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Deutz 1015 - User Manual

Deutz 1015
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Operation Manual
1015
26 388/1
Please read and observe the information
given in this Operation Manual. This will
enable you to avoid accidents, preserve the
manufacturer’s warranty and maintain the
engine in peak operating condition.
This engine has been built exclusively for
the application specified in the scope of
supply, as described by the equipment manu-
facturer and is to be used only for the
intended purpose. Any use exceeding that
scope is considered to be contrary to the
intended purpose. The manufacturer will
not assume responsibility for any damage
resulting therefrom. The risks involved are
to be borne solely by the user.
Use in accordance with the intended pur-
pose also implies compliance with the con-
ditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated by person-
nel trained in its use and the hazards in-
volved.
The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be ob-
served.
When the engine is running, there is a risk of
injury through:
- turning/hot components
- engines with positive ignition
- ignition systems (high electrical voltage)
You must avoid contact at all times!
Unauthorized engine modifications will in-
validate any liability claims against the manu-
facturer for resultant damage.
Manipulations of the injection and regulating
system may also influence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaran-
teed under such conditions.
Do not change, convert or adjust the cooling
air intake area to the blower.
The manufacturer shall not be held respon-
sible for any damage which results from
such work.
When carrying out maintenance/repair op-
erations on the engine, the use of DEUTZ
original parts is prescribed. These are spe-
cially designed for your engine and guaran-
tee perfect operation.
Non-compliance results in the expiry of the
warranty!
Maintenance and cleaning of the engine
should only be carried out when the engine
is switched off and has cooled down.
You must ensure that the electrical systems
have been switched off and the ignition key
has been removed.
Accident prevention guidelines concerning
electrical systems (e.g. VDE-0100/-0101/-
0104/-0105 Electrical protective measures
against dangerous touch voltage) are to be
observed.
When cleaning with fluids, all electrical com-
ponents are to be covered impermeably.
Safety guidelines / Accident prevention
Property of American Airlines
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Summary

Safety Guidelines and Accident Prevention

General Safety Instructions

Read manual, intended purpose, trained personnel, observe safety guidelines.

Operational Hazards and Precautions

Risks from hot components, electrical systems, unauthorized mods, and maintenance rules.

General Engine Information and Safety

DEUTZ Engine Overview and Care

Features, quality, maintenance practices, and service recommendations.

Safety Warnings and Notices

Explanation of safety symbols, asbestos, and California Proposition 65.

Engine Description and Identification

Model Designation and Rating Plate

Details on model designation, rating plate, and engine serial number.

Engine Views and Cylinder Layout

Illustrations of engine components and cylinder numbering.

Engine Operation and Commissioning

Initial Setup and Fluid Filling

Procedures for filling engine oil, air cleaner, fuel, and coolant.

Starting and Monitoring Procedures

Steps for starting the engine and monitoring key parameters.

Engine Operation Procedures

Engine Starting with Cold-Starting Aid

Using flame-type heater plugs for starting in cold conditions.

Engine Shutdown Procedures

Steps for mechanical and electric shutdown of the engine.

Monitoring Engine Status

Oil Pressure and Coolant Temperature Monitoring

Interpreting oil pressure pilot lamps/gauges and coolant temperature indicators.

Fluid Level Monitoring

Checking and interpreting coolant and lube oil level indicators.

Engine Control and Shutdown

Engine Shutdown Methods

Procedures for mechanical and electric shutdown.

Engine Starting Without Cold-Starting Aid

Steps for starting the engine using the ignition key.

Operating Conditions and Adjustments

Winter Operation Guidelines

Recommendations for oil viscosity, fuel, coolant, and additional jobs in winter.

High Temperature and Altitude Operation

Considerations for engine performance and potential derating at high altitudes/temperatures.

Operating Media Specifications

Lube Oil Quality and Viscosity Selection

Defining lube oil quality grades and selecting viscosity based on ambient temperature.

Fuel Quality and Winter Grade

Specifications for diesel fuel quality, sulfur content, and winter grade usage.

Coolant Quality and Treatment

Water quality requirements and coolant protectant concentration.

Operating Media Details

Approved Lube Oils for High Load

List of approved lube oils from various producers for specific engine applications.

Diesel Fuel and Winter Grade Guidance

Specifications for diesel fuel quality, sulfur content, and winter grade usage.

Winter-Grade Fuel and Kerosene Additives

Guidelines for using winter-grade fuel and adding kerosene at low temperatures.

Coolant System Specifications

Water Quality for Coolant

Limits for water quality parameters like pH, chloride, sulphate, and hardness.

Coolant Treatment and Protectants

Importance of coolant treatment, use of DEUTZ protectants, and warnings about mixing.

Cooling System Protection Chart

Table showing protective agent concentration for different freezing protection temperatures.

Routine Maintenance Schedule

Industrial Engine Maintenance Tasks

Schedule of maintenance tasks for industrial engines based on operating hours.

Maintenance Task Codes Explanation

Explanation of symbols used in the maintenance schedule (check, adjust, clean, replace).

Maintenance Schedule Variations

Additions for EPA Approved Engines

Specific maintenance values and requirements for engines with EPA approval.

Vehicle Engine Maintenance Tasks

Schedule of maintenance tasks for vehicle engines based on mileage and service groups.

Vehicle Engine Maintenance by Mileage

Vehicle Maintenance Schedules by Kilometrage

Maintenance tasks for vehicle engines based on mileage and average speed.

Maintenance Task Reference Sections

Cross-reference of maintenance tasks to specific sections for detailed procedures.

Maintenance Chart and Job Log

Engine Maintenance Chart Labels

Self-adhesive labels for engine maintenance, including visual aids for tasks.

Completed Maintenance Jobs Log

Table to record and sign off completed maintenance jobs by running hours.

Service and Maintenance Overview

Lubrication System Servicing

Details on oil change intervals, checking oil level, and renewing the oil filter.

Fuel System Servicing

Procedures for fuel filter renewal, leak line replacement, and pre-filter cleaning.

Cooling System Servicing

Intervals for cleaning, draining, filling, bleeding, and cleaning the engine.

Engine Lubrication System Service Details

Industrial Engine Oil Change Intervals

Lube oil change intervals for industrial engines based on quality grade and engine version.

Vehicle Engine Oil Change Intervals

Lube oil change intervals for vehicle engines based on application, engine version, and mileage.

Lubrication System Maintenance Tasks

Checking and Changing Engine Oil

Steps for checking oil level and performing an engine oil change.

Renewing the Oil Filter

Procedure for removing and replacing the oil filter cartridge.

Fuel System Service Procedures

Renewing Fuel Filter

Steps for replacing the fuel filter cartridge and related safety warnings.

Fuel Pre-filter Element Service

Procedures for cleaning or replacing the fuel pre-filter element and bleeding the system.

Cooling System Service Procedures

Cooling System Cleaning Intervals

Factors affecting cleaning intervals and guide values for different applications.

Draining and Filling the Cooling System

Steps for draining coolant and filling/bleeding the cooling system.

Engine Cleaning Methods

Procedures for cleaning the engine using compressed air or cold cleaning agent.

Combustion Air Cleaner Maintenance

Dry-Type Air Cleaner Cleaning Intervals

Factors influencing cleaning intervals and indications for servicing dry-type air cleaners.

Dry-Type Air Cleaner Servicing

Procedures for cleaning the dust discharge valve and filter cartridge.

Air Cleaner and Belt Drive Service

Cyclone-Type Precleaner and Oil Bath Air Cleaner Service

Procedures for emptying cyclone precleaners and cleaning oil bath air cleaners.

Alternator V-Belt Checks and Tensioning

How to inspect, retension, or renew the alternator V-belt.

Engine Adjustments and Belt Drives

V-Belt Renewing Procedures

Steps for renewing V-belts, including slackening bolts and tensioning.

Valve Clearance Checking and Adjustment

Procedures for checking and adjusting valve clearances on a cooled engine.

Valve Clearance Adjustment Procedures

Adjusting Valve Clearances

Detailed steps for adjusting valve clearance using specific sequences and tools.

Valve Clearance Adjustment Schematics

Schematics illustrating valve overlap and adjustment sequences for different engine models.

Accessory Maintenance and Checks

Battery and Cable Connection Checks

How to check battery cleanliness, terminals, and connections.

Electrolyte Level and Specific Gravity Checks

Procedures for checking battery electrolyte level and specific gravity.

Accessory Systems and Lifting Equipment

Battery Specific Gravity and State of Charge

Table relating specific gravity to battery state of charge and safety warnings.

Alternator System and Lifting Tackle Use

Notes on alternator system safety and proper use of lifting tackle for engine transport.

Troubleshooting Engine Issues

Diagnosis Chart Overview

Introduction to using the diagnosis chart for identifying and rectifying engine problems.

Engine Troubleshooting Guide

Common Engine Problems and Causes

Lists common engine troubles (starting, stalling, overheating, poor performance) and their potential causes.

Remedial Measures for Engine Issues

Provides corrective actions (check, adjust, renew, clean, top up, bleed) for identified engine problems.

Engine Problem Diagnosis and Solutions

Troubleshooting Specific Engine Faults

Detailed causes and remedies for issues like incorrect valve clearance, leaking injection lines, and air in fuel system.

Troubleshooting Fuel and Coolant Issues

Diagnosing problems related to fuel filters, fuel quality, and lack of coolant.

Engine Preservation for Storage

Engine Preservation Measures

Steps to protect the engine from rust during extended shutdown periods using preservatives.

Removing Engine Preservatives

Procedures for removing preservatives before recommissioning the engine.

Engine Specifications and Settings

Engine Model Specifications

Technical data like cylinders, bore, stroke, displacement, and weight for different models.

Engine Performance and Cooling Data

Details on engine speed, valve clearance, injection pressure, and coolant specifications.

Lubrication and Fuel System Specs

Information on lube oil viscosity, oil pressure, capacity, and fuel system settings.

Technical Specifications and Tools

Torque Wrench Settings

Specified torque values for various engine components during assembly or maintenance.

Required Tools and Gauges

Information on obtaining essential tools, such as the V-belt tension gauge.

Important Notices and Compliance

California Proposition 65 Warnings

Information regarding warnings required for products sold in California concerning diesel exhaust.

Operator Manual Warning Placement

Guidelines on where and how warnings must appear in the operator manual.

DEUTZ Service and Support

DEUTZ Global Presence and Services

Information on DEUTZ's worldwide network of service partners and product support.

Service Literature and Resources

Details on obtaining service literature, CD-ROMs, and contacting DEUTZ AG.

Deutz 1015 Specifications

General IconGeneral
Engine TypeDiesel
Number of Cylinders6
Fuel SystemDirect Injection
Rated Speed2100 rpm
Compression Ratio17.5:1
AspirationTurbocharged
Cooling SystemLiquid-cooled

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