Operation Manual

1015

DEUTZ
 Safety guidelines / Accident prevention
a Please read and observe the nformation
qiven in this Operation Manual. Thls will
enable you to avoid accidents, preserve the
manufacturer's waranty and maintain the
engine in peak operaUng condition.
? aThis engine has been built exclusively for
o the application specified in the scope of
supply, as described by the equipment
manufacturer and is to be used only for the
intended purpose. Any use exceeding that
scope is considered to be contrary to the
intended purpose. The manufacturer will not
assume responsibility for any damage
resulting therefrom. The risks involved are
to be borne solely by the user.
a Use in accordance with the intended pur-
pose also implies compliance with the con-
ditions laid down by lhe manufacturer for
operalion, maintenance and servicing. The
engine should only be operated by person-
nel trained in its use and the hazards in-
volved-
a The relevanl accident prevenr:ol^ gLiidelines
and other generally accepted safety and
lndustrial hygiene regulations rnust be ob-
served.
a When lhe englne is running, there is a risk
of inlury throughi
- turning/hot components
- engines with positive ignition
- ignition syslems (hlgh electrical voltage)
You must svoid contact at a I timesl
a Unauthorized engine modiflcations will in-
validate any liability claims against the
manufacturer for resultant damage.
l\,4anipulations of the injection and regulating
system may also influence the performance
of the enqine, and its emissions. Adherence
to legislation on pollution cannot be guaran-
a
teed under such conditions.
Do not change, conve( o. adjust the cooling
air intake area to the blower.
The manufacturer shall not be held respon-
sible for any damage which results from
such work.
a When carrying olrt maintenance/repair op-
erations on the engine, the use of DEUTZ
original parts ls prescribed. These are spe- Eng
cially designed for your engine and guaran- Seh
tee perfect operation.
Non-compliance results in the expiry of the
warranty! Plea
quot
deal
l, Marnle'rance ano cleaning of rhe engine vice.
shoLld only be carried out when lhe engine
is switched off and has cooled down.
You must ensure that the electrical systems
have been switched off and the ign,tion key
has been removed.
Accidenl prevenlion guidelines concerling
electrical systems (e.9. VDE-0'100101011 In vi1
0104/-0105 Electdcal protective measures chan(
against dangerous touch voltage) are to be illust;
obsetued.
When cleaning with fluids, all electrical com-
.suble
rn pa
ponents are to be covered appro
lmpermeably.
 OperationManual
will in-
the
1015

cooling

respon-
0297 9684 en

rpalr oP-
DEUTZ
are spe- Engine
guaran_ Serial Number:

rv ol the
Please enter here the engine serial number. By
quoting this number yoli !i,ill help to facilitate
dezling with questions concerning Customer Ser-
engine vice, Repairs and Spare Parts (see Seclion 2.1).
engine

01 ln view of continuous design improvements or

measures
are to be
changes, the techn;cal specifications and the
illustrations shown in this Operation l\,4anual are DEI'TZ
subject to alteration. Repriniing and reproduction,
in part or in whole, are subject to our written
approval.
 Foreword

Dear Customer,

Liquid-cooled DEU]-Z engjnes are desiqned lor a

01040 spectrum o, applicattons.Consequen y, a
uoe.range 0t variants are ottered t0 meet the
speclrc requtrements of each tndividual case.

Your engine is appropriately equipped for the

rnstaitalton concerned. which means that nol
all the.components described in this operation
Manuat are necessarily mounted t0 your engine.

We have endeavoured to hiOhltOht anv difterences

s0lhat y0u will be able to locate the operatjng and
marnlenance tnstructions relevanl t0 your engine
quickly and easity.

Please read this Manual betore starting y0ur

engine. and always observe the ope,atiio and
maintenance instructions.

Should you have any;nquiries we shall be oleased

to provide advice.

Sincerely,

DEUTZ AG
 Table of Gontents
1. General 3.5 operatingConditions 6.3.4 Cleaniog engine
2. Description ol Engine 3.5.1 Winter operatioo 6.4 Combustion Air Cleaner
?1 f,lodelDesignation 3.5.2 High Ambient TemDerature. Hioh 6.4.1 Cleaninglntervals
Altitude
_ HaI |q Htate 6.4.2 Dry-Type Air Cleaner
2' 2 LocaUon of Rating Plate 4. ope.ating Media 6.4.3 RemovingCyclone-Typeprecleaner
?' 3 Engine SerialNumber 4.1 Lube oil 6.4.4 Cleaning 0il Bath Air Cleaner
2' I N!mbering of Cylinders 4.1.1 ouality Grade 6.5 Belt Drives
2.2 Enginelllustrations 4.1.2 Viscosity 6.5.1 Checking Alternator V-Belt
2.2-t Cy. BankA BF6 M 1015 4.2 tuel 6.5.2 Retensioning/BenewingAlternatorV-
2 2.2 Cyi. Bank B BF6 [I 1015 4.2.1 ouality Grade
Belt

2.2.3 Cyl. Bank A BFB tvt 1015 4.2.2 Winter G rade Fuel
6.6 Adjustmenis
2 2: Cyl. Bank B BF8 1015[,,1 4.3 Coolant
6.6.1 Checking/Adjusting Valve Clearances
2 3 LLrb". oil CircLrlt
6.6.1.1 Valve Clearance AdJJstment Schematrc
4.3.1 Water ouality for Coolant prepamtion
6.7
2 1'
Accessories
Lube0ilCircuitSchematic'1015 4.3.2 CoolantPreparation
6.7.'1 Battery
4.3.3 Cooling System Protective Agents
6.7.2
0peration Three"PhaseAlternator
C:n-iss oning 5. Roulile Mainterance 6.7.3 Lifting Tackle
. .O i Engine oil 5.1 MaintenanceSchedule 't.
: .T,o oil Bath Air Cleanerwith Engine 5.2 l\4aintenanceChart Troubleshooting
7.1 Dia0nosis Chart
5.3 Completed Maintenance Jobs
: rc the Fuel Tank
8. Eogim Preservalion
i_ .l Bleeding ihe Cooling System 6. SEruice and Mai enance
8.'l Preseryation
6.1 Lubrication System
::':'PrEpa.al ons 6.1.1 0ilChange lntervals s. Specification Dala
:-1-: 6.1.2 Changino Engine oil, Checking oit Levet 9.1 Engine Specifications and Settings
::r:' : S:a'i rg 6.'1.3 Renewing 0ilFilter 9.2 Torque Wrench Settings
i,': -::'-: S. slerrs 6.2 FuelSystem 9.3 Tools
:-: -: a c':ssure 6.2.1 Renewing FuelFilter
:::.-::iar!EraiLrre 6.2.2 Charge Fuel Leakage Line 10. Service
::r:_: La,: 6.2.3 Fuel Pre-filter Element
--::: :,: Clean/Replace il necessary
6.3 Cooling System
!.'=:_:-:: S. -:lot,/n 6.3.1 Cleaning lntervals
::::_::_-:t:,,. 6.3.2 Draining Cooling System
6.3.3 Filling/Bleeding Cooling Systenl
 General
DEUfZ Diesel Engines Care and Maintenance Service

a= T: product of many years of research and Sound care a"d rrlainrenance practices will ensure Please contact one 0f our authorized service
:r,: cp:rlent. The resulting know-holv, coupled thatthe engine conanues t0 meel lhe reouirements
.-: t'.rgenl quality slandards, guarantee lheir placed on tt. Becommendd service inteivals must
representatives in the event of breakdowns or ior
spare pads inquiries. 0ur trained specialists will
:-: sr/ice lite. high reliability and low luel be observed and servic and maintenance work carry 0,1 repairs quickly and professiona y, using
::rs-mDl on carrid out conscientiouslv. 0nry oenutne spare parts.
: J..ts lloul saying lhal DEUTZ Diesel Enoines
,y Special care shoutd be tiken under abnormally 0rigr4alparts from DEI.JTZ AG are always pr0duced
-:r: r-e tghest standards tor environmental demanding operating conditioos. in accordance with slate-01-the-art technoloov.
:-::a!'i on. Please turn l0 the end 0l this manual lor firther
service information.

Berare ol Bunning Engine Safety

California
Proposilion 65 Waming

-:--::-: :-; ia do\,/r before carrying out mainte- This symbol is usd lor all safetv
-i',:E :- -
=:: , rlork.
:i i::: :.-:
Ensure thatthe engine cannot
sladed. Risk oi accidents.
warnin0s. Plase lollow them DieseJ engine exhausl and some 0l its consti-
tuents are known to the State of California to
carefully. The attention of operating
dr';-: ;; ,111 is complete, be sure to refit any Dersonnel should be drawn to thesc cause cancet birth delects, and other repro-
=-i.: i-::-i:-a:!s
rF:,:'' that may have been removed.
'-: la-1, r.r'i e lhe engtne is running.
safety instructions. Genral safety
and acciderl prevenlron regulalions laid down
ductive harm
bi
- :-*: ; :-::- Jl saf et/ regulations when running
-, -
law must also be obsPrvcrl-
:a :-: -: _ a: erclosed space or underground.

Asbestos

DEIITZ oriainal parts are asbestos,

 Description ol Engine

2.1 Model llesignation

2.2 Engine Illustrations
2.3 Luhe OilCircuit
 2.1 Model Designation
Desctiption of Engine
2.1.2 Location ot Bating Plate 2.1.3 Engine Serial Xumber
2.1.1 Rating Plate

-"+#
'.'\.ii :a:1i:
t r..
-,+\^-l-
l'- :d-| 26 3901r

.: r. : -: -:. c _ -tc ) s'a lped on lhe

The model des gnalion A. lhe elgine seridl The rating pLate C ls ailixed to ihe crankcas.
:. Lc:_:, :=:: i :,, a_o or Ile 'oling Plale
n-mber B and thipertormance 0ala are slalped
on the rat ng Plate.

When ordering spare pans. it is essellial Io quole

the mooe'disl'Onalion and the elgine serial
number
2.1 Model Designation Description of Engine

2.1.4 llumbering ot Cylindels

--,: lr .oefs are numbeled consecutively for

: :':, bank A or B, beginninqat flywheelend.
Description of Engine 2.2 Engine lllustration

2.2.1 Cyl. Bank A - Bt6M 1015

15
14

3 ..,
'2
i3
i.+
15

7
2.2 Engine lllustration Description of Engine
2.2.2 Ctl. Eank B - BFOM1015

16 Charge air pipe

17 0ildipstick
18 0il drain plug
19 SAE housing
20 Flywheel
21 Exhaustturbocharger
22 iniection pump
23 Flame-type hBater plug (A-side)
 Description of Engine
2.2 Engine lllustration
,r"",r*-^-rr,,*"
I
!.'-rLi::-.Eochargr
!ra:, s: -a-.;ic d
:
l S1a1:i
a 0ll' t::.r:ck
0 0..
i : : :er
LLJb:
I !.0:ll F, :r ,!rlh vibralion damper
I U0a a1 c!nnlctton fTom heat exchanoer to
EnE n:
r0 0ilcoo:r
t1 Fan
12 Exha!st stack
13 Charge air prpe to lhe charge air c0oler
11 l-larn-lype heater plug system (B-side)
2.2 Engine lllustration Description ol Engine

2.2A qL Bank B - BFBM 1015

14 Flame-type heater plug system (A-side)

'15 0iliiller neck
16 Cylinder head
17 Alternator
18 0itdipstick
19 SAE housing
20 Flywheel
2'1 Compressor
22 Fuel connecting line
Desoription ol Engine 2.3 Lube 0il Circuit

2.3.1 lube oil Ci]cuit Schemalic 1015

Wet Sump Lubricatio[

1 oil paf
24 27 21 12 13 23 2g 16 17 14 18 19 15 10 2 lflake pipe
3 0ll pump
4 overpressure re lef valve
5 0il cooler
6 Spin on o ilter
7 Ma n oil bores
I firain bearing
9 Big-end bearing
10 Camshaft bearing
1l 0i supply to iniection pump
12 lnjction pump
il 13 Return ll,re from injection pump t0 crankcase
14 Line to spray nozzl
I 15 Spray nozzle with pressure-hoiding valve for
piston cooling
16 Tappel with control groove for pulse
lubrication of rocker arms
17 Pushrod,0ilsupply to rocker arm lubrication
18 Bocker arm
l9 oil return bore in cy inder head to crankcase.
20 0il pressure sensor / 0il pressure switch
21 oil line to exhaust turbocharger
22 Exhaustturbocharger
23 oil line t0 compressor (hydr. pLrmp)
24 Compressor
25 Hydraulic pump
26 Pressure-holding valve (adjustable)
2s ?6 22 28 27 oil return linefr0m compressor (hydr. pump)
to crankcase
28 0il return line from turbochargerto crankcase
 Engine 0peration

3.1 Commissioning
l
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 Operating Gonditions
 Engine 0peration 3.1 Gommissioning g.

3.1.1 Filling in Engine oil 3.1.2 Filling oil Bath Ah Gleaner with 3.1.3 Filling the Fuel Tank
Engine 0il 3.1

FUEL I

t
\
As a rule, the engines are delivred without oil
filling.
Fill engine o I into bowl 1 of oil bath air cleaner
lllted) up to the arrow mark.
(ll Use.only commrciafgrade diesel fuel. For
qudlty g'aoe. see 4.2.
fuel a , :

FilLin lube oilthrough the 0illlller neck (arrow). F0r oil quality grade and 0il viscosity, see 4.1. Use summer- or winter-grade fuel, depending 0n
For oil filling volume, see 9.1. the ambient temperature
For oil qualiry grade and oll viscosity, see 4.1.
a::
='
a --:
::

a l;If:Jrll;l;,tliff*#*,.,"
a 3lTj,,,:,*::-,.il:: T::
 tng 3.1 Commissioning Engine 0peration

3.1.{ Filling/Bleeding Cooting 3.1.5 other Preparations

$em
1015
a Check oarTery and battel cab,e connections,
see671

a Tria I run

- Upo" conp,eting the Oreparations 'un the

erg:1e lor a storl lrial run of abour l0
minutes under low load.

During and atter trialrun

- Check the engine for leaks.

Aller lhe engine has been stopped

. Check o;l level and lop Lp il necessarv. see
6.12
- Retension V-belts. see 6.5

a Breaking-in
a -:--:il coolant inlet 1 and coolant ouflet 2 to
.-!--:'coolant tank.
Dur'rg lhe Dreak;ng-in phase, ir is
:n00n recormended to check the o I leveltwice a day.
a = - t!!.iant nto cooling system. Atter tl'e breakino-in phase, checkin0 once a
dav will be sliJi.ient
a ::: ,-; -e a-d -un up r0 notmal operalinq
':-::-!:r.lt-e Untl thrmostat opens {line 2

a ,.i,.-,rr rt ,r*, ,n external coolinq system,

-:: -: ::olant ii necessary.
 Engine 0peration
3.2 Stafting g

3.2,1 ElectriG Stalting

without Cold-Starting Aid
f

\*tr
Before starting, make sur that Fi
nobody is standino in the
immediate vicintty 0fth-e enOine or
drven machine
After repair work:
Cneck whether all removeo
0Jards ate p.1 bdck ,n
piace and all rools are 'emoved trom trie
erqire
When slarting with ltame.rype fealer nluos. do
n0t Lse ary orher ad0ilronal Stdrtinq ar0; (e g.
rnjectt0n wtlh stad piloi). Accident hazard!
A\\,@E
lmporlanl: Never start the engine wilh s[eed
governor removed.
Disconnect ba ery!
*E
a Drsengage rhe clJrch to separate l,te e.gine
a lnsert key.
Trom the driven equipment.
- Posiiion 0 = no operatin0 voltaoe. a-
a i\,,l0ve speed control lever I in direction ol
arrow at least to middle speed position. a Turn key clockwise.
- Posjti0n 1 = operating voltage, a--
a lvlove shuldown levr 2 t0 ,,Bun 00siti0n
(0pposite d rectron of arrow, item.1) - Pilot lamps light up.

aTurn key runner Llock$,rsp againsr sorirg

Do nor actJaLe the srarter lor rnore tndn 20 aciion
se-conds at a iime. li rhe engine does not
slari,
wart one minute betore repeating the attempt. - Position 2 = starting.

does nor srart atter two attempts. a

ll^tr-:!ql,
racelhr
Release key as soon as the engine starts iirif: --
Lause w:tf
(see /.11
thp aid o'rle Dia0nos,( Charl
Pilotlampsgoout.
I
32 Starting Engine 0peration

tE Cold-Starting Aid
hlype lleater Phg Sfstem

\, o{Er]

6)'ffi
a Ed key. a Turn key lurther clockwise aoainst spring
- P!6ition 0 = no operatinq voltaoe. action to
- Position 2 = starting
a irn key clockwise.
- fooition 1 = operating voltage, a Belease key as soon as the engine srarls firing.

- Pilct lamps 1+2+3 lioht up. - Pilot lamps qo out.

- PrElrcat until heater plug indicator 3 blinks,

rEx 30 seconds

- SEine is ready for operation.

lmportant: The starting process

must be carried out within the 30
seconds, otherwise repeat stading
attempt.
 Engine 0peration
3.3 Monitoring Systems

3.3.1 Engine oil Pressure

3.3,2 Coolant Temperature
0il Pressure Pilot lamp 0il Pressure Gauge

aThe oil pressure o,lot an p

,ioh.s
u0 w,th aJFe oo1te. ot the oil pressure Qduoe musr
0perdtrng v0rtage applied dno enqrre shrr oil. a'lhe oo.nter 0'lhe rer.0eratute ind,cdtor shou'c
.ndtcale the mtnimum 0,, oressu.e g.11.
isee remarn 1 thegreenseclo.an0enler lnevelJuw.
a The o,l pressure pi,ol lamp Tusl 0o ou-whpr greee- seclor ontv.r exceptionat cases. li lh(
lfeengrne is tunntnq. p0tnler enlers tle otanqe sector tne en0tne
t!
overhedr.ng. Iu.n ir o+f and eslablish lhelauir
from the Diagnosis Chart (see 7.j
).
I Systems 3.3 Monitoring Systems Engine 0peration
ure
3-3.3 Coolant level 3.3.4 hbe oil level
I

\-r\-r\-r\-,\-r\-/
min
j'a ndicator shoulo
.d efter the }/ellow- a j-np oi coolant level indicator lights up a Lamp 0l lube oi level indicator lights up
:rnracl via lloal switch/level sens0r when mir. (contact via float swdch/level sensor whel mr'r.
:: cnal cases. lf th
i.:or the engine is :irlant level has been reached): lube oil level has been reached);
--.n engine off and establish cause from the Turn engine otf and establish cause frori the
:stablish the cause
i: 7 1). : ?onosis Chad (see 7.1) Diagnosis Chart (see 7.1)

a =rncli0nal check ot coolant levell a Functiona check oi Iube oil level:

-se.t key in posit on 1 or 2
: oat swilch or levelsensor)
: ot lamp lights up for ab0ut 2 seconds
- Coolant levl o.k.: lamp goe; out
- Coolant level not o.k.: lamp does nol go out.
lnsert key in position 1 or 2
{Float switch or levl sensor)
Pilot lamp lights up for aboul 2 sec0nds
- Lub oil level o.k.i lamp ooes out
- Lube oil level nol o.k.: lamp does nol g0 out.
 Engine 0peration
3.4 Startinr
3.4.1 Mechanical Sh[tdowl
3.4.2 Etectdc Shutdown

F^
\,z\ cltlr
L-'

@f'H
f-']If ...-. [-;_-l
i

a Setspeed controllever j to towspeed posttion.

(to positjon 0) and
a Acluate.slluldown lwer 2 until engine
comes to
'Jll'#'ffilji{;lx#.e
;jfr i,"J,lli,!ffilfl 'lf f llf X'dlll fl , ?',?','i:
4 Starting L5 Operating Gonditions Engine Operation

lil finter operation

a -r.c 3li Viscosity a Cold-Slarting Aids

- Si{: the oil viscosity (SAE grade) - Al temperatures near or below freezinO point
icairding to the ambienl temperature starl with flame-type heater pluO, see 3.2.j.
:?,?rl'-g at tne time when the enoine is
4.1.2.
This not only lowers the startino timrl
=1rd temperature, but proves also usetulat tern-
- .-=. shoder periods between oil changes peralures normally not requ:riag a starting
.-:r operating at temperatures below:10
"_ -14'F), see 6.1.1.
a Battery
a : ES: :uel

- -- ,L'lergrade diesel luel lo. operation

- Cold starting requires a good state ot charge
of the battery, see 6.7.1.
:i.:,1 0 'C (+32 "t), see 4.2.2.
- The starting limit temoerature can be
Iowered-by 4-5 "C by heating the battery up
a :,:,:,a-i
to +20 'C (+65 'F). To do so, removc the
-= Lte watr / antifreezB mix to suit the
,r,r:s:
battery and store in a warm plae.
,: temperature ljkely to occur {max. -35
,31 "F), see 4.3.1.

a t,:::.al Maintenance Jobs

- :-1- the sludge from the fuel tank once a
.-< lby undoing the sludge drain plug).
- -.: ,si:aed)
the oil filling in the oil bath air cleaner
' to the prevailinq ambient
::-:9rature as in the case of engine oil.
- r-::-pe'aiures beiow -20 "C (-4 "F)
_:-rale the'lywheel rinO qea'with low-
grease, e.g. B0sch FI I V31,
=-r:rature
-:- r me t0 time through the pinion hole (if
_:::5Sary
remove starter).
Engine 0pemtion 3.5 0perating Gonditions

3.5.2 High Ambienl Temperature,

High Altitude

a With increasing altitude and rising ambient

tempbratures the density oi the air. tends t0
decrease, which affects the maximum power
--.-!J.-.c
output, the exhaust gas qualiiy, the
temperature level ano in efireme cases. the
slarling behavi0ur. Under tralslent Iunring
conditions, operation is permissibl at altituds
up to 1000 rneters at ambient temperatures up
to 30 'C {86'F)
lf an engine is operated under more severe
condirions (at hrgher atitudes or ambient tem-
peratures) it wrll be necessary to reduce lie
injected luel quartity and thus ergine powe(

a ln case 0l doubt concerning sucn engine

applications. ask your engrne 0r eqJipment
supplier whether. ;n tneinlerest 0f operational
reliab llty. service life a1d elhausl gas qudlily
(smokel), an engine deraling had been
cons:oered necessary, 0r s rply co"taci y0ur
service representative.
 0perating Media

4.1 Lube Oil

4.2 Fuel
4.3 Goolant
 4.1 Luhe 0il
0perating Media

4.1.1 0uality Grade 4.1.2 Viscosity

The lube oilqualitygrade s d efined by specilication s. Genera|v, nult' araoe oils suall be used : :- : -
npated rooms al temoeratLres t5"C. d : -.5 -
The followinq lube 0il speciiications are apploved;
graoeorlscalbeused.rhe ndi.ated Lbe c : .:::
lube oil quality class: -lust, olcourse, aLso be 0bserved'0 s -: i-;=-:
oils.
As fie viscositv of lube o. s de[':-j=--
classifi cation/specifi cation temperatu'e, ihe choice o' Sl: :.:'
Il snould be qovelned bv iF: :-::--
DEUTZ- DQC I DOC II DOC
lemperalure oreva.ling al i': :_:_:
ooeratino siie.
0otimum oPe'alrng behavioLr *']l ::
ACEA- E2-S6 E3-96/E5-02 E4-99

CG4/CH4 attained ii vou take the accompanyrng :

API- cFtcF4 vrscositv dia'granr as a quide

DHD-1 Shorlrl the temoerature lall

tempora' .
oelow the litnits oi tne SAE qlad: '=i:-::
Worldwide
cold starting may be afiected but the "'r!'-:
will noi be damaged.
ll in doubt. contact your service representative
ln order to keep wear io a minimum. do '::
exceed application limits l0r exie'!':
oeriods 01 time.
hil -bv d;cLaled
bv lhe seasons rd-::
"hanoes usrnq 'nulli-q'adp lu0e o
avoided
tr-qrdde 0,s - particularly
' : '
lo,! 'l''l l- -"'-
,lin reduce luel consum0tlolr.
I Lube 0il
1.1 Lube 0il 0perating Media

t 1.2.1 Specilic lube oil

delinilions
--r:.lcharged engines with uprated power and
Lube 0ils l0r engines with upraled power and engines with high l0ading
I
.q-:s with high loading

--E : s lsted in enclosure 1 are to be used

r- r: followinq enoines and applications:
.'_'5 CP
a: :rg nes in CHP planls
a i :ngines in gensets operatin0 in parallel
":- the mains/with each other
a :-!lnes in combines with:
--E- ire high-grade oils according t0 ACEA or APl. ln
most ofthese oils a.e partly synlhetic, some even
=i::-
'-r :r.thelic (5W-40) and thus achive the lhemal
r:: _, .equired for the relevanl application and are
:--:- s'red by a low lndency to cause deposits ln the
: :-:'::iand inlhe
-- charuea rpipeswithclosed'circult
-,=.:;:::'ealher

9nglne

ol30 298 !

-l
 Operating Media

4.2.1 0uality crade 4.2.2 Wintercrade Fuel

llse commercial brands of diesel fuel with a sulfur Al low tenperalures. waxi.g rnav occJ, ano c,lo
c0ntent of less than 0.5"b. ll the sLlfJr conteot is the 'uel system. causinq opera[i0na. lro_o,e :
h'gher tnan 0.5",. oil change,ntervals s10ul0 oe case 0f sub-1e.0 {+32 "F)ambtent lemperat_r:s :
reduced-see611 's recormended to use wilier-orade o,esct ..-i
(down l0 -15 'C = +5 "f). i\orra,v s-ch ,.r
:
The iollowing specifications / standards are ofered ar the firling stalions in Oood rrme ce,:..
approved: the cold season starts. Dieselluer corlatn -! a- i -
rives (,.Super Diesel'J is ireqLelrly atso on s'd . .:
a CEN EN 5S0 or DIN/EN 590 use at tmperatures down lo -20 "C (-.1 'F
a DIN 51 601 (Feb.]986) aAl ren perarures below -15 "C tr 5
-c,
t. ::
"C l-4 'Fl, ke.osene snourd be aodeJ r: :
a BS 2869 (1988):A1 and A2 d.esel luel. The re.evanr perce4rd0es a.: : ,:.
:-

in the diagram at the noht '

O AST[,4 D975-88i 1-D and 2"D
a NATo Code F-54 and F-75
The xhaust emissi0n levels delermtned during
certification always refer to the reference fuel
specilied by lhe supervisirq authorirrec lor sucf
certilicatlon.
ll summer-grade diesel iLe, has -o :? .;:-. j:
terperatures below zer0 (.32 ,rr. _f r. ::..
kerosene may be added (sFe dtdo-a^ J: :.: . :. :
ln n,oslcdses. a0equale .es.sla-,. r0 :J c : : j I ustration legend:
attained by adding a flow'-pro\e. rlle al: : .:
Ask your seryice representative for th s.

Diesel lueis mLst never be mxed

l\,4ixintankonlyl Fillintheappropriate
with qtrol (n0rmalafd supergrade
amount of kerosene first, then add
the dieselfuel.
t.2 Fuel {.3 cootant 0perating Media

aJ.1

-'
ouality ol water lor coolant
in lhe recirculaling waler
syslem
,2-es
4.3.2 Coolant tleatmenl

the case of liq uid-cooled engines, special attenti0n

4.3.3 Cooling syslem prolectants

I
Listed below must nol be exceeded. ln DEUTZ cooling system protectanls musl be purchased
r tr-:a. ic examine the qualily of your water, a tesl case must be paid to the treatment and control 0l the in drums under order No. 01011490 (5 litrcs) or 1221
:e ordered from DEUTZ under Oder No. 1213 coolant, as the enqine may otherwise becom dam- 1500 (210 lilres). These are nitdte, amine and phos-
=-
:n: aged as a result 0f corrosion, cavitation and f reezing. phatejrce, and provide efiective proteclion against
The treatment of the coolant is carried out by conosion, cavilalion and freezing,
Ihtn max adding a cooling system protectant t0 the coolirg lf ihe above menlioned cooling system protectant is
water. unavailable, the following poducls may be used in
r- .z ,e at 20 'C /68' F 6.5 8.5 The cooling systeff musr be conliluously moni- exceptional cases.
t0red, see 5.1. ln addition to checking the coolant
:;_a..: ion content 100
lever, this also involves checking the c0ncentralion Manulacturer Prcduci deslonation
i-:ra:: ron content 100 of the cooling system protectant. AVIA Antifreeze Extrc
The c00ling system protectant concentrati0n can
-=':rdness ['dGF 3 20 ARAL Antilreeze Extra
be checked with commercially available testers BASF Glysantin G 48
(example: gelo glycomat @).
DEA DEA kylarfrostsskydd
SHELL SHELLGlycoShell

The coolinq system prcleclant in lhe coolanlshould not

fall below or exceed lhe tollowinq concenlr aiion:
Cooling syslem protectant Water

max. 45 Vol. Yo 55%

min.35Vol.% 650/o

Filling volume, see Chapter 9.1.

The lseofolhercooling system protectants, e.g. chemi-
cal anti-co(osion agents, is possible in exceptional
:-e added cases. Consu t DEIJTZ Service.
The use ofafti-conoslon olls ls not pemltted.

: ill ln the approPriate

:s:ne lirst, then add
lf nitrate-based cooling system
protectants are mixed with
amine-based agents, danger-
ous nitrosamlnes are formed. 4ffi11,'i11'rm-r
0perating Media
4.3 Coolant

Cooling Svstem protect on

6ootins
"ffiiapacitv*) I
Protective Protection
agent against freezing to
'18 I 20 22 25 27 30 35
[% by vol.l rcI
Protective agent
ILiters]
35 6,3 7,0
--l 7,7 8,7 5 9,5 '10,5 11 ,2 12,3
40 -28 7,2 8,0 8,8 10 10,8 12 12,8 14i
45 8,1 oo
9,0 11,3 12,2 3,5 14,4
1 15,8
50 45 9,0 10 11 t z,c '13,5 lc 17,5
, ror cootant capacity ofyour engine. see section 9.1.
Note: Consull head-oFfrce regard ng figures in the grey
field.
.3 Goolant Routine maintenance

5.1 Maintenance Schedule

5.2 Maintenance Chafr
5.3 Gompleted Maintenance Johs
H0uilne matnlenance
5.1 Maintenance schedule ,
-
lndustriel engines
Th spcif ed engine maintenatce values arE
perm,ss ble q0.Ine.od nd^ijlLns Depen0rn.
0n usage, reducd malntenance intrvals may be
recessa'/. c0roly ,vrll rhe Ln t ralulactLrer .
0pelatng tlSl'LCIiOTS f l\,,lat1tera1Ce jIUSI Only OE

carried out by authorised serutce prsonnel.

Seclion
6.1.2/3.3.4
6.1.1t61 2

6.2.1 -

622
#
4.2
4.3.1/213

l*
6.4.3/6 4 !
6.7.1
#

6.5.1
#
#

6.3.1/6.3 j
9.2
ie schedult 5.r Maintenance schedule Routine maintenance

ngines
:3nance values : : runnino- ln priod or when c0mmissioning new or
Additions and
axirnums. Depenc.; modilications lor engines
^ce interyals may :E
unit manufactura-:
with EPA approval
in operating hours {otl}every:
:erance rnust onlY :): The specitied engine maintenance values are
i:e personnel. permissible rec0mmended maximums. Depending
0n Nage, reduced mainlenance inlervals may be

-Isr"ti., necessary: comply wilh the unit manufactureas

-TnTrEtI
1611/6 1.2
I l-l-l-lSllears
operatinq instructions. il lllaintenance must 0nly be
caried out by authorised seryice personnel.
6.1.3
16.2.1
16.2.2 int. deoend,no on en0ine a0D.). see TB 0199-99-3002 6.1 .1t6.1.2
l#
lA,
----------l-.li:--
'--t | 43 it2t3

-1- I6 4.3/6.4.r

--t-
lo.z.r
13.3 *
6.6.1
1651
l#

t-
/6^tr
-T63r
-----T- lg'z

l#
o
houllnE malmtsflaflGG b.I Marnlenancescneoule
5-'

0r when commissionino new or overhauled en0ines

Vehicle engines
or during 1st trial run,
Th s0ecltied engine maintenance values are
permissible recornmendd maximums. Depnding
Klomelrage (lm)everyi Seruice 0r0!ps lnnual lilomelrage avenq speed apfior. 0n usage, reduced rnaintenance inlervals may be

Sruice group I
(tm) apDlor.lm/h
necessary; comply wth the unit manufacturels
I <30000 20
> 30 bis 100 000
0peraiing instructions. + l\ilaintenance must only be
ll 40
lll > 100 000 60 carried 0ul by auth0Iised service personnel.

6.1.1/6.1.2 a

H
E
scne0ule
5.1 Maintenance schedule Routine maintenance
rnes
:ire values are
I
I
:-:rk 2x daily be,ore or during 1st trial run, during running- lf neworoverhauld engines
-,ns DependLng I
.
tr.rvals mav be I
I every 200 km or daily

-- manuiactuiers I
]J

: ce must onlY be I

:rrsonnel. I

I section I

I 6.1.2/3.3 4 I

I 6.1.1/6.1 2

---tr6.r.3
I I

16.2.2
l{
1a,
.-+- | 4 3.1t213

t-
| 4.3.214.3.3
16.4.3/6.4.{
l#
167.1
133
I
16.6.1
1651
l#
ln

1631/63r
I
ls.2
l-

-
 H0uItne matntenance 5.1 Maintenance schedulr

r Vehicle engines
Ths specified engine maintenance values ar.
prmissibl recommnded maximurns. DependinO
0n Jsdge. red.lced mdi enance.nle'vats may oi
ncessary; c0mply wiih the ufit fitanufacturrs
operating insfuLti0ls. , \,4d tlenarce nLsl0nry b.
carrid out by auth0rised servlce pers0nnel.

Seclion
6.1.2t3.3.4
6.1.1/6.1.2
6.1.3
6.21

*
42
4.3.1t213

6.4.3t6.4.:
*
6.7.1
3.3
6.6.1
6.5.1
#
 schedule
5.2 Maintenance Ghart Routine Maintenance

lnes --maintenance cha(s shown here are supplied as self-adhesive label with each engine. lt should be affixed where it can be cjeady seen on lhe engine
I t r-'n equipment. Check that this is the casel
:_ince values
-rums. DePendin!
are
lf necessary ask your engine or equipment supplierlor a fresh supply of labelsl Routine maintenance work
tEJd be canied out according to the schedule in 5.'1. E
i lntervaLs may be
,- i manulactureis
,-rnce must only bg

#ffiw
_
: !ersonnel. Ikaflstoff -vorfilter wartunp
Serri., _:j5_t ,+:l_ b=n)s=*g
r=+:-#drfll hL i-+r'- r."a*.*
fuel prefilter Mainteriance
Pr6flltrecombust. xntretien
Ptcflltro.ombust. Mantenimiento
-T6l '?Lr3?

-t= ffiffiffi
*-i\l \
-1;" -d=?1\ffi/&fr 1'

____------:::-
143.1t2t) ..::21 T lLt )
-@@ffi' T--ztf--s-__lf----;_-l
I,*d il2',t ll r&
&truffi
I

l# DEI'TZ
Itr /.1
- --]r;. -
l6 6.1 -
--la.lr
----+;-- v-id5F t4 r.ne. h LmF
chbE d.l.nhlo fi]tuk.

lO.S.tl6.:.r A Srop {he engine

n,";*
berore
out anv maintena4ce A.
E('TZ
-#'-l# 1:\ We move your world. E
 Routine Maintenance
5.3 Completed Maintenance

4
/f
{t

sf,
5r
,
l1i :llp,T,g 9r
n",,
uury compreted maintenance "no
oGil*LJ uns;;;+
jobs can be record;d
sz
and signed off in rhe above tabre.
D4
5.3 Completed Mainter-5 Routine Maintenance

imninghoun Date l-- lHe Senature / StamD

=r-5l
2a75 3II)
31% w
3375 3m0

3625 3750

3875 4m
41% 4m
4375 45m

M 47fi
4f75 5m0

5125 5250

5375 56m

5625 5/50

Duly completed mainienance.iobs can be recorded and signed off in the above table.
]louune MalIlIEnance 5.3 Gompleted Maintenance Jobs

Duly completed maintenance jobs can be recorded

and signed off in the above tabte.
ance Jobt
5.3 Gompleted Maintenance Jobs Routine Maintenance

Dulymmpleted maintenance jobscan be recorded and signed offin the abovetable.

Routine Maintenance 5.3 Gompleted Maintenance

Duly completed maintenance jobs can be recorded and signed ofi in the above table.
 Gompleted Maintenancs Ib Routine Maintenance

Duly completed maintenancejobs can be recorded and signed off in t above table.
 Seruice and Maintenance

6.1 Ebrication System

6.2 Frelffiem
0.3 GoolingSystem
6.4 Gombustion Air Gleaner
6.5 Belt llrives
6.6 Adiustments
6.7 Aecessodes
 uerutce ano Matntenance 6.1 Lubrication

6.1,1 oil change lnteruals

t'
a The first oilchange after commissioning or a lf, for vehicle engines. lube oit change
recommissioning following repair work is intervals are determined by operating hours,
caried out afrer 50 running hours, the lube oil chango intervais indicated in o
for"Oil use under normalduty,
ta_ble 6.'1.1.1.
a The oil change intervals are dependent on
- Lubeoilquality
: willapply.
^
,t
- Sultur content in the tud t
- Engine applilation
-
a Should, within a year, the engine run less than
the hours stated in the table, the oitmustbe
*
changed at least once a year
-=
a The table refers to thefollowing conditions: E
- For dieselfuel max. sulfur content > 0.5 % i-
by wt.
- Continuous ambienttemperature down to
(+14 "F)
-10'c -t
a lfthe sulfur gontent is > 0.5 to > 1 % or the
continuous ambient temperature belory -10 .C
(+14 "fl,the intervals between the oilchanges
should be hah/ed

a ln the case of fuels containing sulfur > .l % ,

ask your srvice represenblive.

Change the oil with the engine ofibut sti warm

(lube oil iemperature approx. 80 .C / 76 "F).
.1
n System
6.1 lubrication System Service and Maintenance

C.1 .1.1 Lube 0il change interyals l0r industrial and marine engines

-ecial DEUTZ release list

S=ndard lube oil code for building
and nonraod vehicles

=ng
tne Engine version Lube oil change intervals in op. hours
sries

. r15
1015C from Nonroad Stufe tt

BF6M1O1sMCP<3OOKW
BF8M101sMCP<400kw
BF6M101sMCP>300kw
BFBM1OlsMCP>4OOKW

_:.:-sels as referred to here are unils operating in parajlel with the mains / with each other.
=-:-gency power units are dealt with in TC 0f99-9S-.1126
Service and Maintenance 6.1 Lubrication

6,1,1.20i1 change intervals lor vehicle engines

Euro l, except for

Euro ll

hours, the lube oil change lntervals indicated in table 4 1 for "oil
tf, for vehicle engines, lube oil change intervals are determined by operating
under normal duty" will aPPIY.
r System
6.1 lubrication S]rstem Seruice and Maintenance
i.I.2 Checkingoitlevet/
Ghanging Engine 0il
i.I.2.1 Checking Oil leyet 6.1.2.2 Engine oil Change

$,
asLrre 4.'1.2.1

20 000
20 000
-oTm
30 000 + 80'C
.!0 000 +176"F
60 000 I

.- for "Oil us
LOI
I

a :nsure that the engine or vehicle is on a
:vel surface.
a nmediatelybeforetheoiitevelismeasured.
:Te engine should shouid be driven at low
r ing speed for approx. 2 minutes.
a:/vitch off the engine.
a tu I out the oil dipstick.
a ,','pe off with a non-flbrous. clean cloth
a -sert up to the stop and pLrll outaqatn.
a :-eck theoillevelan6,J.-.sssarv fll uo to
re 'N4Ax' level
- lf the oil level is jost above the 'MlN'
.narking, extra oil must be added.
--: cil level must !ot fall below the ,'MlN,,
-, ' ng.
a Ensure that the engine or vehicle is on a
level surface.
a Allow the engine to warm up
-Lube oil temperature approx. 80'C.
a Switch off the engjne.
a Place oil trav under the enoine
O Unscrew drain pluq.
a Drain oil.
a F,l o:l dra'n plug. with lhe new gasket and
tighten flrmly (for torque, see 9.2).
a Fillwith lube oil.
For grade / viscosity, see 4.1
For quanlity, see 9.1
a Check oll level, see 6.1.2.1
Be carefLll when draining hot oil -
dangerofscalds! Do not let used oil
run into the soil but catch it in a

-
 Seryice and Maintenance 6.1 Lubrication
6.1.3 Benewing 0il Filtel

a With fitted torsion lock: a Clean sealing surface of the filter carrier if
Loosen .screws and slide clamps necessary.
a Tighten orl fike. cartridge lighfly by giv r; a
downwards. a final half turn
a Lrghtly oil the rubber Qasket of the new orl
a Undo the orl fijter cartridqe witn commerciat
-: I
filter cartndqe. a l{ a lors,on lock ts titled slide clamos .
tool and spin off. a Screw in the rewcartridge fingertighlaqainst
a Catch any escaping oil. into position and tighten screws.
Ine qasket.
a Check oil level, see 6.1.2. a -

a Check oil pressure, see 3.3.1.

a Check seahng of oil fjlter cartridoe fc.

Beware of hot oil: leaks
Danger of scalding!
rn Systen 6.2 Fuelsystem
Seruice and Maintenance

A,

l-58-BrT:.

ightly by givini a Close fuel stopcock. a Clean sealing surface of filter carrier if a 'Ighten
fuel flter crtridge irmly.
necessary
a Undo fuel filter cartridqe with commercial
sride clamps L: tool and spin ofi. a Open fuel stopcock.
icTews. a Apply lightfilm of oit or diesel fuel to rubber
gasket of new tud flter cartridge.
a Catch any escapjng fuel. a Checkforleaks.

a Screw in lhe cadridge fingertight against the

).3.1. gaskeL

ler cadridge f:-

When working on the fuel

system, keep open flames
awayl
Do not smoke! Bleeding ofthe tuelsystem is notnecessary
Service and Maintenanoe 6.2 FuelSystem

Replace ,uel oil leak line 6.2.3 Fuel Pre-rilter Element

Clean/Replace il necessary

Changing the filter element 5:

Change at least once a year or as requirec a
(drop in performance also after pLrrging)
a Turr o'f the engine orswitch to otnerf lter r a
case of changeover filter
a Closethefuelstopcockorsupply (if available
a Loosen the cover screws 3 diagonally
a Remove the cover 2
a Remove the spring cassette 4
a Remove the filter element 5 from the bracke:
a lnsert new filter element 5 a
a P ace spring cassette 4 on the element
a Check that the cover seal is fit properly in the a

cover 2 and check for damage (change ' :

necessary)
a Tlghten the cover 2 with the screws 3
diagonally (torque 6 Nm)
a Check the cover 2 for proper fit and leaks
a Close the iuel shut-off valve. Clean (purge)- remove water: a Bleed the fuel system, see 6.2.3.
a Remove valve cover. a Turn off engine or, in the case of a change-
a Loosen and remove banjo bolts 7. over filter, switch over to the other filter.
a Bemove rubber hoses l, 3, 4, unlons 2 and 0- a Close the fue stopcock or supply. (if
flnqs 6 and dispose olin ac(o dd-ce wilh e1v available)
'onmerlal reguldtions. barjo Lnion 5 an0 0aljo a Open the bleed screw 1 on the cover 2 ll:it> The connection of a warninq syster
bolt 7 can be re-used. a Place the fuel coilector underneath the fuel Dq' (ramp/hom)viacontacts7isspecillec
a Connecl new oil leak ne (conplete/ wilh ballo pre-filter. lmmediate maintenance is necessary whe_
union 5 to rubber hoses. a Ernpty water and dirl from the bowl 6 by the warning system is triggered.
Fasten 0il leak lin using existinO banjo bolt 7 and opening (press in and turn slightly without
two new o-rings 6. using force)the drain cock 8 and close the
a Re-fit valve cover drain cock 8 aqain Naked flarnes are ciohibrre:
a
a
0pen luel shut-oifvalve.
Check for leaks after start-Lt p.
a
a
Close lhe bleed screw 1 onthecover2 again
Bleedthefuel pipe according to irrsiructions,
see 6.2.5 opposite /
/i\' \
^
t*,"*v"Ji'lf, #JI,"
di.ro"" of old fuel in an
"'
enviro -
mentallv 1rrenoly wavl
 6.3Coolingffin Serice and Mainbnance
13.1 Cleanirg lnteruals 631 l-!*!$steat 6.3.3 Filling / Bleeding Coollng
Sfstem

r as requirec
a The degree of soiling of the cooler units is a Fill with coolant and bleed cooling system
dependenton the type of engine appiication. according to manufacturer's instructions.
purging)
r a The danger of soiling is increased due to
) otherfilter residues of oil and fuelonthe engine. Check
extra carefully, therefore. for leakag es when
l_v(if available
applications involve high dust fallout.
iagonallY
a More severe soiling can occur, e.g. in the
case of:
4
mthebrack - Construction site application dueto heavily
dust-laden eir
E element
a ln view of the varying conditions of
application, the cleaning intervals must be
properlyinth
determined from case to case. The cleaning
Ee (change i intervals stated in the table can be taken as
guide values.
sqews 3

rfit and leaks

i2.3.
Checking / Cleaning lntervals a Place tray under drain plug 1.
a Removedrain plug 1 and sealing ring below
Xllues I
Engine Application coolant inlet.
2000 Ships, gensets in enclosed a Drain coolant.
ming syster spaces, pumps a Filling / bleeding as under 6.3.3
s7 isspecified
a Screw on drain plug 1 with new sealing ring
1000 Vehicles on paved roads and tighten (see 9.2).
cessary wher
d. 500 Mobile gensets a Check for leaks.

250 Vehicles on construction sites and

rnpaved roads, Construction
are p-oh-i6iiec
Be careful when drainlng hot
on the fu equipment, compressors, under
qround miningequipment coolant. Danger of scaldingl
r smoke! Catch drained coolant and
elin anenvkoF 125 Farm equipment dispose of in accordance with
antipollution reguiationsl
Service and Maintenance 6.3 Gooling Slstem

6.3,4 Cleaning engine

- with compressed air - with cold cleaning agent

a
I

a Blow compressed air onto enoine
Wash out loosened dirl parti;les from V-
space with waterjot.
a Make sure that drain holes 1 of V-space
al
aSpray engine with commercial cold a Let engine run up to operating
cleansing agent and let stand for about 1O lemperature afler each wet-cleaninq
mln procedure allowing any remaining water
to evaporate, thus avoiding corrosion.
a Then spray clean with strong waterjet (do
not spray water direc y onto sensitive
components such as alternalor, starter,
wiring, electronic components).
a*
=
tr
a Make sure that drain holes 1 of V-space
are lree.

Clean onlywith engine

I sfstem 6.4Comtustion Aikr Service and Maintenance
6.4.1 Cleaning Inteff*

a The degree of soiling of tlE @rhEb,

arr cleaner depends on trE arErt d
dust contained in the air afld fE dE d
the filter used. tf very dusty * b b be
expected. a cyclone-type predaE ca.l
be fitted to the air cleaner.

a Consequenfly, the cleanirE irE \/"als

cannot be fixed generally, bd have tl be
determined from case lo cas-

a When a dry{ype air cleaner is usd. wnen

indi-cated by the service indicaior o,
switch.

a Air cleaner servicing is needed when :

- Service lndicator
the red sector 1 is fully visible when lhe
ling engine is ofi.
*cleaning
maining water - Service Switch
g conosion. the yellow pilot light comes on when the
engine is running.

aAfter having carried out servjce work,

reset the signal by pressing the button of
the service indicator. Ihe service
indicator is ready to resume its function.
Service and Maintenance

6.4.2 Dry-Type Air Cleanel

Dust Discharge Valve

a Check cartridge for damage to fllter paper
(by s1,n 1q I1e paper lhrough with a hght\
ajd rsoJct seal'nq element. Renew l'
necessaray.

a After havinq serviced the filter cartridge

flve liaaes. or after two years at the latest
renew safety cartridge 4 (never clean!).
To do this, proceed as follows:
- [Jndo hex. nut 5 and remove cartridge
4.
- lnsert new cartridge, insert and tighter
hex. nut.

a lnstarl carlridqe 3, place hood 2 back i-

posit on and secllre fastening clamps 1'

a Empw oust discharqe valve 1 by pr"ssing a Release fastening clamPs 1.

apart'lips of discharge slot as indicated by
the arrows. a Take off hood 2 and remove cartridge 3.

a Clean drscharge slot from lime lo time.
a Remove any caked dirt bY Pressrng
together the upper sectior of the valve.
a Clean cartridge, replace at least once a
year.
a Clean cartridge 3:
- blow throdgh w;th dry compressed air
(max. 5 bar) from inside to outside, or
- in difficult cases, lap out, taking care
not to damage the cartridge, or
- wash oLlt according to manufacturer's
instructions.
rGleanel 6.4 Gombustion Air Clea Seruice and Maintenance

6.4.3 Emptying Cyclone-Type a4I *-a 6 ,"* Air Cleanel

Precleaner

to fllter paper
h with a light).
nt. Renew if

ilter cartridge
i ai the latesl
ver clean!).
YS:

Eve cartridge

rt and tighten

)od 2 back in
E clamps'1.

a Undo wing nut 'l and remove covea 2.
a Remove collector bowl 3 from lowersection
4 and empty. Remove leaves, sbaw and
other foreign matter from lower section of
precleaner
a Reposition collecto. bowl3 onto lowersection
4, fasten cover 2 in place bytightening wing
nut 1 a
a Tum engine off and wait about 10 minutes
for the oil to drain from filter housing 1.
a Release snap clips 2 and remove oil cup 3
together with filter element 4. lf.ecessary
press element outwith a screwdrivea laking
care not to damage rubber gasket 5.
a Remove dirty oiland sludge. Clean oilcup.
Clean filter element4 in dieselfueland allow
to drip-dry.
a Clean filter housing 1 if very dirty.
a lnspectand replace rubbergaskets 5 and 6
if necessary
a Fill oil cup with engine oil up to the mark Never clean air cleaner with
(arrow) (for viscosity, see 4.1.2). petrol (gasoline)!
a Refit oil cup and element lo frlter housing Dispose of old oil in accorrdance
and secure with snap clips. with anti-pollution regulations!
Service and Maintenance 6.5 Belt Drives

6.5.1 Checking Alternator V-Belt 6.5.2 Retemioning / Renewing

Alternator V-Belt

Checking -Read off the valuer Turn the gauge Retensioning

a lnspect entire V-belt for damage sideways to see the exact spot where the a Slacken hex. bolts 1, 2 and 3. I
a Renew damaqed V-belts. top of the black rndicator arm '1 intersects a Turn lock nut2 in direction A untilconect .-
a After installing new belts, run engine for 15 scale 5 (arrow). For settings, see 9.1. belt tension is attained. a
minutes, then check belt tension. -lf necessary retension belt and measure a Tighien bolts '1, 2 and 3.
a Use a belttension gauge (see 9.3)tocheck agarn. a
belt tension.
-Place indicator arm '1 into gauge.
-Position gauge on V-belt 2, midway
between the pulleys, with flange 3 on
bottom of gauge against
the edqe of bell.
- Press slowly on the black pad 4 at right Check / retension and renew
angles to belt2 untilthe spring is heard or
felt to trigger. V-belts only with the engine off.
Refit bell guard, if provided.
- Carefully remove the gauge without a\ering
the position of the indicator arm 1-
 6.5 Belt 0dves Seruice and Maintenance

*aEiirE
a Slacken hex. bofts '1
, 2 and 3.

a Tum lock nut 2 in direclion B as fur as it will go.

Now the new V-belt can be easily placed in
position.

a lghten bolts 1,2 and 3 until correct V-belt

bnsion is attained (see Seclion 6.5.1 ).
Service and Maintenance 6.6 Adjustments

6.6.1 Checking / Adiffiting Valve

Clearances

\
a Before adjusting valve ciearance, allow a Check valve clearance 1 between rocker
engine to cooldown forat least 30 minutes. arm/tappet contact face 2 and valve stem at
The oil temperature should be below 80 'C 3 with feeler gauge (there should only be a
(176 "F). slight resistance when feeler b'ade is
a Position crankshaft as per schematic, see inserted).
6.6.1.1.
a Slacken bolts 1. For permissible valve clearance, see 9.1.
a Remove rocker cover2 togetherwith gasket
3.
.C
-.

at
:i
 Adjustmerts Seruice and Maintenance

a lf necessary, adjust valve deaiance as

follows:
- Loosen lock nut 4 using wrench 7.
- Adjust set screw 5 by means of
screwdriver 6 in such a mannerthatwith
lock nut 4 tightened (wrench), the
conect valve clearanc 1 is attained.

a Check the valve clearances at each ofthe

remaining cylinders and adjust if
necessary

a Refit rocker cover (together with new

gasket if necessary).
 Seruice and Maintenance 6.6 Adjustments

]ilffi
I
Firing Order BFGM 1015: Firing Order BFSM 10't 5:
Al -83-A3-82-A2-81 41 - B4-A4- Bl - 83 -A3 - 82 -A2

Adjusting
ilmenb I u.roo;uo,nr* Service and Maintenanoe

a Adjuslment
Tum crankshaft according to sequence
shown in the diagram (starting with cyl. l).
The valves of the relevant cylinder overlap,
marked in white, (exhaust valves aboutto
A1 MA3 A1 A2 A3 A4 close, inlet valves about to open). Adjust

f&\
\L clearance of valves, marked in black,
according to schematic. lvlarkthe respective
rocker arm with chalk to show that the

A adjustment has been done.

tr!
trtr

A1 A2 A3

fx fx
A4
Seruice and Maintenanoe 6.7 Accessories

6.7.1 Battery
6.7.1.lchecking Battery 6.7.1.2 Checkirg Electrolyte Lsvel 6.7.1.3 Checking Speciric cravity
and Cable Connections
o, Electrolyte

t
L

' N.4

9r

a Keep battery clean and dry.
a Undo soiled terminals.
a Clean battery plus and minus poles and
terminals and apply a film of acid-free and
acid-resistant grease.
a When reconnectJng, ensLlregood contaclol
terrinals. Faslen oa.rpi'lg bortsfingertignt.
a Remove cellcaps 1.
a lf electroly,te test elements 2 are fltted:
The levelshoujd be h,gh enoLrgh lo wel the
bottom of these
a lf no such elements are provided :
Check to make sure that the levet is 1O-.15
mm above the top edge of the plales.
a Top up with drstilled water if necessarV.
a Flt cell caps back rn position.
a l\4ea su re the specific gravity ofthe individ u a I
cells with a commercial hydrometer
The measured values (see adjacent table)
indicate the state of charge of the battery
During the measurement, the temperature
ofthe electroly,te should preferably read 20
"C
 6.7 Accessode SerYice and Maintenanoe

$* Gravity

in lks/ll fBe (degErs Bard) State of Charge

Normal Tropics tffi Trotb

1.2A &. z7 Fully charged

1.20 1.12 21 16 Half charged, recharge

1.12 1.08 16 't'l Discharged, charge up immediately

' MeasurementoftEspe&grdveyh"86(de-
ot6#ad riEay used bd4/.
glees Baurne)'E

heindividual
rEter
ircent iable)
'the battery
hmperature
$ly read 20

The gases emitted by the battery

are explosive! Avoid icrmation of
sparks in the vicinity of battery
keep away any open iarnes!
Do not allow acid to come into
contacl with skin or clothing!
Wear proteclive gogglesl
Do not place tools on battery!
Service and Maintenance 6.7 Accessories

6.7.2 Three-Phase Alternatol 6.7.3 litting Tackle

Notes on the three-phase syslem:

aWhen the engine is running, never
disconnect the cables beiween battery
alternator and regulator.
a Where itis, however, necessary to start and
operate the engine without battery,
disconnect the regulator irom the alternator
before starting.
a Be sure nol to confuse the battery terminals.
a Renew a defective charging pilot light bulb
immediately.
a Engine cleaning: Do not splay with water/
steam iet directly against alternator!
Warm up engine to allow water residues to
evaporate.
a Do no loosen connecting cable between
battery ald alternaior during engine
operation.
a The habit of touching a lead against frame a Fortransporting the engine, always use the
to check whether it is live must under no proper lifting tackle.
circumstances be applied with a three-phase a Remove lifting tackle.
electric system.
a ln case of electric welding, connect the -Do notsiartengine with lifting tackle fitted.
earth terminal of the welding unit direct to
the part to be welded.

use the proper riftins

f\fl},:r
, Trorbledrootihg
Troubleshooting 7.1 Diagnosis Ghart

a lt engine problems occur, they frequenfly have

their cause in improper operation or
maintenance of the engine.

a So. in case of lrouble, always check first

whether the operaling and maintenance
instructions have been observed

a A helpful Diaqrosis Chart is to be found on the

opposite page.

a lf you cannot identi, the cause of the trouble

or are unable to rectily il yourselt. contact your
service representative.

Before starting, make sure that

nobody isstanding in the
immediate vicinity 0fthe engioe or
driven machine.
After repairs:
lmporlant Never slart elgine wilh the speed
0ovemor rEmoved.
DisBonnect battery telminals!
scrrartf 7.1 Diagnosis Chart

I
Troubles Remedial Measure
to stari Check P
bLi rur$ o. sEl6 Adjust E
bo iEt tpmpe{a'oJre monitor
e becomes gives waming (coolant) Renew W
EnS!!_Cryspoo.E@nnanc _ Clean R
tngin. not*kingraffi Top up A
E
-"*r"r,td."* Lower level S
Er,-or 09._911_99!!!mprg!_!xc$!ye Bleed L

"t
I causes Section l
a Not decldched (declutch where possible) 0peration P
a Below start limit temperature P
a Engine shutdown leverstill in stop position (shutdown solenoid defective) P
a a aE oi evettoo high P
a oittevettoo tow s
a aIaf kcessiveinctinationofengine PIE
a Speed control lever set to middle position PIE
a a .1.I. Dirty air cleaner/ defective tu6ocharger Combustion Ak P/W
a a a Air cleaner service switch/indicator defective P
a a
- LDA- delective (leakinq line) P
a a a Charge air pipe leaking Plw
a Coolant pump defective Cooling System P/R
a a a Chaee air cooler dirty P/R
a Coolant heat e^changer dirty P/R
a Coolant thermostat does not open P
a Battery defective or discharged Electrics P
LDA = manifold pressure compensator Table 1 of 2
Troubleshooting 7.1 Diagnosis Ghart

Troubles Remedial Measure

fails to start Check P
but runs orstalls Adjust E
becomestoo monitor Renew W
En tne Clean R
noi on all Top up A
ine has little or no oilpressule Lower Level S
ine oil consumption excessive Bleed L
Engine smokes - blue

- white
- black
,, Section
a Cable connection to starter loose or oxidized Electrics P
a Starter defective or pinion does not enqage P
a a a . ffiffi&ffig . o lncorrect valve clearance Engine E
a a a a

ffi
Leaking iniection line P
Vent pipe cloqqed (coolant heat exchanqer) P la
Flame-type heater piuq system defectiye P
a a a a .ffi. a lnjector defective P/W
a a a a Air in fuelsystem (lack offuel) PIL
a a a a Fuel f ilter / prelllter conlaminate P/R/W
a a lncorrect lube 0ilSAE class or quality qrade 0perating llledia W
a a xffi . &ffiffi. Fuelquality grade not corresponding io specification under 4.2.1 P/W
a lack of coolant PIA
b Ghart
Engine Preseryation
krre
P

tll
R

A
8.1 Preseruation
s
L

P
P
E

P
P/E
P
P lw
P IL
P/B/!X
Edia w
Plw
Pt^
 Engine Preservation 8.1 Preservation

8,1 Preservation

lf the e0gine is t0 be shut down for an extended

period, it is necessary t0 take preservaU0n
measures t0 prevent rust formation. The
preservation measures described here wr I 0'otect
the ergine for a per:od 0t up lo dbout 6 n;onrns.
Before .eusing the enq ne, .e Dreservdtives must
be removcd

a Anti-corr;si0n oils to Specification:

- t\,,fl1-L 212608
- TL 9'150-037/2
- Nato Code C 640 / 642

a Becommended cleansitg agent t0r removing

preservattvPs:

- Petroleum berzine {hazardous maleria,s

class A3)

Preserving the E[gine:

aClean engine (in case ol need with c0ld
a Run engine ior about 10 minutes. a Drain oif anti-corrosion agent, see 6.3.3.
cleansing agent). a Stop engine.
Bemoving EIgine Pteservatives:
Clean cooling sysiem accord,rq -o
a Turn enqine severaltimes bv hand.
manufacturels inskuchons. Wnen r",ning engine w.th slarter, luve a Remove antr-cot'os'on agent ton the grooves
a Run engine untilwarm and stop. shutdown lever lo slop posilion. ofthe V-belt p!lleys.
aDrain engire oil, see 6.1.2, and fill in anti- a Re.n0ve V-bett 2 and sto,e in wraoDed
corrosion oil cnnditinn
a Fit V-bek 2. Belension. i'necessa.y, atter shorl
period ot operation, see 6.5.
a Drain coolant, see 6.3.3.
aSpray qrooves oi V-!elt pu eys with alti-
a Fill in anti-corrosion a0ent, see 4.3.3. aRemove plugs 1,3 and 4 and plug kom
a Clean oil bath a,r cleaner, r,p.ovided. see 6 4.J, exhaust discharge opening.
and fill in anti-corrosion oil O Ctose .oota,tt inter and our,pr open,nqs 3 a-0
a r inta[e opening 4. a Fill in coolant according t0
a Drain iuelfrom tank. instructions 0f
radiator manulactu rer.
a Prepare a mixture of 90% dieselfuel and a C ose exhaust discharge openino.
i0%
ant -corrosion oil and iill up tank. a Slart up engine.
 $pecification llata

9.1 Engine Specilications and Settings

9.2 Torque Wrench Settings
9.3 Tools

| 6.3.3.

n the 0rooves

ry. after short

d plug kom

6lructions of
 Specilication Data 9.1 Eilgine Specifications and Settings

lvlodel 1015 BF6t\,,1 1015 BFSM 1015 8F6M 1015 C/CP# BFSM 1015 C/CP#

Number of cylinders
Cylinder arrangement c
90" Vee-anole
Bore c
Imm] 132
Stroke lmml P
145
Total displacement
Icm'l 11906 15874 T{
Compression ratio lel c(
WorkinO cycle / combustion systm TI
4-stroke TC enoine/direct injection
Direction of rotation TT
counter-clockwise

Weight incl. cooling system lapprox. kol Co

Consult headquarlers
Weight Mo cooling system acc. to DtN 70020-A
Iapprox. kgl 1060 830 1060 De
Engine power tkwl 250-3201) De
228-3001) 304-4001)

Speed
Irpml Lul
Valve clearance, enoin cold 5)
lmml inlet 0.25 .ol / exhaust SA
lnjector opening pressure lbai 290 bat Mir
Commencement ol delivery rCA BTDC] ,) atl
Firing order 1-6-3-5-2-4 1-8-4-5-7 -3-6-2 1-6-3-5-2-4 1-8-4-5-7-3-6-2 0it
A1-83-A3'82-A2-81 At-84-A4-81,83-43-82-A2 A 1 -83-A3. B2-A2- B I A1 - 84 -A4,S1 -83-A3-82,A2 0ir
V-belttension:
tension / retension r) Olr
Alternator 55 amperes tNl 450 / 200-350'50
Altemator 120 amperes IN] 550 / 300-450 '50

1)
Engine power, speed, commencement of delivery, etc. are stamped 0n the rating ptate, see
2..t.
2)
Retension aiter running for 15 minutes under load.
Ettings
9.1 Engine SedficC- - Scnirgs Speeification llata
5 C|CP#
Model 1015 BF6M '1015 BFSM 1015 BF6M 1015 C/CP# BFSM 1015 C/CP#

Bl Cooling system
/ cooling system
Coolant quantity lil] 21 t MtK.
lapprox- 21 I MFK"

Perm. cont. coolaflt temperdrre ErIiE qJ gt

rcl
874
=
Temperature ditf ereflc
coolant inlet/ outlet
biEl
I
rcl
Thermostat starts opeoiE d rc1
Thermostat fully opfl frun rcl
Coolant pump

60 Delivery pressure in
lbarl
po') ]
Delivery rate in
lm%l

Lubrication
SAE oil (see 4.1)
l\4in. oil pressure with engine warm (120 .C)
= at low idle / rated speed lbarl
:1-3-6-2
-*"nr* |
0il capacity (initial flling) withoutfilter lapprox.lit.l
0il capacity (iflitialfilling) engine-mounted filter Iapprcx. Iit.l
oil capacity (initial lilling), separate filter lapprox. lit.l
|

3) Approximate figures
can vary depending on the design. oecisive is always lhe 0p[er dipstick mark.
4) 3 baratengine
speed n = 2100 rpm'
5) see 6.1.1 (only synthetic
lube oil, see 4.'1.2.1)
* Mr(
Enoine radiator
Specification Data 9.2 Torque Wrench Settings

Preloading [Nm] TighteninO [" deo.]

Tolal
Location lst 2nd 3rd 1st 2nd 3rd 4th Notes
lxml
Staqe Sta0e Stage Staoe Staoe Staqe Staoe

Rocker cover 22

lnspection Cover 22

Rocker arm setscrew 20

rigid mounling 30 45

flexible mounting 106

Air iniake manifold 21

Exhaust manifold

0ildrain plug 100

The
ord
lnjector mounting 60
Fa.
lnjection line mounting Pos
D-4
0ilpan 24

engine mounted
0il filter cartridge 27
or separate

Coolant drain plug 38

Pin-type heater plugs / pipe union 4

9.3lools Specificatior Daila
V-belt Tension Gauge

The V-belt lension gauge can be obtained und8r

order number 8115 fiom:

FA. WILBAR
Posthch 140580
D-42826 Remscheid
 ilotes

CAUF0R TA PRopostTt0il 65 l F0RMATIor{

f o GALIFoR tA cusroMEns At{B

TO GUSTOMERS SEttI G OIESEI EI{GII{E EQUIPMEIIT I TO OR
FOR UsE III GATIFOR IA.
PropositicT 55 a Caitornia law. requires warnings on products which expose individuals in California to chemicals listed under that law,
including car-:. - :-an'r cals in diesel engine exhaust.
0bligations ol Iaarfasur6 ol Diesel-Powered 0ll-Boad Equi0ment. The California Superior Court has approved either of the following
two methods .'i rtrEDliance with Proposition 65 requirements by manufactures ol off-road equipment containing diesel engines. (The court
order coniajr "! trese provisions is attached.)
1 . 0 n-Eou iomefll Wa rn ing. Place the warn ing pictu red in attachment 1 0n all eq u ipment shipped by you into or lor sale in Calilorn ia after
Januat '1996. 'l-he v/arning
1. must be in a iocation where it is easily visible to the operator o.f the equipmenl when (s)he is operating the
equiprnem- Tle ,,,rarning must be secured to the equipment. lf warnings or operating instructions are provided thr0ugh a digital display,
you mar' usee tiat method of providino warning.
2. 00erator ilan0al Warning. When the operaior manual is next rvised or by December 31, '1995 whichever is earlier, place the warning
in attachrEnt 2 ir the operaior manual. The warning may be either printed in the manual or on a sticker.

The wamixg rnust aDpear in one 0f the jollowing locations:

. lnside The front cover
. lnside the back cover
. outside lhe front cover
. outside the back cover
. As the first page of text
Under either alternative. the warning must appear in the same size, printand tormat as the attachment selected or be of an equally conspicu0us
size and format. lf the warning is provided in an on-screen display, the warning must contain the lanOuaqe in the attachment and must be
provided at the lime of 0r in connecti0n with ignition in the same manner as other safety warnings electronically communicaled on screen.
0bli0ati0n oJ Resellers 0{ Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, piease call Deutz Corporation Product Supp0rt Department.
l{otes

lllarnings to Place on Equipment

Warning in the Manual

GALIFORIIIA
GAI.IFORIIlA
Proposition 65 Warning
Proposition 65 Warning
Diesel engine exhausl and some 0l its
Diesel engine exhausl and some of ils
constituenls are known lo lhe State ol
c0nstiluenls are known l0 lhe Slale 0,
Calilornia to cause cancer, bi h
Calilornia lo cause Gancer, birth
delects, and olher repr0duclive harm.
defects, and olher repr0duclive harm.

0l

cAUF0Rl{tA
E
Proposition 65 Warning
Diesel engine exhaust and s0me o, its constituents are known
to.the State of Calilornia Io cause cancer, birth delecls, and _.!

olher reproductiue harm.

-
 :-
DEUTZ OiI

Wffi

A
DEUTZ Oit DQC il-05
ACEA E5,02 / E3-96 / 83,04
DEUTZ Oit DQC ilt-05 DEUrZ Oil DQc lv-0s (Synthetic)
ACEA E7-04 / E5 02 / E3-96184-04 /A3-04 ACEA E7 04 / E5-02 / E4 99
AP CG4 APIC 4 / SL GLOBAL DHD 1

TLS.15W4OD
DQC il-05)
orurz Oet
DEUTZ tv-swio
oOC lV-5W30
Oel DQC I
(DQC IV-05)
0101 633 5L
20L 0101 6332 20 I 0101 7849 I
209 L 0101 6333
2!91_ 01012!t0 ]
 t

DEUTZ AG
DEUTZ MOTOR
OttostraBe 1

D-5u49 Kiiln
Telefon: +49 (o) z zr-8 zz-o
Telefax +49 (o) 2 21-8 22-58 50
Internet: www'deutz.com
eMail: irtfo@deutz.com

kinted in Germany
All rights reserved

DEUTZ Theenginecompany.
6th Edition, O o5l2oo3
order No.: 0297 9684 en

!
I