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 Safety guidelines / Accident prevention
O Please read and observe the information
given ¡n this Operation Manual. This will
enable you to avoid accidents, preserve the
manufacturer's warranty and maintain the
engine in peak operating condition.
? O This 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.
O Use in accordance with the intended pur-
pose also implies compliance with the con-
ditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated by person-
nel trained in its use and the hazards in-
volved.
O The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be ob-
served.
O When the engine is running, there is a risk
of injury through:
- turning/hot components
- engines with positive ignition
- ignition systems (high electrical voltage)
You must avoid contact at all times!
O Unauthorized engine modifications will in-
validate any liability claims against the
manufacturer for resultant damage.
Manipulations of the injection and regulating
system may also influence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaran-
teed under such conditions.
O Do not change, convert or 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.
O When carrying out maintenance/repair op-
erations on the engine, the use o'f DEUIZ
original parts is prescribed These are spe-
cially designed for your engine and guaran-
tee perfect operation.
Non-compliance results in the expiry of the
warrantyl
O Maintenance and cleaning of the engine
should only be carried out when the engine
is switched off and has cooled down.
You must ensure that the electrical systems
have been switched off and the ignition key
has been removed
Accident prevention guidelines concerning
electrical systems (e.9. VDE-0100Ê01011-
0104/-0105 Electrical protective measures
against dangerous touch voltage) are to be
observed
When cleaning with fluids, all electrical com-
ponents are to be covered
impermeably.
 OperationManual

1015

0297 9684 en

Engine
Serial Number:

Please enter here the engine serial number. By

quoting this number you will help to facilitate
dealing with questions concerning Customer Ser-
vice, Repairs and Spare Parts (see Section 2.'1).

ln view of continuous design improvements or

changes, the technical specifications and the
illustrations shown in this Operation Manual are
subject to alteration. Reprinting and reproduction,
in part or in whole, are subject to our written
approval.
Foreword

Dear Gustomel,

Liquid-cooled DEUTZ engines are designed for a

broad spectrum of applications.Consequently, a
wide range of variants are offered to meet the
specific requirements of each individual case.

Your engine is appropriately equipped for the

installation concerned, which means that not
all the components described in this 0peration
Manual are necessarily mounied to your engine

We have endeavoured to highlight any differences

so that you will be able to locate the operating and
ma¡ntenance instructions relevant to your engine
quickly and easily.

Please read this Manual before starting your

engine, and always observe the operating and
maintenance ¡nstructions.

Should you have any inquiries we shall be pleased

to provide advice.

Sincerely,

DEUTZ AG
 Table of Gontents

t. General 3.5 0peratingConditìons 6.3.4 Cleaning engine

2. Description of Engine 3.5.1 Winter 0peration 6.4 Combustion Air Cleaner

3.5.2 High Ambient Temperature, High 6.4.1 Cleaninglntervals
2.1 Model Designation Altitude 6 42 Dry-Type Air Cleaner
211 Rating Plate 6.4.3 RemovingCyclone-TypePrecleaner
2.1 2 Location of Rating Plate 4. 0pemling Media 6.4.4 Cleaning0il Bath Air Cleaner
21.3 Engine Serial Number 4.1 Lube 0iì 6.5 Belt Drives
21.4 4.1 1 Quality Grade
6.5 1 Checking Alternator V-Belt
Numbering of Cylinders
2.2 4.1 2 Viscosity
6 5.2 Retensioning/Renewing Alternator V-
Enginelllustrations
2.2.1 Cyl. Bank A BF6 M 1 015 4.2 Fuel Belt
2.2.2 Cyl. Bank B BF6 M 1015 4 21 Ouality Grade 6.6 Adjustments
2.2.3 Cyl. Bank A BF8 M 1 01 5 4.2.2 Winter Grade Fuel 6 6.1 Checking/Adjusting Valve Clearances
2.2.4 Cyl. Bank B BFB M 1015 4.3 Coolant 6.6.1.1 Valve Clearance Adjustment Schematic
23 Lube 0il Circuit 4,3.1 Water 0uality for Coolant Preparation 6.7 Accessories
2.3.1 Lube 0il Circuit Schematic 1015 4.3.2 CoolantPreparation 6.7.1 Battery
4.3.3 Cooling System Protective Agents 6.7.2 Three-PhaseAlternator
3. operation 6.7.3
3.1 Commissioning 5. Routine Maintenance Lifting Tackle

3.1.1 Filling in Engine Oil 5.1 MaintenanceSchedule 7. Troubleshooting

3.1.2 Filling 0il Bath Air Cleaner with Engine 5.2 Maintenance Chart 7.1 Diagnosis Chart
0it 5.3 Completed Maintenance Jobs
3.1.3 Filling the Fuel Tank L Engine Preservation
3.1.4 Filling/Bleeding the Cooling System 6. Service and Maintenance 8.1 Preservation
1015 6 1 Lubrication System
3.1.5 0therPreparations 6.1.1 Oil Change lntervals 9. Specificalion Data
3.2 Starting 6.1.2 Changing Engine 0il, Checking 0il Level 9.1 Engine Specifications and Setlings
3.2.1 Electric Stafting .3 Renewing 0il Filter
6.1 9.2 Torque Wrench Settings
3.3 Monitoring Systems 6.2 Fuel System 9.3 Tools
3.3.1 Engine 0il Pressure 6.2.1 Renewing Fuel Filter
10. Seruice
3.3.2 CoolantTemperature 6.2.2 Change Fuel Leakage Line
3.3.3 Coolant Level 6.2.3 Fuel Pre-filter Element
3.3.4 Lube 0il Level Clean/Replace if necessary
3.4 Stopping 6.3 Cooling System
341 MechanicalShutdown 6.3 1 Cleaning lntervals
3.4.2 ElectricShutdown 6.3.2 Draining Cooling System
6.3.3 Filling/BleedingCoolingSystem

DEUTZ Diesel Engines
are the product of many years of research and
development. The resulting know-how, coupled
with stringent quality standards, guarantee the¡r
long service life, high reliability and low fuel
consumption.
It goes without saying that DEUTZ Dlesel Engines
meet the highest standards for environmental
protection.
Beware of Running Engine
Shut the engine down before carrying out mainte-
nance or repair work Ensure thatthe engine cannot
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
panels and guards that may have been removed.
Never fill the fuel tank while the engine is running.
0bserve industrial safety regulations when running
the engine in an enclosed space or underground.
Gare and Maintenance
Sound care and maintenance practices will ensure
that the engi ne contin ues to meet the req ui rements
placed on it. Recommended service intervals must
be observed and service and maintenance work
canied out conscientiously
Special care should be taken under abnormally
demanding operating conditions.
Safety
This symbol is used for all safety
warnings. Please follow them
carefully. The attention of 0perating
personnel should be drawn to these
safety instructions. General safety
and accident prevention regulations laid down by
iaw must also be observed.
Asbestos
DEUTZ original pafts are asbestos-
free
General
Service
Please contact one of our authorized service
representatives in the event of breakdowns or for
spare parts inquiries. 0ur trained specialists will
carry out repairs quickly and professionally, using
0nly genurne spare pafts.
0riginal parts from DEUTZ AG are always produced
in accordance with state-of-the-art techn0logy.
Please turn to the end of this manual for further
service information.
California
Proposition 65 Warning
Diesel engine exhaust and some of its consti-
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
 Description of Engine

2.1 Model Designation

2.2 Engine lllustrations
2.3 lube Oil Gircuit
Description of Engine 2.1 Model Designation

2.1.1 Rating Plate 2.1.2 Localion of Bating Plate 2.1.3 Engine Serial l{umbet

The model designation A, the engine serial The rating plale C is affixed to the crankcase The engine serial number is stamped on the
number B and the performance data are stamped crankcase iteself (arrow) and on the rating pìate.
on the rating plate.

When ordering spare parts, it ìs essentiaì to quote

the model designation and the engine serial
number.
2.1 Model Designation Description of Engine

2.1.4 llumbering of Gylinders

The cylinders are numbered consecutively for

either cyl. bank A or B, begìnning at flywheel end.
Description of Engine 2.2 Engtne III ustrati on

2.2.1 Gyl. Bank A - BF6M 1015

1 0il iller neck

f

2 Cylinder head
15 3 Exhaust manifold
4 SAE housing
14 5 Crankcase
6 Starter
7 Oil pan
2 8 0ii filter
9 Coolant connection from heat exchanger to
eng rne
10 Vibration damper
3 11 V-belt pulley
12 Alternator
1 3 Coolant connection to heat exchanger
14 Solenoid (shutdown solenoid)
15 Flame-type heater plug (B-side)

7
2.2 Engine Illustration Description of Engine
2.2,2 Êyl. Bank B - 8F6M1015

16 Charge air pipe

17 0il dipstick
1B Oil drain plug
16 19 SAE housing
20 Flywheel
21 Exhaustturbocharger
17 22 lnjection pump
23 Flame-type heater plug (A-side)
Description of Engine 2.2 Engine III ustrati on

2.2,3 Gyl. Bank A - BFSM 101 5

1 Exhaust turbocharger
2 Exhaust manifold
3 Crankcase
4 Starter
5 0il filler neck
6 Oil pan
7 Lube oil filter
B V-belt pulley with vibration damper
9 Coolant connection from heat exchanger to
eng ner

10 0il cooler
11 Fan
12 Exhaust stack
'13
Charge air pipe t0 the charge air cooler
14 Flame-type heater plug system (B-side)

10

9
2.2 Engine lllustration Description of Engine

2.2.4 GVl. Bank B - BFSM 1015

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

15 0ll f ilier neck
16 Cylinder head
17 Alternator
14 18 0il dipstick
19 SAE housing
20 Flywheel
21 Compressor
15 22 Fuel connecting line

__tsF
Description of Engine 2.3 lube Oil Gircuit

2.3.1 lube OilCircuit Schematic 1015

Wet Sump [ubrication

1 Oil pan
24 2t 21 12 13 1123 20161714 18191510 7 2 lntake pipe
3 0il pump
4 Overpressure reljef valve
5 Oil cooler
6 Spin-on oil filter
7 Main oil bores
8 Main bearing
9 Big-end bearing
10 Camshaft bearing
11 0il supply to injection pump
12 Injection pump
13 Return line from injection pump to crankcase
¡ '14 Line to spray nozzle
Fr-rr--¡
15 Spray nozzle with pressure-holding valve for
piston cooling
1 6 Tappet with control groove for pulse
Iubrication of rocker arms
17 Pushrod, oil supply to rocker arm lubrication
18 Rocker arm
19 0il return bore in cylinder head to crankcase.
20 0il pressure sensor / oil pressure switch
21 0il line to exhaust turbocharger
22 Exhaustturbocharger
23 Oil line to compressor (hydr. pump)
24 Compressor
25 Hydraulic pump
26 Pressure-holding valve (adjustable)
25 26 22 28 27 0il return line from compressor (hydr. pump)
to crankcase
28 0il return line from turbocharger to crankcase
 Engine 0peration

3.1 Gommissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 0perating Conditions
 Engine 0peration 3.1 Gommissioning

3.1.1 Filling in Engine Oil 3.f .2 Filling Oil Bath Air Gleaner with 3.1.3 Filling the Fuel Tank
Engine 0il

FUEL

26398t0

As a rule, the engines are delivered without oil
f illinq.
Fill in lube oil through the oil filler neck (anow).
For oil filling volume, see 9.1.
For oil quality grade and oil viscosity, see 4.1.
Fill engine oil into bowl 1 of oil bath air cleaner (if Use only commercial-grade diesel fuel. For fuel
fitted) up to the arrow mark. quality grade, see 4.2.
For oil quality grade and oil viscosity, see 4.1. Use summer- or winter-grade fuel, depending on
the ambient temperature.

Never fill oil into the precleaner's Stop engine before filling the fuel
dust collecto¡ if provided. tan k!
0bserve strict cleanliness! Do not
spill any fuel!
3.1 Gommissioning Engine 0peration

3.1.4 Filling/Bleeding Cooling 3.1.5 0ther Preparations

System
1015
o Check battery and battery cable connections,
see 6.7.1 .

O Trial run
- Upon completing the preparations run the
engine for a short trial run of about 10
minutes under low load.

During and after trial run

- Check the engine for leaks.

After the engine has been stopped

- Check oil level and top up if necessary, see
6.1.2
- Retension V-belts, see 6.5.

o Breaking-in
o Connect coolant inlet 1 and coolant outlet 2 to During the breaking-in phase, it is
external coolant tank. recommended to check the oil leveì twice a day.

O Fill in coolant into cooling system. After the breaking-in phase, checking once a
day will be sufficient.
O Start engine and run up to normal 0peratìng
temperature until thermostat opens (line 2
warms up).

O Check coolant level in external cooling system,

top up coolant if necessary.
Engine Operation 3.2 Stafting

3.2.1 Electric Stafting

without Cold-Stafl ing Aid

Before starting, make sure that

nobody is standing in the
immediate vicinity of the engine or
driven machine.
After repair work :

Check whether all removed guards are put back in

place and all tools are removed from the engine.
When starting with flame-type heater plugs, do
not use any other additional startlng aids (e.g
injection with start pilot). Accident hazard!
lmportant: Never start the engine with speed
governor removed.
D¡sconnect battery!

O Disengage the clutch to separate the engine O lnsert key.

from the driven equipmenl.
- Position 0 = no operating voltage.
O Move speed control lever 1 in direction of o Turn key clockwise.
arrow at least to middle speed position.
- Position 1 = operating voltage,
O Move shutdown lever 2 to ,,Run" position
(opposite direction of arrow, item.1).
- Piloi lamps light up.

O Turn key further clockwise against spring

action.
Do not acluate the starter for more than 20
seconds at a time. lf the engine does not start, - Position2=starting.
wait one minute before repeating the attempt
lf the engine does not start after two attempts, O Release key as soon as the engine starts firing.
trace the cause with the aid of the Diagnosis Chart - Pilot lamps go out.
(see 7.1 ).
3.2 Stafiing Engine 0peration

with Gold-Stailing Aid

Flame-Type Heater Plug System

O lnsert
-
key.
"fl
Position 0 = no operating voltage
O Turn key further clockwise against spring
action to
- Position2=starting
O Turn key clockwise
- Position 1 = operat¡ng voltage, a Release key as soon as the engine starts firing.

- Pilot lamps 1+2+3 light up. - Pilot lamps go out.

- Preheat until heater plug indicator 3 blinks,

max. 30 seconds.
- Engine is ready for operatlon.

lmportant: The starting process

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

3.3.1 Engine Oil Pressure 3.3.2 Goolant Temperature

Oil Pressure Pilot Lamp Oil Pressure Gauge

O The oil pressure pilot lamp lights up with
operating voltage applied and engine shut off.
O The oil pressure pilot lamp must go out when
the engine is running.
O The pointer of the oil pressure gauge musl O The pointer of the temperature indicator should
indicate the minimum oil pressure (see 9.1). remain in the green sector and enter the yellow-
greeen sector only in exceptional cases. lf the
pointer enters the orange sector, the engine is
overheating. Turn it off and establish the cause
from the Diagnosis Chart (see 7.1).
3.3 Monitoring Systems
3.3.3 Coolant level
O Lamp of coolant level indicator lights up
(contact via f loat switch/level sensor when min
coolant level has been reached):
Turn engine off and establish cause from the
Diagnosis Chaft (see 7.1 )
O Functional check of coo¡ant leve¡:
lnsert key in position 1 or 2
(Float switch or level sensor)
Pilot lamp lights up f0r about 2 seconds
- Coolant level o k : lamp goes out
- Coolant level not o.k.: lamp does not go out
Engine Operation
3.3.4 lube Oil level
278t 1
O Lamp of lube oil level indicator lights up
(contact via f loat switch/level sensor when min.
lube oil level has been reached):
Turn engine off and establish cause from the
Diagnosis Chart (see 7.1 )
O Functional check of lube oil levei:
lnsert key in position 1 or 2
(Float switch or level sensor)
Pilot lamp lights up for about 2 seconds
- Lube oil level o k.: lamp goes out
- Lube oil level not o k : lamp does not go out
Engine 0peration 3.4 Starting

3.4.1 Mechanical Shutdown 3.4.2 ElectricShutdown

'1
O Set speed control lever to low speed position. O Turn key counter-clockwise (to position 0) and
pull off. Pilot lamps go out.
O Actuate shutdown lever 2 until engine comes to
standstill. Charging-current and oil pressure
pilot lamps light up when engine has come to
standstill.
3.5 0perating Conditions Engine Operation

3.5.1 Winter Operation

O Lube 0il Viscosity O Cold-Starting Aids

- Select the oil viscosity (SAE qrade)
according to the ambient temperature
- Attemperatures near or belowfreezing point
start with flame-type heater plug, see 3.2.1.
prevailing at the time when lhe engine is
This not only lowers the starting limit
started 4.1.2.
temperature, but proves also useful at tem-
- Keep shorter periods between oil changes peratures normally not requiring a starting
when operating at temperatures below -10 aid

I
'C (+14'F), see 6.1.1.
O Battery
O Diesel Fuel
- Cold starting requires a good state of charge
- Use winter-grade diesel fuel for operation of the battery, see 6.7.1.
below 0'C (+32 "F), see 4.2.2.
- The stafting limit temperature can be
lowered by 4-5 "C by heating the battery up
O Coolant to +20 "C (+65 'F). To do so, remove the
- Set the water / antifreeze mix to suit the battery and store in a warm place.
lowest temperature likely to occur (max. -35
"C /-31 "F), see 4 3 1.

O Additional lVlaintenance Jobs

- Drain the sludge from the fuel tank once a
week (by undoing the sludge drain plug).
- Adjust the oil filling in the oil bath air cleaner
(if fitted) to the prevaillng ambient
temperature as in the case of engine oil
- At temperatures below -20 "C (-4 'F)
lubricate the flywheel ring gear with low-
temperature grease, eg Bosch Fl 1 V31,
from time to time through the pinion hole (if
necessary remove starter).
Engine 0peration 3.5 0perating Gonditions

3.5.2 High Ambient Temperature,

High Altitude

a With increasing altitude and rising ambient

temperatures the density of the air. tends to
decrease, which affects the maximum power \W./oc
output, the exhaust gas quality, the
temperature level and in extreme cases, the
starting behaviour. Under transient running
conditions, operation is permissible at altitudes
up to 1000 meters at ambient temperatures up
o.-,
to 30'C (86'F)
lf an engine is operated under more severe
conditions (at higher altitudes or ambient tem-
peratures) it will be necessary to reduce the
injected fuel quantity and thus engine power.

O ln case of doubt concerning such engine

applications, ask your engine or equipment
supplier whether, in the interest of operational
reliabillty, service life and exhaust gas quality
(smoke!), an engine derating had been
considered necessary, or simply contact your
service representative.
Operating Media
0perating Media 4.1 Lube 0il

4.1.1 Ouality Grade 4.1.2 Viscosity

The I u be oil quality g rade is defi ned by specifications Generally, multi-grade oils shall be used ln closed
The following lube oil specìfications are approved: heated rooms at temperatures >5'C, also single-
grade oils can be used. The indicated lube oil grades
lube oil quality class:
must, of course, also be observed for single-grade
oils.
classification/specification As the viscosity of lube oil is dependent on
temperature, the choice of
SAE grade
DEUÎZ- DQC I DQC II DQC ilt should be
governed by the ambjent
temperature prevailing atthe engine
ACEA- E2-96 E3-96/E5-02 E4-99 operating site
0ptimum operating behaviour will be
AP- CFICF4 cG4tcH4
Worldwide DHD-1

lf in doubt, contact your seruice representative

ln order to keep wear to a m¡nimum, do not
exceed application limits for extended
periods of time.
0il changes dictated by the seasons can be
avoided by using multi-orade lube oils. Mul-
-
ti-grade oils particularly lowJriction oils -
also reduce fuel consumption.
4.1 Lube 0il 0perating Media

4.1.2.1 Specific lube oil Lube oils lor engines with uprated power and engines with high loading
definitions
Turbocharged engines with uprated power and Produce¡
engines with high loading

The oils Iisted in enclosure 1 are to be used

for the following engines and applications:
o1015 CP
O all engines in CHP plants
O all engines in gensets operating in parallel
with the mains/with each other
O engines in combines with:
These are high-grade oils according t0 ACEA 0r API In
additi0n most ofthese oils are partly synthetic, some even
fully synthetic (5W-40) and thus achieve the thermal
stability required f0r the relevant applicati0n and are
distinguished by a low tendency to cause deposits in the
turbochargerand inthe chârge air p¡peswith closed-circuit
crenkcase breather
Operating Media 4.2 Fuel
4.2.1 Ouality Grade 4.2.2 Winter-Grade Fuel

Use commercial brands of diesel fuel with a sulfur At low temperatures, waxing may occur and clog
content of less than 0 5%. lf the sulfur content is the fuel system, causing operational trouble. ln +32 0
higher than 0.5%, oil change intervals should be case of sub-zero (+32'F) ambient temperatures it
reduced, see 6.1.1. is recommended to use winter-grade diesel fuel +23 -5 I
(down to -15 "C = +5 'F) Normally, such fuel is
The following specifications / standards are offered at the filling stations in good time before +14 - 10
approved: the cold season starts. D¡esel fuel containing addi-
tives (,,Super Diesel") is frequently also on sale for + 5 - 15

o CEN EN 590 or DIN/EN 590
o DIN 51 601 (Feb.1986)
o BS 2869 (1988): A1 and A2
o ASTM D975-88: 1-D and 2-D
O NATo Code F-54 and F-75
The exhaust emission levels determined during
certification always refer to the reference fuei
specified by the supervising authorities for such
certification
use at temperatures down t0 -20'C (-4 'F).
-4 -20
O At temperatures below -15 'C (+5 'F) or -20 - tJ -zc
'C (-4 'F), kerosene should be added to the
diesel fuel. The relevant percentages are given
in the diagram at the right.
lf summer-grade diesel fuel has to be used at
temperatures below zero (+32 'F), up to 60%
kerosene may be added (see diagram at the right).
ln most cases, adequate resistance to cold is also lllustration legend:
attained by adding a flow improver (fuel additive).
Ask your service representative for this.
Summer diesel fuel

ll Winter diesel fuel

A Ambient temperature

B Percentage of kerosene added

rüi,l:,iläå:
a
iiffiå',ti.i'i'.rl"ìt

f\ ilfrJii;#Ë5llriîåî:risrlî,å
4.3 Goolant Operating Media

4.3.1 Ouality of watet for coolant 4.3.2 Goolanttreatment 4.3.3 Gooling system protectants
in the recirculating water
system
The values listed below must not be exceeded. I n the case of I iquid-cooled engines, special attention DEUTZ cooling system protectants must be purchased
ln order to examine the quality of your water, a test case must be paid to the treatment and control of the in drums under Order No. 01011490 (5 litres) or '1221
can be ordered from DEUTZ under Order No. 1213 coolant, as the engine may otherwise become dam- 1500 (210 litres) These are nitrite, amine and phos-
0382. aged as a result of corrosion, cavitation and freezi ng. phate-free, and provide effective protection against
The treatment of the coolant is carried out by corrosion, cavitation and freezing.
Water oualitv mn max adding a cooling system protectant to the cooling lf the above mentioned cooling system protectant is
water. unavailable, the following products may be used in
ph value at 20 "C /68' F 65 85 The cooling system must be continuously moni- exceptìonal cases
tored, see 5 1 ln addition to checking the coolant
Chloride ion conient [mo/dm3] 100
level, this also involves checking the concentration Manufacturer Product desiqnation
Sulohate ion content [mq/dm3 '100 of the cooling system protectant. AVIA AVlAAntifreeze Extra
The cooling system protectant concentration can ARAL Antifreeze Extra
Total hardness ['dGH] 3 20 be checked with commercially available testers BASF Glysantin G 48
(example: gefo glycomat @). DEA kylarfrostsskydd
DEA
SHELL SHELLGlycoShell

The cooling system protectant in the coolant should not

fall below or exceed the following concentration:
Cooling system protectant Water

max.45 Vol,o/o 550/a

min. 35 Vol % 65%

Filling volume, see Chapter 9 1

The use of other cooling system protectants, e.g. chemi-
cal anti-corrosion agents, is possible in exceptional
cases Consuìt DEUTZ Service.
The use of anti-corrosion oils is not permitted

lf nitrite-based cooling system Cooling system protectants must

protectants are mixed with be disposed of in an environmen-
amine-based agents, danger- tally-friendly manner.
ous nitrosamines are formed.
Operating Media 4.3 Goolant

Gooling System Protection

Cooling system capacity ")
ILiters]
Protective I Protection
agent I against freezing to
18 20 22 25 27 30 32 35
[% by vol.] I fcl Protective agent
ILiters]
35 -22 63 70 77 8,75 95 10,5 11,2 12,3

40 -28 72 80 88 10 10,8 12 12,8 14

45 -35 81 90 99 11,3 12,2 13,5 144 15,8

50 45 90 10 11 12,5 13,5 15 16 17,5

*)For coolant capacity of your engine, see Section g 1.
Note: Consult head-office regarding figures in the grey field
 Routine maintenance

5.1 MaintenanceSchedule
5.2 Maintenance Ghafi
5.3 Completed Maintenance Johs

o
O
o
N
o
 Routine maintenance 5.1 Maintenance schedule

check = O =o clean = I
lndustriel engines
che :k 2x daily before or during 1sl un, during running- In period or when commissioning new or overhauled engines
.lJ CVCI 10 )H or daily
permissible recommended maximums. Depending
ll
on usage, reduced maintenance intervals may be
n rperating hr urs (( lH) er ery:
necessary; comply with the unit manufacturels
operating instructions. # l\4aintenance must only be

a
l- o
o
o
o
o
Years carried 0ul by authorised service personneì

-l-
ôlo
ôlo o
N
-l- @
N
0peration Section
O o Lube oil level, top up if necessarv 6.1.2t3.3 4
I I Lube oil (oil chanqe int. dependinq on enqine a00.), see TR 0199-99-3002 6.1.1t61 2
I 0ilfilter cafiridoe 6.1.3
I Fuel fiìter cartridoe o-¿. t

o T Fuel leakage lines (should be replaced in there entiretv) o¿¿

T lnjection valve #
a Fuel pre-cleaner 42
a a ^ I Coolant (additive concentration) 4.3.1t2t3
T Coolant pumo
a a Coolant level
o o I lntake air cleaner (if avaiiable, maintain according to maintenance indicator) 6.4.316.4.4
a o lntercooier (drain lube oil/condensation)
a ^ Batterv and cable connectors rr. /. I

a a Engine monotorinq svstem, Warninq svstem 3.3 #

o Valve clearance (adjust if necessary) b.b. I

a o I V-belts (retension if necessary, replaced if damaqed) 651

I Crankcase pressure-relief valve/iniection valve #
a I Crankcase pressure vent valve #
a O Check engine for leaks (visual inspection)
a Draininq bores between cvlinder banks, enqine cleanino 6 3.1/6.3.4
o a ^ o Enqine mount (reolaced if damaqed) 92
o
o o o Fasteners, hose connections/clios
N
o I General overhaul #
5.1 Maintenanceschedule Routine maintenance

Gh€Gk =* =O clean =A I
che :k 2x daily before or during
.1st
trial run, during running- In period or when commissioning new or overhauled engines Additions and
ll eve 10 0H or daily
modifications for eng¡nes
l,
in operating hours (0H) every:
w¡th EPA approval
The specified engine maintenance values are
permissible recommended maximums. Depending
on usage, reduced maintenance intervals may be
necessary; comply with the unit manufacturels
operating lnstructions. # Maintenance must only be
I lol-l-l8l
olololololol
Years canied out by authorised service personnel.
-l-lì_l*l-lì_l-l-
6lololololNl I

0peration Section
a I Lube oil (oil chanqe int. deoendìnq on enoine aoo.). see TR 0199-99-3002 6.1.1t61.2
I lnjection valve #
o lntercooler (drain lube oil/condensation) #
o ^ lntercooler inlet, clean as necessary
O ^I I Crankcase pressure vent valve #
Exhaust Turbo-Charqer outlet. clean as necessarv
^

o
o
o
N
o
 Routine maintenance 5.1 Maintenance schedule

check =o =o clean = À T
Vehicle eng¡nes
check 2x daily before or during 1 st trial run, during running- ln period or when commissioning new or overhauled engines
The specified engine maintenance values are
U evef 200 km or daily
t Kilr rmelri rge (k m) ev Bry: Seruice groupe Annual kilomelrage average speed approx. on usage, reduced mainlenance intervals may be
Ser vice g r0up
(km) approx. km/h
necessary; comply with the unit manufacturefs
I <30000 20
a O o
o O ll > 30 bis 00 000
1 40 operating instructions. # Mainlenance must only be
o
o
Õ
o
a
o o
o
O
o
Years
ilt > 100 000 60 carried out by authorised service personnel

a a
o o o
N
N
o
N
-l* 0peration
Lube oil level, top up if necessarv
Section
61 2t3.3 4
I T Lube oil (oil chanoe inl. dependino on enqine aoo.). see TR 0199-99-3002 6.1.1t6.1.2
T 0il filter cartridoe 613
I Fuel filter cartridoe 6.2.1
a I Fuel leakage lines (should be replaced in there entiretv) 622
I lnjection valve #
A Fuel ore-cleaner 42
o I Coolant (additive concentration) 4.3.1/2t3
T Coolant pump
o a Coolant level 4.3.2t4.3.3
a a I lntake air cleaner (if available, maintain accordino to maintenance indicator) 6.4.3t6.4 4
a a lntercooler (drain lube oil/condensation) #
a ^ Batterv and cable connectors 6.7.1
a a Enoine monotorino svstem
o Valve ciearance (adjust if necessary) b.b. I

o O I V-belts (retension if necessarv, replaced if damaqed) 6.5 1

I Crankcase pressure-relief valve/iniection valve t

a I Crankcase pressure vent valve
a o Check engine for leaks (visual inspection)
Draining bores between cvlinder banks, enqine cleanino 6.3.1/6.3 4
o a ^ o Engine mount (replaced if damaqed) 92
o
O O a Fasteners, hose connections/cliDs
N
o I General overhaul #
5.1 Maintenanceschedule Routine ma¡ntenance

CllOcK =a =O clean = I
che ^
;k2xdailybeforeorduring1sttrialrun,duringrunning-lnperiodorwhen@ Vehicle eng¡nes
]J eve 'y 20A km or daily The specified engine maintenance values are
permissible recommended maximums. Depending
u (l m) el ery:
Kit )metrage Seruice groupe Annual kilometraqe average speed approx
on usage, reduced maintenance intervals may be
Se vrce gr0up (km) approx. km/h
I <30000 20
necessary; comply with the unit manufacturer's

o oo o
o lÕ
IO ll > 30 bis 100 000 40 operating instructions. # Maintenance must only be
o
o
O
oo o
o
OO
o
o
tô
lo
læ
Years
ilt > 100 000 60 carried 0ut by authorised service personnel.

O a
N
-l- 0peration Section
Lube oil level, top up if necessary 6.1213.3.4
I I Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1t61 2
I 0il filter caftridge 6 1.3
T Fuel filter cartridge 6.21
a I Fuel leakage lines (should be replaced in there entiretv) 6.2.2
I I njection valve #
Fuel pre-cleaner 42
^O I Coolant (additive concentration) 4.3.1t2t3
I Coolant pump
o a Coolant level
o O T lntake air cleaner (if available, maintain accordinq to maintenance indicator) 6.4.3t6.4.4
o a lntercooler (drain lube oil/condensation) #
a ^ Battery and cable connectors 6.7.1
a a Engine monotorinq svstem # 3.3
o Valve clearance (adjust if necessarv) b.b. I

o o I V-belts (retension if necessary, replaced if damaqed) 6.5.1

I Crankcase pressure-relief valve/injection valve #
o I Crankcase pressure vent valve #
a o Check engine for leaks (visual inspection)
Draininq bores between cvlinder banks. enqine cleanino 6 3.1/6 3.4
a ^ a En0ine mount (replaced if damaoed) 92 O
a o Fasteners, h0se connections/clips o
o
N
I General overhaul # o
 Routine maintenance 5.1 Maintenanceschedule

check =a =o clean = À I
cher 2x daily before or during 1 st trial run, during running- ln period or when commìssioning new or overhauled engines
Vehicle eng¡nes
The specified engine maintenance values are
lJ ever 200 km or day
U
Kilc melrí rge (k n) ev ¡ry: Service groupe Annual kilomefrage avetage speed approx. 0n usage, reduced maintenance inlervals may be
Ser rice g roup I
(km) approx. km/h
necessary; comply wìth the unit manufacturels
I <30000 20
ll > 30 bis 100 000
-l
Õt o
o
o
Õ
o
o
o
o
o
o
o
o
o
o
Õ
o
Yeals
ilt >100000
40
60
operating instructìons. # Maintenance must 0nly be
carried out by authorised service personnel.

a a
ol
ól o N @ o
-l- 0peration
Lube oil level, top up if necessary
Secl¡on
6.1.2t3.3.4
I I Lube oil (oil chanqe int dependinq on enoine app.), see TR 01 99-99-3002 6.1.1t6.1.2
I 0il filter cartridoe 6.1.3
I Fuel filter cartridqe 6 2.1
a I Fuel leakaqe lines (should be reolaced in there entiretv) 6.2.2
T lniection valve #
Fuel ore-cleaner 42
^a I Coolant (additive concentration) 4.3.1t2t3
t Coolant pump
o a Coolant level
o o I lntake air cleaner (if available, maintain accordinq to maintenance indicato0 6.4.316.4.4
a O Intercooler (drain lube oil/condensation) #
a ^ Batterv and cable connectors 6.7.1
a a Enoine monotorino svstem JJ
o Valve clearance (adiust if necessarv) 6.6.1
a o I V-belts (retension if necessary, replaced if damaged) 6.5.1
T Crankcase pressure-relief valve/iniection valve #
O I Crankcase oressure vent valve
o O Check enqìne for leaks (visual insoection)
Draining bores between cylinder banks, engine cleaninq 6.3.1/6.3.4

o O ^ o Enqine mount (replaced if damaqed) 92

o
o a o Fasteners, hose connections/clips
N
o I General overhaul #
5.2 Maintenance Ghail Routine Maintenance

The maintenance chafts shown

E
!'.rgrg
are supplied as self-adhesive label with each engine. lt should be afüxed where it can be clearly seen on the engine
or driven equipment. Check that this is the case! lf necessary ask your engine or equip-ment supplier for a fresh supply of labels! Routine maintenance
work
should be canied out according to the schedule in 5.1.

Aufkleber

Kraftstoff-Vorfilter Wartune
Fuel prefilter Mainteriance
PréfiItrecombust. Entretien
P¡efiltrocombust. Mantenimiento

Stop the engine before

carrying out any maintenance
work We move your world.
Routine Maintenance 5.3 Gompleted Maintenance Jobs

Running hours Date Signature / Stamp Runnino hours Date Sionature / Stamo

50-150"

125 2û
375 500

625 7û
875 1000

1125 QN
1375 1500

1625 17û

1875 æm

2115 2û
2375 2ffi
2625 z7û
* after commissioning of new and overhauled engines
Duly completed maintenance jobs can be recorded and signed off in the above table.
5.3 Gompleted Maintenance Jobs Routine Maintenance

ìunning hours Date Siqnature / Stamo ìunn¡ng hourr Date Signature / Stamo

2875 3000

3125 32n
3375 3500

%25 3750

æ75 4000

4125 42æ

4375 45in

ß25 47û
Æ75 5000

5125 52fi
5375 5500

ffi25 57û
Duly completed maintenance jobs can be recorded and signed off in the above table.
Routine Maintenance 5.3 Gompleted Maintenance Jobs

ìunning hour: Date Sionature / Stamo Runnino hours Date Signature / Stamp

5875 6000

6125 6250

6375 6500

6625 6750

6875 7000

7125 7250

7375 7500

7625 7750

7825 8000

8125 8250

8375 8500

8625 8750

Duly completed maintenance jobs can be recorded and signed off in the above tiable.
5.3 Gompleted Maintenance Jobs Routine Maintenance

ìunninq hours Date Sionature / Stamo lunning hours Date Siqnature / Stamo

8875 9000

8125 82fl
8375 8500

8625 8750

8875 9000

9125 92û
9375 95m

%25 9750

9825 10000

10125 102û

10375 10500

107æ

tpleted mi rintenance jobs can be recorded and signe d off in the bovetablr
Routine Maintenance 5.3 Gompleted Maintenance Jobs

ìunning hours Date Sìgnature / Stamp lunninq hours Date Sionature / Stamp

1 0875 11000

11125 11250

11375 11500

11625 11750

11875 1 2000

12125 12250

12375 1 2500

12625 12750

12825 1 3000

13125 1 3250

1 3375 1 3500

1 3625 1 3750

Duly completed maintenance jobs can be recorded and signed off in the above table.
5.3 Gompleted Maintenance Jobs Routine Maintenance

ìunnino hours Date Signalure / Stamp ìunnino hours Date Sionature / Stamo

13875 14000

14125 142æ

14375 14500

14625 147û
1ß75 15000

15125 152æ

15375 15500

1æ25 157û
15825 16000

16125 162û
16375 16500

tpleted mr aintenance jobs can be recorded and signe, bovetabl,

 Service and Maintenance

6.1 lubrication System

6.2 Fuel System
6.3 Cooling System
6.4 Gombustion Air Gleaner
6.5 Belt Driues
6.6 Adjustments
6.7 Accessories
Seruice and Maintenance 6.1 lubrication System

6.1.1 0¡l Change lnteryals

O The first oil change after commissioning or O lf, for vehicle engines, lube oil change
recommissioning following repair work is intervals are determined by operating hours,
canied out after 50 running hours. the lube oil change intervals indicated in
tab|e 6.1.1.1. for"Oil use undernormalduty"
O The oil change intervals are dependenton : will apply.
- Lube oil quality
- Sulfurcontent in thefuel
- Engineapplication

O Should, within a yea¡ the engine run less than

the hours stated in the table, the oil must be
changed at least once a year.

O The table refers to the following conditions:

- Fordieselfuel max. sulfurcontent> 0.5 %
by vvt.

- Continuous ambient temperature down to

-10'C (+14'F)
O lf the sulfur content is > 0.5 to > I % or the
continuous ambient temperature below-1 0'C
(+14'F), the intervals between the oil changes
should be halved.

O ln the case of fuels containing sulfur > 1 % ,

ask your service representative.

Change the oil with the engine off but still warm
(lube oil temperature approx. 80 'C / 176 'F).
6.1 lubrication System Service and Maintenance

6.1.1.1 lube oil change interyals for industrial and marine engines
Lube oil grade
Deutz lube oil qualitv class DQC I DQC II DQC III
ACEA-specfication E2-96 E3-96/E5-02 E4-99
API-specfication CFICF4 CG4ICH4
Worldwide specfication DHD-1
special DEUTZ release list siehe Kao.4.1.2.1
Standard lube oil code for building EO EO...C
equipment and nonraod vehicles EOAEOB
Engine Engine version Lube oilchange intervals in op. hours
senes Oil use I Oil use I oit ,."
normal hiqh I normal h¡qh I nor-"t hioh
101 5 All enoines except for: 25C, 125 500 250 500 250
1015C from Nonroad Stufe ll 500 250 500 250
1 01 5CP 500 250
BF6M101sMCP<300kW 500 250 500 250
BFBMIOlsMCP<4OOKW 500 250 500 250
BF6M101sMCP>300kW 500 250
BF8M101sMCP>400kW 500 250
* Gensets as referred
to here are units operat¡ng in parallel with the mains / with each other.
Emergency power units are dealt with in TC 0199-99-1126.
Seruice and Maintenance 6.1 lubtication System

6.1.1.20¡l change interuals for vehicle engines

Lubeoil-quality
Deutz lube oil quality class DecI I Dacil I Decilr
ACEA-specification E2-96 E3-96/E5-02 E4-99
API-specification cFtcF4 CG-4.ICH4
worldwide soecification DHD-1
soecial DEUTZ release Enclosure 4.1.2.1
\pplicatíon Enqine version Lube oil chanoe intervals in km
iite vehicles
;itv busses
IoË*zs 1015
I 01 sCP
Euro l, exceptfor
Euro ll
15 000 20
20
000
000
o- o-
-ocal tratf¡c u,t 1U't þ Euro l, except for ;ZU UUU 30 000
o¡o40
ED .E
ñ-\ 1 01 sCP Euro ll 30 000
-ong distance 1015 Euro l, except for 50 000 40 000
raffic äÈuo 't0r5cP Euro ll 60 000

lf, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4 1. for "Oil use
under normal duty" will apply.
6.f Lubrication System Seruice and Maintenance

6.1.2 Checking Oil Level/

Changing Engine Oil
6.1.2.1 Checking Oil Level 6.1.2.2 Engine Oil Ghange

orL
?
+ 80'c
+176'F
fruax
Lg
I

(rurru
O Ensure that the engine or vehicle is on a
level surface.
O lmmediatelybeforetheoil level is measured,
the engine should should be driven at low
idling speed for approx. 2 minutes.
O Switch off the engine.
O Pull out the oil dipstick.
O Wipe ofi with a non-fìbrous, clean cloth.
O lnsert up to the stop and pull out again.
O Check the oil level and if necessary fill up to
the "MAX" level
- lf the oil level is just above the "MlN"
marking, extra oil must be added.
The oil level must not fall below the "MlN"
markin g.
O Ensure that the engine or vehicle is on a
level surface.
O Allow the engine to warm up
-Lube oil temperature approx. 80"C.
O Switch off the engine.
O Place oil tray under the engine.
O Unscrew drain plug.
O Drain oil
O Fit oil drain plug, with the new gasket and
tighten firmly (for torque, see 9.2).
O Fill with lube oil.
- For grade / viscosity, see 4.1
- For quantity, see 9.1
O Check oil level, see 6.1.2 1
Be careful when draining hot oil -
danger of scalds! Do not let used oil
run into the soil but catch it in a
Service and Maintenance 6.1 Lubrication System

6.1.3 Renewing Oil Filter

O With fitted torsion lock:
Loosen screws and slide clamps
downwards.
O Undo the oil fìlter cartridge with commercial
tool and spin off.
O Catch any escaping oil.
O Clean sealing surface of the fìlter carrier if
necessary.
O Lightly oil the rubber gasket of the new oil
filter cartridge.
a Screw in the new cartridge fingertightagainst
the gasket.
O ïighten oil filter cartridge tightly by giving
a final half turn.
O lf a torsion lock is fÌtted, slide clamps up
into position and tighten screws.
O Check oil level, see 6.1.2.

O Check oil pressure, see 3.3 1.

O Check sealing of oil filter cartridge for

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

6.2.1 Renewing Fuel Filter

O Close fuel stopcock. O Clean sealing surface of filter carrier if O Tighten fuel filter cartridge firmly,
necessary
O Undo fuel filter cartridge with commercial O Openfuelstopcock.
tool and spin off. O Apply light film of oil or diesel fuel to rubber
gasket of newfuelfilter cartridge. O Checkforleaks.
O Catch any escaping fuel.
O Screw in the cartridge finger tight against the
gasket.

When working on the fuel

system, keep open flames
awayl
Bleeding of the fuel system is not necessary.
Do not smoke!
Seruice and Maintenance 6.2 FuelSystem

6.2.2 Replace fuel oil leak line 6.2.3 Fuel Pre-filter Element
Glean/Replace if necessary

Changing the filter element 5:

O Close the fuel shut-off valve.
a Remove valve cover.
O Loosen and remove banjo bolts 7
O Remove rubber hoses 1, 3, 4, unions 2 and 0-
rings 6 and dispose of in accordance with envi-
ronmental regulations; banjo union 5 and banjo
bolt 7 can be re-used.
O Connect new oil leak line (complete) with banjo
union 5 to rubber hoses.
Clean (purge) - remove water:
O Turn offengine or, in the case ofa change-
over filter, switch over to the other filter.
O Close the fuel stopcock or supply. (if
available)
O Open the bleed screw 1 on the cover2
O Place the fuel collector underneath the fuel
pre-filter.
O Empty water and dirt from the bowl 6 by
Change at least once a year or as required
(drop in performance also after purging)
O Turn off the engine or switch to otherfilter in
case of changeover filter
O Close thefuel stopcock orsupply (if available)
O Loosen the cover screws 3 diagonally
O Remove the cover 2
O Remove the spring cassette 4
O Removethefilterelement5fromthebracket
O lnsert new fìlter element 5
O Place spring cassette 4 on the element
O Checkthatthe coverseal isfitproperly inthe
cover 2 and check for damage (change if
necessary)
O Tighten the cover 2 with the screws 3
diagonally (torque 6 Nm)
O Check the cover 2 for proper fit and leaks
O Bleed the fuel system, see 6.2.3.
Eg ¿:ffi^tffi ii åxslå å3 il i.'':'"ì,Ei
lmmediate maintenance is necessary when
the warning system is triggered.

A::
Fasten oi I leak I ine usi ng existi ng banjo bolt 7 and opening (press in and turn slightly without
two new O-rìngs 6. using force) the drain cock B and close the
o Re-fit valve cover. drain cock 8 again
o 0pen fuel shut-off valve. O Closethe bleed screw'1 onthecover2 again
O Check for leaks after start-up. O Bleedthefuel pipeaccordingto instructions,
see 6.2.5 opposite
6.3 Gooling System Service and Maintenance

6.3.1 Cleaninglntervals 6.3.2 Draining Cooling System 6.3.3 Filling / Bleeding Cooling
System

O The degree of soiling of the cooler units is O Fill with coolant and bleed cooling system
dependenton the type ofengine application. according to manufacturer's instructions.
O The danger of soiling is increased due to
residues ofoil and fuel on the engine. Check
extra carefully, therefore, for leakages when
applications involve high dust fallout.
O More severe soiling can occur! e.g. in the
case of:
- Construction siteapplication dueto heavily
dust-laden air.
O ln view of the varying conditions of
application, the cleaning intervals must be
determined from case to case. The cleaning
intervals stated in the table can be taken as
guide values.

Checking / Cleaning lntervals O Place tray under drain plug 1.

Guide values O Remove drain plug 1 and sealing ring below
ngine Application
I e
coolant inlet.
O Drain coolant.
2000 Ships, gensets in enclosed
spaces, pumps O Filling / bleeding as under 6.3.3
O Screw on drain plug 1 with new sealing ring
I 000 Vehicles on paved roads and tighten (see 9.2).
O Check for leaks.
500 Mobile gensets
250 Vehicles on construction s¡tes and
unpaved roads, Construction
equipment, compressors, under- Be careful when draining hot
ground m¡ning equipment coolant Danger of scalding!
Catch drained coolant and
125 Farm equipment dispose of in accordance with
antipollution regulationsl
Service and Maintenance 6.3 Gooling System

6.3.4 Cleaning engine

- with cold cleaning agent
- with compressed air

O Blow compressed air onto engine
Wash out loosened dirt particles from V-
space with water jet.
O Make sure that drain holes 1 of V-space
are free.
OSpray engine with commercial cold O Let engine run up to operating
cleansing agent and let stand for about 1 0 temperature after each wet-cleaning
mrn procedure allowing any remaining water
to evaporate, thus avoiding corrosion.
O Then spray clean with strong water jet (do
not spray water directly onto sensitive
components such as alternator, starter,
wiring, electronic components).

O Make sure that drain holes 1 of V-space

are free.

Clean onlywith engine stationary

l\
6.4 Gombustion Air Cleaner Seruice and Maintenance

6.4.1 Cleaning lntervals

O The degree of soiling of the combustion

air cleaner depends on the amount of
dust contained in the air and the size of
the filter used. lf very dusty air is to be
expected, a cyclone{ype precleaner can
be fitted to the air cleaner.

O Consequently, the cleaning intervals

cannot be fixed generally, but have to be
determined from case to case.

O When a dry{ype air cleaner is used, when

indi-cated by the service indicator or
switch

O Air cleaner servicing is needed when :

- Service lndicator
the red sector 1 is fully visible when the
engine is off.
- Service Switch
the yellow pilot light comes on when the
engrne rs runntng.

O After having carried out service work,

reset the signal by pressing the button of
the service indicator. The service
indicator is ready to resume its function
Service and Maintenance
6.4.2 Dry-Type Air Cleaner
Dust llischarge Ualve
O Empty dust discharge valve 1 by pressing
apart lips of discharge slot as indicated by
the arrows.
O Clean discharge slot from time to time.
O Remove any caked dirt by pressing
together the upper section of the valve.
Filter Cartridge
O Release fastening clamps 1.
O Take off hood 2 and remove cartridge 3.
O Clean cartridge, replace at least once
year.
O Clean cartridge 3:
- blow through with dry compressed air
(max. 5 bar) from inside to outside, or
- in difficult cases, tap out, taking care
not to damage the cartridge, or
- wash out according to manufacturer's
instructions.
6.4 Combustion Air Cleaner
O Check cartridge for damage to filter paper
(by shining the paper through with a light),
and inspect sealing element. Renew if
necessaray
O After having serviced the filter cartridge
five times, or after two years at the latest,
renew safety cartridge 4 (never clean!).
To do this, proceed as follows:
- Undo hex nut 5 and remove cartridge
4.
- lnsert new cartrìdge, insert and tighten
hex. nut.
O lnstall cartridge 3, place hood 2 back in
position and secure fastening clamps 1.
a
Never clean filter cartridge with
petrol (gasoline) or hot liquids!
6.4 Gombustion Air Gleaner
6.4.3 Emptying Cyclone-Type
Precleaner
O Undo wing nut 1 and remove cover2.
O Remove collector bowl 3 from lower section
4 and empty. Remove leaves, straw and
other foreign matter from lower section of
precleaner
O Reposition collector bowl 3 onto lowersection
4, fasten cover 2 in place by tightening wing
nut 1.
Seruice and Maintenance
6.4.4 Cleaning Oil Bath Air Cleaner
O Turn engine off and wait about 10 minutes
for the oil to drain from filter housing 1.
O Release snap clips 2 and remove oil cup 3
together with filter element 4. lf necessary,
press elementoutwith a screwdriver, taking
care not to damage rubber gasket 5.
O Remove dirty oil and sludge. Clean oil cup.
O Clean filterelement 4 in dieselfuel and allow
to drip-dry.
O Clean fìlter housing 1 if very dirty
O lnspect and replace rubber gaskets 5 and 6
if necessary.
O Fill oil cup with engine oil up to the mark Never clean air cleaner with
(arrow) (for viscosity, see 41 2) petrol (gasoline)!
O Refit oil cup and element to filter 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 Retensioning / Renewing

Altemator U-Belt

Ghecking - Read off the value: Turn the gauge Retensioning

O lnspect entire V-belt for damage sideways to see the exact spot where the O Slacken hex. bolts 1,2 and 3.
O Renew damaged V-belts. top of the black indicator arm 1 intersects O Turn lock nut 2 in direction A until correct V-
O After installing new belts, run engine for 1S scale 5 (arrow) For settings, see 9.1. belt tension is attained.
minutes, then check belt tension. -lf necessary retension belt and measure O Tighten bolts 1, 2 and 3
O Use a belt tension gauge (see 9.3) to check agarn
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 edge of belt.
-Press slowly on the black pad 4 at right Check / retension and renew
angles to belt 2 until the spring is heard or
felt to trigger. V-belts only with the engine off
Carefully remove the gauge without altering Refit belt guard, if provided.
-
the position of the indicator arm 1.
 6.5 Belt Drives Service and Maintenance

Reneúting

O Slacken hex. bolts 1,2 and 3.

O Tum lock nut 2 in direction B asfaras itwillgo

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

O Tighten bolts 1, 2 and 3 until correct V-belt

tension is attained (see Section 6.5.1).
Seruice and Maintenance 6.6 Adjustments

6.6.1 Checking / Adjusting Ualve

Glearances

O Before adjusting valve clearance, allow
engine to cool down for at least 30 minutes.
The oil temperature should be below 80 'C
(176'F).
O Position crankshaft as per schematic, see
6.6.1.1
O Slacken bolts 1.
O Remove rockercover2togetherwith gasket
.t
O Check valve clearance 1 between rocker
arm/tappet contact face 2 and valve stem
3 with feeler gauge (there should only be a
slight resistance when feeler blade is
inserted).
For permissible valve clearance, see 9 1
6.6 Adjustments Seruice and Maintenance

O lf necessary, adjust valve clearance as

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

O Check the valve clearances at each of the

remaining cylinders and adjust if
necessary.

O Refit rocker cover (together with new

gasket if necessary)
Seruice and Maintenance 6.6 Adjustments

6.6.1.1 Ualve Glearance Adjustment Schematic

Firing Order BF6M 1015: Firing Order BFSM 1015:

A1 -83-A3-B,2-A2-81 A1 -84-A4- 81 -83-A3-B,2-A2
Sequence 1 2 3 4 5 6 1 2 3 4 5 6 7 I
Valve overla¡ A1 B3 A3 82 A2 B1 n! A1 B4 A4 B1 B3 A3 82 A2
ntr
Adjusting 82 A2 B1 A1 B3 A3 !! B3 A3 82 A2 A1 B4 A4 B1
nn
6.6 Adiustments Service and Maintenance

O Adjustment
Turn crankshaft according to sequence
TT TT TI shown in the diagram (starting with cyl. 1).
TT TI TT The valves of the relevant cylinder overlap,
marked in white, (exhaust valves about to
A1 A2 A3 A4 close, inlet valves about to open). Adjust

IX
clearance of valves, marked in black,

IXÄ
according to schematic. Markthe respective
rocker arm with chalk to show that the
adjustment has been done.

81 B2 83 84
TT TT
TT IT
nn
ntr
TT
tr!
TT
TI
D¡ II
A1 A2 A3 A4

IXÀ
Seruice and Maintenance 6.7 Accessoiles

6.7.1 Battery
6.7.1 .1 Ghecking Battery 6.l.1.2Ghecking Electrolyte Leuel 6.7.1.3 Checking Specific Grauity
and Cable Gonnections of Electrolyte

O Keep battery clean and dry.
O Undo soiled terminals.
O Clean battery plus and minus poles and
terminals and apply a film of acid-free and
acid-resistant grease.
O When reconnecting, ensure good contact of
terminals Fasten clamping boltsfingertight.
O Remove cell caps 1
O lf electrolyte test elements 2 are fìtted:
The level should be high enough to wet the
botiom of these.
O lf no such elements are provided :
Check to make sure that the level is 10-15
mm above the top edge of the plates
O Top up with distilled water if necessary.
O Fit cell caps back in position
O Measure the specific gravity of the individual
cells with a commercial hydrometer.
The measured values (see adjacent table)
indicate the state of charge of the battery.
During the measurement, the temperature
of the electrolyte should preferably read 20
"c.
6.7 Accessoiles Seruice and Maintenance

Specific Gravity

in [ks/l] ["8é (degrees Baumé) State of Charge

Normal Tropics Normal Tropics

128 123 32 27 Fully charged

120 112 24 l6 Half charged, recharge

112 108 16 11 Discharged, charge up immediately

* Measurement of the specific gravity in 'Bé (de-

grees Baumé) is obsolete and rarely used today.

The gases emitted bythe battery

are explosive!Avoid formation of
sparks in the vicinity of battery
keep away anyopen fames!
Do not allow acid to come inio
contact with skin or clothing!
Wear protective goggles!
Do not place tools on battery!
Seruice and Maintenance 6.7 Accessories

6.7.2 Three-Phase Altemator 6.7.3 Lifting Tackle

Notes on the three-phase system:

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

rhe ProPer riftins

7\äioîåi'*
 Troubleshooting

7.1 Diagnosis Ghaft

Troubleshooting 7.1 Diagnosis Ghafi

O lf engine problems occur, they frequently have

their cause in improper operation or
maintenance of the engine.

O So, in case of trouble, always check first

whether the operating and maintenance
instructions have been observed.

O A helpful Diagnosis Chaft is to be found on the

opposite page.

O lf you cannot identify the cause of the trouble

or are unable to reclify it yourself, contact your
service representative.

Before stafting, make sure that

nobody is standing the in
immediate vicinity of the engine or
driven machine.
After repairs :

lmponant: Never start engine with the speed

governor removed.
DisGonnect battery teminals!
7.1 Diagnosis Ghaft Ttoubleshooting

Troubles
Remedial Measure
fails (or difficult) to start Check P
but runs or stalls Adjust E
becomes too monitor Renew W
Clean R
not on all Top up A
ine has little or no oil pressure Lower level s
ine oil consumption excessive Bleed L
tine smokes - blue

- white
| - black
| | Causes Section
o Not declutched (declutch where possible) 0peration P
a Below stad limit temperature P
o Engine shutdown lever still in stop pos¡tion (shutdown solenoid defective) P
o o o 0il level too hiqh P
o Oil level too low s
o a a Excessive inclination of engine PIE
o Speed control lever set to middle position PIE
o o o a o Dirty air cleaner / defective turb0charqer Combustion Air P/W
a o a Air cleaner service switch/indicator defective P
a o LDA* defective (leaking line) P
o o o Charge air pipe leaking P/W
a Coolant pump defective Cooling System P/R
a a o Charqe air cooler dirtv P/R
o Coolant heat exchanqer dirty P/R
o Coolant thermostat does not open P
o Batterv defective or discharqed Electr¡cs P
LDA = manifold pressure compensator fablel of2
Troubleshooting 7.1 Diagnosis Chart

Troubles Remedial Measure

fas to start Check P

Eng ine starts, but runs unevenlV or stalls Adjust E

E becomes too monitor Renew W

Enç ne Clean R
not on all Top up A
En( ine has little or no oil pressure Lower Level s
ine oil consumption excessive Bleed L
ine smokes - blue

- white
- black
Section
a Cable connection to starter loose or oxidized Electrlcs P
a Starter defective or pinion does not engage P
a o a o a o lncorrect valve clearance Engine E
o o o o Leakinq iniection line P
a Vent pipe cloqqed (coolant heat exchanqer) P/B
o o Flame-type heater pluq system defective P
o o o o o o o lniector defective P/W
a a o o Air in fuel system (lack of fuel) P/L
o a o o Fuel filter / prefilter contaminate P/R^,11
o o lncorrect iube oil SAE class or quality grade 0peratinq Media W
o a o o Fuel quality grade not corresponding to specification under 4.2.1 P/W
o Lack of coolant PIA
 Engine Preseryation

8.1 Preseruation
Engine Preservation 8.1 Preservation

8.1 Preseruation

lf the engine is to be shut down for an extended

period, it is necessary to take preservation
measures to prevent rust formation. The
preservation measures described here will protect
the engine for a period of up to about 6 months
Before reusing the engine, the preservatives must
be removed,.

O Anti-corrosion oils to Specification:

- MtL-L 212608
- TL 9150-037/2
- Nato Code C640 I 642
O Recommended cleansing agent for removing
p reservatives:
- Petroleum benzine (hazardous materials
class A3)

Preserving the Engine:

O Run engine for about 1 0 minutes O Drain off anti-corrosion agent, see 6.3.3.
O Clean engine (in case of need with cold
cleansing agent). O Stop engine.
Removing Engine Preservatives:
Clean cool¡ng system according to O Turn engine several times by hand.
manufacturer's instructions When turning engine with stafier, move O Remove anti-corrosion agent from the grooves
O Run engine until warm and stop. shutdown iever to stop position. of the V-belt pulleys.
ODrain engine oil, see 6.1.2, and fill in anti- O Remove V-belt 2 and store in wrapped O Fit V-belt 2. Retension, if necessary, after short
corrosion oil condition period of operation, see 6.5.
O Drain coolani, see 6 3.3.
O Spray grooves of V-belt pulleys with anti-
O Fill in anti-corrosion agent, see 4 3 3 corrosion agent O Remove plugs 1, 3 and 4 and plug from
exhausi discharge opening.
O Clean oil bath air cleaner, if provided, see 6.4.3,
O Close coolant inlet and outlet 0penings 3 and
and fill in anti-corrosion oil.
air intake opening 4 O Fill in coolant according to instructions of
O Drain fuel from tank. radiator manufacturer.
O Close exhaust discharge opening.
O Prepare a mixture of 90% diesel fuel and 10%
anti-corrosion oil and fill up tank. O Start up engine.
 Specification Data

9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings
9.3 Tools
Specification Data 9.1 Engine Specifications and Settings

Model 1015 BF6M 1015 BFSM 1015 BF6M 1015 C/CP# BFSM 1015 C/CP#

Number of cylinders
Cylinder arrangement
Bore lmml
Stroke lmml
Total displacement Icm'] 15874 11906 15874
Compression ratio Ie]
Working cycle / combustion system 4-stroke TC engine/direct injection
Directlon of rotation co u nter-clockwise

Weight incl. cooling system [approx. kg] Consult headquarters

Weight w/o cooling system acc. to DIN 70020-A [approx. kg] 1 060
Engine power lkwl 304-400 1)

Speed Irpm]
s)
')
Valve clearance, engine cold Imm] inlet 0.25 +o'1
/ exhaust 0.3 +01

lnjector opening pressure Ibar] 290 bar

Commencement of dellvery ["cA BTDC]
')
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
A1 -83-43-82-42-81 A1 -84-A4-81 -83-A3-82-A2 A1 -83-A3-82-A2-81 A1 -84-A4-81 -83-A3-82-A2
V-belt tension: tension / retension 2)
Alternator 55 amperes tNl 450 / 200-350 '50
Alternator 120 amperes tNl 550/300-450.s0

r) Engine powe¡ speed, commencement of delivery, etc. are stamped on the rating plate, see 2.1.
2)
Retension after running for 1 5 minutes under load.
9.1 Engine Specifications and Settings Specification Data
Model 1015 BF6M 1015 BFSM 1015 BF6M 1015 C/CP# BFSM 1015 C/CP#

Cooling system / cooling system

Coolant quantity fapprox. lit.] 1 7 + [¡FK^
21 + ùrFK
1 7 + rrrFK'
21 +MFK',

Perm. cont coolant temperature engine outlet t"cl max 103

Temperature difference between
coolant inlet / outlet t"cl max.5
Thermostat stafts opening at t"cl 87 t2

Thermostat fully open from t"cl 102

Coolant pump
Delivery pressure in lbarl
Delivery rate in Im3/h]

Lubrication forced-feed lubrication

SAE oil (see 4.1 ) 15W40
Min 0il pressure with engine warm (120'C)
at low idle / rated speed lbarl
0il capacity (initial filling) without filter fapprox. lit ] 34Ð 45 3)
34Ð 458
0il capacity (initial filling) engine-mounted filter [approx. lit ] 36. Ð 47" 3)
36. 3)
47* 3)

0il capacity (initial filling), separate filter [approx. lit.] 38 3)

50 3)
38 3)
50 3)

s) Approximate figures can vary depending on the design. Decisive is always the upper dipstick mark.
a) 3 bar at engine speed n 21 00 rpm r
=
s) see 6.1 1 (only synthetic lube oil, see 4.1.2 1
)
* MFK
Engine rad¡ator
Specification Data 9.2 Torque Wrench Settings

Preloading INm] Tiqhtening ['deg.]

Total
Location '1
st 2nd 3rd 1st 2nd 3rd 4rh Notes
lNml
Staoe Staoe Stage Stage Stage Stage Stage

Rocker cover 22

lnspection Cover 22

Rocker arm setscrew 20

rigid mounting 30 45

flexible mounting 106

Air intake manifold 21

Exhaust manifold 61

0il drain plug 100

lnjector mounting 60

lnjection line mounting 25

0il pan 24

0il filter cartridge engine mounted

27
or separate

Coolant drain plug ea

Pinìype heater plugs i pipe union 4

9.3 Tools Specificat¡on Data
V-belt Tension Gauge

The V-belt tension gauge can be obtained under

order number 8115 from:

Fa WILBAR
Postfach 14 05 B0
D-42826 Remscheid
 l{otes

GnuroRun PRoposrron 65 lnronMATtoN

To Gnlr¡onilrA cusrouERs At{D
TO GUSTOMERS SETLING DIESET ET{GII{E EQUIPMEI{T II{TO OB
FoR usE rn Gnuronr¡n.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
The California Superior Court has approved either of the following
two melhods of compliance with Proposition 65 requirements by manufaclures of off-road equipment containing diesel engines. (The court
order containing these provisions is altached.)
1. 0n-Equinment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible 1o the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. lf warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2.OperatorManual Warning.Whentheoperatormanual isnextrevisedorbyDecember3l,l995whicheverisearlier,placethewarning
in atlachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.

The warning must appear in one of ihe following locations:

o lnside The front cover
o lnside the back cover
¡ Outside the front cover
o Outside the back cover
o As the first page of text
U nder either alternative, the warn ing m ust appear in the same size, p rint and f ormat as the allachment selected or be of an eq ually co nspicuous
size and format. lf the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
0bligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
llotes

Warnings to Place on Equipment Warning in the Manual

cAuF0Rl{tA CATIFORilIA

Proposition 65 Warning Proposition 65 Warning

Diesel engine exhaust and some of its Diesel engine exhaust and some of its
constituents are known to the State of constituents are known to the State of
Galifornia to cause cancer, birth California to cause cancer, bifih
defects, and other reproductive harm. defects, and other reproductive harm.

0f

GAtIFORl{IA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known

to the State of Galifornia to cause cancer, birth defecls, and
other reproductive harm.
 DEUTZ OiI

DEUTZ O¡I DQC II.O5 DEUTZ O¡t DQC ilt-05 DEUTZ Oil DQC lV-05 (Synthetic)
ACEA E5-02 / E3-96 / 83-04 ACEA E7-04 / E5-O2 I E3-96 I B4-O4 I A3-O4 ACEA E7-04 / E5-02 I E4-99
API CG-4 API CI-4 / SL GLOBAL DHD-1

TLS-15W4OD TLX-1OW4OFE DEUÎZ Oel DQC lV-5W30

tDoc il-05) (DQC ilr-05) (DQC rV-05)
5L 0101 6331 5L 0101 6335 5L
20L 0101 6332 20L ol0l 6336 20L 0101 7849
209 L 0101 6333 209 L 0101 6337 209 L 0101 7850
 DEUTZ AG
DEUTZ MOTOR
Ottostraße r
D-5rr49 Kõln
Telefon: +49 (o) zzt-8zz-o
Telefax: +49 (o) zzr-8 zz-3525
Internet: www.deutz.com
eMail: info@deutz.com

Printed in Germany
All rights reserved
6th Edition, @ o5lzoo3
The engine company. Order No.: ozgT g684en
(o9 rr)