Operation Manual 1015 Marine

Operation Manual
1015 Marine
Safety guidelines / Accident prevention
● Please read and observe the information

given in this Operation Manual. This will ● Unauthorized engine modifications will in-
enable you to avoid accidents, preserve the validate any liability claims against the manu-
manufacturer’s warranty and maintain the facturer for resultant damage.
engine in peak operating condition. Manipulations of the injection and regulating
system may also influence the performance
● This engine has been built exclusively for of the engine, and its emissions. Adherence
the application specified in the scope of to legislation on pollution cannot be guaran-
supply, as described by the equipment manu- teed under such conditions.
facturer and is to be used only for the
intended purpose. Any use exceeding that ● Do not change, convert or adjust the cooling
scope is considered to be contrary to the air intake area to the blower.
intended purpose. The manufacturer will The manufacturer shall not be held respon-
not assume responsibility for any damage sible for any damage which results from
resulting therefrom. The risks involved are such work.
to be borne solely by the user.
● When carrying out maintenance/repair op-
● Use in accordance with the intended pur- erations on the engine, the use of DEUTZ
pose also implies compliance with the con- original parts is prescribed. These are spe-
ditions laid down by the manufacturer for cially designed for your engine and guaran-
operation, maintenance and servicing. The tee perfect operation.
engine should only be operated by person- Non-compliance results in the expiry of the
nel trained in its use and the hazards in- warranty!
volved.
● Maintenance and cleaning of the engine
● The relevant accident prevention guidelines should only be carried out when the engine
and other generally accepted safety and is switched off and has cooled down.
industrial hygiene regulations must be ob- You must ensure that the electrical systems
served. have been switched off and the ignition key
has been removed.
● When the engine is running, there is a risk of Accident prevention guidelines concerning
injury through: electrical systems (e.g. VDE-0100/-0101/-
- turning/hot components 0104/-0105 Electrical protective measures
- engines with positive ignition against dangerous touch voltage) are to be
- ignition systems (high electrical voltage) observed.
You must avoid contact at all times! 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
General
DEUTZ diesel engines Service and maintenance Service

1
are the product of many years of research and de- will ensure that the engine continues to meet your Please contact one of our authorised service rep-
velopment. The resulting know-how, coupled with requirements. resentatives in the event of breakdowns or for spare
stringent quality standards, guarantees their long Recommended service intervals must be observed parts enquiries. Our trained specialists will carry
service life, high reliability and low fuel consump- and maintenance work carried out conscientiously. out repairs quickly and professionally, using only
tion. Special care should be taken under abnormally genuine spare parts. Genuine spare parts from
It goes without saying that the highest standards demanding operating conditions. DEUTZ AG are always manufactured to the highest
for environmental protection are also met. technical standards.
A table of service contact numbers is given at the
end of this Operation Manual.
Beware of running engine Safety

California
Proposition 65 Warning
Shut the engine down before carrying out mainte- All safety instructions in this
nance or repair work. Ensure that the engine can- Manual are designated by the ac-
not be accidentally started - accidents may other-
wise occur.
When the work is complete, be sure to refit any
! companying symbol. Please follow
them carefully.
The attention of operating person-
Diesel engine exhaust and some of its consti-
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
panels and guards that have been removed. nel should be drawn to these safety ductive harm.
Never fill the fuel tank while the engine is running. instructions.
Observe industrial safety regulations when running General safety and accident prevention regulations
the engine in an enclosed space or underground. laid down by law must also be observed.
Asbestos
DEUTZ genuine spare parts are as-

bestos-free.
© 2000
General 1.1 Technical installation instructions
Foreword 1.1.1 Engine room 1.1.2 Foundation

1
The trouble-free function of the drive systems and Overall planning is required in order to ensure that 1015 series Marine engines can be rigidly mounted,
modules is predominantly dependent on compli- the engine system can be operated in its environ- but should preferably be elastically mounted. In
ance with certain technical guidelines. ment. This plan must ensure that sufficient space both cases, the foundation must be sufficiently
is available for the connections to the engine. It stable to absorb strain without leading to founda-
This task should be met by this planning and in- must additionally be ensured that sufficient space tion deformation.
stallation guideline, though not all installation situ- is available for operation and maintenance work (a On the one hand, this strain is the result of exter-
ations, of course, can be listed. In such cases, width of approx. 1 m around the engine and the nal forces such as the motion of the sea and load
DEUTZ should be consulted as regards installation entire system). This requirement is dispensed with conditions in the case of ships, and chassis strain
advice. if this involves special installations in fast ships for in the case of vehicles. In the case of rigid mount-
naval applications and in yachts. In these cases, ing, the engine and the foundation should form a
The following specifications are non-binding. The DEUTZ specifies the necessary measures, though single unit whose resonant frequency must exceed
”Technical Installation Instructions” are not sub- installation is the responsibility of the installation the excitation frequency of the alternating torques.
ject to the revision service. Binding documents are company. The engine and deformation-stable foundation
drawn up on an order-related basis. Modifications For twin engines, axle spaces of 2000 mm are re- alone are not sufficient for mounting this unit onto
and further developments are taken into consider- quired for 1015 Marine engines, with a free pas- a soft substructure, or onto a hull which is soft as
ation in subsequent editions, with the result that sage between the engines of 75 mm. The machine a result of its design. The forces which stem from
only the most recent edition is valid. room must be of a sufficient height that pistons the engine, including the foundation, must be trans-
and sleeves can be withdrawn with lifting gear. Each ferred in dampened form to the hull via large-area
Deutz AG ® machine room must have a sufficiently large aper- transitions. In the case of elastic mounting, the
ture so that the engine or the module can be in- mass forces and moments are predominantly ab-
serted and removed without having to be disas- sorbed by the elastic mounting, with the result that
sembled. 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.
© 2000
1.1 Technical installation instructions General
1.1.3 Foundation in fibre-reinforced 1.1.4 Rigid mounting 1.1.5 Elastic mounting

plastic hulls
1
The dimensions of the foundations must be such Rigid mounting can only be provided if a stiff foun- The following standard mounting versions are avail-
that deformation due to the forces arising from the dation is available. Rigidly mounted ship’s engines able:
vessel dynamics and propeller thrust is avoided. must be aligned towards the driven machine. 1015 1. Free-standing transmission:
These forces which occur depend on the type of Marine engines should not be rigidly mounted (vi- The drive engine is free-standing and elastically
ship and the operating conditions (motion of the brations)! mounted, and the transmission is rigidly screwed
sea, high speed, acceleration) and reach a multiple It must be ensured that the flanges which are to be onto the ship’s foundation. Propeller thrust is ab-
of the weight of the engine and transmission in the connected must be parallel and concentric. Align- sorbed by the transmission.
event of impermissible loading. For this reason, ment bearing clearance must be checked when- Alignment is to be carried out according to the sec-
longitudinal members should, wherever possible, ever an engine is commissioned (installation guide- tion entitled ”Rigid mounting”, whereby the axial
be routed from the stern to the bow and should be line). and radial run-out of the shaft connections must
supported via floor plates and transverse members Alignment must be carried out so that the same be adhered to in accordance with the permissible
in order to avoid the transverse deformation of the clearance is available on both sides of the align- radial and axial shift in the elastic couplings be-
longitudinal member. ment bearing. tween the engine and the driven machine.
In order to achieve this, the total clearance is ini- The elastic mounting elements may be equipped
In the case of fibre-reinforced plastic foundations tially determined with a gauge by shifting the crank- with a height adjustment system which facilitates
and hulls, the provision of a steel or aluminium shaft in an axial direction. The crankshaft is then the alignment operations. Subsequent alignment
foundation frame or a transverse traverse is rec- moved into the central position so that the same of the system is necessary if the settling dimen-
ommended for rigidly and elastically mounted en- clearance is created on both sides of the alignment sion has reached twice the value of the increase in
gines in order to reinforce the foundation. The con- bearing. Further alignment can now be carried out, height. This subsequent alignment can be carried
nection to the ship’s foundation or hull must be whereby it must be noted that the elastic coupling out by adjusting the height of the elastic mount-
designed such that the transfer of the propeller between the engine and the transmission must be ing.
thrust is guaranteed. installed without axial tension.
Following alignment, adapters are positioned be-
One important factor which exerts an influence on neath the elastic mounting elements, or these are
alignment is the torsion of the hull. For this rea- underpoured with casting resin. Spring deflection
son, final alignment can only be carried out when should be checked and documented at the follow-
all equipment has been installed in the ship, and all ing intervals:
tanks are at least 50% full. 2 weeks following commissioning, then after 3
months, and at further intervals of 6 months un-
This is the responsibility of the installation com- til the settling process has been completed.
pany/shipyard.
© 2000
1.1.6 Combustion air system

1
2. Flanged transmission: As axial clearance cannot be defined in the case of A) Various requirements are made as regards com-
The drive engine and the transmission are con- propeller shaft drives and, in particular, elastically bustion air intake:
nected via the flywheel housing and the transmis- mounted engines, flanged external bearings must The engine outputs sold by DEUTZ are based
sion flange casing, with the result that the engine be provided in these cases in order to absorb axial on reference conditions according to DIN ISO
and the transmission form one compact unit. The thrust. 3046, in accordance with the DEUTZ sales docu-
transmission is mounted on the ship’s foundation Please enquire of our installation advice department ments.
via Silent-bloc bearings, and on the engine via 2 for details of the lengths of these flanged external Deviating conditions necessitate reductions in
coordinated, elastic bearings, whereby the propel- bearings, i.e. these generally have to be integrated engine output (e.g.: intake air temperature too
ler thrust is absorbed via the transmission’s Silent- into the powertrain. high or too low, percentage of dust in the intake
bloc bearings. In this version, the elastic coupling In cases in which propeller shaft drives do not per- air too high, permissible exhaust gas
between the engine and the transmission does not mit the installation of a flanged external bearing, backpressure exceeded etc.).
have to absorb any vibrations as a result of the DEUTZ AG (installation advice) must be consulted. If engines are used in regions with constantly
elastic mounting. The alignment of the engine/ Installation and drive options low temperatures, a reduction in engine output
transmission to the propeller shaft is to be carried Power reduction/combustion air requirements/en- is necessary in order to maintain maximum per-
out in accordance with the section entitled ”Rigid gine room ventilation, oblique positions, etc. must missible ignition pressures. (Consultation with
mounting”, whereby axial and radial run-out must be coordinated with our installation advice depart- DEUTZ installation advice department required.)
correspond to the specifications of the transmis- ment. B) Resistance in shutters or intake apertures, in
sion and propulsion manufacturer. The elastic con- The entire drive must be tested as regards torsional lines, manifolds and air filters occurs on the in-
nection of the transmission to the propeller shaft vibration. take side. Resistance may assume considerable
is not generally necessary. This should be coordi- Notes regarding commissioning: values.
nated with the propeller and shaft manufacturer. The engine operating values must be entered in Intake resistance, measured just before the com-
The elastic support elements are equipped with stop the DEUTZ commissioning report. These values are pressor, but still in the pipe with the larger cross-
limiters, with the result that system-side limiters the prerequisite of the release of the engine’s war- section, must not exceed the following value at
are not required. ranty. full load and nominal speed. Supercharged 1015
In the section entitled ”Rigid mounting”, reference Marine engines: max. 30 mbar.
is made to the fact that 1015 Marine engines have C) The 1015 Marine series engines must be
identical alignment bearing play on each side of equipped with combustion air filters, regardless
the alignment bearing. 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
© 2000
advice department must be consulted.

1.1 Technical installation instructions General
1.1.7 Exhaust system 1.1.8 Cooling water system

1
Additional installation instructions for using the The exhaust gas backpressure has a considerable Pipeline systems for the recirculating water sys-
engines in fast ships influence on the engine’s output, fuel consump- tem.
In the case of very confined engine rooms, espe- tion and thermal strain. The maximum permissible The pipelines for the coolant (treated water with a
cially in the case of ”fast ships” (e.g. yachts, naval exhaust gas backpressure must not, therefore, be pH value of 6.5-8.5 and a total hardness of 3-
vessels, catamarans, etc.), it may, under certain exceeded in order to maintain the output which is 12 °dGh and anti-corrosion agents) must be manu-
circumstances, be difficult to supply combustion sold. The exhaust gas backpressure is caused by factured from seamless steel pipe. Galvanised steel
air within the prescribed temperature range. If the flow resistance in pipelines, manifolds, compen- pipes and copper pipes are impermissible. Cool-
reduction in output necessitated by the excessively sators, armatures, waste heat boilers, silencers, ant additives may strip the zinc coating. When anti-
high temperature in the engine room is unaccept- spark arresters, rain covers and chimneys. All types corrosion oils are used, the emulsion may crack
able, the intake of combustion air from the deck is of resistance must be taken into consideration on and lose its protective effect. Anti-corrosion oils
taken into consideration in the planning phase. determination of the exhaust gas backpressure. must not be used in cooling systems to which a
In this case, it must be ensured that the air intake If the permissible exhaust gas backpressure is ex- room heater is connected. Chemical anti-corrosion
is free of spray water, exhaust gas and warm air. ceeded, the power output has to be reduced. agents are simple to use and monitor. Comprehen-
In order to avoid the transmission of engine struc- sive statements regarding water quality and the use
ture-borne noise via the exhaust line, the exhaust of anti-corrosion and antifreeze agents can be found
line must be suspended. in the Operation Instructions.
When designing the exhaust system, the regula- Following bending and welding, pipelines must be
tions of the labour protection associations, the flushed with a hot soda solution. The following must
maritime employer’s liability insurance associations be taken into consideration with regard to the di-
and the classification associations must be com- mensions of the pipelines:
plied with. The flow rates in the recirculating water system
should not exceed 3.5 m/s outside the engine.
Exhaust silencers
In order to dampen the noise of the exhaust, ab- The pipelines must be routed so that they are short
sorption and reflection silencers, or a combination and not subject to tension. Sharp pipe manifolds
of both types of silencer, are used. and pipe constrictions must be avoided. Materials
for seals, rubber bushings, pipes and lines which
Ingress of sea water into exhaust systems carry coolant must be resistant to anti-corrosion
In the case of engine installations in yachts, naval agents. These must also be resistant to external
vessels and catamarans, the spraying of sea water influences due to fuel and lube oil.
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
© 2000
the permissible exhaust gas backpressure is main-
tained, with the ingress of sea water.
1
Installation instructions for the untreated water 3. Special measures in the case of fast ships
system Positive pressures on the intake side of the at-
Untreated water refers not only to sea water, but tached untreated water pump must be ensured
also to water from inland waterways, water from throughout the entire operating range - during
rivers and all other untreated water. Special mea- displacement mode and in semi-floating and full-
sures for the pipeline system are required in all of floating mode.
these cases. This is achieved by positioning the intake fittings
on the bottom of the hull. The design and posi-
Three basic requirements are made of the untreated tion of these intake fittings and their intake cross-
water intake: sections depend on the intake pressure, i.e. the
1. Untreated water filtration speed and form of the ship. Due to the required
Sieves manufactured from punched sheet metal knowledge of the pressure conditions on the
are preferable to wire mesh. These filters pro- bottom of the ship’s hull, the requisite defini-
tect the cooling system against damage caused tions can only be carried out by the shipyards.
by abrasive substances and against soiling which Particularly critical conditions exist in the case
may arise due to the ingress of foreign bodies. of hydroplanes.
The untreated water filters must be positioned
as near to the hull as possible. Materials for untreated water lines
In the case of ships which predominantly oper- Chemical and electrolytic corrosion occurs in un-
ate in soiled waters or waters which contain sand treated water systems. DEUTZ uses CuNi30Fe,
and silt, or in the case of dredgers, untreated high-strength brass and red bronze as materials
water filtration requires particular care. for the untreated water lines which are attached to
2. Intake level of the attached untreated water the engine.
pump As a result of the oxide layers which form on their
When the untreated water filter is clean, the re- surfaces, these materials provide the maximum
sistance between the untreated water intake and possible protection against chemical corrosion. The
the untreated water pump should be less than plate heat exchangers in the sea water system are
the intake level of the pump, as resistance in- manufactured from titanium.
creases as the degree of soiling increases. The
marine engines are equipped with an untreated In the case of separately positioned coolers, DEUTZ
water pump. The max. permissible intake level prescribes the use of non-ferrous metals such as
is 0.3 bar (static level incl. dynamic resistance). CuNiFe, CuNi30Fe or CuZn20AI for all untreated
Prior to starting the engine, it must be ensured water lines.
© 2000
that the pump is charged with untreated water.

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

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
© 2000
© 31 169 0

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
turbocharger
7 Turbocharger
9 Thermostat
10 Intercooler
11 Coolant return from intercooler to
thermostat
12 Coolant return to TC or keel cooler
© 2000
© 31 171 0
© 2000
© 31 172 0

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
turbocharger
5 Turbocharger (TC)
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
© 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
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
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. Use only commercial-grade diesel fuel. For fuel
Pour lube oil into the oil filler neck (arrow). grade, see 4.2.
Oil capacity, see 9.1. If necessary, insert a fuel pre-filter.
For oil grade and viscosity, see 4.1. 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 Engine operation
3.1.3 Fill / bleed cooling system 3.1.4 Other preparations

3
● Check battery and cable connections, see 6.7.1.
● Trial run
2 1 - 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
© 31 177 0 © 31 142 0
phase.
After engine is broken in, checking once a day
Engine coolant circuit Bleeding the engine will be sufficient.
● Connections for coolant inlet 1 and coolant out- - Automatic bleeding at expansion tank.
let 2 are connected to coolant reservoir. Untreated water system: ● When commissioning preserved engines
● Fill cooling system with coolant via expansion ● Connect untreated water to connection 1. reverse the procedures as outlined in Chapter
tank. ● Untreated water return 2. 8.1
● Start engine and warm it up until thermostat ● It must be ensured, on system side, that air in-
opens (line 2 warms up). clusions in sea water pump intake system are
● Check coolant level at cooling system/expansion reduced to a minimum in all ship/module oper-
tank, and top up with coolant if necessary ating conditions.
● Suitable sea water filter and sea valve chest
bleeding is required.
Pipework must always be inclined to

! prevent air pockets.
© 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.
● Bring shut-off lever into operating position (so- ● Insert key and turn further clockwise against
lenoid de-energised) counter to the direction of spring pressure.
the arrow 2. - Position 2 = start
Do not actuate the starter for more than 20 sec-
onds at a time. If the engine does not catch, wait ● Solenoid 3 is switched such that the engine is ● Release key as soon as engine fires
for one minute then try again. only shut off by actuating a shut-off button pro- - The pilot lights will go out.
If the engine does not catch after two attempts, vided by the customer (shut-off circuit, i.e. shut-
refer to the Fault Table (see 7.1). off solenoid requires operating current).
© 2000
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- ● The pointer of the oil pressure gauge must dis- ● The engine temperature gauge pointer should
ating voltage on and engine off. play the minimum oil pressure (see 9.1). always remain in the green sector. It should
rarely enter the yellow-green sector. If the pointer
● The oil pressure pilot light must be extinguished enters the orange sector, the engine is overheat-
when the engine is running. ing.
Turn off and establish the cause from the Fault
Table (see 7.1).
© 2000
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 Engine operation
3.5.1 Winter operation

3
● Lube oil viscosity ● Cold start assistance
- Select the oil viscosity (SAE grade) according - At temperatures near or below freezing point,
to the ambient temperature before starting the use flame glow plug system if necessary, see
engine, see 4.1.2. 3.2.1.
- Increase oil change frequency when operat- The flame glow plug system not only lowers
ing below -10°C, see 6.1.1. the starting limit temperature, but provides
easier starting at temperatures normally not
● Diesel fuel requiring a starting aid.
- Use winter-grade diesel fuel for operation be-
low 0 °C, see 4.2.2. ● Battery
- Efficient cold starting necessitates that the
● Coolant battery is well-charged, see 6.7.1.
- Mixture ratio of anti-freeze / water for mini- - The starting limit temperatures can be low-
mum temperature (max. -35°C), see 4.3.1. ered by 4-5°C by heating the battery up to
about 20°C. (To do so, remove the battery and
● Additional maintenance work store in a warm place).
© 26 248 0
- 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).
© 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 adding.
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
© 2000

5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
© 2000

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
© 2000

10875 11000
11125 11250
11375 11500
11625 11750
11875 12000
12125 12250
12375 12500
12625 12750
12825 13000
13125 13250
13375 13500
13625 13750
© 2000
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
© 2000

© 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 ● Run engine until warm. If manual suction pump is fitted
position. ● Ensure that the engine or vehicle is in a level ● Open shut-off valve (handwheel) to oil sump.
● Engine warm: position. ● Place suction pump hose in oil pan.
Shut engine off, wait for 5 minutes and check - Lube oil temperature approx. 80°C. ● Operate manual suction pump until oil sump is
oil level. ● Switch off the engine. empty.
● Engine cold: In standard version ● Close shut-off valve (handwheel) to oil sump.
Check oil level. ● Place oil tray under the engine. ● Pour in lube oil.
● Remove the oil dipstick. ● Unscrew oil drain screw. - for grade / viscosity, see 4.1
● Wipe the dipstick with a clean, non-fibrous cloth. ● Drain oil. - for quantity, see 9.1
● Insert it to the stop and remove again. ● Screw oil drain screw in with new seal ring ● Check oil level, see 6.1.2.1.
● Check the oil level, and if necessary, top up to and tighten. (Tightening torque, see 9.2). ● After start check for leaks and retighten if nec-
the “MAX” mark. ● Pour in lube oil. essary.
- If the oil level is only just above the “MIN” - for grade / viscosity, see 4.1 Caution when draining hot oil: risk of
mark, more oil must be added. - 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: ● Clean the filter carrier sealing surface, if neces- ● Tighten the lube oil filter cartridge with another
Undo tensioning screws and remove tensioning sary. half-turn.
clamps downwards.
● Lightly oil the rubber gasket of the new lube oil ● If locking piston is available:
● Undo the lube oil filter cartridge using a com- filter cartridge. Position tensioning clamps and tighten with
mercial tool and turn to remove. tensioning screws.
● Manually screw in the new cartridge until the
● Catch any escaping oil. gasket is flush. ● 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. ● Clean any dirt from the filter carrier sealing sur- ● Hand-tighten fuel filter cartridge.
face.
● Undo fuel filter cartridge with commercial tool ● Open fuel shut-off valve.
and turn to remove. ● Apply light film of oil or diesel fuel to the rubber
gasket of the new fuel filter cartridge. ● Check for leaks.
● Catch any escaping fuel.
● 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. ● Clean engine with cold-cleaning compound. ● Once the cleaning agent has drained via the
Rinse away any dirt from between cylinder banks drainage bores, the bores should be blasted with
using water jet. ● Spray the engine with the commercial cold- compressed air again or flushed using a power-
● Ensure that drainage bores 1 between cylinder cleaning compound and allow to react for ful water jet.
banks are free. approx. 10 mins.
● Whenever the engine has been wet-cleaned, run
● Then spray clean with a powerful water jet (do the engine until warm so that any remaining
not spray sensitive engine parts - e.g. alternator water evaporates and the risk of rusting is
cabling, electronic components - directly). 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 ● Remove cover 2 and seal 3.
rubber seals. ● Carefully remove impeller 4 and clean.
● Clean plates and seal. - Replace impeller after 1000 OH or if damaged
● Inspect visually for cracks and damage, and re- ● Fit impeller 4.
place plates/seals if necessary. ● Mount cover 2 with new seal 3.
● For assembly, see chap. 9.1 ● 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 Adjustments
6.6.1 Check valve clearance (adjust

6 if necessary)
EX IN
2 2
2 1
1 1
3 3 3
© 26 406 0 © 26 404 0
● Before adjusting valve clearance, allow engine ● Check valve clearance 1 between rocker arm
to cool down for at least 30 minutes. The oil thrust piece 2 and valve stem 3 with feeler gauge
temperature should be below 80°C. (there should be only slight resistance when
● Position crankshaft as per schematic, see feeler blade is inserted).
6.6.1.1. For permissible valve clearance, see 9.1.
● Loosen screw 1.
● Remove valve cover 2 with gasket 3.
© 2000
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. ● Remove sealing caps 1. ● Measure the electrolyte density of individual cells
with a commercial hydrometer.
● Undo dirty clamps. ● If testers 2 are present: The hydrometer reading (see table on following
Electrolyte level should reach the base of these. page) indicates the battery’s state of charge.
● Clean battery terminal posts (+ and -) and During measurement, the temperature of the
clamps, and grease with acid-free and acid- ● Without testers: electrolyte should preferably be 20°C.
resistant grease. Electrolyte level should be 10-15 mm above top
of plates.
● When reassembling, ensure that clamps make
good contact. Hand-tighten clamp bolts. ● If necessary, top up with distilled water.
● 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) ———————————————————— 15 W 40 ———————————————————
Min. oil pressure when hot [bar] ————————————————————— 1.0 ————————————————————
(120°C)
and at low idling/rated speed
Initial quantity of oil
- sump only [approx. ltr.] ———————— 34 3) ————————— 34 3) ————————— 45 3) ————————
- with system [approx. ltr.] ———————— 36* 3) ————————— 36* 3) ———————— 47* 3) ———————
- with filter + system [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-
facturer, we offer — worldwide — a com-
prehensive range of diesel and gas motors
spanning from 4kW to 7,400kW. Our products are
perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job

reliably all over the world. We are determined to
preserve the high standard of performance and
dependability of our motors, thus keeping our
customers satisfied at all times. Therefore we are
represented worldwide through a network of highly
competent service partners who will meet the
needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors

which pack a lot of inventive genius. DEUTZ also
means reliable service and comprehensive support
to enhance your motor’s performance.
This index Sales & Service offers you an overview Order-No.: 0312 0807 (CD-ROM)
of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the DEUTZ AG
range of services provided. But even when no direct Deutz-Mülheimer Str. 147-149
product responsibility is mentioned, your DEUTZ D-51057 Köln
partner will be happy to help you with expert advice.
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Obtainable from the local service Partner reponsible Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. for you or from: Telex: 8812-0 khd d
http://www.deutz.de
DEUTZ AG — at your service.

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Operation Manual

● Please read and observe the information

Engine serial number:

Technical modifications required to improve our engines are

We have endeavoured to highlight any differences

Please read this Manual before starting your en-

This task should be met by this planning and in-

The following specifications are non-binding. The

1. General 2.4.3 Coolant circuit 4. Operating media

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

DEUTZ diesel engines Service and maintenance Service

Beware of running engine Safety

DEUTZ genuine spare parts are as-

Foreword 1.1.1 Engine room 1.1.2 Foundation

1.1.3 Foundation in fibre-reinforced 1.1.4 Rigid mounting 1.1.5 Elastic mounting

1.1.6 Combustion air system

advice department must be consulted.

1.1.7 Exhaust system 1.1.8 Cooling water system

that the pump is charged with untreated water.

© 26 332 0 © 26 389 0 © 31 191 0

2.1.4 Cylinder numbering

The cylinders are numbered sequentially from fly-

2.2.1 Side A untreated water cooling system

2.2.2 Side B untreated water cooling system

Note: Coolant level sensor must be connected.

2.2.3 Side A outer skin cooling system

1 Keel cooler connecting plate

2.2.4 Side B outer skin cooling system

2.3.1 Lube oil schematic 1015

© 26 394 0 28 Return line from turbocharger to crankcase

2.4.1 Coolant circuit

2.4.2 Coolant circuit

2.4.3 Coolant circuit

2.4.4 Coolant circuit

2.5.1 Remote operation

2.5.2 Remote operation

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

2.5.3 Monitoring system variants

Designation Panel variant Comments BAI = Bus Analog Interface

3.1.1 Pour in engine oil 3.1.2 Pour in fuel

Never fill the tank while the en-

! gine is running. Ensure cleanli-

ness! Do not spill fuel!

3.1.3 Fill / bleed cooling system 3.1.4 Other preparations

During and after the trial run

After the engine has been turned off

Pipework must always be inclined to

3.2.1 Electric starting

Before starting, make sure that

● Before starting the engine, disconnect driven ● Insert key

With cold start assistance

● Turn key clockwise

● Turn key further clockwise against spring -pres-

3.3.1 Engine oil pressure 3.3.2 Coolant temperature

© 25752 1 © 25 754 0 © 26 246 0

3.3.3 Coolant level

● The coolant level gauge lamp lights up (contact

3.4.1 Mechanical shut-off 3.4.2 Electrical shut-off

● Solenoid is in de-energised operating position;

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