Operation Manual 1012 1013
! ● Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer’s warranty and maintain the engine in peak operating condition. ● This engine has been built exclusively for the application specified in the scope of supply, as described by the equipment manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose.
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 Operation Manual are necessarily mounted on your engine.
Contents 1. 2. 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 General Engine Description Model Rating Plate Position of the Rating Plate Engine Serial Number Cylinder numbering Engine Illustrations Operation side 1012 Starter side 1012 Operation side 1012 E Starter side 1012 E Operation side 1013 Starter side 1013 Operation side 1013 E Starter side 1013 E Starter side Unit Engine BF4M 1013 EC 2.2.10 Operation side Unit Engine BF4M 1013 EC 2.2.
Contents 6. Service and Maintenance 6.1 Lubrication System 6.1.1 Oil Change Intervals 6.1.2 Checking Oil Level / Changing Engine Oil 6.1.3 Changing Oil Filter 6.1.4 Cleaning/Changing Oil filter (Cup) 6.2 Fuel System 6.2.1 Changing Fuel Filter 6.2.2 Replace fuel filter 6.2.3 Clean/Replace Fuel Pre-Filter, Filter Element 6.2.4 Venting the Fuel System with Preliminary Fuel Filter 6.2.5 Clean/Replace Fuel Pre-Filter, Filter Element 6.2.6 Vent Fuel System with Fuel Pre-Filter 6.2.
General DEUTZ Diesel Engines Care and Maintenance Service are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection. Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it.
1
Engine Description 2 2.1 2.2 2.3 2.4 2.
Engine Description 2 2.1.1 Rating Plate 2.1 Model 2.1.2 Rating Plate Location 26 332 0 The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering spare parts. 2.1.3 Engine Serial Number 26231 1 The rating plate C is attached to the crankcase. 26232 1 The engine serial number is also stamped on the crankcase itself (arrow).
Engine Description 2.1 Model 2.1.4 Cylinder Numbering 2 26233 0 Cylinders are numbered consecutively, beginning at the flywheel end.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2 2.2 Engine Illustrations 2.2.
Engine Description 2.2 Engine Illustrations 2 2.2.
Engine Description 2 2.3 Lube Oil Circuit 2.3.
Engine Description 2.3 Lube Oil Circuit 2.3.
Engine Description 2 2.4 Fuel System 2.4.
Engine Description 2.5 Cooling System 2 2.5.
Engine Description 2 2.5 Cooling System 2.5.
Engine Description 2.
Engine Description 2 2.5 Cooling System 2.5.
Engine Description 2.5 Cooling System 2.5.
Engine Description 2 2.
Engine Operation 3 3.1 3.2 3.3 3.4 3.
Engine Operation 3 3.1 Commissioning 3.1.1 Adding Engine Oil 3.1.2 Filling Oil Bath Air Cleaner 26243 0 As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil quantities, see 9.1. For oil grade and viscosity, see 4.1. 24980 2 3.1.3 Adding Fuel 26244 0 Fill oil cup 1 of the oil bath air cleaner (if fitted) with oil up to the arrow. For oil grade and viscosity, see 4.1. Use only commercial-grade diesel fuel. For fuel grade, see 4.2.
Engine Operation 3.1 Commissioning 3.1.4 Filling/Venting the Cooling System 3.1.5 Other Preparations ● 1012/1013 See section 6.3.4 ● Check battery and cable connections, see 6.7.1. ● 1012 E/1013 E See section 6.3.6 ● Unit engine (with frontal radiator) See section 6.3.8. ● Trial run - After the engine has been prepared, let it run for about 10 minutes without load. During and after trial run - Check the engine for leaks.
Engine Operation 3 3.2 Starting 3.2.1 Electric Starting Starting without Cold-Start Aid Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with glow plugs, do not use any other starter substance (e.g. injection with start pilot). Doing so could result in an accident.
Engine Operation 3.2 Starting 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 3.3 Monitoring Systems 3.3.1 Engine Oil Pressure Oil Pressure Pilot Light Oil Pressure Gauge Oil Pressure Indicator 25752 1 ● The oil pressure pilot light comes on with operating voltage on and engine off. ● The oil pressure pilot light should go out when the engine is running. 25753 0 ● The pointer must remain in the green sector over the entire operating range. 25754 0 ● The pointer must indicate the minimum oil pressure (see 9.1).
Engine Operation 3.3 Monitoring Systems 3.3.2 Coolant Temperature 3 3.3.3 Coolant Level / Coolant Level Gauge 26246 0 ● The coolant temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn it off and establish the cause from the Diagnosis Chart (see 7.1). 26247 0 ● When the engine is cold, coolant level 1 should be above the KALT-COLD mark.
Engine Operation 3 3.4 Stopping 3.4.1 Engines with Mechanical Shutdown 26266 0 ● Move speed control lever 1 to low idle. ● 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. 3.4.
Engine Operation 3.5 Operating Conditions 3 3.5.1 Winter Operation ● Lube Oil Viscosity – Select the oil viscosity (SAE grade) according to the ambient temperature when the engine is started (see 4.1.2). – Increase oil change frequency when operating below –10°C, see 6.1.1. ● Battery – Efficient cold starting requires a healthy battery (see 6.7.1). – The starting limit temperature can be lowered by 4-5°C by heating the battery up to about +20°C. To do so, remove the battery and store in a warm place.
Engine Operation 3 3.5 Operating Conditions 3.5.2 High Ambient Temperature, 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 conditions, the engine can be used at altitudes up to 1000 meters / 3400 feet and temperatures up to 30°C.
Operating Media 4 © 2002 4.1 Lube Oil 4.2 Fuel 4.
Operating Media 4 4.1.1 Quality Grade 4.1.2 Viscosity Lube oils are differentiated by Deutz according to their performance and quality class. Oils of other, comparable specifications can be used. Generally, multi-grade oils shall be used. In closed heated rooms at temperatures >5°C, also single-grade oils can be used.
Operating Media 4.1.2.1 Specific lube oil definitions The oils listed in the table are to be used for the following engines and applications: ● 1013FC ● all engines in block-type thermal power stations ● all engines in gensets operating in parallel with the mains / with each other ● engines in harvesting machines These are high-grade oils.
Operating Media 4 4.2 Fuel 4.2.1 Quality Grade 4.2.2 Winter-Grade Fuel Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulfur content is higher than 0.5%, oil change intervals should be reduced (see 6.1.1). Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0 °C, winter-grade fuel (suitable down to -20 °C) should be used.
Operating Media 4.3.1 Water Quality for Coolant Preparation 4.3.2 Coolant Preparation 4.3.3 Cooling System Protective Liquid The values given below must not be exceeded. A test kit (order number 1213 0382) can be obtained from DEUTZ Service to check the quality of the water available. The preparation and monitoring of coolant in liquid-cooled engines is especially important because corrosion, cavitation and freezing can lead to engine damage.
Operating Media 4.3 Coolant 4 Cooling System Protection Cooling system capacity *) [Liters] Cooling system protection [Vol %] Cooling protective agent [°C] 18 35 –22 2.8 7.0 7.7 8.75 9.5 40 –28 7.2 8.0 8.8 10.0 45 –35 8.1 9.0 9.9 50 –45 9.0 10.0 11.0 22 25 27 30 32 35 10.5 11.2 12.3 10.8 12.0 12.8 14.0 11.3 12.2 13.5 14.4 15.8 12.5 13.5 15.0 16.0 17.5 Cooling system protective liquid [Liters] *) For quantity of coolant in your engine, see Section 9.1.
Routine Maintenance 5 © 2002 5.1 Maintenance Schedule 5.2 Maintenance Chart 5.
Routine Maintenance 5 Maintenance step= E Check= ● 5.
Routine Maintenance 5.1 Maintenance Schedule 5 Check= ● Adjust= ❍ Clean= ▲ Replace= ■ Before or during 1st test run, during commissioning check twice daily or when commissioning new or reconditioned engines Every 10 operating hours or daily In operating hours (OH), every E10 ● ● ● *E70 1012 Engines 10000OH *E70 1013 Engines 13000OH The specified engine maintenance times are the max. permissible recommended times. Depending on the application shorter maintenance times may be necessary.
Routine Maintenance 5.2 Maintenance Chart 5.2.
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 engine or driven equipment. in. a ex. in. h Std. 0,3 mm 0.012 in. 0,5 mm 0.020 in. 5 OIL 500 1500 ex. ER WAT Check that this is the case. 10 AIR 10 ca. 15 mm 0.6 in. If necessary, ask your engine or equipment supplier for a fresh supply of labels.
Routine Maintenance 5.2 Maintenance Chart © 2002 5 BFM 1012 BFM 1013 0297 4979 1 The maintenance chart shown here is supplied as self-adhesive label with each engine. It should be affixed where it can be seen clearly on the engine or driven equipment. Check that this is the case. If necessary, ask your engine or equipment supplier for a fresh supply of labels. Routine work should be carried out according to the schedule in 5.1.
Routine Maintenance 5.2 Maintenance Chart BFM 1013E 5 0297 4985 1 The maintenance chart shown here is supplied as self-adhesive label with each engine. It should be affixed where it can be seen clearly on the engine or driven equipment. Check that this is the case. If necessary, ask your engine or equipment supplier for a fresh supply of labels. Routine work should be carried out according to the schedule in 5.1.
Routine Maintenance 5 Hours. Date Signaure / Stamp 50-150* 5.3 Completed Maintenance Jobs Hours - 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.
Routine Maintenance 5.3 Completed Maintenance Jobs Hours Date Signaure / Stamp Hours 2875 3000 3125 3250 3375 3500 3625 3750 3875 4000 4125 4250 4375 4500 4625 4750 4875 5000 5125 5250 5375 5500 5625 5750 The maintenance jobs duly completed can be recorded in the above table.
Routine Maintenance 5 Hours. Date Signaure / Stamp 5.3 Completed Maintenance Jobs Hours 5875 6000 6125 6250 6375 6500 6625 6750 6875 7000 7125 7250 7375 7500 7625 7750 7825 8000 8125 8250 8375 8500 8625 8750 The maintenance jobs duly completed can be recorded in the above table.
Hours Date Signaure / Stamp Hours 8875 9000 9125 9250 9375 9500 9625 9750 9875 10000 10125 10250 10375 10500 10625 10750 10825 11000 11125 11250 11375 11500 11625 11750 The maintenance jobs duly completed can be recorded in the above table.
5 Hours.
Service and Maintenance 6 Lubrication System Fuel System Cooling System Combustion Air Cleaner Belt Drives Adjustments Accessories © 2002 6.1 6.2 6.3 6.4 6.5 6.6 6.
Service and Maintenance 6 6.1.1 Oil Change Intervals ● The oil change intervals are dependent on the engine application and the quality of the lube oil. ● If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year. ● The table refers to the following conditions: – For diesel fuel: sulfur content max. 0.5 % by weight. – Continuous ambient temperatures down to -10 °C / +14°F ● For fuels – with sulfur content is > 0.
Service and Maintenance 6.1 Lubrication System 6 6.1.1.1 Equipment Engines Lube oil grade Deutz lube oil quality class DQC I DQC II DQC III ACEA-specfication E2-96 E3-96/E5-02 E4-99 CF/CF-4 CG-4/CH-4 Worldwide specification - DHD-1 special DEUTZ release list - - API-specfication Standard lube oil code for building equipment and nonraod vehicles Engine EO.. . Oil use All engines except for: see chap. 4.1.2.1 EO...C - Lube oil change intervals in op. hours normal 1012 - EO...
Service and Maintenance 6 6.1.1.2 Oil change intervals for vehicle engines Deutz lube oil quality class ACEA-specification API-specification CF/CF-4 worldwide specification special DEUTZ release Application Site vehicles/ Stadtbusse city busses © 2002 Long distance Lube oil-quality DQC I E2-96 CG-4/CH-4 - DQC II E3-96/E5-02 DHD-1 DQC III E4-99 - - - see chap. 4.1.2.1 Engine version 1012/1013 BF4M1013FC 25 BF6M1013FC Average speed in km/h approx. Local traffic 6.
6.1 Lubrication System Service and Maintenance 6 6.1.2 Checking Oil Level / Changing Engine Oil 6.1.2.1Checking Oil Level 6.1.2.2 Changing Engine Oil ● Ensure that the engine or vehicle is on a level surface. ● – Warm engine ● Switch off engine, wait 5 minutes and check the oil level ● –Cold engine Check the oil level ● Remove the dipstick ● Wipe off with a non-fibrous, clean cloth. ● Insert up to the stop and pull out again.
Service and Maintenance 6 6.1 Lubrication System 6.1.3 Changing Oil Filter © 25 880 0 ● With fitted torsion lock: Loosen screws and slide clamps downwards. ● Undo the filter cartridge with commercial tool and spin off. © 25 882 0 © 25 881 0 ● Clean any dirt from the filter carrier rim. ● Lightly oil the rubber gasket of the new oil filter cartridge. ● Screw in the new cartridge finger tight against the gasket.
6.1 Lubrication System Service and Maintenance 6 6.1.4 Cleaning/Changing Oil filter (Cup) 1 2 3 4 © 30 074 0 ! Caution: hot oil! Risk of scalding! ● Replace rubber seal 2 and apply a small amount of grease ● Carefully insert the new paper filter cartridge 3 in guide 4. ● Tighten lube oil filter cover 1 in the clockwise direction (25 Nm). ● Start the engine. ● Check the oil level, see 6.1.2. ● Check the oil pressure, see 3.3.1. ● Check lube oil filter fitting for leaks.
Service and Maintenance 6 6.2 Fuel System 6.2.1 Changing Fuel Filter © 25 880 0 © 25 882 0 © 25 881 0 ● Close fuel stopcock. ● Clean any dirt from the filter carrier rim. ● Undo fuel filter cartridge with commercial tool and spin off. ● Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge. ● Catch any fuel. ● Screw in the new cartridge finger tight against the gasket.
Service and Maintenance 6.2 Fuel System 6.2.2 Replace Fuel Filter 6 © 36 650 0 © 25 881 0 © 25 882 0 z Close the fuel shut-off valve. z Undo fuel filter cartridge with commercial tool and spin off. z Apply light film of oil or diesel fuel to the rubber gasket of the new original DEUTZ fuel filter cartridge. z Catch any escaping fuel. z Manually screw in the new cartridge until the gasket is flush. z Open fuel shut-off valve. z Bleed fuel system, see 6.2.4.
Service and Maintenance 6 6.2 Fuel System 6.2.3 Clean/Replace Fuel Pre-Filter, Filter Element 6.2.4 Venting the Fuel System 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. © 2002 © 25 801 0 Clean: ● Close fuel stopcock. ● Place the fuel pan beneath the preliminary fuel filter.
Service and Maintenance 6.2.5 Clean/Replace Fuel Pre-Filter, Filter Element 6.2.6 Vent Fuel System with Fuel Pre-Filter © 30 084 0 © 36 649 0 Clean/Replace: z Close the fuel shut-off valve. z Place fuel collection container beneath the fuel pre-filter. z Loosen the drain screw 7+9 and drain fuel. z Turn the filter element housing 4 with gasket 3 and filter element 3 anti-clockwise and remove.
Service and Maintenance 6 6.2 Fuel System 6.2.7 Clean/Replace/Vent Fuel Pre-Filter, Filter Element © 2002 © 36648 0 Clean: z Close the fuel shut-off valve. z Place fuel collection container beneath the fuel pre-filter. z Loosen the drain screw 5 and drain fuel/ water. z Turn filter cartridge 2 and dirt trap 3 anticlockwise and remove. z Turn dirt trap 3 anticlockwise and remove. z Empty emulsion into the fuel collection container and clean the dirt trap 3.
Service and Maintenance 6.2.8 Clean / purge or change fuel pre-filter © 31 811 2 Clean (purge) - remove water: ● Turn off engine or, in the case of a changeover filter, switch over to the other filter. ● Close the fuel stopcock or supply. (if available) ● Open the bleed screw 1 on the cover 2 ● Place the fuel collector underneath the fuel pre-filter.
Service and Maintenance 6 6.2.10 Changing Fuel Leakage Line 6.2 Fuel System 6.2.11 Changing Fuel Leakage Pipes 5 © 30 084 0 © 2002 ● Set engine controller to stop position ● Open fuel stopcock ● Loosen pressure holding valve 9 Catch any fuel which escapes and dispose of in an environmentally-friendly way ● Turn engine with starter (max. 20 sec.) until fuel with no air bubbles escapes from pressure holding valve 9. ● Tighten up pressure holding valve 9.
6.3.1 Cleaning Intervals Service and Maintenance Cold Cleansing Agent – Spray the heat exchanger with a commercial cold cleansing agent and let stand for about 10 minutes. – First spray clean with a water jet from position 3 then from position 1 (do not spray sensitive engine components directly with a water jet, eg generator, cables, electronic components, fan drive). Cleaning with steam or with hot water – Remove oil and grease residues with the jet set at a gentle setting.
Service and Maintenance 6 6.3 Cooling System 6.3.4 Filling / Venting Cooling System 1012 / 1013 6.3.3 Draining Cooling System 1012 / 1013 2 1 4 3 © 26 260 3 © 30 082 0 © 2002 ● Place container under drain plug 3. ● Unscrew cap 1. ● Unscrew drain plug 3 fully. ● Drain coolant. ● Drain the remaining fluid from the engine oil cooler (coolant duct). ● Screw in the sealing plug 3 up to the first notch and screw in the sealing plug on the oil cooler (arrow).
Service and Maintenance 1012 E / 1013 E © 26 341 0 ● Place a container under sealing plug 1. ● Remove sealing plug 1 from the crankcase. ● Drain off the coolant. ● Tighten sealing plug 1 again. ● If sealing plug 1 is not accessible, the system can be drained at the engine oil cooler (coolant duct). Filling/venting the cooling system: See section 6.3.6. ! Be careful when draining hot coolant – danger of scalds! Collect drained coolant and dispose of according to environmental regulat-ions. 6 6.3.
Service and Maintenance 6 6.3 Cooling System 6.3.7 Draining the Cooling System 1013 E Short engine Unit Engine (4 Cylinders) © 2002 BFM 1013E 0297 4985 1 1 ● Loosen vent plug position 2 and sealing plug position 3. ● Add coolant up to the maximum marking or filler limit (heater valve of the system must be opened – if fitted). ● Tighten vent plug position 2 + sealing plug position 3. ● Close radiator cap position 1. ● Start engine and warm up until thermostat opens. ● Switch off engine.
Service and Maintenance 6.3 Cooling System Unit engine (6 cylinders) 1 6.3.9 Draining the Charge-Air Cooler 6 1 1 2 © 30 277 0 ● Open the cap 1 of the expansion tank. ● Place a container beneath sealing plug 2. ● Unscrew the sealing plug 2. ● Drain off coolant. ● In case of clogging, rinse the radiator through with clear water. ● Tighten sealing plug 2. Filling/venting the cooling system: see section 6.3.
Service and Maintenance 6 6.4 Combustion Air Cleaner 6.4.1 Cleaning Intervals © 25 885 1 ● The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner. ● Cleaning intervals will have to be determined from case to case. © 2002 ● If a dry type air cleaner is used, clean when indicated by the service indicator or switch.
6.4 Combustion Air Cleaner © 25 886 0 ● Undo wing nut 1 and remove cover 2. ● Remove collector bowl 3 from lower section 4 and empty. Clean leaves, straw and other foreign matter from lower section of precleaner. ● Reposition collector bowl 3 onto lower section 4, fasten cover 2 in place by tightening wing nut 1. 6 6.4.3 Cleaning Oil Bath Air Cleaner © 25 887 0 ● Turn engine off and wait about 10 minutes for the oil to drain from filter housing 1.
Service and Maintenance 6 6.4 Combustion Air Cleaner 6.4.4 Dry Type Air Cleaner Filter Cartridge Dust Discharge Valve © 25 888 1 ● Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows. ● Clean discharge slot from time to time. © 2002 ● Remove any caked dirt by pressing together the upper section of the valve. © 25 889 0 ● Undo clip fasteners 1. ● Take off hood 2 and remove cartridge 3. ● Clean cartridge (replace at least once a year).
Service and Maintenance 6.5 Belt Drives 6 6.5.1 Checking V-Belts 1013 © 26 315 0 © 26 255 0 ● Inspect entire V-belt for damage. ● Replace damaged V-belts. ● After installing new belts, run engine for 15 minutes, then check belt tension. ● Use a V-belt tension gauge (see 9.3) to check belt tension. – Place indicator arm 1 into gauge. – Position gauge on V-belt 2, midway between the pulleys, with flange 3 on bottom of gauge against the edge of belt.
Service and Maintenance 6 6.5 Belt Drives 6.5.4 Tensioning Coolant / Fuel Pump Belts 1012 6.5.3 Changing Fan / Alternator Belts 1012 6.5.2 Tensioning Fan / Alternator Belts 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 correct belt tension is achieved. ● Press alternator in direction of arrow B.
Service and Maintenance 6.5 Belt Drives © 26 315 0 © 26 255 0 ● Remove fan belt as described in 6.5.3. 6 6.5.7 Changing Coolant / Fuel Pump Belts 1012 E 6.5.6 Tensioning Coolant / Fuel Pump Belts 1012 E 6.5.5 Changing Coolant / Fuel Pump Belts 1012 ● Slacken off bolts 1 and 2. © 26 261 1 ● Slacken off bolts 1 and 2. ● Push fuel pump 3 in direction of arrow. ● Slacken off bolts 1 and 2. ● Push fuel pump 3 in direction of arrow (B).
Service and Maintenance 6 6.5.8 Tensioning Alternator Belt 6.5 Belt Drives 6.5.9 Changing Alternator Belt 1012 E 1012 E © 26 449 0 © 26 449 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 turning bolt 3 until correct belt tension is achieved. ● Slacken off bolts 1, 2 and 4. ● Tighten bolts 1, 2 and 4. ● Fit new belt. ● Adjust bolt 3 until the V-belt can be removed.
Service and Maintenance 6.5 Belt Drives 6.5.11 Tensioning Coolant / Fuel Pump belts 1013 © 26 345 0 ● Slacken off bolts 1 and 2. – Tensioning: Insert square wrench in square and pull in direction of arrow until correct belt tension is achieved. – Changing: Insert square wrench in square and loosen in opposite direction of arrow. Tension new belt as described above. 6 6.5.12 Changing Coolant / Fuel Pump Belts 1013 © 26 450 0 © 26 450 0 ● Slacken off bolts 1 and 2.
Service and Maintenance 6 6.5.13 Tensioning /Changing Alternator Belt 1013 6.5.14 Tensioning Coolant /Fuel Pump Belts 1013 E © 26 449 0 Tensioning: ● Slacken off bolts 1, 2 and 3. ● Move alternator 5 in direction of arrow (A) until correct belt tension is achieved. ● Re-tighten bolts 1, 2 and 3. 6.5 Belt Drives 6.5.15 Changing Coolant / Fuel Pump Belts 1013 E © 26 380 0 © 26 383 0 ● Slacken off bolts 1 and 2. ● Slacken off bolts 1 and 2.
Service and Maintenance 6.5 Belt Drives 6 6.5.16 Tensioning /Changing Compressor Belt © 24 598 1 ● Remove hex. bolts 1. ● Take off outer half-pulley 2. © 24 599 1 ● To retension belt, remove one or more shims 3 – as may be required – from inside. Place removed shim(s) outside on removed halfpulley 2. ● Replace belt if necessary. ! Check, tension and change belts only with the engine off. Refit guard, if provided. © 2002 ● Turn engine over while tightening bolts 1 to prevent belt being pinched.
Service and Maintenance 6 6.6 Adjustments 6.6.1 Checking / Adjusting Valve Clearances 19691 2 ● Slacken off breather valve and swing to one side. ● Remove rocker cover. 26262 1 ● Adjust valve clearance if necessary: – Release locknut 4. – Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened. ● Position crankshaft as per schematic 6.6.1.1 © 2002 ● Before adjusting valve clearance, allow engine to cool down for at least 30 minutes.
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. © 26 263 2 © 2002 6.
Service and Maintenance 6 6.7.1 Battery 6.7.1.1Checking Battery and Cable Connectors 6.7.1.3Checking Specific Gravity of Electrolyte 6.7.1.2Checking Electrolyte Level © 25 895 0 © 24 232 3 ● Keep battery clean and dry. ● Remove caps 1. ● Undo dirty clamps. ● If testers 2 are used, the electrolyte should come up to their base. ● Clean terminal posts (+ and –) and clamps of the battery, and grease with acid-free and acid-resistant grease. ● When reassembling, ensure that clamps make good contact.
Service and Maintenance 6.7 Accessories 6 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 ! The gases emitted by the battery are explosive. Keep sparks and naked flames away from the battery. Do not allow battery acid to come into contact with skin or clothing. Wear protective goggles. Do not rest tools on the battery.
Service and Maintenance 6 6.7.2 Three-Phase Alternator 6.7 Accessories 6.7.3 Lifting Tackle Notes on the three-phase system: ● Never disconnect the cables between battery, alternator and regulator while the engine is running. ● If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting. ● Be sure not to confuse the battery terminals. ● Replace defective bulb of the charge pilot lamp immediately.
© 2002 6
© 2002 6
Troubleshooting 7.1 Diagnosis Chart 7 7.
Troubleshooting 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 immediate vicinity of the engine or driven machine.
7.1 Diagnosis Chart Fault Engine fails or is difficult to start Engine starts but runs unevenly or stalls Engine overheats.
Troubleshooting 7 7.1 Diagnosis Chart Fault Engine fails or is difficult to start Engine starts but runs unevenly or stalls Engine overheats.
Engine Preservation 8.1 Preservation 8 8.
Engine Preservation 8 8.1 Preservation 8.1 Preservation If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rust formation. The preservative measures described here will protect the engine for up to 6 months. The procedure will have to be reversed before the engine is recommissioned.
Technical Specifications 9 9.1 Engine Specifications and Settings 9.2 Torque Wrench Settings 9.
Technical Specifications 9 9.
9.1 Engine Specifications and Settings Model BFM1012 / E Cooling system Coolant quantity 1012/C [litres approx.] 1012 E/EC 5) [litres approx.] 1012 unit engine (with frontal radiator) [litres approx.
Technical Specifications 9 Model Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle/Combustion system [mm] [mm] [cm3] [ε]. Charge air cooler Direction of rotation 9.
9.1 Engine Specifications and Settings Model 1013 /E Cooling system Coolant quantity 1013 / C / CP [litres approx.] 1013 E / EC / ECP 5) [litres approx.] 1013 unit engine (with frontal radiator) [litres approx.
Technical Specifications 9 9.1 Engine Specifications and Settings Model ————————— BF4M 1013 FC ———————— BF6M 1013 FC ————————— Number of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle/Combustion system ———————————— 4 ————————————— 6 ———————————— ————————————————— vertical, in line ———————————————— ——————————————————— 108 —————————————————— ——————————————————— 130 —————————————————— ——————————— 4764 ———————————— 7146 ——————————— ——————————————————— 17.
9.1 Engine Specifications and Settings Technical Specifications Model 1013 FC ————————— BF4M 1013 FC ———————— BF6M 1013 FC ————————— Cooling system Coolant quantity 1013 FC 5) [litres approx.
Technical Specifications 9 9.2 Torque Wrench Settings Preload [Nm] Torquing Load [Nm] Location Total [Nm] Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Remarks Stage 4 Rocker cover 8,5 Rocker arm setscrew 21 Mount, flywheel side 187 Mount, turbocharger side 187 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 M16 x40 8.8 A4C M16 x40 8.
Technical Specifications 9.3 Tools TORX 25899 0 A TORX wrench set is used with engines in the 1012/1013 series. This system was chosen because of the many advantages it offers: ● Outstanding accessibility to bolts. ● High load transfer when loosening and tightening. ● Almost impossible for socket to slide off or break.
Technical Specifications 9 Filling aid BFM 1012/1013 Filling aid BFM 1012/1013 E 32 039 0 31 145 0 The filling aid is obtainable under order No. 170 140 from: Fa. Wilbär Postfach 14 05 80 D-42826 Remscheid 9.2 Tools The filling aid is obtainable under order No. 170 150 from: Fa.
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 constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 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 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.
Notes 9
Service en Order-No. : 0312 0806 Knowing it’s DEUTZ DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry. As an independent motor manufacturer, we offer — worldwide — a comprehensive range of diesel and gas motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers’ individual requirements. Over 1.4 million DEUTZ motors do their job reliably all over the world.
