Loading...
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 pur- |
|
pose also implies compliance with the con- |
|
ditions laid down by the manufacturer for |
|
operation, maintenance and servicing. The |
|
engine should only be operated by person- |
|
nel trained in its use and the hazards |
|
involved. |
|
● The relevant accident prevention guidelines |
|
and other generally accepted safety and |
|
industrial hygiene regulations must be ob- |
|
served. |
|
● 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 invalidateanyliabilityclaimsagainstthemanufacturer 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.
You 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.
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.
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
2.1Model 2.1.1 Rating Plate
2.1.2 Position of the Rating Plate 2.1.3 Engine Serial Number 2.1.4 Cylinder numbering
2.2Engine Illustrations
2.2.1Operation side 1012
2.2.2Starter side 1012
2.2.3Operation side 1012 E
2.2.4Starter side 1012 E
2.2.5Operation side 1013
2.2.6Starter side 1013
2.2.7Operation side 1013 E
2.2.8Starter side 1013 E
2.2.9Starter side
Unit Engine BF4M 1013 EC
2.2.10Operation side
Unit Engine BF4M 1013 EC
2.2.11Starter side
Unit Engine BF6M 1013 EC
2.2.12Operation side
Unit Engine BF6M 1013 EC
2.3Lube Oil Circuit Schematic
2.3.1Lube Oil Circuit 1012 / 1012 E
2.3.2Lube Oil Circuit 1013 / 1013 E
2.4Fuel System
2.4.1Fuel System Plan
2.5Engine cooling
2.5.1Cooling System Schematic 1012
2.5.2Cooling System Schematic 1012 E
2.5.3Cooling System Schematic 1013
2.5.4Cooling System Schematic 1013 E/ 1013 E
3.Engine Operation
3.1Commissioning
3.1.1Pour in Engine Oil
3.1.2Filling Oil Bath Air Cleaner
3.1.3Pour in Fuel
3.1.4Filling / Venting the Cooling System
3.1.5Other Preparations
3.2Starting
3.2.1Starting
3.3Monitoring Operation
3.3.1Engine Oil Pressure
3.3.2Coolant temperature
3.3.3Coolant Level / Coolant Level
Gauge
3.4Shutting off
3.4.1Mechanical shut-off
3.4.2Electrical shut-off
3.5 Operating conditions
3.5.1Winter Operation
3.5.2High Ambient Temperature, High Altitude
4 Operating Media
4.1Lube Oil
4.1.1Quality
4.1.2Viscosity
4.2Fuel
4.2.1Quality Grade
4.2.2Winter-Grade Fuel
4.3Coolant
4.3.1Water Quality for Coolant Preparation
4.3.2Coolant Preparation
4.3.3Cooling System Protective Liquid
5.Routine Maintenance
5.1Maintenance Schedule
5.2Maintenance Chart
5.3Maintenance Record
Contents
6.Service and Maintenance
6.1 Lubrication System
6.1.1Oil Change Intervals
6.1.2Checking Oil Level / Changing Engine Oil
6.1.3Changing Oil Filter
6.1.4Cleaning/Changing Oil filter (Cup)
6.2Fuel System
6.2.1Changing Fuel Filter
6.2.2Replace fuel filter
6.2.3Clean/Replace Fuel Pre-Filter, Filter Element
6.2.4Venting the Fuel System
with Preliminary Fuel Filter
6.2.5Clean/Replace Fuel Pre-Filter, Filter Element
6.2.6Vent Fuel System with Fuel Pre-Filter
6.2.7Clean/Replace/Vent Fuel Pre-Filter, Filter Element
6.2.8Clean / purge or change fuel
pre-filter
6.2.9Venting the Fuel System with Preliminary Fuel Filter
6.2.10Changing Fuel Leakage Line
6.2.11Changing Fuel Leakage Pipes
6.3 Cooling System
6.3.1Cleaning Intervals
6.3.2Cleaning Cooling System
6.3.3Draining Cooling System 1012 / 1013
6.3.4Filling / Venting Cooling System 1012 / 1013
6.3.5Draining the Cooling System 1012 E / 1013 E
6.3.6Filling/Venting the Cooling System 1012 E/1013 E
6.3.7Draining the Cooling System Unit Engine
6.3.8Filling/Venting the Cooling System Unit Engine
6.3.9Draining the Charge-Air Cooler
6.4Combustion 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
6.5Belt Drives
6.5.1Checking V-Belts
6.5.2Tensioning Fan / Alternator Belts 1012
6.5.3Changing Fan / Alternator Belts 1012
6.5.4Tensioning Coolant / Fuel Pump Belts 1012
6.5.5Changing Coolant / Fuel Pump Belts 1012
6.5.6Tensioning Coolant / Fuel Pump Belts 1012 E
6.5.7Changing Coolant / Fuel Pump Belts 1012 E
6.5.8Tensioning Alternator Belt 1012 E
6.5.9Changing 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
6.6Adjustments
6.6.1 Checking / Adjusting Valve
Clearances
6.7 Accessories
6.7.1 Battery
6.7.1.1Checking Battery and Cable Connectors
6.7.1.2Checking Electrolyte Level
6.7.1.3Checking Specific Gravity of Electrolyte
6.7.2Three-Phase Alternator
6.7.3Lifting Tackle
7.Faults, Causes and Remedies
7.1Fault Table
8.Engine Preservation
8.1Preservation
9.Technical Specification
9.1Engine Specifications and Settings
9.2Screw Tightening Torques
9.3Tools
10.Service
General
DEUTZ Diesel Engines |
Care and Maintenance |
Service |
|
1 |
|
|
|
|
|
|
|
|
|
|
are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption.
It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.
Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously.
Special care should be taken under abnormally demanding operating conditions.
Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts.
Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.
Beware of Running Engine |
Safety |
Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents.
When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.
This symbol is used for all safety warnings. Please follow them ! carefully. The attention of operating personnel should be drawn to these safety instructions. General safety
and accident prevention regulations laid down by law must also be observed.
Asbestos
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.
DEUTZ original parts are asbestosfree.
1
Engine Description
2
2.1Model
2.2Engine Illustrations
2.3Lube Oil Circuit
2.4Fuel System
2.5Cooling System
Engine Description |
2.1 Model |
2 |
|
|
|
|
|
|
2.1.1 Rating Plate |
2.1.2 Rating Plate Location |
2.1.3 Engine Serial Number |
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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.
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).
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
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 |
Coolant filler neck with cap |
|
|
|
|
|
|
|
|
|
2 |
Expansion tank |
|
1 |
2 |
3 |
4 |
5 |
6 |
7 |
|
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 |
8 |
Induction air line between dry air filter and |
|
|
|
|
|
|
|
|
9 |
exhaust turbocharger |
|
|
|
|
|
|
|
|
|
|
Exhaust turbocharger |
|
|
|
|
|
|
|
|
|
|
10 |
Coolant line from crankcase to engine fluid |
|
|
|
|
|
|
|
|
9 |
|
radiator |
|
|
|
|
|
|
|
|
11 |
Charge-air cooler |
|
|
|
|
|
|
|
|
|
|
12 |
Engine fluid radiator |
|
|
|
|
|
|
|
|
|
13 |
Coolant line from engine fluid radiator to engine |
|
|
|
|
|
|
|
|
|
|
thermostat |
|
12 |
|
|
|
|
|
|
10 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
13 |
|
11 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2630 |
088336 |
0 |
|
2.2 Engine Illustrations |
Engine Description |
2.2.10 Service Side |
|
2 |
|
||
Unit Engine BF4M 1013 EC |
|
|
|
|
|
|
3 |
Ventilation line from cylinder head to expansion |
13 |
|
tank |
13 |
Charge-air line from charge-air cooler to engine |
|
|
14 |
Protective guard |
3 |
|
|
14 |
|
|
3026089337 |
0 |
|
Engine Description |
2.2 Engine Illustrations |
2 |
2.2.11 Starter Side |
|
|
|
|
|
|
|
Unit Engine BF6M 1013 EC |
|
|
|
|
||||
|
|
|
|
|
||||
|
1 |
2 |
3 |
4 |
5 |
6 |
7 |
|
|
8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
30 087 |
0 |
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
8Coolant line from engine fluid radiator to engine thermostat
2.2 Engine Illustrations |
Engine Description |
2.2.12 Service Side |
|
2 |
|
Unit Engine BF4M 1013 EC |
|||
|
|||
|
|
|
|
|
|
9 |
Engine fluid radiator |
|
|
10 |
Charge-air cooler |
|
|
11 |
Protective guard |
|
9 |
|
|
11 |
10 |
|
|
|
30 086 |
0 |
|
Engine Description |
2.3 Lube Oil Circuit |
2 |
|
|
|
2.3.1 |
Lube Oil Circuit Schematic |
||
|
|
1012 / 1012 E |
|
|
|
|
|
1 Oil pan
2 Air intake manifold
3 Lube oil pump
3a Back leak fuel valve
3b Pressure-relief valve
4 Lube oil cooler
5 Lube oil filter
6 Main oil gallery
7 Crankshaft bearing
8 Conrod bearing
9 Camshaft bearing
10 Line to spray nozzle
11 Spray nozzle for 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 |
2.3.2Lube 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
10Spray nozzle line
11Spray nozzle for piston cooling
12Tappet w/ control bore for pulse lubrication of rocker arms
13Pushrod (designed for lube oil supply of rocker arms)
14Rocker arm
15Return line to oil pan
16Oil sensor
17Oil line to exhaust turbocharger
18Exhaust turbocharger
19Oil line to compressor or hydraulic pump
20Compressor
21Hydraulic pump
22Return line to compressor or hydraulic pump
23Return to oil pan
24Exhaust 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
2.5 Cooling System |
Engine Description |
2.5.1 Cooling System Schematic
1012
2
1Coolant filler
2 Thermostat housing
3 Coolant pump
4 Lube oil cooler
5Cylinder cooling
6 Cylinder head cooling
7Heat exchanger
8Return from thermostat to coolant pump
housing
9Ventilation line from cylinder head to heat exchanger (expansion tank)
26240 2
Engine Description |
2.5 Cooling System |
22.5.2 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
Loading...