Operation Manual

1015 Marine
Safety guidelines / Accident prevention
● Please read and observe the information
given in this Operation Manual. This will
enable you to avoid accidents, preserve the
manufacturer’s warranty and maintain the
engine in peak operating condition.
● This engine has been built exclusively for
the application specified in the scope of
supply, as described by the equipment manu-
facturer 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.
● 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.
● The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be ob-
served.
● 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!
● Unauthorized engine modifications will in-
validate any liability claims against the manu-
facturer 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.
● 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.
● When carrying out maintenance/repair op-
erations on the engine, the use of DEUTZ
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
warranty!
● 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.g. VDE-0100/-0101/-
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.
 Operation Manual
1015 Marine

0297 9749 en

Engine serial number:

Please enter the engine serial number here. This number should
be quoted when enquiring about customer service, repairs or
spare parts (see Section 2.1).

Technical modifications required to improve our engines are

reserved with regard to specification data and other technical
information contained in this Operation Manual. No parts of
this Manual may be reproduced in any form or by any means
without our written approval.

© 2000
 Foreword

Dear Customer,

Liquid-cooled Deutz engines are designed for a We are available to help with any additional enqui-
large number of applications. Consequently, a wide ries
range of variants are offered to meet the require-
ments of specific cases. Sincerely,
Your engine is appropriately equipped for the in-
stallation concerned, which means that not all of DEUTZ AG ®
the components described in this Operation Manual
are necessarily mounted on your engine.

We have endeavoured to highlight any differences

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

Please read this Manual before starting your en-

gine, and always observe the operating and main-
tenance instructions.
The trouble-free function of the drive systems and
modules is predominantly dependent on compli-
ance with certain technical guidelines.

This task should be met by this planning and in-

stallation guideline, though not all installation situ-
ations, of course, can be listed. In such cases,
DEUTZ should be consulted as regards installation
advice.

The following specifications are non-binding. The

“Technical Installation Instructions” are not sub-
ject to the revision service. Binding documents are
drawn up on an order-related basis. Modifications
and further developments are taken into consider-
ation in subsequent editions, with the result that
only the most recent edition is valid.
© 2000
 Contents

1. General 2.4.3 Coolant circuit 4. Operating media

1.1.1 Engine room Outer skin cooling system 4.1 Lube oil
1.1.2 Foundation BF8M 1015 MC 4.1.1 Grade
1.1.3 Foundation in fibre-reinforced plastic 2.4.4 Coolant circuit 4.1.2 Viscosity
hulls Untreated water cooling system 4.2 Fuel
1.1.4 Rigid mounting BF8M 1015 MC 4.2.1 Grade
1.1.5 Elastic mounting 2.5 Electrics 4.2.2 Winter fuel
1.1.6 Combustion air system 2.5.1 Remote operation 4.3 Coolant
1.1.7 Exhaust system Standard version 4.3.1 Quality of water for coolant in the
1.1.8 Cooling water system Installation example: engine monitoring recirculating water system
system 4.3.2 Coolant treatment
2.5.2 Remote operation 4.3.3 Cooling system protectants
2. Engine description Extended version
2.1 Model Installation example: engine monitoring
2.1.1 Rating plate system 5. Routine maintenance
2.1.2 Position of the rating plate 5.1 Maintenance schedule
2.1.3 Engine serial number 3. Engine operation 5.2 Maintenance schematic
2.1.4 Cylinder numbering 5.3 Maintenance work completed
2.2 Engine schematic 3.1 Commissioning
2.2.1 Side A untreated water cooling system 3.1.1 Pour in engine oil
Example: BF8M 1015MC 3.1.2 Pour in fuel
2.2.2 Side B untreated water cooling system 3.1.3 Fill / bleed cooling system
Example: BF8M 1015MC 3.1.4 Other preparations
2.2.3 Side A outer skin cooling system 3.2 Starting
Example: BF8M 1015MC 3.2.1 Electric starting
2.2.4 Side B outer skin cooling system 3.3 Monitoring systems
Example: BF8M 1015MC 3.3.1 Engine oil pressure
2.3 Lube oil circuit 3.3.2 Coolant temperature
2.3.1 Lube oil schematic 1015 3.3.3 Coolant level
Wet sump lubrication 3.4 Shut-off
2.4 Coolant circuit 3.4.1 Mechanical shut-off
2.4.1 Coolant circuit 3.4.2 Electrical shut-off
Outer skin cooling system 3.5 Operating conditions
BF6M 1015 M 3.5.1 Winter operation
2.4.2 Coolant circuit 3.5.2 High ambient temperature
Untreated water cooling system High altitude
BF6M 1015 M

© 2000
 Contents

6. Service and maintenance 7. Faults, causes and remedies

6.1 Lubrication system 7.1 Fault table
6.1.1 Oil change intervals
6.3.2 Check oil level / change engine oil 8. Engine preservation
6.3.2.1 Check oil level 8.1 Preservation
6.3.2.2 Engine oil change
6.1.3 Replace oil filter
6.2 Fuel system 9. Technical specification
6.2.1 Replace fuel filter 9.1 Engine specifications and settings
6.2.2 Replace fuel oil leak line 9.2 Screw tightening torques
6.3 Cooling system 9.3 Tools
6.3.1 Cleaning intervals
6.3.2 Drain cooling system 10. Service
6.3.3 Fill / bleed cooling system
6.3.4 Clean cooling system
6.3.5 Test/clean untreated water cooler
6.3.6 Replace untreated water pump impeller
6.4 Combustion air filter
6.4.1 Cleaning intervals
6.4.2 Dry-type air cleaner
6.5 Belt drives
6.5.1 Test alternator V-belt
6.5.2 Tension / change generator v-belt
6.6 Adjustments
6.6.1 Check valve clearance (adjust if
necessary)
6.6.1.1 Valve clearance adjustment plan
6.7 Accessories
6.7.1 Battery
6.7.2 Rotary current alternator
6.7.3 Transportation shackles
© 2000

DEUTZ diesel engines
are the product of many years of research and de-
velopment. The resulting know-how, coupled with
stringent quality standards, guarantees their long
service life, high reliability and low fuel consump-
tion.
It goes without saying that the highest standards
for environmental protection are also met.
Beware of running engine
Shut the engine down before carrying out mainte-
nance or repair work. Ensure that the engine can-
not be accidentally started - accidents may other-
wise occur.
When the work is complete, be sure to refit any
panels and guards that have been removed.
Never fill the fuel tank while the engine is running.
Observe industrial safety regulations when running
the engine in an enclosed space or underground.
Service and maintenance
will ensure that the engine continues to meet your
requirements.
Recommended service intervals must be observed
and maintenance work carried out conscientiously.
Special care should be taken under abnormally
demanding operating conditions.
Safety
All safety instructions in this
Manual are designated by the ac-
! companying symbol. Please follow
them carefully.
The attention of operating person-
nel should be drawn to these safety
instructions.
General safety and accident prevention regulations
laid down by law must also be observed.
Asbestos
DEUTZ genuine spare parts are as-
bestos-free.
General
Service
1
Please contact one of our authorised service rep-
resentatives in the event of breakdowns or for spare
parts enquiries. Our trained specialists will carry
out repairs quickly and professionally, using only
genuine spare parts. Genuine spare parts from
DEUTZ AG are always manufactured to the highest
technical standards.
A table of service contact numbers is given at the
end of this Operation Manual.
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.
© 2000
 General
Foreword
1
The trouble-free function of the drive systems and
modules is predominantly dependent on compli-
ance with certain technical guidelines.
This task should be met by this planning and in-
stallation guideline, though not all installation situ-
ations, of course, can be listed. In such cases,
DEUTZ should be consulted as regards installation
advice.
The following specifications are non-binding. The
”Technical Installation Instructions” are not sub-
ject to the revision service. Binding documents are
drawn up on an order-related basis. Modifications
and further developments are taken into consider-
ation in subsequent editions, with the result that
only the most recent edition is valid.
Deutz AG ®
© 2000
1.1 Technical installation instructions
1.1.1 Engine room
Overall planning is required in order to ensure that
the engine system can be operated in its environ-
ment. This plan must ensure that sufficient space
is available for the connections to the engine. It
must additionally be ensured that sufficient space
is available for operation and maintenance work (a
width of approx. 1 m around the engine and the
entire system). This requirement is dispensed with
if this involves special installations in fast ships for
naval applications and in yachts. In these cases,
DEUTZ specifies the necessary measures, though
installation is the responsibility of the installation
company.
For twin engines, axle spaces of 2000 mm are re-
quired for 1015 Marine engines, with a free pas-
sage between the engines of 75 mm. The machine
room must be of a sufficient height that pistons
and sleeves can be withdrawn with lifting gear. Each
machine room must have a sufficiently large aper-
ture so that the engine or the module can be in-
serted and removed without having to be disas-
sembled.
1.1.2 Foundation
1015 series Marine engines can be rigidly mounted,
but should preferably be elastically mounted. In
both cases, the foundation must be sufficiently
stable to absorb strain without leading to founda-
tion deformation.
On the one hand, this strain is the result of exter-
nal forces such as the motion of the sea and load
conditions in the case of ships, and chassis strain
in the case of vehicles. In the case of rigid mount-
ing, the engine and the foundation should form a
single unit whose resonant frequency must exceed
the excitation frequency of the alternating torques.
The engine and deformation-stable foundation
alone are not sufficient for mounting this unit onto
a soft substructure, or onto a hull which is soft as
a result of its design. The forces which stem from
the engine, including the foundation, must be trans-
ferred in dampened form to the hull via large-area
transitions. In the case of elastic mounting, the
mass forces and moments are predominantly ab-
sorbed by the elastic mounting, with the result that
forces which are not predominantly greater than
the weight forces take effect. Please enquire of our
installation advice department with regard to en-
gine moments.
1.1 Technical installation instructions
1.1.3 Foundation in fibre-reinforced
plastic hulls
The dimensions of the foundations must be such
that deformation due to the forces arising from the
vessel dynamics and propeller thrust is avoided.
These forces which occur depend on the type of
ship and the operating conditions (motion of the
sea, high speed, acceleration) and reach a multiple
of the weight of the engine and transmission in the
event of impermissible loading. For this reason,
longitudinal members should, wherever possible,
be routed from the stern to the bow and should be
supported via floor plates and transverse members
in order to avoid the transverse deformation of the
longitudinal member.
In the case of fibre-reinforced plastic foundations
and hulls, the provision of a steel or aluminium
foundation frame or a transverse traverse is rec-
ommended for rigidly and elastically mounted en-
gines in order to reinforce the foundation. The con-
nection to the ship’s foundation or hull must be
designed such that the transfer of the propeller
thrust is guaranteed.
1.1.4 Rigid mounting
Rigid mounting can only be provided if a stiff foun-
dation is available. Rigidly mounted ship’s engines
must be aligned towards the driven machine. 1015
Marine engines should not be rigidly mounted (vi-
brations)!
It must be ensured that the flanges which are to be
connected must be parallel and concentric. Align-
ment bearing clearance must be checked when-
ever an engine is commissioned (installation guide-
line).
Alignment must be carried out so that the same
clearance is available on both sides of the align-
ment bearing.
In order to achieve this, the total clearance is ini-
tially determined with a gauge by shifting the crank-
shaft in an axial direction. The crankshaft is then
moved into the central position so that the same
clearance is created on both sides of the alignment
bearing. Further alignment can now be carried out,
whereby it must be noted that the elastic coupling
between the engine and the transmission must be
installed without axial tension.
One important factor which exerts an influence on
alignment is the torsion of the hull. For this rea-
son, final alignment can only be carried out when
all equipment has been installed in the ship, and all
tanks are at least 50% full.
This is the responsibility of the installation com-
pany/shipyard.
General
1.1.5 Elastic mounting
1
The following standard mounting versions are avail-
able:
1. Free-standing transmission:
The drive engine is free-standing and elastically
mounted, and the transmission is rigidly screwed
onto the ship’s foundation. Propeller thrust is ab-
sorbed by the transmission.
Alignment is to be carried out according to the sec-
tion entitled ”Rigid mounting”, whereby the axial
and radial run-out of the shaft connections must
be adhered to in accordance with the permissible
radial and axial shift in the elastic couplings be-
tween the engine and the driven machine.
The elastic mounting elements may be equipped
with a height adjustment system which facilitates
the alignment operations. Subsequent alignment
of the system is necessary if the settling dimen-
sion has reached twice the value of the increase in
height. This subsequent alignment can be carried
out by adjusting the height of the elastic mount-
ing.
Following alignment, adapters are positioned be-
neath the elastic mounting elements, or these are
underpoured with casting resin. Spring deflection
should be checked and documented at the follow-
ing intervals:
2 weeks following commissioning, then after 3
months, and at further intervals of 6 months un-
til the settling process has been completed.
© 2000
 General
1
2. Flanged transmission:
The drive engine and the transmission are con-
nected via the flywheel housing and the transmis-
sion flange casing, with the result that the engine
and the transmission form one compact unit. The
transmission is mounted on the ship’s foundation
via Silent-bloc bearings, and on the engine via 2
coordinated, elastic bearings, whereby the propel-
ler thrust is absorbed via the transmission’s Silent-
bloc bearings. In this version, the elastic coupling
between the engine and the transmission does not
have to absorb any vibrations as a result of the
elastic mounting. The alignment of the engine/
transmission to the propeller shaft is to be carried
out in accordance with the section entitled ”Rigid
mounting”, whereby axial and radial run-out must
correspond to the specifications of the transmis-
sion and propulsion manufacturer. The elastic con-
nection of the transmission to the propeller shaft
is not generally necessary. This should be coordi-
nated with the propeller and shaft manufacturer.
The elastic support elements are equipped with stop
limiters, with the result that system-side limiters
are not required.
In the section entitled ”Rigid mounting”, reference
is made to the fact that 1015 Marine engines have
identical alignment bearing play on each side of
the alignment bearing.
© 2000
1.1 Technical installation instructions
As axial clearance cannot be defined in the case of
propeller shaft drives and, in particular, elastically
mounted engines, flanged external bearings must
be provided in these cases in order to absorb axial
thrust.
Please enquire of our installation advice department
for details of the lengths of these flanged external
bearings, i.e. these generally have to be integrated
into the powertrain.
In cases in which propeller shaft drives do not per-
mit the installation of a flanged external bearing,
DEUTZ AG (installation advice) must be consulted.
Installation and drive options
Power reduction/combustion air requirements/en-
gine room ventilation, oblique positions, etc. must
be coordinated with our installation advice depart-
ment.
The entire drive must be tested as regards torsional
vibration.
Notes regarding commissioning:
The engine operating values must be entered in
the DEUTZ commissioning report. These values are
the prerequisite of the release of the engine’s war-
ranty.
1.1.6 Combustion air system
A) Various requirements are made as regards com-
bustion air intake:
The engine outputs sold by DEUTZ are based
on reference conditions according to DIN ISO
3046, in accordance with the DEUTZ sales docu-
ments.
Deviating conditions necessitate reductions in
engine output (e.g.: intake air temperature too
high or too low, percentage of dust in the intake
air too high, permissible exhaust gas
backpressure exceeded etc.).
If engines are used in regions with constantly
low temperatures, a reduction in engine output
is necessary in order to maintain maximum per-
missible ignition pressures. (Consultation with
DEUTZ installation advice department required.)
B) Resistance in shutters or intake apertures, in
lines, manifolds and air filters occurs on the in-
take side. Resistance may assume considerable
values.
Intake resistance, measured just before the com-
pressor, but still in the pipe with the larger cross-
section, must not exceed the following value at
full load and nominal speed. Supercharged 1015
Marine engines: max. 30 mbar.
C) The 1015 Marine series engines must be
equipped with combustion air filters, regardless
of whether they take air in from outside or from
the engine room.
Where the engines are used in environments
with a high incidence of dust, e.g. cement works
or textile factories, and in areas in which there
is a risk of sand storms, the DEUTZ installation
advice department must be consulted.
1.1 Technical installation instructions
Additional installation instructions for using the
engines in fast ships
In the case of very confined engine rooms, espe-
cially in the case of ”fast ships” (e.g. yachts, naval
vessels, catamarans, etc.), it may, under certain
circumstances, be difficult to supply combustion
air within the prescribed temperature range. If the
reduction in output necessitated by the excessively
high temperature in the engine room is unaccept-
able, the intake of combustion air from the deck is
taken into consideration in the planning phase.
In this case, it must be ensured that the air intake
is free of spray water, exhaust gas and warm air.
1.1.7 Exhaust system
The exhaust gas backpressure has a considerable
influence on the engine’s output, fuel consump-
tion and thermal strain. The maximum permissible
exhaust gas backpressure must not, therefore, be
exceeded in order to maintain the output which is
sold. The exhaust gas backpressure is caused by
flow resistance in pipelines, manifolds, compen-
sators, armatures, waste heat boilers, silencers,
spark arresters, rain covers and chimneys. All types
of resistance must be taken into consideration on
determination of the exhaust gas backpressure.
If the permissible exhaust gas backpressure is ex-
ceeded, the power output has to be reduced.
In order to avoid the transmission of engine struc-
ture-borne noise via the exhaust line, the exhaust
line must be suspended.
When designing the exhaust system, the regula-
tions of the labour protection associations, the
maritime employer’s liability insurance associations
and the classification associations must be com-
plied with.
Exhaust silencers
In order to dampen the noise of the exhaust, ab-
sorption and reflection silencers, or a combination
of both types of silencer, are used.
Ingress of sea water into exhaust systems
In the case of engine installations in yachts, naval
vessels and catamarans, the spraying of sea water
into the exhaust system is usual. The sea water
must be sprayed in in such a manner that the ex-
haust cross-sections do not become sealed, and
the permissible exhaust gas backpressure is main-
tained, with the ingress of sea water.
General
1.1.8 Cooling water system
1
Pipeline systems for the recirculating water sys-
tem.
The pipelines for the coolant (treated water with a
pH value of 6.5-8.5 and a total hardness of 3-
12 °dGh and anti-corrosion agents) must be manu-
factured from seamless steel pipe. Galvanised steel
pipes and copper pipes are impermissible. Cool-
ant additives may strip the zinc coating. When anti-
corrosion oils are used, the emulsion may crack
and lose its protective effect. Anti-corrosion oils
must not be used in cooling systems to which a
room heater is connected. Chemical anti-corrosion
agents are simple to use and monitor. Comprehen-
sive statements regarding water quality and the use
of anti-corrosion and antifreeze agents can be found
in the Operation Instructions.
Following bending and welding, pipelines must be
flushed with a hot soda solution. The following must
be taken into consideration with regard to the di-
mensions of the pipelines:
The flow rates in the recirculating water system
should not exceed 3.5 m/s outside the engine.
The pipelines must be routed so that they are short
and not subject to tension. Sharp pipe manifolds
and pipe constrictions must be avoided. Materials
for seals, rubber bushings, pipes and lines which
carry coolant must be resistant to anti-corrosion
agents. These must also be resistant to external
influences due to fuel and lube oil.
© 2000
 General
1
Installation instructions for the untreated water
system
Untreated water refers not only to sea water, but
also to water from inland waterways, water from
rivers and all other untreated water. Special mea-
sures for the pipeline system are required in all of
these cases.
Three basic requirements are made of the untreated
water intake:
1. Untreated water filtration
Sieves manufactured from punched sheet metal
are preferable to wire mesh. These filters pro-
tect the cooling system against damage caused
by abrasive substances and against soiling which
may arise due to the ingress of foreign bodies.
The untreated water filters must be positioned
as near to the hull as possible.
In the case of ships which predominantly oper-
ate in soiled waters or waters which contain sand
and silt, or in the case of dredgers, untreated
water filtration requires particular care.
2. Intake level of the attached untreated water
pump
When the untreated water filter is clean, the re-
sistance between the untreated water intake and
the untreated water pump should be less than
the intake level of the pump, as resistance in-
creases as the degree of soiling increases. The
marine engines are equipped with an untreated
water pump. The max. permissible intake level
is 0.3 bar (static level incl. dynamic resistance).
Prior to starting the engine, it must be ensured
© 2000
that the pump is charged with untreated water.
1.1 Technical installation instructions
3. Special measures in the case of fast ships
Positive pressures on the intake side of the at-
tached untreated water pump must be ensured
throughout the entire operating range - during
displacement mode and in semi-floating and full-
floating mode.
This is achieved by positioning the intake fittings
on the bottom of the hull. The design and posi-
tion of these intake fittings and their intake cross-
sections depend on the intake pressure, i.e. the
speed and form of the ship. Due to the required
knowledge of the pressure conditions on the
bottom of the ship’s hull, the requisite defini-
tions can only be carried out by the shipyards.
Particularly critical conditions exist in the case
of hydroplanes.
Materials for untreated water lines
Chemical and electrolytic corrosion occurs in un-
treated water systems. DEUTZ uses CuNi30Fe,
high-strength brass and red bronze as materials
for the untreated water lines which are attached to
the engine.
As a result of the oxide layers which form on their
surfaces, these materials provide the maximum
possible protection against chemical corrosion. The
plate heat exchangers in the sea water system are
manufactured from titanium.
In the case of separately positioned coolers, DEUTZ
prescribes the use of non-ferrous metals such as
CuNiFe, CuNi30Fe or CuZn20AI for all untreated
water lines.
 Engine description

2
2.1 Model
2.2 Engine schematics
2.3 Lube oil plan
2.4 Coolant circuit
2.5 Electrical system

© 2000
 Engine description 2.1 Model

2.1.1 Rating plate 2.1.2 Position of the rating plate 2.1.3 Engine serial number
2

A B

C
D

© 26 332 0 © 26 389 0 © 31 191 0

The model A, the engine serial number B and the The rating plate C is attached to the crankcase. The engine serial number is stamped on the oil fil-
performance data are stamped on the rating plate. ter housing (arrow) as well as the rating plate.
The model and engine serial number must be given
when ordering parts.
© 2000
2.1 Model Engine description

2.1.4 Cylinder numbering

2

© 26 391 0

The cylinders are numbered sequentially from fly-

wheel 1 for each cylinder bank A or B.

© 2000
 Engine description 2.2 Engine schematic

2.2.1 Side A untreated water cooling system

2 Example: BF8M 1015MC

1 Fuel gallery
2 Lube oil feed to turbocharger
12 13 14 15 1 3 Turbocharger
4 Coolant return
2 5 Coolant feed from heat exchanger to engine
6 Starter
7 Oil dipstick
3 8 Oil sump
9 Lube oil filter
10 Coolant feed to the exhaust manifolds
11 Untreated water pump
12 Untreated water cooler
13 Expansion tank
14 Injection pump
15 Lube oil cooler
4

11 5

10

9 8 7 6
© 2000

© 31 050 0
2.2 Engine schematic Engine description

2.2.2 Side B untreated water cooling system

Example: BF8M 1015MC
2
16 Untreated water feed to pump
17 Coolant pump
23 24 25 26 12 18 Untreated water pump
19 Vibration damper
20 Alternator
21 SAE housing
22 Exhaust manifold
23 Intercooler
24 Injection valve
25 Charge air line
26 Untreated water return

Note: Coolant level sensor must be connected.

22 16

17
18
21
19

20

© 2000
© 31 051 0
 Engine description 2.2 Engine schematic

2.2.3 Side A outer skin cooling system

2 Example: BF8M 1015MC

1 Keel cooler connecting plate

2 Coolant pump
10 11 12 1 3 Lube oil filter
4 Vibration damper
5 Oil sump
9 6 Starter
7 Exhaust manifold
8 Turbocharger
9 Bleed line from turbocharger to expansion
tank
10 Injection valve
11 Charge air line
12 Fuel filter system
8

7 3

6 5
© 2000

© 31 135 0
2.2 Engine schematic Engine description

2.2.4 Side B outer skin cooling system

Example: BF8M 1015 MC
2
13 Intercooler
14 SAE housing
16 17 18 16 13 15 Engine mount
16 Engine suspension
17 Thermostat housing
18 Solenoid

7 14

15

© 2000
© 31 133 0
 Engine description 2.3 Lube oil circuit

2.3.1 Lube oil schematic 1015

2 Wet sump lubrication

1 Oil sump
2 Intake line
3 Lube oil pump
4 Pressure-relief valve
5 Lube oil cooler
6 Lube oil replacement filter
7 Main oil holes
8 Crankshaft bearing
9 Con-rod bearing
10 Camshaft bearing
11 Oil feed to injection pump
12 Injection pump
13 Return line from injection pump to
crankcase
14 Line to spray nozzle
15 Spray nozzle with pressure-maintenance
valve for piston cooling
16 Valve lifter with rocker arm impulse
lubrication
17 Stop rod, oil supply for rocker arm
lubrication
18 Rocker arm
19 Oil return bore to crankcase in cylinder
head
20 Oil pressure sensor / oil pressure switch
21 Oil line to turbocharger
22 Turbocharger
23 Oil line to compressor (hydr. pump)
24 Compressor
25 Hydraulic pump
26 Pressure-maintenance valve (adjustable)
27 Return line from compressor (hydr. pump)
to crankcase
© 2000

© 26 394 0 28 Return line from turbocharger to crankcase

Engine description

© 2000
 Engine description 2.4 Coolant circuit

2.4.1 Coolant circuit

2 Outer skin cooling system
BF6M 1015 M
1 Coolant inlet from expansion tank
2 Coolant feed line to coolant pump
3 Coolant pump
4 Coolant inlet into crankcase
5 Coolant inlet to exhaust manifold
6 Coolant inlet from exhaust manifold to
turbocharger
7 Turbocharger (TC)
8 Coolant return from TC to thermostat
9 Thermostat
10 Coolant return to TC/keel cooler
11 Coolant outlet to outer skin/keel cooler
© 2000

© 31 168 0
2.4 Coolant circuit Engine description

© 2000
© 31 167 0
 Engine description 2.4 Coolant circuit

2.4.2 Coolant circuit

2 Untreated water cooling system
BF6M 1015 M
Untreated water system
A Untreated water inlet (e.g. from sea)
B Untreated water pump
C Untreated water line to untreated water
cooler
D Untreated water cooler
E Untreated water outlet from untreated
water cooler
F Untreated water outlet via thermostat to
sea

Coolant circuit
1 Coolant feed from expansion tank to
coolant pump
2 Coolant inlet for coolant pump into
crankcase (CC)
3 Coolant outlet from coolant pump
of manifold to thermostat
4 Coolant supply from exhaust manifold to
turbocharger
5 Turbocharger
6 Coolant outlet from turbocharger
7 Coolant supply to thermostat
8 Thermostat
9 Coolant outlet from thermostat housing
(coolant pump/expansion tank)
© 2000

© 31 170 0
2.4 Coolant circuit Engine description

© 2000
© 31 169 0
 Engine description 2.4 Coolant circuit

2.4.3 Coolant circuit

2 Outer skin cooling system
BF8M 1015 MC
1 Coolant inlet from expansion tank or keel
cooler
2 Coolant supply to coolant pump
3 Coolant pump
4 Coolant inlet into crankcase
5 Thermostat/exhaust manifold coolant
distributor
6 Coolant inlet from exhaust manifold to
turbocharger
7 Turbocharger
8 Coolant return from TC to thermostat
9 Thermostat
10 Intercooler
11 Coolant return from intercooler to
thermostat
12 Coolant return to TC or keel cooler
© 2000

© 31 171 0
2.4 Coolant circuit Engine description

© 2000
© 31 172 0
 Engine description 2.4 Coolant circuit

2.4.4 Coolant circuit

2 Untreated water cooling system
BF8M 1015 MC
Untreated water coolant circuit
A Untreated water inlet
B Untreated water pump
C Untreated water feed line from untreated
water pump to untreated water cooler
D Untreated water cooler
E Untreated water inlet to untreated water
cooler
F Untreated water outlet from untreated
water cooler via thermostats
G Untreated water outlet (e.g. to sea)

Coolant circuit
1 Coolant inlet into crankcase from
expansion tank via coolant pump
2 Coolant pump
3 Coolant inlet to exhaust manifold and
thermostat
4 Coolant inlet from exhaust manifold to
turbocharger
5 Turbocharger (TC)
6 Coolant return from TC to thermostat
7 Thermostat
8 Coolant return from thermostat
9 Coolant return from thermostat to
intercooler
10 Intercooler
11 Coolant return line to expansion tank via
untreated water cooler
© 2000

© 31 173 0
2.4 Coolant circuit Engine description

© 2000
© 31 174 0
 Engine description 2.5 Electrical system

2.5.1 Remote operation

2 Standard version (24 volts only)
Installation example: engine monitoring system

C2 C6 C7
C B
C9 C10 C11

C1

C9
B7
C8

C3 C4 C5 B3 B
B2

A
A1
B1

A2 A
B4 B6
A3 B5

A4

A5
© 2000

© 31 181 0
2.5 Electrical system Engine description

2
Supplied by Deutz: C9 Warning contacts are integrated in panel
A Engine wiring harness (various cross- C10 Cable connection attached to bridge switch
sections) box
A1 Speed sensor C11 Counterplug to engine switch box
A2 Coolant level switch C12 Connection for dimmer light
A3 Oil pressure sensor customer option
A4 Coolant temperature sensor
A5 Control leads * Two functions are available for setting
I Starter 1 ”Pulse” = input of a known number of pulses
II Alternator per revolution at:
III Start-stop - induction-type pulse generator
Order proposal I - terminal W on the starter in the engine
Contents: After approx. 3 seconds a pulse figure appears in
B1 Wiring harness connected to switch box the display with the last digit flashing, e.g. ”P14.50”
B2 Terminal strip * means 14.50 pulses per revolution.
B3 Relay * Set to the appropriate pulse figure by repeated
B4 Fuses * © 31 182 0 pressing. Wait a further 3 seconds, then set the
B5 PG threaded connections on B6 next digit
(for customer’s use) * ”P14.50” etc.
B6 Terminal strip 25-way * Once you are finished, do not press again.
B7 Cable connection for monitoring panel The display changes to the set operating hours.
* Contained in switch box The procedure is then complete.
may not always be present - “Black Box” 2 ”Adjust” = speed indicator is compared with a
C Bridge/engine monitoring panel reference speed via a rev counter and set.
Contents: Selection of functions:
C1 Instrument panel housing optional ● Switch off operating power
C2 Speed indicator ● Press button on rear of speed indicator and hold
C3 Coolant level lamp down (see arrow)
C4 Alternator charging light/battery charge ● Supply operating power (switch ignition on)
indicator ● ”Pulse” or ”Adjust” appear alternately in display
C5 Coolant temperature indicator every 2 seconds
C6 Lube oil pressure indicator ● Release button on appropriate option to select
C7 Engine shut-off (emergency-off push- relevant function

© 2000
button) Setting: see chapter 2.5.2
C8 Ignition switch on/off/start © 31 183 0
 Engine description 2.5 Electrical system

2.5.2 Remote operation

2 Extended version (24 volts only)
Installation example: engine monitoring system
D2 D3 D4 D5 PANEL P2 D2 D3 D4 D5 D6 PANEL P3
D
D12
D14

D1 D1

D6 D7 D8 D9 D10 D11 D7 D8 D9 D10 D11 D12 D13

C C1 C4
C2 C5
C6 C3

A A7 B
A6 B4 B4 B4 B4

A5 B9

A4 B1
A8
A3
B2 B3 B B6 B7
B8 B5
A2

A1
© 2000

A9 © 31 180 1
2.5 Electrical system Engine description

2
Order proposal II D9 Coolant temperature gauge with warning D8 Alarm acknowledgement
B Engine switch box light D9 Battery charge indicator
B1 Wiring harness connected to switch box D10 Dimmer D10 Coolant temperature indicator
B2 Terminal strip * D11 Ignition switch (start-stop) D11 Exhaust temperature gauge
B3 Relay 4x (1x delay)* D12 BAI (Bus Anolog Interface) D12 Dimmer
B4 Fuses 2x * * Fitted in instrument case D13 Ignition switch (start-stop)
B5 2x PG threaded connections (for D14 BAI (Bus Anolog Interface)
customer’s use) * Panel 3 * Fitted in instrument case
B6 Change-over switch (e.g. engine/bridge) D1 Instrument panel
B7 Terminal strip 25-way * D2 Speed indicator with operating time * Two functions are available for setting
B8 2x PG threaded connections (for counter 1 ”Pulse” = input of a known number of pulses
customer’s use) * D3 Lube oil pressure indicator with warning per revolution at:
B9 Cable connection to customer’s distributor light - induction-type pulse generator
box D4 Transmission oil temperature gauge - terminal W on the starter in the engine
* Contained in switch box D5 Charge air pressure indicator After approx. 3 seconds a pulse figure appears in
may not always be present - “Black Box” D6 Engine shut-off (emergency-off push- the display with the last digit flashing, e.g. ”P14.50”
button) means 14.50 pulses per revolution.
C Distributor box (customer-side) D7 Coolant level warning light Set to the appropriate pulse figure by repeated
Only with more than one panel pressing. Wait a further 3 seconds, then set the
C1 Terminal strips next digit
C2 Control leads + CAN-bus ”P14.50” etc.
Once you are finished, do not press again.
D Bridge/engine monitoring panel The display changes to the set operating hours.
Panel 2 The procedure is then complete.
D1 Instrument panel 2 ”Adjust” = speed indicator is compared with a
D2 Speed indicator with operating time reference speed via a rev counter and set.
counter Selection of functions:
D3 Lube oil pressure indicator with warning ● Switch off operating power
light ● Press button on rear of speed indicator and hold
D4 Transmission oil temperature gauge P 14.50 down (see Fig. 31 183_0)
D5 Engine shut-off (emergency-off push- ● Supply operating power (switch ignition on)
button) ● ”Pulse” or ”Adjust” appear alternately in display
D6 Coolant level warning light every 2 seconds
● Release button on appropriate option to select

© 2000
D7 Alarm acknowledgement
D8 Battery charge indicator © 31 184 0 relevant function
 Engine description 2.5 Electrical system

2.5.3 Monitoring system variants

2 Example:

Designation Panel variant Comments BAI = Bus Analog Interface

Conversion of EDB data inputs.
P1 P2 P3
(Electronic Data Box
Analog indicator instruments SAE J 1708 log)
(round instruments)
Speed x x x Including operating time counter Engine-specific programming;
Engine oil pressure with warning light x x x Telltale 0.5 bar serial input data arriving via the
CAN-bus are generated here.
Coolant temperature with warning light x x x Telltale 108°C - Instrument signals
Transmission oil temp. with warning light x x Telltale 135°C (via pulses)
Exhaust temperature with warning light x Depending on engine type max. 310-500°C and
Charge air pressure with warning light x Max. 1.6 bar - warning signals
are converted into analog signals
Lamps
for displaying in the output
Coolant level x x x Illuminates if insufficient coolant “MIN” gauges and retained.
Charge indicator x x x e.g. battery or alternator
Instrument lighting
Constant illumination x Via voltage supply ON
Dimmer x x ON - OFF / bright - dark
Warning
Buzzer x x Signal from BAI
Warning contact sensor x Contained in panel wiring harness
Switch
Key-operated switch x x x Position: OFF - ON - START
Button
Stop button x x x In engine switch cabinet via time-delay relay
Lamp test / acknowledge button x x In ON position
Data processing/transmission
BAI x x Fitted in panel
Housing
© 2000

x x Cable passage
 Engine operation

3
3.1 Commissioning
3.2 Starting
3.3 Monitoring operation
3.4 Shutting off
3.5 Operating conditions

© 2000
 Engine operation 3.1 Commissioning

3.1.1 Pour in engine oil 3.1.2 Pour in fuel

3

OIL
FUEL

© 26 397 0 © 26 398 0

As a rule, engines are delivered without oil.
Pour lube oil into the oil filler neck (arrow).
Oil capacity, see 9.1.
For oil grade and viscosity, see 4.1.
Use only commercial-grade diesel fuel. For fuel
grade, see 4.2.
If necessary, insert a fuel pre-filter.
If in doubt, ask the nearest service representative.
Use summer or winter-grade fuel, depending on
the ambient temperature.

Never fill the tank while the en-

! gine is running. Ensure cleanli-

© 2000

ness! Do not spill fuel!

3.1 Commissioning
3.1.3 Fill / bleed cooling system
© 31 177 0
Engine coolant circuit
● Connections for coolant inlet 1 and coolant out-
let 2 are connected to coolant reservoir.
● Fill cooling system with coolant via expansion
tank.
● Start engine and warm it up until thermostat
opens (line 2 warms up).
● Check coolant level at cooling system/expansion
tank, and top up with coolant if necessary
2 1
© 31 142 0
Bleeding the engine
- Automatic bleeding at expansion tank.
Untreated water system:
● Connect untreated water to connection 1.
● Untreated water return 2.
● It must be ensured, on system side, that air in-
clusions in sea water pump intake system are
reduced to a minimum in all ship/module oper-
ating conditions.
● Suitable sea water filter and sea valve chest
bleeding is required.
Pipework must always be inclined to
! prevent air pockets.
Engine operation
3.1.4 Other preparations
3
● Check battery and cable connections, see 6.7.1.
● Trial run
- After engine has been prepared, let it run for
about 10 minutes, though not under full load.
During and after the trial run
- Check engine for leaks.
After the engine has been turned off
- Check oil level and top up if necessary, see
6.1.2.
- Retension V-belts, see 6.5.
● Running in
Check oil level twice a day during running-in
phase.
After engine is broken in, checking once a day
will be sufficient.
● When commissioning preserved engines
reverse the procedures as outlined in Chapter
8.1
© 2000
 Engine operation 3.2 Starting

3.2.1 Electric starting

3 Without cold start assistance

Before starting, make sure that

nobody is standing in the imme-
! diate vicinity of the engine or
driven machine. 2
P 0
1 – +
After repair work:
Check that all guards have been replaced and that 1
all tools have been removed from the engine.
When starting with flame glow plugs, do not use
any other starter substance (e.g. injection with start 2 2
pilot). Risk of accident!
Caution: If the speed regulator has been removed,
the engine must not be started under any circum-
stances.
Disconnect the battery. 1 3

© 26 400 0 © 26 411 0

● Before starting the engine, disconnect driven ● Insert key

units from the engine. - Position 0 = no operating voltage.

● Bring speed adjustment lever 1 into at least the ● Turn key clockwise
middle speed position in the direction of the ar- - Position 1 = operating voltage
row. - Pilot lights 1 and 2 illuminate.

Do not actuate the starter for more than 20 sec-
onds at a time. If the engine does not catch, wait
for one minute then try again.
If the engine does not catch after two attempts,
refer to the Fault Table (see 7.1).
© 2000
● Bring shut-off lever into operating position (so-
lenoid de-energised) counter to the direction of
the arrow 2.
● Solenoid 3 is switched such that the engine is
only shut off by actuating a shut-off button pro-
vided by the customer (shut-off circuit, i.e. shut-
off solenoid requires operating current).
● Insert key and turn further clockwise against
spring pressure.
- Position 2 = start
● Release key as soon as engine fires
- The pilot lights will go out.
3.2 Starting Engine operation

With cold start assistance

3
Flame glow plug system

P 0
– +
1
1

2 2

© 26 411 0

● Insert key
- Position 0 = no operating voltage.

● Turn key clockwise

- Position 1 = operating voltage.
- Pilot lights 1+2+3 illuminate
- Preheating until glow-plug indicator 3 flashes,
max. 30 seconds
- Engine is ready to start

● Turn key further clockwise against spring -pres-

sure
- Position 2 = start Caution: The engine must be started
within 30 seconds; if not, repeat the
● Release key as soon as engine fires. ! starting procedure.

© 2000
- The pilot lights will go out.
 Engine operation 3.3 Monitoring operation

3.3.1 Engine oil pressure 3.3.2 Coolant temperature

3
Oil pressure lamp Oil pressure gauge

© 25752 1 © 25 754 0 © 26 246 0

● The oil pressure pilot light comes on with oper-
ating voltage on and engine off.
● The oil pressure pilot light must be extinguished
when the engine is running.
© 2000
● The pointer of the oil pressure gauge must dis-
play the minimum oil pressure (see 9.1).
● The engine temperature gauge pointer should
always remain in the green sector. It should
rarely enter the yellow-green sector. If the pointer
enters the orange sector, the engine is overheat-
ing.
Turn off and establish the cause from the Fault
Table (see 7.1).
3.3 Monitoring operation Engine operation

3.3.3 Coolant level

3

min © 26 291 1

● The coolant level gauge lamp lights up (contact

is made via level sensor when coolant level is at
min.):
Turn off and establish the cause from the Fault
Table (see 7.1).
● Coolant level functional test: key in position 1 or
2 (level sensor)
Pilot light illuminates
- Coolant level OK: light goes out
- Coolant level not OK: light remains illuminated

© 2000
 Engine operation 3.4 Shut-off

3.4.1 Mechanical shut-off 3.4.2 Electrical shut-off

3

P 0
2 1 – +
1

2 2

1 3

© 26 401 0 © 26 411 0

● Move speed adjustment lever 1 to low idle. ● Move speed adjustment lever 1 to low idle.

● Move shut-off lever 2 in the direction of the ar- ● Move shut-off lever 2 in the direction of the ar-
row until the engine comes to a stop. The charge row until the engine comes to a stop. The charge
indicator and the oil pressure pilot light illumi- indicator and the oil pressure pilot light illumi-
nate when the engine stops. nate when the engine stops.

● Turn key counterclockwise (to position 0) and ● Turn key counterclockwise (to position 0) and
remove. The pilot lights will go out. remove. The pilot lights will go out.

● Solenoid is in de-energised operating position;

shut-off is only possible when energised.

If possible, do not switch off the engine when un-

© 2000

der full load. Subsequently allow the engine to idle

for approx. 2 mins.
3.5 Operating conditions
3.5.1 Winter operation
● Lube oil viscosity
- Select the oil viscosity (SAE grade) according
to the ambient temperature before starting the
engine, see 4.1.2.
- Increase oil change frequency when operat-
ing below -10°C, see 6.1.1.
● Diesel fuel
- Use winter-grade diesel fuel for operation be-
low 0 °C, see 4.2.2.
● Coolant
- Mixture ratio of anti-freeze / water for mini-
mum temperature (max. -35°C), see 4.3.1.
● Additional maintenance work
- Drain the viscous sludge from the fuel tank
once a week (undo the sludge drain screw).
- Below -20°C, after removing the starter if nec-
essary, smear the ring gear on the flywheel
via the pinion bore from time to time with cold-
resistant grease (e.g. Bosch grease FT 1 V 31).
Engine operation
3
● Cold start assistance
- At temperatures near or below freezing point,
use flame glow plug system if necessary, see
3.2.1.
The flame glow plug system not only lowers
the starting limit temperature, but provides
easier starting at temperatures normally not
requiring a starting aid.
● Battery
- Efficient cold starting necessitates that the
battery is well-charged, see 6.7.1.
- The starting limit temperatures can be low-
ered by 4-5°C by heating the battery up to
about 20°C. (To do so, remove the battery and
store in a warm place).
© 26 248 0
© 2000
 Engine operation 3.5 Operating conditions

3.5.2 High ambient temperature

3 High altitude

● Air density decreases as altitude or ambient tem-

perature increase. As a result of this, the engine’s
maximum output, the quality of the exhaust gas,
the temperature level and, in extreme cases,
starting behaviour, are impaired.
Under transient conditions, the engine can be
used at altitudes up to 500 m and temperatures
up to 45°C.
If the engine is to operate under more severe
conditions (at higher altitudes or temperatures),
it will be necessary to reduce the injected fuel
quantity and, thus, engine power.

● If you have any doubts about engine operation

under these or similar conditions, ask your en-
gine or equipment supplier whether the engine
© 25901 1
has been derated in the interests of reliability,
service life and exhaust gas quality (smoke!).
Otherwise contact your service representative.
© 2000
 Operating media

4
4.1 Lube oil
4.2 Fuel
4.3 Coolant

© 2000
 Operating media 4.1 Lube oil

4.1.1 Grade 4.1.2 Viscosity

4
Lube oils are differentiated according to their per- As the viscosity of the lube oil is dependent on tem-
formance and quality class. In common use are perature, the choice of SAE grade should be gov-
specifications named after the API (American Pe- erned by the ambient temperature prevailing at the
troleum Institute) and ACEA European Engine Oil engine operating site.
Sequences. Optimum operating behaviour will be attained if you
take the accompanying oil viscosity chart as a
Approved API oils: guide.
Should the temperature fall temporarily below the
Turbocharged engines: CF-4 CH-4 CG-4 limits of SAE grade selected, cold starting may be
affected but the engine will not be damaged.
Approved ACEA oils: In order to keep wear to a minimum, do not ex-
ceed application limits for extended periods of time.
Turbocharged engines: E1-E3/96 + E4-98 Oil changes dictated by the seasons can be avoided
by using multi-grade lube oils. Multi-grade oils,
If in doubt, ask the nearest service representative. particularly light-flowing oils, also reduce fuel con-
sumption.

with pre-warming only

© 2000

© 30 298 1
4.1 Lube oil Operating media

4.1.2.1 Special lube oil

specifications Lube oils
4
for engines with high output and engines with high workload
Supercharged, high-output engines and engines Manufacturer Lube oil type SAE class Availability
with a high workload AGIP Agip Sigma Ultra TFE 10W-40 Worldwide
AGIP Autol Valve Ultra FE 10W-40 Germany
The oils listed at right must be used for the follow- ARAL GmbH Aral MegaTurboral 10W-40 Worldwide
ing engines or applications: ARAL GmbH Aral SuperTurboral 5W-30 Worldwide
● 1015 Marine BAYWA BayWa Super Truck 1040 MC 10W-40 Southern Germany
● all engines in cogeneration plants
BAYWA BayWa Turbo 4000 10W-40 Southern Germany
● all engines in power units with mains or parallel
operation Castrol GmbH Castrol SYNTRUCK 5W-40 Europe, North America, Brazil
Argentina, Australia, South Africa
● engines in harvesting machines
Castrol GmbH Castrol DYNAMAX 7.5W-40 Europe, North America, Brazil
Argentina, Australia, South Africa
On the one hand, these oils have the high quality CHEVRON Chevron Delo 400 Synthetic 5W-40 North America
specified to ACEA or API standards. In addition,
ESSO Essolube XTS 501 10W-40 Europe
these oils are partially synthetic, or in some cases
even fully synthetic (5W-40), and therefore achieve FINA FINA KAPPA FIRST 5W-30 Europe
the thermal stability required for the application and FINA FINA KAPPA ULTRA 10W-40 Europe
have a low tendency to forming deposits in the FUCHS DEA DEA Cronos Synth 5W-40 Germany, Europe
event of closed crankcase venting in the turbo- FUCHS DEA DEA Cronos Premium LD 10W-40 Germany, Europe
charger and in the charge-air lines. FUCHS DEA Fuchs Titan Cargo MC 10W-40 Worldwide
FUCHS DEA Deutz Oel TLL 10W-40 MB 10W-40 Germany
FUCHS DEA DEA Cronos Premium FX 10W-40 Europe
FUCHS DEA Fuchs Titan Unic Plus MC 10W-40 Worldwide
MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, Africa
MOBIL OIL Mobil Delvac 1 5W-40 Worldwide
MOBIL OIL Mobil Delvac XHP Extra 10W-40 Europe, SE Asia
BP OIL International BP Vanellus HT Extra 10W-40 Europe
Shell International Shell Myrina TX / 5W-30 Europe, name
Shell Rimula Ultra varies from country to country
Shell International Shell Myrina TX / 10W-40 Europe, name
Shell Rimula Ultra varies from country to country
TOTAL TOTAL RUBIA TIR 86000 10W-40 Worldwide
Schmierölraffinerie Wintershall TFG 10W-40 Europe
Salzbergen GmbH

© 2000
The table will be updated as required.
 Operating media 4.2 Fuel

4.2.1 Grade 4.2.2 Winter fuel

4
Use commercially available diesel fuel with less than Waxing may occur at low temperatures, clogging +32 0
0.5% sulphur content. If the sulphur content is the fuel system and reducing engine efficiency. Use I
higher, oil change intervals should be reduced (see winter-grade fuel (down to -20°C) for operation +23 -5
6.1.1). below 0°C. This is made available within good time
by filling stations prior to the start of the winter +14 - 10
The following fuel specifications / standards are season.
approved:
+ 5 - 15
● Kerosene must be added at temperatures below
● DIN EN 590 -20°C. The relevant percentages are given in the
- 4 - 20
adjacent graph.
● BS 2869: A1 and A2 ● Special diesel fuels may be used in arctic cli-
- 13 - 25
(with A2, take note of the sulphur content!) matic zones down to -44°C.
II
● ASTM D 975-88; 1-D and 2-D If summer-grade diesel fuel must be used at tem- - 22 - 30
peratures below 0°C, up to 60% kerosene can also 0 10 20 30 40 50 60 %
● NATO Code F-54 and F-75 be added (see graph). °F °C B
A
© 26 441
26441 11
Exhaust emission values which may be determined In most cases, adequate resistance to cold can also
in the case of type approval tests always refer to be obtained by adding a flow improver (additive). Legend:
the reference fuel prescribed by the authorities for Please consult your DEUTZ partner.
the type approval test. I Summer-grade diesel fuel
II Winter-grade diesel fuel
A Ambient temperature
B Percentage of kerosene added

Mix in tank only! Fill with the ap-

Diesel fuels must never be mixed propriate amount of kerosene first,
! with petrol (normal and super grade
petrol)! ! then add the diesel fuel.
© 2000
4.3 Coolant Operating media

4.3.1 Quality of water for coolant in 4.3.2 Coolant treatment 4.3.3 Cooling system protectants
the recirculating water system
4
The values listed below must not be exceeded. In the case of liquid-cooled engines, special atten- DEUTZ cooling system protectants must be pur-
In order to examine the quality of your water, a test tion must be paid to the treatment and control of chased in drums under Order No. 01011490 (5
case can be ordered from DEUTZ under Order No. the coolant, as the engine may otherwise become litres) or 1221 1500 (210 litres). These are nitrite,
1213 0382. damaged as a result of corrosion, cavitation and amine and phosphate-free, and provide effective
freezing. protection against corrosion, cavitation and freez-
The treatment of the coolant is carried out by add- ing.
ing a cooling system protectant to the cooling wa- If the above mentioned cooling system protectant
Water quality min. max. ter. is unavailable, the following products may be used
pH value at 20°C 6.5 8.5 The cooling system must be continuously moni- in exceptional cases.
tored, see 5.1. In addition to checking the coolant
Chloride ion content [mg/dm3] - 100 Manufacturer Product designation
level, this also involves checking the concentra-
tion of the cooling system protectant. AVIA AVIA Antifreeze Extra
Sulphate ion content [mg/dm3] - 100 The cooling system protectant concentration can ARAL Antifreeze Extra
Total hardness [°dGH] 3 20 be checked with commercially available testers (ex- BASF Glysantin G 48
ample: gefo glycomat ®). DEA DEA Cooler Antifreeze
SHELL SHELLGlycoShell
The cooling system protectant in the coolant should
not fall below or exceed the following concentra-
tion:
Cooling system protectants Water
max. 45% v/v 55%
min. 35% v/v 65%
Filling volume, see Chapter 9.1.
The use of other cooling system protectants, e.g.
chemical anti-corrosion agents, is possible in ex-
ceptional cases. Consult DEUTZ Service.
The use of anti-corrosion oils is not permitted.

If nitrite-based cooling system

protectants are mixed with amine-
! based agents, dangerous nitro- Cooling system protectants must be

© 2000
samines are formed.
! disposed of in an environmentally-
friendly manner.
 Operating media

4
© 2000
 Routine maintenance

5
5.1 Maintenance schedule
5.2 Maintenance schematic
5.3 Maintenance work completed

© 2000
 Routine maintenance 5.1 Maintenance schedule

check= ● adjust= ❍ clean= ▲ replace= ■

5 Max. permissible guideline times in operating hours (OH)
Marine engines
The quoted engine maintenance times are the max. permissible guideline times. De-
1= check 2x daily before or during 1st trial run, during running- pending on usage, reduced maintenance intervals may be necessary, comply with the
unit manufacturer’s operating instructions. # Work may only be carried out by
In period or when commissioning new or overhauled engines authorised service personnel.
2= after 50 – 150 OH for first time Times as a function of output group:
3= every 10 OH or daily A= 12.000 OH B= 8.000 OH C= 4.000 OH D= 12.000 OH PRP= 12.000 OH
Years
1 2 3 250 500 1000 6000 1 2 3 4 Operation Section
● ● Lube oil level, top up if necessary 6.1.2/3.3.4
● ● Check engine for leaks (visual inspection) –
● ■ Intake/dry-type air cleaner (if available, maintain according to maint. ind.) 6.4.3 /6.4.4
● ● Battery and cable connectors 6.7.1
▲ ▲ ▲ ▲ Cooling system (only if required, e.g. in event of increase in coolant temperature) 6.3.5/9.2
● ▲ Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4.
● ■ ■ ■ Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/ 6.1.2
■ ■ ■ Oil filter cartridge (at every lube oil change) 6.1.3
■ ■ Fuel filter cartridge (fuel leakage lines should be replaced in their entirety) 6.2.1/ 6.2.2
● ❍ Valve clearance (adjust if necessary) 6.6.1#
● ● Engine mount (replace if damaged) 9.2
● ● ■ V-belts (retension if necessary) 6.5.1
● ● Engine monitoring system, warning system 3.3 #
● ▲ Fuel pre-cleaner 4.2
● ● Fasteners 9.2
● ● ● ■ Coolant (additive conc. of anti-freeze or chem. anti-corrosion agent) 6.3.2/ 6.3.3
■☛ ■ Coolant pump /☛untreated water pump impeller # 6.3.6
● ● Coolant level 4.3.2/ 4.3.3
● ● Fasteners, hose connections / clips -
● ● ▲ Intercooler (drain lube oil/condensation) #
● ■ Crankcase pressure-relief valve / injection valve #
© 2000

■ General overhaul #
5.2 Maintenance schematic Routine maintenance

5
The maintenance schematic shown on this page is
supplied as a self-adhesive label with each engine.
It should be affixed where it can be seen clearly on
the engine or driven equipment.
a
1000
1015 M h
Std. AIR
in.
Check that this is the case. 10
ex.
If necessary, ask your engine or equipment sup-
plier for a fresh supply of labels.
Routine work should be carried out according to in.= 0,25 mm
0.009 in.
the schedule in 5.1. 0,30 mm 1000 FU
ex.= 0.012 in.
EL

125 - 1000
2000

10 OIL
max.

500 500 500

OIL

OIL

© 0297 7950 0

Stop the engine before carrying out

© 2000
any maintenance work.
!
 Routine maintenance 5.3 Maintenance work completed

Op. hours Date Signature/stamp

5 Op. hours Date Signature/stamp

50-150* -

125 250

375 500

625 750

875 1000

1125 1250

1375 1500

1625 1750

1875 2000

2115 2250

2375 2500

2625 2750
* following commissioning of new and overhauled engines.
Duly completed maintenance jobs can be recorded and signed off in the above chart.
© 2000
5.3 Maintenance work completed Routine maintenance

Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5
2875 3000

3125 3250

3375 3500

3625 3750

3875 4000

4125 4250

4375 4500

4625 4750

4875 5000

5125 5250

5375 5500

5625 5750

Duly completed maintenance jobs can be recorded and signed off in the above chart.

© 2000
 Routine maintenance 5.3 Maintenance work completed

Op. hours Date Signature/stamp

5 Op. 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 chart.
© 2000
5.3 Maintenance work completed Routine maintenance

Op. hours Date Signature/stamp Op. hours Date Signature/stamp

5
8875 9000

8125 8250

8375 8500

8625 8750

8875 9000

9125 9250

9375 9500

9625 9750

9825 10000

10125 10250

10375 10500

10625 10750

Duly completed maintenance jobs can be recorded and signed off in the above chart.

© 2000
 Routine maintenance 5.3 Maintenance work completed

Op. hours Date Signature/stamp

5 Op. hours Date Signature/stamp

10875 11000

11125 11250

11375 11500

11625 11750

11875 12000

12125 12250

12375 12500

12625 12750

12825 13000

13125 13250

13375 13500

13625 13750

Duly completed maintenance jobs can be recorded and signed off in the above chart.
© 2000
5.3 Maintenance work completed Routine maintenance

Op. hours Date Signature/stamp Op. hours Date Signature/stamp

13875 14000
5
14125 14250

14375 14500

14625 14750

14875 15000

15125 15250

15375 15500

15625 15750

15825 16000

16125 16250

16375 16500

16625 16750

Duly completed maintenance jobs can be recorded and signed off in the above chart.

© 2000
 Routine maintenance 5.3 Maintenance work completed

Op. hours Date Signature/stamp

5 Op. hours Date Signature/stamp
© 2000
 Service and maintenance

6
6.1 Lubrication system
6.2 Fuel system
6.3 Cooling system
6.4 Combustion air filter
6.5 Belt drives
6.6 Adjustments
6.7 Accessories

© 2000
 Service and maintenance 6.1 Lubrication system

6 6.1.1 Oil change intervals

● The first lube oil change after commissioning or Lube oil intervals in OH
recommissioning following repair work takes Marine engines
Turbocharged engines
place after 50 – 150 op. hours.
Lube oil grade API classification CF-4 CG-4/ CH-4
● The lube oil change intervals depend on: ACEA classification E1+E2-96 E3-96+E4-98
- oil grade
- sulphur content of fuel Normal oil stress, e.g.:
- engine application
Continuous operation without time restriction (100% load) 250 500
● If the engine runs fewer hours during the year
than stated in the table, the oil should be changed Naval vessels, tugboats,
at least once a year. compartment boats, ferries and harbour boats,
● The table opposite refers to the following condi- river and sea-going boats, marine drive engine
tions: Lube oil grade API classification CF-4 CG-4/ CH-4
- fuel with a sulphur content of 0.5% w/w
- continuous ambient temperatures down to ACEA classification E1+E2-96 E3-96+E4-98
-10°C (+14°F).
High oil stress, e.g.:
● If the sulphur content is > 0.5 to 1% or the
Cont. operation with time restriction (110-120% load) 250 250
continuous ambient temperature is below -10°C
(+14°F), the intervals between oil changes Marine auxiliary drive/generator drive,
should be halved.
fast boats,catamarans, yachts, hydroplanes,
● For fuels with a sulphur content of > 1% please
passenger service boats, cruise liners
consult your service agent.
© 2000

Change the oil with the engine off but still warm
(lube oil temperature approx. 80°C).
6.1 Lubrication system Service and maintenance

6.1.2 Check oil level / change

engine oil
6
6.1.2.1 Check oil level 6.1.2.2 Engine oil change

© 25 729 0 © 26 022 0 © 26 023 0

● Ensure that the engine or vehicle is in a level
position.
● Engine warm:
Shut engine off, wait for 5 minutes and check
oil level.
● Engine cold:
Check oil level.
● Remove the oil dipstick.
● Wipe the dipstick with a clean, non-fibrous cloth.
● Insert it to the stop and remove again.
● Check the oil level, and if necessary, top up to
the “MAX” mark.
- If the oil level is only just above the “MIN”
mark, more oil must be added.
● Run engine until warm. If manual suction pump is fitted
● Ensure that the engine or vehicle is in a level ● Open shut-off valve (handwheel) to oil sump.
position. ● Place suction pump hose in oil pan.
- Lube oil temperature approx. 80°C. ● Operate manual suction pump until oil sump is
● Switch off the engine. empty.
In standard version ● Close shut-off valve (handwheel) to oil sump.
● Place oil tray under the engine. ● Pour in lube oil.
● Unscrew oil drain screw. - for grade / viscosity, see 4.1
● Drain oil. - for quantity, see 9.1
● Screw oil drain screw in with new seal ring ● Check oil level, see 6.1.2.1.
and tighten. (Tightening torque, see 9.2). ● After start check for leaks and retighten if nec-
● Pour in lube oil. essary.
- for grade / viscosity, see 4.1 Caution when draining hot oil: risk of
- for quantity, see 9.1
●Check oil level, see 6.1.2.1. ! scalding! Do not let used oil run into

© 2000
the ground but collect it in a container!
● After start check for leaks and retighten if nec- Dispose of this in accordance with en-
essary. vironmental regulations!
The level must not fall below the “MIN” mark.
 Service and maintenance 6.1 Lubrication system

6.1.3 Replace oil filter

6

© 25 880 0 © 25 881 0 © 25 882 0

● With attached locking piston:
Undo tensioning screws and remove tensioning
clamps downwards.
● Undo the lube oil filter cartridge using a com-
mercial tool and turn to remove.
● Catch any escaping oil.
● Clean the filter carrier sealing surface, if neces-
sary.
● Lightly oil the rubber gasket of the new lube oil
filter cartridge.
● Manually screw in the new cartridge until the
gasket is flush.
● Tighten the lube oil filter cartridge with another
half-turn.
● If locking piston is available:
Position tensioning clamps and tighten with
tensioning screws.
● Check oil level, see 6.1.2.

● Check oil pressure, see 3.3.1.

● Check lube oil filter cartridge seal for leaks.

Caution is required in the case

© 2000

! of hot oil: risk of scalding!

6.2 Fuel system Service and maintenance

6.2.1 Replace fuel filter

6

© 25 880 0 © 25 881 0 © 25 882 0

● Close the fuel shut-off valve.
● Undo fuel filter cartridge with commercial tool
and turn to remove.
● Catch any escaping fuel.
● Clean any dirt from the filter carrier sealing sur- ● Hand-tighten fuel filter cartridge.
face.
● Open fuel shut-off valve.
● Apply light film of oil or diesel fuel to the rubber
gasket of the new fuel filter cartridge. ● Check for leaks.
● Manually screw in the new cartridge until the
gasket is flush.

Keep naked flames away when The fuel system does not need to be bled.

© 2000
! working on the fuel system.
Do not smoke!
 Service and maintenance 6.2 Fuel system

6.2.2 Replace fuel oil leak line

6

3
1
2
4
6
3

5
7
© 31 891 0

● Close the fuel shut-off valve.

● Remove valve cover.
● Loosen and remove banjo bolts 7.
● Remove rubber hoses 1, 3, 4, unions 2 and O-
rings 6 and dispose of in accordance with envi-
ronmental regulations; banjo union 5 and banjo
bolt 7 can be re-used.
● Connect new oil leak line (complete) with banjo
union 5 to rubber hoses.
Fasten oil leak line using existing banjo bolt 7
and two new O-rings 6.
● Re-fit valve cover.
● Open fuel shut-off valve.
● Check for leaks after start-up.
© 2000
6.3 Cooling system Service and maintenance

6.3.1 Cleaning intervals 6.3.2 Drain cooling system 6.3.3 Fill / bleed cooling system
6
● The amount of contamination in the coolers de-
pends on the engine application.
● Oil and fuel residues on the engine increase the
risk of contamination. Therefore pay special at- 1
tention to leaks if the engine is used in dusty
environments.
● Serious contamination occurs, for example,
when there is a high level of air-borne dust.
● Because applications vary, cleaning intervals
have to be determined from case to case.
1

© 31 144 0 © 31 130 0

● Position a collecting pan beneath screw plug 1. Fill:

● Remove screw plug 1 and O-ring below coolant ● Open sealing cap on expansion tank
feed. - fill with coolant up to upper edge (max.)
● Drain coolant. ● Close the sealing cap.
● Fill / bleed as in 6.3.3. Bleed:
● Screw in screw plug 1 with new O-ring and ● Cooling system is bled via pressure-relief spring
tighten (see 9.2). on sealing cap.
● Check for leaks.

Caution when draining hot coolant: Caution: Only open expansion tank
risk of scalding! (sealing cap) when cold: risk of scald-
! !

© 2000
Collect coolant on draining. ing if pressure is too high!
Dispose of this in accordance with
environmental regulations!
 Service and maintenance 6.3 Cooling system

6.3.4 Clean cooling system

6 - Using compressed air - Using cold-cleaning compound

1 4
2 3
3 2
4 1
B 1 A 4
2 3
3 2
4 1
A B

1
1
© 26 454 1 © 26 455 1

● Blast engine with compressed air.
Rinse away any dirt from between cylinder banks
using water jet.
● Ensure that drainage bores 1 between cylinder
banks are free.
● Clean engine with cold-cleaning compound.
● Spray the engine with the commercial cold-
cleaning compound and allow to react for
approx. 10 mins.
● Then spray clean with a powerful water jet (do
not spray sensitive engine parts - e.g. alternator
cabling, electronic components - directly).
● Once the cleaning agent has drained via the
drainage bores, the bores should be blasted with
compressed air again or flushed using a power-
ful water jet.
● Whenever the engine has been wet-cleaned, run
the engine until warm so that any remaining
water evaporates and the risk of rusting is
avoided.

● Ensure that drainage bores 1 between cylinder

banks are free.

Clean the engine only when it is

switched off and has cooled down
© 2000

!
6.3 Cooling system Service and maintenance

6.3.5 Test/clean untreated water 6.3.6 Untreated water pump

cooler Replace impeller
6

1 5 8 4
3
2

3 7 6 2
A

1 4
© 31 156 0 © 31 188 0 © 31 189 0

● Remove screws 1 – 8. ● Unscrew bolt 1.

● Remove front pressure plate and plate block with
rubber seals.
● Clean plates and seal.
● Inspect visually for cracks and damage, and re-
place plates/seals if necessary.
● For assembly, see chap. 9.1
● Remove cover 2 and seal 3.
● Carefully remove impeller 4 and clean.
- Replace impeller after 1000 OH or if damaged
● Fit impeller 4.
● Mount cover 2 with new seal 3.
● Tighten bolts 1.

After starting the engine, check for

© 2000
leaks and retighten bolts 1 if nec-
! essary.
 Service and maintenance 6.4 Combustion air filter

6.4.1 Cleaning intervals 6.4.2 Dry-type air cleaner

6
● The amount of dirt in the air cleaner depends on
the amount of dust in the air and the size of the
air cleaner used. If a high level of dust is antici-
pated, a cyclone-type precleaner can be fitted 1
upstream of the air cleaner.

● Cleaning intervals must therefore be determined

from case to case.

● If dry-type air filters are used, cleaning should

only be carried out according to the service in-
dicator or service switch.

● Air cleaner servicing is needed when on the:

- service indicator
the red signal 1 is fully visible when the en-
© 25 885 1 © 31 129 0
gine is off
- service switch
the yellow pilot light comes on when the en- ● The dry-type air cleaner must be replaced after
gine is running. 1000 hours of operation.
- To do so, loosen hose clip, remove dry-type
● After carrying out service work, reset the signal air cleaner.
by pressing the button on the service indicator.
The service indicator is now ready for operation ● Insert new dry-type air cleaner and tighten with
again. the hose clip.

Never clean air cleaner with gaso-

© 2000

line.
!
Service and maintenance

© 2000
 Service and maintenance 6.5 Belt drives

6.5.1 Test alternator V-belt 6.5.2 Tension / change alternator

6 V-belt

© 26 403 0 © 26 261 1 © 25 997 1

Check - Carefully remove gauge without altering po- Tension

● Inspect whole V-belt visually for damage. sition of indicator arm 1. ● Slacken off hexagon bolts 1, 2 and 3.
● Replace damaged V-belts. - Read off the value where the indicator arm 1 ● Turn locking nut 2 in direction A until correct V-
● After installing new belts, run engine for 15 min- intersects scale 5 (arrow). For settings, see belt tension has been reached.
utes, then check belt tension. 9.1. ● Retighten bolts 1, 2 and 3.
● To check the tension of the V-belt, use a tension - If necessary, retension belt and measure
gauge (see 9.3). again.
- Place indicator arm 1 into gauge.
- Position gauge on V-belt 2, midway between
pulleys, with flange 3 on bottom of gauge
against edge of belt.
- Push steadily on black pad 4 at right angles
to V-belt 2 until spring is heard or felt to dis-
engage. Check, tension and change V-belts
only with the engine off. If neces-
© 2000

! sary, reinstall V-belt guard.

6.5 Belt drives Service and maintenance

© 25 998 0

Replace
● Slacken off hexagon bolts 1, 2 and 3.
● Turn locking nut 2 in direction B until end of stop.
New V-belt can easily be fitted in this position.
● Retighten bolts 1, 2 and 3 as per 6.5.1 until cor-
rect V-belt tension has been achieved.

© 2000
 Service and maintenance
6.6.1 Check valve clearance (adjust
6 if necessary)
2 1
3 3
© 26 406 0
● Before adjusting valve clearance, allow engine
to cool down for at least 30 minutes. The oil
temperature should be below 80°C.
● Position crankshaft as per schematic, see
6.6.1.1.
● Loosen screw 1.
● Remove valve cover 2 with gasket 3.
© 2000
6.6 Adjustments
EX IN
2 2
1 1
3
© 26 404 0
● Check valve clearance 1 between rocker arm
thrust piece 2 and valve stem 3 with feeler gauge
(there should be only slight resistance when
feeler blade is inserted).
For permissible valve clearance, see 9.1.
6.6 Adjustments Service and maintenance

IN 6
IN
7
EX
EX

4 5
© 26 405 0

● Adjust valve clearance if necessary:

- Loosen locknut 4 with ring spanner 7.
- Use screwdriver 6 to turn setscrew 5 so that
correct clearance 1 is attained after locknut 4
has been tightened.
● Check and adjust valve clearance on all remain-
ing cylinders.
● Reinstall cylinder head cover (with new gasket
if necessary).

© 2000
 Service and maintenance 6.6 Adjustments

6.6.1.1 Valve clearance adjustment schematic

6
BF6M 1015 ignition sequence: BF8M 1015 ignition sequence:
A1 - B3 - A3 - B2 - A2 - B1 A1- B4 - A4 - B1 - B3 - A3 - B2 - A2

Order 1 2 3 4 5 6 1 2 3 4 5 6 7 8

Overlap A1 B3 A3 B2 A2 B1 A1 B4 A4 B1 B3 A3 B2 A2

Adjust B2 A2 B1 A1 B3 A3 B3 A3 B2 A2 A1 B4 A4 B1
© 2000
6.6 Adjustments Service and maintenance

6
● Setting
Turn crankshaft in order shown opposite (start-
ing at 1).
Valves of corresponding cylinder overlap, shown
in white, (exhaust valves not yet closed, intake
A1 A2 A3 A1 A2 A3 A4 valves starting to open). Adjust clearance of
valves marked in black on schematic. Mark re-
spective rocker arm with chalk to show that ad-
justment has been carried out.

B1 B2 B3 B1 B2 B3 B4

A1 A2 A3 A1 A2 A3 A4

B1 B2 B3 B1 B2 B3 B4

© 2000
© 26 407 0
 Service and maintenance 6.7 Accessories

6.7.1 Battery
6 6.7.1.1 Check battery and cable 6.7.1.2 Check electrolyte level 6.7.1.3 Check electrolyte density
connections

© 25 895 0 © 24 232 3 © 25 896 0

● Keep battery clean and dry.
● Undo dirty clamps.
● Clean battery terminal posts (+ and -) and
clamps, and grease with acid-free and acid-
resistant grease.
● When reassembling, ensure that clamps make
good contact. Hand-tighten clamp bolts.
● Remove sealing caps 1.
● If testers 2 are present:
Electrolyte level should reach the base of these.
● Without testers:
Electrolyte level should be 10-15 mm above top
of plates.
● If necessary, top up with distilled water.
● Measure the electrolyte density of individual cells
with a commercial hydrometer.
The hydrometer reading (see table on following
page) indicates the battery’s state of charge.
During measurement, the temperature of the
electrolyte should preferably be 20°C.

● Screw sealing caps back in.

© 2000
6.7 Accessories Service and maintenance

6
Electrolyte density
in [kg/ l] in [°Bé (Baumé scale)*] Charge status
Normal Tropical Normal Tropical
1.28 1.23 32 27 Well charged
1.20 1.12 24 16 Semi-charged, recharge
1.12 1.08 16 11 Discharged, immediately recharge

* Measurement of electrolyte density in ° Bé

(Baumé scale) is out of date and rarely used to-
day.

The gases emitted by the battery are

explosive! Keep sparks and naked
! flames away from the battery!
Do not allow battery acid to come
into contact with skin or clothing!

© 2000
Wear protective goggles!
Do not rest tools on the battery!
 Service and maintenance 6.7 Accessories

6.7.2 Rotary current alternator 6.7.3 Transportation shackles

6
Notes on the three-phase system:
● Never disconnect the cables between battery,
alternator and regulator while the engine is run- 1
ning.

● If, however, it is necessary to start and operate

the engine without the battery, disconnect the 2
regulator from the alternator before starting.

● Be sure not to confuse the battery terminals.

● Replace defective charge indicator bulb imme-

diately.

● When cleaning the engine: do not spray the al-

ternator with a direct jet of water/steam!
© 31 131 0 © 24 410 0
Allow the engine to run warm so that the re-
maining water evaporates.
● Always use proper lifting tackle when transport-
● Do not disconnect the cables between the bat- ing the engine.
tery and alternator while the engine is running.
● Remove the lifting tackle and eyebolts.
● Touching a lead against the frame to check - Do not start the engine with the lifting tackle
whether it is live must not be carried out under connected.
any circumstances.

● In case of electric welding, connect the ground

terminal on the welder directly to the piece be-
ing welded.

Use only the correct lifting gear.

© 2000

!
 Faults, causes and remedies

7.1 Fault table

© 2000
 Faults, causes and remedies

7
● Faults can often be attributed to incorrect op-
eration or even maintenance.

● Each time a fault occurs, check whether all op-

erating and maintenance regulations have been
complied with.

● An appropriate fault table can be found on the

opposite page.

● If you cannot ascertain the cause of a fault or

cannot rectify the fault, please contact DEUTZ
SERVICE.

Before starting, make sure that nobody is standing

in the immediate vicinity of the engine or driven
machine.
In the event of repair work:
Caution: If the speed regulator has
been removed, the engine must
not be started under any circum-
! stances.
© 2000

Disconnect the battery.

7.1 Fault table Faults, causes and remedies
Faults Action
Engine does not start or is difficult to start (starting speed is not achieved on starting) Check C 7
Engine starts, but runs irregularly or stalls Adjust A
Engine becomes excessively hot. Temperature warning system responds Replace R
Engine output is deficient Clean Cl
Engine does not run on all cylinders Top up T
Engine oil pressure is non-existent or excessively low Reduce Rd
Engine oil consumption excessive Bleed B
Engine smokes - blue
- white
- black
Cause Section
● ● Below starting limit temperature Engine operation C
● ● Oil level too low T
● ● ● ● Oil level too high Rd
● ● ● Excessive inclination of engine C/A
● ● Adjust throttle to half actuation travel C/A
● ● ● Air cleaner clogged / turbocharger defective Combustion air C/R
● ● ● Air cleaner service switch / indicator defective C
● ● ● Charge air line leaking C/R
● ● ● Exhaust manifold/silencer soiled C/Cl
● ● ● ● ● Turbocharger blocked / leaking / defective C/R
● Coolant pump defective or air in coolant system C/Cl
● ● ● Intercooler soiled/blocked Cooling system C/Cl
● ● Coolant heat exchanger/untreated water/keel cooler soiled/blocked C/Cl
● ● ● ● V-belt torn or loose (fuel pump in belt drive) C/R
● ● Cooling air temperature rise / heating short circuit C
● ● ● ● Lube oil cooler soiled / leaking C/Cl
● Battery defective or not charged (battery capacity too low) Electrics C

© 2000
● Starter cable connections loose or oxidised (electrical circuit) C
● Starter solenoid defective or pinion does not engage C
Table 1 of 2
 Faults, causes and remedies 7.1 Fault table

Faults Action
7 Engine does not start or is difficult to start (starting speed is not achieved on starting) Check C
Engine starts, but runs irregularly or stalls Adjust A
Engine becomes excessively hot. Temperature warning system responds Replace R
Engine output is deficient Clean Cl
Engine does not run on all cylinders Top up T
Engine oil pressure is non-existent or excessively low Reduce Rd
Engine oil consumption excessive Bleed B
Engine smokes - blue
- white
- black
Cause Section
● ● Engine regulator defective Electrics C/R
● ● ● ● ● Incorrect valve clearance Engine A
● ● ● ● Injection line leaks C
● Bleed line blocked or coolant heat exchanger defective C/Cl
● ● Sheathed glow plugs defective C
● ● ● ● ● ● ● Injection valve/unit pump defective C/R
● ● Crankcase bleed system blocked / defective C/Cl/R
● ● Oil filter defective (intake line contains air or is blocked) C/Cl/B
● ● ● ● Air/water in the fuel system C/Cl/B
● ● ● Fuel filter / fuel pre-cleaner soiled Operating media C/Cl
● ● ● ● Incorrect engine lube oil SAE class or grade C/R
● ● ● ● Fuel grade not as per operating manual C/R
● Coolant level too low C/T
Table 2 of 2
© 2000
 Engine preservation

8.1 Preservation

© 2000
 Engine preservation 8.1 Preservation

8.1 Preservation
8
If the engine is to remain idle for an extended pe- Preserve engine: Remove engine preservation:
riod of time, it is necessary to take protective mea- ● Clean engine (possibly with cold-cleaning com- ● Remove anti-corrosion agent from grooves in
sures to prevent the formation of corrosion. The pound). V-belt pulleys.
preservative measures described here will protect Clean cooler according to cooling system
the engine for up to approx. 6 months. The proce- manufacturer’s specifications. ● Install V-belts. Retension after brief operation if
dure will have to be reversed before the engine is Clean/flush untreated water/keel cooler and con- necessary, see 6.5.
recommissioned. nect to clean water.
● Run engine until warm, then turn off. ● Remove screw plugs for coolant + untreated
● Anti-corrosion oils to specification: ● Drain engine oil, see 6.1.2, and fill with anti-cor- water/keel cooler inlet and outlet apertures, in-
- MIL-L 21260B rosion oil. take aperture and exhaust gas outlet and con-
- TL 9150-037/2 ● Drain coolant, see 6.3.2. nect if necessary.
- Nato Code C 640 / 642 ● Drain water from untreated water cooler.
● Top up anti-corrosion agent, see 4.3.3. ● Top coolant up according to cooling system
● Recommended cleaning agent to remove pre- ● Drain fuel tank. manufacturer’s specifications.
servatives: ● Make up a mixture of 90% diesel fuel and 10%
- Petroleum benzine (hazardous materials class anti-corrosion oil, and refill fuel tank. ● Commission engine.
A3) ● Allow the engine to run for approx. 10 mins.
● Switch off the engine.
● Manually turn the engine over several times.
When turning over with starter, set shut-off le-
ver to stop position.
● Drain water from untreated water/keel cooler and
seal outlet aperture and intake aperture with
screw plugs.
● Remove V-belts and store wrapped and recum-
bent.
● Spray grooves on V-belt pulleys with anti-cor-
rosion spray.
● Seal coolant inlet and outlet apertures and in-
take aperture.
● Seal exhaust gas outlet.
● Drain anti-corrosion agent, see 6.3.2.
© 2000
 Technical specification

9
9.1 Technical specification
9.2 Torque wrench settings
9.3 Tools

© 2000
 Technical specification 9.1 Engine specifications and settings

9 Design type 1015 Marine —————— BF6M 1015M ————— BF6M 1015 MC ———— BF8M 1015 MC —————

No. of cylinders ————————— 6 ——————————— 6 —————————— 8 ————————

Cylinder configuration —————————————————— V - 90° layout ——————————————————
Bore [mm] ———————————————————— 132 ————————————————————
Stroke [mm] ———————————————————— 145 ————————————————————
Total displacement [cm3] ———————— 11906 ————————— 11906 ———————— 15874 ———————
Compression ratio [ε] ————————————————————— 17 ————————————————————
Working cycle / combustion system ———————————— 4-stroke turbocharged engine/direct injection ————————————
Direction of rotation —————————————————— Counter-clockwise —————————————————

Weight incl. cooling system to DIN 70020-A

Untreated water cooling system [approx. kg] ———————— 1080 ————————— 1180 ————————— 1380 ————————
Outer skin cooling system (keel cooling)[app. kg] ———————— 1020 ————————— 1110 ————————— 1300 ————————
Engine output [kW] ——————— 187-240 1) ——————— 228-330 1) ——————— 304—440 1) ——————
Speed [rpm] ————————————————————— 1) ————————————————————
Valve clearance with cold engine 5) [mm] ——————————————— Intake 0.25 + 0.1/ exhaust 0.3 + 0.1 ——————————————

Injector opening pressure [bar] ———————————————————— 290 bar ———————————————————

Start of feed [°KW BTDC] ————————————————————— 1) ————————————————————
Firing order of the engine —— 1-6-3-5-2-4 ——— 1-6-3-5-2-4 ———— 1-8-4-5-7-3-6-2 ———— 1-8-4-5-7-3-6-2 ———
— A1-B3-A3-B2-A2-B1 —— A1-B3-A3-B2-A2-B1 —— A1-B4-A4-B1-B3-A3-B2-A2 —— A1-B4-A4-B1-B3-A3-B2-A2 ——
V-belt tension: ————————————————— Pretension / retension 2) ————————————————
Alternator 80 amps [N] —————————————————— 450 / 200- 350 ± 50 —————————————————
Alternator 140 amps [N] —————————————————— 550 / 300- 450 ± 50 —————————————————

1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1.
2)
Retension after engine has been operated under load for 15 minutes.
© 2000
9.1 Engine specifications and settings Technical specification

Design type 1015 M —————— BF6M 1015 M ————— BF6M 1015 MC ———— BF8M 1015 MC ————— 9
Cooling system (single or dual-circuit) ————————————— Liquid-cooled / cooling system protection ————————————
Coolant volume at .
Coolant volume for engine only
with untreated water cooling [approx. ltr.] ———————— 28 —————————— 50 —————————— 55 ————————
with keel cooling [approx. ltr.] ———————— 18 —————————— 38 —————————— 43 ————————
Perm. constant coolant temperature
Engine outlet [°C] ——————————————————— max.103 ———————————————————
Temperature difference between
coolant - inlet/outlet [°C] ———————————————————— max. 5 ———————————————————
Thermostat opening commencement at [°C] ———————————————————— 79 ±2 ————————————————————
Thermostat fully open from [°C] ———————————————————— 94 ±2 ————————————————————
Coolant pump
4)
Feed pressure in [bar] ————————————————————— ————————————————————
Volumetric capacity
of recirculating water system [m3/h] ———————— 40 —————————— 40 —————————— 42 ————————

Lubrication ————————————————— Pressure lubrication —————————————————

SAE oil (see 4.1)
Min. oil pressure when hot
(120°C)
and at low idling/rated speed
Initial quantity of oil
- sump only
- with system
- with filter + system
———————————————————— 15 W 40 ———————————————————
[bar] ————————————————————— 1.0 ————————————————————
[approx. ltr.] ———————— 34 3) ————————— 34 3) ————————— 45 3) ————————
[approx. ltr.] ———————— 36* 3) ————————— 36* 3) ———————— 47* 3) ———————
[approx. ltr.] ———————— 38 3) ————————— 38 3) ————————— 50 3) ————————

3)
Approx. values may vary depending on version. The upper oil dipstick mark is always authoritative.
4)
3 bar at engine speed n = 2100 rpm
5)
See note to 6.1.1
* Engine coolant cooler

© 2000
 Technical specification 9.2 Torque wrench settings

Pretighten [Nm] Retighten [Nm]

Installation location Total Comments
1st stage 2nd stage 3rd stage 1st stage 2nd stage 3rd stage 4th stage [Nm]

Cylinder head cover 22

Cylinder head bolt 22

Rocker arm adjustment screw 20

Foot Rigid mounting 30 45

Foot Elastic mounting 106

Air intake 21

Exhaust manifold 61

Oil drain screw 100

Injection valve attachment 60

Injection line attachment 25

Oil sump 24

Lube oil filter cartridge 27 on engine or separate

Coolant drain plug 38

© 2000
9.2 Torque wrench settings Technical specification

Untreated water heat exchanger

9
● Screw guide bolts into baseplate.
● Assemble plate block (place end plate 1 on pressure plate and end plate 2 on baseplate) and locate on guide bolts with pressure plate.
● Tighten plate on guide bolts by tightening each nut alternately * by two turns until stop is reached.

No. of plates Turns of End spacing * A Limit value* Comments

mounting screws [mm] [mm]
26 1.5 + 1 91±0.2 90 # M14X 200 to DIN 912 8.8 A4C
34 1.5 + 1 119 ±0.2 117.8 # M14X 230 to DIN 912 8.8 A4C

* Fasten mounting screws in the order 1-8, as per drawing.

# Only tighten to limit value with leaky heat exchanger.

1 5 8 4

3 7 6 2
A

© 2000
© 31 156 0
 Technical specification 9.3 Tools

V-belt tension gauge

9

26002 0

The V-belt tension gauge can be obtained under

order number 8115 from:

WILBÄR
Postfach 14 05 80
D-5630 Remscheid
© 2000
 Notes

en Warnings to Place on Equipment Warning in the Manual

CALIFORNIA CALIFORNIA

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
California to cause cancer, birth California to cause cancer, birth
defects, and other reproductive harm. defects, and other reproductive harm.

or

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
 Notes

CALIFORNIA PROPOSITION 65 INFORMATION en

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
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.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment 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 to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 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 the following locations:

● Inside The front cover
● Inside the back cover
● Outside the front cover
● Outside the back cover
● As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If 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.
Obligation 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.
 Service

Knowing it’s DEUTZ Order-No.: 0312 0806 10

en DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manu-
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