Deutz FL 1011F User manual

1Gerade
Operation Manual
B/F L 1011F
B/FM 1011F
26 451
9683en_k00_vo 16.11.2000, 8:45 Uhr1

●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 manu-
facturer 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 pur-
pose also implies compliance with the con-
ditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated by person-
nel trained in its use and the hazards in-
volved.
●The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be ob-
served.
●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 in-
validate any liability claims against the manu-
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 adjust the cooling
air intake area to the blower.
The manufacturer shall not be held respon-
sible for any damage which results from
such work.
●When carrying out maintenance/repair op-
erations on the engine, the use of DEUTZ
original parts is prescribed. These are spe-
cially designed for your engine and guaran-
tee 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 com-
ponents are to be covered impermeably.
Safety guidelines / Accident prevention
00_GB.p65 04.02.2002, 14:232

3Gerade
Engine Serial Number
Pleaseentertheengineserialnumberhere.Thisnumber
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-
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.
1Gerade
Operation Manual
B/F L 1011F
B/FM 1011F
9683en_k00_vo 16.11.2000, 8:45 Uhr3

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 require-
ments of specific cases.
Your engine is appropriately equipped for the instal-
lation 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
Foreword
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5 5Gerade
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
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
Index
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7Gerade
7Gerade
1
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.
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.
General
!
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.
Asbestos
DEUTZ original parts are asbestos-
free.
Safety
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.
Beware of Running Engine
Shut the engine down before carrying out mainte-
nance 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.
California
Proposition 65 Warning
Diesel engine exhaust and some of its consti-
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
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Engine Description
2.1 Model
2.2 Engine Illustration
2.3 Lube Oil Circuit Schematic
2.4 Fuel System Schematic
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Engine Description
2.1.1 Rating Plate
The model A, the engine serial number Band the
performance data are stamped on the rating plate.
The model and engine serial number must be given
when ordering parts.
2.1.2 Rating Plate Location
The rating plate Cis attached to the valve cover.
2.1.3 Engine Serial Number
The engine serial number Bis stamped on the
crankcase Das well as the rating plate.
2.1 Model
AB
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2.1.4 Cylinder Numbering
2.1 Model
Cylinders are numbered consecutively, beginning
at the flywheel end.
2.1.5 Fuel Delivery Lock
The manufacturer shall not be held liable for dam-
ages resulting from adjustments made to the regu-
lator 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
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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
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17
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4
5
6
7
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2.2 Engine Illustrations Engine Description
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
2.2.2 Exhaust side
FL 1011F
30
29
28
27
26
23
24
22
25
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Engine Description
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
2.2 Engine Illustrations
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24
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2.2.4 Exhaust side
BFL 1011F
Engine Description2.2 Engine Illustrations
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
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Engine Description 2.2 Engine Illustrations
2.2.5 Service Side
FM 1011F
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
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2.2 Engine Illustrations Engine Description
2.2.6 Exhaust side
FM 1011F
22 Cylinder head
23 Exhaust manifold line
24 Flywheel with ring gear
25 Starter
26 Front cover
27 Crankcase
28 Intake pipe
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Engine Description
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
2.2 Engine Illustrations
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2.2.8 Exhaust side
BFM 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
Engine Description
2.2 Engine Illustrations
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Engine Description 2.3 Oil Circuit
2.3.1 Lube Oil Circuit Schematic
1 Oil sump
2 Intake manifold
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
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