Operation Manual

1012 1013

ENGLISCH Kapitel 00 Seite 1

q Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturers warranty and maintain the engine in peak operating condition. q This engine has been built exclusively for the application specified in the scope of supply as described by the equipment manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose. The manufacturer will not assume responsibility for any damage resulting therefrom. The risks involved are to be borne solely by the user. q Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation, maintenance and servicing. The engine should only be operated by personnel trained in its use and the hazards involved. q The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed. q Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage. Manipulations of the injection and regulating system may also influence the performance of the engine, and its emissions. Adherence to legislation on pollution cannot be guaranteed under such conditions. q Do not alter, modify or adapt the cooling air intake area to the fan. The manufacturer will not assume responsibility for any damage resulting therefrom.

ENGLISCH Kapitel 00 Seite 2

Operation Manual

1012 1013

0297 9682 en
Engine serial number:
Please enter the engine serial number here. This number should be quoted when inquiring about Customer Service, Repairs or Spare Parts (see Section 2.1).

All rights reserved. Technical modifications required to improve our engines are reserved with regard to specification data and other technical information contained in this Operation Manual. No part of this Manual may be reproduced in any form or by any means without our written approval.

ENGLISCH Kapitel 00 Seite 3

Foreword

Dear Customer, Liquid-cooled DEUTZ engines are designed for a large number of applications. Consequently, a wide range of variants are offered to meet the requirements of specific cases. Your engine is appropriately equipped for the installation concerned, which means that not all of the components described in this Operation Manual are necessarily mounted to your engine. We have endeavored to highlight any differences so that you will be able to locate the operating and maintenance instructions relevant to your engine quickly and easily. Please read this Manual before starting your engine, and always observe the operating and maintenance instructions. We are available to help with any additional inquiries. Sincerely, DEUTZ AG

ENGLISCH Kapitel 00 Seite 4

Table of contents
1. 2. General Engine Description
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 1013 2.5.4 Cooling System Schematic 1013 E

4.

Operating Media

2.1 Model 2.1.1 Rating Plate 2.1.2 Rating Plate Location 2.1.3 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 2.2.5 Service Side 1013 2.2.6 Starter Side 1013 2.2.7 Service Side 1013 E 2.2.8 Starter Side 1013 E 2.2.9 Starter Side Unit Engine BF4M 1013 EC 2.2.10 Service Side Unit Engine BF4M 1013 EC 2.2.11 Starter Side Unit Engine BF6M 1013 EC 2.2.12 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

3.
3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.2.1 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.5 3.5.1 3.5.2

Engine Operation
Commissioning Adding Engine Oil Filling Oil Bath Air Cleaner Adding Fuel Filling/Venting the Cooling System Other Preparations Other Preparations Starting Electric Starting Monitoring Systems Engine Oil Pressure Coolant Temperature Coolant Level/Level Gauge Stopping Engines with Mechanical Shutdown Engines with Electrical Shutdown Operating Conditions Winter Operation High Ambient Temperature, High Altitude

4.1 Lube Oil 4.1.1 Quality Grade 4.1.2 Viscosity 4.2 Fuel 4.2.1 Quality Grade 4.2.2 Winter Grade Fuel 4.3 Coolant 4.3.1 Water Quality for Coolant Preparation 4.3.2 Coolant Preparation 4.3.3 Antifreeze/Chemical Corrosion Inhibitors

5.
5.1 5.2 5.3

Routine Maintenance
Maintenance Schedule Maintenance Chart Maintenance Record

ENGLISCH Kapitel 00 Seite 5

Table of contents
6. Service and Maintenance
6.1 Lubrication System 6.1.1 Oil Change Intervals 6.1.2 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 Element 6.2.3 Venting the Fuel System with Preliminary Fuel Filter 6.2.4 Venting the Fuel System w/o Preliminary Fuel Filter 6.2.5 Changing Fuel Leakage Pipes 6.3 Cooling System 6.3.1 Cleaning Intervals 6.3.2 Cleaning Cooling System 6.3.3 Draining Cooling System 1012 / 1013 6.3.4 Filling / Venting Cooling System 1012 / 1013 6.3.5 Draining the Cooling System 1012 E / 1013 E 6.3.6 Filling/Venting the Cooling System 1012 E / 1013 E 6.3.7 Draining the Cooling System Unit Engine 6.3.8 Filling/Venting the Cooling System Unit Engine 6.3.9 Draining the Charge Air Cooler 6.4 Combustion Air Cleaner 6.4.1 Cleaning Intervals 6.4.2 Emptying Cyclone-Type Precleaner 6.4.3 Cleaning Oil Bath Air Cleaner 6.4.4 Dry Type Air Cleaner 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 Belts 1012 6.5.5 Changing Coolant / Fuel Pump Belts 1012 6.5.6 Tensioning Coolant / Fuel Pump Belts 1012 E 6.5.7 Changing Coolant / Fuel Pump Belts 1012 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 Belts 1013 6.5.12 Changing Coolant / Fuel Pump Belts 1013 6.5.13 Tensioning / Changing Alternator Belt 1013 6.5.14 Tensioning Coolant / Fuel Pump Belts 1013 E 6.5.15 Changing Coolant / Fuel Pump Belts 1013 E 6.5.16 Tensioning / Changing Compressor Belt 6.6 Adjustments 6.6.1 Checking / Adjusting Valve Clearances 6.6.1.1 Valve Clearance Adjustment Schematic 6.7 Accessories 6.7.1 Battery 6.7.1.1 Checking the Battery and Cable Connections 6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Specific Gravity of Electrolyte 6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

7.
7.1

Troubleshooting
Diagnosis Chart

8.
8.1

Engine Preservation
Preservation

9.
9.1 9.2 9.3

Technical Specifications
Engine Specifications and Settings Torque Wrench Settings Tools

10. Service

ENGLISCH Kapitel 00 Seite 6

ENGLISCH Kapitel 00 Seite 7

ENGLISCH Kapitel 00 Seite 8

General
DEUTZ Diesel Engines Care and Maintenance Service

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.

Beware of Running Engine

Safety

California
Proposition 65 Warning

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

This symbol is used for all safety warnings. Please follow them carefully. The attention of operating personnel should be drawn to these safety instructions. General safety and accident prevention regulations laid down by law must also be observed.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Asbestos

DEUTZ original parts are asbestosfree.

7 Gerade
9689en_K01_neu 7 30.09.1999, 15:45 Uhr

8
9689en_K01_neu 8 30.09.1999, 15:45 Uhr

Engine Description 2
2.1 2.2 2.3 2.4 2.5 Model Engine Illustrations Lube Oil Circuit Fuel System Cooling System

ENGLISCH Kapitel 2 Seite 1

7380en_k02_pdf 1 01.10.1999, 16:20 Uhr

Engine Description 2
2.1.1 Rating Plate 2.1.2 Rating Plate Location

2.1 Model
2.1.3 Engine Serial Number

26 332 0

26231 1

26232 1

The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering spare parts.

The rating plate C is attached to the crankcase.

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

ENGLISCH Kapitel 2 Seite 2

7380en_k02_pdf 2 01.10.1999, 16:20 Uhr

2.1 Model
2.1.4 Cylinder Numbering

Engine Description 2

26233 0

Cylinders are numbered consecutively, beginning at the flywheel end.

ENGLISCH Kapitel 2 Seite 3

7380en_k02_pdf 3 01.10.1999, 16:20 Uhr

Engine Description 2
2.2.1 Service Side 1012

2.2 Engine Illustrations

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Oil filler (option: between filters) Coolant filler Cooling fan Coolant pump Belt pulley Fuel pump Engine mount Fuel filter Lube oil filter Oil pan Dipstick Lube oil cooler Mounting facility for hydraulic pumps Alternator Back leak fuel pipe with pressure-regulating valve 16 Cylinder head

26234 1

ENGLISCH Kapitel 2 Seite 4

7380en_k02_pdf 4 01.10.1999, 16:20 Uhr

2.2 Engine Illustrations

2.2.2 Starter Side 1012

Engine Description 2
17 18 19 20 21 22 23 24 25 26 Lifting points Exhaust turbocharger Speed governor SAE housing Flywheel Starter motor Hydraulic oil cooler Coolant heat exchanger Coolant level gauge Bleeder valve

26235 1

ENGLISCH Kapitel 2 Seite 5

7380en_k02_pdf 5 01.10.1999, 16:20 Uhr

Engine Description 2
2.2.3 Service Side 1012 E

2.2 Engine Illustrations

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Oil filler (option: between filters) Coolant inlet Coolant pump Alternator Belt pulley Engine mount Fuel pump Fuel filter Lube oil filter Oil pan Dipstick Lube oil cooler Mounting facility for hydraulic pump Back leak fuel pipe with pressure-regulating valve 15 Cylinder head

26236 0

ENGLISCH Kapitel 2 Seite 6

7380en_k02_pdf 6 01.10.1999, 16:21 Uhr

2.2 Engine Illustrations

2.2.4 Starter Side 1012 E

Engine Description 2
16 17 18 19 20 21 22 23 24 Lifting points Exhaust turbocharger Speed governor SAE housing Flywheel Starter motor Coolant outlet to heat exchanger Exhaust manifold Air intake manifold

26237 0

ENGLISCH Kapitel 2 Seite 7

7380en_k02_pdf 7 01.10.1999, 16:21 Uhr

Engine Description 2
2.2.5 Service Side 1013

2.2 Engine Illustrations

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Oil filler (option: between filters) Alternator Coolant pump Fan Belt Pulley Vibration damper Fuel pump Engine mount Fuel filter Lube oil filter Oil pan Dipstick Lube oil cooler Hydraulic pumps (or compressor) Fuel pipe Solenoid Lube oil line to turbocharger Cylinder head

26 333 0

ENGLISCH Kapitel 2 Seite 8

7380en_k02_pdf 8 01.10.1999, 16:21 Uhr

2.2 Engine Illustrations

2.2.6 Starter Side 1013

Engine Description 2
19 20 21 22 23 24 25 26 27 Lifting points Exhaust turbocharger Speed governor SAE housing Flywheel Starter motor Coolant level gauge Bleeder valve Coolant filler cap

26 334 0

ENGLISCH Kapitel 2 Seite 9

7380en_k02_pdf 9 01.10.1999, 16:21 Uhr

Engine Description 2
2.2.7 Service Side 1013 E

2.2 Engine Illustrations

1 2 3 4 5 6 7 8 9 10 11 12

Oil filler Coolant pump Fuel pump Vibration damper Lube oil filter Engine mount Fuel filter Oil pan Dipstick Lube oil cooler Mounting facility for hydraulic pump Back leak fuel pipe with pressure-regulating valve 13 Cylinder head A Coolant inlet

26 336 0

ENGLISCH Kapitel 2 Seite 10

7380en_k02_pdf 10 01.10.1999, 16:21 Uhr

2.2 Engine Illustrations

2.2.8 Starter Side 1013 E

Engine Description 2
14 15 16 17 18 19 20 21 22 23 Lifting points Crankcase breather valve Speed governor SAE housing Flywheel Starter motor Exhaust turbocharger Fan Exhaust manifold Air intake manifold

26 337 0

ENGLISCH Kapitel 2 Seite 11

7380en_k02_pdf 11 01.10.1999, 16:21 Uhr

Engine Description 2
2.2.9 Starter Side Unit Engine BF4M 1013 EC
1 2 3 4 5 6 7 8 9 10 11 12 13

2.2 Engine Illustrations

8 9

Coolant filler neck with cap Expansion tank Vent line from cylinder head to expansion tank Coolant line from engine crankcase to engine fluid radiator Expansion line from expansion tank to radiator Charge air line from exhaust turbocharger to charge-air cooler Dry air filter Induction air line between dry air filter and exhaust turbocharger Exhaust turbocharger Coolant line from crankcase to engine fluid radiator Charge-air cooler Engine fluid radiator Coolant line from engine fluid radiator to engine thermostat

12

10

13

11
26 088 0 30 336

ENGLISCH Kapitel 2 Seite 12

7380en_k02_pdf 12 01.10.1999, 16:21 Uhr

2.2 Engine Illustrations

2.2.10 Service Side Unit Engine BF4M 1013 EC

Engine Description 2
13
3 Ventilation line from cylinder head to expansion tank 13 Charge-air line from charge-air cooler to engine 14 Protective guard

14

30 089 0 26 337

ENGLISCH Kapitel 2 Seite 13

7380en_k02_pdf 13 01.10.1999, 16:21 Uhr

Engine Description 2
2.2.11 Starter Side Unit Engine BF6M 1013 EC
1 2 3 4 5 6 7 8

2.2 Engine Illustrations

Filler neck with cap Expansion tank Vent line from cylinder head to expansion tank Expansion line from expansion tank to coolant pump Coolant line from crankcase to engine fluid radiator Charge-air line from charge-air cooler to engine Charge-air line from exhaust turbocharger to charge-air cooler Coolant line from engine fluid radiator to engine thermostat

8
30 087 0

ENGLISCH Kapitel 2 Seite 14

7380en_k02_pdf 14 01.10.1999, 16:21 Uhr

2.2 Engine Illustrations

2.2.12 Service Side Unit Engine BF4M 1013 EC

Engine Description 2
9 Engine fluid radiator 10 Charge-air cooler 11 Protective guard

11

10
30 086 0

ENGLISCH Kapitel 2 Seite 15

7380en_k02_pdf 15 01.10.1999, 16:21 Uhr

Engine Description 2
2.3.1 Lube Oil Circuit Schematic 1012 / 1012 E

2.3 Lube Oil Circuit

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 piston cooling 12 Tappet w/ control bore for pulse lubrication of rocker arms 13 Pushrod (designed for lube oil supply of rocker arms) 14 Rocker arm 15 Return line to oil pan 16 Oil sensor 17 Oil line to exhaust turbocharger 18 Exhaust turbocharger 19 Oil line to compressor or hydraulic pump 20 Compressor 21 Hydraulic pump 22 Return line to compressor or hydraulic pump 23 Line to mass balancing gear (2x) 24 Counterbalancing shafts 25 Exhaust turbocharger return to crankcase
26238 1

ENGLISCH Kapitel 2 Seite 16

7380en_k02_pdf 16 01.10.1999, 16:22 Uhr

2.3 Lube Oil Circuit

2.3.2 Lube Oil Circuit Schematic 1013 / 1013 E

Engine Description 2
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 Spray nozzle line 11 Spray nozzle for piston cooling 12 Tappet w/ control bore for pulse lubrication of rocker arms 13 Pushrod (designed for lube oil supply of rocker arms) 14 Rocker arm 15 Return line to oil pan 16 Oil sensor 17 Oil line to exhaust turbocharger 18 Exhaust turbocharger 19 Oil line to compressor or hydraulic pump 20 Compressor 21 Hydraulic pump 22 Return line to compressor or hydraulic pump 23 Return to oil pan 24 Exhaust turbocharger return to crankcase
26 335 0

ENGLISCH Kapitel 2 Seite 17

7380en_k02_pdf 17 01.10.1999, 16:22 Uhr

Engine Description 2
2.4.1 Fuel System Schematic

2.4 Fuel System

1 2 3 4 5 6 7 8 9 10 11 12 13

Fuel tank Line to fuel pump Fuel pump Line to fuel filter Fuel filter Line to injection pumps Injection pump Line to injector Injector Back leak fuel pipe Banjo bolt with pressure-regulating valve Return line to fuel tank Keep this spacing as wide as possible

26239 1

ENGLISCH Kapitel 2 Seite 18

7380en_k02_pdf 18 01.10.1999, 16:22 Uhr

2.5 Cooling System

2.5.1 Cooling System Schematic 1012
1 2 3 4 5 6 7 8 9

Engine Description 2
Coolant filler Thermostat housing Coolant pump Lube oil cooler Cylinder cooling Cylinder head cooling Heat exchanger Return from thermostat to coolant pump housing Ventilation line from cylinder head to heat exchanger (expansion tank)

26240 2

ENGLISCH Kapitel 2 Seite 19

7380en_k02_pdf 19 01.10.1999, 16:22 Uhr

Engine Description 2
2.5.2 Cooling System Schematic 1012 E entrance regulation
1 2 3 4 5 6 7

2.5 Cooling System

Thermostat housing Coolant pump Lube oil cooler Cylinder cooling Cylinder head cooling Heat exchanger Ventilation line expansion tank - coolant pump 8 Line from engine to heat exchanger 9 Ventilation line from cylinder head to expansion tank 10 Expansion tank 11 Line from heat exchanger to thermostat

26241 4

ENGLISCH Kapitel 2 Seite 20

7380en_k02_pdf 20 01.10.1999, 16:22 Uhr

2.5 Cooling System

Engine Description 2
1 2 3 4 5 6 7 8 9 10 11 Thermostat housing Cooling fluid pump Lubricating oil cooler Cylinder cooling Cylinder head cooling Heat exchanger Compensation setting of compensation tank t o cooling fluid pump Line (Crankcase) from thermostat to heat exchanger Ventilation line from cylinder head to compensation tank Compensation tank Line from heat exchanger to cooling fluid pump

1012 E escape regulation

30 816 0

ENGLISCH Kapitel 2 Seite 21

7380en_k02_pdf 21 01.10.1999, 16:22 Uhr

Engine Description 2
2.5.3 Cooling System Schematic 1013
1 2 3 4 5 6 7 8 9

2.5 Cooling System

Coolant filler Thermostat housing Coolant pump Lube oil cooler Cylinder cooling Cylinder head cooling Heat exchanger Expansion line coolant pump/expansion tank Ventilation line from cylinder head to heat exchanger (expansion tank)

26 338 1

ENGLISCH Kapitel 2 Seite 22

7380en_k02_pdf 22 01.10.1999, 16:22 Uhr

2.5 Cooling System

2.5.4 Cooling System Schematic 1013 E entrance regulation
1 2 3 4 5 6 7

Engine Description 2
Thermostat housing Coolant pump Lube oil cooler Cylinder cooling Cylinder head cooling Heat exchanger Ventilation line expansion tank - coolant pump 8 Line from engine to heat exchanger 9 Ventilation line from cylinder head to expansion tank 10 Expansion tank 11 Line from heat exchanger to thermostat

26 339 1

ENGLISCH Kapitel 2 Seite 23

7380en_k02_pdf 23 01.10.1999, 16:22 Uhr

Engine Description 2
1013 E escape regulation
1 2 3 4 5 6 7 8 9 10 11

2.5 Cooling System

Thermostat housing Cooling fluid pump Lubricating oil cooler Cylinder cooling Cylinder head cooling Heat exchanger Compensation setting of compensation tank t o cooling fluid pump Line (Crankcase) from thermostat to heat exchanger Ventilation line from cylinder head to compensation tank Compensation tank Line from heat exchanger to cooling fluid pump

30 817 0

ENGLISCH Kapitel 2 Seite 24

7380en_k02_pdf 24 01.10.1999, 16:22 Uhr

Engine Operation 3
3.1 3.2 3.3 3.4 3.5 Commissioning Starting Monitoring Systems Stopping Operating Conditions

ENGLISCH Kapitel 3 Seite 1

Engine Operation 3
3.1.1 Adding Engine Oil 3.1.2 Filling Oil Bath Air Cleaner

3.1 Commissioning
3.1.3 Adding Fuel

26243 0

24980 2

26244 0

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.

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.

Use only commercial-grade diesel fuel. For fuel grade, 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 on the ambient temperature.

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

Never fill the fuel tank while the engine is running. Keep the filler cap area clean and do not spill fuel.

ENGLISCH Kapitel 3 Seite 2

3.1 Commissioning
3.1.4 Filling/Venting the Cooling System
q 1012/1013 See section 6.3.4 q 1012 E/1013 E See section 6.3.6 q Unit engine (with frontal radiator) See section 6.3.8.

Engine Operation
3.1.5 Other Preparations

q Check battery and cable connections, see 6.7.1. q Trial run - After the engine has been prepared, let it run for 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. q Breaking-in During the break-in phase - about 200 operating hours - check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient. q Commissioning conserved engines Remove conservation materials as outlined in section 8.1

ENGLISCH Kapitel 3 Seite 3

Engine Operation 3
3.2.1 Electric Starting

3.2 Starting

Starting without Cold-Start Aid

Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with glow plugs, do not use any other starter substance (e.g. injection with start pilot). Doing so could result in an accident. Important: Never start the engine with speed governor removed. Disconnect battery.

26245 0

25745 0

q Disengage the clutch to separate the engine from the driven equipment. q Move speed control lever 1 in direction of arrow at least to middle speed position. q Move shutdown lever 2 to operating position (in opposite direction of arrow).

q Insert key. Position 0 = no operating voltage. q Turn key clockwise. Position 1 = operating voltage. Pilot lights 1 and 2 come on. q Push the key in and turn it further clockwise against spring pressure. Position 2 = no function Position 3 = start q Release key as soon as engine fires. Pilot lights go out.

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

ENGLISCH Kapitel 3 Seite 4

3.2 Starting

Engine Operation 3

Starting with Heater Plugs

25746 1

q Insert key. Position 0 = no operating voltage. q Turn key clockwise. Position 1 = operating voltage. Pilot lights come on. Leave to preheat until pilot lights go out. q Push key in and turn further clockwise against spring pressure. Position 2 = no function. Position 3 = start. q Release key as soon as engine fires. Pilot lights go out.

ENGLISCH Kapitel 3 Seite 5

Engine Operation 3
3.3.1 Engine Oil Pressure Oil Pressure Pilot Light Oil Pressure Indicator

3.3 Monitoring Systems

Oil Pressure Gauge

25752 1

25753 0

25754 0

q The oil pressure pilot light comes on with operating voltage on and engine off. q The oil pressure pilot light should go out when the engine is running.

q The pointer must remain in the green sector over the entire operating range.

q The pointer must indicate the minimum oil pressure (see 9.1).

ENGLISCH Kapitel 3 Seite 6

3.3 Monitoring Systems

3.3.2 Coolant Temperature 3.3.3 Coolant Level / Coolant Level Gauge

Engine Operation 3

26246 0

26247 0

q The coolant temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn it off and establish the cause from the Diagnosis Chart (see 7.1).

q When the engine is cold, coolant level 1 should be above the KALT-COLD mark. q Top up with coolant if the level falls below the MIN mark on the sight glass, or if the coolant warning switch comes on. Unscrew the filler cap. Top up with coolant up to the upper edge of the filler neck. Tighten the filler cap q If it is not possible to carry out a check at the inspection opening, if required carry out a check at the filler neck: If you cannot see any fluid: - topping up is required.

q If a level switch is fitted, the engine is shut down automatically when the level falls below the MIN marking.

ENGLISCH Kapitel 3 Seite 7

Engine Operation 3
3.4.1 Engines with Mechanical Shutdown 3.4.2 Engines with Electrical Shutdown

3.4 Stopping

26266 0

25746 2

q Move speed control lever 1 to low idle. q Operate shutdown lever 2 until the engine comes to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops. q Turn key counterclockwise (to Position 0) and remove. The pilot lights will go out.

q Turn key counterclockwise (to Position 0) and remove. The pilot lights will go out.

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

ENGLISCH Kapitel 3 Seite 8

3.5 Operating Conditions

3.5.1 Winter Operation

Engine Operation 3
q 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 to about +20C. To do so, remove the battery and store in a warm place.

q 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 operating below 10C, see 6.1.1. q Diesel Fuel Use winter-grade diesel fuel for operation below 0C, see 4.2.2. q Coolant Set the water/antifreeze mix to suit the lowest likely temperature (max. 35C), see 4.3.1. q 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 with low-temperature grease, such as Bosch FT 1 V 31. To do so, remove the starter and introduce the grease through the pinion hole. q 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 limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

26248 0

ENGLISCH Kapitel 3 Seite 9

Engine Operation 3
3.5.2 High Ambient Temperature, High Altitude
q As the altitude and ambient temperature rise, the density of the air tends to decrease, which affects the maximum power output of the engine, the exhaust gas quality and, in extreme cases, the starting behavior. Under transient conditions, the engine can be used at altitudes up to 1000 meters / 3400 feet and temperatures up to 30C. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and, thus, engine power. q If you have any doubts about engine operation under these or similar conditions, ask your engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise, contact the nearest service representative.

3.5 Operating Conditions

C 0

F 32

25901 1

ENGLISCH Kapitel 3 Seite 10

Operating Media 4
4.1 Lube Oil 4.2 Fuel 4.3 Coolant

ENGLISCH Kapitel 4 Seite 1

Operating Media 4
4.1.1 Quality Grade 4.1.2 Viscosity

4.1 Lube Oil

Lube oils are differentiated according to their performance and quality class. In common use are specifications named after the API (American Petroleum Institute) and ACEA (European Oil Sequences). 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

As the viscosity of lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site. Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of the SAE grade selected, cold starting may be affected but the engine will not be damaged. In order to keep wear to a minimum, do not exceed application limits for extended periods of time. Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. Multigrade oils - particularly low-friction oils - also reduce fuel consumption.

Only with preheating

30 298 1

ENGLISCH Kapitel 4 Seite 2

4.2 Fuel
4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel

Operating Media 4
+32 +23 0 I -5

Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulfur content is higher than 0.5%, oil change intervals should be reduced (see 6.1.1). The following fuel specifications/standards are approved: q EN 590 q BS 2869: A1 and A2 q ASTM D975-96: 1-D and 2-D q NATO Code F-34/F-35, F44, F-54 and F-63

Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0 C, wintergrade fuel (suitable down to -20 C) should be used. This fuel is usually available from filling stations well in advance of the cold months. q At temperatures below -20C/, kerosene should be added to the diesel fuel. The relevant percentages are given in the diagram at the right q Special diesel fuels can be used for climatic zones down to - 44 C. If summer-grade diesel fuel must be used at temperatures below 0C, up to 60% kerosene can be added (see diagram). In most cases, adequate resistance to cold can be obtained by adding a flow improver (additive). Please contact your DEUTZ partner.

+14 - 10 + 5 - 15 - 4 - 20 - 13 - 25 II - 22 - 30 F C 0
A

10

20

30

40

50
B

60 %
26441 25 790 11

Legend: I II A B Summer diesel fuel Winter diesel fuel Outside temperature

Percentage of kerosene to be added

Mix in tank only. Fill with the appropriate amount of kerosene first, then add the diesel fuel.

ENGLISCH Kapitel 4 Seite 3

----

Operating Media 4
4.3.1 Water Quality for Coolant Preparation
The values given below must not be exceeded. A test kit (order number 1213 0382) can be obtained from DEUTZ Service to check the quality of the water available. Water quality pH-value at 20C /68 F Chloride ion content [mg/dm3] Sulfate ion content Total hardness [mg/dm3] [dGH] min. 6.5 3 max. 8.5 100 100 20

4.3 Coolant
4.3.2 Coolant Preparation 4.3.3 Cooling System Protective Liquid
DEUTZ cooling system protective agents can be obtained under order number 01011490 (5 litres) or 1221 1500 (210 litres). These are nitrite-, amine- and phosphate-free and provide effective protection against corrosion, cavitation and freezing. If the above-mentioned cooling system agents are not available, the following products can be used in exceptional cases. Manufacturer Product description AVIA AVIA Antifreeze Extra BASF Glysantin G 48 DEA DEA radiator antifreeze SHELL SHELL GlycoShell The concentration of the cooling system protective liquid in the coolant may not fall below/exceed the following limits: Cooling system protective liquid Water max. 45 Vol.% 55% min. 35 Vol.% 65% For the quantity, see table overpage and information in section 9.1. Other cooling system protective liquids, e.g. chemical corrosion inhibitors, can, in exceptional circumstances, be used in the coolant, in consultation with DEUTZ Service. Order the cooling system protective liquid from: DEUTZ Service Cooling system protective liquids must be disposed of in accordance with environmental regulations.

The preparation and monitoring of coolant in liquid-cooled engines is especially important because corrosion, cavitation and freezing can lead to engine damage. The coolant is prepared by admixing a cooling system protective liquid with the cooling water. The cooling system must be monitored regularly (see 5.1). The water level and the cooling system protective liquid concentration should both be checked. The cooling system protective liquid concentration can be checked with a commercially available tester (e.g. gefo glycomat ).

!
ENGLISCH Kapitel 4 Seite 4

When nitrite-based cooling system protective liquids are mixed with amine-based liquids, harmful nitrosamines are formed.

4.3 Coolant

Operating Media 4 Cooling System Protection

Cooling system capacity *) [Liters]

Cooling system protective agent [Vol %]

Cooling protection [C]

18

20

22

25

27

30

32

35

Cooling system protective liquid [Liters]

22 28 35 45 2.8 7.2 8.1 9.0 7.0 8.0 9.0 10.0 7.7 8.8 9.9 11.0 8.75 10.0 11.3 12.5 9.5 10.8 12.2 13.5 10.5 12.0 13.5 15.0 11.2 12.8 14.4 16.0 12.3 14.0 15.8 17.5

35 40 45 50

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

ENGLISCH Kapitel 4 Seite 5

Routine Maintenance 5
5.1 Maintenance Schedule 5.2 Maintenance Chart 5.3 Maintenance Record

ENGLISCH Kapitel 5 Seite 1

Routine Maintenance 5
once after 2) 50-150
q q q q q q q q q q q q q q q q q 7) q q q q q q q q q q q q q q q 7) q q q q q q

5.1 Maintenance Schedule

check clean renew 2000 3000
q q q q q q q q

Every 10 h or daily
q

In running hours (h)1)

every 125 250 500 1000 1500

Section Job 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 Coolant 6) Coolant , additive-concentration Coolant level

6.1.2/ 3.1.6 6.4 6.7.1 6.3.1/ 6.3.2 6.1.1/ 6.1.2 6.1.3 6.2.1 6.2 / 6.3 6.2.5 6.6.1 9.2 6.5 3.3/ 9.3

q
q q q

q
q q

6.3.3/ 6.3.4 4.3.2/ 4.3.3 3.3.3

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

The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please observe the operating instructions of the equipment manufacturer. 1) recommended maximum 5) oil grade API-CD or ACEA E1-E3-96+E4-98 for turbocharged 8) system cleaning 2) commissioning new and reconditioned engines engines, for oil change intervals, see 6.1.1 9) check twice a day during the run-in phase 3) clean if needed 6) check antifreeze or if necessary chemical concentration every 10) drain off any lube oil/condensation water that has collected 4) change if required. If fitted, service according to maint500 OH in the charge-air cooler, see section 6 .3.9 enance indicator 7) or change at least every 2 years

ENGLISCH Kapitel 5 Seite 2

5.2 Maintenance Chart

Routine Maintenance
in. a
in.

ex.
1500

0,3 mm 0.012 in. 0,5 mm 0.020 in.

h Std.
500

OIL

The maintenance chart shown here is supplied as self-adhesive label with each engine. It should be affixed 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 supplier for a fresh supply of labels. Routine work should be carried out according to the schedule in 5.1.

ex.

R WATE

AIR

10 10
ca. 15 mm 0.6 in.

500 1252000

1000

FU

EL

OIL
max.

10 500

OIL

1013
0297 7782
0

a in. ex.

h Std.
1500
in. ex.
0,3 mm 0.012 in. 0,5 mm 0.020 in.

OIL

500
WATE R

AIR

10

10

ca. 15 mm 0.6 in.

1252000

500

1000

FU

EL

Stop the engine before carrying out any maintenance work.

OIL
max.

10 500
OIL

BF4/6M 1012/E/C
0297 7783 0

ENGLISCH Kapitel 5 Seite 3

Routine Maintenance 5
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.

5.2 Maintenance Chart

BFM 1012 BFM 1013

ENGLISCH Kapitel 5 Seite 4

0297 4979 1

5.2 Maintenance Chart

Routine Maintenance 5

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.

0297 4985 1

BFM 1013E

BFM 1012E BFM 1013E

ENGLISCH Kapitel 5 Seite 5

0297 4987 1

Routine Maintenance 5
Hours. Date Signaure / Stamp Hours

5.3 Completed Maintenance Jobs

Date Signaure / Stamp

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.

250 500 750 1000 1250 1500 1750 2000 2250 2500 2750

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

5.3 Completed Maintenance Jobs

Hours Date Signaure / Stamp Hours Date

Routine Maintenance
Signaure / Stamp

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

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

Routine Maintenance 5
Hours. Date Signaure / Stamp Hours

5.3 Completed Maintenance Jobs

Date Signaure / Stamp

5875 6125 6375 6625 6875 7125 7375 7625 7825 8125 8375 8625
The maintenance jobs duly completed can be recorded in the above table.

6000 6250 6500 6750 7000 7250 7500 7750 8000 8250 8500 8750

Quelle:50 /MUS_Kap_5.3 en/W12# BA Seite

Hours

Date

Signaure / Stamp

Hours

Date

Signaure / Stamp

8875 9125 9375 9625 9875 10125 10375 10625 10825 11125 11375 11625
The maintenance jobs duly completed can be recorded in the above table.

9000 9250 9500 9750 10000 10250 10500 10750 11000 11250 11500 11750

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

Hours.

Date

Signaure / Stamp

Hours

Date

Signaure / Stamp

Quelle:52 /MUS_Kap_5.3 en/W12# BA Seite

Service and Maintenance 6

6.1 Lubrication System 6.2 Fuel System 6.3 Cooling System 6.4 Combustion Air Cleaner 6.5 Belt Drives 6.6 Adjustments 6.7 Accessories

ENGLISCH Kapitel 6 Seite 1

Service and Maintenance 6

6.1.1 Oil Change Intervals

6.1 Lubrication System

q The oil change intervals are dependent on the engine application and the quality of the lube oil. q If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year. q 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 q 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 oil changes should be halved. q In the case of fuels containing more than 1 % sulfur, contact your service representative.

Oil Grade API Classification

Turbocharged engine CF-4 CG-4 CH-4 E1 E3/96 + E4-98

ACEA Classification

Oil Change Intervals Equipment Engines Automotive Engines

Service Group I II III

Average Speed [km] 25 40 60

[OH] 500

[km] 10 000 20 000 30 000

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

ENGLISCH Kapitel 6 Seite 2

6.1 Lubrication System

6.1.2 6.1.2.1 Checking Oil Level / Changing Engine Oil Checking Oil Level

Service and Maintenance 6

6.1.2.2 Changing Engine Oil

25 729 0

26 022 0

26 023 0

q Ensure that the engine or vehicle is on a level surface. q Warm engine q Switch off engine, wait 5 minutes and check the oil level q Cold engine Check the oil level q Remove the dipstick q Wipe off with a non-fibrous, clean cloth. q Insert up to the stop and pull out again. q 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.

q Run the engine warm q Ensure that the engine or vehicle is on a level surface Lube oil temperature approx. 80C. q Switch off the engine.

q Place an oil tray beneath the engine q Unscrew drain plug. q Drain oil. q Fit oil drain plug with new gasket and tighten firmly (for torque, see 9.2). q Fill with lube oil For grade/viscosity, see 4.1. For quantity, see 9.1. q Check oil level, see 6.1.2.1

Be careful when draining hot oil - danger of scalds! Do not let used oil run into the soil but catch it in a container ready for proper disposal.

ENGLISCH Kapitel 6 Seite 3

Service and Maintenance 6

6.1.3 Changing Oil Filter

6.1 Lubrication System

25880 0

25881 0

25882 0

q With fitted torsion lock: Loosen screws and slide clamps downwards. q Undo the filter cartridge with commercial tool and spin off. q Catch any dripping oil.

q Clean any dirt from the filter carrier rim. q Lightly oil the rubber gasket of the new oil filter cartridge. q Screw in the new cartridge finger tight against the gasket.

q Check that the cartridge is correctly seated against the gasket and tighten with a final halfturn. q If a torsion lock is fitted: Slide clamps up into position and tighten screws. q Check oil level (see 6.1.2). q Check oil pressure (see 3.3.1).

Beware of burns from hot oil.

!
ENGLISCH Kapitel 6 Seite 4

q Check cartridge seal.

6.1 Lubrication System

6.1.4 Cleaning/Changing Oil filter (Cup)

Service and Maintenance 6

1 2 3 4
300 74 0

q Switch off the engine. q Loosen the lube oil filter cap 1 and unscrew in an anticlockwise direction. q Carefully lift the paper filter cartridge 3 out of guide 4. q Catch any dripping oil. q Change the paper filter cartridge 3. q Clean any dirt from the filter carrier rim and the lube oil filter cover 1 and guide 4. q Replace rubber seal 2 and apply a small amount of grease

q Carefully insert the new paper filter cartridge 3 in guide 4. q Tighten lube oil filter cover 1 in the clockwise direction (25 Nm). q Start the engine. q Check the oil level, see 6.1.2. q Check the oil pressure, see 3.3.1. q Check lube oil filter fitting for leaks.

Caution: hot oil! Risk of scalding!

ENGLISCH Kapitel 6 Seite 5

Service and Maintenance 6

6.2.1 Changing Fuel Filter

6.2 Fuel System

25880 0

25881 0

25882 0

q Close fuel stopcock. q Undo fuel filter cartridge with commercial tool and spin off. q Catch any fuel.

q Clean any dirt from the filter carrier rim. q Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge. q Screw in the new cartridge finger tight against the gasket.

q Check that the cartridge is seated correctly against the gasket and tighten with a final halfturn. q Open fuel stopcock. q Check for leaks.

Keep naked flames away when working on the fuel system. Do not smoke!

The fuel system does not need to be bled.

ENGLISCH Kapitel 6 Seite 6

6.2 Fuel System

6.2.2 Cleaning/Changing Fuel Pre-Filter Element

Service and Maintenance

6.2.3 Venting the Fuel System with Preliminary Fuel Filter Bleeding:

8 7 6 5

1 2 3 4
25 801 0 30 084 0

q Place the fuel pan beneath the preliminary fuel filter. q Loosen drain plug 4 and observe the draining fluid. When fuel instead of water starts to flow, retighten drain plug 4. q Check for leaks after the engine has been started.

Venting:
q During initial commissioning, after maintenance work or if the tank is run empty it is essential to vent the fuel system. q Set engine controller to stop position q Place fuel collecting trough under the filter housing (5) / pressure control valve (9). q Open fuel stopcock, pressure control valve (9), vent screw (8) q Turn engine with starter (max. 20 sec.) until fuel with no air bubbles escapes from vent screw (8) and pressure holding valve (9). q Tighten vent screw 8 (tightening torque 15 Nm) and pressure control valve 9. q Set engine controller to start position and start q When the engine has started check for leaks

Cleaning:
q Close fuel stopcock. q Place the fuel pan beneath the preliminary fuel filter. q Remove drain plug 4 and drain off fuel. q Unscrew clamping screw 1, remove filter housing 5 with filter insert 3. q Clean sealing surface of the filter bracket 7 and filter insert housing 5 of any dirt. q Insert new sealing ring 6 and filter insert 3 (change as necessary). Push the filter insert up to approx. 3 cm over the edge of the housing onto the guide in the filter housing 5.

q Press filter housing 5 with filter insert 3 and sealing ring 6 against the filter console 7 and screw into place with clamping screw 1 (tightening torque 25 Nm). Note: it must be possible to push the upper seal 2 on filter insert 3 over the guide bracket on filter console 7. q Tighten drain plug 4. q Open fuel stopcock. q Check for leaks after the engine has been started.

Changing:
q Replace defective filter insert 3.

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

ENGLISCH Kapitel 6 Seite 7

Service and Maintenance 6

6.2.4 Changing Fuel Leakage Line 6.2.5 Changing Fuel Leakage Pipes

6.2 Fuel System

30 084 0

30 034 0

q Set engine controller to stop position q Open fuel stopcock q Loosen pressure holding valve (9) Catch any fuel which escapes and dispose of in an environmentally-friendly way q Turn engine with starter (max. 20 sec.) until fuel with no air bubbles escapes from pressure holding valve (9). q Tighten up pressure holding valve (9). q Set engine controller to start position and start q When the engine has started check for leaks

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

q Close fuel stopcock q Dismantle valve cap cover q Remove rubber hoses (3) from the injection valves q Dismantle rubber hoses (1), (3) and (4) and connection piece (2) and dispose of in an environmentally-friendly way q Fit new rubber hoses (1), (3) and (4) and connection piece (2) q Connect rubber hoses (3) to injection valves q Remount valve cap cover q Open fuel stopcock q When the engine has started check for leaks

ENGLISCH Kapitel 6 Seite 8

6.3 Cooling System

6.3.1 Cleaning Intervals 6.3.2 Cleaning Cooling System

Service and Maintenance 6

Cold Cleansing Agent Spray the heat exchanger with a commercial cold cleansing agent and let stand for about 10 minutes. First spray clean with a water jet from position 3 then from position 1 (do not spray sensitive engine components directly with a water jet, eg generator, cables, electronic components, fan drive). Cleaning with steam or with hot water Remove oil and grease residues with the jet set at a gentle setting. q Refit service flap. q Run the engine up to normal operating temperature to evaporate any remaining water.

q The amount of contamination in the cooling system depends on the engine application. q Spilled oil or fuel on the engine increases the risk of contamination. Be especially careful if the engine is used in dusty environments. q 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 chopped straw in the vicinity of the machine. q Because applications vary, cleaning intervals have to be determined from case to case. The cleaning intervals given in the table below can be used as a guide. Checking / Cleaning Intervals Suggested OH Application 2000 1000 500 250 Ships, gensets in enclosed spaces, pumps Vehicles on paved roads Tractors, forklift trucks, mobile gensets Vehicles on construction sites and unpaved roads, construction equipment, compressors,underground mining equipment Agricultural machinery, harvester tractors

26252 0

Series 1012/1013 q Place a cleaning bath under the heat exchanger (it. 2). q 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.

Series 1012E/1013E q If an external cooling system is fitted, follow the manufacturers instructions. Unit engine q Clean as described under series 1012/1013. The cleaning jet must be positioned parallel to the cooling-air ducts.

125

Hose pressure: max. 100 bar

ENGLISCH Kapitel 6 Seite 9

Service and Maintenance 6

6.3.3 Draining Cooling System 1012 / 1013

6.3 Cooling System

6.3.4 Filling / Venting Cooling System 1012 / 1013

2 1 4
ca. 5 m

2 1 4

3
30 082 0

ca. 10 mm

3
26260 2

q Place container under drain plug 3. q Unscrew cap 1. q Unscrew drain plug 3 fully. q Drain coolant. q Drain the remaining fluid from the engine oil cooler (coolant duct). q 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

Be careful when draining hot coolant danger of scalds! Collect drained coolant and dispose of according to environmental regulat-ions.

If a heater is connected to the cooling system, all heater valves must be opened during filling. Depending on the water content and the installation position of the heater, it may be required to repeat the last point several times to vent the heater system.

q Unscrew cap 1 q Loosen sealing plug 2 q Unscrew vent plug 4. q Unscrew sealing plug 3 (10 mm) up to the first notch. q Add coolant up to the max. marking or fill-up limit (heater valve if fitted of the unit must be opened). q Tighten sealing plug 2 (tightening torque 18 Nm) q Tighten vent plug 4 (tightening torque 40 Nm) q Tighten sealing plug 3. q Close cap 1. q Start engine and warm up until thermostat opens. q Switch off engine. q Check coolant level (see section 3.3.3) and top up as required.

ENGLISCH Kapitel 6 Seite 10

6.3 Cooling System

6.3.5 Draining the Cooling System 1012 E / 1013 E 6.3.6 Filling/Venting the Cooling System 1012 E/1013 E Standard engine

Service and Maintenance 6

Venting q The cooling systems, which are built in line with our installation guidelines, are vented automatically after they have been filled. q With external cooling systems in accordance with the specifications of the manufacturer.

26 341 0

BFM 1012E BFM 1013E

q Place a container under sealing plug 1. q Remove sealing plug 1 from the crankcase. q Drain off the coolant. q Tighten sealing plug 1 again. q If sealing plug 1 is not accessible, the system can be drained at the engine oil cooler (coolant duct). Filling/venting the cooling system: See section 6.3.6. Be careful when draining hot coolant danger of scalds! Collect drained coolant and dispose of according to environmental regulat-ions.

q Open radiator cap position 1. q Loosen vent plug position 2. q Add coolant up to the maximum marking or filler limit (heater valve of the system must be opened if fitted). q Tighten vent plug position 2 + sealing plug position 3. q Close radiator cap position 1. q Start engine and warm up until thermostat opens. q Switch off engine. q Check coolant level when the engine is cold and top up as required. q Close the radiator sealing plug position 1.

0297 4987 1

ENGLISCH Kapitel 6 Seite 11

Service and Maintenance 6

1013 E Short engine
Venting q The cooling systems, which are built in line with our installation guidelines, are vented automatically after they have been filled. q With external cooling systems in accordance with the specifications of the manufacturer. q Start the engine and warm up until the thermostat opens.

6.3 Cooling System

6.3.7 Draining the Cooling System Unit Engine (4 Cylinders)

0297 4985 1

2
30 299 0

BFM 1013E

q Loosen vent plug position 2 and sealing plug position 3. q Add coolant up to the maximum marking or filler limit (heater valve of the system must be opened if fitted). q Tighten vent plug position 2 + sealing plug position 3. q Close radiator cap position 1. q Start engine and warm up until thermostat opens. q Switch off engine. q Check coolant level when the engine is cold and top up as required. q Close the radiator sealing plug position 1.

q Open the cap 1 of the expansion tank. q Place a container beneath knurled screw 2. q Unscrew the knurled screw 2 in an anticlockwise direction until coolant is emitted. q Drain off coolant. q In case of clogging, rinse the radiator through with clear water. q Tighten knurled screw 2. Filling/venting the cooling system: see section 6.3.8

ENGLISCH Kapitel 6 Seite 12

6.3 Cooling System

6.3.8 Filling/Venting the Cooling System Unit Engine

Service and Maintenance

6.3.9 Draining the Charge-Air Cooler

Unit engine (6 cylinders)

2
30 277 0

2
30 277 0

1
30 191 0

q Open the cap 1 of the expansion tank. q Place a container beneath sealing plug 2. q Unscrew the sealing plug 2. q Drain off coolant. q In case of clogging, rinse the radiator through with clear water. q Tighten sealing plug 2. Filling/venting the cooling system: see section 6.3.8

Be careful when draining hot coolant - danger of scalds! Collect drained coolant and dispose of according to environmental regulations.

q Open the cap 1 of the expansion tank. q Slowly add coolant up to the max. marking or filler limit. q Close the cap. q Start the engine and warm up until the thermostat opens, the upper coolant line warms up tangibly. q Briefly run the engine at nominal output (fixed setting), this rinses out any pockets. q Switch off the engine and leave to cool down. q Open cap 1, add coolant up to the max. marking or filler limit and close the cap 1. q 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 coolant is added. Depending on the coolant contents and the installation location of the heater, it may be necessary to repeat the procedure several times.

q Loosen the drain plug 1 on the end of the charge-air cooler. q Drain off any oil residues that may be remaining. q Close the drain plug 1.

ENGLISCH Kapitel 6 Seite 13

Service and Maintenance 6

6.4.1 Cleaning Intervals

6.4 Combustion Air Cleaner

q The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner. q Cleaning intervals will have to be determined from case to case. q If a dry type air cleaner is used, clean when indicated by the service indicator or switch. q Air cleaner servicing is needed when: Service Indicator the red signal 1 is fully visible when the engine is off. Service Switch the yellow pilot light comes on when the engine is running. q After carrying out service work, reset the signal by pressing the button on the service indicator.

25885 1

ENGLISCH Kapitel 6 Seite 14

6.4 Combustion Air Cleaner

6.4.2 Emptying Cyclone Type Precleaner

Service and Maintenance

6.4.3 Cleaning Oil Bath Air Cleaner

25886 0

25887 0

q Undo wing nut 1 and remove cover 2. q Remove collector bowl 3 from lower section 4 and empty. Clean leaves, straw and other foreign matter from lower section of precleaner. q Reposition collector bowl 3 onto lower section 4, fasten cover 2 in place by tightening wing nut 1.

q Turn engine off and wait about 10 minutes for the oil to drain from filter housing 1. q Release snap clips 2 and remove oil cup 3 together with filter element 4. If necessary prize element out with a screwdriver, taking care not to damage the rubber gasket 5. q Remove dirty oil and sludge. Clean oil cup. q Clean filter element 4 in diesel fuel and allow to drip-dry.

q Clean filter housing 1 if very dirty. q Inspect and replace rubber gaskets 5 and 6 if necessary. q Fill oil cup with engine oil up to the mark (arrow) (for viscosity, see 4.1.2). q Refit oil cup and element to filter housing and secure with snap clips. Never clean air cleaner with gasoline. Dispose of old oil in accordance with environmental regulations.

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

ENGLISCH Kapitel 6 Seite 15

Service and Maintenance 6

6.4.4 Dry Type Air Cleaner Dust Discharge Valve Filter Cartridge

6.4 Combustion Air Cleaner

25888 1

25889 0

q Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows. q Clean discharge slot from time to time. q Remove any caked dirt by pressing together the upper section of the valve.

q Undo clip fasteners 1. q Take off hood 2 and remove cartridge 3. q Clean cartridge (replace at least once a year). q Clean cartridge 3: Blow out from inside out with dry compressed air (max. 5 bar), or in difficult cases, tap out, taking care not to damage the cartridge, or wash according to manufacturers instructions. q Check paper filter (light showing through) and gaskets for damage. Replace if necessary.

q After five air cleaner services or after two years at the latest, replace safety cartridge 4 (never clean). To do so: Undo hex. nut 5 and remove cartridge 4. Install new cartridge, insert and tighten hex. nut. q Install cartridge 3, replace hood 2 and do up clip fasteners. Never clean filter cartridge with gasoline or hot fluids.

ENGLISCH Kapitel 6 Seite 16

6.5 Belt Drives

6.5.1 Checking V-Belts 1012 1013

Service and Maintenance 6

26 255 0

26 315 0

26 261 1

q Inspect entire V-belt for damage. q Replace damaged V-belts. q After installing new belts, run engine for 15 minutes, then check belt tension. q Use a V-belt tension gauge (see 9.3) to check belt tension. Place indicator arm 1 into gauge. Position gauge on V-belt 2, midway between the pulleys, with flange 3 on bottom of gauge against the edge of belt. Push slowly on the black pad 4 at right angles to belt 2 until the spring is heard or felt to trigger.

q Carefully remove the gauge without altering the position of the indicator arm. Read off the value: Turn the gauge sideways to see the exact spot where the top of the black indicator arm 1 intersects scale 5 (arrow). For settings, see 9.1. If necessary, retension belt and measure again.

Check, tension and change belts only with the engine off. Refit belt guard, if provided.

ENGLISCH Kapitel 6 Seite 17

Service and Maintenance 6

6.5.2 Tensioning Fan / Alternator Belts 1012 6.5.3 Changing Fan / Alternator Belts 1012

6.5 Belt Drives

6.5.4 Tensioning Coolant / Fuel Pump Belts 1012

1 4

1 4

A 2 B 3
26 449 0

A 2 B 3
26 449 0

A
26 450 0

q Slacken off bolts 1, 2 and 3. q Press alternator 5 in direction of arrow A until correct belt tension is achieved. q Re-tighten bolts 1, 2 and 3.

q Slacken off bolts 1, 2 and 3. q Press alternator in direction of arrow B. q Remove and replace belt.

q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction of arrow (A) until correct belt tension is achieved. q Re-tighten bolts 1 and 2.

q Tension belt in accordance with 6.5.3. q Re-tighten bolts 1, 2 and 3.

Check, tension and change belts only with the engine off. Refit belt guard, if provided.

ENGLISCH Kapitel 6 Seite 18

6.5 Belt Drives

6.5.5 Changing Coolant / Fuel Pump Belts 1012 6.5.6 Tensioning Coolant / Fuel Pump Belts 1012 E

Service and Maintenance

6.5.7 Changing Coolant / Fuel Pump Belts 1012 E

A
26 450 0 26 254 0 26 267 0

q Remove fan belt as described in 6.5.3. q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction of arrow (B). q Remove and replace belt. q Push fuel pump in direction of arrow (A) until correct belt tension is achieved. q Tighten bolts 1 and 2. q Reinstall fan belt and tension as described in 6.5.2.

q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction of arrow until correct belt tension is achieved. q Tighten bolts 1 and 2.

q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction of arrow. q Remove and replace belt. q Push fuel pump in opposite direction of arrow until correct belt tension is achieved. q Tighten bolts 1 and 2.

Check, tension and change belts only with the engine off. Refit belt guard, if provided.

ENGLISCH Kapitel 6 Seite 19

Service and Maintenance 6

6.5.8 Tensioning Alternator Belt 1012 E 6.5.9 Changing Alternator Belt 1012 E

6.5 Belt Drives

26 250 0

26 251 0

q Slacken off bolts 1, 2 and 4. q Move alternator 5 in direction of arrow by turning bolt 3 until correct belt tension is achieved. q Tighten bolts 1, 2 and 4.

q Remove fuel pump belt as described in 6.5.7. q Slacken off bolts 1, 2 and 4. q Adjust bolt 3 until the V-belt can be removed. q Fit new belt. q Adjust bolt 3 until the correct belt tension is achieved.

Check, tension and change belts only with the engine off. Refit belt guard, if provided.

q Tighten bolts 1, 2 and 4. q Reinstall fuel pump belt and tension as described in 6.5.6.

ENGLISCH Kapitel 6 Seite 20

6.5 Belt Drives

6.5.10 Tensioning / Changing Fan Belt 1013 6.5.11 Tensioning Coolant / Fuel Pump belts 1013

Service and Maintenance

6.5.12 Changing Coolant / Fuel Pump Belts 1013

3
26 345 0

A
26 450 0

A
26 450 0

q Slacken off bolts 1 and 2. Tensioning: Insert square wrench in square and pull in direction of arrow until correct belt tension is achieved. Changing: Insert square wrench in square and loosen in opposite direction of arrow. Tension new belt as described above. q Tighten bolts 1 and 2.

q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction (A) of arrow until correct belt tension is achieved. q Tighten bolts 1 and 2.

q Remove fan / alternator belt as described in 6.5.10 and 6.5.13. q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction (B) of arrow. q Remove and replace belt. q Push fuel pump in direction (A) of arrow until correct belt tension is achieved.

Check, tension and change belts only with the engine off. Refit belt guard, if provided.

q Tighten bolts 1 and 2. q Reinstall fan / alternator belt and retension as described in 6.5.10 and 6.5.13.

ENGLISCH Kapitel 6 Seite 21

Service and Maintenance 6

6.5.13 Tensioning /Changing Alternator Belt 1013 6.5.14 Tensioning Coolant /Fuel Pump Belts 1013 E

6.5 Belt Drives

6.5.15 Changing Coolant / Fuel Pump Belts 1013 E

1 4

A 2 B 3
26 449 0 26 380 0 26 383 0

Tensioning: q Slacken off bolts 1, 2 and 3. q Move alternator 5 in direction of arrow (A) until correct belt tension is achieved. q Re-tighten bolts 1, 2 and 3. Changing: q Slacken off bolts 1, 2 and 3. q Move alternator 5 in direction of arrow (B) until belt is exposed. q Remove and replace belt, tension (see above). q Re-tighten bolts 1, 2 and 3.

q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction of arrow until correct belt tension is achieved. q Tighten bolts 1 and 2.

q Slacken off bolts 1 and 2. q Push fuel pump 3 in direction of arrow. q Remove and replace belt. q Push fuel pump 3 in opposite direction of arrow until correct belt tension is achieved. q Tighten bolts 1 and 2. Check, tension and change belts only with the engine off. Refit belt guard, if provided.

!
ENGLISCH Kapitel 6 Seite 22

6.5 Belt Drives

6.5.16 Tensioning / Changing Compressor Belt

Service and Maintenance 6

24598 1

24599 1

q Remove hex. bolts 1. q Take off outer half-pulley 2. q Replace belt if necessary.

q To retension belt, remove one or more shims 3 as may be required from inside. Place removed shim(s) outside on removed halfpulley 2. q Turn engine over while tightening bolts 1 to prevent belt being pinched.

Check, tension and change belts only with the engine off. Refit guard, if provided.

ENGLISCH Kapitel 6 Seite 23

Service and Maintenance 6

6.6.1 Checking / Adjusting Valve Clearances

6.6 Adjustments

19691 2

26262 1

q Slacken off breather valve and swing to one side. q Remove rocker cover. q Position crankshaft as per schematic 6.6.1.1 q Before adjusting valve clearance, allow engine to cool down for at least 30 minutes. The oil temperature should be below 80 C / 176 F. q Check valve clearance between rocker arm / tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1.

q Adjust valve clearance if necessary: Release locknut 4. Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened. q Check and adjust valve clearance on all remaining cylinders. q Replace rocker cover (use new gasket if needed). q Swing breather valve back into position and secure.

ENGLISCH Kapitel 6 Seite 24

6.6 Adjustments
6.6.1.1 Valve Clearance Adjustment Schematic

Service and Maintenance 6

q Crankshaft Position 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been done.

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

26 263 2

ENGLISCH Kapitel 6 Seite 25

Service and Maintenance 6

6.7.1 Battery 6.7.1.1 Checking Battery and Cable Connectors 6.7.1.2 Checking Electrolyte Level

6.7 Accessories

6.7.1.3 Checking Specific Gravity of Electrolyte

25895 0

24232 3

25896 0

q Keep battery clean and dry. q Undo dirty clamps. q Clean terminal posts (+ and ) and clamps of the battery, and grease with acid-free and acidresistant grease. q When reassembling, ensure that clamps make good contact. Do up clamp bolts finger tight.

q Remove caps 1. q If testers 2 are used, the electrolyte should come up to their base. q If testers are not used, the electrolyte level should be 10-15 mm above the top of the plates. q If necessary, top up with distilled water. q Replace caps.

q Measure the specific gravity of individual cells with a commercial hydrometer. The hydrometer reading (see table on following page) indicates the state of charge. During measurement, the temperature of the electrolyte should preferably be 20C / 68F.

ENGLISCH Kapitel 6 Seite 26

6.7 Accessories

Service and Maintenance 6

Specific Gravity

in [kg/l] Normal 1.28 1.20 1.12 Tropics 1.23 1.12 1.08

in B [Baum]* Normal 32 24 16 Tropics 27 16 11

State of Charge

Fully charged Half charged, recharge Discharged, recharge immediately

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

The gases emitted by the battery are explosive. Keep sparks and naked flames away from the battery. Do not allow battery acid to come into contact with skin or clothing. Wear protective goggles. Do not rest tools on the battery.

ENGLISCH Kapitel 6 Seite 27

Service and Maintenance 6

6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

6.7 Accessories

Notes on the three-phase system: q Never disconnect the cables between battery, alternator and regulator while the engine is running. q If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting. q Be sure not to confuse the battery terminals. q Replace defective bulb of the charge pilot lamp immediately. q Cleaning the engine: Do not spray water/steam directly onto the alternator. Run the engine up to normal operating temperature to evaporate any remaining water. q The habit of touching a lead against the frame to check whether it is live must under no circumstances be used with three-phase electrical systems. q In the case of electric welding, connect the ground terminal on the welder directly to the piece being welded. Use only the correct lifting tackle.
26264 0 26265 0

q Always use proper lifting transporting the engine.

tackle

when

!
ENGLISCH Kapitel 6 Seite 28

7.1 Diagnosis Chart

Troubleshooting 7
7.1 Diagnosis Chart

ENGLISCH Kapitel 7 Seite 1

Troubleshooting 7
q If engine problems occur, they frequently have their cause in improper operation or engine maintenance. q If problems do occur, always check first that the operating and maintenance instructions have been followed. q A diagnosis chart is given on the facing page. q If you cannot identify the cause of the problem or are unable to rectify it yourself, please contact DEUTZ Service.

7.1 Diagnosis Chart

Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. Important: When carrying out repair work, never start the engine with speed governor removed. Disconnect battery.

ENGLISCH Kapitel 7 Seite 2

7.1 Diagnosis Chart

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 Cause Not declutched (where possible) q Below starting limit temperature q q q q Engine shutdown lever in stop position (faulty solenoid) Oil level too low q q Oil level too high q q q q q q q Excessive inclination of engine Speed control lever set to middle position q q q q Dirty air cleaner/Faulty turbocharger q q q Air cleaner service switch/indicator defective q q LDA* defective (leaking line) q q q Charge air line leaking q Coolant pump defective q q Charge air cooler contaminated Coolant heat exchanger dirty q q q q q q Cooling fan defective, split or loose V-belt (belt-driven fuel pump) Cooling air temperature rise/ hot air recirculation q q Battery defective or discharged q *LDA = Aneroid device

Troubleshooting
Remedy Check Adjust Replace Clean Top up Lower level P E W R A S

Section Operation

Combustion air

Cooling system

Electrics

P P P A S P/E P/E P/W P P P/W P/R P/R P/R P/W P P

Table 1 of 2

ENGLISCH Kapitel 7 Seite 3

Troubleshooting 7

7.1 Diagnosis Chart

Remedy Check Adjust Replace Clean Top up Lower level

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 Cause Electrics cable connections to starter, electrical system loose or oxidized q Starter defective or pinion does not engage q q q q q q Incorrect valve clearance Leaking injection line q q q q Vent pipe blocked (coolant heat exchanger) q Glow plugs defective q q q q q q q q q Injector defective Air in fuel system q q q q Fuel filter/prefilter dirty q q q q Oil filter defective q Incorrect lube oil SAE class or quality q q q Fuel quality not as per Operation Manual q q q q Coolant level too low q

P E W R A S

P P Engine E P P/R P P/W P/W P/ R /W W Operating media W P/ W P/ A Table 2 of 2

Section Electrics

ENGLISCH Kapitel 7 Seite 4

8.1 Preservation

Engine Preservation 8
8.1 Preservation

ENGLISCH Kapitel 8 Seite 1

Engine Preservation 8
8.1 Preservation

8.1 Preservation

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rust formation. The preservative measures described here will protect the engine for up to 6 months. The procedure will have to be reversed before the engine is recommissioned. q Anti-corrosion oils to specification: MIL-L-21260B TL 9150-037/2 NATO code C 640/642 q Recommended cleansing agent to remove preservatives when recommissioning engine: Petroleum benzine (hazardous materials class A3) Preserving Engine: q Clean engine (with cold cleansing agent if preferred). See 6.3.2. q Run engine until warm, then turn off. q Drain engine oil (see 6.1.2) and fill with anticorrosion oil. q Drain coolant (see 6.3.3/6.3.5). q Fill with anti-corrosion agent (see 4.3.3). q If necessary, clean oil bath air cleaner (see 6.4.3) and fill with anti-corrosion oil. q Drain fuel tank. q Make up a mixture of 90% diesel fuel and 10% anti-corrosion oil, and refill fuel tank. q Run engine for about 10 minutes. q Turn engine off. q Turn engine over manually several times. If using starter, set shutdown lever to stop position. q Remove V-belts 1 and store in wrapped condition. q Spray grooves of V-belt pulleys 2 with anticorrosion agent. q Close off intake ports 3 and exhaust ports 4. q Lightly grease and replace coolant filler 5. q Drain anti-corrosion agent (see 6.3.3 / 6.3.5). q Start engine. Removing Engine Preservatives: q Remove anti-corrosion agent from grooves in V-belt pulleys 2. q Install V-belts 1. Retension after brief operation is necessary (see 6.5). q Remove covers from intake port 3 and exhaust port 4. q Fill with coolant (see 6.3.4 / 6.3.5).

26 268 1

ENGLISCH Kapitel 8 Seite 2

Technical Specifications 9
9.1 Engine Specifications and Settings 9.2 Torque Wrench Settings 9.3 Tools

ENGLISCH Kapitel 9 Seite 1

7380en_k09_pdf 1 04.10.1999, 12:01 Uhr

Technical Specifications 9
Model

9.1 Engine Specifications and Settings

BF4M 1012 BF4M 1012 C BF6M 1012 BF6M 1012 C BF4M 1012 E BF4M 1012 EC BF6M 1012 E BF6M 1012 EC 4 4 6 6 vertical, in line 94 115 3192 3192 4788 4788 17.5 4-stroke diesel with turbocharging and direct injection w/o w/ w/o w/ counter-clockwise [kg approx.] contact company headquarters [kg approx.] 330 332 435 437

Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle/Combustion system Charge air cooler Direction of rotation Weight 1012 / C incl. cooling system Weight 1012 E / EC w/o cooling system as per DIN 70020-A Engine power Speed Valve clearance with cold engine Injector opening pressure Start of delivery Firing order of engine V-belt tension: Generator fan Fuel pump - coolant pump Compressor
1) 2)

[mm] [mm] [cm3] [].

[kW] 1). [rpm] 1). [mm] Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. [bar] 250/275 [crank angle bTDC] 1). 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4 Pre-tension / re-tension 2). [N] 450 / 300 50. [N] 450 / 300 50. [N] 550 / 450 50.

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1 Retension 15 minutes after the engine has been driven under load

ENGLISCH Kapitel 9 Seite 2

7380en_k09_pdf 2 04.10.1999, 12:01 Uhr

9.1 Engine Specifications and Settings

Model BFM1012 / E Cooling system Coolant quantity 1012/C [litres approx.] 1012 E/EC 5) [litres approx.] 1012 unit engine (with frontal radiator) [litres approx.] Permissible continuous coolant temperature Engine outlet, with performance group I [C] Engine outlet, with performance group II-IV [C] Thermostat initial opening at Thermostat full open temperature Coolant prewarming Coolant pump Delivery pressure in Delivery rate in Power consumption in Lubrication

Technical Specifications 9

BF4M 1012 BF4M 1012 C BF6M 1012 BF6M 1012 C BF4M 1012 E BF4M 1012 EC BF6M 1012 E BF6M 1012 EC Liquid-cooled/Cooling system protection 9.3 10.0 12.2 13.6 5.6 5.6 7.3 7.3 15.9 18.1 max.110 6) . max.105 6) .

[C] 83 7) . [C] 95 8) . (4 . [bar] [m3 /h] [kW]

9) 9)

. . 9) .

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
3) 4)

[litres approx.] 10.0 3) . 10.0 3). 14.0 3). 14.0 3).

Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum. 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 87C 8) 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)

ENGLISCH Kapitel 9 Seite 3

7380en_k09_pdf 3 04.10.1999, 12:01 Uhr

Technical Specifications 9
Model

9.1 Engine Specifications and Settings

Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle/Combustion system Charge air cooler Direction of rotation

[mm] [mm] [cm3] [].

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 4 4 6 6 6 vertical, in line 108 130 4764 4764 7146 7146 7146 17.5 4-stroke diesel with turbocharging and direct injection w/o w/ w/o w/ w/ counter-clockwise

Weight 1013 / CP incl. cooling system [kg approx.] contact company headquarters Weight 1013 E / EC / ECP w/o cooling system as per DIN 70020-A [kg approx.] 455 455 600 600 600 Engine power [kW] Speed [rpm] Valve clearance with cold engine [mm] Injector opening pressure [bar] Start of delivery [crank angle bTDC] Firing order of engine V-belt tension: Generator fan Fuel pump - coolant pump Compressor
1) 2)

1). 1). Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. 250/275 1). 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 Pre-tension / re-tension 2).

[N] 450 / 300 50. [N] 450 / 300 50. [N] 550 / 375 50.

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1 Retension 15 minutes after the engine has been driven under load

ENGLISCH Kapitel 9 Seite 4

7380en_k09_pdf 4 04.10.1999, 12:01 Uhr

9.1 Engine Specifications and Settings

Model 1013 /E Cooling system Coolant quantity 1013 / C / CP [litres approx.] 1013 E / EC / ECP 5) [litres approx.] 1013 unit engine (with frontal radiator) [litres approx.] Permissible continuous coolant temperature Engine outlet, with performance group I [C] Engine outlet, with performance group II-IV [C] Thermostat initial opening at Thermostat full open temperature Coolant prewarming Coolant pump Delivery pressure in Delivery rate in Power consumption in Lubrication

Technical Specifications 9

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 Liquid-cooled/Cooling system protection 12.1 13.6 15 16.3 16.9 7.2 7.2 9.8 9.8 9.8 17.5 19.7 22 23.7 23.7 max.110 6) . max.105 6) .

[C] 83 7) . [C] 95 8) . (4 . [bar] [m3 /h] [kW]

9) 9)

. . 9) .

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
3) 4)

[litres approx.] 14.0 3) . 14.0 3) . 21.0 3) . 21.0 3).

21.0 3).

Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum. 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 87C 8) 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)

ENGLISCH Kapitel 9 Seite 5

7380en_k09_pdf 5 04.10.1999, 12:01 Uhr

Technical Specifications 9
Model Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle/Combustion system Charge air cooler Direction of rotation

9.1 Engine Specifications and Settings

BF4M 1013 FC BF6M 1013 FC 4 6 vertical, in line 108 130 4764 7146 17.6 4-stroke diesel with turbocharging and direct injection with counter-clockwise

[mm] [mm] [cm3] [].

Weight 1013 FC without cooling system contact company headquarters as per DIN 70020-A [kg approx.] 455 600 Engine power [kW] Speed [rpm] Valve clearance with cold engine [mm] Injector opening pressure [bar] Start of delivery [crank angle bTDC] Firing order of engine V-belt tension: Generator fan Fuel pump - coolant pump Compressor
1) 2)

1). 1). Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. 275 1). 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 Pre-tension / re-tension 2).

[N] 550 / 300 50. [N] 550 / 300 50. [N] 650 / 400 50.

Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1 Retension 15 minutes after the engine has been driven under load

ENGLISCH Kapitel 9 Seite 6

7380en_k09_pdf 6 04.10.1999, 12:01 Uhr

9.1 Engine Specifications and Settings

Model 1013 FC Cooling system Coolant quantity 1013 FC 5) [litres approx.] Permissible continuous coolant temperature Engine outlet, with performance group I [C] Engine outlet, with performance group II-IV [C] Thermostat initial opening at [C] Thermostat full open temperature [C] Coolant prewarming Coolant pump Delivery pressure in [bar] Delivery rate in [m3 /h] Power consumption in [kW] Lubrication

Technical Specifications 9

BF4M 1013 FC BF6M 1013 FC Liquid-cooled/Cooling system protection 7.2 9.8

with flap turbocharger max.110 6) ./ with feast turbocharger max.105 6) . max.105 6). 87 . 102 . (4 .
7) 7)

. . 7) .

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.] 16 3) . 28 3) . Oil capacity (first fill-up) with filter
3)

[litres approx.] 17 3) . 29 3).

Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum.

4) 5) 6)

Only during winter (see 3.5.1) Only engine capacity without radiator. Capacity of external cooling system dependent on cooling system design. Other performance groups have different values. Please contact company headquarters. 7) Please contact company headquarters (varies depending on engine design)

ENGLISCH Kapitel 9 Seite 7

7380en_k09_pdf 7 04.10.1999, 12:01 Uhr

Technical Specifications 9
Location Stage 1 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) Stage 2 Stage 3 Stage 1 Stage 2 Preload [Nm] Torquing Load [Nm]

9.2 Torque Wrench Settings

Total [Nm] Stage 3 Stage 4 8,5 21 187 187 8,5 21 50 16 30 29 21

Remarks

M16x40 8.8 A4C M16x40 8.8 A4C

Torx M14x 1.5

ENGLISCH Kapitel 9 Seite 8

7380en_k09_pdf 8 04.10.1999, 12:01 Uhr

9.3 Tools
TORX V-belt Tension Gauge

Technical Specifications 9

25899 0

26002 0

A TORX wrench set is used with engines in the 1012/1013 series. This system was chosen because of the many advantages it offers: q Outstanding accessibility to bolts. q High load transfer when loosening and tightening. q Almost impossible for socket to slide off or break. TORX tools can be ordered from: WILBR Postfach 14 05 80 D-42826 Remscheid

The V-belt tension gauge can be obtained under order number 91107 from: WILBR Postfach 14 05 80 D-42826 Remscheid

ENGLISCH Kapitel 9 Seite 9

7380en_k09_pdf 9 04.10.1999, 12:01 Uhr

Notes 9

ENGLISCH Kapitel 9 Seite 10

7380en_k09_pdf 10 04.10.1999, 12:01 Uhr

Service en
Knowing its DEUTZ DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry. As an independent motor manufacturer, we offer worldwide a comprehensive range of diesel and gas motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers individual requirements. Over 1.4 million DEUTZ motors do their job reliably all over the world. We are determined to preserve the high standard of performance and dependability of our motors, thus keeping our customers satisfied at all times. Therefore we are represented worldwide through a network of highly competent service partners who will meet the needs of our customers, wherever they are. This is why DEUTZ is not only the name for motors which pack a lot of inventive genius. DEUTZ also means reliable service and comprehensive support to enhance your motors performance. This index Sales & Service offers you an overview of the DEUTZ partners in your vicinity, including the products for which they are responsible and the range of services provided. But even when no direct product responsibility is mentioned, your DEUTZ partner will be happy to help you with expert advice. The Index is constantly updated. Please ask your DEUTZ service partner for the latest edition. DEUTZ AG at your service. Order-No.: 0297 7444

10

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

Obtainable from the local service Partner reponsible for you or from:

DEUTZ AG Deutz-Mlheimer Str. 147-149 D-51057 Kln Phone: 0049-221-822-0 Telefax: 0049-221-822-5304 Telex: 8812-0 khd d http://www.deutz.de

englisch