Deutz FL511W Engine Service Repair Manual Instant Download (Part Number 291-1921)

1
Workshop Manual
ŒEUTŒ
291 1921
01/1987
FL 511/W
2
WORKSHOP MANUAL for Air-cooled DEUTZ DIESEL
Engines
F L 511/ W
Printed material no. 291
1 9 21
Date of issue
O1 /1 987
3

• F O R E W O R D
• This Workshop Manual informs our customers and
  Service partners about repair and adjustment work
  on the DEUTZ diesel engine. It is presumed that
  this work will be carried out by quali fied
  personnel.
• This Manua1 has been made up in a manner which
  ensures quick visual comprehension of the
  contents. This is achieved by illustrations and
  graphic symbols as substitute for the respective
  text. This layout permits universal use, because
  the illustrations and symbols are also largely
  understood by those being unab1e to read and
  write.
• Aspects of operation and maintenance are not
  dealt with in this Manual they are contained in
  the Engine Operation Manua1.
• This Workshop Manual is not regu1ar1y updated.
  Any engineering changes havng been introduced in
  the meantime will be considered in the next
  issue. Therefore, please refer to the Technical
  Circulars where engineering changes are announced
  when appropiate.
• General
• This Workshop Manua1 has been prepared using our
  best knowledge and experience, taking into
  account safety and environmental aspects.
• It has to be ensured that everyone concerned
  with repair or adjustment work on the engine has
  this Workshop Manual available, reads it and
  understands it.
• It has to be ensured that all equipment, hand
  and speciai tools required for proper execution
  of repair work are in good condition.
• Failure to comply with this Workshop Manua1 may
  result in malfunction of the engine, short
  lifetime of components, personal injury or
  damage to porperty and environment for which
  we take nor responsiblity.
• Engine components such as springs, clips,
  flexible retainining rings, e1ectric equipment,
  pipes, etc. invo1ve a risk of damage or
• persona1 injury if handled in an improper way.
  It is therefore essential that no one attempts
  to do any work on the engine unless he has the
  necessary experience of the various tools,
  materials and methods.
• To ensure best efficiency, re1iabitity and 1iIe
  time of the engine and its components, only
  original spare parts may be used for the repair.

4
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Key to Sym bol s
Disassembly of assembly groups
Reassemble to form assembly group
Remove obstructing parts
Reinstall Remount parts which had obstructed disassembl y
Attention! Important notice!
Check Adjust E. g. torque, dimensions, pressur es, etc.
Special tool
Note direction of installation
Visual inspection
Possibly still serviceable Renew if necessary
Renew at each reassembly
Unlock Lock e. g. spl it pin, lock ing plate, etc.
Lock Adhere e. g. with li quid sealant
Guard against personal injury Indir I ion of hazard
Guard against material damage Damage to parts
Prop up Support Hold
Oil
Grease
Mark before disassembly , observe marks when reasse mbling
Balance EI iminate any imbalance
Fi lling Topping up Ref illing e. g. oil, cooling water, etc.
Drain off e. g. oiI, cooIing water, etc.
Loosen Release e. g. loosening a clamping device
Tighten Clamp e. g. tightening a clamping device
Vent
Machining process
67 See Technical Data (For inst. 67 as indication of the line)
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Contents

• Specification data
• Checking and tuning
• Cylinder unit
• Crankshaft, camshaft, crankcase
• Blower side
• Flywheel side
• Fuel injection system
• Power unit, Coolingblower
• Dismantling and reassembling, engine complete
• 1O Special tools

7
1. SPECIFICATION DATA
Index
Page
Genera I engine data. . . . . . . . . . . . . .
. . . . . . . . . .. Fuel injection
system......................... Cylinder
unit............. , ........... ....,.
. Crankshaft assembly............ , ,
............ Engine lubrication. . . . . . . . .
. . . . . . . .,. . . . . . . . ..
1/1 1/2-1/3 1/4-1/8 1/9-1/13 1/14-1/15
After-tightening angles and torque..... ... ,
..... 1/16-1/17
Engine serial numbers and maker s nameplate.....
General notes on repair..... .......... ."..
,. ..
1/18 1/19 1/20
Tightening instructions for bolts and nuts.... .
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General engine dato

Designotion of type FIL S11 W F2L 511 FIL S11 W F2L 511 FIL S11 W F2L 511 F2L SU W
Total piston displocemen f 3 Cm 825 825 Four-stroke diesel Four-stroke diesel Four-stroke diesel
Working cycle 825 825 Four-stroke diesel Four-stroke diesel Four-stroke diesel
Combustion sysfem Direct inection W 2-stage combustion system Direct inection W 2-stage combustion system Direct inection W 2-stage combustion system Direct inection W 2-stage combustion system Direct inection W 2-stage combustion system Direct inection W 2-stage combustion system Direct inection W 2-stage combustion system
4 Bore mm 100 100 100 100 100 100 100
Sfroke mm 105 105 105 105 105 105 105
6 Weight of en- gine occord1ng to VDMA kg 11ó 11ó 11ó 155 155 155 155
7 When focing flywheel leff counferclockwise When focing flywheel leff counferclockwise When focing flywheel leff counferclockwise When focing flywheel leff counferclockwise When focing flywheel leff counferclockwise When focing flywheel leff counferclockwise When focing flywheel leff counferclockwise
8 Roted speed max. ì/min 3X0 3X0 3X0 3X0 3X0 3X0 3X0
9 Minimum id fe speed 950 " 950 " 950 " 950 " 950 " 950 " 950 "
10 Compression ratio Ì7 ì FL 51I W 19 1 Ì7 ì FL 51I W 19 1 Ì7 ì FL 51I W 19 1 Ì7 ì FL 51I W 19 1 Ì7 ì FL 51I W 19 1 Ì7 ì FL 51I W 19 1 Ì7 ì FL 51I W 19 1
11 Compreuion pressure bar 29 - 31 29 - 31 29 - 31 29 - 31 29 - 31 29 - 31 29 - 31
12 Firing order 2 - l 2 - l 2 - l 2 - l
13 Dimensions of engine wifh oiI both air cleo ner and fuel f1l ter
14 Overol I lengfh mm 459, 5 459, 5 459, 5 571 571 571 571
15 Overoll width mm 525 525 525 525 525 525 525
16 Overo Il heighf mm ó94 ó94 ó94 73ì 73ì 73ì 73ì
l/!
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Fue I injection syste m
B
B pegnotion of FlL 511 FlL 511 W FlL 511 W F2L 511 F2L 511 F2L 511 W
17 Fuel ini!i Moke Bosch Bosch Bosch Bosch Bosch Bosch
18 Pressure for festing tightness of rel ief vo lve (drop to140 bar in o minute perm iss) bar 150 150 150 150 150 150
19 Min1mum pressure that must be oftoined wifh he inection pump elemenf (with OÚOUtÓ tOtOtlonS OÍ cronkshoff) bar 300 300 300 300 300 300
20 Governor de Deutz Deutz Deutz Deutz Deutz Deutz
21 ec fi on nozzle Bosch DLLA 149 S 774 FL 5T 1 W DhJOSD 1ó5 DLLA 149 S 774 FL 5T 1 W DhJOSD 1ó5 DLLA 149 S 774 FL 5T 1 W DhJOSD 1ó5 DLLA 149 S 774 FL 5T 1 W DhJOSD 1ó5 DLLA 149 S 774 FL 5T 1 W DhJOSD 1ó5 DLLA 149 S 774 FL 5T 1 W DhJOSD 1ó5
22 Ópening pressure (checking injector 175 FL 511 W 115 115 115
23 Opening pressure (new condifion) bar 180 FL 511 W 8 120 8 120 8 120
24 Commencement .odede o e TDC i cr n s o .
25 Engines without odvonce unif degree / 1/mín 24 FL 511 W 24 FL 511 W 24 FL 511 W 20
26 Engines with odvonce unit degree/1/mín
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Fue I injec tion syste m

Designotion of type F1L 511 FBL Sll W F2L 511 F2L 511 W F2L 511 W
27 Advonce un i"t degree
28 Dimensíon of Inec- 0, 1 82, ó 0, 1 82, ó 0, 1 82, ó 0, 1 82, ó 0, 1 82, ó
29 D istonce befween fhe governor head and the crankcase 84, 7 - 85, 7 84, 7 - 85, 7 84, 7 - 85, 7 84, 7 - 85, 7 84, 7 - 85, 7
NO Diameter of bolls for the govemor s fhrust bear ing 8 8 8 8 8
31 No. of bol Is 19 19 19 19 19
32 Speed odusting shoft AX io Í c lenronce mm 0, 2 - 1, 1 0, 2 - 1, 1 0, 2 - 1, 1 0, 2 - 1, 1 0, 2 - 1, 1
The commencement of injec- tion expressed in
degrees of crank angle ( Kw ) con be translated
into a length "L " in mm marked on the V-bel f
pulley (flywheel) as lollows
d 3, 14 Kw 3ó0
L
1/3
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C ylinder unit

Designotion of fype F1L 511 FIL 5ì 1 W F2L 5ì I F2L Sì 1 W
Cylinder heod
S4 Va Ive guide Oufside d1o- meter mm 0, 05ó l5,00,O45 0, 05ó l5,00,O45 0, 05ó l5,00,O45 0, 05ó l5,00,O45
Number of ovemizes 2 2 2 2
36 Eoch oversize 0, 056 0, 25 0, 045 0, 056 0, 25 0, 045 0, 056 0, 25 0, 045 0, 056 0, 25 0, 045
37 Bare in cyl inder heod mm 0, 011 15,0 0 0, 011 15,0 0 0, 011 15,0 0 0, 011 15,0 0
hJumber of oversizes Each oversize
39 hJumber of oversizes Each oversize
40 Volve gu1de (pressed in) Ins id e diomefer 0, 015 8,0 0 0, 015 8,0 0 0, 015 8,0 0 0, 015 8,0 0
41 Va Ive stern D iometer In lef mm 0 7, 96 - 0, 015 0 7, 96 - 0, 015 0 7, 96 - 0, 015 0 7, 96 - 0, 015
42 Volve stern D1ometer Exhousf mm 0 7, 94 - 0, 02 0 7, 94 - 0, 02 0 7, 94 - 0, 02 0 7, 94 - 0, 02
4S Valve stern cleoronce Inlet normal
44 In let Um1t value
45 Exhoust norma I yy 0, 0ó - 0, 095 0, 0ó - 0, 095 0, 0ó - 0, 095 0, 0ó - 0, 095
46 E1houst Limit value mm 0, 2 0, 2 0, 2 0, 2
47 Valve seoting ring eIdn outside diometer, nominol mm 0 45, ó6 - 0, 02 0 45, ó6 - 0, 02 0 45, ó6 - 0, 02 0 45, ó6 - 0, 02
48 Number of oversizes 3 3 3 3
49 Eoch oversize 0 0, 1 - 0, 02 0 0, 1 - 0, 02 0 0, 1 - 0, 02 0 0, 1 - 0, 02
Exkoust outs id e diometer, nominol 40, 1ó - 0, 02 40, 1ó - 0, 02 40, 1ó - 0, 02 40, 1ó - 0, 02
51 Jumber of ovem izes
51 Jumber of ovem izes 3 3 3 3
52 Eoch oversize 0 0,1-0,02 0 0,1-0,02 0 0,1-0,02 0 0,1-0,02
i/4
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Cylinder unif

Designoti on Designoti on of of FIL 511 F1L 511 W F2L 511 F2L II 1 W
Bore head Intel in cyl inder in cyl inder mm 0, 025 45, 0 0, 025 45, 0 0, 025 45, 0 0, 025 45, 0
54 E h E h E h E h 0,025 40,0 0 0,025 40,0 0 0,025 40,0 0 0,025 40,0 0
55 Vo lve tuI ip 1 nlet Vo lve tuI ip 1 nlet mm mm 0,1 43,0 0,1 43,0 0,1 43,0 0,1 43,0
56 Valve ful ip Exhaust Valve ful ip Exhaust mm mm 0, 1 37, 0 0, 1 37, 0 0, 1 37, 0 0, 1 37, 0
5 7 Vo lve seat w id fñ Inlet Vo lve seat w id fñ Inlet Vo lve seat w id fñ Inlet Vo lve seat w id fñ Inlet o,a , s 0 o,a , s 0 o,a , s 0 o,a , s 0
Exhousf Exhousf mm mm
59 Seat angle - degree I nlef Seat angle - degree I nlef Seat angle - degree I nlef Seat angle - degree I nlef 45 45 45 45
60 xhoust xhoust degree degree 45 45 45 45
61 Rim fhickness Rim fhickness Rim fhickness Rim fhickness 0 0 0 0
61 Inlet mm 1, 0 - 0, 2 1, 0 - 0, 2 1, 0 - 0, 2 1, 0 - 0, 2
6 2 xhoust xhoust mm mm 0 1,8 - 0, 2 0 1,8 - 0, 2 0 1,8 - 0, 2 0 1,8 - 0, 2
63 Wear Iim it Inlet Wear Iim it Inlet Wear Iim it Inlet Wear Iim it Inlet
64 Exhaust Exhaust Exhaust Exhaust
65 Distance va Ive disc/ Cylinder head seal - ing surface Distance va Ive disc/ Cylinder head seal - ing surface Distance va Ive disc/ Cylinder head seal - ing surface Distance va Ive disc/ Cylinder head seal - ing surface
66 Lim it value Lim it value 5, 2 5, 2 5, 2 5, 2
Ve lve c Ieoronc e c Ieoronc e
6 7 when engine is cold I nlet mm when engine is cold I nlet mm when engine is cold I nlet mm when engine is cold I nlet mm
68 Exhoust Exhoust mm mm
69 After repo irs fo cy- I1nder un it Inlef After repo irs fo cy- I1nder un it Inlef After repo irs fo cy- I1nder un it Inlef After repo irs fo cy- I1nder un it Inlef 0,15 0,15 0,15 0,15
7 0 Exhaust Exhaust mm mm 0, 15 0, 15 0, 15 0, 15
71 Clearance between vo lve rockers and fhe coms of the decom- pression gear Coarse adustment Clearance between vo lve rockers and fhe coms of the decom- pression gear Coarse adustment Clearance between vo lve rockers and fhe coms of the decom- pression gear Coarse adustment Clearance between vo lve rockers and fhe coms of the decom- pression gear Coarse adustment
14
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