Deutz Engine BF6M 1013 Operation Manual Deutz Engine 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

2.5 Cooling System Engine Description

1012 E

escape regulation

2

1 Thermostat housing
2 Cooling fluid pump
3 Lubricating oil cooler
4 Cylinder cooling
5 Cylinder head cooling
6 Heat exchanger
7 Compensation setting of compensation tank t

o cooling fluid pump

8 Line (Crankcase) from thermostat to heat

exchanger

9 Ventilation line from cylinder head to

compensation tank
10 Compensation tank
11 Line from heat exchanger to cooling fluid pump

30 816 0

Engine Description

2.5 Cooling System

2

2.5.3 Cooling System Schematic
1013

1 Coolant filler
2 Thermostat housing
3 Coolant pump
4 Lube oil cooler
5 Cylinder cooling

6 Cylinder head cooling
7 Heat exchanger
8 Expansion line coolant pump/expansion

tank

9 Ventilation line from cylinder head to

heat exchanger (expansion tank)

26 338 1

2.5 Cooling System Engine Description

2.5.4 Cooling System Schematic
1013 E
entrance regulation

2

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

26 339 1

Engine Description

2.5 Cooling System

2

1013 E
escape regulation

1 Thermostat housing
2 Cooling fluid pump
3 Lubricating oil cooler
4 Cylinder cooling
5 Cylinder head cooling
6 Heat exchanger
7 Compensation setting of compensation tank t

o cooling fluid pump

8 Line (Crankcase) from thermostat to heat

exchanger

9 Ventilation line from cylinder head to

compensation tank

10 Compensation tank
11 Line from heat exchanger to cooling fluid pump

30 817 0

3.1 Commissioning

3.2 Starting

3.3 Monitoring Systems

3.4 Stopping

3.5 Operating Conditions

Engine Operation

3

Engine Operation 3.1 Commissioning

3

3.1.1 Adding Engine Oil

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.

3.1.2 Filling Oil Bath Air Cleaner

24980 2

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.

3.1.3 Adding Fuel

26244 0

Use only commercial-grade diesel fuel. For fuel
grade, see 4.2.
If required use a preliminary fuel filter.
If in doubt, please ask your service representative.
Use summer or winter-grade fuel, depending on
the ambient temperature.

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

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

3.1 Commissioning Engine Operation

3.1.4 Filling/Venting the Cooling
System

● 1012/1013

See section 6.3.4

● 1012 E/1013 E

See section 6.3.6

● Unit engine (with frontal radiator)

See section 6.3.8.

3.1.5 Other Preparations

● Check battery and cable connections, see 6.7.1.

● Trial run

- After the engine has been prepared, let it run
for about 10 minutes without load.

During and after trial run

- Check the engine for leaks.

After the engine has been turned off

- Check the oil level and top up if necessary, see

6.1.2.

- Tighten the V-belt, see 6.5.

● Breaking-in

During the break-in phase - about 200 operat­ing hours - check the oil level twice a day.
After the engine is broken in, checking once a
day will be sufficient.

3

● Commissioning conserved engines

Remove conservation materials as outlined in
section 8.1

Engine Operation

3.2 Starting

3

3.2.1 Electric Starting

Before starting, make sure that
nobody is standing in the imme-

!

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.

diate vicinity of the engine or driven
machine.
After repair work:

26245 0

● Disengage the clutch to separate the engine
from the driven equipment.

Starting without Cold-Start Aid

25745 0

● Insert key.
– Position 0 = no operating voltage.

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

● Move speed control lever 1 in direction of
arrow at least to middle speed position.

● Move shutdown lever 2 to operating position
(in opposite direction of arrow).

● Turn key clockwise.
– Position 1 = operating voltage.
– Pilot lights 1 and 2 come on.

● Push the key in and turn it further clockwise
against spring pressure.
– Position 2 = no function
– Position 3 = start

● Release key as soon as engine fires.
– Pilot lights go out.

3.2 Starting Engine Operation

Starting with Heater Plugs

3

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

25752 1 25753 0 25754 0

● The oil pressure pilot light comes on with
operating voltage on and engine off.

Oil Pressure Indicator

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

Oil Pressure Gauge

● The pointer must indicate the minimum oil
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

26246 0 26247 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).

3.3.3 Coolant Level /
Coolant Level Gauge

● When the engine is cold, coolant level 1 should

be above the KALT-COLD mark.

● Top up with coolant if the level falls below the

MIN mark on the sight glass, or if the coolant
warning switch comes on.
– Unscrew the filler cap.
– Top up with coolant up to the upper edge of

the filler neck.

– Tighten the filler cap

3

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

● 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

26266 0 25746 2

● 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.

3.4.2 Engines with Electrical
Shutdown

● Turn key counterclockwise (to Position 0) and

remove. The pilot lights will go out.

● 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

● 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 operat-

ing below –10°C, see 6.1.1.

● 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

– 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.

3

● 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.

26248 0

● 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

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.
If the engine is to operate under more severe
conditions (at higher altitudes or tempe­ratures), it will be necessary to reduce the
injected fuel quantity and, thus, engine power.

● If you have any doubts about engine operation
under these or similar conditions, ask your
engine or equipment supplier whether the
engine has been derated in the interests of
reliability, service life and exhaust gas quality
(smoke). Otherwise, contact the nearest
service representative.

C

F

0 32

25901 1

4.1 Lube Oil

4.2 Fuel

4.3 Coolant

Operating Media

4

© 2002

Operating Media 4.1 Lube Oil

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.

Approved oils:

Deutz DQC I DQC II DQC III
ACEA E2-96 E3/96/E5-02 E4-99
API CF/CF-4 CH-4/CG-4 ­DHD - DHD-1 -

The precise assignment of the admissible
oil qualities to the engines is indicated in
chapter 6.1.1.
If in doubt, contact your service represen­tative.

Generally, multi-grade oils shall be used. In
closed heated rooms at temperatures >5°C,
also single-grade oils can be used.

As the viscosity of lube oil is dependent on
temperature, the choice of SAE grade
should be governed by the ambient
temperature prevailing at the engine
operating site.
Optimum operating behaviour will be
attained if you take the accompanying oil
viscosity diagram as a guide.
Should the temperature fall temporarily
below the limits of the SAE grade selected,
cold starting may be affected but the engine
will not be damaged.
In order to keep wear to a minimum, do not
exceed application limits for extended
periods of time.

Synthetic lube oils feature an improved
temperature and oxidation stability.

© 2002

Only with preheating

30 298 1

4.1 Lube Oil Operating Media

4.1.2.1 Speci fic lu be 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. In addition, most of
these oils are partly synthetic, some even
fully synthetic (5W-40), and thus achieve the
thermal stability required for the relevant
application and are distinguished by a low
tendency to cause deposits in the
turbocharger and in the charge air pipes with
closed-circuit crankcase breather.

The table will be extended as and when required.

Lube oils for engines with uprated power

and engines with high loading

Producer Type of lube oil SAE class Availability
DEUTZ DEUTZ Oil TLX-10W40FE 10W-40 Europe

A D D I N O L ADDINOL Super Truck MD 1048 1 0 W - 4 0 E u r ope, Asia

ADDINOL Ultra Truck MD 0538 5W-30 Europe, Asia

AGIP Agip Sigma Ultra TFE 10W-40 worldwide

Autol Valve Ultra FE 10W-40 Germany

ARAL Aral MegaTurboral 10 W -4 0 worldwide

Aral SuperTurboral 5W-30 worldwide
AVIA TURBOSYNTH HT-E 10W-40 Germany
BAYWA BayWa Super Truck 1040 MC 10 W- 40 So ut h Ge rma ny

BayWa Turbo 4000 10W-40 South Germany
BP OIL International BP Vanellus E7 Plus 10W-40 Europe

BP Vanellus E7 Supreme 5W-40 Europe
Castrol Castrol SYNTRUCK 5W-40 Europe, North America, Brazil,

Argentina, Australia, South Africa

Castrol Castrol DYNAMAX 7,5W-40 Europe, North America, Brazil,

Argentina, Australia, South Africa
CEPSA EUROTRANS SHPD 10W-40 Spain, Portugal
CHEVRON Chevron Delo 400 Synthtic 5W-40 North America
DEA DEA Cronos Synth 5W-30 Germany, Europe

DEA Cronos Premium LD 10W-40 Germany, Europe

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

EXPERTY MX 1010

ELF PERFORMANCE

EXPERTY MX 1012

FINA KAPPA FIRST 5W-30 Europe

FINA KAPPA ULTRA 10W-40 Europe

10 W- 4 0 worldwide
10W-40 Germany, Benelux,

Scandinavia, Austria

4

© 2002

Operating Media 4.2 Fuel

4

4.2.1 Quality Grade

Use commercially available diesel fuel with
less than 0.5% sulphur content. If the sulfur
content is higher than 0.5%, oil change
intervals should be reduced (see 6.1.1).

The following fuel specifications/standards
are approved:
(refer to TR 0199-3002)

● Diesel fuel

- DIN EN 590

- BS 2869: A1 and A2
(with A2, take note of the sulfur content!)

- ASTM D 975-88; 1-D and 2-D

- NATO Code F-54and F-75

- ISO 8217 DMX

- ISO 8217 DMA

● Light heating oil

according to DIN 51603
ASTM D 396; 1 and 2
BS 2869 Class D

● Jet fuel

- F34/F35/F44 (kerosene)

- F54 (equivalent to diesel fuel according to
DIN EN 590)

- XF 63 (equivalent to F34+F35 with addi­ tives)

4.2.2 Winter-Grade Fuel

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. This fuel is usually
available from filling stations well in advance
of the cold months.

● At temperatures below -20°C/, kerosene
should be added to the diesel fuel. The
relevant percentages are given in the dia­gram at the right

● Special diesel fuels can be used for climatic
zones down to - 44 °C.

If summer-grade diesel fuel must be used at
temperatures below 0°C, up to 60% kerosene
can be added (see diagram).

In most cases, adequate resistance to cold
can be obtained by adding a flow improver
(additive). Please contact your Deutzpartner.

Legend:

I Summer diesel fuel
II Winter diesel fuel
A Outside temperature

Percentage of kerosene to be added

B

● Bio diesel fuel

- according to DIN 51606- F AME

Exhaust emission values which may be
determined in the cause of type approval tests
always refer to the reference fuel prescribed
by the authorities for the type approval test.

© 2002

Diesel fuels must never be
mixed with petrol (normal and
super grade petrol)!

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

4.3 Coolant Operating Media

4.3.1 W ater Quality for Coolant
Preparation

The values given below must not be
exceeded.
A test kit (order number 1213 0382) can be
obtained from DEUTZ Service to check the
quality of the water available.

Water quality min. max.

pH-value at 20°C /68° F 6.5 8.5
Chloride ion content [mg/dm3]
Sulfate ion content [mg/dm3] – 100
Total hardness [°dGH] 3 20

– 100

4.3.2 Coolant Preparation

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

®

).

4.3.3 Cooling System Protective
Liquid

DEUTZ cooling system protective agents
can be obtained under order number
01011490 (5 litres) or 1221 1500 (210 litres).
These are nitrite-, amine- and phosphate­free and provide effective protection
against corrosion, cavitation and freezing.
If the above-mentioned cooling system
agents are not available, the following
products can be used in exceptional cases.

Manufacturer Product description

AVIA AVIA Antifreeze Extra

BASF Glysantin G 48

DEA DEA radiator antifreeze

SH EL L SHELL GlycoShell

The concentration of the cooling system
protective liquid in the coolant may not fall
below/exceed the following limits:

Cooling system protective liquid

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

Water

4

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

Cooling system protective liquids
must be disposed of in accor­dance with environmental
regulations.

© 2002

4

Operating Media 4.3 Coolant

Cooling System Protection

Cooling system capacity *)

Cooling Cooling

system protective

18 20 22 25 27 30 32 35

protection agent

[Vol %] [°C]

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.

[Liters]

Cooling system protective liquid

[Liters]

© 2002

Routine Maintenance

5.1 Maintenance Schedule

5.2 Maintenance Chart

5.3 Maintenance Record

5

© 2002

5

Routine Maintenance 5.1 Maintenance Schedule

Maintenance step= E 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 E20 E30 E40 E50 E60 E70* Years

500 1000

●●

■

■

●

●● ■

●●

●● ■

●

●●

●● ■

* When the warning system responds (lamp/horn), the fuel pre-filter must be emptied immediately

1500 2 0 00

■

● ■

▲

▲ ▲

●

●

❍

10000

13000

1 2

■

*E70=1012 Engines 10000OH

*E70=1013 Engines 13000OH

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

Industrial engines

The specified engine maintenance times are
the max. permissible recommended times.
Depending on the application shorter
maintenance times may be necessary. Please
refer to manufacturer’s operating manual.
# Maintenance work to be carried out only by
authorised service personnel.

© 2002

5.1 Maintenance Schedule Routine Maintenance

Maintenance step= E 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 E20 E30 E40 E50 E60 E 70* Ye ar s

500 1000 1500 200010000 13000 1 2

●●

●●

●

●●

■

*E70 1012 Engines 10000OH
*E70 1013 Engines 13000OH

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 #

Industrial engines

The specified engine maintenance times are
the max. permissible recommended times.
Depending on the application shorter
maintenance times may be necessary. Please
refer to manufacturer’s operating manual.
# Maintenance work to be carried out only by
authorised service personnel.

5

Maintenance step= E Check= ● Adjust= ❍ Clean= ▲ Replace= ■

max. permissible recommended times in operating hours (OH), every
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

E1 0 E2 0 E30 E40 E50 E60 E70* Years

500 1000

1500 3000 4000 10000

■

1 2

*1012 Engines 10000 OH
*1013 Engines 13000 OH

Operation Section

Injection valve #

Expansions or modifications for

engines with EP A acceptance

The specified engine maintenance times are the max.
permissible recommended times. Depending on the
application shorter maintenance times may be necessary.
Please refer to manufacturer’s operating manual.
# Maintenance work to be carried out only by authorised
service personnel.

© 2002

Routine Maintenance 5.2 Maintenance Chart

5

5.2.1 Additional maintenance

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 oper ator, au thorize d traine d 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

1500

10

125­2000

10

in.

ex.

0,3 mm

0.012 in.

0,5 mm

0.020 in.

500

Std.

OIL

h

15 mm

ca.

0.6 in.

500

10

500

1000

OIL

ATER

W

FUEL

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.

a

in.

ex.

AIR

OIL

max.

1013

5

!

Stop the engine before
carrying out any maintenance
work.

0297 7782

0

0,3 mm

0.012 in.

0,5 mm

0.020 in.

h

Std.

500

OIL

500

WATER

10

15 mm

ca.

0.6 in.

500

1000

OIL

FUEL

OIL

max.

a

in.

1500

ex.

AIR

in.

ex.

10

125­2000

10

BF4/6M 1012/E/C

0297 7783

0

© 2002

5

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.
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.

© 2002

BFM 1012
BFM 1013

0297 4979 1

Standard engine

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.
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.

5

Short engine

BFM 1013E

0297 4985 1

© 2002

Routine Maintenance 5.3 Completed Maintenance Jobs

5

Hours.

50-150

125

375

625

875

1125

1375

1625

1875

Date

*

Signaure / Stamp Hours

-

Date

Signaure / Stamp

250

500

750

1000

1250

1500

1750

2000

2115

2375

2625

* Commissioning new and overhauled engines
The maintenance jobs duly completed can be recorded in the above table.

2250

2500

2750

5.3 Completed Maintenance Jobs Routine Maintenance

Hours

2875

3125

3375

3625

3875

4125

4375

4625

4875

Date

Signaure / Stamp Hours Date Signaure / Stamp

5

3000

3250

3500

3750

4000

4250

4500

4750

5000

5125

5375

5625

The maintenance jobs duly completed can be recorded in the above table.

5250

5500

5750

Routine Maintenance 5.3 Completed Maintenance Jobs

5

Hours.

5875

6125

6375

6625

6875

7125

7375

7625

7825

Date

Signaure / Stamp Hours

6000

6250

6500

6750

7000

7250

7500

7750

8000

Date

Signaure / Stamp

8125

8375

8625

The maintenance jobs duly completed can be recorded in the above table.

8250

8500

8750

Hours

8875

Date

Signaure / Stamp Hours Date Signaure / Stamp

5

9000

9125

9375

9625

9875

10125

10375

10625

10825

11125

11375

9250

9500

9750

10000

10250

10500

10750

11000

11250

11500

11625

The maintenance jobs duly completed can be recorded in the above table.

11750

5

Hours.

Date

Signaure / Stamp Hours

Date

Signaure / Stamp

Service and Maintenance

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

6

© 2002

Service and Maintenance 6.1 Lubrication System

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 > 0.5 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.

● If, for vehicle engines, lube oil change
intervals are determined by operating hours,
the lube oil change intervals indicated in table

6.1.1.1. for “Oil use under normal duty” will
apply.

● In the case of fuels containing more than
1 % sulfur, contact your service repre-
sentative.

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

© 2002

6.1 Lubrication System Service and Maintenance

6.1.1.1 Equipment Engines
Lube oil grade

Deutz lube oil quality class

ACEA-specfication E2-96 E3-96/E5-02 E4-99
API-specfication CF/CF-4 CG-4/CH-4 ­Worldwide specification
special DEUTZ release list
Standard lube oil code for building
equipment and nonraod vehicles

Engine Engine version Lube oil change intervals in op. hours
series Oil use Oil use Oil use

1012

All engines except for:
eng. in harv. machines, block-typethermal
power stat., gensets* - - 500

DQC I DQC II DQC III

- DHD-1 -

- - see chap. 4.1.2.1

EO.. . EO...C -

EO...A, EO...B

normal high normal high normal high

250 500 500

6

1013

* 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.

All engines except for:
engines from nonroad stage II
eng. in harv. machines, block-typethermal
power stat., gensets* - - 500
BF4M1013FC - - 500
BF6M1013FC, P ≤ 200 kW - - 500
BF6M1013FC, P > 200 kW - - 250

250 500 500

- 500 500

© 2002

Service and Maintenance 6.1 Lubrication System

6

6.1.1.2 Oil change intervals for vehicle engines Lube oil-quality

Deutz lube oil quality class DQC I 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

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

Local 40 BF4M1013FC Euro II ≤ 14 l oil contents (first filling) - - 15 000
traffic > 14 l oil contents (first filling) - - 30 000

Average speed in km/h approx.

Long 60 BF4M1013FC Euro II ≤ 14 l oil contents (first filling) - - 20 000
distance > 14 l oil contents (first filling) - - 40 000

© 2002

Engine version Lube oil change intervals in km

1012/1013 Euro I 10 000 15 000 20 000

Euro II

Euro III - - 20 000

1012/1013 Euro I 15 000 20 000 30 000

Euro II

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

Euro II

Euro III - - 40 000

BF6M1013FC Euro II ≤ 19 l oil contents (first filling) - - 20 000

Euro III - - 40 000

and

Euro III, except for: - 15 000 20 000

> 19 l oil contents (first filling) - - 20 000

and

Euro III, except for: - 20 000 30 000

> 19 l oil contents (first filling) - - 30 000

and

Euro III, except for: - 30 000 40 000

> 19 l oil contents (first filling) - - 40 000

6.1 Lubrication System Service and Maintenance

6.1.2 Checking Oil Level /
Changing Engine Oil

6.1.2.1Checking Oil Level 6.1.2.2 Changing Engine Oil

© 25 729 0

● 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.

● Check oil level, if required top up to the

“MAX” level
– If the oil level is just above the “MIN” mark,
it should be topped up.

The oil level must not drop below the “MIN”
mark.

● Run the engine warm

● Ensure that the engine or vehicle is on a

level surface
– Lube oil temperature approx. 80°C.

● Switch off the engine.

© 26 022 0 © 26 023 0

● Place an oil tray beneath the engine

● Unscrew drain plug.

● Drain oil.

● Fit oil drain plug with new gasket and

tighten firmly (for torque, see 9.2).

● Fill with lube oil
– For grade/viscosity, see 4.1.
– For quantity, see 9.1.

● Check oil level, see 6.1.2.1

Be careful when draining hot oil ­danger of scalds! Do not let used oil

!

run into the soil but catch it in a
container ready for proper disposal.

6

© 2002

Service and Maintenance 6.1 Lubrication System

6

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.

● Catch any dripping oil.

© 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.

© 25 882 0

● Check that the cartridge is correctly seated
against the gasket and tighten with a final
half-turn.

● If a torsion lock is fitted:
Slide clamps up into position and tighten
screws.

● Check oil level (see 6.1.2).

© 2002

!

Beware of burns from hot oil.

● Check oil pressure (see 3.3.1).

● Check cartridge seal.

6.1 Lubrication System Service and Maintenance

6.1.4 Cleaning/Changing Oil
filter (Cup)

1

2

3

4

© 30 074 0

● Switch off the engine.

● Loosen the lube oil filter cap 1 and unscrew

in an anticlockwise direction.

● Carefully lift the paper filter cartridge 3 out
of guide 4.

● Catch any dripping oil.

● Change the paper filter cartridge 3.

● Clean any dirt from the filter carrier rim and

the lube oil filter cover 1 and guide 4.

6

● 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.

!

Caution: hot oil!
Risk of scalding!

© 2002

Service and Maintenance 6.2 Fuel System

6

6.2.1 Changing Fuel Filter

© 25 880 0

● Close fuel stopcock.

● Undo fuel filter cartridge with commercial tool

and spin off.

● Catch any fuel.

© 25 881 0

● Clean any dirt from the filter carrier rim.

● Apply light film of oil or diesel fuel to the rubber

gasket of the new fuel filter cartridge.

● Screw in the new cartridge finger tight
against the gasket.

© 25 882 0

● Check that the cartridge is seated correctly
against the gasket and tighten with a final
half-turn.

● Open fuel stopcock.

● Check for leaks.

© 2002

Keep naked flames away
when working on the fuel

! !

system. Do not smoke!

The fuel system does not
need to be bled.

6.2 Fuel System Service and Maintenance

6.2.2 Replace Fuel Filter

© 36 650 0

z Close the fuel shut-off valve.
z Undo fuel filter cartridge with commercial

tool and spin off.

z Catch any escaping fuel.
z Clean any dirt from the filter carrier sealing

surface 1.

© 25 881 0

z Apply light film of oil or diesel fuel to the

rubber gasket of the new original DEUTZ
fuel filter cartridge.

z Manually screw in the new cartridge until

the gasket is flush.

z Tighten the fuel filter cartridge with a final

half-turn.

6

© 25 882 0

z Open fuel shut-off valve.
z Bleed fuel system, see 6.2.4.

Also loosen the bleed screw 4 until air-free
fuel emerges.

z Tighten the bleed screw 4
z Check for leaks.

The fuel system needs to be
bled.

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

© 2002

Service and Maintenance 6.2 Fuel System

6

6.2.3 Clean/Replace Fuel Pre-Filter,
Filter Element

© 25 801 0

Clean:

● Close fuel stopcock.

● Place the fuel pan beneath the preliminary

fuel filter.

● Remove drain plug 4 and drain off fuel.

● Unscrew clamping screw 1, remove filter

housing 5 with filter insert 3.

● Clean sealing surface of the filter bracket

7 and filter insert housing 5 of any dirt.

● Insert new sealing ring 6 and filter insert

3 (change as necessary).
–Push the filter insert up to approx. 3 cm

over the edge of the housing onto the
guide in the filter housing 5.

© 2002

© 30 084 0

● Press filter housing 5 with filter insert 3 and
sealing ring 6 against the filter console 7
and screw into place with clamping screw
1 (tightening torque 25 Nm).
Note: it must be possible to push the upper
seal 2 on filter insert 3 over the guide
bracket on filter console 7.

● Tighten drain plug 4.

● Open fuel stopcock.

● Check for leaks after the engine has been

started.

Replace:

● Replace defective filter insert 3.

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.

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

housing 5 / pressure control valve 9.

● Open fuel stopcock, pressure control valve

9, vent screw 8

● Turn engine with starter (max. 20 sec.)

until fuel free from air bubbles escapes
from vent screw 8 and pressure holding
valve 9.

● Tighten vent screw 8 (tightening torque 15

Nm) and pressure control valve 9.

● Set engine controller to start position and

start

● When the engine has started check for

leaks

Keep naked flames away when
working on the fuel system. Do

!

not smoke! Dispose of waste
fuel in an environmentally­friendly manner!

6.2 Fuel System Service and Maintenance

6.2.5 Clean/Replace Fuel Pre-Filter,
Filter Element

© 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.

z Clean any dirt from the sealing face of the

filter carrier and filter element housing 4
and sludge chamber 4 and filter element
(replace if necessary).

z Insert new round sealing rings 2+3+6.
z Screw in filter element housing 4 and filter

element (max. torque 25

–5

Nm).

© 30 084 0

z Tighten the drain screw 7+9
z Open fuel shut-off valve.
z Bleed system
z Check for leaks after starting the engine.

6.2.6 Vent Fuel System with Fuel
Pre-Filter

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
valve 9.

z Open fuel shut-off valve, pressure

maintenance valve 9, vent screw 10.

z Vent system, turn over engine with the

starter (max. 20 sec.) up to vent screw 10
and pressure retention valve 9.

z Firmly tighten vent screw 10 (tightening

torque 25
valve 9.

z Bring engine regulator into start position

and start.

z Check for leaks after starting the engine.

-5

Nm) and pressure maintenance

Keep naked flames away when
working on the fuel system. Do
not smoke!
Dispose of wastefuel in an
environmentally-friendly
manner!

6

© 2002

Service and Maintenance 6.2 Fuel System

6

6.2.7 Clean/Replace/Vent Fuel
Pre-Filter, Filter Element

© 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.

z Screw the filter cartridge 2 and dirt trap 3

together. Wet the filter cartridge with fuel,
wet the sealing surfaces 8 slightly with oil.

z Mount clockwise.

© 2002

z Open the fuel shut-off valve and bleed the

system.

z Check for leaks after starting the engine.

Replace:

z Replace defective filter cartridge 2.
z Clean any dirt from the filter carrier 1

sealing surface 8.

z Wet the filter cartridge 2 with fuel, wet the

sealing surfaces 8 slightly with oil.

z Mount the filter cartridge 2 and dirt trap 3

clockwise.

z Open fuel shut-off valve.
z Check for leaks and vent the system after

starting the engine.

Vent:

z Loosen the vent screw 7 slightly.
z Actuate the pump until fuel free from air

bubbles emerges.

z Tighten the vent screw.
A= connection possibility for:

Electrical connection for water/fuel level
sensor in the dirt trap

Work may only be performed
on the fuel system with the
engine switched off.
No naked flames! Do not smoke!
Dispose of waste fuel in an
environmentally-friendly
manner.

6.2 Fuel System Service and Maintenance

6.2.8 Clean / purge or change fuel
pre-filter

© 31 81 1 2

Clean (purge) - remove water:

● Turn of f 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.

● Empty water and dirt from the bowl 6 by
opening (press in and turn slightly without
using force) the drain cock 8 and close the
drain cock 8 again

● Close the bleed screw 1 on the cover 2
again

● Bleed the fuel pipe according to
instructions, see 6.2.5 opposite

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
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)

● Tighten the cover 2 with the screws 3
diagonally (torque 6 Nm)

● Check the cover 2 for proper fit and leaks

● Bleed the fuel system, see 6.2.3.

The connection of a warning system

(lamp/horn) via contacts 7 is
specified. Immediate maintenance is
necessary when the warning system is
triggered.

Naked flames are prohibited
when working on the fuel

!

system! Do not smoke!
Dispose of old fuel in an environ­mentally friendly way!

6.2.9 Venting the Fuel System
with Preliminary Fuel Filter

9

© 31 812 0

● 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

pressure control valve 9.

● Open fuel stopcock (if available) and
pressure control valve 9.

● Turn engine with starter (max. 20 sec.) or
use hand fuel pump (if available), until fuel
with no air bubbles escapes from pressure
holding valve 9.

● Tighten pressure control valve 9.

● Set engine controller to start position and

start

● When the engine has started check for
leaks

6

© 2002

Service and Maintenance 6.2 Fuel System

6

6.2.10 Changing Fuel Leakage
Line

© 30 084 0

● 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.

● Set engine controller to start position and start

● When the engine has started check for leaks

Avoid naked flames when
working on the fuel system. Do
not smoke. Dispose of waste

© 2002

!

fuel in an environmentally­friendly way

6.2.1 1 Changing Fuel Leakage
Pipes

5

© 30 034 1

● Close fuel stopcock

● Dismantle valve cap cover

● Loosen hose clamps 6 with hose clamp

pliers TN 8020 (see chap.9.3).

● Remove rubber hoses 3 and hose clamps

6 from the injection valves.

● Loosen pressure holding valve 9

● Dismantle hose clamps 6, rubber hoses 1,

3 and 4 and connection piece 2 and dispose
of in an environmentally-friendly way.

● Mounting new fuel leakage pipes:

Slide rubber hoses 3 (lubricate inside with
mounting grease) with hose clamps 6 on
the connection nipples of the injection
valves and close with hose clamp pliers TN

8020.

6

© 30 901 0

● Mounting pressure holding valve 9:
Tighten up new ring piece with bolt 5.

● Remount valve cap cover

● Set engine controller to start position and

start

● When the engine has started check for
leaks

Ensure that the hose clamp lock
shows to the injection valve and

!

the hose clamp can't fall into the
motor housing.

6.3 Cooling System Service and Maintenance

6.3.1 Cleaning Intervals

● The amount of contamination in the cooling
system depends on the engine application.

● Spilled oil or fuel on the engine increases the
risk of contamination. Be especially careful if
the engine is used in dusty environments.

● Serious contamination can occur, for
example:
– on construction sites where there is a

high level of air-borne dust.

– in harvesting application where there are

high concentrations of chaff and chopped
straw in the vicinity of the machine.

● Because applications vary, cleaning in­tervals have to be determined from case
to case. The cleaning intervals given in
the table below can be used as a guide.

Checking / Cleaning Intervals

Suggested OH

2000 Ships, gensets in enclosed

1000 Vehicles on paved roads

500 Tractors, forklift trucks,

250 Vehicles on construction sites

125 Agricultural machiner,

Application

spaces, pumps

mobile gensets

and unpaved roads, construc­tion equipment, compressors,
underground mining equipment

harvester tractors

6.3.2 Cleaning Cooling System

© 26 252 1

Series 1012/1013

● Place a cleaning bath under the heat ex­changer (it. 2).

● Remove the service flap on the heat ex­changer (see insert).

Compressed Air

– Blow out heat exchanger with com-

pressed air (first from it. 3, then from
it. 1).
Be careful not to damage the cooling
fins.

– Wash out loosened dirt with a hose.

Cold Cleansing Agent

– Spray the heat exchanger with a com-

mercial 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.

● Refit service flap.

● Run the engine up to normal operating

temperature to evaporate any remaining
water.

Series 1012E/1013E

● If an external cooling system is fitted, follow
the manufacturer’s instructions.

Unit engine

● Clean as described under series 1012/1013.
The cleaning jet must be positioned parallel to
the cooling-air ducts.

Hose pressure: max. 100 bar

6

© 2002

Service and Maintenance 6.3 Cooling System

6

6.3.3 Draining Cooling System

1012 / 1013

1 4

© 30 082 0

● 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).

Be careful when draining hot
coolant – danger of scalds!

!

© 2002

Collect drained coolant and
dispose of according to envi­ronmental regulations.

2

3

Fill/vent the cooling system: see section

6.3.4

If a heater is connected to the
cooling system, all heater

!

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

6.3.4 Filling / Venting
Cooling System
1012 / 1013

© 26 260 3

● Unscrew cap 1.

● Loosen sealing plug 2.

● Unscrew vent plug 4.

● Unscrew sealing plug 3 (10 mm) up to the

first notch.

● Add coolant up to the max. marking or fill-up
limit (heater valve – if fitted – of the unit must
be opened).

● Tighten sealing plug 2 (tightening torque 18 Nm)

● Tighten vent plug 4 (tightening torque 40 Nm)

● Tighten sealing plug 3.

● Close cap 1.

● Start engine and warm up until thermostat

opens.

● Switch off engine.

● Check coolant level (see section 3.3.3) and

top up as required.

6.3 Cooling System Service and Maintenance

6.3.5 Draining the Cooling System

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.

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

BFM 1012E
BFM 1013E

● Open radiator cap position 1.

● Loosen vent plug position 2.

● 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.

● Check coolant level when the engine is cold

and top up as required.

● Close the radiator sealing plug position 1.

0297 4987 1

6

Venting

● The cooling systems, which are built in line
with our installation guidelines, are vented
automatically after they have been filled.

● With external cooling systems in accordance
with the specifications of the manufacturer.

© 2002

Service and Maintenance 6.3 Cooling System

6

1013 E
Short engine

BFM 1013E

● 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.

● Check coolant level when the engine is cold

and top up as required.

● Close the radiator sealing plug position 1.

0297 4985 1

Venting

● The cooling systems, which are built in line
with our installation guidelines, are vented
automatically after they have been filled.

● With external cooling systems in accordance
with the specifications of the manufacturer.

● Start the engine and warm up until the
thermostat opens.

6.3.7 Draining the Cooling System

Unit Engine (4 Cylinders)

1

2

© 30 299 0

● Open the cap 1 of the expansion tank.

● Place a container beneath knurled screw 2.

● Unscrew the knurled screw 2 in an anti-

clockwise direction until coolant is emitted.

● Drain off coolant.

● In case of clogging, rinse the radiator through

with clear water.

● Tighten knurled screw 2.
Filling/venting the cooling system:
see section 6.3.8

© 2002

6.3 Cooling System Service and Maintenance

Unit engine (6 cylinders)

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 6.3.8

Be careful when draining hot

coolant - danger of scalds!

!

Collect drained coolant and

dispose of according to envi-

ronmental regulations.

6.3.8 Filling/Venting the Cooling
System
Unit Engine

1

2

© 30 277 0

● Open the cap 1 of the expansion tank.

● Slowly add coolant up to the max. marking or

filler limit.

● Close the cap.

● Start the engine and warm up until the thermostat

opens, the upper coolant line warms up tangibly.

● Briefly run the engine at nominal output (fixed

setting), this rinses out any pockets.

● Switch off the engine and leave to cool down.

● 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.

If a heater is connected to the cooling
system, the heater valves must be

opened when coolant is added. De­pending on the coolant contents and the installation
location of the heater, it may be necessary to
repeat the procedure several times.

6.3.9 Draining the Charge-Air

6

Cooler

1

© 30 191 0

● Loosen the drain plug 1 on the end of the
charge-air cooler.

● Drain off any oil residues that may be
remaining.

● Close the drain plug 1.

© 2002

Service and Maintenance 6.4 Combustion Air Cleaner

6

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.

● Air cleaner servicing is needed when:
– Service Indicator

the red signal 1 is fully visible when the
engine is off.

– Service Switch

the yellow pilot light comes on when the
engine is running.

● If a dry type air cleaner is used, clean when
indicated by the service indicator or switch.

© 2002

● After carrying out service work, reset the
signal by pressing the button on the service
indicator.

6.4 Combustion Air Cleaner Service and Maintenance

6.4.2 Emptying Cyclone T ype
Precleaner

© 25 886 0 © 25 887 0

● Undo wing nut 1 and remove cover 2.

● Remove collector bowl 3 from lower sec-

tion 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.

6.4.3 Cleaning Oil Bath Air
Cleaner

● Turn engine off and wait about 10 minutes

for the oil to drain from filter housing 1.

● Release snap clips 2 and remove oil cup 3

together with filter element 4. If necessary
prize element out with a screwdriver,
taking care not to damage the rubber
gasket 5.

● Remove dirty oil and sludge. Clean oil cup.

6

● Clean filter housing 1 if very dirty.

● Inspect and replace rubber gaskets 5 and

6 if necessary.

● Fill oil cup with engine oil up to the mark
(arrow) (for viscosity, see 4.1.2).

● Refit oil cup and element to filter housing
and secure with snap clips.

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

● Clean filter element 4 in diesel fuel and
allow to drip-dry.

!

Never clean air cleaner with
gasoline. Dispose of old oil in
accordance with environmen­tal regulations.

© 2002

Service and Maintenance 6.4 Combustion Air Cleaner

6

6.4.4 Dry Type Air Cleaner

Dust Discharge V alve

© 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.

● Remove any caked dirt by pressing

together the upper section of the valve.

© 2002

Filter Cartridge

© 25 889 0

● Undo clip fasteners 1.

● Take off hood 2 and remove cartridge 3.

● Clean cartridge (replace at least once a

year).

● Clean cartridge 3:
– Blow out from inside out with dry com-

pressed air (max. 5 bar), or

– in difficult cases, tap out, taking care

not to damage the cartridge, or

– wash according to manufacturer’s

instructions.

● Check paper filter (light showing through)
and gaskets for damage. Replace if
necessary.

● After five air cleaner services or after
two years at the latest, replace safety
cartridge 4 (never clean).
To do so:
– Undo hex. nut 5 and remove cartridge 4.
– Install new cartridge, insert and tighten

hex. nut.

● Install cartridge 3, replace hood 2 and do
up clip fasteners.

Never clean filter cartridge
with gasoline or hot fluids.

!

6.5 Belt Drives Service and Maintenance

6.5.1 Checking V-Belts

1012

© 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.

– Push slowly on the black pad 4 at right angles

to belt 2 until the spring is heard or felt to
trigger.

1013

© 26 315 0

● Carefully remove the gauge without altering
the position of the indicator arm.

– Read off the value: Turn the gauge sideways

to see the exact spot where the top of the
black indicator arm 1 intersects scale 5
(arrow). For settings, see 9.1.

– If necessary, retension belt and measure

again.

Check, tension and change

belts only with the engine off.

!

Refit belt guard, if provided.

6

© 26 261 1

© 2002

Service and Maintenance 6.5 Belt Drives

6

6.5.2 T ensioning Fan /
Alternator Belts
1012

● Slacken off bolts 1, 2 and 3.

© 26 449 0

6.5.3 Changing Fan /
Alternator Belts
1012

● Slacken off bolts 1, 2 and 3.

© 26 449 0

6.5.4 T ensioning Coolant /
Fuel Pump Belts
1012

© 26 450 0

● Slacken off bolts 1 and 2.

● Press alternator 5 in direction of arrow A until

correct belt tension is achieved.

● Re-tighten bolts 1, 2 and 3.

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

© 2002

!

● Press alternator in direction of arrow B.

● Remove and replace belt.

● Tension belt in accordance with 6.5.3.

● Re-tighten bolts 1, 2 and 3.

● Push fuel pump 3 in direction of arrow (A)

until correct belt tension is achieved.

● Re-tighten bolts 1 and 2.

6.5 Belt Drives Service and Maintenance

6.5.5 Changing Coolant /
Fuel Pump Belts
1012

© 26 255 0

● Remove fan belt as described in 6.5.3.

6.5.6 T ensioning Coolant /
Fuel Pump Belts
1012 E

● Slacken off bolts 1 and 2.

© 26 315 0

6.5.7 Changing Coolant /

6

Fuel Pump Belts
1012 E

© 26 261 1

● Slacken off bolts 1 and 2.

● Slacken off bolts 1 and 2.

● Push fuel pump 3 in direction of arrow (B).

● Remove and replace belt.

● Push fuel pump in direction of arrow (A) until

correct belt tension is achieved.

● Tighten bolts 1 and 2.

● Reinstall fan belt and tension as described in

6.5.2.

● Push fuel pump 3 in direction of arrow until

correct belt tension is achieved.

● Tighten bolts 1 and 2.

Check, tension and change

belts only with the engine off.

!

Refit belt guard, if provided.

● Push fuel pump 3 in direction of arrow.

● Remove and replace belt.

● Push fuel pump in opposite direction of arrow

until correct belt tension is achieved.

● Tighten bolts 1 and 2.

© 2002

Service and Maintenance 6.5 Belt Drives

6

6.5.8 T ensioning Alternator Belt

1012 E

© 26 449 0

● Slacken off bolts 1, 2 and 4.

6.5.9 Changing Alternator Belt

1012 E

© 26 449 0

● Remove fuel pump belt as described in 6.5.7.

© 26 450 0

● Move alternator 5 in direction of arrow by
turning bolt 3 until correct belt tension is
achieved.

● Tighten bolts 1, 2 and 4.

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

© 2002

!

● Slacken off bolts 1, 2 and 4.

● Adjust bolt 3 until the V-belt can be removed.

● Fit new belt.

● Adjust bolt 3 until the correct belt tension is

achieved.

● Tighten bolts 1, 2 and 4.

● Reinstall fuel pump belt and tension as

described in 6.5.6.

6.5 Belt Drives Service and Maintenance

6.5.10 T ensioning /
Changing Fan Belt
1013

● 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.

● Tighten bolts 1 and 2.

© 26 345 0

6.5.1 1 Tensioning Coolant /
Fuel Pump belts
1013

© 26 450 0

● Slacken off bolts 1 and 2.

● Push fuel pump 3 in direction (A) of arrow

until correct belt tension is achieved.

● Tighten bolts 1 and 2.

Check, tension and change

belts only with the engine off.

!

Refit belt guard, if provided.

6.5.12 Changing Coolant /
Fuel Pump Belts
1013

© 26 450 0

● Remove fan / alternator belt as described in

6.5.10 and 6.5.13.

● Slacken off bolts 1 and 2.

● Push fuel pump 3 in direction (B) of arrow.

● Remove and replace belt.

● Push fuel pump in direction (A) of arrow until

correct belt tension is achieved.

● Tighten bolts 1 and 2.

● Reinstall fan / alternator belt and retension as

described in 6.5.10 and 6.5.13.

6

© 2002

Service and Maintenance 6.5 Belt Drives

6

6.5.13 T ensioning /Changing
Alternator Belt
1013

© 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.

Changing:

● Slacken off bolts 1, 2 and 3.

● Move alternator 5 in direction of arrow (B)

until belt is exposed.

● Remove and replace belt, tension (see

above).

● Re-tighten bolts 1, 2 and 3.

© 2002

6.5.14 T ensioning Coolant /Fuel
Pump Belts
1013 E

© 26 380 0

● Slacken off bolts 1 and 2.

● Push fuel pump 3 in direction of arrow until

correct belt tension is achieved.

● Tighten bolts 1 and 2.

6.5.15 Changing Coolant /
Fuel Pump Belts
1013 E

© 26 383 0

● Slacken off bolts 1 and 2.

● Push fuel pump 3 in direction of arrow.

● Remove and replace belt.

● Push fuel pump 3 in opposite direction of

arrow until correct belt tension is achieved.

● Tighten bolts 1 and 2.

Check, tension and change
belts only with the engine off.

!

Refit belt guard, if provided.

6.5 Belt Drives Service and Maintenance

6.5.16 T ensioning /Changing
Compressor Belt

● Remove hex. bolts 1.

● Take off outer half-pulley 2.

● Replace belt if necessary.

© 24 598 1

6

© 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.

● Turn engine over while tightening bolts 1 to
prevent belt being pinched.

!

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

© 2002

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

side.

● Remove rocker cover.

● Position crankshaft as per schematic 6.6.1.1

● Before adjusting valve clearance, allow

engine to cool down for at least 30 minutes.
The oil temperature should be below 80 °C /
176 °F.

● 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.

● Check and adjust valve clearance on all
remaining cylinders.

● Replace rocker cover (use new gasket if
needed).

● Check valve clearance between rocker arm /
tappet contact face 2 and valve stem 3 with
feeler gauge 6 (there should be only slight
resistance when feeler blade is inserted).

© 2002

For permissible valve clearance, see 9.1.

● Swing breather valve back into position
and secure.

6.6 Adjustments Service and Maintenance

● 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.

6

© 26 263 2

● Crankshaft Position 2:

Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in

black on schematic.

© 2002

Service and Maintenance 6.7 Accessories

6

6.7.1 Battery

6.7.1.1Checking Battery and Cable
Connectors

© 25 895 0

● Keep battery clean and dry.

● Undo dirty clamps.

● 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. Do up clamp bolts finger
tight.

6.7.1.2Checking Electrolyte
Level

© 24 232 3 © 25 896 0

● Remove caps 1.

● If testers 2 are used, the electrolyte should

come up to their base.

● If testers are not used, the electrolyte level

should be 10-15 mm above the top of the
plates.

● If necessary, top up with distilled water.

● Replace caps.

6.7.1.3Checking Specific
Gravity of Electrolyte

● Measure the specific gravity of individual

cells with a commercial hydrometer.
The hydrometer reading (see table on

following page) indicates the state of charge.
During measurement, the temperature of the
electrolyte should preferably be 20°C / 68°F.

© 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.

6

!

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.

© 2002

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 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.

● Cleaning the engine: Do not spray water/
steam directly onto the alternator. Run the
engine up to normal operating temperature to
evaporate any remaining water.

● Always use proper lifting tackle when
transporting the engine.

© 26 264 0 © 26 265 0

● 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.

© 2002

Use only the correct lifting
tackle.

!

6

© 2002

6

© 2002

7.1 Diagnosis Chart Troubleshooting

7.1 Diagnosis Chart

7

7

Troubleshooting 7.1 Diagnosis Chart

● 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-

!

with speed governor removed.

Disconnect battery.

diate vicinity of the engine or
driven machine.
Important: When carrying out
repair work, never start the engine