Professional Documents
Culture Documents
Engine Series
DEUTZ 1015
DEUTZ AG
Service Engineering
Cologne Training Center
Course-attendant trainee documentation
for service training
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.
Service-Training
Table of contents
2.1 Cylinder..............................................................................................................................2-1
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1. Engine plan
Working cycle / combustion system Four-stroke diesel with direct injection and
exhaust turbocharging.
Min. oil pressure [bar], at low idling and with war- 1.0
med-up engine (120°C oil temperature)
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A – side, 6 cylinders
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B – side, 6 cylinder
Bild 1015-0001b
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A – side, 8 cylinder
Bild 1015-0002a
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B – side, 8 cylinder
Bild 1015-0002b
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B F 8 M 1015 C/P
Uprating
Serial index
Liquid-cooled
No. of cylinders
Exhaust turbocharger
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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
• 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).
Bild 1015-0006
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Bild 1015-0008
7 ISO
8 ISO
11 1/min
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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.
Bild 1015-0010
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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
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).
Bild 1015-0013
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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.
Bild 1015-0014
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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).
.
Bild 1015-0011
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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
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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
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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.
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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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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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.
This average value (0.42) must be compared with the following table and the cylinder head gasket
can be determined.
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The gear drive on the vibration damper side is arranged in the auxiliaries carrier and comprises the
following drives:
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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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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Bild 1015-0030
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Bild 1015-0031
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4. Fuel system
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.
Bild 1015-0040
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.
DEUTZ AG TU-DEA-1-04
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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.
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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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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Bild 1015-0043
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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.
Bild 1015-0044
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5. Cooling system
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
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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 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:
max. 45 % -35°C
40 % -28°C
min. 35 % -22°C
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