Engine serial number: Please entor the engine sorial number hora. The ‘number shuld be quoted when enquiring about fustomer service, repairs o° spare parts (see Section 2.1) Techical modifications required to improve our ‘onginos ere resarved with fogerd fo spaciicaion ‘dala and other techeical fnormaton contained In this Operation Vanual. Noparsofthis Manvalmay be raprogucadin any form orby any means witout ‘our wren approval Operation Manual 1012 1013 Operation Manual 1012 1013 0297 9682 en AForeword (© Please read and observa the information ‘ven inthis Operation Manual. Tris wit tenable you fo avoid accents, preserve the manufacturer's waranty and mainiain the engine in poak operating condition. © This engine has boon bul exclusively for the appleation specied in the scope of suppl, 28 describod by the equipment menutacturer ends tobe used only forthe intended purpose. Any use exceeding that ‘scope is Considered fo be contrary Yo the intordod purpoca. The manufacturer will fot assume responsibly for any camage resulting therettom. The sks involved ae ‘oe bome solely by ine user (©.Use in sccordance withthe Intended pur- ‘Bose alco implies compliance with the oon fitons laid down by the manufacturer for ‘operaion,mainienance and servicing. The engine should only be operated by person- fe! tained in ils use and the hazards Involved. (© Therelevantaccidentprevention guidelines and other generaly accepted safely and industrial hygiene regulations must be ob- saved (© Vvhen the engine s running, there is @rsk of injury through *tumingihot components engines with postive ignition ignition systems (high electrical voltage) ‘You must vod contact at al imost {© Unauthorizod engine modifications wil in- vacate anylabliycainsaganstineman Facturer or resutant damage. Manipulations oftheinjecon and regulating systemmy iso lnflence ine performance ‘oftheengine,anditsemissions. Adhorence tolagisiatononpolufon cannotbe guaran- tea under such conditions. (© Donotchange, convert oracjustihe cooling ai intake ares to the Slower. ‘Themanulacturer shall nol beheldrespon- ibe for any damage which results from such work. ‘@ When carying out maintenancelrepairop- ‘erations oa the engine, the use of DEUTZ ‘orighal parts is prescribed. These are Specially designed for Your engine end ‘guarantee perfect operation. ‘Non-comptance results inthe oxpiy ofthe warranty! ‘© Maintenance and cleaning of the engine should only be cared out when te engine 'S switched off and has cooled down, Youmustansure that he electrical systems have beon switched off and the fniton key has been removed, Accident prevention guldeines conceming electrical systems (e.g. VDE-0100-01011 01041-0109 Electrica protecivemeasures ‘against dangerous ouch volage) are tobe observed, ‘When cleaning with fuids, ll electrical componontseretobe covered inpormeably ese sees ste eo see aaE ese aaa eSeeoSEaeeeRERESSEE Dear Customer, Liguid-cooled Deutz engines are designed for a large number of epplications Consaquenly, a wide range of variants are offered to meel the requirements of speci: ‘Your engine i appropriately quipped for tho instaiaton concerned, which mesns tat not allot he components desorbed inthis Opa- raton Manual are necessary mounted on ‘your engine We have endeavoured to highlight any sifferences so that you wl be abie fo locato the operaing snd maintenance inetrustions relevant fo your engine quieky and easly, Please read this Manual before staring your engine, and always observe the operating ‘nd maintenance instructions, We ace avaiable to help with any addtional enquiries, Sincerely, DEUTZAG.4. General 2. Engine Description 2.1 Model 2.1.4 RatingPiato 2.1.2 Position of the Rating Plate 2.1°3 Engine Serial Number 2.114 Cylinder numbering 22 Engineltustrations 22.1 Operation sido 1012 222 Starter side 1012 223 Operation side 1012 & 224 Starter ide 1012 E 225 Operation side 1013 228. Starer side 1013 227 Operation side 1019 228 Starter side 1013 228. Starer sice UnitEngine BF#M 1013 =C 2.2.40 Operation side UnitEngine BF4M 10130 22.11 Starer sie UnitEngine BFEM 10130 2.2.12 Operation side Unt Engine SAM 1013EC 23 Lube Oi Circuit Soneratic 234 Lube Oil Clout 1012/1012 232 Lube Oil Grcult 1018/1013 24 FuelSystem 24. Fuel System Plon 25 Engine cooling 25.1 Cooling System Schematic 1012 25.2 Cooling System Schematic 1012 E 283 Cooling System Schematic 1013 254 Cooling Systom Schematic 1013 EF 1013 Engine Operation Cemmiesonng 4 “Bourinenghe ot 2 Filing OV Gath A Cleaner 3 Pout Fust 4 Filing Venting the Cooling System 5 _ Other Preparations staring 224 Staring 33 Monitoring Operaton 332. Englna Ol Pressure 332 Coolant temperetire 383 CoolantLevel/ Coolant Level Gauge 24 shuting of 24.4 Mechanical shutoft 342 Electical shutof 3.5. Operating conditions 3.5.1 Winter Operaton 215.2 High Ament Temperature High ‘tude 4a ana 432 42 424 422 43 434 432 433 54 52 33 Contents Operating Media Lube oi Quality Viscosity Fl Quality Groce Wintor-Grade Fuel Coolant ‘Water Quality for Coolant Preparation Coolant Preparation Cooling System Protective Liqus Routine Maintenance Maintenance Schedule Maintenance Chart Maintenance RecoréContents 8. ea Baa B12 B13 Bad 52 524 822 623 6824 625 626 627 63 634 632 833 834 635 636 6a7 638 639 Service and Maintenance Lubrication System (Of change Intervals Check Of Leva Grange Engine Ol Roplace OilFitor Caaning Changing Ol ite (Cup) Fuel System ‘Changing Fuel iter Cleaning /Chenging Fuel Pre-Fiter Element Verting the Fuel Systor with Preliminary FuelFter loan purge or change fuel pre iter ‘Venting the Fuel System with Preliminary Fuel Fier ‘Changing tho Fuel Leakage Line ‘Changing the Fuel Leakage Pipes ‘Coating System CCleening ntervas (Cleaning the Cooling System Draining the Cooling Systm so12r1013 Filing Venting the Cooling System ro1g013 Draining the Cooling System 102 E/ 1013 Filing / Venting the Cooling System 1O12E/ 1013 Draining te Cooling System UnitEngine Filing / Venting the Cooling System UnitEnaine Draining the Charge-Air Cooler 84 Combustion Ar Cloaner 8.4.1 Cleaning Intorvas 84.2 Emptying Cyctone Type Precleaner 84.3 Cleaning Oi Bath Air Cleaner 64.4 Dry Type Air Cleaner 85 Balt Drives 6.5.1 Checking V-Belts 852 Tensioning Fan’ Atemator Belts 1012 6.5.3 Changing Fan Altwmator Belts 1012 85.4 Tersioning Cootant/Fuel Pump Belts 1072 65.5 Changing Coolant/ Fuel Pump Belis ro12 65.8 Tensioning Coolant/Fuel Pump Bolts 1012 8.5.7 Changing Coolant/ Fue! Pump Belts TOE 858 Tensioning Aliemator Belt 1012 E 85.9 Changing Aliornalor Blt 1012 & 8.5.10 Tonsioning / Changing Fan Bot 1018 6.5.11 Tensioning Coolant/Fuel Pump Balls 1013 6.5.12 Changing Coolant/ Fuel Pump Belts roa 6.5.13 Tonsioning / Changing Alternator Balt 1013, 8.5.14 Tensioning Cootant/ Fuel Pump Bells 1019 65.18 Changing Coolent/ Fuel Pump Belis 1013E 6.5.16 Tensioning / Changing Compressor 66 664 Bet Adjustments Checking Adjusting Valve Clearances 8.6.1.1 Valve Clearance Adjustment 67 674 Schematic Accessories Battery 6.7.4.4 Checking Battery and Cable Connectors 6.7.1.2 Checking Electrolyte Level 6.7.13 Checking Specie Gravy of Bleetoiyie 6.7.2 Throe-Phase Allernator 6.7.3 Lifting Tackle 7. m4 8 aa 8 9a 92 93 10, Faults, Causes and Remedios FaultTable Engine Preservation Preservation Technical Specification Engine Specifications and Setings Screw Tightening Torques To's Sorviceaxe the product of many years of research and Aovetopmect. The resulting know-how, coupled with stringent quailty standards, guarantee thle long servic ie, nigh reality and low fue) consumption. ges without saying that DEUTE Diesel Engines teat the highest standards for environmental protection Beware of Running Engine ‘Shut th angne down efor carrying out mainta- ‘nance epa work Ensure atte engine cannot be accidental stated, Fisk of aoscets. ‘When the work is complete, be sure to ret any panels and guards tat may have boen removed. Never il the fo! tan white eines runing. Observe industri salty equations when rung the engire in an enclosed pees or underground Gare and Maintenance Sound car and rantennce practices wil ensure thatthe engine coninvsto mee! the requirements pacadon Recommended serioeintrvale mst be observed and sorviee and reinenance Work Carfed out conscientious. Special care should be tan undorstnormaly \lemancing operating condions. Safety “This symbol is used for al salty warnings. Please follow tham caefullyTheatietionot operating Detsonnelshovldbedrawn these ‘sit nstuctlons. General saoty and acident prevention regulations fa dow by law mustalso be observe. Asbestos DEUIZ orginal parts are asbestos: fro, fe 1 Please contact one of our authorized service ‘eprasantaives in tho event of breakdowns or for spare pals inquiries, Ou rained specalss wil youre ce a rsa. srg only ganuine spare Origialparts For DEUTZAG are alvays produced Ingecovdance wih tale-o-te-artteennaogy Please turn to te end ofthis marual Yor further service information. California Proposition 85 Warning : Diesel engine exhaust and some ofits const- tuenis are known tothe Si of Calforna to ‘aus cancer, bith defects, and athe repro= sue harm,BF6M 1013 BF4M 1013EEngine Description 2.1 Model 2.2 Engine Illustrations 2.3 Lube Oil Circuit 2.4 Fuel System 2.5 Cooling SystemEngine Description 2.1 Model 2.1.41 Rating Plate 2.1.2 Rating Plate Location 2.1.3 Engine Serial Number : sae pera] paar ‘Te model A the engine seal number Band the Te ating plate Ci attach to the crankcase perormance at ae stamped on he rating plate ‘Te model and engine serial number must be given ven ordering sare part 2.1 Model Engine Description 2.1.4 Bytinder Numbering GOOO 4/3{2]1 cae — [esas] ‘ylndas are numbered consecutiv, beginning alte tye! endEngine Description 2.2 Engine Illustrations j 2.21 Service Side 1012 2.2 Engine Illustrations 2.2.2 Starter Side 1012 1 Ol ier (option between ters) 2 Coolant faler 3 Cooling fn 4 Coolnt pump 5. Balt pulley 8 Fuel pump 7 Engino mount 8 Fual fier 8. Lubeol ter 41D ilpan 11 Dipsick 12 Lube oll cooker 413 Mounting fait for byéavic pumps 14 Ateratr 15, Back leak tel pe with pressure-eglating va 16 Oyinder head Engine Description 17 iting points 48 Exhaust urbocharger 18 Speed governor 20 SAEhousing 21 Fywneel 22 Starter motor 23 Hydraulic ol cooler 24 Coolant heat exchanger 25 Goolantevel gauge 26 Bleader vaioEngine Description 2.2 Engine Illustrations 2.2.3 Service Side 1012 E 41 ilfler(opton:betweon fits) 12 11 109 8 2 Coola iret 3 Coolant pump 4 Storator 5 Balt pulley 8 Engine mount 1 Ful pump 8 Fualtier 9 Lube ol ftar 10 Olipan 11 Dipstick 12 Lubeoit cooker 13 Mounting fcity for hydraulic pump 14 Bac ak ol be wih pressure ogsaing va 15 inder head ps] 2.2 Engine Illustrations 2.2.4 Starter Side 1012 E Engine Description 18 Ling points 17 Exhaust turbocharger 18 Speed governor 19 SAE housing 20 Flynt! 21. Starter motor 22 Coolant outetto heat exchanger 23 Exhaust mails 24 Arinake manfoksEngine Description 2.2 Engine Illustrations 2.2.8 Service Side 1013 2.2 Engine Illustrations 2.2.6 Starter Side 1013 1 Ober (option: between ters) 5 Belt Pubey 6 Viton damper 7 Fuel pump 8 Engine mount 8 Fuel iter 10 Lube of fiter 11 Ollpan 12 Dipstck 13 Lube ol cooler ‘4 Hydraue pumps (or compressor) 15. Fuel pipe 16. Solenaié 47 Lube ol ne to turbocharger 18 Cylinder head Engine Description 19 Liting points 20 Exnaustturboenarger 21. Speed governor 22 SAB housing 23. Fywhee! 24 Starter motor 27 Coolant ilar capEngine Description 2.2 Engine Illustrations 2.2.7 Service Side 1013 E 2.2 Engine Illustrations 2.2.8 Starter Side 1013 E 4 olfiler 2 Coolant pump 3. Ful pump 4 bration damper 5 Fualfitor 6 Engine mount 7 Lube otter 8 Olipan 9 dipstick 10. Lubo oil cooer 11 Mounting fcity for hydreutic pump 12 Back leak oe pipe with pressure-regulating vale 13. Ojnder head '® Gootant net i Engine Description 14 ‘iting points 18 Grenkcase breather vave 16 Speed governor AT SAEovsing 48 Flywheel 18. Stcer motor 20 Exraus turbocharger 2 Fan 22 Exhaust manifold 23. Ainake manifoldEngine Description 2.2 Engine Illustrations 2.2.9 Starter Side Unit Engine BF4M 1013 EC iw Ll -' ail 13 W 2.2 Engine Illustrations 1 Coolant ster neck with cap 2 Exoansion tank 3 Venting rom cinder headto expansion tank 4 Conant ine from engin crankcase o engine ‘uid radiator 5. Expansoninetrom expansion tanto raator 8 Seacctera cha 1 Darter 8 Induction a ine betozn dy a itr nd er 10 Coolant ine rom crankcase to engio fad 11. Chargeair cooler 42 Engine Td racator 18 Colantineromenginefuiradatoroengine thermostat Engine Description 2.2.10Service Side Unit Engine BF4M 1013 EC 8. Ventletiontinaromeylindernoad ooxpansion tank 13 Chargeairinetromcturge-ircotertvengine 14 rotectvequaraEngine Description 2.2.41 Starter Side Unit Engine BFEM 1013 EC 2.2 Engine Illustrations 1 Filler nek wth cap 2 Expansion tank 23 Venttine from eynder heat expansion ten 4 Bxoansionlinefromexparsiontanktocoolnt pump 5 Coolant ine rom crankcase to engine td a 8 Charge airtin trom charge a colrto engine 7 Chargeair ie rom edaust tuocnager chargearcocer 8 Coolntline am ercinefudaatorto engine moka por} 2.2 Engine Illustrations 2.2.42Service Site Unit Engine BF4M 1013 EC Engine Description Engine Mid radiator 10 Gharg-ar cooler 11 Broteive guard pao]Engine Description 2.3 Lube Oil Circuit 2.8.1 Lube Oil Circuit Schematic 1012/1012 1 Olan 20 22 21 18 19 17 23 16 121310141511 9 6 4 Pat tar sloorsa 3. Lune oll pump 2 Back lek us ave ‘3 Pressure valve 4 Lube al cooler 5 Lube ol fier 5 Man ol gallery 7 Grankshatt bearing 8 Conred bearing 8 Camshaft bearing 40 Line to spray nozzle 11 Spray nome tor piston cooing "2 Tappet wf control bore for pulse lublcaton cofrovker arms 18 Pushrod (designed for tube oll eupely of ster ars) 14, Rocker arm 46 Retumn ine oo pan 16 Gilsensor 17 line to exhaust ubocherger 48. Exhaust turbocnarger 19 ine o compressor o yratie pump 20 Compressor 21. ‘ysraule pump 22 Return to compressor ohyeraatic pump 23 Une to mass tatancing gear (23) 24 Gounteralancing statis 2 Exhaust turbocharger return to erenkease 2.3 Lube Oil Circuit Engine Description 2.3.2 Lube Oil Cireuit Schematic 1013 / 1013 E 1 opin 2 Arle mains 8 Lineal uo 4a Back oak uel valve Sp Prassure-lit valve 4 Lubec coler 5 Lube fer 8 Main ol galley 7 Crankshaft bearing 8 Conrad bearing 9 Gamshat bearing 10 Spray none 41 Spray nozzle for ison cooling 412 Tappet w/ conto! bore {or pulse hbricaton of rocker ams 18 Pod (ast forte ol sunt of 14 ‘Rocker arm 15. Roturm ine tool pan 18 Ol sensor 17 Olio to exhaust uxbocharger 18 Exhaust turbocharger 48 ilin to compressor or hyrauli pump 20. Compressor 21 Hydraulic pump 22 Return ne to compressor or hysaule pump 25 Rotunto oll pan 24 ‘Exhaust turbocharger return t crankcaseEngine Description 2.4.1 Fuel System Schematic 2.5 Cooling System 2.4 Fuel System 1 Fueltank 2 inet tuel pump 3 Fual pump 4 Line to fuel ter 5 Fuel fer 6 Line toinietion pumps 7 Inecten pump 8 Lina to injctor 9 Ineetor 10 Bac leak ue! pipe 11. Banjo bol wit pressureregulatng vale 42 Return ine to fue tank 13. Kopp this spacing as wide as possible Engine Description 2.5.1. Cooling System Schematic 1012 Coolant fer Themostt housing Coolant pump abe leader Oyler eaoting (ulin ead cocting tt exch et Return rom thermostat to coolant pump Venton fine tom eylinger head to beat xchange (expansion ank)Engine Description 2.5 Cooling System 2.8.2 Cooling System Schematic WIZE entrance regulation 2.5 Cooling System 1, Termastat housing 2 Gaolant pump 3 Lubec cooler 4 Gyinder cooing 5. Ojinder head cooling 5 he Venison ine expansion tank- celent 8 2 Line from engine to et exchanger 3 rian ine tom cyinder neato xgansion ak 10 Expansion tank {Tine from heat exchanger to thermostat Engine Description WIZE escape regulation 3, Temosta housing 2 Cooling uid pump 3 Lubcenting of cooler 4 Ofinder cooing 5 Ojinder heat cooling 6 Hest exctanger 7 Compensation seting of compensation tank {0 cooing fuid pump 8 Lin (rankcase) from thermostat to heat exchanger 8 entiation ne rom oytindor head to compensation tank 30 Compensation tan 11 Linefromheatexchangetocooing igpumpEngine Description 2.5 Cooling System 2.5.3 Cooling System Schematic 1013 2.5 Cooling System Coolant filer Thermostat housing Coolant pump Late ol cooler Heat exchanger Exgansion line coolant umpfexpanion tank ‘entation tne from cynde ead to het exchanger (expansion tank) Engine Description 2.5.4 Cooling System Schematic 1O13E entrance regulation 1 2 3 3 5 é 7 8 8 ‘Thermostat housing ‘Gootant pump (ylindar coating (Gylindar head cooing ect onchange Ventition ine expansion tank - coolant pomp {ine rom enone to neat exchanger entiation ine rom tylinger ned ta cexgansion ‘ane 10 Expansion tank +1 Lin rom beat exchanger to thermastatEngine Description 2.5 Cooling System 13E escape regulation 4 Thermostat housing 2 Cooling fui pump 3 Lutilatng ol cooler 4 Qing ang 7 Campensatan suiting of compensation tank {2coDing Mud pump 8 Line (Crankcasa) rom thermostat o heat exchanger entiation ne rom cyinar nea to ‘compensation an 40 Compensation tank 11 Linetrombsateschangetocooting tid pump Engine Operation 3.1 Commissioning 3.2 Starting 3.3 Monitoring Systems 3.4 Stopping 3.5 Operating ConditionsEngine Operation 3.1 Commissioning 3.1.1. Adding Engine Oi 3.1.2 Filling Oi! Bath Air Cleaner 3.4.3 Adding Fuel FUEL ‘saul, engines ae delved empty fo Purl al int the ci il neck (arron), For ol quantities, see 2.1, For ol gra an viscosty, 804.1, Fl oll cup 1 of he ll athe leaner (fed) yi ol upto te arrow Forol grace and viscosty, co 4, Do not fll tho preceanor dust cobactor (ited) wt 3.1 Commissioning the Cooling 3.1.5 Other Preparations e xorzno1s ‘© check batery and cable connections se€ 6.7.1 See senan 834 oil rn © sorzenoise ~ Arte engine has ben prepared tt ren Seo senion 83.6 for about 10 minutes without fed (© Unitangin with ronaldo) During and ater tal un See sexton B38, het teenie for es ‘Aer the engine tas been tuned off ~ Checkthe ol velandtop up navessary, see 62. «Tight the V-te 0065. . ing ‘uring the breicn phase» about 200 opert- ‘ng nous check the a evel twice a day. ‘er the engine is broken i, checking once @ ay wi ba satin. ‘© Commissioning conserve engines ‘Remove conservation maofls 28 outine in sexion 81 Use only commeria-grae diesel ful, For fel rade, 004.2. require use a prelininary ful ite. tin doubt please eakyour service represertaine. Use summer er winter-grade ful, depending on the ambient temperature ovr il the fue tank while the engin Is runing. Koop to filer ap ara lean and nt spl fu Engine OperationEngine Operation 3.2 Starting 3.2.4 Electric Starting Make sure. that no-one ip standing in the danger area of the engine’ “machine botore switching. on. AMter_ pais: Check ‘whether ‘all_protecton dovices are mounted and al ols have been ‘amoved from the engine. Do net use any adebonel starting aids (2.9. ction with start pit) when stating with heating. ‘plugs. Danger of accidenist Aitenton: The engine may never be started with the "speed governor | removed. Disconnect the battery terminals! If the engine does not start properly with futomatic staring of the heating: Mange (Gtartor doas not get any currant due to ‘malfunction in the aquipmenicustomer side tlectcal cairo), the stat procedure must bbe aborted completly (se anton switch to OFF, interupt power supply forthe heating flange). Botore restaring the engine, the faut rust be sliminatod to ‘avoid any ‘overhoating damage to the heating fange! ‘charge air hoses. Do ret ecluaie the stare for more than 20 ‘seconds, Ifthe engine does not catch, wait ‘minus then ty again. Hi the engine does not catch after two attemas, Fter to the Diagnosis Chart (see 74). 3.2 Starting Starting without Cold-Start Aid pasta) ‘© Disengage the clutch to separate the ‘ongine from the drvon equipment, (© Novo spaed contl lever 1 in drection of arrow atleast to mide speed pasion. @ Move shutdown lever 2 to operating position (in opposite rection of arrow). @ insert key. Postion 0 = no operating voltage, (© Tum key clockwise. ston 1 = operating vottage. = Pilot ights 1 and 2 came on. Push the Key in and tum farther (© Release kay as soon as engine fres. Pot lights go out Engine Operation ‘Starting with Heater Plugs © insert. = Position 10 operating voltage. (© Tun key clocvise ~ Poston 1 = operating voltage. ~ Plot lights come on: Leave fo probe ut plot hts go out (© Push key n and tur further clockwise aglest ‘ping pressure. Poston function, = Position 3 = ear. ‘© Release ey as soon as engine ts, = Plt ights go outEngine Operation 3.3 Monitoring Systems 3.8.1 Engine Oil Pressure Oi! Pressure Pilot Light Oil Pressure Indicator fez} aT} © The ail pressure pot tight comes on wih operating votage on and engine of (© The ol pressure plat ight should go out when ‘he engine is runing. 3.3 Monitoring Systems (© The pointer must remain in me green sector ‘ver the entire operating range. (©The polotr must indicate the minimum oi ur (3268.1), Engine Operation 3.8.2 Coolant Temperature 3.3.3 Coolant Level / Coolant Level Gauge ‘© The coolant tamporture gauge pointarshouls remain in the green sector most of etme. Should rrey enter the yelw-aren sector. I ‘he ponte the orange sector the ei isvavareatng. Tum i off and esebish t tause from he Diagnosis Cart (see 71). (© wan the engin is cold coolant evel shoud Deabove te KALT-COLD mark Yep up with ck tie el low he [MA sar on the sit glass, or he coolant waning swith comes on “Cnsctew he ier cp, Top up wth coolant upto the upper eg afte ler neck, ~Tighen the ler cap (© if 11's not posse fo cary outa check tthe Ingpacton opaning, i equled carry out & check he ler neo Ft cannot see any fe Topplag up is equte. eit ee Se tes, te ening shut ‘on automatically when te level fal below {the Matt marking, ‘Version wit oat switch ‘© When underuting the MY marking, a switch ‘contact wl By means of aoa swith be given toa cstomersided emote indication swaing Hoh / how or Switehgear “shutaown deviceEngine Operation 3.4 Stopping 1 Engines with Mechanical Shutdown 3.4.2. Engines with Electrical ‘Shutdown [are] ‘© Move speed control ovr 1 to low ile (© Operate shutdown lover 2 unt the engine ‘comes oa sto. The charge plot ight and the oi pressure pk light wil come on wien the engine stops. (© Turn toy counteeiockose (to Poston 0) and remove. The pot ight wi go out Wier posse, donot switch ie engine of rom ‘ul oad. Leave running in isle Tor approx. 2 minutes, 3.5 Operating Conditions (© Turnkey counterclockwise (to Psion 0) and romove. The pit ign wl go out 3.5.1 Winter Operation (© Lobe Ot Viseosity = Select the oll viscosity (SAE grate) ‘ecoting tothe ambient temperature when the engines stated (80 4.1.2). ~ Increase of change frequency when operat- Ing blow ~10°0,se0611. Fuel 2 winler-grade dist fuel for operation © Coolant ~ Sel the waterfantironze mito suit the lowest ily temperature (max ~25°0),s60 423.41 (© Adational Maintonanee Work “Drain the svdge from the Tue nk once a ‘week by undoing the cain pug, ~ Aajust he ol vel inthe ll ba ir lanes (tea) te suit th ambient empeature = At temperatures below -20°C, brea the ‘tyweel rig. oar from time to time wih lon tport gras, sue ae Stch Fr V's1. To. do so, remove tha starter and Inoue pees trough he pinion nate, (© Cold-stat Aids tongues ear ory tas, ise glow plugs if nacassary (Gee 3.21), This: not only Towers, the. satng lt tamporature, but provides easier stating Temperatures normaly not reguling a starting ai ebatery = Effelent cold staring requires: a heathy tater (92 87.1. The Staring. init temperature can_ be lowered by 45°C by beating heb up to ‘bout 420°C. To do so, reve te Batty ‘and store ina warm pace.Engine Operation 3.5 Operating Conditions 3.5.2 High Ambient Temperature, High Altitude (© As the atituse and ambient temperature ise, te doosty ofthe al tends fo deeoese, which affects the maximum power ouput of the engig, he exhaust gas qualty and, extreme case, the staring senior. Under transient Conlon, tie engine canbe sed at altodes up fo 1000 meters / $400 feet and temperae {ures upto aor. It th engine ist operate under more severe condilons (at higher atudes ‘or iempe- atures), tl be necessary To reduce the Injected wet quantity an, ths, engine power. © Ifyou have any doubs abot engine operation under these or simfarcondlians, ask your ‘engine or ecuipmentsuppber whethar the engine fas been deratod a te Itoest of reliably, service We and exaust gas qually {Smoke} Otneruse, comact the nearest Santee represent. Operating Media 4.1 Lube Oil 4.2 Fuel 4.3 Coolant ©2002Operating Media 44.1 Quality Grade Lube oils ere differentiated by Deutz ‘ccorting to their performance and quality Glass Ok ototer comparablsectiestene ‘Approved oils: bet] o0c1 [ooo [ooo lacea| 2-96 | es/g0ves-02| 4-99 Jai | crera [ouascena | po 7 papa | Tho procise assignment of the admissible cil quaitles to the engines is indicated in chepter 6.1.1. Trin doubt, contact your service represen tative 4.1 Lube 01 4.1.2 Viscosity Generally, muit-grade olls shall bo used. In ‘osed heated rooms at temperatures 35°, also single-prade ols can be used. ‘As the vscosy of hive 03 fs dapendent on tempera, the. choice of SAE. grade ShoUld be" governed by” the ambient temperature “preveling "atthe “engine ‘operating site. 7 Ca Spiieum operating behaviour wil be attained ¥ you take the accompanying of cosy diagram 96a gue Should” tha tomperatire. fal temporarty betow the mis of the SAE grade selected, oid stating maybe afected but the engine wine be damages. Inorder to Keep wesr toa minimum, donot xcoed appeaton mis fr extended porieds of imo. Synthae lube oils feature an improved temperature snd oxidation salty 4.1 Lube 15. 10. (acavm}+—_| |, lor. 5 10. RETA i Vay anioiues faa} Operating Media 441.24 Specific lube oil definitions ‘Tho ol std inthe table aro to be used for the flloning engines and applications: e013. all engines in biock-type thermal power Stations 1@.31 ongines in gansets operating in pall! ‘uth tho maine [with each other ‘@ oagines in harvesting machines ‘These ate high-orade ol. In abéton, mast of hese oils are pacly synthetic, some even {uly symthaic (O40), and thus achieve the thermal stabiliy requtred tor the celevant application and are distinguished by 2 low tendency to. cause ceposiis In the Turbocharger ao in the charge alr pipes wh vlosed-ciruit crankcase breather ‘The labo wllbo edondod as and when quired, Tobe oils Tor engines with uprated power nd engines with high loading roducer___Typo_of tube a SAE elacs [Av jpeurz ‘DeUYZ OW Tix-raWiare t0W-40 [europe Jrooivot ——_|ADONOL Sx rax NO TOK) 10W-40 Asie [ASONOL Uva Tnx Wo Osa] ‘Sw20 ts lacie Ina Sige Uice TEE | vov-10 |wondwice [Auto Vawe tea Fe | dawteso |Sermany Jara [al epauboral| Sow-t8 |worawice Ira Superturbora ‘3W-30 |wortawige lavia. fUrsosvainit-c | savicte |Sermany lea lana Supe Taek tn oc] Y0¥N-k0 [South Germany lncywva Turbo 4000 fow-ad [Sou Germany lee on mienatira oe Vanaiue er mue | tawt0 | europe Isp Vanslus £7 Supreme | s¥-a0) |Surope Jcestrot \esetror synTaUCK ‘58-40 | Europe, Noth Amerie Argentina Austral Icostrot lcastot ovNawax 78-40 Iceesa leuroraans seo | tons lctievron —_|enoven Des 400 symtc | ‘sw-a0 joea ISEA" Cronos Syn S080 | Germany. Europe IDeA Cronos Premium Lo] tones [Germany, Europe [BEA Grones Premium &x | 40"-40 | Europe lesso [essosoe xt 501 jowero |evrope Flite eurore [ruse Tian gage we | 1an-40 |worduie woh Tan Gorge Sx | '3W.30. [ered Fuste Ton une Blue ic | 10W%-40. |worawrce Joon. on ites Detac' She Swe40) |Europe, SE Asia, Ake Mobi Gelvee 5-40 |wordwce Motil Bsives HP extra | soW-40 |Zaropo, SE Asia lccrmicrsvatinesteWintershalt 166 vow-ad | Eorene Issivecgen [shat inernaiona! |shelt myring Tx 1 v.20 |wrope, atteont Rima Urs osention in some country Nayina Tx roweao | 2urope, tfocent Rinuin‘Uite Sosenglion in rome country |rexaco Super TOK tow-4o | row.sa |eurone ss Premium re sn-00| ‘Sw.se lEwere frovan rina evefrova ‘RUBIA rik @s0o” | {00-10 | wordwise IEC PeRFoRMANcE | tow-40. [wort IExpenty wx toro Ete PeRronmance | tow-40 |cermany, Benetun lexpenty mx ove Scansinaviny Aveta IFINA KAPPA FIRST sw-so [Europe FINA mappa ULTRA | 10-40 [europe ©2002Operating Media 42.1 Quality Grade Use commercially available diosol fuel wth less than 0.6% suiphur content. I the sulfur ‘content is higher than 0.5%, ol change intervals should be reduced (see 6.1.1) ‘The folowing fuel specticatons/standards ‘are approved (refer to TF 0199-3002) (© Diesel tuo! DIN ENS90 =BS 2608: At and AZ (oi A2, take note ofthe sulfur content) ASTM D 975-88; 1-D and 2D NATO Code F-Stand Fo75 1808217 DMX Tis0.8217 OMA @ Light heating ot! ‘according to BIN 51009 ASTM 0 396; 1 and 2 BS 2860 Ciase 6 0 set fuel FadlF35/Fad (kerosene) “54 (equivalentto diesel uel accorcing to DINEN'599), AE 99 (enalnt to F467 96 wth ad tives) © Bio diesel fuel + according 10 DIN S1606- FAME Exhaust emission values which may be etermined in tie cause cf iype approval tests aivays refor to the reference ‘uel prescribed by the authoies forthe type approval test, 4.3 Coolant 4.2.2 Winter-Grade Fuel than 0."C, winter-grade fue (suitable down {o-20°C) shouldbe used. This uelis usually ‘avaliable from fling sietions well in advance ofthe cold months. © At tomperatures below -20°C/, korosone ‘should be added to the diesel fuel, The relevant percentages are gven inte dae ‘gram a he right © Special diesel fuels can beusedfor climatic zones down to 44°C, It summer-grade ciosel ful must be used at tormperatures below 0°C, upto 60% kerosene can be added (see clagram). In most cases, adequate resistance io cold can be obiained by adding a fow improver (Gdeitve)-Ploaso contactyour eutaperiner, Diasel fuels must never be ‘mixed with petrol (normal and ‘super grade petro} 4.2 Fuel 4 a Ts 22 Legend: T [Summer doset fas! I] Winter diesel Tuer Oulsioe temperature 3B [Percentage ofkeroseno tbe aad) Mix tank ony. Fl with the approptatoamountot keresane fist, then ade the disse! Tel, Operating Media 4.3.1 Water Quality for Coolant Preparation ‘The values gen below must not be ‘exceeced. ‘itost kt (order number 1213 0382) can be ‘obtained from DEUTZ Service to chook the {aly ofthe water avaliable. [Water quality min. [ max. provaue at 20" eer [65 | 85 Chioride ion content rnglams| — | 109 [Suate fon content imgioms}|— | 100 Total hardness ['4GH) 3 [20 4.3.2 Coolant Preparation “The preparation end monitoring of coolantin Iquig-cooled engines 's especially important because corrosion, cavitation and freezing an foad to engine damage, “The coolant is prepared by admixing a coating system protective quid with the fooling water The cooing system must be monitored regulaty (see 8.1). The weer level and the fealng system protective liguid concen talon should both bs checks The cooing system protective | iqud ‘coneaniration can be Shecked with a commersialy avaliable tesier (0.9. gefo ‘lycomat ‘When nittite-based cooling system protective liguids. are rrixed wih amine-based quis, armiulnivosamines ere 4.3.3 Cooling System Protective Liquid DEUTZ cooling system protective agents can bo oblaned under oféer number 1011490 (5 res) or 1221 1500 (210 Ires). “These are tie, arrine- and phosohaie- fie and provide effective "protection ‘against conosion, cavitalon and freezing the above-mentones cooing system agents afe not avalable, tho folowing products can be used in exceptional cases. fanufacturer| Product description AVIA” | AVIA Anifieeze Exte BASF ‘Giysaniin G 48 DEA | DEA radiator anifreoze SHELL SHELL Glyeosned ‘The concentialion of the cooing system protective bquid in the coolant may net fal Belowexceed the folowing fini: (Coot eiveliqud | Water tax. 45 Vol rnin, 35 VoL¥e 85%, For the quently, see table overpage and Information in section 9.4. (ther cooling system protective quis, eg. chemical cortosion ‘inibiors, can, in ‘exceptional crcumstances, be used in the oolant, in conaulation wih DEUTZ Service, ‘Oreer the cooing system protective liquid ‘fom: DEUTZ Serves Coaingsysiemprotectiveliquds ‘must be disposed of in accor dance with environmental regulation. ©2002Operating Media 4,3 Coolant Cooling System Protection Cooling system capacity *) Cooling Cooling [Liters] system protective | is | 2 | 2 |] 2 | 2 | 0 | a | 3 protection agent [vol %] PC] Cooling system protective [Liters] ff 35 “2 28 | 70 | 77 | a75 | 95 | 105 | 112 | 123 40 28 72 | eo | aa | wo | wa | 120 | we | 140 4s 38 si | oo | 99 | 143 | 122 | 135 | 144 | 150 50 48 so | 10 | +10 | 5 | 125 | 150 | te0 | 175 *) For quanlty of coolant in you engine, 00 Socon 0.1. Note For fguosnoray fl retr bac to heatofie Routine Maintenance 5.1 Maintenance Schedule §.2 Maintenance Chart 5.3 Maintenance Record © 2002VarinnacasiopsE Grade 8 fahsteO Cea Repo i aor or dusng Tat ot un, dng commissioning check twice estes een daily or when commissioning new or reconditioned engines The specified engine maintenance times are vey 10 parang ness or Sly eax. poms esarmende es In operating hours (OH), every _ros10r2Ergeston000H| marnonatce mes nay bs neces, Please feroi0:Sengnes!S00005| rr to manus opersing manual 10] 20] E90 E40 50 0] E80] e70"| vars 1 tarenance werkt be carded ot only by 500] 1000) S00) 2000] 3000) + | 1) 2 jauthorised service personnel. Operation Section ERIE Lube of ve, op up as necessary et2a.g a Lib of oer real os 6 ogra appar ee TROTOODOINE [6.16-12 i iar cri (or ever be ot chnge) ais Fuel reat zt ject vave z Fel fl oakago nes (oplace arse) ize Fuel pre-fiter * (change filter eement if necessary) [4276224 Goolnt (dive consotraton) aavars Goolnt aid love 5 Version wi foal ewe, ceo TROTSDABADE [a8 Fi_[ Beacon ar tr (F prosont sone as par maintenance dpi) — [ea Charge cooler (drain lube oll | condensate) 639 Baty snd cable connectors — era Shoathedeamant gov plugs = Engi nenleee, Waring satan FE Vibe dara (st ¥ neccsney, calor Wrabas Soa) aim * When the warning system responds (lampthom), the fuel pre-lter must be emplled immediately " Changing the pre-fitar cacriga depends on the degree of soling of the fuel used. If fuels whitch dont meet tha requirements of TR 0199-93. 8008 (620 4.2.1) aro usod tho warranty with be voided. 5.1 Maintenance Schedule Routine Maintenance ore Maitonance sop E “Agust=O Gear &_ Replaces Industrial engines Every 10 operating hours or dally ‘Before oF during Tat test run, ding commissioning check twice daly or when commissioning new or reconionad engines ‘The specified engine maintenance times are the max, permissible recommended times. [Depending on te application shorter In operating hours (OF), every ‘maintenance tes may be necessary. Pease| “E7O1012E nines 1000008 | Fer to manufaciue's operating manual. Every 10 operating hours ar daly Beore or during 1st est run, during commissioning check twice daly of when commissioning new or reconloned engines “£70 1013ngnes 190000H | Maintenance work tobe carted out only by 10 | £20 eso e40 eso eso] E60 70" Wveor| authorised service personnel, |s00|1000|1500|2000)2000 412 operation Section ° . Lea i] Vbatia (elgnion oF replace Bs necessary) 35 ole SETE Te Joneck engine for leaks (visual inspection) iE . =e eres F a]engine bearing firings (renew if damaged) oz ° 2 = [Check cooing system boarings — rubber and retaining elements = . or ms hangs, hose connections F camp = = jor overhaul z Mainienance stog=€ _Chack=@ _Adjust=O Cleans Replace Expansions or modifications for THaK parmiaaDl recommended times i operatng hours engines with EPA acceptance ine speed engine minenence tes are he mex. puss veconmendod tes, Depending on the Gopoalonchorr mantnance tes may be necessary Paaso refer to manoctrers operating maria In operating hours (OH), every "o12Engnest00000H | Hfznterence work o be cetied cut ony by authorised lero Jex0 | es0 E40 E50 E80 E60 70°] Years | -sraeqhests0000H | service personnel. 500 |1000|1500]3000 4500 112 |operation Section 2 [injection valve = 130K # = Injection valve > 130K # © 2002Routine Maintenance 5.2.1 Additional maintenance Treva Waintenance | Stages Erecutoh Matter s08h E70 ee day E20 Daly check routhe operator, euboried waned sa we0Bir £90 inspection auhorzed waned tat 70008 E40 ended napaton ‘auhoried vaod sat 20008 0 Eeended irtemediaie overhau authorized vaod sal So00BR (EPA) 0 ‘ended temedate overhaul auorznd voted ola 00008 (01) E70 Mar ovettau authorized tated lal ‘onan tora) | E70 Mar overant uhorzed rained la 5.2 Maintenance Chart Routine Maintenance The mainienance chart shown here is supplied a3 selradhasive label with each engine Itshould bo affixed where ican be Seen clearly on the engine or driven cequpment. ‘Check that this i the case. tr nacessary, ask your engin or aqupmont "Supple fora ean suppy of labels. Routine work shouldbe carried outaccording to tho schedule in 5.1 —Septheerghre mie A faring ou sy marvonance wore BF4/6M 1012/E/C © 2002Routine Maintenance 5.2 Maintenance Chart Zoutine work should be carted cut accoing te sehecule mat aA 1X el BFM 1012E BFM1013E DEUTz BFM 1012 BFM 1013 ‘Standard engine 5.2 Maintenance Chart Routine Maintenance “The eaintonance chart shown here le supplied as saltachesive label wih each engine. I should be affixed where R can be seen clearly on tho engine or drven equipment ‘Check that this is the case. fee err IFrneoassary, ask your engine or equipment supplir for a fresh supply of labels, Routine work should be caried out aGsording tothe schedule in 61 Krafistoff-Vorfllter Wartung Fuel prefilter ‘Maintenance ire combust. Entretien Prefilto combust. Mantenimiento z Short engineRoutine Maintenance 5.3 Completed Maintenance Jobs [Hours Date ‘Signaure / Stamp Hours, Date ‘Signaure / Stamp 50-180" : 125 : 250 375 500 625 750 875 1000 1125 1250 1375 1500 : 1625 1750 : 1875 2000 2116 2250 2375 2500 2625 2750 * Commissioning new and overhauled egines ‘The maintenance jos uly complete can be rcarded nthe above table, 5.3 Completed Maintenance Jobs Routine Maintenance ‘Hours: Date | ‘Signaure/ Stamp Hours: Date ‘Signaure / Stamp. 2875 3000 3125 3250 [ 3375, 3500 3625 3750 3875 4000 4125 4250 4375 4500 4625 4750 4875 5000 5125 5260 | 5375 5600 5625, 6750 ‘he maltarance ts dy contd cant carded inh toe alRoutine Maintenance 5.3 Completed Maintenance Jobs i fovs._|_bae Snare Siang Hows [tute Signa Samo 5875 6000 6125 6250 6375 6500 6625 6750 6875 7000 7125 7260 7378 7500 7625 7150 7826 8000 8125 8250 8375 8500 8626 8750 ‘The maintenance jobs cul completed can be recorded inthe above abe, 5.3 Completed Maintenance Jobs Routine Maintenance fours | bie Saar Sip Ts Sais Sa i 8875, 9000 9125 9250 9375 9500 9625 9750 9875 10000 10125 10250 10375 10500 10625 10750 10825 11000 14125 11250 11375 11500 11625 11750 Te mantrance os dy competed can be ected int ove alePHADAAG Tbh oNe Service and Maintenance Lubrication System Fuel System Cooling System Combustion Air Cleaner Belt Drives Adjustments Accessories 2002: @ Service and Maintenance 6.1 Lubrication System 6 4 Oil Change Intervals © The oll change intervals are dependent on the engine application and the qualty of the lube of. iF ho engine runs fewer hours during the year than stated in the table, tre ol Su be changed at least once a year. © The lable refers tothe oowing cond tion: = For diesel fuel: sulfur content max. 0.5 ‘ by weight = Continucus aimblent temperatures down ton0"C/ 14°F @ For foes “with eulfur content fs > 0.5 to 4 % ~ continuous ambient temperature bolow orca r with bio- 200K 8 ie 8/8 * Gensets as referred to here are units operating in parallel with the mains 7 with each other. Emergency power units are dealt with in TC 0199-99-1126. ©2002Service and Maintenance 6.1 Lubrication System 6.1.4.2 Ol change intervals for vehicle engines Lube oltqualiy Deutz lube oll quality cass pact pacit pac nt ‘ACE Napectfcaton E296 EROGEST EES ‘APtspeccaion CHOFT TEACH = = ‘worlwide speciation = DED 7 special DEUTZ release : - 200 chap. A121 Apricaton |” ,JEngineversion Lube oil change intervals in km torartors Eurot 10.000 15000 20000, Euro Lane Euro I excaptfor 7 15.000 20000, A sie |. RTC Ewoll_= 141 contents (rst Rg) = = 10.000 : ohiclest |) 318 Ta eantants (st fing) 7 20000 Stadtbuseel | Evel : = 20.000 i BROS Euroll 78 (ol conten (rst Bing) = 10000 > 191i eorents (sting) = 20000 Euro = 20000 FOTOS Earot 75000 250 s0 000 Euro and Euro excoptor: 7 20000 30.000, ETOCS Euroll_ $141 of contents (rs ling) - ~ 18000 > 14 ol contents (st fling) : > 30000 Euro : = 30000 ROTC Exoll_=701 of eontants (Wat Ang) > 45 000 > 191 ol contents (st fing) : > $6 000 Ewell - 30000 TOE WoT a0 393 a0 000 a0 095 Evroll and Euro tl, excopt for : 30000 40000, Long SrawioraFC Euroll = 14 Vl contents (st fing) > 20000 distance > 14 | ol contents (st ng) > 40000 Evol : 240000 BFaMTOTEEC Euroll_< 78 contents (at Ming) 20.000 > 18 lol contents st ling) : > 40000 Evil > 40.000 6.1 Lubrication System Service and Maintenance 64.2 Checking Oil Level / Changing Engine Oil 6.1.24 Checking Oil Level 6.1.2.2. Changing Engine Oil OIL ? <}qmax <-MIN fore) + 80°C +176°F OIL- oa (© Ensure thatthe engine or vehicle s on @ evel surface. Warm engine © Switzn off angine, walt § minutes and ‘hock the ol level ©-Coid engine ‘Ghack the ol evel @ Remove the dipstick Wipe of wih @non-fbrau, cea ch. Insert up tothe stop and pul out again (© Check oil teat, If required top up to the "MAX evel =ftieollevelisjustabovetna" MIN" mark, it should be topped up. ‘Tha ol level must not crop below the “MINT ark Run the engine warm ‘@ Ensure thatthe engine or vehicle is on a Iovel surtaoe Lube ol temperature approx. 0°C. (© Swish of he engine {@ Place an of tray beneath the engine Unserow drain pug. Drsinal, Fail drain plug wit new gasket and tighten firmly (or torque, see ®.2). ‘@Fillvith lube of Fr gradeNiscosily, see 4.1. or Guan, $66 ‘@ Chock al fovs, 500: i2a othe gol But catch in a Be cach wn dig a ot ect ween cg tat SeService and Maintenance 6.1 Lubrication System 6.1.3 Changing Oil Filter Saar } ETI) Ssaap] (© With tite torsion occ (© Croan eny cit fom the fiter carer sim. (© Check tht the carte is corecty seated Loosen soeus and. side clamps down- ‘gains the gacket and lighten wih @ fal wards. ‘© Lignty ol the ruber gasket of re new of ——_haletur, ‘er eatlsge. (© Undo the iter cxtisge with commercial tool (© La torsion lock’ et: ‘and spn of (@-Scew in the new cartidoe finger Soht Slide’ clamps up io postion and tihlon ‘against te gasket screws. (© Catch any dipping ol. (© Chock ol ove (600 6.1.2), Beware of bums from hat cd 6.1 Lubrication System ‘© Check ol pressure (500 3.3.1), (© Check carvidge sec. Service and Maintenance 6.1.4 Cleaning/Changing Oil filter (Cup) sm @ Switch off the engine. 1 Leeson lubool tercap 1 andunscrow in'an aneloccvase drecion © Coretaty i he paper er catidge 3 out once 9 Galen ery ripping lt Ghange the paper iter caridge 3, leamanyctem the liter caer in and the lube flor overt and guide A ‘Caution: het oll Risk of scalding! (© Replace rubber seal 2 end apply smal amount of grease © Cérafully insert the new paper fitor cariidge in guide 4 © Tighterlubs ol ttercovertintheciocavise irection (25 Nm). @ Siar the engine. neck tho ol lave, see 6.1.2. heck the oll pressure, S03 3.3.1. 18 Check hoe ol ier ting fo leaks, 2002Service and Maintenance 6.2.1 Changing Fuel iter 6.2 Fuel System praiaiTo] (© Cose tus stoprack (© Undo fuel iter carte wth commercial tool ‘and sein off © Catch any fue. ‘Koop naked flames away when working on” the. fuel systom, Do not smoke! 6.2 Fuel System (© Crean ary dt fom the fiter carer im. (© Appylght fim of oto: desl uelo the rubber ‘gasket of the ra uel fer eardge, © Scou in the new coridge Srger ht ‘against the gasket. ba _ (©-Check that tho carte is seated comecty gest east are gon wth a (© Open fue stopcock (© Chock orleaks. A ‘The fuel system does not need to be Bled, Service and Maintenance 622 Cleaning/Changing Fuel Pro-Filter Element Cleaning: ‘Close fuel stopcock. {8 Place the Tuo! pan beneath the preiminary ‘uel tr. Romove draln plug 4 and drain of tut (8 Unscrew camping screw 1, remove fiter housing 5 with fer insert 3, (© Ciean sealing surface of he fier bracket 7 and fiter insert housing 5 of any di. (@ insert new seatng ring 6 and titer insert a ferango as necessary) “push te filer Insert Up to approx. Som ‘ver the age ofthe housing onto the (uide in the fiter housing 8, ‘© Pross filer housing Sith iter insert 3 and ‘sealing ring 6 against the fiter console 7 ‘and screw into placa with camping serow ghtoning torque 25 Nm) NNate:itmust be possible o push the upper seal 2 on ‘iter insert 3 over the guide bracket on filer console 7. (9 Tiohten drain plug 4. © Open fuel stopcock # chock foro ir to engine hs been stare Changing: (© Replace defective fiter insert 3. 6.2.3 Venting the Fuel System with Preliminary Fuel Filter Bleeding: {© Place the fuel pan beneath the prefminery {uel ter ‘@ Loosen drain plug 4 and observe the ‘raining fuld. Whon fue instead of water ‘Starts to flow, rotighten drain pug 4 (© Check for lacks afer the engine has been started, Venting @ During initia! commissioning, after ‘maintenance work of I the terk is run Erplytssessenialtoventthe ful system. ‘© Set engine controller to stop positon jace fue! collecting vough under the fiter housing (6)/ prossure contro vave (8), (© Span el stones, pressuraconta va @), vent screw (6). ‘e Furn engine wit starter (max. 20 sec) ‘unl fuel with no a Budles escapes rorn tse ard sae ing ae ( (© Titer vont socow 8 (ightoning torque 15 Nm) ane pressure contol vale 8, ‘© Set engine controler to start postion and start ‘@ When the engine has started check for Teak “Avoid naked flames when ‘working onthe uslsysiom.Oo gy ‘ot smoko, Dispose of waste {ust in an environmentaliye ‘Wendly way; Service and Maintenance 6.2 Fuel System 624 Clean / purge or change fuel pre-fiter (© Turn of engine of in the case ofa change- ‘vor fier, swich over to tre ater fir. © Close the fuel stopcock or supply. {it svallabl) (Gpen the bleed screw 1 on the cover 2 ( Plce nett etecarunceraath he ft presite. (© Empty water and dit from the bow! 8 by ‘pening (prass in and tur sight without Using force) the drain cock & and cose the Grain cock 8 again (@.Ciose the bleed serow 4 on the cover 2 @5leed the fuel pipe according to instructions, see 6.29 opposite 6.2 Fuel System hanging the fitor element 5: Change at least once a year or as required (top n performance also ster purging) (@'Tum of the engine or swich to olor itor in case of changeover fiter © Close the fuel stopcock or supply (if avatable} ‘@ Loosen tne cover serous 3 dagonally Remove the cover 2 Remove the spring cessetle 4 18 Remove thefitererementS fromthe bracket @ incor new fiter element 5 {© Place spring cassette 4 on the element ‘Ghack that the cover seal propery in the cover2 and creck or demage (ehange necessary) (© Tighton the cover 2 wih the screws 3 diagonal (torque 6 Nm) {© Check the cover 2 for proper ft and fet Bleed the fuel systom, s00 6.23. Tie conoaion ofa waning olen US (mpinorn) via contacts 7 ie speciied inmedlatemalnanance Is necestary wher ine wari ysam tore Naked flames are proniblied when working on the fuel system! Do not smoke! Bispose ofodtuelinan environ mentally rendly wayl 625 Venting the Fuel System with Preliminary Fuel Filter ‘@ During initiat_commissioni maintenanee worl oF i the tank is run smpty itis essertaltoventthe velsysiem. at engine controler to stop postion ‘@ Place fuel collecting tough under the pressure contol valve 9. © Open fuel stopcock (if avaiable) and proscure contra valve 9. ‘0 Fam engine with starter (max. 20 e€c, or use hand fue pump (favalabie), unt fuel with no ar bubbles escapes rom pressure holding valve 8 Ita pressure contol valve 2. © Set angine controle to start postion and tart then the engine has sated check for aks Service and Maintenance 626 Changing Fuel Leakage Line 627 Changing Fuol Leakage Pipes ‘© Set engine controle to stop poston pen fv stopcock LLeosen pressure holding valve & Catch any fuelwhich eszapes and dispose of in an envronmentaly-tiendly way @ Turn engine wit slarer (max. 20 sec) nil ue wth no ar bubbles escapes fem pressure holding valve 3. €@ Tighten up pressure holding valve 9. tongue conole'to sla positon ard stat 12 te engin has started check fo leas ‘Avoid naked flames when working on the ual system. Do Not smnoke. Dispose of waste fuel in an environmentally: friendly way 1 Close fuel stopoock mania valve cap cover Loosen tose clamps 6 vith hose clamp pilers TN 8020 (see chap 23). © Remove rubber hoses 3 and hose camps from the injection valves. © Loosen prossure hoicing valve 9 Dismantl hose clamps 6, rubber hoses 1, 3and4and connection piece 2and dispose of in an envronmentaly-tiendly Way (© Mounting new tus! ieakage pies: ‘Side rubber hoses 3 (ubicate inside with maunting grease) with hose clamps 6 on the connection nipples of the injection valves and logo nitshose clamp pers TN 3020, © Mounting pressure hong valve & Tighten up new sng pleco with bol. © Remount valve cap caver Sat engine contoter to start postion and start @ When the engine hes started check for looks Ensure thatthe nose clamp lock shows othe injocton valve and the hase clamp canta into the motor housing : 9Service and Maintenance 63.1 Cl ing Intervals (© The amount of contamination inthe eeaing system depends on the angine appcatien, (© pled ail or fue on the engin incresses the ‘sk of contarinaten. Be especially cre {he engine is used in dusty ervronmenis. Serius contamination can occur, for example: on construction sites where there Is @ high level of al-borne dust. — in harvesting appicaton whore thare ore high concentatons of chaff 2nd chopped Sra in the vein of he mach. @ Because appicatons vary, clearing in- lervals have to be determined fom case lo case. The cleaning intervals given in the table below can be Used as a gu ‘Checking T Cleaning Intervals ‘Suggested | Application ‘2000 | Ships, gensets in encosed ‘spaces, Pumps 7000__| Vettes on paved roads 500 | Teaors, fran tacks, mobile gonsels 250 | Vehicis on constucion aes ‘and unpaved roads, consi tion equipment, compressors, 6.3.2 Cleaning Cooling System Series 1012/1013, (© Piace a cleaning bath under the heat ex: ‘changer (Rt 2). (© Remove the service tap on the heat ex: changer (see inser Compressed Air "Blow ‘out heat exchanger with com- pressed air (frst from ik 3, then from ES) Be careful not to damage the cooling fins. 6.3 Cooling System Cold, Cteansing Agent Spray the Neel exchanger with @ com- ‘moreal cold cleansing agent and et Stand for about 10 minutes. — Fit spray cloan wih a water jot from positon 3 then from positon 1 (do.nat Spray “senstive engine comoonents directly with a water jo, e9 generator, ‘cables, elecronic components, fai ‘iive), ning with steam or with hot water Remove of and grease residues with {ho Jot sot ata gent setng. © Refit service fap (@ Run the engine up to normal operating temperature to evaporate any remaining water. Sores 10126013 Fn extemal cooing system fed Row the manufacture’ nstuctons, cl Unit engine (© Clean 26 doertied under sori 101211013. ‘The ceaningjat must be positoned paral to the cooling ducts. Lies aniseed eons = Wash out loosened dirt with @ hose. S| Ara racer, rene oe Fos presse: nae TOD bar 6.3 Cooling System Service and Maintenance 6.3.3 Ds Cooling Syster 6.3.4 Filling / Venting eee eee Cooling System 1012/1013 1012/1013 (© Piacecontanor under drain ug 3. © Unscrew cap 1. Unscrew dan plo 3 fay. Drain eoolre. (© Drain the rerhing fd from the engine ‘paler (coat dud, ‘@ Screw in the seaing glug 3 up tothe frst notch end serewin Ue seating ag on he ‘cooler (aro) dispose of accorcing 10 envi- ronmental regulations. Fillvent the cooling system: soo section 634 A ‘Wa heatar ie connected to the cooling system, all heater Valves must be opened during ‘ang. Depending on the water content and the installation ofthe heater, may ba Fequiredtoropeat the last point Several imasto vent ihe heater systam, tug 4 (3 Uracen seating pla 9 (10 em) up to he Ast cela up tothe max, mr o ° 7 or {ent (caer eve ied of ur mast te opened) i ercmustueereae ts fering trquo 40) art engine and warm up unl thermostat opens. 2 Belch of ongne Chose sola avo (coe socten 2.83) and top up as equi ©2002Service and Maintenance 6.3 Cooling System 6.3.5 Draining the Cooling system 1012/1013 (© Piace 2 container under seaing pug 1 Remowe seating plug 1 fom the crankcase. Drain of te conint, Tighten sealing pug“ agin. 10 FSoateg plug 1 not accceeble, the este ‘can be dranod at the engine ol ecole (coniant cua) Fingheatig the cooling sytem: See sacion 636. danger of Collect drained ‘coolant and codons 6.3 Cooling System iNenting the Cooling System 1012 E013 E Standard engine BFM1013E {© open racstor cap poston 1 .coson vent pug poston 2 (@ Add coolant up fo the maximum marking or ‘ile it hate valve of he system rust be opened ~ fied) (© Tighion vent plug positon 2 + sealing plug poston 3, 82 radar cap positon 1 ‘© Suat engine erd warm Up uni thermastat opens. © Switch off enone. ‘Check coolant eve! when the engine is old ‘nd fp up as required. (© Close the raiator seal plug postion 1. Venting ©The cooling systms, which are bull in tna ‘wih cur Instalaton guidelines, are vented ‘2utomalcally afer they have boon led. (0 Wit exemal cooing systoms in accordance with the specications of the manufacturer Service and Maintenance 1013E Short engine (© Loosen vont plug postion 2 ans seafng plug Es (© Adc coolant up tothe maximum marking or flor ik (eater valve ofthe system rouse Soened ~ i ited), Gas racist cap postin 1 Stan engine and arm up Unt themes ‘opens. © Swich of engine. ‘Check cootet evel wen the engine is old ‘and top up as required. (© Cioeo the raator sealing pg poston 1. Venting (9° Te eaoing systems, which are buat inte ww our Insatesion guidlines. are veried auternatcally afer hey have besn fled. (9 With external cooing systems in accordance wih the specteatons of the manufacturer. ‘eStart the engine and warm up unl the ‘ermesat opens. 6.3.7 Draining the Cooling System Unit Engine (4 Cylinders) (© Opan the cap 1 ofthe expansion tank. (9 Place a container beneath krues sor 2, @ Urscrew the frurled screw 2 in an ent ‘lockwae Grecton und cocartis omited. © Drain ff coolant @ Incase of gang rinse the radiator through with clear water (© Tighten krusied sor 2. Flingiveting the cooing system see secon 83.8 ©2002Service and Maintenance 6.3 Cooling System Unit engine (6 cylinders) 6.38 Filling/Venting the Cooling System Unit Engine 9 Draining the Charge-Air Cooler s00 secton 8.38 Be careful when drahing hot coolant = danger of ‘scale! Collect drained’ coolant and sispose of according 1> onvi- ‘omental regulations. 6.4 Combustion Air Cleaner 6.4.1 Cleaning Intervals (© The amount of dit inthe ai cesner deponds onthe amount of cust nthe ar and te sia the ar loemor used. ra high ivel of dusts anipates, a cyelonerype predeaner can be ed tone at cleaner (© Cheering rtowvais wat have tobe determines from case lo case. I a ry type ar cleaner is used, lean when Indeated by the serie indicator or sich. @ and warm up ui the Pemestt ‘in fe ange ron ep fac tanya gta ft com ae Ta hesler i comacied ate enoing TES system, the heater valves must be ‘pened wien coolant added. Do. pondingonthacanantcertonsandiholntaion fbcaton af the Hester may be necessary 10 Service and Maintenance (© Ar loanor servicing is needed when: = Service Indicator the red signal tls fully visible when the engine is of. . Service Switch the yellow pot ght comes on when the engine Is runing, (© Afior canying out serico work, rosat tho ‘Sigal by pressing the buton on the service oeator (© Loosen the drain plug 7/00 the end of te charger cope. Dial of any oF resdues tat may be remaining. (© Cioso the drain plug 4 8 gS eService and M: intenance 6.4 Combustion Air Cleaner 64.2 Emptying Cyclone Type Precleaner 6.4.3 Cleaning Oil Bath Air Cleaner ere (© Undo wing nut 1 and remove cover 2. (© Remove collector bow 8 from lower sec- n4and emply. Clesn leaves, sia and ‘ther foreign matter from lower seston of precleaner. © Reposition colsctor bowl 3 onto lower section 4, fasten oover 2 in place. by tightening wing nut 7. Never ft colocior bowl with of, Replace collector bow! if damaged. 6.4 Combustion Air Cleaner (© Tum engine off and watt about 19 minutes for te of to drain ftom fer housing 1 (© Release snap cips 2 and remove ol cup togethor with fiter elemant 4 necessary prize element out with a sorewdtver faking care not to damage the rubber gasket 5 ‘© Remove dry oll and sludge. Clean of up. © Cioan fiter element 4 in cesel fuel anc allow to dtip-y, (©.Clean fiter housing 1 if very dy. (© inspect and replace eipber gaskats § end O irrecessary, (© Fl oi cup with engine oil up to the mark (erow} (or viscosity, see 4.1.2). ‘© Reiit ol cup and elemant to fitr housing ‘and secure wih snap clip, A Never clean air deaner with esctine, Dispose af old ci in 2ccordarice with environmen fal regulations. Service and Maintenance 6.4.4 Dry Type Air Cleaner Dust Discharge Valve Fiiter Cartridge & a Ea (© Empty dust discharge valve 1 by pressing ‘apart lips of discharge clet ag Indicated by artows, (© Clean discharge sit trom time to time. @ Remove any caked dit by pressing together the upper section of the valve (© Undo clip fasteners 1. (© Take off hood 2 and remove oartidge 3. (@-Cican cartidge (replace al least once & yea). (© Olen cartridge 3: = Blow out from inside out wth dry com prossad air (max, 5 bar), oF in dificult cases, tap out, taking core ‘otto damage the cartiege, or Wash according to manufacturer's Insttutions. (© Check paper fiter (ight showing through) ‘and gaskets for damage. Replace. If necessary. @Ater five air cleaner sorvioss or after ‘wo. years at the latest, replace safety cartidge 4 (never clear) Todo so: = Undo hex. nutS and remove cartridge 4 ~ Install new cartridge, insert end tighten rox: rut © Install carvidge 3, replace hood 2 and do up alp fasteners” A ‘Naver clean filer cendge wi gesoline or hot fis. g 3Service and Maintenance 6.5 Belt Drives I 6.5.1 Checking V-Belts 1012 inspect erie Ve for damage © carey cove gig wat along {he poston of te csor a ( Reslace damaged bes, ~ Readof he vem fe gage sioways (© Aer insttng new bots, un enn or 15 Back idan ant recs ese 8 thes, en check be inson {erow) For seings, seo 8 — WP rceeony,rtesion bel end measure ote 3 von mist nae ow oe ‘check belt tension. Cash y = de eee Hla rae tt , Sebeee seat oceans aaa eer siowy onthe pad at gangs SEf cy wt cine ot a EiaI Zeal eo sing ete rt ft Dl uaro proved 6.5 Belt Drives Service and Maintenance 6.5.2 Tensioning Fan/ 6.5.3 Changing Fan/ 6.5.4 Tensioning Coolant/ Alternator Belts Alternator Belts Fuel Pump Belts 1012 1012 1012 (© Slackon off bots 1, 2 and 3. (© Stacken off bts 1, 22nd 3 (© Siackon off bots 1 and2. (© Press atemater Sin cirecion of arow Aundl —@ Press altar in direction of arrow 8, (Punt pare 3 in oon of arow (8) ‘caret be tension i ached. ‘ut coe bal toneion is acteved. (© Remove and replace bet ‘@ Re-sghian bolts 1 2nd 2 ‘© Re-ighion bolts 1,2.and 3. ‘check, tension and change Dells caly with the engine of. Rofl belt guar, if provided (© Tension bet in accordance wih 653. ‘@ Re-ightonbotts 1,2nd3. ©2002Service and Maintenance 6.5 Belt Drives 65.5 Changing Coolant / 6.5.6 Ten: 6.5.7 Changing Coolant / Fuel Pump Belts Fuel Pump Belts, Fuel Pump Belts. 1012E 1012E (© Remove fan belt as desorbed in 65:3. © Siacken off bots 1 and 2. (© Slacken off bls 1 and 2 © Slacken of bots 4 and 2. (© Push fuel pump 3 in drecion of rou. (© Push fuel pump 3n drecton of erow uni (© Puch fool pump 3 in cteton of arow (8). correct bel tonsion is achived ‘© Remove andrepace belt, (© Remove and replace ek, (© Tighten bots 1 and 2 (Push ue pug incpposte drecion of arow ‘cores balt onsen ie achieved (Bas po deci of ero (A ure correct bek tension i (© Tien bolts 1 ana 2 (© Tighten bots 1 and2 ‘Check, tension and chenge (© Rinstal fan belt and tonsion as decribed in bolts Sny with tho ongine of 652. Ff lt guard, if provided. 6.5 Belt Drives Service and Maintenance 6.5.8 Tensioning Alternator Belt 6.5.9 Changing Alternator Belt a 1012E 1012E © Stacken of bots 1, 2and 4, (© Remove tue pump bet as desorbed in 6.57. (@Move atemator 5 in direction of arow by © Slacken of bos 1,2 and 4 furring batt 3 unt carect belt toncon achieved, (© Acjust bit unt he Vb can be removed. (© Tighten bts 1, 2and 4, (© Fitnow bet (© Adjust bolt 3 unt te caret bit tonsion fs achieved, © Tighten bots 1,2 and 4 __ Gheck, tension and change Delt cnly with the engine ct @ Rehnaa fuel pump belt end tension 2s Refit bet guard, if provced, described in 58. ©2002Service and Maintenance 6.5 Belt Drives 6.5.10 Tensioning/ 6.5.11 Tensioning Coolant / 6.5.12 Changing Coolant / Changing Fan Bolt Fuel Pump belts Fuel Pump Belts 1013 1013, 1013, (© Sooke of bots 1 and 2. (© Stcken of bls and 2 © Remove fan sematr betas deserted in = Tensioing eS i0erd 8513. Inger square vrnch in square and pull @ Push fel pump 3 n decon (A) of aon {gfsquare prench in square and pel © il oes bak tension eset © Siacken of bots 1 and 2. tension fe achioved. come (© Taher 4 and 2 ‘© Push hs! pump Sin drecton ©) of aro. Ingott square wrench in square end 7 loosen in oppoate dhrecton ‘of erov. fereerory entries Poe ‘Tension new bolt ae deseibed above (© Puch pumpin drecion (A) of row ui (© Ten bois 1 ana 2 ‘comect bat tnsion is achiove. ‘Check, tension and changa © Tighlenbols 1 ana 2. balls only withthe engine of, Refi bell guara, if provided. @ Resa fan/ alteator bet and retension as, esatbed in 65:10 and 8.13. 6.5 Belt Drives Service and Maintenance 6.5.13 Tensioning /Changing 6.5.14 Tensioning Coolant /Fuel 6.5.15 Changing Coolant / Alternator Belt Pump Belts Fuel Pump Belts 1013, 1013E 1013E Tensioning: (© Stacien of bots 1 and 2 (© Sieckon offbots 1 and 2. (@'Siacken of bots 1, 2 and 3 : (© Nove dlamor S'in diecion of arow (A) @ Push fut pump 3 in deecton of row wnt! @ Push fel pump 2 in dreton of arom. ‘nt coect bal tension 's achieved, ‘correct bel tension is achieved. (© Revihten bos 1, 2nd 3. (© Remove and rplaco bot. (© Tichton bots 1 and 2. Changing: (© Push fs! pump 3 In apposte drecton of (© Slacken off bots 1, 2nd 3. ‘aon untl coer bes terion Is achieved, (@ hove steratr 5! in deen of arow (6) ntl bok exposed, (© Tighten bos t a2 (@omove and replace bet, tension (see above). EEE eee eee eee e Rotghientots 1,2ond3. Check, tonsion and change belts enly with the engine of Felt bat guard, if provided. ©2002Service and Maintenance 6.5 Belt Drives 6.5.16 Tensioning/ ‘Changing Compressor Belt ‘© Romove hex. bots 1 (© Toke off outer hat pulloy 2. (© Replace bat if novessary heck, tension and change belts caly wih the engine of. Ret guard, if provided, 8 6.6 Adjustments (© Tum engine over whe tightening bots 1 to raven! bel beng pinched. Service and Maintenance 6.6.1 Checking / Adjusting Valve Clearances ras] (© Siocken off breather valve and swing to one ‘ie (© Remove rocker cover. (© Poston crankshaft a per schematic 68.1.1 Before adjusting valve clearance, alow tere to ool down fra ost 9 inden. Thal tonportre shel bo bow 80°C (© Check vahe clearance between rocker arm / lng enlace 2 ava sn 9h fel goons, Chee sho be oy ht realstanoe when feser blade is neorted), For pormissbio vale clearance, se 8.1 1 Aust vo oarance if necossany: “Release c Use eefewatver 7 to wm sotscrow 5 50 nat te correct clearance Is atained ‘er locknut 4 has been tghtones, (© Check and adjust valve clearance on al remaining oyider. (© Roplace rocker cover (use new gasket if needed). (© Swing breather valve back nto positon and secure. ©2002Service and Maintenance 6.6 Adjustments 6.7 Accessories @-Cranksnatt Position 1: Tun crankshaft unt both valves in rice | oven oat va shat Sn). Aust ‘of valves marked in black on ‘schema. Mark respective rocker arm With chalk 10 Show that adjustment has been done. © Crankshaft Position 2: “Tum crankshaft one fll revolution (360°). ‘Adjust clearance of valves. marked in black on schomate. Service and Maintenance Battery 4 Checking Battery and Cable Connectors 6.7.1.2 Checking Electrolyte 6.7.1.3 Checking Speci Gravity of Electrolyte (© Keep batery lean and dry. © Undo dey dams. (© Clean terminal posts (+ and —} and clamps of the battery, and grease with acc-ree ard acideesistant grease, (© When reassembling, ensure tht clams ake good contac. Bo up damp bots ger tort (© Remove caps 1. 1 estore 2 ar used, the electro should como up fo ei base, © if esters ars not used, the elective tvel Should be 10-15 mm above the tp of he @ Measure the specie gravy of individual cals ih 2 commercial hycrometer. ‘The tyctometer reading (600 table on following page) incatos tho stata of charge. Dureg measurement, ha temperature of the ‘ect sould preerably be 20°C / 68°F. ©2002Service and Maintenance 6.7 Accessories Specific Gravity inka in-BePBaune) ‘Stata of Charge Normal | Tropios | Namal | Tropics 128 | 123 | a2 | 27 Faby charged sao | 12 | m | Haif charged, rocharge saz | 108 [ie | m1 Discharged, recharge immediatly * Measurement of specific gravity in “BE is ‘out of date and rarely used Today. ‘Thegases omitedby hebattery are explosive, Koop sparks and Naked flames away from the Battery. Bo ot allow battery acid to come inlo contact wih skin or Shthing. Wear protective goggles. Dorot rest tools an te battry. 6.7 Accessories Service and Maintenance 6.7.2 Three-Phase Alternator Noles on the three-phase system: (© Norer disconnect tie cables between bat. ‘ery, stemalor and regulator whe the engine is nnning. © i, nowever, tis necessary to sian and ope- rate the engine witout the battery, ciscor- ect the regulator from tne llemetor before staring (©-8e sure nett confuse the battery trina. (© Replace defecive bub of the charge pict ‘emp imnecatey (© cleaning tho engine: Do not seray weld Steam crey ete tne store Run He srgne ptoromaloperatgterparareo evaporate ary remaing was (© Thehatitoficuching lead agains te freme to check whether i's ive must under no Groursioncas bo used wih threephase ectical systems, (© in tye case of eoctic welding, connect the ‘ound tania on fe weter Srocy to the Blece being welded, 6.7.3 Lifting Tackle tie @ Aways use proper ing tackle when transporing the ange, Use only tha corect iting tacke, ©2002Troubleshooting 7.1 Diagnosis ChartTroubleshooting 7.1 Diagnosis Chart ‘©: engine probs occur, they frequently have the ause i impreper operaten or Ege (© probiems do oosur, always check test that ‘me operating and maintenance Inst ucons rave been followed (© A ciagnosischartis gen onthe facing pave. it you cannot ident the cause of the problem or are unable to rectly it yoursal, lease ontat DEUTZ Serve, Beloe sang, make sue tat het sng tine dle of hs engi dren racine Imprent Ween ening. out {ez wok ver sat he enn vin sped gmuerortmove Damea born, 7.1 Diagnosis Chart Troubleshooting Fault, ‘Remedy Eighe ISO TCT Sa tek tre a us nr OE Mist ie oes Teerue nor wn fees W Tage gas pn peoarce Gen OR og onal RS ww A hie at eo of ee Loverine! —§ Tne alcosimplon ie Suh =bic ase Sia 7 he eae are po) Gpralo|—F es Tel igi terse a OE gle statown een ton posh [anh SRN) a = Til ow A ett igh - z esse ibn eg PIE ef ‘Speed control lever set to middle position PIE ty acne Fuk boca Cana ar [ PW E AF Genet ser sich eva a : OR" delete (ean e) a : hare ine eng Pw al Sait pee Gang at | ; Cars coke coiarined FIR 7 lar at xanga iy FIR ele ak deli, pt ob ER oT al a PI : Cook a eng rse/otaealon a * ate dior shred teas —[F FLDA=Anerld doo Tue 1612Troubleshooting 7.1 Diagnosis Chart Taal Remedy ge SOE oT chee —F Eire a a rns nv oS — wists Tigh ipa TGS WaT fice Ww ‘Engine gives poor performance SEE Clean R Ee a ager = To A Engine has little or no oil pressur PEE Lowerlevel = S Engh ol consunpton exces igie snaes = Due ae a Cause Seana 2 5 epic al colons Sa See on oom ora —Eeetics LP : Sarr Slee prion does rol enage a 2 Te [rere veces eee aig ectn is r [Wat ie Be (cn a aT] a Pra 2 e Glow plugs detective Pe | & cr eect FTW Arlt ystm Pi {a erate dy rin Ole ace W ate Troe te of SAE as ray Tamra W | Ft iy ets pr Operon ana ri Coot eo Wk Taezot2 Engine Preservation 8.1 PreservationEngine Preservation 8.1 Preservation the engine Is t remain ida for an ecenced Dsiod of time, fs necessary to tae protective Measures to provet rust formaton. The prex servatve measures destribed here wipotec the engin for vp to 6 months. The procedure wil ann obo tase efor the ene 1 r- (© Anti corrosion als to spectcton = MiLs-212¢03 = 11 9150-0572 = NATO code C E4042 © Fecommended cleansing agent to remove Drservatves when recommissionng engin: “Petroleum benzing (hazardous. mateals ass 43} Preserving Engine: ‘©-Clean engine (with cold cleansing agent preterred). See 6.32 ‘© Fun engine unt warm, then tun ft. (© Druin engine ol (se 6.1.2) and with at corrosion ol (© Drain coniant 92 53.9835). (© Fl with ant-corasion agent (ee 4.3.9). tinezessay clean ol bath air cleaner se66.43) sand fl with ant coresion ol (© Drain fel ark. (© Wakeup a misture of 90% dlose ful and 10% ‘ani-corosion al, and ref fel tank. 8.1 Preservation [aszea] (© Run engine for about 10 minutes. © Tum engine of (© Tum engine over manually several times, If using tare, setshatdownteveriostop poston. ‘© Remove bast andstorein wrapped conten. ‘© Spray grooves of V-bak pulleys 2 with ant coresian agent. (© Coes of nike ports 9 and exhaust ports 4, (© Light grease and replace cook filer (© rain ant-corosion ageat (se 6.33/65) Removing Engine Preservatives: (© Bamove am-comosion agent from grooves in Vebat pales 2 (© instal V-belts. Retension ater ra operation Isnecassary (e606). ‘© Romove coves trom nike port Sand exhaust por 4 (© Fil wit cooient se2 6.34/63.) © Siar engine. Technical Specifications 9.1 Engine Specifications and Settings 9.2 Torque Wrench Settings 9.3 ToolsTechnical Specifications 9.1 Engine Specifications and Settings model Fam 1012 —— Fam woi26 ‘BFOM 1012, Brom 1012 C BFaM 1012 ——BFaw 1072 EC BFEM 1012 — aFeM 1012 EC Number of eyiders 4 4 6 6 Gylnder arrangement vertical in ine Bore {rom 94 Stoke [rom 115 Toll displacement len] 3192 3192 4788. 4788 omession ratio fal 15 Working eyl/Gombustion system “4-stroko Giese with turbocharging and dec inection charge at cooler wo w ive w Ditection of rattion counter loki Wight 1012/ ine. cooing system [kg approx] contact company headquarters ‘Weloht 1912 £/£C wi cooing system as per DIN 70020-4 {ho 2porox} 20 332 485 «sr Engine power cr o ‘Speed (rom) Valve earance with col engine [en Inlet 08**' 7 outlet 0.5», Injector opening pressure (bay) 2500275 ‘Star of aeivery [Porank angle bT0G} ; ing order of engine cary 142 153624 158624 be tension: Pretension eension, Generator fan ~ 50/3005, Fue! pump coon pump i 550/300, Compressor i 650/400" ‘Engine powoy, speed, start of very ae Stamped on engine vlog pa, 20 lo OT elena 16 minutes afar the engine as boon driven under load 9.1 Engine Specifications and Settings Technical Specifications Model BFMT012/e Bran 1012 —— pram 1012.0 BFEM 1012 — BFEMINIZc — BFAM 1012E — BFA 1012 EC BFEM 1012 —— FEM 1012 EC Coating systom Liquid cooldCooing system proacton. Coola quantity 101206 fives approx) 93 100 122 138 woizee » {ites approx] 58 86: 73 3 1612 unit engine (wi onal adator [tres approx] 158 181 = = Permissible cominuous colant temperature Engine oul, with performance group! rey max.1109. Engine out, with performance group LV [°C] max.05® Thecmostat intel opening at ro, 337 ‘Thermostat ful open temperature to] -—— 958 Cectat prewarning * Gootant pump Delivery pressure in [bay] ’ Datvry rate (07 5 Power consumption in te a wbrcation foree-fed tubriaton (i temperature ino pan re 128 ‘in, ot pressure wth engine warm (12076 ané SAE oil 15 40) and tow ile speed [bar] 08 ‘Ol eapacy (frst fil-up) without fer lies approx} a5 85, 1259) 1253) i capaci (frst fitup) with iter Nes approx) 1008, 100% 140% 140%, 5 approrimte figures can vary depending on tha design. The upper marking on the cipstck is avays the maximum. ‘© Only during winter (ee62.5.1) "Only engine capaiywrihout radiator. Capac of extemal cating system dependent on cooling system design, ‘© Ofer performance groups have erent values, Please contact company headquarters 2 With external coog systems with out conto, the temperature at hich te themostat opens is 87°C ‘With external coaling systems with outetconl the temperature at which the thermostats fully opened is 102° '® Pease contact company headaualrs (varies Gapending on engine design),Technical Specifications 9.1 Engine Specifications and Settings Model _braorg ara rae ——— ratios — are 0130 —— pretto130>— - — BRAM 1013EC ———-BFBM 101SE —BFEM1013EC-—— BFSM 1013ECP - Numbor of orders 4~ 6 yireerarengement ‘ Bare’ Stoke “Totalspacoment [ex] ara CComeression ato ——— 175- Weng cytetCersbuson system 4-toke cecal win tbocharging and dec injection —~ Charge sirconer |— wio Direction of rotation Weight 1018/CPinc. cooing stem kg approx ‘Waght 1013 E/EC /ECP wio casing sysiem as per DIN 7OCA0-A Engine poner Speed ‘Vaio clearanes wih old engine Injector pening pressure ‘Start dlvery oH Fidng order of engine 159624 — 153624. 153624 — Vebat tensor: retension tans 3, nnn Generator fan 350/300 mene us pump-cootat pump 5350/3 Compressor 50/400", Blower Cravkshalt (Doublaba) 1900/8008, Engine power, speed, start of dobry are stamped on ence ring plete, se also 2.4 2 Relension {Sinus afer the engin has been civen under load 9.1 Engine Specifications and Settings Technical Specifications Tor a13 —srurus — semen — erewane — erowanac — Eran ors e— sre ioro co — arom ors sre s0v9e6 —aran trac —| Cosin ssn UictanedCocin sem pein ———— Cook gary foreroren ties approx) |] 121 13s 's 183. 129 {oiae/eo/ oes fee ppex) | — 72 12 so. oe 82 {o13 untenae th txt at ts appre] 178 87 2 wr ar Formsstle conus cover emoea> Engrectecwitpotorane gpl (0) macit08 Enpre ule wih ptomanc praup HVC] mraciose Termosat ial opening at ra aw. Thermal opt temperate ral a Cola pevering " Crt ump Delve pesertin bal . Daley ein rel “ Pover vases n ‘et Ms Lubin tet ee beaten Ot tompera nl gan ra wa 125 Heol presse wth nie warn (rb and SA 01194 and oi pn oe Oi cacy tha) wiht respon] [-— 79 re 2 me 2 ot caucy st ip) wih ar (Reseppex) L— 1402, 1408, —— 210%, 210%, —— roa ' Approximate figures can vary depending onthe design, The upper marking on the cpstik is vay the maximum ‘Only during winter (see 35.1) © Oni engine eapaiy without radiator, Capacity of ecemal cooling system dependant on cooing sytem design ® Ofer pertrmance groups have different values, Please contact company headquarters. ‘ith etemal cooling sytem wth out contol, the iemporture at whi the Mermostat opens is 87°C ‘tn external eotng star with out contol, the tomparture at whe the thermostat fu opened is 102° ‘ease contact company peadguaters(vares dapencing on engine design)Technical Specifications 9.1 Engine Specifications and Settings Model BAM 1013 FC # BOM 1015 FC # Number of finders 4 6 Oyler arengemant vere nine Bore {om 108 Stoke {rom 130 Total isplacament, [em] 768. 78 Compression aio fa. 178 ‘Working cyteCombustion system stroke disel with trbocharing and rect injection ‘Garg alrcooer with Decton of rtation counterclockwise ‘Weight tors Fo without coaingsystom contact company heedeuarters per DIN 70020-4 (ho approx 455 600 Engine power wm ® Speed {tom} 4, Vale clearance with cold engine (em) Init o,s**! 7 outer 5 Inector opening pressure toad) 25 Star of daivery [Perankangte br0C} 9, Finng order of engine 1342 1342 — 158624 159624 — 159624 bet tension: Pretesion/e-tesion Generator fan ™ 550/900, Fuel pump coolant pump i] 550/300 Compressor ay 50/400, "Engine powet, speed, stato dlvery ae stamped on engine rating plate, sea also 2.1 * Retension 15 minus aftr te engin has been driven under oad 9.1 Engine Specifications and Settings Technical Specifications ‘Model 1013 FO BAM A013 FC BFEMIO1E FoF Godling system LUguid-ooledCooing system protection Cocian quantiy 1013FO 9 lives approx) 12 98 Permissible continous coolant empeatue Engine cut, with performance group | fre) win tingaltype charg: (ubochargs) mat 10 wth ad charge ebctarger max05 9, Engine cute, wth perormance group Iv (°C) wit hinged-ypeefarger (turbocharger + with fed charger (urboctarger ma. 105 8, ‘Thermostat inal opening at rc) a ‘Thermostat full open temperature re) 102, eon rewarming « Coolant pump Delivery pressure in [bal a Delivery ae in [n'a a Power consumption te) a Lubeicaton ‘orced-ee0hubcation ‘Ga temperature ino pan may. 125 7 Min, of pressure wth engine warm (126°C and SAE ol 15 W 40) and io idle sped fbar] a8 (i capacity (lst fitap) without iter fives approx 182. (i capacity (st ihup) wth iter [ives approx] B99 57 Approcimate utes can vary depending on the design. The upper marking 4 On curing winter (se62.5.1) ‘on te dipstick is alvays the maximum. Only engine capacity witout raator. Capac of extemal cooing system dependent on cootng system design. ‘Other pafomance groups have ifetent values Please contact company headquarters. "lease contact company headquarters (ates depending on engine design) #Se041.21Technical Specifications 9.2 Torque Wrench Settings Prete tm) Torquing Lot foe sage | Sane | saaes | sme | sao»2 | sameo | Sagee | mm | Renate Tiler corer 35 fir am eosen 7 Mount ree sie vor [ieyanea Mount troearge se cor [yaaa ‘rae maid 85 Exhaust manifold 7 ee a “| a an en 0 ror moerig| 6 | tom Tieton ening wo | wens Ol pan cast on 2 (tpn teat mata) 2 9.3 Tools Technical Specifications TORK V-belt Tension Gauge aT ps] Aro rns we hg The Ve cen ug cn ed dr SE tat cy emt tes oe toning sty nate LE (@ High load transfer when loosening and tghten- 042826 Remschsid 7 (© Aimest impossible for sockot ta sige off or beak TORY tots can be oad fro: WILBAR Postach 1405 80 42625 RemscheldTechnical Specifications 9.3 Tools Filling aid Filling aid BFL 1012/1013 BFM 10121013 saen ii essen] ‘The fling aid is obtainable under order No. The fling aid is obtainable under eros No. 470-440 from: era Fa. Wilbar FAWILBAR Postfach 140580 Postfach 14 05 80 D-42826 Remscheid ssrewiulfniieneeneNotes Warnings to Place on Equipment Warning in the Manual CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Diesel engine exhaust and some of its constituents are known to the State of constituents are known to the State of California to cause cancer, birth California to cause cancer, birth defects, and other reproductive harm. defects, and other reproductive harm. or CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some ofits constituentsare known to the State of California to cause cancer, birth defects, and other reproductive harm. Notes CALIFORNIA PROPOSITION 65 INFORMATION ‘To GALIFORNIA CUSTOMERS AND ‘TO CUSTOMERS SELLING DIESEL ENGINE EQUIPMENT INTO OR FOR USE IN CALIFORNIA. Proposition 65, a California law, requires warnings on products which expose individuals in California to chemicals listed under that law, including certain chemicals in diesel engine exhaust, n Power iigment, The California Superior Court has approved ether of the following {vo methods of compliance with Proposition 65 requirements by manufactures of offroad equipment containing diesel engines. (The court ‘order containing these provisions is attached.) 1 On-Equiament Waming, Place the warning pictured in attachment 1 on all equipment shipped by you into or forsale in California after January 1, 1996, The warning must be in 2 location where itis easily visile to the operator ofthe equipment when (s)he is operating the equipment. The warning must be secured to the equipment. If warnings or operating instructions are provided through a digital display, You may usee that method af providing warning. 2. Operator Manual Warning. Wen the operator manual is next revised or by December 31, 1995 whichever Is earlier, place the warning imattachment 2 in the operator manual. The warning may be either printed in the manual or on a sticker, ‘The warning must appear in one of the following locations: Inside The front cover Inside the back cover ‘© Outside the front cover ‘© Outside the back cover «© As the first page of text Under eitheraltemative, the warning must appearin the same size, printandformatas theattachment elected or be ofan equally conspicuous size and format. Ifthe warning is provided in an on-screen dispay, the warning must contain the language in the attachment and must be Provided at the time of orn connection with ignition in the same manner as other safety warnings electronically communicated on screen, ‘Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel engine sold in California ‘Should you have any quastions, please call Deutz Corporation Product Support Department.up 2996 L6¢0 70N Japs0 ‘hureduros auySua ayy ZingG 002/80 0"uoRIpa V7 6+ ououa Hox Egors-c sbeLic ns ioUNEyN-NAG YOLOW Z1N3a ‘ev zinaa