Operation Manual
Operation Manual
Operation Manual
1015
1
26 388/
Safety guidelines / Accident prevention
1015
0297 9684 en
Engine
Serial Number:
Dear Customer,
Sincerely,
DEUTZ AG
Table of Contents
Shut the engine down before carrying out mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
2 2.1.1 Rating Plate 2.1.2 Location of Rating Plate 2.1.3 Engine Serial Number
A B
D
C
The model designation A, the engine serial The rating plate C is affixed to the crankcase. The engine serial number is stamped on the
number B and the performance data are stamped crankcase iteself (arrow) and on the rating plate.
on the rating plate.
26 391 0
11 6
10 9 8 7
26 392 0
2.2 Engine Illustration Description of Engine
21
20 19 18
26 393 0
Description of Engine 2.2 Engine Illustration
1 Exhaust turbocharger
14 2 Exhaust manifold
3 Crankcase
4 Starter
5 Oil filler neck
13 1 6 Oil pan
7 Lube oil filter
8 V-belt pulley with vibration damper
9 Coolant connection from heat exchanger to
engine
12 10 Oil cooler
11 Fan
12 Exhaust stack
13 Charge air pipe to the charge air cooler
2 14 Flame-type heater plug system (B-side)
11
3
10
9 4
8 7 6 5
26 412 0
2.2 Engine Illustration Description of Engine
16
21
17
20 19 18
26 413 0
Description of Engine 2.3 Lube Oil Circuit
1 Oil pan
2 Intake pipe
3 Oil pump
4 Overpressure relief valve
5 Oil cooler
6 Spin-on oil filter
7 Main oil bores
8 Main bearing
9 Big-end bearing
10 Camshaft bearing
11 Oil supply to injection pump
12 Injection pump
13 Return line from injection pump to
crankcase
14 Line to spray nozzle
15 Spray nozzle with pressure-holding valve for
piston cooling
16 Tappet with control groove for pulse
lubrication of rocker arms
17 Pushrod, oil supply to rocker arm lubrication
18 Rocker arm
19 Oil return bore in cylinder head to crankcase.
20 Oil pressure sensor / oil pressure switch
21 Oil line to exhaust turbocharger
22 Exhaust turbocharger
23 Oil line to compressor (hydr. pump)
24 Compressor
25 Hydraulic pump
26 Pressure-holding valve (adjustable)
27 Oil return line from compressor (hydr.
26 394 0 pump) to crankcase
28 Oil return line from turbocharger to
crankcase
Engine Operation
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 Operating Conditions
Engine Operation 3.1 Commissioning
3 3.1.1 Filling in Engine Oil 3.1.2 Filling Oil Bath Air Cleaner with
Engine Oil
3.1.3 Filling the Fuel Tank
OIL
FUEL
As a rule, the engines are delivered without Fill engine oil into bowl 1 of oil bath air Use only commercial-grade diesel fuel. For
oil filling. cleaner (if fitted) up to the arrow mark. fuel quality grade, see 4.2.
Fill in lube oil through the oil filler neck For oil quality grade and oil viscosity, see 4.1. Use summer- or winter-grade fuel,
(arrow). depending on the ambient temperature.
For oil filling volume, see 9.1.
For oil quality grade and oil viscosity, see 4.1.
Never fill oil into the Stop engine before filling the
precleaner’s dust collector, if fuel tank!
! provided. ! Observe strict cleanliness! Do
not spill any fuel!
3.1 Commissioning Engine Operation
● Trial run
– Upon completing the preparations run the
engine for a short trial run of about 10
2 minutes under low load.
● Breaking-in
● Connect coolant inlet 1 and coolant outlet 2 to During the breaking-in phase, it is
external coolant tank. recommended to check the oil level twice a day.
● Fill in coolant into cooling system. After the breaking-in phase, checking once a
day will be sufficient.
● Start engine and run up to normal operating
temperature until thermostat opens (line 2
warms up).
P 0
– +
1
1
2 2
26 411 0
● The oil pressure pilot lamp lights up with ● The pointer of the oil pressure gauge must ● The pointer of the temperature indicator should
operating voltage applied and engine shut off. indicate the minimum oil pressure (see 9.1). remain in the green sector and enter the yellow-
greeen sector only in exceptional cases. If the
● The oil pressure pilot lamp must go out when pointer enters the orange sector, the engine is
the engine is running. overheating. Turn it off and establish the cause
from the Diagnosis Chart (see 7.1).
3.3 Monitoring Systems Engine Operation
min 26 291 1
min 26 278 1
● Lamp of coolant level indicator lights up ● Lamp of lube oil level indicator lights up
(contact via float switch/level sensor when min. (contact via float switch/level sensor when min.
coolant level has been reached): lube oil level has been reached):
Turn engine off and establish cause from the Turn engine off and establish cause from the
Diagnosis Chart (see 7.1) Diagnosis Chart (see 7.1)
P 0
2 1 – +
1
2 2
1 3
26 401 0 26 411 0
● Set speed control lever 1 to low speed position. ● Turn key counter-clockwise (to position 0) and
pull off. Pilot lamps go out.
● Actuate shutdown lever 2 until engine comes to
standstill. Charging-current and oil pressure
pilot lamps light up when engine has come to
standstill.
3.5 Operating Conditions Engine Operation
The lube oil quality grade is defined by Generally, multi-grade oils shall be used. In
specifications. The following lube oil closed heated rooms at temperatures >5°C,
specifications are approved: also single-grade oils can be used. The
indicated lube oil grades must, of course, also
lube oil quality class: be observed for single-grade oils.
classification/specification As the viscosity of lube oil is dependent on
temperature, the choice of SAE grade
DEUTZ- DQC I DQC II DQC III should be governed by the ambient
temperature prevailing at the engine
ACEA- E2-96 E3-96/E5-02 E4-99 operating site.
Optimum operating behaviour will be
API- CF/CF-4 CG-4/CH-4 - attained if you take the accompanying oil
viscosity diagram as a guide.
Worldwide - DHD-1 - Should the temperature fall temporarily
below the limits of the SAE grade selected,
cold starting may be affected but the engine
If in doubt, contact your service representative will not be damaged.
In order to keep wear to a minimum, do not
exceed application limits for extended
periods of time.
Oil changes dictated by the seasons can be
avoided by using multi-grade lube oils. Mul-
ti-grade oils - particularly low-friction oils -
also reduce fuel consumption.
Use commercial brands of diesel fuel with a At low temperatures, waxing may occur and
sulfur content of less than 0.5%. If the sulfur clog the fuel system, causing operational +32 0
content is higher than 0.5%, oil change trouble. In case of sub-zero (+32 °F) I
intervals should be reduced, see 6.1.1. ambient temperatures it is recommended to +23 -5
use winter-grade diesel fuel (down to –15 °C
The following specifications / standards are = +5 °F). Normally, such fuel is offered at the +14 - 10
approved: filling stations in good time before the cold
+ 5 - 15
season starts. Diesel fuel containing additi-
l CEN EN 590 or DIN/EN 590 ves („Super Diesel”) is frequently also on - 4 - 20
sale for use at temperatures down to –20 °C
l DIN 51 601 (Feb.1986) (–4 °F). - 13 - 25
II
l BS 2869 (1988): A1 and A2 l At temperatures below –15 °C (+5 °F) or – - 22 - 30
20 °C (–4 °F), kerosene should be added
l ASTM D975-88: 1-D and 2-D to the diesel fuel. The relevant 0 10 20 30 40 50 60 %
°F °C
A B
percentages are given in the diagram at ' 26441 1
l NATO Code F-54 and F-75 the right.
The exhaust emission levels determined If summer-grade diesel fuel has to be used Illustration legend:
during certification always refer to the at temperatures below zero (+32 °F), up to
reference fuel specified by the supervising 60% kerosene may be added (see diagram
authorities for such certification. at the right). I Summer diesel fuel
Diesel fuels must never be mixed Mix in tank only! Fill in the
with petrol (normal and super appropriate amount of kerosene
grade petrol)! first, then add the diesel fuel.
4.3 Coolant Operating Media
4.3.1 Quality of water for coolant 4.3.2 Coolant treatment 4.3.3 Cooling system protectants
in the recirculating water
4
system
The values listed below must not be exceeded. In the case of liquid-cooled engines, special DEUTZ cooling system protectants must be purchased
In order to examine the quality of your water, a test case attention must be paid to the treatment and in drums under Order No. 01011490 (5 litres) or 1221
can be ordered from DEUTZ under Order No. 1213 control of the coolant, as the engine may 1500 (210 litres). These are nitrite, amine and phos-
0382. otherwise become damaged as a result of phate-free, and provide effective protection against
corrosion, cavitation and freezing. corrosion, cavitation and freezing.
Water quality min max The treatment of the coolant is carried out by adding a If the above mentioned cooling system protectant is
cooling system protectant to the cooling water. unavailable, the following products may be used in
ph value at 20 °C /68° F 6.5 8.5 The cooling system must be continuously monitored, exceptional cases.
Chloride ion content [mg/dm3] - 100 see 5.1. In addition to checking the coolant level, this
also involves checking the concentration of the cooling Manufacturer Product designation
Sulphate ion content [mg/dm3] - 100 system protectant. AVIA AVIA Antifreeze Extra
The cooling system protectant concentration can be ARAL Antifreeze Extra
Total hardness [°dGH] 3 20 checked with commercially available testers (example: BASF Glysantin G 48
gefo glycomat®). DEA DEA kylarfrostsskydd
SHELL SHELLGlycoShell
4
Cooling System Protection
Cooling system capacity *)
[Liters]
Protective Protection
18 20 22 25 27 30 32 35
agent against freezing to
[% by vol.] [°C]
Protective agent
[Liters]
12000
1000
6000
250
500
Operation Section
2
Lube oil level, top up if necessary 6.1.2/3.3.4
Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Fuel leakage lines (should be replaced in there entirety) 6.2.2
Injection valve #
V Fuelpre-cleaner 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant pump –
Coolant level –
Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4
V Intercooler (drain lube oil/condensation) –
Battery and cable connectors 6.7.1
Engine monotoring system, Warning system 3.3 #
Valve clearance (adjust if necessary) 6.6.1
V-belts (retension if necessary, replaced if damaged) 6.5.1
Crankcase pressure-relief valve/injection valve #
Crankcase pressure vent valve #
Check engine for leaks (visual inspection) –
V Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4
Engine mount (replaced if damaged) 9.2
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5.1 Maintenance schedule Routine maintenance
12000
1000
4000
6000
250
500
Operation Section
2
Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2
Injection valve #
V Intercooler (drain lube oil/condensation) #
V Intercooler inlet, clean as necessary –
Crankcase pressure vent valve #
V Exhaust Turbo-Charger outlet, clean as necessary –
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Routine maintenance 5.1 Maintenance schedule
120 000
240 000
10 000
20 000
III > 100 000 60 carried out by authorised service personnel.
5000
Operation Section
2
Lube oil level, top up if necessary 6.1.2/3.3.4
Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Fuel leakage lines (should be replaced in there entirety) 6.2.2
Injection valve #
V Fuelpre-cleaner 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant pump –
Coolant level 4.3.2/4.3.3
Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4
V Intercooler (drain lube oil/condensation) #
Battery and cable connectors 6.7.1
Engine monotoring system 3.3
Valve clearance (adjust if necessary) 6.6.1
V-belts (retension if necessary, replaced if damaged) 6.5.1
Crankcase pressure-relief valve/injection valve #
Crankcase pressure vent valve #
Check engine for leaks (visual inspection) –
V Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4
Engine mount (replaced if damaged) 9.2
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5.1 Maintenance schedule Routine maintenance
240 000
480 000
10 000
20 000
40 000
III > 100 000 60 carried out by authorised service personnel.
Operation Section
2
Lube oil level, top up if necessary 6.1.2/3.3.4
Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Fuel leakage lines (should be replaced in there entirety) 6.2.2
Injection valve #
V Fuelpre-cleaner 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant pump –
Coolant level –
Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4
V Intercooler (drain lube oil/condensation) #
Battery and cable connectors 6.7.1
Engine monotoring system # 3.3
Valve clearance (adjust if necessary) 6.6.1
V-belts (retension if necessary, replaced if damaged) 6.5.1
Crankcase pressure-relief valve/injection valve #
Crankcase pressure vent valve #
Check engine for leaks (visual inspection) –
V Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4
Engine mount (replaced if damaged) 9.2
© 2000
Fasteners, hose connections/clips –
Generaloverhaul #
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Routine maintenance 5.1 Maintenance schedule
1.000.000
120.000
360.000
III > 100 000 60 carried out by authorised service personnel.
30.000
60.000
Operation Section
2
Lube oil level, top up if necessary 6.1.2/3.3.4
Lube oil (oil change int. depending on engine app.), see TR 0199-99-3002 6.1.1/6.1.2
Oil filter cartridge 6.1.3
Fuel filter cartridge 6.2.1
Fuel leakage lines (should be replaced in there entirety) 6.2.2
Injection valve #
V Fuelpre-cleaner 4.2
Coolant (additive concentration) 4.3.1/2/3
Coolant pump –
Coolant level –
Intake air cleaner (if available, maintain according to maintenance indicator) 6.4.3/6.4.4
V Intercooler (drain lube oil/condensation) #
Battery and cable connectors 6.7.1
Engine monotoring system 3.3
Valve clearance (adjust if necessary) 6.6.1
V-belts (retension if necessary, replaced if damaged) 6.5.1
Crankcase pressure-relief valve/injection valve #
Crankcase pressure vent valve #
Check engine for leaks (visual inspection) –
V Draining bores between cylinder banks, engine cleaning 6.3.1/6.3.4
Engine mount (replaced if damaged) 9.2
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5.2 Maintenance Chart Routine Maintenance
The maintenance charts shown here are supplied as self-adhesive label with each engine. It should be affixed where it can be clearly seen on the engine
or driven equipment. Check that this is the case! If necessary, ask your engine or equipment supplier for a fresh supply of labels! Routine maintenance work 5
should be carried out according to the schedule in 5.1.
5 Running hours Date Signature / Stamp Running 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
* after commissioning of new and overhauled engines
Duly completed maintenance jobs can be recorded and signed off in the above table.
5.3 Completed Maintenance Jobs Routine Maintenance
Running hours Date Signature / Stamp Running hours Date Signature / Stamp 5
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
Duly completed maintenance jobs can be recorded and signed off in the above table.
Routine Maintenance 5.3 Completed Maintenance Jobs
5 Running hours Date Signature / Stamp Running hours Date Signature / Stamp
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
Duly completed maintenance jobs can be recorded and signed off in the above table.
5.3 Completed Maintenance Jobs Routine Maintenance
Running hours Date Signature / Stamp Running hours Date Signature / Stamp 5
8875 9000
8125 8250
8375 8500
8625 8750
8875 9000
9125 9250
9375 9500
9625 9750
9825 10000
10125 10250
10375 10500
10625 10750
Duly completed maintenance jobs can be recorded and signed off in the above table.
Routine Maintenance 5.3 Completed Maintenance Jobs
5 Running hours Date Signature / Stamp Running hours Date Signature / Stamp
10875 11000
11125 11250
11375 11500
11625 11750
11875 12000
12125 12250
12375 12500
12625 12750
12825 13000
13125 13250
13375 13500
13625 13750
Duly completed maintenance jobs can be recorded and signed off in the above table.
5.3 Completed Maintenance Jobs Routine Maintenance
Running hours Date Signature / Stamp Running hours Date Signature / Stamp 5
13875 14000
14125 14250
14375 14500
14625 14750
14875 15000
15125 15250
15375 15500
15625 15750
15825 16000
16125 16250
16375 16500
16625 16750
Duly completed maintenance jobs can be recorded and signed off in the above table.
5
Service and Maintenance
Change the oil with the engine off but still warm
(lube oil temperature approx. 80 °C / 176 °F).
6.1 Lubrication System Service and Maintenance
6.1.1.1 Lube oil change intervals for industrial and marine engines 6
Lube oil grade
Deutz lube oil quality class DQC I DQC II DQC III
ACEA-specfication E2-96 E3-96/E5-02 E4-99
API-specfication CF/CF-4 CG-4/CH-4 -
Worldwide specfication - DHD-1 -
special DEUTZ release list - - siehe Kap.4.1.2.1
Standard lube oil code for building EO.. . EO...C -
equipment and nonraod vehicles EO...A, EO...B
Engine Engine version Lube oil change intervals in op. hours
series Oil use Oil use Oil use
normal high normal high normal high
1015 All engines except for: 250 125 500 250 500 250
If, for vehicle engines, lube oil change intervals are determined by operating hours, the lube oil change intervals indicated in table 4.1. for “Oil use
under normal duty” will apply.
6.1 Lubrication System Service and Maintenance
● Ensure that the engine or vehicle is on a level ● Ensure that the engine or vehicle is on a level ● Place oil tray under the engine.
surface. surface. ● Unscrew drain plug.
● Immediately before the oil level is measured, the ● Allow the engine to warm up ● Drain oil.
engine should should be driven at low idling – Lube oil temperature approx. 80°C. ● Fit oil drain plug, with the new gasket and tighten
speed for approx. 2 minutes. ● Switch off the engine. firmly (for torque, see 9.2).
● Switch off the engine. ● Fill with lube oil.
● Pull out the oil dipstick. – For grade / viscosity, see 4.1
● Wipe off with a non-fibrous, clean cloth. – For quantity, see 9.1
● Insert up to the stop and pull out again. ● Check oil level, see 6.1.2.1
● Check the oil level and if necessary fill up to the
“MAX” level.
– If the oil level is just above the “MIN” marking,
extra oil must be added.
Be careful when draining hot oil – danger
The oil level must not fall below the “MIN” marking.
of scalds! Do not let used oil run into the
! soil but catch it in a container ready for
Service and Maintenance 6.1 Lubrication System
● With fitted torsion lock: ● Clean sealing surface of the filter carrier if ● Tighten oil filter cartridge tightly by giving a fi-
Loosen screws and slide clamps downwards. necessary. nal half turn.
● Undo the oil filter cartridge with commercial ● Lightly oil the rubber gasket of the new oil filter ● If a torsion lock is fitted, slide clamps up into
tool and spin off. cartridge. position and tighten screws.
● Catch any escaping oil. ● Screw in the new cartridge finger tight against ● Check oil level, see 6.1.2.
the gasket.
● Check oil pressure, see 3.3.1.
● Close fuel stopcock. ● Clean sealing surface of filter carrier if ● Tighten fuel filter cartridge firmly.
necessary.
● Undo fuel filter cartridge with commercial tool ● Open fuel stopcock.
and spin off. ● Apply light film of oil or diesel fuel to rubber
gasket of new fuel filter cartridge. ● Check for leaks.
● Catch any escaping fuel.
● Screw in the cartridge finger tight against the
gasket.
6 6.2.2 Replace fuel oil leak line 6.2.3 Fuel Pre-filter Element
Clean/Replace if necessary
6.3.1 Cleaning Intervals 6.3.2 Draining Cooling System 6.3.3 Filling / Bleeding Cooling
System
6
● The degree of soiling of the cooler units is ● Fill with coolant and bleed cooling system
dependent on the type of engine application. according to manufacturer’s instructions.
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 0
● Blow compressed air onto engine ● Spray engine with commercial cold cleansing ● Let engine run up to operating temperature
Wash out loosened dirt particles from V-space agent and let stand for about 10 min. after each wet-cleaning procedure allowing
with water jet. any remaining water to evaporate, thus
● Then spray clean with strong water jet (do not avoiding corrosion.
● Make sure that drain holes 1 of V-space are free. spray water directly onto sensitive components
such as alternator, starter, wiring, electronic
components).
!
Service and Maintenance 6.4 Combustion Air Cleaner
● Clean discharge slot from time to time. ● Clean cartridge, replace at least once a year.
25886 0 25887 0
● Undo wing nut 1 and remove cover 2. ● Turn engine off and wait about 10 minutes for ● Fill oil cup with engine oil up to the mark
the oil to drain from filter housing 1. (arrow) (for viscosity, see 4.1.2).
● Remove collector bowl 3 from lower section 4
and empty. Remove leaves, straw and other ● Release snap clips 2 and remove oil cup 3 ● Refit oil cup and element to filter housing and
foreign matter from lower section of together with filter element 4. If necessary, secure with snap clips.
precleaner. press element out with a screwdriver, taking
care not to damage rubber gasket 5.
● Reposition collector bowl 3 onto lower section
4, fasten cover 2 in place by tightening wing ● Remove dirty oil and sludge. Clean oil cup.
nut 1.
● Clean filter element 4 in diesel fuel and allow to
drip-dry.
● Clean filter housing 1 if very dirty. Never clean air cleaner with petrol
(gasoline)!
● Inspect and replace rubber gaskets 5 and 6 if
necessary.
! Dispose of old oil in accorrdance
with anti-pollution regulations!
6.5 Belt Drives Service and Maintenance
25 998 0
Renewing
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 tappet contact face 2 and valve stem 3 with
temperature should be below 80 °C (176 °F). feeler gauge (there should only be a slight
resistance when feeler blade is inserted).
● Position crankshaft as per schematic, see For permissible valve clearance, see 9.1.
6.6.1.1.
● Slacken bolts 1.
IN 6
IN
7
EX
EX
4 5
26 405 0
Sequence 1 2 3 4 5 6 1 2 3 4 5 6 7 8
Valve overlap A1 B3 A3 B2 A2 B1 A1 B4 A4 B1 B3 A3 B2 A2
Adjusting B2 A2 B1 A1 B3 A3 B3 A3 B2 A2 A1 B4 A4 B1
Service and Maintenance 6.6 Adjustments
6
● Adjustment
Turn crankshaft according to sequence shown
in the diagram (starting with cyl. 1).
The valves of the relevant cylinder overlap,
A1 A2 A3 A1 A2 A3 A4 marked in white, (exhaust valves about to
close, inlet valves about to open). Adjust
clearance of valves, marked in black,
according to schematic. Mark the respective
rocker arm with chalk to show that the
adjustment has been done.
B1 B2 B3 B1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4
B1 B2 B3 B1 B2 B3 B4
26 407 0
6.7 Accessories Service and Maintenance
6.7.1 Battery
6.7.1.1 Checking Battery and Cable 6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Specific Gravity of
6
Connections Electrolyte
● Keep battery clean and dry. ● Remove cell caps 1. ● Measure the specific gravity of the individual
cells with a commercial hydrometer.
● Undo soiled terminals. ● If electrolyte test elements 2 are fitted: The measured values (see adjacent table)
The level should be high enough to wet the indicate the state of charge of the battery.
● Clean battery plus and minus poles and bottom of these. During the measurement, the temperature of
terminals and apply a film of acid-free and acid- the electrolyte should preferably read 20 °C.
resistant grease. ● If no such elements are provided :
● When reconnecting, ensure good contact of Check to make sure that the level is 10-15 mm
terminals. Fasten clamping bolts finger tight. above the top edge of the plates.
Specific Gravity
7
● If engine problems occur, they frequently have
their cause in improper operation or
maintenance of the engine.
Troubles
Engine fails (or difficult) to start
Remedial Measure
Check P
7
Engine starts, but runs unevenly or stalls Adjust E
Engine becomes too hot, temperature monitor gives warning (coolant) Renew W
Engine gives poor performance Clean R
Engine not working on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive Bleed L
Engine smokes – blue
– white
– black
Causes Section
● Not declutched (declutch where possible) Operation P
● Below start limit temperature P
● Engine shutdown lever still in stop position (shutdown solenoid defective) P
● ● ● Oil level too high P
● Oil level too low S
● ● ● Excessive inclination of engine P/E
● Speed control lever set to middle position P/E
● ● ● ● ● Dirty air cleaner / defective turbocharger Combustion Air P / W
● ● ● Air cleaner service switch/indicator defective P
● ● LDA* defective (leaking line) P
● ● ● Charge air pipe leaking P/W
● Coolant pump defective Cooling System P / R
● ● ● Charge air cooler dirty P/R
● Coolant heat exchanger dirty P/R
● Coolant thermostat does not open P
● Battery defective or discharged Electrics P
* LDA = manifold pressure compensator Table 1 of 2
Troubleshooting 7.1 Diagnosis Chart
8.1 Preservation
Engine Preservation 8.1 Preservation
8 8.1 Preservation
Model 1015 BF6M 1015 BF8M 1015 BF6M 1015 C/ CP BF8M 1015 C / CP
9
Number of cylinders 6 8 6 8
Cylinder arrangement 90° Vee-angle
Bore [mm] 132
Stroke [mm] 145
Total displacement [cm3] 11906 15874 11906 15874
Compression ratio [ε] 17
Working cycle / combustion system 4-stroke TC engine/direct injection
Direction of rotation counter-clockwise
1
Speed [rpm] )
Valve clearance, engine cold 5) [mm] inlet 0.25 + 0,1
/ exhaust 0.3 + 0,1
Injector opening pressure [bar] 290 bar
1
Commencement of delivery [°CA BTDC] )
Firing order 1-6-3-5-2-4 1-8-4-5-7-3-6-2 1-6-3-5-2-4 1-8-4-5-7-3-6-2
A1-B3-A3-B2-A2-B1 A1-B4-A4-B1-B3-A3-B2-A2 A1-B3-A3-B2-A2-B1 A1-B4-A4-B1-B3-A3-B2-A2
V-belt tension: tension / retension 2)
Alternator 55 amperes [N] 450 / 200-350 ± 50
Alternator 120 amperes [N] 550 / 300-450 ± 50
1)
Engine power, speed, commencement of delivery, etc. are stamped on the rating plate, see 2.1.
2)
Retension after running for 15 minutes under load.
9.1 Engine Specifications and Settings Specification Data
Model 1015 BF6M 1015 BF8M 1015 BF6M 1015 C/ CP# BF8M 1015 C// CP#
9
Cooling system liquid-cooled / cooling system protection
+ MFK*
Coolant quantity [approx. lit.] 17 21 + MFK* 17 + MFK* 21 + MFK*
Perm. cont. coolant temperature engine outlet [°C] max.103
Temperature difference between
coolant inlet / outlet [°C] max.5
Thermostat starts opening at [°C] 87 ±2
Thermostat fully open from [°C] 102
Coolant pump
4
Delivery pressure in [bar] )
Delivery rate in [m3/h] 22,5 4)
30 4)
22,5 4) 30 4)
3)
Approximate figures can vary depending on the design. Decisive is always the upper dipstick mark.
4)
3 bar at engine speed n = 2100 rpm -1
5)
see 6.1.1 (# only synthetic lube oil, see.4.1.2.1)
MFK
* Engine radiator
Specification Data 9.2 Torque Wrench Settings
9 Location
Preloading [Nm] Tightening [° deg.]
Total
Notes
1st 2nd 3rd 1st 2nd 3rd 4th [Nm]
Stage Stage Stage Stage Stage Stage Stage
Rocker cover 22
Inspection Cover 22
rigid mounting 30 45
Mount
flexible mounting 106
Exhaust manifold 61
Injector mounting 60
Oil pan 24
engine mounted
Oil filter cartridge 27
or separate
26002 0
Fa. WILBÄR
Postfach 14 05 80
D-42826 Remscheid
Notes
CALIFORNIA CALIFORNIA
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
9
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