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1015 Installation Manual 1015/C/CP
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TABLE OF CONTENTS
1. ENGINE COOLING SYSTEM
1. Engine Cooling System
1.1 General
1.2 Engine coolant circuit
1.3 Cooling system versions
1.4 Radiator dimensioning
1.5 Seperate expansion tank with radiator- fan system
1.6 Coolant pump
1.7 Piping and fittings
1.8 Additional coolers
1.9 Heating system
1.10 Wiring diagrams of cooling circuits
1.11 Fans
1.12 Cooling air ducting
1.13 Filtration of cooling air
2. COMBUSTION AIR SYSTEM
2.1 GENERAL
2.2 Intake resistance
2.3 Air cleaner system
2.4 Dimensioning the air cleaners
2.5 Combustion air piping
2.6 Combustion air temperature rise
2.7 Combustion air noise
2.8 Crankcase breather
2.9 Pressurizing of hydraulic oil tanks
2.10 Charge air cooling
3. EXHAUST SYSTEM
3.1 General
3.2 Permissible resistance in the exhaust system
3.3 Measuring the exhaust back pressure
3.4 Dimensioning the exhaust pipe and determining the piping resistance
3.5 Silencer and tailpipe lengths
3.6 Flexible exhaust pipe joints
3.7 Engine brake ( exhaust brake flap)
3.8 Nomograph for determining the exhaust piping resistance
3.9 Exhaust scrubbers
3.10 Catalytic converters
3.11 Particulate filters
3.12 Exhaust heat exchanger
3.13 Exhaust tailpipe/water ingress guard
3.14 Condensate separator
4. FUEL SYSTEM
4.1 General
4.2 Fuel system with different tank positions
4.3 Routing and dimensioning of fuel lines
4.4 Fuel temperature rise
4.5 Fuel tanks
4.6 Fuel filtration
4.7 Fuel filtration under extreme operating conditions
4.8 Water seperator
4.9 Engine operation at low temperatures
4.10 Types of fuel line connections
5 ENGINE MOUNTING CONFIGURATIONS
5.1 General
5.2 Flexible mounting
5.3 Rigid mounting
5.4 Mounting of engine/generator in the case of gernerating sets
5.5 Filting mounting elements to engine SAE housing
6 LUBRICATION SYSTEM
6.1 External full- flow oil filtration systems
6.2 Secondary- flow lube oil microfilter
6.3 Dry sump lubrication
7 POWER TRANSMISSION
7.1 Couplings
7.2 Installation of universal shafts
7.3 Power take- offs
8 AIR COMPRESSOR
8.1 Mounting location
8.2 Compressor/sizes
8.3 Line connections/line layout
8.4 Pressure regulating systems
8.5 Cooling/lubrication of compressor
8.6 Compressor layout
8.7 Compressor with drive- through axle for PAS pump
9 OPERATION AT LOW TEMPERATURES
9.1 Radiator cover (winter cover)
10 ELECTRICS/ ELECTRONICS
10.1 Batteries
10.2 Starter motor and battery sizes
10.3 Dimensioning of cable between starter and battery
10.4 Dimensioning of control cable to starter motor
10.5 Power relay for starter motor actuation
10.6 Start interlocking relay
10.7 Dimensioning of various cable cross sections
10.8 Alternators and regulators
10.9 Three-phase alternators
10.10 Dimensioning of B+ cable from alternator
10.11 Protection of flame flow plugs
10.12 Solenoid for engine shutdown
10.13 Electronic engine equipment
11 SOUND INSULATIION AND SOUND ABSORPTION
11.1 General
11.2 Sound insulation
11.3 Sound absorption
11.4 Sound insulating and absorbing materials
11.5 Additional measures required for engine enclosures
11.6 Notes
12 VIBRATION DAMPER
12.1 Cooling of vibration damper
13 ACCESSIBILITY FOR SERVICE AND MAINTENANCE JOBS
13.1 General
13.2 Maintenance jobs requiring easy and convenient access
13.3 Maintenance jobs not requiring easy and convenient access
14 ENGINE ROOM VENTILATION
14.1 Radiant heat
14.2 Air mass flow for ventilation of engine room
15 INSTALLATION SURVEY VIA MEASUREMENTS
15.1 Temperature test
15.2 Pressure measurements
16 ANNEX
16.2 Formula correlations concerning fans and coolant pumps
16.1 Calculation formula for internal combustion engines
16.3 Engine coolant
16.4 Explanations of graphic symbols on the following piping diagrams
16.5 Piping diagram - coolant
16.6 Piping diagram - combustion air
16.7 Piping diagram - exhaust gas
16.8 Piping diagram - fuel
16.9 Piping diagram - lube oil
16.10 Piping diagram - compressed air
17 Checklist starter
Nội dung
Modification index 01 Modification index 01 In the electronic pocket-book all necessary changes and supplements will be registered at short notice A list showing the request of modification, date and modification index see below Modification- Date Modification index 00 01.10.2004 none 01 24.02.2005 Chapter 17, Checklist for inspection of starter motor syst Modification index 01 DEUTZ AG, Installation Manual BFM 1015 Modification index 01 Modification index 01 Modification index 01 Modification index 01 17 Checklist for inspection of starter motor system 17- Modification index 01 DEUTZ AG, Installation Manual BFM 1015 Modification index 00 Modification index 00 Modification index 00 Modification index 01 Modification index 01 Modification index 00 Modification index 01 Modification index 00 Modification index 00 Modification index 00 Modification index 00 Modification index 00 Modification index 00 17 Checklist for inspection of starter motor system Cable laying, cable dimensioning, cable connection: • Main cable (to terminal 30) and control cable (to terminal 50) have to be routed in that way that they not come into contact (prevent short circuit) • The cables have to be fixed approx 300mm after starter motor connection forthe first time • At terminal 50 only the control line to starter motor coming from a relay or from starter switch is allowed Additional electrical consumer e.g relays have to be connected at terminal 45 • The permitted resistance of control cable (terminal 50) and battery main cable (terminal 30) can be rough calculated with cross section, cable length (incl ground cable, if available) number of transitions (add per transition 0,05mOhm) Forthe starter motor the permitted total resistance is cable resistance plus battery internal resistance Admissible values see starter drawing or installation guide line Power relay for activating starter: This relay should be similar to Bosch relay 332 002 150, the following data should be checked: • Switch-on voltage lower than 8Volt • admissible electrical power 10% over value on starter motor drawing, e.g HE starter 60Amps, relay 66Amps • for short time (under sec.) 250Amps must be permitted • relay should be switched off when voltage is between 1,5 to 4,0V Start blocking relay: A minimum waiting time of (6) sec must be observed • after the drop of signal of terminal 50 • after drop of signals of "W", "D", "n" • after starter has been switched off by speed signal • start function must be blocked as long a speed signal occurs DEUTZ AG, Installation Manual BFM 1015 ...Modification index 01 In the electronic pocket-book all necessary changes and supplements will be registered at short notice A list showing the request of modification, date and... index 00 01.10.2004 none 01 24.02.2005 Chapter 17, Checklist for inspection of starter motor syst Modification index 01 DEUTZ AG, Installation Manual BFM 1015 Modification index 01 Modification... Modification index 01 Modification index 01 17 Checklist for inspection of starter motor system 17- Modification index 01 DEUTZ AG, Installation Manual BFM 1015 Modification index 00 Modification