Deutz Engine 1012 1013 ser

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<ul><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 1/104</p><p>Operation M</p><p>1012</p><p>1013</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 2/104</p><p> Please read and observe the information givenin this Operation Manual. This will enable youto avoid accidents, preserve the manufacturerswarranty and maintain the engine in peakoperating condition.</p><p> This engine has been built exclusively for theapplication specified in the scope of supply asdescribed by the equipment manufacturer and is to be used only for the intended purpose.Any use exceeding that scope is considered tobe contrary to the intended purpose. Themanufacturer will not assume responsibility forany damage resulting therefrom. The risksinvolved are to be borne solely by the user.</p><p> Use in accordance with the intended purposealso implies compliance with the conditionslaid down by the manufacturer for operation,maintenance and servicing. The engine shouldonly be operated by personnel trained in its useand the hazards involved.</p><p> The relevant accident prevention guidelinesand other generally accepted safety andindustrial hygiene regulations must beobserved.</p><p> Unauthorized engine modifications willinvalidate any liability claims against the manu-facturer for resultant damage.Manipulations ofthe injection and regulating system may alsoinfluence the performance of the engine, and itsemissions. Adherence to legislation onpollution cannot be guaranteed under suchconditions.</p><p> Do not alter, modify or adapt the cooling airintake area to the fan. The manufacturer will notassume responsibility for any damage resulting</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 3/104</p><p>0297 9682</p><p>Operation M</p><p>1012</p><p>1013</p><p>Engineserial number:</p><p>Please enter the engine serial number here. Thisnumber should be quoted when inquiring aboutCustomer Service, Repairs or Spare Parts (see Section2.1).</p><p>All rights reserved. Technical modifications required to</p><p>improve our engines are reserved with regard tospecification data and other technical informationcontained in this Operation Manual No part of this</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 4/104</p><p>Dear Customer,</p><p>Liquid-cooled DEUTZ engines are designedfor a large number of applications.Consequently, a wide range of variants areoffered to meet the requirements of specificcases.</p><p>Your engine is appropriately equipped forthe installation concerned, which means thatnot all of the components described in this</p><p>Operation Manual are necessarily mountedto your engine.</p><p>We have endeavored to highlight anydifferences so that you will be able to locatethe operating and maintenance instructionsrelevant to your engine quickly and easily.</p><p>Please read this Manual before starting yourengine, and always observe the operatingand maintenance instructions.</p><p>We are available to help with any additional</p><p>Foreword</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 5/104</p><p>Table </p><p>1. General</p><p>2. Engine Description2.1 Model</p><p>2.1.1 Rating Plate</p><p>2.1.2 Rating Plate Location2.1.3 Engine Serial Number</p><p>2.1.4 Cylinder Numbering</p><p>2.2 Engine Illustrations</p><p>2.2.1 Service Side 1012</p><p>2.2.2 Starter Side 1012</p><p>2.2.3 Service Side 1012 E</p><p>2.2.4 Starter Side 1012 E</p><p>2.2.5 Service Side 1013</p><p>2.2.6 Starter Side 1013</p><p>2.2.7 Service Side 1013 E2.2.8 Starter Side 1013 E2.2.9 Starter Side</p><p>Unit Engine BF4M 1013 EC2.2.10 Service Side</p><p>Unit Engine BF4M 1013 EC2.2.11 Starter Side</p><p>Unit Engine BF6M 1013 EC2.2.12 Service Side</p><p>Unit Engine BF6M 1013 EC</p><p>2.3 Lube Oil Circuit</p><p>2.3.1 Lube Oil Circuit Schematic 1012/1012 E</p><p>2.3.2 Lube Oil Circuit Schematic 1013/1013 E</p><p>2.4 Fuel System</p><p>2.4.1 Fuel System Schematic</p><p>2.5 Cooling System</p><p>2.5.1 Cooling System Schematic 1012</p><p>2.5.2 Cooling System Schematic 1012 E</p><p>2.5.3 Cooling System Schematic 10132.5.4 Cooling System Schematic 1013 E</p><p>3. Engine Operation3.1 Commissioning</p><p>3.1.1 Adding Engine Oil</p><p>3.1.2 Filling Oil Bath Air Cleaner3.1.3 Adding Fuel3.1.4 Filling/Venting the Cooling System3.1.5 Other Preparations</p><p>3.1.6 Other Preparations</p><p>3.2 Starting3.2.1 Electric Starting</p><p>3.3 Monitoring Systems</p><p>3.3.1 Engine Oil Pressure</p><p>3.3.2 Coolant Temperature</p><p>3.3.3 Coolant Level/Level Gauge</p><p>3.4 Stopping</p><p>3.4.1 Engines with Mechanical Shutdown</p><p>3.4.2 Engines with Electrical Shutdown</p><p>3.5 Operating Conditions</p><p>3.5.1 Winter Operation</p><p>3.5.2 High Ambient Temperature, High Altitude</p><p>4. Operating M4.1 Lube Oil</p><p>4.1.1 Quality Grade</p><p>4.1.2 Viscosity</p><p>4.2 Fuel</p><p>4.2.1 Quality Grade4.2.2 Winter Grade4.3 Coolant</p><p>4.3.1 Water Quality</p><p>4.3.2 Coolant Prep</p><p>4.3.3 Antifreeze/Ch</p><p>5. Routine Ma5.1 Maintenance S</p><p>5.2 Maintenance C</p><p>5.3 Maintenance R</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 6/104</p><p>Table of contents</p><p>6. Service and Maintenance6.1 Lubrication System</p><p>6.1.1 Oil Change Intervals6.1.2 Changing Engine Oil, Checking Oil Level</p><p>6.1.3 Changing Oil Filter</p><p>6.1.4 Cleaning/Changing Oil Filter (Cup)6.2 Fuel System</p><p>6.2.1 Changing Fuel Filter</p><p>6.2.2 Cleaning / Changing Fuel Pre-Filter</p><p>Element6.2.3 Venting the Fuel System</p><p>with Preliminary Fuel Filter</p><p>6.2.4 Venting the Fuel Systemw/o Preliminary Fuel Filter</p><p>6.2.5 Changing Fuel Leakage Pipes</p><p>6.3 Cooling System</p><p>6.3.1 Cleaning Intervals6.3.2 Cleaning Cooling System</p><p>6.3.3 Draining Cooling System 1012 / 10136.3.4 Filling / Venting Cooling System</p><p>1012 / 10136.3.5 Draining the Cooling System</p><p>1012 E / 1013 E6.3.6 Filling/Venting the Cooling System</p><p>1012 E / 1013 E6.3.7 Draining the Cooling System</p><p>Unit Engine6.3.8 Filling/Venting the Cooling System</p><p>Unit Engine6.3.9 Draining the Charge Air Cooler</p><p>6.5 Belt Drives</p><p>6.5.1 Checking V-Belts</p><p>6.5.2 Tensioning Fan / Alternator Belts 1012</p><p>6.5.3 Changing Fan / Alternator Belts 1012</p><p>6.5.4 Tensioning Coolant / Fuel Pump Belts1012</p><p>6.5.5 Changing Coolant / Fuel Pump Belts1012</p><p>6.5.6 Tensioning Coolant / Fuel Pump Belts1012 E</p><p>6.5.7 Changing Coolant / Fuel Pump Belts1012 E</p><p>6.5.8 Tensioning Alternator Belt 1012 E</p><p>6.5.9 Changing Alternator Belt 1012 E</p><p>6.5.10 Tensioning / Changing Compressor /Alternator Belts 1013</p><p>6.5.11 Tensioning Coolant / Fuel Pump Belts1013</p><p>6.5.12 Changing Coolant / Fuel Pump Belts1013</p><p>6.5.13 Tensioning / Changing Alternator Belt1013</p><p>6.5.14 Tensioning Coolant / Fuel Pump Belts1013 E</p><p>6.5.15 Changing Coolant / Fuel Pump Belts1013 E</p><p>6.5.16 Tensioning / Changing Compressor Belt</p><p>6.6 Adjustments</p><p>6.6.1 Checking / Adjusting Valve Clearances6.6.1.1 Valve Clearance Adjustment Schematic</p><p>6.7.1.3 Checking Specific</p><p>6.7.2 Three-Phase Alter</p><p>6.7.3 Lifting Tackle</p><p>7. Troubleshootin</p><p>7.1 Diagnosis Chart</p><p>8. Engine Preserv8.1 Preservation</p><p>9. Technical Spec9.1 Engine Specification9.2 Torque Wrench Set</p><p>9.3 Tools</p><p>10. Service</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 7/104</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 8/104</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 9/104</p><p>DEUTZ Diesel Engines</p><p>are the product of many years of research anddevelopment. The resulting know-how, coupled</p><p>with stringent quality standards, guarantee theirlong service life, high reliability and low fuelconsumption.It goes without saying that DEUTZ Diesel Enginesmeet the highest standards for environmentalprotection.</p><p>Service</p><p>Please contact one orepresentatives in the </p><p>spare parts inquiries. carry out repairs quickonly genuine spare paOriginal parts from DEUin accordance with staPlease turn to the endservice information.</p><p>!</p><p>Care and Maintenance</p><p>Sound care and maintenance practices will ensurethat the engine continues to meet the requirements</p><p>placed on it. Recommended service intervals mustbe observed and service and maintenance workcarried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.</p><p>Asbestos</p><p>Safety</p><p>This symbol is used for all safetywarnings. Please follow themcarefully. The attention of operatingpersonnel should be drawn to thesesafety instructions. General safety</p><p>and accident prevention regulations laid down bylaw must also be observed.</p><p>Beware of Running Engine</p><p>Shut the engine down before carrying out mainte-nance or repair work. Ensure that the engine cannotbe accidentally started. Risk of accidents.When the work is complete, be sure to refit anypanels and guards that may have been removed.Never fill the fuel tank while the engine is running.Observe industrial safety regulations when runningthe engine in an enclosed space or underground.</p><p>CalPropositio</p><p>Diesel engine exhaustuents are known to cause cancer, birth dductive harm.</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 10/104</p><p>1</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 11/104</p><p>2.1 Model</p><p>2.2 Engine Illustrations2.3 Lube Oil Circuit</p><p>2.4 Fuel System</p><p>2.5 Cooling System</p><p>Engine </p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 12/104</p><p>2</p><p>Engine Description</p><p>26 332 0 26231 1</p><p>2.1.1 Rating Plate 2.1.2 Rating Plate Location</p><p>The rating plate Cis attached to the crankcase.The model A, the engine serial number Band theperformance data are stamped on the rating plate.The model and engine serial number must begiven when ordering spare parts.</p><p>2.1.3 Engine Serial </p><p>The engine serial number crankcase itself (arrow).</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 13/104</p><p>2.1 Model Engine </p><p>26233 0</p><p>2.1.4 Cylinder Numbering</p><p>Cylinders are numbered consecutively, beginningat the flywheel end.</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 14/104</p><p>2</p><p>Engine Description 2.2 Engine </p><p>2.2.1 Service Side 1012</p><p> 1 Oil filler (option: betwe</p><p> 2 Coolant filler</p><p> 3 Cooling fan</p><p> 4 Coolant pump</p><p> 5 Belt pulley</p><p> 6 Fuel pump</p><p> 7 Engine mount</p><p> 8 Fuel filter</p><p> 9 Lube oil filter</p><p>10 Oil pan</p><p>11 Dipstick</p><p>12 Lube oil cooler</p><p>13 Mounting facility for hy14 Alternator</p><p>15 Back leak fuel pipe wvalve</p><p>16 Cylinder head</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 15/104</p><p>2.2 Engine Illustrations Engine </p><p>2.2.2 Starter Side 1012</p><p>17 Lifting points</p><p>18 Exhaust turbocha</p><p>19 Speed governor</p><p>20 SAE housing</p><p>21 Flywheel</p><p>22 Starter motor</p><p>23 Hydraulic oil coole</p><p>24 Coolant heat exch</p><p>25 Coolant level gaug</p><p>26 Bleeder valve</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 16/104</p><p>2</p><p>Engine Description 2.2 Engine </p><p>2.2.3 Service Side 1012 E</p><p> 1 Oil filler (option: betwe</p><p> 2 Coolant inlet</p><p> 3 Coolant pump 4 Alternator</p><p> 5 Belt pulley</p><p> 6 Engine mount</p><p> 7 Fuel pump</p><p> 8 Fuel filter</p><p> 9 Lube oil filter</p><p>10 Oil pan</p><p>11 Dipstick</p><p>12 Lube oil cooler</p><p>13 Mounting facility for h14 Back leak fuel pipe w</p><p>valve</p><p>15 Cylinder head</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 17/104</p><p>2.2 Engine Illustrations Engine </p><p>16 Lifting points</p><p>17 Exhaust turbocha</p><p>18 Speed governor19 SAE housing</p><p>20 Flywheel</p><p>21 Starter motor</p><p>22 Coolant outlet to h</p><p>23 Exhaust manifold</p><p>24 Air intake manifol</p><p>2.2.4 Starter Side 1012 E</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 18/104</p><p>2</p><p>Engine Description 2.2 Engine </p><p> 1 Oil filler (option: betwe</p><p> 2 Alternator</p><p> 3 Coolant pump 4 Fan</p><p> 5 Belt Pulley</p><p> 6 Vibration damper</p><p> 7 Fuel pump</p><p> 8 Engine mount</p><p> 9 Fuel filter</p><p>10 Lube oil filter</p><p>11 Oil pan</p><p>12 Dipstick</p><p>13 Lube oil cooler14 Hydraulic pumps (or c</p><p>15 Fuel pipe</p><p>16 Solenoid</p><p>17 Lube oil line to turboc</p><p>18 Cylinder head</p><p>2.2.5 Service Side 1013</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 19/104</p><p>2.2 Engine Illustrations Engine </p><p>2.2.6 Starter Side 1013</p><p>19 Lifting points</p><p>20 Exhaust turbocha</p><p>21 Speed governor22 SAE housing</p><p>23 Flywheel</p><p>24 Starter motor</p><p>25 Coolant level gaug</p><p>26 Bleeder valve</p><p>27 Coolant filler cap</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 20/104</p><p>2</p><p>Engine Description 2.2 Engine </p><p> 1 Oil f il ler</p><p> 2 Coolant pump</p><p> 3 Fuel pump 4 Vibration damper</p><p> 5 Fuel filter</p><p> 6 Engine mount</p><p> 7 Lube oil filter</p><p> 8 Oil pan</p><p> 9 Dipstick</p><p>10 Lube oil cooler</p><p>11 Mounting facility for h</p><p>12 Back leak fuel pipe w</p><p>valve13 Cylinder head</p><p> A Coolant inlet</p><p>2.2.7 Service Side 1013 E</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 21/104</p><p>2.2 Engine Illustrations Engine </p><p>14 Lifting points</p><p>15 Crankcase breathe</p><p>16 Speed governor17 SAE housing</p><p>18 Flywheel</p><p>19 Starter motor</p><p>20 Exhaust turbochar</p><p>21 Fan</p><p>22 Exhaust manifold</p><p>23 Air intake manifold</p><p>2.2.8 Starter Side 1013 E</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 22/104</p><p>2</p><p>Engine Description 2.2 Engine </p><p>1 Coolant filler neck with2 Expansion tank</p><p>3 Vent line from cylinder4 Coolant line from engifluid radiator</p><p>5 Expansion line from ex6 Charge air line from ex</p><p>charge-air cooler7 Dry air filter8 Induction air line betw</p><p>exhaust turbocharger9 Exhaust turbocharger</p><p>10 Coolant line from cranradiator</p><p>11 Charge-air cooler12 Engine fluid radiator13 Coolant line from engin</p><p>thermostat</p><p>2.2.9 Starter Side</p><p> Unit Engine BF4M 1013 EC</p><p>8</p><p>9</p><p>1012</p><p>1 2 3 4 5 6 7</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 23/104</p><p>2.2 Engine Illustrations Engine </p><p>3 Ventilation line frotank</p><p>13 Charge-air line from14 Protective guard</p><p>2.2.10Service Side</p><p>Unit Engine BF4M 1013 EC</p><p>13</p><p>3</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 24/104</p><p>2</p><p>Engine Description 2.2 Engine </p><p>2.2.11Starter Side</p><p>Unit Engine BF6M 1013 EC</p><p>1 Filler neck with cap2 Expansion tank</p><p>3 Vent line from cylinder4 Expansion line from expump</p><p>5 Coolant line from cranradiator</p><p>6 Charge-air line from cha7 Charge-air line from ex</p><p>charge-air cooler8 Coolant line from engin</p><p>thermostat</p><p>1 32 4 5 6 7</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 25/104</p><p>2.2 Engine Illustrations Engine </p><p>2.2.12Service Side</p><p>Unit Engine BF4M 1013 EC</p><p>9 Engine fluid radia10 Charge-air cooler</p><p>11 Protective guard</p><p>9</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 26/104</p><p>2</p><p>Engine Description 2.3 Lub</p><p>2.3.1 Lube Oil Circuit Schematic1012 / 1012 E</p><p> 1 Oil pan</p><p> 2 Air intake manifold</p><p> 3 Lube oil pump 3a Back leak fuel valve</p><p> 3b Pressure-relief valve</p><p> 4 Lube oil cooler</p><p> 5 Lube oil filter</p><p> 6 Main oil gallery</p><p> 7 Crankshaft bearing</p><p> 8 Conrod bearing</p><p> 9 Camshaft bearing</p><p>10 Line to spray nozzle</p><p>11 Spray nozzle for piston12 Tappet w/ control borof rocker arms</p><p>13 Pushrod (designed frocker arms)</p><p>14 Rocker arm</p><p>15 Return line to oil pan</p><p>16 Oil sensor</p><p>17 Oil line to exhaust turb</p><p>18 Exhaust turbocharger</p><p>19 Oil line to compressor</p><p>20 Compressor21 Hydraulic pump</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 27/104</p><p>2.3 Lube Oil Circuit Engine </p><p>2.3.2 Lube Oil Circuit Schematic1013 / 1013 E</p><p> 1 Oil pan</p><p> 2 Air intake manifol</p><p> 3 Lube oil pump 3a Back leak fuel valv</p><p> 3b Pressure-relief va</p><p> 4 Lube oil cooler</p><p> 5 Lube oil filter</p><p> 6 Main oil gallery</p><p> 7 Crankshaft bearin</p><p> 8 Conrod bearing</p><p> 9 Camshaft bearing</p><p>10 Spray nozzle line</p><p>11 Spray nozzle for p</p><p>12 Tappet w/ controof rocker arms</p><p>13 Pushrod (designerocker arms)</p><p>14 Rocker arm</p><p>15 Return line to oil p</p><p>16 Oil sensor</p><p>17 Oil line to exhaust</p><p>18 Exhaust turbocha</p><p>19 Oil line to compre</p><p>20 Compressor21 Hydraulic pump</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 28/104</p><p>2</p><p>Engine Description 2.4 </p><p>2.4.1 Fuel System Schematic</p><p> 1 Fuel tank</p><p> 2 Line to fuel pump</p><p> 3 Fuel pump 4 Line to fuel filter</p><p> 5 Fuel filter</p><p> 6 Line to injection pump</p><p> 7 Injection pump</p><p> 8 Line to injector</p><p> 9 Injector</p><p>10 Back leak fuel pipe</p><p>11 Banjo bolt with pressu</p><p>12 Return line to fuel tank</p><p>13 Keep this spacing as w</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 29/104</p><p>2.5 Cooling System Engine </p><p>1 Coolant f iller2 Thermostat housi</p><p>3 Coolant pump4 Lube oil cooler5 Cylinder cool ing6 Cylinder head coo7 Heat exchanger8 Return from therm</p><p>housing9 Ventilation line fro</p><p>exchanger (expan</p><p>2.5.1 Cooling System Schematic1012</p></li><li><p>5/19/2018 Deutz Engine 1012 1013 ser</p><p> 30/104</p><p>2</p><p>Engine Description 2.5 Coo</p><p>2.5.2 Cooling System Schematic1012 Eentrance regulation</p><p>1 Thermostat housing2 Coolant pump</p><p>3 Lube oil cooler4 Cylinder cool ing5 Cylinder head cooling6 Heat exchanger7 Ventilation line expans</p><p>pump8 Line from engine to...</p></li></ul>