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Service Training

Engine Series
DEUTZ 1015

DEUTZ AG
Service Engineering
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Course-attendant trainee documentation
for service training

Product-related engine technology

engine series DEUTZ 1015

Property of:

Attention:

This course attendant trainee documentation is conducive for effective explanation and
illustration about the contruction and function of engine, components and systems. The
contents of figures are only according to the date of printing actual documentation and
are not subject to be updated.
Obligatory upon operation, maintenance and repair are only the engineering data
and intructions of the actual technical printed material such as operation manuals,
workshop manuals, adjusting- and repair-instructions, technical circulars and ser-
vice bulletins.
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Table of contents

Table of contents ......................................................................................................................0-1

1. Engine plan ....................................................................................................................1-1

1.1 Technical data ...................................................................................................................1-1


1.2 Engine view........................................................................................................................1-2
1.3 Model designation ..............................................................................................................1-6
1.4 Nameplate and engine serial number................................................................................1-7
1.5 Cylinder numbering............................................................................................................1-7
1.6 Description of nameplate...................................................................................................1-8

2. Design structure ...........................................................................................................2-1

2.1 Cylinder..............................................................................................................................2-1

2.2 Drive system......................................................................................................................2-2


2.2.1 Connecting rod ..................................................................................................................2-2
2.2.2 Piston.................................................................................................................................2-3
2.2.3 Piston cooling ....................................................................................................................2-4
2.2.4 Crankshaft .........................................................................................................................2-5

2.3 Cylinder head.....................................................................................................................2-6


2.3.1 Design structure ................................................................................................................2-6
2.3.2 Valves ................................................................................................................................2-6
2.3.3 Valve clearance adjustment ..............................................................................................2-8
2.3.4 Determining cylinder head gasket .....................................................................................2-9

2.4 Gear drives ........................................................................................................................2-12


2.4.1 Vibration damper side........................................................................................................2-12
2.4.2 Flywheel side .....................................................................................................................2-13

3. Lube oil system .............................................................................................................3-1

3.1 Lube oil circuit....................................................................................................................3-1


3.2 Lube oil pressure ...............................................................................................................3-2

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4. Fuel system.................................................................................................................... 4-1


4.1 Fuel circuit......................................................................................................................... 4-1
4.2 Setting the commencement of delivery ............................................................................ 4-2
4.2.1 Electrical setting unit for the commencement of delivery................................................. 4-4
4.2.2 Fixing pin ........................................................................................................................... 4-6

5. Cooling system............................................................................................................. 5-1


5.1 Cooling circuit.................................................................................................................... 5-1
5.2 Coolant .............................................................................................................................. 5-2

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1. Engine plan

1.1 Technical data BFM 1015

BF6M 1015 BF8M 1015


BF6M 1015C BF8M 1015C

Number of cylinders / arrangement 6 / V – 90° 8 / V – 90°

Bore [mm] 132

Stroke [mm] 145

Displacement [ltrs.] 11.9 15.9

Working cycle / combustion system Four-stroke diesel with direct injection and
exhaust turbocharging.

Firing order 1-6-3-5-2-4 1-8-4-5-7-3-6-2

Direction of rotation When facing flywheel counter-clockwise

Rated speed [rpm] See engine nameplate

Power [kW] See engine nameplate

Valve clearance: Inlet / exhaust [mm] 0.25 / 0.3

Commencement of delivery See engine nameplate

Injector opening pressure [bar] 290+8

Engine lube oil system Forced-feed circulation lubrication

Min. oil pressure [bar], at low idling and with war- 1.0
med-up engine (120°C oil temperature)

Type of cooling Liquid-cooled with integrated oil cooler.

Thermostat opens at: [°C] 87


fully opened at: [°C] 102

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1.2 Engine view

A – side, 6 cylinders

Bild 1015-0001a

1 – Oil filling socket 10 – Vibration damper


2 – Cylinder head 11 – V-belt pulley
3 – Exhaust manifold 12 – Alternator
4 – Adapter housing 13 – Coolant outlet to cooler
5 – Crankcase 14 – Engine shutdown solenoid
6 – Starter 15 – Flame plug
7 – Oil pan 16 – Coolant pump
8 – Lube oil filter 17 – Lube oil cooler
9 – Coolant inlet from radiator

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B – side, 6 cylinder

Bild 1015-0001b

18 – Charge air line 22 – Flywheel


19 – Oil dipstick 23 – Exhaust turbocharger
20 – Oil drain plug 24 – Injection pump (in engine V-space)
21 – Adapter housing 25 – Flame plug

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A – side, 8 cylinder

Bild 1015-0002a

1 – Exhaust turbocharger 8 – V-belt pulley with vibration damper


2 – Exhaust manifold 9 – Coolant inlet from cooler
3 – Crankcase 10 – Lube oil cooler
4 – Starter 11 – Fan
5 – Oil filling socket 12 – Charge air line from charge air cooler
6 – Oil pan 13 – Charge air line to charge air cooler
7 – Lube oil filter 14 – Flame plug

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B – side, 8 cylinder

Bild 1015-0002b

14 – Flame plug 19 – Adapter housing


15 – Oil filling socket 20 – Flywheel
16 – Cylinder head 21 – Compressors (option)
17 – Alternator 22 – Connections fuel lines
18 – Oil dipstick

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1.3 Model designation

B F 8 M 1015 C/P

Uprating

Charge air cooler

Piston stroke in cm (approx.)

Serial index

Liquid-cooled

No. of cylinders

High-speed 4-stroke engine

Exhaust turbocharger

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1.4 Nameplate and engine number

In the case of series 1015, the nameplate is affixed to the crankcase left-hand side (B-side) above
the vibration damper. Above the nameplate, the engine serial number (2) is stamped again into the
crankcase. For engines from about 02/2000, the engine serial number is stamped in on the front A-
side besides the threaded bore of the transport eye, visible from above (3).

The engine model (1) and the engine serial number (2) must be indicated when ordering spare
parts.

Bild 1015-0003a

1.5 Cylinder numbering

• The cylinders are numbered beginning at the flywheel end. For engines with V-shaped ar-
rangement of the cylinders, the cylinder number is added one letter for the respective cylinder
line (seen from the flywheel).

Left cylinder line = A Right cylinder line = B

• Facing the flywheel, the sense of rotation of the engine is counter-clockwise.

Bild 1015-0006

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1.6 Description of the nameplate

Bild 1015-0008

Item Description Remark

1 Engine model e.g. BF8M 1015 C

2 Engine code For engines certified according to the Commission's


directives 88/195/EWG .

3 Engine serial number -

4 Commencement of delivery COD in ° C/A

5 kW (G) "Total power" , fan not running

6 kW (S) "Continuous power" , fan completely running

7 ISO

8 ISO

10 1/min Rated speed of the engine.

11 1/min

12 kW (G) red. Reduced "total power", on-site conditions items 14,15.

13 kW (S) red. Reduced "continuous power", on-site conditions items


14,15.

14 Air temperature in °C For ambient conditions on site.

15 Altitude above sea level in m For ambient temperatures on site.

16 For free disposal

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2. Design structure

2.1 Cylinders

The cylinders of series 1015 are executed as wet liners which are only available with the standard
bore of 132 mm. At the cylinder liner collar (1), metal is sealing against metal.

At the liner foot, in the crankcase, two O-rings (2) are installed which are functioning as seal be-
tween coolant and crankcase interior.

3 – Piston cooling nozzle


4 – Drain screw for coolant in the engine block.

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2.2 Crankshaft assembly

2.2.1 Connecting rod

The connecting rods of series 1015 are forged and, for increasing the resistance moment against
being bent, they include a concave rod part. In view of the different crankshaft versions between 6-
and 8-cylinder engines (see chapter 2.2.4), the connection rods are different. At its base, the con-
nection rod of the 8-cyliner engine is provided with a unilaterally distinct contact surface.

The connection rod bearing shells are different on their rod- and cover side and must not be ex-
changed by mistake. The rod-side bearing shell is a sputter-type bearing and is dark-eloxed on its
back.

A – 8-cyliner
B – 6-cyliner

Bild 1015-0011

When assembling connecting rod and piston, it must be


made sure that the concave surface (1) of the connecting
rod is showing to the side where the recess (2) for the cool-
ing oil nozzle is arranged at the piston.

Connecting rod and cover are forming pairs. The pair num-
bers of rod and cover must be on one side when installing
the conrod.

Bild 1015-0012

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2.2.2 Piston

The pistons of series 1015 are of cast aluminium alloy. The piston bowl is arranged centrally.

The pistons are equipped with 3 piston rings. For the 1st ring, the piston is provided with a ring car-
rier of steel.

The cross section of the 1st piston ring is asymmetrical (trapezoidal ring). The cross section of the
2nd piston ring is conical (compression ring). When installing the piston, the TOP mark at the ring
gap must point upwards. The 3rd ring is the bevelled-edge oil control ring (oil scraper ring).

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2.2.3 Piston cooling

In the interest of thermal relief, the pistons are cooled with lubrication oil via piston cooling nozzles.
The nozzles are bolted to the crankcase and must be aligned with a special tool.

Every nozzle comprises a spring-loaded ball valve opening at 0.8 – 1.1 bar. It is arranged in the
banjo bolt.

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2.2.4 Crankshaft

The crankshafts of series 1015 are forged and have bolted balance weights.

The crankshaft of the 8-cylinder engine (A) has continuous bearing journals as the firing distance is
identical to the V-angle of the engine, i.e. 90°.

As the V-angle of the engine is 90°, the firing distance of the 6-cylinder engine however is 120°, the
6-cylinder engines are fitted with a "split-pin" crankshaft (B) to balance the resulting vibrations.

In the case of this design – as common for V-engines – two opposite connection rods are acting on
one bearing journal. At this crankshaft (B), the bearing journal for both connection rods is shifted by
30° in itself. This is the difference between 120° (firing distance of the 6-cylinder engine) and 90° (V-
angle).

.
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2.3 Cylinder head

2.3.1 Design structure

The cylinder heads of series 1015 are made of grey cast iron. The cylinder head base is plain. The
injector (6) is protruding by about 5 mm over the planed surface; therefore, it is not permitted to
place the cylinder heads on this surface with installed injectors.

2.3.2 Valves
Every cylinder head has tow inlet an two exhaust valves. Inlet- and exhaust valves are differing in
their geometry.

Exhaust Inlet

Bild 1015-0015 Bild 1015-0016

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During the installation, the rocker pedestal must be aligned as directed in the workshop manual.
Every rocker (1, 3) has two rocker arm tappets at the end of which the setting screws (2) for the
valve clearance are arranged.

The rocker shaft and the rocker arms are lubricated via the inlet rod (9). In position (4), the oil return
to the crankcase is arranged.

Bild 1015-0017

1 – Inlet valve rocker arm


2 – Setting screws
3 – Exhaust valve rocker arm
4 – Oil return
6 – Injector
8 – Outlet rod
9 – Inlet rod

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2.3.3 Setting the valve clearance

A wrong valve clearance can entail damage to the engine due to thermal and mechanical overload.
Therefore, it must be checked at specified intervals (see operation manual) and newly set, if re-
quired.

The valve clearance must be checked and set at an oil temperature of <80°C.

Valve clearance: Inlet 0.25 mm Exhaust 0.3 mm

For setting the valve clearance, follow the table given below:

BF6M 1015

Cylinder 1 2 3 4 5 6

Overlap A1 B3 A3 B2 A2 B1

Setting B2 A2 B1 A1 B3 A3

BF8M 1015

Cylinder 1 2 3 4 5 6 7 8

Overlap A1 B4 A4 B1 B3 A3 B2 A2

Setting B3 A3 B2 A2 A1 B4 A4 B1

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2.3.4 Determining cylinder head gasket

The distance between cylinder head and piston base in the top dead centre position of the piston is
decisive for the compression ratio and, hence, for:

• power
• specific consumption and
• exhaust gas quality.

This distance is set via the thickness of the cylinder head gasket. In this way, the manufacturing
tolerances of the crankcase (T1), the crankshaft (T2), the connection rod (T3) and the piston (T4)
are balanced.

Bild 1015-0018

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There are cylinder head seals of three different


thicknesses. They are characterised by one, two or
three holes (1). The holes (1) of the used seals are
arranged such that they can be recognised also with
mounted cylinder head.

Bild 1015-0019

Measured is the distance from the cylinder liner collar to the piston base in the top dead centre posi-
tion of the piston. Here, the size of protruding of the cylinder liner collar over the crankcase surface
is considered for the measurement. To avoid measuring errors, the liner must be fixed.

To perform the measurement, a special tool is available, which has been designed according to the
design characteristics of series 1015 (see picture 1015-0020).

It comprises two standard dial gauges (2), a measuring device (3) and a ground setting plate (1) for
the zero calibration of the dial gauges (2). Prior to every new measurement, it should be repeated
and, in any case, upon the least doubt of its permanent correctness. During the measurement, the
measuring device (3) is centred with the two adapter pins of the water passages (4) from the
crankcase to the cylinder head and kept in position.

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Bild 1015-0020

In the top dead centre position of the piston, the values are read from both dial gauges and the
arithmetic mean value determined.

Example: 1st dial gauge 0.39 mm


2nd dial gauge 0.45 mm
resulting in 0.84 : 2 = 0.42 mm

This average value (0.42) must be compared with the following table and the cylinder head gasket
can be determined.

Piston projection Identification of the cylinder


(average) head gasket

- 0.05 - 0.10 mm 1 hole


>0.10 - 0.30 mm 2 holes
>0.30 - 0.81 mm 3 holes

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2.4 Gear drives

Series 1015 has a gear drive at each engine side.

2.4.1 Vibration damper side

The gear drive on the vibration damper side is arranged in the auxiliaries carrier and comprises the
following drives:

1 - Raised fan drive i = 0.96 or


Raised fan drive i = 1.36
2 - Coolant pump
3 - Idler gear
4 - Lube oil pressure pump
5 - Crankshaft
6 - Lube oil intake pump (oil-pan dependent)
7 - Auxiliary PTO, e.g. for hydraulic pump, raw water pump etc.

If the fan is driven by the crankshaft, the raised fan is omitted. The transmission of the raised fan is
realised by the arrangement of its drive gear at the idler gear.

Bild 1015-0021

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2.4.2 Flywheel end

The flywheel-end gear drive comprises:

1 – Injection pump drive


2 – Idler gear
3 – Auxiliary PTO, e.g. for air compressor
4 – Camshaft gear
5 - Crankshaft
6 – Auxiliary PTO, e.g. for air compressor
7 – Idler gear

Bild 1015-0022

Camshaft- and crankshaft gear comprise marked teeth for setting the control times.

One of the marked teeth of the crankshaft must fit between the two marked teeth of the camshaft.

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NOTES

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3. Lube oil system

3.1 Lube oil circuit

Bild 1015-0030

1 - Oil pan 16 - Tappet with pulse lubrication


2 - Intake pipe 17 - Pushrod, oil supply for rocker
3 - Lube oil pump lubrication
4 - Pressure relief valve 18 - Rocker
5 - Lube oil cooler 19 - Oil return bore in cylinder head
6 - Lube oil filter 20 - Oil pressure sensor
7 - Main oil gallery 21 - Oil line to exhaust turbocharger
8 - Crankshaft bearing 22 - Exhaust turbocharger
9 - Big end bearing 23 - Oil line to compressor
10 - Camshaft bearing 24 - Compressor
11 - Oil supply to injection pump 25 - Hydraulic pump
12 - Injection pump 26 - Pressure regulating valve
13 - Oil return line from injection pump 27 - Return line from compressor
14 - Line to piston cooling nozzle 28 - Return line from turbocharger
15 - Piston cooling nozzle with valve (0.8 – 1.1 bar)

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3.2 Lube oil pressure

Bild 1015-0031

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4. Fuel system

4.1 Fuel circuit

For series 1015, Bosch injection pumps of type P are used which achieve a peak injection pressure
of up to 1100 bar. The injection takes place via an injector with 8 jets, which is vertically-centrically
arranged in the cylinder head. For the speed regulation, mechanical Bosch regulators or optional
electronic regulators such as EMR, GAS, GenDec are used.

The low-pressure system is represented below.

Bild 1015-0040

1 – Injection pump 6 – Fuel feed pump a – to injection pump


2 – Fuel filter 7 – Press. holding valve, p = 2 bar b – to filter
3 – Preliminary fuel filter 8 – Solenoid valve c – from tank
4 – Manual feed pump 9 – Flame plugs d – Fuel return
5 – Fuel tank

To avoid that the feed pump takes in heated up fuel, for the design it must be considered that the
intake- and return pipe in the tank have a distance to each other of at least 500 mm. In the fuel
scheme, this distance is designated 'X'. For some installations, it is required that the fuel return
from the injection pump and the injectors, respectively, is separately directed back to the tank.

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4.2 Setting the commencement of delivery

Beyond the injector opening pressure and the cetane number, also the injection pump delivery
commencement determines the ignition time and is, thus, also responsible for engine rating, con-
sumption and exhaust gas quality. Therefore, its careful setting is of high importance.

For series 1015, there are two methods for setting the injection pump delivery commencement,
while searching for and setting of the commencement of delivery for the engine is identical.

A special tool is available for searching the


position delivery commencement for the en-
gine. Mount the tool at a specified flange at the
adapter housing.

It comprises a turning device (4) for the fly-


wheel ring gear, a spring-loaded bolt (3) and a
graduated disc (2). When turning the flywheel,
the bolt (3) slides over the teeth of the ring
gear and automatically engages in a special
groove in the ring gear.

Important: For series 1015, only use the


black (outer) scale (1) on the
graduated disk.

Bild 1015-0041

Thus, the engine is in the top dead centre position cylinder A1. As, however, it must be distin-
guished between top dead centre ignition and change cycle and as there are two grooves on the
ring gear, which are shifted by 90°, the top dead centre ignition cylinder A1 must be exactly deter-
mined with the valve overlapping of cylinder B2 (6-cylinder) or B3 (8-cylinder).

After the top dead centre position ignition of cylinder A1 has been determined, set the angle indica-
tor of the turning device to zero. This position is marked on the scale with a red point. Starting from
there, the engine is turned into the desired position of delivery commencement (see nameplate)
with the aid of the graduation.

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The injection pump (1) is driven via a toothed wheel by the camshaft (5) to whose drive gear (3) a
second gear (4) is mounted. This gear (2) is fastened to the flange of the injection pump camshaft
with six bolts in oblong holes. There is an old an a new clearance-optimised drive gear.

For the former drive gear, the backlash must be between 0.04 and 0.29 mm. It is set by the selec-
tion of the suitable pump drive gear. Here, three gears are available which can be identified by a
minus-, zero- or plus-mark. For further instructions, see the workshop manual.

A former pump drive gear (2) must only replaced by a clearance-optimised one, if the respective
drive gear (4) on the camshaft is also replaced. In case of clearance optimisation, the backlash
must not be set.

Bild 1015-0042

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4.2.1 Electrical setting device for the delivery commencement

The former method for setting the delivery commencement of the injection pump was realised via
an electrical setting instrument (LED's), which receives its signal from an indicator mounted on the
injection pump camshaft. Engines with this setting method have the non-clearance optimised drive
gear on the injection pump camshaft. The following picture shows the arrangement of the setting
device.

Position 1 means that, in this case, the engine has been turned with the turning device into the posi-
tion 15° before top dead centre cylinder A1. For setting the injection pump delivery commencement,
first, the screws of the drive gear are unscrewed.

After opening of the locking cap (C), the pump camshaft is turned counter-clockwise into the stroke
of cylinder A1, until the signal lug is visible in front of the bore. The signal lug is now fixed with a
special pin.

Then, the pump is installed as directed (workshop manual and chapter 5.3) and the fixing pin for
the signal lug removed. Now, the sensor (D) of the setting device is screwed into the opened bore
(C) duly considering the positioning with the aid of an adapter spring.

The device is switched on now by connecting the cable terminal (E) with the engine ground. Now,
the injection pump camshaft is turned in the turning direction (backlash), until both of the LED's (A)
and (B) are just lighted.

Now, the accessible screws of the pump drive gear are tightened and the delivery commencement
checked at the turning device.

If no correction is required, the residual bolts of the drive gear are tightened.

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4.2.2 Fixing pin

With the new method for setting the delivery commencement, the injection pump camshaft (1) is
kept in the position delivery commencement for the plunger of cylinder A1 with the aid of a fixing pin
(2). The drive gear (3) has an additional oblong hole to provide sufficient free space for the pin (2)
upon the installation of the injection pump.

The fixing (5) of the pin (2) at the pump housing (6) is sealed by the manufacturer after the comple-
tion of the pump.

After the installation of the injection pump, the screws of the drive gear (3) are tightened.

Then, check the delivery commencement. If nor an electric delivery commencement setting device
nor a fixing pin (3) should exist, it is still possible to set the delivery commencement by the high-
pressure method.

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5. Cooling system

5.1 Cooling circuit

The cooling circuits of series 1015 are closed circuits with thermostat-controlled outlet regulation.
The coolant is prepared on water basis with additives.

Bild 1015-0050

1 – Heat exchanger (transmission) 6 – Thermostat


2 – Heat exchanger (engine) 7 – Cylinder and cylinder heads
3 – Expansion tank 8 – Air compressors
4 – Heat exchanger 9 – Coolant pump
5 – Heat exchanger (engine oil)

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5.2 Coolant

Liquid-cooled engines must be filled with a processed coolant as, otherwise, serious damage can
occur to the engine by freezing, cavitation and corrosion.

The used water must absolutely have the following values:

Water quality min. max.

ph-value at 20 °C 6.5 8.5


3
Chloride-ion content (mg/dm ) - 100
3
Sulphate-ion contents (mg/dm ) - 100
Total hardness (°dGH) 3 12

The coolant is prepared by admixing an anti-freeze agent to the water. An anti-freeze free from ni-
trite, amine and phosphate is offered by DEUTZ SERVICE via its spare parts service. The suitability
for the respective application of other anti-freeze agents should expressly approved by DEUTZ
SERVICE.

The anti-freeze must not exceed or fall below the following the following concentration:

Anti-freeze Freezing protection up to °C

max. 45 % -35°C
40 % -28°C
min. 35 % -22°C

The coolant concentration is checked with commercial testing instrument.

Anti-freeze must be disposed of in a way kind to the environment.

TU-DEA-1-05 DEUTZ AG
5-2 Edition: 28.05.01 Service Engineering
1015 TU en-pdf.doc © Cologne Training Center

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