Service Training 1015 Englisch PDF
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Service Training
Engine Series DEUTZ 1015
DEUTZ AG Service Engineering
Cou rseCours e-at atte tend ndan antt train trainee ee d docu ocumen mentat tation ion for service training
Product-related engine technology
engine series DEUTZ 1015
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Attention: This course attendant trainee documentation is conducive for effective explanation and illustration about the contruction and function of engine, components and systems. The contents of figures are only according to the date of printing actual documentation and are not subject to be updated.
Obligatory upon operation, maintenance and repair are only the engineering data and intructions of the actual technical printed material such as operation manua manuals, ls, workshop manuals, adjusting- and repair-instructions, technical circulars and service bulletins.
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Table of contents contents ......................................... ........................................ ........................................ ........................................ .....................................0-1 .................0-1 Table of contents .....................
1.
Engine plan ................... ....................................... ........................................ ........................................ ........................................ ..................................... .................1-1
1.1 1.2 1.3 1.4 1.5 1.6
Technical data ...................................... .......................................................... ........................................ ........................................ .....................................1-1 .................1-1 Engine view........................................... view............................................................... ........................................ ........................................ .....................................1-2 .................1-2 Model designation designation................... ....................................... ........................................ ........................................ ......................................... ...............................1-6 ..........1-6 Nameplate and engine serial number................................................. number...................................................................... ...............................1-7 ..........1-7 Cylinder numbering..................................... numbering......................................................... ........................................ ......................................... ...............................1-7 ..........1-7 Description of nameplate............................................. nameplate................................................................. ........................................ ..................................1-8 ..............1-8
2.
Design structure .................... ........................................ ........................................ ........................................ ........................................ ........................... .......2-1
2.1
Cylinder..............................................................................................................................2-1
2.2 Drive system......................................................... system............................................................................. ......................................... ......................................... ....................2-2 2-2 2.2.1 Connecting rod ........................................ ............................................................ ........................................ ........................................ ..................................2-2 ..............2-2 2.2.2 Piston.................................................................................................................................2-3 2.2.3 Piston cooling ....................................... ........................................................... ........................................ ........................................ .....................................2-4 .................2-4 2.2.4 Crankshaft ........................................ ............................................................ ........................................ ......................................... ......................................... ....................2-5 2-5 2.3 2.3.1 2.3.2 2.3.3 2.3.4
Cylinder head..................................................... head......................................................................... ........................................ ........................................ ........................2-6 ....2-6 Design structure ...................................... .......................................................... ........................................ ........................................ ..................................2-6 ..............2-6 Valves Valves ......................................... ............................................................. ........................................ ........................................ ........................................ ...........................2-6 .......2-6 Valve clearance adjustment ........................................ ............................................................ ........................................ ..................................2-8 ..............2-8 Determining cylinder head gasket ...................................... .......................................................... ........................................ ...........................2-9 .......2-9
2.4 2.4.1
Gear drives ....................................... ........................................................... ........................................ ......................................... ......................................... ....................2-12 2-12 Vibration damper side..................................................... side......................................................................... ......................................... ...............................2-12 ..........2-12
2.4.2
Flywheel side ........................................ ............................................................ ........................................ ........................................ .....................................2-13 .................2-13
3.
Lube oil system .................. ...................................... ........................................ ........................................ ......................................... ............................... ..........3-1
3.1 3.2
Lube oil circuit....................................................... circuit........................................................................... ......................................... ......................................... ....................3-1 3-1 Lube oil pressure ........................................ ............................................................ ........................................ ......................................... ...............................3-2 ..........3-2
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Service-Training
4.
Fuel system system.................. ....................................... ......................................... ........................................ ........................................ ..................................... ................. 4-1
4.1 4.2 4.2.1 4.2.2
Fuel circuit ........................................ ............................................................ ........................................ ........................................ ......................................... .....................4-1 4-1 Setting the commencement of delivery ....................................... ........................................................... ..................................... .................4-2 4-2 Electrical setting unit for the commencement of delivery............................................. delivery................................................. .... 4-4 Fixing pin ....................................... ........................................................... ........................................ ........................................ ........................................ ........................ .... 4-6
5.
Cooling system system.................. ...................................... ........................................ ........................................ ......................................... ............................... .......... 5-1
5.1 5.2
Cooling circuit.......................................... circuit.............................................................. ........................................ ........................................ .................................. ..............5-1 5-1 Coolant ....................................... ........................................................... ........................................ ........................................ ........................................ ........................... ....... 5-2
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1. Engine plan 1.1 Technical data BFM 1015
BF6M 1015 BF6M 1015C Number of cylinders / arrangement
BF8M 1015 BF8M 1015C
6 / V – 90°
8 / V – 90°
Bore [mm]
132
Stroke Strok e [mm]
145
Displacement Displacem ent [ltrs.]
11.9
W orking cycle / combustion system
15.9
Four-stroke diesel with direct injection and exhaust turbocharging.
Firing order
1-6-3-5-2-4
1-8-4-5-7-3-6-2 1-8-4-5-7-3-6- 2
Direction of rotation
When facing flywheel counter-clockwi counter-clo ckwise se
Rated speed [rpm]
See engine nameplate
Power [kW]
See engine nameplate
Valve clearance:
Inlet / exhaust [mm]
0.25 / 0.3
Commencement Commenceme nt of delivery
See engine nameplate 290+8
Injector opening pressure [bar] Engine lube oil system
Forced-feed circulation lubrication
Min. oil pressure pressure [bar], at low idling and with warmed-up engine (120°C oil temperature) Type of cooling Thermostatt Thermosta
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1.0
Liquid-cooled with integrated oil cooler. opens at: [°C] fully opened at: [°C]
87 102
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Service-Training 1.2 Engine view A – side, 6 cylinders
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1 – Oil filling socket 2 – Cylinder head 3 – Exhaust manifold 4 – Adapter housing 5 – Crankcase Cran kcase 6 – Starter 7 – Oil pan 8 – Lube oil filter 9 – Coolant inlet from radiator
1-2
10 – Vibration damper 11 – V-belt pulley 12 – Alternator Alternator 13 – Coolant outlet to cooler 14 – Engine shutdown solenoid 15 – Flame plug 16 – Coolant pump 17 – Lube oil cooler
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B – side, 6 cylinder
Bild 1015- 0001b
18 – Charge air line 19 – Oil dipstick dipstic k 20 – Oil drain plug 21 – Adapter housing
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22 – Flywheel 23 – Exhaust turbocharger 24 – Injection pump (in engine V-space) -space ) 25 – Flame plug
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Service-Training A – side, 8 cylinder
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1 – Exhaust turbocharger 2 – Exhaust manifold 3 – Crankcase Cran kcase 4 – Starter 5 – Oil filling socket 6 – Oil pan 7 – Lube oil filter
1-4
8 – V-belt pulley with vibration damper 9 – Coolant inlet from cooler 10 – Lube oil cooler 11 – Fan 12 – Charge air line from charge air cooler 13 – Charge air line to charge air cooler 14 – Flame plug
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B – side, 8 cylinder
Bild 1015- 0002b
14 – Flame plug 15 – Oil filling socket 16 – Cylinder head 17 – Alternator 18 – Oil dipstick
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19 – Adapter housing 20 – Flywheel 21 – Compressors Compre ssors (option) (option ) 22 – Connections fuel lines
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Service-Training 1.3 Model designation
B F 8 M 1015 C/P Uprating Charge air cool cooler er Piston stroke in cm (approx.) Serial index Liquid-cooled No. of cylinders High-speed 4-stroke engine Exhaust turbocharger
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1.4 Nameplate and engine nu number mber
In the case of series 1015, the nameplate is affixed to the crankcase left-hand side (B-side) above the vibration damper. Above the nameplate, the engine serial number (2) is stamped again into the crankcase. For engines from about 02/2000, the engine serial number is stamped in on the front Aside besides the threaded bore of the transport eye, visible from above (3). The engine model (1) and the engine serial number (2) must be indicated when ordering spare parts.
Bild 1015- 0003a
1.5 Cylinder numbering •
The cylinders are numbered beginning at the flywheel end. For en engine gines s with V-shape -sh aped d ararrangement of the cylinders, the cylinder number is added one letter for the respective cylinder line (seen from the flywheel).
Left cylinder line = A •
Right cylinder line = B
Facing the flywheel, the sense of rotation of the engine is counter-clockwise.
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Service-Training 1.6 Description of the nameplate
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Item Ite m Description
Remark
1
Engine model
e.g. BF8M 1015 C
2
Engine code
For engines certified according to the Commission's directives 88/195/EWG .
3
Engine serial number
-
4
Commencement Commenceme nt of delivery
COD in ° C/A
5
kW (G)
"Total power" , fan not running
6
kW (S)
"Continuous power" , fan completely running
7
ISO
8
ISO
9
1-8
10
1/min
Rated speed of the engine.
11
1/min
12
kW (G) red.
Reduced "total power", on-site conditions items 14,15.
13
kW (S) red.
Reduced "continuous power", on-site conditions items 14,15.
14
Air temperature in °C
For ambient conditions on site.
15
Altitude Altitude above sea level in m
For ambient temperatures on site.
16
For free disposal
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2. Design structure 2.1 Cylinders
The cylinders of series 1015 are executed as wet liners which are only available with the standard bore of 132 mm. At the cylinder liner collar (1), metal is sealing against metal. At the liner foot, in the crankcase, crankcase, two O-rings (2) are installed which are functioning functioning as seal between coolant and crankcase interior.
3 – Piston cooling nozzle 4 – Drain screw for coolant in the engine block.
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Service-Training 2.2 Cranksha Crankshaft ft assembly 2.2.1 2.2 .1 Connecting rod
The connecting rods of series 1015 are forged and, for increasing the resistance moment against being bent, they include a concave rod part. In view of the different crankshaft versions between 6and 8-cylinder engines (see chapter 2.2.4), the connection rods are different. At its base, the connection rod of the 8-cyliner engine is provided with a unilaterally distinct contact surface. The connection rod bearing shells are different on their rod- and cover side and must not be exchanged by mistake. The rod-side bearing shell is a sputter-type bearing and is dark-eloxed on its back.
A – 8-cyliner 8-cyliner B – 6-cyliner
Bild 1015-0011
When assembling connecting rod and piston, it must be made sure that the concave surface (1) of the connecting rod is showing to the side where the recess (2) for the cooling oil nozzle is arranged at the piston. Connecting rod and cover are forming pairs. The pair numbers of rod and cover must be on one side when installing the conrod.
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2.2.2 Piston
The pistons of series 1015 are of cast aluminium alloy. The piston bowl is arranged centrally. The pistons are equipped with 3 piston rings. For the 1st ring, the piston is provided with a ring carrier of steel. The cross section of the 1st piston ring is asymmetrical (trapezoidal ring). The cross section of the 2nd piston ring is conical (compression ring). When installing the piston, the TOP mark at the ring gap must point upwards. The 3rd ring is the bevelled-edge oil control ring (oil scraper ring).
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Service-Training 2.2.3 2.2 .3 Piston cooling
In the interest of thermal relief, the pistons are cooled with lubrication oil via piston cooling nozzles. The nozzles are bolted to the crankcase and must be aligned with a special tool. Every nozzle no zzle comprises comp rises a spring-loaded spring- loaded ball ball valve opening at 0.8 – 1.1 bar. It It is arranged arranged in the banjo bolt.
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2.2.4 Crankshaft
The crankshafts of series 1015 are forged and have bolted balance weights. The crankshaft of the 8-cylinder engine (A) has continuous bearing journals as the firing distance is identical to the V-angle of the engine, i.e. 90°. As the V-angle of the engine engine is 90°, 90°, the firing firing distance distance of the 6-cylin 6-cylinder der engine engine however however is 120°, the 6-cylinder engines are fitted with a "split-pin" crankshaft (B) to balance the resulting vibrations. In the case of this design – as common for V-engines – two opposite connection rods are acting on one bearing journal. At this crankshaft (B), the bearing journal for both connection rods is shifted by 30° in itself. This is the difference differen ce between 120° (firing d distance istance of the 6-cylinder engine) and 90° (Vangle).
. Bild 1015-0011
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Service-Training 2.3
Cylinder head
2.3.1 Design structure The cylinder heads of series 1015 are made of grey cast iron. The cylinder head base is plain. The injector (6) is protruding by about 5 mm over the planed surface; therefore, it is not permitted to place the cylinder heads on this surface with installed injectors.
2.3.2 Valves Every cylinder head has tow inlet an two exhaust valves. Inlet- and exhaust valves are differing in their geometry.
Exhaust
Inlet
Bild 1015-0015
2-6
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During the installation, the rocker pedestal must be aligned as directed in the workshop manual. Every rocker (1, 3) has two rocker arm tappets at the end of which the setting screws (2) for the valve clearance are arranged. The rocker shaft and the rocker arms are lubricated via the inlet rod (9). In position (4), the oil return to the crankcase is arranged.
Bild 1015-0017
1 – Inlet valve rocker arm 2 – Setting screws 3 – Exhaust valve rocker arm 4 – Oil return 6 – Injector 8 – Outlet rod 9 – Inlet rod
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Service-Training 2.3.3 2.3 .3 Setting the valve clear clearance ance A wrong valve valve clearanc clearance e can entail entail damage damage to the engine engine due to thermal thermal and mechan mechanical ical overload overload.. Therefore, it must be checked at specified intervals (see operation manual) and newly set, if required. The valve clearance must be checked and set at an oil temperature of 0.10 - 0.30 mm >0.30 - 0.81 mm
1 hole 2 holes 3 holes
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Service-Training 2.4 Gear drives Series 1015 has a gear drive at each engine side.
2.4.1 Vibration damper side The gear drive on the vibration damper side is arranged in the auxiliaries carrier and comprises the following drives: dr ives:
1 - Raised fan drive drive i = 0.96 or Raised fan drive i = 1.36 2 - Coolant pump 3 - Idler gear 4 - Lube oil pressure pump 5 - Crankshaft 6 - Lube oil intake pump (oil-pan dependent) 7 - Auxiliary PTO, e.g. for hydraulic pump, raw water pump etc. If the fan is driven by the crankshaft, the raised fan is omitted. The transmission of the raised fan is realised by the arrangement of its drive gear at the idler gear.
Bild 1015-0021
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2.4.2 Flywheel end
The flywheel-end gear drive comprises:
1 – Injection pump drive 2 – Idler gear 3 – Auxiliary PTO, e.g. for air compressor 4 – Camshaft gear 5 - Crankshaft 6 – Auxiliary PTO, e.g. for air compressor 7 – Idler gear
Bild 1015-0022
Camshaft- and crankshaft gear comprise marked teeth for setting the control times. One of the marked teeth of the crankshaft must fit between the two marked teeth of the camshaft.
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Service-Training NOTES
2-14
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3. Lube oil system 3.1 Lube oil circuit
Bild 1015-0030
1 - Oil pan 2 - Intake Intake pipe 3 - Lube oil pump 4 - Pressure relief valve 5 - Lube oil cooler 6 - Lube oil filter 7 - Main oil gallery 8 - Crankshaft bearing 9 - Big end bearing 10 - Camshaft Camshaft bearing 11 - Oil supply to injection pump 12 - Injection pump 13 - Oil return line from injection pump 14 - Line to piston cooling nozzle 15 - Piston cooling nozzle with valve (0.8 – 1.1 bar)
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16 - Tappet with pulse lubrication 17 - Pushrod, oil supply for rocker lubrication 18 - Rocker 19 - Oil return bore in cylinder head 20 - Oil pressure pressur e sensor 21 - Oil line to exhaust turbocharger 22 - Exhaust turbocharger 23 - Oil line to compressor compresso r 24 - Compressor 25 - Hydraulic pump 26 - Pressure regulating valve 27 - Return line from compressor 28 - Return line from turbocharger
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Service-Training 3.2 Lube oil p pressure ressure
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4. Fuel system 4.1 Fuel circuit For series 1015, Bosch injection pumps of type P are used which achieve a peak injection pressure of up to 1100 bar. The injection takes place via an injector with 8 jets, which is vertically-centrically arranged in the cylinder head. For the speed regulation, mechanical Bosch regulators or optional electronic regulators such as EMR, GAS, GenDec are used. The low-pressure low-pressure system is represented below.
Bild 1015-0040
1 – Injection pump
6 – Fuel feed pump
a – to injection pump
2 – Fuel filter
7 – Press. holding valve, p = 2 bar
b – to filter
3 – Preliminary fuel filter
8 – Solenoid Solenoid valve
c – from tank
4 – Manual feed pump
9 – Flame plugs
d – Fuel return
5 – Fuel tank
To avoid that the feed pump takes in heated up fuel, for the design it must be considered that the intake-- and return pipe in the tank have a distance to each other of at least 500 mm. In the fuel intake scheme, this distance is designated 'X'. For some installations, it is required that the fuel return from the injection pump and the injectors, respectively, is separately directed back to the tank.
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Service-Training 4.2 Setting the commenceme commencement nt of delive delivery ry
Beyond the injector opening pressure and the cetane number, also the injection pump delivery commencement determines the ignition time and is, thus, also responsible for engine rating, consumption and exhaust gas quality. Therefore, its careful setting is of high importance. For series 1015, there are two methods for setting the injection pump delivery commencement, while searching for and setting of the commencement of delivery for the engine is identical.
A special special tool is available available for searching searching the position delivery de livery commencement commen cement for the enengine. Mount the tool at a specified flange at the adapter housing. It comprises a turning device (4) for the flywheel ring gear, a spring-loaded bolt (3) and a graduated disc (2). When turning the flywheel, the bolt (3) slides over the teeth of the ring gear and automatically engages in a special groove in the ring gear.
Important: For series 1015, only use the black (outer) scale (1) on the graduated disk.
Bild 1015-0041
Thus, the engine is in the top dead centre position cylinder A1. As, however, it must be distinguished between top dead centre ignition and change cycle and as there are two grooves on the ring gear, which are shifted by 90°, the top dead centre ignition cylinder A1 must be exactly determined with the valve overlapping of cylinder B2 (6-cylinder) or B3 (8-cylinder). After the top dead centre position After position ignition ignition of cylin cylinder der A1 has been been determin determined, ed, set set the angle angle indicator of the turning device to zero. This position is marked on the scale with a red point. Starting from there, the engine is turned into the desired position of delivery commencement (see nameplate) with the aid of the graduation.
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The injection pump (1) is driven via a toothed wheel by the camshaft (5) to whose drive gear (3) a second gear (4) is mounted. This gear (2) is fastened to the flange of the injection pump camshaft with six bolts in oblong holes. There is an old an a new clearance-optimised drive gear. For the former drive gear, the backlash must be between 0.04 and 0.29 mm. It is set by the selection of the suitable pump drive gear. Here, three gears are available which can be identified by a minus-, zero- or plus-mark. For further instructions, see the workshop manual. A former pump drive gear (2) must only replaced replaced by a clearance clearance-optimised -optimised one, if the respective respective drive gear (4) on the camshaft is also replaced. In case of clearance optimisation, the backlash must not be set.
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Service-Training 4.2.1 Electrical setting device for the delivery commencement
The former method for setting the delivery commencement of the injection pump was realised via an electrical setting instrument (LED's), which receives its signal from an indicator mounted on the injection pump camshaft. Engines with this setting method have the non-clearance optimised drive gear on the injection pump camshaft. The following picture shows the arrangement of the setting device. Position 1 means that, in this case, the engine has been turned with the turning device into the position 15° before top dead centre cylinder A1. For setting the injection pump delivery commencement, first, the screws of the drive gear are unscrewed. After opening opening of the locking locking cap cap (C), the pump pump camshaft camshaft is turned turned counter-clock counter-clockwise wise into into the stroke of cylinder A1, until the signal lug is visible in front of the bore. The signal lug is now fixed with a special pin. Then, the pump is installed as directed (workshop manual and chapter 5.3) and the fixing pin for the signal lug removed. Now, the sensor (D) of the setting device is screwed into the opened bore (C) duly considering the positioning with the aid of an adapter spring. The device is switched on now by connecting the cable terminal (E) with the engine ground. Now, the injection pump camshaft is turned in the turning direction (backlash), until both of the LED's (A) and (B) are just lighted. Now, the accessible screws of the pump drive gear are tightened and the delivery commencement checked at the turning device. If no correction is required, the residual bolts of the drive gear are tightened.
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Service-Training 4.2.2 Fixing pin
With the new method for setting the delivery commencement, the injection pump camshaft (1) is kept in the position delivery commencement for the plunger of cylinder A1 with the aid of a fixing pin (2). The drive gear (3) has an additional oblong hole to provide sufficient free space for the pin (2) upon the installation of the injection pump. The fixing (5) of the pin (2) at the pump housing (6) is sealed by the manufacturer after the completion of the pump. After the instal installatio lation n of the inject injection ion pump, pump, the the screws screws of the the drive drive gear (3) are tightened. tightened. Then, check the delivery commencement. If nor an electric delivery commencement setting device nor a fixing pin (3) should exist, it is still possible to set the delivery commencement by the highpressure method.
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5. Cooling system 5.1 Cooling circuit
The cooling circuits of series 1015 are closed circuits with thermostat-controlled outlet regulation. The coolant is prepared on water basis with additives.
Bild 1015-0050
1 – Heat exchanger (transmission)
6 – Thermostat
2 – Heat exchanger (engine)
7 – Cylinder and cylinder heads
3 – Expansion tank
8 – Air compressors compre ssors
4 – Heat exchanger
9 – Coolant pump
5 – Heat exchanger (engine oil)
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Service-Training 5.2 Coolant
Liquid-cooled engines must be filled with a processed coolant as, otherwise, serious damage can occur to the engine by freezing, cavitation and corrosion. The used water must absolutely have the following values:
Water quality ph-value at 20 °C 3 Chloride-ion content (mg/dm ) 3 Sulphate-ion contents (mg/dm ) Total hardness (°dGH)
min.
max.
6.5 3
8.5 100 100 12
The coolant is prepared by admixing an anti-freeze agent to the water. An anti-freeze free from nitrite, amine and phosphate is offered by DEUTZ SERVICE via its spare parts service. The suitability for the respective application of other anti-freeze agents should expressly approved by DEUTZ SERVICE.
The anti-freeze must not exceed or fall below the following the following concentration: Anti-freeze Ant i-freeze max. 45 % 40 % min. 35 %
Freezing Freezing prot protection ection up to °C -35°C -28°C -22°C
The coolant concentration is checked with commercial testing instrument.
Anti-freeze An ti-freeze must be disposed of in a way kind to the environment.
5-2
TU-DEA-1-05 TU-DEA-105 Edition: 28. Edition: 28.05.01 05.01 1015 TU en-pdf.doc
DEUTZ AG Service Engineering © Cologne Training Center
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