Deutz 1012 User manual

ENGLISCH • Kapitel 00 • Seite 1
Operation Manual
1012
1013

ENGLISCH • Kapitel 00 • Seite 2
●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.
●Unauthorized engine modifications will
invalidate any liability claims against the manu-
facturer 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 alter, modify or adapt the cooling air
intake area to the fan. The manufacturer will not
assume responsibility for any damage resulting
therefrom.

ENGLISCH • Kapitel 00 • Seite 3
0297 9682 en
Operation Manual
1012
1013
Engine
serial number:
Please enter the engine serial number here. This
number should be quoted when inquiring about
Customer Service, Repairs or Spare Parts (see Section
2.1).
All rights reserved. Technical modifications required to
improve our engines are reserved with regard to
specification data and other technical information
contained in this Operation Manual. No part of this
Manual may be reproduced in any form or by any
means without our written approval.

ENGLISCH • Kapitel 00 • Seite 4
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
to your engine.
We have endeavored 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
inquiries.
Sincerely,
DEUTZ AG
Foreword

ENGLISCH • Kapitel 00 • Seite 5
Table of contents
1. General
2. Engine Description
2.1 Model
2.1.1 Rating Plate
2.1.2 Rating Plate Location
2.1.3 Engine Serial Number
2.1.4 Cylinder Numbering
2.2 Engine Illustrations
2.2.1 Service Side 1012
2.2.2 Starter Side 1012
2.2.3 Service Side 1012 E
2.2.4 Starter Side 1012 E
2.2.5 Service Side 1013
2.2.6 Starter Side 1013
2.2.7 Service Side 1013 E
2.2.8 Starter Side 1013 E
2.2.9 Starter Side
Unit Engine BF4M 1013 EC
2.2.10 Service Side
Unit Engine BF4M 1013 EC
2.2.11 Starter Side
Unit Engine BF6M 1013 EC
2.2.12 Service Side
Unit Engine BF6M 1013 EC
2.3 Lube Oil Circuit
2.3.1 Lube Oil Circuit Schematic 1012/1012 E
2.3.2 Lube Oil Circuit Schematic 1013/1013 E
2.4 Fuel System
2.4.1 Fuel System Schematic
2.5 Cooling System
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
3. Engine Operation
3.1 Commissioning
3.1.1 Adding Engine Oil
3.1.2 Filling Oil Bath Air Cleaner
3.1.3 Adding Fuel
3.1.4 Filling/Venting the Cooling System
3.1.5 Other Preparations
3.1.6 Other Preparations
3.2 Starting
3.2.1 Electric Starting
3.3 Monitoring Systems
3.3.1 Engine Oil Pressure
3.3.2 Coolant Temperature
3.3.3 Coolant Level/Level Gauge
3.4 Stopping
3.4.1 Engines with Mechanical Shutdown
3.4.2 Engines with Electrical Shutdown
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 Grade
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 Antifreeze/Chemical Corrosion Inhibitors
5. Routine Maintenance
5.1 Maintenance Schedule
5.2 Maintenance Chart
5.3 Maintenance Record

ENGLISCH • Kapitel 00 • Seite 6
Table of contents
6. Service and Maintenance
6.1 Lubrication System
6.1.1 Oil Change Intervals
6.1.2 Changing Engine Oil, Checking Oil Level
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 Cleaning / Changing Fuel Pre-Filter
Element
6.2.3 Venting the Fuel System
with Preliminary Fuel Filter
6.2.4 Venting the Fuel System
w/o Preliminary Fuel Filter
6.2.5 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
6.5.10 Tensioning / Changing Compressor /
Alternator Belts 1013
6.5.11 Tensioning Coolant / Fuel Pump Belts
1013
6.5.12 Changing Coolant / Fuel Pump Belts
1013
6.5.13 Tensioning / Changing Alternator Belt
1013
6.5.14 Tensioning Coolant / Fuel Pump Belts
1013 E
6.5.15 Changing Coolant / Fuel Pump Belts
1013 E
6.5.16 Tensioning / Changing Compressor Belt
6.6 Adjustments
6.6.1 Checking / Adjusting Valve Clearances
6.6.1.1 Valve Clearance Adjustment Schematic
6.7 Accessories
6.7.1 Battery
6.7.1.1 Checking the Battery and Cable
Connections
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. Troubleshooting
7.1 Diagnosis Chart
8. Engine Preservation
8.1 Preservation
9. Technical Specifications
9.1 Engine Specifications and Settings
9.2 Torque Wrench Settings
9.3 Tools
10. Service

ENGLISCH • Kapitel 00 • Seite 7

ENGLISCH • Kapitel 00 • Seite 8

7Gerade
7Gerade
1
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.
Service
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.
General
!
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.
Asbestos
DEUTZ original parts are asbestos-
free.
Safety
This symbol is used for all safety
warnings. Please follow them
carefully. The attention of operating
personnel should be drawn to these
safety instructions. General safety
and accident prevention regulations laid down by
law must also be observed.
Beware of Running Engine
Shut the engine down before carrying out mainte-
nance 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.
California
Proposition 65 Warning
Diesel engine exhaust and some of its consti-
tuents are known to the State of California to
cause cancer, birth defects, and other repro-
ductive harm.
9689en_K01_neu 30.09.1999, 15:45 Uhr7

88
1
9689en_K01_neu 30.09.1999, 15:45 Uhr8

ENGLISCH• Kapitel2 •Seite 1
2
2.1␣ Model
2.2␣ Engine Illustrations
2.3␣ Lube Oil Circuit
2.4␣ Fuel System
2.5␣ Cooling System
Engine Description
7380en_k02_pdf 01.10.1999, 16:20 Uhr1

ENGLISCH• Kapitel2 •Seite 2
2
Engine Description 2.1␣ Model
26 332 0 26231 1 26232 1
2.1.1 Rating Plate 2.1.2 Rating Plate Location
The rating plate Cis attached to the crankcase.The model A, the engine serial number Band 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
The engine serial number is also stamped on the
crankcase itself (arrow).
7380en_k02_pdf 01.10.1999, 16:20 Uhr2

ENGLISCH• Kapitel2 •Seite 3
2
2.1␣ Model Engine Description
26233 0
2.1.4 Cylinder Numbering
Cylinders are numbered consecutively, beginning
at the flywheel end.
7380en_k02_pdf 01.10.1999, 16:20 Uhr3

ENGLISCH• Kapitel2 •Seite 4
2
Engine Description 2.2 Engine Illustrations
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
7380en_k02_pdf 01.10.1999, 16:20 Uhr4

ENGLISCH• Kapitel2 •Seite 5
2
2.2␣ Engine Illustrations Engine Description
2.2.2 Starter Side 1012
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
7380en_k02_pdf 01.10.1999, 16:20 Uhr5

ENGLISCH• Kapitel2 •Seite 6
2
Engine Description 2.2␣ Engine Illustrations
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
7380en_k02_pdf 01.10.1999, 16:21 Uhr6

ENGLISCH• Kapitel2 •Seite 7
2
2.2␣ Engine Illustrations Engine Description
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
2.2.4 Starter Side 1012 E
26237 0
7380en_k02_pdf 01.10.1999, 16:21 Uhr7

ENGLISCH• Kapitel2 •Seite 8
2
Engine Description 2.2␣ Engine Illustrations
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
2.2.5 Service Side 1013
7380en_k02_pdf 01.10.1999, 16:21 Uhr8

ENGLISCH• Kapitel2 •Seite 9
2
2.2␣ Engine Illustrations Engine Description
2.2.6 Starter Side 1013
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
7380en_k02_pdf 01.10.1999, 16:21 Uhr9

ENGLISCH• Kapitel 2 • Seite10
2
Engine Description 2.2␣ Engine Illustrations
1 Oil filler
2 Coolant pump
3 Fuel pump
4 Vibration damper
5 Lube oil filter
6 Engine mount
7 Fuel 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
2.2.7 Service Side 1013 E
26 336 0
7380en_k02_pdf 01.10.1999, 16:21 Uhr10