Workshop ManualB/FM 100
© 2001 / 0297 9984
Workshop ManualF4M 100
2M3M
BF4M 2M3M
F4M 100
0297 9985 en
In view of continuous designs, theimprovementstechnical orspe cifications and the illukstratiohopMansualshownare insubjectthis alteration. Reprinting andin reproduction,whole,are subjectin partto our written approval.
© 2001 / 0
© 2001 / 0297 9985
F O R E W O R D
Reliable engine operationexecutedis dependentrepairs ason welpro |
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This Workshop Manual describesationsfortheanyappreoparirat |
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engine and engine componentshiswork.Itwillis presumedbecarri. |
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The Manual has been laidhensionout toofensurethe contentsquick |
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placed adjacent to thelybriefshow textheworkinpassagesoperto |
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Aspects of operation andinmaintenancethe respectivare dealOp |
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For spare parts ordersataloguthe respectiveshould besparerefep |
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This |
Workshop |
Manualeerings notchangesubjectservicet tois |
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Therefore please |
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toTechnicalthe informatioCirculaepair |
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General information: |
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Please read carefullygivenandobservein thistheWor |
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avoid |
accidents |
andalwaysenurefunctionthat |
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Make sure that this WorkshopilableforManual this |
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or adjustments and thatstoodthe. contents a |
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Non-compliance with thresulterepairin malfuncinstr |
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damage as well as personalanufacturerinjuriesshallfo |
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liability. |
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The accident preventiongenreguralationslyrecogna |
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safety and occupational. medicine are t |
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A prerequisite for equiredsccssfulequipment,repair ih |
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are available and in perfect working |
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Optimal operation economy,ityof reliabilitytheengine |
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when genuine |
parts of DEUTZ AG are us |
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Engine components |
suchngs,as springs,etc.may claca |
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handled with care. |
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Engine repairs must beithcarriintendedoutusein |
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equipment manufacturer. approvedForconversionby DEU |
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specific purpose should be used. |
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© 2001 / 0
INDEX
This manual contains pergtinentherepairinformationof DEUTZregardiwater |
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injection DieselB/FM engines1008/F. |
type |
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INDEX |
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TROUBLESHOOTING CHART - B/FM 1008/F SERIES9_________ |
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SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS10 |
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I |
GENERAL _________________ |
12 |
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POWER RATINGS FOR B/FM 1008/F GENSET SPEC DIESEL ENGI |
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B/FM 1008 SERIES - TECHNICAL SPECIFICATIONS AND |
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CAPACITIES F2/3/4M 1008, BF4M 1008 __________________ |
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FLUID CAPACITIES (STANDARD) F2/3/4M 1008, BF4M 1008 __ |
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FM 1008 F SERIES - TECHNICACITIESLSP CIF2/3/4MICATIONS1008AND FCAP_____ |
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FLUID CAPACITIES (STANDARD) F2/3/4M 1008 F___________ |
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POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES F2 |
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POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES B/ |
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POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES F2 |
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GENERAL ENGINEERING DRAWINGS - F2/3M 1008 ___________ |
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GENERAL ENGINEERING DRAWINGS - B/F4M 1008___________ |
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GENERAL ENGINEERING DRAWINGS - F2/3/4M 1008 F _______ |
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B/FM 1008/F SERIES MAINTENANCE SCHEDULE _____________ |
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RECOMMENDED OIL______________________________________ |
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DIESEL FUEL SPECIFICATIONS __________________________ |
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ANTI-FREEZE / COOLANT SPECIFICATIONS / DETAILS - B/FM |
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DRIVING TORQUES FOR STANDARD SCREWS _________________ |
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SEALANT AND THREAD LOCK LOCATIONS/DETAILS ___________ |
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CRITICAL TORQUE SPECIFICATIONS ______________________ |
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SPECIAL TOOLS_______________________________________ |
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II |
DISASSEMBLY- |
REASSEMBLY |
31 |
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Air filter support - (intake manifold) ______________ |
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Air restriction switch ______________________________ |
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Alternator / cooling fan drive belt_________________ |
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Camshaft journal / support bore specifications______ |
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Camshaft journal / support measurement ______________ |
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Camshaft lobe measurement procedure__________________ |
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Camshaft lobe specifications ________________________ |
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Camshaft removal / replacement ______________________ |
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Camshaft timing pulley ______________________________ |
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Connecting bearing / rod cap installation___________ |
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Connecting rod / connectingions rod bearings specificat |
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Connecting rod alignment ____________________________ |
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Connecting rod-piston assembly balance ______________ |
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Cooling fan _________________________________________ |
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Cooling fan support _________________________________ |
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Crankcase vacuum regulator valve (B/FM 1008/F) ______ |
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Crankshaft end play _________________________________ |
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Crankshaft journal inspection / measurement _________ |
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Crankshaft journal specifications ___________________ |
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Crankshaft lubrication drillings-typical ____________ |
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Crankshaft pulley ___________________________________ |
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Crankshaft seals - front and rear ___________________ |
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© 2001 / 0297 9985 |
4 |
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INDEX
PAGE
Crankshaft timing pulley ________________________
Cylinder class __________________________________
Cylinder head installation_______________________
Cylinder head removal ____________________________
Cylinder head tightening procedureF4M 1008/F, B Cylinder head tightening procedureF2/3M 1008/F_ Cylinder inspection / dimensional specifications Cylinder surface finish __________________________
Dry type air filterstandard engine mounted _____
Exhaust manifold_________________________________
Flywheel / ring gear_____________________________
Front / rear main bearing caps / bearings________
Fuel rail ________________________________________
Fuel tank - (optional accessory) _________________
General piston notes ____________________________
Governor fork____________________________________
Governor springs_________________________________
Head gasket selection/ installation _____________
Hydraulic drive componentsno. 3 pto____________
Hydraulic pump pto- (no. 3 pto) __________________
Idler pulley _____________________________________
Injection pump control rod ______________________
Limiting speed governor _________________________
Main and connecting rod bearings ________________
Main bearing caps / bearingscenter _____________
Main bearing clearance ___________________________
No. 2 pto (crankshaft pulley) with “ringfeder”- F Oil bath air filter ______________________________
Oil pan removal / installation___________________
Oil pump assembly ________________________________
Oil pump assembly to the engine__________________
Oil pump inspection ______________________________
Piston / connecting rod disassembly and piston in Piston / connecting rod installation _____________
Piston balance ___________________________________
Piston class, weight imbalance and genuine Deutz Piston cooling jetsBF4M 1008 ___________________
Piston protrusion________________________________
Piston removal___________________________________
Piston ring assembly location ____________________
Piston ring end gap______________________________
Piston ring to piston land clearance ____________
Piston wrist pin installation / retaining snap ri Precision speed governor -(gensets)______________
Pre-combustion chamber installation ______________
Pre-combustion chamber removal___________________
Pre-combustion chamber ring nut __________________
Pre-combustion chamber-overview__________________
Rocker arm assembly______________________________
Speed governor___________________________________
Speed governor reassembly ________________________
Thrust bearings __________________________________
Thrust surface specifications-crankshaft end _____
play corrections_________________________________
Timing belt / timing pulley arrangement __________
Timing belt cover________________________________
Timing belt installationtiming procedure ______
Timing belt removal _____________________________
Timing belt tension procedure ____________________
Timing belt tensioning proceduresetup __________
Timing pulley - reference marks __________________
Undersized bearingsrod and main _______________
Unit injector check valve ________________________
Unit injector removal / installation _____________
Valve / rocker cover _____________________________
5 |
© 2001 / 0 |
INDEX
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
PAGE
/ rocker cover gasket _________________________
adjustment ____________________________________
guide installation guidelines and post installa guides / valve guide bore _____________________
recess and seat sealing width _________________
removal_______________________________________
seats _________________________________________
specifications ________________________________
springs _______________________________________
stem seal installation ________________________
timing angles _________________________________
timing confirmation____________________________
III TURBOCHARGER ___________ |
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Turbocharger identification _________________________ |
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Turbocharger components _____________________________ |
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Turbocharger pressure testing _______________________ |
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Turbocharger waste gate adjustement-bench method ____ |
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IV |
LUBRICATION SYSTEM ______ |
60 |
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Lubrication system __________________________________ |
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Oil pick-up screen and oil drain back tube__________ |
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Oil pump specification ______________________________ |
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Oil filter __________________________________________ |
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Oil pressure testing________________________________ |
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COOLING SYSTEM ___________ |
63 |
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B/FM 1008/F cooling system schematic ________________ |
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Cooling system pressureoncheck/radiator cap inspecti |
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Coolant pump details ________________________________ |
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Thermostat __________________________________________ |
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VI |
FUEL SYSTEM____________ |
65 |
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Barrel and plunger detail- (typical) current ________ |
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unit injectors (example- 6590-285) __________________ |
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Barrel and plunger detailearly unit injectors (typi |
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Early unit injectors________________________________ |
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Engine timing reference marks _______________________ |
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Equalization tool installation, plumbing____________ |
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Fuel filter assembly ________________________________ |
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Fuel rate adjustment details ________________________ |
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Fuel system schematic _______________________________ |
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Fuel system special tools ___________________________ |
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Fuel transfer pump __________________________________ |
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Fuel transfer pump push rod protrusion ______________ |
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Injector ____________________________________________ |
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Injector nozzle protrusion __________________________ |
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Late/ intermediate unit injectors ___________________ |
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Static injection testnjectorsinstrumentationearly unit i |
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Static timing adjustment ____________________________ |
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Tdc determination and ingstatic injection timing check |
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Unit injector _______________________________________ |
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Unit injector components ____________________________ |
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Unit injector delivery equalizationpreparation ____ |
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Unit injector delivery equalizationpreparation (con |
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Unit injector fire ring _____________________________ |
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Unit injector plunger reassembly ____________________ |
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© 2001 / 0297 9985 |
6 |
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INDEX
PAGE
Unit injector popping ntpressurelow prtessureting proceandadurejustm( intermediate unit injectors) _____________________
Unit injector popping pressure testing and adjust injectorsall ref. No’s other than 272, 272-, 27 Unit injector reassembly (cont.) _________________
Unit injector ring nut removal / replacement _____
Unit injector test stand specifications __________
VII ELECTRICAL SYSTEM 65
12V electrical schematic-marelli 14V-33A _________
12V electrical schematic - 20/30 A flywheel alter
12V electrical schematic-iskra 14V-33A ___________
Battery sizing ___________________________________
Battery sizing ___________________________________
Bosch 12V/1.1 kW starter motor (DW 12V) _________
BOSCH 12V/1.6 kW starter motor (DW 12V) __________
Electrical system service precautions / warning __ Engine side wiring harness for the Deutz supplied Flywheel alternator - 12V________________________
Glow plug ________________________________________
Glow plug controller / relay with coolant temp. S Iskra 14V/33A performance curve __________________
Iskra alternator - 14V/33A _______________________
Deutz supplied control panel ____________________
Marelli AA 125 R, 14V/45A performance curve ______
Marelli alternator (AA 125 R) - 14V-45A__________
Oil pressure (low) switch, coolant temperature (h Performance curve - 20A flywheel alternator______
Performance curve - 30A flywheel alternator______
Performance curve - BOSCH 12V/1.1 kW (DW 12V) sta Performance curve - BOSCH 12V/1.6 kW (DW 12V) sta Temperature sensor (thermistor)__________________
Voltage regulator connection details (flywheel al
VIII TESTING-OPERATIONAL-ADJUSTEMENTS 84
Governor / unit injector rack adjustment ________
High (maximum) speed adjustment __________________
Idle speed adjustment ____________________________
Injection pump control rod stroke limit adjustmen Power, torque device and speed adjustments-dynamo Torque device adjustment (without dynamometer) ___
Torque device details ____________________________
IX STORAGE ________________ |
86 |
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Storage __________________________________________ |
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Storage |
- 1 to 6 months__________________________ |
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Storage |
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in excess of 6 |
months _________________ |
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Preparing |
the engine for |
use after storage _______ |
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7 |
© 2001 / 0 |
NOTE
© 2001 / 0297 9985 |
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TROUBLESHOOTING CHART-B/FM |
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pressure |
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POSSIBLE CAUSEwill |
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Engine Engine Engine Poor Unsteady Black White Blue Low Oil Excessive Wet Overheating Engine |
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Low fuel level |
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Fuel supply/ return lines• •clogged•• |
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Clogged fuel tank vent |
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Fuel pump faulty |
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Unit injector(s) faulty/• |
worn• |
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Unit injector settings |
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Injection pump rack |
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Glow plug controller |
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Glow plug relay inoperable• |
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Starter defective |
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Battery / battery cable• connections corroded |
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Key switch defective |
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Governor linkage |
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Governor spring |
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Governor / |
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linkage•• |
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Thermostat |
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9 |
© 2001 / 0 |
SAFETY AND WARNING DECALS - SAFETY |
|
SAFETY ANDRNINGW DECALS |
|
DANGER |
CAUTION |
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! |
Failure to complyFailurewith tohe comply |
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instructions |
couldinstructionsesult in could |
damage to personstechnicaland damage |
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property |
machine and/or syst |
SAFETY INSTRUCTIONS
●DeutzessentialEnginesfor areusersbuilttostructionsscomplyintoasupplysafewithgivenandtheirthelonginservicingperformathe-esults,lastingtherelatisafetceiniw recommendations listed below.
●Themeetenginetheessentialhas beensafetymadeequisitesufaacandcordingturer'shealthhavetobeenspecificatisafeguardingmachinetakent,tolawsasnsmanr p
in merit. All uses of theficallyengineestablishedbeyond thosecannotasspect conforming to the use declinesfined byallDeutzliabilwhitychom forthussuchand operations.
●Theconcerningfollowingengineindicationsoperationthofthearetheinrelativededicatparticular,machineroutinedintoorderalongthemainteksusewito
●Thethisusercouldmustleadreadto theseseriousbecomeinstructionsdangerfamiliarfor carefullyhiswithpersonallurethe operaandtods vicinity of the machine.
●Theoperationengineandmaytheonlyderivingbeisusednealsobydangersortechniciansessentialassembled.Thiswheoncowhonaveditareitsmachiall,ioncomad
extraordinary maintenancelatteropercase,tionsmustwhich,onlyecificallinbethecarr trained by Deutz and whoe existingwork compliancedocumentationwith. th
●Variationsremoval of seals,tothe demountingfunctionne,ribedadjustmentslandparameinrefittingtheerstooperationoftheofthespeed,fuelpartsandngif
unauthorized personnel shall relieve Deutz from all comply with the laws in merit.
●Onthestarting,caseof manualmake surestartntallativethat-ups,astheactionspossible,makeengineurecanisunlessthtakeasittingdifferthehorizoplactherewal.m
or dangerous objects, alsomadeconsideringby the operatorthe movementord.Pull(thusexcluding self-winding startingenan only),emergencyis .not permit ● Make sure that the machine rturningisstable. to prevent the
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SAFETY AND WARNING DECALS - SA
● Become familiar with how top adjusttheenginethe .rotation s
●Nevermonoxide,startantheodourlessenginehereandinngthyaishighlyclosedstainsufficientspoisonousplaceinplacesorventilsgaswhercarwhests. this gas can lead to unconsciousness and death.
●Theis dustenginethatmustcannoteasilyadequoperflacatmmableteechinandfireplmclearlyatceunlesrials,containdicatespecificintakeneingexpthe have been certified for the machine.
●To prevent fire hazards, alwaysmeterkeepfromthebuildingsmachine
● derivingChildren fromandanimalstheiroperationmustfrombe .keptoperating machinesduedista
●Fuelthe fuelis inflammablecontaineraway.Thehenalongtheank enginewithmustanyonlyis ragsoffbel.filledsoakeandThorm
of porous material aresuresoakedthatinthefuelgroundor oiloris.floostaMak has not soaked up any fuel or oil.
● Fullyspace fortightenthe fuelthetanktoingexpandplug.Do .eachnot filltime theafteranrefukaderi
●Fuel vapour is highlyrtoxicin a.welOnlyventilatedrefueloutdoorsplace
●Do not smoke or use naked flames when refuelling.
●Theand/orenginemachinemustitselfbestarted.gpecificDoaidsnotn hatcomplianceuseinstructionswereauxiliarynotwithineinstaengith(rl Startpilot’).
●Beforeguards havestarting,been refittedremoveserviceany.toolsthethatenginewereand/oallused
●Duringparticularoperation,. the omesurfacedangerouslyof the enginehot.Avoidtemcan b
●Beforewhilst proceedingtheengine withisrunningany operation. on the engin
●Thein thiscoolantcase,fluidonlycircuitopencarrytheisoutradiatorunderany inspectionspressureplug d.orandNeveexpun
garments and goggles.doIfnotthereapproachis an theelectricenginesthefanw also start operating whentill.theOnlyenginecleanistheat coolanissta standstill.
●Whensafeguardcleaningthe environmtheoil-thaterialcoolednt.theTheinairoldspongyoilfilter,-oilcooledfilteringismakediairnspooilsufirdsem
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reservoir |
of the separatorilled withpre-filteroil. must not be |
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● allowThe oilthemustoilbetodrainedcomeilinto° TwhilstC)~.contact80Particularthe enginewithcaretheis skinishotnore. |
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● |
safeguardMake sure |
thethatenvironmentthe drainedtheoil.oil,tcontainstheoil |
filterarewaydispinano |
● |
Pay attention to the temperaturelteritselfof theis |
replacedoilfilte. |
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●Onlycontainingcheck,nitritestopup andfromatchangethedobeinengineotgthemixedcontaincoolantiswithoffthesefluidothersandne",suc
dangerous for the health,idiscanpollutingform. Theandcoolantmustthehecf way to safeguard the environment.
●Duringdisconnectoperationsand insulatethattteryinvtstheolveftpothesitipreaccessengineventwiretoaccidentatopand/ormovingofthe starter motor from being energized.
●Only check belt tension when the engine is off.
●Onlymachine;use inthethiseyeboltscase,einstallmanufacturertheengineyeboltse.d ThesbyDshouldeinstalledutzliftingobethemoveusebypoie
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© 2001 / 0 |
I GENERAL
All pertinent informationicationneededan sparforenginepartsomidentifordtheringengi data plate. Additionally,“K”thenumbermaximumand engineapprovalspeed,enginecod s data plate. The location below,oftheisdataidenticalplate, forasustrialshowall engines. Please supply ationheengineto yourdataAuthorizedplate informwhenDEUTZ ordering replacement partsinquiriesor when. making technical
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