Deutz BF6M 1013 Operation Manual
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. The manufacturer will
not assume responsibility for any damage
resulting therefrom. The risks involved are
to be borne solely by the user.
● Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for
operation, maintenance and servicing. The
engine should only be operated by personnel trained in its use and the hazards
involved.
● The relevant accident prevention guidelines
and other generally accepted safety and
industrial hygiene regulations must be observed.
● When the engine is running, there is a risk
of injury through:
- turning/hot components
- engines with positive ignition
- ignition systems (high electrical voltage)
You must avoid contact at all times!
● Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage.
Manipulations of the injection and regulating
system may also influence the performance
of the engine, and its emissions. Adherence
to legislation on pollution cannot be guaranteed under such conditions.
● Do not change, convert or adjust the cooling
air intake area to the blower.
The manufacturer shall not be held responsible for any damage which results from
such work.
● When carrying out maintenance/repair operations on the engine, the use of DEUTZ
original parts is prescribed. These are
specially designed for your engine and
guarantee perfect operation.
Non-compliance results in the expiry of the
warranty!
● Maintenance and cleaning of the engine
should only be carried out when the engine
is switched off and has cooled down.
Y ou must ensure that the electrical systems
have been switched off and the ignition
key has been removed.
Accident prevention guidelines concerning
electrical systems (e.g. VDE-0100/-0101/
-0104/-0105 Electrical protective measures
against dangerous touch voltage) are to be
observed.
When cleaning with fluids, all electrical
components are to be covered impermeably.
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).
Operation Manual
1012
1013
0297 9682 en
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.
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. Engine Description
2.1 Model
2.1.1 Rating Plate
2.1.2 Position of the Rating Plate
2.1.3 Engine Serial Number
2.1.4 Cylinder numbering
2.2 Engine Illustrations
2.2.1 Operation side 1012
2.2.2 Starter side 1012
2.2.3 Operation side 1012 E
2.2.4 Starter side 1012 E
2.2.5 Operation side 1013
2.2.6 Starter side 1013
2.2.7 Operation side 1013 E
2.2.8 Starter side 1013 E
2.2.9 Starter side
Unit Engine BF4M 1013 EC
2.2.10 Operation side
Unit Engine BF4M 1013 EC
2.2.11 Starter side
Unit Engine BF6M 1013 EC
2.2.12 Operation side
Unit Engine BF6M 1013 EC
2.3 Lube Oil Circuit Schematic
2.3.1 Lube Oil Circuit 1012 / 1012 E
2.3.2 Lube Oil Circuit 1013 / 1013 E
2.4 Fuel System
2.4.1 Fuel System Plan
2.5 Engine cooling
2.5.1 Cooling System Schematic 1012
2.5.2 Cooling System Schematic 1012 E
2.5.3 Cooling System Schematic 1013
2.5.4 Cooling System Schematic 1013 E/
1013 E
3. Engine Operation
3.1 Commissioning
3.1.1 Pour in Engine Oil
3.1.2 Filling Oil Bath Air Cleaner
3.1.3 Pour in Fuel
3.1.4 Filling / Venting the Cooling System
3.1.5 Other Preparations
3.2 Starting
3.2.1 Starting
3.3 Monitoring Operation
3.3.1 Engine Oil Pressure
3.3.2 Coolant temperature
3.3.3 Coolant Level / Coolant Level
Gauge
3.4 Shutting off
3.4.1 Mechanical shut-off
3.4.2 Electrical shut-off
3.5 Operating conditions
3.5.1 Winter Operation
3.5.2 High Ambient Temperature, High
Altitude
4 Operating Media
4.1 Lube Oil
4.1.1 Quality
4.1.2 Viscosity
4.2 Fuel
4.2.1 Quality Grade
4.2.2 Winter-Grade Fuel
4.3 Coolant
4.3.1 Water Quality for Coolant
Preparation
4.3.2 Coolant Preparation
4.3.3 Cooling System Protective Liquid
5. Routine Maintenance
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Record
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
6.2.7 Clean/Replace/Vent Fuel Pre-Filter,
Filter Element
6.2.8 Clean / purge or change fuel
pre-filter
6.2.9 Venting the Fuel System
with Preliminary Fuel Filter
6.2.10 Changing Fuel Leakage
Line
6.2.11 Changing Fuel Leakage Pipes
6.3 Cooling System
6.3.1 Cleaning Intervals
6.3.2 Cleaning Cooling System
6.3.3 Draining Cooling System
1012 / 1013
6.3.4 Filling / Venting Cooling System
1012 / 1013
6.3.5 Draining the Cooling System
1012 E / 1013 E
6.3.6 Filling/Venting the Cooling System
1012 E/1013 E
6.3.7 Draining the Cooling System
Unit Engine
6.3.8 Filling/Venting the Cooling System
Unit Engine
6.3.9 Draining the Charge-Air Cooler
6.4 Combustion Air Cleaner
6.4.1 Cleaning Intervals
6.4.2 Emptying Cyclone Type Precleaner
6.4.3 Cleaning Oil Bath Air Cleaner
6.4.4 Dry Type Air Cleaner
6.5 Belt Drives
6.5.1 Checking V-Belts
6.5.2 Tensioning Fan / Alternator Belts
1012
6.5.3 Changing Fan / Alternator Belts 1012
6.5.4 Tensioning Coolant / Fuel Pump Belts
1012
6.5.5 Changing Coolant / Fuel Pump Belts
1012
6.5.6 Tensioning Coolant / Fuel Pump Belts
1012 E
6.5.7 Changing Coolant / Fuel Pump Belts
1012 E
6.5.8 Tensioning Alternator Belt 1012 E
6.5.9 Changing Alternator Belt 1012 E
6.5.10Tensioning / Changing Fan Belt 1013
6.5.11Tensioning Coolant / Fuel Pump belts
1013
6.5.12Changing Coolant / Fuel Pump Belts
1013
6.5.13Tensioning / Changing Alternator
Belt 1013
6.5.14Tensioning Coolant / Fuel Pump Belts
1013 E
6.5.15Changing Coolant / Fuel Pump Belts
1013 E
6.5.16Tensioning / Changing Compressor
Belt
6.6 Adjustments
6.6.1 Checking / Adjusting Valve
Clearances
6.7 Accessories
6.7.1 Battery
6.7.1.1 Checking Battery and Cable
Connectors
6.7.1.2 Checking Electrolyte Level
6.7.1.3 Checking Specific Gravity of
Electrolyte
6.7.2 Three-Phase Alternator
6.7.3 Lifting Tackle
7. Faults, Causes and Remedies
7.1 Fault Table
8. Engine Preservation
8.1 Preservation
9. Technical Specification
9.1 Engine Specifications and Settings
9.2 Screw Tightening Torques
9.3 Tools
10. Service
General
DEUTZ Diesel Engines
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.
Beware of Running Engine
Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot
be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any
panels and guards that may have been removed.
Never fill the fuel tank while the engine is running.
Observe industrial safety regulations when running
the engine in an enclosed space or underground.
Care and Maintenance
Sound care and maintenance practices will ensure
that the engine continues to meet the requirements
placed on it. Recommended service intervals must
be observed and service and maintenance work
carried out conscientiously.
Special care should be taken under abnormally
demanding operating conditions.
Safety
This symbol is used for all safety
warnings. Please follow them
!
and accident prevention regulations laid down by
law must also be observed.
carefully. The attention of operating
personnel should be drawn to these
safety instructions. General safety
Service
1
Please contact one of our authorized service
representatives in the event of breakdowns or for
spare parts inquiries. Our trained specialists will
carry out repairs quickly and professionally, using
only genuine spare parts.
Original parts from DEUTZ AG are always produced
in accordance with state-of-the-art technology.
Please turn to the end of this manual for further
service information.
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.
Asbestos
DEUTZ original parts are asbestosfree.
1
2.1 Model
2.2 Engine Illustrations
2.3 Lube Oil Circuit
2.4 Fuel System
2.5 Cooling System
Engine Description
2
Engine Description
2.1 Model
2
2.1.1 Rating Plate 2.1.2 Rating Plate Location
26 332 0
The rating plate C is attached to the crankcase.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 26232 1
The engine serial number is also stamped on the
crankcase itself (arrow).
2.1 Model Engine Description
2.1.4 Cylinder Numbering
26233 0
Cylinders are numbered consecutively, beginning
at the flywheel end.
2
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
Engine Description
2.2 Engine Illustrations
2
2.2.3 Service Side 1012 E
1 Oil filler (option: between filters)
2 Coolant inlet
3 Coolant pump
4 Alternator
5 Belt pulley
6 Engine mount
7 Fuel pump
8 Fuel filter
9 Lube oil filter
10 Oil pan
11 Dipstick
12 Lube oil cooler
13 Mounting facility for hydraulic pump
14 Back leak fuel pipe with pressure-regulating
valve
15 Cylinder head
26236 0
2.2 Engine Illustrations Engine Description
2.2.4 Starter Side 1012 E
2
16 Lifting points
17 Exhaust turbocharger
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
Engine Description
2.2 Engine Illustrations
2
2.2.5 Service Side 1013
1 Oil filler (option: between filters)
2 Alternator
3 Coolant pump
4 Fan
5 Belt Pulley
6 Vibration damper
7 Fuel pump
8 Engine mount
9 Fuel 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 Engine Illustrations Engine Description
2.2.6 Starter Side 1013
2
19 Lifting points
20 Exhaust turbocharger
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
Engine Description
2.2 Engine Illustrations
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
12 Back leak fuel pipe with pressure-regulating
valve
13 Cylinder head
A Coolant inlet
26 336 0
2.2 Engine Illustrations Engine Description
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
20 Exhaust turbocharger
21 Fan
22 Exhaust manifold
23 Air intake manifold
26 337 0
Engine Description
2.2 Engine Illustrations
2
2.2.9 Starter Side
Unit Engine BF4M 1013 EC
1 2 3 4 5 6 7
12
8
9
10
1 Coolant filler neck with cap
2 Expansion tank
3 Vent line from cylinder head to expansion tank
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
exhaust turbocharger
9 Exhaust turbocharger
10 Coolant line from crankcase to engine fluid
radiator
11 Charge-air cooler
12 Engine fluid radiator
13 Coolant line from engine fluid radiator to engine
thermostat
1113
26 336 0
30 088 0
2.2 Engine Illustrations Engine Description
2.2.10 Service Side
Unit Engine BF4M 1013 EC
3
13
2
3 Ventilation line from cylinder head to expansion
tank
13 Charge-air line from charge-air cooler to engine
14 Protective guard
14
26 337 030 089 0
Engine Description
2.2 Engine Illustrations
2
2.2.11 Starter Side
Unit Engine BF6M 1013 EC
1 32
4 5 6 7
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
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 Engine Illustrations Engine Description
2.2.12 Service Side
Unit Engine BF4M 1013 EC
2
9 Engine fluid radiator
10 Charge-air cooler
11 Protective guard
9
1011
30 086 0
2
Engine Description
2.3.1 Lube Oil Circuit Schematic
1012 / 1012 E
2.3 Lube Oil Circuit
1 Oil pan
2 Air intake manifold
3 Lube oil pump
3a Back leak fuel valve
3b Pressure-relief valve
4 Lube oil cooler
5 Lube oil filter
6 Main oil gallery
7 Crankshaft bearing
8 Conrod bearing
9 Camshaft bearing
10 Line to spray nozzle
11 Spray nozzle for piston cooling
12 Tappet w/ control bore for pulse lubrication
of rocker arms
13 Pushrod (designed for lube oil supply of
rocker arms)
14 Rocker arm
15 Return line to oil pan
16 Oil sensor
17 Oil line to exhaust turbocharger
18 Exhaust turbocharger
19 Oil line to compressor or hydraulic pump
20 Compressor
21 Hydraulic pump
22 Return line to compressor or hydraulic pump
23 Line to mass balancing gear (2x)
24 Counterbalancing shafts
25 Exhaust turbocharger return to crankcase
26238 1
2.3 Lube Oil Circuit Engine Description
2.3.2 Lube Oil Circuit Schematic
1013 / 1013 E
2
1 Oil pan
2 Air intake manifold
3 Lube oil pump
3a Back leak fuel valve
3b Pressure-relief valve
4 Lube oil cooler
5 Lube oil filter
6 Main oil gallery
7 Crankshaft bearing
8 Conrod bearing
9 Camshaft bearing
10 Spray nozzle line
11 Spray nozzle for piston cooling
12 Tappet w/ control bore for pulse lubrication
of rocker arms
13 Pushrod (designed for lube oil supply of
rocker arms)
14 Rocker arm
15 Return line to oil pan
16 Oil sensor
17 Oil line to exhaust turbocharger
18 Exhaust turbocharger
19 Oil line to compressor or hydraulic pump
20 Compressor
21 Hydraulic pump
22 Return line to compressor or hydraulic pump
23 Return to oil pan
24 Exhaust turbocharger return to crankcase
26 335 0
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
2.5.2 Cooling System Schematic
1012 E
entrance regulation
1 Thermostat housing
2 Coolant pump
3 Lube oil cooler
4 Cylinder cooling
5 Cylinder head 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
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