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Operation M

1012

1013

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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.

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.

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.

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

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.

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

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0297 9682

Operation M

1012

1013

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 to

improve our engines are reserved with regard tospecification data and other technical informationcontained in this Operation Manual No part of this

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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 this

Operation 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 additional

Foreword

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Table

1. General

2. Engine Description2.1 Model

2.1.1 Rating Plate

2.1.2 Rating Plate Location2.1.3 Engine Serial Number

2.1.4 Cylinder Numbering

2.2 Engine Illustrations

2.2.1 Service Side 1012

2.2.2 Starter Side 1012

2.2.3 Service Side 1012 E

2.2.4 Starter Side 1012 E



2.2.7 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 EC

2.3 Lube Oil Circuit

2.3.1 Lube Oil Circuit Schematic 1012/1012 E

2.3.2 Lube Oil Circuit Schematic 1013/1013 E

2.4 Fuel System

2.4.1 Fuel System Schematic

2.5 Cooling System

2.5.1 Cooling System Schematic 1012

2.5.2 Cooling System Schematic 1012 E

2.5.3 Cooling System Schematic 10132.5.4 Cooling System Schematic 1013 E

3. Engine Operation3.1 Commissioning

3.1.1 Adding Engine Oil

3.1.2 Filling Oil Bath Air Cleaner3.1.3 Adding Fuel3.1.4 Filling/Venting the Cooling System3.1.5 Other Preparations

3.1.6 Other Preparations

3.2 Starting3.2.1 Electric Starting

3.3 Monitoring Systems

3.3.1 Engine Oil Pressure

3.3.2 Coolant Temperature

3.3.3 Coolant Level/Level Gauge

3.4 Stopping

3.4.1 Engines with Mechanical Shutdown

3.4.2 Engines with Electrical Shutdown

3.5 Operating Conditions

3.5.1 Winter Operation

3.5.2 High Ambient Temperature, High Altitude

4. Operating M4.1 Lube Oil

4.1.1 Quality Grade

4.1.2 Viscosity

4.2 Fuel

4.2.1 Quality Grade4.2.2 Winter Grade4.3 Coolant

4.3.1 Water Quality

4.3.2 Coolant Prep

4.3.3 Antifreeze/Ch

5. Routine Ma5.1 Maintenance S

5.2 Maintenance C

5.3 Maintenance R

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Table of contents

6. Service and Maintenance6.1 Lubrication System

6.1.1 Oil Change Intervals6.1.2 Changing Engine Oil, Checking Oil Level

6.1.3 Changing Oil Filter

6.1.4 Cleaning/Changing Oil Filter (Cup)6.2 Fuel System

6.2.1 Changing Fuel Filter

6.2.2 Cleaning / Changing Fuel Pre-Filter

Element6.2.3 Venting the Fuel System

with Preliminary Fuel Filter

6.2.4 Venting the Fuel Systemw/o Preliminary Fuel Filter

6.2.5 Changing Fuel Leakage Pipes

6.3 Cooling System

6.3.1 Cleaning Intervals6.3.2 Cleaning Cooling System

6.3.3 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 Cooler

6.5 Belt Drives

6.5.1 Checking V-Belts

6.5.2 Tensioning Fan / Alternator Belts 1012

6.5.3 Changing Fan / Alternator Belts 1012

6.5.4 Tensioning Coolant / Fuel Pump Belts1012

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

6.5.8 Tensioning Alternator Belt 1012 E

6.5.9 Changing Alternator Belt 1012 E

6.5.10 Tensioning / Changing Compressor /Alternator Belts 1013

6.5.11 Tensioning Coolant / Fuel Pump Belts1013

6.5.12 Changing Coolant / Fuel Pump Belts1013

6.5.13 Tensioning / Changing Alternator Belt1013

6.5.14 Tensioning Coolant / Fuel Pump Belts1013 E

6.5.15 Changing Coolant / Fuel Pump Belts1013 E

6.5.16 Tensioning / Changing Compressor Belt

6.6 Adjustments

6.6.1 Checking / Adjusting Valve Clearances6.6.1.1 Valve Clearance Adjustment Schematic

6.7.1.3 Checking Specific

6.7.2 Three-Phase Alter

6.7.3 Lifting Tackle

7. Troubleshootin

7.1 Diagnosis Chart

8. Engine Preserv8.1 Preservation

9. Technical Spec9.1 Engine Specification9.2 Torque Wrench Set

9.3 Tools

10. Service

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DEUTZ Diesel Engines

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

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.

Service

Please contact one orepresentatives in the

spare parts inquiries. carry out repairs quickonly genuine spare paOriginal parts from DEUin accordance with staPlease turn to the endservice information.

!

Care and Maintenance

Sound care and maintenance practices will ensurethat the engine continues to meet the requirements

placed on it. Recommended service intervals mustbe observed and service and maintenance workcarried out conscientiously.Special care should be taken under abnormallydemanding operating conditions.

Asbestos

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.

CalPropositio

Diesel engine exhaustuents are known to cause cancer, birth dductive harm.

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1

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2.1 Model

2.2 Engine Illustrations2.3 Lube Oil Circuit

2.4 Fuel System

2.5 Cooling System

Engine

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2

Engine Description

26 332 0 26231 1

2.1.1 Rating Plate 2.1.2 Rating Plate Location

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.

2.1.3 Engine Serial

The engine serial number crankcase itself (arrow).

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2.1 Model Engine

26233 0

2.1.4 Cylinder Numbering

Cylinders are numbered consecutively, beginningat the flywheel end.

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2

Engine Description 2.2 Engine


1 Oil filler (option: betwe

2 Coolant filler

3 Cooling fan

4 Coolant pump

5 Belt pulley

6 Fuel pump

7 Engine mount

8 Fuel filter

9 Lube oil filter

10 Oil pan

11 Dipstick

12 Lube oil cooler

13 Mounting facility for hy14 Alternator

15 Back leak fuel pipe wvalve

16 Cylinder head

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2.2 Engine Illustrations Engine


17 Lifting points

18 Exhaust turbocha

19 Speed governor

20 SAE housing

21 Flywheel

22 Starter motor

23 Hydraulic oil coole

24 Coolant heat exch

25 Coolant level gaug

26 Bleeder valve

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2




2 Coolant inlet

3 Coolant pump 4 Alternator

5 Belt pulley

6 Engine mount

7 Fuel pump

8 Fuel filter

9 Lube oil filter

10 Oil pan

11 Dipstick

12 Lube oil cooler

13 Mounting facility for h14 Back leak fuel pipe w

valve

15 Cylinder head

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16 Lifting points

17 Exhaust turbocha

18 Speed governor19 SAE housing

20 Flywheel

21 Starter motor

22 Coolant outlet to h

23 Exhaust manifold

24 Air intake manifol


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2



2 Alternator

3 Coolant pump 4 Fan

5 Belt Pulley

6 Vibration damper

7 Fuel pump

8 Engine mount

9 Fuel filter

10 Lube oil filter

11 Oil pan

12 Dipstick

13 Lube oil cooler14 Hydraulic pumps (or c

15 Fuel pipe

16 Solenoid

17 Lube oil line to turboc

18 Cylinder head


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19 Lifting points

20 Exhaust turbocha


23 Flywheel

24 Starter motor

25 Coolant level gaug

26 Bleeder valve

27 Coolant filler cap

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2


1 Oil f il ler

2 Coolant pump

3 Fuel pump 4 Vibration damper

5 Fuel filter

6 Engine mount

7 Lube oil filter

8 Oil pan

9 Dipstick

10 Lube oil cooler

11 Mounting facility for h

12 Back leak fuel pipe w

valve13 Cylinder head

A Coolant inlet


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14 Lifting points

15 Crankcase breathe


18 Flywheel

19 Starter motor

20 Exhaust turbochar

21 Fan

22 Exhaust manifold

23 Air intake manifold


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2


1 Coolant filler neck with2 Expansion tank

3 Vent line from cylinder4 Coolant line from engifluid radiator

5 Expansion line from ex6 Charge air line from ex

charge-air cooler7 Dry air filter8 Induction air line betw

exhaust turbocharger9 Exhaust turbocharger

10 Coolant line from cranradiator

11 Charge-air cooler12 Engine fluid radiator13 Coolant line from engin

thermostat

2.2.9 Starter Side


8

9

1012

1 2 3 4 5 6 7

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3 Ventilation line frotank

13 Charge-air line from14 Protective guard

2.2.10Service Side


13

3

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2


2.2.11Starter Side


1 Filler neck with cap2 Expansion tank

3 Vent line from cylinder4 Expansion line from expump

5 Coolant line from cranradiator

6 Charge-air line from cha7 Charge-air line from ex

charge-air cooler8 Coolant line from engin

thermostat

1 32 4 5 6 7

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2.2.12Service Side


9 Engine fluid radia10 Charge-air cooler

11 Protective guard

9

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2

Engine Description 2.3 Lub

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 bearing

10 Line to spray nozzle

11 Spray nozzle for piston12 Tappet w/ control borof rocker arms

13 Pushrod (designed frocker arms)

14 Rocker arm

15 Return line to oil pan

16 Oil sensor

17 Oil line to exhaust turb

18 Exhaust turbocharger

19 Oil line to compressor

20 Compressor21 Hydraulic pump

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2.3 Lube Oil Circuit Engine

2.3.2 Lube Oil Circuit Schematic1013 / 1013 E

1 Oil pan

2 Air intake manifol

3 Lube oil pump 3a Back leak fuel valv

3b Pressure-relief va

4 Lube oil cooler

5 Lube oil filter

6 Main oil gallery

7 Crankshaft bearin

8 Conrod bearing

9 Camshaft bearing

10 Spray nozzle line

11 Spray nozzle for p

12 Tappet w/ controof rocker arms

13 Pushrod (designerocker arms)

14 Rocker arm

15 Return line to oil p

16 Oil sensor

17 Oil line to exhaust

18 Exhaust turbocha

19 Oil line to compre

20 Compressor21 Hydraulic pump

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2

Engine Description 2.4

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 pump

7 Injection pump

8 Line to injector

9 Injector

10 Back leak fuel pipe

11 Banjo bolt with pressu

12 Return line to fuel tank

13 Keep this spacing as w

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2.5 Cooling System Engine

1 Coolant f iller2 Thermostat housi

3 Coolant pump4 Lube oil cooler5 Cylinder cool ing6 Cylinder head coo7 Heat exchanger8 Return from therm

housing9 Ventilation line fro

exchanger (expan

2.5.1 Cooling System Schematic1012

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2

Engine Description 2.5 Coo

2.5.2 Cooling System Schematic1012 Eentrance regulation

1 Thermostat housing2 Coolant pump

3 Lube oil cooler4 Cylinder cool ing5 Cylinder head cooling6 Heat exchanger7 Ventilation line expans

pump8 Line from engine to he9 Ventilation line from cy

expansion tank10 Expansion tank11 Line from heat exchan

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1012 Eescape regulation

1 Thermostat housi2 Cooling fluid pum

3 Lubricating oil co4 Cylinder cooling5 Cylinder head coo6 Heat exchanger7 Compensation set

o cooling fluid pum8 Line (Crankcase)

exchanger9 Ventilation line fro

compensation tan10 Compensation tan11 Line from heat exc

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2


2.5.3 Cooling System Schematic1013

1 Coolant f il ler

2 Thermostat housing

3 Coolant pump4 Lube oi l cooler

5 Cylinder cooling6 Cylinder head cooling7 Heat exchanger8 Expansion line coolant

tank9 Ventilation line from cy

heat exchanger (expan

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2.5.4 Cooling System Schematic1013 Eentrance regulation

1 Thermostat housi2 Coolant pump

3 Lube oil cooler4 Cylinder cool ing5 Cylinder head coo6 Heat exchanger7 Ventilation line ex

pump8 Line from engine 9 Ventilation line fro

expansion tank10 Expansion tank11 Line from heat ex


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2


1013 Eescape regulation

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

o cooling fluid pump8 Line (Crankcase) from

exchanger9 Ventilation line from c

compensation tank10 Compensation tank11 Line from heat exchang

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Engine

3.1 Commissioning

3.2 Starting3.3 Monitoring Systems

3.4 Stopping

3.5 Operating Conditions

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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-gradgrade, see 4.2.If required use a preliminarIf in doubt, please ask yourUse summer or winter-grathe ambient temperature.

26243 0 24980 2

Engine Operation 3.1 Co

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3.1 Commissioning Engin

3.1.4 Filling/Venting the CoolingSystem

3.1.5 Other Preparations

Check battery and cable connections, see 6.7.1.

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.

Breaking-in

During 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.

Commissioning conserved enginesRemove conservation materials as outlined insection 8.1

1012/1013See section 6.3.4

1012 E/1013 ESee section 6.3.6

Unit engine (with frontal radiator)See section 6.3.8.

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3

Engine Operation

!

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.

Disengage the clutch to separate the enginefrom the driven equipment.

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

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

Starting without Cold

Insert key. Position 0 = no operat

Turn key clockwise. Position 1 = operating Pilot lights 1 and 2 com

Push the key in and tuagainst spring pressure.

Position 2 = no functioPosition 3 start

26245 0

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3.2 Starting Engin

Starting with Heater Plugs

Insert key. Position 0 = no operating voltage.

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

pilot lights go out.

Push key in and turn further clockwise against

spring pressure.Position 2 no f nction

25746 1

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3

Engine Operation 3.3 Monitor

3.3.1 Engine Oil Pressure

Oil Pressure Pilot Light

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

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

Oil Pressure Indicator

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

Oil Pressure Gauge

The pointer must indicpressure (see 9.1).

25752 1 25753 0

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3.3 Monitoring Systems Engin

3.3.2 Coolant Temperature

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

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

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

26246 0 26247 0

If a level switch isdown automaticallythe MIN marking.

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3

Engine Operation 3

3.4.1 Engines with MechanicalShutdown

Move speed control lever 1 to low idle.

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.

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

3.4.2 Engines with ElectricalShutdown

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

26266 0 25746 2

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3.5 Operating Conditions Engin

3.5.1 Winter Operation

Lube Oil Viscosity Select the oil viscosity (SAE grade)

according to the ambient temperature when

the engine is started (see 4.1.2). Increase oil change frequency when operat-

ing below 10C, see 6.1.1.

Diesel Fuel Use winter-grade diesel fuel for operation

below 0C, see 4.2.2.

Coolant Set the water/antifreeze mix to suit the lowest

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

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.

Cold-Start Aids

At temperatures near or below freezing point,use glow plugs if necessary (see 3 2 1)

Battery Efficient cold starting requires a healthy

battery (see 6.7.1).

The starting limit temperature can belowered 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 Altitude

As the altitude and ambient temperature rise,the density of the air tends to decrease, whichaffects the maximum power output of the

engine, 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.

If you have any doubts about engine operationunder these or similar conditions, ask your

engine or equipment supplier whether theengine has been derated in the interests ofreliability, service life and exhaust gas quality(smoke). Otherwise, contact the nearestservice representative.

C F

0 32

25901 1

Engine Operation 3.5 Operatin

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Opera

4.1 Lube Oil

4.2 Fuel4.3 Coolant

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4

Operating Media

4.1.1 Quality Grade

Lube oils are differentiated according to theirperformance and quality class. In common useare specifications named after the API (American

Petroleum 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 prevailing

at 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.

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4.2 Fuel Opera

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 be

reduced (see 6.1.1).

The following fuel specifications/standards areapproved:

EN 590

BS 2869: A1 and A2

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

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

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.

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

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 can

be added (see diagram).

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

4.2.2 Winter-Grade Fuel

0 10 2

0

- 5

- 10

- 15

- 20

- 25

- 30

+32

+23

+14

+ 5

- 4

- 13

- 22

A

F C

II

Legend:

I Summer

II Winter d

A Outside te

B Percentage of ke

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4

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

of 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

4.3.1 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 can

lead 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 SysteLiquid

DEUTZ cooling system probtained under order numbor 1221 1500 (210 litre

amine- and phosphate-freprotection against corrofreezing.If the above-mentioned coonot available, the followingin exceptional cases.

Manufacturer ProAVIA AVIABASF GDEA DEA

SHELL SH

The concentration of the ctive liquid in the coolant mathe following limits:

Cooling system protectivmax. 45 Vol.%min. 35 Vol.%

For the quantity, see tablmation in section 9.1.Other cooling system pchemical corrosion inhibitocircumstances, be used in ation with DEUTZ Servic

system protective liquid fro

----

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4.3 Coolant Opera

18 20 22 25 27 30

35 22 2.8 7.0 7.7 8.75 9.5 10.5

40 28 7.2 8.0 8.8 10.0 10.8 12.0

45 35 8.1 9.0 9.9 11.3 12.2 13.5

50 45 9.0 10.0 11.0 12.5 13.5 15.0

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.

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Routine M

5.1 Maintenance Schedule

5.2 Maintenance Chart

5.3 Maintenance Record

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5

Routine Maintenance 5.1 Maintenan

clean

renew

Job

In running hours (h)1)every

check

Every10 hor

daily 1500 2000 3000100050025012550-150

Oil level 2) 9)

Engine for leakages Oil bath 3)- and dry type air cleaners 4)

Battery and lead connections

Cooling system (dep. on engine use)3) 8)

Engine oil (dep. on engine use)5)

Oil filter cartridge

Fuel filter cartridge

Fuel prefilter

Fuel leakage lines

Valve clearance (readjust if nec.)

Engine mounts (retighten if necessary)

V-belts (retension if nec.)

Alarm system, engine mounts

Radiator bearing rubber/locking elements

Glow plugs

Coolant6)

Coolant , additive-concentration

Coolant level

onceafter2)

7)

7)

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

or 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 M

0297 7782 0

1013

1000

10

1500

10

10

AIR

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.

hStd.

0,3 mm0.012 in.in.

0,5 mm0.020 in.ex.

1500

10

125-2000

in.

a

ex.

AIR

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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 Mainte

74

9 7 9

1

BFM1012

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5.2 Maintenance Chart Routine M

1

The service diagram for series 1012/1013 (filling the cooling system, venting, bleeding) featured on this page is stuck on the engine asCheck 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.

Routine Maintenance 5.3 Completed Maintenance Jobs

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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

p

50-150*

125

375

625

875

1125

1375

1625

1875

2115

2375

2625

* Commissioning new and overhauled engines

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

5.3 Completed Maintenance Jobs Routine Maintenance

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

DateHours Signaure / Stamp Hours Date Signaure / Stamp 5

p

2875

3125

3375

3625

3875

4125

4375

4625

4875

5125

5375

5625


3000

3250

3500

3750

4000

4250

4500

4750

5000

5250

5500

5750

Routine Maintenance 5.3 Completed Maintenance Jobs

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Hours. DateDate Signaure / Stamp Hours Signaure / Stamp5


5875

6125

6375

6625

6875

7125

7375

7625

7825

8125

8375

8625

6000

6250

6500

6750

7000

7250

7500

7750

8000

8250

8500

8750

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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

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Hours. DateDate Signaure / Stamp Hours Signaure / Stamp5

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Service and M

6.1 Lubrication System6.2 Fuel System

6.3 Cooling System

6.4 Combustion Air Cleaner

6.5 Belt Drives

6.6 Adjustments

6.7 Accessories

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6

Service and Maintenance 6.1 Lubrica

6.1.1 Oil Change Intervals

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

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

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

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.

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

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]

Equipment Engines

Automotive Engines I 25II 40III 60

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6.1 Lubrication System Service and M

26 022 025 729 0

6.1.2 Checking Oil Level / Changing Engine Oil

6.1.2.1 Checking Oil Level 6.1.2.2 Changing Engine Oil

Run the engine warm Ensure that the engine or vehicle is on a level

surface Lube oil temperature approx. 80C.

Switch off the engine.

Place an oil tray ben Unscrew drain plug Drain oil. Fit oil drain plug w

firmly (for torque, s Fill with lube oil

For grade/viscosit For quantity, see 9

Check oil level, see

Ensure that the engine or vehicle is on a levelsurface.

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

oil level Cold engine

Check the oil level Remove the dipstick Wipe off with a non-fibrous, clean cloth. Insert up to the stop and pull out again. Ch k il l l if q i d t t th

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6

Service and Maintenance 6.1 Lubrica

6.1.3 Changing Oil Filter

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

Undo the filter cartridge with commercial tooland spin off.

Catch any dripping oil.

Clean any dirt from the filter carr ier rim.

Lightly oil the rubber gasket of the new oil filtercartridge.

Screw in the new cartridge finger tight againstthe gasket.

Check that the cartridgagainst the gasket and tturn.

If a torsion lock is fittedSlide clamps up into screws.

Check oil level (see 6.1.2

Ch k il (

25881 025880 0

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6.1 Lubrication System Service and M

6.1.4 Cleaning/Changing Oil filter(Cup)

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

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

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

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

f

Carefully insert the new paper filter cartridge 3 inguide 4.

Tighten lube oil filter cover 1 in the clockwisedirection (25 Nm).

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

300 74 0

2

3

4

1

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6

Close fuel stopcock.

Undo fuel filter cartridge with commercial tooland spin off.

Catch any fuel.

Clean any dirt from the filter carr ier rim.

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

Screw in the new cartridge finger tight againstthe gasket.

Check that the cartridgagainst the gasket and tturn.

Open fuel stopcock.

Check for leaks.

6.2.1 Changing Fuel Filter

25880 0 25881 0

Service and Maintenance 6.2

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6.2.2 Cleaning/Changing FuelPre-Filter Element

6.2.3 Venting th with Prelim

6.2 Fuel System Service and M

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.

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

Bleeding: Place the fuel pan b

filter.

Loosen drain plug fluid. When fuel insretighten drain plug

Check for leaks after

Venting: During initial comm

work or if the tank isvent the fuel system

Set engine controlle Place fuel collectin

housing (5) / pressu Open fuel stopcockvent screw (8)

Turn engine with stawith no air bubbles eand pressure holdin

Tighten vent screw and pressure contro

Set engine controlle When the engine ha

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

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

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

filter insert housing 5 of any dirt.

I t li i 6 d filt i t 3

1

2

3

8

5 4

7

6

25 801 0 30 084 0

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6 6.2.4 Changing Fuel Leakage Line

Set engine controller to stop position Open fuel stopcock Loosen pressure holding valve (9)

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

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

Tighten up pressure holding valve (9). Set engine controller to start position and start

Wh h i h d h k f l k

30 034 0


Close fuel stopcock Dismantle valve cap cover Remove rubber hoses (3) from the injection

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

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

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

Connect rubber hoses (3) to injection valves

R l

6.2.5 Changing Fuel LeakagePipes

30 084 0

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6.3 Cooling System Service and M

6.3.1 Cleaning Intervals 6.3.2 Cleaning Cooling System

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

Spilled oil or fuel on the engine increases the

risk of contamination. Be especially careful ifthe engine is used in dusty environments.

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.

Because applications vary, cleaning intervalshave to be determined from case to case. Thecleaning intervals given in the table below can

be used as a guide.

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

(it. 2).

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).

Checking / Cleaning Intervals

Suggested OH Application

2000 Ships, gensets in enclosedspaces, pumps

1000 Vehicles on paved roads

500 Tractors, forkl if t trucks, mobilegensets

Cold Cleansing Agent Spray the heat ex

cold cleansing ag10 minutes.

First spray cleaposition 3 then frosensitive engine cwater jet, eg gecomponents, fan

Cleaning with steam o Remove oil and g

set at a gentle set

Refit service flap. Run the engine up

erature to evaporate

Series 1012E/1013E If an external cooli

the manufacturers

Unit engine Clean as described

The cleaning jet muthe cooling-air duct

26252 0

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6

Service and Maintenance 6.3 Coo

6.3.3 Draining Cooling System

1012 / 1013

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

cooler (coolant duct). 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 / VentCooling Syste1012 / 1013

Unscrew cap 1 Loosen sealing plug 2 Unscrew vent plug 4. Unscrew sealing plug 3

notch. Add coolant up to the m

limit (heater valve if fibe opened).

Tighten sealing plug 2 (tig Tighten vent plug 4 (tigh

ca.10mm

ca.5mm1

30 082 0

3

2

1 4

If a heater is connected to the

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6.3.5 Draining the Cooling System1012 E / 1013 E

Place a container under sealing plug 1. Remove sealing plug 1 from the crankcase. Drain off the coolant. Tighten sealing plug 1 again. 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.

26 341 0


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

02

974987

1

BFM 1012E

BFM 1013E

1

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

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

Tighten vent plug position 2 + sealing plugposition 3.

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

opens.

Venting The cooling system

with our installatioautomatically after t

With external cooliwith the specificatio

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6

02

974985

1

BFM 1013E

1013 EShort engine

Service and Maintenance 6.3 Coo

Loosen vent plug position 2 and sealing plugposition 3.

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

Tighten vent plug position 2 + sealing plugposition 3.

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

opens.

Venting The cooling systems, which are built in line

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

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

Start the engine and warm up until thethermostat opens.

6.3.7 Draining the CUnit Engine (4

1

2

Open the cap 1 of the ex Place a container beneat Unscrew the knurled

clockwise direction until Drain off coolant. In case of clogging, rins

with clear water. Tighten knurled screw 2

Filling/venting the coolinsee section 6.3.8

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6.3.8 Filling/Venting the CoolingSystemUnit Engine

Unit engine (6 cylinders)

1

2 30 277 0

1

2

30 277 0

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

with clear water. Tighten sealing plug 2.

Filling/venting the cooling system:see section 6.3.8

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

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

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

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

6.3.9 Draining t

Loosen the drain pcharge-air cooler.

Drain off any oiremaining.

Close the drain plug

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6

Service and Maintenance 6.4 Combustion

6.4.1 Cleaning Intervals

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 be

fitted to the air cleaner.

Cleaning intervals will have to be determinedfrom case to case.

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

Air cleaner servicing is needed when:

Service Indicatorthe red signal 1 is fully visible when theengine is off.

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

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

25885 1

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6.4 Combustion Air Cleaner Service and M

6.4.2 Emptying Cyclone TypePrecleaner

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

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.

Remove dirty oil and sludge. Clean oil cup.

Undo wing nut 1 and remove cover 2.

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

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

Clean filter housing

Inspect and replacenecessary.

Fill oil cup with e(arrow) (for viscosi

Refit oil cup and elesecure with snap cl

6.4.3 Cleaning Oil Bath Air Cleaner

25887 025886 0

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6

Service and Maintenance 6.4 Combustion

6.4.4 Dry Type Air Cleaner

Dust Discharge Valve Filter Cartridge

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

Clean discharge slot from time to time.

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

Undo clip fasteners 1.

Take off hood 2 and remove cartridge 3.

Clean cartridge (replace at least once a year).

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

After five air cleaner servat the latest, replace saclean).To do so: Undo hex. nut 5 and r Install new cartridge,

nut.

Install cartridge 3, replaclip fasteners.

25888 1 25889 0

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6.5 Belt Drives Service and M

6.5.1 Checking V-Belts

1012

Inspect entire V-belt for damage.

Replace damaged V-belts.

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

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

Place indicator arm 1 into gauge.

1013

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

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6

1

4

3

2

5

A

B


6.5.2 Tensioning Fan /Alternator Belts1012

6.5.3 Changing Fan /Alternator Belts1012

Slacken off bolts 1, 2 and 3.

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

Re-tighten bolts 1, 2 and 3.


Press alternator in direction of arrow B.

Remove and replace belt.

Tension belt in accordance with 6.5.3.

Re-tighten bolts 1, 2 and 3.

6.5.4 Tensioning CoFuel Pump Be1012

Slacken off bolts 1 and 2

Push fuel pump 3 in direcorrect belt tension is ac

Re-tighten bolts 1 and 2

26 449 0

1

4

3

2

5

A

B

26 449 0

1

A3

2

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6.5.5 Changing Coolant /Fuel Pump Belts1012

6.5.6 Tensioning Coolant /Fuel Pump Belts1012 E

6.5.7 Changing Fuel Pump1012 E

Remove fan belt as described in 6.5.3.

Slacken off bolts 1 and 2.

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

Remove and replace belt.

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


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

Tighten bolts 1 and 2.

Slacken off bolts 1 a

Push fuel pump 3 in

Remove and replace

Push fuel pump in ountil correct belt ten

Tighten bolts 1 and

26 254 0

1

A

B

3

2

26 450 0

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6

Service and Maintenance6.5

6.5.8 Tensioning Alternator Belt1012 E


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

Tighten bolts 1, 2 and 4.

6.5.9 Changing Alternator Belt1012 E

Remove fuel pump belt as described in 6.5.7.


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

Fit new belt.

Adjust bolt 3 until the correct belt tension isachieved.

26 250 0 26 251 0

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6.5 Belt Drives

Service and M6.5.12 Changing

Fuel Pum1013

6.5.10 Tensioning /Changing Fan Belt1013

6.5.11 Tensioning Coolant /Fuel Pump belts1013


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.


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


Remove fan / alter6.5.10 and 6.5.13.

Slacken off bolts 1 a

Push fuel pump 3 in

Remove and replace

Push fuel pump in

26 450 026 345 0

1

A

B

3

2

1

3

2

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6

1

4

3

2

5

A

B

Service and Maintenance6.5

6.5.13 Tensioning /ChangingAlternator Belt1013

6.5.14 Tensioning Coolant /FuelPump Belts1013 E

6.5.15 Changing CooFuel Pump Be1013 E


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


Slacken off bolts 1 and 2

Push fuel pump 3 in dire

Remove and replace bel

Push fuel pump 3 in arrow until correct belt t


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

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

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

belt is exposed.

26 380 026 449 0

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

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

Remove hex. bolts 1.

Take off outer half-pulley 2.

Replace belt if necessary.

6.5.16 Tensioning /Changing Compressor Belt

24598 1 24599 1

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6


Slacken off breather valve and swing to oneside.

Remove rocker cover.

Position crankshaft as per schematic 6.6.1.1

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

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.

Check and adjust valve clearance on allremaining cylinders.

Replace rocker cover (use new gasket if

6.6.1 Checking /Adjusting Valve Clearances

19691 2

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6.6 Adjustments Service and M

6.6.1.1 Valve Clearance Adjustment Schematic

Crankshaft Position

Turn crankshaft untoverlap (exhaust vvalve about to open)

marked in blackotive rocker arm withment has been done

Crankshaft Position

Turn crankshaft one

Adjust clearance of schematic.

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6


6.7.1 Battery6.7.1.1 Checking Battery and Cable

Connectors6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Sp

Electrolyte

Keep battery clean and dry.

Undo dirty clamps.

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

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

Remove caps 1.

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

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

If necessary, top up with distilled water.

Measure the specific grawith a commercial hydro

The hydrometer readingpage) indicates the stameasurement, the templyte should preferably be

25895 0 24232 3

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6.7 Accessories Service and M

The gases emitted by the batteryare explosive. Keep sparks and

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.

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6


6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

Notes on the three-phase system:

Neverdisconnect the cables between battery,alternator and regulator while the engine is

running.

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

Be sure not to confuse the battery terminals.

Replace defective bulb of the charge pilot lampimmediately.

Cleaning the engine: Do not spray water/steam

directly onto the alternator. Run the engine upto normal operating temperature to evaporateany remaining water.

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

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

Always use proper lifting tackle whentransporting the engine.

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7.1 Diagnosis Chart Trou

7.1 Diagnosis Chart

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Troubleshooting7.1 Dia

7

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

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

A diagnosis chart is given on the facing page.

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 or

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7.1 Diagnosis ChartTrou

Not declutched (where possible)

Below starting limit temperature

Engine shutdown lever in stop position (faulty solenoid)

Oil level too low

Oil level too highExcessive inclination of engine

Speed control lever set to middle position

Dirty air cleaner/Faulty turbocharger

Air cleaner service switch/indicator defective

LDA* defective (leaking line)

Charge air line leaking

Coolant pump defective

Charge air cooler contaminated

Cause

Fault

Engine fails or is difficult to start

Engine starts but runs unevenly or stalls

Engine overheats. Temperature monitor gives warning

Engine gives poor performance

Engine not firing on all cylinders

Engine has little or no oil pressure

Engine oil consumption excessive

Engine smokes - blue

- white

- black

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Troubleshooting7.1 Dia

7

Fault Re

Engine fails or is difficult to start Ch

Engine starts but runs unevenly or stalls Ad

Engine overheats. Temperature monitor gives warning Re

Engine gives poor performance Cle

Engine not firing on all cylinders To

Engine has little or no oil pressure Lo

Engine oil consumption excessive

Engine smokes - blue

- white

- black

Cause

Electrics cable connections to starter, electrical system loose or oxidized

Starter defective or pinion does not engage

Incorrect valve clearance

Leaking injection line

Vent pipe blocked (coolant heat exchanger)Glow plugs defective

Injector defective

Air in fuel system

Fuel filter/prefilter dirty

Oil filter defective

Incorrect lube oil SAE class or quality Ope

Fuel quality not as per Operation Manual

Coolant level too low

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8.1 Preservation Engine P

8.1 Preservation

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Engine Preservation 8.1 P

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 the

engine for up to 6 months. The procedure willhave to be reversed before the engine is re-commissioned.

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

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

class A3)

Preserving Engine:

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

Run engine until warm, then turn off.

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

Drain coolant (see 6.3.3/6.3.5).

Fill with anti-corrosion agent (see 4.3.3).

Run engine for about 10 minutes.

Turn engine off.

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

Remove V-belts 1 and store in wrapped condition.

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

Removing Engine Preserv

Remove anti-corrosion V-belt pulleys 2.

Install V-belts 1. Retensiis necessary (see 6.5).

Remove covers from intport 4.

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Technical Spe

9.1 Engine Specifications and Settings9.2 Torque Wrench Settings

9.3 Tools

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9

Technical Specifications 9.1 Engine Specifications

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

Number of cylinders 4 4 6 Cylinder arrangement vertical, in line Bore [mm] 94 Stroke [mm] 115 Total displacement [cm3] 3192 3192 4788

Compression ratio []. 17.5 Working cycle/Combustion system 4-stroke diesel with turbocharging and direct injection

Charge air cooler w/o w/ w/o 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

Engine power [kW] 1).

Speed [rpm] 1). Valve clearance with cold engine [mm] I nlet 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

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

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

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9.1 Engine Specifications and Settings Technical Spe

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

Cooling system Liquid-cooled/Cooling system protectioCoolant quantity1012/C [litres approx.] 9.3 10.0 12.2 1012 E/EC 5) [litres approx.] 5.6 5.6 7.3 1012 unit engine (with frontal radiator) [litres approx.] 15.9 18.1 Permissible continuous coolant temperature

Engine outlet, with performance group I [C] max.1106)

. 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) .

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

3)Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum.4) O l d i i t ( 3 5 1)

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9


Model BF4M 1013 BF4M 1013 C BF6M 1013 BF6M 1013 C BF4M 1013 E BF4M 1013 EC BF6M 1013 E BF6M 1013 EC B

Number of cylinders 4 4 6 6 Cylinder arrangement vertical, in line Bore [mm] 108 Stroke [mm] 130 Total displacement [cm3] 4764 4764 7146 7146

Compression ratio [

]. 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 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

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


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

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

Cooling system Liquid-cooled/Cooling system protection Coolant quantity1013 / C / CP [litres approx.] 12.1 13.6 15 16.3 1013 E / EC / ECP 5) [litres approx.] 7.2 7.2 9.89.8 1013 unit engine (with frontal radiator) [litres approx.] 17.5 19.7 22 23.7 Permissible continuous coolant temperature

Engine outlet, with performance group I [C] max.1106)

. 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) .


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) .

Oil capacity (first fill-up) with filter [litres approx.] 14.0 3) . 14.0 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) O l d i i t ( 3 5 1)

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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 []. 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 1-5-3-6-2-4 1-5-3-6-2-4


Generator fan [N] 550 / 300 50. Fuel pump - coolant pump [N] 550 / 300 50. Compressor [N] 650 / 400 50.

1) Engine power speed start of delivery are stamped on engine rating plate see also 2 1

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Model 1013 FC BF4M 1013 FC BF6M 1013 FC

Cooling system Liquid-cooled/Cooling system protection Coolant quantity1013 FC 5) [litres approx.] 7.2 9.8 Permissible continuous coolant temperatureEngine outlet, with performance group I [C] with f lap turbocharger max.110 6) ./ with feast turbocharger max.105Engine outlet, with performance group II-IV [C] max.105 6).

Thermostat initial opening at [C] 87 . Thermostat full open temperature [C] 102 . Coolant prewarming (4 . Coolant pumpDelivery pressure in [bar] 7) . Delivery rate in [m3/h] 7) . Power consumption in [kW] 7) .


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.] 16 3) . 28 3) .

Oil capacity (first fill-up) with filter [litres approx.] 17 3) . 29 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) O l i i i h di C i f l li d d li d i

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9

Technical Specifications 9.2 Torque Wre

Preload [Nm] Torquing Load [Nm]TotaLocation

Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage 4

8

1

1

8

Rocker cover

Rocker arm setscrew

Mount, flywheel side

Mount, turbocharger side

Air intake manifold

Exhaust manifold

Oil drain plug

Injector mounting

Injection line mounting

Oil pan (cast iron)

Oil pan (sheet metal)

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9.3 Tools Technical Spe

TORX V-belt Tension Gauge

The V-belt tension gauge can be obtained underorder number 91107from:

WILBRPostfach 14 05 80D-42826 Remscheid

A TORX wrench set is used with engines in the1012/1013 series. This system was chosenbecause of the many advantages it offers:

Outstanding accessibility to bolts.

High load transfer when loosening and tighten-ing.

Almost impossible for socket to slide off orbreak.

25899 0 26002 0

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9

Notes

10

Service

Knowing its DEUTZ

DEUTZ h l t d f ll i t

Order-No.: 0297 7444

en

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DEUTZ has always stood for excellence in motorconstruction, pioneering many developments in

the industry. As an independent motor manu-facturer, we offer worldwide a com-prehensive range of diesel and gas motorsspanning from 4kW to 7,400kW. Our products areperfectly tailored to meet our customers individualrequirements.

Over 1.4 million DEUTZ motors do their jobreliably all over the world. We are determined topreserve the high standard of performance anddependability of our motors, thus keeping ourcustomers satisfied at all times. Therefore we arerepresented worldwide through a network of highlycompetent service partners who will meet theneeds of our customers, wherever they are.

This is why DEUTZ is not only the name for motorswhich pack a lot of inventive genius. DEUTZ alsomeans reliable service and comprehensive supportto enhance your motors performance.

This index Sales & Service offers you an overviewof the DEUTZ partners in your vicinity, including theproducts for which they are responsible and therange of services provided. But even when no directproduct responsibility is mentioned, your DEUTZpartner will be happy to help you with expert advice.

The Index is constantly updated. Please ask yourDEUTZ service partner for the latest edition.

DEUTZ AG at your service.

Order-No.: 0297 7445 (CD-ROM)

DEUTZ AGDeutz-Mlheimer Str. 147-149D-51057 Kln

Phone: 0049-221-822-0Telefax: 0049-221-822-5304Telex: 8812-0 khd dhttp://www.deutz.de

Obtainable from the local service Partner reponsiblefor you or from:

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