(1) Introduction to the BFM1013 diesel engine. The Deutz BFM1013 diesel engine is an inline engine with two types: four-cylinder and six-cylinder.The biggest structural feature of this diesel engine is the use of a single pump fuel injection system (including two major categories: mechanical control and electronic control), as shown in Figure 1-17.
The mechanical single pump diesel engine uses a speed governor to control the speed of the diesel engine. The injector is a common mechanical injector, and the emission index can reach the Euro II standard.The fuel supply time of the electronically controlled single pump is electronically controlled, but the injector is also a common mechanical injector (as shown in Figure 1-18), and the emission index can reach the Euro III standard.The single pump is one of the latest technologies of diesel engines. It makes combustion more suitable for the needs of working conditions, so that the combustion is more complete and efficient, reducing exhaust pollution and fuel consumption.In addition to the above advantages, the single pump system also has the following advantages.① Driven by the camshaft through the tappet, it has a compact structure and good rigidity. ② The injection pressure can reach up to 160.0MPa.
⑤ Good speed regulation performance. ⑥ Has a self-exhaust function. ⑦ Easy maintenance and easy pump replacement. (2) Main parameters of BFM1013 diesel engine The main technical parameters of BFM1013 diesel engine are shown in Table 1-6. ③ Small installation space. ④ The high-pressure oil pipe is short and standardized.
(1) Basic requirements for the first use of diesel engine When a new diesel engine (i.e. new equipment) is put into operation for the first time, the following aspects should be noted. ① Regardless of the length of the original running time of the diesel engine, it is recommended to replace the engine oil and oil filter before it is put into formal use.This is because the brand of the test oil used by the equipment manufacturer may not be the same as the brand of the oil used by the user. To avoid mixing different brands of oil, the engine oil and oil filter (including bypass oil filter or centrifugal filter, etc.) should be replaced before the new equipment is put into use for the first time.
(2) Precautions for starting and stopping the diesel engine ① Preparation before starting.After cleaning the diesel tank and replacing the diesel filter, or when using a new diesel engine or a diesel engine after overhaul for the first time, the fuel system must be vented, otherwise, the diesel engine may not start.
fine filter and use a hand pump to pump diesel until bubble-free diesel flows out of the bleed hole. ② Precautions for starting a diesel engine are as follows: a.Disconnect the working device and ensure the engine starts without load. b. Position the throttle lever to 1/4 of full throttle. c. Start the engine. As soon as the engine ignites, release the start switch immediately.Note: During each start, the starter motor must not operate continuously for more than 10 seconds.If the engine fails to start three times in a row, wait at least 1 minute before starting again. d. After starting the engine, allow it to preheat for at least 3 minutes before operating at full load.During winter operation, the preheating time should be extended (at least 5 minutes). e. After starting, carefully monitor the engine oil pressure.③ Precautions for shutting down a diesel engine.A diesel engine should not be shut down suddenly from full load.Under normal circumstances, it should be idled for 3-5 minutes after unloading, allowing the engine temperature to cool before shutting down.It is best to wait until the oil temperature is below 70°C and the cylinder head temperature is below 80°C before shutting down the engine. In special circumstances, the engine should also be shut down after unloading the engine whenever possible. If a diesel engine suddenly stops while in use (at full load), it is imperative to immediately rotate the crankshaft to prevent residual heat buildup in the engine's moving parts, which can cause problems such as "cylinder scuffing," "shaft seizure," and "burned bearings."
(3) Precautions for winter operation of diesel engines When using a diesel engine in winter, the following points must be noted.
① Winter engine oil must be used.Different brands of winter engine oil should be selected according to the ambient temperature.For details, please refer to the oil selection requirements or the relevant requirements of the instruction manual.
② Use winter fuel.When the ambient temperature is above 0 to 10°C, use 10# diesel.When the ambient temperature is -10 to -30°C, use -30# diesel.When the ambient temperature is below -30°C, use -50# diesel.If the incorrect diesel is used, for example, using 0# diesel at -5°C, wax precipitation from the diesel may clog the filter, causing the engine to malfunction.Therefore, it is essential to use diesel that is appropriate for the ambient temperature.
③ Drain (or clean) the sediment from the fuel tank at least monthly.
④ When the ambient temperature is below -20°C, regularly apply cold-resistant grease to the flywheel ring gear to ensure proper starting.
⑤ When starting a diesel engine in winter, pay special attention to the following points.
a. If the cold start limit temperature is too low, use a preheating device.
b. Ensure the battery is fully charged.
c. Use flame heating plugs.When the ambient temperature is below -25°C, you can use flame heating plugs to preheat and start the diesel engine.To do this: Place the start switch in the preheat position, preheat for 60 seconds, wait for the yellow indicator light to illuminate, and then preheat for another 20-30 seconds before starting the diesel engine.If the engine fails to start successfully once, preheat it for another 1-3 minutes before starting again.Each start should not exceed 10 seconds.
d. When the ambient temperature is below -25°C, the engine must be preheated entirely by other means before starting.For example, hot air generated by a combustion heating device can be used to circulate the engine's internal heat, or the oil in the oil pan can be preheated using a special heating device.
e. When used in winter, the engine should generally not be operated at low temperatures, low speeds (n ≤ 800 rpm), and no load for more than 30 minutes.
f. When starting the engine, avoid operating it at maximum idling speed.
(4) Precautions for diesel engine operation in summer The weather is hot in summer, and the operating environment becomes relatively harsh for air-cooled diesel engines.In order to ensure the normal operation of air-cooled diesel engines in summer, special attention should be paid to the following points.
① The continuous working time of the diesel engine at full load should not exceed 60 minutes. If the operation limit requires continuous operation for a long time, it should be slowed down (n=800~900r/min) after at least 60 minutes and cooled for 3~5 minutes. This can avoid abnormal damage caused by overheating of the diesel engine.
② Select engine oil suitable for summer use according to the ambient temperature. Regularly check the oil quality. If the oil appears black or deteriorates, replace it immediately.
③ Regularly check the operation of the fan system and clean the fan hydraulic coupling regularly; ensure that the fan thermostat and electronic control device are always in good condition.
④ Regularly clean cooling surfaces such as the cylinder liner, cylinder head, and oil radiator to prevent excessive dust accumulation on the cooling surfaces, which may affect the engine's overall heat dissipation efficiency.
⑤ Do not shut down the engine immediately at full load. Run the engine at idle speed (800-900 rpm) for at least 3-5 minutes before shutting down. It is best to wait until the oil temperature is below 70°C and the cylinder head temperature is below 80°C before shutting down.
⑥ If the diesel engine suddenly stops at full load under special circumstances, measures must be taken to prevent "cylinder pulling" or "shaft seizure" failures.
FL513 series air-cooled diesel engine structure introduction Deutz FL513 series diesel engine (as shown in Figure 1-8) marks the beginning of a new era of air-cooled diesel engines.This series of diesel engines uses independent cylinder liners with heat sinks and a one-cylinder-one-head modular structure. The parts are highly versatile and have a wide range of uses.
With the gradual application of electronic technology, the environmental adaptability of diesel engines has gradually increased.Compared with the FL413F series diesel engines, the technical progress of the FL513 series diesel engines mainly includes the following aspects.
(1) Improvement of combustion chamber The FL513 series air-cooled diesel engines have undergone major changes in the structural shape of the combustion chamber (compared with the FL413F model).The combustion chamber of the non-supercharged model has been improved from an oblique cylindrical (U) combustion chamber to a W-shaped combustion chamber; although the supercharged models all have W-shaped combustion chambers, their structural dimensions have changed significantly, as shown in Figure 1-9.
Through the improvement of the combustion chamber, the diesel engine's combustion system has been improved and the combustion has been more complete, thus greatly improving the various performance indicators of the diesel engine.
①The A-type pump was changed to a P-type pump, which increased the pump oil pressure (the plunger diameter was increased).
②Injector nozzle improvement.The nozzle holes of the non-supercharged diesel engine were changed from 2 holes to 4 holes, and the injection pressure was increased.
③Reduced fuel consumption and improved torque characteristics, as shown in Figure 1-10.
(3) Improvement of output power
The FL513 model basically retains the basic structural features of the FL413F model: V-type 90° angle, also divided into inline 5, 6 cylinder, V-type 6, 8, 10, 12 cylinder supercharged and non-supercharged models.The turbocharged diesel engine has reduced its rated speed (from 2500r/min to 2300r/min) by improving the combustion mode and the injection pump system, while the non-turbocharged diesel engine has reduced its rated speed (from 2500r/min to 2300r/min) by increasing the cylinder diameter (from 125mm to 128mm), improving the fuel supply system (injection pump) and the combustion mode. The rated power has not only remained unchanged, but also widened the power output range of the diesel engine, thereby greatly improving the adaptability, reliability and service life of the diesel engine.In addition, the overall noise of the diesel engine has also been reduced.The power comparison curve of the BF8L513 and F8L413F diesel engines is shown in Figure 1-11. (4) Improvement of exhaust emission indicators After a series of improvement measures, the exhaust indicators of the FL513 model have been greatly reduced compared with the FL413F model, as shown in Figure 1-12.The emission indicators of the FL513 model have been greatly improved and can meet the requirements of the Euro II standard.
(5) FL413F/513 diesel engine combustion process ① The "D" process of Deutz diesel engine combustion: The axis of the oblique cylindrical combustion chamber (as shown in Figure 1-13) intersects the cylinder centerline at an acute angle.Two oil jets of equal thickness and at an acute angle (28°) are sprayed into the vicinity of the oblique cylindrical combustion chamber wall.The oil jets are blown to the periphery by a strong rotating airflow with an intake tangential velocity of approximately 90 m/s (swirl ratio of approximately 2.6).The oil-air mixture at the center of the combustion chamber has an appropriate concentration and ignites first (the ignition delay period is approximately 2° to 3° crankshaft angle).The oil-air mixture at the combustion chamber wall has a higher concentration and, due to the low temperature, the chemical reaction is controlled and does not ignite immediately.Subsequently, due to the effect of thermal mixing, the combustion gases at the combustion chamber walls flow toward the center. Due to their lower temperature and higher density, the combustion gases at the center are flung toward the chamber walls by the centrifugal force of the swirling vortex, remixing with the denser fuel-air mixture at the chamber walls and further burning. The Deutz "D" combustion process is characterized by low combustion noise, avoidance of combustion shock during startup, reliable startup at ambient temperatures above -15°C, good fuel economy, and low thermal load.The Deutz "D" combustion process is used in the FL413F series non-turbocharged diesel engine. ②Deutz diesel engine combustion "Z" process. The Deutz "Z" process utilizes a W-shaped combustion chamber (as shown in Figure 1-14).Fuel is injected directly into the combustion chamber at high pressure through a four-hole injector.The fuel-air mixture is formed by the axial rotation of the air along the cylinder liner (swirl ratio 1.7 ± 0.2) and the "squeeze turbulence" inherent in the combustion chamber.
(6) FL513/413F Diesel Engine Main Technical Parameters The FL513/413F series air-cooled diesel engines have a wide variety of models, and only some models are included. Their main technical parameters are shown in Table 1-1.
(7) Structural features of FL513 series air-cooled diesel engines ① High degree of standardization, serialization and universalization.The commonality of all engine parts is very high, reaching more than 67% by type and about 85% by number.Whether it is a 6-cylinder engine, an 8-cylinder engine or a 12-cylinder engine, except for the crankcase, crankshaft, camshaft, oil pan, injection pump and intake and exhaust pipes, other parts are universal or basically universal. ② Simple structure and easy maintenance.The one-cylinder-one-head structure facilitates maintenance services such as cylinder pulling, replacement of pistons, cylinder liners and piston rings, and adjustment of valve clearance. ③ Long service life, good reliability and low failure rate.Due to the use of an air cooling system, the failure rate of the cooling system is greatly reduced. Compared with water-cooled diesel engines, the failure rate is reduced by about 34% (as shown in Figure 1-15).The service life can reach more than 10,000 hours.When used on railways or in construction machinery, this series of diesel engines operates at reduced power, with actual operating power at least 10% below rated power. This further extends the engine's service life and significantly reduces the likelihood of engine failure and damage. ④ Low noise and exhaust pollution.This series of diesel engines utilizes advanced combustion theories and noise reduction technologies, resulting in significantly lower noise levels than water-cooled diesel engines of the same power while also significantly reducing emissions.The low-pollution (FL513W) model of this series of diesel engines boasts very high emission standards, making it particularly suitable for use in underground mines and tunnels, and is highly sought after by users. ⑤ Excellent economic performance.This series of diesel engines boasts a fuel consumption rate of 225g/kW·h under rated conditions and a minimum fuel consumption rate of 216g/kW·h, representing oil consumption less than 1% of total fuel consumption.Furthermore, their reliable service life and low failure rate significantly reduce the engine's operating costs, further improving its overall economic performance.⑥ Good power performance and strong adaptability. a. Strong environmental adaptability: Can be used normally in an ambient temperature of -40-50°C.
b. Wide power range (64 to 386 kW), meeting a variety of applications.This series of diesel engines is widely used in trucks, construction machinery, mining machinery, luxury coaches, railway maintenance equipment, and special vehicles. c. The output power of the FL513 series air-cooled diesel engine includes fan power consumption, and its output power is close to the net output power of the diesel engine, thus providing excellent power performance.
! WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.
1 Position the machine on level ground. Roll the loader shovel forward and rest it on the ground. Retract the extending dipper if fitted. Close the backhoe bucket. Swing in the dipper. Lower the boom until the bucket rests on the ground. Lower the stabilisers to the ground. Stop the engine. Remove the starter key.
2 Remove the element assembly a Remove screws A. Remove the cover plate B and gasket C Note: If gasket C is a rubber type it can be reused provided it is undamaged. If the gasket is a cork type it must be discarded and a new gasket fitted on assembly. b Remove spring D. c Hold handle E and pull the element assembly from the hydraulic tank.
3 Remove the element from its canister. a Hold canister F. b Hold handle E and rotate the element G 90° anticlockwise. c Pull on handle E, the element G should separate from its canister F. Discard the old element. d Remove and discard seal H. e Clean the inside of canister F. New machines are fitted with a 5 micron filter element which must be replaced at the first 100 hour service with a 10 micron filter element.
4 Fit the new element. a Fit a new seal H. b Make sure that seal J is fitted in the new element. c Push the element G into its canister F and rotate the element 90° to lock it into position. Check that the element has locked into position by pulling on handle E. d Install the element assembly in the hydraulic tank. e Fit spring D and gasket C, (see ‘Note’ at step 2). f Fit cover plate B and tighten screws A to 21 Nm (15.5 lbf ft). g Check oil level and replenish as required through filler. Fit and tighten the filler cap as described on previous page.
Checking the Coolant ! WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system.
1 Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key. 2 Open the bonnet, see Engine Panels, Opening and Closing the Bonnet. 3 The coolant level should be between the COLD/MIN and the HOT/MAX marks on coolant reservoir B. Fill with pre-mixed water/antifreeze if necessary.
Changing the Coolant ! WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system.
! WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking
2 Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key. 3 Open the bonnet, see Engine Panels, Opening and Closing the Bonnet. 4 Drain the oil:
! CAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug.
a Place a container of suitable size beneath the drain plug. b Remove drain plug C and its 'O' ring. Let the oil drain out, then clean and refit the drain plug with a new 'O' ring. Tighten to 34 Nm (25 lbf ft).
5 Change the filter: a Unscrew the filter canister D. Remember that it will be full of oil. b Check that adapter G is secure. c Clean the filter head F. d Add clean engine lubricating oil to the new filter canister. Allow enough time for the oil to pass through the filter element. e Smear the seal E on the new filter with oil. Screw in the new filter canister - hand tight only.
6 Fill the engine to the max mark on the dipstick with new oil through the filler. See Service Capacities and Lubricants for recommended oil grades. Wipe off any spilt oil. Check for leaks. Make sure the filler cap is correctly refitted. 7 Make sure the engine will not start and turn the starter switch to operate the starter motor until the oil pressure light is extinguished. (To make sure the engine will not start, remove the engine shut-off solenoid fuse, housed in the fuse box). 8 Insert the engine shut-off solenoid fuse and operate the engine. Check for leaks. When the engine has cooled, check the oil level.
