DEUTZ FL1011 OPERATORS/Service Manual

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

● 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 in- validate 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 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 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. Safety guidelines / Accident prevention 00_GB.p65 04.02.2002, 14:23 2

3 Gerade 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- 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. 1 Gerade Operation Manual B/F L 1011F B/FM 1011F 9683en_k00_vo 16.11.2000, 8:45 Uhr 3

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 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 9683en_k00_vo 16.11.2000, 8:45 Uhr 4

1 5 5 Gerade 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 9683en_k00_vo 16.11.2000, 8:45 Uhr 5

26 451 9683en_k00_vo 16.11.2000, 8:45 Uhr 6

7 Gerade 7 Gerade 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 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. 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. 9689en_K01_neu 30.09.1999, 15:45 Uhr 7

8 8 1 9689en_K01_neu 30.09.1999, 15:45 Uhr 8

9 Gerade 2 9 Engine Description 2.1 Model 2.2 Engine Illustration 2.3 Lube Oil Circuit Schematic 2.4 Fuel System Schematic 7343en_k02_pdf 05.10.1999, 9:20 Uhr 9

10 2 26 332 2 26 421 1 26 422 0 * 0 0 0 2 2 1 3 5 * C 23045678 D Engine Description 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. 2.1.2 Rating Plate Location The rating plate C is attached to the valve cover. 2.1.3 Engine Serial Number The engine serial number B is stamped on the crankcase D as well as the rating plate. 2.1 Model A B 7343en_k02_pdf 05.10.1999, 9:21 Uhr 10

DEUTZ FL1011 OPERATORS/Service Manual

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