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Werkstatthandbuch

1011 F

Workshop Manual

1011 F

0297	Werkstatthandbuch
9765	1011 F

0297	Workshop Manual
9765	1011 F

Manuel d’Atelier

1011 F

Manuale d’officina

1011 F

0297	Manuel d’Atelier
9766	1011 F

0297	Manuale d’officina
9766	1011 F

Werkstatthandbuch

Workshop Manual

Manuel d’Atelier

Manual de Taller 1011 F

0297 9765

V O R W O R T

Die sachgerechte Ausführung von Reparaturund Einstellarbeiten ist Voraussetzung für einen zuverlässigen Motorbetrieb.

In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparaturund Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, daß die Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.

Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der Inhalte zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den jeweils behandelten Arbeitsgang visualisieren.

Betriebsund Wartungshinweise sind der entsprechenden Betriebsanleitung zu entnehmen.

Zur Ersatzteilbestellung ist die jeweilige Ersatzteilliste zugrunde zu legen.

Das vorliegende Werkstatthandbuch unterliegt keinem Änderungsdienst. Änderungen werden jeweils bei Neuauflage eingearbeitet.

Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.

Allgemeine Hinweise:

—Lesen und beachten Sie die Informationen dieses Werkstatthandbuches. Sie vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten Motor.

—Stellen Sie sicher, daß dieses Werkstatthandbuch jedem an Reparaturoder Einstellarbeiten Beteiligten zur Verfügung steht und daß der Inhalt verstanden wird.

—Die Nichtbeachtung dieser Reparaturanleitung kann zu Funktionsstörungen und Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller keine Haftung übernommen wird.

—Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzuhalten.

—Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderlichen Ausrüstungen, Handund Spezialwerkzeuge, sowie deren einwandfreier Zustand.

—Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei

Verwendung von Original Teilen der DEUTZ AG sichergestellt.

—Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsachgemäßer Behandlung erhöhte Verletzungsgefahr.

—Die Instandsetzung des Motors muß der bestimmungsgemäßen Verwendung — definiert durch den Gerätehersteller — entsprechen. Bei Umbauten dürfen nur von der DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt werden.

F O R E W O R D

Reliable engine operation is dependent on properly executed repairs as well as adjustment work.

This Workshop Manual describes the appropriate operations for any repair and adjustment work on the engine and engine components. It is presumed that this work will be carried out by qualified personnel.

This operation manual has been designed for quick and easy understanding. Therefore the concise text passages are accompanied by pictographs to illustrate the relevant operation.

Aspects of operation and maintenance are dealt with in the respective Operation Manual.

For spare parts orders the respective spare parts catalogue should be referred to.

This Workshop Manual is not subject to engineering change service and is valid until next issue.

Therefore please refer to the information in our Technical Circulars when carrying out repairs.

General information:

—Please read carefully and observe the instructions given in this Workshop Manual to avoid accidents and ensure that your engine always functions properly and reliably.

—Make sure that this Workshop Manual is readily available for all those carrying out repairs or adjustments and that the contents are well understood.

—Non-compliance with these repair instructions may result in malfunction and engine damage as well as personal injuries for which the manufacturer shall not accept any liability.

—The accident prevention regulations and all other generally recognized regulations on safety and occupational medicine are to be observed.

—A prerequisite for successful repair is that all required equipment, hand and special tools are available and in perfect working order.

—Optimal operation economy, reliability and durability of the engine can only be ensured when genuine parts of DEUTZ AG are used.

—Engine components such as springs, clamps, snap rings, etc. may cause injury if not handled with care.

—Engine repairs must be carried out in accordance with intended use as defined by the equipment manufacturer. For conversions, only parts approved by DEUTZ AG for a specific purpose should be used.

P R É F A C E

Un fonctionnement fiable du moteur suppose l’exécution en bonne et due forme des travaux de réparation et de réglage.

Le présent Manuel d’atelier décrit la suite des travaux de réparation et de réglage à effectuer sur le moteur et ses éléments. Cela suppose que les travaux sont réalisés par un personnel spécialisé et qualifié.

En vue d’une compréhension rapide du contenu, le manuel d’atelier comporte, en plus des textes brefs, des symboles visualisant l’opération à réaliser.

Les indications relatives au service et à l’entretien figurent dans les instructions de service correspondantes.

Pour la commande de pièces de rechange, il convient de se baser sur la liste des pièces de rechange correspondante.

Le présent manuel d’atelier n’est soumis à aucun service de modifications. Les modifications seront incorporées à chaque réédition du Manuel.

Pour les réparations, veuillez respecter les indications de nos circulaires techniques.

Remarques générales:

—Veuillez lire attentivement les informations du présent Manuel d’ Atelier et en tenir compte. Vous éviterez ainsi des accidents et disposerez en même temps d’ un moteur fonctionnel et en parfait état de marche.

—Assurez-vous que chaque personne chargée des travaux de réparation et de mise

au point dispose bien de ce Manuel d’ Atelier et en comprenne bien le contenu.

—Le non-respect de ces instructions de réparation peut entraîner des pannes, avaries de moteur et accidents de personnes, pour lesquels le constructeur ne peut en aucun cas assumer la responsabilité.

—Il convient de respecter les consignes générales de sécurité et de prévention des accidents en vigueur.

—La condition préalable de la bonne exécution des réparations est la mise à disposition de tous les équipements, outillages manuels et spéciaux requis, en parfait état de fonctionnement.

—Seule l’utilisation de pièces de rechange d’origine DEUTZ AG garantit une rentabilité et fiabilité optimales ainsi qu’une longue durée de vie.

—Les éléments du moteur notamment les ressorts, attaches, bagues élastiques etc.,

peuvent entraîner, en cas de non-respect des prescriptions, des blessures graves.

—La remise en état du moteur doit répondre à son utilisation propre, définie par le constructeur de l’engin. En cas de modification, seules les pièces autorisées par DEUTZ AG dans le cas de l’application concernée, peuvent être utilisées.

P R O L O G O

Una ejecución competente de trabajos de reparación y ajuste es requisito fundamental para un funcionamiento seguro del motor.

En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los trabajos serán realizados por personal técnico especializado.

Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado símbolos significativos a los textos explicatorios, visualizando así el trabajo a realizar.

Informaciones con respecto al manejo y al servicio de entretenimiento del motor, se encuentran en el Manual de Instrucciones de Servicio correspondiente.

Para pedidos de repuestos servirá de base el respectivo catálogo de repuestos.

El presente manual para talleres no está sujeto a un servicio continuado de modificaciones e innovaciones. Cada nueva edición incluye todas las modificaciones del caso.

Al efectuar reparaciones, aconsejamos asimismo tomar en cuenta las advertencias pertinentes de nuestras circulares técnicas.

Advertencias generales:

—Le recomendamos la detenida lectura y observancia de las informaciones contenidas en este Manual de taller. Así evitará accidentes y dispondrá de un motor que funciona perfectamente.

—Haga lo necesario para que este Manual esté a disposición de toda persona que participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el contenido.

—Al no tenerse en cuenta estas instrucciones de reparación, podrán surgir perturbaciones en el funcionamiento y averías en el motor así como lesiones de personas para las cuales el fabricante no asume responsabilidad alguna.

—Se cumplirán las normas aplicables para la prevención de accidentes así como todas las demás normas de seguridad y medicina laboral generalmente aceptadas.

—Es condición para la correcta reparación que estén disponibles todos los requeridos equipos, herramientas manuales y especiales en perfecto estado.

—Máxima rentabilidad, fiabilidad y larga duración quedan garantizadas únicamente al emplearse repuestos originales de DEUTZ AG.

—Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. , aumentan en caso de tratamiento incorrecto el peligro de lesiones.

—El reacondicionado del motor deberá corresponder al empleo previsto definido por el fabricante del equipo. En caso de transformaciones, se deberán emplear únicamente piezas admitidas por DEUTZ AG para el respectivo uso previsto.

Inhalts-Verzeichnis

Table of Contents

Sommaire

Indice

Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols

Caractéristiques techniques / Légende des symbols

Datos técnicos / Leyenda de símbolos

Prüfen und Einstellen

Checking and adjusting

Contrôle et réglage

Verificación y ajustes

Bauteile instand setzen

Repair of components

Mise en état des composants

Reparación de componentes

Demontage und Montage, Motor komplett

Disassembly and reassembly of complete engine

Démontage et montage moteur complet

Despiece y ensamblado conjunto de motor

Werkzeuge

Tools

Outils

Herramientas

Technische Daten
Specification data
Caractéristiques techniques
Datos técnicos	1011 F

Inhalts-Verzeichnis	Technische Daten
Table of Contents	Specification data
Sommaire	Caractéristiques techniques
Indice	Datos técnicos


Deutsch	Werkstatthandbuch 1011 F
Ventilspiel	2.00.01 — 2.00.02
Kompressionsdruck	2.00.03 — 2.00.04
Einspritzventil	2.00.05 — 2.00.07
Einspritzpumpe	2.00.09 — 2.00.10

English
1. Specification data			Page
Specification data	_______________________________________	1.00.02 -1.00.07
Schematic for valve clearance adjustment _______________________________	1.00.09
Tightening order for cylinder head bolts ________________________________	1.00.11
Key to symbols	_______________________________________	1.00.13

Français
1. Caractéristiques techniques	Page
Caractéristiques techniques	_______________________________________	1.00.02 — 1.00.07
Schéma de réglage des soupapes _____________________________________	1.00.09
Ordre à respecter lors du serrage dàpproche de définitif des fis de cul. ________	1.00.11
Explication des légendes	_______________________________________	1.00.13

Español
1. Datos técnicos			Página
Datos técnicos	_______________________________________	1.00.02 — 1.00.07
Esquema para el ajuste del juego de válvulas ____________________________	1.00.09
Sucesión de los trabajos al apretar los tornillos de culata ___________________	1.00.11
Leyenda de símbolos	_______________________________________	1.00.13

Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos

Werkstatthandbuch 1011 F

	Deutsch		English		Français		Español
	Motorgewicht	Engine weight		Poids du moteur		Peso del motor
1	ohne Starter,	without starter		sans démarreur		sin arrancador,
mit Generator	with generator		avec génératrice		con generador
ca. kg	approx. kg		approx. kg		aprox. kg


	Gesamthubvolumen	Engine swept volume		Cylindrée totale		Cilindrada total
	cm3	cm3		cm3		cm3

	Bohrung	Bore		Alésage		Calibre
	mm	mm		mm		mm

	Hub	Stroke		Course		Carrera
	mm	mm		mm		mm

	Drehrichtung	Direction of rotation		Sens de rotation		Sentido de giro

	Nenndrehzahl	Rated speed		Régime nominal		Régimen nominal
	max. 1/min	max. rpm		maxi tr/mn		máx. r/min

	Niedrigste	Minimum		Ralenti extrême		Régimen mín.
	Leerlaufdrehzahl	idle speed				en vacío
	1/min	rpm		tr/mn		r/min

	Arbeitsweise	Working cycle		Principe de fonction-		Sistema de trabajo
					nement

1.00.02

Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos

Werkstatthandbuch 1011 F

F2 — 4L 1011 F

BF4L 1011 F

F3 — 4M 1011 F

BF4M 1011 F

F2L = 167

F3L = 208

257

F3M = 200

249

F4L = 250

F4M = 243

F2L = 1366

F3L = 2049

2732

F3M = 2184

2912

F4L = 2732

F4M = 2912

105

112

auf Schwungrad gesehen links

When facing flywheel counter-clockwise

Vu sur volant à gauche

Mirándose sobre el volante a izquierdas

3300

3000

2800

900 ±50

Viertakt — Diesel

Four-stroke diesel

Diesel 4 temps

Diesel a 4 tiempos

1.00.03

Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos

Werkstatthandbuch 1011 F

	Deutsch		English		Français		Español
	Verbrennungs-	Combustion		Principe de		Sistema de
1	verfahren	system		combustion		combustión


	Verdichtungs-	Compression		Taux de		Relación de
	verhältnis	ratio		compression		compresión

	Kompressionsdruck	Compression pressure		Compression		Pressión de
							compresión
	bar	bar		bars		bar

	Zündfolge	Firing order		Ordre d’allumage		Orden de
							encendido

	Abmessungen des	Dimensions of		Dimensions du		Dimensiones del
	Motors mit	engine incl.		moteur avec volant		motor con
	Anschlußgehäuse	standard flywheel		standard		volante
	(normal)					(normal)

	größte Länge	Max. length		Longueur HT		Longitud máx.
	mm	mm		mm		mm

	größte Breite	Max. width		Largeur HT		Anchura máx.
	mm	mm		mm		mm

	größte Höhe	Max. height		Hauteur HT		Altura máx.
	mm	mm		mm		mm

1.00.04

Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos

Werkstatthandbuch 1011 F

F2 — 4L 1011 F		BF4L 1011 F		F3-4M 1011 F		BF4M 1011 F

Direkteinspritzung

Direct injection

Injection directe 1

Inyección directa

1	— 2
1	-2 — 3		1 -2 — 3
1 -3 — 4 — 2	1 -3 — 4 — 2	1 -3 — 4 — 2	1 -3 — 4 — 2

F2L = 487
F3L = 599	710	F3M = 599	710
F4L = 710	F4M = 710

451	495	451	495

F2L = 683
F3L = 678	703	F3M = 678	703
F4L = 703	F4M = 703

1.00.05

Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos

Werkstatthandbuch 1011 F

	Deutsch		English		Français		Español
	Steuerzeiten ohne	Valve timing without	Calage distribution sans	Cotas de reglaje sin
	Stößelund Ventilspiel	valve clearance	jeu aux culbuteurs	juegos de válvulas y
1					réglé	de empujadores


	Einlaß öffnet	Inlet opens	Admission ouvre	Admisión abre
	vor OT	before TDC	avant PMH	a. PMS
	Grad	degrees	degrés	grados

	Einlaß schließt	Inlet closes	Admission ferme	Admisión cierra
	nach UT	after BDC	après PMB	t. PMI
	Grad	degrees	degrés	grados

	Auslaß öffnet	Exhaust opens	Echappement ouvre	Escape abre
	vor UT	before BDC	avant PMB	a. PMI
	Grad	degrees	degrés	grados

	Auslaß schließt	Exhaust closes	Echappement ferme	Escape cierra
	nach OT	after TDC	après PMH	t. PMS
	Grad	degrees	degrés	grados

	Schmieröldruck in	Lube oil pressure at low	Pression d’huile au bas	Presión de aceite lubri-
	niedrigem Leerlauf	idling	ralent	cante a marcha lenta
	Temperatur ca. 110° C	Temperature approx.	température ca. 110° C	en vacío Tempera-
	Öl SAE 20W/20	110° C oil SAE 20W/20	huile SAE 20W/20	tura aprox. 110° C
							aceite SAE 20W/20
	Minimum bar	min. bar	mini bars	mín. bar

	Absteuerventil	Pressurestat	Clapet régulateur	Válvula reguladora
					final	final
	bar	bar	bars	bar

1.00.06

Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos

			Werkstatthandbuch 1011 F

F2 — 4L 1011 F	BF4L 1011 F	F3 — 4M 1011 F		BF4M 1011 F

				1

45	47	45	47

65	63	65	63

76	99,5	76	99,5

44	51,5	44	51,5

		1,4

F2 -3L = 6,5	7		F3L = 6,5	7
F4L = 7			F4L = 7

1.00.07

Technische Daten Specification data Caractéristiques techniques Datos técnicos

Werkstatthandbuch 1011 F

Ventilspieleinstellschema

Schematic for valve clearance adjustment

Schéma de réglage des soupapes

Esquema para el ajuste de holgura de válvulas

Werkstatthandbuch 1011 F

English

Français

Español

Crankshaft position

Position de l’arbre à cames

Posición del cigüeñal

Kurbelwellenstellung

Turn engine until valves of cylinder

Virer le moteur jusqu’au chevau-

Gírese el motor, hasta que las válvulas

No. 1 overlap.

chement des soupapes au cylindre 1.

del cilindro N° 1 coincidan en su

posición momentánea.

Motor bis zum Erreichen der Ventilüber-

Motor um eine volle Umdrehung (360°)

Not ready for adjustment.

non réglable

no ajustable

schneidung am Zyl. Nr. 1 durchdrehen.

weiterdrehen.

Crankshaft position

Position de l’arbre à cames

Posición del cigüeñal

nicht einstellbar

einstellbar

Turn engine further by one complete

Tourner le moteur d’un tour complet

Continuese girando el motor por una

revolution (360°).

(360°)

rotación completa (360°)

Ready for adjustment.

réglable

ajustable

1.00.09

Reihenfolge beim Anziehen der Zylinderkopfschrauben Tightening order for cylinder head bolts

Ordre à respecter lors du serrage d’approche et définitif des vis de cul. Sucesión de los trabajos al apretar los tornillos de culata

Werkstatthandbuch 1011 F

Krümmerseite,Manifold side,

Coté coudes, Lado codo

			2-Zylinder

4	2	6	2-cylinder
			2-cylindres
5	1	3	2 cilindros

Krümmerseite,Manifold side,

Coté coudes, Lado codo

				3-Zylinder

7	3	4	6	3-cylinder
				3-cylindres
5	1	2	8	3 cilindros

Krümmerseite,Manifold side,

Coté coudes, Lado codo

					4-Zylinder

8	6	4	5	9	4-cylinder
					4-cylindres
10	3	1	2		4 cilindros
7

1 1

Krümmerseite,Manifold side,

Coté coudes, Lado codo

			2-Zylinder

4	2	6	2-cylinder
			2-cylindres
5	1	3	2 cilindros

Krümmerseite,Manifold side,

Coté coudes, Lado codo

				3-Zylinder

7	3	4	6	3-cylinder
				3-cylindres
5	1	2	8	3 cilindros

Krümmerseite,Manifold side,

Coté coudes, Lado codo

					4-Zylinder

8	6	4	5	9	4-cylinder
					4-cylindres
10	3	1	2		4 cilindros
7

1.00.11

Bildzeichenerklärung

Werkstatthandbuch 1011 F

Bildzeichenerklärung

Zerlegen

Personenschäden verhüten

Zerlegen

Personenschäden verhüten

von Baugruppen

Hinweis auf Gefahrenstelle

von Baugruppen

Hinweis auf Gefahrenstelle

Zusammenbauen

Materialschaden verhüten

Zusammenbauen

Materialschaden verhüten

zu einer Baugruppe

Teilbeschädigung

zu einer Baugruppe

Teilbeschädigung

Abbauen — Ausbauen

Unterbauen — Abstützen —

Abbauen — Ausbauen

Unterbauen — Abstützen —

behindernder Teile

Abfangen

behindernder Teile

Abfangen

Einbauen — Anbauen

Einölen

Einbauen — Anbauen

Einölen

Teile, die beim Ab-/ Ausbau hinderten

Achtung, wichtiger Hinweis

Einfetten

Achtung, wichtiger Hinweis

Einfetten

Prüfen — Einstellen

Markieren

Prüfen — Einstellen

Markieren

z. B. Drehmomente, Maße, Drücke usw.

vor dem Zerlegen, beachten beim

z. B. Drehmomente, Maße, Drücke usw.

vor dem Zerlegen, beachten beim

Zusammenbau

Spezialwerkzeug

Wuchten

Spezialwerkzeug

Wuchten

Ausgleichen von Unwuchten

Einbaurichtung beachten

Einfüllen — Auffüllen — Nachfüllen

Einbaurichtung beachten

Einfüllen — Auffüllen — Nachfüllen

z. B. Öl, Kühlwasser usw.

Kontrollieren — Prüfen

Ablassen

Kontrollieren — Prüfen

Ablassen

Sichtprüfung

z. B. Öl, Kühlwasser usw.

Sichtprüfung

z. B. Öl, Kühlwasser usw.

Bedingt wiederverwendbar

Lösen

Bedingt wiederverwendbar

Lösen

Bei Bedarf auswechseln

z. B. Lockern einer Spanneinrichtung

Bei Bedarf auswechseln

z. B. Lockern einer Spanneinrichtung

Beim Zusammenbau immer

Spannen

Beim Zusammenbau immer

Spannen

erneuern

z. B. Anziehen einer Spanneinrichtung

erneuern

z. B. Anziehen einer Spanneinrichtung

Entsichern — Sichern

Entlüften

Entsichern — Sichern

Entlüften

z. B. Splint, Sicherungsblech usw.

Sichern — Kleben

Spanabhebende Bearbeitung

Sichern — Kleben

Spanabhebende Bearbeitung

z. B. Dichtmittel flüssig

1.00.13

Key to Symbols

Werkstatthandbuch 1011 F

Key to Symbols

Disassembly

Guard against personal injury

Disassembly

Guard against personal injury

of assembly groups

Indication of hazard

of assembly groups

Indication of hazard

Reassembly

Guard against material damage

Reassembly

Guard against material damage

to form assembly group

Damage to parts

to form assembly group

Damage to parts

Remove

Prop up — Support — Hold

Remove

Prop up — Support — Hold

obstructing parts

Reinstall — Remount

Oil

Reinstall — Remount

Oil

parts which had obstructed disassembly

Attention! Impartant notice!

Grease

Attention! Impartant notice!

Grease

Check — Adjust

Mark

Check — Adjust

Mark

e. g. torque dimensions, pressures, etc.

before disassembly, observe marks when

reassembling

e. g. torque dimensions, pressures, etc.

reassembling

Special tool

Balance

Special tool

Balance

Eliminate any imbalance

Note direction of installation

Filling — Topping up — Refilling

Note direction of installation

Filling — Topping up — Refilling

e. g. oil, cooling water, etc.

Visual inspection

Drain off

Visual inspection

Drain off

e. g. oil, cooling water, etc.

Possibly still serviceable

Loosen — Release

Possibly still serviceable

Loosen — Release

Renew if necessary

e. g. loosening a clamping device

Renew if necessary

e. g. loosening a clamping device

Renew at each reassembly

Tighten — Clamp

Renew at each reassembly

Tighten — Clamp

e. g. tightening a clamping device

Unlock — Lock

Vent

Unlock — Lock

Vent

e. g. split pin, locking plate, etc.

Lock — Adhere

Machining process

Lock — Adhere

Machining process

e. g. with liquid sealant

1.00.13

Légende des symboles

Werkstatthandbuch 1011 F
Légende des symboles	Légende des symboles

Déassemblage

d’un ensemble constructif

Assemblage

des composants d’un ensemble constructif

Démontage

d’eléments entravant l’accés

Remontage — Remise en place

d’eléments qui entravaient l’accés

Remarque importante!

Utilisation impérative

p. ex.: couple-moteur, cotes, pressions etc.

Utilisation impérative

d’un outil specialise

Respecter l’ordre de montage

Vérification — Contrôle

à vue

Réutilisation sous certaines conditions

à remplacer,si besoin est

Prévention aux accidents profession				Déassemblage		Prévention aux accidents profession
attirer l’attention sur un risque eventuel	1	1		d’un ensemble constructif		attirer l’attention sur un risque eventuel
d’ accident				d’ accident

Prévention à la détérioration de				Assemblage		Prévention à la détérioration de
matériels						matériels
Risque d’endommager des piéces				des composants d’un ensemble constructif		Risque d’endommager des piéces

Monter sur tréteaux — freiner par				Démontage		Monter sur tréteaux — freiner par
sabots — immobiliser par un moyen						sabots — immobiliser par un moyen
quelconque				d’eléments entravant l’accés		quelconque

Huiler				Remontage — Remise en place		Huiler
				d’eléments qui entravaient l’accés

Graisser				Remarque importante!		Graisser
employer lubrificant plastique						employer lubrificant plastique

Repérage en cours de démontage				Utilisation impérative		Repérage en cours de démontage
permet un remontage correct!				p. ex.: couple-moteur, cotes, pressions etc.		permet un remontage correct!

Equilibrer				Utilisation impérative		Equilibrer
éliminer le balourd				d’un outil specialise		éliminer le balourd

Premier garnissage — remplissage —				Respecter l’ordre de montage		Premier garnissage — remplissage —
garnissage d’appoint						garnissage d’appoint
p. ex.: Huile eau de refroidissement etc.						p. ex.: Huile eau de refroidissement etc.

Vidanger — soutirer				Vérification — Contrôle		Vidanger — soutirer
p. ex.: Huile eau de refroidissement etc.				à vue		p. ex.: Huile eau de refroidissement etc.

Desserrer				Réutilisation sous certaines		Desserrer
p. ex.: desserrage d’un dispositiv				conditions
			à remplacer,si besoin est		p. ex.: desserrage d’un dispositiv

A remplacer systématiquement	Serrer	A remplacer systématiquement	Serrer
lors de remontage	p. ex.: serrage entre un dispositif	lors de remontage	p. ex.: serrage entre un dispositif

Arracher la goupille — goupiller	Faire la purge d’air	Arracher la goupille — goupiller	Faire la purge d’air
freiner par tôle-arrétoir		freiner par tôle-arrétoir

Freiner — coller	Usinage par enlèvement de copeaux	Freiner — coller	Usinage par enlèvement de copeaux
p. ex. avec páte hermétique, ou frein liquide		p. ex. avec páte hermétique, ou frein liquide

1.00.13

Leyenda de símbolos

Werkstatthandbuch 1011 F

Leyenda de símbolos

Desarmar

Evitar accidentes

Desarmar

Evitar accidentes

grupos de construcción

indica puntos de peligro

grupos de construcción

indica puntos de peligro

Rearmar

Evitar daños materiales

Rearmar

Evitar daños materiales

un grupo de construcción

averia de piezas

un grupo de construcción

averia de piezas

Desmontar

Calzar — Apoyar

Desmontar

Calzar — Apoyar

partes que puedan estorbar

Montar — Incorporar

Aceitar

Montar — Incorporar

Aceitar

partes que puedan estorbar en

el desmontaje

!Atención! Indicación importante

Engrasar

!Atención! Indicación importante

Engrasar

Verificar — Graduar — Ajustar

Marcar

Verificar — Graduar — Ajustar

Marcar

(p. ej. pares, medidas, presiones)

antes del desmontaje — controlar la marcación

en el remontaje

(p. ej. pares, medidas, presiones)

en el remontaje

Herramienta especial

Equilibar

Herramienta especial

Equilibar

Aeliminar desequilibros o excentricidad

Observar la dirección de montaje

Lienar — Rellenar — Completar

Observar la dirección de montaje

Lienar — Rellenar — Completar

p. ej. aceite, agua refrigerante, etc.

Control

Evacuar — Vaciar

Control

Evacuar — Vaciar

verificación visual

p. ej. aceite, agua refrigerante, etc.

verificación visual

p. ej. aceite, agua refrigerante, etc.

Re-utilización condicional

Soltar

Re-utilización condicional

Soltar

sustituir en caso necesario

p. ej. un sistema de fijación o tensado

sustituir en caso necesario

p. ej. un sistema de fijación o tensado

Sustituir en cada montaje

Tensar — Apretar

Sustituir en cada montaje

Tensar — Apretar

p. ej. un sistema de fijación o tensado

Desafianzar — Afianzar (mecánicamente)

Purgar el aire

Desafianzar — Afianzar (mecánicamente)

Purgar el aire

(p. ej. pasador de aletas, chapa de seguridad,

etc.)

Afianzar — Pegar

Mecanización con arranque de

Afianzar — Pegar

Mecanización con arranque de

p. ej. con medio liquido

virutas

p. ej. con medio liquido

virutas

1.00.13

Prüfen und Einstellen

Checking and adjusting

Contrôle et réglage

Verificación y ajustes 1011 F

Inhalts-Verzeichnis	Prüfen und Einstellen
Table of Contents	Checking and adjusting
Sommaire			Contrôle et réglage
Indice			Verificación y ajustes


Deutsch		Werkstatthandbuch 1011 F
2. Prüfen und Einstellen	Seite
Ventilspiel _______________________________________________________	2.00.01 — 2.00.02
Kompressionsdruck ________________________________________________	2.00.03 — 2.00.04
Einspritzventil	____________________________________________________	2.00.05 — 2.00.07
Einspritzpumpe ___________________________________________________	2.00.09 — 2.00.10

English
2. Checking and adjusting	Page
Valve clearance ___________________________________________________	2.00.01 — 2.00.02	2
Compression pressure ______________________________________________	2.00.03 — 2.00.04
Injector _________________________________________________________	2.00.05 — 2.00.07
Injection pump ___________________________________________________	2.00.09 — 2.00.10

Français

2. Contrôle et réglage

Page

Jeu aux soupapes _________________________________________________ 2.00.01 — 2.00.02 Taux de compression ______________________________________________ 2.00.03 — 2.00.04 Soupape injectrice _________________________________________________ 2.00.05 — 2.00.07 Pompe d’injection _________________________________________________ 2.00.09 — 2.00.10

Español

2. Verificación y ajustes

Pagina

Juego de válvulas _________________________________________________ 2.00.01 — 2.00.02 Presión de compresión _____________________________________________ 2.00.03 — 2.00.04 Inyector _________________________________________________________ 2.00.05 — 2.00.07

Bomba de inyección _______________________________________________ 2.00.09 — 2.00.10

Prüfen und Einstellen	Ventilspiel
Checking and adjusting	Valve clearance
Contrôle et réglage	Jeu de soupapes
Verificación y ajustes	Juego de válvulas

		English		Français
		The standard valve clearance can be		Le réglage standard du jeu des
		adjusted:		soupapes est possible
		with engine cold or warm after cooling		sur moteur froid ou chaud après une
		down for at least 0.5 h.		période de refroidissement d’au moins
				30 minutes.
		Oil temperature ≤ 80°C.		Température de l’huile ≤ 80˚C.
		Note: The valve clearance is to be in-		Nota: à chaque changement du joint de

		creased by 0.1 mm at every cy-		culasse augmenter le jeu aux
		linder head gasket renewal.		soupapes de 0,1 mm.
		The standard valve clearance is		Après 500 heures de marche
		to be adjusted after completion		procéder au réglage standard du
		of 500 hours of operation.		jeu des soupapes.
2		Cylinder head cover has been removed.		Le cache-culbuteurs a été déposé.
	1. Turn engine until valves of cyl. No.		1. Virer le moteur jusqu’à ce que les

		1 overlap.		soupapes soient en bascule, cyl. no. 1.

		For valve clearance adjustment		Schéma de réglage du jeu aux
		schematic see Specification Data.		soupapes voir caractéristiques
				techniques.
		Note: Valves overlapping means:		Nota: le chevauchement des soupapes
		Exhaust valve about to close.		signifie: soupape d’échappement
		Inlet valve about to open.		pas encore fermée et soupape
		Neither pushrod can be turned		d’admission commence à
		in this position.		s’ouvrir. Les deux tiges de
				culbuteurs ne peuvent plus
				tourner.

2.	Adjust valve clearance on respec-	2.	Régler le jeu des soupapes au
	tive cylinder with feeler gauge.		cylindre correspondant avec une
				jauge d’épaisseur.
Note: Inlet valve clearance:	0.3 mm	Nota: Jeu soupape ADM:	0,3 mm
	Exhaust valve clearance: 0.5 mm		Jeu soupape ECH:	0,5 mm
3.	Tighten locknut.		3.	Serrer le contre-écrou
	Tightening specification: 20 ±2 Nm		Consigne de serrage 20 ± 2 Nm
	Recheck the adjustment with feeler		Effectuer un nouveau contrôle du
	gauge.			serrage avec une jauge d’épaisseur.

Español

El ajuste del juego estándar de válvulas es posible:

Con el motor frío o con el motor caliente después de un período de enfriamiento de por lo menos media hora.

Temperatura del aceite: ≤ 80°C.

Nota: El juego de válvulas debe aumentarse por 0,1 mm a cada cambio de la junta de culata,. Tras 500 horas de servicio se ajustará el juego estándar.

La tapa de culata está desmontada.

1.Girar el cigüeñal hasta que se crucen las válvulas en el cilindro 1.

Para el esquema de ajuste del juego de válvulas, véanse los Datos Técnicos.

Nota: Cruce de válvulas significa: La válvula de escape aún no está cerrada y la de admisión comienza a abrirse. En esta posición, no es posible girar las dos varillas de empuje.

2.Ajustar el juego de válvulas en el cilindro correspondiente mediante la galga de espesores.

Nota: Juego de válvulas
— admisión:	0,3 mm
— escape:	0,5 mm

3.Apretar la contratuerca.

Prescripción de apriete: 20 ± 2 Nm.

Comprobar nuevamente el ajuste efectuado, mediante la galga de espesores.

2.00.01

Ventilspiel	Prüfen und Einstellen
Valve clearance	Checking and adjusting
Jeu de soupapes	Contrôle et réglage
Juego de válvulas	Verificación y ajustes


Deutsch	Werkstatthandbuch 1011 F

Die Standard-Ventilspieleinstellung ist möglich:

Am kaltenoder am warmen Motor nach einer Abkühlzeit von mindestens 0,5 h. Öltemperatur ≤ 80° C

Hinweis: Bei jedem Zylinderkopf-Dichtungswech- sel ist das Ventilspiel um 0,1 mm zu erhöhen.

Nach 500 Bh ist das Standard-Ventil- spiel einzustellen.

Zylinderkopfhaube ist abgebaut

1.Motor durchdrehen bis zum Erreichen der

Ventilüberschneidung, Zyl. Nr. 1.

Ventilspieleinstellschema siehe Techn. Daten

Hinweis: Ventilüberschneidung bedeutet: Auslaßventil ist noch nicht geschlossen, Einlaßventil beginnt zu öffnen. Dabei sind beide Stoßstangen nicht drehbar.

2.Ventilspieleinstellung am entsprechenden Zylinder mit Fühlerlehrenblatt einstellen.

Hinweis: Ventilspiel Einlaß:	0,3 mm
Ventilspiel Außlaß:	0,5 mm

3.Kontermutter festdrehen.

Anziehvorschrift: 20 ± 2 Nm

Einstellung nochmals mit Fühlerlehrenblatt überprüfen.

2.00.01

Prüfen und Einstellen	Ventilspiel
Checking and adjusting	Valve clearance
Contrôle et réglage	Jeu de soupapes
Verificación y ajustes	Juego de válvulas

Werkstatthandbuch 1011 F

Deutsch

4. Dichtung aufsetzen.

5.Zylinderkopfhaube montieren. Schrauben festdrehen.

Anziehvorschrift: 8,5 Nm

2.00.02

Ventilspiel		Prüfen und Einstellen
Valve clearance		Checking and adjusting
Jeu de soupapes		Contrôle et réglage
Juego de válvulas		Verificación y ajustes


English	Français	Español
4. Put gasket in place.	4. Mettre en place le joint.	4. Colocar la junta.

5. Fit cylinder head cover. Tighten	5. Monter le cache-culbuteurs.	5. Montar la tapa de culata. Apretar
bolts.	Bloquer les vis.	los tornillos.
Tightening specification: 8.5 Nm	Consigne de serrage: 8,5 Nm.	Prescripción de apriete: 8,5 Nm.

2.00.02

Prüfen und Einstellen						Kompressionsdruck
Checking and adjusting						Compression pressure
Contrôle et réglage						Taux de compression
Verificación y ajustes						Presión de compresión


	English			Français			Español
	Commercial tools required:			Outillage usuel:			Herramientas comerciales:
	Compression tester __________ 8005		Compressiomètre ___________ 8005		Compresímetro _____________ 8005
	Torx tool kit ________________ 8189		Jeu d’outils Torx ____________ 8189		Juego de herramientas Torx	___ 8189
	Special tools required:			Outil spécial:			Herramientas especiales:
	Connector ______________	100 120		Pièce de raccordement ____	100 120		Pieza de empalme ________	100 120
	Special wrench			Clé spéciale pour			Llave especial para
	for injection line __________	110 490		conduite d’injection _______	110 490		tubo de inyección ________	110 490

	Injectors have been removed, valve	Les injecteurs ont été déposés et le	Los inyectores están desmontados y
	clearance has been checked.	jeu des soupapes contrôlé.	el juego de válvulas está controlado.
2	1. Insert connector with new special	1. Mettre en place la pièce de	1. Introducir la pieza de empalme con
seal.	raccordement avec un joint spécial	la junta especial nueva.
		neuf.

2. Fit clamping pad. Tighten bolt.

2.Placer la griffe de serrage et serrer le boulon.

2.Colocar la garra de sujeción. Apretar el tornillo.

3.If necessary, screw on adapter for connector.

3.Si nécessaire mettre en place l’adaptateur de la pièce de raccordement.

3.De ser necesario, enroscar el adaptador para la pieza de empalme.

2.00.03

Kompressionsdruck	Prüfen und Einstellen
Compression pressure	Checking and adjusting
Taux de compression	Contrôle et réglage
Presión de compresión	Verificación y ajustes

Deutsch

Handelsübliche Werkzeuge:

Kompressionsdruckprüfer ___________ 8005 Torx-Werkzeugsatz ________________ 8189

Spezialwerkzeuge:

Anschlußstück _________________ 100 120 Spezialschlüssel für Einspritzleitung __ 110 490

Einspritzventile sind ausgebaut, Ventilspiel ist kontrolliert.

1.Anschlußstück mit neuer Spezialdichtung einsetzen.

Werkstatthandbuch 1011 F

2. Spannpratze aufsetzen. Schraube festdrehen.	4

3. Falls notwendig Adapter für Anschlußstück	4
aufschrauben.

2.00.03

Prüfen und Einstellen	Kompressionsdruck
Checking and adjusting	Compression pressure
Contrôle et réglage	Taux de compression
Verificación y ajustes	Presión de compresión

Werkstatthandbuch 1011 F


			9

2			5

Deutsch

4.Kompressionsdruckprüfer anschließen. Motor mit Starter durchdrehen. Kompressionsdruck:

F 1011 F	25-30 bar
BF 1011 F	22-27 bar

Der gemessene Kompressionsdruck ist abhängig von der Anlaßdrehzahl während des Meßvorganges und der Höhenlage des Motoraufstellortes.

Grenzwerte sind daher nicht genau festlegbar. Empfohlen wird die Kompressionsdruckmessung nur als Vergleichsmessung aller Zylinder eines Motors untereinander anzusehen. Sind mehr als 15% Abweichung ermittelt worden, sollte durch die Demontage der betroffenen Zylindereinheit die Ursache ermittelt werden.

Hinweis: Einspritzventil mit neuer Spezialdichtung einsetzen und festdrehen.

Anziehvorschrift: 21 Nm

Einspritzleitungen festdrehen.

Anziehvorschrift: 22 + 2 Nm

Die Leckölleitung ist grundsätzlich zu erneuern.

2.00.04

Kompressionsdruck	Prüfen und Einstellen
Compression pressure	Checking and adjusting
Taux de compression	Contrôle et réglage
Presión de compresión	Verificación y ajustes

English

4.Connect compression tester. Turn engine with starter.

Compression pressure:

F engine	25-30 bar
BF engine	22-27 bar

The measured compression pressure is dependent on the starting speed during the measuring process and also on the altitude of the engine site. Therefore it is difficult to specify precise limit values. It is recommended to use the compression pressure measurement only for comparison of compression pressures of all cylinders in one engine. If a difference in pressure in excess of 15 % is determined, the cylinder unit concerned should be dismantled to establish the cause.

Note: Fit injector with new special seal and tighten.

Tightening specification: 21 Nm

Tighten injection lines.

Tightening specification: 22 + 2 Nm

The leakage fuel line must always be renewed.

Français

4.Brancher le compressiomètre. Virer le moteur au démarreur Pression de compression

Moteur F	25-30 bars
Moteur BF	22-27 bars

Le taux de compression mesuré dépend de la vitesse de démarrage durant le relevé des mesures, et de l’altitude du lieu d’implantation du moteur.

Des valeurs limites précises ne peuvent donc pas être fixées. Il est conseillé de considérer la mesure du taux de compression uniquement comme mesure comparative pour tous les cylindres d’un moteur. En cas d’écart supérieur à 15 %, la cause pourra être déterminée en démontant l’unité cylindre concernée.

Nota: monter l’injecteur avec un joint spécial et serrer.

Consigne de serrage: 21 Nm.

Serrer les tuyauteries d’injection.

Consigne

de serrage 22 + 2 Nm.

Toujours remplacer la tubulure de retour de fuites.

Español

4.Conectar el compresímetro. Girar el motor con ayuda del arrancador. Presión de compresión:

Motor F	25 — 30 bar
Motor BF	22 — 27 bar

El valor de compresión medido depende de la velocidad de arranque durante la medición y de la altitud del lugar de instalación del motor.

Por tanto, no es posible fijar valores 2 límite exactos. La medición de

compresión se aconseja solamente como una medida de comparación entre todos los cilindros de un mismo motor. Si se verifican diferencias superiores al 15%, es conveniente buscar la causa, desmontando la unidad de cilindro afectada.

Nota: Montar el inyector con una junta especial nueva y apretar.

Prescripción de apriete: 21 Nm.

Apretar las tuberías de inyección.

Prescripción

de apriete: 22 + 2 Nm.

La tubería de combustible sobrante deberá ser sustituida, en todos los casos, por otra nueva.

2.00.04

Prüfen und Einstellen	Einspritzventil
Checking and adjusting	Injector
Contrôle et réglage	Soupape injectrice
Verificación y ajustes	Inyector

English

Commercial tools required:

Nozzle tester _______________ 8008

Long socket a/flats 15 ________ 8021

Special tool required:

Retainer for injector _______ 110 110

	Note: Utmost cleanliness must be en-
	sured when working on the in-
	jection equipment. For testing
2	the injector use only pure test oil
to ISO 4113 or clean diesel fuel.

Caution!

Beware of injection nozzle fuel jet. The fuel penetrates deeply into the skin tissue and may cause blood poisening.

1.Connect injector to nozzle tester.

2.Checking opening pressure

With pressure gauge switched on, slowly press down lever of nozzle tester. The pressure at which the gauge pointer stops or suddenly drops, is the opening pressure.

Opening pressure for initial setting:

Genset engines = 250 + 8 bar

Automotive engines = 210 + 8 bar

Français

Outillage usuel:

Banc d’essais d’injecteurs _____ 8008 Clé à douille longue de 15 _____ 8021

Outillage spécial:

Dispositif d’immobilisation

pour injecteur ___________ 110 110

Nota: tous les travaux à effectuer sur les injecteurs doivent être réalisés dans de parfaites conditions de propreté. Pour contrôler les injecteurs n’utiliser que du gazole d’essai pur selon ISO 4113 ou du combustible diesel parfaitement propre.

Attention!

Tenir les mains à l’écart des jets de gazole, la force de pénétration de ceuxci est telle qu’ils peuvent créer des blessures graves et amener un empoisonnement du sang.

1.Monter l’injecteur sur la pompe d’essais d’injecteurs.

2.Contrôle de la pression d’ouverture

Le manomètre étant branché, appuyer lentement sur le levier de la pompe d’essai d’injecteurs. La pression à laquelle l’aiguille s’arrête ou chute brusquement, est la pression maxi ou pression d’ouverture.

Valeur de contrôle de pression d’ouverture pour nouveau tarage : Moteurs de groupe: 250 + 8 bars Moteurs de véhicule: 210 + 8 bars

2.00.05

Español

Herramientas comerciales:

Comprobador para inyectores __ 8008 Llave de vaso largo de 15 _____ 8021

Herramientas especiales:

Soporte de inyectores _____ 110 110

Nota: Al trabajar en el equipo de inyección, se deberá observar máxima limpieza. Para la prueba de los inyectores sólo se utilizará aceite de ensayo puro según ISO 4113 o combustible diesel limpio.

Atención:

No acercar nunca las manos a los chorros del inyector, pues el combustible se introduce en la carne y destruye los tejidos. Si llega a la sangre, produce grave intoxicación.

1.Empalmar el inyector al comprobador.

2.Comprobación de la presión de apertura

Con el manómetro conectado, empujar la palanca del comprobador lentamente hacia abajo. La presión a la que la aguja

se detiene o cae repentinamente, es la presión de apertura.

Presión de apertura para el nuevo ajuste en motores:

para grupos

electrógenos = 250 + 8 bar. para vehículos = 210 + 8 bar.

Einspritzventil	Prüfen und Einstellen
Injector	Checking and adjusting
Soupape injectrice	Contrôle et réglage
Inyector	Verificación y ajustes

Deutsch

Handelsübliche Werkzeuge:

Düsenprüfgerät ____________________ 8008 Lange Stecknuß SW 15 ______________ 8021

Spezialwerkzeug:

Halter für Einspritzventil __________ 110 110

Hinweis: Bei Arbeiten an der Einspritzausrüstung auf größte Sauberkeit achten. Zur Prüfung der Einspritzventile nur reines Prüföl nach ISO 4113 oder sauberen Dieselkraftstoff verwenden.

Achtung !

Hände weg vom Düsenstrahl. Der Kraftstoff dringt tief in das Fleisch ein und kann zur Blutvergiftung führen.

1.Einspritzventil an das Düsenprüfgerät anbauen.

2.Prüfung des Öffnungsdruckes

Hebel des Düsenprüfgerätes bei zugeschaltetem Manometer langsam niederdrücken. Der Druck bei dem der Zeiger stehen bleibt oder plötzlich abfällt, ist der Öffungsdruck.

Öffnungsdruck für die Neueinstellung: Aggregat — Motoren = 250 + 8 bar Fahrzeug — Motoren = 210 + 8 bar

Werkstatthandbuch 1011 F

2.00.05

Prüfen und Einstellen	Einspritzventil
Checking and adjusting	Injector
Contrôle et réglage	Soupape injectrice
Verificación y ajustes	Inyector

Werkstatthandbuch 1011 F


			8
2			r

Deutsch

3.Einstellen des Öffnungsdruckes am Einspritzventil

Überwurfmutter abschrauben, alle Teile ausbauen.

Folge der Einzeldemontage

1.Überwurfmutter

2.Einspritzdüse

3.Zwischenstück

4.Druckbolzen

5.Druckfeder

6.Ausgleichscheiben

4.Durch Auswahl der erforderlichen Scheibe Druck einstellen. Stärkere Scheibe ergibt höheren Öffnungsdruck. Einspritzventil zusammenbauen. Überwurfmutter festdrehen.

Anziehvorschrift: 45 ± 5 Nm

Einspritzventil auf dem Düsenprüfgerät erneut prüfen.

5.Prüfung auf Dichtheit

Düse und Düsenhalter abtrocknen — mit Luft trockenblasen. Handhebel des Prüfgerätes langsam niederdrücken, bis ca. 20 bar unterhalb des vorher abgelesenen Öffnungsdruckes erreicht werden.

2.00.06

Einspritzventil	Prüfen und Einstellen
Injector	Checking and adjusting
Soupape injectrice	Contrôle et réglage
Inyector	Verificación y ajustes

English

3.Adjusting the opening pressure on the injector

Unscrew cap nut and remove all parts

Sequence of parts disassembly

1.Cap nut

2.Injection nozzle

3.Adapter

4.Thrust pin

5.Compression spring

6.Shims

4.Adjust pressure by selecting appropriate shim. A thicker shim increases the opening pressure. Reassemble injector. Tighten cap nut.

Tightening specification: 45 ± 5 Nm

Recheck injector on nozzle tester.

5.Checking for tightness

Dry nozzle and nozzle holder — blow out with compressed air. Press down handlever of nozzle tester slowly until a pressure of about

20 bar below the previous opening pressure reading is attained.

Français

3.Tarage de la pression d’ouverture sur injecteur

Dévisser l’écrou-raccord et déposer toutes les pièces.

Suite du démontage des pièces

1.Ecrou-raccord

2.Injecteur

3.Pièce intermédiaire

4.Tige poussoir

5.Ressort de pression

6.Rondelles d’épaisseur

4.Régler la pression en prenant le nombre de rondelles nécessaires. Des rondelles plus épaisses entraînent une pression d’ouverture plus grande. Remonter l’injecteur et serrer l’écrou-raccord.

Consigne de serrage: 45 ± 5 Nm

Contrôler à nouveau l’injecteur

à l’aide de la pompe d’essai d’injecteurs.

5.Contrôle de l’étanchéité

Sécher l’injecteur et le porteinjecteur par jet d’air. Appuyer lentement sur le levier de la pompe d’essai jusqu’à obtention d’environ 20 bars en-dessous de la pression d’ouverture lue auparavant.

Español

3.Ajuste de la presión de apertura en el inyector

Desenroscar la tuerca de unión y desmontar todas las piezas.

Secuencia del despiece

1.Tuerca de unión

2.Inyector propiamente dicho

4.Perno de presión

5.Muelle de presión

6.Arandelas de reglaje

4.Ajustar la presión eligiendo la arandela adecuada. Una arandela más gruesa da una presión de apertura más elevada. Rearmar el inyector. Apretar la tuerca de unión.

Prescripción

de apriete: 40 ± 5 Nm.

Volver a ensayar el inyector sobre el comprobador.

5.Comprobación de estanqueidad

Secar el inyector y el portainyector, soplándolos con aire comprimido. Empujar la palanca de mano del comprobador lentamente hacia abajo hasta alcanzar un valor de aprox. 20 bar por debajo de la presión de apertura leída previamente.

2.00.06

Prüfen und Einstellen	Einspritzventil
Checking and adjusting	Injector
Contrôle et réglage	Soupape injectrice
Verificación y ajustes	Inyector

English

6.Nozzle is tight if there is no dripping within a period of 10 seconds.

7.In case of a drip, the injector must be dismantled and cleaned to remedy the leak. If this does not cure the leak, the injector must be replaced.

Reworking is not permissible.

8.Buzzing and spray pattern test

Switch off pressure gauge of tester.

The buzzing test permits an audible check of the ease of movement of the nozzle needle in the nozzle body. New injectors emit a different buzzing sound as compared to used injectors. It deteriorates due to wear in the needle seat area. If an injection nozzle does not buzz despite cleaning, it must be renewed.

A used injector should buzz clearly during rapid actuation of the handlever, while exhibiting a well atomized spray pattern. The spray pattern may differ noticeably from that of a new injector.

Français

6.L’injecteur est étanche lorsqu’il ne goutte plus durant 10 secondes.

7.Si l’injecteur goutte, le déposer et le nettoyer pour supprimer le manque d’étanchéité. En cas d’échec, remplacer l’injecteur.

Ne jamais rectifier l’injecteur.

8.Contrôle du crissement caractéristique de l’injecteur

Débrancher le manomètre de la pompe d’essai.

Le contrôle du crissement permet un contrôle audible de l’injecteur dont l’aiguille doit retomber d’ellemême dans son logement. Les injecteurs neufs présentent par rapport aux injecteurs usagés un crissement différent. L’usure se produisant au niveau du siège de l’aiguille entraîne une dégradation du crissement. Si, après nettoyage, l’injecteur refuse de crisser, il faut le remplacer.

Un injecteur usagé doit, après actionnement rapide du levier de commande, émettre un crissement audible et pulvériser de manière bien homogène. La forme du jet peut alors, à la différence d’un injecteur neuf, être tout à fait différente.

Español

6.El inyector es estanco si, pasados 10 segundos, no sale ni una gota de líquido.

7.Si cae una gota, el inyector debe ser desarmado y limpiado para eliminar la falta de estanqueidad. Si esto no surte efecto, es necesario reemplazar el inyector.

No están permitidos trabajos de repaso.

8.Comprobación del ronquido y chorro

Desconectar el manómetro del comprobador.

La comprobación del ronquido permite controlar acústicamente la facilidad de movimiento de la aguja dentro del cuerpo del inyector. Inyectores nuevos tienen un ronquido diferente de los usados. El desgaste en la zona de asiento de la aguja lo empeora. Si el inyector no produce el ronquido característico del mismo a pesar de su limpieza anterior, es necesario sustituirlo por otro nuevo.

Un inyector usado tiene que roncar de forma audible y producir un chorro bien pulverizado si se acciona la palanca rápidamente. La forma del chorro puede diferir, en tal caso, claramente de la producida por un inyector nuevo.

2.00.07

Einspritzventil	Prüfen und Einstellen
Injector	Checking and adjusting
Soupape injectrice	Contrôle et réglage
Inyector	Verificación y ajustes

Deutsch

6.Düse ist dicht, wenn innerhalb 10 Sekunden kein Tropfen abfällt.

7.Fällt ein Tropfen ab, ist das Einspritzventil zu zerlegen und die Undichtigkeit durch Reinigen zu beseitigen. Ist das nicht erfolgreich, muß die Einspritzdüse erneuert werden.

Nacharbeit ist nicht zulässig.

8.Schnarrund Strahlprüfung

Manometer des Prüfgerätes abschalten.

Die Schnarrprüfung ermöglicht eine hörbare Prüfung der Leichtgängigkeit der Düsennadel im Düsenkörper. Neue Einspritzventile haben gegenüber gebrauchten ein geändertes Schnarrverhalten.

Durch Verschleiß im Nadelsitzbereich verschlechtert es sich. Schnarrt eine Einspritzdüse trotz Reinigung nicht, muß sie durch eine neue ersetzt werden.

Ein gebrauchtes Einspritzventil muß bei schneller Hebeltätigkeit hörbar schnarren und dabei gut zerstäubt abspritzen. Das Strahlbild kann dabei gegenüber dem eines neuen Einspritzventils deutlich unterschiedlich sein.

Werkstatthandbuch 1011 F

2.00.07

Prüfen und Einstellen	Einspritzpumpe
Checking and adjusting	Injection pump
Contrôle et réglage	Pompe d’injection
Verificación y ajustes	Bomba de inyección

English

Commercial tool required:

Injection pump tester _________ 8006

Special tool required:

Special wrench

for injection line __________ 110 490

The following inspection for injection pumps with parts no 0417 9573 and

0417 9981 (with con-stant pressure valve).

The injection pump is tested on the engine to make sure that the delivery valve and pump element are not leaking. For the test, it is essential that the fuel feed system is operating properly and that there is no air in the fuel system.

Injection lines have been removed.

1.Connect injection pump tester to delivery valve holder.

2.Turn crankshaft via V-belt pulley, while bleeding tester at the screw plug.

Français

Outillage usuel:

Appareil de contrôle de la pompe d’injection _________________ 8006

Outillage spécial:

Clé spéciale pour

conduite d’injection ________ 110490

Dans le cas des pompes à injection portant le numéro de pièce 0417 9573 et 0417 9981

(avec soupape de pression constante), il est impossible d’effecteur le contrôle décrit ciaprès.

Le contrôle de la pompe d’injection se fait sur le moteur même au niveau de l’étanchéité de la soupape de refoulement et de l’élément de pompe. Ce contrôle suppose une alimentation en combustible irréprochable et l’absence d’air dans le système d’injection.

Les conduites d’injection sont déposées.

1.Raccorder l’appareil de contrôle de la pompe d’injection au support de la soupape de refoulement.

2.Virer le vilebrequin par la poulie à gorge et purger l’appareil de contrôle par le bouchon obturateur.

Español

Herramienta comercial:

Comprobador de bombas

de inyección _______________ 8006

Herramienta especial:

Llave especial para

tuberías de inyección ______ 110 490

Si se tatra de bombas de inyección con el N° de pieza 0417 9573 y 0417 9981 (con válvula de presión constante) no es posible

Ilevar a cabo la siguiente prueba.

La bomba de inyección es ensayada sobre el motor en cuanto a estanqueidad de la válvula de presión y del elemento de bomba.

Condición previa para la comprobación es que el abastecimiento del combustible sea impecable y no exista aire en el sistema de combustible.

Las tuberías de inyección están desmontadas.

1.Conectar el comprobador de bombas de inyección al soporte de la válvula de presión.

2.Girar el cigüeñal a través de la polea de correa trapezoidal, purgando de aire el comprobador en el tapón roscado.

3.Turn crankshaft until a pressure of 150 bar is applied to the delivery valve. The pressure may drop by 10 bar within one minute.

3.Virer le vilebrequin jusqu’à obtention d’une pression de 150 bars à la soupape de refoulement. Cette pression peut tomber de 10 bars en l’espace d’une minute.

3.Girar el cigüeñal hasta que la válvula de presión cuente con una presión de 150 bar, admitiéndose una caída de presión de 10 bar dentro de un minuto.

2.00.09

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Источник

Deutz Engines 912, BF4M2012, F4M2011, BF4M2011, 1011F operators, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

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Deutz Engines

Modern technologies and materials, top quality, dependability, durability, and longevity are all features of Deutz diesel engines manufactured in Germany. German brand engines have high specific power and torque at the lightest possible weight for power plants with such specs. As a result, Deutz engines, which use the company’s unique innovations, can function well even in the most adverse circumstances and at a high maximum load for extended periods without diminishing motor resources or increasing overhaul time, therefore saving operational expenses.

After years of research at the company’s scientific and design bureaus, Deutz engineers developed motors that balance low operating costs and little impact on the environment. Because of their low fuel consumption, power plants from the German company Deutz are among the most cost effective in the world per kilowatt-hour produced, and they conform to the strictest standards for environmental protection. This means you may save money on gasoline and put Deutz generator installations close to where people live and work.

The Deutz 413 Series consists of V-shaped (V-Twin) diesel engines with 6, 8, 10, or 12 cylinders, a horizontal selection shaft, and valves in the upper location (OHV) for use in industrial and domestic applications. Focused on usage in sub-zero temperatures (down to -30 degrees Celsius), the 137 hp. (100 kW) to 322 hp. (236 kW) range of power and forced air conditioning;

Four-stroke, overhead-valve (OHV), horizontal power-shaft (HPS), and forced-air-cooled (FAC.) Deutz 912 Series diesel engines are designed for typical circumstances and may produce anywhere from 47 horsepower (34 kilowatts) to 111 horsepower (70 kW) (82 kW). The W models have a two-stage fuel combustion mechanism;

The Deutz 913 Series consists of 4-stroke, 3, 4, and 6-cylinder diesel engines with OHV, a horizontal power shaft, and forced air cooling, designed for use in typical circumstances and ranging in output from 59 horsepower (44 kilowatts) to 191 horsepower (141 kilowatts);

The Deutz 914 Series consists of four-stroke, three-, four-, five-, and six-cylinder diesel engines designed for professional and household appliances, featuring overhead valves, a horizontal power shaft, and forced air cooling, and optimized for normal conditions of operation between 59 horsepower (44 kilowatts) and 189 horsepower (141 kilowatts);

The Deutz 912/914 Genset Series includes 19 hp (14 kW) to 97.9 hp (4-stroke, 2, 3, 4, 6, 6-cylinder, OHV, horizontal air-cooled shaft, air-cooled) diesel engines for electro generators designed for usage in normal and harsh climatic situations (73 kW) manufactured with a mechanical or electronic (optional) fuel supply regulator;

The Deutz 1008 Series is a line of four-stroke, 2, 3, and 4-cylinder diesel engines designed for use in construction machinery, featuring overhead valves (OHV), a horizontal power shaft, liquid cooling, and an emphasis on operating in harsh environments, with outputs ranging from 17.7 horsepower (13 kilowatts) to 42 horsepower (31 kilowatts).

The Deutz 1011 Series is a line of 30-liter, 4-stroke, 2-, 3-, and 4-cylinder diesel engines used in construction machinery. These engines have overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for usage in harsh climates. (22 kW) up to (89.5 hp) (61 kW). Gas emission regulations that are in line with those of the European Union’s STEP II and the United States CFR 40, part 89, Tier II;

The Deutz 1013 Series consists of 4-stroke, 4- and 6-cylinder diesel engines with OHV, the horizontal power shaft, liquid cooling, and an output range of 154 hp (115 kW) to 313 hp (233 kW) for use in industrial and construction equipment in both mild and severe climates.

The Deutz 1015 Series consists of 6- and 8-cylinder V-shaped diesel engines with OHV, a horizontal power shaft, liquid cooling, and an output range of 407 hp (300 kW) to 598 hp (440 kW) that are designed for usage in typical climates.

The Deutz 1013/1015 Genset Series consists of four-stroke, six- and eight-cylinder diesel engines for electric generators, with overhead valves (OHV), a horizontal power shaft, liquid cooling, and an output ranging from 103 horsepower (77 kilowatts) to 571 horsepower (362 kilowatts) (426 kW) produced using both a mechanical regulator and electronic control (as an extra);

With power ranging from 31 horsepower (23 kilowatts) to 88 horsepower (65 kilowatts), the Deutz 2011 Series consists of 2, 3, 4, and 4-cylinder diesel engines for mobile medium-power mobile equipment with OHV, horizontal power shaft, air or liquid cooling, and an emphasis on operation in normal climatic conditions; the L models feature a heat exchanger.

The Deutz TCD 2011 Series is a line of air-cooled, OHV, horizontally-mounted, 2- and 3-cylinder diesel engines for medium-power mobile equipment ranging in output from 31 to 100 horsepower (23 to 74 kilowatts) (74.9 kW). Meet the gas emission requirements of European Union (EU) STEP III and United States (US) Tier 3;

Deutz f4m2011

The Deutz 2012 Series is a line of four- and six-cylinder diesel engines designed for medium-power mobile equipment. They feature overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for use in typical climates. Their output ranges from 101.8 horsepower (74.9 kilowatts) to 210 horsepower (155 kilowatts).

The Deutz TCD 2012 Series is a four-stroke and six-cylinder diesel engine line designed for medium-power mobile equipment. They feature overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for use in temperate climates.

The Deutz 2011/2012 Genset Series consists of four-stroke 2, 3, and 4-cylinder diesel engines for electric generators with overhead valves, horizontal power shafts, liquid or air cooling, and a primary focus on operation in both normal and difficult climatic conditions, with outputs ranging from 15.5 horsepower (11.4 kilowatts) to 101 horsepower (75 kilowatts);

The Deutz TCD2013 Series is a line of four- and six-cylinder diesel engines designed for use in mobile medium-power equipment. These engines feature overhead valves (OHV), a horizontal power shaft, liquid cooling, and are optimized for use in temperate climates. Their output ranges from 173 horsepower (129 kilowatts) to 325.9 horsepower (243 kW). Meet the requirements for gas emissions set out by the European Union’s STEP III A and the United States’ Tier 3;

The Deutz TCD2013 Genset Series consists of four- and six-cylinder diesel engines with an output ranging from 121 horsepower (90 kilowatts) to 314 horsepower (234 kilowatts) with an emphasis on normal climate operating.

The Deutz TCD 2015 Series consists of 6 and 8-cylinder, OHV, the horizontal power shaft, liquid-cooled, industrial diesel engines designed for usage in typical climates and capable of producing between 489 horsepower (360 kilowatts) and 670 horsepower (500 kilowatts);

The Deutz TCD 2.9-16 liter Series consists of 4, 6, and 8-cylinder diesel engines for mobile equipment; their engine volumes range from 2.9 to 16 liters; they feature overhead valves (OHV), a horizontal power shaft, water cooling, and are optimized for use in extreme climates; their outputs range from 50 horsepower (36.9 kW) to 697 horsepower (600 lb-ft) (520 kW).

Источник

Сборник руководств по ремонту дизельных двигателей Deutz, в котором мы собрали различные справочники, workshop manual, руководства по ремонту и обслуживанию, схемы и коды самодиагностики и прочее. В архиве вы найдете руководства по ремонту и обслуживанию дизельных двигателей Deutz B/FM 1008/F, 1011F, 1012, 1013, WH 912, 913, FL511, TCD 2015, 226, TD / TCD 2012 L04 / 06 2V, TD / TCD 2013 L04/06 2V, D 2008 / 2009. Все руководства Deutz в формате pdf некоторые из них отсканированные руководства, а другие изначально в компьютерном варианте. Языки, в которых представлена документация Deutz где-то английский текст изложения технических работ, где-то русский, где-то немецкий. Все руководства выпущены с 1986 года по 2011 год выпуска. Все технические работы, узлы и агрегаты очень хорошо проиллюстрированы. В каждом руководстве представлены пошаговые инструкции по ремонту всех представленных двигателей. Для того чтобы легче было искать неисправность даны коды самодиагностики неисправностей для некоторых моделей двигателей. Представленные руководства по ремонту моторов Deutz B/FM 1008/F, 1011F, 1012, 1013, WH 912, 913, FL511, TCD 2015, 226, TD / TCD 2012 L04 / 06 2V, TD / TCD 2013 L04 / 06 2V, D 2008 / 2009, разбиты на отдельные файлы.

Год выпуска: 1986-2011 г.
Автор: Deutz
Издательство: Deutz
Формат: PDF
Качество: Изначально компьютерное (eBook) и отсканированные книги
Язык авто-книги : Английский, Русский, Немецкий

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Operation Manual

B/F L 1011F

B/FM 1011F

1 Gerade

9683en_k00_vo

16.11.2000, 8:45 Uhr

Related Manuals for Deutz BL 1011F

Summary of Contents for Deutz BL 1011F

Page 1
Operation Manual B/F L 1011F B/FM 1011F 1 Gerade 9683en_k00_vo 16.11.2000, 8:45 Uhr…
Page 2
G When carrying out maintenance/repair op- G Use in accordance with the intended pur- erations on the engine, the use of DEUTZ pose also implies compliance with the con- original parts is prescribed. These are spe-…
Page 3
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.
Page 4
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 require- ments of specific cases. Your engine is appropriately equipped for the instal-…
Page 5: Table Of Contents

Index General Operating Conditions 6.5.3 Changing V-Belts 3.5.1 Winter Operation Adjustments Engine Description 3.5.2 High Ambient Temperature, 6.6.1 Checking / Adjusting Valve Clearances Model High Altitude Accessories 2.1.1. Rating Plate 6.7.1 Battery 2.1.2 Rating Plate Location 6.7.2 Three-Phase Alternator Operating Media 2.1.3 Engine Serial Number 6.7.3…
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9683en_k00_vo 16.11.2000, 8:45 Uhr…
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It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced meet the highest standards for environmental demanding operating conditions.
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9689en_K01_neu 30.09.1999, 15:45 Uhr…
Page 9: Engine Description

Engine Description 2.1 Model 2.2 Engine Illustration 2.3 Lube Oil Circuit Schematic 2.4 Fuel System Schematic 9 Gerade 7343en_k02_pdf 05.10.1999, 9:20 Uhr…
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Engine Description 2.1 Model 2.1.2 Rating Plate Location 2.1.1 Rating Plate 2.1.3 Engine Serial Number 26 332 2 26 421 1 26 422 0 The model A, the engine serial number B and the The rating plate C is attached to the valve cover. The engine serial number B is stamped on the performance data are stamped on the rating plate.
Page 11: Cylinder Numbering

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. 11 Gerade 7343en_k02_pdf 05.10.1999, 9:21 Uhr…
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Engine Description 2.2 Engine Illustrations 2.2.1 Service Side FL 1011F Oil filler neck (valve-gear cover) Charge-air line / air-intake line Fan with integrated generator Narrow V-belt Solenoid Toothed belt cover V-belt pulley on crankshaft Oil sump Cut-out handle Speed control lever Oil dipstick Crankshaft housing Oil fill point (on side of crankcase)
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Engine Description 2.2 Engine Illustrations 2.2.2 Exhaust side FL 1011F Date plate Connection housing (SAE) Flywheel with ring gear Starter Front cover Crankcase Cylinder head Exhaust manifold pipe Air-intake pipe 26444 0 13 Gerade 7343en_k02_pdf 05.10.1999, 9:21 Uhr…
Page 14: Engine Illustrations

Engine Description 2.2 Engine Illustrations 2.2.3 Service Side BFL 1011F Oil filler neck (valve-gear housing cover) Charge-air line / air-intake line Fan with integrated generator Narrow V-belt Solenoid Wheel-house cover V-belt pulley on crankshaft Oil sump Cut-out handle Speed control lever Oil dipstick Crankshaft housing Oil fill point (on side of crankcase)
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Engine Description 2.2 Engine Illustrations 2.2.4 Exhaust side BFL 1011F Cylinder head Exhaust manifold pipe Flywheel with ring gear Starter Crankshaft housing Inlet line to TC (Lube oil) Return line from TC (Lube oil) Induction pipe Turbocharger (TC) Intake manifold Air-intake line 26448 0 15 Gerade…
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Engine Description 2.2 Engine Illustrations 2.2.5 Service Side FM 1011F Oil filler neck (valve-gear housing) Charge-air line / air-intake line Generator Narrow V-belt Solenoid Wheel-house cover V-belt pulley on crankshaft Oil sump Cut-out handle Speed control lever Oil dipstick Crankshaft housing Oil fill point (on side of crankcase) Fuel pump Easy-change fuel filter…
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Engine Description 2.2 Engine Illustrations 2.2.6 Exhaust side FM 1011F Cylinder head Exhaust manifold line Flywheel with ring gear Starter Front cover Crankcase Intake pipe 26 447 0 17 Gerade 7343en_k02_pdf 05.10.1999, 9:21 Uhr…
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Engine Description 2.2 Engine Illustrations 2.2.7 Service Side BFM 1011F Oil filler neck (valve-gear housing cover) Charge-air line / air-intake line Generator Narrow V-belt Solenoid Wheel-house cover V-belt on crankshaft Oil sump Cut-out handle Speed control lever Oil dipstick Crankshaft housing Oil fill point (on side of crankcase) Fuel pump Easy-change fuel filter…
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Engine Description 2.2 Engine Illustrations 2.2.8 Exhaust side BFM 1011F Cylinder head Exhaust manifold pipe Flywheel with ring gear Starter Crankshaft housing Inlet line to TC (Lube oil) Return line from TC (Lube oil) Induction pipe Turbocharger (TC) Intake manifold Air-intake line 26 448 0 19 Gerade…
Page 20: Oil Circuit

Engine Description 2.3 Oil Circuit 2.3.1 Lube Oil Circuit Schematic Oil sump Intake manifold Oil pump Main oil duct Oil-cooled cylinder Cylinder head cooling neck Oil duct for rocker arm lubrication Rocker arm Oil manifold for the thermostat Intake to external engine oil cooler Return from external engine oil cooler Thermostat housing with slide thermostat Oil duct to oil filter…
Page 21: Fuel System

Engine Description 2.4 Fuel System 2.4.1 Fuel system schematic Fuel line from tank to fuel pump Fuel pump Fuel line from fuel pump to easy-change fuel filter Easy-change fuel filter Fuel line from filter to injection pump Injection pumps Fuel distributor line Injection lines Injection valves Fuel leakage line…
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Engine Operation 3.1 Commissioning 3.2 Starting 3.3 Monitoring Systems 3.4 Stopping 3.5 Operating Conditions 23 Gerade…
Page 23: Engine Operation

Engine Operation 3.1 Commissioning 3.1.1 Adding Engine Oil 3.1.1.1 Initial Engine Oil Fill-Up 3.1.1.2 Initial Engine Oil Fill-up for B/FM1011F Series for B/FM 1011F Series Fill oil into the oil sump up to the “max.” mark on Fill oil into the oil sump up to the “min.” mark on the engine dip stick (for oil top-up quantity see the engine dip stick.
Page 24: Adding Fuel

Engine Operation 3.1 Commissioning 3.1.2 Filling Oil Bath Air Filter with 3.1.3 Adding Fuel 3.1.1.3 Initial Engine Oil Fill-Up for Engine Oil 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). FUEL Start up the engine and allow to run at a lower idling speed for approx.
Page 25: Additional Maintenance Work

Engine Operation 3.1 Commissioning 3.1.5 Additional Maintenance Work 3.1.4 Other Preparations Check battery and cable connections, see 6.7.1 When commissioning new and reconditioned en- gines, the following additional maintenance work Transport hooks must be carried out: Remove if fitted (see 6.7.3) After 50-150 OH Trial run Change lube oil,…
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27 Gerade…
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Engine Operation 3.2 Starting 3.2.1 Electric Starting Starting without Cold-Start Aid Before starting, make sure that no- body is standing in the immediate vicinity of the engine or driven ma- chine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine.
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Engine Operation 3.2 Starting with Cold-Start Aid with Cold-Start Aid – Glow Plug – Ether Starting System 25 746 2 25 746 2 25 963 0 Insert key. Insert key Starting fluid is injected automatically in switch – Position 0 = no operating voltage –…
Page 29: Monitoring Systems

Engine Operation 3.3 Monitoring Systems 3.3.1 Engine Oil Pressure Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge 25 752 1 25 753 0 25 754 0 The oil pressure pilot light comes on with oper- The pointer must remain in the green sector over The pointer must indicate the minimum oil ating voltage on and engine off.
Page 30: Coolant Temperature

Engine Operation 3.3 Monitoring Systems 3.3.2 Coolant Temperature Engine Temperature Gauge 24 985 0 The engine temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating.
Page 31: Mechanical Shutdown

Engine Operation 3.4 Stopping 3.4.1 Mechanical Shutdown 3.4.2 Electrical Shutdown (Ignition Key) 25 746 2 26 424 0 Move speed control lever 1 to low idle. Turn key counterclockwise (to position 0) and Operate shutdown lever 2 until the engine comes remove.
Page 32: Operating Conditions

Engine Operation 3.5 Operating Conditions 3.5.1 Winter Operation Lube Oil Viscosity Battery – Select the oil viscosity (SAE grade) accord- – Efficient cold starting requires a healthy ing to the ambient temperature when the battery, see 6.7.1. engine is started, see 4.1.2. –…
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If you have any doubts about engine operation under these or similar conditions, ask your en- gine or equipment supplier whether the engine has been derated in the interests of reliability, 25 901 1 service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.
Page 34: Operating Media

Operating Media 4.1 Lube Oil 4.2 Fuel 4.3 Coolant ENGLISCH • Kapitel 4 • Seite 1…
Page 35: Lube Oil

Operating Media 4.1 Lube Oil 4.1.1 Quality Grade 4.1.2 Viscosity Lube oils are differentiated by Deutz Generally, multi-grade oils shall be used. In according to their performance and quality closed heated rooms at temperatures >5°C, class. Oils of other, comparable specifications also single-grade oils can be used.
Page 36: Quality Grade

ASTM D 396; 1 and 2 BS 2869 Class D can be obtained by adding a flow improver Summer diesel fuel (additive). Please contact your Deutz partner. ● Jet fuel Winter diesel fuel — F34/F35/F44 (kerosene) — F54 (equivalent to diesel fuel according to…
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Routine Maintenance 5.1 Maintenance Schedule 5.2 Maintenance Chart 5.3 Maintenance Work Completed 39 Gerade…
Page 39: Maintenance Schedule

Routine Maintenance 5.1 Maintenance Schedule check Operating Hours (OP) every 1) once clean every after Section 10 OH change or daily 50-150 Operation Oil level in engine / separate container 9) 6.1.2/3.1.4 Engine leaks Oil bath- and dry type air cleaners 3) 4) 5) Battery and cable connectors 6.7.1 Cooling system (depending on engine use 3)
Page 40: Routine Maintenance

Routine Maintenance 5.2 Maintenance Chart 0,3 mm The maintenance chart shown here is supplied as a self- 0.012 in. adhesive label with each engine. It should be affixed Std. 0,5 mm 125- where it can be seen clearly on the engine or driven 0.020 in.
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Routine Maintenance 5.2 Maintenance Chart The maintenance chart shown here is supplied as a self- adhesive label with each engine. It should be affixed 0,3 mm where it can be seen clearly on the engine or driven 0.012 in. Std. equipment.
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Routine Maintenance 5.3 Completed Maintenance Jobs Hours Date Signaure / Stamp Hours Date Signaure / Stamp 50-150 1000 1125 1250 1375 1500 1625 1750 1875 2000 2115 2250 2375 2500 2625 2750 * Commissioning new and overhauled engines The maintenance jobs duly completed can be recorded in the above table. 49_en…
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Routine Maintenance 5.3 Completed Maintenance Jobs Hours. Date Signaure / Stamp Hours Date Signaure / Stamp 2875 3000 3125 3250 3375 3500 3625 3750 3875 4000 4125 4250 4375 4500 4625 4750 4875 5000 5125 5250 5375 5500 5625 5750 The maintenance jobs duly completed can be recorded in the above table.
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Routine Maintenance 5.3 Completed Maintenance Jobs Hours Date Signaure / Stamp Hours Date Signaure / Stamp 5875 6000 6250 6125 6375 6500 6750 6625 7000 6875 7250 7125 7500 7375 7750 7625 8000 7825 8250 8125 8500 8375 8750 8625 The maintenance jobs duly completed can be recorded in the above table.
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Seite 46Gasmotor 1015…
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Service and Maintenance 6.1 Lubrication System 6.2 Fuel System 6.3 Cooling System 6.4 Combustion Air System 6.5 Belt Drives 6.6 Adjustments 6.7 AccessoriesService and Maintenance…
Page 47: Service And Maintenance

Service and Maintenance 6.1 Lubrication System 6.1.1 Oil Change Intervals Lube oil intervals in OH Lube oil intervals in OH Installed engines Naturally aspirated engines Turbocharged engines CC 1) CD/CE 1) CD/CE/CF-4 API classification — Lube oil quality The oil change intervals are dependent on the D5 2) (SHPD) 3) D5 2) (SHPD) 3) CCMC classification…
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Service and Maintenance 6.1 Lubrication System 6.1.2 Checking Oil Level / Changing Engine Oil 6.1.2.2 Changing the Engine Oil 6.1.2.1 Checking Oil Level 25729 0 26022 0 26023 0 Check the oil level with the engine switched off. Allow the engine to warm up. Place oil tray under the engine.
Page 49: Changing Oil Filter

Service and Maintenance 6.1 Lubrication System 6.1.3 Changing Oil Filter 25880 0 25881 0 25882 0 Undo the filter cartridge using a commercial tool Clean any dirt from the filter carrier rim. Tighten the oil filter cartridge with another half- and spin off.
Page 50: Changing Fuel Filter

Service and Maintenance 6.2 Fuel System 6.2.1 Changing Fuel Filter 25880 0 25881 0 25882 0 Close fuel stopcock. smoke. the gasket. Clean any dirt from the filter cartridge with a final Tighten the fuel filter cartridge with a final half- Undo fuel filter cartridge with commercial tool half-turn.
Page 51: Change Fuel Leakage Line

Service and Maintenance 6.2 Fuel System 6.2.2 Fuel Pump 6.2.3 Change Fuel Leakage Line Cleaning the Strainer 26 436 0 30 015 0 Close the fuel shutoff valve. Close the fuel shut-off valve. Mount the fuel strainer cover 2. Disconnect rubber hoses 3 from the injection Loosen and unscrew the hexagonal nut 1.
Page 52: Cooling System

Service and Maintenance 6.3 Cooling System 6.3.1 Cleaning Intervals The amount of contamination in the cooling Inspection and cleaning system depends on the engine application. intervals Engine application Spilled oil or fuel on the engine increases the risk of contamination. Be especially careful if the Recommended engine is used in dusty environments.
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Service and Maintenance 6.4 Combustion Air Filter 6.4.1 Cleaning Intervals The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is antici- pated, a cyclone-type precleaner can be fitted to the air cleaner.
Page 54: Combustion Air Filter

Service and Maintenance 6.4 Combustion Air Filter 6.4.2 Emptying Cyclone Type 6.4.3 Cleaning Oil Bath Air Cleaner Precleaner 25 886 0 25 887 1 Undo wing nut 1 and remove cover 2. Turn engine off and wait about 10 minutes for the Clean filter housing 1 if very dirty.
Page 55: Combustion Air Cleaner

Service and Maintenance 6.4 Combustion Air Cleaner 6.4.4 Dry Type Air Cleaner Dust Discharge Valve Filter Cartridge 25 888 1 25 889 0 Empty dust discharge valve 1 by pressing apart Undo clip fasteners 1. After five cleaner services or after two years at lips of discharge slot as indicated by arrows.
Page 56: Belt Drives

Service and Maintenance 6.5 Belt Drives 6.5.1 Checking V-Belts 26 427 0 26 261 0 Inspect entire V-belt for damage. – Carefully remove the gauge without alter- Replace damaged V-belts. ing the position of the indicator arm 1. After installing new belts, run engine for 15 –…
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Service and Maintenance 6.5 Belt Drives 6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts 26 426 0 26 425 0 Slacken off bolts 1, 2 and 3. Slacken off bolts 1, 2 and 3. Adjust alternator 4 in direction of arrow by Adjust alternator 4 in direction of arrow by turning bolt 3.
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Service and Maintenance 59 Gerade…
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Service and Maintenance 6.6 Adjustments 6.6.1 Checking / Adjusting Valve Clearances 19 691 2 25 893 0 Remove the cylinder head cover. Adjust valve clearance if necessary: Position crankshaft as per schematic 6.6.1.1. – Release locknut 4. Before adjusting valve clearance, allow engine to –…
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Service and Maintenance 6.6 Adjustments 6.6.1.1 Valve Clearance Adjustments Schematic Crankshaft Position 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been done.
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Service and Maintenance 6.7 Accessories 6.7.1 Battery 6.7.1.1 Checking Battery and Cable 6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Electrolyte Connectors Density 25 895 0 24 232 3 25 896 0 Keep battery clean and dry. Remove caps 1. Measure the electrolyte density of individual Undo dirty clamps.
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Service and Maintenance 6.7 Accessories Electrolyte density in ° Bé (Baumégrad)* in kg/l State of Charge Normal Tropics Normal Tropics 1.28 1.23 Fully charged 1.20 1.12 Half charged, recharge 1.12 1.08 Discharged, recharge immediately * Measurement of electrolyte density in ° Bé (Baumé-grad) is out of date and rarely used today.
Page 63: Three-Phase Alternator

Service and Maintenance 6.7 Accessories 6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle Notes on the three-phase system: Never disconnect the cables between battery, alternator and regulator while the engine is run- ning. If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting.
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Service and Maintenance 6.7 Accessories 6.7.4 Ether Starting System 6.7.4.1 Changing the Fluid Container 25 965 0 25 956 0 Before removing the container, clean the con- Place the container 1 on the solenoid valve 2 and tainer support and the top of the solenoid valve. tighten by hand.
Page 65: Engine Cleaning

Service and Maintenance 6.8 Engine Cleaning 6.8.1 Engine Cleaning Preparation Switch off the engine. Remove engine covers and cooling air hood. Replace them after cleaning and before the test run. Cover electrical / electronic components / con- nections (eg. generator, starter, governor, sole- noid).
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Faults, Causes and Remedies 7.1 Diagnosis Chart…
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In the event of a fault, always check whether the operating and servicing regulations have been ad- hered to. A corresponding fault table can be found on the adjacent page. If you cannot ascertain the cause of a fault or cannot rectify the fault, please contact DEUTZ SERVICE.
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Faults, Causes and Remedies 7.1 Diagnosis Chart Fault Remedy Engine fails or is difficult to start Check Engine starts but runs unevenly or stalls Adjust Engine overheats. Temperature monitor gives warning Replace Engine gives poor performance Clean Engine not firing on all cylinders Top up Engine has little or no oil pressure Lower level…
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Faults, Causes and Remedies 7.1 Diagnosis Chart Fault Remedy Engine fails or is difficult to start Check Engine starts but runs unevenly or stalls Adjust Engine overheats. Temperature monitor gives warning Replace Engine gives poor performance Clean Engine not firing on all cylinders Top up Engine has little or no oil pressure Lower level…
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Engine Preservation 8.1 Preservation 9929en…
Page 71: Engine Preservation

Engine Preservation 8.1 Preservation 8.1.2 Removing Engine 8.1.1 Preserving Engine Preservatives G Clean engine using high-pressure equipment G Remove anti-corrosion agent from grooves in If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to (or with cold-cleansing agent in emergency).
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Technical Specifications 9.1 Engine Specifications and Settings 9.2 Torque Wrench Settings 9.3 Tools 73 Gerade…
Page 73: Technical Specifications

Technical Specifications 9.1 Engine Specifications and Settings Model —— F2L 1011F —— F3L 1011F ————— F4L 1011F — F4L 1011FL* —— Numbers of cylinders ——— 2 —————— 3 ————————— 4 ————— 4 ———— Cylinder arrangement ————————————— vertical in line —————————————— Bore [mm] ————————————————…
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Technical Specifications 9.1 Engine Specifications and Settings Model ——— BF3L 1011F/L ———————— BF4L 1011F/FT —— Number of cylinders ————— 3 ———————————— 4 —————— Cylinder arrangement —————————— vertical in line ——————————— ———————————— 91 ————————————— Bore [mm] ———— 105/112 ——————————— 105 ————— Stroke [mm] ————…
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Technical Specifications Model ——— F3M 1011F ———————— F4M 1011F —— Number of cylinders ————— 3 ———————————— 4 ———— Cylinder arrangement —————————— vertical in line ———————— Bore [mm] ———————————— 91 ——————————— Stroke [mm] ————— 112 ———————————— 112 ——— [cm 3 ] Total displacement ————…
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Technical Specifications 9.1 Engine Specifications and Settings Model ——— BF3M 1011 F ———————— BF4M 1011 F ——— ————— 3 ———————————— 4 —— Number of cylinders —————————— vertical, in line —————————— Cylinder arrangement Bore [mm] ———————————— 91 ————————————— Stroke [mm] ———————————— 112 ————————————…
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Technical Specifications 9.2 Torque Wrench Settings Preload [Nm] Torquing Load [Nm] Location Total [Nm] Remarks Stage Stage Stage Stage Stage Stage Stage Rocker cover Rocker arm set screw Air intake manifold Exhaust manifold Oil drain plug Injector mounting TORX Injector line mounting Oil pan (cast iron) Oil pan (sheet metal)
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Technical Specifications 9.3 Tools TORX V-belt Tension Gauge 25899 0 26002 0 A TORX wrench set (order number 8189) is used The V-belt tension gauge can be obtained under with engines in the 1011 series. order number 91 107 from: This system was chosen because of the many advantages it offers: COMPANY WILBÄR…
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Notes Warnings to Place on Equipment Warning in the Manual CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Diesel engine exhaust and some of its constituents are known to the State of constituents are known to the State of California to cause cancer, birth California to cause cancer, birth defects, and other reproductive harm.
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Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California. Should you have any questions, please call Deutz Corporation Product Support Department.
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Notes…
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This is why DEUTZ is not only the name for motors which pack a lot of inventive genius. DEUTZ also means reliable service and comprehensive support to enhance your motor’s performance.

Источник

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Summary of Contents for Deutz BL 1011F

Page 5: Table Of Contents

Page 9: Engine Description

Page 11: Cylinder Numbering

Page 14: Engine Illustrations

Page 20: Oil Circuit

Page 21: Fuel System

Page 23: Engine Operation

Page 24: Adding Fuel

Page 25: Additional Maintenance Work

Page 29: Monitoring Systems

Page 30: Coolant Temperature

Page 31: Mechanical Shutdown

Page 32: Operating Conditions

Page 34: Operating Media

Page 35: Lube Oil

Page 36: Quality Grade

Page 39: Maintenance Schedule

Page 40: Routine Maintenance

Page 47: Service And Maintenance

Page 49: Changing Oil Filter

Page 50: Changing Fuel Filter

Page 51: Change Fuel Leakage Line

Page 52: Cooling System

Page 54: Combustion Air Filter

Page 55: Combustion Air Cleaner

Page 56: Belt Drives

Page 63: Three-Phase Alternator

Page 65: Engine Cleaning

Page 71: Engine Preservation

Page 73: Technical Specifications