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ENGLISCH Kapitel 00 Seite 1

Operation Manual

10121013


l 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.

l 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.

l 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.

l The relevant accident prevention guidelinesand other generally accepted safety andindustrial hygiene regulations must beobserved.

l 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.

l Do not alter, modify or adapt the cooling airintake area to the fan. The manufacturer will notassume responsibility for any damage resultingtherefrom.


0297 9682 en

Operation Manual

10121013

Engineserial number:

Please enter the engine serial number here. Thisnumber should be quoted when inquiring aboutCustomer Service, Repairs or Spare Parts (see Section2.1).

All rights reserved. Technical modifications required toimprove our engines are reserved with regard tospecification data and other technical informationcontained in this Operation Manual. No part of thisManual may be reproduced in any form or by anymeans without our written approval.


Dear Customer,

Liquid-cooled DEUTZ engines are designedfor a large number of applications.Consequently, a wide range of variants areoffered to meet the requirements of specificcases.

Your engine is appropriately equipped forthe installation concerned, which means thatnot all of the components described in thisOperation Manual are necessarily mountedto your engine.

We have endeavored to highlight anydifferences so that you will be able to locatethe operating and maintenance instructionsrelevant to your engine quickly and easily.

Please read this Manual before starting yourengine, and always observe the operatingand maintenance instructions.

We are available to help with any additionalinquiries.

Sincerely,

DEUTZ AG

Foreword


Table of contents

1. General

2. Engine Description2.1 Model2.1.1 Rating Plate2.1.2 Rating Plate Location2.1.3 Engine Serial Number2.1.4 Cylinder Numbering2.2 Engine Illustrations2.2.1 Service Side 10122.2.2 Starter Side 10122.2.3 Service Side 1012 E2.2.4 Starter Side 1012 E2.2.5 Service Side 10132.2.6 Starter Side 10132.2.7 Service Side 1013 E2.2.8 Starter Side 1013 E2.2.9 Starter Side

Unit Engine BF4M 1013 EC2.2.10 Service Side

Unit Engine BF4M 1013 EC2.2.11 Starter Side

Unit Engine BF6M 1013 EC2.2.12 Service Side

Unit Engine BF6M 1013 EC2.3 Lube Oil Circuit2.3.1 Lube Oil Circuit Schematic 1012/1012 E2.3.2 Lube Oil Circuit Schematic 1013/1013 E

2.4 Fuel System2.4.1 Fuel System Schematic2.5 Cooling System2.5.1 Cooling System Schematic 10122.5.2 Cooling System Schematic 1012 E2.5.3 Cooling System Schematic 10132.5.4 Cooling System Schematic 1013 E

3. Engine Operation3.1 Commissioning3.1.1 Adding Engine Oil3.1.2 Filling Oil Bath Air Cleaner3.1.3 Adding Fuel3.1.4 Filling/Venting the Cooling System3.1.5 Other Preparations3.1.6 Other Preparations3.2 Starting3.2.1 Electric Starting3.3 Monitoring Systems3.3.1 Engine Oil Pressure3.3.2 Coolant Temperature3.3.3 Coolant Level/Level Gauge3.4 Stopping3.4.1 Engines with Mechanical Shutdown3.4.2 Engines with Electrical Shutdown3.5 Operating Conditions3.5.1 Winter Operation3.5.2 High Ambient Temperature, High Altitude

4. Operating Media4.1 Lube Oil4.1.1 Quality Grade4.1.2 Viscosity4.2 Fuel4.2.1 Quality Grade4.2.2 Winter Grade Fuel4.3 Coolant4.3.1 Water Quality for Coolant Preparation4.3.2 Coolant Preparation4.3.3 Antifreeze/Chemical Corrosion Inhibitors

5. Routine Maintenance5.1 Maintenance Schedule5.2 Maintenance Chart5.3 Maintenance Record


Table of contents

6. Service and Maintenance6.1 Lubrication System6.1.1 Oil Change Intervals6.1.2 Changing Engine Oil, Checking Oil Level6.1.3 Changing Oil Filter6.1.4 Cleaning/Changing Oil Filter (Cup)6.2 Fuel System6.2.1 Changing Fuel Filter6.2.2 Cleaning / Changing Fuel Pre-Filter

Element6.2.3 Venting the Fuel System

with Preliminary Fuel Filter6.2.4 Venting the Fuel System

w/o Preliminary Fuel Filter6.2.5 Changing Fuel Leakage Pipes6.3 Cooling System6.3.1 Cleaning Intervals6.3.2 Cleaning Cooling System6.3.3 Draining Cooling System 1012 / 10136.3.4 Filling / Venting Cooling System

1012 / 10136.3.5 Draining the Cooling System

1012 E / 1013 E6.3.6 Filling/Venting the Cooling System

1012 E / 1013 E6.3.7 Draining the Cooling System

Unit Engine6.3.8 Filling/Venting the Cooling System

Unit Engine6.3.9 Draining the Charge Air Cooler6.4 Combustion Air Cleaner6.4.1 Cleaning Intervals6.4.2 Emptying Cyclone-Type Precleaner6.4.3 Cleaning Oil Bath Air Cleaner6.4.4 Dry Type Air Cleaner

6.5 Belt Drives6.5.1 Checking V-Belts6.5.2 Tensioning Fan / Alternator Belts 10126.5.3 Changing Fan / Alternator Belts 10126.5.4 Tensioning Coolant / Fuel Pump Belts

10126.5.5 Changing Coolant / Fuel Pump Belts

10126.5.6 Tensioning Coolant / Fuel Pump Belts

1012 E6.5.7 Changing Coolant / Fuel Pump Belts

1012 E6.5.8 Tensioning Alternator Belt 1012 E6.5.9 Changing Alternator Belt 1012 E6.5.10 Tensioning / Changing Compressor /

Alternator Belts 10136.5.11 Tensioning Coolant / Fuel Pump Belts

10136.5.12 Changing Coolant / Fuel Pump Belts

10136.5.13 Tensioning / Changing Alternator Belt

10136.5.14 Tensioning Coolant / Fuel Pump Belts

1013 E6.5.15 Changing Coolant / Fuel Pump Belts

1013 E6.5.16 Tensioning / Changing Compressor Belt6.6 Adjustments6.6.1 Checking / Adjusting Valve Clearances6.6.1.1 Valve Clearance Adjustment Schematic6.7 Accessories6.7.1 Battery6.7.1.1 Checking the Battery and Cable

Connections6.7.1.2 Checking Electrolyte Level

6.7.1.3 Checking Specific Gravity of Electrolyte6.7.2 Three-Phase Alternator6.7.3 Lifting Tackle

7. Troubleshooting7.1 Diagnosis Chart

8. Engine Preservation8.1 Preservation

9. Technical Specifications9.1 Engine Specifications and Settings9.2 Torque Wrench Settings9.3 Tools

10. Service

7 Gerade7 Gerade

1DEUTZ Diesel Engines

are the product of many years of research anddevelopment. The resulting know-how, coupledwith 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.

Service

Please contact one of our authorized servicerepresentatives in the event of breakdowns or forspare parts inquiries. Our trained specialists willcarry out repairs quickly and professionally, usingonly genuine spare parts.Original parts from DEUTZ AG are always producedin accordance with state-of-the-art technology.Please turn to the end of this manual for furtherservice information.

General

!

Care and Maintenance

Sound care and maintenance practices will ensurethat the engine continues to meet the requirementsplaced on it. Recommended service intervals mustbe observed and service and maintenance workcarried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.

Asbestos

DEUTZ original parts are asbestos-free.

Safety

This symbol is used for all safetywarnings. Please follow themcarefully. The attention of operatingpersonnel should be drawn to thesesafety instructions. General safety

and accident prevention regulations laid down bylaw must also be observed.

Beware of Running Engine

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.

CaliforniaProposition 65 Warning

Diesel engine exhaust and some of its consti-tuents are known to the State of California tocause cancer, birth defects, and other repro-ductive harm.

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2.1 Model2.2 Engine Illustrations2.3 Lube Oil Circuit2.4 Fuel System2.5 Cooling System

Engine Description

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Engine Description 2.1 Model

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2.1.1 Rating Plate 2.1.2 Rating Plate Location

The rating plate C is attached to the crankcase.The model A, the engine serial number B and theperformance data are stamped on the rating plate.The model and engine serial number must begiven when ordering spare parts.

2.1.3 Engine Serial Number

The engine serial number is also stamped on thecrankcase itself (arrow).

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2.1 Model Engine Description

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2.1.4 Cylinder Numbering

Cylinders are numbered consecutively, beginningat the flywheel end.

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Engine Description 2.2 Engine Illustrations

2.2.1 Service Side 1012

1 Oil filler (option: between filters) 2 Coolant filler 3 Cooling fan 4 Coolant pump 5 Belt pulley 6 Fuel pump 7 Engine mount 8 Fuel filter 9 Lube oil filter10 Oil pan11 Dipstick12 Lube oil cooler13 Mounting facility for hydraulic pumps14 Alternator15 Back leak fuel pipe with pressure-regulating

valve16 Cylinder head

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2.2 Engine Illustrations Engine Description

2.2.2 Starter Side 1012

17 Lifting points18 Exhaust turbocharger19 Speed governor20 SAE housing21 Flywheel22 Starter motor23 Hydraulic oil cooler24 Coolant heat exchanger25 Coolant level gauge26 Bleeder valve

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2.2.3 Service Side 1012 E

1 Oil filler (option: between filters) 2 Coolant inlet 3 Coolant pump 4 Alternator 5 Belt pulley 6 Engine mount 7 Fuel pump 8 Fuel filter 9 Lube oil filter10 Oil pan11 Dipstick12 Lube oil cooler13 Mounting facility for hydraulic pump14 Back leak fuel pipe with pressure-regulating

valve15 Cylinder head

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16 Lifting points17 Exhaust turbocharger18 Speed governor19 SAE housing20 Flywheel21 Starter motor22 Coolant outlet to heat exchanger23 Exhaust manifold24 Air intake manifold

2.2.4 Starter Side 1012 E

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1 Oil filler (option: between filters) 2 Alternator 3 Coolant pump 4 Fan 5 Belt Pulley 6 Vibration damper 7 Fuel pump 8 Engine mount 9 Fuel filter10 Lube oil filter11 Oil pan12 Dipstick13 Lube oil cooler14 Hydraulic pumps (or compressor)15 Fuel pipe16 Solenoid17 Lube oil line to turbocharger18 Cylinder head

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2.2.5 Service Side 1013

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2.2.6 Starter Side 1013

19 Lifting points20 Exhaust turbocharger21 Speed governor22 SAE housing23 Flywheel24 Starter motor25 Coolant level gauge26 Bleeder valve27 Coolant filler cap

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1 Oil filler 2 Coolant pump 3 Fuel pump 4 Vibration damper 5 Fuel filter 6 Engine mount 7 Lube oil filter 8 Oil pan 9 Dipstick10 Lube oil cooler11 Mounting facility for hydraulic pump12 Back leak fuel pipe with pressure-regulating

valve13 Cylinder head A Coolant inlet

2.2.7 Service Side 1013 E

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14 Lifting points15 Crankcase breather valve16 Speed governor17 SAE housing18 Flywheel19 Starter motor20 Exhaust turbocharger21 Fan22 Exhaust manifold23 Air intake manifold

2.2.8 Starter Side 1013 E

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1 Coolant filler neck with cap2 Expansion tank3 Vent line from cylinder head to expansion tank4 Coolant line from engine crankcase to engine

fluid radiator5 Expansion line from expansion tank to radiator6 Charge air line from exhaust turbocharger to

charge-air cooler7 Dry air filter8 Induction air line between dry air filter and

exhaust turbocharger9 Exhaust turbocharger

10 Coolant line from crankcase to engine fluidradiator

11 Charge-air cooler12 Engine fluid radiator13 Coolant line from engine fluid radiator to engine

thermostat

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2.2.9 Starter Side Unit Engine BF4M 1013 EC

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8

9

1012

1113

1 2 3 4 5 6 7

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3 Ventilation line from cylinder head to expansiontank

13 Charge-air line from charge-air cooler to engine14 Protective guard

2.2.10 Service SideUnit Engine BF4M 1013 EC

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13

14

3

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2.2.11 Starter SideUnit Engine BF6M 1013 EC

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1 Filler neck with cap2 Expansion tank3 Vent line from cylinder head to expansion tank4 Expansion line from expansion tank to coolant

pump5 Coolant line from crankcase to engine fluid

radiator6 Charge-air line from charge-air cooler to engine7 Charge-air line from exhaust turbocharger to

charge-air cooler8 Coolant line from engine fluid radiator to engine

thermostat

1 32

8

4 5 6 7

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2.2.12 Service SideUnit Engine BF4M 1013 EC

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9 Engine fluid radiator10 Charge-air cooler11 Protective guard

9

1011

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Engine Description 2.3 Lube Oil Circuit

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2.3.1 Lube Oil Circuit Schematic1012 / 1012 E

1 Oil pan 2 Air intake manifold 3 Lube oil pump 3a Back leak fuel valve 3b Pressure-relief valve 4 Lube oil cooler 5 Lube oil filter 6 Main oil gallery 7 Crankshaft bearing 8 Conrod bearing 9 Camshaft bearing10 Line to spray nozzle11 Spray nozzle for piston cooling12 Tappet w/ control bore for pulse lubrication

of rocker arms13 Pushrod (designed for lube oil supply of

rocker arms)14 Rocker arm15 Return line to oil pan16 Oil sensor17 Oil line to exhaust turbocharger18 Exhaust turbocharger19 Oil line to compressor or hydraulic pump20 Compressor21 Hydraulic pump22 Return line to compressor or hydraulic pump23 Line to mass balancing gear (2x)24 Counterbalancing shafts25 Exhaust turbocharger return to crankcase

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2.3 Lube Oil Circuit Engine Description

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2.3.2 Lube Oil Circuit Schematic1013 / 1013 E

1 Oil pan 2 Air intake manifold 3 Lube oil pump 3a Back leak fuel valve 3b Pressure-relief valve 4 Lube oil cooler 5 Lube oil filter 6 Main oil gallery 7 Crankshaft bearing 8 Conrod bearing 9 Camshaft bearing10 Spray nozzle line11 Spray nozzle for piston cooling12 Tappet w/ control bore for pulse lubrication

of rocker arms13 Pushrod (designed for lube oil supply of

rocker arms)14 Rocker arm15 Return line to oil pan16 Oil sensor17 Oil line to exhaust turbocharger18 Exhaust turbocharger19 Oil line to compressor or hydraulic pump20 Compressor21 Hydraulic pump22 Return line to compressor or hydraulic pump23 Return to oil pan24 Exhaust turbocharger return to crankcase

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Engine Description 2.4 Fuel System

2.4.1 Fuel System Schematic

1 Fuel tank 2 Line to fuel pump 3 Fuel pump 4 Line to fuel filter 5 Fuel filter 6 Line to injection pumps 7 Injection pump 8 Line to injector 9 Injector10 Back leak fuel pipe11 Banjo bolt with pressure-regulating valve12 Return line to fuel tank13 Keep this spacing as wide as possible

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2.5 Cooling System Engine Description

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1 Coolant filler2 Thermostat housing3 Coolant pump4 Lube oil cooler5 Cylinder cooling6 Cylinder head cooling7 Heat exchanger8 Return from thermostat to coolant pump

housing9 Ventilation line from cylinder head to heat

exchanger (expansion tank)

2.5.1 Cooling System Schematic1012

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Engine Description 2.5 Cooling System

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2.5.2 Cooling System Schematic1012 Eentrance regulation

1 Thermostat housing2 Coolant pump3 Lube oil cooler4 Cylinder cooling5 Cylinder head cooling6 Heat exchanger7 Ventilation line expansion tank - coolant

pump8 Line from engine to heat exchanger9 Ventilation line from cylinder head to

expansion tank10 Expansion tank11 Line from heat exchanger to thermostat

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1012 Eescape regulation

1 Thermostat housing2 Cooling fluid pump3 Lubricating oil cooler4 Cylinder cooling5 Cylinder head cooling6 Heat exchanger7 Compensation setting of compensation tank t

o cooling fluid pump8 Line (Crankcase) from thermostat to heat

exchanger9 Ventilation line from cylinder head to

compensation tank10 Compensation tank11 Line from heat exchanger to cooling fluid pump

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2.5.3 Cooling System Schematic1013

1 Coolant filler2 Thermostat housing3 Coolant pump4 Lube oil cooler5 Cylinder cooling6 Cylinder head cooling7 Heat exchanger8 Expansion line coolant pump/expansion

tank9 Ventilation line from cylinder head to

heat exchanger (expansion tank)

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22.5.4 Cooling System Schematic1013 Eentrance regulation

1 Thermostat housing2 Coolant pump3 Lube oil cooler4 Cylinder cooling5 Cylinder head cooling6 Heat exchanger7 Ventilation line expansion tank - coolant

pump8 Line from engine to heat exchanger9 Ventilation line from cylinder head to

expansion tank10 Expansion tank11 Line from heat exchanger to thermostat

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1013 Eescape regulation

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1 Thermostat housing2 Cooling fluid pump3 Lubricating oil cooler4 Cylinder cooling5 Cylinder head cooling6 Heat exchanger7 Compensation setting of compensation tank t

o cooling fluid pump8 Line (Crankcase) from thermostat to heat

exchanger9 Ventilation line from cylinder head to

compensation tank10 Compensation tank11 Line from heat exchanger to cooling fluid pump

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Engine Operation

3.1 Commissioning3.2 Starting3.3 Monitoring Systems3.4 Stopping3.5 Operating Conditions


3 3.1.1 Adding Engine Oil

As a rule, engines are delivered empty of oil.Pour lube oil into the oil filler neck (arrow).For oil quantities, see 9.1.For oil grade and viscosity, see 4.1.

3.1.2 Filling Oil Bath Air Cleaner

Fill oil cup 1 of the oil bath air cleaner (if fitted)with oil up to the arrow.For oil grade and viscosity, see 4.1.

3.1.3 Adding Fuel

Use only commercial-grade diesel fuel. For fuelgrade, see 4.2.If required use a preliminary fuel filter.If in doubt, please ask your service representative.Use summer or winter-grade fuel, depending onthe ambient temperature.

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Do not fill the precleaner dustcollector (if fitted) with oil.

Never fill the fuel tank while theengine is running. Keep the fillercap area clean and do not spill fuel.

Engine Operation 3.1 Commissioning


3

3.1 Commissioning Engine Operation

3.1.4 Filling/Venting the CoolingSystem

3.1.5 Other Preparations

l Check battery and cable connections, see 6.7.1.

l Trial run- After the engine has been prepared, let it runfor about 10 minutes without load.

During and after trial run- Check the engine for leaks.

After the engine has been turned off- Check the oil level and top up if necessary, see

6.1.2.- Tighten the V-belt, see 6.5.

l Breaking-inDuring the break-in phase - about 200 operat-ing hours - check the oil level twice a day.After the engine is broken in, checking once aday will be sufficient.

l Commissioning conserved enginesRemove conservation materials as outlined insection 8.1

l 1012/1013See section 6.3.4

l 1012 E/1013 ESee section 6.3.6

l Unit engine (with frontal radiator)See section 6.3.8.


3

Engine Operation 3.2 Starting

!

3.2.1 Electric Starting

Before starting, make sure thatnobody is standing in the imme-diate vicinity of the engine or drivenmachine.After repair work:

Check that all guards have been replaced and thatall tools have been removed from the engine.When starting with glow plugs, do not use anyother starter substance (e.g. injection with startpilot). Doing so could result in an accident.Important:Never start the engine with speed governorremoved. Disconnect battery.

Do not actuate the starter for more than 20seconds. If the engine does not catch, wait aminute then try again.If the engine does not catch after two attempts,refer to the Diagnosis Chart (see 7.1).

l Disengage the clutch to separate the enginefrom the driven equipment.

l Move speed control lever 1 in direction ofarrow at least to middle speed position.

l Move shutdown lever 2 to operating position(in opposite direction of arrow).

Starting without Cold-Start Aid

l Insert key. Position 0 = no operating voltage.

l Turn key clockwise. Position 1 = operating voltage. Pilot lights 1 and 2 come on.

l Push the key in and turn it further clockwiseagainst spring pressure. Position 2 = no function Position 3 = start

l Release key as soon as engine fires. Pilot lights go out.

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3.2 Starting Engine Operation

Starting with Heater Plugs

l Insert key. Position 0 = no operating voltage.

l Turn key clockwise. Position 1 = operating voltage. Pilot lights come on. Leave to preheat until

pilot lights go out.

l Push key in and turn further clockwise againstspring pressure. Position 2 = no function. Position 3 = start.

l Release key as soon as engine fires. Pilot lights go out.

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3

Engine Operation 3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

Oil Pressure Pilot Light

l The oil pressure pilot light comes on withoperating voltage on and engine off.

l The oil pressure pilot light should go out whenthe engine is running.

Oil Pressure Indicator

l The pointer must remain in the green sectorover the entire operating range.

Oil Pressure Gauge

l The pointer must indicate the minimum oilpressure (see 9.1).

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3.3 Monitoring Systems Engine Operation

3.3.2 Coolant Temperature

l The coolant temperature gauge pointer shouldremain in the green sector most of the time. Itshould rarely enter the yellow-green sector. Ifthe pointer enters the orange sector, the engineis overheating. Turn it off and establish thecause from the Diagnosis Chart (see 7.1).

3.3.3 Coolant Level /Coolant Level Gauge

l When the engine is cold, coolant level 1 shouldbe above the KALT-COLD mark.

l Top up with coolant if the level falls below theMIN mark on the sight glass, or if the coolantwarning switch comes on. Unscrew the filler cap. Top up with coolant up to the upper edge of

the filler neck. Tighten the filler cap

l If it is not possible to carry out a check at theinspection opening, if required carry out acheck at the filler neck:If you cannot see any fluid:- topping up is required.

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l If a level switch is fitted, the engine is shutdown automatically when the level falls belowthe MIN marking.


3

Engine Operation 3.4 Stopping

3.4.1 Engines with MechanicalShutdown

l Move speed control lever 1 to low idle.

l Operate shutdown lever 2 until the enginecomes to a stop. The charge pilot light and theoil pressure pilot light will come on when theengine stops.

l Turn key counterclockwise (to Position 0) andremove. The pilot lights will go out.

3.4.2 Engines with ElectricalShutdown

l Turn key counterclockwise (to Position 0) andremove. The pilot lights will go out.

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Where possible, do not switch the engine off fromfull load. Leave running in idle for approx. 2minutes.


3

3.5 Operating Conditions Engine Operation

3.5.1 Winter Operation

l Lube Oil Viscosity Select the oil viscosity (SAE grade)

according to the ambient temperature whenthe engine is started (see 4.1.2).

Increase oil change frequency when operat-ing below 10C, see 6.1.1.

l Diesel Fuel Use winter-grade diesel fuel for operation

below 0C, see 4.2.2.

l Coolant Set the water/antifreeze mix to suit the lowest

likely temperature (max. 35C), see 4.3.1.

l Additional Maintenance Work Drain the sludge from the fuel tank once a

week by undoing the drain plug. Adjust the oil level in the oil bath air cleaner

(if fitted) to suit the ambient temperature. At temperatures below 20C, lubricate the

flywheel ring gear from time to time withlow-temperature grease, such as Bosch FT 1V 31. To do so, remove the starter andintroduce the grease through the pinion hole.

l Cold-Start Aids At temperatures near or below freezing point,

use glow plugs if necessary (see 3.2.1).This not only lowers the starting limittemperature, but provides easier starting attemperatures normally not requiring astarting aid.

l Battery Efficient cold starting requires a healthy

battery (see 6.7.1). The starting limit temperature can be

lowered by 4-5C by heating the battery up toabout +20C. To do so, remove the batteryand store in a warm place.

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3 3.5.2 High Ambient Temperature,High Altitudel As the altitude and ambient temperature rise,

the density of the air tends to decrease, whichaffects the maximum power output of theengine, the exhaust gas quality and, in extremecases, the starting behavior. Under transientconditions, the engine can be used at altitudesup to 1000 meters / 3400 feet and tempera-tures up to 30C.If the engine is to operate under more severeconditions (at higher altitudes or tempe-ratures), it will be necessary to reduce theinjected fuel quantity and, thus, engine power.

l If you have any doubts about engine operationunder these or similar conditions, ask yourengine or equipment supplier whether theengine has been derated in the interests ofreliability, service life and exhaust gas quality(smoke). Otherwise, contact the nearestservice representative.

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Engine Operation 3.5 Operating Conditions


4

Operating Media

4.1 Lube Oil4.2 Fuel4.3 Coolant


4

Operating Media 4.1 Lube Oil

4.1.1 Quality Grade

Lube oils are differentiated according to theirperformance and quality class. In common useare specifications named after the API (AmericanPetroleum Institute) and ACEA (European OilSequences).

Approved API Oils:Turbocharged engines: CF-4 CG-4 CH-4

Approved ACEA Oils:Turbocharged engines: E1-E3/96 + E4-98

If in doubt, contact your service representative

4.1.2 Viscosity

As the viscosity of lube oil is dependent ontemperature, the choice of SAE grade should begoverned by the ambient temperature prevailingat the engine operating site.Optimum operating behaviour will be attained ifyou take the accompanying oil viscosity diagramas a guide.Should the temperature fall temporarily below thelimits of the SAE grade selected, cold starting maybe affected but the engine will not be damaged.In order to keep wear to a minimum, do not ex-ceed application limits for extended periods oftime.Oil changes dictated by the seasons can beavoided by using multi-grade lube oils. Multi-grade oils - particularly low-friction oils - also re-duce fuel consumption.

Only with preheating 30 298 1


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4.2 Fuel Operating Media

4.2.1 Quality Grade

Use commercially available diesel fuel with lessthan 0.5% sulphur content. If the sulfur content ishigher than 0.5%, oil change intervals should bereduced (see 6.1.1).

The following fuel specifications/standards areapproved:

l EN 590

l BS 2869: A1 and A2

l ASTM D975-96: 1-D and 2-D

l NATO Code F-34/F-35, F44, F-54 and F-63

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Waxing may occur at low temperatures, cloggingthe fuel system and reducing engine efficiency. Ifthe ambient temperature is less than 0 C, winter-grade fuel (suitable down to -20 C) should be used.This fuel is usually available from filling stationswell in advance of the cold months.

l At temperatures below -20C/, kerosene shouldbe added to the diesel fuel. The relevantpercentages are given in the diagram at the right

l Special diesel fuels can be used for climaticzones down to - 44 C.

If summer-grade diesel fuel must be used attemperatures below 0C, up to 60% kerosene canbe added (see diagram).

In most cases, adequate resistance to cold can beobtained by adding a flow improver (additive).Please contact your DEUTZ partner.

Mix in tank only. Fill with theappropriate amount of kerosenefirst, then add the diesel fuel.!

4.2.2 Winter-Grade Fuel

0 10 20 30 40 50 60 %

0

- 5

- 10

- 15

- 20

- 25

- 30

+32

+23

+14

+ 5

- 4

- 13

- 22

BA

F C

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Legend:

I Summer diesel fuel

II Winter diesel fuel

A Outside temperature

B Percentage of kerosene to be added


4

The values given below must not be exceeded.A test kit (order number 1213 0382) can beobtained from DEUTZ Service to check the qualityof the water available.

Water quality min. max.

pH-value at 20C /68 F 6.5 8.5

Chloride ion content [mg/dm3] 100

Sulfate ion content [mg/dm3] 100

Total hardness [dGH] 3 20

Operating Media 4.3 Coolant

4.3.1 Water Quality for CoolantPreparation

4.3.2 Coolant Preparation

The preparation and monitoring of coolant in li-quid-cooled engines is especially importantbecause corrosion, cavitation and freezing canlead to engine damage.The coolant is prepared by admixing a coolingsystem protective liquid with the cooling water.The cooling system must be monitored regularly(see 5.1). The water level and the cooling systemprotective liquid concentration should both bechecked.The cooling system protective liquid concent-ration can be checked with a commerciallyavailable tester (e.g. gefo glycomat ).

4.3.3 Cooling System ProtectiveLiquid

DEUTZ cooling system protective agents can beobtained under order number 01011490 (5 litres)or 1221 1500 (210 litres). These are nitrite-,amine- and phosphate-free and provide effectiveprotection against corrosion, cavitation andfreezing.If the above-mentioned cooling system agents arenot available, the following products can be usedin exceptional cases.

Manufacturer Product descriptionAVIA AVIA Antifreeze ExtraBASF Glysantin G 48DEA DEA radiator antifreeze

SHELL SHELL GlycoShellThe concentration of the cooling system protec-tive liquid in the coolant may not fall below/exceedthe following limits:

Cooling system protective liquid Watermax. 45 Vol.% 55%min. 35 Vol.% 65%

For the quantity, see table overpage and infor-mation in section 9.1.Other cooling system protective liquids, e.g.chemical corrosion inhibitors, can, in exceptionalcircumstances, be used in the coolant, in consult-ation with DEUTZ Service. Order the coolingsystem protective liquid from: DEUTZ Service

!When nitrite-based cooling systemprotective liquids are mixed withamine-based liquids, harmful nitro-samines are formed.

!Cooling system protective liquidsmust be disposed of in accordancewith environmental regulations.

----


4

4.3 Coolant Operating Media

18 20 22 25 27 30 32 35

35 22 2.8 7.0 7.7 8.75 9.5 10.5 11.2 12.3

40 28 7.2 8.0 8.8 10.0 10.8 12.0 12.8 14.0

45 35 8.1 9.0 9.9 11.3 12.2 13.5 14.4 15.8

50 45 9.0 10.0 11.0 12.5 13.5 15.0 16.0 17.5

Cooling system protective liquid[Liters]

Cooling system capacity *)[Liters]

Cooling system Cooling protectionprotective agent [C]

[Vol %]

Cooling System Protection

*) For quantity of coolant in your engine, see Section 9.1.Note: For figures in gray field, refer back to head-office.


5

Routine Maintenance

5.1 Maintenance Schedule5.2 Maintenance Chart5.3 Maintenance Record


5

Routine Maintenance 5.1 Maintenance Schedule

clean

renew

Job

SectionIn running hours (h)1)

every

check

1) recommended maximum2) commissioning new and reconditioned engines3) clean if needed4) change if required. If fitted, service according to maint-

enance indicator

Every10 hor

daily 1500 2000 3000100050025012550-150

l Oil level 2) 9) 6.1.2/ 3.1.6l Engine for leakagesl Oil bath 3)- and dry type air cleaners 4) 6.4l Battery and lead connections 6.7.1l Cooling system (dep. on engine use) 3) 8) 6.3.1/ 6.3.2

l Engine oil (dep. on engine use) 5) 6.1.1/ 6.1.2l Oil filter cartridge 6.1.3l Fuel filter cartridge 6.2.1

l Fuel prefilter 6.2 / 6.3l l Fuel leakage lines 6.2.5l Valve clearance (readjust if nec.) 6.6.1l Engine mounts (retighten if necessary) 9.2l V-belts (retension if nec.) 6.5l Alarm system, engine mounts 3.3/ 9.3l Radiator bearing rubber/locking elementsl Glow plugs

l Coolant 6) 6.3.3/ 6.3.4l Coolant , additive-concentration 4.3.2/ 4.3.3l Coolant level 3.3.3

l Hose connections / clamps on air intake side, CAC 10) 6.3.3/9-6.2.5

onceafter2)

The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please observe the operating instructions ofthe equipment manufacturer.

l

l

l

l

l l l l l

l l

l l

l l

l l

l l

7)

l l

l l

l l

l

l l

l

l

7)

l

l

l

5) oil grade API-CD or ACEA E1-E3-96+E4-98 for turbochargedengines, for oil change intervals, see 6.1.1

6) check antifreeze or if necessary chemical concentration every500 OH

7) or change at least every 2 years

8) system cleaning9) check twice a day during the run-in phase

10) drain off any lube oil/condensation water that has collectedin the charge-air cooler, see section 6 .3.9


5

!Stop the engine before carrying outany maintenance work.

The maintenance chart shown here is supplied asself-adhesive label with each engine. It should beaffixed where it can be seen clearly on the engineor driven equipment.

Check that this is the case.

If necessary, ask your engine or equipment supp-lier for a fresh supply of labels.

Routine work should be carried out according tothe schedule in 5.1.

5.2 Maintenance Chart Routine Maintenance

0297 7782 0

1013

1000

10

1500

10

10AIR

a

OILmax.

in.

500 OIL

FUEL

WATER

0,3 mm0.012 in.in.0,5 mm0.020 in.ex.

hStd.

500

125-2000

500

OIL

ex.

ca.15 mm0.6 in.

500

hStd.

0,3 mm0.012 in.in.0,5 mm0.020 in.ex.

BF4/6M 1012/E/C

1500

10

10

500

10

1000

500

125-2000

in.

a

ex.

FUEL

OILmax.

OIL

OIL

AIRWATE

R

ca.15 mm0.6 in.

0297 7783 0


5

The service diagram for series 1012/1013 (fillingthe cooling system, venting, bleeding) featured onthis page is stuck on the engine as a servicing aid.

Check that this is the case!

If the sticker is not on the engine, ask for areplacement from your engine or vehicle supplier.

For a full description regarding servicing, seeSections 3.1.4, 6.3.3 and 6.3.4.

Routine Maintenance 5.2 Maintenance Chart

0

2

9

7

4

9

7

9

1

BFM 1012BFM 1013


5

5.2 Maintenance Chart Routine Maintenance

0

2

9

7

4

9

8

5

1

BFM 1013E 0 2 97

4

9

8

7

1

BFM 1012EBFM 1013E

1

The service diagram for series 1012/1013 (filling the cooling system, venting, bleeding) featured on this page is stuck on the engine as a servicing aid.Check that this is the case!

If the sticker is not on the engine, ask for a replacement from your engine or vehicle supplier.For a full description regarding servicing, see Sections 3.1.4, 6.3.3 and 6.3.4.

Quelle:48 /MUS_Kap_5.3 en/W12# BA Seite

Hours. DateDate Signaure / Stamp Hours Signaure / Stamp5 -

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

Routine Maintenance 5.3 Completed Maintenance Jobs

50-150*

125

375

625

875

1125

1375

1625

1875

2115

2375

2625

* Commissioning new and overhauled enginesThe maintenance jobs duly completed can be recorded in the above table.

Quelle:49 /MUS_Kap5.3 en/W12# BA Seite

DateHours Signaure / Stamp Hours Date Signaure / Stamp 5

5.3 Completed Maintenance Jobs Routine Maintenance

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625

The maintenance jobs duly completed can be recorded in the above table.

3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750


Hours. DateDate Signaure / Stamp Hours Signaure / Stamp5


Routine Maintenance 5.3 Completed Maintenance Jobs

5875

6125

6375

6625

6875

7125

7375

7625

7825

8125

8375

8625

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

Quelle:51 /MUS_Kap5.3 en/W12# BA Seite

DateHours Signaure / Stamp Hours Date Signaure / Stamp 58875

9125

9375

9625

9875

10125

10375

10625

10825

11125

11375

11625


9000

9250

9500

9750

10000

10250

10500

10750

11000

11250

11500

11750


Hours. DateDate Signaure / Stamp Hours Signaure / Stamp5


6

Service and Maintenance

6.1 Lubrication System6.2 Fuel System6.3 Cooling System6.4 Combustion Air Cleaner6.5 Belt Drives6.6 Adjustments6.7 Accessories


6

Service and Maintenance 6.1 Lubrication System

6.1.1 Oil Change Intervals

l The oil change intervals are dependent on theengine application and the quality of the lubeoil.

l If the engine runs fewer hours during the yearthan stated in the table, the oil should bechanged at least once a year.

l The table refers to the following conditions: For diesel fuel: sulfur content max. 0.5 % by

weight. Continuous ambient temperatures down to

-10 C / +14F

l For fuels with sulfur content is > 0.5 to 1 %or continuous ambient temperature below

-10 C/+14F with bio-diesel fuels in accordance with DIN

51606-FAME the intervals between oilchanges should be halved.

l In the case of fuels containing more than 1 %sulfur, contact your service representative.

Change the oil with the engine off but still warm(lube oil temperature approx. 80 C).

Oil Grade Turbocharged engine

API Classification CF-4CG-4CH-4

ACEA Classification E1 E3/96 + E4-98

Oil Change Intervals Service Group Average Speed [km] [OH] [km]

Equipment Engines 500

Automotive Engines I 25 10 000II 40 20 000III 60 30 000


6

6.1 Lubrication System Service and Maintenance

26 023 0 26 022 0 25 729 0

Be careful when draining hot oil - dangerof scalds! Do not let used oil run intothe soil but catch it in a container readyfor proper disposal.

6.1.2 Checking Oil Level /Changing Engine Oil

6.1.2.1 Checking Oil Level 6.1.2.2 Changing Engine Oil

l Run the engine warml Ensure that the engine or vehicle is on a level

surface Lube oil temperature approx. 80C.

l Switch off the engine.

l Place an oil tray beneath the enginel Unscrew drain plug.l Drain oil.l Fit oil drain plug with new gasket and tighten

firmly (for torque, see 9.2).l Fill with lube oil

For grade/viscosity, see 4.1. For quantity, see 9.1.

l Check oil level, see 6.1.2.1

l Ensure that the engine or vehicle is on a levelsurface.

l Warm enginel Switch off engine, wait 5 minutes and check the

oil levell Cold engine

Check the oil levell Remove the dipstickl Wipe off with a non-fibrous, clean cloth.l Insert up to the stop and pull out again.l Check oil level, if required top up to the

MAX level If the oil level is just above the MIN mark,it should be topped up. !

The oil level must not drop below the MIN mark.


6

Service and Maintenance 6.1 Lubrication System

6.1.3 Changing Oil Filter

l With fitted torsion lock:Loosen screws and slide clamps downwards.

l Undo the filter cartridge with commercial tooland spin off.

l Catch any dripping oil.

l Clean any dirt from the filter carrier rim.

l Lightly oil the rubber gasket of the new oil filtercartridge.

l Screw in the new cartridge finger tight againstthe gasket.

l Check that the cartridge is correctly seatedagainst the gasket and tighten with a final half-turn.

l If a torsion lock is fitted:Slide clamps up into position and tightenscrews.

l Check oil level (see 6.1.2).

l Check oil pressure (see 3.3.1).

l Check cartridge seal.Beware of burns from hot oil.

25881 0 25882 025880 0

!


6

6.1 Lubrication System Service and Maintenance

6.1.4 Cleaning/Changing Oil filter(Cup)

l Switch off the engine.l Loosen the lube oil filter cap 1 and unscrew in

an anticlockwise direction.l Carefully lift the paper filter cartridge 3 out of

guide 4.l Catch any dripping oil.l Change the paper filter cartridge 3.l Clean any dirt from the filter carrier rim and the

lube oil filter cover 1 and guide 4.l Replace rubber seal 2 and apply a small amount

of grease

l Carefully insert the new paper filter cartridge 3 inguide 4.

l Tighten lube oil filter cover 1 in the clockwise direction (25 Nm).

l Start the engine.l Check the oil level, see 6.1.2.l Check the oil pressure, see 3.3.1.l Check lube oil filter fitting for leaks.

300 74 0

!

2

3

4

1

Caution: hot oil!Risk of scalding!


6

l Close fuel stopcock.

l Undo fuel filter cartridge with commercial tooland spin off.

l Catch any fuel.

l Clean any dirt from the filter carrier rim.

l Apply light film of oil or diesel fuel to the rubbergasket of the new fuel filter cartridge.

l Screw in the new cartridge finger tight againstthe gasket.

l Check that the cartridge is seated correctlyagainst the gasket and tighten with a final half-turn.

l Open fuel stopcock.

l Check for leaks.

6.2.1 Changing Fuel Filter

Keep naked flames away whenworking on the fuel system. Do notsmoke!

The fuel system does not need to be bled.

25880 0 25881 0 25882 0

Service and Maintenance 6.2 Fuel System

!


66.2.2 Cleaning/Changing FuelPre-Filter Element 6.2.3 Venting the Fuel System with Preliminary Fuel Filter

6.2 Fuel System Service and Maintenance

l Press filter housing 5 with filter insert 3 andsealing ring 6 against the filter console 7 andscrew into place with clamping screw 1(tightening torque 25 Nm).Note: it must be possible to push the upper seal2 on filter insert 3 over the guide bracket on filterconsole 7.

l Tighten drain plug 4.l Open fuel stopcock.l Check for leaks after the engine has been started.

Changing:l Replace defective filter insert 3.

Bleeding:l Place the fuel pan beneath the preliminary fuel

filter.l Loosen drain plug 4 and observe the draining

fluid. When fuel instead of water starts to flow,retighten drain plug 4.

l Check for leaks after the engine has been started.

Venting:l During initial commissioning, after maintenance

work or if the tank is run empty it is essential tovent the fuel system.

l Set engine controller to stop positionl Place fuel collecting trough under the filter

housing (5) / pressure control valve (9).l Open fuel stopcock, pressure control valve (9),

vent screw (8)l Turn engine with starter (max. 20 sec.) until fuel

with no air bubbles escapes from vent screw (8)and pressure holding valve (9).

l Tighten vent screw 8 (tightening torque 15 Nm)and pressure control valve 9.

l Set engine controller to start position and startl When the engine has started check for leaks

Cleaning:l Close fuel stopcock.l Place the fuel pan beneath the preliminary fuel

filter.l Remove drain plug 4 and drain off fuel.l Unscrew clamping screw 1, remove filter housing

5 with filter insert 3.l Clean sealing surface of the filter bracket 7 and

filter insert housing 5 of any dirt.l Insert new sealing ring 6 and filter insert 3

(change as necessary). Push the filter insert up to approx. 3 cm overthe edge of the housing onto the guide in thefilter housing 5.

1

2

3

8

5 4

7

6

25 801 0

Avoid naked flames when workingon the fuel system. Do not smoke.Dispose of waste fuel in an en-vironmentally-friendly way

30 084 0

!


6 6.2.4 Changing Fuel Leakage Line

l Set engine controller to stop positionl Open fuel stopcockl Loosen pressure holding valve (9)

Catch any fuel which escapes and dispose of inan environmentally-friendly way

l Turn engine with starter (max. 20 sec.) until fuelwith no air bubbles escapes from pressureholding valve (9).

l Tighten up pressure holding valve (9).l Set engine controller to start position and startl When the engine has started check for leaks

30 034 0

Service and Maintenance 6.2 Fuel System

Avoid naked flames when workingon the fuel system. Do not smoke.Dispose of waste fuel in an environmentally-friendly way

l Close fuel stopcockl Dismantle valve cap coverl Remove rubber hoses (3) from the injection

valvesl Dismantle rubber hoses (1), (3) and (4) and

connection piece (2) and dispose of in anenvironmentally-friendly way

l Fit new rubber hoses (1), (3) and (4) andconnection piece (2)

l Connect rubber hoses (3) to injection valvesl Remount valve cap coverl Open fuel stopcockl When the engine has started check for leaks

6.2.5 Changing Fuel LeakagePipes

30 084 0

!


6

6.3 Cooling System Service and Maintenance

6.3.1 Cleaning Intervals 6.3.2 Cleaning Cooling System

l The amount of contamination in the coolingsystem depends on the engine application.

l Spilled oil or fuel on the engine increases therisk of contamination. Be especially careful ifthe engine is used in dusty environments.

l Serious contamination can occur, for example: on construction sites where there is a high

level of air-borne dust. in harvesting application where there are

high concentrations of chaff and choppedstraw in the vicinity of the machine.

l Because applications vary, cleaning intervalshave to be determined from case to case. Thecleaning intervals given in the table below canbe used as a guide.

Series 1012/1013l Place a cleaning bath under the heat exchanger

(it. 2).

l Remove the service flap on the heat exchanger(see insert).

Compressed Air Blow out heat exchanger with compressed

air (first from it. 3, then from it. 1).Be careful not to damage the cooling fins.

Wash out loosened dirt with a hose.

Checking / Cleaning IntervalsSuggested OH Application

2000 Ships, gensets in enclosedspaces, pumps

1000 Vehicles on paved roads

500 Tractors, forklift trucks, mobilegensets

250 Vehicles on construction sitesand unpaved roads, constructionequipment, compressors,under-ground mining equipment

125 Agricultural machinery, harvestertractors

Cold Cleansing Agent Spray the heat exchanger with a commercial

cold cleansing agent and let stand for about10 minutes.

First spray clean with a water jet fromposition 3 then from position 1 (do not spraysensitive engine components directly with awater jet, eg generator, cables, electroniccomponents, fan drive).

Cleaning with steam or with hot water Remove oil and grease residues with the jet

set at a gentle setting.

l Refit service flap.l Run the engine up to normal operating temp-

erature to evaporate any remaining water.

Series 1012E/1013El If an external cooling system is fitted, follow

the manufacturers instructions.

Unit enginel Clean as described under series 1012/1013.

The cleaning jet must be positioned parallel tothe cooling-air ducts.

Hose pressure: max. 100 bar

26252 0


6

Service and Maintenance 6.3 Cooling System

6.3.3 Draining Cooling System

1012 / 1013

l Place container under drain plug 3.l Unscrew cap 1.l Unscrew drain plug 3 fully.l Drain coolant.l Drain the remaining fluid from the engine oil

cooler (coolant duct).l Screw in the sealing plug 3 up to the first notch

and screw in the sealing plug on the oil cooler(arrow).Fill/vent the cooling system: see section 6.3.4

6.3.4 Filling / VentingCooling System1012 / 1013

l Unscrew cap 1l Loosen sealing plug 2l Unscrew vent plug 4.l Unscrew sealing plug 3 (10 mm) up to the first

notch.l Add coolant up to the max. marking or fill-up

limit (heater valve if fitted of the unit mustbe opened).

l Tighten sealing plug 2 (tightening torque 18 Nm)l Tighten vent plug 4 (tightening torque 40 Nm)l Tighten sealing plug 3.l Close cap 1.l Start engine and warm up until thermostat

opens.l Switch off engine.l Check coolant level (see section 3.3.3) and top

up as required.

26260 2

ca. 10 mm

ca. 5 mm1 4

2

3 30 082 0

3

2

1 4

If a heater is connected to thecooling system, all heater valvesmust be opened during filling.Depending on the water contentand the installation position of the

heater, it may be required to repeat the last pointseveral times to vent the heater system.

Be careful when draining hotcoolant danger of scalds! Collectdrained coolant and dispose ofaccording to environmentalregulat-ions.

!!


66.3.5 Draining the Cooling System1012 E / 1013 E

l Place a container under sealing plug 1.l Remove sealing plug 1 from the crankcase.l Drain off the coolant.l Tighten sealing plug 1 again.l If sealing plug 1 is not accessible, the system

can be drained at the engine oil cooler (coolantduct).

Filling/venting the cooling system:See section 6.3.6.

Be careful when draining hotcoolant danger of scalds! Collectdrained coolant and dispose ofaccording to environmentalregulat-ions.

26 341 0


6.3.6 Filling/Venting the CoolingSystem 1012 E/1013 EStandard engine

0

2

9

7

4

9

8

7

1

BFM 1012EBFM 1013E

1

l Open radiator cap position 1.l Loosen vent plug position 2.l Add coolant up to the maximum marking or

filler limit (heater valve of the system must beopened if fitted).

l Tighten vent plug position 2 + sealing plugposition 3.

l Close radiator cap position 1.l Start engine and warm up until thermostat

opens.l Switch off engine.l Check coolant level when the engine is cold and

top up as required.l Close the radiator sealing plug position 1.

Ventingl The cooling systems, which are built in line

with our installation guidelines, are ventedautomatically after they have been filled.

l With external cooling systems in accordancewith the specifications of the manufacturer.

!


6

0

2

9

7

4

9

8

5

1

BFM 1013E

1013 EShort engine

Service and Maintenance 6.3 Cooling System

l Loosen vent plug position 2 and sealing plugposition 3.

l Add coolant up to the maximum marking orfiller limit (heater valve of the system must beopened if fitted).

l Tighten vent plug position 2 + sealing plugposition 3.

l Close radiator cap position 1.l Start engine and warm up until thermostat

opens.l Switch off engine.l Check coolant level when the engine is cold and

top up as required.l Close the radiator sealing plug position 1.

Ventingl The cooling systems, which are built in line

with our installation guidelines, are ventedautomatically after they have been filled.

l With external cooling systems in accordancewith the specifications of the manufacturer.

l Start the engine and warm up until thethermostat opens.

6.3.7 Draining the Cooling SystemUnit Engine (4 Cylinders)

1

2

l Open the cap 1 of the expansion tank.l Place a container beneath knurled screw 2.l Unscrew the knurled screw 2 in an anti-

clockwise direction until coolant is emitted.l Drain off coolant.l In case of clogging, rinse the radiator through

with clear water.l Tighten knurled screw 2.

Filling/venting the cooling system:see section 6.3.8

30 299 0


6


!

6.3.8 Filling/Venting the CoolingSystemUnit Engine

Unit engine (6 cylinders)

1

2 30 277 0

1

2 30 277 0

l Open the cap 1 of the expansion tank.l Place a container beneath sealing plug 2.l Unscrew the sealing plug 2.l Drain off coolant.l In case of clogging, rinse the radiator through

with clear water.l Tighten sealing plug 2.

Filling/venting the cooling system:see section 6.3.8

Be careful when draining hot coolant- danger of scalds! Collect drainedcoolant and dispose of according toenvironmental regulations.

l Open the cap 1 of the expansion tank.l Slowly add coolant up to the max. marking or

filler limit.l Close the cap.l Start the engine and warm up until the thermostat

opens, the upper coolant line warms up tangibly.l Briefly run the engine at nominal output (fixed

setting), this rinses out any pockets.l Switch off the engine and leave to cool down.l Open cap 1, add coolant up to the max. marking

or filler limit and close the cap 1.l Once the engine has been run once, check the

coolant level when the engine is cold.If a heater is connected to the cooling system,the heater valves must be opened when cool-ant is added. Depending on the coolant cont-

ents and the installation location of the heater, it may benecessary to repeat the procedure several times.

6.3.9 Draining the Charge-Air Cooler

1 30 191 0

l Loosen the drain plug 1 on the end of thecharge-air cooler.

l Drain off any oil residues that may beremaining.

l Close the drain plug 1.


6

Service and Maintenance 6.4 Combustion Air Cleaner

6.4.1 Cleaning Intervals

l The amount of dirt in the air cleaner dependson the amount of dust in the air and the size ofthe air cleaner used. If a high level of dust isanticipated, a cyclone-type precleaner can befitted to the air cleaner.

l Cleaning intervals will have to be determinedfrom case to case.

l If a dry type air cleaner is used, clean whenindicated by the service indicator or switch.

l Air cleaner servicing is needed when: Service Indicator

the red signal 1 is fully visible when theengine is off.

Service Switchthe yellow pilot light comes on when theengine is running.

l After carrying out service work, reset the signalby pressing the button on the service indicator.

25885 1


6

6.4 Combustion Air Cleaner Service and Maintenance

Never clean air cleaner withgasoline. Dispose of old oil inaccordance with environmentalregulations.

6.4.2 Emptying Cyclone TypePrecleaner

l Turn engine off and wait about 10 minutes forthe oil to drain from filter housing 1.

l Release snap clips 2 and remove oil cup 3together with filter element 4. If necessary prizeelement out with a screwdriver, taking care notto damage the rubber gasket 5.

l Remove dirty oil and sludge. Clean oil cup.

l Clean filter element 4 in diesel fuel and allow todrip-dry.

l Undo wing nut 1 and remove cover 2.

l Remove collector bowl 3 from lower section 4and empty. Clean leaves, straw and otherforeign matter from lower section ofprecleaner.

l Reposition collector bowl 3 onto lower section4, fasten cover 2 in place by tightening wingnut 1.

l Clean filter housing 1 if very dirty.

l Inspect and replace rubber gaskets 5 and 6 ifnecessary.

l Fill oil cup with engine oil up to the mark(arrow) (for viscosity, see 4.1.2).

l Refit oil cup and element to filter housing andsecure with snap clips.

6.4.3 Cleaning Oil Bath Air Cleaner

Never fill collector bowl with oil. Replace collectorbowl if damaged.

25887 025886 0

!


6

Service and Maintenance 6.4 Combustion Air Cleaner

6.4.4 Dry Type Air Cleaner

Dust Discharge Valve Filter Cartridge

l Empty dust discharge valve 1 by pressing apartlips of discharge slot as indicated by arrows.

l Clean discharge slot from time to time.

l Remove any caked dirt by pressing togetherthe upper section of the valve.

l Undo clip fasteners 1.

l Take off hood 2 and remove cartridge 3.

l Clean cartridge (replace at least once a year).

l Clean cartridge 3: Blow out from inside out with dry com-

pressed air (max. 5 bar), or in difficult cases, tap out, taking care not to

damage the cartridge, or wash according to manufacturers instruc-

tions.

l Check paper filter (light showing through) andgaskets for damage. Replace if necessary.

l After five air cleaner services or after two yearsat the latest, replace safety cartridge 4 (neverclean).To do so: Undo hex. nut 5 and remove cartridge 4. Install new cartridge, insert and tighten hex.

nut.

l Install cartridge 3, replace hood 2 and do upclip fasteners.

Never clean filter cartridge withgasoline or hot fluids.

25888 1 25889 0

!


6

6.5 Belt Drives Service and Maintenance

6.5.1 Checking V-Belts

1012

l Inspect entire V-belt for damage.

l Replace damaged V-belts.

l After installing new belts, run engine for 15 mi-nutes, then check belt tension.

l Use a V-belt tension gauge (see 9.3) to checkbelt tension.

Place indicator arm 1 into gauge. Position gauge on V-belt 2, midway between

the pulleys, with flange 3 on bottom of gaugeagainst the edge of belt.

Push slowly on the black pad 4 at right anglesto belt 2 until the spring is heard or felt totrigger.

Check, tension and change beltsonly with the engine off. Refit beltguard, if provided.

1013

l Carefully remove the gauge without altering theposition of the indicator arm.

Read off the value: Turn the gauge sideways tosee the exact spot where the top of the blackindicator arm 1 intersects scale 5 (arrow). Forsettings, see 9.1.

If necessary, retension belt and measure again.

26 255 0 26 315 0 26 261 1

!


6

1

4

3

2

5

A

B

Service and Maintenance 6.5 Belt Drives


6.5.2 Tensioning Fan /Alternator Belts1012

6.5.3 Changing Fan /Alternator Belts1012

l Slacken off bolts 1, 2 and 3.

l Press alternator 5 in direction of arrow A untilcorrect belt tension is achieved.

l Re-tighten bolts 1, 2 and 3.


l Press alternator in direction of arrow B.

l Remove and replace belt.

l Tension belt in accordance with 6.5.3.

l Re-tighten bolts 1, 2 and 3.

6.5.4 Tensioning Coolant /Fuel Pump Belts1012

l Slacken off bolts 1 and 2.

l Push fuel pump 3 in direction of arrow (A) untilcorrect belt tension is achieved.

l Re-tighten bolts 1 and 2.

26 449 0 26 450 0

1

4

3

2

5

A

B26 449 0

1

A

B

3

2

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6



6.5.5 Changing Coolant /Fuel Pump Belts1012

6.5.6 Tensioning Coolant /Fuel Pump Belts1012 E

6.5.7 Changing Coolant /Fuel Pump Belts1012 E

l Remove fan belt as described in 6.5.3.


l Push fuel pump 3 in direction of arrow (B).


l Push fuel pump in direction of arrow (A) untilcorrect belt tension is achieved.

l Tighten bolts 1 and 2.

l Reinstall fan belt and tension as described in6.5.2.


l Push fuel pump 3 in direction of arrow untilcorrect belt tension is achieved.



l Push fuel pump 3 in direction of arrow.


l Push fuel pump in opposite direction of arrowuntil correct belt tension is achieved.


26 267 026 254 0

1

A

B

3

2

26 450 0

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6



6.5.8 Tensioning Alternator Belt1012 E


l Move alternator 5 in direction of arrow byturning bolt 3 until correct belt tension isachieved.

l Tighten bolts 1, 2 and 4.

6.5.9 Changing Alternator Belt1012 E

l Remove fuel pump belt as described in 6.5.7.


l Adjust bolt 3 until the V-belt can be removed.

l Fit new belt.

l Adjust bolt 3 until the correct belt tension isachieved.

l Tighten bolts 1, 2 and 4.

l Reinstall fuel pump belt and tension asdescribed in 6.5.6.

26 250 0 26 251 0

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6



6.5.12 Changing Coolant /Fuel Pump Belts1013

6.5.10 Tensioning /Changing Fan Belt1013

6.5.11 Tensioning Coolant /Fuel Pump belts1013

l Slacken off bolts 1 and 2. Tensioning:

Insert square wrench in square and pull indirection of arrow until correct belt tension isachieved.

Changing:Insert square wrench in square and loosen inopposite direction of arrow. Tension new beltas described above.



l Push fuel pump 3 in direction (A) of arrow untilcorrect belt tension is achieved.


l Remove fan / alternator belt as described in6.5.10 and 6.5.13.


l Push fuel pump 3 in direction (B) of arrow.


l Push fuel pump in direction (A) of arrow untilcorrect belt tension is achieved.


l Reinstall fan / alternator belt and retension asdescribed in 6.5.10 and 6.5.13.

26 450 026 345 0 26 450 0

1

A

B

3

2

1

A

B

3

2

!


6

1

4

3

2

5

A

B



6.5.13 Tensioning /ChangingAlternator Belt1013

6.5.14 Tensioning Coolant /FuelPump Belts1013 E

6.5.15 Changing Coolant /Fuel Pump Belts1013 E


l Push fuel pump 3 in direction of arrow untilcorrect belt tension is achieved.



l Push fuel pump 3 in direction of arrow.


l Push fuel pump 3 in opposite direction ofarrow until correct belt tension is achieved.


Tensioning:l Slacken off bolts 1, 2 and 3.l Move alternator 5 in direction of arrow (A) until

correct belt tension is achieved.l Re-tighten bolts 1, 2 and 3.

Changing:l Slacken off bolts 1, 2 and 3.l Move alternator 5 in direction of arrow (B) until

belt is exposed.l Remove and replace belt, tension (see above).l Re-tighten bolts 1, 2 and 3.

26 383 026 380 026 449 0

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6


Check, tension and change beltsonly with the engine off. Refitguard, if provided.

l To retension belt, remove one or more shims3 as may be required from inside. Placeremoved shim(s) outside on removed half-pulley 2.

l Turn engine over while tightening bolts 1 toprevent belt being pinched.

l Remove hex. bolts 1.

l Take off outer half-pulley 2.

l Replace belt if necessary.

6.5.16 Tensioning /Changing Compressor Belt

24598 1 24599 1

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6

Service and Maintenance 6.6 Adjustments

l Slacken off breather valve and swing to oneside.

l Remove rocker cover.

l Position crankshaft as per schematic 6.6.1.1

l Before adjusting valve clearance, allow engineto cool down for at least 30 minutes. The oiltemperature should be below 80 C / 176 F.

l Check valve clearance between rocker arm /tappet contact face 2 and valve stem 3 withfeeler gauge 6 (there should be only slightresistance when feeler blade is inserted).For permissible valve clearance, see 9.1.

l Adjust valve clearance if necessary: Release locknut 4. Use screwdriver 7 to turn setscrew 5 so that

the correct clearance is attained after locknut4 has been tightened.

l Check and adjust valve clearance on allremaining cylinders.

l Replace rocker cover (use new gasket ifneeded).

l Swing breather valve back into position andsecure.

6.6.1 Checking /Adjusting Valve Clearances

19691 2 26262 1


6

6.6 Adjustments Service and Maintenance

6.6.1.1 Valve Clearance Adjustment Schematic

l Crankshaft Position 1:Turn crankshaft until both valves in cylinder 1overlap (exhaust valve about to close, inletvalve about to open). Adjust clearance of valvesmarked in black on schematic. Mark respec-tive rocker arm with chalk to show that adjust-ment has been done.

26 263 2

l Crankshaft Position 2:Turn crankshaft one full revolution (360).Adjust clearance of valves marked in black onschematic.


6

Service and Maintenance 6.7 Accessories

6.7.1 Battery6.7.1.1 Checking Battery and Cable

Connectors6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Specific Gravity of

Electrolyte

l Keep battery clean and dry.

l Undo dirty clamps.

l Clean terminal posts (+ and ) and clamps ofthe battery, and grease with acid-free and acid-resistant grease.

l When reassembling, ensure that clamps makegood contact. Do up clamp bolts finger tight.

l Remove caps 1.

l If testers 2 are used, the electrolyte shouldcome up to their base.

l If testers are not used, the electrolyte levelshould be 10-15 mm above the top of theplates.

l If necessary, top up with distilled water.

l Replace caps.

l Measure the specific gravity of individual cellswith a commercial hydrometer.

The hydrometer reading (see table on followingpage) indicates the state of charge. Duringmeasurement, the temperature of the electro-lyte should preferably be 20C / 68F.

25895 0 24232 3 25896 0


6

6.7 Accessories Service and Maintenance

The gases emitted by the batteryare explosive. Keep sparks andnaked flames away from thebattery.Do not allow battery acid to come

into contact with skin or clothing.Wear protective goggles.Do not rest tools on the battery.

Specific Gravity

in [kg/l] in B [Baum]* State of Charge

Normal Tropics Normal Tropics

1.28 1.23 32 27 Fully charged

1.20 1.12 24 16 Half charged, recharge

1.12 1.08 16 11 Discharged, recharge immediately

* Measurement of specific gravity in B is out ofdate and rarely used today.

!


6

Service and Maintenance 6.7 Accessories

Use only the correct lifting tackle.

6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

Notes on the three-phase system:

l Never disconnect the cables between battery,alternator and regulator while the engine isrunning.

l If, however, it is necessary to start and operatethe engine without the battery, disconnect theregulator from the alternator before starting.

l Be sure not to confuse the battery terminals.

l Replace defective bulb of the charge pilot lampimmediately.

l Cleaning the engine: Do not spray water/steamdirectly onto the alternator. Run the engine upto normal operating temperature to evaporateany remaining water.

l The habit of touching a lead against the frameto check whether it is live must under nocircumstances be used with three-phaseelectrical systems.

l In the case of electric welding, connect theground terminal on the welder directly to thepiece being welded.

l Always use proper lifting tackle whentransporting the engine.

26264 0 26265 0

!


7.1 Diagnosis Chart Troubleshooting

7

7.1 Diagnosis Chart


Troubleshooting 7.1 Diagnosis Chart

7

l If engine problems occur, they frequently havetheir cause in improper operation or enginemaintenance.

l If problems do occur, always check first thatthe operating and maintenance instructionshave been followed.

l A diagnosis chart is given on the facing page.

l If you cannot identify the cause of the problemor are unable to rectify it yourself, pleasecontact DEUTZ Service.

Before starting, make sure thatnobody is standing in the imme-diate vicinity of the engine ordriven machine.Important: When carrying outrepair work, never start the engine

with speed governor removed.Disconnect battery.

!


7.1 Diagnosis Chart Troubleshooting

7

Not declutched (where possible) OperationBelow starting limit temperatureEngine shutdown lever in stop position (faulty solenoid)Oil level too lowOil level too highExcessive inclination of engineSpeed control lever set to middle positionDirty air cleaner/Faulty turbocharger Combustion airAir cleaner service switch/indicator defectiveLDA* defective (leaking line)Charge air line leakingCoolant pump defective Cooling systemCharge air cooler contaminatedCoolant heat exchanger dirtyCooling fan defective, split or loose V-belt (belt-driven fuel pump)Cooling air temperature rise/ hot air recirculationBattery defective or discharged Electrics

PPPAS

P / EP / EP / W

PP

P / WP / RP / RP / RP / WPP

Sectionl

l l

l l

l l

l l l l

l l l

l

l l l

l l l

l l

l l l

l

l l

l

l l l l l

l l

l

Cause

Fault Remedy

*LDA = Aneroid device Table 1 of 2

Engine fails or is difficult to start Check PEngine starts but runs unevenly or stalls Adjust E

Engine overheats. Temperature monitor gives warning Replace WEngine gives poor performance Clean R

Engine not firing on all cylinders Top up AEngine has little or no oil pressure Lower level S

Engine oil consumption excessiveEngine smokes - blue

- white- black


Troubleshooting 7.1 Diagnosis Chart

7

l

l

l l l l l

l l l l

l

l l

l l l l l l l

l l l l

l l l l

l

l l l

l l l l

l

Fault RemedyEngine fails or is difficult to start Check P

Engine starts but runs unevenly or stalls Adjust EEngine overheats. Temperature monitor gives warning Replace W

Engine gives poor performance Clean REngine not firing on all cylinders Top up A

Engine has little or no oil pressure Lower level SEngine oil consumption excessive

Engine smokes - blue- white- black

Section CauseElectrics cable connections to starter, electrical system loose or oxidized Electrics PStarter defective or pinion does not engage PIncorrect valve clearance Engine ELeaking injection line PVent pipe blocked (coolant heat exchanger) P / RGlow plugs defective PInjector defective P / WAir in fuel system P / WFuel filter/prefilter dirty P/ R /WOil filter defective WIncorrect lube oil SAE class or quality Operating media WFuel quality not as per Operation Manual P/ WCoolant level too low P/ A

Table 2 of 2


8.1 Preservation Engine Preservation

8

8.1 Preservation


Engine Preservation 8.1 Preservation

8 8.1 Preservation

If the engine is to remain idle for an extendedperiod of time, it is necessary to take protectivemeasures to prevent rust formation. The pre-servative measures described here will protect theengine for up to 6 months. The procedure willhave to be reversed before the engine is re-commissioned.

l Anti-corrosion oils to specification: MIL-L-21260B TL 9150-037/2 NATO code C 640/642

l Recommended cleansing agent to removepreservatives when recommissioning engine: Petroleum benzine (hazardous materials

class A3)

Preserving Engine:

l Clean engine (with cold cleansing agent ifpreferred). See 6.3.2.

l Run engine until warm, then turn off.

l Drain engine oil (see 6.1.2) and fill with anti-corrosion oil.

l Drain coolant (see 6.3.3/6.3.5).

l Fill with anti-corrosion agent (see 4.3.3).

l If necessary, clean oil bath air cleaner (see 6.4.3)and fill with anti-corrosion oil.

l Drain fuel tank.l Make up a mixture of 90% diesel fuel and 10%

anti-corrosion oil, and refill fuel tank.

l Run engine for about 10 minutes.

l Turn engine off.

l Turn engine over manually several times. Ifusing starter, set shutdown lever to stop position.

l Remove V-belts 1 and store in wrapped condition.

l Spray grooves of V-belt pulleys 2 with anti-corrosion agent.

l Close off intake ports 3 and exhaust ports 4.

l Lightly grease and replace coolant filler 5.

l Drain anti-corrosion agent (see 6.3.3 / 6.3.5).

Removing Engine Preservatives:

l Remove anti-corrosion agent from grooves inV-belt pulleys 2.

l Install V-belts 1. Retension after brief operationis necessary (see 6.5).

l Remove covers from intake port 3 and exhaustport 4.

l Fill with coolant (see 6.3.4 / 6.3.5).

l Start engine.

26 268 1


9

Technical Specifications

9.1 Engine Specifications and Settings9.2 Torque Wrench Settings9.3 Tools

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Technical Specifications 9.1 Engine Specifications and Settings

Model BF4M 1012 BF4M 1012 C BF6M 1012 BF6M 1012 C BF4M 1012 E BF4M 1012 EC BF6M 1012 E BF6M 1012 EC

Number of cylinders 4 4 6 6 Cylinder arrangement vertical, in line Bore [mm] 94 Stroke [mm] 115 Total displacement [cm3] 3192 3192 4788 4788 Compression ratio [ e ]. 17.5 Working cycle/Combustion system 4-stroke diesel with turbocharging and direct injection

Charge air cooler w/o w/ w/o w/ Direction of rotation counter-clockwise

Weight 1012 / C incl. cooling system [kg approx.] contact company headquarters Weight 1012 E / EC w/o cooling systemas per DIN 70020-A [kg approx.] 330 332 435 437

Engine power [kW] 1). Speed [rpm] 1). Valve clearance with cold engine [mm] Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1.

Injector opening pressure [bar] 250/275 Start of delivery [crank angle bTDC] 1). Firing order of engine 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4

V-belt tension: Pre-tension / re-tension 2).

Generator fan [N] 450 / 300 50. Fuel pump - coolant pump [N] 450 / 300 50. Compressor [N] 550 / 450 50.

1) Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.12) Retension 15 minutes after the engine has been driven under load

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9

9.1 Engine Specifications and Settings Technical Specifications

Model BFM1012 / E BF4M 1012 BF4M 1012 C BF6M 1012 BF6M 1012 C BF4M 1012 E BF4M 1012 EC BF6M 1012 E BF6M 1012 EC

Cooling system Liquid-cooled/Cooling system protection Coolant quantity1012/C [litres approx.] 9.3 10.0 12.2 13.6 1012 E/EC 5) [litres approx.] 5.6 5.6 7.3 7.3 1012 unit engine (with frontal radiator) [litres approx.] 15.9 18.1 Permissible continuous coolant temperatureEngine outlet, with performance group I [C] max.110 6) . Engine outlet, with performance group II-IV [C] max.105 6) .

Thermostat initial opening at [C] 83 7) . Thermostat full open temperature [C] 95 8) . Coolant prewarming (4 . Coolant pumpDelivery pressure in [bar] 9) . Delivery rate in [m3 /h] 9) . Power consumption in [kW] 9) .

Lubrication forced-feed lubrication

Oil temperature in oil pan [C] 125 Min. oil pressure with engine warm(120C and SAE oil 15 W 40) and low idle speed [bar] 0.8 Oil capacity (first fill-up) without filter [litres approx.] 8.5 3) . 8.5 3) . 12.5 3) . 12.5 3) .

Oil capacity (first fill-up) with filter [litres approx.] 10.0 3) . 10.0 3). 14.0 3). 14.0 3).

3) Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum.4) Only during winter (see 3.5.1)5) Only engine capacity without radiator. Capacity of external cooling system dependent on cooling system design.6) Other performance groups have different values. Please contact company headquarters.7) With external cooling systems with outlet control, the temperature at which the thermostat opens is 87C8) With external cooling systems with outlet control, the temperature at which the thermostat is fully opened is 102C.9) Please contact company headquarters (varies depending on engine design)

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Model BF4M 1013 BF4M 1013 C BF6M 1013 BF6M 1013 C BF6M 1013 CP BF4M 1013 E BF4M 1013 EC BF6M 1013 E BF6M 1013 EC BF6M 1013 ECP

Number of cylinders 4 4 6 6 6 Cylinder arrangement vertical, in line Bore [mm] 108 Stroke [mm] 130 Total displacement [cm3] 4764 4764 7146 7146 7146 Compression ratio [ e ]. 17.5 Working cycle/Combustion system 4-stroke diesel with turbocharging and direct injection

Charge air cooler w/o w/ w/o w/ w/ Direction of rotation counter-clockwise

Weight 1013 / CP incl. cooling system [kg approx.] contact company headquarters Weight 1013 E / EC / ECP w/o cooling systemas per DIN 70020-A [kg approx.] 455 455 600 600 600

Engine power [kW] 1). Speed [rpm] 1). Valve clearance with cold engine [mm] Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. Injector opening pressure [bar] 250/275 Start of delivery [crank angle bTDC] 1). Firing order of engine 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

V-belt tension: Pre-tension / re-tension 2).

Generator fan [N] 450 / 300 50. Fuel pump - coolant pump [N] 450 / 300 50. Compressor [N] 550 / 375 50.

1) Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.12) Retension 15 minutes after the engine has been driven under load

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9

9.1 Engine Specifications and Settings Technical Specifications

Model 1013 /E BF4M 1013 BF4M 1013 C BF6M 1013 BF6M 1013 C BF6M 1013 CP BF4M 1013 E BF4M 1013 EC BF6M 1013 E BF6M 1013 EC BF6M 1013 ECP

Cooling system Liquid-cooled/Cooling system protection Coolant quantity1013 / C / CP [litres approx.] 12.1 13.6 15 16.3 16.9 1013 E / EC / ECP 5) [litres approx.] 7.2 7.2 9.8 9.8 9.8 1013 unit engine (with frontal radiator) [litres approx.] 17.5 19.7 22 23.7 23.7 Permissible continuous coolant temperatureEngine outlet, with performance group I [C] max.110 6) . Engine outlet, with performance group II-IV [C] max.105 6) .

Thermostat initial opening at [C] 83 7) . Thermostat full open temperature [C] 95 8) . Coolant prewarming (4 . Coolant pumpDelivery pressure in [bar] 9) . Delivery rate in [m3 /h] 9) . Power consumption in [kW] 9) .

Lubrication forced-feed lubrication

Oil temperature in oil pan [C] max. 125 Min. oil pressure with engine warm(120C and SAE oil 15 W 40) and low idle speed [bar] 0.8 Oil capacity (first fill-up) without filter [litres approx.] 13 3) . 13 3) . 20 3) . 20 3) . 20 3) .

Oil capacity (first fill-up) with filter [litres approx.] 14.0 3) . 14.0 3) . 21.0 3) . 21.0 3). 21.0 3).

3) Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum.4) Only during winter (see 3.5.1)5) Only engine capacity without radiator. Capacity of external cooling system dependent on cooling system design.6) Other performance groups have different values. Please contact company headquarters.7) With external cooling systems with outlet control, the temperature at which the thermostat opens is 87C8) With external cooling systems with outlet control, the temperature at which the thermostat is fully opened is 102C.9) Please contact company headquarters (varies depending on engine design)

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9


Model BF4M 1013 FC BF6M 1013 FC

Number of cylinders 4 6 Cylinder arrangement vertical, in line Bore [mm] 108 Stroke [mm] 130 Total displacement [cm3] 4764 7146 Compression ratio [ e ]. 17.6 Working cycle/Combustion system 4-stroke diesel with turbocharging and direct injection

Charge air cooler with Direction of rotation counter-clockwise

Weight 1013 FC without cooling system contact company headquarters as per DIN 70020-A [kg approx.] 455 600

Engine power [kW] 1). Speed [rpm] 1). Valve clearance with cold engine [mm] Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. Injector opening pressure [bar] 275 Start of delivery [crank angle bTDC] 1). Firing order of engine 1-3-4-2 1-3-4-2 1-5-