Starter
			26	Front cover
			27	Crankcase
			28	Cylinder head
29			29	Exhaust manifold pipe
			30	Air-intake pipe
28	23
27
26	24
25
	26444	0

Engine Description

2.2 Engine Illustrations

22.2.3 Service Side BFL 1011F

21						1
20						2
19						3
18						4
17						5
16						6
15						7
14
13	12	11	10	9	8	26 443	0

1 Oil filler neck (valve-gear housing cover) 2 Charge-air line / air-intake line

3 Fan with integrated generator

4Narrow V-belt

5Solenoid

6Wheel-house cover

7 V-belt pulley on crankshaft

8Oil sump

9Cut-out handle

10Speed control lever

11Oil dipstick

12Crankshaft housing

13Oil fill point (on side of crankcase)

14Fuel pump

15Easy-change fuel filter

16Connection facility for oil heater

17Charge-air pressure full-load stop (LDA)

18Lube oil easy-change filter

19Removable coolant intake hood

20Injection pumps

21Oil cooler

2.2 Engine Illustrations

Engine Description

	2.2.4 Exhaust side		2
	BFL 1011F

				22	Cylinder head
				23	Exhaust manifold pipe
	32			24	Flywheel with ring gear
				25	Starter
				26	Crankshaft housing
				27	Inlet line to TC (Lube oil)
	31	22		28	Return line from TC (Lube oil)
				29	Induction pipe
				30	Turbocharger (TC)
		23		31	Intake manifold
	30			32	Air-intake line
	29
	28
		24
	27
	26
	25
		26448	0

Engine Description

2.2 Engine Illustrations

22.2.5 Service Side FM 1011F

21						1
20						2
19						3
18						4
17						5
16						6
15						7
14
13	12	11	10	9	8	26 453	0

1 Oil filler neck (valve-gear housing)

2Charge-air line / air-intake line

3Generator

4Narrow V-belt

5Solenoid

6Wheel-house cover

7 V-belt pulley on crankshaft

8Oil sump

9Cut-out handle

10Speed control lever

11Oil dipstick

12Crankshaft housing

13Oil fill point (on side of crankcase)

14Fuel pump

15Easy-change fuel filter

16Connecting facility for oil heater

17Lube oil easy-change filter

18Injection pumps

19Connection for oil cooler

20Leakage-fuel line

21Injection valves

2.2 Engine Illustrations	Engine Description
2.2.6 Exhaust side			2
FM 1011F

			22	Cylinder head
			23	Exhaust manifold line
			24	Flywheel with ring gear
28			25	Starter
			26	Front cover
			27	Crankcase
	22		28	Intake pipe
27	23
26
25	24
	26 447	0

Engine Description

2.2 Engine Illustrations

22.2.7 Service Side BFM 1011F

21						1
20						2
19						3
18						4
17						5
16						6
15						7
14
13	12	11	10	9	8	26 446	0

1 Oil filler neck (valve-gear housing cover)

2Charge-air line / air-intake line

3Generator

4Narrow V-belt

5Solenoid

6 Wheel-house cover

7 V-belt on crankshaft

8Oil sump

9Cut-out handle

10Speed control lever

11Oil dipstick

12Crankshaft housing

13Oil fill point (on side of crankcase)

14Fuel pump

15Easy-change fuel filter

16Connecting facility for oil heater

17Charge-air pressure full-load stop (TC)

18Lube oil easy-change

19Injection pumps

20Oil cooler connection

21Injection valves

2.2 Engine Illustrations

Engine Description

	2.2.8 Exhaust side		2
	BFM 1011F

			22	Cylinder head
			23	Exhaust manifold pipe
			24	Flywheel with ring gear
32			25	Starter
			26	Crankshaft housing
			27	Inlet line to TC (Lube oil)
	22		28	Return line from TC (Lube oil)
31			29	Induction pipe
			30	Turbocharger (TC)
			31	Intake manifold
30	23		32	Air-intake line
29
28
	24
27
26
25
	26 448	0

Engine Description

2.3 Oil Circuit

2	2.3.1 Lube Oil Circuit Schematic
										1	Oil sump
			9	15	8	11		19		2	Intake manifold
										3	Oil pump
										4	Main oil duct
								18		5	Oil-cooled cylinder
	10									6	Cylinder head cooling neck
										7	Oil duct for rocker arm lubrication
								7		8	Rocker arm
	12									9	Oil manifold for the thermostat
										10	Intake to external engine oil cooler
								6		11	Return from external engine oil cooler
										12	Thermostat housing with slide thermostat
										13	Oil duct to oil filter
	13							5		14	Oil filter
										15	Oil duct to the cam, con-rod and
											crankshaft bearing
								20		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
								1
	14	17	18	16		2	3	4	26 430	0

2.4 Fuel System	Engine Description
2.4.1 Fuel system schematic			2

					1	Fuel line from tank to fuel pump
10				9	2	Fuel pump
					3	Fuel line from fuel pump to easy-change
						fuel filter
12					4	Easy-change fuel filter
				8	5	Fuel line from filter to injection pump
					6	Injection pumps
					7	Fuel distributor line
11					8	Injection lines
				7	9	Injection valves
					10	Fuel leakage line
					11	Fuel overflow pipe
				6	12	Fuel return line to tank
1
4	3	2	5	26 437	0

Engine Operation

3

3.1Commissioning

3.2Starting

3.3Monitoring Systems

3.4Stopping

3.5Operating Conditions

Engine Operation

3.1 Commissioning

3	3.1.1	Adding Engine Oil
		3.1.1.1 Initial Engine Oil Fill-Up

for B/FM1011F Series

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

OIL
26 432	0

●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.

●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. 95oC).

●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.

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.

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

3.1.1.3Initial 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	3.1.3 Adding Fuel	3
Engine Oil

FUEL

	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.

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 col-

lector (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

33.1.4 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 necessary, see 9.2

After 500 OH

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