Operacion Deutz

Operation Manual
1012
1013
● Please read and observe the information ● Unauthorized engine modifications will in-
given in this Operation Manual. This will validate any liability claims against the manu-
enable you to avoid accidents, preserve facturer for resultant damage.
the manufacturer’s warranty and maintain Manipulations of the injection and regulating
the engine in peak operating condition. system may also influence the performance
!
of the engine, and its emissions. Adherence
● This engine has been built exclusively for to legislation on pollution cannot be guaran-
the application specified in the scope of teed under such conditions.
supply, as described by the equipment
manufacturer and is to be used only for the ● Do not change, convert or adjust the cooling
intended purpose. Any use exceeding that air intake area to the blower.
scope is considered to be contrary to the The manufacturer shall not be held respon-
intended purpose. The manufacturer will sible for any damage which results from
not assume responsibility for any damage such work.
resulting therefrom. The risks involved are
to be borne solely by the user. ● When carrying out maintenance/repair op-
erations on the engine, the use of DEUTZ
● Use in accordance with the intended pur- original parts is prescribed. These are
pose also implies compliance with the con- specially designed for your engine and
ditions laid down by the manufacturer for guarantee perfect operation.
operation, maintenance and servicing. The Non-compliance results in the expiry of the
engine should only be operated by person- warranty!
nel trained in its use and the hazards
involved. ● Maintenance and cleaning of the engine
should only be carried out when the engine
● The relevant accident prevention guidelines is switched off and has cooled down.
and other generally accepted safety and You must ensure that the electrical systems
industrial hygiene regulations must be ob- have been switched off and the ignition
served. key has been removed.
Accident prevention guidelines concerning
● When the engine is running, there is a risk electrical systems (e.g. VDE-0100/-0101/
of injury through: -0104/-0105 Electrical protective measures
- turning/hot components against dangerous touch voltage) are to be
- engines with positive ignition observed.
- ignition systems (high electrical voltage) When cleaning with fluids, all electrical
You must avoid contact at all times! components are to be covered impermeably.
Operation Manual
1012
1013
0297 9682 en
Engine serial
number:
Please enter the engine serial number here. This

number should be quoted when enquiring about
customer service, repairs or spare parts (see
Section 2.1).
Technical modifications required to improve our

engines are reserved with regard to specification
data and other technical information contained in
this Operation Manual. No parts of this Manual may
be reproduced in any form or by any means without
our written approval.
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 Ope-
ration Manual are necessarily mounted on
your engine.
We have endeavoured 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

enquiries
Sincerely,
DEUTZ AG
Contents
1. General 2.5 Engine cooling 4 Operating Media

2.5.1 Cooling System Schematic 1012 4.1 Lube Oil
2. Engine Description 2.5.2 Cooling System Schematic 1012 E 4.1.1 Quality
2.1 Model 2.5.3 Cooling System Schematic 1013 4.1.2 Viscosity
2.1.1 Rating Plate 2.5.4 Cooling System Schematic 1013 E/ 4.2 Fuel
2.1.2 Position of the Rating Plate 1013 E 4.2.1 Quality Grade
2.1.3 Engine Serial Number 4.2.2 Winter-Grade Fuel
2.1.4 Cylinder numbering 3. Engine Operation 4.3 Coolant
2.2 Engine Illustrations 3.1 Commissioning 4.3.1 Water Quality for Coolant
2.2.1 Operation side 1012 3.1.1 Pour in Engine Oil Preparation
2.2.2 Starter side 1012 3.1.2 Filling Oil Bath Air Cleaner 4.3.2 Coolant Preparation
2.2.3 Operation side 1012 E 3.1.3 Pour in Fuel 4.3.3 Cooling System Protective Liquid
2.2.4 Starter side 1012 E 3.1.4 Filling / Venting the Cooling System
2.2.5 Operation side 1013 3.1.5 Other Preparations
5. Routine Maintenance
3.2 Starting
2.2.6 Starter side 1013 5.1 Maintenance Schedule
3.2.1 Starting
2.2.7 Operation side 1013 E 5.2 Maintenance Chart
3.3 Monitoring Operation
2.2.8 Starter side 1013 E 5.3 Maintenance Record
3.3.1 Engine Oil Pressure
2.2.9 Starter side
3.3.2 Coolant temperature
Unit Engine BF4M 1013 EC
3.3.3 Coolant Level / Coolant Level
2.2.10 Operation side
Gauge
3.4 Shutting off
2.2.11 Starter side
3.4.1 Mechanical shut-off
3.4.2 Electrical shut-off
2.2.12 Operation side
3.5 Operating conditions
3.5.1 Winter Operation
2.3 Lube Oil Circuit Schematic
3.5.2 High Ambient Temperature, High
2.3.1 Lube Oil Circuit 1012 / 1012 E
Altitude
2.3.2 Lube Oil Circuit 1013 / 1013 E
2.4 Fuel System
2.4.1 Fuel System Plan
Contents
6. Service and Maintenance 6.3.6 Filling/Venting the Cooling System 6.5.14Tensioning Coolant / Fuel Pump Belts
6.1 Lubrication System 1012 E/1013 E 1013 E
6.1.1 Oil Change Intervals 6.3.7 Draining the Cooling System 6.5.15Changing Coolant / Fuel Pump Belts
6.1.2 Checking Oil Level / Changing Engine Oil Unit Engine 1013 E
6.1.3 Changing Oil Filter 6.3.8 Filling/Venting the Cooling System 6.5.16Tensioning / Changing Compressor
Unit Engine Belt
6.1.4 Cleaning/Changing Oil filter (Cup)
6.2 Fuel System 6.3.9 Draining the Charge-Air Cooler 6.6 Adjustments
6.2.1 Changing Fuel Filter 6.4 Combustion Air Cleaner 6.6.1 Checking / Adjusting Valve
Clearances
6.2.2 Replace fuel filter 6.4.1 Cleaning Intervals
6.7 Accessories
6.2.3 Clean/Replace Fuel Pre-Filter, Filter 6.4.2 Emptying Cyclone Type Precleaner
Element 6.7.1 Battery
6.4.3 Cleaning Oil Bath Air Cleaner
6.2.4 Venting the Fuel System 6.7.1.1 Checking Battery and Cable
6.4.4 Dry Type Air Cleaner
with Preliminary Fuel Filter Connectors
6.5 Belt Drives
6.2.5 Clean/Replace Fuel Pre-Filter, Filter 6.7.1.2 Checking Electrolyte Level
6.5.1 Checking V-Belts
Element 6.7.1.3 Checking Specific Gravity of
6.5.2 Tensioning Fan / Alternator Belts Electrolyte
6.2.6 Vent Fuel System with Fuel Pre-Filter 1012
6.2.7 Clean/Replace/Vent Fuel Pre-Filter, 6.7.2 Three-Phase Alternator
6.5.3 Changing Fan / Alternator Belts 1012
Filter Element 6.7.3 Lifting Tackle
6.5.4 Tensioning Coolant / Fuel Pump Belts
6.2.8 Clean / purge or change fuel 1012
pre-filter 7. Faults, Causes and Remedies
6.5.5 Changing Coolant / Fuel Pump Belts
6.2.9 Venting the Fuel System 1012 7.1 Fault Table
with Preliminary Fuel Filter
6.5.6 Tensioning Coolant / Fuel Pump Belts
6.2.10 Changing Fuel Leakage 1012 E 8. Engine Preservation
Line 8.1 Preservation
6.5.7 Changing Coolant / Fuel Pump Belts
6.2.11 Changing Fuel Leakage Pipes 1012 E
6.3 Cooling System 6.5.8 Tensioning Alternator Belt 1012 E 9. Technical Specification
6.3.1 Cleaning Intervals 6.5.9 Changing Alternator Belt 1012 E 9.1 Engine Specifications and Settings
6.3.2 Cleaning Cooling System 6.5.10Tensioning / Changing Fan Belt 1013 9.2 Screw Tightening Torques
6.3.3 Draining Cooling System 6.5.11Tensioning Coolant / Fuel Pump belts 9.3 Tools
1012 / 1013 1013
6.3.4 Filling / Venting Cooling System 6.5.12Changing Coolant / Fuel Pump Belts 10. Service
1012 / 1013 1013
6.3.5 Draining the Cooling System 6.5.13Tensioning / Changing Alternator
1012 E / 1013 E Belt 1013
General
DEUTZ Diesel Engines Care and Maintenance Service
1
are the product of many years of research and Sound care and maintenance practices will ensure Please contact one of our authorized service
development. The resulting know-how, coupled that the engine continues to meet the requirements representatives in the event of breakdowns or for
with stringent quality standards, guarantee their placed on it. Recommended service intervals must spare parts inquiries. Our trained specialists will
long service life, high reliability and low fuel be observed and service and maintenance work carry out repairs quickly and professionally, using
consumption. carried out conscientiously. only genuine spare parts.
It goes without saying that DEUTZ Diesel Engines Special care should be taken under abnormally Original parts from DEUTZ AG are always produced
meet the highest standards for environmental demanding operating conditions. in accordance with state-of-the-art technology.
protection. 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 mainte- This symbol is used for all safety
nance or repair work. Ensure that the engine cannot warnings. Please follow them Diesel engine exhaust and some of its consti-
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
! carefully. The attention of operating
personnel should be drawn to these
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
panels and guards that may have been removed. safety instructions. General safety
Never fill the fuel tank while the engine is running. and accident prevention regulations laid down by
Observe industrial safety regulations when running law must also be observed.
the engine in an enclosed space or underground.
Asbestos
DEUTZ original parts are asbestos-

free.
1
Engine Description
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit
2.4 Fuel System
2.5 Cooling System
Engine Description 2.1 Model
2.1.1 Rating Plate 2.1.2 Rating Plate Location 2.1.3 Engine Serial Number
2
26 332 0 26231 1 26232 1
The model A, the engine serial number B and the The rating plate C is attached to the crankcase. The engine serial number is also stamped on the
performance data are stamped on the rating plate. crankcase itself (arrow).
The model and engine serial number must be
given when ordering spare parts.
2.1 Model Engine Description
2.1.4 Cylinder Numbering

2
26233 0
Cylinders are numbered consecutively, beginning

at the flywheel end.
Engine Description 2.2 Engine Illustrations
2 2.2.1 Service Side 1012
1 Oil filler (option: between filters)

2 Coolant filler
3 Cooling fan
4 Coolant pump
5 Belt pulley
6 Fuel pump
7 Engine mount
8 Fuel filter
9 Lube oil filter
10 Oil pan
11 Dipstick
12 Lube oil cooler
13 Mounting facility for hydraulic pumps
14 Alternator
15 Back leak fuel pipe with pressure-regulating
valve
16 Cylinder head
26234 1
2.2 Engine Illustrations Engine Description
2.2.2 Starter Side 1012

2
17 Lifting points
18 Exhaust turbocharger
19 Speed governor
20 SAE housing
21 Flywheel
22 Starter motor
23 Hydraulic oil cooler
24 Coolant heat exchanger
25 Coolant level gauge
26 Bleeder valve
26235 1
2 2.2.3 Service Side 1012 E

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 hydraulic pump
valve
15 Cylinder head
26236 0
2.2.4 Starter Side 1012 E

2
16 Lifting points
18 Speed governor
19 SAE housing
20 Flywheel
21 Starter motor
22 Coolant outlet to heat exchanger
23 Exhaust manifold
24 Air intake manifold
26237 0
2 2.2.5 Service Side 1013

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 cooler
14 Hydraulic pumps (or compressor)
15 Fuel pipe
16 Solenoid
17 Lube oil line to turbocharger
18 Cylinder head
26 333 0
2.2.6 Starter Side 1013

2
19 Lifting points
21 Speed governor
22 SAE housing
23 Flywheel
24 Starter motor
25 Coolant level gauge
26 Bleeder valve
27 Coolant filler cap
26 334 0
2 2.2.7 Service Side 1013 E
1 Oil filler
2 Coolant pump
3 Fuel pump
4 Vibration damper
5 Fuel filter
6 Engine mount
7 Lube oil filter
8 Oil pan
9 Dipstick
10 Lube oil cooler
11 Mounting facility for hydraulic pump
valve
13 Cylinder head
A Coolant inlet
26 336 0
2.2.8 Starter Side 1013 E 2

14 Lifting points
15 Crankcase breather valve
16 Speed governor
17 SAE housing
18 Flywheel
19 Starter motor
21 Fan
22 Exhaust manifold
26 337 0
2 2.2.9 Starter Side

1 Coolant filler neck with cap

2 Expansion tank
3 Vent line from cylinder head to expansion tank
1 2 3 4 5 6 7 4 Coolant line from engine crankcase to engine
fluid radiator
5 Expansion line from expansion tank to radiator
6 Charge air line from exhaust turbocharger to
charge-air cooler
7 Dry air filter
8 Induction air line between dry air filter and
8 exhaust turbocharger
10 Coolant line from crankcase to engine fluid
radiator
9 11 Charge-air cooler
12 Engine fluid radiator
13 Coolant line from engine fluid radiator to engine
thermostat
10
12
13 11
26
30 088
336 0
2.2.10 Service Side

2
3 Ventilation line from cylinder head to expansion
tank
13 13 Charge-air line from charge-air cooler to engine
14 Protective guard
14
30
26 089
337 0
2.2.11 Starter Side

2 Unit Engine BF6M 1013 EC
1 Filler neck with cap

2 Expansion tank
3 Vent line from cylinder head to expansion tank
4 Expansion line from expansion tank to coolant
1 2 3 4 5 6 7 pump
5 Coolant line from crankcase to engine fluid
radiator
6 Charge-air line from charge-air cooler to engine
7 Charge-air line from exhaust turbocharger to
charge-air cooler
8 Coolant line from engine fluid radiator to engine
thermostat
8
30 087 0
2.2.12 Service Side

2
9 Engine fluid radiator
10 Charge-air cooler
11 Protective guard
11 10
30 086 0
Engine Description 2.3 Lube Oil Circuit
2.3.1 Lube Oil Circuit Schematic

2 1012 / 1012 E
1 Oil pan
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
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
2.3 Lube Oil Circuit Engine Description
2.3.2 Lube Oil Circuit Schematic
1013 / 1013 E 2
1 Oil pan
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
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
Engine Description 2.4 Fuel System
2 2.4.1 Fuel System Schematic
1 Fuel tank
2 Line to fuel pump
3 Fuel pump
4 Line to fuel filter
5 Fuel filter
6 Line to injection pumps
7 Injection pump
8 Line to injector
9 Injector
10 Back leak fuel pipe
11 Banjo bolt with pressure-regulating valve
12 Return line to fuel tank
13 Keep this spacing as wide as possible
26239 1
2.5 Cooling System Engine Description
2.5.1 Cooling System Schematic

1012
2
1 Coolant filler
2 Thermostat housing
3 Coolant pump
4 Lube oil cooler
5 Cylinder cooling
6 Cylinder head cooling
7 Heat exchanger
8 Return from thermostat to coolant pump
housing
9 Ventilation line from cylinder head to heat
exchanger (expansion tank)
26240 2
Engine Description 2.5 Cooling System

2 1012 E
entrance regulation
2 Coolant pump
3 Lube oil cooler
4 Cylinder cooling
6 Heat exchanger
7 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
1012 E 2
escape regulation
2 Cooling fluid pump
3 Lubricating oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Compensation setting of compensation tank t
o cooling fluid pump
8 Line (Crankcase) from thermostat to heat
exchanger
compensation tank
10 Compensation tank
11 Line from heat exchanger to cooling fluid pump
30 816 0

2 1013
1 Coolant filler
3 Coolant pump
4 Lube oil cooler
5 Cylinder cooling
7 Heat exchanger
8 Expansion line coolant pump/expansion
tank
heat exchanger (expansion tank)
26 338 1

1013 E 2
entrance regulation
2 Coolant pump
3 Lube oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Ventilation line expansion tank - coolant
pump
8 Line from engine to heat exchanger
expansion tank
10 Expansion tank
11 Line from heat exchanger to thermostat
26 339 1
2 1013 E
escape regulation
2 Cooling fluid pump
3 Lubricating oil cooler
4 Cylinder cooling
6 Heat exchanger
7 Compensation setting of compensation tank t
o cooling fluid pump
8 Line (Crankcase) from thermostat to heat
exchanger
compensation tank
10 Compensation tank
11 Line from heat exchanger to cooling fluid pump
30 817 0
Engine Operation
3.1 Commissioning
3.2 Starting
3.3 Monitoring Systems
3.4 Stopping
3.5 Operating Conditions
Engine Operation 3.1 Commissioning
3 3.1.1 Adding Engine Oil 3.1.2 Filling Oil Bath Air Cleaner 3.1.3 Adding Fuel
26243 0 24980 2 26244 0
As a rule, engines are delivered empty of oil. Fill oil cup 1 of the oil bath air cleaner (if fitted) Use only commercial-grade diesel fuel. For fuel
Pour lube oil into the oil filler neck (arrow). with oil up to the arrow. grade, see 4.2.
For oil quantities, see 9.1. For oil grade and viscosity, see 4.1. If required use a preliminary fuel filter.
For oil grade and viscosity, see 4.1. 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 Never fill the fuel tank while the
collector (if fitted) with oil. engine is running. Keep the filler
cap area clean and do not spill fuel.
3.1 Commissioning Engine Operation
3.1.4 Filling/Venting the Cooling

System
3.1.5 Other Preparations
3
● 1012/1013 ● Check battery and cable connections, see 6.7.1.
See section 6.3.4
● Trial run
● 1012 E/1013 E - After the engine has been prepared, let it run
See section 6.3.6 for about 10 minutes without load.
● Unit engine (with frontal radiator) During and after trial run
See section 6.3.8. - 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 a
day will be sufficient.
● Commissioning conserved engines

Remove conservation materials as outlined in
section 8.1
Engine Operation 3.2 Starting
3 3.2.1 Electric Starting
Starting without Cold-Start Aid

Before starting, make sure that
nobody is standing in the imme-
! diate 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
● Disengage the clutch to separate the engine ● Insert key.

from the driven equipment. – Position 0 = no operating voltage.
● Move speed control lever 1 in direction of ● Turn key clockwise.

arrow at least to middle speed position. – Position 1 = operating voltage.
– Pilot lights 1 and 2 come on.
● Move shutdown lever 2 to operating position
(in opposite direction of arrow). ● Push the key in and turn it further clockwise
against spring pressure.
– Position 2 = no function
– Position 3 = start
Do not actuate the starter for more than 20
seconds. If the engine does not catch, wait a ● Release key as soon as engine fires.
minute then try again. – Pilot lights go out.
If the engine does not catch after two attempts,
refer to the Diagnosis Chart (see 7.1).
3.2 Starting Engine Operation
3
Starting with Heater Plugs
25746 1
● 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 function.
– Position 3 = start.
● Release key as soon as engine fires.

– Pilot lights go out.
Engine Operation 3.3 Monitoring Systems
3 3.3.1 Engine Oil Pressure
Oil Pressure Pilot Light Oil Pressure Indicator Oil Pressure Gauge
25752 1 25753 0 25754 0
● The oil pressure pilot light comes on with ● The pointer must remain in the green sector ● The pointer must indicate the minimum oil
operating voltage on and engine off. over the entire operating range. pressure (see 9.1).
● The oil pressure pilot light should go out when

the engine is running.
3.3 Monitoring Systems Engine Operation
3.3.2 Coolant Temperature 3.3.3 Coolant Level /

Coolant Level Gauge
3
26246 0 26247 0
● The coolant temperature gauge pointer should ● When the engine is cold, coolant level 1 should ● If a level switch is fitted, the engine is shut
remain in the green sector most of the time. It be above the KALT-COLD mark. down automatically when the level falls below
should rarely enter the yellow-green sector. If the MIN marking.
the pointer enters the orange sector, the engine ● Top up with coolant if the level falls below the
is overheating. Turn it off and establish the MIN mark on the sight glass, or if the coolant
cause from the Diagnosis Chart (see 7.1). 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
● 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.
Engine Operation 3.4 Stopping
3 3.4.1 Engines with Mechanical

Shutdown
3.4.2 Engines with Electrical
Shutdown
26266 0 25746 2
● Move speed control lever 1 to low idle. ● Turn key counterclockwise (to Position 0) and
remove. The pilot lights will go out.
● 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.
● 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.
3.5 Operating Conditions Engine Operation
3.5.1 Winter Operation

3
● Lube Oil Viscosity ● Battery
– Select the oil viscosity (SAE grade) – Efficient cold starting requires a healthy
according to the ambient temperature when battery (see 6.7.1).
the engine is started (see 4.1.2). – The starting limit temperature can be
– Increase oil change frequency when operat- lowered by 4-5°C by heating the battery up to
ing below –10°C, see 6.1.1. about +20°C. To do so, remove the battery
and store in a warm place.
● Diesel Fuel
– Use winter-grade diesel fuel for operation
below 0°C, see 4.2.2.
● Coolant
– Set the water/antifreeze mix to suit the lowest
likely temperature (max. –35°C), see 4.3.1.
● Additional Maintenance Work

26248 0
– 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 –20°C, 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.
● 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.
Engine Operation 3.5 Operating Conditions
3.5.2 High Ambient Temperature,

3 High Altitude
● 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
C F
conditions, the engine can be used at altitudes
up to 1000 meters / 3400 feet and tempera-
tures up to 30°C.
If the engine is to operate under more severe
conditions (at higher altitudes or tempe-
ratures), it will be necessary to reduce the
0 32
injected fuel quantity and, thus, engine power.
● 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 25901 1
reliability, service life and exhaust gas quality
(smoke). Otherwise, contact the nearest
service representative.
Operating Media
4.1 Lube Oil

4.2 Fuel
4.3 Coolant
© 2002
Operating Media 4.1 Lube Oil
4 4.1.1 Quality Grade 4.1.2 Viscosity
Lube oils are differentiated by Deutz Generally, multi-grade oils shall be used. In
according to their performance and quality closed heated rooms at temperatures >5°C,
class. Oils of other, comparable specifications also single-grade oils can be used.
can be used.
As the viscosity of lube oil is dependent on
temperature, the choice of SAE grade
should be governed by the ambient
Approved oils: temperature prevailing at the engine
operating site.
Optimum operating behaviour will be
Deutz DQC I DQC II DQC III attained if you take the accompanying oil
viscosity diagram as a guide.
ACEA E2-96 E3/96/E5-02 E4-99
Should the temperature fall temporarily
API CF/CF-4 CH-4/CG-4 - below the limits of the SAE grade selected,
cold starting may be affected but the engine
DHD - DHD-1 - will not be damaged.
In order to keep wear to a minimum, do not
exceed application limits for extended
The precise assignment of the admissible periods of time.
oil qualities to the engines is indicated in
chapter 6.1.1. Synthetic lube oils feature an improved
If in doubt, contact your service represen- temperature and oxidation stability.
tative.
© 2002
Only with preheating 30 298 1

4.1 Lube Oil Operating Media
Lube oils for engines with uprated power
4.1.2.1 Specific lube oil
definitions Producer
and engines with high loading
Type of lube oil SAE class Availability
4
DEUTZ DEUTZ Oil TLX-10W40FE 1 0 W- 4 0 Europe
ADDINOL ADDINOL Super Truck MD 1048 10W-40 Europe, Asia
The oils listed in the table are to be used ADDINOL Ultra Truck MD 0538 5W-30 Europe, Asia
for the following engines and applications: AGIP Agip Sigma Ultra TFE 10W-40 worldwide
● 1013FC Autol Valve Ultra FE 10W-40 Germany
● all engines in block-type thermal power ARAL Aral MegaTurboral 10W-40 worldwide
Aral SuperTurboral 5W-30 worldwide
stations AVIA TURBOSYNTH HT-E 10W-40 Germany
● all engines in gensets operating in parallel BAYWA BayWa Super Truck 1040 MC 10W-40 South Germany
with the mains / with each other BayWa Turbo 4000 10W-40 South Germany
● engines in harvesting machines BP OIL International BP Vanellus E7 Plus 10W-40 Europe
BP Vanellus E7 Supreme 5W-40 Europe
These are high-grade oils. In addition, most of Castrol Castrol SYNTRUCK 5W-40 Europe, North America, Brazil,
Argentina, Australia, South Africa
these oils are partly synthetic, some even
Castrol Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil,
fully synthetic (5W-40), and thus achieve the Argentina, Australia, South Africa
thermal stability required for the relevant CEPSA EUROTRANS SHPD 10W-40 Spain, Portugal
application and are distinguished by a low CHEVRON Chevron Delo 400 Synthtic 5W-40 North America
tendency to cause deposits in the DEA DEA Cronos Synth 5W-30 Germany, Europe
turbocharger and in the charge air pipes with DEA Cronos Premium LD 10W-40 Germany, Europe
closed-circuit crankcase breather. DEA Cronos Premium FX 10W-40 Europe
ESSO Essolube XTS 501 10W-40 Europe
FUCHS EUROPE Fuchs Titan Cargo MC 10W-40 worldwide
Fuchs Titan Cargo SL 5W-30 worldwide
Fuchs Titan Unic Plus MC 10W-40 worldwide
MOBIL OIL Mobil Delvac 1 SHC 5W-40 Europe, SE Asia, Afrika
Mobil Delvac 1 5W-40 worldwide
Mobil Delvac XHP Extra 10W-40 Europe, SE Asia
Schmierölraffinerie Wintershall TFG 10W-40 Europe
Salzbergen
Shell International Shell Myrina TX / 5W-30 Europe, different
Shell Rimula Ultra description in some country
Shell Myrina TX / 10W-40 Europa, different
Shell Rimula Ultra description in some country
Texaco Ursa Super TDX 10W-40 10W-40 Europe
Ursa Premium FE 5W-30 5W-30 Europe
TOTAL FINA ELF TOTAL RUBIA TIR 8600 10W-40 worldwide
ELF PERFORMANCE 10W-40 worldwide
© 2002
EXPERTY MX 1010
ELF PERFORMANCE 10W-40 Germany, Benelux,
EXPERTY MX 1012 Scandinavia, Austria
FINA KAPPA FIRST 5W-30 Europe
The table will be extended as and when required. FINA KAPPA ULTRA 10W-40 Europe
Operating Media 4.2 Fuel
4 4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel
Use commercially available diesel fuel with Waxing may occur at low temperatures,
less than 0.5% sulphur content. If the sulfur clogging the fuel system and reducing engine
content is higher than 0.5%, oil change efficiency. If the ambient temperature is less
intervals should be reduced (see 6.1.1). than 0 °C, winter-grade fuel (suitable down
to -20 °C) should be used. This fuel is usually
The following fuel specifications/standards available from filling stations well in advance
are approved: of the cold months.
(refer to TR 0199-3002)
● At temperatures below -20°C/, kerosene
● Diesel fuel should be added to the diesel fuel. The
- DIN EN 590 relevant percentages are given in the dia-
- BS 2869: A1 and A2 gram at the right
(with A2, take note of the sulfur content!) ● Special diesel fuels can be used for climatic
- ASTM D 975-88; 1-D and 2-D zones down to - 44 °C.
- NATO Code F-54and F-75
- ISO 8217 DMX If summer-grade diesel fuel must be used at
- ISO 8217 DMA temperatures below 0°C, up to 60% kerosene
● Light heating oil can be added (see diagram).
according to DIN 51603 Legend:
ASTM D 396; 1 and 2 In most cases, adequate resistance to cold
BS 2869 Class D can be obtained by adding a flow improver I Summer diesel fuel
(additive). Please contact your Deutz partner.
● Jet fuel
- F34/F35/F44 (kerosene) II Winter diesel fuel
- F54 (equivalent to diesel fuel according to A Outside temperature
DIN EN 590)
- XF 63 (equivalent to F34+F35 with addi- B Percentage of kerosene to be added
tives)
● Bio diesel fuel
- according to DIN 51606- FAME
Exhaust emission values which may be Diesel fuels must never be Mix in tank only. Fill with the
© 2002
determined in the cause of type approval tests mixed with petrol (normal and appropriate amount of kerosene
always refer to the reference fuel prescribed super grade petrol)! first, then add the diesel fuel.
by the authorities for the type approval test.
4.3 Coolant Operating Media
4.3.1 Water Quality for Coolant 4.3.2 Coolant Preparation 4.3.3 Cooling System Protective
Preparation Liquid
4
The values given below must not be The preparation and monitoring of coolant in DEUTZ cooling system protective agents
exceeded. liquid-cooled engines is especially important can be obtained under order number
A test kit (order number 1213 0382) can be because corrosion, cavitation and freezing 01011490 (5 litres) or 1221 1500 (210 litres).
obtained from DEUTZ Service to check the can lead to engine damage. These are nitrite-, amine- and phosphate-
quality of the water available. The coolant is prepared by admixing a free and provide effective protection
cooling system protective liquid with the against corrosion, cavitation and freezing.
Water quality min. max. cooling water. If the above-mentioned cooling system
The cooling system must be monitored agents are not available, the following
pH-value at 20°C /68° F 6.5 8.5 regularly (see 5.1). The water level and the products can be used in exceptional cases.
cooling system protective liquid concen- Manufacturer Product description
Chloride ion content [mg/dm3] – 100 tration should both be checked. AVIA AVIA Antifreeze Extra
Sulfate ion content [mg/dm3] – 100 The cooling system protective liquid BASF Glysantin G 48
concentration can be checked with a DEA DEA radiator antifreeze
Total hardness [°dGH] 3 20 commercially available tester (e.g. gefo SHELL SHELL GlycoShell
glycomat® ).
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
When nitrite-based cooling Cooling system protective liquids
© 2002
system protective liquids are must be disposed of in accor-
mixed with amine-based liquids, dance with environmental
harmful nitrosamines are formed. regulations.
Operating Media 4.3 Coolant
4
Cooling System Protection
Cooling system capacity *)
Cooling Cooling [Liters]
system protective 18 20 22 25 27 30 32 35
protection agent
[Vol %] [°C] Cooling system protective liquid
[Liters]
35 –22 2.8 7.0 7.7 8.75 9.5 10.5 11.2 12.3
40 –28 7.2 8.0 8.8 10.0 10.8 12.0 12.8 14.0
45 –35 8.1 9.0 9.9 11.3 12.2 13.5 14.4 15.8
50 –45 9.0 10.0 11.0 12.5 13.5 15.0 16.0 17.5
*) For quantity of coolant in your engine, see Section 9.1.

Note: For figures in gray field, refer back to head-office.
© 2002
Routine Maintenance
5
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Record
© 2002
Routine Maintenance 5.1 Maintenance Schedule
5 Maintenance step= E Check= ● Adjust= ❍ Clean= ▲ Replace= ■

Before or during 1st test run, during commissioning check twice
Industrial engines
daily or when commissioning new or reconditioned engines The specified engine maintenance times are
the max. permissible recommended times.
Every 10 operating hours or daily
Depending on the application shorter
In operating hours (OH), every *E70=1012 Engines 10000OH maintenance times may be necessary. Please
*E70=1013 Engines 13000OH refer to manufacturer’s operating manual.
E10 E20 E30 E40 E50 E60 E70* Years # Maintenance work to be carried out only by
500 1000 1500 2000 10000 13000 1 2 authorised service personnel.
Operation Section
● ● Lube oil level, top up as necessary 6.1.2/3.1.6
■ Lube oil (oil changing interval acc. to engine application), see TR0199-99-3002 6.1.1/6.1.2
■ Oil filter cartridge (for every lube oil change) 6.1.3
■ Fuel filter cartridge 6.2.1
● ■ Flexible fuel leakage lines (replace completely) 6.2.5
● ▲ ■ Fuel pre-filter * (change filter element if necessary) 4.2/ 6.2/2-4
● ● ■ Coolant (additive concentration) 4.3.1/ 2/ 3
● ● Coolant liquid level –
● ● ■ Dry/suction air filter (if present service as per maintenance display) 6.4.3 /4
● ▲ ▲ Charge cooler (drain lube oil / condensate) 6.3.9
● Battery and cable connections 6.7.1
● Sheathed-element glow plugs –
● ● Engine monitoring, warning system 3.3 #
❍ Valve clearance (set if necessary, earlier if noises occur) 6.6.1#
● ● ■ V-belts (retighten or replace as necessary) 6.5
* When the warning system responds (lamp/horn), the fuel pre-filter must be emptied immediately
© 2002
5.1 Maintenance Schedule Routine Maintenance
5
Maintenance step= E Check= ● Adjust= ❍ Clean= ▲ Replace= ■
Industrial engines
The specified engine maintenance times are
daily or when commissioning new or reconditioned engines
the max. permissible recommended times.
Every 10 operating hours or daily Depending on the application shorter
maintenance times may be necessary. Please
In operating hours (OH), every *E70 1012 Engines 10000OH
refer to manufacturer’s operating manual.
*E70 1013 Engines 13000OH # Maintenance work to be carried out only by
E10 E20 E30 E40 E50 E60 E70* Years authorised service personnel.
500 1000 1500 2000 10000 13000 1 2 Operation Section
● ● Check engine for leaks (visual inspection) –
● ● Engine bearing fixings (renew if damaged) 9.2
● Check cooling system bearings – rubber and retaining elements –
● ● Fixings, hose connections / clamp –
■ Major overhaul #
Maintenance step= E Check= ● Adjust= ❍ Clean= ▲ Replace= ■

max. permissible recommended times in operating hours (OH), every
Expansions or modifications for
engines with EPA acceptance
The specified engine maintenance times are the max.
daily or when commissioning new or reconditioned engines permissible recommended times. Depending on the
Every 10 operating hours or daily application shorter maintenance times may be necessary.
Please refer to manufacturer’s operating manual.
In operating hours (OH), every *1012Engines10000OH # Maintenance work to be carried out only by authorised
E10 E20 E30 E40 E50 E60 E70* Years *1013Engines13000OH service personnel.
500 1000 1500 3000 4000 10000 1 2 Operation Section
■ Injection valve #
© 2002
Routine Maintenance 5.2 Maintenance Chart
5.2.1 Additional maintenance

5
Intervals Maintenance Stages Execution
at/after
50 Bh E 10 After commissioning and E50, E60, E70 authorized trained staff
daily E 20 Daily check routine operator, authorized trained staff
500 Bh E 30 Inspection authorized trained staff
1000 Bh E 40 Extended inspection authorized trained staff
3000 Bh E 50 Intermediate overhaul authorized trained staff
6 000 Bh E 60 Extended intermediate overhaul authorized trained staff
12 000 Bh E 70 Major overhaul authorized trained staff
© 2002
5.2 Maintenance Chart Routine Maintenance
The maintenance chart shown here is
supplied as self-adhesive label with each
engine. It should be affixed where it can be a
in.
ex.
0,3 mm
0.012 in.
0,5 mm
h
Std.
OIL 5
0.020 in.
seen clearly on the engine or driven in.
500
1500
equipment. ex.
ER
WAT
Check that this is the case. AIR 10

10
ca. 15 mm
If necessary, ask your engine or equipment 0.6 in.
supplier for a fresh supply of labels. 500

125-
2000
Routine work should be carried out according
to the schedule in 5.1. FU
1000 EL
OIL 10
max.
500
OIL
1013
0297 7782 0
a
h OIL
Std.
in.
1500
ex. 0,3 mm 500
in. 0.012 in.
ex. 0,5 mm
0.020 in.
ER
WAT
AIR
10
10
ca. 15 mm
0.6 in.
125- 500
2000
FU
1000 EL
OIL 10
max.
Stop the engine before
© 2002
500
OIL
carrying out any maintenance BF4/6M 1012/E/C
! work.
0297 7783 0
Routine Maintenance 5.2 Maintenance Chart
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
5 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.
0297 4979 1
BFM 1012
© 2002
Standard engine
BFM 1013
5.2 Maintenance Chart Routine Maintenance
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.
5
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.
0297 4985 1
BFM 1013E
Short engine
© 2002
Routine Maintenance 5.3 Completed Maintenance Jobs
Hours. Date Signaure / Stamp Hours Date Signaure / Stamp

5
50-150* -
125 250
375 500
625 750
875 1000
1125 1250
1375 1500
1625 1750
1875 2000
2115 2250
2375 2500
2625 2750
* Commissioning new and overhauled engines
The maintenance jobs duly completed can be recorded in the above table.
5.3 Completed Maintenance Jobs Routine Maintenance
Hours Date Signaure / Stamp Hours Date Signaure / Stamp

5
2875 3000
3125 3250
3375 3500
3625 3750
3875 4000
4125 4250
4375 4500
4625 4750
4875 5000
5125 5250
5375 5500
5625 5750
Routine Maintenance 5.3 Completed Maintenance Jobs

5
5875 6000
6125 6250
6375 6500
6625 6750
6875 7000
7125 7250
7375 7500
7625 7750
7825 8000
8125 8250
8375 8500
8625 8750
Hours Date Signaure / Stamp Hours Date Signaure / Stamp
5
8875 9000
9125 9250
9375 9500
9625 9750
9875 10000
10125 10250
10375 10500
10625 10750
10825 11000
11125 11250
11375 11500
11625 11750
5
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
© 2002
Service and Maintenance 6.1 Lubrication System
6.1.1 Oil Change Intervals

6
● The oil change intervals are dependent on ● If, for vehicle engines, lube oil change
the engine application and the quality of intervals are determined by operating hours,
the lube oil. the lube oil change intervals indicated in table
6.1.1.1. for “Oil use under normal duty” will
● If the engine runs fewer hours during the apply.
year than stated in the table, the oil should
be changed at least once a year.
● The table refers to the following condi-

tions:
– For diesel fuel: sulfur content max. 0.5
% by weight.
– Continuous ambient temperatures down
to -10 °C / +14°F
● For fuels
– with sulfur content is > 0.5 to 1 %
or
– continuous ambient temperature below
-10 °C/+14°F
or
– with bio-diesel fuels in accordance with
DIN 51606-FAME the intervals between
oil changes should be halved.
● In the case of fuels containing more than

1 % sulfur, contact your service repre-
sentative.
© 2002
Change the oil with the engine off but still

warm (lube oil temperature approx. 80 °C).
6.1 Lubrication System Service and Maintenance
6.1.1.1 Equipment Engines

Lube oil grade
6
Deutz lube oil quality class DQC I DQC II DQC III
ACEA-specfication E2-96 E3-96/E5-02 E4-99
API-specfication CF/CF-4 CG-4/CH-4 -
Worldwide specification - DHD-1 -
special DEUTZ release list - - see chap. 4.1.2.1
Standard lube oil code for building EO.. . EO...C -
equipment and nonraod vehicles EO...A, EO...B
Engine Engine version Lube oil change intervals in op. hours
series Oil use Oil use Oil use
normal high normal high normal high
1012 All engines except for: 250 500 500
eng. in harv. machines, block-typethermal
power stat., gensets* - - 500
1013 All engines except for: 250 500 500
engines from nonroad stage II - 500 500
eng. in harv. machines, block-typethermal
power stat., gensets* - - 500
BF4M1013FC - - 500
BF6M1013FC, P ≤ 200 kW - - 500
BF6M1013FC, P > 200 kW - - 250
© 2002
* Gensets as referred to here are units operating in parallel with the mains / with each other.
Emergency power units are dealt with in TC 0199-99-1126.
6 6.1.1.2 Oil change intervals for vehicle engines

Deutz lube oil quality class DQC I
Lube oil-quality
DQC II DQC III
ACEA-specification E2-96 E3-96/E5-02 E4-99
API-specification CF/CF-4 CG-4/CH-4 - -
worldwide specification - DHD-1 -
special DEUTZ release - - see chap. 4.1.2.1
Application Engine version Lube oil change intervals in km
1012/1013 Euro I 10 000 15 000 20 000
Euro II and Euro III, except for: - 15 000 20 000
Site BF4M1013FC Euro II ≤ 14 l oil contents (first filling) - - 10 000
vehicles/ 25 > 14 l oil contents (first filling) - - 20 000
Stadtbusse Euro III - - 20 000
city busses BF6M1013FC Euro II ≤ 19 l oil contents (first filling) - - 10 000
> 19 l oil contents (first filling) - - 20 000
Average speed in km/h approx.
Euro III - - 20 000

1012/1013 Euro I 15 000 20 000 30 000
Local 40 BF4M1013FC Euro II ≤ 14 l oil contents (first filling) - - 15 000
traffic > 14 l oil contents (first filling) - - 30 000
Euro III - - 30 000
BF6M1013FC Euro II ≤ 19 l oil contents (first filling) - - 15 000
Euro III - - 30 000
1012/1013 Euro I 20 000 30 000 40 000
Long 60 BF4M1013FC Euro II ≤ 14 l oil contents (first filling) - - 20 000
distance > 14 l oil contents (first filling) - - 40 000
Euro III - - 40 000
Euro II ≤ 19 l oil contents (first
© 2002
BF6M1013FC filling) - - 20 000

Euro III - - 40 000
6.1.2 Checking Oil Level /

Changing Engine Oil
6
6.1.2.1Checking Oil Level 6.1.2.2 Changing Engine Oil
© 25 729 0 © 26 022 0 © 26 023 0
● Ensure that the engine or vehicle is on a ● Run the engine warm ● Place an oil tray beneath the engine
level surface. ● Ensure that the engine or vehicle is on a ● Unscrew drain plug.
● – Warm engine level surface ● Drain oil.
● Switch off engine, wait 5 minutes and – Lube oil temperature approx. 80°C. ● Fit oil drain plug with new gasket and
check the oil level ● Switch off the engine. tighten firmly (for torque, see 9.2).
● –Cold engine ● Fill with lube oil
Check the oil level – For grade/viscosity, see 4.1.
● Remove the dipstick – For quantity, see 9.1.
● Wipe off with a non-fibrous, clean cloth. ● Check oil level, see 6.1.2.1
● Insert up to the stop and pull out again.
● Check oil level, if required top up to the
“MAX” level
– If the oil level is just above the “MIN” mark, Be careful when draining hot oil -
© 2002
it should be topped up.
! danger of scalds! Do not let used oil
run into the soil but catch it in a
The oil level must not drop below the “MIN” container ready for proper disposal.
mark.
6 6.1.3 Changing Oil Filter
© 25 880 0 © 25 881 0 © 25 882 0
● With fitted torsion lock: ● Clean any dirt from the filter carrier rim. ● Check that the cartridge is correctly seated
Loosen screws and slide clamps down- against the gasket and tighten with a final
wards. ● Lightly oil the rubber gasket of the new oil half-turn.
filter cartridge.
● Undo the filter cartridge with commercial tool ● If a torsion lock is fitted:
and spin off. ● Screw in the new cartridge finger tight Slide clamps up into position and tighten
against the gasket. screws.
● Catch any dripping oil.
● Check oil level (see 6.1.2).
● Check oil pressure (see 3.3.1).
Beware of burns from hot oil. ● Check cartridge seal.

© 2002
!
6.1.4 Cleaning/Changing Oil 6

filter (Cup)
4
© 30 074 0
● Switch off the engine. ● Replace rubber seal 2 and apply a small
● Loosen the lube oil filter cap 1 and unscrew amount of grease
in an anticlockwise direction. ● Carefully insert the new paper filter
● Carefully lift the paper filter cartridge 3 out cartridge 3 in guide 4.
of guide 4. ● Tighten lube oil filter cover 1 in the clockwise
● Catch any dripping oil. direction (25 Nm).
● Change the paper filter cartridge 3. ● Start the engine.
● Clean any dirt from the filter carrier rim and ● Check the oil level, see 6.1.2.
the lube oil filter cover 1 and guide 4. ● Check the oil pressure, see 3.3.1.
● Check lube oil filter fitting for leaks.
Caution: hot oil!
© 2002
Risk of scalding!
!
Service and Maintenance 6.2 Fuel System
6.2.1 Changing Fuel Filter

6
© 25 880 0 © 25 881 0 © 25 882 0
● Close fuel stopcock. ● Clean any dirt from the filter carrier rim. ● Check that the cartridge is seated correctly
against the gasket and tighten with a final
● Undo fuel filter cartridge with commercial tool ● Apply light film of oil or diesel fuel to the rubber half-turn.
and spin off. gasket of the new fuel filter cartridge.
● Open fuel stopcock.
● Catch any fuel. ● Screw in the new cartridge finger tight
against the gasket. ● Check for leaks.
Keep naked flames away The fuel system does not

© 2002
when working on the fuel need to be bled.

! system. Do not smoke!
!
6.2 Fuel System Service and Maintenance
6.2.2 Replace Fuel Filter

6
© 36 650 0 © 25 881 0 © 25 882 0
z Close the fuel shut-off valve. z Apply light film of oil or diesel fuel to the z Open fuel shut-off valve.
z Undo fuel filter cartridge with commercial rubber gasket of the new original DEUTZ z Bleed fuel system, see 6.2.4.
tool and spin off. fuel filter cartridge. Also loosen the bleed screw 4 until air-free
fuel emerges.
z Catch any escaping fuel. z Manually screw in the new cartridge until z Tighten the bleed screw 4
the gasket is flush.
z Clean any dirt from the filter carrier sealing z Check for leaks.
surface 1. z Tighten the fuel filter cartridge with a final
half-turn.
The fuel system needs to be Keep naked flames away when

bled. working on the fuel system. Do
© 2002
not smoke!
6.2.3 Clean/Replace Fuel Pre-Filter, 6.2.4 Venting the Fuel System

6 Filter Element with Preliminary Fuel Filter
Bleed:
● Place the fuel pan beneath the preliminary
fuel filter.
● Loosen drain plug 4 and observe the
draining fluid. When fuel instead of water
starts to flow, retighten drain plug 4.
● Check for leaks after the engine has been
started.
Vent:
● During initial commissioning, after
maintenance work or if the tank is run
empty it is essential to vent the fuel system.
● Set engine controller to stop position
● Place fuel collecting trough under the filter
© 25 801 0 © 30 084 0 housing 5 / pressure control valve 9.
● Open fuel stopcock, pressure control valve
9, vent screw 8
Clean: ● Press filter housing 5 with filter insert 3 and ● Turn engine with starter (max. 20 sec.)
● Close fuel stopcock. sealing ring 6 against the filter console 7 until fuel free from air bubbles escapes
● Place the fuel pan beneath the preliminary and screw into place with clamping screw from vent screw 8 and pressure holding
fuel filter. 1 (tightening torque 25 Nm). valve 9.
● Remove drain plug 4 and drain off fuel. Note: it must be possible to push the upper ● Tighten vent screw 8 (tightening torque 15
● Unscrew clamping screw 1, remove filter seal 2 on filter insert 3 over the guide Nm) and pressure control valve 9.
housing 5 with filter insert 3. bracket on filter console 7. ● Set engine controller to start position and
● Clean sealing surface of the filter bracket ● Tighten drain plug 4. start
7 and filter insert housing 5 of any dirt. ● Open fuel stopcock. ● When the engine has started check for
● Insert new sealing ring 6 and filter insert ● Check for leaks after the engine has been leaks
3 (change as necessary). started.
–Push the filter insert up to approx. 3 cm Keep naked flames away when
over the edge of the housing onto the Replace: working on the fuel system. Do
© 2002
guide in the filter housing 5. ● Replace defective filter insert 3.

! not smoke! Dispose of waste
fuel in an environmentally-
friendly manner!
6.2.5 Clean/Replace Fuel Pre-Filter, 6.2.6 Vent Fuel System with Fuel
Filter Element Pre-Filter
6
Drain Water:
z Place fuel collection container beneath the
fuel pre-filter.
z Loosen drain screw 9 and watch the
draining liquid, tighten the drain screw 9
when water changes to fuel.
z Bleed system
z Check for leaks after starting the engine.
Vent:
z In the event of re-commissioning, following
maintenance work or if the tank has been
run empty, the fuel system must be vented.
z Bring engine regulator into stop position.
z Position fuel collection container beneath
filter housing 9 / pressure maintenance
© 36 649 0 © 30 084 0 valve 9.
z Open fuel shut-off valve, pressure
Clean/Replace: maintenance valve 9, vent screw 10.
z Close the fuel shut-off valve. z Tighten the drain screw 7+9 z Vent system, turn over engine with the
z Place fuel collection container beneath the z Open fuel shut-off valve. starter (max. 20 sec.) up to vent screw 10
fuel pre-filter. z Bleed system and pressure retention valve 9.
z Loosen the drain screw 7+9 and drain fuel. z Check for leaks after starting the engine. z Firmly tighten vent screw 10 (tightening
z Turn the filter element housing 4 with gasket torque 25-5 Nm) and pressure maintenance
3 and filter element 3 anti-clockwise and valve 9.
remove. z Bring engine regulator into start position
z Clean any dirt from the sealing face of the and start.
filter carrier and filter element housing 4 z Check for leaks after starting the engine.
and sludge chamber 4 and filter element
(replace if necessary). Keep naked flames away when
z Insert new round sealing rings 2+3+6. working on the fuel system. Do
z Screw in filter element housing 4 and filter not smoke!
© 2002
element (max. torque 25 –5 Nm). Dispose of wastefuel in an
environmentally-friendly
manner!
6.2.7 Clean/Replace/Vent Fuel

6 Pre-Filter, Filter Element
© 36648 0
Clean: z Open the fuel shut-off valve and bleed the Vent:
z Close the fuel shut-off valve. system. z Loosen the vent screw 7 slightly.
z Place fuel collection container beneath the z Check for leaks after starting the engine. z Actuate the pump until fuel free from air
fuel pre-filter. Replace: bubbles emerges.
z Loosen the drain screw 5 and drain fuel/ z Replace defective filter cartridge 2. z Tighten the vent screw.
water. z Clean any dirt from the filter carrier 1
z Turn filter cartridge 2 and dirt trap 3 sealing surface 8. A= connection possibility for:
anticlockwise and remove. z Wet the filter cartridge 2 with fuel, wet the Electrical connection for water/fuel level
z Turn dirt trap 3 anticlockwise and remove. sealing surfaces 8 slightly with oil. sensor in the dirt trap
z Empty emulsion into the fuel collection z Mount the filter cartridge 2 and dirt trap 3
container and clean the dirt trap 3. clockwise. Work may only be performed
z Screw the filter cartridge 2 and dirt trap 3 z Open fuel shut-off valve. on the fuel system with the
together. Wet the filter cartridge with fuel, z Check for leaks and vent the system after engine switched off.
© 2002
wet the sealing surfaces 8 slightly with oil. starting the engine. No naked flames! Do not smoke!
z Mount clockwise. Dispose of waste fuel in an
environmentally-friendly
manner.
6.2.8 Clean / purge or change fuel

pre-filter
6.2.9 Venting the Fuel System
with Preliminary Fuel Filter
6
Changing the filter element 5:
Change at least once a year or as required
(drop in performance also after purging)
● Turn off the engine or switch to other filter
in case of changeover filter
● Close the fuel stopcock or supply (if 9
available)
● Loosen the cover screws 3 diagonally
● Remove the cover 2
● Remove the spring cassette 4
● Remove the filter element 5 from the bracket
● Insert new filter element 5
● Place spring cassette 4 on the element
● Check that the cover seal is fit properly in
the cover 2 and check for damage (change
if necessary)
© 31 811 2
● Tighten the cover 2 with the screws 3 © 31 812 0
diagonally (torque 6 Nm)
● Check the cover 2 for proper fit and leaks
Clean (purge) - remove water: ● During initial commissioning, after
● Turn off engine or, in the case of a change- ● Bleed the fuel system, see 6.2.3.
maintenance work or if the tank is run
over filter, switch over to the other filter. empty it is essential to vent the fuel system.
● Close the fuel stopcock or supply. (if ● Set engine controller to stop position
available) ● Place fuel collecting trough under the
● Open the bleed screw 1 on the cover 2 The connection of a warning system pressure control valve 9.
● Place the fuel collector underneath the fuel (lamp/horn) via contacts 7 is ● Open fuel stopcock (if available) and
pre-filter. specified. Immediate maintenance is pressure control valve 9.
● Empty water and dirt from the bowl 6 by necessary when the warning system is ● Turn engine with starter (max. 20 sec.) or
opening (press in and turn slightly without triggered. use hand fuel pump (if available), until fuel
using force) the drain cock 8 and close the with no air bubbles escapes from pressure
drain cock 8 again Naked flames are prohibited holding valve 9.
● Close the bleed screw 1 on the cover 2 when working on the fuel ● Tighten pressure control valve 9.
© 2002
again
● Bleed the fuel pipe according to
instructions, see 6.2.5 opposite
! system! Do not smoke!
Dispose of old fuel in an environ-
mentally friendly way!
● Set engine controller to start position and
start
● When the engine has started check for
leaks
6.2.10 Changing Fuel Leakage 6.2.11 Changing Fuel Leakage

6 Line Pipes
5 6
© 30 084 0 © 30 034 1 © 30 901 0
● Set engine controller to stop position ● Close fuel stopcock ● Mounting pressure holding valve 9:
● Open fuel stopcock ● Dismantle valve cap cover Tighten up new ring piece with bolt 5.
● Loosen pressure holding valve 9 ● Loosen hose clamps 6 with hose clamp ● Remount valve cap cover
Catch any fuel which escapes and dispose pliers TN 8020 (see chap.9.3). ● Set engine controller to start position and
of in an environmentally-friendly way ● Remove rubber hoses 3 and hose clamps start
● Turn engine with starter (max. 20 sec.) 6 from the injection valves. ● When the engine has started check for
until fuel with no air bubbles escapes from ● Loosen pressure holding valve 9 leaks
pressure holding valve 9. ● Dismantle hose clamps 6, rubber hoses 1,
● Tighten up pressure holding valve 9. 3 and 4 and connection piece 2 and dispose
● Set engine controller to start position and start of in an environmentally-friendly way.
● When the engine has started check for leaks ● Mounting new fuel leakage pipes:
Slide rubber hoses 3 (lubricate inside with
Avoid naked flames when mounting grease) with hose clamps 6 on Ensure that the hose clamp lock
© 2002
working on the fuel system. Do the connection nipples of the injection shows to the injection valve and
! not smoke. Dispose of waste
fuel in an environmentally-
friendly way
valves and close with hose clamp pliers TN
8020.
! the hose clamp can't fall into the
motor housing.
6.3 Cooling System Service and Maintenance
6.3.2 Cleaning Cooling System

6.3.1 Cleaning Intervals
6
● The amount of contamination in the cooling Cold Cleansing Agent
system depends on the engine application. – Spray the heat exchanger with a com-
mercial cold cleansing agent and let
● Spilled oil or fuel on the engine increases the stand for about 10 minutes.
risk of contamination. Be especially careful if – First spray clean with a water jet from
the engine is used in dusty environments. position 3 then from position 1 (do not
● Serious contamination can occur, for spray sensitive engine components
example: directly with a water jet, eg generator,
– on construction sites where there is a cables, electronic components, fan
high level of air-borne dust. drive).
– in harvesting application where there are Cleaning with steam or with hot water
high concentrations of chaff and chopped – Remove oil and grease residues with
straw in the vicinity of the machine. the jet set at a gentle setting.
● Because applications vary, cleaning in- ● Refit service flap.

tervals have to be determined from case ● Run the engine up to normal operating
to case. The cleaning intervals given in © 26 252 1 temperature to evaporate any remaining
the table below can be used as a guide. water.
Checking / Cleaning Intervals Series 1012/1013 Series 1012E/1013E
Suggested OH Application ● Place a cleaning bath under the heat ex- ● If an external cooling system is fitted, follow
changer (it. 2). the manufacturer’s instructions.
2000 Ships, gensets in enclosed
spaces, pumps ● Remove the service flap on the heat ex- Unit engine
changer (see insert). ● Clean as described under series 1012/1013.
1000 Vehicles on paved roads
The cleaning jet must be positioned parallel to
500 Tractors, forklift trucks, Compressed Air the cooling-air ducts.
mobile gensets – Blow out heat exchanger with com-
pressed air (first from it. 3, then from
250 Vehicles on construction sites it. 1).
and unpaved roads, construc- Be careful not to damage the cooling
tion equipment, compressors, fins.
underground mining equipment
© 2002
– Wash out loosened dirt with a hose.
125 Agricultural machiner,
harvester tractors Hose pressure: max. 100 bar
Service and Maintenance 6.3 Cooling System
6 6.3.3 Draining Cooling System 6.3.4 Filling / Venting

Cooling System
1012 / 1013 1012 / 1013
1 4
3
© 30 082 0 © 26 260 3
● Place container under drain plug 3. Fill/vent the cooling system: see section ● Unscrew cap 1.
● Unscrew cap 1. 6.3.4 ● Loosen sealing plug 2.
● Unscrew drain plug 3 fully. ● Unscrew vent plug 4.
● Drain coolant. ● Unscrew sealing plug 3 (10 mm) up to the
● Drain the remaining fluid from the engine oil first notch.
cooler (coolant duct). ● Add coolant up to the max. marking or fill-up
● Screw in the sealing plug 3 up to the first If a heater is connected to the
limit (heater valve – if fitted – of the unit must
notch and screw in the sealing plug on the oil be opened).
cooling system, all heater ● Tighten sealing plug 2 (tightening torque 18 Nm)
cooler (arrow).
! valves must be opened during
filling.
Depending on the water
● Tighten vent plug 4 (tightening torque 40 Nm)
● Tighten sealing plug 3.
● Close cap 1.
Be careful when draining hot content and the installation ● Start engine and warm up until thermostat
coolant – danger of scalds! position of the heater, it may be
© 2002
opens.
! Collect drained coolant and
dispose of according to envi-
ronmental regulations.
required to repeat the last point
several times to vent the heater
● Switch off engine.
● Check coolant level (see section 3.3.3) and
system. top up as required.
6.3.6 Filling/Venting the Cooling

6.3.5 Draining the Cooling System
System 1012 E/1013 E
6
1012 E / 1013 E Standard engine
0297 4987 1
© 26 341 0 BFM 1012E
BFM 1013E
● Place a container under sealing plug 1. ● Open radiator cap position 1. Venting
● Remove sealing plug 1 from the crankcase. ● Loosen vent plug position 2. ● The cooling systems, which are built in line
● Drain off the coolant. ● Add coolant up to the maximum marking or with our installation guidelines, are vented
● Tighten sealing plug 1 again. filler limit (heater valve of the system must be automatically after they have been filled.
● If sealing plug 1 is not accessible, the system opened – if fitted). ● With external cooling systems in accordance
can be drained at the engine oil cooler ● Tighten vent plug position 2 + sealing plug with the specifications of the manufacturer.
(coolant duct). position 3.
Filling/venting the cooling system: ● Close radiator cap position 1.
See section 6.3.6. ● Start engine and warm up until thermostat
opens.
Be careful when draining hot ● Check coolant level when the engine is cold
and top up as required.
coolant – danger of scalds!
© 2002
● Close the radiator sealing plug position 1.
Collect drained coolant and
! dispose of according to envi-
ronmental regulat-ions.
Service and Maintenance 6.3 Cooling System
6.3.7 Draining the Cooling System

6 1013 E
Short engine Unit Engine (4 Cylinders)
0297 4985 1
2
© 30 299 0
BFM 1013E
● Loosen vent plug position 2 and sealing plug Venting ● Open the cap 1 of the expansion tank.
position 3. ● The cooling systems, which are built in line ● Place a container beneath knurled screw 2.
● Add coolant up to the maximum marking or with our installation guidelines, are vented ● Unscrew the knurled screw 2 in an anti-
filler limit (heater valve of the system must be automatically after they have been filled. clockwise direction until coolant is emitted.
opened – if fitted). ● With external cooling systems in accordance ● Drain off coolant.
● Tighten vent plug position 2 + sealing plug with the specifications of the manufacturer. ● In case of clogging, rinse the radiator through
position 3. ● Start the engine and warm up until the with clear water.
● Close radiator cap position 1. thermostat opens. ● Tighten knurled screw 2.
● Start engine and warm up until thermostat Filling/venting the cooling system:
opens. see section 6.3.8
● Check coolant level when the engine is cold
and top up as required.
© 2002
● Close the radiator sealing plug position 1.

6.3.8 Filling/Venting the Cooling 6.3.9 Draining the Charge-Air

Unit engine (6 cylinders) System Cooler
6
Unit Engine
1 1
2 2 1
© 30 277 0 © 30 277 0 © 30 191 0
● Open the cap 1 of the expansion tank. ● Open the cap 1 of the expansion tank. ● Loosen the drain plug 1 on the end of the
● Place a container beneath sealing plug 2. ● Slowly add coolant up to the max. marking or charge-air cooler.
● Unscrew the sealing plug 2. filler limit. ● Drain off any oil residues that may be
● Drain off coolant. ● Close the cap. remaining.
● Start the engine and warm up until the thermostat
● In case of clogging, rinse the radiator through opens, the upper coolant line warms up tangibly. ● Close the drain plug 1.
with clear water. ● Briefly run the engine at nominal output (fixed
● Tighten sealing plug 2. setting), this rinses out any pockets.
Filling/venting the cooling system: ● Switch off the engine and leave to cool down.
see section 6.3.8 ● Open cap 1, add coolant up to the max.
marking or filler limit and close the cap 1.
● Once the engine has been run once, check the
coolant level when the engine is cold.
Be careful when draining hot
coolant - danger of scalds! If a heater is connected to the cooling
© 2002
! Collect drained coolant and
dispose of according to envi-
system, the heater valves must be
opened when coolant is added. De-
pending on the coolant contents and the installation
ronmental regulations. location of the heater, it may be necessary to
repeat the procedure several times.
Service and Maintenance 6.4 Combustion Air Cleaner
6.4.1 Cleaning Intervals

6
© 25 885 1
● The amount of dirt in the air cleaner depends ● Air cleaner servicing is needed when:
on the amount of dust in the air and the size of – Service Indicator
the air cleaner used. If a high level of dust is the red signal 1 is fully visible when the
anticipated, a cyclone-type precleaner can engine is off.
be fitted to the air cleaner.
– Service Switch
● Cleaning intervals will have to be determined the yellow pilot light comes on when the
from case to case. engine is running.
● If a dry type air cleaner is used, clean when ● After carrying out service work, reset the
indicated by the service indicator or switch. signal by pressing the button on the service
indicator.
© 2002
6.4 Combustion Air Cleaner Service and Maintenance
6.4.2 Emptying Cyclone Type 6.4.3 Cleaning Oil Bath Air

Precleaner Cleaner
6
© 25 886 0 © 25 887 0
● Undo wing nut 1 and remove cover 2. ● Turn engine off and wait about 10 minutes ● Clean filter housing 1 if very dirty.
for the oil to drain from filter housing 1.
● Remove collector bowl 3 from lower sec- ● Inspect and replace rubber gaskets 5 and
tion 4 and empty. Clean leaves, straw and ● Release snap clips 2 and remove oil cup 3 6 if necessary.
other foreign matter from lower section of together with filter element 4. If necessary
precleaner. prize element out with a screwdriver, ● Fill oil cup with engine oil up to the mark
taking care not to damage the rubber (arrow) (for viscosity, see 4.1.2).
● Reposition collector bowl 3 onto lower gasket 5.
section 4, fasten cover 2 in place by ● Refit oil cup and element to filter housing
tightening wing nut 1. ● Remove dirty oil and sludge. Clean oil cup. and secure with snap clips.
● Clean filter element 4 in diesel fuel and

allow to drip-dry. Never clean air cleaner with
© 2002
gasoline. Dispose of old oil in
Never fill collector bowl with oil. Replace
collector bowl if damaged. ! accordance with environmen-
tal regulations.
Service and Maintenance 6.4 Combustion Air Cleaner
6.4.4 Dry Type Air Cleaner

6
Dust Discharge Valve Filter Cartridge
© 25 888 1 © 25 889 0
● Empty dust discharge valve 1 by pressing ● Undo clip fasteners 1. ● After five air cleaner services or after
apart lips of discharge slot as indicated two years at the latest, replace safety
by arrows. ● Take off hood 2 and remove cartridge 3. cartridge 4 (never clean).
● Clean cartridge (replace at least once a To do so:
● Clean discharge slot from time to time. year). – Undo hex. nut 5 and remove cartridge 4.
– Install new cartridge, insert and tighten
● Remove any caked dirt by pressing ● Clean cartridge 3: hex. nut.
together the upper section of the valve. – Blow out from inside out with dry com-
pressed air (max. 5 bar), or ● Install cartridge 3, replace hood 2 and do
– in difficult cases, tap out, taking care up clip fasteners.
not to damage the cartridge, or
– wash according to manufacturer’s
instructions. Never clean filter cartridge
© 2002
with gasoline or hot fluids.

● Check paper filter (light showing through)
and gaskets for damage. Replace if
necessary.
!
6.5 Belt Drives Service and Maintenance
6.5.1 Checking V-Belts

6
1012 1013
© 26 255 0 © 26 315 0 © 26 261 1
● Inspect entire V-belt for damage. ● Carefully remove the gauge without altering
the position of the indicator arm.
● Replace damaged V-belts. – Read off the value: Turn the gauge sideways
to see the exact spot where the top of the
● After installing new belts, run engine for 15 black indicator arm 1 intersects scale 5
minutes, then check belt tension. (arrow). For settings, see 9.1.
– If necessary, retension belt and measure
● Use a V-belt tension gauge (see 9.3) to again.
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. Check, tension and change
© 2002
– Push slowly on the black pad 4 at right angles belts only with the engine off.
to belt 2 until the spring is heard or felt to
trigger.
! Refit belt guard, if provided.
Service and Maintenance 6.5 Belt Drives
6.5.2 Tensioning Fan / 6.5.3 Changing Fan / 6.5.4 Tensioning Coolant /

6 Alternator Belts Alternator Belts Fuel Pump Belts
1012 1012 1012
© 26 449 0 © 26 449 0 © 26 450 0
● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1 and 2.
● Press alternator 5 in direction of arrow A until ● Press alternator in direction of arrow B. ● Push fuel pump 3 in direction of arrow (A)
correct belt tension is achieved. until correct belt tension is achieved.
● Remove and replace belt.
● Re-tighten bolts 1, 2 and 3. ● Re-tighten bolts 1 and 2.
● Tension belt in accordance with 6.5.3.
● Re-tighten bolts 1, 2 and 3.
Check, tension and change

© 2002
belts only with the engine off.

6.5.5 Changing Coolant / 6.5.6 Tensioning Coolant / 6.5.7 Changing Coolant /

Fuel Pump Belts Fuel Pump Belts Fuel Pump Belts
6
1012 1012 E 1012 E
© 26 255 0 © 26 315 0 © 26 261 1
● Remove fan belt as described in 6.5.3. ● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2.
● Slacken off bolts 1 and 2. ● Push fuel pump 3 in direction of arrow.

● Push fuel pump 3 in direction of arrow until
● Push fuel pump 3 in direction of arrow (B). correct belt tension is achieved. ● Remove and replace belt.
● Remove and replace belt. ● Tighten bolts 1 and 2. ● Push fuel pump in opposite direction of arrow
until correct belt tension is achieved.
● Push fuel pump in direction of arrow (A) until
correct belt tension is achieved. ● Tighten bolts 1 and 2.
● Tighten bolts 1 and 2.

© 2002
● Reinstall fan belt and tension as described in belts only with the engine off.
6.5.2.
6.5.8 Tensioning Alternator Belt 6.5.9 Changing Alternator Belt

6
1012 E 1012 E
© 26 449 0 © 26 449 0 © 26 450 0
● Slacken off bolts 1, 2 and 4. ● Remove fuel pump belt as described in 6.5.7.
● Move alternator 5 in direction of arrow by ● Slacken off bolts 1, 2 and 4.

turning bolt 3 until correct belt tension is
achieved. ● Adjust bolt 3 until the V-belt can be removed.
● Tighten bolts 1, 2 and 4. ● Fit new belt.
● Adjust bolt 3 until the correct belt tension is

achieved.
● Tighten bolts 1, 2 and 4.

© 2002
belts only with the engine off. ● Reinstall fuel pump belt and tension as
! Refit belt guard, if provided. described in 6.5.6.
6.5.10 Tensioning / 6.5.11 Tensioning Coolant / 6.5.12 Changing Coolant /

Changing Fan Belt Fuel Pump belts Fuel Pump Belts
6
1013 1013 1013
© 26 345 0 © 26 450 0 © 26 450 0
● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2. ● Remove fan / alternator belt as described in
– Tensioning: 6.5.10 and 6.5.13.
Insert square wrench in square and pull ● Push fuel pump 3 in direction (A) of arrow
in direction of arrow until correct belt until correct belt tension is achieved. ● Slacken off bolts 1 and 2.
tension is achieved.
● Tighten bolts 1 and 2. ● Push fuel pump 3 in direction (B) of arrow.
– Changing:
Insert square wrench in square and ● Remove and replace belt.
loosen in opposite direction of arrow.
Tension new belt as described above. ● Push fuel pump in direction (A) of arrow until
correct belt tension is achieved.
Check, tension and change ● Tighten bolts 1 and 2.
© 2002
! Refit belt guard, if provided. ● Reinstall fan / alternator belt and retension as
described in 6.5.10 and 6.5.13.
6.5.13 Tensioning /Changing 6.5.14 Tensioning Coolant /Fuel 6.5.15 Changing Coolant /
6 Alternator Belt Pump Belts Fuel Pump Belts
1013 1013 E 1013 E
© 26 449 0 © 26 380 0 © 26 383 0
Tensioning: ● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2.

● Slacken off bolts 1, 2 and 3.
● Move alternator 5 in direction of arrow (A) ● Push fuel pump 3 in direction of arrow until ● Push fuel pump 3 in direction of arrow.
until correct belt tension is achieved. correct belt tension is achieved.
● Re-tighten bolts 1, 2 and 3. ● Remove and replace belt.
Changing: ● Push fuel pump 3 in opposite direction of
● Slacken off bolts 1, 2 and 3. arrow until correct belt tension is achieved.
● Move alternator 5 in direction of arrow (B)
until belt is exposed. ● Tighten bolts 1 and 2.
● Remove and replace belt, tension (see
above).
● Re-tighten bolts 1, 2 and 3. Check, tension and change
© 2002

6.5.16 Tensioning /Changing

Compressor Belt
6
© 24 598 1 © 24 599 1
● Remove hex. bolts 1. ● To retension belt, remove one or more shims

3 – as may be required – from inside. Place
● Take off outer half-pulley 2. removed shim(s) outside on removed half-
pulley 2.
● Replace belt if necessary.
● Turn engine over while tightening bolts 1 to
prevent belt being pinched.
© 2002
! Refit guard, if provided.
Service and Maintenance 6.6 Adjustments
6 6.6.1 Checking / Adjusting Valve

Clearances
19691 2 26262 1
● Slacken off breather valve and swing to one ● Adjust valve clearance if necessary:
side. – Release locknut 4.
– Use screwdriver 7 to turn setscrew 5
● Remove rocker cover. so that the correct clearance is attained
after locknut 4 has been tightened.
● Position crankshaft as per schematic 6.6.1.1
● Check and adjust valve clearance on all
● Before adjusting valve clearance, allow remaining cylinders.
engine to cool down for at least 30 minutes.
The oil temperature should be below 80 °C / ● Replace rocker cover (use new gasket if
176 °F. needed).
● Check valve clearance between rocker arm / ● Swing breather valve back into position
© 2002
tappet contact face 2 and valve stem 3 with and secure.

feeler gauge 6 (there should be only slight
resistance when feeler blade is inserted).
For permissible valve clearance, see 9.1.
6.6 Adjustments Service and Maintenance
6
● 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.
● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in
black on schematic.
© 2002
© 26 263 2
Service and Maintenance 6.7 Accessories
6.7.1 Battery
6 6.7.1.1Checking Battery and Cable 6.7.1.2Checking Electrolyte 6.7.1.3Checking Specific
Connectors Level Gravity of Electrolyte
© 25 895 0 © 24 232 3 © 25 896 0
● Keep battery clean and dry. ● Remove caps 1. ● Measure the specific gravity of individual
cells with a commercial hydrometer.
● Undo dirty clamps. ● If testers 2 are used, the electrolyte should
come up to their base. The hydrometer reading (see table on
● Clean terminal posts (+ and –) and clamps of following page) indicates the state of charge.
the battery, and grease with acid-free and ● If testers are not used, the electrolyte level During measurement, the temperature of the
acid-resistant grease. should be 10-15 mm above the top of the electrolyte should preferably be 20°C / 68°F.
plates.
● When reassembling, ensure that clamps
make good contact. Do up clamp bolts finger ● If necessary, top up with distilled water.
tight.
● Replace caps.
© 2002
6.7 Accessories Service and Maintenance
Specific Gravity
in [kg/l] in °Bé [°Baumé]* 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 °Bé 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
© 2002
clothing.
Wear protective goggles.
Do not rest tools on the battery.
Service and Maintenance 6.7 Accessories
6 6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle
Notes on the three-phase system:
● Never disconnect the cables between bat-

tery, alternator and regulator while the engine
is running.
● If, however, it is necessary to start and ope-

rate the engine without the battery, discon-
nect the regulator from the alternator before
starting.
● Be sure not to confuse the battery terminals.
● Replace defective bulb of the charge pilot

lamp immediately.
● Cleaning the engine: Do not spray water/ © 26 264 0 © 26 265 0

steam directly onto the alternator. Run the
engine up to normal operating temperature to ● Always use proper lifting tackle when
evaporate any remaining water. transporting the engine.
● 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.
● In the case of electric welding, connect the

ground terminal on the welder directly to the
piece being welded.
Use only the correct lifting

© 2002
tackle.
!
© 2002
6
6
© 2002
7.1 Diagnosis Chart Troubleshooting
7.1 Diagnosis Chart

Troubleshooting 7.1 Diagnosis Chart
7
● If engine problems occur, they frequently have
their cause in improper operation or engine
maintenance.
● If problems do occur, always check first that

the operating and maintenance instructions
have been followed.
● A diagnosis chart is given on the facing page.
● If you cannot identify the cause of the problem

or are unable to rectify it yourself, please
contact DEUTZ Service.
Before starting, make sure that

nobody is standing in the imme-
! diate vicinity of the engine or
driven machine.
Important: When carrying out
repair work, never start the engine
with speed governor removed.
Disconnect battery.
7.1 Diagnosis Chart Troubleshooting
Fault
Engine fails or is difficult to start
Remedy
Check P
7
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Not declutched (where possible) Operation P
● ● Below starting limit temperature P
● ● Engine shutdown lever in stop position (faulty solenoid) P
● ● Oil level too low A
● ● ● ● Oil level too high S
● ● ● Excessive inclination of engine P/E
● Speed control lever set to middle position P/E
● ● ● Dirty air cleaner/Faulty turbocharger Combustion air P/W
● ● ● Air cleaner service switch/indicator defective P
● ● LDA* defective (leaking line) P
● ● ● Charge air line leaking P/W
● Coolant pump defective Cooling system P/R
● ● Charge air cooler contaminated P/R
● Coolant heat exchanger dirty P/R
● ● ● ● ● Cooling fan defective, split or loose V-belt (belt-driven fuel pump) P/W
● ● Cooling air temperature rise/ hot air recirculation P
● Battery defective or discharged Electrics P
*LDA = Aneroid device Table 1 of 2
Troubleshooting 7.1 Diagnosis Chart
7 Fault
Engine fails or is difficult to start
Remedy
Check P
Engine starts but runs unevenly or stalls Adjust E
Engine overheats. Temperature monitor gives warning Replace W
Engine gives poor performance Clean R
Engine not firing on all cylinders Top up A
Engine has little or no oil pressure Lower level S
Engine oil consumption excessive
Engine smokes - blue
- white
- black
Cause Section
● Electrics cable connections to starter, electrical system loose or oxidized Electrics P
● Starter defective or pinion does not engage P
● ● ● ● ● Incorrect valve clearance Engine E
● ● ● ● Leaking injection line P
● Vent pipe blocked (coolant heat exchanger) P/R
● ● Glow plugs defective P
● ● ● ● ● ● ● Injector defective P/W
● ● ● ● Air in fuel system P/W
● ● ● ● Fuel filter/prefilter dirty P/ R /W
● Oil filter defective W
● ● ● Incorrect lube oil SAE class or quality Operating media W
● ● ● ● Fuel quality not as per Operation Manual P/ W
● Coolant level too low P/ A
Table 2 of 2
8.1 Preservation Engine Preservation
8.1 Preservation
Engine Preservation 8.1 Preservation
8 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 pre-
servative measures described here will protect the
engine for up to 6 months. The procedure will
have 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 remove

preservatives when recommissioning engine:
– Petroleum benzine (hazardous materials
class A3) 26 268 1
Preserving Engine: ● Run engine for about 10 minutes. Removing Engine Preservatives:
● Clean engine (with cold cleansing agent if
● Turn engine off. ● Remove anti-corrosion agent from grooves in
preferred). See 6.3.2.
● Turn engine over manually several times. If V-belt pulleys 2.
● Run engine until warm, then turn off.
using starter, set shutdown lever to stop position.
● Drain engine oil (see 6.1.2) and fill with anti- ● Install V-belts 1. Retension after brief operation
corrosion oil. ● Remove V-belts 1 and store in wrapped condition. is necessary (see 6.5).
● Drain coolant (see 6.3.3/6.3.5). ● Spray grooves of V-belt pulleys 2 with anti- ● Remove covers from intake port 3 and exhaust
● Fill with anti-corrosion agent (see 4.3.3). corrosion agent. port 4.
● If necessary, clean oil bath air cleaner (see 6.4.3) ● Close off intake ports 3 and exhaust ports 4.
● Fill with coolant (see 6.3.4 / 6.3.5).
and fill with anti-corrosion oil.
● Lightly grease and replace coolant filler 5.
● Drain fuel tank. ● Start engine.
● Drain anti-corrosion agent (see 6.3.3 / 6.3.5).
● Make up a mixture of 90% diesel fuel and 10%
anti-corrosion oil, and refill fuel tank.
Technical Specifications
9.1 Engine Specifications and Settings

9.2 Torque Wrench Settings
9.3 Tools
Technical Specifications 9.1 Engine Specifications and Settings
Model ——— BF4M 1012 ——— BF4M 1012 C ———— BF6M 1012 —— BF6M 1012 C ——
9 ——— BF4M 1012 E —— BF4M 1012 EC ———— BF6M 1012 E —— BF6M 1012 EC ——
Number of cylinders ————— 4 ——————— 4 ————————— 6 ——————— 6 ————

Cylinder arrangement ————————————————— vertical, in line ————————————————
Bore [mm] ——————————————————— 94 ——————————————————
Stroke [mm] ——————————————————— 115 ——————————————————
Total displacement [cm3] ————— 3192 —————— 3192 ——————— 4788 —————— 4788 ————
Compression ratio [ε]. ——————————————————— 17.5 ——————————————————
Working cycle/Combustion system ————————— 4-stroke diesel with turbocharging and direct injection ————————
Charge air cooler ————— w/o —————— w/ ———————— w/o —————— w/ ————
Direction of rotation ———————————————— counter-clockwise ———————————————
Weight 1012 / C incl. cooling system [kg approx.] ——————————————— contact company headquarters ————————————
Weight 1012 E / EC w/o cooling system
as per DIN 70020-A [kg approx.] ————— 330 —————— 332 ——————— 435 —————— 437 ————
Engine power [kW] ———————————————————— 1). ——————————————————

Speed [rpm] ———————————————————— 1). ——————————————————
Valve clearance with cold engine [mm] ——————————————— Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. —————————————
Injector opening pressure [bar] —————————————————— 250/275 —————————————————

Start of delivery [°crank angle bTDC] ———————————————————— 1). ——————————————————
Firing order of engine ———— 1-3-4-2 ————— 1-3-4-2 —————— 1-5-3-6-2-4 ——— 1-5-3-6-2-4 ——
V-belt tension: ——————————————— Pre-tension / re-tension 2). ——————————————
Generator fan [N] ————————————————— 450 / 300 ± 50. ————————————————

Fuel pump - coolant pump [N] ————————————————— 450 / 300 ± 50. ————————————————
Compressor [N] ————————————————— 550 / 450 ± 50. ————————————————
1)
Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1
2)
Retension 15 minutes after the engine has been driven under load
9.1 Engine Specifications and Settings Technical Specifications
Model BFM1012 / E ——— BF4M 1012 ——— BF4M 1012 C ———— BF6M 1012 —— BF6M 1012 C ——
Cooling system
——— BF4M 1012 E —— BF4M 1012 EC ———— BF6M 1012 E —— BF6M 1012 EC ——
——————————————— Liquid-cooled/Cooling system protection ————————
9
Coolant quantity
1012/C [litres approx.] ————— 9.3 —————— 10.0 ——————— 12.2 —————— 13.6 ————
1012 E/EC 5) [litres approx.] ————— 5.6 —————— 5.6 ————————— 7.3 —————— 7.3 ————
1012 unit engine (with frontal radiator) [litres approx.] ————— 15.9 —————— 18.1 ———————— — ——————— — ————
Permissible continuous coolant temperature
Engine outlet, with performance group I [°C] —————————————————— max.110 6) . —————————————————
Engine outlet, with performance group II-IV [°C] —————————————————— max.105 6) . —————————————————
Thermostat initial opening at [°C] ——————————————————— 83 7) . ——————————————————

Thermostat full open temperature [°C] ——————————————————— 95 8) . ——————————————————
Coolant prewarming ——————————————————— (4 . ——————————————————
Coolant pump
9)
Delivery pressure in [bar] ——————————————————— . ——————————————————
Delivery rate in [m3 /h] ——————————————————— 9)
. ——————————————————
9)
Power consumption in [kW] ——————————————————— . ——————————————————
Lubrication ——————————————— forced-feed lubrication ——————————————
Oil temperature in oil pan [°C] ——————————————————— 125 ——————————————————

Min. oil pressure with engine warm
(120°C and SAE oil 15 W 40) and low idle speed [bar] ——————————————————— 0.8 ——————————————————
Oil capacity (first fill-up) without filter [litres approx.] ———— 8.5 3) . ————— 8.5 3) . ——————— 12.5 3) . ————— 12.5 3) . ———
Oil capacity (first fill-up) with filter [litres approx.] ———— 10.0 3) . ————— 10.0 3). ——————— 14.0 3). ————— 14.0 3). ———
3)
Approximate figures can vary depending on the design. The upper marking on the dipstick is always the maximum.
4)
Only during winter (see 3.5.1)
5)
Only engine capacity without radiator. Capacity of external cooling system dependent on cooling system design.
6)
Other performance groups have different values. Please contact company headquarters.
7)
With external cooling systems with outlet control, the temperature at which the thermostat opens is 87°C
8)
With external cooling systems with outlet control, the temperature at which the thermostat is fully opened is 102°C.
9)
Please contact company headquarters (varies depending on engine design)
Model —— BF4M 1013 — BF4M 1013 C — BF6M 1013 — BF6M 1013 C — BF6M 1013 CP —
9 —— BF4M 1013 E — BF4M 1013 EC — BF6M 1013 E — BF6M 1013 EC — BF6M 1013 ECP —
————
Number of cylinders ———— 4 —————— 4 ————— 6 —————— 6 ——————— 6 ————
Bore [mm] ——————————————————— 108 ——————————————————
Stroke [mm] ——————————————————— 130 ——————————————————
Total displacement [cm3] ——— 4764 ———— 4764 ————— 7146 ———— 7146 ————— 7146 ———
Working cycle/Combustion system ————————— 4-stroke diesel with turbocharging and direct injection —————————
Charge air cooler ———— w/o —————— w/ ————— w/o ————— w/ ————— w/ ————
Direction of rotation ———————————————— counter-clockwise ————————————————
Weight 1013 / CP incl. cooling system [kg approx.] ————————————— contact company headquarters —————————————
Weight 1013 E / EC / ECP w/o cooling system
as per DIN 70020-A [kg approx.] ———— 455 ————— 455 ————— 600 ———— 600 ————— 600 ———
Engine power [kW] ——————————————————— 1). ———————————————————

Speed [rpm] ——————————————————— 1). ———————————————————
Valve clearance with cold engine [mm] —————————————— Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1. —————————————
Injector opening pressure [bar] —————————————————— 250/275 ——————————————————
Start of delivery [°crank angle bTDC] ——————————————————— 1). ———————————————————
Firing order of engine ——— 1-3-4-2 ———— 1-3-4-2 —— 1-5-3-6-2-4 —— 1-5-3-6-2-4 — 1-5-3-6-2-4 ——
V-belt tension: —————————————— Pre-tension / re-tension 2). ——————————————
Generator fan [N] ————————————————— 450 / 300 ± 50. —————————————————

Fuel pump - coolant pump [N] ————————————————— 450 / 300 ± 50. —————————————————
Compressor [N] ————————————————— 550 / 375 ± 50. —————————————————
1)
2)
Model 1013 /E — BF4M 1013 —— BF4M 1013 C — BF6M 1013 — BF6M 1013 C — BF6M 1013 CP —
Cooling system
— BF4M 1013 E —— BF4M 1013 EC — BF6M 1013 E — BF6M 1013 EC — BF6M 1013 ECP —
———————————— Liquid-cooled/Cooling system protection ———————————
9
Coolant quantity
1013 / C / CP [litres approx.] ——— 12.1 ————— 13.6 ————— 15 ————— 16.3 ————— 16.9 ———
1013 E / EC / ECP 5) [litres approx.] ——— 7.2 —————— 7.2 ————— 9.8 —————— 9.8 ————— 9.8 ———
1013 unit engine (with frontal radiator) [litres approx.] ——— 17.5 ————— 19.7 ————— 22 ————— 23.7 ————— 23.7 ———
Engine outlet, with performance group I [°C] ————————————————— max.110 6) . —————————————————
Engine outlet, with performance group II-IV [°C] ————————————————— max.105 6) . —————————————————
Thermostat initial opening at [°C] —————————————————— 83 7) . ——————————————————

Thermostat full open temperature [°C] —————————————————— 95 8) . ——————————————————
Coolant prewarming ——————————————————— (4 . ———————————————————
Coolant pump
9)
Delivery pressure in [bar] ——————————————————— . ———————————————————
. ———————————————————
9)
Power consumption in [kW] ——————————————————— . ———————————————————
Lubrication ——————————————— forced-feed lubrication ———————————————
Oil temperature in oil pan [°C] —————————————————— max. 125 —————————————————

(120°C and SAE oil 15 W 40) and low idle speed [bar] ——————————————————— 0.8 ———————————————————
Oil capacity (first fill-up) without filter [litres approx.] —— 13 3) . ————— 13 3) . ——— 20 3) . ———— 20 3) . ———— 20 3) . ———
Oil capacity (first fill-up) with filter [litres approx.] —— 14.0 3) . ————— 14.0 3) . ——— 21.0 3) . ———— 21.0 3). ——— 21.0 3). ———
3)
4)
5)
6)
7)
With external cooling systems with outlet control, the temperature at which the thermostat opens is 87°C
8)
With external cooling systems with outlet control, the temperature at which the thermostat is fully opened is 102°C.
9)
Model ————————— BF4M 1013 FC ———————— BF6M 1013 FC —————————

9 Number of cylinders ———————————— 4 ————————————— 6 ————————————
Bore [mm] ——————————————————— 108 ——————————————————
Stroke [mm] ——————————————————— 130 ——————————————————
Total displacement [cm3] ——————————— 4764 ———————————— 7146 ———————————
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 — 1-5-3-6-2-4 ——
V-belt tension: —————————————— Pre-tension / re-tension 2). ——————————————
Generator fan [N] ————————————————— 550 / 300 ± 50. —————————————————

Fuel pump - coolant pump [N] ————————————————— 550 / 300 ± 50. —————————————————
Compressor [N] ————————————————— 650 / 400 ± 50. —————————————————
1)
2)
Model 1013 FC ————————— BF4M 1013 FC ———————— BF6M 1013 FC —————————
Cooling system ———————————— Liquid-cooled/Cooling system protection ———————————

9
Coolant quantity
1013 FC 5) [litres approx.] ——————————— 7.2 ————————————— 9.8 ———————————
Engine outlet, with performance group I [°C] ——— with flap turbocharger max.110 6) ./ with feast turbocharger max.105 6) . ———————
Engine 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 pump
7)
Delivery pressure in [bar] ——————————————————— . ———————————————————
. ———————————————————
7)
Power consumption in [kW] ——————————————————— . ———————————————————
Lubrication ——————————————— forced-feed lubrication ———————————————
Oil temperature in oil pan [°C] —————————————————— max. 125 —————————————————

(120°C 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)
4)
5)
6)
7)
Technical Specifications 9.2 Torque Wrench Settings
9 Preload [Nm] Torquing Load [Nm]

Location Total [Nm] Remarks
Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage 4
Rocker cover 8,5
Rocker arm setscrew 21

M16 x40 8.8
Mount, flywheel side 187
A4C
M16 x40 8.8
Mount, turbocharger side 187
A4C
Air intake manifold 8,5
Exhaust manifold 21
Oil drain plug 50
Injector mounting 16 Torx
Injection line mounting 30 M14x 1.5
Oil pan (cast iron) 29
Oil pan (sheet metal) 21

9.3 Tools Technical Specifications
TORX V-belt Tension Gauge Hose clamp pliers

9
25899 0 26002 0 30 902 0
A TORX wrench set is used with engines in the The V-belt tension gauge can be obtained under The hose clamp pliers can be obtained under order
1012/1013 series. This system was chosen order number 91107 from: number 8020 from
because of the many advantages it offers:
WILBÄR FA.WILBÄR
● Outstanding accessibility to bolts. Postfach 14 05 80 Postfach 14 05 80
● High load transfer when loosening and tighten- D-42826 Remscheid D-42826 Remscheid
ing.
● Almost impossible for socket to slide off or
break.
TORX tools can be ordered from:
WILBÄR
Postfach 14 05 80
D-42826 Remscheid
Technical Specifications 9.2 Tools
Filling aid Filling aid

9 BFM 1012/1013 BFM 1012/1013 E
31 145 0 32 039 0
The filling aid is obtainable under order No.

The filling aid is obtainable under order No. 170 150 from:
170 140 from:
Fa. Wilbär
Fa. Wilbär Postfach 14 05 80
Postfach 14 05 80 D-42826 Remscheid
D-42826 Remscheid
Notes
en Warnings to Place on Equipment Warning in the Manual
CALIFORNIA CALIFORNIA
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Diesel engine exhaust and some of its
constituents are known to the State of constituents are known to the State of
California to cause cancer, birth California to cause cancer, birth
defects, and other reproductive harm. defects, and other reproductive harm.
or
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Notes
CALIFORNIA PROPOSITION 65 INFORMATION en

TO CALIFORNIA CUSTOMERS AND
TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR
FOR USE IN CALIFORNIA.
Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law,
including certain chemicals in diesel engine exhaust.
Obligations of Manufactures of Diesel-Powered Off-Road Equipment. The California Superior Court has approved either of the following
two methods of compliance with Proposition 65 requirements by manufactures of off-road equipment containing diesel engines. (The court
order containing these provisions is attached.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment shipped by you into or for sale in California after
January 1, 1996. The warning must be in a location where it is easily visible to the operator of the equipment when (s)he is operating the
equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display,
you may usee that method of providing warning.
2. Operator Manual Warning. When the operator manual is next revised or by December 31, 1995 whichever is earlier, place the warning
in attachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker.
The warning must appear in one of the following locations:

● Inside The front cover
● Inside the back cover
● Outside the front cover
● Outside the back cover
● As the first page of text
Under either alternative, the warning must appear in the same size, print and format as the attachment selected or be of an equally conspicuous
size and format. If the warning is provided in an on-screen display, the warning must contain the language in the attachment and must be
provided at the time of or in connection with ignition in the same manner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California.
Should you have any questions, please call Deutz Corporation Product Support Department.
Notes
9
Service
Knowing it’s DEUTZ Order-No.: 0312 0806 10

en DEUTZ has always stood for excellence in motor
construction, pioneering many developments in
the industry. As an independent motor manu-
facturer, we offer — worldwide — a com-
prehensive 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 motor’s performance.
This index Sales & Service offers you an overview Order-No.: 0312 0807 (CD-ROM)
of the DEUTZ partners in your vicinity, including the
products for which they are responsible and the DEUTZ AG
range of services provided. But even when no direct Deutz-Mülheimer Str. 147-149
product responsibility is mentioned, your DEUTZ D-51057 Köln
partner will be happy to help you with expert advice.
Phone: 0049-221-822-0
The Index is constantly updated. Please ask your Obtainable from the local service Partner reponsible Telefax: 0049-221-822-5304
DEUTZ service partner for the latest edition. for you or from: Telex: 8812-0 khd d
http://www.deutz.de
DEUTZ AG — at your service.

Operacion Deutz

Uploaded by

Document Informationclick to expand document informationMotor 1013 1012

Document Informationclick to expand document information

Copyright:

Available Formats

Operacion Deutz

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operacion Deutz

Uploaded by

Copyright:

Available Formats

Operation Manual

Please enter the engine serial number here. This

Technical modifications required to improve our

Liquid-cooled Deutz engines are designed

Your engine is appropriately equipped for the

We have endeavoured to highlight any

Please read this Manual before starting your

We are available to help with any additional

1. General 2.5 Engine cooling 4 Operating Media

Beware of Running Engine Safety

DEUTZ original parts are asbestos-

26 332 0 26231 1 26232 1

2.1.4 Cylinder Numbering

Cylinders are numbered consecutively, beginning

2 2.2.1 Service Side 1012

1 Oil filler (option: between filters)

2.2.2 Starter Side 1012

2 2.2.3 Service Side 1012 E

1 Oil filler (option: between filters)

2.2.4 Starter Side 1012 E

2 2.2.5 Service Side 1013

1 Oil filler (option: between filters)

2.2.6 Starter Side 1013

2 2.2.7 Service Side 1013 E

2.2.8 Starter Side 1013 E 2

2 2.2.9 Starter Side

1 Coolant filler neck with cap

2.2.10 Service Side

2.2.11 Starter Side

1 Filler neck with cap

2.2.12 Service Side

2.3.1 Lube Oil Circuit Schematic

2 2.4.1 Fuel System Schematic

2.5.1 Cooling System Schematic

2.5.2 Cooling System Schematic

2.5.3 Cooling System Schematic

2.5.4 Cooling System Schematic

26243 0 24980 2 26244 0

3.1.4 Filling/Venting the Cooling

After the engine has been turned off

● Commissioning conserved engines

3 3.2.1 Electric Starting

Starting without Cold-Start Aid

● Disengage the clutch to separate the engine ● Insert key.

● Move speed control lever 1 in direction of ● Turn key clockwise.

● Turn key clockwise.

● Push key in and turn further clockwise against

● Release key as soon as engine fires.

3 3.3.1 Engine Oil Pressure

25752 1 25753 0 25754 0

● The oil pressure pilot light should go out when

3.3.2 Coolant Temperature 3.3.3 Coolant Level /

● If it is not possible to carry out a check at the

3 3.4.1 Engines with Mechanical

● Turn key counterclockwise (to Position 0) and

Where possible, do not switch the engine off from

3.5.1 Winter Operation